1
MARMIBARC11011E REV A
FANUC Robotics
SYSTEM R-J3iB Controller
ARC Mate 100iB / M–6iB
Mechanical Unit Maintenance Manual
MARMIBARC11011E REV A
B–81545EN/01
This publication contains proprietary information of FANUC Robotics
North America, Inc. furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics
North America, Inc.
FANUC Robotics North America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
2
MARMIBARC11011E REV A
The descriptions and specifications contained in this manual were in effect
at the time this manual was approved. FANUC Robotics North America,
Inc, hereinafter referred to as FANUC Robotics, reserves the right to
discontinue models at any time or to change specifications or design
without notice and without incurring obligations.
FANUC Robotics manuals present descriptions, specifications, drawings,
schematics, bills of material, parts, connections and/or procedures for
installing, disassembling, connecting, operating and programming FANUC
Robotics’ products and/or systems. Such systems consist of robots,
extended axes, robot controllers, application software, the KARELR
programming language, INSIGHTR vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been trained in
one or more approved FANUC Robotics Training Course(s) be permitted
to install, operate, use, perform procedures on, repair, and/or maintain
FANUC Robotics’ products and/or systems and their respective
components. Approved training necessitates that the courses selected be
relevant to the type of system installed and application performed at the
customer site.
WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in
accordance with the instruction manual, may cause
interference to radio communications. As temporarily
permitted by regulation, it has not been tested for
compliance with the limits for Class A computing devices
pursuant to subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such
interference. Operation of the equipment in a residential
area is likely to cause interference, in which case the user,
at his own expense, will be required to take whatever
measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a
regularly scheduled basis at its headquarters in Rochester Hills, Michigan.
For additional information contact
FANUC Robotics North America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
web site: www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
3
MARMIBARC11011E REV A
Copyright E2001 by FANUC Robotics North America, Inc.
All Rights Reserved
The information illustrated or contained herein is not to be reproduced,
copied, translated into another language, or transmitted in whole or in part
in any way without the prior written consent of FANUC Robotics North
America, Inc.
AccuStatR, ArcToolR, KARELR, PaintToolR, PalletToolR,
SOCKETSR, SpotToolR, SpotWorksR, and TorchMateR are
Registered Trademarks of FANUC Robotics.
FANUC Robotics reserves all proprietary rights, including but not limited
to trademark and trade name rights, in the following names:
AccuAirT
AccuChopT
AccuPathT
ARC MateT
ARC Mate System 1T
ARC Mate System 3T
ARC Mate System 5T
AssistToolT
AutoTCPT
BODYWorksT
Cell FinderT
Clean WallT
DispenseToolT
F-200iT
FANUC LASER DRILLT
FlexToolT
HandlingWorksT
INSIGHT IIT
Integrated Process SolutionT
IPC –Integrated Pump ControlT
ISA Integral Servo ApplicatorT
Laser Mate System 3T
LaserProT
LR ToolT
MotionPartsT
Paint StickT
PaintTool 100T
PAINTWorks IIT
PalletMateT
PalletTool PCT
RecipToolT
Robo ChopT
S–420iT
ShapeGenT
SOFT PARTST
SR MateT
SureWeldT
SYSTEM R-J3 ControllerT
TCP MateT
TorchMateT
visPRO–3DT
WebServerT
YagToolT
AccuCalT
AccuFlowT
AccuSealT
ARC Mate Sr.T
ARC Mate System 2T
ARC Mate System 4T
ARCWorks ProT
AutoNormalT
BellToolT
Cal MateT
Center FinderT
CollisionGuardT
F-100T
FabToolT
FlexibellT
HandlingToolT
INSIGHTT
IntelliTrakT
Intelligent Assist DeviceT
IPD Integral Pneumatic DispenserT
ISD Integral Servo DispenserT
Laser Mate System 4T
LaserToolT
MIG EyeT
NoBotsT
PaintProT
PAINTWorksT
PAINTWorks IIIT
PalletMate PCT
PayloadIDT
RemovalToolT
Robo SprayT
S–430iT
SoftFloatT
SpotTool+T
SR ShotToolT
SYSTEM R-J2 ControllerT
SYSTEM R-J3iB ControllerT
TurboMoveT
visLOCT
visTRACT
WebTPT
4
Conventions Used in
this Manual
MARMIBARC11011E REV A
This manual includes information essential to the safety of personnel,
equipment, software, and data. This information is indicated by headings
and boxes in the text.
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set
it apart from other text.
CAUTION
Information appearing under CAUTION concerns the protection
of equipment, software, and data. It is boxed to set it apart
from other text.
NOTE Information appearing next to NOTE concerns related information
or useful hints.
CUSTOMER RESOURCE CENTER
1–800–47–ROBOT
www.fanucrobotics.com
(Canada & United States: 1–800–477–6268) or (International: 011–1–248–377–7159)
TECHNICAL SUPPORT & FIELD SERVICES
Press 1 (24 Hours/365 Days)
Facsimile: (248) 377–7463
PARTS, PART REPAIR & ROBOT
REFURBISHMENT
Press 2 (After Hours: Press 1)
Facsimile: (248) 377–7832
PRODUCT & SYSTEMS TRAINING
Press 3 (8am – 5pm EST; M–F)
Facsimile: (248) 377–7367
MARKETING, SALES, & LITERATURE
REQUESTS
Press 4 (8am – 5pm EST; M–F)
Facsimile: (248) 377–7366
S Technical Support “Hot–Line”
S Service personnel dispatch
S After–hours parts support
(8:00 pm to 8:00 am)
S Parts for down robots
S Replenishment & repair orders
S Warranty part replacement
S Robot software and PACs
S Training class registration
S Consultation for non–standard
training classes or on–site
requests
S Marketing Information
S Application Review
S New Robot Product Sales
S Systems Solution Sales
For best call results have:
S Customer number (if known)
S Company name
S Your name
S Your phone & fax numbers
S Robot & controller type
S “F#” or serial number of robot
S Hour meter reading (if available)
S Software type and edition
S Any error messages and LED
displays (if applicable)
S Your P.O., credit card, or
receiving # for warranty or down
robot or preventive maintenance
service orders
For best call results have:
S Customer number (if known)
S Company name
S Your name
S Your phone & fax numbers
S Part name & number (if known)
S “F#” or serial number of robot,
if available (req’d for warranty)
S P.O., credit card, or receiving #
for warranty, down units, or
software
S Shipping & billing addresses
S Reason for repair (any
symptoms, error codes, or
diagnostic LEDs that were
identified)
For best call results have:
S Customer number (if known)
S Company name
S Your name
S Your phone & fax numbers
S Your billing address
S Types of courses needed
S Special requirements
S Robot and controller type
S Proposed schedules
S Number of people attending
S Student names (if available)
S Method of payment (P.O.,
credit card, etc.)
For best call results have:
S Company name
S Company address
S Your name
S Your phone & fax numbers
S Description of your need
11/01/00
*NOTE: A RETURN AUTHORIZATION (“RA”) FROM “PARTS” IS REQUIRED BEFORE SHIPPING ANY MATERIAL BACK TO
FANUC ROBOTICS FOR PROPER RECEIVING & TRACKING. F# IS LOCATED ON THE ROBOT BASE OR OP. PANEL
SAFETY
MARMIBARC11011E REV A
Safety–1
FANUC Robotics is not and does not represent itself as an expert in safety
systems, safety equipment, or the specific safety aspects of your company
and/or its work force. It is the responsibility of the owner, employer, or
user to take all necessary steps to guarantee the safety of all personnel in
the workplace.
The appropriate level of safety for your application and installation can
best be determined by safety system professionals. FANUC Robotics
therefore, recommends that each customer consult with such professionals
in order to provide a workplace that allows for the safe application, use,
and operation of FANUC Robotic systems.
According to the industry standard ANSI/RIA R15.06, the owner or user is
advised to consult the standards to ensure compliance with its requests for
Robotics System design, usability, operation, maintenance, and service.
Additionally, as the owner, employer, or user of a robotic system, it is your
responsibility to arrange for the training of the operator of a robot system
to recognize and respond to known hazards associated with your robotic
system and to be aware of the recommended operating procedures for your
particular application and robot installation.
FANUC Robotics therefore, recommends that all personnel who intend to
operate, program, repair, or otherwise use the robotics system be trained in
an approved FANUC Robotics training course and become familiar with
the proper operation of the system. Persons responsible for programming
the system-including the design, implementation, and debugging of
application programs-must be familiar with the recommended
programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of
safety in the workplace.
Safety–2
MARMIBARC11011E REV A
CONSIDERING
SAFETY FOR YOUR
ROBOT
INSTALLATION
Safety is essential whenever robots are used. Keep in mind the following
factors with regard to safety:
D The safety of people and equipment
D Use of safety enhancing devices
D Techniques for safe teaching and manual operation of the robot(s)
D Techniques for safe automatic operation of the robot(s)
D Regular scheduled inspection of the robot and workcell
D 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:
D People
D External devices
D Robot(s)
D Tooling
D 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:
D Safety fences, barriers, or chains
D Light curtains
D Interlocks
D Pressure mats
D Floor markings
D Warning lights
D Mechanical stops
D EMERGENCY STOP buttons
D 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.
D
Sponsor your personnel for training in approved FANUC Robotics
training course(s) related to your application. Never permit untrained
personnel to operate the robots.
D
Install a lockout device that uses an access code to prevent
unauthorized persons from operating the robot.
D
Use anti-tie-down logic to prevent the operator from bypassing safety
measures.
D
Arrange the workcell so the operator faces the workcell and can see
what is going on inside the cell.
Safety–3
MARMIBARC11011E REV A
D
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.
D
Position all controllers outside the robot work envelope.
D
Never rely on software as the primary safety element.
D
Mount an adequate number of EMERGENCY STOP buttons or
switches within easy reach of the operator and at critical points inside
and around the outside of the workcell.
D
Install flashing lights and/or audible warning devices that activate
whenever the robot is operating, that is, whenever power is applied to
the servo drive system. Audible warning devices shall exceed the
ambient noise level at the end-use application.
D
Wherever possible, install safety fences to protect against unauthorized
entry by personnel into the work envelope.
D
Install special guarding that prevents the operator from reaching into
restricted areas of the work envelope.
D
Use interlocks.
D
Use presence or proximity sensing devices such as light curtains, mats,
and capacitance and vision systems to enhance safety.
D
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.
D
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).
D
Make provisions for power lockout/tagout at the controller.
D
Eliminate pinch points. Pinch points are areas where personnel could
get trapped between a moving robot and other equipment.
D
Provide enough room inside the workcell to permit personnel to teach
the robot and perform maintenance safely.
D
Program the robot to load and unload material safely.
D
If high voltage electrostatics are present, be sure to provide appropriate
interlocks, warning, and beacons.
D
If materials are being applied at dangerously high pressure, provide
electrical interlocks for lockout of material flow and pressure.
Safety–4
Staying Safe While
Teaching or Manually
Operating the Robot
MARMIBARC11011E REV A
Advise all personnel who must teach the robot or otherwise manually
operate the robot to observe the following rules:
D
D
D
D
D
Never wear watches, rings, neckties, scarves, or loose clothing that
could get caught in moving machinery.
Know whether or not you are using an intrinsically safe teach pendant
if you are working in a hazardous environment.
Before teaching, visually inspect the robot and work envelope to make
sure that no potentially hazardous conditions exist. The work
envelope is the area defined by the maximum motion range of the
robot. These include tooling attached to the wrist flange that extends
this range.
The area near the robot must be clean and free of oil, water, or debris.
Immediately report unsafe working conditions to the supervisor or
safety department.
FANUC Robotics recommends that no one enter the work envelope of
a robot that is on, except for robot teaching operations. However, if
you must enter the work envelope, be sure all safeguards are in place,
check the teach pendant DEADMAN switch for proper operation, and
place the robot in teach mode. Take the teach pendant with you, turn it
on, and be prepared to release the DEADMAN switch. Only the
person with the teach pendant should be in the work envelope.
WARNING
Never bypass, strap, or otherwise deactivate a safety
device, such as a limit switch, for any operational
convenience. Deactivating a safety device is known to
have resulted in serious injury and death.
D
D
D
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
D
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.
Safety–5
MARMIBARC11011E REV A
Staying Safe During
Automatic Operation
Staying Safe During
Inspection
Advise all personnel who operate the robot during production to observe
the following rules:
D
Make sure all safety provisions are present and active.
D
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.
D
Understand the complete task the robot is programmed to perform
before initiating automatic operation.
D
Make sure all personnel are outside the work envelope before
operating the robot.
D
Never enter or allow others to enter the work envelope during
automatic operation of the robot.
D
Know the location and status of all switches, sensors, and control
signals that could cause the robot to move.
D
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.
D
Never assume that a program is complete if the robot is not moving.
The robot could be waiting for an input signal that will permit it to
continue activity.
D
If the robot is running in a pattern, do not assume it will continue to
run in the same pattern.
D
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.
When inspecting the robot, be sure to
D
Turn off power at the controller.
D
Lock out and tag out the power source at the controller according to
the policies of your plant.
D
Turn off the compressed air source and relieve the air pressure.
D
If robot motion is not needed for inspecting the electrical circuits,
press the EMERGENCY STOP button on the operator panel.
D
Never wear watches, rings, neckties, scarves, or loose clothing that
could get caught in moving machinery.
Safety–6
Staying Safe During
Maintenance
MARMIBARC11011E REV A
D
If power is needed to check the robot motion or electrical circuits, be
prepared to press the EMERGENCY STOP button, in an emergency.
D
Be aware that when you remove a servomotor or brake, the associated
robot arm will fall if it is not supported or resting on a hard stop.
Support the arm on a solid support before you release the brake.
When performing maintenance on your robot system, observe the
following rules:
D
Never enter the work envelope while the robot or a program is in
operation.
D
Before entering the work envelope, visually inspect the workcell to
make sure no potentially hazardous conditions exist.
D
Never wear watches, rings, neckties, scarves, or loose clothing that
could get caught in moving machinery.
D
Consider all or any overlapping work envelopes of adjoining robots
when standing in a work envelope.
D
Test the teach pendant for proper operation before entering the work
envelope.
D
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.
D
Whenever possible, perform maintenance with the power turned off.
Before you open the controller front panel or enter the work envelope,
turn off and lock out the 3-phase power source at the controller.
D
Be aware that when you remove a servomotor or brake, the associated
robot arm will fall if it is not supported or resting on a hard stop.
Support the arm on a solid support before you release the brake.
WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
HIGH VOLTAGE IS PRESENT at the input side whenever
the controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.
D
Release or block all stored energy. Before working on the pneumatic
system, shut off the system air supply and purge the air lines.
Safety–7
MARMIBARC11011E REV A
D
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.
D
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.
D
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.
D
Be aware that when you remove a servomotor or brake, the associated
robot arm will fall if it is not supported or resting on a hard stop.
Support the arm on a solid support before you release the brake.
D
When replacing or installing components, make sure dirt and debris do
not enter the system.
D
Use only specified parts for replacement. To avoid fires and damage
to parts in the controller, never use nonspecified fuses.
D
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.
Safety–8
MARMIBARC11011E REV A
KEEPING MACHINE
TOOLS AND
EXTERNAL
DEVICES SAFE
Certain programming and mechanical measures are useful in keeping the
machine tools and other external devices safe. Some of these measures are
outlined below. Make sure you know all associated measures for safe use
of such devices.
Programming Safety
Precautions
Implement the following programming safety measures to prevent damage
to machine tools and other external devices.
Mechanical Safety
Precautions
D
Back-check limit switches in the workcell to make sure they do not
fail.
D
Implement ‘‘failure routines” in programs that will provide appropriate
robot actions if an external device or another robot in the workcell
fails.
D
Use handshaking protocol to synchronize robot and external device
operations.
D
Program the robot to check the condition of all external devices during
an operating cycle.
Implement the following mechanical safety measures to prevent damage to
machine tools and other external devices.
D
Make sure the workcell is clean and free of oil, water, and debris.
D
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.
Safety–9
MARMIBARC11011E REV A
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.
Programming Safety
Precautions
D
Use a low override speed to increase your control over the robot when
jogging the robot.
D
Visualize the movement the robot will make before you press the jog
keys on the teach pendant.
D
Make sure the work envelope is clean and free of oil, water, or debris.
D
Use circuit breakers to guard against electrical overload.
The following safety measures are designed to prevent damage to the robot
during programming:
D
Establish interference zones to prevent collisions when two or more
robots share a work area.
D
Make sure that the program ends with the robot near or at the home
position.
D
Be aware of signals or other operations that could trigger operation of
tooling resulting in personal injury or equipment damage.
D
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.
Safety–10
ADDITIONAL
SAFETY
CONSIDERATIONS
FOR PAINT ROBOT
INSTALLATIONS
MARMIBARC11011E REV A
Process technicians are sometimes required to enter the paint booth, for
example, during daily or routine calibration or while teaching new paths to
a robot. Maintenance personal also must work inside the paint booth
periodically.
Whenever personnel are working inside the paint booth, ventilation
equipment must be used. Instruction on the proper use of ventilating
equipment usually is provided by the paint shop supervisor.
Although paint booth hazards have been minimized, potential dangers still
exist. Therefore, today’s highly automated paint booth requires that
process and maintenance personnel have full awareness of the system and
its capabilities. They must understand the interaction that occurs between
the vehicle moving along the conveyor and the robot(s), hood/deck and
door opening devices, and high-voltage electrostatic tools.
Paint robots are operated in three modes:
D
D
D
Teach or manual mode
Automatic mode, including automatic and exercise operation
Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will
follow a predetermined pattern of movements. In teach mode, the process
technician teaches (programs) paint paths using the teach pendant.
In automatic mode, robot operation is initiated at the System Operator
Console (SOC) or Manual Control Panel (MCP), if available, and can be
monitored from outside the paint booth. All personnel must remain
outside of the booth or in a designated safe area within the booth whenever
automatic mode is initiated at the SOC or MCP.
In automatic mode, the robots will execute the path movements they were
taught during teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines that
require them to remain in the paint booth, they must stay in a designated
safe area.
Safety–11
MARMIBARC11011E REV A
Paint System Safety
Features
Process technicians and maintenance personnel must become totally
familiar with the equipment and its capabilities. To minimize the risk of
injury when working near robots and related equipment, personnel must
comply strictly with the procedures in the manuals.
This section provides information about the safety features that are
included in the paint system and also explains the way the robot interacts
with other equipment in the system.
The paint system includes the following safety features:
D
Most paint booths have red warning beacons that illuminate when the
robots are armed and ready to paint. Your booth might have other
kinds of indicators. Learn what these are.
D
Some paint booths have a blue beacon that, when illuminated,
indicates that the electrostatic devices are enabled. Your booth might
have other kinds of indicators. Learn what these are.
D
EMERGENCY STOP buttons are located on the robot controller and
teach pendant. Become familiar with the locations of all E-STOP
buttons.
D
An intrinsically safe teach pendant is used when teaching in hazardous
paint atmospheres.
D
A DEADMAN switch is located on each teach pendant. When this
switch is held in, and the teach pendant is on, power is applied to the
robot servo system. If the engaged DEADMAN switch is released
during robot operation, power is removed from the servo system, all
axis brakes are applied, and the robot comes to an EMERGENCY
STOP. Safety interlocks within the system might also E-STOP other
robots.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch
is released on a bypassed robot.
D
Overtravel by robot axes is prevented by software limits. All of the
major and minor axes are governed by software limits. Limit switches
and hardstops also limit travel by the major axes.
Safety–12
MARMIBARC11011E REV A
D
EMERGENCY STOP limit switches and photoelectric eyes might be
part of your system. Limit switches, located on the entrance/exit doors
of each booth, will EMERGENCY STOP all equipment in the booth if
a door is opened while the system is operating in automatic or manual
mode. For some systems, signals to these switches are inactive when
the switch on the SCC is in teach mode.
When present, photoelectric eyes are sometimes used to monitor
unauthorized intrusion through the entrance/exit silhouette openings.
D
Staying Safe While
Operating the Paint
Robot
System status is monitored by computer. Severe conditions result in
automatic system shutdown.
When you work in or near the paint booth, observe the following rules, in
addition to all rules for safe operation that apply to all robot systems.
WARNING
Observe all safety rules and guidelines to avoid injury.
WARNING
Never bypass, strap, or otherwise deactivate a safety device,
such as a limit switch, for any operational convenience.
Deactivating a safety device is known to have resulted in
serious injury and death.
D
Know the work area of the entire paint station (workcell).
D
Know the work envelope of the robot and hood/deck and door opening
devices.
D
Be aware of overlapping work envelopes of adjacent robots.
D
Know where all red, mushroom-shaped EMERGENCY STOP buttons
are located.
D
Know the location and status of all switches, sensors, and/or control
signals that might cause the robot, conveyor, and opening devices to
move.
D
Make sure that the work area near the robot is clean and free of water,
oil, and debris. Report unsafe conditions to your supervisor.
D
Become familiar with the complete task the robot will perform
BEFORE starting automatic mode.
D
Make sure all personnel are outside the paint booth before you turn on
power to the robot servo system.
Safety–13
MARMIBARC11011E REV A
Staying Safe During
Maintenance
D
Never enter the work envelope or paint booth before you turn off
power to the robot servo system.
D
Never enter the work envelope during automatic operation unless a
safe area has been designated.
D
Never wear watches, rings, neckties, scarves, or loose clothing that
could get caught in moving machinery.
D
Remove all metallic objects, such as rings, watches, and belts, before
entering a booth when the electrostatic devices are enabled.
D
Stay out of areas where you might get trapped between a moving
robot, conveyor, or opening device and another object.
D
Be aware of signals and/or operations that could result in the triggering
of guns or bells.
D
Be aware of all safety precautions when dispensing of paint is
required.
D
Follow the procedures described in this manual.
When you perform maintenance on the painter system, observe the
following rules, and all other maintenance safety rules that apply to all
robot installations. Only qualified, trained service or maintenance
personnel should perform repair work on a robot.
D
Paint robots operate in a potentially explosive environment. Use
caution when working with electric tools.
D
When a maintenance technician is repairing or adjusting a robot, the
work area is under the control of that technician. All personnel not
participating in the maintenance must stay out of the area.
D
For some maintenance procedures, station a second person at the
control panel within reach of the EMERGENCY STOP button. This
person must understand the robot and associated potential hazards.
D
Be sure all covers and inspection plates are in good repair and in place.
D
Always return the robot to the ‘‘home’’ position before you disarm it.
D
Never use machine power to aid in removing any component from the
robot.
D
During robot operations, be aware of the robot’s movements. Excess
vibration, unusual sounds, and so forth, can alert you to potential
problems.
D
Whenever possible, turn off the main electrical disconnect before you
clean the robot.
Safety–14
MARMIBARC11011E REV A
D
When using vinyl resin observe the following:
– Wear eye protection and protective gloves during application and
removal
– Adequate ventilation is required. Overexposure could cause
drowsiness or skin and eye irritation.
– If there is contact with the skin, wash with water.
D
When using paint remover observe the following:
– Eye protection, protective rubber gloves, boots, and apron are
required during booth cleaning.
– Adequate ventilation is required. Overexposure could cause
drowsiness.
– If there is contact with the skin or eyes, rinse with water for at
least 15 minutes.
B–81545EN/01
PREFACE
PREFACE
This manual explains the maintenance and connection procedures for the
mechanical units (R–J3iB controller) of the following robots. Before
replacing the parts, determine the specification number of the mechanical
unit.:
Model name
FANUC Robot ARC Mate 100iB
(With J2 and J3–axis brake)
FANUC Robot ARC Mate 100iB
(With all axes brake)
FANUC Robot M–6iB
(With J2 and J3–axis brake)
FANUC Robot M–6iB
(With all axes brake)
p–1
Abbreviation
Mechanical unit
specification No.
A05B–1215–B201
ARC Mate 100iB
A05B–1215–B601
A05B–1215–B202
M–6iB
A05B–1215–B602
PREFACE
B–81545EN/01
1)
No.
(1)
(2)
(3)
(4)
(5)
CONTENTS
MODEL
TYPE
No.
DATE
WEIGHT
(Without controller)
FANUC Robot ARC Mate 100iB
A05B–1215–B201
(2–axis brake)
LETTERS
FANUC Robot ARC Mate 100iB
A05B–1215–B601
(6–axis brake)
FANUC Robot M–6iB
(2–axis brake)
A05B–1215–B201
FANUC Robot M–6iB
(6–axis brake)
A05B–1215–B601
134 kg
PRINT
SERIAL
NO.
PRINT
PRODUCTION
YEAR AND
MONTH
Positon of label indicating mechanical unit specification number
p–2
138 kg
134 kg
138 kg
PREFACE
B–81545EN/01
Specification
Item
Specifications
Type
Controlled axes
Installation
Motion range
(Maximum speed)
Maximum speed
Articulated type
6 axes (J1, J2, J3, J4, J5, J6)
Floor, Upside–dowm (Wall & Angle mount)
J1 axis rotation
J2 axis rotation
J3 axis rotation
J4 axis wrist rotation
J5 axis wrist swing
J6 axis wrist rotation
J1 axis
J2 axis
J3 axis
J4 axis
J5 axis
J6 axis
(Note 1)
340° (5.93rad)
250° (4.36rad)
315° (5.60rad)
380° (6.63rad)
280° (4.89rad)
720° (12.57rad)
150°/s (2.62rad/s)
160°/s (2.79rad/s)
170°/s (2.97rad/s)
400°/s (6.98rad/s)
400°/s (6.98rad/s)
500°/s (8.73rad/s)
6kg
Max. load capacity at wrist
Max. load capacity on J3 catting
Allowable load moment at wrist J4 axis
12kg
Drive method
15.7N·m (1.6kgf·m)
9.8N·m (1.0kgf·m)
5.9N·m (0.6kgf·m)
0.63kg·m2 (6.4kgf·cm·s2)
0.22kg·m2 (2.2kgf·cm·s2)
0.061kg·m2 (0.62kgf·cm·s2)
Electric servo drive by AC servo motor
Repeatability
"0.08mm
Allowable load inertia at wrist
J5 axis
J6 axis
J4 axis
J5 axis
J6 axis
Weight of mechanical unit
Installation environment
134kg (2–axis brake type)
138kg (6–axis brake type)
Ambient temperature : 0 – 45°C
Ambient humidity
: Normally :75%RH or less
: Short time 95%RH or less
(within 1 month)
(No dew or frost allowed)
Vibration
: 0.5G (4.9m/s2) or less
NOTE
1 Under the installation condition within ( ), the J1 and J2 axis motion range will be limited.
p–3
PREFACE
B–81545EN/01
Dust–proof/waterproof performance of M–6iB
Normal specification
Wrist+J3 arm
IP67
Other part
IP54
NOTE
Definition of IP code
Definition of IP 67
6=Dust–tight
7=Protection from water immersion
Definition of IP 54
5=Dust–protected
4=Protection from splashing water
Performance of resistant chemicals and resistant solvents
(2)(1) The robot (including severe dust/liquid protection model) cannot
be used with the following liquids because there is fear that rubber
parts (packing, oil seal, O ring etc.) will corrode.
(a) Organic solvents
(b) Coolant including chlorine / gasoline
(c) Acid, alkali and liquid causing rust
(d) Other liquids or solutions, that will harm NBR
(2) When the robots work in the environment, using water or liquid,
complete draining of J1 base must be done. Incomplete draining of
J1 base will make the robot break down.
p–4
PREFACE
B–81545EN/01
RELATED MANUALS
Safety handbook
For the FANUC Robot series, the following manuals are available:
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
ARC TOOL
B–81464EN–3
SEALING TOOL
B–81464EN–4
Maintenancemanual
B–81465EN
B–81465EN–1
(European
specification)
Mechanical unit
Maintenancemanual
FANUC Robot ARC Mate
100iB
M–6iB
B–81545EN
Intended readers :
All persons who use FANUC Robot, system designer
Topics :
Safety items for robot system design, operation, maintenance
Intended readers :
Operator, programmer, maintenance person, system designer
Topics :
Robot functions, operations, programming, setup, interfaces, alarms
Use :
Robot operation, teaching, system design
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to peripheral equipment, maintenance
Use :
Installation, start–up, connection, maintenance
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to the controller, maintenance
Use :
installation, start–up, connection, maintenance
p–5
Table of Contents
B–81545EN/01
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s–1
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–1
I. MAINTENANCE
1. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.1
J1–AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1.2
J2–AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.3
J3–AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1.4
J4–AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
1.5
J5– AND J6–AXIS DRIVE MECHANISMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
1.6
SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS . . . . . . . . . . . . . . .
9
2. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
2.1
DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
2.2
QUARTERLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
2.3
YEARLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
2.4
ONE– AND HALF–YEAR PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
2.5
THREE–YEAR PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
2.6
MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
3.1
GREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
3.2
GREASE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
3.3
BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
4.1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
4.2
TROUBLES AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
4.3
COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . .
31
5. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
5.1
REFERENCE POSITION AND MOVING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
5.2
SIMPLIFIED MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
5.3
MASTERING BY ZERO POSITION MARK ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
5.4
JIG–BASED MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
5.5
CONFIRMING MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
5.6
J5–AXIS GEAR BACKLASH ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
5.7
FACTORY MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
5.8
BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
6. COMPONENT REPLACEMENT AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . .
53
REPLACING THE J1–AXIS MOTOR M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
6.1
c–1
Table of Contents
B–81545EN/01
6.2
REPLACING THE J1–AXIS REDUCER (A97L–0218–0288#33) . . . . . . . . . . . . . . . . . . . . . . . . . .
56
6.3
REPLACING THE J2–AXIS MOTOR M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
6.4
REPLACING THE J2–AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
6.5
REPLACING THE J3–AXIS MOTOR M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
6.6
REPLACING THE J3–AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
6.7
REPLACING THE J4–AXIS MOTOR M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
6.8
REPLACING THE J4–AXIS GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
6.9
REPLACING THE J5–AXIS MOTOR M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
6.10
REPLACING THE J5–AXIS GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
6.11
REPLACING THE J6–AXIS MOTOR M6 AND REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
7. PIPING AND WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
7.1
PIPING DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
7.2
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
7.3
CABLE MOUNTING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
8. CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
8.1
CABLE DRESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
8.2
REPLACING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
II. CONNECTION
1. ROBOT OUTLINE DRAWING AND OPERATION AREA DIAGRAM . . . . . . . . . .
1.1
93
OUTLINE DRAWING AND OPERATION AREA DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94
2. MOUNTING DEVICES ON THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
2.1
WRIST SECTION END EFFECTOR MOUNTING SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98
2.2
DEVICE MOUNTING SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
2.3
SETTING THE SYSTEM VARIABLES FOR SHORTEST–TIME CONTROL . . . . . . . . . . . . . . .
101
2.4
WRIST LOAD CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
2.5
END EFFECTOR AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105
2.6
END EFFECTOR INPUT SIGNALS (RDI/RDO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
2.7
CONNECTOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
3. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.1
TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
3.2
STORING THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
3.3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112
3.4
MAINTENANCE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
3.5
ASSEMBLING THE ROBOT FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117
3.6
AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
3.7
INSTALLATION CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120
c–2
B–81545EN/01
Table of Contents
APPENDIX
A. SPARE PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
B. INTRA–MECHANICAL UNIT CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . 129
C. PERIODIC INSPECTION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
D. MOUNTING BOLT TORQUE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
c–3
I. MAINTENANCE
1
1. CONFIGURATION
MAINTENANCE
B–81545EN/01
CONFIGURATION
Fig. 1 shows the configuration of the mechanical unit.
J3–axis arm
AC servo motor for J4–axis (M4)
AC servo motor for J5–axis (M5)
AC servo motor for J6–axis (M6)
AC servo motor for J3–axis (M3)
Wrist unit
J3–axis casing
J2–axis arm
AC servo motor for J1–axis (M1)
AC servo motor for J2–axis (M2)
J2–axis base
J1–axis base
Fig 1 Mechanical unit configuration
3
1. CONFIGURATION
1.1
J1–AXIS DRIVE
MECHANISM
MAINTENANCE
B–81545EN/01
Fig. 1.1 shows the J1–axis drive mechanism.
The J1–axis drive mechanism is configured in such a way that the J2–axis
base is rotated by reducing the rotation speed of an AC servo motor with
a reducer.
The J2–axis base is supported on the J1–axis base through the reducer.
J1–axis AC servo motor
J2–axis base
J1–axis reducer
J1–axis base
Fig 1.1 J1–axis drive mechanism
4
B–81545EN/01
1.2
J2–AXIS DRIVE
MECHANISM
1. CONFIGURATION
MAINTENANCE
Fig. 1.2 shows the J2–axis drive mechanism. The J2–axis drive
mechanism is configured in such a way that the J2–axis arm is rotated by
reducing the rotation speed of an AC servo motor with a reducer.
The J2–axis arm is supported on the J2–axis base through the reducer.
J2–axis AC servo motor
J2–axis arm
J2–axis base
J2–axis reducer
Fig 1.2 J2–axis drive mechanism
5
1. CONFIGURATION
1.3
J3–AXIS DRIVE
MECHANISM
MAINTENANCE
B–81545EN/01
Fig. 1.3 shows the J3–axis drive mechanism. The J3–axis drive
mechanism is configured in such a way that the J3–axis casing is rotated
by reducing the rotation speed of an AC servo motor with a reducer.
The J3–axis casing is supported on the J2–axis arm through the reducer.
J3–axis reducer
J3–axis AC servo motor
J3–axis casing
J2–axis arm
Fig 1.3 J3–axis drive mechanism
6
B–81545EN/01
1.4
J4–AXIS DRIVE
MECHANISM
MAINTENANCE
1. CONFIGURATION
Fig. 1.4 shows the J4–axis drive mechanism. The J4–axis drive
mechanism is configured in such a way that the J3–axis arm is rotated by
reducing the rotation speed of an AC servo motor with a two–stage gear.
J3–axis arm
Final gear
Second gear
J3–axis casing
Input gear
J4–axis AC servo motor
Fig 1.4 J4–axis drive mechanism
7
1. CONFIGURATION
1.5
J5– AND J6–AXIS
DRIVE MECHANISMS
J5–axis AC servo motor
MAINTENANCE
B–81545EN/01
Fig. 1.5 shows the J5– and J6–axis drive mechanisms. The J5–axis drive
mechanism is configured in such a way that the J6–axis unit is rotated by
reducing the rotation speed of an AC servo motor with a three–stage gear.
The J6–axis drive mechanism is configured in such a way that the output
flange is rotated by reducing the rotation speed of an AC servo motor with
a reducer.
J6–axis unit
J6–axis AC servo motor
Output flange
Input gear
Final gear
Second gear
Third gear
Fig 1.5 J5– and J6–axis drive mechanisms
8
J6–axis reducer
B–81545EN/01
1.6
SPECIFICATIONS OF
THE MAJOR
MECHANICAL UNIT
COMPONENTS
1. CONFIGURATION
MAINTENANCE
1) Motors
ARC Mate 100iB
(two–axis, equipped with a brake): A05B–1215–B201
M–6iB
(two–axis, equipped with a brake): A05B–1215–B202
Specification
Axis
Remark
A06B-0223-B005
J1
a 4/4000i
A06B-0223-B605
J2
a 4/4000i Equipped with a brake
A06B-0202-B605
J3
a 1/5000i Equipped with a brake
A06B-0202-B005
J4
a 1/5000i
A06B-0115-B075#0008
J5
b M0.5/4000
A06B-0114-B075#0008
J6
b M0.4/4000
ARC Mate 100iB
(six–axis, equipped with a brake): A05B–1215–B601
M–6iB
(six–axis, equipped with a brake): A05B–1215–B602
Specification
Axis
Remark
A06B-0223-B605
J1
a 4/4000i Equipped with a brake
A06B-0223-B605
J2
a 4/4000i Equipped with a brake
A06B-0202-B605
J3
a 1/5000i Equipped with a brake
A06B-0202-B605
J4
a 1/5000i Equipped with a brake
A06B-0115-B275#0008
J5
b M0.5/4000
Equipped with a brake
A06B-0114-B275#0008
J6
b M0.4/4000
Equipped with a brake
2) Reducers
Specification
Axis
A97L-0218-0288#33
J1
A97L-0218-0289#153
J2
A97L-0218-0295#161
J3
A97L-0218-0224
J6
3) J4–axis gearbox
Specification
A05B-1215-K401
9
Axis
J4
1. CONFIGURATION
MAINTENANCE
B–81545EN/01
4) Gears
Specification
Axis
A290-7215-X511
J5
A290-7215-V501
J5
A290-7215-V502
J5
A290-7215-X514
J5
5) Stoppers
Specification
Axis
A290-7215-X241
J1
A290-7215-X323
J2
A290-7215-X324
J3
10
Note) 340° stopper
B–81545EN/01
2
MAINTENANCE
2. PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
Performing daily inspection, periodic inspection, and maintenance can
keep the performance of robots in a stable state for a long period.
11
2. PREVENTIVE MAINTENANCE
2.1
DAILY INSPECTION
MAINTENANCE
B–81545EN/01
Clean and maintain each component of robots during everyday system
operations. At the same time, check the components to see if there is a
crack or break in them. Also check and maintain the following items as
required.
a) Before automatic operation
No.
Inspection item
Inspection procedure
1
Pneumatic pressure
check
2
Check on the amount of Put the pneumatic pressure sysoil mist
tem in operation and check the
amount of oil dripping. If the
measured amount of oil dripping
does not meet the rating (one
drop/10 to 20 seconds), make
adjustments, using the oil adjustment knob. The oiler becomes empty after 10 to 20 days
of normal operation.
For
machines
with a
three–piece
pneumatic
option
Make a pneumatic pressure
check, using the three–piece
pneumatic option shown in Fig.
2.1.
If the measured pneumatic pressure does not fall in the range
between 0.5 and 0.7 MPa (5 and
7 kg/cm2), make adjustments,
using the regulator pressure setting handle.
3
Check on the amount of Check to see if the amount of oil
oil
in the three–piece option is within the rated level shown in Fig.
2.1.
4
Check for leakage from Check to see if a joint or hose
the piping
leaks.
If you find a problem, tighten the
joint or replace any defective
component.
5
Whether cables are abnormal
Mechanical unit
See Chapter 8.
6
Battery voltage check
Make sure that when the power
is turned on, the BLAL alarm has
not been raised. If the BLAL
alarm has been raised, replace
the battery as directed in Section 3.3.
7
Whether there is any abnormal vibra- Check that each axis is running
tion, noise, or heat generation in motors smoothly.
8
Whether there is a change to positioning Check to see if there is any disprecision
placement from the previous
position and there are variations
in the stop position.
12
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B–81545EN/01
No.
Inspection item
Inspection procedure
9
Reliable operation of peripheral equip- Check to see if the machine opment
erates exactly according to
directions from the robot and peripheral equipment.
10
Check on the operation of the J2– and See Section 4.2.
J3–axis brakes.
Oiler’s oil inlet
Oiler adjustment knob
Check oiler’s oil level
Oiler
Pressure gauge
Regulator pressure setting handle
Filter
Fig 2.1 Three–piece pneumatic option
b) After automatic operation
Once you are finished with automatic operation, bring the robot to its
reference position, and turn it off.
No.
1
Inspection item
Component cleaning
and inspection
13
Inspection procedure
Clean and maintain each component. At the
same time, check the components to see if
there is a crack or break in them.
2. PREVENTIVE MAINTENANCE
2.2
QUARTERLY
INSPECTION
MAINTENANCE
B–81545EN/01
Inspect the following items at regular intervals of three months. Increase
the locations and the frequency of inspection if the conditions under
which the robot is used and the environment in which it runs require so.
No.
Inspection item
Inspection procedure
1
Loose connector
Check that the motor connectors or other connectors are not loose.
2
Loose bolt
Check that the cover retaining bolts or external
bolts are not loose.
3
Debris removal
Remove any spatter, debris, and dust from the
mechanical unit.
14
MAINTENANCE
B–81545EN/01
2.3
YEARLY INSPECTION
2. PREVENTIVE MAINTENANCE
Inspect the following item at regular intervals of one year.
No.
1
Inspection item
J6 Greasing
15
Inspection procedure
See Section 3.1.
2. PREVENTIVE MAINTENANCE
2.4
ONE– AND
HALF–YEAR
PERIODIC
INSPECTION
MAINTENANCE
B–81545EN/01
Perform the following inspection/maintenance item at regular intervals of
one year and half.
No.
1
Inspection item
Battery replacement
16
Inspection procedure
Replace the battery in the mechanical unit.
(See Section 3.3.)
MAINTENANCE
B–81545EN/01
2. PREVENTIVE MAINTENANCE
2.5
THREE–YEAR
PERIODIC
INSPECTION
No.
Inspection item
1
J1–J5 Grease replacement
17
Inspection procedure
See Section 3.2.
2. PREVENTIVE MAINTENANCE
2.6
MAINTENANCE
TOOLS
MAINTENANCE
B–81545EN/01
You should have the following instruments and tools ready for
maintenance.
a) Measuring instruments
Instrument
Condition
Dial gauge
1/100mm
Calipers
150mm
b) Tools
Phillips screwdrivers
Flat–blade screwdrivers
Box wrenches
Allen wrenches
Torque wrench
Long T wrenches
Adjustable wrenches
Pliers
Long–nose pliers
Cutting pliers
Both–ended wrench
Grease gun
C–ring pliers
Flashlight
18
Use
For positioning precision and backlash
measurement
(large, medium, and small sizes)
(large, medium, and small sizes)
(M3 to M6)
(M3 to M16)
(M5 and M6)
(medium and small sizes)
B–81545EN/01
3
MAINTENANCE
PERIODIC MAINTENANCE
19
3. PERIODIC MAINTENANCE
3. PERIODIC MAINTENANCE
3.1
GREASING
MAINTENANCE
B–81545EN/01
Following is greasing for J6–axis reducer.
When greasing the robot, keep its power turned off.
i) Replenish the robot with grease every 12 months under normal
operating condition. If the robot is subject to work in high duty
environment of high payload/speed/payload inertia, replace the grease
every 6 months.
ii) See Fig. 3.1 and Table 3.1 for greasing points and the method.
Table. 3.1 Greasing points
No.
1
Greasing
point
J6–axis
reducer
Specified
grease
Moly White
RE No.00
(Specification:
A97L-0040-0119)
Amount
of
grease
40cc
Greasing method
Replace the flat–head bolts
and sealing washers of the
J6–axis grease inlet and outlet, and attach the supplied
grease nipple of the J3–axis or
J4–axis to the grease inlet of
the J6–axis. After greasing, remove the grease nipple, and
attach the flat–head bolts and
sealing washers to the grease
inlet and outlet.
CAUTION
If you grease incorrectly, the pressure in the grease bath
may increase steeply, leading to a broken seal, which will
eventually cause grease leakage or malfunction.
When greasing, be sure to follow the cautions stated in
Section 3.2.
20
B–81545EN/01
Grease nipple at the
grease inlet for the
J3-axis reducer
3. PERIODIC MAINTENANCE
MAINTENANCE
Low head bolt and seal
washer at the grease outlet
for the J5-axis reducer
Low head bolt and seal
Grease nipple at the
washer at the grease outlet
grease inlet for the
for the J6-axis reducer
J4-axis reducer
Low head bolt and seal
washer at the grease outlet for the J4-axis reducer
Low head bolt and
seal washer at the grease
outlet for the J6-axis reducer
Seal bolt at the
grease outlet for the
J1-axis reducer
Low head bolt and seal washer at the
grease inlet for the J5-axis reducer
Grease nipple at the grease inlet
for the J2-axis reducer
Grease nipple at the
grease outlet for the
J1-axis reducer
Seal bolt at the
grease outlet for the
J3-axis reducer
Seal bolt at the
grease outlet for the
J2-axis reducer (2 locations)
Fig 3.1 Greasing points
21
3. PERIODIC MAINTENANCE
3.2
GREASE
REPLACEMENT
MAINTENANCE
B–81545EN/01
Follow the procedure stated below to replace the grease in the J1–, J2–,
and J3–axis reducers and the J4– and J5–axis gearboxes once every three
years or after 11,520 hours of operation. See Fig. 3.1 for greasing points.
1) Remove the seal bolts from the J1–, J2–, and J3–axis grease outlets
shown in Fig. 3.1. Also remove the flat–bolts and sealing washers
from the J4– and J5–axis grease outlets.
2) Uncap the grease nipples at the J1–, J2–, J3–, and J4–axis grease inlets.
When the J5–axis grease is supplied remove the flat–head bolt from
the J5–axis grease inlet and attach the grease nipple to the J3–axis or
J4–axis grease inlet.
3) Supply the grease specified in Table 3.2 to the J1–, J2–, and J3–axis
reducers, and J4– and J5–axis gearboxes through their respective
grease nipples. Keep greasing until the new grease pushes out the old
grease and comes out from each grease outlet. Ensure that the amount
of the newly supplied grease equals the amount of the drained grease
so that the grease bath will not become full.
4) Wind sealing tape around the J1–, J2–, and J3–axis seal bolts you
removed, and attach them to the respective grease outlets.
5) Attach the J4– and J5–axis flat–head bolts and the J4– and J5–axis
sealing washers to the respective grease inlets and outlets.
6) When finally returning the grease nipple used at another location to the
original position, be sure to wind sealing tape around the threads part.
In addition, be sure to cap the grease nipple for each axis.
Table. 3.2 Grease to be replaced at regular intervals of three years
Specified grease
Amount of
grease to be
applied (cc)
Robot posture when
greased
About 1100
–
About 570
–
J3–axis reducer
About 300
–
J4–axis gearbox
About 700
–
J5–axis gearbox
About 400
J4=+90°
Kyodo Yushi
J1–axis reducer
J2–axis reducer
Moly White RE No.00
(Specification:
A98L-0040-0119#2.4KG)
22
B–81545EN/01
MAINTENANCE
3. PERIODIC MAINTENANCE
CAUTION
If you grease incorrectly, the pressure in the grease bath will
increase, leading to a broken seal, which will eventually cause
grease leakage or malfunction.
When greasing, be sure to follow the cautions stated below.
1 Before starting greasing, open the grease outlets (remove
bolts and the like from the grease outlets).
2 Using a manual greasing pump, grease gently and slowly.
3 Avoid using a pneumatic pump driven from a factory
pneumatic line as much as possible.
If you cannot avoid using it, observe a greasing speed of 15
cc/s or lower and a pressure of 75 kgf/cm2 or lower.
4 Be sure to use the specified grease. Otherwise, damage to
reducers or a similar abnormality may occur.
5 Before capping the grease outlets, make sure that a grease
flow from the grease outlet has stopped (the remaining
pressure has been released).
6 Wipe off any grease from the floor and robot completely, so
no one will slip on it.
23
3. PERIODIC MAINTENANCE
MAINTENANCE
B–81545EN/01
When replacing or supplying grease, keep the robot in the posture shown
in Fig. 3.2.
Axis
Posture
Free
Fig 3.2 Robot posture for greasing
24
B–81545EN/01
3.3
BATTERY
REPLACEMENT
3. PERIODIC MAINTENANCE
MAINTENANCE
A backup battery is used to keep the reference–position data for each axis
of the robot.
The battery needs to be replaced at regular intervals of one year and half.
Follow this procedure for battery replacement.
1) Keep the power turned on.
Press the EMERGENCY STOP button of the robot to keep it from
moving.
2) Uncap the battery case.
3) Take out the battery from the battery case.
4) Insert a new battery into the battery case while paying attention to the
polarity of the battery.
5) Cap the battery case.
Cap
Battery case
Battery specifications : A98L–0031–0005
(1.5V size–D 4pcs)
Fig 3.3 Battery replacement
25
B–81545EN/01
4
MAINTENANCE
TROUBLESHOOTING
26
4. TROUBLESHOOTING
4. TROUBLESHOOTING
4.1
OVERVIEW
MAINTENANCE
B–81545EN/01
A problem with a mechanical unit may occur due to a combination of
multiple causes. It is difficult to find out the true cause, and an incorrect
measure may make the problem worse. When troubleshooting, it is
important to get hold of the situation of any error accurately and take a
correct measure.
27
4.2
TROUBLES AND
CAUSES
4. TROUBLESHOOTING
MAINTENANCE
B–81545EN/01
Table 4.2 (a) lists the major troubles in the mechanical unit and their
causes. If you cannot find a cause accurately or do not know what measure
to take, please contact FANUC.
Note, however, that lower values of backlash and drop levels listed,
respectively, in Table 4.2 (b) and Table 4.2 (c) and lower are not abnormal.
Table 4.2 (a) Major troubles and causes (1/3)
Symptom
BZAL alarm issued
(battery zero)
Cause
Measure
Remark
The voltage of the memory Replace the battery, and per- See Section 3.3.
backup battery has dropped. form simplified mastering.
See Section 5.3.
Broken pulse coder signal Replace the cable, and per- See Section 8.2.
cable
form simplified mastering.
See Section 5.3.
Incorrect positioning
Something hit the robot.
Correct the taught point.
The robot is not firmly fixed.
Fix it.
See Section 3.2 of Part II,
“Connection”.
Peripheral equipment has Fix it.
shifted.
Load too heavy
Reduce the load.
Load on the wrist:
Limit the operating condition.
Refer to “Descriptions”.
Peripheral equipment:
See Section 2.2 of Part II,
“Connection”.
Incorrect parameter setting
Correct it.
Refer to “Operator’s Manual”.
Broken cable
Replace the cable.
See Section 8.2.
Pulse coder error
Replace the motor.
See Sections 6.1 to 6.11.
Backlash in the mechanical
unit –– see the next section.
Mastering has been set incor- Remaster the robot or use the See Section on mastering.
rectly
Factory Mastering information if the robot motors/cables
or pulse coder battery have
never been disconnected.
28
4. TROUBLESHOOTING
MAINTENANCE
B–81545EN/01
Table 4.2 (a) Major troubles and causes (2/3)
Symptom
Vibration
Cause
The robot
mounted.
is
Measure
Remark
not firmly Tighten the mounting screws. See Section 3.2 of Part II,
“Connection”.
The floor is vibrating (espe- Re–examine the location of
cially when the robot is installation.
installed on the second floor
or above).
Load too heavy
Reduce the load.
Limit the operating condition
Load on the wrist:
Refer to “Descriptions”.
Peripheral equipment:
See Section 2.2 of Part II,
“Connection”.
Servo is not correctly adjust- Adjust the servo section.
ment.
Contact FANUC.
Broken cable
Replace the cable.
See Section 8.2.
Robot not grounded
Ground the robot.
Refer to “Maintenance Manual for the Controller”.
Defective motor
Replace the motor.
See Sections 6.1 to 6.11.
Defective axis printed–circuit Replace the axis printed–cir- Refer to “Maintenance Manuboard
cuit board.
al for the Controller”.
Defective reducer
Replace the reducer.
See Sections 6.2 to 6.11.
Invalid time constant setting
Change the time constant.
Refer to “Operator’s Manual”.
Backlash in the mechanical
unit –– see the next section.
Backlash or wobbling
Abnormal sound
Loose screw or pin
Tighten it (and apply Loctite
to it if specified so)
Defective reducer
Replace the reducer.
See Sections 6.2 to 6.11.
Gear is not correctly adjust- Adjust the gear.
ment.
See Section 5.7.
Worn gear
Adjust or replace the gear.
Contact FANUC.
Worn bearing
Replace the bearing.
Contact FANUC.
Broken casting or other part
Replace the broken compo- Contact FANUC.
nent.
Insufficient grease for gear or Apply grease.
reducer
See Sections 3.1 and 3.2.
Foreign matter in gear or re- Wash the gear or reducer and See Sections 6.2 to 6.11, 3.1,
ducer
apply grease.
and 3.2.
Gear is not correctly adjust- Adjust the gear.
ment.
Contact FANUC.
Worn gear
Adjust or replace the gear.
Contact FANUC.
Worn bearing
Replace the bearing.
Contact FANUC.
Servo section maladjustment Adjust the servo section.
29
Contact FANUC.
4. TROUBLESHOOTING
MAINTENANCE
B–81545EN/01
Table 4.2 (a) Major troubles and causes (3/3)
Symptom
Abnormal heat generation
Arm drop at power turn–off
Cause
Measure
Remark
Insufficient grease for gear or Apply grease.
reducer
See Sections 3.1 and 3.2.
Non–specified grease used
Replace the grease.
See Sections 3.1 and 3.2.
Load too heavy
Reduce the load.
Load on the wrist:
Limit the operating condition.
Refer to “Descriptions”.
Peripheral equipment:
See Section 2.2 of Part II,
“Connection.”
Gear maladjustment
Adjust the gear.
Invalid time constant setting
Change the time constant Refer to “Operator’s Manual”.
setting.
Too large a brake gap
Replace the motor.
Contact FANUC.
See Sections 6.1 to 6.11.
Brake drive relay contact de- Replace the relay
position
Grease leakage
Refer to “Maintenance Manual for the Controller”.
Deteriorated or broken
O–ring, oil seal, or gasket
Replace the O–ring, oil seal, Contact FANUC.
or gasket.
Broken casting or other part
Replace the broken compo- Contact FANUC.
nent.
Loose screw
Tighten it.
Table 4.2 (b) Allowable backlash level for each axis
J1
J2
J3
J4
J5
J6
Backlash in term of
angle (min)
2.5
2.5
2.5
3.0
4.5
3.0
Backlash in term of
displacement (mm)
0.95
(1300)
0.44
(600)
0.44
(600)
0.17
(200)
0.2
(200)
0.17
(200)
NOTE
The backlash in term of displacement (mm) is measured in
the direction of rotation at a distance represented above as
the value enclosed in parentheses.
Table 4.2 (C) Allowable arm drop
At power turn–off time
5mm
At emergency stop time
5mm
30
4. TROUBLESHOOTING
4.3
COMPONENT
REPLACEMENT AND
ADJUSTMENT ITEMS
MAINTENANCE
B–81545EN/01
Adjustments are needed after a component is replaced.
The following table lists components and the adjustment items that must
be made after their replacement. After replacing a component, make
necessary adjustments according to this table.
Component replacement or
function change
Adjustment item
Cable replacement
(a) Cable dressing
(b) Simplified mastering
Change to J1–axis stroke
(a) Change to stopper position
(b) Change to parameter
Battery replacement
Replace the battery with the power
(The battery should be replaced once kept on.
a year.)
No adjustment is needed.
31
MAINTENANCE
B–81545EN/01
5
5. ADJUSTMENTS
ADJUSTMENTS
Each part of the mechanical units of a robot is set to the best condition
before the robot is shipped to the customer. The customer does not need
to make adjustments on the robot when it is delivered.
If a mechanical unit of the robot has a large backlash because of a
long–term use or component replacement, make adjustments according
to this section.
32
5. ADJUSTMENTS
5.1
REFERENCE
POSITION AND
MOVING RANGE
MAINTENANCE
B–81545EN/01
1) Reference position and operation limit
Each controlled axis is provided with a reference position and
operation limit.
A state in which a controlled axis has reached its operation limit is
known as overtravel (OT). For each axis, an overtravel condition can
be detected at the both ends of it. As long as the robot does not
encounter a servo section error or system error that causes a reference
position to be lost, the robot is controlled in such a way that it will not
go out of its operation area.
Fig. 5.1 (a) to Fig. 5.1 (g) show the reference position and operation
area (stroke) of each axis and their mechanical stopper positions.
Fig. 5.1 (h) shows the operation directions (+/– directions) of each
axis.
Stroke
Stroke end
Stroke end
Mechanical stopper
Mechanical stopper
Fig 5.1 (a) J1–axis swiveling (typically 340°)
Note)Motion limit is restricted by the
position of the J3–axis
Mechanical
stopper
Stroke
Stroke end
Stroke end
Mechanical stopper
Fig 5.1 (b) J2–axis rotation
33
B–81545EN/01
5. ADJUSTMENTS
MAINTENANCE
Note)Motion limit is restricted by the
position of the J2–axis
Stroke
Stroke end
Mechanical
stopper
Mechanical
stopper
Stroke end
Fig 5.1 (c) J3–axis rotation
Stroke end
Stroke end
Note) The mechanical stopper are not provided for J4–axis
Fig 5.1 (d) J4–axis rotation
Stroke end
Mechanical stopper
Mechanical stopper
Stroke end
Fig 5.1 (e) J5–axis wrist rotation
34
Stroke
5. ADJUSTMENTS
MAINTENANCE
B–81545EN/01
Stroke end
Stroke end
Stroke
Fig 5.1 (f) J6–axis wrist rotation
Mechanical stopper
Stroke end
J3–axis arm
Interference
angle 170°
J2–axis arm
Interference angle 10°
Stroke end
Mechanical stopper
Fig 5.1 (g) J2/J3 limit interference angle
35
5. ADJUSTMENTS
MAINTENANCE
B–81545EN/01
+
J4–axis
–
J3–axis
+
+
–
–
–
J6–axis
+
J5–axis
–
J2–axis
+
–
J1–axis
+
Fig 5.1 (h) Operation directions of each axis
36
5. ADJUSTMENTS
5.2
SIMPLIFIED
MASTERING
MAINTENANCE
B–81545EN/01
The term simplified mastering refers to a procedure for resuming the
previous position completely after a pulse coder battery backup is
disconnected because of cable replacement.
Simplified mastering cannot be used if the pulse coder phase has changed
mechanically because of a motor or reducer having been replaced. To
calibrate the robot position accurately, perform the jig–based mastering
described in Section 5.4.
1) Procedure
Described below is the simplified mastering to be performed with a
posture of zero degrees for all axes after cable replacement.
1 Before replacing the cable, be sure to take note of the system
variable $DMR_GROUP.$MASTER_COUN[1] to [6] (previous
mastering data).
2 Replace the cable according to the cable replacement procedure
described in Section 8.2.
3 If you want to release brake control, set the system variable
$PARAM_GROUP.$SV_OFF_ENB to FALSE for all axes, turn
off the power, and then perform a cold start.
4 After the power is turned on, the alarm message BZAL alarm is
displayed.
Select “TRUE” for the system variable
$MCR.SPC_RESET, turn off the power, and then perform a cold
start.
5 After the power is turned on again, the message Pulse not
established is displayed. Rotate each axis through 20° or so in
either (+ or –) direction, using an individual–axis feed command,
and then press the alarm reset key to reset this message.
6 By performing an individual–axis feed command for each axis, set
the zero–degree mark within +/–1 mm from the scribed line. (See
Fig. 5.2.) If no reference position has been set up at zero degrees
for all axes, using simplified mastering, go to 7. Otherwise, go to
8.
7 Assign the mastering data in $DMR_GROUP.$MASTER_
COUN[1] to [6] that was taken note of at 1 to the system variable
$DMR_GROUP.$REF_CONUT[1] to [6] (simplified mastering
data). Load the system variable $DMR_GROUP.$REF_POS[1] to
[6] (simplified mastering reference positions) with “0”. Select
“TRUE” for the $DMR_GROUP.$REF_DONE (simplified
mastering completion flag). Now the simplified mastering
reference position has been set up at zero degrees for all axes.
8 Press the screen selection key to select “0” NEXT, and select
SYSTEM from the menu.
9 Press the F1 key TYPE, select the system variable, and set
$MASTER_ENB value in the list to 1. Press the F1 key TYPE and
select MASTER / CAL.
10 Select The system calibration menu from the system positioning
menu, and press the F4 key YES to perform simplified mastering.
Now the mastering data obtained from the pulse coder counter
value is set in the system variable $DMR_GRP.MASTER_COUN,
and the system variable $DMR_GRP.MASTER_DONE
(mastering completion flag) is set to “TRUE”.
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11 Select CALIBRATE from the system positioning menu, and press
the F4 key YES Now positioning is carried out, and teaching and
replaying are enabled.
12 After you are finished with mastering, reset the system variable
$MASTER_ENB to 0.
13 If you released brake control before, re–set the system variable
$PARAM_GROUP.$SV_OFF_ENB for each axis to the previous
value, turn off the power, and then perform a cold start.
Once mastering is completed, update the data sheet supplied together with
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).
J5–axis
J4–axis
J6–axis
J3–axis
J2–axis
J1–axis
Fig 5.2 Marking of the zero–degree position for each axis
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5. ADJUSTMENTS
5.3
MASTERING BY
ZERO POSITION
MARK ALIGNMENT
MAINTENANCE
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Each robot axis is provided with the scribed lines shown in Fig. 5.2 for
positioning. When these markings are aligned to each other, each axis is
at the zero–degree position. If the markings get misaligned because of
motor or reducer replacement, the following procedure can be used for
rough positional calibration. This is a simplified method. To perform
accurate positional calibration, use the jig–based mastering described in
Section 5.4.
1) Procedure (zero–position mastering)
1 If you want to release brake control, set the system variable
$PARAM_GROUP.$SV_OFF_ENB to “FALSE” for all axes, turn
off the power, and then perform a cold start.
2 After the power is turned on, if the alarm message BZAL alarm is
displayed, select “TRUE” for the system variable $MCR.SPC_
RESET, turn off the power, and then perform a cold start.
3 After the power is turned on again, if the message Pulse not
established is displayed, rotate each axis through 20° or so in either
(+ or –) direction, using an individual–axis feed command, and
then press the alarm reset key to reset this message.
4 By performing an individual–axis feed command for each axis, set
each axis to the zero–degree mark. (See Fig. 5.2.)
5 Press the screen selection key to select “0” NEXT, and select
SYSTEM from the menu.
6 Press the F1 key TYPE, select the system variable, and set
$MASTER_ENB value in the list to 1. Press the F1 key TYPE and
select MASTER/CAL.
7 Select ZERO POSITION MASTER from the system positioning
menu, and press the F4 key YES to perform zero–position
mastering. Now the system variable $DMR_GRP.MASTER_
COUN is set with the mastering data obtained from the pulse coder
counter value, and the system variable $DMR_GRP.MASTER_
DONE (mastering completion flag) is set to “TRUE”.
8 Select MASTER/CAL from the system positioning menu, and
press the F4 key YES. Now positioning is carried out, and teaching
and replaying are enabled.
9 After you are finished with mastering, reset the system variable
$MASTER_ENB to 0.
10 If you released brake control before, re–set the system variable
$PARAM_GROUP.$SV_OFF_ENB to the previous value for all
axes, turn off the power, and then perform a cold start.
Once mastering is completed, update the data sheet supplied together with
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).
If you want to perform mastering for a specific axis, use the following
single–axis mastering procedure. New position information for that axis
is stored, and position information for the other axes is preserved.
As for the J2– and J3–axes, each of which is accompanied by the other,
perform mastering for them simultaneously.
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5. ADJUSTMENTS
2) Procedure (single–axis mastering)
1 If you want to release brake control, set the system variable
$PARAM_GROUP.$SV_OFF_ENB to “FALSE” for all axes, turn
off the power, and then perform a cold start.
2 After the power is turned on, if the alarm message BZAL alarm is
displayed, select “TRUE” for the system variable $MCR.SPC_
RESET, turn off the power, and then perform a cold start.
3 After the power is turned on again, if the message Pulse not
established is displayed, rotate each axis through 20° or so in either
(+ or –) direction, using an individual–axis feed command, and
then press the alarm reset key to reset this message.
4 By performing an individual–axis feed command for a desired axis,
set the axis to the zero–degree mark. (See Fig. 5.2.)
5 Press the screen selection key, select “0” NEXT, and select
SYSTEM from the menu.
6 Press the F1 key TYPE, select the system variable, and set
$MASTER_ENB value in the list to 1. Press the F1 key TYPE, and
select MASTER/CAL.
7 Select SINGLE AXIS MASTER from the system positioning
menu. A setting menu for each axis appears. Enter “1” in the (SEL)
column for the axis for which you want to perform mastering.
Enter “0” for the other axes. Enter “0” (zero degrees) in the
MASTERING POSITION column, and press the F5 key EXEC to
perform zero–degree position mastering for the selected axis.
8 Select MASTER/CAL from the system positioning menu, and
press the F4 key YES. Now positioning is carried out, and teaching
and replaying are enabled.
9 After you are finished with mastering, reset the system variable
$MASTER_ENB to 0.
10 If you released brake control before, re–set the system variable
$PARAM_GROUP.$SV_OFF_ENB to the previous value for all
axes, turn off the power, and then perform a cold start.
Once mastering is completed, update the data sheet supplied together with
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).
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5. ADJUSTMENTS
5.4
JIG–BASED
MASTERING
MAINTENANCE
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If the current–position value stored through the pulse coder becomes
different from the actual position of each axis because a major component
of the mechanical unit of the robot is replaced, mastering is performed by
specifying the geometric position of the robot. (Mastering is performed
at a position of J1 = 0 For all robots, mastering is performed at the factory.
When calibrating the robot, have it satisfy the following conditions.
D Level out the installation base for the robot (1 mm/base).
D Remove the hand and all other components from the wrist.
D Keep the robot from any external force.
NOTE
When the robot is being subjected to mastering, it does not
make a axis limit check. Pay sufficient attention to the
operation of the robot axes.
1) Mastering procedure
a) Assembling mastering jigs
i) Assembling the jig base
As shown in Fig. 5.4 (a), attach mastering jig B to mastering jig
C.
Mastering jig B
Mastering jig C
Bolt : M5 16 (3pcs)
Washer : M5 (3pcs)
Fig 5.4 (a) Assembling the jib base
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ii) Attaching to the robot main body
As shown in Fig. 5.4 (b), mount dial gauges to the jig base.
Using a calibration block, set the pointer of each dial gauge to
3.0 mm, and fix the dial gauges with M5 bolts. (Be careful when
tightening the bolts. Tightening them too firmly can break the
dial gauges.)
Calibration block
Dial gauge
(6pcs)
(Push all the dial gauges against the calibration
block, and make adjustments so that they read
3 mm travel).
Fig 5.4 (b) Attaching the dial gauge
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iii) Attaching to the robot main body
As shown in Fig. 5.4 (c), attach the jig base to the J1 base with
bolts and pins.
Pin A
A290-7215-X955
Pin B
A290-7215-X956
Bolt : M12 25 (2pcs)
Washer : M12 (2pcs)
J1 base
Fig 5.4 (c) Attaching to the robot main body
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5. ADJUSTMENTS
iv) Attaching the jig to the wrist
Manually move the wrist axis to a position of J4 = J5 = J6 = 0°.
Attach mastering jig A to the J6–axis in the orientation shown
in Fig. 5.4 (d).
Mastering jig A
Bolt : M6 12 (2pcs)
Washer : M6 (2pcs)
Pin
Fig 5.4 (d) Attaching the jig to the wrist
b) Performing mastering
1 First perform the mastering by zero–degree positioning
described in Section 5.3.
This procedure will set an approximate, temporary coordinate
origin in the robot.
2 To disable brake control, set the system variable
$PARAM_GROUP_SV_OFF_ENB to FALSE for all axes,
turn the power off, and perform a cold start.
3 Press the screen selection key, select “0” NEXT, and then select
SYSTEM from the menu. Press the F1 key TYPE, and select
the system variable. For $DMR_GROUP.$MASTER_DONE
(simplified mastering completion flag), select “FALSE” so that
each axis can move out of the stroke range. When operating the
robot, keep its taught override speed low.
4 Using a single–axis feed command, place the robot in the
mastering posture shown in Fig. 5.4 (e).
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Mastering position
Fig 5.4 (e) Mastering position
5 Press the screen selection key, select “0” NEXT, and select
SYSTEM from the menu. Press the F1 key TYPE, and select
the system variable. In the list, set $MASTER_ENB to 1. Then
press the F1 key TYPE, and select MASTER/CAL.
6 Select FIXTURE POSITION MASTER from the system
positioning menu, and press the F4 function key YES.
Mastering is performed. Now, the system variable $DMR_
GRP.MASTER_COUN is set with the mastering data obtained
from the pulse coder counter value, and the system variable
$DMR_GRP.MASTER_DONE (mastering completion flag) is
set to “TRUE”.
7 Select MASTER/CAL from the system positioning menu, and
press the F4 key YES. Positioning is performed, and teaching
and replaying become enabled.
8 Once you are finished with mastering, reset the system variable
$MASTER_ENB value to 0.
9 To enable brake control, re–set the $PARARM_GROUP.$SV_
OFF_ENB to the previous value for all axes, turn off the power,
and perform a cold start.
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5. ADJUSTMENTS
Once mastering is completed, update the data sheet supplied together with
the robot with the new mastering data ($DMR_GROUP.$MASTER_
COUN[1] to [6]).
If you want to perform mastering for a specific axis, take note of the value
of the mastering data (system variable $DMR_GROUP.$MASTER_
COUN), and then perform mastering for all axes. Once you are finished
with mastering, re–enter the mastering data of the axes other than that
specific axis. New position information for that axis is stored, and
position information for the other axes is preserved.
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5.5
1) Confirming that mastering was performed normally
CONFIRMING
MASTERING
Usually, positioning is performed automatically when the power is
turned on. To confirm that mastering was performed normally, check
that the current–position display matches the actual position of the
robot, using this procedure.
a) Replay the taught operation of the robot to set each axis to zero
degrees, and visually check that the zero–degree position marks
shown in Fig. 5.2 are aligned.
b) Replay a specific portion of the program, and check that the robot
has moved to the taught position.
2) Possible alarms in positioning
The following paragraphs describe alarms that may occur in
positioning and explain how to handle them.
a) BZAL alarm
This alarm is raised if the voltage of the pulse coder backup battery
becomes 0V when the controller power is off. Mastering must be
performed again because the counter has already lost data.
b) BLAL alarm
This alarm indicates that the voltage of the pulse coder backup
battery is too low to run the pulse coder. If this alarm is issued,
replace the backup battery soon while keeping the power on, and
check whether the current–position data is correct, using a method
described in item (1).
c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and
SPHAL alarms
If any of these alarms is issued, contact your FANUC service
representative. A motor may have to be replaced.
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5.6
If the backlash in the J5–axis is greater than the allowable value (output
axis angle of 4.5 minutes) listed in Table 4.2 (b), make backlash
adjustments, using this procedure. (See Fig. 5.6.)
1 Place the robot in a posture of J4 = +90° and J5 = J6 = 0°.
2 Remove the nine M5 10 flat–head bolts, and dismount the J5–axis
gearbox cover (A290–7215–X524) from the J3 arm (A290–7215–
X402).
J5–AXIS GEAR
BACKLASH
ADJUSTMENTS
J3 arm
Gear J5–4
Bolt with washer :
M5 25 (6pcs)
Loctite
Gear 2 assembly
Gear 3 assembly
Seal bolt with washer :
M5 12 (4pcs)
Seal bolt with washer :M5 12 (6pcs)
Plane washer (4pcs)
Low head bolt : M5 10 (9pcs)
Cover J5–1
Reference bolt
(Do not remove the bolt. Just loosen it.
Be sure to replace it with a new one after
adjustments are completed.)
Fig 5.6 J5–axis gear backlash adjustments
1) Gear 3 assembly and gear J5–4 backlash adjustments
1 Remove the four M5 12 seal bolts with a washer, and retract the
gear 2 assembly (A290–7215–V501) to such a point that it will not
be engaged with the gear 3 assembly (A290–7215–V502).
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2 Remove the five M5 12 seal bolts with a washer. These bolts
work not only for mounting but also sealing the gear unit grease
bath. Once you have removed them, replace them with new ones.
In reference to the bolt (Do not remove this bolt; just loosen it.
However, loosening it impairs its ability to seal. Once adjustments
are completed, after the other seal bolts are tightened, replace this
bolt with a new one. Otherwise, grease may leak.) shown in Fig.
5.6, push the gear 3 assembly against the output gear
(A290–7215–X514), and fix the gear 3 assembly temporarily.
After you have fixed the gear 3 assembly temporarily, rotate the J6
housing (output gear) in both positive and negative directions, and
check whether their rotation is abnormally heavy and any portion
has a serious backlash. Repeat the above procedure until any
backlash becomes lower than the maximum allowable value and
the engagement and rotation torque becomes moderate.
3 Once you have completed adjustments, fix the J3 arm with new six
M5 12 seal bolts.
2) Gear 2 assembly and gear 3 assembly backlash adjustments
1 Shift the gear 2 assembly in a direction vertical to the gear 3
assembly and input gear (A290–7215–X511) so that the backlash
is reduced, and fix the gear 2 assembly to the J3 arm with four
M5 12 seal bolts with a washer.
2 Rotate the gear 2 assembly, and check the operation of the J5–axis
by operating it within its stroke (–140° to +140°). Repeat step 1
for reducing the backlash until the gears will not interfere with each
other.
Fix the gear 2 assembly temporarily in the same manner as stated
in (1). Once you have completed adjustments, mount the assembly
with new M5 12 seal bolts with a washer.
3 Make sure that the total backlash in the J5–axis unit is lower than
the maximum allowable value (output axis angle of 4.5 minutes)
listed in Table 4.2 (b). If the requirement is not satisfied, go back
to 1 of procedure (1).
4 Fix the J5–axis gearbox cover to the J3 arm with nine M5 10
flat–head bolts.
5 Apply the specified grease to the J5–axis gearbox by following the
grease replacement procedure stated in Section 3.2.
6 Perform mastering as stated in Sections 5.3 and 5.4.
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5.7
FACTORY
MASTERING
MAINTENANCE
5. ADJUSTMENTS
Mastering using Factory Mastering information:
This procedure is used to recover the mastering information usually lost
during a software installation process.
This type of mastering can be used if all of the conditions are met:
D the motors have never been replaced
D the pulse coder or pulse coder cable have never been disconnected or
replaced
D the pulse coder back–up battery power have never been lost
Procedure:
1 Locate the factory mastering information, which is supplied inside the
robot controller unit.
2 Power up the robot and using a teach pendant manually enter the
factory mastering information into the system variable
$DMR_GROUP. $MASTER_COUNT[1]:
press MENU, press Next Page, press System, press TYPE, press
VARIABLES, locate the SDMR_GROUP and locate the
$MASTER_COUNT[1] system variable inside this group.
3 (include the section from page 37 or 38 on setting $DMR_GROUP.
$MASTER_DONE to TRUE)
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5. ADJUSTMENTS
5.8
BRAKE RELEASE
MAINTENANCE
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When the robot power is off, the brakes of the robot can be released using
the brake release unit (option). In this case, the robot can be put in a
different position. Observe Notes 1 to 4 given below.
NOTE
1 When releasing the brakes of the J2–axis or J3–axis motor
(M2 or M3), support the robot with a crane as shown in Fig.
5.7.
2 When releasing the brakes of the J4–axis to J6–axis motor
(M4 to M6), support the end effector with a crane so that it
will not fall.
3 When releasing the brakes of motors, use slings having a
sufficient tensile strength.
4 Do not release the brakes of more than one motor
simultaneously.
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Fig 5.8 Releasing the brakes of the J2–axis or J3–axis motor
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5. ADJUSTMENTS
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AND ADJUSTMENTS
6
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COMPONENT REPLACEMENT AND ADJUSTMENTS
Adjustments are needed after a component is replaced.
The following table lists components and the adjustment items that must
be made after the components are replaced. After replacing a component,
make necessary adjustments according to this table.
Replacement component
Adjustment item
Motor
(a) Mastering
J1–, J2–, and J3–axis reducers
(a) Mastering
J4–axis gearbox
(a) Mastering
J5–axis gearbox
(a) Mastering
J6–axis reducer
(a) Mastering
NOTE
Be very careful when dismounting and mounting the heavy
components that are listed below.
Component
J3–axis arm (See Fig. 6.8.)
Weight
10.4kg
All components from J3–axis reducer to wrist unit (See
Fig. 6.6.)
31kg
All components from J2–axis arm to wrist unit (See Fig.
6.4. (a).)
38.7kg
All components from J2–axis base to wrist unit (See
Fig. 6.2 (a) and (b).)
69.4kg
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
6.1
REPLACING THE
J1–AXIS MOTOR M1
1 Turn off the controller power.
2 Remove the J1–axis motor connector.
3 Remove the four M8 20 motor mounting bolts. Dismount the motor
from the J1–axis unit. When dismounting the motor, be careful of the
grease that may drop from the motor if the robot is suspended from a
ceiling or mounted on a wall.
4 Remove the M10 hexagonal nut from the motor shaft, and pull out the
gear (A290–7215–X211).
5 Attach the gear to a new motor (with two axes equipped with a brake
(A06B–0223–B005) or six axes equipped with a brake (A06B–0223–
B605)).
6 Attach an M10 spring washer, apply Loctite 242 to the M10 threaded
portion of the motor, and tighten the M10 nut with a specified torque
of [16.7 Nm].
7 Make sure that the O–ring (JB–ORIA–G105) is correctly attached to
the J2 base (A290–7215–X301) portion where the J1–axis motor is to
be mounted, and fasten them with four M8 20 bolts.
8 Attach the cable connector to the J1–axis motor.
9 According to Section 3.2, supply the J1–axis grease bath with the
specified grease.
10 While referencing Chapter 5, perform mastering.
NOTE
If there is a danger that the J1–axis section may swivel, for
example, because the robot is installed on a tilted surface,
fix the J1–axis section during replacement work, for
example, by pushing the J1–axis mechanical stopper
against the J1–axis section.
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Bolt : M8 20 (4pcs)
Washer : M8 (4pcs)
J1–axis motor
Gear
M10 Screw washer
M10 hex agonal nut
Loctite
O–ring
J2 base
Fig 6.1 Replacing the J1–axis motor
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
6.2
REPLACING THE
J1–AXIS REDUCER
(A97L–0218–0288#33)
1 Put the robot in such a position that the J2 base and the portions above
it can be suspended with a crane or the like (hereafter abbreviated as
a crane), and then turn off the controller power.
2 While referencing Section 8.2, pull out the cables below the J2 base
(A290–7215–X301) from the J1–axis hollow pipe section toward the
upper portion of the J2 base.
3 While referencing Section 6.1, remove the J1–axis motor from the J2
base.
4 As shown in Fig. 6.2 (a), remove the eight M10 50 bolts that fasten
the J2 base to the J1–axis reducer.
5 While referencing Section 3.1 of Part II, “Connection,” hoist the J2
base and portions above it slowly.
6 As shown in Fig. 6.2 (a), remove the O–ring (A290–7207–X342),
bearing, and center gear (A290–7215–X212).
7 Remove the six M12 80 bolts that fasten the J1–axis reducer to the
J1 base (A290–7215–X201), and dismount the reducer.
8 As shown in Fig. 6.2 (b), remove the four M4 10 bolts that fasten the
pipe (A290–7215–X213) to the reducer, and dismount the pipe.
9 Make sure that the pipe is fitted with the O–ring (JB–ORIA–G60)
correctly, and attach the pipe to a new reducer (A97L–0218–0288#33)
with four M4 10 bolts.
10 Attach the O–rings (S100 and S150) to the reducer, and fasten the
reducer to a new J1 base with six M12 80 bolts (by applying Loctite
262 and tightening with a torque of [129 Nm]).
11 Mount the center gear, bearing (with Loctite 675 applied to its outer
ring), and O–ring (A290–7207–X342) to the reducer.
12 Fasten the J2 base to the reducer with eight M10 50 bolts (by
applying Loctite 262 and tightening with a torque of [73.5 Nm]). Be
careful not to let the pipe damage the oil seal.
13 According to Section 6.1, mount the J1–axis motor on the J2 base.
14 According to Section 3.2, supply the J1–axis grease bath with the
specified grease.
15 While referencing Chapter 5, perform mastering.
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J1–axis motor
Bolt : M10X50 (8pcs)
Loctite
Washer : M10 (8pcs)
O–ring
Bearing
Bolt : M12
Loctite
O–ring
80 (6pcs)
Washer : M12 (6pcs)
J1–axis reducer
Center gear
O–ring
O–ring
Fig 6.2 (a) Replacing the J1–axis reducer
J1–axis reducer
O–ring (G60)
Pipe
A290–7215–X213
Bolt : M4 10 (4pcs)
Washer : M4 (4pcs)
Fig 6.2 (b) Replacing the J1–axis reducer
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
6.3
REPLACING THE
J2–AXIS MOTOR M2
1 Push the J2–axis section against the mechanical stopper, or fix it in
such a way that it will not swivel when the motor is dismounted, for
example, by placing it in the direction of gravity.
NOTE
If the J2–axis section is not pushed against the stopper
correctly, or it is not placed in the direction of gravity, there
is a danger that the J2–axis section will swivel when the
J2–axis motor is removed.
2 Turn off the controller power.
3 Remove the J2–axis motor connector.
4 Remove the four M8 20 motor mounting bolts, and dismount the
motor from the J2 base.
5 Remove the M6 hexagonal nut that fastens the input spline, and
dismount the input spline. Also remove the draw bolt from the motor
shaft.
6 Apply Loctite 242 to the threaded portion of a new motor
(A06B–0223–B605), and tighten the draw bolt with a torque of [16.7
Nm].
7 Put the input gear over the draw bolt, attach an M6 spring washer,
apply Loctite 242 to the M6 threaded portion of the draw bolt, and
tighten the M6 nut with a torque of [5.5 Nm].
8 Make sure that the O–ring (JB–ORIA–G115) is correctly attached to
the J2 base (A290–7215–X301) portion where the motor is to be
mounted, and fasten the motor to the J2 base with four M8 20 bolts.
Do not force in the motor. Otherwise, the input spline may not settle
in the correct place, possibly causing vibration (if the spline is engaged
correctly, the motor will be mounted smoothly).
9 Attach the cable connector to the J2–axis motor.
10 According to Section 3.2, supply the J2–axis grease bath with the
specified grease.
11 While referencing Chapter 5, perform mastering.
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Draw bolt
Loctite
Input spline
M6 Spring washer
M6 nut
Loctite
J2–axis motor
O–ring
Bolt : M8 20 (4pcs)
Washer : M8 (4pcs)
J2 base
Fig 6.3 Replacing the J2–axis motor
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
6.4
REPLACING THE
J2–AXIS REDUCER
1 Put the robot in such a posture that the J2 arm (A290–7215–X302) and
the components on it can be suspended with a crane, and then turn off
the controller power.
2 Suspend the J2 arm and the components on it with a crane so that they
will not drop when the J2 arm is dismounted.
3 As shown in Fig. 6.4 (a), remove the ten M10 50 bolts that fasten the
J2 arm, dismount the J2 arm and plate (A290–7215–X321) from the
J2–axis reducer, and then dismount adapter 1 (A290–7210–X321). Be
careful not to allow an excessive load to be put on the cables (because
the cables are left attached when the reducer is dismounted).
4 Remove the eight M8 35 bolts that fasten the J2–axis reducer to the
J2 base, and dismount the J2–axis reducer from the J2 base.
5 Attach the O–ring (AS258) to a new reducer (A97L–0218–0289#153),
insert it into the J2 base, and fasten them with eight M8 35 bolts (by
applying Loctite 262 and tightening with a torque of [37.2 Nm]).
6 Degrease both the J2 arm and the J2–axis reducer surfaces that are to
meet each other, and as shown in Fig. 6.4 (b), apply sealant (Loctite
No. 518) to the J2 arm surface on which the J2 reducer is to be
mounted.
7 After attaching adapter 1 (A290–7210–X321) to the J2–axis reducer,
mount the J2 arm on the J2 reducer, insert the plate
(A290–7215–X321), and fasten the J2 arm with ten M10 50 bolts
(by applying Loctite 262 and tightening with a torque of [73.5 Nm]).
8 According to the grease replacement procedure described in Section
3.2, supply the J2–axis grease bath with the specified grease.
9 While referencing Chapter 5, perform mastering.
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Adapter
Bolt : M8 35 (8pcs)
Loctite
Washer : M8 (8pcs)
Plate
J2–axis reducer
O–ring
Bolt : M10 50 (10pcs)
Loctite
Washer : M10 (10pcs)
Fig 6.4 (a) Replacing the J2–axis reducer
Fig 6.4 (b) Applying sealant to the J2–axis reducer
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
NOTE
Observe the following cautions when applying sealant
(Loctite No. 518).
1 Cleaning the surface where sealant is to be applied
1) Remove dust from the surface and the inside of the
threaded holes, for example, by blowing it off.
2) Degrease the surface completely with a cloth dampened
with solvent. Do not spray solvent directly onto the
surface.
3) Wipe off any solvent from the surface with a dry cloth.
Make sure that no solvent is left in the threaded holes or
on any other portion.
4) Always use a new surface of a cloth so that the grease
once wiped up with the cloth will not get on the degreased
surface.
2 Allowing time during which the sealant can cure
To let the applied sealant cure, avoid running the robot and
applying grease for at least four hours after the sealant is
applied.
3 Wiping off excessive sealant
After attaching the cover, wipe off any excessive sealant
that comes out from the sealed section with a cloth or
spatula. Do not use solvent.
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6.5
REPLACING THE
J3–AXIS MOTOR M3
1 Push the J3–axis section to the mechanical stopper, or fix it in such a
way that it will not swivel when the motor is dismounted, for example,
by placing it in the direction of gravity.
NOTE
If the J3–axis section is not pushed against the stopper
correctly, or it is not placed in the direction of gravity, there
is a danger that J3–axis section will swivel when the J3–axis
motor is removed.
2 Turn off the controller power.
3 Remove the connector of a cable leading to the J3–axis motor.
4 Remove the four M6 14 bolts that fasten the J3–axis motor to the J3
casing (A290–7215–X401), and dismount the motor and gasket.
5 Remove the M5 nut from the motor shaft, and dismount the input
spline and draw bolt.
6 Apply Loctite 242 to the threaded portion of a new motor
(A06B–0202–B605), and tighten the draw bolt with a torque of [3.2
Nm].
7 Put the input gear over the draw bolt, attach an M5 spring washer,
apply Loctite 242 to the M5 threaded portion of the draw bolt, and
tighten the M5 nut with a torque of [3.2 Nm].
8 Attach a new gasket (A98L–0040–0042#03), and insert the motor into
the reducer. Keep the J3–axis degrease outlet on the J2 arm side open
(see Fig. 3.1), and look into the outlet to make sure that the input spline
has settled in the correct place. Even one tooth of a shift in engagement
can cause vibration. (If the input spline is engaged correctly, the motor
can get in the reducer smoothly.)
9 Fasten the motor to the J3–axis reducer with four M6 14 bolts. Be
sure to use a new gasket so as to prevent grease leakage.
10 Attach the cable connector to the J3–axis motor.
11 According to Section 3.2, supply the J3–axis grease bath with the
specified grease.
12 While referencing Chapter 5, perform mastering.
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
Packing
J3–axis motor
M5 nut
Loctite
M5 Spring washer
Input gear
Draw bolt
Loctite
J3–axis casing
Bolt : M6 14 (4pcs)
Washer : M6 (4pcs)
Fig 6.5 Replacing the J3–axis motor
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COMPONENT REPLACEMENT
AND ADJUSTMENTS
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6.6
REPLACING THE
J3–AXIS REDUCER
1 Put the robot in such a posture that the J3–axis section and the
components on it can be suspended with a crane, and then turn off the
controller power.
2 While referencing Section 8.2, remove the cable from the J2 arm
section.
Suspend the J3–axis section and the components on it with a crane so
that they will not drop when the reducer is dismounted from the J2 arm.
Be careful not to allow an excessive load to be put on the cable
(because the cables are left attached when the reducer is dismounted).
3 As shown in Fig. 6.6, remove the six M10 45 bolts that fasten the
J3–axis reducer to the J2 arm, and dismount the J3 arm unit from the
J2 arm.
4 While referencing Section 6.5, dismount the J3–axis motor from the
J3 arm unit.
5 Remove ten M6 30 bolts that fasten the J3–axis reducer to the J3
casing (A290–7215–X401), dismount the J3–axis reducer from the J3
casing, and remove the O–ring from the J3–axis reducer.
6 Attach an O–ring (SO120) to a new reducer (A97L–0218–0295#161),
mount the reducer on the J3 casing, and fasten them with ten M6 30
bolts (by applying Loctite 262 and tightening with a torque of [15.7
Nm]).
7 While referencing Section 6.5, mount the J3–axis motor on the J3 arm
unit.
8 Remove the O–ring from the J2 arm, degrease both the J2 arm and the
J3–axis reducer surfaces that are to meet each other, and as shown in
Fig. 6.6 (b), apply sealant (Loctite No. 518) to the J2 arm surface on
which the J3 reducer is to be mounted.
9 Attach adapter 2 (A290–7210–X322) and the O–ring (SO100) to the
J2 arm surface on which the J3–axis reducer is to be mounted.
10 Suspend the J3–axis section and the components on it with a crane, and
fasten the J2 arm and J3–axis reducer with six M10 45 bolts (by
applying Loctite 262 and tightening with a torque of [73.5 Nm]).
11 While referencing Section 8.2, dress the cable into the previous form.
12 According to Section 3.2, supply the J3–axis grease bath with the
specified grease.
13 While referencing Chapter 5, perform mastering.
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
Bolt : M10 45 (6pcs)
Loctite
Washer : M10 (6pcs)
J3 casing
Plate
Adapter
O–ring
Packing
O–ring
J3–axis motor
J3–axis reducer
Bolt : M6 30 (10pcs)
Loctite
Washer : M6 (10pcs)
Fig 6.6 (a) Replacing the J3–axis reducer
Fig 6.6 (b) Applying sealant to the J3–axis reducer
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AND ADJUSTMENTS
MAINTENANCE
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6.7
REPLACING THE
J4–AXIS MOTOR M4
1 Place the robot in a posture of J4 = –90°. Keep this condition until step
<10> (mastering). Note that if the operation for setting the
zero–degree position is performed incorrectly, the cable may be
twisted more than allowed, leading to a broken cable. If the robot is
in a posture of J3 = –90°, grease will not drop when the motor is
dismounted.
2 Turn off the controller power.
3 Remove the connector of a cable leading to the J4–axis motor.
4 As shown in Fig. 6.7, remove the three M6 14 bolts that fasten the
J4–axis motor to the J3 casing (A290–7215–X401), and dismount the
motor.
5 Remove the nut (A290–7215–X412) that fastens the J4–1 gear
(A290–7215–X411) to the motor shaft, and dismount the J4–1 gear
and M5 spring washer.
6 Mount the J4–1 gear to a new motor (with two axes equipped with a
brake (A06B–0202–B005) or six axes equipped with a brake
(A06B–0202–B605)), apply Loctite 242 to the threaded portion of the
motor shaft, and fasten them with a nut (A290–7215–X412) by
tightening with a torque of [9 Nm]. (Be very careful when tightening
the nut because if you do not tighten with the specified torque, the
J4–axis may get out of place.)
7 Make sure that the O–ring (G75) is put accurately in the J3 casing
portion where the motor is to be mounted, and fasten the motor to the
J3 casing with three M6 14 bolts.
8 Attach the cable connector to the J4–axis motor.
9 According to Section 3.2, supply the J4–axis grease bath with the
specified grease.
10 While referencing Chapter 5, perform mastering.
Gear J4–1
M5 Spring washer
Nut
J4–axis motor
Loctite
Bolt : M6 14 (3pcs)
Washer : (3pcs)
O–ring
J3 casing
Fig 6.7 Replacing the J4–axis motor
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
6.8
REPLACING THE
J4–AXIS GEARBOX
1 Turn off the controller power.
2 According to Section 8.2, remove the cables that run from the
J3–/J4–axis motor connectors through the clamps on the J3 casing and
in the J3 arm to the J6–axis motor in the J6 housing, and take them out
from the J3 arm unit.
3 Suspend the J3 arm through an M6 eye bolt with a crane. Remove the
six M6 70 bolts that fasten the J3 arm to the J4 gearbox unit, and
dismount the J3 arm from the J4–axis gearbox unit. (See Fig. 6.8.)
4 Suspend the J4–axis gearbox unit above the J3 casing
(A290–7215–X401) through an M6 eyebolt with a crane. Remove the
six M10 45 bolts that fasten the J4 gearbox unit to the J2 arm, and
dismount the J4 gearbox unit from the J2 arm.
5 According to the procedures described in Sections 6.5, 6.6, and 6.7,
dismount the J3– and J4–axis motors and J3–axis reducer.
6 According to the procedures described in Sections 6.6 and 6.7, mount
the J4–axis motor and J3–axis reducer on a new J4–axis gearbox
(A05B–1215–K401).
Do not forget to insert an O–ring and gasket.
7 Fasten the J4–axis gearbox unit mentioned in <6> with ten M10 45
bolts (by applying Loctite 262 and tightening with a torque of [73.5
Nm]).
8 According to the procedure described in Section 6.5, mount the
J3–axis motor.
9 Suspend the J3 arm with a crane, fasten the J4–axis box with six
M6 70 bolts (by applying Loctite 262 and tightening with a torque
of [15.7 Nm]).
10 According to Section 8.2, dress the cables that run from the clamp on
the J3 casing to the J6–axis motor in the J6 housing through the clamp
in the J3 arm into the previous form. Attach the J3 and J4–axis motor
connectors.
11 According to Section 3.2, supply the J3– and J4–axis grease baths with
the specified grease.
12 While referencing Chapter 5, perform mastering.
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AND ADJUSTMENTS
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Bolt : M6 70 (6pcs)
Loctite
Washer : M6 (6pcs)
J3 arm unit
J3 casing
J3–axis gear box
Fig 6.8 Replacing the J4–axis gearbox unit
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MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
6.9
REPLACING THE
J5–AXIS MOTOR M5
1 Place the robot in a posture of J4 = –90°.
2 Turn off the controller power.
3 As shown in Fig. 6.9, remove the four M6 16 bolts, rotate the J5–2
cover (A290–7215–X502) around the J5–axis to such a point that the
J5 motor can be taken out, and fasten it to the J3 arm
(A290–7215–X402) temporarily.
4 While referencing Section 8.2, detach the clamp (A290–7215–X525)
from the inside of the J3 arm, and take out inline cable connectors
M5M1 and M5P1.
5 Remove the four M5 12 bolts with a washer that fasten the J5–axis
motor to the J3 arm, and dismount the motor from the J3 arm.
6 Remove the two M3 4 setscrews that fasten the J5–1 gear
(A290–7215–X511) to the motor shaft, and pull out the gear. Also
detach the leads from the motor.
7 Bond a new key (JB–HKY–3 3 8A) to a new motor (with two axes
equipped with a brake (A06B–0115–B075#0008) or six axes equipped
with a brake (A06B–0115–B275#0008)) with Loctite 675, mount the
J5–1 gear, and fasten them with setscrews M3 4 (by applying Loctite
242). Be careful not to allow the key to stick out from the gear when
bonding it.
8 Attach the leads that were detached at <6> to the motor.
9 Attach a new gasket (A98L–0040–0042#07) to the motor flange with
Alvania grease, fasten the motor to the J3 arm with four new M5 12
seal bolts with a washer. Be sure to use new seal bolts. Otherwise,
grease may leak.
10 While referencing Section 8.2, attach the inline cable connectors,
attach the clamp to the inside of the J3 arm, and dress the cables into
the previous form.
11 While being careful not to allow the gasket (A290–7215–X527) to
stick out or to be twisted and not to have non–bound cable portions
caught between the gasket and motor flange, fasten the J5–2 cover
with four M6 16 bolts (by applying Loctite 242 and tightening with
a torque of [15.7 Nm]).
12 According to Section 3.2, supply the J5–axis grease bath with the
specified grease.
13 While referencing Chapter 5, perform mastering.
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Cover J5–2
Fixing bolt : M6 16 (4pcs)
Loctite
Connector of cable relay
Washer : M6 (4pcs)
Clamp in J3 arm
Seal bolt with washer : M5 12 (4pcs)
J5–axis motor
Leads attached
to the motor
key
Loctite
Set screw : M3 4 (2pcs)
Loctite
Gear
Packing
Fig 6.9 Replacing the J5–axis motor
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MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
6.10
REPLACING THE
J5–AXIS GEAR
1 To replace the J5–1 gear, follow the motor replacement procedure
stated in Section 6.9.
2 Place the robot in a posture of J4 = +90° and J5 = 0°.
3 Turn off the controller power.
4 According to Section 6.9, dismount the J5–axis motor.
5 As shown in Fig. 6.10, remove the nine M5 10 flat–head bolts, and
dismount the J5–1 cover (A290–7215–X524).
6 Remove the four M5 12 seal bolts with a washer that fasten the gear
2 assembly (A290–7215–V501), and dismount the gear 2 assembly
from the J3 arm.
7 Remove the six M5 12 seal bolts with a washer that fasten the gear
3 assembly (A290–7215–V502), and dismount the gear 3 assembly
from the J3 arm.
8 Remove the six M5 25 bolts that fasten the J5–4 gear
(A290–7215–X514), and dismount the J5–4 gear from the J3 arm.
9 Fasten a new J5–4 gear to the J3 arm with six M5 25 bolts (by
applying Loctite 262 and tightening with a torque of [9 Nm]).
10 According to the backlash adjustment procedure described in Section
5.7, make backlash adjustments on a new gear 3 assembly, and fasten
it to the J3 arm.
11 According to the backlash adjustment procedure described in Section
5.7, make backlash adjustments on a new gear 2 assembly, and fasten
it to the J3 arm.
12 Once the backlash adjustments described in Section 5.7 are
completed, fasten the J5–1 cover to the J3 arm with nine M5 10
flat–head bolts by tightening them with a torque of [4 Nm].
13 According to Section 3.2, supply the J5–axis grease bath with the
specified grease.
14 While referencing Chapter 5, perform mastering.
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J3 arm
A290–7215–X402
Gear J5–4
A290–7215–X514
Bolt with washer : M5 25 (6pcs)
Loctite 262
Gear 3 assembly
A290–7215–V502
Gear 2 assembly
A290–7215–V501
Seal bolt with washer : M5 12 (4pcs)
Seal bolt with washer : M5 12 (6pcs)
Washer : M5 (4pcs)
Low head bolt : M5 10 (9pcs)
Cover J5–1
A290–7215–X524
Basic bolt
(Don’t remove the bolt but loose it.
After adjustment, be sure to replace the new bolt.)
Fig 6.10 Replacing the J5–axis gear
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MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
6.11
REPLACING THE
J6–AXIS MOTOR M6
AND REDUCER
1) Replacing the J6–axis motor M6
1 Place the robot in a posture of J4 = –90° and J5 = 0°.
2 Turn off the controller power.
3 While referencing Section 8.2, dismount the J5–2 cover, remove
the two M4 6 seal bolts that fasten the J5–2 clamp
(A290–7215–X531) in the cover, and release the J5–2 clamp. Now
it is easy to take out the wrist flange. (The J5–2 clamp can move
through the J5 hollow section.)
4 As shown in Fig. 6.11 (a), remove the four M5 25 bolts, and
dismount the wrist flange from the J6 housing
(A290–7215–X501).
5 While referencing Section 8.2, remove the two M3 6 bolts that
fasten the J6 motor connector to the J6 clamp (A290–7215–X534),
and dismount the clamp from the wrist flange.
6 Remove the four M5 12 bolts with a washer that fasten the motor
to the wrist flange, and dismount the motor from the wrist flange.
7 Remove the M3 8 bolts and washers (A290–7215–X532), and
dismount the reducer wave generator from the motor.
8 Fasten the wave generator to the shaft of a new motor (with two
axes equipped with a brake (A06B–0114–B075#0008) or six axes
equipped with a brake (A06B–0114–B275#0008)) with M3 8
bolts by applying Loctite 242 and tightening with a torque of [2
Nm]. (Do not forget to insert washers [A290–7215–X532].) Also
apply a plenty of grease (Moly White RE No. 00) around the wave
generator.
9 Attach a new gasket (A97L–0040–0042#07) to the motor flange
with Alvania grease, and fasten the motor to the wrist flange with
four M5 12 bolts with a washer (by applying Loctite 262). Be
sure to use a new gasket so as to prevent grease leakage.
10 Pass a new gasket (A290–7215–X533) over the cable, and attach
the J6 clamp (A290–7215–X534) to the wrist flange with two
M3 6 bolts. Attach the motor cable connector. It will be
convenient that you hook the gasket on the parallel pins on the J6
housing.
11 After making sure that the gasket (A290–7215–X533) is placed
properly between the J6 housing and wrist flange, fasten the wrist
flange equipped with the motor to the J6 housing with four M5 25
bolts by (applying Loctite 262 and) tightening with a torque of [9
Nm]. At this point, while referencing Section 8.2, be careful to
keep non–bound movable cable portions in the J5–axis hollow
section from being caught in the J6 housing. If the robot is
assembled and put in operation with the cables caught, it is likely
that the service life of the cables may be badly shortened.
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12 While referencing Section 8.2, being careful to keep the
non–bound movable cable portions in the J5–axis hollow section
from being twisted, fasten the J5–2 clamp (A290–7215–X531) to
the J5–2 cover (A290–7215–X502) with two new M4 6 seal
bolts. Be sure to use new bolts. Otherwise, the seal–ability of the
wrist section may get lower. Then, while referencing Section 6.9,
mount the J5–2 cover to the J3 arm (A290–7215–X402).
13 As described in Section 3.2, supply the J6–axis grease bath with the
specified grease.
14 While referencing Chapter 5, perform mastering.
2) Replacing the J6–axis reducer
1 Turn off the controller power.
2 Following procedure (1) on the previous page, remove the J5–2
cover, and dismount the wrist flange from the J6 housing
(A290–7215–X501). Also dismount the motor from the wrist
flange, then wave generator from the motor.
3 While referencing Section 8.2, remove the two M3 6 bolts that
fasten the J6 motor connector and J6 clamp (A290–7215–X534),
and dismount the J6 clamp from the wrist flange.
4 Remove the four M5 12 bolts with a washer that fasten the motor
to the wrist flange, and dismount the motor from the wrist flange.
5 Remove M3 8 bolts and washers (A290–7215–X532), and
dismount the reducer wave generator from the motor.
6 By following procedure (1) on the previous page, mount a new
reducer wave generator to the motor, and apply a plenty of grease
around the wave generator.
7 As shown in Fig. 6.11 (b), remove the eight M3 40 bolts with a
washer that fasten the adapter (A290–7215–X543) to the
cross–roller ring, and dismount the adapter (A290–7215–X543)
from the cross–roller ring.
8 Remove the twelve M3 15 bolts with a washer that fasten the
circular spline, adapter B (A290–7215–X544), and the ring
(A290–7215–X545) to the adapter (A290–7215–X543), and
dismount the adapter from the circular spline. Mount and fasten a
new circular spline together with adapter B (A290–7215–X543)
and the ring to the adapter (A290–7215–X543) with twelve
M3 15 bolts with a washer (by applying Loctite 262 and
tightening with a torque of [2 Nm]).
9 Remove the six M5 12 bolts that fasten the flex spline, and
dismount the flex spline from the cross–roller ring. Position a new
flex spline with the flange (A290–7210–X524) and f3 8 parallel
pins, and fasten it with six M5 12 bolts with a washer (by
applying Loctite 262 and tightening with a torque of [9 Nm]).
10 After making sure that the O–ring (S71) is set properly in the
adapter (A290–7215–X543), mount the cross–roller ring on the
(A290–7215–X543), and fasten them with eight M3 40 bolts
with a washer (by applying Loctite 262 and tightening a torque of
[2 Nm]).
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
11 While referencing (1) in Section 6.11, mount the motor, and also
mount the wrist flange to the J6 housing. Then attach the J5–2
cover.
12 According to Section 3.2, supply the J6–axis grease bath with the
specified grease.
13 While referencing Chapter 5, perform mastering.
Bolt with washer : M5 12 (4pcs)
Clamp
Fixing bolt : M3 6 (2pcs)
Packing
Packing
Wave generator
Wrist flange
Washer
J6 housing
Pin
Bolt : M3 8
Loctite
Washer : M3
Bolt : M5 25 (4pcs)
Loctite
Washer : M5 (4pcs)
Fig 6.11 (a) Replacing the J6–axis motor and reducer
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COMPONENT REPLACEMENT
AND ADJUSTMENTS
MAINTENANCE
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Bolt with washer : M5
Loctite
O–ring
Ring
Flange
Adapter
Wave generator
Flex spline
Cross roler ring
Circular spline
Packing
Adapter
Washer
Bolt : M3
Loctite
Bolt with washer : M3 40 (8pcs)
Loctite
8
Washer : M3
Packing
Straight pin (2pcs)
Bolt with washer: M3 15 (12pcs)
Loctite
Fig 6.11 (b) Replacing the J6–axis reducer
77
12 (6pcs)
7. PIPING AND WIRING
7
MAINTENANCE
PIPING AND WIRING
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7.1
MAINTENANCE
7. PIPING AND WIRING
Fig. 7.1 shows the diagram of piping in the mechanical unit.
PIPING DRAWING
Fig 7.1 (a) Piping diagram
Fig 7.1 (b) Piping diagram (LECO W/F)
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MAINTENANCE
7. PIPING AND WIRING
7.2
Fig. 7.2 (a) and Fig. 7.2 (b) show the diagrams of wiring in the mechanical
unit.
WIRING DIAGRAMS
Controller
B–81545EN/01
Mechanical unit
J1–axis motor
J1–axis connector board
J2–axis motor
J3–axis motor
J4–axis motor
J5–axis motor
J6–axis motor
K102 : 5 pin
K103 : 24 pin
Earth
Battery
Panel union
Famale Rc 3/8
End effector
Air
Panel union
Famale Rc 3/8
J3–axis casing
connector board
Fig 7.2 (a) Wiring in the mechanical unit with two axes equipped with a brake
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7. PIPING AND WIRING
MAINTENANCE
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Controller
Mechanical unit
J1–axis motor
J1–axis connector panel
J2–axis motor
J3–axis motor
J4–axis motor
J5–axis motor
J6–axis motor
K105 : 5 pin
K106 : 24 pin
Earth
Battery
Panel union
Famale Rc 3/8
End effector
Air
Panel union
Famale Rc 3/8
J3–axis casing
connector panel
Fig 7.2 (b) Wiring in the mechanical unit with all axes equipped with a brake
81
7. PIPING AND WIRING
7.3
CABLE MOUNTING
DIAGRAM
MAINTENANCE
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Make the following visual checks to see if there are any cable
abnormalties:
1) Whether the swiveling motion of the robot has caused any local torsion
or bending in the swiveling section.
2) Whether the cables leading to the J2– or J3–axis sections have worn
each other during operation.
3) Whether the route of cables leading to the end effector is appropriate
for the operation of the wrist and the service operation of the robot.
Fig. 7.3 is the mounting diagram of cables in the mechanical unit.
(2–axis brake type)
(6–axis brake type)
(2–axis brake type)
(6–axis brake type)
Fig 7.3 Cables in the mechanical unit
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8. CABLE REPLACEMENT
8
MAINTENANCE
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CABLE REPLACEMENT
Replace the cables of the robot once every four years. If a cable is broken
or damaged, replace it according to the procedure described in this
chapter.
Cautions in handling the
pulse coder cable
When transporting, installing, or maintaining the robot, do not detach the
pulse coder cables carelessly. The cables are provided with the marking
tie shown below. If you detached any cable with the marking tie, you need
to perform mastering for the robot.
Do not detach any connector unless you replace a motor, pulse coder,
reducer, or cable.
BATTERY BACKUP
DON’T
DISCONNECT
MARKING TIE
Fig 8 Marking tie
If there is a break in or any other damage to a cable, replace the cable
according to the procedure described in this chapter. If the connector of
a pulse coder cable (K101, K102, K103, K104, K105, K106, K201, or
K202) is detached, the data about the absolute position of the robot is lost.
Once any of these cables is replaced, perform simplified mastering while
referencing Section 5.3. If the data is lost because of a break in a cable,
also perform simplified mastering to calibrate the robot into the previous
absolute position.
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8.1
CABLE DRESSING
MAINTENANCE
8. CABLE REPLACEMENT
After a cable is replaced individually rather than in kit, clamp it with
rubber bushings and nylon ties (cable ties) at the specified positions listed
in Table 8.1. Otherwise, the cable may sag or become too tight, leading
to a break in the cable.
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Table 8.1 Cable clamp positions
Mark
Cable clamping position
85
Mark
No.
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8.2
REPLACING CABLES
MAINTENANCE
8. CABLE REPLACEMENT
First, place the robot in a posture of the J4–axis being at –90° and all other
axes being at 0°. Before starting cable replacement, put the controller
apart from the robot main body.
1) Replacing the cable kit
1 Cut the nylon ties (cable ties) for the J2–/J3–axis Cornex cover, and
take out the cover from the cable kit.
2 Dismount the J1 connector board from the J1 base. (See Fig. 8.2
(a).)
3 Cut the nylon tie that bounds the rubber boot, and detach the rubber
boot from the cable. Separate the RM1 and RP1 connector inserts
from the connector housing on the J1 connector board. (Dismount
the connector housing from the J1 connector board because
otherwise the rubber boot will get caught on the housing and their
removal will be hindered.)
Dismount the terminals from the battery box.
4 Remove the M1M, M1BK (with six axes equipped with a brake),
M2M, M2BK, M1P, and M2P connectors from the J1–/J2–axis
motor.
5 While referencing Fig. 8.2 (a), remove the two M6 6 bolts that
fasten the plate (A290–7215–X222) in the J1 base, and pull out the
cable from the inside of the J1 base toward the upper section of the
J1 hollow pipe section. The connector inserts mentioned in <3>
tend to get caught inside the pipe. Do not force it out from the pipe.
Otherwise, a break may occur in the cable.
6 While referencing Fig. 8.2 (b), remove the two M6 10 bolts that
fasten the cable cover above the J2 base (A290–7215–X301), and
dismount the cable cover.
7 While referencing Fig. 8.2 (b), remove the two M8 10 bolts that
fasten the plate (A290–7215–X331), and dismount the plate.
8 While referencing Fig. 8.2 (b), remove the four M8 10 cable kit
mounting bolts from the J2 arm, and dismount the cable kit from
the J2 arm.
9 While referencing Section 6.11, dismount the J5–2 cover and wrist
flange unit, and then remove the J6–axis motor connector. Then,
as shown in Fig. 8.2 (c), cut nylon ties (cable ties) for the J6 clamp
(A290–7215–X534) and the J5–2 clamp (A290–7215–X531) [and
also for the support (A290–7215–X529)] to separate the
non–bound cables portions.
10 While referencing Fig. 8.2 (b), remove the four M6 10 bolts that
fasten the plate (A290–7215–X430) on the rear of the J3 casing.
Loosen the nut for the resin bushing that fastens the plate, and slide
the bushing in such a direction that the cable will become loose.
11 As shown in Fig. 8.2 (c), remove the two M5 10 bolts that fasten
the J5–1 clamp (A290–7215–X525), and dismount the J5–1 clamp
from the J3 arm, and pull it out. Then, cut the nylon ties (cable ties),
and pull out the cable from the inside of the wrist toward the rear
of the J3 casing.
12 While referencing Fig. 8.2 (b), remove the two M6 10 bolt that
fasten the plate (A290–7215–X426) on the J3 casing, and dismount
the cable kit completely from the robot main body.
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8. CABLE REPLACEMENT
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13 Mount a new cable kit by reversing the above steps. In this case,
however, do not tighten the nut for the resin bushing on the plate
(A290–7215–X430) behind the J3 casing. After passing the cables
through the J3 arm, pass them through the J5–2 cover
(A290–7215–X502) and gasket (A290–7215–X527), and then
insert them into the J6 housing.
14 After going back to 8 on the previous page, fasten the J5–2 clamp
(A290–7215–X531) together with the support (A290–7215–X529) to
the non–bound cable portions. After fixing the nylon ties, do not
fasten the J5–2 clamp to the J5–2 cover immediately; keep it loose.
15 While referencing Fig. 8.2 (c), attach the J6 clamp
(A290–7215–X534) to the non–bound cable portions. Be careful
to keep non–bound twisted pairs from being twisted. Also
carefully observe a rated clamp distance of 160 mm shown in Fig.
8.2 (c).
16 After making sure that the non–bound twisted pairs are not twisted
in the J5–axis hollow section or not caught in the J6 housing, fasten
the J6 clamp (A290–7215–X534) to the J5–2 cover with two new
M4 6 seal bolts.
Then make sure that J5–1 clamp
(A290–7215–X525) is fastened to the inside of the J3 arm securely,
and mount the J5–2 cover. At this point, make sure that the
non–bound cable portions are not worn against any sheet metal
edge inside the J3 arm and that they are not caught under the J5–2
cover when it is attached. (If it is likely that a non–bound cable
portion may be worn against any sheet metal edge, confine it with
a nylon tie (cable tie) or take a similar measure.)
17 With the nut for the resin bushing on the plate (A290–7215–X430)
behind the J3 casing kept loose, twist the cables passing the J4
hollow section through 90° counter clockwise as viewed from
behind the J3 casing (to prevent the cables from twisting when the
J4–axis is at 0°) so that the cables will not be too tight or not sag
behind the J3 casing. Then tighten the resin nut by hand.
18 Mount the cable kit by going back from 7 to 2.
19 Attach the rubber boot to the previous place.
Before mounting the J1 connector board to the J1 base, push the OT
jumper connector into the rubber boot, and bind the opening of the
rubber boot for both RM1 and RP1 with a nylon tie. While being
careful not to pinch non–bound cable portions, mount the J1
connector board on the J1 base.
20 Mount the J2–/J3–axis Cornex cover on the cable kit again, and
fasten them with a nylon tie (cable tie). (Do not fasten the nylon
tie too tightly.)
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MAINTENANCE
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8. CABLE REPLACEMENT
2) Replacing the cables separately
1 While referencing item (1) of Section 8.2, dismount the cable kit
from the robot main body, and remove the J2–/J3–axis Cornex
cover.
2 While referencing Fig. 8.2 (d), dismount the clamp and grommet
from the cable kit, and replace the cables. After cable replacement,
mount the clamp and grommet, but do not tighten the mounting
bolts.
3 Mount the cable kit on the robot main body as before. (See (1) of
Section 8.2.) Arrange the cables inside and outside the J2–/J3–axis
movable section by shifting the wires so that they are at regular
intervals and look natural. After their length is adjusted, tighten the
mounting bolts for the grommet retaining clamp.
4 Mount the Cornex cover as before. (Tighten the nylon tie but not
firmly.)
Connector insert
(PM1, RP1)
Rubber boot
Connector
housing
Bolt : M4 10
(8pcs)
J1 connector
board
J1 hollow pipe
Plate
A290–7215–X222
Bolt : M6 6 (2pcs)
Fig 8.2 (a) Replacing the cable kit
88
MAINTENANCE
8. CABLE REPLACEMENT
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Plate
A290–7215–X430
Bolt : M6 10 (4pcs)
Plate
A290–7215–X426
Bolt : M6 10 (2pcs)
Cable kit
Bolt : M8 10 (4pcs)
Cable cover
Bolt : M6 10 (2pcs)
Plate
A290–7215–X331
Bolt : M8 10 (2pcs)
J2 base
Fig 8.2 (b) Replacing the cable kit
Packing
A290–7215–X527
Cover J5–2
Bolt : M6 16 (4pcs)
Washer : M6 (4pcs)
Clamp J5–2
A290–7215–X531
Seal bolt : M4 6 (2pcs)
Support
A290–7215–X529
Clamp J5–1
A290–7215–X525
Bolt : M5 10 (2pcs)
Clamp–to–clamp distance : 160 mm
Note) Before putting on the J5–2
cover, make sure that twisted–pair
wires do not cross one another.
Clamp J6
A290–7215–X534
Bolt : M3 6 (2pcs)
Fig 8.2 (c) Replacing the cable kit (wrist section)
89
Wrist flange unit
8. CABLE REPLACEMENT
MAINTENANCE
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clamp
A290–7215–X334
grommet A290–7215–X312
Bolt : M6 10 (2pcs)
Inside cable
Outside cable
clamp
A290–7215–X334
grommet A290–7215–X312
Bolt : M6 6 (2pcs)
Fig 8.2 (d) Adjusting cable length
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II. CONNECTION
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1
CONNECTION
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
ROBOT OUTLINE DRAWING AND OPERATION AREA
DIAGRAM
93
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
1.1
OUTLINE DRAWING
AND OPERATION
AREA DIAGRAM
CONNECTION
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Fig. 1.1 (a) shows the outline drawing and operation area diagram of a
robot with a separate controller.
When installing a peripheral device, be careful not to let it interfere with
the robot main body. While referencing Section 3.2, use 4–f18 through
holes in the base to install the peripheral device.
Fig. 1.1 (b) and (c) show the operation diagrams of the robot.
Motion range of
J5–axis rotation center
J5–axis rotation center
Fig 1.1 (a) Outline drawing and operation area diagram of a robot with a separate controller
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CONNECTION
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
Fig 1.1 (b) Operation diagram of a robot with a separate controller (No. 1)
95
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
CONNECTION
Fig 1.1 (c) Operation diagram of a robot with a separate controller (No. 2)
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2
CONNECTION
MOUNTING DEVICES ON THE ROBOT
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2. MOUNTING DEVICES
ON THE ROBOT
2. MOUNTING DEVICES
ON THE ROBOT
CONNECTION
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2.1
WRIST SECTION END
EFFECTOR
MOUNTING
SURFACE
1) Mounting surface for an ISO flange–type end effector (standard)
Fig. 2.1 (a) sows the end effector mounting surface at the tip of the
wrist. The end effector is engaged using a f50h7 spigot or f25H7
socket, positioned using a 1–f6H8 reamed hole, and fastened using
four M6 self–tapping screws. As for the M6 self–tapping screws,
select those not longer than the tapping depth (10 mm).
depth 10
on pitch
depth 10
equally spaced on
circumference
Fig 2.1 Mounting surface for the ISO flange type end effector
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2.2
DEVICE MOUNTING
SURFACES
2. MOUNTING DEVICES
ON THE ROBOT
CONNECTION
As shown in Fig. 2.2 (a), there are two device mounting surfaces.
NOTE
1 Keep the gravity center of devices mounted on device
mounting surfaces A and B within the area shown by
hatching in Fig. 2.2 (b).
2 The mass of each device mounted on a device mounting
surface shall satisfy the following condition:
1) W + A + B x 18 (kg)
where W : Mass (kg) of the device on the end effector
mounting surface
A : Mass (kg) of the device on device
mounting surface A
B : Mass (kg) of the device on device
mounting surface B
Center of J4–axis
rotation
Center of J3–axis
rotation
depth 10
Mounting surface A
depth 10
Center of J3–axis
rotation
Mounting surface B
Fig 2.2 (a) Device mounting surface dimensions
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2. MOUNTING DEVICES
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Equipment mounting face A
Equipment mounting face B
Fig 2.2 (b) Dimensions of the gravity center position of the device on the device mounting surfaces
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2.3
SETTING THE
SYSTEM VARIABLES
FOR
SHORTEST–TIME
CONTROL
CONNECTION
2. MOUNTING DEVICES
ON THE ROBOT
Setting up appropriately the load conditions, such as mass, moment, and
inertia, of the wrist section and hand mounted on the J3–axis arm of a
robot enables effective use of the robot.
Wrist axis load moment
Load the following system variables with the wrist section load moment
represented using an integer (kgf–m : Input 100 times the following values).
[Input examples]
$PARAM_GROUP.$AXISMOMENT[4] : 160 (J4–axis load moment)
[Example of 0.16 kgf–m]
$PARAM_GROUP.$AXISMOMENT[5] : 100 (J5–axis load moment)
[Example of 0.10 kgf–m]
$PARAM_GROUP.$AXISMOMENT[6] : 60 (J6–axis load moment)
[Example of 0.06 kgf–m]
Wrist axis load inertia
Load the following system variables with the wrist section load inertia
represented using an integer (kgf–cm–S2 : Input 100 times the following
values).
[Input examples]
$PARAM_GROUP.$AXISINERTIA[4] : 640 (J4–axis load inertia)
[Example of 6.4 kgf–cm–S2]
$PARAM_GROUP.$AXISINERTIA[5] : 220 (J5–axis load inertia)
[Example of 2.0 kgf–cm–S2]
$PARAM_GROUP.$AXISINERTIA[6] : 62 (J6–axis load inertia)
[Example of 0.62 kgf–cm–S2]
Mass of the loads
mounted on the J3–axis
arm and J2–axis base
Load the following system variable with the mass of the loads mounted
on the J3–axis arm and J2–axis base represented using an integer (kg)
[Input examples]
$PARAM_GROUP.$ARM_LOAD[1] : 12.25 (mass of the load on the
J3–axis arm)
$PARAM_GROUP.$ARM_LOAD[2] : 0 (mass of the load on the
J2–axis base)
Operation performance
screens
The operation performance screens include the list screen, load setting
screen, and device setting screen. These screens are used to set up
information about loads and that about devices on the robot.
1 Press the screen selection key to display the screen menu.
2 Select SYSTEM on the next page.
3 Press F1 TYPE. The screen switching menu appears.
4 Press F1 Motion Performance. The list screen appears.
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2. MOUNTING DEVICES
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MOTION PERFORMANCE
Group1
No.
PAYLOAD[kg]
1
6.34
2
0.00
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
8
0.00
9
0.00
10
0.00
10%
Comment
[
[
[
[
[
[
[
[
[
[
]
]
]
]
]
]
]
]
]
]
Active PAYLOAD number = 1
[ TYPE ] GROUP DETAIL ARMLOAD SETIND >
>
5 On this screen, you can set up ten different types of load information
(condition No. 1 to No. 10). Place the cursor on the line of a desired
condition number, and press F3 DETAIL. The load setting screen
appears.
MOTION PAYLOAD SET
1.
2.
3.
4.
5.
6.
7.
JOINT
10%
Group 1
Schedule No[
1]:[Comment
]
PAYLOAD
[kg]
6.34
PAYLOAD CENTER X [cm]
–7.99
PAYLOAD CENTER Y [cm]
0.00
PAYLOAD CENTER Z [cm]
6.44
PAYLOAD INERTIA X [kgfcms^2]
0.13
PAYLOAD INERTIA Y [kgfcms^2]
0.14
PAYLOAD INERTIA Z [kgfcms^2]
0.07
[ TYPE ]
GROUP
NUMBER
DEFAULT
HELP
6 On this screen, specify the mass and gravity center position of the load
and the inertia around the gravity center. The X, Y, and Z directions
displayed on the screen correspond to the standard tool coordinates
(with no tool coordinate system set up). When you enter values, the
confirmation message “Path and Cycletime will change. Set it?”
appears. Select F4 YES or F5 NO.
7 Pressing F3 NUMBER brings you to the load setting screen for
another condition number. In a multigroup system, pressing F2
GROUP brings you to the setting screen for another group.
8 Press the previous page key to return to the list screen. Press F5
SETIND, and enter a desired load setting condition number.
9 On the list screen, pressing F4 ARMLOAD brings you to the device
setting screen.
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2. MOUNTING DEVICES
ON THE ROBOT
CONNECTION
MOTION ARMLOAD SET
Group 1
1 ARM LOAD AXIS #1
2 ARM LOAD AXIS #3
[ TYPE ]
GROUP
JOINT
[kg]
[kg]
DEFAULT
10%
0.00
12.25
HELP
10 Specify the mass of the loads on the J2–axis base and J3–axis arm.
When you enter
ARMLOAD AXIS #1[kg] : Mass of the load on the J2–axis base and
ARMLOAD AXIS #3[kg] : Mass of the load on the J3–axis arm,
the confirmation message “Path and Cycletime will change. Set it?”
appears. Select F4 YES or F5 NO.
Once the mass of a device is entered, it is put in effect by turning the
power off and on again.
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2. MOUNTING DEVICES
ON THE ROBOT
2.4
WRIST LOAD
CONDITIONS
CONNECTION
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Fig. 2.4 is the allowable load curves of the wrist of the robot.
Use the robot with the load conditions kept within the range shown on the
graph.
The load inertia is the sum of the offset inertia from the
center of each axis section to the gravity center of the
workpiece and the shape inertia around the gravity center
of the workpiece.
Keep the total load inertia including the shape inertia at or
below the values listed below.
Inertia around the X–axis
Inertia around the Y–axis
Fig 2.4 Wrist section allowable load conditions
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2.5
END EFFECTOR AIR
PIPING
CONNECTION
2. MOUNTING DEVICES
ON THE ROBOT
If you select cables (A05B–1215–H203, –H204, –H205, –H603, –H604
and H605) in the mechanical unit with a pneumatic option, an air pipe
whose inlet is on the J1–axis connector panel and outlet is behind the J3
casing is provided. See Fig. 7.1 of Part I, “Maintenance,” for explanations
about the piping routes. The joint diameter for the air pipe inlet and outlet
is RC3/8 female. No joint is supplied together with the option. The
customer shall arrange for the joints that match the tubes to be used.
105
2. MOUNTING DEVICES
ON THE ROBOT
2.6
END EFFECTOR
INPUT SIGNALS
(RDI/RDO)
CONNECTION
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There are end effector connectors for connecting peripheral devices
behind the J3 casing. Fig. 2.6 (a) and Fig. 2.6 (b) show the pin
arrangement of end effector connectors. Refer to “R–J3iB Controller
Maintenance Manual” for details of input–common settings.
Mechanical unit (K102, K105)
End effector
Fig 2.6 (a) End effector signal arrangement
(one RDI signal and one RDO signal)
Mechanical unit (K103, K106)
End effector
Fig 2.6 (b) End effector signal arrangement (eight RDI signals and eight RDO signals)
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CONNECTION
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2.7
CONNECTOR
SPECIFICATIONS
2. MOUNTING DEVICES
ON THE ROBOT
Table 2.7 (a) lists the makers and models of the connectors used on the
robot mechanical unit. Table 2.7 (b) lists the makers and models of the
connectors used on the mechanical unit of the robot with Lincoln W/F
cable option. Table 2.7 (c) lists the makers and models of the connectors
to be used on user–prepared devices.
Table 2.7 (a) Connector specifications (on the mechanical unit side)
Output side
(J3–axis casing)
Cable name
Maker
RDI/O 1
JMWR1305F
Daiichi Denshi Kogyo K.K.
RDI/O 8
JMWR2524F
Daiichi Denshi Kogyo K.K.
Table 2.7 (b) Connector specifications (on the mechanical unit side)
Cable name
Output side
Lincoln
W/F
cable
MS3100A20–27 SY
(J1–axis base)
Maker
Japan Aviation
Electronics
Industry, LTD.
MS3100A20–27 PY
(J3–axis casing)
Table 2.7 (c) Connector specifications (on the user side)
Output side
(J3–axis casing)
Cable name
Maker
RDI/O 1
JMSP1305M
Daiichi Denshi Kogyo K.K.
RDI/O 8
JMSP2524M
Daiichi Denshi Kogyo K.K.
NOTE
For detailed descriptions of the dimensions of the
connectors, contact FANUC or refer to the respective
catalogs available from the maker.
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3
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
TRANSPORTATION AND INSTALLATION
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3. TRANSPORTATION AND
INSTALLATION
CONNECTION
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3.1
TRANSPORTATION
1) Installation procedure
1 Remove the J1 transportation stopper (red).
2 Using JOINT, rotate the J2– and J3–axis sections in the positive
direction to such a position that the J2– and J3–axis transportation
stoppers can be removed.
3 Remove the J2– and J3–axis transportation stoppers(red).
4 Remove the two M10 eyebolts from the J2 base. Now you are
ready to install the robot.
NOTE
If an overtravel alarm is issued at 2, hold down the shift key
and press the alarm reset key. Then, while holding down the
shift key, feed the J2– and J3–axis sections to such a
position, using JOINT, that the overtravel condition is
released.
2) Carrying the robot with a crane
The robot can be carried by suspending it with a crane. To lift the
robot, hook a strap on the two M10 eyebolts. Once the robot is
installed, remove the transportation stoppers. (See Fig. 3.1.)
These stoppers are bolts for preventing the swiveling axes of the robot
from moving during its transportation. The stoppers are painted or
plated in red. Before starting to operate the robot, be sure to remove
these stoppers.
Be careful not to let the suspending sling get caught on the connectors
of the motors; the connectors may be damaged if the sling get caught
on it.
NOTE
When transporting a robot having two axes that are
equipped with a brake while leaving an end effector
mounted on its wrist, be sure to place soft material such as
sponge rubber between the J2 and J3 arms previously so
that the J4–axis section will not swing. Otherwise, the end
effector or the robot main body may be damaged if the
J4–axis section swings to let the end effector hit the robot
main body during transportation. If the J4–axis section is
caused to rotate beyond its operation range, a break may
occur in the cable.
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Position during shipment
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
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Note)
J1–axis
J2–axis
J3–axis
J4–axis
J5–axis
J6–axis
1. Machine weight
: 138 kg
2. Eyebolts complied with JIS B1168.
[Load capacity
: 150 kg/1]
3. Quantity Eyebolt
Sling
:2
:2
Crane
Load capacity : 300 kg
Sling
Load capacity : 250 kg
M10 Eye bolt
Center
of gravity
Fig 3.1 Carrying the robot with a crane
110
3. TRANSPORTATION AND
INSTALLATION
3.2
STORING THE
ROBOT
CONNECTION
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When storing the robot, keep it in the posture shown in Fig. 3.1.
Be very careful when the robot is in any other posture, because it can fall
down.
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CONNECTION
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3.3
3. TRANSPORTATION AND
INSTALLATION
Fig. 3.3 (a) shows the dimensions of the base of the robot main body.
INSTALLATION
4–f18 through
f26 facing depth 5
Mounting face
Front
J1 rotation center
Mounting face
4–f18 through
f26 facing depth 5
Fig 3.3 (a) Dimensions of the base of the robot main body
112
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81545EN/01
Fig. 3.3 (b) shows an example of installing the robot. In this example, the
sole plate is fixed with four M20 chemical anchors (in strength category
4.8), and the robot base is fastened to the sole plate with four M16 35
bolts (in strength category 12.9). If compatibility must be maintained in
teaching the robot after the robot mechanical unit is replaced, use the butt
surface.
NOTE
The customer shall arrange for the positioning pin, anchor
bolts, and sole plate.
4–f24 through
Mounting face
J1 rotation center
Mounting face
4–M16 through
Robot J1 base
Installation Plate
Robot fixing bolt
M16 35 (4)
Strength class
: 12.9
Tightening torque : 314 Nm
Chemical anchor
M20 (4)
Strength class
: 4.8
Tightening torque : 186 Nm
Fig 3.3 (b) Example of installing the robot
113
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81545EN/01
Fig. 3.3 (c) and Table 3.3 explain what load is put on the J1 base when the
robot is at a rest, accelerating or decelerating, and at an emergency stop.
Fig 3.3 (c) Load and moment applied to the J1 base
Table 3.3 Load and moment applied to the J1 base
Bending moment
MV[kgfm](Nm)
Vertical load
FV[kgf](N)
Torsion moment
MH[kgfm](Nm)
Horizontal load
FH[kgf](N)
[56](549)
[230](2254)
[0](0)
[0](0)
Accelerating or
decelerating
[189](1852)
[297](2911)
[61](598)
[105](1029)
At an emergency stop
[724](7095)
[677](6635)
[231](2264)
[252](2470)
State
At rest
114
3. TRANSPORTATION AND
INSTALLATION
3.4
CONNECTION
B–81545EN/01
Fig. 3.4 (a) shows the clearance required in maintaining the robot.
MAINTENANCE
CLEARANCE
Mastering area
Maintenance area
Fig 3.4 (a) Maintenance clearance layout
115
B–81545EN/01
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
The robot must be kept in the posture shown in Fig. 3.4 (b) during
mastering. Provide such a clearance around the robot that the robot can
take a posture of J1 = 0°.
Mastering posture
Mastering jig
Fig 3.4 (b) Robot posture for mastering
116
3. TRANSPORTATION AND
INSTALLATION
3.5
ASSEMBLING THE
ROBOT FOR
INSTALLATION
CONNECTION
B–81545EN/01
If a separate controller is selected for the robot, the robot connection
cables are detached from the connector board of the mechanical unit (they
are left connected to the controller) when the robot is shipped. When
installing the robot, attach the cables to the connector board of the
mechanical unit shown in Fig. 3.5.
When attaching the connectors, be careful not to pull the cables that have
HARTING connectors.
The customer shall arrange for installation of cable ducts between the
robot main body and its controller.
Fig 3.5 Cable connection panel for the robot mechanical unit
117
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81545EN/01
3.6
Fig. 3.6 (a) shows the air piping of the robot.
If the three–piece pneumatic option is selected, it comes with the air pipe
to be installed between it and the mechanical unit. To use the option, the
customer shall arrange for a three–piece pneumatic option mounting
section that has the self–tapping screw holes whose dimensions and
layout are specified in Fig. 3.6 (b) and for its installation.
The following figure assumes that the FANUC three–piece pneumatic
option is selected. When the customer selects another option, refer to the
interfaces in the following figure to prepare the required parts.
AIR PIPING
Elbow nipple
Straight nipple
In dotted line :
Air hose 3 m
Three–piece pneumatic (option)
Spec : A05B–1302–J011
Outer 10 mm Inner 6.5 mm
Note
Hose used in the mechanical unit has an outer diameter of 12 mm and
an inner diameter of 8 mm.
You can use a different size hose outside the mechanical unit.
Fig 3.6 (a) Air piping
118
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81545EN/01
Fill the oiler in the three–piece pneumatic option with any turbine oil
between #90 and #140 to the specified level.
The customer shall arrange for mounting bolts.
Air filter
Lubricator
Fig 3.6 (b) Three–piece pneumatic option
119
3.7
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81545EN/01
Table 3.7 lists the installation conditions for the robot.
INSTALLATION
CONDITIONS
Table 3.7 Installation conditions
Item
Pneumatic Supply air
pressure
pressure
Consumption
Specification
0.5 to 0.7 MPa (5 to 7 kg/cm2)
(set at 0.5 MPa (5 kg/cm2))
Maximum instantaneous amount: 150 NI/min
(Note 1)
Mechanical unit mass
About 134 kg: Type having two axes equipped
with a brake
About 138 kg: Type having six axes equipped
with a brake
Allowable ambient
temperature
0 to 45°C
Allowable ambient humidity Regularly: 75%RH or below
Short period (within one month):
95%RH (maximum) or below
No condensation is allowed.
Atmosphere
There shall be no corrosive gas (Note 2).
Vibration
0.5 G or less
NOTE
1 This is the capacity of the three–piece pneumatic option.
Use the robot at or below this value.
2 If you cannot avoid using the robot in an adverse
environment with respect to vibration, dust, or coolant,
contact FANUC.
120
APPENDIX
A
A. SPARE PARTS LISTS
APPENDIX
B–81545EN/01
SPARE PARTS LISTS
Table A (a) Cables
A) Two axes equipped with a brake (with no RDI/O signal and without
pneumatic option)
A05B-1215-H201
Cable
Specification
Remark
K101
A05B-1215-D001 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T115
J5 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
B) Two axes equipped with a brake (with one RDI/O signal and without
pneumatic option)
A05B-1215-H202
Cable
Specification
Remark
K102
A05B-1215-D002 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T115
J5 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
C) Two axes equipped with a brake (with one RDI/O signal and with
pneumatic option)
A05B-1215-H203
Cable
Specification
Remark
K102
A05B-1215-D002 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T115
J5 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
D) Two axes equipped with a brake (with eight RDI/O signals and
pneumatic option)
A05B-1215-H204
Cable
Specification
Remark
K103
A05B-1215-D003 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T115
J5 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
123
A. SPARE PARTS LISTS
APPENDIX
B–81545EN/01
E) Six axes equipped with a brake (with no RDI/O signal and without
pneumatic option)
A05B-1215-H601
Cable
Specification
Remark
K104
A05B-1215-D004 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K202
A660-4004-T116
J5 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
F) Six axes equipped with a brake (with one RDI/O signal and without
pneumatic option)
A05B-1215-H602
Cable
Specification
Remark
K105
A05B-1215-D005 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K202
A660-4004-T116
J5 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
G) Six axes equipped with a brake (with one RDI/O signal and with
pneumatic option)
A05B-1215-H603
Cable
Specification
Remark
K105
A05B-1215-D005 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K202
A660-4004-T116
J5 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
H) Six axes equipped with a brake (with eight RDI/O signals and
pneumatic option)
A05B-1215-H604
Cable
Specification
Remark
K106
A05B-1215-D006 J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K202
A660-4004-T116
J5 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
124
B–81545EN/01
A. SPARE PARTS LISTS
APPENDIX
Table A (b) Motors
ARC Mate 100iB
(two axes equipped with a brake) A05B-1215-B201
M–6iB
(two axes equipped with a brake) A05B-1215-B202
Specification
Axis
Remark
A06B-0223-B005
J1
a4/4000i
A06B-0223-B605
J2
a4/4000i with a brake
A06B-0202-B605
J3
a1/5000i with a brake
A06B-0202-B005
J4
a1/5000i
A06B-0115-B075#0008
J5
bM0.5/4000
A06B-0114-B075#0008
J6
bM0.4/4000
ARC Mate 100iB
(six axes equipped with a brake)
A05B-1215-B601
M–6iB
(six axes equipped with a brake)
A05B-1215-B602
Specification
Axis
Remark
A06B-0223-B605
J1
a4/4000i with a brake
A06B-0223-B605
J2
a4/4000i with a brake
A06B-0202-B605
J3
a1/5000i with a brake
A06B-0202-B605
J4
a1/5000i with a brake
A06B-0115-B275#0008
J5
bM0.5/4000 with a brake
A06B-0114-B275#0008
J6
bM0.4/4000 with a brake
Table A (c) Reducers
Specification
Axis
A97L-0218-0288#33
J1
A97L-0218-0289#153
J2
A97L-0218-0295#161
J3
A97L-0218-0224
J6
Table A (d) Motor auxiliary seals
Specification
Axis
A98L-0004-0771#A03TP
J1/J2
A98L-0004-0771#A01TP
J3/J4
125
A. SPARE PARTS LISTS
APPENDIX
B–81545EN/01
Table A (e) J4–axis gearbox
Axis
Specification
A05B-1215-K401
J4
Table A (f) Gears
Specification
Axis
A290-7215-X511
J5
A290-7215-V501
J5
A290-7215-V502
J5
A290-7215-X514
J5
Table A (g) Cover
Specification
Remark
A05B-1215-H351
J2–axis cable protect cover
A05B-1215-H352
J2–axis cable protect cover with Lincoln Electric
wire feed cable
Table A (h) Battery
Specification
A98L-0031-0005
Remark
R20 (1.5 V) Battery
Quantity
4
Table A (i) Grease
Name
Specification
Moly White RE No. 00
A98L-0040-0119#2.4KG
Table A (j) Grease nipples
Name
Specification
Axis
Grease nipple (1/8)
A97L-0218-0013#A110
J2/J3
Grease nipple [elbow type] (1/8)
A97L-0218-0013#C110
J1
Grease nipple (M6)
A97L-0218-0013#A610
J4/J5/J6
126
B–81545EN/01
A. SPARE PARTS LISTS
APPENDIX
Table A (k) O–ring
Location of use
Specification
A98L–0001–0347#S150
J1RV output
A98L–0001–0347#S100
J1RV output
A290–7207–X342
J1RV input
JB–OR1A–G60
J1 pipe
JB–OR1A–G105
J1 motor
JB–OR1A–G115
J2 motor
A98L–0001–0347#S135
J2RV output
A98L–0040–0041#258
J2RV input
A98L–0001–0347#S135
J2RV output
A98L–0001–0347#S100
J3RV output
A98L–0001–0347#S120
J3RV input
JB–OR1A–G75
J4 motor
A98L–0001–0347#S65
J3 arm mounting section
A98L–0001–0347#S71
J6 cross roller mounting section
Table A (l) Gaskets
Specification
Location of use
A98L–0040–0042#03
J4 motor
A98L–0040–0042#07
J5/J6 motor
A290–7215–X527
J5–2 (X502) cover mounting section
A290–7215–X533
Wrist flange mounting section
Table A (m) Stoppers
Specification
Axis
A290–7215–X241
J4
A290–7215–X323
J4
A290–7215–X324
J4
Note) 340° stopper
Table A (n) Seal bolts
Specification
Remark
A97L–0218–0417#081010
J1/J2/J3 grease outlet
A97L–0218–0621#051212
J5–axis motor and J5 gear unit mounting
(with a washer)
127
B–81545EN/01
B
APPENDIX
B. INTRA–MECHANICAL UNIT
CONNECTION DIAGRAMS
INTRA–MECHANICAL UNIT CONNECTION DIAGRAMS
129
B. INTRA–MECHANICAL UNIT
CONNECTION DIAGRAMS
APPENDIX
B–81545EN/01
Fig B (a) Intra–mechanical unit circuit diagram
(two axes with a brake, separate controller)
130
B–81545EN/01
APPENDIX
131
B. INTRA–MECHANICAL UNIT
CONNECTION DIAGRAMS
B. INTRA–MECHANICAL UNIT
CONNECTION DIAGRAMS
APPENDIX
B–81545EN/01
Fig B (b) Intra–mechanical unit circuit diagram
(six axes with a brake, separate controller)
132
B–81545EN/01
APPENDIX
133
B. INTRA–MECHANICAL UNIT
CONNECTION DIAGRAMS
C. PERIODIC INSPECTION TABLE
C
APPENDIX
PERIODIC INSPECTION TABLE
Fig C Periodic inspection table
134
B–81545EN/01
B–81545EN/01
APPENDIX
135
C. PERIODIC INSPECTION TABLE
D MOUNTING BOLT TORQUE LIST
D
APPENDIX
MOUNTING BOLT TORQUE LIST
136
B–81545EN/01
D MOUNTING BOLT TORQUE LIST
APPENDIX
B–81545EN/01
If no tightening torque is specified for a bolt, tighten it according to this
table.
Recommended bolt tightening torque
Unit: Nm (kgf–cm)
Hexagon socket head bolt (steel
in strength category 12.9)
Hexagon socket head bolt
(stainless)
Hexagon socket head boss bolt
Hexagon socket head flush bolt
(steel in strength category 12.9)
Tightening torque
Tightening torque
Tightening torque
Nominal
diameter
Upper limit
Lower limit
Upper limit
Lower limit
Upper 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)
—
—
—
—
137
—
Lower limit
—
Index
B–81545EN/01
[A]
Installation Conditions, 120
Intra–Mechanical Unit Connection Diagrams, 129
Adjustments, 32
Air Piping, 118
Assembling the Robot for Installation, 117
[J]
J1–Axis Drive Mechanism, 4
J2–Axis Drive Mechanism, 5
[B]
J3–Axis Drive Mechanism, 6
Battery Replacement, 25
J4–Axis Drive Mechanism, 7
Brake Release, 51
J5– and J6–Axis Drive Mechanisms, 8
J5–Axis Gear Backlash Adjustments, 48
Jig–based Mastering, 41
[C]
Cable Dressing, 84
[M]
Cable Mounting Diagram, 82
Cable Replacement, 83
Maintenance Clearance, 115
Component Replacement and Adjustment Items, 31
Maintenance Tools, 18
Component Replacement and Adjustments, 53
Mastering by Zero Position Mark Alignment, 39
Configuration, 3
Mounting Bolt Torque List, 136
Confirming Mastering, 47
Mounting Devices on the Robot, 97
Connector Specifications, 107
[O]
[D]
One– and Half–Year Periodic Inspection, 16
Daily Inspection, 12
Outline Drawing and Operation Area Diagram, 94
Device Mounting Surfaces, 99
Overview, 27
[E]
[P]
End Effector Air Piping, 105
Periodic Inspection Table, 134
End Effector Input Signals (RDI/RDO), 106
Periodic Maintenance, 19
Piping and Wiring, 78
Piping Drawing, 79
[F]
Preventive Maintenance, 11
Factory Mastering, 50
[Q]
[G]
Quarterly Inspection, 14
Grease Replacement, 22
Greasing, 20
[R]
Reference Position and Moving Range, 33
[I]
Replacing Cables, 86
Replacing the J1–Axis Motor M1 , 54
Installation, 112
i–1
Index
B–81545EN/01
Replacing the J1–Axis Reducer
(A97L–0218–0288#33), 56
Specifications of the Major Mechanical Unit Components, 9
Replacing the J2–Axis Motor M2 , 58
Storing the Robot, 111
Replacing the J2–Axis Reducer, 60
Replacing the J3–Axis Motor M3 , 63
[T]
Replacing the J3–Axis Reducer, 65
Three–Year Periodic Inspection, 17
Replacing the J4–Axis Gearbox, 68
Transportation, 109
Replacing the J4–Axis Motor M4 , 67
Transportation and Installation, 108
Replacing the J5–Axis Gear, 72
Troubles and Causes, 28
Troubleshooting, 26
Replacing the J5–Axis Motor M5 , 70
Replacing the J6–Axis Motor M6 and Reducer, 74
[W]
Robot Outline Drawing and Operation Area Diagram,
93
Wiring Diagrams, 80
Wrist Load Conditions, 104
Wrist Section End Effector Mounting Surface, 98
[S]
Setting the System Variables for Shortest–Time Control, 101
[Y]
Simplified Mastering, 37
Yearly Inspection, 15
Spare Parts Lists, 123
i–2
Nov., 2001
Date
01
Edition
Contents
Edition
Date
FANUC Robot ARC Mate 100iB / M–6iB MAINTENANCE MANUAL (B–81545EN)
Revision Record
Contents