M-410iB450 Maintenance Manual (B-81925EN 04)

FANUC > M-410i B/450
MECHANICAL UNIT
MAINTENANCE MANUAL
B-81925EN/04
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller
labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.
• 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-81925EN/04 SAFETY PRECAUTIONS
1 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.
s-1
SAFETY PRECAUTIONS B-81925EN/04
1.1 OPERATOR 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.
(2) Even when the robot is 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.
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.1.1 (a), (b) and (c).
(4) Provide the peripheral devices with appropriate grounding (Class

1, Class 2, or Class 3).
(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 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.
s-2
(9) When adjusting each peripheral device independently, be sure to

turn off the power of the robot.
Limit swith which operates

when the gate is opened.
Fig. 1.1 (a) Safety Fence and Safety gate
Panel board
パネルボード
FENCE1 Note) Terminals FENCE1 and FENCE2 are on the PC board
FENCE1
in the operator’s panel.
FENCE2
FENCE2
Fig. 1.1 (b) Limit switch circuit diaram of the safety fence (For R-J3iB CONTROLLER)
Panel
パネルボードboard
EAS1
EAS1 Note) Terminals EAS1, EAS11 and EAS2, 21 are on the PC
board in the operator’s panel.
EAS11
EAS11 Refer to the R-30iA CONTROLLER MAINTENANCE
EAS2
EAS2 MANUAL.
EAS21
EAS21
Fig. 1.1 (c) Limit switch circuit diaram of the safety fence (For R-30iA CONTROLLER)
s-3
1.1.1 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) If it is not necessary for the robot to operate, turn off the power
of the robot controller or press the EMERGENCY STOP button,
and then proceed with necessary work
(2) Operate the robot system at a location outside the work area.
(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.
External EMERGENCY
STOP button
Panel PC board
Note) Connect between EMGIN1 and EMGIN 2.

Terminals EMGIN1 and EMGIN2 are on the
Panel PC board
Fig. 1.1.1 (a) Connection Diagram for External Emergency Stop Switch
(For R-J3iB CONTROLLER)
External EMERGENCY
STOP button
外部非常停止スイッチ
Panel board
パネルボード
EES1
EES11
EES2
EES21
Note) Connect between EES1 and EES11 and between EES2 and
EES21.
（注）　EES1-EES11間、 EES2-EES21間に接続します。
Terminals EES1, EES11, EES2 and EES21 are on the Panel
　　　　EES1,EES11、EES2,EES21はパネルボード上にあり
board.
　　　　ます。
Refer to R-30iA CONTROLLER MAINTENANCE MANUAL.
　　　　詳細はR-J3iC制御部保守説明書をご参照下さい。
Fig. 1.1.1 (b) Connection Diagram for External Emergency Stop Switch
(For R-30iA CONTROLLER)
s-4
1.1.2 Safety of the Teach Pendant Operator

While teaching the robot, it is necessary for the operator to enter the
work area of the robot. It is particularly necessary to ensure the
safety of the teach pendant operator.
(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) When entering the robot work area and teaching the robot, be
sure to check the location and condition of the safety devices
(such as the EMERGENCY STOP button and the deadman's
switch on the teach pendant).
The teach pendant supplied by FANUC is provided with a teach pendant

enable switch and a deadman's switch in addition to the EMERGENCY
STOP button. The functions of each switch are as follows.
EMERGENCY STOP button : Pressing this button stops the robot in an
emergency, irrespective to the condition
of the teach pendant enable switch.
Deadman's switch : The function depends on the state of the
teach pendant enable switch.
When the enable switch is on - Releasing the finger from the dead
man's switch stops the robot in an
emergency.
When the enable switch is off-The deadman's switch is ineffective
NOTE
The deadman's switch is provided so that the robot
operation can be stopped simply by releasing finger
from the teach pendant in case of emergency.
s-5
(4) The teach pendant operator should pay careful attention so that
no other workers enter the robot work area.
NOTE
In addition to the above, the teach pendant enable
switch and the deadman's switch also have the
following function.By pressing the deadman's switch
while the enable switch is on, the emergency stop
factor (normally the safety gate) connected to the
controller is invalidated. In this case, it is possible
for an operator to enter the fence during teach
operation without pressing the EMERGENCY STOP
button. In other words, the system understands
that the combined operations of pressing the teach
pendant enable switch and pressing the deadman's
switch indicates the start of teaching.
The teach pendant operator should be well aware
that the safety gate is not functional under this
condition and bear full responsibility to ensure that
no one enters the fence during teaching.
(5) When entering the robot work area, the teach pendant operator
should enable the teach pendant whenever he or she enters the
robot work area. In particular, while the teach pendant enable
switch is off, make certain that no start command is sent to the
robot from any operator's panel other than the teach pendant.
The teach pendant, operator’s box, and peripheral device interface

send each robot start signal. However the validity of each signal
changes as follows depending on the mode of the teach pendant
enable switch and the remote switch on the operator’s panel.
Operator ‘s panel Teach pendant Software remote Teach Operator’s Peripheral

Three modes switch ON/OFF switch condition pendant panel devices
T1/T2 On Independent Allowed to start Not allowed Not allowed
AUTO (Except RIA)
AUTO Off Remote OFF Not allowed Allowed to start Not allowed
AUTO Off Remote ON Not allowed Not allowed Allowed to start
NOTE
When starting the system using the teach pendant
in the RIA specification, the three modes switch
should be T1/T2.
(6) To start the system using the operator's box, make certain that
nobody is in the robot work area and that there are no abnormal
conditions in the robot work area.
s-6
(7) 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.
(8) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
s-7
1.1.3 Safety During Maintenance

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 its
peripheral devices are all in the normal operating condition.
(4) If it is necessary to enter the robot work area for maintenance
when the power is turned on, the worker should indicate that the
machine is being serviced and make certain that no one starts the
robot unexpectedly.
(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.
(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.
s-8
1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES
1.2.1 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) For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in
programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can be stopped according to the states.
1.2.2 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) Employ a limit switch or mechanical stopper to limit the robot
motion so that the robot does not come into contact with its
peripheral devices or tools.
s-9
1.3 SAFETY OF THE ROBOT MECHANISM
1.3.1 Precautions in Operation

(1) When operating the robot in the jog mode, set it at an appropriate
speed so that the operator can manage the robot in any
eventuality.
(2) Before pressing the jog key, be sure you know in advance what
motion the robot will perform in the jog mode.

(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 the predetermined work origin in a motion
program for the robot and program the motion so that it starts
from the origin and terminates at the origin. Make it possible for
the operator to easily distinguish at a glance that the robot motion
has terminated.
1.3.3 Precautions for Mechanisms

(1) Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.
s - 10
1.3.4 Procedure to move arm without drive power in emergency or

abnormal situations
(1) For emergency or abnormal situations (e.g. persons trapped in or
by the robot), brake release unit can be used to move the robot
axes without drive power.
Please order following unit and cable.
Name Specification
Brake release A05B-2450-J350 (Input voltage AC100-115V single phase)
unit A05B-2450-J351 (Input voltage AC200-240V single phase)
A05B-2450-J360 (5m) ,(except A cabinet controller integrated type)

Robot
A05B-2450-J361 (10m),(except A cabinet controller integrated type)
connection
A05B-2525-J045(5m) ,(A cabinet controller integrated type)
cable
A05B-2525-J046(10m) ,(A cabinet controller integrated type)
A05B-2525-J010 (5m) (AC100-150V type)
A05B-2525-J011 (10m) (AC100-150V type)

Power cable
A05B-2450-J364 (5m) (AC200-240V type)
A05B-2450-J365 (10m) (AC200-240V type)
(2) Please make sure that adequate numbers of brake release units are
available and readily accessible for robot system before
installation.
(3) Regarding how to use brake release unit, please refer to Robot
controller maintenance manual.
NOTE
Robot systems installed without adequate number of
brake release units or similar means are not in
compliance with EN ISO 10218-1 nor with the
Machinery Directive and therefore cannot bear the
CE marking.
CAUTION
Robot arm would fall down by releasing its brake
because of gravity. Especially because spring
balancer is used for J2-axis, it is hard to predict
J2-arm movement by the condition of Robot attitude
and end effecter.Therefore it is strongly
recommended to take adequate measures such as
hanging Robot arm by a crane before releasing a
brake.
s - 11
In case of releasing J2-axis motor brake Method of supporting robot arm
Sling
M12 eyebolt
M12 eyebolt
Lever block (2 pcs)
？？ Sling (2 pcs)
Unpredictable
Fig. 1.3.4(a) Releasing J2 motor brake and measures
In case of releasing J3-axis motor brake Method of supporting robot arm
Sling
M12 eyebolt
Fall down
Fig.1.3.4(b) Releasing J3 motor brake and measures
s - 12
1.4 SAFETY OF THE END EFFECTOR

(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.
(3) Provide the end effector with a limit switch, and control the robot
system by monitoring the state of the end effector.
1.5 SAFETY IN MAINTENANCE
(1) Never enter the robot work area while the robot is operating.
Turn off the power before entering the robot work area for
inspection and maintenance.
(2) If it is necessary to enter the robot work area with the power
turned on, first press the EMERGENCY STOP button on the
operator's box.
(3) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system. When replacing the
parts in the pneumatic system, be sure to reduce the pressure in
the piping to zero by turning the pressure control on the air
regulator.
(4) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and turn
off the circuit breaker to protect against electric shock.
(5) 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.
(6) Before restarting the robot, be sure to check that no one is in the
robot work area and that the robot and its peripheral devices are
all in the normal operating state.
s - 13
1.6 WARNING LABEL
(1) Greasing and degreasing label
Fig. 1.6 (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 sub-section 2.2.3 Replacing Grease for
explanations about specified greases, the amount of
grease to be supplied, and the locations of grease
and degrease outlets for individual models.
s - 14
(2) Disassembly prohibitive label
Fig. 1.6 (b) Disassembly Prohibitive Label
Description
Do not disassemble the balance unit. It is very dangerous because a
spring is loaded in it.
(3) Step-on prohibitive label
Fig. 1.6 (c) Step-on Prohibitive Label
Description
Do not step on or climb the robot or controller as it may adversely
affect the robot or controller and you may get hurt if you lose your
footing as well.
s - 15
(4) High-temperature warning label
Fig. 1.6 (d) 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.
s - 16
(5) Balancer replacement label
Fig. 1.6 (e) Balancer Replacement Label
Description
When replacing the balancer, observe the instructions indicated on this
label.
• When replacing the balancer, keep the J2 axis at 0°.
• Use a balancer having a weight of 250 kg.
s - 17
(6) Transportation prohibitive label
アイボルトを横引
しないこと
Do not pull eyebolt
sideways
Fig. 1.6 (h) Transportation prohibitive label

Description
Keep the following in mind when transporting the robot.
Do not pull eyebolts sideways
(7) Range of motion and payload mark label
Below label is added when CE specification is specified.
+180DEG 0DEG
-180DEG
The wrist tip

rotation center
B
Motion area of
the writs tip
rotation center
A
C
A B C MAX. PAYLOAD
(mm) (mm) (mm) (kg)
M-410iB/160 3143 2880 78 160
M-410iB/300 3143 2880 78 300
M-410iB/450 3130 2696 238 450
M-410iB/700 3143 2870 88 700
Fig.1.6(i) Range of motion and payload mark label
s - 18
B-81925EN/04 PREFACE
PREFACE
This manual explains the maintenance and connection procedures for
the mechanical
units of the following robots:
Mechanical unit Maximum

Model name Controller
specification No. load
FANUC Robot M-410iB/450 A05B-1039-B221 450kg R-J3iB
FANUC Robot M-410iB/450 A05B-1039-B231 450kg R-30iA
CAUTION
Note that the models for the R-J3iB controller and
those for the R-30iA controller partly differ in the
specifications of mechanical unit cables.
The label stating the mechanical unit specification number is affixed

in the position shown below. Before reading this manual, determine
the specification number of the mechanical unit.
p-1
PREFACE B-81925EN/04
Position of label indicating mechanical unit specification number
Table 1
No. CONTENTS LETTERS
c –– FANUC Robot M-410iB/450
A05B-1039-B221
d TYPE
A05B-1039-B231
e NO. PRINT SERIAL NO.
PRINT PRODUCTION YEAR AND
f DATE
MONTH
TOTAL WEIGHT WITH
g 2430kg
CONTROLLER
TOTAL WEIGHT
h 2310kg
WITHOUT CONTROLLER
p-2
B-81925EN/04 PREFACE
Specifications
ITEM Specifications
Type Articulated type
Controlled axes 4 axes (J1, J2, J3, J4)
Installation Floor mount
Motion range J1-axis 360° (6.28rad)
J2-axis 145° (2.53rad)
J3-axis 135° (2.36rad)
J4-axis 540° (9.42rad)
Max. motion speed J1-axis 1.22rad/s (70° /s)
J2-axis 1.22rad/s (70° /s)
J3-axis 1.22rad/s (70° /s)
J4-axis 3.14rad/s (180° /s)
Max. load capacity at wrist 450 kg
Allowable load inertia at wrist 196 kgm2 (2000kgfcms2) (NOTE1) (∗1)
294 kgm2 (3000kgfcms2) (NOTE1) (∗2)
Maximum throughput 730 cycles / hour (400 kg)
700 cycles / hour (450 kg)
(NOTE1)
Drive method Electric servo drive by AC servo motor
Repeatability ±0.5 mm
Weight Integrated type controller : 2,430 kg (with control unit)
Remote type controller : 2,310 kg (without control unit)
: 120 kg (controller)
Acoustic noise level less than 70dB
NOTE
This value is equivalent continuous A-weighted sound pressure level
which applied with ISO11201 (EN31201). This value is measured
with the following conditions.
- Maximum load and speed
- Operating mode is AUTO
Installation requirement Ambient temperature : 0~45°C
Ambient humidity
Normally : 75%RH or less (NOTE 3)
Short time (within one month) : Max. 95%RH
Height :
Up to 1,000 meters above the sea level requires, no particular
provision for attitude.
Vibration : 0.5G (4.9m/s2) or less
NOTE
1 The allowable value in the standard inertia mode is indicated on the (∗1) and that in
the high inertia mode is indicated on the (∗2). For details, see Section 2.3 in the
connection manual.
2 When the horizontal range of motion is 2,000 mm and the vertical range of motion
is 400 mm.
3 No dew, nor frost allowed.
p-3
PREFACE B-81925EN/04
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 Topics :
system designer must read and understand Safety items for robot system design, operation, maintenance
thoroughly this handbook
R-J3iB controller Setup and Operations Intended readers :
manual Operator, programmer, maintenance person, system designer
Topics :
HANDLING TOOL Robot functions, operations, programming, setup, interfaces, alarms
B-81464EN-2 Use :
Robot operation, teaching, system design
Maintenance manual Intended readers :
B-81465EN Maintenance person, system designer
Topics :
B-81465EN-1 Installation, connection to peripheral equipment, maintenance
(European Use :
specification) Installation, start-up, connection, maintenance
R-30iA controller Setup and Operations Intended readers :
manual Operator, programmer, maintenance person, system designer
Topics :
HANDLING TOOL Robot functions, operations, programming, setup, interfaces, alarms
B-82594EN-2 Use :
Robot operation, teaching, system design
Maintenance manual Intended readers :
B-82595EN Maintenance person, system designer
B-82595EN-1(For Europe) Topics :
B-82595EN-2 (For RIA) Installation, connection to peripheral equipment, maintenance
Use :
Installation, start-up, connection, maintenance
Mechanical unit Maintenance manual Intended readers :
Maintenance person, system designer
FANUC Robot Topics :
M-410iB/450 Installation, connection to the controller, maintenance
B-81925EN Use :
installation, start-up, connection, maintenance
p-4
B-81925EN/04 TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
PREFACE ....................................................................................................p-1
MAINTENANCE
1 CONFIGURATION .................................................................................. 3
1.1 J1-AXIS DRIVE MECHANISM....................................................................... 4
1.5 MAJOR COMPONENT SPECIFICATIONS ................................................... 6
2 PREVENTIVE MAINTENANCE............................................................... 7
2.1 DAILY CHECKS ............................................................................................ 8
2.2 PERIODIC CHECKS ..................................................................................... 9
2.2.1 Checking for Cable Damage and Twisting ..............................................................9
2.2.2 Checking for Loose Bolts.......................................................................................11
2.2.3 Cleaning .................................................................................................................11
2.2.4 Replacing Grease....................................................................................................12
2.2.5 Procedure for Releasing Residual Pressure within the Grease Bath ......................16
2.2.6 Greasing .................................................................................................................17
2.2.7 Replacing Battery ...................................................................................................18
2.2.8 Replacing the Cables of the Mechanical Unit ........................................................19
2.2.9 Others .....................................................................................................................19
2.3 MAINTENANCE TOOLS ............................................................................. 20
3 TROUBLESHOOTING .......................................................................... 21
3.1 OVERVIEW ................................................................................................. 21
3.2 FAILURES, CAUSES AND MEASURES ..................................................... 22
3.3 BACKLASH MEASUREMENT..................................................................... 30
c-1
TABLE OF CONTENTS B-81925EN/04
4 ADJUSTMENTS.................................................................................... 32
4.1 ADJUSTING LIMIT SWITCHES AND DOGS (OPTION) ............................. 33
4.2 ZERO POINT POSITION AND MOTION LIMIT OF J2-AXIS TO
J4-AXIS ....................................................................................................... 35
4.3 J1-AXIS STROKE MODIFICATION (OPTION)............................................ 37
4.4 SOFTWARE SETTING................................................................................ 40
4.5 MASTERING ............................................................................................... 41
4.5.1 General ...................................................................................................................41
4.5.2 Mastering Method ..................................................................................................42
4.5.3 Resetting Alarms and Preparing for Mastering ......................................................43
4.5.4 Mastering to a Fixture (Master Position Master) ..................................................44
4.5.5 Mastering................................................................................................................48
4.5.6 Zero Degree Mastering...........................................................................................50
4.5.7 Quick Mastering .....................................................................................................52
4.5.8 Single Axis Mastering ............................................................................................54
4.5.9 Mastering Data Entry .............................................................................................57
5 REPLACING PARTS ............................................................................ 59

5.1 PART REPLACEMENT AND CORRESPONDING ADJUSTMENT ............. 60
5.2 REPLACING J1-AXIS MOTOR (M1) AND REDUCER ................................ 61
5.3 REPLACING J2/J3-AXIS MOTOR (M2/M3) AND REDUCER ..................... 68
5.4 REPLACING J4-AXIS MOTOR (M4) AND REDUCER ................................ 77
5.5 REPLACING THE WRIST UNIT .................................................................. 80
5.6 REPLACING THE OPTIONAL J1-AXIS LIMIT SWITCH (OPTION) ........... 82
5.7 REPLACING THE J1-AXIS PENDULUM STOPPER................................... 83
6 WIRING ................................................................................................. 84
7 REPLACING CABLES .......................................................................... 86

7.1 CABLE FORMING ....................................................................................... 87
7.2 REPLACING A CABLE................................................................................ 96
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B-81925EN/04 TABLE OF CONTENTS
CONNECTION
1 ROBOT EXTERNAL DIMENSION ...................................................... 109
2 MOUNTING A DEVICE TO THE ROBOT ........................................... 110

2.1 LOAD CONDITION AT WRIST.................................................................. 111
2.2 COUPLING OF THE END EFFECTOR TO THE WRIST .......................... 114
2.3 LOAD SETTING ........................................................................................ 115
2.3.1 Motion Performance Screens ...............................................................................115
2.3.2 Switching between Modes....................................................................................117
2.4 EQUIPMENT MOUNTING SURFACE....................................................... 119
2.5 AIR SUPPLY.............................................................................................. 120
2.6 INTERFACE FOR END EFFECTOR ......................................................... 122
2.7 SERVO HAND CABLE INTERFACE (OPTION) ........................................ 126
3 TRANSPORTATION AND INSTALLATION ....................................... 128

3.1 TRANSPORTATION.................................................................................. 129
3.2 INSTALLATION ......................................................................................... 131
3.3 MAINTENANCE AREA .............................................................................. 137
3.4 INSTALLATION CONDITION .................................................................... 138
APPENDIX
A SPARE PARTS LIST .......................................................................... 141
B CIRCUIT DIAGRAM ............................................................................ 145
C PERIODIC MAINTENANCE ................................................................ 158
D BOLT TIGHTENING TORQUE TABLE............................................... 160
c-3
MAINTENANCE
B-81925EN/04 MAINTENANCE 1. CONFIGURATION
1 CONFIGURATION
The configuration of the mechanical unit is shown in Fig. 1 (a) and
(b).
Fig. 1 (a) Mechanical unit configuration (Integrated control unit) (M-410iB/450)
Fig. 1 (b) Mechanical unit configuration (Remote control unit) (M-410iB/450)
-3-
1. CONFIGURATION MAINTENANCE B-81925EN/04
1.1 J1-AXIS DRIVE MECHANISM
Fig. 1.1 shows the J1-axis drive mechanism.

Rotation of the J1-axis motor fixed on the J1-axis base is input to the
reducer via the center gear, and the reduced rotation rotates the J2-axis
base.
Fig. 1.1 J1-axis drive mechanism (M-410iB/450)

Rotation of the J2-axis motor fixed on the J2-axis base is directly fed
to the reducer, and the reduced rotation rotates the J2-axis arm.
-4-
B-81925EN/04 MAINTENANCE 1. CONFIGURATION

Rotation of the J3-axis motor fixed on the J3-axis base is directly fed
to the reducer, and the reduced rotation rotates the J3-axis arm.
Fig. 1.4. shows the J4-axis drive mechanism.

Rotation of the J4-axis motor fixed on the J4 casing is input to the
reducer through the center gear, and the reduced rotation rotates the
wrist flange.
NOTE
A non-excited brake is incorporated in the motors
for all axes (J1, J2, J3, and J4 axes) and actuates
at power off or in an emergency.
-5-
1. CONFIGURATION MAINTENANCE B-81925EN/04
1.5 MAJOR COMPONENT SPECIFICATIONS
(1) Motor
Axis Specifications Remarks
J1, J2, J3 A06B-0268-B605#S000 (Model αM30/4000i)
Model αiS 30/4000i
J4 A06B-0235-B605#S000 (Model αM8/4000i)
Model αiS 8/4000
(2) Reducer
J1-axis reducer A97L-0218-0265#450C-37 RV-450C-37
J2-axis reducer A97L-0218-0266#450E-257 RV-450E-257
J3-axis reducer A97L-0218-0266#450E-257 RV-450E-257
J4-axis reducer A97L-0118-0949#70C-36 RV-70C-36
(3) Wrist unit

Specifications Machines
A05B-1039-K501 Wrist replacing unit (without J4 motor)
-6-
B-81925EN/04 MAINTENANCE 2. PREVENTIVE MAINTENANCE
2 PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained for a long time
by performing the periodic maintenance procedures presented in this
chapter.
-7-
2. PREVENTIVE MAINTENANCE MAINTENANCE B-81925EN/04
2.1 DAILY CHECKS
Clean each part, and visually check component parts for damage
before daily system operation. Check the following items as the
occasion demands.
1) Before turning on power

Item Check Items Check points
1 When air control Air pressure Check air pressure using the pressure gauge on the air regulator as
set is provided shown in Fig. 2.1. If it exceeds the specified pressure of max. 0.69MPa
(7kgf/cm2), adjust it using the regulator pressure setting handle.
2 Oiler oil mist Check the drop quantity during wrist or hand motion. If it does not meet
quantity the specified value (1 drop/10-20 sec), adjust it using the oiler control
knob. Under normal usage the oiler becomes empty in about 10 to 20
days.
3 Oiler oil level Check to see that the oiler level is within the specified level shown in
Fig.2.1.
4 Leakage from Check the joints, tubes, etc. for leaks. Tie the joint again, or replace parts,
hose as required.
Fig. 2.1 Air control set (option)
2) After automatic operation

Item Check Items Check points
5 Vibration, abnormal noises, and Check whether the robot moves along and about the axes smoothly
motor heating without unusual vibration or sounds. Also check whether the temperature
of the motors is excessively high.
6 Changing repeatability Check to see that the stop positions of the robot have not deviated from
the previous stop positions.
7 Peripheral devices for proper Check whether the peripheral devices operate properly according to
operation commands from robot.
8 Brakes for each axis Check that the end effector drops within 0.5mm when the power is cut.
-8-
2.2 PERIODIC CHECKS
Perform periodic checks as detailed in the periodic check table shown

in Appendix C. Additional inspection points and intervals should be
added to the table according to the robot’s application, operating
environment, etc.
2.2.1 Checking for Cable Damage and Twisting

(1) Cables used in the mechanical unit
Observe the cables connected to the movable parts of the
mechanical unit, and check whether the cable sleeves are
damaged or whether the cables are excessively bent or twisted.
Also check that the cable connectors are securely attached to the
motors. (See Chapter 6.)
Perform this check with the periodic table (See Appendix C).
Inspection points and check items of the mechanical unit cables
Inspection points of the mechanical unit cables
Movable parts of J1,the upper side and lower side of link for wrist
posture maintenance of rear side of J2 arm, movable part in uniting
part of J2 to J3 and J3 to J4 and fixed department cable who interferes
easily in peripherals
Check items
For cables with a cable cover, open the cover before making the
check.
Check the cables for a sheath break and wear.
If wires of the cable appear, replace it.
カバーを外す
Remove the cover
Fig 2.2.1(a) Check items of cable
-9-
Inspection points of the connectors
- Power/brake connectors of the motor exposed externally

- Robot connection cables and user cables
Check items
- Circular connector: Check the connector for looseness by turning
it manually.
- Square connector: Check the connector for disengagement of its
lever.
Fig 2.2.1 (b) Check items of connector
(2) Cables connected to the teach pendant and operation box

Check whether the cables connected to the teach pendant and
operation box are excessively twisted or damaged.
Perform this check with the periodic table (See Appendix C).
- 10 -
2.2.2 Checking for Loose Bolts

As part of the initial inspection, check that none of the bolts that are
accessible from outside the robot are loose. If any loose bolts are
found, retighten them.
As part of the first quarterly inspection and the first and subsequent
yearly inspections, check whether the major bolts indicated in Fig.
2.2.2 are loose. If any loose bolts are found, retighten them.
See the operation time of Appendix C.
Fig. 2.2.2 Retighten of the major bolts
2.2.3 Cleaning
- Necessary cleaning points, dust on the flat part, sedimentation of

spatters
Clean sediments periodically.
In particular, clean the following points carefully.

1) Vicinity of the balancer rod and shaft
→ If chippings or spatters are attached to the bushing, abnormal
wear may be caused.
2) Vicinity of the wrist axis and oil seal
→ If chippings or spatters are attached to the oil seal, an oil leak
may be caused.
- 11 -
Fig 2.2.3 Cleaning part
- Check if the vicinity of the necessary inspection

points, wrist part,and J3 arm significantly wears due to
rubbing against the welding cable or hand cable.
- Check if there is a trace of a collision around the
hand.
- Check the reducer or grease bath for an oil leak.
→ If oil can be found a day after wiping oil, an oil leak may be
caused.
2.2.4 Replacing Grease

Replace the grease in the J1-, J2-, J3-, and J4-axis reducers every three
years or after 11,520 operating hours, whichever occurs sooner, by
following the procedure explained below.
Table 2.2.4 lists the required grease type and quantity.
Fig. 2.2.4 (a) shows the greasing posture.
Figs. 2.2.4 (b) through (d) show the grease inlets and outlets of each
reducer.
Table 2.2.4 Grease for 3-year periodical replacement

Supply Gun tip
Grease name Quantity
position pressure
J1-axis reducer Kyodo yushi 10.8×10-3m3 (10800ml)
0.15
J2-axis reducer VIGOGREASE 2.3×10-3m3 (2300ml) MPa or
J3-axis reducer RE0 2.3×10-3m3 (2300ml) less
Spec.:
J4-axis reducer 1.6×10-3m3(1600ml) (NOTE)
A98L-0040-0174
NOTE When using a hand pump, apply grease approximately once per 1.5
seconds.
- 12 -
Fig. 2.2.4 (a) Greasing posture
- 13 -
1) To replace on the reducer

1 Turn off the power.
2 Remove the grease outlet plug.
3 Apply new grease as described Table 2.2.4 from the grease
inlet until it comes out from the grease outlet.
4 After applying greasc, rclease the residual preasure within
the grease bath as described in the procedure in section
2.2.5.
CAUTION
If greasing is performed incorrectly, the internal
pressure of the grease bath may suddenly increase,
possibly causing damage to the seal, which would in
turn lead to grease leakage and abnormal operation.
When performing greasing, therefore, observe the
following cautions.
1 Before starting to grease, open the grease outlet
(remove the plug or bolt from the grease outlet).
2 Supply grease slowly without applying excessive
force, using a manual pump.
3 Whenever possible, avoid using a compressed-air
pump, powered by the factory air supply. Even
when using a compressed-air pump unavoidably,
set the gun tip pressure (see Table 2.2.4) to 0.1
5MPa or less during application of grease.
4 Use grease only of the specified type. Grease of
a type other than that specified may damage the
reducer or lead to other problems.
5 After applying grease, release the residual
pressure within the grease bath as described in the
procedure in Section 2.2.5.
6 Wipe off any grease from the floor and robot
completely, so no one will slip on it.
- 14 -
Fig. 2.2.4 (b) Replacing the grease of the J1-axis/J2-axis reducers
Fig. 2.2.4 (c) Replacing the grease of the J3-axis reducer
Fig. 2.2.4 (d) Replacing grease of J4-axis reducer
- 15 -
2.2.5 Procedure for Releasing Residual Pressure within the Grease

Bath
To release the residual pressure in the grease bath after applying
grease, operate the robot for 20 minutes or more for J1 and J2-axis and
for 40 minutes or more for J3 and J4-axis as described in the table
below with the grease nipple of the grease inlet and the plug of the
grease outlet left open for the J1-axis reducer and J4-axis reducer, and
the plug of the grease outlet left open for the J2-axis reducer and
J3-axis reducer.
Attach the reclaim bags under the grease inlet and grease outlet to
prevent spilled grease from splattering.
Operating axis
J1-axis J2-axis J3-axis J4-axis
Grease
replacement part
Axis angle of
J1-axis reducer 80° or more Arbitrary
OVR 50%
Axis angle of
J2-axis reducer Arbitrary 90° or more Arbitrary
OVR 50%
Axis angle of
J3-axis reducer Arbitrary 60° or more Arbitrary
OVR 100%
Axis angle of
J4-axis gear box Arbitrary 60° or more
OVR 100%
If the above operations cannot be performed due to local

circumstances, the same count operation is necessary. (When the
maximum allowable axis angle is 30°, operate the robot for twice
minute of a specified length.)
When multiple axes are greased at the same time, the axes can be run
at the same time.
After the above operation is performed, attach the grease nipple to the
grease inlet and the seal bolt to the grease outlet. When the seal bolt
or grease nipple is reused, be sure to seal it with seal tape.
- 16 -
2.2.6 Greasing
Supply grease to the parts periodically (after the prescribed number of
operating hours or every specified interval, whichever comes earlier).
If the robot is installed in a severe environment, apply grease
whenever necessary. If water splashes on the robot, apply grease
immediately. Table 2.2.6 (a) and Fig. 2.2.6 show greasing points.
Table 2.2.6 (b) shows substitue greases. When performing greasing,
observe the cautions listed in Section 2.2.3.
NOTE
When the robot is used under high-duty
conditions that, for example, require a cooling unit
(fan), perform greasing at half of the standard
interval.
Table 2.2.6 (a) Greasing points

Greasing
Positions Grease Amount Method
interval
Balancer connection Each Supply to the grease nipple 1,920 hours
point bushing 1.0×1.0-5m3 (6 months)
(2 positions) (Each 10 ml)
SHELL ALVANIA GREASE S2
J3-axis cross roller 4.0×10-5m3 Supply to the grease nipple 11,520 hours
(Spec: A97L-0001-0179#2)
ring (40 ml) (Every 3 years)
J4-axis cross roller 2.0×10-5m3 Supply to the grease nipple 11,520 hours
ring (20 ml) (Every 3 years)
NOTE
Old grease is expelled from the bearing rotating
part after new grease is supplied. Wipe off old
grease immediately after supplying grease, and
then again after 50 to 100 hours of operation.
Table 2.2.6 (b) Substitutes for ALVANIA GREASE S2

MOBIL OIL MOBILUX GREASE No.2
ESSO STANDARD VICON No. 2
NIPPON OIL CORPORATION Multinoc2
NIPPON OIL CORPORATION EPNOC AP-2
IDEMITSU KOHSAN DAPHNE COLONEX GREASE No. 2
COSMO OIL LIMAX No. 2
- 17 -
Fig. 2.2.6 Greasing points
2.2.7 Replacing Battery

The position data of each axis is preserved by the backup battery.
The battery needs to be periodically replaced at every 1.5 year. Use
the following procedure to replace when the backup battery voltage
drop alarm occurs.
1 Press the EMERGENCY STOP button to prohibit the robot
motion.
2 Remove the battery case cap.
3 Take out the old batteries from the battery case.
4 Insert new batteries into the battery case.
Pay attention to the direction of batteries.
5 Close the battery case cap.
CAUTION
Batteries must be replaced only while the power
is on. Replacing the batteries while the power is
off will cause the current position data to be lost.
When this occurs, mastering will have to be
performed. (See Sections 4.5.)
- 18 -
Fig. 2.2.7 Replacing Battery
2.2.8 Replacing the Cables of the Mechanical Unit

The cables of the mechanical unit must be replaced periodically (every
15,360 operating hours or every four years, whichever comes earlier).
See Chapter 7 for details of the cable replacement procedure.
2.2.9 Others
Clean the mechanical unit and controller vents whenever cleaning
those are necessary.
- 19 -
2.3 MAINTENANCE TOOLS
The following tools and instruments are required for the maintenance
procedures contained in this manual.
1) Measuring instruments
Instruments Accuracy/Tolerance Applications
Dial gauge accuracy 1/100mm Measurement of
positioning and backlash
Side calipers 150mm
Push/pull tension gauge 98N (10kgf) Measurement of
backlash
2) Tools
Cross-point (+) screwdrivers : Large, medium, and small sizes
Conventional (-) screwdrivers : Large, medium, and small sizes
Box screwdrivers : M3-M6
Hexagonal wrench key sets : M3-M20
(metric)
Adjustable wrenches : Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Double and wrench
Pliers for C-retaining ring
Torque wrench : With hexagon socket head cap screw
for M8 to M16
Grease gun
Eyebolt : M12, M20, M24
Rope
- 20 -
B-81925EN/04 MAINTENANCE 3. TROUBLESHOOTING
3 TROUBLESHOOTING
3.1 OVERVIEW
The cause of a failure in the mechanical unit may be difficult to

localize, because failures can arise from many interrelated factors. If
you fail to take the correct measures, the failure may be aggravated.
So, it is necessary to analyze the symptoms of the failure precisely so
that the true cause can be found.
- 21 -
3. TROUBLESHOOTING MAINTENANCE B-81925EN/04
3.2 FAILURES, CAUSES AND MEASURES
Table 3.2(a) lists the major failures that may occur in the mechanical
unit and their probable causes. If you cannot pinpoint a failure cause
or which measures to apply, contact FANUC.
Table 3.2(a) Failures, causes and measures

Symptom Description Cause Measure
Vibration -The J1 base lifts off the floor [J1 base fastening] -If a bolt is loose, apply loctite
Noise plate as the robot operates. -It is likely that the robot J1 base is not and tighten it to the appropriate
-There is a gap between the J1 securely fastened to the floor plate. torque.
base and floor plate. -Probable causes are a loose bolt, an -Adjust the floor plate surface
-A J1 base retaining bolt is insuffcient degree of surface flatness, flatness to within the specified
loose. or foreign material caught between the tolenrance.
floor plate and floor plate. -If there is any foreign matter
-If the robot is not securely fastened to between the J1 base and floor
the floor plate, the J1 base lifts the plate, remove it.
floor plate as the robot operates, -As the robot operates, the
allowing the base and floor plates to rack or floor on which the robot
strike each other wihich, in turn, leads is mounted vibrates.
to vibration.
-Apply epoxy to the floor [Rack or floor] -Reinforce the rack or floor to
surface and re-install the plate. -It is likely that the rack or floor is not make it more rigid.
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 robot deforms robot control program; doing
the rack or floor, leading to vibration. so might reduce the amount of
vibration.
-Vibration becomes more [Overload] -Check the maximum load that
serious when the robot adopts -It is likely that the load on the robot is the robot can handle once
a specific posture. greater than the maximum rating. more. If the robot is found to
-If the operating speed of the -It is likely that the robot control be overloaded, reduce the
robot is reduced, vibration program is too demanding for the load, or modify the robot
stops. robot hardware. control program.
-Vibration is most noticeable -It is likely that the ACCELERATION -Vibration in a specific portion
when the robot is accelerating. value is excessive. can be reduced by modifying
-Vibration occurs when two or the robot control program while
more axes operate at the same slowig the robot and reducing
time. its acceleration (to minimize
the influenece on the entire
cycle time).
- 22 -

Vibration -Vibration was first noticed [Broken gear, bearing, or reducer] -Operate one axis at a time to
Noise after the robot collided with an - It is likely that collision or overload determine which axis is
(Continuted) object or the robot was applied an excessive force on the vibrating.
overloaded for a long period. drive mechanism, thus damaging the -Remove the motor, and
-The grease of the vibrating geartooth surface or rolling surface of replace the gear , the bearing,
axis has not been exchanged a bearing, or reducer. and the reducer. For the spec.
for a long period. - It is likely that prolonged use of the of parts and the method of
robot while overloaded caused fretting replacement, contact FANUC.
of the gear tooth surface or rolling -Using the robot within its
surface of a bearing, or reducer due to maximum rating prevents
resulting metal fatigue. problems with the drive
- It is likely that foreign matter caught mechanism.
in a gear, bearing, or within a reducer -Regularly changing the grease
caused damage on the gear tooth with a specified type can help
surface or rolling surface of the prevent problems.
bearing, or reducer.
- 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.
- 23 -

Vibration -The cause of problem cannot [Controller, cable, and motor] -Refer to the Controller
Noise be identified from examination -If a failure occurs in a controller Maintenance Manual for
(Continuted) 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 pulse coder 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 pulse coder 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 controller occurs. For the method of
accurately. replacement, contact FANUC.
-If the motor becomes defective, -Check that the robot is
vibration might occur because the supplied with the rated voltage.
motor cannot deliver its rated -Check whether the sheath of
performance. the power cord is damaged. If
-If a power line in a movable cable of so, replace the power cord,
the mechanical section has an and check whether vibration
intermittent break, vibration might still occurs.
occur because the motor cannot -Check whether the sheath of
accurately respond to commands. the cable connecting the
-If a pulse coder wire in a movable mechanical section
part of the mechanical section has an and controller is damaged. If
intermittent break, vibration might so, replace the connection
occur because commands cannot be cable, and check whether
sent to the motor accurately. vibration still occurs.
-If a connection cable between them -If vibration occurs only when
has an intermittent break, vibration the robot assumes a specific
might occur. posture, it is likely that a cable
-If the power source voltage drops in the mechanical unit is
below the rating, vibration might broken.
occur. -Shake the movable part cable
-If a robot control parameter is set to while the robot is at rest, and
an invalid value, vibration might occur. check whether an alarm
occurs. If an alarm or any other
abnormal condition occurs,
replace the mechanical unit
cable.
-Check that the robot 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.
- 24 -

Vibration -There is some relationship [Noise from a nearby machine] -Connect the grounding wire
Noise between the vibration of the -If the robot is not grounded properly, firmly to ensure a reliable
(Continuted) robot and the operation of a electrical noise is induced on the ground potential and prevent
machine near the robot. grounding wire, preventing commands extraneous electrical noise.
from being transferred accurately,
thus leading to vibration.
-If the robot 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
- There is an unusual sound may be an unusual sound during for one or two days on an
during operation at low operation at low speed immediately experiment. Generally, an
speed. after replacement or after a long usual sound will disappear.
period of time.
- 25 -

Rattling -While the robot is not supplied [Mechanical section coupling bolt] -Check that the following bolts
with power, pushing it with the -It is likely that overloading or a for each axis are tight. If any of
hand causes part of the collision has loosened a mounting bolt these bolts is loose, apply
mechanical unit to wobble. in the robot mechanical section. loctite and tighten it to the
-There is a gap on the appropriate torque.
mounting surface of the -Motor retaining bolt
mechanical unit. -Reducer retaining bolt
-Reducer shaft retaining bolt
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
-Backlash is greater than the [Increase in backlash] -Operate one axis at a time to
tolerance stated in the -It is likely that excessive force applied determine which axis has the
applicable operattor’s manual. to the drive mechanism, due to a increased backlash.
(See table 3.2 (c).) collision or overloading, has broken a -Remove the motor, and check
gear or the inside of the reducer, whether any of its gears are
resulting in an increase in the amount broken. If any gear is broken,
of backlash. replace it.
-It is likely that prolonged use without -Check whether any other gear
changing the grease has caused the of the drive mechanism is
tooth surfaces of a gear and the inside damage. If there is no damage
of the reducer to wear out, resulting in gear, replace the reducer.
an increase in the amount of -If the reducer is broken, or if a
backlash. gear tooth is missing, replace
the relevant component. Also,
remove all the grease from the
gear box and wash the inside
of the gear box.
-After replacing the gear or
reducer, add an appropriate
amount of grease.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
- 26 -

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 control
-After a cover was attached to releasing heat efficiently, thus leading program is running. The
the motor, the motor to overheating. allowable average current is
overheated. [Operating condition] specified for the robot
-After the robot control -It is likely that the robot was operated according to its ambient
program or the load was with the maximum average current temperature. Contact FANUC
changed, the motor exceeded. for further information.
overheated. -Relaxing the robot 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 invalid, parameter as described in
overheated. the robot cannot be accelerated or CONTROLLER OPERATOR’S
decelerated normally, so the average MANUAL.
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 mechanism, descriptions of vibration, noise,
thus placing an excessive load on the and rattling.
motor. -Check that, when the servo
[Motor problems] system is energized, the brake
-It is likely that a failure of the motor is released.
brake resulted in the motor running -If the brake remains applied to
with the brake applied, thus placing an the motor all the time, replace
excessive load on the motor. 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.
- 27 -

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 further
oil seal, or a loose seal bolt. grease leakage. However, the
-A crack in a casting can occur due to component should be replaced
excessive force that might be caused as soon as possible, because
in collision. the crack might extend.
-An O-ring can be damaged if it is -O-rings are used in the
trapped or cut during disassembling or locations listed below.
re-assembling. -Motor coupling section
-An oil seal might be damaged if -Reducer (case and shaft)
extraneous dust scratches the lip of coupling section
the oil seal. -Wrist coupling section
-A loose seal bolt might allow grease -J3 arm coupling section
to leak along the threads. -Inside the wrist
-Problems with the grease nipple or -Oil seals are used in the
threads. locations stated below.
-Inside the reducer
-Inside the wrist
-Seal bolts are used in the
locations stated below.
-Grease drain outlet
-Replace the grease nipple.
Dropping axis -An axis drops because the [Brake drive relay and motor] -Check whether the brake drive
brake does not function. -It is likely that brake drive relay relay contacts are stuck to
-An axis drops gradually when contacts are stuck to each other to each other. If they are found to
it should be at rest. keep the brake current flowing, thus be stuck, replace the relay.
preventing the brake from operating -If the brake shoe is worn out,
when the motor is deenergized. if the brake main body is
-It is likely that the brake shoe has damaged, or if oil or grease
worn out or the brake main body is has entered the motor, replace
damaged, preventing the brake from the motor.
operating efficiently.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
Displacement -The robot operates at a point [Mechanical section problems] -If the repeatability is unstable,
other than the taught position. -If the repeatability is unstable, repair the mechanical section
-The repeatability is not within probable causes are a failure in the by referring to the above
the tolerance. drive mechanism or a loose bolt. descriptions of vibration, noise,
-If the repeatability becomes stable it and rattling.
is likely that a collision imposed an -If the repeatability is stable,
excessive load, leading to slipping on correct the taught program.
the base surface or the mating Variation will not occur unless
surface of an arm or reducer. another collision occurs.
-It is likely that the pulse coder is -If the pulse coder is abnormal,
abnormal. replace the motor or the pulse
coder.
-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
robot.
- 28 -

Displacement -Displacement occurred after [Parameter] -Re-enter the previous
(Continuted) a parameter was changed. -It is likely that the mastering data was mastering data, which is known
rewritten in such a way that to be correct.
the robot origin was shifted. -If correct mastering data is
unavailable, perform mastering
again.
BZAL alarm -BZAL is displayed on the -The voltage of the memory backup -Replace the battery.
occured controller screen battery may be low. -Replace the cable.
-The pulse coder cable may be
broken.
Table 3.2 (b) Allowable drop of brake

At emergency stop 0.5mm
NOTE
The value is the drop value from the end effector
mounting face.
Table 3.2 (c) Allowable backlash tolerances

Angle conversion (arc-min) 2.2 2.5 2.5 2.3
Displacement at specified 1.96 0.87 0.95 0.19
mesurement position (mm)
Refer to following page for the measuring method and the measuring
posture.
- 29 -
3.3 BACKLASH MEASUREMENT
Measurement method
1. Maintain the robot in a specified posture. (See Fig. 3.3 (b))
2. Apply positive and negative loads to each axis as shown in Fig.
3.3(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.
Ｌ1
(Ｂ2＝Ｌ1＋Ｌ2)
Ｌ2
Ｌ3 (Ｂ3＝Ｌ3＋Ｌ4)
Ｌ4
Fig. 3.3 (a) Backlash Measurement Method
Backlash B is calculated using the following expression:

B2 + B3
B＝
2
- 30 -
<1> J1-axis measurement posture

Center of mounting
face of wrist
test work
test work
Trestle
3130
Loading position
Trestle test work
When measuring backlash,press Center of mounting
gauge to test work vertically. face of wrist
Loading position
When measuring backlash,press
gauge to test work vertically.

When measuring backlash,press
test work
Trestle
Loading position
test work 280
Loading position
Trestle
When measuring backlash,press Gauge

175
Fig. 3.3 (b) Backlash measuring posture
BACKLASH MEASUREMENT POSTURE
Table.3.3 Measurement posture and tolerance value of backlash

posture
Measured axis
J1-axis -30° 90° 0° -90°
J2-axis -46° 0° -59° 0°
J3-axis -33° 33° -91° 0°
J4-axis -37° 18.5° -92° -96°
- 31 -
4. ADJUSTMENTS MAINTENANCE B-81925EN/04
4 ADJUSTMENTS
Each part of the mechanical unit is carefully adjusted at the factory
before shipment. Therefore it is usually unnecessary for the customer
to make adjustments at the time of delivery. However, after for a long
period of use or after parts are replaced, adjustments may be required.
- 32 -
B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
4.1 ADJUSTING LIMIT SWITCHES AND DOGS (OPTION)
1) Zero point position and motion limit

Zero point and motion limits are provided for each controlled
axis. Reaching the operation limit of controlled axis is called
overtravel (OT). Overtravel is detected at J1-axis only (option).
Overtravel detection function is not prepared at J2-axis to J4
axis.
The robot cannot exceed the motion range unless there is a
failure of the system causing loss of the zero point position, or
there is a system error.
Fig. 4.1 (a) shows the zero point, motion limit OT detection point
and point of mechanical stopper of J1-axis.
Fig. 4.1 (a) Zero point and motion limit of J1-axis
2) How to adjust the J1-axis

1 Set the $MOR_GRP.$CAL_DONE system parameter to
FALSE. This disables the stroke end specified by the
software. As a result, the operator can rotate the robot
around the J1-axis by a jog feed which goes beyond the
stroke end.
2 Loosen the two M6×12 bolts and the two M4×25 bolts that
secure the J1-axis limit switch.
3 Adjust the switch position so that the robot activates the
limit switch when approximately 1.0 degree from each
stroke end. When the dog is pressed, only one side of the
pushing width indication lines on the end of the switch must
be hidden.
- 33 -
4 When the limit switch operates and detects overtravel (OT),

the robot stops, and an error message, “OVERTRAVEL”, is
displayed. To restart the robot, hold on the SHIFT key and
press the RESET key. Then, while holding on the SHIFT
key, release the J1 axis from the limit by JOG feed.
5 Check that the robot also activates the limit switch when the
robot is approx. 1.0 degree from the opposite stroke end in
the same way as above. If the limit switch does not operate
at the position, adjust the position of the switch again.
6 Set the $MOR_GRP.$CAL_DONE system parameter to
TRUE.
7 Turn off the power, then turn it on again to restart the
controller.
Fig. 4.1 (b) Adjusting J1-axis OT (option)
- 34 -
4.2 ZERO POINT POSITION AND MOTION LIMIT OF J2-AXIS

TO J4-AXIS
Fig. 4.2 (a) to (c) show zero point position and motion area and
mechanical stopper of each axis.
Fig. 4.2 (a) J2-axis
Fig. 4.2 (b) J3-axis
- 35 -
Fig. 4.2 (c) J4-axis
- 36 -
4.3 J1-AXIS STROKE MODIFICATION (OPTION)
The J1-axis stroke can be limited depending on the operating

environment of the robot. The stroke can be changed by changing the
locations of the dog and mechanical stopper and the settings of the
parameters using the following procedure. (See Fig. 4.3 (a) to (b) and
Table 4.3)
The stroke can be changed every 45 degrees in the upper limit of +45
degrees to + 180 degrees and the lower limit of -180 degrees to -45
degrees.
Fig. 4.3 (a) Modifying J1-axis stroke (option)
- 37 -
(a) Changing the mechanical stopper and the dog (option) position.
Change the mechanical position and the dog position as shown in
Fig. 4.3 (b).
Fig. 4.3 (b) Modification of J1-axis stroke (option)
- 38 -
(b) Changing system variables

When changing the dog and mechanical stopper, also be sure to
change the following system variables according to the required
strokes.
After changing system variables, turn the power off then back on
again. (The stroke setting described above can be made also by
selecting “SYSTEM” using the “MENUS” key, then selecting
“Axis limit” menu using F1 (TYPE). Refer to the controller
Operator’s Manual for details.
WARNING
After changing system variables, be sure to run the
robot at a low speed and make sure that the robot
stops at the ends of the stroke.
Table 4.3 Modification of system variable

System variable
Lower stroke limit Upper stroke limit
Positions
$PARAM_GROUP $PARAM_GROUP.
$LOWERLIMS[1] $UPPERLIMS[1]
-180° -180 –
-135° -135 –
-90° -90 –
-45° -45 –
0° 0 0
+45° – 45
+90° – 90
+135° – 135
+180° – 180
WARNING
1 If a collision should occur, the J1 axis stopper
becomes deformed to absorb energy, so that the
robot can stop safely. If the stopper is deformed
by mistake, replace it.
2 Do not add threaded holes to the frame, or do not
use a self-made stopper to control the J1 stroke at
any angle other than the one specified; otherwise,
robot operation may be dangerous.
- 39 -
4.4 SOFTWARE SETTING
Axis limit software settings are upper and lower motion degree
limitations. The limits can be set for all robot axes and will stop robot
motion if the robot is calibrated.
Procedure Setting Up Axis Limits

Step 1 Press MENUS.
2 Select SYSTEM.
3 Press F1, [TYPE].
4 Select Axis Limits. You will see a screen similar to the following.
System Axis Limits JOINT 100%
1/16
AXIS GROUP LOWER UPPER
1 1 -150.00 150.00 dg
2 1 -60.00 75.00 dg
3 1 -110.00 50.00 dg
4 1 -240.00 240.00 dg
5 1 0.00 0.00 mm
6 1 0.00 0 00 mm
7 0 0.00 0.00 mm
8 0 0.00 0.00 mm
9 0 0.00 0.00 mm
[ TYPE ]
NOTE
0 indicates the robot does not have these axes.
CAUTION
Do not depend on J1 axis limit software settings to
control the motion range of your robot. Use the axis
limit switches or hardstops also; otherwise injury to
personnel or damage to equipment could occur.
5 Move the cursor to the axis limit you want to set.

6 Type the new value using the numeric keys on the teach pendant.
7 Repeat Steps 5 through 6 until you are finished setting the axis
limits.
CAUTION
You must turn off the controller and then turn it
back on to use the new information; otherwise
injury to personnel or damage to equipment could
occur.
8 Turn off the controller and then turn it back on again in the cold
start mode so the new information can be used.
- 40 -
4.5 MASTERING
Mastering is an operation performed to associate the angle of each

robot axis with the pulse count value supplied from the absolute pulse
coder connected to the corresponding axis motor. To be specific,
mastering is an operation for obtaining the pulse count value
corresponding to the zero position.
4.5.1 General
The current position of the robot is determined according to the pulse
count value supplied from the pulse coder on each axis.
Mastering is factory-performed. It is unnecessary to perform
mastering in daily operations. However, mastering becomes necessary
after:
• Motor replacement.
• Pulse coder replacement.
• Reducer replacement.
• Cable replacement.
• Batteries for pulse count backup in the mechanical unit have gone
dead.
CAUTION
Robot data (including mastering data) and pulse
coder data are backed up by their respective
backup batteries. Data will be lost if the batteries go
dead. Replace the batteries in the control and
mechanical units periodically. An alarm will be
issued to warn the user of a low battery voltage.
- 41 -
4.5.2 Mastering Method

Table 4.5.1 Types of Mastering
Fixture position This is performed using a mastering fixture before
mastering the machine is shipped from the factory.
Zero–position This is performed with all axes set at the 0-degree
mastering (eye mark position. A zero-position mark (eye mark) is
mastering) attached to each robot axis. This mastering is
performed with all axes aligned to their respective
eye marks.
Simplified mastering This is performed at a user-specified position. The
corresponding count value is obtained from the
rotation speed of the pulse coder connected to the
relevant motor and the rotation angle within one
rotation. Simplified mastering uses the fact that the
absolute value of a rotation angle within one rotation
will not be lost.
One–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 in which the control unit
reads the current pulse count value to sense the current position of the
robot.
CAUTION
If mastering is performed incorrectly, the robot 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
Before performing mastering, it is recommended
that the current mastering data be backed up.
- 42 -
4.5.3 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 mismatch”
Procedure
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], and select[Mater/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal]
menu.
2 Toreset the “Servo 062 BZAL” alarm, follow steps 1 to 5.

1 Press the screen slelection 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 Switch the controller power off and on again
3 To reset the “Servo 075 Pulse mismatch” alarm, follow steps 1 to

3.
1 When the controller power is switched on again, the
message “Servo 075 Pulse mismatch” appears again.
2 Rotate the axis for which the message mentioned above has
appeared through 10 degrees in either direction.
3 Pree [FAULT RESET]. The alarm is reset.
- 43 -
4.5.4 Mastering to a Fixture (Master 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 factory-performed. It is unnecessary to
perform it in daily operations.
When mastering the robot, arrange the robot to meet the following
conditions.
• Make the robot mounting base horizontal within 1 mm.

(Set the robot mounting surface so that the levelness of the
entire surface is 1 mm or less.)
• Remove the hand and other parts from the wrist.
• Set the robot in the condition protected from an external force.
Mastering Using a Fixture

1) Mastering procedure
a) Mount the mastering fixture
i) Assembling the fixture base
Assemble the fixture base as shown in Fig. 4.5.4 (a).
Mount the two plate on the base with bolts (M6×20)
Fig. 4.5.4 (a) Assembling the mastering fixture
- 44 -
ii) Mount the dial guage.

Adjust the dial guage to 3.00 mm using the calibration
block, and tighten it with M5×10 bolt as shown in Fig.
4.5.4 (b). (Do not tighten the bolt too strongly. The
dial indicator may be broken.) At this time, check
whether the top of dial guage moves smooth or not.
Fig. 4.5.4 (b) Assembling the dial guage
- 45 -
iii) Mounting the fixture on the J1-axis base

Mount the fixture on the J1-axis base using two bolts
(M16×45) and pin (16-dia straight pin and 16-dia
hexagonal pin), as shown in Fig. 4.5.4 (c). Be
particularly careful to orient the hexagonal pin
correctly.
Fig. 4.5.4 (c) Mounting the fixture on the wrist
- 46 -
iv) Mounting the fixture on the wrist

Mount the fixture on the wrist flange using four bolts
(M10×25) and pin (10-dia straight pin and 10-dia
hexagonal pin), as shown in Fig. 4.5.4 (d). Be
particularly careful to orient the hexagonal pin
correctly.
Fig. 4.5.4 (d) Mounting the fixture on the wrist
- 47 -
4.5.5 Mastering
1) Press MENUS.
2) Press NEXT and select SYSTEM.
3) Press F1, [TYPE].
4) Select Master/Cal.
5) Release brake control, and jog the robot into a posture for
mastering. See the Fig. 4.5.5 for the mastering posture.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM_GROUP.SV_OFF_ENB[*]: FALSE (for
all axes)
After changing the system variables, switch the
control unit power off and on again.
6) Select Fixture Position Master.

7) Press F4, YES. Mastering will be performed automatically.
Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.
8) After positioning is completed, press F5 [DONE].
CAUTION
No check is made on the axis movable range during
mastering. Be very careful when running the robot.
Continuing axis movement may result in the
mechanical stopper being bumped.
- 48 -
M-410iB/450 Mastering
Fig. 4.5.5 Mastering attitude
- 49 -
4.5.6 Zero Degree Mastering

Zero-position mastering (eye mark mastering) is performed with all
axes set at the 0-degree position. A zero-position mark (eye mark) is
attached to each robot axis. This mastering is performed with all axes
set at the 0-degree position using their respective eye 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.
5 Release brake control, and jog the robot into a posture for
mastering.
NOTE
Brake control can be released by setting the
system variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM GROUP.SV OFF ENB[*]: FALSE
(for all axes)
After changing the system variables, switch the
control unit power off and on again.
6 Select Zero Position Master.

7 Press F4, YES. Mastering will be performed automatically.
Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.
8 After positioning is completed, press F5 [DONE]
- 50 -
Table 4.5.6 Attitude with position marks aligned

Position
Axis
M-410iB/450
J1-axis 0 deg
J2-axis 0 deg
J3-axis 0 deg
J4-axis 0 deg
J3-axis
VIEW A J3-axis position mark (layout mark)
VIEW B
J4-axis
J4-axis position mark (layout mark)
J2-axis
J1-axis, J2-axis 0° position mark
J1-axis
J3-axis 0° position mark
J4-axis 0° position mark

J2-axis position mark (layout mark) J1-axis position mark (layout mark)
Fig. 4.5.6 Attitude with position marks aligned
- 51 -
4.5.7 Quick Mastering

Simplified mastering is performed at a user-specified position. The
corresponding count value is obtained from the rotation speed of the
pulse coder connected to the relevant motor and the rotation angle
within one rotation. Simplified mastering uses the fact that the
absolute value of a rotation angle within one rotation will not be lost.
Simplified mastering is factory-performed at the position indicated in
Table 4.5.6. Do not change the setting unless there is any problem.
If it is impossible to set the robot at the position mentioned above, it is
necessary to re-set the simplified mastering reference position using
the following method. (It would be convenient to set up a marker that
can work in place of the eye mark.)
CAUTION
1 Simplified 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 Simplified mastering cannot be used, after the pulse
coder is replaced or after the mastering data is lost
from the robot control unit.
Procedure Recording the Quick Master Reference Position

Step 1 Select SYSTEM.
3 Release brake control, and jog the robot to the simplified

mastering reference position.
Set quick master ref? [NO] 4 Move the cursor to SET QUICK MASTER REF and press
ENTER. Press F4, YES.
CAUTION
If the robot 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 robot mastery.
- 52 -
Procedure Quick Mastering

Step 1 Display the Master/Cal screen
2 Release brake control, and jog the robot to the simplified

mastering reference position.
Quick master? [NO] 3 Move the cursor to QUICK MASTER and press ENTER. Press
F4, YES. Quick mastering data is memorized.
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.
- 53 -
4.5.8 Single Axis Mastering

Single axis mastering is performed for one axis at a time. 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 pulse coder has been
replaced.
SINGLE AXIS MASTER JOINT 30%

1/9
ACTUAL POS (MSTR POS) (SEL) [ST]
J1 25.255 (0.000) (0) [2]
J2 25.550 (0.000) (0) [2]
J3 -50.000 (0.000) (0) [2]
J4 12.500 (0.000) (0) [2]
J5 31.250 (0.000) (0) [2]
J6 43.382 (0.000) (0) [2]
E1 0.000 (0.000) (0) [2]
E2 0.000 (0.000) (0) [2]
E3 0.000 (0.000) (0) [2]
[ TYPE ] GROUP EXEC
Table 4.5.8 Items Set in Single Axis Mastering

Item Description
Current position The current position of the robot is displayed for
(Actual axis) each axis in degree units.
Mastering position A mastering position is specified for an axis to
(Matra pos) be subjected to single axis mastering. It would
be convenient to set to it to the 0°position.
SEL This item is set to 1 for an axis to be subjected
to single axis mastering. Usually, it is 0.
ST This item indicates whether single axis
mastering has been completed for the
corresponding axis. It cannot be changed
directly by the user.
The value of the item is reflected in
$EACHMST_DON (1 to 9).
0 : Mastering data has been lost. Single axis
mastering is necessary.
1 : Mastering data has been lost. (Mastering has
been performed only for the other interactive
axes.) Single axis mastering is necessary.
2 : Mastering has been completed.
- 54 -
Procedure Mastering a Single Axis

Step 1 Select SYSTEM.
3 Select 4, Single Axis Master. You will see a screen similar to

the following.
4 Move the cursor to the SEL column for the unmastered axis and
press the numeric key "1." Setting of SEL is available for one
or more axes.
5 Turn off brake control as required, then jog the robot to the
mastering position.
6 Enter axis data for the mastering position.
- 55 -
7 Press F5 [EXEC]. Mastering is performed. So, SEL is reset to 0,

and ST is re-set to 2 or 1.
8 When single axis mastering is completed, press the previous page

key to resume the previous screen.
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].
- 56 -
4.5.9 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 Press MENUS, then press NEXT and select SYSTEM.
2 Press F1, [TYPE]. Select [Variables]. The system variable screen
appears.
3 Change the mastering data.

The mastering data is saved to the
$DMR_GRP.$MASTER_COUN system variable.
- 57 -
4 Select $DMR_GRP.
5 Select $MASTER_COUN, and enter the mastering data you have

recorded.
6 Press the PREV key.

7 Set $MASTER_DONE to TRUE.
8 Display the positioning screen, and select [6 CALIBRATE], then

press F4 [YES].
9 After completing positioning, press F5 [DONE].
- 58 -
B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
5 REPLACING PARTS
Procedure of replacement for main parts is described.
Replace the main parts according to the procedure.
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 effects 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.
NOTE
Be careful when removing and installing the
following heavy parts.
Parts Weight (approx.) kg

servo motor J1-axis 23
J2-axis 23
J3-axis 23
reducer J1-axis 165
J2-axis 70
J3-axis 70
J4-axis 20
flame colum (1pcs) 50
J1-axis base 230
J2-axis base 350
balancer 250
J2 arm 195
J2 link 70
J3-axis base 60
J3 arm 140
wrist unit 65
Unit that is upper than J2-axis base
1170
(see Fig. 5.2 (e) (f).)
- 59 -
5. REPLACING PARTS MAINTENANCE B-81925EN/04
5.1 PART REPLACEMENT AND CORRESPONDING

ADJUSTMENT
When a part is replaced, the corresponding adjustment must be made.

Table 5.1 lists those parts that can be replaced and the corresponding
adjustment.
After replacing a part, perform the appropriate adjustment, as listed
below.
Table 5.1 Parts to be replaced and adjustment items

Parts to be replaced Adjustment Method
Motor, reducer, gear,
Wrist unit, Mastering See 4.4 to 4.7
Cable (*1)
Limit switch (*2) Adjusting, limit switch See 4.1
*1 Refer to item 7 for replacement of cables.
*2 Refer to item 5.6 for replacement of limit switches.
- 60 -
5.2 REPLACING J1-AXIS MOTOR (M1) AND REDUCER
(1) Replacing the J1-axis motor (M1)

[In case of the integrated control unit]
1 Turn the power off.
2 To provide space in which the J1-axis motor can be
removed, shift the location of the control unit by following
the procedure below (see Fig. 5.2 (a)).
• Remove the bolts (two M6×10) from the connector plate,
and dismount it.
• Remove the bolt (M10×16) from the cable clamp, and
dismount the cable clamp.
• Remove the bolts (two M10×20 bolts and two M10×16)
from the control unit retaining plate, and dismount it.
• Shift the control unit to a location shown in Fig. 5.2 (a).
3 Remove connectors from the J1-axis motor (see Fig. 5.2
(b)).
4 Prepare to wipe off grease that will come out from the
grease bath when the J1-axis motor is dismounted from the
robot. Also cover the control unit with a cloth to protect it
from grease drips.
5 The J1-axis motor is heavy. To support the motor during
removal of it, place a jack or other lifting tool under the
motor in advance.
6 Remove four motor securing bolts (M12×30). Remove the
J1-axis motor from the J1-axis base. Take care not to soil
the transformer with grease.
7 Remove the nut (M20) from the tip of the motor shaft, and
pull out the gear from the motor. The nut can be removed
by holding the two flat portions on the gear with a wrench
to keep the motor shaft from rotating.
8 Replace the motor with a new one. Mount the new motor
as follows :
• Polish the motor mounting surface with an oilstone.
• Mount an auxiliary seal (spec. : A98L-0004-0071#A12TP)
on the motor. Auxiliary seals cannot be reused. Always
use a new seal.
NOTE
A motor whose specification number is terminated
with #S000 has the built-in auxiliary seal.
• Apply Loctite No. 242 (blue) to the thread of the motor.

Take care not to apply Loctite to the tapered part of the
shaft.
• Mount and rotate the nut while holding the two flat
portions on the gear with a wrench to keep the motor
shaft from rotating. Tighten the nut with a tightening
torque of 118 Nm (12.0 kgfm).
• Take care not to damage any tooth flank of the gear.
- 61 -
• Mount the O-ring just in a correct position.

• Replace each removed washer with a new one.
• Those bolts for which no tightening torque is specified
must be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
9 Apply grease (see Section 2).
10 Carry out an adjustment (see Sections 4.5).
Fig. 5.2 (a) Replacing the J1-axis motor (M1) (Integrated control unit)
- 62 -
Fig. 5.2 (b) Replacing the J1-axis motor (M1) (Integrated control unit)
[In case of the separated control unit]

2 Remove the connectors from the J1-axis motor (see Fig. 5.2
(c)).
grease bath when the J1-axis motor is dismounted from the
robot.
4 The J1-axis motor is heavy. To support the motor during
removal of it, place a jack or other lifting tool under the
motor in advance.
5 Remove four motor securing bolts. (M12×30). Dismount
the J1-axis motor from the J1-axis base.
6 Remove the nut M20 from the tip of the motor shaft,
holding the gear with a wrench so that the motor shaft will
not turn. Then, remove the gear from the motor.
7 Replace the motor with a new one. Mount the new motor as
follows :
on the motor. (Auxiliary seals cannot be reused.
Always use a new seal.)
NOTE
- 63 -
• Apply Loctite No. 242 (blue) to the threads of the motor

screws. Take care not to apply Loctite to the tapered part
of the shaft.
• Tighten the nut securely, while holding the two flat
portions or the gear with a wrench. Tighten the nut with a
tightening torque of 118 Nm (12.0 kgfm).
• Take care not to damage any gear tooth flank.
• Mount an O-ring in the correct position.
9 Carry out an adjustment (see Sections 4.5.)
Fig. 5.2 (c) Replacing the J1-axis motor (M1) (Remote control unit)
- 64 -
(2) Replacing the J1-axis reducer

1 Set the J2-axis and J3-axis arms to around the 0-degree
position. Then, turn the power off.
2 To remove the balancer, follow the steps below.
• Prepare to sling up the balancer by mounting eyebolts
(two M12 bolts) to the balancer and threading a strap
through the eyebolts (see Fig. 5.3 (c)).
• Remove the bolts (six M8×20 bolts) from the shaft on the
balancer's movable fulcrum side to dismount the shaft
(see Fig. 5.2 (d)).
• Remove the bolts (twenty-four M8×25 bolts) from the
two shafts (one at the right end and the other at the left
end) on the balancer's fixed fulcrum side to dismount the
shafts.
3 Take out all cables, which are laid between the J1-axis base
and J2-axis base, from the hollow section of the J1-axis
reducer by pulling them toward the J2-axis base side (see
Section 7.2).
4 Remove the J1-axis motor (see 5.2 (1) above).
5 Mount two eyebolts (M12) onto the J3-axis arm. Prepare
to sling up the unit that is above the J2-axis base by
threading strap through the eyebolts on the J2-axis base and
J3-axis arms (see Fig. 5.2 (e)).
6 Remove the grease tube from the J1-axis reducer (see Fig.
5.2 (f)).
7 Remove the J2-axis base mounting bolts (eighteen M16×50
bolts), and separate the units that are above the J2-axis base
from the J1-axis reducer.
grease bath when the J1-axis reducer is dismounted. Also
cover the control unit with a cloth to protect it from grease
drips. Remove the J1-axis reducer mounting bolts
(twenty-four M12×95 bolts) and, dismount the J1-axis
reducer from the J1-axis base. Wipe off any leaking
grease.
9 Dismount the center gear from the J1-axis reducer.
10 Remove the bolts (eight M6×16 bolts) from the pipe, and
dismount it from the J1-axis reducer.
11 Mount the new reducer as follows :
• Polish the reducer mounting surface and the J2 base
mounting surface with an oilstone.
• Apply Loctite No. 262 (red) to the female side of these
bolts indicated as Loctite 262.
• Tighten the following bolts with the stated tightening
torque. See the tightening torque table presented in
Appendix D for the tightening torque for the other bolts.
J1-axis reducer mounting bolt
M12×95 : 128.4 Nm (13.1 kgfm)
J2-axis base mounting bolt
M16×50 : 318.5 Nm (32.5 kgfm)
• Mount the O-ring in the correct position.
- 65 -
• Be careful not to damage the tooth face and flank of the

center gear.
• If it is difficult to insert the shaft on the balancer’s movable
fulcrum side into the slot of the balancer rod section,
remove the balancer rear cover, and screw an M6×40 bolt
(to be prepared by the customer) into the M6 hole used to
mount the cover, and push up the end plate in the
balancer by about 3 mm so that the center of the slot of
the balancer rod section is aligned to the center of the
shaft for easier insertion.
• Before mounting the J1-axis motor, mount the J2-axis
reducer to the J1-axis base in order to prevent damage to
the gear.
• Before attaching the grease tube to the J2-axis reducer,
wind sealing tape around the adapter threads.
12 Form the cables (see Sections 7.1 and 7.2).
13 Supply grease (see Section 2).
14 Perform mastering (see Sections 4.5).
Fig. 5.2 (d) Replacing J1-axis reducer
- 66 -
Fig. 5.2 (e) Replacing J1-axis reducer
Fig. 5.2 (f) Replacing J1-axis reducer
- 67 -
5.3 REPLACING J2/J3-AXIS MOTOR (M2/M3) AND REDUCER
(1) Replacing the J2/J3-axis motor (M2/M3)

1 Removing the motor from the robot allows the arm to fall
down. To keep the arm from falling down, put the robot in
the attitude shown in Fig. 5.3 (a). Thread the eyebolts
with a piece of strap and hang the arm in position with the
strap.
3 Remove the connectors.
4 Remove four seal bolts (M12×30) from the motor to be
replaced (see Fig. 5.3 (b)). Prepare to wipe off grease that
will come out from the grease bath when the motor is
dismounted.
5 Remove the input gear and draw bolt. When removing the
draw bolt and nut (for securing the input gear), hold the
input gear with a wrench so that the motor shaft will not
turn.
as follows :
on the motor. (Auxiliary seals cannot be reused.
Always use a new seal.)
NOTE
• Apply Loctite No. 242 (blue) to the thread part of the

motor and draw bolt. Take care not to apply Loctite to
the tapered part of the shaft.
• When installing the draw bolt nut (for securing the input
gear), hold the two flat portions on the input gear with a
wrench to keep the motor shaft from rotating. The
tightening torque for the nut is 13.2 Nm (1.35 kgfm).
• Mounting a motor to the robot take care not to damage
any tooth flank of the input gear.
• Apply sealant (Loctite Gasket Eliminator No. 518) to the
motor mounting seal bolts in the female side, or wind seal
tape around them.
- 68 -
Fig. 5.3 (a) Attitude at replacing J2/J3-axis motor (M2/M3)
- 69 -
Fig. 5.3 (b) Replacing J2/J3-axis motor (M2/M3)
- 70 -

1 Removing the J2-axis reducer from the robot allows the arm
to fall down. To keep the arm from falling down, put the
robot in the attitude shown in Fig. 5.3 (a), screw an eyebolt
into the M12 hole in the upper section of the J3-axis arm.
Thread the eyebolts with a piece of strap and hang the arm
in position with the strap.
3 Mount eyebolts (two M12 bolts) to the balancer, and sling it
up (see Fig. 5.3 (c)).
4 Remove the bolts (six M8×20 bolts) from the shaft on the
movable fulcrum side of the balancer, and dismount the
shaft (see Fig. 5.3 (d)). Now the balancer can be separated
from the J2-axis arm.
grease bath when the motor is dismounted. Remove the
J2-axis motor mounting seal bolts (four M12×30 bolts), and
dismount the motor (see Section 5.3 (1)). Wipe off any
leaking grease.
grease bath when the J2-axis arm is dismounted. Remove
the J2-axis arm mounting bolts (six M16×60 bolts and
twenty-one M12×50 bolts). Now the J2-axis arm can be
separated from the J2-axis reducer. Wipe off any leaking
grease.
7 Remove the J2-axis reducer mounting bolts (twenty-four
M12×70 bolts), and dismount the J2-axis reducer along with
the motor brackets.
• Polish the reducer mounting surface and motor mounting
surface with an oilstone.
reducer mounting surface. A light, uniform coating of
sealant should be applied to the area shown in Fig. 5.3
(d).
female side of the M12×30 bolts motor mounting, or
wind seal tape around them.
• Apply Loctite No. 262 (red) to the female side of the
other bolts specified in Fig. 5.3 (d).
• Tighten the bolts with the following torque:
See the tightening torque table presented in Appendix D
for the tightening torque for the other bolts.
M12×70 : 128.4 Nm (13.1 kgfm)
J2-axis arm mounting bolt
M16×60 : 318.5 Nm (32.5 kgfm)
M12×50 : 128.4 Nm (13.1 kgfm)
• Mounting a motor to the robot, take care not to damage
any tooth flank of the gear.
- 71 -

• If it is difficult to insert the shaft on the balancer’
movable fulcrum side into the slot of the balancer rod
section, remove the balancer rear cover, and screw an
M6×40 bolt (to be prepared by the customer) into the M6
hole used to mount the cover, and push up the end plate
in the balancer by about 3 mm so that the center of slot of
the balancer rod section is aligned to the center of the
shaft for easier insertion.
Fig. 5.3 (c) Replacing J2-axis reducer
- 72 -
Fig. 5.3 (d) Replacing J2-axis reducer
- 73 -

1 Put the robot in an attitude of J2-axis = 90° and J3-axis =
0°.
3 Remove the bolts (six M8×12 bolts) from the J2-axis arm
cover, and dismount it (see Fig. 5.3 (g)).
4 Remove the J3-axis arm mounting bolts that are used to link
the J3-axis reducer and J3-axis arm (see Fig. 5.3 (e)).
Bolts to be removed: Two M16×45 bolts and seven
M12×35 bolts.
5 Switch the power on, and bring the robot into the attitude
shown in Fig. 5.3 (a) at low speed.
6 Switch the power off.
7 Removing the J3-axis reducer from the robot allows the J3
arm and base to fall down. To keep the J3 arm from
falling down, screw an eyebolt into the M12 hole in the
upper section of the J3 arm, and thread a strap through the
eyebolt, then sling up the arm (see Fig. 5.3 (a)). Also sling
up the J3 base using a strap to keep the J3 base from falling
down (see Fig. 5.3 (f)).
grease bath when the J3-axis motor is dismounted (see Fig.
5.3 (g)). Remove the J3-axis motor mounting bolts (four
M12×30 bolts), and dismount the motor. Wipe off any
leaking grease. (See Section 5.3 (1).)
9 Remove the remaining J3-axis arm mounting bolts that are
used to link the J3-axis reducer and J3-axis arm (see Fig.
5.3 (g)).
Bolts to be removed: Four M16×45 bolts and fourteen
M12×35 bolts.
Now the J3-axis arm can be separated from the J3-axis
reducer. Prepare to wipe off grease that will come out
from the grease bath when the J3-axis arm is dismounted.
Wipe off any leaking grease.
10 Remove the J3-axis reducer mounting bolts (twenty-four
M12×70 bolts), and dismount the J3-axis reducer along with
the motor brackets.
• Polish the reducer mounting surface and motor mounting
surface with an oilstone.
reducer mounting surface. A light, uniform coating of
sealant should be applied to the area shown in Fig. 5.3
(g).
female side of the M12×30 bolts motor mounting, or
wind seal tape around them.
Loctite 262 bolts specified in Fig. 5.3 (g).
- 74 -

M12×70 : 128.4 Nm (13.1 kgfm)
J3-axis arm mounting bolt
M16×45 : 318.5 Nm (32.5 kgfm)
M12×35 : 128.4 Nm (13.1 kgfm)
• Mounting a motor to the robot, take care not to damage
any tooth flank of the input gear.
Fig. 5.3 (e) Replacing the J3-axis reducer
Fig. 5.3 (f) Replacing J3-axis reducer
- 75 -
Fig. 5.3 (g) Replacing J3-axis reducer
- 76 -
5.4 REPLACING J4-AXIS MOTOR (M4) AND REDUCER

(1) Replacing J4-axis motor (M4)
2 Remove connectors from the J4-axis motor(see Fig. 5.4 (a)).
3 Remove four motor securing bolts (M8×20). Then,
remove the motor.
4 Remove a nut from the end of the motor shaft, holding the
gear with a wrench so that the motor shaft will not turn.
Then, remove the gear from the motor.
as follows :
• Apply Loctite No. 242 (blue) to the thread of the motor.
Take care not to apply Loctite to the tapered part of the
shaft.
• Tighten the nut with a torque of 16.7 Nm (1.70 kgfm),
holding the gear with a wrench.
• Take care not to damage any tooth flank of the gear.
Fig. 5.4 (a) Replacing J4-axis motor (M4)
- 77 -

This part describes the procedure for replacing only the J4-axis
reducer. To replace the wrist unit, see Section 5.5.
2 Remove the hand, workpiece, and other loads from the
wrist.
3 Remove fourteen reducer unit securing bolts (M10×85).
Then, remove the reducer unit from the wrist. (See Fig.
5.4 (b).) Prepare to wipe off grease that will come out
from the grease bath when the reduction unit is dismounted.
4 Remove nine wrist flange securing bolts (M12×25). Then,
remove the wrist flange from the reducer unit (see Fig. 5.4
(c)).
5 Replace the three pipe mounting bolts (M6×20) then
remove a pipe and center gear from the reducer unit.
6 Replace the reducer with a new one.
• Polish the reducer mounting surface with an oilstone.
bolts indicated in Fig. 5.4 (b) and (c) as Loctite 262.
Reducer unit securing bolt
M10×85 : 73.5 Nm (7.5 kgfm)
Wrist flange securing bolt
M12×25 : 128.4 Nm (13.1 kgfm)
surface on which the wrist flange is to be mounted to the
reducer. A light, uniform coating of the sealant should be
applied to the area shown in Fig. 5.4 (c).
• Mounting a reducer unit to the wrist, take care not to
damage any tooth flank of the center gear.
- 78 -
Fig. 5.4 (b) Replacing J4-axis reducer
Fig. 5.4 (c) Replacing J4-axis reducer
- 79 -
5.5 REPLACING THE WRIST UNIT
This section describes the procedure for replacing the wrist unit. To
order a replacement wrist unit, use the ordering information
A05B-1039-K501. To replace only the J4-axis reducer, see (2) in
Section 5.4.
2 Remove the hand, workpiece, and other loads from the wrist.
3 Remove the cover from the J3-axis arm (3pcs M6×10) (see Fig.
5.5).
4 Disconnect a connector from the J4-axis motor.
5 Remove the wrist connector box from the wrist unit (see Section
7).
6 Remove the J3-axis link from the wrist unit by following the
steps below.
• Remove the rubber cap from both ends of the J3-axis link.
• Remove the bolts (four M6×12 bolts) from both ends of the
J3-axis link.
• Remove the bolts (eight M8×20 bolts) from the J3 base-side
shaft of the J3-axis link.
• Remove the wrist unit from the J3-axis link.
7 Remove the bolts (eight M8×25 bolts) from the J3-axis link shaft,
and dismount it from the wrist unit.
8 Remove the bolts (four M10×30 bolts) from the wrist subshaft,
and dismount it.
9 Remove the cross-roller internal ring mounting bolts (twelve
M10 ×75 bolts), and dismount the wrist unit from the J3 arm.
10 Remove the cross-roller external ring mounting bolts (eight
M10×45 bolts), and dismount the cross roller from the wrist unit.
11 Remove the J4-axis motor mounting bolts (four M8×20 bolts),
and dismount the motor (see Section 5.4).
12 Mount a new replacement wrist unit as follows :
• Apply grease (SHELL SEKIYU Alvania GREASE S2) to the
oil seal attached to the replacement wrist unit.
surface on which the wrist flange is to be mounted to the
reducer. A light, uniform coating of the sealant should be
applied to the area shown in Fig. 5.4 (c).
- 80 -
Fig. 5.5 Replacing the wrist unit
- 81 -
5.6 REPLACING THE OPTIONAL J1-AXIS LIMIT SWITCH

(OPTION)
1) Remove the limit switch from the metal plate of mounting limit
switch.
2) Disconnect the cable from the limit switch.
3) Replace the limit switch with a new one.
4) Reassemble the unit by reversing the above procedure.
• Those bolts for which no tightening torque is specified must
be tightened according to the APPENDIX D BOLT
5) Adjust the limit switch. (See item 4.1)
Fig. 5.6 Replacing the limit switch
- 82 -
5.7 REPLACING THE J1-AXIS PENDULUM STOPPER
1) Remove the pendulum stopper as shown in Fig. 5.7.

2) Install a new pendulum stopper by reversing the removal
procedure.
Fig. 5.7 Replacing the J1-axis pendulum stopper
- 83 -
6. WIRING MAINTENANCE B-81925EN/04
6 WIRING
Fig. 6 (a), (b) show the wiring diagram in the mechanical unit.
K504(R-J3iB), K554(R-30iA) (J4-axis power, pulsecoder, brake, EE, CE)

K505(R-J3iB), K555(R-30iA) (J4-axis power, pulsecoder, brake, EE, AS, CE)
K506(R-J3iB), K556(R-30iA) (J4 to J5-axis power, pulsecoder, brake, EE, CE)
K507(R-J3iB), K557(R-30iA) (J4 to J5-axis power, pulsecoder, brake, EE, AS, CE)
K556(R-30iA)(J4 to J5-axis power, pulsecoder,brake,EE,AS,CAMERA,CE)
K501, K551 (J1 to J2-axis power, brake, CE)
K502, K552 (J1 to J2-axis pulse coder, brake, CE)
Fig. 6 (a) Wiring diagram in the mechanical unit (Integrated control unit)
- 84 -
B-81925EN/04 MAINTENANCE 6. WIRING
K512(R-J3iB), K562(R-30iA) (J4-axis power, pulsecoder, brake, EE, CE)

K513(R-J3iB), K563(R-30iA) (J4-axis power, pulsecoder, brake, EE, AS, CE)
K514(R-J3iB), K564(R-30iA) (J4 to J5-axis power, pulsecoder, brake, EE, CE)
K515(R-J3iB), K565(R-30iA) (J4 to J5-axis power, pulsecoder, brake, EE, AS, CE)
Fig. 6 (b) Wiring diagram in the mechanical unit (Control unit remote type)
- 85 -
7. REPLACING CABLES MAINTENANCE B-81925EN/04
7 REPLACING CABLES
Replace the cables periodically (every 15,360 operating hours or every
four years, whichever comes earlier). When a cable is broken or
damaged, replace it according to this chapter.
Precautions on handling the pulse coder cable :

The pulse coder cable connector is given the marking tie as shown
below, to prevent careless disconnection at transportation, installation
or maintenance. If the connector with the marking tie is
disconnected, mastering must be executed again.
Do not disconnect the cable except the time to replace the pulse coder
cable.
Fig. 7 Marking tie
- 86 -
B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
7.1 CABLE FORMING
When replacing cables, clamp the cable at the position specified in Fig.
7.1 (a) and (b) using a nylon band. Otherwise, cables are loosened or
forcedly pulled to cause their disconnection.
Fig. 7.1 (a) Clamping position of cables (Integrated control unit)
- 87 -
Fig. 7.1 (b) Clamping position of cables (Remote control unit)
- 88 -
Fig. 7.1 (c) Clamping position of cable (Integrated control unit)
- 89 -
Fig. 7.1 (d) Cable clamp (Control unit remote type)
- 90 -
Fig. 7.1 (e) Clamping position of cables
- 91 -
Fig. 7.1 (f) Clamping position of cables
- 92 -
Fig. 7.1 (g) Clamping position of cables
- 93 -
Fig. 7.1 (h) Clamping position of cables
- 94 -
Fig. 7.1 (i) Clamping position of cables
- 95 -
7.2 REPLACING A CABLE
This section describes the procedure for replacing a cable in the

mechanical unit.
To replace only a damaged cable, follow these instructions.
After replacing a cable, carry out an adjustment. See Sections 4.5

before replacing a cable.
• Replacing procedure (In case of integrated control unit)
1 To facilitate cable replacement, remove the J2-axis balancer
by following the steps below.
• Put the robot in an attitude of J2-axis = 0°.
• Remove the balancer according to step 2 of (2) of Section
5.2.
2 Turn the power off, and then disconnect all cable connectors
to the robot from the controller (Fig. 7.2 (a)).
3 Remove the cable clamp (Fig. 7.2 (b)).
4 Detach the metal plate from the controller exit, then detach
the two metal plates securing the rubber clamp (Fig. 7.2
(b)).
5 Release cables from a rubber clamp (Fig. 7.2 (b)).
6 Pull all cables connected to the robot main body out of the
controller.
7 Remove the air hoses and AS cable (when the AS option is
specified) from the frame connecting plate (Fig. 7.2 (b)).
8 Remove the cover sheet metal from the battery box, and
detach the battery cable terminals from the terminal board
on the rear of the battery box (see Fig. 7.2 (b)).
9 Remove the bolt from the cable clamp in the lower section
of the J1-axis base, and dismount the cable clamp from the
J1-axis base, then cut off the nylon tie clamping the cable
(see Fig. 7.2 (c)).
10 Remove the bolt from the cable clamp on the J2-axis base,
and dismount the cable clamp from the J2-axis base, then
cut off the nylon tie clamping grease tube to the cable clamp,
and dismount the grease tube from the cable clamp (see Fig.
7.2 (d)).
11 Remove all the cable connectors from the motors for the J1-
to J4-axes.
12 Remove the bolts from the wrist connector plate, and
dismount the wrist connector plate from the wrist (see Fig.
7.2 (e)).
13 Remove the bolts from the two cable clamps inside the
J3-axis arm (see Fig. 7.2 (e)).
14 Remove the cable retaining sponge from the inside of the
J3-axis arm through the casting hole of the J3-axis arm (see
Fig. 7.2 (e)).
15 Cut off the nylon tie clamping the cable at the end of the
J2-axis arm, and take out the cable from the clamp (see Fig.
7.2 (e)).
- 96 -
16 Remove the flexible hose holder retaining plate from the

J2-axis arm, and dismount the flexible hose holder from the
J2-axis base (see Fig. 7.2 (f)).
17 Remove the bolt from the flexible hose retaining plate on
the J2 arm side, and dismount it from the J2-axis base (see
Fig. 7.2 (g)).
18 Pull out, toward the J2-axis side, all cables that lead to the
wrist through the J3-axis arm.
19 Remove the J2 link-side flexible hose holder retaining
plates from the J3-axis base, J2-axis link, and J2-axis base,
and dismount the flexible hose holders (see Fig. 7.2 (f)).
20 Remove the bolts from the J2-axis base cover plate and J2
link-side flexible hose retaining plate, and dismount them
from the J2-axis base (see Fig. 7.2 (c)).
21 Pull out, toward the J2-axis base side, all the cables that
lead to the lower section of the J1-axis base through the
hollow pipe of the J1-axis.
22 Pull out the J2-axis arm-side cable and J2-axis link-side
cable through the openings of the left and right walls of the
J2-axis base toward the inside of the left and right walls,
respectively. Now the cables can be dismounted from the
robot.
23 Replace a cable with a new one.
24 Mount the cables as follows :
Care is required in cable forming and clamp positions (see
Fig. 7.1 (a), (c), (e) to (i) and Fig. 7.2 (a) to (g).
• Insert the sponge clamp into the J3-axis arm through the
casting hole of the J3-axis arm. For the position, see Fig.
7.2 (m).
• For the securing positions of the flexible hose, see Fig.
7.1 (i).
• Apply Loctite No. 242 (blue) to the flexible hose
securing bolts (M10×80) (see Fig. 7.2 (f)).
• Apply Loctite No. 242 (blue) to the bolt (M6×12) for
retaining the cable clamp to the J2-axis base.
• Clamp the cables at the marked positions.
• Connect the air hose so that it matches the markings on
the pedestal connector panel and wrist connector plate.
• See the tightening torque table presented in Appendix D
for the tightening torque for the bolts for which no
tightening torque is specified.
- 97 -
• Replacing procedure (in case of remote control unit)

1 To facilitate cable replacement, remove the J2-axis balancer
by following the steps below.
• Put the robot in an attitude of J2-axis = 0°.
• Remove the balancer according to step 2 of (2) of section
5.2.
2 Turn the power off, and then disconnect all cable connectors
to the back of robot pedestal from the controller (RP1, RM1,
RM2) (Fig. 7.2 (i)).
3 Remove air hoses and AS cable (when the AS option is
specified) from the panel (Fig. 7.2 (i)).
4 Remove the metal plate without exerting excessive force to
the internal cables. Note that the internal cables remain
fixed (Fig. 7.2 (j)).
5 Remove battery and grounding wires. Cut nylon ties
clamping the connectors (M4M5M, M4M5BK, J10T, M3P)
(Fig. 7.2 (k)).
6 Remove screws fastening the connector inserts (Fig. 7.2 (j)).
7 Remove the connector housing, and dismount the connector
insert from the housing. Also, dismount the plate retaining
the cable from the connector plate. Then cut off the nylon
tie clamping the cable to the plate, and dismount the plate
(see Fig. 7.2 (l)).
8 Follow cable replacement steps 9 to 22 for a robot with a
control unit incorporated.
9 Replace each cable with a new one.
10 Mount the cables by following the removal steps 9 to 22 in
reverse order. Care is required in cable forming and clamp
positioning (see Fig. 7.1 (b) to (i) and Fig. 7.2 (b), (d) to
(m)).
• Insert the sponge clamp into the J3-axis arm through the
casting hole of the J3-axis arm. For the position, see Fig.
7.2 (f)).
• For the securing positions of the flexible hose, see Fig.
7.1 (i).
• Apply Loctite (blue) to the flexible hose securing bolts
(M10×80).
• Apply Loctite No. 242 (blue) to the bolt (M6 (12) for
retaining the cable clamp to the J2-axis base.
• Clamp the cables at markings on the cables.
11 Temporarily fasten the cable to the cable retaining plate
with a nylon tie, and also temporarily fasten the cable
retaining plate to the connector box. Pull the cable into the
connector box so that the cable does not sag, then fasten it
with a nylon tie (see Fig. 7.2 (m)).
12 Attach a new connector housing to the connector plate.
Remove the cable retaining plate from the connector box,
and attach it to the connector plate (see Fig. 7.2 (l)).
- 98 -
13 Install the cable by following steps 1 to 7 in reverse.

• Connect the air hose so that it matches the markings on
the pedestal connector panel and wrist connector plate.
CRF7 CNJ1
Robot M-410ｉB/450
CNJ2
Motor power
Ｊ１Ｍ
CNJ5 Ｊ２Ｍ
Ｊ３Ｍ
Ｊ４Ｍ
Pulse coder
RDI/RDO
CNG HBK,ROT
BRAKE
CNJ3
CNJ4
CRR64
・Detail of cable connection for servo ampilifier Robot M-410ｉB/450
R-J3iB（Servo amplifier）
ＣＮＪ１Ａ
CRF7
ＣＮＪ１Ｂ
CRR64 ＣＮＪ２Ａ
ＣＮＪ２Ｂ
ＣＮＪ４
CNJ3A
ＣＮＧＣ CNJ3B
ＣＮＧＢ
Pulse coder
ＣＮＧＡ (Pulse coder,RDI/RDO,
HBK,ROT)
BRAKE
Motor power
(J4M)
Motor power
(J3M）
Motor power
(J2M)
Motor power
(J1M)
Fig. 7.2 (a) Replacing a cable (Integrated R-J3iB control unit)
- 99 -
CNJ6
CNJ3 Robot　M-410iB/450
CNJ5 CNJ2
(R-30iA Controller)
CNJ4
CNG Motor power
CNJ1 J1M
J2M
J3M
J4M
pulse coder
RDI/RDO
RI/RO
HBK,ROT
HBK,ROT
BRAKE
CRF8
CRR88
Robot　M-410iB/450
・Detail of the cable connection for servo amplifier (R-30iA Controller)
R-30iA (Servo amplifier)
CNJ1A
CRF8
CNJ1B
CRR88 CNJ2A
CNJ2B
CNJ4
CNJ3A
CNGC CNJ3B
CNGB
Pulse coder
CNGA (Pulse coder,RI/RO,
HBK,ROT)
BRAKE
Motor power
(J4M)
Motor power
(J3M)
Motor power
(J2M)
Motor power
(J1M)
Fig. 7.2 (b) Replacing a cable (Integrated R-30iA control unit)
- 100 -
Fig. 7.2 (c) Replacing a cable (Integrated control unit)
Fig. 7.2 (d) Replacing a cable
- 101 -
Fig. 7.2 (e) Replacing a cable
Fig. 7.2 (f) Replacing a cable
- 102 -
30
Fig. 7.2 (g) Replacing a cable
Fig. 7.2 (h) Replacing a cable
- 103 -
Fig. 7.2 (i) Replacing a cable (Remote control unit)
Fig. 7.2 (j) Replacing a cable (Remote control unit)
- 104 -
Fig. 7.2 (k) Replacing a cable (Remote control unit)
Fig. 7.2 (l) Replacing a cable (Remote control unit)
- 105 -
Fig. 7.2 (m) Replacing a cable (Remote control unit)
- 106 -
CONNECTION
B-81925EN/04 CONNECTION 1. ROBOT EXTERNAL DIMENSION
1 ROBOT EXTERNAL DIMENSION

Fig. 1 shows the external dimensions of the robot. When installing
peripheral devices, be careful to clear away any objects that are in the
robot's motion path in normal operation.
Fig. 1 External dimensions
- 109 -
2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
2 MOUNTING A DEVICE TO THE ROBOT
- 110 -
B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
2.1 LOAD CONDITION AT WRIST
Fig. 2.1 (a) shows the relationships between the horizontal offset of
the center of gravity of the wrist load and the permissible load inertia.
See Fig. 2.1 (b) to check whether the center of gravity of the load is
inside or outside of the wrist.
Fig. 2.1 (c) shows the relationships between the vertical offset of the
center of gravity of the wrist load and permissible load weight. See
Fig. 2.1 (d) for explanations about the vertical offset of the center of
gravity of the wrist load.
The wrist load must fall within the corresponding ranges in Figs. 2.1
(a) and 2.1 (c) and the allowable wrist moment and allowable wrist
inertia conditions must be satisfied.
See Fig. 2.1 (e) for explanations about how to calculate the load inertial.
Fig. 2.1 (a) Line chart of the permissible load for the wrist section
(horizontal offset) (M-410iB/450)
Fig. 2.1 (b) Allowable wrist load condition
- 111 -
Fig. 2.1 (c) Line chart of the permissible load for the wrist section
(vertical offset) (M-410iB/450)
Fig. 2.1 (d) Allowable wrist load condition
- 112 -
Fig. 2.1 (e) Calculating inertia
- 113 -
2.2 COUPLING OF THE END EFFECTOR TO THE WRIST
Fig. 2.2 shows the end effector mounting surface at the end of the
wrist.
Choose bolts and positioning pins, considering the depth of the

corresponding holes. In this case, use steel bolts (strength class 12.9),
which should be tightened to a torque of 470 to 670 Nm (46 to 66
kgfcm).
the
Fig. 2.2 End the effector mounting face
- 114 -
2.3 LOAD SETTING
2.3.1 Motion Performance Screens

The motion performance screens include the MOTION
PERFORMANCE screen, MOTION PAYLOAD SET screen, and
MOTION ARMLOAD SET screen. These screens are used to
specify payload information and equipment information on the robot.
1 Click the [MENUS] key to display the screen menu.
2 Select "6 SYSTEM" from the next page.
3 Click F1 ([TYPE]).
4 Select "MOTION." The MOTION PERFORMANCE screen
appears.
MOTION PERFORMANCE
Group1
No. PAYLOAD [kg] Comment
1 450.00 [ ]
2 450.00 [ ]
3 450.00 [ ]
4 450.00 [ ]
5 450.00 [ ]
6 450.00 [ ]
7 450.00 [ ]
8 450.00 [ ]
9 450.00 [ ]
10 450.00 [ ]
Active PAYLOAD number = 0
[ TYPE ] GROUP DETAIL ARMLOAD SETIND >
INDENT >
5 Ten different pieces of payload information can be set using

condition Nos. 1 to 10 on this screen. Place the cursor on one
of the numbers, and click F3 (DETAIL). The MOTION
PAYLOAD SET screen appears.
MOTION PAYLOAD SET JOINT 10%
Group 1
Schedule No[ 1]:[Comment ]
1. PAYLOAD [kg] 450.00
2. PAYLOAD CENTER X [cm] 0.00
3. PAYLOAD CENTER Y [cm] 0.00
4. PAYLOAD CENTER Z [cm] 0.00
5. PAYLOAD INERTIA X [kgfcms^2] 0.00
6. PAYLOAD INERTIA Y [kgfcms^2] 0.00
7. PAYLOAD INERTIA Z [kgfcms^2] 0.00
[ TYPE ] GROUP NUMBER DEFAULT HELP
- 115 -
手首フランジ
Center of robot flange
xg(cm)
Center of gravity
zg(cm)
2
Iy(kg・cm)
Center of重心
gravity
質量m(kg)
Masss
2
Ix(kg・cm)
yg(cm)
X
Center重心
of gravity
6 Set the payload, gravity center position, and inertia around the
gravity center on the MOTION PAYLOAD SET screen. The X,
Y, and Z directions displayed on this screen correspond to the
respective standard tool coordinates (with no tool coordinate
system set up). When values are entered, the following
message appears: "Path and Cycletime will change. Set it?"
Respond to the message with F4 ([YES]) or F5 ([NO]).
7 Clicking F3 ([NUMBER]) will bring you to the MOTION
PAYLOAD SET screen for another condition number. For a
multigroup system, clicking F2 ([GROUP]) will bring you to the
MOTION PAYLOAD SET screen for another group.
8 Click the previous page key to return to the MOTION
PERFORMANCE screen. Click F5 ([SETIND]), and enter the
desired payload setting condition number.
- 116 -
2.3.2 Switching between Modes

There are two different parameter settings for the M-410iB/450 to
support different load inertia magnitudes. (Before shipment, the
parameter setting in the standard inertia mode is made.)
Standard inertia mode High inertia mode

196kg･m2 294kg･m
2
Allowable load inertia at wrist 2
(2000kgf･cm･s ) (3000kgf･cm･s2)
Be sure to make appropriate parameter settings according to the load,

as described below. (Before shipment, the parameter setting in the
standard inertia mode is made.)
CAUTION
If a workpiece with an inertia exceeding the
allowable inertia in the standard inertia mode is
used in the mode, parts of the mechanical unit may
degrade earlier.
To set parameters, execute setting program, which was stored before

shipment. Since this program sets parameters for the high inertia
mode, if parameters for the standard inertia mode need to be set,
execute the program to reset this program.
Setting method
Specify and execute the program of Table 2.3.2 directly on the
program selection screen or create another program and call the
program within it.
When the program is completely executed, message “SRVO-333

Power off to reset SRVO -333 TURN OFF THE CONTROLLER,
THEN TURN IT ON AGAIN.” appears, prompting you to turn off
and back on the power. If the power is turned off and back on again,
switching of parameters is completed.
[Example of program] (In the case of R-30iA controller)

1: CALL J4UPM44C (i)
Set input parameter i for setting program to the group number of the
robot. When input parameter i is omitted, the parameter settings for
all M-410iB/450’s in the controller are changed for the high inertia
mode.
Table 2.3.2 Programs to change a mode
R-J3iB controller R-30iA controller

Program for setting J4UPSPC.PC J4UPM44C.PC
Program for resetting J4STD.PC J4STM44C.PC
- 117 -
Checking the settings

When the setting program is executed, the settings made are displayed
on the user screen. To display the user screen, press the MENU key
and then select “9 USER.”
[Information displayed on the user screen]

For standard inertia load settings: Standard payload set (GP: X)
Please power off
For high inertia load settings: High payload set (GP: X)
Please power off
X represents the group number set in the parameter.
Exception processing
In the following cases, exception processing is applied, parameters are
not changed, and a message describing the exception processing
appears on the user screen.
(1) When the group set in input parameter i for setting program is
not present

Incorrect group number
When this message appears, specify a correct group number
(2) When the group set in input parameter i for setting program is
not M-410iB/450.

This group is not M-410iB/450
When this message appears, specify a correct group number
- 118 -
2.4 EQUIPMENT MOUNTING SURFACE
Fig. 2.4 shows the positions of holes for mounting the equipment.
Those bolts, for which no tightening torque is specified, tighten as the
table of Appendix D.
Fig. 2.4 Dimensions of the equipment mounting surface
- 119 -
2.5 AIR SUPPLY
There are two air-pressure supply openings on both side of the

pedestal as shown in Fig. 2.5 (a) and (b). The connector is an R 3/8
(PT 3/8) female. As couplings are not supplied, it will be necessary
to prepare couplings that suit to the hose size.
Fig. 2.5 (a) Air-pressure supply connection (Integrated control unit)
- 120 -
Fig. 2.5 (b) Air-pressure supply connection (Remote control unit)
- 121 -
2.6 INTERFACE FOR END EFFECTOR
Fig. 2.6 (a) and (b) show the position of the end effector interface.
End
effector interface (EE) is prepared as basic function. The user cable
(signal lines option) is prepared as an option.
Fig. 2.6 (a) Interface for end effector (Integrated control unit)
- 122 -
Fig. 2.6 (b) Interface for the end effector (Remote control unit)
- 123 -
(1) End effector interface (EE)

Fig. 2.6 (c) and (d) shows pin layout for end effector interface
(EE).
WARNING
The RDO signal for the R-J3iB controller and the
RO signal for the R-30iA controller are
incompatible with each other because different
output formats are used. For details, refer to the
maintenance manuals for the controllers.
Comformable connector
End effector interface (RDI/RDO) (Wrist side) A63L-0001-0234#S2524M
(Fujikura:JMSP2524M)
A63L-0001-0234#R2524F(Fujikura.Ltd)
1 2 3 4
RDO1 RDO2 RDO3 RDO4
5
RDO5
6
RDO6
7
XHBK
8
0V
9
RDI1 End
10 11 12 13 14 15 effector
RDI2 RDI3 RDI4 RDI8 XPPABN RDI5
16 17 18 19 20
RDI6 +24V +24V +24V +24V
21 22 23 24
RDO7 RDO8 RDI7
Please prepare by user.
XHBK : Hand broken
Controller XPPABN : Pneumatic pressure abnormal
Fig. 2.6 (c) Pin layout for the end effector interface (EE) (for R-J3iB controller)
Comformable connector
End effector interface (RI/RO) (Wrist side)
A63L-0001-0234#S2524M
(Fujikura:JMSP2524M)
A63L-0001-0234#R2524F(Fujikura.Ltd)
1 2 3 4
RO1 RO2 RO3 RO4
5
RO5
6
RO6
7
XHBK
8
0V
9
RI1 End
10 11 12 13 14 15 effector
RI2 RI3 RI4 RI8 XPPABN RI5
16 17 18 19 20
RI6 +24V +24V +24V +24V
21 22 23 24
RO7 RO8 0V RI7
Please prepare by user.
XHBK : Hand broken
Controller XPPABN : Pneumatic pressure abnormal
Fig 2.6 (d) Pin layout for the end effector interface (EE) (R-30iA controller)
- 124 -
(2) User cable (signal line) interface (Option)

Fig. 2.6 (e) shows pin layout for user cable (signal line) interface.
Conformable
適合コネクタconnector
A63L-0001-0234#S2524MX(Fujikura
A63L-0001-0234#S2524MX((株)フジクラ)Ltd.)
User cable interface(AS2) (Wrist
ユーザケーブルインタフェース side)
(AS2) (手首側) (Fujikura Ltd.: JMSP2524MX)
(フジクラ仕様;JMSP2524MX)
A63L-0001-0234#R2524FX(Fujikura
A63L-0001-0234#R2524FX((株)フジクラ) Ltd.)
1 2 3 4
S1 S2 S3 S4 End
エンド
5 6 7 8 9
S5 S6 S7 S8 S9 effector
エフェクタ
10 11 12 13 14 15
S10 S11 S12 S13 S14 S15
16 17 18 19 20
S16 S17 S18 S19 S20
21 22 23 24
}
S21 S22 S23 S24
The customer should prepare these devices.

顧客殿にてご用意下さい
The customer should prepare

顧客殿にてご用意下さい
these devices. User cable interface(AS2)
ユーザケーブルインタフェース (AS1)(Wrist
(架台側)side)
A63L-0001-0234#R2524FX(Fujikura Ltd.)
}
A63L-0001-0234#W2524M((株)フジクラ)
1 2 3 4
External
外部信号 9
S4
8
S3
7
S2
6
S1
5
signal 10
S9
11
S8
12
S7
13
S6
14
S5
15
S10 S11 S12 S13 S14 S15
20 19 18 17 16
S20 S19 S18 S17 S16 2
24 23 22 21
S24 S22 S22 S21
Conformable
適合コネクタconnector
A63L-0001-0234#S2524F(Fujikura
A63L-0001-0234#S2524F((株)フジクラ)Ltd.)
(フジクラ仕様;JMSP2524F)
(Fujikura Ltd.: JMSP2524F)
Fig. 2.6 (e) Pin layout for the user cable (signal line) interface (option)
- 125 -
2.7 SERVO HAND CABLE INTERFACE (OPTION)
Fig. 2.7 (a) shows the position of the servo hand cable interface
option.
Fig. 2.7 (a) Interface for the servo hand cable interface (option)
- 126 -
(1) Servo hand cable interface (option)

Fig. 2.7 (b) shows the pin layout for the servo hand cable
interface connector.
NOTE
A connector prepared by the customer for the
servo cable interface must be a straight type; an
elbow type cannot pass through the hole in the J4
axis.
Fig. 2.7 (b) Pin layout for the servo hand cable interface (option)
- 127 -
3. TRANSPORTATION AND INSTALLATION CONNECTION B-81925EN/04
3 TRANSPORTATION AND INSTALLATION
- 128 -
B-81925EN/04 CONNECTION 3. TRANSPORTATION AND INSTALLATION
3.1 TRANSPORTATION
The robot can be transported by a crane or by a forklift.
Fig. 3.1 (a) and (b) show the postures in transportation.
Fig. 3.1 (a) Transportation by crane
- 129 -
Fig. 3.1 (b) Transportation by forklift
CAUTION
When a peripherals are installed on a robot, the
center of gravity of the robot changes and the robot
might become unstable while being transported.
Robot becomes unstable when it is transported
with the end effector applied to wrist ,and it is
dangerous.
Please be sure to remove end effector when robot
is transported.
Use the forklift pockets only to transport the robot
with a forklift. Do not use the forklift pockets for any
other transportation method. Do not use the forklift
pockets to secure the robot.
Before moving the robot by using forklift pockets,
check and tighten any loose bolts on the forklift
pockets.
Do not pull eyebolts sideways.
Prevent the forks of the forklift from having impact
on a transport equipment.
Do not thread a chain or the like through a
transport equipment.
- 130 -
3.2 INSTALLATION
(1) Installing the robot using the standard pedestal
Described below is how to install the robot using the standard pedestal,
which is factory-assembled with the robot.
Fig. 3.2 (a) shows the robot base dimensions. Fig. 3.2 (b) shows an
actual example of robot installation. Secure the floor plate (iron
plate) to the floor using 16 M20 chemical anchors (strength class 4.8).
Table 3.2 (a) and Fig. 3.2 (c) indicate the force and moment applied to
the robot base plate. When installing the robot, be sure that the setup
is strong enough to withstand the indicated force and moment.
Table 3.2(b) indicates the coasting time and distance consumed from
the pressing of the emergency stop button until the robot stops
NOTE
1 If the robot base is secured directly to the floor with
chemical anchors, the anchors may fail due to
fluctuating load during robot operation.
2 Do not provide leveling (with a wedge, for example)
between the robot base and floor plate.
Otherwise, any robot vibration may be accentuated
due to the robot not being in close contact with the
floor plate.
1080
Fig. 3.2 (a) Installation hole dimensions of the robot base
- 131 -
Fig. 3.2 (b) Sample installation
NOTE
1 The customer should prepare the following parts:
• Eight robot securing bolts: M20×40 (strength
class 12.9)
• 16 chemical anchors: M20 (strength class 4.8)
• One floor plate: 32t in thickness
2 The customer is responsible for preparation prior to
installation (mounting of anchors, for example)
- 132 -
Table 3.2(a) Force and moment acting to base plate

At At
At stop acceleration/ emergency
deceleration stop
Vertical moment 27,000 Nm 35,000 Nm 104,000 Nm
: MV (2,755 gfm) (3,571 kgfm) (10,612 kgfm)
Force in vertical direction 28,000 N 31,000 N 56,000 N
: FV (2,857 kgf) (3,163 kgf) (5,714 kgf)
Horizontal moment
0 Nm 10,000 Nm 44,000 Nm
:
(0 kgfm) (1,020 kgfm) (4,490 kgfm)
MH
Force in horizontal direction 0N 9,000 N 21,000 N
: FH (0 kgf) (918 kgf) (2,143 kgf)
Table 3.2 (b) Stopping time and distance when emergency stop
Model J1-axis J2-axis J3-axis
Stopping time [msec] 220 190 140

M-410iB/450
Stopping distance [deg] (rad) 7.7(0.13) 5.3(0.09) 3.9 (0.07)
※ Max payload and max speed
※ Max. payload, and max. inertia posture
Fig. 3.2 (c) Force and moment acting to the robot base
- 133 -
(2) Installing the robot without using the standard pedestal
A robot with a separate control unit can be installed on a

customer-prepared pedestal, without using the standard pedestal,
which is factory-assembled with the robot.
Fig. 3.2 (d) shows how to remove the standard pedestal from the robot.
First put the robot in the attitude of J1-axis = 0°, J2-axis = -45°,
J3-axis = 25°, and J4-axis = 0°, then prepare to sling up the robot
portion above the J1-axis base with rope. Remove the J1-axis
mounting bolts (sixteen M16×65 bolts), and separate the J1-axis base
from the pedestal.
Fig. 3.2 (e) shows the installation interface for the robot. Design a
pedestal while taking care of the following points:
• Provide space required when replacing the J1-axis motor.
• Provide space required when mounting and dismounting the
mastering fixture.
• Provide space for periodic maintenance (such as battery
exchange and degreasing)
• Avoid interference of the robot with the cables and connector
box.
• Make sure that the setup is strong enough to withstand the force
and moment listed in Table 3.2 (b).
To fasten the J1-axis base to the pedestal, use sixteen bolts having a
size of M16 (in strength class 12.9) and a length of at least 65 mm.
- 134 -
Fig. 3.2 (d) How to remove the pedestal (robot with a separate control unit)
- 135 -
322 176
Mastering fixture 88
Battery box
60
Robot front
242
357
371
(500)
172
80
209 250 Required space to 185
replace the J1-axis motor 370
Robot connection cable
Ｂ
65 290 290 65 16-Φ18 Through View A
Tap for earth 65 160 160 65 spot hole Φ26 Depth 20(Back side）
J1-axis base mounting through hole
65
880
65
340
210 210
340
Mastering fixture
65
65
880
Grease outlet
View B
Fig. 3.2 (e) Installation interface for the robot (with a separate control unit) with the standard pedestal removed
- 136 -
3.3 MAINTENANCE AREA
Fig. 3.3 shows the maintenance area of the mechanical unit.
Fig. 3.3 Maintenance area
- 137 -
3.4 INSTALLATION CONDITION
Table 3.4 shows installation condition.
Table 3.4 Installation condition

Items Specifications
Air pressure Max. 7kgf/cm2 (0.69MPa)
Weight of mechanical unit Approx. 2,430kg (with control unit)
Approx. 2,310kg (without control unit)
Allowable ambient temperature 0-45°C
Allowable ambient humidity Usual: Less than 75% RH
Short period (in one month) : Max. 95%
RH or less
Condensation free
Height Up to 1,000 meters above the sea level
requires, no particular provision for
attitude.
Atmosphere Free of corrosive gases (Note)
Vibration Less than 0.5G (4.9 m/s2)
NOTE
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.
- 138 -
APPENDIX
B-81925EN/04 APPENDIX A. SPARE PARTS LIST
A SPARE PARTS LIST
- 141 -
A. SPARE PARTS LIST APPENDIX B-81925EN/04
Table A (a) Cables

No. Specifications Functions Remarks
K501 A660-4004-T257 J1 to J2-axis power, brake For CE,
Integrated control unit
R-J3iB
K502 A660-8014-T699 J1 to J2-axis pulse coder For CE,
R-J3iB
K503 A660-4004-T258 J3-axis power, brake, For CE,
pulse coder Integrated control unit
R-J3iB
pulse coder, EE Integrated control unit
R-J3iB
pulse coder, EE, AS Integrated control unit
R-J3iB
K506 A660-4004-T272 J4 to J5-axis power, For CE,
brake, pulse coder, EE Integrated control unit
R-J3iB
brake, pulse coder, EE, Integrated control unit
AS R-J3iB
J3-axis power, brake, Remote control unit
pulse coder
pulse coder, EE R-J3iB
pulse coder, EE, AS R-J3iB
J4 to J5-axis power, Remote control unit
brake, pulse coder, EE R-J3iB
brake, pulse coder, EE, R-J3iB
AS
R-30iA
R-30iA
pulse coder, EE Integrated control unit
R-30iA
pulse coder, EE, AS Integrated control unit
R-30iA
- 142 -
B-81925EN/04 APPENDIX A. SPARE PARTS LIST
No. Specifications Functions Remarks

brake, pulse coder, EE Integrated control unit
R-30iA
brake, pulse coder, EE, Integrated control unit
AS R-30iA
brake, pulse coder, EE, Remote control unit
AS R-30iA
K563 A660-8015-T890 J1 to J2-axis pulse coder, For CE,
pulse coder, EE, AS R-30iA
brake, pulse coder, EE R-30iA
brake, pulse coder, EE, R-30iA
AS
K566 A05B-1039-D001 J1 to J2-axis pulse coder, For CE,
J4 to J5-axis power, Integrated control unit
brake, pulse coder, EE, R-30iA
AS,CAMERA
K708 A660-8012-T572 Zipper tube For CE,
Remote control unit
K721 A660-8012-T573 J1-axis over travel
Table A (b) Motor

J1, J2, J3 A06B-0268-B605#S000 (Model αM30/4000i)
Model αiS 30/4000
J4 A06B-0235-B605#S000 (Model αM8/4000i)
Model αiS 8/4000
NOTE
When ordering a motor, specify a motor whose
specification number is terminated with #S000.
Table A (c) Reducer

Axis Specifications
J1-axis reducer A97L-0218-0265#450C-37
J2-axis reducer A97L-0218-0266#450E-257
J3-axis reducer A97L-0218-0266#450E-257
J4-axis reducer A97L-0118-0949#70C-36
- 143 -
A. SPARE PARTS LIST APPENDIX B-81925EN/04
Table A (d) Input gear kit

Name Specifications
Input gear kit for A97L-0218-0245#257
J2, J3-axis reducer
Table A (e) Stopper

Name Specifications Remarks
J1-axis pendulum A290-7039-V201 Standard stopper
stopper
J1-axis motion A05B-1039-K201 Optional stopper
range control
stopper
Table A (f) Battery grease

Battery A98L-0031-0005 1.5V size D
Grease A98L-0040-0119#7KG Kyodo yushi
VIGOGREASE RE0
Grease A98L-0001-0179#2-2.5KG Shell Alvania GREASE
S2
Table A (g) Auxiliary seal for motor

Auxiliary seal for A98L-0004-0771#A12TP For Motor J1 to J3
motor
NOTE
A motor whose specification number is
terminated with #S000 has the built-in auxiliary
seal.
- 144 -
B-81925EN/04 APPENDIX B. CIRCUIT DIAGRAM
B CIRCUIT DIAGRAM
- 145 -
B. CIRCUIT DIAGRAM APPENDIX B-81925EN/04
Fig. B (a) Internal circuit diagram (R-J3iB Integrated control unit for CE)
- 146 -
- 147 -
Fig. B (b) Internal circuit diagram (R-J3iB Integrated control unit for CE with servo hand option)
- 148 -
- 149 -
Fig. B (c) Internal circuit diagram (R-J3iB Remote control unit for CE)
- 150 -
- 151 -
Fig. B (d) Internal circuit diagram (R-J3iB Remote control unit for CE with servo hand option)
- 152 -
- 153 -
- 154 -
Fig. B (e) Internal circuit diagram (R-30iA Integrated control unit for CE)
(Including the case where the servo hand option is selected)
- 155 -
Fig. B (f) Internal circuit diagram (R-30iA Integrated control unit for CE)
(Including the case where the servo hand option is selected)
- 156 -
- 157 -
C. PERIODIC MAINTENANCE APPENDIX B-81925EN/04
C PERIODIC MAINTENANCE
FANUC Robot M-410iB/450 Periodic Maintenance Table
1.8 10800 ml
0.9 2300 ml
2300 ml
1600 ml
10 ml
40 ml
20 ml
- 158 -
B-81925EN/04 APPENDIX C. PERIODIC MAINTENANCE
- 159 -
D. BOLT TIGHTENING TORQUE TABLE APPENDIX B-81925EN/04
D BOLT TIGHTENING TORQUE TABLE

Those bolts for which no tightening torque is specified must be
tightened according to the APPENDIX D BOLT TIGHTENING
TORQUE TABLE.
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 effects 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.
- 160 -
B-81925EN/04 APPENDIX D. BOLT TIGHTENING TORQUE TABLE
Table D Recommended Bolt Tightening Torques

Unit : Nm (kgf･cm)
Hexagon socket head pan bolt
Hexagon socket head bolt Hexagon socket head bolt Hexagon socket head
Nominal (Steel : strength rating of 12.9) (Stainless) countersunk bolt
diameter (Steel : strength rating of 12.9)
Tightening torque Tightening torque Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
M3 1.8(18) 1.3(13) 0.76(7.7) 0.53(5.4) ––––––– –––––––
M4 4.0(41) 2.8(29) 1.8(18) 1.3(13) 1.8(18) 1.3(13)
M5 7.9(81) 5.6(57) 3.4(35) 2.5(25) 4.0(41) 2.8(29)
M6 14(140) 9.6(98) 5.8(60) 4.1(42) 7.9(81) 5.6(57)
M8 32(330) 23(230) 14(145) 9.8(100) 14(140) 9.6(98)
M10 66(670) 46(470) 27(280) 19(195) 32(330) 23(230)
M12 110(1150) 78(800) 48(490) 33(340) ––––––– –––––––
(M14) 180(1850) 130(1300) 76(780) 53(545) ––––––– –––––––
M16 270(2800) 190(1900) 120(1200) 82(840) ––––––– –––––––
(M18) 380(3900) 260(2700) 160(1650) 110(1150) ––––––– –––––––
M20 530(5400) 370(3800) 230(2300) 160(1600) ––––––– –––––––
(M22) 730(7450) 510(5200) ––––––– ––––––– ––––––– –––––––
M24 930(9500) 650(6600) ––––––– ––––––– ––––––– –––––––
(M27) 1400(14000) 940(9800) ––––––– ––––––– ––––––– –––––––
M30 1800(18500) 1300(13000) ––––––– ––––––– ––––––– –––––––
M36 3200(33000) 2300(23000) ––––––– ––––––– ––––––– –––––––
- 161 -
B-81925EN/04 INDEX
INDEX
<A> <J>
ADJUSTING LIMIT SWITCHES AND DOGS J1-AXIS DRIVE MECHANISM ...................................... 4
(OPTION) ....................................................................... 33 J1-AXIS STROKE MODIFICATION
ADJUSTMENTS ............................................................ 32 (OPTION) ....................................................................... 37
AIR SUPPLY ................................................................ 120 J2-AXIS DRIVE MECHANISM ...................................... 4
J3-AXIS DRIVE MECHANISM ...................................... 5
<B>
J4-AXIS DRIVE MECHANISM ...................................... 5
BACKLASH MEASUREMENT .................................... 30
<L>
BOLT TIGHTENING TORQUE TABLE .................... 160
LOAD CONDITION AT WRIST................................. 111
<C>
LOAD SETTING.......................................................... 115
CABLE FORMING ........................................................ 87
<M>
Checking for Cable Damage and Twisting .......................9
Checking for Loose Bolts................................................ 11 MAINTENANCE AREA ............................................. 137
CIRCUIT DIAGRAM................................................... 145 MAINTENANCE TOOLS ............................................. 20
Cleaning .......................................................................... 11 MAJOR COMPONENT SPECIFICATIONS................... 6
CONFIGURATION ..........................................................3 Mastering ........................................................................ 48
COUPLING OF THE END EFFECTOR TO MASTERING ................................................................. 41
THE WRIST ................................................................. 114 Mastering Data Entry...................................................... 57
Mastering Method........................................................... 42
<D>
Mastering to a Fixture (Master Position Master) ............ 44
DAILY CHECKS..............................................................8 Motion Performance Screens ........................................ 115
MOUNTING A DEVICE TO THE ROBOT ................ 110
<E>
EQUIPMENT MOUNTING SURFACE ...................... 119
<O>
Others.............................................................................. 19
<F>
OVERVIEW ................................................................... 21
FAILURES, CAUSES AND MEASURES..................... 22
<P>
<G>
PART REPLACEMENT AND
General............................................................................ 41 CORRESPONDING ADJUSTMENT ............................ 60
Greasing .......................................................................... 17 PERIODIC CHECKS ....................................................... 9
PERIODIC MAINTENANCE ...................................... 158
<I>
PREFACE...................................................................... p-1
INSTALLATION.......................................................... 131 PREVENTIVE MAINTENANCE.................................... 7
INSTALLATION CONDITION................................... 138 Procedure for Releasing Residual Pressure
INTERFACE FOR END EFFECTOR .......................... 122 within the Grease Bath.................................................... 16
i-1
INDEX B-81925EN/04
<Q> <T>
Quick Mastering.............................................................. 52 TRANSPORTATION................................................... 129
TRANSPORTATION AND INSTALLATION............ 128
<R>
TROUBLESHOOTING.................................................. 21
REPLACING A CABLE ................................................ 96
<W>
Replacing Battery............................................................ 18
REPLACING CABLES .................................................. 86 WIRING ......................................................................... 84
Replacing Grease ............................................................ 12
<Z>
REPLACING J1-AXIS MOTOR (M1) AND
REDUCER ...................................................................... 61 Zero Degree Mastering ................................................... 50
REPLACING J2/J3-AXIS MOTOR (M2/M3) ZERO POINT POSITION AND MOTION
AND REDUCER ............................................................ 68 LIMIT OF J2-AXIS TO J4-AXIS................................... 35
REPLACING J4-AXIS MOTOR (M4) AND
REDUCER ...................................................................... 77
REPLACING PARTS ..................................................... 59
Replacing the Cables of the Mechanical Unit ................. 19
REPLACING THE J1-AXIS PENDULUM
STOPPER........................................................................ 83
REPLACING THE OPTIONAL J1-AXIS
LIMIT SWITCH (OPTION) .......................................... 82
REPLACING THE WRIST UNIT .................................. 80
Resetting Alarms and Preparing for Mastering ............... 43
ROBOT EXTERNAL DIMENSION ............................ 109
<S>
SAFETY PRECAUTIONS ............................................ s-1
SERVO HAND CABLE INTERFACE
(OPTION) ..................................................................... 126
Single Axis Mastering..................................................... 54
SOFTWARE SETTING.................................................. 40
SPARE PARTS LIST.................................................... 141
Switching between Modes ............................................ 117
i-2
Revision Record
FANUC Robot M-410iB/450 MECHANICAL UNIT MAINTENANCE MANUAL (B-81925EN)
• Addition of procedure of to move arm without drive

power in emergency or abnormal situations
•Change of the note of transportation
04 Dec.,2007 •Addition of Stopping time and distance when
emergency stop
• Addition of sensor cable
•Revice
• Change the name of controller

03 Sep.,2007
(from R-J3iC to R-30iA)
• Addition of the panel board supporting R-J3iC

02 Nov.,2006 • Addition of the model supporting R-J3iC
• Addition of a warning about transportation
01 Jan., 2003
Edition Date Contents Edition Date Contents

M-410iB450 Maintenance Manual (B-81925EN 04)

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1.1 OPERATOR SAFETY

Operator safety is the primary safety consideration. Because it is

The following lists the general safety precautions. Careful

(4) Provide the peripheral devices with appropriate grounding (Class

The circuit breaker installed in the controller is designed to disable anyone

(9) When adjusting each peripheral device independently, be sure to

Limit swith which operates

Fig. 1.1 (a) Safety Fence and Safety gate

1.1.1 Operator Safety

Note) Connect between EMGIN1 and EMGIN 2.

1.1.2 Safety of the Teach Pendant Operator

(1) Unless it is specifically necessary to enter the robot work area,

The teach pendant supplied by FANUC is provided with a teach pendant

The teach pendant, operator’s box, and peripheral device interface

Operator ‘s panel Teach pendant Software remote Teach Operator’s Peripheral

(7) When a program is completed, be sure to carry out a test run

1.1.3 Safety During Maintenance

1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.2.1 Precautions in Programming

1.2.2 Precautions for Mechanism

1.3 SAFETY OF THE ROBOT MECHANISM

1.3.1 Precautions in Operation

1.3.2 Precautions in Programming

1.3.3 Precautions for Mechanisms

1.3.4 Procedure to move arm without drive power in emergency or

Brake release A05B-2450-J350 (Input voltage AC100-115V single phase)

unit A05B-2450-J351 (Input voltage AC200-240V single phase)

A05B-2450-J360 (5m) ,(except A cabinet controller integrated type)

A05B-2525-J010 (5m) (AC100-150V type)

A05B-2525-J011 (10m) (AC100-150V type)

A05B-2450-J365 (10m) (AC200-240V type)

In case of releasing J2-axis motor brake Method of supporting robot arm

Lever block (2 pcs)

Fig. 1.3.4(a) Releasing J2 motor brake and measures

In case of releasing J3-axis motor brake Method of supporting robot arm

Fig.1.3.4(b) Releasing J3 motor brake and measures

1.4 SAFETY OF THE END EFFECTOR

1.4.1 Precautions in Programming

1.5 SAFETY IN MAINTENANCE

1.6 WARNING LABEL

(1) Greasing and degreasing label

Fig. 1.6 (a) Greasing and Degreasing Label

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

(2) Disassembly prohibitive label

Fig. 1.6 (b) Disassembly Prohibitive Label

(3) Step-on prohibitive label

Fig. 1.6 (c) Step-on Prohibitive Label

(4) High-temperature warning label

Fig. 1.6 (d) High-temperature warning label

(5) Balancer replacement label

Fig. 1.6 (e) Balancer Replacement Label

(6) Transportation prohibitive label

Fig. 1.6 (h) Transportation prohibitive label

Do not pull eyebolts sideways

(7) Range of motion and payload mark label

Below label is added when CE specification is specified.

The wrist tip

Fig.1.6(i) Range of motion and payload mark label

Mechanical unit Maximum

The label stating the mechanical unit specification number is affixed

Position of label indicating mechanical unit specification number