Service Manual: Robot

AC SERVO TYPE ROBOT
MODEL
HM-G/A0 SERIES
SERVICE MANUAL
Introduction
This service manual explains the inspection and maintenance procedures to ensure that your Denso robot will continuously
provide intended functions and performance:
(1) Daily inspection and maintenance
(2) 3-month inspection and maintenance
(3) 6-month inspection and maintenance
(4) 1-year inspection and maintenance
(5) 3-year inspection and maintenance
This manual explains the basics of periodic inspection and maintenance. Since the environment in which the robot operates
will vary, refer to the manual to determine the periodic inspection items and inspection intervals.
The manual also explains:
(6) Parts replacement procedures.
Object robot
This manual covers the following type Denso robot:

HM-G/A0 series (Midium-sized horizontal articulated robots)
㹆㹋㸨㸫㸲㸮㸵㸮㸰㸫㹕
less: Standard type
Number of axis : 4 axis W: Dust & splash proof type
UL: UL type
Arm length
less: Standard type Maximum payload 60: 600 mm 3rd axis stroke
S: Overhead fixing type 0: 10 kg 70: 700 mm 2: 200 mm
A: 20 kg 85: 850 mm 3: 300 mm
A0: 1000 mm 4: 400 mm
Request:
Before starting inspection and maintenance, be sure to thoroughly read "SAFETY PRECAUTIONS" on page 1 of
"Denso Robot Operator’s Manual", to ensure safe inspection.
*Any part of this service manual must not be copied without permission.
*The contents in this service manual may be changed without notice.
SAFETY PRECAUTIONS
(1) Before starting inspection/maintenance or replacement of parts, be sure to thoroughly read "SAFETY PRECAUTIONS"
in this manual and "SAFETY PRECAUTIONS" in Denso Robot Owner's Manual (IINSTALLATION & MAINTENANCE
GUIDE), to ensure safe work.
(2) Cautions with marks in following text indicate potential hazards in adjustment and repair, classified as follows:
Indicates an extremely hazardous situation which, if not avoided, will result
DANGER in death or serious injury in the most extreme case.
Indicates a potentially hazardous situation, which, if not avoided, could result

WARNING in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided, may result

CAUTION in minor or moderate injury, or damage to device. (Caution)
Caution: Even if a hazard is classified under " CAUTION", it could lead to serious accident depending on
the situation. Be sure to observe the important contents under the above marks.
1. Cautions when inspecting the body of robot, replacing parts and during adjustment
For inspection of the body of robot, replacement of parts and adjustment, observe the following work procedures, danger,
warning and caution remarks, so that no electric shock or injury occurs, and no parts inside the robot or peripheral devices
are damaged.
(1) Cautions when inspecting or replacing part of robot:
(1) Always wear safety goggles, helmet and shoes during work.
(2) Turn off the power switch on controller, and make sure that the pilot lamp goes out.
DANGER (3) Turn off power to peripheral devices (equipment) of robot.
(4) Disconnect all connectors on the controller.
Contents
Chapter1 Inspection and Maintenance
1-1 Types and Purposes of Inspection and Maintenance.......................... 1-1
1-2 Details of Daily Inspection ................................................................... 1-2

1 Required daily inspection and maintenance .....................................1-2
2 3rd axis air balance adjustment method .......................................... 1-2
1-3 Details of 3-Month Inspection .............................................................. 1-3

1 Required 3-month inspection and maintenance ...............................1-3
1-4 Details of 6-Month Inspection .............................................................. 1-4

1 Required 6-month inspection and maintenance ...............................1-4
2 Point to be lubricated ....................................................................... 1-5
1-5 Details of 1-Year Inspection................................................................. 1-7

1 Required 1-year inspection and maintenance ..................................1-7
2 Inspecting and adjusting timing belts............................................... 1-8
2.1 Inspecting and adjusting 4th axis timing belt A .................................1-8
2.2 Inspecting and adjusting 4th axis timing belt B ...............................1-27
3 Inspecting internal wiring ............................................................... 1-51
3.1 Inspection and overview of internal wiring ......................................1-51
3.2 Internal wiring diagrams..................................................................1-52
3.3 Simple inspection method for internal wiring ..................................1-58
1-6 Details of 2-Year Inspection............................................................... 1-59

1 Required 2-year inspection and maintenance ................................1-59
2 Replacing encoder backup batteries ............................................. 1-60
2.1 When replacing encoder backup battery is needed........................1-60
3 Replacing encoder backup batteries ............................................. 1-61
1
Chapter2 Replacement of Parts
2-1 Details of Part Replacement .................................................................2-1
2-2 Replacing Motors..................................................................................2-2

1 Methods for replacing motors ...........................................................2-3
1.1 1st axis motor replacement method ................................................. 2-3
1.2 2nd axis motor replacement method .............................................. 2-10
1.3 3rd axis motor replacement method ............................................... 2-20
1.4 4th axis motor replacement method ............................................... 2-48
2-3 Replacing the Timing Belts .................................................................2-68

1 Methods for replacing timing belts ..................................................2-68
1.1 Replacement method for 4th axis timing belt A .............................. 2-68
1.2 Replacement method for 4th axis timing belt B .............................. 2-77
2-4 Replacing 3rd Axis Air Balance Cylinder ............................................2-85

1 Methods for replacing 3rd axis air balance cylinder........................2-85
2-5 Replacing Second Arm Assembly ......................................................2-96

1 Methods for replacing second arm assembly .................................2-96
2-6 Replacing Power Conversion Board.................................................2-125

1 Fuses on power supply board.......................................................2-125
2 Procedure for replacing power conversion board ........................ 2-126
2-7 Replacing Bellows (Dust & splash proof specification).....................2-131

1 Methods for replacing bellows ......................................................2-131
1.1 Replacement method for bellows (top) ......................................... 2-131
1.2 Replacement method for bellows (bottom) ................................... 2-136
2-8 Replacing Robot ...............................................................................2-142

1 Overview of robot replacement .....................................................2-142
2 RANG data................................................................................... 2-143
2.1 RANG data label sticking position ................................................ 2-143
2.2 RANG data entry method ............................................................. 2-143
2
Chapter3 Auxiliary Work
3-1 Procedure for Resetting Encoder ........................................................ 3-1

1 Cases when encoder must be reset .................................................3-1
2 Encoder resetting method................................................................ 3-1
3-2 CALSET Operation Method ................................................................. 3-2

1 CALSET setting positions .................................................................3-3
2 How to Attach the 4th Axis CALSET Bolt ........................................ 3-4
3
4
Chapter1
Inspection and Maintenance
This chapter summarizes the periodic inspection of Denso robot:

Be sure to read this before starting inspection.
1 Inspection and Maintenance 1-1 Types and Purposes of Inspection and Maintenance
1-1 Types and Purposes of Perform the five types of inspection and maintenance shown in Table 1-1 to
Inspection and maintain the robot's functions and performance.
Maintenance
Table1-1: Types and Purpose of Inspection and Maintenance
No. Type Purpose

1 Daily inspection Perform this inspection every day before starting work, to ensure safe use of the robot.
3-months Perform this inspection and maintenance every 3 months in order to maintain the robot's precision.
2
inspection
6-months Perform this inspection and maintenance for lubrication every 6 months to prevent serious trouble caused
3
inspection by wear, seizure or breakage of rotating/sliding section of robot.
Perform this inspection and maintenance every year to prevent drift in robot position or defective operation
1-year
4 because of wear or loosening of timing belt, defective operation due to wear of defect internal wiring, or fault
inspection
in controller.
2-year Replace the batteries every 2 years to prevent erasure of position data stored in the robot's electronic abso-
5
inspection lute encoder.
Many inspection and maintenance jobs can only be performed within the movable range of the robot, which creates a
high possibility of accident: To prevent accident, limit inspection and maintenance to operators that attended the "special
CAUTION
training" for industrial robots specified in "Article 59 of Labor Safety and Health Act and related ordinance". Be sure to
read operator's manual, along with this chapter, before starting inspection and maintenance.
1-1
1 Inspection and Maintenance 1-2 Details of Daily Inspection
1-2 Details of Daily Inspection
1 Required daily inspection Perform inspection and maintenance according to Table 1-2 every day before
and maintenance starting work.
Table 1-2: Daily Inspection and Maintenance
Point or operation to be Power to Inspection

No. Criterion Corrective action
inspected controller method
1 Gravity balance of 3rd axis Teaching pendant Air pressure must Adjust air pressure.
(See "2 3rd axis be within normal (See "2 3rd axis air bal-
air balance range. ance adjustment
ON
adjustment method" on page 1-2.)
method" on
page 1-2.)
2 3rd axis air balance 3rd axis air balance adjustment method varies depending on the connected con-
adjustment method troller.
See "Chapter 4. Auxiliary work" on RC7M Controller or RC8 Controller

Service Manual and perform.
1-2
1 Inspection and Maintenance 1-3 Details of 3-Month Inspection
1-3 Details of 3-Month

Inspection
1 Required 3-month Perform inspection and maintenance according to Table 1-3.

inspection and maintenance
Table1-3: 3-Month Inspection and Maintenance
Point or operation to Power to Inspection

be inspected controller method
1 Robot base mounting bolt Use torque No looseness. Tighten to the specified torque.
wrench to mea- Specified torque:
OFF
sure tightening 128 ± 20 Nm
torque. (1306 ± 204 kgf·cm)
2 Motor mounting bolt for Use torque No looseness. Tighten at the specified torque.
each axis wrench to mea- Motor Specified torque
sure tightening
torque. 1st axis 5.9 ± 1.2 Nm
(60.2 ± 12 kgf·cm)
2nd axis 2.9 ± 0.6 Nm
OFF (29.6 ± 5.9 kgf·cm)
3rd axis 2.9 ± 0.6 Nm
(29.6 ± 5.9 kgf·cm)
4th axis 2.9 ± 0.6 Nm
(29.6 ± 5.9 kgf·cm)
1-3
1-4 Details of 6-Month

Inspection
1 Required 6-month If robot is used continuously with grease left degraded, this may cause trouble
inspection and such as abnormal sound, wearing tooth flank of rack, etc. With 6-month inspec-
maintenance tion, lubrication is applied to 3rd axis rack, cylinder shaft and 4th axis shaft. Per-
form lubrication according to Table 1-4.
Table 1-4: 6-Month Inspection and Maintenance
Point or operation to Power to Inspection

1 3rd axis rack
2 3rd axis air balance cylin-
Perform lubrication. (Note)
der shaft
3 Entire 4th axis shaft
OFF
4 3rd axis bellows (Dust & Replace the bellows.
splash proof specifica- (See "2-7 Replacing Bel-
tions) Visual Does not have tares lows (Dust & splash
proof specification)" on
page 2-131.)
The lubrication must be performed every six months based on 2-shift

CAUTION operation (basically, every 2,000 hours for reference). In case of 1-
shift operation, perform lubrication every one year.
1-4
2 Point to be lubricated Table 1-5 shows point to be lubricated.

For dust & splash proof specifications, perform removal bellows fixing bolt
shown in Fig. 1-1.
Table 1-5: Point to Be Lubricated
Point to be Amount of
No. Grease name Remarks
lubricated lubrication
1 3rd axis rack Apply grease to entire tooth flank and rail section.
2 3rd axis air balance EPINOCK Apply grease to entire cylinder shaft.
2 - 3 cc
cylinder shaft AP1
3 4th axis shaft Apply grease to entire 4th axis shaft.
3rd axis rack
Cross-section of 3rd axis rack

Rail section Rail section
Arm tip side Tooth flank
3rd axis air balance

cylinder shaft
4th axis shaft
ze109z
1-5
Bolts Bolts
Bolts
Bolts
5
Fig.1-1: Bellows fixing bolt

After lubrication, fix 16 bellows fixing bolts (M3 x 8).
Tightening torque of bellows fixing bolt:

1.2 ± 0.1 Nm (12.2 ± 1.2 kgf·cm)
CAUTION Replace O-ring with a brand-new one.
1-6
1 Inspection and Maintenance 1-5 Details of 1-Year Inspection
1-5 Details of 1-Year Inspection

1 Required 1-year Perform inspection and maintenance according to Table 1-6.
inspection and
maintenance
Table 1-6: 1-Year Inspection and Maintenance
No. Point or operation to Power to Inspection Criterion Corrective action

1 4th axis timing belt OFF
Inspection method
(1) Visually check the wear of teeth of timing belt.
(2) Measure the tension of the timing belt using a sonic-type belt tensionmeter.
Or use push-pull gauge and scale to measure the deflection of timing belts.
Push-pull gauge 1

NJI
Deflection
Timing belt 5
Criterion standard
(1) The teeth of timing belts must not be worn.
(2) The deflection values must be within the specifications.
Arm length: 600 mm/700 mm, Maximum playload: 10kg type
Axis No. Tension specifications Deflection specifications
4th axis timing belt A 327 - 480 Hz 2.0 - 3.0 mm
4th axis timing belt B 117 - 175 Hz 3.0 - 4.0 mm
Corrective action
(1) Replace the timing belt.
(2) Adjust the tension on timing belt (see"2 Inspecting and adjusting
timing belts" on page 1-8)
2 Internal wiring check OFF Perform inspection, referring to "3 Inspecting internal wiring" on page
1-51.
(1) The timing belts must be inspected every year based on 2-shift
operation (basically, every 4000 hours for reference). In case of 1-
shift operation, inspect the timing belts every two years.
CAUTION
(2) When adjusting the tension on timing belts, do not change the
positions of timing belts that mesh with pulleys: If the positions are
changed, the teaching point will drift.
1-7
2 Inspecting and adjusting The timing belts for driving 4th axis are limited-life parts: As the belts are used,
timing belts the teeth will wear down and the belts will stretch.
If the robot is used with worn teeth or belt stretched, it will cause a defect in
robot, such as position drift.
To prevent this, the 1-year inspection is performed to inspect and adjust the tim-
ing belts.
(1) There are two 4th axis timing belts: One is "4th axis timing belt A"
from 4th axis motor to intermediate shaft, the other is "4th axis tim-
ing belt B" from intermediate shaft to output shaft.
CAUTION
(2) When adjusting the tension on timing belts, do not change the
positions of timing belts that mesh with pulleys. If the positions are
changed, the teaching point will drift.
2.1 Inspecting and adjusting For arm length 600 mm/700 mm, follow the procedure shown in Table 1-7,
4th axis timing belt A and in the case of arm length 850 mm/1000 mm, follow the procedure shown in
Table 1-8.
Table 1-7: Inspection and Adjustment of 4th Axis Timing Belt A(Arm length 600 mm/700 mm) (Cont’d from previous page)
No. Procedure Illustration

1 Turn off power and air supplied to robot.
(1) Be sure to wear safety goggles, helmet and

shoes during this work.
(2) Turn the controller power switch off, and
make sure that the pilot lamp has gone out.
(3) Turn off power and air supply to peripheral Air pipes
CAUTION devices (equipment) of robot.
(4) Disconnect the cables (CN20, 22) from the
robot.
(5) Disconnect the air pipes (AIR1, AIR2) from
the robot.
CN20 CN22 ze135z
2 Remove the four screws (four bolts for dust & splash proof
specifications) holding the user wiring plate.
Second arm cover Bolts
For dust & splash proof specifications, remove
CAUTION the O-ring.
Bolts
User wiring plate

ze110z
(To be cont’d)
1-8

3 Remove the six bolts holding the second arm cover.
*With standard specifications, proceed with step Second arm cover
5.
Bolts
ze486z
4 Remove four bellows stay (top) fixing bolts, and make bellows
free. Bellows stay
Bolts
5
5 While inclining the user wiring plate, pass it through second arm
as shown in the illustration.
User wiring plate
5
(To be cont’d)
1-9

6 Remove the second arm cover.
Standard specifications
(1) For dust & splash proof specification, also
remove packing.
CAUTION (2) For dust & splash proof specification, dis-
connect brake release switch connector.

Second arm
cover
Dust & splash proof specifications
Brake release switch connector

5
7 Remove rubber bush for timing belt inspection at the side face
of second arm.
Rubber bush for timing

belt inspection ze114z
(To be cont’d)
1-10

8 Insert push-pull gauge into inspection window and push the 4th
axis timing belt A with force of 29.0 N (3.0 kgf) using push-pull
gauge and measure amount of deflection using scale. Or, mea-
sure tension of the 4th axis timing belt A using sonic-type belt 4th axis timing belt A
tensionmeter.
Push-pull gauge
or
Sonic-type belt
tensionmeter
Arm tip side
5
Amount of deflection
(2.0 - 3.0 mm)
29.0 N (3.0 kgf)
4th axis
Push-pull gauge timing belt A
ze116z
9 If the amount of deflection is within the following specification,

proceed with step 17.
Specification of deflection of 4th axis timing belt A: 2.0-3.0
mm
4th axis timing belt A tension specification: 327-480 Hz
10 Remove the two bolts holding internal wiring plate and make
internal wiring plate free.
Arm tip side
Internal wiring plate
Bolts
ze526z
(To be cont’d)
1-11

11 Remove the two bolts holding 3rd/4th axis connector plate and
make 3rd/4th axis connector plate free.
3rd/4th axis connector plate
Arm tip side Bolts

5
12 Loosen four bolts holding the 4th axis motor assembly.

4th axis motor assembly
Take care at this time that the relation of posi-
tions where the teeth of belt and pulley mesh
CAUTION
has not changed: If it has changed, CALSET is Bolts
necessary in the final process of work.
4th axis motor plate

Bolts
ze118z
(To be cont’d)
1-12

13 Set flat-head screwdriver to the position shown in the illustra-
tion, and while pressing 4th axis motor assembly in the direction 225 N (23.0 kgf)
of arrow with the force of 225N (23.0 kgf), tighten the four bolts
(M5 x 15) holding the 4th axis motor assembly.
Tightening torque of 4th axis motor assembly holding bolt:

5.9 ± 1.2 Nm (60.2 ± 12 kgf·cm)

ze530z
4th axis intermediate shaft assembly

Inside hole Outside hole
Inside hole
Outside hole 4th axis motor

assembly
Flat-head
screwdriver
4th axis intermediate
shaft assembly
Inside hole
ze531z
Bolts

Bolts
ze118z
(To be cont’d)
1-13

14 Perform re-inspection according to steps 8 and 9.
If the amount of deflection is not within the

specification after adjustment, belt must be
replaced.
CAUTION (See "1.1 Replacement method for
4th axis timing belt A" on page 2-

68).
15 Attach 3rd/4th axis connector plate and tighten the two bolts
(M3 x 8) holding 3rd/4th axis connector plate.
Tightening torque of 3rd/4th axis connector plate fixing bolt:
2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)
Arm tip side Bolts

5
16 Attach internal wiring plate and tighten the two bolts (M3 x 8)
securing internal wiring plate.
Arm tip side
Tightening torque of internal wiring plate holding bolt:
2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)
Bolts
ze526z
17 Attach rubber bush for timing belt inspection.

(To be cont’d)
1-14

18 Install the second arm cover.
(1) For dust & splash proof specification,
replace packing with a brand-new one
between second arm cover and second
CAUTION arm.
(2) For dust & splash proof specifications, Second arm
attach second arm cover after connect cover
brake release switch connector.

5
19 Pass through the user wiring plate from inside the second arm
cover to the outside as shown in the illustration.
*With standard specifications, proceed with step

22.
User wiring plate
5
20 Attach bellows stay (top).
(To be cont’d)
1-15

21 Attach four bolts (M3 x 10) holding bellows stay (top).
Bellows stay
Tightening torque of bellows stay fixing bolt:
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)
Take care that the O ring does not get caught

CAUTION during the process.
Bolts
5
22 Reinstall the second arm cover, and tighten the six bolts holding
the cover. Second arm cover
Tightening torque of second arm cover fixing bolts:

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)
Take care that wires do not get caught

CAUTION
between the cover and second arm.
Bolts
ze486z
23 Fix four bolts (M3 x 8) holding use wiring plate, and then attach
the user wiring plate.
Tightening torque of user wiring plate fixing screws (standard

specifications):
0.59 ± 0.1 Nm (6 ± 1.2 kgf·cm)
Tightening torque of user wiring plate fixing bolts (dust & splash
proof specifications):
1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
(1) For Dust & splash proof specification, User wiring plate
attach O-ring with a brand-new one ze110z
between user wiring plate and second arm
CAUTION
cover.
(2) Take care that the O ring does not get
caught during the process.
(To be cont’d)
1-16

24 Connect the cables (CN20, CN22) and air pipes (AIR1, AIR2,
AIR3, AIR4) to robot, and turn on power to the controller, periph-
eral devices (equipment) of robot, and air supply.
Air pipes
CN20 CN22 ze145z
25 If the positions where the teeth of belt and pulley mesh change
during belt adjustment, perform CALSET for 4th axis. (See "3-
2 CALSET Operation Method" on page 3-2.)
(To be cont’d)
1-17
Table 1-8: 4th Axis Timing Belt A Inspection and Adjustment (Arm length 850 mm/1000 mm) (Cont’d from previous page)


CAUTION
devices (equipment) of robot.
robot.
the robot.
CN20 CN22 ze135z
CAUTION
the O-ring.
Bolts
User wiring plate

ze110z
3 Remove the eight bolts holding the second arm cover.

5.
Bolts
5
free. Bellows stay
Bolts
5
(To be cont’d)
1-18

User wiring plate
5

remove packing.
CAUTION
(2) For dust & splash proof specification, dis-
Second arm
cover

5
7 Remove rubber bush for timing belt inspection at the side face
of second arm.

(To be cont’d)
1-19

8 Insert push-pull gauge into inspection window and push the 4th
axis timing belt A with force of 29.4 N (3.0 kgf) using push-pull
gauge and measure amount of deflection using scale. Or, mea-
sure tension of the 4th axis timing belt A using sonic-type belt
tensionmeter.
Push-pull gauge
or
Sonic-type belt
tensionmeter
4th axis timing belt A

Arm tip side
Amount of deflection
(2.0 - 3.0 mm)
1㸦NJI㸧
4th axis
Push-pull gauge timing belt A
5

Specification of deflection of 4th axis timing belt A: 2.0-3.0
mm
4th axis timing belt A tension specification: 327-480 Hz
10 Remove the two screws holding the internal wiring plate to free
the plate.

Bolts
5
(To be cont’d)
1-20

11 Loosen the four bolts holding the 4th axis motor assembly.
Be careful not to change the position where
the teeth of belts mesh with a pulley at this
CAUTION time. If it has changed, CALSET is necessary Bolts
in the final process of work.

Bolts
ze118z
(To be cont’d)
1-21

tion, and while pressing 4th axis motor assembly in the direction 225 N (23.0 kgf)
of arrow with the force of 225N (23.0 kgf), tighten the four bolts
(M5 x 15) holding the 4th axis motor assembly.
Tightening torque of 4th axis motor fixing bolts:

5.9 ± 1.2 Nm (60.2 ± 12 kgf·cm)

ze530z

Inside hole

assembly
Flat-head
screwdriver
shaft assembly
Inside hole
ze531z
Bolts

Bolts
ze118z
(To be cont’d)
1-22

13 Perform reinspection according to steps 8 and 9.

specified value after adjustment, the belt must
CAUTION be replaced. (See "1.1 Replacement
method for 4th axis timing belt A"
on page 2-68.)
14 Attach the internal wiring plate, tighten the two bolts (M3 x 8)
holding the internal wiring plate.
Tightening torque of internal wiring plate fixing bolts:

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)

Bolts
5
15 Attach rubber bush for timing belt inspection.

(To be cont’d)
1-23

CAUTION arm.

5

20.
User wiring plate
5
(To be cont’d)
1-24

Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)

Bolts
5
20 Reinstall the second arm cover, and tighten the eight bolts hold-
ing the second arm.
Tightening torque of second arm fixing bolts:

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION
Bolts
5

specifications):
0.59 ± 0.1 Nm (6 ± 1.2 kgf·cm)
1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
CAUTION
cover.
(To be cont’d)
1-25

eral devices equipment) of robot, and air supply.
Air pipes
CN20 CN22 ze145z
during belt adjustment, perform CALSET for 4th axis. (See "3-
2 CALSET Operation Method" on page 3-2.)
(To be cont’d)
1-26
2.2 Inspecting and adjusting For arm length 600 mm/700 mm, follow the procedure shown in Table 1-9,
4th axis timing belt B and in the case of arm length 850 mm/1000 mm, follow the procedure shown in
Table 1-10.
Table 1-9: 4th Axis Timing Belt B Inspection and Adjustment (Arm length 600 mm/700 mm) (Cont’d from previous page)


CAUTION
robot.
the robot.
CN20 CN22 ze135z
CAUTION
the O-ring.
Bolts
User wiring plate

ze110z

Second arm cover
5.
Bolts
ze486z
(To be cont’d)
1-27

free. Bellows stay
Bolts
5
User wiring plate
5

remove packing.
CAUTION
Second arm
cover

5
(To be cont’d)
1-28

7 Cut the five insulator locks holding the air pipes.
Insulator lock
5
8 Cut off one insulator lock fixing wiring.
Take care not the cut the wiring during the pro-
CAUTION Insulator lock
cess.
5
9 Cut off the insulator lock fixing the wiring and air pipe (yellow).
Take care not the cut the wiring during the pro- Insulator lock
CAUTION
cess.
5
Arm tip side Bolts

5
(To be cont’d)
1-29

11 Push the 4th axis timing belt B with force of 29.4 N (3.0 kgf)
using push-pull gauge and measure amount of deflection using
scale. Or, measure tension of the 4th axis timing belt B using
sonic-type belt tensionmeter.
Arm tip side
Push-pull gauge
or
Sonic-type belt
4th axis timing belt B
tensionmeter 5
4th axis Push-pull gauge

timing belt B
1㸦NJI㸧
5

Specification of deflection of 4th axis timing belt B:
Maximum payload 10 kg: 3.0-4.0 Hz
4th axis timing belt B tension specification:
Arm length 600 mm/700 mm
Maximum payload 10 kg: 117-175 Hz
Arm length 850 mm/1000 mm
13 Cut off four insulator locks and disconnect 3rd axis motor con-
nector (white: 6P) and 3rd axis encoder connector (white: 4P)
3rd axis motor connector
as shown in the illustration. (white: 6P)
Insulator lock
Insulator lock
3rd axis encoder connector
(white: 4P)
5
(To be cont’d)
1-30

14 Cut off one insulator lock fixing the surge suppressor.
Insulator lock
Surge suppressor
5
15 Cut off one insulator lock fixing terminus capacitor board.
Insulator lock
Terminus capacitor board
5
16 Cut off insulator lock fixing 3rd axis motor.
3rd axis motor
Insulator lock
5
17 Remove the two screws holding the rack cover.

Screws
ze496z
(To be cont’d)
1-31

18 Remove the rack cover.
Rack cover
ze497z
19 Remove the four bolts holding the 3rd axis motor stay.
Bolts (M4 20)

Bolts (M4 40)
5
20 Remove the one bolt holding the rack.

Bolts
Bolts
5
(To be cont’d)
1-32

21 Remove 3rd axis motor assembly.
3rd axis motor assembly ze500z
22 Loosen four bolts holding the 4th axis intermediate shaft assem-
bly. Bolts
Take care at this time that the relation of posi- shaft assembly
tions where the teeth of belt and pulley mesh
CAUTION
has not changed: If it has changed, CALSET is
necessary in the final process of work.
Arm tip side
Bolts
Ze487z
(To be cont’d)
1-33

tion, and while pressing 4th axis motor assembly in the direction
of arrow with the force refer to the table below, tighten the four
bolts (M5 x 15) holding the 4th axis motor assembly.
Tightening torque of 4th axis intermediate shaft

assembly holding bolt: 4th axis timing belt B
6.0 ± 1.2 Nm (61.2 ± 12.2 kgf·cm)
10kg type 607N (62kgf)
ze544z

Outside hole
Inside hole
Rib
Inside hole
Outside hole
Flat-head screwdriver

Inside hole
Rib
ze541z
Bolts
shaft assembly
Arm tip side
Bolts
Ze487z
(To be cont’d)
1-34

24 Perform re-inspection according to steps 11 and 12.

specification after adjustment, belt must be
replaced.
CAUTION (See "1.2 Replacement method for
4th axis timing belt B" on page 2-

77.)
25 Adjust the deflection of 4th axis timing belt A.

(See "2.1 Inspecting and adjusting 4th axis timing
belt A" on page 1-8.)
26 Attach 3rd axis motor assembly to robot body.
27 Attach the bolt (M6 x 16) holding the rack.

Tightening torque of rack fixing bolt:
9.8 ± 2.0 Nm (100.0 ± 20.0kgf·cm)
Bolts
Bolts
5
(To be cont’d)
1-35

28 Attach the two bolts (M4 x 40) and two bolts (M4 x 20) holding
the 3rd axis motor stay.
Tightening torque of 3rd axis motor stay fixing bolt:

2.9 ± 0.6 Nm (29.6 ± 5.9kgf·cm)
Bolts (M4 20)

Bolts (M4 40)
5
29 Reinstall the rack cover.
Rack cover
ze497z
30 Attach the two screws (M3 x 6) holding rack cover.

Screws
Tightening torque of rack cover fixing screw:
0.49 ± 0.1 Nm (5 ± 1kgf·cm)
ze496z
31 Fix the terminus capacitor board to the 3rd axis encoder part
with the insulator lock.
Insulator lock
3rd axis encoder part

5
(To be cont’d)
1-36

32 Fix the surge suppressor to 3rd axis motor wiring and 3rd axis
encoder wiring to the insulator lock.
Insulator lock
Surge suppressor
5
33 Attach insulator lock to 3rd axis motor.
3rd axis motor
Insulator lock
5
34 Connect 3rd axis motor connector (white: 6P) and 3rd axis
encoder connector (white: 4P), and then fix to 3rd/4th axis con-
nector plate with the insulator lock. (white: 6P)
Insulator lock
Insulator lock
(white: 4P)
5
35 Attach the 3rd/4th axis connector plates to the second arm and
tighten the four bolts (M3 x 8) securing the 3rd/4th axis connec-
tor plate. 3rd/4th axis connector plate
Tightening torque of 3rd/4th axis connector plate fixing bolts:

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)
Arm tip side Bolts

5
(To be cont’d)
1-37

36 Fix the air pipe (yellow) and wiring to the 3rd/4th axis connector
plate with the insulator lock as shown in the illustration. 3rd/4th axis connector plate
Insulator lock
Do not tighten up the insulator lock hard. Air
CAUTION pipe could be crushed and necessary air to
flow through.
Air pipe (yellow)
5
37 Fix the wiring to insulator lock with 3rd axis motor attached as
shown in the illustration.
Insulator lock
5
38 Fix five air pipes to the insulator lock with 3rd axis motor
attached as shown in the illustration. Blue Black
Insulator lock
Red
CAUTION pipe could be crushed and necessary air to White
flow through.
Yellow
5
(To be cont’d)
1-38

CAUTION arm.

5

43.
User wiring plate
5
(To be cont’d)
1-39

Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)

CAUTION
during the process.
Bolts
5
43 Reinstall the second arm cover, and tighten the six bolts holding
the cover. Second arm cover

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION
Bolts
ze486z

specifications):
0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm)
1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
CAUTION
cover.
(To be cont’d)
1-40

Air pipes
CN20 CN22 ze145z
during belt adjustment, perform CALSET for 4th axis.
(See "3-2 CALSET Operation Method" on page 3-
2.)
47 If error message of number in 6410s (encoder system down
fault for each axis) appears in teaching pendant, reset the
encoder of corresponding axis and perform CALSET.
(See "3-1 Procedure for Resetting Encoder" on
page 3-1 and "3-2 CALSET Operation Method" on
page 3-2.)
(To be cont’d)
1-41


CAUTION
robot.
the robot.
CN20 CN22 ze135z
CAUTION
the O-ring.
Bolts
User wiring plate

ze110z

5.
Bolts
5
free. Bellows stay
Bolts
5
(To be cont’d)
1-42

User wiring plate
5

remove packing.
CAUTION
Second arm
cover

5
(To be cont’d)
1-43

7 Push the 4th axis timing belt B with force of 29.4 N (3.0 kgf)
using push-pull gauge and measure amount of deflection using
scale.
Or, measure tension of the 4th axis timing belt B using sonic-
type belt tensionmeter.
Arm tip side
Push-pull gauge
or
Sonic-type belt
tensionmeter 5
4th axis Push-pull gauge

timing belt B
1㸦NJI㸧
5
8 If amount of deflection is within the following specification, pro-

ceed with step 17.
Specification of deflection of 4th axis timing belt B:
4th axis timing belt B tension specification:

Bolts
5
(To be cont’d)
1-44

10 Remove the four bolts holding 4th axis connector plate and
make 4th axis connector plate free. Bolts
4th axis connector plate
Bolts
Arm tip side 5
11 Loosen four bolts holding the 4th axis intermediate shaft assem-
bly. Bolts
Be careful not to change the position where shaft assembly
the teeth of belts mesh with a pulley at this
CAUTION
time. If it has changed, CALSET is necessary
in the final process of work.
Arm tip side
Bolts
Ze487z
(To be cont’d)
1-45

tion, and while pressing 4th axis motor assembly in the direction
of arrow with the force refer to the table below, tighten the four
Tightening torque of 4th axis intermediate shaft assembly

holding bolt: 4th axis timing belt B
6.0 ± 1.2 Nm (61.2 ± 12.2 kgf·cm)
ze544z

Outside hole
Inside hole
Rib
Inside hole
Outside hole

Inside hole
Rib
ze541z
Bolts
shaft assembly
Arm tip side
Bolts
Ze487z
(To be cont’d)
1-46

13 Perform reinspection according to steps 7 and 8.

specified value after adjustment, the belt must
CAUTION be replaced. (See "1.2 Replacement
method for 4th axis timing belt B"
on page 2-77.)
14 Adjust the deflection of 4th axis timing belt A.

(See "2.1 Inspecting and adjusting 4th axis timing
belt A" on page 1-8.)
15 Attach the 4th axis connector plate, and then fix four bolts (M3 x
8) holding 4th axis connector plate. Bolts
4th axis connector plate
Tightening torque of 4th axis connector plate fixing bolts:
2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)
Bolts
Arm tip side 5
16 Attach the internal wiring plate, and then fix two bolts (M3 x 8)
holding internal wiring plate.

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)

Bolts
5
(To be cont’d)
1-47

CAUTION arm.

5

21.
User wiring plate
5
(To be cont’d)
1-48

Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)

CAUTION
during the process.
Bolts
5
21 Reinstall the second arm cover, and tighten the eight bolts hold-
ing the cover.

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION
Bolts
5

specifications):
0.59 ± 0.1 Nm (6 ± 1.2 kgf·cm)
1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
CAUTION
cover.
(To be cont’d)
1-49

Air pipes
CN20 CN22 ze145z
during belt adjustment, perform CALSET for 4th axis.
2.)
25 If individual encoder system down fault error appears on the
teaching pendant, reset the encoder for the corresponding axis
and perform CALSET.
page 3-1 and "3-2 CALSET Operation Method" on
page 3-2.)
(To be cont’d)
1-50
3 Inspecting internal wiring
3.1 Inspection and overview The unit has three wiring circuit systems, as shown in Table 1-11: Motor
of internal wiring power, encoder signal, and hand control signal.
Table 1-11 lists the connectors for each circuit system.
Table 1-11: Internal Wiring Circuit and Connectors
No. Internal wiring Corresponding connectors

1 Motor power circuit Motor/encoder connector CN22 4-pin or 6-pin connector for each axis motor
2 Encoder signal circuit Motor/encoder connector CN22 J5 connector of encoder signal for power con-
version board
J5 connector for encoder signal 4-pin connector for each axis encoder
3 Hand control signal circuit Hand control signal connector CN20 Hand control signal connector CN21
Fig. 1-2 to 1-7 show the HM-G/A0 type robot internal wiring diagrams: Use a
tester to check the internal wiring, and make sure that pins of each connector
are conductive, and that the robot body is isolated from each pin (excluding the
GND wire).
When operator checks the wiring for encoder circuit, the encoder is disconnected from the backup battery: This will erase
any data in encoder and could cause the robot to be inoperable. When error of encoder system down occurs after the
CAUTION internal wiring circuit for encoder has been checked, reset the encoder and perform CALSET.
(See "3-1 Procedure for Resetting Encoder" on page 3-1 and "3-2 CALSET Operation Method"
on page 3-2.)
1-51
3.2 Internal wiring diagrams Fig. 1-2 to 1-7 show the HM-G/A0 type robot internal wiring diagrams.
j Red 1: 1st axis motor phase U

White 2: 1st axis motor phase V
r 1st axis motor
Black
p 3: 1st axis motor phase W connector (black)
Green/yellow
4: 1st axis GND
h Red 1: 2nd axis motor phase U

n White 2: 2nd axis motor phase V 2nd axis motor
g Black connector (white)
3: 2nd axis motor phase W
Green/yellow
4: 2nd axis GND
a Red 1: 3rd axis motor phase U

S White 2: 3rd axis motor phase V
T Black 3: 3rd axis motor phase W
Green/yellow 3rd axis motor
4: 3rd axis GND connector (white)
U Yellow 5: 3rd axis brake 24V

N 6: 3rd axis brake 0V
K Red 1: 4th axis motor phase U

E White 2: 4th axis motor phase V 4th axis motor
A Black connector (black)
3: 4th axis motor phase W
Green/yellow
4: 4th axis GND
CN22
3 2 1
1 2
6 5 4
A B C D
1st axis motor connector
E F G H J (Diagram viewed from
K L M N P R pin side mating surface)
S T U V W X Z 1 2 3 3 4
a b c d e f
2nd/4th axis motor connector
g h j k m (Diagram viewed from
n p r s pin side mating surface)
4 5 6
3rd axis motor connectors
CN22 (Diagram viewed from (Diagram viewed from
pin side mating surface) pin side mating surface) ze125z
Fig.1-2: Motor Power System (Standard specification)
1-52
31 Red 1: 1st axis motor phase U

White 2: 1st axis motor phase V 1st axis motor
36
Black 3: 1st axis motor phase W connector (black)
35 Green/yellow
4: 1st axis GND
30 Red 1: 2nd axis motor phase U

34 White 2: 2nd axis motor phase V 2nd axis motor
29 Black 3: 2nd axis motor phase W connector (white)
Green/yellow
4: 2nd axis GND
23 Red 1: 3rd axis motor phase U

16 White 2: 3rd axis motor phase V
17 Black 3: 3rd axis motor phase W
Green/yellow 4: 3rd axis GND 3rd axis motor
connector (white)
18 5: 3rd axis brake 24V
13 6: 3rd axis brake 0V
10 Red 1: 4th axis motor phase U

5 White 2: 4th axis motor phase V 4th axis motor
1 Black 3: 4th axis motor phase W connector (black)
Green/yellow
4: 4th axis GND
CN22
3 2 1
1 2
6 5 4
1 2 3 4
1st axis motor connector
5 6 7 8 9 (Diagram viewed from
10 11 12 13 14 15 pin side mating surface)
16 17 18 19 20 21 22 1 2 3 3 4
23 24 25 26 27 28
2nd/4th axis motor connector
29 30 31 32 33 (Diagram viewed from
34 35 36 pin side mating surface)
4 5 6
3rd axis motor connectors
CN22 (Diagram viewed from (Diagram viewed from
pin side mating surface) pin side mating surface) ze126z
Fig.1-3: Motor Power System (Dust & splash proof specification)
1-53
White
W :0V 8
Black
P :24V 7
Blue 6
M :phase Rx Power
V :phase Rx Purple 5 J1 Encoder
Purple conversion backup battery
4
CN22 Blue
3 board
Black J2
2
White
1
J5
White
1: 1st axis encoder 5/3.6V
Black
2: 1st axis encoder 0V
Blue 1st axis encoder
3: 1st axis encoder phase Rx
Purple 4: 1st axis encoder phase Rx connector (black)
White
1: 2nd axis encoder 5/3.6V
Black
2: 2nd axis encoder 0V 2nd axis encoder
Blue
3: 2nd axis encoder phase Rx connector (white)
Purple
4: 2nd axis encoder phase Rx
White
1: 3rd axis encoder 5/3.6V
Black
2: 3rd axis encoder 0V 3nd axis encoder
Blue
3: 3rd axis encoder phase Rx connector (white)
Purple 4: 3rd axis encoder phase Rx
White
1: 4th axis encoder 5/3.6V
Black
2: 4th axis encoder 0V 4th axis encoder
Blue
3: 4th axis encoder phase Rx connector (black)
Purple
4: 4th axis encoder phase Rx
White
1
Black
2 Terminus capacitor board
Blue
3
Purple
4
connector (white)
4 3 2 1
A B C D
E F G H J 1st to 4th axis
encoder connectors
K L M N P R
(Diagram viewed from
S T U V W X Z 8 7 6 5 4 3 2 1 pin side mating surface)
a b c d e f
4 3 2 1
g h j k m
J5 (Diagram viewed from
n p r s
pin side mating surface)
Terminus
capacitor board connector
CN22 (Diagram viewed from pin side mating surface)
pin side mating surface) ze127z
Fig.1-4: Encoder Signal Circuit (Standard specification)
1-54
White
20:0V 8
red
14:24V 7
Blue 6
12:phase Rx Power J1
19:phase Rx Purple 5 Encoder
Purple conversion backup battery
4
CN22 Blue
3 board
Black
2 J2
White
1
J5
White
Black
1: 1st axis encoder 5/3.6V
2: 1st axis encoder 0V 1st axis encoder
Blue
Purple connector (black)
White
Black 1: 2nd axis encoder 5/3.6V
Blue
2: 2nd axis encoder 0V 2nd axis encoder
3: 2nd axis encoder phase Rx connector (white)
Purple
4: 2nd axis encoder phase Rx
White
Black 1: 3rd axis encoder 5/3.6V
2: 3rd axis encoder 0V 3rd axis encoder
Blue
3: 3rd axis encoder phase Rx connector (white)
Purple
4: 3rd axis encoder phase Rx
White
Black 1: 4th axis encoder 5/3.6V
2: 4th axis encoder 0V 4th axis encoder
Blue
3: 4th axis encoder phase Rx connector (black)
Purple
4: 4th axis encoder phase Rx
White
1
Black
2 Terminus capacitor board
Blue
3 connector (white)
Purple
4 4 3 2 1
1 2 3 4
5 68 9 7 1st to 4th axis
10 11 12 13 14 15 encoder connectors
16 17 18 19 20 21 22 8 7 6 5 4 3 2 1 pin side mating surface)
23 24 25 26 27 28
4 3 2 1
29 30 31 32 33
J5 (Diagram viewed from
34 35 36
Terminus
capacitor board connector
CN22 (Diagram viewed from
pin side mating surface) ze128z
Fig.1-5: Encoder Signal Circuit (Dust & splash proof specification)
1-55
Red Red
1 1
White White
2 2
Black Black
3 3
White White
4 4
Blue Blue
5 5
White White
6 6
Purple Purple
7 7
White White
8 8
Brown Brown
9 9
White White
10 10
Relay connector
(white)
Red Red
11 11
Yellow Yellow
12 12
Black Black
13 13
Yellow Yellow
14 14
Blue Blue
15 15
Yellow Yellow
16 16
Purple Purple
17 17
Yellow Yellow
18 18
Brown Brown
19 19
Yellow Yellow
20 20
Relay connector
(black)
Blue Blue
21 21
Purple Purple
22 22
Red Red
23 23
Black Black
24 24
CN20 Relay connector CN21

(White)
1 2 3 4 4 3 2 1
5 6 7 8 9 9 8 7 6 5
10 11 12 13 14 15 15 14 13 12 11 10
16 17 18 19 20 20 19 18 17 16
21 22 23 24 24 23 22 21
CN20 (Diagram viewed from CN21 (Diagram viewed from

pin side mating surface) pin side mating surface)
ze129z
Fig.1-6: Hand Control Signal System (Standard specification)
1-56
Red Red
1 1
White White
2 2
Black Black
3 3
White White
4 4
Blue Blue
5 5
White White
6 6
Purple Purple
7 7
White White
8 8
Brown Brown
9 9
White White
10 10
Relay connector
(white)
Red Red
11 11
Yellow Yellow
12 12
Black Black
13 13
Yellow Yellow
14 14
Blue Blue
15 15
Yellow Yellow
16 16
Purple Purple
17 17
Yellow Yellow
18 18
Brown Brown
19 19
Yellow Yellow
20 20
Relay connector
(black)
Blue Blue
21 21
Purple Purple
22 22
Red Red
23 23
Black Black
24 24
Relay connector
CN20 CN21
(White)
2 1
1 2 3 4
6 5 4 3
5 6 7 8 9
10 9 8 7
10 11 12 13 14 15
14 13 12 11
16 17 18 19 20 18 17 16 15
21 22 23 22 21 20 19
24 23
24
CN20 (Diagram viewed from CN21 (Diagram viewed from

pin side mating surface) pin side mating surface)
ze130z
Fig.1-7: Hand Control Signal System (Dust & splashproof specification)
1-57
3.3 Simple inspection method The following explains the simple inspection method for wiring in motor power
for internal wiring and encoder signal circuits.
Perform inspection according to Table 1-12.
Table 1-12: Simple Inspection Method for Wiring in Motor Power and Encoder Signal Circuits
1 Turn the controller power switch on.
2 Select manual operation and mode for each axis, and activate
the 1st to 4th axes at full stroke in the + and - directions.
Make sure that area around robot is free of

CAUTION hazard, and set the operation speed to
SP20% or less.
3
Criterion standard
(1) Motor power circuit

There must be no error code of number in 6110s or error of
number in 84404510 (the last digit indicates the axis
number).
(2) Encoder signal circuit
There must be no error code of number in 6420s or error of
number in 844046D0 (the last digit indicates the axis
number).
* Operate the 1st to 4th axes at full stroke: If the above error
code does not appear, it can be judged that there is no dis-
connection in internal wiring.
4 Turn motor power off, and then turn the controller power switch
off.
1-58
1-6 Details of 2-Year Inspection
1 Required 2-year Follow the procedure in Table 1-13.

inspection and
maintenance
Table1-13: 2-Year Inspection and Maintenance
Power to Inspection
No. Point or operation to be inspected Criterion Corrective action
controller method
1 Date for replacing battery in "DATE OF The replacement date has Replace encoder backup
RENEWING BAT." in "SETPRM LIST" on not reached its 2-year batteries.
top of controller expire date.
OFF Visual
(See "3 Replacing
encoder backup bat-
teries" on page 1-61)
1-59
2 Replacing encoder The position data of encoder installed in the servo motor is stored in memoryin-
backup batteries side the encoder.
When the controller is turned off, the data in memory is backed up by battery.
This battery has limited life, and must be replaced periodically.
Neglecting to replace the backup batteries will erase valuable data of

CAUTION
robot in memory and re-teaching may be needed.
2.1 When replacing encoder Shows when replacing encoder backup battery in Table 1-14 and Table 1-
backup battery is needed 15.
Table1-14: When replacing encoder backup battery is needed (RC7M)
No. When replacing encoder backup battery is needed (RC7M) Display meaning
1 (1) When displayed "Replacement date for controller backup bat- The current date has reached to "Battery
tery" in teaching pendant display section next inspection date" data
(2) When displayed "Error 2103" in mini pendant display section
2 When displayed of error 64A1-6 when controller power is on The voltage drop of encoder backup bat-
3 tery
When mark at top left of teaching pendant display section
(The mark will also appear when the
voltage drop of memory backup battery in
the controller.)
Table1-15: When replacing encoder backup battery is needed (RC8)
No. When replacing encoder backup battery is needed (RC8) Display meaning
1 (1) When displayed "inspection date for robot" in teaching pendant display The current date has reached to "encoder
section battery inspection date" data
(2) When displayed "Err8050000E" in mini pendant display section
2 When displayed of error 82404631 - 6 when controller power is on The voltage drop of encoder backup bat-
3 tery
When mark at top left of teaching pendant display section
(The mark will also appear when the
voltage of backup battery for clock in the
controller is low.)
1-60
3 Replacing encoder Replace the batteries according to Table 1-16.

backup batteries
Table1-16: Encoder Backup Battery Replacement Method (Cont’d from previous page)


CAUTION
robot.
the robot.
CN20 CN22 ze135z
2 Remove the four bolts holding the battery cover on the side sur-
face of robot. Bolts
Battery cover
Bolts
ze131z
3 Remove battery cover.
For Dust & splash proof specification, remove

CAUTION Battery cover
O-ring together.
ze132z
(To be cont’d)
1-61

4 Disconnect the J1 connector on power supply conversion
board, and then remove the batteries. Encoder backup battery
(1) Be sure to wear a wrist band and connect

its terminal to the grounded portion before
starting work.
CAUTION (2) Do not touch elements on the printed cir-
cuit board and their terminals with bare
hand (touching could cause them to be
damaged by static electricity).
J1 connector
Power conversion board ze133z
5 Attach brand-new batteries to battery holder, and then connect

Encoder backup battery
the J1 connector.
Battery holder
ze134z
6 Repeat steps 5 and 6 to replace the batteries connected to the

J2 connector.
When replacing batteries, do not disconnect

all connectors (J1-J2) at the same time: If all
CAUTION connectors are disconnected at once, the
position data in encoder could be lost. There-
fore, disconnect them one by one.
7 Reattach the battery cover, and then tighten the four bolts hold-
ing the battery cover. Bolts
Battery cover
(1) For Dust & splash proof specification,
attach O-ring with a brand-new one
CAUTION between battery cover and robot body.
Tightening torque of battery cover fixing bolts:

1.6 ± 0.3 Nm (16.3 ± 3.2 kg·cm)
Bolts
ze131z
(To be cont’d)
1-62

8 Set the date when the battery must be replaced next time. <RC7M>
Operate the teaching pendant using the following procedure: [F6 Set] → [F6 Maint] → [F4 Battery] → [OK] →
[Cancel] → [Cancel]
If the current date on controller is incorrect, the
next replacement date cannot be set correctly. <RC8>
CAUTION Make sure that the current date on controller is
[F6 Set] → [F7 Date and Maintenance] →
correct. [F3 Encoder Battery] → [2-year After Setting] →
[OK] → [OK] → [Cancel] → [Cancel]
(To be cont’d)
1-63
1-64
Chapter2
Replacement of Parts
This chapter summarizes the procedures for replacing parts in robot. Refer
to this chapter when the robot is faulty and replacement of parts is deemed
necessary.
2 Replacement of Parts 2-1 Details of Part Replacement
2-1 Details of Part If defect in parts inside the robot is detected, replace the parts and assembly
Replacement according to Table 2-1.
Table2-1: Replacement of Parts and Assemblies
No. Parts and assemblies Replacement procedure

1 Motors See "2-2 Replacing Motors" on page 2-2.
2 4th axis timing belt See "2-3 Replacing the Timing Belts" on page 2-68.
3 3rd axis air balance cylinder See "2-4 Replacing 3rd Axis Air Balance Cylinder" on page 2-85.
4 Second arm assembly See "2-5 Replacing Second Arm Assembly" on page 2-96.
5 Power conversion board See "2-6 Replacing Power Conversion Board" on page 2-125.
Bellow See "2-7 Replacing Bellows (Dust & splash proof specification)" on
6
page 2-131.
7 Robot body See "2-8 Replacing Robot" on page 2-142.
2-1
2 Replacement of Parts 2-2 Replacing Motors
2-2 Replacing Motors The motors for driving each axis are limited-life parts: If worn motor is used contin-
uously, electrical or mechanical defects could occur. Table 2-2 shows cases
where the motors must be replaced.
Table 2-2: Cases in Which Motors Must be Replaced and Related Phenomena
No. When motor replacement is necessary Phenomena

1 Encoder circuit in servo motor is faulty. Error related to encoder will occur and robot will not operate.
2 Motor shaft locks because of seizure, sticking, Robot will slide heavily, and error(s) of large deviation, over-current and/or
etc. overload will occur.
When motors are replaced, the relation in positions between the robot
axis and position data in encoder may change: If left as is, the robot
cannot be operated normally.
If the position data in encoder is erased by motor replacement, error
message of encoder system down fault will appear.
To prevent the above, perform CALSET to calibrate the relation
CAUTION
between robot axis and position data in encoder after motor replace-
ment.
If error message of encoder system down fault appears, reset the
encoder and perform CALSET.
(See "3-1 Procedure for Resetting Encoder" on page
3-1 and "3-2 CALSET Operation Method" on page 3-2.)
2-2
1 Methods for replacing The following explains the procedures for replacing each axis motor.
motors
1.1 1st axis motor replace- (1) Removing 1st axis motor
ment method Follow the procedure in Table 2-3.
Table 2-3: 1st Axis Motor Removal (Cont’d from previous page)


shoes when doing this work.
make sure that the pilot lamp hes gone
out. Air pipes
CAUTION (3) Turn off power and air supplied to periph-
eral devices (equipment) of robot.
(4) Remove cables (CN20, CN22) connected
to robot body.
(5) Remove air pipes (AIR1 - 4) connected to
robot body. CN20 CN22 ze135z
2 Remove the three screws (five bolts for dust & splash proof
specification) holding the 1st axis motor cover, and remove 1st Bolt
axis motor cover.
For dust & splash proof specification, also

CAUTION
remove O-ring. Arm tip side
Bolts
1st axis motor cover
ze136z
3 Cut off the six insulator locks and disconnect 1st axis motor
connector (black: 6P) and 1st axis encoder connector (black: Insulator locks 1st axis connector
4P). wiring plate
Arm tip side
Insulator locks Insulator locks
1st axis motor

1st axis encoder connector
connector (black: 6P)
(black: 4P) 1st axis motor ze137z
(To be cont’d)
2-3

4 Remove the three bolts holding 1st axis connector wiring plate.
1st axis connector wiring plate
Arm tip side Bolts

Bolt
1st axis motor ze138z
5 Remove 1st axis connector wiring plate.

ze139z
6 Remove a rubber bush for tightening 1st axis coupling bolts.
Rubber bush for tightening

1st axis coupling bolt
ze140z
(To be cont’d)
2-4

7 Move the 1st axis to approximately 0 degrees and loosen the
two 1st axis coupling bolts from the hole for tightening 1st axis
coupling bolt.
Hole for tightening

View from
arrow A
View from
arrow A
1st axis motor
1st axis coupling
1st axis coupling bolts

ze141z
8 Remove the four bolts holding 1st axis motor.

1st axis motor
Bolts Bolts
ze142z
9 Remove 1st axis motor.
1st axis motor
ze143z
(To be cont’d)
2-5
(2) Assembling 1st axis motor

Follow the procedure in Table 2-4.
Table 2-4: Assembling 1st Axis Motor (Cont’d from previous page)

1 Attach 1st axis motor to robot and tighten the four bolts (M5 x
16) securing 1st axis motor.
Tightening torque of 1st axis motor fixing bolts:

1st axis motor
5.9 ± 1.2 Nm (60.2 ± 12.0 kgf·cm)
(1) Be sure to attach the 1st axis motor in the

orientation shown in the illustration.
CAUTION (2) Be sure to degrease inside 1st axis cou-
pling and 1st axis motor shaft before
attaching 1st axis motor.
ze143z
1st axis motor
Bolts Bolts
ze142z
(To be cont’d)
2-6

2 Move the 1st axis to approximately 0 degrees and loosen the
two 1st axis coupling bolts from the hole for tightening 1st axis
coupling bolt located at the side surface of robot.
Tightening torque of 1st axis coupling bolts:

9.0 ± 1.8 Nm (91.8 ± 18.4 kgf·cm)
Hole for tightening

View from
arrow A
View from
arrow A
1st axis motor
1st axis coupling
1st axis coupling bolts

5
3 Attach a rubber bush for 1st axis coupling bolts to the hole for
tightening 1st axis coupling bolt.
Rubber bush for tightening

ze140z
4 Attach 1st axis connector wiring plate to 1st axis motor.

ze139z
(To be cont’d)
2-7

5 Attach the three bolts (M3 x 8) securing 1st axis connector wir-
ing plate. 1st axis connector wiring plate
Tightening torque of 1st axis wiring plate fixing bolts: Arm tip side Bolts
0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm) Bolt
1st axis motor ze138z
6 Connect 1st axis motor connector (black: 6P) and 1st axis
encoder connector (black: 4P). 1st axis motor
Arm tip side connector
(black: 6P)
1st axis encoder

connector
7 Arrange 1st axis motor cable and 1st axis encoder cable as
shown in the illustration and fix using the six insulator locks. Insulator locks 1st axis connector
wiring plate
Arm tip side
(1) Attach insulator locks in the positions
shown in the illustration. Insulator locks Insulator locks
CAUTION (2) Make sure that 1st axis motor cable and
1st axis encoder cable do not touch inner
surface of 1st axis housing.
1st axis motor

1st axis encoder connector
connector (black: 6P)
(To be cont’d)
2-8

8 Attach 1st axis motor cover and tighten the three bolts
(five bolts for dust & splash proof specification). Bolt
Tightening torque of 1st axis motor cover fixing screws

(Standard specification):
0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm) Arm tip side
Tightening torque of 1st axis motor cover fixing bolts Bolts

(Dust & splash proof specification):
1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)
For dust & splash proof specification, attach O- 1st axis motor cover
CAUTION ring between 1st axis motor cover and robot ze136z
body. Be sure to use brand-new O-ring.
AIR3, AIR4) to robot, and turn on power to the controller,
peripheral devices (equipment) of robot, and air supply.
Air pipes
CN20 CN22 ze145z
10 1st axis encoder system down fault error appears on the

teaching pendant: Reset the encoder and perform CALSET.
page 3-1 and "3-2 CALSET Operation Method"
on page 3-2.)
(To be cont’d)
2-9
1.2 2nd axis motor (1) Removing 2nd axis motor

replacement method Follow the procedure in Table 2-5.
Table 2-5: 2nd Axis Motor Removal (Cont’d from previous page)


make sure that the pilot lamp has gone
out. Air pipes
to robot body.
specification) holding user wiring plate.
For dust & splash proof specification, remove
CAUTION
O-ring together.
Bolts
User wiring plate

ze110z
3 Remove the six bolts (eight bolts for 850 mm/1000 mm arm
length) holding second arm cover. Second arm cover
* With standard specifications, proceed with step 5.
Bolts
ze486z
(To be cont’d)
2-10

free. Bellows stay
Bolts
5
5 While inclining the user wiring plate, pass it through second

arm as shown in the illustration.
User wiring plate
5
6 Remove second arm cover.

remove packing.
CAUTION
Second arm
cover

5
(To be cont’d)
2-11

7 Cut off five insulator locks and disconnect 2nd axis motor con-
Insulator locks 2nd axis motor
nector (white: 4P) and 2nd axis encoder connector (white: 4P).
connector
Arm tip side (white: 4P)
2nd axis
Insulator locks encoder
connector
(white: 4P)
Insulator lock
2nd axis motor ze146z
8 Remove the three bolts holding 2nd axis connector wiring

plate. 2nd axis connector wiring plate
Bolts
Bolt
9 Remove 2nd axis connector wiring plate.
2nd axis connector

wiring plate
ze148z
10 Remove rubber bush for tightening 2nd axis coupling bolts,

located at the side surface of second arm. Arm tip side
Second arm
Rubber bush for tightening 2nd axis coupling bolt

ze149z
(To be cont’d)
2-12

11 Move the 2nd axis to approximately 0 degrees and loosen the
two 2nd axis coupling bolts from the hole for tightening 1st axis Arm tip side
Second arm
coupling bolt.
View from
arrow A
Hole for tightening 2nd axis coupling bolt
View from
arrow A
2nd axis motor
2nd axis coupling
2nd axis coupling bolts
ze150z
12 Remove the four bolts holding 2nd axis motor.
Arm tip side
Bolts Bolts
2nd axis motor

ze151z
13 Remove 2nd axis motor.

2nd axis motor
Arm tip side
ze152z
(To be cont’d)
2-13
(2) Assembling 2nd axis motor

Table 2-6: Assembling 2nd Axis Motor (Cont’d from previous page)

1 Attach 2nd axis motor to robot and tighten the four bolts (M4 x
14) securing 2nd axis motor. 2nd axis motor
Tightening torque of 2nd axis motor fixing bolts: Arm tip side
2.9 ± 0.6 Nm (29.6 ± 5.9 kgf·cm)
(1) Be sure to attach the 2nd axis motor in the

CAUTION (2) Be sure to degrease inside 2nd axis cou-
pling and 2nd axis motor shaft before
attaching 2nd axis motor.
ze152z
Arm tip side
Bolts Bolts
2nd axis motor

ze151z
(To be cont’d)
2-14

2 Move the 2nd axis to approximately 0 degrees and loosen the
two 2nd axis coupling bolts from the hole for tightening 2nd Arm tip side
Second arm
axis coupling bolt located at the side surface of second arm.
Tightening torque of 2nd axis coupling bolts:

9.0 ± 1.8 Nm (91.8 ± 18.4 kgf·cm)
View from
arrow A
Hole for tightening 2nd axis coupling bolt
View from
arrow A
2nd axis motor
2nd axis coupling
2nd axis coupling bolts
ze150z
3 Attach a rubber bush for tightening 2nd axis coupling bolts to

the hole for tightening 2nd axis coupling bolt. Arm tip side
Second arm
Rubber bush for tightening 2nd axis coupling bolt

ze149z
4 Attach 2nd axis connector wiring plate to 2nd axis motor.
2nd axis connector

wiring plate
ze148z
(To be cont’d)
2-15

5 Attach the three bolts (M3 x 8) securing 2nd axis connector
wiring plate. 2nd axis connector wiring plate
Bolts
Tightening torque of 2nd axis connector wiring plate fixing

bolts:
0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm)
Bolt
6 Connect 2nd axis motor connector (white: 4P) and 2nd axis
2nd axis motor connector (white: 4P)
encoder connector (white: 4P).
Arm tip side
2nd axis
encoder
connector
(white: 4P)
7 Arrange 2nd axis motor cable and 2nd axis encoder cable as
Insulator locks 2nd axis motor
shown in the illustration and fix using five insulator locks.
connector
Arm tip side (white: 4P)
(1) Attach insulator locks in the positions
shown in the illustration. 2nd axis
CAUTION (2) Make sure that 2nd axis motor cable and Insulator locks encoder
2nd axis encoder cable do not touch inner connector
surface of 2nd arm. (white: 4P)
Insulator lock
(To be cont’d)
2-16

CAUTION arm.

5
User wiring plate
5
(To be cont’d)
2-17

Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)
Take care that the O-ring does not get caught

Bolts
5
12 Attach second arm cover and tighten the six bolts (eight bolts
for 850 mm/1000 mm arm length) securing second arm cover. Second arm cover
Tightening torque of second arm cover fixing bolts

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)
Take care that wires do not get caught between

CAUTION
the cover and second arm.
Bolts
ze486z
13 Attach the four bolts (M3 x 8) securing user wiring plate, and
attach user wiring plate.
Tightening torque of user wiring plate fixing screws

0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm)
Tightening torque of user wiring plate fixing bolts

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
CAUTION
cover.
(2) Take care that the O-ring does not get
(To be cont’d)
2-18

Air pipes
CN20 CN22 ze145z
15 2nd axis encoder system down fault error appears on the

on page 3-2.)
(To be cont’d)
2-19
1.3 3rd axis motor (1) Removing 3rd axis motor

replacement method For arm length 600 mm/700 mm, follow the procedure shown in Table 2-7, and
in the case of arm length 850 mm/1000 mm, follow the procedure shown in
Table 2-8.
Table 2-7: 3rd Axis Motor Removal (Arm length 600 mm/700 mm) (Cont’d from previous page)

1 Release 3rd axis brake and slowly move 3rd axis up to the
lower limit.
(See "Chapter 4. Auxiliary work" on RC7M Controller or
RC8 Controller Service Manual for encoder brake releasing
method.)

out. Air pipes
to robot body.
CAUTION
O-ring together.
Bolts
User wiring plate

ze110z

Second arm cover
Bolts
ze486z
(To be cont’d)
2-20

free. Bellows stay
Bolts
5

User wiring plate
5

remove packing.
CAUTION
Second arm
cover

5
(To be cont’d)
2-21

Insulator lock
5
cess.
5
CAUTION
cess.
5
Arm tip side Bolts

5
(To be cont’d)
2-22

Insulator lock
Insulator lock
(white: 4P)
5
13 Cut off one insulator lock fixing the surge suppressor.
Insulator lock
Surge suppressor
5
14 Cut off one insulator lock fixing terminus capacitor board.
Insulator lock
5
3rd axis motor
Insulator lock
5
(To be cont’d)
2-23

Screws
ze496z
Rack cover
ze497z
Bolts (M4 20)

Bolts (M4 40)
5
(To be cont’d)
2-24

When removing the rack installing bolt, the
CAUTION spline shaft assembly may fall down. Please
note that it is dangerous when working.
Bolts
Bolts
5
21 Remove the four bolts holding the 3rd axis motor.

3rd axis motor
Bolts
Bolts ze501z
(To be cont’d)
2-25

22 Remove the 3rd axis motor from the 3rd axis rack.
3rd axis motor
3rd axis rack assembly

ze502z
23 Loosen the bolt holding the 3rd axis flywheel.

3rd axis flywheel
Allen wrench
ze503z
24 Remove the 3rd axis fly wheel.

3rd axis flywheel
3rd axis motor
ze504z
(To be cont’d)
2-26

lower limit.
method.)

out. Air pipes
CAUTION (3) Turn off power and air supply to peripheral
robot.
(5) Disconnect the air pipes (AIR1 to 4) from
the robot. CN20 CN22 ze135z
CAUTION
the O-ring.
Bolts
User wiring plate

ze110z
Bolts
5
(To be cont’d)
2-27

free. Bellows stay
Bolts
5

User wiring plate
5

remove packing.
CAUTION
Second arm
cover

5
(To be cont’d)
2-28

8 Cut off four insulator locks as shown in the illustration.
Insulator lock
5
9 Remove the two bolts holding 3rd axis connector plate and
make 3rd axis connector plate free.
3rd axis connector plate

Bolts
5
10 Remove the air pipe (yellow) with radio pliers while pressing
the air pipe fittings.
Air pipe (yellow)
5
nector (white: 6P) and 3rd axis encoder connector (white: 4P) 3rd axis encoder connector
(white: 4P)
Insulator lock

(white: 6P) 5
(To be cont’d)
2-29

3rd axis motor
Insulator lock
5

Screws
ze496z
Rack cover
ze497z
Bolts (M4 20)

Bolts (M4 40)
5
(To be cont’d)
2-30

When removing the rack installing bolt, the
CAUTION spline shaft assembly may fall down. Please
note that it is dangerous when working.
Bolts
Bolts
5
18 Remove the four bolts holding the 3rd axis motor.

3rd axis motor
Bolts
Bolts ze501z
(To be cont’d)
2-31

19 Remove the 3rd axis motor from the 3rd axis rack assembly.
3rd axis motor

ze502z
20 Loosen the bolt holding the 3rd axis flywheel.

3rd axis flywheel
Allen wrench
ze503z
21 Remove the 3rd axis flywheel.

3rd axis flywheel
3rd axis motor
ze504z
(To be cont’d)
2-32
(2) Assembling 3rd axis motor

For arm length 600 mm/700 mm, follow the procedure shown in Table 2-9, and
Table 2-10.
Table 2-9: Assembling 3rd Axis Motor (Arm length 600 mm/700 mm) (Cont’d from previous page)

1 Attach 3rd axis flywheel to 3rd axis motor.
3rd axis flywheel
Be sure to attach the 3rd axis flywheel in the
CAUTION
3rd axis motor
ze504z
3rd axis flywheel
3rd axis motor
ze505z
2 Tighten the bolt (M3 x 10) securing 3rd axis flywheel.

3rd axis flywheel
Tightening torque of 3rd axis flywheel fixing screw:
2.0 ± 0.2 Nm (20.4 ± 2.0kgf·cm)
Apply screw lock to the threads of 3rd axis fly-

CAUTION wheel fixing screw.
Allen wrench
ze503z
(To be cont’d)
2-33

3 Apply grease (EPINOCK AP-1) to rack tooth flank of 3rd axis
motor. Apply grease (EPINOCK AP-1)
to tooth flank
3rd axis motor
ze506z
4 Attach 3rd axis motor to 3rd axis rack assembly.
Attach 3rd axis motor in the orientation shown

CAUTION 3rd axis motor
in the illustration.

ze502z
5 Temporarily tighten the four bolts (M4 x 14) securing 3rd axis
3rd axis motor
motor to 3rd axis motor.
Bolts
Bolts ze501z
6 Lightly press 3rd axis motor in the direction of the arrow to

remove play (back-lash adjustment) from 3rd axis, and tighten
Bolts
the four bolts (M4 x 14) securing 3rd axis motor.
Be careful not to press 3rd axis motor assembly

CAUTION
too strongly.
Tightening torque of 3rd axis motor fixing bolts:

2.9 ± 0.6 Nm (29.6 ± 5.9 kgf·cm)
3rd axis motor

Bolts
5
(To be cont’d)
2-34


9.8 ± 2.0 Nm (100.0 ± 20.0kgf·cm)
Bolts
Bolts
5

2.9 ± 0.6 Nm (29.6 ± 5.9kgf·cm)
Bolts (M4 20)

Bolts (M4 40)
5
(To be cont’d)
2-35

Rack cover
ze497z

Screws
0.49 ± 0.1 Nm (5 ± 1kgf·cm)
CAUTION Apply screw lock.
ze496z
3rd axis motor
Insulator lock
5
13 Fix the terminus capacitor board to the 3rd axis encoder part
with the insulator lock.
Insulator lock
3rd axis encoder part

5
(To be cont’d)
2-36

14 Fix the surge suppressor to 3rd axis motor wiring and 3rd axis
encoder wiring to the insulator lock.
Insulator lock
Surge suppressor
5
Insulator lock
Insulator lock
(white: 4P)
5
tighten the four bolts (M3 x 8) securing the 3rd/4th axis con-
nector plate. 3rd/4th axis connector plate
Tightening torque of 3rd/4th axis connector plate fixing bolts:

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)
Arm tip side Bolts

5
17 Fix the air pipe (yellow) and wiring to the 3rd/4th axis connec-
tor plate with the insulator lock as shown in the illustration. 3rd/4th axis connector plate
Insulator lock
CAUTION pipe could be crushed and necessary air to flow
through.
Air pipe (yellow)
5
(To be cont’d)
2-37

Insulator lock
5
Insulator lock
Red
CAUTION pipe could be crushed and necessary air to flow White
through.
Yellow
5

CAUTION arm.

5
(To be cont’d)
2-38

User wiring plate
5

Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)

CAUTION
during the process.
Bolts
5
24 Reinstall the second arm cover, and tighten the six bolts hold-
ing the cover. Second arm cover

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION
Bolts
ze486z
(To be cont’d)
2-39


0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm)

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
CAUTION cover.
Air pipes
CN20 CN22 ze145z
27 3rd axis encoder system down fault error appears on the

on page 3-2.)
(To be cont’d)
2-40

1 Attach 3rd axis flywheel to 3rd axis motor.
3rd axis flywheel
Be sure to attach the 3rd axis flywheel in the
CAUTION orientation shown in the illustration.
3rd axis motor
ze504z
3rd axis flywheel
3rd axis motor
ze505z
2 Tighten the bolt (M3 x 10) securing 3rd axis flywheel.

3rd axis flywheel
Tightening torque of 3rd axis flywheel fixing screw:
2.0 ± 0.2 Nm (20.4 ± 2.0kgf·cm)
Apply screw lock to the threads of 3rd axis fly-

CAUTION
wheel fixing screw.
Allen wrench
ze503z
3 Apply grease (EPINOCK AP-1) to rack tooth flank of 3rd axis

motor. Apply grease (EPINOCK AP-1)
to tooth flank
3rd axis motor
ze506z
(To be cont’d)
2-41

4 Attach 3rd axis motor to 3rd axis rack assembly.
Attach 3rd axis motor in the orientation shown

CAUTION 3rd axis motor
in the illustration..

ze502z
5 Temporarily tighten the four bolts (M4 x 14) securing 3rd axis
3rd axis motor
motor to 3rd axis motor.
Bolts
Bolts ze501z
6 Lightly press 3rd axis motor in the direction of the arrow to

remove play (back-lash adjustment) from 3rd axis, and tighten
Bolts
the four bolts (M4 x 14) securing 3rd axis motor.
Be careful not to press 3rd axis motor assembly

CAUTION
too strongly.
Tightening torque of 3rd axis motor fixing bolts:

2.9 ± 0.6 Nm (29.6 ± 5.9 kgf·cm)
3rd axis motor

Bolts
5
(To be cont’d)
2-42

9.8 ± 2.0 Nm (100.0 ± 20.0kgf·cm)
Bolts
Bolts
5

2.9 ± 0.6 Nm (29.6 ± 5.9kgf·cm)
Bolts (M4 20)

Bolts (M4 40)
5
Rack cover
ze497z
(To be cont’d)
2-43

Screws
0.49 ± 0.1 Nm (5 ± 1kgf·cm)
CAUTION Apply screw lock.
ze496z

3rd axis motor
Insulator lock
5
encoder connector (white: 4P), and then fix to 3rd axis connec- 3rd axis encoder connector
(white: 4P)
tor plate with the insulator lock.
Insulator lock

(white: 6P) 5
14 Attach air pipe (yellow) to the air balance cylinder.
Air pipe (yellow)
5
(To be cont’d)
2-44

15 Attach the 3rd axis connector plates to the second arm and
tighten the four bolts (M3 x 8) securing the 3rd axis connector
plate.
Tightening torque of 3rd axis connector plate fixing bolts:

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)

Bolts
5
16 Fix the air pipes (yellow) and wires with the insulator lock.
Insulator lock
5

CAUTION arm.

5
(To be cont’d)
2-45

User wiring plate
5

Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)

CAUTION
during the process.
Bolts
5
21 Reinstall the second arm cover, and tighten the eight bolts
holding the second arm.

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION
Bolts
5
(To be cont’d)
2-46


0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm)

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
CAUTION cover.
peripheral devices equipment) of robot, and air supply.
Air pipes
CN20 CN22 ze145z
24 3rd axis encoder system down fault error appears on the

on page 3-2.)
(To be cont’d)
2-47
1.4 4th axis motor (1) Removing 4th axis motor

replacement method For arm length 600 mm/700 mm, follow the procedure shown in Table 2-11, and
Table 2-12.
Table 2-11: 4th Axis Motor Removal (Arm length 600 mm/700 mm) (Cont’d from previous page)


out. Air pipes
to robot body.
CAUTION
O-ring together.
Bolts
User wiring plate

ze110z

Second arm cover
Bolts
ze486z
(To be cont’d)
2-48

free. Bellows stay
Bolts
5

User wiring plate
5

remove packing.
CAUTION
Second arm
cover

5
(To be cont’d)
2-49

Arm tip side
Bolts
ze526z
8 Remove the four bolts holding 3rd/4th axis connector plate and
Arm tip side Bolts 5
9 Cut off four insulator locks and disconnect 4th axis motor con-
nector (black: 4P) and 4th axis encoder connector (black: 4P). Insulator lock
4th axis encoder
connector
(black: 4P)
4th axis motor

connector
(black: 4P) Insulator lock
Arm tip side
5
10 Remove the four bolts holding 4th axis motor assembly.

Bolts

Bolts
ze118z
(To be cont’d)
2-50

11 Remove 4th axis motor assembly.
4th axis motor

assembly
Arm tip
side ze166z
(To be cont’d)
2-51


out. Air pipes
robot.
CAUTION
the O-ring.
Bolts
User wiring plate

ze110z
Bolts
5
(To be cont’d)
2-52

free. Bellows stay
Bolts
5

User wiring plate
5

remove packing.
CAUTION
Second arm
cover

5
(To be cont’d)
2-53

the plate.

Bolts
5
8 Remove the four bolts holding 3rd/4th axis connector plate and
make 3rd/4th axis connector plate free. 4th axis motor connector Insulator lock
(black: 4P)
Insulator lock 4th axis encoder

connector
Arm tip side (black: 4P)
5
9 Cut off the insulator lock fixing the 4th axis motor wiring and
4th axis encoder wiring.
Insulator lock
5
4th axis
connector plate
Bolts
Bolts
5
(To be cont’d)
2-54

11 Remove the four bolts holding the 4th axis motor assembly.
Bolts

Bolts
ze118z
4th axis motor

assembly
Arm tip
side ze166z
(To be cont’d)
2-55
(2) Assembling 4th axis motor

Table 2-14.
Table 2-13: Assembling 4th Axis Motor (Arm length 600 mm/700 mm) (Cont’d from previous page)

1 Attach insulator lock to 4th axis motor as shown in the illustra-
tion.
4th axis motor
assembly
Insulator lock
5
2 Attach 4th axis motor assembly to robot body.
4th axis motor

assembly
Arm tip
side ze166z
3 Temporarily tighten the four bolts (M5 x 15) holding 4th axis
motor assembly. 4th axis motor assembly
Bolts

Bolts
ze118z
(To be cont’d)
2-56

tion, and while pressing 4th axis motor assembly in the direc- 225 N (23.0 kgf)
tion of arrow with the force of 225N (23.0 kgf), tighten the four
Tightening torque of 4th axis motor assembly holding bolt:

5.9 ± 1.2 Nm (60.2 ± 12.0 kgf·cm)

ze530z

Inside hole

assembly
Flat-head
screwdriver
shaft assembly
Inside hole
ze531z
Bolts

Bolts
ze118z
(To be cont’d)
2-57

5 Connect 4th axis motor connector (black: 4P) and 4th axis
encoder connector (black: 4P) 4th axis encoder
connector
(black: 4P)
4th axis motor connector

(black: 4P)
Arm tip side
5
6 Fix 4th axis motor connector using the two insulator locks, and
4th axis encoder connector by two insulator locks. Insulator lock
4th axis encoder
connector
(black: 4P)
4th axis motor

connector
Arm tip side
5
Tightening torque of 3rd/4th connector plate fixing bolts:

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)
Arm tip side Bolts

5
8 Attach internal wiring plate, and tighten the two bolts (M3 x 8)
securing internal wiring plate.
Arm tip side
Tightening torque of internal wiring plate fixing bolt:
2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)
Bolts
ze526z
(To be cont’d)
2-58

CAUTION arm.

5
User wiring plate
5
(To be cont’d)
2-59

Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)

Bolts
5

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION
Bolts
ze486z

0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm)

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
CAUTION
cover.
(To be cont’d)
2-60

Air pipes
CN20 CN22 ze145z
16 4th axis encoder system down fault error appears on the

on page 3-2.)
(To be cont’d)
2-61

1 Attach insulator lock to 4th axis motor as shown in the illustra-
tion.
Insulator lock
5
2 Attach 4th axis motor assembly to robot body.
4th axis motor

assembly
Arm tip
side ze166z
3 Temporarily tighten the four bolts (M5 x 15) securing 4th axis
motor assembly. 4th axis motor assembly
Bolts

Bolts
ze118z
(To be cont’d)
2-62

tion, and while pressing 4th axis motor assembly in the direc- 225 N (23.0 kgf)
tion of arrow with the force of 225N (23.0 kgf), tighten the four
Tightening torque of 4th axis motor fixing bolts:

5.9 ± 1.2 Nm (60.2 ± 12.0 kgf·cm)

ze530z

Inside hole

assembly
Flat-head
screwdriver
shaft assembly
Inside hole
ze531z
Bolts

Bolts
ze118z
(To be cont’d)
2-63

encoder connector (black: 4P). 4th axis motor connector
(black: 4P)
4th axis encoder

connector
5
6 Fix 4th axis motor connector using the two insulator locks, 4th
axis encoder connector by two insulator locks. 4th axis motor connector Insulator lock
(black: 4P)

connector
5
7 Fix the 4th axis motor wiring and 4th axis encoder wiring to the
insulator lock.
Insulator lock
5
8 Attach the 4th axis connector plates to the second arm and
tighten the four bolts (M3 x 8) securing the 4th axis connector Bolts
plate. 4th axis connector plate

2.0 ± 0.2 Nm (20.4 ± 2.0 kgf·cm)
Bolts
Arm tip side 5
(To be cont’d)
2-64

9 Attach the internal wiring plate, and then fix two bolts (M3 x 8)
holding internal wiring plate.

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)

Bolts
5

CAUTION arm.

5
User wiring plate
5
(To be cont’d)
2-65


Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)

CAUTION
during the process.
Bolts
5

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION the cover and second arm.
Bolts
5

0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm)

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
CAUTION cover.
(To be cont’d)
2-66

Air pipes
CN20 CN22 ze145z
17 4th axis encoder system down fault error appears on the

on page 3-2.)
(To be cont’d)
2-67
2 Replacement of Parts 2-3 Replacing the Timing Belts
2-3 Replacing the Timing Belts
1 Methods for The following explains the procedures for replacing 4th timing belts.
replacing timing belts
There are two 4th axis timing belts; one is "4th axis timing belt A"
CAUTION from 4th axis motor to intermediate shaft, the other is "4th axis tim-
ing belt B" from intermediate shaft to output shaft.
1.1 Replacement method for (1) Removing 4th axis timing belt A
4th axis timing belt A For arm length 600 mm/700 mm, follow the procedure shown in Table 2-15, and
Table 2-16.
Table 2-15: Removal of 4th Axis Timing Belt A (Arm length 600 mm/700 mm) (Cont’d from previous page)

Follow the steps 1 - 20,, shown in "Table 2-7: 3rd Axis
Motor Removal (Arm length 600 mm/700 mm)"
on page 2-20.
Follow the of steps 7 - 11, shown in "Table 2-11: 4th Axis
on page 2-48.
3 Remove the four bolts holding 4th axis intermediate shaft
assembly. Bolts
shaft assembly
Arm tip side
Bolts
Ze487z
4 Remove 4th axis intermediate shaft assembly.

shaft assembly
Arm tip side

Ze488z
(To be cont’d)
2-68

5 Remove 4th axis timing belt A.
Arm tip side

Ze489z
(To be cont’d)
2-69

Follow the steps 1 - 20, shown in "Table 2-8: 3rd Axis
on page 2-27.
Follow the of steps 7 - 11, shown in "Table 2-12: 4th Axis
on page 2-52.
3 Remove the four bolts holding 4th axis intermediate shaft
assembly. Bolts
shaft assembly
Arm tip side
Bolts
Ze487z
4 Remove 4th axis intermediate shaft assembly.

shaft assembly
Arm tip side

Ze488z

Arm tip side

Ze489z
(To be cont’d)
2-70
(2) Installing 4th axis timing belt A

Table 2-18.
Table 2-17: 4th Axis Timing Belt A Installation (Arm length 600 mm/700 mm) (Cont’d from previous page)

1 Put 4th axis timing belt A inside second arm.
Arm tip side

Ze489z
2 Attach 4th axis timing belt A to lower pulley of 4th axis interme-
diate shaft, and attach 4th axis timing belt B to upper pulley, 4th axis timing belt B
and then attach 4th axis intermediate shaft assembly to sec- 4th axis timing belt A
ond arm.
Arm tip side

shaft assembly Ze490z
intermediate shaft assembly. Bolts
shaft assembly
Arm tip side
Bolts
Ze487z
(To be cont’d)
2-71

tion, and while pressing 4th axis motor assembly in the direc-
tion of arrow with the force refer to the table below, tighten the
four bolts (M5 x 15) holding the 4th axis motor assembly.
Tightening torque of 4th axis intermediate shaft assembly

holding bolt: 4th axis timing belt B
6.0 ± 0.6 Nm (61.2 ± 6.1 kgf·cm)
ze544z

Outside hole
Inside hole
Rib
Inside hole
Outside hole

Inside hole
Rib
ze541z
Bolts
shaft assembly
Arm tip side
Bolts
Ze487z
(To be cont’d)
2-72

5 Attach 4th axis motor assembly.
Follow the steps 2 - 8, shown in "Table 2-13: Assem-
bling 4th Axis Motor (Arm length 600 mm/700
mm)" on page 2-56.
6 Attach 3rd axis motor assembly.
bling 3rd Axis Motor (Arm length 600 mm/700
mm)" on page 2-33.
7 Perform CALSET for 4th axis.
2.)
and perform CALSET.
on page 3-2.)
(To be cont’d)
2-73

1 Put 4th axis timing belt A inside second arm.
Arm tip side

Ze489z
2 Attach 4th axis timing belt A to lower pulley of 4th axis interme-
diate shaft, and attach 4th axis timing belt B to upper pulley, 4th axis timing belt B
and then attach 4th axis intermediate shaft assembly to sec- 4th axis timing belt A
ond arm.
Arm tip side

shaft assembly Ze490z
intermediate shaft assembly. Bolts
shaft assembly
Arm tip side
Bolts
Ze487z
(To be cont’d)
2-74

tion, and while pressing 4th axis motor assembly in the direc-
tion of arrow with the force refer to the table below, tighten the
four bolts (M5 x 15) holding the 4th axis motor assembly.
Tightening torque of 4th axis intermediate shaft assembly hold-

ing bolt: 4th axis timing belt B
6.0 ± 0.6 Nm (61.2 ± 6.1 kgf·cm)
ze544z

Outside hole
Inside hole
Rib
Inside hole
Outside hole

Inside hole
Rib
ze541z
Bolts
shaft assembly
Arm tip side
Bolts
Ze487z
(To be cont’d)
2-75

mm)" on page 2-62.
mm)" on page 2-41.
2.)
and perform CALSET.
on page 3-2.)
(To be cont’d)
2-76
1.2 Replacement method for (1) Removing 4th axis timing belt B
4th axis timing belt B For arm length 600 mm/700 mm, follow the procedure shown in Table 2-19, and
Table 2-20.
Table 2-19: Removal of 4th Axis Timing Belt B (Arm length 600 mm/700 mm) (Cont’d from previous page)

on page 2-20.
Follow the steps 7 - 11, shown in "Table 2-11: 4th Axis
on page 2-48.
Follow the steps 3 - 5 shown in "Table 2-15: Removal of
4th Axis Timing Belt A (Arm length 600 mm/700
mm)" on page 2-68.
4 Remove the eight bolts holding 3rd/4th axis spline nut stay.
Bolts
Bolts
Bolts
Ze491z
5 Lift up 3rd/4th axis spline nut stay using the two screwdrivers,
as shown in the illustration. 3rd/4th axis spline nut stay
Ze492z
(To be cont’d)
2-77

6 Remove 3rd/4th axis spline nut stay from second arm.
3rd/4th axis spline nut stay
Ze493z
7 Remove 4th axis timing belt B.
4th axis pulley

(spline nut side)
Ze494z
(To be cont’d)
2-78

on page 2-27.
Follow the steps 7 - 12, shown in "Table 2-12: 4th Axis
on page 2-52.
Follow the steps 3 - 5 shown in "Table 2-16: Removal of
4th Axis Timing Belt A (Arm length 850 mm/1000
mm)" on page 2-70.
4 Remove the eight bolts holding 3rd/4th axis spline nut stay.
Bolts
Bolts
Bolts
Ze491z
5 Lift up 3rd/4th axis spline nut stay using the two screwdrivers,
as shown in the illustration. 3rd/4th axis spline nut stay
Ze492z
6 Remove 3rd/4th axis spline nut stay from second arm.

Ze493z
(To be cont’d)
2-79

7 Remove 4th axis timing belt B.
4th axis pulley

(spline nut side)
Ze494z
(To be cont’d)
2-80
(2) Installing 4th axis timing belt B

Table 2-22.
Table 2-21: 4th Axis Timing Belt B Installation (Arm length 600 mm/700 mm) (Cont’d from previous page)

1 Attach 4th axis timing belt B to 4th axis pulley (spline nut side).
Arrange 4th axis timing belt inside second arm,

CAUTION
4th axis pulley

(spline nut side)
Ze494z
Ze495z
2 Attach 3rd/4th axis spline nut stay to second arm.

Ze493z
(To be cont’d)
2-81

3 Tighten the eight bolts (M4 x 14) securing 3rd/4th spline nut
stay.
Bolts
Tightening torque of spline nut stay fixing bolts:
4.0 ± 0.4 Nm (40.8 ± 4.1 kgf·cm)
Bolts
Bolts
Ze491z
4 Attach 4th axis timing belt A.

Follow the steps 1 - 4 shown in "Table 2-17: 4th Axis
Timing Belt A Installation (Arm length 600 mm/
700 mm)" on page 2-71.
mm)" on page 2-56.
mm)" on page 2-33.
2.)
and perform CALSET.
on page 3-2.)
(To be cont’d)
2-82

1 Attach 4th axis timing belt B to 4th axis pulley (spline nut side).
Arrange 4th axis timing belt inside second arm,

CAUTION as shown in the illustration.
4th axis pulley

(spline nut side)
Ze494z
Ze495z
2 Attach 3rd/4th axis spline nut stay to second arm.

Ze493z
3 Tighten the eight bolts (M4 x 14) securing 3rd/4th spline nut
stay.
Bolts
Tightening torque of spline nut stay fixing bolts:
4.0 ± 0.4 Nm (40.8 ± 4.1 kgf·cm)
Bolts
Bolts
Ze491z
(To be cont’d)
2-83

4 Attach 4th axis timing belt A.
Follow the steps 1 - 4 shown in "Table 2-18: 4th Axis
Timing Belt A Installation (Arm length 850 mm/
1000 mm)" on page 2-74.
mm)" on page 2-62.
mm)" on page 2-41.
2.)
and perform CALSET.
on page 3-2.)
(To be cont’d)
2-84
2 Replacement of Parts 2-4 Replacing 3rd Axis Air Balance Cylinder
2-4 Replacing 3rd Axis Air

Balance Cylinder
1 Methods for replacing 3rd The following explains the procedures for replacing 3rd axis air balance cylinder.
axis air balance cylinder
(1) Removing 3rd axis air balance cylinder
Table 2-23: Removal of 3rd Axis Air Blance Cylinder (Cont’d from previous page)

lower limit.
method.)

out. Air pipes
to robot body.
3 Remove the four bolts holding user wiring plate.
Bolts
User wiring plate

ze110z
(To be cont’d)
2-85

4 Remove the six bolts (eight bolts for 850 mm/1000 mm arm
length) holding the second arm cover. Second arm cover
Bolts
ze486z

User wiring plate
5
Second arm
cover
ze113z
(To be cont’d)
2-86

7 In case of 600 mm/700 mm arm length type:
In case of 600 mm/700 mm arm length
Remove the two bolts holding 3rd/4th axis connector plate and 3rd/4th axis connector plate
In case of 850 mm/1000 mm arm length type:
Remove the two bolts holding 3rd axis connector plate and
Arm tip side Bolts ze527z
3rd sxis
connector
plate
Arm tip side Bolts \G\
8 Press the release sleeve of the air pipe fittings with radio pliers
and disconnect the air pipe (yellow).
Air pipe (yellow)
ze535z
9 Remove the nut holding floating joint.
Floating joint
Nut
ze195z
(To be cont’d)
2-87

10 Remove floating joint from spline shaft assembly.
Floating joint
Spline shaft assembly

ze549z
11 Remove the six bolts holding 3rd axis air balance cylinder
assembly.
Bolts
Bolts
ze514z
12 Remove 3rd axis air balance cylinder assembly.

cylinder assembly ze515z
13 Loosen nut.
Nut
ze516z
(To be cont’d)
2-88

14 Remove floating joint.
3rd air balance
cylinder assembly
Floating joint
ze517z
15 Remove the four bolts holding cylinder plate.

Bolts
Bolts
ze518z
16 Remove cylinder plate.

3rd air balance
cylinder
Cylinder plate
ze519z
(To be cont’d)
2-89
(2) Installing 3rd axis air balance cylinder

Table 2-24: 3rd Axis Air Balance Cylinder Installation (Cont’d from previous page)

1 Attach cylinder plate to 3rd axis air balance cylinder.
3rd air balance
cylinder
Cylinder plate
ze519z
2 Temporarily tighten the four bolts (M4 x 25) securing cylinder

plate to 3rd axis air balance cylinder assembly. Bolts
Bolts
ze518z
3 Fully tighten nut on the 3rd axis air balance cylinder assembly.
3rd air balance
cylinder assembly
Nut
ze520z
(To be cont’d)
2-90

4 Loosen nut by two turns
.
Apply screw lock to the threads of 3rs axis air

CAUTION balance cylinder assembly.
Two turns
Nut
ze521z
5 Tighten floating joint until it touches the nut of air balance cylin-
der assembly.
4th air balance
cylinder assembly
Nut
Floating joint
ze550z
6 Tighten nut with floating joint hold.
Tightening torque of cylinder shaft fixing nut:

9.0 ± 0.9 Nm (91.8 ± 18.4 kgf·cm)
Nut
Floating joint
ze522z
7 Attach 3rd axis air balance cylinder assembly to 2nd axis arm.

cylinder assembly ze515z
(To be cont’d)
2-91

8 Attach the six bolts (M4 x 12) securing 3rd axis air balance cyl-
inder assembly.
Tightening torque of 3rd axis air balance cylinder assembly fix- Bolts
ing bolt :
2.9 ± 0.6Nm (29.6 ± 5.9 kgf·cm)
Bolts
ze514z
9 Attach floating joint to spline shaft assembly.
Floating joint
Spline shaft assembly

ze549z
10 Attach nut fixing floating joint.
Tightening torque of floating joint fixing nut:

9.0 ± 0.9 Nm (91.8 ± 18.4 kgf·cm) Floating joint
CAUTION Apply screw lock to the threads of floating joint.
Nut
ze195z
11 Connect CN22 connector and release 3rd axis brake.

(To be cont’d)
2-92

12 Move spline shaft assembly up and down two or three times.
Spline shaft assembly ze523z
13 Tighten the four bolts (M4 x 25) securing cylinder plate, tempo-
rarily tightened in previous step.
Tightening torque of cylinder plate fixing bolt:

2.9 ± 0.6 Nm (29.6 ± 5.9 kgf·cm) Bolts
Bolts
ze551z
14 Use radio pliers to hold the air pipe and then connect the air
pipe (yellow) to the air pipe fittings.
Air pipe (yellow)
ze535z
(To be cont’d)
2-93

15 In case of 600 mm/700 mm arm length type:
Attach 3rd/4th axis connector plate and tighten the two bolts 3rd/4th axis connector plate
(M3 x 8) holding 3rd/4th axis connector plate.
Tightening torque of 3rd/4th axis connector plate fixing bolt:

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)
In case of 850 mm/1000 mm arm length type:
Attach 3rd axis connector plate and tighten the two bolts (M3 x
8) holding 3rd axis connector plate.
Arm tip side Bolts ze527z
Tightening torque of 3rd axis connector plate fixing bolt:
2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm) In case of 850 mm/1000 mm arm length
3rd sxis
connector
plate
Arm tip side Bolts \G\
User wiring plate
5
17 Attach second arm cover and tighten the six bolts (eight bolts
for 850 mm/1000 mm arm length) securing second arm cover. Second arm cover

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION
Bolts
ze486z
(To be cont’d)
2-94

\


0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm)
Bolts
User wiring plate

ze110z
19 Connect the cables (CN20) and air pipes (AIR1, AIR2, AIR3,
AIR4) to robot, and turn on power to the controller, peripheral
devices (equipment) of robot, and air supply.
Air pipes
CN20 CN22 ze145z
(To be cont’d)
2-95
2 Replacement of Parts 2-5 Replacing Second Arm Assembly
2-5 Replacing Second Arm

Assembly
1 Methods for replacing The following explains the procedures for replacing second arm assembly.
second arm assembly
(1) Removing second arm assembly
Table 2-26.
Table 2-25: Removal of Second Arm Assembly (Arm length 600 mm/700 mm) (Cont’d from previous page)


out. Air pipes
robot.
CAUTION
the O-ring.
Bolts
User wiring plate

ze110z

Second arm cover
Bolts
ze486z
(To be cont’d)
2-96

free. Bellows stay
Bolts
5

User wiring plate
5

remove packing.
CAUTION
Second arm
cover

5
(To be cont’d)
2-97

Insulator lock
5
cess.
5
CAUTION
cess.
5
Arm tip side Bolts

5
(To be cont’d)
2-98

Insulator lock
Insulator lock
(white: 4P)
5
Insulator lock
nector (black: 6P) and 4th axis encoder connector (black: 4P)
4th axis encoder
as shown in the illustration. connector
(black: 4P)
4th axis motor

connector
5
13 Disconnect the connector connected to terminus capacitor

board.
connector
5
3rd axis motor
Insulator lock
5
(To be cont’d)
2-99

Air pipe (yellow)
5
16 Disconnect three connectors for user wiring (white: 10P, black

10P, and white 5P). Connectors for user wiring
5
17 Disconnect four air pipes (black, blue, red, and white) from the
user wiring plate. User wiring plate Air pipe (blue)
Air pipe (red)
Air pipe (black)
Air pipe (white)
5
the plate.

Bolts
5
(To be cont’d)
2-100

19 Remove the bolt holding saddle of the internal wiring plate.
Bolts
5
20 Remove the saddle from the internal wiring.

Saddle
5
21 Remove the two bolts holding 2nd axis cable guide.

2nd axis cable guide
Wipe off silicone grease with paper cloth from
CAUTION
the 2nd axis cable guide before the process.
Bolts
5
22 Remove the 2nd axis cable guide.

5
(To be cont’d)
2-101

23 Remove the 21 bolts holding second arm assembly.
Arm tip side Bolts
When removing the last bolt, the second arm
CAUTION assembly will fall down. One person should
hold the arm another person remove the bolt.
Bolts
Second arm
Bolts
ze556z
24 Remove second arm assembly.

Second arm assembly
Be sure to perform this work with at least two
CAUTION
persons.
ze557z
(To be cont’d)
2-102

lower limit.
method.)

out. Air pipes
robot.
(5) Disconnect the air pipes (AIR1 to 4) from
CAUTION
the O-ring.
Bolts
User wiring plate

ze110z
Bolts
5
(To be cont’d)
2-103

free. Bellows stay
Bolts
5

User wiring plate
5

remove packing.
CAUTION
Second arm
cover

5
(To be cont’d)
2-104

8 Cut off four insulator locks as shown in the illustration.
Insulator lock
5
9 Remove the two bolts holding 3rd axis connector plate and

Bolts
5
Air pipe (yellow)
5
nector (white: 6P) and 3rd axis encoder connector (white: 4P) 3rd axis encoder connector
(white: 4P)
Insulator lock

(white: 6P) 5
(To be cont’d)
2-105

12 Cut off two locations of the insulator lock fixing the air pipe (yel-
low) and 3rd axis motor wiring.
CAUTION cess.
Insulator lock
R003484
13 Disconnect the connector (white: 4P) connected to terminus

capacitor board.
connector (white: 4P)

5
14 Cut off the two insulator locks fixing the wiring to the 4th axis
connector plate. Insulator lock
CAUTION
cess.
5
15 Remove the two bolts holding 4th axis connector plate and
make 4th axis connector plate free. 4th axis connector board
Bolts
Bolts
5
(To be cont’d)
2-106

16 Cut off four insulator locks and disconnect 4th axis motor con-
nector (black: 4P) and 4th axis encoder connector (black: 4P). 4th axis motor connector Insulator lock
(black: 4P)

connector
5
17 Disconnect three connectors for user wiring (white: 10P, black

5
18 Disconnect four air pipes (black, blue, red, and white) from the
user wiring plate. User wiring plate Air pipe (blue)
Air pipe (red)
Air pipe (black)
Air pipe (white)
5
the plate.
User wiring plate
Bolts
5
(To be cont’d)
2-107

20 Remove the bolt holding saddle of the internal wiring plate.
Bolts
5
21 Remove the saddle from the internal wiring.

Saddle
5
22 Remove the two bolts holding 2nd axis cable guide.

Wipe off silicone grease with paper cloth from
CAUTION
the 2nd axis cable guide before the process.
Bolts
5
23 Remove the 2nd axis cable guide.

5
(To be cont’d)
2-108

24 Remove the 21 bolts holding second arm assembly.
Arm tip side Bolts
When removing the last bolt, the second arm
CAUTION assembly will fall down. One person should
hold the arm another person remove the bolt.
Bolts
Second arm
Bolts
ze556z
25 Remove second arm assembly.

Second arm assembly
CAUTION
persons.
ze557z
(To be cont’d)
2-109
(2) Installing second arm assembly

Table 2-28.
Table 2-27: Second Arm Assembly Installation (Arm length 600 mm/700 mm) (Cont’d from previous page)

1 Install second arm assembly.
Second arm assembly
CAUTION
persons.
ze557z
2 Attach the 14 bolts (M4 x 35) holding second arm assembly.

Arm tip side Bolts
Tightening torque of second arm assembly holding bolt:
4.0 ± 0.4 Nm (40.8 ± 4.1 kgf·cm)
Bolts
Second arm
Bolts
ze556z
3 Attach by passing the internal wiring through 2nd axis cable

guide. 2nd axis cable guide
5
(To be cont’d)
2-110

4 Attach the two bolts (M3 x 8) holding the 2nd axis cable guide.
Tightening torque of 2nd axis cable guide fixing bolts:
2.0 ± 0.2 Nm (20.4 ± 2.0 kgf·cm)
Bolts
5
5 Apply the silicon grease inside 2nd axis cable guide.

Apply the silicon grease
5
6 Attach the saddle to the internal wiring as shown in the illustra-

tion. Insulator lock
Saddle
5
7 Attach the saddle to internal wiring plate and tighten one bolt
(M4 x 10) securing saddle.
Bolts
Tightening torque of saddle fixing bolt:

2.9 ± 0.6 Nm (29.6 ± 5.9 kgf·cm)
5
(To be cont’d)
2-111

8 Pass air pipes (red and white) through internal wiring plate.
User wiring plate
Air pipe (red) Air pipe (white)

5
9 Tighten the two bolts (M3 x 8) holding internal wiring plate and
secure internal wiring plate.
Tightening torque of internal wiring plate fixing bolt:

2.0 ± 0.2 Nm (20.4 ± 2.0 kgf·cm)

Bolts
5
10 Connect four air pipes (black, blue, red, and white) to the user
wiring plate. User wiring plate Air pipe (blue)
Air pipe (red)
Air pipe (black)
Air pipe (white)
5
11 Connect three connectors for user wiring (white: 10P, black

5
(To be cont’d)
2-112

12 Connect air pipe (yellow).
Air pipe (yellow)
5
3rd axis motor
Insulator lock
5
14 Attach the connector (white: 4P) to the terminus capacitor

board.
connector
5
Insulator lock
encoder connector (black: 4P), and then fix to 3rd/4th axis con-
4th axis encoder
nector plate with the insulator lock. connector
(black: 4P)
4th axis motor

connector
5
(To be cont’d)
2-113

Insulator lock
Insulator lock
(white: 4P)
5
Tightening torque of 3rd/4th connector plate fixing bolts:

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)
Arm tip side Bolts

5
18 Fix the air pipe (yellow) and wiring to the 3rd/4th axis connec-
tor plate with the insulator lock as shown in the illustration. 3rd/4th axis connector plate
Insulator lock
CAUTION pipe could be crushed and necessary air to
flow through.
Air pipe (yellow)
5
Insulator lock
5
(To be cont’d)
2-114

Insulator lock
Red
CAUTION pipe could be crushed and necessary air to White
flow through.
Yellow
5

(1) For dust & splash proof specification, Standard specifications
CAUTION arm.

5
User wiring plate
5
(To be cont’d)
2-115


Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)

CAUTION
during the process.
Bolts
5

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION between the cover and second arm.
Bolts
ze486z
26 Individual encoder system down fault error appears on the

teaching pendant: Reset the encoder for the corresponding
axis.
page 3-1.)
27 Perform CALSET for 2nd, 3rd, 4th axis. (See "3-2 CALSET
Operation Method" on page 3-2.)
(To be cont’d)
2-116

1 Pass the internal wiring through and attached the second arm
assembly to the first arm. Second arm assembly

CAUTION persons.
ze557z
2 Attach the 21 bolts (M4 x 35) holding second arm assembly.

Arm tip side Bolts
Tightening torque of second arm assembly holding bolt:
4.0 ± 0.4 Nm (40.8 ± 4.1 kgf·cm)
Bolts
Second arm
Bolts
ze556z
3 Attach by passing the internal wiring through 2nd axis cable

guide. 2nd axis cable guide
5
4 Attach the two bolts (M3 x 8) holding the 2nd axis cable guide.
Tightening torque of 2nd axis cable guide fixing bolts:
2.0 ± 0.2 Nm (20.4 ± 2.0 kgf·cm)
Bolts
5
(To be cont’d)
2-117

5 Apply the silicon grease inside 2nd axis cable guide.
Apply the silicon grease
5
6 Attach the saddle to the internal wiring as shown in the illustra-

tion. Insulator lock
Saddle
5
7 Attach the saddle to internal wiring plate and tighten one bolt
(M4 x 10) securing saddle.
Tightening torque of saddle fixing bolt: Saddle

2.9 ± 0.6 Nm (29.6 ± 5.9 kgf·cm)
Bolts Internal wiring plate

5
8 Attach the internal wiring to the second arm and tighten the
two bolts (M3 x 8) securing the internal wiring plate.
User wiring plate
2.0 ± 0.2 Nm (20.4 ± 2.0 kgf·cm)
Bolts
5
(To be cont’d)
2-118

9 Connect four air pipes (black, blue, red, and white) to the user
wiring plate. User wiring plate Air pipe (blue)
Air pipe (red)
Air pipe (black)
Air pipe (white)
5
10 Connect three connectors for user wiring (white: 10P, black

5
11 Attach the 4th axis motor connector (black: 4P) and 4th axis
encoder connector (black: 4P). 4th axis motor connector
(black: 4P)
4th axis encoder

connector
5
12 Fix 4th axis motor connector using the two insulator locks, 4th
axis encoder connector by two insulator locks. 4th axis motor connector Insulator lock
(black: 4P)

connector
5
(To be cont’d)
2-119

13 Attach the 4th axis connector plates to the second arm and
tighten the four bolts (M3 x 8) securing the 4th axis connector 4th axis connector board
plate. Bolts

2.0 ± 0.2 Nm (20.4 ± 2.0 kgf·cm)
Bolts
5
14 Fix the internal wiring to the 4th axis connector plate with two
insulator locks as shown in the illustration. Insulator lock
5
15 Connect the connector (white: 4P) to the terminus capacitor

board.
connector (white: 4P)

5
16 Attach the air pipe (yellow) and 3rd axis motor wiring to the 4rd
axis connector plate and fix them at two locations with the
insulator lock.
Do not tighten up the insulator lock hard. It

CAUTION
could prevent sufficient air to flow.
Insulator lock
R003484
(To be cont’d)
2-120

encoder connector (white: 4P), and then fix to 3rd axis connec- 3rd axis encoder connector
(white: 4P)
tor plate with the insulator lock.
Insulator lock

(white: 6P) 5
18 Attach air pipe (yellow) to the air balance cylinder.
Air pipe (yellow)
5
19 Attach the 3rd axis connector plates to the second arm and
tighten the four bolts (M3 x 8) securing the 3rd axis connector
plate.
Tightening torque of 3rd axis connector plate fixing bolts:

2.0 ± 0.4 Nm (20.4 ± 4.0 kgf·cm)

Bolts
5
20 Fix the air pipes (yellow) and wires with the insulator lock.
Insulator lock
5
(To be cont’d)
2-121

CAUTION arm.

5
User wiring plate
5
(To be cont’d)
2-122

Bellows stay
1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)

Bolts
5

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm)

CAUTION
Bolts
5

0.59 ± 0.1 Nm (6.0 ± 1.2 kgf·cm)

1.6 ± 0.3 Nm (16.3 ± 3.2 kgf·cm) Bolts
CAUTION
cover.
(To be cont’d)
2-123

Air pipes
CN20 CN22 ze145z
28 Individual encoder system down fault error appears on the

teaching pendant: Reset the encoder for the corresponding
axis. (See "3-1 Procedure for Resetting Encoder"
on page 3-1.)
29 Perform CALSET for 2nd, 3rd, 4th axis. (See "3-2 CALSET
Operation Method" on page 3-2.)
(To be cont’d)
2-124
2 Replacement of Parts 2-6 Replacing Power Conversion Board
2-6 Replacing Power The power supply conversion board converts 24 V source to 5 V, and then stably
Conversion Board supplies it to the encoder circuits of each axis motor.
When the controller is turned off, the power conversion board switches the 5 V
source to 3.6 V source from the encoder backup batteries.
The power conversion board is mounted in the robot.
1 Fuses on power Fuses are installed in each power line of power conversion board, as shown in
supply board Fig. 2-1.
Table 2-29 lists phenomena and troubleshooting steps when fuses have blown.
Top view of power conversion board
F1
Fuse no. Application
F1 For 5 V/3.6 V output protection
For motor encoder protection (when power conver-
F2
J5 sion board is faulty)
F2
zc451z
Fig.2-1: Locations of Fuses on Power Conversion Board
Table2-29: Phenomena and Troubleshooting Steps When Fuses Have Blown (Cont’d from previous page)
Fuse no. Phenomena when blown Troubleshooting

(1) All axis encoder no reception error appears on (1) Check to see whether encoder power source of 5 V in robot
pendant. internal wiring has been shorted to 0 V or body.
(2) Individual axis encoder system down fault error (2) Replace F1 fuse
appears on pendant. (3) If individual axis encoder system down fault error occurs,
F1 (1.3A) replace the F1 fuse, reset the corresponding encoder and
then perform CALSET.
on page 3-2.)
(1) Error message 6424 (4th axis encoder no (1) Replace power conversion board (power conversion board
F2 (1.3A)
reception error) appears on pendant. faulty).
If the power conversion board is faulty, replace it according to "2 Procedure

for replacing power conversion board" on page 2-126.
2-125
2 Procedure for replacing The following explains the procedure for replacing the power supply conversion
power conversion board board.
(1) Removing power conversion board

Follow the procedure shown in Table 2-30.
Table2-30: Power Conversion Board Removal Procedure (Cont’d from previous page)


out. Air pipes
to robot body.
2 Remove the four bolts holding the battery cover.

Bolts
Battery cover
Bolts
ze131z
3 Remove battery cover.
For dust & splash proof specification, also

CAUTION Battery cover
remove the O-ring.
ze132z
(To be cont’d)
2-126

4 Disconnect J1 and J2 connectors on power conversion board.
starting work.
J1 connector
5 Remove two encoder backup batteries.

Battery holder
ze134z
6 Remove the four bolts holding power conversion board.
Bolts Power conversion

board
Bolts
ze219z
7 Disconnect J5 connector (white: 8P) on power conversion

board.
Power conversion board
J5 connector (white: 8P)

ze220z
(To be cont’d)
2-127

8 Remove power conversion board.

ze221z
(To be cont’d)
2-128
(2) Installing power conversion board

Table2-31: Power Conversion Board Installation (Cont’d from previous page)

1 Install power conversion board.
Be sure to install in the orientation shown in the

CAUTION
illustration.

ze221z
2 Connect J5 connector (white: 8P) on power conversion board.
J5 connector (white: 8P)

ze220z
3 Attach the four bolts (M3 x 5) securing power conversion

board.
Bolts Power conversion
Tightening torque of power conversion board assembly fixing board
bolt:
5.9 ± 1.2 Nm (60 ± 12 kgf·cm)
Bolts
ze219z
(To be cont’d)
2-129
Table2-31: Power Conversion Board Installation (Cont’d from previous page)

4 Attach two encoder backup batteries and connect J1 and J2
connectors. Encoder backup battery

starting work.
J1 connector
5 Attach battery cover and tighten the four bolts (M3 x 8) secur-
ing battery cover. Bolts
Battery cover
Tightening torque of battery cover fixing bolt:
1.6 ± 0.3 Nm (16.3 ± 3.3 kgf·cm)
(1) For Dust & splash proof specification,

attach O-ring with a brand-new one
CAUTION between battery cover and robot body.
Bolts
ze131z
6 Connect the cables and air pipes to robot, and turn on power to
the controller, peripheral devices (equipment) of robot, and air
supply.
Air pipes
CN20 CN22 ze145z

and perform CALSET.
on page 3-2.)
(To be cont’d)
2-130
2 Replacement of Parts 2-7 Replacing Bellows (Dust & splash proof specification)
2-7 Replacing Bellows (Dust &

splash proof
specification)
1 Methods for replacing bel- The following explains the procedures for replacing 3rd axis bellows.
lows
1.1 Replacement method for (1) Removing bellows (top)

bellows (top) Follow the procedure in Table 2-32.
Table 2-32: Removing bellows (top) (Cont’d from previous page)

1 Move 3rd axis up to around the middle of the stroke by manual
operation and then turn off the power of the controller.
2 Remove the eight bolts (bottom side) holding bellows.
Bolts
Ze560z
3 Remove the eight bolts (top side) holding bellows.
Bolts
Ze561z
4 Remove the four bolts holding bellows stay (top).
Bolts
Bellows (top)
Ze562z
(To be cont’d)
2-131
Table 2-32: Removing bellows (top) (Cont’d from previous page)

5 Remove bellows stay (top).
Bellows stay (top)
Ze563z
6 Remove bellows (top).
Bellows (top)
Ze564z
7 Snick between bellows (top) and bellows plate using cutter,

etc., and separate bellows plate.
CAUTION Be careful not to scratch bellows plate.
Bellows plate
Ze565z
8 Remove bellows plate.

Remove plates from both top and bottom of bellows.
Bellows plate
Ze566z
(To be cont’d)
2-132
(2) Assembling bellows (top)

Table 2-33: Assembling bellows (top) (Cont’d from previous page)

1 Remove silicon sealing agent adhering to bellows plate.
Bellows plate
Ze567z
2 Apply silicon sealing agent (TSE382-C) to the bellows plate.
Apply silicon sealing agent entire surface of bel-

CAUTION
lows plate evenly.
Bellows plate
Silicon sealing agent

Ze568z
3 Attach bellows plate to bellows (top).

Attach bellows plates to both top and bottom of bellows.
Bellows plate
Ze566z
(To be cont’d)
2-133

4 Attach bellows (top).
Bellows (top)
O-ring
Ze576z
CAUTION Replace O-ring with a brand new-one.
Bellows (top) O-ring

Ze577z
6 Attach the four bolts (M3 x 10) securing bellows stay (top).

1.6 ± 0.2 Nm (16.3 ± 1.6 kgf·cm)
Bolts
Bellows (top)
Ze562z
7 Attach the eight bolts (bottom side)(M3 x 8) securing bellows.

1.2 ± 0.1 Nm (12.2 ± 1.2 kgf·cm)
Bolts
Ze560z
(To be cont’d)
2-134

8 Attach the eight bolts (M3 x 8) (top side) securing bellows.

1.2 ± 0.1 Nm (12.2 ± 1.2 kgf·cm)
Bolts
Ze561z
(To be cont’d)
2-135
1.2 Replacement method for (1) Removing bellows (bottom)

bellows (bottom) Follow the procedure in Table 2-34.
Table 2-34: Removing bellows (bottom) (Cont’d from previous page)

1 Move 3rd axis up to around the middle of the stroke by manual
operation and then turn off the power of the controller.
CAUTION Remove the hand section of user in advance.
2 Remove the eight bolts (bottom side) holding bellows.
Bolts Ze569z
3 Remove the eight bolts (top side) holding bellows.
Bolts
Ze570z
(To be cont’d)
2-136

4 Remove the eight bolts holding bellows stay (bottom).
Bolts Ze571z
5 Remove bellows stay (bottom).
Bellows (bottom)
Ze572z
6 Remove bellows (bottom).
Bellows (bottom)
Ze573z
7 Snick between bellows (bottom) and bellows plate using cutter,

etc. and separate bellows plate.
Bellows plate
Ze565z
(To be cont’d)
2-137

8 Remove bellows plate.
Remove plates from both top and bottom of bellows.
Bellows plate
Ze566z
(To be cont’d)
2-138
(2) Assembling bellows (bottom)

Table 2-35: Assembling bellows (bottom) (Cont’d from previous page)

1 Remove silicon sealing agent adhering to bellows plate.
Bellows plate
Ze567z
2 Apply silicon sealing agent (TSE382-C) to the bellows plate.
Apply silicon sealing agent entire surface of bel-

CAUTION
lows plate evenly.
Bellows plate
Silicon sealing agent

Ze568z
3 Attach bellows plate to bellows (bottom).

Attach bellows plates to both top and bottom of bellows.
Bellows plate
Ze566z
(To be cont’d)
2-139

4 Attach bellows (bottom).
CAUTION Replace O-ring with brand new one.
Bellows (bottom)
Ze573z
5 Attach bellows stay (bottom).
CAUTION Replace O-ring with brand new one.
O-ring
Bellows stay (bottom)
Ze574z
6 Attach the eight bolts (M2.5 x 6) securing bellows stay (bot-

tom).

0.9 ± 0.1 Nm (9.1 ± 0.9 kgf·cm)
Bolts Ze571z
7 Attach the eight bolts (bottom side)(M3 x 8) securing bellows.

1.2 ± 0.1 Nm (12.2 ± 1.2 kgf·cm)
Bolts Ze569z
(To be cont’d)
2-140

8 Attach the eight bolts (M3 x 8) (top side) securing bellows.

1.2 ± 0.1 Nm (12.2 ± 1.2 kgf·cm)
Bolts
Ze570z
(To be cont’d)
2-141
2 Replacement of Parts 2-8 Replacing Robot
2-8 Replacing Robot
1 Overview of robot Fig. 2-2 shows the procedure for replacing the robot.
replacement
1 Set replacement robot body.
Input RANG data

2 (See "2.2 RANG data entry method" on page 2-143 for details)
Perform CALSET
3 (See "3-2 CALSET Operation Method" on page 3-2)
Check software limit

4 Operate 1st to 4th axis at full stroke and make sure that
software limit error appears immediately before the axis
touches the mechanical end.
If the axis touches the mechanical end or the error message
appears in the middle of stroke, it is likely that the RANG data
has been erroneously input or mistake has occurred
in CALSET operation.
5
Fig.2-2: Overview of Robot Body Replacement
2-142
2 RANG data The RANG data is the angle of all axis when the robot body moved to CALSET
setting positions and memorized in the controller.
The RANG data is peculiar data and the value varies by the robot.
If enter the RANG data of other robot to the controller and perform CALSET, robot
coordinates are warped and straight line stability gets worse.
2.1 RANG data label sticking The label described the RANG data is stuck on the base part of the robot body.
position See Fig. 2-3.
Label sticking position
R003546
Fig.2-3: RANG data label sticking position
2.2 RANG data entry method Entry RANG data method varies depending on the connected controller.
2-143
2-144
Chapter3
Auxiliary Work
This chapter summarizes the necessary work to be done in conjunction

with inspection and maintenance, parts replacement, and troubleshooting.
Refer to this chapter whenever it is necessary to perform each job.
3 Auxiliary Work 3-1 Procedure for Resetting Encoder
3-1 Procedure for Resetting If error of encoder system down occurs when the encoder backup batteries are
Encoder dead or motors are replaced, it is necessary to reset the encoder and perform
CALSET. Ignoring this will disable normal operation of the robot.
Reset the encoder and perform CALSET. Not doing so will disable normal opera-
tion of the robot.
The following explains the procedure of resetting the encoder. For CALSET, see
"3-2 CALSET Operation Method" on page 3-2.
1 Cases when encoder Table 3-1 lists the cases when encoder must be reset.
must be reset
Table3-1: Cases When Encoder Must Be Reset and Concurrent Phenomena
No. Cases when reset is necessary Specific phenomena

1 Voltage supplied from backup batteries to motor encoder con- (1) After motor is replaced, encoder system down error occurs.
nectors is shut off (2) After internal wiring is checked, encoder system down error
occurs.
(3) When encoder backup batteries are dead.
(4) Encoder system down error occurs.
2 The motor speed exceeds the allowable value Error of encoder counter overflow occurs.
3 Each axis motor operates abruptly with control power OFF Error of encoder speed error with controller power OFF occurs.
2 Encoder resetting method Encoder resetting method varies depending on the connected controller.
3-1
3 Auxiliary Work 3-2 CALSET Operation Method
3-2 CALSET Operation Method CALSET refers to calibration of relationship between the position data recog-
nized by robot and actual robot position.
CALSET is necessary when position data in encoder was erased after the motor
was replaced, or the backup batteries in encoder are dead.
Executing CALSET will restore the robot calibration data in the controller: This
data is referred to as CALSET. The CALSET data varies for each robot.
Take care when executing CALSET since the motor brakes are
released and the robot will move of its own weight.
CAUTION After completing CALSET, make sure, using manual operation, that
the axes stop immediately before they touch the mechanical end by
software limit.
3-2
1 CALSET setting positions Fig. 3-1 shows the CALSET setting positions of 1st to 4th axes.
Axis CALSET position

1st axis Positive direction rotation end (counterclockwise end when viewed from top)
Position
2nd axis Negative direction rotation end

3rd axis Positive direction rotation end
4th axis Positive direction rotation end set by CALSET bolt (counterclockwise end when viewed from the top)
Floor type Hung type
4th axis (+)

1rd axis (+)
3rd axis (+)

3rd axis (+)
2rd axis (-)
2rd axis (-)

1rd axis (+)
4th axis (+)
5
(1) When performing CALSET, release the brake of axis to CALSET and press it on to mechanical end.
(See "Chapter 4. Auxiliary work" on RC7M Controller or RC8 Controller Service Manual for
encoder brake releasing method.)
CAUTION (2) When performing CALSET for 3rd axis, make sure that air balance is adjusted. If air balance is not
adjusted, 3rd axis may fall down due to its weight when the brake is released.
(See "Chapter 4. Auxiliary work" on RC7M Controller or RC8 Controller Service Manual for air
balance adjusting method.)
Fig.3-1: CALSET setting positions of 1st to 4th axes
3-3
2 How to Attach the 4th Axis Fig. 3-2 shows instructions on how to attach the 4th axis CALSET bolt.
CALSET Bolt
4th axis CALSET bolt

Standard Dust & splash
specifications proof specifications
Mechanical end Bottom bellows

for 4th axis Mechanical end
for 4th axis
1st axis stopper bolt
Stopper

Stopper
Positive direction
5
CAUTION After finishing the CALSET, remove the 4th axis CALSET bolt.
Fig.3-2: How to Attach the 4th Axis CALSET Bolt
3-4
ROBOT HM-G/A0 SERIES
SERVICE MANUAL
First Edition : October, 2017
DENSO WAVE INCORPORATED

Service Department
• Reproduction or translation of any part of this manual without authorization is prohibited.

• The contents of this manual are subject to change without notice.
4-2-12, Toranomon, Minato-ku, Tokyo, Japan 105-0001
http://www.denso-wave.com

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AC SERVO TYPE ROBOT

This manual covers the following type Denso robot:

Indicates a potentially hazardous situation, which, if not avoided, could result

Indicates a potentially hazardous situation, which, if not avoided, may result

(1) Cautions when inspecting or replacing part of robot:

Chapter1 Inspection and Maintenance

1-1 Types and Purposes of Inspection and Maintenance.......................... 1-1

1-2 Details of Daily Inspection ................................................................... 1-2

1-3 Details of 3-Month Inspection .............................................................. 1-3

1-4 Details of 6-Month Inspection .............................................................. 1-4

1-5 Details of 1-Year Inspection................................................................. 1-7

1-6 Details of 2-Year Inspection............................................................... 1-59

2-1 Details of Part Replacement .................................................................2-1

2-2 Replacing Motors..................................................................................2-2

2-3 Replacing the Timing Belts .................................................................2-68

2-4 Replacing 3rd Axis Air Balance Cylinder ............................................2-85

2-5 Replacing Second Arm Assembly ......................................................2-96

2-6 Replacing Power Conversion Board.................................................2-125

2-7 Replacing Bellows (Dust & splash proof specification).....................2-131

2-8 Replacing Robot ...............................................................................2-142

3-1 Procedure for Resetting Encoder ........................................................ 3-1

3-2 CALSET Operation Method ................................................................. 3-2

This chapter summarizes the periodic inspection of Denso robot:

Table1-1: Types and Purpose of Inspection and Maintenance

No. Type Purpose

1-2 Details of Daily Inspection

Table 1-2: Daily Inspection and Maintenance

Point or operation to be Power to Inspection

See "Chapter 4. Auxiliary work" on RC7M Controller or RC8 Controller

1-3 Details of 3-Month

1 Required 3-month Perform inspection and maintenance according to Table 1-3.

Table1-3: 3-Month Inspection and Maintenance

Point or operation to Power to Inspection

1-4 Details of 6-Month

Table 1-4: 6-Month Inspection and Maintenance

Point or operation to Power to Inspection

The lubrication must be performed every six months based on 2-shift

2 Point to be lubricated Table 1-5 shows point to be lubricated.

Table 1-5: Point to Be Lubricated

3rd axis rack

Cross-section of 3rd axis rack

Arm tip side Tooth flank

3rd axis air balance

Fig.1-1: Bellows fixing bolt

Tightening torque of bellows fixing bolt:

CAUTION Replace O-ring with a brand-new one.

1-5 Details of 1-Year Inspection

No. Point or operation to Power to Inspection Criterion Corrective action

Push-pull gauge 1

Timing belt 5

No. Procedure Illustration

(1) Be sure to wear safety goggles, helmet and

User wiring plate

No. Procedure Illustration

User wiring plate

No. Procedure Illustration

connect brake release switch connector.

Push-pull gauge 1

Timing belt 5