< 2-axes SERVO POSITIONER

MECHANICAL UNIT
MAINTENANCE MANUAL

B-82535EN/03
 • Original Instructions

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.

• No part of this manual may be reproduced in any form.

• All specifications and designs are subject to change without notice.

The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.

In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as “impossible”.
B-82535EN/03

PREFACE
This manual describes maintenance and connection work for the servo positioner. Before replacing parts,
check the specifications of the mechanical unit.

Model name Mechanical unit specification No.

2-axes Servo Positioner A05B-1220-J201

(1)

TYPE (2)
NO. (3) WEIGHT
DATE (4) (5) kg

(1)

TYPE (2)
NO. (3) WEIGHT
DATE (4) (5) kg

No. (1) (2) (3) (4) (5)

CONTENTS MODEL TYPE No. DATE WEIGHT kg
PRINT
PRINT PRODUCTION
LETTERS 2-Axes Servo Positioner A05B-1220-J201 295
SERIAL NO. YEAR AND
MONTH

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 B-82535EN/03

Specification
Item Specifications
Controlled axes 2 axes(J1, J2)
Motion range J1-axis 270°(-135°～ +135°) 4.72 rad(-2.36 rad～ +2.36 rad)
J2-axis 480°(-240°～ +240°) 8.38 rad(-4.19 rad～ +4.19 rad)
Maximum speed J1-axis 120°/sec 2.09 rad/sec
(Note 1) J2-axis 190°/sec 3.32 rad/sec
Max payload 500 kg
Allowable load J1-axis 180 kgf･m 1764 N･m
moment J2-axis 70 kgf･m 686 N･m
2 2
J1-axis 3061 kgf･cm･s 300 kg･m
2 2
J2-axis 1020 kgf･cm･s 100 kg･m
Drive method Electric servo drive by AC servo motor
Weight About 295 kg
Required facilities Average power consumption ： 1.0 kW
Input power supply capacity ： 2.0 kVA
Installation Ambient temperature :0 to 45℃ (Note 2)
environment Ambient humidity :Normally 75%RH or less (No dew or frost allowed)
Short time 95%Rh or less (Within 1 month)
Permissible altitude :Above the sea 1000m or less
Vibration :0.5G or less
Free of corrosive gases (Note 3)
Note1) It does not arrive at each axial maximum speed at the short movement distance.
Note2) When positioner is used in low temperature environment that is near to 0ºC, or robot is not operated
for a long time in the environment that is less than 0ºC in a holiday or the night, because viscous
resistance of the drive train is so big that may cause occurrence of collision detect alarm (SRVO –050)
etc. In this case, we recommend performing the warm up operation for several minutes.
Note3) Contact the service representative, if the robot is to be used in an environment or a place subjected to
severe vibrations, heavy dust, cutting oil splash and or other foreign substances.

Dust-proof/drip performance
Normal specification
MECHANICAL UNIT IP54

CAUTION
Definition of IP 54
5=Dust-tight
4=Protection from water immersion

Integrated air hose

Max air pressure 0.49MPa (5kgf/cm2)
3
Max air flow 0.12Nm /min (120Nl/min)

Performance of resistant chemicals and resistant solvents

(1) The positioner (including severe dust/liquid protection model) cannot be used with the following
liquids because there is fear that rubber parts (packing, oil seal, O ring etc.) will corrode.
(a) Organic solvents
(b) Coolant including chlorine / gasoline
(c) Aminergic detergent
(d) Acid, alkali and liquid causing rust
(e) Other liquids or solutions, that will harm NBR
(2) When the positioner work in the environment, using water or liquid, complete draining of J1 base must
be done. Incomplete draining of J1 base will make the positioner break down.
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RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook B-80687EN Intended readers :
All persons who use FANUC Robot, system designer
All persons who use the FANUC Robot and system Topics :
designer must read and understand thoroughly this Safety items for robot system design, operation, maintenance
handbook
R-J3iB Mate Operator’s manual Intended readers: Operator, programmer, maintenance person,
controller LR ARC TOOL system designer
B-82094EN Topics: Robot functions, operations, programming, setup,
LR HANDLING TOOL interfaces, alarms
B-81524EN Use: Robot operation, teaching, system design
Maintenance manual Intended readers: Maintenance person, system designer
B-81525EN Topics: Installation, setup, connection, maintenance
B-81525EN-1 (for Europe) Use: Installation, start-up, connection, maintenance
R-J3iB controller Setup and Operations manual Intended readers :
SPOT TOOL Operator, programmer, maintenance person, system designer
B-81464EN-1 Topics :
ARC TOOL Robot functions, operations, programming, setup, interfaces,
B-81464EN-3 alarms
Use : Robot operation, teaching, system design
Maintenance manual Intended readers :
B-81465EN Maintenance person, system designer
B-81465EN-1 Topics :
(European specification) Installation, connection to peripheral equipment, maintenance
Use :
Installation, start-up, connection, maintenance
R-30iA Mate Operator’s manual Intended readers :
controller LR HANDLING TOOL Operator, programmer, maintenance person, system designer
B-83134EN-1 Topics :
LR ARC TOOL Robot functions, operations, programming, setup, interfaces,
B-83134EN-2 alarms
Alarm code list Use : Robot operation, teaching, system design
B-83124EN-6
Maintenance manual Intended readers :
Standard: Maintenance person, system designer
B-82725EN Topics :
B-82725EN-1 (For Europe) Installation, connection to peripheral equipment, maintenance
B-82725EN-2 (For RIA) Use : Installation, start-up, connection, maintenance
R-30iA controller Operator’s manual Intended readers :
SPOT TOOL+ Operator, programmer, maintenance person, system designer
B-83124EN-1 Topics :
HANDLING TOOL Robot functions, operations, programming, setup, interfaces,
B-83124EN-2 alarms
ARC TOOL Use :
B-83124EN-3 Robot operation, teaching, system design
Maintenance manual Intended readers :
B-82595EN Maintenance person, system designer
B-82595EN-1 Topics :
(European specification) Installation, connection to peripheral equipment, maintenance
B-82595EN-2 Use :Installation, start-up, connection, maintenance
(RIA)
Robot mechanical For the robot mechanical unit, refer to the manual of each robot.
unit

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B-82535EN/03 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral devices installed in a work cell.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.

1 WORKING PERSON
The personnel can be classified as follows.

Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel

Programmer or teaching operator:

• Operates the robot
• Teaches robot inside the safety fence

Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)

- An operator cannot work inside the safety fence.

- A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc..
- To work inside the fence, the person must be trained on proper robot operation.

During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following safety
precautions.

- Use adequate clothing or uniforms during system operation

- Wear safety shoes
- Use helmet

2 WORKING PERSON SAFETY

Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating
space of the robot during automatic operation, adequate safety precautions must be observed.

The following lists the general safety precautions. Careful consideration must be made to ensure operator
safety.

(1) Have the robot system operators attend the training courses held by FANUC.

FANUC provides various training courses. Contact our sales office for details.

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(2) Even when the robot and positioner are stationary, it is possible that the robot is still ready to move
state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure
operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in
motion.
(3) Install a safety fence with a gate so that no operator can enter the work area without passing through
the gate. Equip the gate with an interlock that stops the robot when the gate is opened.
At this time, the positioner as well as the robot must be located within the fence completely.

The controller is designed to receive this interlock signal. When the gate is opened and this signal received, the
controller stops the robot in an emergency. For connection, see Fig.2.

(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such
as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that
stops the robot and positioner when an operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator in charge can turn on the power of
the robot.

The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a
padlock.

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.

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B-82535EN/03 SAFETY PRECAUTIONS

Dual chain
Panel board （Note）

EAS1 In case of R-30iA , R-J3iB

Terminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2
EAS11 are provided on the operation box or on the terminal block
of the printed circuit board.
EAS2
In case of R-30iA Mate , R-J3iB Mate
EAS21 Terminals EAS1,EAS11,EAS2,EAS21 are provided
on the emergency stop board or connector panel.
(in case of Open air type)

Termianls FENCE1,FENCE2 are provided

on the emergency stop board.
Single chain
Panel board
Refer to controller maintenance manual for details.
FENCE1

FENCE2

Fig. 2 Safety fence and gate

2.1 OPERATOR SAFETY

The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.

(1) When the robot and positioner do not need to operate, turn off the power of the robot controller or
press the emergency stop button before work.
(2) The operator must operate the robot system outside the work area of the robot or positioner.
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the
work area unexpectedly and also to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator's reach.

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection,
the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram
below for connection.
Dual chain
External stop button
Panel board
EES1
（Note）
EES11 Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.

EES2 In case of R-30iA , R-J3iB

EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.
EES21
In case of R-30iA Mate , R-J3iB Mate
EES1,EES11,EES2,EES21 are on the emergency stop board
or connector panel (in case of Open air type).
Single chain EMGIN1,EMGIN2 are on the emergency stop board.
External stop button Refer to the maintenance manual of the controller for details.
Panel board
EMGIN1
EMGIN2

Fig.2.1 Connection Diagram for External Emergency Stop Button

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2.2 SAFETY OF THE PROGRAMMER

While teaching the robot, the operator must enter the work area of the robot. The operator must ensure the
safety of the teach pendant operator especially.

(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating
condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other
conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on
the teach pendant) before entering the area.
(4) The programmer must be extremely careful not to let anyone else enter the robot work area.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the
automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence
for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other
people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the
automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of
stop type). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand
that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety
fence. (In case of R-30iA Mate Controller standard specification, there is no mode switch. The automatic operation
mode and the teach mode is selected by teach pendant enable switch.)

Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and
switch function as follows:
(1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY for
detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the mode switch setting status.
(a) Automatic operation mode: The DEADMAN switch is disabled.
(b) Teach mode: Servo power is turned off when the operator releases the DEADMAN switch or when the
operator presses the switch strongly.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iA/ R-30iA Mate employs a 3-position
DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to
its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly,
the robot stops immediately.

The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the
teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should
make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity
of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the
teach pendant enable switch and the remote condition on the software.

In case of R-30iA Controller or CE or RIA specification of R-30iA Mate Controller

Software
Teach pendant
Mode remote Teach pendant Operator panel Peripheral device
enable switch
condition
Local Not allowed Not allowed Not allowed
On
AUTO Remote Not allowed Not allowed Not allowed
mode Local Not allowed Allowed to start Not allowed
Off
Remote Not allowed Not allowed Allowed to start

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Software
Teach pendant
Mode remote Teach pendant Operator panel Peripheral device
enable switch
condition
Local Allowed to start Not allowed Not allowed
On
T1, T2 Remote Allowed to start Not allowed Not allowed
mode Local Not allowed Not allowed Not allowed
Off
Remote Not allowed Not allowed Not allowed
T1,T2 mode:DEADMAN switch is effective.

In case of standard specification of R-30iA Mate Controller

Teach pendant enable switch Software remote condition Teach pendant Peripheral device
On Ignored Allowed to start Not allowed
Off Local Not allowed Not allowed
Remote Not allowed Allowed to start

(5) (Only when R-30iA Controller or CE or RIA specification of R-30iA Mate controller is selected.) To
start the system using the operator’s panel, make certain that nobody is the robot work area and that
there are no abnormal conditions in the robot work area.
(6) When a program is completed, be sure to carry out a test run according to the procedure below.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test run above, execute it in the
automatic operation mode.
(7) While operating the system in the automatic operation mode, the teach pendant operator should leave
the robot work area.

2.3 SAFETY OF THE MAINTENANCE ENGINEER

For the safety of maintenance personnel, pay utmost attention to the following.

(1) Except when specifically necessary, turn off the power of the controller while carrying out
maintenance. Lock the power switch, if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the supply pressure.
(3) Before the start of teaching, check that the robot and positioner and its peripheral devices are all in the
normal operating condition.
(4) When performing maintenance within the work area of the robot or positioner with the power on,
maintenance personnel needs to indicate that maintenance is in progress and exercise caution to
prevent anyone from starting the robot accidentally.
(5) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers
are working nearby, make certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such
as belt conveyor, pay careful attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system stand beside the operator's panel and
observe the work being performed. If any danger arises, the worker should be ready to press the
EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent foreign matter from entering the
system.
(10) When handling each unit or printed circuit board in the controller during inspection, turn off the power
of the controller and also turn off the circuit breaker to protect against electric shock.
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(11) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other
parts of non-specified ratings. They may cause a fire or result in damage to the components in the
controller.

3 SAFETY OF THE TOOLS AND PERIPHERAL

DEVICES
3.1 PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program
to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.
(3) In a system in which the robot or positioner operates in sync with peripheral devices, exercise caution
against mutual interference.
(4) The interlock between the robot and peripheral devices is necessary to check the states of all devices in
the system using the robot or positioner, so that the robot and positioner can be stopped as needed.

3.2 PRECAUTIONS FOR MECHANISM

(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of
grease, water, and dust.
(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.
(3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does
not strike against its peripheral devices or tools.
(4) Observe the following precautions about the mechanical unit cables. When theses attentions are not
kept, unexpected troubles might occur.
• Use mechanical unit cable that have required user interface.
• Don’t add user cable or hose to inside of mechanical unit.
• Please do not obstruct the movement of the mechanical unit cable when cables are added to
outside of mechanical unit.
• In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a
protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the
cable.
• Please do not interfere with the other parts of mechanical unit when install equipments in the
robot.
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid
the system construction that power-off stop would be operated routinely. (Refer to bad case example.)
Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or
cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of
stop type.)
(Bad case example)
• Whenever poor product is generated, a line stops by emergency stop.
• When alteration was necessary, safety switch is operated by opening safety fence and power-off
stop is executed for the robot during operation.
• An operator pushes the emergency stop button frequently, and a line stops.
• An area sensor or a mat switch connected to safety signal operate routinely and power-off stop is
executed for the robot.
(6) Robot stops urgently when collision detection alarm (SV050) etc. occurs. The frequent urgent stop
by alarm causes the trouble of the robot, too. So remove the causes of the alarm.
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4 SAFETY OF THE ROBOT MECHANISM

4.1 PRECAUTIONS IN OPERATION
(1) When operating the robot or positioner in the jog mode, keep an appropriate speed so that the operator
can take a responsive action in any eventuality.
(2) Before pressing the jog key, be sure to understand in advance how the robot or positioner operates by
the key.
(3) Observe the following precautions about the mechanical unit cables. When theses attentions are not
kept, unexpected troubles might occur.
・ Use mechanical unit cable that have required user interface.
・ Don’t add user cable or hose to inside of mechanical unit.
・ Please do not obstruct the movement of the mechanical unit cable when cables are added to outside of
mechanical unit.
・ In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a protective
cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable.
・ Please do not interfere with the other parts of mechanical unit when install equipments in the robot.

4.2 PRECAUTIONS IN OPERATION

(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere
with each other.
(2) Be sure to specify a certain work origin in a motion program for the robot or positioner and make sure
that the motion program starts from and ends at the origin. This makes it clear at a glance whether the
robot has completed work.

4.3 PRECAUTIONS FOR MECHANISMS

(1) Clean the inside of the work area of the robot or positioner to eliminate the effect of oil, water, and
dust.

WARNING
The 2-axis servo positioner has a built-in earth cable. Operate the positioner within the service factor
corresponding to the current, referencing Section 2.5, “SERVICE FACTOR (DUTY) OF EARCH CABLE,” in
Part II, “CONNECTION.” If the service factor is exceeded during operation, the cable temperature may
exceed the maximum allowable temperature, resulting in deterioration or burning of the cable.

5 SAFETY OF THE END EFFECTOR

5.1 Precautions in Programming
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay
after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the
end effector.

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6 STOP TYPE OF ROBOT

The following three robot stop types exist:

Power-Off Stop (Category 0 following IEC 60204-1)

Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
- An alarm is generated and servo power is turned off.
- The robot operation is stopped immediately. Execution of the program is paused.

Controlled stop (Category 1 following IEC 60204-1)

The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
- The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
- An alarm is generated and servo power is turned off.

Hold (Category 2 following IEC 60204-1)

The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
- The robot operation is decelerated until it stops. Execution of the program is paused.

WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.

When the E-Stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or
Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is
different according to the controller type or option configuration.

There are the following 3 Stop patterns.

Stop E-Stop External Servo

Mode FENCE open SVOFF input
pattern button E-Stop disconnect
AUTO P-Stop P-Stop C-Stop C-Stop P-Stop
A T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
AUTO P-Stop P-Stop P-Stop P-Stop P-Stop
B T1 P-Stop P-Stop - P-Stop P-Stop
T2 P-Stop P-Stop - P-Stop P-Stop
AUTO C-Stop C-Stop C-Stop C-Stop C-Stop
C T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
P-Stop: Power-Off stop
C-Stop: Controlled stop
-: Not stop

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The following table indicates the Stop pattern according to the controller type or option configuration.

R-30iA R-30iA Mate

Option Standard Standard RIA CE
RIA type CE type Standard
(Single) (Dual) type type
Standard B (*) A A A A (**) A A
Stop type set (Stop pattern C)
N/A N/A C C N/A C C
(A05B-2500-J570)
(*) R-30iA standard (single) does not have servo disconnect.
(**) R-30iA Mate Standard does not have servo disconnect, and the stop type of SVOFF input is
Power-Off stop.

The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer
to "Software version" in operator's manual of controller for the detail of software version screen.

"Stop type set (Stop pattern C)" option

"Stop type set (Stop pattern C)"(A05B-2500-J570) is an optional function. When this option is loaded, the
stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the
stop type is Power-Off stop which is the normal operation of the system.

Alarm Condition
SRVO-001 Operator panel E-stop Operator panel E-stop is pressed.
SRVO-002 Teach pendant E-stop Teach pendant E-stop is pressed.
SRVO-007 External emergency stops External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA controller)
SRVO-194 Servo disconnect Servo disconnect input (SD4-SD41, SD5-SD51) is open.
(R-30iA controller)
SRVO-218 Ext.E-stop/Servo Disconnect External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA Mate controller)
SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF.
SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.

Controlled stop is different from Power-Off stop as follows:

- In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
- In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems
where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized.
- The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the operator's
manual of a particular robot model for the data of stopping distance and stopping time.

This function is available only in CE or RIA type hardware.

When this option is loaded, this function cannot be disabled.

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.

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 SAFETY PRECAUTIONS B-82535EN/03

7 WARNING LABEL
(1) Greasing and degreasing label

Fig. 7 (a) Greasing and Degreasing Label

Description
When greasing and degreasing, observe the instructions indicated on this label.

1) When greasing, be sure to keep the grease outlet open.

2) Use a manual pump to grease.
3) Be sure to use a specified grease.

CAUTION
See section I.3.1 ″ GREASE REPLACEMENT for explanations about specified
greases, the amount of grease to be supplied, and the locations of grease and
degrease outlets for individual models.

(2) Step-on prohibitive label

Fig. 7 (b) Step-on Prohibitive Label

Description
Do not step on or climb the robot or positioner as it may adversely affect the robot or positioner and you
may get hurt if you lose your footing as well.

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B-82535EN/03 SAFETY PRECAUTIONS

(3) High-temperature warning label

Fig. 7 (c) High-temperature warning label

Description
Be cautious about a section where this label is affixed, as the section generates heat. If you have to
inevitably touch such a section when it is hot, use a protective provision such as heat-resistant gloves.

接触注意
溶接中、内部は高電流が流れます
DO NOT ACCESS
DURING ENERGIZED
HIGH CURRENT INSIDE
Fig. 7 (d) High-current warning label

Description
A large current flows through the positioner during welding.
Do not touch the terminal block or conductor under the cover.

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 SAFETY PRECAUTIONS B-82535EN/03

(4) Transportation label

>400kg

>400kg X2

>400kg X2
>バネ座金 X2
Spring lock washer

I.D. 16.2 O.D. 26.6 Thickness 4

>平座金 X2
Plain washer
内径17 外径30 厚さ3
I.D. 17 O.D. 30 Thickness 3

Fig. 7 (e) Transportation label

Description
When transporting the positioner, observe the instruction on the transportation label. The above label
includes the following instructions.

1) Using a crane

• Use a crane having a load capacity of 400 kg or greater.

• Use at least two slings each having a withstand load of 3920 N (400 kgf) or greater.
• Use two M16 eyebolts with a withstand load of 3920 N (400 kgf) or greater. (The eyebolts are
attached during shipment.)

CAUTION
See section II.3.1 TRANSPORTATION for explanations about the posture should
take when it is transported.

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B-82535EN/03 TABLE OF CONTENTS

TABLE OF CONTENTS
PREFACE ....................................................................................................p-1
SAFETY PRECAUTIONS............................................................................s-1

I. MAINTENANCE
1 CONFIGURATION .................................................................................. 3
1.1 J1-AXIS DRIVE MECHANISM....................................................................... 3
1.2 J2-AXIS DRIVE MECHANISM....................................................................... 4
1.3 SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS . 4
2 PREVENTIVE MAINTENANCE............................................................... 5
2.1 DAILY CHECKS ............................................................................................ 5
2.2 FIRST 1-MONTH (960 HOURS) CHECKS .................................................... 7
2.3 FIRST 3-MONTH CHECK (960 HOURS) ..................................................... 7
2.4 3-MONTH CHECKS (960 HOURS) ............................................................... 7
2.5 1-YEAR CHECKS (3,840 HOURS)................................................................ 7
2.6 1.5-YEAR CHECKS (5,760 HOURS)............................................................. 8
2.7 3-YEAR (11,520 HOURS) CHECKS.............................................................. 8
2.8 4-YEAR (15,360 HOURS) CHECKS.............................................................. 8
2.9 MAINTENANCE TOOLS ............................................................................... 9
3 PERIODIC MAINTENANCE .................................................................. 10
3.1 GREASE REPLACEMENT .......................................................................... 10
3.2 PROCEDURE FOR RELEASING THE GREASE REMAINING PRESSURE
..................................................................................................................... 12
3.3 BATTERY REPLACEMENT ........................................................................ 12
4 TROUBLESHOOTING .......................................................................... 14
4.1 GENERAL ................................................................................................... 14
4.2 PROBLEMS AND CAUSES......................................................................... 14
4.3 BACKLASH MEASUREMENT..................................................................... 21
4.4 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS .................... 22
5 ADJUSTMENTS.................................................................................... 23
5.1 AXIS LIMITS SETUP ................................................................................... 23
5.2 REFERENCE POSITION AND MOVING RANGE....................................... 24
5.3 MASTERING ............................................................................................... 24
5.3.1 Resetting Alarms and Preparing for Mastering ......................................................25

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TABLE OF CONTENTS B-82535EN/03

5.3.2 Fixture Position Master ..........................................................................................26

5.3.3 Zero Position Mastering .........................................................................................31
5.3.4 Quick Mastering .....................................................................................................34
5.3.5 Single Axis Mastering ............................................................................................36
5.3.6 Mastering Data Entry .............................................................................................39
5.3.7 Confirming Mastering ............................................................................................41

6 COMPONENT REPLACEMENT AND ADJUSTMENTS....................... 42

6.1 REPLACING THE J1-AXIS MOTOR M1 ................................................... 42
6.2 REPLACING THE J1-AXIS REDUCER ....................................................... 43
6.3 REPLACING THE J2-AXIS MOTOR M2 ................................................... 46
6.4 REPLACING THE J2-AXIS REDUCER ....................................................... 47
7 PIPING AND WIRING ........................................................................... 49
7.1 PIPING DRAWING ...................................................................................... 49
7.2 CABLE MOUNTING DIAGRAM................................................................... 49
8 CABLE REPLACEMENT ...................................................................... 51
8.1 CABLE DRESSING ..................................................................................... 51
8.2 REPLACING CABLES................................................................................. 52

II. CONNECTION
1 POSITIONER OUTLINE DRAWING AND OPERATION AREA
DIAGRAM.............................................................................................. 57
1.1 OUTLINE DRAWING AND OPERATION AREA DIAGRAM ........................ 57
2 MOUNTING DEVICES ON THE POSITIONER ..................................... 59
2.1 FLANGE MOUNTING SURFACE................................................................ 59
2.2 POSITIONER LOAD CONDITION............................................................... 60
2.3 AIR PIPING IN THE FLANGE...................................................................... 60
2.4 PIN ASSIGNMENT OF THE SIGNAL LINE CONNECTOR ......................... 61
2.5 SERVICE FACTOR (DUTY) OF EARTH CABLE ........................................ 61
2.5.1 About Service Factor (Duty) of Earth Cable..........................................................61
2.5.2 Relationship Between Ambient Temperature and Permissible Current of Earth
Cable ......................................................................................................................62

3 TRANSPORTATION AND INSTALLATION ......................................... 64

3.1 TRANSPORTATION.................................................................................... 64
3.2 STORING THE POSITIONER ..................................................................... 65
3.3 INSTALLATION ........................................................................................... 65

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3.4 MAINTENANCE CLEARANCE.................................................................... 68

3.5 ASSEMBLING THE POSITONER FOR INSTALLATION ............................ 69
3.6 AIR PIPING ................................................................................................. 70
3.7 INSTALLATION CONDITIONS.................................................................... 71

APPENDIX
A SPARE PARTS LISTS .......................................................................... 75
B CONNECTION DIAGRAMS .................................................................. 76
C PERIODIC INSPECTION TABLE.......................................................... 78
D STRENGTH OF BOLT AND BOLT TORQUE LIST.............................. 80

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I. MAINTENANCE
B-82535EN/03 MAINTENANCE 1.CONFIGURATION

1 CONFIGURATION
Fig. 1 shows the configuration of the mechanical unit.

Flange J2 unit
AC servo motor
for J1-axis (with brake)
M1 : J1-axis motor

AC servo motor
for J2-axis (with brake)
M2 : J2-axis motor
Battery
J1 unit

Fig. 1 Mechanical unit configuration

1.1 J1-AXIS DRIVE MECHANISM

Fig. 1.1 shows the J1-axis drive mechanism.
The J1-axis drive mechanism is configured in such a way that the J2 base is rotated by reducing the rotation
speed of an AC servo motor with a reducer.
The J2 base is supported on the J1 base through the reducer.

J2 base

J1-axis reducer
Motor (M1)

J1 base

Fig. 1.1 J1-axis drive mechanism

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1.CONFIGURATION MAINTENANCE B-82535EN/03

1.2 J2-AXIS DRIVE MECHANISM

Fig. 1.2 shows the J2-axis driving mechanism. The J2-axis driving mechanism rotates the flange by
reducing the rotation of the AC servo motor with the reducer.

Motor (M2)
Flange

J2 base

Fig. 1.2 J2-axis drive mechanism

1.3 SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT

COMPONENTS
Refer to Appendix A about the major mechanical unit components.

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B-82535EN/03 MAINTENANCE 2.PREVENTIVE MAINTENANCE

2 PREVENTIVE MAINTENANCE
Daily inspection, periodic inspection, and periodic maintenance can keep the performance of the positioner
stable for a long period of time.

NOTE
The annual operating time of the 2-axis servo positioner is assumed to be 3840
hours. When using the positioner beyond this annual operating time, correct the
maintenance frequency in this chapter, which is determined on assumption that
the positioner is used for 3840 hours per year, and perform maintenance as
appropriate.

2.1 DAILY CHECKS

Clean and maintain each robot component during everyday system operations. At the same time, check the
components to see if there is a crack or break in them. Also check and maintain the following items as
required.

a) Before automatic operation

Item Check items Check points
1 Oil exudation Check there is oil exudation on sealed part of each joint parts.
If there is oil exudation, clean it.

NOTE
1 Oil exudation may be attached (Slightly a loot oil stick) to outside of lip depend on
the movement condition or environment of the circumference. If this oil contents
change to a state of dew, it may fail depend on the movement.
You can prevent oil accumulation by wiping the oil contents which is under of oil
seal of Fig.2.1 (a) before operating robot.
2 Also, motors may become the high temperature and the internal pressure of oil
bath may rise by frequent repetition movement and use in the high temperature
environment. In these cases, you can return internal pressure by releasing oil out
let just after operation of robot. (When opening oil outlet, pay attention oil is not
scattered.)

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2.PREVENTIVE MAINTENANCE MAINTENANCE B-82535EN/03

(1 )
TYPE (2)
NO. (3) WEIGHT
DATE (4) (5) kg

Fig.2.1 (a) Check point of oil seal

Item Check items Check points

1 Air pressure Check air pressure using the pressure gauge on the air regulator as shown in
Fig.2.1 (b). If it does not meet the specified pressure of 0.49 to 0.69 MPa (5-7
kgf/cm2), adjust it using the regulator pressure-setting handle.
2 Lubricator oil mist Check the drop quantity during wrist or hand motion. If it does not meet the
quantity specified value(1 drop/10-20 sec), adjust it using the lubricator control knob. Under
normal usage, the lubricator becomes empty in about 10 to 20 days under normal
operation.
3 Lubricator oil level Check to see that the lubricator level is within the specified level.
4 Leakage from hose Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.
5 Drain Check drain and release it. When quantity of the drain is remarkable, examine the
setting of the air dryer to the air supply side.

Lubricator Adjusting knob

Oil inlet

Lubricator
mist amount check

Lubricator

Regulator Pressure
Filter
pressure
setting
Fig. 2.1 (b) Three-piece pneumatic option

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B-82535EN/03 MAINTENANCE 2.PREVENTIVE MAINTENANCE
b) After automatic operation
Item Check items Check points
1 Vibration, abnormal Check whether the robot moves along and about the axes smoothly without
noises, and motor unusual vibration or sounds. Also, check whether the temperatures of the motors
heating are excessively high.
2 Changing repeatability Check to see that the stop positions of the robot have not deviated from the
previous stop positions.
3 Peripheral devices for Check whether the peripheral devices operate properly according to commands
proper operation from the robot.
4 Brakes for each axis Check that the end effector drops within 5 mm when the power is off.

2.2 FIRST 1-MONTH (960 HOURS) CHECKS

Check the following items once every one-month (320 hours). Additional inspection areas and times should
be added to the table according to the robot’s working conditions, environment, etc. Then every 3 months
thereafter. (See the Section 2.5.)

Item Check items Check points

1 Ventilation portion of
If the ventilation portion of the controller is dusty, turn off power and clean the unit.
controller

2.3 FIRST 3-MONTH CHECK (960 HOURS)

Inspect the following items at regular intervals of about three months. Increase the locations and the
frequency of inspection if necessary (or 960 hours operating).
No. Inspection item Inspection procedure
1 Loose connector Check that the motor connectors or other connectors are not loose.
2 Loose bolt Check that the cover retaining bolts or external bolts are not loose. In particular,
check the following three points.
Base fixing bolts
Bolts fixing fixtures to the flange surface
J2 motor cover retaining bolts
3 Debris removal Remove any spatter, debris, and dust from the mechanical unit.

2.4 3-MONTH CHECKS (960 HOURS)

Check the following item once every 3 months (960 hours).

Item Check items Check points

Ventilation portion of (See Section 2.2.)
1
controller

2.5 1-YEAR CHECKS (3,840 HOURS)

Check the following items once every year (3,840 hours).

No. Inspection item Inspection procedure

1 Loose connector See Section 2.3.
2 Loose bolt See Section 2.3.
3 Debris removal See Section 2.3.

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2.PREVENTIVE MAINTENANCE MAINTENANCE B-82535EN/03

2.6 1.5-YEAR CHECKS (5,760 HOURS)

Perform the following inspection/maintenance item at regular intervals of about one year and half (or 5,760
hours operating).
No. Inspection item Inspection procedure
1 Battery replacement Replace the battery in the mechanical unit. (See Section 3.3.)

2.7 3-YEAR (11,520 HOURS) CHECKS

Perform the following inspection/maintenance item at regular intervals of three year.

No. Inspection item Inspection procedure

1 Grease replacement See Section 3.1.

2.8 4-YEAR (15,360 HOURS) CHECKS

Check the following items once every 4 years (15,360 hours).

Item Check items Check points

1 Replace the Replace mechanical unit cable. (See Chapter 8.)
mechanical unit cable

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B-82535EN/03 MAINTENANCE 2.PREVENTIVE MAINTENANCE

2.9 MAINTENANCE TOOLS

You should have the following instruments and tools ready for maintenance.

a) Measuring instruments
Instrument Condition Use
Dial gauge 1/100mm For positioning precision and backlash measurement
Calipers 150mm

b) Tools
Phillips screwdrivers (large, medium, and small sizes)
Flat-blade screwdrivers (large, medium, and small sizes)
Box wrenches 7 mm wide across wrenches flats (For grease nipple)
Allen wrenches Dihedral width 2.5, 3, 5, 6, 8, 10, 12, 14, 17 (For replacing part)
Torque wrench See Table 2.6.
Long T wrenches (M5, M6 and M8)
Adjustable wrenches (medium and small sizes)
Pliers
Long-nose pliers
Cutting pliers
Both-ended wrench
Grease gun
Gear puller
Separator
Sling (with a withstand load of 2 tons)
C-ring pliers
Tapered reamer drill (used for the φ13 tapered pin during replacement of the J1-axis reducer)
LOCTITE 242
LOCTITE 262
Seal tape
Flashlight

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3.PERIODIC MAINTENANCE MAINTENANCE B-82535EN/03

3 PERIODIC MAINTENANCE
3.1 GREASE REPLACEMENT
The grease for the J1-axis and J2-axis reducers needs to be replaced every three years or 11,520 hours in the
procedure shown below. For greasing points, see Figs. 3.1 (a) and (b).

<1> Remove the seal bolts and plugs of the J1-axis and J2-axis grease outlets shown in Figs. 3.1 (a) and (b).
Use grease outlet 1 in Fig. 3.2 (b) as the J2-axis grease outlet. Only when outlet 1 cannot be used
because of the installation state of the fixture, use grease outlet 2.
<2> Attach the grease nipple supplied with the positioner. Note that the grease nipple is provided for
multipurpose use.
<3> Apply the grease specified in Table 3.1 to the J1-axis and J2-axis grease nipples until the old grease is
replaced and the new grease is output from the grease outlets. At this time, confirm that the same
amount of the old grease as that of applied grease has been output to prevent the grease bath from
overflowing.
<4> After applying grease, release the remaining pressure in the grease bath as instructed by the procedure
in Section 3.2.
<5> Wind seal tape around the removed J1-axis and J-2 axis seal bolts and attach them to the J1-axis and
J2-axis grease outlets.
<6> Attach the plugs to the J1-axis and J2-axis grease inlets.Wind seal tape around the plugs.

CAUTION
When reusing a grease nipple once used, wind sealing tape around the screw.

Table 3.1 Grease to be replaced at regular intervals of three years (11,520 hours)
Specified grease Amount of grease Positioner posture
to be applied Gun tip pressure when greased
Kyodo Yushi
J1-axis reducer VIGOGREASE RE0 About 1180 cc 0.1 MPa or less 0°
J2-axis reducer (Specification: About 980 cc (NOTE) Free
A98L-0040-0174)
NOTE When using a hand pump. apply grease approximately once per two seconds.

Set the posture specified below during replacement of grease.

Posture
Greasing point
J1 J2
J1-axis 0° Free
0°
J2-axis Free
(*-90°)

* Set this posture when using grease outlet 2.

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B-82535EN/03 MAINTENANCE 3.PERIODIC MAINTENANCE

J1-axis reducer grease outlet

seal bolt M8X10

J1-axis reducer grease inlet

taper plug Rc1/8

Fig. 3.1 (a) Grease inlet and outlet of the J1-axis reducer

J2-axis reducer grease outlet 2

seal bolt M8X10

J2-axis reducer grease outlet 2

taper plug Rc1/8

Section A-A J2-axis reducer grease inlet

taper plug Rc1/8

A A

Fig. 3.1 (b) Grease inlet and outlet of the J2-axis reducer

CAUTION
If you grease incorrectly, the pressure in the grease bath will increase, leading to a
broken seal, which will eventually cause grease leakage or malfunction.
When greasing, be sure to follow the cautions stated below.
1 Before starting greasing, open the grease outlets (remove bolts and the like from
the grease outlets).
2 Using a manual greasing pump, grease gently and slowly.
3 Avoid using a pneumatic pump driven from a factory pneumatic line as much as
possible. Even when using a of Table 3.1 less during application of grease.
4 Be sure to use the specified grease. Otherwise, damage to reducers or a similar
abnormality may occur.
5 After applying grease, release the remaining pressure within the grease bath as
described in the procedure in Section 3.2.
6 Wipe off any grease from the floor and positioner completely, so no one will slip on
it.
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3.PERIODIC MAINTENANCE MAINTENANCE B-82535EN/03

3.2 PROCEDURE FOR RELEASING THE GREASE

REMAINING PRESSURE
After applying grease, operate the J1-axis for 20 minutes or more or the J2-axis for 10 minutes or more with
the plug of the grease inlet and the seal bolt of the grease outlet removed in a state in which an axis angle of
60% or more and OVR100% are satisfied and to release the remaining pressure in the grease bath. At this
time, attach a recovery bag to prevent output grease from splattering.
If the above operation cannot be performed due to the environment of the positioner, prolong the operating
time so that an equivalent operation can be performed. (If only a motion angle of 30 degrees can be set,
perform an operation for 20 minutes or more.) After completion of the operation, attach the plugs and seal
bolts to the grease inlets and outlets. When reusing the taper plugs and seal bolts, be sure to seal them with
seal tape.

3.3 BATTERY REPLACEMENT

A backup battery is used to keep the reference-position data for each axis of the positioner.
The battery needs to be replaced at regular intervals of one year and half. Follow this procedure for battery
replacement.

1) Keep the power turned on.

Press the EMERGENCY STOP button of the robot to keep robot and positioner from moving.

CAUTION
Be sure to turn on the power. If the battery is replaced when the power is off, the
current position information is lost, so that mastering becomes necessary.

2) Uncap the battery case.

3) Take out the battery from the battery case.
4) Insert a new battery into the battery case while paying attention to the polarity of the battery.
5) Cap the battery case.

Fig. 3.3 (a) Battery replacement 1

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B-82535EN/03 MAINTENANCE 3.PERIODIC MAINTENANCE

Cap

Battery case Battery specifications: A98L-0031-0005

(1.5V size-D 4 pcs)

Fig. 3.3 (b) Battery replacement 2

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4.TROUBLESHOOTING MAINTENANCE B-82535EN/03

4 TROUBLESHOOTING
4.1 GENERAL
The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems
may become further complicated, if they are not corrected properly. Therefore, it is necessary to keep an
accurate record of problems and to take proper corrective actions.

4.2 PROBLEMS AND CAUSES

Table 4.2 (a) shows the main mechanical unit problems and their causes. If a cause of remedy is unclear,
please contact your FANUC service representative.

Table 4.2 (a) Problems and causes

Symptom Description Cause Measure
Vibration -The J1 base lifts off the base [J1 base fastening] -If a bolt is loose, apply
Noise plate as the positioner -It is likely that the positioner J1 base LOCTITE and tighten it to the
operates. is not securely fastened to the base appropriate torque.
-There is a gap between the plate. -Adjust the base plate surface
J1 base and base plate. -Probable causes are a loose bolt, an flatness to within the specified
-A J1 base retaining bolt is insuffcient degree of surface tolenrance.
loose. flatness, or foreign material caught -If there is any foreign matter
between the base plate and floor between the J1 base and base
plate. plate, remove it.
-If the positioner is not securely
fastened to the base plate, the J1
base lifts the base plate as the
positioner operates, allowing the
base and floor plates to strike each
other wihich, in turn, leads to
vibration.
-The rack or floor vibrates [Rack or floor] -Reinforce the rack or floor to
during operation of the -It is likely that the rack or floor is not make it more rigid.
positioner. suffciently rigid. -If it is impossible to reinforce
-If the rack or floor is not sufficiently the rack or floor, modify the
rigid, reaction from the positioner robot control program; doing
deforms the rack or floor, leading to so might reduce the amount of
vibration. vibration.
-Vibration becomes more [Overload] -Check the maximum load
serious when the positioner -It is likely that the load on the that the positioner can handle
adopts a specific posture. positioner is greater than the once more. If the positioner is
-If the operating speed of the maximum rating. found to be overloaded,
positioner is reduced, -It is likely that the positioner control reduce the load, or modify the
vibration stops. program is too demanding for the positioner control program.
-Vibration is most noticeable positioner hardware. -Vibration in a specific portion
when the positioner is -It is likely that the ACCELERATION can be reduced by modifying
accelerating. value is excessive. the robot control program
-Vibration occurs when two or while slowig the positioner and
more axes operate at the reducing its acceleration (to
same time. minimize the influenece on the
entire cycle time).

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B-82535EN/03 MAINTENANCE 4.TROUBLESHOOTING

Symptom Description Cause Measure

Vibration -Vibration or noise was first [Broken gear, bearing, or reducer] -Operate one axis at a time to
Noise noticed after the positioner - It is likely that collision or overload determine which axis is
(Continued) collided with an object or the applied an excessive force on the vibrating.
positioner was overloaded for drive mechanism, thus damaging the -Remove the motor, and
a long period. geartooth surface or rolling surface of replace the gear , the bearing,
-The grease of the vibrating or a bearing, or reducer. and the reducer. For the spec.
noise occurring axis has not - It is likely that prolonged use of the of parts and the method of
been exchanged for a long positioner while overloaded caused replacement, contact FANUC.
period. fretting of the gear tooth surface or -Using the positioner within its
rolling surface of a bearing, or maximum rating prevents
reducer due to resulting metal problems with the drive
fatigue. mechanism.
- It is likely that foreign material -Regularly changing the
caught in a gear, bearing, or within a grease with a specified type
reducer caused damage on the gear can help prevent problems.
tooth surface or rolling surface of the
bearing, or reducer.
- It is likely that foreign material
caught in a gear, bearing, or within a
reducer cause vibration.
- It is likely that, because the grease
has not been changed for a long
period, fretting occurred on the gear
tooth surface or rolling surface of a
bearing, or reducer due to metal
fatigue.
These factors all generate cyclic
vibration and noise.

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4.TROUBLESHOOTING MAINTENANCE B-82535EN/03

Symptom Description Cause Measure

Vibration -The cause of problem cannot [Controller, cable, and motor] -Refer to the R-30iA Controller
Noise be identified from examination -If a failure occurs in a controller Maintenance Manual for
(Continued) of the floor, rack, or circuit, preventing control commands troubleshooting related to the
mechanical section. from being supplied to the motor controller and amplifier.
normally, or preventing motor -Replace the Pulsecoder for
information from being sent to the the motor of the axis that is
controller normally, vibration might vibrating, and check whether
occur. the vibration still occurs.
-If the Pulsecoder develops a fault, -Also, replace the motor of the
vibration might occur because axis that is vibrating, and
information about the motor position check whether vibration still
cannot be transferred to the occurs. For the method of
controller accurately. replacement, contact FANUC.
-If the motor becomes defective, -Check that the positioner is
vibration might occur because the supplied with the rated
motor cannot deliver its rated voltage.
performance. -Check whether the sheath of
-If a power line in a movable cable of the power cord is damaged. If
the mechanical section has an so, replace the power cord,
intermittent break, vibration might and check whether vibration
occur because the motor cannot still occurs.
accurately respond to commands. -Check whether the sheath of
-If a Pulsecoder wire in a movable the cable connecting the
part of the mechanical section has an mechanical section
intermittent break, vibration might and controller is damaged. If
occur because commands cannot be so, replace the connection
sent to the motor accurately. cable, and check whether
-If a connection cable between them vibration still occurs.
has an intermittent break, vibration -If vibration occurs only when
might occur. the positioner assumes a
-If the power cable has an specific posture, it is likely that
intermittent break, vibration might a cable in the mechanical unit
occur. is broken.
-If the power source voltage drops -Shake the movable part
below the rating, vibration might cable while the positioner is at
occur. rest, and check whether an
-If a robot control parameter is set to alarm occurs. If an alarm or
an invalid value, vibration might any other abnormal condition
occur. occurs, replace the
mechanical unit cable.
-Check that the positioner
control parameter is set to a
valid value. If it is set to an
invalid value, correct it.
Contact FANUC for further
information if necessary.

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B-82535EN/03 MAINTENANCE 4.TROUBLESHOOTING

Symptom Description Cause Measure

Vibration -There is some relationship [Noise from a nearby machine] -Connect the grounding wire
Noise between the vibration of the -If the positioner is not grounded firmly to ensure a reliable
(Continued) positioner and the operation of properly, electrical noise is induced ground potential and prevent
a machine near the positioner. on the grounding wire, preventing extraneous electrical noise.
commands from being transferred
accurately, thus leading to vibration.
-If the positioner is grounded at an
unsuitable point, its grounding
potential becomes unstable, and
noise is likely to be induced on the
grounding line, thus leading to
vibration.
-There is an unusual sound -There may be an unusual sound -Use the specified grease.
after replacement of grease. when using other than the specified -When there is an unusual
-There is an unusual sound grease. sound even for specified
after a long period of time. -Even for the specified grease, there grease, perform operation for
-There is an unusual sound may be an unusual sound during one or two days on an
during operation at low speed. operation at low speed immediately experiment. Generally, an
after replacement or after a long usual sound will disappear.
period of time.
Rattling -While the positioner is not [Mechanical section coupling bolt] -Check that the following bolts
supplied with power, pushing -It is likely that overloading or a for each axis are tight. If any of
it with the hand causes part of collision has loosened a mounting these bolts is loose, apply
the mechanical unit to wobble. bolt in the positioner mechanical LOCTITE and tighten it to the
-There is a gap on the section. appropriate torque.
mounting surface of the -Motor retaining bolt
mechanical unit. -Reducer retaining bolt
-Reducer shaft retaining bolt
-Base retaining bolt
-End effecter retaining bolt

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4.TROUBLESHOOTING MAINTENANCE B-82535EN/03

Symptom Description Cause Measure

Rattling -Backlash is greater than the [Increase in backlash] -Operate one axis at a time to
(Continued) tolerance stated in the -It is likely that excessive force determine which axis has the
applicable maintenance applied to the drive mechanism, due increased backlash.
manual. to a collision or overloading, has -Remove the motor, and
(See Table 4.3 (b).) broken a gear or the inside of the check whether any of its gears
reducer, resulting in an increase in are broken. If any gear is
the amount of backlash. broken, replace it.
-It is likely that prolonged use in -Check whether any other
overload conditions has caused the gear of the drive mechanism
tooth surfaces of a gear and the is damage. If there is no
reducer to wear out, resulting in an damage gear, replace the
increase in the amount of backlash. reducer.
-It is likely that prolonged use without -If the reducer is broken, or if a
changing the grease has caused the gear tooth is missing, replace
tooth surfaces of a gear and the the relevant component. Also,
inside of the reducer to wear out, remove all the grease from the
resulting in an increase in the amount gearbox and wash the inside
of backlash. of the gearbox.
-After replacing the gear or
reducer, add an appropriate
amount of grease.
-Using the positioner within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the
grease with a specified type
can help prevent problems.

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B-82535EN/03 MAINTENANCE 4.TROUBLESHOOTING

Symptom Description Cause Measure

Motor -The ambient temperature of [Ambient temperature] The teach pendant can be
overheating the installation location -It is likely that a rise in the ambient used to monitor the average
increases, causing temperature or attaching the motor current. Check the average
the motor to overheat. cover prevented the motor from current when the robot
-After a cover was attached to releasing heat efficiently, thus control program is running.
the motor, the motor leading to overheating. The allowable average
overheated. [Operating condition] current is specified for the
-After the robot control -It is likely that the positioner was positioner according to its
program or the load was operated with the maximum average ambient temperature.
changed, the motor current exceeded. Contact FANUC for further
overheated. information.
-Relaxing the positioner
control program and
conditions can reduce the
average current, thus
preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of
the motor well ventilated
enables the motor to release
heat efficiently, thus
preventing overheating.
Using a fan to direct air at the
motor is also effective.
-If there is a source of heat
near the motor, it is advisable
to install shielding to protect
the motor from heat radiation.
-After a control parameter was [Parameter] -Input an appropriate
changed, the motor -If data input for a workpiece is parameter as described in
overheated. invalid, the positioner cannot be CONTROLLER
accelerated or decelerated normally, OPERATOR’S MANUAL.
so the average current increases,
leading to overheating.
-Symptom other than stated [Mechanical section problems] -Repair the mechanical unit
above -It is likely that problems occurred in while referring to the above
the mechanical unit drive descriptions of vibration,
mechanism, thus placing an noise, and rattling.
excessive load on the motor. -Check that, when the servo
[Motor problems] system is energized, the
-It is likely that a failure of the motor brake is released.
brake resulted in the motor running If the brake remains applied
with the brake applied, thus placing to the motor all the time,
an excessive load on the motor. replace the motor.
-It is likely that a failure of the motor -If the average current falls
prevented it from delivering its rated after the motor is replaced, it
performance, thus causing an indicates that the first motor
excessive current to flow through the was faulty.
motor.

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4.TROUBLESHOOTING MAINTENANCE B-82535EN/03

Symptom Description Cause Measure

Grease -Grease is leaking from the [Poor sealing] -If a crack develops in the
leakage mechanical unit. -Probable causes are a crack in the casting, sealant can be used
casting, a broken O-ring, a damaged as a quick-fix to prevent
oil seal, or a loose seal bolt. further grease leakage.
-A crack in a casting can occur due to However, the component
excessive force that might be caused should be replaced as soon
in collision. as possible, because the
-An O-ring can be damaged if it is crack might extend.
trapped or cut during disassembling -O-rings are used in the
or re-assembling. locations listed below.
-An oil seal might be damaged if -Motor coupling section
extraneous dust scratches the lip of -Reducer (case and shaft)
the oil seal. coupling section
-A loose seal bolt might allow grease -Oil seals are used in the
to leak along the threads. locations stated below.
-Inside the reducer
-Seal bolts are used in the
locations stated below.
Dropping -An axis drops because the [Brake drive relay and motor] -Check whether the brake
axis brake does not function. -It is likely that brake drive relay drive relay contacts are stuck
-An axis drops gradually when contacts are stuck to each other to to each other. If they are
it should be at rest. keep the brake current flowing, thus found to be stuck, replace the
preventing the brake from operating relay.
when the motor is deenergized. -If the brake shoe is worn out,
-It is likely that the brake shoe has if the brake main body is
worn out or the brake main body is damaged, or if oil or grease
damaged, preventing the brake from has entered the motor,
operating efficiently. replace the motor.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
Displace- -The positioner operates at a [Mechanical section problems] -If the repeatability is
ment point other than the taught -If the repeatability is unstable, unstable, repair the
position. probable causes are a failure in the mechanical section by
-The repeatability is not within drive mechanism or a loose bolt. referring to the above
the tolerance. -If the repeatability becomes stable it descriptions of vibration,
is likely that a collision imposed an noise, and rattling.
excessive load, leading to slipping on -If the repeatability is stable,
the base surface or the mating correct the taught program.
surface of the reducer. Variation will not occur unless
-It is likely that the Pulsecoder is another collision occurs.
abnormal. -If the Pulsecoder is
abnormal, replace the motor
or the Pulsecoder.
-Displacement occurs only in a [Peripheral unit displacement] -Correct the setting of the
specific peripheral unit. -It is likely that an external force was peripheral unit position.
applied to the peripheral unit, thus -Correct the taught program.
shifting its position relative to the
positioner.
-Displacement occurred after [Parameter] -Re-enter the previous
a parameter was changed. -It is likely that the mastering data mastering data, which is
was rewritten in such a way that known to be correct.
the positioner origin was shifted. -If correct mastering data is
unavailable, perform
mastering again.

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B-82535EN/03 MAINTENANCE 4.TROUBLESHOOTING

Symptom Description Cause Measure

BZAL alarm -BZAL is displayed on the -The voltage of the memory backup -Replace the battery.
occurred controller screen. battery is low. -Replace the cable.
-The Pulsecoder cable is defected.
Troubles -Starting of an arc is not good. -The welding earth cable may be -Tighten the connection part
related to arc -An arc is unstable. loosened or broken(NOTE). of the earth cable.
welding -Beads are irregular. -Replace the earth cable.

NOTE
Arc welding troubles may be caused by a welding unit such as a welding power
supply or torch. When a trouble occurs, see the manual of each unit to find the
cause.

4.3 BACKLASH MEASUREMENT

Measurement method
1. Maintain the positioner in a specified posture. (See Fig. 4.3 (a))
2. Apply positive and negative loads to each axis as shown in Fig. 4.3 (a).
3. Remove the loads and measure the displacement.

Apply positive and negative loads to each axis three times and then remove the loads. Calculate the average
of the displacements in the second and third measurements as the backlash.

Stop position
0

+10kgf

Firtst step
-10kgf (Do not measure)

+10kgf
0kgf Second step
L1
-10kgf (B2 =L1+ L2)
f
L2
+10kgf
0kgf Third step
L3 (B3=L3+ L4)
-10kgf
0kgf
L4

Fig. 4.3 (a) Backlash Measurement Method

Backlash B is calculated using the following expression:

B2 + B3
B=
2
Table 4.3 (a) Backlash measurement posture and measurement position
Measured axis J1-axis J2-axis Measurement position (mm)
J1-axis 0° 0° See fig 4.3 (b)
J2-axis 0° 0° See fig 4.3 (b)
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4.TROUBLESHOOTING MAINTENANCE B-82535EN/03

Table 4.3 (b) Allowable rattling of each axis (Backlash)

J1 J2
Angle conversion (min) 2.0 2.5
Displacement conversion (mm) 0.17 0.18
Distance from rotation center to measurement position (mm) 290 250

NOTE
The displacement conversion value indicates backlash in the direction of rotation
from the center of the axis at the distance shown in brackets.

Attach this type of fixture.

Back lash
measurement position

Fig. 4.3 (b) Backlash measurement position (common to the J1- and J2-axes)

4.4 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS

Adjustments are needed after a component is replaced.
The following table lists components and the adjustment items that must be made after their replacement.
After replacing a component, make necessary adjustments according to this table.
Component replacement or function change Adjustment item
Cable replacement (a) Cable dressing
(b) Quick mastering
Battery replacement Replace the battery with the power kept on.
(The battery should be replaced once 1.5 years.) No adjustment is needed.

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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS

5 ADJUSTMENTS
Each part of the mechanical units of a positioner is set to the best condition before the positioner is shipped
to the customer. The customer does not need to make adjustments on the positioner when it is delivered.
If a mechanical unit of the positioner has a large backlash because of a long-term use or component
replacement, make adjustments according to this section.

5.1 AXIS LIMITS SETUP

By setting the movable range of each axis, the movable range of the positioner can be changed from the
standard values.
In the following environments, changing the movable range of the positioner is useful:
• The movable range of the positioner at run time is limited.
• The robot may interfere with tools or peripheral equipment in an area.
• The length of a cable or hose attached for an application is limited.

There are two methods used to prevent the positioner from going beyond the necessary motion range.
These are
• Axis limit software settings (All axes)
• Axis limit mechanical stopper (J1 axis)

CAUTION
1 Changing the movable range of any axis affects the operation range of the
positioner. To avoid trouble, carefully consider a possible effect of the change to
the movable range of each axis in advance. Otherwise, it is likely that an
unexpected condition occurs; for example, an alarm may occur in a previous
taught position.
2 For the J1 axis, do not count merely on software-based limits to the movable
range when changing the movable range of the positioner. Use mechanical
stoppers together so that damage to peripheral equipment and injuries to human
bodies can be avoided. In this case, make the software-specified limits match the
limits based on the mechanical stoppers.
3 Mechanical stoppers are physical obstacles. The positioner cannot move beyond
them. For the J1 axis, it is possible to re-position the mechanical stoppers. The
J2-axis has no mechanical stopper.
4 Movable mechanical stoppers (J1 axis) is deformed in a collision to stop the
positioner. Once a stopper is subject to a collision, it can no longer assure its
original strength and, therefore, may not stop the positioner. When this happens,
replace it with a new one.

Upper Limits
Displays the upper limits of each axis, or the axis limits in a positive direction.

Lower Limits
Displays the lower limits of each axis, or the axis limits in a negative direction.

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5.ADJUSTMENTS MAINTENANCE B-82535EN/03

5.2 REFERENCE POSITION AND MOVING RANGE

Zero point and software motion limits are provided for each controlled axis. Exceeding the software motion
limit of a controlled axis is called overtravel (OT). Overtravel is detected at both ends of the motion limit
for each axis. The positioner cannot exceed the software motion limit unless there is a failure of the system
causing loss of zero point position or there is a system error.
Fig. 5.2 (a) and (b) show the zero point and motion limit (stroke), and mechanical stopper position of each
axis.

0°

＋135° -135°
＋135° ストロークエンド
+135° Stroke end
-135°
-135° ストロークエンド
Stroke end
-138.5° ストッパエンド
-138.5° Stopper end
-138.5° ストッパエンド
-138.5° Stopper end

Fig. 5.2 (a) J1-axis swiveling

0°

-240°
＋240°

-240°
+240°Stroke end Stroke end
ストロークエンド
ストロークエンド
(注） The
(Note) J2軸に機械式ストッパはありません
J2-axis has no mechanical stopper.

Fig. 5.2 (b) J2-axis rotation

5.3 MASTERING
Mastering is an operation performed to associate the angle of each positioner axis with the pulse count value
supplied from the absolute Pulsecoder connected to the corresponding axis motor. To be specific, mastering
is an operation for obtaining the pulse count value corresponding to the zero position.

Mastering method
There are following five methods of mastering.
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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS
Table 5.3 Mastering method
Fixture position This is performed using a mastering fixture before the machine is shipped from the factory.
mastering
Zero-position This is performed with all axes set at the 0-degree position. A zero-position mark (witness
mastering (witness mark) is attached to each positioner axis. This mastering is performed with all axes aligned
mark mastering) to their respective witness marks.
Quick mastering This is performed at a user-specified position. The corresponding count value is obtained
from the rotation speed of the Pulsecoder connected to the relevant motor and the rotation
angel within one rotation. quick mastering uses the fact that the absolute value of a rotation
angel within one rotation will not be lost.
Single axis mastering This is performed for one axis at a time. The mastering position for each axis can be
specified by the user. This is useful in performing mastering on a specific axis.
Mastering data entry Mastering data is entered directly.

Once mastering is performed, it is necessary to carry out positioning, or calibration. Positioning is an

operation is which the controller reads the current pulse count value to sense the current position of the
positioner.

If the backup batteries for the Pulsecoder go dead during cable replacement, quick mastering can be
performed, resetting the positioner exactly to its initial position by calibration.
If replacement of the motors, reducers, or other parts causes mechanical changes in the phases of the
Pulsecoder, quick mastering cannot be performed. In this case, perform fixture position mastering for
accurate position calibration.

CAUTION
f mastering is performed incorrectly, the positioner may behave unexpectedly.
This is very dangerous. So, the positioning screen is designed to appear only
when the $MASTER_ENB system variable is 1 or 2. After performing positioning,
press F5[DONE] on the positioning screen. The $MASTER_ENB system variable
is reset to 0 automatically, thus hiding the positioning screen.

CAUTION
It is recommended that you make a backup of current mastering data before
performing mastering.

5.3.1 Resetting Alarms and Preparing for Mastering

Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and
display the positioning menu.

Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse not established”

Procedure
Step
1 Display the positioning menu by following steps 1 to 6.
1 Press the screen selection key.
2 Press [0 NEXT] and Select [6 SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4 Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER].
5 Press F1 [TYPE] again, and select [Master/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal] menu.

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5.ADJUSTMENTS MAINTENANCE B-82535EN/03

2 To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.

1 Press the screen selection key.
2 Press [0 NEXT] and select [6 SYSTEM].
3 Press F1 [TYPE], and select [Master/Cal] from the menu.
4 Press the F3 [RES_PCA], then press F4 [TRUE].
5 Turn off the controller power and on again.

3 To reset the “Servo 075 Pulse not established” alarm, follow steps 1 to 3.
1 When the controller power is turned on again, the message “Servo 075 Pulse not established”
appears again.
2 Move the axis for which the message mentioned above has appeared till alarm disappears when
press [FAULT RESET] in either direction.

5.3.2 Fixture Position Master

Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the
predetermined fixture position.
Fixture position mastering is accurate because a dedicated mastering fixture is used. Fixture position
mastering is not required in daily operations because it is factory-performed.
When mastering the positioner, arrange the positioner to meet the following conditions.
- Make the positioner mounting base horizontal. (The overall levelness of the positioner mounting
surface shall be 1 mm or less.)
- Remove the hand and other parts form the wrist.
- Set the positioner in the condition protected from an external force.

CAUTION
Be extremely careful in moving the robot during mastering because an axis
movement range is not checked. If fed continuously, an axis hits against any of
the other parts.

Assembling mastering fixtures

Attach the mastering fixture to the positioner as shown in Fig.5.3.2 (a) ,(b).

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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS

PIN A
A290-7220-X935
MASTERING FIXTURE B
A290-7220-X932
Bolt M12X30,2pcs
BOLT M5X16 2pcs
Washer CLAMP
A290-7022-X954,2pcs
Dial gauge 2pcs
PIN B
A290-7220-X956

MASTERING FIXTURE A
A290-7220-X931

Washer 2pcs
Bolt M8X25 2pcs
PIN A
A290-7215-X955

PIN B
A290-7215-X956

Fig. 5.3.2 (a) Attaching the mastering fixture to the 2-axis positioner

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5.ADJUSTMENTS MAINTENANCE B-82535EN/03

Orientation
ダイヤピン
of hexagonal
O12の向き
pin φ12

Orientation
ダイヤピン
O10の向き
of hexagonal
pin φ10

Fig. 5.3.2 (b) Attaching the mastering fixture to the 2-axis positioner

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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS

Mastering
1 Press MENUS.
2 Press NEXT and select SYSTEM.
3 Press F1, [TYPE].
4 Select Master/Cal.
AUTO
SYSTEM Master/Cal G2 JOINT 1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER

3 QUICK MASTER

4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE

Calibrate key select? [NO]

[ TYPE ] YES NO

5 Release brake control, and jog the positioner into the mastering position.
See fig. 5.3.2 (c) for the mastering position.

NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.SSV_OFF_ALL: FALSE
$PARAM_GROUP.SSV_OFF_ENB[*]: FALSE (for all axes)
After changing the system variables, switch the controller power off and on again.
The asterisk (*) indicates the axis number of the positioner.

Slowly move the positioner by axial feed so that the values of dial indicators A and B shown in Fig.
5.3.2 (a) are 3 mm.
6 Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES.

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5.ADJUSTMENTS MAINTENANCE B-82535EN/03

AUTO
SYSTEM Master/Cal G2 JOINT 1%
TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER

3 QUICK MASTER
4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE
ROBOT Calibrated! Cur Jnt Ang(deg):

< 0.0000> < 90.0000> < 0.0000>

< 0.0000> < 0.0000> < 0.0000>

[ TYPE ] LOAD RES_PCA DONE

7 Select “ 6 CALIBRATE “ and press F4, YES. Mastering will be performed

Alternatively, switch the power off and on again. Switching the power on always causes positioning to
be performed.
AUTO
SYSTEM Master/Cal JOINT 1%

TORQUE = [ON ]
1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER

3 QUICK MASTER

4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
< 0.0000> < 0.0000> < 0.0000>
< 0.0000> < 0.0000> < 0.0000>

[ TYPE ] LOAD RES_PCA DONE

8 After positioning is completed, press F5 [DONE].

9 Restore brake control. Reset system variables $PARAM_GROUP.$SV_OFF_ALL and
$PARAM_GROUP.$SV_OFF_ENB to their original values, and turn the power off and then back on.
10 After mastering, update the mastering data listed in the factory-supplied data sheet with new
mastering data ($DMR_GROUP.$MASTER_COUN [1] to [6]).
The asterisk (*) indicates the axis number of the positioner.

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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS

WARNING
Since the axis stroke is not checked during the mastering, be careful to stay clear
of the positioner motion.

Mastering position

J1: 0.000°
J2: 90.000°
Fig. 5.3.2 (c) Mastering position

5.3.3 Zero Position Mastering

Zero-position mastering (witness mark mastering) is performed with all axes set at the 0-degree position. A
zero-position mark (witness mark) is attached to each positioner axis. This mastering is performed with all
axes set at the 0-degree position using their respective witness marks.
Zero-position mastering involves a visual check. It cannot be so accurate. It should be used only as a
quick-fix method.

Procedure Mastering to Zero Degrees

Step
1 Press MENUS.
2 Select NEXT and press SYSTEM.
3 Press F1, [TYPE].
4 Select Master/Cal.

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5.ADJUSTMENTS MAINTENANCE B-82535EN/03

AUTO
SYSTEM Master/Cal G2 JOINT 1%
TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER

4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE

Calibrate zero position master key select? [NO]

[ TYPE ] YES NO

5 Release brake control, and jog the robot into the mastering position. See Fig. 5.3.2 (c) for the
mastering position.

NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.SSV_OFF_ALL: FALSE
$PARAM GROUP.SSV OFF ENB[*]: FALSE (for all axes)
After changing the system variables, switch the controller power off and on again.
The asterisk (*) indicates the axis number of the positioner.

6 Select Zero Position Master.

AUTO
SYSTEM Master/Cal G2 JOINT 1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER

4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE

Robot Mastered! Mastering Data:

<0> <0> <0>
<0> <0> <0>

[ TYPE ] LOAD RES_PCA DONE

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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS
7 Press F4, YES. Mastering will be performed automatically.
AUTO
SYSTEM Master/Cal G2 JOINT 1%
TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER

3 QUICK MASTER
4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):

< 0.0000> < 0.0000> < 0.0000>

< 0.0000> < 0.0000> < 0.0000>

[ TYPE ] LOAD RES_PCA DONE

8 After calibration is completed, press F5[DONE].

9 Reset the brake control release settings to the original state. Set system variables $PARAM_GROUP,
$SV_OFF_ALL, and $SV_OFF_ENB to their original values, then turn off then back on the power.

Table 5.3.3 Posture with position marks aligned

Axis Position
J1-axis 0 deg
J2-axis 0 deg

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5.ADJUSTMENTS MAINTENANCE B-82535EN/03

A A

DETAIL B
DETAIL C
SECTION A-A
J2 J1
Fig. 5.3.3 (a) Marking of the zero-degree for each axis (match mark)

5.3.4 Quick Mastering

Quick mastering is performed at a user-specified position. The corresponding count value is obtained from
the rotation speed of the Pulsecoder connected to the relevant motor and the rotation angle within one
rotation. Quick mastering uses the fact that the absolute value of a rotation angle within one rotation will not
be lost.
Quick mastering is factory-performed at the position indicated in Table 5.3.3. Do not change the setting
unless there is a problem.
If it is impossible to set the robot at the position mentioned above, it is necessary to re-set the quick
mastering reference position using the following method. (It would be convenient to set up a marker that
can work in place of the witness mark.)

CAUTION
1 Quick mastering can be used, if the pulse count value is lost, for example,
because a low voltage has been detected on the backup battery for the pulse
counter.
2 Quick mastering cannot be used, after the Pulsecoder is replaced or after the
mastering data is lost from the robot controller.

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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS

Procedure Recording the Quick Master Reference Position

Step
1Select SYSTEM.
2 Select Master/Cal.
AUTO
SYSTEM Master/Cal G2 JOINT 1%

TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER

3 QUICK MASTER

4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE

Press 'ENTER' or number key to select.

[ TYPE ] LOAD RES_PCA DONE

3 Release brake control, and jog the positioner to the quick mastering reference position.
4 Move the cursor to SET QUICK MASTER REF and press ENTER. Press F4, YES.
Set quick master ref? [NO]

CAUTION
If the positioner has lost mastery due to mechanical disassembly or repair, you
cannot perform this procedure. In this case, master to a fixture or master to zero
degrees to restore positioner mastery.

Procedure Quick Mastering

Step
1 Display the Master/Cal screen
AUTO
SYSTEM Master/Cal JOINT 1%

TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER

3 QUICK MASTER

4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE

Robot Not Mastered!

Quick master? [NO]

[ TYPE ] YES NO

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5.ADJUSTMENTS MAINTENANCE B-82535EN/03

2 Release brake control, and jog the positioner to the quick mastering reference position.
3 Move the cursor to QUICK MASTER and press ENTER. Press F4, YES. Quick mastering data is
memorized.
Quick master? [NO]
4 Move the cursor to CALIBRATE and press ENTER. Calibration is executed. Calibration is executed
by power on again.
5 After completing the calibration, press F5, DONE.
6 Restore brake control. Reset system variables $PARAM_GROUP.$SV_OFF_ALL and
$PARAM_GROUP.$SV_OFF_ENB to their original values, and turn the power off and then back on.
7 After mastering, update the mastering data listed in the factory-supplied data sheet with new mastering
data ($DMR_GROUP.$MASTER_COUN [1] to [6]).
The asterisk (*) indicates the axis number of the positioner.

5.3.5 Single Axis Mastering

Single axis mastering is performed for one axis at a time. When mastering is required only for a specific axis,
perform single axis mastering as described below. New position information is then stored only for that
axis, and the previous position information is preserved for the other axes. The mastering position for each
axis can be specified by the user.
Single axis mastering can be used, if mastering data for a specific axis is lost, for example, because a low
voltage has been detected on the pulse counter backup battery or because the Pulsecoder has been replaced.
AUTO
SINGLE AXIS MASTER G2 JOINT 1%
[ON ]
ACTUAL POS (MSTR POS ) (SEL)[ST]

J1 0.000 ( 0.000) (0) [2]

J2 0.000 ( 0.000) (0) [2]
J3 0.000 ( 0.000) (0) [2]
J4 0.000 ( 0.000) (0) [2]

J5 0.000 ( 0.000) (0) [2]

J6 0.000 ( 0.000) (0) [2]

E1 0.000 ( 0.000) (0) [0]
E2 0.000 ( 0.000) (0) [0]
E3 0.000 ( 0.000) (0) [0]

GROUP EXEC

Table 5.3.5 Items Set in Single Axis Mastering

Item Description
Current position The current position of the positioner is displayed for each axis in degree units.
Mastering position A mastering position is specified for an axis to be subjected to single axis mastering.
It is typically useful to specify a 0° position.
SEL This item is set to 1 for an axis to be subjected to single axis mastering. Usually, it is 0.

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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS

Item Description
ST This item indicates whether single axis mastering has been completed for the
corresponding axis. It cannot be rewritten directly by the user.
The value of the item is reflected in
0 : Mastering data has been lost. Single axis mastering is necessary.
1 : Mastering data has been lost. (Since this value is indicated only when a following
interaction is present, the 2-axis positioner does not enter this state.) Single axis
mastering is necessary.
2 : Mastering has been completed.

Procedure Mastering a Single Axis

Step
1 Select SYSTEM.
2 Select Master/Cal.
AUTO
SYSTEM Master/Cal G2 JOINT 1%

TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER

3 QUICK MASTER
4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE

Press 'ENTER' or number key to select.

3 Select 4, Single Axis Master. You will see a screen similar to the following.
AUTO
SINGLE AXIS MASTER G2 JOINT 1%

[ON ]
ACTUAL POS (MSTR POS ) (SEL)[ST]

J1 0.000 ( 0.000) (0) [2]

J2 0.000 ( 0.000) (0) [2]

J3 0.000 ( 0.000) (0) [2]

J4 0.000 ( 0.000) (0) [2]

J5 0.000 ( 0.000) (0) [2]

J6 0.000 ( 0.000) (0) [2]

E1 0.000 ( 0.000) (0) [0]

E2 0.000 ( 0.000) (0) [0]

E3 0.000 ( 0.000) (0) [0]

GROUP EXEC

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5.ADJUSTMENTS MAINTENANCE B-82535EN/03

4 Move the cursor to the SEL column for the unmastered axis and press the numeric key "1." Setting of
SEL is available per one axis or per plural axes.
5 Turn off brake control as required, then jog the positioner to the mastering position.
6 Enter axis data for the mastering position.
7 Press F5 [EXEC]. Mastering is performed. So, SEL is reset to 0, and ST is re-set to 2 or 1.
AUTO
SINGLE AXIS MASTER G2 JOINT 1%

[ON ]

ACTUAL POS (MSTR POS ) (SEL)[ST]

J1 0.000 ( 0.000) (0) [2]

J2 0.000 ( 0.000) (0) [2]

J3 0.000 ( 0.000) (0) [2]

J4 0.000 ( 0.000) (0) [2]

J5 0.000 ( 0.000) (0) [2]

J6 0.000 ( 0.000) (0) [2]

E1 0.000 ( 0.000) (0) [0]

E2 0.000 ( 0.000) (0) [0]

E3 0.000 ( 0.000) (0) [0]

GROUP EXEC

8 When single axis mastering is completed, press the previous page key to resume the previous screen.
AUTO
SYSTEM Master/Cal G2 JOINT 1%

TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER

3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF

6 CALIBRATE

Press 'ENTER' or number key to select.

9 Select [6 CALIBRATE], then press F4 [YES]. Positioning is performed.

Alternatively, switch the power off and on again. Positioning is performed.
10 After positioning is completed, press F5 [DONE].
11 After mastering, update the mastering data listed in the factory-supplied data sheet with new mastering
data ($DMR_GROUP.$MASTER_COUN [1] to [6]).

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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS

5.3.6 Mastering Data Entry

This function enables mastering data values to be assigned directly to a system variable. It can be used, if
mastering data has been lost, but the pulse count is preserved.

Mastering data entry method

Step
1 Select [6 SYSTEM] and press ENTER.
2 Select [Variable]. The system variable screen appears.

3 Change the mastering data.

The mastering data is saved to the $DMR_GRP.$MASTER_COUN system variable.

4 Select $DMR_GRP. (The asterisk (*) indicates the group number of the positioner.)
ｼｽﾃﾑ ﾍﾝｽｳVariables
SYSTEM G2 ｶｸｼﾞｸ
JOINT 1%
$DMR_GRP[2] 1/25
1 $MASTER_DONE TRUE
2 $OT_MINUS [9] of BOOLEAN
3 $OT_PLUS [9] of BOOLEAN
4 $MASTER_COUN [9] of INTEGER
5 $REF_DONE FALSE
6 $REF_POS [9] of REAL
7 $REF_COUNT [9] of INTEGER
8 $BCKLSH_SIGN [9] of BOOLEAN
9 $EACHMST_DON [9] of INTEGER
10 $SPC_COUNT [9] of INTEGER

[ TYPE
ｶﾞﾒﾝ ] TRUE FALSE

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5.ADJUSTMENTS MAINTENANCE B-82535EN/03

5 Select $MASTER_COUN, and enter the mastering data you have recorded.
ｼｽﾃﾑ ﾍﾝｽｳVariables
SYSTEM G2 ｶｸｼﾞｸ
JOINT 1%
$DMR_GRP[2].$MASTER_COUN 1/9
1 [1] 95678329
2 [2] 10223045
3 [3] 0
4 [4] 0
5 [5] 0
6 [6] 0
7 [7] 0
8 [8] 0
9 [9] 0

[ TYPE
ｶﾞﾒﾝ ]

6 Press the previous page key.

7 Set $MASTER_DONE to TRUE.
ｼｽﾃﾑ ﾍﾝｽｳ
SYSTEM Variables G2 ｶｸｼﾞｸ
JOINT 1%
$DMR_GRP[2] 1/25
1 $MASTER_DONE TRUE
2 $OT_MINUS [9] of BOOLEAN
3 $OT_PLUS [9] of BOOLEAN
4 $MASTER_COUN [9] of INTEGER
5 $REF_DONE FALSE
6 $REF_POS [9] of REAL
7 $REF_COUNT [9] of INTEGER
8 $BCKLSH_SIGN [9] of BOOLEAN
9 $EACHMST_DON [9] of INTEGER
10 $SPC_COUNT [9] of INTEGER

[ TYPE
ｶﾞﾒﾝ ] TRUE FALSE

8 Press F1 [TYPE] and select CALIBRATE.

9 select [6 CALIBRATE], then press F4 [YES].
10 After completing positioning, press F5 [DONE].

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B-82535EN/03 MAINTENANCE 5.ADJUSTMENTS

5.3.7 Confirming Mastering

1) Confirming that mastering was performed normally
Usually, positioning is performed automatically when the power is turned on. To confirm that
mastering was performed normally, check that the current-position display matches the actual position
of the positioner, using this procedure.
a) Replay the taught operation of the robot to set each axis to zero degrees, and visually check that
the zero-degree position marks shown in Fig. 5.2.3 (a) are aligned.
b) Replay a specific portion of the program, and check that the positioner has moved to the taught
position.
2) Possible alarms in positioning
The following paragraphs describe alarms that may occur in positioning and explain how to handle
them.
a) BZAL alarm
This alarm is raised if the voltage of the Pulsecoder backup battery becomes 0V when the
controller power is off. Mastering must be performed again because the counter has already lost
data.
b) BLAL alarm
This alarm indicates that the voltage of the Pulsecoder backup battery is too low to run the
Pulsecoder. If this alarm is issued, replace the backup battery soon while keeping the power on,
and check whether the current-position data is correct, using a method described in item (1).
c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL alarms
If any of these alarms is issued, contact your FANUC service representative. A motor may have
to be replaced.

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6.COMPONENT REPLACEMENT AND ADJUSTMENTS MAINTENANCE B-82535EN/03

6 COMPONENT REPLACEMENT AND

ADJUSTMENTS
Once motors, reducers, and gears are replaced, mastering becomes necessary, Perform mastering according
to Chapter 5 of MAINTENANCE after any of these components is replaced

NOTE
Be very careful when dismounting and mounting the heavy components that are
listed below.

Component Weight (about)

J1-axis motor 23kg
J2-axis motor 10kg
J1-axis reducer 28kg
J2-axis reducer 20kg
J2 unit (including J1-axis reducer) 120kg
Flange 33kg

NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps
and wipe oil off the engaging section. Make sure that there is no solvent in the
taps. Be sure to wipe the excess LOCTITE after tightening bolt.

6.1 REPLACING THE J1-AXIS MOTOR M1

<1> Set dial gauges, and prepare for single axis mastering after replacement.
<2> Turn off the power of the controller.
<3> Hoist the positioner with J2 base as shown in Fig. 6.1.
<4> Remove the ten motor cover mounting bolts (M6×10) and remove the motor cover.
<5> Remove the J1-axis motor connector.
<6> Remove the four motor mounting bolts (M12×30) and washers and then remove the J1-axis motor.
Remove the motor from the J1 unit. Note that grease spills during removal of the motor.
<7> Remove the O-ring.
<8> Apply LOCTITE 242 to the shaft of a new motor, attach the input gear and draw bolt, and fix the new
motor to the J1 base with four motor mounting bolts (M12×30). At this time, replace the O-ring
with a new one and attach it to the prescribed position.
<9> Connect the cable connector to the J1-axis motor.
<10> Attach the motor cover to the J1 base with the ten motor cover mounting bolts (M6×10).
<11> Supply the specified grease to the J1-axis grease bath as described in Section 3.1 of MAINTENANCE.
<12> Perform single axis mastering referring to Subsection 5.3.5 of MAINTENANCE.

NOTE
It is dangerous for the positioner not to be fixed securely because removal of the
motor may turn the flange.

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B-82535EN/03 MAINTENANCE 6.COMPONENT REPLACEMENT AND ADJUSTMENTS

Hang J2 base like this.

O-ring
Nut Bolts M12X30(4pcs)
LOCTITE 242 Washer Bolt M6X10(10pcs)
Tightenin torque 114Nm
J1-axis motor
Washer J1-axis motor cover

Draw bolt
Input Gear

Fig. 6.1 Replacing the J1-axis motor

Part name Specification

O-ring JB-OR1A-G105
Motor A06B-0265-B605#S000

6.2 REPLACING THE J1-AXIS REDUCER

<1> Set dial gauges, and prepare for single axis mastering after replacement.
<2> Put the J1-axis in the 0° posture and turn off the power.
<3> Remove the I/O cables connected to peripheral units from the peripheral units.
<4> Remove the cover, bolts, insulators, collars, flange, and washer plates in the order in which they are
overlaid (see Fig. 6.2 (a)).
<5> Hoist the J2 unit by using eyebolts in the M12 screw holes of the J2-axis reducer.
<6> Remove the five bolts (M6×10) that fix the cable cover and remove the cable cover and shaft (see Fig.
6.2 (b)).
<7> Remove the six bolts (M6×18) that fix the shaft and remove the shaft. At this time, apply LOCTITE
675 to the bearing attached to the shaft.
<8> Remove the 12 bolts (M12×70) that fix the J1-axis reducer to the J1 base and the washers and remove
the J2 unit from the J1-axis assembly (see Fig. 6.2 (c)).
<9> Fix the J2 unit so that steps <9> to <12> can be performed.
<10> Remove the three bolts (M14×110) that fix the J2-axis reducer to the J2 base and the washers and
remove the J2-axis reducer (see Fig. 6.3 (d)).
<11> Remove the three taper pins using a fixture or the like.
<12>Attach a new O-ring to the prescribed position on the J2-axis side correctly, mount a new reducer, and
fix the reducer by tightening three bolts (M14×110) to which LOCTITE is applied with a torque of
204.8 Nm (see Fig. 6.2 (d)).
<13> Extend the taper pin holes with the taper reamer. Insert the taper reamer until its tip reaches 134 mm
below the reducer surface. (It is recommended that paper tape be attached at 134 mm from the tip of
the taper reamer for this machining.) (see Fig. 6.2 (e))
<14> Blow chippings off the taper pin holes with air. At this time, cover the reducer with a vinyl sheet or the
like to prevent chippings from entering the reducer.
<15> Apply LOCTITE 242 to the taper pins and sufficiently hammer them toward the back of the reducer.

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6.COMPONENT REPLACEMENT AND ADJUSTMENTS MAINTENANCE B-82535EN/03

<16> Attach the J2-axis assembly to the J1-axis assembly using bolts (M12×70) (with application of
LOCTITE 262 and a tightening torque of 128.4 Nm) (see Fig. 6.2 (c)). At this time, replace the old
O-ring with a new one.
<17>Attach the shaft to the J1 base by tightening the bolts (M6×18), to which LOCTITE 262 is applied,
with a torque of 157 Nm (see Fig. 6.2 (b)).
<18> Attach the cable cover with the bolts (M6×10) (see Fig. 6.2 (b)).
<19> Attach the flange, collars, insulators, bolts (with application of LOCTITE 262 and a tightening torque
of 128.4 Nm), and cover.
<20> Supply the specified grease to the J1-axis grease bath as instructed by the procedure in Section 3.1 of
MAINTENANCE.
<21> Perform single axis mastering referring to Subsection 5.3.5 of MAINTENANCE.
Cover
Bolt M12X35(9pcs)
LOCTITE 262 Tightening Torque 128.4Nm
Insulator(3pcs)

Washer plate(3pcs)

Collar (9pcs) Flange

Collar

Fig. 6.2 (a) Replacement of the J1-axis reducer 1

SHAFT
Bolt M6X18(8pcs)
LOCTITE 262 Tightening Troque 15.7Nm
Cable Cover

Bolt M6X10(5pcs)

Fig. 6.2 (b) Replacement of the J1-axis reducer 2

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B-82535EN/03 MAINTENANCE 6.COMPONENT REPLACEMENT AND ADJUSTMENTS

J2 unit

O-ring

Bolt M12X70 (12pcs)

Washer
LOCTITE 262 Tightening Torque 128.4Nm

Fig. 6.2 (c) Replacement of the J1-axis reducer 3

Bolt M14X110(3pcs)
Washer
LOCTITE 262 Tightening Torque 204.8Nm

Taper pin (3pcs)

LOCTITE 242

J1-axis reducer J2 base

O-ring

Fig. 6.2 (d) Replacement of the J1-axis reducer 4

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6.COMPONENT REPLACEMENT AND ADJUSTMENTS MAINTENANCE B-82535EN/03

A
G220

265

134 (Deepness of leamer)

A Section A-A
Fig. 6.2 (e) Replacement of the J1-axis reducer 5

Part name Specification

O-ring
JB-OR1A-G220
(between the reducer and J1 base)
O-ring
A98L-0040-0041#265
(between the reducer and J2 base)
Reducer A97L-0218-0804#171

6.3 REPLACING THE J2-AXIS MOTOR M2

<1> Set dial gauges, and prepare for single axis mastering after replacement.
<1> Put the J1-axis in the 90° posture (Fig. 6.3).
<2> Turn off the power of the controller.
<3> Remove the two M5×6 bolts and four M8×12 bolts that fix J2 motor covers 1 and 2 and remove J2
motor covers 1 and 2.
<4> Remove the J2-axis motor connector.
<5> Remove the four motor mounting bolts (M8×20) and remove the motor from the J2 base. Note that
grease spills during removal of the motor.
<6> Remove the C-ring, bearing, gear J21, and O-ring, replace the bearing and O-ring with new ones, and
attach them by reversing the order.
<7> Apply LOCTITE 242 to the threaded portion of a new motor and tighten the nuts with a torque of 16.7
Nm.
<8> Make sure that the O-ring is correctly attached to the motor mounting portion of the J2 base and mount
the motor on the J2 base with four bolts (M8×20). At this time, do not forcibly push and mount the
motor.
<9> Connect the cable connector to the J2-axis motor.
<10> Supply the specified grease to the J2-axis grease bath as described in Section 3.1 of
MAINTENANCE.
<11> Attach J2 motor covers 1 and 2.
<12> Perform single axis mastering referring to Subsection 5.3.5 of MAINTENANCE.

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B-82535EN/03 MAINTENANCE 6.COMPONENT REPLACEMENT AND ADJUSTMENTS

Bolt M5X6,(2pcs)

J2 motor cover 2
O ring
Gear J21
Bearing
C-ring
J2 motor cover 1
Bolt M8X20 (4pcs)
Washer

J2-axis motor

Bolt M8X12,(4pcs)
LOCTITE 242
16.7Nm

Fig. 6.3 Replacing the J2-axis motor

Part name Specification

O-ring JB-OR1A-G105
Motor A06B-0235-B605#S000
Bearing A97L-0001-0194#0000000

6.4 REPLACING THE J2-AXIS REDUCER

<1> Set dial gauges, and prepare for single axis mastering after replacement.
<2> Put the J1-axis in the 0° posture and turn off the power of the controller.
<3> Remove the I/O cables connected to peripheral units from the peripheral units.
<4> Remove the cover (see Fig. 6.4).
<5> Remove the nine M12×35 bolts, three insulators, and three washer plates, and then remove the
remaining parts in the order in which they are overlaid.
<6> Install a new reducer by reversing the above steps.
At this time, replace the O-ring with a new one and attach it to the prescribed position.
<7> Supply the specified grease to the J2-axis grease bath as instructed by the grease replacement
procedure in Section 3.2
<8> Attach J2 motor covers 1 and 2.
<9> Perform single axis mastering referring to Subsection 5.3.5 of MAINTENANCE.

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6.COMPONENT REPLACEMENT AND ADJUSTMENTS MAINTENANCE B-82535EN/03

Cover
Bolt M12X35(9pcs)
LOCTITE 262 Tightening Torque 128.4Nm
Washer plate (3pcs)
Insulator(3pcs)

Flange
Collar
Pipe
O ring
J2-axis reducer

O ring

Fig. 6.4 Replacement of the J1-axis reducer

Part name Specification

O-ring A98L-0040-0041#173
Reducer A97L-0218-0805#37
Oil seal A98L-0040-0047#07070014

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B-82535EN/03 MAINTENANCE 7.PIPING AND WIRING

7 PIPING AND WIRING

7.1 PIPING DRAWING
Fig. 7.1 shows the diagram of piping in the mechanical unit.

Panel union
Rc 3/8 female
(Attached to the back of the adapter）

Connector panel

Panel union
Rc 3/8 female
Fig. 7.1 Piping diagram

7.2 CABLE MOUNTING DIAGRAM

Make the following visual checks to see if there are any cable abnormalities:
1) Whether the swiveling motion of the positioner has caused any tension or bending in the swiveling
section.
2) Confirm that cables do not rub against each other due to the operation of each axis.
3) In particular, confirm that the pipe portion from the J2-axis shaft to the J2-axis reducer pipe is not
damaged.

Fig. 7.2 shows the wiring of the cables in the mechanical unit.

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7.PIPING AND WIRING MAINTENANCE B-82535EN/03

K103
(Welding earth cable)

K101,K102
(M1 to M2 power , Pulsecoder cable)
(1)

TYPE (2)
NO. (3) WEIGHT
DATE (4) (5) kg

K104
(AS cable)

Fig. 7.2 Cables in the mechanical unit

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B-82535EN/03 MAINTENANCE 8.CABLE REPLACEMENT

8 CABLE REPLACEMENT
Replace the cables of the positioner once every about four years (or 15,360 hours operating.) If a cable is
broken or damaged, replace it according to the procedure described in this chapter.

Cautions in handling the Pulsecoder cable

When transporting, installing, or maintaining the positioner, do not detach the Pulsecoder cables carelessly.
The cables are provided with the marking tie shown below. If you detached any cable with the marking tie,
you need to perform mastering for the positioner.
Do not detach any connector unless you replace a motor, Pulsecoder, reducer, or cable.

BATTERY BACKUP

DON'T

DISCONNECT

コネクタ取外不可

Fig. 8 Wire mark

If there is a break in or any other damage to a cable, replace the cable according to the procedure described
in this chapter. If the connector of a Pulsecoder cable (K101) is detached, the data about the absolute
position of the positioner is lost. Once any of these cables is replaced, perform simplified mastering while
referencing Section 5.1. If the data is lost because of a break in a cable, also perform simplified mastering to
calibrate the positioner into the previous absolute position.

8.1 CABLE DRESSING

After a cable is replaced individually rather than in a bundle, clamp it with nylon ties (cable ties) at the
specified positions listed in Table 8.1. Otherwise, the cable might sag or become too tight, leading to a
break in the cable.

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8.CABLE REPLACEMENT MAINTENANCE B-82535EN/03

Table 8.1 Schematic diagram of cables

Mark Schemati diagram of cables Mark No.

M2P

K101
M1P
PP1
+6V
0V

M1M

M1BK

K102
PM1
M2M

M2BK

K103
A
B
C
D
E
F
G
H
J
K

K104
L

I/O A,B,.
M

..,Z
N
I/O

P
Q
R
S
T
U V
W
X
Y
Z

8.2 REPLACING CABLES

1 Remove the J1 and J2 motor covers as described in Chapter 6.
2 Record the Quick Master Reference Position referring to 5.3.4 of MAINTENANCE.
3 Put the J1-axis and J2-axis in the 0° posture and turn off the power of the controller.
4 Remove the cables from the J1-axis and J2-axis motor connectors.
5 Remove the cable cover and connector panel.
6 Remove the cables from the connector panel.

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B-82535EN/03 MAINTENANCE 8.CABLE REPLACEMENT

Bolt M6X10(10 pcs)

Cable cover

Connector panel
Bolt M6X8(4 pcs)

Fig.8.2 (a) Replacing cables 1

7 Remove the M6×12 bolts and remove the clamp.

Bolt M6X12(2 pcs)

Clamp

Fig. 8.2 (b) Replacing cables 2

8 Remove the adapter and remove the cable from the adapter.
9 Cut the cable tie that fixes the cable to the clamp and remove the cables from the clamp.

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8.CABLE REPLACEMENT MAINTENANCE B-82535EN/03

Plate of Pressure terminal interence prevention

(2pcs)
Bolt M8X12(6pcs)

Adapter
CLAMP

Fig. 8.2 (c) Replacing cables 3

10 Pull the cable kit out of the connector board.

11 Insert a new cable kit from the connector board (see Fig. 8.2 (a)).
12 Pass the cable kit under the J1 base and pull its tip out of the end of the flange.
13 Attach the clamp to the side of the J1 base with M6×12 bolts (see Fig. 8.2 (b)).
14 Attach the cable cover to the J1 base with M6×10 bolts (see Fig. 8.2 (a)).
15 Securely attach the cable kit to the clamp with a cable tie, connect it to the adapter, and attach the
adapter with M8×12 bolts (see Fig. 8.2 (c)).
16 Perform quick mastering referring Subsection 5.3.4 of MAINTENANCE.

CAUTION
During assembly, the cable clamp portion of the movable part (between the side of
the J1 base and the adapter) needs to be restored to the original state.

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II. CONNECTION
B-82535EN/03 CONNECTION 1.POSITIONER OUTLINE DRAWING AND OPERATION AREA DIAGRAM

1 POSITIONER OUTLINE DRAWING AND

OPERATION AREA DIAGRAM
When installing peripheral equipment, be careful not to cause interference with the positioner body. For
installation, see Section 3.3 and use 4-φ24 through holes provided on the base.

1.1 OUTLINE DRAWING AND OPERATION AREA DIAGRAM

Figs. 1.1 (a) and (b) show the outer dimensions and the operation area of the positioner, respectively. This
operation area does not depend on the installation type: floor installation, wall hanging, or ceiling hanging.

φ5
00

320 580
90
R2
150
350

243 250

Fig. 1.1 (a) Outline

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1.POSITIONER OUTLINE DRAWING AND OPERATION AREA DIAGRAM CONNECTION B-82535EN/03

Operation are of the J2-axis flange

0
15
J2

R
480° +
(±240°) +
°

135
135

°
-
-
+
+

J1 - -
270°
(±130°)

Fig. 1.1 (b) Operation area diagram

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B-82535EN/03 CONNECTION 2.MOUNTING DEVICES ON THE POSITIONER

2 MOUNTING DEVICES ON THE POSITIONER

NOTE
Before mounting a device, wipe oil off the flange surface well. If not, the position of the
device may be deviated.

2.1 FLANGE MOUNTING SURFACE

(1) Flange mounting surface
The flange mounting surface is shown in Fig. 2.1.

Signal Cable (0.2SQ 12 pairs)

φ113H7 0
+0.035
depth 6

2-Rc3/8 depth 9 For AIR 10-M12 through

+0.027
2-φ12H8 0 depth 12

Fig. 2.1 Flange fixture mounting surface

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2.MOUNTING DEVICES ON THE POSITIONER CONNECTION B-82535EN/03

2.2 POSITIONER LOAD CONDITION

Fig. 2.2 is diagram to limit loads applied to the wrist. Apply a load within the region indicated in the graph.
Apply the conditions of the allowable load moment and the allowable load inertia, too.

750 mm 200 kg

450 mm 300 kg

300 mm 400 kg

210 mm 500 kg

350 mm

233 mm

175 mm

Fig. 2.2 Positioner allowable load condition

Allowable load moment J1-axis 180 kgf･m ( 1764 N･m)

J2-axis 70 kgf･m ( 686 N･m)
2 2
Allowable load inertia J1-axis 3061 kgf･cm･s (300 kg･m )
2 2
J2axis 1020 kgf･cm･s (100 kg･m )

2.3 AIR PIPING IN THE FLANGE

Air piping whose inlet is the J1-axis connector board and outlet is the adapter within the flange is provided.
For the piping route, see Fig. 7.1 of Part I, "Maintenance."
The joint diameter of the inlet and outlet of the air piping is RC3/8 female. Since the joints to be connected
are not supplied, acquire the joints suited to the tubes to be used.

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B-82535EN/03 CONNECTION 2.MOUNTING DEVICES ON THE POSITIONER

2.4 PIN ASSIGNMENT OF THE SIGNAL LINE CONNECTOR

Fig. 2.4 shows the pin assignment of the signal line connector.

A
1BU
AS

B
24-28P
D 2WH C 2YE B 1WH A 1BU 1WH
J 5BU H 4WH G 4RD F 3WH E 3GN

C
Q 8RD P 7BN N 7GN M 6BN L 6YE K 5BN 2YE
V 10BK U 10YE T 9BK S 9BU R 8BN

D
Z 12BK Y 12RD X 11BK W 11GN 2WH
CONNECTION DIAGRAM(SOLDERING SIDE)

E
3GN

0.2mm2 X 24 pcs

F
3WH

G
4RD

H
4WH

J
J2-axis reducer clamp position 5BU

K
5BN

L
6YE

M
6BN

N
7GN
AS

P
7BN

Q
8RD

R
8BN

S
9BU

T
9BK

U
10YE

V
10BK

W
11GN

X
11BK

Y
12RD

Z
12BK

60

2130

Fig. 2.4 Pin assignment of the signal line connector

Table 2.4 (a) Connector specifications (on the mechanical unit side)
Cable name Model Maker/Dealer
Welding power JN1DS10SL1 Japan Aviation Electronics Industry, Ltd.
Signal MS3102A24-28P Fujikura Ltd.
Japan Aviation Electronics Industry, Ltd.

Table 2.4 (b) Connector specifications (on the user side)

Cable name Model Maker/Dealer
Welding power JN1DS10SL1 Japan Aviation Electronics Industry, Ltd.
(FANUC specification:
A63L-0001-0848#A10SL1)
Signal MS3106B24-28S Fujikura Ltd.
Japan Aviation Electronics Industry, Ltd.

2.5 SERVICE FACTOR (DUTY) OF EARTH CABLE

2.5.1 About Service Factor (Duty) of Earth Cable

When the earth cable built-in 2-axes Servo Positioner, operate within the current and the service factor shown
in Fig. 2.5.1. The service factor (duty) of earth cable is calculated from the following expression.

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2.MOUNTING DEVICES ON THE POSITIONER CONNECTION B-82535EN/03

Actual welding time / total operation time per cycle (cycle time) ×100 [%]
Take care that if operation exceeded following service factor, overheating may cause deterioration or burning
of the cable. And, value of Fig. 2.5.1 is in the condition of ambient temperature 30℃. Refer to section 2.5.2 to
find permissible current in different ambient temperature

100

90

80

70

60
Duty (%)

50

40

30

20

10

0
300 320 340 360 380 400 420 440 460 480 500
Current (A)

Fig. 2.5.1 Relationship between current flowing through the earth cable and service factor (duty)
[Ambient temperature 30℃]

NOTE
When a current exceeding the performance of cable flows, ignition or electric shock
can result. So, care should be taken.

2.5.2 Relationship Between Ambient Temperature and Permissible

Current of Earth Cable
The permissible current of earth cable is affected by ambient temperature.
The permissible current in the condition of Service factor (duty) 100% is shown in Fig2.5.2.
Operate within the current shown in Fig.2.5.2.

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B-82535EN/03 CONNECTION 2.MOUNTING DEVICES ON THE POSITIONER

500

450

400
Permissible current value (A)

350

300

250

200

150

100

50

0
0 5 10 15 20 25 30 35 40 45
Ambient temperature (℃)

Fig. 2.5.2 Relationship between ambient temperature and permissible current of earth cable
[Service factor (Duty) 100%]

NOTE
When a current exceeding the performance of cable flows, ignition or electric shock
can result. So, care should be taken.

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3.TRANSPORTATION AND INSTALLATION CONNECTION B-82535EN/03

3 TRANSPORTATION AND INSTALLATION

3.1 TRANSPORTATION
1) Installation procedure
1 Oil is applied to the flange during shipment, so wipe the oil sufficiently.
2 Remove the two M16 eyebolts attached to the J2 base.
3 For ceiling installation, attach the drain plug to the J2 motor cover.

2) Carrying the positioner with a crane

A positioner can be carried by suspending it with a crane.
Hoist the positioner by threading a rope through the two M16 eyebolts (see Fig. 3.1 (a)).
After installing a positioner, remove any transportation stopper and transportation support.
A transportation stopper is a bolt for preventing swivel axis movement during transportation. A
transportation stopper is painted or plated in red. Be sure to remove all transportation stoppers before
starting positioner operation.

CAUTION
When transporting a positioner, be careful not to damage a motor connector with a
sling for lifting the positioner.

CAUTION
When an end effector and peripherals are installed on a positioner, the center of
gravity of the positioner changes and the positioner might become unstable while
being transported.
If the positioner becomes unstable, remove the tooling and place the positioner
into the transportation position. This will position the unit center of gravity
correctly. It is recommended to transport the end effector and peripherals
separately from the positioner.
Before moving the positioner by using transport equipment, check and tighten any
loose bolts on the forklift pockets.

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B-82535EN/03 CONNECTION 3.TRANSPORTATION AND INSTALLATION

Note)
POSITONER TRANSPORTING POSTURE 1.Positioner weight 295kg
J1-axis 0° 2.Eyebolts complied with JIS B1168
3.Eyebolt 2 pcs
J2-axis 0° Spring washer 2 pcs
Plane wasehr 2 pcs

Crane load capacity : 400kg or more

Sling load capacity : 400kg or more

900

500

243 250

Center of gravity
Fig. 3.1 Carrying the positioner with a crane

3.2 STORING THE POSITIONER

When storing the positioner, keep it in the posture shown in Fig. 3.1.

NOTE
A positioner assuming an attitude other than the one for transportation cannot
stand by itself and can fall. Before storing a positioner for a long term, take
measures for securing the positioner to prevent it from falling.

NOTE
The flange surface is likely to rust, so apply antirust oil to the flange surface to
save it for a long period of time.

3.3 INSTALLATION
Fig. 3.3 (a) shows the dimensions of the base of the positioner main body.

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3.TRANSPORTATION AND INSTALLATION CONNECTION B-82535EN/03

Front
(Mounting face)
(Mounting face)
17 30 500 30

17
30

144
250
200

106
406

106
200
243
137
30

205 205 4-φ24

(突き当て面) 245 245
4-M16
121 176 176 114

Fig. 3.3 (a) Dimensions of the base of the positioner main body

Fig. 3.3 (b) shows an example of installing the positioner. In this example, the sole plate is fixed with four
M20 chemical anchors (in strength category 4.8), and the positioner base is fastened to the sole plate with
four M20×70 bolts (in strength category 12.9). If compatibility must be maintained in teaching the robot
after the positioner mechanical unit is replaced, use the mounting face.

NOTE
The customer shall arrange for the positioning pin, anchor bolts, and sole
plate.

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B-82535EN/03 CONNECTION 3.TRANSPORTATION AND INSTALLATION

(Mounting )face)
(突き当て面

4-φ24through
4-φ24 貫通
30 500 30 270

50
(Mounting face)
(突き当て面 )
317

350

FRONT
正面

Installation
設置板 plate
30

1000
406

400
30

(Mounting )face)
(突き当て面

1000 50

490 305

PositionerJ1
ポジショナ J1 ベース
base

Positioner fixing bolt + washer

ポジショナ固定用ボルト+ワッシャ
Chemical anchor M20X70(4個)
ケミカルアンカー M20×70 (4 pcs)
強度区分:12.9
32

M20(4個)
M20 (4 pcs) Strength class: 12.9
締付トルク:529.2 Nm
強度区分:4.8
Strength class: 4.8 Tightening torque: 529.2 Nm
締付トルク:186.2 Nm 186.2 Nm
Tightening torque:
200

Fig. 3.3 (b) Example of installing the positioner

Fig. 3.3 (c) and Table 3.3 (a) explain what load is put on the J1 base when the positioner is at a rest,
accelerating or decelerating, and at an emergency stop.

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3.TRANSPORTATION AND INSTALLATION CONNECTION B-82535EN/03

MV

FH

FV
MH
Fig. 3.3 (c) Load and moment applied to the J1 base

Table 3.3 (a) Load and moment applied to the J1 base

Bending moment Vertical load Torsion moment Horizontal load
State
MV[kgfm](Nm) FV[kgf](N) MH[kgfm](Nm) FH[kgf](N)
At rest [370](3626) [295](2891) [0](0) [0](0)
Accelerating or [455](4459) [667](6536.6) [155](1519) [667](6536.6)
decelerating
At an Power-Off stop [1219](11946.2) [1787](17512.6) [296](2900.8) [1787](17512.6)

3.4 MAINTENANCE CLEARANCE

Fig. 3.4 shows the layout of maintenance clearances.

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B-82535EN/03 CONNECTION 3.TRANSPORTATION AND INSTALLATION

750
750 640 1100

Fig. 3.4 Maintenance clearance layout

3.5 ASSEMBLING THE POSITONER FOR INSTALLATION

The robot connection cables are detached from the connector board of the mechanical unit when the
positioner is shipped (the cables are connected on the controller side). Connect the cables shown in Fig. 3.5
to the connector board of the mechanical unit. During the connection, be careful not to pull the cable
connected to the HARTING connector.
Insert a washer for the earth cable so that the terminal is securely fixed.
In connecting cables between the robot controller and the positioner body, the customer needs to obtain
cable ducts or the like.

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3.TRANSPORTATION AND INSTALLATION CONNECTION B-82535EN/03

Connect the earth cable

from the controller

PM
Connect the power cable form
the controller

PP
Connect the Pulsecoder cable form
the controller

Fig. 3.5 Cable connection panel for the positioner mechanical unit

3.6 AIR PIPING

Fig. 3.6 (a) shows the air piping of the positioner.
In the mechanical unit, two pneumatic tubes are connected. Their outside diameter is 12 mm and their
inside diameter is 8 mm.
If the three-piece pneumatic option is selected, it comes with the air pipe to be installed between it and the
mechanical unit. To use the option, the customer shall arrange for a three-piece pneumatic option mounting
section that has the self-tapping screw holes whose dimensions and layout are specified in Fig. 3.6 (b) and
for its installation.
The following figure assumes that the FANUC three-piece pneumatic option is selected. When the
customer selects another option, refer to the interfaces in the following figure to prepare the required parts.

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B-82535EN/03 CONNECTION 3.TRANSPORTATION AND INSTALLATION

Elbow nipple
R3/8
R3/8
Straight nipple
R3/8

in dotted line
Air tube 3m Three piece pneumatic(opition)
Outer 10mm inner 6.5mm Spec:A05B-1302-J011
Fig. 3.6 Air piping

Fill the lubricator in the three-piece pneumatic option with any turbine oil between #90 and #140 to the
specified level.
The customer shall arrange for mounting bolts.

Fig. 3.6 Three-piece pneumatic option

3.7 INSTALLATION CONDITIONS

Refer to Specification of [PREFACE] about installation conditions.

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APPENDIX
B-82535EN/03 APPENDIX A.SPARE PARTS LISTS

A SPARE PARTS LISTS

Table A (a) Cables
Cable No. Specifications Remarks
K101 A660-8015-T932 Arc welding
K102 A660-8015-T933 Power
K103 A660-8016-T057 Welding ground
K104 A660-8016-T058 Signal

Table A (b) Motor

Specifications Axis Model
A06B-0265-B605#S000 J1 αiS22/4000
A06B-0235-B605#S000 J2 αiS8/4000

Table A (c) Reducer

Specifications Axis Weight
A97L-0218-0804#171 J1 28kg
A97L-0218-0805#37 J2 20kg

Table A (d) Gear

Specifications Name
A290-7216-Z212 Gear J12
A290-7220-X311 Gear J21

Table A (e) O-ring

Specifications Location of use
JB-OR1A-G105 J1 motor
A98L-0040-0041#265 J1 reducer
JB-OR1A-G220 J1 reducer
A98L-0040-0041#173 J2 reducer
JB-OR1A-G95 Pipe
JB-OR1A-G105 J2 motor

Table A(f) Bearing

Specifications Location of use
A97L-0001-0194#0000000 J2 motor

Table A(g) Oil seal

Specifications Location of use
A98L-0040-0047#07070014 J2 reducer

Table A (h) Grease

Specifications Name
A98L-0040-0174 VIGOGREASE RE0

Table A (i) Battery

Specifications Name Q’ty
A98L-0031-0005 1.5V, alkali size D 4 pcs

- 75 -
B.CONNECTION DIAGRAMS APPENDIX B-82535EN/03

B CONNECTION DIAGRAMS

Fig. B Intra-mechanical unit circuit diagram

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B-82535EN/03 APPENDIX B.CONNECTION DIAGRAMS

- 77 -
C.PERIODIC INSPECTION TABLE APPENDIX B-82535EN/03

C PERIODIC INSPECTION TABLE

FANUC 2-AXES SERVO POSITIONER PERIODIC INSPECTION TABLE

Grease First
Working Check 3 6 9
amount check months months months 1 year
2
time years
Item time (H) 320
960 1920 2880 3840 4800 5760 6720 7680 8640 9600 10560
Check the mechanical cable.
1 (damaged or twisted) 0.2H ― ○ ○ ○
Check the motor connector
2 (tightness). 0.2H ― ○ ○ ○
Tighten the loosened flange
3 mounting bolts. 0.2H ― ○ ○ ○
Mechanical unit

Tighten the cover and main

4 bolt. 0.5H ― ○ ○ ○

5 Remove spatter and dust etc. 1.0H ― ○ ○ ○

6 Replacing battery. 0.1H ― ●

Replacing grease of J2 axis
7 reducer. 0.3H 980cc

Replacing grease of J1 axis

8 reducer. 0.3H 1180cc

Replacing cable of mechanical

9 unit. 3.0H ―
Check the robot cable and
10 teach pendant cable. 0.2H ― ○ ○ ○
Controller

Cleaning the ventilator.

11 (Include air filter) 0.2H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

12 Replacing battery NOTE5) 0.1H ―

NOTE) Refer to the controller maintenance manual.

● : requires order of parts

○ : does not require order of parts

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B-82535EN/03 APPENDIX C.PERIODIC INSPECTION TABLE

3 4 5 6 7 8
years years years years years years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 Items

○ ○ ○ ○ ○ 1

○ ○ ○ ○ ○ 2

○ ○ ○ ○ ○ 3

○ ○ ○ ○ ○ 4

○ ○ ○ ○ ○ 5

Overhaul
● ● ● ● 6

● ● 7

● ● 8

(●) 9

○ ○ ○ ○ ○ 10

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 11

● 12

- 79 -
D.STRENGTH OF BOLT AND BOLT TORQUE LIST APPENDIX B-82535EN/03

D STRENGTH OF BOLT AND BOLT TORQUE LIST

NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps
and wipe oil off the engaging section. Make sure that there is no solvent in the
taps. Be sure to wipe the excess LOCTITE after tightening bolt.
Use bolt which strengths are below.
But if it is specified in text, obey it.
Hexagon socket head bolt made by steel
Size is M22 or less : Tensile strength 1200N/mm2 or more
Size is M24 or more : Tensile strength 1000N/mm2 or more
All size of bolt of the plating : Tensile strength 1000N/mm2 or more

Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm2 or more

If no tightening torque is specified for a bolt, tighten it according to this table.

Recommended bolt tightening torques Unit: Nm
Hexagon socket head
button bolt
Hexagon socket head
Hexagon socket head Hexagon socket head Hexagon bolt
bolt
Nominal bolt (stainless) flush bolt (steel)
(Steel)
diameter Low-head bolt
(steel)
Tightening torque Tightening torque Tightening torque Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
M3 1.8 1.3 0.76 0.53 ―――― ―――― ―――― ―――
M4 4.0 2.8 1.8 1.3 1.8 1.3 1.7 1.2
M5 7.9 5.6 3.4 2.5 4.0 2.8 3.2 2.3
M6 14 9.6 5.8 4.1 7.9 5.6 5.5 3.8
M8 32 23 14 9.8 14 9.6 13 9.3
M10 66 46 27 19 32 23 26 19
M12 110 78 48 33 ―――― ―――― 45 31
(M14) 180 130 76 53 ―――― ―――― 73 51
M16 270 190 120 82 ―――― ―――― 98 69
(M18) 380 260 160 110 ―――― ―――― 140 96
M20 530 370 230 160 ―――― ―――― 190 130
(M22) 730 510 ―――― ―――― ―――― ―――― ―――― ――――
M24 930 650 ―――― ―――― ―――― ―――― ―――― ――――
(M27) 1400 960 ―――― ―――― ―――― ―――― ―――― ――――
M30 1800 1300 ―――― ―――― ―――― ―――― ―――― ――――
M36 3200 2300 ―――― ―――― ―――― ―――― ―――― ――――

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B-82535EN/03 INDEX

INDEX
Mastering Data Entry .....................................................39
<Number> MOUNTING DEVICES ON THE POSITIONER.........59
1-YEAR CHECKS (3,840 hours).....................................7
3-MONTH CHECKS (960 hours)....................................7 <O>
3-YEAR PERIODIC INSPECTION (11,520 hours) ........8 ONE-AND HALF-YEAR PERIODIC INSPECTION
4-YEAR (13,820 HOURS) CHECKS ..............................8 (5,760 hours) ................................................................8
OUTLINE DRAWING AND OPERATION AREA
<A> DIAGRAM.................................................................57
ADJUSTMENTS ...........................................................23
AIR PIPING ...................................................................70 <P>
AIR PIPING IN THE FLANGE.....................................60 PERIODIC INSPECTION TABLE ...............................78
ASSEMBLING THE POSITONER FOR PERIODIC MAINTENANCE .......................................10
INSTALLATION .......................................................69 PIN ASSIGNMENT OF THE SIGNAL LINE
AXIS LIMITS SETUP ...................................................23 CONNECTOR ...........................................................61
PIPING AND WIRING .................................................49
<B> PIPING DRAWING.......................................................49
BACKLASH MEASUREMENT ...................................21 POSITIONER LOAD CONDITION .............................60
BATTERY REPLACEMENT .......................................12 POSITIONER OUTLINE DRAWING AND
OPERATION AREA DIAGRAM..............................57
<C> PREFACE .................................................................... p-1
CABLE DRESSING ......................................................51 PREVENTIVE MAINTENANCE ...................................5
CABLE MOUNTING DIAGRAM ................................49 PROBLEMS AND CAUSES.........................................14
CABLE REPLACEMENT.............................................51 PROCEDURE FOR RELEASING THE GREASE
COMPONENT REPLACEMENT AND REMAINING PRESSURE.........................................12
ADJUSTMENT ITEMS .............................................22
COMPONENT REPLACEMENT AND <Q>
ADJUSTMENTS........................................................42 Quick Mastering.............................................................34
CONFIGURATION .........................................................3
Confirming Mastering ....................................................41 <R>
CONNECTION DIAGRAMS........................................76 REFERENCE POSITION AND MOVING RANGE ....24
Relationship Between Ambient Temperature and
<D> Permissible Current of Earth Cable................................62
DAILY INSPECTION .....................................................5 REPLACING CABLES .................................................52
REPLACING THE J1-AXIS MOTOR M1 .................42
<F> REPLACING THE J1-AXIS REDUCER ......................43
First 1-MONTH (960 HOURS) CHECKS .......................7 REPLACING THE J2-AXIS MOTOR M2 .................46
FIRST 3-MONTH CHECNK (960 hours) ......................7 REPLACING THE J2-AXIS REDUCER ......................47
Fixture Position Master ..................................................26 Resetting Alarms and Preparing for Mastering ..............25
FLANGE MOUNTING SURFACE...............................59
<S>
<G> SAFETY PRECAUTIONS ........................................... s-1
GENERAL .....................................................................14 SERVICE FACTOR (DUTY) OF EARTH CABLE......62
GREASE REPLACEMENT ..........................................10 Single Axis Mastering....................................................36
SPARE PARTS LISTS ..................................................75
<I> SPECIFICATIONS OF THE MAJOR MECHANICAL
INSTALLATION...........................................................65 UNIT COMPONENTS ................................................4
INSTALLATION CONDITIONS..................................71 STORING THE POSITIONER......................................65
STRENGTH OF BOLT AND BOLT TORQUE LIST ..80
<J>
J1-AXIS DRIVE MECHANISM .....................................3 <T>
J2-AXIS DRIVE MECHANISM .....................................4 TRANSPORTATION ....................................................64
TRANSPORTATION AND INSTALLATION.............64
<M> TROUBLESHOOTING .................................................14
MAINTENANCE CLEARANCE..................................68
MAINTENANCE TOOLS...............................................9 <Z>
MASTERING ................................................................24 Zero Position Mastering.................................................31
i-1
B-82535EN/03 REVISION RECORD

REVISION RECORD
Edition Date Contents
• Addition note for low temperature
03 Feb., 2012 • Addition check of oil exudation
• Correction of mistakes
• Reflection of a new controller name (R-J3iC→R-30iA)
02 Jun., 2007 • Addition of a description about the earth cable usage ratio
• Correction of mistakes
01 Jan, 2007

r-1
 B-82535EN/03

* B - 8 2 5 3 5 E N / 0 3 *