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MECHANICAL UNIT
MAINTENANCE MANUAL
B-83085EN/03
•
Original Instructions
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
• No part of this manual may be reproduced in any form.
• All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as “impossible”.
B-83085EN/03
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
Thank you for purchasing FANUC Robot.
This chapter describes the precautions which must be observed to ensure the safe use of the robot.
Before attempting to use the robot, be sure to read this chapter thoroughly.
Before using the functions related to robot operation, read the relevant operator's manual to become
familiar with those functions.
For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral devices installed in a work cell.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1
WORKING PERSON
The personnel can be classified as follows.
Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel
Programmer or teaching operator:
• Operates the robot
• Teaches robot inside the safety fence
Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)
-
-
An operator cannot work inside the safety fence.
A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc.
To work inside the fence, the person must be trained on proper robot operation.
During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following
safety precautions.
-
Use adequate clothing or uniforms during system operation
Wear safety shoes
Use helmet
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SAFETY PRECAUTIONS
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B-83085EN/03
DEFINITION OF WARNING, CAUTION AND
NOTE
To ensure the safety of the working person and prevent damage to the machine, this manual indicates
each precaution on safety with "Warning" or "Caution" according to its severity. Supplementary
information is indicated by "Note". Read the contents of each "Warning", "Caution" and "Note" before
attempting to use the robots.
WARNING
Applied when there is a danger of the working person being injured or when
there is a danger of both the working person being injured and the equipment
being damaged if the approved procedure is not observed.
CAUTION
Applied when there is a danger of the equipment being damaged, if the
approved procedure is not observed.
NOTE
Notes are used to indicate supplementary information other than Warnings and
Cautions.
•
3
Read this manual carefully, and store it in a safe place.
WORKING PERSON SAFETY
Working person safety is the primary safety consideration. Because it is very dangerous to enter the
operating space of the robot during automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration must be made to ensure
working person safety.
(1) Have the robot system working persons attend the training courses held by FANUC.
FANUC provides various training courses.
Contact our sales office for details.
(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is
waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working
person safety, provide the system with an alarm to indicate visually or aurally that the robot is in
motion.
(3) Install a safety fence with a gate so that no working person can enter the work area without passing
through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that
the robot is stopped as the safety gate is opened.
The controller is designed to receive this interlocking signal of the door switch. When the gate
is opened and this signal received, the controller stops the robot (Please refer to "STOP
TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see
Fig.3 (a) and Fig.3 (b).
(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
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B-83085EN/03
SAFETY PRECAUTIONS
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools
such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm
that stops the robot when a working person enters the work area.
(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the
power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from turning it on
when it is locked with a padlock.
(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.
(10) Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation
with gloved fingers could cause an operation error.
(11) Programs, system variables, and other information can be saved on memory card or USB memories.
Be sure to save the data periodically in case the data is lost in an accident.
(12) The robot should be transported and installed by accurately following the procedures recommended
by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe
injury to workers.
(13) In the first operation of the robot after installation, the operation should be restricted to low speeds.
Then, the speed should be gradually increased to check the operation of the robot.
(14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the
same time, a check must be made to ensure that there is no risk of hazardous situations. If detected,
such a situation should be eliminated before the operation.
(15) When the robot is used, the following precautions should be taken. Otherwise, the robot and
peripheral equipment can be adversely affected, or workers can be severely injured.
- Avoid using the robot in a flammable environment.
- Avoid using the robot in an explosive environment.
- Avoid using the robot in an environment full of radiation.
- Avoid using the robot under water or at high humidity.
- Avoid using the robot to carry a person or animal.
- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)
(16) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external
emergency , fence etc.) of robot. be sure to confirm the stop movement and do not take the wrong
connection.
(17) When preparing trestle, please consider security for installation and maintenance work in high place
according to Fig.3 (c). Please consider footstep and safety bolt mounting position.
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SAFETY PRECAUTIONS
B-83085EN/03
RP1
Pulsecoder
RI/RO,XHBK,XROT
RM1
Motor power/brake
EARTH
Safety fence
Interlocking device and safety plug that are activated if the
gate is opened.
Fig. 3 (a)
Dual chain
Emergency stop board
orPanel
Panelboard
board
EAS1
EAS11
EAS2
EAS21
Single chain
Panel board
FENCE1
FENCE2
Safety fence and safety gate
(Note)
（Note）
In case of R-30iB, R-30iB Mate
In case of R-30iA
Terminals
are or
provided
on the
TerminalsEAS1,EAS11,EAS2,EAS21
EAS1,EAS11,EAS2,EAS21
FENCE1,FENCE2
emergency
stoponboard.
are provided
the operation box or on the terminal block
of the printed circuit boar d.
In case R-30iA
In case ofEAS1,EAS11,EAS2,EAS21
R-30iA Mate
Terminals
are provided on the
Terminals
EAS1,EAS11,EAS2,EAS21
are provided
emergency stop board or connector panel
on the emergency stop board or connector panel.
(in case of Open air type)
In case R-30iA Mate
Terminals
or FENCE1,FENCE2
TermianlsEAS1,EAS11,EAS2,EAS21
FENCE1,FENCE2 ar e provided
are
on the emergency
stop board or in the connector
on provided
the emergency
stop board.
panel of CRM65 (Open air type).
Refer to controller maintenance manual for details.
Refer to the ELECTRICAL CONNCETIONS Chapter
of CONNECTION of controller maintenance manual for details.
Fig. 3 (b) Limit switch circuit diagram of the safety fence
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SAFETY PRECAUTIONS
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Hook for safety belt
Fence
Steps
Trestle
Footstep
for maintenance
Fig.3 (c) Footstep for maintenance
3.1
OPERATOR SAFETY
The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.
(1) If you do not have to operate the robot, turn off the power of the robot controller or press the
EMERGENCY STOP button, and then proceed with necessary work.
(2) Operate the robot system at a location outside of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering
the work area unexpectedly and to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.
The robot controller is designed to be connected to an external EMERGENCY STOP button.
With this connection, the controller stops the robot operation (Please refer to "STOP TYPE
OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external
EMERGENCY STOP button is pressed. See the diagram below for connection.
Dual chain
External stop button
Emergency stop boa rd
Panel board
o r Pane l boa rd
EES1
EES11
EES2
EES21
Single chain
External stop button
Panel board
(Note)
Connect EES1 and EES11, EES2 and EES21 or EMGIN1
and EMGIN2
（Note）
In
case R-30iB, R-30iB Mate
Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.
EES1,EES11,EES2,EES21 are on the emergency stop board
In case of R-30iA
EES1,EES11,EES2,EES21
or EMGIN1,EMGIN2 are on the panel board.
In
case R-30iA
EES1,EES11,EES2,EES21 or EMGIN1, EMGIN2 are on the
In case of R-30iA Mate
pan
el board.
EES1,EES11,EES2,EES21
are on the emergency stop board
or connector panel (in case of Open air type).
EMGIN1,EMGIN2
are on the emergency stop board.
In
case R-30iA Mate
Terminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2
Refer to the maintenance manual of the controller for details.
are provided on the eme rgency stop board or in the con nector
pan el of CRM65 (Open air type).
EMGIN1
EMGIN2
Refer to the ELECTRICAL CONNCETIONS Chapter
of CONNECTION of controller maintenance manual for details.
Fig.3.1 Connection diagram for external emergency stop button
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SAFETY PRECAUTIONS
3.2
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SAFETY OF THE PROGRAMMER
While teaching the robot, the operator must enter the work area of the robot.
the safety of the teach pendant operator especially.
The operator must ensure
(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal
operating condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and
other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN
switch on the teach pendant) before entering the area.
(4) The programmer must be extremely careful not to let anyone else enter the robot work area.
(5) Programming should be done outside the area of the safety fence as far as possible. If programming
needs to be done in the area of the safety fence, the programmer should take the following
precautions:
－ Before entering the area of the safety fence, ensure that there is no risk of dangerous situations
in the area.
－ Be prepared to press the emergency stop button whenever necessary.
－ Robot motions should be made at low speeds.
－ Before starting programming, check the entire system status to ensure that no remote instruction
to the peripheral equipment or motion would be dangerous to the working person.
Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the
automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety
fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent
other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened
with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The
programmer should understand that the safety gate is disabled and is responsible for keeping other people from
entering the inside of the safety fence. (In case of R-30iA Mate Controller standard specification, there is no mode
switch. The automatic operation mode and the teach mode is selected by teach pendant enable switch.)
Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and
switch function as follows:
(1) Emergency stop button: Causes the stop of the robot (Please refer to "STOP TYPE OF ROBOT" in
SAFETY PRECAUTIONS for detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting
status.
(a)
Disable: The DEADMAN switch is disabled.
(b)
Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the
operator presses the switch strongly.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate/R-30iA/ R-30iA Mate
employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position
DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN
switch or presses the switch strongly, the robot stops immediately.
The working person’s intention of starting teaching is determined by the controller through the dual operation of
setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The
working person should make sure that the robot could operate in such conditions and be responsible in carrying out
tasks safely.
Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000
times per year.
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The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the
validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator
panel, the teach pendant enable switch and the remote condition on the software.
In case of R-30iB/R-30iB Mate/R-30iA Controller or CE or RIA specification of R-30iA Mate Controller
Mode
Teach pendant
enable switch
Software
remote
condition
Local
Remote
Local
Off
Remote
Local
On
T1, T2
Remote
mode
Local
Off
Remote
T1,T2 mode: DEADMAN switch is effective.
On
AUTO
mode
Teach pendant
Operator panel
Peripheral device
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
In case of standard specification of R-30iA Mate Controller
Teach pendant enable switch
Software remote condition
Teach pendant
Peripheral device
On
Off
Ignored
Local
Remote
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
(6) (Only when R-30iB/R-30iB Mate /R-30iA Controller or CE or RIA specification of R-30iA Mate
controller is selected.) To start the system using the operator’s panel, make certain that nobody is the
robot work area and that there are no abnormal conditions in the robot work area.
(7) When a program is completed, be sure to carry out a test operation according to the procedure
below.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low
speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test operation above, execute it in
the automatic operation mode.
(8) While operating the system in the automatic operation mode, the teach pendant operator should
leave the robot work area.
3.3
SAFETY OF THE MAINTENANCE ENGINEER
For the safety of maintenance engineer personnel, pay utmost attention to the following.
(1) During operation, never enter the robot work area.
(2) A hazardous situation may arise when the robot or the system, are kept with their power-on during
maintenance operations. Therefore, for any maintenance operation, the robot and the system should
be put into the power-off state. If necessary, a lock should be in place in order to prevent any other
person from turning on the robot and/or the system. In case maintenance needs to be executed in the
power-on state, the emergency stop button must be pressed.
(3) If it becomes necessary to enter the robot operation range while the power is on, press the
emergency stop button on the operator panel, or the teach pendant before entering the range. The
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maintenance personnel must indicate that maintenance work is in progress and be careful not to
allow other people to operate the robot carelessly.
(4) When entering the area enclosed by the safety fence, the maintenance worker must check the entire
system in order to make sure no dangerous situations exist. In case the worker needs to enter the
safety area whilst a dangerous situation exists, extreme care must be taken, and entire system status
must be carefully monitored.
(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off
and the pressure in the piping should be reduced to zero.
(6) Before the start of teaching, check that the robot and its peripheral devices are all in the normal
operating condition.
(7) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(8) When you maintain the robot alongside a wall or instrument, or when multiple workers are working
nearby, make certain that their escape path is not obstructed.
(9) When a tool is mounted on the robot, or when any moving device other than the robot is installed,
such as belt conveyor, pay careful attention to its motion.
(10) If necessary, have a worker who is familiar with the robot system stand beside the operator panel
and observe the work being performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.
(11) When replacing a part, please contact FANUC service center. If a wrong procedure is followed, an
accident may occur, causing damage to the robot and injury to the worker.
(12) When replacing or reinstalling components, take care to prevent foreign matter from entering the
system.
(13) When handling each unit or printed circuit board in the controller during inspection, turn off the
circuit breaker to protect against electric shock.
If there are two cabinets, turn off the both circuit breaker.
(14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction
or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used.
Such a fuse may cause a fire.
(15) When restarting the robot system after completing maintenance work, make sure in advance that
there is no person in the work area and that the robot and the peripheral devices are not abnormal.
(16) When a motor or brake is removed, the robot arm should be supported with a crane or other
equipment beforehand so that the arm would not fall during the removal.
(17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent
dangerous falls.
(18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated
state, the worker should wear heat-resistant gloves or use other protective tools.
－ Servo motor
－ Inside the controller
－ Reducer
－ Gearbox
－ Wrist unit
(19) Maintenance should be done under suitable light. Care must be taken that the light would not cause
any danger.
(20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to
protect maintenance workers from excessive load. Otherwise, the maintenance workers would be
severely injured.
(21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot
would be adversely affected. In addition, a misstep can cause injury to the worker.
(22) When performing maintenance work in high place, secure a footstep and wear safety belt.
(23) After the maintenance is completed, spilled oil or water and metal chips should be removed from the
floor around the robot and within the safety fence.
(24) When a part is replaced, all bolts and other related components should put back into their original
places. A careful check must be given to ensure that no components are missing or left not mounted.
(25) In case robot motion is required during maintenance, the following precautions should be taken :
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SAFETY PRECAUTIONS
- Foresee an escape route. And during the maintenance motion itself, monitor continuously the
whole system so that your escape route will not become blocked by the robot, or by peripheral
equipment.
- Always pay attention to potentially dangerous situations, and be prepared to press the emergency
stop button whenever necessary.
(26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller
maintenance manual.) A failure to do the periodical inspection can adversely affect the performance
or service life of the robot and may cause an accident
(27) After a part is replaced, a test operation should be given for the robot according to a predetermined
method. (See TESTING section of “Controller operator’s manual”.) During the test execution, the
maintenance staff should work outside the safety fence.
4
4.1
SAFETY OF THE TOOLS AND
PERIPHERAL DEVICES
PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the
program to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care
must be taken in programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect
the states of all devices in the system and can be stopped according to the states.
4.2
PRECAUTIONS FOR MECHANISM
(1) Keep the components of the robot system clean, and operate the robot in an environment free of
grease, water, and dust.
(2) Only use approved cuttings fluids and cleaning fluids.
(3) Use a limit switch or mechanical stopper to limit the robot motion to prevent the robot from
collisions against peripheral devices or tools.
(4) Observe the following precautions about the mechanical unit cables. Failure to follow these
precautions may cause mechanical problems.
•
Use mechanical unit cable that meet user interface requirement.
•
Don not route additional cables or hoses inside the mechanical unit.
•
Do not obstruct the movement of the mechanical unit cables when additional cables are touted
external to the mechanical unit.
•
For models that have exposed cables, do not modify the cable bundle construction (such as by
adding on protective covers, tying on additional cables) that could change the behavior of the
cable motion.
•
When installing user peripheral equipment on the robot mechanical unit, please pay attention
that equipment does not interfere with the robot itself.
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please
avoid the system construction that power-off stop would be operated routinely. (Refer to bad case
example.) Please execute power-off stop after reducing the speed of the robot and stopping it by
hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in
SAFETY PRECAUTIONS for detail of stop type.)
(Bad case example)
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•
Whenever poor product is generated, a line stops by emergency stop and power-off of the robot
is executed.
•
When alteration was necessary, safety switch is operated by opening safety fence and
power-off stop is executed for the robot during operation.
•
An operator pushes the emergency stop button frequently, and a line stops.
•
An area sensor or a mat switch connected to safety signal operate routinely and power-off stop
is executed for the robot.
(6) Robot stops urgently when collision detection alarm (SRVO-050) etc. occurs. Please try to avoid
unnecessary power-off stops. It may cause the trouble of the robot, too. So remove the causes of the
alarm.
5
SAFETY OF THE ROBOT MECHANISM
5.1
PRECAUTIONS IN OPERATION
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can
manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the
jog mode.
5.2
PRECAUTIONS IN PROGRAMMING
(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere
with each other.
(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the
motion so that it starts from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that the robot motion has
terminated.
5.3
PRECAUTIONS FOR MECHANISMS
(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water,
and dust.
5.4
PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER
IN EMERGENCY OR ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons trapped in or pinched by the robot), brake
release unit can be used to move the robot axes without drive power.
Please order following unit and cable.
Name
Brake release unit
Robot connection cable
Specification
A05B-2450-J350 (Input voltage AC100-115V single phase)
A05B-2450-J351 (Input voltage AC200-240V single phase)
A05B-2525-J035 (5m)
A05B-2525-J036 (10m)
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SAFETY PRECAUTIONS
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Name
Specification
A05B-2525-J010 (5m) (AC100-115V Power plug) (*)
A05B-2525-J011 (10m) (AC100-115V Power plug) (*)
A05B-2450-J364 (5m) (AC100-115V or AC200-240V No power plug)
A05B-2450-J365 (10m) (AC100-115V or AC200-240V No power plug)
Power cable
(*) These do not support CE marking.
(2) Please make sure that adequate numbers of brake release units are available and readily accessible
for robot system before installation.
(3) Regarding how to use brake release unit, please refer to Robot controller maintenance manual.
CAUTION
Robot systems installed without adequate number of brake release units or
similar means are neither in compliance with EN ISO 10218-1 nor with the
Machinery Directive and therefore cannot bear the CE marking.
WARNING
Robot arm would fall down by releasing its brake because of gravity. Therefore,
it is strongly recommended to take adequate measures such as supporting
Robot arm by a block etc. before releasing a brake.
Wrist unit
Support
Fall down
Fig. 5.4 Releasing motor brake and measures
6
SAFETY OF THE END EFFECTOR
6.1
PRECAUTIONS IN PROGRAMMING
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time
delay after issuing each control command up to actual motion and ensure safe control.
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(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of
the end effector.
7
STOP TYPE OF ROBOT
The following three robot stop types exist:
Power-Off Stop (Category 0 following IEC 60204-1)
Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
An alarm is generated and servo power is turned off.
The robot operation is stopped immediately. Execution of the program is paused.
Frequent Power-Off stop of the robot during operation can cause mechanical problems of the robot.
Avoid system designs that require routine or frequent Power-Off stop conditions.
Controlled stop (Category 1 following IEC 60204-1)
The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
An alarm is generated and servo power is turned off.
Hold (Category 2 following IEC 60204-1)
The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
The robot operation is decelerated until it stops. Execution of the program is paused.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.
When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off
stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop
pattern is different according to the controller type or option configuration.
s-12
SAFETY PRECAUTIONS
B-83085EN/03
There are the following 3 Stop patterns.
Stop
pattern
A
B
C
P-Stop:
C-Stop:
-:
Mode
Emergency
stop
button
External
Emergency
stop
FENCE open
SVOFF input
Servo
disconnect
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
C-Stop
P-Stop
C-Stop
-
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
AUTO
T1
T2
AUTO
T1
T2
AUTO
T1
T2
Power-Off stop
Controlled stop
Disable
The following table indicates the Stop pattern according to the controller type or option configuration.
R-30iB/R-30iB Mate
Option
Standard
Controlled stop by E-Stop
A (*)
C (*)
(A05B-2600-J570)
(*) R-30iB/R-30iB Mate does not have servo disconnect. R-30iB Mate does not have SVOFF input.
Option
Standard
Stop type set (Stop pattern C)
(A05B-2500-J570)
Standard
(Single)
R-30iA
Standard
RIA
(Dual)
type
CE
type
R-30iA Mate
RIA
Standard
type
CE
type
B (*)
A
A
A
A (**)
A
A
N/A
N/A
C
C
N/A
C
C
(*) R-30iA standard (single) does not have servo disconnect.
(**) R-30iA Mate Standard does not have servo disconnect, and the stop type of SVOFF input is
Power-Off stop.
The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please
refer to "Software version" in operator's manual of controller for the detail of software version screen.
"Controlled stop by E-Stop" option
When "Controlled stop by E-Stop" (A05B-2600-J570) option (For the R-30iA/R-30iA Mate, it is Stop
type set (Stop pattern C) (A05B-2500-J570)) is specified, the stop type of the following alarms becomes
Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is
the normal operation of the system.
s-13
SAFETY PRECAUTIONS
Alarm
SRVO-001 Operator panel E-stop
SRVO-002 Teach pendant E-stop
SRVO-007 External emergency stops
SRVO-194 Servo disconnect
SRVO-218 Ext.E-stop/Servo Disconnect
SRVO-408 DCS SSO Ext Emergency Stop
SRVO-409 DCS SSO Servo Disconnect
B-83085EN/03
Condition
Operator panel emergency stop is pressed.
Teach pendant emergency stop is pressed.
External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA/R-30iB/R-30iB Mate controller)
Servo disconnect input (SD4-SD41, SD5-SD51) is open.
(R-30iA controller)
External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA Mate controller)
In DCS Safe I/O connect function, SSO[3] is OFF.
In DCS Safe I/O connect function, SSO[4] is OFF.
Controlled stop is different from Power-Off stop as follows:
In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
In Controlled stop, physical impact is less than Power-Off stop. This function is effective for
systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be
minimized.
The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the
operator's manual of a particular robot model for the data of stopping distance and stopping time.
For the R-30iA or R-30iA Mate, this function is available only in CE or RIA type hardware.
When this option is loaded, this function cannot be disabled.
The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.
140618
s-14
SAFETY PRECAUTIONS
B-83085EN/03
8
WARNING LABEL
(1) Transportation attention label 1
Fig.8 (a) Transportation attention label
Description
1)
2)
3)
Use a crane having a load capacity of 500 kg or greater.
Use at least four slings each having a withstand load of 980 N (100 kgf) or greater.
Use at least four eyebolts each having a withstand load of 490 N (50 kgf) or greater.
(2) Range of motion and payload mark label
Below label is added when CE specification is specified.
Fig.8 (b) Range of motion and payload mark label
s-15
PREFACE
B-83085EN/03
PREFACE
This manual explains maintenance procedures for the mechanical units of the following robots:
Mechanical unit
specification No.
Model name
FANUC Robot M-1iA/0.5S
FANUC Robot M-1iA/0.5A
FANUC Robot M-1iA/1H
FANUC Robot M-1iA/0.5SL
FANUC Robot M-1iA/0.5AL
FANUC Robot M-1iA/1HL
Maximum load
0.5kg
1kg (Note)
A05B-1522-B201
A05B-1522-B202
A05B-1522-B203
A05B-1522-B204
A05B-1522-B205
A05B-1522-B206
1kg
0.5kg
1kg (Note)
1kg
NOTE
When 1kg payload option is specified.
The label stating the mechanical unit specification number is affixed in the position shown below. Before
reading this manual, determine the specification number of the mechanical unit.
(1)
TYPE
NO.
DATE
(2)
(3)
(4)
WEIGHT
(5)
kg
Position of label indicating mechanical unit specification number
TABLE 1)
(1)
(2)
(3)
(4)
CON
TENTS
MODEL NAME
TYPE
No.
DATE
LETTERS
FANUC Robot M-1iA/0.5S
FANUC Robot M-1iA/0.5A
FANUC Robot M-1iA/1H
FANUC Robot M-1iA/0.5SL
FANUC Robot M-1iA/0.5AL
FANUC Robot M-1iA/1HL
A05B-1522-B201
A05B-1522-B202
A05B-1522-B203
A05B-1522-B204
A05B-1522-B205
A05B-1522-B206
p-1
SERIAL
NO. IS
PRINT
ED
PRODUCTION
YEAR AND
MONTH ARE
PRINTED
(5)
WEIGHT kg
(without controller)
14
17
12
17
20
15
PREFACE
B-83085EN/03
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook B-80687EN
All persons who use the FANUC Robot
and system designer must read and
understand thoroughly this handbook
R-30iA Mate
Operations manual
controller
LR HANDLING TOOL
B-83134EN-1
ALARM CODE LIST
B-83124EN-6
Maintenance manual
Standard:
B-82725EN
B-82725EN-1
(For Europe)
B-82725EN-2
(For RIA)
Intended readers:
Operator , system designer
Topics:
Safety items for robot system design, operation, maintenance
Intended readers:
Operator, programmer, maintenance engineer, system designer
Topics:
Robot functions, operations, programming, setup, interfaces, alarms
Use:
Robot operation, teaching, system design
Intended readers:
Maintenance engineer, system designer
Topics:
Installation, connection to peripheral equipment, maintenance
Use:
Installation, start-up, connection, maintenance
Open air type:
B-82965EN-1
R-30iB Mate
controller
Mechanical unit
OPERATOR’S
MANUAL
Basic Operation
B-83284EN
Alarm Code List
B-83284EN-1
Optional Function
B-83284EN-2
Intended readers:
Operator, programmer, maintenance engineer , system designer
Topics:
Robot functions, operations, programming, setup, interfaces, alarms
Use:
Robot operation, teaching, system design
MAINTENANCE
MANUAL
B-83525EN
R-30iB Mate (Open
Air): B-83555EN
Intended readers:
Maintenance engineer , system designer
Topics:
Installation, connection to peripheral equipment, maintenance
Use:
Installation, start-up, connection, maintenance
Intended readers:
System designer, maintenance engineer
Topics:
Installation, connection to controller, maintenance
Use:
Installation, start-up, connection, maintenance
OPERATOR'S
MANUAL
FANUC Robot
M-1iA
B-83084EN
p-2
TABLE OF CONTENTS
B-83085EN/03
TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
PREFACE ....................................................................................................p-1
1
CHECKS AND MAINTENANCE ............................................................. 1
1.1
PERIODIC MAINTENANCE .......................................................................... 1
1.1.1
1.1.2
1.2
CHECK POINTS............................................................................................ 4
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.3
2
2.2
REPLACING THE BATTERIES
(1-YEAR (3840 Hours) CHECKS (with stand/no stand B))
(1.5-YEAR (5760 Hours) CHECKS (no stand A)) .......................................... 9
APPLYING THE GREASE OF THE WRIST INPUT GEARS
AND THE DRIVE SHAFTS (M-1iA/0.5S,0.5A,0.5SL,0.5AL) (6 MONTHS (1920
HOURS) CHECKS) ..................................................................................... 11
OVERVIEW ................................................................................................. 13
FAILURES, CAUSES AND MEASURES ..................................................... 13
BACKLASH MEASUREMENT..................................................................... 19
COMPONENT REPLACEMENT ........................................................... 24
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
5
MAINTENANCE TOOLS ............................................................................... 8
TROUBLESHOOTING .......................................................................... 13
3.1
3.2
3.3
4
Confirmation of Oil Seepage and Oil Accumulation ...............................................4
Confirmation of the Air Control Set.........................................................................5
Retightening the Link B ...........................................................................................6
Cleaning the Wrist Axis Rotation Parts and the Wrist Gears
(M-1iA/0.5S,0.5A,0.5SL,0.5AL) .............................................................................7
Check the Connectors...............................................................................................7
PERIODIC MAINTENANCE .................................................................... 9
2.1
3
Daily Checks ............................................................................................................1
Periodic Check and Maintenance .............................................................................2
FIGURE OF DRIVE MECHANISM .............................................................. 25
ROBOT CONFIGURATION ......................................................................... 26
REPLACING THE J1/J2/J3-AXIS MOTOR M1/M2/M3................................ 28
REPLACING THE J1/J2/J3-AXIS REDUCER.............................................. 30
REPLACING THE J4/J5/J6-AXIS MOTOR M4/M5/M6
(M-1iA/0.5S,0.5A,0.5SL,0.5AL) ................................................................... 31
REPLACING THE J1/J2/J3 ARM ASSEMBLY ............................................ 33
REPLACING THE J1/J2/J3 LINK B ............................................................. 34
REPLACING THE J4/J5/J6 WRIST INPUT GEAR
(M-1iA/0.5S,0.5A,0.5SL,0.5AL) ................................................................... 36
REPLACING THE J4/J5/J6 DRIVE SHAFT (M-1iA/0.5S,0.5A,0.5SL,0.5AL)
..................................................................................................................... 36
REPLACING THE WRIST UNIT .................................................................. 38
SIMPLE METHOD OF MASTERING........................................................... 38
REPLACING CABLES .......................................................................... 40
c-1
TABLE OF CONTENTS
5.1
5.2
B-83085EN/03
CABLE FORMING ....................................................................................... 41
CABLE REPLACEMENT ............................................................................. 48
APPENDIX
A
SPARE PARTS LIST ............................................................................ 53
B
CIRCUIT DIAGRAM .............................................................................. 55
C
PERIODIC MAINTENANCE TABLE ..................................................... 62
D
MOUNTING BOLT TORQUE LIST ....................................................... 64
c-2
1.CHECKS AND MAINTENANCE
B-83085EN/03
1
CHECKS AND MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter.
(See the APPENDIX A PERIODIC MAINTENANCE TABLE.)
NOTE
The periodic maintenance procedures described in this chapter assume that
the FANUC robot is used for up to 3840 hours a year. In cases where robot use
exceeds 3840 hours/year, adjust the given maintenance frequencies
accordingly. The ratio of actual operation time/year vs. the 3840 hours/year
should be used to calculate the new (higher) frequencies. For example, when
using the robot 7680 hours a year, the maintenance frequency should be
doubled – i.e. the time interval should be divided by 2.
1.1
PERIODIC MAINTENANCE
1.1.1
Daily Checks
Clean each part, and visually check component parts for damage before daily system operation. Check the
following items when necessary.
Check items
Oil seepage
Oil accumulation
Air control set
Vibration, abnormal
noises
Repeatability
Peripheral devices for
proper operation
Brakes for each axis
Warnings
Check points and management
Check there is oil on the sealed part of each joint. If there is an oil seepage, clean them.
Clean the accumulated oil on the lower side of the drive shaft (upper side of he
universal joints). (There is no drive shaft for M-1iA/1H,1HL.)
⇒”1.2.1 Confirmation of Oil Seepage and Oil Accumulation”
( When air control set is used)
⇒”1.2.2 Confirmation of the Air Control Set”
Check whether vibration or abnormal noises occur.
When vibration or abnormal noises occur, perform measures referring to the following
section:
⇒”3.2 FAILURES,CAUSES AND MEASURES”(symptom：Vibration, Noise)
Check to see that the taught positions of the robot have not deviated from the previous
taught positions. When displacement occurs, perform the measures as described in the
following section:
⇒”3.2 FAILURES,CAUSES AND MEASURES”(symptom：Displacement)
Check whether the peripheral devices operate properly according to commands from the
robot and the peripheral devices.
Check that the end effector drops within 0.2 mm when servo power is turned off.
If the end effector (hand) drops, perform the measures as described in the following
section:
⇒”3.2 FAILURES,CAUSES AND MEASURES”(symptom：Dropping axis)
Check whether unexpected warnings occur in the alarm screen on the teach pendant. If
unexpected warnings occur, perform the measures as described in the following manual:
⇒”R-30iB/R-30iB Mate CONTROLLER OPERATOR’S MANUAL (Alarm Code
List)(B-83284EN-1) or R-30iA/R-30iA Mate CONTROLLER OPERATOR’S MANUAL
(Alarm Code List)(B-83124EN-6)”
-1-
1.CHECKS AND MAINTENANCE
1.1.2
B-83085EN/03
Periodic Check and Maintenance
Check the following items at the intervals recommended below based on the total operating time
or the accumulated operating time, which ever comes first.
Check and maintenance intervals
(Operation time, Operation
accumulated time)
1
month
320h
○
3
6
months months
960h
1920h
1
year
3840h
2
years
7680h
3
years
11520h
4
years
15360h
Check and
item
○
Retightening
LINK B
mounting par
○
Check the wear
of the LINK B
ball joint part
○
Cleaning the
controller
ventilation
system
Check for
external
damage or
peeling paint
Only
1st
check
○
Only
1st
check
○
Only
1st
check
○
○
○
Check for water
○
Check the
exposed
connectors
○
Retightening the
end effector
mounting bolts
Only
1st
Check points, management and
maintenance method
maintenance
Check the looseness of LINK B part (12
places), if they are loosened, remove the
LOCTITE 243, then apply LOCTITE 243
on the thread and retighten them.
⇒”1.2.3 Retightening the Link B”
Check the wear of the LINK B ball joint
part. If looseness is large and it cause a
bad influence on the robot accuracy,
replace it. (See Fig.1.2.3.)
If the controller ventilation system is
dusty, turn off power and clean the unit.
Check whether the robot has external
damage due to the interference with the
peripheral devices or peeling paint. If an
interference occurs, eliminate
the cause. Also, if the external damage is
serious and causes a problem in which
the robot cannot be used, replace the
damaged parts.
Check whether the robot is subjected to
water or cutting oils. If water is found,
remove the cause and wipe off the liquid.
Check the exposed connectors.
⇒”1.2.5 Check the Connectors”
Periodic
maintenance
No.
6
7
15
1
2
3
check
○
Only
1st
check
Retighten the end effector mounting
bolts.
Refer to the following section for
tightening torque information:
⇒”4.1 MECHANICAL COUPLING OF
END EFFECTOR TO WRIST” of LR
Mate 200iD/4S,4SH,4SC OPERATOR’S
MANUAL (B-83084EN)
-2-
4
1.CHECKS AND MAINTENANCE
B-83085EN/03
Check and maintenance intervals
(Operation time, Operation
accumulated time)
1
month
320h
3
6
months months
960h
1920h
○
1
year
3840h
Clean foreign
material s such
as dust ,
powder
○
Check for
damage to the
end effector
(hand) cable
Cleaning the
grease around
the wrist input
gear
Check for
damages
to the teach
pendant cable, the
operation box
connection cable
or the robot
connection cable
Supply grease to
wrist input gears
(M-1iA/0.5S,0.5
A,0.5SL,0.5AL)
Supply grease to
Drive shafts
(M-1iA/0.5S,0.5
A,0.5SL,0.5AL)
Only
1st
check
Only
1st
Check
○
Only
1st
Check
○
○
Only
1st
check
○
○
Check points, management and
maintenance method
item
○
1st
○
4
years
15360h
Retightening the
cover bolts and
external main
bolts
check
○
3
years
11520h
○
Only
○
2
years
7680h
Check and
maintenance
Retighten the cover bolts , robot
installation bolts, bolts to be removed for
inspection, and bolts exposed to the
outside. Refer to the recommended bolt
tightening torque guidelines at the end of
the manual. An adhesive to prevent bolts
from loosening is applied to some bolts.
If the bolts are tightened with greater
than the recommended torque, the
adhesive might be removed. Therefore,
follow the recommended bolt tightening
torque guidelines when retightening the
bolts
Check that foreign materials such as
dust , powder does not exist on
the robot main body. If foreign materials
have accumulated, remove them.
Especially, clean the robot movable parts
well (each joint the gear cover, and the
wrist axis rotation parts). When checking
and cleaning the drive shafts, please be
careful no to push the shaft on the drive
shaft.
⇒”1.2.4 Cleaning the wrist axis
rotation part and the wrist gears”
Check whether the end effector
connection cables are unevenly twisted
or damaged. If damage is found, replace
the damaged cables.
Clean the grease of the around of wrist
input gear after removing cover.
⇒”1.2.4 Cleaning the wrist axis
rotation part and the wrist gears”
Check whether the cable connected to
the teach pendant, operation box and
robot are unevenly twisted or damaged.
If damage is found, replace the damaged
cables.
Periodic
maintenance
No.
5
8
9
13
14
Supply grease to wrist input gear.
⇒”2.2 Applying the Grease of the
Wrist Input Gears and Drive Shafts”
11
Supply grease to drive shafts.
⇒”2.2 Applying the Grease of the
Wrist Input Gears and Drive Shafts”
12
-3-
1.CHECKS AND MAINTENANCE
Check and maintenance intervals
(Operation time, Operation
accumulated time)
1
month
320h
3
6
months months
960h
1920h
1
year
3840h
2
years
7680h
○
○
(*)
(*)
3
years
11520h
Check and
Check points, management and
maintenance method
maintenance
item
4
years
15360h
○
B-83085EN/03
Periodic
maintenance
No.
Replacing the
batteries
Replace the mechanical unit batteries
(*) Replacing interval differs depend on
the
mounting types.
⇒”2.1 Replacing the batteries”
11
Replacing the
controller
batteries
Replace the controller batteries
⇒Chapter 7 Replacing batteries of
・R-30iB MATE CONTROLLER
MAINTENANCE MANUAL
(B-83525EN)
・R-30iB MATE CONTROLLER Open
Air MAINTENANCE MANUAL
B-83555EN)
・R-30iA MATE CONTROLLER
MAINTENANCE MANUAL
(B-83725EN)
・For Europe R-30iA MATE
CONTROLLER MAINTENANCE
MANUAL (B-83725EN-1)
・RIA R15.06-19999 COMPLIANT
R-30iA MATE CONTROLLER
MAINTENANCE MANUAL
(B-83725EN-2)
・R-30iA MATE CONTROLLER Open
Air MAINTENANCE MANUAL
B-83555EN)
14
1.2
CHECK POINTS
1.2.1
Confirmation of Oil Seepage and Oil Accumulation
Check items
Check to see whether there is an oil seepage on the bearings. If there are oil contents, clean them.
Clean the accumulated oil on the lower side of the drive shaft (upper side of he universal joints).
(1 point for M-1iA/0.5S,0.5SL , 3 points for M-1iA/0.5A,0.5AL) (There is no drive shaft for
M-1iA/1H,1HL.)
-4-
1.CHECKS AND MAINTENANCE
B-83085EN/03
Check points
Check points
Check points
Fig.1.2.1 (a) Check points of oil seepage
Clean oil accumulated in
this area.
A
Universal joint
Detail A
Fig.1.2.1 (b) Cleaning parts of accumulated oil (example of M-1iA/0.5S J4-axis)
1.2.2
Item
1
2
3
Confirmation of the Air Control Set
Check items
When air control
set is provided.
Air pressure
Leakage
from hose
Drain
Check points
Check air pressure using the pressure gauge on the air regulator as
shown in Fig.1.2.2. If it does not meet the specified pressure of
0.49MPa (5 kg/cm2), adjust it using the regulator pressure setting
handle.
Check the joints, tubes, etc. for leaks.
Repair leaks, or replace parts, as required.
Check drain and release it. When quantity of the drain is remarkable,
examine the setting of the air dryer to the air supply side.
-5-
1.CHECKS AND MAINTENANCE
B-83085EN/03
Pressure
Adjusting Knob
2-6.5×16.5
Length round hole
Rc1/4
AIR OUTLET
Pressure gauge
Rc1/4
AIR SUPPLY
Fig. 1.2.2 Air control set (option)
1.2.3
Retightening the Link B
Check the tightness of LINK B part (12 places), if they are loosened, remove the LOCTITE 243, then
apply LOCTITE 243 on the thread and retighten them.
Apply LOCTITE 243
on the thread.
Link B
ball joint part
Check point
Tightening torque 2.8Nm
Check point
Check point
Apply LOCTITE 243
on the thread.
Link B
ball joint part
Check points
Check point
Tightening torque 2.8Nm
Fig.1.2.3 Checking points of LINK B
-6-
1.CHECKS AND MAINTENANCE
B-83085EN/03
1.2.4
Cleaning the Wrist Axis Rotation Parts and the Wrist Gears
(M-1iA/0.5S,0.5A,0.5SL,0.5AL)
Cleaning points
Clean up the dirty splattered grease around the wrist axis rotation parts , gears and the gear cover.
Clean the grease around the
wrist input gear after removing
cover.
Fig.1.2.4 Cleaning points of the wrist axis rotation parts and the wrist gear
NOTE
When checking and cleaning the drive shafts, please be careful no to push the
shaft on the drive shaft.
1.2.5
Check the Connectors
Inspection points of the connectors
・ Power/brake connectors of the motor exposed externally
・ Robot connection cables, earth terminal and user cables
Check items
・ Circular connector: Check the connector for tightness by turning it manually.
・ Square connector: Check the connector for engagement of its lever.
・ Earth terminal: Check the connector for tightness.
Remove cover
and check here.
Fig. 1.2.5 Connector Inspection points
-7-
1.CHECKS AND MAINTENANCE
1.3
B-83085EN/03
MAINTENANCE TOOLS
The following tools and instruments are required for the maintenance procedures contained in this
manual.
(a) Measuring instruments
Instruments
Accuracy/Tolerance
Applications
Dial gauge accuracy
Slide calipers
1/100 mm
150 mm
Measurement of positioning
(b) Tools
・Torque wrench
・Cross tip (+) screwdrivers
・Flat tip (–) screwdrivers
・Nut driver
・Hexagon wrench set
・Monkey wrench
・Pincers
・Needle nose pliers
・Nippers
・Gear puller
・Separator
・Offset wrench
・Pliers for C–retaining ring
・LOCTITE 243
Large, medium, and small sizes
Large, medium, and small sizes
Width across flats 7
Width across flats 2.5, 3, 4 (for replacing parts)
Middle, little
-8-
2.PERIODIC MAINTENANCE
B-83085EN/03
2
2.1
PERIODIC MAINTENANCE
REPLACING THE BATTERIES
(1-YEAR (3840 Hours) CHECKS (with stand/no stand B))
(1.5-YEAR (5760 Hours) CHECKS (no stand A))
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced
every 1 year in case of with stand/no stand B 1.5 years in case of no stand A. Also, use the following
procedure to replace when the backup battery voltage drop alarm occurs.
Procedure of replacing the battery (with stand /no stand B)
1
Keep the power on. Press the EMERGENCY STOP button to prohibit robot motion.
CAUTION
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.2.1 (a))
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.
The
battery can be taken out
この棒を引っ張ると
by
pulling this stick
バッテリが取り出せます。
バッテリケース
Battery
case
Case
cap
ケースキャップ
Spec.
of battery : A98L-0031-0027
バッテリ仕様:A98L-0031-0027
(C
battery (alkali) 4 pcs)
(単二アルカリ電池
4本)
Fig.2.1 (a) Replacing Batteries (with stand / No stand B)
-9-
2.PERIODIC MAINTENANCE
B-83085EN/03
Procedure of replacing the battery (no stand A)
1
Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.
CAUTION
Be sure to keep the controller 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. 2.1 (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バッテリケーブル
cable
Diameter
About
5mm
O5mm
径 約
(最大 O5.5mm)
(Max. φ5.5mm)
Battery box
バッテリボックス
Battery case
バッテリケース
Spec.
of battery : A98L-0031-0005
バッテリ仕様:A98L-0031-0005
(D (単一アルカリ電池
battery (alkali) 4 pcs)
4本)
Case
cap
ケースキャップ
Fig.2.1 (b) Replacing Batteries (No stand A)
Fig.2.1 (c) shows the external size of external battery box.
When the battery box needs to be built into the controller or other internal units, refer to the outer
dimensions shown in Fig.2.1 (c)
The battery box can be fixed by using M4 flat–head screws. (The bolts do not come with the system.)
A maximum of six terminals can be attached to the backplane of the battery box.
- 10 -
2.PERIODIC MAINTENANCE
B-83085EN/03
Fig.2.1 (c) Outer dimensions of the battery box
2.2
APPLYING THE GREASE OF THE WRIST INPUT GEARS
AND THE DRIVE SHAFTS (M-1iA/0.5S,0.5A,0.5SL,0.5AL)
(6 MONTHS (1920 HOURS) CHECKS)
Supply grease to wrist input gear and the drive shafts at the intervals recommended below based on every
6 months or 1920 hours, which ever comes first. See table 2.2 for the grease name and the quantity.
Table 2.2 Grease for 6-months (1920 hours) periodical replacement
Supply position
Quantity
Grease name
Wrist input gear
Proper quantity
Drive shafts
Proper quantity
JX Nippon Oil & Energy Corporation
TOUGHLIX GREASE RB2 (old name: CG335)
Spec: A98L-0040-0252#0.4kg
For grease replacement or replenishment, move the wrist to the stroke end of the upper side.
CAUTION
Failure to follow proper lubrication procedures may cause the suddenly increase
of the grease bath internal pressure and the damage to the seal, which could
lead to grease leakage and abnormal operation. When greasing, observe the
following cautions.
1 Use specified grease. Use of non-approved grease may damage the gear or
lead to other problems.
2 To prevent slipping accidents and catching fire, completely remove any
excess grease from the floor or robot.
3 When apply grease to the drive shaft, be careful not to push the shaft.
1
2
Turn off the controller power.
Remove the cover.
- 11 -
2.PERIODIC MAINTENANCE
3
4
5
6
B-83085EN/03
Supply new grease to the gear of J4 to J6-axes referring to Fig.2.2 (a).
In case of M-1iA/0.5S,0.5SL there are two places for J4-axis.
In case of M-1iA/0.5A,0.5AL there are six places for J4 to J6-axes.
Supply new grease to the drive shafts groove with a brush or a cylinder referring to Fig.2.2 (b).
In case of M-1iA/0.5S,0.5SL there is one place for J4-axis.
In case of M-1iA/0.5A,0.5AL there are three places for J4 to J6-axes.
Clean up the dirty splattered grease around the gear and gear cover.
Attach cover.
1cm
1cm
Greasing point
Greasing point
Fig.2.2 (a) Supply grease to J4 to J6 gears
Greasing area
of the drive shafts
Fig.2.2 (b) Supply grease to the drive shafts (example of J4-axis)
- 12 -
3.TROUBLESHOOTING
B-83085EN/03
3
TROUBLESHOOTING
3.1
OVERVIEW
The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from
many interrelated factors. If you fail to take the correct measures, the failure may be aggravated.
Therefore, you must analyze the symptoms of the failure precisely so that the true cause can be found.
3.2
FAILURES, CAUSES AND MEASURES
Table 3.2 lists the major failures 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.
Symptom
Vibration
Noise
Table 3.2 Failures, causes and measures
Description
Cause
-The base or pedestal lifts off
the floor plate as the robot
operates.
-There is a gap between the
base or pedestal and floor
plate.
-A base or stand retaining bolt
is loose.
-Apply epoxy to the floor
surface and re-install the plate.
-Vibration becomes more
serious when the robot adopts
a specific posture.
-If the operating speed of the
robot is reduced, vibration
stops.
-Vibration is most noticeable
when the robot is accelerating.
-Vibration occurs when two or
more axes operate at the same
time.
[Base or pedestal fastening]
-It is likely that the robot base or
pedestal is not securely
fastened to the floor plate.
-Probable causes are a loose
bolt, an insufficient degree of
surface flatness, or foreign
material caught between the
floor plate and floor plate.
-If the robot is not securely
fastened to the floor plate, the
base or pedestal lifts the floor
plate as the robot operates,
allowing the base or pedestal
and floor plates to strike each
other which, in turn, leads to
vibration.
[Rack or floor]
-It is likely that the rack or floor
is not sufficiently rigid.
-If the rack or floor is not
sufficiently rigid, reaction from
the robot deforms the rack or
floor, leading to vibration.
[Overload]
-It is likely that the load on the
robot is greater than the
maximum rating.
-It is likely that the robot control
program is too demanding for
the robot hardware.
-It is likely that the
ACCELERATION value is
excessive.
- 13 -
Measure
-If a bolt is loose, apply
LOCTITE and tighten it to the
appropriate torque.
-Adjust the floor plate surface
flatness to within the specified
tolerance.
-If there is any foreign matter
between the base or pedestal
and floor plate, remove it.
-Reinforce the rack or floor to
make it more rigid.
-If reinforcing the rack or floor is
impossible, modify the robot
control program; doing so might
reduce the amount of vibration.
-Check the maximum load that
the robot can handle once
more. If the robot is found to be
overloaded, reduce the load, or
modify the robot control
program.
-Vibration in a specific portion
can be reduced by modifying
the robot control program while
slowing the robot and reducing
its acceleration (to minimize the
influence on the entire cycle
time).
3.TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)
Description
-Vibration or noise was first
noticed after the robot collided
with an object or the robot was
overloaded for a long period.
-The grease of the vibrating or
noise occurring axis has not
been exchanged for a long
period.
B-83085EN/03
Cause
[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 foreign matter
caught in a gear, bearing, or
within a reducer cause
vibration.
- 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.
- 14 -
Measure
-Operate one axis at a time to
determine which axis is
vibrating.
-Remove the motor, and
replace the gear, the bearing,
and the reducer. For the spec.
of parts and the method of
replacement, contact FANUC.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
3.TROUBLESHOOTING
B-83085EN/03
Symptom
Vibration
Noise
(Continued)
Description
Cause
-The cause of problem cannot
be identified from examination
of the floor, rack, or mechanical
section.
[Controller, cable, and motor]
-If a failure occurs in a
controller circuit, preventing
control commands from being
supplied to the motor normally,
or preventing motor information
from being sent to the controller
normally, vibration might occur.
-If the Pulsecoder develops a
fault, vibration might occur
because information about the
motor position cannot be
transferred to the controller
accurately.
-If the motor becomes
defective, vibration might occur
because the motor cannot
deliver its rated performance.
-If a power line in a movable
cable of the mechanical section
has an intermittent break,
vibration might occur because
the motor cannot accurately
respond to commands.
-If a Pulsecoder wire in a
movable part of the mechanical
section has an intermittent
break, vibration might occur
because commands cannot be
sent to the motor accurately.
-If a connection cable between
them has an intermittent break,
vibration might occur.
-If the power cable between
them has an intermittent break,
vibration might occur.
-If the power source voltage
drops below the rating, vibration
might occur.
-If a robot control parameter is
set to an invalid value, vibration
might occur.
- 15 -
Measure
-Refer to the Controller
Maintenance Manual for
troubleshooting related to the
controller and amplifier.
-Replace the Pulsecoder for the
motor of the axis that is
vibrating, and check whether
the vibration still occurs.
-Also, replace the motor of the
axis that is vibrating, and check
whether vibration still occurs.
For the method of replacement,
contact FANUC.
-Check that the robot is
supplied with the rated voltage.
-Check whether the sheath of
the power cord is damaged. If
so, replace the power cord, and
check whether vibration still
occurs.
-Check whether the sheath of
the cable connecting the
mechanical section and
controller is damaged. If so,
replace the connection cable,
and check whether vibration still
occurs.
-If vibration occurs only when
the robot assumes a specific
posture, it is likely that a cable
in the mechanical unit is
broken.
-Shake the movable part cable
while the robot is at rest, and
check whether an alarm occurs.
If an alarm or any other
abnormal condition occurs,
replace the mechanical unit
cable.
-Check that the robot control
parameter is set to a valid
value. If it is set to an invalid
value, correct it. Contact
FANUC for further information if
necessary.
3.TROUBLESHOOTING
Symptom
B-83085EN/03
Description
Vibration
Noise
(Continued)
-There is some relationship
between the vibration of the
robot and the operation of a
machine near the robot.
Rattling
-While the robot is not supplied
with power, pushing it with the
hand causes part of the
mechanical unit to wobble.
-There is a gap on the mounting
face of the mechanical unit.
-Backlash is greater than the
tolerance stated in the
applicable maintenance
manual.
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.
[Mechanical section coupling
bolt]
-It is likely that overloading or a
collision has loosened a
mounting bolt in the robot
mechanical section.
[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.
- 16 -
Measure
-Connect the grounding wire
firmly to ensure a reliable
ground potential and prevent
extraneous electrical noise.
-Check that the following bolts
for each axis are tight. If any of
these bolts is loose, apply
LOCTITE and tighten it to the
appropriate torque.
-Motor retaining bolt
-Reducer retaining bolt
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
-Operate one axis at a time to
determine which axis has the
increased backlash.
-Remove the motor, and check
whether any of its gears are
broken. If any gear is broken,
replace it.
-Check whether any other gear
of the drive mechanism is
damage. If there is no damage
gear, replace the reducer.
-If the reducer is broken, or if a
gear tooth is missing, replace
the relevant component. Also,
remove all the grease or oil
from the gearbox and wash the
inside of the gearbox.
-After replacing the gear or
reducer, add an appropriate
amount of grease or oil.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly applying the grease
or oil with a specified type can
help prevent problems.
3.TROUBLESHOOTING
B-83085EN/03
Symptom
Description
Cause
Rattling
- There is lost motion in the
bearing of a joint
[Damage to the bearing,
release of the pre-load]
- A probable cause is that
excessive force was applied to
the bearing of the joint due to
impact or overload, damaging
the bearing or releasing the
pre-load.
Motor
over-heating
-The ambient temperature of
the installation location
increases, causing the motor to
overheat.
-After the robot control program
or the load was changed, the
motor overheated.
[Ambient temperature]
-It is likely that a rise in the
ambient temperature prevented
the motor from releasing heat
efficiently, thus leading to
overheating.
[Operating condition]
-It is likely that the robot was
operated with the maximum
average current exceeded.
-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.
- 17 -
Measure
- Check the movement of the
joints during operation to
identify the faulty joint.
- Remove each leg, move the
top and bottom joints manually
to check whether the bearings
are damaged and whether
there is lost motion. If a bearing
is damaged or the pre-load is
released, replace the unit
containing the joint.
- This problem can be avoided
by avoiding use at overload.
-The teach pendant can be
used to monitor the average
current. Check the average
current when the robot control
program is running. The
allowable average current is
specified for the robot
according to its ambient
temperature. Contact FANUC
for further information.
-Relaxing the robot control
program and conditions can
reduce the average current,
thus preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of the
robot well ventilated enables
the robot to release heat
efficiently, thus preventing
overheating. Using a fan to
direct air at the motor is also
effective.
-If there is a source of heat near
the motor, it is advisable to
install shielding to protect the
motor from heat radiation.
-Input an appropriate parameter
as described in CONTROLLER
OPERATOR’S MANUAL.
3.TROUBLESHOOTING
Symptom
B-83085EN/03
Description
Motor
over-heating
-Symptom other than stated
above
Grease
leakage
-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.
Cause
Measure
[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.
[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.
-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.
[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.
-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.
- 18 -
-If a crack develops in the
casting, sealant can be used as
a quick-fix to prevent further
grease leakage. However, the
component should be replaced
as soon as possible, because
the crack might extend.
-O-rings are used in the
locations listed below.
-Motor coupling section
-Reducer coupling section
-Wrist coupling section
-J3 arm coupling section
-Inside the wrist
-Oil seals are used in the
locations stated below.
-Inside the reducert
3.TROUBLESHOOTING
B-83085EN/03
Symptom
Description
Displacement -The robot operates at a point
other than the taught position.
-The repeatability is not within
the tolerance.
-Displacement occurs only in a
specific peripheral unit.
-Displacement occurred after a
parameter was changed.
BZAL alarm
occurred
3.3
-BZAL is displayed on the
controller screen
Cause
Measure
[Mechanical section problems]
-If the repeatability is unstable,
probable causes are a failure in
the drive mechanism or a loose
bolt.
-If the repeatability becomes
stable it is likely that a collision
imposed an excessive load,
leading to slipping on the base
surface or the mating surface of
an arm or reducer.
-It is likely that the Pulsecoder
is abnormal.
[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.
-If the repeatability is unstable,
repair the mechanical section
by referring to the above
descriptions of vibration, noise,
and rattling.
-If the repeatability is stable,
correct the taught program.
Variation will not occur unless
another collision occurs.
-If the Pulsecoder is abnormal,
replace the motor or the
Pulsecoder.
- It is likely that the voltage of
the memory backup battery is
low.
- It is likely that the Pulsecoder
cable is defected.
-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.
BACKLASH MEASUREMENT
Measurement method
Move robot to ±5mm or more to X, Y, Z directions and ±1º or more to J4, J6, J6 directions and measure
backlash. 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.
- 19 -
3.TROUBLESHOOTING
B-83085EN/03
5mm or more
or
1º or more
5mm or more
or
1º or more
Positioning
of 0 position
Measurement
Backlash
Positioning
of 0 position
Measurement
Backlash
Fig. 3.3 (a)
Table 3.3 (a)
Measurement axis
X direction
Y direction
Z direction
J4-axis
X direction
Y direction
Z direction
J4-axis
J5-axis
J6-axis
Position
J1-axis
0º
0º
0º
0º
0º
0º
Table 3.3 (c)
Measurement axis
X direction
Y direction
Z direction
Backlash measurement position (M-1iA/0.5S)
J1-axis
0º
0º
0º
0º
Table 3.3 (b)
Measurement axis
Backlash measurement method
J2-axis
0º
0º
0º
0º
J3-axis
0º
0º
0º
0º
Backlash measurement position (M-1iA/0.5A)
Position
J2-axis
J3-axis
J4-axis
J5-axis
0º
0º
0º
30º
0º
0º
0º
30º
0º
0º
0º
30º
0º
0º
0º
30º
0º
0º
0º
0º
0º
0º
0º
30º
J4-axis
-90º
-90º
-90º
-90º
J6-axis
-90º
-90º
-90º
-90º
-180º
-90º
Backlash measurement position (M-1iA/1H)
Position
J2-axis
0º
0º
0º
J1-axis
0º
0º
0º
- 20 -
J3-axis
0º
0º
0º
3.TROUBLESHOOTING
B-83085EN/03
Table 3.3 (d)
X direction
Y direction
Z direction
J4-axis
Position
J1-axis
18.364º
18.364º
18.364º
18.364º
Table 3.3 (e)
Measurement axis
X direction
Y direction
Z direction
J4-axis
J5-axis
J6-axis
J1-axis
18.364º
18.364º
18.364º
18.364º
18.364º
18.364º
Table 3.3 (f)
Measurement axis
J2-axis
18.364º
18.364º
18.364º
18.364º
61 (M-1iA/0.5S,0.5SL)
71.3 (M-1iA/1H,1HL)
J4-axis
-90º
-90º
-90º
-90º
Backlash measurement position (M-1iA/0.5AL)
Position
J2-axis
J3-axis
J4-axis
J5-axis
18.364º
18.364º
0º
30º
18.364º
18.364º
0º
30º
18.364º
18.364º
0º
30º
18.364º
18.364º
0º
30º
18.364º
18.364º
0º
0º
18.364º
18.364º
0º
30º
J6-axis
-90º
-90º
-90º
-90º
-180º
-90º
Backlash measurement position (M-1iA/1HL)
Position
J2-axis
18.364º
18.364º
18.364º
J1-axis
18.364º
18.364º
18.364º
X direction
Y direction
Z direction
J3-axis
18.364º
18.364º
18.364º
18.364º
Measurement position
for X direction
Measurement position
for Z direction
J3-axis
18.364º
18.364º
18.364º
61 (M-1iA/0.5S,0.5SL)
71.3 (M-1iA/1H,1HL)
Measurement axis
Backlash measurement position (M-1iA/0.5SL)
Measurement position
for Y direction
Measurement position
for Z direction
Fig.3.3 (b) Measurement position of X, Y and Z directions (M-1iA/0.5S,0.5SL,1H,1HL)
- 21 -
3.TROUBLESHOOTING
B-83085EN/03
Measurement position
for J4-axis
25
Measurement position
for X direction and J6-axis
Measurement position
for Z direction
61
61
Fig.3.3 (c) Measurement position of J4 direction (M-1iA/0.5S,0.5SL)
Measurement position
for Y direction and J4-axis
9
Measurement position
for Z direction
Fig.3.3 (d) Measurement position of X, Y, Z, J4 and J6 directions (M-1iA/0.5A,0.5AL)
- 22 -
3.TROUBLESHOOTING
9
61
B-83085EN/03
Measurement position
for J5-axis
Fig.3.3 (e) Measurement position of J5 direction (M-1iA/0.5A,0.5AL)
X direction
Y direction
Z direction
J4-axis
J5-axis
J6-axis
Table 3.3 (g) Permissible backlash value (M-1iA/0.5S,0.5A,1H)
M-1iA/0.5S
M-1iA/0.5A
M-1iA/1H
Measuremen Permissible Measurement Permissible Measurement
Permissible
t distance
value
distance
value
distance
value
－
－
－
0.15mm
0.15mm
0.15mm
－
－
－
0.15mm
0.15mm
0.15mm
－
－
－
0.1mm
0.1mm
0.1mm
－
－
25mm
0.15mm
39.5mm
0.8mm
－
－
－
－
83mm
0.85mm
－
－
－
－
42mm
0.6mm
Measurement condition
Teaching speed: Each axis : 1%
OVR:
100%
X direction
Y direction
Z direction
J4-axis
J5-axis
J6-axis
Table 3.3 (h) Permissible backlash value (M-1iA/0.5SL,0.5AL,1HL)
M-1iA/0.5SL
M-1iA/0.5AL
M-1iA/1HL
Measurement Permissible Measurement Permissible Measurement
Permissible
distance
value
distance
value
distance
value
－
－
－
0.2mm
0.2mm
0.2mm
－
－
－
0.2mm
0.2mm
0.2mm
－
－
－
0.1mm
0.1mm
0.1mm
－
－
25mm
0.2mm
39.5mm
0.8mm
－
－
－
－
83mm
0.85mm
－
－
－
－
42mm
0.6mm
Measurement condition
Teaching speed: Each axis : 1%
OVR:
100%
- 23 -
4.COMPONENT REPLACEMENT
4
B-83085EN/03
COMPONENT REPLACEMENT
Once motors, reducers, arm, drive shaft and wrist unit are replaced, mastering becomes necessary,
perform mastering according to Chapter 8 of the Operator’s Manual (B-83084EN) after any of these
components is replaced.
NOTE
1 When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and
taps and wipe oil off the engaging section. Make sure that there is no solvent in
the taps.
Be sure to wipe the excess LOCTITE after tightening screw.
2 Description of [LT243] means LOCTITE 243.
- 24 -
4.COMPONENT REPLACEMENT
B-83085EN/03
4.1
FIGURE OF DRIVE MECHANISM
The drive mechanisms of each axis are shown in the following.
Motor
Reducer
Plate of tip
Fig. 4.1 (a) Drive mechanism of J1/J2/J3-axes
Gear
Universal
joint
Motor
Wrist unit
Fig. 4.1 (b) Drive mechanism of wrist axis (M-1iA/0.5S,0.5A,0.5SL,0.5AL)
- 25 -
4.COMPONENT REPLACEMENT
4.2
B-83085EN/03
ROBOT CONFIGURATION
Fig 4.2 (a) - (c) show robot configuration.
AC servo motor
for J1-axis (M1)
AC servo motor
for J3-axis (M3)
AC servo motor
for J2-axis (M1)
AC servo motor
for J4-axis (M4)
Cover
Stand
J2 link A
J2 link B
J1 link A
J3 link A
J3 link B
J1 link B
J4 casing
End effector
mounting face
Fig. 4.2 (a) Mechanical unit configuration (M-1iA/0.5S,0.5SL)
- 26 -
4.COMPONENT REPLACEMENT
B-83085EN/03
AC servo motor for J1-axis (M1)
AC servo motor for J6-axis (M6)
AC servo motor for J5-axis (M5)
AC servo motor for J3-axis (M3)
AC servo motor for J2-axis (M2)
AC servo motor for J4-axis (M4)
Cover
Stand
J1 link A
J2 link A
J3 link A
J3 link B
J2 link B
J5 casing
J6 casing
J1 link B
J4 casing
End effector
mounting face
Fig. 4.2 (b) Mechanical unit configuration (M-1iA/0.5A,0.5AL)
- 27 -
4.COMPONENT REPLACEMENT
B-83085EN/03
AC servo
motor for J1-axis (M1)
J1軸用ACサーボモータ
(M1)
AC
servo motor for J3-axis
(M3)
J3軸用ACサーボモータ
(M3)
ACJ2軸用ACサーボモータ
servo motor for J2-axis (M2)
Cover
カバー
Stand
スタンド
J2
link A A
J2リンク
J2
link B B
J2リンク
J1
link A A
J1リンク
J3
J3リンク
link A A
J3
link B B
J3リンク
J1
link B B
J1リンク
End effector
エンドエフェクタ
mounting
face
取付け面
Fig. 4.2 (c) Mechanical unit configuration (M-1iA/1H,1HL)
4.3
1
2
3
4
5
6
7
8
9
10
REPLACING THE J1/J2/J3-AXIS MOTOR M1/M2/M3
Turn off the controller power.
Remove cover (1), (3) of Fig.4.3 (a),(b).
Remove the connector of motor.
Remove bolt (6) and adapter (5) of Fig.4.3 (b).
Remove motor mounting bolts (2), then remove motor (1) from reducer. Pay attention that grease
overflows when you remove motor.
Remove set screw (4) of Fig.4.3 (b).
Remove gear (3) from motor shaft referring to Fig.4.3 (b).
Attach gear (3) to new motor, and assemble motor applying the procedure in the reversed sequence.
Attach the connector to the motor.
Perform single axis mastering referring to Section 7.5 of the Operator’s Manual.
- 28 -
4.COMPONENT REPLACEMENT
B-83085EN/03
4
3
1
2
Fig 4.3 (a) Removing the cover (With stand or No stand A)
Parts name
1
2
COVER
BOLT
3
COVER
4
BOLT
Specifications
Q’ty
A290-7522-X203
A290-7522-X231
M-1iA/0.5S,0.5A,1H
A290-7522-X236
M-1iA/0.5SL,0.5AL,1HL A290-7522-X253
A97L-0218-0496#M4X8TC
Locking
Torque (N-m)
Locking
Torque (N-m)
1
4
1
4
4
3
1
2
Fig.4.3 (b)
Parts name
1
2
COVER
BOLT
3
COVER
4
BOLT
Removing the cover
Specifications
A290-7522-X203
A290-7522-X231
M-1iA/0.5S,0.5A,1H
A290-7522-X242
M-1iA/0.5SL,0.5AL,1HL A290-7522-X258
A97L-0218-0496#M4X8TC
- 29 -
(No stand B)
Q’ty
1
4
1
4
4.COMPONENT REPLACEMENT
B-83085EN/03
6
2
4
1
3
7
5
Fig. 4.3 (c) Replacing the J1/J2/J3-axis motor M1/M2/M3 (Figure is example of J1-axis)
Parts are common in J1/J2/J3-axis motor. Table below is about one motor.
Parts name
1
2
3
4
5
6
7
4.4
1
2
3
4
5
MOTOR
BOLT
GEAR
SET SCREW
ADAPTER
BOLT
PIN
Specifications
A06B-0117-B855#0049
A6-BA-5X14
Attached to the reducer
Attached to the reducer
A290-7522-X204
A6-BA-4X12
JB-PH-H8B-3X6S45C
Q’ty
1
4
1
2
1
4
2
Locking
Torque (N-m)
5.6
LT243
0.69
LT243
4.5
REPLACING THE J1/J2/J3-AXIS REDUCER
Remove J1/J2/J3-axis motor referring to Section 4.3.
Remove bolts (8) which mounting reducer to arm.
Remove bolt (9) and reducer (7).
Replace reducer to new one and assemble it applying the procedure in the reversed sequence.
Perform single axis mastering referring to section 7.5 of the Operator’s Manual.
NOTE
When replacing reducer, be sure to replace gear to new, too.
- 30 -
4.COMPONENT REPLACEMENT
B-83085EN/03
6
4
7
9
8
3
Arm
5
Link base
10
Fig. 4.4 Replacing the J1/J2/J3-axis reducer (Figure is example of J1-axis)
Parts are common in J1/J2/J3-axis motor. Table below is about one motor.
Parts name
3
4
5
6
7
8
9
10
4.5
GEAR
SET SCREW
ADPTER
BOLT
REDUCER
BOLT
BOLT
PIN
Specifications
Attached to the reducer
Attached to the reducer
A290-7522-X204
A6-BA-4X12
A97L-0218-0872#45
A6-BA-4X12
A6-BA-3X10
JB-PH-H8B-3X6S45C
Q’ty
1
2
1
4
1
3
4
2
Locking
Torque (N-m)
LT243
0.69
LT243
4.5
LT243
4.5
1.3
REPLACING THE J4/J5/J6-AXIS MOTOR M4/M5/M6
(M-1iA/0.5S,0.5A,0.5SL,0.5AL)
1
2
3
Turn off the controller power.
Remove cover (1), (3) of Fig.4.3 (a) referring to Section 4.3.
In case of J4-axis, remove wrist input gear (11) and gear cover of J4-axis referring to Fig.4.5.
In case of J5-axis, First, remove wrist input gear (11) and gear cover of J4-axis, remove them of
J5-axis next.
In case of J6-axis, First, remove wrist input gear (11) and gear cover of J4/J5-axis, remove them of
J6-axis next.
Remove bolt (7), motor plate (8) and motor (9) from link base.
Remove bolt (3), washer (4) and gear (5) from motor (9).
6
Remove motor mounting bolts (10) and remove motor (9) from motor plate (8).
7
Remove connector of motor (9).
8
Attach key (6), and motor plate (8) to new motor (9).
9
Attach connector to motor (9).
10 Assemble them applying the procedure in the reversed sequence.
11 According to Section 2.2, supply the J4/J5/J6 axis wrist input gear with the grease.
12 Perform single axis mastering referring to Section 7.5 of the Operator’s Manual.
- 31 -
4.COMPONENT REPLACEMENT
B-83085EN/03
1
2
3
When attaching gear,
be careful not to let gear interfere gear cover.
4
5
10 (J5,J6)
6
11
1
12
7
8
9
7
2
10 (J4)
Tighten these mounting bolts while
pushing motor unit to this direction.
Link base
Fig. 4.5 Replacing the J4/J5/J6-axis motor M4/M5/M6 (Figure is example of J4-axis)
Parts name
1
BOLT
2
GEAR COVER
3
4
5
BOLT
WASHER
GEAR J4-1
(J4)
GEAR J56-1
(J5/J6)
6
GEAR J6-1
(J6)
KEY
7
BOLT
8
9
J4 MOTOR
PLATE (J4)
J56 MOTOR
PLATE (J5/J6)
MOTOR
MOTOR
10
BOLT
11
GEAR
12
BOLT
Specifications
A6-BA-4X6
M-1iA/0.5S,0.5A,
0.5AL (J6-axis)
M-1iA/0.5SL,
0.5AL (J4,J5-axes)
A6-BA-3X8
A290-7210-X532
M-1iA/0.5S,0.5A
M-1iA/0.5SL,0.5AL
M-1iA/0.5A
Q’ty
Locking
Torque (N-m)
LT243
1.3
LT243
LT243
4.5
4.5
2
A290-7522-X414
1
A290-7522-X425
1
1
A290-7522-X401
A290-7522-X421
A290-7522-X402
M-1iA/0.5AL
A290-7522-X422
M-1iA/0.5A,0.5AL
A290-7522-X402
1
1
1
A97L-0118-0402#3X3X12BN
J4
A6-BA-4X12
J5,J6
A6-BA-4X12
1
3
4
A290-7522-X412 (*1)
1
A290-7522-X413 (*2)
1
A06B-0114-B855#0048 (*1)
A06B-0117-B855#0049 (*2)
J4
A6-BA-5X12
J5/J6
A6-BA-4X12
M-1iA/0.5S,0.5A,
0.5SL,
A290-7522-X403
0.5AL (J4,J5-axes)
M-1iA/0.5AL
A290-7522-X423
(J6-axis)
A6-BA-3X8
1
1
- 32 -
5.6
4.5
4
1
1
4
LT243
1.3
4.COMPONENT REPLACEMENT
B-83085EN/03
4.6
1
2
3
4
5
6
REPLACING THE J1/J2/J3 ARM ASSEMBLY
Turn off the controller power.
Remove cover (1), (3) of Fig.4.3 (a),(b) referring to Section 4.3.
Remove LINK B referring to Section 4.7.
Remove bolt (4).
Remove bolt (2) and pin (3) and remove arm assembly (1) from link base.
Replace arm assembly (1) to new one and assembly it applying the procedure in the reversed
sequence.
Perform single axis mastering referring to Section 7.5 of the Operator’s Manual.
7
4
3
1
2
Screw part
Fig. 4.6 Replacing the arm (Figure is example of J3-axis)
Table below is about one motor.
Parts name
1
ARM ASS’Y
2
3
4
BOLT
PIN
BOLT
Specifications
A290-7522-V202 (*1)
A290-7522-V203 (*2)
A290-7522-V204 (*3)
A290-7522-V206 (*4)
A290-7522-V207 (*5)
A290-7522-V208 (*6)
A97L-0218-0496#M4X12TC
JB-PH-H8B-3X6S45C
A6-BA-4X12
(*1) In case of J1-axis of M-1iA/0.5S,0.5A,1H
(*2) In case of J2-axis of M-1iA/0.5S,0.5A,1H
(*3) In case of J3-axis of M-1iA/0.5S,0.5A,1H
(*4) In case of J1-axis of M-1iA/0.5SL,0.5AL,1HL
(*5) In case of J2-axis of M-1iA/0.5SL,0.5AL,1HL
(*6) In case of J3-axis of M-1iA/0.5SL,0.5AL,1HL
- 33 -
Q’ty
1
1
1
1
1
1
2
2
3
Locking
Torque (N-m )
LT243
4.5
LT243
4.5
4.COMPONENT REPLACEMENT
4.7
1
2
B-83085EN/03
REPLACING THE J1/J2/J3 LINK B
Turn off the controller power.
Remove bolt (1), joint (2) and washer (3) of one side. (4 places)
(You do not have to remove bolt (1), joint (2) and washer (3) of another side. Assemble them only
when you lost part etc.)
Loosen screw of link of upper side and lower side. When removing first LINK, loosen screw of
upper side and lower side equally.
Attach new LINK B. When attaching last link, tighten screw of upper side and lower side slowly.
Tighten screw with torque of .2.8Nm and apply ThreeBond 1401B to it. In this time, apply
LOCTITE 243 to the thread part.
Attach joint (2) and washer (3) to link.
3
4
5
1
2
3
5
4
3
2
1
1
2
3
You do not have remove these parts
when removing the link.
4
3
2
1
5
Fig 4.7 (a) Replacing LINK B (Figure is example of J3-axis)
Parts name
1
BOLT
2
JOINT
3
4
WASHER
SHAFT
5
LINK B
Specifications
Q’ty
Locking
Torque (N-m)
A97L-0218-0496#M2X4TC
M-1iA/0.5S,0.5A,1H
A290-7522-X303
M-1iA/0.5SL,0.5AL,1HL A290-7522-X309
A290-7522-X305
A290-7522-X304
M-1iA/0.5S,0.5A,1H
A290-7522-V301
M-1iA/0.5SL,0.5AL,1HL A290-7522-V302
8 (*1)
LT243
0.36
LT243
2.8
(*) This is amount when you replace both sides.
- 34 -
4 (*1)
8 (*1)
4 (*1)
2
4.COMPONENT REPLACEMENT
B-83085EN/03
A
DETAIL A
B
Screw part
Screw part
DETAIL B
Fig.4.7 (b) Locking applying area of upper side and lower side of link B
(Figure is example of J2-axis)
Apply LOCTITE 243
after tightening shaft.
Fig.4.7 (c) Locking applying area of upper side and lower side of link
- 35 -
4.COMPONENT REPLACEMENT
4.8
B-83085EN/03
REPLACING THE J4/J5/J6 WRIST INPUT GEAR
(M-1iA/0.5S,0.5A,0.5SL,0.5AL)
1
2
3
4
5
6
Turn off the controller power.
Remove cover (1), (3) of Fig.4.3 (a),(b) referring to Section 4.3.
Loosen the motor plate mounting bolts (3), then slide the motor from the gear.
Remove bolt (1).
Remove gear (2) by using removal tap of Fig.4.8.
In case of J5-axis, remove gear and gear cover of J4-axis.
In case of J6-axis, remove gear and gear cover of J4/J5-axis.
Attach new gear. Assemble it with phase you can use removal tap referring to Fig.4.8.
Fix gear while pushing motor unit to gear so that backlash becomes smallest. Apply the grease on
the gear referring to Section 2.2.
Perform single axis mastering referring to Section 7.5 of the Operator’s Manual.
7
8
When attaching gear,
be careful not to let gear interfere gear cover.
1
2
Assemble it so that removal tap
come to this position
3
Tighten these mounting bolts while
pushing motor unit to this direction.
Fig. 4.8 Replacing the wrist input gear (Figure is example of J4-axis.)
Parts name
1
2
GEAR
3
BOLT
4.9
1
2
3
4
5
6
7
8
BOLT
Specifications
A6-BA-3X8
Except J6 of M-1iA/0.5AL
J6 of M-1iA/0.5AL
A6-BA-4X12
A290-7522-X403
A290-7522-X423
Q’ty
Locking
Torque (N-m)
4
LT243
1.3
LT243
4.5
1
3
REPLACING THE J4/J5/J6 DRIVE SHAFT
(M-1iA/0.5S,0.5A,0.5SL,0.5AL)
Turn off the controller power.
Remove cover (1), (3) of Fig.4.3 (a) referring to Section 4.3.
In case J4-axis, remove wrist input gear and gear cover of J4-axis referring to Section 4.8.
In case J5-axis, remove wrist input gear and gear cover of J4/J5-axis referring to Section 4.8.
In case J6-axis, remove wrist input gear and gear cover of J4/J5/J6-axis referring to Section 4.8.
Remove the set screw (2) and drive shaft assembly (1) from wrist unit.
Remove bolt (3) and pull out drive shaft assembly (1) in the upper direction.
Assemble new drive shaft assembly (1) to robot.
Attach wrist input gear and gear cover referring to Section 4.8.
Perform single axis mastering referring to Section 7.5 of the Operator’s Manual.
- 36 -
4.COMPONENT REPLACEMENT
B-83085EN/03
1
2
Fig. 4.9 (a) Replacing the drive shaft (1/2) (Figure is example of J4-axis)
Parts name
1
DRIVE SHAFT
ASSY
2
SET SCREW
Specifications
M-1iA/0.5S,0.5A
A290-7522-V403
M-1iA/0.5SL,0.5AL
A290-7522-V406
A6-SAKT-4X4
Q’ty
Locking
Torque (N-m)
LT243
1.7
1
2
Match the flat face to motor side.
Motor
3
Match the flat face to motor side.
Fig. 4.9 (b) Replacing the drive shaft (2/2) (Figure is example of J4-axis)
Parts name
3
BOLT
Specifications
A6-BA-3X10
- 37 -
Q’ty
Locking
Torque (N-m)
4
LT243
1.3
4.COMPONENT REPLACEMENT
4.10
1
2
3
4
5
B-83085EN/03
REPLACING THE WRIST UNIT
Turn off the controller power.
Remove set screw referring to Section 4.9 and divide drive shaft and wrist.
Remove LINK B referring to Section 4.7. When removing first LINK, loosen screw of upper side
and lower side equally.
Replace wrist unit to new one and assemble it applying the procedure in the reversed sequence.
Pay attention to the phase referring to Fig.4.10.
In case of M-1iA/0.5S,0.5A,0.5SL,0.5AL, perform single axis mastering for J4 to J6-axis referring
to Section 7.5 of the Operator’s Manual.
Assemble the wrist unit so that
this face comes to front of the
robot.
(M-1iA/0.5A,0.5AL)
Assemble the wrist unit so that
this face comes to front of the
robot.
(M-1iA/0.5S,0.5SL)
Assemble the wrist unit so that
this face comes to front of the
robot.
(M-1iA/1H,1HL)
Fig.4.10 Replacing the wrist unit
4.11
SIMPLE METHOD OF MASTERING
If you use method below, you can mastering the robot easily with good precision.
1
2
3
4
Remove cover (1), (3) of Fig.4.3 (a),(b) referring to Section 4.3.
Move the axis which you want to perform calibration by axial feed so that clearance between
reducer mounting face and upper of arm is 38.5mm referring to Fig.4.11 (a) to (c).
Perform single axis mastering with angle below.
J1-axis : +50º
J2-axis : 0º
J3-axis : 0º
Perform zero degree mastering for wrist axis referring to Section 7.3 of the Operator’s Manual.
- 38 -
4.COMPONENT REPLACEMENT
B-83085EN/03
38.5mm
Fig.4.11 (a) In case of J1-axis
38.5mm
Fig.4.11 (b) In case of J2-axis
38.5mm
Fig.4.11 (c) In case of J3-axis
- 39 -
5.REPLACING CABLES
5
B-83085EN/03
REPLACING CABLES
When the cable is broken or damaged or shows signs of wear, replace it according to this chapter.
Precautions to be observed when handling the Pulsecoder cable
The Pulsecoder cable is provided with a marking tie, as shown below, to warn against disconnecting the
cable during transportation, installation, or maintenance.
If the cable with the marking tie is disconnected, mastering must be performed again. Therefore, do not
disconnect the cable except when replacement of the motor, the Pulsecoder, the reducer, and the cable are
necessary.
BATTERY BACKUP
DON'T
DISCONNECT
コネクタ取外不可
Fig. 5 marking label
If there is a break in or any other damage to a cable, replace the cable according to the procedure
described in this chapter. If the connector of a motor cable is detached, the data about the absolute
position of the robot is lost. Once any of these cables is replaced, perform quick mastering while
referencing Chapter 7 of the Operator’s Manual. If the data is lost because of a break in a cable, also
perform mastering to calibrate the robot into the previous absolute position.
- 40 -
5.REPLACING CABLES
B-83085EN/03
5.1
CABLE FORMING
Fig.5.1 (a) to (i) show cable forming.
Adjust the marking.
J1-axis motor
DETAIL A
Cable K101
Nylon band
J2-axis motor
Washer bolt
A97L-0218-0606#M4X6(2)
EE1
YV1
A
J3-axis motor
J4-axis motor
Mount base
A98L-0001-0573#MB3A
Washer bolt
A97L-0218-0606#M4X6(1)
Fig.5.1 (a) Cable forming (M-1iA/0.5S,0.5SL with stand)
Adjust the marking.
J1-axis motor
Cable K101
DETAIL A
J6-axis motor
J2-axis motor
Nylon band
Washer bolt
A97L-0218-0606#M4X6(2)
EE1
YV1
A
Mount base
A98L-0001-0573#MB3A
J4-axis motor
Washer bolt
A97L-0218-0606#M4X6(1)
J5-axis motor
J3-axis motor
Fig.5.1 (b) Cable forming (M-1iA/0.5A,0.5AL with stand)
- 41 -
5.REPLACING CABLES
B-83085EN/03
J1-axis motor
Cable K101
J2-axis motor
Washer bolt
A97L-0218-0606#M4X6(2)
EE1
YV1
J3-axis motor
Mount base
A98L-0001-0573#MB3A
Washer bolt
A97L-0218-0606#M4X6(1)
Fig.5.1 (c) Cable forming (M-1iA/1H,1HL with stand)
Nylon band
Nylon band
SECTION C-C
DETAIL B
Adjust the marking.
J1-axis motor
Cable K101
Cable K102
EE1
A
NOTE)
Nylon band goes through
the hole of ferrite core.
Cable K102
YV1
J2-axis motor
Nylon band
Washer bolt
A97L-0218-0606#M4X6(2)
B
C
C
D
D
SECTION D-D
SECTION A-A
Bolt
A6-BA-3X4 (2)
Clamp
A290-7522-X230 (1)
Ferrite core
A45L-0001-0029 (1)
Bolt
A6-BA-4X6 (2)
J3-axis motor
J4-axis motor
A
Washer bolt
A97L-0218-0606#M4X6(1)
Mount base
A98L-0001-0573#MB3A
Fig.5.1 (d) Cable forming (M-1iA/0.5S,0.5SL with stand for iRVision)
- 42 -
5.REPLACING CABLES
B-83085EN/03
Nylon band
Nylon band
SECTION C-C
DETAIL B
Adjust the marking.
J1-axis motor
Cable K101
EE1
Cable K102
A
J6-axis motor
Cable K102
YV1
J2-axis motor
NOTE)
Nylon band goes through
the hole of ferrite core.
Washer bolt
A97L-0218-0606#M4X6(2)
B
Nylon band
C
C
D
D
SECTION D-D
Bolt
A6-BA-3X4(2)
SECTION A-A
Clamp
A290-7522-X230(1)
Ferrite core
A45L-0001-0329(1)
Bolt
A6-BA-4X5(2)
J4-axis motor
A
Mount base
A98L-0001-0573#MB3A
Washer bolt
A97L-0218-0606#M4X6(1)
J3-axis motor
J5-axis motor
Fig.5.1 (e) Cable forming (M-1iA/0.5A,0.5AL with stand for iRVision)
Nylon band
Nylon band
SECTION C-C
DETAIL B
Adjust the marking
J1-axis motor
Cable K101
Cable K102
EE1
A
J2-axis motor
Cable K102
YV1
Washer bolt
A97L-0218-0606#M4X6(2)
NOTE)
Nylon band goes through
the hole of ferrite core
B
Nylon band
C
D
D
C
SECTION D-D
Bolt
A6-BA-3X4 (2)
SECTION A-A
Clamp
A290-7522-X230 (1)
Ferrite core
A45L-0001-0029 (1)
Bolt
A6-BA-4X6 (2)
J3-axis motor
A
Washer bolt
A97L-0218-0606#M4X6(1)
Mount base
A98L-0001-0573#MB3A
Fig.5.1 (f) Cable forming (M-1iA/1H,1HL with stand for iRVision)
- 43 -
5.REPLACING CABLES
B-83085EN/03
Adjust the marking.
Bolt
A6-BA-3X6(4)
Cable K101
A
A
Tie up with nylon band.
Cable K131
Nylon band
Battery box terminal side
DETAIL D
DETAIL C
J1-axis motor
J2-axis motor
EE1
YV1
C
Nylon band
Nylon band
D
Cable K103
Cable K131
E
Battery box
A97L-0004-0149(1)
Battery
A98L-0031-0005(4)
Cable K101
Cable K101
Adjust the marking.
DETAIL E
J4-axis motor
Cable cover A290-7522-X228 (1)
Face up the aluminium coated surface.
Mount base
A98L-0001-0573#MB3A (1)
J3-axis motor
SECTION A-A
B
Cable K103
Bolt
A97L-0218-0606#M4X6(2)
Bolt
A97L-0218-0606#M4X6(1)
DETAIL B
Fig.5.1 (g) Cable forming (M-1iA/0.5S,0.5SL no stand A)
Adjust the marking.
Cable K101
Bolt
A6-BA-3X6(4)
A
A
Nylon band
J6-axis motor
DETAIL C
DETAIL D
Tie up with nylon band.
Cable K131
Battery box terminal side
J1-axis motor
J2-axis motor
EE1
YV1
Tie up with nylon band.
C
Nylon band
Cable K103
D
Cable K131
E
Battery box
A97L-0004-0149(1)
Battery
A98L-0031-0005(4)
Cable K101
Cable K101
Adjust the marking.
DETAIL E
J4-axis motor
Mount base
A98L-0001-0573#MB3A (1)
Cable cover
A290-7522-X228(1)
Face up the aluminium coated surface.
J5-axis motor
J3-axis motor
SECTION A-A B
Bolt
A97L-0218-0606#M4X6(2)
BOLT
A97L-0218-0606#M4X6(1)
Cable K103
DETAIL B
Fig.5.1 (h) Cable forming (M-1iA/0.5A,0.5AL no stand A)
- 44 -
5.REPLACING CABLES
B-83085EN/03
Bolt
A6-BA-3X6(4)
Cable K101
A
A
Tie up with nylon bands.
Cable K131
Battery box terminal side
DETAIL D
J1-axis motor
EE1
J2-axis motor
YV1
Nylon band
Nylon band
Cable K103
D
Cable K131
E
Battery box
A97L-0004-0149(1)
Battery
A98L-0031-0005(4)
Cable K101
Cable K101
Adjust the marking
DETAIL E
Cable cover A290-7522-X228 (1)
Face up the aluminum coated surface.
Mount base
A98L-0001-0573#MB3A (1)
J3-axis motor
SECTION A-A
B
Cable K103
Bolt
A97L-0218-0606#M4X6(2)
Bolt
A97L-0218-0606#M4X6(1)
DETAIL B
Fig.5.1 (i) Cable forming (M-1iA/1H,1HL no stand A)
Adjust the marking.
J1-axis motor
EE1
Cable K101
YV1
J2-axis motor
Washer bolt
A97L-0218-0606#M4X6(2)
Nylon band
A
DETAIL A
Washer bolt
A97L-0218-0606#M4X6TC(1)
Nylon band
J4-axis motor
J3-axis motor
Mount base
A98L-0001-0573#MB3A(1)
Fig.5.1 (j) Cable forming (M-1iA/0.5S,0.5SL no stand B)
- 45 -
5.REPLACING CABLES
B-83085EN/03
Adjust the marking.
J1-axis motor
J6-axis motor
Nylon band
EE1
Cable K101
YV1
J2-axis motor
Washer bolt
A97L-0218-0606#M4X6(2)
DETAIL A
A
Nylon band
J4-axis motor
J5-axis motor
J3-axis motor
Washer bolt
A97L-0218-0606#M4X6TC(1)
Mount base
A98L-0001-0573#MB3A(1)
Fig.5.1 (k) Cable forming (M-1iA/0.5A,0.5AL no stand B)
J1-axis motor
EE1
Cable K101
YV1
J2-axis motor
Washer bolt
A97L-0218-0606#M4X6(2)
Washer bolt
A97L-0218-0606#M4X6TC(1)
J3-axis motor
Nylon band
Mount base
A98L-0001-0573#MB3A(1)
Fig.5.1 (l) Cable forming (M-1iA/1H,1HL no stand B)
- 46 -
5.REPLACING CABLES
B-83085EN/03
Adjust the marking.
Nylon band
NOTE)
Nylon band goes through
the hole of ferrite core.
Nylon band
J1-axis motor
Cable K101
Cable K102
Nylon band
EE1
YV1
C
J2-axis motor
Washer bolt
A97L-0218-0606#M4X6(2)
DETAIL A
SECTION D-D
A
Cable K102
Nylon band
D
D
Clamp
A290-7522-X230(1)
Ferrite core
A45L-0001-0329(1)
Bolt
A6-BA-4X5(2)
Bolt
A6-BA-3X4(2)
Washer bolt
A97L-0218-0606#M4X6TC(1)
Nylon band
SECTION C-C
C
J4-axis motor
J3-axis motor
Nylon band
Mount base
A98L-0001-0573#MB3A(1)
Fig.5.1 (m) Cable forming (M-1iA/0.5S,0.5SL no stand B for iRVision)
Adjust the marking.
Nylon band
NOTE)
Nylon band goes through
the hole of ferrite core.
Nylon band
Cable K101
J1-axis motor
EE1
J6-axis motor
YV1
Cable K102
C
J2-axis motor
Washer bolt
A97L-0218-0606#M4X6(2)
DETAIL A
SECTION D-D
A
Cable K102
Nylon band
D
D
Clamp
A290-7522-X230(1)
Ferrite core
A45L-0001-0329(1)
Bolt
A6-BA-4X5(2)
SECTION C-C
Bolt
A6-BA-3X4(2)
Nylon band
C
J4-axis motor
J3-axis motor
J5-axis motor
Nylon band
Washer bolt
A97L-0218-0606#M4X6TC(1)
Mount base
A98L-0001-0573#MB3A(1)
Fig.5.1 (n) Cable forming (M-1iA/0.5A,0.5AL no stand B for iRVision)
- 47 -
5.REPLACING CABLES
B-83085EN/03
Adjust the marking
Nylon band
NOTE)
Nylon band goes throught
the hole of ferrite core
Nylon band
J1-axis motor
Cable K101
Nylon band
Cable K102
EE1
YV1
C
J2-axis motor
DETAIL A
SECTION D-D
Cable K102
Washer bolt
A97L-0218-0606#M4X6(2)
A
D
D
Clamp
A290-7522-X230(1)
Ferrite core
A45L-0001-0329(1)
Bolt
A6-BA-4X5(2)
Washer bolt
A97L-0218-0606#M4X6TC(1)
Bolt
A6-BA-3X4(2)
SECTION C-C
Nylon band
C
J3-axis motor
Nylon band
Mount base
A98L-0001-0573#MB3A(1)
Fig.5.1 (o) Cable forming (M-1iA/1H,1HL no stand B for iRVision)
5.2
CABLE REPLACEMENT
With stand or no stand B
1
2
3
4
5
6
7
8
9
10
Record the Quick Master Reference Position referring to Section 7.4 of the Operator’s Manual. (It is
set to 0° for all axes when robot is shipped.)
Turn off the controller power.
Remove the cover referring to Section 4.3.
Remove connector panel from stand and remove terminal of back of battery box and earth terminal
inside stand referring to Fig.5.2.
Remove connector of each axis motor, EE1 connector and YV1 connector referring to Section 5.1.
Cut nylon band which fix cable to mount base and near J2-axis motor.
Remove cable which connector panel is attached from robot.
Remove cable and air tube from connector plate. When removing Harting connector, keep housing
attached to connector plate and remove insert to inside.
Replace old cable by new one. For its assembly, please apply the steps above in reversed sequence.
Tighten terminal of back battery box with regulated torque.
Perform quick mastering referring to Section 7.4 of the Operator’s Manual.
No stand A
1
2
3
4
5
6
7
8
9
10
11
12
13
Record the Quick Master Reference Position referring to Section 7.4 of the Operator’s Manual. (It is
set to 0° for all axes when robot is shipped.)
Turn off the controller power.
Remove the cover referring to Section 4.3.
Remove cable K101 and K103 referring to detail D of Fig.5.1 (e), (f).
Remove earth terminal referring to detail B of Fig.5.1 (e), (f).
Remove connector of each axis motor, EE1 connector and YV1 connector.
Cut nylon band of detail E referring to Fig.5.1 (e), (f).
Cut nylon band which fix cable to mount base and near J2-axis motor.
Remove terminal of back of battery box.
Remove cable cover.
Pull out cable kit from robot.
Replace old cable by new one. For its assembly, please apply the steps above in reversed sequence.
Tighten terminal of back battery box with regulated torque.
Perform quick mastering referring to Section 7.4 of the Operator’s Manual.
- 48 -
5.REPLACING CABLES
B-83085EN/03
Tightening torque
0.40N・m(4.1kgfcm)
Tie up with nylon band.
-
-
+
+
Terminal side of battery box
Connector panel
Insert
Cable
Fig.5.2 Replacing cables (Figure is example of with stand)
- 49 -
APPENDIX
APPENDIX
B-83085EN/03
A
A.SPARE PARTS LIST
SPARE PARTS LIST
Table A (a)
Cable No.
Specifications
Cables
Function
K101
A660-8017-T192
J1 to J4-axis motor+EE
K101
A660-8017-T193
J1 to J6-axis motor+EE
K101
A660-8018-T695
J1 to J3-axis motor+EE
K101
K101
K101
K101
K101
K101
K102
A660-8017-T241
A660-8017-T242
A660-8018-T696
A660-8018-T003
A660-8018-T004
A660-8018-T697
A05B-1522-D003
J1 to J4-axis motor+EE
J1 to J6-axis motor+EE
J1 to J3-axis motor+EE
J1 to J4-axis motor+EE
J1 to J6-axis motor+EE
J1 to J3-axis motor+EE
Camera
K102
K103
A05B-1522-D004
A660-8017-T229
Camera
Earth
Table A (b)
Axis
J1, J2, J3
J1, J2, J3, J5, J6
J4
Specifications
A06B-0117-B855#0049
A06B-0117-B855#0049
A06B-0114-B855#0048
Motor
Remarks
βiSR0.2/6000 (3pcs/per 1 robot)
βiSR0.2/6000 (5pcs/per 1 robot)
βiSR0.4/6000
Model
M-1iA/0.5S,0.5SL
Floor mount stand
Upside-down stand
M-1iA/0.5A,0.5AL
Floor mount stand
Upside-down stand
M-1iA/1H,1HL
Floor mount stand
Upside-down stand
M-1iA/0.5S,0.5SL no stand A
M-1iA/0.5A,0.5AL no stand A
M-1iA/1H,1HL no stand A
M-1iA/0.5S,0.5SL no stand B
M-1iA/0.5A,0.5AL no stand B
M-1iA/1H,1HL no stand B
Floor mount stand
Upside-down stand
No stand B
No stand A
Table A (c)
Parts name
J1, J2, J3-axis
reducer
Specifications
A97L-0218-0872#45
Model
M-1iA/0.5S,0.5SL,1H,1HL
M-1iA/0.5A,0.5AL
M-1iA/0.5S,0.5SL,0.5A,0.5AL
Reducer
Remarks
HPG reducer (3pcs/per 1 robot)
Model
All models
Table A (d) Gear
Parts name
Specifications
Gear J4-1
A290-7522-X401
Gear J5-1
Gear J56-1
A290-7522-X421
A290-7521-X422
A290-7522-X402
GearJ456-2
A290-7522-X403
Gear J6-2
A290-7522-X423
Location
J4-axis motor (M-1iA/0.5S,0.5A)
J6-axis motor (M-1iA/0.5AL)
J4-axis motor (M-1iA/0.5SL,0.5AL)
J5-axis motor (M-1iA/0.5AL)
M-1iA/0.5A J5, J6-axis motor (2 pcs/per 1 robot)
M-1iA/0.5AL J6-axis motor (1 pc/per 1 robot)
M-1iA/0.5S,0.5SL J4 drive shaft (1 pc/per 1 robot)
M-1iA/0.5A J4/J5/J6 drive shaft (3 pcs/per 1 robot)
M-1iA/0.5AL J4/J5 drive shaft (2 pcs/per 1 robot)
M-1iA/0.5AL J6 drive shaft (1 pc/per 1 robot)
- 53 -
A.SPARE PARTS LIST
Parts name
Joint
J1 arm assembly
J2 arm assembly
J3 arm assembly
J1 arm assembly
J2 arm assembly
J3 arm assembly
LINK B assembly
LINK B assembly
Drive shaft
assembly
Wrist unit
Bolt
Shaft
Washer
Key
Key
APPENDIX
B-83085EN/03
Table A (e) Others (Mechanical unit)
Specifications
Location, model
(M-1iA/0.5S,0.5A,1H) (12 pcs/per 1 robot)
A290-7522-X303
(M-1iA/0.5SL,0.5AL,1HL) (12 pcs/per 1 robot)
A290-7522-X309
J1 (M-1iA/0.5S,0.5A,1H)
A290-7522-V202
J2 (M-1iA/0.5S,0.5A,1H)
A290-7522-V203
J3 (M-1iA/0.5S,0.5A,1H)
A290-7522-V204
J1 (M-1iA/0.5SL,0.5AL,1HL)
A290-7522-V206
J2 (M-1iA/0.5SL,0.5AL,1HL)
A290-7522-V207
J3 (M-1iA/0.5SL,0.5AL,1HL)
A290-7522-V208
J1～J3 (M-1iA/0.5S,0.5A,1H)
A290-7522-V301
(6 pcs/per 1 robot)
J1～J3 (M-1iA/0.5SL,0.5AL,1HL)
A290-7522-V302
(6 pcs/per 1 robot)
M-1iA/0.5S J4 (1 pc/per 1 robot)
A290-7522-V403
M-1iA/0.5A J4, J5, J6 (3 pcs/per 1 robot)
M-1iA/0.5SL J4 (1 pc/per 1 robot)
A290-7522-V406
M-1iA/0.5AL J4, J5, J6 (3 pcs/per 1 robot)
M-1iA/0.5S,0.5SL
A290-7522-T501
M-1iA/0.5A,0.5AL
A290-7522-T502
M-1iA/1H,1HL
A290-7522-X568
A6-BA-2X4
(24 pcs/per 1 robot)
A290-7522-X304
(12 pcs/per 1 robot)
A290-7522-X305
(24 pcs/per 1 robot)
A97L-0118-0402#3X3X M-1iA/0.5S,0.5SL J4 (1 pc/per 1 robot)
M-1iA/0.5A,0.5AL J4 (1 pc/per 1 robot)
12BN
A97L-0118-0402#3X3X M-1iA/0.5A,0.5AL J5, J6 (2 pcs/per 1 robot)
6BN
Table A (f) Battery・grease
Parts name
Battery
Specifications
A98L-0031-0027
Model
All models
A98L-0031-0005
Grease
A98L-0040-0252#0.4KG
All models
- 54 -
Remarks
D battery (alkali) 1.5V (4pcs /per 1 robot)
(With stand , No stand B)
C battery (alkali) 1.5V (4pcs /per 1 robot)
(No stand A)
For the wrist gears and the drive shafts
NIPPON OIL TOUGHLIX GREASE RB2
(old name: LCG335)
B
CIRCUIT DIAGRAM
A63L-0001-0865#1
A63L-0001-0864#CS
J1 MOTOR (βiSR0.2/6000)
M1M
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
J1V1
J1W1
2
3
BK(J1)
M1P
8
9 5V(A1)
10 0V(A1)
A63L-0001-0865#1
A63L-0001-0864#CS
2
3
J2V1
J2W1
BK(J2)
M2P
8
9 5V(B1)
10 0V(B1)
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
24V(OT,A12) 31
RI2
32
RO2
33
5V(B12) 34
PRQJ2 35
XPRQJ2 36
BK(J2)
BKC(J2)
J2U1
J2V1
J2W1
J2G1
BK(J3)
BKC(J3)
J3U1
J3V1
J3W1
J3G1
XHBK
RI3
RO3
5V(C123)
PRQJ3
XPRQJ3
G
49
50
51
52
53
54
55
56
57
58
59
60
Han 72DD
(2.5SQ 10A)
61
62
63
64
65
66
0V(D12) 67 0V(E123456)
RI5
68 RI6
RO5
69 RO6
0V(B12) 70 0V(C123)
71
72
4 6V(BT1)
1
5 XPRQJ1
2
6 PRQJ1
3
7 0V(BT1)
J4U1
J4G1
1
4
BKC(J4)
M4BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
1
4
BK(J4)
M4P
8
9 5V(C1)
10 0V(C1)
4 6V(BT4)
1
5 XPRQJ4
2
6 PRQJ4
3
7 0V(BT4)
1
4
J2U1
J2G1
1
4
BKC(J2)
4 6V(BT2)
1
5 XPRQJ2
2
6 PRQJ2
3
7 0V(BT2)
M3M
A63L-0001-0865#2
A63L-0001-0864#CS
37 BK(J4)
38 BKC(J4)
39 J4U1
40 J4V1
41 J4W1
42 J4G1
43 24V(B1)
44 RI4
45 RO4
46 0V(A1)
47 PRQJ4
48 XPRQJ4
FG
BKC(J1)
J4V1
J4W1
J3 MOTOR (βiSR0.2/6000)
2
3
BK(J1)
BKC(J1)
J1U1
J1V1
J1W1
J1G1
XROT
RI1
RO1
5V(A1)
PRQJ1
XPRQJ1
1
4
M4M
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
M2BK
A63L-0001-0848#E10SL1
A63L-0001-0850
RMP
J1U1
J1G1
J4 MOTOR (βiSR0.4/6000)
M2M
2
3
CONNECTOR PANEL
A63L-0001-0865#1
A63L-0001-0864#CS
J2 MOTOR (βiSR0.2/6000)
A63L-0001-0865#2
A63L-0001-0864#CS
A63L-0001-0865#1
A63L-0001-0864#CS
1
4
M1BK
A63L-0001-0848#E10SL1
A63L-0001-0850
1
2
3
4
5
6
7
8
9
10
11
12
B.CIRCUIT DIAGRAM
APPENDIX
B-83085EN/03
J3V1
J3W1
1
4
J3U1
J3G1
1
4
BKC(J3)
M3BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
BK(J3)
M3P
K101
A660-8017-T192
8
9 5V(B2)
10 0V(B2)
4 6V(BT3)
1
5 XPRQJ3
2
6 PRQJ3
3
7 0V(BT3)
BATTERY
6V
(BT1,BT2,BT3,
BT4,BT5,BT6)
+
EE1
( 単二電池
SIZE C )
0V
(BT1,BT2,BT3,
BT4,BT5,BT6)
-
A1
A2
A3
A4
A5
A6
RI1
RI2
RI3
RI4
RI5
RI6
B1
B2
B3
B4
B5
B6
P12DX
CTM
XHBK
24V(A1)
24V(A2)
24V(B1)
0V(D1)
0V(D2)
B1
B2
B3
B4
P08DX
CTM
0V(E456)
RO2
RO4
RO6
YV1
A1
A2
A3
A4
0V(E123)
RO1
RO3
RO5
DUMMY CONNECTOR
A63L-0002-0066#R12DX
DUMMY CONNECTOR
A63L-0002-0066#R08DX
M-1iA/0.5S (Desktop, Ceiling mount)
Fig. B (a) Circuit diagram (M-1iA/0.5S,0.5SL with stand , no stand B)
- 55 -
B.CIRCUIT DIAGRAM
APPENDIX
B-83085EN/03
J1 MOTOR (βiSR0.2/6000)
A63L-0001-0865#1
A63L-0001-0864#CS
M1M
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
J1V1
J1W1
2
3
BK(J1)
M1P
8
9 5V(A1)
10 0V(A1)
2
3
2
3
J2V1
J2W1
BK(J2)
M2P
8
9 5V(B1)
10 0V(B1)
A63L-0001-0865#2
A63L-0001-0864#CS
25
26
27
28
29
30
24V(OT,A12) 31
RI2
32
RO2
33
5V(B12) 34
PRQJ2 35
XPRQJ2 36
BK(J2)
BKC(J2)
J2U1
J2V1
J2W1
J2G1
BK(J3)
BKC(J3)
J3U1
J3V1
J3W1
J3G1
XHBK
RI3
RO3
5V(C123)
PRQJ3
XPRQJ3
G
37
38
39
40
41
42
43
44
45
46
47
48
FG
BK(J4)
BKC(J4)
J4U1
J4V1
J4W1
J4G1
24V(B1)
RI4
RO4
0V(A1)
PRQJ4
XPRQJ4
Han 72DD
(2.5SQ 10A)
49
61
50
62
51
63
52
64
53
65
54
66
55 0V(D12) 67 0V(E123456)
56 RI5
68 RI6
57 RO5
69 RO6
58 0V(B12) 70 0V(C123)
59
71
60
72
J2U1
J2G1
1
4
BKC(J2)
4 6V(BT2)
1
5 XPRQJ2
2
6 PRQJ2
3
7 0V(BT2)
M3M
2
3
13
14
15
16
17
18
19
20
21
22
23
24
1
4
J3 MOTOR (βiSR0.2/6000)
A63L-0001-0865#1
A63L-0001-0864#CS
BK(J1)
BKC(J1)
J1U1
J1V1
J1W1
J1G1
XROT
RI1
RO1
5V(A1)
PRQJ1
XPRQJ1
4 6V(BT1)
1
5 XPRQJ1
2
6 PRQJ1
3
7 0V(BT1)
J3V1
J3W1
1
4
J3U1
J3G1
1
4
BKC(J3)
M3BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
K101
A660-8017-T241
BK(J3)
M3P
8
9 5V(B2)
10 0V(B2)
4 6V(BT3)
1
5 XPRQJ3
2
6 PRQJ3
3
7 0V(BT3)
BATTERY
6V
(BT1,BT2,BT3,BT4)
+
K131
A660-8016-T498
( 単一電池
SIZE D )
0V
(BT1,BT2,BT3,BT4)
GB2
6V(BT1,BT2,BT3,
BT4)
B 0V(BT1,BT2,BT3,
BT4)
GB2
6V(BT1,BT2,BT3,
BT4)
B 0V(BT1,BT2,BT3,
BT4)
A
A
C
C
A63L-0001-0648#610SL3SJ
A63L-0001-0648#210SL3PJ
EE1
A1
A2
A3
A4
A5
A6
RI1
RI2
RI3
RI4
RI5
RI6
B1
B2
B3
B4
B5
B6
P12DX
CTM
XHBK
24V(A1)
24V(A2)
24V(B1)
0V(D1)
0V(D2)
DUMMY CONNECTOR
A63L-0002-0066#R12DX
Fig. B (b) Circuit diagram (M-1iA/0.5S,0.5SL No stand A)
- 56 -
M4M
J4V1
J4W1
1
4
J4U1
J4G1
1
4
BKC(J4)
M4BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
M2BK
A63L-0001-0848#E10SL1
A63L-0001-0850
1
2
3
4
5
6
7
8
9
10
11
12
BKC(J1)
M2M
A63L-0001-0865#2
A63L-0001-0864#CS
RMP
1
4
J4 MOTOR (βiSR0.4/600
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
J2 MOTOR (βiSR0.2/6000)
A63L-0001-0865#1
A63L-0001-0864#CS
A63L-0001-0865#1
A63L-0001-0864#CS
J1U1
J1G1
M1BK
A63L-0001-0848#E10SL1
A63L-0001-0850
CONNECTOR
1
4
BK(J4)
M4P
8
9 5V(C1)
10 0V(C1)
4 6V(BT4)
1
5 XPRQJ4
2
6 PRQJ4
3
7 0V(BT4)
B.CIRCUIT DIAGRAM
APPENDIX
B-83085EN/03
A63L-0001-0865#1
A63L-0001-0864#CS
J1 MOTOR (βiSR0.2/6000)
M1M
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
BK(J1)
M1P
8
9 5V(A1)
10 0V(A1)
A63L-0001-0865#1
A63L-0001-0864#CS
J2V1
J2W1
BK(J2)
M2P
CONNECTOR PANEL
RMP
1
2
3
4
5
6
7
8
9
10
11
12
BK(J1)
BKC(J1)
J1U1
J1V1
J1W1
J1G1
XROT
RI1
RO1
5V(A1)
PRQJ1
XPRQJ1
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
24V(OT,A12) 31
RI2
32
RO2
33
5V(B12) 34
PRQJ2
35
XPRQJ2
36
BK(J2)
BKC(J2)
J2U1
J2V1
J2W1
J2G1
BK(J3)
BKC(J3)
J3U1
J3V1
J3W1
J3G1
XHBK
RI3
RO3
5V(C123)
PRQJ3
XPRQJ3
G
37
38
39
40
41
42
43
44
45
46
47
48
FG
BK(J4)
BKC(J4)
J4U1
J4V1
J4W1
J4G1
24V(B1)
RI4
RO4
0V(A1)
PRQJ4
XPRQJ4
49
50
51
52
53
54
55
56
57
58
59
60
BK(J5)
BKC(J5)
J5U1
J5V1
J5W1
J5G1
0V(D12)
RI5
RO5
0V(B12)
PRQJ5
XPRQJ5
Han 72DD
(2.5SQ 10A)
61 BK(J6)
62 BKC(J6)
63 J6U1
64 J6V1
65 J6W1
66 J6G1
67 0V(E123456)
68 RI6
69 RO6
70 0V(C123)
71 PRQJ6
72 XPRQJ6
K101
A660-8017-T193
J3V1
J3W1
BKC(J2)
4 6V(BT2)
1
5 XPRQJ2
2
6 PRQJ2
3
7 0V(BT2)
1
4
M3P
8
9 5V(B2)
10 0V(B2)
A63L-0001-0865#1
A63L-0001-0864#CS
J3U1
J3G1
4 6V(BT3)
1
5 XPRQJ3
2
6 PRQJ3
3
7 0V(BT3)
BATTERY
6V
(BT1,BT2,BT3,
BT4,BT5,BT6)
+
EE1
( 単二電池
SIZE C )
0V
(BT1,BT2,BT3,
BT4,BT5,BT6)
-
A1
A2
A3
A4
A5
A6
RI1
RI2
RI3
RI4
RI5
RI6
B1
B2
B3
B4
B5
B6
P12DX
CTM
XHBK
24V(A1)
24V(A2)
24V(B1)
0V(D1)
0V(D2)
DUMMY CONNECTOR
A63L-0002-0066#R12DX
Fig. B (c) Circuit diagram (M-1iA/0.5A,0.5AL with stand , no stand B )
- 57 -
BKC(J4)
4 6V(BT4)
1
5 XPRQJ4
2
6 PRQJ4
3
7 0V(BT4)
J5V1
J5W1
1
4
J5U1
J5G1
1
4
BKC(J5)
M5BK
BK(J5)
M5P
4 6V(BT5)
1
5 XPRQJ5
2
6 PRQJ5
3
7 0V(BT5)
J6 MOTOR (βiSR0.2/6000)
M6M
J6V1
J6W1
1
4
J6U1
J6G1
1
4
BKC(J6)
M6BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
1
4
M5M
2
3
BKC(J3)
J4U1
J4G1
J5 MOTOR (βiSR0.2/6000)
8
9 5V(C2)
10 0V(C2)
A63L-0001-0865#2
A63L-0001-0864#CS
1
4
BK(J4)
M4P
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
1
4
M4BK
2
3
M3BK
BK(J3)
A63L-0001-0865#1
A63L-0001-0864#CS
A63L-0001-0865#2
A63L-0001-0864#CS
1
4
J4V1
J4W1
8
9 5V(C1)
10 0V(C1)
J2U1
J2G1
M3M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
4 6V(BT1)
1
5 XPRQJ1
2
6 PRQJ1
3
7 0V(BT1)
1
4
M4M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
J3 MOTOR (βiSR0.2/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
BKC(J1)
M2BK
8
9 5V(B1)
10 0V(B1)
A63L-0001-0865#1
A63L-0001-0864#CS
1
4
J4 MOTOR (βiSR0.4/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
M2M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
J1U1
J1G1
J2 MOTOR (βiSR0.2/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
1
4
M1BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
J1V1
J1W1
A63L-0001-0865#1
A63L-0001-0864#CS
BK(J6)
M6P
8
9 5V(C3)
10 0V(C3)
4 6V(BT6)
1
5 XPRQJ6
2
6 PRQJ6
3
7 0V(BT6)
B.CIRCUIT DIAGRAM
APPENDIX
B-83085EN/03
J1 MOTOR (βiSR0.2/6000)
A63L-0001-0865#1
A63L-0001-0864#CS
M1M
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
J1V1
J1W1
2
3
BK(J1)
M1P
8
9 5V(A1)
10 0V(A1)
A63L-0001-0865#2
A63L-0001-0864#CS
J2V1
J2W1
2
3
BK(J2)
M2P
8
9 5V(B1)
10 0V(B1)
A63L-0001-0865#2
A63L-0001-0864#CS
25
26
27
28
29
30
24V(OT,A12) 31
RI2
32
RO2
33
5V(B12) 34
PRQJ2 35
XPRQJ2 36
BK(J2)
BKC(J2)
J2U1
J2V1
J2W1
J2G1
BK(J3)
BKC(J3)
J3U1
J3V1
J3W1
J3G1
XHBK
RI3
RO3
5V(C123)
PRQJ3
XPRQJ3
G
37
38
39
40
41
42
43
44
45
46
47
48
FG
BK(J4)
BKC(J4)
J4U1
J4V1
J4W1
J4G1
24V(B1)
RI4
RO4
0V(A1)
PRQJ4
XPRQJ4
49
50
51
52
53
54
55
56
57
58
59
60
BK(J5)
BKC(J5)
J5U1
J5V1
J5W1
J5G1
0V(D12)
RI5
RO5
0V(B12)
PRQJ5
XPRQJ5
Han 72DD
(2.5SQ 10A)
61 BK(J6)
62 BKC(J6)
63 J6U1
64 J6V1
65 J6W1
66 J6G1
67 0V(E123456)
68 RI6
69 RO6
70 0V(C123)
71 PRQJ6
72 XPRQJ6
J3V1
J3W1
4 6V(BT2)
1
5 XPRQJ2
2
6 PRQJ2
3
7 0V(BT2)
1
4
2
3
K101
A660-8017-T242
BK(J3)
M3P
8
9 5V(B2)
10 0V(B2)
1
4
BKC(J3)
4 6V(BT3)
1
5 XPRQJ3
2
6 PRQJ3
3
7 0V(BT3)
+
K131
A660-8016-T498
( 単一電池
SIZE D )
0V
(BT1,BT2,BT3,
BT4,BT5,BT6)
-
GB2
6V(BT1,BT2,BT3,
BT4,BT5,BT6)
B 0V(BT1,BT2,BT3,
BT4,BT5,BT6)
A
C
A63L-0001-0648#610SL3SJ
GB2
6V(BT1,BT2,BT3,
BT4,BT5,BT6)
B 0V(BT1,BT2,BT3,
BT4,BT5,BT6)
A
EE1
A1
A2
A3
A4
A5
A6
C
A63L-0001-0648#210SL3PJ
RI1
RI2
RI3
RI4
RI5
RI6
B1
B2
B3
B4
B5
B6
P12DX
CTM
XHBK
24V(A1)
24V(A2)
24V(B1)
0V(D1)
0V(D2)
DUMMY CONNECTOR
A63L-0002-0066#R12DX
Fig. B (d) Circuit diagram (M-1iA/0.5A,0.5AL No stand A)
- 58 -
BKC(J4)
4 6V(BT4)
1
5 XPRQJ4
2
6 PRQJ4
3
7 0V(BT4)
J5V1
J5W1
1
4
J5U1
J5G1
1
4
BKC(J5)
M5BK
BK(J5)
M5P
4 6V(BT5)
1
5 XPRQJ5
2
6 PRQJ5
3
7 0V(BT5)
J6 MOTOR (βiSR0.2/6000)
M6M
J6V1
J6W1
1
4
J6U1
J6G1
1
4
BKC(J6)
M6BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
1
4
M5M
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
BATTERY
6V
(BT1,BT2,BT3,
BT4,BT5,BT6)
A63L-0001-0865#1
A63L-0001-0864#CS
J4U1
J4G1
J5 MOTOR (βiSR0.2/6000)
8
9 5V(C2)
10 0V(C2)
J3U1
J3G1
M3BK
A63L-0001-0848#E10SL1
A63L-0001-0850
BK(J4)
M4P
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
1
4
M4BK
2
3
BKC(J2)
M3M
2
3
A63L-0001-0865#1
A63L-0001-0864#CS
A63L-0001-0865#2
A63L-0001-0864#CS
1
4
J4V1
J4W1
8
9 5V(C1)
10 0V(C1)
J2U1
J2G1
J3 MOTOR (βiSR0.2/6000)
A63L-0001-0865#1
A63L-0001-0864#CS
13
14
15
16
17
18
19
20
21
22
23
24
4 6V(BT1)
1
5 XPRQJ1
2
6 PRQJ1
3
7 0V(BT1)
1
4
M4M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
M2BK
A63L-0001-0848#E10SL1
A63L-0001-0850
BK(J1)
BKC(J1)
J1U1
J1V1
J1W1
J1G1
XROT
RI1
RO1
5V(A1)
PRQJ1
XPRQJ1
BKC(J1)
M2M
2
3
1
2
3
4
5
6
7
8
9
10
11
12
1
4
J4 MOTOR (βiSR0.4/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
J2 MOTOR (βiSR0.2/6000)
A63L-0001-0865#1
A63L-0001-0864#CS
RMP
J1U1
J1G1
M1BK
A63L-0001-0848#E10SL1
A63L-0001-0850
CONNECTOR
1
4
A63L-0001-0865#1
A63L-0001-0864#CS
BK(J6)
M6P
8
9 5V(C3)
10 0V(C3)
4 6V(BT6)
1
5 XPRQJ6
2
6 PRQJ6
3
7 0V(BT6)
B.CIRCUIT DIAGRAM
APPENDIX
B-83085EN/03
A63L-0001-0865#1
A63L-0001-0864#CS
J1 MOTOR (βiSR0.2/6000)
M1M
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
BK(J1)
M1P
8
9 5V(A1)
10 0V(A1)
A63L-0001-0865#1
A63L-0001-0864#CS
J2V1
J2W1
BK(J2)
M2P
CONNECTOR PANEL
RMP
1
2
3
4
5
6
7
8
9
10
11
12
BK(J1)
BKC(J1)
J1U1
J1V1
J1W1
J1G1
XROT
RI1
RO1
5V(A1)
PRQJ1
XPRQJ1
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
24V(OT,A12) 31
RI2
32
RO2
33
5V(B12) 34
PRQJ2 35
XPRQJ2 36
BK(J2)
BKC(J2)
J2U1
J2V1
J2W1
J2G1
BK(J3)
BKC(J3)
J3U1
J3V1
J3W1
J3G1
XHBK
RI3
RO3
PRQJ3
XPRQJ3
G
37
38
39
40
41
42
43
44
45
46
47
48
SG
49
50
51
52
53
54
24V(B1) 55
RI4
56
RO4
57
0V(A1) 58
59
60
Han 72DD
(2.5SQ 10A)
61
62
63
64
65
66
0V(D12) 67 0V(E123456)
RI5
68 RI6
RO5
69 RO6
0V(B12) 70
71
72
K101
A660-8018-T695
J3V1
J3W1
BK(J3)
M3P
BATTERY
6V
(BT1,BT2,BT3)
+
B1
B2
B3
B4
B5
B6
P12DX
CTM
XHBK
24V(A1)
24V(A2)
24V(B1)
0V(D1)
0V(D2)
B1
B2
B3
B4
P08DX
CTM
0V(E456)
RO2
RO4
RO6
EE1
A1
A2
A3
A4
A5
A6
0V
(BT1,BT2,BT3)
RI1
RI2
RI3
RI4
RI5
RI6
YV1
A1
A2
A3
A4
0V(E123)
RO1
RO3
RO5
DUMMY CONNECTOR
A63L-0002-0066#R12DX
DUMMY CONNECTOR
A63L-0002-0066#R08DX
Fig. B (e) Circuit diagram (M-1iA/1H,0,1HL with stand , no stand B)
- 59 -
J2U1
J2G1
1
4
BKC(J2)
4 6V(BT2)
1
5 XPRQJ2
2
6 PRQJ2
3
7 0V(BT2)
1
4
J3U1
J3G1
1
4
BKC(J3)
M3BK
8
9 5V(B2)
10 0V(B2)
( 単二電池
SIZE C )
1
4
M3M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
4 6V(BT1)
1
5 XPRQJ1
2
6 PRQJ1
3
7 0V(BT1)
J3 MOTOR (βiSR0.2/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
BKC(J1)
M2BK
8
9 5V(B1)
10 0V(B1)
A63L-0001-0865#1
A63L-0001-0864#CS
1
4
M2M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
J1U1
J1G1
J2 MOTOR (βiSR0.2/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
1
4
M1BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
J1V1
J1W1
4 6V(BT3)
1
5 XPRQJ3
2
6 PRQJ3
3
7 0V(BT3)
B.CIRCUIT DIAGRAM
APPENDIX
B-83085EN/03
A63L-0001-0865#1
A63L-0001-0864#CS
J1 MOTOR (βiSR0.2/6000)
M1M
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
BK(J1)
M1P
8
9 5V(A1)
10 0V(A1)
A63L-0001-0865#1
A63L-0001-0864#CS
J2V1
J2W1
BK(J2)
M2P
CONNECTOR
RMP
1
2
3
4
5
6
7
8
9
10
11
12
BK(J1)
BKC(J1)
J1U1
J1V1
J1W1
J1G1
XROT
RI1
RO1
5V(A1)
PRQJ1
XPRQJ1
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
24V(OT,A12) 31
RI2
32
RO2
33
5V(B12) 34
PRQJ2 35
XPRQJ2 36
BK(J3)
BKC(J3)
J3U1
J3V1
J3W1
J3G1
XHBK
RI3
RO3
BK(J2)
BKC(J2)
J2U1
J2V1
J2W1
J2G1
PRQJ3
XPRQJ3
G
37
38
39
40
41
42
43
44
45
46
47
48
SG
49
50
51
52
53
54
24V(B1) 55
RI4
56
RO4
57
0V(A1) 58
59
60
Han 72DD
(2.5SQ 10A)
61
62
63
64
65
66
0V(D12) 67 0V(E123456)
RI5
68 RI6
RO5
69 RO6
0V(B12) 70
71
72
K101
A660-8018-T696
6V
(BT1,BT2,BT3)
+
K131
A660-8016-T498
( 単一電池
SIZE D )
0V
(BT1,BT2,BT3)
GB2
GB2
6V(BT1,BT2,BT3,
BT4)
B 0V(BT1,BT2,BT3,
BT4)
6V(BT1,BT2,BT3,
BT4)
B 0V(BT1,BT2,BT3,
BT4)
A
A
C
C
A63L-0001-0648#610SL3SJ
J3V1
J3W1
B1
B2
B3
B4
B5
B6
P12DX
CTM
XHBK
24V(A1)
24V(A2)
24V(B1)
0V(D1)
0V(D2)
B1
B2
B3
B4
P08DX
CTM
0V(E456)
RO2
RO4
RO6
EE1
A1
A2
A3
A4
A5
A6
A63L-0001-0648#210SL3PJ
RI1
RI2
RI3
RI4
RI5
RI6
YV1
A1
A2
A3
A4
0V(E123)
RO1
RO3
RO5
DUMMY CONNECTOR
A63L-0002-0066#R12DX
DUMMY CONNECTOR
A63L-0002-0066#R08DX
Fig. B (f) Circuit diagram (M-1iA/1H,1HL No stand A)
- 60 -
J2U1
J2G1
1
4
BKC(J2)
4 6V(BT2)
1
5 XPRQJ2
2
6 PRQJ2
3
7 0V(BT2)
1
4
J3U1
J3G1
1
4
BKC(J3)
M3BK
BK(J3)
M3P
8
9 5V(B2)
10 0V(B2)
BATTERY
1
4
M3M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
4 6V(BT1)
1
5 XPRQJ1
2
6 PRQJ1
3
7 0V(BT1)
J3 MOTOR (βiSR0.2/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
BKC(J1)
M2BK
8
9 5V(B1)
10 0V(B1)
A63L-0001-0865#1
A63L-0001-0864#CS
1
4
M2M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
J1U1
J1G1
J2 MOTOR (βiSR0.2/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
1
4
M1BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
J1V1
J1W1
4 6V(BT3)
1
5 XPRQJ3
2
6 PRQJ3
3
7 0V(BT3)
B.CIRCUIT DIAGRAM
APPENDIX
B-83085EN/03
A63L-0001-0865#1
A63L-0001-0864#CS
J1 MOTOR (βiSR0.2/6000)
M1M
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
BK(J1)
M1P
8
9 5V(A1)
10 0V(A1)
A63L-0001-0865#1
A63L-0001-0864#CS
J2V1
J2W1
BK(J2)
M2P
CONNECTOR
RMP
1
2
3
4
5
6
7
8
9
10
11
12
BK(J1)
BKC(J1)
J1U1
J1V1
J1W1
J1G1
XROT
RI1
RO1
5V(A1)
PRQJ1
XPRQJ1
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
24V(OT,A12) 31
RI2
32
RO2
33
5V(B12) 34
PRQJ2
35
XPRQJ2
36
BK(J2)
BKC(J2)
J2U1
J2V1
J2W1
J2G1
BK(J3)
BKC(J3)
J3U1
J3V1
J3W1
J3G1
XHBK
RI3
RO3
PRQJ3
XPRQJ3
G
37
38
39
40
41
42
43
44
45
46
47
48
SG
49
50
51
52
53
54
24V(B1) 55
RI4
56
RO4
57
0V(A1) 58
59
60
Han 72DD
(2.5SQ 10A)
61
62
63
64
65
66
0V(D12) 67 0V(E123456)
RI5
68 RI6
RO5
69 RO6
0V(B12) 70
71
72
K101
A660-8018-T697
J3V1
J3W1
BK(J3)
M3P
BATTERY
6V
(BT1,BT2,BT3)
+
B1
B2
B3
B4
B5
B6
P12DX
CTM
XHBK
24V(A1)
24V(A2)
24V(B1)
0V(D1)
0V(D2)
B1
B2
B3
B4
P08DX
CTM
0V(E456)
RO2
RO4
RO6
EE1
A1
A2
A3
A4
A5
A6
0V
(BT1,BT2,BT3)
RI1
RI2
RI3
RI4
RI5
RI6
YV1
A1
A2
A3
A4
0V(E123)
RO1
RO3
RO5
DUMMY CONNECTOR
A63L-0002-0066#R12DX
DUMMY CONNECTOR
A63L-0002-0066#R08DX
Fig. B (g) Circuit diagram (M-1iA/1H,1HL No stand B)
- 61 -
J2U1
J2G1
1
4
BKC(J2)
4 6V(BT2)
1
5 XPRQJ2
2
6 PRQJ2
3
7 0V(BT2)
1
4
J3U1
J3G1
1
4
BKC(J3)
M3BK
8
9 5V(B2)
10 0V(B2)
( 単二電池
SIZE C )
1
4
M3M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
4 6V(BT1)
1
5 XPRQJ1
2
6 PRQJ1
3
7 0V(BT1)
J3 MOTOR (βiSR0.2/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
BKC(J1)
M2BK
8
9 5V(B1)
10 0V(B1)
A63L-0001-0865#1
A63L-0001-0864#CS
1
4
M2M
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
J1U1
J1G1
J2 MOTOR (βiSR0.2/6000)
2
3
A63L-0001-0865#2
A63L-0001-0864#CS
1
4
M1BK
2
3
A63L-0001-0848#E10SL1
A63L-0001-0850
J1V1
J1W1
4 6V(BT3)
1
5 XPRQJ3
2
6 PRQJ3
3
7 0V(BT3)
C.PERIODIC MAINTENANCE TABLE
C
APPENDIX
B-83085EN/03
PERIODIC MAINTENANCE TABLE
FANUC Robot M-1iA
Working time (H)
1
6
9
3
First
check months months months year
320
960 1920 2880 3840
2
Check
time
Grease
amount
0.1H
―
○
○
○
0.1H
―
○
○
○
3 connector (Loosening)
0.2H
―
○
○
○
4 Tighten the end effector bolt
0.2H
―
○
○
○
2.0H
―
○
○
○
0.2H
―
○
○
○
7 B ball joint part
0.2H
―
8 Remove dust, powder etc.
1.0H
―
○
○
○
0.1H
―
○
○
○
Replacing battery.
(With stand/no stand B)
0.1H
―
●
●
Replacing battery.
(No stand A)
0.1H
―
0.5H
Proper
quantity
●
●
●
●
●
12 Supply grease to drive shafts 0.5H
Proper
quantity
●
●
●
●
●
○
○
○
○
○
Items
1
Check for external
damage or peeling paint
2 Check for water
Check the exposed
Tighten the cover and main
5 bolt.
Retighten the LINK B
Mechanical unit
Periodic Maintenance Table
6 mounting part
Check the wear of the LINK
Check the end effector
9 (hand) cable
10
Supply grease to wrist input
11 gears
Clean the around of wrist
○
○
○
4800
5760
6720
7680
8640
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
9600 10560
●
0.1H
―
○
0.2H
―
○
15 ventilation system
0.2H
―
16 Replacing battery (*2)
0.1H
―
13 input gear (*1)
○
years
Controller
Check the robot cable, teach
14 pendant cable and robot
○
○
connecting cable
Cleaning the controller
○
○
*1 M-1iA/1H,1HL does not have the wrist input gear
*2 Refer to manual of controller
*3 ●: requires order of parts
○: does not require order of parts
- 62 -
○
○
○
○
○
○
○
○
○
○
APPENDIX
B-83085EN/03
C.PERIODIC MAINTENANCE TABLE
3
4
5
6
7
8
years
years
years
years
years
years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720
Item
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
1
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
○
○
○
○
○
6
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
●
●
●
●
●
○
○
○
7
8
Overhaul
○
9
10
●
●
●
●
●
●
●
●
●
●
●
●
●
●
11
●
●
●
●
●
●
●
●
●
●
12
○
○
○
○
○
○
○
○
○
○
13
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
●
○
○
○
○
○
○
○
14
○
○
○
15
16
- 63 -
D.MOUNTING BOLT TORQUE LIST
D
APPENDIX
B-83085EN/02
MOUNTING BOLT TORQUE LIST
NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire length portion of the engaging area of the female threads. If
it is applied to the male threads, the bolts could become loose due to insufficient
adhesion. Clean the bolts and threaded holes and wipe off oil on the engaging
section. Make sure that there is no solvent in the threaded holes. Be sure to wipe
the excess LOCTITE after tightening the bolt.
Use bolt which strengths are below.
But if it is specified in text, obey it.
Hexagon socket head bolt made by steel
Size is M22 or less : Tensile strength 1200N/mm2 or more
Size is M24 or more : Tensile strength 1000N/mm2 or more
All size of bolt of the plating : Tensile strength 1000N/mm2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm2 or more
If no tightening torque is specified for a bolt, tighten it according to this table.
Recommended bolt tightening torques
Nominal
diameter
M3
M4
M5
M6
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
M36
Hexagon socket head
bolt
(Steel)
Tightening torque
Upper limit Lower limit
1.8
1.3
4.0
2.8
7.9
5.6
14
9.6
32
23
66
46
110
78
180
130
270
190
380
260
530
370
730
510
930
650
1400
960
1800
1300
3200
2300
Unit: Nm
Hexagon socket head
button bolt
Hexagon bolt
Hexagon socket head
Hexagon socket head
(steel)
flush bolt
bolt (stainless)
Low-head bolt
(steel)
Tightening torque
Tightening torque
Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
――――
――――
―――
0.76
0.53 ――――
1.8
1.3
1.8
1.3
1.7
1.2
3.4
2.5
4.0
2.8
3.2
2.3
5.8
4.1
7.9
5.6
5.5
3.8
14
9.8
14
9.6
13
9.3
27
19
32
23
26
19
――――
――――
48
33
45
31
――――
――――
76
53
73
51
――――
――――
120
82
98
69
――――
――――
160
110
140
96
――――
――――
230
160
190
130
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
- 64 -
INDEX
B-83085EN/03
INDEX
REPLACING THE J4/J5/J6 WRIST INPUT GEAR
(M-1iA/0.5S,0.5A,0.5SL,0.5AL) ...............................36
REPLACING THE J4/J5/J6-AXIS MOTOR
M4/M5/M6 (M-1iA/0.5S,0.5A,0.5SL,0.5AL) ...........31
REPLACING THE WRIST UNIT.................................38
Retightening the Link B...................................................6
ROBOT CONFIGURATION.........................................26
<A>
APPLYING THE GREASE OF THE WRIST INPUT
GEARS AND THE DRIVE SHAFTS
(M-1iA/0.5S,0.5A,0.5SL,0.5AL) (6 MONTHS (1920
HOURS) CHECKS) ...................................................11
<B>
<S>
BACKLASH MEASUREMENT ...................................19
SAFETY PRECAUTIONS ........................................... s-1
SIMPLE METHOD OF MASTERING .........................38
SPARE PARTS LIST ....................................................53
<C>
CABLE FORMING .......................................................41
CABLE REPLACEMENT.............................................48
CHECK POINTS .............................................................4
Check the Connectors ......................................................7
CHECKS AND MAINTENANCE ..................................1
CIRCUIT DIAGRAM....................................................55
Cleaning the Wrist Axis Rotation Parts and the Wrist
Gears (M-1iA/0.5S,0.5A,0.5SL,0.5AL) .......................7
COMPONENT REPLACEMENT .................................24
Confirmation of Oil Seepage and Oil Accumulation .......4
Confirmation of the Air Control Set.................................5
<T>
TROUBLESHOOTING .................................................13
<D>
Daily Checks ....................................................................1
<F>
FAILURES, CAUSES AND MEASURES....................13
FIGURE OF DRIVE MECHANISM .............................25
<M>
MAINTENANCE TOOLS...............................................8
MOUNTING BOLT TORQUE LIST ............................64
<O>
OVERVIEW ..................................................................13
<P>
Periodic Check and Maintenance .....................................2
PERIODIC MAINTENANCE ......................................1,9
PERIODIC MAINTENANCE TABLE..........................62
PREFACE .................................................................... p-1
<R>
REPLACING CABLES .................................................40
REPLACING THE BATTERIES (1-YEAR (3840
Hours) CHECKS (with stand/no stand B))
(1.5-YEAR (5760 Hours) CHECKS (no stand A)).......9
REPLACING THE J1/J2/J3 ARM ASSEMBLY...........33
REPLACING THE J1/J2/J3 LINK B.............................34
REPLACING THE J1/J2/J3-AXIS MOTOR
M1/M2/M3.................................................................28
REPLACING THE J1/J2/J3-AXIS REDUCER .............30
REPLACING THE J4/J5/J6 DRIVE SHAFT
(M-1iA/0.5S,0.5A,0.5SL,0.5AL)................................36
i-1
REVISION RECORD
B-83085EN/03
REVISION RECORD
Edition
Date
03
Jul., 2014
02
Feb., 2012
01
Feb., 2010
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Contents
Addition of R-30iB Mate
Addition of M-1iA/1H,0.5SL,0.5AL,1HL
Addition of greasing to the drive shafts
Correction of errors
Addition of No stand B
Change replacing method of J4/J5/J6-axes motor
Correction of errors
r-1
B-83085EN/03
* B - 8 3 0 8 5 E N / 0 3 *