FANUC > M-900iA/350
MECHANICAL UNIT
MAINTENANCE MANUAL
B-82135EN/01
• No part of this manual may be reproduced in any form.
• All specifications and designs are subject to change without notice.
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-82135EN/01
SAFETY
SAFETY
FANUC is not and does not represent itself as an expert in safety
systems, safety equipment, or the specific safety aspects of your
company and/or its work force. It is the responsibility of the
owner, employer, or user to take all necessary steps to guarantee
the safety of all personnel in the workplace.
The appropriate level of safety for your application and
installation can best be determined by safety system professionals.
FANUC therefore, recommends that each customer consult with
such professionals in order to provide a workplace that allows for
the safe application, use, and operation of FANUC systems.
Additionally, as the owner, employer, or user of a robotic system,
it is your responsibility to arrange for the training of the operator
of a robot system to recognize and respond to known hazards
associated with your robotic system and to be aware of the
recommended operating procedures for your particular
application and robot installation.
FANUC therefore, recommends that all personnel who intend to
operate, program, repair, or otherwise use the robotics system be
trained in an approved FANUC training course and become
familiar with the proper operation of the system. Persons
responsible for programming the system-including the design,
implementation, and debugging of application programs-must be
familiar with the recommended programming procedures for your
application and robot installation.
The following guidelines are provided to emphasize the
importance of safety in the workplace.
IMPORTANT
Before operating, servicing or in any other way handling
the robot, the "FANUC Robot SAFETY HANDBOOK (B80687EN)" must be thoroughly studied.
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SAFETY
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Considering safety
for your robot
installation
Safety is essential whenever robots are used. Keep in mind the
following factors with regard to safety:
• The safety of people and equipment
• Use of safety enhancing devices
• Techniques for safe teaching and manual operation of the
robot(s)
• Techniques for safe automatic operation of the robot(s)
• Regular scheduled inspection of the robot and workcell
• Proper maintenance of the robot
Keeping people and
equipment safe
The safety of people is always of primary importance in any
situation. However, equipment must be kept safe, too. When
prioritizing how to apply safety to your robotic system, consider
the following:
• People
• External devices
• Robot(s)
• Tooling
• Workpiece
Using safety enhancing
devices
Always give appropriate attention to the work area that surrounds
the robot. The safety of the work area can be enhanced by the
installation of some or all of the following devices:
• Safety fences, barriers, or chains
• Light curtains
• Interlocks
• Pressure mats
• Floor markings
• Warning lights
• Mechanical stops
• EMERGENCY STOP buttons
• DEADMAN switches
Setting up a safe
workcell
A safe workcell is essential to protect people and equipment.
Observe the following guidelines to ensure that the workcell is set
up safely. These suggestions are intended to supplement and not
replace existing federal, state, and local laws, regulations, and
guidelines that pertain to safety.
• Sponsor your personnel for training in approved FANUC
training course(s) related to your application. Never permit
untrained personnel to operate the robots.
• Install a lockout device to prevent unauthorized persons from
operating the robot.
• Use anti-tie-down logic to prevent the operator from bypassing
safety measures.
• Arrange the workcell so the operator faces the workcell and
can see what is going on inside the cell.
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SAFETY
• Clearly identify the work envelope of each robot in the system
with floor markings, signs, and special barriers. The work
envelope is the area defined by the maximum motion range of
the robot, including any tooling attached to the wrist flange that
extend this range.
• Position all controllers outside the robot work envelope.
• Never rely on software as the primary safety element.
• Install flashing lights and/or audible warning devices that
activate whenever the robot is operating, that is, whenever
power is applied to the servo drive system.
• Wherever possible, install safety fences to protect against
unauthorized entry by personnel into the work envelope.
• Install special guarding that prevents the operator from
reaching into restricted areas of the work envelope.
• Use interlocks.
• Use presence or proximity sensing devices such as light
curtains, mats, and capacitance and vision systems to enhance
safety.
• Periodically check the safety joints or safety clutches that can
be optionally installed between the robot wrist flange and
tooling. If the tooling strikes an object, these devices dislodge,
remove power from the system, and help to minimize damage
to the tooling and robot.
• Make sure all external devices are properly filtered, grounded,
shielded, and suppressed to prevent hazardous motion due to
the effects of electro-magnetic interference (EMI), radio
frequency interference (RFI), and electro-static discharge
(ESD).
• Make provisions for power lockout/tagout at the controller.
• Eliminate pinch points. Pinch points are areas where personnel
could get trapped between a moving robot and other
equipment.
• Provide enough room inside the workcell to permit personnel
to teach the robot and perform maintenance safely.
• Program the robot to load and unload material safely.
• If high voltage electrostatics are present, be sure to provide
appropriate interlocks, warning, and beacons.
• If materials are being applied at dangerously high pressure,
provide electrical interlocks for lockout of material flow and
pressure.
Staying safe while
teaching or manually
operating the robot
Advise all personnel who must teach the robot or otherwise
manually operate the robot to observe the following rules:
• Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
• Know whether or not you are using an intrinsically safe teach
pendant if you are working in a hazardous environment.
• Before teaching, visually inspect the robot and work envelope
to make sure that no potentially hazardous conditions exist.
The work envelope is the area defined by the maximum motion
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SAFETY
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•
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range of the robot. These include tooling attached to the wrist
flange that extends this range.
The area near the robot must be clean and free of oil, water, or
debris. Immediately report unsafe working conditions to the
supervisor or safety department.
FANUC recommends that no one enter the work envelope of a
robot that is on. However, if you must enter the work envelope,
be sure all safeguards are in place, and check the teach pendant
DEADMAN switch for proper operation. Take the teach
pendant with you, turn it on, and be prepared to release the
DEADMAN switch. Only the person with the teach pendant
should be in the work envelope.
Know the path that can be used to escape from a moving robot;
make sure the escape path is never blocked.
Isolate the robot from all remote control signals that can cause
motion while data is being taught.
Test any program being run for the first time in the following
manner:
WARNING
Stay outside the robot work envelope whenever a
program is being run. Failure to do so can result in injury.
- Using a low motion speed, single step the program for at least
one full cycle.
- Using a low motion speed, test run the program continuously for
at least one full cycle.
- Using the programmed speed, test run the program continuously
for at least one full cycle.
- Make sure all personnel are outside the work envelope before
running production.
Staying safe during
production operation
Advise all personnel who operate the robot during production to
observe the following rules:
• Know the entire workcell area. The workcell includes the robot
and its work envelope, plus the area occupied by all external
devices and other equipment with which the robot interacts.
• Understand the complete task the robot is programmed to
perform before initiating production operation.
• Make sure all personnel are outside the work envelope before
operating the robot.
• Never enter or allow others to enter the work envelope during
production operation of the robot.
• Know the location and status of all switches, sensors, and
control signals that could cause the robot to move.
• Know where the EMERGENCY STOP buttons are located on
both the robot control and external control devices. Be
prepared to press these buttons in an emergency.
• Never assume that a program is complete if the robot is not
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SAFETY
moving. The robot could be waiting for an input signal that will
permit it to continue activity.
• If the robot is running in a pattern, do not assume it will
continue to run in the same pattern.
• Never try to stop the robot, or break its motion, with your body.
The only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel,
teach pendant, or emergency stop stations around the workcell.
Staying safe during
inspection
When inspecting the robot, be sure to:
• Turn off power at the controller.
• Lock out and tag out the power source at the controller
according to the policies of your plant.
• Turn off the compressed air source and relieve the air pressure.
• If robot motion is not needed for inspecting the electrical
circuits, press the EMERGENCY STOP button on the operator
panel.
• Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
• If power is needed to check the robot motion or electrical
circuits, be prepared to press the EMERGENCY STOP button,
in an emergency.
Staying safe during
maintenance
When performing maintenance on your robot system, observe the
following rules:
• Never enter the work envelope while the robot or a program is
in operation.
• Before entering the work envelope, visually inspect the
workcell to make sure no potentially hazardous conditions
exist.
• Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
• Consider all or any overlapping work envelopes of adjoining
robots when standing in a work envelope.
• Test the teach pendant for proper operation before entering the
work envelope.
• If it is necessary for you to enter the robot work envelope while
power is turned on, you must be sure that you are in control of
the robot. Be sure to take the teach pendant with you, press the
DEADMAN switch, and turn the teach pendant on. Be
prepared to release the DEADMAN switch to turn off servo
power to the robot immediately.
• Whenever possible, perform maintenance with the power
turned off. Before you open the controller front panel or enter
the work envelope, turn off and lock out the 3-phase power
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SAFETY
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source at the controller.
WARNING
Lethal voltage is present in the controller WHENEVER IT
IS CONNECTED to a power source. Be extremely careful
to avoid electrical shock.
HIGH VOLTAGE IS PRESENT at the input side whenever
the controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.
• Release or block all stored energy. Before working on the
pneumatic system, shut off the system air supply and purge the
air lines.
• Isolate the robot from all remote control signals. If
maintenance must be done when the power is on, make sure the
person inside the work envelope has sole control of the robot.
The teach pendant must be held by this person.
• Make sure personnel cannot get trapped between the moving
robot and other equipment. Know the path that can be used to
escape from a moving robot. Make sure the escape route is
never blocked.
• Use blocks, mechanical stops, and pins to prevent hazardous
movement by the robot. Make sure that such devices do not
create pinch points that could trap personnel.
WARNING
Do not try to remove any mechanical component from the
robot before thoroughly reading and understanding the
procedures in the appropriate manual. Doing so can result
in serious personal injury and component destruction.
• Be aware that when you remove a servomotor or brake, the
associated axis will fall if it is not supported or resting on a hard
stop.
• When replacing or installing components, make sure dirt and
debris do not enter the system.
• Use only specified parts for replacement. To avoid fires and
damage to parts in the controller, never use nonspecified fuses.
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SAFETY
• Before restarting a robot, make sure no one is inside the work
envelope; be sure that the robot and all external devices are
operating normally.
• Use appropriate lighting for maintenance work. Take care that
the lighting does not create new dangerous situations.
• If it is necessary to operate the robot during the inspection, pay
careful attention to the robot's motion and be sure to press the
EMERGENCY STOP button immediately when necessary.
• Be careful not to slip on spilled grease during maintenance.
• Do not climb on the robot.
• Some components might be hot. Take care when working on
servo motors or inside the controller. Wear protective clothing
(heart-resistant gloves, etc.) when working on components that
are hot.
• After replacing components, be sure to tighten screws and
fasteners that were loosened.
• The motor and reducer are heavy. Be careful when replacing
them. If the robot collides with a mechanical hard stop, replace
the mechanical hard stop even if it does not seem to be
damaged.
• After replacing parts or making adjustments, be sure to test run
the robot according to the following procedure.
1. Using a low motion speed, single step the program for
at least one full cycle.
2. Using a low motion speed, test run the program
continuously for at least one full cycle.
3. As speed is increased the path may vary slightly. Run
through the program at 5-10% intervals up to 100%.
4. Using the programmed speed, test run the program
continuously for at least one full cycle.
Make sure all personnel are outside the fence before test
running.
• After maintenance work, clean the area around the robot of oil,
water, and debris.
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SAFETY
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Safety procedure for
maintenance
Follow this safety procedure when entering the safeguarded space
for maintenance.
Entering safeguarded
space for maintenance
1. Stop the robot system.
2. Shut off the power to the robot system, and lock the main
breaker to prevent accidental powering on during maintenance.
2'. If you have to enter the safeguarded space while power is
available to the robot system, you must do the following prior
to entering the safeguarded space:
- check the robot system to determine if any conditions exist
that are likely to cause malfunctions, - check that the teach
pendant works correctly, and
- if any damage or malfunction is found, complete the required
corrections and perform a retest before personnel enter the
safeguarded space.
3. Enter the safeguarded space (see "The Safety Sequence for
fence entry" in "FANUC Robot SAFETY HANDBOOK").
4. After maintenance is complete, check that the safeguard
system is effective. If it has been suspended to perform the
maintenance working, return it to its original effectiveness.
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SAFETY
Keeping machine
tools and external
devices safe
Certain programming and mechanical measures are useful in
keeping the machine tools and other external devices safe. These
measures are outlined below.
Programming safety
precautions
Implement the following programming safety measures to prevent
damage to machine tools and other external devices.
• Back-check limit switches in the workcell to make sure they do
not fail.
• Implement "failure routines" in programs that will provide
appropriate robot actions if an external device or another robot
in the workcell fails.
• Use handshaking protocol to synchronize robot and external
device operations.
• Program the robot to check the condition of all external devices
during an operating cycle.
Mechanical safety
precautions
Implement the following mechanical safety measures to prevent
damage to machine tools and other external devices.
• Make sure the workcell is clean and free of oil, water, and
debris.
• Use software limits, limit switches, and mechanical hardstops
to prevent undesired movement of the robot into the work area
of machine tools and external devices.
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SAFETY
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Keeping the robot
safe
Observe the following operating and programming guidelines to
prevent damage to the robot.
Operating safety
precautions
The following measures are designed to prevent damage to the
robot during operation.
• Use a low override speed to increase your control over the
robot when jogging the robot.
• Visualize the movement the robot will make before you press
the jog keys on the teach pendant.
• Make sure the work envelope is clean and free of oil, water, or
debris.
• Use fuses to guard against electrical overload.
Programming safety
precautions
The following safety measures are designed to prevent damage to
the robot during programming:
• Establish interference zones to prevent collisions when two or
more robots share a work area.
• Make sure that the program ends with the robot near or at the
home position.
• Be aware of signals or other operations that could trigger
operation of tooling resulting in personal injury or equipment
damage.
• In dispensing applications, be aware of all safety guidelines
with respect to the dispensing materials.
NOTE
Any deviation from the methods and safety practices
described in this manual must conform to the approved
standards of your company. If you have questions, see
your supervisor.
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Warning labels
1. Greasing and degreasing label
Greasing and Degreasing Label
Description
When greasing and degreasing, observe the instructions indicated
on this label.
1. When greasing, be sure to keep the grease outlet open.
2. Use a manual pump to grease.
3. Be sure to use a specified grease.
NOTE
See MAINTENANCE 3.1 REPLACING GREASE OF THE
DRIVE MECHANISM for explanations about specified
greases, the amount of grease to be supplied, and the
locations of grease and degrease outlets for individual
models.
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2. Step-on prohibitive label
Step-on prohibitive label
Description
Do not step on or climb the robot as it may adversely affect the
robot and you may get hurt if you lose your footing as well.
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SAFETY
3. High-temperature warning label
High-temperature warning label
Description
Be cautious about a section where this label is affixed, as the
section generates heat. If you have to inevitably touch such a
section when it is hot, use a protective provision such as heatresistant gloves.
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4. Transportation label
Transportation label
Description
When transporting the robot, observe the instructions indicated on
this label.
1. Using a forklift
• Use a forklift having a load capacity of
3,000 kg or greater.
• Keep the total weight of the robot to be
transported to within 2,800 kg, because the
withstand load of the forklift bracket
(option) is 13,720 kgN (1,400 kg)
2. Using a crane
• Use a crane having a load capacity of 3,000
kg or greater.
• Use at least four slings each having a
withstand load of 9,800 N (1,000 kgf) or
greater.
• Use at least four eyebolts each having a
withstand load of 6,174 N (630 kgf) or
greater.
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SAFETY
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NOTE
See CONNECTION 3.1 TRANSPORTATION for
explanations about the posture a specific model should
take when it is transported.
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PREFACE
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PREFACE
This manual explains the maintenance and connection procedures
for the following robots:
Mechanical unit
specification No.
Model name
FANUC Robot M900iA/350
A05B-1327-B201
Maximum load
350kg
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.
TABLE 1
No.
(1)
CONTENTS
LETTERS
FANUC Robot
M-900iA/350
(2)
(3)
(4)
(5)
TYPE
No.
DATE
WEIGHT
(Without
controller)
A05B-1327-B201
PRINT
SERIAL NO.
PRINT
PRODUCTION
YEAR AND MONTH
1720kg
Position of label indicating mechanical unit specification number
p-1
PREFACE
B-82135EN/01
Specifications
ITEM
M-900iA/350
Type
Articulated Type
Controlled axes
6 axes (J1, J2, J3, J4, J5, J6)
Installation (NOTE)
Floor mount, Upside-down (Angle mount)
Motion range J1-axis
360° (6.28rad)
Motion range J2-axis
150° (2.62rad)
Motion range J3-axis
223.4° (3.90rad)
Motion range J4-axis
720° (12.57rad)
Motion range J5-axis
250° (4.36rad)
Motion range J6-axis
720° (12.57rad)
Max. Motion speed J1-axis
100°/s (1.75rad/s)
Max. Motion speed J2-axis
95°/s (1.66rad/s)
Max. Motion speed J3-axis
95°/s (1.66rad/s)
Max. Motion speed J4-axis
105°/s (1.83rad/s)
Max. Motion speed J5-axis
105°/s (1.83rad/s)
Max. Motion speed J6-axis
170°/s (2.97rad/s)
Max. load capacity at wrist
350kg
Max. load capacity at J3 arm
25kg
Max. load capacity at J2 arm
550kg
Allowable load moment at wrist J4-axis
1960N m (200kgf m)
Allowable load moment at wrist J5-axis
1960N m (200kgf m)
Allowable load moment at wrist J6-axis
891.8N m (91kgf m)
Allowable load inertia at wrist J4-axis
235.2kg m2 (2400kgf cm s2)
Allowable load inertia at wrist J5-axis
235.2kg m2 (2400kgf cm s2)
Allowable load inertia at wrist J6-axis
156.8kg m2 (1600kgf cm s2)
Drive method
Electric servo drive by AC servo motor
Repeatability
+/- 0.3mm
Weight
Installation enviroment
Approx. 1720kg
Ambient temperature : 0 - 45°C
Ambient humidity
Normally : 75%RH or less No dew, nor frost allowed.
Short time (within one month) : Max 95%RH
Height :
Up to 1,000 meters above the sea level requires, no particular provision for
attitude.
Vibration : 0.5 (4.9m/s2) or less
p-2
PREFACE
B-82135EN/01
NOTE
The operation range of the J1-axis and J2-axis are limited
to the installation condition.
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-J3iB
controller
Setup and Operations
manual
SPOT TOOL
B-81464EN-1
HANDLING TOOL
B-81464EN-2
Intended readers :
All persons who use FANUC Robot, system
designer
Topics :
Safety items for robot system design, operation,
maintenance
Intended readers :
Operator, programmer, maintenance person,
system designer
Topics :
Robot functions, operations, programming,
setup, interfaces, alarms
Use :
Robot operation, teaching, system design
SEALING TOOL
B-81464EN-4
R-J3iB
controller
Maintenance manual
B-81465EN
B-81465EN-1
(European specification)
Mechanical unit
Maintenance manual
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to peripheral equipment,
maintenance
Use :
Installation, start-up, connection, maintenance
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to the controller,
maintenance
Use :
installation, start-up, connection, maintenance
FANUC Robot M-900iA/350
B-82135EN
- Spot welding, general-purpose large robot
p-3
Table of Contents
B-82135EN/01
TABLE OF CONTENTS
SAFETY ............................................................................................. s-1
PREFACE .......................................................................................... p-1
I. MAINTENANCE
1. CONFIGURATION ............................................................................ 3
1.1
1.2
1.3
1.4
1.5
J1-AXIS DRIVE MECHANISM........................................................................4
J2/J3-AXIS DRIVE MECHANISM ...................................................................5
J4-AXIS DRIVE MECHANISM........................................................................6
J5/J6-AXIS DRIVE MECHANISM ...................................................................7
MAJOR COMPONENT SPECIFICATIONS ....................................................8
2. PREVENTIVE MAINTENANCE ........................................................ 9
2.1
2.2
2.3
2.4
2.5
2.6
DAILY CHECKS .............................................................................................10
3-MONTH CHECKS........................................................................................12
1-YEAR CHECKS............................................................................................13
1.5-YEAR CHECKS.........................................................................................14
3-YEAR CHECKS............................................................................................15
MAINTENANCE TOOLS ...............................................................................16
3. PERIODIC MAINTENANCE............................................................ 21
3.1
REPLACING GREASE OF THE DRIVE MECHANISM ..............................22
3.1.1 Grease Replacement Procedure for the J1-Axis/J2-Axis/J3-Axis and J4-Axis Gear Box22
3.1.2 Grease Replacement Procedure for the Wrist ...................................................................22
3.1.3 Attitude for Greasing.........................................................................................................23
3.2
3.3
GREASING POINTS .......................................................................................26
REPLACING THE BATTERIES.....................................................................27
4. TROUBLESHOOTING .................................................................... 28
4.1
4.2
4.3
OVERVIEW .....................................................................................................29
FAILURE AND CAUSE..................................................................................30
BACKLASH MEASUREMENT......................................................................38
5. ADJUSTMENTS.............................................................................. 41
5.1
AXIS LIMITS SETUP......................................................................................42
5.1.1 Zero Point Position and Motion Limit ..............................................................................43
5.1.2 Software Setting ................................................................................................................48
5.1.3 Hard Stopper and Limit Switch Setting ............................................................................50
5.2
5.3
ADJUSTING LIMIT SWITCH (OPTION)......................................................55
MASTERING ...................................................................................................58
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5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
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General ............................................................................................................................. 58
Resetting Alarms and Preparing for Mastering ................................................................ 59
Mastering to a Fixture (Master Position Master) ............................................................. 60
Zero Degree Mastering..................................................................................................... 65
Quick Mastering ............................................................................................................... 68
Single Axis Mastering ...................................................................................................... 69
Mastering Data Entry ....................................................................................................... 72
6. REPLACING PARTS .......................................................................75
6.1
6.2
6.3
6.4
6.5
6.6
6.7
NOTE FOR PART REPLACEMENT ............................................................. 76
REPLACING J1-AXIS MOTOR (M1) AND REDUCER .............................. 78
REPLACING J2-AXIS MOTOR (M2) AND REDUCER .............................. 85
REPLACING J3-AXIS MOTOR (M3) AND REDUCER .............................. 90
REPLACING THE WRIST AXIS MOTORS (M4, M5, AND M6),
WRIST UNIT AND J4 AXIS REDUCER95
SEALANT APPLICATION............................................................................. 99
REPLACING MOTOR COVERS (OPTION) ............................................... 100
7. PIPING AND WIRING ....................................................................101
7.1
7.2
PIPING DIAGRAM ....................................................................................... 102
WIRING DIAGRAM ..................................................................................... 103
8. REPLACING CABLES ..................................................................106
8.1
8.2
8.3
CABLE FORMING ....................................................................................... 108
CABLE REPLACEMENT............................................................................. 111
LIMIT SWITCH REPLACEMENT (OPTION) ............................................ 122
II. CONNECTION
1. ROBOT INTERFERENCE AREA ..................................................129
1.1
1.2
External Dimensions ...................................................................................... 130
Operation Area ............................................................................................... 131
2. MECHANICAL COUPLING TO THE ROBOT ...............................133
2.1
2.2
2.3
2.4
2.5
2.6
2.7
WRIST LOAD CONDITIONS ...................................................................... 134
LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS ARM ............... 135
MECHANICAL COUPLING OF END EFFECTOR TO WRIST ................ 136
EQUIPMENT MOUNTING FACE............................................................... 137
SETTING SYSTEM VARIABLES FOR MINIMUM CYCLE CONTROL 138
AIR SUPPLY (OPTION)............................................................................... 141
INTERFACE FOR OPTION CABLE (OPTION) ......................................... 142
3. TRANSPORTATION AND INSTALLATION..................................154
3.1
3.2
TRANSPORTATION .................................................................................... 155
INSTALLATION ........................................................................................... 160
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3.3
3.4
3.5
3.6
MAINTENANCE AREA ...............................................................................164
AIR PIPING (OPTION) .................................................................................165
INSTALLATION SPECIFICATIONS...........................................................167
STORAGE ......................................................................................................168
APPENDIX
A. SPARE PARTS LIST ................................................................... 171
B. CONNECTION DIAGRAM............................................................ 175
C. PERIODIC MAINTENANCE TABLE ............................................ 179
D. BOLT TIGHTENING TORQUE TABLE........................................ 182
c-3
Table of Contents
B-82135EN/01
I. MAINTENANCE
MAINTENANCE
B-82135EN/01
1
1. CONFIGURATION
1CONFIGURATION
The configuration of the mechanical unit is shown in Fig. 1.
AC SERVO MOTOR (M6)
FOR J6-AXIS
AC SERVO MOTOR (M4)
FOR J4-AXIS
J3-AXIS CASING
END EFFECTOR
MOUNTING FACE
WRIST UNIT
AC SERVO MOTOR (M5)
FOR J5-AXIS
AC SERVO MOTOR (M3)
FOR J3-AXIS
AC SERVO MOTOR (M2)
FOR J2-AXIS
J2 AXIS ARM
J2 AXIS UNIT
AC SERVO MOTOR (M1)
FOR J1-AXIS
Fig. 1 Mechanical unit configuration
—— 3 ——
J1 AXIS UNIT
1. CONFIGURATION
1.1 J1-AXIS
DRIVE
MECHANISM
MAINTENANCE
B-82135EN/01
Fig. 1.1 shows the J1-axis drive mechanism.
The rotation of the J1-axis motor (M1) fastened to the table is
input to the reducer through the center gear, and the output rotates
the table.
Motor (M1)
for J1-axis
Pipe
Pinion gear
Center gear
Table
J1-axis reducer
(Hollow shaft)
J1-axis base
Fig. 1.1 J1-axis drive mechanism
—— 4 ——
MAINTENANCE
B-82135EN/01
1.2 J2/J3-AXIS
DRIVE
MECHANISM
1. CONFIGURATION
Fig. 1.2 shows the J2/J3-axis drive mechanism.
Rotation of the J2-axis motor (M2) is directly fed to the reducer,
and the output moves the J2-axis arm.
Rotation of the J3-axis motor (M3) is directly fed to the reducer,
and the output moves the J3-axis arm via the Link1 and Link2.
J3-axis arm
J3-axis casing
J2-axis arm
J3-axis Link2
Moter (M2)
for J2-axis
Motor (M3)
for J3-axis
J2-axis reducer
J2-axis base
J3-axis Link1
J3-axis reducer
Fig. 1.2 J2/J3-axis drive mechanism
—— 5 ——
J3-axis Link1
1. CONFIGURATION
1.3 J4-AXIS
DRIVE
MECHANISM
MAINTENANCE
B-82135EN/01
Fig. 1.3 shows the J4-axis drive mechanism.
Rotation of the J4-axis motor (M4) is fed to the reducer via the
gear and drive shaft, and the output rotates the J4-axis (all of the
wrist unit).
Motor (M4) for J4-axis
Pinion gear
Drive shaft
Wrist unit
J4-axis reducer
Center gear
Fig. 1.3 J4-axis drive mechanism
—— 6 ——
B-82135EN/01
1.4 J5/J6-AXIS
DRIVE
MECHANISM
MAINTENANCE
1. CONFIGURATION
Fig. 1.4 shows the J5-axis/J6-axis drive mechanism.
The rotation of the J5-axis motor (M5) is input to the reducer via
the gear and drive shaft, and the output moves the J5-axis.
The rotation of the J6-axis motor (M6) is input to the reducer via
the gear anddrive shaft, and the output rotates the J6-axis (wrist
flange).
J6-axis pinion gear
Motor (M6) for J6-axis
J6-axis center gear
J6-axis reducer
J5-axis drive shaft
J6-axis drive shaft
J5-axis reducer
J5-axis center gear
Motor (M5) for J5-axis
J5-axis pinion gear
Fig. 1.4 J5/J6-axis drive mechanism
NOTE
All motors incorporate a brake that is applied when not
energized. These brakes are active at power-off and
emergency stop.
—— 7 ——
1. CONFIGURATION
1.5 MAJOR
COMPONENT
SPECIFICATI
ONS
MAINTENANCE
B-82135EN/01
Table. 1.5 (a) Motor
Motor
Specifications
Model
Axis
M1
A06B-0268B605#S000
α 30/4000is
J1
M2, M3
A06B-0272B605#S000
α 40/4000is
J2, J3
M4, M5, M6
A06B-0238B605#S000
α 12/4000is
J4, J5, J6
Table. 1.5 (b) Reducer
Axis
Specifications
J1
A97L-0218-0347#500C-30
J2
A97L-0218-0348#550F-253
J3
A97L-0218-0348#550F-253
J4
A97L-0218-0349#160E-57
J5
A97L-0218-0350#160E-129
J6
A97L-0218-0251#80E-121
Table. 1.5 (c) Wrist Unit
Specifications
A290-7327-T501
—— 8 ——
B-82135EN/01
2
MAINTENANCE
2. PREVENTIVE MAINTENANCE
2PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained by
performing the periodic maintenance procedures presented in this
chapter.
NOTE
The periodic maintenance procedures described in this
chapter assume that the FANUC robot is used for up to
3840 hours a year. When using the robot beyond this total
operating time, correct the maintenance frequencies
shown in this chapter by calculation in proportion to the
difference between the actual operating time and 3840
hours/year.
—— 9 ——
2. PREVENTIVE MAINTENANCE
2.1 DAILY
CHECKS
MAINTENANCE
B-82135EN/01
Clean each part, and visually check component parts for damage
before daily system operation. Check the following items as the
occasion demands.
1. Before turning on power
When air control set is combined
Item
Check
items
Check points
1
Air
pressure
Check air pressure using the pressure
gauge on the air regulator as shown in Fig.
2.1. If it does not meet the specified
pressure of 0.49 to 0.69 MPa (5-7kgf/cm2),
adjust it using the regulator pressure setting
handle.
2
Oiler oil
mist
quantity
Check the drop quantity during wrist or
hand motion. If it does not meet the
specified value (1 drop/10-20 sec), adjust it
using the oiler control knob. Under normal
usage the oiler becomes empty in about 10
to 20 days under normal operation.
3
Oiler oil
level
Check to see that the oiler level is within
the specified level shown in Fig. 2.1.
4
Leakage
from hose
Check the joints, tubes, etc. for leaks.
Repair leaks, or replace parts, as required.
1
Oil inlet
5
Pressure gauge
2
Adjusting knob
6
Regulator pressure setting handle
3
Lubricator mist amount check
7
Filter
4
Lubricator
Fig. 2.1 Air control set (option)
—— 10 ——
MAINTENANCE
B-82135EN/01
2. PREVENTIVE MAINTENANCE
2. After automatic operation
Item
Check items
Check points
1
Vibration, abnormal
noises, and motor
heating
Check whether the robot moves
along and about the axes
smoothly without unusual
vibration or sounds. Also check
whether the temparature of the
motors are excessively high.
2
Changing
repeatability
Check to see that the stop
positions of the robot has not
deviated from the previous stop
positions.
3
Peripheral devices
for proper operation
Check whether the peripheral
devices operate properly
according to commands from the
robot.
4
Brakes for each axis Check that the end effector drops
within 0.2 mm when the power is
cut.
—— 11 ——
2. PREVENTIVE MAINTENANCE
2.2 3-MONTH
CHECKS
MAINTENANCE
B-82135EN/01
1. Check the following items once every three months.
Additional inspection areas and times should be added to the
table according to the robot's working conditions,
environment, etc.
Item
Check items
Check points
1
Control unit cable
Check whether the cable
connected to the teach
pendant is unevenly twisted.
2
Ventilation portion of
control unit
If the ventilation portion of
the control unit is dusty, tum
off power and clean the unit.
2. First quarterly inspection
Check the following items at the first quarterly inspection, then
every year thereafter.
Item
Check items
Check points
1
Cables used in
mechanical unit
Check whether the jackets of
the mechanical unit cables
are damaged. Also check
whether the cables are
excessively bent or unevenly
twisted. Check that the
connectors of the motors and
connector panels are
securely engaged. See
Section 7.2.
2
Cleaning and checking
each part
Clean each part (remove
chips, etc.) and check
component parts for cracks
and flaws.
3
Further tightening
external main bolts
Further tighten the endeffecter mounting bolts and
external main bolts.
—— 12 ——
MAINTENANCE
B-82135EN/01
2.3 1-YEAR
CHECKS
2. PREVENTIVE MAINTENANCE
Check the following items once every year.
Item
Check items
Check points
1
Cables used in
mechanical unit
(See Section 2.2.)
2
Cleaning each parts and
inspection
(See Section 2.2.)
3
Tightness of major
external bolts
(See Section 2.2.)
—— 13 ——
2. PREVENTIVE MAINTENANCE
2.4 1.5-YEAR
CHECKS
MAINTENANCE
B-82135EN/01
Check the following item once every 1.5 year.
Item
1
Check items
Battery
—— 14 ——
Check points
Replace battery in the
mechanical unit.
Refer to Section 3.3.
MAINTENANCE
B-82135EN/01
2.5 3-YEAR
CHECKS
2. PREVENTIVE MAINTENANCE
Check the following items once every 3 years.
Item
1
Check items
Replacing grease of each
axis, reducer and gear
box
—— 15 ——
Check points
Refer to Section 3.1.
2. PREVENTIVE MAINTENANCE
2.6 MAINTEN
ANCE TOOLS
MAINTENANCE
B-82135EN/01
The following tools and instruments are required for the
maintenance procedures contained in this manual.
1. Measuring instruments
Accuracy/
Capacity
Instruments
Dial gauge
accuracy
1/100 mm
accuracy
Slide calipers
150 mm
capacity
Push/pull
tension gauge
98N (10 kgf)
accuracy
Applications
Measurement of
positioning and backlash
Measurement of backlash
2. Tools
Cross-point(+)screwdrivers :
sizes
Conventional(-)screwdrivers :
sizes
Box screw drivers :
Hexagonal wrench key sets (metric) :
Adjustable wrenches :
Pliers
Cutting pliers
Cutting nippers
Double hexagon offset wrench
Grease gun
Pliers for C-retaining ring
Torque wrench
Gear puller
Spanner :
T-shaped hexagonal wrench :
Large, medium, and small
Large, medium, and small
M6
M3 - M20
Medium and small sizes
30x32mm or 32x36mm
(Thickness : 14 mm or less
for stopping J41 gear
rotation)
M8 (Length : 270 mm or
more.
Used for wrist axis motor
connection)
M12 (Length: 300 mm or
more.
Used for J2 and J3 axis
motor connection)
3. Special Tools
A290-7324-X921 2PCS
(Guide pin (M12) for J1/J2/J3-axis reducer replacement) See Fig.
2.6 (a).
A290-7324-X922
(Spring pin striking tool for J1/J2/J3-axis reducer replacement)
—— 16 ——
B-82135EN/01
MAINTENANCE
2. PREVENTIVE MAINTENANCE
See Fig. 2.6 (b).
A290-7324-X923 2PCS
(Guide pin (M16) for J1/J2/J3-axis reducer replacement) See Fig.
2.6 (c).
A290-7324-X924
(For bearing installation in the J1-axis input gear) See Fig. 2.6 (d).
A290-7327-X910
(Robot hanging tool for J1-axis reducer replacement) See Fig. 2.6
(e).
A290-7321-X947
(For bearing installation in gear J41) See Fig. 2.6 (f).
A290-7327-X924
(For oil seal installation in the J2/J3-axis reducer) See Fig. 2.6 (g)
* For the tools of the robot sling during the J1-axis reducer replacement, consult our service representative.
4. Options (For securing the arm during J2 or J3-axis motor
replacement)
For changing the J2-axis operating range :
A05B-1327-J032
For changing the J3-axis operating range :
A05B-1327-J033
Fig. 2.6 (a) Guide pin (M12) for J1-axis reducer replacement
—— 17 ——
2. PREVENTIVE MAINTENANCE
1
MAINTENANCE
Knurling
Fig. 2.6 (b) Spring pin striking tool for J1-axis reducer replacement
Fig. 2.6 (c) Guide pin (M16) for J1-axis reducer replacement
Fig. 2.6 (d) For bearing installation in the J1-axis input gear
—— 18 ——
B-82135EN/01
B-82135EN/01
MAINTENANCE
2. PREVENTIVE MAINTENANCE
Fig. 2.6 (e) Robot hanging tool for J1-axis reducer replacement
Fig. 2.6 (f) For installing bearing on gear J41
—— 19 ——
2. PREVENTIVE MAINTENANCE
MAINTENANCE
Fig. 2.6 (g) For installing oil seal to the J2/J3-axis reducer
—— 20 ——
B-82135EN/01
B-82135EN/01
3
MAINTENANCE
3PERIODIC MAINTENANCE
—— 21 ——
3. PERIODIC MAINTENANCE
3. PERIODIC MAINTENANCE
3.1 REPLACING
GREASE OF
THE DRIVE
MECHANISM
MAINTENANCE
B-82135EN/01
Replace the wrist grease of the reducers of J1, J2, and J3 axes, and
the J4-axis gear box, every three years or 11,520 hours by using
the following procedures.
Table. 3.1 Grease for 3-year periodical replacement
Models
M-900iA/
350
Supply
position
Quantity
J1-axis
reducer
7000g
(8000ml)
J2-axis
reducer
3000g
(3400ml)
J3-axis
reducer
2700g
(3100ml)
J4-axis
gear box
1900g
(2180ml)
Wrist 1
3200g
(3680ml)
Wrist 2
800g
(920ml)
Grease name
Kyodo yushi VIGOGREASE
RE 0
Spec.: A98L-0040-0174
or
Kyodo yushi Moli white
RE No.00
Spec.: A98L-0040-0119
3.1.1 Grease
Replacement
Procedure for
the J1-Axis/J2Axis/J3-Axis
and J4-Axis
Gear Box
1. Move the robot to the greasing attitude described in Section
3.1.3.
2. Turn off the power.
3. Remove the seal bolt from the grease outlet.
4. Supply new grease until new grease is output from the grease
outlet.
5. Attach the seal bolt onto the grease outlet. When reusing the
seal bolt, be sure to seal the seal bolt with seal tape.
3.1.2 Grease
Replacement
Procedure for
the Wrist
1. Move the robot to the greasing attitude described in Section
3.1.3.
2. Turn off the power.
3. Remove the seal bolt from wrist grease outlet 1.
4. Supply new grease through the wrist grease inlet until new
grease is output from wrist grease outlet 1.
5. Attach the seal bolt onto wrist grease outlet 1. When reusing
the seal bolt, be sure to seal the seal bolt with seal tape.
6. Remove the seal bolt from wrist grease outlet 2.
7. Supply new grease through the wrist grease inlet until new
grease is output from wrist grease outlet 2.
8. Attach the seal bolt onto wrist grease outlet 2. When reusing
the seal bolt, be sure to seal the seal bolt with seal tape.
—— 22 ——
MAINTENANCE
B-82135EN/01
3. PERIODIC MAINTENANCE
NOTE
If greasing is performed incorrectly, the internal pressure
of the grease bath may suddenly increase, possibly
causing damage to the seal, which would in turn lead to
grease leakage and abnormal operation. When
performing greasing, therefore, observe the following
cautions.
1. Before starting to grease, open the grease outlet
(remove the plug or bolt from the grease outlet).
2. Supply grease slowly without applying excessive force,
using a manual pump.
3. Whenever possible, avoid using a compressed-air
pump, powered by the factory air supply. If the use of
a compressed air pump is unavoidable, restrict the
maximum greasing rate to 15 ml/s and the greasing
pressure to 7.35 MPa (75 kgf/cm2).
4. Use grease only of the specified type. Grease of a type
other than that specified may damage the reducer or
lead to other problems.
5. After greasing, confirm that no grease is leaking from
the grease outlet and that the grease bath is not
pressurized, then close the grease outlet.
6. To prevent accidents caused by slipping, completely
remove any excess grease from the floor or robot.
3.1.3 Attitude for
Greasing
For grease replacement or replenishment, use the attitudes
indicated below.
Table. 3.1.3 Attitudes for greasing
Attitude
J1
Attitude
J1
Attitude
J2
Attitude
J3
Attitude
J4
Attitude
J5
J1-axis reducer
Arbitrary
Arbitrary
Arbitrary
Arbitrary
Arbitrary
Arbitrary
J2-axis reducer
Arbitrary
0°
Arbitrary
Arbitrary
Arbitrary
Arbitrary
J3-axis reducer
Arbitrary
0°
0°
Arbitrary
Arbitrary
Arbitrary
J4-axis gear box
Arbitrary
Arbitrary
0°
Arbitrary
Arbitrary
Arbitrary
Wrist
Arbitrary
Arbitrary
0°
0°
0°
0°
Supply position
—— 23 ——
3. PERIODIC MAINTENANCE
MAINTENANCE
B-82135EN/01
Plug at the grease outlet
for the J2-axis reducer
Grease nipple at the grease
inlet for the J1-axis reducer
Plug at the grease outlet
for the J3-axis reducer
Grease nipple at the grease
inlet for the J3-axis reducer
Grease nipple at the grease
inlet for the J2-axis reducer
Grease nipple at the grease
outlet for the J1-axis reducer
[Right side]
[Left side]
Fig. 3.1.3 (a) Replacing grease of J1/J2-axis reducer
Grease outlet for the J3-axis
gear box M6x8 (seal bolt)
Grease nipple at the J3-axis gear box
grease inlet
[Left side]
Fig. 3.1.3 (b) Replacing grease of J3-axis gear box
—— 24 ——
MAINTENANCE
B-82135EN/01
3. PERIODIC MAINTENANCE
Wrist grease outlet 2
plug
[Left side]
Grease nipple at
the wrist grease inlet
Wrist grease outlet 1
plug
[Right side]
Fig. 3.1.3 (c) Replacing grease of wrist
—— 25 ——
3. PERIODIC MAINTENANCE
3.2 GREASING
POINTS
MAINTENANCE
B-82135EN/01
Fig. 3.2 shows the greasing points. If the robot is installed in a
severe environment, apply grease whenever necessary. If water
splashes on the robot, apply grease immediately.
Table 3.2 (b) shows the substitute table grease.
Apply grease every three years or 11,520 hours.
Table. 3.2 (a) Greasing points
Greasing
points
Bearing at
J2/J3-axis
connection
Grease
Amount
Way
SHELL
ALVANIA No. 2
(Spec: A97L0001-0179#2)
20 cc each
(2 locations)
Apply grease
from the grease
nipple.
Table. 3.2 (b) Substitutes for ALVANIA NO.2
MOBIL OIL
MOBILACKS GREASE NO.2
ESSO STANDARD
VICON NO.2
NIPPON OIL
MULTINOC 2
NIPPON OIL
EPNOC AP-2
IDEMITSU
KOHSAN
EPONEX GREASE NO.2
COSMO OIL
DYNAMAX NO.2
Grease nipple at the connection
bearing for J2/J3-axis
Grease nipple at the connection
bearing for J2/J3-axis
Fig. 3.2 Greasing Points
—— 26 ——
B-82135EN/01
3.3 REPLACING
THE
BATTERIES
MAINTENANCE
3. PERIODIC MAINTENANCE
The position data of each axis is preserved by the backup batteries.
The batteries need to be replaced every 1.5 year. Also use the
following procedure to replace when the backup battery voltage
drop alarm occurs.
1. Keep the power on. Press the EMERGENCY STOP button to
prohibit the robot motion.
NOTE
Replacing the batteries with the power supply turned off
causes all current position data to be lost.
Therefore, mastering will be required again.
2. Remove the battery case cap.
3. Take out the old batteries from the battery case.
4. Insert new batteries into the battery case.
Pay attention to the direction of batteries.
5. Close the battery case cap.
Battery case
Case cap
Battery
(1.5V size-D 4 pcs)
Fig. 3.3 Replacing Batteries
—— 27 ——
4. TROUBLESHOOTING
4
MAINTENANCE
4TROUBLESHOOTING
—— 28 ——
B-82135EN/01
B-82135EN/01
4.1 OVERVIEW
MAINTENANCE
4. TROUBLESHOOTING
The cause of a failure in the mechanical unit may be difficult to
localize, because failures can arise from many interrelated factors.
If you fail to take the correct measures, the failure may be
aggravated. So, it is necessary to analyze the symptoms of the
failure precisely so that the true cause can be found.
—— 29 ——
4. TROUBLESHOOTING
4.2 FAILURE
AND CAUSE
MAINTENANCE
B-82135EN/01
Table. 4.2 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. If you have to
replace components or make adjustments to repair the failure, see
Section 5, 6, and 8.
Table. 4.2 Failures and Causes
Symptom
Vibration
Noise
Description
Cause
Measure
- As the robot
operates, its base
plate lifts off the
floor plate.
- There is a gap
between the base
plate and the floor
plate.
- There is a crack in
the weld that fastens
the base plate to the
floor plate.
[Base plate and floor plate fastening]
- It is likely that the base plate is not
securely fastened to the floor plate
because of poor welding.
- If the base plate is not securely
fastened to the floor plate, it lifts as
the robot operates, allowing the base
and floor plates to strike each other
which, in turn, leads to vibration.
- Re-weld the base plate to the floor
plate.
- If the weld is not strong enough,
increase its width and length.
- The J1 base lifts off
the base plate as the
robot operates.
- There is a gap
between the J1 base
and base plate.
- A J1 base retaining
bolt is loose.
[J1 base fastening]
- It is likely that the robot J1 base is
not securely fastened to the base plate.
- Probable causes are a loose bolt, an
insufficient degree of surface flatness,
or foreign material caught between
the base plate and floor plate.
- If the robot is not securely fastened
to the base plate, the J1 base lifts the
base plate as the robot operates,
allowing the base and floor plates to
strike each other which, in turn, leads
to vibration.
- If a bolt is loose, apply loctite and
tighten it to the appropriate torque.
- Adjust the base plate surface
flatness to within the specified
tolerance.
- If there is any foreign matter
between the J1 base and base plate,
remove it.
- As the robot operates, the rack or
floor on which the robot is mounted
vibrates.
- Apply epoxy to the
floor surface and
reinstall the plate.
[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.
- Reinforce the rack or floor to make
it more rigid.
- If it is impossible to reinforce the
rack or floor, modify the robot
control program; doing so might
reduce the amount of vibration.
—— 30 ——
MAINTENANCE
B-82135EN/01
4. TROUBLESHOOTING
Table. 4.2 Failures and Causes
Symptom
Vibration
Noise
Description
Cause
Measure
- 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.
[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.
- 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).
—— 31 ——
4. TROUBLESHOOTING
MAINTENANCE
B-82135EN/01
Table. 4.2 Failures and Causes
Symptom
Vibration
Noise
Description
Cause
Measure
- Vibration was first
noticed after the
robot collided with
an object or the
robot was
overloaded for a
long period.
- The grease of the
vibrating axis has
not been exchanged
for a long period.
[Broken gear, bearing, or reducer]
- It is likely that collision or overload
applied an excessive force on the
drive mechanism, thus damaging the
gear tooth surface or rolling surface of
a bearing, or reducer.
- It is likely that prolonged use of the
robot while overloaded caused
fretting of the gear tooth surface or
rolling surface of a bearing, or reducer
due to resulting metal fatigue.
- It is likely that foreign matter caught
in a gear, bearing, or within a reducer
caused damage on the gear tooth
surface or rolling surface of the
bearing, or reducer.
- It is likely that, because the grease
has not been changed for a long
period, fretting occurred on the gear
tooth surface or rolling surface of a
bearing, or reducer due to metal
fatigue. These factors all geneate
cyclic vibration and noise.
- Operate one axis at a time to
determine which axis is vibrating.
- Find the source of the vibration
while referring to the drive
mechanism drawing of each axis
given in the related maintenance
manual.
- Remove the motor, and check
whether there are any fretting on a
gear tooth surface. If any fretting is
found, replace the gear.
Note) Even a small amount of
damage on a gear tooth surface can
generate a large amount of noise.
Therefore, it is necessary to check
each gear tooth surface carefully.
- Check whether any other gear in
the drive mechanism is abnormal. If
all the gears are found to be
satisfactory, the reducer must be
replaced.
- If there is foreign matter caught in
a gear, or if a gear tooth is missing,
replace the gear. Also, remove all
the grease from the gear box and
wash the inside of the gear box.
- After replacing the gear or reducer,
add an appropriate amount of grease.
- If nothing changes after a gear or
reducer is replaced, it is likely that a
bearing is damaged.
- 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.
—— 32 ——
MAINTENANCE
B-82135EN/01
4. TROUBLESHOOTING
Table. 4.2 Failures and Causes
Symptom
Vibration
Noise
Description
Cause
Measure
- 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 pulse coder develops a fault,
vibration might occur because
information about the motor position
cannot be transferred to the controller
accurately.
- If the motor becomes defective,
vibration might occur because the
motor cannot deliver its rated
performance.
- If a power line in a movable cable of
the mechanical section has an
intermittent break, vibration might
occur because the motor cannot
accurately respond to commands.
- If a pulse coder wire in a movable
part of the mechanical section has an
intermittent break, vibration might
occur because commands cannot be
sent to the motor accurately.
- If a connection cable between them
has an intermittent break, vibration
might occur.
- If the power source voltage drops
below the rating, vibration might
occur.
- If a robot control parameter is set to
an invalid value, vibration might
occur.
- Refer to the R-J3i MODEL B
Controller Maintenance Manual for
troubleshooting related to the
controller and amplifier.
- Replace the pulse coder for the
motor of the axis that is vibrating,
and check whether the vibration still
occurs.
- Also, replace the motor of the axis
that is vibrating, and check whether
vibration still occurs.
- 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.
- There is some
relationship
between the
vibration of the
robot and the
operation of a
machine near the
robot.
[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.
- Connect the grounding wire firmly
to ensure a reliable ground potential
and prevent extraneous electrical
noise.
—— 33 ——
4. TROUBLESHOOTING
MAINTENANCE
B-82135EN/01
Table. 4.2 Failures and Causes
Symptom
Rattling
Description
Cause
Measure
- While the robot is
not supplied with
power, pushing it
with the hand causes
part of the
mechanical unit to
wobble.
- There is a gap on
the mounting
surface of the
mechanical unit.
[Mechanical section coupling bolt]
- It is likely that overloading or a
collision has loosened a mounting
bolt in the robot mechanical section.
Check that the following bolts for
each axis are tight. If any of these
bolts is loose, apply loctite and
tighten it to the appropriate torque.
- Motor retaining bolt
- Reducer retaining bolt
- Reducer shaft retaining bolt
- Base retaining bolt
- Arm retaining bolt
- Casting retaining bolt
- End effecter retaining bolt
- Backlash is greater
than the tolerance
stated in the
applicable
maintenance
manual.
[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
without changing the grease has
caused the tooth surfaces of a gear and
the inside of the reducer to wear out,
resulting in an increase in the amount
of backlash.
- Operate one axis at a time to
determine which axis has the
increased backlash.
- Remove the motor, and check
whether any of its gears are broken.
If any gear is broken, replace it.
- Check whether any other gear of
the drive mechanism is damage. If
there is no damage gear, replace the
reducer.
- If the reducer is broken, or if a gear
tooth is missing, replace the relevant
component. Also, remove all the
grease from the gear box and wash
the inside of the gear box.
- After replacing the gear or reducer,
add an appropriate amount of grease.
- Using the robot within its
maximum rating prevents problems
with the drive mechanism.
- Regularly changing the grease with
a specified type can help prevent
problems.
—— 34 ——
MAINTENANCE
B-82135EN/01
4. TROUBLESHOOTING
Table. 4.2 Failures and Causes
Symptom
Motor
overheating
Description
Cause
Measure
- The ambient
temperature of the
installation location
increases, causing
the motor to
overheat.
- After a cover was
attached to the
motor, the motor
overheated.
- After the robot
control program or
the load was
changed, the motor
overheated.
[Ambient temperature]
- It is likely that a rise in the ambient
temperature or attaching the motor
cover prevented the motor from
releasing heat efficiently, thus leading
to overheating.
[Operating condition]
- It is likely that the robot was
operated with the maximum average
current exceeded.
The teach pendant can be used to
monitor the average current. Check
the average current when the robot
control program is running. The
allowable average current is
specified for the robot according to
its ambient temperature. Contact
FANUC for further information.
- Relaxing the robot control program
and conditions can reduce the
average current, thus preventing
overheating.
- Reducing the ambient
temperature is the most effective
means of preventing overheating.
- Having the surroundings of the
motor well ventilated enables the
motor to release heat efficiently,
thus preventing overheating. Using a
fan to direct air at the motor is also
effective.
- If there is a source of heat near the
motor, it is advisable to install
shielding to protect the motor from
heat radiation.
- 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.
- Input an appropriate parameter as
described in the manual.
- Symptom other
than stated above
[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.
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.
—— 35 ——
4. TROUBLESHOOTING
MAINTENANCE
B-82135EN/01
Table. 4.2 Failures and Causes
Symptom
Grease
leakage
Description
Cause
Measure
- Grease is leaking
from the mechanical
unit.
[Poor sealing]
- Probable causes are a crack in the
casting, a broken O-ring, a damaged
oil seal, or a loose seal bolt.
- A crack in a casting can occur due to
excessive force that might be caused
in collision.
- An O-ring can be damaged if it is
trapped or cut during disassembling
or re-assembling.
- An oil seal might be damaged if
extraneous dust scratches the lip of
the oil seal.
- A loose seal bolt or a plug might
allow grease to leak along the threads.
- Problems with the grease nipple or
threads.
- 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. Refer to the relevant
parts manual for detailed
descriptions of their replacement.
- Motor coupling section
- Reducer (case and shaft) coupling
section
- Wrist coupling section
- J3 arm coupling section
- Inside the wrist
- Oil seals are used in the locations
stated below. Refer to the relevant
parts manual for detailed
descriptions of their replacement.
- J1 axis cable pipe joint
- Inside the reducer
- Inside the wrist
- J2/J3-axis connecting section
- Seal bolts are used in the locations
stated below. Refer to the relevant
parts manual for detailed
descriptions of their replacement.
- J3-axis ring connecting section
- Grease drain outlet
Dropping axis
- An axis drops
because the brake
does not function.
- An axis drops
gradually when it
should be at rest.
[Brake drive relay and motor]
- It is likely that brake drive relay
contacts are stuck to each other to
keep the brake current flowing, thus
preventing the brake from operating
when the motor is deenergized.
- It is likely that the brake shoe has
worn out or the brake main body is
damaged, preventing the brake from
operating efficiently.
- It is likely that oil or grease has
entered the motor, causing the brake
to slip.
—— 36 ——
- Check whether the brake drive
relay contacts are stuck to each
other, as explained in the relevant
manual. If they are found to be stuck,
replace the relay.
- If the brake shoe is worn out, if the
brake main body is damaged, or if
oil or grease has entered the motor,
replace the motor.
MAINTENANCE
B-82135EN/01
4. TROUBLESHOOTING
Table. 4.2 Failures and Causes
Symptom
Description
Cause
Measure
Displacement
- The robot operates
at a point other than
the taught position.
- The repeatability is
not within the
tolerance.
[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.
- 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.
- Displacement
occurs only in a
specific peripheral
unit.
[Peripheral unit displacement]
- It is likely that an external force was
applied to the peripheral unit, thus
shifting its position relative to the
robot.
- Correct the setting of the peripheral
unit position.
- Correct the taught program.
- Displacement
occurred after a
parameter was
changed.
[Parameter]
-It is likely that the mastering data
was rewritten in such a way that the
robot origin was shifted.
- Re-enter the previous mastering
data, which is known to be correct.
- If correct mastering data is
unavailable, perform mastering
again.
—— 37 ——
4. TROUBLESHOOTING
MAINTENANCE
B-82135EN/01
4.3 BACKLASH
MEASURE
MENT
Measurement method
1. Maintain the robot in a specified posture. (See Table. 4.3 (a)
and Fig. 4.3 (b).)
2. Apply positive and negative loads to each axis as shown in Fig.
4.3 (a).
3. Measure the distance moved.
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.
Fig. 4.3 (a) Backlash Measurement Method
Backlash B is calculated using the following expression:
—— 38 ——
MAINTENANCE
B-82135EN/01
4. TROUBLESHOOTING
Measurement posture
and position
Table. 4.3 (a) Backlash Measurement Posture
Measured
axis
Posture
J1
Posture
J2
Posture
J3
Posture
J4
Posture
J5
Posture
J6
J1
Any angle
75°
0°
0°
0°
90°
J2
Any angle
0°
0°
-90°
90°
0°
J3
Any angle
42°
-90°
-90°
90°
90°
J4
Any angle
42°
-90°
-90°
90°
90°
J5
Any angle
0°
0°
-90°
90°
90°
J6
Any angle
0°
0°
0°
-90°
90°
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
⟨1⟩ J1 axis measurement posture
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
When measuring backlash, press the dial
indicator to the center of the workpiece
under test at right angles.
⟨2⟩ J2 axis measurement posture
⟨3⟩ J3 axis measurement posture
Fig. 4.3 (b) Backlash Measurement Posture (1/2)
—— 39 ——
4. TROUBLESHOOTING
MAINTENANCE
B-82135EN/01
When measuring backlash, press the dial
indicator to the center of the workpiece
under test at right angles.
⟨4⟩ J4 axis measuring posture
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
⟨5⟩ J5 axis measuring posture
When measuring backlash,
press the dial indicator to
the center of the workpiece
under test at right angles.
⟨6⟩ J6 axis measuring posture
Fig. 4.3 (b) Backlash Measurement Posture (2/2)
Permissible backlash
values
Table. 4.3 (c) Permissible Backlash Value
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.16
2.00
2.00
2.24
2.55
4.94
Displacement conversion (mm)
1.99
0.73
0.73
0.35
0.39
0.40
Distance between the rotation center
and dial indicator (mm)
3165
1250
1250
530
530
277
—— 40 ——
B-82135EN/01
5
MAINTENANCE
5. ADJUSTMENTS
5ADJUSTMENTS
Each part of the mechanical unit is carefully adjusted at the factory
before shipment. Therefore it is usually unnecessary for the
customer to make adjustments at the time of delivery. However,
after a long period of use or after parts are replaced, adjustments
may be required.
—— 41 ——
5. ADJUSTMENTS
5.1 AXIS LIMITS
SETUP
MAINTENANCE
B-82135EN/01
Axis limits define the motion range of the robot.
The operating range of the robot axes can be restricted because of :
• Work area limitations
• Tooling and fixture interference points
• Cable and hose lengths
There are three methods used to prevent the robot from going
beyond the necessary motion range.
These are
• Axis limit software settings (All axes)
• Axis limit hardstops ((J1, J2, J3-axis) optional)
• Axis limit switches ((J1, J2, J3-axis) optional)
NOTE
1. Changing the movable range of any axis affects the
operation range of the robot. To avoid trouble, carefully
consider a possible effect of the change to the movable
range of each axis in advance. Otherwise, it is likely
that an unexpected condition occurs; for example, an
alarm may occur in a previous taught position.
2. For the J1, J2, and J3 axes, do not count merely on
software-based limits to the movable range when
changing the movable range of the robot. Use
mechanical stoppers together so that damage to
peripheral equipment and injuries to human bodies can
be avoided. In this case, make the software-specified
limits match the limits based on the mechanical
stoppers.
3. Mechanical stoppers are physical obstacles. The robot
cannot move beyond them.
For the J1, J2, and J3 axes, it is possible to re-position
the mechanical stoppers.
For J5-axis, the mechanical stoppers are fixed.
For the J4 and J6 axes, only software-specified limits
are available.
4. For changing J2 and J3 axes interference angles, only
mechanical stoppers are available; a softwarespecified movable range cannot be changed.
5. Movable mechanical stoppers (J1, J2, and J3 axes)
are deformed in a collision to stop the robot. Once a
stopper is subject to a collision, it can no longer assure
its original strength and, therefore, may not stop the
robot. When this happens, replace it with a new one.
Upper Limits
Displays the upper limits of each axis, or the axis limits in a
positive direction.
Lower Limits
Displays the lower limits of each axis, or the axis limits in a
negative direction.
—— 42 ——
MAINTENANCE
B-82135EN/01
5.1.1 Zero Point
Position and
Motion Limit
5. ADJUSTMENTS
Zero point and software motion limit are provided for each
controlled axis. Exceeding the software motion limit of a
controlled axis is called overtravel (OT). Overtravel is detected at
both ends of the motion limit for each axis. The robot cannot
exceed the software motion limit unless there is a failure of the
system causing loss of zero point position or there is a system
error.
Fig. 5.1.1 (a) - Fig. 5.1.1 (g) show the zero point and motion limit,
LS detection position, and mechanical stopper position of each
axis.
Note)
The limit switch (LS) of J1-axis is an option.
Fig. 5.1.1 (a) J1-axis
Mechanical stopper
Note)
Mechanical stopper
The limit switch (LS) of J2-axis is an option.
Motion limit is restricted by the position of the J3-axis.
Fig. 5.1.1 (b) J2-axis
—— 43 ——
5. ADJUSTMENTS
MAINTENANCE
Mechanical stopper
Mechanical stopper
Note)
The limit switch (LS) of J3-axis is an option.
Motion limit is restricted by the position of the J2-axis.
Fig. 5.1.1 (c) J3-axis
—— 44 ——
B-82135EN/01
MAINTENANCE
B-82135EN/01
Mechanical stopper
In
te
rfe
re
5. ADJUSTMENTS
Mechanical stopper
nc
e
an
gl
e
24
J3-axis
Interference angle LS
J3-axis
Interference angle LS
Mechanical stopper
J2-axis
J2-axis
ce
Inter
n
re
rfe
te
In
Mechanical stopper
a
Interference angle LS
fere
nce
angl
ng
ea
nc
ere
erf
Int
e 24
le
Mechanical stopper
24
Interference angle LS
xis
J2-a
J3-axis
er
pp
ica
an
M
h
ec
to
ls
Motion limit is restricted
in the software by the J2-axis position.
Fig. 5.1.1 (d) J2/J3-axis interference angle
—— 45 ——
le
ng
24
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
Limited by software
Note)
OT and the mechanical stopper are not provided for J4-axis.
Fig. 5.1.1 (e) J4-axis
Fig. 5.1.1 (f) J5-axis
—— 46 ——
MAINTENANCE
B-82135EN/01
Limited by software
Note)
OT and mechanical stopper are not provided for J6-axis.
Fig. 5.1.1 (g) J6-axis
—— 47 ——
5. ADJUSTMENTS
5. ADJUSTMENTS
5.1.2 Software
Setting
MAINTENANCE
B-82135EN/01
Axis limit software settings are upper and lower motion degree
limitations. The limits can be set for all robot axes and will stop
robot motion if the robot is calibrated.
Procedure
Setting Up Axis Limits
Step
1.
2.
3.
4.
Press MENUS.
Select SYSTEM.
Press F1, [TYPE].
Select Axis Limits. You will see a screen similar to the
following.
NOTE
0 indicates the robot does not have these axes.
5. Move the cursor to the axis limit you want to set.
WARNING
Do not depend on J1, J2, and J3 axis limit software
settings to control the motion range of your robot. Use the
axis limit switches or hardstops also; otherwise injury to
personnel or damage to equipment could occur.
—— 48 ——
B-82135EN/01
MAINTENANCE
5. ADJUSTMENTS
6. Type the new value using the numeric keys on the teach
pendant.
7. Repeat Steps 5 through 6 until you are finished setting the axis
limits.
WARNING
You must turn off the controller and then turn it back on to
use the new information; otherwise injury to personnel or
damage to equipment could occur.
8. Turn off the controller and then turn it back on again so the new
information can be used.
—— 49 ——
5. ADJUSTMENTS
MAINTENANCE
5.1.3 Hard
Stopper and
Limit Switch
Setting
B-82135EN/01
For the J1-axis, J2-axis and J3-axis, it is possible to re-position
mechanical stoppers.
Change the position of the mechanical stoppers according to the
desired movable range.
The limit switch-based movable range can be changed by
changing the dog positions. The dog for the J1 axis is placed in the
same position as the mechanical stopper.
Item
J1-axis mechanical
stopper, limit switch
J2-axis mechanical
stopper
J2-axis limit switch
J3-axis (J2+J3)
mechanical stopper
Upper limit
Settable in steps of 7.5° degrees in a range of -135° to
+180° degrees
Lower limit
Settable in steps of 7.5° degrees in the range of -180° to
+135° degrees
Space between
the upper and
lower limits
A space of 45° degrees or more is required.
Upper limit
Settable in steps of 15° degrees in the range of -60° to +60°
degrees. A mechanical stopper is also provided at the
upper limit +75° degrees of the standard movable range.
Lower limit
Settable in steps of 15° degrees in the range of -60° to +60°
degrees. A mechanical stopper is also provided at the
lower limit -75° degrees of the standard movable range.
Space between
the upper and
lower limits
A space of 15° degrees or more is required.
Upper limit
Settable in steps of 15° degrees in the range of -60° to +60°
degrees. Also settable to the upper limit +75° degrees of
the standard movable range.
Lower limit
Settable in steps of 15° degrees in the range of -60° to +60°
degrees. Also settable to the lower limit -75° degrees of the
standard movable range.
Space between
the upper and
lower limits
A space of 15° degrees or more is required.
Upper limit
Settable in steps of 15° degrees in the range of -120° to
+75° degrees. A mechanical stopper is also provided at the
upper limit +90° degrees of the standard movable range.
Lower limit
Settable in steps of 15° degrees in the range of -120° to
+75° degrees. A mechanical stopper is also provided at the
lower limit -133.4° degrees of the standard movable range.
Space between
the upper and
lower limits
A space of 15° degrees or more is required.
—— 50 ——
MAINTENANCE
B-82135EN/01
5. ADJUSTMENTS
Item
J3-axis (J2+J3) limit
switch
Upper limit
Settable in steps of 15° degrees in the range of -120° to
+75° degrees. Also settable to the upper limit +90° degrees
of the standard movable range.
Lower limit
Settable in steps of 15° degrees in the range of -120° to
+75° degrees. Also settable to the lower limit -133.4°
degrees of the standard movable range.
Space between
the upper and
lower limits
A space of 15° degrees or more is required.
NOTE
If the newly set operation range does not include 0°, it is
necessary to change it by zero degree mastering so that
0° is included.
Securing hole 1
Securing hole 2
Securing hole 3
Securing hole 4
Securing hole 5
J1 stopper
When using the securing holes 2 and 4 of the J1 stopper
Note) This figure is drawn with the J1-axis viewed from
the top.
When using securing holes 1, 3, and 5 of the J1 stopper
Note) This figure is drawn with the J1-axis viewed from
the top.
Fig. 5.1.3 (a) Mechanical stopper change of J1-axis (option)
—— 51 ——
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
Note) Since the stoppers (A290-7327-X361 and A290-7327-X362) are integrated
with limit switch dogs, dogs (A290-7327-X363 and A290-7327-X364) are not
required when the stoppers and limit switches are both installed.
Front
Front
Mounting stoppers on the minus side
Mounting stoppers on the plus side
This figure is drawn with the J2-axis viewed from the left.
Fig. 5.1.3 (b) Mechanical stopper change of J2-axis (option)
Front
Front
Note) Since the stoppers (A290-7327-X361 and A290-7327-X362) are integrated
with limit switch dogs, dogs (A290-7327-X363 and A290-7327-X364) are not
required when the stoppers and limit switches are both installed.
Mounting stoppers on the minus side
Mounting stoppers on the plus side
This figure is drawn with the robot viewed from the right.
Fig. 5.1.3 (c) Mechanical stopper change of J3-axis (option)
—— 52 ——
MAINTENANCE
B-82135EN/01
5. ADJUSTMENTS
Note) This figure is drawn with the J1-axis viewed from the top.
Install them in the same positions as mechanical stoppers.
Fig. 5.1.3 (d) J1-axis dog (option) change
Front
Mounting dogs on the plus side
Front
Mounting dogs on the minus side
This figure is drawn with the J2-axis viewed from the left.
Fig. 5.1.3 (e) J2-axis dog (option) change
—— 53 ——
MAINTENANCE
B-82135EN/01
Front
Front
5. ADJUSTMENTS
Mounting dogs on the minus side
Mounting dogs on the plus side
This figure is drawn with the robot viewed from the right.
Fig. 5.1.3 (f) J3-axis dog (option) change
—— 54 ——
B-82135EN/01
5.2 ADJUSTING
LIMIT
SWITCH
(OPTION)
MAINTENANCE
5. ADJUSTMENTS
Axis limit switches are overtravel switches that, when tripped, cut
power to the servo motors and an operation is stopped. Overtravel
switches for J1-axis, J2-axis and J3-axis and J2/J3 interference angle are optional.
1. Set the $MOR_GRP.$CAL_DONE system parameter to
FALSE. This disables the motion limit specified by the
software. As a result, the operator can rotate the robot by a jog
feed which goes beyond the motion limit.
2. Loosen the following bolts.
Bolts secure the J1-axis:
Bolts secure the J2-axis:
Bolts secure the J3-axis:
two M8 x 12
two M4 x 25
two M12 x 20
two M6 x 10
two M12 x 20
two M6 x 10
Bolt secure the J2/J3
interference angle:
four M4 x 6
3. Move the limit switch so that the robot activates it at about 0.5
degrees before the stroke end.
Step on the dog, and position the limit switch in such a place
that only one of the step-on allowance indication lines at the tip
of the switch is hidden.
4. When the limit switch operates and detects overtravel (OT), the
robot stops, and an error message, "OVERTRAVEL", is
displayed. To restart the robot, hold on the SHIFT key and
press the RESET key. Then, while holding on the SHIFT key,
move the adjusting axis off the OT limit switch by jogging in
joint mode.
5. Check that the robot also activates the limit switch when the
robot is approx. 0.5 degrees from the opposite stroke end in the
same way as above. If the limit switch does not operate at the
position, adjust the position of the switch again.
6. Set the $MOR_GRP.$CAL_DONE system parameter to
TRUE.
7. Turn off the power, then turn it on again to restart the
controller.
—— 55 ——
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
(Adjusting horizontal direction)
(Adjusting vertical direction)
PT : Pre-travel (Moving before operation)
Over-travel (Moving over operation)
Note) This is the J1 base rear side from the top view.
Fig. 5.2 (a) Adjusting J1-axis limit switch (option)
(Center direction
for adjusting)
Pre-travel (Moving before operation)
Over-travel (Moving over operation)
(Tangential direction
for adjusting)
Fig. 5.2 (b) Adjusting J2-axis limit switch (option)
—— 56 ——
MAINTENANCE
B-82135EN/01
(Center direction
for adjusting)
(Tangential direction
for adjusting)
PT : Pre-travel (Moving before operation)
Over-travel (Moving over operation)
Fig. 5.2 (c) Adjusting J3-axis limit switch (option)
MAX
(PT)
m
1.6 m
m
.8 m
MIN 0
)
T
O
(
A
Detail A
2:1
M4X6
(Center direction for adjusting)
PT : Pre-travel (Moving before operation)
OT : Over-travel (Moving over operation)
Fig. 5.2 (d) Adjusting J2/J3-axis limit switch (option)
—— 57 ——
5. ADJUSTMENTS
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
5.3 MASTERING
Mastering is an operation performed to associate the angle of each
robot axis with the pulse count value supplied from the absolute
pulse coder connected to the corresponding axis motor. To be
specific, mastering is an operation for obtaining the pulse count
value corresponding to the zero position.
5.3.1 General
The current position of the robot is determined according to the
pulse count value supplied from the pulse coder on each axis.
Mastering is factory-performed. It is unnecessary to perform
mastering in daily operations.
However, mastering becomes necessary after:
• Motor replacement.
• Pulse coder replacement.
• Reducer replacement.
• Cable replacement.
• Batteries for pulse count backup in the mechanical unit have
gone dead.
NOTE
Robot data (including mastering data) and pulse coder
data are backed up by their respective backup batteries.
Data will be lost if the batteries go dead. Replace the
batteries in the control and mechanical units periodically.
An alarm will be issued to warn the user of a low battery
voltage.
Mastering method
Table. 5.3.1 Types of Mastering
Jig position mastering
This is performed using a mastering jig before the machine is shipped
from the factory.
Zero-position mastering
(eye mark mastering)
This is performed with all axes set at the 0-degree position.
A zero-position mark (eye mark) is attached to each robot axis.
This mastering is performed with all axes aligned to their respective eye
marks.
Quick mastering
This is performed at a user-specified position. The corresponding count
value is obtained from the rotation speed of the pulse coder connected to
the relevant motor and the rotation angle within one rotation. Simplified
mastering uses the fact that the absolute value of a rotation angle within
one rotation will not be lost.
Single-axis mastering
This is performed for one axis at a time. The mastering position for each
axis can be specified by the user. This is useful in performing mastering
on a specific axis.
Mastering data entry
Mastering data is entered directly.
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B-82135EN/01
MAINTENANCE
5. ADJUSTMENTS
Once mastering is performed, it is necessary to carry out
positioning, or calibration. Positioning is an operation in which the
control unit reads the current pulse count value to sense the current
position of the robot.
NOTE
If mastering is performed incorrectly, the robot may
behave unexpectedly. This is very dangerous. So, the
positioning screen is designed to appear only when the
$MASTER_ENB system variable is 1 or 2. After
performing positioning, press F5 [DONE] on the
positioning screen. The $MASTER_ENB system variable
is reset to 0 automatically, thus hiding the positioning
screen.
5.3.2 Resetting
Alarms and
Preparing for
Mastering
Before performing mastering because a motor is replaced, it is
necessary to release the relevant alarm and display the positioning
menu.
Alarm displayed
"Servo 062 BZAL" or "Servo 075 Pulse mismatch"
Procedure Preparing the
Robot for Mastering
Step
1. To reset the "Servo 062 BZAL" alarm, follow Steps 1 to 7.
1. Press MENUS.
2. Press NEXT and select [SYSTEM].
3. Press F1 [TYPE], and select [Variables] from the
menu.
4. Place the cursor on Master/Cal, then press the
execution key.
5. Place the cursor on $SPC_RESET, then press F4
[TRUE]. The message "TRUE" appears and disappears
immediately.
6. If the message "TRUE" did not appear, retry by
repeating the above step several times.
7. Switch the controller power off and on again.
2. To reset the "Servo 075 Pulse mismatch" alarm, follow Steps 1
to 3.
1. When the controller power is switched on again, the
message "Servo 075 Pulse mismatch" appears again.
2. Rotate the axis for which the message mentioned above
has appeared through 10 in either direction.
3. Press [FAULT RESET]. The alarm is reset.
—— 59 ——
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
3. Display the positioning menu by following Steps 1 to Steps 6.
1. Press MENUS.
2. Press NEXT and select [SYSTEM].
3. Press F1 [TYPE], and select [Variables] from the
menu.
4. Place the cursor on $MASTER_ENB, then key in "1"
and press [ENTER].
5. Press F1 [TYPE], and select [Master/Cal] from the
menu.
6. Select the desired mastering type from the [Master/Cal]
menu.
5.3.3 Mastering to
a Fixture
(Master
Position
Master)
Jig position mastering is performed using a mastering jig. This
mastering is carried out in the predetermined jig position.
Jig position mastering is accurate because a dedicated mastering
jig is used. Jig position mastering is factory-performed. It is
unnecessary to perform it in daily operations.
When mastering the robot, arrange the robot to meet the following
conditions.
• Make the robot mounting base horizontal within 1 mm.
• Remove the hand and other parts from the wrist.
• Set the robot in the condition protected from an external force.
1. Assembling the fixture base
Assemble the fixture base as shown in Fig. 5.3.3 (a).
See 2) for the mount of the dial gauges.
Dial gauges (6 pcs)
Bolt
(4 pcs)
Bolt
(2 pcs)
Plate
Bolt
Plate
(3 pcs)
pin (2 pcs)
Base
Adaptor plate
Fig. 5.3.3 (a) Assembling fixture base
—— 60 ——
Screw hole for eye bolt
(2 pcs)
MAINTENANCE
B-82135EN/01
5. ADJUSTMENTS
2. Mount the dial gauges.
Adjust the dial gauge to 3.00 mm using the calibration block,
and tighten it with M5 bolt as shown in Fig. 5.3.3 (b). (Do not
tighten the bolt too strongly or the dial indicator will be
broken.)
20mm
0
3
M5 Bolt
Calibration block
Fig. 5.3.3 (b) Mounting dial indicator
3. Mount the fixture on the J1-axis base with bolts as shown in
Fig. 5.3.3 (c).
pin (2 pcs)
Bolt
(2 pcs)
Front
J1-axis base
Fig. 5.3.3 (c) Mounting fixture base
—— 61 ——
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
4. Mounting the fixture to the wrist
Mount the fixture to the wrist flange as shown in Fig. 5.3.3 (d).
pin (2 pcs)
Bolt
(4 pcs)
Fig. 5.3.3 (d) Mounting fixture to wrist
Mastering
1.
2.
3.
4.
Press MENUS.
Press NEXT and select SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
5. Release brake control, and jog the robot into a posture for
mastering.
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B-82135EN/01
MAINTENANCE
5. ADJUSTMENTS
See the Fig. 5.3.3 (e) for the mastering posture.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM GROUP.SV_ OFF_ ENB[*]: FALSE
(for all axes)
After changing the system variables, switch the control
unit power off and on again.
6. Select Fixture Position Master.
7. Press F4, YES. Mastering will be performed automatically.
Alternatively, switch the power off and on again.
Switching the power on always causes positioning to be
performed.
8. After positioning is completed, press F5 [DONE].
NOTE
No check is made on the axis movable range during
mastering. Be very careful when running the robot.
Continuing axis movement may result in the mechanical
stopper being bumped.
—— 63 ——
5. ADJUSTMENTS
MAINTENANCE
MASTERING POSITION
(1) ISO FLANGE
AXIS
POSITION
J1
0
deg
J2
+50.039
deg
J3
-106.091
deg
J4
0
deg
J5
-73.909
deg
J6
0
deg
B-82135EN/01
J2
J1
0
deg
J2
+49.82
deg
J3
-104.835
deg
J4
0
deg
J5
-75.165
deg
J6
0
deg
J3
(2) INSULATED ISO FLANGE
AXIS
POSITION
J5
Fig. 5.3.3 (e) Mastering attitude
—— 64 ——
MAINTENANCE
B-82135EN/01
5.3.4 Zero Degree
Mastering
5. ADJUSTMENTS
Zero-position mastering (eye mark mastering) is performed with
all axes set at the 0-degree position. A zero-position mark (eye
mark) is attached to each robot axis. This mastering is performed
with all axes set at the 0-degree position using their respective eye
marks.
Zero-position mastering involves a visual check. It cannot be so
accurate.
It should be used only as a quick-fix method.
Procedure Mastering to
Zero Degrees
Step
1.
2.
3.
4.
Press MENUS.
Select NEXT and press SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
5. Release brake control, and jog the robot into a posture for
mastering.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM GROUP.SV_ OFF ENB[*]: FALSE (for all axes)
After changing the system variables, switch the control
unit power off and on again.
6. Select Zero Position Master.
7. Press F4, YES. Mastering will be performed automatically.
Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.
—— 65 ——
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
Table. 5.3.4 Attitude with position marks aligned
Axis
Position
J1-axis
0 deg
J2-axis
0 deg
J3-axis
0 deg
J4-axis
0 deg
J5-axis
0 deg
J6-axis
0 deg
—— 66 ——
MAINTENANCE
B-82135EN/01
5. ADJUSTMENTS
J6-axis
J3-axis
J5-axis
J2-axis
J4-axis
J1-axis
Vernier mark
Scribing mark
J1-axis
J4-axis
J2-axis
J2-axis
J6-axis
J5-axis
J3-axis
J3-axis (VIEW AA)
J6-axis (VIEW BB)
Fig. 5.3.4 (a) Zero degree position arrow mark for each axis
—— 67 ——
5. ADJUSTMENTS
5.3.5 Quick
Mastering
MAINTENANCE
B-82135EN/01
Quick mastering is performed at a user-specified position. The
corresponding count value is obtained from the rotation speed of
the pulse coder connected to the relevant motor and the rotation
angle within one rotation. Quick mastering uses the fact that the
absolute value of a rotation angle within one rotation will not be
lost.
Quick mastering is factory-performed at the position indicated in
Table. 5.3.4 Do not change the setting unless there is any problem.
If it is impossible to set the robot at the position mentioned above,
it is necessary to re-set the simplified mastering reference position
using the following method.
(It would be convenient to set up a marker that can work in place
of the eye mark.)
NOTE
1. Quick mastering can be used, if the pulse count value
is lost, for example, because a low voltage has been
detected on the backup battery for the pulse counter.
2. Quick mastering cannot be used, after the pulse coder
is replaced or after the mastering data is lost from the
robot control unit.
Procedure Recording the
Quick Master Reference
Position
Step
1. Select SYSTEM.
2. Select Master/Cal.
3. Release brake control, and jog the robot to the quick mastering
reference position.
—— 68 ——
B-82135EN/01
MAINTENANCE
5. ADJUSTMENTS
4. Move the cursor to SET QUICK MASTER REF and press
ENTER. Press F4, YES.
NOTE
If the robot has lost mastery due to mechanical
disassembly or repair, you cannot perform this procedure.
In this case, master to a fixture or master to zero degrees
to restore robot mastery.
Procedure Quick
Mastering
Step
1. Display the Master/Cal screen.
2. Release brake control, and jog the robot to the quick mastering
reference position.
3. Move the cursor to QUICK MASTER and press ENTER. Press
F4, YES.
Quick mastering data is memorized.
4. Move the cursor to CALIBRATE and press ENTER.
Calibration is executed.
Calibration is executed by power on again.
5. After completing the calibration, press F5 Done.
5.3.6 Single Axis
Mastering
Single axis mastering is performed for one axis at a time. The
mastering position for each axis can be specified by the user.
Single axis mastering can be used, if mastering data for a specific
axis is lost, for example, because a low voltage has been detected
on the pulse counter backup battery or because the pulse coder has
been replaced.
—— 69 ——
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
Table. 5.3.6 Items Set in Single Axis Mastering
Item
Description
Current position
(Actual axis)
The current position of the robot is
displayed for each axis in degree units.
Mastering
position
(Matra pos)
A mastering position is specified for an axis
to be subjected to single axis mastering. It
would be convenient to set to it to the 0°
position.
SEL
This item is set to 1 for an axis to be
subjected to single axis mastering. Usually,
it is 0.
ST
This item indicates whether single axis
mastering has been completed for the
corresponding axis. It cannot be changed
directly by the user. The value of the item is
reflected in $EACHMST_DON (1 to 9).
0 : Mastering data has been lost. Single axis
mastering is necessary.
1 : Mastering data has been lost.
(Mastering has been performed only for the
other interactive axes.)
Single axis mastering is necessary.
2 : Mastering has been completed.
Procedure Mastering a
Single Axis
Step
1. Select SYSTEM.
2. Select Master/Cal.
—— 70 ——
B-82135EN/01
MAINTENANCE
5. ADJUSTMENTS
3. Select 4, Single Axis Master. You will see a screen similar to
the following.
4. Move the cursor to the SEL column for the unmastered axis
and press the numeric key "1". Setting of SEL is available for
one or more axes.
5. Turn off brake control as required, then jog the robot to the
mastering position.
6. Enter axis data for the mastering position.
7. Press F5 [EXEC]. Mastering is performed. So, SEL is reset to
0, and ST is re-set to 2 or 1.
—— 71 ——
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
8. When single axis mastering is completed, press the previous
page key to resume the previous screen.
9. Select [6 CALIBRATE], then press F4 [YES]. Positioning is
performed.
Alternatively, switch the power off and on again. Positioning is
performed.
10.After positioning is completed, press F5 [DONE].
5.3.7 Mastering
Data Entry
This function enables mastering data values to be assigned directly
to a system variable.
It can be used if mastering data has been lost but the pulse count is
preserved.
—— 72 ——
B-82135EN/01
MAINTENANCE
5. ADJUSTMENTS
Mastering data entry
method
Step
1. Press MENUS, then press NEXT and select SYSTEM.
2. Press F1, [TYPE]. Select [Variables]. The system variable
screen appears.
3. Change the mastering data.
The mastering data is saved to the
$DMR_GRP.$MASTER_COUN system variable.
4. Select $DMR_GRP.
5. Select $MASTER_COUN, and enter the mastering data you
have recorded.
—— 73 ——
5. ADJUSTMENTS
MAINTENANCE
B-82135EN/01
6. Press the PREV key.
7. Set $MASTER_DONE to TRUE.
8. Display the positioning screen, and select [6 CALIBRATE],
then press F4 [YES].
9. After completing calibration, press F5 [DONE].
—— 74 ——
B-82135EN/01
6
MAINTENANCE
6. REPLACING PARTS
6REPLACING PARTS
This section describes the replacement procedures for the major
components of the mechanical section. When replacing
mechanical components, be sure to follow the respective
procedures.
See Section 8 for how to replace the cables and limit switches.
—— 75 ——
6. REPLACING PARTS
MAINTENANCE
6.1 NOTE FOR
PART
REPLACE
MENT
B-82135EN/01
Once motors, reducers, and gears are replaced, mastering becomes
necessary.
Perform mastering according to Section 5.3 after any of these
components are replaced.
Be very careful when carrying and assembling the heavy
components listed below.
Table. 6.1 Weight of the main parts
Weight
(approximate)
Component
Servo motors
M1
30kg
M2, M3
35kg
M4, M5, M6
15kg
Remarks
Reducers J1-axis
160kg
Reducers J2-axis
95kg
Reducers J3-axis
95kg
Reducers J4-axis
30kg
J2-axis table
90kg
J2-axis arm
150kg
Link
115kg
J3-axis arm
85kg
Wrist unit
110kg
J2-axis casing-wrist unit
365kg
J2-axis arm- wrist unit
515kg
Link is not included.
J2-axis base-wrist unit
1195kg
J1 motor and J2 table are not included.
Controller
180kg
J1 motor is not included.
In case of reusing sealbolts for M-900iA, observe following notes
strictly.
(If possible, change them to new sealbolts)
1. Apply LOCTITE No.242 when reusing sealbolts.
2. Notice the following 3 notes.
a. Remove excessive bits of sealant on the sealbolt.
b. The length of application is 2d (d : diameter of the bolt)
from the tip of the bolt, and spread it evenly around it.
c. Spread LOCTITE No.242 on the entire threaded
portion and rub the 2 bolts together in order to spread it
to the bottom of the groove.
—— 76 ——
B-82135EN/01
1
Loctite No. 242
MAINTENANCE
2
Threaded Portion
Fig. 6.1 Standard application of LOCTITE No.242
—— 77 ——
6. REPLACING PARTS
6. REPLACING PARTS
MAINTENANCE
B-82135EN/01
6.2 REPLACING
J1-AXIS
MOTOR (M1)
AND
REDUCER
1) Replacing J1-axis
motor (M1)
Remove
1. Turn off the power.
2. Remove the pulse coder connector cover (2).
(The cover turns together with the bolt, possibly causing
damage to the connector. Hold the cover to prevent it from
turning.)
3. Remove three connectors of the motor (1).
4. Remove four motor mounting bolts (4) and then remove the
washers (5).
5. Pull out the motor (1) from the 2 base vertically, while being
careful not to scratch the surface of the gear (7) teeth.
6. Remove the bolt (12) and washer (11) from the shaft of the
motor (1).
7. Pull off the gear (7) with bearing (9), C ring (8,10) from the
shaft of the motor (1).
8. Remove the nut (6) from the shaft.
Assembling
1. Polish the flange surface of the motor (1) using an oil stone.
2. Mount the nut (6) on the shaft of the motor (1).
3. Attach the gear (7) with bearing (9), C ring (8, 10) to the shaft
of the motor (1).
Note)
Before attaching the gear (7) to the motor (1), attach the
bearing (9) and the C rings (8, 10) to the gear (7) by using the
jig (A290-7324-X924). (See Fig. 6.2 (b))
4. Mount the bolt (12) and the washer (11) on the motor (1).
5. Mount the motor (1) on the 2 base vertically, while being
careful not to scratch the surface of the gear (7) teeth. When
mounting, make sure that the O-ring (13) is in the prescribed
place.
6. Attach the four motor mounting bolts (4) and washers (5).
7. Attach the three connectors to the motor (1).
8. Attach the pulse coder connector cover (2).
9. Perform mastering. (See the Section 5.3 for mastering.)
—— 78 ——
MAINTENANCE
B-82135EN/01
6. REPLACING PARTS
Fig. 6.2 (a) Replacing J1-axis motor (M1)
Parts list for replacing J1-axis motor
Name
Specifications
Q'ty
1
MOTOR
A06B-0268-B605#S000
1
2
COVER
A290-7324-X101
1
3
BOLT
A6-BA-8X12
1
4
BOLT
A6-BA-12X30
4
5
WASHER
A97L-0001-0823#M12H
4
6
NUT
A290-7324-X151
1
7
J1 GEAR
A290-7327-X221
1
8
C RING
A6-CJR-45
1
9
J1 BEARING1
A97L-0001-0195#09D000A
1
10
C RING
A6-CJR-45
1
11
WASHER
A97L-0001-0823#M8H
1
12
BOLT
A6-BA-8X20
1
13
O RING
JB-OR1A-G125
1
—— 79 ——
Loctite
Torque Nf m
(kgf m)
LT242
118 (12)
LT242
27.5 (2.8)
6. REPLACING PARTS
MAINTENANCE
B-82135EN/01
Fig. 6.2 (b) Bearing Presser
2) Replacing J1-axis
reducer
Remove
WARNING
The special tools listed below are required to replace the
J1-axis reducer. Be sure to prepare the special tools.
Name
Specification
Q'ty
Guide pin
A290-7324-X921
2
Punch
A290-7324-X922
1
Guide pin
A290-7324-X923
2
Adapter
A290-7327-X910
2
Bolt
A6-BA-16x35
12
Nut
A6-N1-20S
4
1. Remove loads such as the hand and workpiece from the wrist.
2. Ensure that the robot assumes the attitude as J1-axis = 0°, J2axis = -75°, J3-axis = +9°, J4-axis = option, J5-axis = 0°, J6axis = option, then turn off the power.
3. Remove the J1 motor (2) according to the previous item.
—— 80 ——
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MAINTENANCE
6. REPLACING PARTS
4. Detach the cable for connection between the control unit and
the robot, and remove the connector panel from the back of the
J1 base (18), then detach the connector.
5. Remove the cable clamp in the J1 base (18) and the cable clamp
on the table (6) so that the cable is disconnected from the J1
unit when the unit above the J2-axis base (1) is lifted up.
6. According to Fig. 6.2 (c), install the hanging jigs onto the robot
to enable the robot to be hung.
7. Remove the J2-axis base (1) fixing bolt and remove the unit
above the J2-axis base (1) from the table (6) by lifting it up with
a crane, with due attention to the cable.
8. Remove the cable fixing bolt (7) and the washer (8) and then
remove the table (6) and the J1 gear 2 (11) (with the bearing
(10)).
9. Remove the reducer mounting bolt (13) and washer (14), then
remove the reducer (16) from the J1 base (18).
The J1-axis reducer and J1 base are positioned with the spring
pin (15).
So, remove the J1-axis reducer by using the J1-axis reducer
removal tap.
Assembling
1. Polish the mounting surface of the J1 base reducer with an
oilstone.
2. After attaching the O-ring (17) to the reducer (16), mount the
reducer onto the J1 base by using the guide pin (A290-7324X921), and position the reducer by striking the spring pin (15)
with the punch (A290-7324-X922). Then, fasten the reducer
with the reducer mounting bolt (13) (Apply LT262 and specify
the terque.) and washer (14).
3. Apply a sealing agent to the shaft surface of the reducer
according to Section 6.6, "SEALANT APPLICATION" and
Fig. 6.2 (e).
4. Attach the O-ring (12).
5. Attach the J1 gear 2 (11) (with the bearing (10)).
6. Attach the table (6) and fix it with the table mounting bolt (7)
(with LT262 applied and the torque specified) and washer (8).
At this time, make sure that the oil seal (9) is placed in the
specified position and the lip does not curl up.
7. Place the unit above the J2-axis base onto the table (6) using
the guide pin (A290-7324-X923) with due attention to the
cables. Then, secure J2-axis base with the bolt.
8. Lay the cables neatly and secure the cable clamp in the J1 base
(18) and the cable clamp on the table (6).
9. Attach the connector to the connector panel on the back of the
J1 base (18) and secure it on the robot.
10.Fasten the J1 motor (2) according to the previous item.
11.Connect the cable for connection between the control unit and
the robot.
12.Apply grease (See Section 3.1, "REPLACING GREASE OF
—— 81 ——
6. REPLACING PARTS
MAINTENANCE
B-82135EN/01
THE DRIVE MECHANISM").
13.Perform mastering (See Section 5.3, "MASTERING").
Fig. 6.2 (c) Replacing J1-axis reducer
—— 82 ——
MAINTENANCE
B-82135EN/01
6. REPLACING PARTS
Fig. 6.2 (d) Replacing J1-axis reducer
Name
Specifications
Q'ty
1
J2 BASE
A290-7327-X301
1
2
MOTOR
Fig.6.2(a)
1
3
BOLT
Fig.6.2(a)
4
4
WASHER
Fig.6.2(a)
4
5
O RING
Fig.6.2(a)
1
6
TABLE
A290-7327-X202
1
7
BOLT
A6-BA-16X85
19
8
WASHER
A97L-0001-0823#M16H
19
—— 83 ——
Loctite
Torque Nf m(kgf m)
LT262
318.5 (32.5)
6. REPLACING PARTS
Name
MAINTENANCE
Specifications
B-82135EN/01
Q'ty
9
OIL SEAL
A98L-0040-0047#13516514
1
10
J1 BEARING2
A97L-0001-0192#3200000
1
11
J1 GEAR2
A290-7327-X222
1
12
O RING
A290-7327-X206
1
13
BOLT
A6-BA-16X95
24
14
WASHER
A97L-0001-0823#M12H
24
15
SPRING PIN
A6-PS-12X30
2
16
REDUCER
A97L-0218-0347#500C-30
1
17
O RING
JB-ORIA-G460
1
18
J1 BASE
A290-7327-X201
1
Loctite
Torque Nf m(kgf m)
LT262
128.4 (13.1)
Loctite 518 applying area
Fig. 6.2 (e) Replacing J1-axis reducer
—— 84 ——
B-82135EN/01
MAINTENANCE
6. REPLACING PARTS
6.3 REPLACING
J2-AXIS
MOTOR (M2)
AND
REDUCER
1) Replacing the J2-axis
motor (M2)
Remove
1. Place the robot in the posture shown in Fig. 6.3 (b), and hoist it
using a sling.
WARNING
When its J2-axis motor is removed, its weight, can cause
the J2-axis arm to move extensively unless the robot is in
a specified attitude, resulting in a very dangerous
situation. If it is impossible to keep the robot in a specified
attitude when its J2-axis motor is replaced, fasten the arm
so firmly that it will not move.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification can
be used to fasten the J2-axis arm. Before starting to
replace the motor, install the stopper and jog-feed the arm
to get it sufficiently close to the stopper.
2. Turn off the power.
3. Remove the four pulse coder connector cover (2). (The cover
turns together with the bolt, possibly causing damage to the
connector. Hold the cover to prevent it from turning.)
4. Detach the three connectors from the J2-axis motor (1).
5. Remove the four motor mounting seal bolts (4) and washers
(5).
6. Pull out the J2-axis motor (1) horizontally, while being careful
not to damage the surface of the gear teeth.
7. Remove the bolt (9) and washer (8), then dismount the input
gear (7), nut (6).
Assembling
1. Polish the flange surface of the J2-axis motor (1) using an oil
stone.
2. Mount the nut (6).
3. Mount and fasten the input gear (7) with bolt (8) and washer
(9).
4. Mount the J2-axis motor (1) horizontally, while being careful
not to damage the surface of the gear teeth. When mounting,
—— 85 ——
6. REPLACING PARTS
MAINTENANCE
5.
6.
7.
8.
9.
B-82135EN/01
make sure that the O-ring (10) is in the prescribed place.
Attach the four motor mounting seal bolts (4) and washers (5).
Attach the three connectors to the J2-axis motor (1).
Attach the pulse coder connector cover (2)
Apply grease.
Perform mastering.
Fig. 6.3 (a) Replacing J2-axis motor (M2)
Name
Specifications
Q'ty
1
MOTOR
A06B-0272-B605#S000
1
2
COVER
A290-7324-X101
1
3
BOLT
A6-BA-8x12
1
4
BOLT
A6-BA-12x25
4
5
WASHER
A97L-0001-0823#M12H
4
6
NUT
It is included in the spec. of INPUT GEAR A97L0218-0363#253
1
7
INPUT GEAR
A97L-0218-0363#253
1
8
WASHER
A30L-0001-0048#8M
1
9
BOLT
A6-BA-8x70
1
10
O RING
JB-OR1A-G125
1
—— 86 ——
Loctite
Torque Nf m
(kgf m)
LT242
118 (12)
LT242
27.5 (2.8)
MAINTENANCE
B-82135EN/01
6. REPLACING PARTS
Use the M10 threaded holes
and the eye bolts (one sling)
Use the M12 threaded holes
and the eye bolts (two slings)
Fig. 6.3 (b) J2-axis motor (M2) and reducer replacing posture
2) Replacing J2-axis
reducer
Disassembling
1. Detach all devices of the wrist flange and place the arm in the
posture shown in Fig. 6.3 (b) and hoist it using a sling.
2. Switch off the power.
3. Detach all of the cables connected to the motor for J2-axis.
4. Remove the J2 motor (1) according to the procedure described
in the previous item.
5. Remove only three sets of bolt (6) and washer (7) that are
separated each other and then insert the guide pins (A2907324-X923) instead.
After inserting the guide pins, remove the remaining bolts (6)
and washers (7).
—— 87 ——
6. REPLACING PARTS
MAINTENANCE
B-82135EN/01
6. Remove the bolt (8) and washer (9) and remove the bracket
(11).
Since the bracket (11) and J2-axis base (16) are positioned by
the spring pin (10), remove them using the bracket extract
threaded holes.
7. Remove only three sets of bolt (12) and washer (13) that are
separated each other and insert the guide pins (A290-7324X921) instead.
After inserting the guide pins, remove the remaining bolts (12)
and washers (13).
8. Remove the reducer (14).
Assembling
1. Attach the oil seal (5) to a new reducer (14) using the punching
jig (A290-7324-X924) and then polish the surface on which the
reducer (14) is mounted with oil stone.
2. Attach the O-ring (15) to the reducer (14), lift it up with a
crane, mount it on the J2 base (16) with the guide pins (A2907824-X921), and fix it with the bolts (12) (with LT262 applied
and the torque specified) and washers (13).
At this time, first insert bolts (12) and washers (13) into the
holes in which no guide pins (A290-7324-X921) are set (A2907324-X921) and tighten them. Next, remove the guide pins,
insert the bolts (12) and washers (13) instead, and tighten them.
3. Attach the bracket (11) to the reducer (14) with the guide pins
(A290-7824-X923) and secure it with the bolts (6) (with
LT262 applied and the torque specified) and washers (7).
At this time, first insert bolts (6) and washers (7) into the holes
in which no guide pins (A290-7324-X923) are set and tighten
them. Next, remove the guide pins, insert the bolts (6) and
washers (7) instead, and tighten them.
4. Align the phase between the bracket (11) and the J2-axis base
(16) with the crane and tighten the bolts (8) (with LT262
applied and the torque specified) and washers (9).
5. Mount the J2-axis motor (1) as described above.
6. Connect the cables leading to the J2-axis motor (1) and
optional cables.
7. Apply grease.
8. Perform mastering.
—— 88 ——
MAINTENANCE
B-82135EN/01
6. REPLACING PARTS
Fig. 6.3 (c) Replacing J2-axis reducer
Name
Specifications
Q’ty
1
MOTOR
Fig.6.3(a)
1
2
BOLT
Fig.6.3(a)
4
3
WASHER
Fig.6.3(a)
4
4
O RING
Fig.6.3(a)
1
5
OIL SEAL
A98L-0040-0047#05507812
1
6
BOLT
A6-BA-16 x 50
19
7
WASHER
A97L-0001-0823#M16H
19
8
BOLT
A6-BA-16 x 40
12
9
WASHER
A97L-0001-0823#M16H
12
10
SPRING PIN
A6-PS-12 x 30
2
11
BRACKET
A290-7327-X306
1
12
BOLT
A6-BA-12 x 65
30
13
WASHER
A97L-0001-0823#M12H
30
14
REDUCER
A97L-0218-0348#550F-253
1
15
O RING
JB-OR1A-G340
1
16
J2 BASE
A290-7327-X301
1
—— 89 ——
Loctite
Torque Nf m(kgf m)
LT262
319 (32.5)
LT262
319 (32.5)
LT262
128 (13.1)
6. REPLACING PARTS
MAINTENANCE
B-82135EN/01
6.4 REPLACING
J3-AXIS
MOTOR (M3)
AND
REDUCER
1) Replacing J3-axis
motor
Disassembling
1. Ensure that the robot assumes the attitude shown in Fig. 6.4 (b)
and hang the robot with a sling.
WARNING
It is very dangerous to remove J3-axis motor when the
robot is not set in the specified posture. This is because
the J3-axis arm may be greatly moved by gravity. If the
robot cannot be set in the specified posture during
replacement of the J3-axis motor, be sure to fix the arm
securely.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification can
be used to fasten the J3-axis arm. Before starting to
remove the motor, install the stopper, and jog-feed the
arm to get it sufficiently close to the stopper.
2. Turn off the power supply.
3. Remove the pulse coder connector cover (2). (At this time,
hold the cover so that it does not rotate. Otherwise, it rotates
together with the bolt, breaking the connector.)
4. Detach the three connectors from the J3-axis motor (1).
5. Remove the four motor mounting seal bolts (4) and washers
(5).
6. Pull out the J3-axis motor (1) horizontally, while being careful
not to damage the surface of the gear teeth.
7. Remove the bolt (9) and washer (8), then dismount the input
gear (7), nut (6).
Assembling
1. Polish the flange surface of the J3-axis motor (1) using an oil
stone.
2. Mount the nut (6).
3. Mount the input gear (7) and fasten with bolt (9) and washer
(8).
4. Mount the J3-axis motor (1) horizontally, while being careful
not to damage the surface of the gear teeth. When mounting,
make sure that the O-ring (10) is in the prescribed place.
—— 90 ——
MAINTENANCE
B-82135EN/01
5.
6.
7.
8.
9.
6. REPLACING PARTS
Attach the four motor mounting bolts (4) and washers (5).
Attach the three connectors to the J3-axis motor (1).
Attach the pulse coder connector cover (2).
Apply grease.
Perform mastering.
Fig. 6.4 (a) Replacing J3-axis motor (M3)
Name
Specifications
Q'ty
1
MOTOR
A06B-0272-B605#S000
1
2
COVER
A290-7324-X101
1
3
BOLT
A6-BA-8 x 12
1
4
BOLT
A6-BA-12 x 25
4
5
WASHER
A97L-0001-0823#M12H
4
6
NUT
It is included in the spec. of INPUT
GEAR
A97L-0218-0363#253
1
7
INPUT GEAR
A97L-0218-0363#253
1
8
WASHER
A30L-0001-0048#8M
1
9
BOLT
A6-BA-8 x 70
1
10
O RING
JB-OR1A-G125
1
—— 91 ——
Loctite
Torque Nf m(kgf m)
LT242
118 (12)
LT242
27.5 (2.8)
6. REPLACING PARTS
MAINTENANCE
B-82135EN/01
Use the M10 threaded holes
and the eye bolts (one sling)
Use the M12 threaded holes
and the eye bolts (two slings)
Fig. 6.4 (b) Changing posture of the J3-axis motor (M3) and reducer
2) Replacing J3-axis
reducer
Disassembling
1. Detach all devices of the wrist flange and control the attitude
as shown in Fig. 6.4 (b), then attach the sling to hang the unit.
2. Turn off the power supply.
3. Detach all cables leading to the J3-axis motor.
4. Remove the J3-axis motor (1) as described above.
5. Remove only three sets of bolt (6) and washer (7) that are
separated each other and insert the guide pins (A290-7324X923) instead.
After inserting the guide pins, remove the remaining bolts (6)
and washers (7).
6. Remove the bolts (8) and washers (9) and remove the bracket
(11).Since the bracket (11) and J2-axis base (16) are positioned
by the spring pin (10), remove them using the bracket extract
threaded holes.
7. Remove only three sets of bolt (12) and washer (18) that are
separated each other and insert the guide pins (A290-7324X921) instead.
After inserting the guide pins, remove the remaining bolts (12)
and washers (13).
—— 92 ——
B-82135EN/01
MAINTENANCE
6. REPLACING PARTS
8. Remove the reducer (14).
Assembling
1. Attach the oil seal (5) to a new reducer (14) using the punching
jig (A290-7324-X924) and then polish the surface on which the
reducer (14) is mounted with oil stone.
2. Attach the O-ring (15) to the reducer (14), lift it up with a
crane, mount it on the J2 base (16) with the guide pins (A2907824-X921), and fix it with the bolts (12) (with LT262 applied
and the torque specified) and washers (13).
At this time, first insert bolts (12) and washers (13) into the
holes in which no guide pins (A290-7324-X921) are set and
tighten them. Next, remove the guide pins, insert the bolts (12)
and washers (13) instead, and tighten them.
3. Attach the bracket (11) to the reducer (14) with the guide pins
(A290-7324-X923) and secure it with the bolts (6) (with
LT262 applied and the torque specified) and washers (7).
At this time, first insert bolts (6) and washers (7) into the holes
in which no guide pins (A290-7324-X923) are set and tighten
them. Next, remove the guide pins, insert the bolts (12) and
washers (13) instead, and tighten them.
4. Align the phase between the bracket (11) and the J2-axis base
(16) with the crane and tighten the bolts (8) (with LT262
applied and the torque specified) and washers (9).
5. Mount the J3-axis motor (1) as described above.
6. Attach the cables leading to the J3-axis motor (1) and optional
cables.
7. Apply grease.
8. Perform mastering.
Fig. 6.4 (c) Replacing the J3-axis reducer
—— 93 ——
6. REPLACING PARTS
MAINTENANCE
Name
Specifications
B-82135EN/01
Q'ty
1
MOTOR
Fig.6.4(a)
1
2
BOLT
Fig.6.4(a)
4
3
WASHER
Fig.6.4(a)
4
4
O RING
Fig.6.4(a)
1
5
OIL SEAL
A98L-0040-0047#05507812
1
6
BOLT
A6-BA-16 x 50
19
7
WASHER
A97L-0001-0823#M16H
19
8
BOLT
A6-BA-16 x 40
12
9
WASHER
A97L-0001-0823#M16H
12
10
SPRING PIN
A6-PS-12 x 30
2
11
BRACKET
A290-7327-X306
1
12
BOLT
A6-BA-12 x 65
30
13
WASHER
A97L-0001-0823#M12H
30
14
REDUCER
A97L-0218-0348#550F-253
1
15
O RING
JB-OR1A-G340
1
16
J2 BASE
A290-7327-X301
1
—— 94 ——
Loctite
Torque Nf m
(kgf m)
LT242
319 (32.5)
LT242
319 (32.5)
LT242
128 (13.1)
B-82135EN/01
MAINTENANCE
6. REPLACING PARTS
6.5 REPLACING
THE WRIST
AXIS
MOTORS
(M4, M5, AND
M6),
WRIST UNIT
AND J4 AXIS
REDUCER
1) Replacing the Wrist
Axis Motors (M4, M5, and
M6)
The following describes the procedure for replacing wrist axis
motors. For convenience, the procedure is provided for each of
three motors, but use only the procedure for the motor to be
replaced.
Disassembling
1. Place the wrist in a posture in which no load is applied to the
wrist axis.
2. Switch off the power.
3. Detach the three connectors from the motor (8) for J4-axis, the
motor (15) for J5-axis and the motor (1) for J6-axis.
4. Remove the motor mounting bolts (2) and washers (3).
5. Pull out the motor (8), (15) and (1), while being careful not to
damage the surface of the gear teeth.
6. In case of J4-axis motor (8), remove the nut (13) and washer
(12), and dismount the gear J41 (11) (with bearing (10) and C
ring (9)).
In case of J5-axis motor (15) remove the nut (18) and washer
(17), and dismount the gear J42 (16).
In case of J6-axis motor (1) remove the nut (6) and washer (5)
and dismount the gear J43 (4).
Assembling
1. Polish the flange surface of the motor (8), (15) and (1) using an
oil stone.
2. In case of J4 motor (8), mount gear J41 (11) (with bearing (10)
and C ring (9)) with the washer (12) and nut (13).
Note)Before attaching the gear J41 (11) to the motor (8), use
the jig A290-7321-X947 to attach the bearing (10) and C-ring
(9) to the gear J41 (11).
In case of J5-axis motor fasten the gear J42 (16) with the
washer (17) and nut (18).
In case of J6-axis motor (1) fasten the gear J43 (4) with the
washer (5) and nut (6).
3. Mount the motor (8), (15) and (1), while being careful not to
damage the surface of the gear teeth. When mounting, make
—— 95 ——
6. REPLACING PARTS
MAINTENANCE
4.
5.
6.
7.
B-82135EN/01
sure that the O-ring (14), (19) and (7) is in the prescribed place.
Also be sure to orient the motor (1) correctly.
Attach the motor mounting bolts (2) and washers (3).
Attach the three connectors to the motor (8), (15) and (1).
Apply grease.
Perform mastering.
NOTE
• When tightening the nut (15), hold the gear (13) with a
30x32mm or 32x36mm spanner (Thickness is 14mm
or less).
• To install a motor, an M8 T-shaped hexagonal wrench
not shorter than 270mm is required.
Fig. 6.5 (a) Replacing the Wrist Axis Motors (M4, M5, M6)
Name
Specifications
Q'ty
1
MOTOR
A06B-0238-B605#S000
1
2
BOLT
A6-BA-8 x 20
9
3
WASHER
A97L-0001-0823#M8H
9
4
GEAR J43
A290-7327-X425
1
5
WASHER
A6-WB-10S
1
6
NUT
A6-N1-10X1.25S-M-N1
1
7
O-RING
JB-OR1A-G105
1
8
MOTOR
A06B-0238-B605#S000
1
—— 96 ——
Loctite
Torque Nf m
(kgf m)
LT242
16.7 (1.7)
MAINTENANCE
B-82135EN/01
Name
Specifications
6. REPLACING PARTS
Q'ty
9
C-RING
A6-CJR-30
1
10
BEARING
A97L-0218-0428#0600000
1
11
GEAR J41
A290-7324-X421
1
12
WASHER
A6-WB-10S
1
13
NUT
A6-N1-10X1.25S-M-N1
1
14
O-RING
JB-OR1A-G105
1
15
MOTOR
A06B-0238-B605#S000
1
16
GEAR J42
A290-7324-X423
1
17
WASHER
A6-WB-10S
1
18
NUT
A6-N1-10X1.25S-M-N1
1
19
O-RING
JB-OR1A-G105
1
2) Replacing the wrist
unit and J4-axis reducer
Loctite
Torque Nf m
(kgf m)
LT242
16.7 (1.7)
LT242
16.7 (1.7)
Disassembling
1. Unload the wrist by removing the hand and any workpiece.
2. Remove the wrist unit mounting bolt (2) and washer (3), then
dismount the wrist unit.
3. Remove the reducer mounting bolt (5) and washer (6), then
dismount the reducer (7) from the J3 arm (9).
Assembling
1. Install the O-ring (8) onto the reducer (7).
2. Mount the reducer (7) to the J3 arm (9) and fasten with the
reducer mounting bolt (5) and washer (6).
3. Install the O-ring (4) in the groove of the end face of the
reducer.
4. Fasten the wrist unit with the wrist unit mounting bolt (2) and
washer (3).
5. Apply grease.
6. Perform mastering.
Fig. 6.5 (b) Replacing the Wrist Unit and J4 Axis Reducer
—— 97 ——
6. REPLACING PARTS
Name
MAINTENANCE
Specifications
B-82135EN/01
Q'ty
1
WRIST ASSY
A290-7327-T501
1
2
BOLT
A6-BA-10X35
20
3
WASHER
A97L-0001-0823#M10H
20
4
O-RING
JB-OR1A-G135
1
5
BOLT
A6-BA-123X45
12
6
WASHER
A97L-0001-0823#M12H
12
7
REDUCER
A97L-0218-0349#160E-57
1
8
O-RING
A98L-0040-0041#271
1
9
J3 ARM
A290-7327-X402
1
—— 98 ——
Loctite
Torque Nf m
(kgf m)
LT262
73.5 (7.5)
LT262
128.4 (13.1)
B-82135EN/01
MAINTENANCE
6. REPLACING PARTS
6.6 SEALANT
APPLICA
TION
Washing and degreasing
the surfaces to be sealed
1. After dismounting the reducer from the arm, apply releasant
(Loctite Gasket Remover) to the arm's surface from which the
reducer was dismounted, then wait until the sealant (Loctite
518) becomes softened (for about 10 minutes). Remove the
softened sealant from the surface using a spatula.
2. Blow air onto the surface to be sealed to remove dust from the
tapped holes.
3. Sufficiently degrease the reducer's surface to be sealed and the
arm's surface to be sealed, using a cloth dampened with
alcohol.
4. Polish the arm's surface to be sealed with an oil stone, and
degrease it with alcohol again.
NOTE
Oil may drip from the inside of the reducer. After
degreasing, make sure that no oil is dripping.
Applying sealant
5. Make sure that the reducer and the arm are dry (with no alcohol
remaining). If they are still wet with alcohol, wipe them dry.
6. Apply sealant (Loctite 518) to the surfaces.
NOTE
The portions to which sealant is to be applied vary from
one axis to another. See descriptions about reducer
replacement for the relevant axes for details.
Assembling
7. To prevent dust from sticking to the portions to which sealant
was applied, mount the reducer as quickly as possible after
sealant application. Be careful not to touch the applied sealant.
If sealant was wiped off, apply again.
8. After mounting the reducer, fasten it with bolts and washers
quickly so that the mated surfaces get closer.
NOTE
Do not grease the reducer before the sealant sets, as it
may allow grease to leak. Before greasing, wait for about
at least one hour after the reducer is mounted.
—— 99 ——
6. REPLACING PARTS
MAINTENANCE
B-82135EN/01
6.7 REPLACING
MOTOR
COVERS
(OPTION)
Replacing the J4-/J5-/J6axis motor cover
1. Remove the four M6x10 bolts and washers that fasten the
motor cover, and remove the two M12x20 bolts and washers
that fasten the plate, then remove the motor cover.
2. To mount the motor covers, reverse the above mounting
procedure steps. In this case, however, first attach the bolts, but
keep them loose so that the motor covers can be put in correct
place;
After the motor covers are positioned properly, tighten the
bolts.
J456 motor cover
Bolt M6X10 (4)
Plate
Bolt M12X20 (2)
Fig. 6.7 Replacing the J4-/J5-/J6-axis motor covers
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7
MAINTENANCE
7PIPING AND WIRING
—— 101 ——
7. PIPING AND WIRING
7. PIPING AND WIRING
7.1 PIPING
DIAGRAM
MAINTENANCE
B-82135EN/01
Fig. 7.1 shows the piping diagram of the mechanical unit.
Dual air line : Panel union x 2
Single air line : Panel union x 1
Rc1/2 Female (outlet)
Air tube x 2
Outside diameter : 12mm
Inside diameter : 8mm
Dual air line : Panel union x 2
Single air line : Panel union x 1
Rc1/2 Female (Inlet)
Fig. 7.1 Piping diagram
—— 102 ——
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7.2 WIRING
DIAGRAM
MAINTENANCE
7. PIPING AND WIRING
Fig 7.2 (a) shows the wiring diagram of the mechanical unit.
(M1~M6 pulse coder,
End-effector (RDI/RDO))
(M1~M6 power, brake)
(User cable (signal))
(User cable (power))
(Devicenet (signal))
(I/O unit model B)
(Load axis (pulse coder))
(Load axis (power, brake))
(Devicenet (power supply))
(J2/J3 intereference angle OT)
Fig. 7.2 (a) Wiring diagram
—— 103 ——
7. PIPING AND WIRING
MAINTENANCE
J2/J3 inter ference angle OT
Fig. 7.2 (b) Wiring block diagram
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MAINTENANCE
Fig. 7.2 (c) Connector locations
—— 105 ——
7. PIPING AND WIRING
8. REPLACING CABLES
8
MAINTENANCE
B-82135EN/01
8REPLACING CABLES
Replace the cables every four years. When the cable is broken or
damaged, or shows signs of wear, replace it according to this
chapter.
Precaution to be
observed when handling
the pulse coder cable
The pulse coder cable is provided with a marking tie, as shown
below, to warn against disconnecting the cable during
transportation, installation, or maintenance. If the cable with the
marking tie is disconnected, mastering must be performed again.
Therefore, do not disconnect the cable except when replacement
of the cable is necessary.
The J1-axis, J2-axis and J3-axis motors are provided with a pulse
coder connector cover, as shown in Fig. 8 (b), to protect the
connectors. Before removing the connectors for cable replacement
or other purposes, remove the covers. In this case, turning the bolt
may also turn the cover, possibly causing damage to the connector.
When removing the cover, hold it to prevent it from turning.
Fig. 8 (a) Marking tie
—— 106 ——
MAINTENANCE
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Detail A
Detail B
B
8. REPLACING CABLES
Pulse coder connector cover
Pulse coder connector cover
C
Pulse coder connector cover
Detail C
Fig. 8 (b) Pulse coder connector cover
—— 107 ——
8. REPLACING CABLES
8.1 CABLE
FORMING
MAINTENANCE
B-82135EN/01
When replacing cables, clamp the cable at the position specified in
Table. 8.1 (a) to Table. 8.1 (c) using a clamp or a nylon band.
Otherwise, cables are loosened or forcedly pulled to cause their
disconnection. Refer to the figures in Section 8.2 for the cable
clamp position not listed in the Table.
Table. 8.1 (a) CABLE CLAMP
Mark
Cable clamping position
—— 108 ——
Mark
Cable
No.
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MAINTENANCE
8. REPLACING CABLES
Table. 8.1 (b) CABLE CLAMP
Mark
Cable clamping position
—— 109 ——
Mark
Cable
No.
8. REPLACING CABLES
MAINTENANCE
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Table. 8.1 (c) CABLE CLAMP
Mark
Cable clamping position
—— 110 ——
Mark
Cable
No.
B-82135EN/01
MAINTENANCE
8. REPLACING CABLES
8.2 CABLE
REPLACE
MENT
This section describes a procedure for periodically replacing all
the (full-option) mechanical unit cables.
If you need to replace a specific cable (because, for example, it is
damaged), do so by referencing this section. See Section 7.2 for
the configuration of the mechanical unit cables.
Cable replacement makes it necessary to perform mastering.
Before attempting replacement, therefore, see Section 5.3.
Replacement procedure
1. Place all the robot axes in their 0-degree position, then set the
control unit power switch to off.
2. Detach, from the connector panel on the rear of the J1-axis
base, the cable leading to the control unit. Remove the
connector panel from the J1 base, then detach all the cable
tubes from the connector panel. When detaching a HARTING
connector, leave its housing on the connector panel; remove
the inserts together with the cable. If the housing is left on the
cable, the cable cannot be pulled out through the J1 axis piping
(Fig. 8.2 (a)).
3. When the robot has J1-axis limit switches (option), remove the
limit switch for the J1-axis from the plate of the J1-axis base,
and remove the terminal in the switch, then pull out the cable
from the cast through hole (Fig. 8.2 (b)).
4. Remove all connectors from the J1-axis through J6-axis
motors. For the precautions that must be taken, see "Precaution
to be observed when handling the pulse coder cable" at the
beginning of Chapter 8.
5. When the robot has the J2-axis, J3-axis, and interference angle
limit switches (option), remove the limit switches from the
mounting plate and remove the terminals in the J2-axis and J3axis limit switches (Fig. 8.2(c)).
6. When the robot has the DS/DP cable (option), remove the cable
from the J2-axis base connector panel (Fig. 8.2(d)).
7. Run the J2-axis and J3-axis motor and pulse coder cables, J2axis and J3-axis limit switch cables (option), and J2-axis DS/
DP cables (option) into the J2 base.
8. Remove the connector panel on the back of the J3-axis casing
(Fig. 8.2(e)).
9. Remove the lower plate 1 of the J3-axis casing (Fig. 8.2(e)).
10.Remove the plate 2 that covers the cable on the J2-axis arm
(Fig. 8.2(e)).
11.Remove the heat-shrink tubing that covers connectors and
remove the interference angle limit switch cable and the J1axis, J2-axis, and J3-axis limit switch cable connectors (Fig.
8.2(c)).
12.Remove the plate 3 that secures the cable on the back of the J2axis arm (Fig. 8.2(e)).
13.Remove the plate 4 that secures the cable on the top of the J2axis base (Fig. 8.2(f)).
14.Remove the plate 5 on the J2-axis base (Fig. 8.2(f)).
15.Remove the bolts that secures the plate 6 in the J1-axis base,
take out the plate, and remove the bolts of the plate that secures
—— 111 ——
8. REPLACING CABLES
MAINTENANCE
B-82135EN/01
the cable (Fig. 8.2(g)).
16.Pull out the cable upward from the pipe of the J1-axis.
This completes cable unit detachment from the robot.
17.When replacing a part of the cables, remove the clamp and
cover from the cable unit. Next, cut the cable tie securing the
cables, then detach the desired cable(s) (Fig. 8.2 (h)).
—— 112 ——
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MAINTENANCE
8. REPLACING CABLES
Install the cable according to the procedure below.
1. Before connecting the cable to the robot, fasten the cable at the
marked position with a cable tie, and install the clamp and
cable cover (Fig. 8.2 (h)).
2. Run the cable from the top of the J2-axis base to the back of J1axis base through the J1-axis pipe.
3. Secure the clamp on the plate 6 within the J1-axis base.
Securely bind the cable with the thick cable tie (T120I)
attached to the clamp and fix the plate on the J1-axis base (Fig.
8.2(g)).
4. Install the upper plate 5 of the J2-axis base (Fig. 8.2(f)).
5. Install the upper plate 4 of the J2-axis base, that fixes cables
(Fig. 8.2(f)).
6. Install the upper plate 3 of the J2-axis base, that fixes cables
(Fig. 8.2(e)).
7. Install the lower plate 1 of the J3-axis casing (Fig. 8.2(e)).
8. Install the connector panel on the back of J3-axis casing (Fig.
8.2(e)).
9. When the robot has the interference angle limit switch (option),
mount it on the mounting plate, run the cable through the
casting hole, connect it to the J1-axis, J2-axis, and J3-axis limit
switch cables with connectors, and cover the connector part
with heat-shrink tubing (Fig. 8.2(c)).
10.Lay the cables straight in the J2-axis arm to relieve mechanical
strain.
11.Install the plate 2 that covers the cable on the back of the J2axis arm (Fig. 8.2(e)).
12.Connect all connectors to the J1-axis, J2-axis, and J3-axis
motors. Attach the pulse coder connector covers to the J1-axis,
J2-axis, and J3-axis motors. For notes on this step, refer to
"Notes on Using Pulse Coder Cables" at the beginning in
Chapter 8. In addition, secure the J3-axis motor cable with a
cable tie considering the routing in the J2 base to prevent
interference during J3 linking.
13.When the robot has the DS/DP cable (option), secure the
connector on the connector panel and secure the connector
panel on the side of the J2 base (Fig. 8.2(d)).
14.When the robot has the J1-axis, J2-axis, and J3-axis limit
switches (option), connect the cable to the limit switch terminal
of each axis and mount the limit switch on the mounting plate
(Figs. 8.2(b) and (c)).
15.Connect the cable and tube to the connector panel on the back
of the J1-axis base. Connect the ground terminal to the J1-axis
base, connect battery terminal to the back of the battery box.
Secure the connector panel on the J1-axis base and connect the
cable for connection with the control unit to the connector
panel (Fig. 8.2(a)).
16.Turn on the power. If an alarm is issued at this time, release it
according to Section 5.3.
17.Perform mastering.
—— 113 ——
8. REPLACING CABLES
MAINTENANCE
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Terminals on the battery box rear surface
Terminals inside J1 axis base
Insert
J1 axis base
Cable in the controller side
Housing
Cable
Board
Fig. 8.2 (a) Replacing the cable
—— 114 ——
MAINTENANCE
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8. REPLACING CABLES
Terminals inside the limit switch
Nylon band
Limit switch
Plate
Plate
Casting hole
Cable
J1 axis base
Fig. 8.2 (b) Replacing the cable
—— 115 ——
8. REPLACING CABLES
MAINTENANCE
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Casting hole
Plate
Nylon clip
Limit switch
Plate
Interference angle limit switch cable
J2-axis arm
J1, J2, J3-axis limit switch cable
Replacing the interference angle
limit switch cable
Terminal connection
inside the limit switch
(Common to J2/J3-axis)
Limit switch
Plate
Plate
Limit
switch
Plate
J2-axis base
Plate
J2 base
Cable
Replacing J3-axis limit switch cable
Replacing J2-axis limit switch cable
Fig. 8.2 (c) Replacing the cable
—— 116 ——
MAINTENANCE
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Connector Panel
DS/DP cable (option)
Fig. 8.2 (d) Replacing the cable
—— 117 ——
8. REPLACING CABLES
8. REPLACING CABLES
MAINTENANCE
Connector panel
Plate 1
Plate 2
Plate 3
Fig. 8.2 (e) Replacing the cable
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MAINTENANCE
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8. REPLACING CABLES
Plate 4
Plate 5
J2-axis base
Fig. 8.2 (f) Replacing the cable
—— 119 ——
8. REPLACING CABLES
MAINTENANCE
B-82135EN/01
Clamp
J1-axis base
Fig. 8.2 (g) Replacing the cable
—— 120 ——
Plate 6
MAINTENANCE
B-82135EN/01
8. REPLACING CABLES
M4M, M4BK, M4P
M5M, M5BK, M5P
M6M, M6BK, M6P
Clamp
Clamp
J3 connector panel
Interference angle OT
Cornex cover
Plate
M1M, M1BK, M1P
M2M, M2BK, M2P
M3M, M3BK, M3P
J1OT, J2OT, J3OT
DP2, DS2
Clamp
Cornex cover
J1 connector panel
Fig. 8.2 (h) Replacing the cable
—— 121 ——
8. REPLACING CABLES
8.3 LIMIT
SWITCH
REPLACE
MENT
(OPTION)
MAINTENANCE
B-82135EN/01
This section explains how to replace limit switches.
See the cable replacement procedure for an explanation of how to
detach the limit switch cables.
NOTE
1. Before limit switch replacement, turn off the power to
the control unit.
2. After a limit switch is installed, be sure to adjust the limit
switch.
1. J1-axis limit switch replacement
1.
Remove the limit switch from the plate on the J1axis base.
2.
Cut the cable tie, and detach the cable from the
plate.
3.
Remove the terminal in the switch, and remove the
limit switch from the cable.
4.
Attach a new limit switch to the cable.
5.
Install the limit switch on the plate.
6.
Fasten the cable to the plate with a cable tie.
2. J2-axis limit switch replacement
1.
Cut the cable tie used to prevent the limit switch
cable from slackening.
2.
Remove the two plates used to fasten the limit
switch to the robot.
3.
Remove the limit switch from the plate.
4.
Remove the terminal in the switch, then remove the
limit switch from the cable.
5.
Attach a new limit switch to the cable.
6.
Install the limit switch on the plate.
7.
Install the two plates used for securing the limit
switch on the robot, on the robot.
8.
Secure the limit switch cable with a cable tie on the
robot to prevent slack.
NOTE
1. If the cable slackens, it may contact with robot
components, causing a break. Exercise care to
prevent the slackening cable being contact with robot
components.
2. At some sections on the cable where the clearance
between the cable and the casting is small, sponge
covers are wound for protection. When securing the
cable, make sure that the sponge covers are placed
near the casting.
9.
Adjust limit switches.
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MAINTENANCE
8. REPLACING CABLES
3. Interference limit switch replacement
1.
Remove the cover plate and cut the cable tie for
preventing the limit switch cable from slacking.
2.
Remove the nylon clip.
3.
Remove the limit switch from the plate.
4.
Remove the heat-shrink tubing, remove the
connector for connection with the J1-axis, J2-axis,
and J3-axis limit switch cables, and then remove the
limit switch.
5.
Install a new limit switch on the plate.
6.
Connect the cable to the J1-axis, J2-axis, and J3-axis
limit switch cable connectors through the casting
hole and cover the connectors with heat-shrink
tubing.
7.
Secure the cable with the nylon clip.
8.
Secure the limit switch cable with a cable tie on the
robot to prevent slack.
NOTE
1. If the cable slackens, it may contact with robot
components, causing a break. Exercise care to
prevent the slackening cable being contact with robot
components.
2. At some sections on the cable where the clearance
between the cable and the casting is small, sponge
covers are wound for protection. When securing the
cable, make sure that the sponge covers are placed
near the casting.
9.
10.
Fasten the cover plate.
Adjust limit switches.
—— 123 ——
8. REPLACING CABLES
MAINTENANCE
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Terminals inside the limit switch
Nylon band
Limit switch
Plate
Plate
Casting hole
Cable
J1-axis base
Fig. 8.3 (a) Replacing the J1-axis limit switch
—— 124 ——
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8. REPLACING CABLES
Casting hole
Plate
Nylon clip
Limit switch
Plate
Interference angle limit switch cable
J2-axis arm
J1, J2, J3-axis limit switch cable
Replacing the interference angle
limit switch cable
Terminal connection
inside the limit switch
(Common to J2/J3-axis)
Limit switch
Plate
Plate
Limit
switch
Plate
J2-axis base
Plate
J2 base
Cable
Replacing J3-axis limit switch cable
Replacing J2-axis limit switch cable
Fig. 8.3 (b) Replacing the J2/J3-axis interference angle limit switch
—— 125 ——
8. REPLACING CABLES
MAINTENANCE
—— 126 ——
B-82135EN/01
II. CONNECTION
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1
CONNECTION
1. ROBOT INTERFERENCE AREA
1ROBOT INTERFERENCE AREA
—— 129 ——
1. ROBOT INTERFERENCE AREA
1.1 External
Dimensions
CONNECTION
B-82135EN/01
Fig. 1 shows the external dimensions of the robot.
When installing peripheral devices, be careful to clear away any
objects that are in the robot´s motion path in normal operation.
Fig. 1.1 to Fig. 1.2 show the operation range of the robot.
J5-axis
rotation center
Motion range of
J5-axis rotation center
Motion interference area
of the J3-axis rear
Fig. 1.1 Mechanical unit operation area
—— 130 ——
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CONNECTION
1. ROBOT INTERFERENCE AREA
1.2 Operation
Area
Fig. 1.2 Mechanical unit operation area (1/2)
NOTE
A to D are equivalent to the point A to D of Fig. 1.1.
—— 131 ——
1. ROBOT INTERFERENCE AREA
Note)
CONNECTION
E to H are equivalent to the point E to H of Fig. 1.1.
Fig. 1.2 Mechanical unit operation area (2/2)
—— 132 ——
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2
CONNECTION
2. MECHANICAL COUPLING TO THE ROBOT
2MECHANICAL COUPLING TO THE ROBOT
—— 133 ——
CONNECTION
2. MECHANICAL COUPLING TO THE ROBOT
2.1 WRIST LOAD
CONDITIONS
B-82135EN/01
Fig. 2.1 contains diagrams that show the wrist load limits.
Apply a load within the region indicated in the graph.
ISO Flange
Insulated ISO flange
Fig. 2.1 Wrist Load Diagram
—— 134 ——
CONNECTION
B-82135EN/01
2.2 LOAD
CONDITIONS
ON J2-AXIS
BASE AND
J3-AXIS ARM
2. MECHANICAL COUPLING TO THE ROBOT
Following shows J2-axis base and J3-axis arm load conditions.
Table. 2.2 Installation condition of loads to be added
Installation site
Loades
Condition
J2 axis base
550kg
The center of gravity must lie within a
radius of 500 mm from the rotation
center of the J1 axis.
J3 axis arm
25kg
See Fig. 2.2 for the positional condition
of the center of gravity.
Allowable load on J3-axis arm is 25kg (Valve etc.)
Allowable load on J2-axis base is 550kg
(Transformer for welding etc.)
Fig. 2.2 Load Conditions on J2-Axis Base and J3-Axis Arm
—— 135 ——
2. MECHANICAL COUPLING TO THE ROBOT
2.3 MECHANICAL
COUPLING
OF END
EFFECTOR
TO WRIST
CONNECTION
B-82135EN/01
Fig. 2.3 (a) and (b) are the diagrams for installing end effectors on
the wrist. To fasten the end effector, first position it with two pin
holes at [D] using fitting [B] or [C], then lock it using screws at
[E]. Select screws and positioning pins of a length that matches the
depth of the tapped and pin holes. Fasten the bolt for fixing the end
effector with following torque: 73.5 +/- 3.4 Nm (750 +/- 35kg
fcm)
128.4+/-6.4Nm
2-φ12 H7 depth 12
Equally spaced
on φ200
circumference [D]
6-M12 depth 20
Equally spaced
on φ200
circumference [E]
Fig. 2.3 (a) End effector mounting face (ISO flange)
2-φ12 H7 depth 12
Equally spaced
on φ200
circumference [D]
6-M12 depth 12
Equally spaced
on φ200
circumference [E]
Fig. 2.3 (b) End effector mounting face (Insulated flange)
—— 136 ——
CONNECTION
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2.4 EQUIPMENT
MOUNTING
FACE
2. MECHANICAL COUPLING TO THE ROBOT
As shown in Fig. 2.4 tapped holes are provided to install
equipment to the robot.
CAUTION
Never perform additional machining operation such as
drilling or tapping on the robot body. This can seriously
affect the saftey and function of the robot.
NOTE
Note that the use of any threaded holes not shown in the
following figure could injure personnel or damage equipment.
6-M10 threaded hole depth 15
2-M12 threaded hole depth 18
(Both side)
4-M12 threaded hole depth 18
4-M12 threaded hole depth 18
3-M12 threaded hole depth 18
4-M12 threaded hole depth 18
2-M8 threaded hole depth 12
Threaded hole for attachment
of J3 OT switch
4-M12 threaded hole depth 18
(Both side)
12-M12 threaded hole depth 18
(Both side)
6-M16 threaded hole depth 25
(Both side)
(See section 11, 2.
For installation of
the forklift bracket)
Fig. 2.4 Equipment mounting surfaces
—— 137 ——
2. MECHANICAL COUPLING TO THE ROBOT
2.5 SETTING
SYSTEM
VARIABLES
FOR
MINIMUM
CYCLE
CONTROL
CONNECTION
B-82135EN/01
It is possible to make an effective use of the robot by setting
payload conditions such as the weight, moment, and inertia of the
hands and other objects attached to the wrist section, J3, and J2
axis arms of the robot appropriately.
• Wrist axis payload moment
Assign the following system variables with integers (in kgf-m)
representing the moment of the wrist section payload.
[Example of setting system variables]
$PARAM_GROUP.$AXISMOMENT[4]:
200 (J4 axis
payload moment)
$PARAM_GROUP.$AXISMOMENT[5]:
200 (J5 axis
payload moment)
$PARAM_GROUP.$AXISMOMENT[6]:
91 (J6 axis
payload moment)
• Wrist axis payload inertia
Assign the following system variables with integers (in kgf-cm-s2)
representing the inertia of the wrist arm payload.
[Example of setting system variables]
$PARAM_GROUP.$AXISINERTIA[4]:
2400 (J4 axis
payload inertia)
$PARAM_GROUP.$AXISINERTIA[5]:
2400 (J5 axis
payload inertia)
$PARAM_GROUP.$AXISINERTIA[6]:
1600 (J6 axis
payload inertia)
• Weight of the load on the J3 axis arm and J2 axis base
Assign the following system variables with integers (in kg)
representing the weight of the load on the J3 axis arm and J2 axis
base.
[Example of setting system variables]
$PARAM_GROUP.$ARM_LOAD[1]:
25 (J3 axis
arm load weight)
$PARAM_GROUP.$ARM_LOAD[2]:
550 (J2 axis
base load weight)
Motion performance
screens
The motion performance screens include the MOTION
PERFORMANCE screen, MOTION PAYLOAD SET screen, and
MOTION ARMLOAD SET screen.
These screens are used to specify payload information and
equipment information on the robot.
1. Click the [MENUS] key to display the screen menu.
2. Select "6 SYSTEM" from the next page.
3. Click F1 ([TYPE]).
—— 138 ——
B-82135EN/01
CONNECTION
2. MECHANICAL COUPLING TO THE ROBOT
4. Select "MOTION". The MOTION PERFORMANCE screen
appears.
5. Ten different pieces of payload information can be set using
condition No.1 to 10 on this screen. Place the cursor on one of
the numbers, and click F3 (DETAIL). The MOTION
PAYLOAD SET screen appears.
6. Set the payload, gravity center position, and inertia around the
gravity center on the MOTION PAYLOAD SET screen. The
X, Y, and Z directions displayed on this screen correspond to
the respective standard tool coordinates (with no tool
coordinate system set up). When values are entered, the
following message appears: "Path and Cycletime will change.
Set it?" Respond to the message with F4 ([YES]) or F5 ([NO]).
7. Clicking F3 ([NUMBER]) will bring you to the MOTION
PAYLOAD SET screen for another condition number. For a
multigroup system, clicking F2 ([GROUP]) will bring you to
the MOTION PAYLOAD SET screen for another group.
8. Click the previous page key to return to the MOTION
—— 139 ——
2. MECHANICAL COUPLING TO THE ROBOT
CONNECTION
B-82135EN/01
PERFORMANCE screen.
Click F5 ([SETIND]), and enter the desired payload setting
condition number.
9. On the MOTION PERFORMANCE screen, click F4
([ARMLOAD]) to display the MOTION ARMLOAD SET
screen.
10.Specify the weight of the load on the J2 axis base and J3 axis
arm as follows:
ARM LOAD AXIS #1 [kg]: Weight of the load on the J2 axis
base
ARM LOAD AXIS #3 [kg]: Weight of the load on the J3 axis
arm
The following message appears: "Path and Cycletime will
change. Set it?" Respond to the message with F4 ([YES]) or F5
([NO]). Once the arm payload is set up, the settings are
completed by switching the power off and on again.
—— 140 ——
CONNECTION
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2.6 AIR SUPPLY
(OPTION)
2. MECHANICAL COUPLING TO THE ROBOT
There is an air-pressure supply opening on the side of the J1-axis
base and the front of J3-axis casting. The connector is a Rc1/2
female (ISO). As coupling are not supplied, it will be necessary to
prepare couplings which suit to the hose size.
Dual air line : Panel union x 2
Single air line : Panel union x 1
Rc1/2 Female (outlet)
Air tube x 2
Outside diameter : 12mm
Inside diameter : 8mm
Dual air line : Panel union x 2
Single air line : Panel union x 1
Rc1/2 Female (Inlet)
Fig. 2.6 Air-pressure supply connection (option)
—— 141 ——
2. MECHANICAL COUPLING TO THE ROBOT
2.7 INTERFACE
FOR OPTION
CABLE
(OPTION)
CONNECTION
B-82135EN/01
Fig. 2.7 (a) and (b) show the position of the end effector interface.
End effector interface (RDI/RDO), I/O Unit-MODEL B interface,
user cable (signal lines, power lines) and devicenet cable (signal
lines, power lines) are prepared as options.
Fig. 2.7 (a) Interface for Optional cable (Option)
—— 142 ——
CONNECTION
B-82135EN/01
J1-axis base pauel (input)
J3-axis casing panel (output)
End effector
interface
(RDI/RDO)
2. MECHANICAL COUPLING TO THE ROBOT
Air supply
User cable (power) interface
User cable (signal)
interface
User cable (power) interface
User cable (signal) interface
Air supply
View A
View B
View C
With user cable (signal/power)
J1-axis base pauel (input)
J3-axis casing panel (output)
J2-axis casing panel (output)
Devicenet cable
(powere) interface
End effector
interface
(RDI/RDO)
Devicenet cable
(signal) interface
Devicenet cable
(powere) interface
Air supply
Devicenet cable
(signal) interface
Air supply
Devicenet cable
(signal) interface
Devicenet cable
(powere) interface
View A
View C
With devicenet cable (signal/power)
J3-axis casing panel (output)
End effector
interface
(RDI/RDO)
I/O unit MODEL B
interface
View D
J1-axis base pauel (input)
I/O unit MODEL B interface
User cable (power)
interface
User cable (power) interface
Air supply
Air supply
View A
View C
View B
With I/O unit MODEL B and user cable (power)
J3-axis casing panel (output)
J1-axis base pauel (input)
Additional axis motor
cable (power, breake) interface
Additional axis motor
cable (pulse coder)
interface
End effector
interface
(RDI/RDO)
Air supply
Additional axis motor
cable (pulse coder) interface
Air supply
View A
View B
View C
Additional axis motor
cable (power, breake) interface
With additional axis motor cable (pulse coder/power, break)
Fig. 2.7 (b) Interface for Optional cable (Option)
—— 143 ——
2. MECHANICAL COUPLING TO THE ROBOT
CONNECTION
B-82135EN/01
1. End effector interface (RDI/RDO) (option)
Fig. 2.7 (c) show pin layout for end effector interface (RDI/
RDO).
Prepared by user
Fig. 2.7 (c) Pin layout for end effector interface (RDI/RDO) (option)
—— 144 ——
B-82135EN/01
CONNECTION
2. MECHANICAL COUPLING TO THE ROBOT
2. I/O Unit-MODEL B interface (option)
Fig. 2.7 (d) show pin layout for I/O Unit-MODEL B interface.
Prepared by user
Fig. 2.7 (d) Pin layout for I/O Unit-MODEL B interface (option)
—— 145 ——
2. MECHANICAL COUPLING TO THE ROBOT
CONNECTION
B-82135EN/01
3. User cable (signal line) Interface (option)
Fig. 2.7 (e) shows pin layout for user cable (signal line)
interface.
The connector has a code pin for preventing improper
instertion.
For cables prepared by user, use this code pin.
Prepared by user
1
Prepared by user
4
User cable (signal cable) interface code pin position inlet
2
A first pin
5
User cable (signal cable) interface code pin position outlet
3
Code pin
Fig. 2.7 (e) Pin layout for user cable (signal line) interface and code pin layout (option)
—— 146 ——
B-82135EN/01
CONNECTION
2. MECHANICAL COUPLING TO THE ROBOT
4. User cable (power line) Interface (option)
Fig. 2.7 (f) shows pin layout for user cable (power line)
interface.
The connector has a code pin for preventing improper
instertion.
For cables prepared by user, use this code pin.
1
Prepared by user
4
User cable (signal cable) interface code pin position inlet
2
A first pin
5
User cable (signal cable) interface code pin position outlet
3
Code pin
Fig. 2.7 (f) Pin layout for user cable (power line) interface and code pin layout (option)
—— 147 ——
2. MECHANICAL COUPLING TO THE ROBOT
CONNECTION
B-82135EN/01
5. DeviceNet cable (signal line) interface (option)
Fig. 2.7 (g) shows pin layout for DeviceNet cable (signal line)
interface.
Fig. 2.7 (g) Pin layout for DeviceNet cable (signal line) interface (option)
6. DeviceNet cable (power line) interface (option)
Fig. 2.7 (h) shows pin layout for DeviceNet cable (power line)
interface.
Fig. 2.7 (h) Pin layout for DeviceNet cable (power line) interface (option)
—— 148 ——
B-82135EN/01
CONNECTION
2. MECHANICAL COUPLING TO THE ROBOT
7. Additional axis motor cable (pulse coder cable) interface
(optional)
Fig. 2.7 (i) shows the pin layout of the additional axis motor
cable (pulse coder cable) interface.
The connector has a code pin for preventing improper
insertion.
1
Code pin
3
Additional axis motor cable (pulse coder) interface and
code pin layout (inlet)
2
First pin
4
Additional axis motor cable (pulse coder) interface and
code pin layout (outlet)
Fig. 2.7 (i) Pin Layout of the Additional Axis Motor Cable (Pulse Coder Cable)
Interface and Layout Position of the Code Pin (Optional)
—— 149 ——
2. MECHANICAL COUPLING TO THE ROBOT
CONNECTION
B-82135EN/01
8. Additional axis motor cable (power and brake cables) interface
(optional)
Fig. 2.7 (j) shows the pin layout of the additional axis motor
cable (power and brake cables) interface.
The connector has a code pin for preventing improper
insertion.
1
Code pin
3
Additional axis motor cable (power, brake) interface and
code pin layout (inlet)
2
First pin
4
Additional axis motor cable (power, brake) interface and
code pin layout (outlet)
Fig. 2.7 (j) Pin Layout of the Additional Axis Motor Cable (Power and Brake Cables)
Interface and Layout Position of the Code Pin (Optional)
—— 150 ——
CONNECTION
B-82135EN/01
2. MECHANICAL COUPLING TO THE ROBOT
Connector Specifications
Table. 2.7 (a) Connector specifications (Mechanical unit side)
Cable
Input side
(J1 base)
Output side
(J3 casing)
RDI/RDO
--
JMWR2524F
DDK
I/O
--
JMWR2516F
DDK
Manu.
AS
(Signal)
Housing
Insert
Contact
Code pin
09 30 006 0301
09 16 024 3001 (Han 24DD M)
09 15 000 6103
09 30 000 9901
Housing
Insert
Contact
Code pin
09 30 006 0301
09 16 024 3101 (Han 24DD F)
09 15 000 6203
09 30 000 9901
Harting
AP
(Power)
Housing
Insert
Contact
Code pin
09 20 010 0301
09 21 015 3001 (Han 15D M)
09 15 000 6101
09 30 000 9901
Housing
Insert
Contact
Code pin
09 20 010 0301
09 21 015 3101 (Han 15D F)
09 15 000 6201
09 30 000 9901
Harting
Table. 2.7 (b) Connector specifications (User side)
Input side
(J1 base)
Cable
Output side
(J3 casing)
RDI/
RDO
--
JMSP2524M Streight (Appendix)
JMLP2524M Angle
I/O
--
JMSP2516M Streight (Appendix)
JMLP2516M Angle
AS
(Signal)
Side entry
Side entry
Side entry
Side entry
Top entry
Top entry
Top entry
Top entry
Hood
09 30 006
09 30 006
09 30 006
09 30 006
09 30 006
09 30 006
09 30 006
09 30 006
3101 (Han 24DD F)
Insert
09 16 024 3001 (Han 24DD M)
09 15 000 6204 appox. AWG 26-22
09 15 000 6203 appox. AWG 20
09 15 000 6205 appox. AWG 18
09 15 000 6202 appox. AWG 18
09 15 000 6201 appox. AWG 16
09 15 000 6206 appox. AWG 14
Contact
09 15 000 6104 appox. AWG 26-22
09 15 000 6103 appox. AWG 20
09 15 000 6105 appox. AWG 18
09 15 000 6102 appox. AWG 18
09 15 000 6101 appox. AWG 16
09 15 000 6106 appox. AWG 14
Clamp
Select
one
09 00 000 5083
09 00 000 5086
09 00 000 5090
09 00 000 5094 etc.
Clamp
09 00 000 5083
09 00 000 5086
09 00 000 5090
09 00 000 5094 etc.
Code
pin
09 30 000 9901
Code
pin
09 30 000 9901
Hood
09 30 006
09 30 006
09 30 006
09 30 006
09 30 006
09 30 006
09 30 006
09 30 006
Insert
09 16 024
Contact
1540
1541
0542
0543
1440
1441
0442
0443
—— 151 ——
1540
1541
0542
0543
1440
1441
0442
0443
Side entry
Side entry
Side entry
Side entry
Top entry
Top entry
Top entry
Top entry
CONNECTION
2. MECHANICAL COUPLING TO THE ROBOT
B-82135EN/01
Table. 2.7 (b) Connector specifications (User side) (continued)
Input side
(J1 base)
Cable
AP
(power)
Output side
(J3 casing)
Hood
09 20 010
09 20 010
09 20 010
09 20 010
09 20 010
09 20 010
09 21 015 3101 (Han 15D F)
Insert
09 21 015 3001 (Han 15D M)
Contact
Select
one
09 15 000 6204 appox. AWG 26-22
09 15 000 6203 appox. AWG 20
09 15 000 6205 appox. AWG 18
09 15 000 6202 appox. AWG 18
09 15 000 6201 appox. AWG 16
09 15 000 6206 appox. AWG 14
Contact
09 15 000
09 15 000
09 15 000
09 15 000
09 15 000
09 15 000
Clamp
Select
one
09 00 000 5083
09 00 000 5086
09 00 000 5090
09 00 000 5094 etc
Clamp
09 00 000 5083
09 00 000 5086
09 00 000 5090
09 00 000 5094 etc
Code
pin
09 30 000 9901
Code
pin
09 30 000 9901
Hood
Select
one
09 20 010
09 20 010
09 20 010
09 20 010
09 20 010
09 20 010
Insert
1541 Side entry
0540 Side entry
0541 Side entry
1440 Top entry
0440 Top entry
0441 Top entry
1541 Side entry
0540 Side entry
0541 Side entry
1440 Top entry
0440 Top entry
0441 Top entry
6104 appox. AWG 26-22
6103 appox. AWG 20
6105 appox. AWG 18
6102 appox. AWG 18
6101 appox. AWG 16
6106 appox. AWG 14
NOTE
For details, such as the dimensions, of the parts listed
above, refer to the related catalogs offered by the
respective manufacturers, or contact FANUC.
Table. 2.7 (c) Connector specifications (DeviceNet cable) (Mechanical unit side)
Cable
name
Input side
(J1-axis base)
Manu.
Output side
(J2-axis base)
Manu.
Output side
(J3-axis casing)
Manu.
DS
(signal
line)
84854-9101
MOLEX
JAPAN
CO., LTD.
84854-9100
MOLEX
JAPAN
CO.,
LTD.
84854-9100
MOLEX
JAPAN
CO.,
LTD.
DP
(power
line)
Housing
Insert
Contact
HARTING
Electronic
Co., Ltd.
84854-9102
MOLEX
JAPAN
CO.,
LTD.
84854-9102
MOLEX
JAPAN
CO.,
LTD.
09 30 006 0301
(Han 6E)
09 32 010 3001
(Han 10EE M)
09 33 000 6104
—— 152 ——
CONNECTION
B-82135EN/01
2. MECHANICAL COUPLING TO THE ROBOT
Table. 2.7 (d) Connector specifications (DeviceNet cable, on the user equipment side)
Cable
name
Input side
(J1-axis base)
Manu.
Output side
(J2-axis base)
Output side
(J3-axis base)
DS
(signal
line)
MINI connector for use on the device net, 5-pin,
female
MOLEX
JAPAN
CO., LTD
MINI connector
for use on the
device net,
5-pin, male
MINI connector
for use on the
device net,
5-pin, male
DP
(power
line)
Hood.
Select just one.
09 30 006 1540 (Han 6E) Side entry
09 30 006 1541 Side entry
09 30 006 0542 Side entry
09 30 006 0543 Side entry
09 30 006 1440 Top entry
09 30 006 1441 Top entry
09 30 006 0442 Top entry
09 30 0060 0443 Top entry
HARTING
Electronic
Co., Ltd.
MINI connector
for use on the
device net ,
4-pin, male
MINI connector
for use on the
device net,
4-pin, male
Insert
09 32 010 3101 (Han 10 EE F)
Contact
09 33 000
09 33 000
09 33 000
09 33 000
09 33 000
09 33 000
Clamp.
Select just one.
09 00 000 5083
09 00 000 5086
09 00 000 5090
09 00 000 5094
Many other types are available.
6220
6214
6205
6204
6202
6207
AWG 20
AWG 18
AWG 18
AWG 16
AWG 14
AWG 12
Table. 2.7 (e) Connector specifications (Additional axis motor cable, Mechanical unit side)
Cable
Input side (J1-axis base)
Output side (J2-axis base)
Manu.
ARP
(pulse
coder
line)
Housing
Insert
Contact
Code pin
09 30 006 0301
09 16 024 3001 (Han 24DD M)
09 15 000 6103
09 30 000 9901
Housing
Insert
Contact
Code pin
09 30 006 0301
09 16 024 3101 (Han 24DD F)
09 15 000 6203
09 30 000 9901
Harting
AP
(Power
brake
line)
Housing
Insert
Contact
Code pin
09 20 010 0301
09 21 015 3001 (Han 15D M)
09 15 000 6101
09 30 000 9901
Housing
Insert
Contact
Code pin
09 20 010 0301
09 21 015 3101 (Han 15D F)
09 15 000 6203
09 30 000 9901
Harting
—— 153 ——
3. TRANSPORTATION AND INSTALLATION
3
CONNECTION
3TRANSPORTATION AND INSTALLATION
—— 154 ——
B-82135EN/01
B-82135EN/01
3.1 TRANSPORTA
TION
CONNECTION
3. TRANSPORTATION AND INSTALLATION
1. Transportation using a crane
The robot can be transported by lifting it. When transporting
the robot, be sure to change the attitude of the robot to that
shown in Fig. 3.1 (a) and lift by attaching slings to the four
M20 eyebolts.
NOTE
When lifting the robot, take notice so that the motor,
connectors, or cables of the robot are not scratched by
slings.
2. Transportation using a forklift
The robots can also be transported using a forklift (refer to Fig.
3.1 (b)). Transport materials are available as an option.
—— 155 ——
3. TRANSPORTATION AND INSTALLATION
CONNECTION
B-82135EN/01
Crane capacity min 3 ton
Sling capacity min 1.0 ton/sling
Center of gravity
Center of gravity
Note) 1 Robot mechanical unit weight 1720kg
2 Eyebolts complied with JISB 1168.
3 Quantity eyebolt 4
sling 4
4 Do not ship with the tool exceeds the allowable load.
5 Do not lift robot with a base plate attached.
Eyebolt (M20)
Install to the out taps
Spreader bar
ROBOT POSTURE
ON TRANSPORTATION
Fig. 3.1 (a) Transportation using a crane
—— 156 ——
CONNECTION
B-82135EN/01
3. TRANSPORTATION AND INSTALLATION
ROBOT POSTURE
ON TRANSPORTATION
Note) 1 Robot mechanical unit weight 1720kg
2 Eyebolts complied with JISB 1168.
3 Quantity sling
eyebolt
4 4
sling 4
4 Do not ship with heavy tooling.
5 Do not lift robot with a base plate attached.
Center of gravity
Center of gravity
Fork lift
Capacity : 3 ton or more
Fig. 3.1 (b) Transportation using a forklift
—— 157 ——
3. TRANSPORTATION AND INSTALLATION
CONNECTION
M20 THROUGH
When the eyebolts are used, use the threaded holes.
M20 THROUGH
When the eyebolts are used, use the threaded holes.
Fig. 3.1 (c) Eyebolt installation location
—— 158 ——
B-82135EN/01
B-82135EN/01
CONNECTION
3. TRANSPORTATION AND INSTALLATION
6-M16 threaded hole depth 25
(Both side)
Fig. 3.1 (d) Transport equipment installation location
—— 159 ——
3. TRANSPORTATION AND INSTALLATION
B-82135EN/01
Fig. 3.2 (a) shows the robot base dimensions. Fig. 3.2 (b) shows
actual examples of robot installations.
In Fig. 3.2 (b), the floor plate is imbedded in concrete and fastened
with twelve M20 (strength classification 4.8) chemical anchors.
Also fasten the base plate to the robot base using eight M20x60
bolts (strength classification 12.9). Next, position the robot, and
weld the base plate to the floor plate. (Foot length is 10 to 15mm.)
(The base plate is prepared as an option.)
Avoid placing any object in front of the robot on the mounting
surface to facilitate the installation of the mastering fixture, as
shown in Fig. 3.2 (a). (the shaded portion)
For fixing robot
8-φ24 through
φ38 facing depth 5
(mounting face)
(mounting face)
Fig. 3.2 (c) and Table. 3.2 show the force and moment applied to
the base plate at the time of emergency stop.
Rofation
center
of J1-axis
(mounting face)
3.2 INSTALLA
TION
CONNECTION
For eyebolt braket
8-M20 through
Fig. 3.2 (a) Dimensions of the robot base
—— 160 ——
CONNECTION
B-82135EN/01
3. TRANSPORTATION AND INSTALLATION
12-∅24
8-M20
Front
Base plate
Welding part
Welding after positioning
4.8
Base plates
Floor plate
Note) Bury the floor plate in concrete.
Fig. 3.2 (b) Actual installation example
—— 161 ——
3. TRANSPORTATION AND INSTALLATION
CONNECTION
B-82135EN/01
NOTE
1. Parts to be provided by the customer:
Robot mounting bolts:
M20 x 60 (strength classification 12.9 8pcs.
Chemical anchors:
M20 (strength classification 4.8)
12pcs.
Base plates:
thickness 32t
4pcs.
Floor plate:
thickness 32t
1pcs.
2. Installation work (welding, anchoring, etc.) is prepared by the customer.
3. If the robot is operated with any combination other than stated above, it is likely to be
damaged.
Table. 3.2 Force and moment during emergency stop
Model
M-900iA/350
Vertical moment
MV [kNm (kgfm)]
Force in vertical
direction
FV [kN (kgf)]
Horizontal moment
MH [kNm (kgfm)]
Force in horizontal
direction
FH [kN (kgf)]
84.28 (8600)
53.90 (5500)
25.48 (2600)
32.34 (3300)
—— 162 ——
B-82135EN/01
CONNECTION
3. TRANSPORTATION AND INSTALLATION
Fig. 3.2 (c) Force and moment during Emergency Stop
—— 163 ——
3. TRANSPORTATION AND INSTALLATION
3.3 MAINTEN
ANCE AREA
CONNECTION
B-82135EN/01
Fig. 3.3 shows the maintenance area of the mechanical unit. In
mastering, it needs to take the posture in item 5.3.3 of Chapter I.
Be sure to leave enough room for the robot to be mastered.
Maintenance area
(Mechanical unit)
Mastering area
Fig. 3.3 Maintenance area
—— 164 ——
CONNECTION
B-82135EN/01
3.4 AIR PIPING
(OPTION)
Elbow nipple Rc3/8
Rc3/8
3. TRANSPORTATION AND INSTALLATION
Fig. 3.4 (a) shows how to connect air hose to the robot. If the air
control set is specified as an option, the air hose between the
mechanical unit and the air control set is provided. Mount the air
control set using the information in Fig. 3.4 (b).
Straight nipple Rc1/2
Air control set
Air hose 3m Outer 12mm lnner 8mm
In dotted line : optional parts
Note) Pipe used in the mechanical unit has an outer diameter
of 12mm and an inner diameter of 8mm. You can use a
different size pipe outside the mechanical unit.
Fig. 3.4 (a) Air piping Option
—— 165 ——
3. TRANSPORTATION AND INSTALLATION
Air control set
CONNECTION
B-82135EN/01
Fill the oiler having three air components to the specified level
with turbine oil #90 to #140. The machine tool builder is required
to prepare mounting bolts.
4-M6
IN
OUT
Mounting pitch of air control set
Air filter
Lubricator
Fig. 3.4 (b) Air control set Option
—— 166 ——
B-82135EN/01
3.5 INSTALLA
TION
SPECIFICA
TIONS
CONNECTION
3. TRANSPORTATION AND INSTALLATION
Table. 3.5 Installation specifications
Items
Specifications
Air pressure - Pressure
0.49 to 0.69 MPa
(5 to 7 kgf/cm2)
(Set pressure 0.49 MPa
(5 kgf/cm2))
Air pressure - Air flow
Max. peak 150 Nl/min,
0.15 Nm3/min (Note 1)
Weight of mechanical unit
Approx. 1720 kg
Allowable ambient temperature
0 to 45°C
Allowable ambient humidity
Usual: Less than 75% RH
Short period (in one month):
Max. 95% RH or less
Condensation free
Atmosphere
Free of corrosive gases
(Note 1)
Vibration
Less than 0.5 G, 4.9 m/s2
NOTE
1. This value indicates the maximum capacity of the air
control set.
Adjust the air flow to be less than this value.
2. Contact the service representative, if the robot is to be
used in an environment or a place subjected to severe
vibrations, heavy dust, cutting oil splash and or other
foreign substances.
—— 167 ——
3. TRANSPORTATION AND INSTALLATION
3.6 STORAGE
CONNECTION
B-82135EN/01
To store the robot, set it to the same attitude as that used for
transportation. (see II- 3.1)
—— 168 ——
APPENDIX
APPENDIX
B-82135EN/01
A
A. SPARE PARTS LIST
ASPARE PARTS LIST
No.
Table. A (a) Cables (Standard : CE)
Specification
Function
K111
A660-8015-T036
J1 to J6 PULSECODER+ EE
K112
A660-8015-T036
J1 to J6 POWER
Table. A (b) Cables (Option cable : CE)
No.
Specification
Function
K131
A660-8015-T039
AS (USER/SIGNAL)
K132
A660-8015-T040
AP (USER/POWER)
K133
A660-4004-T372
DNS (SIGNAL)
K135
A05B-1327-D001
I/O
K136
A660-8015-T041
ARP
K137
A660-8015-T042
ARM
K138
A660-8015-T043
J123 OT
K139
A660-4004-T376
DNP (POWER)
K140
A05B-1327-D002
J2/J3 Interference angle OT
Table. A (c) Motor
Axis
Specification
Remarks
J1
A06B-0268-B605#S000
Model alpha 30/4000is
J2, J3
A06B-0272-B605#S000
Model alpha 40/4000is
J4, J5, J6
A06B-0238-B605#S000
Model alpha 12/4000is
Table. A (d) Reducer
Axis name
Specification
J1
A97L-0218-0347#500C-30
J2
A97L-0218-0348#550F-253
J3
A97L-0218-0348#550F-253
J4
A97L-0218-0349#160E-57
J5
A97L-0218-0350#160E-129
—— 171 ——
A. SPARE PARTS LIST
APPENDIX
B-82135EN/01
Table. A (d) Reducer
Axis name
J6
Specification
A97L-0218-0251#80E-121
Table. A (e) Gear
Name
Specification
J1-axis spur gear
A290-7327-X221
J1-axis bearing 1
A97L-0001-0195#09D000A
J1-axis C-ring
A6-CJR-45
J1-axis center gear
A290-7327-X222
J1-axis bearing 2
A97L-0001-0192#3200000
J2-axis input gear
A97L-0218-0363#253
J3-axis input gear
A97L-0218-0363#253
J4-axis spur gear
A290-7324-X421
J4-axis bearing
A97L-0218-0428#0600000
J4-axis C-ring
A6-CJR-30
J5-axis spur gear
A290-7324-X423
J6-axis spur gear
A290-7327-X425
Table. A (f) Other (Mechanical unit)
Name
Specifications
Wrist unit
A290-7327-T501
Shaft assembly (link)
A290-7327-V321
J3 arm assembly
A290-7327-V401
Table. A (g) Battery and grease
Name
Specification
Remarks
Battery
A98L-0031-0005
1.5V, size D
Grease
A98L-0040-0174#16KG
Kyodo Yushi
VIGOGREASE RE0
Grease
A98L-0040-0119#16KG
Kyodo Yushi
Moly White RE No. 00
Grease
A97L-0001-0179#2
Shell Alvania No.2
—— 172 ——
APPENDIX
B-82135EN/01
A. SPARE PARTS LIST
Table. A (h) O-ring
Name
Specification
Location
O-ring
JB-OR1A-G125
J1 to J3-axis motor
O-ring
JB-OR1A-G105
J4 to J6-axis motor
O-ring
JB-OR1A-G460
J1-axis reducer
O-ring
A290-7327-X206
O-ring
JB-OR1A-G340
J2/J3-axis reducer
O-ring
A98L-0040-0041#271
J4-axis reducer
O-ring
JB-OR1A-G135
O-ring
JB-OR1A-G210
O-ring
JB-OR1A-G135
O-ring
JB-OR1A-G135
J3-axis arm assembly
Wrist assembly
Table. A (i) Mechanical Stopper
Name
Specification
Location
Collar
A290-7324-X214
For J1-axis
Bush
A97L-0218-0484#3125
Bolt
A6-BA-24X80
Washer
A6-WM-24S
Stopper
A290-7327-X215
Plate
A290-7327-X216
Stopper J2A
A290-7324-X361
Common plus side to the J2-axis and the J3-axis
Stopper J2B
A290-7324-X362
Common minus side to the J2-axis and the J3-axis
—— 173 ——
A. SPARE PARTS LIST
APPENDIX
—— 174 ——
B-82135EN/01
B-82135EN/01
B
APPENDIX
BCONNECTION DIAGRAM
—— 175 ——
B. CONNECTION DIAGRAM
B. CONNECTION DIAGRAM
APPENDIX
Fig. B Connection Diagram
—— 176 ——
B-82135EN/01
B-82135EN/01
APPENDIX
—— 177 ——
B. CONNECTION DIAGRAM
B. CONNECTION DIAGRAM
APPENDIX
—— 178 ——
B-82135EN/01
B-82135EN/01
C
APPENDIX
C. PERIODIC MAINTENANCE TABLE
CPERIODIC MAINTENANCE TABLE
—— 179 ——
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-82135EN/01
FANUC Robot M-900iA/
350 Periodic
Maintenance Table
Greasing Points
Greasing to J2/J3 bearing
—— 180 ——
B-82135EN/01
APPENDIX
—— 181 ——
C. PERIODIC MAINTENANCE TABLE
D. BOLT TIGHTENING TORQUE TABLE
D
APPENDIX
B-82135EN/01
DBOLT TIGHTENING TORQUE TABLE
Those bolts for which no tightening torque is specified must be
tightened according to the following table.
Table. D. Recommended Bolt Tightening Torques (Unit : Nm (kgf cm))
Nominal
diameter
Hexagon socket head bolt
(Steel : strength rating of 12.9)
Hexagon socket head bolt
(Stainless)
Hexagon socket head pan bolt
Hexagon socket head countersunk
bolt
(Steel : strength rating of 12.9)
Tightening torque
Tightening torque
Tightening torque
Upper limit
Lower limit
Upper limit
Lower limit
Upper limit
Lower limit
M3
1.8(18)
1.3(13)
0.76(7.7)
0.53(5.4)
--------
--------
M4
4.0(41)
2.8(29)
1.8(18)
1.3(13)
1.8(18)
1.3(13)
M5
7.9(81)
5.6(57)
3.4(35)
2.5(25)
4.0(41)
2.8(29)
M6
14(140)
9.6(98)
5.8(60)
4.1(42)
7.9(81)
5.6(57)
M8
32(330)
23(230)
14(145)
9.8(100)
14(140)
9.6(98)
M10
66(670)
46(470)
27(280)
19(195)
32(330)
23(230)
M12
110(1150)
78(800)
48(490)
33(340)
--------
--------
(M14)
180(1850)
130(1300)
76(780)
53(545)
--------
--------
M16
270(2800)
190(1900)
120(1200)
82(840)
--------
--------
(M18)
380(3900)
260(2700)
160(1650)
110(1150)
--------
--------
M20
530(5400)
370(3800)
230(2300)
160(1600)
--------
--------
(M22)
730(7450)
510(5200)
--------
--------
--------
--------
M24
930(9500)
650(6600)
--------
--------
--------
--------
(M27)
1400(14000)
940(9800)
--------
--------
--------
--------
M30
1800(18500)
1300(13000)
--------
--------
--------
--------
M36
3200(33000)
2300(23000)
--------
--------
--------
--------
—— 182 ——
INDEX
B-82135EN/01
INDEX
Numerics
G
1.5-YEAR CHECKS 14
1-YEAR CHECKS 13
3-MONTH CHECKS 12
3-YEAR CHECKS 15
General 58
Grease Replacement Procedure for the J1-Axis/J2Axis/J3-Axis and J4-Axis Gear Box 22
Grease Replacement Procedure for the Wrist 22
GREASING POINTS 26
A
ADJUSTING LIMIT SWITCH (OPTION)
ADJUSTMENTS 41
AIR PIPING (OPTION) 165
AIR SUPPLY (OPTION) 141
Attitude for Greasing 23
AXIS LIMITS SETUP 42
H
55
Hard Stopper and Limit Switch Setting
50
I
INSTALLATION 160
INSTALLATION SPECIFICATIONS 167
INTERFACE FOR OPTION CABLE (OPTION)
B
BACKLASH MEASUREMENT 38
BOLT TIGHTENING TORQUE TABLE
142
182
J
C
J1-AXIS DRIVE MECHANISM 4
J2/J3-AXIS DRIVE MECHANISM
J4-AXIS DRIVE MECHANISM 6
J5/J6-AXIS DRIVE MECHANISM
CABLE FORMING 108
CABLE REPLACEMENT 111
CONFIGURATION 3
CONNECTION DIAGRAM 175
5
7
L
DAILY CHECKS
D
LIMIT SWITCH REPLACEMENT (OPTION) 122
LOAD CONDITIONS ON J2-AXIS BASE AND J3AXIS ARM 135
E
M
10
EQUIPMENT MOUNTING FACE
137
MAINTENANCE AREA 164
MAINTENANCE TOOLS 16
MAJOR COMPONENT SPECIFICATIONS 8
MASTERING 58
Mastering Data Entry 72
Mastering to a Fixture (Master Position Master) 60
MECHANICAL COUPLING OF END EFFECTOR
F
FAILURE AND CAUSE
30
i-1
INDEX
TO WRIST 136
MECHANICAL COUPLING TO THE ROBOT
S
133
SAFETY 1
SEALANT APPLICATION 99
SETTING SYSTEM VARIABLES FOR MINIMUM
CYCLE CONTROL 138
Single Axis Mastering 69
Software Setting 48
SPARE PARTS LIST 171
STORAGE 168
N
NOTE FOR PART REPLACEMENT
76
O
OVERVIEW
29
T
TRANSPORTATION 155
TRANSPORTATION AND INSTALLATION
TROUBLESHOOTING 28
P
PERIODIC MAINTENANCE 21
PERIODIC MAINTENANCE TABLE
PIPING AND WIRING 101
PIPING DIAGRAM 102
PREFACE 1
PREVENTIVE MAINTENANCE 9
179
W
WIRING DIAGRAM 103
WRIST LOAD CONDITIONS
Q
Quick Mastering
B-82135EN/01
134
Z
68
Zero Degree Mastering 65
Zero Point Position and Motion Limit
R
REPLACING CABLES 106
REPLACING GREASE OF THE DRIVE MECHANISM 22
REPLACING J1-AXIS MOTOR (M1) AND REDUCER 78
REPLACING J2-AXIS MOTOR (M2) AND REDUCER 85
REPLACING J3-AXIS MOTOR (M3) AND REDUCER 90
REPLACING MOTOR COVERS (OPTION) 100
REPLACING PARTS 75
REPLACING THE BATTERIES 27
REPLACING THE WRIST AXIS MOTORS (M4, M5,
AND M6), WRIST UNIT AND J4 AXIS REDUCER
95
Resetting Alarms and Preparing for Mastering
ROBOT INTERFERENCE AREA 129
59
i-2
43
154
Sept., 2004
Date
01
Edition
Contents
____________________________
Edition
Date
FANUC Robot M-900iA/350 MAINTENANCE MANUAL (B-82135EN)
Revision Record
Contents