MITSUBISHI

Mitsubishi Industrial Robot

RV-6S Series INSTRUCTION MANUAL
ROBOT ARM SETUP & MAINTENANCE

BFP-A8323-A
 Supplemental Instruction

Thank you for purchasing the Mitsubishi Industrial Robot MELFA Series.
This document additionally explains to the Mitsubishi Industrial Robot "RV-6S Series INSTRUVTION MANUAL
(BFP-A8323)".
Therefore, check the content, and use it together with your instruction manual.

1. Outline
When lubricating, removal of the drain bolt or the plug is unnecessary.
The robot which is the target of these supplementary contents is shown below.
No. Target products The discrimination method
Produced in September, The DATE columns of the rated plate of the robot arm are all the robots after
1
2006 and afterwards. '2006-09'.
Produced before August, The robot by which the blue round sticker is stuck on the rated plate of the robot
2
2006. arm.

2. Correction of the lubrication port

Revision place
P5-49 “Fig.5-6：Lubrication positions”
4. J4 axis
*The drain bolt or the plug of lubrication port
all the axes were erased.

5. J5 axis
lubrication port

6. J6 axis
lubrication port

3. J3 axis
lubrication port

1. J1 axis
lubrication port

2. J2 axis
lubrication port

View from A
BFP-A8323-A01-A
3. Change of the lubrication method and notes
Details of change and supplement
A procedure and precautions applicable to the products affected by the change were added to “(2) Lubrication
method” on P5-50. The procedure applicable to the products affected by the change is described below. When
lubricating all other products, follow the original procedure specified in the instruction manual.

(1) Lubrication method of products affected by the change

1) Set the robot to the posture shown in Fig. 5-6.
2) Refer to the "5.3.2Installing/removing the cover" on page 44 and remove the covers.
3) Insert the grease shown in Table 5-5 using a grease gun of manual type from the lubrication grease nipple.
4) Replace the covers with the removal procedure in reverse.

(2) Precautions for lubrication

Take note of the following points when lubricating all products, regardless of whether or not they are affected by
the change.

Use manual grease gun, and inject grease with pressure 0.03Mpa or less. Do not
CAUTION use the grease gun, which derived by the factory air presser to
avoid injecting by too high pressure.

BFP-A8323-A01-A
4. Supplemental note for the installation surface receiving force
Supplemental details
Magnitude of each reaction force added to P2-8 “2.2.3 Installation procedures”.

Table 2-2 shows the maximum reaction force (design values) that may be applied to an installation stand. Please
use these values as reference when designing the installation stand.

ＦＶ
ＭＴ

4-M8×40 hexagon socket bolt

(Four positions)
Spring washer
Plain washer ＭＬ
ＦＨ
ＦＨ

ＭＬ
ＦＨ
ＦＨ
ＦＶ

4-φ9 installation hole 2-φ6 holes

(prepared holes for φ8 positioning pins)
115

Robot front
204
160
122

6.3a (Installation)

96
6.3a (Installation)

102.5
205
115 140
Base bottom

Fig.2-3：Installation dimensions

Table 2-2：Magnitude of each reaction force

Item Unit Value
Tilt moment : ML N･m 892
Torsional moment : MT N･m 892
Horizontal direction translation force : FH N 800
Vertical direction translation force : FV N 1,400

BFP-A8323-A01-A
 Safety Precautions
Always read the following precautions and the separate "Safety
Manual" before starting use of the robot to learn the required
measures to be taken.

CAUTION All teaching work must be carried out by an operator who has received special training.
(This also applies to maintenance work with the power source turned ON.)
→ Enforcement of safety training

CAUTION For teaching work, prepare a work plan related to the methods and procedures of oper-
ating the robot, and to the measures to be taken when an error occurs or when restart-
ing. Carry out work following this plan. (This also applies to maintenance work with the
power source turned ON.)
→ Preparation of work plan

WARNING Prepare a device that allows operation to be stopped immediately during teaching work.
(This also applies to maintenance work with the power source turned ON.)
→ Setting of emergency stop switch

CAUTION During teaching work, place a sign indicating that teaching work is in progress on the
start switch, etc. (This also applies to maintenance work with the power source turned
ON.)
→ Indication of teaching work in progress

WARNING Provide a fence or enclosure during operation to prevent contact of the operator and
robot.
→ Installation of safety fence

CAUTION Establish a set signaling method to the related operators for starting work, and follow
this method.
→ Signaling of operation start

CAUTION As a principle turn the power OFF during maintenance work. Place a sign indicating that
maintenance work is in progress on the start switch, etc.
→ Indication of maintenance work in progress

CAUTION Before starting work, inspect the robot, emergency stop switch and other related
devices, etc., and confirm that there are no errors.
→ Inspection before starting work
The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.

CAUTION Use the robot within the environment given in the specifications. Failure to do so could
lead to a drop or reliability or faults. (Temperature, humidity, atmosphere, noise environ-
ment, etc.)

CAUTION Transport the robot with the designated transportation posture. Transporting the robot
in a non-designated posture could lead to personal injuries or faults from dropping.

CAUTION Always use the robot installed on a secure table. Use in an instable posture could lead
to positional deviation and vibration.

CAUTION Wire the cable as far away from noise sources as possible. If placed near a noise source,
positional deviation or malfunction could occur.

CAUTION Do not apply excessive force on the connector or excessively bend the cable. Failure to
observe this could lead to contact defects or wire breakage.

CAUTION Make sure that the workpiece weight, including the hand, does not exceed the rated load
or tolerable torque. Exceeding these values could lead to alarms or faults.

WARNING Securely install the hand and tool, and securely grasp the workpiece. Failure to observe
this could lead to personal injuries or damage if the object comes off or flies off during
operation.

WARNING Securely ground the robot and controller. Failure to observe this could lead to malfunc-
tioning by noise or to electric shock accidents.

CAUTION Indicate the operation state during robot operation. Failure to indicate the state could
lead to operators approaching the robot or to incorrect operation.

WARNING When carrying out teaching work in the robot's movement range, always secure the pri-
ority right for the robot control. Failure to observe this could lead to personal injuries or
damage if the robot is started with external commands.

CAUTION Keep the jog speed as low as possible, and always watch the robot. Failure to do so
could lead to interference with the workpiece or peripheral devices.

CAUTION After editing the program, always confirm the operation with step operation before
starting automatic operation. Failure to do so could lead to interference with peripheral
devices because of programming mistakes, etc.

CAUTION Make sure that if the safety fence entrance door is opened during automatic operation,
the door is locked or that the robot will automatically stop. Failure to do so could lead to
personal injuries.

CAUTION Never carry out modifications based on personal judgments, or use non-designated
maintenance parts.
Failure to observe this could lead to faults or failures.

WARNING When the robot arm has to be moved by hand from an external area, do not place hands
or fingers in the openings. Failure to observe this could lead to hands or fingers catching
depending on the posture.

CAUTION Do not stop the robot or apply emergency stop by turning the robot controller's main
power OFF. If the robot controller main power is turned OFF during automatic operation,
the robot accuracy could be adversely affected.Moreover, it may interfere with the
peripheral device by drop or move by inertia of the arm.

CAUTION Do not turn off the main power to the robot controller while rewriting the internal
information of the robot controller such as the program or parameters.
If the main power to the robot controller is turned off while in automatic operation or
rewriting the program or parameters, the internal information of the robot controller may
be damaged.
 Revision history
Date of Point Instruction Manual No. Revision Details

2003-10-10 BFP-A8323 First print

2004-05-20 BFP-A8323-A Installing the hand input/output cable was added.

Error in writing correction.
■ Introduction

Thank you for purchasing the Mitsubishi industrial robot.

This instruction manual explains procedures to be taken for unpacking, installing, servicing and inspecting the
robot arm.
Always read through this manual before starting use to ensure correct usage of the robot.

・ No part of this manual may be reproduced by any means or in any form, without prior consent from
Mitsubishi.
・ The details of this manual are subject to change without notice.
・ An effort has been made to make full descriptions in this manual. However, if any discrepancies or
unclear points are found, please contact your dealer.
･ The information contained in this document has been written to be accurate as much as possible.
Please interpret that items not described in this document "cannot be performed.".
Please contact your nearest dealer if you find any doubtful, wrong or skipped point.

Copyright(C) 2003 MITSUBISHI ELECTRIC CORPORATION

 CONTENTS
Page
1 Before starting use ......................................................................................................................................................................... 1-1
1.1 Using the instruction manuals ............................................................................................................................................ 1-1
1.1.1 The details of each instruction manuals ................................................................................................................ 1-1
1.1.2 Symbols used in instruction manual ........................................................................................................................ 1-2
1.2 Safety Precautions ................................................................................................................................................................. 1-3
1.2.1 Precautions given in the separate Safety Manual ............................................................................................. 1-4

2 Unpacking to Installation .............................................................................................................................................................. 2-5

2.1 Confirming the product ......................................................................................................................................................... 2-5
2.2 Installation .................................................................................................................................................................................. 2-6
2.2.1 Unpacking ............................................................................................................................................................................ 2-6
2.2.2 Transportation procedures (Transporting with a crane) ................................................................................. 2-7
2.2.3 Installation procedures .................................................................................................................................................. 2-8
2.2.4 Grounding procedures .................................................................................................................................................... 2-9
(1) Grounding methods ..................................................................................................................................................... 2-9
(2) Grounding procedures ............................................................................................................................................... 2-9
2.2.5 Connecting with the controller ................................................................................................................................ 2-10
2.3 Setting the origin ................................................................................................................................................................... 2-12
2.3.1 Installing the teaching pendant (T/B) ................................................................................................................... 2-12
(1) Installing with the control power OFF .............................................................................................................. 2-12
2.3.2 Setting the origin with the origin data input method ...................................................................................... 2-13
(1) Confirming the origin data ..................................................................................................................................... 2-13
(2) Turning ON the control power ............................................................................................................................. 2-13
(3) Preparing the T/B ..................................................................................................................................................... 2-14
(4) Selecting the origin setting method ................................................................................................................... 2-15
(5) Inputting the origin data ......................................................................................................................................... 2-16
(6) Installing the shoulder coverB ............................................................................................................................. 2-17
2.4 Confirming the operation .................................................................................................................................................... 2-18
(1) JOINT jog operation ................................................................................................................................................. 2-21
(2) XYZ jog operation ...................................................................................................................................................... 2-23
(3) TOOL jog operation .................................................................................................................................................. 2-25
(4) 3-axis XYZ jog operation ....................................................................................................................................... 2-27
(5) CYLNDER jog operation ......................................................................................................................................... 2-29

3 Installing the option devices ..................................................................................................................................................... 3-31

3.1 Installing the solenoid valve set (1S-VD01-02/VD02-02/VD03-02/VD04-02) ........................................ 3-31
3.2 Installing the hand input cable ......................................................................................................................................... 3-34
3.3 Installing the hand output cable ...................................................................................................................................... 3-35
3.4 .Changing the operating range ......................................................................................................................................... 3-36

4 Basic operations ............................................................................................................................................................................ 4-38

5 Maintenance and Inspection ..................................................................................................................................................... 5-39

5.1 Maintenance and inspection interval ............................................................................................................................. 5-39
5.2 Inspection items ..................................................................................................................................................................... 5-40
5.2.1 Daily inspection items .................................................................................................................................................. 5-40
5.2.2 Periodic inspection ........................................................................................................................................................ 5-41
5.3 Maintenance and inspection procedures ..................................................................................................................... 5-42
5.3.1 Robot arm structure ..................................................................................................................................................... 5-42
5.3.2 Installing/removing the cover ................................................................................................................................... 5-44
5.3.3 Inspection, maintenance and replacement of timing belt .............................................................................. 5-46
(1) Timing belt replacement period ......................................................................................................................... 5-46
(2) Inspection, maintenance and replacement of J5-axis timing belt ........................................................ 5-47
(3) Timing belt tension ................................................................................................................................................... 5-48
5.3.4 Lubrication ........................................................................................................................................................................ 5-49
(1) Lubrication position and specifications ............................................................................................................ 5-49

i
 Page
(2) Lubrication method ................................................................................................................................................... 5-50
5.3.5 Replacing the backup battery ................................................................................................................................... 5-51
(1) Replacing the robot arm battery ......................................................................................................................... 5-51
5.4 Maintenance parts ................................................................................................................................................................. 5-52
5.5 Resetting the origin .............................................................................................................................................................. 5-53
5.5.1 Jig method ........................................................................................................................................................................ 5-54
(1) J1 axis origin setting ................................................................................................................................................ 5-55
(2) J2 axis origin setting ................................................................................................................................................ 5-56
(3) J3 axis origin setting ................................................................................................................................................ 5-57
(4) J4 axis origin setting ................................................................................................................................................ 5-58
(5) J5 axis origin setting ................................................................................................................................................ 5-59
(6) J6 axis origin setting ................................................................................................................................................ 5-60
5.5.2 User origin method ........................................................................................................................................................ 5-61
5.5.3 ABS origin method ........................................................................................................................................................ 5-63
5.5.4 Recording the origin data ........................................................................................................................................... 5-65
(1) Confirming the origin data label ........................................................................................................................... 5-65
(2) Confirming the origin data ..................................................................................................................................... 5-65
(3) Recording the origin data ....................................................................................................................................... 5-65
(4) Installing the cover ................................................................................................................................................... 5-65
6Appendix ...............................................................................................................................................................................Appendix-66
Appendix 1 ： Configuration flag ............................................................................................................................ Appendix-66

ii
 1Before starting use

1 Before starting use

This chapter explains the details and usage methods of the instruction manuals, the basic terminology and the
safety precautions.

1.1 Using the instruction manuals

1.1.1 The details of each instruction manuals
The contents and purposes of the documents enclosed with this product are shown below. Use these documents
according to the application.
For special specifications, a separate instruction manual describing the special section may be enclosed.

Safety Manual Explains the common precautions and safety measures to be taken for robot handling,
system design and manufacture to ensure safety of the operators involved with the
robot.

Standard Explains the product's standard specifications, factory-set special specifications, option
Specifications configuration and maintenance parts, etc. Precautions for safety and technology, when
incorporating the robot, are also explained.

Robot Arm
Setup &
Explains the procedures required to operate the robot arm (unpacking, transportation,
Maintenance
installation, confirmation of operation), and the maintenance and inspection procedures.

Controller
Setup, Basic
Operation and Explains the procedures required to operate the controller (unpacking, transportation,
Maintenance installation, confirmation of operation), basic operation from creating the program to
automatic operation, and the maintenance and inspection procedures.

Detailed
Explanation of
Functions and Explains details on the functions and operations such as each function and operation,
Operations commands used in the program, connection with the external input/output device, and
parameters, etc.

Troubleshooting Explains the causes and remedies to be taken when an error occurs. Explanations are
given for each error No.

Using the instruction manuals 1-1

1Before starting use

1.1.2 Symbols used in instruction manual

The symbols and expressions shown in Table 1-1 are used throughout this instruction manual. Learn the meaning
of these symbols before reading this instruction manual.

Table 1-1 ： Symbols in instruction manual

Symbol Meaning

Precaution indicating cases where there is a risk of operator fatality or seri-

DANGER ous injury if handling is mistaken. Always observe these precautions to safely
use the robot.

Precaution indicating cases where the operator could be subject to fatalities

WARNING or serious injuries if handling is mistaken. Always observe these precautions to

safely use the robot.

Precaution indicating cases where operator could be subject to injury or

CAUTION physical damage could occur if handling is mistaken. Always observe these
precautions to safely use the robot.

If a word is enclosed in brackets or a box in the text, this refers to a key on

［ JOINT ］
the teaching pendant.

This indicates to press the (B) key while holding down the (A) key.
［＋／ Ｆ Ｏ Ｒ Ｗ Ｄ ］ ＋ ［＋ Ｘ ］
In this example, the [+/Forward] key is pressed while holding down the [+X/
（Ａ） （Ｂ）
+Y] key.

This indicates to hold down the (A) key, press and release the (B) key, and
［ Ｓ Ｔ Ｅ Ｐ ／ Ｍ Ｏ Ｖ Ｅ ］ ＋ ([ Ｃ Ｏ Ｎ Ｄ ] → [ Ｒ Ｐ Ｌ ↓ ]）
then press the (C) key. In this example, the [Step/Move] key is held down, the
（Ａ） （Ｂ） （Ｃ）
[Condition] key is pressed and released, and the [Replace ↓ key is pressed.

Ｔ ／Ｂ This indicates the teaching pendant.

1-2 Using the instruction manuals

 1Before starting use

1.2 Safety Precautions

Always read the following precautions and the separate "Safety Manual" before starting use of the robot to learn
the required measures to be taken.

CAUTION All teaching work must be carried out by an operator who has received special training.
(This also applies to maintenance work with the power source turned ON.)
→ Enforcement of safety training

CAUTION For teaching work, prepare a work plan related to the methods and procedures of oper-
ating the robot, and to the measures to be taken when an error occurs or when restart-
ing. Carry out work following this plan. (This also applies to maintenance work with the
power source turned ON.)
→ Preparation of work plan

WARNING Prepare a device that allows operation to be stopped immediately during teaching work.
(This also applies to maintenance work with the power source turned ON.)
→ Setting of emergency stop switch

CAUTION During teaching work, place a sign indicating that teaching work is in progress on the
start switch, etc. (This also applies to maintenance work with the power source turned
ON.)
→ Indication of teaching work in progress

DANGER Provide a fence or enclosure during operation to prevent contact of the operator and
robot.
→ Installation of safety fence

CAUTION Establish a set signaling method to the related operators for starting work, and follow
this method.
→ Signaling of operation start

CAUTION As a principle turn the power OFF during maintenance work. Place a sign indicating that
maintenance work is in progress on the start switch, etc.
→ Indication of maintenance work in progress

CAUTION Before starting work, inspect the robot, emergency stop switch and other related
devices, etc., and confirm that there are no errors.
→ Inspection before starting work

Safety Precautions 1-3

1Before starting use

1.2.1 Precautions given in the separate Safety Manual

The points of the precautions given in the separate "Safety Manual" are given below.
Refer to the actual "Safety Manual" for details.

CAUTION Use the robot within the environment given in the specifications. Failure to do so could
lead to a drop or reliability or faults. (Temperature, humidity, atmosphere, noise envi-
ronment, etc.)

CAUTION Transport the robot with the designated transportation posture. Transporting the
robot in a non-designated posture could lead to personal injuries or faults from drop-
ping.

CAUTION Always use the robot installed on a secure table. Use in an instable posture could lead
to positional deviation and vibration.

CAUTION Wire the cable as far away from noise sources as possible. If placed near a noise
source, positional deviation or malfunction could occur.

CAUTION Do not apply excessive force on the connector or excessively bend the cable. Failure
to observe this could lead to contact defects or wire breakage.

CAUTION Make sure that the workpiece weight, including the hand, does not exceed the rated
load or tolerable torque. Exceeding these values could lead to alarms or faults.

WARNING Securely install the hand and tool, and securely grasp the workpiece. Failure to
observe this could lead to personal injuries or damage if the object comes off or flies
off during operation.

WARNING Securely ground the robot and controller. Failure to observe this could lead to mal-
functioning by noise or to electric shock accidents.

CAUTION Indicate the operation state during robot operation. Failure to indicate the state could
lead to operators approaching the robot or to incorrect operation.

WARNING When carrying out teaching work in the robot's movement range, always secure the
priority right for the robot control. Failure to observe this could lead to personal inju-
ries or damage if the robot is started with external commands.

CAUTION Keep the jog speed as low as possible, and always watch the robot. Failure to do so
could lead to interference with the workpiece or peripheral devices.

CAUTION After editing the program, always confirm the operation with step operation before
starting automatic operation. Failure to do so could lead to interference with periph-
eral devices because of programming mistakes, etc.

CAUTION Make sure that if the safety fence entrance door is opened during automatic opera-
tion, the door is locked or that the robot will automatically stop. Failure to do so could
lead to personal injuries.

CAUTION Never carry out modifications based on personal judgments, or use non-designated
maintenance parts.
Failure to observe this could lead to faults or failures.

WARNING When the robot arm has to be moved by hand from an external area, do not place
hands or fingers in the openings. Failure to observe this could lead to hands or fingers
catching depending on the posture.

CAUTION Do not stop the robot or apply emergency stop by turning the robot controller's main
power OFF.
If the robot controller main power is turned OFF during automatic operation, the robot
accuracy could be adversely affected.

CAUTION Do not turn off the main power to the robot controller while rewriting the internal
information of the robot controller such as the program or parameters.
If the main power to the robot controller is turned off while in automatic operation or
rewriting the program or parameters, the internal information of the robot controller
may be damaged.
1-4 Safety Precautions
 2Unpacking to Installation

2 Unpacking to Installation
2.1 Confirming the product
The standard configuration of the robot arm, part of the purchased product, is shown in Table 2-1.
Confirm the parts.
Users who have purchased optional products should refer to the separate "Standard Specifications".

Table 2-1 ： Standard configuration

No. Part name Type Qty. Remarks

1 Robot arm RV-6S series 1 unit

2 Guarantee card 1 copy

3 Installation bolts M8x40 4 pcs.

4 Spring washer for installation bolts For M8 4 pcs.

5 Plain washer for installation bolts For M8 4 pcs.

6 Suspension fitting 2 pcs.

7 Suspension fitting installation bolt 1 set This is installed in the robot arm
8 Fixing plates 1 pcs. at the time of shipment.

9 Fixing plate installation bolt 1 set

Confirming the product 2-5

2Unpacking to Installation

2.2 Installation
2.2.1 Unpacking

Pull off

<1> Tape
<2> Upper lid

（ａ） （ｂ）

Robot arm
! CAUTION
!
Always unpack the
robot at a flat place.
The robot could tilt
over if unpacked at an
unstable place.

（ｃ）

Fig.2-1 ： Unpacking the robot arm

The robot is shipped from the factory in cardboard and wooden frame packing. Always refer to Fig. 2-1 and unpack
the robot. Handle the robot arm according to "2.2.2 Transportation procedures (Transporting with a crane)".
The unpacking process is shown below.
1) Using a knife, etc., slit the tape <1> fixing the upper lid <2> of the cardboard box. (Fig. 2-1 (a))
2) Pull the upper lid <2> of the cardboard box off with both hands. (Fig. 2-1 (b))
3) Remove the hexagon socket bolts <3> (four positions) connecting the sleeper and the base unit. (Fig. 2-1
(c))
4) This completes the unpacking. (Fig. 2-1 (c))

2-6 Installation
 2Unpacking to Installation

2.2.2 Transportation procedures (Transporting with a crane)

Wire

Fixing plate
1300

Suspension fitting
Hexagon socket bolt
(four M10 x 25,
four spring washers for M10)

Front Side
Fig.2-2 ： Transportation procedures (transporting with a crane)

1) Attach the suspension fittings to the left and right sides of the shoulder section, and securely fix with bolts
(four M10 x 25, four spring washers for M10). At this time, fix two of the suspension fitting's three holes at
the side closest to the robot front.
2) Catch wires in the eye bolts installed on the suspension fittings, and quietly suspend the arm.
3) At this time, make sure that the wires, etc., do not interfere with the robot arm or covers. Always place
cloth, etc., at interfering places.
4) When transferring to the installation place, take care not to apply vibration or impact.
5) After installing at the installation place, remove the above suspension fittings.
6) Always follow the above procedures and methods to transport the robot for secondary transportation, such
as when changing the installation position.
If the arm is directly suspended without using the specified suspension fittings, or if it is suspended in the
work posture, the configuration devices could be damaged, and the transportation workers will be subject to
risk due to an inadequate center of gravity position.

Installation 2-7
2Unpacking to Installation

2.2.3 Installation procedures

1) The robot installation surface has been machine

finished. Use the installation holes (4-φ9 holes)
opened at the four corners of the base, and
securely fix the robot with the enclosed installa-
tion bolts (M8 x 40 hexagon socket bolts).

Installation of the robot arm is a very important

step for ensuring the optimum functions of the
robot. Observe the following points when design-
ing.

4-M8×40 hexagon socket bolt 2) Install the robot on a level surface.

(Four positions)
Spring washer
3) It is recommended that the surface roughness of
Plain washer
the table onto which the robot is to be installed
by 6.3a or more. If the installation surface is
rough, the contact with the table will be poor, and
positional deviation could occur when the robot
2-φ6 holes
moves.
4-φ9 installation hole
(prepared holes for φ8 positioning pins)

4) When installing, use a common table to prevent

the position of the devices and jigs subject to
115

robot work from deviating.

Robot front
5) The installation surface must have sufficient
204
160

strength to withstand the arm reaction during

122

operation, and resistance against deformation and

vibration caused by the static (dynamic) load of
6.3a (Installation)
the robot arm and peripheral devices, etc.
96
6.3a (Installation)

102.5 6) Remove the fixing plates after installing the robot.

205
7) When the robot is installed by hanging from the
115 140
ceiling or on the wall, the MEGDIR parameter
Base bottom
must be changed. For more information about
parameters and how to change the parameters,
refer to the separate "Instruction Manual/
Detailed Explana-tion of Functions and Opera-
tions".

Fig.2-3 ： Installation dimensions

2-8 Installation
 2Unpacking to Installation

2.2.4 Grounding procedures

(1) Grounding methods

1) There are three grounding methods as shown in

Fig. 2-4, but the dedicated grounding (Fig. 2-4 (a))
should be used for the robot arm and controller
Controller Controller Controller when possible. (Refer to the separate " Controller
Robot arm and Robot arm and Robot arm and
personal personal personal Setup, Basic Operation and Maintenance" for
computer computer computer
details on the controller grounding.)
2) Use Class D grounding (grounding resistance
100Ω or less).
Dedicated grounding separated from the other
devices should be used.
3) Use a AWG#11(3.5mm2) or more stranded wire for
(a) Dedicated grounding (b) Common grounding (c) Common grounding
(Optimum) (Good) (Normal) the grounding wire. The grounding point should be
as close to the robot arm and controller as possi-
ble, and the length of the grounding wire should
be short.
Fig.2-4 ： Grounding methods

(2) Grounding procedures

Robot arm
1) Prepare the grounding cable (AWG#11(3.5mm2)
or more) and robot side installation screw and
M4×10, SW, PW washer.

2) If there is rust or paint on the grounding screw

section (A), remove it with a file, etc.

3) Connect the grounding cable to the grounding

screw section.

A
Robot grounding cable
(AWG#11 (3.5mm2) or more)
(Prepared by customer)

Fig.2-5 ： Connecting the grounding cable

CAUTION When installing the robot, be sure to allocate a sufficient maintenance space for
connecting the cables between devices and replacing a backup battery at the rear
of the robot.

Installation 2-9
2Unpacking to Installation

2.2.5 Connecting with the controller

<CR3-535M controller>

Controller
Robot arm

CN2

CN1

Motor power cable (7m)

（CN1）
Motor signal cable (7m)
（CN2）
<CR2B-574 controller>

Controller
Robot arm

Motor signal
（ＣＮ2）
Motor power
（ＣＮ1）

CN2

CN1

Motor power cable (5m)

Motor signal cable (5m)

Fig.2-6 ： Connecting the machine cables

2-10 Installation
 2Unpacking to Installation

Carry out the following procedure after installing the controller referring to the separate "Controller Setup, Basic
Operation and Maintenance" manual.

Robot arm
Connector on the
robot arm side
1) Make sure that the power switch on the front of the
controller is turned OFF.
Hook

Projection
2) Connect the machine cable to its corresponding connector
on the robot arm side.
Connector on the
machine cable side

3) After connecting the connector, insert the hook attached

to the connector on the machine cable side to the rear of
the projection of the robot arm connector to fix securely in
place.

Hook
* If you are using a CR2B-574 controller, also connect the
applicable connector on the controller side according to
steps 2) and 3) above.
Projection

Hook
Projection
Minus screwdriver
4) To remove the cable, insert a minus screwdriver into the
hook while padding with a cloth, and remove the cable by
lifting the hook.

Padding

CAUTION The machine cable connectors are dedicated for the controller side and robot arm
side, so take special care when connecting.
If connected incorrectly, the connector pins could bend or break. Thus, even if
connected correctly, the robot will not operate correctly, creating a dangerous
situation.

CAUTION Take special care to the leading of the connection cable. If the cable is pulled with
force or bent excessively, wires could break or the connector could be damaged.

Installation 2-11
2Unpacking to Installation

2.3 Setting the origin

The origin is set so that the robot can be used with a high accuracy. After purchasing the robot, always carry out
this step before starting work. This step must also be carried out if the combination of robot and controller being
used is changed.
There are several methods for setting the origin, but the origin data input method will be explained here. Refer to
"5.5 Resetting the origin" on page 53 for the other methods.
The teaching pendant is required for this operation.
[Caution] If the origin data at shipment is erased due to out of battery, it is necessary to set the origin again.
Refer to "5.5 Resetting the origin" on page 53 and reset the origin using the jig method or ABS origin
method.

2.3.1 Installing the teaching pendant (T/B)

By using the "REMOVE T/B" switch, the T/B can be installed and removed while the controller's control power is
ON. However, in this procedure, the teaching pendant will be installed with the control power OFF.
Refer to the separate "Controller setup, basic operation, and maintenance" for details on installing the teaching
pendant with the control power ON.

(1) Installing with the control power OFF

Display LCD ENABLE/DISABLE switch
1) Confirm that the controller's power supply switch is OFF.

2) Connect the T/B connector to the RS-422 (T/B) connector

on the controller.

3) Do not pull the cable with force or bend it excessively, as

the cable could break or the connector could be damaged.
Emergency stop switch

4) Confirm that the [REMOVE T/B] switch on the side of the

controller is not depressed (is projected).
Operation keys

5) Set the T/B [ENABLE/DISABLE] switch to "DISABLE".

Appearance of teaching pendant
REMOVE T/B switch

Teaching pendant
(T/B)

<Figure shows
the CR3-535M
controller>
Connector

Fig.2-7 ： Installing the T/B (control power OFF)

◇◆◇ [REMOVE T/B] switch ◇◆◇

When using the robot with the T/B, this switch is used to invalidate the emergency stop from the T/B. This is
also used to install the T/B with turning the controller's power supply ON.

2-12 Setting the origin

 2Unpacking to Installation

2.3.2 Setting the origin with the origin data input method
(1) Confirming the origin data
● Origin data history table (Origin Data History) Serial No.ES804008
Date Default . . . . . . . . .
The origin data to be input is noted in the
origin data sheet enclosed with the arm,
Ｄ V!#S29
or on the origin data history table
Ｊ １ 06DTYY attached to the back side of the shoulder
Ｊ ２ 2?HL9X coverB. (Refer to Fig. 2-8).
Ｊ ３ 1CP55V
Ｊ ４ T6!M$Y Referring to "5.3.2 Installing/removing
Ｊ ５ Z2IJ%Z the cover" on page 44, remove the
Ｊ ６ A12%Z0 shoulder coverB, and confirm the value.
Method Ｅ Ｅ ・ Ｎ ・ ＳＰ Ｅ・Ｎ・ Ｅ ・ Ｎ ・ ＳＰ
ＳＰ
The value given in the default setting
(O: AlphabetO, 0: Zero) column is the origin settings set with the
Note) Meanings of symbols in method column calibration jig before shipment.
E: Jig method
N: Not used
SP: Not used

Fig.2-8 ： Origin data label (an example)

WARNING Always install/remove the cover with the controller control power turned OFF.
Failure to do so could lead to physical damage or personal injury should the robot
start moving due to incorrect operations.

(2) Turning ON the control power

CAUTION Confirm that there are no operators near the robot before turning the power ON.

1) Turn the controller [POWER] switch ON.

The control power will be turned ON, and " □ . 100" will appear on the STATUS NUMBER display on the
front of the controller.

Setting the origin 2-13

2Unpacking to Installation

(3) Preparing the T/B

STATUS NUMBER EMG.STOP
Next, prepare to use the T/B
CHANG DISP

1) Set the [MODE] switch on the front of the controller to "TEACH".

MODE SVO ON START RESET

TEACH
AUTO AUTO
(Op.) (Ext.)
REMOVE T/B
SVO OFF STOP END

MODE
TEACH
AUTO AUTO
(Op.) (Ext.)

DISABLE ENABLE 2) Set the T/B [ENABLE/DISABLE] switch to "ENABLE". The menu
selection screen will appear.
The following operations are carried out with the T/B.
DI SABLE ENABLE
P8TB-TE

EMG. STOP

◇◆◇ Operating from the T/B ◇◆◇

Always set the [MODE] switch (mode selection key switch) on the front of the controller to "TEACH", and then
set the T/B [ENABLE/DISABLE] switch to "ENABLE".
When the T/B is valid, only operations from the T/B are possible. Operations from the controller or external
signals will not be accepted.

◇◆◇ When T/B operations are mistaken ◇◆◇

The displayed screen will return to the "menu selection screen" when the [MENU] key is pressed. Carry out the
operations again from this screen. Operations can also be carried out again by setting the T/B [ENABLE/
DISABLE] switch to "DISABLE" once and then setting to "ENABLE".

2-14 Setting the origin

 2Unpacking to Installation

(4) Selecting the origin setting method

<T/B screen> [Keys used]
<MENU>
1.TEACH 2.RUN 1) Press the [5] key on the menu screen, and display the maintenance screen.
+C
3.FILE 4.MONI (J6)
5.MAINT 6.SET 5 STU

<MAINT> 2) Press the [4] key on the maintenance screen, and display the origin setting
1.PARAM 2.INIT method selection screen.
-Y
3.BRAKE 4.ORIGIN (J2)
5.POWER 4 MNO

<ORIGIN> 3) Press the [1] key on the origin setting method selection screen, and select
1.DATA 2.MECH the data input method.
-B INP
3.JIG 4.ABS (J5) The origin data input method will be selected, and the screen for turning
EXE
5.USER 1 DEF
OFF the servo power will appear.

<ORIGIN> 4) Press the [1] and [INP] keys to turn OFF the servo power. The screen for
SERVO OFF inputting the origin data will appear.
OK?(1) -B INP
(J5) EXE
1:EXECUTE 1 DEF

<DATA>D(000000)
1:000000 000000
3:000000 000000
5:000000 000000

◇◆◇ Selecting a menu ◇◆◇

The menu can be selected with one of the following methods.
A: Press the numeral key for the No. of the item to be selected.
B: Using the [ ↓ ] and [ ↑ ] keys, etc., move the cursor to the item to be selected, and then press the [INP] key.

Setting the origin 2-15

2Unpacking to Installation

(5) Inputting the origin data

Input the value confirmed in section "(1) Confirming the origin

Origin data label data" on page 13.
T/B screen (D,J1,J2,J3,J4,J5,J6) The correspondence of the origin data label value and axis to be
<DATA> D( D ) input is shown in Fig. 2-9.
1: J1 J2
3: J3 J4
5: J5 J6

Fig.2-9 ： Correspondence of origin data label and axis

The method for inputting the origin data is explained below. The value shown in Fig. 2-8will be input as an example.
<T/B screen> [Keys used]
<DATA>D(000000)
1) Confirm that the cursor is at the "D" position on the T/B display
1:000000 000000
screen.
3:000000 000000
5:000000 000000

<DATA>D(V00000) 2) Input the D value V!%S29.

1:000000 000000 Inputting "V"
3:000000 000000 +B Press the [VWX] key once while holding down the [CHAR] key. "V" will
POS ＋
5:000000 000000 CHAR
(J5) appear, so release the [CHAR] key. "V" will be set.
6 VWX

Inputting "!"
<DATA>D(V!0000) Press the [#%!] key three times while holding down the [CHAR] key. "!"
1:000000 000000 SPD will appear, so release the [CHAR] key. "!" will be set.
3:000000 000000 POS
CHAR ＋
5:000000 000000 #%!

In the same manner, while holding down the [CHAR] key, press the
<DATA>D(V!0000) SPD ["%"] key twice, and the [STU] key once (input "S").
POS ＋
1:000000 000000 CHAR
#%!
Release the [CHAR] key, and press the [2] key (input "2") and then
3:000000 000000 the [9] key (input "9").
+C
5:000000 000000 POS
＋ (J6) V!%S29 will appear at the "D" data on the teaching pendant screen.
CHAR
5 STU

-A +Y
(J4) (J2)
2 GHI 9 &<>

3) Press the [ ↓ ] key, and move the cursor to the J1 input position.
<DATA>D(V!%S29)
4) Input the J1 value in the same manner as above.
1:000000 000000
RPL
3:000000 000000 ↓ 5) Input the J2, J3, J4, J5 and J6 values in the same manner.
5:000000 000000
6) After inputting all of the values, press the [INP] key. The origin
<DATA>D(V!%S29) setting confirmation screen will appear.
1:A@B&8F G#$Y5#
INP
3:H+7%2H B="!1L
EXE
5:59A37! K8#&6P
7) Press [1] (-B/-P) and [INP] key to end the origin setting
<DATA>D(V!%S29)
CHANGES TO ORIGIN
-B INP
OK? (1) (J5) EXE
1:EXECUTE 1 DEF

2-16 Setting the origin

 2Unpacking to Installation

◇◆◇ Moving the cursor ◇◆◇

Press the [ ↑ ], [ ↓ ], [ ← ] and [ → ] keys.
◇◆◇ Inputting characters ◇◆◇
Hold down the [CHAR] key and press the key with the character to be input on the lower right. Three characters
will scroll each time the character key is pressed.
◇◆◇ Correcting an input ◇◆◇
After returning one character by pressing the [DEL] key, input the character again.

(6) Installing the shoulder coverB

Return the shoulder coverB, removed in section "(1) Confirming the origin data" on page 13 to its original position.
This completes the setting of the origin with the origin data input method.

Always remove and install the cover with the controller power turned OFF. Failure
WARNING to do so could lead to the robot moving because of incorrect operations, or to
physical damage or personal injury.

◇◆◇ If the origin input data is incorrect ◇◆◇

If the origin input data is incorrect, the alarm No. 1760 (origin setting data illegal) will occur when origin data input.
In this case, reconfirm the value input for the origin data.

Setting the origin 2-17

2Unpacking to Installation

2.4 Confirming the operation

In this section, the robot will be moved manually using the T/B to confirm that the operation is correct.
Moving the robot manually is called "jog operation". This operation includes the JOINT jog that moves each axis,
the XYZ jog that moves along the base coordinate system, the TOOL jog that moves along the tool coordinate
system, and the CYLNDER jog that moves along the circular arc.
This operation is carried out while pressing the deadman switch on the back of the T/B.

CAUTION The robot will move during this operation. Make sure that there are no operators
near the robot, and that there are no obstacles, such as tools, in the robot operation
range.

CAUTION To immediately stop the robot, release the deadman switch on the back of the T/B.
The servo power will turn OFF, and the robot will stop.
The robot will also stop if the [EMG.STOP] switch (emergency stop switch) on the
front of the T/B or the [EMG.STOP] switch (emergency stop) on the front of the
controller is pressed.

WARNING Confirm that the origin has been set. If the origin has not been set, "****" will
appear at the current position display on the teaching pendant, the JOINT jog oper-
ation will take place in any jog mode selected.
Refer to "2.3 Setting the origin" on page 12 for details on setting the origin.

＋ J4 axis
－
J3 axis
J5 axis －
－ ＋
＋ ＋
J6 axis －

J2 axis
－
－
＋ ＋
J1 axis

* Each axis moves independently.

Fig.2-10 ： JOINT jog operation

2-18 Confirming the operation

 2Unpacking to Installation

＋Z

h
n gt
le
ool
T ＋Z
－ ＋
＋ －
＋X － ＋Y
＋
Control point

－Ｙ
－Ｘ

＋X ＋Y
－Z
* While maintaining the flange surface posture, the axis moves straight along the base
coordinate system.
Also, while maintaining the flange surface position, the flange surface posture changes.

Fig.2-11 ： XYZ jog operation

－X
th
leng
ol
To
－Y
－Z
－
＋
＋ ＋Y
－ －
＋Z
＋
Control point
＋X

* While maintaining the flange surface posture, the axis moves straight along the tool
coordinate system.
Also, while maintaining the flange surface position, the flange surface posture changes.

Fig.2-12 ： TOOL jog operation

Confirming the operation 2-19

2Unpacking to Installation

＋Z
＋ J4
th
le ng －
ool
T
J5
－
＋

＋
J6 － Control point

－Ｙ
－Ｘ

＋X ＋Y
－Z
* The axis moves straight along the base coordinate system. At this time, the flange surface
posture is not maintained.
Also, the flange surface posture changes. The flange surface position changes at this time.

Fig.2-13 ： 3-axis XYZ jog operation

＋Z

h
n gt
le
ool
T Vertical

Radius Arc

Control point

－Ｙ
－Ｘ

＋X ＋Y
－Z
* The current position is set as the arc centering on the Z axis, and the axis moves along that arc, expands
and contracts in the radius direction, and moves vertically. At this time, the flange surface posture is
maintained. Also, while maintaining the flange surface position, the flange surface posture changes.

Fig.2-14 ： CYLINDER jog operation

2-20 Confirming the operation

 2Unpacking to Installation

(1) JOINT jog operation

Select the JOINT jog mode
Press the [MOVE] + [JOINT] keys to select the
JOINT LOW JOINT jog mode. "JOINT" will appear at the upper
J1 +34.50 STEP
JOINT
left of the screen.
J2 +20.00 MOVE
＋
( )?
J3 +80.00 JOINT jog mode

Each time the [MOVE] + [+] keys are pressed, the

override will increase in the order of LOW → HIGH →
Set the jog speed 3 → 5 → 10 → 30 → 50 → 70 → 100%.
When the [MOVE] + [-] keys are pressed, the
JOINT LOW override will decrease in the reverse order.
J1 +34.50 STEP ＋ － The currently set speed will appear on the upper right
J2 +20.00 MOVE
＋ FORWD BACKWD of the screen.
J3 +80.00 Set the speed
Set the override to 10% here for confirmation work.

J1 axis jog operation

STEP -X STEP +X
＋ (J1) ＋ (J1)
MOVE SPACE PQR MOVE ' ; ^

－ ＋
J1 axis

・ When the [MOVE] + [+X (J1)] keys are pressed, the J1 axis will rotate in the plus direction.
When the [MOVE] + [-X (J1)] keys are pressed, Rotate in the minus direction.

J2 axis jog operation

STEP -Y
＋ (J2)
MOVE 4 MNO

J2 axis
STEP +Y
＋ (J2)
MOVE 9 &< >

・ When the [MOVE] + [+Y (J2)] keys are pressed, the J2 axis will rotate in the plus direction.
When the [MOVE] + [-Y (J2)] keys are pressed, Rotate in the minus direction.

◇◆◇ When the robot is in the transportation posture ◇◆◇

The axes may be outside the movement area. Move these axes toward the inner side of the movement area. If
moved outward, an X
Ｘ will appear on the T/B screen, and the robot will not move.

Confirming the operation 2-21

2Unpacking to Installation

J3 axis jog operation

STEP -Z
＋ (J3)
MOVE 3 JKL

J3 axis

STEP +Z
＋ (J3)
MOVE 8 , @\

・ When the [MOVE] + [+Z (J3)] keys are pressed, the J3 axis will rotate in the plus direction.
When the [MOVE] + [-Z (J3)] keys are pressed, Rotate in the minus direction.

J4, J5 and J6 axis jog

STEP +C
＋ (J6)
MOVE 5 STU STEP -B
＋ (J5) STEP +A
J6 axis ＋
MOVE 1 DEF
＋ (J4)
＋ MOVE 7 YZ_
－ J4 axis
STEP -C －
＋ (J6)
MOVE 0 ABC

J5 axis －
＋ STEP -A
＋ (J4)
MOVE 2 GHI

STEP +B
＋ (J5)
MOVE 6 VWX

・ When the [MOVE] + [+A (J4)] keys are pressed, the J4 axis will rotate in the plus direction.
When the [MOVE] + [-A (J4)] keys are pressed, Rotate in the minus direction.
・ When the [MOVE] + [+B (J5)] keys are pressed, the J5 axis will rotate in the plus direction
When the [MOVE] + [-B (J5)] keys are pressed, Rotate in the minus direction.
・ When the [MOVE] + [+C (J6)] keys are pressed, the J6 axis will rotate in the plus direction
When the [MOVE] + [-C (J6)] keys are pressed, Rotate in the minus direction.

◇◆◇ When an X
Ｘ appears on the T/B screen display ◇◆◇
If the robot is moved outside the movement area, an X
Ｘ will appear. In this case, move the axis in the opposite
direction.

JOINT LOW In the example on the left, the J1 axis is at the limit of the plus side movement area.
X
Ｘ J1 +160.00
J2 +20.00
J3 +80.00

2-22 Confirming the operation

 2Unpacking to Installation

(2) XYZ jog operation

Select the XYZ jog mode
Press the [MOVE] + [XYZ] keys to select the XYZ
XYZ LOW jog mode. "XYZ" will appear at the upper left of
X +134.50 XYZ the screen.
STEP
Y +220.00 MOVE
＋
Z +280.00 XYZ jog mode $":
Each time the [MOVE] + [+] keys are pressed, the
override will increase in the order of LOW → HIGH
Set the jog speed → 3 → 5 → 10 → 30 → 50 → 70 → 100%. When
the [MOVE] + [-] keys are pressed, the override
XYZ LOW will decrease in the reverse order. The currently
X +134.50 set speed will appear on the upper right of the
STEP ＋ －
Y +220.00 MOVE
＋ FORWD BACKWD screen. Set the override to 10% here for
Z +280.00 Set the speed
confirmation work.

Moving along the base coordinate system STEP +Z ＋Z

MOVE
＋ (J3)
8 , @\

＋Z

h
-Y ngt
STEP
＋ (J2) lle
o
To
MOVE 4 MNO
STEP -X
MOVE
＋ (J1)
SPACE PQR

＋X
STEP +X ＋Y
＋ (J1) STEP +Y
MOVE ' ; ^ ＋ (J2)
MOVE 9 &< >

STEP -Z －Ｙ
MOVE
＋ (J3) －Ｘ
3 JKL

＊ The direction of the frange will not change. ＋X ＋Y

－Z

・ When the [MOVE] + [+X (J1)] keys are pressed, the robot will move along the X axis plus direction.
When the [MOVE] + [-X (J1)] keys are pressed, Move along the minus direction.

・ When the [MOVE] + [+Y (J2)] keys are pressed, the robot will move along the Y axis plus direction.
When the [MOVE] + [-Y (J2)] keys are pressed, Move along the minus direction.

・ When the [MOVE] + [+Z (J3)] keys are pressed, the robot will move along the Z axis plus direction.
When the [MOVE] + [-Z (J3)] keys are pressed, Move along the minus direction.

◇◆◇ When the robot is in the transportation posture ◇◆◇

There are directions from which linear movement is not possible from the transportation posture. In this case, an
X
Ｘ will appear on the T/B screen, and the robot will not move. Refer to section "(1) JOINT jog operation" on page
21", and move the robot to a position where linear movement is possible, and then carry out XYZ jog.

◇◆◇ When an X
Ｘ appears on the T/B screen display ◇◆◇
If the robot is moved outside the movement area with any of the axes, an X
Ｘ will appear. In this case, move the
axis in the opposite direction.

XYZ LOW In the example on the left, further linear movement in the same direction is not possible.
X
ＸX +360.00
X
ＸY +280.00
X
ＸZ +170.00

Confirming the operation 2-23

2Unpacking to Installation

Changing the flange surface posture

＋Z
STEP -C STEP +C
＋ (J6) ＋ (J6)
MOVE 0 ABC ＋Z MOVE 5 STU

－ ＋

STEP +A
＋ (J4) th
MOVE 7 YZ_
le ng STEP -B
ol
＋ (J5)
＋ MOVE
To
1 DEF
－
＋X － ＋Y
STEP -A
＋
＋ (J4) STEP +B
MOVE 2 GHI ＋ (J5)
MOVE 6 VWX
Control point

－Ｙ
－Ｘ

* The flange position does not change. ＋X ＋Y

－Z

・ When the [MOVE] + [+A (J4)] keys are pressed, The X axis will rotate in the plus direction.
When the [MOVE] + [-A (J4)] keys are pressed, Rotate in the minus direction.

・ When the [MOVE] + [+B (J5)] keys are pressed, The Y axis will rotate in the plus direction.
When the [MOVE] + [-B (J5)] keys are pressed, Rotate in the minus direction.

・ When the [MOVE] + [+C (J6)] keys are pressed, The Z axis will rotate in the plus direction.
When the [MOVE] + [-C (J6)] keys are pressed, Rotate in the minus direction.

◇◆◇ When alarm No. 5150 occurs ◇◆◇

If alarm No. 5150 (ORIGIN NOT SET) occurs, the origin has not been set correctly. Reconfirm the value input for
the origin data.

◇◆◇ Tool length ◇◆◇

The default tool length is 0mm, and the control point is the center of the end axis.
After installing the hand, set the correct tool length in the parameters. Refer to the separate manual "Detailed
Explanation of Functions and Operations" for details.

2-24 Confirming the operation

 2Unpacking to Installation

(3) TOOL jog operation

Select the TOOL jog mode
Press the [MOVE] + [TOOL] keys to select the
TOOL LOW TOOL jog mode. "TOOL" will appear at the upper
X +134.50 TOOL left of the screen.
STEP
Y +220.00 MOVE
＋
=*/
Z +280.00 TOOL jog mode
Each time the [MOVE] + [+] keys are pressed, the
override will increase in the order of LOW → HIGH
Set the jog speed → 3 → 5 → 10 → 30 → 50 → 70 → 100%. When
the [MOVE] + [-] keys are pressed, the override
TOOL LOW
will decrease in the reverse order. The currently
X +134.50
STEP ＋ － set speed will appear on the upper right of the
Y +220.00 ＋ FORWD
MOVE BACKWD screen. Set the override to 10% here for
Z +280.00 Set the speed confirmation work.

Moving along the tool coordinate system STEP -X

MOVE
＋ (J1)
SPACE PQR

th
l e ng
ol
STEP -Y
To
STEP -Z
MOVE
＋ (J2)
＋ (J3)
4 MNO
MOVE 3 JKL

＋Y
STEP +Y
＋Z MOVE
＋ (J2)
9 &< >
STEP +Z
MOVE
＋ (J3)
8 , @\
＋X
Control point STEP +X
MOVE
＋ (J1)
' ; ^

＊ The direction of the frange will not change.

・When the [MOVE] + [+X (J1)] keys are pressed, the robot will move along the X axis plus direction of the tool
coordinate system.
When the [MOVE] + [-X (J1)] keys are pressed, Move along the minus direction.

・When the [MOVE] + [+Y (J2)] keys are pressed, the robot will move along the Y axis plus direction of the tool
coordinate system.
When the [MOVE] + [-Y (J2)] keys are pressed, Move along the minus direction.

・When the [MOVE] + [+Z (J3)] keys are pressed, the robot will move along the Z axis plus direction of the tool
coordinate system.
When the [MOVE] + [-Z (J3)] keys are pressed, Move along the minus direction.

◇◆◇ When the robot is in the transportation posture ◇◆◇

There are directions from which linear movement is not possible from the transportation posture. In this case,
an X
Ｘ will appear on the T/B screen, and the robot will not move. Refer to section "(1) JOINT jog operation" on
page 21, and move the robot to a position where linear movement is possible, and then carry out TOOL jog.

◇◆◇ When an X
Ｘ appears on the T/B screen display ◇◆◇
If the robot is moved outside the movement area with any of the axes, an X
Ｘ will appear. In this case, move the axis
in the opposite direction.

TOOL LOW In the example on the left, further linear movement in the same direction is not possible.
X
ＸX +360.00
X
ＸY +280.00
X
ＸZ +170.00

Confirming the operation 2-25

2Unpacking to Installation

Changing the flange surface posture

th
leng
l
T oo
STEP +C STEP -B
＋ (J6) ＋ (J5)
MOVE MOVE 1 DEF
5 STU
－
＋
＋ ＋Y STEP +B
－ ＋
＋Z MOVE 6
(J5)
VWX
STEP -C －
MOVE
＋ (J6) ＋ STEP -A
0 ABC
＋X ＋ (J4)
MOVE 2 GHI
STEP +A
＋ (J4)
MOVE 7 YZ_

* The flange position does not change.

・ When the [MOVE] + [+A (J4)] keys are pressed, The X axis will rotate in the plus direction of the tool
coordinate system.
When the [MOVE] + [-A (J4)] keys are pressed, Rotate in the minus direction.

・ When the [MOVE] + [+B (J5)] keys are pressed, The Y axis will rotate in the plus direction of the tool
coordinate system.
When the [MOVE] + [-B (J5)] keys are pressed, Rotate in the minus direction.

・ When the [MOVE] + [+C (J6)] keys are pressed, The Z axis will rotate in the plus direction of the tool
coordinate system.
When the [MOVE] + [-C (J6)] keys are pressed, Rotate in the minus direction.

◇◆◇ When alarm No. 5150 occurs ◇◆◇

If alarm No. 5150 (ORIGIN NOT SET) occurs, the origin has not been set correctly. Reconfirm the value input for
the origin data.

◇◆◇ Tool length ◇◆◇

The default tool length is 0mm, and the control point is the center of the end axis.
After installing the hand, set the correct tool length in the parameters. Refer to the separate manual "Detailed
Explanation of Functions and Operations" for details.

2-26 Confirming the operation

 2Unpacking to Installation

(4) 3-axis XYZ jog operation

Select the 3-axis XYZ jog mode

XYZ456 LOW Press the [MOVE] + [XYZ] keys, and then

X +134.50 XYZ XYZ press only the [XYZ] key. "XYZ456" will appear
STEP
Y +220.00 MOVE
＋ at the upper left of the screen.
Z +280.00 3-axis XYZ jog mode $": $":

Each time the [MOVE] + [+] keys are pressed,

Set the jog speed the override will increase in the order of LOW
→ HIGH → 3 → 5 → 10 → 30 → 50 → 70 →
XYZ456 LOW 100%. When the [MOVE] + [-] keys are pressed,
X +134.50 the override will decrease in the reverse order.
STEP ＋ －
Y +220.00 ＋ FORWD The currently set speed will appear on the
MOVE BACKWD
Z +280.00 Set the soeed upper right of the screen. Set the override to
10% here for confirmation work.

Moving along the base coordinate system STEP +Z ＋Z

MOVE
＋ (J3)
8 , @\

＋Z

th
STEP -Y
le ng
＋ (J2)
ol
To
MOVE 4 MNO
STEP -X
MOVE
＋ (J1)
SPACE PQR

＋X
STEP +X ＋Y
＋ (J1) STEP +Y
MOVE ' ; ^ ＋ (J2)
MOVE 9 &< >

STEP -Z －Ｙ
MOVE
＋ (J3) －Ｘ
3 JKL

* The flange position does change. ＋X ＋Y

－Z

・ When the [MOVE] + [+X (J1)] keys are pressed, the robot will move along the X axis plus direction.
When the [MOVE] + [-X (J1)] keys are pressed, Move along the minus direction.

・ When the [MOVE] + [+Y (J2)] keys are pressed, the robot will move along the Y axis plus direction.
When the [MOVE] + [-Y (J2)] keys are pressed, Move along the minus direction.

・ When the [MOVE] + [+Z (J3)] keys are pressed, the robot will move along the Z axis plus direction.
When the [MOVE] + [-Z (J3)] keys are pressed, Move along the minus direction.

◇◆◇ Jog mode will change when only [XYZ] key is pressed again ◇◆◇
When the [MOVE] + [XYZ] keys are pressed and then only the [XYZ] key is pressed, the upper left display will
change in the order of "XYZ" → "XYZ456" → "CYLNDER". Each jog mode can be selected.

◇◆◇ The flange surface end axis posture cannot be maintained with 3-axis XYZ jog. ◇◆◇
With 3-axis XYZ jog, the flange surface end axis posture (orientation) is not maintained when moving linearly in
the X, Y or Z axis direction.
Use XYZ jog to maintain the posture.

Confirming the operation 2-27

2Unpacking to Installation

Changing the flange surface posture

STEP +C
＋ (J6)
MOVE 5 STU STEP -B
＋ (J5) STEP +A
J6 axis ＋
MOVE 1 DEF
＋ (J4)
＋ MOVE 7 YZ_
－ J4 axis
STEP -C －
＋ (J6)
MOVE 0 ABC

J5 axis －
＋ STEP -A
＋ (J4)
MOVE 2 GHI

STEP +B
＋ (J5)
MOVE 6 VWX

* The flange position changes.

This is the same as the J4, J5 and J6 axis JOINT jog operation.

・ When the [MOVE] + [+A (J4)] keys are pressed, the J4-axis will rotate in the plus direction.
When the [MOVE] + [-A (J4)] keys are pressed, Rotate in the minus direction.

・ When the [MOVE] + [+B (J5)] keys are pressed, the J5-axis will rotate in the plus direction.
When the [MOVE] + [-B (J5)] keys are pressed, Rotate in the minus direction.

・ When the [MOVE] + [+C (J6)] keys are pressed, the J6-axis will rotate in the plus direction.
When the [MOVE] + [-C (J6)] keys are pressed, Rotate in the minus direction.

2-28 Confirming the operation

 2Unpacking to Installation

(5) CYLNDER jog operation

Select the cylindrical jog mode

CYLNDER LOW Press the [MOVE] + [XYZ] keys, and then press
R +134.50 XYZ only the [XYZ] key. "CYLNDER" will appear at the
STEP
T +220.00 MOVE
＋ upper left of the screen.
Z +280.00 CYLNDER jog mode $":

Each time the [MOVE] + [+] keys are pressed, the

Set the jog speed override will increase in the order of LOW → HIGH
CYLNDER LOW → 3 → 5 → 10 → 30 → 50 → 70 → 100%. When
R +134.50 the [MOVE] + [-] keys are pressed, the override will
T +220.00
STEP ＋ － decrease in the reverse order. The currently set
＋ FORWD
Z +280.00
MOVE BACKWD speed will appear on the upper right of the screen.
Set the speed
Set the override to 10% here for confirmation work.

Moving along an arc centering on the Z axis

STEP +Z
MOVE
＋ (J3)
8 , @\
＋Z
Vertical

g th STEP -Y
l len ＋ (J2)
o MOVE 4 MNO
To
－ STEP -X
＋ (J1)
MOVE SPACE PQR
STEP +X
＋ (J1) ＋
MOVE ' ; ^ Radius Arc
STEP +Y
Control point MOVE
＋ (J2)
9 &< >

STEP -Z
＋ (J3)
MOVE 3 JKL －Ｙ
－Ｘ

＊ The direction of the frange will not change. ＋X ＋Y

－Z

Assuming that the current position is on an arc centering on the Z axis, the robot moves along that arc.
・ When the [MOVE] + [+Y (J2)] keys are pressed, the robot will move along the arc in the plus direction.
When the [MOVE] + [-Y (J2)] keys are pressed, Move in the minus direction.

・ When the [MOVE] + [+X (J1)] keys are pressed, the robot will expand in the radial direction.
When the [MOVE] + [-X (J1)] keys are pressed, Contract in the radial direction.

・ When the [MOVE] + [+Z (J3)] keys are pressed, the robot will move along the Z axis plus direction.
When the [MOVE] + [-Z (J3)] keys are pressed, Move along the minus direction.

Confirming the operation 2-29

2Unpacking to Installation

Changing the flange surface posture

＋Z
STEP -C STEP +C
＋ (J6) ＋ (J6)
MOVE 0 ABC ＋Z MOVE 5 STU

－ ＋

STEP +A
＋ (J4) th
MOVE 7 YZ_
l eng STEP -B
o l ＋ (J5)
＋ To
MOVE 1 DEF
－
＋X － ＋Y
STEP -A
＋
＋ (J4) STEP +B
MOVE 2 GHI ＋ (J5)
MOVE 6 VWX

Control point

* The flange position does not change. －Ｙ

－Ｘ
This is the same as the A, B and C axis XYZ jog operation.

＋X ＋Y
－Z

・ When the [MOVE] + [+A (J4)] keys are pressed, The X axis will rotate in the plus direction.
When the [MOVE] + [-A (J4)] keys are pressed, Rotate in the minus direction.

・ When the [MOVE] + [+B (J5)] keys are pressed, The Y axis will rotate in the plus direction.
When the [MOVE] + [-B (J5)] keys are pressed, Rotate in the minus direction.

・ When the [MOVE] + [+C (J6)] keys are pressed, The Z axis will rotate in the plus direction.
When the [MOVE] + [-C (J6)] keys are pressed, Rotates in the minus direction.

2-30 Confirming the operation

 3Installing the option devices

3 Installing the option devices

3.1 Installing the solenoid valve set (1S-VD01-02/VD02-02/VD03-02/VD04-02)

Socket bolt (M4×8, 4 bolts)

(Attached to the solenoid valve)

<4>Socket bolt Ｃ
(M4×8, 4 bolts)

<5>Solenoid valve

Ｂ
<3>No.2 arm cover C Remove

<2>No.2 arm cover B Section A

<1>No.2 arm cover A

No.1 solenoid valve GR7 GR5

No.2 solenoid valve GR3 B port

No.3 solenoid valve GR1 ２
４
６
No.4 solenoid valve ８
GR8

GR6 １
３
５
７
A port

<7>R port

GR4

GR2 <6>P port

Plate

View B View C
Fig.3-1 ： Solenoid valve installation procedures

Installing the solenoid valve set (1S-VD01-02/VD02-02/VD03-02/VD04-02) 3-31

3Installing the option devices

Fig. 3-1 and Fig. 3-2 shows the solenoid valve installation procedures and the solenoid valve connector
connection procedures. The installation procedures are as follow. This work must be carried out with the
controller power turned OFF.
1) Remove the hexagon socket bolts (five M4 x 10) and truss screw (three M3 x 8) that hold the No. 2 arm cover
B <2>, and then remove both the No. 2 arm cover B <2>.
2) Remove the socket bolts <4> (four M4 x 8) that hold the No. 2 arm cover C <3>, and then remove both the No.
2 arm cover C <3>.
3) If you are not using the spare line (ADD: stored in a coil) in section A shown in Fig. 3-1, remove it. The spare
line is connected to a connector inside section A.

Solenoid valve

Connector storage position Cut to an appropriate length

No.2 arm
View from No. 2 arm cover B side
Fig.3-2 ： Solenoid valve installation diagram details 1

4) The length of the two air hoses (φ6) stored in section A is longer than necessary by assuming the use of a
solenoid valve set not manufactured by Mitsubishi. Cut off the air hoses to an appropriate length, and connect
them to the couplings.
5) Of the two air hoses (φ6), the one marked with "AIR IN" is for connecting the quick coupling (P port) <6> of
the solenoid valves, and the other marked with "RETURN" is for connecting the quick coupling (R port) <7> of
the solenoid valves.
6) Using the screw holes of the No. 2 arm cover C <3>, mount the solenoid valves with the socket bolts (four M4
x 8) attached to the solenoid valves. When mounting the solenoid valves, be careful not to damage the sponge
sealing material attached to the opening of section A. If the sealing material is damaged, it may degrade the
protection specification.
7) Connect the connectors of GR1 to GR2 stored in section A to the plugs of GR1 to GR2 coming out of the
solenoid valves. Store the connectors near the location marked with ○ shown in Fig. 3-2. Fig. 3-2 shows a
view when stored.

3-32 Installing the solenoid valve set (1S-VD01-02/VD02-02/VD03-02/VD04-02)

 3Installing the option devices

No.2 arm R port Solenoid valve

P port

Air hose

Fig.3-3 ： Solenoid valve installation diagram details 2

8) When you have completed the installation, reinstall the No.2 arm cover B <2> to its original position, and be
careful not to entangle the cables when you do so.

The connections after the installation appear as in Table 3-1 for single type valves, hand 2 is not applicable.

Table 3-1 ： Solenoid valve ports and hoses: Correspondence of couplings and hand ports
Hand Hand port Solenoid valve port Solenoid valve used
OPEN A
Hand 1 First set
CLOSE B
OPEN A
Hand 2 Second set
CLOSE B
OPEN A
Hand 3 Third set
CLOSE B
OPEN A
Hand 4 Fourth set
CLOSE B

Installing the solenoid valve set (1S-VD01-02/VD02-02/VD03-02/VD04-02) 3-33

3Installing the option devices

3.2 Installing the hand input cable

The procedure for installing the hand input cable is as follows. Conduct work by referring to "Fig. 3-1Solenoid
valve installation procedures" on page 31 and "Fig. 3-4Installing the hand input cable" on page 34 below.
This work must be carried out with the controller power turned OFF.

<4> Socket bolts

（M4×8, 4 bolts）
Grommet

Remove D Remove D
Grommet
Plate

<5> Solenoid valves

<3> No. 2 arm cover C

Cable clamp

Lock nut Plate

HC1 HC2
View D
Fig.3-4 ： Installing the hand input cable

1) Remove the hexagon socket bolts (five M4 x 10) and truss screw (three M3 x 8) that hold the No. 2 arm cover
B <2>, and then remove both the No. 2 arm cover B <2>.
2) Remove the socket bolts <4> (four M4 x 8) that hold the No. 2 arm cover C <3> or the solenoid valves <5>,
and then remove the No. 2 arm cover C <3> or the solenoid valves <5>.
3) If you are not using the spare line (ADD: stored in a coil) in section A shown in Fig. 3-1, remove it. The spare
line is connected to a connector inside section A.
4) The hand input cable can be installed to both the No. 2 arm cover C <3> and the solenoid valves <5>.
5) Remove one of the two grommets on either the No. 2 arm cover C <3> or the solenoid valves <5>. After
removing the grommet, peal off the sealing material left on the hole section of the plate.
6) After removing the lock nut attached to the hand input cable, feed the connector side of the hand input cable
(with a cable clamp) through the hole on the plate. Replace the removed lock nut in position and fasten it
securely.
7) Connect the connectors of "HC1" and "HC2" stored in section A shown in Fig. 3-1 to "HC1" and "HC2" of
the hand input cable.
8) Mount the No. 2 arm cover C <3> or the solenoid valves <5> to section A shown in Fig. 3-1. When mounting,
be careful not to damage the sponge sealing material attached to the opening of section A.
9) When you have completed the installation, reinstall the No.2 arm cover B <2> to its original position, and be
careful not to entangle the cables when you do so.

3-34 Installing the hand input cable

 3Installing the option devices

3.3 Installing the hand output cable

The procedure for installing the hand output cable is as follows. Conduct work by referring to "Fig. 3-1Solenoid
valve installation procedures" on page 31 and "Fig. 3-5Installing the hand output cable" on page 35 below.
This work must be carried out with the controller power turned OFF.

<4> Socket bolts

（M4×8, 4 bolts）
Grommet

Remove D Remove D
Grommet
Plate

<5> Solenoid valves

<3> No. 2 arm cover C

Cable clamp

Lock nut Plate

GR1 GR2
View D
Fig.3-5 ： Installing the hand output cable

1) Remove the hexagon socket bolts (five M4 x 10) and truss screw (three M3 x 8) that hold the No. 2 arm cover
B <2>, and then remove both the No. 2 arm cover B <2>.
2) Remove the socket bolts <4> (four M4 x 8) that hold the No. 2 arm cover C <3> or the solenoid valves <5>,
and then remove the No. 2 arm cover C <3> or the solenoid valves <5>.
3) If you are not using the spare line (ADD: stored in a coil) in section A shown in Fig. 3-1, remove it. The spare
line is connected to a connector inside section A.
4) The hand output cable can be installed to both the No. 2 arm cover C <3> and the solenoid valves <5>.
However, if solenoid valves of three rows or more are used, it is not possible to install a hand output cable
separately because the hand output connectors (2 pcs.) in the forearm and the solenoid valves are already
connected.
5) Remove one of the two grommets on either the No. 2 arm cover C <3> or the solenoid valves <5>. After
removing the grommet, peal off the sealing material left on the hole section of the plate.
6) After removing the lock nut attached to the hand output cable, feed the connector side of the hand output
cable (with a cable clamp) through the hole on the plate. Replace the removed lock nut in position and fasten
it securely.
7) Connect the connectors of "GR1" and "GR2" stored in section A shown in Fig. 3-1 to "GR1" and "GR2" of
the hand output cable.
8) Mount the No. 2 arm cover C <3> or the solenoid valves <5> to section A shown in Fig. 3-1. When mounting,
be careful not to damage the sponge sealing material attached to the opening of section A.
9) When you have completed the installation, reinstall the No.2 arm cover B <2> to its original position, and be
careful not to entangle the cables when you do so.

Installing the hand output cable 3-35

3Installing the option devices

3.4 .Changing the operating range

The operating range of the J1 axis can be changed to the range shown in Table 3-2. (Option)

Table 3-2 ： Operating range alternative range

Axis Standard Alternative angle
Angle +170 +135 +90 +45 One of the points shown
+side on the left
Insertion position None Ａ Ｂ Ｃ
Ｊ １
Angle -170 -135 -90 -45 One of the points shown
-side on the left
Insertion position None a b c
Note) The insertion position given in the table indicates the insertion position for the operating range change
stopper. (Refer to Fig. 3-6.)

The operating range is changed with robot arm settings and parameter settings.

(1) Setting the robot arm

1) Move the upper arm to the posture as shown in Fig. 3-6 by jog operation.
2) Turn OFF the controller power.
3) By referring to Table 3-2 and Fig. 3-6, insert the two stoppers (M10 x 20) used to change the movement
range of J1 axis at the angular position to be changed, and fix securely by applying a clamping torque of 70
N ･ m to 86 N ･ m.

CAUTION Do not remove the stopper for the standard specification of ± 170 degree shown in
Fig. 3-6.

Type：1S-DH-02
Specification：
Hexagon socket bolt（2 bolts）
M10 x 20 plating
Strength classification 10.9
Detail of the stopper used to change
the operating range of the J1 axis

Upper arm

（c） （b）
Ａ Stopper for standard
specification of ±170 degree （a）
Front of robot

Ａ (M10 x 20, 1 bolt)

（Ａ）

（Ｃ） （Ｂ）

Robot arm View Ａ-Ａ

Fig.3-6 ： Installation of operating range change option

3-36 .Changing the operating range

 3Installing the option devices

(2) Setting the parameters

1) Change the values of the first element (J1 axis minus side) and second element (J1 axis plus side) of the joint
operating range parameter MEJAR. Set the value to the angle corresponding to the position where the
operating range change stopper was inserted in "(1)Setting the robot arm"above.
Refer to the separate "Instruction Manual/Detailed Explanation of Functions and Operations" for details on
changing the parameter.
2) When completed changing the parameters, turn the controller power OFF and ON. Move the waist axis to the
operating range limit with JOINT jog operation, and confirm that the limit over occurs and the robot stops at
the angle changed for both the +/- sides.

This completes setting the parameters and the changing of the operating range.

.Changing the operating range 3-37

4Basic operations

4 Basic operations
The basic operations from creating the program to automatic operation are explained in section "4. Basic
operations" in the "From Controller Setup to Maintenance" manual. Refer that manual as necessary.

4-38
 5Maintenance and Inspection

5 Maintenance and Inspection

The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are
described in this chapter. The types and replacement methods of consumable parts are also explained.

5.1 Maintenance and inspection interval

Maintenance and inspection are divided into the inspections carried out daily, and the periodic inspections carry
out at set intervals. Always carry these out to prevent unforeseen trouble, to maintain the product for a long time,
and to secure safety.

(1) Inspection schedule

In addition to the monthly inspection, add the following inspection items every three months (estimated at 500 Hr
operation hours).

０ Hr

Monthly inspection

Monthly inspection

５ ０ ０ Hr Monthly inspection 3-month inspection

Monthly inspection

Monthly inspection
Daily inspection

１ ０ ０ ０ Hr Monthly inspection 3-month inspection 6-month inspection

Monthly inspection

Monthly inspection

１ ５ ０ ０ Hr Monthly inspection 3-month inspection

Monthly inspection

Monthly inspection

２ ０ ０ ０ Hr Monthly inspection 3-month inspection 6-month inspection Yearly inspection

６ ０ ０ ０ Hr Monthly inspection 3-month inspection 6-month inspection Yearly inspection 3-year inspection

Operating time

<Guideline for inspection period>

For one shift
8 Hr/day × 20 days/month × 3 months = approx. 500 Hr
10 Hr/day × 20 days/month × 3 months = approx. 600 Hr
For two shifts
15 Hr/day × 20 days/month × 3 months = approx. 1000 Hr

[Caution] When using two lines, the 3-month inspection, 6-month inspection and yearly
inspection must be carried out when half the time has passed.
Fig.5-1 ： Inspection schedule

Maintenance and inspection interval 5-39

5Maintenance and Inspection

5.2 Inspection items

The inspection items for the robot arm are shown below.
Also refer to section "5. Maintenance and inspection" in the "Controller setup, basic operation, and maintenance"
manual, and inspect the controller.

5.2.1 Daily inspection items

Carry out the daily inspections with the procedures given in Table 5-1.

Table 5-1 ： Daily inspection items (details)

Procedure Inspection item (details) Remedies
Before turning power ON (Check the following items before turning the power ON.)
1 Are any of the robot installation bolts loose? Securely tighten the bolts.
(Visual)
2 Are any of the cover tightening screws loose? Securely tighten the screws.
(Visual)

3 Are any of the hand installation bolts loose? Securely tighten the bolts
(Visual)
4 Is the power supply cable securely connected? Securely connect.
(Visual)

5 Is the machine cable between the robot and controller securely Securely connect.
connected?
(Visual)

6 Are there any cracks, foreign contamination or obstacles on the robot Replace with a new part, or take remedial measures.
and controller cover?
7 Is any grease leaking from the robot arm? After cleaning, replenish the grease.
(Visual)
8 Is there any abnormality in the pneumatic system? Are there any air Drain the drainage, and remedy the air leaks (replace
leaks, drain clogging or hose damage? Is the air source normal? the part).
(Visual)

After turning the power ON (Turn the power ON while monitoring the robot.)
1 Is there any abnormal motion or abnormal noise when the power is Follow the troubleshooting section.
turned ON?

During operation (try running with an original program)

1 Check whether the movement points are deviated? Follow the troubleshooting section.
Check the following points if there is any deviation.
1. Are any installation bolts loose?
2. Are any hand installation section bolts loose?
3. Are the positions of the jigs other than the robot deviated?
4. If the positional deviation cannot be corrected, refer to
"Troubleshooting", check and remedy.
2 Is there any abnormal motion or abnormal noise? Follow the troubleshooting section.
(Visual)

5-40 Inspection items

 5Maintenance and Inspection

5.2.2 Periodic inspection

Carry out periodic inspection with the procedures given in Table 5-2.

Table 5-2 ： Periodic inspection items (details)

Procedure Inspection item (details) Remedies
Monthly inspection items
1 Are any of the bolts or screws on the robot arm loose? Securely tighten the bolts.

2 Are any of the connector fixing screws or terminal block terminal Securely tighten the screws.
screws loose?

3 Remove the cover at each section, and check the cables for wear Check and eliminate the cause.
damage and adherence of foreign matter. If the cables are severely damaged, contact the
Mitsubishi Service Department.
3-month inspection items

1 Is the timing belt tension abnormal? If the timing belt is loose or too tense, adjust it.
6-month inspection items
1 Is the friction at the timing belt teeth severe? If the teeth are missing or severe friction is found,
replace the timing belt.
Yearly inspection items
1 Replace the backup battery in the robot arm. Exchange it referring to "5.3.5Replacing the backup
battery" on page 51.
3-year inspection items
1 Lubricate the grease at the harmonic reduction gears for each axis. Lublicate it referring to "5.3.4Lubrication" on page 49.

Inspection items 5-41

5Maintenance and Inspection

5.3 Maintenance and inspection procedures

The procedures for carrying out the periodic maintenance and inspection are described in this section. Thoroughly
read the contents, and follow the instructions. This work can be commissioned to the Mitsubishi Service Depart-
ment for a fee. (Never disassemble, etc., the parts not described in this manual.)
The maintenance parts, etc., required for the customer to carry out maintenance and inspection are described in
"5.4Maintenance parts" on page 52 of this manual. Always contact your dealer when parts are needed.

CAUTION The origin of the machine system could deviate when this work is carried out.
"Review of the position data" and "re-teaching" will be required.

5.3.1 Robot arm structure

An outline structure drawing is shown in . Each part is as shown below.
1) The J1 axis rotation is driven by the J1 axis motor <1> and reduction gears <2> arranged in the base.
Non-excitation magnetic brakes are mounted in the J1axis motor <1>.

2) The J2 axis rotation is driven by the J2 axis motor <3> and reduction gears <4> arranged in the shoulder.
Non-excitation magnetic brakes are mounted in the J2 axis motor <3>.

3) The J3 axis rotation is driven by the J3 axis motor <5> and reduction gears <6> arranged in the shoulder.
Non-excitation magnetic brakes are mounted in the J3 axis motor <5>.

4) The J4 axis rotation is driven by the J4 axis motor <7> and reduction gears <8> arranged in the elbow block.
Non-excitation magnetic brakes are mounted in the J4 axis motor <7>.

5) The rotation of the J5 axis motor <9> arranged in the forearm is conveyed to the reduction gears <11> via
the timing belt <10> to rotate the wrist housing and following parts.
Non-excitation magnetic brakes are mounted in the J5 axis motor <9>.

6) The rotation of the J6 axis is driven by the J6 axis motor <12> arranged in the wrist housing and the reduc-
tion gears <13>.
Non-excitation magnetic brakes are mounted in the J6 axis motor <12>.

5-42 Maintenance and inspection procedures

 5Maintenance and Inspection

<7>J4 axis motor

<8>J6 axis <5>J3 axis motor
reduction gear
<9>J5 axis motor Elbow

Fore arm
<12>J6 axis motor
<13>J6 axis
reduction gear
<6>J3 axis
reduction gear

<10>J5 axis timing belt

<11>J5 axis
Wrist housing reduction gear Upper arm

<2>J1 axis
reduction gear
Shoulder

<3>J2 axis motor

<4>J2 axis
reduction gear

<1>J1 axis motor

Fig 5-2 ： Outline structure of robot arm

Maintenance and inspection procedures 5-43

5Maintenance and Inspection

5.3.2 Installing/removing the cover

（a）
（f） 6. No. 2 arm cover C
（a）
（b）
9. Wrist cover
（c）
（g） 5. Elbow cover A
（d）

2. Shoulder cover B
8. No. 2 arm cover B

4. Shoulder cover

（d）

（h） （ｇ）

（b）

7. No. 2 arm cover A

（e）

3. No. 1 arm cover

1. Bottom plate

（i）

Fig.5-3 ： Installing/removing the cover

CAUTION Check to see that the packing has not been peeled off when the cover was
mounted/removed. If it has been peeled off, report to dealer. If the cover is used
with the packing peeled off, oil mist and others may enter inside the arm and
cause a breakdown.

5-44 Maintenance and inspection procedures

 5Maintenance and Inspection

Table 5-3 ： Cover names

No. Cover names Qty. Remarks
1 Bottom plate １
2 Shoulder cover B １

3 No. 1 arm cover １

4 Shoulder cover 2
5 Elbow cover A 1

6 No. 2 arm cover C １

7 No. 2 arm cover A １
8 No. 2 arm cover B １
9 Wrist cover １

Table 5-4 ： Cover installation screw list

No. Installation screw name Q'ty Remarks

a Socket bolt M4 × 8 8
b Socket bolt M4 × 10 10

c Socket bolt M4 × 30 4
d Socket bolt M4 × 55 8
e Truss screw M4 × 8 8 RV-6S

10 RV-6SL
f Truss screw M4 × 8 4
g Truss screw M4 × 8 5

h Truss screw M3 × 10 2
i Flat head screw M4 × 8 4

(1) Refer to Fig. 5-3 and remove the cover.

(2) The names of the covers are given in Table 5-3, and a list of the cover installation screws is given in Table 5-4.
(3) There are some covers that may be difficult to remove due to the robot posture. In this case, change the robot
posture with jog operation, and then remove the cover.
(4) When attaching the cover after maintenance and inspection, use the detaching procedure in reverse.

The part Nos. and symbols in Table 5-3 and Table 5-4 correspond to Fig. 5-3.

Maintenance and inspection procedures 5-45

5Maintenance and Inspection

5.3.3 Inspection, maintenance and replacement of timing belt

This robot uses a timing belt for the drive conveyance system of the J5 axis. Compared to gears and chains, the
timing belt does not require lubrication and has a low noise. However, if the belt usage method and tension adjust-
ment are inadequate, the life could drop and noise could be generated. Sufficient aging to remove the initial elon -
gation of the belt, and adjustment of the belt tension have been carried out before shipment from the factory.
However, depending on the robot working conditions, elongation will occur gradually over a long time. The tension
must be confirmed during the periodic inspection. The timing belt must be replaced in the following cases.

(1) Timing belt replacement period

The timing belt life is greatly affected by the robot working conditions, so a set time cannot be given. However, if
the following symptoms occur, replace the belt.
1) When cracks from at the base or back of the belt teeth.
2) When the belt expands due to adherence of oil, etc.
3) When the belt teeth wear (to approx. half of the tooth width).
4) When the belt teeth jump due to belt teeth wear.
5) When the belt snaps.

CAUTION Due to the manufacturing of the timing belt, initial wear will occur. Wear chips may
accumulate in the cover after approx. 300 Hr of operating the robot, but this is not a
fault. If the wear chips appear soon after wiping them off, replace the belt.

CAUTION When the belt is replaced, the machine system origin may deviate. In this case, the
position data must be reviewed.

5-46 Maintenance and inspection procedures

 5Maintenance and Inspection

(2) Inspection, maintenance and replacement of J5-axis timing belt

<3>Motor

<2>Timing belt

<1>Motor installation bolt

Mark M4×12（Socket bolt）
<5>Timing pulley
<4>Timing pulley
Fig.5-4 ： Inspection, maintenance and replacement of J5-axis timing belt

■ Inspecting the J5 axis timing belt

1) Confirm that the robot controller power is OFF.
2) Refer to "5.3.2Installing/removing the cover" on page 44, and remove the No. 2 arm cover A.
3) Visually confirm that the symptoms indicated in "(1)Timing belt replacement period" have not occurred with the
timing belt.
4) Confirm that the belt tension is adjusted to slacken approx. 2.3mm when the center of the belt is lightly pressed
with a finger (approx. 1.3N) as shown in "Fig.5-5 ： Belt tension".
■ Adjusting the J5 axis timing belt
1) Carry out steps "1)" and "2)" indicated in " ■ Inspecting the J5 axis timing belt" above.
2) Lightly loosen the two installation bolts <1>. (Do not loosen too much.)
3) Move the motor <3> in the directions of the arrows shown in Fig. 5-4, using the tension adjustment screw while
checking the tension of the timing belt <2>. Lightly pushing the center of the belt with your finger (approxi-
mately 1.3 N), move the motor to the position where the belt flexes about 2.3 mm.
4) The belt tension will increase when moved in the direction of arrow "a", and will decrease when moved in the
direction of arrow "b".
5) If the belt is loosened too much when adjusting the tension causing it to come off the timing pulleys <4> and
<5>, or if the belt and pulley teeth engagement is deviated, the machine system's origin will deviate.
6) After adjusting, securely tighten the two motor installation bolts <1>. Improper tightening can cause the belt to
loosen with vibration.
■ Replacing the J5 axis timing belt
1) Fig. 5-4 shows the methods for inspecting, adjusting and replacing the timing belt.
2) Move the robot posture with the teaching pendant so that the J5 axis may be downward.(Turn it to the direc-
tion of gravity.)
3) Make sure that the pulleys do not move while replacing the belt.
4) If the pulley <4> and <5> position relation deviates, the position could deviate.
5) Make marks on the timing belt <2> and timing pulleys <4> and <5> with a felt-tip pen as shown in Fig. 5-4 so
that the engagement of the timing belt <2> and timing pulleys <4> and <5> does not deviate.
6) Loosen the two motor installation screws <1>, and remove the belt.
7) Copy the marks onto the new timing belt. Make sure that both belts are tense when making the marks.
8) Align the new timing belt with the marks on the timing pulleys <4> and <5>, and install.
9) Refer to steps "3)" to "6)" in " ■ Adjusting the J5 axis timing belt" and "(3)Timing belt tension" to adjust the
tension.
10) The position could deviate after the belt is replaced. Confirm that the position has not deviated. If deviated,
refer to "5.5Resetting the origin" on page 53, and reset the origin position.

Maintenance and inspection procedures 5-47

5Maintenance and Inspection

(3) Timing belt tension

ｆ ： Pressing force
ｓ ： Span
f ｄ ： Slack

Axis Belt type Span ： s (mm) Slack ： d (mm) Pressing force ： f (N)

J5 393-3GT-4 145 2.3 1.3

Fig.5-5 ： Belt tension

The timing belt can satisfactorily convey the drive and keep a durable force only when it has an adequate tension.
The belt tension should not be too tight or too lose. Instead, it should be adjusted to a degree that elasticity is felt
when the belt is pressed with the thumb. If the belt tension is too weak, the belt loosening side will vibrate. On the
other hand, if the belt tension is too strong, a sharp sound will be heard and the belt tension side will vibrate.
The detailed adjustment (tension) is shown in Fig. 5-5.
Check and adjust with the belt pressing force f and the slack amount d between span s.

5-48 Maintenance and inspection procedures

 5Maintenance and Inspection

5.3.4 Lubrication
(1) Lubrication position and specifications

4. J4 axis
lubrication port

J4 axis drain bolt (M4)

5. J5 axis
J6 axis drain plug (M3) lubrication port

6. J6 axis
lubrication port

J5 axis drain bolt (M3)

3. J3 axis
lubrication port

J3 axis drain bolt (M4)

J2 axis drain bolt (M4)
A

1. J1 axis
lubrication port

2. J2 axis
lubrication port J1 axis drain bolt (M4)

View from A
Fig.5-6 ： Lubrication positions

Maintenance and inspection procedures 5-49

5Maintenance and Inspection

Table 5-5 ： Lubrication specifications

Oiling Lubrication oil Default charge Lubrication Lubrication
No. Parts to be lubricated Cover to remove
method (maker) amount interval amount

1 J1 axis reduction gears 60g 14g Shoulder cover B

Grease
2 J2 axis reduction gears nipple 60g 14g No.1 arm cover
WA-610 Grease
3 J3 axis reduction gears Harmonic grease SK-1A 40g 8g No.1 arm cover
6000Hr
4 J4 axis reduction gears Grease （Japan Harmonic 16g 4g
nipple Systems）
5 J5 axis reduction gears WB-610 10g 2g Wrist cover
6 J6 axis reduction gears 10g 2g Wrist cover

The grease nipple position is shown in Fig. 5-6. The lubrication specifications for each place are shown in Fig. 5-6
［Caution］
・ The brands of grease given in Table 5-5 are those filled when the robot is shipped.
・ The lubrication time is a cumulative value of the operation at the maximum speed. If the operation has been
suspended, or if the designated speed is slow, the lubrication time can be lengthened in proportion.
(The "Lubrication interval " in Table 5-5 is usually based on the three-year inspection. 8Hr x 20 days x 36
months = 6000Hr.）
・ Depending on the robot operation state, the lubrication time will fluctuate, so determine the time according to
the state so that the grease does not run out.
・ With the maintenance forecast function of the personal computer support software (option), the guidance of
lubrication time is calculated according to the operating environment of the customer.
・ The numbers in the correspond to the supply positions in Fig. 5-6.
・Avoid excessive lubrication since it may lead to grease leak. Also, the number of lubrications is limited to 3 times.

(2) Lubrication method

1) Set the robot to the posture shown in Fig. 5-6.
2) Refer to the "5.3.2Installing/removing the cover" on page 44 and remove the covers.
3) Remove the drain bolt or plug.
4) Insert the grease shown in Table 5-5 using a grease gun from the lubrication grease nipple.
5) Install the drain bolt or plug.
6) Replace the covers with the removal procedure in reverse.

5-50 Maintenance and inspection procedures

 5Maintenance and Inspection

5.3.5 Replacing the backup battery

An absolute encoder is used for the position detector, so the position must be saved with the backup battery
when the power is turned OFF. The controller also uses a backup battery to save the program, etc. These
batteries are installed when the robot is shipped from the factory, but as these are consumable parts, they must
be replaced periodically by the customer.
The guideline for replacing the battery is one year, but this will differ according to the robot's usage state. When
the battery life nears, the "Battery cumulative time over alarm (Alarm No. 7520)" will occur. Once the alarm
occurs, replace all batteries in the robot arm and controller as soon as possible. Lithium batteries (type: A6BAT
and ER6) are used in both the controller and robot arm.

(1) Replacing the robot arm battery

Don't disconnect connector, etc. While replacing the battery, the encoder position
CAUTION data is saved by the power supplied from the controller. Thus, if the cable
connection is incomplete, the encoder position data will be lost when the controller
power is turned OFF. Several batteries are used in the robot arm, but replace all old
batteries with new batteries at the same time.

<3>Connector box

<2>Installation screw

<1>Battery cover Battery

Lead connector
Fig.5-7 ： Replacing the battery

1) Confirm that the robot arm and controller are connected with a cable.
2) Turn the controller control power ON.
The position data is retained by the power supplied from the controller while replacing the battery. Thus, if
the cable is not connected correctly, or if the controller power is OFF, the position data will be lost.
3) Press the emergency stop button to set the robot in the emergency stop state. This is a measure for safety,
and must always be carried out.
4) Remove the two installation screws<2>, and remove the battery cover <1>.
5) The battery holder is located in the connector box <3>. Remove the old battery from the holder, and discon-
nect the lead connector.
6) Insert the new battery into the holder, and connect the lead connector. Replace all batteries with new ones
at the same time.
7) Carry out steps 4) in reverse to install the parts.
8) Initialize the battery consumption time.
Always carry out this step after replacing the battery, and initialize the battery usage time. Refer to the
separate "Instruction Manual/Detailed Explanation of Functions and Operations" for details on the opera-
tion methods.
[Caution] If the old battery is replaced because it has been used up, it is necessary to set the origin again. Refer
to "5.5Resetting the origin" on page 53 and reset the origin using the jig method or ABS origin method.

Maintenance and inspection procedures 5-51

5Maintenance and Inspection

5.4 Maintenance parts

The consumable parts that must be replaced periodically are shown in Table 5-6, and spare parts that may be
required during repairs are shown in Table 5-7. Purchase these parts from the dealer when required. Some Mit-
subishi-designated parts differ from the maker's standard parts. Thus, confirm the part name, robot arm and con-
troller serial No. and purchase the parts from the dealer.

Table 5-6 ： Consumable part list

No. Part name Type Usage place Q'ty Supplier
1 Timing belt 393-3GT-4 J5 axis 1
M434N4
Mitsubishi Electric
2 Grease SK-1A Reduction gears of each axis An needed
3 Lithium battery A6BAT In battery cover 5

Table 5-7 ： Spare parts list

No. Part name Type Usage place Q'ty Supplier
1 AC servo motor BU240C011G55 J1 axis 1
2 BU240C011G56 J2 axis 1
3 BU240C011G57 J3 axis １
4 BU240C011G58 J4 axis １
Mitsubishi Electric
5 BU240C010G53 J5 axis １
6 BU240C010G54 J6 axis １
7 Stopper BU224D594H01 Mechanical stoppers of the J1 to J3
2 per axis
axes
RV-6S/RV-6SC
8 Reduction gears P961K000P68 J1 axis 1
9 P961K000P51 J2 axis 1
10 P961K000P72 J3 axis １
Mitsubishi Electric
11 P961K000P63 J4 axis １
12 P961K000P76 J5 axis １
13 P961K000P75 J6 axis １
RV-6SL/RV-6SLC
14 Reduction gears P961K000P69 J1 axis 1
15 P961K000P53 J2 axis 1
16 P961K000P73 J3 axis １
Mitsubishi Electric
17 P961K000P63 J4 axis １
18 P961K000P76 J5 axis １
19 P961K000P75 J6 axis １
Note) Confirm the robot arm serial No., and contact the dealer for the type.

5-52 Maintenance parts

 5Maintenance and Inspection

5.5 Resetting the origin

The origin is set so that the robot can be used with a high accuracy. After purchasing the robot, always carry out
this step before starting work. The origin must be reset if the combination of robot and controller being used is
changed or if the motor is changed causing an encoder area. The types of origin setting methods are shown in
Table 5-8.
[Caution] If the old battery is replaced because it has been used up, it is necessary to set the origin again.Reset
the origin using the jig method or ABS origin method.
.
Table 5-8 ： Origin setting method
No Method Explanation Remarks
1 Origin data input The origin data set as the default is input from The setting method is explained in "2.3Setting the
method the T/B. origin" on page 12 .
2 Jig method The origin posture is set with the calibration jig The setting method is explained in "5.5.1Jig method" on
installed. page 54 .
3 User origin method A randomly designated position is set as the Before using this method, the origin must be set with the
origin posture. other method.
The setting method is explained in "5.5.2User origin
method" on page 61.
4 ABS origin method This method is used when the encoder backup Before using this method, the origin must be set with the
data lost in the cause such as battery cutting. other method with same encoder. The setting method is
explained in "5.5.3ABS origin method" on page 63.
Note) Although "OP setting" by the mechanical stopper method can also be selected, it is not recommended for
this robot. Please use one of the methods listed in Table 5-8.

Resetting the origin 5-53

5Maintenance and Inspection

5.5.1 Jig method

The procedure of setting the origin with the calibration jig is shown below.
This operation is carried out with the teaching pendant. Set the [MODE] switch on the front of the controller to
"TEACH", and set the [ENABLE/DISABLE] switch on the teaching pendant to "ENABLE" to enable the teaching
pendant.

The following operation is carried out while lightly pressing the deadman switch on the teaching pendant.
<MENU> <MAINT>
1) Press the [5] key on the Menu screen to select
1.TEACH 2.RUN 1.PARAM 2.INIT
the Maintenance screen.
3.FILE 4.MONI 3.BRAKE 4.ORIGIN
5.MAINT 6.SET 5.POWER
+C
(J6)
5 STU
Select the maintenance screen
<MAINT> <ORIGIN>
1.PARAM 2.INIT 1.DATA 2.MECH 2) Press the [4] key to select the Origin Setting
3.BRAKE 4.ORIGIN 3.JIG 4.ABS screen.
5.POWER 5.USER
-Y
(J2)
4 MNO
Select the Origin Setting screen

<ORIGIN> <TOOL>
1.DATA 2.MECH SERVO OFF
OK ? (1) 3) Press the [3] key to select the jig method. Then,
3.JIG 4.ABS
1:EXECUTE press the [1] key and the [INP] key to turn the
5.USER
servo OFF.
-Z -B INP Then, cancel the brake of each axis, move the
(J3) → (J5) → EXE arm with both hands, and secure it with the OP
Select the jig method 3 JKL 1 DEF
jig.

CAUTION At this point release the brakes and move the arm with both hands.
To ensure safety, the brake-release procedure described below should always be
done by two persons.

5-54 Resetting the origin

 5Maintenance and Inspection

(1) J1 axis origin setting

<TOOL> 12345678 1) Move the J1 axis slowly toward the front using
BRAKE (00000000) both hands. Align the pinhole of the No.1 arm
SET AXIS (11110000) and the pinhole at the base section, feed
-B
ORIGIN :NOT DEF (J5) through the origin jig (φ8) into the pinholes and
Designate the origin setting axis 1 DEF fasten.

Pinhole (J1 axis)

Diagram of the robot viewed from the top

RPL
2) Press the [ ↓ ] key. The cursor will move to
↓ "SET AXIS".
Move the cursor

<TOOL> 12345678 3) Designate the axis for which the origin is to be

BRAKE (00000000) set.. Set "1" for the 1 axis, and set "0" for the
SET AXIS (10000000) other axes. Then, press [INP] key. Next, a
ORIGIN :NOT DEF -B -C INP
confirmation screen will appear.
(J5) ・ (J6) → EXE
Designate the origin setting axis 1 DEF 0 ABC

4) Press the [1] and [INP] keys.

<TOOL> The origin posture will be set.
SET ORIGIN
OK?(1)
-B INP
1:EXECUTE (J5) → EXE
Set the origin 1 DEF 5) Setting of the origin is completed.

<TOOL> 12345678
BRAKE (00000000) 6) Refer to "5.5.4Recording the origin data" on
SET AXIS (10000000) page 65 in this manual, and record the origin data
ORIGIN :COMPLETED on the origin data seal.

◇◆◇ Origin setting axis designation ◇◆◇

Move the cursor to the "SET AXIS" axis No. in the origin setting with the [ ← ] or [ → ] key.
The origin is set only for the axis for which a "1" is displayed on the screen. If the origin is not to be set, press
the [0] key and display a "0".

Resetting the origin 5-55

5Maintenance and Inspection

(2) J2 axis origin setting

<TOOL> 12345678
BRAKE (00000000)
SET AXIS (11110000)
-B 1) Slowly rotate the J2 axis in the direction of
ORIGIN :NOT DEF
(J5) minus 90° with both hands. Align the pinholes
Designate the origin setting axis 1 DEF
of the No. 1 arm and shoulder, feed through the
origin jig (φ8) into the pinholes and fasten.

Pinhole (J2 axis)

RPL
↓
Move the cursor

<TOOL> 12345678 2) Press the [ ↓ ] key. The cursor will move to

BRAKE (00000000) "SET AXIS".
SET AXIS (01000000)
-B -C INP
ORIGIN :NOT DEF (J5) ・ (J6) → EXE
Designate the origin setting axis 1 DEF 0 ABC 3) Designate the axis for which the origin is to be
set.. Set "1" for the 2 axis, and set "0" for the
other axes. Then, press [INP] key. Next, a
confirmation screen will appear.
<TOOL>
SET ORIGIN
OK?(1)
-B INP
1:EXECUTE 4) Press the [1] and [INP] keys.
(J5) → EXE
Set the origin 1 DEF The origin posture will be set.

<TOOL> 12345678
BRAKE (00000000) 5) Setting of the origin is completed.
SET AXIS (01000000)
ORIGIN :COMPLETED
6) Refer to "5.5.4Recording the origin data" on
page 65 in this manual, and record the origin data
on the origin data seal.

◇◆◇ Origin setting axis designation ◇◆◇

Move the cursor to the "SET AXIS" axis No. in the origin setting with the [ ← ] or [ → ] key.
The origin is set only for the axis for which a "1" is displayed on the screen. If the origin is not to be set, press
the [0] key and display a "0".

5-56 Resetting the origin

 5Maintenance and Inspection

(3) J3 axis origin setting

<TOOL> 12345678
BRAKE (00000000)
SET AXIS(11110000)
-B 1) Slowly rotate the J3 axis to the plus direction
ORIGIN :NOT DEF
(J5) with both hands. Align the pinholes of the No. 1
Designate the origin setting axis 1 DEF
and No. 2 arm, feed through the origin jig (φ8)
into the pinholes and fasten.

Pinhole (J3 axis)

RPL
↓
Move the cursor

<TOOL> 12345678 2) Press the [ ↓ ] key. The cursor will move to

BRAKE (00000000) "SET AXIS".
SET AXIS (00100000)
-B -C INP
ORIGIN :NOT DEF (J5) ・ (J6) → EXE
Designate the origin setting axis 1 DEF 0 ABC 3) Designate the axis for which the origin is to be
set.. Set "1" for the 3 axis, and set "0" for the
other axes. Then, press [INP] key. Next, a
confirmation screen will appear.
<TOOL>
SET ORIGIN
OK?(1)
-B INP
1:EXECUTE 4) Press the [1] and [INP] keys.
(J5) → EXE
Set the origin 1 DEF The origin posture will be set.

<TOOL> 12345678
BRAKE (00000000) 5) Setting of the origin is completed.
SET AXIS (00100000)
ORIGIN :COMPLETED
6) Refer to "5.5.4Recording the origin data" on
page 65 in this manual, and record the origin data
on the origin data seal.

◇◆◇ Origin setting axis designation ◇◆◇

Move the cursor to the "SET AXIS" axis No. in the origin setting with the [ ← ] or [ → ] key.
The origin is set only for the axis for which a "1" is displayed on the screen. If the origin is not to be set, press
the [0] key and display a "0".

Resetting the origin 5-57

5Maintenance and Inspection

(4) J4 axis origin setting

<TOOL> 12345678
BRAKE (00000000)
SET AXIS(11110000)
-B 1) Slowly rotate the J4 axis to the plus direction
ORIGIN :NOT DEF
(J5) with both hands. Align the pinholes of the No. 2
Designate the origin setting axis 1 DEF
arm and elbow , feed through the origin jig (φ6)
into the pinholes and fasten.

Pinhole (J4 axis)

RPL
↓
Move the cursor

<TOOL> 12345678 2) Press the [ ↓ ] key. The cursor will move to

BRAKE (00000000) "SET AXIS".
SET AXIS (00010000)
-B -C INP
ORIGIN :NOT DEF (J5) ・ (J6) → EXE
Designate the origin setting axis 1 DEF 0 ABC 3) Designate the axis for which the origin is to be
set.. Set "1" for the 4 axis, and set "0" for the
other axes. Then, press [INP] key. Next, a
confirmation screen will appear.
<TOOL>
SET ORIGIN
OK?(1)
-B INP
1:EXECUTE 4) Press the [1] and [INP] keys.
(J5) → EXE
Set the origin 1 DEF The origin posture will be set.

<TOOL> 12345678
BRAKE (00000000) 5) Setting of the origin is completed.
SET AXIS (00010000)
ORIGIN :COMPLETED
6) Refer to "5.5.4Recording the origin data" on
page 65 in this manual, and record the origin data
on the origin data seal.

◇◆◇ Origin setting axis designation ◇◆◇

Move the cursor to the "SET AXIS" axis No. in the origin setting with the [ ← ] or [ → ] key.
The origin is set only for the axis for which a "1" is displayed on the screen. If the origin is not to be set, press
the [0] key and display a "0".

5-58 Resetting the origin

 5Maintenance and Inspection

(5) J5 axis origin setting

<TOOL> 12345678
BRAKE (00000000)
SET AXIS(11110000)
-B 1) Slowly rotate the J5 axis in the direction of plus
ORIGIN :NOT DEF
(J5) 90° with both hands. Align the pinholes of the
Designate the origin setting axis 1 DEF
No. 2 arm and wrist housing , feed through the
origin jig (φ6) into the pinholes and fasten.
Pinhole (J5 axis)

RPL
↓
Move the cursor

<TOOL> 12345678 2) Press the [ ↓ ] key. The cursor will move to

BRAKE (00000000) "SET AXIS".
SET AXIS (00001000)
-B -C INP
ORIGIN :NOT DEF (J5) ・ (J6) → EXE
Designate the origin setting axis 1 DEF 0 ABC 3) Designate the axis for which the origin is to be
set.. Set "1" for the 5 axis, and set "0" for the
other axes. Then, press [INP] key. Next, a
confirmation screen will appear.
<TOOL>
SET ORIGIN
OK?(1)
-B INP
1:EXECUTE 4) Press the [1] and [INP] keys.
(J5) → EXE
Set the origin 1 DEF The origin posture will be set.

<TOOL> 12345678
BRAKE (00000000) 5) Setting of the origin is completed.
SET AXIS (00001000)
ORIGIN :COMPLETED
6) Refer to "5.5.4Recording the origin data" on
page 65 in this manual, and record the origin data
on the origin data seal.

◇◆◇ Origin setting axis designation ◇◆◇

Move the cursor to the "SET AXIS" axis No. in the origin setting with the [ ← ] or [ → ] key.
The origin is set only for the axis for which a "1" is displayed on the screen. If the origin is not to be set, press
the [0] key and display a "0".

Resetting the origin 5-59

5Maintenance and Inspection

(6) J6 axis origin setting

<TOOL> 12345678
BRAKE (00000000)
SET AXIS(11110000)
-B 1) Slowly move the J6 axis with both hands, and
ORIGIN :NOT DEF
(J5) align the ABS mark of the wrist housing with the
Designate the origin setting axis 1 DEF
ABS mark of the hand mounting flange.

ABS mark

J6 axis
Bolt (M5: 2 bolts)
Prepared by customer

CAUTION The J6-axis dose not have

a mechanical stopper.
When setting the origin
position , do not rotate the
axis more than themotion
range( ± 200 deg.).
RPL
↓
Move the cursor 2) Press the [ ↓ ] key. The cursor will move to
"SET AXIS".
<TOOL> 12345678
BRAKE (00000000)
SET AXIS (00000100) 3) Designate the axis for which the origin is to be
-B -C INP
ORIGIN :NOT DEF set.. Set "1" for the 6 axis, and set "0" for the
(J5) ・ (J6) → EXE
Designate the origin setting axis 1 DEF 0 ABC other axes. Then, press [INP] key. Next, a
confirmation screen will appear.

<TOOL>
SET ORIGIN
OK?(1) 4) Press the [1] and [INP] keys.
-B INP
1:EXECUTE The origin posture will be set.
(J5)
1 DEF
→ EXE
Set the origin

<TOOL> 12345678 5) Setting of the origin is completed.

BRAKE (00000000)
SET AXIS (00000100)
ORIGIN :COMPLETED 6) Refer to "5.5.4Recording the origin data" on
page 65 in this manual, and record the origin data
on the origin data seal.

◇◆◇ Origin setting axis designation ◇◆◇

Move the cursor to the "SET AXIS" axis No. in the origin setting with the [ ← ] or [ → ] key.
The origin is set only for the axis for which a "1" is displayed on the screen. If the origin is not to be set, press
the [0] key and display a "0".

This completes the setting of the origin with the jig method.

5-60 Resetting the origin

 5Maintenance and Inspection

5.5.2 User origin method

CAUTION Before using this method, the origin must be set with the other method.
The setting method is explained in "5.5.2User origin method" on page 61.

The procedure for setting the origin with the user origin method is explained below.
This operation is carried out with the teaching pendant. Set the [MODE] switch on the front of the controller to
"TEACH", and set the [ENABLE/DISABLE] switch on the teaching pendant to "ENABLE" to enable the teaching
pendant.
The operation method is shown below.

When setting the origin for the first time using this method, carry out the operations in order from step 1). For the
second and following time, move the robot arm to the user origin position with jog operation, and accurately posi-
tion all axes. Then start the procedure from step 4).

1) Determine the user origin position

Move the robot to the position to be set as the origin with jog operation. Refer to "2.4Confirming the opera-
tion" on page 18 for details on the jog operation.

CAUTION Choose the user origin position as the position where it doesn't move by the gravity.
This position is left as a guideline to position all axes with jog operation when setting
the origin again with this method.

2) Enter the JOINT jog mode, and display the joint coordinates on the teaching pendant screen. Record the
value of the axis for which the origin is to be set.
3) Input the value recorded in the "user designated origin parameter (USRORG)".
The parameter details and input methods are described in the separate "Instruction Manual/Detailed Explana-
tion of Functions and Operations". Refer to that manual and input the user designated origin position.

<MENU> <MAINT> 4) Next, set the origin.

1.TEACH 2.RUN 1.PARAM 2.INIT Press the [MENU] key to display the Menu
3.FILE 4.MONI 3.BRAKE 4.ORIGIN screen.
5.MAINT 6.SET 5.POWER 5) Press the [5] key to display the Maintenance
screen.
+C
(J6)
Display the maintenance screen 5 STU

6) Press the [4] key to select the Origin Setting

<MAINT> <ORIGIN> screen.
1.PARAM 2.INIT 1.DATA 2.MECH
3.BRAKE 4.ORIGIN 3.JIG 4.ABS
5.POWER 5.USER

-Y
(J2)
Display the origin setting method selection screen 4 MNO
7) Press the [5] key to select the user origin
<ORIGIN> <USER> method.
1.DATA2.MECH SERVO OFF Then, press [1] key and [INP] key to turn OFF
3.JIG4.ABS OK ? ( ) the servo.
5.USER 1:EXECUTE

Resetting the origin 5-61

5Maintenance and Inspection

<USER> 12345678 <USER> 8) Press the [ ↓ ] key, and input "1" for the axis
BRAKE (00000000) CHANGES TO ORIGIN for which the origin is to be set. Press the [INP]
SET AXIS (11111100) OK?( ) key to display the Confirmation screen.
ORIGIN:NOT DEF 1:EXECUTE

RPL -B INP
↓ → (J5) → EXE
Designate the origin setting axis 1 DEF

<USER> <USER>12345678 9) Press the [1] key and then the [INP] key. The
CHANGES TO ORIGIN BRAKE (00000000) origin will be set
OK?(1) SET AXIS(11111100)
1:EXECUTE ORIGIN :NOT DEF
-B INP
(J5) → EXE
Set the origin 1 DEF

This completes the setting of the origin with the user origin method.

5-62 Resetting the origin

 5Maintenance and Inspection

5.5.3 ABS origin method

When the origin setting of the robot is performed for the first time, this product records the angular position of the
origin within one rotation of the encoder as the offset value. If the origin setting is performed according to the
ABS origin method, this value is used to suppress variations in the origin setting operations and to reproduce the
initial origin position accurately.

This operation is carried out with the teaching pendant. Set the [MODE] switch on the front of the controller to
"TEACH", and set the [ENABLE/DISABLE] switch on the teaching pendant to "ENABLE" to enable the teaching
pendant.
First, set to the ABS mark arrow of the axis for which the origin is to be set with jog operation. This can be set for
all axes simultaneously or each axis independently.
When setting the ABS mark, always view the operations from the mark, and set at the end of the triangular mark.
The positions where the ABS mark is attached are shown in Fig. 5-28. Refer to "(1)JOINT jog operation" on page
21" for details on the jog operation.

J4 axis

A
J3 axis

View A
J6 axis

J5 axis

J1 axis

J2 axis

ABS mark

Fig.5-8 ： ABS mark attachment positions

Resetting the origin 5-63

5Maintenance and Inspection

The procedures for setting the origin with the ABS method are explained below.

(1) Select the T/B

<MENU> <MAINT> 1) Press the [5] key on the Menu screen to select
1.TEACH 2.RUN 1.PARAM 2.INIT the Maintenance screen.
3.FILE 4.MONI 3.BRAKE 4.ORIGIN
5.MAINT 6.SET 5.POWER
+C
(J6)
5 STU
Select the Maintenance screen
<MAINT> <ORIGIN> 2) Press the [4] key to select the Origin Setting
1.PARAM 2.INIT 1.DATA 2.MECH screen.
3.BRAKE 4.ORIGIN 3.JIG 4.ABS
5.POWER 5.USER

-Y
(J2)
4 MNO
Select the Origin Setting screen

<ORIGIN> <ABS> 3) Press the [4] key to select the ABS method.
1.DATA 2.MECH SERVO OFF After that, press the [1] key and [INP] key to
3.JIG 4.ABS OK ? (1) turn the servo OFF.
5.USER 1:EXECUTE
-Y -B INP
(J2) → (J5) → EXE
4 MNO 1 DEF
Select the ABS method

<ABS> 12345678 <ABS> 4) Press the [ ↓ ] key, and input "1" for the axis to
BRAKE(00000000) SERVO OFF set the origin in "SET AXIS". Press the [INP]
SET AXIS (11110000) OK ? (1) key to display the Confirmation screen.
ORIGIN :NOT DEF 1:EXECUTE

RPL -B INP
↓ → (J5) → EXE
Execute the origin setting (confirmation) 1 DEF

<ABS> <ABS> 12345678 5) Press the [1] key and then press the [INP] key.
SET ORIGIN BRAKE (00000000) The origin will be set.
OK?(1) SET JIG (11110000)
1:EXECUTE ORIGIN :NOT DEF
-B INP
(J5)
1 DEF
→ EXE
Execute the origin setting

This completes the setting of the origin with the ABS method.

5-64 Resetting the origin

 5Maintenance and Inspection

5.5.4 Recording the origin data

When the origin has been set with the jig method, record that origin data on the origin data label. With this, the ori -
gin can be set with the origin data input method the next time.

Confirm the origin data on the teaching pendant screen (origin data input screen). The origin data label is enclosed
with the arm or attached on the back of the shoulder coverB.
The teaching pendant operation method and shoulder coverB removal method for confirming the origin data is the
same as the methods for setting the origin with the origin data input method. Refer to "2.3.2Setting the origin with
the origin data input method" on page 13, and write the origin data displayed on the teaching pendant onto the
origin label.

(1) Confirming the origin data label

Remove the shoulder coverB.
Refer to "5.3.2Installing/removing the cover" on page 44, and remove the shoulder coverB.

(2) Confirming the origin data

Confirm the value displayed on the teaching pendant's Origin Data Input screen.
Refer to "2.3.2Setting the origin with the origin data input method""(5)Inputting the origin data" , and display the
Origin Data Input screen on the teaching pendant display screen.

(3) Recording the origin data

Write the origin data displayed on the teaching pendant to the origin data label attached to the back of the shoul -
der coverB. Refer to "Fig. 2-8Origin data label (an example)" on page 13, and "Fig. 2-9Correspondence of origin
data label and axis" on page 16 for details on the origin data label.

(4) Installing the cover

Install the shoulder coverB removed in step "(1)Confirming the origin data label" above.
Refer to "5.3.2Installing/removing the cover" on page 44, and replace the shoulder coverB.

This completes the recording of the origin data.

Resetting the origin 5-65

6Appendix

6 Appendix
Appendix 1 ： Configuration flag
The configuration flag indicates the robot posture.
For the 6-axis type robot, the robot hand end is saved with the position data configured of X, Y, Z, A, B and C.
However, even with the same position data, there are several postures that the robot can change to. The posture
is expressed by this configuration flag, and the posture is saved with FL1 in the position constant (X, Y, Z, A, B, C)
(FL1, FL2).
The types of configuration flags are shown below.

(1) RIGHT/LEFT
Q is center of J5 axis rotation in comparison with the plane through the J2 axis vertical to the ground. .

RIGHT LEFT
Ｆ Ｌ １ (Flag １ )
＆Ｂ ００００ ００００
↑
１／０＝ Ｒ Ｉ Ｇ Ｈ Ｔ ／ Ｌ Ｅ Ｆ Ｔ
Note) "&B" is shows the binary
Ｑ

J2 axis
Rotation center

Fig.6-1 ： Configuration flag (RIGHT/LEFT)

(2) ABOVE/BELOW
Q is center of J5 axis rotation in comparison with the plane through both the J3 and the J2 axis. .

BELOW Ｆ Ｌ １ (Flag １ )
＆Ｂ ００００ ００００
↑
ABOVE １ ／ ０ ＝ Ａ Ｂ Ｏ Ｖ Ｅ ／ Ｂ Ｅ Ｌ ＯＷ
J3 axis
Note) "&B" is shows the binary
Rotation center

J2 axis
Rotation center

Fig.6-2 ： Configuration flag (ABOVE/BELOW)

Appendix-66 Configuration flag

 6Appendix

(3) NONFLIP/FLIP (6-axis robot only.)

This means in which side the J6 axis is in comparison with the plane through both the J4 and the J5 axis..

J4 axis Ｆ Ｌ １ (Flag １ )
FLIP
＆Ｂ ００００ ００００
↑
１／０＝ Ｎ Ｏ Ｎ Ｆ Ｌ Ｉ Ｐ ／ Ｆ Ｌ Ｉ Ｐ
Note) "&B" is shows the binary

NON FILIP

J6 axis flange surface

Fig.6-3 ： Configuration flag (NONFLIP/FLIP)

Configuration flag Appendix-67

 HEAD OFFICE : MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100-8310 TELEX : J24532 CABLE MELCO TOKYO
NAGOYA WORKS : 1-14, YADA-MINAMI 5, HIGASHI-KU, NAGOYA, JAPAN

MAY..2004 MEE Printed in Japan on recycled paper. Specifications are subject to change without notice.