MC400L 600 01 (FD)

1610, MMCEN-290-002, 001
INSTRUCTION MANUAL
MANIPULATOR
MC400L-01 [FD11]
MC600-01 [FD11]
2nd edition
・Before attempting to operate the robot, please read through this operating manual
carefully, and comply with all the safety-related items and instructions in the text.
・The installation, operation and maintenance of this robot should be undertaken only
by those individuals who have attended one of our robot course.
・When using this robot, observe the low related with industrial robot and with safety
issues in each country.
・This operating manual must be given without fail to the individual who will be actually
operating the robot.
・Please direct any queries about parts of this operating manual which may not be
completely clear or any inquiries concerning the after-sale service of this robot to
any of the service centers listed on the back cover.
This manual explains the robot specifications, structure of each part and the basic handling precautions for
inspection and maintenance to maintain function of the robot for a long period of time.
It is strongly recommended that this manual is read by robot utilization planners and installation staff as well
as inspectors and maintenance staff for handling robot. And the robot is handled only after understanding this
manual thoroughly.
Chapter 1 Basic specifications .................................................................................................................. 1-1

1.1 List of basic specifications ........................................................................................................ 1-1
1.2 Outline dimensions and operating area of robot ...................................................................... 1-2
1.3 Details of load installation face ................................................................................................. 1-4
1.4 Wiring and piping diagram for application ................................................................................ 1-5
Chapter 2 Precautions for handling ........................................................................................................... 2-1

2.1 Names of robot components .................................................................................................... 2-1
2.2 Transport procedure ................................................................................................................. 2-2
2.3 Installation procedure ............................................................................................................... 2-4
2.4 Allowable load......................................................................................................................... 2-10
2.5 Execution of encoder correction ............................................................................................. 2-14
2.6 Restriction of working envelope.............................................................................................. 2-14
2.7 Test running for main axes (1,2 and 3)................................................................................... 2-14
Chapter 3 Inspection.................................................................................................................................. 3-1

3.1 Inspection items and periods.................................................................................................... 3-1
3.2 Inspection of wirings ................................................................................................................. 3-2
3.3 Inspection of grease ................................................................................................................. 3-3
3.4 Inspection of balancer unit and filling gas................................................................................. 3-4
3.5 Lubrication .............................................................................................................................. 3-10
3.6 Grease replacement ............................................................................................................... 3-14
3.7 Battery replacement................................................................................................................ 3-20
3.8 Balancer protection cover replacement .................................................................................. 3-22
Chapter 4 Troubleshooting ........................................................................................................................ 4-1

4.1 Motor replacement.................................................................................................................... 4-2
4.1.1 Motor replacement (Axis 1, and 5).................................................................................... 4-3
4.1.2 Motor replacement (Axis 2, 3, and 4)................................................................................ 4-5
4.1.3 Motor replacement (Axis 6)............................................................................................... 4-7
4.1.4 Encoder reset.................................................................................................................... 4-9
4.1.5 Encoder correction ............................................................................................................ 4-9
4.1.6 More accurate encoder correction .................................................................................. 4-12
4.2 Encoder replacement.............................................................................................................. 4-16
Chapter 5 Recommended spare parts and special tools for maintenance ............................................... 5-1
Chapter 6 Wiring Diagrams ....................................................................................................................... 6-1
1
For safely using the robot
Read this manual and other concerning manuals carefully prior to installation, operation, maintenance, and
inspection, so you can use all the equipment correctly. Use the robot only after fully understanding the equipment,
all the safety guidelines, and the precautions ( “Precautions for handling industrial robots” and
“Instruction Manual SETUP”, ”Chapter 1 Point on Safety”)
In this manual, we use the symbols shown below to show the level of danger of the each label.
This indicates that the possibilities of danger can occur when the robot is handled incorrectly.
(E.g. Death or serious injuries can occur.) And also includes urgency of warnings in a highly
DANGER dangerous situation. Always observe these precautions to safely use the robot.
(E.g. Death or serious injuries can occur.) Always observe these precautions to safely use the
WARNING robot.
(E.g. Minor injuries or property damage can occur.) Always observe these precautions to safely
CAUTION use the robot.
The following symbol is also used for important checkpoints.
A particularly important checkpoint is shown.

IMPORTANT
Danger and caution signs on manipulator
Following signs are applied on manipulator. These signs location may vary or even may not be on the robot
according to the robot’s type and its axes.
This sign indicates a power supply inlet for the robot. Motor and detecting
device power is supplied to connectors and terminal blocks, which is inside
of the connector covers of each parts of the robot.
Never touch connectors or terminal blocks directly or indirectly with
conductive items when the main power is on, as electric shock may occur.
If connectors or terminal blocks are disconnected when the main power is
on, electric shock or malfunction of the robot may occur. Make sure to turn
OFF the main power on the controller when performing any maintenance.
This sign indicates the parts of the robot, which will become hot.
Carelessly touching the parts, where the signs are may result in serious
burns.
This sign indicates the dangerous area, where operators may get caught by
the robot.
Never come close to the area, where these signs are. Brakes can be
released not only during teaching, but also while the motors are OFF.
Please pay extra attention and make prevention plan in advance when
performing maintenance or any types of work to avoid pinching any parts of
your body before coming close to this area.
Signs for other types of caution and warnings;

Ignoring these signs and disassembling some parts may cause fatal injuries, death, or damage any equipment
around.
Signs for protection;

Chapter 1 Basic specifications
1.1 List of basic specifications
Item Specifications
Robot model MC400L-01 MC600-01
Construction Articulated
Number of axis 6
Drive system AC servo motor
Axis 1 ±3.14 rad (±180°)
Axis 2 -1.83 ～ +1.05 rad (-105 ～ +60°)
-2.27 ～ +0.52 rad -2.44～ +0.52rad
Axis 3
(-130 ～ +30°) （-140 ～ +30°）
Max. Motion range
Axis 4 ±3.67 rad (±210°)
Axis 5 ±2.09 rad (±120°)
Maximum : ±6.28 rad (±360°)
Axis 6
Initial setting : ±3.67 rad (±210°) *4
Axis 1 1.57 rad/s (90°/ｓ)
Axis 2 1.57 rad/s (90°/ｓ)
Axis 3 1.57 rad/s (90°/ｓ)
Max. speed
Axis 4 1.92 rad/s (110°/ｓ)
Axis 5 1.92 rad/s (110°/ｓ)
Axis 6 3.14 rad/s (180°/ｓ)
Wrist 400 kg 600 kg
Max. pay load
Forearm *1 50 kg at maximum
Axis 4 3450 N･m
Allowable
Axis 5 3450 N･m
static load torque
Axis 6 1725 N･m
Axis 4 600 kg･m2
Allowable
Axis 5 600 kg･ｍ2
moment of inertia *2
Axis 6 400 kg･m2
Position repeatability *3 ±0.3 mm
Installation Floor setting
Temperature: 0 to 45 ºC *5
Ambient conditions Humidity: 20 to 85%RH (No dew condensation allowed)
Vibration to the installation face: Not more than 0.5G (4.9 m/s2)
Robot mass 3,050 kg 600 kg

1[rad] = 180/π[°], 1[N･m] = 1/9.8[kgf･m]
- On controller display, axis 1 to 6 is displayed as J1 to J6 for each.
- The specification and externals described in this specification might change without a previous notice for the improvement.
- Explosion-proof is not available.
*1: This value changes by placement and load conditions of a wrist.

*2: The Allowable moment of inertia of a wrist changes with load conditions of a wrist.
*3: This value conforms to "JIS B 8432".
*4: The initial setting of the software limit is ±210°. When installing the cables in the hollow hole part of the Axis 6, please use the robot in the range of
±210°. If the cables do not go through the hollow hole of the axis 6, it is possible to widen the motion range of the Axis 6 up to ±360° considering
the condition. Fr details of how to change the software limit range, refer to the instruction manual “SETUP MANUAL”(Chapter 4).
*5: Permitted height is not higher than 1,000m above sea level. If used in higher place, permitted temperature is affected by height.
1-1
1.2 Outline dimensions and operating area of robot
[MC400L-01]
1-2
[MC600-01]
1-3
1.3 Details of load installation face
■ Wrist
Be sure to screw the M12 end effecter fixing bolts in the wrist not deeper than the screw
depth in the installation face. Screwing the bolts deeper than the screw depth may
CAUTION damage the wrist.
[MC400L-01] [MC600-01]
Tightening torque of
M10 Hex. socket head cap screw
JIS: Strength class 10.9 96 N・m
JIS: Strength class 12.9 116 N・m
■ Upper part of forearm

[MC400L-01] [MC600-01]
1-4
1.4 Wiring and piping diagram for application
Use air pressure not more than 0.49MPa.

IMPORTANT
■ Upper part of forearm - Wiring and piping for application

[MC400L-01] [Mc600-01]
Applicable tube
Outer diameter: φ12
(NOTE) In wiring box BJ3, there are application connectors shown the next page
When connecting cables inside BJ3, select the adequate hole that corresponds to the cable size.
■ Base frame block - Wiring and piping for application

[MC400L-01] [Mc600-01]
(NOTE) In wiring box BJ1, there are application connectors shown in next page. In order to connect
application wires (DeviceNet, or Ethernet), BJ1 panel needs to be processed by customer.
1-5
■ Details of application connectors (standard) [MC400L-01] [Mc600-01]
(1) BJ1-side (Connectors)

User-side Connectors
Wire-side shell : JFM-WSA-4-A (JST)
CONNECTOR
JFM-WSA-4-C (JST)
Guide plate A kit : JFM-GPAK-4 (JST)
Receptacle housing : JFM2FDN-22V-K (JST)
Receptacle contact
CONNECTOR a SJ2F-01GF-P1.0 (JST) 0.20~0.50sq
b: SJ2F-01GF-P1.0 (JST) 0.30~0.75sq
Manual crimp tool
a: YRS-8861
b: YRF-1120
CONNECTOR
Cable diameter suitable for wire-side shell
JFM-WSA-4-A : φ26.2~φ28.0
JFM-WSA-4-C : φ15.5~φ16.5
(Pin location shows the connector equipped on robot body
CONNECTOR and is the view from connecting side.)
Specification of Application wires

Rated voltage maximum AC/DC 115 V
Rated ampere maximum 1 A
(2) BJ3-side (Joint connectors)

Connector models (CN61,CN63)
Housing SMP-10V-BC (JST)
User-side connectors
Housing SMR-10V-B (JST)
Contact SYM-001T-P0.6
(Suitable cable: AWG#22~28)
Manual crimp tool: YRS-121
Connector models (CN62,CN64)

Housing SMP-11V-BC (JST)
Housing SMR-11V-B (JST)
Contact SYM-001T-P0.6
(Suitable cable: AWG#22~28)
Manual crimp tool: YRS-121
1-6
■ Details of application connectors (Standard) [MC400L-01] [MC600-01]
BJ3-side (Joint connectors)
Store in the wiring box “BJ3” on the 1st arm.
Connector models (CNMB7B)

Housing VLP-06V（JST）
Housing VLR-06V（JST）
Retainer VLS-03V（JST）
Contact SVM-61T-P2.0 (Suitable cable: AWG#20～14）
Manual crimp tool YC-590
（Pin location shows the connector equipped on robot body

and is the view from connecting side.）
Connector models （CNE7B）

Housing SMP-11V-BC（JST）
Housing SMR-11V-B（JST）
Contact SYM-001T-P0.6 (Suitable cable:AWG#22～28）
Manual crimp tool YRS-121
（Pin location shows the connector equipped on robot body

and is the view from connecting side.）
1-7
■ Details of DeviceNet Connectors (standard) [MC400L-01] [Mc600-01]
Connector Connector
in wiring box BJ1 in wiring box BJ3
(Pin location shows the connector mounted on robot body and is the view from connecting side.)
CN71A CN71C
Connector Housing VLR-04V VLP-04V
User-side Housing VLP-04V VLR-04V
connector Contact SVF-61T-P2.0 (0.5～2.0 mm2) SVM-61T-P2.0 (0.5～2.0 mm2)
SVF-42T-P2.0 (0.3～1.25 mm2) SVM-42T-P2.0 (0.3～1.25 mm2)
Retainer VLS-02V
Crimp tool YC-590（SV*-61T-P2.0）
YC-592（SV*-42T-P2.0）
CN81A CN81C
Connector 231-635/010-DM 231-305/037/010-DM
User-side Connector 231-305/037/010-DM 231-635/010-DM
connector Crimp tool 231-131
Contact CAN_L, CAN_H ：216-301
V-, V+ ：216-201
Drain ：216-201
Crimp tool ：206-204
(NOTE) Adequate contact and manual crimp tool should be used for each cable.
User-side connectors need to be prepared by customer.
Do not apply external force or fix other cables to the robot cables.
CAUTION
1-8
■ Details of Ethernet Connectors (standard) [MC400L-01] [Mc600-01]
Connector Connector
in wiring box BJ1 in wiring box BJ3
CN71A CN71C
Connector Housing VLR-04V VLP-04V
User-side Housing VLP-04V VLR-04V
connector Contact SVF-61T-P2.0 (0.5～2.0 mm2) SVM-61T-P2.0 (0.5～2.0 mm2)
2 2
SVF-42T-P2.0 (0.3～1.25 mm ) SVM-42T-P2.0 (0.3～1.25 mm )
Retainer VLS-02V
Crimp tool YC-590（SV*-61T-P2.0）
YC-592（SV*-42T-P2.0）
CNLANA CNLANC
Connector RJ45 plug
5-569552-3 5-569552-3
connector
User-side Hood RJ45 type connector RJ45 type connector
connector (any company) (any company)
Pin location shows the connector mounted on robot body and is the view from connecting side.
(NOTE) Adequate contact and manual crimp tool should be used for each cable.
User-side connectors need to be prepared by customer.
1-9
NOTE
1-10
Chapter 2 Precautions for handling
2.1 Names of robot components
The balancer device is internally compressed even in the normal state. Never attempt to
dismount or disassemble this device. Otherwise it will result in a highly hazardous
WARNING situation.
■Name of the operating axis and each of their movement’s direction
Axis5
Axis4
Manufacturing plate
Axis1
Manufacturing number
Axis6
Date of manufacture
Serial robot number
Mass of robot
Axis3 Axis2
(Mass is typed only for CE specification.)
On controller display, axis 1 to 6 is displayed as J1 to J6 for each.
2-1
2.2 Transport procedure
The robot must be transported by personnel who have licenses required for slinging
work, crane operation, forklift truck operation, and others. The weight of the robot and
controller is listed in the Operating Manual and the Maintenance Manual. Check for the
WARNING
weight, and then handle them according to procedures suitable for the weight.
To lift the robot or the controller, follow the procedures specified in the Maintenance
Manual. Following any procedures other than those specified will cause the robot to topple
WARNING over or drop during transport, thus resulting in accidents.
During transport or installation work of the robot, pay utmost care not to cause damage
to wirings. Furthermore, after installing the robot, take protective measures such as using
protective guards so that the wirings will not be damaged by workers or other persons, or
CAUTION
forklift trucks or else.
Please pay utmost care not to hurt the motor and encoder cables by hanging wires.
CAUTION
To transport the robot, make it

a rule to use a crane.
At first, move the robot to the
configuration shown in figure
and mount four M24 hanger
bolts to the robot frame. Then,
be sure to lift the robot using
four hanging wires
(recommended length is 3.5m).
Protect the areas of the robot by
touching wires, cover the wires
by rubber hoses. To see the
area to be protected, please
refer to the drawings below.
[MC400L-01]
2-2
[MC600-01]
2-3
2.3 Installation procedure
The installation location and the installation procedure of the robot are critical factors to maintain
robot functions. The ambient conditions of installation location not only have influence on the life of
mechanical sections of the robot, but also get involved in safety issues. Consequently, strictly
observe the environmental conditions shown below. Furthermore, utmost care should be exerted for
the installation procedure and the foundation for the robot in order to maintain the robot performance.
Strictly observe the installation procedure for the robot provided below.
Installation
To install the robot, give it first priority to thoroughly consider safety of workers and take safety
measures. The following section describes precautions for this purpose.
Safety measures against entry in the robot operating area

While the robot is in operation, workers are in danger of coming in contact with the
robot. To avoid that, install a guard fence so as to keep the worker away from the robot.
Not doing so will cause the workers or other persons to accidentally enter the operating
WARNING
area, thus resulting in accidents.
Guard fence
Refer to information in ISO13857: Safety of machinery – Safety distances to prevent
hazard zones being reached by upper and lower limbs
This figure shows the image of the
guard fence. (Robot appearance
may be different from that of this
manual.)
DANGER
Stop time and angle of axis 1 for a maximum travel

(After emergency stop signal occurred under maximum speed and maximum moment of inertia)
Robot type MC400-01 MC600-01
Stop time 1.46 [sec] 1.53[sec]
Stop angle 0.70 [rad] 0.82[rad]
The guard fence must have construction by which no one can easily get over or move
the guard fence. Provide an access door for the guard fence that must be equipped with a
safety plug and designed not to open unless the safety plug is unplugged.
WARNING If above construction is not secured, someone can get in the guard fence, thus inducing
a hazardous situation.
Design the system so that motor power is turned OFF when safety plug is unplugged
or access door is opened. This can make it possible to detect the entry of a person and
atop the robot automatically. (The controller has an input signal of safety plug and to turn
WARNING
off the motor power.)
Design the system so that low-speed playback mode will become functional in order
to operate the robot with the safety plug unplugged. If the robot is operated at a high
speed under the said condition, no one can escape from the robot, thus resulting in
WARNING
accidents. (The controller has an input signal to select low-speed playback mode.)
Mount Emergency Stop buttons for the robot in locations where workers are able
to immediately press them. If the workers are unable to immediately press the switch,
WARNING accidents may result. (The controller has an input signal of emergency stop.)
2-4
If no guard fence is installed, mount photoelectronic switches and/or mat switches,
etc. at all entrances to the robot operating area in stead of safety plug. These switches
WARNING make it possible to automatically stop the robot when anyone enters the guard fence.
Coat the floor of the hazardous area (the robot operating area) with color paint to
facilitate discrimination of the hazardous area.
WARNING
Safety measures against the robot and peripheral equipment

In order to connect the primary power supply to the controller and the peripheral
equipment, check to be sure that the power on the supply side is turned OFF. Otherwise
it will create a hazardous situation resulting in electric shocks since high voltages such as
WARNING
100VAC, 200VAC, or 400VAC are applied.
Do not install the operation part and the adjustment part in the robot operating area,
such as locations in which a person can get caught in the robot.
Install the robot control panel, interlock panel, and all other operation panels so that they
WARNING
can be operated outside the guard fence.
To install an operation stand, mount an Emergency Stop button on the operation
stand. If any abnormality occurs while the robot is being operated by operation stand, the
WARNING robot will be able to make an emergency stop through pressing this switch.
Do not route wirings, piping, and the like among the robot, control panel, interlock
panel, and others in such a manner that workers will stub their toes over them or forklift
trucks will directly tread them. Otherwise it may cause workers to topple over or the
WARNING
wirings to be broken, thus resulting in accidents.
Do not install the control panel, interlock panel, operation stand, or else in places from
which the movements of the robot are out of sight. When the robot movements go out of
sight, even if an abnormality occurs in any movement, you will delay in taking notice of
WARNING the abnormality, thus resulting in a disaster. Furthermore, you will not find someone near
the robot to cause an accident.
If the robot operating area required is smaller than the operable area possessed by the
robot, limit the robot operating area. The area can be limited by using the software
limit, limit switch, and mechanical stopper. Even if the robot exceeds the normal
WARNING operating area due to an abnormality, this function will enable the robot to stop before
initiating operation.
Install light shielding boards, enclosures, and others to the extent that robot
movement can be seen in directions in which workers may be exposed to spatters during
WARNING welding. Otherwise it may cause injury to workers with welding arcs, spatters, or else.
Provide a large and highly visible display of automatic and manual mode indicating
the operating status of the robot so that it can be recognized even from locations at some
distance. Furthermore, it is effective to provide audible alarm using a buzzer or
WARNING announcement to alert workers to the initiation of automatic operation, thus facilitating
awareness of automatic operation in progress from distant locations.
Eliminate protrusions from the peripheral equipment and the like of the robot to a
minimum. If necessary, be sure to cover them up. Otherwise it may induce a hazardous
WARNING
situation when a worker touches them or is surprised with a sudden movement of the
robot to topple over.
Do not attempt to install the robot so that a worker will need to put his/her hands in the
guard fence to carry in or out workpieces. There may be cases where the robot moves
WARNING when the worker put his/her hands in the guard fence.
2-5
Safety measures against installation work
To install the robot, it is important to position the robot so that no workers will get
pinched by the robot inside or around a device to use the robot. The robot must not come
into contact with any peripheral equipment when operating in the maximum operating
WARNING
range with a tool mounted on it.
Be sure to install the robot according to the specified procedure. Otherwise it will cause
the robot to move or topple over while in operation, thus inducing an imminent hazardous
WARNING situation.
To make wire connections between the robot and the controller or the peripheral equipment,
fully understand the connection procedure for proper wire connections. Making wire
WARNING connections according to improper procedure will cause the robot to malfunction.
Be sure to establish a proper ground for the robot. If equipment such as a welder that
causes substantial noises is needed to use, establish the specified ground for the
WARNING equipment.
During transport or installation of the robot, pay utmost care not to cause damage to
wirings. Furthermore, after installing the robot, take protective measures such as using
protective guards so that the wirings will not be damaged by workers or other persons, or
WARNING
forklift trucks or else.
■ Installation location and ambient conditions
Conditions (temperature, humidity, height and vibration) are written in “Chapter 1 Basic
Specifications”. Further ambient conditions listed below must be observed.
(1) Location with the drainage structure so that swivel base is not flooded, when the liquid such
as water or cutting fluid is splashed on the robot body
(2) Location with no flammable or corrosive fluid or gas.
(3) Type D grounding (the grounding resistance is 100Ω or less) is necessary.
■ Installation procedure
While robot moves, large reaction force is applied to the swiveling base from all directions.
Consequently, the robot should be installed in such a manner that the foundation endures not
only the static loads but also the reaction force caused by robot movement.
Repair uneven spots, cracks, and others on the floor, and then install the robot by following to
the table below. If thickness of floor concrete is less than needed level, an independent
foundation should be constructed. Inspect the foundation prior to the robot installation, and then
construct the foundation, if necessary.
Robot Model MC400L-01, MC600-01

Thickness of floor concrete Not less than 160 mm
8 bolts of M20 (JIS: Strength class 12.9) not less than 65mm
Installation parts *1 8 plain washers of not less than 4.5 mm in thickness
and HRC35 in hardness
Tightening torque *2 560 ± 30 Nm
Allowable repeated tensile *3 Appx. 56,000 N
*1 : Installation parts are not accessory of robot.
*2 : Apply a coating of lubricating oil to the threaded parts of bolts, and then tighten bolts by using torque wrench to the
specified tightening torque.
*3 : This tensile is per installation bolt when robot is installed with all bolts written in table above.
2-6
■ Installation space
To install the robot, lock the swiveling base of the robot.
The mechanical stopper end is located in a position exceeding the specified operating
range (software limit) of axis 1 by 3°. To install the guard fence, refer to the figures in this
WARNING section with consideration given to the wrist configuration and the shape of end effector.
On axis 1, 2 and 3, the robot operating range can be regulated for safety (optional
function). Since optional parts (e.g. limit switches or additional stopper blocks) should be
installed to enable this function, do not independently move the standard parts (e.g.
WARNING
stopper block).
If mechanical stopper collides and robot stops, it’s possible that some parts are already
damaged, for example, mechanical stopper is transformed or fixing bolts are broken. In
this case, sufficient intensity and function can not been kept. Mechanical stopper and
WARNING
reduction gear of collided joint are needed to be replaced to the new one.
[MC400L-01]
2-7
[MC600-01]
[MC400L-01] [MC600-01]
2-8
■ Accuracy of installation surface
When installing robot, strictly observe precautions listed below to cause no deformation in the swivel base.
(1) Make the deviation from the flatness of the 4 plates on the robot installation surface fall within 0.2 mm.
(2) Make the deviation in height between the 4 places of each base plate installation surface and the ro
bot installation surface fall in the range of 0.2 mm (±0.1 mm).
(3) The roughness of the surface of the base plate must be 25S or less in Rmax.
(4) If the two precautions above cannot

be observed, use jack bolts to bring the
four places into even contact with the i
nstallation surface.
■ Welding the base plates
The internal wirings inside the robot base unit may be burned or damaged because of welding
spatters or sparks. Therefore, when welding the base plates with attaching to the robot base unit,
please cover the gaps (4 portions) shown below in advance. After welding the outer side, remove
robot and weld the inside of base plates
Put the robot temporary to fix its position, and weld Remove the robot, and weld the inside of
the outside of base plates. base plates.
4 base plates Install

→ → the
robot
weld the outside of

base plate
Also weld the inside
of base plate
These gaps should be covered
before welding
(Front, back, left, right)
■ Maximum robot generative force
Max. vertical Max. horizontal Max. vertical Max. horizontal

Robot Model generative force generative force generative moment generative moment
FV FH MV MH
MC400L-01
95,300 N 69,500 N 260,400 N･m 225,800 N･m
MC600-01
2-9
2.4 Allowable load
The wrist load is regulated by the allowable pay load mass, allowable static load
torque, and allowable moment of inertia. If wrist load exceeds these allowable
CAUTION
values, this robot is out of guarantee.
Please refer to “1.1 List of basic specifications” and following figures for detail.
■ Torque map for the wrist load
Use the robot under condition that COG of wrist load falls in the range shown in the torque map.
[MC400L-01]
[MC600-
[MC600-01]
01]
2-10
■ Moment of inertia map for the wrist load
Use the robot under condition that static load torque and moment of inertia fall in the range shown
in the figures below.
If the moment of inertia exceeds the specification, maximum speed is automatically
IMPORTANT limited by the software to protect the robot.
[MC400L-01]
(3022,600)
(852,400) (3450,310)
(1725,150)
[MC600-01]
(2869,600)
(852,400)
(3450,207)
(1725,150)
慣性モーメントの大きさにより最適な速度で動作します。
2-11
■ Load on the forearm
Use the robot under condition that COG of the ancillary equipment on the forearm falls in the
range shown below.
[MC400L-01]
[MC600-01]
2-12
2.5 Execution of encoder correction
At NACHI factory, encoder correction is performed under the load condition and robot
posture specified by NACHI. This load condition and robot posture may have influence on
the reference position. So please perform encoder correction for all axes
after all of the load are mounted on wrist and upper arm,
before staring the teaching procedure,
CAUTION by referring to information in “4.1.4 Encoder Correction”. (At this time, encoder resetting
procedure is not required.) If encoder correction is carelessly performed after teaching is
done, all of the taught points are needed to be modified because tool top position may
change largely.
Also encoder correction is necessary when motor / encoder is replaced.
At this time, encoder correction must be performed under the same load condition and
same robot posture as the first time encoder correction that is performed
immediately after the loads are mounted, because load condition and robot posture
may have influence on the reference position. Therefore, the “reference posture” (where
all axes are in “reference position” by using zeroing pin or like that) is recommended as
CAUTION the posture of encoder correction. ( “4.1.4 Encoder Correction”)
Furthermore, sometimes normal encoder correction is not sufficient to recover the taught
positions precisely in case that bigger tool is mounted, etc. In such case, more accurate
encoder correction procedure is recommended by referring to “4.1.5 More accurate
encoder correction”.
2.6 Restriction of working envelope

In case that the actual working robot envelope is limited, operating range of each axis can be
changed from the standard range. Two methods are provided to do this.
With stoppers dismounted, do not operate the robot. Doing so may result in damage to
the peripheral equipment and the like, or death or serious injury.
WARNING
Software itself can not define the working envelope (where any axis never exceed even
when the robot system has fatal error). Restriction of main axis needs to be changed by
WARNING the mechanical stopper and over-travel limit switch (option).
If mechanical stopper collides and robot stops, it’s possible that some parts are already
damaged, for example, mechanical stopper is transformed or fixing bolts are broken. In
this case, sufficient intensity and function can not been kept. Mechanical stopper and
WARNING
reduction gear of collided joint are needed to be replaced to the new one.
(1) Restriction of working envelope by software

Refer to “FD controller instruction manual
SETUP” “Chapter 4 Setup” for this operation.
(2) Restriction of working envelope by adjustable stopper (option)

Working envelope is restricted by changing the position of
mechanical stopper. Applicable axis is limited. Over-travel limit
switch (another option) and software is needed to be changed
at the same time. Please refer to the option manual for detail.
Image of “adjustable stopper”
2.7 Test running for main axes (1,2 and 3)

After the long time stopping, abnormal sound may occur sometimes from main axes (1, 2 and 3).
Cause is the condensation of additive material in grease.
If abnormal sound occurs, please try the test running of corresponding axis by referring to the
procedure written in “3.6 Grease replacement”. Condensation of additive material will be broken
and abnormal sound disappears. Reliability of reduction gear is never affected by this test running.
2-13
NOTE
2-14
Chapter 3 Inspection
To perform daily inspection, repair, or part replacement of the robot, be sure to turn OFF
the power supply. Furthermore, in order to prevent other workers from improperly turning
WARNING ON the power supply, post the warning signs such as “DON’T POWER ON” at the primary
power supply switch and others.
3.1 Inspection items and periods

The inspection should be performed in order to maintain the high performance of the robot for an
extended period of time. Personnel who are engaged in the inspection must create and implement
the inspection program.
Furthermore, perform overhauls every 40,000 operating hours or every 8 years, whichever
comes earlier. For high duty work that temperature in reduction gear case is higher than 55
degree, it is recommended to perform inspections at approximately 1/2 of the periods specified.
Should you have any questions, contact your NACHI representative.
Inspection items and periods

Period
Quarterly
Yearly
Inspection Item Inspection Method Target portion

Daily
○ Robot body Confirming that playback position is same as before. Whole body
○ Cleaning of robot Wiping of dirt, removing of accumulated spatter, dust, Whole body
cutting chips.
○ Wiring Refer to “3.2 Inspection of wirings” Whole body
○ Major bolts Retightening and coating of paint lock to all of exposed Whole body
bolts (refer to “Specified tightening torque” table)
Also for the tool fixing bolts.
○ Limit switch dogs Activate and deactivate the limit switch. Axis 1, 2 and 3
(option) Retightening and coating of paint lock to the fixing bolts.
○ Motor Checking the abnormal heat generation and abnormal All axis
sounds
○ Brake Confirming that robot arm and tool never drop when All axis
motor power is turned ON/OFF.
○ Confirming that robot arm and tool never drop when the All axis
brake release switch (note) is set to OFF.
○ Reduction gear Confirming of no abnormal vibration, no abnormal so All axis
unds and no oil leakage.
○ Steel dust of grease Refer to “3.3 Inspection of grease” Axis 2 and 3
in reduction gears
○ Balancer unit Refer to “3.4 Inspection of balancer unit and filling
○ Balancer fulcrum gas”
bearing
○ Backlash and play Confirming of no backlash by pushing the tool in Axis 4, 5 and 6
forward/backward, right/left, and upward/downward with
hand.
（Note） Brake release switch is option. When operating this switch to ON, robot arm or operated axis drops. Pay
utmost care when operating. Please refer to the instruction manual “Controller” for detail.
Specified tightening torque of bolts

Hexagon socket Hexagon socket cross Hexagon socket Hexagon socket cross
head cap screw recessed button head screw head cap screw recessed button head screw
M3 1.0 N・m M10 67 N・m
M4 3.33 N・m M12 116 N・m
M5 5.0 N・m 4.02 N・m M16 287 N・m
M6 13.8 N・m 9.8 N・m M20 560 N・m
M8 33.3 N・m 13.8 N・m
Tightening torque of hexagon socket head cap screw is for JIS: strength class 12.9. And tightening torque may vary according to the
material and the kind of bolt. Unless specified in drawing, refer to the value in this table.
3-1
3.2 Inspection of wirings
■ Cables cover (hook tube) and clamp portion

・ Whether or not any cable cover has damages
and opening of joined section. (Pay utmost
care not to let any dusts get into the inside of
cover.） Cable cover
・ Whether or not the cable clamp fixing bolts (Black cover)
are loosened or lost. (M6 bolts; tightening Inspection point
torque 9.9 N・m)

・ No foreign parts are found in bracket, fixing Cable cover
(Silver cover)
bolt and cable cover (silver cover) clearance.
Inspection point
・ If any damage is found, repair or replace it.
Option cable
cover (silder) Dust condition
Inspection point Inspection point
■ Wiring around axis 5 motor

・Whether or not any cable sharply bends over
or gets crushed.
・Whether or not any cable shield has scratches
or fractures.
・Whether or not any cable has foreign parts.
・Whether or not any cable tie is broken.
・If any damage is found, repair or replace it.
Inspection
Cable around the
Axis 5
■ Wiring around axis 1 motor

・Open the wiring cover at the center of frame from the lower side and visually inspect the wiring
inside the cover whether or not any cable cover has scratches or fractures and whether or not
the clamp bolts are loosened.
・If any damage is found, repair or replace it.
・After the inspection, re-attach the cover.
12-M6x10
Tightening torque
13.8Nm
Inspection point
Side cover
Never attempt to use any cables other than specified by NACHI.

CAUTION For the replacement, order to your local service center.
3-2
3.3 Inspection of grease
Please check the density of steel dust in the grease of reduction gear every 5,000 hours or every
1 year (in case of high duty work that temperature in reduction gear case is higher than 55 degree,
every 2,500 hours or every half year).
If the measurement result exceeds the criterion, please contact our service center for grease
replacement or reduction gear replacement.
Tools required (prepared by customer)

Name Specification Q’ty
Grease steel dust meter OM-810 (IDEMITSU Kosan Ltd.) is recommended 1
Seal tape (in market) 1
Immediately after removing the drain plug, grease may splash, because internal
pressure is still high, for example soon after robot stops.
CAUTION
Inspection Tightening
Inspection points Grease type Purpose Type Size Criterion of steel dust
amount torque
Axis 1 VIGO Air release Plug Rc-1/4 29.4 N･m
Reduction gear 10 cc
RE No.0 Discharge Plug Rc-1/4 29.4 N･m
Axis 2 Air release Plug Rc-1/4 29.4 N･m
Reduction gear 〃 10 cc
Discharge Plug Rc-1/4 29.4 N･m
Discharge Plug Rc-1/4 29.4 N･m less than
Axis 4 Air release Plug Rc-1/4 29.4 N･m 0.1 %
Link Air release
MOLYWHITE Nipple Rc-1/8 12.7 N･m
Upper support 10 cc
point RE No.00 Discharge Plug Rc-1/8 12.7 N･m
Link Air release Nipple Rc-1/8 12.7 N･m
Lower support 〃 10 cc
point Discharge Plug Rc-1/8 12.7 N･m Less than
Axis 3 Air release 0.5 %
Nipple Rc-1/8 12.7 N･m
Right side 〃 10 cc
support point Discharge Plug Rc-1/8 12.7 N･m
Axis 3 Air release Nipple Rc-1/8 12.7 N･m
Left side support 〃 10 cc
point Discharge Plug Rc-1/8 12.7 N･m
Density of grease: VIGO RE No.0 (Nabtesco) 0.9 g/cc / MOLYWHITE RE No.00 (Nabtesco) 0.87 g/cc
Refer to the figure of “3.5 Lubrication” for detail.
Grease replacement procedure

STEP Work performed
1 In order to prevent the grease from splashing out (this is caused by e.g. rising of internal
pressure or internal temperature), unplug the air release plug in advance. When releasing
the plug, loosen the plug slowly to release the remaining pressure slowly
2 Collect the grease and measure the density of steel dust by using grease steel dust meter.
3 Wipe grease running out from the lubrication port. Then, wind sealing tape around the
threaded part of the socket head plug to prevent the leakage of grease, and plug it again.
4 If the grease leaks out too much when inspecting, lubricate grease. ( refer to “3.5
Lubrication”)
3-3
3.4 Inspection of balancer unit and filling gas
Gas balancer is installed inside the main frame. If gas pressure in balancer unit falls, excessive
stress is applied on motor, thus, results in trouble.
Inspect the gas pressure every year.

If gas pressure falls, fill the gas. If gas pressure falls remarkably, balancer unit itself
IMPORTANT may be broken. Stop using robot immediately.
Gas has high pressure. Observe the adequate law to handle it.
CAUTION
To prepare the worst case, do not stand at the location where the gas is coming out.
CAUTION
Use nitrogen gas （N2）.

IMPORTANT
Nitrogen is suffocation gas. Secure the working space with good ventilation system.
CAUTION
Inspection of balancer unit appearance

STEP Work performed
1 Check that foreign parts do not accumulate on balancer rod and no damage on it.
2 Check that balancer protection cover (silver cover) has no damage and no opening of joined
section. (Pay utmost attention not to let any dusts get into the inside part).
3 Check that foreign parts do not accumulate on the clearance of balancer protection cover.
4 If any damage is found, repair or replace it. (As for the replacement of protection cover, refer
to ”3.8 Balancer protection cover replacement”).
5 Check that no wearing dust is found from the fulcrum bearing of balancer.
Balancer protection cover

Dust condition
Inspection point
Balancer support bearing Balancer rod Balancer support bearing

Inspection point Dust condition Inspection point
Inspection point
3-4
Inspection of gas pressure (Axis 2 gas balancer unit)
Required tools (prepared by customer)
・M6 torque wrench
・Thermometer (to measure the atmospheric temperature)
・Gas inspection tool (Either one of following table)
Kind Parts No. Contents of maintenance tool set
Analog pressure gauge KP-ZJ-013 Quick joint, Analog service gauge
Digital pressure gauge KP-ZJ-014 Quick joint, Digital service gauge
STEP Work performed

Move axis 2 to 90 degree position. Other Portion A
1 Polyethylene cap
axis is free (any position).
Push the emergency stop button to lock the
2
robot arm.
Remove the polyethylene cap and charge
port plug of “portion A”. If gas is released
Charge port plug
3 continuously, please contact our service (M6 wrench)
center.
Detail of “portion A”
Attach the quick joint to the place where the

4 charge port plug was attached.
Quick joint
Connect the analog service gauge or the digital service gauge to the quick joint. At this time, confirm the
click sound. Before connecting, confirm that release valve is surely closed.
In case of using the analog service gauge (KP-ZJ-013)
5 Release valve
In case of using the digital service gauge (KP-ZJ-014)
In case of using the

digital service gauge,
power switch is needed
to be ON.
Please refer to the
Release valve Power button manual of gauge.
Confirm that read pressure satisfy the criterion range written below.
[MC400L-01]: Pressure 12.9±0.2MPa (at atmospheric temperature 20℃)
[MC600-01]: Pressure 15.2±0.2MPa (at atmospheric temperature 20℃)
Pressure may change according to the atmospheric temperature. Please refer to the figure below.
17
MC600-01
16
Criterion range
15
MC400L-01
圧力(MPa)
6 Criterion range
Pressure (MPa)
14
13
12
11
0 5 10 15 20 25 30 35 40 45
周囲温度(℃)
Ambient temperature (C)
If gas pressure satisfies the criterion range, proceed with next step.
If higher than criterion→ How to release gas in case that pressure was higher than criterion range
If lower than criterion→ How to fill gas in case that pressure was lower than criterion range
7 Disconnect the analog service gauge or the digital service gauge from the quick joint.
8 Remove the quick joint and attach the charge port plug and polyethylene cap.
3-5
Inspection of gas pressure (Axis 3 gas balancer unit)
・M6 torque wrench
・Thermometer (to measure the atmospheric temperature)
・Gas inspection tool (Either one of following table)
Kind Parts No. Contents of maintenance tool set

Analog pressure gauge KP-ZJ-013 Quick joint, Analog service gauge
Digital pressure gauge KP-ZJ-014 Quick joint, Digital service gauge
L-shape joint KP-ZJ-066 L-shape joint
STEP Work performed

Move axis 2 to 90 degree position. And move axis 3
1
to 0 degree position. Other axis is free (any position).
Push the emergency stop button to lock the robot
2
arm.
Remove the polyethylene cap and charge port plug of
3 “portion A”. If gas is released continuously, please
contact our service center.
Attach the quick joint to the place where the
4 charge port plug was attached.
Quick joint
Connect the analog service gauge or the digital service gauge to the quick joint. At this time, confirm the
click sound. Before connecting, confirm that release valve is surely closed.
Connection (2)
5 Release valve
Connection (1) In case of using the

digital service gauge,
power switch is needed
L-shape joint to be ON.
（KP-ZJ-066） Please refer to the
Release valve Power button manual of gauge.
Confirm that read pressure satisfy the criterion range written below.
[MC400L-01]: Pressure 10.4±0.2MPa （at 20℃ of ambient temperature）
[MC600-01] : Pressure 6.4±0.2MPa （at 20℃ of ambient temperature）
Pressure may change according to the atmospheric temperature. Please refer to the figure below.
12
MC400L-01
MC400L-01
適正範囲
Criterion range
11
10
圧力((MPa)
MPa)
9
6
Pressure
8 MC600-01
Criterion range
7
5
0 5 10 15 20 25 30 35 40 45
周囲温度(℃)
Ambient temperature
If gas pressure satisfies the criterion range, proceed with next step.
If higher than criterion→ How to release gas in case that pressure was higher than criterion range
If lower than criterion→ How to fill gas in case that pressure was lower than criterion range
Disconnect the L-shape joint from the quick joint. At this time, the joint will be released quickly. Please be
7
careful. Do not be pinched between the robot arm and the joint.
3-6
How to release gas in case that pressure was higher than criterion range
STEP Work performed
Move axis 2 to 90 degree position. And move axis 3 to 0 degree position. Other axis is free (any position).
1
(This is the same position with the gas pressure check posture)
Operate the release valve to adjust the gas pressure.
2 For the settlement of gas pressure, wait for 2 or 3 minutes before reading the pressure.
After gas pressure satisfies the criterion range, proceed with next step.
If the gas is released excessively except the posture, which is recommended then, arm may drop
and can be the possibilities of leading to the serious accident.
CAUTION
How to fill gas in case that pressure was lower than criterion range
・Nitrogen gas cylinder (Recommended cylinder：10L 1.5m3 cylinder)
・Charging equipment (Select one from table below according to its diameter)
Diameter of Nitrogen W22, pitch 14, Male W22, pitch 14, Female W23, pitch 14, Female
gas cylinder Right screw, Metal contacts Right screw, Metal contacts Right screw, Metal contacts
KP-ZJ-015 KP-ZJ-015 + KP-ZJ-019 KP-ZJ-016
Charging equipment (W22, pitch 14, Female, (W22, pitch 14, Female, Right screw, Metal (W23, pitch 14, Male,
Right screw, Metal contacts) contacts) + (Female->Male joint) Right screw, Metal contacts)
STEP Work performed Checkpoints

Confirm valve position of the charging equipment. Select the charging equipment
Valve 1 is CW (close) direction according to the size of nitrogen gas
Valve 2 is CCW (decrease) direction cylinder.
And connect the charging equipment to nitrogen gas cylinder.
Secondary pressure Source pressure
(this pressure is adjusted by valve 2) (nitrogen gas cylinder) Check list before connection
(charging equipment)
1 □Valve 1 = CW (close)
□Valve 2 = CCW (decrease)
(service gauge)
□Release valve 1 = CW (close)
CCW Valve 2
(Decrease)
3-7
Then attach the charging equipment to analog (or digital) service gauge.
Release valve Charging equipment
Analog service gauge Do not use

Valve 1 Valve 2 seal tape for
charging
equipment
Charging equipment and joint.
2 (Seal tape
may cause the
air leakage)
Valve 1
Valve 2
Release valve Digital service gauge

Open the valve of nitrogen gas cylinder.

Open
Operate the valve 2 of the charging equipment to CW

(increase) direction and set the pressure a little higher than the
specified pressure.
CW
(Increase)
Open the valve 1 of the charging equipment slowly to CCW

(open) direction and fill gas of the analog service gauge or the
5
digital service gauge a little higher than the specified pressure.
Close the valve 1 and wait for 2 or 3 minutes for the settlement
6
of gas pressure.
Check whether or not gas pressure satisfies the criterion
range. If pressure is higher than the criterion range, release
7 valve to adjust gas pressure. If pressure is lower than the
criterion range, fill the nitrogen gas again.
3-8
Close the valve of nitrogen gas cylinder.
Close
Disconnect the analog service gauge or the digital service Inside the balancer is already high
gauge from the quick joint. pressure, so you can hear the air leak
sound and it is difficult to disconnect
Quick joint the gauge. Do not fall down by pulling
9 reaction.
Remove the quick joint and attach the charge port plug and If polyethylene cap is forgotten, it is
polyethylene cap. possible that charge port plug can not
been removed.
10
Charge Port Plug
Open the valve 1 and valve 2 of the charging equipment to

11 release gas from the hose.
Then remove the charging equipment from the cylinder.
3-9
3.5 Lubrication
For lubrication and grease replacement, never use grease other than specified type.
Specified type of grease is written in this manual.
CAUTION
If grease other than specified type is used, chemical reaction with original grease
occurs and grease will change in quality. Insufficient lubricating efficiency may cause the
IMPORTANT unexpected shortening of robot life time.
Periodical lubrication is needed for some portion and grease replacement is needed for
other portion. Please do the correct maintenance (lubrication and grease replacement) by
CAUTION referring to this manual.
In order to prevent the internal pressure from rising due to pressure caused by the
lubrication, unplug the air vent plug. Its location is written in this manual.
CAUTION
Please lubricate every 5,000 hours or every 1 year (in case of high duty work that temperature in
reduction gear case is higher than 55 degree, every 2,500 hours or every half year). No lubrication
is required for any points other than those specified.

Grease gun with a nozzle of not more than 17 mm in diameter 1
Hose nozzle KP-ZJ-067 (Grease gun connection screw Rc1/8) 1
Long nozzle KP-ZJ-069 (Grease gun connection screw Rc1/8) 1
Use a grease gun with a nozzle of not more than 17 mm in diameter.

Note that lubricating grease more than the recommended amount may result in leakage
of grease or faulty robot locus. When making up the grease, feed the same amount of
IMPORTANT grease as the leaked one. When replacing the grease or lubrication, feed the specified
amount of grease.
CAUTION
Lubrication
Lubrication point Lubrication port Applicable Grease Remark
amount
Axis 2
Bearing of balancer upper Balancer upper fulcrum Long Time PD2 +1
10 0 cc
portion
Axis 2
Bearing of balancer lower Balancer lower fulcrum (ditto) (ditto)
portion
Axis 3
Bearing of balancer upper Balancer upper fulcrum (ditto) (ditto)
portion
Axis 3
Bearing of balancer lower Balancer lower fulcrum (ditto) (ditto)
portion
Refer to the figure on next page for detail.
3-10
Lubricating procedure (Axis 2 balancer upper fulcrum bearing / Axis 3 balancer lower
fulcrum bearing)
STEP Work performed
1 In order to prevent the internal pressure from rising due to pressure caused by the lubrication, unplug
the air vent plug. If the pressure caused by the lubrication is applied to the oil seal part, leakage of
grease will result.
2 Lubricate using grease gun.
3 Wipe grease running out from the lubrication port. Then, wind sealing tape around the threaded part of
the socket head plug to prevent the leakage of grease, and plug it again.
(Tightening torque of socket head plug: Rc-1/8 : 12.7 Nm)
Lubricating procedure (Axis 2 balancer lower fulcrum bearing)

STEP Work performed
In order to prevent the internal pressure from rising due to pressure caused by the lubrication, unplug the
1 air vent plug. If the pressure caused by the lubrication is applied to the oil seal part, leakage of grease will
result.
Attach the KP-ZJ-069 (Long nozzle) to the grease gun and lubricate. At this time, fill the KP-ZJ-069 (Long
nozzle) with the grease in advance.
Lubrication port
Grease gun
KP-ZJ-69
Air vent
Wipe grease running out from the lubrication port. Then, wind sealing tape around the threaded part of the
3 socket head plug to prevent the leakage of grease, and plug it again.
(Tightening torque of socket head plug: Rc-1/8 : 12.7 Nm)
Lubricating procedure (Axis 3 balancer upper fulcrum bearing)

STEP Work performed
Unplug the lower side socket head plug (PD2 10cc/year) and attach the grease nipple Rc-1/8 instead. (This
grease nipple is on the main frame of the robot) And then perform the lubrication work. In order to prevent
the internal pressure from rising due to pressure caused by the lubrication, unplug the air vent plug. If the
pressure caused by the lubrication is applied to the oil seal part, leakage of grease will result.
1
Grease nipple
Rc-1/8 is here
Attach the KP-ZJ-067 (Hose nozzle) to the grease gun and lubricate. At this time, fill the KP-ZJ-067 (Hose
nozzle) with the grease in advance.
Grease gun Air vent
Change to the Lubrication port

(PD2 10cc/year)
grease nipple
KP-ZJ-67 (Socket head plug)
After the lubrication, remove the grease nipple Rc1/8 and attach it back to the original position (Main frame
of the robot). Wipe grease running out from the lubrication port. Then, wind sealing tape around the
3 threaded part of the socket head plug to prevent the leakage of grease, and plug it again.
(Tightening torque of socket head plug: Rc-1/8 : 12.7 Nm, 2 portions)
3-11
Lubrication port (and air release position)
Location of grease inspection, lubrication and grease replacement (1)
3-12
Grease replacement port (and drain port)
Grease inspection port (and air release position)
For grease inspection, open “給油口/LUB.PORT” and inspection point, and then collect grease. Now, air is
released from “給油口/LUB.PORT”.
Location of grease inspection, lubrication and grease replacement (2)
3-13
3.6 Grease replacement
For lubrication and grease replacement, never use grease other than specified type.
Specified type of grease is written in this manual.
CAUTION
If grease other than specified type is used, chemical reaction with original grease
occurs and grease will change in quality. Insufficient lubricating efficiency may cause the
IMPORTANT unexpected shortening of robot life time.
Periodical lubrication is needed for some portion and grease replacement is needed for
other portion. Please do the correct maintenance (lubrication and grease replacement) by
CAUTION referring to this manual.
Lubricating work must be done keeping the feeding speed to 40cc per 10 seconds or
less. If lubricating is done rapidly, the oil seal may be broken and grease leakage may
CAUTION occur because of rise of pressure inside robot.
Please replace grease every 20,000 operating hours or every 4 years (in case of high duty work
that temperature in reduction gear case is higher than 55 degree, every 10,000 operating hours or
every 2 years).
Grease gun with a nozzle of not more than 17 mm in diameter, with lubrication amount counter 1
Drain connector Rc-1/4,φ12 1
Drain hose φ12X9 0.2m 1
Maximum 0.2Mpa and adjustable every approx. 0.01Mpa
Air precision regulator 1
SMC “PRECISION REGULATOR IR2000-02BG-X1” is recommended
Air supply source (in market) 1
Weight meter which can measure the weight of ejected grease + container 1
Use a grease gun with lubrication amount counter, with a nozzle of not more than
17 mm in diameter.
If such grease gun can not be prepared, measure the weight of the grease can
before/after the lubrication work to confirm the amount.
IMPORTANT Note that lubricating grease more than the recommended amount may result in leakage
of grease or faulty robot locus. When making up the grease, supply the same amount of
grease as the leaked one. When replacing the grease or lubrication, supply the specified
amount of grease.
CAUTION
In case that robot operation with slow speed playback or teaching operation is
necessary, never get into the robot moving envelope while playback.
And perform above procedure with two persons one pair. One person keeps to be
CAUTION ready to push the emergency button anytime, other person operates the robot paying
much attention. Please ensure the escape route in advance.
3-14
Grease replacement procedure (Other than Axis 5)
STEP Work performed
1 Move the robot to the adequate posture for the work. (refer to the figures on next page)
2 Place a container to receive grease ejected under the drain port *1.
3 Unplug the socket head plug [Rc-1/4] from the drain port. To prevent the robot from getting
dirty, attach a drain connector [Rc-1/4, φ12] and a drain tube [φ12×9, maximum length is
0.2m]
4 Unplug the socket head plug from the lubrication port *1, and attach the grease nipple [Rc-
1/4].
Grease nipple
Rc-1/4 is here
5 Use a grease gun to feed grease. At this time, operation must be done keeping the feeding
speed to 40cc per 10 seconds or less. Keep the operation until the grease color that is
pushed out from the drain port change to a color of new grease.
6 When the lubricated amount reaches the specified amount, confirm lubricated amount and
ejected amount. Lubricated amount can be calculated by comparing the grease can’s weight
before and after the lubrication work or checking the counter display on the grease gun.
Ejected amount can be calculated by measuring the weight of the container.
7 If lubricated amount is larger than ejected amount, too much (surplus) grease remains inside
the gear box. To make them same, use air to push the grease out. Supply air from the
lubrication port and eject the surplus grease from the drain port. Be sure that the air pressure
should be kept under 0.025Mpa by using precise regulator.
If only air comes out from the drain port and grease does not come out, move the target axis
slowly referring to the figure while supplying air, and push the grease out.
8 If lubricated amount is less than ejected amount, grease is lacked inside the gear box. To
make them same, swap the inlet and outlet, and feed the lacked amount of grease from the
drain port.
9 Wrap seal tapes on socket head plug [Rc-1/4] and attach to the lubrication port.
Wrap seal tapes on socket head plug [Rc-1/4] and attach to the drain port.
*1: Refer to the figure of “3.5 Lubrication” for detail of lubrication port and drain port.
After grease replacement, abnormal sound may occur sometimes. If abnormal sound occurs,
please perform running for grease by following to the procedure written below.
Running program example
Running program Sp eed Interpolation ACC Ang le of Ang le of
Only target axis moves Targ et a xis other than target axis
Step 1 40% JOINT 1 (*) any
between 2 steps
Step 2 40% JOINT 1 (*) any
Travel distance ; Appx. 100 degree
Step 3 DELAY [0.5 ] FN50 Timer
Speed ; 40 to 60% Step 4 END FN92 Program End
Operating time ; Appx. １ hour
10
If sufficient travel distance is difficult to
keep, make operating time longer.
(Ex; if distance is half, operating time
should be 2 times longer than above
value.)
Axis 1 mo ves Axis 2 moves Axi s 3 moves

betwee n 2 ste ps betwe en 2 steps between 2 steps
(*) -50°~ +50° (*) +30 °~ +130° (*) -60°~ +40°
3-15
Grease replacement procedure (Axis 5)
STEP Work performed
1 Move the robot to the adequate posture for the work. (refer to the figures on next page)
2 Place a container to receive grease ejected under the drain port *1.
3 Unplug the socket head plug [Rc-1/4] from the drain port. To prevent the robot from getting
dirty, attach a drain connector [Rc-1/4, φ12] and a drain tube [φ12×9, maximum length is
0.2m]
4 Supply air from the Air release port (*1) and eject the grease from the drain port. (The amount
to be ejected is 1100cc) Be sure that the air pressure should be kept under 0.025Mpa by
using precise regulator.
Ejected amount can be calculated by comparing the container weight before and after.
If the ejected amount of the grease is not enough, move the Axis 5 slowly referring to the
figure while supplying air, and push the grease out.
5 Attach the grease nipple [Rc-1/4] to the lubrication port. (The lubrication port of the Axis 5 is
the same with the drain port.)
Grease nipple
Rc-1/4 is here
6 Use a grease gun to feed grease. At this time, operation must be done keeping the feeding
speed to 40cc per 10 seconds or less. The rated amount of the grease is in the table
shown as below. Lubricated amount can be calculated by comparing the grease can’s weight
before and after the lubrication work or checking the counter display on the grease gun.
7 Wrap seal tapes on socket head plug [Rc-1/4] and attach to the lubrication port.
Wrap seal tapes on socket head plug [Rc-1/4] and attach to the drain port.
*1: Refer to the figure of “3.5 Lubrication” for detail of lubrication port and drain port.
Replacement Applicable Lubrication Lubrication

Application Size Tightening torque
point grease amount port
Axis 1 VIGO More than Lubrication Plug Rc-1/4 29.4 Nm
reduction gear RE No. 0 45,00 cc Drain Plug Rc-1/4 29.4 Nm
Axis 2 More than Lubrication Plug Rc-1/4 29.4 Nm
(ditto)
reduction gear 2,300 cc Drain Plug Rc-1/4 29.4 Nm
(ditto)
(ditto)
(ditto)
(ditto)
Density of grease: VIGO RE No.0 ; 0.9 g/cc
3-16
Moving range
in slow speed
Axis 1 Connection of drain hose and connector

Axis 1 Recommended posture and moving range
Moving range in
slow speed Recommended posture
Axis 1 Any
Axis 2 90°
Axis 3 Any
Axis 2 Connection of drain hose and connector Axis 2 Recommended posture and moving range
Recommended posture
Axis 1 Any
Axis 2 90°
Axis 3 0°
Moving range in slow s

peed
Axis 3 Recommended posture and moving range

Axis 3 connection of the drain port
3-17
Recommended posture
Axis 1 Any
Axis 2 0° (*)
Axis 3 90° (*)
Axis 4 0°
Axis 5 0°
Axis 6 0°
Moving range in slow

speed
Axis 4,5,6 connection of the drain port

Axis 4,5,6 Recommended posture and moving range
(*) If Axis 2 and 3 cannot make this angle, make the upper arm angle horizontal.
Air supply
Air precision regulator
Pushing out the surplus grease using air pressure
3-18
How to replace the grease in the support bearings (link and hinge)
(1) Place a container to receive grease ejected under the drain port.
(2) Remove the socket head plug RC-1/8 in the drain port.
(3) Use a grease gun to feed grease. At this time, operation must be done keeping the feeding speed to
40cc per 10 seconds or less. Keep the operation until the grease color that is pushed out from the drain
port change to a color of new grease.
(4) Wrap seal tapes on socket head plug [Rc-1/8] and attach to the drain port.
(NOTE) Socket head plugs are in the lubrication port of the hinge support points. Please attach grease
nipples RC-1/8 instead of the socket head plugs and start the lubrication work shown as above.
Lubrication
Replacement point Applicable grease Application Lubrication port Size Tightening torque
amount
Link MOLYWHITE Air release Nipple Rc-1/8 12.7 N･m

Upper fulcrum 250 cc
RE No.00 Drain Plug Rc-1/8 12.7 N･m
Link Air release Nipple Rc-1/8 12.7 N･m
Lower fulcrum (ditto) 250 cc
Drain Plug Rc-1/8 12.7 N･m
Axis3 Air release Nipple Rc-1/8 12.7 N･m
Right side fulcrum (ditto) 200 cc
Air release Nipple Rc-1/8 12.7 N･m
Axis3
Left side fulcrum (ditto) 200 cc
Density of grease: MOLYWHITE RE No.00 ; 0.87 g/cc
3-19
3.7 Battery replacement
The robot uses lithium batteries for the backup of encoder data. If the battery voltage drops below
the given limit, the data will not be kept normal.
Replace the batteries every 8 years. (Under a condition of 8 hours ON and 16 hours
IMPORTANT OFF every day)
The replacement period varies with use environments (mainly temperatures).
Furthermore, if the battery voltage drops below the given limit, an error indicating the
IMPORTANT voltage drop will be displayed on the controller. In this case, be sure to replace the
battery corresponding to the error displayed.
Replace the batteries with controller power ON. Replacing the battery with controller
IMPORTANT power OFF can result in encoder data error, thus requiring the resetting of the encoder.
Do not store the batteries in places with high temperature and high humidity. Store them
in well-ventilated places to avoid dew condensation. It is recommended to store the
IMPORTANT batteries in places with less temperature changes at ambient temperatures (20±15°C)
and relative humidity of not more than 70%.
Discarding lithium batteries according to your local trash separation rule
When discarding used lithium batteries, insulate the electrical terminals.
IMPORTANT And then follow the respective trash separation rules in your local district
and discard them separately as “Used lithium batteries”.
Tools required Torque wrench for M5 (Tightening torque 5.0 Nm)

Double coated adhesive tape
Nipper, Cable tie
Battery replacement procedure

STEP Work performed
1 Turn ON the controller power.
2 Lock the robot by pressing the emergency stop button.
Remove the bolts of the battery
unit fitting panel on BJ1 BOX
left side.
Pull out the battery unit from the BJ1 BOX.
Battery Unit KP-ZA-011

Disconnect the connecters.
Although a warning message (encoder battery
voltage down) is displayed, there is no problem.
Please proceed with the next procedures.
5
3-20
STEP Work performed
Remove the cable tie C to remove the battery unit from the case.
Do not cut the orange

Double coated cable tie. This can be vinyl bag
adhesive tape used again.
6
C B case
7 Attach the new battery.
To replace battery unit To replace the respective batteries one by one

Connect 7 connectors. (1) Replace the concerned battery to a new one.
Install the battery unit to the case with (2) Fix each battery with double coated adhesive tape.
cable tie C. (3) Put the battery in the vinyl bag and fasten cable tie A.
(4) Fasten the vinyl bag with cable tie B.
8
Finally, install the battery unit to the case with cable tie C.
To robot side (CNBAT1～6,2A)
Place the battery unit fitting plate to the original position and fix it with bolts.
9
If the battery unit fitting plate is damaged, please replace it.
10 Turn OFF the controller power and ON again.
3-21
3.8 Balancer protection cover replacement
Balancer protection cover
Axis 2 balancer
Axis 3 balancer
Balancer
protection cover
Protection cover (silver cover) is used to protect the balancer shaft from the damage and the
accumulating of welding spatters or cutting dusts.
If any loosening or transformation is found in inspection, please correct it. And if remarkable damage
is found, please replace it.

Name Purpose Q’ty Remarks
Nippers To cut the steel band or the cable 1 (Get this in the market)
tie (orange plastic band) Basically, this is not used.
But, use this if necessary.
(e.g. When it is very
difficult to remove the
band)
Pliers To fasten / flat the steel band 1 (Get this in the market)
Please prepare one that
can hold the steel band
tightly.
Parts cleaning spray To clean the balancer rod and inner 1 (Get this in the market)
(Degreaser) surface of the protection cover.
E.g. “ThreeBond 2706”
Agent for penetrative To lubricate / rustproof the rod 1 (Get this in the market)
lubrication (spray) surface and the lip of the scraper
“ThreeBond 1801B” part.
3-22
Balancer protection covers replacement procedure
STEP Work Point
Install 2 steel bands to the new protection cover by The position of the steel band should be left
referring to the following picture. side.
Steel band (long)
Face (Silver)
Steel band (short)
(In case of Axis2 balancer) This is only to keep the enough work space.
Set the Axis 2 to 90 degrees. The angle of other axes does not matter.
(In case of Axis3 balancer)
Set the Axis 3 to 0 degrees.
Then turn OFF the controller power OFF.
Axis2 is 0
degree.
Axis2 is 90
degrees.
Remove the cover in the following order. Steel band edge is very sharp. Be careful to
1. Cut the steel band on the upper and lower side of handle it.
cover, by using nipper.
2. Remove cover.
Balancer cover Cut the steel band on the upper Open the cover and
and lower side of cover, by using remove it.
nipper
4
Cut the left corner of
steel band
Case side Rod side

(top) (bottom)
Wipe and clean the balancer rod surface. Use a parts If dusts remain on the surface, the seal part of
cleaner spray (degreaser) and clean wiping cloth. After the unit may be damaged and cause oil leakage
that, spray “ThreeBond 1801B” to the whole rod etc. And, pay attention not to damage the rod
surface and the lip portion of the scraper part. Then surface. And, parts cleaner must be applied only
wipe the rod surface lightly so that thin oil slick is left.) for the metal surface of the rod. Because it may
damage the scraper part in the balancer. Be
careful.
5
Spray “ThreeBond 1801B” to the
whole rod surface and the lip portion
Clean the rod surface. of the scraper part. Then wipe the
rod surface so that thin oil slick is
left.)
3-23
STEP Work Point
Attach the new cover to the balancer. Attach the cover so that its silver surface faces
Turn and adjust the position of the magic tape the outside. Please pay attention not to make
fastening line so that its position faces the back side of wrinkles on the magic tape when closing it.
the robot to avoid the welding spatter, cutting dusts etc.
that come from the front side of the robot.
Magic tape and

Balancer protection cover Front side of the robot the steel band
head part
Axis 2 balancer
Axis2 balancer
The magic tape

and the steel band
head part should
be in this area. Back side of the robot Axis 3
Balancer
Align the position of the steel band (upper side) to the Pay attention to the surface/backside of the head
groove of the balancer unit case and then fasten the part of the steel band. The tip of the band comes
steel band lightly using finger. out from the cover.
Align the steel band position to Insert the steel band Then fasten it lightly
the groove of the case. to its head part. using finger.
9 This surface should

face outside
(1) (2) (3) (4)

Before fastening the steel band tightly, adjust the If the head part’s position is not adjusted, the tip
position of the head part. The head part should be of the band cannot be inserted to the hole. If the
placed around the stitch line of the cover. Insert the tip of the band comes out, it scratches the
steel band in the hole of the cover. surface of the cast part and the band will be
broken.
The head part of the band should be Leave the margin so that the band
placed around the stitch. can be pinched by the pliers.
10
Insert the steel band to this hole

of the cover.
3-24
STEP Work Point
Fasten the steel band tightly using pliers. After Fasten the band paying attention not to change
fastening, please confirm that the cover does not turn the position of the head part.
or come out by shaking it.
This work may become easier
Pliers when pinching this portion with
pliers and turn toward the
arrow direction.
11
Fix the twist of the steel band and make it flat. If the twist is too large, the portion may scratch
(Make surface of the band become lower than the top the surface of the cast part of the robot and
edge of the head part.) cause a steel band’s breakage, scratch noise,
etc.
Make these twists flat using

the pliers.
12
Next, fasten the lower steel band (rod side) lightly Pay attention to the surface/backside of the head
using finger. part of the steel band. The tip of the band comes
out from the cover.
This surface should
face outside
13
(1) Insert the steel band to its head. (2) Then fasten it lightly using finger.
Before fastening the steel band tightly, adjust the This work should be done before fastening the
position of the head part. The head part should be steel band tightly. (After fastening the band
placed around the stitch line of the cover. Then insert tightly, this work will become difficult.)
the steel band in the hole of the cover. It is recommended to insert the tip of the band to
Insert the steel band to the hole before tightening the band using finger.
The head part
should be placed this hole of the cover.
around the stitch
14 line of the cover.
Leave the margin so that the band

can be pinched by the pliers.
3-25
STEP Work Point
Fasten the steel band tightly using pliers. This work may become easier when pinching
Pliers the portion around the head part with pliers
and turn toward arrow direction.
This work may become easier
when pinching this portion with
pliers and turn toward the
arrow direction.
Pick at the cover around the position shown in the

15 picture and then lift it with small power (0.1 – 0.2kgf). If
the position of the steel band does not change, it is OK.
Pick around here and If the steel band is fastened too much or the
lift a little with small band is pinched with the cover, it becomes
power.
difficult to adjust the position of the steel band. In
a case like that, cut the steel band and replace it
with new one.
Fix the twist of the steel band and make it flat. If big twists are left, a cover breakage,
(Make surface of the band become lower than the top interference between the steel band and other
edge of the head part.)
parts, etc. may occur.
Head part of the steel Make the steel band
band flat using pliers.
16
Attach the new light tape on the cover. (This is for the
2nd axis balancer. Not for the 3rd axis balancer.)
Balancer
Attach the tape at this

17
position. Align the tape
New light tape to the bottom line of the
case.
Cover
Turn ON the robot controller power and move the robot Check that the steel band does not get loose or
18 manually. Please check there is not interference, scratch the cover or the robot surface.
scratch sound, etc.
3-26
Chapter 4 Troubleshooting
■Troubleshooting procedures
When any abnormality occurs during robot movement or operation, if there is no problem with controller, then it
is due to the damage of mechanical parts. To solve troubles promptly, it is necessary to have a grasp of
symptoms, and then judge which part is defective to cause the trouble.
Step 1: Which axis has caused the abnormality?

First, judge which axis has caused the abnormal symptom. If abnormality doesn’t appear with movement and
hard to judge, then check abnormal sounds, heat and backlash to find it.
Step 2: Which part has damages?
If the abnormal axis is found out, examine what part is the cause. You might find several causes to one
symptom.
Step 3: Steps for defective parts
If the defective parts are found, please fix them. Some can be fixed by customers, but for difficult tasks,
please contact NACHI Service Department.
Trouble symptom
Shaking while in operation
Abnormal heat generation

Gravity drop of axis
Sway when stopped
Abnormal deviation
Irregular twitching
Abnormal sound
Displacement
Malfunction
Overload
Counter-measure
Defective
Part
・Please replace the encoder, in case there are some points in which position data shows
irregular change, and there is no problem with wirings.
Encoder ○ ○ ○ ○ ○
･When the drive unit is replaced with another controller and symptom is transferred, replace the drive
unit.
・Turn motors off, and check, whether or not the brake makes “click sound” by operating the
brake release switch *1 (option) ON/OFF. If no click sound, brake line (wiring) may be
Brake ○ ○ ○ ○ broken. Manipulator wiring needs to be replaced. Please contact our Nachi Service
Department
・If click sound is heard, replace the motor since brake is inside the motor body.
・Check whether or not abnormal vibration or heat or sound occurs while robot moves. If
some abnormality is found, check the density of steel dust in the grease of reduction gear
Motor ○ ○ ○ ○ ○ ○ ○ ○ ○
(refer to "3.3 Inspection of grease") If density exceeds the criterion, reduction gear needs to
be replaced. Please contact our Service Department.
・If density has no problem, replace the motor. If abnormality occurs in axis 2, balancer unit
and their bearings need to be checked also by referring to the explanation written below.
・If possible, set the brake release switch (option) to ON and check, whether or not you can
Reduction sense the abnormality by pushing robot arm with your hand. If you can sense some
○ ○ ○ ○ ○
gear abnormality, replace the motor.
・If trouble can not solved by replacing motor, reduction gear needs to be replaced. Please
contact our Service Department.
・Check the pressure of nitrogen gas in balancer unit. If the pressure is out of criterion range, nitrogen
gas needs to be filled or released. If the pressure is within criterion range, replace the motor or the
reduction gear. If the pressure does not raise up sufficiently, balancer unit itself needs to be replaced.
Balancer
○ ○ ○ ○ ○ ○ ○ Please contact our Technical Department. (Refer to "3.4 Inspection of balancer unit and filling gas")
bearing
・Check whether or not abnormal vibration or sound occurs from the bearings of balancer unit. If some
abnormality is found, bearings or balancer unit itself needs to be replaced. Please contact our
Technical Department.
・Check whether or not fixing bolts are loose. If they are loose, tight them with proper torque.
Check whether or not foreign obstacles are caught in swivel base or base plates. If some
parts are found, remove them. Check whether or not base plates have unevenness. If
Installation plate,
○ ○ ○ ○ found, correct them within the criterion level. (refer to "2.3 Installation procedure").
Raiser
・Check whether or not floor/raiser have any unevenness. If that stiffness is not enough,
replace the floor/raiser or modify the robot teaching program, i.e., “Reduce the step speed”
or “Record smooth parameter”. (Refer to “Basic Operations manual” ”Chapter 4 Teaching”)
・If the tool is not stiff enough, tool itself may repeat vibrate near the stop position. In this
case, robot teaching program is needed to be modified. For example, “Reducing the step
speed” or “Recording smooth parameter”. (Refer to “Basic Operations manual” ”Chapter 4
Tool ○ Teaching”)
・Examine the weight, COG and inertia of the tool. If one of them does not meet the
specification, reduce the load of the tool. Also if one of them does not match with tool
parameter, modify tool parameter.
*1 <Caution> When operating the brake release switch, never forget that robot arm must be held using a crane, chain hoist or other means before
releasing. If brake release switch is operated without supporting robot arm, in case of axis 2, forearm will fall down to the front or back (:*Due to
the payload and robot posture.) In case of axis 3, forearm will fall down. In case of wrist axes, wrist and tool will fall down or rotate quickly. All
these possibilities can lead to serious injuries
4-1
4.1 Motor replacement
Never forget to hold robot arm or wrist/tool in advance. If motor is disengaged without
supporting them, forearm will fall down to the front or to the backwards. (due to the
payload and robot posture) in case of axis 2, forearm will fall down in case of axis 3, wrist
and tool will fall down or will rotate quickly in case of wrist axes, possibly resulting in
serious injury.
To hold robot arm, use a crane
or chain block etc. To hold axis 2
and 3, wooden blocks or fixing jig
WARNING set (option) can be used.
Note that zeroing pin and block
are not for supporting arm.
Furthermore, Never attempt to
hold robot arm with hands.
If the motor is dismounted
アームを保持せずに
without holding the arm<
モータを外すと…
When touching the motor immediately after robot stop operating, be sure that motor is
NOT HOT and then touch it with attention.
CAUTION
The motor mass is listed below. Because of its weight, handle the motor with full
attention
Robot type Axis 1,4,5,6 Axis 2,3 Axis 6
CAUTION All 20.7 kg 28.4 kg 11.0 kg
This work includes some jobs that should be conducted with motors ON. Consequently,
be sure to conduct the work at least by a pair of two persons. One person must stay on
guard to press an Emergency Stop button at any time, while the other person must
CAUTION promptly finish the work with thorough attention paid to the robot operating area.
Furthermore, prior to starting the work, check for safe corridors.
Tools required(*Customer preparation required.)

Part name Axis Part No. (Model)
Axis1 M3 torque wrench
Torque wrench M5 torque wrench (Long type L>=220 mm)
Axis 2,3,4
Or M5 L type torque wrench
Axis 6 M6 torque wrench
Axis 5 and 6 M5 torque wrench
Torque wrench L type Torque wrench Axis 1 and 5 M5 torque wrench (Long type L>=120 mm)
Axis 1 to 5 M12 torque wrench (Long type L>=280 mm)
Axis 6 M8 torque wrench (Long type L>=280 mm)
Locking agent Axis 1,5, and 6 ThreeBond 1374
Axis 5 LONGTIME PD2 (Compatible; ALVANIA RA-J)
Grease
Axis 1,2,3,4, and 6 VIGO grease RE No.0
Lubrication Axis 1 to 5 ThreeBond 1801B
DV24V power supply Axis 1,2,3, and 5 (purchase in market)
Dial gauge Axis 1,2,3, and 5 (purchase in market)
Be absolutely sure to use the torque wrench to tighten

the bolts with the specified torque.
In case of tightening the bolts on circumference,
tighten them equally and gradually.
Order to tighten bolts
To enable quick replacement, “Coupling gear set” is prepared as a spare part.
“Coupling gear set” includes motor fixing bolts and sheet packing. When replacing a motor and
using this “Coupling gear set”, replace all the old bolts, O-rings and sheet packing to new ones in
spite of their damage level.(*Those are included in this set.)
4-2
4.1.1 Motor replacement (Axis 1, and 5)
STEP Required work Check points

If possible, operate the robot arm manually to the reference If zeroing pin is inserted in advance, there is
1 position and insert zeroing pin. some case that the work after replacement
Refer to “4.1.5 Encoder correction” is easier.
2 Hold the arm using a crane, chain block or other ways.
3 Turn OFF the controller power.
Disconnect the connectors (encoder and power) from the ・Remember that the encoder data will be
motor. lost when the encoder connector is
disconnected.
・ Do not apply large pressure onto the
Encoder encoder connector. If large pressure is
4
applied, the connector may be broken.
Power
Loosen the motor fixing bolts and dismount the motor from ・Do not to apply excessive impact to the
the robot. motor shaft.
Axis 5 motor fixing bolts

Axis 1 motor fixing bolts 4-M12X35
4-M12X35 Axis 5 motor
(Tightening torque: 116 Nm)
(Tightening torque: 116 Nm)
6 Remove the encoder plug cover if necessary.

Refer to “4.2 Encoder replacement”
Remove the gear assembly from the motor shaft. ・Do not apply excessive impact to the motor
shaft.
(a) Loosen the fixing bolts and remove the gear. ・To remove bearing, remove the snap ring
(b) Remove the bearing from the shaft. and use a pulley remover in market and
(c) Remove the fixing bolts and remove the shaft. align the hook on the internal bearing. (Do
(d) Remove the collar, the ring(x2), and the holder. not align the hook on the external bearing to
avoid any damages on it)
Axis 1 Gear assembly Axis 5 Gear assembly
4-3
Attach the removed shaft to the new motor. ・Apply a thin coating of ThreeBond 1801B to
(a) Attach the holding plate, the shaft of the new motor and two rings in
ring X2 and collar. advance.
(b) Attach the shaft using the ・Do not apply excessive impact to the motor
fixing bolts.
shaft.
・Pay attention to the direction of ring.
Direction of ring
After assembly, measure the run-out tolerance of gear.
If the run-out tolerance exceeds 0.1 mm, loosen the gear
8 fixing bolts and repeat the steps from (b)
<How to measure the run-out fluctuation > Axis

第 1 軸：1 73mm
: 73mm
・It is necessary to release the brake inside the motor and rotate Axis
第 5 軸：5 55mm
: 55mm
gear by hand. To release the brake, supply DC24V voltage
between pin A and pin B in the CNMB* connector. (A:+24V,
B:0V)
・The run-out fluctuation should be measured using a dial gauge
by referring to right figure.
CNMB* connector
CNMB*コネクタ
Attach the removed gear assembly to the shaft. ・The bearing should be installed by pushing
(a) Attach the bearing to the shaft. the inner side ring using collar etc. If the
9 (b) Attach the gear to the shaft. At this time, apply one or two outer ring is pushed, the bearing may be
drops of locking agent (ThreeBond 1374) to the threads at broken.
the ends of the bolts, and then tighten the bolts.
Mount the motor to the robot. ・Remember not to damage the gear surf
If the sheet packing is damaged, please replace it to the new ace when attaching the motor.
one. Locate it carefully by referring to the following figure. ・If the sheet packing is damaged, replace
Place the sheet packing so that it.
4 portions of cut hole are
coincident with the spot facing
10 groove of motor. (mark ※)
11 Connect the connectors (encoder and power) to the motor.

Perform encoder reset of replaced motor.
13
Refer to “4.1.4 Encoder reset”
Perform encoder correction of replaced motor.
14
Refer to “4.1.5 Encoder correction”
Remove the zeroing pin. ・If axis is operated by mistake without
Ensure that the robot operation presents no problem. removing zeroing pin, pin and/or pin hole
15 may be deformed and it’ll be impossible to
remove zeroing pin and perform encoder
correction properly in the future.
4-4
4.1.2 Motor replacement (Axis 2, 3, and 4)

Hold the arm using a crane, chain block or other means. In If the motor of Axis 2 or Axis 3 is removed
case of Axis 2 or Axis 3, use wooden brick or arm fixing jig without holding the arm, the arm may move
(option) to fix the arm securely. forward or backward and result in serious
And, when performing this work after releasing the gas injury.
2 pressure of the Axis 2 gas balancer, please pay special
attention to the robot posture because the arm may fall
down.
Refer to “How to release gas in case that pressure
was higher than criterion range” in the Chapter 3.
Disconnect the connectors ・Remember that the encoder data will be
(encoder and power) from Encoder
エンコーダ lost when the encoder connector is
the motor. disconnected.
4 ・ Do not apply large pressure onto the
Power encoder connector. If large pressure is
パワー applied, the connector may be broken.
In case of axis 2 and 3, place a vinyl bag for catching the ・Case of axis 2 or 3, grease will come out
grease under the motor. when the motor is removed.
・Fix the vinyl bag firmly by using adhesi
ve tape or some other ways
5
Prepare vinyl bag here to
ビニール袋でグリースを
catch the grease as it oozes
受け止める準備をしてく
out.
ださい。
Loosen the motor fixing bolts and disconnect the motor from ・Before disconnecting motor, be sure that
the robot. NO STRESS ON ROTATING DIRECTION
OF MOTOR while attachment bolts are
loosened. If motor can not be rotated by
hand, this shows that there are some
pressures around the motor. In this case,
motor will rotate in such high speed as soon
as attachment bolts are removed, and might
RESULT IN SERIOUS INJURY. Double
Axis 2 motor fixing bolts Axis 3 motor fixing bolts check the way of holding robot arm.
4-M12X35 4-M12X35 ・Do not apply excessive force on the motor
6 (Tightening torque 116 Nm) (Tightening torque 116 Nm)
shaft.
・Be sure not to damage lip of the oil seal by
the gear attached to the motor shaft.
Axis 4 motor fixing bolts
4-M12X35
(Tightening torque 116 Nm)
Remove the encoder plug cover if necessary.

7
4-5
Remove the gear assembly from the motor shaft. ・Do not apply excessive force to the motor
shaft.
(a) Loosen the fixing bolts and remove the gear. ・To remove bearing, remove the snap ring
(b) Remove the collar, ring X2 and holding plate. first then, using pulley remover in market to
remove bearing. (By knocking the bearing to
In case of axis 4, bearing needs to be removed at first remove might cause damages on bearing.
if M5 long type torque wrench is used. So hook the pulley remover finger to the
inner side of bearing)
Axis 2,3 Gear assembly Axis 4 Gear assembly

Attach the removed gear assembly to the new motor. ・Apply a thin coating of ThreeBond
(a) Attach the holding plate, 1801B to the shaft of the new motor
ring X2 and collar. and two rings in advance.
(b) Attach the gear using the ・Do not apply excessive impact to the
fixing bolts. motor shaft.
・Pay attention to the direction of ring.
Direction of ring ・The bearing should be installed by
pushing the inner side ring using collar
In case of axis 4, bearing needs to be mounted at first if etc. If the outer ring is pushed, the
M5 long type torque wrench is used. bearing may be broken.
After assembly, measure the run-out tolerance of gear.

9
If the run-out tolerance exceeds 0.1 mm, loosen the gear fixing
bolts and repeat the steps from (b)
<How to measure the run-out fluctuation > Axis 2,3軸：170mm

第 2、3 : 170mm
・It is necessary to release the brake inside the Axis 4 : 105mm
第 4 軸：105ｍｍ
motor and rotate gear by hand. To release the
brake, supply DC24V voltage between pin A and
pin B in the CNMB* connector. (A:+24V, B:0V)
・The fluctuation should be measured using a dial
gauge by referring to this drawings
CNMB* connector
CNMB*コネクタ
Remove the encoder plug cover if necessary.

10
4-6
Mount the motor to the robot. ・Be sure to use torque wrench to tighten
If the sheet packing is damaged, please replace it to the new bolts. Tightening should be done equally and
one. Locate it carefully by referring to the following figure. gradually.
・Be sure not to damage the gear surface
Make sure to set 4 cut holes when attaching the motor.
of sheet packing matches
with the spot facing notches
11 of the motor. (※marked)

In case of Axis 2 or 3, supply the same amount of grea
13 se as the lost grease. (VIGO grease RE No.0)
15
16
Remove the zeroing pin. ・If axis is operated without removing zeroing
Make sure that there is no problem with the robot operation. pin by mistake, then pin and pin hole may be
disfigured. And furthermore, it becomes
17
impossible to remove zeroing pin and
perform encoder correction properly in the
future.
4.1.3 Motor replacement (Axis 6)

Hold the tool and the wrist unit using a crane, chain block or
2 other means.
Disconnect the connectors (encoder and power) from the ・Remember that the encoder data will be
motor. lost when the encoder connector is
disconnected.
・ Do not apply large pressure onto the
encoder connector. If large pressure is
4 applied, the connector may be broken.
Power Encoder
4-7
Loosen the motor fixing bolts and dismount the motor from ・Before dismounting motor, confirm that no
the robot. stress is applied on motor rotating direction
while attachment bolts are loosened. If
motor can not been rotated by hand, some
stress still remains. In this case, motor will
rotate in high speed when attachment bolts
are removed, and possibly resulting in
serious injury. Improve the way of holding
5 robot arm.
Axis 6 motor fixing bolts ・Do not to apply excessive impact to the
3-M8X35
※ motor shaft.
(Torque : 33.3 Nm) ・Take care not to damage the oil seal lip
The bolt of ※ mark (M8X25) by the gear attached to the motor shaft.
should be removed in the next
step.
Remove the gear assembly from the motor shaft. ・Do not to apply excessive impact to the
motor shaft.
(a) Remove the inner side fixing bolts to dismount the gear.
(b) Remove the motor case fixing bolts to dismount the
motor case.
6
O-ring
ROA-043
O-ring
CO0554A
Axis 6 motor gear assembly

Attach the gear assembly to the new motor. ・ Wipe and clean the shaft of the new
motor in advance to remove the dusts and
Attach the gear to the attachment shaft. At this time, a the redundant oil etc.
7 ・Do not to apply excessive impact to the
pply one or two drops of locking agent (ThreeBond 137
4) to the threads at the ends of the bolts, and then tig motor shaft.
hten the bolts.
Mount the motor to the robot. ・Bear in mind to use torque wrench to
tighten bolts. Tightening should be done
equally and gradually.
8 ・ Bear in mind not to damage the gear
surface when attaching the motor.
・If the O-ring is damaged, replace it with
new one.

11
12 Refer to “4.1.5 Encoder correction”
Remove the zeroing pin. ・ If axis is operated by mistake without
Ensure that the robot operation presents no problem. removing zeroing pin, pin and/or pin hole
13 may be deformed and it’ll be impossible to
remove zeroing pin and perform encoder
correction properly in the future.
4-8
4.1.4 Encoder reset
This procedure is to initializing clearing the internal memory in encoder itself.

This procedure is absolutely necessary for the recovery after encoder is replaced or encoder
connector is disconnected or encoder batteries are disconnected or error 0030 (encoder absolute
data error) has been occurred.
No special tools are required for encoder reset procedure.

Please refer to the instruction manual “SETUP”, “4.3.3 Encoder reset and encoder correction”.
4.1.5 Encoder correction
This procedure is to registering the “encoder correction data” so that encoder data becomes the
“pre-determined value” at the “pre-determined position”. This position is called “Reference
position”. Zeroing pin and blocks are used to make this posture.
After performing encoder reset, THIS PROCEDURE MUST BE PERFORMED.
Because the load condition and robot posture may have influence on the reference position,
perform encoder correction for all axes after all of the load are equipped on wrist and upper
arm AND before staring the teaching procedure. (There is no need for encoder resetting
procedure.)
(1) For this procedure, following tools are required.

zeroing pin and block (OP-T2-090 ; option)
Please prepare these tools by referring to ”Chapter 5 Recommended spare parts and
special tools for maintenance”.
(2) By referring to the figures on next page, move the robot (target axis) to the reference
position in manual operation (speed 2 or 3)
As for axis 1, 2, 3, 5 and 6: The zeroing pin is inserted at the reference position.
As for axis 4: After attaching zeroing block, the zeroing pin is inserted at the reference
position.
(3) Register the encoder correction data by referring to the instruction manual “SETUP”, “4.3.3
Encoder reset and encoder correction”.
(4) Confirm that current position data matches with “Encoder data of reference position”.
Current position data can be read in <Service utilities> [4 Monitor 2] [2 Axis Position].
(5) Make sure to remove the zeroing pin (and block).
And confirm that there is no problem with the robot operation.
When motor is replaced, it’s possible that software stroke error occurs and robot can not
arrive in the reference position. Because software is checking the working envelop
INFO. although the position data is not correct.
In this case, once register the encoder correction data in that (incorrect) position. After
that, turn the motor power on again and move the robot to the correct reference position.
(now working envelop is already refreshed.) Finally register the encoder correction data
again.
If robot is operated without removing zeroing pin, pin itself or pin hole may be disfigured..
If robot is operated without removing zeroing block, parts where block is equipped, arm
and tool may be seriously damaged because zeroing block interferes with arm or tool.
CAUTION
Be sure to remove zeroing pin and zeroing block before starting operation.
4-9
Reference position and its encoder data are explained in following figures.
These encoder data are very important to check the successful procedure of encoder
IMPORTANT correction.
■ Reference position (Zeroing pin insertion points) of Axis 1, 2 and 3
Encoder data
of reference position
Axis 1 80,000[Hex]
Axis 2 80,000[Hex]
Axis 3 80,000[Hex]
4-10
■Reference position (Zeroing pin insertion points) of Axis 4
■Reference position (Zeroing pin insertion points) of Axis 5 and 6
Encoder data
of reference position
Axis 4 80,000[Hex]
Axis 5 80,000[Hex]
Axis 6 80,000[Hex]
4-11
4.1.6 More accurate encoder correction
Sometimes normal encoder correction (using zeroing pins and blocks) is not sufficient to recover
the taught positions precisely in case that bigger tool is equipped, etc. In such case, modify (re-
calculate) the encoder correction value by following procedure after here.
Tools required;
・Jig that can fixed on the ground or on the table for “Reference teach point”
・Calculator (Needed to re-calculate the encoder correction)
Preparation
1 Making a program of “Reference teach point”
Within the robot motion range, install the jig for “Reference teach point“ that is fixed
on the ground or on the table. Make a program including a step where robot TCP is
precisely match with the “Reference teach point”. This step is called “Step of reference
teach point” here in after. This procedure must be done before the teaching operation is
started.
(Example 1)
Secure the same clearance

around the circumference
(several millimeters)
Teach
this point Jig
TCP
基準点 teach point
Reference
Fixed side tip of Table

welding gun
Notes: In case of welding gun, precise “Step of reference teach point” can not be
obtained when worn tip is used or tip is not pushed in enough.
(Example 2)
Tool
Jig
Teach
this point

Reference
TCP
Table
S ecure the same clearance
around the circumference
(several millimeters)
4-12
More accurate encoder correction
In case that motor / encoder is replaced or encoder reset is performed at the same time
for plural axis, position recovery by this procedure is very difficult.
CAUTION This procedure must be performed for only one axis (one by one).
Sample for axis 1

1 Perform encoder reset and normal encoder correction
Perform encoder reset and normal encoder correction by following to
“4.1.4 Encoder reset” and
“4.1.5 Encoder correction”
(*This operation requires you to switch qualification to EXPERT.)
2 Check the difference from “Reference teach point”
By check GO operation, move the robot to the “Step of reference teach point” and stop
the robot in status that align with the axis. (Cursor line changes to yellow in the display).
If the distance from TCP and “Reference teach point” are acceptable range for work,
＋
then procedures after this is not required. If it’s not acceptable, please modify the
encoder correction value of target axis by following the procedure next.
Difference

Reference
ツール先端
TCP
(Caution)
*Check GO operation must be started from the position where it doesn’t interfere with
the jig.
3 Take a note of encoder current data (A)
While holding the enabling switch, open <Constant setting> [3 Machine constants] –
[4 Encoder correction]. Then read the “Encoder current data” in [Data input] screen and
take a note. Consider this numerical value as (A).
Encoder correction Encoder current

values data
MC400L-01:
Take a note of this
numerical value= (A)
4-13
4 Move TCP to “Reference teach point” in manual operation
Move the robot by manual operation for the target axis of encoder correction (J1 axis
in this case.) with 2 or 3 slow speeds to make sure that TCP matches with “Reference
teach point”.
＋
Difference X- X+
X- X+
Move TCP to “Reference

teach point” in single axis
manual operation
(Supplement)
If the axis that does not concern with the target axis was moved by mistake, please
retry the procedure from step 2.
5 Take a note of encoder current data (B) after TCP is moved
While holding the enabling switch, open again <Constant setting> [3 Machine
constants] – [4 Encoder correction]. Then read the “Encoder current data” at [Data
input] screen and take a note. Consider this numerical value as (B).
Encoder correction Encoder current

values data
MC400L-01:
Take a note of this
numerical number = (B)
6 Press the Emergency Stop button to turn the motor power OFF.
(At this time, enable switch can be released.)
7 Re-calculate the encoder correction value

Calculate
(Encoder correction value) – ( (A) – (B) )
Calculate by calculator and put the result to the edit box of “Encoder correction values”
at the same screen. (*Utilize the table of next page for your convenience.)
8 Press f12 [Complete].
>> The adjusted encoder correction value is saved in the internal memory.
(*Caution!)
*Remember, until you press [Complete] key, the encoder correction value WILL
NOT BE SAVED into the internal memory.
9 Turn the Emergency Stop button right to release, and turn the motor power ON again.
4-14
10 By check GO operation, move the robot again and confirm that TCP surely aligns with
“Reference teach point”. If not, new encoder correction value calculated in step 7 is
wrong. Try the calculation again.
OK NG
(Supplement)
Target of this procedure is to get the encoder correction value so that TCP aligns with
“Reference teach point” at high accuracy. Therefore, it is possible that, Instead of doing
step 2 to 6, changing (adjusting) the encoder correction value manually little by little
while checking the TCP position visually.
11 If necessary, try check GO operation of work program and confirm the positioning
accuracy of taught points.
(Reference) Utilize this table to calculate encoder correction
Encoder current data Encoder current data

Original encoder Re-calculated encoder
where TCP doesn’t align after moved (where TCP
correction value correction value
Axis with “Reference teach aligns with “Reference
point” teach point”)
(C) (C)-((A)-(B))
(A) (B)
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Register this value

as the “new encoder
correction value”
(Example)
Encoder current data Encoder current data
Original encoder Re-calculated encoder
where TCP doesn’t align after moved (where TCP
correction value correction value
Axis with “Reference teach aligns with “Reference
point” teach point”)
(C) (C)-((A)-(B))
(A) (B)
520249 -
Axis 1 522027 522017 520249 (522027 - 522017)
= 520239
4-15
4.2 Encoder replacement
Since encoder can be separated from motor on all axes, the encoder is replaceable. However, tool
may not be inserted due to the robot posture. In this case, replace the whole motor unit by referring
to “4.1 Motor replacement”. This section describes the encoder replacement procedure when the
robot is in good posture where encoder can be replaced.
Required tools (*Customer preparation required.)

Part name Axis Part No. (Model) Remark
Axis 1 M3 torque wrench
Torque
M3 torque screwdriver which meets the tightening torque of 0.59 to 0.88 Nm
screwdriver
All axes M3 setscrew torque screwdriver which meets the tightening torque of 0.59 to 0.88 Nm
Locking agent Threebond 1374
Encoder replacement procedure (common for all axes)

If possible, operate the robot arm manually to the If zeroing pin is inserted in advance, there
1 reference position and insert zeroing pin. is some case that the work after
Refer to “4.1.5 Encoder correction” replacement is easier.
2 Turn off the controller power.
Remove the encoder plug cover. Axis 1: standard
3
Axis 2 and 3: optional
4 Disconnect the encoder connectors.
Disconnect the encoder from the motor.
(a) Loosen the fixing bolts and remove the encoder cover. ・At this time, do not to cause tension to the
5 (b) Remove the two bolts that fix the encoder fixing spring. encoder lead wire.
(c) Remove the two set screws that fix the encoder boss
part, and then pull out the encoder assembly from the
motor shaft.
Encoder protective cover Encoder lead wire

Encoder cover Motor base
2-M3X20
Tightening torque: 1.0 Nm Lead wire sheath
Washer 2-M3
Forming direction
4 - M3×20
Tightening torque after coating of
screw lock: 0.59 to 0.88 Nm
Lead wire rises here

エンコーダプラグカバー
Encoder Plug Cover
Encoder Plug Cover

Outline figure of encoder
4-16
Positioning plate
Encoder cover packing
2 - M3×10
Tightening torque after coating of screw Encoder cover
lock: 0.59 to 0.88 Nm
2 - M3×4 (Coming with encoder)
Tightening torque 0.59 to 0.88N・m
U-slot of boss part

Encoder Location pin
Dismounting of encoder unit Cross-section of encoder cover

Mount the new encoder to the motor. Clean the shaft and the installation surface
carefully in advance.
(a) Insert the encoder so that the U-slot of the encoder
boss part is aligned with the location pin on the motor
side.
・For this purpose, use the new setscrews
(b) Insert the encoder until the encoder boss part hits the (with screw lock) that comes with the
positioning plate of the motor shaft, and then tighten the encoder.
set screws of the boss part
6
(c) Tighten the encoder fixing spring by fixing bolts. ・Apply one or two drips of locking agent to
the bolts.
(d) Form the lead wire riser part so that the encoder lead ・At this time, apply one or two drips of
wire will follow the outer circumference of the protective locking agent to the bolts.
cover. Then, with the sheath of the lead wire pulled to the ・At this time, put the encoder packing in
riser part, put the encoder cover in place. After that, place.
tighten the fixing bolts.
7 Attach the removed encoder plug cover.

8 Connect the connector to the encoder.
9 Turn on the controller power.
Perform encoder reset of replaced encoder.
10
Perform encoder correction of replaced encoder.
11
Remove the zeroing pin.
12
Ensure that the robot operation presents no problem.
4-17
NOTE
4-18
Chapter 5 Recommended spare parts and
special tools for maintenance
Recommended spare parts are listed below. To purchase any parts, check the manufacturing No.
and date of the robot, and then contact our Service Department.
Classification A: Periodical maintenance parts B: Spare parts
Recommended spare parts
Robot model Remark
Classification
Recommended/unit
MC400L-01
MC600-01
Part No.
Name
(Model)
In use/unit
A GREASE ALVANIA-RA-J-16KG － 1 ○ ○ ALVANIA RA-J 16KG *1
A GREASE LONGTIME-PD2-18KG － 1 ○ ○ LONGTIME PD2 *1
A GREASE VIGOG-RE0-16KG － 1 ○ ○ VIGOGREASE RE0 16KG *1
A GREASE PM/W-16KG － 1 ○ ○ MOLYWHITE RE No.00 *1
A BATTERY ER17/50H 4 4 ○ ○ *2
A BATTERY UNIT KP-ZA-011 1 1 ○ ○ 4pcs of battery *3
A COVER SET SP-CS-015 1 1 ○ ○ Axis 1
A COVER SET SP-CS-016 2 1 ○ ○ Balancer protection cover (Axis 2 and 3)
B AC SERVO MOTOR MDMU402S2V3 3 1 ○ ○ Axis 1,4, and 5
B AC SERVO MOTOR MDMU602S2V3 2 1 ○ ○ Axis 2 and 3
B AC SERVO MOTOR MSMA302D7V3 1 1 ○ ○ Axis 6
B ENCODER DVOP3560 6 1 ○ ○ All axes *4
B COUPLING GEAR SET KP-ZH-193 1 1 ○ ○ Axis 1
B COUPLING GEAR SET KP-ZH-194 2 1 ○ ○ Axis 2 and 3
B BJ1 UNIT ASSY SP-BJ1-196 1 1 ○ ○ Robot cables *5
B BJ3 UNIT ASSY SP-BJ3-039 1 1 ○ Cables for hollow arm portion *6
B BJ3 UNIT ASSY SP-BJ3-040 1 1 ○ Cables for hollow arm portion *6
(*1) If MSDS (Material Safety Data Sheet) for chemical material such as grease is necessary, customer needs to require it to the
chemical material supplier.
(*2) In case of purchasing this in China, please order ER18505-2. This is compatible with ER17/50H.
(*3) In case of purchasing this in China, please order KP-ZA-011CN. This is compatible with KP-ZA-011. When replacing all
batteries in robot, please order battery unit which consists of all needed batteries.
(*4) When encoder cover is damaged, encoder itself may be damaged already. Please replace not only encoder cover but also
encoder itself.
(*5) The motor power cables (Axis 1 to 7) , the encoder cables (Axis 1 to 7), BJ 3B OX
the LS cables (Axis 1 to 3), and the application cables (see "1.4 Wiring and
piping diagram for application") are included in this cable set. The cables of
the hollow arm portion are not included. (See the right figure)
(*6) The motor power cables (Axis 5 and 6) and the encoder cables (Axis 5 and 6) A xis 4
motor
are included in this cable set. (See the following figure) BJ 1 UNIT
A SSY
BJ3 UNIT A SSY
(Hatched portion)
To the
B J2B OX ,
a xis 1 /2 /3
mot ors
BJ 3BOX
Axis 5/6 motors

A pplicat ion wirings/hoses are not
included in the BJ3 UNIT. B J1 PANEL
<Reference> Seals listed below are included in COUPLING GEAR SET and or so. Please refer them to order individually.
MC400L-01 MC600-01
Flange sheet packing included in COUPLING GEAR SET of axis 1 to 5 Seal : 037-0676-001
Seals included in Axis 6 coupling gear set O-ring : CO0554A
Seals included in Axis 6 coupling gear set O-ring : ROA-043
5-1
The fixtures listed below are required tools for maintenance work or for efficient work. To purchase
any parts, check the manufacturing No. and date of the robot, and then contact our Service
Department.
Special tools for maintenance (option)
Robot model
MC400L-01
MC600-01
Part No.
Name Remark
(Model)
ACCESSORY OP-T2-090 ○ ○ Zeroing pin & block
Axis 2
H-AXIS FIXING SET KP-ZD-030 ○ ○ Fixing jig set
Axis 3
MAINTENANCE TOOL KP-ZJ-068 ○ ○ Fixing jig set
Gas balancer unit
MAINTENANCE TOOL KP-ZJ-013 ○ ○ Analog pressure gauge
Gas balancer unit
MAINTENANCE TOOL KP-ZJ-014 ○ ○ Digital pressure gauge
Gas balancer unit
MAINTENANCE TOOL KP-ZJ-066 ○ ○ pressure measurement tool (L-shape joint)
Gas balancer unit
MAINTENANCE TOOL KP-ZJ-015 ○ ○ Charging equipment (W22,picth14,Female)
Gas balancer unit
MAINTENANCE TOOL KP-ZJ-016 ○ ○ Charging equipment (W23,picth14,Male)
Gas balancer unit
MAINTENANCE TOOL KP-ZJ-019 ○ ○ Joint of Female->Male (W22)
Gas balancer unit fulcrum portion
MAINTENANCE TOOL KP-ZJ-067 ○ ○ Grease lubrication hose
Gas balancer unit fulcrum portion
MAINTENANCE TOOL KP-ZJ-069 ○ ○ Grease lubrication long nozzle
Contents of OP-T2-090 (Zeroing pin & zeroing block) (option)

Name Marking Appearance etc.
Axis 1,4,5,6 Zeroing pin
Axis 2,3 Zeroing pin
MC-400L
J4
or
Axis 4 fixed side Zeroing block
MC400L/500P/
600/700
J4
Axis 4 moving side Zeroing block ST J4
MC-400L
J5/J6
Axis 5 moving side / Axis 6 fixed side or
Zeroing block MC400L/500P/
600/700
J5/J6
Axis 4 fixed side fixing bolt Hex. socket head cap screw 2-M8X60
Axis 4 moving side fixing bolt Hex. socket head cap screw 2-M8X25
Axis 5 moving side / Axis 6 fixed side
Hex. socket head cap screw 2-M8X25
fixing bolt
Tightening torque for M8 bolt: 33.3 Nm
5-2
Chapter 6 Wiring Diagrams
6-1
Motor/brake wiring connection diagram (1)
6-2
Motor/brake wiring connection diagram (2)
6-3
6-4
*1 Shorting at insulation cap with standard.
Encoder connection diagram (1)

Encoder wiring connection diagram (2)
6-5
DeviceNet connection diagram Ethernet connection diagram
6-6
Application connection diagram
6-7
制御装置側ロボット側
CONTROLLER SIDE ROBOT SIDE
CNP1A
(1) (2) (3)
U11 V11 W11
U12 V12 W12
CNP1B
(1) (2) (3)
U13 V13 W13
CNP2A
(1)
U21
(2)
V21
(3)
W21
CNR01
U22 V22 W22
CNP2B
(1) (2) (3)
U23 V23 W23 CONNECTOR 11
(B1) U12 V12 W12 BA1 W13 (B6)
CNP3A (A1) U11 V11 W11 PB1 U13 V13 (A6)
(1) (2) (3)
U32 V32 W32 (B1) U22 V22 W22 BA2 W23 (B6)
(A1) U21 V21 W21 PB2 U23 V23 (A6)
CNP3B
(1) (2) (3)
(B1) U32 V32 W32 BA3 W33 G (B6)
(A1) U31 V31 W31 PB3 U33 V33 (A6)
CNBK1
(1) (2) (3) CONNECTOR 14
B PB1 PB2 PB3
A BA1 BA2 BA3 未使用 / NOT USED
ECE
Wire harness connection (1)
6-8
CNP4A
(1) (2) (3)
U41 V41 W41
CNP4B
(1) (2) (3)
U42 V42 W42
CNP5A
(1)
U51
(2)
V51
(3)
W51
CNR02
CNP5B
(1) (2) (3)
(B1) U42 V42 W42 BA4 (B6)
CNP6A (A1) U41 V41 W41 PB4 (A6)
(1) (2) (3)
(B1) U52 V52 W52 BA5 (B6)
(A1) U51 V51 W51 PB5 (A6)
CNP6B
(1) (2) (3)
(B1) U62 V62 W62 BA6 (B6)
(A1) U61 V61 W61 PB6 (A6)
CNP7A
(1) (2) (3)
(B1) U72 V72 W72 BA7 TS2 G (B6)
(A1) U71 V71 W71 PB7 TS+ (A6)
CNP7B
(1) (2) (3)
U72 V72 W72
CNBK2
(1) (2) (3) (4) (5)
B PB4 PB5 PB6 PB7 TS2
A BA4 BA5 BA6 BA7 TS+
ECE
6-9
CNEC1
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
B P5E1 M5E1 P5E2 M5E2 P5E3 M5E3 LS1- LS2-
A S1+ S1- S2+ S2- S3+ S3- LS1+ LS2+
CNEC2
CNR04
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
B P5E4 M5E4 P5E5 M5E5 P5E6 M5E6 P5E7 M5E7
A S4+ S4- S5+ S5- S6+ S6- S7+ S7-
CONNECTOR 41
LS LS
(B1) S1- S2- S3- S4- S5- S6- S7- 1- 2- (B11)
CNALM (A1) S1+ S2+ S3+ S4+ S5+ S6+ S7+ LS
1+
LS
2+
(A11)
(1) (2) (3)
E24 M24 ALM CONNECTOR 42
(B1) M5E1 M5E2 M5E3 M5E4M5E5 M5E6M5E7 M24 (B11)
(A1) P5E1 P5E2 P5E3 P5E4 P5E5 P5E6 P5E7 ALM E24 (A11)
CONNECTOR 43
(B1) (B11)
未使用 / NOT USED
(A1) (A11)
Connector “CNALM” is not used for this robot.
6-10
http://www.nachi-fujikoshi.co.jp/
Shiodome Sumitomo Bldg. 17F,

Phone: Fax:
Japan Main Office 1-9-2 Higashi-Shinbashi
+81-3-5568-5245 +81-3-5568-5236
Minato-ku, TOKYO, 105-0021 JAPAN
Nachi Robotic Systems Inc. (NRS) http://www.nachirobotics.com/
North America Headquarters Phone: 248-305-6545 Fax: 248-305-6542 42775 W. 9 Mile Rd. Novi, Michigan 48375, U.S.A
Indiana Service Center Phone: 248-305-6545 Fax: 248-305-6542 Greenwood, Indiana
Ohio Service Center Phone: 248-305-6545 Fax: 248-305-6542 Cincinnati, Ohio
South Carolina Service Center Phone: 248-305-6545 Fax: 248-305-6542 Greenville, South Carolina
Canada Branch Office Phone: 905-760-9542 Fax: 905-760-9477 89 Courtland Ave., Unit No.2, Concord, Ontario, L4K 3T4, CANADA
Urbina No.54, Parque Industrial Naucalpan, Naucalpan de

Mexico Branch Office Phone :+52-555312-6556 Fax:+52-55-5312-7248
Juarez, Estado de Mexico C.P. 53489, MEXICO
NACHI EUROPE GmbH http://www.nachi.de/

Phone: Fax:
Central Office Germany Bischofstrasse 99, 47809, Krefeld, GERMANY
+49-2151-65046-0 +49-2151-65046-90
Phone: Fax: Unit 3, 92, Kettles Wood Drive, Woodgate Business Park,
U.K. branch
+44-0121-423-5000 +44-0121-421-7520 Birmingham B32 3DB, U.K.
Phone: Fax: Obchodni 132, 251 01 Cestlice, PRAGUE-EAST

Czech branch
+ 420-255-734-000 +420-255-734-001 CZECH REPUBLIC
Phone: Fax: Ataturk Mah. Mustafa Kemal Cad. No:10/1A 34758

Turkey branch
+ 90-(0)216-688-4457 +90-(0)216-688-4458 Atasehir / Istanbul - TURKEY
NACHI AUSTRALIA PTY. LTD. http://www.nachi.com.au/

Robotic Division & Phone: Fax:
38, Melverton Drive, Hallam, Victoria 3803, , AUSTRALIA
Victoria office +61-(0)3-9796-4144 +61-(0)3-9796-3899
Phone: Fax:
Sydney office Unit 1, 23-29 South Street, Rydalmere, N.S.W, 2116, AUSTRALIA
+61-(0)2-9898-1511 +61-(0)2-9898-1678
Phone: Fax:
Brisbane office 7/96 Gardens Dr,Willawong,QLD 4110, , AUSTRALIA
+61-(0)7-3272-4714 +61-(0)7-3272-5324
NACHI SHANGHAI CO., LTD. http://www.nachi.com.cn/

Phone: Fax: 11F Royal Wealth Centre, No.7
Shanghai office
+86-(0)21-6915-2200 +86-(0)21-6915-2200 Lane 98 Danba Road Putuo District, Shanghai 200062, China
NACHI KOREA http://www.nachi-korea.co.kr/

2F Dongsan Bldg.
Phone: Fax:
Seoul office 276-4, Sungsu 2GA-3DONG, Sungdong-ku,
+82-(0)2-469-2254 +82-(0)2-469-2264
Seoul 133-123, KOREA
Copyright NACHI-FUJIKOSHI CORP.

Robot Division
1-1-1, FUJIKOSHIHONMACHI, TOYAMA CITY, JAPAN 930-8511
Phone +81-76-423-5137
Fax +81-76-493-5252
NACHI-FUJIKOSHI CORP. holds all rights of this document. No part of this manual may be photocopied or
reproduced in any from without prior written consent from NACHI-FUJIKOSHI CORP. Contents of this document
may be modified without notice. Any missing page or erratic pagination in this document will be replaced.
In case that an end user uses this product for military purpose or production of weapon, this product may be liable
for the subject of export restriction stipulated in the Foreign Exchange and Foreign Trade Control Law. Please go
through careful investigation and necessary formalities for export.
Original manual is written in Japanese.

MC400L 600 01 (FD)

Uploaded by

Copyright:

Available Formats

You might also like

MC400L 600 01 (FD)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MC400L 600 01 (FD)

Uploaded by

Copyright:

Available Formats

1610, MMCEN-290-002, 001

Chapter 1 Basic specifications .................................................................................................................. 1-1

Chapter 2 Precautions for handling ........................................................................................................... 2-1

Chapter 3 Inspection.................................................................................................................................. 3-1

Chapter 4 Troubleshooting ........................................................................................................................ 4-1

Chapter 6 Wiring Diagrams ....................................................................................................................... 6-1

The following symbol is also used for important checkpoints.

A particularly important checkpoint is shown.

Signs for other types of caution and warnings;

Signs for protection;

Robot mass 3,050 kg 600 kg

*1: This value changes by placement and load conditions of a wrist.

■ Upper part of forearm

Use air pressure not more than 0.49MPa.

■ Upper part of forearm - Wiring and piping for application

■ Base frame block - Wiring and piping for application

(1) BJ1-side (Connectors)

Specification of Application wires

(2) BJ3-side (Joint connectors)

Connector models (CN62,CN64)

Connector models (CNMB7B)

（Pin location shows the connector equipped on robot body

Connector models （CNE7B）

（Pin location shows the connector equipped on robot body

■Name of the operating axis and each of their movement’s direction

Serial robot number

(Mass is typed only for CE specification.)

On controller display, axis 1 to 6 is displayed as J1 to J6 for each.

To transport the robot, make it

Safety measures against entry in the robot operating area

Stop time and angle of axis 1 for a maximum travel

Safety measures against the robot and peripheral equipment

■ Installation location and ambient conditions

Robot Model MC400L-01, MC600-01

(4) If the two precautions above cannot

■ Welding the base plates

4 base plates Install

weld the outside of

■ Maximum robot generative force

Max. vertical Max. horizontal Max. vertical Max. horizontal

2.6 Restriction of working envelope

(1) Restriction of working envelope by software

(2) Restriction of working envelope by adjustable stopper (option)

2.7 Test running for main axes (1,2 and 3)

3.1 Inspection items and periods

Inspection items and periods

Inspection Item Inspection Method Target portion

Specified tightening torque of bolts

■ Cables cover (hook tube) and clamp portion

torque 9.9 N・m)

■ Wiring around axis 5 motor

■ Wiring around axis 1 motor

Never attempt to use any cables other than specified by NACHI.

Tools required (prepared by customer)

Grease replacement procedure

Inspect the gas pressure every year.

Use nitrogen gas （N2）.

Inspection of balancer unit appearance