Mlpen 221 011 - LP 01 (Ax20fd11)

1402, MLPEN-221-011,001
MANIPULATOR
INSTRUCTION MANUAL
LP-01 series [AX20/FD11]

11th edition
・Before attempting to operate the robot, please read through this operating manual
carefully, and comply with all the safety-related items and instructions in the text.
・The installation, operation and maintenance of this robot should be undertaken only
by those individuals who have attended one of our robot course.
・When using this robot, observe the low related with industrial robot and with
safety issues in each country.
・This operating manual must be given without fail to the individual who will be actually
operating the robot.
・Please direct any queries about parts of this operating manual which may not be
completely clear or any inquiries concerning the after-sale service of this robot to any
of the service centers listed on the back cover.
This manual explains the robot specifications, structure of each part and the basic handling precautions for
inspection and maintenance to maintain function of the robot for a long period.
It is recommended that this manual is read by robot utilization planners and installation staff as well as
inspectors and maintenance staff for robot operation and the robot is handled only after understanding this
manual completely.
Chapter 1 Basic specifications ............................................................................................................ 1-1

1.1 List of basic specifications.................................................................................................. 1-1
1.2 Outline dimensions and operating area ............................................................................. 1-2
1.3 Details of load mounting face ............................................................................................. 1-3
1.4 Wiring and piping diagram for application .......................................................................... 1-5
1.5 Operating range adjustment............................................................................................... 1-7
1.6 Coordinate systems for manual operation ....................................................................... 1-10
1.7 Precautions for tool setting ............................................................................................... 1-11
1.8 Brake release switch (option) ........................................................................................... 1-13
Chapter 2 Precautions for handling..................................................................................................... 2-1

2.1 Names of robot components .............................................................................................. 2-1
2.2 Transport procedure ........................................................................................................... 2-2
2.3 Installation procedure ......................................................................................................... 2-4
2.4 Allowable load .................................................................................................................... 2-9
2.5 Performing encoder correction ......................................................................................... 2-11
2.6 Emergency stop during transportation of work-piece....................................................... 2-11
Chapter 3 Inspection ........................................................................................................................... 3-1

3.1 Inspection items and periods.............................................................................................. 3-1
3.2 Inspection of major bolts..................................................................................................... 3-3
3.3 Inspection of wrist............................................................................................................... 3-3
3.4 Inspection of wirings ........................................................................................................... 3-4
3.5 Inspection of grease ........................................................................................................... 3-7
3.6 Inspection of cooling fan................................................................................................... 3-11
Chapter 4 Maintenance ....................................................................................................................... 4-1

4.1 Lubrication .......................................................................................................................... 4-1
4.2 Grease replacement ........................................................................................................... 4-2
4.3 Battery replacement ........................................................................................................... 4-8
Chapter 5 Troubleshooting.................................................................................................................. 5-1

5.1 Probing into causes of troubles .......................................................................................... 5-1
5.2 Motor replacement.............................................................................................................. 5-6
5.2.1 Motor replacement (J1,J2,J3 of LP130/180 and J1,J2 of LP210) .............................. 5-7
5.2.2 Motor replacement (J2 of LP210) ............................................................................. 5-12
5.2.3 Motor replacement (J4)............................................................................................. 5-15
5.2.4 Encoder reset............................................................................................................ 5-18
5.2.5 Encoder correction.................................................................................................... 5-20
5.3 Encoder replacement ....................................................................................................... 5-24
Chapter 6 Recommended spare parts and special tools for maintenance ......................................... 6-1
Chapter 7 Wiring diagrams.................................................................................................................. 7-1

For safe use of the robot
Read this manual carefully prior to installation, operation, maintenance, or inspection and use equipment
correctly. Use the robot only after fully understanding the equipment, all safety points, and
comments/suggestions.
Instruction manual “Precautions for handling industrial robots”
Instruction manual “INSTALLATION” (for AX controller) “Chapter 1 Point on safety”
Instruction manual “SETUP” (for FD controller) “Chapter 1 Point on safety”
The following table shows the importance of the following tags/marks in this Operation manual:
Case where a mistake made in handling is likely to cause the user to be exposed to the danger
of death or serious injury and where the degree of the urgency (imminence) of the warning given
DANGER for the danger to occur is at the high end of the scales (including high-level danger).
Cases where a mistake made in handling is likely to cause the user to be exposed to the danger
of death or serious injury.
WARNING
Cases where a mistake made in handling is likely to cause the user to be exposed to the danger
of minor injuries or of property damage only.
CAUTION
And, the other notes use a mark like the one shown as below.
This indicates the other special notes.

IMPORTANT
Labels and marks on manipulator
Following labels and marks are affixed on manipulator. Their location and their existence itself may vary
according to the robot type.
This mark indicates a power supply inlet for the robot. Motor power and detecting
device power is supplied to connectors and terminal blocks under various
connector covers on the robot baring this mark.
Do not touch connectors or terminal blocks directly or indirectly with conductive
items with mains power supplied, as electric shock may occur. If connectors or
terminal blocks are removed with mains power on, electric shock or malfunction of
the robot may result. Turn OFF main power on the controller when performing any
maintenance.
This mark indicates hot parts on the robot.

Carelessly touching labeled hot parts may result in serious burns.
This mark indicates area operators may get caught by the robot.
Places bearing this mark should never be touched. Brakes can be released not
only during teaching but also while the motors are OFF. Take adequate steps to
prevent your hands or other parts of your body from being pinched when these
areas are touched during maintenance work, etc.
Another caution and warning labels;

If these labels are ignored and, for example, some part is disassembled, this may cause fatal or serious
accidents.
Protection labels;
Chapter 1 Basic specifications
1.1 List of basic specifications
Item Specifications
Robot model LP130-01 LP180-01 LP210-01
Construction Articulated construction
Degrees of freedom 4
Drive system AC servo system
Swivel
Max. operating range
J1 ±3.14 rad
Arm
J2 Forward/backward +0.71 ~ -1.65 rad
J3 Up/down +0.30 ~ -2.04 rad

Wrist
J4 Rotation ±6.28 rad
J1 Swivel 2.27 rad/s 2.01 rad/s 1.83 rad/s

Arm
Max. speed
J2 Forward/backward 2.01 rad/s 1.75 rad/s 1.73 rad/s
J3 Up/down 2.01 rad/s 1.83 rad/s 1.75 rad/s

Wrist
J4 Rotation 6.98 rad/s 6.28 rad/s 5.24 rad/s
Max. Wrist 130 kg 180 kg 210 kg

payload Upper part of
Forearm *1 25 kg at maximum
Allowable static
2
load torque of J4 Rotation 50 kgm 69 kgm2 100 kgm2
wrist
Position repeatability *2 ±0.3 mm ±0.4 mm
Air pressure -101.3 ~ 690 kPa

Air 2-φ12×8 (to the wrist unit)
20 wires (to the wrist unit)
Application signals
6 wires (to the fore arm)
Installation Floor mounting
Temperature: 0 ～ 45 ºC *3
Ambient conditions Humidity: 20 to 85%RH (No dew condensation allowed)
Vibration to the installation face: Not more than 0.5G (4.9 m/s2)
Robot mass 1,150 kg

1[rad] = 180/π[° ], 1[N-m] = 1/9.8[kgf･m]
*1: This load varies depending on its mounting position and the weight of wrist payload.
*2: This value is determined under the rule of JIS B 8432.
*3: Permitted height is not higher than 1,000m above sea level. If used in higher place, permitted temperature is affected by height.
1-1
1.2 Outline dimensions and operating area
[LP130-01] [LP180-01] [LP210-01]
1-2
1.3 Details of load mounting face
■ Wrist
For the tool fixing bolts, use the mounting P.C.D. shown below.
Besides the mounting P.C.D. shown below, different P.C.D. (option) is available. For details, contact
our Service Division.
Be sure to screw the M10 tool fixing bolts in the wrist not deeper than the screw depth in
the mounting face. Screwing the bolts deeper than the screw depth may damage the
CAUTION wrist.
Be sure to use P.C.D.125 when the weight of end effecter is 100kg or higher or the
moment of inertia is larger than 25kgm2. (But if the stiffness of attachment bolt was
CAUTION considered inside tool, above size is unnecessary.)
When installing the end effecter (gripper etc.), please insert a positioning pin using the
hole of φ10H7 to avoid rotation.
CAUTION
[LP130-01] [LP180-01] [LP210-01]
1-3
■ Left side of wrist unit
Ancillary equipment can be mounted on the left side of wrist unit.
The equipment to be mounted on the wrist should be selected so that the sum of those
masses (including the end-effecter and the work-piece) is less than the payload mass of
CAUTION the wrist.
Because the material of the tap is aluminum cast, the length of the screw depth should
be from 14 to 15 mm. (The tap is through)
CAUTION
[LP130-01] [LP180-01] [LP210-01]
1-4
1.4 Wiring and piping diagram for application
Use air pressure from -101.3 [KPa] to 690 [KPa].

IMPORTANT
■ Upper part of forearm - wiring and piping diagram for application

[LP130-01] [LP180-01] [LP210-01]
■ Base frame - Wiring and piping diagram for application

[LP130-01] [LP180-01] [LP210-01]
1-5
■ Details of application connectors
(1) BJ1 side (connector)

Connectors for application cables
Wire-side shell : JFM-WSA-4-A (JST)
or JFM-WSA-4-C (JST)
Guide plate A kit : JFM-GPAK-4 (JST)
Receptacle housing : JFM2FDN-22V-K (JST)
Receptacle contact :
a : SJ2F-01GF-P1.0 (JST) (0.20 - 0.50sq)
b : SJ2F-21GF-P1.0 (JST) (0.30 - 0.75sq)
Manual crimp tool :
a : YRS-8861
b : YRF-1120
Cable diameter suitable for wire-side shell
JFM-WSA-4-A : φ26.2~φ28.0
JFM-WSA-4-C : φ15.5~φ16.5
(Pin allocation shows the view of the connector mounted on the robot
seen from the connection side.)
Specification of Application wires :

Rated voltage maximum AC/DC 115 V
Rated ampere maximum 1 A
(2) BJ3･BJ4 side (connector)
BJ4 side connector BJ3 side connector

Key position “standard” Key position “X”
(This pin allocation shows the view seen from the connection side.)
Connector type (CNR10A) N/MS3102A24-28S (JAE)

Receptacle N/MS3106B24-28P (JAE)
Connector type (CNR10D) N/MS3102A24-28SX (JAE)
Receptacle N/MS3106B24-28PX (JAE)
Do not apply external force or fix other cables to the robot cables.
CAUTION
1-6
1.5 Operating range adjustment
With stoppers dismounted, do not operate the robot. Doing so may result in damage to
the peripheral equipment and the like, or death or serious injury.
WARNING
When changing the mechanical stopper’s position, change the position of the over-
travel limit switch and the setting of the software limit also. If not changed, the mechanical
stopper may be damaged. And, the mechanical stopper should be installed outside of the
WARNING
motion range defined by the software limit function and the over-travel limit switch.
■ J1-axis adjustable stopper (option)
Mounting the standard stopper and the additional stopper (option) of the same shape as that of the
standard stopper makes it possible to adjust the operating angle of the J1 axis in steps of 10°. In this
case, a maximum operating range of the J1 axis comes to ±150°.
(1) Dismount the stopper from the standard mounting position, and then mount the stoppers
according to an angle to be adjusted. (Fixing bolt: M12 × 105 × 4 bolts)
(2) Adjust the software limit according to the angle adjusted. (Refer to Instruction manual
“INSTALLATION” (for AX) or “SETUP” (for FD).
The end of a mechanical stopper is provided in a position exceeding the software limit of
IMPORTANT J1 axis by 3°.
Optional part to be used;

OP-S5-012
(for LP130-01, LP180-01, LP210-01)
1-7
NEVER mount a stopper only on the front (lower) side or the rear (upper) side.
WARNING
It is possible to adjust the operating angle of J2 axis.
(1) Unscrew the setscrews from the standard stopper B on the adjustable side, and then
dismount the stopper B from the standard stopper A.
(2) Mount the adjustable stopper (option) at an angle to be adjusted. (Fixing bolt: M8 × 50 × 2
bolts)
(3) Mount the standard stopper B to the adjustable stopper, and then fix them with the set-
screws.
(4) Mount the adjustable dog (option) of the limit switch according to the adjusted angle.

OP-A5-024
(for LP130-01, LP180-01, LP210-01)
1-8
It is possible to adjust the movement of J3 axis.
(1) Mount the adjustable dog (option) of the limit switch according to the adjusted angle.

OP-S4-006
(for LP130-01, LP180-01, LP210-01)
1-9
1.6 Coordinate systems for manual operation
When moving a robot in manual mode, it is possible to select a coordinate system which is used as a
reference coordinate system.
J1
+ -
Joint coordinate system -
(J1, J2, J3, J4) J3
+
J4
- +
- +Z
+Y J2
+
+X
+Z
Tool coordinate
system
+X +Y
Machine coordinate
system
+Z
+X +Y
User coordinate system

(Pallet coordinate system)
1 - 100
(NOTES)
To select a user coordinate system number for manual operation, please use the following operations.
(1) Select a pallet number using software key <Select Pallet>. By this operation, the appropriate user coordinate
system attached to the pallet is automatically selected.
(*) For details, refer to "6.2.1 Select Pallet" in the operating manual "Palletize Function Part1 Advanced Palletize
Function" (for AX) or “Palletize Function” (for FD).
(2) Set a user coordinate system number in [Constant Setting] [5 Operation Constants] [5 Coordinate regis
tration] in advance. (If the number is set here, it becomes possible to select the user coordinate system u
sing [INTERP/COORD.] key.
1-10
1.7 Precautions for tool setting
■ [Constant Setting][3 Machine Constants][1 Tool Constants] screen
Parameter Description Setting method

A name can be set for each of the tools. A tool
name may consist of not more than 16 alpha
Tool Name The name of the tool. numeric and symbols. For the operation, refer to
[2.5 To input characters] of the "Basic operations
manual".
The coordinates of the Tool Center
Length Point (= the origin of the tool It is not necessary to modify this setting.
coordinate system) The initial setting can be used as it is.
Angles to determine the direction of (NOTE1)
Angle the tool coordinate system.
Calculate the coordinates of the COG referring
The coordinates of the center of the
C of G gravity of the tool
to the drawing of the tool and the work-piece a
nd input the values manually. (NOTE 2)
Please use [Service Utilities] [19 Automatic COG
Weight Weight of the tool.
Setting] (NOTE 2)
Please use [Inertia Set] key of [Easy Setting]
Inertia Moment of inertia of the tool.
(NOTE 3)
The maximum rotation radius of the Manually input the value. For details, refer to the
Max. radius tool. This is used for a interference instruction manual "Installation Manual" (for AX) or
area detection etc. “SETUP” (for FD).
(NOTE 1)
- If this settings (Length and Angle) are modified after making a palletize pattern, it may become necessary to
modify the palletize pattern again.
(NOTE 2)
- In case of this robot (LP-01 series), only "Weight" is calculated and set when executing "Automatic COG Setting"
function ("COG" values will not change). Those COG coordinates should be calculated referring to the drawing
of the tool and the work-piece and inputted manually. (See [0 ■ (Reference) Setting example of a COG of a
tool])
- To get a better motion control, make 2 settings of "Without a work-piece (not holding a work-piece)" and "With a
work-piece (Holding a work-piece)" and make settings of "Weight" and "COG" respectively for those 2 tool
settings.
- Refer to the instruction manual "Installation Manual" (for AX) or “SETUP” (for FD) also.
(NOTE 3)
- "Automatic tool moment of inertia setting function" is not available.
- This setting should be done after finishing the setting of "COG" and the "Weight" of the tool.
1-11
■ (Reference) The initial setting of the tool coordinate system
The position and the direction of the tool coordinate system when "Length" and "Angle" are the initial
settings are shown in the following picture.
+Y
In the initial setting, the origin of the tool

coordinate system is located on the center
+X (0,0,0) of the tool flange.
+Z
■ (Reference) Setting example of a COG of a tool
Wrist coordinate system
The coordinates of the "C of G" (center of the gravity of the tool) should be set based on the "Wrist
coordinate system" which is fixed on the wrist flange (mounting flange) center. For example, if the "C
of G" is located on a position like the figure shown as above, the coordinates of the "C of G" are;
(x,y,z) for "C of G" = (100, 50, 200)
■ (Reference) J3 angle for "Automatic COG Setting" function
For both pose1 and pose2, use poses in which a large unbalance torque is added to the J3 a
xis. (in a range within ±30 [deg] ) But, the pose1 and the pose2 must be different.
(Example) Pose1 : -90 [deg] / Pose2 : -60 [deg]
Pose2 : -60 [deg]

J3 axis
Rotation center
Pose1 : -90 [deg]
1-12
1.8 Brake release switch (option)
Only needed switches (same quantity as axis number) are mounted on the brake release switch
(option). Pay utmost attention to operate these switches.
Please refer to “AX20 controller maintenance manual” or “FD controller instruction manual /
Controller Maintenance”.
PO
WRE
1 2
A B
AB2
1 B 1 A 1 1
B 1
A B1 A 1
B B
1
2 2
1
A 2
B 1
2
A
B 1
A 2 A
B 2
1 1
2 1
3 2 1
A C
1 B
2
1
3 2
J 8 J 9 J 1 J0 1 J1 1 J2 1 3J 1 4
J4
J3
J 1 J 2 J 3 J 4 J 5 J 6 J 7
DRIV E UNIT POWER
SUPPLY
UNIT
J2
J1
Sample of brake release switch (option) : Type 1 of AX20 controller
1-13
NOTE
1-14
Chapter 2 Precautions for handling
2.1 Names of robot components
製造銘板
MFG. Name plate
The over travel limit switches are redundant circuit type as standard.
IMPORTANT (Robot shipped before February 2012 has single circuit type.)
The balancer device is internally compressed even in the normal state. Never attempt to
dismount or disassemble this device. Otherwise it will result in a highly hazardous
WARNING situation.
Manufacturing plate Operating axis name
Manufacturing number
Date of manufacture
Serial robot number
Mass of robot
(Mass is typed only for CE specification.)
2-1
2.2 Transport procedure
The robot must be transported by personnel who have licenses required for slinging
work, crane operation, forklift truck operation, and others. When the transportation work
is covered by the personnel who does not have necessary skill, it will cause the robot to
WARNING topple over or drop during transport, thus resulting in hazards.
To lift the robot or the controller, follow the procedures specified in the Maintenance
Manual. Following any procedures other than those specified will cause the robot to
WARNING topple over or drop during transport, thus resulting in accidents.
During transport or installation work of the robot, pay utmost care not to cause
damage to wirings. Furthermore, after installing the robot, take protective measures
such as using protective guards so that the wirings will not be damaged by workers or
WARNING other persons, or forklift trucks or else.
[LP130-01] [LP180-01] [LP210-01]

To transport the
robot, make it a rule
to use a crane.
First, put the robot
into the configuration
shown in the figure
and mount the four
M20 hanging bolts to
the robot frame.
Then, be sure to lift
the robot using four
hanging wires.
Protect areas that
contact the robot,
using rubber hoses to
cover the wire ropes.
For the areas to be
covered with the
rubber hoses, refer to
the figure shown as
below.
Hanging bolts
installation
holes
(4-M20)
Never use taps

marked ※ to hang
the robot.
(4-M20)
2-2
If hanging wires push the encoder connectors and the wires/tubes, the connectors or the
wires/tubes may be broken when hanging the robot. When hanging a robot, please pay attention
not to make the wires touch the encoder connectors and the wires/tubes.
COG position for transporting posture (without a wrist load) is shown below.
2-3
2.3 Installation procedure
The installation location and the installation procedure of the robot are critical factors to maintain
robot functions. The ambient conditions of installation location not only have influence on the life of
mechanical sections of the robot, but also get involved in safety issues. Consequently, strictly
observe the environmental conditions shown below. Furthermore, utmost care should be exerted for
the installation procedure and the foundation for the robot in order to maintain the robot performance.
Strictly observe the installation procedure for the robot provided below.
Installation
To install the robot, give it first priority to thoroughly consider safety of workers and take safety
measures. The following section describes precautions for this purpose.
Safety measures against entry in the robot operating area

While the robot is in operation, workers are in danger of coming in contact with the robot.
To avoid that, install a guard fence so as to keep the worker away from the robot. Not
WARNING
doing so will cause the workers or other persons to accidentally enter the operating area,
thus resulting in accidents.
Guard fence
Refer to information in ISO13857: Safety of machinery – Safety distances to prevent
hazard zones being reached by upper and lower limbs
This figure shows the image of the
guard fence. (Robot appearance
may be different from that of this
manual.)
DANGER
Stop time and angle of J1 for a maximum travel

((After emergency stop signal occurred under maximum speed)
LP130-01、LP180-01 LP210-01
Stop time 0.83 [sec] 0.68 [sec]
Stop angle 0.74 [rad] 0.58 [rad]
The guard fence must have construction by which no one can easily get over or move
the guard fence. Provide an access door for the guard fence that must be equipped with a
safety plug and designed not to open unless the safety plug is unplugged.
WARNING If above construction is not secured, someone can get in the guard fence, thus inducing
a hazardous situation.
Design the system so that motor power is turned OFF when safety plug is unplugged
or access door is opened. This can make it possible to detect the entry of a person and
atop the robot automatically. (The controller has an input signal of safety plug and to turn
WARNING
off the motor power.)
Design the system so that low-speed playback mode will become functional in order
to operate the robot with the safety plug unplugged. If the robot is operated at a high
speed under the said condition, no one can escape from the robot, thus resulting in
WARNING
accidents. (The controller has an input signal to select low-speed playback mode.)
2-4
Mount Emergency Stop buttons for the robot in locations where workers are able
to immediately press them. If the workers are unable to immediately press the switch,
WARNING accidents may result. (The controller has an input signal of emergency stop.)
If no guard fence is installed, mount photoelectronic switches and/or mat switches,
etc. at all entrances to the robot operating area to use them in place of the safety plug.
WARNING
These switches make it possible to automatically stop the robot when anyone enters the
guard fence.
Coat the floor of the hazardous area (the robot operating area) with color paint to
facilitate discrimination of the hazardous area.
WARNING
Safety measures against the robot and peripheral equipment
In order to connect the primary power supply to the controller and the peripheral
equipment, check to be sure that the power on the supply side is turned OFF. Otherwise
it will create a hazardous situation resulting in electric shocks since high voltages such as
WARNING
100VAC, 200VAC, or 400VAC are applied.
Do not install the operation part and the adjustment part in the robot operating area,
such as locations in which a person can get caught in the robot.
Install the robot control panel, interlock panel, and all other operation panels so that they
WARNING
can be operated outside the guard fence.
To install an operation stand, mount an Emergency Stop button on the operation
stand. If any abnormality occurs while the robot is being operated by the use of the
WARNING
operation stand, the robot will be able to make an emergency stop through pressing this
switch.
Do not route wirings, piping, and the like among the robot, control panel, interlock
panel, and others in such a manner that workers will stub their toes over them or forklift
trucks will directly tread them. Otherwise it may cause workers to topple over or the
WARNING
wirings to be broken, thus resulting in accidents.
Do not install the control panel, interlock panel, operation stand, or else in places from
which the movements of the robot are out of sight. When the robot movements go out of
sight, even if an abnormality occurs in any movement, you will delay in taking notice of
WARNING the abnormality, thus resulting in a disaster. Furthermore, you will not find someone near
the robot to cause an accident.
If the robot operating area required is smaller than the operable area possessed by the
robot, limit the robot operating area. The area can be limited by using the software
limit, limit switch, and mechanical stopper. Even if the robot exceeds the normal
WARNING operating area due to an abnormality, this function will enable the robot to stop before
initiating operation.
Install light shielding boards, enclosures, and others to the extent that the movements
of the robot can be monitored in directions in which workers may be exposed to spatters
during welding. Otherwise it may cause injury to workers with welding arcs, spatters, or
WARNING
else.
Provide a large and highly visible display of automatic and manual mode indicating
the operating status of the robot so that it can be recognized even from locations at some
WARNING distance. Furthermore, it is effective to provide audible alarm using a buzzer or
announcement to alert workers to the initiation of automatic operation, thus facilitating
awareness of automatic operation in progress from distant locations.
Eliminate protrusions from the peripheral equipment and the like of the robot to a
minimum. If necessary, be sure to cover them up. Otherwise it may induce a hazardous
WARNING situation when a worker touches them or is surprised with a sudden movement of the
robot to topple over.
Do not attempt to install the robot so that a worker will need to put his/her hands in the
guard fence to carry in or out workpieces. There may be cases where the robot moves
WARNING when the worker put his/her hands in the guard fence.
2-5
Safety measures against installation work
To install the robot, it is important to position the robot so that no workers will get
pinched by the robot inside or around a device to use the robot. The robot must not come
WARNING into contact with any peripheral equipment when operating in the maximum operating
range with a tool mounted on it.
Be sure to install the robot according to the specified procedure. Otherwise it will cause
the robot to move or topple over while in operation, thus inducing an imminent hazardous
WARNING situation.
To make wire connections between the robot and the controller or the peripheral equipment,
fully understand the connection procedure for proper wire connections. Making wire
WARNING connections according to improper procedure will cause the robot to malfunction.
Be sure to establish a proper ground for the robot. If equipment such as a welder that
causes substantial noises is needed to use, establish the specified ground for the
WARNING equipment.
During transport or installation of the robot, pay utmost care not to cause damage to
wirings. Furthermore, after installing the robot, take protective measures such as using
WARNING protective guards so that the wirings will not be damaged by workers or other persons, or
forklift trucks or else.
■ Installation location and ambient conditions
Conditions (temperature, humidity, height and vibration) are written in “Chapter 1 Basic
Specifications”. Further ambient conditions listed below must be observed.
(1) Location with the drainage structure so that swivel base is not flooded, when the liquid such
as water or cutting fluid is splashed on the robot body
(2) Location with no flammable or corrosive fluid or gas.
(3) Type D grounding (the grounding resistance is 100Ω or less) is necessary.
■ Installation procedure
While robot moves, large reaction force is applied to the swiveling base from all directions.
Consequently, the robot should be installed in such a manner that the foundation endures
reaction force caused by accelerating or decelerating the speed to lock the robot, not to mention
that it endures static loads.
Repair uneven spots, cracks, and others on the floor, and then install the robot by following to the
table below. If thickness of floor concrete is less than needed level, an independent foundation
should be constructed. Inspect the foundation prior to the robot installation, and then construct
the foundation, if necessary.
Robot Model LP130-01 LP180-01 LP210-01

Thickness of floor concrete Not less than 160 mm
8 bolts of M20 (JIS: Strength class 12.9) not less than 65mm
Installation parts *1 8 plain washers of not less than 4.5 mm in thickness
and HRC35 in hardness
Tightening torque 560 ± 30 Nm
Approximately Approximately Approximately
Allowable repeated tensile *2
35,000 N 42,000 N 46,000 N
*1 : Installation parts are not accessory of robot.
*2 : This tensile is per installation bolt when robot is installed with all bolts written in table above.
2-6
■ Installation space
To install the robot, lock the swiveling base of the robot.
The mechanical stopper end is located in a position exceeding the specified operating
range (software limit) of the J1 axis by 3 degrees. To install the guard fence, consider the
WARNING motion range specification, the wrist configuration and the shape of end effecter etc.
On the J1, J2, and J3 axes, the robot operating range can be regulated for safety
(optional function). Since optional parts should be installed to enable this function, do not
WARNING independently move the standard parts (e.g. stopper block).
If mechanical stopper collides and robot stops, it’s possible that some parts are already
damaged, for example, mechanical stopper is transformed or fixing bolts are broken. In
this case, sufficient intensity and function can not been kept. Mechanical stopper and
WARNING
reduction gear of collided joint are needed to be replaced to the new one.
[LP130-01] [LP180-01] [LP210-01]
2-7
■ Accuracy of installation surface
When installing the robot, strictly observe precautions listed below to cause no deformation in the
swiveling base.
(1) Ensure that the flatness of the four plates on the installation surface of the robot is within 1.0
mm.
(2) Make the deviation in height between the four robot installation surface plates and the
installation surface fall in the range of 1.0 (±0.5 mm).
(3) If the two precautions above

cannot be observed, use jack bolts
to bring the four places into even
contact with the installation
surface.
■ Welding the base plates
The internal wirings inside the robot base unit may be burned or damaged because of welding
spatters or sparks. Therefore, when welding the base plates with attached to the robot base unit,
please cover the 4 gaps shown in the following picture in advance.
4 base plates
weld the outside of

base plate
These gaps should be covered

before performing the welding
(Front, back, left, right)
■ Maximum robot generative force
Max. vertical Max. horizontal Max. vertical Max. horizontal

Robot Model generative force generative force generative moment generative moment
FV FH MV MH
LP130-01 40,800 N 28,700 N 80,400 N･m 69,900 N･m
LP180-01 45,700 N 33,100 N 96,600 N･m 84,400 N･m
LP210-01 48,600 N 35,700 N 106,300 N･m 93,200 N･m
2-8
2.4 Allowable load
The wrist load is regulated by the allowable pay load mass, allowable static load
torque, and allowable moment of inertia. If wrist load exceeds these allowable
CAUTION
values, this robot is out of guarantee.
Please refer to “1.1 List of basic specifications” and following figures for detail.
■ Torque map for the wrist load

Use the robot under condition that COG of wrist load falls in the range shown below.
Distance from Distance from Distance from

J4 rotation J4 rotation J4 rotation
center [m] center [m] center [m]
Distance from flange face [m]

１80Kg 210Kg
130Kg
150Kg 180Kg
100Kg
130Kg 150Kg
80Kg
100Kg 130Kg
60Kg
[LP130-01] [LP180-01] [LP210-01]
2-9
■ Load on the forearm
Ancillary equipment can be mounted to the upper part of robot forearm. If the wrist load mass is
maximum, use the ancillary equipment on the load condition that the load gravity center falls in the
shaded range, referring to the figure below. Furthermore, if the wrist load mass is small, the
location where the ancillary equipment can be mounted will change according to the mass and
COG (the maximum mass is 25kg).
For details, request the technical information to our Engineering department.
[LP130-01] [LP180-01] [LP210-01]
It is possible to mount an ancillary equipment on the fore arm using taps shown below Because the
material of the tap is aluminum cast, the length of the screw depth of the bolts should be from 14 to 15
mm.
2-10
2.5 Performing encoder correction
At NACHI factory, encoder correction is performed under the load condition and robot
posture specified by NACHI. This load condition and robot posture may have influence on
the reference position. So please perform encoder correction for all axes
after all of the load are mounted on wrist and upper arm,
before staring the teaching procedure,
CAUTION by referring to information in “5.2.4 Encoder Correction”. (At this time, encoder resetting
procedure is not required.) If encoder correction is carelessly performed after teaching is
done, all of the taught points are needed to be modified because tool top position may
change largely.
Also encoder correction is necessary when motor / encoder is replaced.
At this time, encoder correction must be performed under the same load condition and
same robot posture as the first time encoder correction that is performed
CAUTION
immediately after the loads are mounted, because load condition and robot posture
may have influence on the reference position. Therefore, the “reference posture” (where
all axes are in “reference position” by using zeroing pin or like that) is recommended as
the posture of encoder correction. ( “5.2.4 Encoder Correction”)
2.6 Emergency stop during transportation of work-piece
While the work-piece is in transport, if an operator makes an emergency stop of the robot
or the robot detects an error to make an emergency stop, the work-piece in transport may
CAUTION be damaged.
While paying careful attention for the operator not to become victim to the damaged work-
piece, remove it from or around the robot.
CAUTION
2-11
NOTE
2-12
Chapter 3 Inspection
To perform daily inspection, repair, or part replacement of the robot, be sure to turn OFF
the power supply. Furthermore, in order to prevent other workers from improperly turning
WARNING ON the power supply, post the warning signs such as “DON’T POWER ON” at the primary
power supply switch and others.
3.1 Inspection items and periods
The inspection should be performed in order to maintain the high performance of the robot for an
extended period of time. Personnel who are engaged in the inspection must create and implement
the inspection program.
Furthermore, perform overhauls every 20,000 operating hours or every 4 years, whichever
comes earlier. For high frequency of works in which the estimated lifespan becomes 20,000 hours
or less, it is recommended to perform inspections at approximately 1/2 of the periods specified.
Should you have any questions, contact your NACHI representative.
Inspection items and periods (1)

Period
No. Inspection Item Inspection Method Criterion Remark
Quarterly
Yearly
Daily
Common to Whole Robot and Each Axis

1 Cleaning of robot Wiping of dirt or the like
Removing dusts
2 Related to Visual check of cables for damage 3.4
manipulator wirings Visual check of the cable clamp fixing bolts for the
coating of paint
Visual check for cable covers for damage
Visual check for cable covers (if it is open or not.)
Retighten the fixing bolts, and then apply a coating
of paint lock to them.
3 Major bolts Visual check of the coating of paint 3.3
Refasten the fixing bolts, and then apply a coating of
paint lock to them.
4 Limit switch dogs Activate and deactivate the limit switch to check E0065 occurs
them for functions.
5 Motors Check for abnormal heat generation.
Check for any abnormal sounds.
6 Brakes Set the brake release switch to ON and OFF to With the brake Motors with a
check it for operation. release switch set brake for all
Note: When setting the brake release switch to ON, to “OFF”, the arm axes
the robot arm or the operating axis will drop. or the end effecter
Consequently, to check the switch for the operation, does not drop.
set it back to “OFF” within one second.
7 Support point of the Visual check of the gap between the links 3.5
link Visual check of the gap between the shaft and the
plate
Check by hearing for any abnormal sounds
Visual check for any vibration or shaking
8 Support point of the Visual check of the installation angle of the bearings 3.5
balancer and the shafts
Check for deformation of the plate
Check for grease leakage from the seal part
(NOTE) Brake release switch is controller option.
3-1
Inspection items and periods (2)
Period
No. Inspection Item Inspection Method Criterion Remark
Quarterly
Yearly
Daily
Related to J1, J2, and J3 axes

9 Grease in bearings Check for grease steel dust density 3.5
3.5
10 Reduction gears Check by hearing for any abnormal sounds
Grease in reduction Checking the density of steel dust in the grease 3.5

gears
Related to J4
11 Reduction gears Check by hearing for any abnormal sounds
12 End effecter fixing Visual check of the fixing bolts for paint coating
bolts conditions
13 Backlash and play Apply loads to each axis in the forward and reverse No backlash or
rotating directions to check it for any backlash and play to be felt by
play. hand.
Option parts
14 Cooling fans Check for rotation 3.6
Check for oil and dusts
Visual check of the fixing bolts for paint coating
conditions
3-2
3.2 Inspection of major bolts
Recommended torque is shown in the figure below. Be sure to use a torque wrench to
fasten the bolts to proper torque, and then apply a coating of paint lock to them.
CAUTION Furthermore, be careful not to needlessly refasten bolts that are not unfastened.
[LP130-01] [LP180-01] [LP210-01]

To fix the bracket for wiring
To install
the robot

To fix J1 axis motor
To fix the
bracket for
wiring

To fix the bracket
To fix J2 axis motor for wiring
To fix end effecter
3.3 Inspection of wrist
Apply loads to the end effecter (e.g.

gripper unit etc.) mounted to the wrist tip
in the forward/backward, right/left, and
upward/downward, and then check it for
any backlash and play felt by hand. End effecter
3-3
3.4 Inspection of wirings
If any damage is found on cables and tubes, immediately repair or replace the part.
To purchase any manipulator wiring, contact to your local service center. NEVER attempt to use
any cables other than specified by NACHI. For the replacement, order to your local service center
■ Inspection points: Cables cover (hook tube) and clamp portion
Check for the following items.

Check if the connectors of the motors or encoders loosen or not.
Holes and fractures on the cable cover / Damage of the hook tube (*)
Check if the cable cover fastening part loosens or not (*)
Check if the clamp bolt gets unfastened or comes off.
(*) When checking or replacing the cover, please pay special attention not to let any dusts get
into the inside part of the cover.
If damage to the
cover is observed,
replace it.
If the cover is not
closed, close
(fasten) the cover.
If any unfastened
bolt is observed,
refasten the bolt to
the specified torque,
and then put
marking on it. The
M6 bolts and the M8
bolts are used
3-4
■ Inspection points : Cables and hoses around the fore arm
Check for the following items.

Check if the connectors of the motors or encoders loosen or not.
Check if the relay connector loosens or not.
Check if the relay connector is securely installed on the installation panel.
Check if the nut of the bulk head female union (joint) is securely installed on the installation panel.
Check if any cable sharply bends over or gets crushed or not.
Check if any cable shield has scratches or fractures or not.
Check if any hose surface has scratches or fractures or not.
Check if any cable tie is broken or not.
Check if the fixing bolts of the cable clamping saddle loosen or not.
J4-axis
Encoder cable
J3-axis
Motor cable
J4-axis
Motor cable
J3-axis
Encoder cable
Application cable Application hose
3-5
■ Inspection points : J1 axis wiring
Open the wiring cover at the center of the frame from the lower side and visually inspect the wiring
inside the cover.
Check for the items below;
Check if any cable cover has scratches or fractures.
Check if the clamp bolt gets unfastened or comes off.
After inspection, refasten (close) the cable cover.

(*) When checking cables and hoses inside the wiring cover, please pay special attention
not to let any dusts get into the inside part of the cover or stick to the cables and hoses.
Open the cover

from the lower side
Wiring cover
2-M6X10
Tightening torque：8.8Nm
Phase of close position

(Closing position should be ★2-M6X10 Inspection point
balancer side) Tightening torque：8.8Nm
(Apply locking agent)
Open the side cover on the swivel base and visually inspect the internal cables/hoses.
Check for the items below;

Check if any cable cover has scratches or fractures.
Check if any cable scratches on the floor or the installation plate’s surface.
After the inspection, re-attach the cover and tighten the fixing bolts at specified torque and apply
marking on them.
Inspection point (oblique lines) 8-M6X10
5-M6X10 Inspect internal wiring from both sides, Tightening torque：13.8Nm
Tightening torque：13.8Nm because wiring is separated in the base.
3-6
3.5 Inspection of grease
Please check the density of steel dust in the grease in designated interval written in “3.1 Inspection
items and periods”.
If the measurement result exceeds its criterion, please contact our service center for grease
replacement or reduction gear replacement.
Required tools
・ Grease steel dust meter
Recommended grease steel dust meter OM-810 (Idemitsu Kosan Ltd.)
・ Grease gun (Lubrication amount counter function, A nozzle of less than 17 mm in diameter.)
・ Seal tape
If the grease leaks out too much when inspecting the steel dust density, lubricate grease
using a grease gun. For lubrication, use a grease gun with a nozzle of less than 17 mm in
diameter. Note that lubricating grease more than the leaked amount may result in leakage
of grease or faulty robot locus.
CAUTION
After the completion of inspection/lubrication, in order to prevent the leakage of grease,
be sure to wind sealing tape around the grease nipples and socket head plug.
A grease gun that has a capacity to measure the lubrication amount is recommended. If
a grease gun like this can not be prepared, please measure the weight of the grease can
CAUTION before/after the lubrication work to confirm the amount.
Immediately after removing the drain plug, grease may splash, because internal
pressure is still high, for example soon after robot stops,
CAUTION
3-7
■ Grease inspection of reduction gear
No Inspection Applied Inspection Tightening

Purpose Type Size Criterion
. points Grease type amount torque
J1 axis 12.7 N･m
MOLYWHITE Air release Plug Rc-1/8
1 Reduction 10 cc
gear RE No.00 Discharge Plug Rc-1/4 29.4 N･m
grease steel
J2 axis Air release Plug Rc-1/8 12.7 N･m dust density
2 Reduction 〃〃
gear Discharge Plug Rc-1/4 29.4 N･m 0.1 % or less
J3 axis Air release Plug Rc-1/4 29.4 N･m
3 Reduction 〃〃
gear Discharge Plug Rc-1/4 29.4 N･m
Density of grease : MOLYWHITE RE No.00 0.87g/cc
<Notes>
・ In order to prevent the grease from splashing out (this is caused by e.g. rising of internal
pressure or internal temperature), unplug the air release plug shown in figure in advance.
When releasing the plug, loosen the plug slowly to release the remaining pressure slowly.
・ After the completion of inspection, wipe grease running out from the lubrication port. Then,
wind sealing tape around the threaded part of the socket head plug to prevent the leakage
of grease, and plug it again.
・ When inspecting J2 and J3 axis, please make the reference pose of the robot in advance.
3-8
■ Grease inspection of link support points
Applied Inspection Tightening

No. Inspection points Purpose Type Size Criterion
Grease type amount torque
Upper link MOLYWHITE Air release Grease nipple Rc-1/8 12.7 N･m
1 10 cc
wrist side RE No.00 Discharge Plug Rc-1/8 12.7 N･m
Upper link Air release Grease nipple Rc-1/8 12.7 N･m

2 〃〃
J3 axis side Discharge Plug Rc-1/8 12.7 N･m
Lower link Air release Grease nipple Rc-1/8 12.7 N･m
3 〃〃
J3 axis side Discharge Plug Rc-1/8 12.7 N･m grease steel
Lower link Air release Grease nipple Rc-1/8 12.7 N･m dust density
4 〃〃
J2 axis side Discharge Plug Rc-1/8 12.7 N･m 0.5 % or less
Left side support Air release Grease nipple Rc-1/8 12.7 N･m
5 〃〃
point of the wrist Discharge Plug Rc-1/8 29.4 N･m
Right side support Air release Grease nipple Rc-1/8 12.7 N･m
6 〃〃
point of the wrist Discharge Plug Rc-1/8 12.7 N･m
Hinge support Air release Grease nipple Rc-1/8 12.7 N･m
7 〃〃
portion Discharge Plug Rc-1/8 12.7 N･m
<Notes>
3-9
■ Grease inspection of balancer support points
Inspection Applied Inspection Tightening

No. Purpose Type Size Criterion
points Grease type amount torque
Balancer support Air release Grease nipple Rc-1/8 12.7 N･m
MOLYWHITE
1 point 10 cc
RE No.00 Discharge Plug Rc-1/8 12.7 N･m
(forward)
grease steel
Balancer support Air release Grease nipple Rc-1/8 12.7 N･m dust density
2 point 〃〃
(Back / left) Discharge Plug Rc-1/8 12.7 N･m
0.5 % or less
Balancer support Air release Grease nipple Rc-1/8 12.7 N･m
3 point 〃〃
(Back / right) Discharge Plug Rc-1/8 12.7 N･m
<Notes>
3-10
3.6 Inspection of cooling fan
Perform inspections for J1 axis cooling fan referring to the following descriptions. (Cooling fan is
optional for the robots shipped on July 2012 or before, standard for the robots shipped on August
2012 or after.)
• Check if the cooling fan normally rotates when the enable switch is grasped in Teach mode
(=servo ON),
• Check if the fan is dirty or not. (e.g. Oil and dusts, etc.)
If the cooling fan is defective, replace it. And, if the fan is dirty because of oil or dusts etc.,
clean/wipe the fan.
And, if the encoder cover fixing bolts (2-M8×15) and the finger guard fixing bolts (4-M4×35) have
been removed, apply locking agent (ThreeBond 1374) 1 or 2 drops to the screw thread of the bolts
and tighten those bolts again with their rated torque by referring to the figure shown below.
When cleaning/wiping the cooling fan, be sure to turn OFF the primary power and
confirm that the rotation of the cooling fan has surely stopped in advance.
CAUTION If the cleaning work is done while the fan is rotating, the finger of the worker or the
cleaning cloth etc. is caught and result in injury etc.
If the robot is operated with the cooling fan is stopped, the motor temperature will go up
and the performance of the robot will not be drawn out. Therefore, please be sure to
CAUTION perform the inspection.
The power supply lines for the cooling fan are connected to the motor brake's control
lines. Therefore, the cooling fan does not rotate in the condition where the motor brake is
CAUTION locked (=the servo OFF condition)
3-11
NOTE
3-12
Chapter 4 Maintenance
To perform daily inspection, repair, or part replacement of the robot, be sure to turn OFF
the power supply. Furthermore, in order to prevent other workers from improperly turning
ON the power supply, post the warning signs such as “DON’T POWER ON” at the primary
WARNING
power supply switch and others.
4.1 Lubrication
For lubrication and grease replacement, never use grease other than specified type.
Specified type of grease is written in this manual.
CAUTION
If grease other than specified type is used, chemical reaction with original grease
occurs and grease will change in quality. Insufficient lubricating efficiency may cause the
IMPORTANT unexpected shortening of robot life time.
Periodical lubrication is needed for some portion and grease replacement is needed for
other portion. Please do the correct maintenance (lubrication and grease replacement) by
CAUTION referring to this manual.
In order to prevent the internal pressure from rising due to pressure caused by the
lubrication, unplug the air vent plug. Its location is written in this manual.
CAUTION
Lubricate the mechanical sections of the robot with grease not only when insufficient grease is
observed by checking but also at regular intervals of time. Lubrication frequency is normally every
12 months, but, it should be every 6 months If the frequency of the robot movement is high.
Regarding the criteria, refer to the section of “3.1 Inspection items and periods”.
№ Lubrication point Lubrication port Cycle Grease type Amount Remarks
1
J4 axis
Front side of the wrist unit 12 months
Long Time ＋１
reduction gear PD2 3 ０cc
・ In order to prevent the internal pressure from rising due to pressure caused by the lubrication,
unplug the air vent plug shown below If the pressure caused by the lubrication is applied to the
oil seal part, leakage of grease will result.
・ Unplug the socket head plug and plug a grease nipple Rc-1/8 instead and then lubricate.
・ After the completion of lubrication, wipe grease running out from the lubrication port. Then,
wind sealing tape around the threaded part of the socket head plug to prevent the leakage of
grease, and plug it again. (Tightening torque of socket head plug: Rc-1/8 12.7 Nm)
For lubrication, use a grease gun with a nozzle of not more than 17 mm in diameter.
Furthermore, for lubrication points with an air release hole specified, unplug the plug
CAUTION according to the figures, and then lubricate them.
Note that lubricating grease more than the recommended amount may result in leakage
of grease or faulty robot locus. Furthermore, no lubrication is required for any points other
CAUTION than those specified.
4-1
4.2 Grease replacement
For lubrication and grease replacement, never use grease other than specified type.
Specified type of grease is written in this manual.
CAUTION
If grease other than specified type is used, chemical reaction with original grease
occurs and grease will change in quality. Insufficient lubricating efficiency may cause the
IMPORTANT unexpected shortening of robot life time.
Periodical lubrication is needed for some portion and grease replacement is needed for
other portion. Please do the correct maintenance (lubrication and grease replacement) by
CAUTION referring to this manual.
Lubricatiing work must be done keeping the feeding speed to 40cc per 10 seconds or
less. If lubricating is done rapidly, the oil seal may be broken and grease leakage may
CAUTION occur because of rise of pressure inside robot.
Replace grease every 10,000 operating hours or every 2 years whichever comes earlier. If the
frequency of the robot movement is high, the replacement frequency should be every 5,000
operating hours or every 1 year whichever comes earlier regarding the criteria, refer to the section
of “3.1 Inspection items and periods”.
Replacement Lubrication Lubrication port

№ Grease Application Size Torque
point amount *1
J1 reduction 3400 cc Lub. Plug Rc-1/8 12.7 N･m
1 Gear or more Drain Plug Rc-1/4 29.4 N･m
2
J2 reduction MOLYWHITE 1500 cc Lub. Plug Rc-1/8 12.7 N･m
Gear RE No.00 or more Drain Plug Rc-1/4 29.4 N･m
J3 reduction 1000 cc Lub. Plug Rc-1/4 29.4 N･m
3 gear (*2) or more Drain Plug Rc-1/4 29.4 N･m
40 cc Lub. Grease nipple Rc-1/8 ---
4 Upper link (front)
or more Drain Plug Rc-1/8 12.7 N･m
5 Upper link (back)
6 Lower link (upper)
7 Lower link (lower)
Wrist 90 cc Lub. Grease nipple Rc-1/8 ---
8 (left) MOLYWHITE or more Drain Plug Rc-1/8 12.7 N･m
Wrist RE No.00 70 cc Lub. Grease nipple Rc-1/8 12.7 N･m
9 (right) or more Drain Plug Rc-1/8 12.7 N･m
Hinge support 55 cc Lub. Plug Rc-1/8 ---
10 point (*2) or more Drain Plug Rc-1/8 12.7 N･m
Balancer 40 cc Lub. Grease nipple Rc-1/8 ---
11 (front) or more Drain Plug Rc-1/8 12.7 N･m
12 (left) or more Drain Plug Rc-1/8 12.7 N･m
13 (right) or more Drain Plug Rc-1/8 12.7 N･m
Density of grease ; MOLYWHITE RE No. 00 0.87g/cc
(*1) If a "Plug" is attached to the lubrication port, please remove it and install a grease nipple (See next
figure) instead and lubricate.
(*2) The grease bus of the "Hinge support point"(No.10) and the "J3 reduction gear"(No.3) are
connected inside the robot. Therefore, the drain port of No.10 and the lubrication port of No.3 is the
same. To avoid the mixture of grease, grease replacement of "J3 reduction gear"(No.3) should be
done after the completion of the grease replacement of "Hinge support point"(No.10).
4-2
[LP130-01] [LP180-01] [LP210-01]
Recommended posture
for grease replacement
J1 reduction gear
J1 -90°
J2 any
J3 any
J4 any
J2 reduction gear
J1 any
J2 90°
J3 any
J4 any
J3 reduction gear
J1 any
J2 90°
J3 -90°
J4 any
Other portion
J1 any
J2 90°
J3 -90°
J4 any
Grease replacement portions
4-3
Tools required (prepared by customer)
Name Specification Q’ty
Grease gun with a nozzle of not more than 17 mm in diameter, with lubrication amount counter 1
Drain connector Rc-1/4,φ12 1
Drain hose φ12X9 0.2m 1
Maximum 0.2Mpa and adjustable every approx. 0.01Mpa
Air precision regulator 1
SMC “PRECISION REGULATOR IR2000-02BG-X1” is recommended
Air supply source (in market) 1
Weight meter which can measure the weight of ejected grease + container 1
Seal tape (in market) 1
For lubrication, use a grease gun with a nozzle of not more than 17 mm in diameter.
Note that lubricating grease more than the recommended amount may result in leakage of
grease or faulty robot locus.
CAUTION After the completion of lubrication, in order to prevent the leakage of grease, be sure to
wind sealing tape around the grease nipples and socket head plug.
A grease gun that has a capacity to measure the lubrication amount is recommended. If
a grease gun like this can not be prepared, please measure the weight of the grease can
CAUTION before/after the lubrication work to confirm the amount.
Immediately after removing the drain plug, grease may splash, because internal
pressure is still high, for example soon after robot stops,
CAUTION
Grease replacement procedure of J1 axis reduction gear

(1) Place a container to receive grease ejected under the ejection outlet. In advance,
confirm the weight of the container.
(2) Unplug the socket head plug [Rc-1/4] from the ejection outlet. To prevent the robot from
getting dirty, attach a drain connector [Rc-1/4, φ12] and a drain tube [φ12×9, maximum
length is 0.2m]
(3) Unplug the socket head plug [Rc-1/8] from the inlet, and attach the grease nipple [Rc-
1/8]
(4) Use a grease gun to feed grease. At this time, grease feeding operation must be done
keeping the feeding speed to 40cc per 10 seconds. The amount of the grease to be
lubricated is shown in pre-described table. Keep the feeding operation until the color of
the grease that is pushed out from the ejection outlet change to a color of new grease.
(5) When the lubricated (fed) amount reaches the designated values, confirm the
(a):lubricated amount and the (b):ejected amount. (a) can be calculated by comparing
the grease can’s weight before and after the lubrication work or checking the counter
display on the grease gun. (b) can be calculated by measuring the weight of the
container(for this calculation, please check the weight of the empty container measured
in step (1) in advance).
(6) If (a) is larger than (b), too much (surplus) grease remains inside the gear box. To make
(a) and (b) the same, use air to push the grease out. Supply air from the lubrication inlet
and eject the surplus grease from the ejection outlet. Be sure that the air pressure should
be kept under 0.025Mpa by using precise regulator.
If only air comes out from the ejection outlet and grease does not come out, move the
J1 axis while supplying air referring to the figure to push the grease out.
(7) If (a) is less than (b), grease is lacked inside the gear box. To make (a) and (b) the
same, swap the inlet and outlet, and supply the lacked amount of grease from the
ejection outlet.
(8) Wrap seal tapes on socket head plug [Rc-1/8] and attach to the inlet (LUB.PORT).
Wrap seal tapes on socket head plug [Rc-1/4] and attach to the outlet (DRAIN).
In case that robot operation with slow speed playback or teaching operation is
necessary, never get into the robot moving envelope while playback.
And perform above procedure with two persons one pair. One person keeps being ready
WARNING to push the emergency button anytime, other person operates the robot paying much
attention. Please ensure the escape route in advance.
4-4
Connection of the drain tube and the connector
Air supply
Precision regulator
for air supply
SMC PRECISION REGULATOR

IR2000-02BG-X1 (SMC)
Max. supply pressure1.0Mpa
Output pressure 0.005 ～ 0.2MPa
(or equivalent)
Connection of a precise regulator for air supply
5 times for 60° range
J1 axis low speed motion range
4-5
length is 0.2m]
1/8]
ejection outlet.
Connection of the drain tube and the connector J2 axis low speed motion range

length is 0.2m]
1/4]
4-6
ejection outlet.
Connection for J3 axis lubrication
J3 axis low speed motion range
Grease replacement procedure of Link, Wrist, Hinge and Balancer

(2) Unplug the socket head plug [Rc-1/8] from the ejection outlet.
(NOTE) The Hinge support point lubrication port (inlet) has a socket head plug. When lubricating,
attach a grease nipple instead of the socket in advance.
4-7
4.3 Battery replacement
The robot uses lithium batteries for the backup of encoder data.
If the battery voltage drops below the given limit, the data will not be kept normal.
Replace batteries every 8 years, under the condition that operation time length is
IMPORTANT 8h/day and shut down the power 16h/day.
The replacement period varies with use environments (mainly temperatures).
If the battery voltage drops below the given limit, an error indicating the voltage drop will
IMPORTANT be displayed on the controller. In this case, replace the battery.
Replace the battery with the power supply of the controller turned ON.
Replacing the battery with the power supply turned OFF can result in the encoder data
IMPORTANT error, thus requiring the resetting of the encoder..
Do not store the batteries in places with high temperature and high humidity. Store them
in well-ventilated places to avoid dew condensation. It is recommended to store the
IMPORTANT batteries in places with less temperature changes at ambient temperatures (20±15°C)
and relative humidity of not more than 70%.
Discarding lithium batteries according to your local trash separation rule
When discarding used lithium batteries, insulate the electrical terminals.
IMPORTANT And then follow the respective trash separation rules in your local district
and discard them separately as “Used lithium batteries”.
Tools required
Torque wrench for M4 (Tightening torque : 3.33 Nm)
Torque wrench for M6 (Tightening torque : 13.38 Nm)
Double coated adhesive tape
Nipper and Cable tie
Battery replacement procedure
STEP Work performed
1 Turn ON the primary power of the robot controller.
2 Lock the robot by pressing the emergency stop button.
Remove the bolts(4-M6) of the battery unit fitting board on the BJ1 BOX left side.
4 - M6 (13.8N•m)
Pull out the battery unit from the BJ1 BOX.
4-8
Disconnect the connecters CNBAT1 - CNBAT4.
CNBAT1 – CNBAT4
5
Although a warning message of
encoder battery voltage is displayed,
there is no problem. Please proceed
with the next procedures.
Remove the cable tie C to remove the battery unit from the case.
vinyl bag
B
C
A
Do not cut the orange
6 cable tie.
This is reusable.
Double coated adhesive tape Case
Install a new battery unit to the case with the cable tie C.
When replacing the batteries one by one, please follow the procedures shown below.
(1) Fix each battery with double coated adhesive tape.
7
(2) Put the battery in the plastic bag and fasten the cable tie A.
(3) Fasten the plastic bag with the cable tie B.
(4) Install the battery to the case with the cable tie C.
8 Connect CNBAT1 - CNBAT4.
Place the battery unit fitting plate to the original position and fix it with the fixing bolts (4-M6).
9 (Tightening torque : 13.8N•m)
If the battery unit fitting plate is damaged, please replace it.
10 Turn OFF the primary power of the robot controller and turn it ON again.
4-9
NOTE
4-10
Chapter 5 Troubleshooting
5.1 Probing into causes of troubles
To perform daily inspection, repair, or part replacement of the robot, turn OFF the power
supply. Furthermore, in order to prevent other workers from improperly turning ON the
WARNING power supply, post the warning signs such as “DON’T POWER ON”.
If any abnormality occurs in the robot, do not attempt to directly operate the robot. Inform
the abnormality to the maintenance personnel who received the given education and
training immediately, and then probe the cause of the abnormality to deal with it.
WARNING Furthermore, incorporate the said course in the Operation Rules and establish a
framework to surely implement the Rules.
When any abnormality occurs in the robot movement or operation, if no external causative factors
can be discerned, the abnormality will result from damage to mechanical parts. To promptly solve
troubles, it is necessary to have a good grasp of symptoms and then probe what part is defective to
cause the trouble.
Step 1 What axis has caused the abnormality?

Judge what axis has caused the abnormal symptom, first. For abnormalities hard to be judged since
they do not appear in the robot movement, check for the following points.
・Any places producing abnormal sounds?
・Any places generating abnormal heat?
・Any places having backlash/play?
Step 2 What part has damage?

If the axis causing the abnormality is probed, check what part is the cause of the abnormality. A
number of parts can be the cause of a single symptom. (Refer to following table)
Step 3 Measures against defective parts

If the defective parts are probed, take measures. Some measures can be taken by customers. For
measures hard to be taken, contact our Service Department.
Defective part Reduction Fulcrum

Brakes Motors Encoder Belt Tool
Symptom gear bearing
Overload *1 ○ ○ ○ ○ ○
Displacement ○ ○ ○ ○
Abnormal sound ○ ○ ○ ○ ○
Shaking while in operation *2 ○ ○ ○
Sway when stopped *3 ○ ○ ○ ○ ○
Irregular twitching *4 ○ ○ ○
Abnormal deviation ○ ○
Gravity drop of axis ○ ○ ○
Abnormal heat generation ○ ○ ○
Malfunction and runaway ○ ○
*1
: A symptom, which will occur when a load exceeding the rated specification conditions of the motor is applied.
To be more precise, a thermal relay or a circuit protector will be tripped.
*2
: A symptom, which the robot causes vibration while in operation.
*3
: A symptom, which the robot will repeat oscillations several times near the stop position when it makes a stop.
*4
: A symptom, which the robot twitches at irregular intervals of time in the holding configuration.
5-1
Check and remedy by each part is explained after here.
The brake release switch must be operated in order to move the robot without supplying
power to its motors (in the Motors OFF status). An axis whose brake has been released is
free to move, and since the arm may drop or move either backward / forward or up/down
WARNING as a result, it must be supported by a crane, chain hoist or other means without fail before
the brake release switch is operated.
■ Balancer bearing
If balancer bearing is damaged, vibration or abnormal sounds will be produced, thus resulting in
overload.
(1) Checking method

• (Front portion of balancer) Check whether or not the plate shown in Fig.5.3.1-2 is
transformed. Furthermore check whether or not (1) bearing attachment portion has some
incline (2) grease leaks from seal.
• (Rear left and rear right portion of balancer) Check whether or not (1) shaft has some
incline (2) grease leaks from seal. (Refer to Fig.5.3.1-3 and Fig.5.3.1-4)
• Check whether or not the robot hits against the peripheral equipment or else before an
abnormality occurs.
Fig. 5.3.1-1 Checking location
Fig. 5.3.1-2 Checking location Fig. 5.3.1-3 Checking location Fig. 5.3.1-4 Checking location
Front portion of balancer Rear left portion of balancer Rear right portion of balancer
(2) Remedy
Replace the defective bearing. For this purpose, it is necessary to dismount the balancer
unit. Because there is a spring compressed with very strong power inside the balancer
unit, it is very dangerous part. Therefore, please contact our service department if it is
necessary to dismount.
5-2
■ Support bearing
If support bearing is damaged, vibration or abnormal sounds will be produced, thus resulting in
overload. And, if looseness occurs in the bearing nut that fixes the bearings, gap may occur in the
bearing. This gap may cause damage to the bearing.
(1) Checking method

• Check whether or not there is a gap in the bearing by pushing wrist unit, fore-arm (No.1
arm) or upper-arm (No.2 arm).
(If chain block etc. is available, use it to hold the No.1 arm and the No.2 arm to make a
condition in which any load / torque is not added to the reduction gears and check if there
is a gap or not.)
• Check if the gap is within ±1.0 [mm] at the respective link support points (see figure
below)
abnormality occurs.
(2) Remedy
Replace the bearing. For this purpose, in order to lift the robot arm, equipment such as a
chain block should be provided. If it is hard to replace the bearing, contact our service
department.
5-3
■ Reduction gear
If a reduction gear is damaged, vibration or abnormal sounds will be produced. In this case,
normal operation will be impaired to cause overload or abnormal deviation, thus resulting in
abnormal heat generation. Furthermore, the robot will completely stop or cause displacement.
J1, J2, and J3 axes

(1) Checking method
• While in operation, check for any vibration or abnormal sounds, or abnormal heat generation
from the reduction gear part.
• Turn OFF the motors, check the reduction gear for backlash/play or scratch, and whether or
not any abnormality is felt by hand through holding the forearm to swivel the robot with the
brake release switch (option) of the J1 axis set to “ON”. To check J2 and J3 axis, upper arm
must be held using crane or chain block before releasing. Move the arm by operating crane
or chain block and check whether or not any abnormality is felt by hand.
abnormality occurs.
(The reduction gear may be damaged by shocks given when the robot hits against it.)
Never forget that upper arm must be held using crane or chain block before releasing.
Especially as for J2 axis, upper arm may fall down or may jump up due to the payload
WARNING
and robot posture. After supporting upper arm, release brake by inching operation to see
the moving direction of upper arm and to secure that supporting method is adequate.
(2) Remedy
• Replace the reduction gear. For this purpose, in order to lift the robot arm, equipment such
as a chain block should be provided. If it is hard to replace the bearing, contact our Service
Department.
Wrist axis (J4)

(1) Checking method
• While in operation, check for any vibration or abnormal sounds, or abnormal heat generation
from the reduction gear part.
• Check the reduction gear for backlash/play through applying loads to the end effecter (e.g. a
spot gun or hand unit).
• Turn OFF the motors, and then check whether or not the axis moves by hand with the brake
release switch (option) set to “ON”. If the axis does not move, the reduction gear may have
an abnormality.
abnormality occurs.
(The reduction gear may be damaged by shocks given when the robot hits against it.)
(2) Remedy
• If J4 axis reduction gear is abnormal. just replace J4 axis reduction gear.
■ Brakes
If any brake causes an abnormality, an axis may drop with the motors “OFF”. Furthermore, with
the motors “ON”, the brake may remain applied, thus resulting in overload or noises.
(1) Checking method

With the Motors OFF state, check whether or not the brake produces operating sounds
through setting the brake release switch to “ON” and “OFF”. If the brake produces no
operating sounds, it is assumed that the brake has a broken wiring.
(In order to set the brake release switch to “ON” or “OFF”, pay utmost care for the drop of
the robot arm.
Never forget that upper arm must be held using crane or chain block before releasing.
Especially as for J2 axis, upper arm may fall down or may jump up due to the payload
WARNING
and robot posture. After supporting upper arm, release brake by inching operation to see
the moving direction of upper arm and to secure that supporting method is adequate.
5-4
(2) Remedy
Check for brake wirings. Since the motor with an integrated brake for all axes is used, if
no wirings are broken, replace the motor referring to information in “5.4 Motor
Replacement”.
■ Motors
If the motor causes an abnormality, malfunctions (e.g. shaking while in operation, sway when
stopped, or irregular twitching) will result. Furthermore, abnormal heat generation or abnormal
sounds may result. Since the same symptoms as those caused when the reduction gear is
damaged appear, it is hard to judge whether the abnormality results from the motor or the
reduction gear. In this connection, investigate the reduction gear and the bearing at the same time.
(1) Checking method

Check for any abnormal sounds or abnormal heat generation.
(2) Remedy
Replace the motor referring to information in “5.4 Motor Replacement”.
■ Encoders
If the encoder causes an abnormality, the robot will cause displacement, malfunction, or runaway,
thus leading to sway when stopped or irregular twitching. Furthermore, this abnormality will almost
never result in symptoms such as mechanical noises, heat generation, or vibration.
(1) Checking method

Check the encoder data for any errors.
Align the zeroing pin with the reference position, and then check the position data for any
errors.
Move each axis of the robot to check whether or not there are any points in which data
(bits) show irregular changes.
Check the drive unit model number of the controller. (The model of the drive unit varies
with the number of robot axes in use and the motor capacity of each axis.)
If any drive unit of the corresponding model for the same model of controller is available,
replace the drive unit to check whether or not the symptom is transferred to this drive unit,
referring to information in the “Part Replacement Procedure” section in the Maintenance
Manual for the Controller.
(2) Remedy
Check for brake wirings. If no wirings are broken, replace the encoder unit.
When the drive unit is replaced with the one of another controller, if the symptom is
transferred to the controller to which the drive unit is installed, replace this drive unit with
new one.
Caution on the encoders

If the battery has discharged completely or if the battery is not connected properly so
that the encoder has been left standing without any power supplied to it from the
controller, the data stored inside the encoder may be lost and the encoder itself may not
CAUTION operate properly. This state is detected as an abnormality in the encoder system when
the encoder operation is checked at power-on. When abnormal encoder circuit condition
has been detected, encoders must be reset.
■ Tool
(1) Checking method

・If the tool which is not so rigid has been mounted on the robot, the tool itself may repeat
oscillations several times near the stop position.
(2) Remedy
・Robot teaching program is needed to be modified. For example, reducing the step speed
or recording “smooth” parameter. ( “Basic Operations manual” ”Chapter 4 Teaching”)
5-5
5.2 Motor replacement
Never forget to hold robot arm or wrist/tool in advance. If motor is dismounted without
supporting them, forearm will fall down or will jump up (due to the payload and robot
posture) in case of axis 2, forearm will fall down in case of axis 3, wrist and tool will fall
down or will rotate quickly in case of wrist axes, possibly resulting in serious injury.
To hold robot arm, use a crane or
chain block etc. In case of axis 2
and 3, wooden blocks or fixing jig
set (option) can be used.
WARNING Note that zeroing pin and block
are not for supporting arm.
Furthermore, Never attempt to
hold robot arm with hands.
Dismounting motor
from robot without
holding arm...
When touching the motor immediately after robot stops, check that motor is not hot and
then touch it with care.
CAUTION
The motor mass is listed below. Consequently, handle the motor with care.
Robot type J1 J2 J3 J4
LP130-01, LP180-01 28.0 kg 11.0 kg
CAUTION LP210-01 28.0 kg 28.4 kg 28.0 kg 11.0 kg
This work includes some jobs that should be conducted with motors ON. Conseq
uently, be sure to conduct the work at least by a pair of two persons. One person
must stay on guard to press an Emergency Stop button at any time, while the ot
CAUTION her person must promptly finish the work with thorough attention paid to the robot
operating area. Furthermore, prior to starting the work, check for safe corridors.
Tools required (prepared by customer)

Part name Axis name Part No. (Model)
Torque wrench M5 torque wrench (Long type: L>= 200 mm)
J1,J2,J3,J4
Or M5 L type torque wrench
J1,J2,J3 M12 torque wrench (Long type: L>= 280 mm)
Torque wrench L-shape Torque wrench J4 M8 torque wrench (Long type: L>= 280 mm)
Locking agent J1,J2,J3,J4 ThreeBond 1374
J4 LONGTIME PD2
Grease
J1,J2,J3 MOLYWHITE RE No.00
Lubrication J1,J2,J3 ThreeBond 1801B
Be absolutely sure to use the torque wrench to tighten

the bolts.
In case of the bolts on circumference, tighten them
equally and gradually.
Order to tighten bolts
The “coupling gear set” includes motor fixing bolts, or seals also. When replacing a motor unit, it is
recommended to replace the old bolts, seals etc. to the new ones that are included in the set in
spite of their damage level
5-6
5.2.1 Motor replacement (J1,J2,J3 of LP130/180 and J1,J2 of LP210)
STEP Work performed Checkpoints

Turn on the power of the controller, select the TEACH If Motors cannot be turned ON due to an
1 mode, and turn the Motors ON. abnormality or axis operations cannot be
performed, start from step 3.
Refer to "5.2.5 Encoder correction" to proceed with Never use zeroing pin to support arm.
2 the axis operation to the position where the zeroing
pin can be inserted and to insert the zeroing pin.
Secure the arm using J2 axis fixing jig set (option) or As for J2 axis, if Motors ON cannot be
crane, chain block or other means. selected due to an abnormality or axis
3 operations cannot be performed, it is
possible to secure the arm using J2
axis fixing jig set (option).
Be absolutely sure to follow the above instructions to secure the arm ahead of time.
Removing the motor without first securing the arm may cause the J2 axis to move
forward or backward, and cause the J3 axis to drop, resulting in a serious accident.
WARNING If motor fixing bolts are loosened without supporting robot arm, motor body may rotate
with high speed because robot arm moves, resulting in a serious accident.
Turn the Motors OFF first, and then turn OFF the
4
power of the controller.
Disconnect the connectors (encoder and power) from Bear in mind that the encoder data
the motor. will be lost when the encoder
connector is disconnected.
Encoder
Power
5
Remove the encoder plug cover. Concerning the bolt

6
locations, refer to the following figure.
[Robots shipped on July 2012 or before]
2-M8X15
2-Washers for M8
5-7
[Robots shipped on August 2012 or after]
2-M8X15
2-Washers for M8

Place a vinyl bag for catching the grease under the •In the case of the J2 or J3 axis,
motor. (In the case of J1 axis, it is not necessary to grease will ooze out when the
attach the vinyl bag.) motor is removed.
•Fix the vinyl bag securely in place
using adhesive tape or some other
means.
7 Take steps to catch the

grease as it oozes out
using a vinyl bag.
5-8
Remove the motor attachment bolt shown below, and •Before removing bolts, while bolts
remove the motor from the robot. are loosened, check that no stress
exists toward the motor rotating
J1,J2,J3 axis direction. If motor is stable even
4-M12X30 when rotated by hand, some stress
still remains so motor may rotate
with high speed when removed from
robot body. Please check the
supporting of robot arm.
[LP130-01][LP180-01] • Exercise caution since the J1, J2
and J3 axis motors are heavy.
• Do not to apply excessive impact to
the motor shaft.
• Take care not to damage the oil
8 seal lip by the gear attached to the
motor shaft.
• Bear in mind that when J2 axis
motor is removed, J2 axis may move
forward or backward depending on
the state of the frame balancer.
Remove the gear-assembly from the motor. • Do not apply excessive impact to
J1,J2,J3 the motor shaft.
(a) Remove the following bolts, and remove the
9 gear.
J1/J2 :6-M5X25
J3 :6-M5X20
(b) Attach the collar, ring X2 and holding plate.
Motor gear ASSY (J1 axis) Motor gear ASSY (J2 and J3)
5-9
Apply a thin coating of ThreeBond 1801B to the shaft of •When attaching the rings, make
the new motor and two rings before attaching the gear- sure they are pointing in the
assy to the new motor. proper direction.
Attach the gear-assy, which was removed, to the new
motor.
(a) Attach the holding plate, ring X2 and collar.

(b) Using the following bolts, attach the gear.
J1: 6-M5X25 (Tightening torque : 9.8 N·m)
J2,J3 • Do not to apply excessive impact

(c) Check the run-out tolerance of the gear. to the motor shaft.
10 (The run-out tolerance should be under 0.1mm) • Be absolutely sure to use the
If the run-out tolerance exceeds 0.1 mm, loosen the torque wrench to attach the bolts.
gear fixing bolts and repeat the steps from (b). Then tighten bolts gradually &
uniformly using a torque wrench.
<How to measure the run-out tolerance>

- To check the run-out tolerance, it is necessary to J2 axis : Gear with the stamp of RV-450E3-231 → 173mm
release the brake inside the motor and rotate the Gear without stamp → 180mm
gear by hand. To release the brake, add DC24V J3 axis : 158mm (irrelevant to the stamp)
voltage between pin A and pin B in the CNMB*
connector.(A:+24V, B:0V)
- The run-out tolerance should be measured on the
oil-seal touching surface using a dial gauge like
shown as below.
- Please refer to “Chapter 6 Recommended Spare
Parts and Special Tools for Maintenance” to know
the way for identifying similar gears.
CNBM* Connector
Attach motor with following bolts. • Bear in mind to use torque
wrench to fasten the bolts.
J1,J2 Fastening should be done equally
4-M12X30 (Tightening torque : 116 N·m) and gradually.
J3 • Bear in mind not to damage the
4-M12X30 (Tightening torque : 104 N·m) gear surface when attaching the
motor.
If sheet packing of motor is damaged,
please replace it to new one. Its
11 direction is as showed in right figure.
Cut portion of sheet
packing must be
correspond to the through
tap of motor
5-10
Attach the removed encoder plug cover to the new motor.
J1,J2,J3
Attach the encoder plug cover with following bolts. At this
time, apply one or two drops of locking agent
(ThreeBond 1374) to the threads at the ends of the bolts,
and then tighten the bolts.
2-M8X15 (Tightening torque : 22.8 N·m)
2-washers for M8
12
Connect the connectors (encoder and power) to the

13
motor.
During the replacement of J2 and J3-axis motors
grease can be lost. Estimate amount of grease lost
14
during replacement procedure and replenishment.
(grease : MOLYWHITE RE No.00)
Perform encoder reset on the axis concerned.
15
( "5.2.4 Encoder reset ")
Perform encoder correction the axis concerned.
16
( "5.2.5 Encoder correction ")
Remove the zeroing pin. • Bear in mind that performing an axis
operation by mistake without first having
removed the zeroing pin may deform the pin
17 and/or pin hole and make it impossible to
remove the pin and implement encoder
correction properly in the future.
18 Ensure that robot operation presents no problem.
If encoder correction of J2 and J3 axes were performed in wrong position (that is not the
reference position) J3 angle limitation between the ground can not be correctly checked.
Unexpected collision may occur between the wrist (wrist attitude is kept) and J3 axis and
this may cause the serious damage to the robot arm.
CAUTION If angle limitation error occurs before inserting the zeroing pin, once perform encoder
correction and proceed with encoder correction again.
This now completes the J1, J2 or J3 axis motor replacement.
5-11
5.2.2 Motor replacement (J2 of LP210)

Turn on the power of the controller, select the TEACH If Motors cannot be turned ON due to an
1 mode, and turn the Motors ON. abnormality or axis operations cannot be
performed, start from step 3.
Refer to "5.2.5 Encoder correction" to proceed with Never use zeroing pin to support arm.
2 the axis operation to the position where the zeroing
pin can be inserted and to insert the zeroing pin.
Secure the arm using J2 axis fixing jig set (option) or As for J2 axis, if Motors ON cannot be
crane, chain block or other means. selected due to an abnormality or axis
3 operations cannot be performed, it is
possible to secure the arm using J2
axis fixing jig set (option).
Be absolutely sure to follow the above instructions to secure the arm ahead of time.
Removing the motor without first securing the arm may cause the J2 axis to move
forward or backward, and cause the J3 axis to drop, resulting in a serious accident.
WARNING If motor fixing bolts are loosened without supporting robot arm, motor body may rotate
with high speed because robot arm moves, resulting in a serious accident.
Turn the Motors OFF first, and then turn OFF the
4
power of the controller.
Encoder Power
Place a vinyl bag for catching the grease under the •Grease will ooze out when the motor
motor. is removed.
•Fix the vinyl bag securely in place
Take steps to catch the using adhesive tape or some other
grease as it oozes out means.
6 using a vinyl bag.
5-12
Remove the motor attachment bolt shown below, and •Before removing bolts, while bolts
remove the motor from the robot. are loosened, check that no stress
exists toward the motor rotating
4-M12X30 direction. If motor is stable even
when rotated by hand, some stress
still remains so motor may rotate
with high speed when removed from
robot body. Please check the
supporting of robot arm.
• Exercise caution since motors are
7 heavy.
• Do not apply excessive impact to
the motor shaft.
• Take care not to damage the oil
seal lip by the gear attached to the
motor shaft.
• Bear in mind that when J2 axis
motor is removed, J2 axis may move
forward or backward depending on
the state of the frame balancer.
Remove the gear-assembly from the motor. • Do not apply excessive impact to
the motor shaft.
(a) Remove the following bolts, and remove the
8 gear.
6-M5X25, 6-M5X50
(b) Attach the collar, ring X2 and holding plate.
Motor gear ASSY (LP210 J2 axis)
5-13
Apply a thin coating of ThreeBond 1801B to the shaft of •When attaching the rings, make
the new motor and two rings before attaching the gear- sure they are pointing in the proper
assy to the new motor. direction.
Attach the gear-assy, which was removed, to the new
motor.

9 (c) Check the run-out tolerance of the gear.
If the run-out tolerance exceeds 0.35 mm, loosen the

gear fixing bolts and repeat the steps from (b).
• Do not to apply excessive impact
to the motor shaft.
• Be absolutely sure to use the
torque wrench to attach the bolts.
Then tighten bolts gradually &
Apply a thin coating of ThreeBond 1801B to the •When attaching the rings, make
assembled shaft and two rings. sure they are pointing in the proper
Attach the gear-assy, which was removed, to the new direction.
motor.

(c) Check the run-out tolerance of the gear.
If the run-out tolerance exceeds 0.11 mm, loosen the

gear fixing bolts and repeat the steps from (b).
• Do not to apply excessive impact

to the motor shaft.
10 • Be absolutely sure to use the
<How to measure the run-out tolerance>
- To check the run-out tolerance, it is 75mm 225mm
necessary to release the brake inside the
motor and rotate the gear by hand. To
release the brake, add DC24V voltage
between pin A and pin B in the CNMB*
connector.(A:+24V, B:0V)
- The run-out tolerance should be
measured on the oil-seal touching surface
using a dial gauge like shown as below.
- Please refer to “Chapter 6
Recommended Spare Parts and Special measuring position measuring position
CNBM* Connector
Tools for Maintenance” to know the way of step 9 of step 10
for identifying similar gears.
Attach motor with following bolts. • Bear in mind to use torque wrench to
4-M12X30 (Tightening torque : 116 N·m) fasten the bolts. Fastening should be done
11 If sheet packing of motor is damaged, please replace it equally and gradually.
• Bear in mind not to damage the gear
to new one. surface when attaching the motor.
12
motor.
After here, follow “5.2.1 Motor replacement (J1,J2,J3 of LP130/180 and J1,J2 of LP210)” step 13.
5-14
5.2.3 Motor replacement (J4)

Turn on the power of the controller, select the TEACH If Motors cannot be turned ON due to
1 mode, and turn the Motors ON. an abnormality or axis operations
cannot be performed, start from step 3.
Refer to "5.2.5 Encoder correction" to proceed with the The work to be performed after
axis operation to the position where the zeroing block motor replacement is made easier
can be inserted and to insert the zeroing block. if the zeroing block is left inserted
2
ahead of time. If the zeroing block
cannot be inserted, start from
step3.
Turn the Motors OFF first, and then turn OFF the power Never use zeroing pin to support
3
of the controller. wrist.
Encoder
Power
5-15
Dismount the motor from the robot by removing the • Do not to apply excessive impact
following bolts. to the motor shaft.
4-M8X30
(Supplement) To release the brake, add DC24V

In some cases, it may be difficult to pull the motor out voltage between pin A and pin B in
from the wrist unit because of a sheet packing (seal) the CNMB* connector. (A:+24V,
that is tightly adhering to the motor flange. In this case, B:0V)
the motor can be pulled out by releasing the brake of the
motor and rotating motor itself to tear the sheet packing
off.
Follow the steps below to remove the gear attached to • Do not to apply excessive impact
the motor shaft. to the motor shaft.
(a) Remove the gear from the motor shaft by removing
the following bolts (inner side)
J4 : 5-M5X15
5-16
Attach the gear, which was removed, to the new motor. • Clean the shaft of the new motor.
(Remove dusts, redundant oil, etc.)
(a) Attach the gear to the motor shaft using the • Do not to apply excessive impact
following bolts. At this point, apply one or two drops to the motor shaft.
of locking agent (ThreeBond 1374) to the threads at • Be absolutely sure to use the
the ends of the bolts, and then tighten the bolts. torque wrench to attach the bolts.
7 J4 axis : 5-M5X15 (Tightening torque : 8.1 N·m) uniformly using a torque wrench.
Apply the appropriate amount of grease (LONGTIME • Be absolutely sure to use the
PD2) to the gear teeth (enough to cover the teeth), and torque wrench to attach the bolts.
attach the motor to the robot using the following bolts. Then tighten bolts gradually &
8
4-M8X30 (Tightening torque : 30.4 N·m) • Take care not to damage the
gear teeth.
• If the seal of the motor flange is
damaged, please replace it.
9
motor.
10
Perform encoder correction the axis concerned. • If a motor has been replaced in a
( "5.2.5 Encoder correction ") posture that prevents the zeroing
block from being inserted, proceed
with encoder reset and encoder
correction to enable axis operation,
11
and then once more move the axis
to the position where the zeroing
block can be inserted, and proceed
correction again.
Remove the zeroing block. And attach the cover using • Bear in mind that performing an
the bolts (2-M8). axis operation by mistake without
removing the zeroing block may
deform the block and/or the
attachment bracket for the zeroing
block and make it impossible to
12 remove the block and implement
encoder correction properly in the
future.
• If the zeroing block cannot be
removed, move the axis a little at a
time at manual speed 2, and then
remove the block.
This now completes the J4 axis motor replacement.
5-17
5.2.4 Encoder reset
When encoder data has been corrupted due to some problem or motor replacement it is necessary
to reset an encoder and compensate for any offset between actual encoder position and pin
(reference) position. In cases like this, encoder reset must be performed first so follow the steps
below to initiate encoder reset.
The encoder data will be initialized when encoder reset is performed so the robot will no
longer move properly. Upon completion of encoder reset, therefore, be absolutely sure to
use the zeroing pin / zeroing block to perform encoder correction. If the work program is
played back without encoder correction having been performed correctly, the robot may
WARNING
act incorrectly so that the operator may be caught or sandwiched by the robot parts,
possibly resulting in death or serious injury.
After performing the motor connections, the following errors may arise due to the
discharge of the super capacitor inside the encoder. (Example: In cases where, for
instance, a new motor whose super capacitor is charged has been connected)
E0050: Encoder counter overflow/underflow
E0052: Encoder battery charge low
CAUTION
In a case like this, supply power to the controller for at least 10 minutes, and then reset
the encoder. After this, turn the controller power off and then back on to restore the
normal state.
Encoder reset procedure

Tools required
No special tools are necessary for encoder rest procedure.
1 After supplying the power to the controller for at least 10 minutes, proceed
with the following procedures.
2 Select [Teach] mode.
3 Switch the operator qualification to EXPERT or higher.
4 Select [Constant Setting] [3 Machine Constants] [4 Encoder Correction].
>> A screen such as the one shown below will appear.
5 Press f9 [Encoder Reset].

5-18
AX 6 Align the cursor with the axis for which encoder reset is to be performed, and
ON press [ENABLE] + [ON/1].
＋
1 >> The check mark for the axis concerned is now set to ON.
FD
＋ Point
• To clear the check mark, press [ENABLE] + [OFF / 2].
• To set the check mark for all the axes at the same time, press f8 [All Select].
7 After the axes have been selected, press f12 [Execute].

>>The following message will be displayed by axis for which the checkmark is
placed. Then, press the [OK].
Encoder resetting will be executed.

8 If the encoder reset is normally complete, the following message will be
displayed.
This now completes the encoder reset procedure. Refer to the next section, and proceed with
"Encoder correction".
5-19
5.2.5 Encoder correction
After performing encoder reset procedure, encoder correction must be implemented. This is to
registering the “encoder correction value” so that encoder data becomes the pre-determined value
at the pre-determined position (this is called reference position, zeroing pin / block can be
inserted here).
Reference position (zeroing pin / block position) and its encoder data are explained in
following pictures. These encoder data are very important to check the successful
IMPORTANT procedure of encoder correction.
[LP130-01] [LP180-01] [LP210-01]
Encoder data
Of reference position
Ｊ1 axis 80,000[Hex]
Reference position of J1,J2,J3 axis (Zeroing pin position)
5-20
[LP130-01] [LP180-01] [LP210-01]
Encoder data
of reference position
Reference position of J4 axis (Zeroing block insertion position)
In cases where a motor has been damaged while the robot was moving, for instance, it
may be necessary to replace the motor and implement encoder reset at a position
where the zeroing pin/zeroing block cannot be inserted. In such a case, an error may
occur during axis operation, making it impossible to move the robot any further. At times
CAUTION
like this, robot movement can be resumed by provisionally implementing encoder
correction at the position concerned so move the axis to the position where the zeroing
pin / zeroing block can be inserted, and proceed with encoder reset and encoder
correction again.
CAUTION
this may cause the serious damage to the robot arm.
Some of this work is done while power is supplied to the motor. Therefore, perform
pinning in pairs. One person must stand guard and ready to press an emergency stop
button. The other person must work quickly and carefully within the robot operating area.
An escape route should be determined before starting pinning work. If these actions are
WARNING
neglected, the robot may act incorrectly so that the operator may be caught or
sandwiched by the robot parts, possibly resulting in death or serious injury.
Before performing axis operations, be absolutely sure to remove the zeroing pins/
zeroing block. Performing axis operation with the zeroing pins / zeroing block still in place
may bend the pins/block, damage the pin holes / attachment bracket for the zeroing block
or cause other problems. Bear in mind that if any of these problems has arisen, it will no
CAUTION
longer be possible to perform encoder correction accurately and corrections will have to
be made to the work program.
5-21
Encoder correction procedure
Tools required
For this procedure, zeroing pin and block (OP-T2-*** ; option) is necessary.
Please prepare these tools by referring to “Chapter 6 Recommended Spare Parts and
Special Tools for Maintenance”.
1 Select the [TEACH] mode, and turn the Motors ON.

2 Switch the operator qualification to EXPERT or higher.
3 Select [Constant Setting] [3 Machine Constants] [4 Encoder Correction].
4 Press the f8 [Record Posi.] key.

>> The screen shown below will now appear.
5 As for J1,J2 and J3 axis

Remove the resin plug in the zeroing pin insertion hole.
As for J4 axis
Remove the covers for the zeroing block installation.
X- X+ RX- RX+
6 Move the axis at manual speed 2 or 3 to the reference position, and insert the
Y- Y+ RY- RY+ zeroing pin in the pin hole (for J1,J2,J3) or insert the zeroing block in the
Z- Z+ RZ- RZ+ attachment bracket (for J4).
At this point, the encoder correction value is still incorrect so exercise

sufficient caution in operating the robot.
(Caution)
At this point, J3 angle limitation between the ground can not be
correctly checked. Unexpected collision may occur between the wrist
and J3 axis, and this may cause the serious damage to the robot arm.
Please operate robot carefully.
5-22
AX 7 Align the cursor with the axis whose reference position is adjusted (zeroing
pin / zeroing block is inserted), press the [ENTER] key followed by the
[O.WRITE/REC] key.
>> The [Encoder correction value] is now adjusted so that the current
machine position will be set as the encoder data of reference position.
FD
Encoder correction values
If encoder correction is required for other axes as well, repeat steps 5) and 7)
for the axes concerned.
8 Upon completion, remove the zeroing pin and zeroing block. Attach the resin
plug and the cover which covers the zeroing block attachment points to its
original position.
9 Press the Emergency Stop button on the teach pendant to turn OFF the
motor power.
10 Press f12 [Complete].
>> The adjusted encoder correction value is saved in the internal memory.
(Caution)
Until [Complete] is pressed, the encoder correction value will not be
saved into the internal memory. This point should be borne in mind.
11 Using [Service Utilities] [2 Monitor 1] [1 Axis
Data Monitor], check that the current value of
the axes for which encoder correction was
performed is encoder data of reference
position.
This now completes the encoder correction procedure. After checking that the zeroing pin and
zeroing block have been removed, move the axes by operating them manually to check that their
movements are problem-free.
5-23
5.3 Encoder replacement
Since this robot is of encoder separation type on all axes, the encoder is replaceable. With the
encoder assembled in the robot, however, the assembly jig may not be inserted depending on the
robot configuration. In this case, referring to information in “5.4 Motor Replacement”, replace the
whole motor unit. The following section describes the replacement procedure when the robot is
configured so that the encoder can be replaced.
Tools Required (Prepared by customer)

Part name Axis Part No. (Model) Remark
Torque wrench J1,J2,J3 M4 torque wrench *2
Torque M3 torque screwdriver which meets the tightening torque of 0.59 to 0.88 Nm
J4
screwdriver M3 setscrew torque screwdriver which meets the tightening torque of 0.59 to 0.88 Nm
Locking agent All axes Threebond 1374
Encoder replacement procedure (J1,J2,J3 of LP130/180 and J1,J2 of LP210)

Turn ON the primary power of the controller, select the If the Motors cannot be turned ON
TEACH mode, and turn Motors ON. or axis operations cannot be
1
performed due to an abnormality,
start the procedure from step 3.
If axis operations can be performed, refer to The work to be performed after
"5.2.5Encoder correction" to proceed with the axis encoder replacement is made
2
operation to the position where the zeroing pin can be easier if the zeroing pins are
inserted, and to insert the zeroing pin. inserted ahead of time.
After making Motors OFF status, turn OFF the primary
3
power supply of the controller.
4 Disconnect the encoder connectors.
Remove two encoder plug cover. Refer the following
drawing.
5
Refer to “5.2.1Motor replacement (J1,J2,J3 of
LP130/180 and J1,J2 of LP210)” step 6 drawing.
Dismount the encoder from the motor.
(a) Dismount the encoder cover by removing the
following bolts.
6 J1,J2,J3 4-M4X15
(b) Pull out the encoder unit straightly. Do not rotate the
encoder unit while pulling out it.
(Remove the boss and the encoder together.)
エンコーダ
Encoder
ネジロック塗布後の締付トルク
Tightening torque after coating
1.43～1.67 N・m
Outline of the encoder unit Encoder removal
5-24
Attach the boss to the encoder aligning the phase
of .the positioning plate.
(a) Remove the boss from the encoder unit that was If the boss is sticking to the motor
pulled out from the motor. shaft, remove it from the shaft.
(b) Adjust the angle of the positioning plate of the new
encoder so that the angle becomes the same with that
of the old encoder.
7
Adjusting the angle of the positioning plate
(c) Attach the boss to the encoder unit matching its

angle to the positioning plate.
Attaching the boss to the encoder
5-25
Fix the encoder to the motor. Pay attention not to damage the O-
ring of the encoder when installing
(a) After aligning the direction of the motor connector the encoder unit.
and the encoder connector, insert the encoder unit so
that the U-groove of the boss and the positioning plate
shape fit in each other and the projection portion and
the dent of the boss also fit in each other.
Positioning plate, and the boss
(b) Insert the positioning pin (attached to the encoder If the positioning pin enters the
unit) into the positioning hole on the encoder unit and positioning hole on the motor side,
then rotate the angle of the encoder to left/right a little the angle of the encoder unit will be
so that the edge of the pin goes thorough to the locked. Confirm that the angle is
positioning hole on the motor side securely locked.
Positioning holes
• At this point, apply one or two
(c) With the positioning pin is inserted, fix the encoder
drops of locking agent (ThreeBond
unit to the motor with the following bolts. Concerning the
1374) to the threads at the ends of
position of the bolts.
the bolts, and then tighten the bolts.
• Be absolutely sure to use the
J1,J2,J3
4-M4X15 (Tightening torque : 1.43 to 1.67 N･m) Then tighten bolts gradually &
After tightening the bolts, pull out the positioning pin.
5-26
Attach the removed encoder plug cover to the new
motor.
J1,J2,J3
Attach the encoder plug cover with the following bolts.
At this point, apply one or two drops of locking agent
(ThreeBond 1374) to the threads at the ends of the
bolts, and then tighten the bolts.
2-M8X15 (Tightening torque : 22.8 N･m)
2-washers for M8
10 Connect the connector to the encoder.

11
Perform encoder correction the axis concerned. • If a motor has been replaced in a
( "5.2.5 Encoder correction ") posture that prevents the zeroing
block from being inserted, proceed
correction to enable axis operation,
12
and then once more move the axis
to the position where the zeroing
block can be inserted, and proceed
correction again.
CAUTION this may cause the serious damage to the robot arm.
If angle limitation error occurs before inserting the zeroing pin, once perform encoder
correction and proceed with encoder correction again.
Now completes the encoder replacement for J1, J2, and J3.
5-27
Encoder replacement procedure (J4 of LP130/180/210 and J2 of PL210)
Turn ON the primary power of the controller, select the If the Motors cannot be turned ON
TEACH mode, and turn Motors ON. or axis operations cannot be
1
performed due to an abnormality,
start the procedure from step 3.
If axis operations can be performed, refer to "5.2.5 The work to be performed after
Encoder correction" to proceed with the axis operation encoder replacement is made
2
to the position where the zeroing block can be inserted, easier if the zeroing block is
and to insert the zeroing block. inserted ahead of time.
After making Motors OFF status, turn OFF the primary
3
power supply of the controller.
4 Disconnect the encoder connectors.
Remove the encoder unit from the motor.
(a) Dismount the encoder cover removing the following

bolts. At this time, dismount the encoder
J4 cover in order not to cause tension
4-M3X20 to the encoder lead wire.
5 (b) Remove the bolts that fix the encoder fixing spring.
2-M3X10
(c) Remove the two set screws that fix the encoder boss
part, and then pull out the encoder assembly from the
motor shaft.
2-M3X4
Encoder Encoder lead wire

Protective cover
Lead wire sheath
Forming direction
4-M3x20
Fastening torque after coating of screw
lock: 0.59 to 0.88 Nm
Lead wire riser part
Overview of the encoder unit (J4)
5-28
Positioning plate
Encoder cover packing
2 - M3×10
Tightening torque after coating of screw Encoder cover
lock: 0.59 to 0.88 Nm
2 - M3×4 (Coming with encoder)
Tightening torque 0.59 to 0.88N・m
U-slot of boss part

Encoder Location pin
Dismounting of encoder unit Cross-section of encoder cover

Fix the encoder to the motor.
(a) Insert the encoder so that the U-slot of the encoder

boss part is aligned with the positioning pin on the For this purpose, be sure to use
motor side. the new setscrews with screw lock
that come with the encoder.
(b) Insert the encoder until the encoder boss part hits the
positioning plate of the motor shaft, and then torque
the set screws of the boss part
2-M3X4 (tightening torque: from 0.59 to 0.88 N·m)
6 (c) Fix the encoder fixing spring by the following 2 bolts.

2-M3X10 (tightening torque: from 0.59 to 0.88 N·m)
(d) Form the lead wire riser part so that the encoder lead At this time, apply one or two drips
wire will follow the outer circumference of the protective of locking agent (ThreeBond 1374)
cover. Then, with the sheath of the lead wire pulled to to the bolts.
the riser part, put the encoder cover in place. After that, At this time, put the encoder
torque the following bolts. packing in place.
J4
4-M3X20 (tightening torque : 0.59 to 0.88 N·m)
4-washers for M3
7 Connect the connector to the encoder.

8
Perform encoder correction the axis concerned.
9
( "5.2.5 Encoder correction ")
Now completes the encoder replacement for J4 axis.
5-29
NOTE
5-30
Chapter 6 Recommended spare parts and
special tools for maintenance
Recommended spare parts are listed below. To purchase any parts, check the manufacturing No.
and date of the robot, and then contact our Service Department.
Classification A: Periodical maintenance parts B: Spare parts
Recommended spare parts

Robot model
Recommended/unit
Classification
Part No.
Name Remark
In use/unit
(Model) LP130-01 LP180-01 LP210-0
A GREASE PM/W-16KG － 1 ○ ○ ○ MOLYWHITE RE No. 00

A GREASE LONGTIME-PD2-18KG － 1 ○ ○ ○ LONGTIME PD2
A BATTERY ER17/50H 4 4 ○ ○ ○ Refer to "4.3 Battery replacement"
A BATTERY UNIT KP-ZA-009 1 1 ○ ○ ○ for the replacement period (*1)
A COVER SET SP-CS-004 1 1 ○ ○ ○ J1 axis
B AC SERVO MOTOR R2AA22500HCPF0 3 1 ○ J1,2,3 ○ J1,2,3 ○ J1,3
B AC SERVO MOTOR MSMA302D7V3 1 1 ○ J4 ○ J4 ○ J4
B AC SERVO MOTOR MDMU602S2V3 1 1 ○ J2
B ENCODER PA035-017BC00L 3 1 ○ J1,2,3 ○ J1,2,3 ○ J1,3 (*2)
B ENCODER DVOP3560 1 1 ○ J4 ○ J4 ○ J2,4 (*2)
B COUPLING GEAR SET KP-ZH-109 1 1 ○ J1 ○ J1 ○ J1
B COUPLING GEAR SET KP-ZH-116 1 1 ○ J2 ○ J2
B COUPLING GEAR SET KP-ZH-166 1 1 ○ J2
Cables from BJ1 to the fore arm
B BJ1 UNIT ASSY SP-BJ1-142 1 1 ○ ○ (for the robots shipped on
November 2012 or before)
Cables from BJ1 to the fore arm
B BJ1 UNIT ASSY SP-BJ1-177 1 1 ○ ○ ○ (for the robots shipped on
December 2012 or after)
B BJ3 UNIT ASSY SP-BJ3-019 1 1 ○ ○ ○ From the fore arm to the wrist unit
Sheet packing
B SEAL 037-0572-000 1 1 ○ ○ ○ for battery unit fitting plate
J1 axis motor cooling fan (*3)
B FAN MOTOR ASSY SP-E5-021 1 1 ○ ○ (for the robots shipped on
November 2012 or before)
J1 axis motor cooling fan
B FAN MOTOR ASSY SP-E5-022 1 1 ○ ○ ○ (for the robots shipped on
December 2012 or after)
(*1) When replacing the all batteries, please choose battery unit (KP-ZA-009)
(*2) When encoder cover is damaged, encoder itself may be damaged already. Please replace not only encoder cover but also encoder itself.
(*3) As for the robots shipped on July 2012 or before, this part is for the option OP-P6-004 (cooling fan).
If MSDS (Material Safety Data Sheet) for chemical material such as grease is necessary, customer needs to require it to the chemical material
supplier.
<Reference> Following seals and O rings are necessary for the motor replacement procedure. “COUPLING GEAR SET” include
these parts. This list is just the reference when ordering them individually.
Usage Name Type Notes
Sheet packing for J1 motor replacement SEAL 037-0623-000
Sheet packing for J2 and J3 motor replacement SEAL 037-0566-002 Applicable to all robot
Sheet packing for J4 motor replacement SEAL 037-0600-001
6-1
(Reference 2) These gears are included in COUPLING GEAR SET of J1-J3 axis. Please refer to the following notes to
identify similar gears.
KP-ZH-109 (J1 axis) KP-ZH-116 (J2 axis)
KP-ZH-113 (J3 axis) KP-ZH-166 (J2 axis)
The fixtures listed below are required fixture for maintenance work or for efficient work.
When purchasing these tools, please contact to your local service center while confirming the robot
manufacturing no. and manufactured date.
Special tools for maintenance (option)
Part No. Robot model
Name Remark
(Model) LP130-01 LP180-01 LP210-01
Zeroing pin
ACCESSORY OP-T2-059 ○ ○ ○ & zeroing block
CONTROLLER BCUNIT20-40 ○ ○ ○ Bypass cable unit
J2 axis
H-AXIS FIX JIG SET KP-ZD-004 ○ ○ ○
Fixing jig set
Contents of OP-T2-059 (Zeroing pin & zeroing block) (option)

Applied
Name Marking Appearance, etc
Robot model
J1 Zeroing pin
J2,J3 Zeroing pin

LP130-01
LP180-01
LP210-01
J4 Zeroing block LP J4
Hex. socket head cap screw 4-M6X20

The tightening torque for M6 bolt is 13.8 N•m
These parts such as pins and blocks can not been purchased one by one.
6-2
Chapter 7 Wiring diagrams
Robot parts layout
7-1
Wiring/piping connection diagram
[Robots shipped on November 2012 or before]
7-2
J1 axis cooling fan connection for the robots
shipped on August 2012 to November 2012
7-3
Wiring/piping connection diagram
[Robots shipped on December 2012 or after]
Wire connection diagram for motor and brake (1)
[Robots shipped on November 2012 or before]
7-4
[Robots shipped on December 2012 or after]
7-5
7-6
Wire connection diagram for encoder (1)
7-7
Wire connection diagram for encoder (2)
7-8
Wire connection diagram for application
7-9
AX20 controller Wire harness connection (1)
7-10
AX20 controller Wire harness connection (2)
7-11
制御装置側ロボット側
CONTROLLER SIDE ROBOT SIDE
CNP1A
(1) (2) (3)
U11 V11 W11
U12 V12 W12
CNP1B
(1) (2) (3)
U13 V13 W13
U14 V14 W14
CNP3A
(1)
U21
(2)
V21
(3)
W21
CNR01
U22 V22 W22
CNP3B
(1) (2) (3)
U23 V23 W23 CONNECTOR 11
U24 V24 W24
(B1) U12 V12 W12 BA1 U14 (B6)
(A1) U11 V11 W11 PB1 U13 (A6)
CONNECTOR 12
(B1) V14 W14 V24 W24 (B6)
(A1) V13 W13 V23 W23 (A6)
CONNECTOR 13
(B1) U22 V22 W22 BA2 U24 G (B6)
(A1) U21 V21 W21 PB2 U23 (A6)
CNBK1
(1) (2) (3) CONNECTOR 14
B PB1 PB2
A BA1 BA2 未使用 / NOT USED
ECE
FD11 controller Wire harness connection (1)
7-12
CNP4A
(1) (2) (3)
U31 V31 W31
U32 V32 W32
CNP4B
(1) (2) (3)
U33 V33 W33
U34 V34 W34
CNP6A
(1)
U41
(2)
V41
(3)
W41
CNR02
CNP6B
(1) (2) (3)
U42 V42 W42 CONNECTOR 21
(B1) U32 V32 W32 BA3 (B6)
(A1) U31 V31 W31 PB3 (A6)
CONNECTOR 22
(B1) U34 V34 W34 (B6)
(A1) U33 V33 W33 (A6)
CONNECTOR 23
(B1) U42 V42 W42 BA4 (B6)
(A1) U41 V41 W41 PB4 (A6)
CONNECTOR 24
(B1) TS2 G (B6)
(A1) TS+ (A6)
CNBK2
(1) (2) (3) (4) (5)
B PB3 PB4 TS2
A BA3 BA4 TS+
ECE
7-13
CNEC1
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
B P5E1 M5E1 P5E2 M5E2 LS1- LS2-
A S1+ S1- S2+ S2- LS1+ LS2+
CNEC2
CNR04
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
B P5E3 M5E3 P5E4 M5E4
A S3+ S3- S4+ S4-
CONNECTOR 41
LS LS
(B1) S1- S2- S3- S4- 1- 2- (B11)
CNALM (A1) S1+ S2+ S3+ S4+
LS
1+
LS
2+
(A11)
(1) (2) (3)
E24 M24 ALM CONNECTOR 42
(B1) M5E1 M5E2 M5E3 M5E4 M24 (B11)
(A1) P5E1 P5E2 P5E3 P5E4 ALM E24 (A11)
CONNECTOR 43
(B1) (B11)
未使用 / NOT USED
(A1) (A11)
Connector “CNALM” is not used for this robot.
7-14
http://www.nachi-fujikoshi.co.jp/
Shiodome Sumitomo Bldg. 17F,

Phone: Fax:
Japan Main Office 1-9-2 Higashi-Shinbashi
+81-3-5568-5245 +81-3-5568-5236
Minato-ku, TOKYO, 105-0021 JAPAN
Nachi Robotic Systems Inc. (NRS) http://www.nachirobotics.com/
North America Headquarters Phone: 248-305-6545 Fax: 248-305-6542 22285 Roethel Drive, Novi, Michigan 48375-4700 U.S.A.
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+49-2151-65046-0 +49-2151-65046-90 http://www.nachirobotics.eu/
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Phone: Fax: Obchodni 132, 251 01 Cestlice, PRAGUE-EAST

Czech branch
+ 420-255-734-000 +420-255-734-001 CZECH REPUBLIC
NACHI AUSTRALIA PTY. LTD. http://www.nachi.com.au/

Robotic Division & Phone: Fax:
38, Melverton Drive, Hallam, Victoria 3803, , AUSTRALIA
Victoria office +61-(0)3-9796-4144 +61-(0)3-9796-3899
Phone: Fax:
Sydney office Unit 1, 23-29 South Street, Rydalmere, N.S.W, 2116, AUSTRALIA
+61-(0)2-9898-1511 +61-(0)2-9898-1678
Phone: Fax:
Brisbane office 7/96 Gardens Dr,Willawong,QLD 4110, , AUSTRALIA
+61-(0)7-3272-4714 +61-(0)7-3272-5324
NACHI SHANGHAI CO., LTD.
Phone: Fax: 11F Royal Wealth Centre, No.7
Shanghai office
+86-(0)21-6915-2200 +86-(0)21-6915-2200 Lane 98 Danba Road Putuo District, Shanghai 200062, China
NACHI KOREA http://www.nachi-korea.co.kr/
2F Dongsan Bldg.
Phone: Fax:
Seoul office 276-4, Sungsu 2GA-3DONG, Sungdong-ku,
+82-(0)2-469-2254 +82-(0)2-469-2264
Seoul 133-123, KOREA
Copyright NACHI-FUJIKOSHI CORP.

Robot Division
1-1-1, FUJIKOSHIHONMACHI, TOYAMA CITY, JAPAN 930-8511
Phone +81-76-423-5137
Fax +81-76-493-5252
NACHI-FUJIKOSHI CORP. holds all rights of this document. No part of this manual may be photocopied or
reproduced in any from without prior written consent from NACHI-FUJIKOSHI CORP. Contents of this document
may be modified without notice. Any missing page or erratic pagination in this document will be replaced.
In case that an end user uses this product for military purpose or production of weapon, this product may be liable
for the subject of export restriction stipulated in the Foreign Exchange and Foreign Trade Control Law. Please go
through careful investigation and necessary formalities for export.
Original manual is written in Japanese.

Mlpen 221 011 - LP 01 (Ax20fd11)

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Mlpen 221 011 - LP 01 (Ax20fd11)

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1402, MLPEN-221-011,001

LP-01 series [AX20/FD11]

Chapter 1 Basic specifications ............................................................................................................ 1-1

Chapter 2 Precautions for handling..................................................................................................... 2-1

Chapter 3 Inspection ........................................................................................................................... 3-1

Chapter 4 Maintenance ....................................................................................................................... 4-1

Chapter 5 Troubleshooting.................................................................................................................. 5-1

Chapter 7 Wiring diagrams.................................................................................................................. 7-1

This indicates the other special notes.

This mark indicates hot parts on the robot.

Another caution and warning labels;

J2 Forward/backward +0.71 ~ -1.65 rad

J3 Up/down +0.30 ~ -2.04 rad

J4 Rotation ±6.28 rad

J1 Swivel 2.27 rad/s 2.01 rad/s 1.83 rad/s

J2 Forward/backward 2.01 rad/s 1.75 rad/s 1.73 rad/s

J3 Up/down 2.01 rad/s 1.83 rad/s 1.75 rad/s

J4 Rotation 6.98 rad/s 6.28 rad/s 5.24 rad/s

Max. Wrist 130 kg 180 kg 210 kg

Air pressure -101.3 ~ 690 kPa

Robot mass 1,150 kg

[LP130-01] [LP180-01] [LP210-01]

[LP130-01] [LP180-01] [LP210-01]

Ancillary equipment can be mounted on the left side of wrist unit.

[LP130-01] [LP180-01] [LP210-01]

Use air pressure from -101.3 [KPa] to 690 [KPa].

■ Upper part of forearm - wiring and piping diagram for application

■ Base frame - Wiring and piping diagram for application

(1) BJ1 side (connector)

Specification of Application wires :

(2) BJ3･BJ4 side (connector)

BJ4 side connector BJ3 side connector

Connector type (CNR10A) N/MS3102A24-28S (JAE)

■ J1-axis adjustable stopper (option)

Optional part to be used;

It is possible to adjust the operating angle of J2 axis.

Optional part to be used;

It is possible to adjust the movement of J3 axis.

Optional part to be used;

User coordinate system

■ [Constant Setting][3 Machine Constants][1 Tool Constants] screen

Parameter Description Setting method

In the initial setting, the origin of the tool

■ (Reference) Setting example of a COG of a tool

Wrist coordinate system

■ (Reference) J3 angle for "Automatic COG Setting" function

Pose2 : -60 [deg]

Pose1 : -90 [deg]

Sample of brake release switch (option) : Type 1 of AX20 controller

Manufacturing plate Operating axis name

Serial robot number

(Mass is typed only for CE specification.)

[LP130-01] [LP180-01] [LP210-01]

Never use taps

Safety measures against entry in the robot operating area

Stop time and angle of J1 for a maximum travel

Safety measures against the robot and peripheral equipment

■ Installation location and ambient conditions

Robot Model LP130-01 LP180-01 LP210-01

[LP130-01] [LP180-01] [LP210-01]

(3) If the two precautions above

■ Welding the base plates

weld the outside of