FANUC Robot R-2000iB
MECHANICAL UNIT
MAINTENANCE MANUAL
MARMC200B05061E REV. C
This publication contains proprietary information
of FANUC Robotics America, Inc. furnished for
customer use only. No other uses are authorized
without the express written permission of
FANUC Robotics America, Inc.
FANUC Robotics America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 48309–3253
B-82235EN/03
The descriptions and specifications contained in this manual were in
effect at the time this manual was approved for printing. FANUC
Robotics America, Inc, hereinafter referred to as FANUC Robotics,
reserves the right to discontinue models at any time or to change
specifications or design without notice and without incurring
obligations.
FANUC Robotics manuals present descriptions, specifications,
drawings, schematics, bills of material, parts, connections and/or
procedures for installing, disassembling, connecting, operating and
programming FANUC Robotics’ 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 Robotics recommends that only persons who have been
trained in one or more approved FANUC Robotics Training
Course(s) be permitted to install, operate, use, perform procedures
on, repair, and/or maintain FANUC Robotics’ 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 radio
frequency 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 Robotics conducts courses on its systems and products on
a regularly scheduled basis at its headquarters in Rochester Hills,
Michigan. For additional information contact
FANUC Robotics America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
Copyright 2007 by FANUC Robotics America, Inc.
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 Robotics America, Inc.
AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,
KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,
PalletTool, SOCKETS, SOFT PARTS SpotTool,
TorchMate, and YagTool are Registered Trademarks of FANUC
Robotics.
FANUC Robotics 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 CollisionGuard
DispenseTool F-100 F-200i FabTool FANUC LASER
DRILL Flexibell FlexTool HandlingTool HandlingWorks
INSIGHT INSIGHT II IntelliTrak Integrated Process Solution
Intelligent Assist Device IPC -Integrated Pump Control IPD
Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD
Integral Servo Dispenser Laser Mate System 3 Laser Mate
System 4 LaserPro LaserTool LR Tool MIG Eye
MotionParts 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 SOF PARTS SpotTool+ SR Mate
SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM RJ3 Controller SYSTEM R-J3iB Controller TCP Mate
TurboMove TorchMate visLOC visPRO-3D visTRAC
WebServer WebTP YagTool
 FANUC LTD 2007
•
•
No part of this manual may be reproduced in any form.
All specifications and designs are subject to change without notice.
Conventions
This manual includes information essential to the safety of
personnel, equipment, software, and data. This information is
indicated by headings and boxes in the text.
!
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set it
apart from other text.
!
CAUTION
Information appearing under CAUTION concerns the protection of
equipment, software, and data. It is boxed to set it apart from
other text.
NOTE Information appearing next to NOTE concerns related
information or useful hints.
!"#$ % &
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+ '% ( % ,' - . #/% + 0*1& + /' ( ,' ( )% /' % 2 ( ,' &
/' % ()% % 2 ( % (* '% /' & ( '% (
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Safety
FANUC Robotics 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 best be determined by safety
system professionals. FANUC Robotics 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 Robotic 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.
FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair,
or otherwise use the robotics system be trained in an approved FANUC Robotics 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
Keeping People and Equipment Safe
The safety of people is always of primary importance in any situation. However, equipment must be
kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following:
i
Safety
• People
• 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.
• Sponsor your personnel for training in approved FANUC Robotics 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.
ii
Safety
• 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.
• 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.
iii
Safety
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.
• 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 Robotics 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.
iv
Safety
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.
• 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 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.
v
Safety
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.
• 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 an applicator bell cup can continue to spin at a very high speed even if the robot is
idle. Use protective gloves or disable bearing air and turbine air before servicing these items.
• 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.
vi
Safety
• 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.
• 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.
vii
Safety
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 software limits, limit switches, and mechanical hardstops to prevent undesired movement of
the robot into the work area of machine tools and external devices.
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.
viii
Safety
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 personal 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.
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.
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.
ix
Safety
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.
• 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 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. 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 SCC 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 know 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.
xi
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.
• 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.
1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulated
dust.
2. 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.
3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust.
4. When the dust has been removed, the covers must be replaced immediately.
5. 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 .
• 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.
xii
Safety
• 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.
• 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.
xiii
Safety
— 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.
xiv
B-82235EN/03
1
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
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.
s-1
SAFETY PRECAUTIONS
1.1
B-82235EN/03
OPERATOR SAFETY
Operator 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 operator safety.
(1) Have the robot system operators 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 operator
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 operator can enter the
work area without passing through the gate. Install an interlock
switch, 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 interlock signal of the door switch.
When the gate is opened and this signal received, the controller stops the
robot in an emergency. For connection, see Fig.1.1.
(4) Provide the peripheral devices with appropriate grounding (Class
A, Class B, Class C, and Class D).
(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 an
operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator
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.
s-2
B-82235EN/03
SAFETY PRECAUTIONS
(9) When adjusting each peripheral device independently, be sure to
turn off the power of the robot.
Interlock switch and safety plug when the door is opening.
Fig. 1.1 Safety Fence and Safety Gate
NOTE
Terminals EAS1, EAS11, EAS2, and EAS21 are on
the PC board in the operator box or operator panel.
s-3
SAFETY PRECAUTIONS
1.1.1
B-82235EN/03
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 it is not necessary for the robot to operate, 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
also 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 when the external EMERGENCY STOP button is pressed.
See the diagram below for connection.
NOTE
Connect to EES1 and EES11, EES2 and EES21.
Fig. 1.1.1 Connection Diagram for External Emergency Stop Button
s-4
B-82235EN/03
1.1.2
SAFETY PRECAUTIONS
Safety of the Teach Pendant Operator
While teaching the robot, it is necessary for the operator to enter the
work area of the robot. It is particularly necessary to ensure the safety
of the teach pendant operator.
(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) When entering the robot work area and teaching the robot, be sure
to check the location and condition of the safety devices (such as
the EMERGENCY STOP button and the DEADMAN switch on
the teach pendant).
(4) The teach pendant operator should pay careful attention so that no
other workers enter the robot work area.
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 enters the emergency stop state.
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.
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 when pressed.
(2) DEADMAN switch: Functions differently depending on the mode switch
setting status.
(a) Automatic operation mode: The DEADMAN switch is disabled.
(b) Teach mode: Causes an emergency stop when the operator
releases the DEADMAN switch or when the operator presses the
switch strongly.
Note) The DEADMAN switch is provided to place the robot in the
emergency stop state when the operator releases the teach
pendant or presses the pendant strongly in case of emergency.
The R-J3iC 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 enters the emergency stop state.
The operator's intention of starting teaching is determined by the control unit
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 can operate in such conditions and be
responsible in carrying out tasks safely.
s-5
SAFETY PRECAUTIONS
B-82235EN/03
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
On
AUTO mode
Off
On
T1, T2 mode
Off
Software
remote
condition
Teach pendant Operator panel
Peripheral
device
Local
Remote
Local
Remote
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Local
Remote
Local
Remote
Allowed to start
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
(5) To start the system using the operator's panel, make certain that
nobody is in the robot work area and that there are no abnormal
conditions in the robot work area.
(6) When a program is completed, be sure to carry out a test run
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 run above, execute it in the automatic operation mode.
(7) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
s-6
B-82235EN/03
1.1.3
SAFETY PRECAUTIONS
Safety During Maintenance
For the safety of maintenance personnel, pay utmost attention to the
following.
(1) During operation, never enter the robot work area.
(2) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power switch,
if necessary, so that no other person can turn it on.
(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 disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(5) Before the start of teaching, check that the robot and its peripheral
devices are all in the normal operating condition.
(6) Do not operate the robot in the automatic mode while anybody is
in the robot work area.
(7) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(8) 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.
(9) 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.
(10) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(11) When handling each unit or printed circuit board in the controller
during inspection, turn off the circuit breaker to protect against
electric shock.
(12) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
(13) 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.
s-7
SAFETY PRECAUTIONS
B-82235EN/03
1.2
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES
1.2.1
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.
1.2.2
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) Employ a limit switch or mechanical stopper to limit the robot
motion so that the robot does not come into contact with its
peripheral devices or tools.
s-8
B-82235EN/03
SAFETY PRECAUTIONS
1.3
SAFETY OF THE ROBOT MECHANISM
1.3.1
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.
1.3.2
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.
1.3.3
Precautions for Mechanisms
(1) Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.
1.4
SAFETY OF THE END EFFECTOR
1.4.1
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.
s-9
SAFETY PRECAUTIONS
1.5
B-82235EN/03
WARNING LABEL
(1) Greasing and degreasing label
Fig. 1.5 (a) Greasing and degreasing label
Description
When greasing and degreasing, observe the instructions indicated on
this label.
1)
2)
3)
When greasing, be sure to keep the grease outlet open.
Use a manual pump to grease.
Be sure to use a specified grease.
CAUTION
See section 2 PERIODIC MAINTENANCE for
explanations about specified greases, the amount of
grease to be supplied, and the locations of grease
and degrease outlets for individual models.
s-10
B-82235EN/03
SAFETY PRECAUTIONS
(2) Disassembly prohibitive label
Fig. 1.5 (b) Disassembly prohibitive label
Description
Do not disassemble the balance unit. It is very dangerous because a
spring is loaded in it. (For R-2000iB, a disassembly prohibitive label is
affixed only to the balancer.)
(3) Step-on prohibitive label
Fig. 1.5 (c) Step-on Prohibitive Label
Description
Do not step on or climb the robot or controller as it may adversely affect
the robot or controller and you may get hurt if you lose your footing as
well.
s-11
SAFETY PRECAUTIONS
B-82235EN/03
(4) High-temperature warning label
Fig. 1.5 (d) High-Temperature Warning Label
Description
Be cautious about a section where this label is affixed, as the section
generates heat. If you have to inevitably touch such a section when it is
hot, use a protective provision such as heat-resistant gloves.
s-12
B-82235EN/03
SAFETY PRECAUTIONS
(5) Transportation label
>2500kg
<550kg x4
<550kg x4
>2500kg
>1000kg x4
>630kg x4
Fig. 1.5 (e) Transportation Label (R-2000iB/165F,210F,125L,175L)
Fig. 1.5 (f) Transportation Label (R-2000iB/165R,200R,100P)
s-13
SAFETY PRECAUTIONS
B-82235EN/03
>2500kg
<600kg X4
>2500kg
>1000kg X4
>630kg X4
Fig. 1.5 (g) Transportation Label (R-2000iB/165CF)
Description
When transporting the robot, observe the instructions indicated on this
label.
1)
Using a forklift
•
•
Use a forklift having a load capacity of 2,500 kg or greater.
Keep the total weight of the robot to be transported to within 2,200
kg, because the withstand load of the forklift bracket (option) is
5,390 N (550 kgf).
2)
Using a crane
•
•
Use a crane having a load capacity of 2,500 kg or greater.
Use at least four slings each having a withstand load of 9,800 N
(1000 kgf) or greater.
Use at least four eyebolts each having a withstand load of 6174 N
(630 kgf) or greater.
•
CAUTION
Transportation labels are model-specific. Before
transporting the robot, see the transportation label
affixed to the J2 base side.
See Sub-section 1.1 TRANSPORTATION for
explanations about the posture a specific model
should take when it is transported.
s-14
B-82235EN/03
SAFETY PRECAUTIONS
(6) Balancer replacement label
150kg
J2=0°
Fig. 1.5 (h) Balancer replacement label (R-2000iB/165F, 210F, 125L, 175L)
300kg
J2=-90°
Fig. 1.5 (i) Balancer replacement label (R-2000iB/165R, 200R,100P)
Description
When replacing the balancer, observe the instructions indicated on this
label.
The above balancer replacement label indicates the following:
•
While replacing the balancer, keep the J2-axis at 0° for the
R-2000iB/165F, 210F, 125L and 175L and keep the J2-axis at
-90° for the R-2000iB/165R, 200R and 100P.
•
The weight of the balancer is as follows:
•
For the R-2000iB/165F, 210F, 125L and 175L the mass of the
balancer is 150 kg.
•
For the R-2000iB/165R, 200R and 100P the mass of the balancer
is 300 kg.
•
The R-2000iB/165CF has no balancer.
CAUTION
For replacing the balancer, see section 4.6
REPLACING THE BALANCER.
s-15
SAFETY PRECAUTIONS
B-82235EN/03
(7) Transportation prohibitive label
(When transportation equipment option is specified.)
アイボルトを横引
しないこと
Do not pull eyebolt
sideways
輸送部材に衝撃を
与えないこと
Do not have impact
on this part
輸送部材にチェーン
などを掛けないこと
Do not chain, pry,
or strap on this part
Fig. 1.5 (j) Transportation prohibitive label
Description
Keep the following in mind when transporting the robot.
1)
2)
3)
Do not pull eyebolts sideways
Prevent the forks of the forklift from having impact on a transport
equipment.
Do not thread a chain or the like through a transport equipment.
s-16
B-82235EN/03
SAFETY PRECAUTIONS
(8) Transportation prohibitive label
(When transportation equipment option A05B-1329-H075 is
specified.)
1) ロボット設置後、輸送部材は必ず
取り外して下さい。
Remove the transport equipment
after installing the robot．
2) 運搬する際は必ずワークを
取り外して下さい。
Remove all loads when transporting
the robot. (Wrist and arm)
3) 必ずマニュアルに記載の姿勢にて
運搬して下さい。
Always Place the robot in shipping
position (refer to the manual) when
transporting the robot．
Transport Equipment
Fig. 1.5(k) Transportation prohibitive label (When A05B-1329-H075 is specified.)
Description
1)
2)
3)
Remove the transport equipment after installing the robot.
Remove all loads when transporting the robot. (Wrist and arm)
Always place the robot in shipping position (refer to the manual)
when transporting the robot.
s-17
PREFACE
B-82235EN/03
PREFACE
This manual explains the maintenance and connection procedures for
the mechanical units of the following robots:
Model name
FANUC Robot R-2000iB/165F
FANUC Robot R-2000iB/210F
FANUC Robot R-2000iB/165R
FANUC Robot R-2000iB/200R
FANUC Robot R-2000iB/100P
FANUC Robot R-2000iB/125L
FANUC Robot R-2000iB/175L
FANUC Robot R-2000iB/165CF
Mechanical unit
specification No.
A05B-1329-B201
A05B-1329-B205
A05B-1329-B221
A05B-1329-B225
A05B-1329-B231
A05B-1329-B261
A05B-1329-B265
A05B-1324-B541
Maximum load
165kg
210kg
165kg
200kg
100kg
125kg
175kg
165kg
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)
FANUC LTD
WEIGHT
(5) kg
OSHINO-MURA.
YAMANASHI PREF. JAPAN
p-1
PREFACE
B-82235EN/03
CONTENTS
LETTERS
Table 1 Position of label indicating mechanical unit specification number
(1)
(2)
(3)
(4)
(5)
WEIGHT
TYPE
No.
DATE
(Without controller)
FANUC Robot
A05B-1329-B201
1170kg
R-2000iB/165F
FANUC Robot
A05B-1329-B205
1240kg
R-2000iB/210F
FANUC Robot
A05B-1329-B221
1480kg
R-2000iB/165R
PRINT
FANUC Robot
A05B-1329-B225
1540kg
R-2000iB/200R
PRODUCTION
PRINT
SERIAL NO. YEAR AND
FANUC Robot
A05B-1329-B231
1560kg
MONTH
R-2000iB/100P
FANUC Robot
R-2000iB/125L
FANUC Robot
R-2000iB/175L
FANUC Robot
R-2000iB/165CF
A05B-1329-B261
1190kg
A05B-1329-B265
1260kg
A05B-1324-B541
1050kg
REPLATED 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-J3iC controller
FANUC Robot R-2000iB
Mechanical unit
Operations manual
SPOT TOOL+
B-82284EN-1
HANDLING TOOL
B-82284EN-2
DISPENSE TOOL
B-82284EN-4
SERVO GUN
FUNCTION
B-82454EN
Maintenance manual
B-82285EN
B-82285EN-1
(For Europe)
B-82285EN-2
(RIA)
Operations manual
B-82234EN
p-2
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 the controller,
maintenance
Use :
installation, start-up, connection, maintenance
Intended readers :
System designer, Maintenance person
Topics :
Installation, connection to the controller,
maintenance
Use :
installation, start-up, connection, maintenance
TABLE OF CONTENTS
B-82235EN/03
TABLE OF CONTENTS
SAFETY PRECAUTIONS ...........................................................................s-1
PREFACE ....................................................................................................p-1
I. MAINTENANCE
1
CHECKS AND MAINTENANCE ............................................................. 3
1.1
1.2
1.3
1.4
1.5
1.6
2
DAILY CHECKS ............................................................................................ 4
3-MONTH (960 HOURS) CHECKS ............................................................... 6
1-YEAR (3,840 HOURS) CHECKS.............................................................. 10
1.5-YEAR (5,760 HOURS) CHECKS........................................................... 10
3-YEAR (11,520 HOURS) CHECKS............................................................ 10
MAINTENANCE TOOLS ............................................................................. 11
PERIODIC MAINTENANCE .................................................................. 13
2.1
2.2
2.3
GREASING THE BALANCER SHAFT (1 YEAR (3840 HOURS) PERIODIC
MAINTENANCE) ......................................................................................... 14
REPLACING THE BATTERIES (1.5 YEAR (5,760 HOURS) CHECKS) ...... 15
REPLACING THE GREASE OF THE DRIVE MECHANISM (3 YEARS (11,520
HOURS) CHECKS) ..................................................................................... 17
2.3.1
Grease replacement procedure of the J1, J2, J3-axis reducer .................................18
2.3.2
Grease Replacement Procedure for the J4-Axis Gear Box.....................................21
2.3.3
Grease Replacement Procedure for the Wrist (R-2000iB/165F, 210F, 165R, 200R,
100P, 125L, 175L) .................................................................................................23
2.3.4
Grease Replacement Procedure for the J4-axis Gear box and Wrist
(R-2000iB/165CF) .................................................................................................24
2.3.5
3
TROUBLESHOOTING .......................................................................... 27
3.1
3.2
3.3
4
Procedure for Releasing Residual Pressure from the Grease Bath.........................25
OVERVIEW ................................................................................................. 28
FAILURES, CAUSES AND MEASURES ..................................................... 28
BACKLASH MEASUREMENT..................................................................... 36
REPLACING PARTS ............................................................................ 47
4.1
4.2
NOTE FOR PART REPLACEMENT............................................................ 48
REPLACING J1-AXIS MOTOR (M1) AND REDUCER ................................ 50
c-1
TABLE OF CONTENTS
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
CABLE WIRING......................................................................................... 107
CABLE FORMING ..................................................................................... 115
CABLE REPLACEMENT ........................................................................... 139
LIMIT SWITCH REPLACEMENT (OPTION) ............................................. 160
MASTERING ....................................................................................... 164
6.1
6.2
6.3
7
REPLACING J2-AXIS MOTOR (M2) AND REDUCER ................................ 63
REPLACING J3-AXIS MOTOR (M3) AND REDUCER ................................ 76
REPLACING THE WRIST AXIS MOTORS (M4, M5, AND M6), WRIST UNIT,
AND J4 AXIS REDUCER............................................................................. 89
REPLACING FANS ..................................................................................... 97
REPLACING THE BALANCER.................................................................... 98
SEALANT APPLICATION.......................................................................... 102
REPLACING MOTOR COVERS (OPTION) .............................................. 103
REPLACING CABLES ........................................................................ 105
5.1
5.2
5.3
5.4
6
B-82235EN/03
GENERAL ................................................................................................. 165
RESETTING ALARMS AND PREPARING FOR MASTERING ................. 167
MASTERING TO A FIXTURE (MASTER POSITION MASTER)................ 168
SEVERE DUST/LIQUID PROTECTION PACKAGE ........................... 181
7.1
7.2
SEVERE DUST/LIQUID PROTECTION PACKAGE (OPTION)................. 181
7.1.1
Severe Dust/Liquid Protection Characteristics.....................................................182
7.1.2
Configuration of the Severe Dust/Liquid Protection Package..............................183
7.1.3
Notes on Specifying Severe Dust/Liquid Protection Package..............................184
REPLACING SEVERE DUST/LIQUID PROTECTION PACKAGE
COMPONENTS ......................................................................................... 185
7.2.1
Replacing Motor Covers ......................................................................................185
7.2.2
Replacing Cable Covers .......................................................................................185
7.2.3
Replacing the Batteries and Battery Box Cover...................................................188
APPENDIX
A
B
C
D
SPARE PARTS LIST ......................................................................................... 193
CIRCUIT DIAGRAM........................................................................................... 200
PERIODIC MAINTENANCE TABLE .................................................................. 208
BOLT TIGHTENING TORQUE TABLE .............................................................. 216
c-2
I. MAINTENANCE
B-82235EN/03
1
MAINTENANCE
1. CHECKS AND MAINTENANCE
CHECKS AND MAINTENANCE
Optimum performance of the robot can be maintained by performing
the periodic maintenance procedures presented in this chapter.
(See the APPENDIX D 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. When using the robot
beyond this total operating time, correct the
maintenance frequencies shown in this chapter by
calculation in proportion to the difference between
the actual operating time and 3840 hours/year.
-3-
1. CHECKS AND MAINTENANCE
1.1
MAINTENANCE
B-82235EN/03
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
When air control set is combined
Item
Check items
Air pressure
1
Oiler oil mist
quantity
2
3
4
Oiler oil level
Leakage from
hose
Check points
Check air pressure using the pressure gauge on
the air regulator as shown in Fig.1.1. If it does
not meet the specified pressure of 0.49 to 0.69
MPa (5-7 kgf/cm2), adjust it using the regulator
pressure setting handle.
Check the drop quantity during wrist or hand
motion. If it does not meet the specified value (1
drop/10-20 sec), adjust it using the oiler control
knob. Under normal usage the oiler becomes
empty in about 10 to 20 days under normal
operation.
Check to see that the oiler level is within the
specified level.
Check the joints, tubes, etc. for leaks. Repair
leaks, or replace parts, as required.
Oil inlet
Adjusting knob
Lubricator
mist amount check
Lubricator
Filter
Regulator
pressure
setting handle
Pressure gauge
Fig. 1.1 Air control set
-4-
1. CHECKS AND MAINTENANCE
MAINTENANCE
B-82235EN/03
(2) After automatic operation
Item
1
Check items
Vibration, abnormal
noises, and motor
heating
2
Changing
repeatability
3
Peripheral devices for
proper operation
4
Brakes for each axis
-5-
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
0.2 mm when the power is cut.
1. CHECKS AND MAINTENANCE
1.2
MAINTENANCE
B-82235EN/03
3-MONTH (960 HOURS) CHECKS
Check the following items once every three months (960 hours).
Additional inspection areas and times should be added to the table
according to the robot's working conditions, environment, etc.
(1) 3-month (960 hours)checks
Item
1
2
Check items
Control unit cable
Ventilation portion
of control unit
Check points
Check whether the cable connected to the
teach pendant is unevenly twisted.
If the ventilation portion of the control unit is
dusty, tum off power and clean the unit.
Check the following items at the first quarterly (960 hours) inspection,
then every year (3,840 hours) thereafter.(See the Section 1.3.)
(2) First quarterly inspection(960 hours)
Check items
Cables used in
mechanical unit
1
2
Cleaning and checking
each part
3
Further tightening
external main bolts
Check points
Check whether the jackets of the
mechanical unit cables are damaged.
Also check whether the cables are
excessively bent or unevenly twisted.
Check that the connectors of the motors
and connector panels are securely
engaged.(NOTE1)
Clean each part (remove chips, etc.)
and check component parts for cracks
and flaws.(NOTE2)
Further tighten the end-effecter
mounting bolts and external main
bolts.(NOTE3)
Note 1 Inspection points and check items of the mechanical unit cables and
connectors
Inspection points of the mechanical unit cables
Fixed part cables likely to interfere with the J1, J2, and J3 movable
parts and peripheral devices
For the J1-axis, inspect the cables from above the J2 base and from the
side by removing the metal plate on the side of the J1 base.
Check items
For cables with a cable cover, open the cover before making the
check.
Check the cables for a sheath break and wear.
If wires of the cable appear, replace it.
-6-
MAINTENANCE
B-82235EN/03
1. CHECKS AND MAINTENANCE
カバーを外す
Remove
the cover
Fig. 1.2 (a) Check Items of Mechanical unit cable
Inspection points of the connectors
- Power/brake connectors of the motor exposed externally
- Robot connection cables 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.
Fig. 1.2 (b) Check items of connector
-7-
1. CHECKS AND MAINTENANCE
MAINTENANCE
B-82235EN/03
Note 2 Cleaning
- Necessary cleaning points, dust on the flat part, sedimentation of
spatters
Clean sediments periodically.
In particular, clean the following points carefully.
1) Vicinity of the balancer rod and shaft
→ If chippings or spatters are attached to the bushing, abnormal wear
may be caused.
2) 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 gun or 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. 1.2 (c) Cleaning part
-8-
MAINTENANCE
B-82235EN/03
1. CHECKS AND MAINTENANCE
Note 3 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.
-9-
1. CHECKS AND MAINTENANCE
1.3
MAINTENANCE
B-82235EN/03
1-YEAR (3,840 HOURS) CHECKS
Check the following items once every year (3,840 hours).
Item
1
2
3
4
1.4
Check itmes
Greasing balancer
bushing
Cables used in
mechanical unit
Cleaning each
parts and
inspection
Tightness of major
external bolts
Check points
Grease balancer bushing.(See Section 2.1.)
（See Section 1.2.）
（See Section 1.2.）
（See Section 1.2.）
1.5-YEAR (5,760 HOURS) CHECKS
Check the following item once every 1.5 year (5,760 hours).
Item
1
1.5
Check itmes
Battery
Check points
Replace battery in the mechanical unit. (See
Section 2.2)
3-YEAR (11,520 HOURS) CHECKS
Check the following items once every 3 years (11,520 hours).
Item
1
Check itmes
Replacing grease
of each axis,
reducer and gear
box
- 10 -
Check points
(See Section 2.3.)
MAINTENANCE
B-82235EN/03
1.6
1. CHECKS AND MAINTENANCE
MAINTENANCE TOOLS
The following tools and instruments are required for the maintenance
procedures contained in this manual.
(a) Measuring instruments
Instruments
Dialgauge accuracy
Accuracy/Tolerance
1/100 mm
Slide calipers
Push/pull tension
gauge
150 mm
98 N (10 kgf)
Applications
Measurement of positioning
and backlash
Measurement of backlash
(b) Tools
-
-
-
Cross-point(+) screwdriver : Large, medium, small
Conventional(-) screwdriver:Large, medium, small
Box screwdriver
: M6
Hex wrench set
: M3 to M20
Adjustable wrench
: Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Double hexagon offset wrench
Grease gun
Pliers for C-retaining ring
Torque wrench
Gear puller
Hexagonal socket
: M12(Tip length: 70mm or more. Used
for J3 reducer connection)
Socket
: M33(Width across flats 50mm. Used
for R-2000iB/165F, 210F, 125L,
175L standard balancer connection)
M42(Width across flats 65mm. Used
for R-2000iB/165R, 200R, 100P
standard balancer connection)
Spanner
: 30×32mm or 32×36mm
(Thickness: 14mm or less for stopping
J41 gear rotation)
T-shaped hexagonal wrench
: M8(Length:200mm or more. Used for
wrist axis motor connection)
: M12(Length:280mm or more. Used
for J3-axis motor connection)
Special Tools
Common to R-2000iB/165F, 210F, 165R, 200R, 100P,
125L and 175L
A290-7324-X921 2pcs
(Guide pin (M12) for J1-, J2-, J3-axis reducer replacement)
See Fig. 1.6 (a).
- 11 -
1. CHECKS AND MAINTENANCE
MAINTENANCE
B-82235EN/03
A290-7324-X922
(Spring pin striking tool for J1-axis reducer replacement)
See Fig. 1.6 (b).
A290-7324-X923 2pcs
(Guide pin (M16) for J1-axis reducer replacement)
See Fig. 1.6(c).
Fig. 1.6 (a) Guide pin (M12) for J1-, J2, J3-axis reducer replacement
Fig. 1.6 (b) Spring pin striking tool for J1-axis reducer replacement
Fig. 1.6 (c) Guide pin (M16) for J1-, J2-, J3-axis reducer replacement
- 12 -
B-82235EN/03
2
MAINTENANCE
PERIODIC MAINTENANCE
- 13 -
2. PERIODIC MAINTENANCE
2. PERIODIC MAINTENANCE
2.1
MAINTENANCE
B-82235EN/03
GREASING THE BALANCER SHAFT (1 YEAR (3840
HOURS) PERIODIC MAINTENANCE)
Be sure to grease the balancer shaft at specified intervals as shown in
Tables 2.1 (a) and 2.1 (b). When the installation environment of the
robot is bad, however, greasing needs to be made as appropriate. If
water splashes on the robot, supply grease immediately. Fig.2.1
shows the greasing points of the balancer shaft.
Table 2.1 (a)
Recommended grease
Showa Shell Sekiyu K. K.
Alvania grease S2
Specification:
A97L-0001-0179#2
Greasing the Balancer Shaft
Amount of grease
Greasing interval
10 ml for each
1 year or every 3840
(two points)
hours of accumulated
operation
Table 2.1 (b) Grease Alternative to Alvania Grease S2
Mobile Sekiyu K.K.
Mobilux grease No. 2
Esso Standard
Beacon No. 2
Nippon Oil Corporation
Multinoc 2
Nippon Oil Corporation
Epinoc AP-2
Idemitsu Kosan Co., Ltd.
Eponex grease No. 2
Cosmo Oil Co., Ltd.
Dynamax No. 2
Greasing the balancer shaft
Grease nipple
Right side
Left side
Fig. 2.1 Balancer shaft greasing points
- 14 -
MAINTENANCE
B-82235EN/03
2.2
2. PERIODIC MAINTENANCE
REPLACING THE BATTERIES (1.5 YEAR (5,760 HOURS)
CHECKS)
The position data of each axis is preserved by the backup batteries.
The batteries need to be replaced every 1.5 year (or time a total
operating time of 5,760 hours is reached.). Also use the following
procedure to replace when the backup battery voltage drop alarm
occurs.
Procedure of replacing the battery
1
Keep the power on. Press the EMERGENCY STOP button to
prohibit the robot motion.
CAUTION
Be sure to keep the power 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
Remove the battery case cap. (Fig. 2.2 (a), (b))
Take out the old batteries from the battery case.
Insert new batteries into the battery case. Pay attention to the
direction of batteries.
Close the battery case cap.
Battery case
Case cap
Battery
(1.5V size-D)
Fig. 2.2 (a) Replacing the battery
(R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 15 -
2. PERIODIC MAINTENANCE
MAINTENANCE
B-82235EN/03
Fig. 2.2 (b) Replacing the battery (R-2000iB/165CF)
- 16 -
MAINTENANCE
B-82235EN/03
2.3
2. PERIODIC MAINTENANCE
REPLACING THE GREASE OF THE DRIVE MECHANISM
(3 YEARS (11,520 HOURS) CHECKS)
Replace the grease of the reducers of J1, J2, and J3 axes, and the
J4-axis gear box and wrist, every three years or 11,520 hours by using
the following procedures.
See table 2.3 (a) for the grease name and the quantity.
Models
R-2000iB/165F
R-2000iB/165R
R-2000iB/125L
R-2000iB/210F
R-2000iB/200R
R-2000iB/175L
R-2000iB/100P
R-2000iB/165CF
Table 2.3 (a) Grease for 3-year periodical replacement
Greasing
Quantity
Gun tip pressure
4900g（5500ml）
J1-axis reducer
3100g（3500ml）
J2-axis reducer
2200g（2500ml）
J3-axis reducer
1700g（1900ml）
J4-axis gear box
2100g（2400ml）
wrist 1
700g（800ml）
wrist 2
4900g（5500ml）
J1-axis reducer
3100g（3500ml）
J2-axis reducer
2350g（2640ml）
J3-axis reducer
1700g（1900ml）
J4-axis gear box
3400g（3800ml）
wrist 1
1000g（1100ml）
0.15MPa or less
wrist 2
(NOTE)
4900g（5500ml）
J1-axis reducer
3100g（3500ml）
J2-axis reducer
2200g（2500ml）
J3-axis reducer
1700g（1900ml）
J4-axis gear box
3400g（3800ml）
Wrist 1
1000g（1100ml）
Wrsit 2
J1-axis gear box
3600g (4100ml)
J2-axis gear box
2300g (2600ml)
J3-axis gear box
1400g (1600ml)
J4-axis gear box
3400g (3950ml)
wrist 1
wrist 2
350g (400ml)
Grease name
Kyodo yushi
VIGOGREASE RE0
Spec :
A98L-0040-0174
NOTE
When a manual pump is used for greasing, the
standard rate is two pumping cycles per three
seconds.
For grease replacement or replenishment, use the attitudes indicated
below.
- 17 -
2. PERIODIC MAINTENANCE
MAINTENANCE
Supply position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist
B-82235EN/03
Table 2.3 (b) Attitudes for greasing
(R-2000iB/165F, 210F, 125L, 175L, 165CF)
Attitude
J1
J2
J3
J4
J5
Arbitrary
Arbitrary
0°
0°
Arbitrary
J6
Arbitrary
0°
0°
0°
Arbitrary
Arbitrary
Arbitrary
0°
0°
0°
Table 2.3 (c) Attitudes for greasing (R-2000iB/165R, 200R, 100P)
Attitude
Supply position
J1
J2
J3
J4
J5
J6
J1-axis reducer
Arbitrary
Arbitrary
J2-axis reducer
-90°
Arbitrary
Arbitrary Arbitrary
Arbitrary
J3-axis reducer
-90°
90°
J4-axis gear box
90°
Arbitrary
Wrist
90°
0°
0°
0°
2.3.1
Grease replacement procedure of the J1, J2, J3-axis reducer
1
2
3
4
5
Move the robot to the greasing attitude described in Section 2.3
(b) and (c).
Turn off the power.
Remove the seal bolt from grease outlet.（Fig.2.3.1(a) to (d)）
Supply new grease through the wrist grease inlet until new grease
is output from wrist grease outlet.
Release residual pressure using the procedure given in Section
2.3.5.
J2 reducer outlet
M12×15 (Seal bolt)
J2 reducer inlet
Grease nipple
Left side
Right side
J1 reducer inlet
Grease nipple
J1 reducer outlet
M12×15 (Seal bolt)
Fig. 2.3.1 (a) Replacing grease of the J1/J2-axis reducer (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 18 -
MAINTENANCE
B-82235EN/03
J1 reducer inlet
Grease nipple
2. PERIODIC MAINTENANCE
J2 reducer outlet
M6×8 (Seal bolt)
J2 reducer inlet
Grease nipple
J1 reducer outlet
Grease nipple
(Back of the connector panel)
Fig. 2.3.1 (b) Replacing grease of the J1/J2-axis reducer (R-2000iB/165CF)
J3-axis reducer outlet
M12×15 (Seal bolt)
Left side
J3 reducer inlet
Grease nipple
Right side
Fig. 2.3.1 (c) Replacing grease of the J3-axis reducer (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 19 -
2. PERIODIC MAINTENANCE
MAINTENANCE
B-82235EN/03
J3-axis reducer outlet
J3軸減速機排脂口
M6M6X8
×8 (Seal
bolt)
(シールボルト)
J3 reducer
inlet
J3軸減速機給脂口
Grease
nipple
グリスニップル
Fig. 2.3.1 (d) Replacing grease of the J3-axis reducer (R-2000iB/165CF)
- 20 -
2.3.2
2. PERIODIC MAINTENANCE
MAINTENANCE
B-82235EN/03
Grease Replacement Procedure for the J4-Axis Gear Box
R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L
1
2
3
4
5
Move the robot to the greasing attitude described in Section 2.3
(b) and (c).
Turn off the power.
Remove the seal bolt from the grease outlet and the air inlet.（Fig.
2.3.2(a)）
Supply new grease until new grease is output from the grease
outlet.
Release residual pressure using the procedure given in Section
2.3.5.
J4-axis gear box air inlet
M12×15 (seal bolt)
J4-axis gear box outlet
M12×15 (seal bolt)
J4-axis gear box inlet
Grease nipple
Fig. 2.3.2 (a) Replacing grease of the J4-axis gear box (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 21 -
2. PERIODIC MAINTENANCE
MAINTENANCE
B-82235EN/03
R-2000iB/165CF
1
2
3
4
5
Move the robot to the greasing attitude described in Section 2.3
(b).
Turn off the power.
Remove the seal bolt from the grease outlet.（Fig. 2.3.2(b)）
Supply new grease until new grease is output from the grease
outlet.
Release residual pressure using the procedure given in Section
2.3.5.
J4-axis gear box ,Wrist outlet 1
J4軸ギアボックス・手首排脂口1
M6×8 (seal bolt)
M6X8 (シールボルト)
J4-axis
gear box, Wrist inlet 1
J4軸ギアボックス・手首給脂口1
Grease
nipple
グリスニップル
Fig. 2.3.2 (b) Replacing grease of the J4-axis gear box (R-2000iB/165CF)
- 22 -
2.3.3
2. PERIODIC MAINTENANCE
MAINTENANCE
B-82235EN/03
Grease Replacement Procedure for the Wrist (R-2000iB/165F,
210F, 165R, 200R, 100P, 125L, 175L)
1
2
3
4
5
6
7
8
Move the robot to the greasing attitude described in table 2.3 (b)
and (c).
Turn off the power.
Remove the sealant plug of wrist grease outlet 1 (Figs.2.3.3(a)
and 2.3.3 (b)).
Supply grease to the wrist grease inlet until new grease outputs
from wrist grease outlet 1.
Attach the sealant plug to wrist grease outlet 1.
Next, remove the sealant plug (or the seal bolt for the 210F,
200R, 100P and 175L) of wrist grease outlet 2.
Supply new grease through the wrist grease inlet until new grease
is output from wrist grease outlet 2
Release residual pressure using the procedure given in Section
2.3.5.
Wrist grease outlet 2
M6×6 (seal bolt)
Wrist grease outlet 2
R1/8 (sealant plug)
Left side
Left side
Wrist grease outlet 1
R1/8 (sealant plug)
Wrist grease inlet
grease nipple
Wrist grease outlet 1
R1/4 (sealant plug)
Wrist grease inlet
grease nipple
Right side
Fig. 2.3.3 (a) Replacing grease of the wrist
(R-2000iB/165F, 165R, 125L)
Right side
Fig. 2.3.3 (b) Replacing grease of the wrist
(R-2000iB/210F, 200R, 100P, 175L)
- 23 -
2. PERIODIC MAINTENANCE
2.3.4
MAINTENANCE
B-82235EN/03
Grease Replacement Procedure for the J4-axis Gear box and
Wrist (R-2000iB/165CF)
1
2
3
4
5
6
7
8
Wrist grease inlet 2
grease nipple
Move the robot so that it takes the posture for greasing, shown in
table 2.3 (b).
Turn off the power.
Remove the seal bolt from wrist grease outlet 1.
Supply grease to wrist grease inlet 1 until new grease outputs
from wrist grease outlet 1.
Attach the seal bolt to wrist grease outlet 1. To reuse the seal
bolt, be sure to wind seal tape around the seal bolt.
Remove the seal bolt of wrist grease outlet 2.
Supply new grease to wrist grease inlet 2 until new grease is
output from wrist grease outlet 2.
Release residual pressure using the procedure given in Section
2.3.5.
J3-axis reducer outlet
M6×8 (seal bolt)
J4-axis gear box
wrist grease outlet
M6×8 (seal bolt)
Wrist grease outlet 2
M6×8 (seal bolt)
J4-axis gear box
wrist grease outlet
J3 reducer inlet Grease nipple
Grease nipple
Fig. 2.3.4 (a) Replacing grease of the J3-axis reducer, J4-axis gear box, wrist (R-2000iB/165CF)
1
2
3
4
5
6
CAUTION
If greasing is performed incorrectly, the internal pressure of the grease bath may
suddenly increase, possibly causing damage to the seal, which would in turn lead
to grease leakage and abnormal operation. When performing greasing, therefore,
observe the following cautions.
Before starting to grease, open the grease outlet (remove the plug or bolt from the
grease outlet).
Supply grease slowly, using a manual pump.
Whenever possible, avoid using an air pump, which is powered by the factory air
supply.
If the use of an air pump is unavoidable, supply grease with the pump at a
pressure lower than or equal to the gun tip pressure (see Table 2.3 (a)).
Use grease only of the specified type. Grease of a type other than that specified
may damage the reducer or lead to other problems.
After greasing, release residual pressure from the grease bath using the
procedure given in Section 2.3.5, and then close the grease outlet.
To prevent accidents caused by slipping, completely remove any excess grease
from the floor or robot.
- 24 -
2.3.5
2. PERIODIC MAINTENANCE
MAINTENANCE
B-82235EN/03
Procedure for Releasing Residual Pressure from the Grease
Bath
Release residual pressure as described below.
Under the grease inlets and outlets, attach bags for collecting grease so
that grease does not spatter when it comes out of the inlets or outlets.
Grease
replacement
position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Motion angle
OVR
Operating
time
Open
point
80° or more
90° or more
70° or more
J4 : 60° or more
J5 : 120° or more
J6 : 60° or more
50%
50%
50%
20 minutes
20 minutes
20 minutes
A
A
A
100%
20 minutes
B
100%
10 minutes
C
J4 : 60° or more
J5 : 120° or more
J6 : 60° or more
Wrist
In the case of A
Open the grease inlets and outlets and perform running.
In the case of B
Open the grease outlets only and perform running.
In the case of C
Open all of the grease inlets and outlets shown below and perform
running.
Wrist grease outlet 2
R1/8 (plug with sealant)
Left side
Also open here
Wrist grease
inlet
Grease nipple
Wrist grease outlet 1
R1/8 (plug with sealant)
Right side
Fig. 2.3.5 (a) Open Points for Releasing Residual Pressure from the
Wrist (R-2000iB/165F, 165R, 125L)
- 25 -
2. PERIODIC MAINTENANCE
MAINTENANCE
B-82235EN/03
Wrist grease outlet 2
M6×6 (seal bolt)
Left side
Also open here
Wrist grease outlet 1
R1/4 (plug with sealant)
Wrist grease
inlet
Grease nipple
Right side
Fig. 2.3.5 (b) Open Points for Releasing Residual Pressure from the
Wrist (R-2000iB/210F, 200R, 100P, 175L)
Wrist grease outlet 1
M6×8 (seal bolt)
Also
open
ここも開ける
here
Left side
Wrist grease
inlet 1
Grease nipple
Wrist grease outlet 2
M6×8 (seal bolt)
Right side
Wrist grease inlet 2
Grease nipple
Fig. 2.3.5 (c) Open Points for Releasing Residual Pressure from the
Wrist (R-2000iB/165CF)
If the above operation cannot be performed due to the environment of
the robot, prolong the operating time so that an equivalent operation
can be performed. (If only half of the predetermined motion angle
can be set, perform an operation for a period of time twice as long as
the specified time.) After completion of the operation, attach the seal
bolts and grease nipples to the grease inlets and outlets. When
reusing the seal bolts and grease nipples, be sure to seal them with seal
tape.
- 26 -
B-82235EN/03
3
MAINTENANCE
TROUBLESHOOTING
- 27 -
3. TROUBLESHOOTING
3. TROUBLESHOOTING
3.1
MAINTENANCE
B-82235EN/03
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 (a) lists the major failures that may occur in the mechanical
unit and their probable causes. If you cannot pinpoint a failure cause
or which measures to apply, contact FANUC.
Table 3.2 (a) Failures, causes and measures
Symptom
Description
Cause
[Base plate and floor plate fastening]
Vibration
-As the robot operates, its
-It is likely that the base plate is not
Noise
base plate lifts off the floor
securely fastened to the floor
(Continuted) plate.
plate because of poor welding.
-There is a gap between the
-If the base plate is not securely
base plate and the floor plate.
fastened to the floor plate, it lifts as
-There is a crack in the weld
the robot operates, allowing the base
that fastens the base plate to
and floor plates to strike each other
the floor plate.
which, in turn, leads to vibration.
[J1 base fastening]
-The J1 base lifts off the base
-It is likely that the robot J1 base is not
plate as the robot operates.
-There is a gap between the J1 securely fastened to the base plate.
-Probable causes are a loose bolt, an
base and base plate.
insuffcient degree of surface flatness,
-A J1 base retaining bolt is
or foreign material caught between the
loose.
base plate and floor plate.
-If the robot is not securely fastened to
the base plate, the J1 base lifts the
base plate as the robot operates,
allowing the base and floor plates to
strike each other wihich, in turn, leads
to vibration.
-Apply epoxy to the floor
[Rack or floor]
surface and re-install the plate. -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.
- 28 -
Measure
-Re-weld the base plate to the
floor plate.
-If the weld is not strong
enough, increase its width
and length.
-If a bolt is loose, apply loctite
and tighten it to the
appropriate torque.
-Adjust the base plate surface
flatness to within the specified
tolenrance.
-If there is any foreign matter
between the J1 base and
base plate, remove it.
-As the robot operates, the
rack or floor on which the
robot is mounted vibrates.
-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.
MAINTENANCE
B-82235EN/03
Symptom
Description
Vibration
-Vibration becomes more
Noise
serious when the robot adopts
(Continuted) 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.
-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 exchanged
for a long period.
Cause
[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.
[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 matter 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 changed 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.
- 29 -
3. TROUBLESHOOTING
Measure
-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).
-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 changing the
grease with a specified type
can help prevent problems.
3. TROUBLESHOOTING
Symptom
Description
-The cause of problem cannot
Vibration
be identified from examination
Noise
(Continuted) of the floor, rack, or
mechanical section.
MAINTENANCE
Cause
[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 pulse coder 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 pulse coder 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 source voltage drops
below the rating, vibration might
occur.
-If a robot control parameter is set to
an invalid value, vibration might occur.
- 30 -
B-82235EN/03
Measure
-Refer to the R-J3iC
Controller Maintenance
Manual for troubleshooting
related to the controller and
amplifier.
-Replace the pulse coder 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.
MAINTENANCE
B-82235EN/03
Symptom
Description
Vibration
-There is some relationship
Noise
between the vibration of the
(Continuted) robot and the operation of a
machine near the robot.
-There is an unusual sound
after replacement of grease.
-There is an unusual sound
after a long period of time.
-There is an unusual sound
during operation at low speed.
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 surface of the
mechanical unit.
Cause
[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.
-There may be an unusual sound
when using other than the specified
grease.
-Even for the specified grease, there
may be an unusual sound during
operation at low speed immediately
after replacement or after a long
period of time.
[Mechanical section coupling bolt]
-It is likely that overloading or a
collision has loosened a mounting bolt
in the robot mechanical section.
- 31 -
3. TROUBLESHOOTING
Measure
-Connect the grounding wire
firmly to ensure a reliable
ground potential and prevent
extraneous electrical noise.
-Use the specified grease.
-When there is an unusual
sound even for specified
grease, perform operation for
one or two days on an
experiment. Generally, an
usual sound will disappear.
-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
-Reducer shaft retaining bolt
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
3. TROUBLESHOOTING
Symptom
Rattling
Description
-Backlash is greater than the
tolerance stated in the
applicable maintenance
manual.(See Section 3.3.)
MAINTENANCE
Cause
[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.
- 32 -
B-82235EN/03
Measure
-Operate one axis at a time to
determine which axis has the
increased backlsh.
-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 changing the
grease with a specified type
can help prevent problems.
MAINTENANCE
B-82235EN/03
Symptom
Motor
overheating
Description
-The ambient temperature of
the installation location
increases, causing
the motor to overheat.
-After a cover was attached to
the motor, the motor
overheated.
-After the robot control
program or the load was
changed, the motor
overheated.
Cause
[Ambient temperature]
-It is likely that a rise in the ambient
temperature or attaching the motor
cover 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.
-After a control parameter was
changed, the motor
overheated.
[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.
-Symptom other than stated
above
- 33 -
3. TROUBLESHOOTING
Measure
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 motor well ventilated
enables the motor 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.
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
Grease
leakage
Description
-Grease is leaking from the
mechanical unit.
Dropping axis -An axis drops because the
brake does not function.
-An axis drops gradually when
it should be at rest.
MAINTENANCE
Cause
[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.
-Problems with the grease nipple or
threads.
[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.
- 34 -
B-82235EN/03
Measure
-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 (case and shaft)
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 outlet
-Replace the grease nipple.
-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.
MAINTENANCE
B-82235EN/03
Symptom
Description
Displacement -The robot operates at a point
(Continuted) other than the taught position.
-The repeatability is not within
the tolerance.
-Displacement occurs only in a
specific peripheral unit.
-Displacement occurred after a
parameter was changed.
BZAL alarm
occured
-BZAL is displayed on the
controller screen.
Cause
[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 pulse coder is
abnormal.
[Peripheral unit displacement]
-It is likely that an external force was
applied to the peripheral unit, thus
shifting its position relative to the
robot.
[Parameter]
-It is likely that the mastering data
was rewritten in such a way that
the robot origin was shifted.
-The voltage of the memory backup
battery is low.
-The pulse coder cable is defected.
- 35 -
3. TROUBLESHOOTING
Measure
-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 pulse coder is abnormal,
replace the motor or the pulse
coder.
-Correct the setting of the
peripheral unit position.
-Correct the taught program.
-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.
3. TROUBLESHOOTING
3.3
MAINTENANCE
B-82235EN/03
BACKLASH MEASUREMENT
Measurement method
1
2
3
Maintain the robot in a specified posture. (See Table 3.3(a) and
Fig. 3.3(b) to (d).)
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
+10kg
Firtst step
(Do not measure)
-10kg
+10kg
L1
-10kg
0kg
L2
0kg
+10kg
0kg
L3
-10kg
0kg
Second step
(B2 =L 1+ L2)
Third step
(B3=L 3+ L4)
L4
Fig. 3.3 (a)
Backlash measurement method
Backlash B is calculated using the following expression:
B＝
B2 + B3
2
- 36 -
3. TROUBLESHOOTING
MAINTENANCE
B-82235EN/03
Measurement posture and position
Table 3.3 (a) Backlash measurement posture (R-2000iB/165F, 210F, 125L, 175L, 165CF)
Posture
Measured axis
J1
J2
J3
J4
J5
J6
J1
Any angle
75°
0°
0°
0°
0°
J2
Any angle
0°
82°
0°
0°
-90°
165F, 210F 165CF
Any angle
40°
-90°
-90°
90°
0°
125L, 175L
165F, 210F, 165CF
(Any angle)
Any angle
(40°)
40°
(-90°)
-90°
(-90°)
-90°
(90°)
90°
(0°)
0°
NOTE
125L, 175L
(Any angle)
(40°)
(-90°)
(-90°)
(90°)
(0°)
NOTE
J5
Any angle
0°
0°
-90°
90°
0°
J6
Any angle
0°
0°
0°
-90°
0°
J3
J4
NOTE
When the R-2000iB/125L, 175L are set to a posture
(J3 at -90°) in which no gravity is applied to the J3
and J4 axes, the robot wrist interferes with the J1
base ground side. Therefore, backlashes for the
J3 and J4 axes cannot be measured, unless
sufficient operating space is provided in the lower
area ahead of the robot, for example, by installing
the robot on the pedestal.
- 37 -
3. TROUBLESHOOTING
MAINTENANCE
B-82235EN/03
<1> J1 axis measuring posture
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
<2> J2 axis measuring posture
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
<3> J3 axis measuring posture
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
Fig. 3.3 (b)
Backlash measurement posture (1/2) (R-2000iB/165F, 210F, 125L, 175L, 165CF)
- 38 -
MAINTENANCE
B-82235EN/03
3. TROUBLESHOOTING
<4> J4 axis measuring posture
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
<6> J6 axis measuring posture
<5> J5 axis measuring posture
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
Fig. 3.3 (b) Backlash measurement posture (2/2) (R-2000iB/165F, 210F, 125L, 175L, 165CF)
- 39 -
3. TROUBLESHOOTING
MAINTENANCE
Table 3.3 (b) Backlash measurement posture
(R-2000iB/165R, 200R, 100P)
Measured
Posture
axis
J1
J2
J3
J4
J5
J1
Any angle
15°
60°
0°
0°
J2
----------J3
Any angle
-30°
0°
-90°
0°
J4
Any angle
30°
0°
-90°
90°
J5
Any angle
65°
90°
-90°
90°
J6
Any angle
65°
90°
0°
-90°
B-82235EN/03
J6
90°
--90°
90°
90°
90°
NOTE
NOTE
For the R-2000iB/165R, 200R and 100P the
balancer force or gravity is always applied to the
J2-axis, so the backlash of the J2-axis cannot be
measured.
- 40 -
MAINTENANCE
B-82235EN/03
3. TROUBLESHOOTING
<1> J1 axis measuring posture
When measuring backlash, press the
dial indicator against the center of the
workpiece to be tested at right angles.
<2> J3 axis measuring posture
When measuring backlash, press the
dial indicator against the center of the
workpiece to be tested at right angles.
Fig. 3.3 (c) Backlash measurement posture (1/2) (R-2000iB/165R, 200R)
- 41 -
3. TROUBLESHOOTING
MAINTENANCE
B-82235EN/03
<3> J4 axis measuring posture
When measuring backlash,
press the dial indicator against
the center of the workpiece to
be tested at right angles.
<4> J5 axis measuring posture
<5> J6 axis measuring posture
When measuring backlash,
press the dial indicator against
the center of the workpiece to
be tested at right angles.
When measuring backlash,
press the dial indicator against
the center of the workpiece to
be tested at right angles.
Fig. 3.3 (c) Backlash measurement posture (2/2) (R-2000iB/165R, 200R)
- 42 -
MAINTENANCE
B-82235EN/03
3. TROUBLESHOOTING
<1> J1 axis measuring posture
When measuring backlash,
press the dial indicator against
the center of the workpiece to
be tested at right angles.
<2> J3 axis measuring posture
When measuring backlash,
press the dial indicator against
the center of the workpiece to
be tested at right angles.
Fig. 3.3 (d) Backlash measurement posture (1/2) (R-2000iB/100P)
- 43 -
3. TROUBLESHOOTING
MAINTENANCE
B-82235EN/03
<3> J4 axis measuring posture
When measuring backlash,
press the dial indicator against
the center of the workpiece to
be tested at right angles.
<4> J5 axis measuring posture
When measuring backlash,
press the dial indicator against
the center of the workpiece to
be tested at right angles.
<5> J6 axis measuring posture
When measuring backlash,
press the dial indicator against
the center of the workpiece to
be tested at right angles.
Fig. 3.3 (d) Backlash measurement posture (2/2) (R-2000iB//100P)
- 44 -
3. TROUBLESHOOTING
MAINTENANCE
B-82235EN/03
Permissible backlash values
Table 3.3 (c) Permissible backlash value（R-2000iB/165F）
Angle conversion
(arc-min)
Displacement
conversion (mm)
Distance between the
rotation center and dial
indicator (mm)
J1
J2
J3
J4
J5
J6
2.46
2.00
2.00
2.38
3.30
6.43
2.25
0.63
0.74
0.36
0.50
0.56
3149
1075
1280
519
519
301
Table 3.3 (d) Permissible backlash value（R-2000iB/210F）
J1
J2
J3
J4
J5
J6
Angle conversion
2.46
2.00
2.00
2.29
2.99
5.56
(arc-min)
Displacement
2.25
0.63
0.74
0.37
0.48
0.60
conversion (mm)
Distance between the
rotation center and dial 3178
1075
1280
548
548
370
indicator (mm)
Table 3.3 (e) Permissible backlash value（R-2000iB/165R）
J1
J2
J3
J4
J5
J6
Angle conversion
2.37
--2.00
2.30
3.06
6.41
(arc-min)
Displacement
2.35
--1.03
0.35
0.46
0.56
conversion (mm)
Distance between the
rotation center and dial 3402
--1768
519
519
301
indicator (mm)
Table 3.3 (f) Permissible backlash value（R-2000iB/200R）
J1
J2
J3
J4
J5
J6
Angle conversion
2.37
--2.00
2.28
2.86
4.91
(arc-min)
Displacement
2.29
--0.98
0.38
0.48
0.53
conversion (mm)
Distance between the
rotation center and dial 3328
--1682
572
572
370
indicator (mm)
Table 3.3 (g) Permissible backlash value（R-2000iB/100P）
J1
J2
J3
J4
J5
J6
Angle conversion
2.37
--2.00
2.28
2.99
5.49
(arc-min)
Displacement
2.83
--1.50
0.59
0.77
1.49
conversion (mm)
Distance between the
rotation center and dial 4101
--2575
885
885
935
indicator (mm)
- 45 -
3. TROUBLESHOOTING
MAINTENANCE
B-82235EN/03
Table 3.3 (h) Permissible backlash value（R-2000iB/125L）
J1
J2
J3
J4
J5
J6
Angle conversion
2.37
2.00
2.00
2.32
3.39
8.27
(arc-min)
Displacement
2.32
0.63
0.95
0.28
0.41
0.72
conversion (mm)
Distance between the
rotation center and dial 3368
1075
1635
412
412
299
indicator (mm)
Table 3.3 (i) Permissible backlash value（R-2000iB/175L）
J1
J2
J3
J4
J5
J6
Angle conversion
2.46
2.00
2.00
2.29
2.99
5.56
(arc-min)
Displacement
2.40
0.63
0.86
0.35
0.45
0.49
conversion (mm)
Distance between the
rotation center and dial 3349
1075
1480
519
519
301
indicator (mm)
Table 3.3 (j) Permissible backlash value（R-2000iB/165CF）
J1
J2
J3
J4
J5
J6
Angle conversion
2.40
2.00
2.00
2.14
3.28
7.28
(arc-min)
Displacement
1.33
0.32
0.52
0.32
0.49
0.62
conversion (mm)
Distance between the
rotation center and dial 1912
550
887
513
513
294
indicator (mm)
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 angle and displacement
conversions according to the table.
NOTE
For the R-2000iB/165R, 200R,100P the balancer
force or gravity is always applied to the J2-axis, so
the backlash of the J2-axis cannot be measured.
- 46 -
B-82235EN/03
4
MAINTENANCE
4. REPLACING PARTS
REPLACING PARTS
This section describes the replacement procedures for the major
components of the mechanical section. When replacing mechanical
components, be sure to follow the respective procedures. See Section
5 for how to replace the cables and limit switches.
- 47 -
4. REPLACING PARTS
4.1
MAINTENANCE
B-82235EN/03
NOTE FOR PART REPLACEMENT
Once motors, reducers, and gears are replaced, mastering becomes
necessary, Perform mastering according to Section 6 after any of
these components is replaced.
Be very careful when carrying and assembling the heavy components
listed below.
Table 4.1 Weight of the main parts
Weight
Component
(approximate)
165F,210F,165R,200R,100P, 25kg
125L, 175L
M1,M2,M3
165CF
30kg
Servo motors
165F,210F,165R,200R,100P, 15kg
M4,M5,M6
125L, 175L
165CF
10kg
165F,210F,165R,200R,100P, 91kg
125L, 175L
J1-axis
165CF
80kg
165F,210F,165R,200R,100P, 56kg
125L, 175L
J2-axis
165CF
70kg
Reducers
165F,165R,100P,125L
37kg
J3-axis
210F,200R,175L
56kg
165CF
50kg
165F,165R,125L
12kg
J4-axis
210F,200R,100P,175L
17kg
165CF
15kg
165F,210F,125L,175L
140kg
J2-axis arm
165R,200R,100P
150kg
165CF
100kg
165F,125L
105kg
Balancer
210F,175L
120kg
165R,200R,100P
300kg
165F,165R,125L
50kg
Wrist unit
210F,200R,100P,175L
80kg
165CF
55kg
165F
790kg
210F
845kg
165R
930kg
200R
960kg
J2-axis base to wrist unit
100P
990kg
125L
810kg
175L
865kg
165CF
710kg
- 48 -
Remarks
J1-axis motor and
the balancer are not
included.
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Weight
(approximate)
435kg
490kg
450kg
495kg
520kg
455kg
515kg
370kg
295kg
350kg
370kg
315kg
380kg
270kg
180kg
Component
J2-axis arm to wrist unit
J3-axis casing to wrist unit
165F
210F
165R
200R
100P
125L
175L
165CF
165F,165R
210F,200R
100P
125L
175L
165CF
Controller
Remarks
J2-axis reducer is
not included.
In case of reusing sealbolts for R-2000iB, observe following notes
strictly. (If possible, change them to new sealbolts)
Apply LOCTITE No. 242 when reusing sealbolts.
(However, seal tape needs to be wound around the seal bolts used
as a plug.)
Notice the following 3 notes.
(a) Remove excessive bits of sealant on the sealbolts.
(b) The length of application is 2d (d: diameter of the bolt)
from the tip of the bolt, and spread it evenly around it.
(c) Spread LOCTITE No.242 on the entire threaded portion and
rub the 2 bolts together in order to spread it to the bottom of
the groove.
LOCTITE No.242
Threaded portion
Fig. 4.1 Standard application of LOCTITE No. 242
- 49 -
4. REPLACING PARTS
4.2
MAINTENANCE
B-82235EN/03
REPLACING J1-AXIS MOTOR (M1) AND REDUCER
・Replacing J1-axis motor (M1)
(R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
Remove
1
2
3
4
5
6
7
Turn off the power.
Remove the pulse coder connector cover (2). (The cover turns
together with the bolts, possibly causing damage to the connector.
Hold the cover to prevent it from turning.)
Remove three connectors of the motor (1).
Remove three motor mounting bolts (4) and then remove the
washers (5).
Pull out the motor (1) from the 2 base vertically, while being
careful not to scratch the surface of the input gear (6) teeth.
Remove the bolt (10), washer (9), and O-ring (11) from the shaft
of the motor (1).
Pull off the input gear (6) with bearing (7), C ring (8) from the
shaft of the motor (1).
Assembling
1
2
3
4
5
6
7
8
Polish the flange surface of the motor (1) using an oil stone.
Mount the input gear (6) [with bearing (7), and C ring (8)] on the
shaft of the motor (1).
∗Before attaching the input gear (6) to the motor (1), attach
the bearing (7) and the C rings (8) to the input gear (6) by
using the jig (A290-7329-X921). (See Fig. 4.2 (a) Bearing
presser.)
Mount the bolt (10) and the washer (9) on the motor (1).
Place the new O-ring (11) in the specified position, and mount
the motor (1) on the J2-axis base vertically while being careful
not to damage the surface of the teeth of the input gear (6).
Attach the three motor mounting bolts (4) and washers (5).
Attach the three connectors to the motor (1).
Attach the pulse coder connector cover (2).
Perform mastering. (See the section 6 for mastering.)
- 50 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Bearing presser
Name
Specifications
Q’ty
1
2
3
4
5
6
7
8
MOTOR
COVER
BOLT
BOLT
WASHER
INPUT GEAR
BEARING
C RING
A06B-0041-B605#S042
A290-7324-X101
A6-BA-8X12
A6-BA-12X30
A97L-0001-0823#M12H
A97L-0218-0801#229
A97L-0001-0196#08Z000A
A6-CJR-40
1
1
1
3
3
1
1
1
9
WASHER
(INPUT GEAR is attached.)
1
10
11
BOLT
O RING
(INPUT GEAR is attached.)
JB-OR1A-G125
1
1
Loctite
LT242
Torque N-m
(kgf-m)
15.7(1.6)
Fig. 4.2 (a) Replacing J1-axis motor (M1) (R-2000iB/165F, 210F, 165R, 200R, 100P,125L,175L)
- 51 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
・Replacing J1-axis motor (M1) (R-2000iB/165CF)
Remove
1
2
3
4
5
6
7
Turn off the power.
Remove the pulse coder connector cover (2). (The cover turns
together with the bolts, possibly causing damage to the connector.
Hold the cover to prevent it from turning.)
Remove three connectors of the motor (1).
Remove four motor mounting bolts (4) and then remove the
washers (5).
Pull the motor (1) vertically out of the J1-aixs base while being
careful not to damage the surface of the gear teeth.
Remove the nut (8), washer (7), and O-ring (9) from the shaft of
the motor (1).
Remove the gear (6) from the shaft of the motor (1).
Assembling
1
2
3
4
5
6
7
8
Polish the flange surface of the motor (1) using an oil stone.
Attach the gear (6) to the shaft of the motor (1).
Attach the nut (8) and washer (7) to the motor (1).
Place the new O-ring (9) in the specified position , and mount the
motor (1) on the J1-axis base vertically while being careful not to
damage the surface of the gear teeth.
Attach the three motor mounting bolts (4) and washers (5).
Attach the three connectors to the motor (1).
Attach the pulse coder connector cover (2).
Perform mastering. (See the section 6 for mastering.)
- 52 -
Name
1
2
3
4
5
6
7
8
9
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
MOTOR
COVER
BOLT
BOLT
WASHER
J1 GEAR 1
WASHER
NUT
O RING
Specifications
Q’ty
A06B-0267-B605#S000
A290-7324-X101
A6-BA-8X12
A6-BA-12X30
A97L-0001-0823#M12H
A290-7321-X221
A97L-0001-0610#20
A6-N1-20X1.5S-M-NI
JB-OR1A-G125
1
1
1
4
4
1
1
1
1
Torque N-m
(kgf-m)
Loctite
LT242
118 (12)
Fig. 4.2 (b) Replacing J1-axis motor (M1) (R-2000iB/165CF)
- 53 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Replacing J1-axis reducer
(R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
WARNING
The special tools listed below are required to
replace the J1-axis reducer. Be sure to prepare
the psecial tools. If the robot is hung without using
the special tools, the robot can fall.
Remove
Tools to replace the J1-axis reducer
(R-2000iB/165F, 210F, 165R, 200R, 100P,125L,175L)
Name
Guide pin
Punch
Guide pin
Specification
A290-7324-X921
A290-7324-X922
A290-7324-X923
Q’ty
2
1
2
Tools to replace the J1-axis reducer
(R-2000iB/165F, 210F, 125L,175L)
Name
Hanging jig right
Hanging jig left
1
2
3
4
5
6
7
8
9
Specification
A290-7329-X922
A290-7329-X923
Q’ty
1
1
Remove loads such as the hand and workpiece from the wrist.
Remove the balancer according to Section 4.7 REPLACING
THE BALANCER.
(For R-2000iB/165F, 210F, 125L, 175L)
Ensure that the robot assumes the attitude shown in Fig. 4.2 (c).
(J2= -40°, J3= -30°)
(For the R-2000iB/165R, 200R, 100P)
For the posture, contact FANUC as needed.
Turn off the power. Remove the connection cable of the robot
controller.
Remove the J1-axis motor according to the previous item.
Remove the connector panel from the back of the J1 base, then
detach the connector.
Remove the J1 base cable clamp and the J2 base cable clamp,
then pull out the cable from the center pipe toward the J2 base.
(See section 5.3 REPLACING CABLE.)
Remove the bolt (5), then remove the plate (4).
Remove the bolt (8) and washer (7), then remove the stopper (6).
(For R-2000iB/165F, 210F, 125L, 175L)
According to Fig. 4.2 (c), install the hanging jigs
(A290-7329-X922, A290-7329-X923) onto the robot to enable
the robot to be hung. The hanging jig for the left side and the
hanging jig for the right side are not identical. Instead, the
installation directions of the hanging jigs are predetermined.
Install the hanging jigs so that the hole of each hanging jig is
positioned on the front side of the robot.
- 54 -
MAINTENANCE
B-82235EN/03
10
11
4. REPLACING PARTS
(For the R-2000iB/165R, 200R, 100P)
For the posture, contact FANUC as needed.
Remove the J2 base mounting bolt (1) and washer (2), and hang
the main robot unit for separation from the J1 unit. At this time,
be careful not to damage the oil seal (9). The J2-axis base and
J1-axis reducer are positioned with the spring pin (3). Be careful
when handing the robot.
Remove the reducer mounting bolt (10), washer (11), and O-ring
(13) and then remove the reducer (12) from the J1-axis base.
Assembling
1
Polish the mounting surface of the J1 base reducer with an
oilstone.
2 After attaching the new O-ring (13) to the reducer (12), mount the
reducer onto the J1 base by using the guide pin (A290-324-X921)
(See Fig.4.2(d)), Then, fasten the reducer with the reducer
mounting bolt (10) and washer (11). At this time, ensure that the
O-ring is not removed.
3 Apply the sealant in the form of beads to the shaft surface of the
reducer as Fig. 4.2 (g). See section 4.7.
4 Place the main robot unit on the J1 unit by using the guide pin
(A290-7324-X923). (See Fig.4.2(e) and (f).) Then, perform
positioning by striking the spring pin (3) with the punch
(A290-7324-X922), then perform fastening with the J2 base
mounting bolt (1) and washer (2). At this time, check that the oil
seal (9) is installed in position, and ensure that the lip is not turned
up when the robot is installed.
5 Install the plate (4) and stopper (6) in postiion.
6 Lay the cables neatly, and fasten the J1 base clamp and J2 base
clamp. See section 5.3 REPLACING CABLE.
7 Fasten the J1-axis motor as the previous item.
8 Attach the connector onto the connector panel on the back of the
J1 base, then attach the cable for connection between the control
unit and the robot.
9 Mount the balancer onto the robot according to Section 4.7.
10 Apply grease. (See section 2.3 REPLACING THE GREASE OF
THE DRIVE MECHANISM.)
CAUTION
If greasing is performed before the sealant hardens,
grease leakage can occur. Before performing
greasing, wait one hour or more after installation.
If grease overflows through the grease inlet, check
that the overflow of grease through the grease inlet
has stopped and the internal remaining pressure
has been eliminated, before inserting a plug into the
grease inlet.
11 Perform mastering (See section 6 MASTERING.)
- 55 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
NOTE)
The hanging jig for the left side and the hanging jig for
the right side are not identical.
Namely, the screw hole positions on the left hanging jig
are different from those on the right hanging jig.
So, note that the hanging jig for one side cannot be
installed on the other side.
Eyebolt (M20)
Position on the front side
of the robot.
Eyebolt (M20)
Hanging jig (A290-7329-X992)
(3pcs)
Hanging jig (A290-7329-X923)
(3pcs)
Fig. 4.2 (c) J1-axis reducer replacing posture (R-2000iB/165F, 210F, 125L, 175L)
- 56 -
Name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
BOLT
WASHER
SPRING
PIN
PLATE
BOLT
STOPPER
WASHER
BOLT
OIL SEAL
BOLT
WASHER
REDUCER
O RING
PIPE
BOLT
WASHER
O RING
Specifications
Q’ty
A6-BA-16X50
A97L-0001-0823#M16H
12
12
A6-PS-10X30
1
A290-7329-X321
A6-BA-6X10
A290-7329-X215
A97L-0001-0823#M12H
A6-BA-12X35
A98L-0040-0047#13016014
A6-BA-12X85
A97L-0001-0823#M12H
A97L-0218-0382#320CA229
A98L-0040-0041#281
A290-7329-X231
A6-BA-6X16
A97L-0001-0823#M6H
JB-OR1A-G125
1
2
1
4
4
1
16
16
1
1
1
4
4
1
LT262
Torque N-m
(kgf-m)
318(32.5)
LT262
128(13.1)
Loctite
Fig. 4.2 (d) Replacing J1-axis reducer (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 57 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Guide pin
Fig. 4.2 (e) Guide pin at replacing J1-axis reducer
Insert two guide pins (A290-7324-X921) into
any diagonal pair on this circumference.
Insert two guide pins (A290-7324-X921) into
any diagonal pair on this circumference.
Insert two guide pins
(A290-7324-X923) into any
diagonal pair on this
circumference.
Insert two guide pins (A290-7324-X923) into
any diagonal pair on this circumference.
J1-axis base side
J1-axis reducer
Fig. 4.2 (f)
Insert the spring pin into
this reamer bore.
J2-axis base side
Insertion positions of the guide pins and spring pin
- 58 -
B-82235EN/03
MAINTENANCE
4. REPLACING PARTS
Note) Take special care and check that there are no gaps of sealant around part A.
LOCKTITE No.518 APPLYING AREA
Fig. 4.2 (g) Applying sealant to the J1-axis reducer
- 59 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Replacing J1-axis reducer (R-2000iB/165CF)
Remove
1
2
3
4
5
6
7
8
9
10
11
Remove loads such as the hand and workpiece from the wrist.
Place the robot in the posture for transportation.
Turn off the power.
Remove the J1-axis motor as described above
Remove the connection cable between the controller and the
robot, remove the J1-axis base rear connector panel, and remove
the connector.
Remove the cable clamp in the J1-axis base, the connector panel
on the side of J1-axis base, and the cable clamp of the J1-axis
base so that the cable is released from the J1-axis unit when the
robot body is hoisted.
Remove the J1-axis base mounting bolt (1) and washer (2) and
hoist the robot body to separate it from the J1-axis unit while
being careful not to damage the cable.
Remove the cable mounting bolt (3) and washer (4) and then
remove the table (5).
Remove the bearing (7) and center gear (8).
Remove the reducer mounting bolt (9), washer (10), and O-ring
(11) and then remove the reducer (12) from the J1-axis base.
Remove the pipe mounting bolt (16), washer (15), and O-ring
(13) and then remove the pipe (14) from the reducer (12).
Assembling
1
2
3
4
5
6
7
8
9
10
11
Place the new O-ring (13) in the specified position, attach the
pipe (14) to the reducer (12), and secure the pipe with the pipe
mounting bolt (16) and washer (15).
Apply sealant (see Section 4.8, "SEALANT APPLICATION"
and Fig. 4.2 (i)).
Place the new O-ring (11) in the specified position, mount the
reducer (12) on the J1-axis base, and secure the reducer with the
reducer mounting bolt (9) and washer (10).
Install the center gear (8) and bearing (7).
Install the table (5) and secure the table with the table installation
bolt (3) and washer (4). At this time, make sure that the oil seal
(6) is attached in the specified position.
Place the robot body on the J1-axis unit while being careful not
to damage the cable and secure the robot with the J1-axis base
mounting bolt (1) and washer (2).
Perform forming of the cable and secure the clamp in the J1-axis
base, the connector panel on the side of J1-axis base, and the
J1-axis base clamp.
Attach the connector to the connector panel on the rear of the
J1-axis base and fix it to the robot. Then, connect the
connection cable between controller and the robot.
Secure the motor as described above.
Apply grease. (See section 2.3 REPLACING THE GREASE OF
THE DRIVE MECHANISM.)
Perform mastering (See section 6 MASTERING)
- 60 -
Name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
BOLT
WASHER
BOLT
WASHER
TABLE
OIL SEAL
BEARING
J1 GEAR 2
BOLT
WASHER
O RING
RV
REDUCER
O RING
PIPE
WASHER
BOLT
Specifications
Q’ty
A6-BA-12X75
A97L-0001-0823#M12H
A6-BA-12X85
A97L-0001-0823#M12H
A290-7321-X202
A98L-0040-0047#12515514
A97L-0001-0192#3000000
A290-7321-X222
A6-BA-18X145
A97L-0001-0823#M18H
A98L-0040-0041#281
16
16
15
15
1
1
1
1
9
9
1
A97L-0218-0237#320C-35
1
JB-OR1A-G135
A290-7321-X231
A97L-0001-0823#M6H
A6-BA-6X16
1
1
4
4
Torque N-m
(kgf-m)
Loctite
LT262
128.4 (13.1)
LT262
441 (45)
Fig. 4.2 (h) Repasing J1-axis reducer (R-2000iB/165CF)
- 61 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
CAUTION
注意
Apply Loctite 518 to the parts indicated by bold lines in beady
太線部にシール剤(ロックタイト518)をビード状（幅2mm以上)に切れ
form (with a width of 2 mm or more) without interruption.
目なく塗布してください。
Fig. 4.2 (i) Replacing J1-axis reducer (R-2000iB/165CF)
- 62 -
MAINTENANCE
B-82235EN/03
4.3
4. REPLACING PARTS
REPLACING J2-AXIS MOTOR (M2) AND REDUCER
・Replacing the J2-axis motor (M2)
(R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
Remove
1
Place the motor in the posture shown in Fig. 4.3(d) and (e) and
hoist it using a sling.
WARNING
When its J2-axis motor is removed, its weight, in
conjunction with the righting moment of its balancer,
can cause the J2-axis arm to move extensively
unless the robot is in a specified attitude, resulting in
a very dangerous situation. (To be specific, the arm
may drop in the gravity direction or rise up
depending on the status of the load and the attitude
of the robot.) Fasten the arm so firmly that it will not
move.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification
can be used to fasten the J2-axis arm. Before
starting to replace the motor, install the stopper and
jog-feed the arm to get it sufficiently close to the
stopper; however, a minimum constraint angle of
this option is 15° so it is impossible to
simultaneously keep the arm from dropping and
rising. If it is unknown how the arm will behave
when the J2-axis motor is removed, use a crane
and the stopper to keep the arm, respectively, from
dropping and rising.
2
3
4
5
6
7
Turn off the power.
(In case of R-2000iB/165F, 210F, 165R, 200R, 125L, 175L)
Remove the pulse coder connector cover (2). (The cover turns
together with the bolts, possibly causing damage to the connector.
Hold the cover to prevent it from turning.)
(In case of R-2000iB/100P)
Remove the fan.
(See section 4.6 REPLACING THE BALANCER.)
Remove the three connectors from the J2-axis motor (1).
Remove the four motor mounting seal bolts (4) and washers (5).
Pull out the J2-axis motor (1) horizontally, while being careful not
to damage the surface of the gear teeth.
Remove the bolt (8), washer (7), and O-ring (9) and then remove
the input gear (6).
- 63 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Assembling
1
2
3
4
5
6
7
8
Polish the flange surface of the J2-axis motor (1) using an oil
stone.
Mount and fasten the input gear (6) with bolt (8) and washer (7).
Place the new O-ring (9) in the specified position, and mount the
J2-axis motor (1) horizontally while being careful not to damage
the surface of the gear teeth.
Attach the four motor mounting seal bolts (4) and washers (5).
Attach the three connectors to the J2-axis motor (1).
(In case of R-2000iB/165F, 210F, 165R, 200R, 125L, 175L)
Attach the pulse coder connector cover (2).
(In case of R-2000iB/100P)
Remove the fan.
(See section 4.6 REPLACING THE BALANCER.)
Apply grease.(See section 2.3 REPLACING THE GREASE OF
THE DRIVE MECHANISM.)
Perform mastering.(See section 6 MASTERING.)
- 64 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
For the R-2000iB/165R, 200R, 100P note
that the motor connector is attached to the
side of the motor. The replacement
procedure is the same as that for the
R-2000iB/165F or other models.
Name
1
2
3
4
5
MOTOR
COVER
BOLT
BOLT
WASHER
6
INPUT GEAR
7
8
9
SEAL WASHER
BOLT (NOTE)
O RING
Specifications
A06B-0041-B605#S042
A290-7324-X101
A6-BA-8X12
A6-BA-12X30
A97L-0001-0823#M12H
165F
A97L-0218-0802#236
125L
210F
100P
A97L-0218-0802#290
175L
165R
A97L-0218-0802#252
200R
A97L-0218-0802#303
(INPUT GEAR is attached.)
(INPUT GEAR is attached.)
JB-OR1A-G125
Q’ty
Loctite
Torque N-m
(kgf-m)
1
1
1
4
4
1
1
1
1
LT242
15.7 (1.6)
NOTE The bolt specification differs between the robots shipped in November 2006 and later and those shipped in
October 2006 and earlier because the shape of the input gear was changed.
Note that the M6 × 65 bolt is used for the robots shipped in October 2006 and earlier and the M6 × 70 bolt is
used for the robots shipped in November 2006 and later.
Fig. 4.3 (a) Replacing the motor (M2) for J2-axis (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 65 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Replacing the J2-axis motor (R-2000iB/165CF)
Remove
1
2
3
4
5
6
Place the robot in the posture shown in Fig. 4.3 (h) and hoist it
using a sling.
Turn off the power
Remove the three connectors of the motor (1).
Remove the four motor mounting seal bolts (2) and washers (3).
Pull out the motor (1) horizontally while being careful not to
damage the surface of the gear teeth.
Remove the nut (7) and washer (6) and then remove the input
gear (5), draw bolt (4), and O-ring (8).
Assembling
1
2
3
4
5
6
7
8
Polish the flange surface of the motor (1) using an oil stone.
Attach the draw bolt (4).
Attach the input gear (5) and secure it with the washer (6) and
nut (7).
Place the new O-ring (8) in the specified position, and mount the
motor (1) horizontally while being careful not to damage the
surface of the gear teeth.
Attach the four motor mounting seal bolts (2) and washers (3).
Attach the three connectors to the motor (1).
Apply grease. (See section 2.3 REPLACING THE GREASE OF
THE DRIVE MECHANISM)
Perform mastering (See section 6 MASTERING)
- 66 -
1
2
3
4
5
6
7
8
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Name
Specifications
Q’ty
MOTOR
BOLT
WASHER
DRAW BOLT
INPUT GEAR
WASHER
NUT
O RING
A06B-0267-B605#S000
A97L-0118-0706#M12X30
A97L-0001-0823#M12H
Included in A97L-0218-0245#210.
A97L-0218-0245#210
Included in A97L-0218-0245#210.
Included in A97L-0218-0245#210.
JB-OR1A-G125
1
4
4
1
1
1
1
1
Torque N-m
(kgf-m)
Loctite
LT242
118 (12)
LT242
26.5 (2.7)
Fig. 4.3 (b) Replacing the J2-axis motor (M2) (R-2000iB/165CF)
Replacing J2-axis reducer
(R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
・Remove
Common tool for replacing the J2-axis reducer
Name
Guide pin
1
2
Specifications
A290-7324-X921
Q’ty
2
Place the arm in the posture shown in Fig. 4.3(d) and (e).
Turn off the power
- 67 -
4. REPLACING PARTS
MAINTENANCE
3
4
5
6
B-82235EN/03
Detach all of the cables connected to the J3 through J6-axis
motors and option cables, and pull out the cables to the outside of
the J2 base.
Remove the balancer (1) according to section 4.7 REPLACING
THE BALANCER.
Hoist the arm using a sling as Fig.4.3(d) and (e).
Remove the J2-axis motor (2) according to the procedure
described in the previous item.
WARNING
If the balancer is left installed on the robot when the
J2-axis motor is removed, the weight of the robot, in
conjunction with the righting moment of its balancer,
can cause the J2-axis arm to move extensively,
resulting in a very dangerous situation. Before
starting to remove the J2-axis motor, be sure to
remove the balancer and sling the arm, using a
crane.
7
8
Remove the J2 arm mounitng bolts (4) and washers (5), then
remove the J2 arm by using a guide pin as shown in Fig.4.3(d).
At this time, apply a sufficient tension to the sring. Then,
remove the O-ring (6).
Remove the reducer mounting bolt (7) and washer (8), remove
the reducer (9) with guide pin, and remove the O-ring (10).
Assembling
1
2
3
4
5
6
7
8
Place the new O-ring (10) in the specified position and install the
new reducer (9) with the bolt (7) and washer (8) via the guide pins
as shown in Fig. 4.3 (f).
Place the new O-ring (6) in the groove of the reducer. When it is
difficult to fix the O-ring, apply a small amount of grease and then
attach the O-ring to the groove.
By using a guide pin, fasten the J2 arm (4) to the reducer (9) with
the bolts (4) and washers (5). At this time, be sure that the O-ring
(6) is not removed.
Mount the J2-axis motor (2) according to the procedure described
earlier.
Mount the balancer (1) according to section 4.7 REPLACING
THE BALANCER.
Attach the cables for connection to the J3 through J6-axis motors
and the option cables.
Apply grease. (See section 2.3 REPLACING TH E GREASE OF
THE DRIVE MECHANISM.)
Perform mastering.(See section 6 MASTERING.)
- 68 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
J2-axis arm
Name
1
BALANCER
ASSY
2
3
4
5
6
7
8
MOTOR
O RING
BOLT
WASHER
O RING
BOLT
WASHER
9
REDUCER
10
O RING
Specifications
Q’ty
165F
A290-7329-V301
125L
210F
A290-7329-V302
175L
165R
A290-7324-V311
200R
100P
A06B-0041-B605#S042
JB-OR1A-G125
A6-BA-12X50
A97L-0001-0823#M12H
JB-OR1A-G190
A6-BA-12X60
A97L-0001-0823#M12H
165F
A97L-0218-0383#450N-236
125L
210F
A97L-0218-0383#450N-290
100P
175L
165R
A97L-0218-0383#450N-252
200R
A97L-0218-0383#450N-313
JB-OR1A-G280
Loctite
Torque N-m
(kgf-m)
1
1
1
30
30
1
24
24
LT262
128 (13.1)
LT262
128 (13.1)
1
1
Fig. 4.3 (c) Replacing J2-axis reducer (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 69 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Hang the J3-axis reducer in a sling (one sling)
Use the M10 threaded holes and the eye bolts
(two slings)
Fig. 4.3 (d) J2-axis motor and reducer replacing posture (R-2000iB/165F, 210F, 125L, 175L)
Hang the J3-axis reducer in a sling (one sling)
Use the M10 threaded holes and the eye bolts
(two slings)
Fig. 4.3 (e) Stud bolts at replacing J2-axis reducer (R-2000iB/165R, 200R, 100P)
- 70 -
MAINTENANCE
B-82235EN/03
4. REPLACING PARTS
J2-axis reducer
Guide pin (M12)
Guide pin (M12)
J2-axis
arm
Fig. 4.3 (f) Guide pins for replacement of the J2-axis reducer
(R-2000iB/165F,210F,165R,200R,100P, 125L, 175L)
Replacing J2-axis reducer (R-2000iB/165CF)
Common tool for replacing the J2-axis reducer
(R-2000iB/165CF)
Name
Specifications
Q’ty
Guide pin
A290-7324-X921
1
Guide pin
A290-7324-X923
1
Remove
1
2
3
4
5
Set the robot in the posture shown in Fig. 4.3 (h) and hoist it
using a sling.
Turn off the power.
Remove the J2-axis arm mounting bolts (3) and (5) and the
washers (4) and (6) and then remove the J2-axis arm (7) via the
guide pins as shown in Fig. 4.3 (i). At this time, apply a
sufficient tension to the sling.
Remove the motor (1) as described above.
Remove the reducer mounting bolt (8) and the washer (9),
remove the reducer (10) via the guide pins as shown in Fig. 4.3
(i), and remove the O-ring (11).
Assembling
1
Place the new O-ring (11) in the specified position and install the
new reducer (10) with the bolt (8) and washer (9) via the guide
pins as shown in Fig. 4.3 (g).
- 71 -
4. REPLACING PARTS
MAINTENANCE
2
3
4
B-82235EN/03
Fix the motor (1) as described above.
Apply sealant to the reducer (see Section 4.8, "SEALANT
APPLICATION").
Attach the new O-ring (13) and ring (12) to the J2-axis arm.
CAUTION
Do not apply grease to the O-ring (13).
Otherwise, hardening of sealant is prevented,
causing a grease leak. When it is difficult to fix
the O-ring, apply a small amount of sealant to the
O-ring and then attach it to the O-ring groove of the
J2-axis arm.
5
Fix the J2-axis arm to the reducer (10) via the guide pins with
J2-axis arm mounting bolts (3) and (5) and washers (4) and (6).
At this time, make sure that the O-ring (13) and ring (12) are
placed in the specified positions.
CAUTION
The J2-axis arm needs to be intimately attached in
one operation so that the seal surface that was
once brought into contact with the corresponding
member does not separate from it. If the seal
surface that was once brought into contact with the
corresponding member separates from it, the
O-ring may fall off. When the seal surface
incorrectly separates from it, check the state of
sealant on the seal surface and the attachment of
the O-ring again and then perform reassembly.
6
7
Apply grease. (See section 2.3 REPLACING THE GREASE OF
THE DRIVE MECHANISM)
Perform mastering (See section 6 MASTERING)
- 72 -
1
2
3
4
5
6
7
8
9
10
11
12
13
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Name
Specifications
MOTOR
O RING
BOLT
WASHER
BOLT
WASHER
J2 ARM
BOLT
WASHER
RV REDUCER
O RING
RING
O RING
A06B-0267-B605#S000
JB-OR1A-G125
A6-BA-16X55
A97L-0001-0823#M16H
A6-BA-12X45
A97L-0001-0823#M12H
A290-7321-X314
A6-BA-12X55
A97L-0001-0823#M12H
A97L-0218-0238#450E-210
JB-OR1A-G300
A290-7321-X316
A98L-0001-0347#S265
Q’ty
1
1
6
6
21
21
1
24
24
1
1
1
1
Loctite
LT262
318.5 (32.5)
LT262
128.4 (13.1)
LT262
128.4 (13.1)
図 4.3 (g) Replacing J2-axis recuder (R-2000iB/165CF)
- 73 -
Torque N-m
(kgf-m)
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Fig. 4.3 (h) Posture during replacement of the J2-axis motor (M2) and the reducer (R-2000iB/165CF)
J2-axis arm
Guide pin (M12)
Guide pin (M16)
J2-axis reducer
Fig. 4.3 (i) Using of guide pin (R-2000iB/165CF)
- 74 -
B-82235EN/03
MAINTENANCE
4. REPLACING PARTS
CAUTION
Apply sealant (Loctite 518) to the areas indicated by
the bold line in the above figure.
Fig. 4.3 (j) Replacing J2-axis reducer (R-2000iB/165CF)
- 75 -
4. REPLACING PARTS
4.4
MAINTENANCE
B-82235EN/03
REPLACING J3-AXIS MOTOR (M3) AND REDUCER
・Replacing J3-axis motor (M3)
(R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
Remove
1
Ensure that the robot assumes the attitude shown in Fig. 4.4 (d)
and (e), and hang the robot with a sling.
CAUTION
If the J3-axis arm is not slung in a specified manner
when the J3-axis motor is removed, the arm may
drop, resulting in a very dangerous situation. If it is
impossible to sling the J3-axis arm in a specified
manner, fasten it so that it will not move. <Axis
constraint by the operation range modification
option> An optional stopper for operation range
modification can be used to fasten the J3-axis arm.
Before starting to remove the motor, install the
stopper in the dropping direction, and jog-feed the
arm to get it sufficiently close to the stopper.
2
3
4
5
Turn off the power supply.
In case of R-2000iB/100P, remove the fan.
Detach the three connectors from the J3-axis motor (1).
Remove the four motor mounting seal bolts (2) and washers (3).
NOTE
To remove and install the J3-axis motor, an M12
T-shaped hexagonal wrench not shorter than 250
mm is require.
6
7
Pull out the J3-axis motor (1) horizontally, while being careful not
to damage the surface of the gear teeth.
Remove the bolt (6) and washer (5), then dismount the input gear
(4).
Assembling
1
2
3
4
5
6
Polish the flange surface of the J3-axis motor (1) using an oil
stone.
Mount and fasten the input gear (4) with bolt (5) and washer (6).
Place the new O-ring (7) in the specified position, and mount the
J3-axis motor (1) horizontally while being careful not to damage
the surface of the gear teeth.
Attach the four motor mounting seal bolts (2) and washers (3).
Attach the three cable connectors to the J3-axis motor (1).
In case of R-2000iB/100P, mount the fan. (See Section 4.6
REPLACING THE BALANCER.)
- 76 -
7
8
Name
1
2
3
MOTOR
BOLT
WASHER
4
INPUT GEAR
5
6
7
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
SEAL
WASHER
BOLT(NOTE)
O RING
Apply grease. (See section 2.3 REPLACING TH E GREASE OF
THE DRIVE MECHANISM.)
Perform mastering. (See section 6 MASTERING.)
Specifications
Q’ty
A06B-0041-B605#S042
A6-BA-12X30
A97L-0001-0823#M12H
165F
165R
A97L-0218-0803#235
100P
125L
210F
200R
A97L-0218-0802#270
175L
1
4
4
(INPUT GEAR is attached.)
1
(INPUT GEAR is attached.)
JB-OR1A-G125
1
1
Loctite
Torque N-m
(kgf-m)
1
LT242
15.7 (1.6)
*1 The bolt specification differs between the robots shipped in November 2006 and later and those shipped in October
2006 and earlier because the shape of the input gear was changed.
Note that the M6 × 65 bolt is used for the robots shipped in October 2006 and earlier and the M6 × 70 bolt is used
for the robots shipped in November 2006 and later.
Fig. 4.4 (a) Replacing J3-axis motor (M3) (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 77 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Replacing J3-axis motor (M3) (R-2000iB/165CF)
Remove
1
2
3
4
5
6
Ensure that the robot assumes the attitude shown in Fig. (h).
Turn off the power supply.
Remove the three connectors of the motor (1).
Remove the four motor mounting seal bolts (2) and washers (3).
Pull out the motor (1) horizontally while being careful not to
damage the surface of the gear teeth.
Remove the nuts (7) and washers (6) and then remove the input
gear (5), draw bolt (4), and O-ring (8).
Assembling
1
2
3
4
5
6
7
8
Polish the flange surface of the motor (1) using an oil stone.
Attach the draw bolt (4).
Attach the input gear (5) and secure it with the washer (6) and
nut (7).
After attaching the new O-ring (8), mount the motor (1)
horizontally while being careful not to damage the surface of the
gear teeth.
Attach the four motor mounting seal bolts (2) and washers (3).
Attach the three connectors to the motor (1).
Apply grease (see Section 2.3, “REPLACING THE GREASE
OF THE DRIVE MECHANISM”.
Perform mastering (See Chapter 6, "MASTERING").
NOTE
For the attachment of the J3-aixs motor (1), an
M12T type hexagon wrench with a length of 370
mm or more is required.
- 78 -
1
2
3
4
5
6
7
8
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Name
Specifications
MOTOR
BOLT
WASHER
DRAW BOLT
INPUT GEAR
WASHER
NUT
O RING
A06B-0267-B605#S000
A97L-0118-0706#M12X30
A97L-0001-0823#M12H
Included in A97L-0218-0227#190.
A97L-0218-0227#190
Included in A97L-0218-0227#190.
Included in A97L-0218-0227#190.
JB-OR1A-G125
Q’ty
1
4
4
1
1
1
1
1
Torque N-m
(kgf-m)
Loctite
LT242
118 (12)
LT242
26.5 (2.7)
Fig. 4.4 (b) Replacing the J2-axis motor (M3) (R-2000iB/165CF)
- 79 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
・Replacing the J3-axis reducer
(R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
Remove
Common tool for replacing the J3-axis reducer
Name
Specifications
Q’ty
Guide pin
A290-7324-X921
2
1
Place the reducer in the location of Fig.4.4(d) and (e), and hoist it
using a sling.
WARNING
If the J3-axis arm is not slung in a specified manner
when the J3-axis motor is removed, the arm may
drop. resulting in a very dangerous situation.
If it is impossible to sling the J3-axis arm in a
specified manner, fasten it so that it will not move.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification
can be used to fasten theJ3-axis arm. Before
starting to remove the motor, install the stopper in
the dropping direction, and jog-feed the J3-axis arm
to get it sufficiently close to the stopper.
2
3
4
5
6
7
Switch off the power.
In case of 100P, remove the fan of J3 motor before removing the
cable. (See Section 4.6 REPLACING THE BALANCER.)
Detach the cables leading to the J3 to J6-axis motors, and all
option cables, then pull out them from the J2 arm.
Remove the J3-axis motor (1) and O-ring (2) as described above.
Remove the J2 arm mounting bolts (3) and washers (4), then
remove the J3-axis unit by using a guide pin as shown in
Fig.4.4(f). At this time, apply a sufficient tension to the sling.
Remove the reducer mounting bolt (5) and washer (6), then
dismount the reducer (8) with using the guide pin.(See Fig.4.4(f).)
NOTE
When installing the J3 axis reducer, attach an M12
hexagonal socket (with a tip not shorter than 70
mm) to a torque wrench, and tighten the bolt.
Assembling
1
2
3
Place the new O-ring (9) in the specified position and install the
new reducer (8) with the bolt (5) and washer (6) via the guide pins
as shown in Fig. 4.4 (f).
Place the new O-ring (7) in the groove of the reducer. When it is
difficult to fix the O-ring, apply a small amount of grease and then
attach the O-ring to the groove.
Fix J3-axis unit to the J2-axis arm with the bolt (3) and washer (4)
via the guide pins (see Fig. 4.4 (f)).
- 80 -
MAINTENANCE
B-82235EN/03
4
5
6
7
4. REPLACING PARTS
Attach the J3-axis motor (1) and the new O-ring (2) as described
above.
Attach the cables and option cables to be connected to the J3- to
J6-axis motors.
Supply grease (see Section 2.3, “REPLACING THE GREASE OF
THE DRIVE MECHANISM”).
Perform mastering (See Chapter 6, “MASTERING”).
- 81 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
J2-axis arm
[R-2000iB/165F,165R,100P, 125L]
Name
1
2
3
4
5
6
7
8
9
MOTOR
O RING
BOLT
WASHER
BOLT
WASHER
O RING
REDUCER
O RING
Specifications
A06B-0041-B605#S042
JB-OR1A-G125
A6-BA-12X50
A97L-0001-0823#M12H
A6-BA-12X65
A97L-0001-0823#M12H
JB-OR1A-G170
A97L-0218-0384#320N-235
A98L-0040-0041#272
Q’ty
1
1
24
24
18
18
1
1
1
Loctite
Torque N-m
(kgf-m)
LT262
128 (13.1)
LT262
128 (13.1)
[R-2000iB/210F,200R, 175L]
Name
1
2
3
4
5
6
7
8
9
MOTOR
O RING
BOLT
WASHER
BOLT
WASHER
O RING
REDUCER
O RING
Specifications
Q’ty
A06B-0041-B605#S042
JB-OR1A-G125
A6-BA-12X50
A97L-0001-0823#M12H
A6-BA-12X60
A97L-0001-0823#M12H
JB-OR1A-G190
A97L-0218-0383#450N-270
JB-OR1A-G280
1
1
30
30
24
24
1
1
1
Loctite
Torque N-m
(kgf-m)
LT262
128 (13.1)
LT262
128 (13.1)
Fig. 4.4 (c) Replacing J3-axis reducer (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 82 -
B-82235EN/03
MAINTENANCE
4. REPLACING PARTS
Use the M10 threaded holes and the eye bolts
(two slings)
Fig. 4.4 (d) J3-axis reducer replacing posture (R-2000iB/165F, 210F, 125L, 175L)
- 83 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Use the M10 threaded holes and the eye bolts
(two slings)
図 4.4 (e) J3-axis reducer replacing posture (R-2000iB/165R, 200R, 100P)
Guide pin (M12)
Guide pin (M12)
J3-axis reducer
J2-axis arm
Fig. 4.4 (f)
Using of guide pin
- 84 -
MAINTENANCE
B-82235EN/03
4. REPLACING PARTS
・Replacing the J3-axis reducer (R-2000iB/165CF)
Remove
Common tool for replacing the J3-axis reducer
(R-2000iB/165CF)
Name
Specifications
Q’ty
Guide pin
A290-7324-X921
1
Guide pin
A290-7324-X923
1
1
Place the reducer in the location of Fig.4.4(h), and hoist it using a
sling.
WARNING
If the J3-axis arm is not slung in a specified manner
when the J3-axis motor is removed, the arm may
drop. resulting in a very dangerous situation.
If it is impossible to sling the J3-axis arm in a
specified manner, fasten it so that it will not move.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification
can be used to fasten theJ3-axis arm. Before
starting to remove the motor, install the stopper in
the dropping direction, and jog-feed the J3-axis arm
to get it sufficiently close to the stopper.
2
3
4
5
6
Switch off the power.
Detach the cables leading to the J3 to J6-axis motors, and all
option cables, then pull out them from the J2 arm.
Remove the J3-axis motor (1) and O-ring (2) as described above.
Remove the J2 arm mounting bolts (3), (5) and washers (4), (6),
then remove the J3-axis unit by using a guide pin as shown in
Fig.4.4(i). At this time, apply a sufficient tension to the sling. (See
Fig.4.4(h).)
Remove the reducer mounting bolt (10) and washer (11), then
dismount the reducer (7), (12) with using the guide pin.
NOTE
When installing the J3 axis reducer, attach an M12
hexagonal socket (with a tip not shorter than 70
mm) to a torque wrench, and tighten the bolt.
Assembling
1
2
3
By using a guide pin as shown in Fig.4.4(i), install a new reducer
(9) with the bolt (10) and washer (11). At this time, check that
the O-ring (12) is installed in position. (See Fig. 4.4 (h))
Apply sealant to the reduce (see Section 4.8, “SEALANT
APPLICATION.”
Attach the new O-ring (7) and ring (8) to the J2-axis arm (13).
- 85 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
CAUTIOIN
Do not apply grease to the O-ring (7). Otherwise,
hardening of sealant is prevented, causing a grease
leak. When it is difficult to fix the O-ring, apply a
small amount of sealant to the O-ring and then
attach it to the O-ring groove of the J2-axis arm.
4
Fix the J3-axis unit to the J2-axis arm (13) with the bolts
(3) and (5) and the washers (4) and (6) via the guide pins.
At this time, make sure that the O-ring (7) and ring (8) are
placed in the specified positions.
CAUTIOIN
The J3-axis arm needs to be intimately attached in
one operation so that the seal surface that was once
brought into contact with the corresponding member
does not separate from it. If the seal surface that
was once brought into contact with the
corresponding member separates from it, the O-ring
may fall off. When the seal surface incorrectly
separates from it, check the state of sealant on the
seal surface and the attachment of the O-ring again
and then perform reassembly.
5
6
7
8
Attach the J3-axis motor (1) and new O-ring (2) in as described
above.
Attach the cables and option cables to be connected to the J3- to
J6-axis motors.
Supply grease (see Section 2.3, “REPLACING THE GREASE
OF THE DRIVE MECHANISM”).
Perform mastering (See Chapter 6, “MASTERING”).
- 86 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
J3-axis reducer
NOTE
After degreasing the seal surface, apply
sealant (Loctite 518) to the diagonally
shaded area in the left figure.
In particular, apply sealant to the A areas
without interruption.
1
2
3
4
5
6
7
8
9
10
11
12
13
Name
Specifications
Q’ty
MOTOR
O RING
BOLT
WASHER
BOLT
WASHER
O RING
RING
REDUCER
BOLT
WASHER
O RING
J2-axis ARM
A06B-0267-B605#S000
JB-OR1A-G125
A6-BA-10X35
A97L-0001-0823#M10H
A6-BA-16X45
A97L-0001-0823#M16H
A98L-0001-0347#S240
A290-7321-X317
A97L-0218-0239#320E-190
A6-BA-12X50
A97L-0001-0823#M12H
JB-OR1A-G270
A290-7321-X314
1
1
18
18
6
6
1
1
1
16
16
1
1
Loctite
LT262
73.5 (7.5)
LT262
318 (32.5)
LT262
128 (13.1)
図 4.4 (g) Replacing J3-axis reducer (R-2000iB/165CF)
- 87 -
Torque N-m
(kgf-m)
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Fig. 4.4 (h) J3-axis reducer replacing pasture (R-2000iB/165CF)
Guide
pin (M16)
Stud bolt
(M16)
Guide
pin(M12)
(M12)
Stud bolt
J3-axis unit
J3-axis reducer
Fig. 4.4 (i) Using of guide pin (R-2000iB/165CF)
- 88 -
MAINTENANCE
B-82235EN/03
4.5
4. REPLACING PARTS
REPLACING THE WRIST AXIS MOTORS (M4, M5, AND
M6), WRIST UNIT, AND J4 AXIS REDUCER
・Replacing the wrist axis motors (M4, M5, and M6)
(R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
Remove
1
2
3
4
5
6
Place the wrist in a posture in which no load is applied to the
wrist axis.
Turn off the power.
Detach the three cable connectors from the motor (1).
Remove the three motor mounting bolts (2) and washers (3).
Pull out the motor (1), while being careful not to damage the
surface of the gear teeth.
Remove the nut (6), washer (5), and dismount the gear (6).
Assembling
1
2
3
4
5
6
7
Polish the flange surface of the motor (1) using an oil stone.
Mount the gear (4) to the motor shaft with washer (5) and nut (6).
Place the new O-ring (7) in the specified position, and mount the
motor (1) while being careful not to damage the surface of the
gear teeth. At this time, make sure that the ring (7) is attached in
the specified position. Also note the orientation (connector
phase) in which the motor (1) is mounted.
Attach the three motor mounting bolts (2) and washer (3).
Attach the three cable connectors to the motor (1).
Apply grease (See section 2.3 REPLACING THE GREASE OF
THE DRIVE MECHANISM.)
Perform mastering. (See section MASTERING.)
NOTE
1 When tightening the nut (6), hold the gear (4) with a
30x32mm or 32x36mm spanner (Thickness is
14mm or less).
2 To install a motor, an M8 T-shaped hexagonal
wrench not shorter than 250mm is required.
- 89 -
4. REPLACING PARTS
Name
1
2
3
MOTOR
BOLT
WASHER
GEAR J41
（J4-axis gear）
4
GEAR J51
（J5-axis gear）
GEAR J61
（J6-axis gear）
5
6
7
WASHER
NUT
O-RING
MAINTENANCE
Specifications
B-82235EN/03
Q’ty
A06B-0238-B605#S000
A6-BA-8X20
A97L-0001-0823#M8H
165F
210F
165R
A290-7329-X421
200R
100P
175L
125L
A290-7324-X421
165F
A290-7324-Z423
165R
210F
A290-7329-Y423
200R
A290-7324-Y423
100P
175L
125L
A290-7324-X423
165F
A290-7324-Z425
165R
210F
200R
A290-7329-Y425
100P
175L
125L
A290-7329-Z425
(MOTOR is attached.)
(MOTOR is attached.)
JB-OR1A-G105
3
9
9
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
3
Loctite
LT242
Torque N-m
(kgf-m)
16.7 (1.7)
Fig. 4.5 (a) Replacing the motor (M4, M5, M6) for wrist axis (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
- 90 -
MAINTENANCE
B-82235EN/03
4. REPLACING PARTS
・Replacing the wrist axis motors (M4, M5, and M6) (R-2000iB/165CF)
Remove
1
2
3
4
5
6
Place the wrist in a posture in which no load is applied to the
wrist axis.
Turn off the power.
Detach the three cable connectors from the motor (1).
Remove the three motor mounting bolts (2) and washers (3).
Pull out the motor (1), while being careful not to damage the
surface of the gear teeth.
For the J4-axis motor, remove the O-ring (4), nut (11), and
washer (7) and then remove the gear (11) (including bearing (10)
and C-ring (9)).
For the J5/J6-axis motor, remove the O-ring (4), nut (8), and
washer (7) and then remove the gear (6).
Assembling
1
2
3
4
5
6
7
Polish the flange surface of the motor (1) using an oil stone.
For the J4-axis motor, fix the gear (10) (including the bearing (9)
and C-ring (8)) with the washer (6) and nut (11).
* Before attaching the gear (10) to the motor (1), attach the
bearing (9) and C-ring (8) to the gear (10) with the jig
(A290-7321-X947).
For the J5-/J6-axis motor, fix the gear (5) with the washer (6) and
nut (7).
Place the new O-ring (4) in the specified position, and mount the
motor (1) while being careful not to damage the surface of the
gear teeth. Also note the orientation in which the motor (1) is
mounted.
Attach the three motor mounting bolts (2) and washer (3).
Attach the three cable connectors to the motor (1).
Apply grease (See section 2.3 REPLACING THE GREASE OF
THE DRIVE MECHANISM.)
Perform mastering. (See section MASTERING.)
NOTE
1 When tightening the nut (11), hold the gear (11) with
a 30x32mm or 32x36mm spanner (Thickness is
14mm or less).
2 To install a motor, an M8 T-shaped hexagonal
wrench not shorter than 200mm is required.
- 91 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
23
4
5 67
4
1
8 9 10 7 11
23
1
2
3
4
5
6
7
8
9
10
11
Name
Specifications
MOTOR
BOLT
WASHER
O-RING
GEAR J5-axis 1
GEAR J6-axis 1
WASHER
NUT
C-RING
BEARING
GEAR J4-axis 1
NUT
A06B-0235-B605#S000
A6-BA-8X20
A97L-0001-0823#M8H
JB-OR1A-G105
A290-7321-Y423
A290-7321-Y425
A97L-0001-0610#10
A6-N1-10X1.25S-M-N1
A6-CJR-30
A97L-0218-0428#0600000
A290-7321-Y421
A290-7321-X409
Q’ty
3
9
9
3
1
1
3
2
1
1
1
1
Loctite
Torque N-m
(kgf-m)
LT242
16.7 (1.7)
LT242
16.7 (1.7)
Fig. 4.5 (b) Replacing the wrist axis motors (M4, M5 and M6) (R-2000iB/165CF)
- 92 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
・Replacing the wrist unit and J4-axis reducer（R-2000iB/165F, 165R, 125L）
Remove
1
2
3
Remove the load, such as the hand and workpiece, from the wrist.
Remove the wrist unit mounting bolt (1) and washer (2). then
remove the wrist unit.
Remove the reducer mounting bolt (4), washer (5), and O-ring (7)
and then remove the reducer (6) from the J3-axis arm.
Assembling
1
2
3
4
5
6
1
2
3
4
5
6
7
Attach O-ring (7) to the reducer (6) .
Mount the reducer (6) on the J3 arm, and fasten them with the
reducer mounting bolt (4) and washer (5).
Attach the O-ring (3) to the groove in the reducer side.
Fasten the wrist unit with the wrist unit mounting bolt (1) and
washer (2).
Apply grease. (See section 2.3 REPLACING THE GREASE OF
THE DRIVE MECHANISM.)
Perform mastering.(See section 6 MASTERING.)
Name
Specifications
Q’ty
BOLT
WASHER
O-RING
BOLT
WASHER
REDUCER
O-RING
A6-BA-8X35
A97L-0001-0823#M8H
JB-OR1A-G115
A6-BA-8X35
A97L-0001-0823#M8H
A97L-0218-0385#70N-35
A98L-0040-0041#260
18
18
1
16
16
1
1
LT262
Torque N-m
(kgf-m)
37.2(3.8)
LT262
37.2(3.8)
Loctite
Fig. 4.5 (c) Replacing the wrist unit and J4-axis reducer（R-2000iB/165F, 165R, 125L）
- 93 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
・Replacing the wrist unit and J4-axis reducer
(R-2000iB/210F, 200R, 100P, 175L)
Remove
1
2
3
Unload the wrist by removing the hand and any workpiece.
Remove the wrist unit mounting bolt (1), washer (2), and O-ring
(3) and then remove the wrist unit.
Remove the reducer mounting bolt (4), washer (5), and O-ring
(7) and then remove the reducer (6) from the J3-axis arm.
Assembling
1
2
3
4
5
6
7
Install the O-ring (7) onto the groove of the end face of the
reducer (6).
Mount and fasten the reducer (6) to the J3 arm with the reducer
mounting bolt (4) and washer (5).
Install the O-ring (3) in the wrist unit.
Apply sealant. (See section 4.8 SEALANT APPLICATION.)
Fasten the wrist unit with the wrist unit mounting bolt (1) and
washer (2).
Apply grease. (See section 2.3 REPLACING TH E GREASE OF
THE DRIVE MECHANISM.)
Perform mastering. (See section 6 MASTERING.)
J4-axis reducer
NOTE
Degrease the surface to be sealed,
and apply sealant (Loctite 518) to the
area indicated by hatching (Shown left).
1
2
3
4
5
6
7
Name
BOLT
WASHER
O-RING
BOLT
WASHER
REDUCER
O-RING
Specifications
A6-BA-8X40
A97L-0001-0823#M8H
A290-7302-X552
A6-BA-10X35
A97L-0001-0823#M10H
A97L-0218-0342#110E-46
JB-OR1A-G190
Q’ty
24
24
1
12
12
1
1
Loctite
LT262
Torque N-m (kgf-m)
37.2(3.8)
LT262
73.5(7.5)
Fig. 4.5 (d) Replacing the wrist unit and J4-axis reducer (R-2000iB/210F, 200R, 100P, 175L)
- 94 -
MAINTENANCE
B-82235EN/03
4. REPLACING PARTS
・Replacing the wrist unit and J4-axis reducer (R-2000iB/165CF)
Remove
1
2
3
4
Remove the hand, workpiece, or other loads from the wrist.
Remove the wrist unit mounting bolt (1), washer (2), and O-ring
(3) and then remove the wrist unit.
Remove the adaptor mounting bolt (5) and washer (6) and then
remove the adaptor (4).
Remove the reducer mounting bolt (8), washer (9), and O-ring
(10) and then remove the reducer (7) from the adaptor (11).
Assembling
1
2
3
4
5
6
Apply sealant (see Section 4.7, “SEALANT APPLICATION”).
Place the new O-ring (10) in the specified position, mount the
reducer (7) on the adaptor (11), and secure the reducer with the
reducer mounting bolt (8) and washer (9).
Mount the adaptor (4) and fix it with the adaptor mounting bolt
(5) and washer (6).
Place the new O-ring (3) in the specified position, mount the
wrist unit, and secure it with the wrist unit mounting bolt (1) and
washer (2).
Apply grease (see Section 2.3, “REPLACING THE GREASE
OF THE DRIVE MECHANISM”).
Perform mastering (See Chapter 6, “MASTERING”).
- 95 -
4. REPLACING PARTS
Name
1
2
3
4
5
6
7
8
9
10
11
BOLT
WASHER
O RING
ADAPTER
BOLT
WASHER
RV REDUCER
BOLT
WASHER
O RING
ADAPTER
MAINTENANCE
Specifications
Q’ty
A6-BA-8X30
A97L-0001-0823#M8H
A98L-0001-0347#S125
A290-7321-X413
A6-BA-8X20
A97L-0001-0823#M8H
A97L-0218-0240#80E-37
A6-BA-8X30
A97L-0001-0823#M8H
A290-7302-X552
A290-7321-X412
16
16
1
1
18
18
1
16
16
1
1
B-82235EN/03
LT262
Torque N-m
(kgf-m)
37.2 (3.8)
LT262
37.2 (3.8)
LT262
37.2 (3.8)
Loctite
Fig. 4.5 (e) Replacing the wrist unit and J4-axis reducer (R-2000iB/165CF)
- 96 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
4.6
REPLACING FANS
The R-2000iB/100P is equipped with cooling fans for the J1, J2, and
J3-axis motors. The procedure for replacing the fns is the same for
all axes. The following example describes the procedure for the
J2-axis.
Disassembling
1 Turn off the power.
2 Remove the grounding cable from the fan body.
3 Remove the fan cable.
4 Remove bolts 1, washers 2, and fan cover 3.
At this time, be careful not to break the pulse coder connector of
the motor.
Assembling
1
Mount fan cover 3 and secure it with bolts 1 and washers 2.
At this time, be careful not to break the pulse coder connector of
the motor.
2
Connect the fan cable.
3
Connect the gorunding cable to the fan body.
1
3
2
1
2
3
Name
BOLT
WASHER
FAN COVER
Specifications
Q’ty
Loctite
A6-BA-8X12
2
A6-WM-8S
2
A290-7324-Y641
1
Fig. 4.6 Replacing fan
- 97 -
Torque N-m (kgf-m)
4. REPLACING PARTS
4.7
MAINTENANCE
B-82235EN/03
REPLACING THE BALANCER
Replacement procedure (R-2000iB/165F, 210F, 125L, 175L)
Remove
1
2
3
4
5
6
7
8
Orient the robot to allow replacement of the J2-axis motor (M2)
and reducer.
Turn off the power.
Remove the button head bolt (1), and attach two M12 eyebolts to
the balancer, then lift the balancer with a crane.
Loosen the U nut (3) so that no tension is applied to the balancer.
Remove the bolt (4).
Remove the bolt (5) and washer (6), then pull out the shaft
assembly (7).
Remove the bolt (8) then remove the shaft (9).
Lift the balancer assembly (10).
Assembling
1
2
3
4
5
6
7
Determine the shaft position after lifting the balancer. Next,
insert the shaft (9) then install the bolt (8).
Lay down the balancer with the crane. Next, remove the sling
from the back of the balancer then lift the balancer with the sling
on the front shaft side only.
Determine the position of the front shaft then insert the shaft (7)
so that the tapped hole is positioned horizontally. Next, install
the bolt (5) and washer (6).
Hold the bearing of the shaft by using the bolts (4) so that the
balancer does not move horizontally. At this time, tighten the
bolts one by one gradually while adjusting the position of the
balancer so that the outer ring is not damaged.
Tighten the U nut (3) by the specified torque then secure the
cover (2) with the mounting bolt (1).
Lay down the balancer with the crane then remove the two M12
eyebolts.
Supply grease to the grease nipple attached to the shaft (9).
(See Section 2.1 GREASING THE BALANCER SHAFT.)
- 98 -
MAINTENANCE
B-82235EN/03
4. REPLACING PARTS
Replacement procedure (R-2000iB/165R, 200R, 100P)
Remove
1
2
3
4
5
6
7
Place the robot in the posture for the replacement of the J2-axis
motor (M2) and reducer.
Turn off the power.
Remove the bolt (1) and cover (2), attach two M12 eyebolts to
the balancer, and hoist it with a crane.
Loosen the U-nut (3) so that the tension of the balancer is not
applied.
Remove the bolt (4) and washer (5) and then pull out the shaft
assembly (6).
Remove the bolt (7), washer (8), and grease nipple (10) and then
pull out the shaft (9).
Hoist the balancer (11).
Assembling
1
2
3
4
5
6
Determine the position of the rear shaft of the balancer, insert the
shaft (9), and attach the bolt (7), washer (8), and grease nipple
(10).
Lower the crane once, remove the sling at the back of the
balancer, and hoist the balancer with only the sling on the front
shaft side.
Determine the position of the front shaft, insert the shaft (6) so
that the draw tap positions horizontally, and attach the bolt (4)
and washer (5).
Tighten the U-nut (3) with the specified torque and fix the cover
(2) with the mounting bolt (1).
Remove the balancer from the crane and then remove the two
M12 eyebolts.
Supply grease to the grease nipple attached to the shaft (9) (see
Section 2.1, “GREASING THE BALANCER SHAFT”).
WARNING
Never disassemble the balancer. The balancer
contains a large compressed spring. If the balancer
is disassembled without using a special jig, the
internal spring will extend, and can expose you to
danger. When replacing the balancer, be sure to
replace the balancer assembly.
NOTE
To attach the U-nut (3), mount the M33 socket with
a diagonal side length of 50 mm on a torque wrench
and perform tightening (for the R-2000iB/165F,
210F, 125L, 175L) or mount the M42 socket with a
diagonal side length of 65 on a torque wrench and
perform tightening (for the R-2000iB/165R, 200R,
100P).
- 99 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Eyebolt (M12)
Remove four outside bolts
Grease nipple
Name
1
2
3
4
5
6
7
8
BOLT
COVER
U NUT
BOLT
BOLT
WASHER
SHAFT ASSY
BOLT
9
SHAFT
10
BALANCER
ASSY
Specifications
Q’ty
A6-BA-6X10
A290-7324-X391
A97L-0001-0660#BMN133
A6-BA-6X16
A6-BA-6X20
A97L-0001-0823#M6H
A290-7329-V351
A6-BA-6X10
A290-7329-X382
A290-7329-X384
A6-BA-6X10(4)
165F
A290-7329-V301
125L
210F
A290-7329-V302
175L
2
1
1
2
4
4
1
4
Loctite
Torque N-m
(kgf-m)
319 (32.5)
2
1
Fig. 4.7 (a) Replacing the balancer (R-2000iB/165F, 210F, 125L, 175L)
- 100 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
Eyebolt (M12)
Remove four bolts
Grease nipple
1
2
3
4
5
6
7
8
9
10
11
Name
Specifications
BOLT
COVER
U NUT
BOLT
WASHER
SHAFT ASSY
BOLT
WASHER
SHAFT
GREASE NIPPLE
BALANCER ASSY
A6-BA-6X10
A290-7324-Y391
A97L-0001-0660#BMN142
A6-BA-12X35
A97L-0001-0823#M12H
A290-7324-V361
A6-BA-8X20
A97L-0001-0823#M8H
A290-7324-Y382
A97L-0218-0013#A610
A290-7324-V311
Q’ty
2
1
1
8
8
1
8
8
2
2
1
Loctite
Torque N-m
(kgf-m)
319 (32.5)
Fig. 4.7 (b) Replacing the balancer (R-2000iB/165R, 200R, 100P)
- 101 -
4. REPLACING PARTS
4.8
MAINTENANCE
B-82235EN/03
SEALANT APPLICATION
Washing and degreasing the surfaces to be sealed
1
2
3
4
After dismounting the reducer from the arm, apply releasant
(Loctite Gasket Remover) 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 alcohol.
Polish the arm’s surface to be sealed with an oil stone, and
degrease it with alcohol again.
CAUTION
Oil may drip from the inside of the reducer. After
degreasing, make sure that no oil is dripping.
Applying sealant
1
2
Make sure that the reducer and the arm are dry (with no alcohol
remaining). If they are still wet with alcohol, wipe them dry.
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
1
2
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.
CAUTION
Do not grease the reducer before the sealant
sets, as it may allow grease to leak. Before
greasing, wait for about at least one hour after
the reducer is mounted.
- 102 -
4.9
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
REPLACING MOTOR COVERS (OPTION)
・Replacing the J1-/J2-axis motor cover
1
2
Remove the M8x12 bolts (three for the J1-axis and two for the
J2-axis) and remove the motor cover.
To mount the motor cover, reverse the above mounting procedure
steps.
J2 motor cover
J1 motor cover
Fig. 4.9 (a) Replacing J1/J2-axis motor cover (R-2000iB/165F, 210F, 125L, 175L)
J1 motor cover
×
×
J2 motor cover
Fig. 4.9 (b) Replacing J1/J2-axis motor cover (R-2000iB/165R, 200R) (Severe dust/liquid protection is specified.)
- 103 -
4. REPLACING PARTS
MAINTENANCE
B-82235EN/03
・Replacing the J3-/J4-/J5-/J6-axis motor cover
1
2
3
M6×10(3)
Fastened to the
J3 casing
Remove the six M6x10 bolts and washers that fasten the lower
motor cover, then remove the motor cover. If there is no motor
cover, go to step 2.
Remove the five M6x10 bolt that fastens the motor cover together
with the cable clamp metal, and the related washers, then remove
the motor cover.
To mount the motor covers, reverse the above mounting procedure
steps. In this case, however, first attach the bolts, but keep them
loose so that the motor covers can be put in correct place;
otherwise the upper motor cover tap may be destroyed. After the
motor covers are positioned properly, tighten the bolts.
J3456 motor cover (upper)
M6×10(3)
Fastened to the
upper cover
M6×10(2)
Fastened to the
J3 casing
M6×10(3)
Fastened to the
J3 casing
J3456 motor cover (lower)
Fig. 4.9 (c) Replacing J3/J4/J5/J6-axis motor cover
- 104 -
5
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
REPLACING CABLES
Replace the cables every four years (15,360 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 pulse coder cable
The pulse coder 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 pulse coder, the reducer, and the
cable are necessary.
The J1-axis and J2-axis motors are provided with a pulse coder
connector cover, as shown in Fig. 5 (b), to protect the connectors.
Before removing the connectors for cable replacement or other
purposes, remove the covers. In this case, turning the bolt may also
turn the cover, possibly causing damage to the connector. When
removing the cover, hold it to prevent it from turning.
Fig. 5 (a)
- 105 -
Marking Tie
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Pulse coder connector cover
Fig. 5 (b)
- 106 -
Pulse coder connector cover
MAINTENANCE
B-82235EN/03
5.1
5. REPLACING CABLES
CABLE WIRING
Following are the routing of the robot cables, the connector wiring,
and the robot internal cables.
K111/K511 (M1 to M6 pulse coder, end effector (RDI/RDO))
/K515 (M1 to M6 pulse coder, end effector (RDI/RDO)) Support for SDLP
K112/K512 (M1 to M6 power, brake)
K113/K513 (M1 to M6 pulse coder)
K131/K531 (User cable (signal))
K132/K532 (User cable (power supply))
K133/K533 (Device net (signal))
K134/K534 (Device net (power supply, J2J3))
K135/K535 (Device net (power supply, J1J2J3)
K136/K536 (I/O unit model B)
K137 (OT short-circuit cable)
K138 (OT cable)
K139/K539 (Additional axis (pulse coder))
K140/K540 (Additional axis (power, brake))
NOTE) K∗∗∗/K∗∗∗ : Standard/CE marking
SEVERE DUST LIQUID OPTION: Dustproof and dipproof enhanced option
Fig.5.1 (a)
Routing of the robot cables (R-2000iB/165F, 210F, 125L, 175L)
K211/K611 (M1 to M6 pulse coder, end effector (RDI/RDO))
/K615 (M1 to M6 pulse coder, end effector (RDI/RDO)) Support for SDLP
K212/K612 (M1 to M6 power, brake)
K213/K613 (M1 to M6 pulse coder)
K231/K631 (User cable (signal))
K232/K632 (User cable (power supply))
K233/K633 (Device net (signal))
K235/K635 (Device net (power supply)
K236/K636 (I/O unit model B)
K239/K639 (Additional axis (pulse coder))
K240/K640 (Additional axis (power, brake))
K238
(J123OT)
NOTE) K∗∗∗/K∗∗∗ : Standard/CE marking
SEVERE DUST LIQUID OPTION:
Dustproof and dipproof enhanced option
Fig. 5.1 (b)
Routing of the robot cables (R-2000iB/165R, 200R, 100P)
- 107 -
5. REPLACING CABLES
MAINTENANCE
K123/K523 (M1 to M6 pulse coder, end effector (RDI/RDO))
K115/K515 (M1 to M6 power, brake)
K231/K631 (User cable (signal))
K232/K632 (User cable (power supply))
K233/K633 (Device net (signal))
K235/K635 (Device net (power supply)
K236/K636 (I/O unit model B)
K282
(J123OT)
K239/K639 (Additional axis (pulse coder))
K240/K640 (Additional axis (power, brake))
NOTE) K∗∗∗/K∗∗∗ : Standard/CE marking
Fig. 5.1 (c)
Routing of the robot cables (R-2000iB/165CF)
Fig. 5.1 (d) Connector wiring (R-2000iB/165F, 210F, 125L, 175L)
- 108 -
B-82235EN/03
MAINTENANCE
B-82235EN/03
Fig. 5.1 (e) Connector wiring (R-2000iB/165R, 200R)
Fig. 5.1 (f)
Connector wiring (R-2000iB/100P)
- 109 -
5. REPLACING CABLES
5. REPLACING CABLES
MAINTENANCE
Fig. 5.1 (g) Connector wiring (R-2000iB/165CF)
- 110 -
B-82235EN/03
MAINTENANCE
B-82235EN/03
Fig. 5.1 (h)
5. REPLACING CABLES
Robot internal cables (R-2000iB/165F, 210F, 125L, 175L)
- 111 -
5. REPLACING CABLES
MAINTENANCE
Fig. 5.1 (i)
Robot internal cables (R-2000iB/165R, 200R)
- 112 -
B-82235EN/03
Fig. 5.1 (j)
ARM1
ARP1
I/O
DP1
DS1
AP1
AS1
FAN
RP1
RM1
J1 CONNECTOR PANEL
MECHANICAL UNIT
K642
K211/K611
K212/K612
- 113 -
M2M
M2BK
M3M
M3BK
ƒ¿iSR30/3000
WITH BRAKE
M3P
ƒ¿iSR30/3000
WITH BRAKE
M2P
M5M
M5BK
M6M
M6BK
Robot internal cables (R-2000iB/100P)
W2516F
DP2
(OPTION)
R-2000iB/100P(R-J3iC)
BLOCK DIAGRAM
ARM2
(OPTION)
K240/K640
DS2
(OPTION)
ARP2
(OPTION)
K239/K639
(OPTION )
I/O
DP3
(OPTION)
K235/K635
K236/K636
DS3
(OPTION)
K233/K633
EE
J3 CONNECTOR PANEL
ƒ¿iS12/4000
WITH BRAKE
M6P
ƒ¿iS12/4000
WITH BRAKE
M5P
AP2
(OPTION)
J3 MOTOR
J2 MOTOR
J1 MOTOR
K232/K632
J2 CONNECTOR PANEL
M3 FAN
J3 FAN
M1BK
AS2
(OPTION)
J3OT(OPTION)
J2OT(OPTION)
M2 FAN
J2 FAN
M1M
ƒ¿iSR30/3000
WITH BRAKE
M1P
M4BK
K231/K631
K238
+
J1OT(OPTION)
BATTERY
-
M1 FAN
J1 FAN
M4M
ƒ¿iS12/4000
WITH BRAKE
M4P
J6 MOTOR
J5 MOTOR
J4 MOTOR
MAINTENANCE
NOTE) K***/K*** : Normal/CE cable
K211 : A660-8015-T843
K212 : A660-8015-T844
K231 : A660-2006-T383
K232 : A660-8015-T849
K233 : A660-8015-T851
K235 : A660-8015-T855
K236 : A05B-1329-D007
K238 : A660-8015-T857
K239 : A660-8015-T858
K240 : A660-8015-T860
K611 : A660-8015-T846
K612 : A660-8015-T847
K631 : A660-2006-T384
K632 : A660-8015-T850
K633 : A660-8015-T852
K635 : A660-8015-T856
K636 : A05B-1329-D008
K639 : A660-8015-T859
K640 : A660-8015-T861
K642 : A05B-1329-D012
CP3
CRF8
CRR64
CNGB
CNGA
CNJ6
CNJ5
CNJ4
CNJ3A
CNJ2A
CNJ1A
CONTROL UNIT
B-82235EN/03
5. REPLACING CABLES
5. REPLACING CABLES
MAINTENANCE
Fig. 5.1 (k)
Robot internal cables (R-2000iB/165CF)
- 114 -
B-82235EN/03
MAINTENANCE
B-82235EN/03
5.2
5. REPLACING CABLES
CABLE FORMING
When replacing cables, clamp the cable at the position specified in
Table 5.2 (a) to (w) using a clamp or a nylon band. Otherwise, cables
can be loosened or pulled by force to cause their disconnection.
Refer to the figures in section 5.3 for the cable clamp.
- 115 -
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (a) Cable clamp position (R-2000iB/165F, 210F, 125L, 175L) (NON-CE)
Stamp
Cable clamp position
- 116 -
Stamp
Cable
No.
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (b) Cable clamp position (R-2000iB/165F, 210F, 125L, 175L) (NON-CE)
Stamp
捺印
Cable clamp position
ケーブルのクランプ配置図
BATTERY BACKUP
-
DON'T
DISCONNECT
M1P-K113
GB1
M2P
BATTERY BACKUP
DON'T
DISCONNECT
M2P-K113
コネクタ取付不可
M3P-K113
コネクタ取付不可
ケーブル
Cable
番号
No.
+6V
0V
M1P
+
Stamp
捺印
M3P
BATTERY BACKUP
DON'T
DISCONNECT
RP1
K113
BATTERY BACKUP
DON'T
DISCONNECT
M4P-K113
コネクタ取付不 可
BATTERY BACKUP
DON'T
DISCONNECT
M5P-K113
コネ クタ取付不可
M6P-K113
コネ クタ取付不可
BATTERY BACKUP
DON'T
DISCONNECT
- 117 -
M4P
M5P
M6P
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (c) Cable clamp position (R-2000iB/165F, 210F, 125L, 175L) (NON-CE)
Stamp
Cable clamp position
- 118 -
Stamp
Cable
No.
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (d) Cable clamp position (R-2000iB/165F, 210F, 125L, 175L) (NON-CE)
ケーブル
Stamp
捺印 Cable
番号
No.
Cable clamp position
ケーブル模式図
Stamp
捺印
I/O
I/O
COM
NC
J2OTK138
J123OT
J3 NC
J3COM
J2 NC
K138
J2COM
NC
J1 NC
J1COM
COM
J1OTK138
COM
30
37
NC
J3OTK138
OT
K136
I/O-K136
ARP2 K139
ARP1
+
ARP-K139
-
+6V
0V
ARM1
ARM2 K140
ARM-K140
- 119 -
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (e) Cable clamp position (R-2000iB/165F, 210F, 125L, 175L) (CE)
Stamp
Cable clamp position
- 120 -
Stamp
Cable
No.
Table 5.2 (f)
Cable clamp position (R-2000iB/165F, 210F, 125L, 175L) (CE)
Stamp
捺印
Cable clamp position
ケーブルのクランプ配置図
BATTERY BACKUP
-
DON'T
DISCONNECT
M1P-K513
GB1
M2P
BATTERY BACKUP
DON'T
M2P-K513
DISCONNECT
コネクタ取付不可
M3P
BATTERY BACKUP
DON'T
DISCONNECT
M3P-K513
Cable
ケーブル
番号
No.
+6V
0V
M1P
+
Stamp
捺印
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
コネクタ取付不 可
RP1
K513
BATTERY BACKUP
DON'T
DISCONNECT
M4P-K513
コネ クタ取付不可
BATTERY BACKUP
DON'T
DISCONNECT
M5P-K513
コネ クタ取付不可
M6P-K513
コネク タ取 付不可
BATTERY BACKUP
DON'T
DISCONNECT
+
-
DON'T
D IS CONN EC T
コネクタ取付不可
DON'T
D IS CONN EC T
コネクタ取付不可
M3P-K515
コネクタ取付不可
RP1
M6P
M2P
BATTE RY BAC KU P
M2P-K515
M5P
+6V
0V
M1P
BATTE RY BAC KU P
M1P-K515
GB1
M4P
M3P
BATTE RY BAC KU P
DON'T
D IS CONN EC T
K515
BA TTERY BA CKU P
DO N 'T
DIS CO N NEC T
M4P-K515
コネクタ取付不可
EE-K515
BA TTER Y BA CKU P
DO N 'T
DI SCO N NEC T
M5P-K515
コネクタ取付不可
BA TTERY BA CKU P
DO N 'T
DIS CO N NEC T
M6P-K515
コネクタ取付不可
M4P
M5P
M6P
EE
- 121 -
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (g) Cable clamp position (R-2000iB/165F, 210F, 125L, 175L) (CE)
Stamp
Cable clamp position
Stamp
AS2
AP2
- 122 -
Cable
No.
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (h) Cable clamp position (R-2000iB/165F, 210F, 125L) (CE)
Stamp
捺印
Cable clamp position
ケーブルのクランプ配置図
I/O
Stamp
捺印
Cable
ケーブル
番号
No.
I/O
K536
I/O-K536
ARP2 K539
ARP1
+
ARP-K539
-
+6V
0V
ARM1
ARM2 K540
ARM-K540
LMP1
LMP1
3DV
3DV-K591
K591
CAM-K592
K592
3DV-K591
CAMERA
CAM-K592
- 123 -
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (i) Cable clamp position (R-2000iB/165R, 200R) (NON-CE)
ケーブル
Stamp
捺印 Cable
番号
No.
Cable clamp position
ケーブルのクランプ配置図
+6V
0V
M1P
+
Stamp
捺印
BA TTERY BAC KU P
-
DO N'T
M1P-K211
GB1
DIS CO NN EC T
コネクタ取付不可
M2P
BA TTERY BAC KU P
DO N'T
DIS CO NN EC T
M2P-K211
コネクタ取 付不可
M3P
BA TTERY BAC KU P
DO N'T
M3P-K211
DIS CO NN EC T
コネクタ取付不可
RP1
K211
BAT TE RY BAC KUP
DO N'T
M4P-K511
D ISC O NN ECT
コネクタ取付不可
BATTE RY BAC KUP
DO N'T
D ISC O NN EC T
M5P-K511
コネクタ取付不可
BAT TE RY BAC KUP
DO N'T
M6P-K511
D ISC O NN ECT
コネクタ取付不可
M4P
M5P
M6P
EE-K211
EE
M6M
M6BK
M6M-K 212
M5M
M5BK
M5M-K212
M4M
M4BK
M4M-K212
RM1
M3M-K212
M1M-K212
M2M-K212
M1BK
M3M K212
M3BK
M2M
M2BK
M1M
M1BK
- 124 -
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (j) Cable clamp position (R-2000iB/165R, 200R) (NON-CE)
Cable clamp position
ケーブルのクランプ配置図
Stamp
捺印
Stamp
捺印
AS1
ケーブル
Cable
番号
No.
AS2 K231
AS-K231
AP1
AP2 K232
AP-K232
DS3
DS1
K233
DS1-K133
DS2
DS2
DP2
DP2
DP4
DP1
DS3
DP4
DP1-K134
DP3
- 125 -
DP3
K235
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (k) Cable clamp position (R-2000iB/165R, 200R) (NON-CE)
Cable clamp position
ケーブルのクランプ配置図
Stamp
捺印
I/O
Cable
ケーブル
番号
No.
I/O
K236
J2OTK238
J123OT
J3 NC
J3COM
J2 NC
K238
J2COM
NC
J1 NC
J1COM
COM
J1OTK238
COM
30
37
NC
COM
NC
I/O-K236
J3OTK238
OT
Stamp
捺印
ARP2 K239
ARP1
+
ARP-K239
-
+6V
0V
ARM1
ARM2 K240
ARM-K240
- 126 -
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (l) Cable clamp position (R-2000iB/165R, 200R) (CE)
Cable
Stamp
捺印 ケーブル
番号
No.
Cable clamp position
ケーブルのクランプ配置図
+6V
0V
M1P
+
Stamp
捺印
BATTER Y BAC KUP
-
D ON'T
M1P-K611
GB1
D ISC ONN ECT
コネクタ取付不可
M2P
BATTER Y BAC KUP
D ON'T
D ISC ONN ECT
M2P-K611
コネクタ取付不可
M3P
BATTER Y BAC KUP
D ON'T
M3P-K611
D ISC ONN ECT
コネクタ取付不可
RP1
K611
B ATTER Y B ACK UP
D ON 'T
M4P-K611
DI SC ON NE CT
コネクタ取付不可
B ATTER Y B ACK UP
D ON 'T
DI SC ON NE CT
M5P-K611
コネクタ取付不可
B ATTER Y B ACK UP
D ON 'T
DI SC ON NE CT
M6P-K611
コネクタ取付不可
M4P
M5P
M6P
EE-K611
EE
M6M
M6BK
M6M-K612
M5M
M5BK
M5M-K612
M4M
M4BK
M4M-K612
RM1
M3M-K612
M1M-K612
M2M-K612
M1BK
M3M K612
M3BK
M2M
M2BK
M1M
M1BK
- 127 -
5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (m) Cable clamp position (R-2000iB/165R, 200R, 100P) (CE)
Cable clamp position
ケーブルのクランプ配置図
Stamp
捺印
BA TTERY BAC KU P
-
DON 'T
M1P-K613
GB1
DIS CONN EC T
コネクタ取付不可
M2P
BA TTERY BAC KU P
DON 'T
M2P-K613
DIS CONN EC T
コネク タ取 付不可
M3P
BA TTERY BAC KU P
RP1
DON 'T
M3P-K613
ケーブル
Cable
番号
No.
+6V
0V
M1P
+
Stamp
捺印
DIS CONN EC T
コネクタ取付不可
K613
BATTE RY BAC KUP
D ON'T
M4P-K613
D ISC ONN ECT
コネクタ取付不可
BATTE RY BAC KUP
DO N'T
D ISC O NN ECT
M5P-K613
コネクタ取付不可
BATTE RY BAC KUP
D ON'T
D ISC ONN ECT
コネクタ取付不可
BA TTER Y BA CKU P
-
DON 'T
M1P-K615
GB1
DI SCON NEC T
コネクタ取付不可
DON 'T
DI SCON NEC T
コネクタ取付不可
M3P
BA TTER Y BA CKU P
DON 'T
M3P-K515
M6P
M2P
BA TTER Y BA CKU P
M2P-K615
M5P
+6V
0V
M1P
+
M6P-K613
M4P
DI SCON NEC T
コネクタ取付不可
RP1
K615
B ATTER Y B ACK UP
D ON 'T
M4P-K615
DI SC ON NE CT
コネクタ取付不可
EE-K515
B ATTER Y B ACK UP
D O N'T
M5P-K615
DI SC ON NE CT
コネクタ取付不可
B ATTER Y B ACK UP
D ON 'T
M6P-K615
DI SC ON NE CT
コネクタ取付不可
M4P
M5P
M6P
EE
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Table 5.2 (n) Cable clamp position (R-2000iB/165R, 200R, 100P) (CE)
Cable clamp position
ケーブルのクランプ配置図
Stamp
捺印
Stamp
捺印
AS1
Cable
ケーブル
番号
No.
AS2 K631
AS-K531
AP1
AP2 K632
AP-K532
DS3
DS1
K633
DS1-K133
DS2
DS2
DP2
DP2
DP4
DP1
DS3
DP4
K635
DP1-K134
DP3
DP3
I/O
I/O
I/O-K636
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5. REPLACING CABLES
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Table 5.2 (o) Cable clamp position(R-2000iB/165R, 200R, 100P) (CE)
Stamp
捺印
Cable clamp position
ケーブルのクランプ配置図
Stamp
捺印
Cable
ケーブル
番号
No.
ARP2 K239
ARP1
+
ARP-K239
-
+6V
0V
ARM2 K240
ARM1
ARM-K240
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5. REPLACING CABLES
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Table 5.2 (p) Cable clamp position(R-2000iB/100P) (CE)
Cable clamp position
ケーブル模式図
Stamp
捺印
Cable
ケーブル
番号
No.
FAN1
K6
42
Stamp
捺印
FAN
FAN
FAN1
FAN2 K642
FAN2
FAN3
FAN3
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5. REPLACING CABLES
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Table 5.2 (q) Cable clamp position(R-2000iB/165R, 200R) (CE)
Stamp
捺印
Cable clamp position
ケーブル模式図
Stamp
捺印
Cable
ケーブル
番号
No.
LMP1
LMP1
3DV
3DV-K691
K691
CAM-K692
K692
3DV-K691
CAMERA
CAM-K692
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5. REPLACING CABLES
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Table 5.2 (r) Cable clamp position (R-2000iB/165CF) (NON-CE)
ケーブル
Stamp
捺印 Cable
番号
No.
Cable clamp position
ケーブルのクランプ配置図
+6V
0V
M1P
+
Stamp
捺印
B ATTER Y B ACK UP
-
D ON 'T
M1P-K123
GB1
DI SC ON NE CT
コネク タ取 付不可
M2P
B ATTER Y B ACK UP
D ON 'T
DI SC ON NE CT
M2P-K123
コネクタ取付不可
M3P
B ATTER Y B ACK UP
D ON 'T
DI SC ON NE CT
M3P-K123
コネクタ取付不可
RP1
K123
BA TTER Y BA CKU P
DON 'T
M4P-K123
DI SCON NEC T
コネクタ取付 不可
BA TTER Y BA CKU P
DO N 'T
DI SCO N NEC T
M5P-K123
コネクタ取付 不可
BA TTER Y BA CKU P
DON 'T
M6P-K123
DI SCON NEC T
コネクタ取付 不可
M4P
M5P
M6P
EE-K123
EE
M6M
M6BK
M6M-K115
M5M
M5BK
M5M-K115
M4M
M4BK
M4M-K115
RM1
M3M-K115
M1M-K115
M2M-K115
M1BK
M3M K115
M3BK
M2M
M2BK
M1M
M1BK
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5. REPLACING CABLES
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Table 5.2 (s) Cable clamp position (R-2000iB/165CF) (NON-CE)
Cable clamp position
ケーブルのクランプ配置図
Stamp
捺印
AS1
Stamp
捺印
Cable
ケーブル
番号
No.
AS2 K143
AS-K143
AP1
AP2 K144
AP-K144
DS3
DS1
K273
DS1-K133
DS2
DS2
DP2
DP2
DP4
DP1
DS3
DP4
K274
DP1-K134
DP3
DP3
I/O K282
I/O
I/O-K282
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5. REPLACING CABLES
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Table 5.2 (t)
Stamp
Cable clamp position (R-2000iB/165CF) (NON-CE)
Stamp
捺印
Cable clamp position
ケーブル模式図
D-3
COM
X
OT
123
NC
J3OTK282
J2OTK282
COM
NC
捺印
Cable
ケーブル
番号
No.
J3 NC
J3COM
J2 NC
K282
J2COM
J123OT
COM
NC
J1 NC
J1COM
J1OTK282
ARP2 K221
ARP1
+
ARP-K221
-
+6V
0V
ARM1
ARM2 K286
ARM-K286
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5. REPLACING CABLES
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B-82235EN/03
Table 5.2 (u) Cable clamp position (R-2000iB/165CF)
Cable
Stamp
捺印 ケーブル
番号
No.
Cable clamp position
ケーブルのクランプ配置図
+6V
0V
M1P
+
Stamp
捺印
BATTE RY BAC KUP
-
DON'T
M1P-K523
GB1
D ISC ONN EC T
コネクタ取付不可
M2P
BATTE RY BAC KUP
DON'T
D ISC ONN EC T
M2P-K523
コネクタ取付不 可
M3P
BATTE RY BAC KUP
DON'T
D ISC ONN EC T
M3P-K523
コネクタ取付 不可
RP1
K523
BATTER Y B ACK UP
D ON'T
M4P-K523
D ISC ONNE CT
コネクタ取付不可
BATTER Y B AC KUP
D ON'T
D ISC ONN ECT
M5P-K523
コネクタ取付不可
BATTER Y B ACK UP
D ON'T
M6P-K523
D ISC ONNE CT
コネクタ取付不可
M4P
M5P
M6P
EE-K523
EE
M6M
M6BK
M6M-K515
M5M
M5BK
M5M-K515
M4M
M4BK
M4M-K515
RM1
M3M-K515
M1M-K515
M2M-K515
M1BK
M3M K515
M3BK
M2M
M2BK
M1M
M1BK
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5. REPLACING CABLES
MAINTENANCE
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Table 5.2 (v) Cable clamp position (R-2000iB/165CF) (CE)
Cable clamp position
ケーブルのクランプ配置図
Stamp
捺印
AS1
Stamp
捺印
Cable
ケーブル
番号
No.
AS2 K536
AS-K536
AP1
AP2 K546
AP-K546
DS3
DS1
K542
DS1-K133
DS2
DS2
DP2
DP2
DP4
DP1
DS3
DP4
K543
DP1-K134
DP3
DP3
I/O K281
I/O
I/O-K281
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5. REPLACING CABLES
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Table 5.2 (w) Cable clamp position (R-2000iB/165CF) (CE)
Stamp
捺印
Cable clamp position
ケーブルのクランプ配置図
ARP1
Stamp
捺印
Cable
ケーブル
番号
No.
ARP2 K545
+
ARP-K545
-
+6V
0V
ARM1
ARM2 K544
ARM-K544
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B-82235EN/03
5.3
MAINTENANCE
5. REPLACING CABLES
CABLE REPLACEMENT
This section describes a procedure for periodically replacing all the
(full-option) mechanical unit cables.
If you need to replace a specific cable (because, for example, it is
damaged), do so by adopting the appropriate procedures. See section
5.1 for the configuration of the mechanical unit cables.
Cable replacement makes it necessary to perform mastering. Before
attempting replacement, therefore, see section 6 MASTERING.
Replacement procedure (R-2000iB/165F, 210F, 125L, 175L)
Remove
Remove the cables as the following procedure.
<J1-axis base>
1
Place all the robot axes in their 0-degree position, then set the
control unit power switch to off.
2
Detach the cable leading to the control unit from the connector
panel on the rear of the robot. Remove the connector panel from
the J1 base, then detach all the cable tubes from the connector
panel. Remove the terminal on the rear of the battery box and the
ground terminal in the J1-axis base. Separate the housing and
insert of the HARTING connector from each other.; If the
housing is left on the cable, the cable cannot be pulled out
through the J1 axis piping. (Fig.5.3(a))
3
When the robot has limit switches (option), remove the limit
switch for the J1-axis from the plate of the J1-axis base, and
remove the terminal in the switch, then pull out the cable from
the cast through hole. (Fig.5.3(b))
4
Remove all connectors from the J1-axis through J6-axis motors.
For the precautions that must be taken, see “Precautions to be
observed when handling the pulse coder cable” at the beginning
of Chapter 5.
5
Remove the cover plate attached to the J2-axis base. If a
DNS/DNP cable (option) is connected, remove the cable from
the connector panel jointly secured to the cover plate. (Fig.
5.3(d))
6
The upper part of the J1-axis has a plate for clamping the cable.
The plate is fastened to the J2-axis base. Remove the bolt and
cable cover attached to the plate, then drop the cable with the
clamp in the pipe. (Fig.5.3(e))
7
Remove and pull out the plate from within the J1-axis base as
much as possible, then remove the bolt fastening the clamp.
(Fig.5.3(i))
8
Pull out the cable upward from the pipe of the J1-axis.
<J2-axis base and J2-axis arm>
9
Remove the bolts fastening the left plate of the J2-axis base, and
pull out the cable to the lower side of the J2-axis arm by running
the cable under the balancer. (Fig.5.3(o))
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5. REPLACING CABLES
MAINTENANCE
10
11
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Remove the cover plate of the J2-axis arm. Then, remove the
bolts fastening the plate of the J2-axis arm. (Fig5.3(m))
If the robot has limit switches (option), remove the limit switches
for the J2-axis and J3-axis from the plate of the J2-axis arm, and
remove the terminals in the switches, then pull out the cables
from the cast through hole of the J2-axis arm.(Fig. 5.3(n))
<J3-axis casing>
12 Remove the left plate B of the J3-axis casing. (Fig.5.3(o))
13 Remove the connector panel from the front of the J3-axis casing.
(Fig. 5.3(p))
14 Remove the right plate C of the J3-axis casing. Pull out the J3 to
J6-axis motor cables with the plate through hole of the front side.
(See Fig.5.3(r).)
15 At last, remove the left plate A of the J3-axis casing.
This completes cable unit detachment from the robot.
16
When replacing a part of the cables, remove the clamp and cable
cover from the cable unit. Next, cut the cable tie securing the
cables, then detach the desired cable(s). (See Fig.5.3(u).)
Assembling
Install the cable according to the procedure below.
1
2
3
4
5
Fasten the cable unit to the J2-axis arm with the bolts. Don’t be
wrong the up and down. When a limit switch is used, run the
cable through the cast through hole of the J2-axis arm, and
connect the switch terminal for the J2-axis and J3-axis, then
install the switch onto the plate of the J2-axis arm. Pull out any
excess cable toward the J2-axis arm cover, then bind the excess
cable with the main cable by using a nylon tie. Next, install the
cover plate on the J2-axis arm. (Fig. 5.3(m),(n))
Pull out the cable toward the back of the robot by running the
cable under the balancer. Then, fasten the left plate of theJ2-axis
base and the plate under the balancer. Be careful to lay the cable
so that mechanical strain is not caused between the plate under
the balancer and the cable. (Fig. 5.3(k))
Fasten the plate A to the left of the J3-axis casing.
Run the J3 to J6 axis motor cables from the front of the J3 axis
casing to the back side through the casting hole then attach plate
C. (See Fig. 5.3 (o).)
Accommodate any excessive cables in the J3 axis casing and
secure the connector panel on the front of the J3 axis casing. (See
Fig. 5.3 (p).)
Finally, retain the cables with plate B. (See Fig. 5.3 (o).)
Run the cable through the J1-axis pipe from the top of the J2-axis
base, then pull out the cable toward the back of the J1-axis base.
Fasten the clamp onto the plate in the J1-axis base. Bind tightly
the cables with a thick cable tie (Approx. W:7.6mm) running
through the clamp, then fasten the plate to the J1-axis base.
(Fig.5.3(i))
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MAINTENANCE
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6
7
8
9
10
11
12
5. REPLACING CABLES
Fasten the clamp and cable cover to the plate at the top of the
J1-axis. Bind tightly the cables with a thick cable tie Approx.
(W:7.6mm) running through the clamp, then fasten the plate to
the J2-axis base. (Fig.5.3(e))
Fasten the cover plate to the J2-axis base. If a DNS/DNP cable
(option) is used, fasten the connector onto the connector panel,
then fasten the connector panel together with the cover plate.
(Fig.5.3(d))
Attach all connectors to the J1-axis through J6-axis motors.
Make sure that the pulse coder connector covers are attached to
the J1-axis and J2-axis motors.
When the robot has limit switches (option), run the cable through
the cast through hole of the J1-axis base, then connect the cable
to the terminal in the switch. Next, fasten the switch to the plate
on the J1-axis base. (Fig.5.3(b))
Connect the cables and tubes to the connector panel on the back
of the robot. Connect the ground terminal to the J1-axis base,
then connect the battery terminal to the back of the battery box.
Next, fasten the connector panel to the J1-axis base, then connect
the cable used for connection with the control unit to the
connector panel. (Fig.5.3(a))
Turn on the power. If an alarm is issued at this time, release it
according to section 6.2.
Perform mastering. (See section 6 MASTERING.)
Replacement procedure (R-2000iB/165R, 200R, 100P)
Remove
Remove the cables as the following procedure.
<J1-axis base>
1
Place all the robot axes in their 0-degree position, then set the
control unit power switch to off.
2
Detach the cable leading to the control unit from the connector
panel on the rear of the robot. Remove the connector panel from
the J1 base, then detach all the cable tubes from the connector
panel. Remove the terminal on the rear of the battery box and the
ground terminal in the J1-axis base. Separate the housing and
insert of the HARTING connector from each other.; If the
housing is left on the cable, the cable cannot be pulled out
through the J1 axis piping. (Fig.5.3(a))
3
When the robot has limit switches (option), remove the limit
switch for the J1-axis from the plate of the J1-axis base, and
remove the terminal in the switch, then pull out the cable from
the cast through hole. (Fig.5.3(b))
4
In case of 100P, remove the J1, J2 and J3-axis fan cables and the
fan. (See section 4.6 REPLACING FANS.) Remove all
connectors from the J1-axis through J6-axis motors. For the
precautions that must be taken, see “Precautions to be observed
when handling the pulse coder cable” at the beginning of Chapter
5.
5
Remove the cover plate attached to the J2-axis base. If a
DNS/DNP cable (option) is connected, remove the cable from
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5. REPLACING CABLES
MAINTENANCE
6
7
8
B-82235EN/03
the connector panel jointly secured to the cover plate. (Fig.
5.3(f))
The upper part of the J1-axis has a plate for clamping the cable.
The plate is fastened to the J2-axis base. Remove the bolt and
cable cover attached to the plate, then drop the cable with the
clamp in the pipe. (Fig.5.3(g))
Remove and pull out the plate from within the J1-axis base as
much as possible, then remove the bolt fastening the clamp.
(Fig.5.3(i))
Pull out the cable upward from the pipe of the J1-axis.
<J2-axis base and J2-axis arm>
9
Remove the bolts fastening the left plate of the J2-axis base, and
pull out the cable to the lower side of the J2-axis arm by running
the cable under the balancer.
10 Remove the cover plate of the J2-axis arm. Then, remove the
bolts fastening the plate of the J2-axis arm. (Fig5.3(m))
11 If the robot has limit switches (option), remove the limit switches
for the J2-axis and J3-axis from the plate of the J2-axis arm, and
remove the terminals in the switches, then pull out the cables
from the cast through hole of the J2-axis arm.(Fig. 5.3(n))
<J3-axis casing>
12 Remove the left plate B of the J3-axis casing. (Fig.5.3(o))
13 Remove the connector panel from the front of the J3-axis casing.
(Fig. 5.3(p))
14 Remove the right plate C of the J3-axis casing. Pull out the J3 to
J6-axis motor cables with the plate through hole of the front side.
(See Fig.5.3(r).)
15 At last, remove the left plate A of the J3-axis casing.
This completes cable unit detachment from the robot.
16
When replacing a part of the cables, remove the clamp and cable
cover from the cable unit. Next, cut the cable tie securing the
cables, then detach the desired cable(s). (See Fig.5.3(v).)
Assembling
Install the cable according to the procedure below.
1
2
Fasten the cable unit to the J2-axis arm with the bolts. Don’t be
wrong the up and down. When a limit switch is used, run the
cable through the cast through hole of the J2-axis arm, and
connect the switch terminal for the J2-axis and J3-axis, then
install the switch onto the plate of the J2-axis arm. Pull out any
excess cable toward the J2-axis arm cover, then bind the excess
cable with the main cable by using a nylon tie. Next, install the
cover plate on the J2-axis arm. (Fig. 5.3(l),(m))
Pull out the cable toward the back of the robot by running the
cable under the balancer. Then, fasten the left plate of theJ2-axis
base and the plate under the balancer. Be careful to lay the cable
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3
4
5
6
7
8
9
10
11
12
5. REPLACING CABLES
so that mechanical strain is not caused between the plate under
the balancer and the cable. (Fig. 5.3(l))
Fasten the plate A to the left of the J3-axis casing.
Run the J3 to J6 axis motor cables from the front of the J3 axis
casing to the back side through the casting hole then attach plate
C. (See Fig. 5.3 (o).)
Accommodate any excessive cables in the J3 axis casing and
secure the connector panel on the front of the J3 axis casing.
(See Fig. 5.3 (r).)
Finally, retain the cables with plate B. (See Fig. 5.3 (p).)
Run the cable through the J1-axis pipe from the top of the J2-axis
base, then pull out the cable toward the back of the J1-axis base.
Fasten the clamp onto the plate in the J1-axis base. Bind tightly
the cables with a thick cable tie(Approx. W:7.6mm) running
through the clamp, then fasten the plate to the J1-axis base.
(Fig.5.3(i))
Fasten the clamp and cable cover to the plate at the top of the
J1-axis. Bind tightly the cables with a thick cable tie Approx.
(W:7.6mm) running through the clamp, then fasten the plate to
the J2-axis base. (Fig.5.3(g))
Fasten the cover plate to the J2-axis base. If a DNS/DNP cable
(option) is used, fasten the connector onto the connector panel,
then fasten the connector panel together with the cover plate.
(Fig.5.3(f))
Attach all connectors to the J1-axis through J6-axis motors.
Make sure that the pulse coder connector covers are attached to
the J1-axis and J2-axis motors.
In case of 100P, mount the J1, J2 and J3-axis fan cables and the
fan. (See the section 4.6.)
When the robot has limit switches (option), run the cable through
the cast through hole of the J1-axis base, then connect the cable
to the terminal in the switch. Next, fasten the switch to the plate
on the J1-axis base. (Fig.5.3(b))
Connect the cables and tubes to the connector panel on the back
of the robot. Connect the ground terminal to the J1-axis base,
then connect the battery terminal to the back of the battery box.
Next, fasten the connector panel to the J1-axis base, then connect
the cable used for connection with the control unit to the
connector panel.
Turn on the power. If an alarm is issued at this time, release it
according to section 6.2.
Perform mastering. (See section 6 MASTERING.)
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Replacement procedure (R-2000iB/165CF)
Remove
Remove the cables as the following procedure.
<J1-axis base>
1
Place all the robot axes in their 0-degree position, then set the
control unit power switch to off.
2
Detach the cable leading to the control unit from the connector
panel on the rear of the robot. Remove the connector panel from
the J1 base, then detach all the cable tubes from the connector
panel. Remove the terminal on the rear of the battery box and the
ground terminal in the J1-axis base. Separate the housing and
insert of the HARTING connector from each other.; If the
housing is left on the cable, the cable cannot be pulled out
through the J1 axis piping. (Fig.5.3(c))
3
Remove the connector panel on the side of the J1-axis base and
then remove the connector and tube.
4
When the robot has limit switches (option), remove the limit
switch for the J1-axis from the plate of the J1-axis base, and
remove the terminal in the switch, then pull out the cable from
the cast through hole.
5
Remove all connectors from the J1-axis through J6-axis motors.
For the precautions that must be taken, see “Precautions to be
observed when handling the pulse coder cable” at the beginning
of Chapter 6.
6
When the DNS/DNP cable (optional) is connected, remove the
connector fixed on the J2-axis base.
7
The upper part of the J1-axis has a plate for clamping the cable.
The plate is fastened to the J2-axis base. Remove the bolt and
cable cover attached to the plate, then drop the cable with the
clamp in the pipe. (Fig.5.3(h))
8
Remove and pull out the plate from within the J1-axis base as
much as possible, then remove the bolt fastening the clamp.
(Fig.5.3(j))
9
Pull out the cable upward from the pipe of the J1-axis.
<J2-axis base and J2-axis arm>
10 Remove the bolt that fixes the plate to the left of the J2-axis base
and pull it out of the J2 base. (Fig. 5.3 (s))
11 Remove the plate that fixes the cable to the J2-axis arm. (Fig. 5.3
(t))
12 If the robot has limit switches (option), remove the limit switches
for the J2-axis and J3-axis from the plate of the J2-axis arm, and
remove the terminals in the switches, then pull out the cables
from the cast through hole of the J2-axis arm.
<J3-axis casing>
13 Remove the bolt that fixes the plate to the left of the J3-axis
casing.
14 Remove the connector box at the right front of the J3-axis casing
and then remove the cables and tubes from the connector box.
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MAINTENANCE
B-82235EN/03
5. REPLACING CABLES
15
To replace part of the cables, remove the clamp and cable cover
from the cable unit. Then, cut the cable tie that bundles the cable
to be replaced and then remove the cable. (Fig. 5.3 (w))
1
Before attaching the cables to be the robot, bundle the cables
with cable ties at marking positions and attach the clamps and
cable covers. (Fig. 5.3 (q))
Fix the cable unit to the J2-axis arm with bolts. When the limit
switch is attached, pass the cables through the mold hole of the
J2-axis arm, connect the switch terminals for the J2-axis and
J3-axis, and attach the switch to the plate of the J2-axis arm. Pull
out the excess part of the cable to the J2-axis arm cover side and
fix it with a cable tie to the cable line. Attach the cover plate to
the J2-axis arm. (Fig. 5.3 (t))
Fix the plate to the left of the J2-axis base.
Fix the plate to the left side of the J3-axis casing. Connect the
cable and tube to the connector box on the right side of the
J3-axis casing and then fix the connector box to the J3-axis
casing. (Figs. 5.3 (q) and (s))
Pass the cable from above the J2-axis base to the back of the
J1-axis base through the J1-axis pipe.
Fix the clamp to the plate within the J1-axis base. Fix the plate to
the J1-axis base. (Fig. 5.3 (j))
Fix the plate to the J2-axis base on the upper side of the J1-axis.
(Fig. 5.3 (h))
When the DNS/DNP cable (optional) is attached, fix the
connector to the connector panel and then fix the connector panel
to the J2 base.
Connect all connectors to the J1- to J6-axis motors.
When the limit switch (optional) is attached to the robot, connect
the cables to the terminals in the switch. Fix the switch to the
plate on the J1-axis base.
Connect the cables and tubes to the connector panel on the side
of the J1-axis base and fix the connector panel to the J1 base.
Connect the cables to the connector panel on the back of the
robot. Connect the grounding terminal to the J1-axis base and
connect the battery terminals to the back of the battery box. Fix
the connector panel to the J1-axis base and connect the
connection cable, one end of which is connected to the controller,
to the connector panel. (Fig. 5.3 (c))
Turn on the power. Clear the alarm that occurs at this time as
described in Section 6.2.
Perform mastering (See Chapter 6, “MASTERING”).
Assembling
2
3
4
5
6
7
8
9
10
11
12
13
14
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Ground terminal in the J1-axis base
Terminals on the battery box
rear surface
Housing
Insert
Cable
Connector panel
J1-axis base
Cable of
the controller
Fig. 5.3 (a) J1-axis connector panel (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
Limit switch
Plate
Plate
Casting hole
J1-axis base
Terminal inside the limit switch
Cable
Fig.5.3 (b) J1-axis limit switch (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Ground terminal in the J1-axis base
VIEW A
VIEW B
Battery box
Terminals on the battery box
rear surface
Fig. 5.3 (c) J1-axis connector panel (R-2000iB/165CF)
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
J2-axis base
Cover plate
Connector panel
DNS/DNP cable
(Option)
Fig. 5.3 (d) J2-axis base right side 1 (R-2000iB/165F, 210F, 125L, 175L)
J2-axis base
Clamp
Plate
Fig. 5.3 (e) J2-axis base right side 2 (R-2000iB/165F, 210F, 125L, 175L)
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
J2-axis base
Cover plate
DNS/DNP cable (option)
Connector panel
Fig. 5.3 (f)
J2-axis base right side 3 (R-2000iB/165R, 200R, 100P)
Clamp
J2-axis base
Plate
Fig. 5.3 (g) J2-axis base right side 4 (R-2000iB/165R, 200R, 100P)
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Cable tie
Clamp above the J1-axis
J1-axis cable outlet
Plate
DNS/DNP cable
(option)
Cable tie
Fig. 5.3 (h) J2-axis base right side 5 (R-2000iB/165CF)
Plate
Plate
J1-axis base
Fig. 5.3 (i) Plate in the J1-axis base (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
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MAINTENANCE
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5. REPLACING CABLES
Clamp
J1-axis base
Plate
Fig 5.3 (j) Plate in the J1-axis base (R-2000iB/165CF)
Plate
J2-axis base
Fig. 5.3 (k) J2-axis base left side 1 (R-2000iB/165F, 210F, 125L, 175L)
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5. REPLACING CABLES
MAINTENANCE
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Plate
J2-axis base
Fig. 5.3 (l) J2-axis base left side 2 (R-2000iB/165R, 200R, 100P)
Plate
Cover plate
J2-axis arm
Fig. 5.3 (m) J2-axis arm (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
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5. REPLACING CABLES
MAINTENANCE
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Limit switch
for J3-axis
Casting hole
Sponge for
protection
Plate
Plate
Casting hole
Limit switch
for J2-axis
Terminals inside the limit switch
Fig. 5.3 (n) J2/J3-axis limit switch (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
J3-axis casing
Plate A
Plate B
Fig. 5.3 (o) J3-axis casing left side (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
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5. REPLACING CABLES
MAINTENANCE
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J3-axis casing
Connector panel
Fig. 5.3 (p)
J3-axis casing connector panel (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
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MAINTENANCE
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5. REPLACING CABLES
J3-axis casing
Connector panel
Plate
Fig. 5.3 (q)
J3-axis casing connector panel (R-2000iB/165CF)
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5. REPLACING CABLES
MAINTENANCE
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J3-axis casing
Plate C
Fig. 5.3 (r) J3-axis casing right side (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
Plate
Clamp
J3-axis casing
Fig. 5.3 (s) J3-axis casing right side (R-2000iB/165CF)
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5. REPLACING CABLES
MAINTENANCE
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J3-axis limit switch
(optional)
J2-axis arm
Cable fixation plate
J2-axis base
J2-axis limit switch
(optional)
Fig. 5.3 (t)
Cable fixation plate
Replacing cables（R-2000iB/165CF）
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Cable cover
Clamp cover
Clamp
Clamp
Fig. 5.3 (u) Overview of cabling (R-2000iB/165F, 210F, 125L, 175L)
Cable cover
Cable cover
Clamp
Clamp
Fig. 5.3 (v) Overview of cabling (R-2000iB/165R, 200R, 100P)
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Clamp
Clamp
Cable cover
To the J3-axis and
wrist motor
To the connector panel
All cables are bundled by two
cable ties T1201 and loosely
attached.
Fig. 5.3 (w) Overview of cabling (R-2000iB/165CF)
- 159 -
5. REPLACING CABLES
5.4
MAINTENANCE
B-82235EN/03
LIMIT SWITCH REPLACEMENT (OPTION)
This section explains how to replace limit switches.
See the cable replacement procedure for an explanation of how to
detach the limit switch cables.
CAUTION
1 Before limit switch replacement, turn off the power to
the control unit.
2 After a limit switch is installed, be sure to adjust the
limit switch.
(R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
1. J1-axis limit switch replacement
1
2
3
4
5
6
Remove the limit switch from the plate on the J1-axis base.
Cut the cable tie, and detach the cable from the plate.
Remove the terminal in the switch, and remove the limit switch
from the cable.
Attach a new limit switch to the cable.
Install the limit switch on the plate.
Fasten the cable to the plate with a cable tie.
2. J2-axis limit switch replacement
1
2
3
4
5
6
7
8
Remove the cover plate of the J2-axis arm, then cut the cable tie
used to prevent the limit switch cable from slackening.
Remove the plate of the J2-axis arm used to fasten the limit
switch.
Remove the limit switch from the plate.
Remove the terminal in the switch, then remove the limit switch
form the cable.
Attach a new limit switch to the cable.
Install the limit switch on the plate.
Install the plate on the J2-axis arm.
Pull the limit switch cable slackening in the J2-axis arm toward
the cover of the J2-axis arm, then tie the cable to the cables for
the mechanical section.
CAUTION
1 If a cable is slackening, the cable can rub against
the casting and can break as the robot moves.
Ensure that the cable does not slacken to rub
against the casting.
2 At some sections on the cable (J2: one section, J3:
two sections) where the clearance between the
cable and the casting is small, sponge covers are
wound for protection. When securing the cable,
make sure that the sponge covers are placed near
the casting shown in the figure.
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MAINTENANCE
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9
10
5. REPLACING CABLES
Fasten the cover plate to the J2-axis arm. Finally, adjust all limit
switches.
Now adjust all limit switches. (See the OPERATOR’S
MANUAL.)
(R-2000iB/165CF)
3. J2-axis limit switch replacement
1
2
3
4
5
6
7
Remove the plate to which the J2-axis limit switch is fixed.
Remove the J2-axis limit switch from the plate.
Remove the cable from the limit switch.
Fix a new limit switch to the cable.
Fix the limit switch to the plate.
Fix the plate to the J2-axis base.
Fix the cable to the J2-axis base with the plate.
4. J3-axis limit switch replacement
1
Remove the cable fixation plate of the J2-axis arm and cut the
cable tie that prevents the limit switch cable from being loosened.
Remove the plate of the J2-axis arm used to fasten the limit
switch.
Remove the limit switch from the plate.
Remove the terminal in the switch, then remove the limit switch
form the cable.
Attach a new limit switch to the cable.
Install the limit switch on the plate.
Install the plate on the J2-axis arm.
Pull the limit switch cable slackening in the J2-axis arm toward
the cover of the J2-axis arm, then tie the cable to the cables for
the mechanical section.
2
3
4
5
6
7
8
CAUTION
1 If a cable is slackening, the cable can rub against
the casting and can break as the robot moves.
Ensure that the cable does not slacken to rub
against the casting.
2 At some sections on the cable where the clearance
between the cable and the casting is small, sponge
covers are wound for protection. When securing the
cable, make sure that the sponge covers are placed
near the casting shown in the figure.
9
10
Fix the cable fixation plate to the J2-axis arm.
Finally, adjust all limit switches.
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
Limit switch for J1-axis
Plate
Nylon tie
Plate
Terminal in the limit switch
Fig.5.4 (a) Replacing the J1-axis limit switch (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
Limit switch
for J3-axis
Casting hole
Sponge for
protection
Sponge for
protection
Plate
Plate
Casting hole
Cover plate
Limit switch
for J2-axis
Fig. 5.4 (b) Replacing J2/J3-axis limit switch (R-2000iB/165F, 210F, 165R, 200R, 100P, 125L, 175L)
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5. REPLACING CABLES
MAINTENANCE
B-82235EN/03
J1-axis limit switch
J2-axis limit switch
Plate
Plate
Bolt M4×25
Spring washer
Plate
Limit switch
Plate
Fixation of the limit switch
J3-axis limit switch
Plate
Sponge for protection
Terminal in the limit switch
Fig. 5.4 (c) Replacing J2/J3-axis limit switch
- 163 -
(R-2000iB/165CF)
6. MASTERING
6
MAINTENANCE
B-82235EN/03
MASTERING
Mastering is an operation performed to associate the angle of each
robot axis with the pulse count value supplied from the absolute pulse
coder connected to the corresponding axis motor. To be specific,
mastering is an operation for obtaining the pulse count value
corresponding to the zero position.
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MAINTENANCE
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6.1
6. MASTERING
GENERAL
The current position of the robot is determined according to the pulse
count value supplied from the pulse coder on each axis.
Mastering is factory-performed. It is unnecessary to perform
mastering in daily operations. However, mastering becomes necessary
after:
Motor replacement
Pulse coder replacement
Reducer replacement
Cable replacement
Batteries for pulse count backup in the mechanical unit have
gonedead.
WARNING
Robot data (including mastering data) and pulse
coder data are backed up by their respective backup
batteries. Data will be lost if the batteries go dead.
Replace the batteries in the control and mechanical
units periodically. An alrm will be issued to warn the
user of a low battery voltage.
Mastering method
There are following five methods of mastering.
Table 6.1 Mastering method
Jig position mastering
This is performed using a mastering jig before the
machine is shipped from the factory.
Zero-position mastering This is performed with all axes set at the 0-degree
(eye mark mastering)
position. A zero-position mark (eye mark) is
attached to each robot axis. This mastering is
performed with all axes aligned to their respective
eye marks.
Simplified mastering
This is performed at a user-specified position. The
corresponding count value is obtained from the
rotation speed of the pulse coder connected to the
relevant motor and the rotation angle within one
rotation. simplified mastering uses the fact that the
absolute value of a rotation angle within one rotation
will not be lost.
One-axis mastering
This is performed for one axis at a time. The
mastering position for each axis can be specified by
the user. This is useful in performing mastering on a
specific axis.
Mastering data entry
Mastering data is entered directly.
This MAINTENANCE MANUAL describes jig position mastering
that is mainly required during replacement of parts. For other
mastering methods, refer to OPERATOR'S MANUAL.
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6. MASTERING
MAINTENANCE
B-82235EN/03
Onece mastering is performed, it is necessary to carry out positioning,
or calibration. Positioning is an operation is which the control unit
reads the current pulse count value to sense the current positon of the
robot.
CAUTION
If mastering is performed incorrectly, the robot may
behave unexpectedly. This is very dangerous. So,
the positioning screen is desinged to appear only
when the $MATER_ENB system variable is 1 or 2.
After performing positioning, press F5[DONE] on the
positioning screen. The $MASTER_ENB system
variable is reset to 0 automatically, thus hiding the
positioning screen.
CAUTION
Before mastering is performed, it is recommended
that the current mastering data be backed up.
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MAINTENANCE
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6.2
6. MASTERING
RESETTING ALARMS AND PREPARING FOR
MASTERING
Before performing mastering because a motor is replaced, it is
necessary to release the relevant alarm and display the positioning
menu.
Alarm displayed
“Servo 62 BZAL” or “Servo 075 Pulse mismatch”
Procedure
1
2
3
Display the positioning menu by following steps 1 to 6.
1
Press the screen selection key.
2
Select [6 SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variable] from the
menu.
4 Place the cursor on $MASTER_ENB, then key in “1” and
press [ENTER].
5
Press F1 [TYPE], and select[Mater/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal]
menu.
To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.
1
Press the MENUS key.
2
Select [0 NEXT] and select [6 SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variable] from the
menu.
4 Place the cursor on F3 RES_PCA, then press F4 [TRUE].
The message “ TRUE” appears and disappears immediately.
5
Switch the controller power off and on again
To reset the “Servo 075 Pulse mismatch” alarm, follow steps 1 to
3.
1 When the controller power is switched on again, the
message “Servo 075 Pulse mismatch” appears again.
2 Rotate the axis for which the message mentioned above has
appeared through 10 degrees in either direction.
3
Pree [FAULT RESET]. The alarm is reset.
- 167 -
6. MASTERING
6.3
MAINTENANCE
B-82235EN/03
MASTERING TO A FIXTURE (MASTER POSITION
MASTER)
Jig position mastering is performed using a mastering jig. This
mastering is carried out in the predetermined jig position.
Jig position mastering is accurate because a dedicated mastering jig is
used.
When mastering the robot, arrange the robot to meet the following
conditions.
- Make the robot mounting base horizontal within 1 mm.
- Remove the hand and other parts form the wrist.
- Set the robot in the condition protected from an external force.
Assembling the fixture base
1
Assemble the fixture base as shown in Fig. 6.3 (a) to (h).
Bolt
M5×20 (4pcs)
Plate
φ16 pin
(2pcs)
Bolt
M12×30 (2pcs)
Base
Adapter plate
Plate
Bolt
M5×20 (3pcs)
Fig. 6.3 (a) Assembling the fixture base (R-2000iB/165F, 210F, 125L, 175L, 165CF)
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6. MASTERING
MAINTENANCE
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Adapter plate
Base
M12×30 (2pcs)
Bolt
φM16 pin
(2pcs)
Plate
M5×20 (4pcs)
Bolt
Plate
Bolt
M5×20 (3pcs)
Fig. 6.3 (b) Assembling the fixture base (R-2000iB/165R, 200R, 100P)
2
Adjust the dial gauge to 3.00 mm using the calibration block, and
tighten it with M5 bolt as shown in Fig. 6.3 (b) . (Do not tighten
the bolt too strongly or the dial indicator will be broken.)
M5 bolt
Calibration block
Fig. 6.3 (c)
3
Mounting dial indicator
Mount the fixture to the wrist flange as shown Fig. 6.3 (d) to (f).
Bolt
M12×30 (2pcs)
Pin
φ10(2pcs)
Front
View A
J1-axis base
Fig. 6.3 (d) Assembling the fixture base (R-2000iB/165F, 210F, 125L, 175L)
- 169 -
6. MASTERING
MAINTENANCE
B-82235EN/03
Bolt
M12×30 (2pcs)
φ10 pin
(2pcs)
Front
J1-axis base
Make sure that there is not interference between the mastering jig and the base (J1 base installation part).
Fig. 6.3 (e) Assembling the fixture base (R-2000iB/165R, 200R, 100P)
Bolt
M12×30 (2pcs)
φ10 pin
(2pcs)
J1-axis base
Front
Fig. 6.3 (f)
Assembling the fixture base (R-2000iB/165CF)
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MAINTENANCE
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4
6. MASTERING
Assemble the fixture to the wrist flange as shown in Fig. 6.3 (g)
to (i).
Bolt
M10×35 (4pcs)
Pin
φ10 (2pcs)
Fig. 6.3 (g) Assembling the fixture to the wrist flange (R-2000iB/165F, 210F, 165R, 125L, 175L)
CAUTION
Before attaching the jig to the wrist, be sure to
remove the FANUC flange adaptor and special
flange abaptor.
Abaptors, mastering cannot be performed under the
correct attitude.
- 171 -
6. MASTERING
MAINTENANCE
Bolt
M10×35 (4pcs)
Pin
φ10 (2pcs)
Fig. 6.3 (h) Assembling the fixture to the wrist flange (R-2000iB/165R, 200R, 100P)
Pin
φ10 (2pcs) or φ9 (2pcs)
Bolt
M10×40 (4pcs) or M10×35 (4pcs)
Fig. 6.3 (i) Assembling the fixture to the wrist flange (R-2000iB/165CF)
- 172 -
B-82235EN/03
6. MASTERING
MAINTENANCE
B-82235EN/03
Mastering
1
2
3
4
Press MENUS.
Press NEXT and select SYSTEM.
Press F1, [TYPE].
Select Mater/Cal.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
5
LOAD
RES_PCA
DONE
Release brake control, and jog the robot into a posture for
mastering.
A to E (see Fig. 6.3 (d)) of the jig attached to the wrist are dial
gauges A to E (see Figs. 6.3 (g) to (i)) and make adjustments so
that dial gauges A to E indicate 3 mm. A posture as shown in
Fig. 6.3 (j) to (o) should be taken. See this figure for reference.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.$SV_OFF_ALL: FALSE
$PARAM_GROUP.$SV_OFF_ENB[*]: FALSE (for all
axes)
After changing the system variables, switch the
control unit power off and on again.
6
Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES.
"MASTER POSITION" shown in Figs. 6.3 (j) to (o) is set in this
position.
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6. MASTERING
MAINTENANCE
B-82235EN/03
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE
POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>
[ TYPE ]
7
LOAD
RES_PCA
DONE
Select “ 6 CALIBRATE “ and press F4, YES. Mastering will be
performed
Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000> <
0.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
[ TYPE ]
LOAD
- 174 -
RES_PCA
DONE
MAINTENANCE
B-82235EN/03
8
6. MASTERING
After positioning is completed, press F5 [DONE].
WARNING
Since the axis stroke is not checked during the
mastering, be careful to stay clear of the robot
motion.
Fig. 6.3 (j) Mastering posture (R-2000iB/165F)
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6. MASTERING
MAINTENANCE
Fig. 6.3 (k) Mastering posture (R-2000iB/210F)
Fig. 6.3 (l)
Mastering posture（R-2000iB/165R）
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MAINTENANCE
Fig. 6.3 (m) Mastering posture (R-2000iB/200R)
Fig. 6.3 (n) Mastering posture (R-2000iB/100P)
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6. MASTERING
6. MASTERING
MAINTENANCE
Fig. 6.3 (o) Mastering posture (R-2000iB/125L)
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MAINTENANCE
Fig. 6.3 (p) Mastering posture (R-2000iB/175L)
- 179 -
6. MASTERING
6. MASTERING
MAINTENANCE
Fig. 6.3 (q) Mastering posture (R-2000iB/165CF)
- 180 -
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7
7.1
MAINTENANCE
7. SEVERE DUST/LIQUID
PROTECTION PACKAGE
SEVERE DUST/LIQUID PROTECTION
PACKAGE
SEVERE DUST/LIQUID PROTECTION PACKAGE
(OPTION)
The package is intended to improve the Severe dust/Liquid protection
characteristics of the robot so that it can be used in a severe
environment. It is also intended to improve the rust resistance of the
robot so that it can be used for a longer time.
Model
R-2000iB/165F, 125L
R-2000iB/210F, 175L
R-2000iB/165R
R-2000iB/200R
- 181 -
Severe dust/liquid protection
specification
A05B-1329-J801
A05B-1329-J802
A05B-1329-J803
A05B-1329-J804
7. SEVERE DUST/LIQUID
PROTECTION PACKAGE
7.1.1
MAINTENANCE
B-82235EN/03
Severe Dust/Liquid Protection Characteristics
The following table lists the IEC529-based Severe dust/Liquid
protection characteristics of the R-2000iB.
Standard
J3-axis arm and wrist
section
Drive unit of the main
body
Main body
Main
body : IP56
本体部：IP56
IP67
Severe dust/liquid
protection package
IP67
IP66
IP66
IP54
IP56
J3J3軸アーム+手首部：IP67
arm + Wrist unit : IP67
Fig. 7.1.1 Severe dust/Liquid protection characteristics of the R-2000iB
- 182 -
7.1.2
7. SEVERE DUST/LIQUID
PROTECTION PACKAGE
MAINTENANCE
B-82235EN/03
Configuration of the Severe Dust/Liquid Protection Package
The following table lists the major differences between the R-2000iB
standard specification and severe dust/liquid protection package.
Standard specifications
Entire mechanical unit
Black oxide finish steel bolt
Black oxide finish washer
Bolts
Covers
J3-axis connector panel
EE, I/O connectors
Non-waterproof connector
Severe dust/liquid protection option
Main unit
J3-axis arm and wrist
FR coating bolt
FR coating bolt
Stainless bolt
Black chromate washer
Black chromate washer
Stainless bolt
Black oxide finish steel bolt
J1-axis motor cover
J2-axis motor cover
J3-axis motor covers (upper and lower)
Battery box cover
Cable cover in mechanical unit (for all exposed cables)
Waterproof connector
Waterproof EE
connector
防水形EEコネクタ
J3-,
J4-, J5-, J6-axis
J3456軸モータカバー(上)
motor cover (upper)
J3-,J3456軸モータカバー(下)
J4-, J5-, J6-axis
motor cover (lower)
J1-axis
moter cover
J1軸モータカバー
J2軸モータカバー
J2-axis
moter cover
ケーブルカバー
Cable
cover
Battery
box cover
バッテリボックスカバー
Fig. 7.1.2
Configuration of the severe dust/liquid protection package
- 183 -
7. SEVERE DUST/LIQUID
PROTECTION PACKAGE
7.1.3
MAINTENANCE
B-82235EN/03
Notes on Specifying Severe Dust/Liquid Protection Package
1
The liquids below cannot be applied because they may cause
deterioration or corrosion of the rubber parts (such as packings,
oil seals, and O-rings) used in the robot.
(a) Organic solvent
(b) Chlorine- or gasoline-based cutting fluid
(c) Amine-based cleaning fluid
(d) Liquid or solution that includes a corrosive such as an acid
or alkali or causes rust
(e) Some other liquid or solution to which nitrile rubber (NBR)
does not have resistance
2
When the robot is used in an environment where a liquid such as
water is dashed over the robot, great attention should be given to
drainage under the J1-axis base.
A failure may be caused if the J1-axis base is kept immersed in
water due to poor drainage.
- 184 -
B-82235EN/03
7. SEVERE DUST/LIQUID
PROTECTION PACKAGE
MAINTENANCE
7.2
REPLACING SEVERE DUST/LIQUID PROTECTION
PACKAGE COMPONENTS
7.2.1
Replacing Motor Covers
Replace motor covers as required according to Section 4.9. Ensure
that all bolts are stainless.
7.2.2
Replacing Cable Covers
Cable covers are attached to all otherwise exposed cables in the
undesirable–environment option. After a cable or cable cover is
replaced, mount the cover as shown in Fig.7.2.2 (a) and (b).
NOTE
Fasten a cable cover end to a connector or cable
with a nylon tie while gathering wrinkles in the
cable cover end neatly.
NOTE
Mount each cable cover in such a manner that the
Magic Tape (Velcro tape) on it is downward or that
its covering side (male side) laps over the other
side from above, so as to keep water from getting
or lingering in the cover.
ケーブル
Cable
ケーブルカバー
Cable
cover
マジックテープ
Magic
tape
良い例
Example of good
covering
- 185 -
Example悪い例
of bad covering
7. SEVERE DUST/LIQUID
PROTECTION PACKAGE
Fig. 7.2.2 (a)
MAINTENANCE
Mounting the cable cover (R-2000iB/165F, 210F, 125L, 175L)
- 186 -
B-82235EN/03
MAINTENANCE
B-82235EN/03
Fig. 7.2.2 (b)
7. SEVERE DUST/LIQUID
PROTECTION PACKAGE
Mounting the cable cover (R-2000iB/165R, 200R)
- 187 -
7. SEVERE DUST/LIQUID
PROTECTION PACKAGE
7.2.3
MAINTENANCE
B-82235EN/03
Replacing the Batteries and Battery Box Cover
Replacing the batteries
1
2
3
Remove the six SUS bolts (M4×10), then the battery box cover
plate.
Replace the batteries according to Section 2.2.
Mount the battery box cover plate with the six SUS bolts
(M4×10).
Replacing the battery box cover
NOTE
When the battery box cover is replaced, the power
must be kept on in the same manner as for the
batteries, because the battery box will be opened.
If the battery box cover is replaced while the power
is off, the current position information will be lost,
resulting in mastering becoming necessary.
Keep the emergency stop button held down for
safety purposes when replacing the battery box
cover.
1
2
3
4
5
Remove the six SUS bolts (M4×10), then the battery box cover
plate.
Remove the lid of the battery box, and take out the batteries.
Remove the two M4×12 flush bolts that fasten the battery box
and battery box cover together to the J1–axis connector board,
then remove the battery box and battery box cover.
Remove the battery cable terminals from the rear of the battery
box, and replace the battery box.
Reverse the above steps to mount the battery box and battery box
cover.
- 188 -
MAINTENANCE
B-82235EN/03
Battery box cover
バッテリボックスカバー
バッテリボックス
Battery
box
バッテリ(4個)
Batteries (4)
バッテリボックス蓋
Battery
box lid
Plate
プレート
Flush
M4×12 (2)
皿ネジbolts
M4X12(2個)
M4X10SUS(6個)
M4×10
SUS (6)
Fig. 7.2.3 Replacing the battery box cover
- 189 -
7. SEVERE DUST/LIQUID
PROTECTION PACKAGE
APPENDIX
APPENDIX
B-82235EN/03
A
A. SPARE PARTS LIST
SPARE PARTS LIST
Table A (a)
Ｎo.
K111
K112
K113
K211
K212
K213
K123
K115
Ｎo.
K511
K512
K513
K515
K611
K612
K613
K615
K523
K515
Specifications
A660-8015-T300
A660-8015-T301
A660-8015-T412
A660-8015-T843
A660-8015-T844
A660-8015-T845
A660-8015-T904
A660-8014-T269
Cables (Standard)
Function
J1 to J6 PULSECODER+EE
J1 to J6 POWER
J1 to J6 PULSECODER
J1 to J6 PULSECODER+EE
J1 to J6 POWER
J1 to J6 PULSECODER
J1 to J6 PULSECODER+EE
J1 to J6 POWER
Models
R-2000iB/165F, 210F, 125L,
175L
R-2000iB/165R, 200R, 100P
R-2000iB/165CF
Table A (b) Cables (Standard : CE)
Specifications
Function
Models
R-2000iB/165F, 210F, 125L,
A660-8015-T350
J1 to J6 PULSECODER+EE
175L
A660-8015-T351
J1 to J6 POWER
A660-8015-T413
J1 to J6 PULSECODER
A660-8015-T927
J1 to J6 PULSECODER+EE
(Severe dust liquid option)
R-2000iB/165R, 200R, 100P
A660-8015-T846
J1 to J6 PULSECODER+EE
A660-8015-T847
A660-8015-T848
A660-8015-T941
A660-8015-T908
A660-8014-T266
J1 to J6 POWER
J1 to J6 PULSECODER
J1 to J6 PULSECODER+EE
(Severe dust liquid option)
J1 to J6 PULSECODER+EE
J1 to J6 POWER
- 193 -
R-2000iB/165R, 200R
R-2000iB/165CF
A. SPARE PARTS LIST
APPENDIX
Table A (c)
Ｎo.
K131
K132
K133
K134
K135
K136
K137
K138
K139
K140
K231
K232
K233
K235
K236
K137
K238
K239
K240
K143
K144
K273
K274
K291
K282
K221
K286
Specifications
A660-2006-T290
A660-8015-T612
A660-8015-T614
A660-8015-T616
A660-8015-T618
A05B-1329-D003
A660-2006-T207
A660-8015-T352
A660-8015-T620
A660-8015-T622
A660-2006-T383
A660-8015-T849
A660-8015-T851
A660-8015-T855
A05B-1329-D007
A660-2006-T207
A660-8015-T857
A660-8015-T858
A660-8015-T860
A660-8014-T364
A660-8014-T365
A660-4003-T939
A660-4003-T940
A05B-1321-D017
A660-8013-T449
A660-8014-T020
A660-8014-T030
Cables (Option)
Function
AS(USER/SIGNAL)
AP(USER/POWER)
DNS(SIGNAL)
DNP(POWER) (J1J2J3)
DNP(POWER) (J2J3)
I/O Unit MODEL B
J123 OT short circuit cable
J123 OT
ARP
ARM
AS(USER/SIGNAL)
AP(USER/POWER)
DNS(SIGNAL)
DNP(POWER) (J1J2J3)
I/O Unit MODEL B
J123 OT short circuit cable
J123 OT
ARP
ARM
AS(USER/SIGNAL)
AP(USER/POWER)
DNS(SIGNAL)
DNP(POWER) (J1J2J3)
I/O Unit MODEL B
J123 OT
ARP
ARM
B-82235EN/03
- 194 -
Models
R-2000iB/165F, 210F, 125L,
175L
R-2000iB/165R, 200R, 100P
R-2000iB/165CF
APPENDIX
B-82235EN/03
Ｎo.
K531
K532
Table A (d) Cables (Option : CE)
Specifications
Function
A660-2006-T291
AS(USER/SIGNAL)
A660-8015-T613
AP(USER/POWER)
K533
K534
K535
A660-8015-T615
A660-8015-T617
A660-8015-T619
DNS(SIGNAL)
DNP(POWER) (J1J2J3)
DNP(POWER) (J2J3)
K536
K539
A05B-1329-D004
A660-8015-T621
I/O Unit MODEL B
ARP
K540
A660-8015-T623
ARM
K591
K592
A660-8015-T944
A05B-1329-D013
3DV
CAMERA
K631
K632
K633
A660-2006-T384
A660-8015-T850
A660-8015-T852
AS(USER/SIGNAL)
AP(USER/POWER)
DNS(SIGNAL)
K635
K636
A660-8015-T856
A05B-1329-D008
DNP(POWER) (J1J2J3)
I/O Unit MODEL B
K639
A660-8015-T859
ARP
K640
K642
K691
A660-8015-T861
A05B-1329-D012
A660-8015-T946
ARM
FAN CABLE
3DV
K692
A05B-1329-D014
CAMERA
K536
K546
A660-8014-T366
A660-8014-T367
AS(USER/SIGNAL)
AP(USER/POWER)
K542
K543
K281
K545
K544
A660-4004-T149
A660-4004-T150
A05B-1321-D006
A660-8014-T363
A660-8014-T362
DNS(SIGNAL)
DNP(POWER) (J1J2J3)
I/O Unit MODEL B
ARP
ARM
Axis
J1,J2,J3
J4,J5,J6
J1,J2,J3
J4,J5,J6
Specifications
A06B-0041-B605#S042
A06B-0238-B605#S000
A06B-0267-B605#S000
A06B-0235-B605#S000
A. SPARE PARTS LIST
Models
R-2000iB/165F, 210F, 125L,
175L
R-2000iB/165R, 200R, 100P
R-2000iB/100P
R-2000iB/165R, 200R
R-2000iB/165CF
Table A (e) Motor
Remarks
Models
αiSR30/3000
R-2000iB/165F, 210F, 165R, 200R,
100P, 125L, 175L
αiS12/4000
αiS30/3000
R-2000iB/165CF
αiS8/4000
- 195 -
A. SPARE PARTS LIST
Name
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
APPENDIX
B-82235EN/03
Table A (f) Reducer
Specifications
Models
R-2000iB/165F, 210F, 125L, 165R, 200R,
A97L-0218-0382#320CA229
100P, 175L
R-2000iB/165CF
A97L-0218-0237#320C-35
R-2000iB/165F, 125L
A97L-0218-0383#450N-236
R-2000iB/210F, 100P, 175L
A97L-0218-0383#450N-290
R-2000iB/165R
A97L-0218-0383#450N-252
R-2000iB/200R
A97L-0218-0383#450N-313
R-2000iB/165CF
A97L-0218-0238#450E-210
R-2000iB/165F, 165R, 100P, 125L
A97L-0218-0384#320N-235
R-2000iB/210F, 200R, 175L
A97L-0218-0383#450N-270
R-2000iB/165CF
A97L-0218-0239#320E-190
R-2000iB/165F, 165R , 125L
A97L-0218-0385#70N-35
R-2000iB/210F, 200R, 100P, 175L
A97L-0218-0342#110E-46
R-2000iB/165CF
A97L-0218-0240#80E-37
When the J5- or J6-axis reducer is broken, replace the wrist unit.
- 196 -
APPENDIX
B-82235EN/03
Table A (g) Gear
Specifications
Models
R-2000iB/165F, 210F, 125L, 165R, 200R,
A97L-0218-0801#229
100P, 175L
A97L-0001-0196#08Z000A
A6-CJR-40
R-2000iB/165CF
A290-7321-X221
Name
J1-axis input gear
J1-axis bearing
J1-axis C-ring
J1-axis spur gear
J1-axis center gear
J1-axis bearing
J2-axis input gear
(NOTE)
J3-axis input gear
(NOTE)
J4-axis spur gear
J5-axis spur gear
J6-axis spur gear
*
-
-
Name
Balancer
Wrist unit
A. SPARE PARTS LIST
A290-7321-X222
A97L-0001-0192#3000000
A97L-0218-0802#236
R-2000iB/165F, 125L
A97L-0218-0802#252
A97L-0218-0802#290
A97L-0218-0802#313
R-2000iB/165R
R-2000iB/210F, 100P, 175L
R-2000iB/200R
A97L-0218-0245#210
A97L-0218-0803#235
R-2000iB/165CF
R-2000iB/165F, 125L, 165R, 100P
A97L-0218-0802#270
A97L-0218-0227#190
A290-7329-X421
A290-7324-X421
A290-7321-Y421
R-2000iB/210F, 200R, 175L
R-2000iB/165CF
R-2000iB/165F, 210F, 165R, 200R, 100P,
175L
R-2000iB/125L
R-2000iB/165CF
A290-7324-Z423
R-2000iB/165F, 165R
A290-7329-Y423
A290-7324-X423
R-2000iB/210F, 200R, 100P, 175L
R-2000iB/125L
A290-7321-Y423
A290-7324-Z425
A290-7329-Y425
R-2000iB/165CF
R-2000iB/165F, 165R
R-2000iB/210F, 200R, 100P, 175L
A290-7329-Z425
A290-7321-Y425
R-2000iB/125L
R-2000iB/165CF
The shapes of J2- and J3-axis input gears have been changed
since November 2006. Accordingly, their input gear mounting
bolts have been changed in length.
The whole length of the input gear for the robots shipped in
October 2006 and earlier is 92 mm. The input gear mounting
bolt must be M6 × 65.
The whole length of the input gear for the robots shipped in
November 2006 and later is 97 mm. The input gear mounting
bolt must be M6 × 70.
Table A (h) Other (Mechanical unit)
Specifications
Models
R-2000iB/165F, 125L
A290-7329-V301
R-2000iB/210F, 175L
A290-7329-V302
R-2000iB/165R, 200R, 100P
A290-7324-V311
A290-7329-T501
A290-7324-T515
A290-7321-T503
- 197 -
R-2000iB/165F, 165R, 125L
R-2000iB/210F, 200R, 100P, 175L
R-2000iB/165CF
A. SPARE PARTS LIST
Name
Battery
Grease
Grease
APPENDIX
B-82235EN/03
Table A (i) Battery and grease
Specifications
Models
A98L-0031-0005
All models
R-2000iB/165F,125L,165R,
A98L-0040-0174#15KG
100P
R-2000iB/210F,200R, 175L
A98L-0040-0174#17KG
R-2000iB/165CF
A98L-0040-0174#12.8KG
A97L-0001-0179#2
All models
Table A (j)
O-ring
Models
Remarks
1.5V, size D
Kyodo Yushi
VIGOGREASE RE0
Shell Alvania Grease S2
Name
O-ring
Specifications
JB-OR1A-G125
Location
Motor for J1 to
J3-axis
Motor for J4 to
J6-axis
J1-axis reducer
All models
O-ring
JB-OR1A-G105
All models
O-ring
A98L-0040-0041#281
O-ring
A98L-0040-0041#281
R-2000iB/165F, 210F, 165R, 200R,
100P, 125L, 175L
R-2000iB/165CF
O-ring
JB-OR1A-G135
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
JB-OR1A-G190
JB-OR1A-G280
JB-OR1A-G300
A98L-0001-0347#S265
JB-OR1A-G170
A98L-0040-0041#272
JB-OR1A-G190
JB-OR1A-G280
R-2000iB/165F, 210F, 165R, 200R,
100P, 125L, 175L
R-2000iB/165CF
J2-axis reducer
R-2000iB/165F, 165R, 100P, 125L
J3-axis reducer
O-ring
O-ring
JB-OR1A-G270
A98L-0001-0347#S240
R-2000iB/165CF
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
JB-OR1A-G115
A98L-0040-0041#260
A290-7302-X552
JB-OR1A-G190
A290-7302-X552
A98L-0001-0347#S125
R-2000iB/165F, 165R, 125L
R-2000iB/210F, 200R, 175L
R-2000iB/210F, 200R, 100P, 175L
R-2000iB/165CF
- 198 -
J4-axis reducer
APPENDIX
B-82235EN/03
Name
Stopper
Stopper 2
Table A (k) Mechanical stopper
Specifications
Models
R-2000iB/165F, 210F, 125L, 175L
A290-7329-X215
R-2000iB/165R, 200R, 100P
A290-7329-Y215
R-2000iB/165CF
A290-7321-X215
A290-7324-X214
A97L-0218-0484#3125
A6-BA-24X80
A6-WM-24S
A290-7329-X341
A290-7329-Y341
A290-7329-X342
R-2000iB/165F, 210F, 165R, 200R,
100P, 125L, 175L
Plate
Stopper J3A
A290-7329-Y342
A290-7321-Y345
A290-7329-X411
Stopper J3B
A290-7329-X412
Stopper J3A
A290-7321-X461
R-2000iB/165R, 200R, 100P
R-2000iB/165CF
R-2000iB/165F, 210F, 165R, 200R,
100P, 125L, 175L
R-2000iB/165F, 210F, 165R, 200R,
100P, 125L, 175L
R-2000iB/165CF
Stopper J3B
A290-7321-X461
R-2000iB/165CF
Collar
Bush
Bolt
Washer
Stopper J2A
Stopper J2B
R-2000iB/165F, 210F, 125L, 175L
R-2000iB/165R, 200R, 100P
R-2000iB/165F, 210F, 125L, 175L
- 199 -
A. SPARE PARTS LIST
Location
For J1-axis
For J2-axis plus
side
For J2-axis
minus side
For J2-axis
For J3-axis plus
side
For J3-axis
minus side
For J3-axis plus
side
For J3-axis
minus side
B. CIRCUIT DIAGRAM
B
APPENDIX
CIRCUIT DIAGRAM
Fig. B (a) Circuit diagram (R-2000iB/165F, 210F, 125L, 175L)
- 200 -
B-82235EN/03
B-82235EN/03
APPENDIX
R-2000iB/165F,210F,125L,175L(R-J3iC)
CIRCUIT DIAGRAM
- 201 -
B. CIRCUIT DIAGRAM
B. CIRCUIT DIAGRAM
APPENDIX
Fig. B (b) Circuit diagram (R-2000iB/165R, 200R)
- 202 -
B-82235EN/03
B-82235EN/03
APPENDIX
- 203 -
B. CIRCUIT DIAGRAM
B. CIRCUIT DIAGRAM
APPENDIX
Fig. B (c) Circuit diagram (R-2000iB/100P)
- 204 -
B-82235EN/03
B-82235EN/03
APPENDIX
- 205 -
B. CIRCUIT DIAGRAM
B. CIRCUIT DIAGRAM
APPENDIX
Fig. B (d) Circuit diagram (R-2000iB/165CF)
- 206 -
B-82235EN/03
B-82235EN/03
APPENDIX
- 207 -
B. CIRCUIT DIAGRAM
C. PERIODIC MAINTENANCE TABLE
C
APPENDIX
B-82235EN/03
PERIODIC MAINTENANCE TABLE
FANUC Robot R-2000iB/165F,165R,125L
Working time (H)
Items
1
Check the mechanical cable.
(damaged or twisted)
Check the motor connector.
(loosening)
Check
time
Periodic Maintenance Table
3
6
9
1
First
Oil
Grease check months months months year
960 1920 2880 3840
amount 320
2
years
4800
5760
6720
7680
0.2H
―
○
○
○
0.2H
―
○
○
○
0.2H
―
○
○
○
4 bolt.
2.0H
―
○
○
○
5 Remove spatter and dust etc.
1.0H
―
○
○
○
6 Replacing battery. *
0.1H
―
0.5H
5500cc
0.5H
3500cc
0.5H
2500cc
0.5H
1900cc
11 reducer(J4/J5/J6-axis) for wrist 0.5H
3200cc
2
3 Tighten the end effector bolt.
Tighten the cover and main
Replacing grease of J1 axis
7 reducer*
Replacing grease of J2 axis
8 reducer*
Replacing grease of J3 axis
9 reducer*
Replacing grease of J4-axis
10 gear box*
8640
9600 10560
●
Replacing grease of
axis*
12
13
Point of grease nipple
14
0.1H
10cc
each
4.0H
―
13 teach pendant cable
0.2H
―
○
○
○
○
○
○
○
○
○
○
○
○
14 Cleaning the ventilator
0.2H
―
○
○
○
○
○
○
○
○
○
○
○
○
15 Check the source voltage *
0.2H
―
○
16 Replacing battery *
0.1H
―
15 Greasing to balancer bushing∗
●
●
16
17
Replacing cable of mechanical
18 unit *
Control unit
Check the robot cable and
○
○
○
○
For descriptions about the items marked with an asterisk(*), refer to “R-J3iC Control Unit Maintenance Manual.”
●: requires exchange of parts
○: does not require exchange of parts
- 208 -
○
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-82235EN/03
3
4
5
6
7
8
years
years
years
years
years
years
1152 1248 1344 1440 1536 1632 1728 1824 1920 2016 2112 2208 2304 2400 2496 2592 2688 2784 2880 2976 3072
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Item
○
○
○
○
○
1
○
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
●
●
●
6
●
●
7
●
●
8
●
●
9
●
●
10
●
●
Overhaul
●
11
12
13
14
●
●
●
●
15
●
16
17
18
●
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
19
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
20
○
○
○
○
○
○
○
○
○
○
21
22
●
- 209 -
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-82235EN/03
FANUC Robot R-2000iB/210F, 200R, 175L
Working time (H)
Items
1
Check the mechanical cable.
(damaged or twisted)
Check the motor connector.
(loosening)
Check
time
Periodic Maintenance Table
3
6
9
1
Oil
First
Grease check months months months year
960 1920 2880 3840
amount 320
2
years
4800
5760
6720
7680
0.2H
―
○
○
○
0.2H
―
○
○
○
0.2H
―
○
○
○
4 bolt.
2.0H
―
○
○
○
5 Remove spatter and dust etc.
1.0H
―
○
○
○
6 Replacing battery. ∗
0.1H
―
0.5H
5500cc
0.5H
3500cc
0.5H
2640cc
0.5H
1900cc
0.5H
4900cc
2
3 Tighten the end effector bolt.
Tighten the cover and main
Replacing grease of J1 axis
reducer∗
Replacing grease of J2 axis
8
reducer∗
Replacing grease of J3 axis
9
reducer∗
Replacing grease of J4-axis
10
gear box∗
Replacing grease of
11 reducer(J4/J5/J6-axis) for wrist
axis∗
7
8640
9600 10560
●
12
Point of grease nipple
13
14
0.1H
10cc
each
4.0H
―
0.2H
―
○
○
○
○
○
○
○
○
○
○
○
○
14 Cleaning the ventilator
0.2H
―
○
○
○
○
○
○
○
○
○
○
○
○
15 Check the source voltage ∗
0.2H
―
○
16 Replacing battery ∗
0.1H
―
15 Greasing to balancer bushing∗
●
●
16
17
Replacing cable of mechanical
unit ∗
Check the robot cable and
13 teach pendant cable
Control unit
18
○
○
○
○
For descriptions about the items marked with an asterisk(*), refer to “R-J3iC Control Unit Maintenance Manual.”
●: requires exchange of parts
○: does not require exchange of parts
- 210 -
○
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-82235EN/03
3
4
5
6
7
8
years
years
years
years
years
years
1152 1248 1344 1440 1536 1632 1728 1824 1920 2016 2112 2208 2304 2400 2496 2592 2688 2784 2880 2976 3072
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Item
○
○
○
○
○
1
○
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
●
●
●
6
●
●
7
●
●
8
●
●
9
●
●
10
●
●
●
●
Overhaul
●
11
12
13
14
●
●
●
●
15
●
16
17
18
●
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
19
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
20
○
○
○
○
○
○
○
○
○
○
21
22
●
- 211 -
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-82235EN/03
FANUC Robot R-2000iB/100P
Working time (H)
Items
1
Check the mechanical cable.
(damaged or twisted)
Check the motor connector.
(loosening)
Check
time
Periodic Maintenance Table
6
9
1
3
Oil
First
Grease check months months months year
960 1920 2880 3840
amount 320
2
years
4800
5760
6720
7680
0.2H
―
○
○
○
0.2H
―
○
○
○
0.2H
―
○
○
○
4 bolt.
2.0H
―
○
○
○
5 Remove spatter and dust etc.
1.0H
―
○
○
○
6 Replacing battery. ∗
0.1H
―
0.5H
5500cc
0.5H
3500cc
0.5H
2500cc
0.5H
1900cc
0.5H
4900cc
2
3 Tighten the end effector bolt.
Tighten the cover and main
Replacing grease of J1 axis
7
reducer∗
Replacing grease of J2 axis
8
reducer∗
Replacing grease of J3 axis
9
reducer∗
Replacing grease of J4-axis
10
gear box∗
Replacing grease of
11 reducer(J4/J5/J6-axis) for wrist
axis∗
8640
9600 10560
●
9
8
7
10
12
13
Point of grease nipple
14
0.1H
10cc
each
4.0H
―
0.2H
―
○
○
○
○
○
○
○
○
○
○
○
○
20 Cleaning the ventilator
0.2H
―
○
○
○
○
○
○
○
○
○
○
○
○
21 Check the source voltage ∗
0.2H
―
○
22 Replacing battery ∗
0.1H
―
15 Greasing to balancer bushing∗
●
●
16
17
Replacing cable of mechanical
unit ∗
Check the robot cable and
19 teach pendant cable
Control unit
18
○
○
○
○
○
For descriptions about the items marked with an asterisk(*), see this manual or refer to “R-J3iC Control Unit Maintenance
Manual.”
●: requires exchange of parts
○: does not require exchange of parts
- 212 -
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-82235EN/03
3
4
5
6
7
8
years
years
years
years
years
years
1152 1248 1344 1440 1536 1632 1728 1824 1920 2016 2112 2208 2304 2400 2496 2592 2688 2784 2880 2976 3072
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Item
○
○
○
○
○
1
○
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
●
●
●
6
●
●
7
●
●
8
●
●
9
●
●
10
●
●
Overhaul
●
11
12
13
14
●
●
●
●
15
●
16
17
18
●
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
19
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
20
○
○
○
○
○
○
○
○
○
○
21
22
●
- 213 -
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-82235EN/03
FANUC Robot R-2000iB/165CF
Working time (H)
Items
1
Check the mechanical cable.
(damaged or twisted)
Check the motor connector.
(loosening)
Check
time
Periodic Maintenance Table
6
9
1
3
Oil
First
Grease check months months months year
960 1920 2880 3840
amount 320
2
years
4800
5760
6720
7680
0.2H
―
○
○
○
0.2H
―
○
○
○
0.2H
―
○
○
○
4 bolt.
2.0H
―
○
○
○
5 Remove spatter and dust etc.
1.0H
―
○
○
○
6 Replacing battery. ∗
0.1H
―
0.5H
4100cc
0.5H
2600cc
0.5H
1600cc
0.5H
3950cc
0.5H
400cc
2
3 Tighten the end effector bolt.
Tighten the cover and main
Replacing grease of J1 axis
7
reducer∗
Replacing grease of J2 axis
8
reducer∗
Replacing grease of J3 axis
9
reducer∗
Replacing grease of J4-axis
10 gear box(J4/J5-axis) for wrist
axis∗
Replacing grease of
11
reducer(J6-axis) for wrist axis∗
8640
9600 10560
●
12
13
Point of grease nipple
14
15
16
17
Replacing cable of mechanical
unit ∗
Check the robot cable and
13 teach pendant cable
Control unit
18
4.0H
―
0.2H
―
○
○
○
○
○
○
○
○
○
○
○
○
14 Cleaning the ventilator
0.2H
―
○
○
○
○
○
○
○
○
○
○
○
○
15 Check the source voltage ∗
0.2H
―
○
16 Replacing battery ∗
0.1H
―
○
○
○
○
For descriptions about the items marked with an asterisk(*), refer to “R-J3iC Control Unit Maintenance Manual.”
●: requires exchange of parts
○: does not require exchange of parts
- 214 -
○
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-82235EN/03
3
4
5
6
7
8
years
years
years
years
years
years
1152 1248 1344 1440 1536 1632 1728 1824 1920 2016 2112 2208 2304 2400 2496 2592 2688 2784 2880 2976 3072
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Item
○
○
○
○
○
1
○
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
●
●
●
6
●
●
7
●
●
8
●
●
9
●
●
10
●
●
●
●
Overhaul
●
11
12
13
14
15
16
17
18
●
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
19
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
20
○
○
○
○
○
○
○
○
○
○
21
22
●
- 215 -
D. BOLT TIGHTENING TORQUE TABLE
D
APPENDIX
B-82235EN/03
BOLT TIGHTENING TORQUE TABLE
Those bolts for which no tightening torque is specified must be
tightened according to the following table.
Table D
Recommended Bolt Tightening Torque
Unit : Nm (kgf⋅cm):
Nominal
size
M3
M4
M5
M6
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
M36
Hexagon socket head bolt
(steel: strength class of 12.9)
Tightening torque
Upper limit
Lower limit
1.8(18)
1.3(13)
4.0(41)
2.8(29)
7.9(81)
5.6(57)
14(140)
9.6(98)
32(330)
23(230)
66(670)
46(470)
110(1150)
78(800)
180(1850)
130(1300)
270(2800)
190(1900)
380(3900)
260(2700)
530(5400)
370(3800)
730(7450)
510(5200)
930(9500)
650(6600)
1400(14000)
940(9800)
1800(18500)
1300(13000)
3200(33000)
2300(23000)
Hexagon socket head bolt
(stainless)
Tightening torque
Upper limit
Lower limit
0.76(7.7)
0.53(5.4)
1.8(18)
1.3(13)
3.4(35)
2.5(25)
5.8(60)
4.1(42)
14(145)
9.8(100)
27(280)
19(195)
48(490)
33(340)
76(780)
53(545)
120(1200)
82(840)
160(1650)
110(1150)
230(2300)
160(1600)










- 216 -
Hexagon socket head pan bolt
Hexagon socket head
counter-sunk bolt
(steel: strength rating of 12.9)
Tightening torque
Upper limit
Lower limit


1.8(18)
1.3(13)
4.0(41)
2.8(29)
7.9(81)
5.6(57)
14(140)
9.6(98)
32(330)
23(230)




















INDEX
B-82235EN/03
INDEX
GREASING THE BALANCER SHAFT (1
Number
YEAR (3840 HOURS) PERIODIC
1.5-YEAR (5,760 HOURS) CHECKS ...........10
MAINTENANCE) ..................................... 14
1-YEAR (3,840 HOURS) CHECKS ..............10
L
3-MONTH (960 HOURS) CHECKS .............. 6
LIMIT SWITCH REPLACEMENT (OPTION)
3-YEAR (11,520 HOURS) CHECKS ............10
................................................................. 160
B
M
BACKLASH MEASUREMENT ...................36
MAINTENANCE TOOLS ............................ 11
BOLT TIGHTENING TORQUE TABLE ...216
MASTERING.............................................. 164
C
MASTERING TO A FIXTURE (MASTER
CABLE FORMING .....................................115
POSITION MASTER)............................. 168
CABLE REPLACEMENT...........................139
N
CABLE WIRING .........................................107
CHECKS AND MAINTENANCE ................. 3
NOTE FOR PART REPLACEMENT .......... 48
CIRCUIT DIAGRAM ..................................200
Notes on Specifying Severe Dust/Liquid
Protection Package ................................. 184
Configuration of the Severe Dust/Liquid
Protection Package..................................183
O
D
OVERVIEW .................................................. 28
DAILY CHECKS............................................ 4
P
F
PERIODIC MAINTENANCE ...................... 13
FAILURES, CAUSES AND MEASURES....28
PERIODIC MAINTENANCE TABLE....... 208
Procedure for Releasing Residual Pressure
G
from the Grease Bath ............................... 25
GENERAL ...................................................165
R
Grease Replacement Procedure for the J4-Axis
Gear Box ....................................................21
Replacing Cable Covers.............................. 185
Grease Replacement Procedure for the J4-axis
REPLACING CABLES............................... 105
Gear box and Wrist (R-2000iB/165CF).....24
REPLACING FANS ..................................... 97
REPLACING J1-AXIS MOTOR (M1) AND
Grease Replacement Procedure for the Wrist
REDUCER................................................. 50
(R-2000iB/165F, 210F, 165R, 200R, 100P,
REPLACING J2-AXIS MOTOR (M2) AND
125L, 175L)................................................23
REDUCER................................................. 63
Grease replacement procedure of the J1, J2,
REPLACING J3-AXIS MOTOR (M3) AND
J3-axis reducer ..........................................18
REDUCER................................................. 76
i-1
INDEX
B-82235EN/03
Replacing Motor Covers..............................185
REPLACING MOTOR COVERS (OPTION)103
REPLACING PARTS....................................47
REPLACING SEVERE DUST/LIQUID
PROTECTION PACKAGE COMPONENTS
..................................................................185
REPLACING THE BALANCER ..................98
REPLACING THE BATTERIES (1.5 YEAR
(5,760 HOURS) CHECKS) ........................15
Replacing the Batteries and Battery Box Cover
..................................................................188
REPLACING THE GREASE OF THE DRIVE
MECHANISM (3 YEARS (11,520 HOURS)
CHECKS)...................................................17
REPLACING THE WRIST AXIS MOTORS (M4,
M5, AND M6), WRIST UNIT, AND J4 AXIS
REDUCER .................................................89
RESETTING ALARMS AND PREPARING
FOR MASTERING ..................................167
S
SEALANT APPLICATION.........................102
Severe Dust/Liquid Protection Characteristics
..................................................................182
SEVERE DUST/LIQUID PROTECTION
PACKAGE ...............................................181
SEVERE DUST/LIQUID PROTECTION
PACKAGE (OPTION) .............................181
SPARE PARTS LIST ..................................193
T
TROUBLESHOOTING.................................27
i-2
Revision Record
FANUC Robot R-2000iB MECHANICAL UNIT MAINTENANCE MANUAL (B-82235EN)
• Addition of the R-2000iB/100P, 175L
• Addition of the NOTE for J2/J3-axis input gear
• Correction of description errors
03
02
Feb., 2007
• Addition of the R-2000iB/165R, 200R, 165CF
• Changes in the method of clearing an alarm
• Addition of the procedure for releasing the residual
Nov.,2006 pressure in the grease bath
• Correction of the troubleshooting table
• Addition of descriptions of the dustproof and dipproof
enhanced package
• Correction of description errors
01
Apr.,2006
Edition
Date
Contents
Edition
Date
Contents