1axis Positioner Maintenance Manual (B-82545EN 03)

< 1-Axis SERVO POSITIONER
MECHANICAL UNIT
MAINTENANCE MANUAL
B-82545EN/03
• Original Instructions
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
• No part of this manual may be reproduced in any form.

• All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
B-82545EN/03
PREFACE
This manual describes maintenance and connection work for the servo positioner. Before replacing parts,
check the specifications of the mechanical unit.
Model name Mechanical unit specification No. Remarks

1-Axis Servo Positioner A05B-1220-J101 300kg payload (Hollow type)
1-Axis Servo Positioner A05B-1220-J102 300kg/500kg payload (Hollow type)
1-Axis Servo Positioner A05B-1220-J103 1000kg/1500kg payload (Hollow type)
1-Axis Servo Positioner A05B-1220-J104 1000kg/1500kg payload (Compact type)
(1)
TYPE (2)
NO. (3) WEIGHT
DATE (4) (5) ｋｇ
OSHINO-MURA.
YAMANASHI PREF.JAPAN
No. (1) (2) (3) (4) (5)

CONTENTS MODEL TYPE No. DATE WEIGHT
1-Axis Servo Positioner A05B-1220-J101 PRINT 85 kg
1-Axis Servo Positioner A05B-1220-J102 PRINT SERIAL PRODUCTION 280kg
LETTERS
1-Axis Servo Positioner A05B-1220-J103 NO. YEAR AND 85 kg
1-Axis Servo Positioner A05B-1220-J104 MONTH 130kg
NOTE
The following abbreviations are used herein.
300kg payload (Hollow type) : 300kg payload 1-axis servo positioner (Hollow type)
300kg/500kg payload (Hollow type) : 300kg/500kg payload 1-axis servo positioner
(Hollow type)
1000kg/1500kg payload (Hollow type) : 1000kg/1500kg payload 1-axis servo
positioner (Hollow type)
1000kg/1500kg payload (Compact type) : 1000kg/1500kg payload 1-axis servo
positioner (Compact type)
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B-82545EN/03
Specification (1/3)
Item Specifications
Model 300kg payload 1-axis servo positioner (Hollow type)

740°(-370°～ +370°) 12.9 rad(-6.46 rad～ +6.46 rad)
Motion range
Continuous rotation is available.
Maximum operation speed (*1) 160°/sec 2.79 rad/sec 130°/sec 2.27 rad/sec
Max. load capacity (*2) 300 kg 500 kg
Allowable load moment 36 kgf･m 353 N･m 60 kgf･m 588 N･m
Allowable bending moment 250 kgf･m 2450 N･m
2 2
Allowable load inertia 2,350 kgf･cm･s 230 kg･m 3,673 kgf･cm･s2 360 kg･m2
Drive method Electric servo drive by AC servo motor
Weight About 85 kg
About 47 kg-(Follower unit (insulated flange)
Follower unit (option) weight (*3)
About 16 kg-(Follower unit (non-insulated flange)
Ambient temperature 0 - 45°CAmbient humidity
Normally: 75%RH or less :
Short time 95%RH or less(within 1 month)
Installation environment
(No dew or frost allowed)
Vibration : 0.5G or less
Free of corrosive gases (*4)
(*1) It does not arrive at each axial maximum speed at the short movement distance.
(*2) 300kg payload 1-axis servo positioner (Hollow type) does not support 500kg. Refer to Section 2.2 of
CONNECTION about changing method of payload specifications.
(*3) Two follower units (A05B-1220-J151,A05B-1220-J152) are prepared as option.
(*4) Contact the service representative, if the robot is to be used in an environment or a place subjected to
severe vibrations, heavy dust, cutting oil splash and or other foreign substances.
Specification (2/3)
Item Specifications
Model 300kg/500kg payload 1-axis servo positioner (Hollow type)

740°(-370°～ +370°) 12.9 rad(-6.46 rad～ +6.46 rad)
Motion range
Max. load capacity (*2) 300 kg 500 kg
Allowable load moment 36 kgf･m 353 N･m 60 kgf･m 588 N･m
Allowable bending moment 400 kgf･m 3,920 N･m
2 2
Weight About 88 kg
Short time 95%RH or less (within 1 month)
(*2) Refer to Section 2.2 of CONNECTION about changing method of payload specifications.
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B-82545EN/03
Specification (3/3)
Item Specifications
1000kg/1500kg payload 1-axis servo positioner (Hollow type)
Model
1000kg/1500kg payload 1-axis servo positioner (Compact type)
740°(-370°～ +370°) 12.9 rad(-6.45 rad～ +6.45 rad)
Motion range
Max. load capacity (*2) 1000 kg 1,500 kg
Allowable load moment 160 kgf･m 1,568 N･m 200 kgf･m 1,960 N･m
2100 kgf･m 20,580 N･m (*5) 2,100 kgf･m 20,580 N･m (*5)
Allowable bending moment
720 kgf･m 7,056 N･m (*6) 720 kgf･m 7,056 N･m (*6)
2 2
About 280 kg (1000kg/1500kg payload (Hollow type))
Weight
About130 kg (1000kg/1500kg payload (Compact type))
Short time 95%RH or less (within 1 month)
(*2) Refer to Section 2.2 of CONNECTION about changing method of payload specifications.
(*5) 1000kg/1500kg payload 1-axis servo positioner (Hollow type)
(*6) 1000kg/1500kg payload 1-axis servo positioner (Compact type)
Dust-proof/drip performance
Normal specification
MECHANICAL UNIT IP54
CAUTION
Definition of IP 54
5=Dust-tight
4=Protection from water immersion
Performance of resistant chemicals and resistant solvents

(1) The positioner (including severe dust/liquid protection model) cannot be used with the following
liquids because there is fear that rubber parts (packing, oil seal, O-ring etc.) will corrode.
(a) Organic solvents
(b) Coolant including chlorine / gasoline
(c) Aminergic detergent
(d) Acid, alkali and liquid causing rust
(e) Other liquids or solutions, which will harm NBR
(2) When the positioner work in the environment, using water or liquid, complete draining of base must be
done. Incomplete draining of base will make the positioner break down.
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B-82545EN/03
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 All persons who use FANUC Robot, system designer
designer must read and understand thoroughly this Topics:
handbook Safety items for robot system design, operation, maintenance
R-J3iB Mate Setup and Operations manual Intended readers:
controller LR ARC TOOL Operator, programmer, maintenance person, system designer
B-82094EN Topics:
LR HANDLING TOOL Robot functions, operations, programming, setup, interfaces,
B-81524EN alarms Use: Robot operation, teaching, system design
Maintenance manual Intended readers:
B-81525EN Maintenance person, system designer
B-81525EN-1(For Europe) Topics:
Installation, connection to peripheral equipment, maintenance
Use: Installation, start-up, connection, maintenance
R-J3iB controller Setup and Operations manual Intended readers:
SPOT TOOL Operator, programmer, maintenance person, system designer
B-81464EN-1 Topics:
HANDLING TOOL Robot functions, operations, programming, setup, interfaces,
B-81464EN-2 alarms
ARC TOOL Use:
B-81464EN-3 Robot operation, teaching, system design
Maintenance manual Intended readers:
B-81465EN Maintenance person, system designer
B-81465EN-1(For Europe) Topics:
Installation, connection to peripheral equipment, maintenance
Use: Installation, start-up, connection, maintenance
R-30iA Mate Operator’s Manual Intended readers:
controller LR HANDLING TOOL Operator, programmer, maintenance person, system designer
B-82724EN-1 Topics:
LR ARC TOOL Robot functions, operations, programming, setup, interfaces,
B-82724EN-2 alarms
ALARM CODE LIST Use:
Maintenance Manual Intended readers: Maintenance person, system designer
B-82725EN Topics:
B-82725EN-1(For Europe) Installation, connection to peripheral equipment, maintenance
B-82725EN-2(For RIA) Use: Installation, start-up, connection, maintenance
R-30iA controller Setup and Operations manual Intended readers:
SPOT TOOL+ Operator, programmer, maintenance person, system designer
B-83124EN-1 Topics:
HANDLING TOOL Robot functions, operations, programming, setup, interfaces,
B-83124EN-2 alarms
ARC TOOL Use:
ALARM CODE LIST
B-83124EN-6
Maintenance manual Intended readers: Maintenance person, system designer
B-82595EN Topics:
B-82595EN-1(For Europe) Installation, connection to peripheral equipment, maintenance
B-82595EN-2 Use: Installation, start-up, connection, maintenance
(For RIA)
(For Europe)
Robot For the robot mechanical unit, refer to the manual of each robot.
mechanical unit
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B-82545EN/03 SAFETY PRECAUTIONS
1 SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety precautions when operating a robot and
positioner and its peripheral devices installed in a work cell.
1.1 WORKING PERSON

The personnel can be classified as follows.
Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel
Programmer or teaching operator:

• Operates the robot
• Teaches robot inside the safety fence
Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)
- An operator cannot work inside the safety fence.

- A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc..
- To work inside the fence, the person must be trained on proper robot operation.
During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following safety
precautions.
- Use adequate clothing or uniforms during system operation

- Wear safety shoes
- Use helmet
1.2 OPERATOR SAFETY

Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating
space of the robot during automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration must be made to ensure operator
safety.
(1) Have the robot system operators attend the training courses held by FANUC.
FANUC provides various training courses. Contact our sales office for details.
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SAFETY PRECAUTIONS B-82545EN/03
(2) Even when the robot and positioner are stationary, it is possible that the robot is still ready to move
state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure
operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in
motion.
(3) Install a safety fence with a gate so that no operator can enter the work area without passing through
the gate. Equip the gate with an interlock that stops the robot when the gate is opened.
At this time, the positioner as well as the robot must be located within the fence completely.
The controller is designed to receive this interlock signal. When the gate is opened and this signal received, the
controller stops the robot in an emergency. For connection, see Fig.1.2(a).
(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such
as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that
stops the robot and positioner when an operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator in charge can turn on the power of
the robot.
The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a
padlock.
(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.
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Dual chain
Panel board （Note）
EAS1 In case of R-30iA , R-J3iB

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

on the emergency stop board.
Single chain
Panel board
Refer to controller maintenance manual for details.
FENCE1
FENCE2
Fig. 1.2 (a) Safety fence and gate
1.2.1 Operator Safety

The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.
(1) When the robot and positioner do not need to operate, turn off the power of the robot controller or
press the emergency stop button before work.
(2) The operator must operate the robot system outside the work area of the robot or positioner.
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the
work area unexpectedly and also to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator's reach.
The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection,
the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram
below for connection.
Dual chain
External stop button
Panel board
EES1
（Note）
EES11 Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.
EES2 In case of R-30iA , R-J3iB

EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.
EES21
In case of R-30iA Mate , R-J3iB Mate
EES1,EES11,EES2,EES21　are on the emergency stop board
or connector panel (in case of Open air type).
Single chain EMGIN1,EMGIN2　are on the emergency stop board.
External stop button Refer to the maintenance manual of the controller for details.
Panel board
EMGIN1
EMGIN2
Fig.1.2.1 (b) Connection Diagram for External Emergency Stop Button
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1.2.2 Safety of the Teach Pendant Operator

When teaching the robot and positioner, the teach pendant operator needs to enter the work area of the robot
or positioner. The teach pendant operator must give special consideration to safety.
(1) When it is not necessary to enter the work area of the robot or positioner, perform work outside the
work areas.
(2) Before teaching work, check that the robot, positioner, and peripheral device are not placed in a
dangerous or abnormal state.
(3) When it is necessary to enter the work area of the robot or positioner for teaching work, check the place
and state of safety apparatus such as the emergency stop button and dead man's switch of the teach
pendant.
The teach pendant supplied by FANUC is provided with a teach pendant enable switch and a deadman's switch in
addition to the EMERGENCY STOP button. The functions of each switch are as follows.
EMERGENCY STOP button: Pressing this button stops the robot in an emergency, irrespective to the condition
of the teach pendant enable switch.
Deadman's switch: The function depends on the state of the teach pendant enable switch.
When the enable switch is on - Releasing the finger from the dead man's switch stops the robot in an emergency.
When the enable switch is off - The deadman's switch is ineffective
NOTE
The deadman's switch is provided so that the robot operation can be stopped
simply by releasing finger from the teach pendant in case of emergency.
(4) The teach pendant operator needs to exercise special caution to prevent other people from entering the
work area of the robot or positioner.
NOTE
In addition to the above, the teach pendant enable switch and the deadman's
switch also have the following function. By pressing the deadman's switch while
the enable switch is on, the emergency stop factor (normally the safety gate)
connected to the controller is invalidated. In this case, it is possible for an operator
to enter the fence during teach operation without pressing the EMERGENCY
STOP button. In other words, the system understands that the combined
operations of pressing the teach pendant enable switch and pressing the
deadman's switch indicates the start of teaching.
The teach pendant operator should be well aware that the safety gate is not
functional under this condition and bear full responsibility to ensure that no one
enters the fence during teaching.
(5) When entering the work area of the robot or positioner, the teach pendant operator always needs to
enable the teach pendant. In particular, when the teach pendant enable switch is disabled, the teach
pendant operator needs to exercise caution to prevent the robot from being started by an operator's
panel other than the teach pendant.
The teach pendant, operator panel, and peripheral device interface send each robot start signal. However, the validity
of each signal changes as follows depending on the ON/OFF switch on the Teach pendant and the three modes
switch on the Operator’s panel and Remote condition on the software.
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Software
Operator ‘s panel Teach pendant Teach Operator’s Peripheral
remote
Three modes switch ON/OFF switch pendant panel devices
condition
T1/T2 On Independent Allowed to start Not allowed Not allowed
AUTO (Except RIA)
AUTO Off Remote OFF Not allowed Allowed to start Not allowed
AUTO Off Remote ON Not allowed Not allowed Allowed to start
NOTE
When starting the system using the teach pendant in the RIA specification, the
three modes switch should be T1/T2.
(6) To start the robot by the operator's panel, confirm that there are no people near the robot or positioner
and that there is no abnormality.
(7) When a program is completed, be sure to carry out a test run according to the procedure below.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test run above, execute it in the
automatic operation mode.
(8) While operating the system in the automatic operation mode, the teach pendant operator should leave
the robot work area.
1.2.3 Safety during Maintenance

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

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

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

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

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

(1) Clean the inside of the work area of the robot or positioner to eliminate the effect of oil, water, and
dust.
1.5 SAFETY OF THE END EFFECTOR

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

The following three robot stop types exist:
Power-Off Stop (Category 0 following IEC 60204-1)

Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
- An alarm is generated and servo power is turned off.
- The robot operation is stopped immediately. Execution of the program is paused.
Controlled stop (Category 1 following IEC 60204-1)

The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
- The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
- An alarm is generated and servo power is turned off.
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Hold (Category 2 following IEC 60204-1)

The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
- The robot operation is decelerated until it stops. Execution of the program is paused.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.
When the E-Stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or
Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is
different according to the controller type or option configuration.
There are the following 3 Stop patterns.
Stop E-Stop External Servo

Mode FENCE open SVOFF input
pattern button E-Stop disconnect
AUTO P-Stop P-Stop C-Stop C-Stop P-Stop
A T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
AUTO P-Stop P-Stop P-Stop P-Stop P-Stop
B T1 P-Stop P-Stop - P-Stop P-Stop
T2 P-Stop P-Stop - P-Stop P-Stop
AUTO C-Stop C-Stop C-Stop C-Stop C-Stop
C T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
P-Stop: Power-Off stop
C-Stop: Controlled stop
-: Not stop
The following table indicates the Stop pattern according to the controller type or option configuration.
R-30iA R-30iA Mate

Option Standard Standard RIA CE
RIA type CE type Standard
(Single) (Dual) type type
Standard B (*) A A A A (**) A A
Stop type set (Stop pattern C)
N/A N/A C C N/A C C
(A05B-2500-J570)
(*) R-30iA standard (single) does not have servo disconnect.
(**) R-30iA Mate Standard does not have servo disconnect, and the stop type of SVOFF input is
Power-Off stop.
The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer
"Software version" in operator's manual of controller for the detail of software version screen.
"Stop type set (Stop pattern C)" option

"Stop type set (Stop pattern C)"(A05B-2500-J570) is an optional function. When this option is loaded, the
stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the
stop type is Power-Off stop which is the normal operation of the system.
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Alarm Condition
SRVO-001 Operator panel E-stop Operator panel E-stop is pressed.
SRVO-002 Teach pendant E-stop Teach pendant E-stop is pressed.
SRVO-007 External emergency stops External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA controller)
SRVO-194 Servo disconnect Servo disconnect input (SD4-SD41, SD5-SD51) is open.
(R-30iA controller)
SRVO-218 Ext.E-stop/Servo Disconnect External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA Mate controller)
SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF.
SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.
Controlled stop is different from Power-Off stop as follows:

- In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
- In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems
where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized.
- The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer the operator's
manual of a particular robot model for the data of stopping distance and stopping time.
This function is available only in CE or RIA type hardware.
When this option is loaded, this function can not be disabled.
The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.
s-9
1.7 WARNING LABEL

(1) Greasing and degreasing label
Fig. 1.7 (a) Greasing and Degreasing Label
Description
When greasing and degreasing, observe the instructions indicated on this label.
1) When greasing, be sure to keep the grease outlet open.

2) Use a manual pump to grease.
3) Be sure to use a specified grease.
CAUTION
See section I 3.1 ″ GREASE REPLACEMENT for explanations about specified
greases, the amount of grease to be supplied, and the locations of grease and
degrease outlets for individual models.
(2) Step-on prohibitive label
Fig. 1.7 (b) Step-on Prohibitive Label
Description
Do not step on or climb the robot or controller as it may adversely affect the robot and positioner and you
may get hurt if you lose your footing as well.
(3) High-temperature warning label

s-10
Fig. 1.7 (c) High-temperature warning label
Description
Be cautious about a section where this label is affixed, as the section generates heat. If you have to
inevitably touch such a section when it is hot, use a protective provision such as heat-resistant gloves.
(4) Transportation label
>200kg
>200kg
>150kg
Fig. 1.7 (d) Transportation label (300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
Description
When transporting the positioner, observe the instruction on the transportation label. The above label
includes the following instructions.
1) Using a crane
• Use a crane having a load capacity of 1960 N (200 kg) or greater.
• Use one sling having a withstand load of 1960 N (200 kgf) or greater.
• Use two eyebolts with a withstand load of 1470 N (150 kgf) or greater. (The eyebolts are
attached during shipment.)
s-11
>600kg
>600kg
>450kg
Fig. 1.7 (e) Transportation label (1000kg/1500kg payload (Hollow type))
Description
1) Using a crane
>400kg
>400kg
>220kg
Fig. 1.7 (f) Transportation label (1000kg/1500kg payload (Compact type))
Description
1) Using a crane
s-12
B-82545EN/03 TABLE OF CONTENTS
TABLE OF CONTENTS
PREFACE ....................................................................................................p-1
1 SAFETY PRECAUTIONS.....................................................................s-1
I. MAINTENANCE
1 CONFIGURATION .................................................................................. 3
2 PREVENTIVE MAINTENANCE............................................................... 4
2.1 DAILY INSPECTION ..................................................................................... 4
2.2 First 1-month (960 hours) checks .................................................................. 5
2.3 First 3-MONTH CHECKS (960 hours) ........................................................... 5
2.4 3-MONTH CHECKS (960 hours) ................................................................... 5
2.5 1-YEAR CHECKS (3,840 hours).................................................................... 5
2.6 1.5-YEAR CHECKS (5,760 hours)................................................................. 6
2.7 3-YEAR CHECKS (11,520 hours).................................................................. 6
2.8 MAINTENANCE TOOLS ............................................................................... 6
3 PERIODIC MAINTENANCE .................................................................... 7
3.1 GREASE REPLACEMENT ............................................................................ 7
3.2 PROCEDURE FOR RELEASING THE GREASE REMAINING PREESSURE
....................................................................................................................... 9
3.3 BATTERY REPLACEMENT .......................................................................... 9
4 TROUBLESHOOTING .......................................................................... 11
4.1 GENERAL ................................................................................................... 11
4.2 PROBLEMS AND CAUSES......................................................................... 11
4.3 BACKLASH MEASUREMENT..................................................................... 17
4.4 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS .................... 19
5 ADJUSTMENTS.................................................................................... 20
5.1 REFERENCE POSITION AND MOVING RANGE....................................... 20
5.2 MASTERING ............................................................................................... 21
5.2.1 Resetting Alarms and Preparing for Mastering ......................................................22
5.2.2 Fixture Position Master ..........................................................................................22
5.2.3 Zero Position Mastering .........................................................................................30
5.2.4 Quick Mastering .....................................................................................................33
5.2.5 Single Axis Mastering ............................................................................................35
5.2.6 Mastering Data Entry .............................................................................................38
5.2.7 Confirming Mastering ............................................................................................40
6 COMPONENT REPLACEMENT AND ADJUSTMENTS....................... 41

6.1 REPLACING THE MOTOR ......................................................................... 41
6.2 REPLACING THE REDUCER ..................................................................... 45
6.3 SEALANT APPLICATION (1000kg/1500kg payload (Hollow type))
(1000kg/1500kg payload (Compact type))................................................... 47
7 PIPING AND WIRING ........................................................................... 50
c-1
TABLE OF CONTENTS B-82545EN/03
7.1 WIRING DIAGRAMS ................................................................................... 50

7.2 CABLING (WHEN THE HARTING CONNECTOR OPTION IS SELECTED)50
8 CABLE REPLACEMENT ...................................................................... 51
8.1 REPLACING CABLES................................................................................. 51
II. CONNECTION
1 POSITIONER OUTLINE DRAWING ..................................................... 57
1.1 OUTLINE DRAWING AND OPERATION AREA DIAGRAM ........................ 57
2 MOUNTING DEVICES ON THE POSITIONER ..................................... 60
2.1 POSITIONER LOAD CONDITION............................................................... 60
2.2 CHANGING METHOD OF PAYLOAD SPECIFICATION............................. 64
2.2.1 Method of executing KAREL program by using “Call program”..........................65
2.2.2 Method of executing KAREL program directly.....................................................67
3 TRANSPORTATION AND INSTALLATION ......................................... 70

3.1 TRANSPORTATION.................................................................................... 70
3.2 STORING THE POSITIONER ..................................................................... 72
3.3 INSTALLATION ........................................................................................... 72
3.4 MAINTENANCE CLEARANCE.................................................................... 86
3.5 ASSEMBLING THE POSITIONER FOR INSTALLATION ........................... 88
3.6 INSTALLATION CONDITIONS.................................................................... 88
APPENDIX
A SPARE PARTS LISTS .......................................................................... 91
B CONNECTION DIAGRAMS .................................................................. 93
C PERIODIC INSPECTION TABLE.......................................................... 96
D STRENGTH OF BOLT AND BOLT TORQUE LIST.............................. 98
c-2
I. MAINTENANCE
B-82545EN/03 MAINTENANCE 1.CONFIGURATION
1 CONFIGURATION
Fig. 1 shows the configuration of the mechanical unit.
The axis drive mechanism is configured in such a way that the flange base is rotated by reducing the rotation
speed of an AC servo motor with a reducer.
The flange base is supported on the base through the reducer.
Flange
Reducer
Base
Motor
Fig. 1 Mechanical unit configuration
Refer to Appendix A about the major mechanical unit components.
-3-
2.PREVENTIVE MAINTENANCE MAINTENANCE B-82545EN/03
2 PREVENTIVE MAINTENANCE
Daily inspection, periodic inspection, and periodic maintenance can keep the performance of the positioner
stable for a long period of time.
NOTE
The annual operating time of the 1-axis servo positioner is assumed 3,840 hours.
When using the positioner beyond this annual operating time, correct the
maintenance frequency in this chapter, which is determined on assumption that
the positioner is used for 3,840 hours per year, and perform maintenance as
appropriate.
2.1 DAILY INSPECTION

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

Item Check items Check points
1 Air pressure Check air pressure using the pressure gauge on the air regulator as shown in Fig.7.1.1. If
it does not meet the specified pressure of 0.49 to 0.69 MPa (5-7 kgf/cm2), adjust it using
the regulator pressure-setting handle.
2 Lubricator oil Check the drop quantity during wrist or hand motion. If it does not meet the specified
mist quantity value(1 drop/10-20 sec), adjust it using the lubricator control knob. Under normal usage,
the lubricator becomes empty in about 10 to 20 days under normal operation.
3 Lubricator oil Check to see that the lubricator level is within the specified level.
level
4 Leakage from Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.
hose
5 Drain Check drain and release it. When quantity of the drain is remarkable, examine the setting
of the air dryer to the air supply side.
Oil inlet Adjusting knob
Lubricator
mist amount check
Lubricator
Regulator Pressure gauge

Filter
pressure
setting handle
Fig. 2.1 Three-piece pneumatic option
-4-
B-82545EN/03 MAINTENANCE 2.PREVENTIVE MAINTENANCE
b) After automatic operation

1 Vibration, abnormal Check whether the robot moves along and about the axes smoothly without
noises, and motor unusual vibration or sounds. Also, check whether the temperatures of the motors
heating are excessively high.
2 Changing repeatability Check to see that the stop positions of the robot have not deviated from the
previous stop positions.
3 Peripheral devices for Check whether the peripheral devices operate properly according to commands
proper operation from the robot.
4 Brakes for each axis Check that the end effector drops within 5 mm when the power is off.
2.2 First 1-month (960 hours) checks

Check the following items once every one-month (320 hours). Additional inspection areas and times should
be added to the table according to the robot’s working conditions, environment, etc. Then every 3 months
thereafter. (See the Section 2.4.)

1 Ventilation portion of controller If the ventilation portion of the controller is dusty, turn off power and clean
the unit.
2.3 First 3-MONTH CHECKS (960 hours)

Check the following items at the first quarterly inspection, then every year thereafter.(See the Section 2.5.)
No. Inspection item Inspection procedure

1 Loose connector Check that the motor connectors or other connectors are not loose.
2 Loose bolt Check that the cover retaining bolts or external bolts are not loose. In
particular, check the following three points.
1 axis positioner, Follower unit base fixing bolts
Bolts fixing jigs to the flange surface
motor cover retaining bolts
3 Debris removal Remove any spatter, debris, and dust from the mechanical unit.
2.4 3-MONTH CHECKS (960 hours)

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

1 Ventilation portion of controller (See Section 2.2.)
2.5 1-YEAR CHECKS (3,840 hours)

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

1 Loose connector See Section 2.3.
2 Loose bolt See Section 2.3.
3 Debris removal See Section 2.3.
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2.PREVENTIVE MAINTENANCE MAINTENANCE B-82545EN/03
2.6 1.5-YEAR CHECKS (5,760 hours)

Check the following item once every 1.5 year (5,760 hours).

1 Battery replacement Replace the battery in the mechanical unit. (See Section 3.3.)
2.7 3-YEAR CHECKS (11,520 hours)

Check the following item once every 3 year (11,520 hours).

1 Grease replacement See Section 3.1.
2.8 MAINTENANCE TOOLS

You should have the following instruments and tools ready for maintenance.
a) Measuring instruments
Instrument Condition Use
Dial gauge 1/100mm For positioning precision and backlash measurement
Calipers 150mm
b) Tools
Phillips screwdrivers (large, medium, and small sizes)
Flat-blade screwdrivers (large, medium, and small sizes)
Box wrenches 7 mm wide across wrenches flats (For grease nipple)
Allen wrenches Dihedral width 2.5, 3, 5, 6, 8, 10, 12, 14, 17 (For replacing part)
Torque wrench
Long T wrenches (M5, M6)
Adjustable wrenches (medium and small sizes)
Pliers
Long-nose pliers
Cutting pliers
Both-ended wrench
Grease gun
C-ring pliers
Flashlight
Seal tape
LOCTITE 242, 262, 675
Sling
Gear puller
Separator
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B-82545EN/03 MAINTENANCE 3.PERIODIC MAINTENANCE
3 PERIODIC MAINTENANCE
3.1 GREASE REPLACEMENT
The grease for the reducers needs to be replaced every three years or 11,520 hours in the procedure shown
below. For greasing points, see Figs. 3.1 (a) to (c).
<1> Remove the seal bolts and plugs of the grease outlets shown in Figs. 3.1(a) to (c).
<2> Attach the grease nipple supplied with the positioner.
<3> Apply the grease specified in Table 3.1(a) to (c) until the old grease is replaced and the new grease is
output from the grease outlets. Use grease outlet 1 shown in Figs. 3.1 (a) to (c). Only when grease
outlet 1 cannot be used due to the installation state of the jig, use grease outlet 2. At this time, confirm
that the same amount of the old grease as that of applied grease has been output to prevent the grease
bath from overflowing.
<4> After applying grease, release the remaining pressure in the grease bath as instructed by the procedure
in Section 3.2.
CAUTION
When reusing a grease nipple once used, wind sealing tape around the screw.
Table 3.1 (a) Grease to be replaced at regular intervals of three years (11,520 hours)
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
Specified grease Amount of grease to Positioner posture when
Gun tip pressure
Kyodo Yushi be applied greased
Reducer VIGOGREASE RE0 About 980 ml 0.1 MPa or less Grease outlet 1 is used : 0°
(Specification: A98L-0040-0174) (NOTE) Grease outlet 2 is used : free
NOTE When using a hand pump, apply grease approximately once per two seconds.
Table 3.1 (b) Grease to be replaced at regular intervals of three years (11,520 hours)
(1000kg/1500kg payload (Hollow type))
Gun tip pressure
Reducer VIGOGREASE RE0 About 5500 ml 0.15 MPa or less Grease outlet 1 is used : 0°
(Specification: A98L-0040-0174) (NOTE) Grease outlet 2 is used : free
NOTE When using a hand pump, apply grease approximately twice per three seconds.
Table 3.1 (c) Grease to be replaced at regular intervals of three years (11,520 hours)
(1000kg/1500kg payload (Compact type))
Gun tip pressure
Reducer VIGOGREASE RE0 About 1193 ml 0.15 MPa or less
free
(Specification: A98L-0040-0174) (NOTE)
NOTE When using a hand pump, apply grease approximately twice per three seconds.
-7-
3.PERIODIC MAINTENANCE MAINTENANCE B-82545EN/03
Taper plug Rc1/8

排脂口 1 シールボルト
Seal bolt M12X15
排脂口 2 シールボルト for grease outlet 1
for grease outlet 2
Taper plug Rc1/8

for
給脂grease
口埋 inlet
栓
Fig. 3.1 (a) Grease inlet and outlet

Seal bolt M12X15

Seal
排脂口2 bolt シールボルト
M12X15 for grease outlet 1
for grease outlet 2 排脂口1 シールボルト
Taper
給脂口plug 埋栓 Rc1/8
for grease inlet
Fig. 3.1 (b) Grease inlet and outlet (1000kg/1500kg payload (Hollow type))
Taper plug Rc1/8

for grease inlet
A
75°
A Taper plug Rc1/8

for grease outlet
SECTION A-A
Fig. 3.1 (c) Grease inlet and outlet (1000kg/1500kg payload (Compact type))
-8-
B-82545EN/03 MAINTENANCE 3.PERIODIC MAINTENANCE
CAUTION
If you grease incorrectly, the pressure in the grease bath will increase, leading to a
broken seal, which will eventually cause grease leakage or malfunction.
When greasing, be sure to follow the cautions stated below.
1 Before starting greasing, open the grease outlets (remove bolts and the like from
the grease outlets).
2 Using a manual greasing pump, grease gently and slowly.
3 Avoid using a pneumatic pump driven from a factory pneumatic line as much as
possible.
Even when using Table 3.1 (a) to (c) or less during application of grease.
4 Be sure to use the specified grease. Otherwise, damage to reducers or a similar
abnormality may occur.
5 After applying grease, release the remaining pressure within the grease bath as
described in the procedure in Section 3.2.
6 Wipe off any grease from the floor and positioner completely, so no one will slip on
it.
3.2 PROCEDURE FOR RELEASING THE GREASE

REMAINING PREESSURE
After applying grease, to release remaining pressure from the grease bath, perform a repetitive operation
with a motion angle of at least 60 degrees and OVR100% for 10 minutes or more while leaving the grease
inlets and outlets open.
Under the grease inlets and outlets, attach bags for collecting grease so that grease does not spatter when it
comes out of the inlets or outlets.
If the above operation cannot be performed due to the environment of the positioner, prolong the operating
time so that an equivalent operation can be performed. (If only a motion angle of 30 degrees can be set,
perform an operation for 20 minutes or more.) After completion of the operation, attach the plugs and seal
bolts to the grease inlets and outlets. When reusing the taper plugs and seal bolts, be sure to seal them with
seal tape.
3.3 BATTERY REPLACEMENT

A backup battery is used to keep the reference-position data for the positioner.
The battery needs to be replaced at regular intervals of one year and half. Follow this procedure for battery
replacement.
This section describes the battery replacement procedure to follow when the HARTING connector option is
selected. Replace the battery on the controller side when the HARTING connector option is not selected.
1) Keep the power turned on.

Press the EMERGENCY STOP button of the robot to keep robot and positioner from moving.
CAUTION
Be sure to turn on the power. If the battery is replaced when the power is off, the
current position information is lost, so that mastering becomes necessary.
2) Uncap the battery case.

3) Take out the battery from the battery case.
4) Insert a new battery into the battery case while paying attention to the polarity of the battery.
-9-
3.PERIODIC MAINTENANCE MAINTENANCE B-82545EN/03
5) Cap the battery case.
Fig. 3.3 (a) Battery replacement 1

(300kg load capacity (Hollow type)) , (300kg/500kg load capacity (Hollow type))
, (1000kg/1500kg payload (Hollow type))
Fig. 3.3 (b) Battery replacement 1

Cap
Battery case Battery specifications: A98L-0031-0005

(1.5V size-D 4 pcs)
Fig. 3.3 (c) Battery replacement 2
- 10 -
B-82545EN/03 MAINTENANCE 4.TROUBLESHOOTING
4 TROUBLESHOOTING
4.1 GENERAL
The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems
may become further complicated, if they are not corrected properly. Therefore, it is necessary to keep an
accurate record of problems and to take proper corrective actions.
4.2 PROBLEMS AND CAUSES

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

Symptom Description Cause Measure
Vibration -The base lifts off the floor plate [Base fastening] -If a bolt is loose, apply
noise as the positioner operates. -It is likely that the positioner LOCTITE and tighten it to the
-There is a gap between the base is not securely fastened to appropriate torque.
base and floor plate. the floor plate. -Adjust the floor plate surface
-A base retaining bolt is loose. -Probable causes are a loose flatness to within the specified
bolt, an insufficient degree of tolerance.
surface flatness, or foreign -If there is any foreign matter
material caught. between the base and floor
-If the positioner is not securely plate, remove it.
fastened to the floor plate, the
base lifts the floor plate as the
positioner operates, allowing
the base and floor plates to
strike each other, which, in turn,
leads to vibration.
-The rack or floor vibrates [Rack or floor] -Reinforce the rack or floor to
during operation of the -It is likely that the rack or floor make it more rigid.
positioner. is not sufficiently rigid. -If it is impossible to reinforce
-If the rack or floor is not the rack or floor, modify the
sufficiently rigid, reaction from robot control program; doing so
the positioner deforms the rack might reduce the amount of
or floor, leading to vibration. vibration.
-Vibration becomes more [Overload] -Check the maximum load that
serious when the positioner -It is likely that the load on the the positioner can handle once
adopts a specific posture. positioner is greater than the more. If the positioner is found
-If the operating speed of the maximum rating. to be overloaded, reduce the
positioner is reduced, vibration -It is likely that the positioner load, or modify the positioner
stops. control program is too control program.
-Vibration is most noticeable demanding for the positioner -Vibration in a specific portion
when the positioner is hardware. can be reduced by modifying
accelerating. -It is likely that the the robot control program while
ACCELERATION value is slowing the positioner and
excessive. reducing its acceleration (to
minimize the influence on the
entire cycle time).
- 11 -
4.TROUBLESHOOTING MAINTENANCE B-82545EN/03

Vibration -Vibration was first noticed after [Broken gear, bearing, or -Remove the motor, and
noise the positioner collided with an reducer] replace the gear , the bearing,
(Continued) object or the positioner was - It is likely that collision or and the reducer. For the spec.
overloaded for a long period. overload applied an excessive of parts and the method of
-The grease has not been force on the drive mechanism, replacement, contact FANUC.
exchanged for a long period. thus damaging the geartooth -Using the positioner within its
surface or rolling surface of a maximum rating prevents
bearing, or reducer. problems with the drive
- It is likely that prolonged use of mechanism.
the positioner while overloaded -Regularly changing the grease
caused fretting of the gear tooth with a specified type can help
surface or rolling surface of a prevent problems.
bearing, or reducer due to
resulting metal fatigue.
- It is likely that foreign matter
caught in a gear, bearing, or
within a reducer caused
damage on the gear tooth
surface or rolling surface of the
bearing, or reducer.
- It is likely that, because the
grease has not been changed
for a long period, fretting
occurred on the gear tooth
surface or rolling surface of a
bearing, or reducer due to metal
fatigue.
These factors all generate
cyclic vibration and noise.
- 12 -

Vibration -The cause of problem cannot [Controller, cable, and motor] -Refer to the Controller
Noise be identified from examination -If a failure occurs in a controller Maintenance Manual for
(Continued) of the floor, rack, or mechanical circuit, preventing control troubleshooting related to the
section. commands from being supplied controller and amplifier.
to the motor normally, or -Replace the pulsecoder for the
preventing motor information motor, and check whether the
from being sent to the controller vibration still occurs.
normally, vibration might occur. -Also, replace the motor, and
-If the pulsecoder develops a check whether vibration still
fault, vibration might occur occurs. For the method of
because replacement, contact FANUC.
information about the motor -Check that the positioner is
position cannot be transferred supplied with the rated voltage.
to the controller accurately. -Check whether the sheath of
-If the motor becomes the power cord is damaged. If
defective, vibration might occur so, replace the power cord, and
because the motor cannot check whether vibration still
deliver its rated performance. occurs.
-If a connection cable between -Check whether the sheath of
them has an intermittent break, the cable connecting the
vibration might occur. mechanical section and
-If the power cable has an controller is damaged. If so,
intermittent break, vibration replace the connection cable,
might occur. and check whether vibration still
-If the power source voltage occurs.
drops below the rating, vibration -Check that the positioner
might occur. control parameter is set to a
-If a robot control parameter is valid value. If it is set to an
set to an invalid value, vibration invalid value, correct it. Contact
might occur. FANUC for further information if
necessary.
-There is some relationship [Noise from a nearby machine] -Connect the grounding wire
between the vibration of the -If the positioner is not firmly to ensure a reliable
positioner and the operation of grounded properly, electrical ground potential and prevent
a machine near the positioner. noise is induced on the extraneous electrical noise.
grounding wire, preventing
commands from being
transferred accurately, thus
leading to vibration.
-If the positioner is grounded at
an unsuitable point, its
grounding potential becomes
unstable, and noise is likely to
be induced on the grounding
line, thus leading to vibration.
-There is an unusual sound -There may be an unusual -Use the specified grease.
after replacement of grease. sound when using other than -When there is an unusual
-There is an unusual sound the specified grease. sound even for specified
after a long period of time. -Even for the specified grease, grease, perform operation for
-There is an unusual sound there may be an unusual one or two days on an
during operation at low speed. sound during operation at low experiment. Generally, a usual
speed immediately after sound will disappear.
replacement or after a long
period of time.
- 13 -

Rattling -While the positioner is not [Mechanical section coupling -Check that the following bolts
supplied with power, pushing it bolt] are tight. If any of these bolts is
with the hand causes part of the -It is likely that overloading or a loose, apply LOCTITE and
mechanical unit to wobble. collision has loosened a tighten it to the appropriate
-There is a gap on the mounting mounting bolt in the positioner torque.
surface of the mechanical unit. mechanical section. -Motor retaining bolt
-Reducer retaining bolt
-Reducer shaft retaining bolt
-Base retaining bolt
-End effecter retaining bolt
-Backlash is greater than the [Increase in backlash] -Remove the motor, and check
tolerance stated in the -It is likely that excessive force whether any of its gears are
applicable maintenance applied to the drive mechanism, broken. If any gear is broken,
manual. due to a collision or replace it.
(See Table 4.3 (b) and (c).) overloading, has broken a gear -Check whether any other gear
or the inside of the reducer, of the drive mechanism is
resulting in an increase in the damage. If there is no damage
amount of backlash. gear, replace the reducer.
-It is likely that prolonged use in -If the reducer is broken, or if a
overload conditions has caused gear tooth is missing, replace
the tooth surfaces of a gear and the relevant component. Also,
the reducer to wear out, remove all the grease from the
resulting in an increase in the gear box and wash the inside of
amount of backlash. the gear box.
-It is likely that prolonged use -After replacing the gear or
without changing the grease reducer, add an appropriate
has caused the tooth surfaces amount of grease.
of a gear and the inside of the -Using the positioner within its
reducer to wear out, resulting in maximum rating prevents
an increase in the amount of problems with the drive
backlash. mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
- 14 -

Motor -The ambient temperature of [Ambient temperature] -The teach pendant can be
overheating the installation location -It is likely that a rise in the used to monitor the average
increases, causing ambient temperature or current. Check the average
the motor to overheat. attaching the motor cover current when the robot control
-After a cover was attached to prevented the motor from program is running. The
the motor, the motor releasing heat efficiently, thus allowable average current is
overheated. leading to overheating. specified for the positioner
-After the robot control program [Operating condition] according to its ambient
or the load was changed, the -It is likely that the positioner temperature. Contact FANUC
motor was operated with the for further information.
overheated. maximum average current -Relaxing the positioner control
exceeded. program and conditions can
reduce the average current,
thus preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of the
motor well ventilated enables
the motor to release heat
efficiently, thus preventing
overheating. Using a fan to
direct air at the motor is also
effective.
-If there is a source of heat
near the motor, it is advisable
to install shielding to protect the
motor from heat radiation.
-After a control parameter was [Parameter] -Input an appropriate
changed, the motor -If data input for a workpiece is parameter as described in
overheated. invalid, the positioner cannot be CONTROLLER OPERATOR’S
accelerated or decelerated MANUAL.
normally, so the average
current increases, leading to
overheating.
-Symptom other than stated [Mechanical section problems] -Repair the mechanical unit
above -It is likely that problems while referring to the above
occurred in the mechanical unit descriptions of vibration, noise,
drive mechanism, thus placing and rattling.
an excessive load on the motor. -Check that, when the servo
[Motor problems] system is energized, the brake
-It is likely that a failure of the is released.
motor brake resulted in the If the brake remains applied to
motor running with the brake the motor all the time, replace
applied, thus placing an the motor.
excessive load on the motor. -If the average current falls
-It is likely that a failure of the after the motor is replaced, it
motor prevented it from indicates that the first motor
delivering its rated was faulty.
performance, thus causing an
excessive current to flow
through the motor.
- 15 -

Grease -Grease is leaking from the [Poor sealing] -If a crack develops in the
leakage mechanical unit. -Probable causes are a crack in casting, sealant can be used as
the casting, a broken O-ring, a a quick-fix to prevent further
damaged oil seal, or a loose grease leakage. However, the
seal bolt. component should be replaced
-A crack in a casting can occur as soon as possible, because
due to excessive force that the crack might extend.
might be caused in collision. -O-rings are used in the
-An O-ring can be damaged if it locations listed below.
is trapped or cut during -Motor coupling section
disassembling or -Reducer (case and shaft)
re-assembling. coupling section
-An oil seal might be damaged if -Oil seals are used in the
extraneous dust scratches the locations stated below.
lip of the oil seal. -Inside the reducer
-A loose seal bolt and grease -Seal bolts and nipples are used
nipple might allow grease to in the locations stated below.
leak along the threads. -Grease drain inlet and outlet
Axis rotation -An axis rotates because the [Brake drive relay and motor] -Check whether the brake drive
brake does not function. -It is likely that brake drive relay relay contacts are stuck to each
-An axis rotates gradually when contacts are stuck to each other other. If they are found to be
it should be at rest. to keep the brake current stuck, replace the relay.
flowing, thus preventing the -If the brake shoe is worn out, if
brake from operating when the the brake main body is
motor is deenergized. damaged, or if oil or grease has
-It is likely that the brake shoe entered the motor, replace the
has worn out or the brake main motor.
body is damaged, preventing
the brake from operating
efficiently.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
Displaceme -The positioner operates at a [Mechanical section problems] -If the repeatability is unstable,
nt point other than the taught -If the repeatability is unstable, repair the mechanical section
position. probable causes are a failure in by referring to the above
-The repeatability is not within the drive mechanism or a loose descriptions of vibration, noise,
the tolerance. bolt. and rattling.
-If the repeatability becomes -If the repeatability is stable,
stable it is likely that a collision correct the taught program.
imposed an excessive load, Variation will not occur unless
leading to slipping on the base another collision occurs.
surface or the mating surface of -If the pulsecoder is abnormal,
an arm or reducer. replace the motor or the
-It is likely that the pulsecoder is pulsecoder.
abnormal.
-Displacement occurs only in a [Peripheral unit displacement] -Correct the setting of the
specific peripheral unit. -It is likely that an external force peripheral unit position.
was applied to the peripheral -Correct the taught program.
unit, thus shifting its position
relative to the positioner.
-Displacement occurred after a [Parameter] -Re-enter the previous
parameter was changed. -It is likely that the mastering mastering data, which is known
data was rewritten in such a to be correct.
way that -If correct mastering data is
the positioner origin was unavailable, perform mastering
shifted. again.
- 16 -

BZAL alarm -BZAL is displayed on the -The voltage of the memory -Replace the battery.
occurred controller screen backup battery may be low. -Replace the cable.
-The pulsecoder cable may be
defected.
Troubles -Starting of an arc is not good. -The welding ground cable may -Tighten the connection part of
related to -An arc is unstable. be loosened or broken(NOTE). the ground cable.
arc welding -Beads are irregular. -Replace the ground cable.
NOTE
Arc welding troubles may be caused by a welding unit such as a welding power
supply or torch. When a trouble occurs, see the manual of each unit to find the
cause.
4.3 BACKLASH MEASUREMENT

Measurement method
1. Maintain the positioner in a specified posture. (See Fig. 4.3 (a))
2. Apply positive and negative loads to each axis as shown in Fig. 4.3 (a).
3. Remove the loads and measure the displacement.
Apply positive and negative loads three times and then remove the loads. Calculate the average of the
displacements in the second and third measurements as the backlash.
Stop position
0
+10kgf
Firtst step
-10kgf (Do not measure)
+10kgf
0kgf Second step
L1
-10kgf (B2 =L1+ L2)
f
L2
+10kgf
0kgf Third step
L3 (B3=L3+ L4)
-10kgf
0kgf
L4
Fig. 4.3 (a) Backlash Measurement Method
Backlash B is calculated using the following expression:

B2 + B3
B=
2
- 17 -
Table 4.3 (a) Backlash measurement posture and measurement position

Measured posture Measurement position (mm)
0° See fig 4.3 (b)
Table 4.3 (b) Backlash allowable rattling of each axis

(300kg payload (hollow type)), (300kg/500kg payload (Hollow type)),
Angle conversion (arc-min) 2.5
Displacement conversion (mm) 0.127
Distance from rotation center to measurement position (mm) 175
Table 4.3 (c) Backlash allowable rattling of each axis

Table 4.3 (d) Backlash allowable rattling of each axis

NOTE
The displacement conversion value indicates play in the direction of rotation from
the center of the axis at the distance shown in brackets.
Backlash
measurement position
(*)
Install the fixture like this.

(*)
350mm : 300kg payload (Hollow type), 300kg/500kg payload (Hollow type)
450mm : 1000kg/1500kg payload (Hollow type)
300mm : 1000kg/1500kg payload (Compact type)
Fig. 4.3 (b) Backlash measurement position

- 18 -
4.4 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS

Adjustments are needed after a component is replaced.
The following table lists components and the adjustment items that must be made after their replacement.
After replacing a component, make necessary adjustments according to this table.
Component replacement or function change Adjustment item

Cable replacement Quick mastering
Battery replacement Replace the battery with the power kept on.
(The battery should be replaced once 1.5 years.) No adjustment is needed.
- 19 -
5.ADJUSTMENTS MAINTENANCE B-82545EN/03
5 ADJUSTMENTS
Each part of the mechanical units of a positioner is set to the best condition before the positioner is shipped
to the customer. The customer does not need to make adjustments on the positioner when it is delivered.
If a mechanical unit of the positioner has a large backlash because of a long-term use or component
replacement, make adjustments according to this section.
5.1 REFERENCE POSITION AND MOVING RANGE

Zero point and software motion limits are provided for controlled axis. Exceeding the software motion
limit of a controlled axis is called overtravel (OT). Overtravel is detected at both ends of the motion limit
for each axis. The positioner cannot exceed the software motion limit unless there is a failure of the system
causing loss of zero point position or there is a system error.
Fig. 5.1 (a) shows the zero point and motion limit (stroke).
Fig. 5.1 (b) shows the motion direction (+/−).
+370°
0°
-370°
(NOTE) There is not a mechanical stopper.

Fig. 5.1 (a) Axis swiveling
- 20 -
B-82545EN/03 MAINTENANCE 5.ADJUSTMENTS
+ 740°
(±370°)
Fig. 5.1 (b) Axis motion direction
5.2 MASTERING
Mastering method
There are following five methods of mastering.
Table 5.2 Mastering methods

Fixture position mastering This is performed using a mastering fixture before the machine is shipped
from the factory.
Zero-position mastering (witness This is performed with all axes set at the 0-degree position. A zero-position
mark mastering) mark (witness mark) is attached to each positioner axis. This mastering is
performed with all axes aligned to their respective witness marks.
Quick mastering This is performed at a user-specified position. The corresponding count value
is obtained from the rotation speed of the pulsecoder connected to the
relevant motor and the rotation angel within one rotation. Quick mastering
uses the fact that the absolute value of a rotation angel within one rotation will
not be lost.
Single axis mastering This is performed for one axis at a time. The mastering position for each axis
can be specified by the user. This is useful in performing mastering on a
specific axis.
Mastering data entry Mastering data is entered directly.
Once mastering is performed, it is necessary to carry out positioning, or calibration. Positioning is an

operation is which the controller reads the current pulse count value to sense the current position of the
positioner.
If the backup batteries for the pulsecoder go dead during cable replacement, quick mastering can be
performed, resetting the positioner exactly to its initial position by calibration.
If replacement of the motors, reducers, or other parts causes mechanical changes in the phases of the
pulsecoder, quick mastering cannot be performed. In this case, perform fixture position mastering for
accurate position calibration.
- 21 -
CAUTION
If mastering is performed incorrectly, the positioner may behave unexpectedly.
This is very dangerous. Therefore, the positioning screen is designed to appear
only when the $MATER_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.
NOTE
It is recommended that you back up the current mastering data before performing
mastering.
5.2.1 Resetting Alarms and Preparing for Mastering

Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and
display the positioning menu.
Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse not established”
Procedure
1 Display the positioning menu by following steps 1 to 6.
1 Press the screen selection key.
2 Press [0 NEXT] and select [6 SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4 Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER].
5 Press F1 [TYPE], and select [Master/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal] menu.
2 To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.

1 Press the screen selection key.
2 Press [0 NEXT] and Select [6 SYSTEM].
3 Press F1 [TYPE], and select [Master/Cal] from the menu.
4 Place the cursor on F3 RES_PCA, then press F4 [TRUE].
5 Turn off the controller power and on again.
3 To reset the “Servo 075 Pulse not established” alarm, follow steps 1 to 3.
1 When the controller power is turned on again, the message “Servo 075 Pulse not established”
appears again.
2 Rotate the axis for which the message mentioned above has appeared through 10 degrees in either
direction.
3 Press [FAULT RESET]. The alarm is reset.
5.2.2 Fixture Position Master

Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the
predetermined fixture position.
Fixture position mastering is accurate because a dedicated mastering fixture is used. Fixture position
mastering is not required in daily operations because it is factory-performed.
When mastering the positioner, arrange the positioner to meet the following conditions.
- Make the positioner mounting base horizontal.
(Set the positioner mounting surface so that the levelness of the entire surface is 1 mm or less.)
- Remove the hand and other parts form the wrist.
- 22 -
- Set the positioner in the condition protected from an external force.
CAUTION
Be extremely careful in moving the positioner during mastering because an axis
movement range is not checked.
Assembling mastering fixtures

Attach the mastering fixture to the positioner as shown in Fig. 5.2.2 (a) to (h).
Remove the seal from the mastering fixture attaching surface.

Be sure to restore the original condition after completion of mastering.
Pin D
A290-7220-X956 Mastering fixture　B
A290-7220-X952
Pin C
Bolt A290-7220-X955
M10X20(2pcs)
Bolt
M5X16
Clamp
A290-7022-X954
Mastering fixture A
A290-7220-X951
Bolt Dial gauge

M8X20(2pcs)
Pin B
A290-7220-X953
Pin A
A290-7220-X954
Fig. 5.2.2 (a) Attaching the mastering fixture to the 1-axis positioner
- 23 -
Fig. 5.2.2 (b) Attaching the mastering fixture to the 1-axis positioner
(300kg payload (hollow type)) , (300kg/500kg payload (Hollow type))
Bolt
M5X16
Clamp
A290-7022-X954
Mastering fixture A
A290-7220-X957
Pin A
A290-7220-X953
Pin B
A290-7220-X954
Bolt
M8X20(2pcs)
Fig. 5.2.2 (c) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Hollow type))
- 24 -
Mastering fixture B
A290-7220-X958
Bolt
M16X30(2pcs)
Pin D
A290-7220-X956
Pin C
A290-7220-X955
Fig. 5.2.2 (d) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Hollow type))
The direction
of pin O6 The direction
of pin O10
Fig. 5.2.2 (e) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Hollow type))
- 25 -
Bolt
M5X16
Clamp
A290-7022-X954
Mastering fixture A
A290-7220-X961 Dial gauge
Bolt
M8X20 (2 pcs)
Pin B
A290-7220-X954
Pin A
A290-7220-X953
Fig. 5.2.2 (f) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Compact type))
Mastering fixture B
A290-7220-X962
Bolt
M12X30 (2pcs)
Pin C
A290-7220-X955
Pin D
A290-7220-X956
Fig. 5.2.2 (g) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Compact type))
- 26 -
The direction of
pin O6
The direction of
pin O10
Fig. 5.2.2 (h) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Compact type))
Mastering
1 Press MENUS.
2 Press NEXT and select SYSTEM.
3 Press F1, [TYPE].
4 Select Mater/Cal.
AUTO
SYSTEM Master/Cal G2 JOINT 1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER

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

6 CALIBRATE
Calibrate key select? [NO]

[ TYPE ] YES NO
5 Release brake control, and jog the positioner into a posture for mastering.
See fig. 5.2.2 (i) to (k) for the mastering posture.
NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.(∗)SSV_OFF_ALL: FALSE
$PARAM_GROUP.(∗)SSV_OFF_ENB[*]: FALSE (for all axes)
After changing the system variables, turn off the controller power and on again.
[*] is the axis number of the positioner.
Slowly move the positioner by axial feed so that the values of dial indicators shown in Fig. 5.2.2 (a),
(c) and (f) are 3 mm.
- 27 -
6 Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES.
AUTO
TORQUE = [ON ]

3 QUICK MASTER

6 CALIBRATE
Robot Mastered! Mastering Data :
< 0.0000> < 90.0000> < 0.0000>

< 0.0000> < 0.0000> < 0.0000>
[ TYPE ] LOAD RES_PCA DONE
7 Select “ 6 CALIBRATE “ and press F4, YES. Mastering will be performed

Alternatively, turn off the controller power and on again. Turning on the controller power on always
causes positioning to be performed.
AUTO
SYSTEM Master/Cal JOINT 1%
TORQUE = [ON ]
3 QUICK MASTER
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):

< 0.0000> < 0.0000> < 0.0000>
< 0.0000> < 0.0000> < 0.0000>
Quick master ? [NO]

[ TYPE ] YES NONE
8 After positioning is completed, press F5 [DONE].

9 Restore brake control. Reset system variables $PARAM_GROUP.$SV_OFF_ALL and
$PARAM_GROUP.$SV_OFF_ENB to their original values, and turn the power off and then back on.
- 28 -
10 After mastering, update the mastering data listed in the factory-supplied data sheet with new mastering
data ($DMR_GROUP.$MASTER_COUN [*]).
([*] is the axis number of the positioner.).
Mastering position :0°

Fig. 5.2.2 (i) Mastering position
(300kg payload (Hollow type)), (300kg/500kg payload (Hollow type))
Mastering position : 0°
Fig. 5.2.2 (j) Mastering position (1000kg/1500kg payload (Hollow type)
- 29 -
Mastering position
:0°
Fig. 5.2.2 (k) Mastering position (1000kg/1500kg payload (Compact type)
5.2.3 Zero Position Mastering

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

Step
1 Press MENUS.
2 Select NEXT and press SYSTEM.
3 Press F1, [TYPE].
4 Select Master/Cal.
- 30 -
AUTO
TORQUE = [ON ]

3 QUICK MASTER

6 CALIBRATE
Calibrate zero position master key select? [NO]

[ TYPE ] YES NO
5 Release brake control, and jog the robot into a posture for mastering. See Fig. 5.2.3 (a) to (c) for the
mastering posture.
NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.SSV_OFF_ALL: FALSE
$PARAM GROUP.SSV OFF ENB[*]: FALSE
(for all axes)
After changing the system variables, turn off the controller power and on again.
([*] is the axis number of the positioner.)
6 Select Zero Position Master.
AUTO
TORQUE = [ON ]
3 QUICK MASTER

6 CALIBRATE
Robot Mastered! Mastering Data:
<0>
- 31 -
7 Press F4, YES. Mastering will be performed automatically.

Alternatively, turn the power off and then back on. Mastering is performed.
When the power is turned off and then back on, mastering is always performed.
AUTO
TORQUE = [ON ]

3 QUICK MASTER

6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
< 0.0000>
Quick master? [NO]
[ TYPE ] YES NO
8 After calibration is completed, press F5[DONE].

9 Reset the brake control release settings to the original state. Set system variables $PARAM_GROUP,
$SV_OFF_ALL, and $SV_OFF_ENB to their original values, then turn off then back on the power.
Detail A
Fig. 5.2.3 (a) Marking of the zero-degree for each axis (witness mark)
- 32 -
Detail B
Fig. 5.2.3 (b) Marking of the zero-degree for each axis (witness mark) (1000kg/1500kg payload (Hollow type))
A
Detail A
Fig. 5.2.3 (c) Marking of the zero-degree for each axis (witness mark) (1000kg/1500kg payload (Compact type))
5.2.4 Quick Mastering

Quick mastering is performed at a user-specified position. The corresponding count value is obtained from
the rotation speed of the pulsecoder connected to the relevant motor and the rotation angle within one
rotation. Quick mastering uses the fact that the absolute value of a rotation angle within one rotation will not
be lost.
Quick mastering is factory-performed at the zero-degree position. Do not change the setting unless there is
a problem.
If it is impossible to set the positioner at the position mentioned above, it is necessary to re-set the quick
mastering reference position using the following method. (It would be convenient to set up a marker that
can work in place of the position mark.)
- 33 -
CAUTION
1 Quick mastering can be used, if the pulse count value is lost, for example,
because a low voltage has been detected on the backup battery for the pulse
counter.
2 Quick mastering cannot be used, after the pulsecoder is replaced or after the
mastering data is lost from the robot controller.
3 This operation cannot be performed if mastering data is lost as a result of
mechanical disassembly or maintenance. In this case, perform zero position
mastering or fixture position mastering to recover the mastering data.
Procedure Recording the Quick Master Reference Position

Step
1 Select SYSTEM.
2 Select Master/Cal.
AUTO
TORQUE = [ON ]

3 QUICK MASTER

6 CALIBRATE
Press 'ENTER' or number key to select.
3 Release brake control, and jog the positioner to the quick mastering reference position.
4 Move the cursor to SET QUICK MASTER REF and press ENTER. Press F4, YES.
Set quick master ref? [NO]
- 34 -
Procedure Quick Mastering

Step
1 Display the Master/Cal screen
AUTO
SYSTEM Master/Cal JOINT 1%
TORQUE = [ON ]

3 QUICK MASTER

6 CALIBRATE
Robot Not Mastered!
Quick master? [NO]

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

Single axis mastering is performed for one axis at a time. The mastering position for each axis can be
specified by the user. Single axis mastering can be used, if mastering data for a specific axis is lost, for
example, because a low voltage has been detected on the pulse counter backup battery or because the
pulsecoder has been replaced.
- 35 -
Table 5.2.5 Items Set in Single Axis Mastering

Item Description
Current position
The current position of the robot is displayed for each axis in degree units.
(Actual axis)
A mastering position is specified for an axis to be subjected to single axis mastering.
Mastering position (MSTR POS)
It would be convenient to set to it to the 0° position.
This item is set to 1 for an axis to be subjected to single axis mastering.
SEL
Usually, it is 0.
This item indicates whether single axis mastering has been completed for the
corresponding axis. It cannot be changed directly by the user. The value of the item
is reflected in $EACHMST_DON (1 to 9).
0 : Mastering data has been lost. Single axis mastering is necessary.
ST
1 : Mastering data has been lost.
(Mastering has been performed only for the other interactive axes.)
Single axis mastering is necessary.
2 : Mastering has been completed.
Procedure Mastering a Single Axis
Step
1. Select SYSTEM.
2. Select Master/Cal.
3. Select 4, Single Axis Master. You will see a screen similar to the following.
- 36 -
4. Move the cursor to the SEL column for the unmastered axis and press the numeric key “1”. Setting
of SEL is available for one or more axes.
5. Turn off brake control as required, and then jog the robot to the mastering position.
6. Enter axis data for the mastering position.
7. Press F5 [EXEC]. Mastering is performed. Therefore, SEL is reset to 0, and ST is re-set to 2 or 1.
SINGLE AXIS MASTER JOINT 30%

GROUP EXEC
1/9
ACTUAL POS (MSTR POS) (SEL) [ST]
F5 J1 25.255 (0.000) (0) [2]
J2 25.550 (0.000) (0) [2]
J3 -50.000 (0.000) (0) [2]
J4 12.500 (0.000) (0) [2]
J5 0.000 (0.000) (0) [2]
J6 0.000 (0.000) (0) [2]
E1 0.000 (0.000) (0) [2]
E2 0.000 (0.000) (0) [2]
E3 0.000 (0.000) (0) [2]
GROUP EXEC
8. When single axis mastering is completed, press the previous page key to resume the previous
screen.
9. Select [6 CALIBRATE], then press F4 [YES]. Positioning is performed. Alternatively, turn off the
- 37 -
controller power and on again. Positioning is performed.

10. After positioning is completed, press F5 [DONE].
11. Return brake control to original setting, and turn off the controller power and on again.
5.2.6 Mastering Data Entry

This function enables mastering data values to be assigned directly to a system variable. It can be used, if
mastering data has been lost, but the pulse count is preserved.
Mastering data entry method
Step
1 Select [6 SYSTEM] and press ENTER.
2 Select [Variable]. The system variable screen appears.
3 Change the mastering data.

The mastering data is saved to the $DMR_GRP(∗).$MASTER_COUN system variable.(∗ is the axis
number of the positioner.)
4 Select $DMR_GRP. (* is the group number of the postioner.)
- 38 -
ｼｽﾃﾑﾍﾝｽｳVariables
SYSTEM G2 ｶｸｼﾞｸ
JOINT 1%
$DMR_GRP[2] 1/25
1 $MASTER_DONE TRUE
2 $OT_MINUS [9] of BOOLEAN
3 $OT_PLUS [9] of BOOLEAN
4 $MASTER_COUN [9] of INTEGER
5 $REF_DONE FALSE
6 $REF_POS [9] of REAL
7 $REF_COUNT [9] of INTEGER
8 $BCKLSH_SIGN [9] of BOOLEAN
9 $EACHMST_DON [9] of INTEGER
10 $SPC_COUNT [9] of INTEGER
[ TYPE
ｶﾞﾒﾝ ] TRUE FALSE
5 Select $MASTER_COUN, and enter the mastering data you have recorded.
ｼｽﾃﾑﾍﾝｽｳVariables
SYSTEM G2 ｶｸｼﾞｸ
JOINT 1%
$DMR_GRP[2].$MASTER_COUN 1/9
1 [1] 95678329
2 [2] 10223045
0
3 [3] 0
4 [4] 0
5 [5] 0
6 [6] 0
7 [7] 0
8 [8] 0
9 [9] 0
[ TYPE
ｶﾞﾒﾝ ]
6 Press the previous page key.

7 Set $MASTER_DONE to TRUE.
- 39 -
ｼｽﾃﾑﾍﾝｽｳ
SYSTEM Variables G2 ｶｸｼﾞｸ
JOINT 1%
$DMR_GRP[2] 1/25
1 $MASTER_DONE TRUE
2 $OT_MINUS [9] of BOOLEAN
3 $OT_PLUS [9] of BOOLEAN
4 $MASTER_COUN [9] of INTEGER
5 $REF_DONE FALSE
6 $REF_POS [9] of REAL
7 $REF_COUNT [9] of INTEGER
8 $BCKLSH_SIGN [9] of BOOLEAN
9 $EACHMST_DON [9] of INTEGER
10 $SPC_COUNT [9] of INTEGER
[ TYPE
ｶﾞﾒﾝ ] TRUE FALSE
8 Press F1 [TYPE] and select CALIBRATE.

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

1) Confirming that mastering was performed normally
Usually, positioning is performed automatically when the power is turned on. To confirm that
mastering was performed normally, check that the current-position display matches the actual position
of the positioner, using this procedure.
a) Replay the taught operation of the positioner to set zero degrees, and visually check that the
zero-degree position marks shown in Subsection 5.2.3 are aligned.
b) Replay a specific portion of the program, and check that the positioner has moved to the taught
position.
2) Possible alarms in positioning
The following paragraphs describe alarms that may occur in positioning and explain how to handle
them.
a) BZAL alarm
This alarm is raised if the voltage of the pulsecoder backup battery becomes 0V when the
controller power is off. Mastering must be performed again because the counter has already lost
data.
b) BLAL alarm
This alarm indicates that the voltage of the pulsecoder backup battery is too low to run the
pulsecoder. If this alarm is issued, replace the backup battery soon while keeping the power on,
and check whether the current-position data is correct, using a method described in item (1).
c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL alarms
If any of these alarms is issued, contact your FANUC service representative. A motor may have
to be replaced.
- 40 -
B-82545EN/03 MAINTENANCE 6.COMPONENT REPLACEMENT AND ADJUSTMENTS
6 COMPONENT REPLACEMENT AND

ADJUSTMENTS
Once motors, reducers, and gears are replaced, mastering becomes necessary, Perform mastering according
to Chapter 5 of MAINTENANCE after any of these components is replaced.
NOTE
Be very careful when dismounting and mounting the heavy components that are
listed below.
Component Weight (about) Load capacity

Motor 10kg 300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
Motor 22kg 1000kg/1500kg payload (Hollow type)
Reducer 20kg 300kg payload (Hollow type)
Reducer 91kg 1000kg/1500kg payload (Hollow type)
Reducer 45kg 1000kg/1500kg payload (Compact type)
Flange 16kg 300kg payload (Hollow type)
Flange 28kg 1000kg/1500kg payload (Hollow type)
Flange 9kg 1000kg/1500kg payload (Compact type)
NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps
and wipe oil off the engaging section. Make sure that there is no solvent in the
taps.
Be sure to wipe the excess LOCTITE after tightening bolt.
6.1 REPLACING THE MOTOR

In the case of 300kg payload (Hollow type) , 300kg/500kg payload (Hollow
type)
1 Set dial gauges and prepare for single axis mastering after replacement.
2 Turn off the controller power.
3 Remove the four M8×12 bolts and remove the motor cover.
(Only when the motor cover option is selected)
4 After removing the battery box fixing plate while referencing Fig. 6.1 (b), remove the four M6×10
bolts and remove the connector box.
(Only when the HARTING connector option is selected)
5 Remove the motor connector.
6 Remove the four M8×20 motor mounting bolts, washer, and remove the motor.
7 Attach the input gear to a new motor, and reverse the removal steps to mount the motor. Replace the
O-rings with new ones, and put the new O-rings in place. See Fig. 6.1 (a) for the tightening torque and
LOCTITE application.
8 Supply the grease bath with the specified grease as described in Section 3.1.
- 41 -
6.COMPONENT REPLACEMENT AND ADJUSTMENTS MAINTENANCE B-82545EN/03
9 Perform single axis mastering while referencing Chapter 5.
Washer Motor cover

(When Motor cover option is specified.)
Nut Bolt
LOCTITE 242 M8X20,4pcs
Tightening Torque 16.7Nm Motor
C ring
O ring
Washer
Bearing
Input Gear Bolt
M8X12,4pcs
(When Harting connector option or
Motor cover option is specified.)
Connector box
(Harting connector option is specified.)
Plate for fixtation of Battery Box

(When Harting connector option is specified.)
Fig. 6.1 (a) Replacing the motor

Replacing parts (300kg payload (Hollow type))

Part name Specification
O-ring JB-OR1A-G105
Motor A06B-0235-B605#S000
Bearing A97L-0001-0195#06Z000A
Oil seal A98L-0040-0047#07010014
Replacing parts (300kg/500kg payload (Hollow type))

O-ring JB-OR1A-G105
Motor A06B-0235-B605#S000
Bearing A97L-0218-0903#6306R
Oil seal A98L-0040-0047#07010014
Battery box
Bolt
M6X10,4pcs
Battery box
mounting plate
Fig. 6.1 (b) Removing the connector box (when the HARTING connector option is selected)
- 42 -
In the case of 1000 kg/1500kg payload (Hollow type)

4 After removing the battery box fixing plate while referencing Fig. 6.1 (b), remove the four M6×10
bolts and remove the connector box.
(Only when the HARTING connector option is selected)
O-rings with new ones, and put the new O-rings in place. See Fig. 6.1 (c) for the tightening torque and
Nut Washer
ワッシャ
Draw bolt
ドローボルト
LOCTITE 242 LOCTITE 242
ロックタイト242塗布
ナット CCリング
ring 締付トルク 118N.m
Tightening Torque 118N.m
Tightening Torque 3.2N.m
ロックタイト242塗布
締付トルク3.2N.m OOリング
ring
アルバニヤグリースS2を塗布
Alvania grease S2 Motor cover
ワッシャ,4個モータカバー
(Motor cover option is
Washer 4pcs (モータカバーオプション選択時)
selected.)
ボルト
Bolt M12×30.4pcs
M12X30,4本
Motor
モータ
Bearing
ベアリング
Input gear
インプットギヤ
Connector box ボルト

Bolt
(Harting connector optionM8X12,4本 M8×12.4pcs
(ハーテイングコネクタオプション又は
is setected.) (Harting connector option or
モータカバーオプション選択時)
分線箱 motor cover option is selected.)
(ハーテイングコネクタオプション選択時)
Plate for fixation of Battery Box
バッテリボックス固定用プレート
(ハーテイングコネクタオプション選択時)
(Harting connector option
is setected.)
Fig. 6.1 (c) Replacing the motor (1000kg/1500kg payload (Hollow type))

O-ring JB-OR1A-G125
Motor A06B-0265-B605#S000
Bearing A97L-0001-0196#09Z000A
Oil seal A98L-0040-0047#13016014
- 43 -
In the case of 1000 kg/1500kg payload (Compact type)

O-rings with new ones, and put the new O-rings in place. See Fig. 6.1 (d) for the tightening torque and
O ring
Bolt　M5X25
Appy LOCTITE 242.
Tightening torque : 3.2Nm
Draw nut Motor cover
Input gear Appy LOCTITE 242. (When motor cover option is specified.)
Tightening torque : 118Nm
Motor
Bolt
M12X30, 4pcs
Washer 4pcs
Bolt
M8X12, 4pcs
(When motor cover option is specified.)
Connector box
(When harting connector option is specified.)
Fig. 6.1 (d) Replacing the motor (1000kg/1500kg payload (Compact type))
Replacing parts (1000kg/1500kg payload (Compact type))

O-ring JB-OR1A-G125
Motor A06B-0265-B605#S000
Seal bolt (for motor mounting 4pcs) A97L-0218-0423#122210
NOTE
Replace the bearing or oil seal only when it is broken.
- 44 -
6.2 REPLACING THE REDUCER

In the case of 300kg payload (Hollow type) , 300kg/500kg payload (Hollow
type)
1 Remove the motor as Section 6.1.
2 Remove the covers, bolts, insulators A and B, collar, flange, and insulator in that order.
3 Pull the pipe out of the reducer.
4 Remove the 11 M10×45 bolts with washers that fasten the reducer on the base, and remove the
reducer.
5 Remove the gear.
6 Reverse the removal steps to mount a new reducer. Replace the O-rings with new ones, and put the
new O-rings in place. Be careful not to damage the oil seal.
See Fig. 6.2 (a) for the tightening torque and LOCTITE application.
7 Install the motor as Section 6.1.
Bolt
M10X45,11pcs
Apply LOCTITE 262.
Tightening torque 73.5Nm Washer plate, 3pcs
O ring Flange
Apply Shell Alvania Bolt　M12X35
grease S2. (300kg payload (Hollow type) :, 9pcs
Washer 300kg/500kg payload (Hollow type) : 12pcs)
Reducer Apply LOCTITE 262.
Tightening torque 128.4Nm
Cover, 3pcs
Insulator B
Gear Insulator A, 3pcs
O ring Collar
Base Apply Shell Alvania (300kg payload (Hollow type) :, 9pcs
grease S2. 300kg/500kg payload (Hollow type) : 12pcs)
Pipe Insert after the insulator A.
Insulator C
Fig. 6.2 (a) Replacing the reducer (300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
Replacing parts (300kg payload (Hollow type))

O-ring (pipe) JB-OR1A-G95
O-ring (reducer) A98L-0040-0041#173
Reducer A97L-0218-0805#37
Input gear A290-7220-X111
Center gear A290-7216-X212

Reducer A97L-0218-0891#37
Input gear A290-7220-Z111
Center gear A290-7216-X212
- 45 -
In the case of 1000 kg/1500kg payload (Hollow type)

1 Remove the motor as described in Section 6.1.
2 Remove the covers, bolts, washers, insulators A and B, flanges, insulators C in that order.
3 Remove the 15 bolts (M16×50) that fix the reducer and base and then remove the reducer and the
components ahead of it.
4 Remove the 16 bolts (M12×85) and washers that secure the reducer and adapter and remove the
reducer from the adapter.
5 Apply sealant to a new reducer as described in Section 6.3 and assemble these components in the
reverse order. Replace the O-rings with new ones and put them in place. Be careful not to damage the
oil seal. For the tightening torque and the application of LOCTITE, see Fig. 6.2 (b).
6 Mount the motor as described in Section 6.1.
8 Perform single axis mastering as described in Chapter 5.
Bolt
M16X50,15 pcs O ring Insulator B,18 pcs
LOCTITE 262Nm Apply Alvania grease S2 (Insert after the insulator A.)
Bolt Insulator A,18 pcs
M12X85,16 pcs Pipe Insulator C
LOCTITE 262 Washer ,18 pcs
Washer,15 pcs Tightening torque 128.4Nm Adapter Bolt
Washer,16 pcs Flange M12X35,18 pcs
Reducer LOCTITE 262
Cover,18 pcs
Base
Fig. 6.2 (b) Replacing the reducer (1000kg/1500kg payload (Hollow type))

Reducer A97L-0218-0819
In the case of 1000 kg/1500kg payload (Compact type)

1 Set dial gauges, and prepare for single axis mastering after replacement.
2 Remove flange mounting bolts M10×22(24 pcs) , M12×22(9 pcs) to flange and remove flange.
3 Remove reducer mounting bolts M12×50(16 pcs) and washers (16 pcs) to base and remove reducer.
4 Apply sealant to a new reducer as described in Section 6.3 and assemble these components in the reverse
order. Replace the O-rings with new ones and put them in place. Be careful not to damage the oil seal. For
the tightening torque and the application of LOCTITE, see Fig. 6.2 (c).
6 Perform single axis mastering as described in Chapter 5.
- 46 -
Flange
Bolt
M12X50, 16pcs
Bolt Apply LOCTITE 262.
Tightening torque : 128.4Nm O ring
M12X22, 9pcs Appy SHELL ALVANIA GREASE S2.
Apply LOCTITE 262.
Tightening torque : 128.4Nm Washer　16pcs
Base
Reducer
Bolt
M10X22, 24pcs
Apply LOCTITE 262.
Tightening torque : 73.5Nm
Fig. 6.2 (c) Replacing the reducer (1000kg/1500kg payload (Compact type))
Replacing parts (1000kg/1500kg payload (Compact type))

Reducer (reducer) A97L-0218-0889#171
6.3 SEALANT APPLICATION

Washing and degreasing the surfaces to be sealed
1 After dismounting the reducer from the arm, apply releasant (LOCTITE Gasket Remover etc.) to the
arm’s surface from which the reducer was dismounted, then wait until the sealant (LOCTITE 518)
becomes softened (for about 10 minutes). Remove the softened sealant from the surface using a
spatula.
2 Blow air onto the surface to be sealed to remove dust from the tapped holes.
3 Sufficiently degrease the reducer’s surface to be sealed and the other surface to be sealed, using a cloth
dampened with oil and grease remover. Do not spray oil and grease remover directly onto the surface.
4 Polish the arm’s surface to be sealed with an oil stone, and degrease it with removal and cleaner again.
CAUTION
Oil may drip from the inside of the reducer. After degreasing, make sure that no oil
is dripping.
Applying sealant
5 Make sure that the reducer and the arm are dry (with no oil and grease remover remaining). If they are
still wet with oil and grease remover, wipe them dry. Always use a new surface of a cloth so that the
grease once wiped up with the cloth will not get on the degreased surface. Make sure that no ingredient
of oil and grease remover is left in the threaded holes or on any other portion. If ingredient is left, it
may prevent stiffening of sealant.
6 Apply sealant (LOCTITE 518) to the surfaces.
- 47 -
CAUTION
See descriptions about reducer replacement for the relevant axes for details.
Assembling
7 To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as
quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant was
wiped off, apply again.
8 After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get
closer.
9 After attaching the reducer, wipe off any excessive sealant that comes out from the sealed section with
a cloth or spatula. Do not use oil and grease remover.
CAUTION
Do not grease or move the reducer before the sealant sets, as it may allow grease
to leak. Before greasing or moving, wait for about at least four hour after the
reducer is mounted.
APPLY SEALANT (LOCTITE 518) TO THE PART.
Fig. 6.3 (a) Applying sealant to the reducer (1000kg/1500kg payload (Hollow type))
- 48 -
LOCTITE 518 applying area
Take special care and check

that there are no gaps of
sealant around these parts.
Fig. 6.3 (b) Applying sealant to the reducer (1000kg/1500kg payload (Compact type))
- 49 -
7.PIPING AND WIRING MAINTENANCE B-82545EN/03
7 PIPING AND WIRING

7.1 WIRING DIAGRAMS
Fig. 7.1 shows the wiring in the mechanical unit when the HARTING connector option is selected. The
controller and motor are directly connected to each other when the HARTING connector option is not
selected.
Connector panel
K102
Motor
M1BK
M1M
K101
M1P
+
Battery
-
Fig. 7.1 Wiring in the mechanical unit
7.2 CABLING (WHEN THE HARTING CONNECTOR OPTION IS

SELECTED)
Fig. 7.2 shows the cabling in the mechanical unit when the HARTING connector option is selected. (There
are no cables in the mechanical unit when the HARTING connector option is not selected.)
K101
Pulsecoder cable
K102
Motor cable
Fig. 7.2 Wiring in the mechanical unit

- 50 -
B-82545EN/03 MAINTENANCE 8.CABLE REPLACEMENT
8 CABLE REPLACEMENT
If a cable is broken or damaged, replace it according to the procedure described in this chapter.
Cautions in handling the pulsecoder cable

When transporting, installing, or maintaining the positioner, do not detach the pulsecoder cables carelessly.
The cables are provided with the marking tie shown below. If you detached any cable with the marking tie,
you need to perform mastering for the robot.
Do not detach any connector unless you replace a motor, pulsecoder, reducer, or cable.
BATTERY BACKUP
DON'T
DISCONNECT
コネクタ取外不可
Fig. 8 Wire mark
If there is a break in or any other damage to a cable, replace the cable according to the procedure described
in this chapter. If the connector of a pulsecoder cable (K101) is detached, the data about the absolute
position of the positioner is lost. Once any of these cables is replaced, perform quick mastering while
referencing Section 5.2. If the data is lost because of a break in a cable, also perform quick mastering to
calibrate the positioner into the previous absolute position.
8.1 REPLACING CABLES

When the HARTING connector option is not selected, turn off the power to the controller, directly remove
the motor connector, and replace the cables. When the HARTING connector option is selected, use the
procedure below to replace the cables.
In the case of 300kg payload (Hollow type) ,

300kg/500kg payload (Hollow type),
1 Make sure that the quick mastering reference point is set with reference to Subsection 5.2.4.
3 Remove the motor cover while referencing Chapter 6.
4 Remove the four M6X10 bolts from the battery box fixing plate, and remove the plate together with
the battery. Take care not to break the battery connection cable by excessively pulling it.
5 Remove the three M8X12 bolts that fasten the connector box, and remove the connector box.
6 Remove the motor connector and the cable.
- 51 -
8.CABLE REPLACEMENT MAINTENANCE B-82545EN/03
7 Detach the cables from the connector box. The K101 cable can be detached from the connector box by
removing the four M4X8 bolts, and the K102 cable can be detached by removing the four M3X8 bolts,
housing, and insert.
8 Remove the battery connection cable.
9 Remove the ground wire.
10 Reverse the removal steps to install new cables. Take care not to cause the cables to be caught and cut
in metal plates while installing them. Also, take care not to break the cables by pulling them.
11 Perform quick mastering. (See Chapter 5).
Motor cover
Bolt
M8X12,4pcs
Fig.8.1 (a) Replacing cables 1

300kg payload (Hollow type) , 300kg/500kg payload (Hollow type) , 1000kg/1500kg payload (Hollow type)
Battery box
Bolt
M6X10,4pcs
Battery box
mounting plate
Fig. 8.1 (b) Replacing cables 2
- 52 -
B-82545EN/03 MAINTENANCE 8.CABLE REPLACEMENT
Connector
for cable K102
Connector
for cable K101
Connector box
Bolt Bolt
M4X8(4pcs) M3X8(4pcs)
Bolt
M8X12(3pcs)
Fig. 8.1 (c) Replacing cables 3
In the case of 1000kg/1500kg payload (Compact type)

1 Make sure that the quick mastering reference point is set with reference to Subsection 5.2.4.
3 Remove the motor cover while referencing Chapter 6.
4 Remove the two M6X10 bolts from the battery box fixing plate, and remove the plate together with the
battery. Take care not to break the battery connection cable by excessively pulling it.
5 Remove the motor connector and the cable.
6 Detach the cables from the connector box. The K101 cable can be detached from the connector box by
removing the four M4X8 bolts, and the K102 cable can be detached by removing the four M3X8 bolts,
housing, and insert.
7 Remove the battery connection cable.
8 Remove the ground wire.
9 Reverse the removal steps to install new cables. Take care not to cause the cables to be caught and cut
in metal plates while installing them. Also, take care not to break the cables by pulling them.
10 Perform quick mastering. (See Chapter 5).
- 53 -
8.CABLE REPLACEMENT MAINTENANCE B-82545EN/03
Bolt
M8X12,4pcs
Motor cover
Bolt
M4X8,4pcs
Connector of
Connector box
cable K101
Connector of
cable K102
Bolt
M4X8,4pcs
Fig. 8.1 (d) Replacing cables 1

1000kg/1500kg payload (Compact type)
Battery box
Bolt
M6X10,2pcs
Battery box
mounting plate
Fig. 8.1 (e) Replacing cables 2

- 54 -
II. CONNECTION
B-82545EN/03 CONNECTION 1.POSITIONER OUTLINE DRAWING
1 POSITIONER OUTLINE DRAWING

When installing peripheral equipment, be careful not to cause interference with the positioner body. For
installation, see Section 3.3 of CONNECTION and use through holes provided on the base.
1.1 OUTLINE DRAWING AND OPERATION AREA DIAGRAM

Figs. 1.1 (a) to (e) show the outer dimensions and the operation area of the positioner and follower unit.
Motor cover option
2-φ10 H8 +0.022
0
3-φ10 H8 +0.022
0 Through 380
Through for mastering
374
0
30
φ 12-M10
Through
Equally spaced
15°
φ350
360
φ11
Depth3 H7 +0.03
5
6 0
185
65
f tφ
sha
ow
Holl
φ
27
0
207 143
Harting connector option
409 183
Fig. 1.1 (a) Outline of 1 axis positioner

- 57 -
1.POSITIONER OUTLINE DRAWING CONNECTION B-82545EN/03
582
12-M16 573
Depth 25
2-O10H8+0.022 Motor cover option
Equally spaced 0
Depth 8
O
32
0
6-M12 0
Depth 20
O 260 Equally spaced
O 450
485
O1
Dep 60 H7
th 8 +0.0
260
40
0
0 329.5
12 259
O
er 654
met 293.5
d ia
w Harting connector option
llo
Ho
Fig. 1.1 (b) Outline of 1 axis positioner (1000kg/1500kg payload (Hollow type))
Motor cover option 12-M12

2-O10H8 +0.002
0
Through
399.5 Depth 8
10-M12
O Depth 12
27 Equally spaced
0
30
O1
300
400.5
141.5 255
Harting connector option
170.5
503
Fig. 1.1 (c) Outline of 1 axis positioner (1000kg/1500kg payload (Compact type))
- 58 -
B-82545EN/03 CONNECTION 1.POSITIONER OUTLINE DRAWING
343
4-
Th O 12-M10
rou 10 Through
gh H 8 Equally spaced
　E
qu 0+0.022
qlly
sp
ac
ed
15°
O 350
360
O 11
Dept 3 H7 +0.035
h6 0
185
0
30 O
O 2 70
Ho
llo
w
di
am
169
et
118
er
205
O
231
65
Fig. 1.1 (d) Outline of follower unit (insulated flange)
144.5
2-O10H7 +0.015
0
0
10-M12 13
Through O
35
+0.0
0 H7
0
Hollow d O 10
iameter
O 65
O 170
185
83
310
Fig. 1.1 (e) Outline of follower unit (non-insulated flange)
- 59 -
2.MOUNTING DEVICES ON THE POSITIONER CONNECTION B-82545EN/03
2 MOUNTING DEVICES ON THE POSITIONER

NOTE
Wipe oil off the flange surface before mounting the unit. Otherwise, the unit may
be misaligned.
2.1 POSITIONER LOAD CONDITION

Fig. 2.1 (a) to (d) show the positioner load conditions.
Use the positioner so that the load condition falls within the range in the table and the allowable load inertia
and allowable load moment in the table are satisfied.
Payload（kg)
300
250
200
150
120
Payload vs Payload C.G

Displacement (mm)
300
240
180
144
120
Fig. 2.1 (a) Positioner allowable load condition (300kg load capacity)
300kg payload (Hollow type) , 300kg/500kg payload (Hollow type)
300kg pay load capacity

Allowable load moment (Mr) 36 kgf.m (353 N.m)
Allowable bending moment (Mb) 250kgf.m (2,450 N.m)
Allowable load inertia (J) 2,350 kgf.cm.s2(240kg.m2)
- 60 -
B-82545EN/03 CONNECTION 2.MOUNTING DEVICES ON THE POSITIONER
500
Payload（kg)
400
300
200

Displacement (mm)
300
200
150
120
Fig. 2.1 (b) Positioner allowable load condition (500kg payload capacity)
300kg payload (Hollow type) , 300kg/500kg payload (Hollow type)
500kg payload capacity

Allowable load moment (Mr) 60 kgf.m (588 N.m)
Allowable bending moment (Mb) 400kgf.m (3,920 N.m)
- 61 -
1000
Payload（kg) 800
700
600
500

Displacement (mm)
320
267
229
200
160
Fig. 2.1 (c) Positioner allowable load condition (1000kg payload capacity)
1000kg/1500kg payload (Hollow type),1000kg/1500kg payload (Compact type)

Allowable load moment (Mr) 160 kgf.m (1,568 N.m)
Allowable bending moment (Mb) 2,100kgf.m (20,580 N.m)
- 62 -
1500
1400
1300
1200
1100
Payload（kg)

Displacement (mm)
182
167
154
143
133
Fig. 2.1 (d) Positioner allowable load condition (1500kg payload capacity)
1000kg/1500kg payload (Hollow type),1000kg/1500kg payload (Compact type)

Allowable load moment (Mr) 200 kgf.m (1,960 N.m)
Allowable bending moment (Mb) 2,100kgf.m (20,580 N.m)
- 63 -
2.2 CHANGING METHOD OF PAYLOAD SPECIFICATION

About Max payload shift function
In Positioner, the best two servo motion parameters are prepared. The best addition and subtraction velocity
operation can be achieved by setting the parameter matched to the payload specification. The parameter is
changed by executing the following KAREL programs (It is abbreviated as KAREL for Changing method
of payload specification thereafter.)
1000kg/1500kg payload (Hollow type) (A05B-1220-J102)
P1HSET10.PC: 1000kg payload specification

300kg/500kg payload (Hollow type) (A05B-1220-J103)

1000kg/1500kg payload (Compact type) (A05B-1220-J104)
P1CSET10.PC: 1000kg payload specification

P1CSET15.PC: 1500kg payload specification
It explains the procedure as an example of 1000kg/1500kg payload (Hollow type) (A05B-1220-J102)at the
following.
Positioner is set to specified payload specification by customer when it is shipped.
CAUTION
When positioner over payload specification of set, (Refer to specification table in
PREFACE and Section 2.1.of CONNECTION), set in appropriate payload
specification. If the positioner is operated with wrong setting, the function and the
lifetime of the robot would deteriorate.
Method of shifting
There are the following two in the method of executing KAREL for changing method of payload
specification. Please use it properly according to the purpose.
1) Method of executing KAREL program by using “Call program” → Refer to Subsection 2.2.1.
• The KAREL program is set in the program call instruction of the TP program and the parameter is set
by specifying with the argument that shows the group number, and executing it. The parameter of
1-axis positoner of a specific group can be switched in this method.
Instruction that calls Example of program： Group number

program specification for
１： CALL P1HSET10(１) argument
2) Method of executing KAREL program directly → Refer to Subsection 2.2.2.

• Select and execute the KAREL program in program select screen.
• Two or more 1-axis positoner exists in the multi group system, and it is possible to change in this
method bringing the parameter of two or more 1-axis positoner together to set the parameter for the
same load as them.
- 64 -
NOTE
1. Execute KAREL for Changing method of payload specification in the state of cold start mode.
2. Be careful that the tracks and the cycle time of an existing instruction program change if KAREL for
changing method of payload specification is executed. It depends as follows, and it explains the
method of executing KAREL for Changing method of payload specification.
2.2.1 Method of executing KAREL program by using “Call program”

∗ The following procedures assume the thing of changing 1-axis positoner of the first group to the
1000kg payload specification.
Execution procedure
1 Call the system variable screen.
MENU key → Select “System” and press F1 key(screen) → Select “System variables”
2 Set system variables $KAREL_ENB to 1.

3 Open TP program edit screen.
4 Select “call program” from among the program instruction
F1 key (INST) →Select “CALL” →Select “CALL program”
Then, the following screens are displayed.
SYST-039 Operation Mode T2 Selected

PROGRAM list JOINT 10 %
1 A1 5
2 HOME_IO 6
3 P1HSET10 7
4 P1HSET15 8
A1
1/2
1: CALL . . .
[ End ]
Select item
PROGRAM MACRO KAREL STRINGS
5 Press F3 key (KAREL). Then, select KAREL P1HSET10 of 1000kg payload specification from
among that because it becomes the following screens.
- 65 -

KAREL list JOINT 10 %
1 GEMDATA 5 MEM_PORT
2 GET_HOME 6 PSCOLD
3 P1HSET10 7
4 P1HSET15 8
A1
1/2
1: CALL . . .
[ End ]
Select item
PROGRAM MACRO KAREL STRINGS
6 Press F4 key (select). Choose “CONSTANT” from there. Then, it becomes the following screens.

A1 LINE 0 T2 ABORTED
A1 JOINT 10%
1/2
1: CALL P1HSET10 ( Constant )

[ End ]
[ CHOICE ]
7 The group number (It is 1 here) is put with the cursor in “Constant”.

A1 JOINT 10%
1/2
1: CALL P1HSET10 ( 1)
[ End ]
POINT TOUCHUP>
- 66 -
8 Execute this program.
Push FWD key while pushing SHIFT key.
Then, the following screens are displayed. This shows the thing that KAREL P1HSET10.PC of
1000kg payload specification is executed.
SERVO-333 Power off to reset
USER JOINT 10%
This means specification is
changed to payload 1000kg
1000kg parameter set . ( GP : 1)
specification.
－－－－－－－－ WARNING －－－－－－－－－－
－ Path and Cycle Time is Changed ！！－
－－－－－－－－－－－－－－－－－－－－－－－－－
Please power off

Please turn off the controller
power and turn it on.
9 Turn on the controller power again.
The change of the parameter ends above.
2.2.2 Method of executing KAREL program directly

Use scene
For instance, it is assumed that the following multi group systems exist.
1st group: 1-axis positoner
2nd group: 1-axis positoner
When the method of the explanation in this chapter is used to do 1-axis positoner of the 1st group and 2nd
group here to 1000kg payload specification, it is possible to set the 1st group and 2nd group to the parameter
of an acceptable 1000kg payload specification at the same time.
NOTE
If you want to 1-axis positoner of 1st group to 1000kg payload specification and 1-axis positoner of 2nd
group to 1500kg payload specification, Method of this chapter cannot be used.
In that case, please make two programs as follows, and do the parameter change by the method of Chapter 1.
1 Turn on the controller power again after executing the program 1.

2 Turn on the controller power again after executing the program 2.
- 67 -
Example of program
1st group is Max
Program 1: payload 1000kg
1: call P1HSET10(１) specification
Program 2:
1: call P1HSET15(２) 2nd group is Max
payload 1500kg
specification
Execution procedure
1 Call the system variable screen.
MENU key → Press F1 key (screen) after selecting “system”→ Select system variables
2 Set system variables $KAREL_ENB to 1.

3 Call program select screen and select “
program select key→ select KAREL by F1 key （type）
Then, three KAREL programs are displayed as follows.
Select G1 JOINT 10%
710186 bytes free 1/7
No . Program name Comment
1 GEMDATE PC [ GEM Vars ]
2 GET_HOME PC [ Get Home Pos ]
3 P1HSET10 PC [ 1000kg payload ]
5 MEM_PORT PC [ ]
6 PSCOLD PC [ ]
[ TYPE ] CREATE DELETE MONITOR [ ATTR ] >
4 Match the cursor to the KAREL program of the load that wants to be set, and push the ENTER key. It
is time when it selected P1HSET10.PC that is KAREL of 1000kg payload specification as follows.
The selected program name is displayed to two places as follows.
P1HSET10 LINE 0 T2 ABORTED

Select G1 JOINT 10%
710186 bytes free 3/7
No . Program name Comment
Selected program name is 1 GEMDATE PC [ GEM Vars ]
2 GET_HOME PC [ Get Home Pos ]
shown. 3 P1HSET10 PC [ 1000kg payload ]
5 MEM_PORT PC [ ]
6 PSCOLD PC [ ]
P1HSET10 is selected
[ TYPE ] CREATE DELETE MONITOR [ ATTR ] >
- 68 -
5 Execute the program.
Push FWD key while pushing SHIFT key.
Then, the following screens are displayed. This is case of executing KAREL P1HSET10.PC of Max
payload 1000kg specification.
This means 1st group is SERVO-333 Power off to reset

P1HSET10 LINE 0 T2 ABORTED
changed to Max payload USER JOINT 10%
1000kg specification.

This means 2nd group is
－－－－－－－－ WARNING －－－－－－－－－－
changed to Max payload － Path and Cycle Time is Changed ！！－
1000kg specification. －－－－－－－－－－－－－－－－－－－－－－－－－
Please power off
Please turn off the power

supply and turn it on.
6 Turn on the controller power again.
The change of the parameter ends above.
- 69 -
3.TRANSPORTATION AND INSTALLATION CONNECTION B-82545EN/03
3 TRANSPORTATION AND INSTALLATION

3.1 TRANSPORTATION
The positioner can be transported by suspending it. For the 300 kg payload (Hollow type) or 300
kg/500kg payload (Hollow type), thread a rope through the M10 eyebolts. For the 1000 kg/1500kg
payload (Hollow type), thread a rope through the M16 eyebolts. For the 1000 kg/1500kg payload
(Compact type), thread a rope through the M12 eyebolts. (See Figs. 3.1 (a) to (c).) After installation,
remove transport equipment. In case of 1000 kg/1500kg payload (Compact type), a metal plate for
prevention of fall is attached when Harting option is selected, so remove it after installation.
CAUTION
When transporting a positioner, be careful not to damage a motor connector with a
sling for lifting the positioner.
CAUTION
When an end effector and peripherals are installed on a positioner, the center of
gravity of the positioner changes and the positioner might become unstable while
being transported.
If the positioner becomes unstable, remove the tooling and place the positioner
into the transportation position. This will position the unit center of gravity
correctly. It is recommended to transport the end effector and peripherals
separately from the positioner.
Do not pull the eyebolt horizontally.

Do not thread a chain or the like through the transport member.
Before moving the positioner by using transport equipment, check and tighten any
loose bolts.
- 70 -
B-82545EN/03 CONNECTION 3.TRANSPORTATION AND INSTALLATION
NOTE)
1.Weight of positioner : 85kg
　 2 Eyebolt complied with JIS B 1168.
3 Eyebolt 1pcs
　 4 When you transport positoner , take out all works.
Crane capacity min　: 200kg (1960N) or greater

Sling capacity min　: 200kg (1960N) or greater
Positioner posture
for transportation : Arbitrary
>200kg (1960N)
Transport
equipment
>200kg (1960N)
>150kg (1470N)
Fig. 3.1 (a) Carrying the positioner with a crane

NOTE)
3 Eyebolt 1pcs

Positioner posture
Transport
equipment
>600kg (5880N)
>600kg (5880N)
>450kg (4410N)
Fig. 3.1 (b) Carrying the positioner with a crane (1000kg/1500kg payload (Hollow type))
- 71 -
NOTE)
3 Eyebolt 1pcs

Positioner posture
>400kg
Transport
equipment
>400kg
>220kg
Fig. 3.1 (c) Transportation using a crane (1000kg/1500kg payload (Compact type))
3.2 STORING THE POSITIONER

When storing the positioner, keep it in the posture with the following NOTES.
NOTE
Before storing a positioner for a long term, take measures for securing the
positioner to prevent it from falling.
NOTE
The flange surface is likely to rust, so apply antirust oil to the flange surface to
save it for a long period of time.
3.3 INSTALLATION
(1) Before installation
Wipe oil off the flange because it is factory-oiled.
There is no insulated flange for 1000kg/1500kg payload (Compact type) (Spec : A05B-1220-J104)
and follower unit (non-insulated flange) (Spec : A05B-1220-J152), so it is necessary to prepare the
structure for insulation by customer. Examine it referring to Fig.3.3 (a). Please pay attention not to do
conduction with a bolt fixing an insulation plate enough.
- 72 -
Washer for prevention

the cave-in of the bolt
Flange
Make clearlance.
Insulated plate
(bakelite etc.)
Fig. 3.3 (a) Structure for insulation
Fig. 3.3 (b) to (f) shows the dimensions of the base of the positioner main body and the follower unit.
182 182
6-O14
貫通
THROUGH
2-O10H8 +0.022
47
0
貫通
THROUGH
47
51
29
207
Fig. 3.3 (b) Dimensions of the base of the positioner main body
- 73 -
297.5 297.5
4-O24
貫通
THROUGH
2-O10H8 +0.022
0
貫通
THROUGH
200
132
32
329.5
Fig. 3.3 (c) Dimensions of the base of the positioner main body (1000kg/1500kg payload (Hollow type))
6-O24
220 220 THROUGH
2-O10H8 +0.022
0
THROUGH
78
78
397.5
74.25
255 248.5
Fig. 3.3 (d) Dimensions of the base of the positioner main body (1000kg/1500kg payload (Compact type))
- 74 -
6-O18
Through
Use M12 bolts
Use GT washer.
56
2-O10H8
Through
116
56
31
87 87
113
Fig. 3.3 (e) Dimensions of the base of the positioner follower unit (insulated flange)
310
15 15
144.5
25
25
Fig. 3.3 (f) Dimensions of the base of the positioner follower unit (non-insulated flange)
- 75 -
Fig. 3.3 (g) shows an example of installing the 300kg payload (Hollow type) or 300kg/500kg payload
(Hollow type) positioner and the follower unit (insulated flange). In this example, the sole plate is fixed
with four M20 chemical anchors (in strength category 4.8), and the positioner base is fastened to the sole
plate with six M12×40 bolts (in strength category 12.9). The follower unit base is fastened with six
M12×70 bolts (in strength category 12.9) and six GT washers.
When compatibility must be maintained in teaching the positioner mechanical unit replacement, use the
mounting surface.
NOTE
The customer shall arrange for the positioning pin, anchor bolts, and sole plate.
29 47 47 56 56 31
350 4-Φ24　THROUGH
350
INSTALLATION BOARD
50
318
(MOUNTING FACE) (MOUNTING FACE)
413
900
364
174
FRONT
409
FRONT
(MOUNTING FACE)
(MOUNTING FACE)
(MOUNTING FACE)
2400 50
FOLLOWER UNIT BASE
POSITIONER BASE
CHEMICAL ANCHOR FOLLOWER UNIT BASE MOUNTING BOLT
M20(4PCS) POSITIONER MOUNTING BOLT M12×70(6PCS)
STRENGTH CLASSIFICATION:4.8 M12X40(6pcs) STRENGTH CLASSIFICATION:12.9
TIGHTENING TORQUE:186.2 Nm STRENGTH CLASSIFICATION:12.9 TIGHTENING TORQUE:128.4 Nm
TIGHTTENING TORQUE:110 Nm GT WASHER (6PCS)(NOTE 2)
32
200
Fig. 3.3 (g) Example of installing the positioner

(300kg payload (Hollow shaft)), (300kg/500kg payload (Hollow shaft)) and follower unit (insulated flange)
NOTE
- Install the positioner and follower unit so that their axial centers are aligned. For
the installation, follow the guidelines provided by the contractor and use a level or
three-dimensional measuring instrument to ensure that the positioner and follower
unit are centered.
The allowable moment for the reducer is 2,450 N . m (250 kgf . m). Install the
reducer so as not to exceed the allowable moment by placing the reducer
off-center.
- Be sure to use the supplied GT washers for the installation of the follower unit.
- 76 -
Fig. 3.3 (h) shows an example of installing the 300kg payload (Hollow type) or 300kg/500kg payload
(Hollow type) positioner and the follower unit (non-insulated flange). In this example, the sole plate is fixed
with four M20 chemical anchors (in strength category 4.8), and the positioner base is fastened to the sole
plate with six M12×40 bolts six M12×50or (in strength category 12.9). The follower unit base is fastened
with two M20×50 bolts (in strength category 12.9).
mounting surface.
NOTE
350
29 47 47 308.5
350 4-Φ24　through
Installation board
50
318
(Mounting face)
900
364
Front
409
247
Front
(Mounting face)
(Mounting face)
2400
50
Follower unit base
Positioner base Follower unit mouting bolt

M20×50(2 pcs)
Positioner mounting bolt Strength classification : 12.9
Chemical anchor M12X40(6 pcs) (*1) or Tightening torque : 530 Nm
M20(4 pcs) M12X50(6 pcs) (*2)
Strength classification:4.8 Strength classification : 12.9
Tightening torque:186.2 Nm Tightening toruqe : 110 Nm
32
200
(*1) 300kg payload (Hollow type)

(*2) 300kg/500kg payload (Hollow type)
Fig. 3.3 (h) Example of installing the positioner
(300kg payload (Hollow shaft)),(300kg/500kg payload (Hollow shaft)) and follower unit
(non-insulated flange)
NOTE
- When the follower unit is installed in the customer site, the axial centers of the
positioner and follower unit must be aligned. For the installation, follow the
guidance provided by the contractor and use a level or three-dimensional
measuring instrument to ensure that the positioner and follower unit are centered.
The allowable moment for the reducer is 20,580 N×m (2100 kgf×m). Install the
follower unit so that the allowable moment is not exceeded because it is placed
off-center.
- 77 -
Fig. 3.3 (i) shows an example of installing the 1000kg/1500kg payload capacity type positioner and
follower unit (insulated flange).
In this example, the sole plate is fixed with four M20 chemical anchors (in strength category 4.8), and the
positioner base is fastened to the sole plate with four M20×40 bolts (in strength category 12.9). The
follower unit base is fastened to the sole plate with six M12×70 bolts (in strength category 12.9).
mounting surface.
NOTE
32 100 100
56 56 31 319
4-Φ24　through
(Mounting face)
Installation board
50
230
(Mounting face)
(Mounting face)
Front
900
174
Front
595
(Mounting face)
(Mounting face)
2400 50
Follower unit base
Chemical anchor Positioner base Follower unit mouting bolt

M20(4 pcs) M12×70(6 pcs)
Positioner mounting bolt Strength classification : 12.9
Strength classification:4.8 M20X40(4 pcs)
Tightening torque:186.2 Nm Tightening torque : 110 Nm
Strength classification : 12.9 GT washer (6 pcs)(Note 2)
Tightening toruqe : 450 Nm 32
200
Fig. 3.3 (i) Example of installing the positioner

(When using 1000kg/1500kg payload (Hollow shaft) and follower unit (insulated flange)
NOTE
- Install the positioner and follower unit so that their axial centers are aligned. For
the installation, follow the guidelines provided by the contractor and use a level or
three-dimensional measuring instrument to ensure that the positioner and follower
unit are centered.
The allowable moment for the reducer is 2,0580 N . m (2100 kgf . m). Install the
reducer so as not to exceed the allowable moment by placing the reducer
off-center.
- Be sure to use the supplied GT washers for the installation of the follower unit.
- 78 -
Refer to Table 3.3 (a) about size of bolt, number, and tightening torque.
Table 3.3 (a) Base mounting bolts of positioner and follower unit
300kg 300kg/500kg 1000kg/1500kg 1000kg/1500kg Follower unit
Follower unit
Model payload payload payload payload （non-insulated
（insulated flange）
(Hollow type) (Hollow type) (Hollow type) (Compact type) flange）
Mounting
M12 M12 M20 M20 M12 M20
bolt
Q’ty 6 6 4 4 4 2
Tightening
110 110 450 530 110 530
torque [Nm]
Matching the center of 1-axis positioner and follower unit

Example of matching the center is shown below. Match the center of 1-axis positioner and follower unit
referring to below.
When the parallel degree of hardness and the installation side of a footstool installing 1 axis positioner and
follower unit is bad, 1 axis positioner and follower unit give off vibration and allophone at the time of
driving, and it becomes the cause that you invite damage for the early stage.
1 Install 1-axis positioner and follower unit to common footstool and perform leveling.
2 Insert fixture which you can confirm hollow hole of follower unit. (See Fig.3.3 (j))
3 Rotate the positioner and confirm that a change of laser floodlight equal to or less than 0.5mm at 1m
4 Set a projection of the light device to flange surface of drive side so that it is vertical to flange and it is
near rotation center.
5 Rotate the positioner and adjust the position of follower side so that match the position of rotation
center of light of projection of the light device and rotation center of follower side. If laser light
penetrate fixture for matching position, you can confirm matching position is performed.
6 Move the position of fixture to the depth of hollow hole to adjust the degree of leaning .
And adjust it to match the center.
- 79 -
A A
1-axis positioner
Follower unit
Laser light
Mounting fixure
(follower unit side)
Mounting fixture
(positioner side)
A laser floodlight
Section A-A
Fig.3.3 (j) Example of matching the center of 1-axis positioner and follower unit
- 80 -
Assemble fixture of positioner side referring to Fig.3.3 (k).
Screw
M4X8 (3)
Bolt
M4X20 (3)
Laser floodlight
Holder
A290-7220-X971
Adapter
A290-7220-X972 (for 300kg payload (Hollow type) or 300kg/500kg payload (Hollow type))
A290-7220-X973 (for 1000kg/1500kg payload (Hollow type)
A290-7220-X974 (for 1000kg/1500kg payload (Compact type)
Fig.3.3 (k) Installation of fixture of positioner side
Fig.3.3 (l) to (o) shows example of fixture for matching the center. Fixture (positioner side) is installed to a
projection of the light device by insertion. Fixture (follower unit side) is installed to pipe by insertion.
64.5
+0.1
3-O6 THRU
17 0 EQ.SP
(9 ) 5
14
14
3-M4 THRU
14
62
9
( 34 )
20
THRU
EQ.SP
貫通
周上等配 A A
SECTION 断面
(5 )
+0.1
13.7 0
SECTION A-A
Fig.3.3 (l) Holder (Spec: A290-7220-X971)
- 81 -
10 A
3-M4 THRU
EQ.SP
-0.15
-0.20
O 40
O 113
THRU 貫通
EQ.SP 周上等配
SECTION 断面
SECTION A-A A
Fig.3.3 (m) Adapter for 300kg payload (Hollow type),300kg/500kg payload (Hollow type)
(Spec:A290-7220-X972)
10 B
3-M4 THRU
EQ.SP
-0.15
O 160 -0.20
O 40
SECTION B-B
THRU 貫通
EQ.SP 周上等配
SECTION 断面
B
Fig.3.3 (n) Adapter for 1000kg/1500kg payload (Hollow type) (Spec:A290-7220-X973)
10 A
3-M4 THRU
EQ.SP
-0.15
-0.20
O 40
O 100
THRU 貫通
EQ.SP 周上等配
SECTION 断面
SECTION A-A A
Fig.3.3 (o) Adapter for 1000kg/1500kg payload (Compact type) (Spec:A290-7220-X974)
- 82 -
20
.2 0
-0 0.25
A O
65
-
B
C
O2
SECTION 断面
a O 0.03 B
A n 0.05 C
SECTION A-A
Fig.3.3 (p) Adapter for follower unit (insulated flange) (Spec:A290-7220-X975)
.20
-0 0 .2 5
20
-
67
A O
C
B O2
SECTION 断面
a O 0.03 B
A n 0.05 C
SECTION A-A
Fig.3.3 (q) Adapter for follower unit (non-insulated flange) (Spec:A290-7220-X976)
Laser floodlight is assumed below.

KOCHI TOYONAKA GIKEN CO.LTD TYPE : GLM-A2 or GLM-A3
Refer to Fig.3.3 (r) about permissible angle of inclination of 1-axis positioner and follower unit.
If angle of inclination is more than it , it cause reduction life of 1-axis servo positioner and follower unit.
ang
le o
f in
clin
ati
on
Permissible angle of inclination　: 4min (0.067°)
Fig.3.3 (r) Permissible angle of inclination of positioner and follower unit

- 83 -
When inserting fixture to follower unit (non-insulated flange), Insert fixture after removing sleeve of he
side where flange does not come with referring to 3.3 (s).
Remove this sleeve

and insert fixture.
Fig.3.3 (s) Removing the sleeve of follower unit (non-insulated flange)
Fig. 3.3 (t) and Table 3.3 (b) to (e) explain what load is put on the base when the positioner is at a rest,
accelerating or decelerating, and at a Power-Off stop.
Fig. 3.3 (t) Load and moment applied to the base
Table 3.3 (b) Load and moment applied to the base 300kg payload
(300kg payload (hollow type)) , (300kg/500kg payload (Hollow type))
MV FV MH FH
State
[Kg・m] (N・m) [Kg] (N) [Kg・m] (N・m) [Kg] (N)
At rest 36 353 385 3773 0 0 0 0
Accelerating or
200 1961 411 4024 24 236 26 251
decelerating
At a Power-Off stop 334 3276 432 4230 44 430 47 457
- 84 -
Table 3.3 (c) Load and moment applied to the base 500kg payload
MV FV MH FH
State
At rest 60 588 585 5733 0 0 0 0
Accelerating or
227 2221 613 6005 17 165 28 272
decelerating
Table 3.3 (d) Load and moment applied to the base 1000kg payload
(1000kg/1500kg payload (Hollow type) , (1000kg/1500kg payload (Compact type)
MV FV MH FH
State
At rest 160 1568 1280 12544 0 0 0 0
Accelerating or
407 3989 1365 13377 193 1891 85 833
decelerating
Table 3.3 (e) Load and moment applied to the base 1500kg payload
(1000kg/1500kg payload (Hollow type) , (1000kg/1500kg payload (Compact type)
MV FV MH FH
State
At rest 200 1960 1585 15533 0 0 0 0
Accelerating or
384 3760 1638 16057 15 143 53 524
decelerating
- 85 -
3.4 MAINTENANCE CLEARANCE

Fig. 3.4 (a) and (b) show the layout of maintenance clearances.
500 600
450
450
Fig. 3.4 (a) Maintenance clearance layout

(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type)) ,
(1000kg/1500kg load capacity (Compact type))
- 86 -
500 800
570
570
Fig. 3.4 (b) Maintenance clearance layout (1000kg/1500kg payload (Hollow type))
- 87 -
3.5 ASSEMBLING THE POSITIONER FOR INSTALLATION

The robot connection cables are detached from the mechanical unit when the robot is shipped (the cables are
connected on the controller side). When the HARTING connector option is not selected, directly connect
the cable for direct motor connection to the motor connector.
When the HARTING connector option is selected, connect the cables shown in Fig. 3.5 to the connector
box of the mechanical unit. During the connection, take care not to pull the HARTING connector cable.
In connecting cables between the robot controller and the positioner body, the customer needs to obtain
cable ducts or the like.
PP
Connect the pulsecoder cable from the
controller.
PM
Connect the power cable from the controller
Fig. 3.5 Cable connection panel for the positioner mechanical unit
3.6 INSTALLATION CONDITIONS

Refer to Specification of [PREFACE] about installation conditions.
- 88 -
APPENDIX
B-82545EN/03 APPENDIX A.SPARE PARTS LISTS
A SPARE PARTS LISTS

Table A (a) Cables (When the HARTING connector option is selected.)
Cable No. Specifications Remarks Load capacity
K101 A660-8016-T096 Pulsecoder 300kg payload (Hollow type)
K102 A660-8016-T097 Motor power, brake 300kg payload (Hollow type)
K101 A660-8016-T241 Pulsecoder 1000kg/1500kg payload (Hollow type)
K102 A660-8016-T243 Motor power, brake 1000kg/1500kg payload (Hollow type)
K101 A660-8017-T441 Pulsecoder 1000kg/1500kg payload (Compact type)
K102 A660-8017-T442 Motor power, brake 1000kg/1500kg payload (Compact type)
Table A (b) Motor

Specifications Model Load capacity
A06B-0235-B605#S000 αiS8/4000 300kg payload (Hollow type)
A06B-0265-B605#S000 αiS22/4000 1000kg/1500kg payload (Hollow type)
Table A (c) Reducer

Specifications Weight Load capacity
A97L-0218-0805#37 20kg 300kg payload (Hollow type)
A97L-0218-0819 91kg 300kg/500kg payload (Hollow type)
A97L-0218-0891#37 20kg 300kg/500kg payload (Compact type)
A97L-0218-0889#171 45kg 1000kg/1500kg payload (Compact type)
Table A (d) Gear

Specifications Name Load capacity
A290-7216-X212 Center gear 300kg payload (Hollow type)
A290-7220-X111 Input gear 300kg payload (Hollow type)
A290-7220-X151 Input gear 1000kg/1500kg payload (Compact type)
A290-7220-Z111 Input gear 300kg/500kg payload (Hollow type)
Table A (e) Insulator , collar

Specifications Name Q’ty Use position Model
A290-7220-X325 Insulator 3 Flange 300kg payload (Hollow type)
A98L-0040-0211#121512 Collar 9 Flange 300kg payload (Hollow type)
A290-7220-X326 Cover 3 Flange 300kg payload (Hollow type)
A98L-0040-0211#121512 Insulator A 18 Flange 1000kg/1500kg payload (Hollow type)
A98L-0040-0222#30152 Insulator B 18 Flange 1000kg/1500kg payload (Hollow type)
A290-7220-X144 Cover 18 Flange 1000kg/1500kg payload (Hollow type)
A290-7220-Z325 Insulator 3 Flange 300kg/500kg payload (Hollow type)
A98L-0040-0211#121512 Collar 12 Flange 300kg/500kg payload (Hollow type)
A290-7220-Z326 Cover 3 Flange 300kg/500kg payload (Hollow type)
- 91 -
A.SPARE PARTS LISTS APPENDIX B-82545EN/03
Table A (f) Bearing

Specifications Load capacity
A97L-0001-0192#1600000 300kg/500kg payload (Hollow type)
A97L-0001-0195#06Z000A 300kg payload (Hollow type)
A97L-0001-0196#09Z000A 1000kg/1500kg payload (Hollow type)
A97L-0218-0903#6306R 300kg/500kg payload (Hollow type)
Table A (g) O ring

Specifications Use position Load capacity
JB-OR1A-G105 Motor 300kg payload (Hollow type)
JB-OR1A-G95 Pipe 300kg payload (Hollow type)
A98L-0040-0041#173 Reducer 300kg payload (Hollow type)
JB-OR1A-G125 Motor, pipe 1000kg/1500kg payload (Hollow type)
A98L-0040-0041#281 Reducer 1000kg/1500kg payload (Hollow type)
JB-OR1A-G270 Reducer 1000kg/1500kg payload (Compact type)
Table A (h) Oil seal

Specifications Use position Load capacity
A98L-0040-0047#07010014 Pipe 300kg payload (Hollow type)
A98L-0040-0047#13016014 Pipe 1000kg/1500kg payload (Hollow type)
Table A (i) Grease

Specifications Name Load capacity
A98L-0040-0174#1kg VIGOGREASE RE0 300kg payload (Hollow type)
A98L-0040-0174#4.9kg 1000kg/1500kg payload (Hollow type)
Table A (j) Grease nipple

Specifications Name
A98L-0218-0013#A110 Grease nipple (1/8)
Table A (k) Seal bolt

Parts name Specifications Use position
Seal bolt A97L-0218-0417#121515 Outlet 2 (300kg payload (Hollow type))
Outlet 1,2 (1000kg/1500kg payload (Hollow type))
Taper plug A97L-0001-0436#2-1D Outlet 1 (300kg payload (Hollow type))
Inlet, Outlet (1000kg/1500kg payload (Compact type))
NOTE
For the locations of outlet 1 and 2, see I.MAINTENANCE 3.1.
Table A (l) Battery

Specifications Name Q’ty
A98L-0031-0005 1.5V, size D 4 pcs
- 92 -
B-82545EN/03 APPENDIX B.CONNECTION DIAGRAMS
B CONNECTION DIAGRAMS
Fig. B shows the circuit in the mechanical unit when the HARTING connector option is selected. When the
option is not selected, a direct connection is established from the motor.
- 93 -
B.CONNECTION DIAGRAMS APPENDIX B-82545EN/03
CONNECTOR PANEL
PM M TYPE
Han 15D
(2.5SQ 10A) K102
C1 B1 BK(J1) A1 J1U1
C2 B2 BKC(J1) A2 J1V1
C3 B3 A3 J1W1
C4 B4 A4 J1G1
C5 B5 A5
G Ｇ
A66L-0001-0401#10
(1.25SQ*10C)Φ11.8
PP M TYPE Han 24DD

(2.5SQ 10A)
21 17 13 9 5V(A1) 5 0V(A1) 1 K101 A66L-0001-0464#1
(0.2SQ*4P)Φ6.7
22 18 14 10 6 2
23 19 15 11 7 3 PRQJ1
24 20 16 12 8 4 XPRQJ1
6V
BT1 +
BATTERY
0V
-
BT1
Fig. B Connection diagram
- 94 -
B-82545EN/03 APPENDIX B.CONNECTION DIAGRAMS
MOTOR (αiS8/4000) (*1)

J1 (αiS22/4000) (*2)
A63L-0001-0648#810SL3SJ
A63L-0001-0653#04A
M1 BK 10SL-3P(1.25SQ 13A)
A BK(J1) B BKC(J1) C
A63L-0001-0881#1810S
A63L-0001-0881#10C M1 M 18-10P
A J1U1 C J1W1
B J1V1 D J1G
A63L-0001-0848#A10SL1 M1 P 10SL1(0.3SQ 3A)

A63L-0001-0850 4 6V(BT1)
8 5V(A1) 1
5 XPRQJ1
9 2
6 PRQJ1
10 0V(A1) 3 FG
7 OV(BT1)
(*1) 300kg payload 1-axis Servo Positioner (Hollow type) or

300kg/500kg payload 1-axis Servo Positioner (Hollow type)
(*2) 1000kg/1500kg payload 1-axis Servo Positioner (Hollow type) or
1000kg/1500kg payload 1-axis Servo Positioner (Compact type)
1-axis Servo Positioner

:MOVABLE
- 95 -
C.PERIODIC INSPECTION TABLE APPENDIX B-82545EN/03
C PERIODIC INSPECTION TABLE

FANUC 1-AXIS SERVO POSITIONER PERIODIC INSPECTION TABLE
Grease First
Working Check 3 6 9
amount check months months months 1 year
2
time years
Item time (H) 320
960 1920 2880 3840 4800 5760 6720 7680 8640 9600 10560
Check the mechanical cable.
1 (damaged or twisted) NOTE1) 0.2H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Check the motor connector
2 (tightness). 0.2H ― ○ ○ ○
Tighten the loosened flange
3 mounting bolts. 0.2H ― ○ ○ ○
Tighten the cover and main
4 bolt. 0.5H ― ○ ○ ○
Mechanical unit
5 Remove spatter and dust etc. 1.0H ― ○ ○ ○
6 Replacing battery. NOTE2) 0.1H ― ●

Replacing grease of reducer.
300kg payload (Hollow type)
300kg/500kg payload
0.3H 980ml
(Hollow type) NOTE3)

7
1000kg/1500kg payload 1.0H 5500ml
(Hollow type) NOTE3)
1000kg/1500kg payload 0.3H 1193ml
(Compact type) NOTE3)
Check the robot cable, teach
8 pendant cable and robot 0.2H ○ ○ ○
Controller
connecting cable
Cleaning the ventilator.
9 NOTE4)
0.2H ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
10 Replacing battery NOTE5) 0.1H
NOTE1) Check this when Harting connector option is selected.

The cycle of replacing is necessary to be shortened. Refer to MAINTENANCE 8 in replacing the cable.
NOTE2) Refer to the manual MAINTENANCE 2.6.
NOTE3) Refer to Fig. 3.1 (a) and (b) of the Section 3.1 in MAINTENANCE.
NOTE4) Clean the positioner properly in case of using the positioner under much dust existing.
NOTE5) Refer to the controller maintenance manual.
●: requires order of parts

○: does not require order of parts
- 96 -
B-82545EN/03 APPENDIX C.PERIODIC INSPECTION TABLE
3 4 5 6 7 8
years years years years years years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 Items
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 1
○ ○ ○ ○ ○ 2
○ ○ ○ ○ ○ 3
○ ○ ○ ○ ○ 4
○ ○ ○ ○ ○ 5
Overhaul
● ● ● ● 6
● ●
● ● 7
● ●
○ ○ ○ ○ ○ 8
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 9
● 10
- 97 -
D.STRENGTH OF BOLT AND BOLT TORQUE LIST APPENDIX B-82545EN/03
D STRENGTH OF BOLT AND BOLT TORQUE

LIST
NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it is
applied to the entire longitudinal portion in the engaging section of the female threads. If it
is applied to the male threads, the bolts may be loosened because sufficient adhesion
cannot be obtained. Remove the dust within the bolts and taps and wipe oil off the
engaging section. Make sure that there is no solvent in the taps. Be sure to wipe the
excess LOCTITE after tightening bolt.
Use bolt which strengths are below.
But if it is specified in text, obey it.
Hexagon socket head bolt made by steel
Size is M22 or less : Tensile strength 1200N/mm2 or more
Size is M24 or more : Tensile strength 1000N/mm2 or more
All size of bolt of the plating : Tensile strength 1000N/mm2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm2 or more
If no tightening torque is specified for a bolt, tighten it according to this table.

Recommended bolt tightening torques Unit: Nm
Hexagon socket head
button bolt
Hexagon socket head
Hexagon socket head Hexagon socket head Hexagon bolt
bolt
Nominal bolt (stainless) flush bolt (steel)
(Steel)
diameter Low-head bolt
(steel)
Tightening torque Tightening torque Tightening torque Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
M3 1.8 1.3 0.76 0.53 ―――― ―――― ―――― ―――
M4 4.0 2.8 1.8 1.3 1.8 1.3 1.7 1.2
M5 7.9 5.6 3.4 2.5 4.0 2.8 3.2 2.3
M6 14 9.6 5.8 4.1 7.9 5.6 5.5 3.8
M8 32 23 14 9.8 14 9.6 13 9.3
M10 66 46 27 19 32 23 26 19
M12 110 78 48 33 ―――― ―――― 45 31
(M14) 180 130 76 53 ―――― ―――― 73 51
M16 270 190 120 82 ―――― ―――― 98 69
(M18) 380 260 160 110 ―――― ―――― 140 96
M20 530 370 230 160 ―――― ―――― 190 130
(M22) 730 510 ―――― ―――― ―――― ―――― ―――― ――――
M24 930 650 ―――― ―――― ―――― ―――― ―――― ――――
(M27) 1400 960 ―――― ―――― ―――― ―――― ―――― ――――
M30 1800 1300 ―――― ―――― ―――― ―――― ―――― ――――
M36 3200 2300 ―――― ―――― ―――― ―――― ―――― ――――
- 98 -
B-82545EN/03 INDEX
INDEX
<Number> <O>
1.5-YEAR CHECKS (5,760 hours)..................................6 OUTLINE DRAWING AND OPERATION AREA
1-YEAR CHECKS (3,840 hours).....................................5 DIAGRAM.................................................................57
3-MONTH CHECKS (960 hours)....................................5
3-YEAR CHECKS (11,520 hours)...................................6 <P>
PERIODIC INSPECTION TABLE ...............................96
<A> PERIODIC MAINTENANCE .........................................7
ADJUSTMENTS ...........................................................20 PIPING AND WIRING .................................................50
ASSEMBLING THE POSITIONER FOR POSITIONER LOAD CONDITION .............................60
INSTALLATION .......................................................88 POSITIONER OUTLINE DRAWING ..........................57
PREFACE .................................................................... p-1
<B> PREVENTIVE MAINTENANCE ...................................4
BACKLASH MEASUREMENT ...................................17 PROBLEMS AND CAUSES.........................................11
BATTERY REPLACEMENT .........................................9 PROCEDURE FOR RELEASING THE GREASE
REMAINING PREESSURE ........................................9
<C>
CABLE REPLACEMENT.............................................51 <Q>
CABLING (WHEN THE HARTING CONNECTOR Quick Mastering.............................................................33
OPTION IS SELECTED)...........................................50
CHANGING METHOD OF PAYLOAD <R>
SPECIFICATION.......................................................64 REFERENCE POSITION AND MOVING RANGE ....20
COMPONENT REPLACEMENT AND REPLACING CABLES .................................................51
ADJUSTMENT ITEMS .............................................19 REPLACING THE MOTOR .........................................41
COMPONENT REPLACEMENT AND REPLACING THE REDUCER .....................................45
ADJUSTMENTS........................................................41 Resetting Alarms and Preparing for Mastering ..............22
CONFIGURATION .........................................................3
Confirming Mastering ....................................................40 <S>
CONNECTION DIAGRAMS........................................93 SAFETY PRECAUTIONS ........................................... s-1
SEALANT APPLICATION
<D> (1000kg/1500kg payload (Hollow type))
DAILY INSPECTION .....................................................4 (1000kg/1500kg payload (Compact type)).................47
Single Axis Mastering....................................................35
<F> SPARE PARTS LISTS ..................................................91
First 1-month (960 hours) checks.....................................5 STORING THE POSITIONER......................................72
First 3-MONTH CHECKS (960 hours)............................5 STRENGTH OF BOLT AND BOLT TORQUE LIST ..98
Fixture Position Master ..................................................22
<T>
<G> TRANSPORTATION ....................................................70
GENERAL .....................................................................11 TRANSPORTATION AND INSTALLATION.............70
GREASE REPLACEMENT ............................................7 TROUBLESHOOTING .................................................11
<I> <W>
INSTALLATION...........................................................72 WIRING DIAGRAMS...................................................50
INSTALLATION CONDITIONS..................................88
<Z>
<M> Zero Position Mastering.................................................30
MAINTENANCE CLEARANCE..................................86
MAINTENANCE TOOLS...............................................6
MASTERING ................................................................21
Mastering Data Entry .....................................................38
Method of executing KAREL program by using “Call
program”.....................................................................65
Method of executing KAREL program directly.............67
MOUNTING DEVICES ON THE POSITIONER .........60
i-1
B-82545EN/03 REVISION RECORD
REVISION RECORD
Edition Date Contents
• Addition of 300kg/500kg payload (Hollow type)
• Addition of1000kg/1500kg payload (Compact type)
03 Oct., 2010
• Change 1000kg load capacity to of1000kg/1500kg payload (Hollow type)
• Correction of mistakes
02 July, 2007 • Addition of 1000kg load capacity
01 May, 2007
r-1
B-82545EN/03
* B - 8 2 5 4 5 E N / 0 3 *

1axis Positioner Maintenance Manual (B-82545EN 03)

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< 1-Axis SERVO POSITIONER

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

Model name Mechanical unit specification No. Remarks

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

Model 300kg payload 1-axis servo positioner (Hollow type)

Model 300kg/500kg payload 1-axis servo positioner (Hollow type)

Performance of resistant chemicals and resistant solvents

1.1 WORKING PERSON

Programmer or teaching operator:

- An operator cannot work inside the safety fence.

- Use adequate clothing or uniforms during system operation

1.2 OPERATOR SAFETY

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

Termianls FENCE1,FENCE2 are provided

Fig. 1.2 (a) Safety fence and gate

1.2.1 Operator Safety

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

Fig.1.2.1 (b) Connection Diagram for External Emergency Stop Button

1.2.2 Safety of the Teach Pendant Operator

1.2.3 Safety during Maintenance

1.3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.3.1 Precautions in Programming

1.3.2 Precautions for Mechanism

1.4 SAFETY OF THE ROBOT MECHANISM

1.4.1 Precautions in Operation

1.4.2 Precautions in Programming

1.4.3 Precautions for Mechanisms

1.5 SAFETY OF THE END EFFECTOR

1.5.1 Precautions in Programming

1.6 STOP TYPE OF ROBOT

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

Controlled stop (Category 1 following IEC 60204-1)

Hold (Category 2 following IEC 60204-1)

There are the following 3 Stop patterns.

Stop E-Stop External Servo

R-30iA R-30iA Mate

"Stop type set (Stop pattern C)" option

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

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

When this option is loaded, this function can not be disabled.

1.7 WARNING LABEL

Fig. 1.7 (a) Greasing and Degreasing Label

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

(2) Step-on prohibitive label

Fig. 1.7 (b) Step-on Prohibitive Label

(3) High-temperature warning label

Fig. 1.7 (c) High-temperature warning label

(4) Transportation label

Fig. 1.7 (e) Transportation label (1000kg/1500kg payload (Hollow type))

Fig. 1.7 (f) Transportation label (1000kg/1500kg payload (Compact type))

6 COMPONENT REPLACEMENT AND ADJUSTMENTS....................... 41

7.1 WIRING DIAGRAMS ................................................................................... 50

3 TRANSPORTATION AND INSTALLATION ......................................... 70

Fig. 1 Mechanical unit configuration

Refer to Appendix A about the major mechanical unit components.

2.1 DAILY INSPECTION

a) Before automatic operation

Oil inlet Adjusting knob

Regulator Pressure gauge

Fig. 2.1 Three-piece pneumatic option

b) After automatic operation

2.2 First 1-month (960 hours) checks

Item Check items Check points