B-83645EN/04 4.

REPLACING PARTS

4.5 REPLACING THE J3-AXIS MOTOR (M3) AND REDUCER

4.5.1 Replacing the J3-axis Motor (M3)

(R-2000iC/165F/210F/125L/220U/165R/210R/100P)
Removal
1 Set the dial gauges at the J3-axis, and prepare for single axis mastering after replacement.
2 Ensure that the robot assumes the posture shown in Fig. 4.5.1 (b) to (d), and hang the robot with a
sling.

WARNING
If you try to remove the J3-axis motor without fastening the J3 arm first, the J3
arm may move, posing a serious danger to you. Fasten the arm so that it does
not move.

3 Turn off the controller power.

4 Remove the motor cover when it is attached. (See Section 4.10 REPLACING THE MOTOR
COVERS)
5 When a fan is not attached, remove the Pulsecoder connector guard (2). (The cover might turn
together with the bolts, possibly causing damage to the connector. Hold the guard to prevent it from
turning.)
If a fan is to be mounted, remove the fan. (See Section 4.11 REPLACING THE FANS.)
6 Detach the three connectors from the J3-axis motor (1).
7 Remove the four motor mounting bolts (4) and washers (5).

NOTE
To remove and install the J3-axis motor, use an M12 T-shaped hexagonal
wrench not shorter than 250 mm.

8 Pull out the J3-axis motor (1) horizontally, while being careful not to damage the surface of the gear
teeth.
9 Remove the bolt (8) and washer (7) and the O-ring (9), then dismount the gear (6).

Assembly
1 Polish the flange surface of the J3-axis motor (1) using an oilstone.
2 Mount and fasten the gear (6) with a bolt (8) and a washer (7).
3 Place the new O-ring (9) in the specified position, and mount the J3-axis motor (1) horizontally
while being careful not to damage the surface of the gear teeth.
4 Attach the three motor mounting bolts (4) and washers (5).
5 Attach the three cable connectors to the J3-axis motor (1).
6 When a fan was not attached, attach the Pulsecoder connector guard (2).
If a fan was mounted, mount the fan. (See Section 4.11 REPLACING THE FANS.)
7 Attach the motor cover if it was attached. (See Section 4.10 REPLACING THE MOTOR COVERS)
8 Apply grease to the J3-axis reducer. (See Section 2.3.)
9 Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the
robot-specific Operator’s Manual.

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Tip
<Axis control by making use of the operating range change option>
The safety is improved if the stopper (option) for changing the operating range is
also used for supporting the J3 arm. Press the arm against the mounted stopper
by jogging the arm, and fine-tune the J3-axis angle so that no torque is applied
to the motor.
<Removing the motor>
Before removing the motor, loosen all the three mounting bolts and try to turn the
motor by hand. If a force acts on the motor to cause the motor to be turned
strongly in one direction, check whether the arm is correctly held in place, before
the removing bolts.

Torque N-m
Parts name Specifications Q’ty Locking
(kgf-m)
165F/210F/125L
A06B-2041-B605#0042
1 MOTOR /220U/165R/210R 1
100P A06B-2041-B605#0142
2 COVER A290-7324-X101 1
3 BOLT A6-BA-8X16 1
4 BOLT A6-BA-12X30 3
5 WASHER A97L-0001-0823#M12H 3
210F/220U/210R A290-7333-X405
6 GEAR 165F/125L/165R A290-7333-Y405 1
100P A290-7333-Z405
7 SEAL WASHER A30L-0001-0048#6SUS 1
8 BOLT A6-BA-6X75 1 LT243 15.7 (1.6)
9 O-RING JB-OR1A-G125 1
Fig. 4.5.1 (a) Replacing the J3-axis motor (M3)

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Use eyebolts (M10) (two slings)

Fig. 4.5.1 (b) J3-axis motor and reducer replacing posture (R-2000iC/165F/210F/125L)

Use eyebolts (M10) (two slings)

Fig. 4.5.1 (c) J3-axis motor and reducer replacing posture (R-2000iC/165R/210R/100P)
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Wind sling around the wrist

unit (one sling)

Fig. 4.5.1 (d) J3-axis motor and reducer replacing posture (R-2000iC/220U)

4.5.2 Replacing the J3-axis Reducer

(R-2000iC/165F/210F/125L/220U/165R/210R/100P)
NOTE
The special tools listed below are required to replace the J3-axis reducer.

Common tool for replacing the J3-axis reducer

Parts name Specifications Q’ty
Guide pin (M12) A290-7324-X921 2

Removal
1 Set dial gauges at J3-axis, and prepare for single axis mastering after replacement.
2 Set the Quick Master Reference Position. Refer to the QUICK MASTERING, QUICK
MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual. (All the axes
are set to 0º before shipment.)
3 Place the robot in the posture shown in Fig. 4.5.1 (b) to (d), and rig the J3 arm as shown.
4 Turn off controller power.
5 Remove the motor cover when it is attached. (See Section 4.10 REPLACING THE MOTOR
COVERS)
6 Detach the cables leading to the J3 to J6-axis motors, and all option cables, then pull out them from
the J2 arm.
7 Remove the J3-axis motor according to Subsection 4.5.1.
8 Remove the J2 arm mounting bolts (1) and washers (2), then remove the J3 unit by using a guide pin
as shown in Fig. 4.5.2 (b). At this time, apply a sufficient tension to the sling.
9 Remove the reducer mounting bolts (3) and washers (4), then dismount the reducer (6) using the
guide pin.

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NOTE
When installing the J3 axis reducer, attach an M12 hexagonal socket (with a tip
not shorter than 70 mm) to a torque wrench, and tighten the bolt.

Assembly
1 Place the new O-ring (7) in the specified position and install the new reducer (6) with bolts (3) and
washers (4) via the guide pins as shown in Fig. 4.5.2 (b).
2 Place the new O-ring (5) in the groove of the reducer. When the O-ring will not stay in the O-ring
groove, apply a small amount of grease and then attach the O- ring to the groove.
3 Fix the J3 unit to the J2 arm with the bolt (1) and washer (2) via the guide pins (see Fig. 4.5.2 (b)).
4 Attach the J3-axis motor according to Subsection 4.5.1.
5 Attach the cables and option cables to be connected to the J3- to J6-axis motors.
6 Attach the motor cover when it was attached. (See Section 4.10 REPLACING THE MOTOR
COVERS)
7 Apply grease to the J3-axis reducer. (See Section 2.3.)
8 Perform quick mastering and perform single axis mastering on J3-axis. Refer to the QUICK
MASTERING, QUICK MASTERING FOR SINGLE AXIS and SINGLE AXIS MASTERING of
the robot-specific Operator’s Manual.

NOTE
If the motor gear has been damaged, replace it when you replace the reducer.

Torque N-m
Parts name Specifications Q’ty Locking
(kgf-m)
1 BOLT A6-BA-12X60 33 LT263 128 (13.1)
2 WASHER A97L-0001-0823#M12H 33
3 BOLT A6-BA-12X65 24 LT263 128 (13.1)
4 WASHER A97L-0001-0823#M12H 24
5 O-RING JB-OR1A-G145 1
165F/125L/165R A97L-0218-0989#218
6 REDUCER 210F/220U/210R A97L-0218-0989#261 1
100P A97L-0218-0989#245
7 O-RING A98L-0040-0041#272 1
Fig. 4.5.2 (a) Replacing the J3-axis reducer

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J3 unit
Guide pin (M12)
A290-7324-X921

Guide pin (M12)

A290-7324-X921

J3-axis reducer
J2 arm

Fig. 4.5.2 (b) Guide pins for replacement of the J3-axis reducer

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B-83645EN/04 4. REPLACING PARTS

4.5.3 Replacing the J3-axis Motor (M3) (R-2000iC/270F/210L)

Removal
1 Set the dial gauges at the J3-axis, and prepare for single axis mastering after replacement.
2 Ensure that the robot assumes the posture shown in Fig. 4.5.3 (b), and hang the robot with a sling.

WARNING
If you try to remove the J3-axis motor without fastening the J3 arm first, the J3
arm may move, posing a serious danger to you. Fasten the arm so that it does
not move.
3 Turn off controller power.
4 Remove the motor cover when it is attached. (See Section 4.10 REPLACING THE MOTOR
COVERS)
5 When a fan is not attached, remove the Pulsecoder connector guard (2). (The cover might turn
together with the bolts, possibly causing damage to the connector. Hold the guard to prevent it from
turning.)
If a fan is to be mounted, remove the fan. (See Section 4.11 REPLACING THE FANS.)
6 Detach the three connectors from the J3-axis motor (1).
7 Remove the three motor mounting bolts (4) and washers (5).

NOTE
To remove and install the J3-axis motor, use an M12 T-shaped hexagonal
wrench not shorter than 250 mm.
8 Pull out the J3-axis motor (1) horizontally, while being careful not to damage the surface of the gear
teeth.
9 Remove the O-ring (10), the bolt (9), the seal washer (8), the gear (7) and the draw nut (6).
Assembly
1 Polish the flange surface of the J3-axis motor (1) using an oilstone.
2 Install the draw nut (6) on the shaft of the J3-axis motor (1).
3 Install the gear (7) on the shaft of the J3-axis motor (1), then fix it with a bolt (9) and a washer (8).
4 Place the new O-ring (10) in the specified position, and mount the J3-axis motor (1) horizontally
while being careful not to damage the surface of the gear teeth.
5 Attach the three motor mounting bolts (4) and washers (5).
6 Attach the three cable connectors to the J3-axis motor (1).
7 When a fan was not attached, attach the Pulsecoder connector guard (2).
If a fan was mounted, mount the fan. (See Section 4.11 REPLACING THE FANS.)
8 Attach the motor cover if it was attached. (See Section 4.10 REPLACING THE MOTOR COVERS)
9 Apply grease to the J3-axis reducer. (See Section 2.3.)
10 Perform single axis mastering. Refer to the SINGLE AXIS MASTERING section of the
robot-specific Operator’s Manual.

Tip
<Axis control by making use of the operating range change option>
Safety is improved if the stopper (option) for changing the operating range is
also used for supporting the J3 arm. Press the arm against the mounted stopper
by jogging the arm, and fine-tune the J3-axis angle so that no torque is applied
to the motor.
<Removing the motor>
Before removing the motor, loosen all three mounting bolts and try to turn the
motor by hand. If a force acts on the motor to cause the motor to be turned
strongly in one direction, check whether the arm is correctly held in place, before
removing the bolts.
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Torque N-m
Parts name Specifications Q’ty Locking
(kgf-m)
1 MOTOR A06B-2268-B605 1
2 COVER A290-7324-X101 1
3 BOLT A6-BA-8X16 1
4 BOLT A6-BA-12X30 3
5 WASHER A97L-0001-0823#M12H 3
6 DRAW NUT A290-7324-X151 1 LT243 118 (12)
7 GEAR J3 A290-7337-X405 1
8 SEAL WASHER A30L-0001-0048#8SUS-2 1
9 BOLT A6-BA-8X75 1 LT243 27.5 (2.8)
10 O-RING JB-OR1A-G125 1
Fig. 4.5.3 (a) Replacing the J3-axis motor (M3)

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Use eyebolts (M10) (two slings)

Fig. 4.5.3 (b) J3-axis reducer replacing posture (R-2000iC/270F/210L)

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4.5.4 Replacing the J3-axis Reducer (R-2000iC/270F/210L)

NOTE
The special tools listed below are required to replace the J3-axis reducer.

Common tool for replacing the J3-axis reducer

Parts name Specifications Q’ty
Guide pin (M12) A290-7324-X921 2

Removal
1 Set dial gauges at J3-axis, and prepare for single axis mastering after replacement.
2 Set the Quick Master Reference Position. Refer to the QUICK MASTERING, QUICK
MASTERING FOR SINGLE AXIS sections of the robot-specific Operator’s Manual. (All the axes
are set to 0º before shipment.)
3 Place the robot in the posture shown in Fig 4.5.3 (b), and rig the J3 arm as shown.
4 Turn off controller power.
5 Remove the motor cover when it is attached. (See Section 4.10 REPLACING THE MOTOR
COVERS)
6 Detach the cables leading to the J3 to J6-axis motors, and all option cables, then pull out them from
the J2 arm.
7 Remove the J3-axis motor according to Subsection 4.5.3.
8 Remove the J2 arm mounting bolts (1) and washers (2), then remove the J3 unit by using a guide pin
as shown in Fig. 4.5.4 (b). At this time, apply a sufficient tension to the sling.
9 Remove the reducer mounting bolts (3) and washers (4), then dismount the reducer (6) using the
guide pin.

NOTE
When installing the J3-axis reducer, attach an M12 hexagonal socket (with a tip
not shorter than 70 mm) to a torque wrench, and tighten the bolt.
Assembly
1 Place the new O-ring (7) in the specified position and install the new reducer (6) with bolts (3) and
washers (4) via the guide pins as shown in Fig. 4.5.4 (b).
2 Clean sealant applying surface of J2 arm referring to Section 4.9 SEALANT APPLICATION.
3 Place the new O-ring (5) in the groove of the reducer. At this time, apply LOCTITE 518 on the
O-ring installation groove of the J2 arm to prevent it from falling out. (Do not apply grease.)
4 Spread excess sealant on the whole surface of the O-ring (5) after installing the O-ring (5). At this
time, confirm that the O-ring (5) is in the inner part of the groove referring to Fig. 4.5.4 (c).
5 Apply sealant on the J3 arm mounting face of the reducer (6) as shown in Fig. 4.5.4 (d). See also,
Section 4.9 SEALANT APPLICATION.
6 Secure the J3 unit to the J2 arm with the bolt (1) and washer (2) via the guide pins (see Fig. 4.5.4
(b)).

TIP
<Confirmation after installing the J2 arm>
Please confirm witness mark attaching surface of J2 arm matches the witness
mark attaching surface of the J3 arm as shown in Fig. 4.5.4 (e). If these do not
match, the O-ring (5) might be bitten.
7 Attach the J3-axis motor according to Subsection 4.5.3.
8 Attach the cables and option cables to be connected to the J3 to J6-axis motors.
9 Attach the motor cover when it was attached. (See Section 4.10 REPLACING THE MOTOR
COVERS)
10 Apply grease to the J3-axis reducer. (See Section 2.3.)
11 Perform quick mastering and perform single axis mastering to J3-axis. Refer to the QUICK
MASTERING and SINGLE AXIS MASTERING of the robot-specific Operator’s Manual.
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NOTE
If the motor gear has been damaged, replace it when you replace the reducer.

Torque N-m
Parts name Specifications Q’ty Locking
(kgf-m)
A6-BA-10X45 27 LT263 73.5 (7.5)
1 BOLT
A6-BA-12X50 12 LT263 128 (13.1)
A97L-0001-0823#M10H 27
2 WASHER
A97L-0001-0823#M12H 12
3 BOLT A6-BA-12X45 30 LT263 129 (13.2)
4 WASHER A97L-0001-0823#M12H 30
5 O-RING JB-OR1A-G295 1
6 REDUCER A97L-0318-0234#309 1
7 O-RING A98L-0040-0041#276 1
Fig. 4.5.4 (a) Replacing the J3-axis reducer

J3 unit

Guide pin (M12)

A290-7324-X921 Guide pin (M12)
A290-7324-X921

J3-axis reducer

J2 arm

Fig. 4.5.4 (b) Guide pins for replacement of the J3-axis reducer
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In the state of
O-ring (5) is in the inner part.

O-ring (5)
Detail A

J2 arm
NOTE)
Please verify the O-ring (5) is in the ineer part of the installation groove.
(If the O-ring (5) is not in the inner part, it might be pinched.)

Fig. 4.5.4 (c) Confirmation during installing the O-ring (5)

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B-83645EN/04 4. REPLACING PARTS

Note : Apply sealant as dotted line. Then spread

it on the whole sealant surface
(Take special care and check that there
are no gaps of sealant around the part A)

LOCTITE 518 applying area

Fig. 4.5.4 (d) Applying sealant to the J3-axis reducer

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Witness mark
attaching surface

Detail A
After installing the J3 arm
Witness mark attaching
face meets

Confirmation after installing the J3 arm

NOTE)
Please verify witness mark attachng surface of the J3 arm matches the
witness mark attachging surface of the J2 arm.
(If it does not match, the O-ring (5) might be pinched.)
Fig. 4.5.4 (e) Confirmation after installing the J3 arm

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