FANUC > M-410i B/450
MECHANICAL UNIT
MAINTENANCE MANUAL
B-81925EN/04
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller
labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.
• No part of this manual may be reproduced in any form.
• All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
B-81925EN/04
1
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety
precautions when operating a robot and its peripheral devices installed
in a work cell.
s-1
SAFETY PRECAUTIONS
1.1
B-81925EN/04
OPERATOR SAFETY
Operator safety is the primary safety consideration. Because it is
very dangerous to enter the operating space of the robot during
automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions.
consideration must be made to ensure operator safety.
Careful
(1) Have the robot system operators attend the training courses held
by FANUC.
FANUC provides various training courses.
details.
Contact our sales office for
(2) Even when the robot is stationary, it is possible that the robot is
still ready to move state and is waiting for a signal. In this state,
the robot is regarded as still in motion. To ensure operator
safety, provide the system with an alarm to indicate visually or
aurally that the robot is in motion.
(3) Install a safety fence with a gate so that no operator can enter the
work area without passing through the gate. Equip the gate
with an interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. When the gate is
opened and this signal received, the controller stops the robot in an
emergency. For connection, see Fig.1.1 (a), (b) and (c).
(4) Provide the peripheral devices with appropriate grounding (Class
1, Class 2, or Class 3).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the
robot motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an
interlock to a visual or aural alarm that stops the robot when an
operator enters the work area.
(8) If necessary, install a safety lock so that no one except the
operator in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone
from turning it on when it is locked with a padlock.
s-2
SAFETY PRECAUTIONS
B-81925EN/04
(9) When adjusting each peripheral device independently, be sure to
turn off the power of the robot.
Limit swith which operates
when the gate is opened.
Fig. 1.1 (a)
Safety Fence and Safety gate
Panel board
パネルボード
FENCE1
FENCE1
Note) Terminals FENCE1 and FENCE2 are on the PC board
in the operator’s panel.
FENCE2
FENCE2
Fig. 1.1 (b) Limit switch circuit diaram of the safety fence (For R-J3iB CONTROLLER)
Panel
board
パネルボード
EAS1
EAS1
EAS11
EAS11
EAS2
EAS2
Note) Terminals EAS1, EAS11 and EAS2, 21 are on the PC
board in the operator’s panel.
Refer to the R-30iA CONTROLLER MAINTENANCE
MANUAL.
EAS21
EAS21
Fig. 1.1 (c) Limit switch circuit diaram of the safety fence (For R-30iA CONTROLLER)
s-3
SAFETY PRECAUTIONS
1.1.1
B-81925EN/04
Operator Safety
The operator is a person who operates the robot system. In this sense,
a worker who operates the teach pendant is also an operator.
However, this section does not apply to teach pendant operators.
(1) If it is not necessary for the robot to operate, turn off the power
of the robot controller or press the EMERGENCY STOP button,
and then proceed with necessary work
(2) Operate the robot system at a location outside the work area.
(3) Install a safety fence with a safety gate to prevent any worker
other than the operator from entering the work area unexpectedly
and also to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator's
reach.
The robot controller is designed to be connected to an external
EMERGENCY STOP button. With this connection, the controller stops the
robot operation when the external EMERGENCY STOP button is pressed.
See the diagram below for connection.
External EMERGENCY
STOP button
Panel PC board
Note) Connect between EMGIN1 and EMGIN 2.
Terminals EMGIN1 and EMGIN2 are on the
Panel PC board
Fig. 1.1.1 (a)
Connection Diagram for External Emergency Stop Switch
(For R-J3iB CONTROLLER)
External EMERGENCY
STOP button
外部非常停止スイッチ
Panel
board
パネルボード
EES1
EES11
EES2
EES21
Note) Connect between EES1 and EES11 and between EES2 and
EES21.
（注） EES1-EES11間、 EES2-EES21間に接続します。
Terminals EES1, EES11, EES2 and EES21 are on the Panel
EES1,EES11、EES2,EES21はパネルボード上にあり
board.
ます。
Refer
to R-30iA CONTROLLER MAINTENANCE MANUAL.
詳細はR-J3iC制御部保守説明書をご参照下さい。
Fig. 1.1.1 (b)
Connection Diagram for External Emergency Stop Switch
(For R-30iA CONTROLLER)
s-4
B-81925EN/04
1.1.2
SAFETY PRECAUTIONS
Safety of the Teach Pendant Operator
While teaching the robot, it is necessary for the operator to enter the
work area of the robot. It is particularly necessary to ensure the
safety of the teach pendant operator.
(1) Unless it is specifically necessary to enter the robot work area,
carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral
devices are all in the normal operating condition.
(3) When entering the robot work area and teaching the robot, be
sure to check the location and condition of the safety devices
(such as the EMERGENCY STOP button and the deadman's
switch on the teach pendant).
The teach pendant supplied by FANUC is provided with a teach pendant
enable switch and a deadman's switch in addition to the EMERGENCY
STOP button. The functions of each switch are as follows.
EMERGENCY STOP button
: Pressing this button stops the robot in an
emergency, irrespective to the condition
of the teach pendant enable switch.
Deadman's switch
: The function depends on the state of the
teach pendant enable switch.
When the enable switch is on - Releasing the finger from the dead
man's switch stops the robot in an
emergency.
When the enable switch is off-The deadman's switch is ineffective
NOTE
The deadman's switch is provided so that the robot
operation can be stopped simply by releasing finger
from the teach pendant in case of emergency.
s-5
SAFETY PRECAUTIONS
B-81925EN/04
(4) The teach pendant operator should pay careful attention so that
no other workers enter the robot work area.
NOTE
In addition to the above, the teach pendant enable
switch and the deadman's switch also have the
following function.By pressing the deadman's switch
while the enable switch is on, the emergency stop
factor (normally the safety gate) connected to the
controller is invalidated. In this case, it is possible
for an operator to enter the fence during teach
operation without pressing the EMERGENCY STOP
button. In other words, the system understands
that the combined operations of pressing the teach
pendant enable switch and pressing the deadman's
switch indicates the start of teaching.
The teach pendant operator should be well aware
that the safety gate is not functional under this
condition and bear full responsibility to ensure that
no one enters the fence during teaching.
(5) When entering the robot work area, the teach pendant operator
should enable the teach pendant whenever he or she enters the
robot work area. In particular, while the teach pendant enable
switch is off, make certain that no start command is sent to the
robot from any operator's panel other than the teach pendant.
The teach pendant, operator’s box, and peripheral device interface
send each robot start signal. However the validity of each signal
changes as follows depending on the mode of the teach pendant
enable switch and the remote switch on the operator’s panel.
Operator ‘s panel
Three modes switch
T1/T2
AUTO (Except RIA)
AUTO
AUTO
Teach pendant Software remote
ON/OFF switch
condition
Teach
pendant
Operator’s
panel
Peripheral
devices
On
Independent
Allowed to start
Not allowed
Not allowed
Off
Off
Remote OFF
Remote ON
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Allowed to start
NOTE
When starting the system using the teach pendant
in the RIA specification, the three modes switch
should be T1/T2.
(6) To start the system using the operator's box, make certain that
nobody is in the robot work area and that there are no abnormal
conditions in the robot work area.
s-6
B-81925EN/04
SAFETY PRECAUTIONS
(7) When a program is completed, be sure to carry out a test run
according to the procedure below.
(a) Run the program for at least one operation cycle in the
single step mode at low speed.
(b) Run the program for at least one operation cycle in the
continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed and check
that the system operates automatically without trouble.
(e) After checking the completeness of the program through the
test run above, execute it in the automatic operation mode.
(8) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
s-7
SAFETY PRECAUTIONS
1.1.3
B-81925EN/04
Safety During Maintenance
For the safety of maintenance personnel, pay utmost attention to the
following.
(1) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power
switch, if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(3) Before the start of teaching, check that the robot and its
peripheral devices are all in the normal operating condition.
(4) If it is necessary to enter the robot work area for maintenance
when the power is turned on, the worker should indicate that the
machine is being serviced and make certain that no one starts the
robot unexpectedly.
(5) Do not operate the robot in the automatic mode while anybody is
in the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay
careful attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system
stand beside the operator's panel and observe the work being
performed. If any danger arises, the worker should be ready to
press the EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(10) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and also
turn off the circuit breaker to protect against electric shock.
(11) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
s-8
B-81925EN/04
SAFETY PRECAUTIONS
1.2
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES
1.2.1
Precautions in Programming
(1) Use a limit switch or other sensor to detect a dangerous condition
and, if necessary, design the program to stop the robot when the
sensor signal is received.
(2) Design the program to stop the robot when an abnormal
condition occurs in any other robots or peripheral devices, even
though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in
programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can be stopped according to the states.
1.2.2
Precautions for Mechanism
(1) Keep the component cells of the robot system clean, and operate
the robot in an environment free of grease, water, and dust.
(2) Employ a limit switch or mechanical stopper to limit the robot
motion so that the robot does not come into contact with its
peripheral devices or tools.
s-9
SAFETY PRECAUTIONS
1.3
SAFETY OF THE ROBOT MECHANISM
1.3.1
Precautions in Operation
B-81925EN/04
(1) When operating the robot in the jog mode, set it at an appropriate
speed so that the operator can manage the robot in any
eventuality.
(2) Before pressing the jog key, be sure you know in advance what
motion the robot will perform in the jog mode.
1.3.2
Precautions in Programming
(1) When the work areas of robots overlap, make certain that the
motions of the robots do not interfere with each other.
(2) Be sure to specify the predetermined work origin in a motion
program for the robot and program the motion so that it starts
from the origin and terminates at the origin. Make it possible for
the operator to easily distinguish at a glance that the robot motion
has terminated.
1.3.3
Precautions for Mechanisms
(1) Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.
s - 10
SAFETY PRECAUTIONS
B-81925EN/04
1.3.4
Procedure to move arm without drive power in emergency or
abnormal situations
(1) For emergency or abnormal situations (e.g. persons trapped in or
by the robot), brake release unit can be used to move the robot
axes without drive power.
Please order following unit and cable.
Name
Specification
Brake release
A05B-2450-J350 (Input voltage AC100-115V single phase)
unit
A05B-2450-J351 (Input voltage AC200-240V single phase)
A05B-2450-J360 (5m) ,(except A cabinet controller integrated type)
Robot
connection
cable
A05B-2450-J361 (10m),(except A cabinet controller integrated type)
A05B-2525-J045(5m) ,(A cabinet controller integrated type)
A05B-2525-J046(10m) ,(A cabinet controller integrated type)
A05B-2525-J010 (5m) (AC100-150V type)
Power cable
A05B-2525-J011 (10m) (AC100-150V type)
A05B-2450-J364 (5m) (AC200-240V type)
A05B-2450-J365 (10m) (AC200-240V type)
(2) Please make sure that adequate numbers of brake release units are
available and readily accessible for robot system before
installation.
(3) Regarding how to use brake release unit, please refer to Robot
controller maintenance manual.
NOTE
Robot systems installed without adequate number of
brake release units or similar means are not in
compliance with EN ISO 10218-1 nor with the
Machinery Directive and therefore cannot bear the
CE marking.
CAUTION
Robot arm would fall down by releasing its brake
because of gravity. Especially because spring
balancer is used for J2-axis, it is hard to predict
J2-arm movement by the condition of Robot attitude
and end effecter.Therefore it is strongly
recommended to take adequate measures such as
hanging Robot arm by a crane before releasing a
brake.
s - 11
SAFETY PRECAUTIONS
In case of releasing J2-axis motor brake
B-81925EN/04
Method of supporting robot arm
Sling
M12 eyebolt
？
M12 eyebolt
Lever block (2 pcs)
Sling (2 pcs)
？
Unpredictable
Fig. 1.3.4(a) Releasing J2 motor brake and measures
In case of releasing J3-axis motor brake
Method of supporting robot arm
Sling
M12 eyebolt
Fall down
Fig.1.3.4(b)
Releasing J3 motor brake and measures
s - 12
B-81925EN/04
SAFETY PRECAUTIONS
1.4
SAFETY OF THE END EFFECTOR
1.4.1
Precautions in Programming
(1) To control the pneumatic, hydraulic and electric actuators,
carefully consider the necessary time delay after issuing each
control command up to actual motion and ensure safe control.
(3) Provide the end effector with a limit switch, and control the robot
system by monitoring the state of the end effector.
1.5
SAFETY IN MAINTENANCE
(1) Never enter the robot work area while the robot is operating.
Turn off the power before entering the robot work area for
inspection and maintenance.
(2) If it is necessary to enter the robot work area with the power
turned on, first press the EMERGENCY STOP button on the
operator's box.
(3) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system. When replacing the
parts in the pneumatic system, be sure to reduce the pressure in
the piping to zero by turning the pressure control on the air
regulator.
(4) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and turn
off the circuit breaker to protect against electric shock.
(5) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
(6) Before restarting the robot, be sure to check that no one is in the
robot work area and that the robot and its peripheral devices are
all in the normal operating state.
s - 13
SAFETY PRECAUTIONS
1.6
B-81925EN/04
WARNING LABEL
(1) Greasing and degreasing label
Fig. 1.6 (a) Greasing and Degreasing Label
Description
When greasing and degreasing, observe the instructions indicated on
this label.
1)
2)
3)
When greasing, be sure to keep the grease outlet open.
Use a manual pump to grease.
Be sure to use a specified grease.
CAUTION
See sub-section 2.2.3 Replacing Grease for
explanations about specified greases, the amount of
grease to be supplied, and the locations of grease
and degrease outlets for individual models.
s - 14
B-81925EN/04
SAFETY PRECAUTIONS
(2) Disassembly prohibitive label
Fig. 1.6 (b)
Disassembly Prohibitive Label
Description
Do not disassemble the balance unit. It is very dangerous because a
spring is loaded in it.
(3) Step-on prohibitive label
Fig. 1.6 (c)
Step-on Prohibitive Label
Description
Do not step on or climb the robot or controller as it may adversely
affect the robot or controller and you may get hurt if you lose your
footing as well.
s - 15
SAFETY PRECAUTIONS
B-81925EN/04
(4) High-temperature warning label
Fig. 1.6 (d)
High-temperature warning label
Description
Be cautious about a section where this label is affixed, as the section
generates heat. If you have to inevitably touch such a section when it
is hot, use a protective provision such as heat-resistant gloves.
s - 16
B-81925EN/04
SAFETY PRECAUTIONS
(5) Balancer replacement label
Fig. 1.6 (e)
Balancer Replacement Label
Description
When replacing the balancer, observe the instructions indicated on this
label.
•
When replacing the balancer, keep the J2 axis at 0°.
•
Use a balancer having a weight of 250 kg.
s - 17
SAFETY PRECAUTIONS
B-81925EN/04
(6) Transportation prohibitive label
アイボルトを横引
しないこと
Do not pull eyebolt
sideways
Fig. 1.6 (h) Transportation prohibitive label
Description
Keep the following in mind when transporting the robot.
Do not pull eyebolts sideways
(7) Range of motion and payload mark label
Below label is added when CE specification is specified.
+180DEG
-180DEG
0DEG
B
The wrist tip
rotation center
A
M-410iB/160
M-410iB/300
M-410iB/450
M-410iB/700
Fig.1.6(i)
A
(mm)
3143
3143
3130
3143
B
(mm)
2880
2880
2696
2870
C
Motion area of
the writs tip
rotation center
C
MAX. PAYLOAD
(mm)
(kg)
78
160
78
300
238
450
88
700
Range of motion and payload mark label
s - 18
B-81925EN/04
PREFACE
PREFACE
This manual explains the maintenance and connection procedures for
the mechanical
units of the following robots:
Model name
Mechanical unit
specification No.
FANUC Robot M-410iB/450
FANUC Robot M-410iB/450
A05B-1039-B221
A05B-1039-B231
Maximum
Controller
load
R-J3iB
450kg
R-30iA
450kg
CAUTION
Note that the models for the R-J3iB controller and
those for the R-30iA controller partly differ in the
specifications of mechanical unit cables.
The label stating the mechanical unit specification number is affixed
in the position shown below. Before reading this manual, determine
the specification number of the mechanical unit.
p-1
PREFACE
B-81925EN/04
Position of label indicating mechanical unit specification number
Table 1
No.
CONTENTS
c
––
d
TYPE
e
NO.
f
DATE
TOTAL WEIGHT WITH
CONTROLLER
TOTAL WEIGHT
h
WITHOUT CONTROLLER
g
p-2
LETTERS
FANUC Robot M-410iB/450
A05B-1039-B221
A05B-1039-B231
PRINT SERIAL NO.
PRINT PRODUCTION YEAR AND
MONTH
2430kg
2310kg
PREFACE
B-81925EN/04
Specifications
ITEM
Type
Controlled axes
Installation
Motion range
J1-axis
J2-axis
J3-axis
J4-axis
Max. motion speed
J1-axis
J2-axis
J3-axis
J4-axis
Max. load capacity at wrist
Allowable load inertia at wrist
Maximum throughput
Drive method
Repeatability
Weight
Acoustic noise level
Installation requirement
Specifications
Articulated type
4 axes (J1, J2, J3, J4)
Floor mount
360°
(6.28rad)
145°
(2.53rad)
135°
(2.36rad)
540°
(9.42rad)
1.22rad/s (70° /s)
1.22rad/s (70° /s)
1.22rad/s (70° /s)
3.14rad/s (180° /s)
450 kg
196 kgm2 (2000kgfcms2) (NOTE1) (∗1)
294 kgm2 (3000kgfcms2) (NOTE1) (∗2)
730 cycles / hour (400 kg)
700 cycles / hour (450 kg)
(NOTE1)
Electric servo drive by AC servo motor
±0.5 mm
Integrated type controller : 2,430 kg (with control unit)
Remote type controller
: 2,310 kg (without control unit)
: 120 kg (controller)
less than 70dB
NOTE
This value is equivalent continuous A-weighted sound pressure level
which applied with ISO11201 (EN31201). This value is measured
with the following conditions.
- Maximum load and speed
- Operating mode is AUTO
Ambient temperature : 0~45°C
Ambient humidity
Normally : 75%RH or less (NOTE 3)
Short time (within one month) : Max. 95%RH
Height :
Up to 1,000 meters above the sea level requires, no particular
provision for attitude.
Vibration : 0.5G (4.9m/s2) or less
NOTE
1 The allowable value in the standard inertia mode is indicated on the (∗1) and that in
the high inertia mode is indicated on the (∗2). For details, see Section 2.3 in the
connection manual.
2 When the horizontal range of motion is 2,000 mm and the vertical range of motion
is 400 mm.
3 No dew, nor frost allowed.
p-3
PREFACE
B-81925EN/04
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook
B-80687EN
All persons who use the FANUC Robot and
system designer must read and understand
thoroughly this handbook
R-J3iB controller Setup and Operations
manual
HANDLING TOOL
B-81464EN-2
Maintenance manual
B-81465EN
R-30iA controller
B-81465EN-1
(European
specification)
Setup and Operations
manual
HANDLING TOOL
B-82594EN-2
Maintenance manual
B-82595EN
B-82595EN-1(For Europe)
B-82595EN-2 (For RIA)
Mechanical unit
Maintenance manual
FANUC Robot
M-410iB/450
B-81925EN
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 :
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-4
TABLE OF CONTENTS
B-81925EN/04
TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
PREFACE ....................................................................................................p-1
MAINTENANCE
1
CONFIGURATION .................................................................................. 3
1.1
1.2
1.3
1.4
1.5
2
PREVENTIVE MAINTENANCE............................................................... 7
2.1
2.2
2.3
3
J1-AXIS DRIVE MECHANISM....................................................................... 4
J2-AXIS DRIVE MECHANISM....................................................................... 4
J3-AXIS DRIVE MECHANISM....................................................................... 5
J4-AXIS DRIVE MECHANISM....................................................................... 5
MAJOR COMPONENT SPECIFICATIONS ................................................... 6
DAILY CHECKS ............................................................................................ 8
PERIODIC CHECKS ..................................................................................... 9
2.2.1
Checking for Cable Damage and Twisting ..............................................................9
2.2.2
Checking for Loose Bolts.......................................................................................11
2.2.3
Cleaning .................................................................................................................11
2.2.4
Replacing Grease....................................................................................................12
2.2.5
Procedure for Releasing Residual Pressure within the Grease Bath ......................16
2.2.6
Greasing .................................................................................................................17
2.2.7
Replacing Battery ...................................................................................................18
2.2.8
Replacing the Cables of the Mechanical Unit ........................................................19
2.2.9
Others .....................................................................................................................19
MAINTENANCE TOOLS ............................................................................. 20
TROUBLESHOOTING .......................................................................... 21
3.1
3.2
3.3
OVERVIEW ................................................................................................. 21
FAILURES, CAUSES AND MEASURES ..................................................... 22
BACKLASH MEASUREMENT..................................................................... 30
c-1
TABLE OF CONTENTS
4
ADJUSTMENTS.................................................................................... 32
4.1
4.2
4.3
4.4
4.5
5
B-81925EN/04
ADJUSTING LIMIT SWITCHES AND DOGS (OPTION) ............................. 33
ZERO POINT POSITION AND MOTION LIMIT OF J2-AXIS TO
J4-AXIS ....................................................................................................... 35
J1-AXIS STROKE MODIFICATION (OPTION)............................................ 37
SOFTWARE SETTING................................................................................ 40
MASTERING ............................................................................................... 41
4.5.1
General ...................................................................................................................41
4.5.2
Mastering Method ..................................................................................................42
4.5.3
Resetting Alarms and Preparing for Mastering ......................................................43
4.5.4
Mastering to a Fixture (Master Position Master) ..................................................44
4.5.5
Mastering................................................................................................................48
4.5.6
Zero Degree Mastering...........................................................................................50
4.5.7
Quick Mastering .....................................................................................................52
4.5.8
Single Axis Mastering ............................................................................................54
4.5.9
Mastering Data Entry .............................................................................................57
REPLACING PARTS ............................................................................ 59
5.1
5.2
5.3
5.4
5.5
5.6
5.7
PART REPLACEMENT AND CORRESPONDING ADJUSTMENT ............. 60
REPLACING J1-AXIS MOTOR (M1) AND REDUCER ................................ 61
REPLACING J2/J3-AXIS MOTOR (M2/M3) AND REDUCER ..................... 68
REPLACING J4-AXIS MOTOR (M4) AND REDUCER ................................ 77
REPLACING THE WRIST UNIT .................................................................. 80
REPLACING THE OPTIONAL J1-AXIS LIMIT SWITCH (OPTION) ........... 82
REPLACING THE J1-AXIS PENDULUM STOPPER................................... 83
6
WIRING ................................................................................................. 84
7
REPLACING CABLES .......................................................................... 86
7.1
7.2
CABLE FORMING ....................................................................................... 87
REPLACING A CABLE................................................................................ 96
c-2
TABLE OF CONTENTS
B-81925EN/04
CONNECTION
1
ROBOT EXTERNAL DIMENSION ...................................................... 109
2
MOUNTING A DEVICE TO THE ROBOT ........................................... 110
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3
LOAD CONDITION AT WRIST.................................................................. 111
COUPLING OF THE END EFFECTOR TO THE WRIST .......................... 114
LOAD SETTING ........................................................................................ 115
2.3.1
Motion Performance Screens ...............................................................................115
2.3.2
Switching between Modes....................................................................................117
EQUIPMENT MOUNTING SURFACE....................................................... 119
AIR SUPPLY.............................................................................................. 120
INTERFACE FOR END EFFECTOR ......................................................... 122
SERVO HAND CABLE INTERFACE (OPTION) ........................................ 126
TRANSPORTATION AND INSTALLATION ....................................... 128
3.1
3.2
3.3
3.4
TRANSPORTATION.................................................................................. 129
INSTALLATION ......................................................................................... 131
MAINTENANCE AREA .............................................................................. 137
INSTALLATION CONDITION .................................................................... 138
APPENDIX
A
SPARE PARTS LIST .......................................................................... 141
B
CIRCUIT DIAGRAM ............................................................................ 145
C
PERIODIC MAINTENANCE ................................................................ 158
D
BOLT TIGHTENING TORQUE TABLE............................................... 160
c-3
MAINTENANCE
MAINTENANCE
B-81925EN/04
1
1. CONFIGURATION
CONFIGURATION
The configuration of the mechanical unit is shown in Fig. 1 (a) and
(b).
Fig. 1 (a)
Mechanical unit configuration (Integrated control unit) (M-410iB/450)
Fig. 1 (b)
Mechanical unit configuration (Remote control unit) (M-410iB/450)
-3-
1. CONFIGURATION
1.1
MAINTENANCE
B-81925EN/04
J1-AXIS DRIVE MECHANISM
Fig. 1.1 shows the J1-axis drive mechanism.
Rotation of the J1-axis motor fixed on the J1-axis base is input to the
reducer via the center gear, and the reduced rotation rotates the J2-axis
base.
Fig. 1.1 J1-axis drive mechanism (M-410iB/450)
1.2
J2-AXIS DRIVE MECHANISM
Fig. 1.2 shows the J2-axis drive mechanism.
Rotation of the J2-axis motor fixed on the J2-axis base is directly fed
to the reducer, and the reduced rotation rotates the J2-axis arm.
Fig. 1.2 J2-axis drive mechanism (M-410iB/450)
-4-
B-81925EN/04
1.3
MAINTENANCE
1. CONFIGURATION
J3-AXIS DRIVE MECHANISM
Fig. 1.3 shows the J3-axis drive mechanism.
Rotation of the J3-axis motor fixed on the J3-axis base is directly fed
to the reducer, and the reduced rotation rotates the J3-axis arm.
Fig. 1.3 J3-axis drive mechanism (M-410iB/450)
1.4
J4-AXIS DRIVE MECHANISM
Fig. 1.4. shows the J4-axis drive mechanism.
Rotation of the J4-axis motor fixed on the J4 casing is input to the
reducer through the center gear, and the reduced rotation rotates the
wrist flange.
Fig. 1.4 J4-axis drive mechanism (M-410iB/450)
NOTE
A non-excited brake is incorporated in the motors
for all axes (J1, J2, J3, and J4 axes) and actuates
at power off or in an emergency.
-5-
1. CONFIGURATION
1.5
MAINTENANCE
B-81925EN/04
MAJOR COMPONENT SPECIFICATIONS
(1) Motor
Axis
Specifications
J1, J2, J3
A06B-0268-B605#S000
J4
A06B-0235-B605#S000
Remarks
(Model αM30/4000i)
Model αiS 30/4000i
(Model αM8/4000i)
Model αiS 8/4000
(2) Reducer
Axis
Specifications
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
A97L-0218-0265#450C-37
A97L-0218-0266#450E-257
A97L-0218-0266#450E-257
A97L-0118-0949#70C-36
Remarks
RV-450C-37
RV-450E-257
RV-450E-257
RV-70C-36
(3) Wrist unit
Specifications
Machines
A05B-1039-K501
Wrist replacing unit (without J4 motor)
-6-
B-81925EN/04
2
MAINTENANCE
2. PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained for a long time
by performing the periodic maintenance procedures presented in this
chapter.
-7-
2. PREVENTIVE MAINTENANCE
2.1
MAINTENANCE
B-81925EN/04
DAILY CHECKS
Clean each part, and visually check component parts for damage
before daily system operation. Check the following items as the
occasion demands.
1)
Item
1
Before turning on power
Check Items
When air control
set is provided
Check points
Air pressure
2
Oiler oil mist
quantity
3
Oiler oil level
4
Leakage from
hose
Check air pressure using the pressure gauge on the air regulator as
shown in Fig. 2.1. If it exceeds the specified pressure of max. 0.69MPa
(7kgf/cm2), adjust it using the regulator pressure setting handle.
Check the drop quantity during wrist or hand motion. If it does not meet
the specified value (1 drop/10-20 sec), adjust it using the oiler control
knob. Under normal usage the oiler becomes empty in about 10 to 20
days.
Check to see that the oiler level is within the specified level shown in
Fig.2.1.
Check the joints, tubes, etc. for leaks. Tie the joint again, or replace parts,
as required.
Fig. 2.1 Air control set (option)
2)
Item
5
Vibration, abnormal noises, and
motor heating
6
Changing repeatability
7
Peripheral devices for proper
operation
Brakes for each axis
8
After automatic operation
Check Items
Check points
Check whether the robot moves along and about the axes smoothly
without unusual vibration or sounds. Also check whether the temperature
of the motors is excessively high.
Check to see that the stop positions of the robot have not deviated from
the previous stop positions.
Check whether the peripheral devices operate properly according to
commands from robot.
Check that the end effector drops within 0.5mm when the power is cut.
-8-
MAINTENANCE
B-81925EN/04
2.2
2. PREVENTIVE MAINTENANCE
PERIODIC CHECKS
Perform periodic checks as detailed in the periodic check table shown
in Appendix C. Additional inspection points and intervals should be
added to the table according to the robot’s application, operating
environment, etc.
2.2.1
Checking for Cable Damage and Twisting
(1) Cables used in the mechanical unit
Observe the cables connected to the movable parts of the
mechanical unit, and check whether the cable sleeves are
damaged or whether the cables are excessively bent or twisted.
Also check that the cable connectors are securely attached to the
motors. (See Chapter 6.)
Perform this check with the periodic table (See Appendix C).
Inspection points and check items of the mechanical unit cables
Inspection points of the mechanical unit cables
Movable parts of J1,the upper side and lower side of link for wrist
posture maintenance of rear side of J2 arm, movable part in uniting
part of J2 to J3 and J3 to J4 and fixed department cable who interferes
easily in peripherals
Check items
For cables with a cable cover, open the cover before making the
check.
Check the cables for a sheath break and wear.
If wires of the cable appear, replace it.
カバーを外す
Remove the
cover
Fig 2.2.1(a) Check items of cable
-9-
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B-81925EN/04
Inspection points of the connectors
-
Power/brake connectors of the motor exposed externally
Robot connection cables and user cables
-
Circular connector: Check the connector for looseness by turning
it manually.
Square connector: Check the connector for disengagement of its
lever.
Check items
-
Fig 2.2.1 (b) Check items of connector
(2) Cables connected to the teach pendant and operation box
Check whether the cables connected to the teach pendant and
operation box are excessively twisted or damaged.
Perform this check with the periodic table (See Appendix C).
- 10 -
MAINTENANCE
B-81925EN/04
2.2.2
2. PREVENTIVE MAINTENANCE
Checking for Loose Bolts
As part of the initial inspection, check that none of the bolts that are
accessible from outside the robot are loose. If any loose bolts are
found, retighten them.
As part of the first quarterly inspection and the first and subsequent
yearly inspections, check whether the major bolts indicated in Fig.
2.2.2 are loose. If any loose bolts are found, retighten them.
See the operation time of Appendix C.
Fig. 2.2.2 Retighten of the major bolts
2.2.3
Cleaning
-
Necessary cleaning points, dust on the flat part, sedimentation of
spatters
Clean sediments periodically.
In particular, clean the following points carefully.
1) Vicinity of the balancer rod and shaft
→ If chippings or spatters are attached to the bushing, abnormal
wear may be caused.
2) Vicinity of the wrist axis and oil seal
→ If chippings or spatters are attached to the oil seal, an oil leak
may be caused.
- 11 -
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B-81925EN/04
Fig 2.2.3 Cleaning part
- Check if the vicinity of the necessary inspection
points, wrist part,and J3 arm significantly wears due to
rubbing against the welding cable or hand cable.
- Check if there is a trace of a collision around the
hand.
- Check the reducer or grease bath for an oil leak.
→ If oil can be found a day after wiping oil, an oil leak may be
caused.
2.2.4
Replacing Grease
Replace the grease in the J1-, J2-, J3-, and J4-axis reducers every three
years or after 11,520 operating hours, whichever occurs sooner, by
following the procedure explained below.
Table 2.2.4 lists the required grease type and quantity.
Fig. 2.2.4 (a) shows the greasing posture.
Figs. 2.2.4 (b) through (d) show the grease inlets and outlets of each
reducer.
Table 2.2.4 Grease for 3-year periodical replacement
Gun tip
Supply
Grease name
Quantity
pressure
position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
Kyodo yushi
VIGOGREASE
RE0
Spec.:
A98L-0040-0174
10.8×10-3m3 (10800ml)
2.3×10-3m3 (2300ml)
2.3×10-3m3 (2300ml)
1.6×10-3m3(1600ml)
0.15
MPa or
less
(NOTE)
NOTE When using a hand pump, apply grease approximately once per 1.5
seconds.
- 12 -
B-81925EN/04
MAINTENANCE
2. PREVENTIVE MAINTENANCE
Fig. 2.2.4 (a) Greasing posture
- 13 -
2. PREVENTIVE MAINTENANCE
MAINTENANCE
1)
B-81925EN/04
To replace on the reducer
1
Turn off the power.
2
Remove the grease outlet plug.
3
Apply new grease as described Table 2.2.4 from the grease
inlet until it comes out from the grease outlet.
4
After applying greasc, rclease the residual preasure within
the grease bath as described in the procedure in section
2.2.5.
CAUTION
If greasing is performed incorrectly, the internal
pressure of the grease bath may suddenly increase,
possibly causing damage to the seal, which would in
turn lead to grease leakage and abnormal operation.
When performing greasing, therefore, observe the
following cautions.
1 Before starting to grease, open the grease outlet
(remove the plug or bolt from the grease outlet).
2 Supply grease slowly without applying excessive
force, using a manual pump.
3 Whenever possible, avoid using a compressed-air
pump, powered by the factory air supply. Even
when using a compressed-air pump unavoidably,
set the gun tip pressure (see Table 2.2.4) to 0.1
5MPa or less during application of grease.
4 Use grease only of the specified type. Grease of
a type other than that specified may damage the
reducer or lead to other problems.
5 After applying grease, release the residual
pressure within the grease bath as described in the
procedure in Section 2.2.5.
6 Wipe off any grease from the floor and robot
completely, so no one will slip on it.
- 14 -
B-81925EN/04
MAINTENANCE
2. PREVENTIVE MAINTENANCE
Fig. 2.2.4 (b) Replacing the grease of the J1-axis/J2-axis reducers
Fig. 2.2.4 (c) Replacing the grease of the J3-axis reducer
Fig. 2.2.4 (d) Replacing grease of J4-axis reducer
- 15 -
2. PREVENTIVE MAINTENANCE
2.2.5
MAINTENANCE
B-81925EN/04
Procedure for Releasing Residual Pressure within the Grease
Bath
To release the residual pressure in the grease bath after applying
grease, operate the robot for 20 minutes or more for J1 and J2-axis and
for 40 minutes or more for J3 and J4-axis as described in the table
below with the grease nipple of the grease inlet and the plug of the
grease outlet left open for the J1-axis reducer and J4-axis reducer, and
the plug of the grease outlet left open for the J2-axis reducer and
J3-axis reducer.
Attach the reclaim bags under the grease inlet and grease outlet to
prevent spilled grease from splattering.
Operating axis
Grease
replacement part
J1-axis
J2-axis
J1-axis reducer
Axis angle of
80° or more
OVR 50%
J2-axis reducer
Arbitrary
J3-axis reducer
J4-axis
Arbitrary
Axis angle of
90° or more
OVR 50%
Arbitrary
J4-axis gear box
J3-axis
Arbitrary
Arbitrary
Axis angle of
60° or more
OVR 100%
Arbitrary
Axis angle of
60° or more
OVR 100%
If the above operations cannot be performed due to local
circumstances, the same count operation is necessary. (When the
maximum allowable axis angle is 30°, operate the robot for twice
minute of a specified length.)
When multiple axes are greased at the same time, the axes can be run
at the same time.
After the above operation is performed, attach the grease nipple to the
grease inlet and the seal bolt to the grease outlet. When the seal bolt
or grease nipple is reused, be sure to seal it with seal tape.
- 16 -
2.2.6
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B-81925EN/04
Greasing
Supply grease to the parts periodically (after the prescribed number of
operating hours or every specified interval, whichever comes earlier).
If the robot is installed in a severe environment, apply grease
whenever necessary. If water splashes on the robot, apply grease
immediately. Table 2.2.6 (a) and Fig. 2.2.6 show greasing points.
Table 2.2.6 (b) shows substitue greases. When performing greasing,
observe the cautions listed in Section 2.2.3.
NOTE
When the robot is used under high-duty
conditions that, for example, require a cooling unit
(fan), perform greasing at half of the standard
interval.
Table 2.2.6 (a) Greasing points
Positions
Balancer connection
point bushing
(2 positions)
J3-axis cross roller
ring
J4-axis cross roller
ring
Greasing
interval
Grease
Amount
Method
Supply to the grease nipple
1,920 hours
(6 months)
SHELL ALVANIA GREASE S2
(Spec: A97L-0001-0179#2)
Each
1.0×1.0-5m3
(Each 10 ml)
4.0×10-5m3
(40 ml)
2.0×10-5m3
(20 ml)
Supply to the grease nipple
11,520 hours
(Every 3 years)
11,520 hours
(Every 3 years)
Supply to the grease nipple
NOTE
Old grease is expelled from the bearing rotating
part after new grease is supplied. Wipe off old
grease immediately after supplying grease, and
then again after 50 to 100 hours of operation.
Table 2.2.6 (b) Substitutes for ALVANIA GREASE S2
MOBIL OIL
ESSO STANDARD
NIPPON OIL CORPORATION
NIPPON OIL CORPORATION
IDEMITSU KOHSAN
COSMO OIL
- 17 -
MOBILUX GREASE No.2
VICON No. 2
Multinoc2
EPNOC AP-2
DAPHNE COLONEX GREASE No. 2
LIMAX No. 2
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B-81925EN/04
Fig. 2.2.6 Greasing points
2.2.7
Replacing Battery
The position data of each axis is preserved by the backup battery.
The battery needs to be periodically replaced at every 1.5 year. Use
the following procedure to replace when the backup battery voltage
drop alarm occurs.
1
Press the EMERGENCY STOP button to prohibit the robot
motion.
2
Remove the battery case cap.
3
Take out the old batteries from the battery case.
4
Insert new batteries into the battery case.
Pay attention to the direction of batteries.
5
Close the battery case cap.
CAUTION
Batteries must be replaced only while the power
is on. Replacing the batteries while the power is
off will cause the current position data to be lost.
When this occurs, mastering will have to be
performed. (See Sections 4.5.)
- 18 -
MAINTENANCE
B-81925EN/04
2. PREVENTIVE MAINTENANCE
Fig. 2.2.7 Replacing Battery
2.2.8
Replacing the Cables of the Mechanical Unit
The cables of the mechanical unit must be replaced periodically (every
15,360 operating hours or every four years, whichever comes earlier).
See Chapter 7 for details of the cable replacement procedure.
2.2.9
Others
Clean the mechanical unit and controller vents whenever cleaning
those are necessary.
- 19 -
2. PREVENTIVE MAINTENANCE
2.3
MAINTENANCE
B-81925EN/04
MAINTENANCE TOOLS
The following tools and instruments are required for the maintenance
procedures contained in this manual.
1)
Measuring instruments
Instruments
Accuracy/Tolerance
Applications
Dial gauge accuracy
1/100mm
Measurement of
positioning and backlash
Side calipers
Push/pull tension gauge
150mm
98N (10kgf)
Measurement of
backlash
2) Tools
Cross-point (+) screwdrivers : Large, medium, and small sizes
Conventional (-) screwdrivers : Large, medium, and small sizes
Box screwdrivers
: M3-M6
Hexagonal wrench key sets : M3-M20
(metric)
Adjustable wrenches
: Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Double and wrench
Pliers for C-retaining ring
Torque wrench
: With hexagon socket head cap screw
for M8 to M16
Grease gun
Eyebolt
: M12, M20, M24
Rope
- 20 -
MAINTENANCE
B-81925EN/04
3
3.1
3. TROUBLESHOOTING
TROUBLESHOOTING
OVERVIEW
The cause of a failure in the mechanical unit may be difficult to
localize, because failures can arise from many interrelated factors. If
you fail to take the correct measures, the failure may be aggravated.
So, it is necessary to analyze the symptoms of the failure precisely so
that the true cause can be found.
- 21 -
3. TROUBLESHOOTING
3.2
MAINTENANCE
B-81925EN/04
FAILURES, CAUSES AND MEASURES
Table 3.2(a) lists the major failures that may occur in the mechanical
unit and their probable causes. If you cannot pinpoint a failure cause
or which measures to apply, contact FANUC.
Table 3.2(a)
Symptom
Vibration
Noise
Description
-The J1 base lifts off the floor
plate as the robot operates.
-There is a gap between the J1
base and floor plate.
-A J1 base retaining bolt is
loose.
-Apply epoxy to the floor
surface and re-install the plate.
-Vibration becomes more
serious when the robot adopts
a specific posture.
-If the operating speed of the
robot is reduced, vibration
stops.
-Vibration is most noticeable
when the robot is accelerating.
-Vibration occurs when two or
more axes operate at the same
time.
Failures, causes and measures
Cause
[J1 base fastening]
-It is likely that the robot J1 base is not
securely fastened to the floor plate.
-Probable causes are a loose bolt, an
insuffcient degree of surface flatness,
or foreign material caught between the
floor plate and floor plate.
-If the robot is not securely fastened to
the floor plate, the J1 base lifts the
floor plate as the robot operates,
allowing the base and floor plates to
strike each other wihich, in turn, leads
to vibration.
[Rack or floor]
-It is likely that the rack or floor is not
suffciently rigid.
-If the rack or floor is not sufficiently
rigid, reaction from the robot deforms
the rack or floor, leading to vibration.
[Overload]
-It is likely that the load on the robot is
greater than the maximum rating.
-It is likely that the robot control
program is too demanding for the
robot hardware.
-It is likely that the ACCELERATION
value is excessive.
- 22 -
Measure
-If a bolt is loose, apply loctite
and tighten it to the appropriate
torque.
-Adjust the floor plate surface
flatness to within the specified
tolenrance.
-If there is any foreign matter
between the J1 base and floor
plate, remove it.
-As the robot operates, the
rack or floor on which the robot
is mounted vibrates.
-Reinforce the rack or floor to
make it more rigid.
-If it is impossible to reinforce
the rack or floor, modify the
robot control program; doing
so might reduce the amount of
vibration.
-Check the maximum load that
the robot can handle once
more. If the robot is found to
be overloaded, reduce the
load, or modify the robot
control program.
-Vibration in a specific portion
can be reduced by modifying
the robot control program while
slowig the robot and reducing
its acceleration (to minimize
the influenece on the entire
cycle time).
MAINTENANCE
B-81925EN/04
Symptom
Description
-Vibration was first noticed
Vibration
after the robot collided with an
Noise
(Continuted) object or the robot was
overloaded for a long period.
-The grease of the vibrating
axis has not been exchanged
for a long period.
3. TROUBLESHOOTING
Cause
Measure
[Broken gear, bearing, or reducer]
- It is likely that collision or overload
applied an excessive force on the
drive mechanism, thus damaging the
geartooth surface or rolling surface of
a bearing, or reducer.
- It is likely that prolonged use of the
robot while overloaded caused fretting
of the gear tooth surface or rolling
surface of a bearing, or reducer due to
resulting metal fatigue.
- It is likely that foreign matter caught
in a gear, bearing, or within a reducer
caused damage on the gear tooth
surface or rolling surface of the
bearing, or reducer.
- It is likely that, because the grease
has not been changed for a long
period, fretting occurred on the gear
tooth surface or rolling surface of a
bearing, or reducer due to metal
fatigue.
These factors all generate cyclic
vibration and noise.
-Operate one axis at a time to
determine which axis is
vibrating.
-Remove the motor, and
replace the gear , the bearing,
and the reducer. For the spec.
of parts and the method of
replacement, contact FANUC.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
- 23 -
3. TROUBLESHOOTING
Symptom
MAINTENANCE
Description
-The cause of problem cannot
Vibration
be identified from examination
Noise
(Continuted) of the floor, rack, or
mechanical section.
B-81925EN/04
Cause
Measure
[Controller, cable, and motor]
-If a failure occurs in a controller
circuit, preventing control commands
from being supplied to the motor
normally, or preventing motor
information from being sent to the
controller normally, vibration might
occur.
-If the pulse coder develops a fault,
vibration might occur because
information about the motor position
cannot be transferred to the controller
accurately.
-If the motor becomes defective,
vibration might occur because the
motor cannot deliver its rated
performance.
-If a power line in a movable cable of
the mechanical section has an
intermittent break, vibration might
occur because the motor cannot
accurately respond to commands.
-If a pulse coder wire in a movable
part of the mechanical section has an
intermittent break, vibration might
occur because commands cannot be
sent to the motor accurately.
-If a connection cable between them
has an intermittent break, vibration
might occur.
-If the power source voltage drops
below the rating, vibration might
occur.
-If a robot control parameter is set to
an invalid value, vibration might occur.
-Refer to the Controller
Maintenance Manual for
troubleshooting related to the
controller and amplifier.
-Replace the pulse coder for
the motor of the axis that is
vibrating, and check whether
the vibration still occurs.
-Also, replace the motor of the
axis that is vibrating, and
check whether vibration still
occurs. For the method of
replacement, contact FANUC.
-Check that the robot is
supplied with the rated voltage.
-Check whether the sheath of
the power cord is damaged. If
so, replace the power cord,
and check whether vibration
still occurs.
-Check whether the sheath of
the cable connecting the
mechanical section
and controller is damaged. If
so, replace the connection
cable, and check whether
vibration still occurs.
-If vibration occurs only when
the robot assumes a specific
posture, it is likely that a cable
in the mechanical unit is
broken.
-Shake the movable part cable
while the robot is at rest, and
check whether an alarm
occurs. If an alarm or any other
abnormal condition occurs,
replace the mechanical unit
cable.
-Check that the robot control
parameter is set to a valid
value. If it is set to an invalid
value, correct it. Contact
FANUC for further information
if necessary.
- 24 -
MAINTENANCE
B-81925EN/04
Symptom
Description
Vibration
-There is some relationship
Noise
between the vibration of the
(Continuted) robot and the operation of a
machine near the robot.
- There is an unusual sound
after replacement of grease.
- There is an unusual sound
after a long period of time.
- There is an unusual sound
during operation at low
speed.
3. TROUBLESHOOTING
Cause
Measure
[Noise from a nearby machine]
-If the robot is not grounded properly,
electrical noise is induced on the
grounding wire, preventing commands
from being transferred accurately,
thus leading to vibration.
-If the robot is grounded at an
unsuitable point, its grounding
potential becomes unstable, and
noise is likely to be induced on the
grounding line, thus leading to
vibration.
- There may be an unusual sound
when using other than the specified
grease.
- Even for the specified grease, there
may be an unusual sound during
operation at low speed immediately
after replacement or after a long
period of time.
-Connect the grounding wire
firmly to ensure a reliable
ground potential and prevent
extraneous electrical noise.
- 25 -
- Use the specified grease.
- When there is an unusual
sound even for specified
grease, perform operation
for one or two days on an
experiment. Generally, an
usual sound will disappear.
3. TROUBLESHOOTING
Symptom
Rattling
MAINTENANCE
B-81925EN/04
Description
Cause
Measure
-While the robot is not supplied
with power, pushing it with the
hand causes part of the
mechanical unit to wobble.
-There is a gap on the
mounting surface of the
mechanical unit.
[Mechanical section coupling bolt]
-It is likely that overloading or a
collision has loosened a mounting bolt
in the robot mechanical section.
-Backlash is greater than the
tolerance stated in the
applicable operattor’s manual.
(See table 3.2 (c).)
[Increase in backlash]
-It is likely that excessive force applied
to the drive mechanism, due to a
collision or overloading, has broken a
gear or the inside of the reducer,
resulting in an increase in the amount
of backlash.
-It is likely that prolonged use without
changing the grease has caused the
tooth surfaces of a gear and the inside
of the reducer to wear out, resulting in
an increase in the amount of
backlash.
-Check that the following bolts
for each axis are tight. If any of
these bolts is loose, apply
loctite and tighten it to the
appropriate torque.
-Motor retaining bolt
-Reducer retaining bolt
-Reducer shaft retaining bolt
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
-Operate one axis at a time to
determine which axis has the
increased backlash.
-Remove the motor, and check
whether any of its gears are
broken. If any gear is broken,
replace it.
-Check whether any other gear
of the drive mechanism is
damage. If there is no damage
gear, replace the reducer.
-If the reducer is broken, or if a
gear tooth is missing, replace
the relevant component. Also,
remove all the grease from the
gear box and wash the inside
of the gear box.
-After replacing the gear or
reducer, add an appropriate
amount of grease.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
- 26 -
MAINTENANCE
B-81925EN/04
3. TROUBLESHOOTING
Symptom
Description
Cause
Measure
Motor
overheating
-The ambient temperature of
the installation location
increases, causing
the motor to overheat.
-After a cover was attached to
the motor, the motor
overheated.
-After the robot control
program or the load was
changed, the motor
overheated.
[Ambient temperature]
-It is likely that a rise in the ambient
temperature or attaching the motor
cover prevented the motor from
releasing heat efficiently, thus leading
to overheating.
[Operating condition]
-It is likely that the robot was operated
with the maximum average current
exceeded.
-After a control parameter was
changed, the motor
overheated.
[Parameter]
-If data input for a workpiece is invalid,
the robot cannot be accelerated or
decelerated normally, so the average
current increases, leading to
overheating.
[Mechanical section problems]
-It is likely that problems occurred in
the mechanical unit drive mechanism,
thus placing an excessive load on the
motor.
[Motor problems]
-It is likely that a failure of the motor
brake resulted in the motor running
with the brake applied, thus placing an
excessive load on the motor.
-It is likely that a failure of the motor
prevented it from delivering its rated
performance, thus causing an
excessive current to flow through the
motor.
The teach pendant can be
used to monitor the average
current. Check the average
current when the robot control
program is running. The
allowable average current is
specified for the robot
according to its ambient
temperature. Contact FANUC
for further information.
-Relaxing the robot control
program and conditions can
reduce the average current,
thus preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of
the motor well ventilated
enables the motor to release
heat efficiently, thus preventing
overheating. Using a fan to
direct air at the motor is also
effective.
-If there is a source of heat
near the motor, it is advisable
to install shielding to protect
the motor from heat radiation.
-Input an appropriate
parameter as described in
CONTROLLER OPERATOR’S
MANUAL.
-Symptom other than stated
above
- 27 -
Repair the mechanical unit
while referring to the above
descriptions of vibration, noise,
and rattling.
-Check that, when the servo
system is energized, the brake
is released.
-If the brake remains applied to
the motor all the time, replace
the motor.
-If the average current falls
after the motor is replaced, it
indicates that the first motor
was faulty.
3. TROUBLESHOOTING
Symptom
Grease
leakage
MAINTENANCE
Description
-Grease is leaking from the
mechanical unit.
Dropping axis -An axis drops because the
brake does not function.
-An axis drops gradually when
it should be at rest.
Displacement -The robot operates at a point
other than the taught position.
-The repeatability is not within
the tolerance.
-Displacement occurs only in a
specific peripheral unit.
B-81925EN/04
Cause
Measure
[Poor sealing]
-Probable causes are a crack in the
casting, a broken O-ring, a damaged
oil seal, or a loose seal bolt.
-A crack in a casting can occur due to
excessive force that might be caused
in collision.
-An O-ring can be damaged if it is
trapped or cut during disassembling or
re-assembling.
-An oil seal might be damaged if
extraneous dust scratches the lip of
the oil seal.
-A loose seal bolt might allow grease
to leak along the threads.
-Problems with the grease nipple or
threads.
-If a crack develops in the
casting, sealant can be used
as a quick-fix to prevent further
grease leakage. However, the
component should be replaced
as soon as possible, because
the crack might extend.
-O-rings are used in the
locations listed below.
-Motor coupling section
-Reducer (case and shaft)
coupling section
-Wrist coupling section
-J3 arm coupling section
-Inside the wrist
-Oil seals are used in the
locations stated below.
-Inside the reducer
-Inside the wrist
-Seal bolts are used in the
locations stated below.
-Grease drain outlet
-Replace the grease nipple.
-Check whether the brake drive
relay contacts are stuck to
each other. If they are found to
be stuck, replace the relay.
-If the brake shoe is worn out,
if the brake main body is
damaged, or if oil or grease
has entered the motor, replace
the motor.
[Brake drive relay and motor]
-It is likely that brake drive relay
contacts are stuck to each other to
keep the brake current flowing, thus
preventing the brake from operating
when the motor is deenergized.
-It is likely that the brake shoe has
worn out or the brake main body is
damaged, preventing the brake from
operating efficiently.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
[Mechanical section problems]
-If the repeatability is unstable,
probable causes are a failure in the
drive mechanism or a loose bolt.
-If the repeatability becomes stable it
is likely that a collision imposed an
excessive load, leading to slipping on
the base surface or the mating
surface of an arm or reducer.
-It is likely that the pulse coder is
abnormal.
[Peripheral unit displacement]
-It is likely that an external force was
applied to the peripheral unit, thus
shifting its position relative to the
robot.
- 28 -
-If the repeatability is unstable,
repair the mechanical section
by referring to the above
descriptions of vibration, noise,
and rattling.
-If the repeatability is stable,
correct the taught program.
Variation will not occur unless
another collision occurs.
-If the pulse coder is abnormal,
replace the motor or the pulse
coder.
-Correct the setting of the
peripheral unit position.
-Correct the taught program.
Symptom
3. TROUBLESHOOTING
MAINTENANCE
B-81925EN/04
Description
Cause
Measure
Displacement -Displacement occurred after
(Continuted) a parameter was changed.
[Parameter]
-It is likely that the mastering data was
rewritten in such a way that
the robot origin was shifted.
BZAL alarm
occured
-The voltage of the memory backup
battery may be low.
-The pulse coder cable may be
broken.
-Re-enter the previous
mastering data, which is known
to be correct.
-If correct mastering data is
unavailable, perform mastering
again.
-Replace the battery.
-Replace the cable.
-BZAL is displayed on the
controller screen
Table 3.2 (b) Allowable drop of brake
At emergency stop
0.5mm
NOTE
The value is the drop value from the end effector
mounting face.
Table 3.2 (c) Allowable backlash tolerances
J1-axis J2-axis J3-axis
Angle conversion (arc-min)
Displacement at specified
mesurement position (mm)
2.2
1.96
2.5
0.87
2.5
0.95
J4-axis
2.3
0.19
Refer to following page for the measuring method and the measuring
posture.
- 29 -
3. TROUBLESHOOTING
3.3
MAINTENANCE
B-81925EN/04
BACKLASH MEASUREMENT
Measurement method
1.
2.
Maintain the robot in a specified posture. (See Fig. 3.3 (b))
Apply positive and negative loads to each axis as shown in Fig.
3.3(a).
3.
Remove the loads and measure the displacement.
Apply positive and negative loads to each axis three times and
then remove the loads.
Calculate the average of the
displacements in the second and third measurements as the
backlash.
Ｌ1
(Ｂ2＝Ｌ1＋Ｌ2)
Ｌ2
Ｌ3
(Ｂ3＝Ｌ3＋Ｌ4)
Ｌ4
Fig. 3.3 (a)
Backlash Measurement Method
Backlash B is calculated using the following expression:
B＝
B2 + B3
2
- 30 -
3. TROUBLESHOOTING
MAINTENANCE
B-81925EN/04
<1> J1‑axis measurement posture
<3> J3‑axis measurement posture
Center of mounting
face of wrist
test work
test work
Trestle
3130
Loading position
test work
Trestle
When measuring backlash,press
gauge to test work vertically.
Center of mounting
face of wrist
Loading position
When measuring backlash,press
gauge to test work vertically.
<4> J4‑axis measurement posture
<2> J2‑axis measurement posture
When measuring backlash,press
gauge to test work vertically.
test work
Trestle
Loading position
test work
280
Loading position
Trestle
When measuring backlash,press
gauge to test work vertically.
Gauge
175
Fig. 3.3 (b) Backlash measuring posture
BACKLASH MEASUREMENT POSTURE
Table.3.3 Measurement posture and tolerance value of backlash
Measured axis
posture
J1-axis
J2-axis
J3-axis
J4-axis
J1-axis
-30°
90°
0°
-90°
J2-axis
-46°
0°
-59°
0°
J3-axis
-33°
33°
-91°
0°
J4-axis
-37°
18.5°
-92°
-96°
- 31 -
4. ADJUSTMENTS
4
MAINTENANCE
B-81925EN/04
ADJUSTMENTS
Each part of the mechanical unit is carefully adjusted at the factory
before shipment. Therefore it is usually unnecessary for the customer
to make adjustments at the time of delivery. However, after for a long
period of use or after parts are replaced, adjustments may be required.
- 32 -
MAINTENANCE
B-81925EN/04
4.1
4. ADJUSTMENTS
ADJUSTING LIMIT SWITCHES AND DOGS (OPTION)
1)
Zero point position and motion limit
Zero point and motion limits are provided for each controlled
axis. Reaching the operation limit of controlled axis is called
overtravel (OT). Overtravel is detected at J1-axis only (option).
Overtravel detection function is not prepared at J2-axis to J4
axis.
The robot cannot exceed the motion range unless there is a
failure of the system causing loss of the zero point position, or
there is a system error.
Fig. 4.1 (a) shows the zero point, motion limit OT detection point
and point of mechanical stopper of J1-axis.
Fig. 4.1 (a)
2)
Zero point and motion limit of J1-axis
How to adjust the J1-axis
1
Set the $MOR_GRP.$CAL_DONE system parameter to
FALSE. This disables the stroke end specified by the
software. As a result, the operator can rotate the robot
around the J1-axis by a jog feed which goes beyond the
stroke end.
2
Loosen the two M6×12 bolts and the two M4×25 bolts that
secure the J1-axis limit switch.
3
Adjust the switch position so that the robot activates the
limit switch when approximately 1.0 degree from each
stroke end. When the dog is pressed, only one side of the
pushing width indication lines on the end of the switch must
be hidden.
- 33 -
4. ADJUSTMENTS
MAINTENANCE
4
5
6
7
Fig. 4.1 (b)
B-81925EN/04
When the limit switch operates and detects overtravel (OT),
the robot stops, and an error message, “OVERTRAVEL”, is
displayed. To restart the robot, hold on the SHIFT key and
press the RESET key. Then, while holding on the SHIFT
key, release the J1 axis from the limit by JOG feed.
Check that the robot also activates the limit switch when the
robot is approx. 1.0 degree from the opposite stroke end in
the same way as above. If the limit switch does not operate
at the position, adjust the position of the switch again.
Set the $MOR_GRP.$CAL_DONE system parameter to
TRUE.
Turn off the power, then turn it on again to restart the
controller.
Adjusting J1-axis OT (option)
- 34 -
B-81925EN/04
4.2
4. ADJUSTMENTS
MAINTENANCE
ZERO POINT POSITION AND MOTION LIMIT OF J2-AXIS
TO J4-AXIS
Fig. 4.2 (a) to (c) show zero point position and motion area and
mechanical stopper of each axis.
Fig. 4.2 (a) J2-axis
Fig. 4.2 (b) J3-axis
- 35 -
4. ADJUSTMENTS
MAINTENANCE
B-81925EN/04
Fig. 4.2 (c) J4-axis
- 36 -
B-81925EN/04
4.3
MAINTENANCE
4. ADJUSTMENTS
J1-AXIS STROKE MODIFICATION (OPTION)
The J1-axis stroke can be limited depending on the operating
environment of the robot. The stroke can be changed by changing the
locations of the dog and mechanical stopper and the settings of the
parameters using the following procedure. (See Fig. 4.3 (a) to (b) and
Table 4.3)
The stroke can be changed every 45 degrees in the upper limit of +45
degrees to + 180 degrees and the lower limit of -180 degrees to -45
degrees.
Fig. 4.3 (a) Modifying J1-axis stroke (option)
- 37 -
4. ADJUSTMENTS
MAINTENANCE
B-81925EN/04
(a) Changing the mechanical stopper and the dog (option) position.
Change the mechanical position and the dog position as shown in
Fig. 4.3 (b).
Fig. 4.3 (b)
Modification of J1-axis stroke (option)
- 38 -
B-81925EN/04
4. ADJUSTMENTS
MAINTENANCE
(b) Changing system variables
When changing the dog and mechanical stopper, also be sure to
change the following system variables according to the required
strokes.
After changing system variables, turn the power off then back on
again. (The stroke setting described above can be made also by
selecting “SYSTEM” using the “MENUS” key, then selecting
“Axis limit” menu using F1 (TYPE). Refer to the controller
Operator’s Manual for details.
WARNING
After changing system variables, be sure to run the
robot at a low speed and make sure that the robot
stops at the ends of the stroke.
Table 4.3 Modification of system variable
System variable
Upper stroke limit
Lower stroke limit
Positions
$PARAM_GROUP.
$PARAM_GROUP
$UPPERLIMS[1]
$LOWERLIMS[1]
-180°
-135°
-90°
-45°
0°
+45°
+90°
+135°
+180°
-180
-135
-90
-45
0
–
–
–
–
–
–
–
–
0
45
90
135
180
WARNING
1 If a collision should occur, the J1 axis stopper
becomes deformed to absorb energy, so that the
robot can stop safely. If the stopper is deformed
by mistake, replace it.
2 Do not add threaded holes to the frame, or do not
use a self-made stopper to control the J1 stroke at
any angle other than the one specified; otherwise,
robot operation may be dangerous.
- 39 -
4. ADJUSTMENTS
4.4
MAINTENANCE
B-81925EN/04
SOFTWARE SETTING
Axis limit software settings are upper and lower motion degree
limitations. The limits can be set for all robot axes and will stop robot
motion if the robot is calibrated.
Procedure Setting Up Axis Limits
Step 1
2
3
4
Press MENUS.
Select SYSTEM.
Press F1, [TYPE].
Select Axis Limits. You will see a screen similar to the following.
System Axis Limits
JOINT
100%
1/16
AXIS
1
2
3
4
5
6
7
8
9
[ TYPE ]
GROUP
1
1
1
1
1
1
0
0
0
LOWER
UPPER
-150.00
-60.00
-110.00
-240.00
0.00
0.00
0.00
0.00
0.00
150.00
75.00
50.00
240.00
0.00
0 00
0.00
0.00
0.00
dg
dg
dg
dg
mm
mm
mm
mm
mm
NOTE
0 indicates the robot does not have these axes.
CAUTION
Do not depend on J1 axis limit software settings to
control the motion range of your robot. Use the axis
limit switches or hardstops also; otherwise injury to
personnel or damage to equipment could occur.
5
6
7
Move the cursor to the axis limit you want to set.
Type the new value using the numeric keys on the teach pendant.
Repeat Steps 5 through 6 until you are finished setting the axis
limits.
CAUTION
You must turn off the controller and then turn it
back on to use the new information; otherwise
injury to personnel or damage to equipment could
occur.
8
Turn off the controller and then turn it back on again in the cold
start mode so the new information can be used.
- 40 -
MAINTENANCE
B-81925EN/04
4.5
4. ADJUSTMENTS
MASTERING
Mastering is an operation performed to associate the angle of each
robot axis with the pulse count value supplied from the absolute pulse
coder connected to the corresponding axis motor. To be specific,
mastering is an operation for obtaining the pulse count value
corresponding to the zero position.
4.5.1
General
The current position of the robot is determined according to the pulse
count value supplied from the pulse coder on each axis.
Mastering is factory-performed. It is unnecessary to perform
mastering in daily operations. However, mastering becomes necessary
after:
• Motor replacement.
• Pulse coder replacement.
• Reducer replacement.
• Cable replacement.
• Batteries for pulse count backup in the mechanical unit have gone
dead.
CAUTION
Robot data (including mastering data) and pulse
coder data are backed up by their respective
backup batteries. Data will be lost if the batteries go
dead. Replace the batteries in the control and
mechanical units periodically. An alarm will be
issued to warn the user of a low battery voltage.
- 41 -
4. ADJUSTMENTS
4.5.2
MAINTENANCE
B-81925EN/04
Mastering Method
Table 4.5.1 Types of Mastering
Fixture position
mastering
Zero–position
mastering (eye mark
mastering)
This is performed using a mastering fixture before
the machine is shipped from the factory.
This is performed with all axes set at the 0-degree
position. A zero-position mark (eye mark) is
attached to each robot axis. This mastering is
performed with all axes aligned to their respective
eye marks.
Simplified mastering This is performed at a user-specified position. The
corresponding count value is obtained from the
rotation speed of the pulse coder connected to the
relevant motor and the rotation angle within one
rotation. Simplified mastering uses the fact that the
absolute value of a rotation angle within one rotation
will not be lost.
One–axis mastering This is performed for one axis at a time. The
mastering position for each axis can be specified by
the user. This is useful in performing mastering on a
specific axis.
Mastering data entry Mastering data is entered directly.
Once mastering is performed, it is necessary to carry out positioning,
or calibration. Positioning is an operation in which the control unit
reads the current pulse count value to sense the current position of the
robot.
CAUTION
If mastering is performed incorrectly, the robot may
behave unexpectedly. This is very dangerous. So,
the positioning screen is designed to appear only
when the $MASTER_ENB system variable is 1 or 2.
After performing positioning, press F5 [DONE] on
the positioning screen. The $MASTER_ENB
system variable is reset to 0 automatically, thus
hiding the positioning screen.
CAUTION
Before performing mastering, it is recommended
that the current mastering data be backed up.
- 42 -
MAINTENANCE
B-81925EN/04
4.5.3
4. ADJUSTMENTS
Resetting Alarms and Preparing for Mastering
Before performing mastering because a motor is replaced, it is
necessary to release the relevant alarm and display the positioning
menu.
Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse mismatch”
Procedure
1
Display the positioning menu by following steps 1 to 6.
1
Press the screen selection key.
2
Press [0 NEXT] and select [6 SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variable] from the
menu.
4 Place the cursor on $MASTER_ENB, then key in “1” and
press [ENTER].
5
Press F1 [TYPE], and select[Mater/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal]
menu.
2
Toreset the “Servo 062 BZAL” alarm, follow steps 1 to 5.
1
Press the screen slelection key.
2
Press [0 NEXT] and select [6 SYSTEM].
3 Press F1 [TYPE], and select [Master / Cal] from the menu.
4 Press the F3 [RES_PCA] then press F4 [TRUE].
5
Switch the controller power off and on again
3
To reset the “Servo 075 Pulse mismatch” alarm, follow steps 1 to
3.
1 When the controller power is switched on again, the
message “Servo 075 Pulse mismatch” appears again.
2 Rotate the axis for which the message mentioned above has
appeared through 10 degrees in either direction.
3
Pree [FAULT RESET]. The alarm is reset.
- 43 -
4. ADJUSTMENTS
4.5.4
MAINTENANCE
B-81925EN/04
Mastering to a Fixture (Master Position Master)
Fixture position mastering is performed using a mastering fixture.
This mastering is carried out in the predetermined fixture position.
Fixture position mastering is accurate because a dedicated mastering
fixture is used.
Fixture position mastering is factory-performed. It is unnecessary to
perform it in daily operations.
When mastering the robot, arrange the robot to meet the following
conditions.
• Make the robot mounting base horizontal within 1 mm.
(Set the robot mounting surface so that the levelness of the
entire surface is 1 mm or less.)
• Remove the hand and other parts from the wrist.
• Set the robot in the condition protected from an external force.
Mastering Using a Fixture
1)
Mastering procedure
a) Mount the mastering fixture
i) Assembling the fixture base
Assemble the fixture base as shown in Fig. 4.5.4 (a).
Mount the two plate on the base with bolts (M6×20)
Fig. 4.5.4 (a) Assembling the mastering fixture
- 44 -
B-81925EN/04
MAINTENANCE
ii)
4. ADJUSTMENTS
Mount the dial guage.
Adjust the dial guage to 3.00 mm using the calibration
block, and tighten it with M5×10 bolt as shown in Fig.
4.5.4 (b). (Do not tighten the bolt too strongly. The
dial indicator may be broken.) At this time, check
whether the top of dial guage moves smooth or not.
Fig. 4.5.4 (b) Assembling the dial guage
- 45 -
4. ADJUSTMENTS
MAINTENANCE
B-81925EN/04
iii) Mounting the fixture on the J1-axis base
Mount the fixture on the J1-axis base using two bolts
(M16×45) and pin (16-dia straight pin and 16-dia
hexagonal pin), as shown in Fig. 4.5.4 (c). Be
particularly careful to orient the hexagonal pin
correctly.
Fig. 4.5.4 (c)
- 46 -
Mounting the fixture on the wrist
B-81925EN/04
MAINTENANCE
4. ADJUSTMENTS
iv) Mounting the fixture on the wrist
Mount the fixture on the wrist flange using four bolts
(M10×25) and pin (10-dia straight pin and 10-dia
hexagonal pin), as shown in Fig. 4.5.4 (d). Be
particularly careful to orient the hexagonal pin
correctly.
Fig. 4.5.4 (d)
- 47 -
Mounting the fixture on the wrist
4. ADJUSTMENTS
4.5.5
MAINTENANCE
B-81925EN/04
Mastering
1)
2)
3)
4)
Press MENUS.
Press NEXT and select SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
5)
Release brake control, and jog the robot into a posture for
mastering. See the Fig. 4.5.5 for the mastering posture.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM_GROUP.SV_OFF_ENB[*]: FALSE (for
all axes)
After changing the system variables, switch the
control unit power off and on again.
6)
7)
8)
Select Fixture Position Master.
Press F4, YES. Mastering will be performed automatically.
Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.
After positioning is completed, press F5 [DONE].
CAUTION
No check is made on the axis movable range during
mastering. Be very careful when running the robot.
Continuing axis movement may result in the
mechanical stopper being bumped.
- 48 -
B-81925EN/04
MAINTENANCE
M-410iB/450 Mastering
Fig. 4.5.5 Mastering attitude
- 49 -
4. ADJUSTMENTS
4. ADJUSTMENTS
4.5.6
MAINTENANCE
B-81925EN/04
Zero Degree Mastering
Zero-position mastering (eye mark mastering) is performed with all
axes set at the 0-degree position. A zero-position mark (eye mark) is
attached to each robot axis. This mastering is performed with all axes
set at the 0-degree position using their respective eye marks.
Zero-position mastering involves a visual check. It cannot be so
accurate. It should be used only as a quick-fix method.
Procedure Mastering to Zero Degrees
Step 1
2
3
4
5
Press MENUS.
Select NEXT and press SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
Release brake control, and jog the robot into a posture for
mastering.
NOTE
Brake control can be released by setting the
system variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM GROUP.SV OFF ENB[*]: FALSE
(for all axes)
After changing the system variables, switch the
control unit power off and on again.
6
7
8
Select Zero Position Master.
Press F4, YES. Mastering will be performed automatically.
Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.
After positioning is completed, press F5 [DONE]
- 50 -
4. ADJUSTMENTS
MAINTENANCE
B-81925EN/04
Table 4.5.6 Attitude with position marks aligned
Position
Axis
M-410iB/450
J1-axis
J2-axis
J3-axis
J4-axis
0 deg
0 deg
0 deg
0 deg
J3-axis
VIEW A
J3-axis position mark (layout mark)
VIEW B
J4-axis
J4-axis position mark (layout mark)
J2-axis
J1-axis, J2-axis 0° position mark
J1-axis
J3-axis 0° position mark
J2-axis position mark (layout mark) J1-axis position mark (layout mark)
Fig. 4.5.6 Attitude with position marks aligned
- 51 -
J4-axis 0° position mark
4. ADJUSTMENTS
4.5.7
MAINTENANCE
B-81925EN/04
Quick Mastering
Simplified mastering is performed at a user-specified position. The
corresponding count value is obtained from the rotation speed of the
pulse coder connected to the relevant motor and the rotation angle
within one rotation. Simplified mastering uses the fact that the
absolute value of a rotation angle within one rotation will not be lost.
Simplified mastering is factory-performed at the position indicated in
Table 4.5.6. Do not change the setting unless there is any problem.
If it is impossible to set the robot at the position mentioned above, it is
necessary to re-set the simplified mastering reference position using
the following method. (It would be convenient to set up a marker that
can work in place of the eye mark.)
CAUTION
1 Simplified mastering can be used, if the pulse count
value is lost, for example, because a low voltage
has been detected on the backup battery for the
pulse counter.
2 Simplified mastering cannot be used, after the pulse
coder is replaced or after the mastering data is lost
from the robot control unit.
Procedure Recording the Quick Master Reference Position
Step 1
2
3
Set quick master ref? [NO]
4
Select SYSTEM.
Select Master/Cal.
Release brake control, and jog the robot to the simplified
mastering reference position.
Move the cursor to SET QUICK MASTER REF and press
ENTER. Press F4, YES.
CAUTION
If the robot has lost mastery due to mechanical
disassembly or repair, you cannot perform this
procedure. In this case, master to a fixture or
master to zero degrees to restore robot mastery.
- 52 -
MAINTENANCE
B-81925EN/04
4. ADJUSTMENTS
Procedure Quick Mastering
Step 1
2
Quick master? [NO]
3
4
5
Display the Master/Cal screen
Release brake control, and jog the robot to the simplified
mastering reference position.
Move the cursor to QUICK MASTER and press ENTER. Press
F4, YES.
Quick mastering data is memorized.
Move the cursor to CALIBRATE and press ENTER.
Calibration is executed. Calibration is executed by power on
again.
After completing the calibration, press F5 Done.
- 53 -
4. ADJUSTMENTS
4.5.8
MAINTENANCE
B-81925EN/04
Single Axis Mastering
Single axis mastering is performed for one axis at a time. The
mastering position for each axis can be specified by the user.
Single axis mastering can be used, if mastering data for a specific axis
is lost, for example, because a low voltage has been detected on the
pulse counter backup battery or because the pulse coder has been
replaced.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
25.255
25.550
-50.000
12.500
31.250
43.382
0.000
0.000
0.000
JOINT 30%
(MSTR POS)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
[ TYPE ]
(SEL)
(0)
(0)
(0)
(0)
(0)
(0)
(0)
(0)
(0)
1/9
[ST]
[2]
[2]
[2]
[2]
[2]
[2]
[2]
[2]
[2]
GROUP EXEC
Table 4.5.8
Item
Current position
(Actual axis)
Mastering position
(Matra pos)
SEL
ST
- 54 -
Items Set in Single Axis Mastering
Description
The current position of the robot is displayed for
each axis in degree units.
A mastering position is specified for an axis to
be subjected to single axis mastering. It would
be convenient to set to it to the 0°position.
This item is set to 1 for an axis to be subjected
to single axis mastering. Usually, it is 0.
This item indicates whether single axis
mastering has been completed for the
corresponding axis. It cannot be changed
directly by the user.
The value of the item is reflected in
$EACHMST_DON (1 to 9).
0 : Mastering data has been lost. Single axis
mastering is necessary.
1 : Mastering data has been lost. (Mastering has
been performed only for the other interactive
axes.) Single axis mastering is necessary.
2 : Mastering has been completed.
MAINTENANCE
B-81925EN/04
4. ADJUSTMENTS
Procedure Mastering a Single Axis
Step 1
2
Select SYSTEM.
Select Master/Cal.
3
Select 4, Single Axis Master. You will see a screen similar to
the following.
4
Move the cursor to the SEL column for the unmastered axis and
press the numeric key "1." Setting of SEL is available for one
or more axes.
Turn off brake control as required, then jog the robot to the
mastering position.
Enter axis data for the mastering position.
5
6
- 55 -
4. ADJUSTMENTS
MAINTENANCE
B-81925EN/04
7
Press F5 [EXEC]. Mastering is performed. So, SEL is reset to 0,
and ST is re-set to 2 or 1.
8
When single axis mastering is completed, press the previous page
key to resume the previous screen.
9
Select [6 CALIBRATE], then press F4 [YES]. Positioning is
performed.
Alternatively, switch the power off and on again. Positioning is
performed.
After positioning is completed, press F5 [DONE].
10
- 56 -
MAINTENANCE
B-81925EN/04
4.5.9
4. ADJUSTMENTS
Mastering Data Entry
This function enables mastering data values to be assigned directly to
a system variable. It can be used if mastering data has been lost but the
pulse count is preserved.
Mastering data entry method
Step 1
2
3
Press MENUS, then press NEXT and select SYSTEM.
Press F1, [TYPE]. Select [Variables]. The system variable screen
appears.
Change the mastering data.
The mastering data is saved to the
$DMR_GRP.$MASTER_COUN system variable.
- 57 -
4. ADJUSTMENTS
MAINTENANCE
B-81925EN/04
4
Select $DMR_GRP.
5
Select $MASTER_COUN, and enter the mastering data you have
recorded.
6
7
Press the PREV key.
Set $MASTER_DONE to TRUE.
8
Display the positioning screen, and select [6 CALIBRATE], then
press F4 [YES].
After completing positioning, press F5 [DONE].
9
- 58 -
5
5. REPLACING PARTS
MAINTENANCE
B-81925EN/04
REPLACING PARTS
Procedure of replacement for main parts is described.
Replace the main parts according to the procedure.
NOTE
When applying LOCTITE to the important bolt
tightening points, make sure that it is applied to the
entire longitudinal portion in the engaging section of
the female threads. If it is applied to the male
threads, the bolts may be loosened because
sufficient effects cannot be obtained. Remove the
dust within the bolts and taps and wipe oil off the
engaging section. Make sure that there is no solvent
in the taps.
NOTE
Be careful when removing and installing the
following heavy parts.
Parts
servo motor
Weight (approx.) kg
J1-axis
J2-axis
J3-axis
J1-axis
J2-axis
J3-axis
J4-axis
reducer
flame colum (1pcs)
J1-axis base
J2-axis base
balancer
J2 arm
J2 link
J3-axis base
J3 arm
wrist unit
Unit that is upper than J2-axis base
(see Fig. 5.2 (e) (f).)
- 59 -
23
23
23
165
70
70
20
50
230
350
250
195
70
60
140
65
1170
5. REPLACING PARTS
5.1
MAINTENANCE
B-81925EN/04
PART REPLACEMENT AND CORRESPONDING
ADJUSTMENT
When a part is replaced, the corresponding adjustment must be made.
Table 5.1 lists those parts that can be replaced and the corresponding
adjustment.
After replacing a part, perform the appropriate adjustment, as listed
below.
Table 5.1 Parts to be replaced and adjustment items
Parts to be replaced
Adjustment
Method
Motor, reducer, gear,
Wrist unit,
Cable (*1)
Limit switch (*2)
*1
*2
Mastering
See 4.4 to 4.7
Adjusting, limit switch
See 4.1
Refer to item 7 for replacement of cables.
Refer to item 5.6 for replacement of limit switches.
- 60 -
B-81925EN/04
5.2
MAINTENANCE
5. REPLACING PARTS
REPLACING J1-AXIS MOTOR (M1) AND REDUCER
(1) Replacing the J1-axis motor (M1)
[In case of the integrated control unit]
1
Turn the power off.
2
To provide space in which the J1-axis motor can be
removed, shift the location of the control unit by following
the procedure below (see Fig. 5.2 (a)).
• Remove the bolts (two M6×10) from the connector plate,
and dismount it.
• Remove the bolt (M10×16) from the cable clamp, and
dismount the cable clamp.
• Remove the bolts (two M10×20 bolts and two M10×16)
from the control unit retaining plate, and dismount it.
• Shift the control unit to a location shown in Fig. 5.2 (a).
3
Remove connectors from the J1-axis motor (see Fig. 5.2
(b)).
4
Prepare to wipe off grease that will come out from the
grease bath when the J1-axis motor is dismounted from the
robot. Also cover the control unit with a cloth to protect it
from grease drips.
5
The J1-axis motor is heavy. To support the motor during
removal of it, place a jack or other lifting tool under the
motor in advance.
6
Remove four motor securing bolts (M12×30). Remove the
J1-axis motor from the J1-axis base. Take care not to soil
the transformer with grease.
7
Remove the nut (M20) from the tip of the motor shaft, and
pull out the gear from the motor. The nut can be removed
by holding the two flat portions on the gear with a wrench
to keep the motor shaft from rotating.
8
Replace the motor with a new one. Mount the new motor
as follows :
• Polish the motor mounting surface with an oilstone.
• Mount an auxiliary seal (spec. : A98L-0004-0071#A12TP)
on the motor. Auxiliary seals cannot be reused. Always
use a new seal.
NOTE
A motor whose specification number is terminated
with #S000 has the built-in auxiliary seal.
• Apply Loctite No. 242 (blue) to the thread of the motor.
Take care not to apply Loctite to the tapered part of the
shaft.
• Mount and rotate the nut while holding the two flat
portions on the gear with a wrench to keep the motor
shaft from rotating. Tighten the nut with a tightening
torque of 118 Nm (12.0 kgfm).
• Take care not to damage any tooth flank of the gear.
- 61 -
5. REPLACING PARTS
MAINTENANCE
9
10
B-81925EN/04
• Mount the O-ring just in a correct position.
• Replace each removed washer with a new one.
• Those bolts for which no tightening torque is specified
must be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
Apply grease (see Section 2).
Carry out an adjustment (see Sections 4.5).
Fig. 5.2 (a) Replacing the J1-axis motor (M1) (Integrated control unit)
- 62 -
B-81925EN/04
MAINTENANCE
5. REPLACING PARTS
Fig. 5.2 (b) Replacing the J1-axis motor (M1) (Integrated control unit)
[In case of the separated control unit]
1
Turn the power off.
2
Remove the connectors from the J1-axis motor (see Fig. 5.2
(c)).
3
Prepare to wipe off grease that will come out from the
grease bath when the J1-axis motor is dismounted from the
robot.
4
The J1-axis motor is heavy. To support the motor during
removal of it, place a jack or other lifting tool under the
motor in advance.
5
Remove four motor securing bolts. (M12×30). Dismount
the J1-axis motor from the J1-axis base.
6
Remove the nut M20 from the tip of the motor shaft,
holding the gear with a wrench so that the motor shaft will
not turn. Then, remove the gear from the motor.
7
Replace the motor with a new one. Mount the new motor as
follows :
• Polish the motor mounting surface with an oilstone.
• Mount an auxiliary seal (spec. : A98L-0004-0771#A12TP)
on the motor. (Auxiliary seals cannot be reused.
Always use a new seal.)
NOTE
A motor whose specification number is terminated
with #S000 has the built-in auxiliary seal.
- 63 -
5. REPLACING PARTS
MAINTENANCE
8
9
B-81925EN/04
• Apply Loctite No. 242 (blue) to the threads of the motor
screws. Take care not to apply Loctite to the tapered part
of the shaft.
• Tighten the nut securely, while holding the two flat
portions or the gear with a wrench. Tighten the nut with a
tightening torque of 118 Nm (12.0 kgfm).
• Take care not to damage any gear tooth flank.
• Mount an O-ring in the correct position.
• Replace each removed washer with a new one.
• Those bolts for which no tightening torque is specified
must be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
Apply grease (see Section 2).
Carry out an adjustment (see Sections 4.5.)
Fig. 5.2 (c) Replacing the J1-axis motor (M1) (Remote control unit)
- 64 -
B-81925EN/04
MAINTENANCE
5. REPLACING PARTS
(2) Replacing the J1-axis reducer
1
Set the J2-axis and J3-axis arms to around the 0-degree
position. Then, turn the power off.
2
To remove the balancer, follow the steps below.
• Prepare to sling up the balancer by mounting eyebolts
(two M12 bolts) to the balancer and threading a strap
through the eyebolts (see Fig. 5.3 (c)).
• Remove the bolts (six M8×20 bolts) from the shaft on the
balancer's movable fulcrum side to dismount the shaft
(see Fig. 5.2 (d)).
• Remove the bolts (twenty-four M8×25 bolts) from the
two shafts (one at the right end and the other at the left
end) on the balancer's fixed fulcrum side to dismount the
shafts.
3
Take out all cables, which are laid between the J1-axis base
and J2-axis base, from the hollow section of the J1-axis
reducer by pulling them toward the J2-axis base side (see
Section 7.2).
4
Remove the J1-axis motor (see 5.2 (1) above).
5
Mount two eyebolts (M12) onto the J3-axis arm. Prepare
to sling up the unit that is above the J2-axis base by
threading strap through the eyebolts on the J2-axis base and
J3-axis arms (see Fig. 5.2 (e)).
6
Remove the grease tube from the J1-axis reducer (see Fig.
5.2 (f)).
7
Remove the J2-axis base mounting bolts (eighteen M16×50
bolts), and separate the units that are above the J2-axis base
from the J1-axis reducer.
8
Prepare to wipe off grease that will come out from the
grease bath when the J1-axis reducer is dismounted. Also
cover the control unit with a cloth to protect it from grease
drips.
Remove the J1-axis reducer mounting bolts
(twenty-four M12×95 bolts) and, dismount the J1-axis
reducer from the J1-axis base. Wipe off any leaking
grease.
9
Dismount the center gear from the J1-axis reducer.
10 Remove the bolts (eight M6×16 bolts) from the pipe, and
dismount it from the J1-axis reducer.
11 Mount the new reducer as follows :
• Polish the reducer mounting surface and the J2 base
mounting surface with an oilstone.
• Apply Loctite No. 262 (red) to the female side of these
bolts indicated as Loctite 262.
• Tighten the following bolts with the stated tightening
torque. See the tightening torque table presented in
Appendix D for the tightening torque for the other bolts.
J1-axis reducer mounting bolt
M12×95 : 128.4 Nm (13.1 kgfm)
J2-axis base mounting bolt
M16×50 : 318.5 Nm (32.5 kgfm)
• Mount the O-ring in the correct position.
- 65 -
5. REPLACING PARTS
MAINTENANCE
12
13
14
B-81925EN/04
• Be careful not to damage the tooth face and flank of the
center gear.
• Replace each removed washer with a new one.
• If it is difficult to insert the shaft on the balancer’s movable
fulcrum side into the slot of the balancer rod section,
remove the balancer rear cover, and screw an M6×40 bolt
(to be prepared by the customer) into the M6 hole used to
mount the cover, and push up the end plate in the
balancer by about 3 mm so that the center of the slot of
the balancer rod section is aligned to the center of the
shaft for easier insertion.
• Before mounting the J1-axis motor, mount the J2-axis
reducer to the J1-axis base in order to prevent damage to
the gear.
• Before attaching the grease tube to the J2-axis reducer,
wind sealing tape around the adapter threads.
Form the cables (see Sections 7.1 and 7.2).
Supply grease (see Section 2).
Perform mastering (see Sections 4.5).
Fig. 5.2 (d) Replacing J1-axis reducer
- 66 -
B-81925EN/04
MAINTENANCE
5. REPLACING PARTS
Fig. 5.2 (e) Replacing J1-axis reducer
Fig. 5.2 (f)
- 67 -
Replacing J1-axis reducer
5. REPLACING PARTS
5.3
MAINTENANCE
B-81925EN/04
REPLACING J2/J3-AXIS MOTOR (M2/M3) AND REDUCER
(1) Replacing the J2/J3-axis motor (M2/M3)
1
Removing the motor from the robot allows the arm to fall
down. To keep the arm from falling down, put the robot in
the attitude shown in Fig. 5.3 (a). Thread the eyebolts
with a piece of strap and hang the arm in position with the
strap.
2
Turn the power off.
3
Remove the connectors.
4
Remove four seal bolts (M12×30) from the motor to be
replaced (see Fig. 5.3 (b)). Prepare to wipe off grease that
will come out from the grease bath when the motor is
dismounted.
5
Remove the input gear and draw bolt. When removing the
draw bolt and nut (for securing the input gear), hold the
input gear with a wrench so that the motor shaft will not
turn.
6
Replace the motor with a new one. Mount the new motor
as follows :
• Polish the motor mounting surface with an oilstone.
• Mount an auxiliary seal (spec. : A98L-0004-0771#A12TP)
on the motor. (Auxiliary seals cannot be reused.
Always use a new seal.)
NOTE
A motor whose specification number is terminated
with #S000 has the built-in auxiliary seal.
7
8
• Apply Loctite No. 242 (blue) to the thread part of the
motor and draw bolt. Take care not to apply Loctite to
the tapered part of the shaft.
• When installing the draw bolt nut (for securing the input
gear), hold the two flat portions on the input gear with a
wrench to keep the motor shaft from rotating. The
tightening torque for the nut is 13.2 Nm (1.35 kgfm).
• Mount the O-ring in the correct position.
• Mounting a motor to the robot take care not to damage
any tooth flank of the input gear.
• Apply sealant (Loctite Gasket Eliminator No. 518) to the
motor mounting seal bolts in the female side, or wind seal
tape around them.
• Replace each removed washer with a new one.
• Those bolts for which no tightening torque is specified
must be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
Apply grease (see Section 2).
Carry out an adjustment (see Sections 4.5).
- 68 -
B-81925EN/04
MAINTENANCE
Fig. 5.3 (a)
- 69 -
5. REPLACING PARTS
Attitude at replacing J2/J3-axis motor (M2/M3)
5. REPLACING PARTS
MAINTENANCE
Fig. 5.3 (b) Replacing J2/J3-axis motor (M2/M3)
- 70 -
B-81925EN/04
B-81925EN/04
MAINTENANCE
5. REPLACING PARTS
(2) Replacing the J2-axis reducer
1
Removing the J2-axis reducer from the robot allows the arm
to fall down. To keep the arm from falling down, put the
robot in the attitude shown in Fig. 5.3 (a), screw an eyebolt
into the M12 hole in the upper section of the J3-axis arm.
Thread the eyebolts with a piece of strap and hang the arm
in position with the strap.
2
Turn the power off.
3
Mount eyebolts (two M12 bolts) to the balancer, and sling it
up (see Fig. 5.3 (c)).
4
Remove the bolts (six M8×20 bolts) from the shaft on the
movable fulcrum side of the balancer, and dismount the
shaft (see Fig. 5.3 (d)). Now the balancer can be separated
from the J2-axis arm.
5
Prepare to wipe off grease that will come out from the
grease bath when the motor is dismounted. Remove the
J2-axis motor mounting seal bolts (four M12×30 bolts), and
dismount the motor (see Section 5.3 (1)). Wipe off any
leaking grease.
6
Prepare to wipe off grease that will come out from the
grease bath when the J2-axis arm is dismounted. Remove
the J2-axis arm mounting bolts (six M16×60 bolts and
twenty-one M12×50 bolts). Now the J2-axis arm can be
separated from the J2-axis reducer. Wipe off any leaking
grease.
7
Remove the J2-axis reducer mounting bolts (twenty-four
M12×70 bolts), and dismount the J2-axis reducer along with
the motor brackets.
8
Mount the new reducer as follows :
• Polish the reducer mounting surface and motor mounting
surface with an oilstone.
• Apply sealant (Loctite Gasket Eliminator No. 518) to the
reducer mounting surface. A light, uniform coating of
sealant should be applied to the area shown in Fig. 5.3
(d).
• Apply sealant (Loctite Gasket Eliminator No. 518) to the
female side of the M12×30 bolts motor mounting, or
wind seal tape around them.
• Apply Loctite No. 262 (red) to the female side of the
other bolts specified in Fig. 5.3 (d).
• Tighten the bolts with the following torque:
See the tightening torque table presented in Appendix D
for the tightening torque for the other bolts.
J2-axis reducer mounting bolt
M12×70 : 128.4 Nm (13.1 kgfm)
J2-axis arm mounting bolt
M16×60 : 318.5 Nm (32.5 kgfm)
M12×50 : 128.4 Nm (13.1 kgfm)
• Mount the O-ring in the correct position.
• Mounting a motor to the robot, take care not to damage
any tooth flank of the gear.
- 71 -
5. REPLACING PARTS
MAINTENANCE
9
10
B-81925EN/04
• Replace each removed washer with a new one.
• If it is difficult to insert the shaft on the balancer’
movable fulcrum side into the slot of the balancer rod
section, remove the balancer rear cover, and screw an
M6×40 bolt (to be prepared by the customer) into the M6
hole used to mount the cover, and push up the end plate
in the balancer by about 3 mm so that the center of slot of
the balancer rod section is aligned to the center of the
shaft for easier insertion.
Apply grease (see Section 2).
Carry out an adjustment (see Sections 4.5).
Fig. 5.3 (c) Replacing J2-axis reducer
- 72 -
B-81925EN/04
MAINTENANCE
Fig. 5.3 (d) Replacing J2-axis reducer
- 73 -
5. REPLACING PARTS
5. REPLACING PARTS
MAINTENANCE
B-81925EN/04
(3) Replacing the J3-axis reducer
1
Put the robot in an attitude of J2-axis = 90° and J3-axis =
0°.
2
Turn the power off.
3
Remove the bolts (six M8×12 bolts) from the J2-axis arm
cover, and dismount it (see Fig. 5.3 (g)).
4
Remove the J3-axis arm mounting bolts that are used to link
the J3-axis reducer and J3-axis arm (see Fig. 5.3 (e)).
Bolts to be removed: Two M16×45 bolts and seven
M12×35 bolts.
5
Switch the power on, and bring the robot into the attitude
shown in Fig. 5.3 (a) at low speed.
6
Switch the power off.
7
Removing the J3-axis reducer from the robot allows the J3
arm and base to fall down. To keep the J3 arm from
falling down, screw an eyebolt into the M12 hole in the
upper section of the J3 arm, and thread a strap through the
eyebolt, then sling up the arm (see Fig. 5.3 (a)). Also sling
up the J3 base using a strap to keep the J3 base from falling
down (see Fig. 5.3 (f)).
8
Prepare to wipe off grease that will come out from the
grease bath when the J3-axis motor is dismounted (see Fig.
5.3 (g)). Remove the J3-axis motor mounting bolts (four
M12×30 bolts), and dismount the motor. Wipe off any
leaking grease. (See Section 5.3 (1).)
9
Remove the remaining J3-axis arm mounting bolts that are
used to link the J3-axis reducer and J3-axis arm (see Fig.
5.3 (g)).
Bolts to be removed: Four M16×45 bolts and fourteen
M12×35 bolts.
Now the J3-axis arm can be separated from the J3-axis
reducer. Prepare to wipe off grease that will come out
from the grease bath when the J3-axis arm is dismounted.
Wipe off any leaking grease.
10 Remove the J3-axis reducer mounting bolts (twenty-four
M12×70 bolts), and dismount the J3-axis reducer along with
the motor brackets.
11 Mount the new reducer as follows :
• Polish the reducer mounting surface and motor mounting
surface with an oilstone.
• Apply sealant (Loctite Gasket Eliminator No. 518) to the
reducer mounting surface. A light, uniform coating of
sealant should be applied to the area shown in Fig. 5.3
(g).
• Apply sealant (Loctite Gasket Eliminator No. 518) to the
female side of the M12×30 bolts motor mounting, or
wind seal tape around them.
• Apply Loctite No. 262 (red) to the female side of the
Loctite 262 bolts specified in Fig. 5.3 (g).
• Tighten the bolts with the following torque:
- 74 -
MAINTENANCE
B-81925EN/04
12
13
5. REPLACING PARTS
• Those bolts for which no tightening torque is specified
must be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
J3-axis reducer mounting bolt
M12×70 : 128.4 Nm (13.1 kgfm)
J3-axis arm mounting bolt
M16×45 : 318.5 Nm (32.5 kgfm)
M12×35 : 128.4 Nm (13.1 kgfm)
• Mount the O-ring just in a correct position.
• Mounting a motor to the robot, take care not to damage
any tooth flank of the input gear.
• Replace each removed washer with a new one.
Apply grease (see Section 2).
Carry out an adjustment (see Sections 4.5).
Fig. 5.3 (e) Replacing the J3-axis reducer
Fig. 5.3 (f)
- 75 -
Replacing J3-axis reducer
5. REPLACING PARTS
MAINTENANCE
Fig. 5.3 (g) Replacing J3-axis reducer
- 76 -
B-81925EN/04
B-81925EN/04
5.4
MAINTENANCE
5. REPLACING PARTS
REPLACING J4-AXIS MOTOR (M4) AND REDUCER
(1) Replacing J4-axis motor (M4)
1
Turn the power off.
2
Remove connectors from the J4-axis motor(see Fig. 5.4 (a)).
3
Remove four motor securing bolts (M8×20).
Then,
remove the motor.
4
Remove a nut from the end of the motor shaft, holding the
gear with a wrench so that the motor shaft will not turn.
Then, remove the gear from the motor.
5
Replace the motor with a new one. Mount the new motor
as follows :
• Polish the motor mounting surface with an oilstone.
• Apply Loctite No. 242 (blue) to the thread of the motor.
Take care not to apply Loctite to the tapered part of the
shaft.
• Tighten the nut with a torque of 16.7 Nm (1.70 kgfm),
holding the gear with a wrench.
• Mount the O-ring just in a correct position.
• Take care not to damage any tooth flank of the gear.
• Replace each removed washer with a new one.
• Those bolts for which no tightening torque is specified
must be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
6
Apply grease (see Section 2).
7
Carry out an adjustment (see Sections 4.5).
Fig. 5.4 (a) Replacing J4-axis motor (M4)
- 77 -
5. REPLACING PARTS
MAINTENANCE
B-81925EN/04
(2) Replacing the J4-axis reducer
This part describes the procedure for replacing only the J4-axis
reducer. To replace the wrist unit, see Section 5.5.
1
Turn the power off.
2
Remove the hand, workpiece, and other loads from the
wrist.
3
Remove fourteen reducer unit securing bolts (M10×85).
Then, remove the reducer unit from the wrist. (See Fig.
5.4 (b).) Prepare to wipe off grease that will come out
from the grease bath when the reduction unit is dismounted.
4
Remove nine wrist flange securing bolts (M12×25). Then,
remove the wrist flange from the reducer unit (see Fig. 5.4
(c)).
5
Replace the three pipe mounting bolts (M6×20) then
remove a pipe and center gear from the reducer unit.
6
Replace the reducer with a new one.
7
Mount the new reducer as follows :
• Polish the reducer mounting surface with an oilstone.
• Apply Loctite No. 262 (red) to the female side of the
bolts indicated in Fig. 5.4 (b) and (c) as Loctite 262.
• Tighten the bolts with the following torque:
Reducer unit securing bolt
M10×85 : 73.5 Nm (7.5 kgfm)
Wrist flange securing bolt
M12×25 : 128.4 Nm (13.1 kgfm)
• Those bolts for which no tightening torque is specified
must be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
• Mount the O-ring just in a correct position.
• Apply sealant (Loctite Gasket Eliminator No. 518) to the
surface on which the wrist flange is to be mounted to the
reducer. A light, uniform coating of the sealant should be
applied to the area shown in Fig. 5.4 (c).
• Mounting a reducer unit to the wrist, take care not to
damage any tooth flank of the center gear.
• Replace each removed washer with a new one.
8
Apply grease (see Section 2).
9
Carry out an adjustment (see Sections 4.5).
- 78 -
B-81925EN/04
MAINTENANCE
5. REPLACING PARTS
Fig. 5.4 (b) Replacing J4-axis reducer
Fig. 5.4 (c) Replacing J4-axis reducer
- 79 -
5. REPLACING PARTS
5.5
MAINTENANCE
B-81925EN/04
REPLACING THE WRIST UNIT
This section describes the procedure for replacing the wrist unit. To
order a replacement wrist unit, use the ordering information
A05B-1039-K501. To replace only the J4-axis reducer, see (2) in
Section 5.4.
1
Turn the power off.
2
Remove the hand, workpiece, and other loads from the wrist.
3
Remove the cover from the J3-axis arm (3pcs M6×10) (see Fig.
5.5).
4
Disconnect a connector from the J4-axis motor.
5
Remove the wrist connector box from the wrist unit (see Section
7).
6
Remove the J3-axis link from the wrist unit by following the
steps below.
• Remove the rubber cap from both ends of the J3-axis link.
• Remove the bolts (four M6×12 bolts) from both ends of the
J3-axis link.
• Remove the bolts (eight M8×20 bolts) from the J3 base-side
shaft of the J3-axis link.
• Remove the wrist unit from the J3-axis link.
7 Remove the bolts (eight M8×25 bolts) from the J3-axis link shaft,
and dismount it from the wrist unit.
8
Remove the bolts (four M10×30 bolts) from the wrist subshaft,
and dismount it.
9
Remove the cross-roller internal ring mounting bolts (twelve
M10 ×75 bolts), and dismount the wrist unit from the J3 arm.
10 Remove the cross-roller external ring mounting bolts (eight
M10×45 bolts), and dismount the cross roller from the wrist unit.
11 Remove the J4-axis motor mounting bolts (four M8×20 bolts),
and dismount the motor (see Section 5.4).
12 Mount a new replacement wrist unit as follows :
• Apply grease (SHELL SEKIYU Alvania GREASE S2) to the
oil seal attached to the replacement wrist unit.
• Replace each removed washer with a new one.
• Apply sealant (Loctite Gasket Eliminator No. 518) to the
surface on which the wrist flange is to be mounted to the
reducer. A light, uniform coating of the sealant should be
applied to the area shown in Fig. 5.4 (c).
13 Apply grease (see Section 2).
14 Carry out an adjustment (see Sections 4.5).
- 80 -
B-81925EN/04
MAINTENANCE
Fig. 5.5 Replacing the wrist unit
- 81 -
5. REPLACING PARTS
5. REPLACING PARTS
5.6
MAINTENANCE
B-81925EN/04
REPLACING THE OPTIONAL J1-AXIS LIMIT SWITCH
(OPTION)
1)
2)
3)
4)
5)
Remove the limit switch from the metal plate of mounting limit
switch.
Disconnect the cable from the limit switch.
Replace the limit switch with a new one.
Reassemble the unit by reversing the above procedure.
• Those bolts for which no tightening torque is specified must
be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
Adjust the limit switch. (See item 4.1)
Fig. 5.6 Replacing the limit switch
- 82 -
MAINTENANCE
B-81925EN/04
5.7
5. REPLACING PARTS
REPLACING THE J1-AXIS PENDULUM STOPPER
1)
2)
Remove the pendulum stopper as shown in Fig. 5.7.
Install a new pendulum stopper by reversing the removal
procedure.
• Those bolts for which no tightening torque is specified must
be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
Fig. 5.7 Replacing the J1-axis pendulum stopper
- 83 -
6. WIRING
6
MAINTENANCE
B-81925EN/04
WIRING
Fig. 6 (a), (b) show the wiring diagram in the mechanical unit.
K504(R-J3iB), K554(R-30iA) (J4-axis power, pulsecoder, brake, EE, CE)
K505(R-J3iB), K555(R-30iA) (J4-axis power, pulsecoder, brake, EE, AS, CE)
K506(R-J3iB), K556(R-30iA) (J4 to J5-axis power, pulsecoder, brake, EE, CE)
K507(R-J3iB), K557(R-30iA) (J4 to J5-axis power, pulsecoder, brake, EE, AS, CE)
K556(R-30iA)(J4 to J5-axis power, pulsecoder,brake,EE,AS,CAMERA,CE)
K501, K551 (J1 to J2-axis power, brake, CE)
K502, K552 (J1 to J2-axis pulse coder, brake, CE)
Fig. 6 (a) Wiring diagram in the mechanical unit (Integrated control unit)
- 84 -
B-81925EN/04
MAINTENANCE
6. WIRING
K512(R-J3iB), K562(R-30iA) (J4-axis power, pulsecoder, brake, EE, CE)
K513(R-J3iB), K563(R-30iA) (J4-axis power, pulsecoder, brake, EE, AS, CE)
K514(R-J3iB), K564(R-30iA) (J4 to J5-axis power, pulsecoder, brake, EE, CE)
K515(R-J3iB), K565(R-30iA) (J4 to J5-axis power, pulsecoder, brake, EE, AS, CE)
Fig. 6 (b) Wiring diagram in the mechanical unit (Control unit remote type)
- 85 -
7. REPLACING CABLES
7
MAINTENANCE
B-81925EN/04
REPLACING CABLES
Replace the cables periodically (every 15,360 operating hours or every
four years, whichever comes earlier). When a cable is broken or
damaged, replace it according to this chapter.
Precautions on handling the pulse coder cable :
The pulse coder cable connector is given the marking tie as shown
below, to prevent careless disconnection at transportation, installation
or maintenance.
If the connector with the marking tie is
disconnected, mastering must be executed again.
Do not disconnect the cable except the time to replace the pulse coder
cable.
Fig. 7 Marking tie
- 86 -
MAINTENANCE
B-81925EN/04
7.1
7. REPLACING CABLES
CABLE FORMING
When replacing cables, clamp the cable at the position specified in Fig.
7.1 (a) and (b) using a nylon band. Otherwise, cables are loosened or
forcedly pulled to cause their disconnection.
Fig. 7.1 (a) Clamping position of cables (Integrated control unit)
- 87 -
7. REPLACING CABLES
MAINTENANCE
Fig. 7.1 (b) Clamping position of cables (Remote control unit)
- 88 -
B-81925EN/04
B-81925EN/04
MAINTENANCE
7. REPLACING CABLES
Fig. 7.1 (c) Clamping position of cable (Integrated control unit)
- 89 -
7. REPLACING CABLES
MAINTENANCE
Fig. 7.1 (d) Cable clamp (Control unit remote type)
- 90 -
B-81925EN/04
B-81925EN/04
MAINTENANCE
Fig. 7.1 (e) Clamping position of cables
- 91 -
7. REPLACING CABLES
7. REPLACING CABLES
MAINTENANCE
Fig. 7.1 (f) Clamping position of cables
- 92 -
B-81925EN/04
B-81925EN/04
MAINTENANCE
Fig. 7.1 (g) Clamping position of cables
- 93 -
7. REPLACING CABLES
7. REPLACING CABLES
MAINTENANCE
Fig. 7.1 (h) Clamping position of cables
- 94 -
B-81925EN/04
B-81925EN/04
MAINTENANCE
Fig. 7.1 (i) Clamping position of cables
- 95 -
7. REPLACING CABLES
7. REPLACING CABLES
7.2
MAINTENANCE
B-81925EN/04
REPLACING A CABLE
This section describes the procedure for replacing a cable in the
mechanical unit.
To replace only a damaged cable, follow these instructions.
After replacing a cable, carry out an adjustment. See Sections 4.5
before replacing a cable.
•
Replacing procedure (In case of integrated control unit)
1
To facilitate cable replacement, remove the J2-axis balancer
by following the steps below.
• Put the robot in an attitude of J2-axis = 0°.
• Remove the balancer according to step 2 of (2) of Section
5.2.
2
Turn the power off, and then disconnect all cable connectors
to the robot from the controller (Fig. 7.2 (a)).
3
Remove the cable clamp (Fig. 7.2 (b)).
4
Detach the metal plate from the controller exit, then detach
the two metal plates securing the rubber clamp (Fig. 7.2
(b)).
5
Release cables from a rubber clamp (Fig. 7.2 (b)).
6
Pull all cables connected to the robot main body out of the
controller.
7
Remove the air hoses and AS cable (when the AS option is
specified) from the frame connecting plate (Fig. 7.2 (b)).
8
Remove the cover sheet metal from the battery box, and
detach the battery cable terminals from the terminal board
on the rear of the battery box (see Fig. 7.2 (b)).
9
Remove the bolt from the cable clamp in the lower section
of the J1-axis base, and dismount the cable clamp from the
J1-axis base, then cut off the nylon tie clamping the cable
(see Fig. 7.2 (c)).
10 Remove the bolt from the cable clamp on the J2-axis base,
and dismount the cable clamp from the J2-axis base, then
cut off the nylon tie clamping grease tube to the cable clamp,
and dismount the grease tube from the cable clamp (see Fig.
7.2 (d)).
11 Remove all the cable connectors from the motors for the J1to J4-axes.
12 Remove the bolts from the wrist connector plate, and
dismount the wrist connector plate from the wrist (see Fig.
7.2 (e)).
13 Remove the bolts from the two cable clamps inside the
J3-axis arm (see Fig. 7.2 (e)).
14 Remove the cable retaining sponge from the inside of the
J3-axis arm through the casting hole of the J3-axis arm (see
Fig. 7.2 (e)).
15 Cut off the nylon tie clamping the cable at the end of the
J2-axis arm, and take out the cable from the clamp (see Fig.
7.2 (e)).
- 96 -
MAINTENANCE
B-81925EN/04
16
17
18
19
20
21
22
23
24
25
7. REPLACING CABLES
Remove the flexible hose holder retaining plate from the
J2-axis arm, and dismount the flexible hose holder from the
J2-axis base (see Fig. 7.2 (f)).
Remove the bolt from the flexible hose retaining plate on
the J2 arm side, and dismount it from the J2-axis base (see
Fig. 7.2 (g)).
Pull out, toward the J2-axis side, all cables that lead to the
wrist through the J3-axis arm.
Remove the J2 link-side flexible hose holder retaining
plates from the J3-axis base, J2-axis link, and J2-axis base,
and dismount the flexible hose holders (see Fig. 7.2 (f)).
Remove the bolts from the J2-axis base cover plate and J2
link-side flexible hose retaining plate, and dismount them
from the J2-axis base (see Fig. 7.2 (c)).
Pull out, toward the J2-axis base side, all the cables that
lead to the lower section of the J1-axis base through the
hollow pipe of the J1-axis.
Pull out the J2-axis arm-side cable and J2-axis link-side
cable through the openings of the left and right walls of the
J2-axis base toward the inside of the left and right walls,
respectively. Now the cables can be dismounted from the
robot.
Replace a cable with a new one.
Mount the cables as follows :
Care is required in cable forming and clamp positions (see
Fig. 7.1 (a), (c), (e) to (i) and Fig. 7.2 (a) to (g).
• Insert the sponge clamp into the J3-axis arm through the
casting hole of the J3-axis arm. For the position, see Fig.
7.2 (m).
• For the securing positions of the flexible hose, see Fig.
7.1 (i).
• Apply Loctite No. 242 (blue) to the flexible hose
securing bolts (M10×80) (see Fig. 7.2 (f)).
• Apply Loctite No. 242 (blue) to the bolt (M6×12) for
retaining the cable clamp to the J2-axis base.
• Clamp the cables at the marked positions.
• Connect the air hose so that it matches the markings on
the pedestal connector panel and wrist connector plate.
• See the tightening torque table presented in Appendix D
for the tightening torque for the bolts for which no
tightening torque is specified.
Carry out an adjustment (see Sections 4.5).
- 97 -
7. REPLACING CABLES
MAINTENANCE
•
B-81925EN/04
Replacing procedure (in case of remote control unit)
1
To facilitate cable replacement, remove the J2-axis balancer
by following the steps below.
• Put the robot in an attitude of J2-axis = 0°.
• Remove the balancer according to step 2 of (2) of section
5.2.
2
Turn the power off, and then disconnect all cable connectors
to the back of robot pedestal from the controller (RP1, RM1,
RM2) (Fig. 7.2 (i)).
3
Remove air hoses and AS cable (when the AS option is
specified) from the panel (Fig. 7.2 (i)).
4
Remove the metal plate without exerting excessive force to
the internal cables. Note that the internal cables remain
fixed (Fig. 7.2 (j)).
5
Remove battery and grounding wires. Cut nylon ties
clamping the connectors (M4M5M, M4M5BK, J10T, M3P)
(Fig. 7.2 (k)).
6
Remove screws fastening the connector inserts (Fig. 7.2 (j)).
7
Remove the connector housing, and dismount the connector
insert from the housing. Also, dismount the plate retaining
the cable from the connector plate. Then cut off the nylon
tie clamping the cable to the plate, and dismount the plate
(see Fig. 7.2 (l)).
8
Follow cable replacement steps 9 to 22 for a robot with a
control unit incorporated.
9
Replace each cable with a new one.
10 Mount the cables by following the removal steps 9 to 22 in
reverse order. Care is required in cable forming and clamp
positioning (see Fig. 7.1 (b) to (i) and Fig. 7.2 (b), (d) to
(m)).
• Insert the sponge clamp into the J3-axis arm through the
casting hole of the J3-axis arm. For the position, see Fig.
7.2 (f)).
• For the securing positions of the flexible hose, see Fig.
7.1 (i).
• Apply Loctite (blue) to the flexible hose securing bolts
(M10×80).
• Apply Loctite No. 242 (blue) to the bolt (M6 (12) for
retaining the cable clamp to the J2-axis base.
• Clamp the cables at markings on the cables.
• Those bolts for which no tightening torque is specified
must be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
11 Temporarily fasten the cable to the cable retaining plate
with a nylon tie, and also temporarily fasten the cable
retaining plate to the connector box. Pull the cable into the
connector box so that the cable does not sag, then fasten it
with a nylon tie (see Fig. 7.2 (m)).
12 Attach a new connector housing to the connector plate.
Remove the cable retaining plate from the connector box,
and attach it to the connector plate (see Fig. 7.2 (l)).
- 98 -
7. REPLACING CABLES
MAINTENANCE
B-81925EN/04
13
Install the cable by following steps 1 to 7 in reverse.
• Connect the air hose so that it matches the markings on
the pedestal connector panel and wrist connector plate.
Carry out an adjustment (see Sections 4.5).
14
CNJ1
CRF7
Robot M‑410ｉB/450
CNJ2
Motor power
Ｊ１Ｍ
CNJ5
Ｊ２Ｍ
Ｊ３Ｍ
Ｊ４Ｍ
Pulse coder
RDI/RDO
HBK,ROT
CNG
BRAKE
CRR64
CNJ4
CNJ3
・Detail of cable connection for servo ampilifier
Robot M‑410ｉB/450
R‑J3iB（Servo amplifier）
ＣＮＪ１Ａ
CRF7
ＣＮＪ１Ｂ
CRR64
ＣＮＪ２Ａ
ＣＮＪ２Ｂ
ＣＮＪ４
CNJ3A
ＣＮＧＣ
CNJ3B
ＣＮＧＢ
Pulse coder
(Pulse coder,RDI/RDO,
HBK,ROT)
ＣＮＧＡ
BRAKE
Motor power
(J4M)
Motor power
(J3M）
Motor power
(J2M)
Motor power
(J1M)
Fig. 7.2 (a) Replacing a cable (Integrated R-J3iB control unit)
- 99 -
7. REPLACING CABLES
CNJ3
MAINTENANCE
CNJ6
CNJ5
CNG
CNJ4
CNJ2
CNJ1
B-81925EN/04
Robot M-410iB/450
(R-30iA Controller)
Motor power
J1M
J2M
J3M
J4M
pulse coder
RDI/RDO
RI/RO
HBK,ROT
HBK,ROT
BRAKE
CRF8
CRR88
・Detail of the cable connection for servo amplifier
R-30iA (Servo amplifier)
Robot M-410iB/450
(R-30iA Controller)
CNJ1A
CRF8
CNJ1B
CRR88
CNJ2A
CNJ2B
CNJ4
CNJ3A
CNGC
CNJ3B
CNGB
Pulse coder
(Pulse coder,RI/RO,
HBK,ROT)
CNGA
BRAKE
Motor power
(J4M)
Motor power
(J3M)
Motor power
(J2M)
Motor power
(J1M)
Fig. 7.2 (b) Replacing a cable (Integrated R-30iA control unit)
- 100 -
B-81925EN/04
MAINTENANCE
7. REPLACING CABLES
Fig. 7.2 (c) Replacing a cable (Integrated control unit)
Fig. 7.2 (d) Replacing a cable
- 101 -
7. REPLACING CABLES
MAINTENANCE
Fig. 7.2 (e) Replacing a cable
Fig. 7.2 (f) Replacing a cable
- 102 -
B-81925EN/04
MAINTENANCE
B-81925EN/04
7. REPLACING CABLES
30
Fig. 7.2 (g) Replacing a cable
Fig. 7.2 (h) Replacing a cable
- 103 -
7. REPLACING CABLES
MAINTENANCE
B-81925EN/04
Fig. 7.2 (i) Replacing a cable (Remote control unit)
Fig. 7.2 (j) Replacing a cable (Remote control unit)
- 104 -
B-81925EN/04
MAINTENANCE
7. REPLACING CABLES
Fig. 7.2 (k) Replacing a cable (Remote control unit)
Fig. 7.2 (l) Replacing a cable (Remote control unit)
- 105 -
7. REPLACING CABLES
MAINTENANCE
B-81925EN/04
Fig. 7.2 (m) Replacing a cable (Remote control unit)
- 106 -
CONNECTION
B-81925EN/04
1
CONNECTION
1. ROBOT EXTERNAL DIMENSION
ROBOT EXTERNAL DIMENSION
Fig. 1 shows the external dimensions of the robot. When installing
peripheral devices, be careful to clear away any objects that are in the
robot's motion path in normal operation.
Fig. 1 External dimensions
- 109 -
2. MOUNTING A DEVICE TO THE ROBOT
2
CONNECTION
B-81925EN/04
MOUNTING A DEVICE TO THE ROBOT
- 110 -
B-81925EN/04
2.1
CONNECTION
2. MOUNTING A DEVICE TO THE ROBOT
LOAD CONDITION AT WRIST
Fig. 2.1 (a) shows the relationships between the horizontal offset of
the center of gravity of the wrist load and the permissible load inertia.
See Fig. 2.1 (b) to check whether the center of gravity of the load is
inside or outside of the wrist.
Fig. 2.1 (c) shows the relationships between the vertical offset of the
center of gravity of the wrist load and permissible load weight. See
Fig. 2.1 (d) for explanations about the vertical offset of the center of
gravity of the wrist load.
The wrist load must fall within the corresponding ranges in Figs. 2.1
(a) and 2.1 (c) and the allowable wrist moment and allowable wrist
inertia conditions must be satisfied.
See Fig. 2.1 (e) for explanations about how to calculate the load inertial.
Fig. 2.1 (a) Line chart of the permissible load for the wrist section
(horizontal offset) (M-410iB/450)
Fig. 2.1 (b) Allowable wrist load condition
- 111 -
2. MOUNTING A DEVICE TO THE ROBOT
CONNECTION
B-81925EN/04
Fig. 2.1 (c) Line chart of the permissible load for the wrist section
(vertical offset) (M-410iB/450)
Fig. 2.1 (d) Allowable wrist load condition
- 112 -
B-81925EN/04
CONNECTION
2. MOUNTING A DEVICE TO THE ROBOT
Fig. 2.1 (e) Calculating inertia
- 113 -
2. MOUNTING A DEVICE TO THE ROBOT
2.2
CONNECTION
B-81925EN/04
COUPLING OF THE END EFFECTOR TO THE WRIST
Fig. 2.2 shows the end effector mounting surface at the end of the
wrist.
Choose bolts and positioning pins, considering the depth of the
corresponding holes. In this case, use steel bolts (strength class 12.9),
which should be tightened to a torque of 470 to 670 Nm (46 to 66
kgfcm).
the
Fig. 2.2 End the effector mounting face
- 114 -
CONNECTION
B-81925EN/04
2.3
LOAD SETTING
2.3.1
Motion Performance Screens
2. MOUNTING A DEVICE TO THE ROBOT
The motion performance screens include the MOTION
PERFORMANCE screen, MOTION PAYLOAD SET screen, and
MOTION ARMLOAD SET screen. These screens are used to
specify payload information and equipment information on the robot.
1
Click the [MENUS] key to display the screen menu.
2
Select "6 SYSTEM" from the next page.
3
Click F1 ([TYPE]).
4
Select "MOTION." The MOTION PERFORMANCE screen
appears.
MOTION PERFORMANCE
Group1
No.
PAYLOAD [kg]
1
450.00
[
2
450.00
[
3
450.00
[
4
450.00
[
5
450.00
[
6
450.00
[
7
450.00
[
8
450.00
[
9
450.00
[
10
450.00
[
Comment
]
]
]
]
]
]
]
]
]
]
Active PAYLOAD number = 0
[ TYPE ] GROUP DETAIL ARMLOAD SETIND >
INDENT
>
5
Ten different pieces of payload information can be set using
condition Nos. 1 to 10 on this screen. Place the cursor on one
of the numbers, and click F3 (DETAIL). The MOTION
PAYLOAD SET screen appears.
MOTION PAYLOAD SET
JOINT
Group 1
Schedule No[
1]:[Comment
1. PAYLOAD
[kg]
2. PAYLOAD CENTER X [cm]
3. PAYLOAD CENTER Y [cm]
4. PAYLOAD CENTER Z [cm]
5. PAYLOAD INERTIA X [kgfcms^2]
6. PAYLOAD INERTIA Y [kgfcms^2]
7. PAYLOAD INERTIA Z [kgfcms^2]
[ TYPE ]
GROUP
- 115 -
NUMBER
DEFAULT
10%
]
450.00
0.00
0.00
0.00
0.00
0.00
0.00
HELP
2. MOUNTING A DEVICE TO THE ROBOT
CONNECTION
B-81925EN/04
Center of robot flange
手首フランジ
Center
of gravity
xg(cm)
zg(cm)
X
2
Iy(kg・cm)
Z
Center of重心
gravity
Masss
質量m(kg)
Center重心
of gravity
yg(cm)
2
Ix(kg・cm)
X
Y
6
7
8
Set the payload, gravity center position, and inertia around the
gravity center on the MOTION PAYLOAD SET screen. The X,
Y, and Z directions displayed on this screen correspond to the
respective standard tool coordinates (with no tool coordinate
system set up). When values are entered, the following
message appears: "Path and Cycletime will change. Set it?"
Respond to the message with F4 ([YES]) or F5 ([NO]).
Clicking F3 ([NUMBER]) will bring you to the MOTION
PAYLOAD SET screen for another condition number. For a
multigroup system, clicking F2 ([GROUP]) will bring you to the
MOTION PAYLOAD SET screen for another group.
Click the previous page key to return to the MOTION
PERFORMANCE screen. Click F5 ([SETIND]), and enter the
desired payload setting condition number.
- 116 -
CONNECTION
B-81925EN/04
2.3.2
2. MOUNTING A DEVICE TO THE ROBOT
Switching between Modes
There are two different parameter settings for the M-410iB/450 to
support different load inertia magnitudes. (Before shipment, the
parameter setting in the standard inertia mode is made.)
Standard inertia mode High inertia mode
2
196kg･m2
294kg･m
Allowable load inertia at wrist
2
(2000kgf･cm･s )
(3000kgf･cm･s2)
Be sure to make appropriate parameter settings according to the load,
as described below. (Before shipment, the parameter setting in the
standard inertia mode is made.)
CAUTION
If a workpiece with an inertia exceeding the
allowable inertia in the standard inertia mode is
used in the mode, parts of the mechanical unit may
degrade earlier.
To set parameters, execute setting program, which was stored before
shipment. Since this program sets parameters for the high inertia
mode, if parameters for the standard inertia mode need to be set,
execute the program to reset this program.
Setting method
Specify and execute the program of Table 2.3.2 directly on the
program selection screen or create another program and call the
program within it.
When the program is completely executed, message “SRVO-333
Power off to reset SRVO -333 TURN OFF THE CONTROLLER,
THEN TURN IT ON AGAIN.” appears, prompting you to turn off
and back on the power. If the power is turned off and back on again,
switching of parameters is completed.
[Example of program] (In the case of R-30iA controller)
1: CALL J4UPM44C (i)
Set input parameter i for setting program to the group number of the
robot. When input parameter i is omitted, the parameter settings for
all M-410iB/450’s in the controller are changed for the high inertia
mode.
Table 2.3.2 Programs to change a mode
Program for setting
Program for resetting
- 117 -
R-J3iB controller
J4UPSPC.PC
J4STD.PC
R-30iA controller
J4UPM44C.PC
J4STM44C.PC
2. MOUNTING A DEVICE TO THE ROBOT
CONNECTION
B-81925EN/04
Checking the settings
When the setting program is executed, the settings made are displayed
on the user screen. To display the user screen, press the MENU key
and then select “9 USER.”
[Information displayed on the user screen]
For standard inertia load settings: Standard payload set (GP: X)
Please power off
For high inertia load settings:
High payload set (GP: X)
Please power off
X represents the group number set in the parameter.
Exception processing
In the following cases, exception processing is applied, parameters are
not changed, and a message describing the exception processing
appears on the user screen.
(1) When the group set in input parameter i for setting program is
not present
[Information displayed on the user screen]
Incorrect group number
When this message appears, specify a correct group number
(2) When the group set in input parameter i for setting program is
not M-410iB/450.
[Information displayed on the user screen]
This group is not M-410iB/450
When this message appears, specify a correct group number
- 118 -
B-81925EN/04
2.4
CONNECTION
2. MOUNTING A DEVICE TO THE ROBOT
EQUIPMENT MOUNTING SURFACE
Fig. 2.4 shows the positions of holes for mounting the equipment.
Those bolts, for which no tightening torque is specified, tighten as the
table of Appendix D.
Fig. 2.4 Dimensions of the equipment mounting surface
- 119 -
2. MOUNTING A DEVICE TO THE ROBOT
2.5
CONNECTION
B-81925EN/04
AIR SUPPLY
There are two air-pressure supply openings on both side of the
pedestal as shown in Fig. 2.5 (a) and (b). The connector is an R 3/8
(PT 3/8) female. As couplings are not supplied, it will be necessary
to prepare couplings that suit to the hose size.
Fig. 2.5 (a) Air-pressure supply connection (Integrated control unit)
- 120 -
B-81925EN/04
CONNECTION
2. MOUNTING A DEVICE TO THE ROBOT
Fig. 2.5 (b) Air-pressure supply connection (Remote control unit)
- 121 -
2. MOUNTING A DEVICE TO THE ROBOT
2.6
CONNECTION
B-81925EN/04
INTERFACE FOR END EFFECTOR
Fig. 2.6 (a) and (b) show the position of the end effector interface.
End
effector interface (EE) is prepared as basic function. The user cable
(signal lines option) is prepared as an option.
Fig. 2.6 (a) Interface for end effector (Integrated control unit)
- 122 -
B-81925EN/04
CONNECTION
2. MOUNTING A DEVICE TO THE ROBOT
Fig. 2.6 (b) Interface for the end effector (Remote control unit)
- 123 -
2. MOUNTING A DEVICE TO THE ROBOT
CONNECTION
B-81925EN/04
(1) End effector interface (EE)
Fig. 2.6 (c) and (d) shows pin layout for end effector interface
(EE).
WARNING
The RDO signal for the R-J3iB controller and the
RO signal for the R-30iA controller are
incompatible with each other because different
output formats are used. For details, refer to the
maintenance manuals for the controllers.
End effector interface (RDI/RDO) (Wrist side)
A63L-0001-0234#R2524F(Fujikura.Ltd)
1
RDO1
5
RDO5
10
RDI2
2
RDO2
6
RDO6
11
RDI3
16
RDI6
7
XHBK
12
RDI4
17
+24V
21
RDO7
3
RDO3
4
RDO4
8
0V
13
RDI8
18
+24V
9
RDI1
14
XPPABN
19
+24V
22
RDO8
Comformable connector
A63L-0001-0234#S2524M
(Fujikura:JMSP2524M)
23
15
RDI5
End
effector
20
+24V
24
RDI7
Please prepare by user.
XHBK : Hand broken
Controller
XPPABN : Pneumatic pressure abnormal
Fig. 2.6 (c) Pin layout for the end effector interface (EE) (for R-J3iB controller)
Comformable connector
A63L-0001-0234#S2524M
(Fujikura:JMSP2524M)
End effector interface (RI/RO) (Wrist side)
A63L-0001-0234#R2524F(Fujikura.Ltd)
1
RO1
5
RO5
10
RI2
2
RO2
6
RO6
11
RI3
16
RI6
3
RO3
7
XHBK
12
RI4
17
+24V
21
RO7
Controller
8
0V
13
RI8
18
+24V
22
RO8
4
RO4
9
RI1
14
XPPABN
19
+24V
23
0V
15
RI5
End
effector
20
+24V
24
RI7
Please prepare by user.
XHBK : Hand broken
XPPABN : Pneumatic pressure abnormal
Fig 2.6 (d) Pin layout for the end effector interface (EE) (R-30iA controller)
- 124 -
CONNECTION
B-81925EN/04
2. MOUNTING A DEVICE TO THE ROBOT
(2) User cable (signal line) interface (Option)
Fig. 2.6 (e) shows pin layout for user cable (signal line) interface.
User cable
interface(AS2) (Wrist
side)
ユーザケーブルインタフェース
(AS2) (手首側)
A63L‑0001‑0234#R2524FX((株)フジクラ)
A63L-0001-0234#R2524FX(Fujikura
Ltd.)
1
S1
5
S5
10
S10
2
S2
6
S6
11
S11
16
S16
3
S3
12
S12
8
S8
13
S13
18
S18
22
S22
14
S14
19
S19
23
S23
End
エンド
エフェクタ
effector
9
S9
15
S15
20
S20
24
S24
}
21
S21
4
S4
7
S7
17
S17
Conformable
適合コネクタconnector
A63L-0001-0234#S2524MX(Fujikura
Ltd.)
A63L-0001-0234#S2524MX((株)フジクラ)
(Fujikura
Ltd.: JMSP2524MX)
(フジクラ仕様;JMSP2524MX)
The customer
should prepare these devices.
顧客殿にてご用意下さい
External
外部信号
signal
}
The customer
should prepare
顧客殿にてご用意下さい
these devices.
User
cable interface(AS2)
ユーザケーブルインタフェース
(AS1)(Wrist
(架台側)side)
A63L‑0001‑0234#W2524M((株)フジクラ)
A63L-0001-0234#R2524FX(Fujikura
Ltd.)
1
S4
9
S9
10
S10
2
S3
8
S8
11
S11
20
S20
12
S12
19
S19
24
S24
3
S2
4
S1
7
S7
6
S6
13
S13
18
S18
23
S22
5
S5
14
S14
17
S17
22
S22
15
S15
16
S16
2
21
S21
Conformable
適合コネクタconnector
A63L-0001-0234#S2524F(Fujikura
Ltd.)
A63L-0001-0234#S2524F((株)フジクラ)
(フジクラ仕様;JMSP2524F)
(Fujikura
Ltd.: JMSP2524F)
Fig. 2.6 (e) Pin layout for the user cable (signal line) interface (option)
- 125 -
2. MOUNTING A DEVICE TO THE ROBOT
2.7
CONNECTION
B-81925EN/04
SERVO HAND CABLE INTERFACE (OPTION)
Fig. 2.7 (a) shows the position of the servo hand cable interface
option.
Fig. 2.7 (a) Interface for the servo hand cable interface (option)
- 126 -
B-81925EN/04
CONNECTION
2. MOUNTING A DEVICE TO THE ROBOT
(1) Servo hand cable interface (option)
Fig. 2.7 (b) shows the pin layout for the servo hand cable
interface connector.
NOTE
A connector prepared by the customer for the
servo cable interface must be a straight type; an
elbow type cannot pass through the hole in the J4
axis.
Fig. 2.7 (b) Pin layout for the servo hand cable interface (option)
- 127 -
3. TRANSPORTATION AND INSTALLATION CONNECTION
3
B-81925EN/04
TRANSPORTATION AND INSTALLATION
- 128 -
B-81925EN/04
3.1
CONNECTION
3. TRANSPORTATION AND INSTALLATION
TRANSPORTATION
The robot can be transported by a crane or by a forklift.
Fig. 3.1 (a) and (b) show the postures in transportation.
Fig. 3.1 (a) Transportation by crane
- 129 -
3. TRANSPORTATION AND INSTALLATION CONNECTION
B-81925EN/04
Fig. 3.1 (b) Transportation by forklift
CAUTION
When a peripherals are installed on a robot, the
center of gravity of the robot changes and the robot
might become unstable while being transported.
Robot becomes unstable when it is transported
with the end effector applied to wrist ,and it is
dangerous.
Please be sure to remove end effector when robot
is transported.
Use the forklift pockets only to transport the robot
with a forklift. Do not use the forklift pockets for any
other transportation method. Do not use the forklift
pockets to secure the robot.
Before moving the robot by using forklift pockets,
check and tighten any loose bolts on the forklift
pockets.
Do not pull eyebolts sideways.
Prevent the forks of the forklift from having impact
on a transport equipment.
Do not thread a chain or the like through a
transport equipment.
- 130 -
CONNECTION
B-81925EN/04
INSTALLATION
(1) Installing the robot using the standard pedestal
Described below is how to install the robot using the standard pedestal,
which is factory-assembled with the robot.
Fig. 3.2 (a) shows the robot base dimensions. Fig. 3.2 (b) shows an
actual example of robot installation. Secure the floor plate (iron
plate) to the floor using 16 M20 chemical anchors (strength class 4.8).
• Those bolts for which no tightening torque is specified must
be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
Table 3.2 (a) and Fig. 3.2 (c) indicate the force and moment applied to
the robot base plate. When installing the robot, be sure that the setup
is strong enough to withstand the indicated force and moment.
Table 3.2(b) indicates the coasting time and distance consumed from
the pressing of the emergency stop button until the robot stops
NOTE
1 If the robot base is secured directly to the floor with
chemical anchors, the anchors may fail due to
fluctuating load during robot operation.
2 Do not provide leveling (with a wedge, for example)
between the robot base and floor plate.
Otherwise, any robot vibration may be accentuated
due to the robot not being in close contact with the
floor plate.
1080
3.2
3. TRANSPORTATION AND INSTALLATION
Fig. 3.2 (a) Installation hole dimensions of the robot base
- 131 -
3. TRANSPORTATION AND INSTALLATION CONNECTION
B-81925EN/04
Fig. 3.2 (b) Sample installation
NOTE
1 The customer should prepare the following parts:
• Eight robot securing bolts: M20×40 (strength
class 12.9)
• 16 chemical anchors: M20 (strength class 4.8)
• One floor plate: 32t in thickness
2 The customer is responsible for preparation prior to
installation (mounting of anchors, for example)
- 132 -
CONNECTION
B-81925EN/04
3. TRANSPORTATION AND INSTALLATION
Table 3.2(a) Force and moment acting to base plate
At
At
emergency
At stop
acceleration/
stop
deceleration
Vertical moment
:
MV
Force in vertical direction
:
FV
Horizontal moment
:
MH
Force in horizontal direction
:
FH
Table 3.2 (b)
35,000 Nm
(3,571 kgfm)
31,000 N
(3,163 kgf)
104,000 Nm
(10,612 kgfm)
56,000 N
(5,714 kgf)
0 Nm
(0 kgfm)
10,000 Nm
(1,020 kgfm)
44,000 Nm
(4,490 kgfm)
0N
(0 kgf)
9,000 N
(918 kgf)
21,000 N
(2,143 kgf)
Stopping time and distance when emergency stop
Model
M-410iB/450
27,000 Nm
(2,755 gfm)
28,000 N
(2,857 kgf)
Stopping time [msec]
Stopping distance [deg] (rad)
J1-axis
J2-axis
J3-axis
220
190
140
7.7(0.13)
5.3(0.09)
3.9 (0.07)
※ Max payload and max speed
※ Max. payload, and max. inertia posture
Fig. 3.2 (c) Force and moment acting to the robot base
- 133 -
3. TRANSPORTATION AND INSTALLATION CONNECTION
B-81925EN/04
(2) Installing the robot without using the standard pedestal
A robot with a separate control unit can be installed on a
customer-prepared pedestal, without using the standard pedestal,
which is factory-assembled with the robot.
Fig. 3.2 (d) shows how to remove the standard pedestal from the robot.
First put the robot in the attitude of J1-axis = 0°, J2-axis = -45°,
J3-axis = 25°, and J4-axis = 0°, then prepare to sling up the robot
portion above the J1-axis base with rope. Remove the J1-axis
mounting bolts (sixteen M16×65 bolts), and separate the J1-axis base
from the pedestal.
Fig. 3.2 (e) shows the installation interface for the robot. Design a
pedestal while taking care of the following points:
• Provide space required when replacing the J1-axis motor.
• Provide space required when mounting and dismounting the
mastering fixture.
• Provide space for periodic maintenance (such as battery
exchange and degreasing)
• Avoid interference of the robot with the cables and connector
box.
• Make sure that the setup is strong enough to withstand the force
and moment listed in Table 3.2 (b).
To fasten the J1-axis base to the pedestal, use sixteen bolts having a
size of M16 (in strength class 12.9) and a length of at least 65 mm.
- 134 -
B-81925EN/04
CONNECTION
3. TRANSPORTATION AND INSTALLATION
Fig. 3.2 (d) How to remove the pedestal (robot with a separate control unit)
- 135 -
3. TRANSPORTATION AND INSTALLATION CONNECTION
322
Mastering fixture
176
88
172
371
357
242
(500)
60
Battery box
B-81925EN/04
Robot front
80
Ａ
209
Required space to
250
Robot connection cable
Ｂ
65
290
65 160
290
160 65
65
16‑Φ18 Through
spot hole Φ26 Depth 20(Back side）
185
370
View A
J1-axis base mounting through hole
340
65
210
340
210
65
880
65
Tap for earth
replace the J1‑axis motor
65
Mastering fixture
880
Grease outlet
View B
Fig. 3.2 (e) Installation interface for the robot (with a separate control unit) with the standard pedestal removed
- 136 -
B-81925EN/04
3.3
CONNECTION
3. TRANSPORTATION AND INSTALLATION
MAINTENANCE AREA
Fig. 3.3 shows the maintenance area of the mechanical unit.
Fig. 3.3 Maintenance area
- 137 -
3. TRANSPORTATION AND INSTALLATION CONNECTION
3.4
B-81925EN/04
INSTALLATION CONDITION
Table 3.4 shows installation condition.
Table 3.4 Installation condition
Items
Specifications
Air pressure
Weight of mechanical unit
Allowable ambient temperature
Allowable ambient humidity
Height
Atmosphere
Vibration
Max. 7kgf/cm2 (0.69MPa)
Approx. 2,430kg (with control unit)
Approx. 2,310kg (without control unit)
0-45°C
Usual: Less than 75% RH
Short period (in one month) : Max. 95%
RH or less
Condensation free
Up to 1,000 meters above the sea level
requires, no particular provision for
attitude.
Free of corrosive gases (Note)
Less than 0.5G (4.9 m/s2)
NOTE
Contact the service representative, if the robot is
to be used in an environment or a place subjected
to severe vibrations, heavy dust, cutting oil splash
and or other foreign substances.
- 138 -
APPENDIX
B-81925EN/04
A
APPENDIX
SPARE PARTS LIST
- 141 -
A. SPARE PARTS LIST
A. SPARE PARTS LIST
APPENDIX
B-81925EN/04
No.
Specifications
Table A (a) Cables
Functions
K501
A660-4004-T257
J1 to J2-axis power, brake
K502
A660-8014-T699
J1 to J2-axis pulse coder
K503
A660-4004-T258
J3-axis power, brake,
pulse coder
K504
A660-4004-T259
J4-axis power, brake,
pulse coder, EE
K505
A660-4004-T271
J4-axis power, brake,
pulse coder, EE, AS
K506
A660-4004-T272
J4 to J5-axis power,
brake, pulse coder, EE
K507
A660-4004-T273
K511
A660-8014-T785
K512
A660-8014-T786
K513
A660-8014-T787
K514
A660-8014-T788
K515
A660-8014-T789
K551
A660-4004-T573
J4 to J5-axis power,
brake, pulse coder, EE,
AS
J1 to J2-axis power, brake
J3-axis power, brake,
pulse coder
J1 to J2-axis pulse coder
J4-axis power, brake,
pulse coder, EE
J1 to J2-axis pulse coder
J4-axis power, brake,
pulse coder, EE, AS
J1 to J2-axis pulse coder
J4 to J5-axis power,
brake, pulse coder, EE
J1 to J2-axis pulse coder
J4 to J5-axis power,
brake, pulse coder, EE,
AS
J1 to J2-axis power, brake
K552
A660-8015-T899
J1 to J2-axis pulse coder
K554
A660-4004-T564
J4-axis power, brake,
pulse coder, EE
K555
A660-4004-T565
J4-axis power, brake,
pulse coder, EE, AS
- 142 -
Remarks
For CE,
Integrated control unit
R-J3iB
For CE,
Integrated control unit
R-J3iB
For CE,
Integrated control unit
R-J3iB
For CE,
Integrated control unit
R-J3iB
For CE,
Integrated control unit
R-J3iB
For CE,
Integrated control unit
R-J3iB
For CE,
Integrated control unit
R-J3iB
For CE,
Remote control unit
For CE,
Remote control unit
R-J3iB
For CE,
Remote control unit
R-J3iB
For CE,
Remote control unit
R-J3iB
For CE,
Remote control unit
R-J3iB
For CE,
Integrated control unit
R-30iA
For CE,
Integrated control unit
R-30iA
For CE,
Integrated control unit
R-30iA
For CE,
Integrated control unit
R-30iA
A. SPARE PARTS LIST
APPENDIX
B-81925EN/04
No.
Specifications
Functions
K556
A660-4004-T566
J4 to J5-axis power,
brake, pulse coder, EE
K557
A660-4004-T567
K562
A660-8015-T889
K563
A660-8015-T890
K564
A660-8015-T891
K565
A660-8015-T892
K566
A05B-1039-D001
K708
A660-8012-T572
J4 to J5-axis power,
brake, pulse coder, EE,
AS
J1 to J2-axis power,
brake, pulse coder, EE,
AS
J1 to J2-axis pulse coder,
J4-axis power, brake,
pulse coder, EE, AS
J1 to J2-axis pulse coder,
J4 to J5-axis power,
brake, pulse coder, EE
J1 to J2-axis pulse coder,
J4 to J5-axis power,
brake, pulse coder, EE,
AS
J1 to J2-axis pulse coder,
J4 to J5-axis power,
brake, pulse coder, EE,
AS,CAMERA
Zipper tube
K721
A660-8012-T573
J1-axis over travel
Table A (b) Motor
Specifications
Axis
J1, J2, J3
A06B-0268-B605#S000
J4
A06B-0235-B605#S000
Remarks
For CE,
Integrated control unit
R-30iA
For CE,
Integrated control unit
R-30iA
For CE,
Remote control unit
R-30iA
For CE,
Remote control unit
R-30iA
For CE,
Remote control unit
R-30iA
For CE,
Remote control unit
R-30iA
For CE,
Integrated control unit
R-30iA
For CE,
Remote control unit
Remarks
(Model αM30/4000i)
Model αiS 30/4000
(Model αM8/4000i)
Model αiS 8/4000
NOTE
A motor whose specification number is terminated
with #S000 has the built-in auxiliary seal.
When ordering a motor, specify a motor whose
specification number is terminated with #S000.
Axis
Table A (c) Reducer
Specifications
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
- 143 -
A97L-0218-0265#450C-37
A97L-0218-0266#450E-257
A97L-0218-0266#450E-257
A97L-0118-0949#70C-36
A. SPARE PARTS LIST
APPENDIX
B-81925EN/04
Table A (d) Input gear kit
Name
Input gear kit for
J2, J3-axis reducer
Specifications
A97L-0218-0245#257
Table A (e) Stopper
Specifications
Name
J1-axis pendulum
stopper
J1-axis motion
range control
stopper
Remarks
A290-7039-V201
Standard stopper
A05B-1039-K201
Optional stopper
Table A (f) Battery grease
Specifications
Name
Battery
Grease
A98L-0031-0005
A98L-0040-0119#7KG
Grease
A98L-0001-0179#2-2.5KG
Name
Auxiliary seal for
motor
Remarks
1.5V size D
Kyodo yushi
VIGOGREASE RE0
Shell Alvania GREASE
S2
Table A (g) Auxiliary seal for motor
Specifications
Remarks
A98L-0004-0771#A12TP
For Motor J1 to J3
NOTE
A motor whose specification number is
terminated with #S000 has the built-in auxiliary
seal.
- 144 -
B-81925EN/04
B
APPENDIX
CIRCUIT DIAGRAM
- 145 -
B. CIRCUIT DIAGRAM
B. CIRCUIT DIAGRAM
APPENDIX
Fig. B (a) Internal circuit diagram (R-J3iB Integrated control unit for CE)
- 146 -
B-81925EN/04
B-81925EN/04
APPENDIX
- 147 -
B. CIRCUIT DIAGRAM
B. CIRCUIT DIAGRAM
APPENDIX
B-81925EN/04
Fig. B (b) Internal circuit diagram (R-J3iB Integrated control unit for CE with servo hand option)
- 148 -
B-81925EN/04
APPENDIX
- 149 -
B. CIRCUIT DIAGRAM
B. CIRCUIT DIAGRAM
APPENDIX
Fig. B (c) Internal circuit diagram (R-J3iB Remote control unit for CE)
- 150 -
B-81925EN/04
B-81925EN/04
APPENDIX
- 151 -
B. CIRCUIT DIAGRAM
B. CIRCUIT DIAGRAM
APPENDIX
B-81925EN/04
Fig. B (d) Internal circuit diagram (R-J3iB Remote control unit for CE with servo hand option)
- 152 -
B-81925EN/04
APPENDIX
- 153 -
B. CIRCUIT DIAGRAM
B. CIRCUIT DIAGRAM
APPENDIX
- 154 -
B-81925EN/04
B-81925EN/04
APPENDIX
B. CIRCUIT DIAGRAM
Fig. B (e) Internal circuit diagram (R-30iA Integrated control unit for CE)
(Including the case where the servo hand option is selected)
- 155 -
B. CIRCUIT DIAGRAM
APPENDIX
Fig. B (f) Internal circuit diagram (R-30iA Integrated control unit for CE)
(Including the case where the servo hand option is selected)
- 156 -
B-81925EN/04
B-81925EN/04
APPENDIX
- 157 -
B. CIRCUIT DIAGRAM
C. PERIODIC MAINTENANCE
C
APPENDIX
B-81925EN/04
PERIODIC MAINTENANCE
FANUC Robot M-410iB/450 Periodic Maintenance Table
1.8
10800 ml
0.9
2300 ml
2300 ml
1600 ml
10 ml
40 ml
20 ml
- 158 -
B-81925EN/04
APPENDIX
- 159 -
C. PERIODIC MAINTENANCE
D. BOLT TIGHTENING TORQUE TABLE
D
APPENDIX
B-81925EN/04
BOLT TIGHTENING TORQUE TABLE
Those bolts for which no tightening torque is specified must be
tightened according to the APPENDIX D BOLT TIGHTENING
TORQUE TABLE.
NOTE
When applying Loctite to the important bolt
tightening points, make sure that it is applied to the
entire longitudinal portion in the engaging section of
the female threads. If it is applied to the male
threads, the bolts may be loosened because
sufficient effects cannot be obtained. Remove the
dust within the bolts and taps and wipe oil off the
engaging section. Make sure that there is no
solvent in the taps.
- 160 -
APPENDIX
B-81925EN/04
Table D
D. BOLT TIGHTENING TORQUE TABLE
Recommended Bolt Tightening Torques
Unit : Nm (kgf･cm)
Nominal
diameter
M3
M4
M5
M6
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
M36
Hexagon socket head bolt
(Steel : strength rating of 12.9)
Hexagon socket head bolt
(Stainless)
Tightening torque
Upper limit
Lower limit
Tightening torque
Upper limit
Lower limit
1.8(18)
4.0(41)
7.9(81)
14(140)
32(330)
66(670)
110(1150)
180(1850)
270(2800)
380(3900)
530(5400)
730(7450)
930(9500)
1400(14000)
1800(18500)
3200(33000)
0.76(7.7)
1.8(18)
3.4(35)
5.8(60)
14(145)
27(280)
48(490)
76(780)
120(1200)
160(1650)
230(2300)
–––––––
–––––––
–––––––
–––––––
–––––––
1.3(13)
2.8(29)
5.6(57)
9.6(98)
23(230)
46(470)
78(800)
130(1300)
190(1900)
260(2700)
370(3800)
510(5200)
650(6600)
940(9800)
1300(13000)
2300(23000)
- 161 -
0.53(5.4)
1.3(13)
2.5(25)
4.1(42)
9.8(100)
19(195)
33(340)
53(545)
82(840)
110(1150)
160(1600)
–––––––
–––––––
–––––––
–––––––
–––––––
Hexagon socket head pan bolt
Hexagon socket head
countersunk bolt
(Steel : strength rating of 12.9)
Tightening torque
Upper limit
Lower limit
–––––––
1.8(18)
4.0(41)
7.9(81)
14(140)
32(330)
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
1.3(13)
2.8(29)
5.6(57)
9.6(98)
23(230)
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
–––––––
INDEX
B-81925EN/04
INDEX
<A>
<J>
ADJUSTING LIMIT SWITCHES AND DOGS
J1-AXIS DRIVE MECHANISM ...................................... 4
(OPTION) ....................................................................... 33
J1-AXIS STROKE MODIFICATION
ADJUSTMENTS ............................................................ 32
(OPTION) ....................................................................... 37
AIR SUPPLY ................................................................ 120
J2-AXIS DRIVE MECHANISM ...................................... 4
J3-AXIS DRIVE MECHANISM ...................................... 5
<B>
J4-AXIS DRIVE MECHANISM ...................................... 5
BACKLASH MEASUREMENT .................................... 30
<L>
BOLT TIGHTENING TORQUE TABLE .................... 160
LOAD CONDITION AT WRIST................................. 111
<C>
LOAD SETTING.......................................................... 115
CABLE FORMING ........................................................ 87
<M>
Checking for Cable Damage and Twisting .......................9
Checking for Loose Bolts................................................ 11
MAINTENANCE AREA ............................................. 137
CIRCUIT DIAGRAM................................................... 145
MAINTENANCE TOOLS ............................................. 20
Cleaning .......................................................................... 11
MAJOR COMPONENT SPECIFICATIONS................... 6
CONFIGURATION ..........................................................3
Mastering ........................................................................ 48
COUPLING OF THE END EFFECTOR TO
MASTERING ................................................................. 41
THE WRIST ................................................................. 114
Mastering Data Entry...................................................... 57
Mastering Method........................................................... 42
<D>
Mastering to a Fixture (Master Position Master) ............ 44
DAILY CHECKS..............................................................8
Motion Performance Screens ........................................ 115
MOUNTING A DEVICE TO THE ROBOT ................ 110
<E>
<O>
EQUIPMENT MOUNTING SURFACE ...................... 119
Others.............................................................................. 19
<F>
OVERVIEW ................................................................... 21
FAILURES, CAUSES AND MEASURES..................... 22
<P>
<G>
PART REPLACEMENT AND
General............................................................................ 41
CORRESPONDING ADJUSTMENT ............................ 60
Greasing .......................................................................... 17
PERIODIC CHECKS ....................................................... 9
PERIODIC MAINTENANCE ...................................... 158
<I>
PREFACE...................................................................... p-1
INSTALLATION.......................................................... 131
PREVENTIVE MAINTENANCE.................................... 7
INSTALLATION CONDITION................................... 138
Procedure for Releasing Residual Pressure
INTERFACE FOR END EFFECTOR .......................... 122
within the Grease Bath.................................................... 16
i-1
INDEX
B-81925EN/04
<Q>
<T>
Quick Mastering.............................................................. 52
TRANSPORTATION................................................... 129
TRANSPORTATION AND INSTALLATION............ 128
<R>
TROUBLESHOOTING.................................................. 21
REPLACING A CABLE ................................................ 96
<W>
Replacing Battery............................................................ 18
WIRING ......................................................................... 84
REPLACING CABLES .................................................. 86
Replacing Grease ............................................................ 12
<Z>
REPLACING J1-AXIS MOTOR (M1) AND
REDUCER ...................................................................... 61
Zero Degree Mastering ................................................... 50
REPLACING J2/J3-AXIS MOTOR (M2/M3)
ZERO POINT POSITION AND MOTION
AND REDUCER ............................................................ 68
LIMIT OF J2-AXIS TO J4-AXIS................................... 35
REPLACING J4-AXIS MOTOR (M4) AND
REDUCER ...................................................................... 77
REPLACING PARTS ..................................................... 59
Replacing the Cables of the Mechanical Unit ................. 19
REPLACING THE J1-AXIS PENDULUM
STOPPER........................................................................ 83
REPLACING THE OPTIONAL J1-AXIS
LIMIT SWITCH (OPTION) .......................................... 82
REPLACING THE WRIST UNIT .................................. 80
Resetting Alarms and Preparing for Mastering ............... 43
ROBOT EXTERNAL DIMENSION ............................ 109
<S>
SAFETY PRECAUTIONS ............................................ s-1
SERVO HAND CABLE INTERFACE
(OPTION) ..................................................................... 126
Single Axis Mastering..................................................... 54
SOFTWARE SETTING.................................................. 40
SPARE PARTS LIST.................................................... 141
Switching between Modes ............................................ 117
i-2
Revision Record
FANUC Robot M-410iB/450 MECHANICAL UNIT MAINTENANCE MANUAL (B-81925EN)
04
• Addition of procedure of to move arm without drive
power in emergency or abnormal situations
•Change of the note of transportation
Dec.,2007 •Addition of Stopping time and distance when
emergency stop
• Addition of sensor cable
•Revice
03
Sep.,2007
02
• Addition of the panel board supporting R-J3iC
Nov.,2006 • Addition of the model supporting R-J3iC
• Addition of a warning about transportation
01
Jan., 2003
Edition
Date
• Change the name of controller
(from R-J3iC to R-30iA)
Contents
Edition
Date
Contents