FANUC > LR Mate 200*C

MECHANICAL UNIT

MAINTENANCE MANUAL

B-82585EN/02

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

No part of this manual may be reproduced in any form. All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japans Foreign Exchange and Foreign Trade Law. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as impossible.

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SAFETY PRECAUTIONS

1
1.1

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

WORKING PERSON
The personnel can be classified as follows.

Operator: Power ON/OFF for robot controller Start of robot program with operators panel Programmer or teaching operator: Operate for Robot Teaching inside safety fence Maintenance engineer: Operate for Robot Teaching inside safety fence Maintenance (adjustment, replacement)
An operator cannot work inside the safety fence. A programmer, Teaching operator and maintenance engineer can work inside the safety fence. The workings inside safety fence are lifting, setting, teaching, adjusting, maintenance, etc. To work inside the fence, the person must be trained for the robot.

Table 1 lists the workings of outside the fence. In this table, the symbol means the working allowed to be carried out by the personnel.

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SAFETY PRECAUTIONS
Table 1 List of workings outside the fence Operator Programmer or Teaching operator Power ON/OFF for Robot controller Select operating mode (AUTO, T1, T2) Select Remote/Local mode Select robot program with teach pendant Select robot program with external device Start robot program with operators panel Start robot program with teach pendant Reset alarm with operators panel Reset alarm with teach pendant Set data on the teach pendant Teaching with teach pendant Emergency stop with operators panel Emergency stop with teach pendant Emergency stop with safety fence open Maintain for operators panel Maintain for teach pendant

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Maintenance engineer

In operating, programming and maintenance, the programmer, teaching operator and maintenance engineer take care of their safety using the following safety protectors, for example. Use adequate clothes, uniform, overall for operation Put on the safety shoes Use helmet

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SAFETY PRECAUTIONS

1.2

WORKING PERSON SAFETY

Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety. (1) Have the robot system working person attend the training courses held by FANUC. FANUC provides various training courses. Contact our sales office for details. (2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlock switch, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened. The controller is designed to receive this interlock signal of the door switch. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1. (4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D). (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when a working person enters the work area. (8) If necessary, install a safety lock so that no one except the working person in charge can turn on the power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

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

Fig.1.2 Safety fence and safety gate

E-stop board
FENCE1 FENCE11

NOTE Terminal FENCE1 and terminal FENCE11 are on the PC board in the E-stop unit. NOTE Please drop the power supply of the robot control system at once when the worker is placed by the robot by any chance or it is confined, push the robot arm directly, change posture, and liberate the worker.

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SAFETY PRECAUTIONS

1.2.1

General Person Safety

The general person is a person who operates the robot system. In this sense, a worker who operates power on/off of the robot system or the teach pendant is also a general person. The general person cant operate inside a safety fence. (1) Operate the robot system at a location outside of the safety fence. (2) If it is not necessary for the robot to operate, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work. (3) Install an EMERGENCY STOP button within the general persons reach. The robot controller is designed to be able to connect to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

E-stop board
EMGIN1 EMGIN11

Fig.1.2.1 Circuit diagram for external emergency stop button

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1.2.2

Safety of the Teaching Operator

While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teaching operator. (1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating condition. (3) When entering the robot work area and teaching the robot, be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the DEADMAN switch on the teach pendant). (4) The teaching operator should pay careful attention so that no other workers enter the robot work area. Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and switch function as follows: (1) Emergency stop button: Causes an emergency stop when pressed. (2) DEADMAN switch: Functions differently depending on the mode switch setting status. (a) When the switch is set to the enable position: An emergency stop is made by releasing the DEADMAN switch. (b) When the switch is set to the disable position: The DEADMAN switch is disabled. The operators intention of starting teaching is determined by the control unit through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot can operate in such conditions and be responsible in carrying out tasks safely. The teach pendant and peripheral device interface each send a robot start signal. However, the validity of each signal changes depending on the teach pendant enable switch and the remote condition of the software.

Table 1.2.2(a) STANDARD Teach pendant enable switch On Off

Software remote condition Ignored Local Remote

Teach pendant Allowed to start Not allowed Not allowed

Peripheral device Not allowed Not allowed Allowed to start

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Table 1.2.2(b) CE/RIA Teach pendant Mode enable switch On AUTO mode Off On T1, T2 mode Off

Software remote condition Local Remote Local Remote Local Remote Local Remote

Teach pendant Not allowed Not allowed Not allowed Not allowed Allowed to start Allowed to start Not allowed Not allowed

Operator panel Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Not allowed Not allowed

Peripheral device Not allowed Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Not allowed

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

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1.2.3

Safety During Maintenance

For the safety of maintenance personnel, pay utmost attention to the following. (1) During operation, never enter the robot work area. (2) Except when specifically necessary, turn off the power of the controller while carrying out maintenance. Lock the power switch, if necessary, so that no other person can turn it on. (3) If it becomes necessary to enter the robot operation range while the power is on, press the emergency stop button on the operator panel, or the teach pendant before entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly. (4) When disconnecting the pneumatic system, be sure to reduce the supply pressure. (5) Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition. (6) Do not operate the robot in the automatic mode while anybody is in the robot work area. (7) When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed. (8) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful attention to its motion. (9) If necessary, have trained worker who knows the robot system well stand beside the operator panel, and observe the operation. In case any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time. (10) During replacing or reinstalling components, Take care not to let foreign matter enter the system. (11) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit breaker to protect against electric shock. (12) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in damage to the components in the controller. (13) When restarting the robot system after completing maintenance work, make sure in advance that there is no person in the work area and that the robot and the peripheral devices are not abnormal.

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SAFETY PRECAUTIONS

1.3
1.3.1

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

Precautions in Programming
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal. (3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can stop them according to the their states.

1.3.2

Precautions for Mechanism

(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust. (2) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot does not strike against its peripheral devices or tools.

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1.4
1.4.1

SAFETY OF THE ROBOT MECHANISM

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

1.4.2

Precautions in Programming
(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

1.4.3

Precautions for Mechanisms

(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water, and dust.

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SAFETY PRECAUTIONS

1.5
1.5.1

SAFETY OF THE END EFFECTOR

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

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1.6

WARNING LABEL
(1) Transportation attention label 1

500kg

100kg 4

80kg4

Fig. 1.6(a) Transportation attention label 1

Description
1) 2) 3) Use a crane having a load capacity of 500 kg or greater. Use at least four slings each having a withstand load of 980 N (100 kgf) or greater. Use at least four eyebolts each having a withstand load of 784 N (80 kgf) or greater.

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SAFETY PRECAUTIONS

(2) Transportation attention label 2

CAUTION

DO NOT PULL EYBOLTS SIDEWAYS.

REMOVE EYEBOLTS,BEFORE USE

Fig.1.6 (b) Transportation attention label 2

Description
Keep the following in mind about eyebolt. 1) 2) Dont pull eyebolt side ways. Remove eyebolt before use.

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(3) Greasing attention label (When A05B-1139-K021 is specified.)

grease

applying

kit:

CAUTION
2.5mm 1cc Please knead a tube and make grease soft before supply grease to cylinder. When you give a plunger 2.5mm push, 1cc grease is injected.
/AXIS /AMOUNT

J1 J2 J3 J4 J5 J6

3cc(7mm) 3cc(7mm) 2cc(5mm) 2cc(5mm) 2cc(5mm) 2cc(5mm) A370-3031-0130

/AT GRESING

Fig.1.6(c) Greasing attention label

Description
Keep the following in mind about grease applying kit. 1) Please knead a tube and make grease soft before supply grease to cylinder. 2) When you give a plunger 2.5mm push, 1ml grease is injected.

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SAFETY PRECAUTIONS

(4) Range of motion and payload mark label Below label is added when CE specification is specified.

0deg

-180deg +180deg MOTION RANGE OF J5-AXIS ROTATION CENTER

J5-AXIS ROTATION CENTER

D
UNIT:mm

A B C D STANDARD 959 228 704 513 LONG ARM 1147 393 892 742

MAX.PAYLOAD:5kg
Fig.1.6 (d) Range of motion and payload mark label

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PREFACE

PREFACE
This manual explains the maintenance and connection procedures for the mechanical units of the following robots:
Model name FANUC Robot LR Mate 200iC Mechanical unit specification No. A05B-1139-B201 Maximum load Remarks 3-axes brake type Non-severe dust/liquid protection specification 6-axes brake type Non-severe dust/liquid protection specification 3-axes brake type severe dust/liquid protection specification 6-axes brake type severe dust/liquid protection specification 6-axes brake type Non-severe dust/liquid protection specification 6-axes brake type severe dust/liquid protection specification 6-axes brake type Clean class 100 specification 6-axes brake type Clean class 100 specification 6-axes brake type Washing specification 3-axes brake type Non-severe dust/liquid protection specification 5-axes brake type Non-severe dust/liquid protection specification 3-axes brake type severe dust/liquid protection specification 5-axes brake type severe dust/liquid protection specification

FANUC Robot LR Mate 200iC

A05B-1139-B202

FANUC Robot LR Mate 200iC

A05B-1139-B203

FANUC Robot LR Mate 200iC

A05B-1139-B204

A05B-1139-B211 FANUC Robot LR Mate 200iC/5L A05B-1139-B212 5kg FANUC Robot LR Mate 200iC/5LC FANUC Robot LR Mate 200iC/5C FANUC Robot LR Mate 200iC/5WP FANUC Robot LR Mate 200iC/5H A05B-1139-B213 A05B-1139-B221 A05B-1139-B231 A05B-1139-B101

FANUC Robot LR Mate 200iC/5H

A05B-1139-B102

FANUC Robot LR Mate 200iC/5H

A05B-1139-B103

FANUC Robot LR Mate 200iC/5H

A05B-1139-B104

NOTE The following abbreviations are used herein. STANDARD : LR Mate 200iC 5L : LR Mate 200iC/5L 5LC : LR Mate 200iC/5LC 5C : LR Mate 200iC/5C 5WP : LR Mate 200iC/5WP 5H : LR Mate 200iC/5H

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PREFACE

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The label stating the mechanical unit specification number is affixed in the position shown below. Before reading this manual, determine the specification number of the mechanical unit.

(1)

TYPE NO. DATE

(2) (3) (4)

WEIGHT (5)
OSHINO-MURA. YAMANASHI PREF.JAPAN

TABLE 1 (1)
CONTENTS -

(2)
TYPE A05B-1139-B201

(3)
No.

(4)
DATE

(5)
WEIGHT (Without controller)

FANUC Robot LR Mate 200iC FANUC Robot LR Mate 200iC/5L FANUC Robot LR Mate 200iC/5LC FANUC Robot LR Mate 200iC/5C FANUC Robot LR Mate 200iC/5WP FANUC Robot LR Mate 200iC/5H

A05B-1139-B202 A05B-1139-B203 A05B-1139-B204 A05B-1139-B211 A05B-1139-B212 A05B-1139-B213 A05B-1139-B221 A05B-1139-B231 A05B-1139-B101 A05B-1139-B102 A05B-1139-B103 A05B-1139-B104 PRINT SERIAL NO. PRINT PRODUCTION YEAR AND MONTH

27kg

29kg

LETTERS

27kg

26kg

Positon of label indicating mechanical unit specification number

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PREFACE

RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook B-80687EN All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook R-30iA Mate controller Operations manual LR HANDLING TOOL B-82724EN-1 Intended readers: All persons who use FANUC Robot, system designer Topics: Safety items for robot system design, operation, maintenance Intended readers: Operator, programmer, maintenance person, system designer Topics: Robot functions, operations, programming, setup, interfaces, alarms Use: Robot operation, teaching, system design Intended readers: Maintenance person, system designer Topics: Installation, connection to peripheral equipment, maintenance Use: Installation, start-up, connection, maintenance Intended readers: System designer, Maintenance person Topics: Installation, connection to controller, maintenance Use: Installation, start-up, connection, maintenance

Maintenance manual B-82725EN B-82725EN-1 (For Europe) B-82725EN-2 (For RIA)

Mechanical unit

Operators manual FANUC Robot LR Mate 200iC B-82584EN

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TABLE OF CONTENTS

TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1 PREFACE ....................................................................................................p-1 1 CHECKS AND MAINTENANCE ............................................................. 1
1.1 1.2 1.3 1.4 1.5 1.6 DAILY CHECKS ............................................................................................ 2 First 1-Month (320 hours operating) Check ................................................... 5 3-month (960 hours) checks .......................................................................... 5 1-year (3,840 hours) checks .......................................................................... 7 1.5-year (5,760 hours) checks ....................................................................... 7 2-year (7,680 hours) checks (LR Mate 200iC /5WP) 4-year (15,360 hours) checks (LR Mate 200iC, LR Mate 200iC/5L , /5C, /5LC, /5H) ............................................................................. 8 MAINTENANCE TOOLS ............................................................................... 9 REPLACING THE BATTERIES (1-YEAR CHECKS (battery built-in type)) (1.5-YEAR CHECKS (external battery type))............................................... 12 REPLENISH THE GREASE OF THE DRIVE MECHANISM (4 years (11,520 hours) checks) .................................................................. 15
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 Grease replacement procedure of the J1-axis reducer ............................................17 Grease replacement procedure of the J2-axis reducer ............................................18 Grease replacement procedure of the J3-axis reducer ............................................19 Grease replacement procedure of the J4-axis reducer ............................................20 Grease replacement procedure of the J5/J6-axis reducer .......................................22

1.7

PERIODIC MAINTENANCE .................................................................. 11

2.1

2.2

TROUBLESHOOTING .......................................................................... 23
3.1 3.2 3.3 OVERVIEW ................................................................................................. 24 FAILURES, CAUSES AND MEASURES ..................................................... 25 BACKLASH MEASUREMENT..................................................................... 32 FIGURE OF DRIVE MECHANISM .............................................................. 38 REPLACING J1-AXIS MOTOR.................................................................... 41 REPLACING J1-AXIS REDUCER ............................................................... 43 REPLACING J2-AXIS MOTOR.................................................................... 49 REPLACING J2-AXIS REDUCER ............................................................... 53
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REPLACING PARTS ............................................................................ 36

4.1 4.2 4.3 4.4 4.5

TABLE OF CONTENTS 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18

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REPLACING J3-AXIS MOTOR.................................................................... 57 REPLACING J3-AXIS REDUCER ............................................................... 59 REPLACING J4-AXIS MOTOR.................................................................... 62 REPLACING J4-AXIS REDUCER ............................................................... 64 REPLACING J5-AXIS MOTOR.................................................................... 68 REPLACING J5-AXIS REDUCER ............................................................... 71 REPLACING J6-AXIS MOTOR.................................................................... 74 REPLACING WRIST UNIT .......................................................................... 77 REPLACING J6-AXIS REDUCER ............................................................... 80 REPLACING J3 BELT ................................................................................. 82 REPLACING J5/J6 BELT ............................................................................ 84 REPLACING SOLENOID VALVE ................................................................ 86 SEALANT APPLICATION............................................................................ 88 CABLE WIRING........................................................................................... 90 CABLE FORMING ....................................................................................... 92 CABLE AND AIR TUBE REPLACEMENT ................................................... 95
5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 REPLAING CABLE K101 and Air tube (Connector plate to J2 base)..................95 REPLAING CABLE K106, K107, K108 and Air tube (J2 base to J3 casing) ..................................................................................................................102 REPLAING CABLE K102, K103, K104, K105, K109, K110, K111, K112, K113 ..........................................................................................................108 REPLAING CABLE K104 ..................................................................................109 REPLAING AIR TUBE .......................................................................................110

REPLACING CABLES .......................................................................... 89

5.1 5.2 5.3

ADJUSTMENTS.................................................................................. 117
6.1 6.2 ADJUSTING TENSION OF BELT.............................................................. 118 MASTERING ............................................................................................. 120
6.2.1 6.2.2 RESETTING ALARMS AND PREPARING FOR MASTERING .....................121 FIXTURE POSITION MASTER.........................................................................122

APPENDIX A B C D SPARE PARTS LIST .......................................................................... 131 CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM................................ 141 PERIODIC MAINTENANCE TABLE ................................................... 160 MOUNTING BOLT TORQUE LIST ..................................................... 166
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1.CHECKS AND MAINTENANCE

CHECKS AND MAINTENANCE

Optimum performance of the robot can be maintained by performing the periodic maintenance procedures presented in this chapter. (See the APPENDIX A PERIODIC MAINTENANCE TABLE.)

NOTE The periodic maintenance procedures described in this chapter assume that the FANUC robot is used for up to 3840 hours a year. When using the robot beyond this total operating time, correct the maintenance frequencies shown in this chapter by calculation in proportion to the difference between the actual operating time and 3840 hours/year.

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1.1

DAILY CHECKS
Clean each part, and visually check component parts for damage before daily system operation. Check the following items as the occasion demands. (1) Before turning on power
Item 1 Check items When air Air pressure control set is provided. Check points Check air pressure using the pressure gauge on the air regulator as shown in Fig.1.1.If it does not meet the specified pressure of 0.49MPa (5 kg/cm2), adjust it using the regulator pressure setting handle. Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required. Check the supply pressure using the air purge kit shown in Fig.1.1 (b). If it does not meet the specified pressure of 10 KPa (0.1 kgf/cm2), adjust it using the regulator pressure setting handle. Check whether the color of the dew point checker is blue. When it is not blue, identify the cause and replace the dryer. Maintenance for air purge kit, refer to the operators manual attached kit. Check whether each axis moves smoothly

2 3 When air purge kit is prorided.

Leakage from hose Supply pressure

Dryer

5 6

Vibration, abnormal noises and motor heating Changing repeatability

7 8 9

Check whether the stop positions of the robot have not deviated from the previous stop positions. Peripheral devices for Check whether the peripheral devices operate proper operation properly according to commands from robot. Each axis brake Refer to 3.2. Cleaning and checking each Clean each part (remove chips, etc.) and part check component parts for cracks and flaws.

Pressure Adjusting Knob

2-6.516.5 Length round hole Rc1/4 AIR OUTLET

Pressure gauge Rc1/4 AIR SUPPLY

Fig.1.1(a) Air control set

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1.CHECKS AND MAINTENANCE

Pneumatic tube

Dry air

Filter and regulator

Dew point checker 2-7x11 Length round hole Air outlet (O6 Air tube)

Pressure gauge Pneumatic air outlet Air inlet (O10 air tube) Pressure adjustment knob
S S

Dryer unit

(2) After turning on power

Item Check items Vibration, abnormal noises, and motor heating Check points Check whether the robot moves along and about the axes smoothly without unusual vibration or sounds. Also, check whether the temperatures of the motors are excessively high. Check to see that the stop positions of the robot have not deviated from the previous stop positions. Check whether the peripheral devices operate properly according to commands from the robot. Check that the end effector drops within 2 mm when the power is cut.

Changing repeatability Peripheral devices for proper operation Brakes for each axis

3 4

Fig.1.1(b)

Air purge kit (option)

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(Note 1) Cleaning
Necessary cleaning points, dust on the flat part, sedimentation of spatters Clean sediments periodically. In particular, clean the following points carefully. Vicinity of the wrist axis and oil seal If chippings or spatters are attached to the oil seal, an oil leak may be caused. Check if the vicinity of the necessary inspection points, wrist part, and J3 arm significantly wears due to rubbing against the welding cable or hand cable. Check if there is a trace of a collision around the hand. Check the reducer or grease bath for an oil leak. If oil can be found a day after wiping oil, an oil leak may be caused.

Fig 1.1(c) Cleaning part

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1.CHECKS AND MAINTENANCE

1.2

First 1-Month (320 hours operating) Check

Check the following items after the first one-month operation (or 320 hours operating) First 1-month check
Item 1 Check items Control unit cable and robot connecting cable Check points Check whether the cable connected to the teach pendant and robot is unevenly twisted.

1.3

3-month (960 hours) checks

Check the following items once every three months (960 hours). Additional inspection areas and times should be added to the table according to the robots working conditions, environment, etc. (1) 3-month checks
Item 1 Check items Control unit cable and robot connecting cable Ventilation portion of control unit Cleaning and checking each part Check points (See Section 1.2)

2 3

If the ventilation portion of the control unit is dusty, turn off the power and clean the unit. (See Section 1.1)

Check the following items at the first quarterly inspection, then every year thereafter. (See the Section 1.4.) (2) First quarterly inspection
Item 1 2 Check items Connector used in mechanical unit Further tightening external main bolts Check points Check that the connectors of the connector panels are securely engaged. (NOTE2) Tighten the end-effecter mounting bolts and external main bolts. (NOTE3)

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(NOTE 2) Inspection points of the connectors

Robot connection cables, earth terminal and user cables

Check items
Circular connector: Check the connector for looseness by turning it manually. Square connector: Check the connector for disengagement of its lever. Earth terminal: Check the terminal for looseness by turning.

Fig 1.3 Check items of connector

(NOTE 3) Points to be retightened

The end effecter mounting bolts, robot installation bolts, and bolts to be removed for inspection need to be retightened. The bolts exposed to the outside of the robot need to be retightened. For the tightening torque, see the recommended bolt tightening torque shown in the Appendix. A loose prevention agent (adhesive) is applied to some bolts. If the bolts are tightened with greater than the recommended torque, the loose prevention agent may be removed. So, follow the recommended tightening torque when retightening them.

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1.4

1-year (3,840 hours) checks

Check the following items about once every year (3,840 hours).
Item 1 2 3 Check items Tightness of major external bolts Tightness of major external bolts Battery (battery built-in type) Check points (See Section 1.3) (See Section 1.3) Replace battery in the mechanical unit. (See Section 2.1)

1.5

1.5-year (5,760 hours) checks

Check the following items about once every year (5,760 hours).
Item 1 Check items Battery (external battery type) Check points Replace battery in the mechanical unit. (See Section 2.1)

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1.6

2-year (7,680 hours) checks (LR Mate 200iC /5WP) 4-year (15,360 hours) checks (LR Mate 200iC, LR Mate 200iC/5L , /5C, /5LC, /5H)
Check the following items in the cycle that is shorter among every four years and 15,360 hours.
Item 1 Check itmes Greasing of reducers of each axis Check points Specified grease Harmonic grease 4BNo.2 Spec:A98L-0040-0230#2KG Greasing kit (tube of grease plus injector) Spec:A05B-1139-K021 Tube of grease (80 g) Spec:A05B-1139-K022 Do not use Harmonic grease SK-3 or unspecified grease.

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1.7

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

Instrument Tension meter

Specifications

Vendor

Manufacturer model No. DOCTOR TENSION TYPE-

Application Adjustment of belt tension

A97L-0218-0700 Mitsuboshi Belting Ltd.

Instruments Dialgauge accuracy Slide calipers

Accuracy/Tolerance 1/100 mm 150 mm

Applications Measurement of positioning and backlash

(b) Tools Torque wrench Setting 5.6Nm(57kgfcm) Setting 5.4Nm(55kgfcm) Setting 4.5Nm(46kgfcm) Setting 2.0Nm(20kgfcm) Setting 1.3Nm(13kgfcm) Cross tip (+) screwdrivers Flat tip () screwdrivers Box driver Hex-head wrench set Monkey wrench Pincers Radio pincers Nippers Glasses wrench Pliers for Cretaining ring Loctite 242262518638 Grease applying kit A05B-1139-K021 (It is options that grease (80g) for the grease greasing with the injection syringe and the tube makes a set.) grease in tube (80g) A05B-1139-K022 M5 M4 M4 M3, M4 M3 Large, medium, and small sizes Large, medium, and small sizes M2.5 to M6 M2.5 to M6 Middle, little

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O5

Fig 1.7 example of cylinder

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2.PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

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2.1

REPLACING THE BATTERIES (1-YEAR CHECKS (battery built-in type)) (1.5-YEAR CHECKS (external battery type))
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every 1 year in case of battery built-in J1 base type 1.5 years in case of external battery type. Also, use the following procedure to replace when the backup battery voltage drop alarm occurs.

Procedure of replacing the battery (battery built-in type)

1 Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.

CAUTION Replacing the batteries with the power supply turned off causes all current position data to be lost. Therefore, mastering will be required again.
2 3 4 When severe dust/liquid protection or 5LC,5WP,5C is selected, remove the battery case cap. (Fig. 2.1(a)) Loosen the plate screw, take out the lid of the battery box, and replace battery. Battery can be taken out by pulling the stick, which is center of the battery box. Assemble them by the opposite procedure. Pay attention to the direction of batteries. Please exchange packing absolutely when severe dust/liquid protection specification or 5LC,5WP,5C is selected.
C battery(4pcs) FANUC specA98L-0031-0027 The battery can be taken out by pulling this stick Lid of battery bolx Plate screwM4X12(2pcs)

Packing A290-7139-X253 (*) Bolt with plate processing hex-head hole M4X20(4pcs) (*) Battery box cover (*)

(*)Severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5C,5WP are specified.

Fig.2.1 (a) Replacing the battery (battery built-in type)

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Procedure of replacing the battery (external battery type)

1 Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.

CAUTION Be sure to keep the power on. Replacing the batteries with the power supply turned off causes all current position data to be lost. Therefore, mastering will be required again.
2 3 4 5 Remove the battery case cap. (Fig. 2.1(b)) Take out the old batteries from the battery case. Insert new batteries into the battery case. Pay attention to the direction of batteries. Close the battery case cap.

External battery bolx Battery cable DiameterAbout O5mm (Max O5.5mm)

Battery case

Case cap Battery spec;A98L-0031-0005 (D battery4pcs)

Fig.2.1 (b) Replacing the battery (external battery type)

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Fig 2.1(c) shows the external size of external battery box. When the battery box needs to be built into the control unit or other internal units, refer to the outer dimensions shown in Fig.2.1(c) The battery box can be fixed by using M4 flathead screws. (The bolts do not come with the system.) A maximum of six terminals can be attached to the backplane of the battery box.

Fig.2.1(c) Outer dimensions of the battery box

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2.PERIODIC MAINTENANCE

2.2

REPLENISH THE GREASE OF THE DRIVE MECHANISM (4 years (11,520 hours) checks)
Replacing the grease of the reducers every four years or 15,360 hours by using the following procedures. For the grease name and quantity, see the table 2.2 (a).
Table 2.2 (a) Grease for 4-year periodical Replacement Greasing points Greasing amount Specified grease J1-axis reducer J2-axis reducer J3-axis reducer J4-axis reducer J5-axis reducer J6-axis reducer 2.7g(3ml) 2.7g(3ml) 1.8g(2ml) 1.8g(2ml) 1.8g(2ml) 1.8g(2ml)

Harmonic grease 4BNo.2 Spec: A98L-0040-0230

For grease replacement, use the attitudes indicated below.

Table 2.2 (b) Attitudes for greasing Supply position J1-axis reducer J2-axis reducer J3-axis reducer J4-axis reducer J5-axis reducer J6-axis reducer J1 -90 J2 90
Arbitrary Arbitrary Arbitrary Arbitrary

Attitude J3 J4

J5

J6

Arbitrary Arbitrary

CAUTION The following maintenance kits are prepared for the grease greasing. Greasing kit: A05B-1139-K021 (This a set of greasing syringe and grease in tube.) Grease in tube: A05B-1139-K022 There is no J6-axis for LR Mate 200iC/5H

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1 2

3 4

NOTE If greasing is performed incorrectly, the internal pressure of the grease bath may suddenly increase, possibly causing damage to the seal, which would in turn lead to grease leakage and abnormal operation. When performing greasing, therefore, observe the following cautions. In case of J1-axis and J3-axis, before starting to grease, open the grease outlet (remove the seal bolt from the grease outlet). Use grease only of the specified type. Grease of a type other than that specified may damage the reducer or lead to other problems. Do no use Harmonic grease SK-3 To prevent accidents caused by slipping, completely remove any excess grease from the floor or robot. Please fill a necessary amount to the injection syringe after softening grease in the tube massaging it by the hand when you use the grease greasing kit. Please install the nozzle in the point of the injection syringe. Please remove the nozzle and do the cap when you do not use the injection syringe.

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2.2.1

Grease replacement procedure of the J1-axis reducer

1 2 3 4 5 Move the robot to the attitude of J1=-90 and J2=90. Turn off the power. Remove the bolt/seal bolt (1) and cover U (2). In case of packing is attached, remove packing (3), too. Remove seal bolt of two places refer to fig.2.2.1. Supply regulated amount grease through the grease inlet by using injection syringe. Pay attention that grease inlet differs in case of floor mount and top mount. At this time, note that grease might come out from the side not used. Assemble parts in the opposite procedure. In case of packing is attached,be sure to replace packing.
2 4

6
1

J1-axis reducer grease inlet seal bolt (In case of top mount)

J1-axis reducer grease inlet seal bolt (In case of floor mount)

Fig. 2.2.1 Replacing grease of the J1-axis reducer Name BOLT SEAL BOLT SEAL BOLT Specification Amount Loctite Torque N-m (kgf-cm)

A6-BA-4X8 4 1 A97L-0218-0496#M4X10BC(*1) 4 4.5 N-m (46kgf-cm) A97L-0218-0496#M4X10EN(*2) 4 A290-7139-X332(*3) 1 2 COVER U A290-7139-Y332(*4) 1 A290-7139-Z332(*5) 1 3 PACKING A290-7139-X356 (*6) 1 4 COVER A290-7139-X347 1 (*1) When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H is specified. (*2) When LR Mate 200iC/5LC,5WP 5C is specified. (*3) When LR Mate 200iC,LR Mate 200iC/5L,5H is specified. (*4) When LR Mate 200iC,LR Mate 200iC/5C,5LC is specified. (*5) When LR Mate 200iC,LR Mate 200iC/5WP is specified. (*6) When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP 5C is specified.

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2.2.2

Grease replacement procedure of the J2-axis reducer

1 2 Turn off the power. Remove the seal bolt (1), (2) and remove cover S (3) and packing (4). Supply grease through the grease inlet by using injection syringe. Be sure to spread it to round in the gear because a regulated amount is a standard. Attach cover S (3) and packing (4). In this time, note the installation phase. Be sure to replace packing. When reusing the seal bolt, be sure to seal it with seal tape.
Spread the round grease on the tooth side like this.

Pay attention to direction

3 2 4

A DETAIL A

Fig. 2.2.2 Replacing grease of the J2-axis reducer Name Specification Amount 2 2 2 2 1 1 Loctite Torque N-m (kgf-cm) 2.0 N-m (46kgf-cm) 2.0 N-m (46kgf-cm) 2.0 N-m (46kgf-cm) 2.0 N-m (46kgf-cm)

SEAL BOLT A97L-0218-0738#040808BC(*1) 1 SEAL BOLT A97L-0218-0738#040808EN(*2) SEAL BOLT A97L-0218-0595#040808BC(*1) 2 SEAL BOLT A97L-0218-0595#040808EN(*2) 3 COVER S A290-7139-X309 4 PACKING A290-7139-X351 (*1) When LR Mate 200iC,LR Mate 200iC/5L,5H is specified. (*2) When LR Mate 200iC/5LC,5WP,5C is specified.

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2.2.3

Grease replacement procedure of the J3-axis reducer

1 2 Turn off the power. Remove the bolt/seal bolt (1) and J2 arm cover (2). In case of packing is attached, remove packing (3), too. Supply regulated amount grease through the grease inlet by using injection syringe. Please use arbitrary one as a greasing inlet. Attach J2 arm cover. In case of packing is attached,be sure to replace packing of. When reusing the seal bolt, be sure to seal it with seal tape.

3
4

J3-axis reducer grease inlet seal bolt

Fig. 2.2.3 Replacing grease of the J3-axis reducer Name BOLT SEAL BOLT SEAL BOLT Specification Amount Loctite Torque N-m (kgf-cm)

A97L-0218-0504#M4X10 3 2.0 N-m (20kgf-cm) 1 A97L-0218-0496#M4X12BC(*1) 8 4.5 N-m (46kgf-cm) A97L-0218-0496#M4X12EN(*2) 8 4.5 N-m (46kgf-cm) A290-7139-X306 1 A290-7139-X308 (*1) 1 2 J2 ARM COVER A290-7139-Y308 (*3) 1 A290-7139-Z308 (*4) 1 3 PACKING A290-7139-X355 (*5) 1 (*1) When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H is specified. (*2) When LR Mate 200iC/5LC,5WP,5C is specified. (*3) When LR Mate 200iC/5LC,5C is specified. (*4) When LR Mate 200iC/5WP is specified. (*5) When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

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2.2.4

Grease replacement procedure of the J4-axis reducer

NOTE Fig. 2.2.4 is an example of standard type. In case of 5H type, read J5/J6 as J4/J5.
1

2 3

Turn off the power. Remove the bolt/seal bolt (1) and J3 cover (2). In case of packing is attached, remove packing (3), too. Supply regulated amount grease through the grease inlet by using injection syringe. Please note that grease might come out immediately after in the greasing or the greasing. Please note greasing excessively even in that case. Attach J3 cover. In this time, be sure to replace packing . When reusing the seal bolt, be sure to seal it with seal tape.
J4-axis reducer grease inlet seal bolt

Fig. 2.2.4 Replacing grease of the J4-axis reducer (LR Mate 200iC)

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Specification Amount Loctite Torque N-m (kgf-cm)

Name 1 BOLT PLATED BOLT PLATED BOLT

A97L-0218-0504#M4X10 3 2.0 N-m (20kgf-cm) A97L-0218-0496#M4X12BC(*1) 6 2.0 N-m (20kgf-cm) A97L-0218-0496#M4X12EN(*2) 6 2.0 N-m (20kgf-cm) A290-7139-X404 1 A290-7139-X406 (*1) 1 2 J3 COVER A290-7139-Y406 (*3) 1 A290-7139-Z406 (*4) 1 3 PACKING A290-7139-X451 (*5) 1 (*1) When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H is specified. (*2) When LR Mate 200iC/5LC,5WP 5C is specified. (*3) When LR Mate 200iC/5LC,5C is specified. (*4) When LR Mate 200iC/5WP is specified. (*5) When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP 5C is specified.

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2.2.5

Grease replacement procedure of the J5/J6-axis reducer

NOTE Fig. 2.2.5 is an example of standard type. In case of 5H type, read J5/J6 as J4/J5.
1 2 Turn off the power. Supply regulated amount grease through the grease inlet by using injection syringe. Please note that grease might come out immediately after in the greasing or the greasing. Please note greasing excessively even in that case.

J6-axis reducer grease inlet seal bolt J5-axis reducer grease inlet seal bolt

Fig. 2.2.5 Replacing grease of the J5/J6-axis reducer (LR Mate 200iC) Replacing grease of the J4/J5-axis reducer (LR Mate 200iC/5H)

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3.TROUBLESHOOTING

TROUBLESHOOTING

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3.1

OVERVIEW
The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from many interrelated factors. If you fail to take the correct measures, the failure may be aggravated. Therefore, it is necessary to analyze the symptoms of the failure precisely so that the true cause can be found.

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3.TROUBLESHOOTING

3.2

FAILURES, CAUSES AND MEASURES

Table 3.2 lists the major failures that may occur in the mechanical unit and their probable causes. If you cannot pinpoint a failure cause or which measures to apply, contact FANUC.

Table 3.2 (a) Failures, causes and measures Symptom Description Vibration Noise -The J1 base lifts off the floor plate as the robot operates. -There is a gap between the J1 base and floor plate. -A J1 base retaining bolt is loose.

Cause [J1 base fastening] -It is likely that the robot J1 base is not securely fastened to the floor plate. -Probable causes are a loose bolt, an insufficient degree of surface flatness, or foreign material caught between the floor plate and floor plate. -If the robot is not securely fastened to the floor plate, the J1 base lifts the floor plate as the robot operates, allowing the base and floor plates to strike each other, which, in turn, leads to vibration. [Rack or floor] -It is likely that the rack or floor is not sufficiently rigid. -If the rack or floor is not sufficiently rigid, reaction from the robot deforms the rack or floor, leading to vibration. [Overload] -It is likely that the load on the robot is greater than the maximum rating. -It is likely that the robot control program is too demanding for the robot hardware. -It is likely that the ACCELERATION value is excessive.

Measure -If a bolt is loose, apply Loctite and tighten it to the appropriate torque. -Adjust the floor plate surface flatness to within the specified tolerance. -If there is any foreign matter between the J1 base and floor plate, remove it.

-Apply epoxy to the floor surface and re-install the plate.

-Vibration becomes more serious when the robot adopts a specific posture. -If the operating speed of the robot is reduced, vibration stops. -Vibration is most noticeable when the robot is accelerating. -Vibration occurs when two or more axes operate at the same time.

-Reinforce the rack or floor to make it more rigid. -If it is impossible to reinforce the rack or floor, modify the robot control program; doing so might reduce the amount of vibration. -Check the maximum load that the robot can handle once more. If the robot is found to be overloaded, reduce the load, or modify the robot control program. -Vibration in a specific portion can be reduced by modifying the robot control program while slowing the robot and reducing its acceleration (to minimize the influence on the entire cycle time).

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3.TROUBLESHOOTING
Symptom Vibration Noise (Continued) Description -Vibration was first noticed after the robot collided with an object or the robot was overloaded for a long period. -The grease of the vibrating axis has not been exchanged for a long period. Cause [Broken gear, bearing, or reducer] - It is likely that collision or overload applied an excessive force on the drive mechanism, thus damaging the gear tooth surface or rolling surface of a bearing, or reducer. - It is likely that prolonged use of the robot while overloaded caused fretting of the gear tooth surface or rolling surface of a bearing, or reducer due to resulting metal fatigue. - It is likely that foreign matter caught in a gear, bearing, or within a reducer caused damage on the gear tooth surface or rolling surface of the bearing, or reducer. - It is likely that, because the grease has not been changed for a long period, fretting occurred on the gear tooth surface or rolling surface of a bearing, or reducer due to metal fatigue. These factors all generate cyclic vibration and noise.

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Measure -Operate one axis at a time to determine which axis is vibrating. -Remove the motor, and replace the gear, the bearing, and the reducer. For the spec. of parts and the method of replacement, contact FANUC. -Using the robot within its maximum rating prevents problems with the drive mechanism. -Regularly changing the grease with a specified type can help prevent problems.

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

Symptom Vibration Noise (Continued)

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3.TROUBLESHOOTING
Symptom Vibration Description -There is some relationship between the vibration of the robot and the operation of a machine near the robot. Cause [Noise from a nearby machine] -If the robot is not grounded properly, electrical noise is induced on the grounding wire, preventing commands from being transferred accurately, thus leading to vibration. -If the robot is grounded at an unsuitable point, its grounding potential becomes unstable, and noise is likely to be induced on the grounding line, thus leading to vibration. [Mechanical section coupling bolt] -It is likely that overloading or a collision has loosened a mounting bolt in the robot mechanical section.

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Measure -Connect the grounding wire firmly to ensure a reliable ground potential and prevent extraneous electrical noise.

Rattling

-While the robot is not supplied with power, pushing it with the hand causes part of the mechanical unit to wobble. -There is a gap on the mounting face of the mechanical unit.

-Check that the following bolts for each axis are tight. If any of these bolts is loose, apply Loctite and tighten it to the appropriate torque. -Motor retaining bolt -Reducer retaining bolt -Base retaining bolt -Arm retaining bolt -Casting retaining bolt -End effecter retaining bolt -Operate one axis at a time to determine which axis has the increased backlash. -Remove the motor, and check whether any of its gears are broken. If any gear is broken, replace it. -Check whether any other gear of the drive mechanism is damage. If there is no damage gear, replace the reducer. -If the reducer is broken, or if a gear tooth is missing, replace the relevant component. Also, remove all the grease from the gear box and wash the inside of the gear box. -After replacing the gear or reducer, add an appropriate amount of grease. -Using the robot within its maximum rating prevents problems with the drive mechanism. -Regularly applying the grease with a specified type can help prevent problems.

-Backlash is greater than the tolerance stated in the applicable maintenance manual. (See Section 3.3.)

[Increase in backlash] -It is likely that excessive force applied to the drive mechanism, due to a collision or overloading, has broken a gear or the inside of the reducer, resulting in an increase in the amount of backlash. -It is likely that prolonged use has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash. -It is likely that prolonged use without changing the grease has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash.

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3.TROUBLESHOOTING
Description -The ambient temperature of the installation location increases, causing the motor to overheat. -After the robot control program or the load was changed, the motor overheated. Cause [Ambient temperature] -It is likely that a rise in the ambient temperature prevented the motor from releasing heat efficiently, thus leading to overheating. [Operating condition] -It is likely that the robot was operated with the maximum average current exceeded. Measure -The teach pendant can be used to monitor the average current. Check the average current when the robot control program is running. The allowable average current is specified for the robot according to its ambient temperature. Contact FANUC for further information. -Relaxing the robot control program and conditions can reduce the average current, thus preventing overheating. -Reducing the ambient temperature is the most effective means of preventing overheating. -Having the surroundings of the robot well ventilated enables the robot to release heat efficiently, thus preventing overheating. Using a fan to direct air at the motor is also effective. -If there is a source of heat near the motor, it is advisable to install shielding to protect the motor from heat radiation. -Input an appropriate parameter as described in CONTROLLER OPERATORS MANUAL.

Symptom Motor overheating

-After a control parameter was changed, the motor overheated.

-Symptom other than stated above

[Parameter] -If data input for a workpiece is invalid, the robot cannot be accelerated or decelerated normally, so the average current increases, leading to overheating. [Mechanical section problems] -It is likely that problems occurred in the mechanical unit drive mechanism, thus placing an excessive load on the motor. [Motor problems] -It is likely that a failure of the motor brake resulted in the motor running with the brake applied, thus placing an excessive load on the motor. -It is likely that a failure of the motor prevented it from delivering its rated performance, thus causing an excessive current to flow through the motor.

-Repair the mechanical unit while referring to the above descriptions of vibration, noise, and rattling. -Check that, when the servo system is energized, the brake is released. If the brake remains applied to the motor all the time, replace the motor. -If the average current falls after the motor is replaced, it indicates that the first motor was faulty.

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3.TROUBLESHOOTING
Symptom Grease Description -Grease is leaking from the mechanical unit. Cause [Poor sealing] -Probable causes are a crack in the casting, a broken O-ring, a damaged oil seal, or a loose seal bolt. -A crack in a casting can occur due to excessive force that might be caused in collision. -An O-ring can be damaged if it is trapped or cut during disassembling or re-assembling. -An oil seal might be damaged if extraneous dust scratches the lip of the oil seal. -A loose seal bolt might allow grease to leak along the threads.

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Measure -If a crack develops in the casting, sealant can be used as a quick-fix to prevent further grease leakage. However, the component should be replaced as soon as possible, because the crack might extend. -O-rings are used in the locations listed below. -Motor coupling section -Reducer coupling section -Wrist coupling section -J3 arm coupling section -Inside the wrist -Oil seals are used in the locations stated below. -Inside the reducer -Inside the wrist -Seal bolts are used in the locations stated below. -Grease drain inlet and outlet -Check whether the brake drive relay contacts are stuck to each other. If they are found to be stuck, replace the relay. -If the brake shoe is worn out, if the brake main body is damaged, or if oil or grease has entered the motor, replace the motor.

Dropping axis -An axis drops because the brake does not function. -An axis drops gradually when it should be at rest.

[Brake drive relay and motor] -It is likely that brake drive relay contacts are stuck to each other to keep the brake current flowing, thus preventing the brake from operating when the motor is deenergized. -It is likely that the brake shoe has worn out or the brake main body is damaged, preventing the brake from operating efficiently. -It is likely that oil or grease has entered the motor, causing the brake to slip.

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3.TROUBLESHOOTING
Description Cause [Mechanical section problems] -If the repeatability is unstable, probable causes are a failure in the drive mechanism or a loose bolt. -If the repeatability becomes stable, it is likely that a collision imposed an excessive load, leading to slipping on the base surface or the mating surface of an arm or reducer. -It is likely that the pulse coder is abnormal. [Peripheral unit displacement] -It is likely that an external force was applied to the peripheral unit, thus shifting its position relative to the robot. [Parameter] -It is likely that the mastering data was rewritten in such a way that the robot origin was shifted. Measure -If the repeatability is unstable, repair the mechanical section by referring to the above descriptions of vibration, noise, and rattling. -If the repeatability is stable, correct the taught program. Variation will not occur unless another collision occurs. -If the pulse coder is abnormal, replace the motor or the pulse coder. -Correct the setting of the peripheral unit position. -Correct the taught program.

Symptom

Displacement -The robot operates at a point other than the taught position. -The repeatability is not within the tolerance.

-Displacement occurs only in a specific peripheral unit.

-Displacement occurred after a parameter was changed.

BZAL alarm occurred

-BZAL is displayed on the controller screen

- It is likely that the voltage of the memory backup battery is low. - It is likely that the pulse coder cable is defected. Table 3.2 (b) Allowable drops At power off At emergency stop

-Re-enter the previous mastering data, which is known to be correct. -If correct mastering data is unavailable, perform mastering again. -Replace the battery. -Replace the cable.

2 mm 2 mm

NOTE Each value indicates the amount by which an end effector mounting surface may fall.

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3.3

BACKLASH MEASUREMENT
1 2 3 Maintain the robot in a specified posture. (See Table 3.3.) Apply positive and negative loads to each axis as shown in Fig.3.3 (a). Remove the loads and measure the displacement.

Measurement method

Measure backlash by applying positive and negative loads to each axis three times. Average the values measured in the last two measurements for each axis, and use the averages as a measured backlash for the respective axes.

Stop position
0

+3kg -3kg

Firtst step (Do not measure)

+3kg

-3kg 0kg
L2

L1

0kg

Second step (B2 =L 1+ L2)

+3kg 0kg
L3

-3kg 0kg
L4

Third step (B3=L 3+ L4)

Fig. 3.3 (a) Backlash measurement method

Backlash B is calculated using the following expression:

B=
B2 + B3 2

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B-82585EN/02 Table 3.3(a) Backlash measurement posture, position and permissible value Measurement J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis axis J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary 90 0 90 0 90 90 0 90 -90 90 0 0 0 0 0 0 0 0 0 0 0 -90 -90 -90 90 0 180 90 0 or 180 90 or -90

3.TROUBLESHOOTING

Measurement position Rotation center of J5-axis Rotation center of J3-axis of J2 arm Rotation center of J5-axis 100mm from rotation center of J4-axis 206mm from rotation center of J5-axis 100mm from rotation center of J6-axis

Table 3.3(b) Distance at axis and measurement position and permissible value for backlash Measured Distance at axis and measurement position axis (mm) Permissible value (mm)

LR Mate 200iC, LR Mate 200iC, LR Mate 200iC/5C, LR Mate 200iC/5L,5LC LR Mate 200iC/5C, LR Mate 200iC/5L,5LC 5WP,5H 5WP,5H J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis 695 300 320 100 180 100 885 400 410 100 180 100 0.40 0.17 0.19 0.16 0.18 0.15 0.51 0.23 0.24 0.16 0.18 0.15

NOTE In case of 5H type, read J5/J6 as J4/J5.

100 Loading position

Measurement position (Rotation center of J5-axis)

Fig.3.3 (b) Backlash measurement position of J1-axis

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Loading position

Measurement position

Fig.3.3(c) Backlash measurement position of J2-axis

100

100

Measurement position

Loading position

Fig.3.3 (d) Backlash measurement position of J3-axis

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3.TROUBLESHOOTING

Rotation center of J4-axis (J6-axis) Loading position 100 Measurement position

Fig.3.3 (e) Backlash measurement position of J4-axis

100 100
Fig.3.3 (f) Backlash measurement position of J5-axis

Measurement position Loading position

100 Loading position Measurement position

Fig.3.3 (g) Backlash measurement position of J6-axis

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REPLACING PARTS
When replacing a part, subsequent adjustment is required. When removing or mounting a motor, apply force in the direction of the shaft only. If excessive force is applied in any other direction, the motor and/or reducer may be damaged. If a motor and associated parts to be assembled incur a phase mismatch, assembly might prove impossible. Carefully check the state of the parts before removing them. Assemble a new Oring and packing for seal securing after you exchange parts for spec of seal.

CAUTION The packing must not be reused. To maintain dust and drip preventive effects, replace the old packing with new ones and then perform assembly.
To secure the performance of the seal, replace seal bolt to new one after replacing parts as much as possible. If it is not possible to prepare it, peel off the sealant, spread Loctite on the internal thread, and recycle.

NOTE When applying Loctite to the important bolt tighteningpoints, make sure that it is applied to the entire longitudinal portion in the engaging section of the female threads. If it is applied to the male threads, the bolts may be loosened because sufficient effects cannot be obtained. Remove the dust within the bolts and taps and wipe oil off the engaging section. Make sure that there is no solvent in the taps.
When tightening a bolt, always observe the tightening torque, if specified those bolts for which no tightening torque is specified must be tightened according to the table of APPENDIX. Assemble the reducer to the vertical direction as much as possible when you assemble it. When installing bolt to reducer, make the applying order a corner and tighten uniformly. When applying Loctite 518 to reducer, pay attention Loctite doesnt enter inside the reducer. Spread it after softening grease mixing it when you do not softly spread grease easily.

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4.REPLACING PARTS NOTE The following abbreviations are used herein. STANDARD : LR Mate 200iC 5L : LR Mate 200iC/5L 5LC : LR Mate 200iC/5LC 5C : LR Mate 200iC/5C 5WP : LR Mate 200iC/5WP 5H : LR Mate 200iC/5H

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4.1

FIGURE OF DRIVE MECHANISM

The drive mechanisms of each axis are shown in the following.

CAUTION When robot is 5H,please read J5/J6 as J4/J5.

J2 AXIS BASE

PIPE

J1 AXIS REDUCER (HOLLOW SHAFT)

OUTPUT GEAR INPUT GEAR

J1 AXIS BASE

MOTOR (M1) FOR J1 AXIS

Fig. 4.1 (a) Drive mechanism of J1-axis

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4.REPLACING PARTS
J2 AXIS ARM

J2 AXIS REDUCER

J2 AXIS BASE

MOTOR (M2) FOR J2 AXIS

Fig. 4.1 (b) Drive mechanism of J2-axis

J3 AXIS HOUSING J3 AXIS REDUCER

J3 AXIS OUTPUT PULLY

J2 AXIS ARM

BELT

MOTOR (M3) FOR J3 AXIS J3 AXIS INPUT PULLY

Fig. 4.1 (c) Drive mechanism of J3-axis

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4.REPLACING PARTS
J4 AXIS OUTPUT GEAR

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J4 AIXS REDUCER

PIPE

J3 AIXS ARM

MOTOR (M4) FOR J4 AXIS J4 AXIS INPUT GEAR J3 AXIS HOUSING

Fig. 4.1 (d) Drive mechanism of J4-axis
J5 AXIS OUTPUT PULLY

J5 AXIS INPUT PULLY MOTOR (M5) FOR J5 AXIS

J5 AXIS REDUCER

BELT J6 AXIS OUTPUT GEAR

J3 AIXS ARM J6 AXIS REDUCER

J6 AXIS INPUT GEAR BELT MOTOR (M5) FOR J5 AXIS J6 AXIS OUTPUT PULLY J6 AXIS HOUSING

J6 AXIS INPUT PULLY

Fig. 4.1 (e) Drive mechanism of J5/J6-axis

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4.REPLACING PARTS

4.2

REPLACING J1-AXIS MOTOR

1 2 3 4 Move the robot posture to J1=90 and J2=-90. Remove robot from floor plate, and turn off the power of the controller. Make it to posture in which the motor (2) can be removed. When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L, 5H or LR Mate 200iC/5LC, 5WP, 5C is specified, remove plated bolt (12), cover B (11) and packing (13). (When not severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H is specified, there are not.) Remove bolt (1) and motor (2). In this time, note that there is a possibility that grease goes out. Remove cable K101 from motor (1). Wipe the grease of the gear off. In this time, pay attention not to damage the tooth side. Remove O-ring (3) and seal bolt (4), and remove washer plate (5), gear (6), holder (7), O-ring (8) and key (9) sequentially. Assemble it in the opposite procedure after exchanging Motor, packing and O-ring for the new article. In this time, pay attention to the following. - When motor is attached, confirm the thing that the oil seal is at the position, and note that the lip cannot be turned over. - Spread grease on surroundings about the gear. Perform mastering (See subsection 6.2 and refer to section 8 of OPERATORS MANUAL.).

Replacing procedure

5 6 7 8 9

10

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13

12 11

8 7 5 3 4

9 10 6

2 1 A

VIEW A
Fig. 4.2 Replacing J1-axis motor Parts Name 1 2 3 4 5 BOLT MOTOR O-RING SEAL BOLT WASHER PLATE Specifications Number Loctite Torque N-m (kgf-cm)

A6-BA-5X20 4 A06B-0116-B855#0048 1 A98L-0001-0347#S46 1 A97L-0218-0423#030606 3 1.3Nm (13kgfcm) A290-7139-X231 1 A290-7139-X211(*1) 1 6 GEAR J1-1 A290-7139-X213(*2) 1 7 HOLDER A290-7139-X221 1 8 O-RING A98L-0001-0347#S46 1 9 KEY JB-HKY-3X3X12B 1 10 OIL SEAL A98L-0040-0223#01001805 1 A290-7139-X233 (*3) 1 11 COVER B A290-7139-Y233 (*4) 1 PLATED BOLT A97L-0218-0496#M4X8BC (*3) 9 4.5Nm (46kgfcm) 12 PLATED BOLT A97L-0218-0496#M4X8EN (*4) 9 4.5Nm (46kgfcm) 13 PACKING A290-7139-X252 (*5) 1 (*1) When LR Mate 200iC,LR Mate 200iC/5C,5WP,5H is specified. (*2 )When LR Mate 200iC/5L,5LC is specified. (*3) When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H is specified. (*4) When LR Mate 200iC/5LC,5WP,5C is specified. (*5) When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP 5C is specified.

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4.3

REPLACING J1-AXIS REDUCER

1 2 Turn off the power of the controller. Remove cover B (When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.) and J1 motor referring to 4.2. (The gear need not be removed.) Remove bolt/plated bolt (5), J2 base cover (6) and sponge (7). When packing is attached, remove packing (19), too. Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106, K107 and K108 referring to Fig.5.3.1 (b) in Section 5. Remove bolt/seal bolt (1) and cover U (2). When packing is attached, remove packing (18), too. Pull out cable K101 to the J1 base side. In this time, pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relayed connector caught. Remove bolt (3), (4) and remove J1 base (17) by using tap for pulled out. In this time, pay attention that there is a possibility that grease goes out. (Refer to Fig.4.3(d)) Wipe the grease of the gear (13) off. In this time, do not damage the tooth side. Remove bolt/seal bolt (14) and reducer (10). Remove seal bolt (12) and gear (13). Assemble the gear (13) to wave generator (11) of the new reducer (10). Keep the horizontal and install a new main body of the reducer in J2 base. In this time, put O-ring (8) without forgetting after it exchanges it for the new article. Fill grease to the reducer. It is total 19ml greasing in inside of reducer, gear and bearing of wave generator. When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified, spread the sealant on the reducer referring to Fig.4.3 (b). Attach new wave generator (11) to the reducer. In this time, put wave washer (9) without forgetting. Phase to reducer and assemble J1 base (17) referring to Fig.4.2(c). In this time, put O-ring (15) without forgetting. Assemble bolt (4) after previously assembling all bolt (3). Put J1 motor, cable and cover in the reverse order of 2-6.

Replacing procedure

3 4 5 6

7 8 9 10 11 12 13 14

15 16 17

CAUTION Do not apply grease to the O-ring (15). Otherwise, hardening of sealant is prevented, causing a grease leak.

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18 Pass the cable K101 through J2 base side, and connect it with the relay connector. In this time, pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relayed connector caught. 19 Attach J2 base cover (6) by bolt/plated bolt (5) after sponge (7) is attached inside of J2 base. When severe dust/liquid protection specification is specified, replace packing (19) to new one, and attach it. 20 Attach J1 motor referring to Section 4.2. 21 When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified, attach cover B. 22 Attach robot to floor plate. 23 Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.).

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4.REPLACING PARTS

18

1 2 5

8 9 10 11 12 13 15 14

19

16

17

4 3
Fig. 4.3 (a) Replacing J1-axis reducer

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4.REPLACING PARTS
Parts Name BOLT 1 SEAL BOLT SEAL BOLT 2 COVER U 3 BOLT 4 BOLT BOLT 5 PLATED BOLT PLATED BOLT 6 J2 BASE COVER 7 SPONGE 8 O-RING 9 WAVE-WASHER 10 J1 REDUCER 11 12 13 WAVE GENERATOR SEAL BOLT GEAR J1-2 BOLT SEAL BOLT SEAL BOLT O-RING J1 RING Specifications A6-BA-4X8(*1) A97L-0218-0546#040808BC(*2) A97L-0218-0546#040808EN(*3) A290-7139-X332 A6-BA-4X12 A6-BA-4X20 A97L-0218-0504#M4X10(*1) A97L-0218-0496#M4X12BC (*2) A97L-0218-0496#M4X12EN (*3) A290-7139-X305(*1) A290-7139-X307 (*2) A290-7139-Y307 (*5) A290-7139-Z307 (*6) A290-7139-X346 (Attached to J1 REDUCER) (Attached to J1 REDUCER) A97L-0218-0812#80(*4) A97L-0218-0812#80C(*3) (Attached to J1 REDUCER) Number 4 4 4 1 7 9 3 8 8 1 1 1 1 1 1 1 1 1 1 Loctite

B-82585EN/02

Torque N-m (kgf-cm) 4.5Nm (46kgfcm) 4.5Nm (46kgfcm) 4.5Nm (46kgfcm) 4.5Nm (46kgfcm) 2.0Nm (20kgfcm) 4.5Nm (46kgfcm) 4.5Nm (46kgfcm)

A97L-0218-0423#030505 6 A290-7139-X212 1 A6-BA-4X30(*1) 12 5.4Nm (55kgfcm) 14 A97L-0218-0546#043016BC(*2) 12 5.4Nm (55kgfcm) A97L-0218-0546#043016EN(*3) 12 5.4Nm (55kgfcm) 15 (Attached to J1 REDUCER) 1 16 A290-7139-X241 1 A290-7139-X201(*4) 1 17 J1 BASE A290-7139-Y201(*5) 1 A290-7139-Z201(*6) 1 18 PACKING A290-7139-X356 (*7) 1 19 PACKING A290-7139-X354 (*7) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*5) When LR Mate 200iC/5LC,5C is specified. (*6) When LR Mate 200iC/5WP is specified. (*7) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

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4.REPLACING PARTS

APPLY LOCTITE 518 TO THE PART OF THE J1 BASE SIDE. DON'T PUT LOCTITE INSIDE THE REDUCER.
Fig. 4.3 (b) Range to J1-axis reducer of sealant spreading (When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.)

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M4X20 M4X12

Fig. 4.3 (c) Assembled phase of J1-axis reducer

M4 tap for pulled out (2 places)

Fig. 4.3 (d) Position of taps for pulled out to remove J1 base.

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4.REPLACING PARTS

4.4

REPLACING J2-AXIS MOTOR

1 2 3 4 5 6 7 8 9 Turn off the power of the controller. Remove bolt/plated bolt (1) and J2 base cover (2). When packing is attached, remove packing (19), too. Remove sponge (3). Cut the nylon band, which connect cable and clamp (5). Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106, K107 and K108 referring to Fig.5.3.1 (b) in Section 5. Remove bolt (4) and clamp (5). Remove bolt (6) and support (7). When packing is attached, remove packing (20), too. Remove seal bolt (8) and (9), cover S (10), packing (21). In this time, pay attention that there is a possibility that grease goes out. Remove seal bolt (11), washer (12), wave generator (18), O-ring (17), key (16) and Motor (14) to which shaft (15) attaches.

Replacing procedure

CAUTION When the motor is removed, the arm moves downward by its weight. Hold the arm so that the arm does not collide with any other objects.
10 Remove cable K102 and K103 from motor (14). 11 Assemble it in the opposite procedure after exchanging Motor, O-ring, packing and shaft (15) for the new article. In this time, pay attention to the following. Spread Loctite 638 referring to Fig.4.4(b) when you apply shaft(15). Be sure to attach wave generator(18) after attaching motor(14). Spread grease inside of reducer. Pay attention the phase when you apply the cover S (10) referring to Fig.4.4(c). 12 Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.).

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21

8 10 11 12 18

17 16 15 20 14

13 7 5 4 3 19 2 1
Fig. 4.4(a) Replacing J2-axis motor

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4.REPLACING PARTS
Specifications Number Loctite Torque N-m (kgf-cm)

Parts Name BOLT 1 PLATED BOLT PLATED BOLT

A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm) A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm) A290-7139-X305(*1) 1 A290-7139-X307 (*2) 1 2 J2 BASE COVER A290-7139-Y307 (*4) 1 A290-7139-Z307 (*5) 1 3 SPONGE A290-7139-X346 1 4 BOLT A6-BA-4X8 2 5 CLAMP J2-1 A290-7139-X333 1 6 SEAL BOLT A97L-0218-0423#041212 7 4.5Nm (46kgfcm) A290-7139-X303(*6) 1 7 SUPPORT A290-7139-Y303(*4) 1 A290-7139-Z303(*5) 1 SEAL BOLT A97L-0218-0595#040808BC(*6) 2 2.0Nm (20kgfcm) 8 SEAL BOLT A97L-0218-0595#040808EN(*3) 2 2.0Nm (20kgfcm) SEAL BOLT A97L-0218-0738#040808BC(*6) 2 2.0Nm (20kgfcm) 9 SEAL BOLT A97L-0218-0738#040808EN(*3) 2 2.0Nm (20kgfcm) A290-7139-X309(*6) 1 10 COVER S A290-7139-Y309(*4) 1 A290-7139-Z309(*5) 1 11 SEAL BOLT A97L-0218-0423#031616 1 1.3Nm (13kgfcm) 12 WASHER A290-7210-X532 1 13 SEAL BOLT A97L-0218-0423#051212 4 14 MOTOR A06B-0116-B855#0048 1 15 SHAFT A290-7139-X322 1 LT638 16 KEY JB-HKY-3X3X12B 1 17 O RING JB-OR1A-G45 4 18 WAVE GENERATOR (Attached to J2 REDUCER) 1 19 PACKING A290-7139-X354 (*7) 1 20 PACKING A290-7139-X352 (*7) 1 21 PACKING A290-7139-X351 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC/5LC,5C is specified. (*5) When LR Mate 200iC/5WP is specified. (*6) When LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*7)When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

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Spread grease on the inside diameter.. A

A
Fig. 4.4(b) Apply Loctite 638 to shaft

VIEW A

A97L-0218-0738#040808BC(LR Mate 200iC,LR Mate 200iC/5L,5H) A97L-0218-0738#040808EN(LR Mate 200iC/5C,5LC,5WP) NOTE) PAY ATTENTION TO THE ASSEMBLED PHASE

A97L-0218-0595#040808BC(LR Mate 200iC,LR Mate 200iC/5L,5H) A97L-0218-0595#040808EN(LR Mate 200i/5C,5LC,5WP)

Fig. 4.4(c) Assembled phase of cover S and bolt

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4.REPLACING PARTS

4.5

REPLACING J2-AXIS REDUCER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 Turn off the power of the controller. Remove the robot from floor plate and knock down it sidewise. Remove bolt/plated bolt (1), J2 base cover (2) and sponge (3). When packing is attached, remove packing (25), too. Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106, K107 and K108 referring to Fig.5.3.1 (b) in Section 5. Remove bolt (5) and clamp (4). Cut the nylon band, which connect cable and clamp. Remove bolt (6) and support (7). When severe dust/liquid protection specification is specified, remove packing (26), too. Remove seal bolt (8) and (9), cover S (10) and packing (11). In this time, pay attention that there is a possibility that grease goes out. Remove seal bolt (12), washer (13) and wave generator (14). Remove seal bolt (19), motor (18) and O-ring (20), (21). Remove bolt/seal bolt (15) and J2 arm (17) to which reducer (24) is attached. Remove bolt (22) and remove reducer (24) from J2 arm (17). Exchange reducer, O-ring, packing (when severe dust/liquid protection is specified) for new parts in the following order. Attach new reducer to the J2 arm (17) by using bolt/seal bolt (22). When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified, spread the sealant on the reducer referring to Fig.4.5 (b).

Replacing procedure

CAUTION Do not apply grease to the O-ring (23). Otherwise, hardening of sealant is prevented, causing a grease leak.
15 Attach J2 motor (18) to the J2 arm. Be sure to make the decelerator the horizontal about the procedure of 16 and 17. 16 Attach J2 base (16) to the reducer (24) by using bolt/seal bolt (22). In this time, put O-ring (23) without forgetting. 17 Fill grease to the reducer. It is total 26ml greasing in inside of reducer, gear and bearing of wave generator. 18 Attach wave generator (14) to the J2 base (16). 19 Attach cover S (10). In this time, pay attention to the phase referring to Fig.4.4(c). 20 Attach support (7) by using bolt (6). When packing is attached, be sure to replace packing (26) to new one and attach there. 21 Fix cable to the clamp (4) by using nylon band, attach support (7) by using bolt (5)

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22 Attach J2 base cover (2) by using bolt/plated bolt (1). In this time, put sponge (3) without forgetting, be sure to replace packing (25) to new one and attach there. 23 Attach robot to floor plate. 24 Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.).

8 10 11 12 13 14 15 16 22 23 24

17

21 20 26 18 7 4 25 2 1
Fig. 4.5(a) Replacing J2-axis reducer

19

5 3

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4.REPLACING PARTS
Specifications A97L-0218-0504#M4X10(*1) A97L-0218-0496#M4X12BC (*2) A97L-0218-0496#M4X12EN (*3) A290-7139-X305(*1) A290-7139-X307 (*2) A290-7139-Y307 (*4) A290-7139-Z307 (*5) A290-7139-X346 A290-7139-X333 A6-BA-4X8 A97L-0218-0423#041212 A290-7139-X303(*6) A290-7139-Y303(*4) A290-7139-Z303(*5) A97L-0218-0595#040808BC(*6) A97L-0218-0595#040808EN(*3) A97L-0218-0738#040808BC(*6) A97L-0218-0738#040808EN(*3) A290-7139-X309(*6) A290-7139-Y309(*4) A290-7139-Z309(*5) A290-7139-X351 A97L-0218-0423#031616 A290-7210-X532 A6-BA-4X20 A290-7139-X301(*6) A290-7139-Y301(*4) A290-7139-Z301(*5) A290-7139-X302 (*7) A290-7139-X310*8 A290-7139-Y302*9 A290-7139-Y310*10 A290-7139-Z302*5 A06B-0116-B855#0048 A97L-0218-0423#051212 JB-OR1A-G45 (Attached to J2 REDUCER) A6-BA-4X35 A97L-0218-0546#043516BC(*6) A97L-0218-0546#043516EN(*3) (Attached to J2 REDUCER) A97L-0218-0813#120(*11) A97L-0218-0813#120C(*3) A290-7139-X354 (*11) A290-7139-X352 (*11) Number 3 8 8 1 1 1 1 1 1 2 7 1 1 1 2 2 2 2 1 1 1 1 1 1 1 16 1 1 1 1 1 1 1 1 1 4 1 1 12 12 12 1 1 1 1 1 Loctite Torque N-m (kgf-cm) 2.0Nm (20kgfcm) 4.5Nm (46kgfcm) 4.5Nm (46kgfcm)

Parts Name BOLT 1 PLATED BOLT PLATED BOLT 2 J2 BASE COVER 3 4 5 6 SPONGE CLAMP J2-1 BOLT SEAL BOLT

4.5Nm (46kgfcm)

7 SUPPORT SEAL BOLT SEAL BOLT SEAL BOLT 9 SEAL BOLT 8 10 COVER S 11 PACKING 12 SEAL BOLT 13 WASHER 15 BOLT 16 J2 BASE

2.0Nm (20kgfcm) 2.0Nm (20kgfcm) 2.0Nm (20kgfcm) 2.0Nm (20kgfcm)

1.3Nm (13kgfcm)

14 WAVE GENERATOR (Attached to J2 REDUCER)

17 J2 ARM

18 19 20 21

MOTOR SEAL BOLT O RING O RING BOLT 22 SEAL BOLT SEAL BOLT 23 O RING 24 J2 REDUCER 25 PACKING 26 PACKING

5.4Nm (55kgfcm) 5.4Nm (55kgfcm) 5.4Nm (55kgfcm)

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4.REPLACING PARTS

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(*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC/5LC,5C is specified. (*5) When LR Mate 200iC/5WP is specified. (*6) When LR Mate 200iC, LR Mate 200iC/5H,5L is specified. (*7) When LR Mate 200iC, LR Mate 200iC/5H is specified. (*8) When LR Mate 200iC/5L is specified. (*9) When LR Mate 200iC/5C is specified. (*10) When LR Mate 200iC/5LC is specified. (*11)When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

APPLY LOCTITE 518 TO THE PART OF THE COVER S SIDE. DON'T PUT LOCTITE INSIDE THE REDUCER.
Fig. 4.5 (b) Range to J2-axis reducer of sealant spreading (When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.)

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4.REPLACING PARTS

4.6

REPLACING J3-AXIS MOTOR

1 2 3 Turn off the power of the controller. Remove bolt/plated bolt (3) and J2 arm cover (4). When packing is attached, remove packing (14), too. Loosen a bolt (6) a little and lower the tension of the belt (5) and remove belt (5).

Replacing procedure

CAUTION When removing the belt, put the part beyond the J3 housing on a workbench to prevent the arm from dropping
4 5 6 According to Section 5.3.1, remove J2 base cover and relay of cable K101 and air tube. (Referring to Fig.5.3.1 (a), (b)) According to Section 5.3.1, remove clamp J2-1 and cut the nylon band, which connect cable and air tube to clamp. (Referring to Fig.5.3.1 (a), (b)) Remove seal bolt (1) and guide arm (2). Do not add power forcibly when you remove guide arm. When packing is attached, remove packing (13), too. Pay attention that the load doesnt rest upon cable and air tube so that an upper cable and the air tube may work from guide arm without removing. Remove clamp J2-2 referring to Fig.5.3.2 (e) of Section 5.3.2. (It is not necessary to cut nylon band.) Pull lower cable from guide arm from J2 base to guide arm. In this time, pull out the cable after it pushes into the robot on the tip of the part of the relayed connector and it passes it. Remove bolt (12) and motor (11). Remove seal bolt (7), washer plate (8) and pulley (9). Remove cable K104 and K105 from motor (11). Assemble it in the opposite procedure after exchanging Motor and packing for the new article. In this time, pay attention to the following. Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. When installing guide arm, assemble it horizontally so as not to damage oil seal. Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.).

7 8 9 10 11 12

13

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4.REPLACING PARTS

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3 4

VIEW 5

2 6 7 9 11 12 13

14
Fig. 4.6 Replacing J3-axis motor Parts Name 1 SEAL BOLT Specifications Number

10 1

Loctite

Torque N-m (kgf-cm)

A97L-0218-0423#051616(*1) 4 5.6Nm (57kgfcm) A97L-0218-0546#051616BC(*2) 4 5.6Nm (57kgfcm) A97L-0218-0546#051616EN(*3) 4 5.6Nm (57kgfcm) 2 GUIDE ARM A290-7139-X304 1 BOLT A97L-0218-0504#M4X10 (*1) 3 2.0Nm (20kgfcm) 3 PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm) PLATED BOLT A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm) A290-7139-X306 (*4) 1 A290-7139-X308 (*2) 1 4 J2 ARM COVER A290-7139-Y308 (*5) 1 A290-7139-Z308 (*6) 1 5 BELT A98L-0040-0190#007-098 1 6 BOLT A97L-0218-0504#M5X12 3 5.6Nm (57kgfcm) 7 SEAL BOLT A97L-0218-0423#030606 3 8 WASHER PLATE A290-7139-X231 1 9 PULLEY A290-7139-X311 1 10 KEY JB-HKY-3X3X12B 1 11 MOTOR A06B-0115-B855#0048 1 12 BOLT A6-BA-5X12 4 13 PACKING A290-7139-X353 (*7) 1 14 PACKING A290-7139-X355 (*7) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC,LR Mate 200iC/5H,5Lis specified (*5) When LR Mate 200iC/5LC,5C is specified. (*6) When LR Mate 200iC/5WP is specified. (*7)When severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP 5C is specified.

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4.7

REPLACING J3-AXIS REDUCER

1 2 3 Turn off the power of the controller. Remove guide arm referring to Section 4.6. Remove J2 arm cover and belt referring to section 4.6.

Replacing procedure

CAUTION When removing the belt, put the part beyond the J3 housing on a workbench to prevent the arm from dropping
4 5 Remove seal bolt (1), washer (2) and pulley (3). Remove bolt (4) andJ2 arm to which reducer (8) attach. Note that there is a possibility that grease goes out. 6 Remove bolt/seal bolt (6) and reducer (8). 7 Replace reducer to new one and install to J3 arm unit horizontally. In this time, put wave washer (10) and O-ring (9) without forgetting. 8 Fill grease to the reducer. It is total 10ml greasing in inside of reducer, gear and bearing of wave generator 9 Attach wave generator (7) to reducer. 10 When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified, spread sealant to the reducer referring to Fig.4.7 (b) 11 Attach J3 arm unit to which reducer attach to the J2 arm. In this time, put O-ring (11) without forgetting.

CAUTION Do not apply grease to the O-ring (11). Otherwise, hardening of sealant is prevented, causing a grease leak.
12 Install pulley (3) and belt. 13 Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. 14 Install J2 arm cover referring to Section 4.6. 15 Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.).

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1 2 4

11 5 7 6 8 9 10 12

Fig. 4.7(a) Replacing J3-axis reducer

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4.REPLACING PARTS
Specifications Number Loctite Torque N-m (kgf-cm)

Parts Name 1 2 3 4 5 SEAL BOLT WASHER PULLEY BOLT KEY BOLT 6 SEAL BOLT SEAL BOLT 7 WAVE GENERATOR

A97L-0218-0423#030606 1 1.3Nm (13kgfcm) A290-7210-X532 1 A290-7139-X312 1 A6-BA-3X16 16 2.0Nm (20kgfcm) (Attached to J3 REDUCER) 1 A6-BA-3X25(*1) 12 2.0Nm (20kgfcm) A97L-0218-0546#032504BC(*2) 12 2.0Nm (20kgfcm) A97L-0218-0546#032504EN(*3) 12 2.0Nm (20kgfcm) (Attached to J3 REDUCER) 1 A97L-0218-0814#100 (*4) 1 8 J3 REDUCER A97L-0218-0814#100C (*3) 1 9 O-RING (Attached to J3 REDUCER) 1 10 WAVE WASHER (Attached to J3 REDUCER) 1 11 O-RING (Attached to J3 REDUCER) 1 A290-7139-X401 (*4) 1 12 J3 HOUSING A290-7139-Y401 (*5) 1 A290-7139-Z401 (*6) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC, LR Mate 200iC/5H,5L is specified (*5) When LR Mate 200iC/5LC,5C is specified. (*6) When LR Mate 200iC/5WP is specified.

APPLY LOCTITE 518 TO THE PART OF THE PULLEY SIDE. DON'T PUT LOCTITE INSIDE THE REDUCER.
Fig. 4.7 (b) Range to J3-axis reducer of sealant spreading (When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L or LR Mate 200iC/5C,5LC,5WP is specified)

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4.8

REPLACING J4-AXIS MOTOR

Replacing procedure CAUTION This section is for standard type. This mechanical part does't exist in 5H. If you replace J4-axis motor of 5H, refer to Section 4.10
1 2 3 Turn off the power of the controller. Remove bolt/plated bolt (1) and J3 cover (2). When packing is attached, remove packing (13), too. Remove bolt (12), motor (11) and O-ring (3). Note that there is a possibility that grease goes out.

CAUTION
When the motor is removed, the J3 arm can be rotated. Do as the J3arm is put on the stand so that the arm should not collide with surroundings. 4 5 6 7 Wipe the grease of the gear (6) off. In this time, pay attention not to damage the tooth side. Remove cable K107 and K109 from motor (11). Remove seal bolt (4), washer plate (5), gear (6), key (7), holder (8) and O-ring (9). Assemble it in the opposite procedure after exchanging Motor-ring and packing for the new article. - Confirm the thing that the oil seal is at the position, and note that the lip cannot be turned over. - Spread grease on surroundings of the gear. Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.).

9 7 10

1 12 2

11

13

Fig. 4.8 Replacing J4-axis motor

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4.REPLACING PARTS
Specifications Number Loctite Torque N-m (kgf-cm)

Parts Name BOLT 1 PLATED BOLT PLATED BOLT

A97L-0218-0504#M4X10 (*1) 4 2.0Nm (20kgfcm) A97L-0218-0496#M4X12BC (*2) 6 2.0Nm (20kgfcm) A97L-0218-0496#M4X12EN (*3) 6 2.0Nm (20kgfcm) A290-7139-X404 (*4) 1 A290-7139-X406 (*2) 1 2 J3 COVER A290-7139-Y406 (*5) 1 A290-7139-Z406 (*6) 1 3 O-RING A98L-0001-0347#S46 1 4 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm) 5 WASHER PLATE A290-7139-X231 1 6 GEAR J4-1 A290-7139-X411 1 7 KEY JB-HKY-3X3X12B 1 8 HOLDER A290-7139-X221 1 9 O-RING A98L-0001-0347#S46 1 10 OIL SEAL A98L-0040-0223#01001805 1 No brake A06B-0114-B205#0048 11 MOTOR 1 With brake A06B-0114-B855#0048 12 BOLT A6-BA-5X20 4 13 PACKING A290-7139-X451 (*7) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC, LR Mate 200iC/5Lis specified (*5) When LR Mate 200iC/5LC,5C is specified. (*6) When LR Mate 200iC/5WP is specified. (*7) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L or LR Mate 200iC/5C,5LC,5WP is specified

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4.9

REPLACING J4-AXIS REDUCER

Replacing procedure CAUTION This section is for standard type. This mechanical part does't exist in 5H. If you replace J4-axis reducer of 5H, refer to Section 4.11.
1 2 3 4 Turn off the power of the controller. Remove J3 arm cover, relay connector and air tube referring to Section 4.10. Remove J3 cover and cut the nylon band, which connect cable to clamp (2) referring to section 4.8. Pull out the cable of the J3 arm to the J3 casing side through the pipe. In this time, pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relayed connector caught. Remove bolt (1) and clamp (2). Remove bolt (3), (4) and J3 arm (13). Pay attention not to damage oil seal. Note that there is a possibility that grease goes out. Wipe the grease of the gear (12) off. In this time, pay attention not to damage the tooth side. Remove bolt/plated bolt (6) and reducer (10). Remove seal bolt (5) and pipe (9). Remove seal bolt (7) and gear (12). Assemble it in the opposite procedure after exchanging reducer for the new article. - When installing reducer, spread grease on teeth of Wave generator, and install O-ring (11) without forgetting. (In case of J4-axis reducer, wave generator is assembled in reducer when it is shipped.) Also, pay attention to the phase of bolts referring to Fig.4.9(c). - Spread grease on surroundings of the gear. - When installing reducer to J3 casing apply bolt (3) after applying all bolt (4). - When installing J3 arm, confirm the thing that the oil seal (8) is at the position, and note that the lip cannot be turned over. - When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L or LR Mate 200iC/5C,5LC,5WP is specified, spread sealant to the each part referring to Fig.4.9 (b).

5 6 7 8 9 10 11

CAUTION Do not apply grease to the O-ring (11). Otherwise, hardening of sealant is prevented, causing a grease leak.
12 Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.).

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6 7

9 13

10 11

12

Fig. 4.9(a) Replacing J4-axis reducer Parts Name 1 2 3 4 5 BOLT CLAMP J4-1 BOLT BOLT SEAL BOLT BOLT PLATED BOLT PLATED BOLT SEAL BOLT OIL SEAL PIPE Specifications Number Loctite Torque N-m (kgf-cm)

A6-BA-4X8 1 A290-7139-X432 2 A6-BA-3X30 4 2.0Nm (20kgfcm) A6-BA-3X35 10 2.0Nm (20kgfcm) A97L-0218-0423#030606 4 1.3Nm (13kgfcm) A6-BA-3X25(*1) 9 2.0Nm (20kgfcm) 6 A97L-0218-0496#M3X25BC (*2) 9 2.0Nm (20kgfcm) A97L-0218-0496#M3X25EN (*3) 9 2.0Nm (20kgfcm) 7 A97L-0218-0423#030505 6 1.3Nm (13kgfcm) 8 A98L-0040-0049#02603707 1 9 A290-7139-X421 1 A97L-0218-0815#80(*4) 1 LT518 10 J4 REDUCER A97L-0218-0815#80C(*3) 1 LT518 11 O-RING (Attached to J4 REDUCER) 1 12 GEAR J4-2 A290-7139-X412 1 A290-7139-X402(*4) 1 13 J3 ARM 1 A290-7139-Y402(*5) 1 A290-7139-Z402(*6) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC, LR Mate 200iC/5Lis specified (*5) When LR Mate 200iC/5LC,5C is specified. (*6) When LR Mate 200iC/5WP is specified.

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4.REPLACING PARTS
A

B-82585EN/02

Pipe

J3 casing side of reducer(*1) PIPE J3 casing side of J3 arm Apply Loctite 518 to the

or

part (*1)

SECTION A-A

(*1)Severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H or LR Mate 200iC/5C,5LC,5WP

Applying area of LT518 Severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5H or LR Mate 200iC/5C,5WP Severe dust/liquid protection specification of LR Mate 200iC/5L or LR Mate 200iC/5LC

Fig. 4.9(b) Spread range of sealant

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4.REPLACING PARTS

M3X35(10) M3X30(4) (M3X35)

Fig. 4.9(c) Spread range of sealant

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4.10

REPLACING J5-AXIS MOTOR

Replacing procedure CAUTION This mechanism becomes J4 axis in 5H. When you replace part of 5H, read J5/J6 as J4/J5.
1 2 3 4 5 Turn off the power of the controller. Remove bolt/plated bolt (1) and J3 arm cover (2). When packing is attached, remove packing (12), too. Remove bolt/plated bolt (3) and J3 arm cover (4). When packing is attached, remove packing (13), too. Loosen a bolt (5) a little and lower the tension of the belt (6) and remove belt (6). Remove the bolt (14) when you do not remove the belt easily. Pull cable from upper side of J5-axis motor and remove all relay connector.

CAUTION
When the belt is removed, the wrist moves to bellow side. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 6 7 8 9 Remove bolt (5) and motor (11). Remove cable K110, K111 from motor (11). Remove seal bolt (7), washer (8), motor pulley (9) and key (10). Assemble it in the opposite procedure after exchanging motor and packing for the new article. Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. 10 Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.). In this time, perform not only J5-axis but also J6-axis.

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4 11 9 7 8 A 5 2

10

13 3
Fig. 4.10(a) Replacing J5-axis motor

6 12

TENSION ADJUSTING BOLT 14

VIEW A
Fig. 4.10(b) Replacing J5-axis motor

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4.REPLACING PARTS
Parts Name BOLT 1 PLATED BOLT PLATED BOLT Specifications Number Loctite

B-82585EN/02

Torque N-m (kgf-cm)

A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm) A97L-0218-0496#M4X12EN (*3) 11 4.5Nm (46kgfcm) A290-7139-X405(*1) 1 A290-7139-X407 (*2) 1 2 J3 ARM COVER A290-7139-Y407 (*4) 1 A290-7139-Z407 (*5) 1 BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) 3 PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm) PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 4.5Nm (46kgfcm) A290-7139-X405(*1) 1 A290-7139-X407 (*2) 1 4 J3 ARM COVER A290-7139-Y407 (*4) 1 A290-7139-Z407 (*5) 1 5 BOLT A97L-0218-0504#M5X12 3 5.6Nm (57kgfcm) 6 BELT A98L-0040-0227#006-152 1 7 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm) 8 WASHER A290-7210-X532 1 9 MOTOR PULLEY A290-7139-X413 1 10 KEY JB-HKY-3X3X6B 1 With brake A06B-0117-B855#0049 1 11 MOTOR No brake A06B-0117-B205#0049 1 12 PACKING A290-7139-X454 (*6) 1 13 PACKING A290-7139-X454 (*6) 1 14 BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm) (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC/5LC,5C is specified. (*5) When LR Mate 200iC/5WP is specified. (*6) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L or LR Mate 200iC/5C,5LC,5WP is specified

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4.REPLACING PARTS

4.11

REPLACING J5-AXIS REDUCER

Replacing procedure CAUTION This mechanism becomes J4 axis in 5H.When you replace part of 5H, read J5/J6 as J4/J5.
1 2 3 4 Turn off the power of the controller. Remove both side of J3-arm cover referring to Section 4.10. Remove belt (1) referring to Section 4.10. Pull out cable from upper side of J5-axis motor and remove all relay of cable.

CAUTION
When the belt is removed, the wrist moves to bellow side. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 5 6 7 Remove seal bolt (2), washer plate (3) and pulley (4) Remove key (6) and bolt (7). Remove seal bolt (8) and J3 arm (9). When severe dust/liquid protection specification is specified, remove packing (16), too. In this time, pay attention not to damage oil seal (5). Pay attention that there is a possibility that grease goes out, too. 8 Remove relay of cable K112, K113 and K106, K107. 9 Remove bolt/plated bolt (10) and remove reducer (13). 10 Replace reducer and packing to new one, and assemble robot by opposite procedure. In this time, pay attention below. - Fill grease to the reducer. It is total 7ml greasing in inside of reducer, gear and bearing of wave generator and install it horizontally. Install O-ring (11) and (14) and wave washer (15) without forgetting. - Apply grease to the lip of the Oil seal (5) - Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. - When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L or LR Mate 200iC/5C,5LC,5WP is specified, spread sealant to the reducer referring to Fig.4.11 (b).

CAUTION Do not apply grease to the O-ring (11). Otherwise, hardening of sealant is prevented, causing a grease leak.
11 Perform mastering (See subsection 6.2 and refer to section 8 of OPERATORS MANUAL.). In this time, perform not only J5-axis but also J6-axis.

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9 8

16 1

12

13 14 15
Parts Name 1 2 3 4 5 6 7 8 BELT SEAL BOLT WASHER PLATE PULLEY OIL SEAL KEY BOLT SEAL BOLT Specifications

6 11 10
Number 1 3 1 1 1 1 12 7 1 1 1 9 9 9 1 1 1 1 1 1 1 Loctite

3 4

Fig. 4.11(a) Replacing J5-axis reducer Torque N-m (kgf-cm) 1.3Nm (13kgfcm)

A98L-0040-0227#006-152 A97L-0218-0423#030606 A290-7139-X231 A290-7139-X414 A98L-0040-0223#01001805 JB-HKY-3X3X6B A6-BA-3X8 A97L-0218-0423#041616 A290-7139-X403(*1) 9 J3 ARM 2 A290-7139-Y403(*2) A290-7139-Z403(*3) BOLT A6-BA-3X22(*4) 10 PLATED BOLT A97L-0218-0496#M3X22BC (*5) PLATED BOLT A97L-0218-0496#M3X22EN (*6) 11 O-RING (Attached to J5 REDUCER) 12 WAVE GENERATOR (Attached to J5 REDUCER) A97L-0218-0816#50(*1) 13 J5 REDUCER A97L-0218-0816#50C(*6) 14 O-RING (Attached to J5 REDUCER) 15 WAVE WASHER (Attached to J5 REDUCER) 16 PACKING A290-7139-X453 (*7) (*1) When LR Mate 200iC, LR Mate 200iC/5L,5H is specified.

2.0Nm (20kgfcm) 4.5Nm (46kgfcm)

2.0Nm (20kgfcm) 2.0Nm (20kgfcm) 2.0Nm (20kgfcm)

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(*2 )When LR Mate 200iC/5LC,5C is specified. (*3) When LR Mate 200iC/5WP is specified. (*4) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H (*5) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H (*6) When LR Mate 200iC/5LC,5WP,5C is specified. (*7) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP 5C is specified.

APPLY LOCTITE 518 TO OF O-RING(11) SIDE. DON'T PUT LOCTITE INSIDE THE REDUCER.
Fig. 4.11(b) Spread range of sealant to J5-reducer (When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP 5C is specified.)

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4.12

REPLACING J6-AXIS MOTOR

Replacing procedure CAUTION This mechanism becomes J5 axis in 5H.When you replace part of 5H,read J6 as J5.
1 2 3 Turn off the power of the controller. Remove both side of J3 arm cover of J3 arm. Loosen tension adjusting bolt and lower tension and remove belt (1) referring to Fig. 6.1.1(b). Loose the bolt (9) and remove pulley if it is difficult to remove the belt.

CAUTION
When the belt (1) is removed, the wrist moves to bellow side. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 4 Loosen bolt (2) and lower tension and remove belt (3).

CAUTION
When the belt (3) is removed, the wrist become rotatable, When end effector is attached, fix it so that the wrist should not collide with surroundings. 5 6 7 8 Remove bolt (2) motor (8). Remove cable K112, K113 from motor (8). Remove seal bolt (4), washer (5), motor pulley (6) and key (7). Assemble it in the opposite procedure after exchanging motor and packing for the new article. Adjust the tension of the belt referring to Section 6.1 after the installation of the belt Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.). In this time, perform not only J6-axis but also J5-axis.

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1 A 2 4 5 6 8

7 B 3
Fig. 4.12(a) Replacing J6-axis motor

TENSION ADJUSTING BOLT

TENSION ADJUSTING BOLT

VIEW A

VIEW B
Fig. 4.12(b) Replacing J6-axis motor

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4.REPLACING PARTS
Parts Name 1 BELT FLANGE 2 SOCKET BOLT 3 BELT 4 SEAL BOLT 5 WASHER 6 MOTOR PULLEY 7 KEY 8 MOTOR 9 BOLT Specifications A98L-0040-0227#006-152 A97L-0218-0504#M5X12 A98L-0040-0227#006-100 A97L-0218-0423#030606 A290-7210-X532 A290-7139-X413 JB-HKY-3X3X6B No brake A06B-0117-B205#0049 With brake A06B-0117-B855#0049 A97L-0218-0423#030606 Number 1 3 1 1 1 1 1 1 3 Loctite

B-82585EN/02

Torque N-m (kgf-cm)

1.3Nm (13kgfcm)

1.3Nm (13kgfcm)

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4.13

REPLACING WRIST UNIT

Replacing procedure CAUTION If you replace unit of 5H, read J5/J6 as J4/J5.
1 2 3 Turn off the power of the controller. Replacing both side of J3 arm cover of J3 arm referring to Section 4.10. Remove belt (1), (8) referring to Section 4.12.

CAUTION
When the belt (1), (8) is removed, the wrist moves to bellow side or rotate. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 4 5 6 7 8 9 10 Remove seal bolt (9), washer (10), pulley (11) and key (12). Remove seal bolt (13) and J3 arm (14). When packing is attached, remove packing (21), too. Remove relay of cable K112, K113 of J6-axis motor and cable K107 and K108. Remove seal bolt (2), washer plate (3) and pulley (4) Remove bolt (7), wrist unit (20) and key (5). In this time, pay attention not to damage oil seal. Pay attention that there is a possibility that grease goes out, too. Remove bolt/plated bolt (19) and J5-axis reducer (16). Replace wrist unit to new one and attach it. Attach reducer horizontally after apply greasing to gear of reducer. In this time, replace wave washer (15), O-ring (17), (18) without forgetting, too. Apply greasing to the lip of the oil seal (6). Assemble it in the reverse order of 3-8. Adjust belt referring to Section 6.1. Install J3 arm cover. Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.). In this time, perform not only J6-axis but also J5-axis.

11 12 13 14

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14 13 8 1012 9

21 1 16 15 17 18 19
Fig. 4.13 Replacing wrist unit

5 2 7 4 3

11

20

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4.REPLACING PARTS
Specifications A98L-0040-0227#006-152 A97L-0218-0423#030606 A290-7139-X23 1 A290-7139-X414 JB-HKY-3X3X6B A98L-0040-0223#01001805 A6-BA-3X8 A98L-0040-0227#006-100 A97L-0218-0423#030606 A290-7210-X532 A290-7139-X413 JB-HKY-3X3X6B A97L-0218-0423#041616 A290-7139-X403(*1) A290-7139-Y403(*2) A290-7139-Z403(*3) (Attached to J5 REDUCER) A97L-0218-0816#50(*1) A97L-0218-0816#50C(*4) (Attached to J5 REDUCER) (Attached to J5 REDUCER) A6-BA-3X22(*5) A97L-0218-0496#M3X22BC (*6) A97L-0218-0496#M3X22EN (*4) A290-7139-V501(*5) A290-7139-V502 (*6 A290-7139-V521 (*2) A290-7139-V531 (*3) A290-7139-X453 (*7) Number 1 3 1 1 1 1 12 1 1 1 1 1 7 1 1 1 1 1 1 1 1 9 9 9 1 1 1 1 1 Loctite Torque N-m (kgf-cm) 1.3Nm (13kgfcm)

Parts Name 1 2 3 4 5 6 7 8 9 10 11 12 13 BELT SEAL BOLT WASHER PLATE PULLEY KEY OIL SEAL BOLT BELT SEAL BOLT WASHER MOTOR PULLEY KEY SEAL BOLT

2.0Nm (20kgfcm) 1.3Nm (13kgfcm)

4.5Nm (46kgfcm)

14 J3 ARM 2 15 WAVE WASHER 16 J5 REDUCER 17 O-RING 18 O-RING BOLT 19 PLATED BOLT PLATED BOLT 20 WRIST ASSY

2.0Nm (20kgfcm) 2.0Nm (20kgfcm) 2.0Nm (20kgfcm)

21 PACKING

(*1) When LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2 )When LR Mate 200iC/5LC,5C is specified. (*3)When LR Mate 200iC/5WP is specified. (*4 )When LR Mate 200iC/5LC,5WP,5C is specified. (*5) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H (*6) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H (*7) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP 5C is specified.

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4.14

REPLACING J6-AXIS REDUCER

Replacing procedure CAUTION This mechanism becomes J5 axis in 5H.When you replace part of 5H,read J6 as J5.
1 2 3 4 5 6 7 8 Make to posture that J6 turns to the right under and turn off the power of the controller as shown in Fig.4.14 (a). Remove bolt (1) and reducer. Remove seal bolt (3), washer (4) and wave generator (5). Remove O-ring (6). Apply greasing to bearing of wave generator (5) to which attach new reducer and install to the robot. Greasing total 6ml inside and gear of reducer (2) and wave generator by using the injection syringe. Install new reducer (2) to the robot. In this time, replace O-ring (6) to new one, too. Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.). In this time, perform not only J6-axis but also J5-axis.

6 5 4 3 2 1
Fig. 4.14(a) Replacing J6-axis reducer

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4.REPLACING PARTS

M3X25

Fig. 4.14(b) Assembling phase of J6-axis reducer Parts Name BOLT 1 PLATED BOLT PLATED BOLT Specifications Number Loctite Torque N-m (kgf-cm)

A6-BA-3X25 (*1) 8 2.0Nm (20kgfcm) A97L-0218-0496#M3X25BC (*2) 8 2.0Nm (20kgfcm) A97L-0218-0496#M3X25EN (*3) 8 2.0Nm (20kgfcm) A97L-0218-0817#50(*4) 1 2 REDUCER A97L-0218-0817#50C(*3) 1 3 SEAL BOLT A97L-0218-0432#030808 1 1.3Nm (13kgfcm) 4 WASHER A290-7210-X532 1 5 WAVE GENERATOR (ATTACHED TO J6 REDUCER) 1 6 O RING (ATTACHED TO J6 REDUCER) 1 2.0Nm (20kgfcm) (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP 5C is specified. (*4) When LR Mate 200iC, LR Mate 200iC/5H,5L is specified.

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4.15

REPLACING J3 BELT
1 2 3 Turn off the power of the controller. Remove blot/plated bolt (1) and J2 arm cover (2). When packing is attached, remove packing (3), too. Loosen tension adjusting bolt and lower tension and remove belt (4) referring to Fig.4.15.

Replacing procedure

CAUTION When removing the belt, put the part beyond the J3 housing on a workbench to prevent the arm from dropping.
Replace belt and packing to new one and do the opposite procedure. In this time, pay attention below. - Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. 5 Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.). 4

2 3

TENSION ADJUSTING BOLT

Fig. 4.15 Replacing J3 belt

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4.REPLACING PARTS
Specifications Number Loctite Torque N-m (kgf-cm)

Parts Name BOLT 1 PLATED BOLT PLATED BOLT

A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm) A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm) A290-7139-X306(*1) 1 A290-7139-X308 (*2) 1 2 J2 ARM COVER A290-7139-Y308 (*4) 1 A290-7139-Z308 (*5) 1 3 PACKING A290-7139-X355 (*6) 1 4 BELT A98L-0040-0190#007-098 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC/5LC,5C is specified. (*5) When LR Mate 200iC/5WP is specified. (*6) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

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4.16

REPLACING J5/J6 BELT

Replacing procedure CAUTION

When replacing 5H,please read J5/J6 as J4/J5. 1 2 3 4 Turn off the power of the controller. Remove bolt/plated bolt (1) and J3 arm cover (2). When packing is attached, remove packing (3), too. Remove bolt/plated bolt (4) and J3 arm cover (5). When packing is attached, remove packing (6), too. In case of replacing J5 belt, loosen tension adjusting bolt and lower tension and remove belt referring to Fig.6.1.1 (b). In case of replacing J6 belt, loosen tension adjusting bolt and lower tension and remove belt referring to Fig.6.1.1(c).

CAUTION
When the belt (7) is removed, the wrist moves to bellow side or rotate. Do as the wrist is put on the stand so That the wrist should not collide with surroundings.

CAUTION
When the belt (8) is removed, the wrist become rotatable, When end effector is attached, fix it so that the wrist should not collide with surroundings. Replace belt and packing to new one and do the opposite procedure. In this time, pay attention below. - Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. 6 Perform mastering (See sub section 6.2 and refer to section 8 of OPERATORS MANUAL.). When J5 belt is replaced, perform mastering not only J5-axis but also J6-axis. 5

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4.REPLACING PARTS

6 5

3 2

1 4 8
Fig. 4.16 Replacing J5/J6 belt Parts Name BOLT 1 PLATED BOLT PLATED BOLT Specifications Number Loctite Torque N-m (kgf-cm)

A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm) A97L-0218-0496#M4X12EN (*3) 11 4.5Nm (46kgfcm) A290-7139-X405(*1) 1 A290-7139-X407 (*2) 1 2 J3 ARM COVER A290-7139-Y407 (*4) 1 A290-7139-Z407 (*5) 1 3 PACKING A290-7139-X454 (*6) 1 BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) 4 PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm) PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 4.5Nm (46kgfcm) A290-7139-X405(*1) 1 A290-7139-X407 (*2) 1 5 J3 ARM COVER A290-7139-Y407 (*4) 1 A290-7139-Z407 (*5) 1 6 PACKING A290-7139-X454 (*6) 1 7 BELT A98L-0040-0227#006-152 1 8 BELT A98L-0040-0227#006-100 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC/5LC,5C is specified. (*5) When LR Mate 200iC/5WP is specified. (*6) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

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4.17

REPLACING SOLENOID VALVE

1 2 3 4 5 Make J3-axis to posture in which SV PLATE is removed easily. Turn off the power of the controller. Remove bolt (1), (3) and SV PLATE (2). When severe dust/liquid protection specification is specified, remove packing (5), too. Remove relay of air tube and take solenoid valve out. Replace solenoid valve and packing to new one, and do the opposite procedure.

Replacing procedure

5 1 2

3 4

Fig. 4.17 Replacing Solenoid valve

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4.REPLACING PARTS
Specifications Number Loctite Torque N-m (kgf-cm)

Parts Name BOLT PLATED BOLT 1 PLATED BOLT PLATED BOLT

A6-BA-4X8(*1) 4 A97L-0218-0546#040808BC(*2) 4 A97L-0218-0546#040808EN(*3) 4 A97L-0218-0546#041010EN(*4) 4 A290-7139-X433 1 2 SV PLATE A290-7139-Y433(*3) 1 A290-7139-Z433(*4) 1 BOLT A6-BA-4X8(*1) 2 PLATED BOLT A97L-0218-0546#040808BC(*2) 2 3 PLATED BOLT A97L-0218-0546#040808EN(*3) 2 PLATED BOLT A97L-0218-0546#041010EN(*4) 2 1 A97L-0218-0113#D3R or A97L-0218-0113#D3 or SOL VALVE 4 A97L-0218-0113#D2 or A97L-0218-0113#D1 5 PACKING A290-7139-X452 (*5) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5C is specified. (*4) When LR Mate 200iC/5WP is specified. (*5) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

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4.18

SEALANT APPLICATION
1 After dismounting the reducer from the arm, apply releasant (Loctite Gasket Remover) to the arms surface from which the reducer was dismounted, then wait until the sealant (Loctite 518) becomes softened (for about 10 minutes). Remove the softened sealant from the surface using a spatula. Blow air onto the surface to be sealed to remove dust from the tapped holes. Sufficiently degrease the reducers surface to be sealed and the arms surface to be sealed, using a cloth dampened with alcohol. Polish the arms surface to be sealed with an oil stone, and degrease it with alcohol again.

Washing and degreasing the surfaces to be sealed

2 3 4

CAUTION Oil may drip from the inside of the reducer. After degreasing, make sure that no oil is dripping. Applying sealant
5 6 Make sure that the reducer and the arm is dry (with no alcohol remaining). If they are still wet with alcohol, wipe them dry. Apply sealant (Loctite 518) to the surfaces.

CAUTION The portions to which sealant is to be applied vary from one axis to another. See descriptions about reducer replacement for the relevant axes for details. Assembling
7 To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant was wiped off, apply again. After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get closer.

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5.REPLACING CABLES

REPLACING CABLES
Replace the cables every four years (15,360 hours). When the cable is broken or damaged or shows signs of wear, replace it according to this chapter.

Precautions to be observed when handling the pulse coder cable

The pulse coder cable is provided with a marking tie, as shown below, to warn against disconnecting the cable during transportation, installation, or maintenance. If the cable with the marking tie is disconnected, mastering must be performed again. Therefore, do not disconnect the cable except when replacement of the motor, the pulse coder, the reducer, and the cable are necessary.

BATTERY BACKUP DON'T DISCONNECT

Fig. 5 marking label

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5.1

CABLE WIRING
Followings are the routing of the robot cables.
K114 (End effector) K112 (J6 power) K113 (J6 pulse coder)

K108 (RO)

K110 (J5 power) K111 (J5 pulse coder)

K106 (J4 to J6 power) K107 (J4 to J6 pulse coder)

K109 (J4 power)

K102 (J2 power) K103 (J2 pulse coder)

K104 (J3 power) K105 (J3 pulse coder)

K101 ( toJ6 power,pulse coder)

Fig.5.1 (a) Routing of the robot cables (LR Mate 200iC, LR Mate 200iC/5L,5LC,5C,5WP,)

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5.REPLACING CABLES
K114 (End effector) K112 (J5 power) K113 (J5 pulse coder)

K108 (RO)

K110 (J4 power) K111 (J4 pulse coder)

K106 (J4 to J5 power) K107 (J4 to J5 pulse coder)

K102 (J2 power) K103 (J2 pulse coder)

K104 (J3 power) K105 (J3 pulse coder)

K101 ( to J5 power pulse coder)

Fig. 5.1 (b) Routing of the robot cables (LR Mate 200iC/5H)

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5.2

CABLE FORMING
When replacing cables, clamp the cable at the position specified in Fig.5.2 (a) to (d) using a clamp or a nylon band. Otherwise, cables can be loosened or pulled by force to cause their disconnection. Refer to the Fig.5.2 (a) to (d) for the cable clamp.

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5.REPLACING CABLES
relay in J2 base Clamp J2-1
M2M1
M2M1 K102

Clamp J2-2
M2M

M2M

M2BK

K102

M2BK M3M

Connector plate
M3M1
M3M1 K104

M3BK

M1M

M1M

K104

Clamp J2-2 Clamp J4-1 Clamp J3-1

M3M

M3BK

relay in J3 arm
M4M1 K109 M4M

M4M1

M4M

M456M1

M456M1 K106

M1BK

M1BK

K109
M5M1

K106 Clamp J1-1

K101

Clamp J4-2
M6M1

K110

M 5M1 K110

M5M

M5M

M2P1

K103
M3P1
BA ERY B TT ACKUP DON 'T DIS CONNE CT

M2P1 K103

Clamp J2-2
M3P
BA ER B TT Y ACKUP DO N'T DI ONN SC ECT

M2P

B ATT ERY BACKUP DON'T DI SCONNECT

BA ER B TT Y ACKUP DO N'T DI ONN SC ECT

M2P K112

M3P M4P
M4P

M1P

BAT TERY BACKUP DON'T D ISCONNECT

M1P

K105

M3P1 K105

Clamp J2-2

BA ERY BACKUP TT DON'T DI SCONNECT

Clamp J4-1
M5P1
BAT TERY BACKUP DON'T D ISCONNECT

relay in J3 arm
M5P1 K111 M5P
BATT ERY B KUP AC DON'T DI SCONN T EC

M 6M1 K112

M6M

M6M

M5P

M456PEE1

K107

M456PEE1 K107

K101

B ATT ERY BACKUP DON'T DI SCONNECT

Clamp J4-2
M6P1
BAT TERY BACKUP DON'T D ISCONNECT

K111

Clamp J3-1
EE1

K113

M6P1 K113

M6P

BATTERY BAC KUP DON'T DISCONNEC T

M6P

K114
YV1

K108

YV1 K108

YV2

Connected to solenoid valve

Fig.5.2 (a) Cable externals chart of Mechanical unit (LR Mate 200iC 3-axes brake type)
relay in J2 base Clamp J2-1
M2M1 M2M1 K102 M2M

Clamp J2-2 M2M

M2BK

K102

M2BK M3M relay in J3 arm

M3M1

M3M1 K104

M3M

Connector plate

Clamp J2-2

M3BK

M4M1

M4M1 K109

M4M

K104

M3BK

EE1 K114

EE

EE

M4M

M1M

M1M
M456M1 M456M1 K106

Clamp J4-1

M4BK

K109

M4BK M5M

M5M1

M1BK

M1BK Clamp J1-1

K106 Clamp J3-1

Clamp J4-2

M5BK

K110

M5M1 K110

M5M

M5BK M6M

K 101

M6M1

M2P1

K103
M3P1
BATTERY BACKUP DON'T DISCONNECT

M2P1 K103

Clamp J2-2
M3P
BATTERY BACKUP DON'T DISCONNECT

M2P

BATTERY BACKUP DON'T DISCONNECT

BATTERY BACKUP DON'T DISCONNECT

M3P M4P

M1P

BATTERY BACKUP DON'T DISCONNECT

M1P

K105

M3P1 K105

Clamp J2-2

Clamp J4-1
M5P1

M4P

BATTERY BACKUP DON'T DISCONNECT

relay in J3 arm

M6BK

M2P

K112

M6M1 K112

M6M

M6BK

M456PEE1

M456PEE1 K107

K101

BATTERY BACKUP DON'T DISCONNECT

Clamp J4-2
M6P1
BATTERY BACKUP DON'T DISCONNECT

K111

M5P1 K111

M5P

BATTERY BACKUP DON'T DISCONNECT

BATTERY BACKUP DON'T DISCONNECT

M5P

K107

M6P K113
M6P1 K113 M6P
BATTERY BACKUP DON'T DISCONNECT

Clamp J3-1
EE1

K114
YV1

K108

YV1 K108

YV2

Connected to solenoid valve

Fig.5.2 (b) Cable externals chart of Mechanical unit (LR Mate 200iC, LR Mate 200iC/5L,5LC,5C,5WP 6-axes brake type)

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EE1 K114

EE

EE

5.REPLACING CABLES
relay in J2 base Clamp J2-1
M2M1
M2M1 K102

B-82585EN/02

Clamp J2-2
M2M

M2M

M2BK

K102

M2BK M3M

Conncetor plate
M3M1
M3M1 K104

M3BK

M1M

M1M

K104

Clamp J2-2

M3M

M3BK

relay in J3 arm
M4M1 K109 M4M

M4M1H

M4M

M456M1

M456M1 K106

M1BK

M1BK

K110 Clamp J3-1

M5M1H

K106 Clamp J1-1

K101

Clamp J4-2 Clamp J4-1 Clamp J2-2

M3P
BATT Y BAC P ER KU DO N'T DI ONNEC SC T

K112

M2P1

K103
M3P1
BATT ERY BACKUP DON 'T D ISCON CT NE

M2P1 K103

M2P

BATTER BACKU Y P DO N'T DISC ONNECT

BATT Y BAC P ER KU DO N'T DI ONNEC SC T

M2P

M3P

M1P

BATTE RY BACK UP D ON'T DIS CONNECT

M1P

K105

M3P1 K105

Clamp J2-2

Clamp J4-1 Clamp J4-2

M4P1H
BAT TE RY BAC KUP DON' T DIS CONNE CT

relay in J3 arm
M4P1 K111 M4P
BATT ERY B ACKUP DON 'T DI SCO ECT NN

M 5M1 K 110

M5M

M5M

M4P

K111
M5P1H

K107

M456PEE1 K107

M456PEE1

K101

BATTER BACKU Y P DO N'T DISC ONNECT

Clamp J3-1
EE1

K113

M5P1 K113

M5P

BAT TE RY BAC KUP DON' T DIS CONNE CT

BA TTERY B ACKUP DON 'T DISCO ECT NN

M5P

K114
YV1

K108

YV1 K108

YV2

Connected to solenoid valve

Fig.5.2(c) Cable externals chart of Mechanical unit (LR Mate 200iC/5H 3-axes brake type)
relay in J2 base Clamp J2-1
M2M1
M2M1 K102

Clamp J2-2
M2M

M2M

M2BK

K102

M2BK M3M

Connector plate
M3M1
M3M1 K104

M3BK

M1M

M1M

K104

Clamp J2-2

M3M

EE1 K114

EE

EE

M3BK

M4M1 K110

M4M1H

M4M

relay in J3 arm

M4M

M456M1

M456M1 K106

M1BK

M1BK

K106 Clamp J1-1

K101

Clamp J3-1 Clamp J4-1

Clamp J4-2
M5M1H M5M1 K112

M4BK

K110

M4BK M5M

M2P1

K103
M3P1
B TER BACKUP AT Y DO N'T DI ONN T SC EC

M2P1 K103

Clamp J2-2
M3P
B ATT Y BAC P ER KU DO T N' DI ON SC NEC T

M2P

BATTERY B ACKUP DON'T DISCONN ECT

BATT Y BAC P ER KU DO T N' DI ON SC NEC T

M2P

M3P

M1P

BAT RY BA UP TE CK D 'T ON D CO IS NNE CT

M1P

K105

M3P1 K105

Clamp J2-2

Clamp J4-1 Clamp J4-2

M4P1H
BAT TE RY BAC KU P DON' T DISC ONNE CT

relay in J3 arm
M4P1 K111 M4P
BATTERY BACKUP DON'T DISCONNECT

M5BK

K112

M5M

M5BK

M4P

K111

M5P1H

Clamp J3-1
EE1

K113

M5P1 K113

M5P

K107

M456PEE1 K107

M456PEE1

K101

BATTERY B ACKUP DON'T DISCONN ECT

BAT TE RY BAC KU P DON' T DISC ONNE CT

B ATTER BACKUP Y DO N'T DISC ONNECT

M5P

K114
YV1

K108

YV1 K108

YV2

Connected to solenoid valve

Fig.5.2 (d) Cable externals chart of Mechanical unit (LR Mate 200iC/5H 5-axes brake type)

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EE1 K114

EE

EE

B-82585EN/02

5.REPLACING CABLES

5.3

CABLE AND AIR TUBE REPLACEMENT

This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables. See section 5.1 for the configuration of the mechanical unit cables. It is necessary to perform after cable replacement. Refer to chapter 6 MASTERING or chapter 8 OPERATORS MANUAL in advance. (If pulse coder cable is not replaced, mastering is not necessary.)

5.3.1

REPLAING CABLE K101 and Air tube (Connector plate to J2 base)

1 Turn off the power of the controller and remove cable of controller side from connector plate of back of J1-axis. 2 Remove robot from floor plate, knock down the robot sidewise. 3 Remove J2 base cover referring to Fig.5.3.1 (a). 4 Remove all relay of cable K102, K103, K104, K105, K106, K107, K108 and K101.Remove relay of air tube similarly. (In case of LR Mate 200iC/5C,5LC there are two white air tube and one black air tube, In case of other models there is one white air tube and one black air tube.) 5 Remove bolt (5) and cover U (6). When packing is attached, remove packing (7), too. 6 If necessary, remove cover B. (See Fig.5.3.1(c)) 7 Cut the nylon band which connect cable and air tube to clamp J1-2. 8 Cut the nylon band of battery box terminal and remove cable. 9 Remove connector plate. 10 Pull cable and air tube in J2 base to J1 base side. In this time pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes 11 Replace cable and air tube for the new article and assemble them by opposite procedure. When packing is attached, be sure to replace packing to new one. 12 Perform mastering (See section 6.2 and referring to chapter 8 of OPERATORS MANUAL.).

Replacing procedure

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5.REPLACING CABLES

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4 5 6 7 3

Fig.5.3.1 (a) Remove the J2 base cover Parts name BOLT 1 PLATED BOLT PLATED BOLT Specifications Number Loctite Torque N-m (kgf-cm)

A97L-0218-0504#M4X10(*1) 3 2.0Nm(20kgfcm) A97L-0218-0496#M4X12BC (*2) 8 4.5Nm(46kgfcm) A97L-0218-0496#M4X12EN (*3) 8 4.5Nm(46kgfcm) A290-7139-X305(*1) 1 A290-7139-X307 (*2) 1 2 J2 BASE COVER A290-7139-Y307 (*4) 1 A290-7139-Z307 (*5) 1 3 SPONGE A290-7139-X346 1 4 PACKING A290-7139-X354 (*6) 1 A6-BA-4X8(*1) 4 5 BOLT A97L-0218-0546#040808BC(*2) 4 A97L-0218-0546#040808EN(*3) 4 6 COVER U A290-7139-X332 1 7 PACKING A290-7139-X356(*6) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC/5LC,5C is specified. (*5) When LR Mate 200iC/5WP is specified. (*6) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

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5.REPLACING CABLES

B B
K102 Cable K102 K103 Cable K103 AIR 1 (BLACK) Panel union AIR 2 (WHITE)

Pulsecoder line (BLUEXWHITE) AIR 1 (BLACK)

SECTION A-A
J2-1 Clamp J2-1 A290-7139-X333 Power line (REDXWHITE) AIR 2 (WHITE) M2M1 M3M1

K104 Cable K104 K105 Cable K105 YV1 M456PEE1 M3P1

SECTION B-B

M2P1

DETAIL C

M456M1

Fig.5.3.1 (b) Replace the cable in J2 base

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5.REPLACING CABLES
D

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E E K102 Cable K102 K103 Cable K103

AIR 1 (O4 BLACK) EXT (O4 WHITE) Panel union AIR 2 (O6 WHITE)

SECTION D-D
K104 Cable K104 K105 Cable K105 Pulsecoder line (BLUEXWHITE) AIR 1 (O4 BLACK) J2-1 Clamp J2-1 A290-7139-X333 Power line (REDXWHITE) AIR 2 (O6 WHITE) M2M1 M3M1

EXT (O4 WHITE) YV1

SECTION E-E

M456PEE1 M3P1 M2P1

DETAIL F

M456M1

Fig.5.3.1 (c) Replace the cable in J2 base (LR Mate 200iC/5L,5LC)

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5.REPLACING CABLES

Fig.5.3.1(d) Remove the cover B (When only severe dust/liquid protection specification is specified) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified. Parts name 1 PLATED BOLT PLATED BOLT Specifications Number Loctite Torque N-m (kgf-cm) A97L-0218-0496#M4X8BC(*1) 9 4.5Nm(46kgfcm) A97L-0218-0496#M4X8EN(*2) 9 4.5Nm(46kgfcm) A290-7139-X233(*1) 1 2 COVER B A290-7139-Y233(*2) 1 3 PACKING A290-7139-X252 1 (*1) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When LR Mate 200iC/5LC,5WP,5C is specified.

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5.REPLACING CABLES
TIE UP WITH NYLON BAND.

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BATTERY BOX TERMINAL SIDE

Power line (REDXWHITE) AIR 2 (WHITE) AIR 1 (BLACK)

ADJUST THE MARKING.

Pulsecoder line AIR 2 (BLUEXWHITE) (WHITE) J1-2 Clamp J1-2 A290-7139-X331 Nylon band

AIR 1 (BLACK)
C

(LR Mate 200iC/5LC,5C)

Except LR Mate 200iC/5LC,5C

DETAIL C

(REDXWHITE) AIR 2 (O6 WHITE) AIR 1 (O4 BLACK) EXT (O4 WHITE)
ADJUST THE MARKING.

Pulsecoder line (BLUEXWHITE) J1-2 Clamp J1-2 A290-7139-X331 Nylon band

DETAIL C
(LR Mate 200iC/5LC,5C)

Fig.5.3.1 (e) Replace the cable in J1 base

NO.1 PIN
Fig.5.3.1 (f) Replace the parts of connector plate

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5.REPLACING CABLES
Specifications Number Loctite Torque N-m (kgf-cm)

Parts name BOLT 1 PLATED BOLT PLATED BOLT 2 BOLT

A6-BA-4X10(*1) 4 2.0Nm(20kgfcm) A97L-0218-0496#M4X10BC (*2) 4 4.5Nm(46kgfcm) A97L-0218-0496#M4X10EN (*3) 4 4.5Nm(46kgfcm) A6-BA-4X8 4 LT242 A290-7139-X233(*4) 1 3 CON.PLATE A290-7139-Y233(*3) 1 4 PACKING A290-7139-X251 (*5) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*5) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

Clamp J1-1 A290-7139-X234

Pulse coder line (BLUEXWHITE)

Power line (REDXWHITE)

Fig.5.3.1 (g) Clamp of J1 base

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5.3.2

REPLAING CABLE K106, K107, K108 and Air tube (J2 base to J3 casing)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Turn off the power of the controller and remove cable of controller side from connector plate of back of J1-axis. Remove the J3 arm cover which is in view of in front of the robot, it is left referring to Fig.5.3.2 (a). When packing is attached, remove packing, too. Drag cable to remove the relay easily. Remove relay of K106 and K110, K112. Remove relay of K107 and K111, K113. Cut the nylon band, which connect cable to clamp J4-2 referring to Fig.5.3.2 (b). Remove J3 cover referring to Fig.5.3.2(c). Remove air tube of six in diameter which color is black and white that has come from J2 base to J3 casing. When packing is attached, remove packing, too. Cut the nylon band, which connect cable to clamp J4-1 referring to Fig.5.3.2 (d). Pull out the cable of the J3 arm to the J3 casing side. In this time, pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes. Remove relay of cable K106 and K109 (In case of LR Mate 200iC/5H,there is no K109.) Cut the nylon band, which connect cable to clamp J3-2 referring to Fig.5.3.2 (d). Remove J2 base cover referring to Section 4.4. When packing is attached, remove packing, too. Cut the nylon band, which connect cable to clamp J2-2 referring to Fig.5.3.2 (e). Remove relay to K101 and air tube. Remove clamp J2-1 from J2 base referring to Fig.5.3.1 (b). Remove guide arm. When packing is attached, remove packing. Remove clamp J3-1 from guide arm. Drag the cable from the upper part and the lower side of the guide arm. In this time, drag it after it passes it on the tip of the part of the connector. Cut the nylon band which connect cable and air tube to clamp J3-2 and sheet referring to Fig.5.3.2 (g) and (h). Replace cable and air tube for the new article and assemble it by opposite procedure. When packing is attached, be sure to replace packing to new one. Perform mastering (See section 6.2 and referring to chapter 8 of OPERATORS MANUAL.).

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5.REPLACING CABLES

3 2 1
Fig.5.3.2 (a) Remove the J2 arm cover Parts name BOLT 1 PLATED BOLT PLATED BOLT Specifications Number Loctite Torque N-m (kgf-cm)

A97L-0218-0504#M4x10(*1) 3 2.0Nm(20kgfcm) A97L-0218-0496#M4X12BC (*2) 11 4.5Nm(46kgfcm) A97L-0218-0496#M4X12EN (*3) 11 4.5Nm(46kgfcm) A290-7139-X405 (*1) 1 A290-7139-X407 (*2) 1 2 J3 ARM COVER A290-7139-Y407 (*4) 1 A290-7139-Z407 (*5) 1 3 PACKING A290-7139-X454 (*6) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC/5LC,5C is specified. (*5) When LR Mate 200iC/5WP is specified. (*6) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

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5.REPLACING CABLES
BLACK YELLOW RED BLUE

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GREEN CABLE

CLEAR NYLON BAND ORANGE

DETAIL D

SECTION C-C

NYLON BAND

MARKING

J4-2 A290-7139-X334

NYLON BAND

Cable

Air tube

Fig.5.3.2 (b) Clamp of J3 arm part

1 3 2

Fig.5.3.2(c) Remove the J3 cover

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5.REPLACING CABLES
Specifications Number Loctite Torque N-m (kgf-cm)

Parts name BOLT 1 PLATED BOLT PLATED BOLT

A97L-0218-0504#M4X10(*1) 4 2.0Nm(20kgfcm) A97L-0218-0417#M4X12BC (*2) 6 4.5Nm(46kgfcm) A97L-0218-0417#M4X12EN (*3) 6 4.5Nm(46kgfcm) A290-7139-X404 (*1) 1 A290-7139-X406 (*2) 1 2 J3 COVER A290-7139-Y406 (*4) 1 A290-7139-Z406 (*5) 1 3 PACKING A290-7139-X451 (*6) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC/5LC,5C is specified. (*5) When LR Mate 200iC/5WP is specified. (*6) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.
AIR2 (WHITE) AIR1 (BLACK) Pulse coder line (BLUEXWHITE) Power line (REDXWHITE)
Cable

NYLON BAND
Cable and air tube

Clamp J4-1 A290-7139-X432 Air tube (O3.18 7pcs)

Clamp J3-2 A290-7139-X431

DETAIL E
AIR TUBE (O6 2pcs) Cable and air tube NYLON BAND

NYLON BAND

Cable AIR1(BLACK)

1A(RED) H002,H003,H004

2A(YELLOW) H003,H004 2B(GREEN) H003,H004 Air tube (O3.18 7pcs) Power line (REDXWHITE)

1B(BLUE) H002,H003,H004 3B(ORANGE) H004 3A(CLEAR) H004

SECTION D-D

AIR TUBE (O6 2;pcs)

Pulse coder line (BLUEXWHITE)

DETAIL F

Fig.5.3.2 (d) Cable clamp in parts of J3 casing

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5.REPLACING CABLES

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Clamp J2-2 A290-7139-X334

CABLE K103 CABLE K105

CABLE K102 CABLE K104

DETAIL H

SECTION G-G

Fig.5.3.2 (e) Cable clamp in J3 casing part

2 1 3 4

Fig.5.3.2 (f) Remove the guide arm Parts name SEAL BOLT 1 SEAL BOLT SEAL BOLT 2 GUIDE ARM 3 BOLT 4 PACKING Specifications A97L-0218-0423#051616(*1) A97L-0218-0546#051616BC(*2) A97L-0218-0546#051616EN(*3) A290-7139-X304(*4) A290-7139-Y304(*5) A290-7139-Z304(*6) A6-BA-4X8 A290-7139-X353 (*7) Number 4 4 4 1 1 1 2 1 Loctite Torque N-m (kgf-cm) 5.6Nm(57kgfcm) 5.6Nm(57kgfcm) 5.6Nm(57kgfcm)

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5.REPLACING CABLES

(*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*5) When LR Mate 200iC/5LC,5C is specified. (*6) When LR Mate 200iC/5WP is specified. (*7) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified. Table 5.3.2 Air tube

(*1) H002,H003,H004,H005,H012,H013,H014,H017,H018,H022,H023,H032,H033 is specified (*2) H004,H005,H014,H015 is specified (*3) H003,H004,H005,H013,H014,H015,H018,H023,H024,H033 is specified

NYLON BAND

NYLON BAND

2 SECOND MARKING AIR 1 (BLACK)

NYLON BAND

ADJUST THE MARKING.

CABLE K107 CABLE K108 3 THIRD MARKING

AIR 2 (WHITE)

NYLON BAND
CABLEK106

SHEET

NYLON BAND
J3-1 A290-7521-X335

J2-2 CLAMP J2-2 A290-7139-X334 (1)

Fig.5.3.2 (g) Cable clamp inside the guide arm (LR Mate 200iC, LR Mate 200iC/5L,5WP,5H)
NYLON BAND

NYLON BAND

2 SECOND MARKING AIR 1 (O4 BLACK) EXT (O4 WHITE)

NYLON BAND

ADJUST THE MARKING.

CABLE K107 CABLE K108 3 THIRD MARKING

AIR 2 (6O WHITE)

NYLON BAND
J2-2 CLAMP A290-7139-X334

SHEET

NYLON BAND

CABLE K106

J3-1 CLAMP J3-1 A290-7139-X335 (1)

Fig.5.3.2 (h) Cable clamp inside the guide arm (LR Mate 200iC/5C,5LC)

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5.3.3

REPLAING CABLE K102, K103, K104, K105, K109, K110, K111, K112, K113
1 2 Turn off the power of the controller. (In case of except LR Mate 200iC/5H) In case of cable K102 and K103, remove J2-axis motor, In case of cable K104 and K105, remove J3-axis motor. In case of cable K109, remove J4-axis motor. In case of cable K110 or K111, remove J5-axis motor. In case of cable K112 or K113, remove J6-axis motor. See section 4 about replacing procedure of motor. (In case of LR Mate 200iC/5H) In case of cable K102 and K103 remove J2-axis motor, In case of cable K104 and K105, remove J3-axis motor. In case of cable K110 or K111, remove J4-axis motor. In case of cable K112 or K113, remove J5-axis motor. See section 4 about replacing procedure of motor. Replace cable to new one and assemble it by opposite procedure. Install motor referring to Section 4. In case of replacing K103 or K104 or K105 or K109 or K111 or K112 or K113, perform mastering referring to section 6.2 or chapter 8 of Operators manual.

3 4 5

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5.REPLACING CABLES

5.3.4

REPLAING CABLE K104

1 2 3 4 5 Turn off the power of the controller. Remove J3 arm cover. (See Fig.5.3.2 (a)) Remove nut on J3 arm. Remove relay of K107 and cable K114. Replace cable to new one, and assemble it by opposite procedure. Spread Loctite referring to Fig.5.3.4 and tighten nut with the specified torque. When packing is attached, be sure to replace packing.
relay to cable K107 Nut (Attached to K114) Tightening torque3.0Nm (31kgfcm) LT262

Cable K114

Fig.5.3.4 Replace the cable K114

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5.3.5

REPLAING AIR TUBE

Replacing procedure of air tube between connector plate to J2 base

1 See section 5.3.1.

Replacing procedure of air tube between J2 base to J3 casing

1 See section 5.3.2.

Replacing procedure of air tube between J3 casing to J3 arm

1 2 3 4 5 6 7 8 9 Turn off the power of the controller. Remove J3 arm cover. (See Fig.5.3.2 (a)) Remove air tube from panel union on J3 motor. Cut the nylon band, which connects air tube to clamp J4-2. Remove J3 cover. (See Fig.5.3.2(c)) Cut the nylon band, which connects air tube to clamp J4-1. Remove the cover of solenoid valve (See Fig.5.3.5(h)) Drag air tube from the part removed by 7. Replace air tube to new one, and install them by opposite procedure. When packing is attached , be sure to replace packing.

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5.REPLACING CABLES

580 300 AIR 1 ( BLACK) 570 290 AIR 2 ( WHITE) Connector panel

J2 J2 base

Fig.5.3.5 (a) Marking of air tube (connector plate to J2 base)( LR Mate 200iC, LR Mate 200iC/5L,5WP,5H)

580 300 AIR 1 (4 BLACK) 570 290 AIR 2 (6 WHITE) 570 290 EXT (4 WHITE) Connector panel J2 J2 base

Fig.5.3.5 (b) Marking of air tube (connector plate to J2 base)(LR Mate 200iC/5C,5LC)

700 340 AIR 1 ( BLACK) 910 570 AIR 2 ( WHITE) J3 J3 casing J2 J2 base 290 290

Fig.5.3.5 (c) Marking of air tube (J2 base to J3 casing) ( LR Mate 200iC, LR Mate 200iC/5WP,5H)

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800 340 AIR 1 ( BLACK) 1010 570 AIR 2 ( WHITE) J3 J3 casing 390 J2 J2 base 390

Fig.5.3.5 (d) Marking of air tube (J2 base to J3 casing) ( LR Mate 200iC/5L)

700 340 AIR 1 (4 BLACK) 910 AIR 2 (6 WHITE) 570 290 290

700 340 EXT (4 WHITE) J3 J3 casing J2 J2 base 290

Fig.5.3.5 (e) Marking of air tube (J2 base to J3 casing) ( LR Mate 200iC/5C)

800 340 AIR 1 (4 BLACK) 1010 AIR 2 (6 WHITE) 570 390 390

800 EXT (4 WHITE) J3 J3 casing 340 390 J2 J2 base

Fig.5.3.5 (f) Marking of air tube (J2 base to J3 casing) ( LR Mate 200iC/5LC)

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5.REPLACING CABLES
RED BLUE

BLACK YELLOW

GREEN
KEY DIRECTION

CABLE

CLEAR NYLON BAND ORANGE

Plug

DETAIL C

SECTION B-B

Panel union

NYLON BAND

MARKING

J4-2 A290-7139-X334

NYLON BAND

A05B-1139-

BLACK (*1)

CLEAR (*2)

ORANGE YELLOW GREEN (*2) (*3) (*3)

RED (*1)

BLUE (*1)

DETAIL A

(*)Refer to table 5.3.

Fig.5.3.5(g) Remove the air tube in J3 arm
1

3 4

Fig.5.3.2 (h) Remove the cover of solenoid valve part

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5.REPLACING CABLES
Parts name BOLT 1 SEAL BOLT SEAL BOLT BOLT 2 SEAL BOLT SEAL BOLT Specifications Number Loctite

B-82585EN/02

Torque N-m (kgf-cm)

A6-BA-4X8(*1) 4 A97L-0218-0546#040808BC(*2) 4 4.5Nm(46kgfcm) A97L-0218-0546#040808EN(*3) 4 4.5Nm(46kgfcm) A6-BA-4X8(*1) 2 A97L-0218-0546#040808BC(*2) 2 4.5Nm(46kgfcm) A97L-0218-0546#040808EN(*3) 2 4.5Nm(46kgfcm) A290-7139-X433(*4) 1 3 SV PLATE A290-7139-Y433(*5) A290-7139-Z433(*6) 4 PACKING A290-7139-X452 (*7) 1 (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is specified. (*4) When LR Mate 200iC,LR Mate 200iC/5L,5H is specified. (*5) When LR Mate 200iC/5LC,5C is specified. (*6) When LR Mate 200iC/5WP is specified. (*7) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.

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5.REPLACING CABLES
Panel union () Air tube (White)

() Air tube (White) () Air tube (Black)

() Air tube (Black)

H001,H006
is specified Panel union () Air tube (Black) () Air tube (Red) () Air tube (White) () Air tube (Black) () Air tube (Blue)

Solenoid valve A97L-0218-0113#D1

Air tube

H002,H032
is specified

Panel union () Air tube (White) () Air tube (Black) Solenoid valve A97L-0218-0113#D2 (1) Air tube () Air tube (Black) () Air tube (Green)

() Air tube (Yellow)

() Air tube (Red)

() Air tube (Blue)

H003,H013,H033
is specified

Panel union

() Air tube (White)

Solenoid valve A97L-0218-0113#D3R (1) (H005,H015) is specified A97L-0218-0113#D3(1) (H004,H014) is specified

Air tube

() Air tube (Black)

() Air tube (Black)

() Air tube (Clear)

( Air tube (Orange)

() Air tube (Yellow)

() Air tube (Green)

() Air tube (Red)

() Air tube (Blue)

H004,H005,H014,H015
is specified

Fig.5.3.5 (i) Remove the air tube of solenoid valve part (LR Mate200iC, LR Mate200iC/5C,5WP,5H)

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5.REPLACING CABLES
Panel union

B-82585EN/02

() Air tube (White)

Panel union Air tube

Solenoid valve A97L-0218-0113#D1 (1)

() Air tube (Black)

() Air tube (Black)

() Air tube (Red)

() Air tube(Blue)

Air tube

H017,H022
is specified
Panel union () Air tube (White)

Solenoid valve A97L-0218-0113#D2 (1) Panel union Air tube

() Air tube (Black)

() Air tube (Black)

() Air tube(Yellow)

() Air tube (Green)

() Air tube(Red)

() Air tube (Blue)

Air tube

H018,H023
is specified
Panel union () Air tube (White)

() Air tube (Black) Solenoid valve A97L-0218-0113#D3(1)

() Air tube (Black)

() Air tube (Clear) () Air tube (Yellow)

() Air tube (Orange)

Panel union Air tube

() Air tube (Green)

() Air tube (Red)

() Air tube (Blue)

Air tube

H024
is specified

Fig.5.3.5 (j) Remove the air tube of solenoid valve part (LR Mate 200iC/5L,5LC)

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6.ADJUSTMENTS

ADJUSTMENTS
Each part of the mechanical units of a robot is set to the best condition before the robot is shipped to the customer. The customer does not need to make adjustments on the robot when it is delivered.

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6.1

ADJUSTING TENSION OF BELT

Please use the following tension meters for the tension adjustment of the belt.

Instrument Tension meter

Specifications A97L-0218-0700

Vendor Mitsuboshi Belting Ltd.

Manufacturer model No. Application DOCTOR TENSION TYPE- Adjustment of belt tension

1 2 3 4 5

Move the robot posture to J2=0 and J3=0. Remove the bolt and arm cover (refer to Chapter 5). When severe dust/liquid protection specification is selected, remove packing, too. Adjust it so that it may loosen tension-adjusting bolts and the tension may reach a regulated value. Attach arm cover. In case of severe dust/liquid protection specification, be sure to replace packing to new one. In this time, tighten the bolt with the specified torque.

TENSION ADJUSTING BOLT

Fig. 6.1(a) Adjusting tension of J3 belt Table. 6.1(a) Measurement condition of J3 belt BELT TENSION MASS WIDTH SPAN 855N 0.0367kg 7mm 175mm

NOTE This is example of LR Mate 200iC. In case of LR Mate 200iC/5H, please read J5/J6 as J4/J5.

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6.ADJUSTMENTS
TENSION ADJUSTING BOLT

Fig. 6.1(b) Adjusting tension of J5 belt

TENSION ADJUSTING BOLT

Fig. 6.1(c) Adjusting tension of J6 belt

Table 6.1(b) Measurement condition of J5 belt BELT TENSION MASS WIDTH SPAN 27.52.5N 0.0171kg 6mm 180mm

Table 6.1(c) Measurement condition of J6 belt BELT TENSION MASS WIDTH SPAN 27.52.5N 0.0171kg 6mm 110mm

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6.2

MASTERING
Mastering is an operation performed to associate the angle of each robot axis with the pulse count value supplied from the absolute pulse coder connected to the corresponding axis motor. To be specific, mastering is an operation for obtaining the pulse count value corresponding to the zero position. The current position of the robot is determined according to the pulse count value supplied from the pulse coder on each axis. Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However, mastering becomes necessary after: - Motor replacement - Pulse coder replacement - Reducer replacement - Cable replacement - Batteries for pulse count backup in the mechanical unit have gone dead.

NOTE Robot data (including mastering data) and pulse coder data are backed up by their respective backup batteries. Data will be lost if the batteries go dead. Replace the batteries in the control and mechanical units periodically. An alarm will be issued to warn the user of a low battery voltage.

Mastering method
There are following five methods of mastering.
Fixture position mastering Zero-position mastering (eye mark mastering) This is performed using a mastering fixture before the machine is shipped from the factory. This is performed with all axes set at the 0-degree position. A zero-position mark (eye mark) is attached to each robot axis. This mastering is performed with all axes aligned to their respective eye marks. This is performed at a user-specified position. The corresponding count value is obtained from the rotation speed of the pulse coder connected to the relevant motor and the rotation angel within one rotation. Simplified mastering uses the fact that the absolute value of a rotation angel within one rotation will not be lost. This is performed for one axis at a time. The mastering position for each axis can be specified by the user. This is useful in performing mastering on a specific axis. Mastering data is entered directly.

Simplified mastering

One-axis mastering

Mastering data entry

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This MAINTENANCE MANUAL describes fixture position mastering that is mainly required during replacement of parts. For other mastering methods, refer to OPERATORS MANUAL. Once mastering is performed, it is necessary to carry out positioning, or calibration. Positioning is an operation is which the control unit reads the current pulse count value to sense the current position of the robot.

NOTE If mastering is performed incorrectly, the robot may behave unexpectedly. This is very dangerous. Therefore, the positioning screen is designed to appear only when the $MASTER_ENB system variable is 1 or 2. After performing positioning, press F5 [DONE] on the positioning screen. The $MASTER_ENB system variable is reset to 0 automatically, thus hiding the positioning screen. CAUTION It is recommended that the current mastering data be backed up before mastering is performed.

6.2.1

RESETTING ALARMS AND PREPARING FOR MASTERING

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

Alarm displayed
Servo 062 BZAL or Servo 075 Pulse mismatch

Procedure
1 Display the positioning menu by following steps 1 to 6. 1 Press the screen selection key. 2 Press [0 NEXT] and Select [6 SYSTEM]. 3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu. 4 Place the cursor on $MASTER_ENB, then key in 1 and press [ENTER]. 5 Press F1 [TYPE], and select [Mater/Cal] from the menu. 6 Select the desired mastering type from the [Master/Cal] menu. To reset the Servo 062 BZAL alarm, follow steps 1 to 5. 1 Press the screen selection key. 2 Press [0 NEXT] and Select [6 SYSTEM]. 3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu. 4 Press the F3 RES_PCA, then press F4 [TRUE]. 5 Switch the controller power off and on again. To reset the Servo 075 Pulse mismatch alarm, follow steps 1 to 3.
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6.ADJUSTMENTS
1 2 3

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When the controller power is switched on again, the message Servo 075 Pulse mismatch appears again. Rotate the axis for which the message mentioned above has appeared through 10 degrees in either direction. Press [FAULT RESET]. The alarm is reset.

6.2.2

FIXTURE POSITION MASTER

Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the predetermined fixture position. Fixture position mastering is accurate because a dedicated mastering fixture is used. When mastering the robot, arrange the robot to meet the following conditions. - Make the robot mounting base horizontal within 1 mm. (Set the robot mounting face so that the levelness of the entire surface is 1 mm or less.) - Remove the hand and other parts form the wrist. - Set the robot in the condition protected from an external force.

Assembling the fixture base

1 Assemble the fixture base as shown in Fig. 6.2.2 (a).

PIN A290-7139-X913 PIN A290-7139-X914 M8X20(4pcs)

FIXTURE BASE A A290-7139-X911 FIXTURE BASE B A290-7139-X912 PLATE A290-7137-X913 M5X16 (2pcs)

PLATE A290-7137-X912 M5X16(2pcs)

Fig. 6.2.2(a) Assembling the fixture base

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6.ADJUSTMENTS
2 Mount the fixture on the J1axis base with bolts as shown in Fig.6.2.2 (b)

M8X25(4pcs) PIN A290-7139-X914 PIN A290-7139-X913

Fig. 6.2.2 (b) Mounting dial indicator

Mount the fixture to the wrist flange as shown Fig.6.2.2 (c). By using the calibration block, adjust the dial gage needle to 3.00 mm and fasten it with M-5 bolt. (In case of LR Mate 200iC/5H, the dial gage No.3 is not necessary to adjust.)

NOTE The dial gage could be damaged if the bolt is fastened too tight.

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6.ADJUSTMENTS
FIXTURE D A290-7135-X966 NO.3 NO.5

B-82585EN/02

How to assemble diag gauge

NO.2 NO.6

NO.1

BOLT M5 NO.4 CLAMP CALIBRATION BLOCK

FIXTURE A A290-7139-X916

FIXTURE C A290-7139-X917

FIXTURE B A290-7131-X964

Fig. 6.2.2 (c) Mounting the wrist fixture

Assemble the fixture to the wrist flange as shown in Fig. 6.2.2 (d).

PIN A290-7130-X966 M5X16(4pcs)

Fig. 6.2.2 (d) Assembling the fixture to the wrist flange

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6.ADJUSTMENTS

Mastering
1 2 3 4 Press MENUS. Press NEXT and select SYSTEM. Press F1, [TYPE]. Select Mater/Cal.
JOINT 10%

SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSTIION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALLIBRATE Press ENTER or number key to select. [ TYPE ] LOAD RES_PCA

DONE

Release brake control, and jog the robot into a posture for mastering.

NOTE Brake control can be released by setting the system variables as follows: $PARAM_GROUP.$SV_OFF_ALL: FALSE $PARAM_GROUP.$SV_OFF_ENB[*]: FALSE (for all axes) After changing the system variables, switch the control unit power off and on again.
To prevent an error from occurring due to axis backlash at this time, ensure that the dial gage needle is adjusted to a specified position in the decreasing direction. If the needle is adjusted in the reverse direction, start all over again. (In case of LR Mate 200iC, LR Mate 200iC/5L,5LC,5C,5WP) 1) Move the robot gradually so that dial gages No.1 through No. 6 shown in Fig.6.2.2 (c) touch the points indicated by arrows No. 1 through No. 6 shown in Fig.6.2.2 (e). 2) Move the J6 axis so that dial gages No.1 and No.2 indicate same value. 3) Set the corresponding value of dial gauges No.4 and No.5 and move the J1axis and the J4axis so that the dial gauge No.3 may show 3.00mm. When the value of dial gauge No.1 and No.2 deviates, modify it to make correspond. 4) Move the J2, J3, and J5 axes so that dial gages No.2, No.3 and No.4 indicate 3.00 mm. 5) After the operations above, check that all dial gages indicate 3.00 mm.
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(In case of LR Mate 200iC/5H) 1) Move the robot gradually so that dial gages No.1, No.2, No.4, No.5 and No.6 shown in Fig.6.2.2 (c) touch the points indicated by arrows No.1, No.2, No.4, No.5 and No.6 shown in Fig.6.2.2 (e). (Dial gauge No.3 is not used.) 2) Move the J5 axis so that dial gages No.1 and No.2 indicate same value. 3) Move the J1 axis so that dial gages No.4 and No.5 indicate same value. 4) Move the J2, J3, and J4 axes so that dial gages No. 1,No.5, No.6 indicate 3.00 mm. 5) After the operations above, check that all dial gages indicate 3.00 mm. 6 7 Select 1 FIXTURE POSITION MASTER and Press F4, YES. MASTER POSITION shown in Figs. 6.2.2(e) is set in this position. Select 6 CALIBRATE and press F4, YES. Mastering will be performed. Alternatively, switch the power off and on again. Switching the power on always causes positioning to be performed. After positioning is completed, press F5 [DONE].

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

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6.ADJUSTMENTS

MASTERING POSITION LR Mate 200iC, LR Mate 200iC/5WP,5C AXIS POSITION J1 90 deg J2 61.112 deg -85.965 deg J3 J4 0 deg -94.035 deg J5 J6 0 deg

NO.1 NO.6 NO.2 NO.3(*) NO.5

MASTERING POSITION LR Mate 200iC/5H AXIS POSITION 90 deg J1 J2 61.112 deg -85.965 deg J3 -94.035 deg J4 0 deg J5
(*)In case of LR Mate 200iC /5H,NO.3 is not used. NO.4

Fig. 6.2.2 (e) Mastering posture (LR Mate 200iC, LR Mate 200iC/5WP,5C)

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NO.6 NO.1 NO.2 NO.3 NO.5

MASTERING POSITION LR Mate 200iC/5L,5LC AXIS POSITION 90 deg J1 J2 52.147 deg -94.284 deg J3 J4 0 deg -85.716 deg J5 J6 0 deg

NO.4
Fig. 6.2.2 (f) Mastering posture (LR Mate 200iC/5L,5LC)

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APPENDIX

B-82585EN/02

APPENDIX

A.SPARE PARTS LIST

A
K101 K102 K103 K104 K105 K106 K107 K108 K109 K110 K111 K112 K113 K114 K131

SPARE PARTS LIST

Remarks RMP(Standard,5C) RMP(5WP) J2 power J2 pulse coder J3 power J3 pulse coder Relay of J4, J5, J6 power J4 pulse coder A660-4004-T709 A660-2006-T659 A660-2006-T660 (3-axis brake type) A660-4004-T710 (6-axis brake type) A660-2006-T661 (3-axis brake type) A660-4004-T711 (6-axis brake type) A660-2006-T662 A660-2006-T663 (3-axis brake type) A660-4004-T712 (6-axis brake type) A660-2006-T664 A660-2006-T665 A660-8016-T498#L5R003 J6 pulse coder End effector External battery cable (When external battery option is selected) J5 pulse coder J6 power J5 power Relay of J5, J6 pulse coder Relay of end effector Relay of YV J4 power A660-8016-T285 A660-8016-T495 A660-4004-T706 A660-2006-T657 A660-4004-T707 A660-2006-T658 A660-4004-T708

Table A (a1) List of Basic cable (Specifications of Standard,5WP,5C) Name Specifications

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A.SPARE PARTS LIST

APPENDIX

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Table A (a2) List of Basic cable (Specifications of 5L,5LC) Name Specifications K101 K102 K103 K104 K105 K106 K107 K108 K109 K110 K111 K112 K113 K114 K131 A660-8016-T285 A660-4004-T822 A660-2006-T789 A660-4004-T823 A660-2006-T790 A660-4004-T824 A660-4004-T825 A660-2006-T791 A660-2006-T710 A660-2006-T711 A660-2006-T662 A660-4004-T712 A660-2006-T664 A660-2006-T665 A660-8016-T498#L5R003 RMP J2 power J2 pulsecoder J3 power J3 pulsecoder

Remarks

Relay of J4, J5, J6 power J4 pulsecoder Relay of J5, J6 pulsecoder Relay of end effector Relay of YV J4 power J5 power J5 pulse coder J6 power J6 pulsecoder End effector External battery cable (When external battery option is selected)

Table A (a3) List of Basic cable (5H) Name K101 K102 K103 K104 K105 K106 K107 K108 K110 K111 K112 K113 K114 K131

Specifications RMP J2 power J2 pulse coder J3 power J3 pulse coder

Remarks

A660-8016-T285 A660-4004-T706 A660-2006-T657 A660-4004-T707 A660-2006-T658 A660-4004-T810 A660-4004-T811 A660-2006-T659 A660-2006-T771 (3-axis brake type) A660-4004-T812 (5-axis brake type) A660-2006-T772 A660-2006-T773 (3-axis brake type) A660-4004-T813 (5-axis brake type) A660-2006-T774 A660-2006-T665 A660-8016-T498#L5R003

Relay of J4, J5 power Relay of J4, J5 pulse coder Relay of end effector Relay of YV J4 power J4 pulse coder J5 power J5 pulse coder End effector External battery cable (When external battery option is selected)

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APPENDIX

A.SPARE PARTS LIST

Table A (b1) Motor (Standard, 5L,5LC,5WP,5C) Name Specifications iSR1/6000 iSR0.5/6000 iSR0.4/4000 iSR0.4/4000 iSR0.2/4000 iSR0.2/4000 A06B-0116-B855#0048 A06B-0115-B855#0048 A06B-0114-B205#0048 A06B-0114-B855#0048 A06B-0117-B205#0049 A06B-0117-B855#0049 J1, J2-axis J3-axis

Remarks

J4-axis (3-axis brake type) J4-axis(6-axis brake type) J5,J6-axis(3-axis brake type) J5,J6-axis(6-axis brake type)

(*) When J2-axis motor is replaced , please order shaft A290-7139-X322 at the same time. Table A (b2) Motor (5H) Name iSR1/6000 iSR0.5/6000 iSR0.2/4000 iSR0.2/4000

Specifications A06B-0116-B855#0048 A06B-0115-B855#0048 A06B-0117-B205#0049 A06B-0117-B855#0049 J1,J2-axis J3-axis

Remarks

J4,J5-axis(3-axis brake type) J4,J5-axis(6-axis brake type)

(*) When J2-axis motor is replaced , please order shaft A290-7139-X322 at the same time.

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A.SPARE PARTS LIST

Table A (c) Reducer Name

APPENDIX

B-82585EN/02

Specifications A97L-0218-0812#80 A97L-0218-0812#80C A97L-0218-0813#120 A97L-0218-0813#120C A97L-0218-0814#100 A97L-0218-0814#100C A97L-0218-0815#80 A97L-0218-0815#80C A97L-0218-0816#50 A97L-0218-0816#50C A97L-0218-0817#50 A97L-0218-0817#50C

Remarks J1-axis(Standard.5L,5H) J1-axis(5C,5LC,5WP) J1-axis(Standard.5L,5H) J2-axis(5C,5LC,5WP) J3-axis(Standard.5L,5H) J3-axis(5C,5LC,5WP) J4-axis(Standard,5L) J4-axis(5C,5LC,5WP) J5-axis(Standard.5L), J5-axis(5C,5LC,5WP) J6-axis(Standard.5L), J6-axis(5C,5LC,5WP) J5-axis(5H) J4-axis(5H)

Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive

NOTE When arranging in the reducer machine unit, the waving generator is built into the main body of the reducer machine beforehand as for J4-axis of Standard,5L,5LC,5WP or 5C reducer. As for other reducers, the waving generator is separated from the main body of the reducer machine.
Table A (d) Gear Name GEAR J1-1 GEAR J1-2 GEAR J4-1 GEAR J4-2 Table A (e) Pulley, shaft, key Name Pulley Pulley Pulley Pulley Motor pulley Shaft Key Key Specifications A290-7139-X211 A290-7139-X213 A290-7139-X212 A290-7139-X411 A290-7139-X412 Remarks J1-axis(Standard,5WP,5C,5H) J1-axis(5L,5LC) J1-axis J4-axis(Standard,5L,5LC,5WP,5C) J4-axis(Standard,5L,5LC,5WP,5C)

Specifications A290-7139-X311 A290-7139-X312 A290-7139-X414 A290-7139-X415 A290-7139-X413 A290-7139-X322 JB-HKY-3X3X12B JB-HKY-3X3X6B J3-axis J3-axis

Remarks

J5-axis(Standard,5L,5LC,5WP,5C) J4-axis(5H) J6-axis(Standard,5L,5LC,5WP,5C) J5-axis(5H) J5,J6-axis(Standard,5L,5LC,5WP,5C) J4,J5-axis(5H) J2-axis Motor, pulley, gear Motor, pulley, gear

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APPENDIX

A.SPARE PARTS LIST

Table A (f) Bearing Bearing Belt Belt Belt

Bearing, belt Name

Specifications A97L-0001-0192#08Z000A A97L-0218-0596 A98L-0040-0190#007-098 A98L-0040-0227#006-100 A98L-0040-0227#006-152 J1-axis reducer

Remarks

J4-axis reducer(Standard.5L,5LC,5WP,5C) J3-axis motor J5-axis motor (Standard.5L,5LC,5WP,5C) J4-axis motor (5H) J6-axis motor (Standard.5L,5LC,5WP,5C) J5-axis motor (5H)

Table A (g) Packing(When severe dust/liquid protection specification of standard,5L,5H or 5WP,5C,5LC is specified) Name Specifications Remarks Packing Packing Packing Packing (*) Packing Packing Packing Packing Packing Packing Packing Packing Packing A290-7139-X251 A290-7139-X252 A290-7139-X253 A290-7139-X351 A290-7139-X352 A290-7139-X353 A290-7139-X354 A290-7139-X355 A290-7139-X356 A290-7139-X451 A290-7139-X452 A290-7139-X453 A290-7139-X454 Connector plate Cover B Battery box Cover S Support Guide arm J2 base cover J2 arm over Cover U J3 base cover SV plate J3 arm J3 arm cover (2pcs/1 machines)

(*) This packing is attached when non-severe dust/liquid protection specification of Standard,5L,5H Table A (h) Oil seal, O-RING Name

Specifications A98L-0040-0223#01001805 A98L-0040-0049#02603707 A98L-0040-0223#01001805 A98L-0001-0347#S46 A98L-0001-0347#S35 JB-OR1A-G45

Remarks J1, J4-axis motor (Standard,5L,5LC5WP,5C) J1-axis motor (5H) J4-axis reducer (Standard,5L,5LC5WP,5C) J5-axis reducer (Standard,5L,5LC5WP,5C) J4-axis reducer (5H) J1, J4-axis motor (Standard,5L,5LC5WP,5C) J1-axis motor (5H) J1-axis reducer J2-axis motor

Oil seal Oil seal Oil seal O-RING O-RING O-RING

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A.SPARE PARTS LIST

Table A (i) Seal bolt Name

APPENDIX

B-82585EN/02

Specifications

Remarks J 1, J3, J4, J5, J6-axis motor J2, J3, J5-axis reducer Wrist unit, J4 pipe J 1, J3, J4, J5-axis motor J2, J3, J4-axis reducer Wrist unit 5H Standard,5L, 5LC,5WP,5C

Seal bolt

A97L-0218-0423#030606

Seal bolt Seal bolt Seal bolt

A97L-0218-0423#031616 A97L-0218-0423#051212 A97L-0218-0546#043016BC A97L-0218-0546#043016EN

J2-axis motor J2-axis motor J1-axis reducer(Standard,5L,5H Severe dust/liquid protection specification) J1-axis reducer (5C,5LC,5WP) J2-axis reducer(Standard,5L,5H Severe dust/liquid protection specification) J2-axis reducer (5C,5LC,5WP) J3-axis reducer(Standard,5L,5H Severe dust/liquid protection specification) J3-axis reducer (5C,5LC,5WP) GEAR J1-2, GEAR J4-2 (Standard,,5L,5LC,5WP,5C) GEAR J1-2 (Specifications of 5H) J1 pipe Support Cover S(Standard,5L,5H) Cover S (5C,5LC,5WP) Cover S Standard,5L,5H) Cover S (5C,5LC,5WP) Guide arm Guide arm(Standard,5L,5H Severe dust/liquid protection specification) Guide arm(5C,5LC,5WP) J3 arm cover Cover U Standard,5L,5H Severe dust/liquid protection specification) Cover U (5C,5LC,5WP) J1 grease outlet J3, J4, J5, J6 grease inlet (Standard,5L,5LC,5WP,5C) J3, J4, J5 grease inlet (5H) J3 grease outlet

Seal bolt

A97L-0218-0546#043516BC A97L-0218-0546#043516EN

Seal bolt

A97L-0218-0546#032504BC A97L-0218-0546#032504EN

Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt

A97L-0218-0423#030505 A97L-0218-0423#040808 A97L-0218-0423#041212 A97L-0218-0595#040808BC A97L-0218-0595#040808EN A97L-0218-0738#040808BC A97L-0218-0738#040808EN A97L-0218-0423#051616 A97L-0218-0546#051616BC A97L-0218-0546#051616EN

Seal bolt Seal bolt

A97L-0218-0423#041616 A97L-0218-0546#040808BC A97L-0218-0546#040808EN

Seal bolt

A97L-0218-0417#060606

Seal bolt

A97L-0218-0417#040505

- 136 -

B-82585EN/02

APPENDIX

A.SPARE PARTS LIST

Table A (j) Spring pin, Stopper, Wrist unit, Sheet Name Specifications Spring pin Stopper A6-PS-5X18S A290-7139-X441 J3 Stopper J3Stopper

Remarks

J6-axis reducer is included (Standard,5L not severe dust/liquid A290-7139-V501 protection specification) J5-axis reducer is included (5H not severe dust/liquid protection specification ) J6-axis reducer is included Wrist unit A290-7139-V502 (Standard,5L severe dust/liquid protection specification) J5-axis reducer is included (5H severe dust/liquid protection specification ) A290-7139-V521 A290-7139-V531 Sheet A290-7139-X345 A290-7139-X349 J6-axis reducer is included (5C,5LC) J6-axis reducer is included (5WP) J2-axis motor(Standard,5WP,5C,5H) J2-axis motor(5L,5LC)

- 137 -

A.SPARE PARTS LIST

Table A (k)

APPENDIX

B-82585EN/02

Air tube (Standard,5WP,5C,5H) Name Specifications A97L-0218-0114#ABL640R0 A97L-0218-0010#AAL580R0 A97L-0218-0114#BBL570R0 A97L-0218-0010#BAL570R0 A97L-0218-0114#ABL700R0 A97L-0218-0010#AAL700R0 A97L-0218-0114#BBL910R0 A97L-0218-0010#BAL700R0

Remarks 6mm BLACK AIR1 Connector plate to J2base 4mm BLACK AIR1 (5C) Connector plate to J2base 6mm WHITE AIR2 Connector plate to J2base 4mm WHITE EXT(5C) Connector plate to J2base 6mm BLACK AIR1 J2 base to J3 casing 4mm BLACK AIR1 (5C) J2 base to J3 casing 6mm WHITE AIR2 J2 base to J3 casing 4mm 4mm WHITE WHITE EXT(5C) EXHAUST J2 base to J3 casing J3 casing 3.18mm BLACK AIR1

Air tube Air tube Air tube Air tube Air tube Air tube Air tube Air tube Air tube (H002,H003,H004,H005,H022, H023,H024,H032, H033 Air tube (H002,H003,H004,H005,H022, H023,H024,H032, H033 Air tube (H002,H003,H004,H005,H022, H023,H024,H032,H033 Air tube (H002,H003,H004,H005,H022, H023,H024,H032,H033 Air tube (H003,H004,H005,H023,H024, H033 Air tube (H003,H004,H005,H023,H024, H033 Air tube (H004,H005,H024 Air tube (H004,H005,H024

A97L-0218-0010#BAL150R0

A97L-0218-0010#AFL855R0

J3 casing to J3 arm 3.18mm RED A1

A97L-0218-0010#CFL745R0

J3 casing to J3 arm 3.18mm BLUE B1

A97L-0218-0010#DFL745R0

J3 casing to J3 arm 3.18mm YELLOW A2

A97L-0218-0010#EFL745R0

J3 casing to J3 arm 3.18mm GREEN B2

A97L-0218-0010#FFL745R0

J3 casing to J3 arm 3.18mm CLEAR J3 casing to J3 arm 3.18mm ORANGE B3 J3 casing to J3 arm A3

A97L-0218-0010#GFL745R0 A97L-0218-0010#HFL745R0

- 138 -

B-82585EN/02

APPENDIX

A.SPARE PARTS LIST

Table A (k2)

Air tube(5L,5LC) Name

Specifications

Remarks 6mm BLACK AIR1(5L) Connector plateJ2 base 4mm BLACK AIR1 (5C) Connector plateJ2 base 6mm 4mm WHITE WHITE AIR2 EXT(5C) Connector plateJ2 base Connector plateJ2 base 6mm BLACK AIR1(5L) J2 baseJ3 casing 4mm BLACK AIR1(5C) J2 baseJ3 casing 6mm 4mm 4mm WHITE WHITE WHITE AIR2 EXT(5C) EXHAUST J2 baseJ3 casing J2 baseJ3 casing J3 casing 3.18mm BLACK AIR1 J3 casing to J3 arm 3.18mm RED A1

Air tube Air tube Air tube Air tube Air tube Air tube Air tube Air tube Air tube Air tube H012,H013,H014,H015, H017,H018 Air tube H012,H013,H014,H015, H017,H018 Air tube H012,H013,H014,H015, H017,H018 Air tube H013,H014,H015,H018 Air tube H013,H014,H015,H018 Air tube H014,H015 Air tube H014,H015

A97L-0218-0114#ABL580R0 A97L-0218-0010#AAL580R0 A97L-0218-0114#BBL570R0 A97L-0218-0010#BAL570R0 A97L-0218-0114#ABL800R0 A97L-0218-0010#AAL800R0 A97L-0218-0114#BBL1R013 A97L-0218-0010#BAL800R0 A97L-0218-0010#BAL150R0

A97L-0218-0010#AFL945R0

A97L-0218-0010#CFL835R0

J3 casing to J3 arm 3.18mm BLUE B1

A97L-0218-0010#DFL835R0

J3 casing to J3 arm 3.18mm YELLOW J3 casing to J3 arm 3.18mm GREEN J3 casing to J3 arm 3.18mm CLEAR A3 J3 casing to J3 arm 3.18mm ORANGE B3 J3 casing to J3 arm B2 A2

A97L-0218-0010#EFL835R0 A97L-0218-0010#FFL835R0 A97L-0218-0010#GFL835R0 A97L-0218-0010#HFL835R0

- 139 -

A.SPARE PARTS LIST

APPENDIX

B-82585EN/02

Table A (l) Solenoid valve (Either the following is installed by the option specification) (except H001,H006,H011 and H016) Name Specifications Remarks Solenoid valve Solenoid valve Solenoid valve Solenoid valve Table A (m) Battery Name Battery Battery A97L-0218-0113#D1 A97L-0218-0113#D2 A97L-0218-0113#D3 A97L-0218-0113#D3R Double solenoidX1(2 positionX1) Double solenoidX2(2 positionX2) Double solenoidX3(2 positionX3) Double solenoidX3 (2 positonX2, 3 positionX1)

Specifications A98L-0031-0027 A98L-0031-0005 C battery/1.5V

Remarks

(When battery built-in option is selected) D battery/1.5V (When external battery option is selected) Table A (n) Grease Name Grease

Specifications A98L-0040-0230#2KG

Remarks Harmonic grease 4BNo.2

- 140 -

B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

CIRCUIT DIAGRM

DIAGRAM,

AIR

PRESSURE

- 141 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

APPENDIX

B-82585EN/02

A63L-0001-0865#1 A63L-0001-0864#CS

J1 MOTOR (iSR1/6000) M1M

2 3 J1V1 J1W1 1 4 J1U1 J1G1

A63L-0001-0865#2 A63L-0001-0864#CS

M1BK
2 3 A63L-0001-0848#E10SL1 A63L-0001-0850 BK(J1) 1 BKCOM1(J1) 4

M1P
8 9 +5V(A1) 10 0V(A1)

4 +6V(BT1) 1 5 XPRQJ1 2 6 PRQJ1 3 7 0V(BT1)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M2M1 (
X-KEY BLACK

A1 J2U1 A2 BK(J2) A3 J2W1

F06DX CTM B1 J2G1 B2 J2V1 B3 BKCOM1(J2)

A63L-0001-0865#1 A63L-0001-0864#CS

J2 MOTOR (iSR1/6000) M2M

2 3 J2V1 J2W1 1 4 J2U1 J2G1

K102 A660-4004-T706 A63L-0001-0865#2 A63L-0001-0864#CS

M2BK
2 3 BK(J2) 1 BKCOM1(J2) 4

A63L-0002-0066#R06DY A63L-0002-0066#CRM

M2P1 ( Y-KEY ) BLACK

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

F06DY CTM A1 +6V(BT2) B1 0V(BT3) A2 PRQJ2 B2 XPRQJ2 A3 +5V(B1) B3 0V(B1)

A63L-0001-0848#E10SL1 A63L-0001-0850

M2P
K103 A660-2006-T657 8 9 +5V(B1) 10 0V(B1)

4 +6V(BT2) 1 5 XPRQJ2 2 6 PRQJ2 3 7 0V(BT2)

M3M1
A1 J3U1 A2 BK(J3) A3 J3W1

J1 CONNECTOR PANEL RMP

1 2 3 4 5 6 7 8 9 10 11 12 BK(J1)
BKCOM1(J1)

(
37 38 39 40 41 42 43 44 45 46 47 48 SG (BK(J4)) 49 (BKCOM1(J4)) 50 J4U 51 J4V 52 J4W 53 J4G 54 +24V(B1) 55 RI4 56 RO4 57 0V(A1) 58 PRQJ4 59 60 XPRQJ4 Han 72DD (2.5SQ 10A) (BK(J5)) 61 (BK(J6)) (BKCOM1(J5)) 62 (BKCOM1(J6)) J5U 63 J6U J5V 64 J6V J5W 65 J6W J5G 66 J6G 0V(D1,D2) 67 0V(E1,E2,E3, E4,E5,E6) RI5 68 RI6 RO5 69 RO6 0V(B1,B2) 70 0V(C1,C2,C3) PRQJ5 71 PRQJ6 72 XPRQJ6 XPRQJ5

Y-KEY WHITE

F06DYW CTM B1 J3G1 B2 J3V1 B3 BKCOM1(J3)

A63L-0001-0865#1 A63L-0001-0864#CS

J3 MOTOR (iSR0.5/6000) M3M

2 3 J3V1 J3W1 1 4 J3U1 J3G1

K104 A660-4004-T707 A63L-0001-0865#2 A63L-0001-0864#CS

M3BK
2 3 BK(J3) 1 BKCOM1(J3) 4

J1U1 J1V1 J1W1 J1G1 XROT RI1 RO1 +5V(A1) PRQJ1 XPRQJ1

13 14 15 16 17 18 19 20 21 22 23 24

25 26 J2U1 27 J2V1 28 J2W1 29 J2G1 30 +24V(OT,A1,A2) 31 RI2 32 RO2 33 +5V(B1,B2) 34 PRQJ2 35 36 XPRQJ2
BKCOM1(J2)

BK(J2)

BK(J3)
BKCOM1(J3)

J3U1 J3V1 J3W1 J3G1 XHBK RI3 RO3

+5V(C1,C2,C3)

A63L-0002-0066#R06DXW A63L-0002-0066#CRM K101 A660-8016-T285

M3P1 ( X-KEY ) WHITE

F06DXW CTM A1 +6V(BT3) B1 0V(BT3) A2 PRQJ3 B2 XPRQJ3 A3 +5V(B2) B3 0V(B2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M3P
K105 A660-2006-T658 8 9 +5V(B2) 10 0V(B2)

4 +6V(BT3) 1 5 XPRQJ3 2 6 PRQJ3 3 7 0V(BT3)

PRQJ3 XPRQJ3 G

A63L-0002-0066#R20DX A63L-0002-0066#CRM

X-KEY BLACK

F20DX CTM J4U B1 J4G (BK(J4)) B2 J4V J4W B3 (BKCOM1(J4)) B4 J5G B5 J5U J5V B6 (BK(J5)) (BKCOM1(J5)) B7 J5W J6U B8 J6G (BK(J6)) B9 J6V A10 J6W B10 (BKCOM1(J6))

M456M1
A1 A2 A3 A4 A5 A6 A7 A8 A9

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M4M1
K106 A660-4004-T708

X-KEY BLACK

A1 J4U A2 A3 J5W

F06DX CTM B1 J4G B2 J4V B3

K109 A660-2006-T660

BATTERY
+6V (BT1,BT2,BT3, BT4,BT5,BT6)

+
A63L-0002-0066#R20DY A63L-0002-0066#CRM

( ) SIZE C
0V (BT1,BT2,BT3, BT4,BT5,BT6)

( Y-KEY ) BLACK

F20DY CTM B1 XPRQJ4 B2 0V(BT4,BT5,BT6) PRQJ5 B3 XPRQJ5 +5V(C1,C2,C3) B4 0V(C1,C2,C3) PRQJ6 B5 XPRQJ6 +24V(A1,A2) B6 XHBK +24V(B1) B7 0V(D1,D2) RI1 B8 RI2 RI3 B9 RI4 A10 RI5 B10 RI6

M456PEE1
A1 A2 A3 A4 A5 A6 A7 A8 A9 PRQJ4
+6V(BT4,BT5,BT6)

K107 A660-4004-T709

A63L-0002-0066#R08DX A63L-0002-0066#CRM

YV1
A1 0V(E1,E3,E5) A2 RO1 A3 RO3 A4 RO5

( X-KEY ) BLACK

F08DX CTM B1 0V(E2,E4,E6) B2 RO2 B3 RO4 B4 RO6

K108 A660-2006-T659

NOTE) 1. (***) SIGNALS ARE NOT USED.

2. A05C-1139-B202 REFER TO A05C-1139-B202 IF SPECIFIED OPTIONS.

Fig. B (a) CIRCUIT DIAGRM (LR Mate 200iC 3-axes brake type)

- 142 -

B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M5M1
A1 J5U A2 A3 J5W

( X-KEY ) BLACK
A63L-0002-0066#R06DY A63L-0002-0066#CRM

F06DX CTM B1 J5G B2 J5V B3

A63L-0001-0865#1 A63L-0001-0864#CS

J5 MOTOR (iSR0.2/6000) M5M

2 3 J5V J5W 1 4 J5U J5G

K110 A660-2006-T661

M5P1 )

Y-KEY BLACK

F06DY CTM A1 +6V(BT5) B1 0V(BT5) A2 PRQJ5 B2 XPRQJ5 A3 +5V(C2) B3 0V(C2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M5P
8 9 +5V(C2) 10 0V(C2)

K111 A660-2006-T662

4 +6V(BT5) 1 5 XPRQJ5 2 6 PRQJ5 3 7 0V(BT5)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M6M1 (
Y-KEY WHITE

A1 J6U A2 A3 J6W

F06DYW CTM B1 J6G B2 J6V B3

A63L-0001-0865#1 A63L-0001-0864#CS

J6 MOTOR (iSR0.2/6000) M6M

2 3 J6V J6W 1 4 J6U J6G

K112 A660-2006-T663

A63L-0002-0066#R06DXW A63L-0002-0066#CRM

M6P1 (
X-KEY WHITE

F06DXW CTM A1 +6V(BT6) B1 0V(BT6) A2 PRQJ6 B2 XPRQJ6 A3 +5V(C3) B3 0V(C3)

A63L-0001-0848#E10SL1 A63L-0001-0850

M6P
K113 A660-2006-T664

8 9 +5V(C3) 10 0V(C3)

4 +6V(BT6) 1 5 XPRQJ6 2 6 PRQJ6 3 7 0V(BT6)

A63L-0002-0066#R12DX A63L-0002-0066#CRM

EE1
A1 A2 A3 A4 A5 A6 RI1 RI2 RI3 RI4 RI5 RI6 B1 B2 B3 B4 B5 B6

( X-KEY ) BLACK

F12DX CTM XHBK +24V(A1) +24V(A2) +24V(B1) 0V(D1) 0V(D2)

EE
K114 A660-2006-T665 2

1 RI2 3

A63L-0002-0072#12SN RI1 9 +24V(A2) 8 +24V(A1) 10 +24V(B1) 12 0V(D2) 7 XHBK RI3 11 0V(D1) 6 RI6 4 RI4 5 RI5

A63L-0001-0865#1 A63L-0001-0864#CS

J4 MOTOR (iSR0.4/6000) M4M

2 3 J4V J4W 1 4 J4U J4G

A63L-0001-0848#E10SL1 A63L-0001-0850

M4P

8 9 +5V(C1) 10 0V(C1)

4 +6V(BT4) 1 5 XPRQJ4 2 6 PRQJ4 3 7 0V(BT4)

A05B-1139-H002 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 R12DX CRM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

A05B-1139-H004 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

YV2

( X-KEY ) BLACK

A1 RO1 A2 RO2 A3 A4 A5 A6

F12DX CTM B1 0V(E1) B2 0V(E2) B3 B4 B5 B6

SOLENOID VALVE A97L-0218-0113#D1

SOLENOID VALVE A97L-0218-0113#D3

A05B-1139-H003 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4)

A05B-1139-H005 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

SOLENOID VALVE A97L-0218-0113#D2

SOLENOID VALVE A97L-0218-0113#D3R

LR Mate 200iC (3BK)

: MOVABLE

- 143 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

APPENDIX

B-82585EN/02

A05B-1139-H301 SPECIFIED A05B-1139-H302 A05B-1139-H321(5C)

SPECIFIED A05B-1139-H321(5C)

A63L-0001-0865#1 A63L-0001-0864#CS

J1 MOTOR (iSR1/6000) M1M

2 3 J1V1 J1W1 1 4 J1U1 J1G1

A63L-0001-0865#2 A63L-0001-0864#CS

M1BK
2 3 A63L-0001-0848#E10SL1 A63L-0001-0850 BK(J1) 1 4
BKCOM1(J1)

M1P
8 9 +5V(A1) 10 0V(A1)

4 +6V(BT1) 1 5 XPRQJ1 2 6 PRQJ1 3 7 0V(BT1)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M2M1 ( X-KEY ) BLACK

A63L-0002-0066#R06DY A63L-0002-0066#CRM

F06DX CTM A1 J2U1 B1 J2G1 A2 BK(J2) B2 J2V1 A3 J2W1 B3 BKCOM1(J2)

A63L-0001-0865#1 A63L-0001-0864#CS

J2 MOTOR (iSR1/6000) M2M

2 3 J2V1 J2W1 1 4 J2U1 J2G1

K102 A660-4004-T706 A63L-0001-0865#2 A63L-0001-0864#CS

M2BK
2 3 BK(J2) 1 4
BKCOM1(J2)

M2P1 )

Y-KEY BLACK

F06DY CTM A1 +6V(BT2) B1 0V(BT3) A2 PRQJ2 B2 XPRQJ2 A3 +5V(B1) B3 0V(B1)

A63L-0001-0848#E10SL1 A63L-0001-0850 K103 A660-2006-T657

M2P
8 9 +5V(B1) 10 0V(B1)

4 +6V(BT2) 1 5 XPRQJ2 2 6 PRQJ2 3 7 0V(BT2)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M3M1 J1 CONNECTOR PANEL RMP

1 2 3 4 5 6 7 8 9 10 11 12
BKCOM1(J1)

(
49 50 51 52 53 54 55 56 57 58 59 60
BKCOM1(J5)

Y-KEY WHITE

F06DYW CTM A1 J3U1 B1 J3G1 A2 BK(J3) B2 J3V1 A3 J3W1 B3 BKCOM1(J3)

A63L-0001-0865#1 A63L-0001-0864#CS

J3 MOTOR (iSR0.5/6000) M3M

2 3 J3V1 J3W1 1 4 J3U1 J3G1

K104 A660-4004-T707 A63L-0001-0865#2 A63L-0001-0864#CS

BK(J1) 13 14 J1U1 15 J1V1 16 J1W1 17 J1G1 18 XROT 19 RI1 20 RO1 21 +5V(A1) 22 PRQJ1 23 XPRQJ1 24

BK(J2) 25 26 27 J2U1 28 J2V1 29 J2W1 30 J2G1 +24V(OT,A1,A2) 31 32 RI2 33 RO2 +5V(B1,B2) 34 PRQJ2 35 XPRQJ2 36
BKCOM1(J2)

BK(J3) 37 BK(J4) 38 BKCOM1(J4) 39 J4U J3U1 40 J4V J3V1 41 J4W J3W1 42 J4G J3G1 43 +24V(B1) XHBK 44 RI4 RI3 45 RO4 RO3 +5V(C1,C2,C3) 46 0V(A1) PRQJ3 47 PRQJ4 XPRQJ3 48 XPRQJ4 G SG
BKCOM1(J3)

Han 72DD (2.5SQ 10A) BK(J5) 61 BK(J6) 62 BKCOM1(J6) 63 J6U J5U 64 J6V J5V 65 J6W J5W 66 J6G J5G 0V(D1,D2) 67 0V(E1,E2,E3, E4,E5,E6) 68 RI6 RI5 69 RO6 RO5 0V(B1,B2) 70 0V(C1,C2,C3) PRQJ5 71 PRQJ6 XPRQJ5 72 XPRQJ6

M3BK
2 3 BK(J3) 1 4
BKCOM1(J3)

A63L-0002-0066#R06DXW A63L-0002-0066#CRM K101 A660-8016-T285

M3P1

( X-KEY ) WHITE

F06DXW CTM A1 +6V(BT3) B1 0V(BT3) A2 PRQJ3 B2 XPRQJ3 A3 +5V(B2) B3 0V(B2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M3P
8 9 +5V(B2) 10 0V(B2)

K105 A660-2006-T658

4 +6V(BT3) 1 5 XPRQJ3 2 6 PRQJ3 3 7 0V(BT3)

M456M1
A63L-0002-0066#R20DX A63L-0002-0066#CRM A1 A2 A3 A4 A5 A6 A7 A8 A9

X-KEY BLACK

F20DX CTM J4U B1 J4G BK(J4) B2 J4V J4W B3 BKCOM1(J4) B4 J5G B5 J5U J5V B6 BK(J5) BKCOM1(J5) B7 J5W J6U B8 J6G BK(J6) B9 J6V A10 J6W B10 BKCOM1(J6)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M4M1
K106 A660-4004-T708

X-KEY BLACK

F06DX CTM A1 J4U B1 J4G A2 BK(J4) B2 J4V A3 J5W B3 BKCOM1(J4)

K109 A660-4004-T710

BATTERY
+6V (BT1,BT2,BT3, BT4,BT5,BT6)

+
A63L-0002-0066#R20DY A63L-0002-0066#CRM

M456PEE1
A1 A2 A3 A4 A5 A6 A7 A8 A9 PRQJ4
+6V(BT4,BT5,BT6)

( ) SIZE C
0V (BT1,BT2,BT3, BT4,BT5,BT6)

( Y-KEY ) BLACK

F20DY CTM B1 XPRQJ4 B2 0V(BT4,BT5,BT6) B3 XPRQJ5 +5V(C1,C2,C3) B4 0V(C1,C2,C3) PRQJ6 B5 XPRQJ6 +24V(A1,A2) B6 XHBK +24V(B1) B7 0V(D1,D2) RI1 B8 RI2 RI3 B9 RI4 A10 RI5 B10 RI6 PRQJ5

K107 A660-4004-T709

A63L-0002-0066#R08DX A63L-0002-0066#CRM

YV1

( X-KEY ) BLACK

A1 0V(E1,E3,E5) A2 RO1 A3 RO3 A4 RO5

F08DX CTM B1 0V(E2,E4,E6) B2 RO2 B3 RO4 B4 RO6

K108 A660-2006-T659

Fig.B(b)

Circuit diagram (LR Mate 200iC 6-axes brake type When H301 is specified) (LR Mate 200iC/5C When H321 is specified)

- 144 -

B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M5M1 ( X-KEY ) BLACK

A63L-0002-0066#R06DY A63L-0002-0066#CRM

F06DX CTM A1 J5U B1 J5G A2 BK(J5) B2 J5V A3 J5W B3 BKCOM1(J5)

A63L-0001-0865#1 A63L-0001-0864#CS

J5 MOTOR (iSR0.2/6000) M5M

2 3 J5V J5W 1 4 J5U J5G

K110 A660-4004-T711 A63L-0001-0865#2 A63L-0001-0864#CS

M5BK
2 3 BK(J5) 1 4
BKCOM1(J5)

M5P1

( Y-KEY ) BLACK
A63L-0002-0066#R06DYW A63L-0002-0066#CRM

F06DY CTM A1 +6V(BT5) B1 0V(BT5) A2 PRQJ5 B2 XPRQJ5 A3 +5V(C2) B3 0V(C2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M5P
8 9 +5V(C2) 10 0V(C2)

K111 A660-2006-T662

4 +6V(BT5) 1 5 XPRQJ5 2 6 PRQJ5 3 7 0V(BT5)

M6M1

Y-KEY WHITE

F06DYW CTM A1 J6U B1 J6G A2 BK(J6) B2 J6V A3 J6W B3 BKCOM1(J6)

A63L-0001-0865#1 A63L-0001-0864#CS

J6 MOTOR (iSR0.2/6000) M6M

2 3 J6V J6W 1 4 J6U J6G

K112 A660-4004-T712 A63L-0001-0865#2 A63L-0001-0864#CS

M6BK
2 3

BK(J6)

1 4

BKCOM1(J6)

A63L-0002-0066#R06DXW A63L-0002-0066#CRM

M6P1 (
X-KEY WHITE

F06DXW CTM A1 +6V(BT6) B1 0V(BT6) A2 PRQJ6 B2 XPRQJ6 A3 +5V(C3) B3 0V(C3)

A63L-0001-0848#E10SL1 A63L-0001-0850

M6P
K113 A660-2006-T664

8 9 +5V(C3) 10 0V(C3)

4 +6V(BT6) 1 5 XPRQJ6 2 6 PRQJ6 3 7 0V(BT6)

A63L-0002-0066#R12DX A63L-0002-0066#CRM

EE1 )
A1 A2 A3 A4 A5 A6 RI1 RI2 RI3 RI4 RI5 RI6 B1 B2 B3 B4 B5 B6

X-KEY BLACK

F12DX CTM XHBK +24V(A1) +24V(A2) +24V(B1) 0V(D1) 0V(D2)

EE
K114 A660-2006-T665 2

1 RI2 3

A63L-0002-0072#12SN RI1 9 +24V(A2) 8 +24V(A1) 10 +24V(B1) 12 0V(D2) 7 XHBK RI3 11 0V(D1) 6 RI6 4 RI4 5 RI5

A63L-0001-0865#1 A63L-0001-0864#CS

J4 MOTOR (iSR0.4/6000) M4M

2 3 J4V J4W 1 4 J4U J4G

K109 A660-4004-T710 A63L-0001-0865#2 A63L-0001-0864#CS

M4BK
2 3 A63L-0001-0848#E10SL1 A63L-0001-0850 BK(J4) 1 4
BKCOM1(J4)

M4P
8 9 +5V(C1) 10 0V(C1)

4 +6V(BT4) 1 5 XPRQJ4 2 6 PRQJ4 3 7 0V(BT4)

A05B-1139-H002,-H022 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 R12DX CRM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

A05B-1139-H004,-H024 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

YV2

( X-KEY ) BLACK

A1 RO1 A2 RO2 A3 A4 A5 A6

F12DX CTM B1 0V(E1) B2 0V(E2) B3 B4 B5 B6

SOLENOID VALVE A97L-0218-0113#D1

SOLENOID VALVE A97L-0218-0113#D3

A05B-1139-H003,-H023 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4)

A05B-1139-H005 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

SOLENOID VALVE A97L-0218-0113#D2

SOLENOID VALVE A97L-0218-0113#D3R

LR Mate 200iC (6BK) LR Mate 200iC/5C

- 145 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

APPENDIX

B-82585EN/02

A05B-1139-H302
SPECIFIED A05B-1139-H302

A63L-0001-0865#1 A63L-0001-0864#CS

J1 MOTOR (iSR1/6000) M1M

2 3 J1V1 J1W1 1 4 J1U1 J1G1

A63L-0001-0865#2 A63L-0001-0864#CS

M1BK
2 3

BK(J1)

1 4

BKCOM1(J1)

A63L-0001-0848#E10SL1 A63L-0001-0850

M1P

8 9 +5V(A1) 10 0V(A1)

4 +6V(BT1) 1 5 XPRQJ1 2 6 PRQJ1 3 7 0V(BT1)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M2M1 (
X-KEY BLACK

F06DX CTM A1 J2U1 B1 J2G1 A2 BK(J2) B2 J2V1 A3 J2W1 B3 BKCOM1(J2)

A63L-0001-0865#1 A63L-0001-0864#CS

J2 MOTOR (iSR1/6000) M2M

2 3 J2V1 J2W1 1 4 J2U1 J2G1

K102 A660-4004-T706 A63L-0001-0865#2 A63L-0001-0864#CS

M2BK
2 3

BK(J2)

1 4

BKCOM1(J2)

A63L-0002-0066#R06DY A63L-0002-0066#CRM

M2P1 )

Y-KEY BLACK

F06DY CTM A1 +6V(BT2) B1 0V(BT3) A2 PRQJ2 B2 XPRQJ2 A3 +5V(B1) B3 0V(B1)

A63L-0001-0848#E10SL1 A63L-0001-0850 K103 A660-2006-T657

M2P

8 9 +5V(B1) 10 0V(B1)

4 +6V(BT2) 1 5 XPRQJ2 2 6 PRQJ2 3 7 0V(BT2)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M3M1

J1 CONNECTOR PANEL RMP

1 2 3 4 5 6 7 8 9 10 11 12 BK(J1) 13 14 J1U1 15 J1V1 16 J1W1 17 J1G1 18 XROT 19 20 RI1 RO1 21 +5V(A1) 22 PRQJ1 23 XPRQJ1 24
BKCOM1(J1)

(
49 50 51 52 53 54 55 56 57 58 59 60 Han 72DD (2.5SQ 10A) BK(J5) 61 BK(J6) 62 BKCOM1(J6) J5U 63 J6U J5V 64 J6V J5W 65 J6W J5G 66 J6G 0V(D1,D2) 67 0V(E1,E2,E3, E4,E5,E6) RI5 68 RI6 RO5 69 RO6 0V(B1,B2) 70 0V(C1,C2,C3) PRQJ5 71 PRQJ6 XPRQJ5 72 XPRQJ6
BKCOM1(J5)

Y-KEY WHITE

F06DYW CTM A1 J3U1 B1 J3G1 A2 BK(J3) B2 J3V1 A3 J3W1 B3 BKCOM1(J3)

A63L-0001-0865#1 A63L-0001-0864#CS K104 A660-4004-T707 A63L-0001-0865#2 A63L-0001-0864#CS

J3 MOTOR (iSR0.5/6000) M3M

2 3 J3V1 J3W1 1 4 J3U1 J3G1

M3BK
2 3

BK(J3)

BK(J2) 25 26 J2U1 27 J2V1 28 J2W1 29 J2G1 30 +24V(OT,A1,A2) 31 RI2 32 RO2 33 +5V(B1,B2) 34 PRQJ2 35 XPRQJ2 36
BKCOM1(J2)

BK(J3) 37 BK(J4) 38 BKCOM1(J4) J3U1 39 J4U J3V1 40 J4V J3W1 41 J4W J3G1 42 J4G XHBK 43 +24V(B1) RI3 44 RI4 RO3 45 RO4 +5V(C1,C2,C3) 46 0V(A1) PRQJ3 47 PRQJ4 XPRQJ3 48 XPRQJ4 G SG
BKCOM1(J3)

1 4

BKCOM1(J3)

A63L-0002-0066#R06DXW A63L-0002-0066#CRM K101 A660-8016-T495

M3P1

X-KEY WHITE

F06DXW CTM A1 +6V(BT3) B1 0V(BT3) A2 PRQJ3 B2 XPRQJ3 A3 +5V(B2) B3 0V(B2)

A63L-0001-0848#E10SL1 A63L-0001-0850 K105 A660-2006-T658

M3P

8 9 +5V(B2) 10 0V(B2)

4 +6V(BT3) 1 5 XPRQJ3 2 6 PRQJ3 3 7 0V(BT3)

M456M1
A63L-0002-0066#R20DX A63L-0002-0066#CRM A1 A2 A3 A4 A5 A6 A7 A8 A9

X-KEY BLACK

F20DX CTM J4U B1 J4G BK(J4) B2 J4V J4W B3 BKCOM1(J4) B4 J5G B5 J5U J5V B6 BK(J5) BKCOM1(J5) B7 J5W J6U B8 J6G BK(J6) B9 J6V A10 J6W B10 BKCOM1(J6)

A63L-0002-0066#R06DX A63L-0002-0066#CRM K106 A660-4004-T708

M4M1 )

X-KEY BLACK

F06DX CTM A1 J4U B1 J4G A2 BK(J4) B2 J4V A3 J5W B3 BKCOM1(J4)

K109 A660-4004-T710

BATTERY
+6V (BT1,BT2,BT3, BT4,BT5,BT6)

+
K131 A660-8016-T498

( ) SIZE D
0V (BT1,BT2,BT3, BT4,BT5,BT6)

GB2
A B C

+6V(BT1,BT2,BT3, BT4,BT5,BT6) 0V(BT1,BT2,BT3, BT4,BT5,BT6)

GB2
A B C

M456PEE1
A63L-0002-0066#R20DY A63L-0002-0066#CRM A1 A2 A3 A4 A5 A6 A7 A8 A9 PRQJ4
+6V(BT4,BT5,BT6)

+6V(BT1,BT2,BT3, BT4,BT5,BT6) 0V(BT1,BT2,BT3, BT4,BT5,BT6)

A63L-0001-0648#610SL3SJ

A63L-0001-0648#210SL3PJ

( Y-KEY ) BLACK

F20DY CTM B1 XPRQJ4 B2 0V(BT4,BT5,BT6) B3 XPRQJ5 +5V(C1,C2,C3) B4 0V(C1,C2,C3) PRQJ6 B5 XPRQJ6 +24V(A1,A2) B6 XHBK +24V(B1) B7 0V(D1,D2) RI1 B8 RI2 RI3 B9 RI4 A10 RI5 B10 RI6 PRQJ5

K107 A660-4004-T709

A63L-0002-0066#R08DX A63L-0002-0066#CRM

YV1

( X-KEY ) BLACK

A1 0V(E1,E3,E5) A2 RO1 A3 RO3 A4 RO5

F08DX CTM B1 0V(E2,E4,E6) B2 RO2 B3 RO4 B4 RO6

K108 A660-2006-T659

Fig.B(c)

Circuit diagram (LR Mate 200iC 6-axes brake type When H302 is specified)

- 146 -

B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M5M1 (
X-KEY BLACK

F06DX CTM A1 J5U B1 J5G A2 BK(J5) B2 J5V A3 J5W B3 BKCOM1(J5)

A63L-0001-0865#1 A63L-0001-0864#CS

J5 MOTOR (iSR0.2/6000) M5M

2 3 J5V J5W 1 4 J5U J5G

K110 A660-4004-T711 A63L-0001-0865#2 A63L-0001-0864#CS

M5BK
2 3

BK(J5)

1 4

BKCOM1(J5)

A63L-0002-0066#R06DY A63L-0002-0066#CRM

M5P1 ( Y-KEY ) BLACK

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

F06DY CTM A1 +6V(BT5) B1 0V(BT5) A2 PRQJ5 B2 XPRQJ5 A3 +5V(C2) B3 0V(C2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M5P
K111 A660-2006-T662

8 9 +5V(C2) 10 0V(C2)

4 +6V(BT5) 1 5 XPRQJ5 2 6 PRQJ5 3 7 0V(BT5)

M6M1

Y-KEY WHITE

F06DYW CTM A1 J6U B1 J6G A2 BK(J6) B2 J6V BKCOM1(J6) A3 J6W B3

A63L-0001-0865#1 A63L-0001-0864#CS

J6 MOTOR (iSR0.2/6000) M6M

2 3 J6V J6W 1 4 J6U J6G

K112 A660-4004-T712 A63L-0001-0865#2 A63L-0001-0864#CS

M6BK
2 3

BK(J6)

1 4

BKCOM1(J6)

A63L-0002-0066#R06DXW A63L-0002-0066#CRM

M6P1

X-KEY WHITE

F06DXW CTM A1 +6V(BT6) B1 0V(BT6) A2 PRQJ6 B2 XPRQJ6 A3 +5V(C3) B3 0V(C3)

A63L-0001-0848#E10SL1 A63L-0001-0850

M6P

K113 A660-2006-T664

8 9 +5V(C3) 10 0V(C3)

4 +6V(BT6) 1 5 XPRQJ6 2 6 PRQJ6 3 7 0V(BT6)

A63L-0002-0066#R12DX A63L-0002-0066#CRM

EE1
A1 A2 A3 A4 A5 A6

( X-KEY ) BLACK

RI1 RI2 RI3 RI4 RI5 RI6

B1 B2 B3 B4 B5 B6

F12DX CTM XHBK +24V(A1) +24V(A2) +24V(B1) 0V(D1) 0V(D2)

EE
K114 A660-2006-T665 2 1 RI2 3

A63L-0002-0072#12SN RI1 9 +24V(A2) 8 +24V(A1) 10 +24V(B1) 12 0V(D2) 7 XHBK RI3 11 0V(D1) 6 RI6 4 RI4 5 RI5

A63L-0001-0865#1 A63L-0001-0864#CS

J4 MOTOR (iSR0.4/6000) M4M

2 3 J4V J4W 1 4 J4U J4G

K109 A660-4004-T710 A63L-0001-0865#2 A63L-0001-0864#CS

M4BK
2 3 A63L-0001-0848#E10SL1 A63L-0001-0850

BK(J4)

1 4

BKCOM1(J4)

M4P

8 9 +5V(C1) 10 0V(C1)

4 +6V(BT4) 1 5 XPRQJ4 2 6 PRQJ4 3 7 0V(BT4)

A05B-1139-H002 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 R12DX CRM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

A05B-1139-H004 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

YV2

X-KEY BLACK

A1 RO1 A2 RO2 A3 A4 A5 A6

F12DX CTM B1 0V(E1) B2 0V(E2) B3 B4 B5 B6

SOLENOID VALVE A97L-0218-0113#D1

SOLENOID VALVE A97L-0218-0113#D3

A05B-1139-H003 YV2
A1 RO1 A2 RO2 A3 RO3 A4 RO4 A5 A6 F12DX CTM B1 0V(E1) B2 0V(E2) B3 0V(E3) B4 0V(E4) B5 B6

A05B-1139-H005 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

SOLENOID VALVE A97L-0218-0113#D2

SOLENOID VALVE A97L-0218-0113#D3R

: MOVABLE

- 147 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

APPENDIX

B-82585EN/02

A05B-1139-H006
SPECIFIED A05B-1139-H006
A63L-0001-0865#1 A63L-0001-0864#CS

J1 MOTOR (iSR1/6000) M1M

2 3 J1V1 J1W1 1 4 J1U1 J1G1

A63L-0001-0865#2 A63L-0001-0864#CS

M1BK
2 3 A63L-0001-0848#E10SL1 A63L-0001-0850

BK(J1)

1 BKCOM1(J1) 4

M1P
8 9 +5V(A1) 10 0V(A1)

4 +6V(BT1) 1 5 XPRQJ1 2 6 PRQJ1 3 7 0V(BT1)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M2M1 ( X-KEY ) BLACK

A63L-0002-0066#R06DY A63L-0002-0066#CRM

A1 J2U1 A2 BK(J2) A3 J2W1

F06DX CTM B1 J2G1 B2 J2V1 B3 BKCOM1(J2)

A63L-0001-0865#1 A63L-0001-0864#CS

J2 MOTOR (iSR1/6000) M2M

2 3 J2V1 J2W1 1 4 J2U1 J2G1

K102 A660-4004-T706 A63L-0001-0865#2 A63L-0001-0864#CS

M2BK
2 3 BK(J2) 1 BKCOM1(J2) 4

M2P1 (
Y-KEY BLACK

F06DY CTM A1 +6V(BT2) B1 0V(BT3) B2 XPRQJ2 A2 PRQJ2 A3 +5V(B1) B3 0V(B1)

A63L-0001-0848#E10SL1 A63L-0001-0850

M2P
K103 A660-2006-T657

8 9 +5V(B1) 10 0V(B1)

4 +6V(BT2) 1 5 XPRQJ2 2 6 PRQJ2 3 7 0V(BT2)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M3M1 J1 CONNECTOR PANEL RMP

1 2 3 4 5 6 7 8 9 10 11 12 13 BKCOM1(J1) 14 15 J1U1 16 J1V1 17 J1W1 18 J1G1 19 XROT 20 RI1 21 RO1 +5V(A1) 22 PRQJ1 23 XPRQJ1 24 BK(J1) BK(J2) 25 BKCOM1(J2) 26 J2U1 27 J2V1 28 J2W1 29 J2G1 30 +24V(OT,A1,A2) 31 RI2 32 RO2 33 +5V(B1,B2) 34 35 PRQJ2 36 XPRQJ2 37 BK(J4) BKCOM1(J3) 38 BKCOM1(J4) J3U1 39 J4U J3V1 40 J4V J3W1 41 J4W J3G1 42 J4G XHBK 43 +24V(B1) RI3 44 RI4 RO3 45 RO4 +5V(C1,C2,C3) 46 0V(A1) PRQJ3 47 PRQJ4 XPRQJ3 48 XPRQJ4 G SG BK(J3) 49 50 51 52 53 54 55 56 57 58 59 60 Han 72DD (2.5SQ 10A) 61 BK(J6) BKCOM1(J5) 62 BKCOM1(J6) J5U 63 J6U J5V 64 J6V J5W 65 J6W J5G 66 J6G 0V(D1,D2) 67 0V(E1,E2,E3, E4,E5,E6) RI5 68 RI6 RO5 69 RO6 0V(B1,B2) 70 0V(C1,C2,C3) 71 PRQJ6 PRQJ5 72 XPRQJ6 XPRQJ5 BK(J5)

Y-KEY WHITE

A1 J3U1 A2 BK(J3) A3 J3W1

F06DYW CTM B1 J3G1 B2 J3V1 B3 BKCOM1(J3)

A63L-0001-0865#1 A63L-0001-0864#CS

J3 MOTOR (iSR0.5/6000) M3M

2 3 J3V1 J3W1 1 4 J3U1 J3G1

K104 A660-4004-T707 A63L-0001-0865#2 A63L-0001-0864#CS

M3BK
2 3

BK(J3)

1 BKCOM1(J3) 4

A63L-0002-0066#R06DXW A63L-0002-0066#CRM K101 A660-8016-T285

M3P1 (
X-KEY WHITE

F06DXW CTM A1 +6V(BT3) B1 0V(BT3) B2 XPRQJ3 A2 PRQJ3 A3 +5V(B2) B3 0V(B2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M3P
K105 A660-2006-T658

8 9 +5V(B2) 10 0V(B2)

4 +6V(BT3) 1 5 XPRQJ3 2 6 PRQJ3 3 7 0V(BT3)

M456M1
A63L-0002-0066#R20DX A63L-0002-0066#CRM A1 A2 A3 A4 A5 A6 A7 A8 A9 J4U BK(J4) J4W

( X-KEY ) BLACK

F20DX CTM B1 J4G B2 J4V B3 BKCOM1(J4) B4 J5G B5 J5U J5V B6 BK(J5) BKCOM1(J5) B7 J5W J6U B8 J6G BK(J6) B9 J6V A10 J6W B10 BKCOM1(J6)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M4M1

K106 A660-4004-T708

( X-KEY ) BLACK

F06DX CTM B1 J4G A1 J4U A2 BK(J4) B2 J4V BKCOM1(J4) B3 A3 J5W

K109 A660-4004-T710

BATTERY
+6V (BT1,BT2,BT3, BT4,BT5,BT6)

+
A63L-0002-0066#R20DY A63L-0002-0066#CRM

( ) SIZE C
0V (BT1,BT2,BT3, BT4,BT5,BT6)

( Y-KEY ) BLACK

F20DY CTM B1 XPRQJ4 B2 0V(BT4,BT5,BT6) B3 XPRQJ5 +5V(C1,C2,C3) B4 0V(C1,C2,C3) B5 XPRQJ6 PRQJ6 +24V(A1,A2) B6 XHBK +24V(B1) B7 0V(D1,D2) B8 RI2 RI1 B9 RI4 RI3 A10 RI5 B10 RI6

M456PEE1
A1 A2 A3 A4 A5 A6 A7 A8 A9 PRQJ4
+6V(BT4,BT5,BT6)

PRQJ5

K107 A660-4004-T709

A63L-0002-0066#R08DX A63L-0002-0066#CRM

YV1

( X-KEY ) BLACK

F08DX CTM A1 0V(E1,E3,E5) B1 0V(E2,E4,E6) A2 RO1 B2 RO2 A3 RO3 B3 RO4 A4 RO5 B4 RO6

K108 A660-2006-T659

Fig.B(d)

Circuit diagram (LR Mate 200iC 6-axes brake type When H006 is specified) (LR Mate 200iC/5C H006 is specified)

- 148 -

B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M5M1 (
X-KEY BLACK

A1 J5U A2 BK(J5) A3 J5W

F06DX CTM B1 J5G B2 J5V B3 BKCOM1(J5)

A63L-0001-0865#1 A63L-0001-0864#CS

J5 MOTOR (iSR0.2/6000) M5M

2 3 J5V J5W 1 4 J5U J5G

K110 A660-4004-T711 A63L-0001-0865#2 A63L-0001-0864#CS

M5BK
2 3 BK(J5) 1 4
BKCOM1(J5)

A63L-0002-0066#R06DY A63L-0002-0066#CRM

M5P1 (
Y-KEY BLACK

F06DY CTM A1 +6V(BT5) B1 0V(BT5) A2 PRQJ5 B2 XPRQJ5 A3 +5V(C2) B3 0V(C2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M5P
K111 A660-2006-T662

8 9 +5V(C2) 10 0V(C2)

4 +6V(BT5) 1 5 XPRQJ5 2 6 PRQJ5 3 7 0V(BT5)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M6M1 (
Y-KEY WHITE

A1 J6U A2 BK(J6) A3 J6W

F06DYW CTM B1 J6G B2 J6V B3 BKCOM1(J6)

A63L-0001-0865#1 A63L-0001-0864#CS

J6 MOTOR (iSR0.2/6000) M6M

2 3 J6V J6W 1 4 J6U J6G

K112 A660-4004-T712 A63L-0001-0865#2 A63L-0001-0864#CS

M6BK
2 3

BK(J6)

1 4

BKCOM1(J6)

A63L-0002-0066#R06DXW A63L-0002-0066#CRM

M6P1 (
X-KEY WHITE

F06DXW CTM A1 +6V(BT6) B1 0V(BT6) A2 PRQJ6 B2 XPRQJ6 A3 +5V(C3) B3 0V(C3)

A63L-0001-0848#E10SL1 A63L-0001-0850

M6P
K113 A660-2006-T664 8 9 +5V(C3) 10 0V(C3)

4 +6V(BT6) 1 5 XPRQJ6 2 6 PRQJ6 3 7 0V(BT6)

A63L-0002-0066#R12DX A63L-0002-0066#CRM

EE1
A1 A2 A3 A4 A5 A6 RI1 RI2 RI3 RI4 RI5 RI6 B1 B2 B3 B4 B5 B6

( X-KEY ) BLACK

F12DX CTM XHBK +24V(A1) +24V(A2) +24V(B1) 0V(D1) 0V(D2)

EE
K114 A660-4004-T864 1 2 3 4 0V(E1) 0V(E2) 0V(D1) 0V(D2) 5 6 7 8 9 10 RO1 RO2 RO3 RO4 RO5 RO6 11 12 13 14 15 16

A63L-0002-0072#20SN RI1 RI2 17 XHBK RI3 18 +24V(A1) RI4 19 +24V(A2) RI5 20 +24V(B1) RI6

A63L-0001-0865#1 A63L-0001-0864#CS

J4 MOTOR (iSR0.4/6000) M4M

2 3 J4V J4W 1 4 J4U J4G

K109 A660-4004-T710 A63L-0001-0865#2 A63L-0001-0864#CS

M4BK
2 3 A63L-0001-0848#E10SL1 A63L-0001-0850

BK(J4)

1 4

BKCOM1(J4)

M4P

8 9 +5V(C1) 10 0V(C1)

4 +6V(BT4) 1 5 XPRQJ4 2 6 PRQJ4 3 7 0V(BT4)

A05B-1139-H006 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 R12DX CRM 0V(E1) 0V(E2) (0V(E3)) (0V(E4)) (0V(E5)) (0V(E6))

YV2 ( X-KEY ) BLACK

A1 A2 A3 A4 A5 A6

RO1 RO2 RO3 RO4 RO5 RO6

B1 B2 B3 B4 B5 B6

F12DX CTM 0V(E1) 0V(E2) (0V(E3)) (0V(E4)) (0V(E5)) (0V(E6))

A63L-0002-0066#R08DX A63L-0002-0066#CRM

RO
A1 A2 A3 A4 0V(E1) RO1 RO3 RO5 B1 B2 B3 B4

K116 A660-2006-T834

( X-KEY ) BLACK

F08DX CTM 0V(E2) RO2 RO4 RO6

: MOVABLE

- 149 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

APPENDIX

B-82585EN/02

A63L-0001-0865#1 A63L-0001-0864#CS

J1 MOTOR (iSR1/6000) M1M

2 3 J1V1 J1W1 1 4 J1U1 J1G1

A63L-0001-0865#2 A63L-0001-0864#CS

M1BK
2 3 BK(J1) 1 BKCOM1(J1) 4

A63L-0001-0848#E10SL1 A63L-0001-0850

M1P
8 9 +5V(A1) 10 0V(A1)

4 +6V(BT1) 1 5 XPRQJ1 2 6 PRQJ1 3 7 0V(BT1)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M2M1 )
A1 J2U1 A2 BK(J2) A3 J2W1

X-KEY BLACK

F06DX CTM B1 J2G1 B2 J2V1 B3 BKCOM1(J2)

A63L-0001-0865#1 A63L-0001-0864#CS

J2 MOTOR (iSR1/6000) M2M

2 3 J2V1 J2W1 1 4 J2U1 J2G1

K102 A660-4004-T822 A63L-0001-0865#2 A63L-0001-0864#CS

M2BK
2 3 BK(J2) 1 BKCOM1(J2) 4

A63L-0002-0066#R06DY A63L-0002-0066#CRM

M2P1 )

Y-KEY BLACK

F06DY CTM A1 +6V(BT2) B1 0V(BT3) A2 PRQJ2 B2 XPRQJ2 A3 +5V(B1) B3 0V(B1)

A63L-0001-0848#E10SL1 A63L-0001-0850

M2P
8 9 +5V(B1) 10 0V(B1)

K103 A660-2006-T789

4 +6V(BT2) 1 5 XPRQJ2 2 6 PRQJ2 3 7 0V(BT2)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M3M1
A1 J3U1 A2 BK(J3) A3 J3W1

J1 CONNECTOR PANEL RMP

1 2 3 4 5 6 7 8 9 10 11 12 BK(J1)
BKCOM1(J1)

(
49 50 51 52 53 54 55 56 57 58 59 60 Han 72DD (2.5SQ 10A) 61 BK(J6) 62 BKCOM1(J6) J5U 63 J6U J5V 64 J6V J5W 65 J6W J5G 66 J6G 0V(D1,D2) 67 0V(E1,E2,E3, E4,E5,E6) RI5 68 RI6 RO5 69 RO6 0V(B1,B2) 70 0V(C1,C2,C3) 71 PRQJ6 PRQJ5 72 XPRQJ6 XPRQJ5 BK(J5)
BKCOM1(J5)

Y-KEY WHITE

F06DYW CTM B1 J3G1 B2 J3V1 B3 BKCOM1(J3)

A63L-0001-0865#1 A63L-0001-0864#CS

J3 MOTOR (iSR0.5/6000) M3M

2 3 J3V1 J3W1 1 4 J3U1 J3G1

K104 A660-4004-T823 A63L-0001-0865#2 A63L-0001-0864#CS

M3BK
2 3 BK(J3) 1 BKCOM1(J3) 4

J1U1 J1V1 J1W1 J1G1 XROT RI1 RO1 +5V(A1) PRQJ1 XPRQJ1

13 14 15 16 17 18 19 20 21 22 23 24

BK(J2) 25 26 J2U1 27 J2V1 28 J2W1 29 J2G1 30 +24V(OT,A1,A2) 31 RI2 32 RO2 33 +5V(B1,B2) 34 35 PRQJ2 36 XPRQJ2
BKCOM1(J2)

BK(J3) 37 BK(J4) 38 BKCOM1(J4) J3U1 39 J4U J3V1 40 J4V J3W1 41 J4W J3G1 42 J4G XHBK 43 +24V(B1) RI3 44 RI4 RO3 45 RO4 +5V(C1,C2,C3) 46 0V(A1) 47 PRQJ4 PRQJ3 48 XPRQJ4 XPRQJ3 G SG
BKCOM1(J3)

A63L-0002-0066#R06DXW A63L-0002-0066#CRM K101 A660-8016-T285

M3P1

X-KEY WHITE

F06DXW CTM A1 +6V(BT3) B1 0V(BT3) A2 PRQJ3 B2 XPRQJ3 A3 +5V(B2) B3 0V(B2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M3P
8 9 +5V(B2) 10 0V(B2)

K105 A660-2006-T790

4 +6V(BT3) 1 5 XPRQJ3 2 6 PRQJ3 3 7 0V(BT3)

M456M1
A63L-0002-0066#R20DX A63L-0002-0066#CRM A1 A2 A3 A4 A5 A6 A7 A8 A9 J4U BK(J4) J4W

( X-KEY ) BLACK

F20DX CTM B1 J4G B2 J4V B3 BKCOM1(J4) B4 J5G B5 J5U J5V B6 BK(J5) BKCOM1(J5) B7 J5W J6U B8 J6G BK(J6) B9 J6V A10 J6W B10 BKCOM1(J6)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M4M1
K106 A660-4004-T824

( X-KEY ) BLACK

A1 J4U A2 BK(J4) A3 J5W

F06DX CTM B1 J4G B2 J4V B3 BKCOM1(J4)

K109 A660-4004-T710

BATTERY
+6V (BT1,BT2,BT3, BT4,BT5,BT6)

+
A63L-0002-0066#R20DY A63L-0002-0066#CRM

M456PEE1
A1 A2 A3 A4 A5 A6 A7 A8 A9 PRQJ4
+6V(BT4,BT5,BT6)

( ) SIZE C
0V (BT1,BT2,BT3, BT4,BT5,BT6)

( Y-KEY ) BLACK

F20DY CTM B1 XPRQJ4 B2 0V(BT4,BT5,BT6) B3 XPRQJ5 +5V(C1,C2,C3) B4 0V(C1,C2,C3) PRQJ6 B5 XPRQJ6 +24V(A1,A2) B6 XHBK +24V(B1) B7 0V(D1,D2) B8 RI2 RI1 B9 RI4 RI3 A10 RI5 B10 RI6 PRQJ5

K107 A660-4004-T825

A63L-0002-0066#R08DX A63L-0002-0066#CRM

YV1

( X-KEY ) BLACK

A1 0V(E1,E3,E5) A2 RO1 A3 RO3 A4 RO5

F08DX CTM B1 0V(E2,E4,E6) B2 RO2 B3 RO4 B4 RO6

K108 A660-2006-T791

NOTE) 1. A05C-1139-B202 REFER TO A05C-1139-B202 IF SPECIFIED OPTIONS.

Fig.B(e)

Circuit diagram (LR Mate 200iC/5L)

- 150 -

B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M5M1 ( X-KEY ) BLACK

A63L-0002-0066#R06DY A63L-0002-0066#CRM

F06DX CTM A1 J5U B1 J5G A2 BK(J5) B2 J5V A3 J5W B3 BKCOM1(J5)

A63L-0001-0865#1 A63L-0001-0864#CS K110 A660-4004-T711 A63L-0001-0865#2 A63L-0001-0864#CS

J5 MOTOR (iSR0.2/6000) M5M

2 3 J5V J5W 1 4 J5U J5G

M5BK
2 3 BK(J5) 1 4
BKCOM1(J5)

M5P1 (
Y-KEY BLACK

F06DY CTM A1 +6V(BT5) B1 0V(BT5) A2 PRQJ5 B2 XPRQJ5 A3 +5V(C2) B3 0V(C2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M5P
K111 A660-2006-T662 8 9 +5V(C2) 10 0V(C2)

4 +6V(BT5) 1 5 XPRQJ5 2 6 PRQJ5 3 7 0V(BT5)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M6M1 ( Y-KEY ) WHITE

A63L-0002-0066#R06DXW A63L-0002-0066#CRM

F06DYW CTM A1 J6U B1 J6G A2 BK(J6) B2 J6V A3 J6W B3 BKCOM1(J6)

A63L-0001-0865#1 A63L-0001-0864#CS

J6 MOTOR (iSR0.2/6000) M6M

2 3 J6V J6W 1 4 J6U J6G

K112 A660-4004-T712 A63L-0001-0865#2 A63L-0001-0864#CS

M6BK
2 3

BK(J6)

1 4

BKCOM1(J6)

M6P1 (
X-KEY WHITE

F06DXW CTM A1 +6V(BT6) B1 0V(BT6) A2 PRQJ6 B2 XPRQJ6 A3 +5V(C3) B3 0V(C3)

A63L-0001-0848#E10SL1 A63L-0001-0850

M6P
K113 A660-2006-T664

8 9 +5V(C3) 10 0V(C3)

4 +6V(BT6) 1 5 XPRQJ6 2 6 PRQJ6 3 7 0V(BT6)

A63L-0002-0066#R12DX A63L-0002-0066#CRM

EE1 )
A1 A2 A3 A4 A5 A6

X-KEY BLACK

RI1 RI2 RI3 RI4 RI5 RI6

B1 B2 B3 B4 B5 B6

F12DX CTM XHBK +24V(A1) +24V(A2) +24V(B1) 0V(D1) 0V(D2)

EE
K114 A660-2006-T665 2

1 RI2 3

A63L-0002-0072#12SN RI1 9 +24V(A2) 8 +24V(A1) 10 +24V(B1) 12 0V(D2) 7 XHBK RI3 11 0V(D1) 6 RI6 4 RI4 5 RI5

A63L-0001-0865#1 A63L-0001-0864#CS

J4 MOTOR (iSR0.4/6000) M4M

2 3 J4V J4W 1 4 J4U J4G

A63L-0001-0865#2 A63L-0001-0864#CS

M4BK
2 3

BK(J4)

1 4

BKCOM1(J4)

A63L-0001-0848#E10SL1 A63L-0001-0850

M4P

8 9 +5V(C1) 10 0V(C1)

4 +6V(BT4) 1 5 XPRQJ4 2 6 PRQJ4 3 7 0V(BT4)

A05B-1139-H012 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 R12DX CRM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

A05B-1139-H014 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

YV2

( X-KEY ) BLACK

A1 RO1 A2 RO2 A3 A4 A5 A6

F12DX CTM B1 0V(E1) B2 0V(E2) B3 B4 B5 B6

SOLENOID VALVE A97L-0218-0113#D1

SOLENOID VALVE A97L-0218-0113#D3

A05B-1139-H013 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4)

A05B-1139-H015 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

SOLENOID VALVE A97L-0218-0113#D2

SOLENOID VALVE A97L-0218-0113#D3R

LR Mate 200iC/5L

: MOVABLE

- 151 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

APPENDIX

B-82585EN/02

A63L-0001-0865#1 A63L-0001-0864#CS

J1 MOTOR (iSR1/6000) M1M

2 3 J1V1 J1W1 1 4 J1U1 J1G1

A63L-0001-0865#2 A63L-0001-0864#CS

M1BK
2 3 A63L-0001-0848#E10SL1 A63L-0001-0850 BK(J1) 1 BKCOM1(J1) 4

M1P
8 9 +5V(A1) 10 0V(A1)

4 +6V(BT1) 1 5 XPRQJ1 2 6 PRQJ1 3 7 0V(BT1)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M2M1

( X-KEY ) BLACK
A63L-0002-0066#R06DY A63L-0002-0066#CRM

F06DX CTM A1 J2U1 B1 J2G1 A2 BK(J2) B2 J2V1 A3 J2W1 B3 BKCOM1(J2)

A63L-0001-0865#1 A63L-0001-0864#CS

J2 MOTOR (iSR1/6000) M2M

2 3 J2V1 J2W1 1 4 J2U1 J2G1

K102 A660-4004-T706 A63L-0001-0865#2 A63L-0001-0864#CS

M2BK
2 3 BK(J2) 1 BKCOM1(J2) 4

M2P1 )

Y-KEY BLACK

F06DY CTM A1 +6V(BT2) B1 0V(BT3) A2 PRQJ2 B2 XPRQJ2 A3 +5V(B1) B3 0V(B1)

A63L-0001-0848#E10SL1 A63L-0001-0850

M2P
8 9 +5V(B1) 10 0V(B1)

K103 A660-2006-T657

4 +6V(BT2) 1 5 XPRQJ2 2 6 PRQJ2 3 7 0V(BT2)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M3M1 J1 CONNECTOR PANEL RMP

1 2 3 4 5 6 7 8 9 10 11 12 BK(J1) 13 14 15 J1U1 16 J1V1 17 J1W1 18 J1G1 19 XROT 20 (RI1) 21 RO1 +5V(A1) 22 PRQJ1 23 XPRQJ1 24
BKCOM1(J1)

( Y-KEY ) WHITE
49 50 51 52 53 54 55 56 57 58 59 60 Han 72DD (2.5SQ 10A) BK(J5) 61 BK(J6) 62 BKCOM1(J6) J5U 63 J6U J5V 64 J6V J5W 65 J6W J5G 66 J6G (0V(D1,D2)) 67 0V(E1,E2,E3, E4,E5,E6) (RI5) 68 (RI6) RO5 69 RO6 0V(B1,B2) 70 0V(C1,C2,C3) PRQJ5 71 PRQJ6 XPRQJ5 72 XPRQJ6
BKCOM1(J5)

F06DYW CTM B1 J3G1 A1 J3U1 A2 BK(J3) B2 J3V1 B3 BKCOM1(J3) A3 J3W1

A63L-0001-0865#1 A63L-0001-0864#CS

J3 MOTOR (iSR0.5/6000) M3M

2 3 J3V1 J3W1 1 4 J3U1 J3G1

K104 A660-4004-T707 A63L-0001-0865#2 A63L-0001-0864#CS

M3BK
2 3 BK(J3) 1 BKCOM1(J3) 4

BK(J2) 25 26 J2U1 27 J2V1 28 J2W1 29 J2G1 30 +24V(OT,A1,A2) 31 (RI2) 32 RO2 33 +5V(B1,B2) 34 PRQJ2 35 XPRQJ2 36
BKCOM1(J2)

BK(J3) 37 BK(J4) 38 BKCOM1(J4) J3U1 39 J4U J3V1 40 J4V J3W1 41 J4W J3G1 42 J4G (XHBK) 43 (+24V(B1)) (RI3) 44 (RI4) RO3 45 RO4 +5V(C1,C2,C3) 46 0V(A1) PRQJ3 47 PRQJ4 XPRQJ3 48 XPRQJ4 G SG
BKCOM1(J3)

A63L-0002-0066#R06DXW A63L-0002-0066#CRM K101 A660-8016-T495

M3P1 (
X-KEY WHITE

F06DXW CTM A1 +6V(BT3) B1 0V(BT3) A2 PRQJ3 B2 XPRQJ3 A3 +5V(B2) B3 0V(B2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M3P
K105 A660-2006-T658 8 9 +5V(B2) 10 0V(B2)

4 +6V(BT3) 1 5 XPRQJ3 2 6 PRQJ3 3 7 0V(BT3)

M456M1
A63L-0002-0066#R20DX A63L-0002-0066#CRM A1 A2 A3 A4 A5 A6 A7 A8 A9

( X-KEY ) BLACK

F20DX CTM J4U B1 J4G BK(J4) B2 J4V J4W B3 BKCOM1(J4) B4 J5G B5 J5U J5V B6 BK(J5) BKCOM1(J5) B7 J5W J6U B8 J6G BK(J6) B9 J6V A10 J6W B10 BKCOM1(J6)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M4M1
K106 A660-4004-T708

( X-KEY ) BLACK

F06DX CTM B1 J4G A1 J4U A2 BK(J4) B2 J4V B3 BKCOM1(J4) A3 J5W

K109 A660-4004-T710

BATTERY
+6V (BT1,BT2,BT3, BT4,BT5,BT6)

+
K131 A660-8016-T498

( ) SIZE D
0V (BT1,BT2,BT3, BT4,BT5,BT6)

GB2
A B C

+6V(BT1,BT2,BT3, BT4,BT5,BT6) 0V(BT1,BT2,BT3, BT4,BT5,BT6)

GB2
A B C

M456PEE1
A63L-0002-0066#R20DY A63L-0002-0066#CRM A1 A2 A3 A4 A5 A6 A7 A8 A9 PRQJ4
+6V(BT4,BT5,BT6)

+6V(BT1,BT2,BT3, BT4,BT5,BT6) 0V(BT1,BT2,BT3, BT4,BT5,BT6)

A63L-0001-0648#610SL3SJ

A63L-0001-0648#210SL3PJ

( Y-KEY ) BLACK

F20DY CTM B1 XPRQJ4 B2 0V(BT4,BT5,BT6) B3 XPRQJ5 +5V(C1,C2,C3) B4 0V(C1,C2,C3) PRQJ6 B5 XPRQJ6 (+24V(A1,A2)) B6 (XHBK) (+24V(B1)) B7 (0V(D1,D2)) (RI1) B8 (RI2) (RI3) B9 (RI4) A10 (RI5) B10 (RI6) PRQJ5

K107 A660-4004-T709

A63L-0002-0066#R08DX A63L-0002-0066#CRM

YV1
A1 0V(E1,E3,E5) A2 RO1 A3 RO3 A4 RO5

( X-KEY ) BLACK

F08DX CTM B1 0V(E2,E4,E6) B2 RO2 B3 RO4 B4 RO6

K108 A660-2006-T659

Fig.B(f)

Circuit diagram (LR Mate 200iC/5WP)

- 152 -

B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M5M1 (
X-KEY BLACK

A1 J5U A2 BK(J5) A3 J5W

F06DX CTM B1 J5G B2 J5V B3 BKCOM1(J5)

A63L-0001-0865#1 A63L-0001-0864#CS

J5 MOTOR (iSR0.2/6000) M5M

2 3 J5V J5W 1 4 J5U J5G

K110 A660-4004-T711 A63L-0001-0865#2 A63L-0001-0864#CS

M5BK
2 3

BK(J5)

1 BKCOM1(J5) 4

A63L-0002-0066#R06DY A63L-0002-0066#CRM

M5P1 )

Y-KEY BLACK

F06DY CTM A1 +6V(BT5) B1 0V(BT5) A2 PRQJ5 B2 XPRQJ5 A3 +5V(C2) B3 0V(C2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M5P
8 9 +5V(C2) 10 0V(C2)

K111 A660-2006-T662

4 +6V(BT5) 1 5 XPRQJ5 2 6 PRQJ5 3 7 0V(BT5)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M6M1
A1 J6U A2 BK(J6) A3 J6W

( Y-KEY ) WHITE
A63L-0002-0066#R06DXW A63L-0002-0066#CRM

F06DYW CTM B1 J6G B2 J6V B3 BKCOM1(J6)

A63L-0001-0865#1 A63L-0001-0864#CS

J6 MOTOR (iSR0.2/6000) M6M

2 3 J6V J6W 1 4 J6U J6G

K112 A660-4004-T712 A63L-0001-0865#2 A63L-0001-0864#CS

M6BK
2 3 A63L-0001-0848#E10SL1 A63L-0001-0850 BK(J6) 1 BKCOM1(J6) 4

M6P1 (
X-KEY WHITE

F06DXW CTM A1 +6V(BT6) B1 0V(BT6) A2 PRQJ6 B2 XPRQJ6 A3 +5V(C3) B3 0V(C3)

M6P
K113 A660-2006-T664

8 9 +5V(C3) 10 0V(C3)

4 +6V(BT6) 1 5 XPRQJ6 2 6 PRQJ6 3 7 0V(BT6)

A63L-0002-0066#R12DX A63L-0002-0066#CRM

( X-KEY ) BLACK

A63L-0001-0865#1 A63L-0001-0864#CS

J4 MOTOR (iSR0.4/6000) M4M

2 3 J4V J4W 1 4 J4U J4G

K109 A660-4004-T710 A63L-0001-0865#2 A63L-0001-0864#CS

M4BK
2 3 BK(J4) 1 BKCOM1(J4) 4

A63L-0001-0848#E10SL1 A63L-0001-0850

M4P
8 9 +5V(C1) 10 0V(C1)

4 +6V(BT4) 1 5 XPRQJ4 2 6 PRQJ4 3 7 0V(BT4)

A05B-1139-H032 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 R12DX CRM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

YV2
A1 RO1 A2 RO2 A3 A4 A5 A6

( X-KEY ) BLACK

F12DX CTM B1 0V(E1) B2 0V(E2) B3 B4 B5 B6

SOLENOID VALVE A97L-0218-0113#D1

A05B-1139-H033 YV2
A1 RO1 A2 RO2 A3 RO3 A4 RO4 A5 A6 F12DX CTM B1 0V(E1) B2 0V(E2) B3 0V(E3) B4 0V(E4) B5 B6

LR Mate 200iC/5WP
SOLENOID VALVE A97L-0218-0113#D2

: MOVABLE

- 153 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

APPENDIX

B-82585EN/02

A63L-0001-0865#1 A63L-0001-0864#CS

J1 MOTOR (iSR1/6000) M1M

2 3 J1V1 J1W1 1 4 J1U1 J1G1

A63L-0001-0865#2 A63L-0001-0864#CS

M1BK
2 3

BK(J1)

1 4

BKCOM1(J1)

A63L-0001-0848#E10SL1 A63L-0001-0850

M1P
8 9 +5V(A1) 10 0V(A1)

4 +6V(BT1) 1 5 XPRQJ1 2 6 PRQJ1 3 7 0V(BT1)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M2M1 )
A1 J2U1 A2 BK(J2) A3 J2W1

X-KEY BLACK

F06DX CTM B1 J2G1 B2 J2V1 B3 BKCOM1(J2)

A63L-0001-0865#1 A63L-0001-0864#CS

J2 MOTOR (iSR1/6000) M2M

2 3 J2V1 J2W1 1 4 J2U1 J2G1

K102 A660-4004-T706 A63L-0001-0865#2 A63L-0001-0864#CS

M2BK
2 3

BK(J2)

1 4

BKCOM1(J2)

A63L-0002-0066#R06DY A63L-0002-0066#CRM

M2P1 )

Y-KEY BLACK

F06DY CTM A1 +6V(BT2) B1 0V(BT3) A2 PRQJ2 B2 XPRQJ2 A3 +5V(B1) B3 0V(B1)

A63L-0001-0848#E10SL1 A63L-0001-0850

M2P
8 9 +5V(B1) 10 0V(B1)

K103 A660-2006-T657

4 +6V(BT2) 1 5 XPRQJ2 2 6 PRQJ2 3 7 0V(BT2)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M3M1
A1 J3U1 A2 BK(J3) A3 J3W1

J1 CONNECTOR PANEL RMP

1 2 3 4 5 6 7 8 9 10 11 12 BK(J1) 13 14 15 J1U1 16 J1V1 17 J1W1 18 J1G1 19 XROT 20 RI1 21 RO1 +5V(A1) 22 PRQJ1 23 XPRQJ1 24
BKCOM1(J1)

(
49 50 51 52 53 54 55 56 57 58 59 60 Han 72DD (2.5SQ 10A) (BK(J4)) 61 (BK(J5)) (BKCOM1(J4)) 62 (BKCOM1(J5)) J4U 63 J5U J4V 64 J5V J4W 65 J5W J4G 66 J5G 0V(D1,D2) 67 0V(E1,E2,E3, E4,E5,E6) RI5 68 RI6 RO5 69 RO6 0V(B1,B2) 70 0V(C1,C2) PRQJ4 71 PRQJ5 XPRQJ4 72 XPRQJ5

Y-KEY WHITE

F06DYW CTM B1 J3G1 B2 J3V1 B3 BKCOM1(J3)

A63L-0001-0865#1 A63L-0001-0864#CS

J3 MOTOR (iSR0.5/6000) M3M

2 3 J3V1 J3W1 1 4 J3U1 J3G1

K104 A660-4004-T707 A63L-0001-0865#2 A63L-0001-0864#CS

M3BK
2 3

BK(J3)

BK(J2) 25 26 J2U1 27 J2V1 28 J2W1 29 J2G1 30 +24V(OT,A1,A2) 31 RI2 32 RO2 33 +5V(B1,B2) 34 35 PRQJ2 36 XPRQJ2
BKCOM1(J2)

BK(J3) 37 (BK(X)) 38 (BKCOM1(X)) J3U1 39 (XU) J3V1 40 (XV) J3W1 41 (XW) J3G1 42 (XG) XHBK 43 +24V(B1) RI3 44 RI4 RO3 45 RO4 +5V(C1,C2) 46 0V(A1) PRQJ3 47 (PRQX) XPRQJ3 48 (XPRQX) G SG
BKCOM1(J3)

1 4

BKCOM1(J3)

A63L-0002-0066#R06DXW A63L-0002-0066#CRM K101 A660-8016-T285

M3P1

X-KEY WHITE

F06DXW CTM A1 +6V(BT3) B1 0V(BT3) A2 PRQJ3 B2 XPRQJ3 A3 +5V(B2) B3 0V(B2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M3P

K105 A660-2006-T658

8 9 +5V(B2) 10 0V(B2)

4 +6V(BT3) 1 5 XPRQJ3 2 6 PRQJ3 3 7 0V(BT3)

M456M1
A63L-0002-0066#R20DX A63L-0002-0066#CRM A1 A2 A3 A4 A5 A6 A7 A8 A9 (XU) (BK(X)) (XW)

( X-KEY ) BLACK

F20DX CTM B1 (XG) B2 (XV) B3 (BKCOM1(X)) B4 J4G B5 J4U J4V B6 (BK(J4)) (BKCOM1(J4)) B7 J4W J5U B8 J5G (BK(J5)) B9 J5V A10 J5W B10 (BKCOM1(J5))

K106 A660-4004-T810

BATTERY
+6V (BT1,BT2,BT3, BT4,BT5)

+
A63L-0002-0066#R20DY A63L-0002-0066#CRM

M456PEE1 F20DY CTM

A1 A2 A3 A4 A5 A6 A7 A8 A9 (PRQX) PRQJ4 PRQJ5
+6V(BT4,BT5)

( ) SIZE C
0V (BT1,BT2,BT3, BT4,BT5)

( Y-KEY ) BLACK

B1 (XPRQX) B2 0V(BT4,BT5) B3 XPRQJ4 B4 0V(C1,C2) B5 XPRQJ5 +24V(A1,A2) B6 XHBK +24V(B1) B7 0V(D1,D2) RI1 B8 RI2 RI3 B9 RI4 A10 RI5 B10 RI6
+5V(C1,C2)

K107 A660-4004-T811

A63L-0002-0066#R08DX A63L-0002-0066#CRM

YV1

( X-KEY ) BLACK

F08DX CTM A1 0V(E1,E3,E5) B1 0V(E2,E4,E6) A2 RO1 B2 RO2 A3 RO3 B3 RO4 A4 RO5 B4 RO6

K108 A660-2006-T659

NOTE) 1. (***) SIGNALS ARE NOT USED.

2. A05C-1139-B202 REFER TO A05C-1139-B202 IF SPECIFIED OPTIONS.

Fig. B(g) CIRCUIT DIAGRAM (LR Mate 200iC/5H 3-axes brake type)

- 154 -

B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M4M1H (
X-KEY BLACK

A1 J4U A2 A3 J4W

F06DX CTM B1 J4G B2 J4V B3

A63L-0001-0865#1 A63L-0001-0864#CS

J4 MOTOR (iSR0.2/6000) M4M

2 3 J4V J4W 1 4 J4U J4G

K110 A660-2006-T771

A63L-0002-0066#R06DY A63L-0002-0066#CRM

M4P1H (
Y-KEY BLACK

F06DY CTM A1 +6V(BT4) B1 0V(BT4) B2 XPRQJ4 A2 PRQJ4 A3 +5V(C1) B3 0V(C1)

A63L-0001-0848#E10SL1 A63L-0001-0850

M4P
K111 A660-2006-T772 8 9 +5V(C1) 10 0V(C1)

4 +6V(BT4) 1 5 XPRQJ4 2 6 PRQJ4 3 7 0V(BT4)

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

M5M1H ( Y-KEY ) WHITE

A63L-0002-0066#R06DXW A63L-0002-0066#CRM A1 J5U A2 A3 J5W

F06DYW CTM B1 J5G B2 J5V B3

A63L-0001-0865#1 A63L-0001-0864#CS

J5 MOTOR (iSR0.2/6000) M5M

2 3 J5V J5W 1 4 J5U J5G

K112 A660-2006-T773

M5P1H (
X-KEY WHITE

F06DXW CTM A1 +6V(BT5) B1 0V(BT5) B2 XPRQJ5 A2 PRQJ5 A3 +5V(C2) B3 0V(C2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M5P
K113 A660-2006-T774

8 9 +5V(C2) 10 0V(C2)

4 +6V(BT5) 1 5 XPRQJ5 2 6 PRQJ5 3 7 0V(BT5)

A63L-0002-0066#R12DX A63L-0002-0066#CRM

EE1 )
A1 A2 A3 A4 A5 A6

X-KEY BLACK

RI1 RI2 RI3 RI4 RI5 RI6

B1 B2 B3 B4 B5 B6

F12DX CTM XHBK +24V(A1) +24V(A2) +24V(B1) 0V(D1) 0V(D2)

EE
K114 A660-2006-T665 2

1 RI2 3

A63L-0002-0072#12SN RI1 9 +24V(A2) 8 +24V(A1) 10 +24V(B1) 12 0V(D2) 7 XHBK RI3 11 0V(D1) 6 RI6 4 RI4 5 RI5

A05B-1139-H002 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 R12DX CRM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

A05B-1139-H004 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

YV2
A1 RO1 A2 RO2 A3 A4 A5 A6

( X-KEY ) BLACK

F12DX CTM B1 0V(E1) B2 0V(E2) B3 B4 B5 B6

SOLENOID VALVE A97L-0218-0113#D1

SOLENOID VALVE A97L-0218-0113#D3

A05B-1139-H003 YV2
A1 RO1 A2 RO2 A3 RO3 A4 RO4 A5 A6 F12DX CTM B1 0V(E1) B2 0V(E2) B3 0V(E3) B4 0V(E4) B5 B6

A05B-1139-H005 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

SOLENOID VALVE A97L-0218-0113#D2

SOLENOID VALVE A97L-0218-0113#D3R

LR Mate 200iC/5H (3BK)

: MOVABLE

- 155 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

APPENDIX

B-82585EN/02

A63L-0001-0865#1 A63L-0001-0864#CS

J1 MOTOR (iSR1/6000) M1M

2 3 J1V1 J1W1 1 4 J1U1 J1G1

A63L-0001-0865#2 A63L-0001-0864#CS

M1BK
2 3 BK(J1) 1 BKCOM1(J1) 4

A63L-0001-0848#E10SL1 A63L-0001-0850

M1P
8 9 +5V(A1) 10 0V(A1)

4 +6V(BT1) 1 5 XPRQJ1 2 6 PRQJ1 3 7 0V(BT1)

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M2M1 (
X-KEY BLACK

A1 J2U1 A2 BK(J2) A3 J2W1

F06DX CTM B1 J2G1 B2 J2V1 B3 BKCOM1(J2)

A63L-0001-0865#1 A63L-0001-0864#CS

J2 MOTOR (iSR1/6000) M2M

2 3 J2V1 J2W1 1 4 J2U1 J2G1

K102 A660-4004-T706 A63L-0001-0865#2 A63L-0001-0864#CS

M2BK
2 3 BK(J2) 1 BKCOM1(J2) 4

A63L-0002-0066#R06DY A63L-0002-0066#CRM

M2P1

( Y-KEY ) BLACK
A63L-0002-0066#R06DYW A63L-0002-0066#CRM

F06DY CTM A1 +6V(BT2) B1 0V(BT3) A2 PRQJ2 B2 XPRQJ2 A3 +5V(B1) B3 0V(B1)

A63L-0001-0848#E10SL1 A63L-0001-0850

M2P
8 9 +5V(B1) 10 0V(B1)

K103 A660-2006-T657

4 +6V(BT2) 1 5 XPRQJ2 2 6 PRQJ2 3 7 0V(BT2)

M3M1
A1 J3U1 A2 BK(J3) A3 J3W1

J1 CONNECTOR PANEL RMP

1 2 3 4 5 6 7 8 9 10 11 12 BK(J1)
BKCOM1(J1)

(
49 50 (XU) 51 (XV) 52 (XW) 53 (XG) 54 +24V(B1) 55 RI4 56 RO4 57 0V(A1) 58 (PRQX) 59 (XPRQX) 60 (BK(X))
(BKCOM1(X))

Y-KEY WHITE

F06DYW CTM B1 J3G1 B2 J3V1 B3 BKCOM1(J3)

A63L-0001-0865#1 A63L-0001-0864#CS

J3 MOTOR (iSR0.5/600 M3M

2 3 J3V1 J3W1 1 4 J3U1 J3G1

K104 A660-4004-T707 A63L-0001-0865#2 A63L-0001-0864#CS

J1U1 J1V1 J1W1 J1G1 XROT RI1 RO1 +5V(A1) PRQJ1 XPRQJ1

13 14 15 16 17 18 19 20 21 22 23 24

25 26 J2U1 27 J2V1 28 J2W1 29 J2G1 30 +24V(OT,A1,A2) 31 RI2 32 RO2 33 +5V(B1,B2) 34 PRQJ2 35 XPRQJ2 36 BK(J2)
BKCOM1(J2)

BK(J3) 37 38 J3U1 39 J3V1 40 J3W1 41 J3G1 42 XHBK 43 RI3 44 RO3 45 +5V(C1,C2) 46 PRQJ3 47 XPRQJ3 48 G SG
BKCOM1(J3)

Han 72DD (2.5SQ 10A) BK(J4) 61 BK(J5) 62 BKCOM1(J5) J4U 63 J5U J4V 64 J5V J4W 65 J5W J4G 66 J5G 0V(D1,D2) 67 0V(E1,E2,E3, E4,E5,E6) RI5 68 RI6 RO5 69 RO6 0V(B1,B2) 70 0V(C1,C2) PRQJ4 71 PRQJ5 XPRQJ4 72 XPRQJ5
BKCOM1(J4)

M3BK
2 3 BK(J3) 1 BKCOM1(J3) 4

A63L-0002-0066#R06DXW A63L-0002-0066#CRM K101 A660-8016-T285

M3P1

( X-KEY ) WHITE

F06DXW CTM A1 +6V(BT3) B1 0V(BT3) A2 PRQJ3 B2 XPRQJ3 A3 +5V(B2) B3 0V(B2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M3P

K105 A660-2006-T658

8 9 +5V(B2) 10 0V(B2)

4 +6V(BT3) 1 5 XPRQJ3 2 6 PRQJ3 3 7 0V(BT3)

M456M1
A63L-0002-0066#R20DX A63L-0002-0066#CRM A1 A2 A3 A4 A5 A6 A7 A8 A9 (XU) (BK(X)) (XW)

( X-KEY ) BLACK

F20DX CTM B1 (XG) B2 (XV) (BKCOM1(X)) B3 B4 J4G B5 J4U J4V B6 BK(J4) BKCOM1(J4) B7 J4W J5U B8 J5G BK(J5) B9 J5V A10 J5W B10 BKCOM1(J5)

K106 A660-4004-T810

BATTERY
+6V (BT1,BT2,BT3, BT4,BT5)

+
A63L-0002-0066#R20DY A63L-0002-0066#CRM

M456PEE1 F20DY CTM

B1 (XPRQX) B2 0V(BT4,BT5) B3 XPRQJ4 B4 0V(C1,C2) PRQJ5 B5 XPRQJ5 +24V(A1,A2) B6 XHBK +24V(B1) B7 0V(D1,D2) RI1 B8 RI2 RI3 B9 RI4 A10 RI5 B10 RI6 A1 A2 A3 A4 A5 A6 A7 A8 A9 (PRQX) PRQJ4
+6V(BT4,BT5)

( ) SIZE C
0V (BT1,BT2,BT3, BT4,BT5)

+5V(C1,C2)

K107 A660-4004-T811

( Y-KEY ) BLACK

A63L-0002-0066#R08DX A63L-0002-0066#CRM

YV1

( X-KEY ) BLACK

F08DX CTM A1 0V(E1,E3,E5) B1 0V(E2,E4,E6) A2 RO1 B2 RO2 A3 RO3 B3 RO4 A4 RO5 B4 RO6

K108 A660-2006-T659

NOTE) 1. (***) SIGNALS ARE NOT USED. 2. A05C-1139-B202 REFER TO A05C-1139-B202 IF SPECIFIED OPTIONS.

Fig. B(h) CIRCUIT DIAGRAM (LR Mate 200iC/5H 6-axes brake type)

- 156 -

B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

A63L-0002-0066#R06DX A63L-0002-0066#CRM

M4M1 ( X-KEY ) BLACK

A63L-0002-0066#R06DY A63L-0002-0066#CRM

A1 J4U A2 BK(J4) A3 J4W

F06DX CTM B1 J4G B2 J4V B3 BKCOM1(J4)

A63L-0001-0865#1 A63L-0001-0864#CS

J4 MOTOR (iSR0.2/6000) M4M

2 3 J4V J4W 1 4 J4U J4G

K110 A660-4004-T812 A63L-0001-0865#2 A63L-0001-0864#CS

M4BK
2 3 A63L-0001-0848#E10SL1 A63L-0001-0850 BK(J4) 1 BKCOM1(J4) 4

M4P1 ( Y-KEY ) BLACK

A63L-0002-0066#R06DYW A63L-0002-0066#CRM

F06DY CTM A1 +6V(BT4) B1 0V(BT4) A2 PRQJ4 B2 XPRQJ4 A3 +5V(C1) B3 0V(C1)

M4P
K111 A660-2006-T772 8 9 +5V(C1) 10 0V(C1)

4 +6V(BT4) 1 5 XPRQJ4 2 6 PRQJ4 3 7 0V(BT4)

M5M1 (
Y-KEY WHITE

A1 J5U A2 BK(J5) A3 J5W

F06DYW CTM B1 J5G B2 J5V B3 BKCOM1(J5)

A63L-0001-0865#1 A63L-0001-0864#CS

J5 MOTOR (iSR0.2/6000) M5M

2 3 J5V J5W 1 4 J5U J5G

K112 A660-4004-T813 A63L-0001-0865#2 A63L-0001-0864#CS

M5BK
2 3

BK(J5)

1 BKCOM1(J5) 4

A63L-0002-0066#R06DXW A63L-0002-0066#CRM

M5P1 ( X-KEY ) WHITE

F06DXW CTM A1 +6V(BT5) B1 0V(BT5) A2 PRQJ5 B2 XPRQJ5 A3 +5V(C2) B3 0V(C2)

A63L-0001-0848#E10SL1 A63L-0001-0850

M5P
K113 A660-2006-T774

8 9 +5V(C2) 10 0V(C2)

4 +6V(BT5) 1 5 XPRQJ5 2 6 PRQJ5 3 7 0V(BT5)

A63L-0002-0066#R12DX A63L-0002-0066#CRM

EE1 )
A1 A2 A3 A4 A5 A6 RI1 RI2 RI3 RI4 RI5 RI6 B1 B2 B3 B4 B5 B6

X-KEY BLACK

F12DX CTM XHBK +24V(A1) +24V(A2) +24V(B1) 0V(D1) 0V(D2)

EE
K114 A660-2006-T665 2 1 RI2 3

A63L-0002-0072#12SN RI1 9 +24V(A2) 8 +24V(A1) 10 +24V(B1) 12 0V(D2) 7 XHBK RI3 11 0V(D1) 6 RI6 4 RI4 5 RI5

A05B-1139-H002 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 R12DX CRM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

A05B-1139-H004 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

YV2

( X-KEY ) BLACK

A1 RO1 A2 RO2 A3 A4 A5 A6

F12DX CTM B1 0V(E1) B2 0V(E2) B3 B4 B5 B6

SOLENOID VALVE A97L-0218-0113#D1

SOLENOID VALVE A97L-0218-0113#D3

A05B-1139-H003 YV2
A1 RO1 A2 RO2 A3 RO3 A4 RO4 A5 A6 F12DX CTM B1 0V(E1) B2 0V(E2) B3 0V(E3) B4 0V(E4) B5 B6

A05B-1139-H005 YV2
A1 A2 A3 A4 A5 A6 RO1 RO2 RO3 RO4 RO5 RO6 B1 B2 B3 B4 B5 B6 F12DX CTM 0V(E1) 0V(E2) 0V(E3) 0V(E4) 0V(E5) 0V(E6)

SOLENOID VALVE A97L-0218-0113#D2

SOLENOID VALVE A97L-0218-0113#D3R

LR Mate 200iC/5H (5BK)

: MOVABLE

- 157 -

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

APPENDIX

B-82585EN/02

J1 connector plate AIR 1 J1 connector plate AIR 2

J3 arm

J3 casing Exhaust port RO1

RO2

RO2

RO1

Fig. B(i) Air pressure diagram (Double solenoid valve1 A05B-1139-H002,H012,H017,H022,H032 is specified)

J1 connector plate AIR 1 J1 connector plate AIR 2

J3 arm

J3 casing Exhaust port RO3 RO1

RO2 RO4

RO4

RO3

RO2

RO1

Fig. B(j) Air pressure diagram (Double solenoid valve2 A05B-1139-H003,H013,H018,H023,H033 is specified)

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B-82585EN02

APPENDIX

B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

J1 connector plate AIR 1 J1 connector plate AIR 2

J3 arm

J3 casing Exhaust port RO5 RO3 RO1

RO2 RO6 RO4 RO2 RO1

RO6

RO5

RO4

RO3

Fig. B(k) Air pressure diagram (Double solenoid valve3 A05B-1139-H004,H014,H024 is specified)

J1 connector plate AIR 1 J1 connector plate AIR 2

J3 arm

J3 casing Exhaust port RO5 RO3 RO1

RO2 RO4

RO6 RO2 RO1

RO6

RO5

RO4

RO3

Fig. B(l) Air pressure diagram (Double solenoid valve3R A05B-1139-H005,H015 is specified)

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C.PERIODIC MAINTENANCE TABLE

APPENDIX

B-82585EN/02

C
Items 1

PERIODIC MAINTENANCE TABLE

FANUC Robot LR Mate 200iC, LR Mate 200iC/5C, /5L, /5LC Periodic Maintenance Table

Working time (H)

Check the exposed connector.(loosening)

Check time

1 First Oil 6 9 3 Grease check months months months years amount 320 960 1920 2880 3840

2 years 4800 5760 6720 7680 8640 9600 10560

0.2H 0.2H 2.0H 1.0H 0.1H 0.1H 0.5H 4.0H 0.2H 0.2H 0.2H 0.1H

2 Tighten the end effector bolt. 3 bolt.

Tighten the cover and main

Mechanical unit

4 Remove spatter and dust etc.

Replacing battery. (if built-in batteries are specified) Replacing battery. (if external batteries are specified)

6 Greasing the reducers. 7 unit *1

Replacing cable of mechanical Check the robot cable and

14ml

8 teach pendant cable Control unit

9 Cleaning the ventilator 10 Check the source voltage *1 11 Replacing battery *1

*1 Refer to manual of controller. *2 : requires exchange of parts : does not require exchange of parts

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B-82585EN/02

APPENDIX

C.PERIODIC MAINTENANCE TABLE

3 years

4 years

5 years

6 years

7 years

8 years

11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720

Item 1 2 3

5 Overhaul

6 7

8 9 10 11

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C.PERIODIC MAINTENANCE TABLE

APPENDIX

B-82585EN/02

FANUC Robot LR Mate 200iC/5WP

Periodic Maintenance Table

Working time (H) Items 1 connector.(loosening) 2 Tighten the end effector bolt. Mechanical unit
Check the exposed

1 First Check Oil 6 9 3 time Grease check months months months years amount 320 960 1920 2880 3840

2 years 4800 5760 6720 7680 8640 9600 10560

0.2H 0.2H

3 Tighten the cover and main bolt. 2.0H 4 Remove spatter and dust etc. 5 battery)
Replacing battery.(external

1.0H 0.1H 0.5H 4.0H 0.2H 0.2H 0.2H 0.1H

6 Greasing the reducers. 7 unit *

Replacing cable of mechanical Check the robot cable and teach

14ml

8 pendant cable Control unit

9 Cleaning the ventilator 10 Check the source voltage *1 11 Replacing battery *1

*1 Refer to manual of controller. *2 : requires exchange of parts : does not require exchange of parts

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B-82585EN/02

APPENDIX

C.PERIODIC MAINTENANCE TABLE

3 years

4 years

11520 12480 13440 14400 15360

Item 1 2 3

Overhaul

4 5 6 7 8 9 10 11

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C.PERIODIC MAINTENANCE TABLE

APPENDIX

B-82585EN/02

FANUC Robot LR Mate 200iC/5H

Periodic Maintenance Table

Working time (H) Items 1

Check the exposed connector.(loosening)

Check time

1 First Oil 6 9 3 Grease check months months months years amount 320 960 1920 2880 3840

2 years 4800 5760 6720 7680 8640 9600 10560

0.2H 0.2H 2.0H 1.0H 0.1H 0.1H 0.5H 4.0H 0.2H 0.2H 0.2H 0.1H

2 Tighten the end effector bolt. 3 bolt.

Tighten the cover and main

Mechanical unit

4 Remove spatter and dust etc.

Replacing battery. (if built-in batteries are specified) Replacing battery. (if external batteries are specified)

6 Greasing the reducers. 7 unit *

Replacing cable of mechanical Check the robot cable and

12ml

8 teach pendant cable Control unit

9 Cleaning the ventilator 10 Check the source voltage *1 11 Replacing battery *1

*1 Refer to manual of controller. *2 : requires exchange of parts : does not require exchange of parts

- 164 -

B-82585EN/02

APPENDIX

C.PERIODIC MAINTENANCE TABLE

3 years

4 years

5 years

6 years

7 years

8 years

11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720

Item 1 2 3

5 Overhaul

6 7

8 9 10 11

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D.MOUNTING BOLT TORQUE LIST

APPENDIX

B-82585EN/02

MOUNTING BOLT TORQUE LIST

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

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B-82585EN/02

APPENDIX

D.MOUNTING BOLT TORQUE LIST

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

Recommended bolt tightening torques
Hexagon socket head bolt (Steel in strength category 12.9) Tightening torque Upper limit Lower limit M3 M4 M5 M6 M8 M10 M12 (M14) M16 (M18) M20 (M22) M24 (M27) M30 M36 1.8(18) 4.0(41) 7.9(81) 14(140) 32(330) 66(670) 110(1150) 180(1850) 270(2800) 380(3900) 530(5400) 730(7450) 930(9500) 1400(14000) 1800(18500) 3200(33000) 1.3(13) 2.8(29) 5.6(57) 9.6(98) 23(230) 46(470) 78(800) 130(1300) 190(1900) 260(2700) 370(3800) 510(5200) 650(6600) 960(9800) 1300(13000) 2300(23000) Hexagon socket head bolt (stainless) Tightening torque Upper limit Lower limit 0.76(7.7) 1.8(18) 3.4(35) 5.8(60) 14(145) 27(280) 48(490) 76(780) 120 (1200) 160(1650) 230(2300) 0.53(5.4) 1.3(13) 2.5(25) 4.1(42) 9.8(100) 19(195) 33(340) 53(545) 82(840) 110(1150) 160(1600) -

Unit: Nm (kgf-cm)
Hexagon socket head boss bolt Hexagon socket head flush bolt (steel in strength category 12.9) Tightening torque Upper limit Lower limit 1.8(18) 4.0(41) 7.9(81) 14(140) 32(330) 1.3(13) 2.8(29) 5.6(57) 9.6(98) 23(230) -

Nominal diameter

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B-82585EN/02

INDEX

INDEX
<Number>
1.5-year (5,760 hours) checks ...........................................7 1-year (3,840 hours) checks ..............................................7 2-year (7,680 hours) checks (LR Mate 200iC /5WP) 4-year (15,360 hours) checks (LR Mate 200iC, LR Mate 200iC/5L , /5C, /5LC, /5H) ...................8 3-month (960 hours) checks ..............................................5

<M>
MAINTENANCE TOOLS ............................................... 9 MASTERING ............................................................... 120 MOUNTING BOLT TORQUE LIST ........................... 166

<O>
OVERVIEW ................................................................... 24

<A>
ADJUSTING TENSION OF BELT .............................. 118 ADJUSTMENTS .......................................................... 117

<P>
PERIODIC MAINTENANCE ........................................ 11 PERIODIC MAINTENANCE TABLE ........................ 160 PREFACE...................................................................... p-1

<B>
BACKLASH MEASUREMENT .................................... 32

<R>
REPLACING CABLES.................................................. 89 REPLACING J1-AXIS MOTOR.................................... 41 REPLACING J1-AXIS REDUCER................................ 43 REPLACING J2-AXIS MOTOR.................................... 49 REPLACING J2-AXIS REDUCER................................ 53 REPLACING J3 BELT................................................... 82 REPLACING J3-AXIS MOTOR.................................... 57 REPLACING J3-AXIS REDUCER................................ 59 REPLACING J4-AXIS MOTOR.................................... 62 REPLACING J4-AXIS REDUCER................................ 64 REPLACING J5/J6 BELT .............................................. 84 REPLACING J5-AXIS MOTOR.................................... 68 REPLACING J5-AXIS REDUCER................................ 71 REPLACING J6-AXIS MOTOR.................................... 74 REPLACING J6-AXIS REDUCER................................ 80 REPLACING PARTS..................................................... 36 REPLACING SOLENOID VALVE............................... 86 REPLACING THE BATTERIES (1-YEAR CHECKS (battery built-in type)) (1.5-YEAR CHECKS (external battery type))................................... 12 REPLACING WRIST UNIT .......................................... 77 REPLAING AIR TUBE ............................................... 110 REPLAING CABLE K101 and Air tube (Connector plate to J2 base)............................................ 95 REPLAING CABLE K102, K103, K104, K105, K109, K110, K111, K112, K113 .................................. 108 REPLAING CABLE K104........................................... 109 REPLAING CABLE K106, K107, K108 and Air tube (J2 base to J3 casing) ...................................... 102

<C>
CABLE AND AIR TUBE REPLACEMENT ................. 95 CABLE FORMING ........................................................ 92 CABLE WIRING............................................................ 90 CHECKS AND MAINTENANCE ...................................1 CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM ...................................................................... 141

<D>
DAILY CHECKS..............................................................2

<F>
FAILURES, CAUSES AND MEASURES..................... 25 FIGURE OF DRIVE MECHANISM .............................. 38 First 1-Month (320 hours operating) Check ......................5 FIXTURE POSITION MASTER.................................. 122

<G>
Grease replacement procedure of the J1-axis reducer............................................................................. 17 Grease replacement procedure of the J2-axis reducer............................................................................. 18 Grease replacement procedure of the J3-axis reducer............................................................................. 19 Grease replacement procedure of the J4-axis reducer............................................................................. 20 Grease replacement procedure of the J5/J6-axis reducer............................................................................. 22

i-1

INDEX
REPLENISH THE GREASE OF THE DRIVE MECHANISM (4 years (11,520 hours) checks) ............. 15 RESETTING ALARMS AND PREPARING FOR MASTERING....................................................... 121

B-82585EN/02

<S>
SAFETY PRECAUTIONS ............................................ s-1 SEALANT APPLICATION............................................ 88 SPARE PARTS LIST.................................................... 131

<T>
TROUBLESHOOTING .................................................. 23

i-2

Revision Record FANUC Robot LR Mate 200iC MECHANICAL UNIT MAINTENANCE MANUAL (B-82585EN)

Addition of LR Mate 200iC/5L,5LC,5WP,5C

02 Feb.,2008 Addition of Air pressure diagram

Revice

01

Nov., 2007

Edition

Date

Contents

Edition

Date

Contents