S-420i Mechanical Unit Maintenance (B-80505EN - 06)

( R--J2 CONTROLLER )
S-420i
Maintenance MANUAL
B - 8 0505EN / 06
E FA N U C LT D , 1 9 9 6
B--80505E/06 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
IMPORTANT!
Before operating, servicing or in any other way handling the
robot, the ”FANUC Robot SAFETY HANDBOOK
(B--80687E)” must be thoroughly studied.
Consider the following notes in addition to the items described in the

SAFETY HANDBOOK.
D Please use appropriate lighting (e.g. a handy light) for maintenance
work. The lighting shall not create new dangerous situations.
D Whenever possible, perform maintenance, inspection and adjusting
with the power function off.
D When replacing parts, be sure to use those specified by FANUC.
D When replacing or installing components, make sure dirt and debris
do not enter the system.
D Be aware that when you remove a servomotor or brake, the associated
axis will fall if it is not supported or resting on a hard stop.
D Make sure personnel cannot get trapped between the moving robot and
other equipment. Know the path that can be used to escape from a
moving robot. Make sure the escape route is never blocked.
D If it is necessary to operate the robot during the inspection, pay careful
attention to the robot’s motion and be sure to press the EMERGENCY
STOP button immediately when necessary.
D Be careful not to slip during maintenance by spilling grease.
D Do not climb on the robot.
D Be careful when touching the hot parts below.
(1) Servo motor (CAUTION LABEL fixed)
(2) Inside of controller
If touching is unavoidable, wear protective garments (heat resistant
gloves, etc.).
D Do not try to remove any mechanical component from the robot before
thoroughly reading and undestanding the procedures in the manual.
Doing so can result in serious personal injury and component
destruction.
D After replacement, be sure to fix all removed parts that include
screws.
D The motor and reducer are heavy. Be careful when replacing.
D After replacing parts or performing adjustment, be sure to test
operation according to the following procedure.
1. Using a low motion speed, single step the program for at least one
full cycle.
2. Using a low motion speed, test run the program continuously for
at least one full cycle.
s--1
SAFETY PRECAUTIONS B--80505E/06
3. As speed is increased. the path may vary slightly. Run through the
program at 5--10% intervals up to 100%.
4. Using the programmed speed, test run the program continuously
for at least one full cycle.
Make sure all personnel are outside the fence before test running.
D After maintenance work, the robot must be clean of oil, water, or
debris.
s--2
B--80505E/06 PREFACE
PREFACE
This manual describes the maintenance and connection of the following

robot mechanical unit.
Mechanical unit
Load
Product name specification Remark
capacity
number
FANUC Robot S--420i F A05B--1313--B201 120kg
FANUC Robot S--420i F/2.85 A05B--1313--B281 120kg
FANUC Robot S--420i W A05B--1313--B203 155kg
FANUC Robot S--420i S A05B--1313--B241 80kg
FANUC Robot S--420i L A05B--1313--B261 75kg
FANUC Robot S--420i R A05B--1313--B401 100kg
FANUC Robot S--420i R/120 A05B--1313--B402 120kg
FANUC Robot S--420i W A05B--1318--B203 155kg Compact type
FANUC Robot S--420i F/2.85 A05B--1313--B581 120kg With positioning surface
FANUC Robot S--420i W/175 A05B--1313--B511 175kg
FANUC Robot S--420i W/2.85 A05B--1313--B521 155kg
FANUC Robot S--420i R/120 A05B--1313--B602 120kg
FANUC Robot S--420i F A05B--1318--B701 120kg Compact type
FANUC Robot S--420i L A05B--1318--B761 75kg With positioning surface
FANUC Robot S--420i F A05B--1313--B701 120kg Severe dust/liquid
FANUC Robot S--420i F/2.85 A05B--1313--B781 120kg protection
FANUC Robot S--420i W A05B--1313--B703 155kg (Only remote controller)
FANUC Robot S--420i R A05B--1313--B801 100kg With positioning surface
FANUC Robot S--420i F A05B--1320--B501 120kg High duty type
FANUC Robot S--420i R/120 A05B--1320--B602 120kg With positioning surface
The mechanical unit specification numbers are attached at the following

positions. Therefore, read the description in each section when checking.
p--1
PREFACE B--80505E/06
The attachment position for the mechanical unit specification number
p--2
Table Specifications
Item S-420i F S-420iF/ S-420i W S-420i S-420iW/ S-420i S S-420i L S-420i R S-420i R/120
2.85 W/175 2.85
Type Articulated type

Controlled axes 6 axes (J1, J2, J3, J4, J5, J6)
Reach 2.4 m 2.85 m 2.4 m 2.4 m 2.85 m 2.25m 3.0m 3.1m
Installation Floor mount Rack mount
Motion J1 axis 360° 360° 360° 360° 360° 360° 360° 360° 360°
g
range (6.28rad) (6.28rad) (6.28rad) (6.28rad) (6.28rad) (6.28rad) (6.28rad) (6.28rad) (6.28rad)
J2 axis 142° 142° 142° 142° 142° 142° 142° 123° 123°
(2.48rad) (2.48rad) (2.48rad) (2.48rad) (2.48rad) (2.48rad) (2.48rad) (2.15rad) (2.15rad)
J3 axis 135° 135° 135° 135° 135° 135° 135° 106° 106°
J4 axis 600° 600° 600° 600° 600° 480° 600° 600° 600°
J5 axis 260° 260° 260° 260° 260° 260° 260° 260° 260°
J6 axis 720° 720° 720° 720° 720° 720° 720° 720° 720°
Maximum J1 axis 100°/sec 90°/sec 90°/sec 90°/sec 90°/sec 70°/sec 100°/sec 100°/sec 90°/sec
speed (1.75rad/ (1.57rad/ (1.57rad/ (1.57rad/ (1.57rad/ (1.22rad/ (1.75rad/ (1.75rad/ (1.57rad/
sec) sec) sec) sec) sec) sec) sec) sec) sec)
J2 axis 110° 100° 100° 100° 100° 110° 110° 100° 90°
(1.92rad/ (1.75rad/ (1.75rad/ (1.75rad/ (1.75rad/ (1.92rad/ (1.92rad/ (1.75rad/ (1.57rad/
J3 axis 100° 90° 75° 75° 75° 100° 100° 100° 90°
J4 axis 210° 210° 140° 140° 140° 210° 210° 210° 210°
J5 axis 150° 150° 110° 110° 110° 150° 150° 150° 150°
J6 axis 210° 210° 140° 140° 140° 210° 210° 210° 210°
Maximum Wrist 120kg 120kg 155kg 175kg 155kg 80kg 75kg 100kg 120kg
load
J3 arm 20kg 20kg 20kg 20kg 20kg 20kg 20kg 20kg 20kg
capacity
J2 base 250kg 250kg 250kg 250kg 250kg 250kg 250kg 250kg 250kg
Allowable J4 axis 60kgfm 60kgfm 86kgfm 90kgfm 86kgfm 54kgfm 53kgfm 57kgfm 60kgfm
load (588Nm) (588Nm) (842Nm) (882Nm) (842Nm) (529Nm) (519Nm) (558Nm) (588Nm)
momentt
J5 axis 60kgfm 60kgfm 86kgfm 90kgfm 86kgfm 54kgfm 53kgfm 57kgfm 60kgfm
at wrist *1
(588Nm) (588Nm) (842Nm) (882Nm) (842Nm) (529Nm) (519Nm) (558Nm) (588Nm)
J6 axis 30kgfm 30kgfm 50kgfm 52kgfm 50kgfm 28kgfm 27kgfm 29kgfm 30kgfm
(294Nm) (294Nm) (490Nm) (510Nm) (490Nm) (274Nm) (264Nm) (284Nm) (294Nm)
Allowable J4 axis 306kgfcms2 306kgfcms2 486kgfcms2 472kgfcms2 486kgfcms2 376kgfcms2 387kgfcms2 337kgfcms2 306kgfcms2
load iner- (30.0kgm2) (30.0kgm2) (47.6kgm2) (46.3kgm2) (47.6kgm2) (36.8kgm2) (37.9kgm2) (33.0kgm2) (30.0kgm2)
ti att wrist
tia i t
J5 axis 306kgfcms2 306kgfcms2 486kgfcms2 472kgfcms2 486kgfcms2 376kgfcms2 387kgfcms2 337kgfcms2 306kgfcms2
*1
(30.0kgm2) (30.0kgm2) (47.6kgm2) (46.3kgm2) (47.6kgm2) (36.8kgm2) (37.9kgm2) (33.0kgm2) (30.0kgm2)
J6 axis 77kgfcms2 77kgfcms2 164kgfcms2 158kgfcms2 164kgfcms2 100kgfcms2 104kgfcms2 86kgfcms2 77kgfcms2
(7.5kgm2) (7.5kgm2) (16.1kgm2) (15.5kgm2) (16.1kgm2) (9.8kgm2) (10.1kgm2) (8.4kgm2) (7.5kgm2)
Max. weld force 500kg
Repeatability 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm
Weight *2 1500kg 1600kg 1500kg 1600kg 1600kg 1500kg 1600kg 1700kg 1700kg
Installation condition Ambient temperature : 0 to 45°C
Humidity : Normal 75% RH or less
Short period (One month or less) 95% RH or less (No dew, nor frost allowed)
Vibration : 0.5G (4.9m/s2) or less
NOTE
The direction of weld reaction force should always be
through the cross point of J4, J5 and J6 axes.
p--3
PREFACE B--80505E/06
NOTE
1 At maximum payload. Allowable load moment and inertia at
wrist are changed by load.
2 Including Controller (i F/i W/i S/i L), Not including controller
(i R, i R/120)
Table of dust proof water proof performance

Standard model Severe dust/liquid protection
Wrist + J3 arm IP55 IP67
Other part IP54 IP55
MANUALS For the FANUC Robot series, the following manuals are available:
Safety handbook Intended readers :

B--80687E All persons who use FANUC Robot, system designer
Topics :
All persons who use the FANUC Robot and system de- Safety items for robot system design, operation, maintenance
signer must read and understand thoroughly this handbook
R--J2 controller Setup and Operations Intended readers :
manual Operator, programer, maintenance person, system designer
Topics :
SPOT TOOL Robot functions, operations, programing, setup, interfaces, alarms
B--80524E--10 Use :
HANDLING TOOL Robot operation, teaching, system design
B--80524E--11
SEALING TOOL
B--80524E--14
Maintenance manual Intended readers :
B--80525E Maintenance person, system designer
Topics :
B--80525E--1 Installation, connection to peripheral equipment, maintenance
(European Use :
specification) Installation, start--up, connection, maintenance
Mechanical unit Maintenance manual Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to the controller, maintenance
Use :
installation, start--up, connection, maintenance
FANUC Robot S--420iF/iL/iW/iR/iS B--80505E
-- Spot welding, general--purpose large robot
WARNING
1 For S--420i of severe dust/liquid protection, set up the regulated air--pressure.
Otherwise, not only the sufficient performance of dust proof/water proof can’t be obtained but
also the oil seals may be broken. It must be set the air pressure to 0.20.05kgf/cm2.
2 Prepare the dry air for purge line, removed water. The air filter only remove garbage and oil
from air flows, can’t remove water and vapor. Moist air will damage to the robot.
p--4
NOTE
1 Definitions of the IP protection levels.
-- Formal definition of IP67.
6=”dust--tight; no ingress of dust”
7=”protected against the effects of temporary immersion
in water; ingress of water in quantities causing harmful
effects shall not be possible when the enclosure is
temporarily immersed in water under standardized
conditions of pressure”
5=”dust protected; ingress of dust is not totally prevented
but dust shall not penetrate in a quantity to interfere
with satisfactory operation of the apparatus or to
impair safety”
5=”protected against water jets; water projected in jets
against the enclosure from any direction shall have no
harmful effects”
5=’dust protected; ingress of dust is not totally prevented
but dust shall not penetrate in a quantity to interfere
with satisfactory operation of the apparatus or to
impair safety”
4=”protected against splashing water; water splashed
against the enclosure from any direction shall have no
harmful effects”
2 ”Severe dust/liquid protection” in not retrofittable.
Performance of resistant The following materials can’t use the robot, severe dust/liquid protection model,
chemicals and resistant because they will harm rubber parts (packings, oil seals O--rings).
solvents 1) Organic solvents
Aromatic hydrocarbon
Petroleum hydrocarbon, ether
2) Coolant for machine tools
3) Other liquid or solution, that they will harm NBR.
p--5
I MAINTENANCE
B--80505E/06 MAINTENANCE 1. CONFIGURATION
1
CONFIGURATION
The configuration of the mechanical unit is shown in Fig. 1 (a) to (f).
Fig.1(a) Mechanical unit configuration (S--420iF, W, W/175)
3
1. CONFIGURATION MAINTENANCE B--80505E/06
Fig.1(b) Mechanical unit configuration (S--420iF/2.85, S--420iW/2.85)
Fig.1(c) Mechanical unit configuration (S--420iS)
4
Fig.1(d) Mechanical unit configuration (S--420iL)
Fig.1(e) Mechanical unit configuration (S--420iR)
5
Fig.1(f) Mechanical unit configuration (Compact type)
6
1.1 Fig. 1.1 shows the J1--axis drive mechanism.

Rotation of the J1--axis motor (M1)(α22/2000 or αM30/3000HV) is
J1--AXIS DRIVE input to the reducer via the center gear, and the output rotates the table.
MECHANISM The table is held to the base via a cross roller bearing.
J1 motor (M1)
(α22/2000 or αM30/3000HV)
Fig.1.1 J1--axis drive mechanism
1.2 Fig. 1.2 (a) shows the J2/J3--axis drive mechanism.

J2/J3--AXIS DRIVE
directly fed to the reducer, and the output moves the J2--axis.
MECHANISM
directly fed to the reducer. The reducer output is coupled to the J3--axis
link 1 and moves the J3--axis arm via the J3--axis link 2.
J3--axis arm
J3--axis link 2
J2--axis arm
J3--axis link 1
J3 motor
(M3)(α22/2000 or
αM30/3000HV)
J2 motor
(M2)(α22/2000 or J3--axis reducer
αM30/3000HV)
J2--axis reducer
Fig.1.2(a) J2/J3--axis drive mechanism
7
Fig. 1.2 (b) shows the J2/J3--axis drive mechanism on S--420i compact
type.
The rotation of J3--axis motor is inputted to the reducer via bevel gear. The
output of reducer is linked to J3--axis link 1, and the J3--aixs arm is moved
via the J3--axis link 2.
At the same time, the rotation of J2--axis motor is inputted to the reducer
via the bevel gear, and the reducer output moves the J2--axis arm.
Fig.1.2(b) J2/J3--axis drive mechanism (Compact type)
1.3 Fig. 1.3 shows the J4--axis drive mechanism.

Rotation of the J4--axis motor (M4)(α22/1500) is transmitted to the
J4--AXIS DRIVE
reducer through the center gear, and the reducer output directly rotates the
MECHANISM J4--axis (J3--axis arm + wrist unit).
J4--axis reducer
(Hollow shaft)
Fig.1.3 J4--axis drive mechanism
8
1.4 Fig. 1.4 shows the J5/J6--axis drive mechanism.

Rotation of the J5--axis motor (M5)(α12/2000) is reduced with four gears
J5/J6--AXIS DRIVE
and fed to rotate the J6--axis unit. This causes J5--axis to rotate (wrist
MECHANISM bending).
Rotation of the J6--axis motor (M6)(αM6/300) is directly fed to the
reducer and rotates the wrist flange.
Fig.1.4 J5/J6--axis drive mechanism
NOTE
An electrically released brake is incorporated in the motors for all axes (J1, J2, J3, J4, J5, and
J6 axes) and applies at power off or in an emergency stop.
9
1.5 1) Motor
MAJOR COMPONENT Motor Specifications Model Axis Remark
M1 A06B--0147--B675 α 22/2000 J1
SPECIFICATIONS A06B--0186--B675#0011 α M30/3000HV High duty
M2 A06B--0147--B675 α 22/2000 J2
A06B--0186--B675#0011 α M30/3000HV High duty
M3 A06B--0147--B675 α 22/2000 J3
A06B--0186--B675#0011 α M30/3000HV S--420iW/2.85
M4 A06B--0146--B675 α 22/1500 J4
M5 A06B--0142--B675#0006 α 12/2000 J5
M6 A06B--0162--B675#0006 α M6/3000 J6
2) Reducer
Axis Specifications Model
J1--axis reducer A97L--0118--0939#250C--35 S--420i F/W/S/L/R
J2--axis reducer A97L--0118--0940#250A--118 S--420i F/S/L
A97L--0118--0940#250A--129 S--420i W/R
A97L--0118--0940#250A--141 S--420i R/120
J3--axis reducer A97L--0118--0941#250A--129 S--420i F/S/L/R
A97L--0118--0941#250A--141 S--420i F2.85/R120
A97L--0118--0941#250A--171 S--420i W
J6--axis reducer A97L--0118--0942#30A--81 S--420i F/S/L/R
A97L--0118--0942#30A--121 S--420i W
3) Gear
Axis Specifications Model
J1--axis pinion
p gear
g A290--7313--X221 S--420i F/W/L/R
A290--7313--Y221 S--420i S
A290--7313--Z221 S--420i R/120 F/2.85, W/2.85
J1--axis center gear
g A290--7313--X222 S--420i F/W/L/R
A290--7313--Y222 S--420i S
A290--7313--Z222 S--420i R/120 F/2.85, W/2.85
J4--axis pinion
p gear
g A290--7313--X404 S--420i F/S/L/R
A290--7313--Y404 S--420i W
J4--axis center gear
g A290--7313--X405 S--420i F/S/L/R
A290--7313--Y405 S--420i W
J5--axis gear
g 1 assemblyy A290--7313--V521 S--420i F/S/L/R
A290--7313--V524 S--420i W
J5--axis gear
A290--7313--V525 S--420i W
J5--axis gear
A290--7313--V526 S--420i W
J5--axis gear
g 4 A290--7313--X508 S--420i F/S/L/R
A290--7313--Y508 S--420i W
J2/J3 gear box assembly A290--7313--V351 S--420i F/W/S/L (Compact type)
4) Others
Item Specifications Model
Wrist unit A290--7313--T501 S--420i F/S/L/R
(Standard
(St d d model)d l)
A290--7313--T503 S--420i W
Wrist unit A290--7313--T511 S--420i F/L/R
(S
(Severe dust/liquid
d t/li id protection)
t ti )
A290--7313--T513 S--420i W
10
B--80505E/06 MAINTENANCE 2. PREVENTIVE MAINTENANCE
2
PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained for a long time by

performing the periodic maintenance procedures presented in this
chapter.
2.1 Clean each part, and visually check component parts for damage before
daily system operation. Check the following items as the occasion
DAILY CHECKS demands.
1) Before turning on power
Item Check items Check points
When air Air pressure Check air pressure using the pressure gauge on the air regulator as shown in Fig.
1 control set is 2.1. If it does not meet the specified pressure of 5 -- 7 kgf/cm2 (0.49 to 0.69 MPa),
combined adjust it using the regulator pressure setting handle.
Oiler oil mist Check the drop quantity during wrist or hand motion. If it does not meet the specified
2 quantity value (1 drop/10 -- 20 sec), adjust it using the oiler control knob. Under normal usage
the oiler becomes empty in about 10 to 20 days under normal operation.
3 Oiler oil level Check to see that the oiler level is within the specified level shown in Fig. 2.1.
Leakage from Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.
4
hose
Oil inlet Adjusting knob

Oiler mist amount check
Oiler
Pressure gauge
Filter Regulator pressure setting handle
Fig.2.1 Air control set
11
2. PREVENTIVE MAINTENANCE MAINTENANCE B--80505E/06
Severe dust/liquid protection

Air pressure Check air pressure using the pressure gauge on the air filter unit as shown in follow-
1 ing figure. If it does not meet the specified pressure of 0.20.05kgf/cm2, adjust it
using the regurator pressure setting handle.
Stains of filter elements Check to see element. If it has harsh stains, change elements. Refer to following
2
item.
3 Leakage from horse Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.
WARNING
For severe dust/liquid protection of the S--420i, set up the regulated air--pressure.
Otherwise, not only the sufficient performance of dust proof/water proof cannot be obtained but
also the oil seals might be broken. Set the air pressure to 0.20.05kgf/cm2.
2) After automatic operation

Vibration, abnormal noises, Check whether the robot moves along and about the axes smoothly without unusual
5 and motor heating vibration or sounds. Also check whether the temparature of the motors are exces-
sively high.
Changing repeatability Check to see that the stop positions of the robot has not deviated from the previous
6
stop positions.
Peripheral devices for proper Check whether the peripheral devices operate properly according to commands
7
operation from the robot.
8 Brakes for each axis Check that the end effector drops within 0.2 mm when the power is cut.
12
B--80505E/06 MAINTENANCE 2. PREVENTIVE MAINTENANCE
2.2 1) Check the following items once every three months. Additional
inspection areas and times should be added to the table according to the
3--MONTH CHECKS robot’s working conditions, environment, etc.

Control unit cable Check whether the cable connected to the teach pendant is unevenly
1
twisted.
Ventilation portion of control unit If the ventilation portion of the control unit is dusty, tum off power and
2
clean the unit.
2) First quarterly inspection

Check the following items at the first quarterly inspection, then every
year thereafter.
4 Cables used in mechanical unit Check whether the jackets of the mechanical unit cables are damaged.
Also check whether the cables are excessively bent or unevenly twisted.
Check that the connectors of the motors and connector panels are se-
curely engaged.See section 7.2.
Clean each part (remove chips, etc.) and check component parts for
5 Cleaning and checking each part
cracks and flaws.
Further tightening external main
6 Further tighten the end--effecter mounting bolts and external main bolts.
bolts
2.3 Check the following item once every six months.

6--MONTH CHECKS
1 Greasing balancer bushing Grease to the balancer bushing. Refer to item 3.2.
2.4 Check the following items once every year.

ANNUAL CHECKS
1 Battery Replace battery in the mechanical unit. Refer to 3.3.
2 Cables used in mechanical unit Refer to previous item.
3 Cleaning each parts and inspec- Refer to previous item.
tion
4 Tightness of major external bolts Refer to previous item.
5 Greasing of balancer joint bearing Supply grease to the bearing (only for the S--420i R).
(See Section 3.2.)
6 Filter element Replace filter elements in the air filter unit. Refer to 3.4.
2.5 Check the following items once every 3 years.

3--YEAR CHECKS
1 Replacing grease of each axis, re- Refer to item 3.1
ducer and gear box
2 Greasing to cross--roller bearing Grease to the required positions. Refer to item 3.2.
13
2. PREVENTIVE MAINTENANCE MAINTENANCE B--80505E/06
2.6 The following tools and instruments are required for the maintenance
procedures contained in this manual.
MAINTENANCE
TOOLS 1) Measuring instruments
Instruments Accuracy/Tolerance Applications
Dialgauge accuracy 1/100 mm Measurement of positioning and backlash
Slide calipers 150 mm
Push/pull tension gauge 10 kgf (98N) Measurement of backlash
2) Tools
Cross--point(+)screwdrivers : Large, medium, and small sizes
Conventional(--)screwdrivers : Large, medium, and small sizes
Hexagonal wrench key sets : M3 -- M16
(metric)
Adjustable wrenches : Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Double hexagon offset wrench
Grease gun
Pliers for C--retaining ring
Torque wrench
Dial indicator and base
2.7 For severe dust/liquid protection of the S--420i, follow the attached
caution stickers, and pay attention to the air pressure and purge and
CAUTION STICKERS maintenance of the air filter. Place them, where the robot operator can see
FOR DAILY CHECKS them easily ; on the front of the R--J2 controller, and the front of operating
(ONLY SEVERE box near the main switch.
DUST/LIQUID
PROTECTION)
14
B--80505E/06 MAINTENANCE 3. PERIODIC MAINTENANCE
3
PERIODIC MAINTENANCE
3.1 Replace the grease of the reducers of J1, J2, J3, J4, and J6 axes, and the
J5--axis gear box, every three years or 20,000 hours by using the following
REPLACING GREASE procedures.
OF THE DRIVE
MECHANISM 3.1 Grease for 3--year periodical replacement
Supply position Grease name Quantity

J1--axis reducer 4670 cc (4130g)
Kyodo yushi
J5--axis gear box Moly white Re no.00 4770 cc (4220g)
J6--axis reducer (Spec.: A98L--0040--0119) 370 cc (330g)
J2--axis reducer and gear box 2600 cc (2300g)
(Compact type)
J3--axis reducer and gear box 2600 cc (2300g)
(Compact type)
1) Replacing procedure of grease to the reducer and the gear box

1 Turn off the power.
2 Remove the grease outlet plug. Also remove the ventilation
plug for J5--axis.
3 Apply new grease from the grease inlet until it comes out
from the grease outlet.
4 Remount the plug at the grease outlet.
NOTE
1 Be sure to use the procedure described in this manual when
supplying grease at the grease nipple. If an attempt is made
to supply grease without unplugging the grease outlet, the
seal may be broken, and grease leakage may result.
2 Check for grease leakage due to the broken seal if one of the
following occurs when supplying new grease at the grease
inlet:
. Old grease is slow in coming out of the grease outlet.
. Very little old grease comes out of the grease outlet.
3 To prevent accidents caused by slipping, completely
remove any excess grease from the floor or robot.
15
3. PERIODIC MAINTENANCE MAINTENANCE B--80505E/06
Fig.3.1 (a) Replacing grease of J1--axis reducer (S--420iF/W/S/L)
Fig.3.1 (b) Replacing grease of J1--axis reducer (S--420iR)
16
(Standard type)
(Compact type)
Fig.3.1 (c) Replacing grease of J2/J3--axis reducer
17
Fig.3.1 (d) Replacing grease of J4--axis reducer
Fig.3.1 (e) Replacing grease of J5--axis gear box
Fig.3.1 (f) Replacing grease of J6--axis reducer
18
When replacing or supplying grease, orient the robot as shown in Fig 3.1
(g). For the S--420i R, position the robot to the zero--degree attitude.
Fig.3.1 (g) Greasing posture (S--420iF/W/S/L)
19
3.2 Supply grease to the parts periodically. If the robot is installed in a severe
environment, apply grease whenever necessary. If water splashes on the
GREASING robot, apply grease immediately. Fig. 3.2(a), (b) and Table 3.2(a) show
greasing points.
Table 3.2 (b) Shows substitute greases.
Table3.2 (a) Greasing points
Positions Grease Amount Method Greasing interval

J1--axis cross 40 cc each Every 3 years
roller bearing (2 locations) Supply to the grease nipple
Balancer 100 cc each Every 3 years

(2 locations) Supply to the grease nipple
Balancer bushing 10 cc each Every 6 months

SHELL ALVANIA No. 2 (4 locations)
Supply to the grease nipple
(Spec: A97L--0001--0179#2) (S--420iR has 2
locations)
J2/J3--axis 20 cc each Every 3 years
joint bearing (2 locations) Supply to the grease nipple
Balancer joint bearing 20 cc each Every year

(Only for S--420iR) (2 locations) Supply to the grease nipple
Table3.2 (b) Substitutes for ALVANIA NO.2
MOBIL OIL MOBILACK GREASE NO.2 NIPPON OIL EPNOC NO.2

ESSO STANDARD VICON NO.2 IDEMITSU KOHSAN DAPHNE COLONEX GREASE NO.2
MITSUBISHI DIAMOND MULTIPURPOSE GREASE NO.2 COSMO OIL LIMAX NO.2
Fig.3.2 (a) Greasing points (S--420iF/W/S/L)
20
Fig.3.2 (b) Greasing points (S--420iR)
21
3.3 The position data of each axis is preserved by the backup battery. The
battery needs to be periodically replaced every year. Also use the
REPLACING following procedure to replace when the backup battery voltage drop
BATTERY alarm occurs.
1 Keep the power on. Press the EMERGENCY STOP button to
prohibit the robot motion.
Replacing the battery with the power supply turned off causes all
current position data to be lost. Therefore, mastering will be
required again.
2 Remove the battery case cap.
3 Take out the old batteries from the battery case.
4 Insert new batteries into the battery case.
Pay attention to the direction of batteries.
5 Close the battery case cap.
Fig.3.3 Replacing Battery
22
3.4 Severe dust/liquid protection for the S--420i is used to purge air into the
wrist and J3--axis arm. Air filter elements (air filter, and oil mist filter)
REPLACING FILTER need to be periodically replaced every year. Use the following procedure
ELEMENT to replace the filter element when harsh stains exist.
WARNING
If harsh stains exist on the filter element, it cannot hold oil,
and will make flowing oil and mist.
1) Turn off the power.

2) Shut off the purge air.
NOTE
Be sure to shut off the primary valve.
3) Check that the air filter’s gauge indicated zero.
WARNING
When air filter and oil mist filter are broken up, it reduces
residual pressure; otherwise you could injure personnel or
damage equipment.
4) Replace the filter element as shown in the following figure. Air filters
and oil mist filter are replaced at the same time.
Fig.3.4 Replacing Battery
23
4. TROUBLESHOOTING MAINTENANCE B--80505E/06
4
TROUBLESHOOTING
4.1 The source of mechanical unit problems may be difficult to locate because
of overlapping causes. Problems may become further complicated, if they
GENERAL are not corrected properly. Therefore, it is necessary to keep an accurate
record of problems and to take proper corrective actions.
4.2 Table 4.1 shows the main mechanical unit problems and their causes. If
a cause of remedy is unclear, please contact this company.
PROBLEMS AND
CAUSES Table4.1 Problems and causes
Symptom Cause Remedy Remarks

The robot does not correctly Low voltage of the memory Replace the battery. Refer to section 3.3.
return to the zero position. backup battery
Unusual external start signal Investigate the cause.
Incorrect parameter Revise parameters. Refer to the parameter table
in Setup and Operations
manual.
Position offset The robot has been hit. Revise the teaching points.
The robot is not firmly fas- Re--tighten.
tened.
Peripheral device was Reposition.
shifted.
Incorrect parameters. Revise parameters. Refer to the parameter table
in Setup and Operations
manual.
Defective pulse coder cable Replace the cable. Refer to section 8.
APC (Absolute Position Replace the motor or the Refer to sections 6.
Checker) malfunction. pulse coder.
Play in mechanical unit. See
below.
Vibration The robot is not firmly fas- Re--tighten.
tened.
Floor vibration. (especially Investigate the installation
when installed above the first location.
floor)
Incorrect servo adjustment. Adjust the servo. Contact the service repre-
sentative.
Defective cable. Replace the cable. Refer to section 8.
Not grounded. Connect to ground.
Defective motor. Replace the motor. Refer to section 6.
Defective reducer. Replace the reducer. Refer to sections 6.
Incorrect time constant Revise the time constant Refer to the parameters.
Play in mechanical units. See
below.
24
B--80505E/06 MAINTENANCE 4. TROUBLESHOOTING
Symptom Cause Remedy Remarks

There is play. Loose screws or pins. Tighten and apply LOCTITE
(See Table 4.2 (b).) as specified.
Defective reducer. Replace the reducer. Refer to section 6.
There is play. Incorrect gear adjustment. Adjust the gears. Refer to section 5.4.
(See Table 4.2.)
42)
Worn gears. Replace the gears. Refer to section 6.
Worn bearings. Replace the bearings. Contact the service repre-
sentative.
Cracked casting, etc. Replace cracked parts. Contact the service repre-
sentative.
Unusual noise Insufficient gear or reducer Lubricate. Refer to section 3.
lubrications.
Foreign matter in gears or re- Clean and lubricate. Refer to section 3.
ducer.
Excessive pressure on bear- Reduce the pressure on the Contact the service repre-
ings. bearings. sentative.
Defective reducer. Replace the reducer. Refer to section 6.
Incorrect gear adjustment. Adjust the gears. Refer to section 5.4.
Worn gears. Replace the gears. Refer to section 6.
Worn bearings. Replace the bearings. Contact the service repre-
sentative.
Incorrect servo adjustment. Adjust the servo. Contact the service repre-
sentative.
Insufficient lubrication to the Lubricate (900 cc) Refer to section 3.2.
inside of balancer
Unusual heating Insufficient gear or reducer Lubricate. Refer to section 3.
lubrication.
Specified grease not used. Replace with the specified Refer to section 3.
grease.
Excessive pressure on bear- Reduce the pressure on the Contact the service repre-
ings. bearings. sentative.
Excessive load. Reduce the load/restrict
movement conditions.
Incorrect gear adjustment. Adjust the gears. Refer to section 5.4.
Incorrect time constant. Revise the time constant. Refer to the parameters.
Drops when the power Brake gap too large. Replace the motor. Refer to section 6 and Table
supply is off 4 3 (*).
4.3 (*)
Fused brake drive relay. Replace the relay.
Grease leakage Deteriorated O--ring, oil seal Replace the O--ring, oil seal
or packing. or packing.
Cracked casting, etc. Replace cracked parts. Contact the service repre-
sentative.
Loose screws. Tighten.
(*) Refer to the maintenance manual of the controller.
25
4.3
THE MEASUREMENT (1) Method
1 Move the robot to the designated posture(Refer to table 4.3(a),
OF THE BACKLASH
and Fig 4.3 (b) ).
2 Release the brake control (Refer P85).
3 Apply pressure on each axis as Fig 4.3 (a).
4 Measure the moving distance.
Apply pressure on each axis 3 times, and measure the moving distance at
2nd and 3rd attempt. The backlash is calculated by the average of them.
Home Position
0
+10kg
1st attempt (Dont measure)
--10kg
+10kg
L1 2nd attempt (B2 = L1 + L2)

--10kg
L2 +10kg
--10kg L3 3rd attempt (B3 = L3 + L4)
L4
Fig.4.3 (a) How to measure the backlash
B2 + B3
The backlash is calculated as B = .
2
(2) Measuring posture and position.
1 For iF, iF/2.85, iW, iW/175, iW/285, iS, iL,
Table4.3 (a) Posture for measuring backlash
Measuring Posture
axis
J2 J3 J4 J5 J6
J1 70_ 0_ ------ ------ ------
J2 0_ 0_ ------ --90_ ------
J3 50_ --90_ --90_ --90_ 90_
J4 50_ --90_ 90_ 90_ --90_
J5 70_ 0_ 90_ 90_ --180_
J6 70_ 0_ 90_ 90_ --90_
26
Fig.4.3 (b) Posture for measuring backlash
Table4.3 (b) Position for measuring backlash
Item A B C D E F
S--420iF 2193 1190 1300 233 233 250
S--420iW 2193 1190 1300 251 251 323
S--420iW/175 2193 1190 1300 220 220 298
S--420iW/2.85 2655 1190 1752 251 251 323
S--420iS 2043 1190 1150 377 377 350
S--420iL 2795 1190 1902 408 408 360
S--420iF/2.85 2655 1190 1752 233 233 250
2 For iR,iR/120
Table4.3 (c) Posture for measuring backlash
Measuring Posture
axis
J2 J3 J4 J5 J6
J1 0_ 30_ ------ ------ ------
J2 ------ ------ ------ ------ ------
J3 --20_ 0_ ------ ------ ------
J4 --20_ 0_ --90_ 90_ --90_
J5 --30_ 0_ 180_ 30_ 0_
J6 --30_ 0_ --90_ 30_ 0_
27
Fig.4.3 (c) Posture for measuring backlash
NOTE
In the case of S--420iR and iR/120, the backlash of J2 can’t
measure. Because the gravity acts on the direction of J2,
constantly.
(3) Allowable backlash tolerances
Table4.3 (d) Allowable backlash tolerances (S--420iF)
J1 J2 J3 J4 J5 J6
Angle conversion (arc--min) 3.1 1.45 0.89 11.98 4.79 14.18
Displacement conversion (mm) 1.98 0.5 0.33 1.51 0.6 1.03
Distance (mm) 2193 1190 1300 433 433 250
Table4.3 (e) Allowable backlash tolerances (S--420iW)
J1 J2 J3 J4 J5 J6
Distance (mm) 2193 1190 1300 451 451 323
28
Table4.3 (f) Allowable backlash tolerances (S--420iW/175)
J1 J2 J3 J4 J5 J6
Distance (mm) 2193 1190 1300 440 440 298
Table4.3 (g) Allowable backlash tolerances (S--420iW/2.85)
J1 J2 J3 J4 J5 J6
Distance (mm) 2655 1190 1752 451 451 323
Table4.3 (h) Allowable backlash tolerances (S--420iS)
J1 J2 J3 J4 J5 J6
Angle conversion (arc--min) 3.34 1.45 1 6.74 2.7 7.24
Distance (mm) 2043 1190 1150 577 577 350
Table4.3 (i) Allowable backlash tolerances (S--420iL)
J1 J2 J3 J4 J5 J6
Displacement conversion (mm) 1.94 0.5 0.33 1.5 0.6 1
Distance (mm) 2795 1190 1902 608 608 360
Table4.3 (j) Allowable backlash tolerances (S--420iF/2.85)
J1 J2 J3 J4 J5 J6
Distance (mm) 2655 1190 1752 433 433 250
Table4.3 (k) Allowable backlash tolerances (S--420iR,iR/120)
J1 J2 J3 J4 J5 J6
Angle conversion (arc--min) 2.21 ------ 0.98 14.37 4.79 11.35
Displacement conversion (mm) 2 ------ 0.5 1.81 0.6 0.83
Distance (mm) 3113 ------ 1752 496 496 288
29
5. ADJUSTMENTS MAINTENANCE B--80505E/06
5
ADJUSTMENTS
Each part of the mechanical unit is carefully adjusted at the factory before
shipment. Therefore it is usually unnecessary for the customer to make
adjustments at the time of delivery. However, after for a long period of use
or after parts are replaced, adjustments may be required.
5.1 Axis limits define the motion range of the robot. The operating range of
the robot axes can be restricted because of:
AXIS LIMITS SETUP
D Work area limitations
D Tooling and fixture interference points
D Cable and hose lengths
There are three methods used to prevent the robot from going beyond
the necessary motion range. These are
D Axis limit software settings
D Axis limit switches -- optional
D Axis limit hardstops
WARNING
Do not use axis software limits as the only method for
restricting robot motion. Change the hard stops to match
the software modifications, otherwise injury to personnel
and damage to equipment can occur.
Software Settings Axis limit software settings are upper and lower motion degree
limitations. The limits can be set for all robot axes and will stop robot
motion if the robot is calibrated. If the robot is not calibrated,
overtravel limit switches or hardstops are contacted two to three
degrees beyond the software limits. Overtravel switches for axis 1 are
available as an option.
Limit Switches Axis limit switches are overtravel switches that, when tripped, cut
power to the servo motors. These are located about 0.5 degrees
beyond the software limits. Overtravel switches for J1--axis are
available as an option.
Hardstops Axis limit hardstops are physical barriers that are located two or three
degrees beyond the overtravel limit switch or software setting on the
three major axes. The robot cannot move beyond a hardstop.
Setting the axis limits software settings changes the motion range of
the robot. The axis limit screen displays the current upper and lower
axis limits, for each robot axis, in degrees.
Upper Limits Displays the upper limits of each axis, or the axis limits in a positive
direction.
30
B--80505E/06 MAINTENANCE 5. ADJUSTMENTS
Lower Limits Displays the lower limits of each axis, or the axis limits in a negative
direction.
Saving Limits After you change the axis limits, turn off the controller and then turn it
on again so the new settings can be used.
CAUTION
Changing the axis limits will affect the robot work area, and
could change robot motion. Anticipate the effects of
changing axis limits before changing them; otherwise
unexpected results could occur, such as errors in previously
recorded positions.
31
5.1.1 Zero point and software motion limit are provided for each controlled
Zero Point Position axis. The robot cannot exceed the software motion limit unless there is
a failure of the system causing loss of zero point position or there is a
and Motion Limit system error.
Exceeding the software motion limit of a controlled axis is called
overtravel (OT). Overtravel is detected at both ends of J1--axis by an
optional adjustable OT switch. Overtravel is not detected on any other
axis.
The total travel (stroke) of J1--axis through J5--axis beyond the software
motion limit is restricted by a mechanical stopper. A mechanical stopper
is not provided for J6--axis.
Fig.5.1.1 (a) -- (j) show the zero point and motion limit OT detection
position, and mechanical stopper position of each axis.
Fig.5.1.1 (a) J1--axis (S--420iF/W/S/L/R)
32
Fig.5.1.1 (b) J2--axis (S--420iF/W/S/L)
Fig.5.1.1 (c) J2--axis (S--420iR)
33
Fig.5.1.1 (d) J3--axis (S--420iF/W/S/L)
Fig.5.1.1 (e) J3--axis (S--420iR)
Fig.5.1.1 (f) J2/J3--axis interference angle (S--420iF/W/S/L/R)
34
Fig.5.1.1 (g) J4--axis (S--420iF/W/L/R)
( + 250_)
( -- 250_)
Fig.5.1.1 (h) J4--axis (S--420iS)
35
Fig.5.1.1 (i) J5--axis (S420iF/W/S/L/R)
Fig.5.1.1 (j) J6--axis (S--420iF/W/S/L/R)
36
5.1.2 Axis limit software settings are upper and lower motion degree
Software Setting limitations. The limits can be set for all robot axes and will stop robot
motion if the robot is calibrated.
Use Procedure 5--1 to set up axis limits.
Procedure 5--1 Setting Up Axis Limits
Step 1 Press MENUS.

2 Select SYSTEM.
3 Press F1, [TYPE].
4 Select Axis Limits. You will see a screen similar to the following.
System Axis Limits JOINT 100%
1/16
AXIS GROUP LOWER UPPER
1 1 -180.00 180.00 dg
2 1 -70.00 72.00 dg
3 1 -105.00 30.00 dg
4 1 -300.00 300.00 dg
5 1 -130.00 130.00 dg
6 1 -360.00 360 00 dg
7 0 0.00 0.00 mm
8 0 0.00 0.00 mm
9 0 0.00 0.00 mm
[ TYPE ]
NOTE
0 indicates the robot does not have these axes.
5 Move the cursor to the axis limit you want to set.
WARNING
Do not depend on axis limit software settings to control the
motion range of your robot. Use the axis limit switches or
hardstops also; otherwise injury to personnel or damage to
equipment could occur.
6 Type the new value using the numeric keys on the teach pendant.
7 Repeat Steps 5 through 6 until you are finished setting the axis
limits.
WARNING
You must turn off the controller and then turn it back on to
use the new information; otherwise injury to personnel or
damage to equipment could occur.
8 Turn off the controller and then turn it back on again so the new
information can be used.
37
5.1.3 The J1--axis stroke can be limited depending on the operating

Hard Stopper and Limit environment of the robot. The stroke can be changed by changing the
locations of the dog and mechanical stopper and the settings of the motion
Switch Setting limits using the following procedure.
The stroke can be changed every 15 degrees in the upper limit of --135
degrees to +180 degrees and the lower limit of --180 degrees to +135
degrees.
If mastering position (0 degree) does not exist within the changed stroke,
the stroke must be reset so that it contains 0 degree position.
Changing the dog position and the mechanical stopper

Change the dog position and the mechanical position as shown in Figs.
5.1.3 (a), (b) to match with a desired stroke position.
Fig.5.1.3 (a) Mechanical stopper locations
Fig.5.1.3 (b) Dog (option) locations
38
5.2 Axis limit switches are overtravel switches that, when tripped, cut power
to the servo motors. These are located 10.5 degrees beyond the software
ADJUSTING J1--AXIS limits. Overtravel switches for axis 1 are available as an option.
LIMIT SWITCH
(OPTION) The optional J1--axis OT limit switch is actuated by a pivoting
dog mounted on a bracket bolted to the rotating J1--axis table. See
Figure 5.2. Use these steps to adjust the OT switch.
The J1--axis stroke may be limited by moving the mechanical
stoppers and OT limit switch dog. Refer to Section 5.3. When
the J1--axis stroke is to be limited, a second mechanical stopper
and dog must be used.
1 Set the $MOR_GRP.$CAL_DONE system parameter to
FALSE. This disables the motion limit specified by the
software. As a result, the operator can rotate the robot around
the J1--axis by a jog feed which goes beyond the motion limit.
2 Press the emergency stop button to stop the robot moving.
3 Loosen the two M6×8 bolts and the two M4X25 bolts that
secure the J1--axis limit switch.
4 Move the limit switch so that the robot activates it at about
0.5 degrees before the stroke end around the J1--axis.
5 When the limit switch operates and detects overtravel (OT),
the robot stops, and an error message, ”OVERTRAVEL”, is
displayed. To restart the robot, hold on the SHIFT key and
press the RESET key. Then, while holding on the SHIFT key,
move the J1--axis off the OT limit switch by jogging in joint
mode.
6 Check that the robot also activates the limit switch when the
robot is approx. 0.5 degrees from the opposite stroke end in
the same way as above. If the limit switch does not operate
at the position, adjust the position of the switch again.
7 Set the $MOR_GRP.$CAL_DONE system parameter to
TRUE.
8 Turn off the power, then turn it on again to restart the
controller.
Fig.5.2 Adjusting J1--axis OT (option)
39
5.3 When you master a robot you define the physical location of the robot by
synchronizing the mechanical information with the robot’s positional
MASTERING information. A robot must be mastered to operate properly. Robots are
usually mastered before they leave FANUC However, it is possible that
a robot might lose its mastering data and require to be remastered.
5.3.1
You can master the robot using several different methods. Refer to Table
General
5.3.1 to select the method that best meets your needs.
Table5.3.1 Mastering Methods
Mastering Method When to Use

Mastering to a fixture D When mastery is lost due to mechanical
(Master Position disassembly or repair.
Master) D When a quick master reference position was not
previously set.
D Method of choice for P--and A--series robots.
Used for S-- and M--series robots when extreme
precision is required.
mastering to zero de- D When mastery is lost due to mechanical
grees disassembly or repair.
D When a quick master reference position was not
previously set.
D Method of choice for S-- and M--series robots
when extreme precision is not required.
Single axis mastering When mastery was lost due to mechanical disas-
sembly or repair of a single axis (usually due to mo-
tor replacement).
Recording the quick To record mastering data as a reference for future
master reference posi- quick mastering.
tion
Quick mastering To retrieve mastery data that has been stored as a
quick master reference position when mastery is lost
due to an electrical or software problem. Do not use
if mastery is lost due to mechanical disassembly or
repair.
Quick mastering is a convenient way to master an robot after you have

recorded a reference position. You cannot quick master a robot unless the
reference position was taught before mastering was lost.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
40
5.3.2 When you power up the robot after disconnecting the pulse coder backup
Resetting Alarms and batteries you may see a SRVO--062 BZAL or SRV0--038 Pulse mismatch
alarm. Before mastering the robot you must reset the alarm and rotate the
Preparing for motor of each axis that lost battery power to prepare the robot for
Mastering mastering.
Use Procedure 5--2 to reset these alarms and prepare the robot for
mastering.
Procedure 5--2 Preparing the Robot for Mastering
Condition H You see a SRVO--062 BZAL or SRVO--038 Servo mismatch

alarm.
Step 1 Replace the robot batteries with four new 1.5 volt alkaline
batteries, size D. Observe the direction arrows in the battery box
for proper orientation of the batteries.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the
following; otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key “1” and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
e Select Master/Cal. You will see a screen similar to the
following.
SYSTEM Master/Cal JOINT 10%
1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press ’ENTER’ or number key to select.
[ TYPE ] LOAD RES_PCA DONE
41
6 To reset a SRVO--062 alarm when RES_PCA does not appear on

the Master/Cal menu, do the following:
a Press F1, [TYPE].
b Select Variables.
c Move the cursor to $MCR and press ENTER.
d Move the cursor to $SPC_RESET and press F4, TRUE.
The value will change to TRUE momentarily, and will then change
to FALSE.
e If the value does not change to TRUE momentarily, repeat
Step 6.
f Press RESET on the operator box.
7 Perform a cold start.
a Turn off the robot.
b Press and hold the FAULT RESET button on the operator box.
c While still pressing FAULT RESET, press the ON button on
the operator box.
8 If the SRVO--062 alarm is still present; there is a battery, cable or
pulse coder problem. Refer to the SYSTEM R-J2 Controller Series
Electrical Connection and Maintenance Manual for further
information.
9 If a SRVO--038 alarm is present at this time, repeat step 6 to reset
it. It is not necessary to cold start the robot after resetting to clear
this alarm.
10 Rotate each axis that lost battery power by at least one motor
revolution in either direction.
a Jog each rotary axis at least twenty degrees.
b Jog each linear axis at least thirty millimeters.
11 Perform any of the mastering procedures from the MASTER/CAL
menu.
42
5.3.3 When a major part of the robot mechanical unit is replaced and the actual
Mastering to a Fixture position of each axis is displaced from the current value stored through
an absolute pulse coder (hereinafter abbreviated as APC), the mastering
(Master Position is executed to set the geometric position of the robot. Mastering has been
Master) performed before shipment.
When mastering the robot, arrange the robot to meet the following
conditions.
D Make the robot mounting base horizontal within 1 mm.
D Remove the hand and other parts from the wrist.
D Set the robot in the condition protected from an external force.
D Have the appropriate mastering fixture for your robot.
D Clear any servo faults that prevent you from jogging the robot.
D Jog each axis that has lost mastery at least one motor turn.
NOTE
Since the axis stroke is not checked during the mastering,
be careful to stay clear of the robot motion.
1) Assembling the fixture base

Assemble the fixture base as shown in Fig. 5.3.3 (a).
Bolts
M5X20
Plate Bolts
M5X20
Base
ADAPTOR Plate
Note) The shape of the adapter plate varies with the model.
Fig.5.3.3 (a) Assembling fixture base
43
2) Mount the dial gauges.

Adjust the dial gauge to 3.00 mm using the calibration block, and
tighten it with M5 bolt as shown in Fig. 5.3.3 (b). (Do not tighten the
bolt too strongly or the dial indicator will be broken.)
A
B
F
0
3 M5 bolt C
20 E
Calibration block
Fig.5.3.3 (b) Mounting dial indicator
3) Mount the fixture on the J1--axis base with bolts as shown in Fig.
5.3.3(c), (d).
Fig.5.3.3 (c) Mounting fixture base (S--420iF/W/S/L)
44
Fig.5.3.3 (d) Mounting fixture base (S--420iR)
4) Mounting the fixture to the wrist

Mount the fixture to the J6--axis flange as shown in Fig. 5.3.3 (e).
Fig.5.3.3 (e) Mounting fixture to wrist
45
5) To release the brake control, set the system variable

$PARAM_GROUP.$SV_OFF_ALL to false. Then set system
variable $PARAM_GROUP.$SV_OFF_ENB for each axis to false,
turn off the power, and power on.
6) Jog each axis to a calibration point or near it where calibration using
a fixture is to be performed. (See Fig. 5.3.3 (f) to (j).) When jogging
the robot, be careful not to hit the wrist of the robot onto the mastering
fixture.
7) Jog the robot slowly until the dial indicators A to F shown in Fig.
5.3.3 (b) meet arrows A to F shown in Fig. 5.3.3(e).To set each axis
to the mastering fixture position, jog the robot in a direction in which
the dial indicator reading decreases to prevent an error caused by axis
backlash.
8) Press MENUS.
9) Select SYSTEM.
10)Press F1, [TYPE].
11)Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 12.
a) Select VARIABLE from the [TYPE] menu.
b) Move the cursor to $MASTER_ENB.
c) Press the numeric key “1” and then press ENTER on the teach
pendant.
d) Press F1, [TYPE].
e) Select Master/Cal. You will see a screen similar to the following:

3 QUICK MASTER
6 CALIBRATE

12)Select Master Position Master.
13)Press F4, YES. Mastering will be performed automatically.
14)Select Calibrate.
15)Press F4, YES.
16)To re-enable brake control, set system variable
$PARAM_GROUP.$SV_OFF_ALL to true. Then set system
variable $PARAM_GROUP.$SV_OFF_ENB for each axis to true.
17)Turn off the power, and power on.
46
Fig.5.3.3 (f) Mastering attitude (S--420iF, W, W/175)
Fig.5.3.3 (g) Mastering attitude (S--420iF, 2.85, W/2.85)
47
Fig.5.3.3 (h) Mastering attitude (S--420iS)
Fig.5.3.3 (i) Mastering attitude (S--420iL)
48
Fig.5.3.3 (j) Mastering attitude (S--420iR)
49
5.3.4 When you master to zero degrees, you position all axes at their zero degree
Zero Degree Mastering witness marks and record the zero degree position.
Use Procedure 5--3 to master to zero degrees.
Procedure 5--3 Mastering to Zero Degrees
Condition H You have cleared any servo faults that prevent you from jogging
the robot.
H You have jogged each axis that has lost mastery at least one motor
turn. (Procedure 5--2).
Step 1 Using the joint coordinate system, jog each axis of the robot to the
zero degree witness mark.
2 Press MENUS.
3 Press SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
following.
50

3 QUICK MASTER
6 CALIBRATE
6 Select Zero Position Master.

7 Press F4, YES. Mastering will be performed automatically.
8 Select Calibrate.
9 Press F4, YES.
Table5.3.4 Attitude with position marks aligned
Axis S--420iF/W/S/L S--420iR

J1--axis 0 deg 0 deg
J2--axis 0 deg --15 deg
J3--axis 0 deg +15 deg
NOTE
For the S--420i R, the attitude assumed by aligning the
position marks differs from the zero--degree attitude.
51
Fig.5.3.4 Zero degree position arrow mark for each axis
52
5.3.5 Quick mastering allows you to minimize the time required to remaster the
Quick Mastering robot using a reference position you established when the robot was
properly mastered. You cannot quick master the robot unless you have
previously recorded this quick master reference position.
Record the quick master reference position when the robot is properly
mastered. The best time to record the quick master reference position
is when the robot is still factory-mastered.
If you lose mastery due to an electrical or software problem, you can
use this reference position to master the robot in a minimum amount of
time. If you lose mastery due to mechanical disassembly or repair, you
must master to a fixture or perform zero degree mastering.
Use Procedure 5--4 to record the quick master reference position. Use
Procedure 5--5 to quick master the robot.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
53
Procedure 5--4 Recording the Quick Master Reference Position
Condition H The robot is properly mastered.

1 Align the witness marks on the robot. This is the zero position,
which will be the quick master reference position. .
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
following.

3 QUICK MASTER
6 CALIBRATE
6 Move the cursor to SET QUICK MASTER REF and press

ENTER.
Set quick master ref? [NO] 7 Press F4, YES.
54
Procedure 5--5 Quick Mastering the Robot
Condition H The robot has lost mastery due to an electrical or software

problem.
NOTE
If the robot has lost mastery due to mechanical disassembly
or repair, you cannot perform this procedure. In this case,
master to a fixture or master to zero degrees to restore robot
mastery.
H The quick master reference position was recorded before the robot
lost mastery.
H You have cleared any servo faults that prevent you from jogging
the robot.
turn.
1 Jog the robot to the quick master reference position (zero degree
position).
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
following.
55

3 QUICK MASTER
6 CALIBRATE
6 Move the cursor to QUICK MASTER and press ENTER.

Quick master? [NO] 7 Press F4, YES.
8 Move the cursor to CALIBRATE and press ENTER
9 Press F4, YES.
56
5.3.6 You can master a single axis of an S-series robot when mastery was lost
Single Axis Mastering due to mechanical disassembly or repair of a single axis.
Use Procedure 5--6 to master a single axis.
Procedure 5--6 Mastering a Single Axis
Condition H You have cleared any servo faults that prevent you from jogging
the robot.
turn. (Procedure 5--2).
Step 1 Using the joint coordinate system, jog the unmastered axis of the
robot to the zero degree witness mark.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
following.

3 QUICK MASTER
6 CALIBRATE
[ TYPE ] LOAD RES_PCA
6 Select 4, Single Axis Master. You will see a screen similar to the
following.
57
SINGLE AXIS MASTER JOINT 10%

1/9
ACTUAL POS (MSTR POS) (SEL) [ST]
J1 0.000 ( 0.000) (0) [2]
J2 3.514 ( 35.000) (0) [0]
J3 -7.164 (-100.000) (0) [2]
J4 -357.366 ( 0.000) (0) [2]
J5 -1.275 ( -80.000) (0) [2]
J6 4.571 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [0]
E2 0.000 ( 0.000) (0) [0]
E3 0.000 ( 0.000) (0) [0]
[ TYPE ] GROUP EXEC
7 Move the cursor to the MSTR POS column for the unmastered
axis and press the “0” key.
8 Continuously press and hold the DEADMAN switch and turn the
teach pendant ON/OFF switch to ON.
9 Move the cursor to the SEL column for the unmastered axis and
press the numeric key “1.”
10 Press ENTER.
11 Press F5, EXEC. Mastering will be performed automatically.
12 Press PREV.
13 Select Calibrate.
14 Press F4, YES.
58
5.4 When the backlash of the J5--axis exceeds the tolerance (six minutes),
listed in Table 4.2, adjust the backlash as described below.
ADJUSTING J5--AXIS
1) Adjusting the backlash of the gear 1 and gear 2 assemblies
BACKLASH a) Position a lever type dial test indicator on the notched portion of
the U nut of the gear 1 assembly and secure the indicator. (Make
the measurement at a point 36 mm from the center of rotation of
the gear 1 assembly.)
b) While holding the gear 2 assembly still, measure the play in the
gear 1 assembly.
c) Change the thickness of the spacers used with each assembly to
adjust the backlash to within 0 to 0.15 mm. (The J5--axis must
have some backlash.)
2) Adjusting the backlash of the gear 2, 3, and 4 assemblies.
a) Position a lever type dial indicator on the tooth surface of the gear
4 assembly and secure the indicator. (Make the measurement at
a point 136 mm from the center of rotation of the gear 4
assembly.)
b) While holding the gear 2 assembly still, measure the play in the
gear 4 assembly.
c) Adjust the position of the gear 3 assembly so that the backlash
within 0 to 0.10 mm. (The J5--axis must have some backlash.)
Fig.5.4 Adjusting J5--axis Backlash
59
6. REPLACING PARTS MAINTENANCE B--80505E/06
6
REPLACING PARTS
Replace the main parts of the mechanical unit as described below.
6.1
1) When a part is replaced, the corresponding adjustment must be made.
PART REPLACEMENT Table 6.1 lists those parts that can be replaced and the corresponding
AND CORRESPONDING adjustment. After replacing a part, perform the appropriate
ADJUSTMENT adjustment, as listed below.
Table 6.1 Parts to be Replaced and Adjustment Items
Parts to be replaced Adjustment Method
Motor, reducer, gear Mastering See 5.3
Wrist unit Mastering See 5.3
Cable (*) Mastering See 5.3
Limit switch (*) Adjusting, limit switch See 5.2
* Refer to Section 1, item 8 for replacement of cables and limit switches.
NOTE
The following components are heavy. Be particularly
careful when carrying or assembling them.
Component Weight (approximate)

J1, J2, J3, J4 (M1, M2, M3, M4) 30 kg
Servo motors
J5 (M5) 20 kg
J1--axis 55 kg
Reducers J2-- and J3--axes 50 kg
J4--axis 20 kg
J1--axis table 60 kg
J1--axis holder 30 kg
J1--axis cross roller bearing 30 kg
J2--axis arm 90 kg
Balancer (S--420 iF/W/S/L) 45 kg
J3--axis link 1 285 kg
Wrist unit 100 kg
J2--J6--axis unit (See Fig. 6.2 (b).) 1100 kg
J4--J6--axis unit (See Fig. 6.3 (j).) 300 kg
Balancer (S--420 iR) 100 kg
J3--axis link 1 (with add. weight) 345 kg
Controller (i--cabinet) 100 kg
J2/J3 gear box (Compact type) 25 kg
60
B--80505E/06 MAINTENANCE 6. REPLACING PARTS
In case of reusing sealbolts for S--420i, observe following notes strictly.

(If possible, change them to new sealbolts)
1) Apply LOCTITE to the sealbolts.
2) Notice the following 3 notes.
a) Remove excessive bits of sealant on the sealbolt. (Not necessary
to remove sealant which is fixed tightly.)
b) The length of application is 2d (d : diameter of the bolt) from the
tip of the bolt, and spread it evenly around it.
c) Spread LOCTITE on whole threaded portion and rubbing 2 bolts
together in order to spread it to the bottom of groove.
Fig.6.1 Standard application of sealant
61
6.2
1) Replacing J1--axis motor (Fig. 6.2 (a) )
REPLACING J1--AXIS 1 Turn off the power.
MOTOR (M1) AND 2 Remove the J1--axis motor connectors. (For the S--420i R,
REDUCER remove the cover from the J2 angle base.)
3 Remove four motor mounting bolts (M12×35) and then remove
the motor.
4 Remove the nut and gear in order.
5 Replace the motor, and remount a new motor reversing above
procedure. Polish the motor flange with oil stone. Apply
LOCTITE No. 242 to the thread of the nut. Be careful not to
damage the tooth surface of the spur gear. Install an O ring
correctly.
6 Perform mastering (Refer to section 5.3).
Fig.6.2 (a) Replacing J1--axis motor (M1)
62
2) Replacing J1--axis reducer (Fig. 6.2 (b) )

2 Remove J1--axis motor (M1) by the above procedure.
3 When equipped with integrated controller, open the side cover of
the controller and disconnect the cables.
4 Remove the controller mounting bolts (M10 x 30 2pcs and M10
x 35 2 pcs) and remove the controller.
5 Remove the cables and air tubes from the connector box (option)
at the side of J1--axis base and remove the grease supply tube.
6 Remove two M8 x 12 bolts in the J1--axis base and extract a plate
with a cable halfway.
7 Remove a cable clamp and nylon band attached to the plate and
draw out the plate from J1--axis base.
8 Remove J2--base mounting bolts (M12 x 35 12 pcs) and lift up
the robot body taking care of the cable to separate the J1--axis
unit. (For the S--420i R, remove the 9 bolts (M12x35) and 3 bolts
(M12x80) securing the J2 angle base.)
9 Remove the table mounting bolts (M12 x 70 13 pcs) and remove
the table.
10 Remove the holder mounting bolts (M12×45 12 pcs) and remove
the holder.
11 Remove the center gear.
12 Remove the reducer mounting bolts (M16×110 9 pcs) and
remove the reducer with cross roller bearing from the J1--axis
base.
13 Remove the cross roller bearing and the pipe from the reducer.
14 Replace the reducer.
15 Reassemble by reversing the above procedure. Polish the reducer
and motor flange mounting surfaces using an oil stone. Apply
LOCTITE No. 262 to the bolts shown in Fig. 6.2 (b). Coat sealant
enough to the connections between the bolts and the J1 base.
Install O ring at a correct position.
Be careful not to damage the tooth surface of the center gear.
16 Form the cables (Refer to section 8).
17 Lubricate with grease (Refer to section 3).
63
Fig.6.2 (b) Replacing J1--axis reducer
64
6.3
1) Replacing the J2/J3--axis motor (M2/M3)
REPLACING i) Standard type (See Fig. 6.3(a))
J2/J3--AXIS MOTOR 1 Turn off the power.
(M2/M3) AND 2 Suspend the J3--axis arm with a rope. Also, suspend the J3--axis
REDUCER link for safety. (See Fig. 6.3(c).) (For S--420iR, suspend it as
shown in Fig. 6.3(d).)
3 Remove the connectors.
4 Remove the mounting bolts (M12×40) of the motor to be
replaced, and remove the motor to be replaced.
5 Remove the nut, the input gear and the draw bolt in order.
6 Replace the motor, and remount a new motor reversing the above
procedure.
Polish the motor flange with an oil stone. Apply LOCTITE No.
242 to the draw bolt and the motor thread.
Mount the O--ring correctly.
Use new motor mounting sealbolts. (In case of reusing sealbolts,
apply LOCTITE No.242 to them. (Refer to section 6.1)
Be careful not to damage the tooth surface of the input gear.
7 Replenish the grease (Refer to section 3).
Fig.6.3 (a) Replacing J2/J3--axis motor (M2/M3)
65
ii) Compact type (See Fig. 6.3(b))

2 Suspend the J3--axis arm with a rope. Also, suspend the J3--axis
link for safety. (See Fig. 6.3(c).)
3 Remove the connectors.
4 Remove the mounting bolts (M12×35) of the motor to be
replaced, and remove the motor to be replaced.
5 Remove the draw bolt and input spline in order.
6 Replace the motor, and remount a new motor reversing the above
procedure.
Polish the motor flange with an oil stone. Apply LOCTITE No.
242 to the draw bolt and the motor thread.
Mount the O--ring correctly.
Be careful not to damage the tooth surface of the input gear.
7 Replenish the grease (Refer to section 3).
Fig.6.3 (b) Replacing J2/J3--axis motor (Compact type)
66
Fig.6.3 (c) J2/J3--axis reducer replacing posture (S--420iF/W/S/L)
67
Fig.6.3 (d) J2/J3--axis reducer replacing posture (S--420iR)
68
2) Replacing J3--axis reducer

i) Standard type (See Fig. 6.3(e))
1 Turn off the power supply.
2 Remove J3--axis motor (M3) following the above procedure.
3 Remove the bracket mounting bolts (M12×60 16 pcs), and then
the bracket.
4 Remove the reducer mounting bolts (M16×140 3 pcs) and taper
pin (φ16×60 3 pcs).
5 Remove and replace the reducer.
6 Remount a new reducer reversing the above procedure. Polish the
reducer mounting surface and the motor flange mounting surface
using an oil--stone.
Apply LOCTITE No. 262 to the bolts shown in Fig. 6.3 (e).
Apply LOCTITE No. 242 to the taper pins removed in the step 4,
and insert the pins after reaming.
⋅Take care to use the O--ring at the specified position.
⋅Use new motor mounting sealbolts. (In case of reusing sealbolts,
⋅Be careful not to damage the tooth surface of the input gear.
7 Apply grease to the reducer (Refer to section 3).
Reducer mounting
bolts M16 x 140
Fig.6.3 (e) Replacing J3--axis reducer
69
ii) Compact type (See Fig. 6.3(f))

1 Turn off the power supply.
2 Remove J3--axis motor (M3) following the above procedure.
3 Remove the gear box mounting bolts (M12×60 8 pcs, M12×50
8 pcs)
4 Remove the reducer mounting bolts (M16×140 3 pcs) and taper
pin (φ16×60 3 pcs).
5 Remove and replace the reducer.
6 Remount a new reducer reversing the above procedure. Polish the
reducer mounting surface and the motor flange mounting surface
using an oil--stone.
Apply LOCTITE No. 262 to the bolts shown in Fig. 6.3 (f).
Apply LOCTITE No. 242 to the taper pins removed in the step 4,
and insert the pins after reaming.
⋅Take care to use the O--ring at the specified position.
⋅Be careful not to damage the tooth surface of the input gear.
Fig.6.3 (f) Replacing J3--axis reducer (Compact type)
70
Guide Rods Guide Rods
Fig.6.3 (g) Replacing J2/J3--axis reducer
71

i) In case of S--420iF/W/S/L
1 Position the J2--axis to 0 degrees.
3 Remove the cables, threaded through the connection section of
the J3--axis arm into the cable track, from the mechanical unit.
(See item 8.)
4 Suspend the J3--axis arm with a rope.
WARNING
THE J2--AXIS MUST BE SET TO ZERO DEGREES
BEFORE ATTEMPTING TO REMOVE THE SPRING
BALANCERS. OTHERWISE, INJURY TO PERSONNEL
MAY RESULT.
5 Remove the C ring from the shaft of the J2/J3--axis connection

section, then remove the balancer.
6 Remove the bolts (M8x25 6pcs) from the lower part of the link
1/link 2 connection section, then remove the shaft.
7 Remove (M10x110 16pcs) bolts from the J2/J3--axis connection
section, then remove the shaft.
8 Remove the J4--axis unit and link 2 from the robot. (See Fig. 6.3
(j).)
9 Suspend the J2--axis arm with a rope. Remove the J2--axis motor
(M2) as described previously. Butt the J2--axis arm against the
front stopper.
10 Suspend link 1 with a rope. Remove the J3--axis motor (M3),
bracket or gear box (compact type) and reduction unit.
WARNING
LINK 1 IS A COUNTERWEIGHT FOR THE J4--AXIS UNIT.
IT MUST BE SECURELY RIGGED BEFORE REMOVING
THE SHAFT OR IT MIGHT FALL. INJURY TO
PERSONNEL MAY RESULT.
11 Remove shaft mounting bolts (M12x100 8pcs) and remove the

shaft.
12 Remove link 1.
13 Again suspend the J2--axis arm with a rope. Remove the
(M12x60) bracket mounting bolts and bracket with the J2--axis
set to 0 degrees.
14 Remove the reduction--unit mounting bolts (M16x50 6pcs and
M10x35 18pcs). Insert guide rods, threaded M12, into the bracket
mounting bolt holes and withdraw the reduction unit, as shown
in Fig.6.3 (g).
15 Separate the J2--axis arm from the robot.
16 Replace the reduction unit.
72
17 Reassemble the unit by reversing the above procedure. Keep the

following points in mind.
Polish the surface where the reduction unit is mounted, as well
as the motor flange, with an oilstone. Apply Loctite No. 262 to
the bolts specified in Fig. 6.3. (h), (i).
Mount the O--ring in the specified position.
Be careful not to scratch the teeth surfaces of the input gear.
Arrange the cables correctly. (See item 8.)
18 Perform regreasing. (See item 3.)
19 Perform mastering. (See item 5.3.)
Bracket mounting
bolts M12 x 60
Fig.6.3 (h) Replacing J2--axis reducer
73
ii) For the S--420i R

1 Set the J2--axis arm to --85 and the J3--axis arm to +45 , then turn
the power off.
2 Perform steps 3 and 4 in (i).
3 Remove the four balancer securing bolts (M12x40) and C--ring,
then remove the balancer.
4 Perform step 6 in (i).
5 Remove the U--shaped nut and bearing, then remove the housing
from the shaft.
6 Perform steps 7 to 12 in (i). (Fig. 6.3 (k))
7 Support the J2--axis with a rope, set the J2--axis arm to --85 , then
remove the bracket.
8 Perform steps 14 to 19 in (i).
Fig.6.3 (i) Replacing J2--axis reducer (Compact type)
74
Fig.6.3 (j) Replacing J2--axis reducer (S--420iF/W/S/L)
Fig.6.3 (k) Replacing J2--axis reducer (S--420iR)
75
6.4
1) Replacing J4--axis motor (M4)
REPLACING J4--AXIS 1 Set the posture of the wrist such that no load is applied to the wrist
MOTOR (M4) AND axis.
J4--AXIS REDUCER 2 Turn off the power.
3 Remove the connector.
4 Remove four bolts (M12 x 40 2pcs, M12 x 55 2pcs) for mounting
the motor, then the motor.
5 Remove the nut and take out the center gear.
6 Replace the motor with a new one. And reassemble it in a reverse
order. Also replace the O--ring (as a precaution). Apply Locktite
No. 242 to the threaded portion of the motor shaft.
Be sure to mount the O- -ring at the appropriate
position. Pay special attention so as not to scratch the
tooth face of the super gear.
7 Apply grease to the motor (Refer to section 3).
76

1 Remove any load on the robot’s wrist such as a hand or a
workpiece.
3 Remove the plate, a grommet and cable ties (See Fig. 6.4(b)).
4 Remove the plate of the J3--axis arm, remove all the connectors,
cable ties and the plates. Pull out the cables from J3--axis arm.
Refer to Fig.8.2 (g) to (i)
5 Remove the J4--axis motor (M4) by the procedure shown above.
6 Remove six gear box mounting bolts (M10 x 50) and, then the
gear box.
7 Remove the center gear.
8 Support the J3--axis arm with a crane. Remove J3--axis arm
mounting mounting bolts (M14 x 95 6 pcs), then J3--axis arm.
9 Remove the reducer mounting bolts (M10 x 30), and remove the
reducer.
10 Replace the reducer.
11 Reassemble the removed components. Polish the surface on
which the reducer is to be mounted with an oilstone to remove
burrs. Apply Loctite No. 262 to the bolts shown in Fig. 6.4(b).
Be sure to mount the O- -ring at the appropriate position.
Pay special attention so as not to scratch the tooth face
of the center gear.
12 Form the cables (Refer to section 8).
77
6.5
1 Remove loads from the robot’s wrist such as a hand and
REPLACING WRIST workpieces. Support the wrist with a crane.
UNIT 2 Turn off the power.
3 Remove the J3--axis arm plate, then remove the connectors, cut
the cable ties and the plates. Refer to Fig.8.2 (h), (i).
4 Remove the wrist unit mounting bolts (M12 x 35 8 pcs) and the
wrist unit.
5 Replace the wrist unit with a new one. Reassemble the removed
components.
Spring pin for alignment

φ12 x 30
Fig.6.5 Replacing wrist unit
78
6.6
REPLACING J5--AXIS 1 Remove loads from the robot’s wrist such as a hand and
MOTOR (M5) AND workpieces.
J5--AXIS REDUCER 2 Turn off the power.
3 Remove the J5--axis cover, the connector of the J5--axis motor
(M5), then the plate. Cut the nylon cable tie. (See Section 8.2,
”Replacing the Cables.”)
4 Remove the bolt (M12 x 40) for mounting the motor, then remove
the motor.
5 Remove the draw bolt and spline from the motor shaft.
6 Replace the motor with a new one. Also replace the O--ring (as
a precaution). Reassemble the removed components.
Be sure to mount the O--ring at the appropriate position.
Fasten the excess part of the cable to the plate with a nylon tie.
See 8.2 for an explanation of how to lay the cable.
79
2) Replacing J5--axis gear

1 Remove J5--axis motor (M5) by the previous method.
2 Remove drain plugs from the J5--axis cover and drain grease.
3 Remove four gear 1 assembly bolts (M6 x 16) and remove the
gear 1 assembly. (Fig.6.6 (b))
4 Remove ten J5--axis cover mounting bolts (M6 x 16) (M6 x 40
for S--420iW), two spring pins (6 dia. x 20) gasket and the cover.
(Fig.6.6 (b))
5 Remove six gear 3 assembly bolts (M12 x 30) while rotating gear
3 and remove gear 3 assembly. (Fig.6.6 (c))
6 Remove eight J5--axis gear 2 mounting bolts (M6 x 16) and the
gear 2 assembly.
7 Remove sixteen J5--axis gear 4 assembly seal bolts (M10 x 50)
and gear 4 (Do not re--use the seal volts.)
8 Change the gear.
9 Adjust backlash and assemble it in the reverse order (See 5.4).
Apply Loctite No. 262 to the bolts shown in the figure. Change
the gasket to a new one, and fix it temporarily with tightening
torque of 1.0--1.6 kgfm. Retighten it after 20--60 minutes with 1.6
kgfm. Use new gear4 mounting sealbolts. (In case of reusing
sealbolts, apply LOCTITE No.262 to them. (Refer to section 6.1))
10 Refill with grease.
J5--axis gear 1
assembly
Cover mounting
bolts M6x16
(M6 x 40 for S--420iW)
Gasket
80
Fig.6.6 (c) Replacing J5--axis gear
81
6.7
REPLACING J6--AXIS 1 Remove loads from the robot’s wrist such as a hand and
MOTOR (M6) AND workpieces.
J6--AXIS REDUCER 2 Turn off the power at the position of J5=--90 degrees.
3 Remove the cover, motor cover and cable connectors.
4 Remove J5--axis cover 2, a plate, a grommet and a clamp. (Do not
remove plate and Teflon sheet attached to the J5--axis cover 2).
5 Remove rubber block mounting bolts and take out the cable.
6 Remove four bolts (M8×22) for mounting the motor, then remove
the motor.
7 Remove the nut, input gear and the draw bolt.
8 Replace the motor with a new one. Reassemble the removed
components. Polish the motor flange with oil stone. Apply
Locktite No. 242 to the threaded portion of the motor shaft.
Be sure to mount the O--ring at the appropriate position. Pay
special attention so as not to scratch the tooth face of the input
gear. Use new motor mounting sealbolts. (In case of reusing
sealbolts, apply LOCTITE No.242 to them. (Refer to section 6.1)
Fasten two bolts (M4 x 60) of the rubber block, so that the ends
protrude 2.5mm through the plate.
10 Perform cable forming (See section 8).
(Do not
overstrike)
Washer
82
Fig.6.7 (b) Replacing J6--axis motor
83

1 Remove loads from the robot’s wrist such as a hand and
workpieces.
3 Remove the flange mounting bolts (M14 x 25 4pcs and M6 x 20
4pcs) and the wrist flange.
4 Remove eight bolts (M8 x 40) for mounting the reducer, then
remove the reducer.
5 Replace the reducer with a new one. Reassemble the removed
components. Be sure to mount the O--ring at the appropriate
position. Pay special attention so as not to scratch the tooth face
of the center gear. Apply Loctite gasket eliminator No. 518 to the
flange mounting face of the reducer. Apply Loctite No. 262 to the
bolts shown in Fig. 6.7 (c).
LOCTITE
Gasket Eliminator
No.518
Flange mounting bolts
Tool mounting
flange
Fig.6.7 (c) Replacing J6--axis reducer
84
6.8 By using the optional brake release unit, the motor brake for each a axis
can be released while power is not supplied, enabling the attitude of the
RELEASING A robot to be changed arbitrarily.
BRAKE (OPTION) When using the brake release unit, observe the following precautions:
NOTE
1 When releasing the brake of the J2-- or J3--axis motor, support
the robot using a crane, as shown in Fig. 6.8 (a) to (d).
2 When releasing the brake of the J4--, J5--, or J6--axis motor,
support the end effector using a crane, to prevent it from fall.
3 Before releasing a brake, apply sufficient tension to the sling.
4 Do not release the brake for two or more axes
simultaneously.
Fig.6.8 (a) J2--axis brake releasing (S--420iF/W/S/L)
Fig.6.8 (b) J3--axis brake releasing (S--420iF/W/S/L)
85
Fig.6.8 (c) J2--axis brake releasing (S--420iR)
Fig.6.8 (d) J3--axis brake releasing (S--420iR)
86
B--80505E/06 MAINTENANCE 7. PIPING AND WIRING
7
PIPING AND WIRING
7.1 Fig. 7.1 (a) and (b) show the piping diagram of the mechanical unit.
PIPING DIAGRAM
Fig.7.1 (a) Piping diagram
87
7. PIPING AND WIRING MAINTENANCE B--80505E/06
Fig.7.1 (b) Piping diagram for purge air (for severe dust/liquid protection)
88
7.2 Fig. 7.2 (a) to (t) show the wiring diagram of the mechanical unit.
WIRING DIAGRAM
Fig.7.2 (a) Wiring diagram (schematics) in mechanical unit (S--420iF, W, W/175, integrated type)
89
K524 (Devicenet (Signal)) [option]

K525 (Devicenet (Power)) [option]
Fig.7.2 (b) Wiring diagram (schematics) in mechanical unit (S--420iF, W, W/175, Remote type)
Fig.7.2 (c) Wiring diagram (schematics) in mechanical unit (S--420iF/2.85, S--420iW/2.85 Integrated type)
90

Fig.7.2 (d) Wiring diagram (schematics) in mechanical unit (S--420iF/2.85, S--420iW/2.85, Remote type)
Fig.7.2 (e) Wiring diagram (schematics) in mechanical unit (S--420iS, Integrated type)
91

Fig.7.2 (f) Wiring diagram (schematics) in mechanical unit (S--420iS, Remote type)
Fig.7.2 (g) Wiring diagram (schematics) in mechanical unit (S--420iL, Integrated type)
92

Fig.7.2 (h) Wiring diagram (schematics) in mechanical unit (S--420iL, Remote type)
Fig.7.2 (i) Wiring diagram (schematics) in mechanical unit (S--420iR)
93
Fig.7.2 (j) Wiring diagram (block) in mechanical unit (S--420iF, W, W/175, Integrated type)
94
Fig.7.2 (k) Wiring diagram (block) in mechanical unit (S--420iF, W, W/175, Remote type)
95
Fig.7.2 (l) Wiring diagram (block) in mechanical unit (S--420iF/2.85, W/2.85, Integrated type)
96
Fig.7.2 (m) Wiring diagram (block) in mechanical unit (S--420iF/2.85, W/2.85, Remote type)
97
Fig.7.2 (n) Wiring diagram (block) in mechanical unit (S--420iS, Integrated type)
98
Fig.7.2 (o) Wiring diagram (block) in mechanical unit (S--420iS, Remote type)
99
Fig.7.2 (p) Wiring diagram (block) in mechanical unit (S--420iL, Integrated type)
100
Fig.7.2 (q) Wiring diagram (block) in mechanical unit (S--420iL, Remote type)
101
Fig.7.2 (r) Wiring diagram (block) in mechanical unit (S--420iR)
102
(AS2, AP2, EE,

I/O, AIR2, DS3, DP3)
(DS2, DP2)
(AS1, AP1, AIR1, DS1, DP1)
Fig.7.2 (s) Connector locations
103
S--420i F2.85/W2.85/R
(AS1, AP1, AIR1, DS1, DP1)
Fig.7.2 (t) Connector locations
104
B--80505E/06 MAINTENANCE 8. REPLACING CABLE
8
REPLACING CABLE
Replace the cable every four years. 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 cable is necessary.
BATTERY BACKUP
DON’T
DISCONNECT
MARKING TIE
105
8. REPLACING CABLE MAINTENANCE B--80505E/06
8.1 Fig. 8.1 (a) to (g) shows the cable clamp position.
CABLE FORMING When replacing cables, clamp the cable at the position specified in Figure
8.1 (a) to (g) using a clamp or a nylon band. Otherwise, cables are
loosened or forcedly pulled to cause their disconnection. Refer to the
figures in section 8.2 for the cable clamp position not listed in the Table.
Table8.1 (a) Cable clamp position
106
Table8.1 (b) Cable clamp position
107
Table8.1 (c) Cable clamp posiiton
108
Table8.1 (d) Cable clamp posiiton
109
Table8.1 (e) Cable clamp posiiton
110
Table8.1 (f) Cable clamp posiiton
111
Table8.1 (g) Cable clamp posiiton
112
Table8.1 (h) Cable clamp posiiton
MARK CABLE CLAMPING POSITION MARK CABLE No.
DS 3 K524
DS 1
DS 2
DP 3 K525
DP 1
DP 2
113
8.2 This section describes the procedure for replacing all cables during
routine cable replacement for the mechanical unit.
REPLACING THE
To replace one or a few damaged cables only, refer to this section to
CABLES replace them.
The cables in the mechanical unit consist of those for the basic axes (J1
to J4 axes) and those for the wrist section (J5 and J6 axes). They can be
divided into two parts at the connector section of the J3--axis arm. (See
Fig. 7.2)
WARNING
Removing the cables will cause loss of mastering data, so
mastering must be performed once the cables have been
replaced. (When the pulse coder cable is not to be replaced,
mastering is not required.) Before replacing the cables, refer
to Item 5.7, ”Quick Mastering.”
Perform cable replacement with each axis at the zero degree
mark.
Cable replacement procedure

1) Replacing the cables for the basic axes
1 Turn off the power. Remove the side cover of the controller, then
disconnect all cables. Separate the controller from the robot.
(For the S--420i F/W/S/L having a separate control unit or the
S--420i R, disconnect the cables (except those for the mechanical
unit) from the connector panel, remove the connector panel, then
disconnect the mechanical unit cables.)
2 Disconnect the cables from the J1-- to J4--axis motors. (M1 to
M4)
3 Remove the optional connector panel, then remove the
connectors and air tube. (See Fig. 8.2 (a) (b) (c).)
4 Remove the plate from the J1--axis base. Draw the plate out of the
base and remove its clamps and cable ties. (See Fig. 8.2 (d).)
5 Remove the two plates from the J2--axis base. Remove the
clamps and cable ties from the plates, then remove the cable track.
(See Fig. 8.2 (e).)
(For the S--420i R, remove the cover from the J2 angle base, then
remove the clamp and cable tie. See Fig. 8.2 (f).)
6 Remove the cable track and cover from the J2--axis arm. Cut the
cable ties. (See Fig. 8.2 (g).)
7 Draw the plate, together with the cables, out of the cast hole in
the upper part of the J2--axis arm. Remove the clamps and cable
ties. (See Fig. 8.2 (h).)
8 Remove all plates, clamps, and cable ties from the J3--axis casing.
9 Remove the two covers from the J3--axis arm. Cut the cable ties
and remove all connectors. Also, remove the plates. (Fig. 8.2
(i).)
10 Draw the grommet out of the J3--axis casing, then remove the
cables.
2) Replacing the cables for the wrist section
114
11 Perform step 9 described above.

12 Remove the J6--axis cover. Remove all connectors. (See Fig. 6.7
(a).)
13 Remove the J6--axis motor cover and rubber block. Draw out the
cables.(See Fig. 6.7 (a).)
14 Remove the J5--axis cover, then remove the supprt mounted on
the J5--axis cover. (See Fig. 8.2 (j).)
15 Cut the cable ties for the support, then remove the cables.
16 Remove the clamps, cable ties, plates and grommet, as shown in
Fig. 8.2 (j).
17 Draw the cables out of the robot. Open the lid of the cable track
with a screwdriver and draw the cables out of the track. (See Fig.
8.2 (k).). Replace the cables.
18 Assemble the cables by reversing the above procedure. Arrange
the cables correctly and clamp them at the correct positions. (See
Figs. 8.1 (a) to (e), and 8.2 (a) to (k).)
19 Perform mastering. (See 5.3 through 5.4)
Fig.8.2 (a) Replacing the cable
115
Fig.8.2 (b) Replacing the cable (Severe dust/liquid protection)
J1 BASE PANEL (INPUT) J3 CASING PANEL (OUTPUT)
User cable (signal) Air supply DeviceNet cable

interface
(power) interface
User cable (power) DeviceNet cable

interface (signal) interface
End effector
interface (RDI/RDO)
Air supply
I/O unit model
Binterface
DeviceNet cable DeviceNet cable

(power) interface (signal) interface
J2 BASE PANEL (OUTPUT)
Fig.8.2 (c) Replacing the cable (With DeviceNet Cable)
116
Fig.8.2 (d) Replacing the cable
(DP)
(DS)
(DP)
(DP)
(DS) (DS)
Fig.8.2 (e) Replacing the cable
117
Fig.8.2 (f) Replacing the cable
(DS) (DP) (DS)

(DP)
Fig.8.2 (g) Replacing the cable
118
Fig.8.2 (h) Replacing the cable
119
S420i F2.85/W2.85/R
Fig.8.2 (i) Replacing the cable
120
Fig.8.2 (j) Replacing the cable
Fig.8.2 (k) Replacing the cable
121
8.3
REPLACING THE 1) Remove the limit--switch box, then remove the limit switch from the
box.
OPTIONAL J1--AXIS
2) Disconnect the cable from the limit switch.
LIMIT SWITCH 3) Open the side cover of the controller. Disconnect the limit--switch
(OPTION) cable.
If the remote controller is employed, remove the connector plate at
the base of robot. Disconnect the limit switch cable at back side of P1
connector.
4) Remove the side cover of the J1--axis. Draw out the cable. Replace
the limit switch with a new one.
5) Reassemble the unit by reversing the above procedure.
6) Adjust the limit switch. (See item 5.2)
Fig.8.3 J1--axis limit switch mounting diagram
122
II CONNECTION
B--80505E/06 CONNECTION 1. ROBOT INTERFERENCE AREA
1
ROBOT INTERFERENCE AREA
Fig. 1 (a), (d), (g), (j) and (m) shows the external dimensions of the robot.
Fig. (b), (e), (h) and (k) shows the external dimensions of the compact
type robot.
When installing peripheral devices, be careful to clear away any objects
that are in the robot’s motion path in normal operation. Fig. (c), (f), (i),
(l) and (n) shows operation range of the robot.
NOTE
If an adjacent type controller is used, when the robot moves
along the J3 axis in the positive direction, the gap between
link 1 and the controller becomes small, and an object like
a tool or part (if placed on the controller) may be caught
between link 1 and the controller, leading to damage to the
controller. Be careful when starting the robot. (See part P in
the figure.)
125
1. ROBOT INTERFERENCE AREA CONNECTION B--80505E/06
Fig.1 (a) Mechanical unit external dimensions (S--420iF, W, W/175)
NOTE
Restrict the robot’s operation to avoid hitting the adjacent type controller. (shading)
If |J1| ≧ 115_ and J2 ≧ --5_, the robot is not allowed to move into the area for which the following
expression is satisfied:
J3+3/10×J2 ≧ --66.5_
126
Fig.1 (b) Mechanical unit external dimensions (S--420iF/W Compact type)
NOTE
If |J1| ≧ 115_ and J2 ≧ --5_, the robot is not allowed to move
into the area for which the following expression is satisfied:
J3+3/10×J2 ≧ --66.5_
127
(Note) Figures A to H show posture at positions A to H shown in Fig. 1 (a), (b).
Fig.1 (c) Mechanical unit stroke limits
128
Fig.1 (d) Mechanical unit external dimensions (S--420iF/2.85, S--420iW/2.85)
NOTE
Restrict the robot’s operation to avoid hitting the adjacent
type controller (shading)
If |J1| ≧ 115_ and J2 ≧ --20_, the robot is not allowed to
move into the area for which the following expression is
satisfied:
J3+J2/2 ≧ --60_
129
Fig.1 (e) Mechanical unit external dimensions (S--420iF/2.85 Compact type)
NOTE
satisfied:
J3+J2/2 ≧ --60_
130
(Note) Figures A to H show posture at positions A to H shown in Fig.1 (d), (e).
Fig.1 (f) Mechanical unit stroke limits (S--420iF/2.85, S420iW/2.85)
131
Fig.1 (g) Mechanical unit external dimensions (S--420iS)
NOTE
If |J1| ≧ 115_ and J2 ≧ 5_, the robot is not allowed to move
J3+J2/5 ≧ --74_
132
Fig.1 (h) Mechanical unit external dimensions (S--420iS Compact type)
NOTE
If |J1| ≧ 115_ and J2 ≧ 5_, the robot is not allowed to move
J3+J2/5 ≧ --74_
133
(Note) A to H correspond to the points of Fig.1 (g), (h).
Fig.1 (i) Mechanical unit stroke limits (S--420iS)
134
Fig.1 (j) Mechanical unit external dimensions (S--420iL)
NOTE
If |J1| ≧ 115_ and J2 ≧ --20_ , the robot is not allowed to
satisfied:
J3+J2/2 ≧ --60_
135
Fig.1 (k) Mechanical unit external dimensions (S--420iL Compact type)
NOTE
satisfied:
J3+J2/2 ≧ --60_
136
(Note) A to H correspond to the points of Fig.1 (j), (k).
Fig.1 (l) Mechanical unit stroke limits (S--420iL)
137
Fig.1 (m) Mechanical unit external dimensions (S--420iR)
NOTE
Restrict the robot’s operation (shading)
If --61_ ≦ J3 ≦ --41_, the robot is not allowed to move into
the area for which the following expression is satisfied:
J2 ≧ --1.6×J3--94.6_
138
(Note) A to H correspond to the points of Fig.1 (m).
Fig.1 (n) Mechanical unit stroke limits (S--420iR)
139
2. MECHANICAL COUPLING TO
THE ROBOT CONNECTION B--80505E/06
2
MECHANICAL COUPLING TO THE ROBOT
140
B--80505E/06 CONNECTION THE ROBOT
2.1 Fig. 2.1 (a), (b) is a diagram to limit loads applied to the wrist. Apply a
load within the region indicated in the graph.
WRIST LOAD
CONDITIONS
Fig.2.1 (a) Wrist Load Diagram (S--420iF/S/L/R)
141
Fig.2.1 (b) Wrist Load Diagram (S--420iW, W/175)
142
2.2 Fig. 2.7 shows J2--axis base and J3--axis arm load conditions. Keep the
load below the loads shown in Table 2.2 and Fig. 2.2 (a), (b).
LOAD CONDITIONS
ON J2--AXIS BASE Table2.2 Installation condition of loads to be added
AND J3--AXIS ARM
Installation site Loads Condition
Within radius of 500mm from the center of rotation

J2--axis base 250kg
of J1--axis
Within 500mm to the wrist direction from the cen-

J3- -axis arm 20kg
ter of J3- -axis
Fig.2.2(a) Load Conditions on J2--axis base and J3--axis arm (S--420iF/W/S/L)
143
Fig.2.2(b) Load Conditions on J2--axis base and J3--axis arm (S--420iR)
144
2.3 Fig. 2.3 is the diagram for installing end effectors on the wrist. Install the
end effector using a 60 mmφH7 spigot. Using the standard flange as an
MECHANICAL example, position using a dowel pin with 2--φ10H7 reamed holes and
COUPLING OF END fasten using 6--M10 bolts with 6--M10 tapped holes. Take into
EFFECTOR TO consideration the depth of tapped and reamed holes when selecting the
M10 bolts and positioning dowel pins. (Refer to the diagram for the
WRIST
optional dimensions.)
6--M10 tap depth 20

Equally spaced on
φF circumference
2--0G depth 20
Equally spaced on
204 for insulating flange
φF circumference
Standard flange Special flange ISO flange Insulating flange
A Ø60H7 +0.030
0 A Ø76G7 +0.040
+0.010 A Ø80H7 +0.035
0 A Ø80H7 +0.035
0
0
B Ø110h7 --0.035 B Ø108f8 --0.036
--0.090
0
B Ø160h8 --0.063 0
B Ø160h8 --0.063
+0.3
C6 C 10 C 90.15 C8 0
F Ø90 F Ø92 F Ø125 F Ø125
G Ø10H7 +0.015
0 G Ø9H7 +0.015
0 G Ø10H7 +0.015
0 G Ø10H7 +0.015
0
Fig.2.3 End effector mounting face
145
2.4 As shown in Fig. 2.4 (a) to (e), tapped holes are provided to install
equipment to the robot.
EQUIPMENT
MOUNTING FACE
Note)
Note)
These taps can’t be used
for compact type robot.
Fig.2.4 (a) Equipment mounting surfaces (S--420iF, W, W/175)
NOTE
1 For using threaded holes of equipment mounting face. (only severe dust/liquid protection) S--420i
for severe dust/liquid protection is used purge air into wrist and J3 arm. Because it keeps airtight
chamber, equipment mounting face threaded holes, of J3 arm, are used SUS bolts and sealing
washers. When the customers set equipment on J3 arm using these threaded holes (M10), it will
be used coated sealing blots or sealing washers. It will reduce leakage from J3 arm.
2 For S--420i R, severe dust/liquid protection, it fills M12 threaded holes, that is side of angle
base, with M12 sus bolts. Don’t drive the robot in severe dust/liquid environment.
WARNING
Incomplete leakage measure ments on these taps will make air flow and noise increase, and it
will cause low pressure and will break down the robot low pressure.
146
2--
2--
2--
Fig.2.4 (b) Equipment mounting surfaces (S--420iF/2.85, S420iW/2.85)
2--
2--
2--
2--
Fig.2.4 (c) Equipment mounting surfaces (S--420iS)
147
2--
2-- 2--
2--
Fig.2.4 (d) Equipment mounting surfaces (S--420iL)
148
Fig.2.4 (e) Equipment mounting surfaces (S--420iR)
149
2.5 When using the turbo move option, set the load masses (including the
mass of the hand), wrist axis load moment values, and load inertia values.
SETTING OF SYSTEM
Set each load by setting the system variables listed below. Then, turn off
VARIABLES FOR and on the power to use the new information.
TURBO MOVE 1 Load mass at wrist
Set the same values (in kg) for both of $PARAM_GROUP.
$PAYLOAD and $GROUP. $PAYLOAD.
[Example of input]
$PARAM_GROUP. $PAYLOAD : 120
$GROUP. PAYLOAD : 120
2 Wrist axis load moment
Set a load moment (kgf--m) (an integer) to $PARAM_GROUP.
$AXISMOMENT.
[Example of input]
When load moment is as follows;
J4--axis load moment 60 kgf--m
Set system variables as below :
J4--axis load moment $PARAM_GROUP.$AXISMOMENT[4] : 60
3 Wrist axis load inertia
Set a load inertia (kgf--cm--s2) (an integer) to $PARAM_GROUP.
$AXIS INERTIA.
[Example of input]
When load inertia is as follows;
J4--axis load inertia 306 kgf--cm--s2
Set system variables as below:
J4--axis load inertia $PARAM_GROUP.$AXIS INERTIA[4] : 306
4 Load mass at J3--axis arm and J2--axis base.
Set a load mass (kg) to $PARAM_GROUP.$ARM_LOAD.
[Example of input]
$PARAM_GROUP. $ARM_LOAD [1] : 20 (for load at J3--axis
arm.)
$PARAM_GROUP. $ARM_LOAD [2] : 250 (for load at J2--axis
base.)
150
2.6 There is an air--pressure supply opening on the side of the J3--axis base
and the rear of J3--axis casting. The connector is a Rc1/2 female (ISO).
AIR SUPPLY As coupling are not supplied, it will be necessary to prepare couplings
(OPTION) which suit to the hose size.
Fig.2.6 Air--pressure supply connection (option)
151
2.7 Fig. 2.7 show the posiiton of the end effecter interface. End effecter
interface (RDI/RDO), I/O Unit--MODEL B interface and user cable
INTERFACE FOR (signal lines, power lines) and devicenet cable (signal lines, power lines)
END EFFECTER are prepared as options.
(OPTION)
Fig.2.7 (a) Interface for End Effecter (Option)
152
Fig.2.7 (b) Layout of interface for Option cable (Severe dust/liquid protection)
153
J3 CASING PANEL (OUTPUT)
DeviceNet cable (power) interface

(Air supply)
DeviceNet cable
(signal) interface
User cable
(signal) interface
End effector interface
(RDI/RDO)
User cable
(power) interface
I/O unit model
B interface
View A J1 BASE PANEL (INPUT)
User cable (power) interface
User cable (signal) interface
DeviceNet cable (Air supply)

(power) interface
J2 BASE PANEL (OUTPUT)
DeviceNet cable DeviceNet cable (signal)

(power) interface interface
Detail B
DeviceNet cable
(signal) interface
View C
Fig.2.7 (c) Layout of interface for Option cable (With devicenet cable)
154
(1) End effector interface (RDI/RDO) (Option)

Fig. 2.7 (d) shows pin layout for end effector interface (RDI/RDO).
Fig.2.7 (d) Pin layout for end effector interface (RDI/RDO)
(2) I/O Unit--MODEL B interface (Option)

Fig. 2.7 (e) shows pin layout for I/O Unit--MODEL B interface.
Fig.2.7 (e) Pin layout for I/O Unit--MODEL B interface (option)
(3) End effector interface (RDI/RDO) (Option) (Severe dust/liquid

protection)
Fig. 2.7 (f) shows pin layout for end effector interface (RDI/RDO).
Fig.2.7 (f) Pin layout for end effector interface (RDI/RDO)

(Severe dust/liquid protection)
155
(4) I/O Unit--MODEL B interface (Option)

Fig. 2.7 (g) shows pin layout for I/O Unit--MODEL B interface.
Fig.2.7 (g) Pin layout for I/O Unit--MODEL B interface (option)

(Severe dust/liquid protection)
(5) User cable (signal line) Interface (option)

Fig. 2.7 (h) shows pin layout for user cable (signal line) interface.
AS
approx. AWG21
Fig.2.7 (h) Pin layout for user cable (signal line) interface (option)
156
(6) User cable (power line) Interface (option)

Fig. 2.7 (i) shows pin layout for user cable (power line) interface.
AP
approx. AWG17
Fig.2.7 (i) Pin layout for user cable (power line) interface (option)
(7) User cable(for aux. axis, signal line) interface (option)

Fig. 2.7 (j) shows pin layout for user cable (for aux. axis, signal line)
interface.
(This interface is applied in case of using A05B--2351--J310 or J311)
(Separately prepared)
Fig.2.7 (j) Pin layout for user cable (for aux. axis, singnal line) interface(option)
NOTE
A05B--2351--J310 and J312 include a signal cable and two
power cables for aux. axis control.
157
(8) User cable(for aux. axis, power line) interface(option )

Fig. 2.7 (k) shows pin layout for user cable (for aux. axis, power line)
interface.
(Separately prepared)
Fig.2.7 (k) Pin layout for user cable (for aux. axis, power line) interface (option)
NOTE
1 A05B--2351--J310 and J312 include a signal cable and two
power cables for aux. axis control.
2 In case of using the user cable (Power), it is necessary to
select the End Effector whose Continuous Rating Current
is 10.4 A rms. If FANUC servo motor is used, following table
shows the available.
Motor Model Continuous Rating Motor Model Continuous Rating

Current (A rms) Current (A rms)
α 0.5/3000 2.8 α 3/3000 4.6
α 1/3000 2.2 α 6/2000 5.6
α 2/2000 2.2 α 6/3000 10.0
α 2/3000 2.9 α 12/2000 8.8
158
(9) DeviceNet cable (signal line) interface (option)

Fig 2.7 (l) shows pin layout for DeviceNet cable (signal line)
interface.
Fig.2.7 (l) Pin layout for DeviceNet cable (signal line) interface (option)
(10) DeviceNet cable (power line) interface (option)

Fig 2.7 (m) shows pin layout for DeviceNet cable (power line)
interface.
Fig.2.7 (m) Pin layout for DeviceNet cable (power line) interface (option)
159
Table2.7 (a) Connector specifications (Machine side) (S--420iF/W/S/L/R)
Cable Input side (J1 base) Output side (J3 casing) Manu.
RDI/RDO JMWR2524F
DDK
I/O JMWR2516F
AS Housing 09 30 006 0301 Housing 09 30 006 0301
(Signal) Insert 09 16 024 3001 (Han 24DD M) Insert 09 16 024 3101 (Han 24DD F)
Contact 09 15 000 6103 Contact 09 15 000 6203
Harting
AP Housing 09 20 010 0301 Housing 09 20 010 0301
(Power) Insert 09 21 015 3001 (Han 15D M) Insert 09 21 015 3101 (Han 15D F)
Contact 09 15 000 6103 Contact 09 15 000 6203
AS for Housing 09 30 006 0301 (Han 6E) Housing 09 30 006 0301 (Han 6E) Harting
aux. axis Insert 09 16 024 3001 (Han24DD M) Insert 09 16 024 3001 (Han24DD F)
(Signal) Contact 09 15 000 6103 (S1--S4) Contact 09 15 000 6203 (S1--S4)
09 15 000 6104 (S5--S8) 09 15 000 6204 (S5--S10)
Table2.7 (b) Connector specifications (User side) (S--420iF/W/S/L/R)
Cable Input side (J1 base) Output side (J3 casing)

RDI/RDO JMSP2524M Streight (Appendix)
JMLP2524M Angle
I/O JMSP2516M Streight (Appendix)
JMLP2524M Angle
Food 09 30 006 1540 Side Food
1541 entry
0542
0543
← The same
1440 Top
1441 entry
0442
0443
AS Insert 09 16 024 3101 (Han 24DD F) Insert 09 16 024 3001 (Han 24DD M)
(Signal) Contact 09 15 000 6204 appox. AWG 26--22 Contact 09 15 000 6104 appox. AWG 26--22
6203 AWG 20 6103 AWG 20
6202 AWG 18 6102 AWG 18
6201 AWG 16 6101 AWG 16
6206 AWG 14 6106 AWG 14
Clamp 09 00 000 5083 Clamp
5086
← The same
5090
5094 etc.
Food 09 20 010 1541 Side Food
0540 entry
0541
← The same
1440 Top
0440 entry
0441
Insert 09 21 015 3101 (Han 15D F) Insert 09 21 015 3001 (Han 15D M)
AP
Contact 09 15 000 6220 appox. AWG 20 Contact 09 15 000 6120 appox. AWG 20
(Power) 6205 AWG 18 6105 AWG 18
6204 AWG 16 6104 AWG 16
6202 AWG 14 6102 AWG 14
6207 AWG 12 6107 AWG 12
Clamp 09 00 000 5083 Clamp
5086
← The same
5090
5094 etc.
160
Table2.7 (c) Connector specifications (Severe dust/liquid protection) (Machine side)

RDI/RDO housing 09 03 006 0301
_________ Insert 09 16 024 3101 (Han 24DD F)
Contact 09 15 000 6203
I/O housing 09 20 010 0301
_________ Insert 09 21 015 3101 (Han 15D F)
Contact 09 15 000 6202
Table2.7 (d) Appended connector (Severe dust/liquid protection) (Machine side)

RDI/RDO Hood 09 30 006 1440
Insert 09 16 024 3101 (Han 24DD M)
_________
Contact 09 15 000 6104
Clamp 152D (PG13.5)
I/O Hood 09 20 010 1440
Insert 09 21 015 3101 (Han 15D M)
_________
Contact 09 15 000 6102, 6103, 6104
Clamp 152D9 (PG13.5)
Table2.7 (e) Connector specifications (device net cable) (Mechine side) (S--420iF/W/S/L)
Cable Input side Output side Output side

Manufacturer Manufacturer Manufacturer
name (J1--axis base) (J2--axis base) (J3--axis casing)
DS 84854--9101 MOLEX 84854--9100 MOLEX 84854--9100 MOLEX
(signal line) JAPAN CO., JAPAN CO., JAPAN CO.,
LTD. LTD. LTD.
DP Housing 09 30 006 0301 HARTING 84854--9102 MOLEX 84854--9102 MOLEX
(power line) Insert (Han 6E) Elektronik JAPAN CO., JAPAN CO.,
Contact 09 32 010 3001 Co., Ltd. LTD. LTD.
(Han 10EE M)
09 33 00 6104
161
Table2.7 (f) Connector specifications (device net cable, on the user equipment side) (S--420iF/W/S/L)
Input side Manufac- Output side Output side

Cable name
(J1--axis base) turer (J2--axis base) (J3--axis casing)
DS MINI connector for use on the device net MINI connector for use MINI connector for use
(signal line) 5--pin, female 1 on the device net on the device net
5--pin, male 5--pin, male
DP Hood Select 09 30 006 1540 (Han 6E) Side HARTING MINI connector for use MINI connector for use
(power line) just one. 1541 entry Electronik on the device net on the device net
0542 Co., Ltd. 4--pin, male 4--pin, male
0543
1440 Top
1441 entry
0442
0443
Insert 09 32 010 3101 (Han 10 EE F)
Contact 09 33 000 6220 AWG20
6214 AWG18
6205 AWG18
6204 AWG16
6202 AWG14
6207 AWG12
Clamp 09 00 000 5083
Select just 5086
one. 5090
5094
Many other types are available.
162
3. TRANSPORTATION AND
B--80505E/06 CONNECTION INSTALLATION
3
TRANSPORTATION AND INSTALLATION
3.1
1) Transportation using a crane
TRANSPORTATION The robot can be transported by lifting it. When transporting the
robot, be sure to change the attitude of the robot to that shown in Fig.
3.1 (a), (c) and lift by attaching ropes to the four M20 eyebolts.
2) Transportation using a forklift
The robots can also be transported using a forklift (Refer to Fig. 3.1
(a), (c)). Transport materials are available as an option.
NOTE
Always attach the transportation equipment when
transporting the S--420i R. Otherwise, the robot is likely to
fall forward.
163
INSTALLATION CONNECTION B--80505E/06
iF, iW, iW/175 : 2053.3

iS : 1917.3
iF/2.85
iW/2.85 : 2462.9
iL : 2598.9
Fig.3.1 (a) Transportation using a crane (S--420iF/W/S/L)
164
Fig.3.1 (b) Transportation using a forklift (S--420iF/W/S/L)
165
Fig.3.1 (c) Transportation using a crane (S--420iR)
Fig.3.1 (d) Transportation using a forklift (S--420iR)
166
Fig.3.1 (e) Mechanical interface for eyebolt and transport equipment
167
3.2 Proper shipping and handling methods will help preserve the operational
usefulness of the robotic equipment. Robots are handled many times
ROBOT from manufacturing to final installation at the plant. All individuals
TRANSPORTATION involved with handling this robotic equipment should be aware of the
proper methods which must be used. Special items for consideration
CONSIDERATIONS include:
D Lifting with a fork truck (pg. 160)
D Overhead Crane Lifting (pg. 160)
D Type of Transportation Truck to Specify
D Shipping Skids and Base Plates (pg. 162)
D Proper/Improper Securing to a Truck Deck (pg. 165, 166)
D Shipping with Tooling Attached (pg. 164)
Fork truck considerations:

When using a fork truck to lift the robot, be sure that the forks are set wide
enough to slide into the center of the lifting pockets. Never use forks
which are set too narrow or too wide for this feature. Using improperly
set forks can cause crowding of the castings and could potentially damage
them. The proper fork spacing is 41” between forklift pocket centers (or
1,042mm).
Overhead crane lifting:

Many facilities use overhead cranes to move machinery into position.
FANUC provides lifting eyebolts at the base of the robot for this purpose.
To prevent damage to the upper arm components, a spreader bar is
recommended.
Vehicle transportation:
When robots must be transported on highways, it is imperative that the
selected truck be equipped with “air ride” suspension. This type of
suspension provides the most protection to the equipment from road
shocks and damage.
Shipping skids and base plates:

FANUC ships robots on skids designed for the purpose of properly
handling the equipment. When robots are placed into systems, they are
removed from these skids and generally placed on steel floor plates.
These plates are then secured to the floor. In cases where this operation
occurs at the plant, the skids may be discarded. In instances where the
robots are incorporated into systems away from the plant (majority of
cases), the skids must be saved. Upon completion of the system runoff,
the robots (without baseplates) should be placed back onto the shipping
skids for transportation to the plant.
168
Securing robots to the vehicle:

After the robots are placed onto the shipping skids, they can be loaded
onto the truck. Proper securing of the robots involves chaining the
shipping skid to the truck deck. Under NO circumstances should chains
(or other securing devices) be attached to the robot. This practice can
cause irreparable damage to the robotic equipment.
Shipping with tooling attached:

FANUC always recommends that heavy tooling be removed from the
robot arm prior to shipping. There are instances where tooling can be left
on the robot. These include medium/light weight tools, and short distance
moves. In these cases, the tooling could be left on the robot, but arm
blocking is required. The robot should be placed into the shipping
position and blocked with wood supports between the arm and lower
casting. The blocking could be secured with plastic banding which will
prevent marring.
169
Transport
Equipment
Transport
Equipment
Shipping skid
Fig.3.2 (a) Robot Mounted on Proper Shipping Skid
FANUC ships S-420i robots to customers on special shipping skids.

Usually these are made of steel, but on certain models, wood skids are
used. S-420i robots should only be shipped using these skids. Under no
circumstances should the robot be shipped without these skids. Robots
should NOT be shipped with steel mounting plates attached.
170
After a robot is ready for shipment, it must be placed into the shipping
position. This position places the robot directly over the shipping skid
which helps prevent damage from improper handling.
Fig.3.2 (b) Shipping Position of Robot
171
FANUC recommends that all tooling be removed from the robot wrist
prior to shipment. In some cases where robots will be transported over
a short distance, the tooling can remain mounted to the robot wrist. If the
robot is to be shipped with the tooling mounted, it is imperative that the
upper arm is blocked to reduce shipping damages.
Heavy Tooling
Blocking
Fig.3.2 (c) Shipping Robot with Tooling (Special Considerations)
172
To properly transport a robot, it must be mounted to a skid. This robot

skid must be secured to the truck deck. Chains or straps are not to be
attached to any aspect of the robot arm.
Chains or Straps
Truck Deck
Shipping Skid
Truck Deck
Fig.3.2 (d) Proper Robot Securing to Truck
173
Under NO circumstances are chains or straps to be run through the fork

lift pockets. This method can cause structural damage to the robot
mechanical unit and/or peripherals which have been mounted to them.
Never chain through fork pockets
Chains or Straps
Fig.3.2 (e) Improper Robot Securing to Truck
174
3.3 Fig. 3.3 (a) shows the robot base dimensions. Fig. 3.3 (b) shows an actual
example of robot installation. The floor plate should be embedded in
INSTALLATION concrete and fastened with chemical anchors. Also fasten the base plate
to the robot base using M20 x 60 bolts (strength classification 12.9). Next,
position the robot and weld the base plate to the floor plate.
Fig. 3.3 (c) shows another example of the robot installation for S--420iR.
The floor plate should be either welded to the frame or fastended with
eight M20 x 60 bolts (strength classification 12.9). Also fasten the base
plate to the robot base using four M20 x 60 bolts (strength classification
12.9) and four M16 x 60 bolts (strength classification 12.9) with plain
washers. Next, position the robot and weld the base plate to the floor plate.
Avoid placing any object in front of the robot on the mounting surface to
facilitate the installation of the mastering fixture, as shown in Fig. 3.3 (a).
Fig. 3.3 (d) and table 3.3 show force and movement applied to the base
plate during emergency stop state.
Fig.3.3 (a) Installation hole dimensions of the robot base
NOTE
1 Parts to be provided by the customer:
i) S--420iF/W/S/L
Robot mounting bolts : M20 x 60 (strength classification 12.9) 4pcs.
Chemical anchors : M20 (strength classification 4.8) 8pcs.
Base plates : thickness 32 3pcs.
Floor plate : thickness 32
ii) S--420iR
Robot mounting bolts : M16 x 60 (strength classification 12.9) 4pcs.
: M20 x 60 (strength classification 12.9) 4pcs.
(12pcs.)
Plain washers : M16 4pcs.
Base plates : thickness 32 3pcs.
Floor plate : thickness 32
Frame
2 Installation work (welding, anchoring, etc.) is prepared by the customer.
3 S--420i severe dust/liquid protection, installation.
When the robots work in the environment, using water or liquid, complete
draining must need. Incomplete draining will make robot break down.
175
Fig.3.3 (b) Actual installation example (S--420iF/W/S/L)
176
Fig.3.3 (c) Actual installation example (S--420iR)
177
Fig.3.3 (d) Force and moment during emergency stop
Table3.3 Force and moment during emergency stop
Force in vertical Force in horizontal

Vertical moment Horizontal moment
Model direction direction
MV [kgm] MH [kgm]
FV [kg] FH [kg]
S--420i F 4500 3200 1900 1900
S--420i F/2.85 5100 3200 2100 1800
S--420i W 4600 3200 2000 1900
S--420i W/175 4900 3400 2400 2000
S--420i W/2.85 5600 3500 2500 2100
S--420i S 3600 2900 1000 1300
S--420i L 5200 3200 2200 1800
S--420i R 6800 3700 3600 2700
S--420i R/120 6700 3600 3400 2500
178
3.4 Fig. 3.4 (a), (b) shows the maintenance area of the mechanical unit. In
mastering, it needs to take the posture of Fig. 5.3.3 (f)~(j) of Chapter I.
MAINTENANCE Keep the enough space for taking the posture.
AREA
Fig.3.4 (a) Maintenance area (S--420iF/W/S/L)
Fig.3.4 (b) Maintenance area (S--420iR)
179
3.5 Fig. 3.5 (a) shows how to connect air hose to the robot. If the air control
set is specified as an option, the air hose between the mechanical unit and
AIR PIPING the air control set is provided. Mount the air control set using the
information in Fig. 3.5 (b).
Fig.3.5 (a) Air piping Option
NOTE
Pipe used in the mechanical unit has an outer diameter of
12 mm and an inner diameter of 8 mm. You can use a
different size pipe outside the mechanical unit.
Fill the oiler having three air components to the specified level with
turbine oil #90 to #140. The machine tool builder is required to prepare
mounting bolts.
Fig.3.5 (b)Air control set Option
180
3.6 Following figure shows how to connect air tube to the robot. The air tube
between the mechanical unit and air filter unit is provided. If the air tube
PURGE AIR PIPING is extended, use hard tube, because pressure drop is reduced.
(FOR SEVERE
DUST/LIQUID
PROTECTION)
Specification of air filter unit and element
Name Specifications
Air filter unit A97L--0218--0016

Element set for replacing A97L--0218--0016#EL
181
3.7
INSTALLATION Table3.7 Installation specifications
SPECIFICATIONS
Items Specifications
Air Pressure 5 -- 7 kgf/cm2, 0.49 -- 0.69 Mpa (Set pressure 5 kgf/

pressure cm2, 0.49 MPa)
Air flow Max. peak 150 Nl/min, 0.15 Nm3/min (Note 1)
Weight of mechanical Approx. 1500 kg (including controller)
unit → S--420iF/W/S
1600 kg (including Controller)
→ S--420iF/2.85W/175, W/2.85 iL
1700 kg → S--420iR, R/120
Allowable ambient 0 -- 45°C
temperature
Allowable ambient Usual: Less than 75% RH
humidity Short period (in one month): Max. 98% RH or less
Condensation free
Atmosphere Free of corrosive gases (Note 2)
Vibration Less than 0.5 G, 4.9 m/s2
NOTE
1 This value indicates the maximum capacity of the air control
set.
Adjust the air flow to be less than this value.
2 Contact the service representative, if the robot is to be used

in an environment or a place subjected to severe vibrations,
heavy dust, cutting oil splash and or other foreign
substances.
3.8 To store the robot, set it to the same attitude as that used for transportation
(See Fig. 3.1 (a) and (b)) and store it on a level surface.
STORAGE
182
APPENDIX
B--80505E/06 APPENDIX A. SPARE PARTS LIST
A
SPARE PARTS LIST
TableA (a) Cables (for the basic axes)
No. Specifications Function Applicable models

A660--8010--T136
K121 M1 to M6 PULCO S--420i F/W/L
A660--8010--T136#C
with a integrated
A660--4003--T305 control unit
K122 M1 to M6 POWER
A660--4003--T305#C
A660--8010--T223
K123 M1 to M6 PULCO, EE
A660--8010--T223#C
S--420i
S 420i F/W/L
A660--8010--T224
K124 M1 to M6 PULCO with a remote
A660--8010--T224#C
control unit
A660--4003--T319
K125 M1 to M6 POWER
A660--4003--T319#C
K131 A660--8010--T148 M1 to M6 PULCO, EE
K132 A660--4003--T313 M1 to M6 POWER S--420i
S 420i R, R/120
K136 A660--8010--T220 M1 to M6 PULCO
A660--8010--T133
K141 M1 to M6 PULCO S--420i S
A660--8010--T133#C
with a integrated
K142 M1 to M6 POWER
A660--4003--T304#C
A660--8010--T421
A660--8010--T421#C
S--420i
S 420i S
A660--8010--T422
A660--8010--T422#C
control unit
A660--4003--T332
K145 M1 to M6 POWER
A660--4003--T332#C
K161 A660--4003--T297 EXTENSION NOTE2)
S 420i L
S--420i
K162 A660--4003--T298 EXTENSION NOTE2)
A660--8011--T005 S--420i F/2.85
K181 M1 to M6 PULCO
A660--8011--T005#C S 420i W/2.85
S--420i
A660--4003--T377 with a integrated
K182 M1 to M6 POWER control unit
A660--4003--T337#C
A660--8011--T006
A660--8011--T006#C S--420i F/2.85
A660--8011--T007 S--420i W/2.85
K184 M1 to M6 PULCO
A660--8011--T007#C t a remote
with e ote
K185 M1 to M6 POWER
A660--4003--T378#C
NOTE
1 “-- #C” cables are used for compact type mechanical unit.
2 Cable K161, K162 conform to CE Marking.
185
A. SPARE PARTS LIST APPENDIX B--80505E/06
TableA (b) Cables (for the basic axes : CE Marking)

A660--8011--T017
K221 M1 to M6 PULCO S--420i F/W/L
A660--8011--T017#C
with a integrated
K222 M1 to M6 POWER
A660--4003--T381#C
A660--8011--T018
A660--8011--T018#C
S--420i
S 420i F/W/L
A660--8011--T019
A660--8011--T019#C
control unit
A660--4003--T382
K225 M1 to M6 POWER
A660--4003--T382#C
K231 A660--8011--T020 M1 to M6 PULCO, EE
K232 A660--4003--T383 M1 to M6 POWER S--420i
S 420i R, R/120
K236 A660--8011--T021 M1 to M6 PULCO
A660--8011--T022
K241 M1 to M6 PULCO S--420i S
A660--8011--T022#C
with a integrated
K242 M1 to M6 POWER
A660--4003--T384#C
A660--8011--T023
A660--8011--T023#C
S--420i
S 420i S
A660--8011--T024
A660--8011--T024#C
control unit
A660--4003--T385
K245 M1 to M6 POWER
A660--4003--T385#C
A660--8011--T028 S--420i F/2.85
K281 M1 to M6 PULCO
A660--8011--T028#C S 420i W/2.85
S--420i
A660--4003--T386 with a integrated
K282 M1 to M6 POWER control unit
A660--4003--T386#C
A660--8011--T029
A660--8011--T029#C S--420i F/2.85
A660--8011--T030 S--420i W/2.85
K284 M1 to M6 PULCO
A660--8011--T030#C t a remote
with e ote
K285 M1 to M6 POWER
A660--4003--T387#C
NOTE
“-- #C” cables are used for compact type mechanical unit.
TableA (c) Cables (for the basic axes : Severe dust/liquid protection)

K323 A660--8011--T944 M1 to M6 PULCO, EE S--420i F/W/L
K331 A660--8012--T001 M1 to M6 PULCO, EE S--420i R
NOTE
For the remote controller type, the M1 to M6 POWER cable
is the same as for the CE Mark.
186
TableA (d) Cables (for the wrist)

K108 A660--2004--T285 M6P COUPLING
K109 A660--4003--T283 M6MBK COUPLING S--420i
S 420i F/W/S/L/R
K110 A660--4003--T450 EXTENSION
NOTE
Wrist cables conform to CE Marking.
TableA (e) Cables (optional)

K111 A660--2004--T203 EE (RDI/RDO) Integrated type
K112 A660--2004--T204 AS (UER/SIGNAL)
S 420i F/W/S/L
S--420i
K113 A660--2004--T205 AP (USER/POWER)
K114 A660--8009--T796 J1 OT Integrated type
K115 A660--8010--T218 J1 OT Remote type
K119 A660--2004--T325 I/O (STANDARD) S--420i F/W/S/L
with a integrated
K120 A660--4003--T328 I/O (SPECIAL) control unit
K128 A05B--1313--D001 I/O (STANDARD) S--420i F/W/S/L
with a remote
K129 A05B--1313--D003 I/O (SPECIAL) control unit
K133 A660--2004--T330 AS (UER/SIGNAL)
K134 A660--2004--T345 AP (USER/POWER)
S 420i R
S--420i
K138 A05B--1313--D002 I/O (STANDARD)
K139 A05B--1313--D004 I/O (SPECIAL)
K524 A660--4003--T585 DEVICENET (SIGNAL)
S 420i F/W/S/L
S--420i
K525 A660--4003--T586 DEVICENET (POWER)
TableA (f) Cables (optional : Severe dust/liquid protection)

K329 A05B--1313--D023 I/O (SPECIAL) S--420i F/W/L
K339 A05B--1313--D024 I/O (SPECIAL) S--420i R
187
TableA (g) Cables (optional : CE Marking)

K211 A660--2004--T809 EE (RDI/RDO) Integrated type
K212 A660--2004--T804 AS (UER/SIGNAL)
S 420i F/W/S/L
S--420i
K213 A660--2004--T805 AP (USER/POWER)
K219 A660--2004--T817 I/O (STANDARD) S--420i F/W/S/L
with a integrated
K220 A660--4003--T476 I/O (SPECIAL) control unit
K228 A05B--1313--D011 I/O (STANDARD) S--420i F/W/S/L
with a remote
K229 A05B--1313--D013 I/O (SPECIAL) control unit
K233 A660--2004--T807 AS (UER/SIGNAL)
K234 A660--2004--T808 AP (USER/POWER)
S 420i R
S--420i
K238 A05B--1313--D012 I/O (STANDARD)
K239 A05B--1313--D014 I/O (SPECIAL)
TableA (h) Motors
Name (Axis) Specifications Remarks

M1, M2, M3 (J1, J2,J3) A06B--0147--B675 α 22/2000
M4 (J4) A06B--0146--B675 α 22/1500
M5 (J5) A06B--0142--B675#0006 α 12/2000 NOTE5)
M6 (J6) A06B--0162--B175#0006 α M6/3000 NOTE5)
TableA (i) For High duty (M4 to M6 are common)

M1, M2, (J1, J2) A06B--0186--B675#0011 α M30/3000HV
M3 (J3) A06B--0147--B675 α 22/2000
TableA (j) For S--420iW/2.85 (M4 to M6 are common)

M1, M2, (J1, J2) A06B--0147--B675 α 22/2000
M3 (J3) A06B--0186--B675#0011 α M30/3000HV
NOTE
The specification of the motor for J5 and J6 axis
manufactured before August 1995 are
J5 AXIS : A06B--0142--B675#0003
J6 AXIS : A06B--0162--B175#0003
There are two pulse--coder cable which correspond to each

motor.
#0003 : K107 (A660--4003--T233)
#0006 : K110 (A660--4003--T450)
When you change the motor (#0003), you must prepare the
cable--K110 and new motor (#0006).
188
TableA (k) Reducer
Name Specifications Applicable models

A97L--0118--0940#250A--118 S--420i F/S/L
J2--axis
J2 axis reducer A97L--0118--0940#250A--129 S--420i W/R
A97L--0118--0940#250A--141 S--420i R/120
A97L--0118--0941#250A--129 S--420i F/S/L/R
J3--axis
J3 axis reducer A97L--0118--0941#250A--171 S--420i W
A97L--0118--0941#250A--141 S--420i F2.85/R120
A97L--0118--0942#30A--81 S--420i F/S/L/R
J6 axis reducer
J6--axis
A97L--0118--0942#30A--121 S--420i W
TableA (l) Gear

A290--7313--X221 S--420i F/W/L/R
A290--7313--Y221 S--420i S
J1--axis
pinion gear S--420i R/120
A290--7313--Z221 S--420i F/2.85
S--420i W/2.85
A290--7313--X222 S--420i F/W/L/R
A290--7313--Y222 S--420i S
J1--axis
center gear S--420i R/120
A290--7313--Z222 S--420i F/2.85
S--420i W/2.85
J2/J3 gearbox NOTE6)
A290--7313--V351
assembly
J2/J3 gear A S--420i F/W/S/L
A290--7313--V352
assembly Compact type
J2/J3 gear B
A290--7313--V353
assembly
J4--axis
J4 axis A290--7313--X404 S--420i F/S/L/R
pinion gear A290--7313--Y404 S--420i W
J4--axis
J4 axis A290--7313--X405 S--420i F/S/L/R
center gear A290--7313--Y405 S--420i W
J5--axis A290--7313--V521 S--420i F/S/L/R
gear 1
assembly A290--7313--V524 S--420i W
J5--axis A290--7313--V522 S--420i F/S/L/R
gear 2
assembly A290--7313--V525 S--420i W
J5--axis A290--7313--V523 S--420i F/S/L/R
gear 3
assembly A290--7313--V526 S--420i W
J5 axis
J5--axis A290--7313--X508 S--420i F/S/L/R
gear 4 A290--7313--Y508 S--420i W
NOTE
V351 includes V352, V353 and the other parts.
189
TableA (m) Others (mechanical unit)

Balancer A05B--1313--V301 S--420i F/W/S/L
Balancer A05B--1313--V311 S--420i R
Wrist unit A290--7313--V501 S--420i F/S/L/R
Wrist unit A290--7313--V503 S--420i W
Shaft assembly A290--7313--V321 S--420i F/W/S/L/R
J3--axis arm assembly A290--7313--V401 S--420i F/W/L
J3--axis arm assembly A290--7313--V441 S--420i S
J3--axis arm assembly A290--7313--V461 S--420i L/R
J3--axis arm assembly A290--7313--V471 S--420i R
Cable track A97L--0218--0608#27 S--420i F/W/S/L/R
TableA (n) Others (mechanical unit) for severe dust/liquid protection

Balancer A290--7313--V302 S--420i F/W/L
Balancer A290--7313--V312 S--420i R
Wrist unit A290--7313--V551 S--420i F/L/R
Wrist unit A290--7313--V553 S--420i W
J3--axis arm assembly A290--7313--V411 S--420i F/W/L
J3--axis arm assembly A290--7313--V472 S--420i R
Extended arm assembly A290--7313--V462 S--420i L/R
TableA (o) Battery and grease

Battery A98L--0031--0005 1.5 V, size D
Grease A98L--0040--0119#2KG Kyodo Yushi
Moly--white RE No.00
Grease A97L--0001--0179#2 Shell Alvania No.2
TableA (p) O--rings
Name Specifications Location

O--ring JB--ORIA--G125 M1 to M5
O--ring A98L--0001--0347#S115 M6
O--ring A98L--0040--0041#280 J1--axis reducer
O--ring JB--ORIA--G135 J1--axis reducer
O--ring JB--ORIA--G270 J2/J3--axis reducer
O--ring A98L--0001--0347#S70 J4--axis reducer
190
B--80505E/06 APPENDIX B. CONNECTION DIAGRAM
B
CONNECTION DIAGRAM
191
B. CONNECTION DIAGRAM APPENDIX B--80505E/06
Fig.B.1 Internal Connection Diagram (S--420iF, W, W/175, Integrated type)
192
Fig.B.2 Internal Connection Diagram (S--420iF, W, W/175, Remote type)
193
Fig.B.3 Internal Connection Diagram (S--420iF/2.85, W/2.85, Integrated type)
194
Fig.B.4 Internal Connection Diagram (S--420iF/2.85, W/2.85, Remote type)
195
Fig.B.5 Internal Connection Diagram (S--420iS, integrated type)
196
Fig.B.6 Internal Connection Diagram (S--420iS, Remote type)
197
Fig.B.7 Internal Connection Diagram (S--420iL, Integrated type)
198
Fig.B.8 Internal Connection Diagram (S--420iL, Remote type)
199
Fig.B.9 Internal Connection Diagram (S--420iR)
200
B--80505E/06 APPENDIX C. PERIODIC MAINTENANCE TABLE
C
PERIODIC MAINTENANCE TABLE
TableC Maintenance list S--420iF
201
B--80505E/06 Table of Contents
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s--1
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p--1
I MAINTENANCE
1. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 J1--AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 J2/J3--AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 J4--AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 J5/J6--AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 MAJOR COMPONENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 3--MONTH CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 6--MONTH CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 ANNUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 3--YEAR CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 CAUTION STICKERS FOR DAILY CHECKS
(ONLY SEVERE DUST/LIQUID PROTECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 REPLACING GREASE OF THE DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 GREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.4 REPLACING FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 PROBLEMS AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 THE MEASUREMENT OF THE BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 AXIS LIMITS SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1.1 Zero Point Position and Motion Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1.2 Software Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.3 Hard Stopper and Limit Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 ADJUSTING J1--AXIS LIMIT SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3.2 Resetting Alarms and Preparing for Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.3 Mastering to a Fixture (Master Position Master) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.4 Zero Degree Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3.5 Quick Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3.6 Single Axis Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
c--1
Table of Contents B--80505E/06
5.4 ADJUSTING J5--AXIS BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6. REPLACING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.1 PART REPLACEMENT AND CORRESPONDING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 60
6.2 REPLACING J1--AXIS MOTOR (M1) AND REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.3 REPLACING J2/J3--AXIS MOTOR (M2/M3) AND REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.4 REPLACING J4--AXIS MOTOR (M4) AND J4--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.5 REPLACING WRIST UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.8 RELEASING A BRAKE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7. PIPING AND WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.1 PIPING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.2 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8. REPLACING CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.1 CABLE FORMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
8.2 REPLACING THE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.3 REPLACING THE OPTIONAL J1--AXIS LIMIT SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . 122
II CONNECTION
1. ROBOT INTERFERENCE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2. MECHANICAL COUPLING TO THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

2.1 WRIST LOAD CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.2 LOAD CONDITIONS ON J2--AXIS BASE AND J3--AXIS ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.3 MECHANICAL COUPLING OF END EFFECTOR TO WRIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.4 EQUIPMENT MOUNTING FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.5 SETTING OF SYSTEM VARIABLES FOR TURBO MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.6 AIR SUPPLY (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.7 INTERFACE FOR END EFFECTER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

3.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.2 ROBOT TRANSPORTATION CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.4 MAINTENANCE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.5 AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.6 PURGE AIR PIPING (FOR SEVERE DUST/LIQUID PROTECTION) . . . . . . . . . . . . . . . . . . . . . 181
3.7 INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3.8 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
c--2
B--80505E/06 Table of Contents
APPENDIX
A. SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
B. CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
C. PERIODIC MAINTENANCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
c--3
B--80505E/06 Index
[Numbers] [J]
3--month Checks, 13 J1--axis Drive Mechanism, 7
3--year Checks, 13 J2/J3--axis Drive Mechanism, 7
6--month Checks, 13 J4--axis Drive Mechanism, 8
J5/J6--axis Drive Mechanism, 9
[A]
Adjusting J1--axis Limit Switch (Option), 39 [L]
Adjusting J5--axis Backlash, 59 Load Conditions on J2--axis Base and J3--axis Arm,
Adjustments, 30 143
Air Piping, 180

Air Supply (Option), 151
[M]
Annual Checks, 13
Maintenance Area, 179
Axis Limits Setup, 30
Maintenance Tools, 14
Major Component Specifications, 10
[C] Mastering, 40
Cable Forming, 106 Mastering to a Fixture (Master Position Master), 43
Caution Stickers for Daily Checks (Only Severe Dust/ Mechanical Coupling of End Effector to Wrist, 145
Liquid Protection), 14 Mechanical Coupling to the Robot, 140
Configuration, 3
Connection Diagram, 191
[P]
Part Replacement and Corresponding Adjustment, 60
[D] Periodic Maintenance, 15
Daily Checks, 11 Periodic Maintenance Table, 201
Piping and Wiring, 87
Piping Diagram, 87
[E] Preventive Maintenance, 11
Equipment Mounting Face, 146 Problems and Causes, 24
Purge Air Piping (for Severe Dust/Liquid Protection),
181
[G]
Greasing, 20
[Q]
Quick Mastering, 53
[H]
Hard Stopper and Limit Switch Setting, 38
[R]
Releasing A Breake (Option), 85
[I] Replacing Battery, 22
Replacing Cable, 105
Installation, 168, 175
Replacing Filter Element, 23
Installation Specifications, 182
Replacing Grease of the Drive Mechanism, 15
Interface for End Effecter (Option), 152
Replacing J1--axis Motor (M1) and Reducer, 62
i--1
Index B--80505E/06
Replacing J2/J3--axis Motor (M2/M3) and Reducer, 65 [T]

Replacing J4--axis Motor (M4) and J4--axis Reducer,
76 The Measurement of the Backlash, 26
Replacing J5--axis Motor (M5) and J5--axis Reducer,
79 Transportation, 163
Replacing J6--axis Motor (M6) and J6--axis Reducer, Transportation and Installation, 163
82
Replacing Parts, 60 Troubleshooting, 24
Replacing the Cables, 114
Replacing the Optional J1--axis Limit Switch
(Option), 122
Replacing Wrist Unit, 78 [W]
Resetting Alarms and Preparing for Mastering, 41
Robot Interference Area, 125 Wiring Diagram, 89
Wrist Load Conditions, 141
[S]
Setting of System Variables for Turbo Move, 150
Single Axis Mastering, 57 [Z]
Software Setting, 37
Zero Degree Mastering, 50
Spare Parts List, 185
Storage, 182 Zero Point Position and Motion Limit, 32
i--2
Revision Record
FANUC Robot S--420i F/W/S/L/R MECHANICAL UNIT MAINTENANCE MANUAL (B--80505E)
S Additional descriptions for CE marking

05 Dec.,’95 S Additional descriptions for compact type
S Modification of base loading data
S Robot transportation consideration is added in II--Chapter 3.

04 Aug.,’95
S Correction of errors.
03 Apr., ’95 Additional descriptions of S--420 iF/2.85
02 Feb., ’95 Additional descriptions of S--420 iW/iS/iL/iR
S Additional descriptions for severe dust/liquid protection

01 Aug., ’94 06 Dec., ’97 S Modification of the backlash
S Correction of errors.
Revision Date Contents Revision Date Contents

S-420i Mechanical Unit Maintenance (B-80505EN - 06)

Uploaded by

Copyright:

Available Formats

S-420i Mechanical Unit Maintenance (B-80505EN - 06)

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

S-420i Mechanical Unit Maintenance (B-80505EN - 06)

Uploaded by

Copyright:

Available Formats

What safety precautions should be followed when handling robots?

What safety precautions should be followed when handling robots?

What are the major components of the robot?

What are the major components of the robot?

( R--J2 CONTROLLER )

Consider the following notes in addition to the items described in the

This manual describes the maintenance and connection of the following

The mechanical unit specification numbers are attached at the following

The attachment position for the mechanical unit specification number

Type Articulated type

Table of dust proof water proof performance

Safety handbook Intended readers :

The configuration of the mechanical unit is shown in Fig. 1 (a) to (f).

Fig.1(a) Mechanical unit configuration (S--420iF, W, W/175)

Fig.1(b) Mechanical unit configuration (S--420iF/2.85, S--420iW/2.85)

Fig.1(c) Mechanical unit configuration (S--420iS)

Fig.1(d) Mechanical unit configuration (S--420iL)

Fig.1(e) Mechanical unit configuration (S--420iR)

Fig.1(f) Mechanical unit configuration (Compact type)

1.1 Fig. 1.1 shows the J1--axis drive mechanism.

Fig.1.1 J1--axis drive mechanism

1.2 Fig. 1.2 (a) shows the J2/J3--axis drive mechanism.

Fig.1.2(a) J2/J3--axis drive mechanism

Fig.1.2(b) J2/J3--axis drive mechanism (Compact type)

1.3 Fig. 1.3 shows the J4--axis drive mechanism.

Fig.1.3 J4--axis drive mechanism

1.4 Fig. 1.4 shows the J5/J6--axis drive mechanism.

Fig.1.4 J5/J6--axis drive mechanism

Optimum performance of the robot can be maintained for a long time by

Oil inlet Adjusting knob

Fig.2.1 Air control set

Severe dust/liquid protection

2) After automatic operation

Item Check items Check points

2) First quarterly inspection

2.3 Check the following item once every six months.

2.4 Check the following items once every year.

2.5 Check the following items once every 3 years.

Supply position Grease name Quantity

1) Replacing procedure of grease to the reducer and the gear box

Fig.3.1 (a) Replacing grease of J1--axis reducer (S--420iF/W/S/L)

Fig.3.1 (b) Replacing grease of J1--axis reducer (S--420iR)

Fig.3.1 (c) Replacing grease of J2/J3--axis reducer

Fig.3.1 (d) Replacing grease of J4--axis reducer

Fig.3.1 (e) Replacing grease of J5--axis gear box

Fig.3.1 (f) Replacing grease of J6--axis reducer

Fig.3.1 (g) Greasing posture (S--420iF/W/S/L)

Table3.2 (a) Greasing points

Positions Grease Amount Method Greasing interval

Balancer 100 cc each Every 3 years

Balancer bushing 10 cc each Every 6 months

Balancer joint bearing 20 cc each Every year

Table3.2 (b) Substitutes for ALVANIA NO.2

MOBIL OIL MOBILACK GREASE NO.2 NIPPON OIL EPNOC NO.2

Fig.3.2 (a) Greasing points (S--420iF/W/S/L)

Fig.3.2 (b) Greasing points (S--420iR)

Fig.3.3 Replacing Battery

1) Turn off the power.