Service Manual: Robot

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

HS-E series (Small-sized horizontal articulated robots)
HS-4535*E-* * ⇒ None : Standard type

HS-4545*E-* W : Dust & splash-proof type
HS-4555*E-* P : Clean type
Request:
Before starting inspection and maintenance, be sure to thoroughly read "SAFETY PRECAU-
TIONS" on page 1 of "Denso Robot Operator’s Manual (INSTALLATION & MAINTENANCE
GUIDE)" (part no. 410002-1870), to ensure safe inspection.
*Any part of this service manual must not be copied without permission.
*The contents in this service manual may be changed without notice.
SAFETY PRECAUTIONS
(1) Before starting inspection/maintenance or replacement of parts, be sure to thoroughly read

"SAFETY PRECAUTIONS" in this manual and "SAFETY PRECAUTIONS" in Denso Robot
Owner's Manual (IINSTALLATION & MAINTENANCE GUIDE), to ensure safe work.
(2) Cautions with marks in following text indicate potential hazards in adjustment and repair, classi-
fied as follows:
Indicates an extremely hazardous situation which, if not
DANGER avoided, will result in death or serious injury in the most

extreme case.
Indicates a potentially hazardous situation, which, if not
WARNIN avoided, could result in death or serious injury.
G
Indicates a potentially hazardous situation, which, if not
CAUTIO avoided, may result in minor or moderate injury, or damage to
device. (Caution)
N
Caution: Even if a hazard is classified under " CAUTION", it could lead to serious
accident depending on the situation. Be sure to observe the important contents
under the above marks.
1. Cautions when inspecting the body of robot, replacing parts and during adjustment
For inspection of the body of robot, replacement of parts and adjustment, observe the following work
procedures, danger, warning and caution remarks, so that no electric shock or injury occurs, and no
parts inside the robot or peripheral devices are damaged.
(1) Cautions when inspecting or replacing part of robot:
(1) Always wear safety goggles, helmet and shoes during work.
(2) Turn off the power switch on controller, and make sure that the pilot lamp
DANGE goes out.
(3) Turn off power to peripheral devices (equipment) of robot.
R (4) Disconnect all connectors (CN1-CN12) on the controller.
Contents
Chapter1 Inspection and Maintenance
1-1 Types and Purposes of Inspection and Maintenance.......................... 1-1
1-2 Details of Daily Inspection ................................................................... 1-2

1 Required daily inspection and maintenance .....................................1-2
1-3 Details of 3-Month Inspection .............................................................. 1-3

1 Required 3-month inspection and maintenance ...............................1-3
2 Cleaning controller cooling fan filters............................................... 1-4
1-4 Details of 6-month inspection .............................................................. 1-6

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

1 Required 1-year inspection and maintenance ..................................1-7
2 Inspecting and adjusting timing belts............................................... 1-8
1.1Inspecting and adjusting 3rd axis timing belt .....................................1-8
1.2 Inspecting and adjusting 4th axis timing belt A ...............................1-13
1.3 Inspecting and adjusting 4th axis timing belt B ...............................1-17
3 Inspecting Internal Wiring .............................................................. 1-23
1.1Inspection and overview of internal wiring .......................................1-23
1.2 Internal Wiring Diagrams ................................................................1-24
1.3 Simple Inspection Method for Internal Wiring .................................1-30
1-6 Details of 2-Year Inspection............................................................... 1-31

1 Required 2-year inspection and maintenance ................................1-31
2 Replacing encoder backup batteries ............................................. 1-32
3 Replacing memory backup battery ................................................ 1-35
1-7 Limited-Life Parts and Exclusive Devices for Maintenance ............... 1-37
1 Limited-life parts .............................................................................1-37
2 Exclusive devices .......................................................................... 1-37
Chapter2 Replacement of Parts
2-1 Details of Part Replacement ................................................................ 2-1
1
2-2 Replacing Motors..................................................................................2-2
1 Methods for replacing motors ...........................................................2-3
1.11st axis motor replacement method .................................................. 2-3
1.2 2nd axis motor replacement method .............................................. 2-12
1.3 3rd axis motor replacement method ............................................... 2-23
1.4 4th axis motor replacement method ............................................... 2-33
2-3 Replacing the timing belts...................................................................2-43

1 Methods for replacing timing belts ..................................................2-43
1.13rd axis timing belt replacement method ......................................... 2-43
1.2 4th axis timing belt A replacement method..................................... 2-47
1.3 4th axis timing belt B replacement method..................................... 2-49
2-4 Replacing the brakes ..........................................................................2-59

1 Methods for replacing brakes..........................................................2-59
1.13rd axis brake replacement method ................................................ 2-59
1.2 4th axis brake replacement method ............................................... 2-63
2-5 Replacing the second arm assembly..................................................2-66

1 Methods for replacing second arm assembly .................................2-66
2 Top view of second arm assembly................................................. 2-84
2-6 Replacing Power Supply Conversion Board.......................................2-85

1 Fuses on power supply conversion board ......................................2-85
2 Procedure for replacing power supply conversion board............... 2-86
2-7 Replacing Bellows (Dust & splash proof specification).......................2-92

1 Methods for replacing bellows ........................................................2-92
1.1Replacement method for bellows (top) ............................................ 2-92
1.2 Replacement method for bellows (bottom) ..................................... 2-96
2-8 Replacing Bellows (Clean specification)...........................................2-100

1 Methods for replacing bellows ......................................................2-100
1.1Replacement method for bellows (top) .......................................... 2-100
1.2 Replacement method for bellows (bottom) ................................... 2-104
2-9 Replacing Robot ...............................................................................2-108

1 Overview of robot replacement .....................................................2-108
2 Procedure for inputting RANG data ............................................. 2-109
Chapter3 Auxiliary Work
3-1 Motor Brake Releasing Procedure........................................................3-1
2
3-2 Procedure for Resetting Encoder ........................................................ 3-4
1 Cases when encoder must be reset .................................................3-4
2 Encoder resetting method................................................................ 3-5
3-3 CALSET Operation Method ................................................................. 3-8

1 CALSET Operation Method ..............................................................3-8
2 CALSET setting positions .............................................................. 3-13
3
4
Chapter1
Inspection and Maintenance
This chapter summarizes the periodic inspection of Denso

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

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

No. Criterion Corrective action
inspected controller method
1 Connectors : CN1-CN12 of No looseness, Plug in the connectors
controller and destination OFF Visual disconnection properly and clean them.
connectors or dirt
2 Cables : CN1-CN12 of con- No scratches Use insulation tape to
troller or tears protect any damaged
OFF Visual
portion, or replace
cables.
3 LCD on teaching pendant Display must
ON Visual Repair or replace.
be visible
4 Power lamp on controller ON Visual Must light Repair or replace.
5 Controller cooling fan Fan must
Visual
ON rotate nor- Repair or replace.
(Note)
mally.
6 Emergency stop buttons on Press robot stop Robot must
pendant and controller ON button. immediately Repair or replace.
stop.
7 Calibration No error mes-
ON Visual sage or abnor- Repair or replace.
mal sound
8 Safety door Open the switch Robot must Check the switch on
on safety door immediately safety door and wiring to
ON
and the circuit to stop. switch.
switch.
Note : 1. Some of the repair and replacement procedures in the "Corrective action" column require technical
expertise: Consult the Denso Robot Service Department.
2. The proper operation of cooling fan is as shown in Fig. 1-1.
Fig.1-1: Proper operation of Cooling Fan
1-2
1 Inspection and Maintenance 1-3 Details of 3-Month Inspection
1-3 Details of 3-Month

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

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

be inspected controller method
1 Robot base mount- OFF Use torque No looseness. Tighten to the specified
ing bolt wrench to Specified torque: torque.
measure 70 ± 14 Nm
tightening (714 ± 143 kgf·cm)
torque.
2 Motor mounting bolt OFF Use torque No looseness. Tighten at the specified
for each axis wrench to Motor Specified torque.
measure torque
tightening
torque. 1st 5.9 ± 1.2 Nm
axis (60 ± 12
kgf·cm)
2nd 5.9 ± 1.2 Nm
axis (60 ± 12
kgf·cm)
3rd 2.9 ±0.6 Nm
axis (30 ± 6.0
kgf·cm)
4th 2.9 ±0.6 Nm
axis (30 ± 6.0
kgf·cm)
3 Controller cooling fan OFF Visual No dirt Clean the filters

filters (see "2 Cleaning control-
ler cooling fan filters" on
page 1-4).
1-3
2 Cleaning controller The intake and exhaust filters are provided on each side of con-
cooling fan filters troller.
Note : If the filters are clogged, the inside of controller will not be
cooled sufficiently, and the accumulated heat could destroy
the internal parts. If error message 6091-6096 (power module
faulty) appears, the clogging of filters is one possible cause:
Be sure to check the filters, and clean them if necessary.
Follow the procedure in Table 1-4 to clean the filters.
(Cont’d from previous page) Table 1-4: Controller Cooling Fan Filter Cleaning Procedure
No. Procedure Illustration
1 Turn the controller power switch off.
219'4
Power switch OFF zc850z
2 Remove the screws holding the intake filter.
Fixing screws
zc851z
3 Remove the frame for mounting the intake filter, and

then remove the intake filter. Intake filter
Mounting
frame
zc852z
(To be cont’d)
1-4
(Cont’d from previous page) Table 1-4: Controller Cooling Fan Filter Cleaning Procedure
4 Remove the screws holding the exhaust filter.
Fixing screws
zc853z
5 Remove the frame for mounting the exhaust filter,

and then remove the exhaust filter. Exhaust filter
Mounting frame
zc854z
6 (1) Use air blower to clean the filters.

Direction from which
Note1: Blow air in the direction opposite to the normal air cleaning air is blown
flow. Exhaust filter
Note2: Use only dry, oil-free clean air for cleaning.
(2) If dirt is resistant, clean the filter with water. Intake filter
Thoroughly clean with water or lukewarm water
less than 40°C. Cleaning is more effective with
neutral detergent.
Note : After cleaning, dry the filter thoroughly before mount-
ing them.
(3) If the filters do not come clean with air blow or Direction from which
water rinsing, replace them. cleaning air is blown zc855z
7 Reassembly
Use the procedure reverse to steps 2-5 to reinstall
the filters.
(To be cont’d)
1-5
1 Inspection and Maintenance 1-4 Details of 6-month inspection
1-4 Details of 6-month

inspection
1 Required 6-month If robot is used continuously with grease left degraded, this may
inspection and cause trouble such as abnormal sound, wearing bolts and nuts.
maintenance With 6-month inspection, lubrication is applied to rotating or slid-
ing section on 4th axis shaft. Perform lubrication according to
Table 1-5.
Table 1-5: 6-month inspection and maintenance

1 Entire 4th axis shaft OFF Perform lubrication. (Note)
Note : The lubrication must be performed every six months based

on 2-shift operation (basically, every 2,000 hours for refer-
ence). In case of 1-shift operation, perform lubrication every
one year.
2 Point to be lubricated Table 1-6 shows point to be lubricated.
Table 1-6: Point to be lubricated
Point to be Amount of
No. Grease name Remarks
lubricated lubrication
EPINOCK
1 4th axis shaft 2 - 3 cc Apply grease to entire 4th axis shaft.
AP1
Lubricating
zd422z
1-6
1 Inspection and Maintenance 1-5 Details of 1-Year Inspection
1-5 Details of 1-Year Inspection
1 Required 1-year Perform inspection and maintenance according to Table 1-7.

inspection and
maintenance
Table 1-7: 1-Year Inspection and Maintenance

1 3rd and 4th axis tim- OFF
Inspection
ing belts
(1) Visually check the wear of teeth of timing belts.
(2) Use push-pull gauge and scale to measure the deflection of
timing belts.
Push-pull
gauge
Deflection
Timing belt
zd423z
Criterion standard
(1) The teeth of timing belts must not be worn.

(2) The deflection values must be within the specifications.
Axis Weight Deflection

specifications
3rd axis timing belt 9.8 N (1 kgf) 3.0㨪3.5 mm
4th axis timing belt A 29.4 N (3 kgf) 2.5㨪3.0 mm
4th axis timing belt B 29.4 N (3 kgf) 1.5㨪2.0 mm
Corrective
(1) Replace the timing belts.

(2) Adjust the tension on timing belts (see"2 Inspecting and
adjusting timing belts" on page 1-8)
2 Internal wiring OFF Perform inspection, referring to "3 Inspecting Internal Wiring" on
page 1-23.
Note : (1) The timing belts must be inspected every year based on
2-shift operation (basically, every 4000 hours for refer-
ence). In case of 1-shift operation, inspect the timing belts
every two years.
(2) When adjusting the tension on timing belts, do not change
the positions of timing belts that mesh with pulleys: If the
positions are changed, the teaching point will drift.
1-7
2 Inspecting and adjusting The timing belts for driving 3rd and 4th axis are limited-life parts:
timing belts As the belts are used, the teeth will wear down and the belts will
stretch.
If the robot is used with worn teeth or belt stretched, it will cause a
defect in robot, such as position drift.
To prevent this, the 1-year inspection is performed to inspect and
adjust the timing belts.
Note : (1) There are two 4th axis timing belts: One is “4th axis timing
belt A” from 4th axis motor to intermediate shaft, the other
is “4th axis timing belt B” from intermediate shaft to output
shaft.
(2) When adjusting the tension on timing belts, do not change
the positions of timing belts that mesh with pulleys. If the
positions are changed, the teaching point will drift.
2.1 Inspecting and adjusting Perform inspection and adjustment according to Table 1-8.
3rd axis timing belt
(Cont’d from previous page) Table 1-8: 3rd Axis Timing Belt Inspection and Adjustment
219'4
2 Remove the four bolts holding the second arm

Second arm cover
cover, and then remove the cover.
Bolts
zd424z
(To be cont’d)
1-8
3 Disconnect four air pipes (Black/white: ø4, Black/
blue: ø6), two hand control signal connectors (Black/
Second arm cover
white: 10-pin) and brake releasing connector (white:
2-pin).
Hand control signal
connectors
Air pipes
Brake releasing
connector
zd425z
4 Remove the second arm cover.

Note : For Dust & splash-proof/Clean specifica-
tions, remove packing together. Second arm cover
zd426z
5 Remove rubber bush for inspecting timing belt at the

side of second arm.
Rubber bush for inspecting timing belt

zd427z
(To be cont’d)
1-9
6 Insert push-pull gauge into inspection window and
push the 3rd axis timing belt with force of 9.8 N
(1kgf) using push-pull gauge and measure amount
of deflection using scale.
Push-pull gauge

zd428z
Amount of deflection
(3.0 - 3.5 mm)
9.8 N (1 kgf)
3rd axis
Push-pull timing belt
gauge
zd429z
7 If amount of deflection is within the following specifi-

cation, proceed with step 11.
Specification of deflection of 3rd axis timing belt:
3.0 - 3.5 mm
8 Loosen three bolts holding the 3rd axis motor

assembly. 3rd axis motor
Note : Take care at this time that the relation of assembly
positions where the teeth of belt and pulley
mesh has not changed: If it has changed,
CALSET is necessary in the final process
Bolts
zd430z
(To be cont’d)
1-10
9 Set the push-pull gauge as shown in the diagram,
and while pressing the gauge in the direction of the 3rd axis motor
arrow with a force of 176.4 N (18 kgf), tighten three
bolts (M3 x 10) holding the 3rd axis motor assembly.
Tightening torque of 3rd axis motor assembly hold-

ing bolt:
2.0 ± 0.4 Nm (20 ± 4 kgf·cm) Bolts
176.4 N (18 kgf)
Push-pull gauge zd431z
10 Perform re-inspection according to steps 6 and 7.

Note : If the amount of deflection is not within the
specification after adjustment, belt must be
replaced. (See "1.1 3rd axis timing belt
replacement method" on page 2-43)
11 Attach rubber bush for timing belt inspection.

zd427z
12 Connect four air pipes (Black/white: ø4, Black/blue:

ø6), two hand control signal connectors (Black/
Second arm cover
2-pin).
Hand control signal
Note : For Dust & splash-proof/Clean specifica- connectors
tions, attach packing together, before con-
necting air pipes and connectors.
Air pipes
Brake releasing
connector
zd425z
(To be cont’d)
1-11
13 Reinstall the second arm cover, and tighten the four
Second arm cover
bolts (M3 x 45) holding the cover.
Tightening torque of second arm cover fixing bolts

(standard specification):
0.59 ± 0.1 Nm (6 ± 1.2 kgf·cm)

(Dust & splash-proof/Clean specifications):
1.57 ± 0.3 Nm (16 ± 3.2 kgf·cm)
Note : Take care that wires do not get caught Bolts

between the cover and second arm.
zd424z
14 If the positions where the teeth of belt and pulley

mesh change during belt adjustment, perform
CALSET for 3rd axis. (See "3-3 CALSET Operation
Method" on page 3-8)
(To be cont’d)
1-12
4th axis timing belt A
(Cont’d from previous page) Table 1-9: Inspection and Adjustment of 4th Axis Timing Belt A
219'4

Second arm cover
Bolts
zd424z

Second arm cover
2-pin).
Hand control signal
connectors
Air pipes
Brake releasing
connector
zd425z
(To be cont’d)
1-13
4 Remove the second air cover.
zd426z
5 Push the 4th axis timing belt A with force of 29.4 N

(3 kgf) using push-pull gauge and measure amount Measure using scale from notch part.
of deflection using scale.
Push-pull gauge
4th axis timing belt A zd432z
4th axis Push-pull gauge

timing belt A
29.4 N (3 kgf)
Amount of deflection
(2.5 - 3.0 mm)
zd433z

Specification of deflection of 4th axis timing belt A:
2.5 - 3.0 mm
(To be cont’d)
1-14
7 Loosen three bolts holding the 4th axis motor
assembly. 4th axis motor assembly
Note : Take care at this time that the relation of

positions where the teeth of belt and pulley
mesh has not changed: If it has changed,
CALSET is necessary in the final process
Bolts
zd434z
8 Set the push-pull gauge as shown in the diagram,

Arm tip side 4th axis motor assembly
and while pressing the gauge in the direction of the
arrow with a force of 225.4 N (23 kgf), tighten three
bolts (M3 x 10) holding the 4th axis motor assembly.
Tightening torque of 4th axis motor assembly hold-

225.4 N (23 kgf)
ing bolt:
2.0 ± 0.4 Nm (20 ± 4 kgf·cm)
Bolts
Push-pull gauge
zd435z

replaced.
(See "1.2 4th axis timing belt A replace-

Second arm cover
2-pin).
Hand control signal
Air pipes
Brake releasing
connector
zd425z
(To be cont’d)
1-15
11 Reinstall the second arm cover, and tighten the four
Second arm cover

0.59 ± 0.1 Nm (6 ± 1.2 kgf·cm)

Dust & splash-proof/Clean specifications):
1.57 ± 0.3 Nm (16 ± 3.2 kgf·cm)

zd424z

CALSET for 4th axis.
(See "3-3 CALSET Operation Method" on page 3-
8.)
(To be cont’d)
1-16
4th axis timing belt B
(Cont’d from previous page) Table 1-10: Inspection and Adjustment of 4th Axis Timing Belt B
219'4

Second arm cover
Bolts
zd424z

Second arm cover
2-pin).
Hand control signal
connectors
Air pipes
Brake releasing
connector
zd425z
(To be cont’d)
1-17
4 Remove the second air cover.
zd426z
5 Remove rubber bush for timing belt inspection at the

side of second arm.

zd427z
6 Insert push-pull gauge into inspection window and

push the 4th axis timing belt B with force of 29.4 N
(3kgf) using push-pull gauge and visually check
amount of deflection.
Front side
Push-pull gauge
zd436z
Push-pull
gauge
29.4 N (3 kgf)
Amount of
deflection
(1.5 - 2.0 mm)

zd437z
(To be cont’d)
1-18
Note :
Specification of deflection of 4th axis timing belt B:
1.5 - 2.0 mm
8 Remove two bolts fixing 3rd/4th axis connector plate
to make 3rd/4th axis connector plate free.
Bolts
3rd/4th axis connector plate zd438z
9 Loosen three bolts fixing 4th axis intermediate shaft

assembly. 4th axis intermediate
shaft assembly
Bolts
Arm tip side
Bolt
zd439z
10 Remove one pulley C fixing bolt to remove pulley C

plate. 4th axis intermediate
shaft assembly
Bolt
Pulley C
Pulley C plate
zd440z
(To be cont’d)
1-19
11 Attach M4 x 25 bolt to the shaft of 4th axis intermedi-
ate shaft assembly.
Bolt M4 X 25
Shaft
4th axis intermediate

shaft assembly
zd441z
12 Set push-pull gauge to M4 x 25 bolt and while pull-

352.8 N (36 kgf)
ing it in the direction of the arrow with the force of Bolt M4 X 25
352.8 N (36 kgf), tighten three bolts fixing 4th axis
intermediate shaft assembly. After tightening bolts
fixing 4th axis intermediate shaft assembly, remove
M4 x 25 bolt. shaft assembly
Tightening torque of bolt fixing 4th axis intermediate Push-pull gauge

shaft assembly:
2.0 ± 0.4 Nm (20 ± 4 kgf·cm) Bolt
Bolts
zd442z

replaced.
(See "1.3 4th axis timing belt B replace-
ment method" on page 2-49.)
14 Adjust amount of deflection of 4th axis timing belt A.

(See "2.2 Inspecting and adjusting 4th axis tim-
ing belt A" on page 1-13.)
15 Adjust amount of deflection of 3rd axis timing belt.
(See "2.1 Inspecting and adjusting 3rd axis tim-
ing belt" on page 1-8.)
16 Attach pulley C plate and one pulley C fixing bolt
(M4 x 10). 4th axis intermediate
shaft assembly
Tightening torque of pulley C fixing bolt: Bolt
3.9 ± 0.8 Nm (40 ± 8 kgf·cm)
Pulley C
Pulley C plate
zd440z
(To be cont’d)
1-20
17 Attach two bolts (M3 x 8) fixing 3rd/4th axis connec-
tor plate.
Tightening torque of bolt fixing 3rd/4th axis connec-

tor plate: Bolts
2.0 ± 0.4 Nm (20 ± 4 kgf·cm)
18 Attach rubber bush for timing belt inspection.

zd427z

Second arm cover
2-pin).
Hand control signal
Air pipes
Brake releasing
connector
zd425z
20 Reinstall the second arm cover, and tighten four

Second arm cover

0.59 ± 0.1 Nm (6 ± 1.2 kgf·cm)

1.57 ± 0.3 Nm (16 ± 3.2 kgf·cm)

zd424z
(To be cont’d)
1-21
CALSET for 4th axis.
(See "3-3 CALSET Operation Method" on page 3-
8.)
(To be cont’d)
1-22
3 Inspecting Internal Wiring
3.1 Inspection and overview The unit has three wiring circuit systems, as shown in Table 1-11:
of internal wiring Motor power, encoder signal, and hand control signal.
Table 1-11 lists the connectors for each circuit system.
Table 1-11: Internal Wiring Circuit and Connectors
No. Internal wiring Corresponding connectors

1 Motor power circuit Motor/encoder connector CN22 4-pin connector for each axis motor
2 Encoder signal circuit Motor/encoder connector CN22 J5 connector for encoder signal
J5 connector for encoder signal 4-pin connector for each axis encoder
3 Hand control signal circuit Hand control signal connector CN20 Hand control signal connector CN21
Fig. 1-2 to 1-7 show the HS-E type robot internal wiring dia-
grams: Use a tester to check the internal wiring, and make sure
that pins of each connector are conductive, and that the robot
body is isolated from each pin (excluding the GND wire).
Note : When checking the wiring for encoder circuit, the encoder is disconnected from the backup battery: This
will erase any data in encoder and could cause the robot to be inoperable. When error message of num-
ber in 6410s (encoder system down error) after the wiring for encoder circuit has been checked, reset
the encoder and perform CALSET.
(See "3-2 Procedure for Resetting Encoder" on page 3-4 and "3-3 CALSET Operation Method" on
page 3-8.)
1-23
3.2 Internal Wiring Diagrams Fig. 1-2 to 1-7 show the HS-E type robot internal wiring diagrams.
j Red 1: 1st axis motor phase U

Yellow 2: 1st axis motor phase V 1st axis motor
r
Black 3: 1st axis motor phase W connector (white)
p
Green 4: 1st axis GND
h Red 1: 2nd axis motor phase U

n Yellow 2: 2nd axis motor phase V 2nd axis motor
g Black 3: 2nd axis motor phase W connector (black)
Green 4: 2nd axis GND
a Red 1: 3rd axis motor phase U

S Yellow 2: 3rd axis motor phase V 3rd axis motor
T Black 3: 3rd axis motor phase W connector (white)
Green 4: 3rd axis GND
K Red 1: 4th axis motor phase U

E Yellow 2: 4th axis motor phase V 4th axis motor
A Black 3: 4th axis motor phase W connector (red)
Green 4: 4th axis GND
Gray 1: Brake COM Brake releasing

b
Gray
2: Brake 24V connector (white)
U Gray 1: 3rd axis brake 24V 3rd axis brake

Gray 2: 3rd axis brake 0V connector (white)
N
1: 4th axis brake 24V 4th axis brake

2: 4th axis brake 0V connector (black)
1 2
CN22 1 2
A B C D
E F G H J 3rd and 4th axis
K L M N P R brake connectors
(Diagram viewed from 3 4
S T U V W X Z pin side mating surface)
1st to 4th axis
a b c d e f
motor connectors
g h j k m (Diagram viewed from
n p r s pin side mating surface)
1 2
Brake releasing connector
CN22 (Diagram viewed from (Diagram viewed from
pin side mating surface) pin side mating surface) zd443z
Fig.1-2: Motor power circuit (standard specifications)
1-24
31 Red 1: 1st axis motor phase U

Yellow 2: 1st axis motor phase V 1st axis motor
36
Black 3: 1st axis motor phase W connector (white)
35
Green 4: 1st axis GND
30 Red 1: 2nd axis motor phase U

34 Yellow 2: 2nd axis motor phase V 2nd axis motor
29 Black 3: 2nd axis motor phase W connector (black)
Green 4: 2nd axis GND
23 Red 1: 3rd axis motor phase U

16 Yellow 2: 3rd axis motor phase V 3rd axis motor
17 Black 3: 3rd axis motor phase W connector (white)
Green 4: 3rd axis GND
10 Red 1: 4th axis motor phase U

5 Yellow 2: 4th axis motor phase V 4th axis motor
1 Black 3: 4th axis motor phase W connector (red)
Green 4: 4th axis GND
Gray 1: Brake COM Brake releasing

24
Gray
2: Brake 24V connector (white)
18 Gray 1: 3rd axis brake 24V 3rd axis brake

Gray 2: 3rd axis brake 0V connector (white)
13
1: 4th axis brake 24V 4th axis brake

2: 4th axis brake 0V connector (black)
1 2
CN22
1 2
1 2 3 4
5 6 7 8 9 3rd and 4th axis
brake connectors
10 11 12 13 14 15
(Diagram viewed from
16 17 18 19 20 21 22 pin side mating surface) 3 4
23 24 25 26 27 28 1st to 4th axis
motor connectors
29 30 31 32 33
34 35 36
1 2 pin side mating surface)
Brake releasing connector
CN22 (Diagram viewed from zd444z
pin side mating surface)
Fig.1-3: Motor power circuit (Dust & splash-proof/Clean specifications)
1-25
Encoder backup battery

Power conversion
White
W:0V 8
Red
P:24V 7
Blue 6
M:phase Rx
board
V:phase Rx White 5 J1
White
4
CN22 Blue
3
Black J2
2
White
1
J5
White
Black
1: 1st axis encoder 5/3.6V
2: 1st axis encoder 0V 1st axis encoder
Blue
3: 1st axis encoder phase Rx
White connector (white)
White
Black
1: 2nd axis encoder 5/3.6V
2: 2nd axis encoder 0V 2nd axis encoder
Blue
3: 2nd axis encoder phase Rx connector (black)
White
4: 2nd axis encoder phase Rx
White
Black
1: 3rd axis encoder 5/3.6V
2: 3rd axis encoder 0V 3rd axis encoder
Blue
3: 3rd axis encoder phase Rx connector (white)
White
4: 3rd axis encoder phase Rx
White
Black
1: 4th axis encoder 5/3.6V
2: 4th axis encoder 0V 4th axis encoder
Blue
3: 4th axis encoder phase Rx connector (red)
White
4: 4th axis encoder phase Rx
White
1
Black
2 Terminus capacitor board Connector (white)
Blue
3
White
4
4 3 2 1
A B C D
E F G H J
K L M N P R 1st to 4th
S T U V W X Z 8 7 6 5 4 3 2 1
encoder connectors
a b c d e f (Diagram viewed from
g h j k m
J5 (Diagram viewed from
n p r s 4 3 2 1
Terminus capacitor
CN22 (Diagram viewed from board connector
pin side mating surface) (Diagram viewed from
zd445z
Fig.1-4: Encoder signal circuit (Standard specifications)
1-26
Encoder backup battery

Power conversion
White
20:0V 8
Red
14:24V 7
Blue
12:phase Rx 6 J1
board
White 5
19:phase Rx
White
4
CN22 Blue
3
Black
2 J2
White
1
J5
White
Black
1: 1st axis encoder 5/3.6V
2: 1st axis encoder 0V 1st axis encoder
Blue
White connector (white)
White
Black
1: 2nd axis encoder 5/3.6V
2: 2nd axis encoder 0V 2nd axis encoder
Blue
3: 2nd axis encoder phase Rx connector (black)
White
4: 2nd axis encoder phase Rx
White
Black
1: 3rd axis encoder 5/3.6V
2: 3rd axis encoder 0V 3rd axis encoder
Blue
3: 3rd axis encoder phase Rx connector (white)
White
4: 3rd axis encoder phase Rx
White
Black
1: 4th axis encoder 5/3.6V
2: 4th axis encoder 0V 4th axis encoder
Blue
3: 4th axis encoder phase Rx connector (red)
White
4: 4th axis encoder phase Rx
White
1
Black
2 Terminus capacitor board connector (white)
Blue
3
White
4
4 3 2 1
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15
1st to 4th
16 17 18 19 20 21 22 8 7 6 5 4 3 2 1 encoder connectors
23 24 25 26 27 28 (Diagram viewed from
29 30 31 32 33 pin side mating surface)
J5 (Diagram viewed from
34 35 36
pin side mating surface) 4 3 2 1
CN22 (Diagram viewed from Terminus capacitor

pin side mating surface) board connector
zd446z
Fig.1-5: Encoder signal circuit (Dust & splash-proof/Clean specifications)
1-27
Relay connector (white)

Red Red
1 1
White White
2 2
Blue Blue
3 3
White White
4 4
Blue Blue
5 5
White White
6 6
Blue Blue
7 7
White White
8 8
Blue Blue
9 9
White White
10 10
Blue Blue
11 11
White White
12 12
Blue Blue
13 13
White White
14 14
Blue Blue
15 15
White White
16 16
Blue Blue
17 17
White White
18 18
Red Blue
19 19
CN20 Relay connector (black) CN21
1 2 3 4 3 2 1
5 6 7 8 9 7 6 5 4
10 11 12 13 14 15
12 11 10 9 8
16 17 18 19
16 15 14 13
19 18 17
CN20 (Diagram viewed from CN21 (Diagram viewed from

pin side mating surface) pin side mating surface)
zd447z
Fig.1-6: Hand signal circuit (Standard specifications)
1-28
Relay connector (white)

Red Red
A 1
White White
B 2
Blue Blue
C 3
White White
D 4
Blue Blue
E 5
White White
F 6
Blue Blue
G 7
White White
H 8
Blue Blue
J 9
White White
K 10
Blue Blue
L 11
White White
M 12
Blue Blue
N 13
White White
P 14
Blue Blue
R 15
White White
S 16
Blue Blue
T 17
White White
U 18
Red Blue
V 19
CN20 Relay connector (black) CN21
L M A
3 2 1
K U N B 7 6 5 4
J T V P C 12 11 10 9 8
H S R D
16 15 14 13
G F E 19 18 17
CN20 (Diagram viewed from CN21 (Diagram viewed from

pin side mating surface) pin side mating surface)
zd448z
Fig.1-7: Hand signal circuit (Dust & splash-proof/Clean specifications)
1-29
3.3 Simple Inspection Method The following explains the simple inspection method for wiring in
for Internal Wiring motor power and encoder signal circuits.
Perform inspection according to Table 1-12.
Table 1-12: Simple Inspection Method for Wiring in Motor Power and Encoder Signal Circuits
(Cont’d from previous page)

1 Turn the controller power switch on.
POWER
Power switch ON zc877z
2 Select manual operation and mode for each axis,

and activate the 1st to 4th axes at full stroke in the +
and - directions.
Note : Make sure that area around robot is free of
hazard, and set the operation speed to
3
Criterion stan-
(1) Motor power circuit

There must be no error code of number in 6110s
(the last digit indicates the axis number).
(2) Encoder signal circuit
There must be no error code of number in 6420s
(the last digit indicates the axis number).
* Operate the 1st to 4th axes at full stroke: If the

above error code does not appear, it can be
judged that there is no disconnection in internal
wiring.
4 Turn motor power off, and then turn the controller
power switch off.
219'4
1-30
1-6 Details of 2-Year Inspection
1 Required 2-year Replace the two backup batteries shown in Table 1-13 during 2-
inspection and year inspection and maintenance.
maintenance
Table1-13: Backup Batteries
No. Battery Role Place of installation

1 Encoder backup battery Retains servo motor encoder position data Robot
2 Memory backup battery Retains variables, I/O and arm data Controller
The position data of encoder installed in the servo motor is stored

in memory inside the encoder.
The variables, I/O and arm data are stored in memory inside the
controller:
When the controller is turned off, the data in memory is backed up
by battery.
These batteries have limited life, and must be replaced periodi-
cally.
Note : Neglecting to replace the backup batteries will erase valuable

data of robot in memory.
Perform 2-year inspection and maintenance according to Table 1-

14.
Table1-14: 2-Year Inspection and Maintenance
Power to Inspection
No. Point or operation to be inspected Criterion Corrective action
controller method
1 Date for replacing battery in "con- The replacement date Replace encoder and
troller setting table" on top of has not reached its 2- memory backup bat-
OFF Visual
controller year accumulation teries.
limit.
2 (1) Display of "Replacement date 1) "Replacement (See "2 Replacing
for controller backup bat- date for control- encoder backup bat-
tery" in teaching pendant dis- ler backup batteries" on page 1-32
play section ON Visual tery" must not be and "3 Replacing
(2) "Error 2103" in display on displayed. memory backup bat-
operating panel (2) "Error 2103" must tery" on page 1-34.)
not be displayed.
(3) Display of error 64a1-4 when No error 64a1-4 or
controller power is on, or dis- 6103 must be dis-
ON Visual
play of error 6103 when robot played. (Note1)
is being used
(4) mark at top left of teach- ON Visual mark must not be

ing pendant display section displayed. (Note2)
1-31
Table1-14: 2-Year Inspection and Maintenance
Power to Inspection
No. Point or operation to be inspected Criterion Corrective action
controller method
Note1: (1) Error 64a1-4 will appear when the voltage of encoder backup batteries is low.
(2) Error 6103 will appear when the voltage of memory backup battery is low.
When either display is visible, replace the corresponding backup battery immediately.
Note2: The mark will appear whenever error 64a1-4 or 6103 appears. Even if error is cleared, the display
will continue unless the battery is replaced.
1-32
2 Replacing encoder Replace the batteries according to Table 1-15.

backup batteries
(Cont’d from previous page) Table1-15: Encoder Backup Battery Replacement Method
219'4
POWER
Power
Powerswitch
switchOFF
ON zc877z
zc850z
2 Remove the four bolts holding the battery cover on

the rear of robot. Bolts
Battery cover
Bolts
zd449z
3 Remove battery cover.

Note : For Dust & splash-proof/Clean specifica- Battery cover
tions, remove O-ring together.
zd450z
(To be cont’d)
1-33
(Cont’d from previous page) Table1-15: Encoder Backup Battery Replacement Method
4 Disconnect the J1 connector on power supply con-
version board, and then remove the batteries. Power supply conversion board
J1 connector
(1) Be sure to wear a wrist band and
connect its terminal to the grounded
portion before starting work.
NOTE (2) Do not touch elements on the printed
circuit board and their terminals with
bare hand (touching could cause
them to be damaged by static elec-
Encoder backup battery zd451z
5 Attach brand-new batteries, and then connect the J1

connector. Encoder backup battery
Holder zd452z
6 Repeat steps 5 and 6 to replace the batteries con-

nected to the J2 connector.
Note : When replacing batteries, do not discon-
nect all connectors (J1-J2) at the same
time: If all connectors are disconnected at
once, the position data in encoder could be
lost. Therefore, disconnect them one by
7 Reattach the battery cover, and then tighten the four
bolts holding the battery cover Bolts
(standard specifications: M3x8; Dust & splash-proof/
Clean specifications: M3x14).
tions, attach O-ring between battery cover
Battery cover
Tightening torque of battery cover fixing bolts:
1.57 ± 0.3 Nm (16 ± 3.2 kg·cm)
Bolts
zd449z
(To be cont’d)
1-34
3 Replacing memory Replace the battery according to Table 1-16.

backup battery
Note : Before replacing the memory backup battery, create a backup

file for the data accumulated in controller in case of accident.
(Cont’d from previous page) Table1-16: Memory Backup Battery Replacement Method
1 Turn on power to the controller, wait for at least one
minute, and then turn it off.
Note : This is to fully charge the capacitor in order
to retain the data in memory of controller:
Neglecting this process could erase the At least
data when the battery is replaced. 1 minute
POWER POWER
ON OFF
zc882z
2 Remove the screw holding the memory backup bat-

tery holder.
Screw
zc883z
3 Remove the memory backup battery holder.
zc364z
(To be cont’d)
1-35
(Cont’d from previous page) Table1-16: Memory Backup Battery Replacement Method
4 Remove the memory backup battery, and attach
brand-new battery.
Note : Terminate the backup battery replacement
work within 3 minutes after disconnecting
the connector: If more than 3 minutes
elapse, the inherent data could be erased.
zc365z
5 Reattach the memory backup battery unit to the

controller, and then use the screw to tighten it.
Screw
zc883z
6 Set the date when the battery must be replaced next

time.
Operate the teaching pendant using the following
procedure:
[F6 Set] → [F6 Maint] → [F4 Battery]
[OK] → [Cancel] [Cancel]

Note : If the current date on controller is incorrect,
the next replacement date cannot be set
correctly: Make sure that the current date
(To be cont’d)
1-36
1 Inspection and Maintenance 1-7 Limited-Life Parts and Exclusive Devices for Maintenance
1-7 Limited-Life Parts and Table 1-17 and Table 1-18 list the parts that must be periodically
Exclusive Devices for replaced, and exclusive devices necessary for maintenance.
Maintenance
1 Limited-life parts
Table1-17: List of Limited-Life Parts
No. Description Part no. Remarks

1 Controller cooling fan filter 410041-0760 For intake
2 Controller cooling fan filter 410041-1220 For exhaust
3 3rd axis timing belt 410642-0390
4 Between motor and intermediate
4th axis timing belt A 410642-0460
shaft
5 Between intermediate shaft and out-
4th axis timing belt B 410642-0470
put shaft
6 Memory backup battery 410076-0090
7 Encoder backup batteries 410679-0010 Two-battery set
2 Exclusive devices
Table1-18: List of Exclusive Devices
No. Description Part no. Remarks

1 For 4th axis CALSET jig 410192-0040 For 4th axis CALSET
2 Floppy disk drive 410010-0520
Off-line programming software WINCAPS For data backup
3 410090-0840
II
1-37
Chapter2
Replacement of Parts
This chapter summarizes the procedures for replacing parts

in robot. Refer to this chapter when the robot is faulty and
replacement of parts is deemed necessary.
2 Replacement of Parts 2-1 Details of Part Replacement
2-1 Details of Part Replace- If defect in parts inside the controller is detected, replace the parts
ment and assembly according to Table 2-1.
Table2-1: Replacement of Parts and Assemblies
No. Parts and assemblies Replacement procedure

1 Motors See "2-2 Replacing Motors" on page 2-2.
2 3rd/4th axis timing belt See "2-3 Replacing the timing belts" on page 2-43.
3 3rd/4th axis brake See "2-4 Replacing the brakes" on page 2-59.
4 Second arm assembly See "2-5 Replacing the second arm assembly" on page 2-66.
Power supply conversion See "2-6 Replacing Power Supply Conversion Board" on page 2-85.
5
board
Bellows (Dust & splash proof See "2-7 Replacing Bellows (Dust & splash proof specification)" on
6
specification) page 2-92
7 Bellows (Clean specification) See "2-8 Replacing Bellows (Clean specification)" on page 2-100
8 Robot body See "2-9 Replacing Robot" on page 2-108.
2-1
2 Replacement of Parts 2-2 Replacing Motors
2-2 Replacing Motors The motors for driving each axis are life-limited parts: If worn motor
is used, electrical or mechanical defects could occur. Table 2-2
shows cases where the motors must be replaced.
Table 2-2: Cases in Which Motors Must Be Replaced and Phenomena that Occur
No. When motor replacement is necessary Phenomena that occur

1 Encoder circuit in servo motor is faulty Errors related to encoder will occur and robot will not operate.
Motor shaft locks because of seizure, Robot will slide heavily, and errors of large deviation, overcur-
2
sticking, etc. rent and overload will occur.
Note : When motors are replaced, the relation in positions between

the robot axes and position data in encoder may change: If
left as is, the robot cannot be operated normally.
If the position data in encoder is erased by motor replace-
ment, error message of number in 6410s (encoder system
down fault) will appear.
To prevent the above, perform CALSET to calibrate the rela-
tion between robot axes and position data in encoder after
motor replacement.
If error message of number in 6410s (encoder system down
fault) appears, reset the encoder and perform CALSET. ("3-2
Procedure for Resetting Encoder" on page 3-4 and "3-3
CALSET Operation Method" on page 3-8.)
2-2
1 Methods for replacing The following explains the procedures for replacing each axis
motors motor:
1.1 1st axis motor replace- (1) Removing 1st axis motor
ment method Follow the procedure in Table 2-3.
(Cont’d from previous page) Table 2-3: 1st Axis Motor Removal
1 Turn off power and air supplied to robot.
(1) Be sure to wear safety goggles, hel-
met and shoes during this work.
(2) Turn the controller power switch off,
and make sure that the pilot lamp
NOTE goes out.
(3) Turn off power and air supply to
peripheral devices (equipment) of
robot.
219'4
(4) Remove the cables (CN20, 22) from
the robot. Power switch OFF zc850z
CN20
CN22
Air pipes zd453z
2 Remove the four bolts on the base block of robot.
Bolts
Bolts
zd454z
(To be cont’d)
2-3
3 Lay the robot on its side.
Robot
(1) Use at least two operators for this
NOTE work.
(2) Put down some waste, etc. and place
the robot gently on it so that the robot
Wastes
zd455z
4 Remove the three bolts (six for Dust & splash-proof/

Clean specifications) holding the 1st axis motor 1st axis motor cover
cover, and then remove the cover. Bolt Bolt
Note : Also remove the O-ring for Dust & splash-

proof/Clean specifications.
Bolt zd456z
5 Disconnect the 1st axis motor connector (white, 4-

pin) and 1st axis encoder connector (white, 4-pin). 1st axis encoder connector (white, 4-pin)
1st axis motor connector (white, 4-pin)

zd457z
6 Remove the three bolts (black) holding the 1st axis

motor assembly and the two bolts for punched tap Bolt (black)
Bolt for punched tap (gold)
(gold).
Bolts (black) Bolt for punched tap (gold)

zd458z
(To be cont’d)
2-4
7 Insert the two bolts (M5x30) into the punched taps,
and tighten them alternately. M5 x 30 bolt
Note : Do not use the three 1st axis motor assem-

bly fixing bolts as bolts for punched taps:
Doing this could cause the tip of thread to
be crushed, and the bolts will then be
M5 x 30 bolt
zd459z
8 Remove the 1st axis motor assembly.

Note1: During removal, take care that the 1st axis 1st axis motor assembly
wave generator attached to the motor
shaft is not subject to impact.
Note2: Wipe off grease coming inside the 1st axis
base using waste, etc.
zd460z
9 Remove the two bolts from the punched taps.
Bolt for
punched tap
Bolt for
punched tap
zd461z
10 Use a wrench to fix the width across flats of 1st axis

plate, and then remove the bolt holding the 1st axis
plate. Bolt
1st axis plate
zd462z
(To be cont’d)
2-5
11 Remove the 1st axis plate.
1st axis plate
zd463z
12 Remove the 1st axis wave generator and key.
1st axis wave

generator
Key
zd464z
13 Remove the four bolts holding the 1st axis motor

plate, and then remove the 1st axis motor plate.
Bolts
1st axis motor plate Bolts zd465z
(To be cont’d)
2-6
(2) Assembling 1st axis motor

Follow the procedure in Table 2-4.
(Cont’d from previous page) Table 2-4: Assembling 1st Axis Motor
1 Attach the O-ring to the flange of 1st axis motor, and
then attach the key to the 1st axis motor shaft.
Key
Note : Be sure to use brand-new O-ring and key
attached to the 1st axis motor: Reusing the
old O-ring could cause oil leak.
O-ring
zd466z
2 Attach the 1st axis motor plate, and then attach the
four bolts (M5x16) holding the 1st axis motor plate.
Tightening torque of 1st axis motor plate fixing bolts:

5.9 ± 1.2 Nm (60 ± 12 kgf·cm)
Note : Be sure to attach the 1st axis motor plate in Bolts
the orientation shown in the illustration.
1st axis motor plate
zd467z
Wiring
1st axis motor plate
1st axis motor
Punched tap
M4 bolts
Punched tap
zd468z
(To be cont’d)
2-7
3 Attach the 1st axis wave generator to the 1st axis
motor shaft.
Note1: Be sure to attach the 1st axis wave gener-
ator in the orientation shown in the illustra-
tion.
1st axis wave
Note2: Coat the balls of 1st axis wave generator
generator
with grease (4B-No. 2).
Key
zd464z
1st axis wave generator
The side where the balls are

Coat balls visible is toward the motor
with grease
Motor shaft
(4B-No. 2)
zc902z
4 Use a wrench to fix the width across flats of 1st axis

plate, and then attach the bolt (M5x10) holding the
1st axis plate. Bolt
Tightening torque of 1st axis plate fixing bolt:

8.8 ± 1.8 Nm (90 ± 18 kgf·cm) 1st axis plate
zd462z
5 Thinly coat the external periphery of 1st axis wave

generator with harmonic grease (4B-No. 2).
Coat with grease

(4B-No.2).
zd469z
(To be cont’d)
2-8
6 Coat the inside of 1st axis flexible spline with grease
(4B-No. 2). 1st axis circular
1st axis flexible spline
zd470z
Side View
1st axis circular
1st axis flexible spline
Coat inside of flexible spline

with grease (4B-No. 2)
zc905z
7 Attach the two bolts (gold, M5x10) for punched tap

to the 1st axis motor plate.
Tightening torque of bolts for punched tap (gold):

5.9 ± 1.2 Nm (60 ± 12 kgf·cm)
Bolt for
punched tap
(gold)
Bolt for
punched tap
(gold)
zd471z
8 Attach the 1st axis motor assembly to robot, and

then attach the three bolts (M5x30) holding the 1st Bolt (black)
Bolt for punched tap (gold)
axis motor assembly.
Tightening torque of 1st axis motor assembly fixing

bolts:
5.9 ± 1.2 Nm (60 ± 12 kgf·cm)
Note1: Attach the motor assembly so that the
wires are laid out as shown in the illustra-
tion.
Note2: Attach the motor assembly with care so
that the 1st axis wave generator attached Bolts (black) Bolt for punched tap (gold)
zd458z
(To be cont’d)
2-9
9 Connect the 1st axis motor connector (white, 4-pin)
and 1st axis encoder connector (white, 4-pin). 1st axis encoder connector (white, 4-pin)
1st axis motor connector (white, 4-pin)

zd457z
10 Attach the 1st axis motor cover, and then attach the
three (six 1st axis motor cover
for Dust & splash-proof/Clean specifications) bolts Bolt Bolt
(M3x8) holding the cover.
Tightening torque of 1st axis motor cover fixing bolts

(standard specifications): 1.57 ± 0.3 Nm (16 ± 3.2
kgf·cm)
Tightening torque of 1st axis motor cover fixing bolts

(Dust & splash-proof/Clean specifications): 2.0 ± 0.4
Nm (20 ± 4 kgf·cm)
Bolt zd456z
Note : With Dust & splash-proof/Clean specifica-
tions, be sure to attach a brand-new O-ring
between the 1st axis motor cover and
11 Lift the robot, and use the four bolts (M10x30) to fix
the base block.
Tightening torque of robot base block fixing bolts:

70 ± 14 Nm (714 ± 143 kgf·cm)
Bolts
Bolts
zd454z
(To be cont’d)
2-10
12 Connect the cables (CN20, CN22) and air pipes
(AIR1, AIR2, AIR3, AIR4) to robot, and turn on
power to the controller, peripheral devices (equip-
ment) of robot, and air supply.
CN20
CN22
Air pipes zd472z
13 Error message 6411 (1st axis encoder system down

fault) will appear in the teaching pendant: Reset the
encoder and perform CALSET. (See "3-2 Proce-
dure for Resetting Encoder" on page 3-4 and "3-
3 CALSET Operation Method" on page 3-8.)
(To be cont’d)
2-11
1.2 2nd axis motor replace- (1) Removing 1st axis motor
(Cont’d from previous page) Table 2-5: 2nd Axis Motor Removal
NOTE goes out.
robot.
219'4
CN20
CN22
Air pipes zd453z
2 Remove the four bolts holding second arm cover.

Second arm cover
Bolts
zd424z
(To be cont’d)
2-12
Second arm cover
2-pin).
Hand control signal
connectors
Air pipes
Brake releasing
connector
zd425z

tions, also remove packing. Second arm cover
zd426z
5 Remove two bolt fixing wiring stay and make wiring

stay free.
2nd axis motor
Wire stay
Arm tip side
Bolt
2nd axis motor
Arm tip side Wire stay
Bolt zd473z
(To be cont’d)
2-13
6 Cut two insulator locks and disconnect the 2nd axis
encoder connector (black: 4-pin).
Arm tip side
2nd axis motor
2nd axis encoder connector

(black: 4-pin)
Insulator locks
zd474z
7 Cut insulator lock fixing wiring of the 2nd axis motor

and 3rd axis brake.
2nd axis motor
Insulator lock
Arm tip side
zd475z
8 Cut two insulator locks fixing wiring of the 2nd axis

motor. Arm tip side
2nd axis motor
2nd axis motor wiring
Insulator locks
zd476z
9 Cut two insulator locks and disconnect the 2nd axis

motor connector (black: 4-pin) 2nd axis motor
Arm tip side
Insulator locks 2nd axis motor connector

(black: 4-pin)
zd477z
(To be cont’d)
2-14
10 Remove the four bolts holding the 2nd axis motor
assembly. 2nd axis motor assembly
Bolts
Bolts
zd478z
11 Remove 2nd axis motor assembly.
2nd axis motor

assembly
zd479z
12 Remove one bolt holding the 2nd axis plate.
Bolt
2nd axis plate
zd480z
13 Remove the 2nd axis plate.

Bolt
2nd axis plate
zd481z
(To be cont’d)
2-15
14 Remove the 2nd axis wave generator and key.
2nd axis wave

generator
Key
zd482z
15 Remove the four bolts holding the 2nd axis motor

plate and remove the 2nd axis motor plate.
Bolts
2nd axis
Bolts motor plate
zd483z
(To be cont’d)
2-16
(2) Assembling 2nd axis motor

(Cont’d from previous page) Table 2-6: Assembling 2nd Axis Motor
1 Attach the O-ring to the flange of 2nd axis motor,
and then attach the key to the 2nd axis motor shaft.
Key
Note : Be sure to use brand-new O-ring and key
attached to the 2nd axis motor: Reusing
the old O-ring could cause oil leak.
O-ring
zd484z
2 Attach the 2nd axis motor plate, and then attach the
four bolts (M5x16) holding the 2nd axis motor plate. Bolts
Bolts
Tightening torque of 2nd axis motor plate fixing
bolts:
5.9 ± 1.2 Nm (60 ± 12 kgf·cm)
Note : Be sure to attach the 2nd axis motor plate
in the orientation shown in the illustration.
2nd axis
motor plate
zd485z
Punched taps
2nd axis motor
2nd axis motor plate Wiring
zd486z
(To be cont’d)
2-17
3 Attach the 2nd axis wave generator to the 2nd axis
motor shaft.
Note : (1) Be sure to attach the 2nd axis wave
generator in the orientation shown in the
illustration.
(2) Coat the balls of 2nd axis wave genera-
2nd axis wave
generator
Key
zd482z
2nd axis wave generator
Coat balls The side where the balls are

with grease visible is toward the motor
(4B-No. 2)
Motor shaft
zc923z
4 Attach the 2nd axis plate, and then attach the bolt
(M5x10) holding the 2nd axis plate.
Bolt
Tightening torque of 2nd axis plate fixing bolt:
8.8 ± 1.8 Nm (90 ± 18 kgf·cm)
2nd axis plate
zd481z
5 Thinly coat the external periphery of 2nd axis wave

generator with harmonic grease (4B-No. 2).
Coat with grease

(4B-No.2).
zd487z
(To be cont’d)
2-18
6 Coat the inside of 2nd axis flexible spline with
grease (4B-No. 2).
2nd axis flexible spline
2nd axis
circular
zd488z
Side View
2nd axis
flexible spline 2nd axis circular
Coat inside of flexible spline with

grease (4B-No. 2)
zd489z
7 Attach the 2nd axis motor assembly.

Note : (1) Be sure to attach the 2nd axis motor
assembly in the orientation shown in the
illustration.
(2) Attach the motor assembly with care so
2nd axis motor
that the 2nd axis wave generator
assembly
zd479z
8 Attach the four bolts (M4x30) holding the 2nd axis

motor assembly. 2nd axis motor assembly
Tightening torque of 2nd axis motor assembly fixing Bolts

bolt:
2.9 ± 0.6 Nm (30 ± 6 kgf·cm)
Bolts
zd478z
(To be cont’d)
2-19
9 Connect the 2nd axis motor connector (black: 4-pin)
and fix using two insulator locks. 2nd axis motor
Note : Be sure to attach the insulator lock in the

position shown in the illustration.
Arm tip side

(black: 4-pin)
zd477z
10 Fix wiring of the 2nd axis motor using two insulator

locks. Arm tip side
2nd axis motor
Insulator locks
zd476z
11 Fix 2nd axis motor wiring and 3rd axis brake wiring
suing insulator lock.
2nd axis motor
position shown in the illustration. Insulator lock
Arm tip side
zd475z
12 Connect the 2nd axis encoder connector (black: 4-

pin) and fix using two insulator locks.
Arm tip side
2nd axis motor

(black: 4-pin)
Insulator locks
zd474z
(To be cont’d)
2-20
13 Attach the two bolts (M3x8) holding the wiring stay.
Tightening torque of wiring stay fixing bolt:

2nd axis motor
2.0 ± 0.4 Nm (20 ± 4 kgf·cm)
Wire stay
Arm tip side
Bolt
2nd axis motor
Bolt zd473z

Second arm cover
2-pin).
Hand control signal
Air pipes
Brake releasing
connector
zd425z
15 Reinstall the second arm cover.
Second arm cover
zd426z
(To be cont’d)
2-21
16 Tighten the four bolts (M3 x 45) holding the second
Second arm cover
arm cover.

(standard specification): 0.59 ± 0.1 Nm (6 ± 1.2
kgf·cm)

1.57 ± 0.3 Nm (16 ± 3.2 kgf·cm)
Bolts
zd424z

CN20
CN22
Air pipes zd472z
18 Error message 6412 (2nd axis encoder system

down fault) will appear in the teaching pendant:
Reset the encoder and perform CALSET. (See "3-2
Procedure for Resetting Encoder" on page 3-4
and "3-3 CALSET Operation Method" on page 3-
8.)
(To be cont’d)
2-22
1.3 3rd axis motor replace- (1) Removing 3rd axis motor
(Cont’d from previous page) Table 2-7: 3rd Axis Motor Removal
1 Release the 3rd axis brake and slowly move the 3rd
axis to the lower end.
(See "3-1 Motor Brake Releasing Procedure" on
page 3-1.)
goes out.
NOTE
robot.
219'4
CN20
CN22
Air pipes zd453z

Second arm cover
Bolts
zd424z
(To be cont’d)
2-23
Second arm cover
2-pin).
Hand control signal
connectors
Air pipes
Brake releasing
connector
zd425z

tions, also remove packing. Second arm cover
zd426z
6 Cut three insulator locks and disconnect the 3rd axis

motor connector (white: 4-pin) and 3rd axis encoder Insulator locks
connector (white: 4-pin).
3rd axis encoder

connector (white: 4-pin)
Insulator lock
3rd axis motor connector
(white: 4-pin)
zd490z
7 Cut insulator lock fixing the 4th axis brake wiring.

3rd axis motor
Arm tip side
Insulator lock
4th axis brake wiring

zd491z
(To be cont’d)
2-24
8 Cut two insulator locks fixing 3rd/4th axis brake con-
nectors and disconnect 3rd axis brake connector
(white: 2-pin).
Brake Arm tip side
connector
(white: 2-pin)
Insulator locks
zd492z
9 Remove the three bolts holding the 3rd axis motor

assembly. 3rd axis motor
assembly
Bolts zd493z
10 Remove the 3rd axis timing belt from the 3rd axis
pulley A and then remove the 3rd axis motor assem-
3rd axis motor
bly. assembly
3rd axis
pulley A
zd494z
11 Loosen two screws fixing the 3rd axis pulley assem-

bly. 3rd axis pulley 3rd axis brake
assembly
Set screws
3rd axis motor assembly
zd495z
(To be cont’d)
2-25
12 Remove the two bolts holding the 3rd axis motor to
remove the 3rd axis motor.
3rd axis motor
Bolts
zd496z
(To be cont’d)
2-26
(2) Assembling 3rd axis motor

(Cont’d from previous page) Table 2-8: Assembling 3rd Axis Motor
1 Peel off the 3rd axis brake adjustment sheet from
the second arm cover. Second arm cover
3rd axis brake adjustment sheet

zd497z
2 Remove the three bolts holding the 3rd axis brake to

remove the 3rd axis brake. Bolts
3rd axis brake
zd498z
3 Remove the 3rd axis pulley assembly from the 3rd

brake.
Note : Remove the 3rd axis pulley assembly while
moving it horizontally as shown in the illus-
3rd axis pulley
assembly
3rd axis brake zd499z
(To be cont’d)
2-27
4 Attach the 3rd axis pulley assembly to the 3rd axis
motor stay.
3rd axis pulley

assembly
3rd axis motor stay
zd500z
5 Insert the 3rd axis brake adjustment sheet into the

3rd axis motor stay. 3rd axis motor stay
3rd axis brake

adjustment sheet
zd501z
6 Attach the 3rd axis brake to the 3rd axis motor stay.
Note : Be sure to attach the 3rd axis brake in the
orientation shown in the illustration.
3rd axis brake
3rd axis motor stay

zd502z
7 Tighten the three bolts (M3x8) holding the 3rd axis

brake. Bolts
Note : Attach only the three bolts in the positions

shown in the illustration to fix the 3rd axis
Tightening torque of 3rd axis brake fixing bolts:

2.0 ± 0.4 Nm (20 ± 4 kgf·cm)
3rd axis brake
zd498z
(To be cont’d)
2-28
8 Attach the 3rd axis motor and temporarily tighten
two screws fixing the 3rd axis pulley assembly. 3rd axis pulley 3rd axis brake
assembly
Note : (1) Be sure to attach the 3rd axis motor in
the orientation shown in the illustration.
(2) Attach so that the width across flats of
the 3rd axis motor shaft matches set
Set screws
zd495z
Set screw installation holes

3rd axis pulley
assembly
Width across
flats
3rd axis motor shaft
zd503z
9 Tighten the two bolts (M4x10) holding the 3rd axis

motor.
3rd axis motor
Tightening torque of 3rd axis motor fixing bolts:
2.9 ± 0.6 Nm (30 ± 6 kgf·cm)
Bolts
zd496z
10 Tighten two screws fixing the 3rd axis pulley assem-

bly. 3rd axis pulley 3rd axis brake
assembly
Tightening torque of 3rd axis pulley assembly fixing
screws:
1.6 ± 0.3 Nm (16 ± 3.2 kgf·cm)
Set screws
zd495z
(To be cont’d)
2-29
11 Remove the 3rd axis brake adjustment sheet and
paste it on the second arm cover.
Note : After using the 3rd axis brake adjustment
sheet, be sure to return to the original posi-
3rd axis motor

assembly 3rd axis brake
adjustment sheet
zd504z
12 Attach the timing belt to the 3rd axis pulley A and

attach the 3rd axis motor assembly.
3rd axis motor
assembly
3rd axis
pulley A
zd494z
13 Temporarily tighten the three bolts holding the 3rd

axis motor assembly. 3rd axis motor
assembly
Bolts zd493z
14 Set the push-pull gauge as shown in the illustration,

and, while pushing in the direction of the arrow with 3rd axis motor
the force of 176.4 N (18 kgf), tighten the three bolts
(M3x10) holding the 3rd axis motor assembly.
Tightening torque of 3rd axis motor assembly fixing

bolts:
2.0 ± 0.4 Nm (20 ± 4 kgf·cm) Bolts
176.4 N (18 kgf)
(To be cont’d)
2-30
15 Connect the 3rd axis brake connector (white: 2-pin)
and fix the 3rd/4th axis brake connectors using two
insulator locks.
Brake Arm tip side
Note : Be sure to attach the insulator lock in the connector
position shown in the illustration. (white: 2-pin)
Insulator locks
zd492z
16 Fix the 4th axis brake wiring using a insulator lock.

3rd axis motor
Arm tip side
Insulator lock

zd491z
17 Connect the 3rd axis motor connector (white: 4-pin)

and 3rd axis encoder connector (white: 4-pin), and Insulator locks
then fix using three insulator locks.
3rd axis encoder

Insulator lock
(white: 4-pin)
zd490z

Second arm cover
2-pin).
Hand control signal
tions, attach packing to the second arm,
before connecting air pipes and connec-
Air pipes
Brake releasing
connector
zd425z
(To be cont’d)
2-31
19 Reinstall the 2nd arm cover.
Second arm cover
zd426z

Second arm cover
arm cover.

kgf·cm)

1.57 ± 0.3 Nm (16 ± 3.2 kgf·cm)
Bolts
zd424z

CN20
CN22
Air pipes zd472z
22 Error message 6413 (3rd axis encoder system down

(To be cont’d)
2-32
1.4 4th axis motor replace- (1) Removing 4th axis motor
(Cont’d from previous page) Table 2-9: 4th Axis Motor Removal
NOTE goes out.
robot.
219'4
CN20
CN22
Air pipes zd453z

Second arm cover
Bolts
zd424z
(To be cont’d)
2-33
Second arm cover
2-pin).
Hand control signal
tions, also remove the packing.
Air pipes
Brake releasing
connector
zd425z
Second arm cover
zd426z
5 Cut three insulator locks and disconnect the 4th axis

motor connector (red: 4-pin) and 4th axis encoder
connector (red: 4-pin). Insulator locks
4th axis motor

connector
(red: 4-pin) 4th axis encoder
connector
(red: 4-pin)
Insulator lock
zd505z
6 Cut insulator lock fixing the 4th axis brake wiring.

3rd axis motor
Arm tip side
Insulator lock

zd491z
(To be cont’d)
2-34
7 Cut two insulator locks fixing 3rd/4th axis brake con-
nectors and disconnect 4th axis brake connector
(black: 2-pin).
4th brake connector
(black: 2-pin)
Insulator locks
Arm tip side
zd506z
8 Remove the two bolts holding the 3rd/4th axis con-

nector plate to make the 3rd/4th axis connector plate
free.
Bolts
9 Remove the three bolts holding the 4th axis motor

assembly. 4th axis motor
assembly
Bolts
zd507z
10 Remove the 4th axis timing belt A from the 4th axis
pulley B and then remove the 4th axis motor assem- 4th axis motor
bly. assembly
4th axis pulley B

zd508z
(To be cont’d)
2-35
11 Remove one bolt holding the 4th axis flywheel.
4th axis flywheel Bolt
4th axis motor
zd509z
12 Remove the three bolts holding the 4th axis motor.
4th axis motor
Bolts (M4x10)
Bolt (M3x8)
zd510z
13 Hold the 4th axis flywheel by hand and remove the

4th axis motor.
4th axis motor
4th axis flywheel

zd511z
14 Remove the 4th axis pulley B and key.

4th axis pulley B
Key
4th axis motor
zd512z
(To be cont’d)
2-36
15 Remove the 4th axis flywheel and 4th axis plate
4th axis brake
from the 4th axis brake.
4th axis flywheel
4th axis plate
zd513z
(To be cont’d)
2-37
(2) Assembling 4th axis motor

(Cont’d from previous page) Table 2-10: Assembling 4th Axis Motor
1 Attach the key to the 4th axis motor shaft and attach
the 4th axis pulley B.
4th axis pulley B
Note : Be sure to use brand-new key attached to
the 4th axis motor.
Key
4th axis motor
zd512z
2 Attach the 4th axis plate and 4th axis flywheel to the
4th axis brake
4th axis brake.
4th axis flywheel
Note : Be sure to attach the 4th axis plate and 4th
axis flywheel in the orientation shown in
4th axis plate
zd513z
3 Attach the 4th axis motor and tighten the three bolts
(M4x10: two bolts, M3x8: one bolt) holding the 4th
axis motor.
4th axis motor
Note : Be sure to attach the 4th axis motor in the
orientation shown in the illustration.
Bolts (M4x10)
Tightening torque of 4th axis fixing bolts (M4x10):

2.9 ± 0.6 Nm (30 ± 6 kgf·cm)
Tightening torque of 4th axis fixing bolts (M3x8):

2.0 ± 0.4 Nm (20 ± 4 kgf·cm) Bolt (M3x8)
zd510z
(To be cont’d)
2-38
4 Attach one bolt (M3x12) holding the 4th axis fly-
wheel.
Tightening torque of 4th axis flywheel fixing bolt:

2.0 ± 0.4 Nm (20 ± 4 kgf·cm)
4th axis flywheel Bolt
4th axis motor
zd509z
5 Attach the 4th axis timing belt A to the 4th axis pul-
ley B, and attach the 4th axis motor assembly. 4th axis motor
assembly
4th axis pulley B

zd508z
6 Attach the 4th axis motor assembly and temporarily

tighten the three bolts. 4th axis motor
assembly
Bolts
zd507z
7 Set the push-pull gauge in the position shown in the

illustration and, while pushing it in the direction of
the arrow with the force of 225.4 N (23kgf), tighten
the three bolts (M3x10) holding the 4th axis motor
assembly.
225.4 N (23 kgf)
Tightening torque of 4th axis motor assembly fixing
bolts:
2.0 ± 0.4 Nm (20 ± 4 kgf·cm) Bolts
Push-pull gauge
zd435z
(To be cont’d)
2-39
8 Connect the 4th axis brake connector (black: 4-pin)
and fix 3rd / 4th brake connectors using two insula-
tor locks.
4th brake connector
Note : Be sure to attach the insulator lock in the (black: 2-pin)
Insulator locks
Arm tip side
zd506z
9 Fix the 4th axis brake wiring using one insulator

lock. 3rd axis motor
Arm tip side
Insulator lock

zd491z
10 Connect the 4th axis motor connector (red: 4-pin)

and 4th axis encoder connector (red: 4-pin), and fix
using three insulator locks. Insulator locks

4th axis motor
connector
connector
(red: 4-pin)
Insulator lock
zd505z
11 Attach the two bolts (M3x8) holding the 3rd/4th axis

connector plate.
Tightening torque of 3rd/4th axis connector plate fix-

ing bolts: 2.0 ± 0.4 Nm (20 ± 4 kgf·cm) Bolts
(To be cont’d)
2-40
Second arm cover
2-pin).
Hand control signal
Air pipes
Brake releasing
connector
zd425z
Second arm cover
zd426z

Second arm cover
arm cover.

kgf·cm)

(splash-proof/clean specification): 1.57 ± 0.3 Nm (16
± 3.2 kgf·cm)
Bolts
zd424z

CN20
CN22
Air pipes zd472z
(To be cont’d)
2-41
16 Error message 6414 (4th axis encoder system down
(To be cont’d)
2-42
2 Replacement of Parts 2-3 Replacing the timing belts
2-3 Replacing the timing belts
1 Methods for replacing tim- The following explains the procedures for replacing 3rd/4th timing
ing belts belts.
Note : There are two 4th axis timing belts; one is "4th axis timing belt
A" from 4th axis motor to intermediate shaft, the other is "4th
axis timing belt B" from intermediate shaft to output shaft.
1.1 3rd axis timing belt (1) Removing 3rd axis timing belt
replacement method Follow the procedure in Table 2-11.
(Cont’d from previous page) Table 2-11: 3rd Axis Timing Belt Removal
page 3-1.)
NOTE goes out.
robot.
219'4
CN20
CN22
Air pipes zd453z
3 Remove the 3rd axis motor assembly.

Follow the procedure shown in "Table 2-7: 3rd Axis
Motor Removal" on page 2-23.
(To be cont’d)
2-43
(Cont’d from previous page) Table 2-11: 3rd Axis Timing Belt Removal
4 Remove the four bolts holding the 3rd/4th axis spline
nut stay. Bolts
Arm tip side
3rd/4th axis
spline nut stay
Bolts
zd514z
5 Lift up the 3rd/4th axis spline nut stay.

3rd/4th axis
spline nut stay
3rd axis
timing belt
Arm tip side
zd515z
6 Remove the 3rd axis timing belt.

3rd/4th axis
spline nut stay
Arm tip side

zd516z
(To be cont’d)
2-44
(2) Installing 3rd axis timing belt

(Cont’d from previous page) Table 2-12: 3rd Axis Timing Belt Installation
1 Lift up the 3rd/4th axis spline nut stay and install the
3rd axis timing belt to the 3rd axis pulley (spline
side).
3rd axis
pulley
(spline nut side) 3rd/4th axis spline
nut stay
Arm tip side
zd517z
2 Slowly lower the 3rd/4th axis spline nut stay and

attach the four bolts (M4x14) holding the 3rd/4th Bolts
axis spline nut stay.
Tightening torque of 3rd/4th axis spline nut stay fix-

ing bolts:
2.9 ± 0.6 Nm (30 ± 6 kgf·cm) Arm tip side
3rd/4th axis
spline nut stay
Bolts
zd514z
3 Arrange the 3rd axis timing belt as shown in the

illustration. 3rd axis timing belt
Arm tip side

zd518z
(To be cont’d)
2-45
(Cont’d from previous page) Table 2-12: 3rd Axis Timing Belt Installation
4 Install the timing belt to the 3rd axis pulley A and
attach the 3rd axis motor assembly.
3rd axis motor
Follow the procedure shown in "Table 2-8: Assem- assembly
bling 3rd Axis Motor" on page 2-27.
3rd axis
pulley A
zd494z

CN20
CN22
Air pipes zd472z

(To be cont’d)
2-46
1.2 4th axis timing belt A (1) Removing 4th axis timing belt A
(Cont’d from previous page) Table 2-13: 4th Axis Timing Belt A Removal
NOTE goes out.
robot.
219'4
CN20
CN22
Air pipes zd453z
2 Remove the 4th axis motor assembly.

Follow the procedure shown in "Table 2-9: 4th Axis
Motor Removal" on page 2-33.
3 Remove the 4th axis timing belt A.
4th axis motor
assembly
4th axis pulley B

zd508z
(To be cont’d)
2-47
(2) Installing 4th axis timing belt A

(Cont’d from previous page) Table 2-14: 4th Axis Timing Belt A installation
1 Install the 4th axis timing belt A to the pulley C of the
4th axis intermediate shaft assembly.
Pulley C

shaft assembly
zd519z
2 Attach the 4th axis motor assembly.

Follow the procedure No. 5 to 14 shown in "Table 2- 4th axis motor
10: Assembling 4th Axis Motor" on page 2-38. assembly
4th axis pulley B

zd508z

CN20
CN22
Air pipes zd472z

(To be cont’d)
2-48
1.3 4th axis timing belt B (1) Removing 4th axis timing belt B
(Cont’d from previous page) Table 2-15: 4th Axis Timing Belt B Removal
1 Release the 3rd axis brake and move the 3rd axis to
the lower end.
page 3-1.)
NOTE goes out.
robot.
219'4
CN20
CN22
Air pipes zd453z
3 Remove the 4th axis motor assembly and 4th axis

timing belt.
Follow the procedure No. 2 to 10 shown in "Table 2-
9: 4th Axis Motor Removal" on page 2-33.
4 Remove the 3rd axis motor assembly.
Follow the procedure No. 6 to 10 shown in "Table 2-
7: 3rd Axis Motor Removal" on page 2-23.
(To be cont’d)
2-49
5 Remove the three bolts holding the 4th axis interme-
diate shaft assembly. 4th axis intermediate
shaft assembly
Bolts
Arm tip side
Bolt
zd439z
6 Remove the 4th axis intermediate shaft assembly.

4th axis intermediate shaft assembly
Pulley D
4th axis timing bet B
zd520z
7 Remove the four bolts holding the 3rd/4th axis spline

nut stay. Bolts
Arm tip side
3rd/4th axis
spline nut stay
Bolts
zd514z
8 Lift up the 3rd/4th spline nut stay.

3rd/4th axis
spline nut stay
3rd axis
timing belt
Arm tip side
zd515z
(To be cont’d)
2-50
9 Remove the 3rd axis timing belt and 4th axis timing
belt B. 4th axis timing belt B
zd521z
(To be cont’d)
2-51
(2) Installing 4th axis timing belt B

(Cont’d from previous page) Table 2-16: Installing 4th axis timing belt B
1 Lift up the 3rd/4th axis spline nut stay and install the
4th axis timing belt B to the 4th axis pulley (spline 4th axis timing belt B
nut side).
4th axis pulley

(spline nut side)
zd522z
2 Lift up the 3rd/4th spline nut stay and install the 3rd
axis timing belt to the 3rd axis pulley (spline nut
side).
3rd axis
pulley
(spline nut side) 3rd/4th axis spline
nut stay
Arm tip side
zd517z
3 Slowly lower the 3rd/4th axis spline nut stay and

attach the four bolts (M4x14) holding the 3rd/4th Bolts
axis spline nut stay.
Tightening torque of 3rd/4th axis spline nut stay fix-

ing bolts:
2.9 ± 0.6 Nm (30 ± 6 kgf·cm) Arm tip side
3rd/4th axis
spline nut stay
Bolts
zd514z
(To be cont’d)
2-52
4 Install the 4th axis timing belt B to the pulley D of the
4th axis intermediate shaft assembly
4th axis intermediate shaft assembly, and attach the
4th axis intermediate assembly.
Pulley D
4th axis timing bet B
zd520z
5 Temporarily tighten the three bolts holding the 4th

axis intermediate shaft assembly. 4th axis intermediate
shaft assembly
Bolts
Arm tip side
Bolt
zd439z
6 Remove one bolt holding the pulley C to remove pul-

ley C plate. 4th axis intermediate
shaft assembly
Bolt
Pulley C
Pulley C plate
zd440z
7 Attach M4x25 bolt to the 4th axis intermediate shaft

assembly.
Bolt M4 X 25
Shaft

shaft assembly
zd441z
(To be cont’d)
2-53
8 Set the push-pull gauge to M4x25 bolt and, while
352.8 N (36 kgf)
pulling it in the direction of the arrow with the force of Bolt M4 X 25
352.8 N (36kgf), tighten the three bolts (M3x10)
holding the 4th axis intermediate shaft assembly.
After tightening is complete, remove M4x25 bolt.
shaft assembly
Tightening torque of 4th axis intermediate shaft
assembly stay fixing bolts: 2.0 ± 0.4 Nm (20 ± 4 Push-pull gauge
kgf·cm)
Bolt
Bolts
zd442z
9 Attach the pulley C plate and attach bolt (M4x10)

holding the pulley C. 4th axis intermediate
shaft assembly
Tightening torque of pulley C fixing bolts: Bolt
3.9 ± 0.8 Nm (40 ± 8 kgf·cm)
Pulley C
Pulley C plate
zd440z
10 Arrange the 3rd axis timing belt as shown in the

illustration. 3rd axis timing belt
Arm tip side

zd518z
11 Install the 3rd axis timing belt to the 3rd axis pulley A
and attach the 3rd axis motor assembly.
3rd axis motor
assembly
3rd axis
pulley A
zd494z
(To be cont’d)
2-54
12 Temporarily tighten the three bolts holding the 3rd
axis motor assembly. 3rd axis motor
assembly
Bolts zd493z

and while pushing it in the direction of the arrow with 3rd axis motor
the force of 176.4 N (18kgf), tighten the three bolts
(M3x10) holding the 3rd axis motor assembly.
Tightening torque of 3rd axis motor assembly fixing

bolts:
2.0 ± 0.4 Nm (20 ± 4 kgf·cm) Bolts
176.4 N (18 kgf)
14 Install the 4th axis timing belt A to the 4th axis pulley
B and attach the 4th axis motor assembly. 4th axis motor
assembly
4th axis pulley B

zd508z
15 Temporarily tighten the three bolts holding the 4th

axis motor assembly. 4th axis motor
assembly
Bolts
zd507z
(To be cont’d)
2-55
and while pushing it in the direction of the arrow with
the force of 225.4 N (23kgf), tighten the three bolts
(M3x10) holding the 4th axis motor assembly.
Tightening torque of 4th axis motor assembly fixing

225.4 N (23 kgf)
bolts:
2.0 ± 0.4 Nm (20 ± 4 kgf·cm)
Bolts
Push-pull gauge
zd435z
17 Attach the 3rd/4th axis connector plate and attach

the two bolts (M3x8) holding the 3rd/4th axis con-
nector plate.
Tightening torque of 3rd/4th axis connector plate fix- Bolts

ing bolts:
2.0 ± 0.4 Nm (20 ± 4 kgf·cm)

4th axis
and 4th axis brake connector (black: 2-pin), and fix 3rd axis
brake connector
3rd/4th axis brake connectors using two insulator motor
(black: 2-pin)
locks.
Note : Be sure to attach insulator lock in the posi-
tion shown in the illustration. Insulator locks
Arm tip side

3rd axis
brake connector
(white: 2-pin)
zd523z
19 Fix the wiring of 4th axis brake using a insulator

lock. 3rd axis motor
tion shown in the illustration.
Arm tip side
Insulator lock

zd491z
(To be cont’d)
2-56
fix using three insulator locks.
3rd axis encoder

Insulator lock
(white: 4-pin)
zd490z

using three insulator locks. Insulator locks

4th axis motor
connector
connector
(red: 4-pin)
Insulator lock
zd505z

Second arm cover
2-pin).
Hand control signal
Air pipes
Brake releasing
connector
zd425z
Second arm cover
zd426z
(To be cont’d)
2-57
Second arm cover
arm cover.

kgf·cm)

1.57 ± 0.3 Nm (16 ± 3.2 kgf·cm)
Bolts
zd424z

CN20
CN22
Air pipes zd472z

(To be cont’d)
2-58
2 Replacement of Parts 2-4 Replacing the brakes
2-4 Replacing the brakes
1 Methods for replacing The following explains the procedures for replacing 3rd/4th axis
brakes brakes.
1.1 3rd axis brake replace- (1) Removing 3rd axis brake
(Cont’d from previous page) Table 2-17: 3rd axis brake removal
page 3-1.)
NOTE goes out.
robot.
219'4
CN20
CN22
Air pipes zd453z
3 Remove the 3rd axis motor.

Follow the procedure No. 3 to 12 in "Table 2-7: 3rd
Axis Motor Removal" on page 2-23.
(To be cont’d)
2-59
(Cont’d from previous page) Table 2-17: 3rd axis brake removal
4 Remove the three bolts holding the 3rd axis brake to
remove the 3rd axis brake. Bolts
3rd axis brake
zd498z
5 Remove the 3rd axis pulley assembly from the 3rd

axis brake.
Note : While moving the 3rd axis pulley assembly
horizontally, remove it.
3rd axis pulley
assembly
3rd axis brake zd499z
6 Remove the three bolts holding the 3rd axis brake

disc to remove the 3rd axis brake disc. 3rd axis brake disc
Bolts
3rd axis pulley A Bolt

zd524z
(To be cont’d)
2-60
(2) Installing 3rd axis brake

(Cont’d from previous page) Table 2-18: 3rd axis brake installation
1 Remove the 3rd axis brake disc from the 3rd axis
brake assembly.
Note : While moving the 3rd axis pulley assembly 3rd axis brake disc
horizontally, remove it.
zd525z
2 Attach the 3rd axis brake disc to the 3rd axis pulley
A and attach the three bolts holding the 3rd axis 3rd axis brake disc
brake disc. Bolts
Tightening torque of 3rd axis brake disc fixing bolts:

0.69 ± 0.13 Nm (7 ± 1.4 kgf·cm)
3rd axis pulley A Bolt

zd524z
3 Peel off the 3rd axis brake adjustment sheet from

the second arm cover. Second arm cover
3rd axis brake adjustment sheet

zd497z
4 Attach the 3rd axis motor.

Follow the procedure No. 4 to 20 in "Table 2-8:
Assembling 3rd Axis Motor" on page 2-27.
(To be cont’d)
2-61
(Cont’d from previous page) Table 2-18: 3rd axis brake installation
CN20
CN22
Air pipes zd472z

(To be cont’d)
2-62
1.2 4th axis brake replace- (1) Removing 4th axis brake
(Cont’d from previous page) Table 2-19: 4th axis brake removal
NOTE goes out.
robot.
219'4
CN20
CN22
Air pipes zd453z
2 Remove the 4th axis motor.

Follow the procedure No. 2 to 13 in "Table 2-9: 4th
Axis Motor Removal" on page 2-33.
3 Remove the 4th axis flywheel and 4th axis plate
4th axis brake
from the 4th axis brake.
4th axis flywheel
4th axis plate
zd513z
(To be cont’d)
2-63
(Cont’d from previous page) Table 2-19: 4th axis brake removal
4 Remove the three bolts holding the 4th axis brake.
4th axis stay
Bolt
4th axis brake
Bolts
zd526z
5 Remove the 4th axis brake.
4th axis stay
4th axis brake

zd527z
(To be cont’d)
2-64
(2) Installing 4th axis brake

(Cont’d from previous page) Table 2-20: 4th axis brake installation
1 Attach the 4th axis brake.
Note : Be sure to install in the orientation shown 4th axis stay
in the illustration.
4th axis brake

zd527z
2 Attach the three bolts (M3x25) holding the 4th axis

brake.
4th axis stay
Tightening torque of 4th axis brake fixing bolts:
0.69 ± 0.13 Nm (7 ± 1.4 kgf·cm) Bolt
4th axis brake
Bolts
zd526z
3 Attach the 4th axis motor assembly.

Follow the procedure No. 2 to 14 in "Table 2-10:
Assembling 4th Axis Motor" on page 2-38.
CN20
CN22
Air pipes zd472z

(To be cont’d)
2-65
2 Replacement of Parts 2-5 Replacing the second arm assembly
2-5 Replacing the second arm

assembly
1 Methods for replacing The following explains the procedures for replacing second arm
second arm assembly assembly.
(1) Removing second arm assembly

(Cont’d from previous page) Table2-21: Second arm assembly Removal

NOTE goes out.
robot.
219'4
CN20
CN22
Air pipes zd453z

Second arm cover
cover.
Bolts
zd424z
(To be cont’d)
2-66

Second arm cover
2-pin).
Hand control signal
connectors
Air pipes
Brake releasing
connector
zd425z

tions, also remove the packing. Second arm cover
zd426z
5 Cut off three insulator locks and disconnect the 3rd

axis motor connector (white: 4-pin) and 3rd axis Insulator locks
encoder connector (white: 4-pin).
3rd axis encoder

Insulator lock
(white: 4-pin)
zd490z
6 Cut off three insulator locks and disconnect 4th axis

motor connector (red: 4-pin) and 4th axis encoder
connector (red: 4-pin). Insulator locks
4th axis motor

connector
connector
(red: 4-pin)
Insulator lock
zd505z
(To be cont’d)
2-67

7 Cut off three insulator locks and disconnect the 3rd 4th axis
axis brake connector (white: 2-pin) and 4th axis brake connector 3rd axis
brake connector (black: 2-pin). (black: 2-pin) motor
Insulator locks
Arm tip side

3rd axis
brake connector
(white: 2-pin)
zd528z
8 Cut off two insulator locks and disconnect the 2nd

axis encoder connector (black: 4-pin).
Arm tip side
2nd axis motor

(black: 4-pin)
Insulator locks
zd474z
9 Cut off insulator lock fixing the 2nd axis motor and
3rd axis brake wirings.
2nd axis motor
Insulator lock
Arm tip side
zd475z
10 Cut off two insulator locks fixing the 2nd motor wir-
ing. Arm tip side
2nd axis motor
Insulator locks
zd476z
(To be cont’d)
2-68

11 Cut off two insulator locks and disconnect the 2nd
axis motor connector (black: 4-pin). 2nd axis motor
Arm tip side

(black: 4-pin)
zd477z
12 Cut off two insulator locks fixing the air pipes, wiring
of brake releasing connector and hand control con-
nector cable.
Arm tip side 2nd axis

motor
Insulator locks
zd529z
13 Cut off insulator lock fixing the terminus capacitor

board.
Terminus capacitor board
Arm tip side
Insulator lock
zd530z
14 Disconnect the terminus capacitor board connector Terminus capacitor board

(white: 4-pin) to remove terminus capacitor board. connector (white: 4-pin)
zd531z
(To be cont’d)
2-69

15 Apply marking to wire using white marker so that the
tip position of the protective net is indicated. Also
apply marking to protective net using white marker
so that the position of wire fixing saddle is indicated. White marker
Apply marking
using a marker.
Wire fixing saddle

Protective net
zd532z
16 Remove bolt holding the wire fixing saddle.
Wire fixing saddle
Bolt
zd533z
17 Remove the two bolts holding the wire stay.
2nd axis motor
Wire stay
Arm tip side
Bolt
2nd axis motor
Bolt zd473z
(To be cont’d)
2-70

18 Remove the wire stay.
Wire stay
zd534z
19 Remove the wire fixing saddle.
Wire fixing saddle
zd535z
20 Cut off insulator lock fixing the wire protective net.
Wire protective net
Insulator lock
zd536z
21 Cut off two insulator locks fixing the wiring of 3rd/4th

motor and encoder connectors.
Insulator locks
zd537z
(To be cont’d)
2-71

22 Remove the three bolts holding the first arm lower
cover (five for Dust & splash-proof/Clean specifica-
tions) and remove the first arm lower cover.
Note : Also remove the O-ring for Dust & splash-
proof/Clean specifications.
Bolts
First arm lower cover
zd538z
23 Remove the two bolts holding the cable guide B.

Bolt
Cable guide B
Arm tip side
Bolt
zd539z
24 Remove the cable guide B.
Cable guide B
Arm tip side
zd540z
25 Remove the cable guide rail and pull out the wiring
from the cable guide B and cable guide rail.
Cable guide rail
Cable guide B
zd541z
(To be cont’d)
2-72

26 Pull out wiring from lower side of first arm.
Wiring
zd542z
27 Remove the two bolts holding the cable guide A at

the bottom of first arm.
Bolts
Cable guide A
zd543z
28 Remove the cable guide A.
Cable guide A
zd544z
29 Remove the eight bolts holding the second arm

assembly and remove washer plate.
(1) Be sure to perform this work with at
Bolts
least two persons.
NOTE Be sure to hold the second arm by
(2)
hand from the bottom to remove it. If
this is not done, the second arm will
immediately drop when the bolts are
Bolts
Washer plate
zd545z
(To be cont’d)
2-73

30 Remove the second arm assembly.
Second arm assembly
zd546z
(To be cont’d)
2-74
(2) Installing the second arm assembly

(Cont’d from previous page) Table2-22: Second arm assembly installation

1 Install the second arm assembly.
Note :
Be sure to perform this work with at least
NOTE two persons.
Second arm assembly
zd546z
(To be cont’d)
2-75

2 Attach washer plate and attach the eight bolts
(M8x22) holding the second arm assembly.
Tightening torque of second arm assembly holding Bolts

bolts:
37.3 ± 3.7 Nm (380 ± 38 kgf·cm)
Note : When attaching the washer plate, set it so
that the cable guide A installation holes at
the center are positioned as shown in the
Bolts
Washer plate
zd545z
View from
arrow A
View from arrow A
Cable guide A
installation
holes
Arm tip side
zd547z
3 Attach the cable guide A and tighten the two bolts

(M3x6) holding the cable guide A.
Bolts
Tightening torque of cable guide A holding bolts:
0.69 ± 0.13 Nm (7 ± 1.4 kgf·cm)
Cable guide A
zd543z
(To be cont’d)
2-76

4 Pass wiring through from the bottom of the second
arm.
Wiring
zd548z
5 Pass wiring through cable guide rail and cable guide

B, and then attach the cable guide rail to the cable
Cable guide rail
guide B.
Cable guide B
Note1: Pass wiring through in the orientation
shown in the illustration.
Note2: Make sure that the projection of the cable
guide rail fits the groove of cable guide B
and that it moves smoothly.
zd541z
6 Attach the cable guide B and tighten the two bolts

(M4x8) holding the cable guide B. Bolt
Tightening torque of cable guide B holding bolts:

1.6 ± 0.3 Nm (16 ± 3.2 kgf·cm)
Cable guide B
Arm tip side
Bolt
zd539z
7 Attach the wire fixing saddle to wiring.
Wire fixing saddle
zd535z
(To be cont’d)
2-77

8 Attach the wire stay and tighten the two bolts (M3x8)
holding the wire stay.
2nd axis motor
Tightening torque of wire stay holding bolts:
2.0 ± 0.4 Nm (20 ± 4 kgf·cm)
Wire stay
Arm tip side
Bolt
2nd axis motor
Bolt zd473z
9 Attach bolt (M4x10) holding the wire fixing saddle.

Note : When attaching the saddle, match the
marks applied by white marker on the wire
Wire fixing saddle
Tightening torque of wire fixing saddle holding bolts:
2.9 ± 0.6 Nm (30 ± 6 kgf·cm)
Bolt
zd533z
10 Fix the wirings of 3rd/4th motor and encoder using

two insulator locks.
Insulator locks
zd537z
(To be cont’d)
2-78

11 Fix the wire protective net using a insulator lock.
Wire protective net
Insulator lock
zd536z
12 Attach the first arm lower cover and tighten the three
bolts (M3x8)(five for Dust & splash-proof/Clean
specifications) holding the first arm lower cover.
Tightening torque of first arm lower cover holding

bolts
kgf·cm) Bolts
Tightening torque of first arm lower cover holding

bolts First arm lower cover
1.57 ± 0.3 Nm (16 ± 3.2 kgf·cm)
zd538z
13 Arrange four air pipes, and two hand control connec-

tor cables (white: 10-pin and black: 10-pin) and fix
them to wire stay using two insulator locks.
Note : (1) Attach the insulator locks in the position
shown in the illustration.
Arm tip side 2nd axis
(2) Tighten insulator lock with proper force.
motor
If tighten too much, air cannot flow eas-
Insulator locks
zd529z
14 Pass insulator lock through the terminus capacitor

board. Insulator lock

zd549z
(To be cont’d)
2-79

15 Connect the connector to the terminus capacitor Terminus capacitor board
board. connector (white: 4-pin)
zd531z
16 Fix the terminus capacitor board to the wire stay

using insulator lock.
position shown in the illustration. Terminus capacitor board
Arm tip side
Insulator lock
zd530z
17 Connect the 2nd axis motor connector (black: 4-pin)

and fix it using two insulator locks. 2nd axis motor

Arm tip side

(black: 4-pin)
zd477z
18 Fix the 2nd axis motor wiring using two insulator

locks. Arm tip side
2nd axis motor
Insulator locks
zd476z
(To be cont’d)
2-80

19 Fix the 2nd axis motor and 3rd axis brake wirings
using insulator lock.
2nd axis motor
position shown in the illustration. Insulator lock
Arm tip side
zd475z
20 Connect the 2nd axis encoder connector (black: 4-

pin) and fix it using two insulator locks.
Arm tip side
2nd axis motor

(black: 4-pin)
Insulator locks
zd474z

4th axis
and 4th axis brake connector (black: 2-pin), and fix 3rd axis
brake connector
them using three insulator locks. motor
(black: 2-pin)
Insulator locks
Arm tip side

3rd axis
brake connector
(white: 2-pin)
zd523z

them using three insulator locks. Insulator locks

4th axis motor
connector
connector
(red: 4-pin)
Insulator lock
zd505z
(To be cont’d)
2-81

fix them using three insulator locks.
3rd axis encoder

Insulator lock
(white: 4-pin)
zd490z

Second arm cover
2-pin).
Hand control signal
Air pipes
Brake releasing
connector
zd425z
Second arm cover
zd426z
26 Tighten the four bolts (M3x45) holding the second

Second arm cover
arm cover.

kgf·cm)

1.57 ± 0.3 Nm (16 ± 3.2 kgf·cm)
Bolts
zd424z
(To be cont’d)
2-82

27 Connect the cables and air pipes to robot, and turn
on power to the controller, peripheral devices (equip-
CN20
CN22
Air pipes zd472z
28 Error message of number in 6410s (encoder system

8.)
(To be cont’d)
2-83
2 Top view of second arm Fig. 2-1 shows the top view of second arm assembly. Refer to this
assembly diagram for layout of wirings when the second arm assembly is to
be replaced.
Hand control signal connector

(black: 10-pin)
Brake switch connector (white: 2-pin) Hand control signal connector

(white: 10-pin)
2nd axis encoder connector (black: 4-pin)

Air pipe x 4
2nd axis motor connector (black: 4-pin)
Terminus capacitor board connector

(white: 4-pin)
3rd axis brake connector (white: 2-pin)
4th axis brake connector (black: 2-pin) 2nd axis motor
3rd axis motor
4th axis motor
3rd axis motor connector (white: 4-pin)
3rd axis encoder connector (white: 4-pin)

4th axis motor connector (red: 4-pin)
4th axis encoder connector (red: 4-pin)
Arm tip side
zd550z
Fig.2-1: Top view of second arm assembly
2-84
2 Replacement of Parts 2-6 Replacing Power Supply Conversion Board
2-6 Replacing Power Supply The power supply conversion board converts 24 V source to 5 V,
Conversion Board and then stably supplies it to the encoder circuits of each axis
motor.
When the controller is turned off, the power supply conversion
board switches the 5 V source to 3.6 V source from the encoder
backup batteries.
The power supply conversion board is mounted in the robot.
1 Fuses on power supply Fuses are installed in each power line of power supply conversion
conversion board board, as shown in Fig. 2-2.
Table 2-23 lists phenomena and troubleshooting steps when fuses

have blown.
Top view of power supply conversion board
F1
Fuse no. Application
F1 For 5 V/3.6 V output
To be provided when power converter
F2
circuit is faulty
J5
F2
zc1005z
Fig.2-2: Locations of Fuses on Power Supply Conversion Board
Table 2-23: Phenomena and Troubleshooting Steps When Fuses Have Blown
Fuse no. Phenomena when blown Troubleshooting

F1 (1) Error message 6424 (4th axis encoder no (1) Check to see whether encoder power
(1.3A) reception error) appears on pendant. source of 5 V in robot internal wiring has
(2) Error message of number in 6410s (individ- been shorted to 0 V or body.
ual axis encoder system down fault) (2) Replace F1 fuse
appears on pendant. (3) If error message of number in 6410s
appears, replace the F1 fuse, reset the cor-
responding encoder and then perform
CALSET.
(See "3-2 Procedure for Resetting
Encoder" on page 3-4 and "3-3 CALSET
Operation Method" on page 3-8.)
F2 (1) Error message 6424 (4th axis encoder no (1) Replace power supply conversion board
(1.3A) reception error) appears on pendant. (power supply conversion board faulty).
If the power supply conversion board is faulty, replace it according

to "2 Procedure for replacing power supply conversion
board" on page 2-86.
2-85
2 Procedure for replacing The following explains the procedure for replacing the power supply
power supply conversion conversion board.
board
(1) Removing power supply conversion board
Follow the procedure shown in Table 2-18.
(Cont’d from previous page) Table2-24: Power Supply Conversion Board Removal Procedure
NOTE goes out.
robot.
219'4
CN20
CN22
Air pipes zd453z
2 Remove the four bolts holding the battery cover and

the eight bolts holding base plate and also remove Bolts Bolts
the ground terminal.
tions, also remove the O-ring.
Bolts
Bolts
Ground terminal
Bolts
Bolt
zd551z
(To be cont’d)
2-86
3 Remove J1 and J2 connectors on the power supply
conversion board.
Note : (1) Be sure to wear a wrist band and con-
nect its terminal to the grounded portion
before starting work. J1 - J2
(2) Do not touch any elements on the connectors
printed circuit board or their terminals Encoder
with bare hand (touching could cause backup batteries
them to be damaged by static electric-
zd552z
4 Remove two encoder backup batteries.
Encoder backup batteries zd553z
5 Pull out the base plate toward the front.
Base plate
zd554z
6 Remove the four bolts holding the power supply con- Power supply Bolts
version board at the back of the base plate. conversion board
Bolts
zd555z
(To be cont’d)
2-87
7 Disconnect the J5 connector (white: 8-pin) on the
power supply conversion board.
J5 connector
Power supply
conversion board
zd556z
8 Remove the power supply conversion board assem-

bly.
Base plate
Power supply
conversion board
assembly
zd557z
9 Remove four securing supports.

Power supply
conversion board
Securing
supports
Securing
supports
zd558z
10 Remove the power supply conversion board.

Power supply conversion Power supply
board plate conversion board
zd559z
(To be cont’d)
2-88
(2) Assembling power supply conversion board

(Cont’d from previous page) Table2-25: Power Supply Conversion Board Assembly Procedure
1 Attach the power supply conversion board to the
Power supply conversion Power supply
power supply conversion board plate.
board plate conversion board
Note : Be sure to attach the power supply conver-
sion board in the orientation shown in the
zd559z
2 Attach four securing supports.

Power supply
conversion board
Securing
supports
Securing
supports
zd558z
3 Attach the power supply conversion board assembly

to the base plate.
Base plate
Power supply
conversion board
assembly
zd557z
(To be cont’d)
2-89
4 Connect the J5 connector (white: 8-pin) on the
power supply conversion board.
J5 connector
Power supply
conversion board
zd556z
5 Attach the power supply conversion board assembly Power supply Bolts
and tighten the four bolts (M3x5) holding the power conversion board
supply conversion board assembly.
Tightening torque of power supply conversion board

Bolts
assembly holding bolts: 5.9 ± 1.2 Nm (60 ± 12
kgf·cm)
zd555z
6 Attach two encoder backup batteries and connect J1

and J2 connectors.
Encoder backup batteries zd553z
7 Attach the battery cover and base plate and tighten

the four bolts holding the battery cover, eight bolts Bolts Bolts
holding the base plate and also attach the ground
terminal.
(Standard specification: M3x8, Dust & splash-proof/
Clean specifications: M3x14) Bolts
Tightening torque of battery cover/base plate hold-

Bolts
ing bolts:
1.57 ± 0.3 Nm (16 ± 3.2 kgf·cm) Ground terminal
Bolts
Note : For Dust & splash-proof/Clean specifica- Bolt

tions, attach the O-ring to the battery cover zd551z
(To be cont’d)
2-90
8 Connect the cables and air pipes to robot, and turn
on power to the controller, peripheral devices (equip-
CN20
CN22
Air pipes zd472z
9 Error message of number in 6410s (encoder system

8.)
(To be cont’d)
2-91
2 Replacement of Parts 2-7 Replacing Bellows (Dust & splash proof specification)
2-7 Replacing Bellows (Dust &

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

bellows (top) Follow the procedure in Table 2-26.
(Cont’d from previous page) Table 2-26: Removing bellows (top)

1 Move 3rd axis up to around the middle of the stroke by manual
operation and then turn off the power of the controller.
2 Loosen hose band fixing screw.
Screw
zh026z
3 Lift the bellows (top) and loosen the bolt holding the extension
bar.
Bolt
Bellows (top)
zh027z
4 Remove extension bar.

Extension bar
Note : If removal of extension bar is difficult, widen the gap
using flat-head screwdriver (large), etc., and then
remove it. Flat-head
screwdriver (large)
zh028z
(To be cont’d)
2-92

5 Remove the six bolts holding bellows (top).
Six bolts zh029z
6 Remove bellows (top).

Bellows (top)
Extension bar
zh030z
(To be cont’d)
2-93
(2) Assembling bellows (top)

(Cont’d from previous page) Table 2-27: Assembling bellows (top)

1 Remove silicon sealing agent adhering to extension bar plate.
Note : Be careful not to scratch extension bar plate.
Extension bar plate

zh031z
2 Apply silicon sealing agent (TSE382-C) to the extension bar

plate.
Note : Apply silicon sealing agent entire surface of
extension bar plate evenly.
If TSE382-C is not available in USA, etc., TSE392-C or

TSE3925-W can be used as substitute.
Extension bar plate
zh048z
3 Attach bellows (top) to extension bar.

Bellows (top)
Extension bar
zh030z
(To be cont’d)
2-94

4 Attach the six bolts (M3 x 8) securing bellows (top).
Tightening torque of bellows fixing bolt:

1.6 ± 0.3 Nm (16 ± 3 kgf·cm)
Six bolts zh029z
5 Attach extension bar.

Extension bar
Note : If installation of extension bar is difficult, widen the
gap using flat-head screwdriver (large), etc., and
then install it. Flat-head
screwdriver (large)
zh028z
6 Attach the bolt (M5 x 16) securing extension bar.
Tightening torque of extension bar fixing bolt:

8.8 ± 1.8 Nm (90 ± 18 kgf·cm)
Bolt
Bellows (top)
zh027z
7 Tighten the hose band fixing screw.
Screw
zh026z
(To be cont’d)
2-95
1.2 Replacement method for (1) Removing bellows (bottom)

bellows (bottom) Follow the procedure in Table 2-28.
(Cont’d from previous page) Table 2-28: Removing bellows (bottom)

Note : Remove the hand section of user in advance.
2 Remove the twelve bolts holding bellows (bottom).
Twelve bolts
zh032z
3 Remove the four bolts holding bellows plate (bottom).

Four bolts
zh033z
(To be cont’d)
2-96

4 Remove bellows plate (bottom).
Bellows plate (bottom)
zh034z
5 Remove bellows (bottom).
Bellows
(bottom)
zh035z
(To be cont’d)
2-97
(2) Assembling bellows (bottom)

(Cont’d from previous page) Table 2-29: Assembling bellows (bottom)

1 Remove silicon sealing agent adhering to bellows plate (top).
Note : Be careful not to scratch bellows plate (top).
Bellows plate
(top)
zh036z
2 Attach bellows (bottom).
Bellows
(bottom)
zh035z
3 Attach bellows plate (bottom).

Note : Check the orientation of the bellows plate (bottom).
Bellows plate (bottom)
Top
Bottom
Bellows
plate (bottom)
zh053z
(To be cont’d)
2-98

4 Attach the four bolts (M3 x 6) securing bellows plate (bottom).
Tightening torque of bellows plate fixing bolt: Four bolts

1.6 ± 0.3 Nm (16 ± 3 kgf·cm)
zh033z
5 Apply silicon sealing agent (TSE382-C) to the bellows plate

(top).
Note : Apply silicon sealing agent entire surface of bellows
plate (top) evenly.
If TSE382-C is not available in USA, etc., TSE392-C or

Bellows plate
TSE3925-W can be used as substitute.
(top)
zh037z
6 Attach the twelve bolts (M3 x 8) securing bellows (bottom).
Tightening torque of bellows fixing bolt: Twelve bolts

1.6 ± 0.3 Nm (16 ± 3 kgf·cm)
zh032z
(To be cont’d)
2-99
2 Replacement of Parts 2-8 Replacing Bellows (Clean specification)
2-8 Replacing Bellows (Clean

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

bellows (top) Follow the procedure in Table 2-30.

2 Loosen hose band (bottom) fixing screw.
Screw
zh038z
3 Loosen hose band (top) fixing screw.
Screw
zh039z
4 Loosen the stopper bolt.
Stopper bolt
zh040z
(To be cont’d)
2-100

5 Remove stopper.
Stopper
zh041z
6 Remove bellows (top).
Bellows (top)
zh042z
(To be cont’d)
2-101
(2) Assembling bellows (top)


1 Attach the bellows (top) and hose bands (top, bottom).
Hose band (top)
Bellows (top)
Hose band
(bottom) zh043z
2 Attach stopper.
Stopper
zh041z
3 Tighten the stopper bolt (M5 x 16).
Tightening torque of stopper bolt:

3.6 ± 0.7 Nm (36 ± 7 kgf·cm)
Stopper bolt
zh040z
(To be cont’d)
2-102

4 Tighten the screw securing the hose band (top).
Screw
zh039z
5 Tighten the screw securing the hose band (bottom).
Screw
zh038z
(To be cont’d)
2-103
1.2 Replacement method for (1) Removing bellows (bottom)

bellows (bottom) Follow the procedure in Table 2-32.

Note : Remove the hand section of user in advance.
2 Loosen the stopper bolt.
Stopper bolt
zh044z
3 Remove stopper.
Stopper
zh045z
(To be cont’d)
2-104

4 Loosen the screw securing the hose band (bottom).
Screw
zh049z
5 Loosen the screw securing the hose band (top).
Screw
zh046z
6 Remove bellows (bottom).
bellows (bottom)
zh047z
(To be cont’d)
2-105
(2) Assembling bellows (bottom)


1 Attach the bellows (bottom) and hose bands (top, bottom).
Hose band (top)
bellows (bottom)
Hose band (bottom)

zh050z
2 Tighten the screw securing the hose band (top).
Screw
zh046z
3 Tighten the screw securing the hose band (bottom).
Screw
zh049z
(To be cont’d)
2-106

4 Attach stopper.
Note : Check the orientation of the stopper.
Top
Bottom
Stopper
Stopper
zh054z
5 Tighten the stopper bolt (M5 x 16).
Tightening torque of stopper bolt:

3.6 ± 0.7 Nm (36 ± 7 kgf·cm)
Stopper bolt
zh044z
(To be cont’d)
2-107
2 Replacement of Parts 2-9 Replacing Robot
2-9 Replacing Robot
1 Overview of robot Fig. 2-3 shows the procedure for replacing the robot.
replacement
1 Set replacement robot body.
Input RANG data

2 (See "2. Procedure for inputting RANG data"
on page 2-93 for details)
Perform CALSET
3 (See "3-3 CALSET Operation Method" on page 3-8)
Check software limit

4 Operate the 1st to 4th axes at full stroke, and make sure that
error message 6071-6074 (software limit) appears immediately
before the axis touches the mechanical end.
If the axis touches the mechanical end or the error message
appears in the middle of stroke, it is likely that the RANG data
has been erroneously input or mistake has occurred in CALSET
operation.
zd560z
Fig.2-3: Overview of Robot Body Replacement
2-108
2 Procedure for inputting The following explains the procedure for inputting RANG data.
RANG data
(1) RANG data entry procedure
(Cont’d from previous page) Table2-34: RANG Data Entry Procedure

POWER
2 Set the mode select switch on teaching pendant to

MANUAL. Set to MANUAL mode
Note : Make sure at this time that motor power is
zc1016z
3 Push [F2 Arm] on the pendant screen.
zd561z
(To be cont’d)
2-109

4 Push [SHIFT].
zd562z
5 Push [F6 Maint].
zd563z
6 Push [F2 RANG].
zd564z
7 Use cursor key or jog dial to select the axis to which

the RANG data is to be input, and then push [F5
Change].
zd565z
(To be cont’d)
2-110

8 Input the RANG value shown in the label pasted on
robot, and then push [OK].
zd566z
Label pasting position
zd567z
9 Input the RANG values for all axes, and then push
[OK].
zd568z
10 Push [Cancel] twice to restore the original screen.

(To be cont’d)
2-111
Chapter3
Auxiliary Work
This chapter summarizes the necessary work to be done in

conjunction with inspection and maintenance, parts replace-
ment, and troubleshooting.
Refer to this chapter whenever it is necessary to perform
each job.
3 Auxiliary Work 3-1 Motor Brake Releasing Procedure
3-1 Motor Brake Releasing The following describes the procedure for releasing motor brakes.
Procedure
Note : This operation will cause the robot to move of its own weight:
Hold the robot by hand for safe operation, so that the robot
does not impact peripheral devices.
(Cont’d from previous page) Table3-1: Motor Brake Releasing Procedure

POWER

zc1016z
zd561z
(To be cont’d)
3-1

4 Push [SHIFT].
zd562z
5 Push [F6 Maint].
zd563z
6 Push [F3 Brake].
zd569z
7 From the Brake Release Set screen, select [Brake

released] and then push [OK].)
Note : This operation will cause the robot to move
of its own weight: Hold the robot by hand
for safe operation, so that the robot does
zd570z
(To be cont’d)
3-2

8 Make sure of the message, and then push [OK]
twice.
10 To lock brakes, press the robot stop button on the
teaching pendant or controller.
Robot stop button
Teaching pendant
Controller
zc878z
(To be cont’d)
3-3
3 Auxiliary Work 3-2 Procedure for Resetting Encoder
3-2 Procedure for Resetting If error of number in 6410s occurs when the encoder backup batter-
Encoder ies are dead or motors are replaced (if position data in encoder is
erased), it is necessary to reset the encoder and perform CALSET:
Ignoring this will disable normal operation of the robot.
The following explains the procedure of resetting the encoder. For
CALSET, see "3-3 CALSET Operation Method" on page 3-8.
1 Cases when encoder Table 3-2 lists the cases when encoder must be reset.
must be reset
Table 3-2: Cases When Encoder Must Be Reset and Concurrent Phenomena
No. Cases when reset is necessary Specific phenomena

1 Voltage supplied from backup batteries to motor (1)After motor is replaced, error of number in 6410s
encoder connectors is shut off (encoder system down error) occurs.
(2)After internal wiring is checked, error of number
in 6410s occurs.
(3)When encoder backup batteries are dead.
(4)Error of number in 6410s occurs.
2 The motor speed exceeds the allowable value Error of number in 6430s (encoder counter overflow)
occurs.
3 Each axis motor operates abruptly with control Error of number in 6770s (encoder speed error with
power OFF controller power OFF) occurs.
3-4
2 Encoder resetting method The following describes how to reset the encoder.
(Cont’d from previous page) Table 3-3: Encoder Resetting Method

POWER

zc1016z
zd561z
(To be cont’d)
3-5

4 Push [SHIFT].
zd562z
5 Push [F6 Maint].
zd563z
6 Push [F11 ENC rst].
zd571z
7 Input the axis number whose encoder is to be reset,

and then push [OK].
zc572z
(To be cont’d)
3-6

twice.
(To be cont’d)
3-7
3 Auxiliary Work 3-3 CALSET Operation Method
3-3 CALSET Operation Method CALSET refers to calibration of relationship between the position
data recognized by robot and actual robot position.
CALSET is necessary when position data in encoder was erased
after the motor was replaced, or the backup batteries in encoder
are dead.
Executing CALSET will restore the robot calibration data in the
controller: This data is referred to as CALSET. The CALSET data
varies for each robot.
Note : Take care when executing CALSET since the motor brakes
are released and the robot will move of its own weight.
After completing CALSET, make sure, using manual opera-
tion, that the axes stop immediately before they touch the
mechanical end by software limit.
1 CALSET Operation The following describes the CALSET operation method.

Method
(Cont’d from previous page) Table 3-4: CALSET operation procedure

POWER

zc1016z
(To be cont’d)
3-8

3 Release the axis motor brake for which CALSET is
being performed. (For releasing motor brake, see
"3-1 Motor Brake Releasing Procedure" on page
3-1.)
Note : This operation will cause the robot to move
of its own weight: Hold the robot by hand
for safe operation, so that the robot does
4 Manually move the corresponding axis to the

mechanical end of CALSET position. (For CALSET
position, see Fig. 3-1 on page 3-13 .)
Note : The 4th axis do not have a mechanical
end: When executing CALSET for the 4th
axis, it will be necessary to attach CALSET
jig. (see Fig. 3-1 on page 3-13 ).
zd561z
6 Push [SHIFT].
zd562z
(To be cont’d)
3-9

7 Push [F6 Maint].
zd563z
8 Push [F6 CALSET].
zd573z
9 Select the axis for which CALSET is to be executed

on the CALSET setting screen, and then push [OK].
(To select all axes, push [F6 Selct All], and then
push [OK].
Note : Make sure at this time that the correspond-
ing axis does not drift from the mechanical
end which the axis touched in step 4.
zd574z

twice.
12 Move by hand the corresponding axis slightly to the
side opposite to the mechanical end.
(To be cont’d)
3-10

13 Press the robot stop button to lock the motor brakes
of all axes. (After locking, release the stop button.)
Robot stop button
Teaching pendant
Controller
zc878z
14 Turn motor power on.

Motor power ON
zc1031z
15 Push [F2 Arm], and then push [F6 Aux].
zd575z
16 Push [F12 Exec CAL].
zd576z
(To be cont’d)
3-11

17 Make sure that motor power is turned on, and then
push [OK].
zd578z
18 Push [OK], and then push [Cancel] twice to restore

the original screen.
19 Operate the axis for which CALSET has been exe-
cuted at full stroke, and make sure that error of num-
ber in 6070 (software limit) appears immediately
before the axis touches the mechanical end.
Note : Make sure the area surrounding the robot
is safe, and then set the operation speed to
SP20% or less
(To be cont’d)
3-12
2 CALSET setting positions Fig. 3-1 shows the CALSET setting positions of 1st to 4th axes.
Axis CALSET position

1st Positive direction rotation end (counterclockwise end when viewed from top)
2nd Negative direction rotation end
Position
3rd Positive direction rotation end

Positive direction rotation end set by CALSET bolt (counterclockwise end when viewed from the
4th
tip of arm)
2nd axis
1st axis
3rd axis
4th axis
Bolt for 4th axis CALSET
Bolt for 4th axis CALSET
ø6
M4 x 0.7
1st axis stopper bolt
15 7
Positive direction
Note: Do not remove 1st axis stopper bolt. zd578z
Fig.3-1: CALSET Setting Positions of 1st to 4th Axes
3-13
ROBOT HS-E SERIES
SERVICE MANUAL
First Edition : May, 2002
Second Edition : March, 2006
Third Edition : December, 2008
DENSO WAVE INCORPORATED
Service Department
• Reproduction or translation of any part of this manual without authorization is prohibited.

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

Service Manual: Robot

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Service Manual: Robot

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AC SERVO TYPE ROBOT

This manual covers the following type Denso robot:

HS-4535*E-* * ⇒ None : Standard type

(1) Before starting inspection/maintenance or replacement of parts, be sure to thoroughly read

DANGER avoided, will result in death or serious injury in the most

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

Chapter1 Inspection and Maintenance

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

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

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

1-4 Details of 6-month inspection .............................................................. 1-6

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

1-6 Details of 2-Year Inspection............................................................... 1-31

Chapter2 Replacement of Parts

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

2-3 Replacing the timing belts...................................................................2-43

2-4 Replacing the brakes ..........................................................................2-59

2-5 Replacing the second arm assembly..................................................2-66

2-6 Replacing Power Supply Conversion Board.......................................2-85

2-7 Replacing Bellows (Dust & splash proof specification).......................2-92

2-8 Replacing Bellows (Clean specification)...........................................2-100

2-9 Replacing Robot ...............................................................................2-108

Chapter3 Auxiliary Work

3-1 Motor Brake Releasing Procedure........................................................3-1

3-3 CALSET Operation Method ................................................................. 3-8

This chapter summarizes the periodic inspection of Denso

Table1-1: Types and Purpose of Inspection and Maintenance

No. Type Purpose

1-2 Details of Daily Inspection

Table 1-2: Daily Inspection and Maintenance

Point or operation to be Power to Inspection

Fig.1-1: Proper operation of Cooling Fan

1-3 Details of 3-Month

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

Table1-3: 3-Month Inspection and Maintenance

Point or operation to Power to Inspection

3 Controller cooling fan OFF Visual No dirt Clean the filters

Follow the procedure in Table 1-4 to clean the filters.

Power switch OFF zc850z

2 Remove the screws holding the intake filter.

3 Remove the frame for mounting the intake filter, and

5 Remove the frame for mounting the exhaust filter,

6 (1) Use air blower to clean the filters.

1-4 Details of 6-month

Table 1-5: 6-month inspection and maintenance

Point or operation to Power to Inspection

Note : The lubrication must be performed every six months based

2 Point to be lubricated Table 1-6 shows point to be lubricated.

Table 1-6: Point to be lubricated

1-5 Details of 1-Year Inspection

1 Required 1-year Perform inspection and maintenance according to Table 1-7.

Table 1-7: 1-Year Inspection and Maintenance

Point or operation to Power to Inspection

(1) The teeth of timing belts must not be worn.

Axis Weight Deflection

4th axis timing belt B 29.4 N (3 kgf) 1.5㨪2.0 mm

(1) Replace the timing belts.

Power switch OFF zc850z

2 Remove the four bolts holding the second arm

4 Remove the second arm cover.

5 Remove rubber bush for inspecting timing belt at the

Rubber bush for inspecting timing belt

3rd axis timing belt

HS-4535E- * ⇒ None : Standard type