DR-3iB Maintenance Manual (B-84115EN 01) PDF

< Robot DR-3+B
MECHANICAL UNIT
MAINTENANCE MANUAL
B-84115EN/01
© FANUC CORPORATION, 2021

• Original Instructions
Thank you very much for purchasing FANUC Robot.

Before using the Robot, be sure to read the "FANUC Robot series SAFETY HANDBOOK
(B-80687EN)" and understand the content.
• No part of this manual may be reproduced in any form.

• All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual, we endeavor to include all pertinent matters. There are, however, a very
large number of operations that must not or cannot be performed, and if the manual
contained them all, it would be enormous in volume. It is, therefore, requested to assume
that any operations that are not explicitly described as being possible are "not possible".
B-84115EN/01 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
This chapter describes the precautions which must be followed to enable the safe use of the robot. Before
using the robot, be sure to read this chapter thoroughly.
For detailed functions of the robot operation, read the relevant operator's manual to understand fully its
specification.
For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral equipment installed in a work cell.
For safe use of FANUC robots, you must read and follow the instructions in “FANUC Robot series
SAFETY HANDBOOK (B-80687EN)”.
1 PERSONNEL
Personnel can be classified as follows.
Operator:
• Turns the robot controller power ON/OFF
• Starts the robot program from operator panel
Programmer or Teaching operator:

• Operates the robot
• Teaches the robot inside the safeguarded space
Maintenance technician:
• Operates the robot
• Teaches the robot inside the safeguarded space
• Performs maintenance (repair, adjustment, replacement)
- The operator is not allowed to work in the safeguarded space.

- The programmer or teaching operator and maintenance technician are allowed to work in the
safeguarded space. Works carried out in the safeguarded space include transportation, installation,
teaching, adjustment, and maintenance.
- To work inside the safeguarded space, the person must be trained on proper robot operation.
s-1
SAFETY PRECAUTIONS B-84115EN/01
Table 1 (a) lists the work outside the safeguarded space. In this table, the symbol “” means the work
allowed to be carried out by the specified personnel.
Table 1 (a) List of work outside the Safeguarded Space

Programmer or Maintenance
Operator
Teaching operator technician
Turn power ON/OFF to Robot controller   
Select operating mode (AUTO/T1/T2)  
Select remote/local mode  
Select robot program with teach pendant  
Select robot program with external device  
Start robot program with operator’s panel   
Start robot program with teach pendant  
Reset alarm with operator’s panel  
Reset alarm with teach pendant  
Set data on teach pendant  
Teaching with teach pendant  
Emergency stop with operator’s panel   
Emergency stop with teach pendant   
Operator’s panel maintenance 
Teach pendant maintenance 
During robot operation, programming and maintenance, the operator, programmer, teaching operator and
maintenance technician take care of their safety using at least the following safety protectors.
• Use clothes, uniform, overall adequate for the work

• Safety shoes
• Helmet
2 DEFINITION OF SAFETY NOTATIONS

To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution
on safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is
indicated by "NOTE". Read the contents of each "WARNING", "CAUTION" and "NOTE" before
using the robot.
Symbol Definitions
Used if hazard resulting in the death or serious injury of the user will be expected to
WARNING occur if he or she fails to follow the approved procedure.
Used if a hazard resulting in the minor or moderate injury of the user, or equipment
CAUTION damage may be expected to occur if he or she fails to follow the approved
procedure.
Used if a supplementary explanation not related to any of WARNING and CAUTION
NOTE is to be indicated.
s-2
3 PROCEDURE TO MOVE ARM WITHOUT

DRIVE POWER IN EMERGENCY OR
ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons trapped in or sandwiched by the robot), brake
release switch and brake release unit can be used to move the robot axes without drive power.
In case of the brake release switch, you can release J1 to J3-axis brakes by pushing the switch during
turning on controller power.
Please order the following brake release switch or the brake release unit and cable.
Table 3 (a) Order spec. of the brake release switch

Name Specification
Brake release switch A05B-1525-H302
Table 3 (b) Order spec. of the brake release unit

Name Specification
A05B-2660-J350 (Input voltage AC100-115V single phase)
Brake release unit
A05B-2660-J351 (Input voltage AC200-240V single phase)
A05B-2660-J360 ( 5m)
Robot connection cable
A05B-2660-J361(10m)
A05B-2660-J010 ( 5m) (AC100-115V Power plug) (*)
A05B-2660-J011(10m) (AC100-115V Power plug) (*)
Power cable
A05B-2660-J364 ( 5m) (AC100-115V or AC200-240V No power plug)
A05B-2660-J365(10m) (AC100-115V or AC200-240V No power plug)
(*) These do not support CE Marking.
(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.
CAUTION
If the robot is used in 35 degree or more, the brake release switch might be hot.
When touching the brake release switch, special care such as wearing the
protective equipment etc. that can be usable in 70 degree or more, must be
applied in order to avoid burn injury due to high temperature.
Robot systems installed without adequate number of brake release units or
similar means are not in compliance with EN ISO 10218-1 and the Machinery
Directive and therefore cannot bear the CE Marking.
WARNING
Robot arm would fall down by releasing its brake because of gravity. Therefore,
it is strongly recommended to take adequate measures such as hanging Robot
arm by a crane before releasing a brake.
s-3
Brake release switch

ブレーキ解除スイッチ
Detail 詳細
A A (1秒以上スイッチを押すと、ブレーキが解除されます。
(If the switch is pressed 1 second or more, the
スイッチを離すと再びブレーキがかかります)
brake will be released . If the switch is released ,
brake will work again )
Fig. 3 (a) Brake release switch
Support Wrist
手首ユニットunit
支え
Fall down
落下
Fig. 3 (b) Arm operation by the release of motor brake and measures
s-4
4 WARNING & CAUTION LABEL, PLATE

(1) Transportation caution label 1
Fig. 4 (a) Transportation caution label 1
Description
When transporting the robot, observe the instructions indicated on this label.
• Use a crane with a load capacity of 300 kg or greater.

• Use three slings with each load capacity of 250 kg or greater.
• Use three eyebolts with each load capacity of 6174 N (630 kgf) or greater.
アイボルトを横引
しないこと
Do not pull eyebolt
sideways
禁止横向拉拽吊环螺钉
Fig. 4 (b) Transportation caution label 2
Description
Keep the following in mind when transporting the robot.
• Do not pull eyebolts sideways.
s-5
バッテリボックス
B a tt er y b o x
电池盒
バッテリボックスケーブル断線注意
Battery box cable breaking caution
电池盒电电断开警告
Fig. 4 (c) Transportation caution label 3
Description
Keep the following in mind when transporting the robot.
• Pay attention to the battery box cable breaking.
(4) Operating space and load capacity plate

In case of CE specification, the following figure is added to the plate:
Fig. 4 (d) Operating space and load capacity plate
s-6
B-84115EN/01 PREFACE
PREFACE
This manual explains maintenance procedures for the following mechanical units:
Mechanical unit
Model name Maximum load Remarks
specification No.
FANUC Robot DR-3iB/8L A05B-1525-B201 8kg Paint type
FANUC Robot DR-3iB/8L A05B-1525-B202 8kg Plated type
The label stating the mechanical unit specification number is affixed in the following position. Before
reading this manual, verify the specification number of the mechanical unit.
(1)
TYPE (2)
NO. (3)
DATE (4)
WEIGHT (5) kg
Position of label indicating mechanical unit specification number
TABLE 1)
(1) (2) (3) (4) (5)
WEIGHT kg
CONTENTS MODEL NAME TYPE No. DATE
(without controller)
PRODUCTION
A05B-1525-B201
SERIAL NO. YEAR AND
LETTERS FANUC Robot DR-3iB/8L 170
IS PRINTED MONTH ARE
A05B-1525-B202
PRINTED
p-1
PREFACE B-84115EN/01
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook B-80687EN Intended readers:

All persons who use the FANUC Robot and system Operator , system designer
designer must read and understand thoroughly this Topics:
handbook Safety items for robot system design, operation,
maintenance
R-30iB Plus, Operations manual Intended readers:
R-30iB Mate Plus Basic Operation Operator, programmer, maintenance technician,
controller B-83284EN system designer
Alarm Code List Topics:
B-83284EN-1 Robot functions, operations, programming, setup,
OPTIONAL FUNCTION interfaces, alarms
B-83284EN-2 Use:
Robot operation, teaching, system design
Maintenance manual Intended readers:
R-30iB Plus: Maintenance technician, system designer
B-83195EN Topics:
R-30iB Mate Plus: Installation, start-up, connection, maintenance
B-83525EN Use:
R-30iB Mate Plus (Open air type) : Installation, start-up, connection, maintenance
B-83555EN
Mechanical unit Maintenance manual Intended readers:
FANUC Robot DR-3iB Maintenance engineer, system designer
B-84114EN Topics:
Installation, connection to the controller, maintenance
Use:
Installation, start-up, connection, maintenance
This manual uses following terms.

Name Terms in this manual
Connection cable between robot and controller Robot connection cable
Robot mechanical unit Mechanical unit
p-2
B-84115EN/01 TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY PRECAUTIONS ............................................................................ s-1
PREFACE ....................................................................................................p-1
1 CHECKS AND MAINTENANCE ............................................................. 1

1.1 CHECKS AND MAINTENANCE .................................................................... 1
1.1.1 Daily Checks ............................................................................................................ 1
1.1.2 Periodic Checks and Maintenance............................................................................ 2
1.2 CHECK POINT .............................................................................................. 4
1.2.1 Confirmation of Oil Seepage and Abrasion ............................................................. 4
1.2.2 Check the link B ....................................................................................................... 6
1.2.3 Check the Mechanical Unit Connectors ................................................................... 6
1.2.4 Cleaning ................................................................................................................... 7
1.3 MAINTENANCE TOOLS ............................................................................... 7
2 PERIODIC MAINTENANCE .................................................................... 9
2.1 REPLACING THE BATTERIES (1.5-YEAR (5760 HOURS) CHECKS) ......... 9
2.2 REPLACING THE OIL OF THE DRIVE MECHANISM
(1-YEAR (3840 HOURS) CHECKS) ............................................................ 11
2.3 CLEANING AND GREASING OF THE LINK B
(6 MONTHS (1920 HOURS) MAINTENANCE)............................................ 13
2.3.1 Periodic maintenance procedure for paint/seal type link B .................................... 14
2.3.2 Periodic maintenance procedure for plated/seal type link B .................................. 15
2.3.3 Periodic maintenance procedure for plated/boot type link B ................................. 17
2.4 CLEANING .................................................................................................. 19
2.4.1 Cleaning the Robot ................................................................................................. 19
2.4.2 Cleaner (When white painting is specified) ........................................................... 19
3 TROUBLESHOOTING .......................................................................... 20
3.1 TROUBLESHOOTING ................................................................................. 20
3.2 BACKLASH MEASUREMENT ..................................................................... 28
4 REPLACING PARTS ............................................................................ 31
4.1 FIGURE OF DRIVE MECHANISM .............................................................. 32
4.2 MECHANICAL UNIT CONFIGURATION ..................................................... 33
4.3 REPLACING THE J1/J2/J3-AXIS MOTOR (M1/M2/M3).............................. 34
4.4 REPLACING THE J1/J2/J3-AXIS REDUCER.............................................. 35
4.5 REPLACING THE J4 MOTOR UNIT ........................................................... 36
4.6 REPLACING THE J4 -AXIS MOTOR AND THE REDUCER ....................... 37
4.7 REPLACING THE LINK B ........................................................................... 38
4.8 REPLACING THE UNIVERSAL JOINT ....................................................... 41
4.9 REPLACING THE DRIVE SHAFT ............................................................... 42
4.10 REPLACING THE ROD SUPPORT KIT ...................................................... 46
4.11 REPLACING THE WRIST UNIT .................................................................. 47
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TABLE OF CONTENTS B-84115EN/01
4.12 REPLACING THE FAN (OPTION)............................................................... 48

5 REPLACING CABLES .......................................................................... 49
5.1 CABLE FORMING ....................................................................................... 50
5.2 CABLE REPLACEMENT ............................................................................. 52
6 MASTERING ......................................................................................... 57
6.1 OVERVIEW ................................................................................................. 57
6.2 RESETTING ALARMS AND PREPARING FOR MASTERING ................... 59
6.3 FIXTURE POSITION MASTERING ............................................................. 60
6.4 Q&A ............................................................................................................. 67
6.5 VERIFYING MASTERING ........................................................................... 68
APPENDIX
A MAINTENANCE PARTS ....................................................................... 71
B MECHANICAL UNIT CIRCUIT DIAGRAM ............................................ 73
C PERIODIC MAINTENANCE TABLE ..................................................... 76
D STRENGTH OF BOLT AND BOLT TORQUE LIST .............................. 78
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B-84115EN/01 1. CHECKS AND MAINTENANCE
1 CHECKS AND MAINTENANCE

Optimum performance of the robot can be maintained by performing the checks and maintenance
procedures presented in this chapter. (See APPENDIX C PERIODIC MAINTENANCE TABLE.)
NOTE
1 The periodic maintenance procedures described in this chapter assume that the
FANUC robot is used for up to 3840 hours a year. In cases where robot use
exceeds 3840 hours/year, adjust the given maintenance frequencies
accordingly. The ratio of actual operating time/year vs. the 3840 hours/year
should be used to calculate the new (higher) frequencies. For example, when
using the robot 7680 hours a year, the maintenance frequency should be
doubled – i.e. the interval should be divided by 2.
2 Repair the paint detachment immediately if damaged during the maintenance
work. Once leaving those damages without any proper repair, the corrosion and
chemical resistance will not maintain. This repair work is especially important for
the white paint.
1.1 CHECKS AND MAINTENANCE
1.1.1 Daily Checks

Clean each part, and visually check component parts for damage before daily system operation. Check the
following items when necessary.
Check items Check points and management

Oil seepage Check to see if there is oil on the sealed part of each joint. If there is an oil seepage, clean
it.
⇒”1.2.1 Confirmation of Oil Seepage and Abrasion”
Vibration, abnormal Check whether vibration or abnormal noises occur.
noises When vibration or abnormal noises occur, perform measures referring to the following
section:
⇒”3.1 TROUBLESHOOTING”(symptom：Vibration, Noise)
Positioning accuracy Check whether the taught positions of the robot have not deviated from the previous
taught positions. When the displacement occurs, perform the measures as described in
the following section:
⇒”3.1 TROUBLESHOOTING”(Symptom：Displacement)
Peripheral equipment Check whether the peripheral equipment operate properly according to commands from
for proper operation the robot and the peripheral equipment.
Brakes for each axis Check that the end effector mounting face drops within 0.2 mm when servo power is
turned off. If the end effector (hand) drops, perform the measures as described in the
following section:
⇒”3.1 TROUBLESHOOTING”(symptom：Dropping axis)
Warnings Check whether unexpected warnings occur in the alarm screen on the teach pendant. If
unexpected warnings occur, perform the measures as described in the following manual:
⇒”CONTROLLER OPERATOR’S MANUAL (Alarm Code List)(B-83284EN-1)” .
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1. CHECKS AND MAINTENANCE B-84115EN/01
1.1.2 Periodic Checks and Maintenance

Check the following items at the intervals recommended below based on the total operating time or the
accumulated operating time, whichever comes first. (○ : Item needs to be performed.)
Check and maintenance intervals

(Operating time, Accumulated Check and Periodic
Check points, management and
operating time) maintenance maintenance
maintenance method
1
month
3
months
6
months
1
year
1.5
years
2
years
4
years
item table No.
320h 960h 1920h 3840h 5760h 7680h 15360h
○ ○ Cleaning the If the controller ventilation system is

Only controller dusty, turn off power and clean the unit.
1st 19
check ventilation
system
○ Check the Check whether the robot has external
external damage or peeling paint due to the
damage or interference with the peripheral
peeling paint equipment. If an interference occurs,
1
eliminate the cause. Also, if the external
damage is serious, and causes a
problem in which the robot will not
operate, replace the damaged parts.
○ Check for water Check whether the robot is subjected to
water or cutting oils. If water is found,
2
remove the cause and wipe off the
liquid.
○ ○ Check for damages Check whether the cables connected to
Only to the teach the teach pendant, operation box and
1st
check pendant cable, the robot are unevenly twisted or damaged.
operation box If damage is found, replace the 18
connection cable damaged cables.
or the robot
connection cable
○ ○ Check for Check whether the end effector cables
Only damage to the are unevenly twisted or damaged. If
1st 8
Check end effector damage is found, replace the damaged
(hand) cable cables.
○ ○ Check link B Check the LINK B part (6 places) are
Only tightened, if they are loosened, retighten
1st
check them. Check the tightness of the nuts.
6
Check whether there is no damaged,
transformation or crack on the rubber
⇒”1.2.2 Check the Link B”
○ ○ Visual check of Check there is no kink or damage on the
Only wrist motor cable tube of the wrist motor cable 9
1st
check
○ ○ Check the Check the tightening of the connector
Only connection of the panel.
1st 3
check connector panel ⇒”1.2.3 Check the mechanical unit
connectors”
-2-
maintenance method
1
month
3
months
6
months
1
year
1.5
years
2
years
4
years
item table No.
320h 960h 1920h 3840h 5760h 7680h 15360h
○ ○ Retightening the Retighten the end effector mounting

Only end effector bolts.
1st
check mounting bolts Refer to the following section for
tightening torque information:
4
⇒”4.1 END EFFECTOR
INSTALLATION TO WRIST” of the
mechanical unit operator7s manual
(B-84114EN)
○ ○ Retightening the Retighten the robot installation bolts,
Only external main bolts to be removed for inspection, and
1st
check bolts bolts exposed to the outside. Refer to
the recommended bolt tightening torque
guidelines at the end of the manual. An
adhesive to prevent bolts from loosening
5
is applied to some bolts. If the bolts are
tightened with greater than the
recommended torque, the adhesive
might be removed. Therefore, follow the
recommended bolt tightening torque
guidelines when retightening the bolts.
○ ○ Clean foreign Check that foreign materials such as dust
Only materials such as or powder does not exist on the robot
1st
check dust or powder main body. If there is any, remove them.
Especially, clean the robot movable parts 7
well (each joint, around the wrist axis
rotation part).
⇒”1.2.4 Cleaning”
○ ○ Check the (When cooling fans are installed on the
Only operation of the major axis motor) Check whether noise
1st
check cooling fan does not occur at the cooling fan. If
10
noise occurs, replace them. Contact
your local FANUC representative about
replacing methods.
○ Cleaning and Clean and grease the link B.
grease the link B ⇒”2.3 Cleaning and greasing of the 11
link B”
○ Replacing the Replace the mechanical unit batteries.
mechanical unit Regardless of operating time, replace
12
batteries batteries at 1.5 years.
⇒”2.1 Replacing the batteries”
○ Replacing the oil Replace the oil of each axis reducer and
of the reducer gearbox.
13, 14
and wrist ⇒”2.2 Replacing the oil of the Drive
Mechanism”
○ Replacing the Replace the link B.
link B ⇒”4.7 REPLACING THE LINK B” 15
(seal type)
○ Replacing the Replace the link B.
link B ⇒”4.7 REPLACING THE LINK B” 15
(boot type)
○ Replacing the Replace the wrist motor cable.
16
wrist motor cable ⇒”5.2 CABLE REPLACEMENT”
-3-

maintenance method
1
month
3
months
6
months
1
year
1.5
years
2
years
4
years
item table No.
320h 960h 1920h 3840h 5760h 7680h 15360h
○ Replacing the Replace the rod support kit, the drive

rod support kit, shaft and the support plate.
the drive shaft ⇒”4.7 REPLACING THE LINK B” 17
and the support ⇒”4.9 REPLACING THE DRIVE
plate. SHAFT”
○ Replacing the Replace the controller batteries.
controller Regardless of operating time, replace
batteries batteries at 4 years.
⇒Refer to ”Chapter 7 Replacing
batteries” in the following
maintenance manuals.
- R-30iB/ R-30iB Plus
CONTROLLER MAINTENANCE
20
MANUAL (B-83195EN)
- R-30iB Mate/R-30iB Mate Plus
CONTROLLER MAINTENANCE
MANUAL (B-83525EN)
- R-30iB Mate/R-30iB Mate Plus
CONTROLLER (Open Air type)
MAINTENANCE MANUAL (B-
83555EN)
1.2 CHECK POINT
1.2.1 Confirmation of Oil Seepage and Abrasion

Check items
Check whether there is abrasion, oil seepage, transformation and crack. If there is oil seepage, clean it.
Grease is applied on sliding parts. If there is oil seepage which cause dropping, wipe off it.
Cable
Cableclamp
ケーブルクランプclamp
Link ball
リンクボール
Cable clamp
　ケーブルクランプ
Clamp
クランプ Inspection window
覗き窓
Fig. 1.2.1 (a) Check points
-4-
Oil seals are used in the following position. Check the leakage of oil and grease.
Wrist
手首
Link A
リンクA
Fig. 1.2.1 (b) Oil seal locations
Management
 Oil might accumulate on the outside of the seal lip depending on the movement condition or
environment. If the oil changes to a state of liquid，the oil might fall depending on the axis movement.
To prevent oil spots, be sure to wipe away any accumulated oil under oil seals of Fig. 1.2.1 (b) before
you operate the robot.
 Oil content is exposed on bush part or spring part. In that case wipe them off.
 In case of oil seepage, please consider replacing the oil. This replacement potentially can help improve
the seepage situation.
 If you must wipe oil frequently, and opening the grease outlet does not stop the seepage, perform the
measures below.
⇒”3.1 TROUBLESHOOTING”(symptom：Oil leakage)
-5-
1.2.2 Check the link B

Check the LINK B part (6 places) are tightened, if they are loosened, retighten them. Check the tightness
of the nuts. Check whether there is no damaged, transformation or crack on the rubber. (See Fig. 1.2.2 (a))
Appropriate tightening
torque : 29Nm29Nm
適正締め付けトルク
Appropriate tightening
適正締め付けトルク
torque : 29Nm 29Nm
In case of ブーツタイプの場合
the boot type
ゴムの破れ点検
Check the rubber breakage
Fig. 1.2.2 (a) Check points of link B
1.2.3 Check the Mechanical Unit Connectors

Inspection points of the connectors
 Power/brake connectors of the motor exposed externally
 Robot connection cables, earth terminal and user cables
Check items
 Square connector : Check the connector for engagement of its lever.
 Earth terminal : Check the terminal for tightness.
Fig. 1.2.3 (a) Connector Inspection points
-6-
1.2.4 Cleaning
Necessary cleaning points, dust on the flat part, accumulation of weld spatter and oil
Clean sediments periodically. In particular, clean the following points carefully.
Vicinity of the wrist axis and oil seal

If chippings or spatters are attached to the oil seal, an oil leak may be occurred.
Fig. 1.2.4 (a) Cleaning part
1.3 MAINTENANCE TOOLS

The following tools and instruments are required for the maintenance procedures contained in this manual.
(a) Measuring instruments

Instruments Accuracy/Tolerance Applications
Measurement of positioning accuracy
Dial gauge Minimum display 1/100 mm or less
and backlash
(b) Tools
• Torque wrench Width across flats 2.5, 3, 4, 5, 6, 8
• Cross-head screwdrivers Large, medium, and small sizes
• Straight-head screwdrivers Large, medium, and small sizes
• Nut driver Width across flats 7, 8, 10, 12
• Square (octagonal) socket Width across flats 7
• Hexagon wrench set Width across flats 2.5, 3, 4, 5, 6, 8
• Adjustable wrench Medium and small sizes
• Pliers
• Cutting pliers
• Nippers
• Gear puller
• Separator
• Offset box end wrench
• LOCTITE 243,641
• Universal joint adjuster fixture A290-7525-X920 (Fig. 1.3 (a))
-7-
27
13.5 0.8
10
7.3 ±0.05 ( )
2-
R1 R
2
32.5
0 MA
24.5
24.5
X
34
R
0.5
9.5
MA
26
X
150°
R
2-O4.5 25
3
10.9 12 50
5.8 A
11
28
VIEW A
Fig. 1.3 (a) Universal joint height adjusting fixture A290-7525-X920
-8-
B-84115EN/01 2. PERIODIC MAINTENANCE
2 PERIODIC MAINTENANCE
2.1 REPLACING THE BATTERIES
(1.5-YEAR (5760 HOURS) CHECKS)
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every
1.5 years. Also, use the following procedure to replace when the backup battery voltage drop alarm occurs.
1 During battery replacement, hold down the emergency stop button for the sake of safety.
CAUTION
Be sure to keep the power supply turned on. Replacing the batteries with the
power supply turned off causes all current position data to be lost. Therefore,
mastering will be required again.
2 Uncap the battery case (Fig. 2.1 (a)).

3 Take out the old batteries from the battery case.
4 Insert new batteries into the battery case while observing their correct orientation.
5 Cap the battery case.
Remote battery box

別置バッテリボックス
Batteryバッテリケーブル
cable
Diameter
径 About
約O5mm φ5mm
(Maxφ5.5mm )
(最大O5.5mm)
Battery case
バッテリケース Battery spec. : A98L-0031-0005 Case cap
ケースキャップ
バッテリ仕様　:　A98L-0031-0005
(D（単一アルカリバッテリ
battery (alkali) 4 pcs) 4本)
Fig. 2.1 (a) Replacing the battery

-9-
2. PERIODIC MAINTENANCE B-84115EN/01
Fig 2.1 (b) shows the external size of external battery box.
When the battery box needs to be built into the controller or other internal units, refer to the external
dimensions shown in Fig.2.1 (b)
The battery box can be fixed by using M4 flat–head screws. (The bolts do not come with the system.)
A maximum of six terminals can be attached to the backplane of the battery box.
Fig. 2.1 (b) External dimensions of the battery box
Fig. 2.1 (c) shows dimensions for remote battery box installation.
Holes to prevent fromInterfering

皿ねじ干渉回避用穴 with
M4 bolts (4) countersunk screws2-more
2-O5以上 than φ5
M4 ボルト (4) 91 11
(Outside FANUC
お客様にて用意
delivery scope) 80
Interface
インタフェース 40
40 20
6.5
A
11
80
86.5
91
A Tip of the Notch 切欠き 4-M4

screw
ねじの先端部 6 以上
6mm or more
Cable
ケーブル
O 5
O 4
Detail
詳細A A
Fig. 2.1 (c) Dimensions for remote battery box installation
- 10 -
2.2 REPLACING THE OIL OF THE DRIVE MECHANISM

(1-YEAR (3840 HOURS) CHECKS)
Replace the oil of the reducers of J1, J2, and J3 axes, and the wrist in the cycle that is shorter among every
years and 3840 hours of operating, by using the following procedures.
See Table 2.2 (a) for the oil name and the quantity.
Table 2.2 (a) Oil for 1-year (3840 hours) periodical replacement
Model Supply position Quantity Oil name
J1 to J3-axis reducer Each 530ml
DR-3iB/8L Spec: A98L-0040-0255
Wrist 165ml
For oil replacement or replenishment, use the arbitrary posture.
CAUTION
Failure to supply oil correctly may cause damage to the seal, which would in turn
lead to oil leakage and abnormal operation. When performing oiling, therefore,
observe the following cautions.
1 Use specified oil. Use of non-approved oil may damage the reducer or lead to
other problems.
2 To prevent slipping accidents and catching fire, completely remove any
excess oil from the floor or robot.
Oiling of major axis (common to J1/J2/J3-axis)

1 Turn off the controller power.
2 Confirm the position of reducer referring to Fig.2.2 (a).
3 Remove stainless bolt, cover and gasket referring to Fig. 2.2 (b).
4 Put collection bottle under oil outlet and remove taper plug of oil outlet. After exhausting is started,
open taper plug of ventilator hole. (If ventilator hole is opened before exhausting is started, oil shed.
So open ventilator hole after exhausting is started.)
5 If all oil is exhausted, attach taper plug to oil outlet. .If you reuse taper plug, be sure to seal it with seal
tape.
6 Open oil inlet and ventilator hole and supply regulated amount oil to reducer.
7 Attach taper plug of oil inlet and ventilator hole. .If you reuse taper plug, be sure to seal it with seal
tape.
8 Attach cover and gasket. Replace gasket to new one.
- 11 -
J1
J3
J2
Fig. 2.2 (a) Position of major axis reducer
Ventilator hole Oil inlet

空気抜き穴
taper plug R1/4
給油口
taper plug R3/8
テーパプラグ R1/4 テーパプラグ　R3/8
Oil outlet
Link A gasket
リンクAガスケット Flange bolt 排油口
taper plug R3/8
A290-7525-X212 フランジボルト
M8 x 20 (7) テーパプラグ R3/8
A290-7525-X212 M8X20 (7)
Link A cover
リンクAカバー
Fig. 2.2 (b) Supply oil to major axis
- 12 -
Oiling of wrist axis

1 Turn off controller power.
2 Put collection bottle under oil outlet and remove bolt of oil outlet. Next, remove taper plug of ventilator
hole.hexagonal socket whose width across flat is 17mm can be used open and close taper plug of oil
inlet of wrist.
3 If all oil is discharged, attach bolt to oil outlet. If you reuse bolt, be sure to seal it with seal tape.
4 Open oil inlet and ventilator hole and supply regulated amount oil to wrist unit.
5 Attach taper plug of oil inlet and ventilator hole. If you reuse taper plug, be sure to seal it with seal
tape.
Oil inlet
給油口
Seal bolt M10 x 15
シールボルト M10×15
Ventilator hole
空気抜き穴
Seal bolt M10 x 15
シールボルト M10×15
Oil outlet
排油口
Seal bolt M5 x 10
シールボルト M5X10
Fig. 2.2 (c) Supply oil to wrist axis
2.3 CLEANING AND GREASING OF THE LINK B

(6 MONTHS (1920 HOURS) MAINTENANCE)
Periodic maintenance is required for the link B. Clean and grease it at the intervals based on every 6 months,
1920 hours and cycle whichever comes first. For rust prevention, perform cleaning and greasing even if the
robot is not used for a long term. If there are foreign materials or rust, short the maintenance interval. If the
grease is removed by washing, supply grease with washing.
For applying grease, refer to Table 2.3 (a).
Table 2.3 (a) Grease for 6 months (1920 hours) periodical replacement
Supply position Quantity Remarks
A98L-0040-0187#1KG 1kg
Class H1 food grease
A98L-0040-0187#0.4KG 400g
CAUTION
Failure to follow proper greasing procedures may cause a abnormal operation or
rust. When greasing, observe the following precautions.
(1) Use specified grease. Use of non-approved grease may damage the reducer
or lead to other problems.
(2) To prevent an accident such as a fall or fire, remove all the excess grease
from the floor and robot.
- 13 -
Link B type Maintenance method

Paint/Seal type ⇒”2.3.1 Periodic maintenance procedure for paint/seal type link B”
Paint/Boot type Periodic maintenance is not required.
Plated/Seal type ⇒”2.3.2 Periodic maintenance procedure for plated/seal type link B”
Plated/Boot type ⇒”2.3.3 Periodic maintenance procedure for plated/boot type link B”
2.3.1 Periodic maintenance procedure for paint/seal type link B

1 Clean old grease and foreign material on the ball surface. Foreign materials such as iron powder cause
premature failure of the link ball.
2 Supply about 0.1ml grease with syringe etc.
3 Paste the grease on the ball and no paint part of the shank.
4 Wipe off grease so that grease remains thinly.
If grease is removed by washing etc., for rust prevention, apply grease after washing.
Seal Ball (steel) Grease
Shank part
(steel)
Supply grease on
ボール部に塗布
the ball
図6 拭き取り後の状態
Supply grease on the no
シャンク部無塗装箇所に塗布
paint part of the shank
Fig. 2.3.1 (a) Maintenance procedure for paint/seal type link B
- 14 -
2.3.2 Periodic maintenance procedure for plated/seal type link B

3 Paste the grease on the ball and the shank part.
5 Apply grease to the bolt tip for J1-axis lower side link ball. (Fig. 2.3.2 (b))
Grease
Seal Ball (steel)
Shank part (steel)
Supply grease
on the ball
Supply grease on the shank
Fig. 2.3.2 (a) Maintenance method of the plated/seal type link B
- 15 -
Apply grease on the bolt tip (both side)

ボルト先端にグリースを塗布（両側）
Fig. 2.3.2 (b) Grease applying position for the bolt tip of the plated type link B
- 16 -
2.3.3 Periodic maintenance procedure for plated/boot type link B

3 Paste the grease on the shank part.
5 Apply grease to the bolt tip for J1-axis lower side link ball. (Fig. 2.3.3 (b))
Grease
Boot
Shank part (steel)
Supply grease on the shank
Fig. 2.3.3 (a) Maintenance method of the plated/boot type link B
- 17 -
Apply grease on the bolt tip (both side)

ボルト先端にグリースを塗布（両側）
Fig. 2.3.3 (b) Grease applying position for the bolt tip of the plated type link B
- 18 -
2.4 CLEANING
2.4.1 Cleaning the Robot

DR-3iB can be washed with sprinkling water or cleaner diluted properly when white epoxy painting is
specified.
If strong jet strike robot, it is probable that the jet causes excessive water pressure and destroy waterproof
of robot arm. The water or cleaner should be sprinkled from the shower nozzle.
Stains stuck on the robot surface should be wiped with a cloth. Do not brush robot surface hard, because
brushing has possibility to affect the coating on robot surface and sealing on the robot joints.
Do not sprinkle water or cleaner on the controller. After cleaning, supply grease to the link B with referring
to Section 2.3.
2.4.2 Cleaner (When white painting is specified)

When the White Painting type which is resistant to approved chemicals is specified, the DR-3iB can be
spray washed and kept in sanitary condition by daily cleaning.
The cleaners shown in Table 2.4.2 (a) have been proven to have no harmful effects to the robot surface of
DR-3iB when White epoxy paint is specified. Contact your local FANUC representative for use of cleansers
that are not shown in Table 2.4.2 (a).
Make sure the cleaner is properly diluted. If you use cleaner whose dilution ratio is not correct, it may cause
damage to the robot surface. Please use a cleaner and water at a temperature equal to or less than 50 degrees
Celsius.
Alcohol and organic solvent may have damage the robot surface. Do not use them to clean robot.
Table 2.4.2 (a) Cleaners whose harmlessness for the robot surface is confirmed
DILUTION RATE
NAME MAKER TYPE MAIN INGREDIENT
(NOTE 1)
Geron Ⅳ ANDERSON Sanitizer Quaternary ammonium chloride 0.2%
Reg13 ANDERSON Sanitizer Sodium hypochloride 0.15%
FOMENT ANDERSON Alkali cleaner Potassium hydroxide
1.5%
Sodium hypochlorite
SAN-TEC 5 ANDERSON Acid cleaner Hydrogen peroxide
Acetic acid 0.2%
Peroxyacetic acid
NOTE
1 DILUTION RATE = STOCK SOLUTION / (STOCK SOLUTION+WATER)
2 Acid cleaner have to be rinsed diligently and it should never remain on the robot
surface. Robot surface cannot contact with acid cleaner continuously for over 15
minute.
3 The use of cleaner in Table 2.4.2 (a) might be restricted by the law of the country
or the region, and obtaining is difficult.
4 In case the robot paint got damaged during maintenance work, please carefully
repair that damage. If such paint damage is not repaired, corrosion and chemical
resistance cannot be secured anymore. This repair work is especially important
for the white epoxy paint.
- 19 -
3. TROUBLESHOOTING B-84115EN/01
3 TROUBLESHOOTING
The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems
may become further complicated, if they are not corrected properly. Therefore, you must keep an accurate
record of problems and take proper corrective actions.
3.1 TROUBLESHOOTING
Table 3.1 (a) shows the major troubleshooting that may occur in the mechanical unit and their probable
causes. If you cannot pinpoint a failure cause or which measures to take, contact your local FANUC
representative. For troubleshooting except the mechanical unit, refer to “CONTROLLER
MAINTENANCE MANUAL (B-83195EN etc.)” and Alarm Code List (B-83284EN-1).
Table 3.1 (a) Troubleshooting

Symptom Description Cause Measure
Vibration - The base or pedestal lifts [Base or pedestal fastening] - If a bolt is loose, apply
Noise off the floor plate as the - It is likely that the robot LOCTITE and tighten it to
robot operates. base or pedestal is not the appropriate torque.
- There is a gap between securely fastened to the - Adjust the floor plate
the base or pedestal and floor plate. surface flatness to within
floor plate. - Probable causes are a the specified tolerance.
- The base or stand loose bolt, an insufficient - If there is any foreign
retaining bolt is loose. degree of surface flatness, material between the base
or foreign material caught or pedestal and floor plate,
between the floor plate remove it.
and floor plate.
- If the robot is not securely
fastened to the floor plate,
the base or pedestal lifts
the floor plate as the robot
operates, allowing the
base or pedestal and floor
plates to strike each other
which, in turn, leads to
vibration.
- The rack or floor plate [Rack or floor] - Reinforce the rack or floor
vibrates during robot - It is likely that the rack or to make it more rigid.
operation. floor is not rigid enough. - If reinforcing the rack or
- If the rack or floor is not floor is impossible, modify
rigid enough, counterforce the robot control program;
can deform the rack or doing so might reduce the
floor, and cause vibration. amount of vibration.
- 20 -
B-84115EN/01 3. TROUBLESHOOTING

Vibration - Vibration becomes more [Overload] - Check the maximum load
Noise serious when the robot - It is likely that the load on that the robot can handle.
(Continued) adopts a specific posture. the robot is greater than If the robot is overloaded,
- If the operating speed of the maximum rating. reduce the load, or modify
the robot is reduced, - It is likely that the robot the robot control program.
vibration stops. control program is too - Vibration can be reduced
- Vibration is most demanding for the robot by modifying the robot
noticeable when the robot hardware. teach pendant program ;
is accelerating. - It is likely that the reducing speed or
- Vibration occurs when two acceleration value is acceleration while
or more axes operate at excessive. minimizing the effect on
the same time. the entire cycle time.
- Vibration or noise was first [Broken gear, bearing, or - Operate one axis at a time
noticed after the robot reducer] to determine which axis is
collided with an object or - It is likely that collision or vibrating.
the robot was overloaded overload applied an - Remove the motor, and
for a long period. excessive force on the replace the gear, the
- The grease of the vibrating drive mechanism, thus bearing, and the reducer.
or noise occurring axis has damaging the geartooth For the spec. of parts and
not been exchanged for a surface or rolling surface the method of
long period. of a bearing, or reducer. replacement, contact your
- Cyclical vibration and - Prolonged overloaded use FANUC representative.
noise occurs. may cause fretting fatigue - Using the robot within its
on the gear tooth surface maximum rating prevents
or rolling surface of the problems with the drive
bearing and reducer. mechanism.
- It is likely that a foreign - Regularly changing the oil
material caught in a gear, with a specified type can
bearing, or within a help prevent problems.
reducer has damaged
the gear tooth surface or
rolling surface of the
bearing, or reducer.
- It is likely that a foreign
material caught in a gear,
bearing, or within a
reducer is causing
vibration.
- It is likely that, because
the oil 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 or
inadequate lubrication.
- 21 -

Vibration - The cause of problem [Controller, cable, and motor] - Refer to the Controller
Noise cannot be identified from - If a failure occurs in a Maintenance Manual for
(Continued) examination of the floor, controller circuit, troubleshooting related to
rack, or mechanical preventing control the controller and
section. commands from being amplifier.
supplied to the motor - Replace the motor of the
normally, or preventing axis that is vibrating, and
motor information from check whether vibration
being sent to the controller still occurs. For the
normally, vibration might method of replacement,
occur. contact your local
- If the Pulsecoder develops FANUC representative.
a fault, vibration might - If vibration occurs only
occur because information when the robot assumes a
about the motor position specific posture, it is likely
cannot be transferred to that a cable in the
the controller accurately. mechanical unit is broken.
- If the motor becomes - Check whether the sheath
defective, vibration might of the cable connecting
occur because the motor the mechanical section
cannot deliver its rated and controller is damaged.
performance. If so, replace the
- If a power line in a connection cable, and
movable cable of the check whether vibration
mechanical section has an still occurs.
intermittent break, - Check whether the sheath
vibration might occur of the power cord is
because the motor cannot damaged. If so, replace
accurately respond to the power cord, and check
commands. whether vibration still
- If a Pulsecoder wire in a occurs.
movable part of the - Check that the robot is
mechanical section has an supplied with the rated
intermittent break, voltage.
vibration might occur - Check that the robot
because commands control parameter is set to
cannot be sent to the a valid value. If it is set to
motor accurately. an invalid value, correct it.
- If a connection cable Contact your local FANUC
between them has an representative for further
intermittent break, information if necessary.
vibration might occur.
- If the power cable
between them has an
intermittent break,
vibration might occur.
- If the power source
voltage drops below the
rating, vibration might
occur.
- If a robot control
parameter is set to an
invalid value, vibration
might occur.
- 22 -

Vibration - There is a relationship [Noise from a nearby machine] - Connect the grounding
Noise between the vibration of - If the robot is not wire firmly to ensure a
(Continued) the robot and the grounded properly, reliable ground potential
operation of a machine electrical noise can be and prevent extraneous
near the robot. induced on the grounding electrical noise.
wire, preventing
commands 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 causing it to
vibrate.
Rattling - While the robot is not [Mechanical section coupling - Check that the following
supplied with power, bolt] bolts for each axis are
pushing it with the hand - It is likely that overloading tight. If any of these bolts
causes part of the or a collision has loosened is loose, apply LOCTITE
mechanical unit to wobble. a mounting bolt in the and tighten it to the
- There is a gap on the robot mechanical section. appropriate torque.
mounting face of the - Motor retaining bolt
mechanical unit. - Reducer retaining bolt
- Base retaining bolt
- Arm retaining bolt
- Casting retaining bolt
- End effector retaining
bolt
- Backlash is greater than [Increase in backlash] - Operate one axis at a time
the allowance stated in the - It is likely that excessive to determine which axis
applicable maintenance force applied to the drive has the increased
manual. mechanism, due to a backlash.
(See Section 3.2) collision or overloading, - Remove the motor, and
has broken a gear or the check whether any of its
inside of the reducer, gears are broken. If any
resulting in an increase in gear is broken, replace it.
the amount of backlash. - Check whether any other
- It is likely that prolonged gear of the drive
use has caused the tooth mechanism is damage. If
surfaces of a gear and the there is no damage gear,
inside of the reducer to replace the reducer.
wear out, resulting in an - After replacing the gear or
increase in the amount of reducer, add an
backlash. appropriate amount of
- It is likely that prolonged grease or oil.
use without changing the - Using the robot within its
grease has caused the maximum rating prevents
tooth surfaces of a gear problems with the drive
and the inside of the mechanism.
reducer to wear out, - Regularly applying the
resulting in an increase in grease or oil with a
the amount of backlash. specified type can help
prevent problems.
- 23 -

Rattling - There is lost motion in the [Damage to the bearing, - Check the movement of
bearing of a joint release of the pre-load] the joints during operation
- A probable cause is that to identify the faulty joint.
excessive force was
applied to the bearing of
the joint due to impact or
overload, damaging the
bearing or releasing the
pre-load.
Motor over- - The ambient temperature [Ambient temperature] - Reducing the ambient
heating of the installation location - It is likely that a rise in the temperature is the most
increases, causing the ambient temperature effective means of
motor to overheat. prevented the motor from preventing overheat.
- After the robot control releasing heat efficiently, - If there is a source of heat
program or the load was thus leading to near the motor, it is
changed, the motor overheating. advisable to install
overheated. [Operating condition] shielding to protect the
- It is likely that the robot motor from heat radiation.
was operated with the - Relaxing the robot control
maximum average current program and the load
exceeded. condition is an effective
way to reduce the average
current, thus preventing
overheat.
- The teach pendant can
monitor the average
current. Check the
average current when the
robot control program
launched.
- After a control parameter [Parameter] - As for load setting, Input
(load setting etc.) was - If data input for a an appropriate parameter
changed, the motor workpiece is invalid, the referring to Section 4.3.
overheated. robot cannot be
accelerated or decelerated
normally, so the average
current increases, leading
to overheating.
- 24 -

Motor over- - Symptom other than [Mechanical problems] - Repair the mechanical unit
heating stated above - It is likely that problems while referring to the
occurred in the above descriptions of
mechanical unit drive vibration, noise, and
mechanism, thus placing rattling.
an excessive load on the - Check that, when the
motor. servo system is energized,
[Motor problems] the brake is released.
- It is likely that a failure of If the brake remains
the motor brake resulted in applied to the motor all the
the motor running with the time, replace the motor.
brake applied, thus placing - If the average current of
an excessive load on the the motor decreases after
motor. replacement, then the
- It is likely that a failure of former motor was
the motor prevented it defective.
from delivering its rated - If the cooling fan is
performance, thus causing broken, replace it with a
an excessive current to new one.
flow through the motor.
- It is likely that cooling fan
is broken. (J1 to J3-axis)
Oil leakage - Oil is leaking from the [Poor sealing] - If a crack develops in the
mechanical unit. - Probable causes are a casting, sealant can be
crack in the casting, a used as a quick-fix to
broken O-ring, a damaged prevent further oil leakage.
oil seal, or a loose seal However, the component
bolt.
should be replaced as
- A crack in a casting can
soon as possible, because
occur due to excessive
force that might be caused the crack might extend.
in collision. - Oil seals are used in the
- An oil seal might be locations stated below.
damaged if extraneous - Inside the reducer
dust scratches the lip of - Inside the wrist
the oil seal.
Grease - Grease leaks from the - Rubber boot of the Link - Confirm that the rubber
leakage mechanical unit. Ball may be broken. boot of the Link Ball is
broken. If it is broken,
replace the Link Ball
Dropping - An axis drops because the [Brake drive relay and motor] - Check whether the brake
axis brake does not function. - It is likely that brake drive drive relay contacts are
- An axis drops gradually relay contacts are stuck to stuck to each other. If they
when it should be at rest. each other to keep the are found to be stuck,
brake current flowing, thus replace the relay.
preventing the brake from
- Replace the motor after
operating when the motor
confirming whether the
is deenergized.
- It is likely that the brake following symptoms have
shoe has worn out or the occurred.
brake main body is - Brake shoe is worn
damaged, preventing the out
brake from operating - Brake main body is
efficiently. damaged
- It is likely that oil - Oil penetrated the
penetrated the motor, motor
causing the brake to slip.
- 25 -

Displacement - The robot operates at a [Mechanical unit problems] - If the robot is not
point other than the taught - If the robot is not repeatable, repair the
position. repeatable, probable mechanical unit by
- The repeatability is not causes are a failure in the referring to the above
drive mechanism or a descriptions of vibration,
within the tolerance.
loose bolt. noise, and rattling.
- If the robot is repeatable, it - If the robot is repeatable,
is likely that a collision correct the taught
caused slip on the fasting program. The problem will
surface of each axis arm, not reoccur unless another
and reducer. collision occurs.
- It is likely that the - If the Pulsecoder is faulty,
Pulsecoder is faulty. replace the motor.
- Displacement occurs only [Peripheral unit displacement] - Correct the setting of the
in a specific peripheral - It is likely that an external peripheral unit position.
unit. force was applied to the - Correct the taught
peripheral unit, thus program.
shifting its position relative
to the robot.
- Displacement occurred [Parameter] - Re-enter the previous
after a parameter was - It is likely that the optimal mastering data.
changed. mastering data was - If correct mastering data is
overwritten moving the unavailable, perform
robot’s origin. mastering again.
CLALM - Ambient temperature of [Peripheral temperature] - Perform a warm up
alarm the robot installation - When the robot is used in operation or a low speed
occurred. location is low, CLALM a low temperature operation for several
Move error alarm is displayed on the environment that is near to minutes.
excess alarm teach pendant screen. 0ºC, or the robot is not
occurred. - Temperature of the robot operated for a long time in
installation position is low, an environment that is less
“Move error excess” alarm than 0ºC, there will be a
is displayed on the teach large viscous resistance of
pendant screen. the drive train immediately
after starting which will
cause the alarm.
- After changing the motion - It is likely that a robot - If a robot collision has
program or the load collision occurred. occurred, press the
condition, the CLALM [RESET] key while
alarm is displayed. pressing the [SHIFT] key.
- After changing the motion Then, jog the robot in the
program or the load opposite direction while
condition, the “Move error pressing the [SHIFT] key.
excess” alarm is - Check the motion
displayed. program.
- 26 -

CLALM [Overload] - Check the permissible
alarm - It is likely that load value of the robot payload.
occurred. exceeded the permissible If the load exceeds the
Move error value. permissible value, reduce
excess alarm - It is likely that the motion the load or change the
occurred. program is too severe for motion program.
the robot. - Consider minimizing the
 Excessive motion due cycle time by reducing the
to a large “ACC speed or acceleration, and
(value)”. changing the motion
 Tight motion such as program.
reverse motion using - Check that the load setting
“CNT”. is performed correctly.
 Linear motion occurs
near singularity point
where axes revolve in
high speed.
- None of the symptoms - It is likely the vibration - Refer to the Symptoms:
stated above are the occurred. Vibration, Noise section of
problem. this troubleshooting for
more information.
- If the power source - Check that the robot is
voltage drops below the supplied with the proper
rating, a vibration might rated voltage.
occur.
BZAL alarm - BZAL is displayed on the - It is likely that the voltage - Replace the battery.
occurred teach pendant screen of the memory backup - Replace the cable.
battery is low.
- It is likely that the
Pulsecoder cable is
defected.
- 27 -
3.2 BACKLASH MEASUREMENT

Measurement method
Move robot to ±1º or more to each axis direction and measure backlash. Measure backlash by applying
positive and negative loads to each axis three times. Average the values measured in the last two
measurements for each axis, and use the averages as a measured backlash for the respective axes.
5mm or more 5mm or more

or 1°以上 or1°以上
1º or more 1º or more
Position
原位置合せ
of 0 positiont
測定 Measurement
Backlash
バックラッシ
Position
of原位置合せ
0 positiont
測定 Measurement
Backlash
バックラッシ
Fig. 3.2 (a) Backlash measurement method
Table 3.2 (a) Backlash measurement position (DR-3iB/8L)

Posture
Measurement axis
J1-axis J2-axis J3-axis J4-axis
J1-axis 0º 0º 0º Arbitrary
- 28 -
J1リンクB
J1 link B
J1 measurement position
J1測定位置
J3リンクB
J3 link B
J2リンクB
J2 link B
J2J2測定位置
measurement J3
J3測定位置
position measurement
position
40
J4 measurement position
J4測定位置
Fig. 3.2 (b) Measurement position (DR-3iB/8L)
- 29 -
Table 3.2 (b) Backlash allowance (DR-3iB/8L)

Measurement distance Backlash allowance
J1-axis - 0.8mm
J2-axis - 0.8mm
J3-axis - 0.8mm
J4-axis 40mm 0.5mm
Measurement Conditions
Teaching speed: Each axis: 1%
OVR: 100%
- 30 -
B-84115EN/01 4. REPLACING PARTS
4 REPLACING PARTS
Mastering is required inevitably after replacing parts like Motors, Reducer, Universal Joint, Driveshaft, J4
motor unit, Link Ball and Wrist unit. Perform the Mastering referring to Chapter 6.
NOTE
1 When applying LOCTITE to a part, spread the LOCTITE on the entire length of
the engaging part of the female thread. If applied to the male threads, poor
adhesion can occur potentially loosening the bolt. Clean the bolts and the
threaded holes and wipe off the oil on the engaging section. Make sure that
there is no solvent left in the threaded holes. In this case, remove all the excess
LOCTITE when you are finished screwing the bolts into the threaded holes.
2 Description of [LT243] means LOCTITE 243.
Description of [LT263] means LOCTITE 263.
3 Assemble new O-rings and gaskets and seal bolts to ensure dust-proof and drip-
proof performance after removing the parts.
4 When removing or mounting a motor, apply force only in the shaft direction. If
excessive force is applied in any other direction, the motor and/or reducer may
be damaged.
5 If a motor and associated parts to be assembled are not aligned properly,
assembly might prove impossible. Carefully check the state of the parts before
removing them.
6 Observe the specified tightening torque strictly if it’s specified. If not specified,
refer to the tightening torque specified in the APPENDIX D.
- 31 -
4. REPLACING PARTS B-84115EN/01
4.1 FIGURE OF DRIVE MECHANISM

The drive mechanisms of each axis are shown in the following figures.
Reducer
Motor
Fig. 4.1 (a) Drive mechanism of J1/J2/J3-axis
Motor
Reducer
Universal
joint
Wrist unit
Fig. 4.1 (b) Drive mechanism of J4 axis
- 32 -
4.2 MECHANICAL UNIT CONFIGURATION

Fig. 4.2 (a) shows mechanical unit configuration.
J1 link B
J1リンクB
Connector
分線板 plate
J2リンクB
J2 link B J3 link B
J3リンクB
J3 link A
J3リンクA
J1 link AA
J1リンク
J2 link A
J2リンクA
J2 link B
J2リンクB
AC servo motor for J4-axis
J4軸用ACサーボモータ
J3J3リンクB
link B
J1 link B
J1リンクB
J4-axis universal joint

J4軸ユニーバサルジョイント End effector mounting face
エンドエフェクタ取付面


Fig. 4.2 (a) Mechanical unit configuration
- 33 -
4.3 REPLACING THE J1/J2/J3-AXIS MOTOR (M1/M2/M3)

1 Set a dial gauge to axis of motor to be replaced, and prepare for single axis mastering after replacement.
3 Drain oil referring to Section 2.2.
4 Remove the bolts (1) and the gearbox cover (2).
5 Remove the motor connector.
6 Remove bolt (4) and the motor (5).
7 Attach the key (6), the gear (7), the spring washer (8) and the nut (9) to the new motor (5).
8 Replace the O-ring (10) with a new one and attach it to correct position and assemble them applying
the procedure in the reversed sequence.
9 Supply oil referring to Section 2.2.
10 Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the
MECHANICAL UNIT OPERATOR’S MANUAL (B-84114EN).
10
9
8 7 5
6
2
4
Fig. 4.3 (a) Replacing the J1/J2/J3-axis motor (Figure is example of J2-axis)
Parts are common in J1/J2/J3-axis motor. The parts are showed for one axis.
Parts name Specifications Q’ty Locking Torque (N-m )

1 WASHER BOLT A97L-0318-0516#M8X30 8 13.0
A290-7525-X204 or
2 GEARBOX COVER 1
A290-7525-Y204
3 GASKET A290-7525-X208 1
4 BOLT A6-BA-8X25 4
5 MOTOR A06B-2049-B605 1
6 KEY Motor appendix 1
7 GEAR A290-7525-X234 1
8 SPRING WASHER Motor appendix 1
9 NUT Motor appendix 1 LT243 16.7
10 O-RING JB-OR1A-120 1
- 34 -
4.4 REPLACING THE J1/J2/J3-AXIS REDUCER

3 Drain oil referring to Section 2.2.
4 Remove the motor of the replaced axis referring to Section 4.3.
5 Remove the link B referring to Section 4.7.
6 Remove bolts (1), the cover (2) and the gasket (3).
7 Remove bolts (4). Then remove the link A (5).
8 Remove bolts (6). Then remove the reducer (8).
9 Replace reducer by new one and assemble it applying the procedure in the reversed sequence. Replace
the O-ring (7), (9) with new one and attach them to correct position.
10 Attach the link A (5). Wipe of grease of the oil seal lip and the lip contact surface. Then apply new
grease. The gasket can be reused.
11 Attach the motor and the gearbox cover referring to Section 4.3.
12 Supply oil referring to Section 2.2.
Oil seal lip

オイルシール
contact surface
リップ接触部
8
6
9
4
Oil seal
オイルシール 5 3 2
lip
リップ部 7
1
Fig. 4.4 (a) Replacing the J1/J2/J3-axis reducer
Parts are common in J1/J2/J3-axis motor. Table below is about one motor.
Parts name Specifications Q’ty Locking Torque (N-m )

FLANGE SOCKET
1 A97L-0218-0591#M8X20 7 13.0
BOLT
2 LINK A COVER A290-7525-X209 or A290-7525-X210 1
3 GASKET A290-7525-X212 1
4 BOLT A6-BA-8X25 21 37.2
5 LINK A A290-7525-X205 1
6 BOLT A6-BA-6X65 20 15.6
7 O-RING JB-OR1A-G120 1
8 REDUCER A97L-0218-0894#32N 1
9 O-RING JB-OR1A-G105 1
- 35 -
4.5 REPLACING THE J4 MOTOR UNIT

The J4 motor unit includes the J4 -axis motor and the reducer.
Refer to Section 4.6 about replacing only the J4 -axis motors or only the reducers.
1 Set the dial gauges at the J4-axis, and prepare for single axis mastering after replacement.
2 Move robot to J1=J2=J3=0º (recommended), then turn off controller power.
3 Remove the drive shaft and the rod support kit referring to Section 4.9, 4.10.
4 Remove the cables from the J4 motor unit referring to Chapter 5.
5 Remove upper side bolts (1). Then remove the wrist motor unit.
6 Attach the new wrist motor unit.
7 Attach the drive shaft and the rod support kit referring to Section 4.9, 4.10.
8 Attach the wrist cable referring to Chapter 5.
MECHANICAL UNIT OPERATOR’S MANUAL (B-84114EN) and the witness mark.
1
2
Fig. 4.5 (a) Replacing the J4 motor unit
Parts name Specifications Q’ty Locking Torque (N-m)

1 BOLT A6-B-6X30S 5 LT243 5.5
2 PIN JB-PH-H7B-4X10S45C 2
- 36 -
4.6 REPLACING THE J4 -AXIS MOTOR AND THE REDUCER

The J4 motor unit includes the J4-axis motor and the reducer.
Refer to Section 4.5 about replacing procedure of the J4 motor unit.
1 Set a dial gauge to J4 -axis, and prepare for single axis mastering after replacement.
3 Remove the J4 motor unit referring Section 4.5. Removing the J1B SUPPORT KIT of Section 4.10 is
not required.
4 Remove the flange bolt (1). Then remove the casing (2).
5 Remove bolts (16). Then remove the motor (14).
6 Remove bolts (11). Then remove the reducer (8) from the casing (2).
7 Replace the reducer (8) by new one. And attach the parts such as the adapter (7) and the spline adapter
(5). Apply grease on the O-ring (12), and attach it.
8 Attach the key (13) to the new motor (14). And attach it to the reducer (8) with motor mounting bolts
(16). In this time, be careful the two screws (10) do no interfere wire the motor shaft. If interference
may occur, remove the plug (9), then loosen the screws (10). You can adjust the screw position by
sandwiching the two surfaces of the adapter (7) with a spanner.
9 Tighten two screw (10). Then attach the plug (9).
10 Attach the reducer (8) on the casing (2) with bolts (11).
11 Attach the casing (2) with flange bolts (1).
12 According to Section 4.5, attach the J4 motor unit to the specified position.
13 According to Section 4.9, attach the drive shaft and the support kit.
14 According to Chapter 5, attach the wrist cable.
2 1
3
9
10 8 7 5
14 12
15 4
6
13
11
16
Fig. 4.6 (a) Replacing the J4-axis motor and reducer

1 FLANGE BOLT A97L-0218-0591#M5X20 4 LT243 3.2
2 CASING A290-7525-X301 1
3 GASKET A290-7525-X314 1
4 BOLT A6-BA-4X14 6 LT243 4.5
5 SPLINE ADAPTER A290-7525-X317 1
6 BOLT A6-BA-4X14 6 LT243 4.5
7 ADAPTER A290-7525-X316 1
8 REDUCER A97L-0218-0283#9 1
9 PLUG Reducer appendix 1
10 SET SCREW Reducer appendix 2 LT243 2.0
11 BOLT A6-BA-5X20 4 LT243 6.3
12 O-RING Reducer appendix 1
- 37 -

LT638
13 KEY JB-HKY-3X3X12B 1 motor shaft side
only
14 MOTOR A06B-0116-B205#0048 1
15 PIN JB-PH-H7B-4X10S45C 2
16 BOLT A6-BA-5X16 4 LT243 5.6
4.7 REPLACING THE LINK B

For the Link without wrist axis drive shaft (J2/J3-link)
2 Move robot to J1=J2=J3=0º(recommended), then turn off controller power.
3 Sandwich the plane part of the spacer (3), remove the bolt (1). Then remove the support kit (2).
4 Remove the opposite side support kit (2). Removing the spacer is not required.
5 Loosen the hexagon bolts of the link ball at the link B upper side and the lower side of Fig. 4.7 (a).
Then remove the link B (4).
6 Clean the tap hole. Then replace the link B by new one.
7 Apply LOCTITE 243 to the pin tip of the link B as shown in Fig. 4.7 (a). (See Fig. 4.7 (b)).
Then assemble it the reversed sequence.
8 Perform single axis mastering for replaced axis and J4-axis. Refer to the SINGLE AXIS
MASTERING section of the MECHANICAL UNIT OPERATOR’S MANUAL (B-84114EN) and
the witness mark.
Hexagon
六角ボルト bolt part
4
2
Pin
ピン
Fig. 4.7 (a) Replacing the J2, J3 ink B

1 BOLT A6-B-5X20SUS 2 LT243 3.2
2 J23 SUPPORT KIT A05B-1525-K307 2
3 SPACER A290-7525-X320 2
LINK B A290-7525-V311,V312, V313, V314 2 LT243 29
4
WASHER A97L-0318-0431#10018016 4
- 38 -
LT243
B
A LT243
LT243
A
Loctite 243 applying area
LT243塗布範囲
Detail B
6詳細B
places
LT243 6か所
Section A-A
断面 A-A
Fig. 4.7 (b) LOCTITE 243 applying area (example of the J1 link)
- 39 -
For the Link with wrist axis drive shaft (J1-link)

3 According to Section 4.9, 4.5 and Chapter 5, remove the drive shaft, the support kit, the J4 motor cable
and the J4 motor unit.
4 Sandwich the plane part of the spacer (3), remove the bolt (1). Then remove the support kit (2).
5 Remove the opposite side rod support kit (2). Removing the spacer is not required.
6 Loosen the hexagon bolts of the link ball at the link B upper side and the lower side as shown in Fig.
4.7 (c). Then remove the link B (4).
7 Clean the tap hole. Then replace the link B by new one.
8 Apply LOCTITE 243 to the pin tip of the link B as shown in Fig. 4.7 (c). (See Fig. 4.7 (b)).
Then assemble it the reversed sequence.
9 Perform single axis mastering for replaced axis and J4-axis. Refer to the SINGLE AXIS
MASTERING section of the MECHANICAL UNIT OPERATOR’S MANUAL (B-84114EN) and
the witness mark.
Hexagon 六角ボルト
bolt part
ピン
Pin
2
1
Fig. 4.7 (c) Replacing the J1 link B

1 BOLT A6-B-5X20SUS 2 LT243 3.2
2 J1A SUPPORT KIT A05B-1525-K304 2
3 SPACER A290-7525-X320 2
LINK B A290-7525-V311,V312, V313, V314 2 LT243 29
4
WASHER A97L-0318-0431#10018016 4
- 40 -
4.8 REPLACING THE UNIVERSAL JOINT

3 Remove the four set screws (1).
Fig. 4.8 (a) Replacing universal joint

1 SET SCREW A6-SAKT-8X8SUS 4 LT243 12
4 According to Section 4.9, remove the drive shaft.

5 Pull out the universal joint from the wrist unit shaft.
6 Attach the new universal joint. As with Fig. 4.9 (f), hit the screw on the shaft plane part. You can
adjust exactly by using the universal joint height adjustment fixture. (See Fig. 4.8 (d)) Apply
LOCTITE 243 on the screws and tighten them with regulated torque.
7 According to Section 4.9, attach the drive shaft and the rod support kit in the reversed sequence of the
disassembling.
8 Perform single axis mastering for replaced axis. Refer to the SINGLE AXIS MASTERING section of
the MECHANICAL UNIT OPERATOR’S MANUAL (B-84114EN) and the witness mark.
Universal joint height

ユニバーサルジョイント高さ調整冶具
Adjustment fixture
A290-7525-X920
A290-7525-X920
Fig. 4.8 (d) Universal joint height adjuster fixture
- 41 -
4.9 REPLACING THE DRIVE SHAFT

2 Move robot to J1=J2=J3=0º (recommended). Turn off controller power.
3 Remove the set screw which connect universal joint and drive shaft.
Fig. 4.9 (a) Replacing the drive shaft

1 SET SCREW A6-SAKT-8X8SUS 2 LT243 12
4 Remove bolts (2). Then remove the plate (3).
3
3
2
2
3 3
2
Fig.4.9 (b) Removing the metal plate for the rod support kit fixation

2 BOLT A6-B-4X10SUS 8 LT243 1.5
3 PLATE A290-7525-X324 4
4 RUBBER SLEEVE A290-7525-X329 4
- 42 -
(4)
J1B support kit
J1B サポートキット
A290-7525-V305
A290-7525-V305
Slit
スリット
J1C support kit

J1C サポートキット
A290-7525-V306
A290-7525-V306
Fig. 4.9 (c) Removing the rod support kit
5 Pull out the support kit J1B, J1C which have a slit side to outer side. While inclining the support kits,
remove both side link B. (See Fig. 4.9 (c))
6 Pull out the drive shaft from the universal joint while pulling the drive shaft to the motor side.
Then pull out the drive shaft from the J4 motor unit.
7 Remove bolts (5). Then remove the plate (6) and the J1C support kit (7) from the drive shaft.
Then remove the rubber ring on the bearing.
5
6
8
7
Fig. 4.9 (d) Removing the J1C support kit

5 BOLT A6-B-4X10SUS 4 LT243 1.5
6 PLATE A290-7525-X327 1
7 J1C SUPPORT KIT A05B-1525-K306 1
8 RUBBER RING A290-7525-X326 1
- 43 -
8 Attach the rubber ring (8) on the bearing of the new drive shaft. (See Fig.4.9 (e))
9 Apply grease to the spline of the new drive shaft, oil seal lip contact surface and outer circumference
of the rubber ring. (See Fig. 4.9 (f))
10 Insert the bearing with the rubber ring (8) to the hole at the J1C support kit center. (See Fig.4.9 (g))
Tighten the plate (6) with M4 bolt which length is more than 16mm. If the bolt is tightened one by
one, the bearing is installed with inclined status. So tighten four bolts evenly.
11 If the M4 bolts reached the tap hole bottom, replace it with the M4 bolt which length is 10mm. Then
tighten four bolts evenly. Then insert the rubber ring to the end.
12 After insert, remove M4 bolts one by one and replace them with bolts (5). Tighten bolts (5). Then fix
the J1C support kit center part.
13 Rotate the J1C support kit. Then confirm the drive shaft is fixed on the J1C support kit center. If it is
installed in the inclined status, repeat the procedure 10 to 12. You can assemble it if the rubber ring
install fixture is used.
Make the rubber ring smaller side to the lower side

ゴムリングは内径の小さいほうを下にして被せる
when assembling. 　　　
Fig. 4.9 (e) Attaching the rubber ring
Spline
スプライン
Oil seal lip contact surface
オイルシールリップ接触面
Rubber ring outer

ゴムリング外周
circumference
Fig. 4.9 (f) Grease applying area
- 44 -
Rubber ring insert fixture 2

ゴムリング圧入治具2
A290-7525-X939
A290-7525-X939
Rubber ring insert fixture 1

ゴムリング圧入治具1
A290-7525-X938
A290-7525-X938
Fig. 4.9 (g) Inserting the rubber ring
14 Insert the drive shaft spline to the J4 motor unit.

15 Insert the drive shaft to the universal joint. Hit the screw on the drive shaft plane part and tighten it.
(See Fig. 4.9 (a), (h).)
16 Attach the support plate in the reversed sequence of the disassembling procedure. Fi the support plate
on the link B so that both sides become same length. (See Fig. 4.9 (i))
17 Clean the tap hole. Then attach the bolts (2) and the plate (3). Apply LOCTIE 243 on the bolts and
tighten them with regulated torque.
18 Perform single axis mastering for J4-axis. Refer to the SINGLE AXIS MASTERING section of the
Drive shaft
ドライブシャフト
Put the drive shaft
ドライブシャフトをこの面に
to this surface
突き当てること Universal joint
ユニバーサルジョイント
A A
Put the screws

止めねじはドライブシャフト
to the plane part
平面部に突き当てること
断面 A-A
Section A-A
Fig.4.9 (h) Inserting position of the drive shaft
- 45 -
Make both side
412.4
両側を同じ長さにすること
to equal lenght
556.5
Make both side

両側を同じ長さにすること
to equal lenght
Fig.4.9 (i) Height adjustment of the rod support kit
4.10 REPLACING THE ROD SUPPORT KIT

1 According to Section 4.9. remove the drive shaft and the J1C support kit.
2 Remove the bolts (1). Then remove the J1B support kit (2).
3 According to Section 4.9, attach the drive shaft.
Fig. 4.10 (a) Removing the J1B support kit

1 BOLT A6-B-6X30SUS 4 LT243 5.5
J1B ROD SUPPORT
2 A05B-1525-K305 1
KIT
- 46 -
4.11 REPLACING THE WRIST UNIT

3 Put a table under the wrist to place the wrist unit which is separated from main body.
4 Remove the set screw referring to Section 4.8 and remove drive shaft and universal joint.
5 Remove Link B referring to Section 4.7 and separate it from wrist unit.
6 Replace the writ unit by new one and assemble it applying the procedure in the reversed sequence.
Pay attention to the mounting phase referring to Fig. 4.11 (a).
7 Perform single axis mastering for J4-axis. Refer to the SINGLE AXIS MASTERING section of the
J3 J2
J1
J4-axis
J4軸モータ motor
Detail
詳細AA
Assemble them in this phase.
この位相で組み付けること
Fig. 4.11 (a) Replacing the wrist unit
- 47 -
4.12 REPLACING THE FAN (OPTION)

Replacing method and replacing parts are common to J1 to J3-axes.

2 Remove the robot connection cable.
3 Remove the bolts (1). Then remove the gearbox cover (2)
4 Remove the motor power connector and the brake connector.
5 Remove the fan connection cable.
6 Remove the bolts (4). Then remove the fan assembly (5).
7 Replace the fan assembly (5) by new one. Then assemble it in the reversed sequence.
5
3
2
4
Brake connector
ブレーキコネクタ
1
Power connector
動力コネクタ
Fig. 4.12 (a) Replacing the fan

1 BOLT A6-B-8X30SUS 8 13.0
2 GEARBOX COVER A290-7525-X204 1
3 G.COVER PACKING A290-7525-X208 1
4 BOLT A6-BA-6X12 2
5 FAN MOTOR ASSY A290-7525-V205 1
- 48 -
B-84115EN/01 5. REPLACING CABLES
5 REPLACING CABLES
Replace the cables every two years or 7680 hours, whichever comes first. When the cable is broken or
damaged, replace it according to the procedure described in this chapter.
Precautions to be observed when handling the Pulsecoder cable

The Pulsecoder cable is provided with a marking tie, as shown below, to warn against disconnecting the
cable during transportation, installation, or maintenance.
If the cable with the marking tie is disconnected, mastering must be performed again. Therefore, do not
disconnect the cable except when replacement of the motor, the Pulsecoder, the reducer, and the cable are
necessary.
BATTERY BACKUP
DON'T
DISCONNECT
コネクタ取外不可
Fig. 5 (a) Marking label
If there is a break in or any other damage to a cable, replace the cable according to the procedure described
in this chapter. If the Pulsecoder connector of a motor cable is detached, the data about the absolute
position of the robot will be lost. Once any of these cables is replaced, perform quick mastering while
referring to Mastering Chapter of the MECHANICAL UNIT OPERATOR’S MANUAL (B-84114EN). If
the data is lost because of a break in a cable, also perform mastering to calibrate the robot into the previous
absolute position.
- 49 -
5. REPLACING CABLES B-84115EN/01
5.1 CABLE FORMING

Fig. 5.1 (a),(b) show cable forming.
Cable
ケーブル K102K102
A660-8021-T572
A660-8021-T572
Cable K101
ケーブルK101
A660-8021-T571
A660-8021-T571
M1
Clamp plate
クランププレート
Washer bolt A290-7525-X223
A290-7525-X223
ワッシャボルト
M6 x 12 (2) Bolt
ボルト M6M6X12
X 12 (2)(2)
M6X12 (2)
M3
Clamp plate
A290-7525-X223
A290-7525-X223
Bolt
ボルト XM6X12
M6 12 (2) (2)
Fix the marked positon with
マーキングされている箇所を金属検出
Material detection cable tie (MCTS150)
ケーブルタイ(MCTS150)で固定
M2
Clamp plate
A290-7525-X223
A290-7525-X223 Section
断面A-A A-A
Bolt
ボルトXM6X12
M6 12 (2) (2)
A A
B B
Fig. 5.1 (a) Cable forming (1/2)
- 50 -
Connector direction
コネクタキー向き
詳細
Detail C C
No.1 pin
1番ピン
1番ピン
No.1 pin
Cable K131
ケーブル K131 Section B-B
A660-8016-T498#L5R003
A660-8016-T498#L5R003 断面 B-B
Fig. 5.1 (b) Cable forming (2/2)
- 51 -
5.2 CABLE REPLACEMENT

Replacing cables of base part
1 Set the Quick Master Reference Position. Refer to the QUICK MASTERING, sections of the
MECHANICL UNIT OPERATOR’S MANUAL (B-84114EN).
3 Remove the flange bolt M8 x 20 (24 pcs) and washers which fix the two connector plates and the plate.
4 Remove the stainless bolts which fix the connector cover.
5 Remove bolt M6 x 12 which fixes housing HARTING connectors and drop insert of HARTING
connectors with cables to inside of base.
6 Remove bolts M3 x8 which fix the battery cable connection connector.
7 Cut the cable tie which fix the cables on the clamp. (See Fig. 5.1 (a).)
8 Remove the relay connector to the J4 motor cable. (See Fig. 5.2 (b).)
9 According to Section 4.3, remove the major axis motor cover, then remove the major axis motor
connector.
10 If replacing the battery cable K131, remove it from the connector plate and the battery box. (See Fig.
5.1 (b).
11 Replace cables by new article and fix it with cable tie and assemble it as before. (See Fig. 5.1 (a),(b))
12 Perform quick mastering. Refer to the QUICK MASTERING sections of the MECHANICAL UNIT
OPERATOR’S MANUAL (B-84114EN).
Replacing movable part cable ofJ4 axis motor

2 According to Fig. 5.2 (c), remove flange bolt M5 x 12 (4 pcs) which fix the plate. Then remove the
plate.
3 According to Fig. 5.2 (d), remove the stainless bolts M4 x 25 (4 pcs) which fix the clamp and the bolts
M5 x 10 (2 pcs) which fix the metal plate and the washer bolts which fix the earth line. Then remove
the motor connector.
4 According to Fig. 5.2 (e), remove hexagon bolts M6 x 16 (4 pcs) which fix the link A and cables.
5 Replace cable by new one and assemble it applying the procedure in the reversed sequence. Reuse
clamp and bolts.
6 Perform single axis mastering for J4 -axis. Refer to the SINGLE AXIS MASTERING section of the
MECHANICAL UNIT OPERATOR’S MANUAL (B-84114EN) and witness mark.
- 52 -
Bolt M6 x 12
ボルト(4)
TighteningM6x12
torque(4)3.0Nm Bolt (2)
締付けトルク 3.0Nm ボルト (2)
Tightening torque 4.0Nm
締付けトルク 4.0Nm
Cover
カバー
Bolt M6 ボルト
x 12 (8) Washer
ワッシャ
Tightening torque
M6x12 (8) 3.0Nm
締付けトルク 3.0Nm Housing
ハウジング
Insert
インサート
Flange bolt M8 x 20 (8)
フランジボルト
Tightening
M8x20　(8) torque 13.0Nm
締付けトルク 13Nm
Connector
分線板 plate
Washer
ワッシャ A290-7525-X215
A290-7525-X215
Connector
分線板 plate
Gasket
ガスケット
A290-7525-X214
A290-7525-X214 A290-7525-X216
A290-7525-X216
Gasket
ガスケット Flange bolt M8 x 20 (8)
A290-7131-X655 フランジボルト
A290-7131-X655 Tightening
M8x20　(8)torque 13.0Nm
Bolt
ボルトM3 x 8 (4) 締付けトルク 13Nm
Tightening
M3x8 (4) torque 0.69Nm Washer
ワッシャ
締付けトルク
Apply LOCTIE 0.69Nm
243
ロックタイト243塗布のこと Plate
プレート
Gasket A290-7525-X213
A290-7525-X213
ガスケット
A290-7525-X216
A290-7525-X216
Gasket
ガスケット
A290-7525-X216
A290-7525-X216
Fig. 5.2 (a) Replacing cables
- 53 -
Gasket
ガスケット
A290-7525-X219
A290-7525-X219
Plate
プレート
A290-7525-X218
A290-7525-X218
Stainless bolt
ステンレスボルト
M6 x 14 (4)
M6X14 (4)
締付けトルク (47kgfcm)
4.6Nm
Apply LOCTITE 243
ロックタイト243塗布のこと
Fix it to the metal plate with metal detection cable

金属検出ケーブルタイ(MCTS100)で板金に固定
tie (MCTS100).
Fix it to the metal plate with

Washer bolt M5 x 8
ワッシャボルトM5X8 metal金属検出ケーブルタイ
detection cable tie
Cable routing of the M4M1, M4P1 (MCTS100)で板金に固定
(MCTS100).
M4M1・M4P1のケーブルルーティング
Fig. 5.2 (b) Replacing cables
- 54 -
Gasket
ガスケット
A290-7525-X315
A290-7525-X315
Plate
プレート
A290-7525-X330
A290-7525-X330
Flange bolt M5M5X16

フランジボルト x16 (4)
(4)
LOCTITE 243
ロックタイト243
Fig. 5.2 (c) Replacing cables
Stainless
ステンレスボルトbolt M4 x25 (4)
LOCTITE 243
M4x25 (4)
Washer bolt M5 x 8
ワッシャボルト
M5x8
Plateプレート
A290-7525-X331
A290-7525-X331
Bolt M5 x10 (2)
ボルト
Tightening
M5x10torque
(2) 6.3Nm
Fig. 5.2 (d) Replacing cables
- 55 -
Stainless bolt M6 x8 (2)
M6x8 (2) 243
LOCTITE
Tightening
締付けトルクtorque4.6Nm4.6Nm
Stainless bolt M6 x14 (2)
M6x14 (2)
LOCTITE 243
Tightening
締付けトルク torque 4.6Nm
4.6Nm
Fig. 5.2 (e) Replacing cables
- 56 -
B-84115EN/01 6. MASTERING
6 MASTERING
Mastering associates the angle of each robot axis with the pulse count value supplied from the absolute
Pulsecoder connected to the corresponding axis motor. To be specific, mastering is an operation for
obtaining the pulse count value; corresponding to the zero position.
6.1 OVERVIEW
The current position of the robot is determined according to the pulse count value supplied from the
Pulsecoder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However,
mastering becomes necessary after:
・ Motor replacement
・ Pulsecoder replacement
・ Reducer replacement
・ Link B, Link Balls, Drive Shaft and Wrist unit replacement
・ Cable replacement
・ Batteries for pulse count backup in the mechanical unit have gone dead
CAUTION
Robot data (including mastering data) and Pulsecoder data are backed up by
their respective backup batteries. Data will be lost if the batteries die. Replace
the batteries in the controller and mechanical units periodically. An alarm will
alert you when battery voltage is low.
Types of Mastering
Table 6.1 (a) describes the following mastering methods.
Table 6.1 (a) Type of mastering

Fixture position This is performed using a mastering fixture before the machine is shipped from the
mastering factory.
Zero-position This is performed with all axes set at the 0-degree position. A zero-position mark (witness
mastering (witness mark) is attached to each robot axis. This mastering is performed with all axes aligned to
mark mastering) their respective witness marks.
This is used for a quick recovery of mastering when pulse count is reset due to battery
Quick mastering run-out etc. In order to use this, you need to set a reference position in advance.
(all axes at the same time)
This is used for a quick recovery of mastering for single axis when pulse count is reset
Quick mastering
due to battery run-out etc. In order to use this, you need to set a reference position in
for single axis
advance.
This is performed for one axis at a time. The mastering position for each axis can be
Single-axis mastering
specified by the user. This is useful in performing mastering on a specific axis.
Mastering data entry Mastering data is entered directly.
This MAINTENANCE MANUAL describes fixture position mastering that is mainly required during
replacement of parts. For other mastering methods, refer to OPERATOR'S MANUAL.
Once mastering has been performed, positioning (calibration) is necessary. Positioning is an operation
which recognizes the current robot position based on the newly mastered robot pulse counts.
- 57 -
6. MASTERING B-84115EN/01
CAUTION
1 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.
2 Before performing mastering, it is recommended that you back up the current
mastering data.
Mastering procedure of DR-3iB is different from other FANUC robot because it has special structure.
You perform mastering with dialog as below.
1 You perform basic axis (J1 to J3) mastering.
2 Move the basic axis and straight the universal joint. (Auto program is executed.)
3 You perform wrist axis mastering.
4 Match the phase of universal joint.
If the zero position mastering or single axis mastering for wrist axis is performed, primary axis (J1 to J3)
move to 0º automatically.
* When performing the primary axis mastering, if robot exceeded the motion area, mechanical unit
interference might occur and it might cause failure. Be careful. Especially at the beyond the motion
area upper part, the link A and the support plate are easy to interfere.
Interference
干渉箇所
干渉箇所
position
Fig. 6.1 (a) Caution for primary axis mastering (posture exceeded the motion area upper side)
- 58 -
6.2 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
“SRVO-062 BZAL” or “SRVO-075 Pulse not established”
Procedure
1 Display the positioning menu by following the steps 1 to 6.
1 Press the [MENU] key.
2 Press [0 NEXT] and select [6 SYSTEM].
3 Press the F1 ([TYPE]), and select [Variable] from the menu.
4 Place the cursor on $MASTER_ENB, then key in “1” and press the [ENTER] key.
5 Press the F1 ([TYPE]), and select [Master/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal] menu.
2 To reset the “SRVO-062 BZAL” alarm, follow steps 1 to 5.

1 Press the [MENU] key.
3 Press the F1 ([TYPE]), and select [Master/Cal] from the menu.
4 Place the cursor on the F3 ([RES_PCA]), then press the F4 ([YES]).
5 Cycle power of the controller.
3 To reset the “SRVO-075 Pulse not established” alarm, follow the steps 1 to 2.
1 After cycling controller power, the message “SRVO-075 Pulse not established” appears again.
2 Move the axis for which the message mentioned above has appeared in either direction till the
alarm disappears when you press the [RESET] key.
- 59 -
6.3 FIXTURE POSITION MASTERING

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.
When mastering the robot, arrange the robot to meet the following conditions.
- Make the robot mounting base horizontal.
(The overall levelness of the robot mounting surface shall be 1 mm or less.)
- Remove the tooling and other parts from the wrist.
- Make sure no external forces are exerted on the robot.
Fixture assembling
1 Assemble the fixture to robot referring to Fig. 6.3 (a) and (b). The fixture of wrist axis is needed on
procedure 15 of Fixture position master.
Plate
プレート
A290-7525-X903
A290-7525-X903
Bolt
ボルト
M5 M5X16
x 16 (2)
(2)
Fig. 6.3 (a) Assembling the fixture (major axis side)
Plate
プレート
A290-7525-X914
A290-7525-X914
Plate Bolt
ボルト
プレート M4 x 16 (2)
A290-7525-X913
A290-7525-X913 M4X16 (2) A290-7525-X914
A290-7525-X914
Locating
突き当て面 surface
Bolt
ボルト
M6 x 16 (4)
M6X16 (4)
Pin
ピン
A290-7525-X915
A290-7525-X915
Fig. 6.3 (b) Assembling the fixture (wrist side)
2 Adjust the dial gauge to 3.00 mm using the calibration block, and tighten it with M3 bolt as shown in
Fig. 6.3 (c). (Do not tighten the bolt too strongly or the dial gauge might break.)
- 60 -
Gauge block
ゲージブロック
A290-7018-X087
A290-7018-X087
All dial gauges indicate 3mm in calibration.
ダイヤルゲージは、3mmを指すこと。
Fig. 6.3 (c) Mounting dial gauges
Procedure of Fixture position Mastering

1 Press the [MENU] key to show screen menu.
3 Press F1 [TYPE] to show screen switch menu.
4 Select Master/Cal. Master/Cal screen will be displayed.
NOTE
If RUNNING or PAUSED program exists, ABORT it beforehand.
Otherwise, you can not proceed to the following step.
5 Select [FIXTURE POSITION MASTER] and press F4, [Yes].
SYSTEM Maste/Cal
1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTE REF
7 CALIBRATE
Press “ENTER or number key to select
6 The interactive mastering starts. First, do major axis mastering. Assemble the fixture of major axis
and dial gauge referring to Fig. 6.3 (a) to (c).
7 Jog the J2,J3 to the scribe mark position and input [1]. Then the J1 mastering will start.
DR-3iB Master
*** Group 1 FIXTURE POSITION MASTER********
*** Step 1: Major Axis Master ﾞ ***
Jog J2, J3 to the scribe mark position.
If OK, please enter [1]:
- 61 -
8 Let dial gauge of the J1- touch face of Fig.6.3 (d) and make adjustments so that dial gauges indicate 3
mm. A posture as shown in Fig. 6.3 (d) should be taken. See this figure for reference.
DR-3iB Master
*** Group1 FIXTURE POSITION MASTER *********
*** Step 2: Major Axis Motion (J1)
**********
JOG J1 to the mastering position.
Masering posture
マスタリング姿勢
J1
J1
J1=25º J2≒0º J3≒0º J4=arbitrary
J1=25°J2≒0°J3≒0°J4=任意
J2
J2
J1≒0º J2=25º J3≒0º J4=arbitrary
J1≒0°J2=25°J3≒0°J4=任意
J3
J1≒0º J2≒25º J3=25º J4=arbitrary
J3
J1≒0°J2≒0°J3=25°J4=任意
Scribe mark position

ケガキ位置
Fig. 6.3 (d) Fixture position master for the major axis
9 If [1] is inputted, mastering of the J1-axis will be performed.
DR-3iB Master
**********
J1 is mastered!
Mastering Data:
J1: -13513287
Please press [ENTER]:
- 62 -
10 If the [ENTER] is pressed, mastering of the J2-axis will be start. Jog the J1-axis to the approximate
scribe mark positon. Then input [1].
DR-3iB Master
**********
JOG J1 to the scribe mark positions.
11 As with J1-axis, jog the J2-axis so that the scale of the dial gauge comes to 3mm.
DR-3iB Master
*** Step 2: Major Axis Motion (J2)**********
Jog J2 to the mastering position.
12 Jog the J2-axis to the approximate scribe mark position. As with J1,J2-axis, perform mastering of the
J3-axis. Now the major axis mastering is complete. Then the wrist axis mastering will start.
13 To perform the wrist axis mastering, the major axes will move automatically and the upper side and
the lower side of the universal joint will become to straight line. If you input the [1]. The step will go
to next.
DR-3iB Master
*** Step 2: Major Axis Motion *************
In this step, J1～J3 will move to the。

position: J1~J3= 0.0000[deg]
Uninstall all mastering fixtures, and

Ensure that no obstacle exist on the
motion path.
Enter [1] to proceed:
- 63 -
14 Set to AUTO mode and TP disable. Release all alarms an input the [1]. The major axes will move.
DR-3iB Master
*** Step 2: Major Axis Motion *************
Turn to AUTO mode, TP off.

If TP program is running, abort the TP
Program, and reset all alarms.
If OK, please enter [1]
!!!!!!!!!!!!! CAUTION !!!!!!!!!!!!!

Robot will move just after
you enter [1].
15 After moving of the major axes, press the emergency stop button. Then attach the wrist side mastering
fixture referring to Fig. 6.3 (b). Then perform the wrist axis mastering. Rotate the J4-axis by hand,
match it the contact positon in Fig. 6.3 (b).
DR-3iB Master
*** Step 3: Wrist Axis Master ************
Press the EMERGENCY STOP button,

And turn J4 to the mastering positon
by hand.
16 If you input the [1], mastering of the wrist axis will be performed,
DR-3iB Master
*** Step 3: Wrist Axis Master ************
Wrist axis are mastered!

Mastering Data:
J4: -3016942
- 64 -
17 Match the phase of the universal joint. Remove the wrist side mastering fixture, release the emergency
stop, then input the [1].
DR-3iB Master
*** Step 4: U/J Phase Calibration
************
Turn to T1 or T2 mode and TP on,

then
Please reset the EMERGENCY STOP button
IF OK, please enter [1]:
18 Jog the J4 to the posture for matching phase of the universal joint. (See Fig. 6.3 (e))
DR-3iB Master
*** Step 4: U/J Phase Calibration
************
JOG J4 to the universal joint phase

Calibration position.
Positioning
位置合わせ治具 fixture
A290-7525-X919
A290-7525-X919
Keep these faces parallel to

位置合わせ治具でこれらの
each other using the fixture.
面を平行に合わせる
(Roughly matching without
（目視合わせで十分）
any accurate fixture is OK.)
Fig. 6.3 (e) Matching phase of the universal joint
- 65 -
19 If you input the [1], matching phase of the J4 universal joint will be performed.
DR-3iB Master
*** Step 4: U/J Phase Calibration ***********
JOG J4 to the universal joint phase

Calibration position.
J4 universal joint phase is calibrated.

20 If the matching phase of the universal joint is complete, matching phase data will be displayed.
DR-3iB Master
*** Step 4: U/J Phase Calibration ***********
Universal joint phase are calibrated!

Calibration Data:
J4: 4239329
21 After this, mastering is complete.
DR-3iB Master
*** Step 5: End ***
All mastering data have been set!
Please press [ENTER], then select and

Execute “CALIBRATE” in the menu list:
- 66 -
22 If you input the [ENTER] key, the screen will back to the “Master/Cal” menu.
SYSTEM Maste/Cal
1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTE REF
7 CALIBRATE
Press “ENTER or number key to select
23 At last, perform the calibration.
6.4 Q&A
Q Can I change the screen from the interactive mastering dialog to other display?
A Yes. You can come back to the mastering dialog display by pressing [MENU] and [9 User].
Although display of title lines (“DR-3iB Master” to “Step 1: Major Axis Master”) will disappear, you
can proceed with no problem.
Q How to abort the interactive mastering dialog.

A You can abort it by selecting [Function]>[1.ABORT (ALL)].
Be sure to perform mastering again from the first step. If you do not perform it, the robot will fall to a
wrong mastering status.
Q The interactive mastering is stopped by error during [Step 2 : Major Axis Motion] and cannot be
resumed. What should we do?
Q The interactive mastering is stopped by [HOLD] command during [Step 2 : Major Axis Motion] and
cannot be resumed. What should we do?
A In this case, you cannot resume the interactive mastering.
- A message “Mastering procedure will be aborted” will be shown. Press [ENTER] to return to
[Master/Cal] menu. The wrist axis will not be mastered due to the interruption during mastering
process. Perform mastering procedure again to complete mastering.
Q What needs to be done in case a wrist axis was moved by mistake (when performing wrist axis
mastering; or when matching the phase of the universal joint) ?
A please jog the robot back to its original position by manual operation. The original position is
J1,J2,J3=0º .
Note : this operation has an acceptable positional tolerance of ±0.1 deg.
Q Message “Robot Not Mastered!” is displayed and interactive mastering dialog does not start.
A Press the [FCTN] key >[1. ABORT (ALL)] and try mastering again.
Q Warning “SRVO-421 Jnt Phs not calibrated(G1)” is displayed.

A If you try to set $DMR_GRP.$MASTER_DONE = TRUE when
$DMR_M3_GRP.$MASTER2_ENB = FALSE, this warning is posted. On 7DA7/09 or later
software version, for direct Mastering data entry, set $DMR_M3_GRP.$MASTER2_ENB = TRUE
first. After that, set $DMR_GRP.$MASTER_DONE = TRUE
- 67 -
6.5 VERIFYING MASTERING

1 How to verify that the robot is mastered properly:
Usually, positioning is performed automatically when the power is turned on. To check whether
mastering has been performed correctly, examine if the current displayed position matches the actual
robot position by using one or more of the procedures described below:
(1) Reproduce a particular point in a program. Check whether the point agrees with the specified
position.
(2) Set all axes of the robot to their 0-degree (0 rad) positions. Check that the zero-degree position
marks indicated in Section 7.3 of the MECHANICAL UNIT OPERATOR’S MANUAL (B-
841114EN) are aligned. There is no need to use a visual aid.
(3) Using fixtures, set the robot to the mastering position in the same way as when performing
mastering. Check that the displayed current position agrees with the actual mastering position.
If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been
invalidated as a result of an alarm described in 6.2. Alternatively, the mastering data in system variable
$DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation error or for
some other reason.
Compare the data with the values indicated on the supplied data sheet. This system variable is
overwritten whenever mastering is performed. Whenever mastering is performed, record the value
of the system variable on the data sheet.
2 Alarm types displayed during mastering and their solution method:

(1) BZAL alarm
This alarm is displayed if the Pulsecoder's backup battery voltage decreases to 0 V while the
power to the controller is disconnected. Furthermore, if the Pulsecoder connector is removed for
cable replacement, etc. this alarm is displayed as the voltage decreases to 0. Check to see if the
alarm will disappear by performing a pulse reset (See Section 6.2.). Then, cycle controller power
and check if the alarm disappears or not.
The battery may be drained if the alarm is still displayed. Perform a pulse reset, and turn off and
on the controller power after replacing the battery. Note that, if this alarm is displayed, all the
original data held by the Pulsecoder will be lost. Mastering is required.
(2) BLAL alarm
This alarm is output if the voltage of the Pulsecoder's backup battery has fallen to a level where
backup is no longer possible. If this alarm is output, fit a new battery immediately while
keeping the power turned on. Check whether the current position data is valid, using the
procedure described in 1.
(3) Alarm notifications like CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and
SPHAL may indicate trouble with Pulsecoder; contact your local FANUC representative.
- 68 -
APPENDIX
B-84115EN/01 APPENDIX A. MAINTENANCE PARTS
A MAINTENANCE PARTS
Table A (a) Cables
Parts name Specifications Remarks
Cable K101 A660-8021-T571 J1 to J4 Pulsecoder + EE
Cable K102 A660-8021-T572 J1 to J4 power, brake
Cable K103 A05B-1525-K303 J4 motor movable cable
Table A (b) Motor

J1/J2/J3 motor A06B-2049-B605 αiSR12/4000-B (3 pcs / 1 robot)
J4 motor A06B-0116-B205#0048 βiR0.5/6000 (1 pc / 1 robot)
Table A (c) Reducer

J1/J2/J3 reducer A97L-0218-0894#32N (3 pcs / 1 robot)
J1/J2/J3 gear A290-7525-X234 (3 pcs / 1 robot)
J4 reducer A97L-0318-0283#9 (1 pc / 1 robot)
Table A (d) Gasket

Gasket A290-7525-X208 Gearbox cover
Gasket A290-7525-X212 Link A cover (3 pcs / 1 robot）
Gasket A290-7525-X216 Connector panel
Gasket A290-7525-X219 J4 motor cable
Gasket A290-7525-X314 J4 motor unit
Gasket A290-7525-X315 J4 motor unit
Table A (e) O-ring

O-ring JB-OR1A-G120 J1/J2/J3 motor (3 pcs / 1 robot)
O-ring JB-OR1A-G105 J1/J2/J3 reducer (3 pcs / 1 robot)
Table A (f) Bolt

Plug A97L-0001-0436#2-2D Link A (3 pcs / 1 robot)
Plug A97L-0001-0436#2-3D Link A (6 pcs / 1 robot)
Set screw A6-SAKT-8X8SUS Universal joint (4 pcs / 1 robot)
Flange bolt A97L-0318-0494#061207 Wrist unit (1 pc / 1 robot)
Flange bolt A97L-0318-0494#101510 Wrist unit (2 pcs / 1 robot)
- 71 -
A. MAINTENANCE PARTS APPENDIX B-84115EN/01
Table A (g) Maintenance kit (Mechanical unit)

Lubrication seal kit A05B-1525-K001 For J1/J2/J3 reducer,wrist unit
Link A unit A05B-1525-K201 White paint type
Link A unit A05B-1525-K202 Plated type
Brake release switch A05B-1525-K203 For brake release option
J4 motor assembly A05B-1525-K301 White paint type
(including the J4 motor and A05B-1525-K302 Plated type
J4 reducer)
J4 motor cable A05B-1525-K303 J4 (1 pc / 1 robot)
J1A support kit A05B-1525-K304 J1 upper side (1 pc / 1 robot)
J1B support kit A05B-1525-K305 J1 middle side (1 pc / 1 robot)
J1C support kit A05B-1525-K306 J1 lower side (1 pc / 1 robot)
J23 support kit A05B-1525-K307 J2J3 upper side (2 pcs / 1 robot)
Drive shaft A05B-1525-K308 (1 pc / 1 robot)
Universal joint A05B-1525-K309 (1 pc / 1 robot)
A05B-1525-K501 White paint type
Wrist unit
A05B-1525-K502 Plated type
Table A (h) Other (Mechanical unit)

A290-7525-V311 White paint boot type (6 pcs / 1 robot)
A290-7525-V312 White paint seal type (6 pcs / 1 robot)
Link B
A290-7525-V313 Plated・boot type (6 pcs / 1 robot)
A290-7525-V314 Plated・seal type (6 pcs / 1 robot)
Window A98L-0040-0346 (3 pcs / 1 robot)
Fan assy A290-7525-V205 For fan option (3 pcs / 1 robot)
Table A (i) Battery⋅Grease⋅Oil

Battery A98L-0031-0005 1.5V, alkali size D (4pcs / 1 robot)
Grease A98L-0040-0187#0.4KG Link B
Grease A98L-0040-0226#0.05KG Oil seal and drive shaft
Oil A98L-0040-0255#22L J1/J2/J3 reducer, wrist unit
- 72 -
B. MECHANICAL UNIT
B-84115EN/01 APPENDIX CIRCUIT DIAGRAM
B MECHANICAL UNIT CIRCUIT DIAGRAM
- 73 -
B. MECHANICAL UNIT
CIRCUIT DIAGRAM APPENDIX B-84115EN/01
CONNECTOR PANEL J1 MOTOR (αiSR12/4000-B)

Han46EE A63L-0001-0648#81810SB
RM1 (4.0SQ 16A) A63L-0001-0881#10C M1M 18-10P(3.5SQ 23A)
M TYPE
1 34 A J1U1 C J1W1
G FG
2 J1U1 35 J1G1 B J1V1 D J1G1
3 J1U1
14 J1V1 24 J1W1
36 J1G1 K102
15 J1V1 25 J1W1
4 J2U1 37 J2G1 A63L-0001-0648#810SL3SJ
5 J2U1
16 J2V1 26 J2W1
38 J2G1 A660-8021-T572 A63L-0001-0653#04A M1BK 10SL-3P(1.25SQ 13A)
17 J2V1 27 J2W1
6 J3U1 39 J3G1 A BK(J1) B BKC(J1) C
18 J3V1 28 J3W1
7 J3U1 40 J3G1
19 J3V1 29 J3W1
8 J4U1 41 J4G1
9
20 J4V1 30 J4W1
42 A63L-0001-0848#E10SL1 M1P 10SL1(0.3SQ 3A)
21 31
10 43 A63L-0001-0850 4 6V(BT1)
22 32
11 BK(J1) 44 8 5V(A1) 5 XPRQJ1 1
23 BK(J2) 33 BK(J3)
12 BKC(J123) 45 9 6 PRQJ1 2
13 46 10 0V(A1) 0V(BT1) 3 DRAIN
7
0V(A2)
M TYPE Han42DD FAN OPTION (J031) 109P0424J3213
RP1 G SG (2.5SQ 10A) A63L-0001-0987#1SR03XN R04DX

1 RI1 8 RI2 15 RI3 22 RI4 29 RI5 36 RI6 A63L-0001-0989#RMGS
FAN1 TMGS FAN
2 RI7 9 RI8 16 RI9(XPPABN) 23 XHBK 30 FAN(J123) 37 24VF(BRS) B1 B2
3 RO1 10 RO2 17 RO3 24 RO4 31 RO5 38 RO6 A1 FAN(J1) A2 0V(E1)
4 RO7 11 RO8 18 24VF(A1234) 25 0V(E12345) 32 39 BRS
5 5V(A1) 12 5V(B1) 19 5V(C12) 26 0V(A12) 33 0V(B12) 40 0V(C1234) K101
6 PRQJ1 13 PRQJ2 20 PRQJ3 27 PRQJ4 34 41
7 XPRQJ1 14 XPRQJ2 21 XPRQJ3 28 XPRQJ4 35 42 A660-8021-T571 J2 MOTOR (αiSR12/4000-B)
A63L-0001-0881#1810S
A63L-0001-0881#10C M2M 18-10P(3.5SQ 23A)
A J2U1 C J2W1
B J2V1 D J2G1
GB1
A63L-0001-0648#810SL3SJ
6V(BT1,BT2,BT3,BT4) + GB2 GB2 A63L-0001-0653#04A M2BK 10SL-3P(1.25SQ 13A)
+6V(BT1,BT2, +6V(BT1,BT2,
A A A BK(J2) B BKC(J2) C
BATTERY K131 B
BT3,BT4)
0V(BT1,BT2,
BT3,BT4) B
BT3,BT4)
0V(BT1,BT2,
BT3,BT4)
A660-8016-T944
0V(BT1,BT2,BT3,BT4) - A63L-0001-0848#E10SL1 M2P 10SL1(0.3SQ 3A)
A63L-0001-0648#610SL3SJ A63L-0001-0648#210SL3PJ A63L-0001-0850 4 6V(BT2)
8 5V(C1) 5 XPRQJ2 1
9 6 PRQJ2 2
10 0V(C1) 0V(BT2) 3 DRAIN
7
0V(C2)
109P0424J3213
FAN OPTION (J031)
A63L-0001-0987#1SR03XN R04DX
A63L-0001-0989#RMGS
FAN2 TMGS FAN
B1 B2
A1 FAN(J2) A2 0V(E2)
J3 MOTOR (αiSR12/4000-B)
A63L-0001-0881#1810S
A63L-0001-0881#10C M3M 18-10P(3.5SQ 23A)
A J3U1 C J3W1
B J3V1 D J3G1
A63L-0001-0648#810SL3SJ
A63L-0001-0653#04A M3BK 10SL-3P(1.25SQ 13A)
A BK(J3) B BKC(J3) C
A63L-0001-0848#E10SL1 M3P 10SL1(0.3SQ 3A)

A63L-0001-0850 4 6V(BT3)
8 5V(C2) 5 XPRQJ3 1
9 6 PRQJ3 2
10 0V(C3) 0V(BT3) 3 DRAIN
7
0V(C4)
109P0424J3213
FAN OPTION (J031)
A63L-0001-0987#1SR03XN
A63L-0001-0989#RMGS
FAN3
R04DX
TMGS
FAN
B1 B2
A1 FAN(J3) A2 0V(E3)
BRAKE RELEASE SWITCH

OPTION (H302)
P06DX
A63L-0002-0066#P06DX
BRS1 CTM
A63L-0002-0066#CTM AV19LP407
A1 BRS B1 BRS
A2 24VF(BRS) B2
A3 B3 3 BRS 1 2 4 24VF(BRS)
EE INTERFACE
Han24DD
EE F TYPE (0.5SQ 10A)
1 RO1 5 RO5 9 RI1 13 RI8 17 24VF(A1) 21 RO7
2 RO2 6 RO6 10 RI2 14 RI9(XPPABN) 18 24VF(A2) 22 RO8
3 RO3 7 XHBK 11 RI3 15 RI5 19 24VF(A3) 23 0V(E2)
4 RO4 8 0V(E1) 12 RI4 16 RI6 20 24VF(A4) 24 RI7
Fig. B (a) Circuit diagram
- 74 -
B. MECHANICAL UNIT
B-84115EN/01 APPENDIX CIRCUIT DIAGRAM
J4 MOTOR (βiSR1/6000)
A63L-0002-0066#R06DX P06DX A63L-0001-0865#1
A63L-0002-0066#CRM M4M1 CTM A63L-0001-0864#CS M4M MOLEX 55618-0401
A1 J4U1 B1 J4G1 2 J4V1 1 J4U1
A2 B2 J4V1 3 J4W1 4 J4G1
A3 J4W1 B3
A63L-0002-0066#R08DX P08DX
A63L-0002-0066#CRM M4P1 CTM
A1 6V(BT4) B1 0V(BT4,B2)
A2 PRQJ4 B2 XPRQJ4
A3 5V(B1) B3 0V(B1) K103
A4 DRAIN B4 A05B-1525-D001 A63L-0001-0848#E10SL1 M4P 10SL1(0.3SQ 3A)
A63L-0001-0850 4 6V(BT4)
8 5V(B1) 5 XPRQJ4 1
9 6 PRQJ4 2
10 0V(B1) 0V(BT4) 3 DRAIN
7
0V(B2)
- 75 -
C. PERIODIC MAINTENANCE TABLE APPENDIX B-84115EN/01
C PERIODIC MAINTENANCE TABLE

FANUC Robot DR-3iB Periodic Maintenance Table
First 3 6 9 1 2
Accumulated Check Oil
check months months months year years
operating time amount
time (H) 320 960 1920 2880 3840 4800 5760 6720 7680 8640 9600 10560
Cycle
Items count ―
*3 5000k 10000k 15000k 20000k 25000k 30000k 35000k 40000k 45000k 50000k 55000k
Check for external -

1 damage or peeling paint
0.1H ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
2 Check for water 0.1H - ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Check the connector on the
3 connector plate. (Loosening)
0.2H ― ○ ○ ○
4 Tighten the end effector bolt. 0.2H ― ○ ○ ○
Tighten the cover and main
5 bolt.
2.0H ― ○ ○ ○
6 Check the LINK B 0.1H ― ○ ○ ○

7 Remove spatter and dust etc. 1.0H ― ○ ○ ○
Check the end effector (hand)
8 cable 0.1H ― ○ ○ ○
Mechanical unit
Visually check the wrist motor

9 cable 0.1H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Check the operation of
10 the cooling fan 0.1H ― ○ ○ ○
Cleaning and greasing of
11 the link B 0.5H ― ● ● ● ● ●
12 Replacing batteries(*4) 0.1H ― ●

Supply oil to J1/J2/J3-axis Each
13 reducer 0.1H 530ml
● ●
14 Supply oil to wrist 0.1H 165ml ● ●

Replace the Boot type ●
15 link B 4.0H ―
Seal type
Replacing the J4
16 motor cable 4.0H ― ●
Replacing the rod support kit ,
17 the drive shaft and the 4.0H ―
support plat
Check the robot cable, teach
18 pendant cable and robot 0.2H
Controller
― ○ ○ ○
connecting cable
19 Cleaning the ventilator 0.2H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
20 Replacing battery (*1)(*4) 0.1H ―
*1 Refer to “REPLACING UNITS Chapter of MAINTENANCE” of the following manuals.
R-30iB/R-30iB Plus CONTROLLER MAINTENANCE MANUAL (B-83195EN),
R-30iB Mate/R-30iB Mate Plus CONTROLLER MAINTENANCE MANUAL (B-83525EN)
R-30iB Mate/R-30iB Mate Plus (Open Air type) CONTROLLER MAINTENANCE MANUAL
(B-83555EN)
*2 ●: requires order of parts
○: does not require order of parts
*3 If the hand for multiple work is used and picking (placing) motion is required at each work, make
the picking (placing) times to be cycle count.
*4 Regardless of the operating time, replace the mechanical unit batteries at 1.5 year, replace controller
batteries at 4 years.
- 76 -
B-84115EN/01 APPENDIX C. PERIODIC MAINTENANCE TABLE
3 4 5 6 7 8
years years years years years years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 Item
60000k 65000k 70000k 75000k 80000k 85000k 90000k 95000k 100000k 105000k 110000k 115000k 120000k 125000k 130000k 135000k 140000k 145000k 150000k 155000k 160000k
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 1
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2
○ ○ ○ ○ ○ 3
○ ○ ○ ○ ○ 4
○ ○ ○ ○ ○ 5
○ ○ ○ ○ ○ 6
○ ○ ○ ○ ○ 7
○ ○ ○ ○ ○ 8
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 9
○ ○ ○ ○ ○ 10
Overhaul
● ● ● ● ● ● ● ● ● ● 11
● ● ● ● 12
● ● ● ● ● 13
● ● ● ● ● 14
● ●
15
●
● ● 16
● 17
○ ○ ○ ○ ○ 18
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 19
● 20
- 77 -
D. STRENGTH OF BOLT AND BOLT TORQUE LIST APPENDIX B-84115EN/01
D STRENGTH OF BOLT AND BOLT TORQUE

LIST
NOTE
When applying LOCTITE to a part, spread the LOCTITE on the entire length area
of the engaging part of the female thread. If applied to the male threads, poor
adhesion can occur potentially loosening the bolt. Clean the bolts and the
threaded holes and wipe off the oil on the engaging section. Make sure that there
is no solvent left in the threaded holes. In this case, remove all the excess
LOCTITE when you are finished screwing the bolts into the threaded holes.
Adopt following strength bolts. Comply with any bolt specification instructions as specified.
Hexagon socket head bolt made by steel:
Size M22 or less: Tensile strength 1200N/mm2 or more
Size M24 or more: Tensile strength 1000N/mm2 or more
All size plated bolt: Tensile strength 1000N/mm2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc.)
Tensile strength 400N/mm2 or more
Refer to the following tables if the bolts tightening torque are not specified.
Recommended bolt tightening torques Unit: Nm

Hexagon socket head
button bolt
Hexagon socket head
Hexagon socket head Hexagon socket head Hexagon bolt
bolt
Nominal bolt (stainless) flush bolt (steel)
(steel)
diameter Low-head bolt
(steel)
Tightening torque Tightening torque Tightening torque Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
M3 1.8 1.3 0.76 0.53 ―――― ―――― ―――― ―――
M4 4.0 2.8 1.8 1.3 1.8 1.3 1.7 1.2
M5 7.9 5.6 3.4 2.5 4.0 2.8 3.2 2.3
M6 14 9.6 5.8 4.1 7.9 5.6 5.5 3.8
M8 32 23 14 9.8 14 9.6 13 9.3
M10 66 46 27 19 32 23 26 19
M12 110 78 48 33 ―――― ―――― 45 31
(M14) 180 130 76 53 ―――― ―――― 73 51
M16 270 190 120 82 ―――― ―――― 98 69
(M18) 380 260 160 110 ―――― ―――― 140 96
M20 530 370 230 160 ―――― ―――― 190 130
(M22) 730 510 ―――― ―――― ―――― ―――― ―――― ――――
M24 930 650 ―――― ―――― ―――― ―――― ―――― ――――
(M27) 1400 960 ―――― ―――― ―――― ―――― ―――― ――――
M30 1800 1300 ―――― ―――― ―――― ―――― ―――― ――――
M36 3200 2300 ―――― ―――― ―――― ―――― ―――― ――――
- 78 -
B-84115EN/01 INDEX
INDEX
REPLACING THE FAN (OPTION).............................. 48
<B> REPLACING THE J1/J2/J3-AXIS MOTOR
BACKLASH MEASUREMENT ................................... 28 (M1/M2/M3) .............................................................. 34
REPLACING THE J1/J2/J3-AXIS REDUCER ............. 35
<C> REPLACING THE J4 -AXIS MOTOR AND THE
CABLE FORMING ....................................................... 50 REDUCER ................................................................. 37
CABLE REPLACEMENT ............................................. 52 REPLACING THE J4 MOTOR UNIT .......................... 36
CHECK POINT ............................................................... 4 REPLACING THE LINK B .......................................... 38
Check the link B ............................................................... 6 REPLACING THE OIL OF THE DRIVE
Check the Mechanical Unit Connectors ........................... 6 MECHANISM (1-YEAR (3840 HOURS) CHECKS) 11
CHECKS AND MAINTENANCE .................................. 1 REPLACING THE ROD SUPPORT KIT ..................... 46
Cleaner (When white painting is specified) ................... 19 REPLACING THE UNIVERSAL JOINT ..................... 41
Cleaning ...................................................................... 7,19 REPLACING THE WRIST UNIT ................................. 47
CLEANING AND GREASING OF THE LINK B (6 RESETTING ALARMS AND PREPARING FOR
MONTHS (1920 HOURS) MAINTENANCE) .......... 13 MASTERING............................................................. 59
Cleaning the Robot ......................................................... 19
Confirmation of Oil Seepage and Abrasion ..................... 4 <S>
SAFETY PRECAUTIONS ........................................... s-1
<D> STRENGTH OF BOLT AND BOLT TORQUE LIST .. 78
Daily Checks .................................................................... 1
<T>
<F> TROUBLESHOOTING ................................................. 20
FIGURE OF DRIVE MECHANISM ............................. 32
FIXTURE POSITION MASTERING ............................ 60 <V>
VERIFYING MASTERING .......................................... 68
<M>
MAINTENANCE PARTS ............................................. 71
MAINTENANCE TOOLS ............................................... 7
MASTERING ................................................................ 57
MECHANICAL UNIT CIRCUIT DIAGRAM .............. 73
MECHANICAL UNIT CONFIGURATION ................. 33
<O>
OVERVIEW .................................................................. 57
<P>
Periodic Checks and Maintenance ................................... 2
PERIODIC MAINTENANCE ......................................... 9
Periodic maintenance procedure for paint/seal type link
B ................................................................................. 14
Periodic maintenance procedure for plated/boot type
link B .......................................................................... 17
Periodic maintenance procedure for plated/seal type
link B .......................................................................... 15
PERIODIC MAINTENANCE TABLE.......................... 76
PREFACE .................................................................... p-1
<Q>
Q&A ............................................................................... 67
<R>
REPLACING CABLES ................................................. 49
REPLACING PARTS .................................................... 31
REPLACING THE BATTERIES (1.5-YEAR (5760
HOURS) CHECKS) ..................................................... 9
REPLACING THE DRIVE SHAFT .............................. 42
i-1
B-84115EN/01 REVISION RECORD
REVISION RECORD
Edition Date Contents
01 May, 2021
r-1
B-84115EN/01
* B - 8 4 1 1 5 E N / 0 1 *

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< Robot DR-3+B

© FANUC CORPORATION, 2021

Thank you very much for purchasing FANUC Robot.

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

Programmer or Teaching operator:

- The operator is not allowed to work in the safeguarded space.

Table 1 (a) List of work outside the Safeguarded Space

• Use clothes, uniform, overall adequate for the work

2 DEFINITION OF SAFETY NOTATIONS

3 PROCEDURE TO MOVE ARM WITHOUT

Table 3 (a) Order spec. of the brake release switch

Table 3 (b) Order spec. of the brake release unit

Brake release switch

Fig. 3 (a) Brake release switch

4 WARNING & CAUTION LABEL, PLATE

Fig. 4 (a) Transportation caution label 1

• Use a crane with a load capacity of 300 kg or greater.

(2) Transportation caution label 2

Fig. 4 (b) Transportation caution label 2

(3) Transportation caution label 3

Fig. 4 (c) Transportation caution label 3

(4) Operating space and load capacity plate

Fig. 4 (d) Operating space and load capacity plate

Position of label indicating mechanical unit specification number

Safety handbook B-80687EN Intended readers:

This manual uses following terms.

1 CHECKS AND MAINTENANCE ............................................................. 1

4.12 REPLACING THE FAN (OPTION)............................................................... 48

1 CHECKS AND MAINTENANCE

1.1 CHECKS AND MAINTENANCE

1.1.1 Daily Checks

Check items Check points and management

1.1.2 Periodic Checks and Maintenance

Check and maintenance intervals

○ ○ Cleaning the If the controller ventilation system is

○ ○ Retightening the Retighten the end effector mounting

Check and maintenance intervals

○ Replacing the Replace the rod support kit, the drive

1.2 CHECK POINT

1.2.1 Confirmation of Oil Seepage and Abrasion

Fig. 1.2.1 (a) Check points

Fig. 1.2.1 (b) Oil seal locations

1.2.2 Check the link B

Fig. 1.2.2 (a) Check points of link B

1.2.3 Check the Mechanical Unit Connectors

Fig. 1.2.3 (a) Connector Inspection points

Vicinity of the wrist axis and oil seal

Fig. 1.2.4 (a) Cleaning part

1.3 MAINTENANCE TOOLS

(a) Measuring instruments

2 Uncap the battery case (Fig. 2.1 (a)).

Remote battery box

Fig. 2.1 (a) Replacing the battery

Fig. 2.1 (b) External dimensions of the battery box

Holes to prevent fromInterfering

A Tip of the Notch 切欠き 4-M4

Fig. 2.1 (c) Dimensions for remote battery box installation

2.2 REPLACING THE OIL OF THE DRIVE MECHANISM

For oil replacement or replenishment, use the arbitrary posture.

Oiling of major axis (common to J1/J2/J3-axis)

Fig. 2.2 (a) Position of major axis reducer

Ventilator hole Oil inlet

Fig. 2.2 (b) Supply oil to major axis