LR MATE 200id Mechanical unit manual - B-83495EN/01...
FANUC Robot LR Mate 200iD FANUC Robot ARC Mate 50iD MECHANICAL UNIT
MAINTENANCE MANUAL MARMT200D09131E REV. A ©2013 FANUC America Corporation All Rights Reserved.
This publication contains proprietary information of FANUC America Corporation furnished for customer use only. No other uses are authorized without the express written permission of FANUC America Corporation. FANUC America Corporation 3900 W. Hamlin Road Rochester Hills, Michigan 48309–3253
B-83495EN/01
Copyrights and Trademarks This new publication contains proprietary information of FANUC America Corporation furnished for customer use only. No other uses are authorized without the express written permission of FANUC America Corporation. The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC America Corporation, hereinafter referred to as FANUC, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations. FANUC manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC products and/or systems. Such systems consist of robots, extended axes, robot controllers, application software, the KAREL® programming language, INSIGHT® vision equipment, and special tools. FANUC recommends that only persons who have been trained in one or more approved FANUC Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintain FANUC products and/or systems and their respective components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.
WARNING This equipment generates, uses, and can radiate radiofrequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measure may be required to correct the interference.
FANUC conducts courses on its systems and products on a regularly scheduled basis at the company's world headquarters in Rochester Hills, Michigan. For additional information contact FANUC America Corporation Training Department 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253 www.fanucrobotics.com For customer assistance, including Technical Support, Service, Parts & Part Repair, and Marketing Requests, contact the Customer Resource Center, 24 hours a day, at 1-800-47-ROBOT (1-800-477-6268). International customers should call 011-1-248-377-7159. Send your comments and suggestions about this manual to:
[email protected] Copyright © 2013 by FANUC America Corporation All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, downloaded, translated into another language, published in any physical or electronic format, including internet, or transmitted in whole or in part in any way without the prior written consent of FANUC America Corporation. AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®, PalletTool®, SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® are Registered Trademarks of FANUC. FANUC reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™, AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™, ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™, ARC Mate System 5™, ARCWorks Pro™, AssistTool™, AutoNormal™, AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™, Center Finder™, Clean Wall™, DualARM™, LR Tool™, MIG Eye™, MotionParts™, MultiARM™, NoBots™, Paint Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks II™, PAINTWorks III™, PalletMate™, PalletMate PC™, PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™, Robo Chop™, Robo Spray™, S-420i™, S-430i™, ShapeGen™, SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3 Controller™, SYSTEM R-J3iB Controller™, SYSTEM R-J3iC Controller™, SYSTEM R-30iA Controller™, SYSTEM R-30iA Mate Controller™, SYSTEM R-30iB Controller™, SYSTEM R-30iB Mate Controller™, TCP Mate™, TorchMate™, TripleARM™, TurboMove™, visLOC™, visPRO-3D™, visTRAC™, WebServer™, WebTP™, and YagTool™.
©FANUC CORPORATION 2013 No part of this manual may be reproduced in any form.
All specifications and designs are subject to change without notice.
Patents One or more of the following U.S. patents might be related to the FANUC products described in this manual.
FANUC America Corporation Patent List 4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 4,942,539 4,984,745 5,238,029 5,239,739 5,272,805 5,293,107 5,293,911 5,331,264 5,367,944 5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687 5,737,218 5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,726 6,059,092 6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621 6,253,799 6,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143 6,378,190 6,385,508 6,425,177 6,477,913 6,490,369 6,518,980 6,540,104 6,541,757 6,560,513 6,569,258 6,612,449 6,703,079 6,705,361 6,726,773 6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,422 7,399,363
FANUC CORPORATION Patent List 4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207 4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,934,504 4,956,594 4,967,125 4,969,109 4,970,370 4,970,448 4,979,127 5,004,968 5,006,035 5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,107,716 5,111,019 5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360 5,292,066 5,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057 5,329,469 5,333,242 5,337,148 5,371,452 5,375,480 5,418,441 5,432,316 5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,461,478 5,463,297 5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,758 5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194 5,552,687 5,558,196 5,561,742 5,570,187 5,570,190 5,572,103 5,581,167 5,582,750 5,587,635 5,600,759 5,608,299 5,608,618 5,624,588 5,630,955 5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,668,628 5,687,295 5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138 5,742,144 5,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135 5,812,408 5,841,257 5,845,053 5,872,894 5,887,122 5,911,892 5,912,540 5,920,678 5,937,143 5,980,082 5,983,744 5,987,591 5,988,850 6,023,044 6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,693 6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898 6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181 6,236,011 6,236,896 6,250,174 6,278,902 6,279,413 6,285,921 6,298,283 6,321,139 6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,377,869 6,382,012 6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979 6,459,958 6,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588 6,680,461 6,696,810 6,728,417 6,763,284 6,772,493 6,845,296 6,853,881 6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 6,970,802 7,038,165 7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,848 7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294 7,181,313 7,280,687 7,283,661 7,291,806 7,299,713 7,315,650 7,324,873 7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,373,220 7,376,488 7,386,367 7,464,623 7,447,615 7,445,260 7,474,939 7,486,816 7,495,192 7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121
Conventions WARNING Information appearing under the "WARNING" caption concerns the protection of personnel. It is boxed and bolded to set it apart from the surrounding text.
CAUTION Information appearing under the "CAUTION" caption concerns the protection of equipment, software, and data. It is boxed and bolded to set it apart from the surrounding text.
Note Information appearing next to NOTE concerns related information or useful hints.
•
Original Instructions
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content.
• No part of this manual may be reproduced in any form. • All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law”. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as ”impossible”.
Safety FANUC America Corporation is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for your application and installation can be best determined by safety system professionals. FANUC America Corporation therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC America Corporation systems. According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation. Ensure that the robot being used is appropriate for the application. Robots used in classified (hazardous) locations must be certified for this use. FANUC America Corporation therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC America Corporation training course and become familiar with the proper operation of the system. Persons responsible for programming the system–including the design, implementation, and debugging of application programs–must be familiar with the recommended programming procedures for your application and robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace.
CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety: The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot
i
Safety
Keeping People Safe The safety of people is always of primary importance in any situation. When applying safety measures to your robotic system, consider the following: External devices Robot(s) Tooling Workpiece
Using Safety Enhancing Devices Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices: Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEADMAN switches
Setting Up a Safe Workcell A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal, state, and local laws, regulations, and guidelines that pertain to safety.
ii
Sponsor your personnel for training in approved FANUC America Corporation training course(s) related to your application. Never permit untrained personnel to operate the robots. Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot. Use anti–tie–down logic to prevent the operator from bypassing safety measures.
Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell.
Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work envelope is the area defined by the maximum motion range of the robot, including any tooling attached to the wrist flange that extend this range.
Safety
Position all controllers outside the robot work envelope.
Never rely on software or firmware based controllers as the primary safety element unless they comply with applicable current robot safety standards. Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell. Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the end–use application.
Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope. Install special guarding that prevents the operator from reaching into restricted areas of the work envelope. Use interlocks. Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety. Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot. Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electro–magnetic interference (EMI), radio frequency interference (RFI), and electro–static discharge (ESD). Make provisions for power lockout/tagout at the controller.
Eliminate pinch points. Pinch points are areas where personnel could get trapped between a moving robot and other equipment.
Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely. Program the robot to load and unload material safely.
If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons. If materials are being applied at dangerously high pressure, provide electrical interlocks for lockout of material flow and pressure.
Staying Safe While Teaching or Manually Operating the Robot Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules:
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment. iii
Safety
Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range. The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department. FANUC America Corporation recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope.
WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.
Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked.
Isolate the robot from all remote control signals that can cause motion while data is being taught. Test any program being run for the first time in the following manner:
WARNING Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury.
-
Using a low motion speed, single step the program for at least one full cycle. Using a low motion speed, test run the program continuously for at least one full cycle. - Using the programmed speed, test run the program continuously for at least one full cycle. Make sure all personnel are outside the work envelope before running production.
Staying Safe During Automatic Operation Advise all personnel who operate the robot during production to observe the following rules: Make sure all safety provisions are present and active.
iv
Safety
Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external devices and other equipment with which the robot interacts. Understand the complete task the robot is programmed to perform before initiating automatic operation. Make sure all personnel are outside the work envelope before operating the robot.
Never enter or allow others to enter the work envelope during automatic operation of the robot.
Know the location and status of all switches, sensors, and control signals that could cause the robot to move.
Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared to press these buttons in an emergency. Never assume that a program is complete if the robot is not moving. The robot could be waiting for an input signal that will permit it to continue its activity. If the robot is running in a pattern, do not assume it will continue to run in the same pattern. Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.
Staying Safe During Inspection When inspecting the robot, be sure to Turn off power at the controller. Lock out and tag out the power source at the controller according to the policies of your plant. Turn off the compressed air source and relieve the air pressure.
If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel.
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.
If power is needed to check the robot motion or electrical circuits, be prepared to press the EMERGENCY STOP button, in an emergency. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
Staying Safe During Maintenance When performing maintenance on your robot system, observe the following rules: Never enter the work envelope while the robot or a program is in operation.
Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist.
v
Safety
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Consider all or any overlapping work envelopes of adjoining robots when standing in a work envelope. Test the teach pendant for proper operation before entering the work envelope. If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately. Whenever possible, perform maintenance with the power turned off. Before you open the controller front panel or enter the work envelope, turn off and lock out the 3–phase power source at the controller. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only.
Release or block all stored energy. Before working on the pneumatic system, shut off the system air supply and purge the air lines.
Isolate the robot from all remote control signals. If maintenance must be done when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this person.
Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked. Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel.
WARNING Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction.
vi
Safety
Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. When replacing or installing components, make sure dirt and debris do not enter the system. Use only specified parts for replacement. To avoid fires and damage to parts in the controller, never use nonspecified fuses. Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices are operating normally.
KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices.
Programming Safety Precautions Implement the following programming safety measures to prevent damage to machine tools and other external devices. Back–check limit switches in the workcell to make sure they do not fail.
Implement ‘‘failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails. Use handshaking protocol to synchronize robot and external device operations. Program the robot to check the condition of all external devices during an operating cycle.
Mechanical Safety Precautions Implement the following mechanical safety measures to prevent damage to machine tools and other external devices. Make sure the workcell is clean and free of oil, water, and debris.
Use DCS (Dual Check Safety), software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.
vii
Safety
KEEPING THE ROBOT SAFE Observe the following operating and programming guidelines to prevent damage to the robot.
Operating Safety Precautions The following measures are designed to prevent damage to the robot during operation. Use a low override speed to increase your control over the robot when jogging the robot.
Visualize the movement the robot will make before you press the jog keys on the teach pendant. Make sure the work envelope is clean and free of oil, water, or debris. Use circuit breakers to guard against electrical overload.
Programming Safety Precautions The following safety measures are designed to prevent damage to the robot during programming: Establish interference zones to prevent collisions when two or more robots share a work area. Make sure that the program ends with the robot near or at the home position.
Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage. In dispensing applications, be aware of all safety guidelines with respect to the dispensing materials.
NOTE: Any deviation from the methods and safety practices described in this manual must conform to the approved standards of your company. If you have questions, see your supervisor.
ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personnel also must work inside the paint booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.
viii
Safety
Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools. CAUTION Ensure that all ground cables remain connected. Never operate the paint robot with ground provisions disconnected. Otherwise, you could injure personnel or damage equipment. Paint robots are operated in three modes: Teach or manual mode Automatic mode, including automatic and exercise operation Diagnostic mode During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe area within the booth whenever automatic mode is initiated at the SOC or MCP. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.
Paint System Safety Features Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features: Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are.
ix
Safety
Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are. EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E–STOP buttons. An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres. A DEADMAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN switch is released or pressed harder during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also E–STOP other robots.
WARNING An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed robot.
Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. DCS (Dual Check Safety), limit switches and hardstops also limit travel by the major axes.
EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SOC is in teach mode.
When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings.
System status is monitored by computer. Severe conditions result in automatic system shutdown.
Staying Safe While Operating the Paint Robot When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.
WARNING Observe all safety rules and guidelines to avoid injury.
x
Safety
WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.
WARNING Enclosures shall not be opened unless the area is known to be nonhazardous or all power has been removed from devices within the enclosure. Power shall not be restored after the enclosure has been opened until all combustible dusts have been removed from the interior of the enclosure and the enclosure purged. Refer to the Purge chapter for the required purge time.
Know the work area of the entire paint station (workcell). Know the work envelope of the robot and hood/deck and door opening devices. Be aware of overlapping work envelopes of adjacent robots. Know where all red, mushroom–shaped EMERGENCY STOP buttons are located.
Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move.
Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor. Become familiar with the complete task the robot will perform BEFORE starting automatic mode. Make sure all personnel are outside the paint booth before you turn on power to the robot servo system. Never enter the work envelope or paint booth before you turn off power to the robot servo system.
Never enter the work envelope during automatic operation unless a safe area has been designated.
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic devices are enabled. Stay out of areas where you might get trapped between a moving robot, conveyor, or opening device and another object.
Be aware of signals and/or operations that could result in the triggering of guns or bells. Be aware of all safety precautions when dispensing of paint is required. Follow the procedures described in this manual.
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Safety
Special Precautions for Combustible Dusts (Powder Paint) When the robot is used in a location where combustible dusts are found, such as the application of powder paint, the following special precautions are required to insure that there are no combustible dusts inside the robot. Purge maintenance air should be maintained at all times, even when the robot power is off. This will insure that dust can not enter the robot.
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3. 4. 5.
A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dust when maintenance air is not present, it will be necessary to remove the covers and clean out any accumulated dust. Do not energize the robot until you have performed the following steps. Before covers are removed, the exterior of the robot should be cleaned to remove accumulated dust. When cleaning and removing accumulated dust, either on the outside or inside of the robot, be sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened with water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate static electricity and cause an explosion unless special precautions are taken. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust. When the dust has been removed, the covers must be replaced immediately. Immediately after the covers are replaced, run a complete purge cycle. The robot can now be energized.
Staying Safe While Operating Paint Application Equipment When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. WARNING When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials, and NFPA 70 National Electrical Code.
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Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms. High Voltage: High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process. Avoid any accumulation of combustible vapors or coating matter. Follow all manufacturer recommended cleaning procedures. Make sure all interlocks are operational.
Safety
No smoking.
Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material. Disable all air and paint pressure to bell. Verify that the lines are not under pressure.
Staying Safe During Maintenance When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot. Paint robots operate in a potentially explosive environment. Use caution when working with electric tools.
When a maintenance technician is repairing or adjusting a robot, the work area is under the control of that technician. All personnel not participating in the maintenance must stay out of the area.
For some maintenance procedures, station a second person at the control panel within reach of the EMERGENCY STOP button. This person must understand the robot and associated potential hazards. Be sure all covers and inspection plates are in good repair and in place. Always return the robot to the ‘‘home’’ position before you disarm it. Never use machine power to aid in removing any component from the robot.
During robot operations, be aware of the robot’s movements. Excess vibration, unusual sounds, and so forth, can alert you to potential problems. Whenever possible, turn off the main electrical disconnect before you clean the robot. When using vinyl resin observe the following: - Wear eye protection and protective gloves during application and removal. - Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye irritation. - If there is contact with the skin, wash with water. - Follow the Original Equipment Manufacturer’s Material Safety Data Sheets. When using paint remover observe the following: - Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning. - Adequate ventilation is required. Overexposure could cause drowsiness. - If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then seek medical attention as soon as possible. - Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
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SAFETY PRECAUTIONS Thank you for purchasing FANUC Robot. This chapter describes the precautions which must be observed to ensure the safe use of the robot. Before attempting to use the robot, be sure to read this chapter thoroughly. Before using the functions related to robot operation, read the relevant operator's manual to become familiar with those functions. If any description in this chapter differs from that in the other part of this manual, the description given in this chapter shall take precedence. For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell. In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1
WORKING PERSON
The personnel can be classified as follows.
Operator: • Turns robot controller power ON/OFF • Starts robot program from operator’s panel Programmer or teaching operator: • Operates the robot • Teaches robot inside the safety fence Maintenance engineer: • Operates the robot • Teaches robot inside the safety fence • Maintenance (adjustment, replacement) -
-
An operator cannot work inside the safety fence. A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance, etc. To work inside the fence, the person must be trained on proper robot operation.
During the operation, programming, and maintenance of your robotic system, the programmer, teaching operator, and maintenance engineer should take additional care of their safety by using the following safety precautions. -
Use adequate clothing or uniforms during system operation Wear safety shoes Use helmet
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DEFINITION OF WARNING, CAUTION AND NOTE
To ensure the safety of user and prevent damage to the machine, this manual indicates each precaution on safety with "Warning" or "Caution" according to its severity. Supplementary information is indicated by "Note". Read the contents of each "Warning", "Caution" and "Note" before attempting to use the robots.
WARNING Applied when there is a danger of the user being injured or when there is a danger of both the user being injured and the equipment being damaged if the approved procedure is not observed. CAUTION Applied when there is a danger of the equipment being damaged, if the approved procedure is not observed. NOTE Notes are used to indicate supplementary information other than Warnings and Cautions. •
3
Read this manual carefully, and store it in a sales place.
WORKING PERSON SAFETY
Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety. (1) Have the robot system working persons attend the training courses held by FANUC. FANUC provides various training courses.
Contact our sales office for details.
(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened. The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see Fig.3 (a) and Fig.3 (b). (4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D). s-2
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(5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when a working person enters the work area. (8) If necessary, install a safety lock so that no one except the working person in charge can turn on the power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock. (9) When adjusting each peripheral device independently, be sure to turn off the power of the robot (10) Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation with gloved fingers could cause an operation error. (11) Programs, system variables, and other information can be saved on memory card or USB memories. Be sure to save the data periodically in case the data is lost in an accident. (12) The robot should be transported and installed by accurately following the procedures recommended by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe injury to workers. (13) In the first operation of the robot after installation, the operation should be restricted to low speeds. Then, the speed should be gradually increased to check the operation of the robot. (14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the same time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before the operation. (15) When the robot is used, the following precautions should be taken. Otherwise, the robot and peripheral equipment can be adversely affected, or workers can be severely injured. - Avoid using the robot in a flammable environment. - Avoid using the robot in an explosive environment. - Avoid using the robot in an environment full of radiation. - Avoid using the robot under water or at high humidity. - Avoid using the robot to carry a person or animal. - Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.) (16) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external emergency , fence etc.) of robot. be sure to confirm the stop movement and do not take the wrong connection. (17) When preparing trestle, please consider security for installation and maintenance work in high place according to Fig.3 (c). Please consider footstep and safety bolt mounting position.
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RP1 Pulsecoder RI/RO,XHBK,XROT RM1 Motor power/brake
EARTH
Safety fence
Interlocking device and safety plug that are activated if the gate is opened.
Fig. 3 (a)
Dual chain
Emergency stop board orPanel Panelboard board EAS1 EAS11 EAS2 EAS21
Single chain
Panel board
Safety fence and safety gate
(Note) （Note） In case caseofofR-30iB, R-30iAR-30iB Mate In TerminalsEAS1,EAS11,EAS2,EAS21 EAS1,EAS11,EAS2,EAS21 FENCE1,FENCE2 Terminals areorprovided on the are provided onboard. the operation box or on the terminal block emergency stop of the printed circuit boar d. Refer the ELECTRICAL CONNCETIONS Chapter of In casetoof R-30iA Mate CONNECTION of Terminals EAS1,EAS11,EAS2,EAS21 are provided R-30iB controller maintenance (B-83195EN) on the emergency stop board manual or connector panel. or (in caseMate of Open air type) R-30iB controller maintenance manual (B-83525EN) or R-30iB Mate controller (Open Air) maintenance manual Termianls FENCE1,FENCE2 ar e provided (B-83525EN) for details. on the emergency stop board. Refer to controller maintenance manual for details.
FENCE1 FENCE2 Fig. 3 (b) Limit switch circuit diagram of the safety fence
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Hook for safety belt Fence
Steps Trestle Footstep for maintenance
Fig.3 (c) Footstep for maintenance
3.1
OPERATOR SAFETY
The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. (1) If you do not have to operate the robot, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work. (2) Operate the robot system at a location outside of the safety fence (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and to prevent the worker from entering a dangerous area. (4) Install an EMERGENCY STOP button within the operator’s reach. The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external EMERGENCY STOP button is pressed. See the diagram below for connection. Dual chain External stop button Emergency stop boa rd
(Note) Connect EES1 and EES11, EES2 and EES21
Panel board
o r Pane l boa rd
EES1 EES11 EES2 EES21
Single chain External stop button
In case R-30iB, R-30iB Mate EES1,EES11,EES2,EES21 are on the emergenc y stop board （Note） Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.
Refer to the ELECTRICAL CONNCETIONS Chapter of In case of R-30iA CONNECTION of EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board. R-30iB controller maintenance manual (B-83195EN) or In case of R-30iA Mate maintenance manual (B-83525EN) R-30iB Mate controller EES1,EES11,EES2,EES21 are on the emergency stop board or R-30iB Mate controller (Open Air) maintenance manual or connector panel (in case of Open air type). EMGIN1,EMGIN2 are on the emergency stop board. (B-83525EN) for details. Refer to the maintenance manual of the controller for details.
Panel board EMGIN1 EMGIN2
Fig.3.1 Connection diagram for external emergency stop button
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3.2
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SAFETY OF THE PROGRAMMER
While teaching the robot, the operator must enter the work area of the robot. the safety of the teach pendant operator especially.
The operator must ensure
(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating condition. (3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on the teach pendant) before entering the area. (4) The programmer must be extremely careful not to let anyone else enter the robot work area. (5) Programming should be done outside the area of the safety fence as far as possible. If programming needs to be done in the area of the safety fence, the programmer should take the following precautions: － Before entering the area of the safety fence, ensure that there is no risk of dangerous situations in the area. － Be prepared to press the emergency stop button whenever necessary. － Robot motions should be made at low speeds. － Before starting programming, check the entire system status to ensure that no remote instruction to the peripheral equipment or motion would be dangerous to the user. Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence. (In case of R-30iA Mate Controller standard specification, there is no mode switch. The automatic operation mode and the teach mode is selected by teach pendant enable switch.) Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and switch function as follows: (1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type) when pressed. (2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting status. (a) Disable: The DEADMAN switch is disabled. (b) Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the operator presses the switch strongly. Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly, the robot stops immediately. The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely. Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000 times per year.
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The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the teach pendant enable switch and the remote condition on the software.
Mode
Teach pendant enable switch
Software remote condition
Local Remote Local Off Remote Local On T1, T2 Remote mode Local Off Remote T1,T2 mode: DEADMAN switch is effective. AUTO mode
On
Teach pendant
Operator panel
Peripheral device
Not allowed Not allowed Not allowed Not allowed Allowed to start Allowed to start Not allowed Not allowed
Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Not allowed Not allowed
Not allowed Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Not allowed
(6) To start the system using the operator’s panel, make certain that nobody is the robot work area and that there are no abnormal conditions in the robot work area. (7) When a program is completed, be sure to carry out a test operation according to the procedure below. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test operation above, execute it in the automatic operation mode. (8) While operating the system in the automatic operation mode, the teach pendant operator should leave the robot work area.
3.3
SAFETY OF THE MAINTENANCE ENGINEER
For the safety of maintenance engineer personnel, pay utmost attention to the following. (1) During operation, never enter the robot work area. (2) A hazardous situation may arise when the robot or the system, are kept with their power-on during maintenance operations. Therefore, for any maintenance operation, the robot and the system should be put into the power-off state. If necessary, a lock should be in place in order to prevent any other person from turning on the robot and/or the system. In case maintenance needs to be executed in the power-on state, the emergency stop button must be pressed. (3) If it becomes necessary to enter the robot operation range while the power is on, press the emergency stop button on the operator panel, or the teach pendant before entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly. (4) When entering the area enclosed by the safety fence, the maintenance worker must check the entire system in order to make sure no dangerous situations exist. In case the worker needs to enter the safety area whilst a dangerous situation exists, extreme care must be taken, and entire system status must be carefully monitored. (5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off and the pressure in the piping should be reduced to zero. s-7
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(6) Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition. (7) Do not operate the robot in the automatic mode while anybody is in the robot work area. (8) When you maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed. (9) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful attention to its motion. (10) If necessary, have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time. (11) When replacing a part, please contact FANUC service center. If a wrong procedure is followed, an accident may occur, causing damage to the robot and injury to the worker. (12) When replacing or reinstalling components, take care to prevent foreign matter from entering the system. (13) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit breaker to protect against electric shock. If there are two cabinets, turn off the both circuit breaker. (14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used. Such a fuse may cause a fire. (15) When restarting the robot system after completing maintenance work, make sure in advance that there is no person in the work area and that the robot and the peripheral devices are not abnormal. (16) When a motor or brake is removed, the robot arm should be supported with a crane or other equipment beforehand so that the arm would not fall during the removal. (17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent dangerous falls. (18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated state, the worker should wear heat-resistant gloves or use other protective tools. － Servo motor － Inside the controller － Reducer － Gearbox － Wrist unit (19) Maintenance should be done under suitable light. Care must be taken that the light would not cause any danger. (20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to protect maintenance workers from excessive load. Otherwise, the maintenance workers would be severely injured. (21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot would be adversely affected. In addition, a misstep can cause injury to the worker. (22) When performing maintenance work in high place, secure a footstep and wear safety belt. (23) After the maintenance is completed, spilled oil or water and metal chips should be removed from the floor around the robot and within the safety fence. (24) When a part is replaced, all bolts and other related components should put back into their original places. A careful check must be given to ensure that no components are missing or left not mounted. (25) In case robot motion is required during maintenance, the following precautions should be taken : - Foresee an escape route. And during the maintenance motion itself, monitor continuously the whole system so that your escape route will not become blocked by the robot, or by peripheral equipment. - Always pay attention to potentially dangerous situations, and be prepared to press the emergency stop button whenever necessary. (26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller maintenance manual.) A failure to do the periodical inspection can adversely affect the performance or service life of the robot and may cause an accident s-8
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(27) After a part is replaced, a test operation should be given for the robot according to a predetermined method. (See TESTING section of “Controller operator’s manual”.) During the test execution, the maintenance staff should work outside the safety fence.
4 4.1
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal. (3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.
4.2
PRECAUTIONS FOR MECHANISM
(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust. (2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid. (3) Observe the following precautions about the mechanical unit cables. Failure to follow precautions may cause mechanical troubles. (4) Observe the following precautions about the mechanical unit cables. When theses attentions are not kept, unexpected troubles might occur. • Use mechanical unit cable that have required user interface. • Don’t add user cable or hose to inside of mechanical unit. • Please do not obstruct the movement of the mechanical unit cable when cables are added to outside of mechanical unit. • In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable. • When installing user peripheral equipment on the robot mechanical unit, please pay attention that equipment does not interfere with the robot itself.” (5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid the system construction that power-off stop would be operated routinely. (Refer to bad case example.) Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type.) (Bad case example) • Whenever poor product is generated, a line stops by emergency stop. • When alteration was necessary, safety switch is operated by opening safety fence and power-off stop is executed for the robot during operation. • An operator pushes the emergency stop button frequently, and a line stops. • An area sensor or a mat switch connected to safety signal operate routinely and power-off stop is executed for the robot.
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(6) Robot stops urgently when collision detection alarm (SRVO-050) etc. occurs. Please try to avoid unnecessary power-off stops. It may cause the trouble of the robot, too. So remove the causes of the alarm.
5
SAFETY OF THE ROBOT MECHANISM
5.1
PRECAUTIONS IN OPERATION
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality. (2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.
5.2
PRECAUTIONS IN PROGRAMMING
(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.
5.3
PRECAUTIONS FOR MECHANISMS
(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water, and dust.
5.4
PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN EMERGENCY OR ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons is sandwiched or trapped by the robot), turn off the robot controller immediately, change robot posture by directly pressing robot arm and release the worker.
6
SAFETY OF THE END EFFECTOR
6.1
PRECAUTIONS IN PROGRAMMING
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. (2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.
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7
STOP TYPE OF ROBOT
The following three robot stop types exist:
Power-Off Stop (Category 0 following IEC 60204-1) Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is moving, and the motion path of the deceleration is uncontrolled. The following processing is performed at Power-Off stop. An alarm is generated and servo power is turned off. The robot operation is stopped immediately. Execution of the program is paused.
Controlled stop (Category 1 following IEC 60204-1) The robot is decelerated until it stops, and servo power is turned off. The following processing is performed at Controlled stop. The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the program is paused. An alarm is generated and servo power is turned off.
Hold (Category 2 following IEC 60204-1) The robot is decelerated until it stops, and servo power remains on. The following processing is performed at Hold. The robot operation is decelerated until it stops. Execution of the program is paused.
WARNING The stopping distance and stopping time of Controlled stop are longer than the stopping distance and stopping time of Power-Off stop. A risk assessment for the whole robot system, which takes into consideration the increased stopping distance and stopping time, is necessary when Controlled stop is used. When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is different according to the controller type or option configuration. There are the following 3 Stop patterns. Stop pattern
A
B
C
P-Stop: C-Stop: -:
Mode AUTO T1 T2 AUTO T1 T2 AUTO T1 T2
Emergency stop button
External Emergency stop
FENCE open
SVOFF input
Servo disconnect
P-Stop P-Stop P-Stop P-Stop P-Stop P-Stop C-Stop P-Stop P-Stop
P-Stop P-Stop P-Stop P-Stop P-Stop P-Stop C-Stop P-Stop P-Stop
C-Stop P-Stop C-Stop -
C-Stop C-Stop C-Stop P-Stop P-Stop P-Stop C-Stop C-Stop C-Stop
P-Stop P-Stop P-Stop P-Stop P-Stop P-Stop C-Stop P-Stop P-Stop
Power-Off stop Controlled stop Disable
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The following table indicates the Stop pattern according to the controller type or option configuration. R-30iB/ R-30iB Mate
Option Standard Controlled stop by E-Stop
A (*) C (*)
(A05B-2600-J570)
(*) R-30iB / R-30iB Mate does not have servo disconnect. / R-30iB Mate does not have SVOFF input. The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer to "Software version" in operator's manual of controller for the detail of software version screen.
"Controlled stop by E-Stop" option When "Controlled stop by E-Stop" (A05B-2600-J570) option (In case of R-30iA/R-30iA Mate, it is Stop type set (Stop pattern C) (A05B-2500-J570)) is specified, the stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is the normal operation of the system. Alarm SRVO-001 Operator panel E-stop SRVO-002 Teach pendant E-stop SRVO-007 External emergency stops SRVO-408 DCS SSO Ext Emergency Stop SRVO-409 DCS SSO Servo Disconnect
Condition Operator panel emergency stop is pressed. Teach pendant emergency stop is pressed. External emergency stop input (EES1-EES11, EES2-EES21) is open. In DCS Safe I/O connect function, SSO[3] is OFF. In DCS Safe I/O connect function, SSO[4] is OFF.
Controlled stop is different from Power-Off stop as follows: In Controlled stop, the robot is stopped on the program path. This function is effective for a system where the robot can interfere with other devices if it deviates from the program path. In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized. The stopping distance and stopping time of Controlled stop is longer than the stopping distance and stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the operator's manual of a particular robot model for the data of stopping distance and stopping time. In case of R-30iA or R-30iA Mate, this function is available only in CE or RIA type hardware. When this option is loaded, this function cannot be disabled. The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
WARNING The stopping distance and stopping time of Controlled stop are longer than the stopping distance and stopping time of Power-Off stop. A risk assessment for the whole robot system, which takes into consideration the increased stopping distance and stopping time, is necessary when this option is loaded.
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SAFETY PRECAUTIONS
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8
WARNING LABEL
(1) Transportation label
Fig. 8 (a)
Transportation label
Description When transporting the robot, observe the instructions indicated on this label. 1) 2) 3)
Use a crane with a load capacity of 500 kg or greater. Use four slings with each load capacity of 980N (100 kgf) or greater. Use four shackles with each load capacity of 784 N (80 kgf) or greater.
(2) Greasing label (if greasing kit A05B-1142-K021,A05B-1139-K022 is specified)
在将润滑脂装入注射器之前, 请揉搓软管使里面的润滑脂变软。 每向前推动柱塞2.5mm, 就会有1cc的润滑脂被推出来。 轴
量
供脂时
Fig. 8 (b)
Greasing label
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SAFETY PRECAUTIONS
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Description When using a grease kit, observe the instructions indicated on this label. 1) 2) (3)
Before filling the cylinder with grease from tube, squeeze the tube to make the grease in it soft. Pushing in the plunger by 2.5 mm causes a grease of 1 cc to be pushed out.
Motion range and payload label The following label is added if the CE specification is requested.
Fig 8 (c)
Motion range and payload label
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PREFACE
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PREFACE This manual explains maintenance procedures for the mechanical units of the following robots: Model name FANUC Robot LR Mate 200iD FANUC Robot ARC Mate 50iD FANUC Robot LR Mate 200iD/7L FANUC Robot ARC Mate 50iD/7L
Mechanical unit specification No. A05B-1142-B201 A05B-1142-B251 A05B-1142-B301 A05B-1142-B351
Maximum load
Remarks
7kg
NOTE The following abbreviations are used herein. STANDARD : LR Mate 200iD, ARC Mate 50iD 7L : LR Mate 200iD/7L, ARC Mate 50iD/7L The label stating the mechanical unit specification number is affixed in the position shown below. Before reading this manual, determine the specification number of the mechanical unit.
(1)
TYPE NO. DATE
(2) (3) (4)
WEIGHT (5) kg
Position of label indicating mechanical unit specification number TABLE 1）
CONTENTS
(1)
(2)
(3)
(4)
-
TYPE
No.
DATE
FANUC Robot LR Mate 200iD LETTERS
FANUC Robot ARC Mate 50iD FANUC Robot LR Mate 200iD/7L FANUC Robot ARC Mate 50iD/7L
A05B-1142-B201 A05B-1142-B251 A05B-1142-B301
25 SERIAL NO. IS PRINTED
PRODUCTION YEAR AND MONTH ARE PRINTED
A05B-1142-B351
Position of label indicating mechanical unit specification number
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(5) WEIGHT kg (Without controller)
25 27 27
PREFACE
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RELATED MANUALS For the FANUC Robot series, the following manuals are available: Safety handbook B-80687EN All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook R-30iB Mate OPERATOR’S MANUAL controller Basic Operation B-83284EN Alarm Code List B-83284EN-1 Optional Function B-83284EN-2 MAINTENANCE MANUAL Standard : B-83525EN Open Air : B-83555EN
Mechanical unit
Operator’s manual FANUC Robot LR Mate 200iD ARC Mate 50iD B-83494EN
Intended readers : All persons who use FANUC Robot, system designer Topics : Safety items for robot system design, operation, maintenance Intended readers : Operator, programmer, maintenance person, system designer Topics : Robot functions, operations, programming, setup, interfaces, alarms Use : Robot operation, teaching, system design
Intended readers : Maintenance person, system designer Topics : Installation, connection to peripheral equipment, maintenance Use : Installation, start-up, connection, maintenance Intended readers: System designer, Maintenance person Topics: Installation, connection to controller, maintenance Use: Installation, start-up, connection, maintenance
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TABLE OF CONTENTS
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TABLE OF CONTENTS SAFETY PRECAUTIONS............................................................................s-1 PREFACE ....................................................................................................p-1 1
CHECKS AND MAINTENANCE ............................................................. 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
2
PERIODIC MAINTENANCE .................................................................... 9 2.1
2.2
3
REPLACING THE BATTERIES (1-YEAR PERIODIC INSPECTION IF BUILT-IN BATTERIES ARE SPECIFIED) (1.5-YEAR PERIODIC INSPECTION IF EXTERNAL BATTERIES ARE SPECIFIED)................................................................................................... 9 REPLENISH THE GREASE OF THE DRIVE MECHANISM (4 YEARS (15360 HOURS) CHECKS) ........................................................ 11
TROUBLESHOOTING .......................................................................... 13 3.1 3.2 3.3
4
DAILY CHECKS ............................................................................................ 1 FIRST 1-MONTH (320 HOURS) CHECK ...................................................... 3 FIRST 3-MONTH (960 HOURS) CHECKS .................................................... 3 3-MONTH (960 HOURS) CHECKS ............................................................... 6 1-YEAR (3840 HOURS) CHECKS................................................................. 6 1.5-YEAR (5760 HOURS) CHECKS.............................................................. 6 4-YEAR (15360 HOURS) CHECKS............................................................... 6 MAINTENANCE............................................................................................. 7
OVERVIEW ................................................................................................. 13 FAILURES, CAUSES AND MEASURES ..................................................... 13 BACKLASH MEASUREMENT..................................................................... 19
REPLACING PARTS ............................................................................ 23 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16
FIGURE OF DRIVE MECHANISM .............................................................. 24 REPLACING J1-AXIS MOTOR.................................................................... 26 REPLACING J1-AXIS REDUCER ............................................................... 28 REPLACING J2-AXIS MOTOR.................................................................... 32 REPLACING J2-AXIS REDUCER ............................................................... 35 REPLACING J3-AXIS MOTOR.................................................................... 38 REPLACING J3-AXIS REDUCER ............................................................... 40 REPLACING J4-AXIS MOTOR.................................................................... 45 REPLACING J4-AXIS REDUCER ............................................................... 47 REPLACING J5-AXIS MOTOR.................................................................... 51 REPLACING J5-AXIS REDUCER (Standard) ............................................. 52 REPLACING J5-AXIS REDUCER (7L) ........................................................ 56 REPLACING J6-AXIS MOTOR.................................................................... 61 REPLACING WRIST UNIT (Standard) ........................................................ 63 REPLACING WRIST UNIT (7L)................................................................... 65 REPLACING J6-AXIS REDUCER ............................................................... 67 c-1
TABLE OF CONTENTS 4.17 4.18 4.19 4.20
5
REPLACING J3 BELT ................................................................................. 68 REPLACING J5/J6 BELT ............................................................................ 69 REPLACING SOLENOID VALVE ................................................................ 70 SEALANT APPLICATION............................................................................ 71
REPLACING CABLES .......................................................................... 73 5.1 5.2 5.3
CABLE WIRING........................................................................................... 74 CABLE FORMING ....................................................................................... 75 CABLE AND AIR TUBE REPLACEMENT ................................................... 76 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5
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Replacing Cable K101 and Air Tube (Connector panel to J2 base).......................76 Replacing Cable K106, K107, K108,K109 and Air Tube (J2 base to J3 housing) 81 Replacing Cable K102, K103, K104, K105, K109, K110, K111, K112, K113.....85 Replacing Cable K118............................................................................................85 Replacing Air Tube ................................................................................................87
ADJUSTMENTS.................................................................................... 92 6.1
ADJUSTING TENSION OF BELT................................................................ 92
APPENDIX A
SPARE PARTS LIST ............................................................................ 97
B
CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM ............................. 101
C
PERIODIC MAINTENANCE TABLE ................................................... 109
D
MOUNTING BOLT TORQUE LIST ..................................................... 112
E
OPTIONAL CONNECTOR WIRING PROCEDURE ............................ 113
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1.CHECKS AND MAINTENANCE
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1
CHECKS AND MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures presented in this chapter. (See the APPENDIX A PERIODIC MAINTENANCE TABLE.)
NOTE The periodic maintenance procedures described in this chapter assume that the FANUC robot is used for up to 3840 hours a year. In case however the use of the robot exceeds these 3840 hours/year, please adjust the given maintenance frequencies accordingly. The ratio of actual operation time/year vs. the 3840 hours/year should be used for calculating the new (higher) frequencies. For example, when using the robot 7680 hours a year, the maintenance frequency should be doubled – i.e. the time interval should be divided by 2.
1.1
DAILY CHECKS
Clean each part, and visually check component parts for damage before daily system operation. Check the following items as the occasion demands. (1) Before turning on power Item 1
Check items Oil leak
Check points Check if there is any oil leak on sealed part of each joint parts. If there is oil leak, clean it (Note 1)
NOTE 1 Oil leak may be attached (Slightly a loot oil stick) to outside of lip depend on the movement condition or environment of the circumference. If this oil contents change to a state of dew, it may fail depend on the movement. You can prevent oil spot from falling down by wiping the oil contents which is accumulated to under part of oil seal before operation. 2 Also, motors may become the high temperature and the internal pressure of grease bath may rise by frequent repetition movement and use in the high temperature environment. In these cases, you can return internal pressure by releasing grease inlet just after operation of robot. (When opening grease inlet, pay attention grease is not scattered.)
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1.CHECKS AND MAINTENANCE
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Fig. 1.1 (a) Check parts of oil leak Item 1
Check items When air control set is provided.
2 3 4
5
6
When air purge kit is provided.
Check points
Air pressure
Check air pressure using the pressure gauge on the air regulator as shown in Fig.1.1 (b). If it does not meet the specified pressure of 0.49MPa (5 kg/cm2), adjust it using the regulator pressure setting handle.
Leakage from Check the joints, tubes, etc. for leaks. hose Repair leaks, or replace parts, as required. Drain Check drain and release it. When quantity of the drain is remarkable, examine the setting of the air dryer to the air supply side. Supply Check the supply pressure using the air purge kit shown in Fig.1.1 (c). pressure If it does not meet the specified pressure of 10 KPa (0.1 kgf/cm2), adjust it using the regulator pressure setting handle. Dryer Check whether the color of the dew point checker is blue. When it is not blue, identify the cause and replace the dryer. Maintenance for air purge kit, refer to the operator’s manual attached kit. Drain Check drain. When quantity of the drain is remarkable, examine the setting of the air dryer to the air supply side.
Pressure Adjusting Knob
2-6.5×16.5 Length round hole Rc1/4 AIR OUTLET
Pressure gauge Rc1/4 AIR SUPPLY
Fig. 1.1 (b) Air control set
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1.CHECKS AND MAINTENANCE
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Dew point checker 2-7x11 Length round hole Air outlet (O6 Air tube)
Pressure gauge Pneumatic air outlet Air inlet (O10 air tube) Pressure adjustment knob O
S
O
S
Dryer unit
Fig.1.1 (c) Air purge kit (option)
(2) Item
After automatic operation Check items
1
Vibration, abnormal noises, and motor heating
2
Changing repeatability
3
Peripheral devices for proper operation
4
Brakes for each axis
1.2
Check points Check whether the robot moves along and about the axes smoothly without unusual vibration or sounds. Also check whether the temperature of the motors are excessively high. Check to see that the stop positions of the robot have not deviated from the previous stop positions. Check whether the peripheral devices operate properly according to commands from the robot. Check that the end effector drops within 2 mm when the power is cut.
FIRST 1-MONTH (320 HOURS) CHECK
Check the following items at the first month(320 hours ) inspection, then every 3 months (960 hours) thereafter. (See Section 1.4.) First 1-month check Item 1
1.3
Check items Ventilation portion of controller
Check points If the ventilation portion of the controller is dusty, turn off power and clean the unit.
FIRST 3-MONTH (960 HOURS) CHECKS
Check the following items at the first quarterly inspection, then every year (3840 hours) thereafter. (See Section 1.5.) Item
Check items
1
Connector used in mechanical unit
Check the looseness of connector of connector panel. (NOTE 1)
Retightening external main bolts
Retighten the end-effecter mounting bolts and external main bolts.(NOTE 2)
2
Check points
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1.CHECKS AND MAINTENANCE Item 3 4 5
6
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Check items
Check points
Check the mechanical stopper Cleaning and checking each part Check the end effector (hand) cable and external battery cable (option) Check the robot cable, teach pendant cable and robot connecting cable
Check the spring ping of J1/J3-axis mechanical stopper is not transformed, if it is transformed, replace it to new one. (NOTE 3) Clean each part (remove chips, etc.) and check component parts for cracks and flaws. (NOTE 4) Confirm whether there is any damage to the cable. Check whether the cable connected to the teach pendant and robot is unevenly twisted.
(NOTE 1) Inspection points of the connectors •
Robot connection cables, earth terminal and user cables
Check items • • •
Circular connector: Check the connector for looseness by turning it manually. Square connector: Check the connector for disengagement of its lever. Earth terminal: Check the terminal for looseness by turning.
Fig. 1.3 (a) Check items of connector
(NOTE 2) Points to be retightened -
The end effecter mounting bolts, robot installation bolts, and bolts to be removed for inspection need to be retightened. The bolts exposed to the outside of the robot need to be retightened. For the tightening torque, see the recommended bolt tightening torque shown in the Appendix. A loose prevention agent (adhesive) is applied to some bolts. If the bolts are tightened with greater than the recommended torque, the loose prevention agent may be removed. So, follow the recommended tightening torque when retightening them.
(NOTE 3) Check of mechanical stopper and adjustable mechanical stopper. -
Check the spring pin of J1/J3-axis mechanical stopper is not transformed, if it is transformed, replace it to new one. -4-
1.CHECKS AND MAINTENANCE
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J1-axis mechanical stopper Spec.： spring pin：A6-PS-8X20S
J3-axis mechanical stopper Spec.： J3 stopper：A290-7142-X427 spring pin：A6-PS-8X20S
Section A-A
Note： When assembling J3 stopper to spring pin, apply cemedine super X （clear）.
A
A
Fig. 1.3 (b) Check of mechanical stopper
(NOTE 4) Cleaning -
-
Necessary cleaning points, dust on the flat part, spatter depositions Clean sediments periodically. In particular, clean the following points carefully. Vicinity of the wrist axis and oil seal →If chippings or spatters are attached to the oil seal, an oil leak may be caused. Check if the vicinity of the necessary inspection points, wrist part, and J3 arm significantly wears due to rubbing against the welding cable or hand cable. Check if there is a trace of a collision around the hand. Check the reducer or grease bath for an oil leak. → If oil can be found a day after wiping oil, an oil leak may be caused.
Fig. 1.3 (c) Cleaning part
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1.CHECKS AND MAINTENANCE
1.4
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3-MONTH (960 HOURS) CHECKS
Check the following items in the cycle that is shorter between every three months and 960 hours of operating. Additional inspection areas and times should be added to the table according to the robot's working conditions, environment, etc. Item 1
1.5
Check items Ventilation portion of controller
Check points If the ventilation portion of the controller is dusty, tum off power and clean the unit.
1-YEAR (3840 HOURS) CHECKS
Check the following items in the cycle that is shorter between every year and 3840 hours of operating. Item
Check itmes
1 2 3 4 5
Connector used in mechanical unit Retightening external main bolts Check the mechanical stopper Cleaning and checking each part Check the end effector (hand) cable and external battery cable (option) Replacing battery Check the robot cable, teach pendant cable and robot connecting cable
6 7
1.6
Check points (See Section 1.3) (See Section 1.3) (See Section 1.3) (See Section 1.3) (See Section 1.3) Replace battery in the mechanical unit. (See Section 2.1) (See Section 1.3)
1.5-YEAR (5760 HOURS) CHECKS
Check the following items in the cycle that is shorter between every 1.5 years and 5760 hours of operating. Item 1
1.7
Check items Replacing battery (if external batteries are specified)
Check points Replace the batteries in the mechanical unit. (See Section 2.1.)
4-YEAR (15360 HOURS) CHECKS
Check the following items about once in the cycle that is shorter between every four years an 15360 hours. Item
Check itmes
Check points
1
Greasing of reducers of each-axis
Supply grease with each axis reducer (See Section 2.2)
2
Replace the mechanical unit cable
Please refer to Chapter 5 about replacing method.
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1.CHECKS AND MAINTENANCE
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1.8
MAINTENANCE
The following tools and instruments are required for the maintenance procedures contained in this manual. (a) Measuring instruments Instrument
Specifications
Vendor
Manufacturer model No.
Application
Tension meter
A97L-0218-0700
Mitsuboshi Belting Ltd.
DOCTOR TENSION TYPE-Ⅲ
Adjustment of belt tension
Instruments
Accuracy/Tolerance
Applications
Dial gauge accuracy Slide calipers
1/100 mm 150 mm
Measurement of positioning and backlash
(b) Tools ・Torque wrench Large, medium, and small sizes ・Cross tip (+) screwdrivers Large, medium, and small sizes ・Flat tip (–) screwdrivers Width across flats 7 (for grease nipple) ・Nut driver Width across flats 2.5, 3, 4 (for replacing parts) ・Hexagon wrench set Middle, little ・Monkey wrench ・Pincers ・Needle nose pliers ・Nippers ・Gear puller ・Separator ・Offset wrench ・Pliers for C–retaining ring ・LOCTITE 243,263,518,638 ・Grease applying kit A05B-1142-K021 (It is options that grease (80g) for the grease greasing with the injection syringe and the tube makes a set.) ・ grease in tube (80g) A05B-1139-K022
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1.CHECKS AND MAINTENANCE
O5
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Fig 1.8 example of cylinder
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2.PERIODIC MAINTENANCE
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2
PERIODIC MAINTENANCE
2.1
REPLACING THE BATTERIES (1-YEAR PERIODIC INSPECTION IF BUILT-IN BATTERIES ARE SPECIFIED) (1.5-YEAR PERIODIC INSPECTION IF EXTERNAL BATTERIES ARE SPECIFIED)
The position data of each axis is preserved by the backup batteries. If built-in batteries are in use, replace them every year. If external batteries are in use, replace them every year and a half. Also use the following procedure to replace when the backup battery voltage drop alarm occurs.
Procedure of replacing the battery (if built-in batteries are specified) 1
Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.
CAUTION Be sure to keep the power supply turned on. Replacing the batteries with the power supply turned off causes all current position data to be lost. Therefore, mastering will be required again. 2 3 4
Remove the battery case cap.( Fig.2.1 (a)) If it cannot be removed, tap it to side direction with a plastic hammer. Loosen the plate screw and take out the lid of the battery box and replace battery. Battery can be taken out by pulling the stick which is center of the battery box. Assemble them in the reversed sequence. Pay attention to the direction of batteries. It is necessary to exchange gasket.
C battery (4 pcs) FANUC spec.：A98L-0031-0027 The battery can be taken out by pulling this stick Plate screw M4X12(2 pcs) Lid of battery box Gasket A290-7139-X253 Bolt with plate processing hex-head hole M4X20(4 pcs)
Battery box cover
Fig. 2.1 (a)
Replacing the battery (if built-in batteries are specified)
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2.PERIODIC MAINTENANCE
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Procedure of replacing the battery (if external batteries are specified) 1
During battery replacement, hold down the emergency stop button for the sake of safety. CAUTION
Be sure to keep the power supply turned on. Replacing the batteries with the power supply turned off causes all current position data to be lost. Therefore, mastering will be required again. 2 3 4 5
Uncap the battery case (Fig. 2.1 (b)). Take out the old batteries from the battery case. Insert new batteries into the battery case while observing their correct orientation. Cap the battery case. External battery box Battery cable Diameter About O5mm (Max O5.5mm)
Battery case
Case cap Spec. of battery :A98L-0031-0005 (D battery alkali 4pcs)
Fig. 2.1 (b) Replacing the battery (if external batteries are specified)
Fig .2.1 (c) shows the external size of external battery box. When the battery box needs to be built into the controller or other internal units, refer to the outer dimensions shown in Fig.2.1 (c) The battery box can be fixed by using M4 flat–head screws. (The bolts do not come with the system.) A maximum of six terminals can be attached to the backplane of the battery box.
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2.PERIODIC MAINTENANCE
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Fig. 2.1 (c) Outer dimensions of the battery box
2.2
REPLENISH THE GREASE OF THE DRIVE MECHANISM (4 YEARS (15360 HOURS) CHECKS)
Supply the grease of the reducers every four years or 15360 hours by using the following procedures. For the grease name and quantity, see the table 2.2 (a). Table 2.2 (a) Grease for 4-year (15360 hours) periodical greasing Greasing points Greasing amount Specified grease J1-axis reducer J2-axis reducer J3-axis reducer J4-axis reducer J5-axis reducer J6-axis reducer
2.7g(3ml) 2.7g(3ml) 1.8g(2ml) 1.8g(2ml) 1.8g(2ml) 1.8g(2ml)
Harmonic grease 4BNo.2 Spec: A98L-0040-0230
For grease replacement, use the arbitrary postures.
CAUTION The following maintenance kits are prepared for the grease greasing. -Greasing kit: A05B-1142-K021 (This a set of greasing syringe and grease in tube. (80g)) -Grease in tube: A05B-1139-K022 (grease in tube. (80g))
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2.PERIODIC MAINTENANCE
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NOTE Failure to correct greasing, the internal pressure of the grease bath may suddenly increase, may cause damage to the seal performance, which would in turn lead to grease leakage and abnormal operation. When performing greasing, therefore, observe the following cautions. 1 Use grease only of the specified type. Grease of a type other than that specified may damage the reducer or lead to other problems. Do no use Harmonic grease SK-3 2 To prevent accidents caused by slipping, completely remove any excess grease from the floor or robot. 3 Please fill a necessary amount to the injection syringe after softening grease in the tube massaging it by the hand when you use the grease greasing kit. Please install the nozzle in the point of the injection syringe. Please remove the nozzle and do the cap when you do not use the injection syringe. 1
2 3 4
Turn off the controller power. Remove the seal bolts of the grease inlet . Supply a regulated amount of grease by using the injection syringe. Please note that grease might come out immediately after the grease has been supplied, or during the greasing. Even in this case, please do not supply grease beyond the regulated amount specified. Replace seal bolts by new one. When reusing the seal bolt, be sure to seal it with seal tape. J6-axis reducer grease inlet Seal bolt M4X6 J5-axis reducer grease inlet Seal bolt M4X6
J4-axis reducer grease inlet Seal bolt M4X6
J3-axis reducer grease inlet Seal bolt M4X6
J1-axis reducer grease inlet Seal bolt M8X10
J2-axis reducer grease inlet Seal bolt M4X6
Fig.2.2 Applying grease of the reducer
Parts name Seal bolt Seal bolt
Table 2.2 (b) Spec. of seal bolts Specifications A97L-0318-0405#040606EN A97L-0318-0406#081010EN
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Remarks
J2 - J6-axis grease inlet J1-axis grease inlet
5 pcs/1 robot
3.TROUBLESHOOTING
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3
TROUBLESHOOTING
3.1
OVERVIEW
The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from many interrelated factors. If you fail to take the correct measures, the failure may be aggravated. So, it is necessary to analyze the symptoms of the failure precisely so that the true cause can be found.
3.2
FAILURES, CAUSES AND MEASURES
Table 3.2 lists the major failures, causes and measures that may occur in the mechanical unit and their probable causes. If you cannot pinpoint a failure cause or which measures to apply, contact your local FANUC representative.
Symptom Vibration Noise
Table 3.2 Failures, causes and measures Description Cause -The J1 base lifts off the floor plate as the robot operates. -There is a gap bfetween the J1 base and floor plate. -A J1 base retaining bolt is loose.
-Apply epoxy to the floor surface and re-install the plate.
-Vibration becomes more serious when the robot adopts a specific posture. -If the operating speed of the robot is reduced, vibration stops. -Vibration is most noticeable when the robot is accelerating. -Vibration occurs when two or more axes operate at the same time.
[J1 base fastening] -It is likely that the robot J1 base is not securely fastened to the floor plate. -Probable causes are a loose bolt, an insuffcient degree of surface flatness, or foreign material caught between the floor plate and floor plate. -If the robot is not securely fastened to the floor plate, the J1 base lifts the floor plate as the robot operates, allowing the base and floor plates to strike each other wihich, in turn, leads to vibration. [Rack or floor] -It is likely that the rack or floor is not suffciently rigid. -If the rack or floor is not sufficiently rigid, reaction from the robot deforms the rack or floor, leading to vibration. [Overload] -It is likely that the load on the robot is greater than the maximum rating. -It is likely that the robot control program is too demanding for the robot hardware. -It is likely that the ACCELERATION value is excessive.
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Measure -If a bolt is loose, apply LOCTITE and tighten it to the appropriate torque. -Adjust the floor plate surface flatness to within the specified tolenrance. -If there is any foreign material between the J1 base and floor plate, remove it.
-Reinforce the rack or floor to make it more rigid. -If it is impossible to reinforce the rack or floor, modify the robot control program; doing so might reduce the amount of vibration. -Check the maximum load that the robot can handle once more. If the robot is found to be overloaded, reduce the load, or modify the robot control program. -Vibration in a specific portion can be reduced by modifying the robot control program while slowig the robot and reducing its acceleration (to minimize the influenece on the entire cycle time).
3.TROUBLESHOOTING Symptom Vibration Noise (Continued)
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Description
Cause
-Vibration was first noticed after the robot collided with an object or the robot was overloaded for a long period. -The grease of the vibrating axis has not been replenished for a long period.
[Broken gear, bearing, or reducer] - It is likely that collision or overload applied an excessive force on the drive mechanism, thus damaging the geartooth surface or rolling surface of a bearing, or reducer. - It is likely that prolonged use of the robot while overloaded caused fretting of the gear tooth surface or rolling surface of a bearing, or reducer due to resulting metal fatigue. - It is likely that foreign material caught in a gear, bearing, or within a reducer caused damage on the gear tooth surface or rolling surface of the bearing, or reducer. - It is likely that, because the grease has not been replenished for a long period, fretting occurred on the gear tooth surface or rolling surface of a bearing, or reducer due to metal fatigue. These factors all generate cyclic vibration and noise.
- 14 -
Measure -Operate one axis at a time to determine which axis is vibrating. -Remove the motor, and replace the gear , the bearing, and the reducer. For the spec. of parts and the method of replacement, contact FANUC. -Using the robot within its maximum rating prevents problems with the drive mechanism. -Regularly greasing with a specified type can help prevent problems.
3.TROUBLESHOOTING
B-83495EN/01
Symptom Vibration Noise (Continued)
Description
Cause
-The cause of problem cannot be identified from examination of the floor, rack, or mechanical section.
[Controller, cable, and motor] -If a failure occurs in a controller circuit, preventing control commands from being supplied to the motor normally, or preventing motor information from being sent to the controller normally, vibration might occur. -If the Pulsecoder develops a fault, vibration might occur because information about the motor position cannot be transferred to the controller accurately. -If the motor becomes defective, vibration might occur because the motor cannot deliver its rated performance. -If a power line in a movable cable of the mechanical section has an intermittent break, vibration might occur because the motor cannot accurately respond to commands. -If a Pulsecoder wire in a movable part of the mechanical section has an intermittent break, vibration might occur because commands cannot be sent to the motor accurately. -If a connection cable between them has an intermittent break, vibration might occur. -If the power cable between them has an intermittent break, vibration might occur. -If the power source voltage drops below the rating, vibration might occur. -If a robot control parameter is set to an invalid value, vibration might occur.
- 15 -
Measure -Refer to the Controller Maintenance Manual for troubleshooting related to the controller and amplifier. -Replace the Pulsecoder for the motor of the axis that is vibrating, and check whether the vibration still occurs. -Also, replace the motor of the axis that is vibrating, and check whether vibration still occurs. For the method of replacement, contact FANUC. -Check that the robot is supplied with the rated voltage. -Check whether the sheath of the power cord is damaged. If so, replace the power cord, and check whether vibration still occurs. -Check whether the sheath of the cable connecting the mechanical section and controller is damaged. If so, replace the connection cable, and check whether vibration still occurs. -If vibration occurs only when the robot assumes a specific posture, it is likely that a cable in the mechanical unit is broken. -Shake the movable part cable while the robot is at rest, and check whether an alarm occurs. If an alarm or any other abnormal condition occurs, replace the mechanical unit cable. -Check that the robot control parameter is set to a valid value. If it is set to an invalid value, correct it. Contact FANUC for further information if necessary.
3.TROUBLESHOOTING Symptom
B-83495EN/01
Description
Vibration Noise (Continued)
-There is some relationship between the vibration of the robot and the operation of a machine near the robot.
Rattling
-While the robot is not supplied with power, pushing it with the hand causes part of the mechanical unit to wobble. -There is a gap on the mounting face of the mechanical unit.
-Backlash is greater than the tolerance stated in the applicable maintenance manual. (See Section 3.3.)
Cause
Measure
[Noise from a nearby machine] -If the robot is not grounded properly, electrical noise is induced on the grounding wire, preventing commands from being transferred accurately, thus leading to vibration. -If the robot is grounded at an unsuitable point, its grounding potential becomes unstable, and noise is likely to be induced on the grounding line, thus leading to vibration. [Mechanical section coupling bolt] -It is likely that overloading or a collision has loosened a mounting bolt in the robot mechanical section.
-Connect the grounding wire firmly to ensure a reliable ground potential and prevent extraneous electrical noise.
[Increase in backlash] -It is likely that excessive force applied to the drive mechanism, due to a collision or overloading, has broken a gear or the inside of the reducer, resulting in an increase in the amount of backlash. -It is likely that prolonged use has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash. -It is likely that prolonged use without changing the grease has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash.
-Operate one axis at a time to determine which axis has the increased backlash. -Remove the motor, and check whether any of its gears are broken. If any gear is broken, replace it. -Check whether any other gear of the drive mechanism is damage. If there is no damage gear, replace the reducer. -If the reducer is broken, or if a gear tooth is missing, replace the relevant component. Also, remove all the grease from the gear box and wash the inside of the gear box. -After replacing the gear or reducer, add an appropriate amount of grease. -Using the robot within its maximum rating prevents problems with the drive mechanism. -Regularly applying the grease with a specified type can help prevent problems.
- 16 -
-Check that the following bolts for each axis are tight. If any of these bolts is loose, apply LOCTITE and tighten it to the appropriate torque. -Motor retaining bolt -Reducer retaining bolt -Base retaining bolt -Arm retaining bolt -Casting retaining bolt -End effecter retaining bolt
3.TROUBLESHOOTING
B-83495EN/01
Symptom Description Motor -The ambient temperature of overheating the installation location increases, causing the motor to overheat. -After the robot control program or the load was changed, the motor overheated.
-After a control parameter was changed, the motor overheated.
-Symptom other than stated above
Cause
Measure
[Ambient temperature] -It is likely that a rise in the ambient temperature prevented the motor from releasing heat efficiently, thus leading to overheating. [Operating condition] -It is likely that the robot was operated with the maximum average current exceeded.
-The teach pendant can be used to monitor the average current. Check the average current when the robot control program is running. The allowable average current is specified for the robot according to its ambient temperature. Contact FANUC for further information. -Relaxing the robot control program and conditions can reduce the average current, thus preventing overheating. -Reducing the ambient temperature is the most effective means of preventing overheating. -Having the surroundings of the robot well ventilated enables the robot to release heat efficiently, thus preventing overheating. Using a fan to direct air at the motor is also effective. -If there is a source of heat near the motor, it is advisable to install shielding to protect the motor from heat radiation. -Input an appropriate parameter as described in CONTROLLER OPERATOR’S MANUAL.
[Parameter] -If data input for a workpiece is invalid, the robot cannot be accelerated or decelerated normally, so the average current increases, leading to overheating. [Mechanical section problems] -It is likely that problems occurred in the mechanical unit drive mechanism, thus placing an excessive load on the motor. [Motor problems] -It is likely that a failure of the motor brake resulted in the motor running with the brake applied, thus placing an excessive load on the motor. -It is likely that a failure of the motor prevented it from delivering its rated performance, thus causing an excessive current to flow through the motor.
- 17 -
-Repair the mechanical unit while referring to the above descriptions of vibration, noise, and rattling. -Check that, when the servo system is energized, the brake is released. If the brake remains applied to the motor all the time, replace the motor. -If the average current falls after the motor is replaced, it indicates that the first motor was faulty.
3.TROUBLESHOOTING Symptom
B-83495EN/01
Cause
Measure
-Grease is leaking from the mechanical unit.
[Poor sealing] -Probable causes are a crack in the casting, a broken O-ring, a damaged oil seal, or a loose seal bolt. -A crack in a casting can occur due to excessive force that might be caused in collision. -An O-ring can be damaged if it is trapped or cut during disassembling or re-assembling. -An oil seal might be damaged if extraneous dust scratches the lip of the oil seal. -A loose seal bolt might allow grease to leak along the threads.
Dropping axis -An axis drops because the brake does not function. -An axis drops gradually when it should be at rest.
[Brake drive relay and motor] -It is likely that brake drive relay contacts are stuck to each other to keep the brake current flowing, thus preventing the brake from operating when the motor is deenergized. -It is likely that the brake shoe has worn out or the brake main body is damaged, preventing the brake from operating efficiently. -It is likely that oil or grease has entered the motor, causing the brake to slip. [Mechanical section problems] -If the repeatability is unstable, probable causes are a failure in the drive mechanism or a loose bolt. -If the repeatability becomes stable it is likely that a collision imposed an excessive load, leading to slipping on the base surface or the mating surface of an arm or reducer. -It is likely that the Pulsecoder is abnormal.
-If a crack develops in the casting, sealant can be used as a quick-fix to prevent further grease leakage. However, the component should be replaced as soon as possible, because the crack might extend. -O-rings are used in the locations listed below. -Motor coupling section -Reducer coupling section -Wrist coupling section -J3 arm coupling section -Inside the wrist -Oil seals are used in the locations stated below. -Inside the reducer -Inside the wrist -Seal bolts are used in the locations stated below. -Grease drain inlet and outlet -Check whether the brake drive relay contacts are stuck to each other. If they are found to be stuck, replace the relay. -If the brake shoe is worn out, if the brake main body is damaged, or if oil or grease has entered the motor, replace the motor.
Grease leakage
Description
Displacement -The robot operates at a point other than the taught position. -The repeatability is not within the tolerance.
-Displacement occurs only in a specific peripheral unit.
[Peripheral unit displacement] -It is likely that an external force was applied to the peripheral unit, thus shifting its position relative to the robot.
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-If the repeatability is unstable, repair the mechanical section by referring to the above descriptions of vibration, noise, and rattling. -If the repeatability is stable, correct the taught program. Variation will not occur unless another collision occurs. -If the Pulsecoder is abnormal, replace the motor or the Pulsecoder. -Correct the setting of the peripheral unit position. -Correct the taught program.
3.TROUBLESHOOTING
B-83495EN/01
Symptom
Description
Cause
Displacement -Displacement occurred after (Continued) a parameter was changed.
[Parameter] -It is likely that the mastering data was rewritten in such a way that the robot origin was shifted.
BZAL alarm occured
- It is likely that the voltage of the memory backup battery is low. - It is likely that the Pulsecoder cable is defected.
3.3
-BZAL is displayed on the controller screen
Measure -Re-enter the previous mastering data, which is known to be correct. -If correct mastering data is unavailable, perform mastering again. -Replace the battery. -Replace the cable.
BACKLASH MEASUREMENT
Measurement method 1 2 3
Maintain the robot in a specified posture. (See Table 3.3 (a).) Apply positive and negative loads to each axis as shown in Fig.3.3 (a). Remove the loads and measure the displacement. Measure backlash by applying positive and negative loads to each axis three times. Average the values measured in the last two measurements for each axis, and use the averages as a measured backlash for the respective axes.
Stop position 0
+3kgf
Firtst step (Do not measure)
-3kgf
+3kgf 0kgf
L1
-3kgf 0kgf
L2
+3kgf 0kgf L3
-3kgf
Second step (B2 =L1+ L2)
Third step (B3=L3+ L4)
0kg L4
Fig. 3.3 (a) Backlash measurement method
Backlash B is calculated using the following expression: B=
B2 + B3 2
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3.TROUBLESHOOTING
B-83495EN/01
Table 3.3 (a) Backlash measurement posture, position and permissible value Measurement axis
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
J1-axis
Arbitrary
90°
0°
0°
0°
90°
Rotation center of J5-axis
Measurement position
J2-axis
Arbitrary
0°
90°
0°
0°
0°
Rotation center of J3-axis of J2 arm
J3-axis
Arbitrary
90°
-90°
90°
0°
180°
Rotation center of J5-axis
J4-axis
Arbitrary
0°
90°
0°
-90°
90°
J5-axis
Arbitrary
90°
0°
0°
-90°
0° or 180°
J6-axis
Arbitrary
90°
0°
0°
-90°
90° or -90°
100mm from rotation center of J4-axis 180mm from rotation center of J5-axis 100mm from rotation center of J6-axis
Table 3.3 (b) Distance at axis and measurement position and permissible value for backlash Measured Distance at axis and measurement position (mm) axis Standard 7L
Permissible value (mm) Standard
7L
J1-axis
715
910
0.41
0.52
J2-axis
330
440
0.19
0.25
J3-axis
335
420
0.20
0.25
J4-axis
100
0.16
J5-axis
180
0.18
J6-axis
100
0.15
NOTE When measuring backlash under circumstances where the distance between the rotation center and the dial indicator is different from those in the above table, make displacement conversions according to the table.
100 Loading position 715 (Standard) 910 (7L)
Measurement position (J5-axis rotation center)
Fig.3.3 (b) Backlash measurement position of J1-axis
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3.TROUBLESHOOTING
B-83495EN/01
330 (Standard) 440 (7L)
Loading position
Measurement position
335 (Standard) 420 (7L)
Fig.3.3 (c) Backlash measurement position of J2-axis
100
Measurement position
Loading position Fig.3.3 (d) Backlash measurement position of J3-axis
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3.TROUBLESHOOTING
B-83495EN/01
100
Loading position
Measurement position
100
180
Fig.3.3 (e) Backlash measurement position of J4-axis
Measurement position Loading position Fig.3.3 (f) Backlash measurement position of J5-axis
100
Measurement position
Loading position Fig.3.3 (g) Backlash measurement position of J6-axis
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4.REPLACING PARTS
B-83495EN/01
4 • • • •
REPLACING PARTS When replacing a part, subsequent adjustment is required. When removing or mounting a motor, apply force in the direction of the shaft only. If excessive force is applied in any other direction, the motor and/or reducer may be damaged. If a motor and associated parts to be assembled incur a phase mismatch, assembly might prove impossible. Carefully check the state of the parts before removing them. Assemble a new O–ring and gasket for seal securing after you exchange parts for spec of seal.
CAUTION Some gasket must not be reused. To maintain dust and drip preventive effects, replace those old gasket with new ones and then perform assembly. •
To secure the performance of the seal, replace seal bolt to new one after replacing parts as much as possible. If preparing it is impossible, peel off the sealant, spread LOCTITE on the internal thread, and recycle.
NOTE When applying LOCTITE to the important bolt tightening points, make sure that it is applied to the entire longitudinal portion in the engaging section of the female threads. If it is applied to the male threads, the bolts may be loosened because sufficient adhesion cannot be obtained. Remove the dust within the bolts and tapped holes and wipe oil off the engaging section. Make sure that there is no solvent in the tapped holes. Be sure to wipe the excess LOCTITE after tightening bolt. • • • • •
When tightening a bolt, always observe the tightening torque, if specified those bolts for which no tightening torque is specified must be tightened according to the table of APPENDIX. Assemble the reducer to the vertical direction as much as possible when you assemble it. When installing bolt to reducer, make the applying order a corner and tighten uniformly. When applying LOCTITE 518 to reducer, pay attention LOCTITE doesn’t enter inside the reducer. Spread it after softening grease mixing it when you do not softly spread grease easily.
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4.REPLACING PARTS
4.1
B-83495EN/01
FIGURE OF DRIVE MECHANISM
The drive mechanisms of each axis are shown in the Fig.4.1 (a) to (e).
J2 axis base
Pipe J1 axis reducer (Hollow shaft)
Input gear
Motor (M1) for J1 axis
J1 base
Fig. 4.1 (a) Drive mechanism of J1-axis Motor (M2) for J2 axis
J2 arm
J2 axis reducer
J2 base
Fig. 4.1 (b) Drive mechanism of J2-axis
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4.REPLACING PARTS
B-83495EN/01 J3 axis reducer J3 housing J3 axis output pully
Belt
J2 arm
Motor (M3) for J3 axis
J3 axis input pully
Fig. 4.1 (c) Drive mechanism of J3-axis
J4 axis reducer (Hollow shaft)
J3 arm
J3 housing
Pipe
Motor (M4) for J4 axis
J4 axis input gear Fig. 4.1 (d) Drive mechanism of J4-axis
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4.REPLACING PARTS
B-83495EN/01
J5 axis output pully
J5 axis input pully
J6 axis housing J5 axis reducer
Belt
J6 axis reducer Motor (M5) for J5 axis
J3 axis arm Belt Motor (M6) for J6 axis
J6 axis output pully
J6 axis output gear J6 axis input gear
J6 axis input pully Fig. 4.1 (e) Drive mechanism of J5/J6-axis
4.2
REPLACING J1-AXIS MOTOR
Replacing procedure 1 2 3 4 5 6 7 8 9 10
11
Turn off the controller power. Then remove robot from floor plate. Make it to posture in which the motor (5) can be removed. Remove bolts (1) and remove the cover B (2). Remove cable K101 from motor (5). Cut the nylon band and remove the heat exchange plate. Remove bolt (4) and motor (5). At this time, note that grease may go out. Wipe the grease of the gear (11) off. At this time, pay attention not to damage the tooth side. Remove O ring (10) and seal bolt (13), and remove washer plate (12), gear (11), holder (8), O-ring (7) and key (6) sequentially. Attach the new sheet (14) on the motor (5). Assemble it applying the procedure in the reversed sequence. Exchanging Motor and O-ring for the new article. At this time, pay attention to the following. • When motor is attached, confirm the thing that the oil seal (9) is at the position, and note that the lip cannot be turned over. • Spread grease on surroundings about the gear. • Apply LOCTITE 243 on the key. • Be careful not to drop the gasket (3). • Be sure to use heat resistance grade nylon band for mounting of the heat exchange plate. Perform single axis mastering referring to Section 8.5 of operator’s manual.
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4.REPLACING PARTS
B-83495EN/01
3 2 8 12 11
10
4
5
7
1
6
13 9
Fig. 4.2 (a) Replacing J1-axis motor
Name 1 2 3 4 5 6 7 8 9 10
BOLT COVER B GASKET BOLT MOTOR KEY O RING HOLDER OIL SEAL O RING
11
GEAR
12 13 14
WASHER PLATE SEAL BOLT SHEET
Specifications A97L-0218-0496#M4X10BC A290-7142-X204 A290-7142-X205 A6-BA-5X20 A06B-0116-B855#0048 A97L-0118-0402#3X3X12BN A98L-0001-0347#S46 A290-7139-X221 A98L-0040-0223#01001805 A98L-0001-0347#S46 A290-7142-X202 (*1) A290-7142-X248 (*2) A290-7142-X203 A97L-0218-0423#030606 A290-7142-X228
Q’ty 9 1 1 3 1 1 1 1 1 1
LOCTITE
2.0Nm (20kgfcm)
5.6Nm (57kgfcm) LT243
1 1 3 1
(*1) LR Mate 200iD. ARC Mate 50iD (*2) LR Mate 200iD/7L. ARC Mate 50iD/7L
14 Fig. 4.2 (b) Attachment of the sheet on the J1-axis motor
- 27 -
Torque N-m (kgf-cm)
1.3Nm (13kgfcm)
4.REPLACING PARTS
4.3
B-83495EN/01
REPLACING J1-AXIS REDUCER
Replacing procedure 1 2 3 4 5 6
7 8 9 10 11 12 13 14 15
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set in 0° for all axes when robot is shipped.) Turn off the controller power. Remove cover B and J1 motor referring to Section 4.2 (It is not necessary to remove the gear.) Remove plated bolt (15), And remove J2 base cover (16). Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106, K107,K108 and K109 referring to Fig.5.2 in Chapter 5. Pull out cable K101 to the J1 base side. At this time, pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relayed connector caught. Remove bolt (4), (5) and remove J1 base (16) by using removal tap. At this time, pay attention that there is a possibility that grease goes out. (Refer to Fig.4.3 (d)) Wipe the grease of the wave generator (8) off. At this time, do not damage the tooth side. Remove bolt (10) and reducer (11). Keep the horizontal and install a new main body of the reducer in J2 base. At this time, be sure to put O-ring (14) after it exchanges it for the new article. Fill grease to the reducer. Grease in inside of reducer, gear and bearing of wave generator. (Refer to Fig.4.3 (e). Apply sealant on the J1 base referring to Fig.4.3 (b). Attach new wave generator (8) to the reducer. At this time, be sure to put wave washer (12). Phase to reducer and assemble J1 base (6) referring to Fig.4.3 (c). At this time, be sure to put O-ring (9). Assemble bolt (5) after previously assembling all bolt (4). Put J1 motor, cable and cover in the reverse order of 4-6. Be careful not to drop the gasket (17).
CAUTION Do not apply grease to the O-ring (9). Otherwise, hardening of sealant is prevented, causing a grease leak. 16
17 18 19 20 21
Pass the cable K101 through J2 base side, and connect it with the relay connector. At this time, pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relayed connector caught. Attach J2 base cover (16) with plated bolt (15). Confirm that the gasket (16) does not fall out. Attach J1 motor referring to Section 4.2. Attach the cover B. Attach robot to floor plate. Perform quick mastering and perform single axis mastering for J1-axis referring to Section 8.4 and 8.5 of operator’s manual.
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear of J1-axis motor shaft.
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4.REPLACING PARTS
B-83495EN/01
15 16 17 6 11
10
14 13
12 5
9
8
4
7
1 2
3
Fig. 4.3 (a) Replacing J1-axis reducer Name 1 2 3 4 5 6 7
9 10
SEAL BOLT COVER U GASKET BOLT BOLT J1 BASE PIPE WAVE GENERATOR O RING BOLT
11
REDUCER
12 13 14 15 16 17
WAVE WASHER PIPE O RING PLATED BOLT J2 BASE COVER GASKET
8
Specifications
Q’ty
A97L-0218-0546#030606EN A290-7142-X319 A290-7142-X317 A6-BA-4X12 A6-BA-4X20 A290-7142-X201 A290-7142-X312
4 1 1 7 9 1 1
(It is attached to the J1 REDUCER)
1
(It is attached to the J1 REDUCER) A97L-0218-0546#043016BC A97L-0218-0951#70 (*1) A97L-0218-0980#80 (*2) (It is attached to the J1 REDUCER) A290-7142-X311 (It is attached to the J1 REDUCER) A97L-0218-0496#M4X10BC A290-7142-X306 A290-7142-X324
1 12
(*1) LR Mate 200iD. ARC Mate 50iD (*2) LR Mate 200iD/7L. ARC Mate 50iD/7L
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LOCTITE
Torque N-m (kgf-cm) 1.3Nm (13kgfcm)
4.5Nm (46kgfcm) 4.5Nm (46kgfcm)
4.5Nm (46kgfcm)
1 1 1 1 5 1 1
2.0Nm (20kgfcm)
4.REPLACING PARTS
B-83495EN/01
Apply LOCTITE 518 to the
part.
Fig. 4.3 (b) Applying the sealant to the J1-axis reducer Mark is applied to the tapped holes for M4X20. （Tapped holes without the mark are for M4X12.)
Fig. 4.3 (c) Assembled phase of J1-axis reducer
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4.REPLACING PARTS
B-83495EN/01
Removal taps (M4)
Fig. 4.3 (d) Position of removal taps to remove J1 base.
4BNo.2
4BNo.2
Fig.4.3 (e) Grease applying area of the J1-axis
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4.REPLACING PARTS
4.4
B-83495EN/01
REPLACING J2-AXIS MOTOR
Replacing procedure 1 2 3 4 5 6 7 8 9 10 11 12
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set in 0° for all axes when robot is shipped.) Turn off the controller power. Remove plated bolt (1). And remove J2 base cover (2). Cut the nylon band, which connect cable and clamp (5). Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106, K107 ,K108 and K109 referring to Fig.5.3.1 (b) in Chapter 5. Remove bolt (4) and clamp (5). Remove seal bolt (6) and support (7). Remove gasket (19), too. Remove the plated bolt (8) and J2 arm cover (9). Cut the nylon band of the clamp (11). Remove plated bolt (20). And remove cover S (21), gasket (26). At this time, pay attention that grease may go out. Remove seal bolt (22), washer (23), collar (24),wave generator (25). Remove the seal bolt (13) , and remove the motor (14) which O–ring (17) , key (16) and the shaft (15) are attached.
CAUTION When the motor is removed, the J2 arm moves downward by its weight. Hold the arm so that the arm does not collide with any other objects. 13 14
15
Remove cable K102 and K103 from motor (14). Assemble it applying the procedure in the reversed sequence after exchanging Motor, O-ring, gasket (19),(26) and shaft (15) and the sheet (12) for the new article. At this time, pay attention to the following. • Spread LOCTITE 638 referring to Fig.4.4 (b) when you attach shaft (15). • Be sure to attach wave generator (21) after attaching motor (14). Spread grease inside of reducer before assembling it. • Pay attention the phase when you apply the cover S (21) referring to Fig.4.4 (c). • Refer to Fig.4.4 (d) when attaching the sheet (12). • Apply LOCTITE 243 when attaching the key (16). • Be careful not to drop the gasket (3) ,(10). Perform quick mastering and perform single axis mastering for J2-axis referring to Section 8.4 and 8.5 of operator’s manual.
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4.REPLACING PARTS
B-83495EN/01
10
9 8
11
20
21 22 24
25
17
16 15
7
K102
K103
26
14
3 2
1
13 12 5
23 19
6
18
4
Fig. 4.4 (a) Replacing J2-axis motor Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
PLATED BOLT J2 BASE COVER ASSY GASKET BOLT CLAMP SEAL BOLT SUPPORT ASSY PLATED BOLT J2 ARM COVER GASKET CLAMP SHEET SEAL BOLT MOTOR SHAFT KEY O RING PIN GASKET PLATED BOLT COVER S SEAL BOLT WASHER COLLAR
25
WAVE GENERATOR
26
GASKET
Specifications A97L-0218-0496#M4X10BC A290-7142-V303 A290-7142-X324 A6-BA-4X8 A290-7142-X321 A97L-0218-0423#041414 A290-7142-V302 A97L-0218-0496#M4X10BC A290-7142-X307 A290-7142-X325 A290-7142-X322 A290-7142-X330 A97L-0218-0423#051212 A06B-0116-B855#0048 A290-7139-X322 A97L-0118-0402#3X3X12BN JB-OR1A-G45 A6-PS-4X10S A290-7142-X315 A97L-0218-0496#M4X22BC A290-7142-X305 A97L-0218-0423#031616 A290-7120-X532 A97L-0218-0763#410 (It is attached to the J2 REDUCER) A290-7142-X316
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Q’ty 6 1 1 2 1 7 1 6 1 1 1 1 4 1 1 1 1 2 1 4 1 1 1 1 1 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm (20kgfcm)
4.5Nm (46kgfcm) 2.0Nm (20kgfcm)
5.6Nm (57kgfcm)
LT243
4.5Nm (46kgfcm) 1.3Nm (13kgfcm)
4.REPLACING PARTS
B-83495EN/01
Spread grease on the inside diameter A
A
Section A Fig. 4.4 (b) Apply LOCTITE 638 to shaft
Pay attention to the assembled phase.
Fig. 4.4 (c) Assembled phase of cover S
- 34 -
4.REPLACING PARTS
35
B-83495EN/01
12 Fig.4.4 (d) Attachment of the sheet (12)
4.5
REPLACING J2-AXIS REDUCER
Replacing procedure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set in 0° for all axes when robot is shipped.) Turn off the controller power. Remove the robot from floor plate and knock down it sidewise. (Because you must reassemble reducer in a horizontal state.) Remove plated bolt (1). And remove J2 base cover assy (2). Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106, K107 ,K108 and K109 referring to Fig.5.3.1 (b) in Chapter 5. Remove bolt (4) and clamp (5). Cut the nylon band, which connect cable and clamp (5). Remove seal bolt (6) and support (7). Remove gasket (11), too. Remove plated bolt (24), then remove cover S (23) and gasket (17). At this time, pay attention that there is a possibility that grease goes out. Remove seal bolt (22), washer (21), spacer (20) and wave generator (18). Remove seal bolt (8), motor (9) and O-ring (10). Remove bolt (19) and remove the J2 arm which reducer (14) is attached. Remove seal bolt (16) and remove reducer (14) from J2 arm. Exchange reducer, O-ring, gasket for new parts in the following order. Attach new reducer to the J2 arm (18) with seal bolt (16). Attach J2 motor (9) to the J2 arm. Be sure to make the reducer the horizontal about the procedure of 17 and 18. Attach the J2 arm with bolts (19). Be sure to attach the O-ring (15),too. Apply grease to inside of reducer, gear and bearing of wave generator. (See Fig.4.5 (b).) Attach the wave generator (18). Attach cover S (23). At this time, pay attention to the phase referring to Fig.4.4 (c). Attach the support (7) with seal bolt (6). Replace the gasket (11) by new one. Fix the cables on the clamp (5) with nylon bands and attach it to the support (7) with bolt (4). Attach J2 base cover assy (2). At this time, be carful not to drop the gasket (3). Attach robot to floor plate. Perform quick mastering and perform single axis mastering for J2-axis referring to Section 8.4 and 8.5 of operator’s manual.
- 35 -
4.REPLACING PARTS
B-83495EN/01
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear of J2-axis motor shaft. 24 23 22 21 20 19
18
17
16 15 14 13
12
10 11 9
8 7 6 5 4
3 2 1
Fig. 4.5 (a) Replacing J2-axis reducer
- 36 -
4.REPLACING PARTS
B-83495EN/01
Name 1 2 3 4 5 6 7 8 9 10 11 12
PLATED BOLT J2 BASE COVER ASSY GASKET BOLT CLAMP SEAL BOLT SUPPORT ASSY SEAL BOLT MOTOR O RING GASKET PIN
13
O RING
14
REDUCER
15
O RING
16 17
SEAL BOLT GASKET
18
WAVE GENERATOR
19 20 21 22 23 24
BOLT SPACER WASHER SEAL BOLT COVER S PLATED BOLT
Specifications A97L-0218-0496#M4X10BC A290-7142-V303 A290-7142-X324 A6-BA-4X8 A290-7142-X321 A97L-0218-0423#041414 A290-7142-V302 A97L-0218-0423#051212 A06B-0116-B855#0048 JB-OR1A-G45 A290-7142-X315 A6-PS-4X10S (It is attached to the J2 REDUCER) A97L-0218-0952#100 (*1) A97L-0218-0952#120 (*2) (It is attached to the J2 REDUCER) A97L-0218-0546#043516BC A290-7142-X316 (It is attached to the J2 REDUCER) A6-BA-4X20 A97L-0218-0794#410 A290-7210-X532 A97L-0218-0423#031616 A290-7142-X305 A97L-0218-0496#M4X22BC
Q’ty
LOCTITE
5 1 1 2 1 7 1 4 1 1 1 2 1
Torque N-m (kgf-cm) 2.0Nm (20kgfcm)
4.5Nm (46kgfcm) 5.6Nm (57kgfcm)
1 1 12 1 1
4.5Nm (46kgfcm)
12 1 1 1 1 4
4.5Nm (46kgfcm)
1.3Nm (13kgfcm) 4.5Nm (46kgfcm)
(*1) LR Mate 200iD. ARC Mate 50iD (*2) LR Mate 200iD/7L. ARC Mate 50iD/7L
4BNo.2
Fig. 4.5 (b) Applying the grease to the J2-axis reducer
- 37 -
4.REPLACING PARTS
4.6
B-83495EN/01
REPLACING J3-AXIS MOTOR
Replacing procedure 1 2 3
Turn off the controller power. Remove plated bolt (4). And remove J2 arm cover (5). Loosen tension adjusting bolts a little and lower the tension of the belt and remove belt (7) referring to Fig.4.6 (b).
CAUTION When removing the belt, put the part beyond the J3 housing on a workbench to prevent the arm from dropping 4 5 6 7 8 9 10
11
Remove the plated bolt (1) and remove the J2 arm cover (2). Remove the J2 base cover and remove the all relays of K101 and air tubes referring to Subsection 5.3.1. (Refer to Fig.5.3.1 (a),(b).) Remove the bolt (8) and remove the motor plate (9) which is combined to the motor. Remove the seal bolt (10) , washer plate (11) and the pulley (12). Remo the bolt (15) then remove the motor (14) from the motor plate (9). Remove the cable K104 and K105 from the motor (14). Assemble it in the reversed sequence after exchanging motor by the new article. At this time, pay attention to the following. • Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. • Be careful not to drop the gasket (3) ,(6). Perform single axis mastering referring to Section 8.5 of operator’s manual.
- 38 -
4.REPLACING PARTS
B-83495EN/01
5
3
6 7
4
2 1
9 8
10
11
12
14
15
13
K104 K105 Fig. 4.6 (a) Replacing J3-axis motor Name 1 2 3 4 5 6
PLATED BOLT J2 ARM COVER GASKET PLATED BOLT J2 ARM COVER GASKET
7
BELT
8 9 10 11
FLANGE BOLT MOTOR PLATE SEAL BOLT WASHER PLATE
12
PULLEY J3-1
13 14 15
KEY MOTOR BOLT
Specifications A97L-0218-0496#M4X10BC A290-7142-X307 A290-7142-X325 A97L-0218-0496#M4X10BC A290-7142-X307 A290-7142-X325 A98L-0040-0285#006-095 (*1) A98L-0040-0285#006-100 (*2) A97L-0218-0504#M5X12 A290-7142-X308 A97L-0218-0423#030606 A290-7142-X203 A290-7142-X309 (*1) A290-7142-X333 (*2) A97L-0118-0402#3X3X12BN A06B-0115-B855#0048 A6-BA-5X12
(*1) LR Mate 200iD. ARC Mate 50iD (*2) LR Mate 200iD/7L. ARC Mate 50iD/7L
- 39 -
Q’ty
LOCTITE
6 1 1 6 1 1
Torque N-m (kgf-cm) 2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
1 3 1 3 1
1.3Nm (13kgfcm)
1 1 1 4
LT243 5.6Nm (57kgfcm)
4.REPLACING PARTS
B-83495EN/01
Tension adjusting bolt
Fig. 4.6 (b) Adjusting tension of J3 belt
4.7
REPLACING J3-AXIS REDUCER
Replacing procedure 1 2 3 4 5 6 7 8 9 10 11 12 13
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set in 0° for all axes when robot is shipped.) Turn off the controller power. Remove the plated bolt (1) and remove the J2 base cover assy (2). Cut the nylon bands and remove the relay connectors. Remove the bolt (4) and the clamp (5). Remove the seal bolt (6) and the support assy (7). Remove the plated bolt (10) and the J2 arm cover (11). Remove the plated bolt (18) and the J3 cover (19). Remove the relay of the connector and cut the nylon band at the clamp (21). Remove the plated bolt (22) and the J3 arm cover (23). Pull out the air tubes and cut the nylon bands of the clamp (25). Remove the seal bolt (13) and plated bolt (14),(15) and remove the J2 arm 2 (16). Remove the J2 arm cover and the belt referring to procedure 1-3 of Section 4.6.
CAUTION When removing the belt, put the part beyond the J3 housing on a workbench to prevent the arm from dropping 14 15 16 17 18 19 20 21
Remove the seal bolt (26) , the washer (27) and the pulley (28). Remove bolt (29) and J2 arm which reducer (34) is attached. Note that grease may go out. Remove seal bolt (33) and reducer (34). Replace reducer by new one and install to J3 arm unit horizontally. At this time, be sure to put wave washer (36) and O-ring (35). Apply Harmonic grease 4B No.2 to inside of reducer, gear and bearing of wave generator. Refer to Fig.4.7 (f). Attach wave generator (32) to reducer. Spread sealant to the reducer referring to Fig.4.7 (d) and Section 4.20. Attach J3 arm unit which reducer is attached. At this time, be sure to put O-ring (30). - 40 -
4.REPLACING PARTS
B-83495EN/01
CAUTION Do not apply grease to the O-ring (30). prevented, causing a grease leak. 22 23 24 25 26
27
Otherwise, hardening of sealant is
Install pulley (28) and belt. Attach the J2 arm (2), support (7) as the original state. At this time, replace gasket (9) by new one. Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. Attach the J2 arm cover referring Section 4.6. Attach the J2 arm 2, the J2 base cover, the support and the J2 arm cover as the original state. Spread sealant on the J2 arm 2 and J2 arm mounting face of another part. Spread sealant on the J2 arm referring to Fig.4.7 (e). Be careful not to drop the gasket (3),(12),(20) and (24). Perform quick mastering and perform single axis mastering to J3-axis referring to Section 8.4 and 8.5 of operator’s manual. 1 2 3
4
10
5 6
11 7 12 14
13
15
16 8 9 17
Fig. 4.7 (a) Replacing J3-axis reducer
- 41 -
4.REPLACING PARTS Name
B-83495EN/01
Specifications
1 2 3 4 5 6 7 8 9 10 11 12 13
PLATED BOLT J2 BASE COVER ASSY GASKET BOLT CLAMP J2-1 SEAL BOLT SUPPORT ASSY PIN GASKET PLATED BOLT J2 ARM COVER GASKET BOLT
A97L-0218-0496#M4X10BC A290-7142-V303 A290-7142-X324 A6-BA-4X8 A290-7142-X321 A97L-0218-0423#041414 A290-7142-V302 A6-PS-4X10S A290-7142-X315 A97L-0218-0496#M4X10BC A290-7142-X307 A290-7142-X325 A6-BA-4X14
14
PLATED BOLT
A97L-0218-0496#M4X30BC
15
PLATED BOLT
16
J2 ARM 2 ASSY
17
PIN
A97L-0218-0496#M4X45BC A290-7142-V311 (*1) A290-7142-V314 (*2) A6-PS-4X10S
Q’ty
LOCTITE
Torque N-m (kgf-cm)
5 1 1 2 1 7 1 2 1 6 1 1 4 2 (*1) 4 (*2) 3
2.0Nm (20kgfcm)
4.5Nm (46kgfcm)
2.0Nm (20kgfcm)
4.5Nm (46kgfcm) 4.5Nm (46kgfcm) 4.5Nm (46kgfcm)
1 5
(*1) LR Mate 200iD. ARC Mate 50iD (*2) LR Mate 200iD/7L. ARC Mate 50iD/7L
22 23 24
20
21
25
Fig. 4.7 (b) Replacing J3-axis reducer (2/3)
- 42 -
19
18
4.REPLACING PARTS
B-83495EN/01
Name 18 19 20 21 22 23 24 25
PLATED BOLT J3 COVER GASKET CLAMP PLATED BOLT J3 ARM COVER GASKET CLAMP
Specifications
Q’ty
A97L-0218-0496#M4X10BC A290-7142-X404 A290-7142-X409 A290-7142-X415 A97L-0218-0496#M4X10BC A290-7142-X405 A290-7142-X410 A290-7142-X416
LOCTITE
4 1 1 1 7 1 1 1
Torque N-m (kgf-cm) 2.0Nm (20kgfcm)
37 34
29
26 27
30 31
33
35 36
32
28
Fig. 4.7 (c) Replacing J3-axis reducer (3/3)
Name 26 27
SEAL BOLT WASHER
28
PULLEY J3-2
29 30 31 32 33 34 35 36 37
BOLT O RING KEY WAVE GENERATOR BOLT J3 REDUCER O-RING WAVE WASHER J3 HOUSING
Specifications A97L-0218-0423#030606 A290-7210-X532 A290-7142-X310 (*1) A290-7142-X334 (*2) A6-BA-3X16 (It is attached to the J3 REDUCER) A97L-0118-0402#3X3X9BN (It is attached to the J3 REDUCER) A97L-0218-0546#032204BC A97L-0218-0953#80 (It is attached to the J3 REDUCER) (It is attached to the J3 REDUCER) A290-7142-X401
(*1) LR Mate 200iD. ARC Mate 50iD
(*2) LR Mate 200iD/7L. ARC Mate 50iD/7L
- 43 -
Q’ty
LOCTITE
1 1
Torque N-m (kgf-cm) 1.3Nm (13kgfcm)
1 15 1 1 1 12 1 1 1 1
2.0Nm (20kgfcm) LT243 2.0Nm (20kgfcm)
4.REPLACING PARTS
B-83495EN/01
Apply LOCTITE on part Do not apply LOCTITE inside the reducer. Fig. 4.7 (d) Applying sealant on the J3-axis reducer
Pay attention to the sealant applying area.
Remove the grease of the sealant and apply primer. Apply LOCTITE 518 on
part
Fig.4.7 (e) Applying sealant on the J2 arm
- 44 -
4.REPLACING PARTS
B-83495EN/01
4BNo.2
Fig.4.7 (f)
4.8
Grease applying area of the J3-axis
REPLACING J4-AXIS MOTOR
Replacing procedure 1 2 3
Turn off the controller power. Remove plated bolt (1). And remove J3 cover (2). Remove bolt (4), remove the motor (5) with the gear . Note that grease may go out.
CAUTION When the motor is removed, the J3 arm can be rotated. Do as the J3 arm is put on the stand so that the arm should not collide with surroundings. 4 5 6 7
8
Wipe the grease of the gear (11) off. At this time, pay attention not to damage the tooth surface. Remove cable K107 and K111 from motor (5). Remove seal bolt (13), washer plate (12), gear (11), key (10), holder (7) with oil seal (8) and O-ring (6). Assemble it in the reversed sequence after exchanging motor-ring and gasket for the new article. At this time, pay attention to the followings. • Confirm the thing that the oil seal (8) is at appropriate position, and note that the lip cannot be turned over. • Spread Harmonic grease on surroundings of the gear referring to Fig.4.9 (e). • Be careful not to drop the gasket (3). • Apply sealant on the motor shaft before attaching the washer (12) and the seal bolt (13) referring to Fig.4.8 (b) and Section 4.20 . Perform single axis mastering referring to Section 8.5 of operator’s manual.
- 45 -
4.REPLACING PARTS
B-83495EN/01
3 2
8
13 11 12
1
10
9 7
6
5
4
Fig. 4.8 (a) Replacing J4-axis motor
Name 1 2 3 4 5 6 7 8 9 10 11 12 13
PLATED BOLT J3 COVER ASSY GASKET BOLT MOTOR O RING HOLDER OIL SEAL O RING KEY GEAR J4-1 WASHER SEAL BOLT
Specifications
Q’ty
A97L-0218-0496#M4X10BC
4
A290-7142-V404
1
A290-7142-X409 A6-BA-5X16 A06B-0114-B855#0048 A98L-0001-0347#S46 A290-7142-X407 A98L-0040-0223#01502505 A98L-0001-0347#S46 A97L-0118-0402#3X3X12BN A290-7142-X406 A290-7142-X420 A97L-0218-0423#030606
1 3 1 1 1 1 1 1 1 1 1
- 46 -
LOCTITE
Torque N-m (kgf-cm) 2.0Nm (20kgfcm)
5.6Nm (57kgfcm)
LT243
1.3Nm (13kgfcm)
4.REPLACING PARTS
B-83495EN/01
Apply LOCTITE 518 on
part
Fig.4.8 (b) Applying sealant to the J4-axis motor shaft
4.9
REPLACING J4-AXIS REDUCER
Replacing procedure 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set in 0° for all axes when robot is shipped.) Turn off the controller power. Remove J3 arm cover referring to Section 4.10. Remove the J3 cover referring to Section 4.8. Cut the nylon band at the clamp inside the J3 arm. Cut the nylon band at the clamp inside the J3 housing and remove relay connector and air tube. Pull out the air tubes to the J3 housing side. Pull out the cable to the J3 arm side through the pipe. At this time, pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relayed connector caught. Remove bolt (1) and clamp (2). Remove the J4-axis motor referring to Section 4.8. Remove bolt (3), (4) and J3 arm. Pay attention not to damage oil seal (7). Note that there is a possibility that grease goes out. Wipe the grease of the reducer (8) off. At this time, pay attention not to damage the tooth surface. Remove plated bolt (6) and reducer (8). Remove seal bolt (5) , pipe (8) and J4 pipe (9). Assemble it applying the procedure in the reversed sequence after exchanging reducer for the new article. • When installing reducer, spread grease on teeth of Wave generator, and be sure to install O-ring (7). (In case of J4-axis reducer, wave generator is assembled in reducer when it is shipped.) Also, pay attention to the phase of bolts referring to Fig.4.9 (c). • Spread Harmonic grease 4BNo.2 on surroundings of the gear referring to Fig.4.9 (e). • When installing J3 arm, confirm that the oil seal (5) is at appropriate position, and note that the lip cannot be turned over. • Spread sealant to the each part referring to Fig.4.9 (b) and Section 4.20. • Apply grease referring to Fig.4.9 (e). - 47 -
4.REPLACING PARTS
B-83495EN/01
CAUTION Do not apply grease to the O-ring (7). prevented, causing a grease leak. 12
Otherwise, hardening of sealant is
Perform quick mastering and perform single axis mastering for J4-axis referring to Section 8.4 and 8.5 of operator’s manual.
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear of J4-axis motor shaft.
8 10
9
6
3
5
7
1
4 2
Fig. 4.9 (a) Replacing J4-axis reducer
Name 1 2 3 4 5
BOLT CLAMP BOLT BOLT OIL SEAL
6
PLATED BOLT
7 8 9 10
O RING REDUCER J4 PIPE SEAL BOLT
Specifications
Q’ty
A6-BA-4X8 A290-7142-X415 A6-BA-3X30 A6-BA-3X14 A98L-0040-0049#02503507 A97L-0218-0496#M3X25BC or A97L-0218-0496#M3X28BC (*) (It is attached to the J4 REDUCER) A97L-0218-0954#80 A290-7142-X421 A97L-0218-0423#030606
2 1 12 2 1
LOCTITE
2.0Nm (20kgfcm) 2.0Nm (20kgfcm)
9
2.0Nm (20kgfcm)
1 1 1 4
1.3Nm (13kgfcm)
(*) Length of the bolts is different depending on the manufacturing date.
- 48 -
Torque N-m (kgf-cm)
4.REPLACING PARTS
B-83495EN/01
Apply LOCTITE 518 on
part
Fig. 4.9 (b) Applying of the sealant
M3X30 (12)
M3X14 (2)
Fig. 4.9 (c) Assembled phase of J4-axis reducer
- 49 -
4.REPLACING PARTS
B-83495EN/01
J3 arm
J4-axis reducer
Apply LOCTITE on
part
Fig.4.9 (d) Applying sealant on the J4-axis reducer
4BNo.2
Gear Fig.4.9 (e)
Grease applying area of the J4-axis
- 50 -
4.REPLACING PARTS
B-83495EN/01
4.10
REPLACING J5-AXIS MOTOR
NOTE If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). Replacing procedure 1 2 3 4 5
Turn off the controller power. Remove plated bolt (1). And remove J3 arm cover (2). Remove plated bolt (5) . And remove J3 arm cover (6). Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing referring to Section 4.8 and Fig.5.3.2 (c). Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the nylon band which fix the cables referring to Fig.5.3.2 (a).
CAUTION When the belt is removed, the wrist moves to bellow side. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 6 7 8 9
10
Remove bolt (13) and motor (8). Remove cable K113, K114 from motor (8). Remove seal bolt (12), washer (11), motor pulley (10) and key (9). Assemble it in the reversed sequence after exchanging motor and gasket for the new article. • Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. • Be careful not to drop the gasket (3), (7). Perform single axis mastering referring to Section 8.5 of operator’s manual. At this time, perform not only J5-axis but also J6-axis.
5
6 7
3 13
8 9
10
12
11
Fig. 4.10 (a) Replacing J5-axis motor
- 51 -
4
2
1
4.REPLACING PARTS
B-83495EN/01
Tension adjusting bolt
14
Fig. 4.10 (b) Replacing J5-axis motor Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14
PLATED BOLT J3 ARM COVER GASKET BELT PLATED BOLT J3 ARM COVER GASKET MOTOR KEY PULLEY J5-1 WASHER SEAL BOLT BOLT SEAL BOLT
4.11
Specifications A97L-0218-0496#M4X10BC A290-7142-X405 A290-7142-X410 A98L-0040-0286#004-157 A97L-0218-0496#M4X10BC A290-7142-X405 A290-7142-X410 A06B-0117-B855#0049 A97L-0118-0402#3X3X6BN A290-7142-X411 A290-7142-X420 A97L-0218-0423#030606 A97L-0218-0504#M5X12 A97L-0218-0423#030606
Q’ty 7 1 1 1 7 1 1 1 1 1 1 1 4 3
LOCTITE
Torque N-m (kgf-cm) 2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
LT243
1.3Nm (13kgfcm) 5.6Nm (57kgfcm) 1.3Nm (13kgfcm)
REPLACING J5-AXIS REDUCER (Standard)
NOTE If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). Replacing procedure 1 2 3 4 5 6 7
Turn off the controller power. Remove both side of J3-arm cover referring to Section 4.10. Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing referring to Section 4.8 and Fig.5.3.2 (c). Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the nylon band which fix the cables referring to Fig.5.3.2 (a). Remove the seal bolt (14) and remove the J3 arm 2 (15) from the J3 arm 1 (16). At this time, pay attention not to damage the oil seal (6). Remove the J6-axis motor cables. Remove belt (1) referring to Section 4.10.
- 52 -
4.REPLACING PARTS
B-83495EN/01
CAUTION When the belt is removed, the wrist moves to bellow side. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 8 9 10 11
Remove seal bolt (2), washer plate (3) and pulley (4). Remove key (7) and bolt (5). Remove plated bolt (9) and remove reducer (11). At this time, note that grease may go out. Replace reducer by new one, and assemble robot applying the procedure in the reversed sequence. At this time, pay attention below. • Apply grease to inside of reducer, gear and bearing of wave generator and install it horizontally. (Refer to Fig.4.11 (d)). Be sure to install O-ring (8) and (12) and wave washer (13). • Apply grease to the lip of the Oil seal (6) • Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. • Spread sealant to the J3 arm referring to Fig.4.11 (c) and Section 4.20. • Spread sealant to the reducer referring to Fig.4.11 (b) and Section 4.20.
CAUTION Do not apply grease to the O-ring (8). prevented, causing a grease leak. 12
Otherwise, hardening of sealant is
Perform quick mastering and perform single axis mastering for J5/J6-axis referring to Section 8.4 and 8.5 of operator’s manual.
15 16
1
14
12 11
13
9
10
5 7 8
3 2
4 6
Fig. 4.11 (a) Replacing J5-axis reducer
- 53 -
4.REPLACING PARTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B-83495EN/01
Name
Specifications
Q’ty
BELT SEAL BOLT WASHER PLATE PULLEY J5-2 BOLT OIL SEAL KEY O RING PLATED BOLT WAVE GENERATOR REDUCER O-RING WAVE WASHER SEAL BOLT J3 ARM 2 J3 ARM 1
A98L-0040-0286#004-104 A97L-0218-0423#030606 A290-7139-X231 A290-7142-X412 A6-BA-3X8 A98L-0040-0223#01001805 A97L-0118-0402#3X3X6BN (It is attached to the J5 REDUCER) A97L-0218-0496#M3X22BC (It is attached to the J5 REDUCER) A97L-0218-0955#50 (It is attached to the J5 REDUCER) (It is attached to the J5 REDUCER) A97L-0218-0423#041616 A290-7142-X403 A290-7142-X402
1 3 1 1 12 1 1 1 9 1 1 1 1 7 1 1
LOCTITE
1.3Nm (13kgfcm)
2.0Nm (20kgfcm) LT243
Apply LOCTITE 518 to dotted line area of the O ring (8) side. Do not put LOCTITE inside the reducer. Fig. 4.11 (b) Spread range of sealant to J5-reducer
- 54 -
Torque N-m (kgf-cm)
2.0Nm (20kgfcm)
4.5Nm (45kgfcm)
4.REPLACING PARTS
B-83495EN/01
A
A
Note to the selant applying area LT518
Section A-A Note) Remove the sealant, apply LOCTITE 518 on the one side, and apply primar on the other side and assemble them. Remove the excess sealant completely.
Apply LOCTITE 518 on
part.
Fig.4.11 (c) Applying the sealant on the J3 arm (Standard)
- 55 -
4.REPLACING PARTS
B-83495EN/01
4BNo.2
Fig.4.11 (d)
4.12
Grease applying area of the J5-axis
REPLACING J5-AXIS REDUCER (7L)
NOTE If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). Replacing procedure 1 2 3 4 5 6 7 8 9
Turn off the controller power. Remove both side of J3-arm cover referring to Section 4.10. Remove the air tubes of inside the J3 arm. Cut the nylon band which fix cables inside the J3 arm. Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing referring to Section 4.8 and Fig.5.3.2 (c). Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the nylon band which fix the cables referring to Fig.5.3.2 (a). Remove the seal bolt (14), then remove the J3 arm 2 (17) from the J3 arm 1 (18). At this time, pay attention not to damage the oil seal (6). Note that grease may go out. Remove belt (1) referring to Section 4.10. Remove the unit over the J4-axis reducer from the J3 housing referring to Section 4.9.
CAUTION When the belt is removed, the wrist moves to bellow side. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 10 11 12 13
Remove seal bolt (2), washer plate (3) and pulley (4). Remove key (7) and bolt (5). Remove the seal bolt (14),(15) and (16), and remove the J3 arm 2 (17) from the J3 arm 1 (18). At this time, pay attention not to damage the oil seal (6). Note that grease may go out. Remove the plated bolt (9) and remove the reducer (11). Note that grease may go out. - 56 -
4.REPLACING PARTS
B-83495EN/01
14
Replace reducer by new one, and assemble robot applying the procedure in the reversed sequence. At this time, pay attention below. • Apply grease to inside of reducer, gear and bearing of wave generator and install it horizontally. (Refer to Fig.4.11 (d).) Be sure to install O-ring (8) and (12) and wave washer (13). • Apply grease to the lip of the Oil seal (6) • Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. • Spread sealant to the J3 arm referring to Fig.4.12 (b) and Section 4.20. • Spread sealant to the reducer referring to Fig.4.11 (b) and Section 4.20.
CAUTION Do not apply grease to the O-ring (8). prevented, causing a grease leak. 15
Otherwise, hardening of sealant is
Perform single axis mastering to J5-axis and J6-axis referring to Section hapter 8 of operator’s manual.
- 57 -
4.REPLACING PARTS
B-83495EN/01
17 16
18
15
1
14
12 11
13
9
10 8
5 7
4
2
3
6 Fig. 4.12 (a) Replacing J5-axis reducer (7L)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Name
Specifications
Q’ty
BELT SEAL BOLT WASHER PLATE PULLEY J5-2 BOLT OIL SEAL KEY O RING PLATED BOLT WAVE GENERATOR REDUCER O-RING WAVE WASHER SEAL BOLT SEAL BOLT SEAL BOLT J3 ARM 2 J3 ARM 1
A98L-0040-0286#004-104 A97L-0218-0423#030606 A290-7139-X231 A290-7142-X412 A6-BA-3X8 A98L-0040-0223#01001805 A97L-0118-0402#3X3X6BN (It is attached to the J5 REDUCER) A97L-0218-0496#M3X22BC (It is attached to the J5 REDUCER) A97L-0218-0955#50 (It is attached to the J5 REDUCER) (It is attached to the J5 EDUCER) A97L-0218-0423#041616 A97L-0218-0546#042516BC A97L-0218-0546#041212BC A290-7142-X403 A290-7142-X402
1 3 1 1 12 1 1 1 9 1 1 1 1 5 4 2 1 1
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LOCTITE
Torque N-m (kgf-cm) 1.3Nm (13kgfcm)
2.0Nm (20kgfcm) LT243 2.0Nm (20kgfcm)
4.5Nm (45kgfcm) 4.5Nm (45kgfcm) 4.5Nm (45kgfcm)
4.REPLACING PARTS
B-83495EN/01
Apply LOCTITE 518 to dotted lin area of the O ring side. Do not put LOCTITE inside the reducer. Fig. 4.12 (b) Spread range of sealant to J5-reducer
- 59 -
4.REPLACING PARTS
B-83495EN/01
A
A
LT518
Section A-A Note to the sealant applying area Note） Remove the sealant, apply LOCTITE 518 on the one side, and apply primar on the other side and assemble them. Remove the excess sealant completely.
Apply LOCTITE 518 on
part.
Fig.4.12 (c) Applying the sealant on the J3 arm (7L)
- 60 -
4.REPLACING PARTS
B-83495EN/01
4.13
REPLACING J6-AXIS MOTOR
NOTE If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). Replacing procedure 1 2 3
Turn off the controller power. Remove both side of J3 arm cover of J3 arm referring to Section 4.10. Loosen tension adjusting bolt and lower tension and remove belt (1) referring to Fig. 6.1 (b). Loose the bolt (9) and remove pulley if it is difficult to remove the belt.
CAUTION When the belt (1) is removed, the wrist moves to bellow side. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 4
Loosen flange socket bolt (2) and lower tension and remove J6 belt (3).
CAUTION When the belt (3) is removed, the wrist become rotatable, When end effector is attached, fix it so that the wrist should not collide with surroundings. 5 6 7 8 9
Remove the flange socket bolt (2) and the motor (4). Remove cable K116, K117 from motor (4). Remove seal bolt (8), washer (7), motor pulley (6) and key (7). Assemble it in the reversed sequence after exchanging motor and gasket for the new article. ・ Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. Perform single axis mastering referring to Section 8.5 of operator’s manual. At this time, perform not only J6-axis but also J5-axis.
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4.REPLACING PARTS
B-83495EN/01
1 A
4
2 76 5 8
B
3
Fig. 4.13 (a) Replacing J6-axis motor
Tension adjusting bolt
Tension adjusting bolt 9
View A
View B Fig. 4.13 (b) Replacing J6-axis motor
Name 1 2 3 4 5 6 7 8 9
BELT FLANGE SOCKET BOLT BELT MOTOR KEY PULLEY J6-1 WASHER SEAL BOLT SEAL BOLT
Specifications
Q’ty
A98L-0040-0286#004-157
1
A97L-0218-0504#M5X12
4
A98L-0040-0286#004-157 A06B-0117-B855#0049 A97L-0118-0402#3X3X6BN A290-7142-X429 A290-7142-X420 A97L-0218-0423#030606 A97L-0218-0423#030606
1 1 1 1 1 1 1
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LOCTITE
Torque N-m (kgf-cm)
5.6Nm (56kgfcm)
LT243
1.3Nm (13kgfcm) 1.3Nm (13kgfcm)
4.REPLACING PARTS
B-83495EN/01
4.14
REPLACING WRIST UNIT (Standard)
NOTE If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). Replacing procedure 1 2 3 4 5
Turn off the controller power. Replacing both side of J3 arm cover of J3 arm referring to Section 4.10. Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the nylon band which fix the cables referring to Fig.5.3.2 (a). Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing referring to Section 4.8 and Fig.5.3.2 (c). Remove belt (1), (8) referring to Section 4.12.
CAUTION When the belt (1), (8) is removed, the wrist moves to bellow side or rotate. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 6 7 8 9 10
11 12 13 14
Remove seal bolt (13), J3 arm 2 (14). Remove relay of cable K116 and cable K106 of J6-axis motor. Remove seal bolt (2), washer plate (3) and pulley (4). Remove bolt (6), wrist unit (18) and key (5). At this time, pay attention not to damage oil seal (7). Pay attention that grease may go out, too. Replace wrist unit (16) by new one and attach it. Attach reducer horizontally after apply greasing to gear of reducer. At this time, be sure to replace O-ring (15), too. Apply grease to the lip of the oil seal (7). Assemble it in the reverse order of 3-9. Adjust belt referring to Section 6.1. Install J3 arm cover. Perform single axis mastering referring to Section 8.5 of operator’s manual. At this time, perform not only J6-axis but also J5-axis.
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4.REPLACING PARTS
B-83495EN/01
13 14 1
8
7
15 9 10 11 12
4
5
3
2
6 16 Fig. 4.14 Replacing wrist unit (Standard)
Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BELT SEAL BOLT WASHER PLATE PULLEY J5-2 KEY BOLT OIL SEAL BELT SEAL BOLT WASHER PULLEY J6-2 KEY SEAL BOLT J3 ARM 2 O RING WRIST UNIT
Specifications
Q’ty
A98L-0040-0286#004-157 A97L-0218-0423#030606 A290-7139-X231 A290-7142-X412 A97L-0118-0402#3X3X6BN A6-BA-3X8 A98L-0040-0223#01001805 A98L-0040-0286#004-104 A97L-0218-0423#030606 A290-7142-X420 A290-7142-X414 A97L-0118-0402#3X3X6BN A97L-0218-0423#041616 A290-7142-X403 (It is attached to the J5 REDUCER) A290-7142-V501
1 3 1 1 1 12 1 1 1 1 1 1 7 1 1 1
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LOCTITE
Torque N-m (kgf-cm) 1.3Nm (13kgfcm)
LT243 2.0Nm (20kgfcm)
1.3Nm (13kgfcm)
LT243 4.5Nm (46kgfcm)
4.REPLACING PARTS
B-83495EN/01
4.15
REPLACING WRIST UNIT (7L)
NOTE If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). Replacing procedure 1 2 3 4 5
Turn off the controller power. Replacing both side of J3 arm cover of J3 arm referring to Section 4.10. Remove the 2 M4X8 bolts of the clamp (A290-7142-X416) of the J3 arm root side, then cut the nylon band which fix the cables referring to Fig.5.3.2 (a). Remove the J3 cover, then cut the nylon band of the clamp J4 (A290-7142-X415) in the J3 housing referring to Section 4.8 and Fig.5.3.2 (c). Remove belt (1), (8) referring to Section 4.10 and Section 4.12.
CAUTION When the belt (1), (8) is removed, the wrist moves to bellow side or rotate. Do as the wrist is put on the stand so that the wrist should not collide with surroundings. 6 7 8 9 10
11 12 13 14
Remove the unit over the J4-axis reducer from the J3 housing referring to Section 4.9. Remove the seal bolt (13),(14) and (15), and remove the J3 arm 2 (16). Remove seal bolt (2), washer plate (3) and pulley (4). Remove bolt (6), wrist unit (16) and key (5). At this time, pay attention not to damage oil seal (7). Pay attention that grease may go out, too. Replace wrist unit (17) by new one and attach it. Attach reducer horizontally after apply greasing to gear of reducer. At this time, be sure to replace O-ring (18), too. Apply grease to the lip of the oil seal (7). Assemble it in the reverse order of 3-9. Adjust belt referring to Section 6.1. Install J3 arm cover. Perform single axis mastering referring to Section 8.5 of operator’s manual. At this time, perform not only J6-axis but also J5-axis.
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4.REPLACING PARTS
B-83495EN/01
15
16
14
1 13 8
7 5
12 9 10 11
18
4
3
2
6
17 Fig. 4.15 Replacing wrist unit (7L)
Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
BELT SEAL BOLT WASHER PLATE PULLEY J5-2 KEY BOLT OIL SEAL BELT SEAL BOLT WASHER PULLEY J6-2 KEY SEAL BOLT SEAL BOLT SEAL BOLT J3 ARM 2 O RING WRIST UNIT
Specifications
Q’ty
A98L-0040-0286#004-157 A97L-0218-0423#030606 A290-7139-X231 A290-7142-X412 A97L-0118-0402#3X3X6BN A6-BA-3X8 A98L-0040-0223#01001805 A98L-0040-0286#004-104 A97L-0218-0423#030606 A290-7142-X420 A290-7142-X414 A97L-0118-0402#3X3X6BN A97L-0218-0423#041616 A97L-0218-0546#042516BC A97L-0218-0546#041212BC A290-7142-X434 (It is attached to the J5 REDUCER) A290-7142-V501
1 3 1 1 1 12 1 1 1 1 1 1 5 4 2 1 1 1
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LOCTITE
Torque N-m (kgf-cm) 1.3Nm (13kgfcm)
LT243 2.0Nm (20kgfcm)
1.3Nm (13kgfcm)
LT243 4.5Nm (46kgfcm) 4.5Nm (46kgfcm) 4.5Nm (46kgfcm)
4.REPLACING PARTS
B-83495EN/01
4.16
REPLACING J6-AXIS REDUCER
NOTE If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). Replacing procedure 1 2 3 4 5 6 7 8
Make to posture that J6 turns to the right upper and turn off the controller power as shown in Fig.4.16 (a). Remove bolt (1) and reducer. At this time, note that grease may go out. Remove seal bolt (3), washer (4) , wave generator (6) and the key (5). Remove O-ring (7). Apply greasing to bearing of wave generator (6) to which attach new reducer and install to the robot. Grease inside and gear of reducer (2) and wave generator by using the injection syringe.(Refer to Fig.4.16 (c)) Install new reducer (2) to the robot. At this time, replace O-ring (7) by new one, too. Perform single axis mastering referring to Section 8.5 of operator’s manual.
1 2 4
3 5 6
7
Fig. 4.16 (a) Replacing J6-axis reducer Name
Specifications
Q’ty
1 2 3 4
PLATED BOLT REDUCER SEAL BOLT WASHER
A97L-0218-0496#M3X25BC A97L-0218-0956#50 A97L-0218-0423#030808 A290-7210-X532
8 1 1 1
5
KEY
A97L-0118-0402#3X3X6BN
1
6 7
WAVE GENERATOR O RING
(It is attached to the J6 REDUCER) (It is attached to the J6 REDUCER)
1 1
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LOCTITE
Torque N-m (kgf-cm) 2.0Nm (20kgfcm) 1.3Nm (13kgfcm)
4.REPLACING PARTS
B-83495EN/01
M3X25
Fig. 4.16 (b) Assembling phase of J6-axis reducer
4BNo.2
Fig.4.16 (c)
4.17
Grease applying area of the J6-axis
REPLACING J3 BELT
Replacing procedure 1 2 3
Turn off the controller power. Remove plated bolt (1). And remove J2 arm cover (2). Loosen tension adjusting bolt and lower tension and remove belt (4) referring to Fig.4.17.
CAUTION When removing the belt (4), put the part beyond the J3 housing on a workbench to prevent the arm from dropping. 4
5
Replace belt and gasket to new one and do the reversed sequence. At this time, pay attention below. • Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. • Be careful not to drop the gasket (3). Perform single axis mastering referring to Section 8.5 of operator’s manual.
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4.REPLACING PARTS
B-83495EN/01
2
3 4
1
Tension adjusting bolt
Fig. 4.17 Replacing J3 belt Name 1 2 3
PLATED BOLT J2 ARM COVER GASKET
4
BELT
Specifications A97L-0218-0496#M4X10BC A290-7142-X307 A290-7142-X325 A98L-0040-0285#006-095 (*1) A98L-0040-0293#006-100 (*2)
Q’ty 6 1 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm (20kgfcm)
1
(*1) LR Mate 200iD. ARC Mate 50iD (*2) LR Mate 200iD/7L. ARC Mate 50iD/7L
4.18
REPLACING J5/J6 BELT
NOTE If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy may go down. Perform the calibration for load estimation before performing load estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2). Replacing procedure 1 2 3 4
Turn off the controller power. Remove plated bolt (1). And remove J3 arm cover (２). Remove bolt/plated bolt (5). And remove J3 arm cover (6). In case of replacing J5 belt, loosen tension adjusting bolt and lower tension and remove belt referring to Fig.6.1 (b). In case of replacing J6 belt, loosen tension adjusting bolt and lower tension and remove belt referring to Fig.6.1 (c).
CAUTION When the belt (4) is removed, the wrist moves to bellow side or rotate. Do as the wrist is put on the stand so That the wrist should not collide with surroundings.
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4.REPLACING PARTS
B-83495EN/01
CAUTION When the belt (8) is removed, the wrist become possible to rotate. When end effector is attached, fix it so that the wrist should not collide with surroundings. 5
6
Replace belt and gasket to new one and install in the reversed sequence. At this time, pay attention below. • Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. • Be careful not to drop the gasket (3) and (7). Perform single axis mastering referring to Section 8.5 of operator’s manual. When replacing the J5 belt, perform not only J5-axis but also J6-axis when replacing J5 belt.
5
6
7
3
2
1
4
8
Fig. 4.18 Replacing J5/J6 belt Name 1 2 3 4 5 6 7 8
PLATED BOLT J3 ARM COVER GASKET BELT PLATED BOLT J3 ARM COVER GASKET BELT
4.19
Specifications
Q’ty
A97L-0218-0496#M4X10BC A290-7142-X405 A290-7142-X410 A98L-0040-0286#004-104 A97L-0218-0496#M4X10BC A290-7142-X405 A290-7142-X410 A98L-0040-0286#004-157
7 1 1 1 7 1 7 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm (20kgfcm)
2.0Nm (20kgfcm)
REPLACING SOLENOID VALVE
Replacing procedure 1 2 3 4 5
Turn off the controller power. Remove plated bolt (1) and remove the J2 arm cover (2). Remove relay of air tube (φ6mm,φ4mm) and take solenoid valve out. Remove the bolts (4), (5) then remove the solenoid valve. Replace solenoid valve by new one, and assemble it in the reversed sequence. Be careful not to drop the gasket (3). - 70 -
4.REPLACING PARTS
B-83495EN/01
3
6
2
1
5 4
7 Fig. 4.19 Replacing Solenoid valve Name 1 2 3 4 5 6
PLATED BOLT J2 ARM COVER GASKET BOLT BOLT SV PLATE
7
SOLENOID VALVE
4.20
Specifications A97L-0218-0496#M4X10BC A290-7142-X307 A290-7142-X325 A6-BA-4X8 A6-BA-4X8 A290-7142-X327 A97L-0218-0130#D3B or A97L-0218-0130#D3R or A97L-0218-0130#D3 or A97L-0218-0130#D2 or A97L-0218-0130#D1
Q’ty 6 1 1 2 2 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm (20kgfcm)
1
SEALANT APPLICATION
Washing and degreasing the surfaces to be sealed 1
2 3
4
After dismounting the reducer from the member which installed the reducer, apply releasant (LOCTITE Gasket Remover etc.) to the arm’s surface from which the reducer was dismounted, then wait until the sealant (LOCTITE 518) becomes softened (for about 10 minutes). Remove the softened sealant from the surface using a spatula. Blow air onto the surface to be sealed to remove dust from the tapped holes. Sufficiently degrease the reducer’s surface to be sealed and the arm’s surface to be sealed, using a cloth dampened with oil and grease remover. Do not spray oil and grease remover directly onto the surface. Polish the surface of member which installed the reducer to be sealed with an oil stone, and degrease it with removal and cleaner again.
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4.REPLACING PARTS
B-83495EN/01
CAUTION Oil may drip from the inside of the reducer. After degreasing, make sure that no oil is dripping.
Applying sealant 5
6
Make sure that the reducer and the member which installed the reducer are dry (with no oil and grease remover remaining). If they are still wet with oil and grease remover, wipe them dry. Always use a new surface of a cloth so that the grease once wiped up with the cloth will not get on the degreased surface. Make sure that no ingredient of oil and grease remover is left in the threaded holes or on any other portion. If ingredient is left, it may prevent stiffening of sealant. Apply sealant (LOCTITE 518) to the surfaces.
CAUTION The portions to which sealant is to be applied vary from one axis to another. See descriptions about reducer replacement for the relevant axes for details.
Assembling 7
8 9
To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant was wiped off, apply again. After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get closer. After attaching the reducer, wipe off any excessive sealant that comes out from the sealed section with a cloth or spatula. Do not use oil and grease remover.
CAUTION Do not grease or move the reducer before the sealant sets, as it may allow grease to leak. Before greasing or moving, wait for about at least one hour after the reducer is mounted.
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5.REPLACING CABLES
B-83495EN/01
5
REPLACING CABLES
Replace the cables every four years (15360 hours). When the cable is broken or damaged or shows signs of wear, replace it according to this chapter.
Precautions to be observed when handling the Pulsecoder cable The Pulsecoder cable is provided with a marking tie, as shown below, to warn against disconnecting the cable during transportation, installation, or maintenance. If the cable with the marking tie is disconnected, mastering must be performed again. Therefore, do not disconnect the cable except when replacement of the motor, the Pulsecoder, the reducer, and the cable are necessary.
BATTERY BACKUP DON'T DISCONNECT コネクタ取外不可
Fig. 5 marking label
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5.REPLACING CABLES
5.1
B-83495EN/01
CABLE WIRING
Followings are the routing of the robot cables. K118 (EE) K204 (OPTION) (CAMERA/FORCE SENSOR)
K106 (POWER) K107 (PULSECODER) K108 (RO, EE) K202 (OPTION) (CAMERA) K203 (OPTION) (FORCE SENSOR)
K116 (J6 AXIS POWER) K117 (J6 AXIS PULSECODER)
K113 (J5 AXIS POWER) K114 (J5 AXIS PULSECODER)
K109 (RO)
K111 (J4 AXIS POWER)
K104 (J3 AXIS POWER) K105 (J3 AXIS PULSECODER)
K102 (J2 AXIS POWER) K103 (J2 AXIS PULSECODER)
K131 (OPTION) (BATTERY) K201 (OPTION) (CAMERA/FORCE SENSOR)
K101 (POWER, PULSECODER)
Fig.5.1 (a) Routing of the robot cables (Standard)
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5.REPLACING CABLES
B-83495EN/01 K118 (EE) K204 (OPTION) (CAMERA/FORCE SENSOR)
K116 (J6 AXIS POWER) K117 (J6 AXIS PULSECODER)
K106 (POWER) K107 (PULSECODER) K108 (RO, EE) K202 (OPTION) (CAMERA) K203 (OPTION) (FORCE SENSOR) K109 (RO) K111 (J4 AXIS POWER)
K113 (J5 AXIS POWER) K114 (J5 AXIS PULSECODER)
K104 (J3 AXIS POWER) K105 (J3 AXIS PULSECODER)
K102 (J2 AXIS POWER) K103 (J2 AXIS PULSECODER)
K119/K131 (OPTION) (BATTERY) K201 (OPTION) (CAMERA/FORCE SENSOR) K101 (POWER, PULSECODER)
Fig.5.1 (b) Routing of the robot cables (7L)
5.2
CABLE FORMING
When replacing cables, clamp the cable at the position specified in Fig.5.2 using a clamp or a nylon band. Otherwise, cables can be loosened or pulled by force to cause their disconnection. Refer to the Fig.5.2 for the cable clamp.
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5.REPLACING CABLES
B-83495EN/01
M2M
M2M
M2M1 K102
M2BK
M2BK
K102
M3M1 K104
M3M1
M3M
M3M
M3BK M4M1
Ｃｌａmp J2-1
M5M
M5M
M5M1 K113
M5M1
M5BK
M5BK
K113
M1M
M6M
M6M1 K116
BATTERY BACKUP DON'T DISC ONNECT コ ネ クタ 取外 不 可
K117 K118
BATTERY BACKUP DON'T DISCONNECT コ ネ クタ 取 外 不 可
M5P
BATTERY BACKUP DON'T DISCONNECT コ ネ クタ 取 外 不 可
M6P
K114
EE
EE1 K108
EE1
M5P1 K114
コネ ク タ 取 外 不可
M5P M6P EE
YV2
K109
YV1 K109
YV1
+
-
Relay in the J3 housing BATTERY BACKUP DON'T DISC ONNECT
Cｌａmp J2-1 K108
M4P
M6P1 K117
K107
コ ネ ク タ 取 外不 可
EE2
コネ ク タ 取 外不 可
M456P K107
BATTERY BACKUP DON'T DISCONNECT
M456P
M1P
M1P
M6BK
M2P
コ ネ クタ 取 外 不 可
BATTE RY BACKUP DON'T DISC ONNECT
BATTERY BACKUP DON'T DISCONNEC T コ ネ ク タ 取 外不 可
M6BK
M3P
M3P
BATTERY BACKUP DON'T DISCONNECT
Cｌａmp J2-1 K101
K116 M2P
EE2 K118
K105
Â
M4P
コネ ク タ 取 外 不可
s
M5P1
BATTERY BACKUP DON'T DISCONNECT
BATTERY BACKUP DON'T DISCONNECT R l N ^ Žæ ŠO
M6P1
K103
M2P1 K103
コネ ク タ 取 外 不可
M3P1 K105
K101
Cｌａmp J1-1
BATTERY BACKUP DON'T DISCONNECT
M2P1
Ｃｌａmp J1-2
M6M1
Ｃｌａmp J2-1
M1BK
M3P1
M1BK
M6M
M1M
M4BK
M4BK
M456M K106
M456M1
K111 K106
M4M
M4M
M3BK
K104
Relay in the J3 housing
M4M1 K111
M2M1
Relay in the J2 base Cｌａmp J2-1
YV2
Fig.5.2 Cable externals chart of mechanical unit
5.3
CABLE AND AIR TUBE REPLACEMENT
This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables. See Section 5.1 for the configuration of the mechanical unit cables. You must perform mastering after cable replacement. Refer to Chapter 6 MASTERING or chapter 8 OPERATOR’S MANUAL in advance. (If Pulsecoder cable is not replaced, mastering is not necessary.)
5.3.1
Replacing Cable K101 and Air Tube (Connector panel to J2 base)
Replacing procedure 1 2 3 4 5 6 7 8 9 10
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set in 0° for all axes when robot is shipped.) Turn off the controller power and remove cable of controller side from connector plate of back of J1-axis. Remove robot from floor plate, knock down the robot sidewise. Remove J2 base cover (2) referring to Fig.5.3.1 (a). Remove all relay of cable K102, K103, K104, K105, K106, K107, K108 ,K109 and K101.Remove relay of air tube similarly. If necessary, remove cover B. (See Fig.5.3.1 (c)) Cut the nylon band which connect cable and air tube to clamp J1-2 referring to Fig.5.3.1 (b). Cut the nylon band of battery box terminal and remove cable. Remove connector plate referring to Fig.5.3.1 (e), (f). Pull cable and air tube in J2 base to J1 base side. In this time pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes. - 76 -
5.REPLACING CABLES
B-83495EN/01
11 12
Replace cable and air tube for the new article and assemble them applying steps above in reversed sequence. Confirm that the gasket (3) does not fall out. Perform quick mastering referring to Section 8.4 of operator’s manual.
3
2
1
Fig.5.3.1 (a) Remove the J2 base cover Name 1 2 3
PLATED BOLT J2 BASE COVER GASKET
Specifications A97L-0218-0496#M4X10BC A290-7142-X306 A290-7142-X324
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Q’ty 5 1 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm(20kgfcm)
5.REPLACING CABLES
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ClampJ2-1 A290-7142-X321 Match the marking
B
AIR 2 (φ6 white)
Pulsecoder line cable K108 cable K109 (blueXwhite)
AIR 1 (φ6 black)
Power line (redXwhite)
J2/J3 Power line (redXwhite)
Nylon band J2/J3 Pulsecoder line (blueXwhite)
Joint A97L-0142-0214#KQ2L0600 (2)
Detail B
A Nylon band Sheet A290-7142-X328 (1) (Tie up it with cables on A290-7142-X320 with a nylon band) Clamp J1-2 A290-7142-X320 (1) Bolt A6-BA-4X8 (2)
Power line (redXwhite) Nylon band
Pulsecoder line (blueXwhite) AIR 2 (O6 white) AIR 1 (O6 black)
Match the marking
Detail A
Fig.5.3.1 (b) Replace the cable in J2 base
3
Fig.5.3.1 (c) Name 1 2 3
PLATED BOLT COVER B GASKET
2
1
Removing the cover B
Specifications A97L-0218-0496#M4X10BC A290-7142-X204 A290-7142-X205
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Q’ty 9 1 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm(20kgfcm)
5.REPLACING CABLES
B-83495EN/01
Bolt A6-BA-4X8 (2)
Tie up with nylon bands.
-
Washer bolt A97L-0218-0606#M4X6 (2) +
-
+ Tightening torque 0.40Nm (4.1kgfcm)
Battery box terminal side
Washer bolt A97L-0218-0606#M4X6 Apply threebond No.1401B on the connector head of brake and power.
Pulsecoder line (blueXwhite)
Power line (redXwhite)
AIR 2 (O6 white) AIR 1 (O6 black)
Nylon band A
Match the marking
Detail A Fig.5.3.1 (d) Replace the cable in J1 base
Position of No.1 pin (Example of mechanical unit cable A05B-1142-H301)
4
3
1 2
Fig.5.3.1 (e) Replace the parts of connector plate (back side connector plate) Name
Specifications
1 PLATED BOLT A97L-0218-0496#M4X10BC 2 PLATED BOLT A97L-0218-0546#040808BC 3 CON.PLATE (*) A290-7142-X206 4 GASKET A290-7139-X251 (*) Specifications differs depend on the mechanical unit cables.
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Q’ty 5 4 1 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm(20kgfcm)
5.REPLACING CABLES
B-83495EN/01
4
3
1
2
Position of No.1 pin (Example of mechanical unit cable A05B-1142-H351)
Fig.5.3.1 (f) Replace the parts of connector plate (bottom connector plate) Name
Specifications
Q’ty
1 PLATED BOLT A97L-0218-0496#M4X12BC 2 PLATED BOLT A97L-0218-0546#040808BC CON.PLATE (*) 3 A290-7142-X212 4 GASKET A290-7139-X205 (*) Specifications differs depend on the mechanical unit cables.
9 4 1 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm(20kgfcm)
AIR 1 (O6 black) AIR 2 (O6 white)
Power line (redXwhite) Pulsecoder line (blueXwhite) Plated bolt A97L-0218-0546#040808BC (4)
AIR 1 (O6 black)
Clamp J1-1 A290-7142-X220 Match the marking
AIR 2 (O6 white)
CABLE K101 A660-8018-T491
Pulsecoder line (blueXwhite) Power line (redXwhite) Tie up with nylon bands
Fig.5.3.1 (g) Clamp of J1 base
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5.REPLACING CABLES
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5.3.2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Replacing Cable K106, K107, K108,K109 and Air Tube (J2 base to J3 housing)
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set in 0° for all axes when robot is shipped.) Turn off the controller power and remove cable of controller side from connector plate of back of J1-axis. Remove the J3 cover and the gasket referring to Fig.5.3.2 (b). Cut the nylon band, which connect cable to clamp J4-2 referring to Fig.5.3.2 (a). Remove relay of K106 and K111, K113 and K116. Remove relay of K107 and K114, K117. Remove relay of K108 and K118. Remove the relay of the air tube inside the J2 arm. Remove the relay of the cable K109 and the solenoid valve. Remove the air tube of the solenoid valve. Cut the nylon band, which connect cables and air tubes to clamp J4 referring to Fig.5.3.2 (c). Remove the J2 arm cover and the gasket referring to Fig.5.3.2 (e). Cut the nylon band, which connect cables and air tubes to clamp J3-1 referring to Fig.5.3.2 (d). Cut the nylon band, which connect cables and air tubes to clamp J2-2 referring to Fig.5.3.2 (d). Remove the J2 base cover and the gasket referring to Section 4.4. Cut the nylon band, which connect cables and air tubes to clamp J2-1 referring to Fig.5.3.2 (d). Remove relay to K101 and air tube. Pull out the cable from the upper side and the lower side of the guide arm. In this time, pull out it after it passes it on the tip of the part of the connector. Replace cable and air tube for the new article and assemble them applying steps above in reversed sequence. Note that the gasket does not fall out. Perform quick mastering referring to Section 8.4 of operator’s manual.
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5.REPLACING CABLES
B-83495EN/01
Power line (redXwhite) Pulsecoder line (blueXwhite)
Nylon band
Air tube (φ3.2)
Joint A97L-0118-0108#S23-M5 (1)
A A
Section A-A
Clamp J4-2 A290-7142-X416 Bolt M4X8 (2) Fig.5.3.2 (a) Clamp of J3 arm part
2
3
1
Fig.5.3.2 (b) Removing the J3 cover Name 1 2 3
PLATED BOLT J3 COVER GASKET
Specifications A97L-0218-0496#M4X10BC A290-7142-X404 A290-7142-X409
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Q’ty 4 1 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm(20kgfcm)
5.REPLACING CABLES
B-83495EN/01
Pulsecoder line (blueXwhite) Power line (redXwhite)
Air tube (φ3.2) Pulsecoder line (blueXwhite)
Air tube (φ3.2) Match the marking
Power line (redXwhite)
Nylon band
Detail B Nylon band
Clamp J4 A290-7142-X415 Match the marking
Nylon band
Section C-C C C
Section A
B A
Fig.5.3.2 (c) Clamp of J3 housing part
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5.REPLACING CABLES
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Nylon band Pulsecoder line (blueXwhite) Power line (redXwhite)
Match the marking.
Joint A97L-0118-0108#H23-06 (1) (for AIR 1 black φ3.2→φ6)
Clamp J3-1 A290-7142-X323
When H002 - H006,H012 - H016 are specified. cable K109 (blueXwhite)
C
B
B
AIR 1 (φ3.18 black)
Pulsecoder line cable K108 cable K109 (blueXwhite)
AIR 1 (φ6 black)
Detail C
Power line (redXwhite)
Power line (redXwhite)
J2J3 Pulsecoder line (blueXwhite)
AIR 2 (φ6 white)
Sheet A290-7142-X326
Clamp J2-2 A290-7142-X322
Nylon band
Section B-B Match the marking.
A
AIR 1 (φ6 black)
Joint A97L-0142-0214#KQ2L0600 (2)
AIR 2 (φ6 white) Match the marking.
Pulsecoder line cable K108 cable K109 (blueXwhite)
AIR 2 (φ6 white) AIR 1 (φ6 black) J2J3 Power line (redXwhite)
Power line (redXwhite)
J2/J3 Pulsecoder line (blueXwhite) Nylon band
Cable K109
Detail A Fig.5.3.2 (d) Clamp of J2 arm/J2 base part
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5.REPLACING CABLES
B-83495EN/01
2
3
1
Fig.5.3.2 (e) Removing the J2 arm cover Name 1 2 3
SEAL BOLT J2 ARM COVER GASKET
5.3.3 1 2
3 4 5
7 8
A97L-0218-0496#M4X10BC A290-7142-X307 A290-7142-X325
Q’ty 6 1 1
LOCTITE
Torque N-m (kgf-cm) 2.0Nm(20kgfcm)
Replacing Cable K102, K103, K104, K105, K109, K110, K111, K112, K113
Turn off the controller power. In case of cable K102 and K103, remove J2-axis motor. In case of cable K104 and K105, remove J3-axis motor. In case of cable K111, remove J4-axis motor. In case of cable K113 or K114, remove J5-axis motor. In case of cable K116 or K117, remove J6-axis motor. See Chapter 4 about removing procedure of each motor. Replace cable by new one and assemble it applying steps above in reversed sequence. Install motor referring to Chapter 4. In case of replacing K103 or K104 or K105 or K110 or K111 or K112 or K113 or K114 or K116 or K117, perform single axis mastering referring to Section 8.5 of operator’s manual.
5.3.4 1 2 3 4 5 6
Specifications
Replacing Cable K118
Turn off the controller power. Remove the J3 cover and the gasket referring to Fig5.3.2 (b). Cut the nylon bands which fix the cable inside the J3 housing and remove the relay of the cables. Remove the J3 arm cover and the gasket referring to Fig.5.3.4. (a). Cut the nylon bands which fix the cable inside the J3 arm. Remove the washer bolt (3) , connector panel (4) and the gasket (5), then pull out cables (2) from the J3 arm. Remove relay of K108 and remove cable K118. Replace cable by new one, and assemble it applying steps above in reversed sequence. Be sure to replace the gasket (5) of Fig.5.3.4 (b) by new one. - 85 -
5.REPLACING CABLES
B-83495EN/01
3 2 1 Fig.5.3.4 (a) Removing the J3 arm cover Name 1 3 4
PLATED BOLT J3 ARM COVER GASKET
Specifications A97L-0218-0496#M4X10BC(*2) A290-7142-X405 A290-7142-X410
Q’ty
LOCTITE
7 1 1
Torque N-m (kgf-cm) 2.0Nm(20kgfcm)
1 2 3
4 5
Fig.5.3.4 (b) Name 1 2 3 4 5
CAP CABLE K118 WASHER BOLT J3 CON.PLATE S GASKET
Replacing the cable K118
Specifications A97L-0118-0757#F A660-2007-T608 A97L-0318-0407#M4X6EN A290-7142-X417 A290-7142-X418
- 86 -
Q’ty 1 1 4 1 1
LOCTITE
Torque N-m (kgf-cm)
2.0Nm(20kgfcm)
5.REPLACING CABLES
B-83495EN/01
5.3.5
Replacing Air Tube
Replacing procedure of air tube between connector plate to J2 base 1
See Subsection 5.3.1.
Replacing procedure of air tube between J2 base to J3 housing 1
See Subsection 5.3.2.
Replacing procedure of air tube between J3 housing to J3 arm 1 2 3 4 5 6 7 8
9
Turn off the controller power. Remove J3 arm cover. (See Fig.5.3.4 (a)) Remove air tube from panel union on J3 motor. Cut the nylon band, which connects air tube to clamp J4-2 referring to Fig.5.3.2 (a). Remove J3 cover. (See Fig.5.3.2 (b)) Cut the nylon band which connects air tube to clamp J4 referring to Fig.5.3.2 (c). Remove the J2 arm cover and the gasket (See Fig.5.3.2 (e).) In case of replacing black tube, remove the air tube from the tube diameter change joint. In case of replacing air tubes from the solenoid valve, remove the air tubes from the solenoid valve. (See Fig.5.3.2 (d).) Replace air tube by new one, and install them applying steps above in reversed sequence. When gasket is attached , be sure to replace gasket. 585 345
190
AIR 1 (φ6 black) 565 325
190
AIR 2 (φ6 white) → J2
connector panel← Fig.5.3.5 (a) Marking of air tube (connector panel to J2 base) 340
AIR 1 (φ6 black)
50
210 (Standard) 320 (7L)
80 480
AIR 2 (φ6 white) 60
210 (Standard) 320 (7L)
J1←
210
→ J3
Fig.5.3.5 (b) Marking of air tube (J2 base to J3 housing)
- 87 -
5.REPLACING CABLES
B-83495EN/01
930 150
AIR 1 （φ3.18 black)
160
135 (Standard) 220 (7L)
215
270
→ J4
J2←
Fig.5.3.5 (c) Marking of air tube (J3 housing to J3 arm)
150
AIR 1 （φ3.18 white)
160
135 (Standard) 220 (7L)
215
270
→ J4
J2←
Fig.5.3.5 (d) Marking of air tube (when A05B-1142-H001 is specified)
Marking Air tube (O3.18mm blue for 1B)
Air tube (O3.18mm red for 1A)
270
135 (Standard) 220 (7L) 215
160
270
215
160
135 (Standard) 220 (7L)
Fig.5.3.5 (e) Marking of air tube (solenoid valve) (when A05B-1142-H002,H012 are specified)
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5.REPLACING CABLES
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Marking
Air tube (O3.18mm blue for 1B)
270
135 (Standard) 220 (7L) 215
160
Air tube (O3.18mm green for 2B)
270
135 (Standard) 220 (7L) 215
160
270
215
160
215
160
135 (Standard) 220 (7L)
Air tube (O3.18mm yellow for 2A) 270
135 (Standard) 220 (7L)
Air tube (O3.18mm red for 1A)
Fig.5.3.5 (f) Marking of air tube (solenoid valve) (when A05B-1142-H003,H013 are specified) Marking Air tube (O3.18mm blue for 1B)
Air tube (O3.18mm green for 2B)
Air tube (O3.18mm orange for 3B)
135 (Standard) 220 (7L) 215
160
135 (Standard) 270 220 (7L) 215
160
135 (Standard) 220 (7L) 215
160
215
160
215
160
215
160
270
270
270 135 (Standard) 220 (7L)
Air tube (O3.18mm clear for 3A) 270
135 (Standard) 220 (7L)
Air tube (O3.18mm yellow for 2A) 270 Air tube (O3.18mm red for 1A)
135 (Standard) 220 (7L)
Fig.5.3.5 (g) Marking of air tube (solenoid valve) (when A05B-1142-H004,H005,H006,H014,H015,H016 are specified)
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5.REPLACING CABLES
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A
Plug A97L-0218-0019 (1)
Air tube A97L-0218-0010#BFL930R0 (1) (O3.18mm white)
Half union A97L-0118-0108#S23-M5 (1)
Joint A97L-0118-0108#H23-06 (1)
Air tube (O6mm white)
Detail A
white
Fig.5.3.5 (h) Removing the air tubes of the solenoid valve (WhenA05B-1142-H001,H001 is specified)
- 90 -
5.REPLACING CABLES
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A
Check valve A97L-0218-0026#04B-M5
Air tube (O6mm white)
Solenoid valve kit A290-7142-V002 (for A290-7142-V003 (for A290-7142-V004 (for A290-7142-V005 (for A290-7142-V006 (for A290-7142-V012 (for A290-7142-V013 (for A290-7142-V014 (for A290-7142-V015 (for A290-7142-V016 (for Bolt A6-BA-4X8 (2)
A05B-1142-H002) A05B-1142-H003) A05B-1142-H004) A05B-1142-H005) A05B-1142-H006) A05B-1142-H012) A05B-1142-H013) A05B-1142-H014) A05B-1142-H015) A05B-1142-H016)
or or or or or or or or or
Half union A97L-0118-0108#S23-M5 (6)
Cable K109 A660-2007-T602
clear (*1)
orange (*1)
yellow (*2)
green (*2)
red (*3)
blue (*3)
Detail A
(*1) When A05B-1142-H004,H005,H006,H014,H015,H016 are specified (*2) When A05B-1142-H003,H004,H005,H006,H013,H014,H015,H016 are specified (*3) When A05B-1142-H002,H003,H004,H005,H006,H012,H013,H014,H015,H016 are specified
Fig.5.3.5 (i) Removing the air tubes of the solenoid valve (When solenoid valve option is specified)
- 91 -
6.ADJUSTMENTS
6
B-83495EN/01
ADJUSTMENTS
Each part of the mechanical units of a robot is set to the best condition before the robot is shipped to the customer. The customer does not need to make adjustments on the robot when it is delivered.
6.1
ADJUSTING TENSION OF BELT
Please use the following tension meters for the tension adjustment of the belt. Instrument Tension meter
1 2 3 4 5
Specifications
Vendor
Manufacturer model No. Application A97L-0218-0700 Mitsuboshi Belting Ltd. DOCTOR TENSION TYPE-Ⅲ Adjustment of belt tension
Place the robot in the posture to avoid uneven belt tension. (recommended posture: J3=80º,J5=±90º) Remove the bolt and arm cover (refer to Chapter 4). When Gasket is attached, remove gasket, too. Adjust it so that it may loosen tension-adjusting bolts and the tension may reach a specified value. Attach arm cover. When gasket is attached, be sure to replace gasket by new one. In this time, tighten the bolt with the specified torque.
Tension adjusting bolt (Tightening torque 5.6Nm (57kgfcm)
Fig. 6.1 (a) Adjusting tension of J3 belt Table. 6.1 (a) Measurement condition of J3 belt 30 – 40N (Standard) 49 – 65N (7L) 0.0367kg (Standard) 0.029kg (7L) 6mm 167.5mm
BELT TENSION MASS WIDTH SPAN
NOTE The tension of the belt deteriorates slowly, but this is a normal phenomenon. If belt is adjusted frequently. it shorten the life of belt, please don’t adjust belt except case of replacing motor, reducer etc. - 92 -
6.ADJUSTMENTS
B-83495EN/01
Tension adjusting bolt (Tightening torque 5.6Nm (57kgfcm)
Fig. 6.1 (b) Adjusting tension of J5 belt
Tension adjusting bolt (Tightening torque 5.6Nm (57kgfcm)
Fig. 6.1 (c) Adjusting tension of J6 belt Table 6.1 (b) Measurement condition of J5 belt BELT TENSION MASS WIDTH SPAN
15.6 – 20.6N 0.02083kg 4mm 187mm
Table 6.1 (c) Measurement condition of J6 belt BELT TENSION MASS WIDTH SPAN
15.6 – 20.6N 0.02083kg 4mm 116mm
- 93 -
APPENDIX
A
A.SPARE PARTS LIST
APPENDIX
B-83495EN01
SPARE PARTS LIST Name
Table A (a) List of basic cable (Standard) Specifications
K101 K102 K103 K104 K105 K106
A660-8018-T491 A660-4005-T364 A660-2007-T599 A660-4005-T365 A660-2007-T600 A660-4005-T366
K107
A660-4005-T367
K108 K109 K111 K113 K114 K116 K117 K118
A660-2007-T601 A660-2007-T602 A660-4005-T368 A660-4005-T369 A660-2007-T605 A660-4005-T370 A660-2007-T607 A660-2007-T608
K131
A660-8016-T944
K131
A660-8016-T945
K131
A660-8016-T946
Name
RMP J2 power J2 Pulsecoder J3 power J3 Pulsecoder Relay of J4, J5, J6 power J4 Pulsecoder Relay of J5, J6 Pulsecoder Relay of end effector Relay of EE YV J4 power J5 power J5 Pulsecoder J6 power J6 Pulsecoder EE12P External battery cable 5m (When external battery option is selected) External battery cable 7m (When external battery option is selected) External battery cable 14m (When external battery option is selected)
Table A (b) List of basic cable (7L) Specifications
K101 K102 K103 K104 K105 K106
A660-8018-T491 A660-4005-T364#L A660-2007-T599#L A660-4005-T365#L A660-2007-T600#L A660-4005-T366#L
K107
A660-4005-T367#L
K108 K109 K111 K113 K114 K116 K117 K118
A660-2007-T601#L A660-2007-T602#L A660-4005-T368 A660-4005-T369#L A660-2007-T605#L A660-4005-T370#L A660-2007-T607#L A660-2007-T608#L
K131
A660-8016-T944
K131
A660-8016-T945
K131
A660-8016-T946
Remarks
Remarks
RMP J2 power J2 Pulsecoder J3 power J3 Pulsecoder Relay of J4, J5, J6 power J4 Pulsecoder Relay of J5, J6 Pulsecoder Relay of end effector Relay of EE YV J4 power J5 power J5 Pulsecoder J6 power J6 Pulsecoder EE12P External battery cable 5m (When external battery option is selected) External battery cable 7m (When external battery option is selected) External battery cable 14m (When external battery option is selected)
- 97 -
A.SPARE PARTS LIST Name βiSR1/6000(*) βiSR0.5/6000 βiSR0.4/4000 βiSR0.2/4000
APPENDIX
B-83495EN/01
Table A (c) Motor Specifications A06B-0116-B855#0048 A06B-0115-B855#0048 A06B-0114-B855#0048 A06B-0117-B855#0049
Remarks J1,J2-axis J3-axis J4-axis J5,J6-axis
(*) When J2-axis motor is replaced, please order shaft “A290-7139-X322” at the same time.
Name Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive Harmonic drive
Table A (d) Reducer Specifications A97L-0218-0951#70 A97L-0218-0980#80 A97L-0218-0952#100 A97L-0218-0952#120 A97L-0218-0953#80 A97L-0218-0954#80 A97L-0218-0955#50 A97L-0218-0956#50
Remarks J1-axis (Standard) J1-axis (7L) J2-axis (Standard) J2-axis (7L) J3-axis J4-axis J5-axis J6-axis
NOTE When arranging in the reducer machine unit, the waving generator is built into the main body of the reducer machine beforehand as for J4-axis reducer. As for other reducers, the waving generator is separated from the main body of the reducer machine.
Name GEAR J1-1 GEAR J1-1 GEAR J4-1
Name Pulley J3-1 Pulley J3-2 Pulley J3-1 Pulley J3-2 Pulley Pulley Pulley Pulley Shaft Key Key key
Name Belt Belt Belt Belt
Table A (e) Gear Specifications A290-7142-X202 A290-7142-X248 A290-7142-X406
Remarks J1-axis (Standard) J1-axis (7L) J4-axis
Table A (f) Pulley, shaft, key Specifications
Table A (g) Specifications A98L-0040-0285#006-095 A98L-0040-0286#004-104 A98L-0040-0286#004-157 A98L-0040-0293#006-100
- 98 -
Remarks J3-axis motor (Standard) J3-axis reducer (Standard) J3-axis motor (7L) J3-axis reducer (7L) J5-axis motor J5-axis reducer J6-axis motor J6-axis bevel gear J2-axis Motor, pulley, gear (4 pcs/1 robot) Motor, pulley, gear (5 pcs/1 robot) J3-axis reducer
A290-7142-X309 A290-7142-X310 A290-7142-X333 A290-7142-X334 A290-7142-X411 A290-7142-X412 A290-7142-X429 A290-7142-X414 A290-7139-X322 A97L-0118-0402#3X3X12BN A97L-0118-0402#3X3X6BN A97L-0118-0402#3X3X9BN Belt
Remarks J3-axis motor (Standard) J5-axis motor (Standard,7L) J6-axis motor (Stanard,7L) J3-axis motor (7L)
A.SPARE PARTS LIST
APPENDIX
B-83495EN01
Name Gasket Gasket Gasket Gasket Gasket Gasket Gasket
Table A (h) Gasket Specifications A290-7139-X253 A290-7142-X315 A290-7142-X316 A290-7142-X324 A290-7142-X325 A290-7142-X409 A290-7142-X410
Name O-RING O-RING
Table A (i) O-RING Specifications A98L-0001-0347#S46 JB-OR1A-G45
Name Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt Seal bolt
Remarks J1,J4-axis motor J2-axis motor
Table A (j) Seal bolt Specifications A97L-0218-0423#030606 A97L-0218-0423#030606 A97L-0218-0423#051212 A97L-0218-0546#032204BC A97L-0218-0546#043016BC A97L-0218-0546#043516BC A97L-0318-0405#040606EN A97L-0318-0406#081010EN
Name
Remarks Battery box cover J2 base Cover S J2 base cover J2 arm cover 2 pcs/1 robot J3 cover J3 arm cover 2 pcs/1 robot
4 pcs/1 robot
Remarks J4 pipe 4 pcs/1 robot Support 7 pcs/1 robot J2-axis motor 4 pcs/1 robot J3-axis reducer 12 pcs/1 robot J1-axis reducer 12 pcs/1 robot J2-axis reducer 12 pcs/1 robot J2 - J6-axis grease inlet 5 pcs/1 robot J1-axis grease inlet
Table A (k) Spring pin, Stopper, Wrist unit, Sheet, Shaft Specifications Remarks
Spring pin Stopper
A6-PS-8X20S A290-7142-X427
Wrist unit
A290-7142-V501
J3 stopper J3 stopper With J5/J6-axis reducer
Sheet
A290-7142-X228 A290-7142-X330 A290-7139-X322
J1-axis motor J2-axis motor J2-axis motor
Shaft
Name
Table A (l) Specifications
Air tube
A97L-0218-0010#AFL3R003
Air tube
A97L-0218-0114#ABL3R003
Air tube
A97L-0218-0114#ABL3R003
Air tube
A97L-0218-0114#BBL3R003
Air tube
A97L-0218-0114#BBL3R003
Air tube (H001,H011) Air tube (H002,H003,H004,H005, H006,H012,H013,H014,H0 15,H016)
A97L-0218-0114#BFL3R003
A97L-0218-0010#BAL3R003
- 99 -
Air tube Remarks 3.18mm BLACK AIR1 J2 arm to J3 arm 6mm BLACK AIR1 J2 base to J3 casing 6mm BLACK AIR1 Connector plate to J2 base 6mm WHITE AIR2 6mm WHITE AIR2 Connector plate to J2 base 3.18mm WHITE AIR2 J2 arm to J3 casing 4mm WHITE EXHAUST J2 arm to J3 casing
A.SPARE PARTS LIST Name Air tube (H002,H003,H004,H005, H006,H012,H013,H014,H0 15,H016) Air tube (H002,H003,H004,H005, H006,H012,H013,H014,H0 15,H016) Air tube (H003,H004,H005,H006, H013,H014,H015,H016) Air tube (H003,H004,H005,H006, H013,H014,H015,H016) Air tube (H004,H005,H006,H014, H015,H016) Air tube (H004,H005,H006,H014, H015,H016)
APPENDIX Specifications
A97L-0218-0010#CFL3R003
A97L-0218-0010#DFL3R003
B-83495EN/01
Remarks 3.18mm RED 1A J2 arm to J3 casing
3.18mm RED 1B J2 arm to J3 casing
A97L-0218-0010#EFL3R003
3.18mm YELLOW J2 arm to J3 casing
2A
A97L-0218-0010#FFL3R003
3.18mm GREEN 2B J2 arm to J3 casing
A97L-0218-0010#GFL3R003
3.18mm CLEAR 3A J2 arm to J3 casing
A97L-0218-0010#HFL3R003
3.18mm ORANGE 3B J2 arm to J3 casing
Table A (m) Solenoid valve (Either the following is installed by the option specification) (except H001, H011) Name Specifications Remarks Solenoid valve Solenoid valve Solenoid valve Solenoid valve
A97L-0218-0130#D1 A97L-0218-0130#D2 A97L-0218-0130#D3 A97L-0218-0130#D3R
Solenoid valve
A97L-0218-0130#D3B
Name
Table A (n) Battery Specifications
Battery
A98L-0031-0027
Battery
A98L-0031-0005
Name Grease Greasing kit Grease in tube
Double solenoidX1 (2 positionX1) Double solenoidX2 (2 positionX2) Double solenoidX3 (2 positionX3) Double solenoidX3 (3 position (exhaust center) X3) Double solenoidX3 (3 position (closed center) X3)
Remarks C battery/1.5V 4pcs/ per 1 robot (When battery built-in option is selected) D battery/1.5V 4pcs/ per 1 robot (When external battery option is selected)
Table A (o) Grease Specifications A98L-0040-0230 A05B-1142-K021 A05B-1139-K022
Remarks Harmonic grease 4BNo.2
- 100 -
B-83495EN01
B
APPENDIX
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
- 101 -
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
A63L-0001-0865#1 A63L-0001-0864#CS
APPENDIX
J1 MOTOR (βiSR1/6000) M1M 2 3
A63L-0001-0865#2 A63L-0001-0864#CS
2 3
BK(J1)
M1P 8 9 10
1 4
J1U1 J1G1
1 4
BKC(J1)
5V(J1) 0V(J1)
4 6V(BT1) 5 XPRQJ1 6 PRQJ1 7 0V(BT1)
1 2 3
A63L-0001-0865#1 A63L-0001-0864#CS
A63L-0002-0066#R06DX A63L-0002-0066#CRM
M2M1 A1 A2 A3
(
J1V1 J1W1
M1BK
A63L-0001-0848#E10SL1 A63L-0001-0850
X-KEY BLACK
B-83495EN/01
J2U1 BK(J2) J2W1
B1 B2 B3
F06DX CTM J2G1 J2V1 BKC(J2)
J2 MOTOR (βiSR1/6000) M2M 2 3
K102 A660-4005-T364 A660-4005-T364#L
A63L-0001-0865#2 A63L-0001-0864#CS
) M2P1 1 2 3
(
BLACK
A63L-0001-0865#1 A63L-0001-0864#CS
M3M1 A1 A2 A3
J1 CONNECTOR PANEL RMP 1 BK(J1) 2 J1U1 3 J1V1 4 J1W1 5 J1G1 6 XROT 7 RI1 8 RO1 9 RI7 10 5V(J1,J2) 11 PRQJ1 12 XPRQJ1
13 BK(J2) 14 J2U1 15 J2V1 16 J2W1 17 J2G1 18 24VF(OT,A1,A2) 19 RI2 20 RO2 21 RI8 22 5V(J3,J4) 23 PRQJ2 24 XPRQJ2
25 BK(J3) 26 J3U1 27 J3V1 28 J3W1 29 J3G1 30 XHBK 31 RI3 32 RO3 33 RO7 34 5V(J5,J6) 35 PRQJ3 36 XPRQJ3 G
37 BK(J4) 38 39 J4U1 40 J4V1 41 J4W1 42 J4G1 43 RI4 44 RO4 45 RO8 46 0V(J1,J2) 47 PRQJ4 48 XPRQJ4 SG
49 BK(J5) 50 51 J5U1 52 J5V1 53 J5W1 54 J5G1 55 RI5 56 RO5 57 58 0V(J3,J4) 59 PRQJ5 60 XPRQJ5
61 62 63 64 65 66 67 68 69 70 71 72
(
Y-KEY WHITE
J3U1 BK(J3) J3W1
B1 B2 B3
K101 A660-8018-T491
M3P1
1 6V(BT3) 2 PRQJ3 5 XPRQJ3 4 0V(BT3) 3 5V(J3) 7 6 0V(J3)
(
WHITE
)
(
BATTERY
単二電池 SIZE C
0V (BT1,BT2,BT3, BT4,BT5,BT6)
X-KEY BLACK
)
A63L-0002-0205#13SB A63L-0002-0205#2428SCFA
A1 A2 A3 A4 A5 A6 A7 A8 A9
+ (
BLACK
B1 B2 B3 B4 B5 B6 B7 B8 B9
J5G1 J5V1 BKC(J5) J6U1 BK(J6) A10 J6W1 B10
F20DX CTM J4G1 J4V1 BKC(J4) J5U1 BK(J5) J5W1 J6G1 J6V1 BKC(J6)
M456P 7 11
)
J4U1 BK(J4) J4W1
)
3 6V(BT4-BT6) 6 5V(J4) 10 13
K106 A660-4005-T366 A660-4005-T366#L
13PB 2428PCFA 2 XPRQJ4 1 PRQJ4 0V(BT4-BT6) 5 XPRQJ5 4 PRQJ5 9 XPRQJ6 8 PRQJ6 0V(J4) 5V(J5,J6) 12 0V(J5,J6)
K107 A660-4005-T367 A660-4005-T367#L
A63L-0002-0205#13SW A63L-0002-0205#2428SCFA
(
WHITE
)
A63L-0002-0205#7SB A63L-0002-0205#2428SCFA
3 24VF(A1,A2) 2 7 RI6 6 RI5 11 0V(A1,A2) 10 XHBK 13 RI8
BLACK
RI2
1
5 9 12
2 RO2 1 4 RO4 RO5 7 0V(B1-B6) 6
RI1
RI4 RO8 RI7
4 8
K108 A660-2007-T601 A660-2007-T601#L
RO1 3
RO3
RO6
)
注） NOTE) (**)：使用されていない信号 SIGNALS ARE NOT USED **#L：ロングアームタイプでのケーブル仕様 CABLE SPEC. IN CASE OF LONG ARM TYPE
Fig. B (a) Circuit diagram (Standard cable)
- 102 -
RI3 RO7
7PB 2428PCFA
YV1 5
(
13PW 2428PCFA
EE1
K109 A660-2007-T602 A660-2007-T602#L
5V(J2) 0V(J2)
J3V1 J3W1
BK(J3)
M3P 8 9 10
K105 A660-2007-T600 A660-2007-T600#L
1 4
BKC(J2)
4 6V(BT2) 5 XPRQJ2 6 PRQJ2 7 0V(BT2)
1 2 3
1 4
J3U1 J3G1
1 4
BKC(J3)
M3BK 2 3
A63L-0001-0848#E10SL1 A63L-0001-0850
7PW 2428PCFA
M456M
(
A63L-0001-0865#2 A63L-0001-0864#CS
J2U1 J2G1
J3 MOTOR (βiSR0.5/6000) M3M 2 3
K104 A660-4005-T365 A660-4005-T365#L
)
A63L-0002-0205#7SW A63L-0002-0205#2428SCFA
A63L-0002-0066#R20DX A63L-0002-0066#CRM
6V (BT1,BT2,BT3, BT4,BT5,BT6)
F06DYW CTM J3G1 J3V1 BKC(J3)
BK(J2)
M2P 8 9 10
K103 A660-2007-T599 A660-2007-T599#L
)
A63L-0002-0066#R06DYW A63L-0002-0066#CRM
Han 72DD (2.5SQ 10A) BK(J6) BKC(J1-J6) J6U1 J6V1 J6W1 J6G1 0V(A1,A2,B1-B6) RI6 RO6 0V(J5,J6) PRQJ6 XPRQJ6
6V(BT2) PRQJ2 5V(J2)
A63L-0001-0848#E10SL1 A63L-0001-0850
6PB 2428PCFA 4 0V(BT2) 5 XPRQJ2 6 0V(J2)
1 4
M2BK 2 3
A63L-0002-0205#6SB A63L-0002-0205#2428SCFA
J2V1 J2W1
5V(J3) 0V(J3)
4 6V(BT3) 5 XPRQJ3 6 PRQJ3 7 0V(BT3)
1 2 3
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
APPENDIX
B-83495EN01
A63L-0001-0865#1 A63L-0001-0864#CS
A63L-0002-0066#R08DX A63L-0002-0066#CRM
(
X-KEY BLACK
M4M1 A1 A2 A3 A4
)
J4U1 BK(J4) J4W1
B1 B2 B3 B4
F08DX CTM J4G1 J4V1 BKC(J4)
J4 MOTOR (βiSR0.4/6000) M4M 2 3
K111 A660-4005-T368 A63L-0001-0865#2 A63L-0001-0864#CS
(
5V(J4) 0V(J4)
A63L-0001-0865#1 A63L-0001-0864#CS
M5M1 A1 A2 A3
X-KEY BLACK
BK(J4)
M4P 8 9 10
A63L-0002-0066#R06DX A63L-0002-0066#CRM
J5U1 BK(J5) J5W1
B1 B2 B3
F06DX CTM J5G1 J5V1 BKC(J5)
1 4
J4U1 J4G1
M4BK 2 3
A63L-0001-0848#E10SL1 A63L-0001-0850
J4V1 J4W1
1 BKC(J4) 4
4 6V(BT4) 5 XPRQJ4 6 PRQJ4 7 0V(BT4)
J5 MOTOR (βiSR0.2/6000) M5M 2 3
K113 A660-4005-T369 A660-4005-T369#L
A63L-0001-0865#2 A63L-0001-0864#CS
) M5P1 1 2 3
(
BLACK
6V(BT5) PRQJ5 5V(J5)
) M6M1 A1 A2 A3
(
A63L-0001-0848#E10SL1 A63L-0001-0850
J6U1 BK(J6) J6W1
B1 B2 B3
F06DYW CTM J6G1 J6V1 BKC(J6)
A63L-0001-0865#2 A63L-0001-0864#CS
) M6P1
A63L-0001-0848#E10SL1 A63L-0001-0850
7PW 2428PCFA
2 PRQJ6 1 6V(BT6) 5 XPRQJ6 4 0V(BT6) 3 5V(J6) 7 6 0V(J6)
(
WHITE
)
A63L-0002-0205#13SB A63L-0002-0205#2428SCFA
(
BLACK
K117 A660-2007-T607 A660-2007-T607#L
EE2
)
5V(J5) 0V(J5)
J6V1 J6W1
BK(J6)
M6P 8 9 10
5V(J6) 0V(J6)
8
RI1 4 8
RI3 RO7
1 4
BKC(J5)
4 6V(BT5) 5 XPRQJ5 6 PRQJ5 7 0V(BT5)
1 2 3
1 4
J6U1 J6G1
1 4
BKC(J6)
4 6V(BT6) 5 XPRQJ6 6 PRQJ6 7 0V(BT6)
1 2 3
J3 CONNECTOR PANEL EE A63L-0002-0072#12SN
13PB 2428PCFA
3 24VF(A1,A2) 2 RI2 1 7 RI6 6 RI5 5 RI4 11 0V(A1,A2) 10 (XHBK) 9 RO8 12 (RI7) 13 (RI8)
J5U1 J5G1
M6BK 2 3
A63L-0002-0205#7SW A63L-0002-0205#2428SCFA
1 4
J6 MOTOR (βiSR0.2/6000) M6M 2 3
K116 A660-4005-T370 A660-4005-T370#L
BK(J5)
M5P 8 9 10
K114 A660-2007-T605 A660-2007-T605#L A63L-0001-0865#1 A63L-0001-0864#CS
A63L-0002-0066#R06DYW A63L-0002-0066#CRM
Y-KEY WHITE
6PB 2428PCFA 4 0V(BT5) 5 XPRQJ5 6 0V(J5)
J5V1 J5W1
M5BK 2 3
A63L-0002-0205#6SB A63L-0002-0205#2428SCFA
1 2 3
K118 A660-2007-T608 A660-2007-T608#L
7
RO7 6
RO8 12 RI6 5
9 24VF(A1) 1 RI1 0V(A2) 10 24VF(A2) 2 11 0V(A1) 3 RI3 RI5 4 RI4
RI2
A05B-1142-H002,-H012 YV2
13PB 2428PCFA 3
7 11
2 6 10 13
RO2 5 9 12
1
R01 4 8
0V(B2)
0V(B1)
SOLENOID VALVE A97L-0218-0130#D1
A05B-1142-H003,-H013 YV2
13PB 2428PCFA 3
7 11
0V(B4)
R03 6 10 13
2 0V(B3)
RO2 5 9 12
1
R01 4 8
0V(B2)
RO4 0V(B1)
SOLENOID VALVE A97L-0218-0130#D2
A05B-1142-H004,-H014 YV2
13SB 2428SCFA 1
4 8
RO4 0V(B1)
R01 5 9 12
2 RO5 0V(B2) 0V(B5)
RO2 6 10 13
3 RO6 0V(B3) 0V(B6)
YV2
R03 7 11
13PB 2428PCFA 3
0V(B4)
7 11
0V(B4)
R03 6 10 13
2 RO6 0V(B3) 0V(B6)
RO2 5 9 12
1 RO5 0V(B2) 0V(B5)
R01 4 8
RO4 0V(B1)
SOLENOID VALVE A97L-0218-0130#D3
A05B-1142-H005 YV2
13PB 2428PCFA 3
7 11
0V(B4)
R03 6 10 13
2 RO2 RO6 5 0V(B3) 9 0V(B6) 12
1 R01 RO5 4 0V(B2) 8 0V(B5)
RO4 0V(B1)
SOLENOID VALVE A97L-0218-0130#D3B
A05B-1142-H006 YV2
13PB 2428PCFA 3
7 11
0V(B4)
R03 6 10 13
2 RO2 RO6 5 0V(B3) 9 0V(B6) 12
1 R01 RO5 4 0V(B2) 8 0V(B5)
RO4 0V(B1)
SOLENOID VALVE A97L-0218-0130#D3R
- 103 -
:可動部用 MOVABLE
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
APPENDIX
B-83495EN/01
J1 CONNECTOR PANEL K101 A660-8018-T491
BATTERY 6V (BT1,BT2,BT3, BT4,BT5,BT6)
(
GB2
+
単一電池 SIZE D
)
K131 A660-8016-T498
6V(BT1,BT2,BT3, BT4,BT5,BT6)
A
6V(BT1,BT2,BT3, BT4,BT5,BT6)
B
0V(BT1,BT2,BT3, BT4,BT5,BT6)
B
0V(BT1,BT2,BT3, BT4,BT5,BT6)
C
-
0V (BT1,BT2,BT3, BT4,BT5,BT6)
GB2
A
K119 A660-8018-T493
C A63L-0001-0648#610SL3SJ
Fig.B (b)
TERMINAL
A65L-0001-0337#102P
A63L-0001-0648#610SL3SJ
Circuit diagram (when remote type battery is specified)
J3 CONNECTOR PANEL A63L-0002-0205#13SW A63L-0002-0205#2428SCFA
3 24VF(A1,A2) 2 7 RI6 6 RI5 11 0V(A1,A2) 10 XHBK 13 RI8
(
WHITE
1
5 9 12
4 8
RI3 RO7
2 RO2 1 4 RO4 RO5 7 0V(B1-B6) 6
BLACK
)
A63L-0002-0205#13SB A63L-0002-0205#2428SCFA
RO1 3
RO3
RO6
3 24VF(A1,A2) 2 7 RI6 6 RI5 11 0V(A1,A2) 10 XHBK 13 (RI8)
K108 A660-2007-T601
(
K109 A660-2007-T602
(
)
Fig.B (c)
BLACK
13PB 2428PCFA
EE2
RI1
RI4 RO8 RI7
7PB 2428PCFA
YV1 5
BLACK
RI2
)
A63L-0002-0205#7SB A63L-0002-0205#2428SCFA
(
A63L-0002-0205#13SB A63L-0002-0205#2428SCFA
13PW 2428PCFA
EE1
)
D LED+ C LED4 GND(VIDEO) 3 TRG 7 VIDEO 6
FS1 1 2
0V TX2
4 3
A B 12V 2 GND(VD,TRG) 1 GND(HD) 5 HD
LF10WBR-4P 24V TX1
1 5 RI4 9 (RO8) 12 (RI7)
EE
RI1 4 RI3 8 (RO7)
YV2
13PB 2428PCFA
2 RO2 1 R01 3 R03 7 6 RO6 5 RO5 4 11 (0V(B4)) 10 (0V(B3)) 9 0V(B2) 8 13 (0V(B6)) 12 (0V(B5))
RO4 0V(B1)
1 2 3 4
LF13WBR-11P 0V VD
( K201 A05B-1142-D001
5 6 7 8 9 10
RO1 RO2 RO3 RO4 RO5 RO6
11 12 13 14 15 16
BLACK
)
13PB 2428PCFA
CAM-A 2 SHIELD 1 12V 3 LED7 LED+ 6 TRG 5 GND(TRG) 4 11 GND(VIDEO) 10 VIDEO 9 GND(VD) 8 13 GND(HD) 12 HD
0V VD
K202 A660-2007-T609
A63L-0002-0205#5SB A63L-0002-0205#2428SCFA 3
TX1 5
(
BLACK
2 TX2 DRAIN 4
1
5PB 2428PCFA 0V
K203 A660-2007-T610
24V
)
13PB 2428PCFA
CAM3 3 LED7 LED+ 6 11 GND(VIDEO) 10 13
2 SHIELD 1 12V TRG 5 GND(TRG) 4 VIDEO 9 GND(VD) 8 GND(HD) 12 HD
0V VD
J3 CONNECTOR PANEL K204 A05B-1142-D002
CAM2 A 1
0V VD 5
B 12V C LED2 GND(VD,TRG) 3 TRG 6 GND(HD) 7 HD
FS2
A63L-0002-0205#5SB A63L-0002-0205#2428SCFA
FS-B 3
TX1 5
2 TX2 DRAIN 4
1
5PB 2428PCFA 0V
6 5 4
24V
1 2 3
LF13WBR-11S D LED+ 4 GND(VIDEO) VIDEO
LF07WBR-6S 0V TX2 TX1
24V
:可動部用 MOVABLE Fig.B (d)
A63L-0002-0072#20SN RI1 17 XHBK RI2 RI3 18 24VF(A1) RI4 19 24VF(A1) RI5 20 24VF(A2) RI6
:可動部用 MOVABLE
K120 A660-4005-T371
FS-A
A63L-0002-0205#13SB A63L-0002-0205#2428SCFA
0V(B1) 0V(B2) 0V(A1) 0V(A2)
Circuit diagram (when EE20P is specified)
A63L-0002-0205#13SB A63L-0002-0205#2428SCFA
J1 CONNECTOR PANEL CAM1
RI2
Circuit diagram (camera cable / sensor cable)
- 104 -
APPENDIX
B-83495EN01
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
J3 CONNECTOR PANEL CAM2 A 1
0V VD 5
J3 CONNECTOR PANEL CAM2 A 1
0V VD 5
CAM3
LF13WBR-11S D (LED+) B 12V C (LED-) 2 GND(VD,TRG) 3 TRG 4 GND(VIDEO) HD 6 GND(HD) 7 VIDEO
B 12V C LED2 GND(VD,TRG) 3 TRG HD 6 GND(HD) 7
K251 A660-2007-T614
HR10-10R-12P(01)
1 0V 2 12V 10 3 GND(VIDEO) 11 TRG 4 VIDEO 5
K252 A660-4005-T400
Fig.B (e)
0V TX2 TX1
24V
1 2 3
0V TX2 TX1
TRG
8 GND(TRG) 12 GND(VD) 7 VD GND(HD) 6 HD
LF07WBR-3P LED-
FORCE SENSOR(6AXES) FS3 SENSOR CABLE A660-2007-T615
1 2
4 3
0V TX2
LF10WBR-4P 24V TX1
FORCE SENSOR(3AXES) FS3 LF10WBR-12P
J3 CONNECTOR PANEL FS2 LF07WBR-6S 6 5 4
3
LED+ 2
9
Circuit diagram (camera cable)
J3 CONNECTOR PANEL FS2 LF07WBR-6S 1 2 3
8 GND(TRG) 12 GND(VD) 7 VD GND(HD) 6 HD
HR10-10R-12P(01)
1 0V 2 12V 10 3 GND(VIDEO) 11 TRG 4 VIDEO 5
1
24V
TRG
CAM3
LF13WBR-11S D LED+ 4 GND(VIDEO) VIDEO
LED
6 5 4
9
1 SENSOR CABLE A660-2007-T691
2 11
9 10 24V
8
3
7 4
6 5
Fig. B (f) Circuit diagram (force sensor cable)
- 105 -
0V
12
TX1
TX2
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
APPENDIX
B-83495EN/01
J1 connector plate AIR 1
J3 arm
J1 connector plate AIR 2
J2 arm Exhaust port
RO1
RO2
B1
A1
Fig. B(g) Air pressure diagram (Double solenoid valve×1 A05B-1142-H002,H012 is specified)
J1 connector plate AIR 1
J3 arm
J1 connector plate AIR 2
J2 arm Exhaust port
RO3
RO1
RO2 RO4
B2
A2
B1
A1
Fig. B(h) Air pressure diagram (Double solenoid valve×2 A05B-1142-H003,H013 is specified)
- 106 -
B-83495EN01
APPENDIX
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
J1 connector plate AIR 1
J3 arm
J1 connector plate AIR 2
J2 arm Exhaust port
RO5
RO3
RO6
RO4
RO1
RO2
B3
A3
B2
A2
B1
A1
Fig. B(i) Air pressure diagram (Double solenoid valve×3 A05B-1142-H004,H014 is specified)
J1 connector plate AIR 1
J3 arm
J1 connector plate AIR 2
J2 arm Exhaust port
RO3
RO5
RO1
RO4
RO6
B3
RO2
B2 A2
A3
B1 A1
Fig. B(j) Air pressure diagram (Double solenoid valve×3 A05B-1142-H005,H015 is specified)
- 107 -
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
APPENDIX
B-83495EN/01
J1 connector plate AIR 1
J3 arm
J1 connector plate AIR 2
J2 arm Exhaust port
RO3
RO5
RO4
RO6
B3
RO2
B2 A2
A3
RO1
B1 A1
Fig. B(k) Air pressure diagram (Double solenoid valve×3 A05B-1142-H006,H016 is specified)
- 108 -
B-83495EN/01
C
APPENDIX
C.PERIODIC MAINTENANCE TABLE
PERIODIC MAINTENANCE TABLE
- 109 -
C.PERIODIC MAINTENANCE TABLE
APPENDIX
B-83495EN/01
FANUC Robot LR Mate 200iD, ARC Mate 50iD ,LR Mate 200iD/7L, ARC Mate 50iD/7L Periodic Maintenance Table Working time (H) Items Check the exposed connector.(loosening)
1 6 9 3 First Grease check months months months years amount 320 960 1920 2880 3840
2 years 4800
5760
6720
7680
0.2H
―
○
○
○
0.2H
―
○
○
○
2.0H
―
○
○
○
0.1H
―
○
○
○
1.0H
―
○
0.1H
―
○
0.1H
―
0.1H
―
0.5H
14ml
4.0H
―
0.2H
―
11 Cleaning the ventilator
0.2H
―
12 Replacing battery *1
0.1H
―
1
2 Tighten the end effector bolt. 3 4 Mechanical unit
Check time
Tighten the cover and main bolt. Check the mechanical stopper.
5 Remove spatter and dust etc. Check hand cable and
6 external battery cable (option)
7
Replacing battery. (if built-in batteries are specified) Replacing battery. (if external batteries are specified)
8 Greasing the reducers. Replacing cable of mechanical
9 unit *1
○
○
○
○
○
○
○
○
○
●
●
8640
9600 10560
○
○
○
○
○
○
●
Check the robot cable, teach
Controller
10 pendant cable and robot
○
○
○
connecting cable
○
○
*1 Refer to manual of controller. *2 ●: requires order of parts ○: does not require order of parts
- 110 -
○
○
○
○
○
○
○
C.PERIODIC MAINTENANCE TABLE
APPENDIX
B-83495EN/01
3
4
5
6
7
8
years
years
years
years
years
years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720
Item
○
○
○
○
○
1
○
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
●
●
●
●
●
●
●
○ ○
○
○
○
○
5 6
●
●
7
●
8
●
9
○ ○
○
Overhaul
○
○
○ ○
○
○
○
○ ○
○
○
●
○
○ ○
○
○
○
10 ○
○
○
11 12
- 111 -
D.MOUNTING BOLT TORQUE LIST
D
APPENDIX
B-83495EN/01
MOUNTING BOLT TORQUE LIST
NOTE When applying LOCTITE to the important bolt tightening points, make sure that it is applied to the entire longitudinal portion in the engaging section of the female threads. If it is applied to the male threads, the bolts may be loosened because sufficient adhesion cannot be obtained. Remove the dust within the bolts and tapped holes and wipe oil off the engaging section. Make sure that there is no solvent in the tapped holes. Be sure to wipe the excess LOCTITE after tightening bolt. Use bolt which strengths are below. But if it is specified in text, obey it. Hexagon socket head bolt made by steel Size is M22 or less : Tensile strength 1200N/mm2 or more Size is M24 or more : Tensile strength 1000N/mm2 or more All size of bolt of the plating : Tensile strength 1000N/mm2 or more Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc) Tensile strength 400N/mm2 or more If no tightening torque is specified for a bolt, tighten it according to this table. Recommended bolt tightening torques
Nominal diameter
M3 M4 M5 M6 M8 M10 M12 (M14) M16 (M18) M20 (M22) M24 (M27) M30 M36
Hexagon socket head bolt (Steel) Tightening torque Upper limit Lower limit 1.8 1.3 4.0 2.8 7.9 5.6 14 9.6 32 23 66 46 110 78 180 130 270 190 380 260 530 370 730 510 930 650 1400 960 1800 1300 3200 2300
Unit: Nm
Hexagon socket head button bolt Hexagon bolt Hexagon socket head Hexagon socket head (steel) flush bolt bolt (stainless) Low-head bolt (steel) Tightening torque Tightening torque Tightening torque Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit ―――― ―――― ――― 0.76 0.53 ―――― 1.8 1.3 1.8 1.3 1.7 1.2 3.4 2.5 4.0 2.8 3.2 2.3 5.8 4.1 7.9 5.6 5.5 3.8 14 9.8 14 9.6 13 9.3 27 19 32 23 26 19 ―――― ―――― 48 33 45 31 ―――― ―――― 76 53 73 51 ―――― ―――― 120 82 98 69 ―――― ―――― 160 110 140 96 ―――― ―――― 230 160 190 130 ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ―――― ――――
- 112 -
E
E.OPTIONAL CONNECTOR WIRING PROCEDURE
APPENDIX
B-83495EN/01
OPTIONAL CONNECTOR WIRING PROCEDURE
Source of information:
Hirose Electric Co., Ltd.
NOTE1 NOTE2
NOTE1) NOTE2)
Corresponds to A05B-1137-J057. Corresponds to A05B-1137-J058 and A05B-1139-J059.
- 113 -
INDEX
B-83495EN/01
INDEX REPLACING J2-AXIS REDUCER................................ 35 REPLACING J3 BELT................................................... 68 REPLACING J3-AXIS MOTOR.................................... 38 REPLACING J3-AXIS REDUCER................................ 40 REPLACING J4-AXIS MOTOR.................................... 45 REPLACING J4-AXIS REDUCER................................ 47 REPLACING J5/J6 BELT .............................................. 69 REPLACING J5-AXIS MOTOR.................................... 51 REPLACING J5-AXIS REDUCER (7L)........................ 56 REPLACING J5-AXIS REDUCER (Standard) .............. 52 REPLACING J6-AXIS MOTOR.................................... 61 REPLACING J6-AXIS REDUCER................................ 67 REPLACING PARTS..................................................... 23 REPLACING SOLENOID VALVE ............................... 70 REPLACING THE BATTERIES (1-YEAR PERIODIC INSPECTION IF BUILT-IN BATTERIES ARE SPECIFIED) (1.5-YEAR PERIODIC INSPECTION IF EXTERNAL BATTERIES ARE SPECIFIED)................................... 9 REPLACING WRIST UNIT (7L) .................................. 65 REPLACING WRIST UNIT (Standard)......................... 63 REPLENISH THE GREASE OF THE DRIVE MECHANISM (4 YEARS (15360 HOURS) CHECKS).................................................................... 11
1.5-YEAR (5760 HOURS) CHECKS ...............................6 1-YEAR (3840 HOURS) CHECKS ..................................6 3-MONTH (960 HOURS) CHECKS ................................6 4-YEAR (15360 HOURS) CHECKS ................................6
ADJUSTING TENSION OF BELT ................................ 92 ADJUSTMENTS ............................................................ 92
BACKLASH MEASUREMENT .................................... 19
CABLE AND AIR TUBE REPLACEMENT ................. 76 CABLE FORMING ........................................................ 75 CABLE WIRING............................................................ 74 CHECKS AND MAINTENANCE ...................................1 CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM.. 101
DAILY CHECKS..............................................................1
FAILURES, CAUSES AND MEASURES..................... 13 FIGURE OF DRIVE MECHANISM .............................. 24 FIRST 1-MONTH (320 HOURS) CHECK.......................3 FIRST 3-MONTH (960 HOURS) CHECKS ....................3
SAFETY PRECAUTIONS ............................................ s-1 SEALANT APPLICATION ........................................... 71 SPARE PARTS LIST ..................................................... 97
MAINTENANCE .............................................................7 MOUNTING BOLT TORQUE LIST ........................... 112
TROUBLESHOOTING .................................................. 13
OPTIONAL CONNECTOR WIRING PROCEDURE . 113 OVERVIEW ................................................................... 13
PERIODIC MAINTENANCE ..........................................9 PERIODIC MAINTENANCE TABLE......................... 109 PREFACE ......................................................................p-1
Replacing Air Tube ......................................................... 87 Replacing Cable K101 and Air Tube (Connector panel to J2 base).................................................................... 76 Replacing Cable K102, K103, K104, K105, K109, K110, K111, K112, K113............................................ 85 Replacing Cable K106, K107, K108,K109 and Air Tube (J2 base to J3 housing) ....................................... 81 Replacing Cable K118 .................................................... 85 REPLACING CABLES .................................................. 73 REPLACING J1-AXIS MOTOR .................................... 26 REPLACING J1-AXIS REDUCER................................ 28 REPLACING J2-AXIS MOTOR .................................... 32
i-1
REVISION RECORD
B-83495EN/01
REVISION RECORD Edition
Date
01
Sep., 2013
Contents
r-1
B-83495EN/01
* B - 8 3 4 9 5 E N /
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