1703, MEZEN-292-003, 002

MANIPULATOR
INSTRUCTION MANUAL
EZ03V4-02/EZ03F4-02
[CFDL1/CFDL2/CFDL4]
3rd 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 of time.
It is strongly recommended that this manual is read by robot utilization planners and installation staff as well
as inspectors and maintenance staff for handling robot. And the robot is handled only after understanding
this manual thoroughly.

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

1.1 List of basic specifications ................................................................................................................. 1-1
1.2 Robot dimensions and motion range ................................................................................................. 1-2
1.3 Details of payload installation section................................................................................................ 1-6
1.4 Application wiring and piping diagram ............................................................................................... 1-7

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 ........................................................................................................................ 2-5
2.4 Allowable wrist load ........................................................................................................................... 2-9
2.5 Setting of the robot No. at Servo CPU board .................................................................................. 2-10

Chapter 3 Maintenance ............................................................................................................................. 3-1

3.1 Inspection items and periods ............................................................................................................. 3-1
3.2 Maintenance of belt............................................................................................................................ 3-2
3.2.1 Inspection of belt ..................................................................................................................... 3-2
3.3 Lubrication ......................................................................................................................................... 3-7
3.4 Encoder reset and correction........................................................................................................... 3-10
3.4.1 Encoder reset ........................................................................................................................ 3-10
3.4.2 Encoder correction ................................................................................................................ 3-10
3.5 Battery replacement......................................................................................................................... 3-12
3.6 Robot body replacement.................................................................................................................. 3-13

Chapter 4 Recommended spare parts and special tools for maintenance ............................................... 4-1

Chapter 5 Wire-harness connection diagram.................................................................................................. 5-1

To use robot safely
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 “SETUP” (for FD controller) “Chapter 1 Point on safety”

In this manual, we use the symbols shown below to show the level of danger of the each label:

This tell you that the possibilities of danger can occur when the robot is handled incorrectly.(e.g.
Death or serious injuries can occur.) And also includes urgency of warnings in a highly
DANGER dangerous situation. Always observe these precautions to safely use the robot.
This tells you that the possibilities of danger can occur when the robot is handled
incorrectly.(e.g. Death or serious injuries can occur.) Always observe these precautions to safely
WARNING use the robot.
This tells you that the possibilities of danger can occur when the robot is handled incorrectly.
(e.g. Minor injuries or property damage can occur.) Always observe these precautions to safely
CAUTION use the robot.

The following symbol is also used for important checkpoints.

This indicates the other special notes.

IMPORTANT
Danger and caution signs on manipulator
Following labels and marks are affixed on manipulator. Their location and their existence itself may vary
according to the robot type.

This sign indicates a power supply inlet for the robot. Motor power and detecting
device power is supplied to connectors and terminal blocks, which is inside of
the connector covers of each parts of the robot.
Never touch connectors or terminal blocks directly or indirectly with conductive
items when the main power is on, as electric shock may occur. If connectors or
terminal blocks are disconnected when the main power is on, electric shock or
malfunction of the robot may occur. Make sure to turn OFF the main power on the
controller when performing any maintenance.

This sign indicates the parts of the robot, which will become hot.
Carelessly touching the parts, where the signs are may result in serious burns.

This sign indicates the dangerous area, operators may get caught by the robot.
Never come close to the area, where these signs are. Brakes can be released not
only during teaching, but also while the motors are OFF. Please pay extra
attention and make prevention plan in advance when performing maintenance or
any types of work to avoid pinching any parts of your body before coming close to
this area.

Another caution and warning labels;

Ignoring these signs and disassembling some parts may cause fatal injuries, death, or damage any
equipment around.

Protection labels;
Chapter 1 Basic specifications
1.1 List of basic specifications

Item Specifications
EZ03V4-02 EZ03V4-02 EZ03F4-02 EZ03F4-02
Robot model
-4525 -4515 -5525 -5515
Construction SCARA
Number of axis 4
Drive system AC servo motor
Axis 1 250mm 150mm 250mm 150mm
Axis 2 ±170 °
Axis 3 ±180 ° ±145 °
Max. motion range
Axis 4 ±360 °
Axis 5 ---
Axis 6 ---
Axis 1 1400mm/s 1200 mm/s 1400mm/s 1200mm/s
Axis 2 450 °/s
Axis 3 720 °/s
Max. speed *5
Axis 4 2400 °/s
Axis 5 ---
Axis 6 ---
Max. pay load 2 kg (3 kg)
Max. allowable Axis 4 0.05 kg・m2 ( Rated 0.005 kg・m2 )
moment of inertia Axis 5 ---
of wrist *1 Axis 6 ---
Position repeatability *2 ±0.014mm
Max. reach 450mm 550mm
Air piping φ6×2
Application signal wires 10 wires
Installation *3 Ceiling setting Floor setting
Temperature: 0 to 45 ºC *4
Ambient conditions Humidity: 20 to 85%RH (No dew condensation allowed)
Vibration to the installation surface: Not more than 0.5G (4.9 m/s2)
Dust-proof / Drip-proof
IP20
performance *5
Noise level *8 70 dB
Robot mass 42kg 43kg
1[rad] = 180/π[°], 1[N･m] = 1/9.8[kgf･m]
- On controller display, axis 1 to 4 is displayed as J1 to J4 for each.
- The specification and externals described in this specification might change without a previous notice for the improvement
- Explosion resistance is not available.

*1: The Allowable moment of inertia of a wrist changes with load conditions of a wrist.
*2: This value conforms to "JIS B 8432".
*3: Operation range is controlled when setting the wall or slant installation (e.g.: Axis 1 operation range ±30° of the wall
setting)
*4: Permitted height is not higher than 1,000m above sea level. If used in higher place, permitted temperature is affected by
height.
*5: Liquid such as organic compound, acidity, alkalinity, chlorine or gasoline cutting fluid which deteriorates the seal material is
not available to use.
*6: Max. speed on the table shown is maximum value, so it changes depending on the work program and condition of wrist load.
*8: A load equivalent noise level, measured according to the JIS Z 8737-1 (ISO 11201).（Operation at rated load and Max.
speed）

1-1
1.2 Robot dimensions and motion range
【EZ03V4-02-4525】

1-2
【EZ03V4-02-4515】

1-3
【EZ03F4-02-5525】

1-4
【EZ03F4-02-5515】

1-5
 1.3 Details of payload installation section

Be sure to screw M5 tool fixing bolts in the wrist not deeper than the screw depth in the
installation face. Screwing the bolts deeper than the screw depth may damage the wrist.
CAUTION

【EZ03V4-02-4525】【EZ03V4-02-4515】【EZ03F4-02-5525】【EZ03F4-02-5515】

Tool flange center

(Center of wrist coordinate system)
(X,Y,Z) = (0,0,0)

Point A

1-6
1.4 Application wiring and piping diagram
■ When solenoid valve (option) is installed

SOL Valve Air outlet

Silencer MAX. 2pcs (for the tool such
as gripper)

Base Arm 1 Arm 2

Solenoid valves are Note)

installed here - In standard specification, only 2 air
lines (AIR1 to Port1 and AIR2 to
Port5) are connected directly inside
gear box. Plugs are attached on air
outlet.
- Solenoid valves and silencer written
Air outlet Base in this figure are installed when
“solenoid valve” option is selected.

Arm 1

Air outlet

Arm 2
Wrist

1-7
■ Detailed diagram of the application connectors

6 5 4 3 2 1 CN10A

D G A20 A19 A18 A17 A16 A03 A02 A01

3 2 1
C A15 A14 A13 A12 A11 A07 A06 A05 A04
7 6 5 4
B A22 A10 A09 A08 A07 A06 A10 A09 A08
10 9 8

A A21 A05 A04 A03 A02 A01

Connector CNR0101 on base Connector CN10A on wrist 1

Tyco AMP 1939839-1, 1939840-1, 1903112-2 JAE JN1AS10ML1-R
Partner connector type Partner connector type
Tyco AMP 1939847-1, 1939850-1, 1827570-2 JAE JN1DS10SL2

1-8
Chapter 2 Precautions for handling
2.1 Names of robot components

ベース
Base
製造銘板 （右側面）

MFG. Name Plate 第 1 軸モータ （ベース内部）

(right side) Axis 1 Motor (ins ide base)

第 2 軸モータ （ベース内部）

Axis 2 Motor (inside frame)

第 4 軸モータ （ア ーム内部）
Axis 4 Motor (inside Gear box)

第 3 軸モータ （アーム内部）
Axis 3 Motor (inside arm)

アーム１ アーム 2
Arm1 Arm 2

Manufacturing name plate Z+

Manufacturing No.

Date of manufacture Axis 1

Serial robot number
Axis 2
Mass of robot

X-
Z-
(Mass of robot is only for CE specification)
Axis 3
X+
Y-
Y+

RX+ RX- Axis 4

2-1
2.2 Transport procedure

The robot and controller must be transported by personnel who have licenses required for
slinging work, crane operation, forklift truck operation, and others.
WARNING
Before transporting the robot and the controller, be sure to check the weight of them and
the transportation procedures which are described in the Maintenance Service Manual of
WARNING the robot.
When hanging the robot or the controller, please follow the instructions described in the
maintenance manual of them. If the work is done by following the other methods, the
WARNING robot or the controller may fall down and results accidents.
During transport of the robot and controller, pay utmost care not to cause damage to
wirings. Furthermore, after installing the robot, take protective measures such as using
WARNING protective covers so that the wirings will not be damaged by workers or other persons, or
forklift trucks or else.
When transporting robot without fixing, robot may be damaged due to the vibration or
crush during transportations. Before transporting robot, do not forget to install arm fixing
CAUTION fixture which is installed at the time of shipping.

■ Using a transportation brackets

When transporting robot by hand, be sure to conduct the work by more than two persons.
In case of inverted installing, conduct the work by more than three persons
CAUTION

To transport the robot, hold the arm position indicated below. This work must be done by more than
two persons.
In case that arm 1 and 2 position is different, hold the bottom of arm 2 and base in same way. If
robot is hold by only its arm top, robot may be damaged.

Never hang the robot

by holding arm top only.

Both side cover is made by resin.

Never apply stress on it. This
cover may be damaged if robot
is horizontally laid down.

2-2
 ■ Turning over the robot for inverted installation

In order to turn over the robot for inverted installation, rotate the robot with holding the portion
indicated below.
This work must be done by more than three persons

Both side cover is made by

resin. Never apply stress on it.
This cover may be damaged if
robot is horizontally laid down.

2-3
■ Fixing arms when transporting

When transporting robot, install arm fixing bracket, which is installed at the time of shipping.
Set the robot to the posture indicated below, then install arm fixing bracket to fix the arm end.

When transporting robot without fixing, robot may be damaged due to the vibration or crush
during transportations.
CAUTION

【EZ03V4-02-4525】【EZ03V4-02-4515】

Thick washer
Robot posture
Axis 1 0mm
Axis 2 160deg
Axis 3 20deg

Arm fixing bracket Axis 4 0deg

【EZ03F4-02-5525】【EZ03F4-02-5515】

Robot posture
Axis 1 0mm
Axis 2 144deg
Axis 3 -144deg
Axis 4 0deg

Arm fixing bracket

Thick washer

2-4
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, first of all, consider the utmost safety to workers and take serious safety
measures. The following describes precautions for safety.

Safety measures for entering 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 to make sure to keep the worker away from the robot.
Not installing guard fence will cause the workers or other persons to accidentally enter
WARNING
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 axis 1 for a maximum travel

(After emergency stop signal occurred under maximum speed)
EZ03V4-02, EZ03F4-02
Stop time 0.21 [sec]
Stop angle 1.29 [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, anyone can get in the guard fence, thus result in
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 f both the safety plug
WARNING
and to turn off the motor power.)
Design the system so that the robot will move with the low-speed playback mode,
when the safety plug is unplugged. When the robot is operated at a high speed under
the said condition, no one can escape from the robot, thus resulting in accidents. (The
WARNING
controller has an input signal to select low-speed playback mode.)
Set up the Emergency Stop buttons of the robot, where the place that workers can
immediately reach. In case the workers are in the location where he cannot press the
WARNING
switch immediately, accidents may happen. (The controller has an input signal of
“emergency stop”.)

2-5
 In case the guard fence cannot be constructed, install optoelectronic switches
and/or mat switches, etc. at all entrances to the robot operating area in the replacement
WARNING
of safety plug. These switches can function to automatically stop the robot when anyone
enters beyond the guard fence.
By painting the floor of the hazardous area (the robot operating area) with color
WARNING
paint anyone can recognize the hazardous area.

Safety measures for the robot and peripheral equipment locations

In case of connecting the primary power supply to the controller and/or the peripheral
equipment, please make sure that the supply side power is turned OFF. Since high
WARNING voltages such as 100VAC, 200VAC, or 400VAC are applied, electric shocks can occur.

Do not install the operation and the adjustment part within the robot operating area.
Install the robot control panel, interlock panel, and all the other operation panels where
it’s safe, so that they can be operated outside of the guard fence. In case those
WARNING operation panels are installed near the robot, workers can get caught in the robot, when
the robot operation fails.
To set up an operation stand, equip an Emergency Stop button on that operation
stand. If any abnormality occurs while the robot is being operated by using the operation
WARNING stand, make sure that the robot can make an emergency stop by pressing this switch.
Make sure not to route wires and pipes (of the robot itself, control panel, interlock
panel, and etc.) that workers will fall over them or forklift trucks will directly tread them.
WARNING Otherwise workers might fall over and/or might break wires, then cause accidents
Never install the control panel, interlock panel, operation stand and any others in the
places where the movements of the robot are out of your eyesight. Even though an
abnormality had occurred in such situation, it is hard to recognize them. It can also cause
WARNING
serious accidents or even death, if the operator is not aware of the circumstances.
If the necessary operating area of robot is smaller than the maximum motion range of
the robot specification, then limit the robot operating area. The motion range can be
controlled by using the limit switch and mechanical stopper. Even the robot was about to
WARNING move over the regular operating area (due to an abnormality), this function will enable
the robot to stop just before the operation. You can also set up software limit to avoid
errors.
Please install light shielding boards or protectors during welding arcs, if there’s a
possibility that direction of spatters or any other can reach the workers. If that’s the case,
please pay extra attention to the robot movement, when you installing them. Otherwise it
WARNING
may cause injuries to workers by spatters, or any other things.
Provide a display which is large and recognizable so that anyone can notice whether
the robot operation is automatic or manual from far distance. Furthermore, it is effective to
WARNING use a buzzer or announcement to alert workers to initiate the automatic operation. Make
sure that people can easily recognize automatic operation in progress from distant
locations.
Eliminate protrusions from the peripheral equipment and around the robot as possible.
If necessary, make sure to cover them. Otherwise it may cause hazardous situation when
WARNING a worker touches them or even a worker might fall over when he surprised with a sudden
movement of the robot.
Do not make a layout so that a worker will need to put his/her hands into the guard
fence to take in or out work pieces. There are some possibilities when the worker put
WARNING his/her hands in the guard fence, then the robot moves towards that direction, thus result
in accidents.

2-6
 Safety measures for installation work
To install the robot, it is important to install the robot so that no workers will get pinched
or hurt by the robot or a device around them. The robot must not operate in the maximum
operating range with a tool equipped on, and make sure not to touch any peripheral
WARNING
equipment.
Be sure to install the robot according to the specified procedure. Otherwise possibilities
occur that robot’s base may move or robot may fall over while in operation.
WARNING
You must fully understand the connection procedure to make proper wire connections
between the robot and the controller or the robot and the peripheral equipment. Not following
WARNING the proper procedure will cause the malfunction of the robot.
Be sure to establish a proper grounding for the robot. If the equipment makes
substantial noises such as a welder, conduct the specified grounding construction for the
WARNING equipment.
Please pay extra attention not to damage wirings during transportation or installation of
the robot. Furthermore, after installing the robot, apply protective guards to wirings so
WARNING that it won’t be damaged by workers or other persons, or forklift trucks or any other.
Robot is not dust-tight packaged.
If robot is used in clean room, dust or fine particles shall be removed before carrying it in clean
IMPORTANT room. It is recommended that robot should be cleaned by swabbing with isopropyl alcohol (IPA).
Use of other solvents or pure water could be the cause of rust or peel of coating materials.
It is to be noted that cleanliness of robot is worse if it has operated in poor conditions for a long
IMPORTANT time or if it has been left as it was.

■ 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) Construct 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 that the foundation endures not only the static loads but
also the reaction force caused by robot movement.
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.

Thickness of floor concrete Not less than 150 mm

4 bolts of M 8 X 25
(JIS: Strength class 12.9)
Installation parts *1 4 plain washers of
not less than 2.3 mm in thickness
and HRC35 in hardness
Tightening torque *2 33.3 Nm
Allowable repeated tensile *3 Approximately 300 N
*1 : Installation parts are not accessory of robot.
*2 : Apply a coating of lubricating oil to the threaded parts of bolts, and then tighten bolts by using torque wrench to the
specified tightening torque.
*3 : This tensile is per installation bolt when robot is installed with all bolts written in table above.

2-7
■ Installation dimensions
To install the robot, lock the swiveling base of the robot.
The mechanical stopper end is located in a position exceeding the specified working
envelope (software limit) of axis 1. To install the safety fence, please consider all the
WARNING aspects like wrist configuration, shape of the tool and the drawings to install.

On axis 1, 2 and 3, the robot working envelope can be regulated for safety. Optional part
is necessary to enable this function.
WARNING

【EZ03V4-02-4525】
【EZ03V4-02-4515】
【EZ03F4-02-5525】
【EZ03F4-02-5515】

Keep the space

250mm or longer for
cable routing.

■ Accuracy of installation surface

It is strictly recommended to observe precautions below to keep the swiveling base level as flat as
possible to installing robot. (Not to cause dent.)
(1) Level of the flatness of 4 plates on the
installation surface must be within 0.1
mm
(2) Keep the gap between the installation
surface of 4 each base plates and the
installation surface within 0.1 mm (±0.05
mm) in height.

■ Maximum generative force of the robot

Maximum Maximum Maximum Maximum

Vertical horizontal Vertical horizontal
Robot model generative generative generative generative
force force moment moment
FV FH MV MH

【EZ03V4-02-4525】
【EZ03V4-02-4515】
900N 700N 400Nm 300Nm
【EZ03F4-02-5525】
【EZ03F4-02-5515】

2-8
2.4 Allowable wrist load

The wrist load is regulated by the allowable pay load mass, allowable static load
torque, and allowable moment of inertia. If the wrist load exceeds beyond these
CAUTION
allowable values, WE CANNOT GUARANTEE THE FUNCTION OF THE ROBOT.
For detail, please refer to “1.1 List of basic specifications” and following figures.

■ Torque map for the wrist load

Use the robot within condition that COG of wrist load stays in the range shown in the torque map.

Rated condition Maximum condition *1

【EZ03V4-02-4525】
【EZ03V4-02-4515】
【EZ03F4-02-5525】
【EZ03F4-02-5515】

*1 Speed and acceleration is automatically limited.

2-9
2.5 Setting of the robot No. at Servo CPU board
As a reference, DIP switch for setting the robot number (Identification number) is shown below.
This board (UM392 Servo CPU board) is inside the robot.

Setting of the DIP switch has completed at the time of shipment.

There is no necessity for customer to change the setting.

Please let our NACHI service engineer to change the setting of the DIP
switch. In case of removing the parts by opening robot’s cover
carelessly, trouble might occur due to the cable disconnection and the
CAUTION poor connection. Also, the wrong setting can cause the problem such
as robot dysfunction.

Please be careful that we cannot warranty in case of trouble occurred

by removing the board or connector, or changing the setting of the DIP
switch without NACHI agreement.

4
3
2
1
ROBOT#1

N
O
SW1
4
3
2
1
ROBOT#2
N
O
4
3
2
1

ROBOT#3
N
O
4
3
2
1

ROBOT#4
N
O

UM392-10

Setting of SW1

Robot Sign on the SW1

No. 4 3 2 1
1 OFF OFF OFF OFF
2 ON OFF OFF OFF
3 OFF ON OFF OFF
4 ON ON OFF OFF

2-10
(Reference drawing) Setting of the robot number by DIP switch

UM396
Sequence board

x4

UM392
Servo CPU Board

4 2 1 3
Sequence board Servo CPU Board
UM396 UM392
Robot SW1 SW1 Target robot
Number (Inside of the (Inside of the
controller） Robot)
OFF OFF OFF OFF
O CFDL1 Robot 1
4
3
2
1

1 OFF
1 2
N
OFF
CFDL2 Robot 1
CFDL4 Robot 1
N
O

R OBOT#1

ON OFF OFF OFF

O
4
3
2
1

1 ON CFDL2 Robot 2
2 2
N
OFF CFDL4 Robot 2
N
O

ROBOT#2

OFF ON OFF OFF

O
1
4
3
2
1

OFF
3 2
N
ON
CFDL4 Robot 3
N
O

ROBOT#3

ON ON OFF OFF
O
1
4
3
2
1

ON
4 2
N
ON
CFDL4 Robot 4
N
O

ROBOT#4

There is also DIP switch to set the number of the robot at the “Sequence board UM396” ,
INFO. which is located in the CFDL controller. It is necessary to match the settings of the
sequence board side and the robot side as listed above. (This setting is usually completed
before the shipment.)

2-11
NOTE

2-12
Chapter 3 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
CAUTION ON the power supply, post the warning signs such as “DON’T POWER ON”.
Overhaul period is every 20,000 operating hours or every four years, whichever
comes earlier. Overhaul period is calculated under the Nachi regulated motion
pattern. Overhaul period may be shorter due to the customer’s motion pattern.
Standard motion pattern to satisfy above overhaul period is that cycle time duty (*) is 50%
CAUTION or lower.
(*) Cycle time duty = robot moving time / 1 cycle total time.
Stopping time includes pausing time while moving, waiting time until next start and or so.

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 should create and implement
the inspection program. For inspection items, refer to following table.
Furthermore, perform overhauls every 20,000 operating hours or every four years, whichever
comes earlier. Should you have any questions about the inspection and adjustment methods, contact
our Service Department.

Inspection items and periods

Period
Quarterly

Inspection Item Inspection Method Target portion

Yearly
Daily

○ Robot body Confirming that playback position is same as before. Whole body

○ Cleaning of robot Wiping of dirt, removing of accumulated spatter, dust, Whole body
cutting chips.
○ Major bolts Retightening and coating of paint lock to all of exposed Whole body
bolts (refer to “Specified tightening torque” table)
Also for the tool fixing bolts.
○ Motor Checking the abnormal heat generation and abnormal All axis
sounds
○ Brake Confirming that robot arm and tool never drop when All axis
motor power is turned ON/OFF.
○ Confirming that robot arm and tool never drop when the All axis
brake is released.
○ Reduction gear Confirming of no abnormal vibration, no abnormal All axis
sounds and no oil leakage.
○ Ball screw Confirming of no abnormal vibration, no abnormal Axis 1
sounds
○ Belt Refer to “3.2 Maintenance of belt” All axis

Specified tightening torque of bolts

Hexagon socket head Hexagon socket head
cap screw cap SUS screw
M3 1.57 N・m 1.47 N・m
M4 3.63 N・m 3.4 N・m
M5 7.35 N・m 6.9 N・m
M6 12.4 N・m 11.8 N・m
M8 30.4 N・m 28.4 N・m
Tightening torque may vary according to the material and the kind of bolt. Unless specified in drawing, refer to the value in this table.

3-1
3.2 Maintenance of belt
3.2.1 Inspection of belt
Tools required (Customer preparation required
Name Specification Q’ty
Tension Meter (Reference) TSUBAKIMOTO CHAIN Type BDTM101 1
Push-pull gauge Measured Max. load more than 20N, Minimum scale less than 1N 1
Dial gauge Scale increment width 0.01mm 1
Magnet stand For fixing the dial gauge 1
Tension adjustment bolt M4 length 60mm or more (For axis 3,4(2)) 1
Tension adjustment bolt M4 length 25mm (For axis 1) 1

STEP Work performed

1 Turn ON the motor power to get
ready for manual operation.

2 Make the robot posture shown below. Removable cover for

Axis 1 position had better been lower Axis 1,2 belt tension inspection
position for easier work.

3 Press the emergency stop button.

4 Remove the covers.

Removable cover for

axis 4(1) belt tension inspection

Removable cover for

axis 3,4(2) belt tension ins-
pection
Belt inspection posture and Cover locations

5 Remove battery and solenoid valves

Installation bolt Installation bolt
(option) together with the bracket. 2-M4x8(Tightening torque:3.63Nm)
2-M4x8(Tightening torque:3.63Nm)

Solenoid valves Battery

Remove axis 1 belt cover.
Installation bolt
2-M3x5 (Tightening torque: 1.77 Nm)

Axis 1 belt cover

3-2
6 Remove axis 1 moving side wiring bracket together with the wiring.
(Do not separate the connector of the wiring. If encoder is disconnected, encoder reset is
necessary.)
Installation bolt
2-M4x10 (Tightening
Axis 1 moving side
torque:3.63Nm
wiring bracket

Put aside the

removed bracket

It is possible to access the installation

Remove axis 2 belt cover. bolt, when sliding up the cable tie that is
Installation bolt bundling the joint.
2-M3x6 (Tightening
torque :1.77Nm)

Axis 2 belt cover

7 While operating the wrist manually, check for the belt tooth wear and the belt tooth
deddendum (: root of the gear teeth) cracks, or the belt back cracks. (Refer to the below.)
If damaged is found on a belt, replace the belt. Consult NACHI service for replacement.
-Inspection of the belt-
Type of abnormalities External appearance
If the tooth cloth is worn, replacing
the belt is necessary. Tooth
In such a case, the fiber of the tooth
Abnormal wear of tooth cloth is becomes fluffy, and the
(Early stage) rubber is removed. As a result, the
belt color changes to white, and the
texture of the tooth cloth becomes
unclear.

Check the appearance of the belt, and if any of the abnormalities as follows is
observed, replace the belt.
Type of abnormalities External appearance

The tooth cloth is worn out,

and the rubber is exposed.
Abnormal wear of tooth (The face width becomes
thinner.)

The bottom of tooth is

cracked.
Crack

The core wire is

exposed.
Tooth is missing.

The corner is rounded.

Abnormal wear Note:

The side is normal if its Abnormal wear
edge remains sharp, as (The core wire
if it was cut with a knife. has ragged.)

Belt side is tore.

3-3
8 Check the belt looseness using a tension meter.
If looseness is found, adjust the belt tension.
Please refer to the separated tension table for each belt tension adjustment value.
Inspection of the axis 4①
Place the sonic tension meter closer to measure the tension at the measured point below.
Tension adjustment bolt

Idler fixing bolt

3-M3x10(Tightening torque:1.77Nm)

Axis4①Belt
Measured position for tension
Adjustment of the axis4①
Loosen the Idler fixing bolt, and adjust the tension by rotating the tension adjusting bolt evenly.
Tighten the fixing bolt again then, check the tension. Repeat this until reaching the proper tension.

Inspection of the belt of axis 3 and 4②

Place the sonic tension meter closer to measure the tension at the measured point below.

Axis3 Belt
Measured position for tension

Axis4(2)Belt Measured position for tension

Adjustment of the Axis 3, 4(2) belt

Loosen the plate fixing bolt (do not remove), and install the bolt for adjustment to the designated
tapped hole of the plate.
Place the spring scale to the adjustment bolt and adjust the tension by pulling to the arrow direction.
Tighten the fixing bolt again then, check the tension. Repeat this until reaching the proper tension.

Axis 4 Plate fixing bolt Designated tap

3-M4x15(Tightening torque:3.63Nm) for adjustment
bolt

Axis 3,4(2) Removal cover

when adjusting belt tension
10-M3x6 Button bolt (SUS)
(Tightening torque: 1.77Nm)

Designated tap
Axis 3 Plate fixing bolt for adjustment
3-M4x15(Tightening torque:3.63Nm) bolt

3-4
 Inspection of the axis 1 belt
Measure it by placing the tension meter closer at the measuring point below.

Axis1 belt

Tension measuring point

Adjustment of the axis 1 belt

Loosen the plate fixing bolt (do not remove), and install the bolt for adjustment to the designated
tapped hole of the plate.
Place the adjustment bolt to the bracket towards the back, and adjust the tension by screwing in.
Tighten the fixing bolt again then, check the tension. Repeat this until reaching the proper tension.

Axis 1 plate fixing bolt

3-M4x10 (Tightening torque: 3.63Nm)

Designated tap for adjustment bolt

Bolt size: M4x25

Inspection of the axis 2 belt

Since the axis 2 cannot be measured by sonic tension meter, so please inspect it by the load
deflection of the belt as below.

Axis2 belt

① Set the magnet stand, which has installed dial gauge at the bracket in the arm, and set the
terminal of the dial gauge at the center of the belt span and the edge of the belt width (sinc
e the center part of the belt width is used for pressing).

Dial gauge Magnet stand

Measuring point Installing position

3-5
 ② Add pressing load to the center of the belt span by push pull gauge.

Use the wedge-shaped

terminal for push pull
gauge, and hold against the
belt perpendicularly.

Push pull gauge

プッシュプルゲージ Belt
ベルト
Pressing point for
push pull gauge
In case that the dial gauge and
push pull gauge interferes,
make dial gauge axis offset as
right.
ダイヤルゲージ
Dial gauge

③ Read the value of the push pull gauge (Belt pressing load F) when the dial gauge (Belt deflection)
becomes 0.96mm.
④ Convert into belt tension T by the next formula.
Ｔ＝１６×Ｆ－１９ [N] ･･･ Axis 2 belt tension conversion formual

Adjustment of the axis 2 belt

Loosen the plate fixing bolt (Do not remove.), and insert the lever such as flat-bladed screw driver
between the plate and wiring clamp.
Press the plate by lever at fulcrum bolt as fulcrum, and adjust the tension.
Tighten the fixing bolt again then, check the tension. Repeat this until reaching the proper tension.

Axis 2 plate fixing bolt Wiring clamp

Axis 2 plateTightening
3-M4x12( fixing bolt
torque:3.63Nm)
3-M4x12 (Tightening torque:3.63Nm)

Fulcrum bolt

EZ03V4-02-4525,4515 Belt tension

Tension when inspecting Tension when
and adjusting exchanging the belt Setting of the tension meter
(Reuse the belt) (Use the new belt)
Axis1 108～122N 146～160N SPAN:0.106m, MASS:0.062kg/m
Axis2 108～122N 186～204N By the deflection measurement
Axis3 108～122N 146～160N SPAN:0.223m, MASS:0.041kg/m
Axis4① 108～122N 140～154N SPAN:0.225m, MASS:0.041kg/m
Axis4② 42～56N 53～67N SPAN:0.223m, MASS:0.017kg/m

EZ03F4-02-5525,5515 Belt tension

Tension when inspecting Tension when
and adjusting exchanging the belt Setting of the tension meter
(Reuse the belt) (Use the new belt)
Axis1 108～122N 146～160N SPAN:0.106m, MASS:0.062kg/m
Axis2 108～122N 186～204N By the deflection measurement
Axis3 108～122N 146～160N SPAN:0.320m, MASS:0.041kg/m
Axis4① 108～122N 140～154N SPAN:0.225m, MASS:0.041kg/m
Axis4② 42～56N 53～67N SPAN:0.333m, MASS:0.017kg/m

3-6
3.3 Lubrication
Periodically lubricate to the robot.

Lubrication point
№ Lubrication point Lubrication port Cycle Applicable grease Amount Remark
Axis 1 Axis 1 ball screw nut 12 ＋0.5
1 Long Time PD2 1 ０ cc
Ball screw Lubrication port months
Axis 1 Axis 1 base side 12 ＋0.5
2 Long Time PD2 1 ０ cc
LM guide Lubrication port months
Axis 1 Axis 1 bearing holder 12 ＋0.5
3 Long Time PD2 0.5 ０ cc
support bearing Lubrication port months
Axis 4 cross Arm 2 top 12 ＋0.5
4 Long Time PD2 1 ０ cc
roller bearing Lubrication port months

Use a grease gun.

CAUTION
Note that lubricating grease more than the recommended amount may result in
leakage of grease or faulty robot locus.
CAUTION Do not lubricate to the unspecified position.

Tools required (prepared by customer)

Name Specification Q’ty
Recommended nozzle for MG70 Nozzle N (axis 1 LM guide)
Grease gun 1
for MG70 Nozzle H (axis 1 ball screw)
Connector M5, φ6 (axis 4 cross roller bearing) 1
Connector Rc-1/8, φ6 1
Grease nipple Rc-1/8 1
Hose φ6X4, approx. 50mm 1

3-7
No. Required work
1 Turn on the motor power and get ready to operate robot arm manually.

2 Move the robot to the posture indicated below. (axis 2,3 and 4 is in any position for easier work)
Push emergency stop button.
Remove cover indicated below.

EZ03V4-02 EZ03F4-02

Axis 4
lubrication position

Axis 1 cover
J1軸カバー
lubrication position is
inside the cover

Axis 4 Robot model Axis 1 position

lubrication position EZ03V4-02-4525 -120mm
EZ03V4-02-4515 -70mm
EZ03F4-02-5525 +120mm
EZ03F4-02-5515 +70mm

3 With using grease gun, feed the grease from lubrication position indicated below.
As for axis 1 LM guide and ball screw position, specified position is only place for correct lubrication
work.

Axis 1 LM guide
Lubrication grease
nipple (4 position)
Axis 1 support bearing lubrication
(same as axis 4, remove plug and install M5
connect before lubrication)

Axis 1 ball screw

Lubrication nipple

3-8
Remove left and right side plug at the arm top, attach connector [M5,φ6] on one side. (other side is free
to releases air.) Connect hose to connector [Rc-1/8,φ6] and grease nipple [Rc1/8] and feed grease with
using a grease gun.
After finishing lubrication, attach left and right side plug (tightening torque 1.2Nm)

Axis 4 cross roller bearing

Lubrication position

Lubrication

Air release

3-9
3.4 Encoder reset and correction

3.4.1 Encoder reset

This procedure is clearing the internal memory in encoder itself.
This procedure is absolutely necessary for the recovery when robot is replaced, when encoder
connector is disconnected, when encoder batteries are disconnected while controller power OFF,
and when encoder error has been occurred. On the other hand, this procedure is not necessary
after replacing the belt, for example.

No special tools are required for encoder reset procedure.

In case of Compact TP of CFD controller
Refer to CFD controller instruction manual “Start Up” “2.1 Set Up of Robot”
In case of Smart TP of CFD controller
Refer to FD controller instruction manual “SETUP” “4.3.3 Encoder reset and Encoder correction”

Upon completion of this procedure, please conduct “encoder correction” procedure without fail.

3.4.2 Encoder correction

This is very important procedure to define the zero position of robot axis
This procedure is registering the “encoder correction data” so that encoder data becomes the
“pre-determined value” at the “pre-determined position”. This position is called reference
position. Zeroing pin and blocks are used to make this posture.

Reference position and its encoder data are explained in following figures.
These encoder data are very important to check the successful procedure of encoder
IMPORTANT correction.

Axis1 zeroing pin Inserting position of Axis 1 zeroing pin

Encoder data
At reference position
Axis 1 80,000[Hex]
Axis 2 80,000[Hex]
Axis 3 80,000[Hex]
Axis 4 80,000[Hex]

Axis2 zeroing
block

Axis3 zeroing block

Axis4 zeroing block Inserting position of Axis 3 zeroing block

Inserting position of Axis 2 zeroing block
Inserting position of Axis 4 zeroing block

This figure shows that all axis is

in reference position

Reference position (Locations to insert zeroing pin and block）

This figure indicates that all axis

in the reference position.

3-10
 This work includes some jobs that should be conducted with motors ON. Consequently,
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 other person must
CAUTION promptly finish the work with thorough attention paid to the robot operating area.
Furthermore, prior to starting the work, check for safe corridors.

No Contents of operation
1 For this procedure, following tools are required.
zeroing pin and block (OP-T2-*** ; option)
Please prepare these tools by referring to ”Chapter 4 Recommended spare parts and special
tools for maintenance”.
2 Move the robot (target axis) to the reference position in manual operation (speed 2 or 3)
For axis 1: The zeroing pin is inserted at the reference position.
For axis 2, 3 and 4: The zeroing block is mounted at the reference position.
3 Register the encoder correction data

In case of Compact TP of CFD controller

Refer to CFD controller instruction manual “Start Up” “2.1 Set Up of Robot”
In case of Smart TP of CFD controller
Refer to FD controller instruction manual “SETUP” “4.3.3 Encoder reset and Encoder correction”

4 Confirm that current position data is coincident with “Encoder data of reference position”.
5 Remove the zeroing pin (and block).
Ensure that the robot operation presents no problem.

When robot body is replaced, it’s possible that software stroke error occurs and robot can
not arrive in the reference position. Because software is checking the working envelop
INFO. although the position data is not correct.
In this case, once register the encoder correction data in that (incorrect) position. After
that, turn the motor power on again and move the robot to the correct reference position.
(now working envelop is already refreshed.) Finally register the encoder correction data
again.
Axis interference of wrist axis
“Axis interference” exists due to the structure of the wrist on this robot. Because axis 3
interferes to axis 4, axis 3 must be in reference position when performing axis 4 encoder
CAUTION correction.
Otherwise zero position is not been set correctly so robot will not move properly.

3-11
3.5 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 8h/day
IMPORTANT and shut down the power 16h/day.

The replacement period varies depending on usage 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 requirement of the resetting encoder might happen.
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 medium low temperature (20±15°C, less change on temperature)
and less than 70% of relative humidity.
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”.

Required Tools M4 torque wrench, Double-sided adhesive tape, Nipper, Cable tie

No. Required work

Turn ON the power supply of the
1 Battery
controller.
2 Press the emergency stop button.
Remove the fixing bolts of BJ1 panel.

4 Pull out the battery unit from BJ1 box.

Disconnect the connectors CNBAT14 from the battery.
5
An error (encoder battery voltage drop) occurs, but follows the next step. This is not an issue.
Dismount cable tie and remove the battery unit from the case.

The orange cable

tie is reusable, so
do not cut it.
6

CNBAT X 1

7 Set the new battery unit using cable tie on the case.
8 Connect the connectors to the new battery.
9 Reinstall BJ1 panel and fix it with fixing bolt.

3-12
3.6 Robot body replacement
If some trouble happened and it is considered that its cause is robot itself, please replace robot.
This work includes some jobs that should be conducted with motors ON. Consequently,
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 other person must
CAUTION promptly finish the work with thorough attention paid to the robot operating area.
Furthermore, prior to starting the work, check the evacuation route.
“Robot number (Identification No.)” is set to this robot by the switch of the servo CPC
board. Please check whether the number of new robot is same as the previous one when
CAUTION exchanging the robot.

Turn motor power on and operate the robot by manual operation

to safe posture for transporting. （ “2.2 Transport
1
procedure”） If it’s impossible because of error, move the robot
Move robot to safe posture for arm by brake release.
transporting

2 Push emergency stop button and turn controller power off.

Stop the air supply to the robot.

Disconnect all electric cable and air tube such as wires from
Disconnect electric cable and air 3 robot controller and air source.
source, also dismount tool Disengage the tool. (Make a mark on it in order to equip the tool
easily after installation.)

Use a crane.
Install the transporting bracket ( “2.2 Transport procedure”),
4 hook the wire and stretch it lightly, unfasten all of installation
Remove robot
bolts ( “2.3 Installation procedure”), at last hang up the robot
body.

5 Install the new robot.( “2.3 Installation procedure”)

Install new robot Connect all electric cable and air tube.
6 Mount the tool.
Supply the air to the robot.

7 Turn the controller power on.

“Reference position” must be adjusted for all axes.

Adjust reference position At first perform encoder reset procedure ( “3.4.1 Encoder
8
reset”). Then perform encoder correction procedure ( “3.4.2
Encoder correction”).

In teach mode, confirm that all axis can move correctly by

manual operation. Also confirm that TCP fixing movement is
correct by robot coordinate operation.
9 If TCP fixing movement is not correct, check whether tool
mounting position is same as that of previous robot. If it is
correct, tool length parameter needs to be set correctly by “tool
Conform robot behavior length automatic setting”.

In teach mode, conform that robot program can be operated

same as it was by check go and back operation.
10 If robot position differs a little because of the installation position
error and the reference position adjustment error, try to change
the position of teaching program.

3-13
Note

3-14
Chapter 4 Recommended spare parts and
special tools for maintenance
Recommended spare parts are listed in Table shown as below. Please check your robot serial no.
and manufacturing date if you purchase spare parts. Consult NACHI service center for more help.

Classification A: Periodical maintenance parts, B: Spare parts

Recommended spare parts

Robot model
Classification

Recommended/unit
Part No.
Name Remarks

In use/unit
(Model) EZ03V4-02-45** EZ03F4-02-55**

A GREASE LONGTIME-PD2-5KG 1 1 ○ ○ LONGTIME PD2

A BATTERY ER17/50H 1 1 ○ ○ (*1)
B ULTRA PX BELT BG340UP5M15-HC 1 1 ○ ○ Axis 1
B ULTRA PX BELT BG260UP5M15-HC 1 1 ○ ○ Axis 2
B ULTRA PX BELT BG605UP5M10-HC 1 1 ○ - Axis 3
B ULTRA PX BELT BG633UP3M8-HC 1 1 ○ - Axis 4
B ULTRA PX BELT BG645UP5M10-HC 1 1 ○ ○ Axis 4
B ULTRA PX BELT BG800UP5M10-HC 1 1 - ○ Axis 3
B ULTRA PX BELT BG852UP3M8-HC 1 1 - ○ Axis 4
(*1) In case of purchasing this in China, please order ER18505-2. This is compatible with ER17/50H.

The fixtures listed below are required fixture for maintenance work or for efficient work. Please
check your robot serial no. and manufacturing date if you purchase these tools. Consult NACHI
service center for more help.

Special tools for maintenance (option)

Robot model
Part No.
Name Remarks
(Model) EZ03V4-02, EZ03F4-02
Zeroing pin
ACCESSORY OP-T2-099 ○ & zeroing block

Contents of OP-T2-099 (Zeroing pin & zeroing block) (option)

Applied
Name Marking Appearance, etc
Robot model

Axis 1 Zeroing pin

EZ03V4-02
EZ03F4-02
Axis 2,3,4 Zeroing block Z03

4-1
NOTE

4-2
Chapter 5 Wire-harness connection diagram

CFDL controller side Robot side

Pin layout Pin layout

from the arrow side from the arrow side

CFDL CONTROLLER Wire-harness connection (1) CNR01

5-1
 CFDL controller side Robot side

Pin layout
View from contact insertion side from the arrow side

(white) (green) (brawn)

(red) (black) (yellow)

CFDL CONTROLLER Wire-harness connection (2) CNR04

5-2
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Robot Division
1-1-1, FUJIKOSHIHONMACHI, TOYAMA CITY, JAPAN 930-8511
Phone +81-76-423-5137
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Original manual is written in Japanese.