FANUC Robot R-2000iA
MECHANICAL UNIT
MAINTENANCE MANUAL
MARMIBR2I03011E REV. G
This publication contains proprietary information
of FANUC Robotics America, Inc. furnished for
customer use only. No other uses are authorized
without the express written permission of
FANUC Robotics America, Inc.
FANUC Robotics America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 48309–3253
B-81455EN/08
The descriptions and specifications contained in this manual were in
effect at the time this manual was approved for printing. FANUC
Robotics America, Inc, hereinafter referred to as FANUC Robotics,
reserves the right to discontinue models at any time or to change
specifications or design without notice and without incurring
obligations.
FANUC Robotics manuals present descriptions, specifications,
drawings, schematics, bills of material, parts, connections and/or
procedures for installing, disassembling, connecting, operating and
programming FANUC Robotics’ products and/or systems. Such
systems consist of robots, extended axes, robot controllers,
application software, the KAREL programming language,
INSIGHT vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been
trained in one or more approved FANUC Robotics Training
Course(s) be permitted to install, operate, use, perform procedures
on, repair, and/or maintain FANUC Robotics’ products and/or
systems and their respective components. Approved training
necessitates that the courses selected be relevant to the type of
system installed and application performed at the customer site.
! WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in accordance
with the instruction manual, may cause interference to radio
communications. As temporarily permitted by regulation, it
has not been tested for compliance with the limits for Class A
computing devices pursuant to subpart J of Part 15 of FCC
Rules, which are designed to provide reasonable protection
against such interference. Operation of the equipment in a
residential area is likely to cause interference, in which case
the user, at his own expense, will be required to take
whatever measure may be required to correct the
interference.
FANUC Robotics conducts courses on its systems and products on
a regularly scheduled basis at its headquarters in Rochester Hills,
Michigan. For additional information contact
FANUC Robotics America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
Copyright 2007 by FANUC Robotics America, Inc.
All Rights Reserved
The information illustrated or contained herein is not to be
reproduced, copied, downloaded, translated into another language,
published in any physical or electronic format, including internet, or
transmitted in whole or in part in any way without the prior written
consent of FANUC Robotics America, Inc.
AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,
KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,
PalletTool, SOCKETS, SOFT PARTS SpotTool,
TorchMate, and YagTool are Registered Trademarks of FANUC
Robotics.
FANUC Robotics reserves all proprietary rights, including but not
limited to trademark and trade name rights, in the following names:
AccuAir AccuCal AccuChop AccuFlow AccuPath
AccuSeal ARC Mate ARC Mate Sr.  ARC Mate System 1
ARC Mate System 2 ARC Mate System 3 ARC Mate System
4 ARC Mate System 5 ARCWorks Pro AssistTool
AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell
Finder Center Finder Clean Wall CollisionGuard
DispenseTool F-100 F-200i FabTool FANUC LASER
DRILL Flexibell FlexTool HandlingTool HandlingWorks
INSIGHT INSIGHT II IntelliTrak Integrated Process Solution
Intelligent Assist Device IPC -Integrated Pump Control IPD
Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD
Integral Servo Dispenser Laser Mate System 3 Laser Mate
System 4 LaserPro LaserTool LR Tool MIG Eye
MotionParts NoBots Paint Stick PaintPro PaintTool 100
PAINTWorks PAINTWorks II PAINTWorks III PalletMate
PalletMate PC PalletTool PC PayloadID RecipTool
RemovalTool Robo Chop Robo Spray S-420i S-430i
ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate
SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM RJ3 Controller SYSTEM R-J3iB Controller TCP Mate
TurboMove TorchMate visLOC visPRO-3D visTRAC
WebServer WebTP YagTool
 FANUC LTD 2007
•
•
No part of this manual may be reproduced in any form.
All specifications and designs are subject to change without notice.
Conventions
This manual includes information essential to the safety of
personnel, equipment, software, and data. This information is
indicated by headings and boxes in the text.
!
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set it
apart from other text.
!
CAUTION
Information appearing under CAUTION concerns the protection of
equipment, software, and data. It is boxed to set it apart from
other text.
NOTE Information appearing next to NOTE concerns related
information or useful hints.
!"#$ % &
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+ '% ( % ,' - . #/% + 0*1& + /' ( ,' ( )% /' % 2 ( ,' &
/' % ()% % 2 ( % (* '% /' & ( '% (
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Safety
FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or
the specific safety aspects of your company and/or its work force. It is the responsibility of the owner,
employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace.
The appropriate level of safety for your application and installation can best be determined by safety
system professionals. FANUC Robotics therefore, recommends that each customer consult with such
professionals in order to provide a workplace that allows for the safe application, use, and operation of
FANUC Robotic systems.
According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the
standards to ensure compliance with its requests for Robotics System design, usability, operation,
maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your
responsibility to arrange for the training of the operator of a robot system to recognize and respond to
known hazards associated with your robotic system and to be aware of the recommended operating
procedures for your particular application and robot installation.
FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair,
or otherwise use the robotics system be trained in an approved FANUC Robotics training course and
become familiar with the proper operation of the system. Persons responsible for programming the
system-including the design, implementation, and debugging of application programs-must be familiar
with the recommended programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of safety in the workplace.
CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION
Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:
• The safety of people and equipment
• Use of safety enhancing devices
• Techniques for safe teaching and manual operation of the robot(s)
• Techniques for safe automatic operation of the robot(s)
• Regular scheduled inspection of the robot and workcell
• Proper maintenance of the robot
Keeping People and Equipment Safe
The safety of people is always of primary importance in any situation. However, equipment must be
kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following:
i
Safety
• People
• External devices
• Robot(s)
• Tooling
• Workpiece
Using Safety Enhancing Devices
Always give appropriate attention to the work area that surrounds the robot. The safety of the work
area can be enhanced by the installation of some or all of the following devices:
• Safety fences, barriers, or chains
• Light curtains
• Interlocks
• Pressure mats
• Floor markings
• Warning lights
• Mechanical stops
• EMERGENCY STOP buttons
• DEADMAN switches
Setting Up a Safe Workcell
A safe workcell is essential to protect people and equipment. Observe the following guidelines to
ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace
existing federal, state, and local laws, regulations, and guidelines that pertain to safety.
• Sponsor your personnel for training in approved FANUC Robotics training course(s) related to
your application. Never permit untrained personnel to operate the robots.
• Install a lockout device that uses an access code to prevent unauthorized persons from operating
the robot.
• Use anti-tie-down logic to prevent the operator from bypassing safety measures.
• Arrange the workcell so the operator faces the workcell and can see what is going on inside the
cell.
ii
Safety
• Clearly identify the work envelope of each robot in the system with floor markings, signs, and
special barriers. The work envelope is the area defined by the maximum motion range of the
robot, including any tooling attached to the wrist flange that extend this range.
• Position all controllers outside the robot work envelope.
• Never rely on software or firmware based controllers as the primary safety element unless they
comply with applicable current robot safety standards.
• Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the
operator and at critical points inside and around the outside of the workcell.
• Install flashing lights and/or audible warning devices that activate whenever the robot is
operating, that is, whenever power is applied to the servo drive system. Audible warning devices
shall exceed the ambient noise level at the end-use application.
• Wherever possible, install safety fences to protect against unauthorized entry by personnel into
the work envelope.
• Install special guarding that prevents the operator from reaching into restricted areas of the
work envelope.
• Use interlocks.
• Use presence or proximity sensing devices such as light curtains, mats, and capacitance and
vision systems to enhance safety.
• Periodically check the safety joints or safety clutches that can be optionally installed between the
robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove
power from the system, and help to minimize damage to the tooling and robot.
• Make sure all external devices are properly filtered, grounded, shielded, and suppressed to
prevent hazardous motion due to the effects of electro-magnetic interference (EMI), radio
frequency interference (RFI), and electro-static discharge (ESD).
• Make provisions for power lockout/tagout at the controller.
• Eliminate pinch points . Pinch points are areas where personnel could get trapped between a
moving robot and other equipment.
• Provide enough room inside the workcell to permit personnel to teach the robot and perform
maintenance safely.
• Program the robot to load and unload material safely.
• If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and
beacons.
• If materials are being applied at dangerously high pressure, provide electrical interlocks for
lockout of material flow and pressure.
iii
Safety
Staying Safe While Teaching or Manually Operating the Robot
Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the
following rules:
• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.
• Know whether or not you are using an intrinsically safe teach pendant if you are working in
a hazardous environment.
• Before teaching, visually inspect the robot and work envelope to make sure that no potentially
hazardous conditions exist. The work envelope is the area defined by the maximum motion range
of the robot. These include tooling attached to the wrist flange that extends this range.
• The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe
working conditions to the supervisor or safety department.
• FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for
robot teaching operations. However, if you must enter the work envelope, be sure all safeguards
are in place, check the teach pendant DEADMAN switch for proper operation, and place the
robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the
DEADMAN switch. Only the person with the teach pendant should be in the work envelope.
Warning
Never bypass, strap, or otherwise deactivate a safety device, such as a
limit switch, for any operational convenience. Deactivating a safety
device is known to have resulted in serious injury and death.
• Know the path that can be used to escape from a moving robot; make sure the escape path is
never blocked.
• Isolate the robot from all remote control signals that can cause motion while data is being taught.
• Test any program being run for the first time in the following manner:
Warning
Stay outside the robot work envelope whenever a program is being
run. Failure to do so can result in injury.
— Using a low motion speed, single step the program for at least one full cycle.
— Using a low motion speed, test run the program continuously for at least one full cycle.
— Using the programmed speed, test run the program continuously for at least one full cycle.
• Make sure all personnel are outside the work envelope before running production.
iv
Safety
Staying Safe During Automatic Operation
Advise all personnel who operate the robot during production to observe the following rules:
• Make sure all safety provisions are present and active.
• Know the entire workcell area. The workcell includes the robot and its work envelope, plus the
area occupied by all external devices and other equipment with which the robot interacts.
• Understand the complete task the robot is programmed to perform before initiating automatic
operation.
• Make sure all personnel are outside the work envelope before operating the robot.
• Never enter or allow others to enter the work envelope during automatic operation of the robot.
• Know the location and status of all switches, sensors, and control signals that could cause the
robot to move.
• Know where the EMERGENCY STOP buttons are located on both the robot control and external
control devices. Be prepared to press these buttons in an emergency.
• Never assume that a program is complete if the robot is not moving. The robot could be waiting
for an input signal that will permit it to continue activity.
• If the robot is running in a pattern, do not assume it will continue to run in the same pattern.
• Never try to stop the robot, or break its motion, with your body. The only way to stop robot
motion immediately is to press an EMERGENCY STOP button located on the controller panel,
teach pendant, or emergency stop stations around the workcell.
Staying Safe During Inspection
When inspecting the robot, be sure to
• Turn off power at the controller.
• Lock out and tag out the power source at the controller according to the policies of your plant.
• Turn off the compressed air source and relieve the air pressure.
• If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY
STOP button on the operator panel.
• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.
• If power is needed to check the robot motion or electrical circuits, be prepared to press the
EMERGENCY STOP button, in an emergency.
• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is
not supported or resting on a hard stop. Support the arm on a solid support before you release
the brake.
v
Safety
Staying Safe During Maintenance
When performing maintenance on your robot system, observe the following rules:
• Never enter the work envelope while the robot or a program is in operation.
• Before entering the work envelope, visually inspect the workcell to make sure no potentially
hazardous conditions exist.
• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.
• Consider all or any overlapping work envelopes of adjoining robots when standing in a work
envelope.
• Test the teach pendant for proper operation before entering the work envelope.
• If it is necessary for you to enter the robot work envelope while power is turned on, you must be
sure that you are in control of the robot. Be sure to take the teach pendant with you, press the
DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch
to turn off servo power to the robot immediately.
• Whenever possible, perform maintenance with the power turned off. Before you open the
controller front panel or enter the work envelope, turn off and lock out the 3-phase power source
at the controller.
• Be aware that an applicator bell cup can continue to spin at a very high speed even if the robot is
idle. Use protective gloves or disable bearing air and turbine air before servicing these items.
• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is
not supported or resting on a hard stop. Support the arm on a solid support before you release
the brake.
Warning
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to avoid
electrical shock.HIGH VOLTAGE IS PRESENT at the input side
whenever the controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes power from
the output side of the device only.
• Release or block all stored energy. Before working on the pneumatic system, shut off the system
air supply and purge the air lines.
• Isolate the robot from all remote control signals. If maintenance must be done when the power
is on, make sure the person inside the work envelope has sole control of the robot. The teach
pendant must be held by this person.
vi
Safety
• Make sure personnel cannot get trapped between the moving robot and other equipment. Know
the path that can be used to escape from a moving robot. Make sure the escape route is never
blocked.
• Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure
that such devices do not create pinch points that could trap personnel.
Warning
Do not try to remove any mechanical component from the robot
before thoroughly reading and understanding the procedures in the
appropriate manual. Doing so can result in serious personal injury and
component destruction.
• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is
not supported or resting on a hard stop. Support the arm on a solid support before you release
the brake.
• When replacing or installing components, make sure dirt and debris do not enter the system.
• Use only specified parts for replacement. To avoid fires and damage to parts in the controller,
never use nonspecified fuses.
• Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and
all external devices are operating normally.
KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE
Certain programming and mechanical measures are useful in keeping the machine tools and other
external devices safe. Some of these measures are outlined below. Make sure you know all associated
measures for safe use of such devices.
Programming Safety Precautions
Implement the following programming safety measures to prevent damage to machine tools and
other external devices.
• Back-check limit switches in the workcell to make sure they do not fail.
• Implement “failure routines” in programs that will provide appropriate robot actions if an external
device or another robot in the workcell fails.
• Use handshaking protocol to synchronize robot and external device operations.
• Program the robot to check the condition of all external devices during an operating cycle.
vii
Safety
Mechanical Safety Precautions
Implement the following mechanical safety measures to prevent damage to machine tools and other
external devices.
• Make sure the workcell is clean and free of oil, water, and debris.
• Use software limits, limit switches, and mechanical hardstops to prevent undesired movement of
the robot into the work area of machine tools and external devices.
KEEPING THE ROBOT SAFE
Observe the following operating and programming guidelines to prevent damage to the robot.
Operating Safety Precautions
The following measures are designed to prevent damage to the robot during operation.
• Use a low override speed to increase your control over the robot when jogging the robot.
• Visualize the movement the robot will make before you press the jog keys on the teach pendant.
• Make sure the work envelope is clean and free of oil, water, or debris.
• Use circuit breakers to guard against electrical overload.
Programming Safety Precautions
The following safety measures are designed to prevent damage to the robot during programming:
• Establish interference zones to prevent collisions when two or more robots share a work area.
• Make sure that the program ends with the robot near or at the home position.
• Be aware of signals or other operations that could trigger operation of tooling resulting in
personal injury or equipment damage.
• In dispensing applications, be aware of all safety guidelines with respect to the dispensing
materials.
Note Any deviation from the methods and safety practices described in this manual must conform
to the approved standards of your company. If you have questions, see your supervisor.
viii
Safety
ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT
INSTALLATIONS
Process technicians are sometimes required to enter the paint booth, for example, during daily or
routine calibration or while teaching new paths to a robot. Maintenance personal also must work
inside the paint booth periodically.
Whenever personnel are working inside the paint booth, ventilation equipment must be used.
Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.
Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s
highly automated paint booth requires that process and maintenance personnel have full awareness of
the system and its capabilities. They must understand the interaction that occurs between the vehicle
moving along the conveyor and the robot(s), hood/deck and door opening devices, and high-voltage
electrostatic tools.
Paint robots are operated in three modes:
• Teach or manual mode
• Automatic mode, including automatic and exercise operation
• Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will follow a predetermined
pattern of movements. In teach mode, the process technician teaches (programs) paint paths using
the teach pendant.
In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual
Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel
must remain outside of the booth or in a designated safe area within the booth whenever automatic
mode is initiated at the SOC or MCP.
In automatic mode, the robots will execute the path movements they were taught during teach mode,
but generally at production speeds.
When process and maintenance personnel run diagnostic routines that require them to remain in the
paint booth, they must stay in a designated safe area.
Paint System Safety Features
Process technicians and maintenance personnel must become totally familiar with the equipment and
its capabilities. To minimize the risk of injury when working near robots and related equipment,
personnel must comply strictly with the procedures in the manuals.
ix
Safety
This section provides information about the safety features that are included in the paint system and
also explains the way the robot interacts with other equipment in the system.
The paint system includes the following safety features:
• Most paint booths have red warning beacons that illuminate when the robots are armed and ready
to paint. Your booth might have other kinds of indicators. Learn what these are.
• Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic
devices are enabled. Your booth might have other kinds of indicators. Learn what these are.
• EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become
familiar with the locations of all E-STOP buttons.
• An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres.
• A DEADMAN switch is located on each teach pendant. When this switch is held in, and the
teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN
switch is released during robot operation, power is removed from the servo system, all axis
brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within
the system might also E-STOP other robots.
Warning
An EMERGENCY STOP will occur if the DEADMAN switch is released
on a bypassed robot.
• Overtravel by robot axes is prevented by software limits. All of the major and minor axes are
governed by software limits. Limit switches and hardstops also limit travel by the major axes.
• EMERGENCY STOP limit switches and photoelectric eyes might be part of your system.
Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all
equipment in the booth if a door is opened while the system is operating in automatic or manual
mode. For some systems, signals to these switches are inactive when the switch on the SCC is
in teach mode.When present, photoelectric eyes are sometimes used to monitor unauthorized
intrusion through the entrance/exit silhouette openings.
• System status is monitored by computer. Severe conditions result in automatic system shutdown.
Staying Safe While Operating the Paint Robot
When you work in or near the paint booth, observe the following rules, in addition to all rules for
safe operation that apply to all robot systems.
Warning
Observe all safety rules and guidelines to avoid injury.
x
Safety
Warning
Never bypass, strap, or otherwise deactivate a safety device, such as a
limit switch, for any operational convenience. Deactivating a safety device
is known to have resulted in serious injury and death.
Warning
Enclosures shall not be opened unless the area is know to be
nonhazardous or all power has been removed from devices within the
enclosure. Power shall not be restored after the enclosure has been
opened until all combustible dusts have been removed from the interior
of the enclosure and the enclosure purged. Refer to the Purge chapter
for the required purge time.
• Know the work area of the entire paint station (workcell).
• Know the work envelope of the robot and hood/deck and door opening devices.
• Be aware of overlapping work envelopes of adjacent robots.
• Know where all red, mushroom-shaped EMERGENCY STOP buttons are located.
• Know the location and status of all switches, sensors, and/or control signals that might cause the
robot, conveyor, and opening devices to move.
• Make sure that the work area near the robot is clean and free of water, oil, and debris. Report
unsafe conditions to your supervisor.
• Become familiar with the complete task the robot will perform BEFORE starting automatic mode.
• Make sure all personnel are outside the paint booth before you turn on power to the robot
servo system.
• Never enter the work envelope or paint booth before you turn off power to the robot servo system.
• Never enter the work envelope during automatic operation unless a safe area has been designated.
• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.
• Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the
electrostatic devices are enabled.
• Stay out of areas where you might get trapped between a moving robot, conveyor, or opening
device and another object.
• Be aware of signals and/or operations that could result in the triggering of guns or bells.
• Be aware of all safety precautions when dispensing of paint is required.
• Follow the procedures described in this manual.
xi
Safety
Special Precautions for Combustible Dusts (powder paint)
When the robot is used in a location where combustible dusts are found, such as the application of
powder paint, the following special precautions are required to insure that there are no combustible
dusts inside the robot.
• Purge maintenance air should be maintained at all times, even when the robot power is off. This
will insure that dust can not enter the robot.
• A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dust
when maintenance air is not present, it will be necessary to remove the covers and clean out any
accumulated dust. Do not energize the robot until you have performed the following steps.
1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulated
dust.
2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, be
sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened
with water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate static
electricity and cause an explosion unless special precautions are taken.
3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust.
4. When the dust has been removed, the covers must be replaced immediately.
5. Immediately after the covers are replaced, run a complete purge cycle. The robot can now
be energized.
Staying Safe While Operating Paint Application Equipment
When you work with paint application equipment, observe the following rules, in addition to all rules
for safe operation that apply to all robot systems.
Warning
When working with electrostatic paint equipment, follow all national and
local codes as well as all safety guidelines within your organization.
Also reference the following standards: NFPA 33 Standards for Spray
Application Using Flammable or Combustible Materials , and NFPA 70
National Electrical Code .
• Grounding : All electrically conductive objects in the spray area must be grounded. This
includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots,
as well as solvent containers. Grounding is defined as the object or objects shall be electrically
connected to ground with a resistance of not more than 1 megohms.
xii
Safety
• High Voltage : High voltage should only be on during actual spray operations. Voltage should be
off when the painting process is completed. Never leave high voltage on during a cap cleaning
process.
• Avoid any accumulation of combustible vapors or coating matter.
• Follow all manufacturer recommended cleaning procedures.
• Make sure all interlocks are operational.
• No smoking.
• Post all warning signs regarding the electrostatic equipment and operation of electrostatic
equipment according to NFPA 33 Standard for Spray Application Using Flammable or
Combustible Material.
• Disable all air and paint pressure to bell.
• Verify that the lines are not under pressure.
Staying Safe During Maintenance
When you perform maintenance on the painter system, observe the following rules, and all other
maintenance safety rules that apply to all robot installations. Only qualified, trained service or
maintenance personnel should perform repair work on a robot.
• Paint robots operate in a potentially explosive environment. Use caution when working with
electric tools.
• When a maintenance technician is repairing or adjusting a robot, the work area is under the control
of that technician. All personnel not participating in the maintenance must stay out of the area.
• For some maintenance procedures, station a second person at the control panel within reach
of the EMERGENCY STOP button. This person must understand the robot and associated
potential hazards.
• Be sure all covers and inspection plates are in good repair and in place.
• Always return the robot to the ‘‘home’’ position before you disarm it.
• Never use machine power to aid in removing any component from the robot.
• During robot operations, be aware of the robot’s movements. Excess vibration, unusual sounds,
and so forth, can alert you to potential problems.
• Whenever possible, turn off the main electrical disconnect before you clean the robot.
• When using vinyl resin observe the following:
— Wear eye protection and protective gloves during application and removal
— Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye
irritation.
— If there is contact with the skin, wash with water.
xiii
Safety
— Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
• When using paint remover observe the following:
— Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.
— Adequate ventilation is required. Overexposure could cause drowsiness.
— If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then,
seek medical attention as soon as possible.
— Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
xiv
B-81455EN/08
SAFETY
SAFETY
FANUC is not and does not represent itself as an expert in safety
systems, safety equipment, or the specific safety aspects of your
company and/or its work force. It is the responsibility of the owner,
employer, or user to take all necessary steps to guarantee the safety of
all personnel in the workplace.
The appropriate level of safety for your application and installation can
best be determined by safety system professionals. FANUC therefore,
recommends that each customer consult with such professionals in
order to provide a workplace that allows for the safe application, use,
and operation of FANUC systems.
Additionally, as the owner, employer, or user of a robotic system, it is
your responsibility to arrange for the training of the operator of a robot
system to recognize and respond to known hazards associated with your
robotic system and to be aware of the recommended operating
procedures for your particular application and robot installation.
FANUC therefore, recommends that all personnel who intend to
operate, program, repair, or otherwise use the robotics system be trained
in an approved FANUC training course and become familiar with the
proper operation of the system. Persons responsible for programming
the system-including the design, implementation, and debugging of
application programs-must be familiar with the recommended
programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of
safety in the workplace.
IMPORTANT!
Before operating, servicing or in any other way
handling the robot, the “FANUC Robot SAFETY
HANDBOOK (B-80687EN)” must be thoroughly
studied.
s-1
SAFETY
B-81455EN/08
Considering safety for your robot installation
Safety is essential whenever robots are used. Keep in mind the
following factors with regard to safety:
•
The safety of people and equipment
•
Use of safety enhancing devices
•
Techniques for safe teaching and manual operation of the robot(s)
•
Techniques for safe automatic operation of the robot(s)
•
Regular scheduled inspection of the robot and workcell
•
Proper maintenance of the robot
• Keeping people and equipment safe
The safety of people is always of primary importance in any situation.
However, equipment must be kept safe, too. When prioritizing how to
apply safety to your robotic system, consider the following:
•
People
•
External devices
•
Robot(s)
•
Tooling
•
Workpiece
• Using safety enhancing devices
Always give appropriate attention to the work area that surrounds the
robot. The safety of the work area can be enhanced by the installation
of some or all of the following devices:
•
Safety fences, barriers, or chains
•
Light curtains
•
Interlocks
•
Pressure mats
•
Floor markings
•
Warning lights
•
Mechanical stops
•
EMERGENCY STOP buttons
•
DEADMAN switches
• Setting up a safe workcell
A safe workcell is essential to protect people and equipment. Observe
the following guidelines to ensure that the workcell is set up safely.
These suggestions are intended to supplement and not replace existing
federal, state, and local laws, regulations, and guidelines that pertain to
safety.
•
Sponsor your personnel for training in approved FANUC training
course(s) related to your application. Never permit untrained
personnel to operate the robots.
•
Install a lockout device to prevent unauthorized persons from
operating the robot.
•
Use anti-tie-down logic to prevent the operator from bypassing
safety measures.
•
Arrange the workcell so the operator faces the workcell and can
see what is going on inside the cell.
s-2
SAFETY
B-81455EN/08
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Clearly identify the work envelope of each robot in the system
with floor markings, signs, and special barriers. The work
envelope is the area defined by the maximum motion range of the
robot, including any tooling attached to the wrist flange that
extend this range.
Position all controllers outside the robot work envelope.
Never rely on software as the primary safety element.
Install flashing lights and/or audible warning devices that activate
whenever the robot is operating, that is, whenever power is applied
to the servo drive system.
Wherever possible, install safety fences to protect against
unauthorized entry by personnel into the work envelope.
Install special guarding that prevents the operator from reaching
into restricted areas of the work envelope.
Use interlocks.
Use presence or proximity sensing devices such as light curtains,
mats, and capacitance and vision systems to enhance safety.
Periodically check the safety joints or safety clutches that can be
optionally installed between the robot wrist flange and tooling. If
the tooling strikes an object, these devices dislodge, remove power
from the system, and help to minimize damage to the tooling and
robot.
Make sure all external devices are properly filtered, grounded,
shielded, and suppressed to prevent hazardous motion due to the
effects of electro-magnetic interference (EMI), radio frequency
interference (RFI), and electro-static discharge (ESD).
Make provisions for power lockout/tagout at the controller.
Eliminate pinch points. Pinch points are areas where personnel
could get trapped between a moving robot and other equipment.
Provide enough room inside the workcell to permit personnel to
teach the robot and perform maintenance safely.
Program the robot to load and unload material safely.
If high voltage electrostatics are present, be sure to provide
appropriate interlocks, warning, and beacons.
If materials are being applied at dangerously high pressure,
provide electrical interlocks for lockout of material flow and
pressure.
• Staying safe while teaching or manually operating the robot
Advise all personnel who must teach the robot or otherwise manually
operate the robot to observe the following rules:
•
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
•
Know whether or not you are using an intrinsically safe teach
pendant if you are working in a hazardous environment.
•
Before teaching, visually inspect the robot and work envelope to
make sure that no potentially hazardous conditions exist. The
work envelope is the area defined by the maximum motion range
of the robot. These include tooling attached to the wrist flange that
extends this range.
s-3
SAFETY
•
•
•
•
•
B-81455EN/08
The area near the robot must be clean and free of oil, water, or
debris. Immediately report unsafe working conditions to the
supervisor or safety department.
FANUC recommends that no one enter the work envelope of a
robot that is on. However, if you must enter the work envelope, be
sure all safeguards are in place, and check the teach pendant
DEADMAN switch for proper operation. Take the teach pendant
with you, turn it on, and be prepared to release the DEADMAN
switch. Only the person with the teach pendant should be in the
work envelope.
Know the path that can be used to escape from a moving robot;
make sure the escape path is never blocked.
Isolate the robot from all remote control signals that can cause
motion while data is being taught.
Test any program being run for the first time in the following
manner:
WARNING
Stay outside the robot work envelope whenever a
program is being run. Failure to do so can result in
injury.
Using a low motion speed, single step the program for at least
one full cycle.
Using a low motion speed, test run the program continuously
for at least one full cycle.
Using the programmed speed, test run the program
continuously for at least one full cycle.
•
Make sure all personnel are outside the work envelope before
running production.
• Staying safe during production operation
Advise all personnel who operate the robot during production to
observe the following rules:
•
Know the entire workcell area. The workcell includes the robot
and its work envelope, plus the area occupied by all external
devices and other equipment with which the robot interacts.
•
Understand the complete task the robot is programmed to perform
before initiating production operation.
•
Make sure all personnel are outside the work envelope before
operating the robot.
•
Never enter or allow others to enter the work envelope during
production operation of the robot.
•
Know the location and status of all switches, sensors, and control
signals that could cause the robot to move.
•
Know where the EMERGENCY STOP buttons are located on
both the robot control and external control devices. Be prepared to
press these buttons in an emergency.
s-4
SAFETY
B-81455EN/08
•
•
•
Never assume that a program is complete if the robot is not
moving. The robot could be waiting for an input signal that will
permit it to continue activity.
If the robot is running in a pattern, do not assume it will continue
to run in the same pattern.
Never try to stop the robot, or break its motion, with your body.
The only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel,
teach pendant, or emergency stop stations around the workcell.
• Staying safe during inspection
When inspecting the robot, be sure to
•
Turn off power at the controller.
•
Lock out and tag out the power source at the controller according
to the policies of your plant.
•
Turn off the compressed air source and relieve the air pressure.
•
If robot motion is not needed for inspecting the electrical circuits,
press the EMERGENCY STOP button on the operator panel.
•
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
•
If power is needed to check the robot motion or electrical circuits,
be prepared to press the EMERGENCY STOP button, in an
emergency.
• Staying safe during maintenance
When performing maintenance on your robot system, observe the
following rules:
•
Never enter the work envelope while the robot or a program is in
operation.
•
Before entering the work envelope, visually inspect the workcell
to make sure no potentially hazardous conditions exist.
•
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
•
Consider all or any overlapping work envelopes of adjoining
robots when standing in a work envelope.
•
Test the teach pendant for proper operation before entering the
work envelope.
•
If it is necessary for you to enter the robot work envelope while
power is turned on, you must be sure that you are in control of the
robot. Be sure to take the teach pendant with you, press the
DEADMAN switch, and turn the teach pendant on. Be prepared
to release the DEADMAN switch to turn off servo power to the
robot immediately.
•
Whenever possible, perform maintenance with the power turned
off. Before you open the controller front panel or enter the work
envelope, turn off and lock out the 3-phase power source at the
controller.
s-5
SAFETY
B-81455EN/08
WARNING
Lethal voltage is present in the controller
WHENEVER IT IS CONNECTED to a power
source. Be extremely careful to avoid electrical
shock.
HIGH VOLTAGE IS PRESENT at the input side
whenever the controller is connected to a power
source. Turning the disconnect or circuit breaker to
the OFF position removes power from the output
side of the device only.
•
•
•
•
Release or block all stored energy. Before working on the
pneumatic system, shut off the system air supply and purge the air
lines.
Isolate the robot from all remote control signals. If maintenance
must be done when the power is on, make sure the person inside
the work envelope has sole control of the robot. The teach pendant
must be held by this person.
Make sure personnel cannot get trapped between the moving robot
and other equipment. Know the path that can be used to escape
from a moving robot. Make sure the escape route is never
blocked.
Use blocks, mechanical stops, and pins to prevent hazardous
movement by the robot. Make sure that such devices do not create
pinch points that could trap personnel.
WARNING
Do not try to remove any mechanical component
from the robot before thoroughly reading and
understanding the procedures in the appropriate
manual. Doing so can result in serious personal
injury and component destruction.
•
•
•
•
•
•
•
•
Be aware that when you remove a servomotor or brake, the
associated axis will fall if it is not supported or resting on a hard
stop.
When replacing or installing components, make sure dirt and
debris do not enter the system.
Use only specified parts for replacement. To avoid fires and
damage to parts in the controller, never use nonspecified fuses.
Before restarting a robot, make sure no one is inside the work
envelope; be sure that the robot and all external devices are
operating normally.
Use appropriate lighting for maintenance work. Take care that the
lighting does not create new dangerous situations.
If it is necessary to operate the robot during the inspection, pay
careful attention to the robot's motion and be sure to press the
EMERGENCY STOP button immediately when necessary.
Be careful not to slip on spilled grease during maintenance.
Do not climb on the robot.
s-6
SAFETY
B-81455EN/08
•
•
•
•
•
Some components might be hot. Take care when working on
servo motors or inside the controller. Wear protective clothing
(heart-resistant gloves, etc.) when working on components that are
hot.
After replacing components, be sure to tighten screws and
fasteners that were loosened.
The motor and reducer are heavy. Be careful when replacing them.
If the robot collides with a mechanical hard stop, replace the
mechanical hard stop even if it does not seem to be damaged.
After replacing parts or making adjustments, be sure to test run the
robot according to the following procedure.
1. Using a low motion speed, single step the program for at least
one full cycle.
2. Using a low motion speed, test run the program continuously
for at least one full cycle.
3. As speed is increased. the path may vary slightly. Run
through the program at 5-10% intervals up to 100%.
4. Using the programmed speed, test run the program
continuously for at least one full cycle.
Make sure all personnel are outside the fence before test running.
After maintenance work, clean the area around the robot of oil,
water, and debris.
Safety procedure for maintenance
Follow this safety procedure when entering the safeguarded space for
maintenance.
Entering safeguarded space for maintenance
1.
2.
Stop the robot system.
Shut off the power to the robot system, and lock the main breaker
to prevent accidental powering on during maintenance.
2’. If you have to enter the safeguarded space while power is available
to the robot system, you must do the following prior to entering the
safeguarded space:
check the robot system to determine if any conditions exist
that are likely to cause malfunctions,
check that the teach pendant works correctly, and
if any damage or malfunction is found, complete the required
corrections and perform a retest before personnel enter the
safeguarded space.
3. Enter the safeguarded space (see “The Safety Sequence for fence
entry” in “FANUC Robot SAFETY HANDBOOK”.
4. After maintenance is complete, check that the safeguard system is
effective. If it has been suspended to perform the maintenance
working, return it to its original effectiveness.
s-7
SAFETY
B-81455EN/08
Keeping machine tools and external devices safe
Certain programming and mechanical measures are useful in keeping
the machine tools and other external devices safe. These measures are
outlined below.
• Programming safety precautions
Implement the following programming safety measures to prevent
damage to machine tools and other external devices.
•
Back-check limit switches in the workcell to make sure they do
not fail.
•
Implement “failure routines” in programs that will provide
appropriate robot actions if an external device or another robot in
the workcell fails.
•
Use handshaking protocol to synchronize robot and external
device operations.
•
Program the robot to check the condition of all external devices
during an operating cycle.
• Mechanical safety precautions
Implement the following mechanical safety measures to prevent
damage to machine tools and other external devices.
•
Make sure the workcell is clean and free of oil, water, and debris.
•
Use software limits, limit switches, and mechanical hardstops to
prevent undesired movement of the robot into the work area of
machine tools and external devices.
Keeping the robot safe
Observe the following operating and programming guidelines to
prevent damage to the robot.
• Operating safety precautions
The following measures are designed to prevent damage to the robot
during operation.
•
Use a low override speed to increase your control over the robot
when jogging the robot.
•
Visualize the movement the robot will make before you press the
jog keys on the teach pendant.
•
Make sure the work envelope is clean and free of oil, water, or
debris.
•
Use fuses to guard against electrical overload.
• Programming safety precautions
The following safety measures are designed to prevent damage to the
robot during programming:
•
Establish interference zones to prevent collisions when two or
more robots share a work area.
•
Make sure that the program ends with the robot near or at the home
position.
•
Be aware of signals or other operations that could trigger operation
of tooling resulting in personal injury or equipment damage.
s-8
SAFETY
B-81455EN/08
•
In dispensing applications, be aware of all safety guidelines with
respect to the dispensing materials.
NOTE
Any deviation from the methods and safety
practices described in this manual must conform to
the approved standards of your company. If you
have questions, see your supervisor.
Warning labels
(1) Greasing and degreasing label
Greasing and Degreasing Label
Description
When greasing and degreasing, observe the instructions indicated on
this label.
1) When greasing, be sure to keep the grease outlet open.
2) Use a manual pump to grease.
3) Be sure to use a specified grease.
NOTE
See MAINTENANCE 3.1 REPLACING GREASE
OF THE DRIVE MECHANISM for explanations
about specified greases, the amount of grease to be
supplied, and the locations of grease and degrease
outlets for individual models.
(2) Disassembly prohibitive label
s-9
SAFETY
B-81455EN/08
Disassembly Prohibitive Label
Description
Do not disassemble the balance unit. It is very dangerous because a
spring is loaded in it. (For the R-2000iA, a disassembly prohibitive
label is affixed only to the balancer.)
(3) Step-on prohibitive label
Step-on Prohibitive Label
s-10
B-81455EN/08
SAFETY
Description
Do not step on or climb the robot as it may adversely affect the robot
and you may get hurt if you lose your footing as well.
(4) High-temperature warning label
High-Temperature Warning Label
Description
Be cautious about a section where this label is affixed, as the section
generates heat. If you have to inevitably touch such a section when it is
hot, use a protective provision such as heat-resistant gloves.
(5) Transportation label
Transportation Label (R-2000iA/165F, 200F, 200FO, 210F, 125L, 130U)
s-11
SAFETY
B-81455EN/08
>2500kg
<1200kg X2
>2500kg
>1000kg X4
>630kg X4
Transportation Label (R-2000iA/165R, 200R, 100P)
>2500kg
<600kg X4
>2500kg
>1000kg X4
>630kg X4
Transportation Label (R-2000iA/165CF)
s-12
B-81455EN/08
SAFETY
Description
When transporting the robot, observe the instructions indicated on this
label.
1) Using a forklift
•
Use a forklift having a load capacity of 2,500 kg or greater.
•
Keep the total weight of the robot to be transported to within
2,200 kg, because the withstand load of the forklift bracket
(option) is 5,390 N (550 kgf).
2) Using a crane
•
Use a crane having a load capacity of 2,500 kg or greater.
•
Use at least four slings each having a withstand load of 9,800
N (1,000 kgf) or greater.
•
Use at least four eyebolts each having a withstand load of
6,174 N (630 kgf) or greater.
NOTE
Transportation labels are model-specific. Before
transporting the robot, see the transportation label
affixed to the J2 base side.
See CONNECTION 3.1 TRANSPORTATION for
explanations about the posture a specific model
should take when it is transported.
(6) Balancer replacement label
Balancer Replacement Label (R-2000iA/165F, 200F, 200FO, 210F, 125L)
s-13
SAFETY
B-81455EN/08
300kg
J2=-90°
Balancer Replacement Label (R-2000iA/165R, 200R, 100P)
Description
When replacing the balancer, observe the instructions indicated on this
label.
(For R-2000iA/165F, 200F, 200FO, 210F, 125L)
•
When replacing the balancer, keep the J2 axis at 0°.
•
Use a balancer having a weight of 100 kg.
(For R-2000iA/165R, 200R, 100P)
•
When replacing the balancer, keep the J2 axis at -90°.
•
Use a balancer having a weight of 300 kg.
NOTE
See MAINTENANCE 6.7 REPLACING THE
BALANCER for explanations about how to replace
(disassemble and assemble) the balancer.
NOTE
No balancer is provided for the R-2000iA/165CF
and 130U.
s-14
SAFETY
B-81455EN/08
(7) Transportation prohibitive label
(When transportation equipment option is specified.)
アイボルトを横引
しないこと
Do not pull eyebolt
sideways
輸送部材に衝撃を
与えないこと
Do not have impact
on this part
輸送部材にチェーン
などを掛けないこと
Do not chain, pry,
or strap on this part
Transportation prohibitive label
Description
Keep the following in mind when transporting the robot.
1) Do not pull eyebolts sideways
2) Prevent the forks of the forklift from having impact on a transport
equipment.
3) Do not thread a chain or the like through a transport equipment.
s-15
B-81445EN/08
PREFACE
PREFACE
This manual explains the maintenance and connection procedures for
the mechanical units of the following robots:
Model name
Mechanical unit
specification No.
Maximum load
FANUC Robot R-2000iA/165F
FANUC Robot R-2000iA/200F
FANUC Robot R-2000iA/200FO
FANUC Robot R-2000iA/210F
FANUC Robot R-2000iA/165R
FANUC Robot R-2000iA/200R
FANUC Robot R-2000iA/100P
FANUC Robot R-2000iA/165CF
FANUC Robot R-2000iA/125L
FANUC Robot R-2000iA/130U
A05B-1324-B203
A05B-1324-B205
A05B-1324-B206
A05B-1324-B215
A05B-1324-B223
A05B-1324-B225
A05B-1324-B231
A05B-1324-B241
A05B-1324-B263
A05B-1324-B291
165kg
200kg
200kg
210kg
165kg
200kg
100kg
165kg
125kg
130kg
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
No.
B-81445EN/08
Table 1 Positon of label indicating mechanical unit specification number
(1)
(2)
(3)
(4)
CONTENTS
–
LETTERS
FANUC Robot
R-2000iA/165F
FANUC Robot
R-2000iA/200F
FANUC Robot
R-2000iA/200FO
FANUC Robot
R-2000iA/210F
FANUC Robot
R-2000iA/165R
FANUC Robot
R-2000iA/200R
FANUC Robot
R-2000iA/100P
FANUC Robot
R-2000iA/165CF
FANUC Robot
R-2000iA/125L
FANUC Robot
R-2000iA/130U
TYPE
No.
DATE
(5)
WEIGHT
(Without controller)
A05B-1324-B203
1210kg
A05B-1324-B205
1240kg
A05B-1324-B206
1310kg
A05B-1324-B215
1270kg
A05B-1324-B223
A05B-1324-B225
PRINT
SERIAL NO.
PRINT
PRODUCTION
YEAR AND MONTH
1540kg
1570kg
A05B-1324-B231
1630kg
A05B-1324-B241
1050kg
A05B-1324-B263
1230kg
A05B-1324-B291
1210kg
p-2
B-81445EN/08
PREFACE
Specifications (1/2)
ITEM
R-2000iA/165F R-2000iA/200F R-2000iA/200FO R-2000iA/210F R-2000iA/165R R-2000iA/200R R-2000iA/100P
Type
Articulated Type
Controlled axes
6 axes (J1, J2, J3, J4, J5, J6)
Installation
Floor mount
Rack mount
J1-axis
360° (6.28rad)
360° (6.28rad)
360° (6.28rad)
360° (6.28rad)
360° (6.28rad)
360° (6.28rad)
360° (6.28rad)
J2-axis
135° (2.36rad)
135° (2.36rad)
135° (2.36rad)
135° (2.36rad)
185° (3.23rad)
185° (3.23rad) 185°/s (3.23rad)
J3-axis 361.8° (6.31rad) 367.4° (6.41rad) 350.4° (6.12rad) 361.8° (6.31rad) 365° (6.37rad)
365° (6.37rad) 365°/s (6.37rad)
Motion range
J4-axis
720° (12.57rad) 720° (12.57rad) 720° (12.57rad) 720° (12.57rad) 720° (12.57rad) 720° (12.57rad) 720° (12.57rad)
J5-axis
250° (4.36rad)
250° (4.36rad)
250° (4.36rad)
250° (4.36rad)
250° (4.36rad)
250° (4.36rad)
250° (4.36rad)
J6-axis
720° (12.57rad) 720° (12.57rad) 720° (12.57rad) 720° (12.57rad) 720° (12.57rad) 720° (12.57rad) 720° (12.57rad)
J1-axis 105°/s (1.83rad/s) 90°/s (1.57rad/s) 90°/s (1.57rad/s) 95°/s (1.66rad/s) 105°/s (1.83rad/s) 90°/s (1.57rad/s) 105°/s (1.83rad/s)
J2-axis 105°/s (1.83rad/s) 85°/s (1.48rad/s) 85°/s (1.48rad/s) 90°/s (1.57rad/s) 90°/s (1.57rad/s) 85°/s (1.48rad/s) 90°/s (1.57rad/s)
Max motion
J3-axis 105°/s (1.83rad/s) 90°/s (1.57rad/s) 90°/s (1.57rad/s) 95°/s (1.66rad/s) 105°/s (1.83rad/s) 90°/s (1.57rad/s) 105°/s (1.83rad/s)
speed
J4-axis 130°/s (2.27rad/s) 110°/s (1.92rad/s) 110°/s (1.92rad/s) 120°/s (2.09rad/s) 130°/s (2.27rad/s) 110°/s (1.92rad/s) 120°/s (2.09rad/s)
J5-axis 130°/s (2.27rad/s) 110°/s (1.92rad/s) 110°/s (1.92rad/s) 120°/s (2.09rad/s) 130°/s (2.27rad/s) 110°/s (1.92rad/s) 120°/s (2.09rad/s)
J6-axis 210°/s (3.67rad/s) 155°/s (2.71rad/s) 155°/s (2.71rad/s) 190°/s (3.32rad/s) 210°/s (3.67rad/s) 155°/s (2.71rad/s) 190°/s (3.32rad/s)
at wrist
165kg
200kg
210kg
210kg
165kg
200kg
100kg
Max. load
at J3 arm
25kg
25kg
25kg
25kg
25kg
–
25kg
capacity
at J2 base
550kg
550kg
550kg
550kg
550kg
550kg
550kg
921N·m
1274N·m
1274N·m
1333N·m
921N·m
1274N·m
980N·m
J4-axis
(94kgf·m)
(130kgf·m)
(130kgf·m)
(136kgf·m)
(94kgf·m)
(130kgf·m)
(100kgf·m)
Allowable
load moment
921N·m
1274N·m
1274N·m
1333N·m
921N·m
1274N·m
980N·m
J5-axis
at wrist
(94kgf·m)
(130kgf·m)
(130kgf·m)
(136kgf·m)
(94kgf·m)
(130kgf·m)
(100kgf·m)
J6-axis 461N·m (47kgf·m) 686N·m (70kgf·m) 686N·m (70kgf·m) 706N·m (72kgf·m) 461N·m (47kgf·m) 686N·m (70kgf·m) 706N·m (72kgf·m)
NOTE 1
NOTE 1
141.1kg·m2
117.6kg·m2
117.6kg·m2
117.6kg·m2
225.4kg·m2
(1200kgf·cm·s2) (1440kgf·cm·s2)
78.4kg·m2
78.4kg·m2
J4-axis
(800kgf·cm·s2) (1200kgf·cm·s2)
(800kgf·cm·s2) (1200kgf·cm·s2) (2300kgf·cm·s2)
NOTE 1
NOTE 1
215.6kg·m2
215.6kg·m2
(2200kgf·cm·s2) (2200kgf·cm·s2)
NOTE 1
NOTE 1
117.6kg·m2
141.1kg·m2
Allowable
117.6kg·m2
117.6kg·m2
225.4kg·m2
(1200kgf·cm·s2) (1440kgf·cm·s2)
78.4kg·m2
78.4kg·m2
J5-axis
load inertia
(800kgf·cm·s2) (1200kgf·cm·s2)
(800kgf·cm·s2) (1200kgf·cm·s2) (2300kgf·cm·s2)
NOTE
1
NOTE
1
at wrist
215.6kg·m2
215.6kg·m2
(2200kgf·cm·s2) (2200kgf·cm·s2)
NOTE 1
NOTE 1
58.8kg·m2
78.4kg·m2
2
2
2
58.8kg·m
58.8kg·m2
196kg·m2
40.18kg·m2
(600kgf·cm·s )
(800kgf·cm·s2)
40.18kg·m
J6-axis
(410kgf·cm·s2)
(600kgf·cm·s2)
(410kgf·cm·s2)
(600kgf·cm·s2) (2000kgf·cm·s2)
NOTE 1
NOTE 1
196.0kg·m2
196.0kg·m2
(2000kgf·cm·s2) (2000kgf·cm·s2)
Drive method
Electric servo drive by AC servo motor
Repeatability
±0.2mm
±0.3mm
Weight
1210kg
1240kg
1310kg
1270kg
1540kg
1570kg
1630kg
Acoustic noise level
98.1 dB
(NOTE 3)
Ambient temperature : 0 - 45°C
Ambient humidity
Normally : 75%RH or less
No dew, nor frost allowed.
Installation environment
Short time (within one month)
: Max 95%RH
Height :
Up to 1,000 meters above the sea level required, no particular provision for attitude.
Vibration : 0.5G (4.9m/s2) or less
NOTE
1 The allowable load in standard inertia mode is shown in upper half and the allowable
load in high inertia mode in lower half. For details, see Section 2.7 in the connection
manual.
2 R-2000iA/200FO with kinematics software for the stud welding specification can't be
used in high inertia mode.
3 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
p-3
PREFACE
B-81445EN/08
The R-2000iA/200F, 200FO can be applied to stud welding under the
following conditions.
1) Maximum resistance force: 4,900 N (500 kgf)
2) J1-axis allowable moment by resistance force: 7,840 Nm (800
kgfm)
3) Resistance force passes the rotation center of three wrist axes.
4) Resistance force acts on the horizontal surface from below.
5) Use the mechanical software that conforms to the each stud
welding specification instead of the standard specification. In
addition, the collision detection function and deposition detection
function are disabled.
NOTE
For use conditions other than the above, contact
FANUC.
Specifications (2/2)
ITEM
Type
Controlled axes
Installation
J1-axis
J2-axis
J3-axis
Motion range
J4-axis
J5-axis
J6-axis
J1-axis
J2-axis
Max motion
J3-axis
speed
J4-axis
J5-axis
J6-axis
at wrist
Max. load
at J3 arm
capacity
at J2 base
J4-axis
Allowable load
moment
J5-axis
at wrist
J6-axis
J4-axis
Allowable
inertia
at wrist
load
J5-axis
J6-axis
Drive method
Repeatability
Weight
Acoustic noise level
(NOTE 3)
Installation environment
R-2000iA/165CF
360° (6.28rad)
165°/s (2.88rad)
250°/s (4.36rad)
720° (12.57rad)
250° (4.36rad)
720° (12.57rad)
110°/s (1.92rad/s)
90°/s (1.57rad/s)
100°/s (1.75rad/s)
130°/s (2.27rad/s)
130°/s (2.27rad/s)
210°/s (3.67rad/s)
165kg
25kg
550kg
911N·m (93kgf·m)
911N·m (93kgf·m)
451N·m (46kgf·m)
2
88.2kg·m
2
(900kgf·cm·s )
2
88.2kg·m
2
(900kgf·cm·s )
2
44.1kg·m
2
(450kgf·cm·s )
±0.15mm
1050kg
R-2000iA/125L
Articulated Type
6 axes (J1, J2, J3, J4, J5, J6)
Floor mount
360° (6.28rad)
135° (2.36rad)
352.4° (6.15rad)
720° (12.57rad)
250° (4.36rad)
720° (12.57rad)
105°/s (1.83rad/s)
105°/s (1.83rad/s)
105°/s (1.83rad/s)
170°/s (2.97rad/s)
170°/s (2.97rad/s)
260°/s (4.54rad/s)
125kg
20kg
550kg
588N·m (60kgf·m)
588N·m (60kgf·m)
343N·m (35kgf·m)
2
58.8kg·m
2
(600kgf·cm·s )
2
58.8kg·m
2
(600kgf·cm·s )
2
22.54kg·m
2
(230kgf·cm·s )
Electric servo drive by AC servo motor
±0.2mm
1230kg
R-2000iA/130U
Upside-down
360° (6.28rad)
135° (2.36rad)
367.5° (6.41rad)
720° (12.57rad)
250° (4.36rad)
720° (12.57rad)
905°/s (1.57rad/s)
85°/s (1.48rad/s)
90°/s (1.57rad/s)
110°/s (1.92rad/s)
110°/s (1.92rad/s)
155°/s (2.71rad/s)
130kg
25kg
550kg
686N·m (70kgf·m)
686N·m (70kgf·m)
343N·m (35kgf·m)
2
40.9kg·m
2
(417kgf·cm·s )
2
40.9kg·m
2
(417kgf·cm·s )
2
10.2kg·m
2
(104kgf·cm·s )
±0.3mm
1210kg
78.1 dB
Ambient temperature : 0 - 45°C
Ambient humidity
Normally : 75%RH or less
No dew, nor frost allowed.
Short time (within one month) : Max 95%RH
Height :
Up to 1,000 meters above the sea level required, no particular provision for attitude.
2
Vibration : 0.5G (4.9m/s ) or less
p-4
PREFACE
B-81445EN/08
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook B-80687EN
All persons who use the FANUC Robot and
system designer must read and understand
thoroughly this handbook
R-J3iB controller
Setup and Operations
manual
SPOT TOOL
B-81464EN-1
HANDLING TOOL
B-81464EN-2
SEALING TOOL
B-81464EN-4
Maintenance manual
B-81465EN
Mechanical unit
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
B-81465EN-1
Use :
(European
Installation, start-up, connection, maintenance
specification)
Maintenance manual
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to the controller, maintenance
Use :
Installation, start-up, connection, maintenance
FANUC Robot R-2000iA B-81455EN
- Spot welding, general-purpose large robot
p-5
TABLE OF CONTENTS
B-81455EN/08
TABLE OF CONTENTS
SAFETY.......................................................................................................s-1
PREFACE ....................................................................................................p-1
I.
1
MAINTENANCE
CONFIGURATION .................................................................................. 3
1.1
1.2
1.3
1.4
1.5
1.6
2
PREVENTIVE MAINTENANCE............................................................. 15
2.1
2.2
2.3
2.4
2.5
2.6
3
J1-AXIS DRIVE MECHANISM....................................................................... 6
J2-AXIS DRIVE MECHANISM....................................................................... 7
J3-AXIS DRIVE MECHANISM....................................................................... 8
J4-AXIS DRIVE MECHANISM....................................................................... 9
J5/J6-AXIS DRIVE MECHANISM ................................................................ 10
MAJOR COMPONENT SPECIFICATIONS ................................................. 11
DAILY CHECKS .......................................................................................... 16
3-MONTH (960 HOURS) CHECKS ............................................................. 18
1-YEAR (3,840 HOURS) CHECKS.............................................................. 22
1.5-YEAR (5,760 HOURS) CHECKS........................................................... 22
3-YEAR (11,520 HOURS) CHECKS............................................................ 22
MAINTENANCE TOOLS ............................................................................. 23
PERIODIC MAINTENANCE .................................................................. 29
3.1
REPLACING THE GREASE OF THE DRIVE MECHANISM ....................... 30
3.1.1
Grease Replacement Procedure for the J1-Axis/J2-Axis/J3-Axis and J4-Axis Gear
Box .........................................................................................................................31
3.1.2
Grease Replacement Procedure for the Wrist (R-2000iA/165F, 210F, 165R, 100P
and 125L) ...............................................................................................................31
3.1.3
Grease Replacement Procedure for the Wrist (R-2000iA/200F, 200FO, 200R, 165CF
and 130U)...............................................................................................................31
3.2
3.3
4
3.1.4
Attitude for Greasing..............................................................................................32
3.1.5
Procedure for Releasing Residual Pressure from the Grease Bath.........................36
GREASING OF THE BALANCER SHAFT................................................... 38
REPLACING THE BATTERIES ................................................................... 39
TROUBLESHOOTING .......................................................................... 41
4.1
OVERVIEW ................................................................................................. 42
c-1
TABLE OF CONTENTS
4.2
4.3
5
5.2
5.3
6.6
6.7
6.8
6.9
Zero Point Position and Motion Limit ...................................................................63
5.1.2
Software Setting .....................................................................................................70
5.1.3
Hard Stopper and Limit Switch Setting..................................................................71
ADJUSTING LIMIT SWITCH (OPTION) ...................................................... 83
MASTERING ............................................................................................... 87
5.3.1
General ...................................................................................................................87
5.3.2
Resetting Alarms and Preparing for Mastering ......................................................88
5.3.3
Mastering to a Fixture (Master Position Master)....................................................89
5.3.4
Zero Position Mastering .......................................................................................103
5.3.5
Quick Mastering ...................................................................................................112
5.3.6
Single Axis Mastering ..........................................................................................114
5.3.7
Mastering Data Entry ...........................................................................................117
NOTE FOR PART REPLACEMENT.......................................................... 120
REPLACING J1-AXIS MOTOR (M1) AND REDUCER .............................. 122
REPLACING J2-AXIS MOTOR (M2) AND REDUCER .............................. 135
REPLACING J3-AXIS MOTOR (M3) AND REDUCER .............................. 149
REPLACING THE WRIST AXIS MOTORS (M4, M5, AND M6), WRIST UNIT,
AND J4 AXIS REDUCER........................................................................... 163
REPLACING FANS ................................................................................... 175
REPLACING THE BALANCER.................................................................. 177
SEALANT APPLICATION.......................................................................... 181
REPLACING MOTOR COVERS (OPTION) .............................................. 182
PIPING DIAGRAM..................................................................................... 185
WIRING DIAGRAM.................................................................................... 188
REPLACING CABLES ........................................................................ 198
8.1
8.2
8.3
9
5.1.1
PIPING AND WIRING ......................................................................... 184
7.1
7.2
8
AXIS LIMITS SETUP ................................................................................... 62
REPLACING PARTS .......................................................................... 119
6.1
6.2
6.3
6.4
6.5
7
FAILURE AND CAUSE................................................................................ 43
BACKLASH MEASUREMENT..................................................................... 50
ADJUSTMENTS.................................................................................... 61
5.1
6
B-81455EN/08
CABLE FORMING ..................................................................................... 200
CABLE REPLACEMENT ........................................................................... 215
LIMIT SWITCH REPLACEMENT (OPTION) ............................................. 234
SEVERE DUST/LIQUID PROTECTION PACKAGE ........................... 238
c-2
TABLE OF CONTENTS
B-81455EN/08
9.1
9.2
SEVERE DUST/LIQUID PROTECTION PACKAGE (OPTION)................. 239
9.1.1
Severe Dust/Liquid Protection Characteristics.....................................................239
9.1.2
Configuration of the Severe Dust/Liquid Protection Package..............................240
9.1.3
Cautions for Specifying the Severe Dust/Liquid Protection Package ..................241
REPLACING SEVERE DUST/LIQUID PROTECTION PACKAGE
COMPONENTS ......................................................................................... 242
9.2.1
Replacing Motor Covers ......................................................................................242
9.2.2
Replacing Cable Covers .......................................................................................242
9.2.3
Replacing the Batteries and Battery Box Cover...................................................245
9.2.4
Replacing the EE (I/O) Cable...............................................................................246
II. CONNECTION
1
ROBOT INTERFERENCE AREA........................................................ 249
1.1
1.2
2
MECHANICAL COUPLING TO THE ROBOT..................................... 280
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
EXTERNAL DIMENSION .......................................................................... 250
OPERATION AREA................................................................................... 260
WRIST LOAD CONDITIONS ..................................................................... 281
LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS ARM ................... 304
MECHANICAL COUPLING OF END EFFECTOR TO WRIST .................. 311
INSTALLING A FANUC/SPECIAL FLANGE ADAPTER (R-2000iA/165F, 210F,
165R AND 125L) ....................................................................................... 323
EQUIPMENT MOUNTING FACE .............................................................. 324
SETTING SYSTEM VARIABLES FOR MINIMUM CYCLE CONTROL...... 333
SETTING THE LOAD INERTIA (R-2000iA/200FO, 210F) ......................... 336
AIR SUPPLY (OPTION) ............................................................................ 339
INTERFACE FOR OPTION CABLE (OPTION) ......................................... 342
TRANSPORTATION AND INSTALLATION ....................................... 356
3.1
3.2
3.3
3.4
3.5
3.6
TRANSPORTATION.................................................................................. 357
INSTALLATION ......................................................................................... 375
MAINTENANCE AREA .............................................................................. 382
AIR PIPING (OPTION) .............................................................................. 385
INSTALLATION SPECIFICATIONS .......................................................... 387
STORAGE ................................................................................................. 389
c-3
TABLE OF CONTENTS
B-81455EN/08
APPENDIX
A
SPARE PARTS LIST .......................................................................... 393
B
CONNECTION DIAGRAM................................................................... 401
C
PERIODIC MAINTENANCE TABLE ................................................... 412
D
BOLT TIGHTENING TORQUE TABLE............................................... 422
c-4
I. MAINTENANCE
B-81455EN/08
1
MAINTENANCE
1. CONFIGURATION
CONFIGURATION
The configuration of the mechanical unit is shown in Fig.1.
Fig.1 (a) Mechanical unit configuration (R-2000iA/165F, 200F, 200FO, 210F, 125L, 130U)
NOTE
No balancer is provided for the R-2000iA/130U.
-3-
1. CONFIGURATION
MAINTENANCE
B-81455EN/08
Fig.1 (b) Mechanical unit configuration (R-2000iA/165R, 200R, 100P)
NOTE
The fan of R-2000iA/100P is installed in the J1, J2
and J3-axis motors.
-4-
B-81455EN/08
MAINTENANCE
Fig.1 (c) Mechanical unit configuration (R-2000iA/165CF)
-5-
1. CONFIGURATION
1. CONFIGURATION
1.1
MAINTENANCE
B-81455EN/08
J1-AXIS DRIVE MECHANISM
Fig.1.1 shows the J1-axis drive mechanism.
In the case of R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P,
125L and 130U the rotation of the J1-axis motor (M1) fastened to the
J2-axis base is directly input to the reducer, and the output rotates the
J2-axis base.
For the R-2000iA/165CF, the rotation of the J1-axis motor (M1)
fastened to the table is input to the reducer through the center gear, and
the output rotates the table.
Fig.1.1 (a) J1-axis drive mechanism (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.1.1 (b) J1-axis drive mechanism (R-2000iA/165CF)
-6-
B-81455EN/08
1.2
MAINTENANCE
1. CONFIGURATION
J2-AXIS DRIVE MECHANISM
Fig.1.2 shows the J2-axis drive mechanism.
Rotation of the J2-axis motor (M2) is directly fed to the reducer, and the
output moves the J2-axis arm.
Fig.1.2 J2-axis drive mechanism
-7-
1. CONFIGURATION
1.3
MAINTENANCE
B-81455EN/08
J3-AXIS DRIVE MECHANISM
Fig.1.3 shows the J3-axis drive mechanism.
Rotation of the J3-axis motor (M3) is directly fed to the reducer, and the
output moves the J3-axis arm.
Fig.1.3 J3-axis drive mechanism
-8-
B-81455EN/08
1.4
MAINTENANCE
1. CONFIGURATION
J4-AXIS DRIVE MECHANISM
Fig.1.4 shows the J4-axis drive mechanism.
Rotation of the J4-axis motor (M4) is fed to the reducer via the gear, and
the output rotates the J4-axis (all of the wrist unit).
Fig.1.4 J4-axis drive mechanism
-9-
1. CONFIGURATION
1.5
MAINTENANCE
B-81455EN/08
J5/J6-AXIS DRIVE MECHANISM
Fig.1.5 shows the J5-axis/J6-axis drive mechanism.
The rotation of the J5-axis motor (M5) is input to the reducer via the
gear and drive shaft, and the output moves the J5-axis.
The rotation of the J6-axis motor (M6) is input to the reducer via the
gear and drive shaft, and the output rotates the J6-axis (wrist flange).
Fig.1.5 J5/J6-axis drive mechanism
NOTE
All motors incorporate a brake that is applied when not energized. These brakes are
active at power-off and emergency stop.
- 10 -
1.6
1. CONFIGURATION
MAINTENANCE
B-81455EN/08
MAJOR COMPONENT SPECIFICATIONS
Motor
M1, M2, M3
M4, M5, M6
Table1.6 (a) Motor
Specifications
Model
αiS 30/3000
A06B-0267-B605#S000
(α 30/3000is)
αiS 8/4000
A06B-0235-B605#S000
(α 8/4000is)
Axis
J1, J2, J3
J4, J5, J6
Table1.6 (b) Reducer (R-2000iA/165F)
Axis
J1
J2
J3
Specifications
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
J4
A97L-0218-0355#320C-205
A97L-0218-0285#205
A290-7324-X151
A97L-0218-0370#450E-210
A97L-0218-0379#210
A290-7324-X151
A97L-0218-0371#320E-201
A97L-0218-0380#201
A290-7324-X151
A97L-0218-0281#70F-45
NOTE
The reducer specifications for the J1, J2, and J3
axes include the input gear, but do not include the
draw nut.
The input gear specifications for the J1, J2, and J3
axes include the draw nut.
Table1.6 (c) Reducer (R-2000iA/200F, 200FO, 200R, 130U)
Axis
J1
J2
J3
Specifications
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
J4
A97L-0218-0355#320C-205
A97L-0218-0285#205
A290-7324-X151
A97L-0218-0370#450E-257
A97L-0218-0379#257
A290-7324-X151
A97L-0218-0371#320E-219
A97L-0218-0380#219
A290-7324-X151
A97L-0218-0249#110E-46
NOTE
The reducer specifications for the J1, J2, and J3
axes include the input gear, but do not include the
draw nut.
The input gear specifications for the J1, J2, and J3
axes include the draw nut.
- 11 -
1. CONFIGURATION
MAINTENANCE
B-81455EN/08
Table1.6 (d) Reducer (R-2000iA/210F)
Axis
J1
J2
J3
Specifications
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
J4
A97L-0218-0355#320C-205
A97L-0218-0285#205
A290-7324-X151
A97L-0218-0370#450E-257
A97L-0218-0379#257
A290-7324-X151
A97L-0218-0372#410F-236
A97L-0218-0381#236
A290-7324-X151
A97L-0218-0342#110E-46
NOTE
The reducer specifications for the J1, J2, and J3
axes include the input gear, but do not include the
draw nut.
The input gear specifications for the J1, J2, and J3
axes include the draw nut.
Table1.6 (e) Reducer (R-2000iA/165R)
Axis
J1
J2
J3
Specifications
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
J4
A97L-0218-0355#320C-205
A97L-0218-0285#205
A290-7324-X151
A97L-0218-0370#450E-231
A97L-0218-0379#231
A290-7324-X151
A97L-0218-0371#320E-201
A97L-0218-0380#201
A290-7324-X151
A97L-0218-0281#70F-45
NOTE
The reducer specifications for the J1, J2, and J3
axes include the input gear, but do not include the
draw nut.
The input gear specifications for the J1, J2, and J3
axes include the draw nut.
- 12 -
1. CONFIGURATION
MAINTENANCE
B-81455EN/08
Table1.6 (f) Reducer (R-2000iA/100P)
Axis
J1
J2
J3
Specifications
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
J4
A97L-0218-0355#320C-205
A97L-0218-0285#205
A290-7324-X151
A97L-0218-0370#450E-257
A97L-0218-0379#257
A290-7324-X151
A97L-0218-0371#320E-201
A97L-0218-0380#201
A290-7324-X151
A97L-0218-0342#110E-46
NOTE
The reducer specifications for the J1, J2, and J3
axes include the input gear, but do not include the
draw nut.
The input gear specifications for the J1, J2, and J3
axes include the draw nut.
Table1.6 (g) Reducer (R-2000iA/165CF)
Axis
Specifications
J1
J2
J3
J4
A97L-0218-0237#320C-35
A97L-0218-0238#450E-210
A97L-0218-0239#320E-190
A97L-0218-0240#80E-37
Table1.6 (h) Reducer (R-2000iA/125L)
Axis
J1
J2
J3
Specifications
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
Reducer
Input gear
Draw nut
J4
A97L-0218-0355#320C-205
A97L-0218-0285#205
A290-7324-X151
A97L-0218-0370#450E-210
A97L-0218-0379#210
A290-7324-X151
A97L-0218-0371#320E-201
A97L-0218-0380#201
A290-7324-X151
A97L-0218-0281#70F-45
NOTE
The reducer specifications for the J1, J2, and J3
axes include the input gear, but do not include the
draw nut.
The input gear specifications for the J1, J2, and J3
axes include the draw nut.
- 13 -
1. CONFIGURATION
MAINTENANCE
B-81455EN/08
Table1.6 (i) Wrist unit
Axis
Specifications
R-2000iA/165F, 165R
A290-7324-T503
R-2000iA/200F, 200FO, 200R, 130U
A290-7321-T505
R-2000iA/210F, 100P
A290-7324-T515
R-2000iA/165CF
A290-7321-T503
R-2000iA/125L
A290-7324-T563
- 14 -
B-81455EN/08
2
MAINTENANCE
2. PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained by performing
the periodic maintenance procedures presented in this chapter.
NOTE
The periodic maintenance procedures described in
this chapter assume that the FANUC robot is used
for up to 3840 hours a year. When using the robot
beyond this total operating time, correct the
maintenance frequencies shown in this chapter by
calculation in proportion to the difference between
the actual operating time and 3840 hours/year.
- 15 -
2. PREVENTIVE MAINTENANCE
2.1
MAINTENANCE
B-81455EN/08
DAILY CHECKS
Clean each part, and visually check component parts for damage before
daily system operation. Check the following items as the occasion
demands.
1)
Before turning on power
When air control set is combined
Item
1
Check items
Air pressure
2
Oiler oil mist quantity
3
Oiler oil level
4
Leakage from hose
Check points
Check air pressure using the pressure gauge
on the air regulator as shown in Fig.2.1. If it
does not meet the specified pressure of 0.49
to 0.69 MPa (5-7 kgf/cm2), adjust it using the
regulator pressure setting handle.
Check the drop quantity during wrist or hand
motion. If it does not meet the specified value
(1 drop/10-20 sec), adjust it using the oiler
control knob. Under normal usage the oiler
becomes empty in about 10 to 20 days under
normal operation.
Check to see that the oiler level is within the
specified level shown in Fig.2.1.
Check the joints, tubes, etc. for leaks. Repair
leaks, or replace parts, as required.
Fig.2.1 Air control set
- 16 -
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B-81455EN/08
2)
After automatic operation
Item
Check items
Check points
1
Vibration, abnormal
noises, and motor
heating
2
Changing
repeatability
3
Peripheral devices for
proper operation
4
Brakes for each axis
Check whether the robot moves along and
about the axes smoothly without unusual
vibration or sounds. Also check whether the
temperature of the motors are excessively
high.
Check to see that the stop positions of the
robot have not deviated from the previous
stop positions.
Check whether the peripheral devices
operate properly according to commands
from the robot.
Check that the end effector drops within 0.2
mm when the power is cut.
- 17 -
2. PREVENTIVE MAINTENANCE
2.2
MAINTENANCE
B-81455EN/08
3-MONTH (960 HOURS) CHECKS
1)
Check the following items once every three months (or 960 hours
operating). Additional inspection areas and times should be added
to the table according to the robot's working conditions,
environment, etc.
Item
1
Check items
Control unit cable
2
Ventilation portion of
control unit
2)
Check points
Check whether the cable connected to the
teach pendant is unevenly twisted.
If the ventilation portion of the control unit is
dusty, tum off power and clean the unit.
First quarterly inspection
Check the following items at the first quarterly inspection, then
every year thereafter.
Item
Check items
1
Cables used in
mechanical unit
2
Cleaning and
checking each part
3
Further tightening
external main bolts
Check points
Check whether the jackets of the mechanical
unit cables are damaged. Also check whether
the cables are excessively bent or unevenly
twisted. Check that the connectors of the
motors and connector panels are securely
engaged. See section 7.2. (NOTE 1)
Clean each part (remove chips, etc.) and
check component parts for cracks and flaws.
(NOTE 2)
Further tighten the end-effecter mounting
bolts and external main bolts. (NOTE 3)
Note 1 Inspection points and check items of the mechanical unit cables and
connectors
Inspection points of the mechanical unit cables
Fixed part cables likely to interfere with the J1, J2, and J3 movable
parts and peripheral devices.
For the J1-axis, inspect the cables from above the J2 base and from the
side by removing the metal plate on the side of the J1 base.
Check items
For cables with a cable cover, open the cover before making the
check.
Check the cables for a sheath break and wear.
If wires of the cable appear, replace it.
- 18 -
MAINTENANCE
B-81455EN/08
2. PREVENTIVE MAINTENANCE
カバーを外す
Remove
the cover
Fig.2.2 (a) Check Items of Mechanical unit cable
Inspection points of the connectors
-
Power/brake connectors of the motor exposed externally
Robot connection cables and user cables
-
Circular connector: Check the connector for looseness by turningit
manually.
Square connector: Check the connector for disengagement of its
lever.
Check items
-
Fig.2.2 (b) Check items of connector
- 19 -
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B-81455EN/08
Note 2 Cleaning
-
-
Necessary cleaning points, dust on the flat part, sedimentation of
spatters
Clean sediments periodically.
In particular, clean the following points carefully.
1) Vicinity of the balancer rod and shaft
→ If chippings or spatters are attached to the bushing,
abnormal wear may be caused.
2) Vicinity of the wrist axis and oil seal
→ If chippings or spatters are attached to the oil seal, an oil
leak may be caused.
Check if the vicinity of the necessary inspection points, wrist part,
and J3 arm significantly wears due to rubbing against the welding
cable or hand cable.
Check if there is a trace of a collision around the gun or hand.
Check the reducer or grease bath for an oil leak.
→ If oil can be found a day after wiping oil, an oil leak may be
caused.
Fig.2.2 (c) Cleaning part
- 20 -
MAINTENANCE
B-81455EN/08
2. PREVENTIVE MAINTENANCE
Note 3 Points to be retightened
-
The end effecter mounting bolts, robot installation bolts, and bolts
to be removed for inspection need to be retightened.
The bolts exposed to the outside of the robot need to be
retightened. For the tightening torque, see the recommended bolt
tightening torque shown in the Appendix.
A loose prevention agent (adhesive) is applied to some bolts. If the
bolts are tightened with greater than the recommended torque, the
loose prevention agent may be removed. So, follow the
recommended tightening torque when retightening them.
- 21 -
2. PREVENTIVE MAINTENANCE
2.3
MAINTENANCE
B-81455EN/08
1-YEAR (3,840 HOURS) CHECKS
Check the following items once every year (or 3,840 hours operating).
Item
Check items
1
Greasing balancer
bushing
Cables used in
mechanical unit
Cleaning each parts
and inspection
Tightness of major
external bolts
2
3
4
2.4
Check points
Grease balancer bushing.
(See Section 3.2.)
(See Section 2.2.)
(See Section 2.2.)
(See Section 2.2.)
1.5-YEAR (5,760 HOURS) CHECKS
Check the following item once every 1.5 year (or 5,760 hours
operating).
Item
1
2.5
Check items
Battery
Check points
Replace battery in the mechanical unit. Refer
to Section 3.3.
3-YEAR (11,520 HOURS) CHECKS
Check the following items once every 3 years (or 11,520 hours
operating).
Item
Check items
1
Replacing grease of
each axis, reducer
and gear box
- 22 -
Check points
Refer to Section 3.1.
2.6
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B-81455EN/08
MAINTENANCE TOOLS
The following tools and instruments are required for the maintenance
procedures contained in this manual.
1)
Measuring instruments
Instruments
Accuracy/Capacity
Dial gauge accuracy
1/100 mm accuracy
Slide calipers
Push/pull tension gauge
150 mm capacity
98N (10 kgf) accuracy
2)
Applications
Measurement of
positioning and
backlash
Measurement of
backlash
Tools
Cross-point(+)screwdrivers : Large, medium, and small sizes
Conventional(-)screwdrivers : Large, medium, and small sizes
Box screw drivers
: M6
Hexagonal wrench key sets : M3 - M20
(metric)
Adjustable wrenches
: Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Double hexagon offset wrench
Grease gun
Pliers for C-retaining ring
Torque wrench
Gear puller
Hexagonal socket
: M12 (Tip length: 70mm or more.
Usedfor J3 reducer connection)
Socket
: Width across flats 50mm. (Used for
R-2000iA/165F, 200F, 200FO,
210F, 125L standard balancer
connection)
: Width across flats 65mm. (Used for
R-2000iA/165R, 200R, 100P
standard balancer connection)
Spanner
: 30×32mm or 32×36mm (Thickness:
14 mm or less for stopping J41 gear
rotation)
T-shaped hexagonal wrench : M8 (Length: 200 mm or more.
Used for wrist axis motor
connection)
M12 (Length: 280 mm or more.
Used for J3-axis motor connection)
- 23 -
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B-81455EN/08
Special Tools
Common to R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R,
100P, 125L and 130U
A290-7324-X921 2PCS
(Guide pin (M12) for J1, J2, J3-axis reducer replacement)
See Fig.2.6 (a).
A290-7324-X922
(Spring pin striking tool for J1-axis reducer replacement)
See Fig.2.6 (b).
A290-7324-X923 2PCS
(Guide pin (M16) for J1, J2, J3-axis reducer replacement)
See Fig.2.6 (c).
A290-7324-X924
(For bearing installation in the J1-axis input gear)
See Fig.2.6 (d).
Common to R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U
A290-7324-X925 4PCS
(Robot hanging tool for J1-axis reducer replacement)
See Fig.2.6 (e).
A290-7324-X926 1PCS
(Robot hanging tool for J1-axis reducer replacement)
See Fig.2.6 (f).
A290-7324-X927 1PCS
(Robot hanging tool for J1-axis reducer replacement)
See Fig.2.6 (g).
A290-7324-X928 1PCS
(Robot hanging tool for J1-axis reducer replacement)
See Fig.2.6 (h).
Common to R-2000iA
A290-7321-X947
(For bearing installation in gear J41)
See Fig.2.6 (i).
•
Options (For securing the arm during J2 or J3-axis motor
replacement)
For changing the J2-axis operating range :
A05B-1324-J032 (R-2000iA/165F, 200F, 200FO,
210F, 125L and 130U)
A05B-1324-J037 (R-2000iA/165R, 200R, 100P)
A05B-1321-J035 (R-2000iA/165CF)
For changing the J3-axis operating range :
A05B-1324-J033 (R-2000iA/165F, 125L)
A05B-1324-J035 (R-2000iA/200F, 200FO, 130U)
A05B-1324-J030 (R-2000iA/210F)
A05B-1324-J038 (R-2000iA/165R, 100P)
A05B-1324-J039 (R-2000iA/200R)
A05B-1321-J033 (R-2000iA/165CF)
- 24 -
B-81455EN/08
MAINTENANCE
2. PREVENTIVE MAINTENANCE
Fig.2.6 (a) Guide pin (M12) for J1, J2, J3-axis reducer replacement
Fig.2.6 (b) Spring pin striking tool for J1-axis reducer replacement
Fig.2.6 (c) Guide pin (M16) for J1, J2, J3-axis reducer replacement
- 25 -
2. PREVENTIVE MAINTENANCE
MAINTENANCE
Fig.2.6 (d) For bearing installation in the J1-axis input gear
Fig.2.6 (e) Robot hanging tool for J1-axis reducer replacement
- 26 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
2. PREVENTIVE MAINTENANCE
Fig.2.6 (f) Robot hanging tool for J1-axis reducer replacement
Fig.2.6 (g) Robot hanging tool for J1-axis reducer replacement
- 27 -
2. PREVENTIVE MAINTENANCE
MAINTENANCE
Fig.2.6 (h) Robot hanging tool for J1-axis reducer replacement
Fig.2.6 (i) For installing bearing on gear J41
- 28 -
B-81455EN/08
B-81455EN/08
3
MAINTENANCE
PERIODIC MAINTENANCE
- 29 -
3. PERIODIC MAINTENANCE
3. PERIODIC MAINTENANCE
3.1
MAINTENANCE
B-81455EN/08
REPLACING THE GREASE OF THE DRIVE MECHANISM
Replace the wrist grease of the reducers of J1, J2, and J3 axes, and the
J4-axis gear box, every three years or 11,520 hours by using the
following procedures.
Models
Table 3.1 Grease for 3-year (11,520 hours) periodical replacement
Supply position
Quantity
Gun tip pressure
Grease name
R-2000iA/165F
R-2000iA/165R
R-2000iA/125L
R-2000iA/200F
R-2000iA/200FO
R-2000iA/200R
R-2000iA/130U
R-2000iA/210F
R-2000iA/100P
R-2000iA/165CF
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist 1
Wrist 2
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist 1
Wrist 2
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist 1
Wrist 2
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist 1
Wrist 2
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist 1
Wrist 2
6500g (7300ml)
2530g (2860ml)
2160g (2440ml)
1440g (1620ml)
2130g (2400ml)
640g (720ml)
6500g (7300ml)
2530g (2860ml)
2160g (2440ml)
1440g (1620ml)
3500g (4000ml)
350g (400ml)
6500g (7300ml)
2700g (3100ml)
2300g (2600ml)
1500g (1700ml)
3400g (3800ml)
1000g (1100ml)
6500g (7300ml)
2530g (2860ml)
2400g (2700ml)
1500g (1700ml)
3400g (3800ml)
1000g (1100ml)
3600g (4100ml)
2300g (2600ml)
1400g (1600ml)
3400g (3950ml)
0.15MPa
or
less
(NOTE)
Kyodo yushi
VIGO GREASE
RE 0
Spec.:
A98L-0040-0174
350g (400ml)
NOTE) When a manual pump is used for greasing, the standard rate is two pumping cycles per
three seconds.
- 30 -
MAINTENANCE
B-81455EN/08
3.1.1
Grease Replacement Procedure
for the J1-Axis/J2-Axis/J3-Axis and J4-Axis Gear Box
1
2
3
4
5
3.1.2
Move the robot to the greasing attitude described in Section 3.1.4.
Turn off the power.
Remove the seal bolt from the grease outlet. (For J1-axis of
R-2000iA/165CF, remove the grease nipple of the outlet.)
Supply new grease until new grease is output from the grease
outlet.
Release residual pressure using the procedure given in Section
3.1.5.
Grease Replacement Procedure for the Wrist
(R-2000iA/165F, 210F, 165R, 100P and 125L)
1
2
3
4
5
6
7
8
3.1.3
3. PERIODIC MAINTENANCE
Move the robot to the greasing attitude described in Section 3.1.4.
Turn off the power.
Remove the seal bolt the plug with seal for 210F from wrist grease
outlet 1.
Supply new grease through the wrist grease inlet until new grease
is output from wrist grease outlet 1.
Attach the seal bolt the plug with seal for 210F onto wrist grease
outlet 1. When reusing the seal bolt or the plug with seal, be sure
to seal the seal bolt with seal tape.
Remove the seal bolt from wrist grease outlet 2.
Supply new grease through the wrist grease inlet until new grease
is output from wrist grease outlet 2.
Release residual pressure using the procedure given in Section
3.1.5.
Grease Replacement Procedure for the Wrist
(R-2000iA/200F, 200FO, 200R, 165CF and 130U)
1
2
3
4
5
6
7
8
Move the robot to the greasing attitude described in Section 3.1.4.
Turn off the power.
Remove the seal bolt from wrist grease outlet 1.
Supply new grease through the wrist grease inlet 1 until new
grease is output from wrist grease outlet 1.
Attach the seal bolt onto wrist grease outlet 1. When reusing the
seal bolt, be sure to seal the seal bolt with seal tape.
Remove the seal bolt from wrist grease outlet 2.
Supply new grease through the wrist grease inlet 2 until new
grease is output from wrist grease outlet 2.
Release residual pressure using the procedure given in Section
3.1.5.
- 31 -
3. PERIODIC MAINTENANCE
MAINTENANCE
B-81455EN/08
NOTE
If greasing is performed incorrectly, the internal
pressure of the grease bath may suddenly increase,
possibly causing damage to the seal, which would in
turn lead to grease leakage and abnormal operation.
When performing greasing, therefore, observe the
following cautions.
1 Before starting to grease, open the grease outlet
(remove the plug or bolt from the grease outlet).
2 Supply grease slowly without applying excessive
force, using a manual pump.
3 Whenever possible, avoid using a compressed-air
pump, powered by the factory air supply. If the use
of an air pump is unavoidable, supply grease with
the pump at a pressure lower than or equal to the
gun tip pressure (See Table 3.1.)
4 Use grease only of the specified type. Grease of a
type other than that specified may damage the
reducer or lead to other problems.
5 After greasing, release residual pressure using the
procedure given in Section 3.1.5.
6 To prevent accidents caused by slipping, completely
remove any excess grease from the floor or robot.
3.1.4
Attitude for Greasing
For grease replacement or replenishment, use the attitudes indicated
below.
Table 3.1.4 (a) Attitudes for greasing (R-2000iA/165F, 200F, 200FO, 210F, 165CF, 125L and 130U)
Supply position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist
Attitude
J1
J2
Arbitrary
Arbitrary
0°
0°
Arbitrary
J3
J4
J5
J6
Arbitrary
Arbitrary
Arbitrary
0°
0°
0°
Arbitrary
0°
0°
0°
Table 3.1.4 (b) Attitudes for greasing (R-2000iA/165R, 200R and 100P)
Supply position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist
Attitude
J1
Arbitrary
J2
Arbitrary
-90°
-90°
Arbitrary
J3
J4
J5
J6
Arbitrary
Arbitrary
Arbitrary
0°
0°
0°
Arbitrary
90°
90°
90°
- 32 -
B-81455EN/08
MAINTENANCE
3. PERIODIC MAINTENANCE
Fig.3.1.4 (a) Replacing grease of J1/J2-axis reducer
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.3.1.4 (b) Replacing grease of J1/J2-axis reducer (R-2000iA/165CF)
- 33 -
3. PERIODIC MAINTENANCE
MAINTENANCE
Fig.3.1.4 (c) Replacing grease of J3-axis reducer and J4-axis gear box
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.3.1.4 (d) Replacing grease of wrist (R-2000iA/165F, 210F, 165R and 125L)
- 34 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
3. PERIODIC MAINTENANCE
Fig.3.1.4 (e) Replacing grease of wrist (R-2000iA/200F, 200FO, 200R and 130U)
Fig.3.1.4 (f) Replacing grease of wrist (R-2000iA/210F and 100P)
- 35 -
3. PERIODIC MAINTENANCE
MAINTENANCE
B-81455EN/08
Fig.3.1.4 (g) Replacing grease of J3-axis reducer/J4 gear box/wrist (R-2000iA/165CF)
3.1.5
Procedure for Releasing Residual Pressure from the Grease
Bath
Release residual pressure as described below.
Under the grease inlets and outlets, attach bags for collecting grease so
that grease does not spatter when it comes out of the inlets or outlets.
Grease
replacement
position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Motion angle
OVR
Operating
time
Open
point
80° or more
90° or more
70° or more
J4 : 60° or more
J5 : 120° or more
J6 : 60° or more
50%
50%
50%
20 minutes
20 minutes
20 minutes
A
A
A
100%
20 minutes
B
100%
10 minutes
C
J4 : 60° or more
J5 : 120° or more
J6 : 60° or more
Wrist
In the case of A
Open the grease inlets and outlets and perform running.
In the case of B
Open the grease outlets only and perform running.
In the case of C
Open all of the grease inlets and outlets shown below and perform
running.
- 36 -
B-81455EN/08
3. PERIODIC MAINTENANCE
MAINTENANCE
Wrist grease outlet 2
M6×8 (seal bolt)
Left side
Also open here
Wrist grease
inlet
Grease nipple
Wrist grease outlet 1
M6×8 (seal bolt)
Right side
Fig.3.1.5 (a) In case of R-2000iA/165F, 165R, 125L, 100P and 210F
Wrist grease outlet 1
M6×8 (seal bolt)
Also
open
ここも開ける
here
Left side
Wrist grease
inlet 1
Grease nipple
Wrist grease outlet 2
M6×8 (seal bolt)
Right side
Wrist grease inlet 2
Grease nipple
Fig.3.1.5 (b) In case of R-2000iA/200F, 200FO, 200R, 130U and 165CF
If the above operation cannot be performed due to the environment of
the robot, prolong the operating time so that an equivalent operation can
be performed. (If only half of the predetermined motion angle can be
set, perform an operation for a period of time twice as long as the
specified time.) After completion of the operation, attach the seal bolts
and grease nipples to the grease inlets and outlets. When reusing the
seal bolts and grease nipples, be sure to seal them with seal tape.
- 37 -
3. PERIODIC MAINTENANCE
3.2
MAINTENANCE
B-81455EN/08
GREASING OF THE BALANCER SHAFT
Fig.3.2 shows the balancer shaft greasing points. No balancer is
provided for the R-2000iA/165CF and 130U.
Apply grease
periodically according to Table 3.2 (a). If the robot is installed in a
severe environment, apply grease whenever necessary. If water
splashes on the robot, apply grease immediately.
Table 3.2 (a) Greasing of the Balancer Shaft
Grease
Amount
Greasing interval
SHELL
ALVANIA Grease S2
(Spec: A97L-0001-0179#2)
10 ml each
(2 locations)
Every 1 year
or
every time a total operating
time of 3840 hours is reached.
Table 3.2 (b) Substitutes for ALVANIA Grease S2
MOBIL OIL
ESSO STANDARD
NIPPON OIL
NIPPON OIL
IDEMITSU KOHSAN
COSMO OIL
MOBILACKS GREASE NO.2
VICON NO.2
MULTINOC 2
EPINOC AP-2
EPONEX GREASE NO.2
DYNAMAX NO.2
Fig.3.2 Greasing for the Balancer Shaft (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P and 125L)
NOTE
No balancer is provided for the R-2000iA/165CF
and 130U.
- 38 -
MAINTENANCE
B-81455EN/08
3.3
3. PERIODIC MAINTENANCE
REPLACING THE BATTERIES
The position data of each axis is preserved by the backup batteries. The
batteries need to be replaced every 1.5 year. Also use the following
procedure to replace when the backup battery voltage drop alarm
occurs.
1
Keep the power on. Press the EMERGENCY STOP button to
prohibit the robot motion.
NOTE
Replacing the batteries with the power supply turned
off causes all current position data to be lost.
Therefore, mastering will be required again.
2
3
4
5
Remove the battery case cap.
Take out the old batteries from the battery case.
Insert new batteries into the battery case.
Pay attention to the direction of batteries.
Close the battery case cap.
Fig.3.3 (a) Replacing Batteries
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
- 39 -
3. PERIODIC MAINTENANCE
MAINTENANCE
B-81455EN/08
Fig.3.3 (b) Replacing Batteries (R-2000iA/165CF)
- 40 -
B-81455EN/08
4
MAINTENANCE
TROUBLESHOOTING
- 41 -
4. TROUBLESHOOTING
4. TROUBLESHOOTING
4.1
MAINTENANCE
B-81455EN/08
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.
- 42 -
MAINTENANCE
B-81455EN/08
4.2
4. TROUBLESHOOTING
FAILURE AND CAUSE
Table 4.2 lists the major failures that may occur in the mechanical unit
and their probable causes. If you cannot pinpoint a failure cause or
which measures to apply, contact FANUC. If you have to replace
components or make adjustments to repair the failure, see Sections 5, 6,
and 8.
Symptom
Vibration
Noise
Description
Table 4.2 Failures and Causes
Cause
Measure
- Re-weld the base plate to the
- As the robot operates, its base [Base plate and floor plate
floor plate.
fastening]
plate lifts off the floor plate.
- If the weld is not strong enough,
- There is a gap between the base - It is likely that the base plate is
not securely fastened to the floor increase its width and length.
plate and the floor plate.
plate because of poor welding.
- There is a crack in the weld that
fastens the base plate to the floor - If the base plate is not securely
fastened to the floor plate, it lifts
plate.
as the robot operates, allowing
the base and floor plates to strike
each other which, in turn, leads
to vibration.
- If a bolt is loose, apply loctite and
[J1 base fastening]
- The J1 base lifts off the base
- It is likely that the robot J1 base is tighten it to the appropriate
plate as the robot operates.
not securely fastened to the base torque.
- There is a gap between the J1
- Adjust the base plate surface
plate.
base and base plate.
- A J1 base retaining bolt is loose. - Probable causes are a loose bolt, flatness to within the specified
tolerance.
an insufficient degree of surface
- If there is any foreign matter
flatness, or foreign material
between the J1 base and base
caught between the base plate
plate, remove it.
and floor plate.
- As the robot operates, the rack or
- If the robot is not securely
fastened to the base plate, the J1 floor on which the robot is
mounted vibrates.
base lifts the base plate as the
robot operates, allowing the base
and floor plates to strike each
other which, in turn, leads to
vibration.
- Reinforce the rack or floor to
- Apply epoxy to the floor surface [Rack or floor]
and re-install the plate.
- It is likely that the rack or floor is make it more rigid.
- If it is impossible to reinforce the
not sufficiently rigid.
rack or floor, modify the robot
- If the rack or floor is not
control program; doing so might
sufficiently rigid, reaction from
reduce the amount of vibration.
the robot deforms the rack or
floor, leading to vibration.
- 43 -
4. TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)
MAINTENANCE
B-81455EN/08
Description
Cause
Measure
- Vibration becomes more serious [Overload]
- Check the maximum load that
when the robot adopts a specific - It is likely that the load on the
the robot can handle once more.
posture.
robot is greater than the
If the robot is found to be
- If the operating speed of the
maximum rating.
overloaded, reduce the load, or
robot is reduced, vibration stops. - It is likely that the robot control
modify the robot control program.
- Vibration is most noticeable
program is too demanding for the - Vibration in a specific portion can
when the robot is accelerating.
robot hardware.
be reduced by modifying the
- Vibration occurs when two or
robot control program while
more axes operate at the same
slowing the robot and reducing
time.
its acceleration (to minimize the
influence on the entire cycle
time).
- Vibration was first noticed after [Broken gear, bearing, or reducer] - Operate one axis at a time to
the robot collided with an object - It is likely that collision or
determine which axis is vibrating.
or the robot was overloaded for a overload applied an excessive
- Find the source of the vibration
long period.
force on the drive mechanism,
while referring to the drive
- The grease of the vibrating axis
thus damaging the gear tooth
mechanism drawing of each axis
has not been exchanged for a
surface or rolling surface of a
given in the related maintenance
long period.
bearing, or reducer.
manual.
- It is likely that prolonged use of - Remove the motor, and check
the robot while overloaded
whether there are any fretting on
caused fretting of the gear tooth
a gear tooth surface. If any
surface or rolling surface of a
fretting is found, replace the
bearing, or reducer due to
gear.
resulting metal fatigue.
Note) Even a small amount of
- It is likely that foreign matter
damage on a gear tooth surface
caught in a gear, bearing, or
can generate a large amount of
within a reducer caused damage noise. Therefore, it is necessary
on the gear tooth surface or
to check each gear tooth surface
rolling surface of the bearing, or
carefully.
reducer.
- Check whether any other gear in
- It is likely that, because the
the drive mechanism is
grease has not been changed for abnormal. If all the gears are
a long period, fretting occurred
found to be satisfactory, the
on the gear tooth surface or
reducer must be replaced.
rolling surface of a bearing, or
- If there is foreign matter caught in
reducer due to metal fatigue.
a gear, or if a gear tooth is
These factors all generate cyclic
missing, replace the gear. Also,
vibration and noise.
remove all the grease from the
gear box and wash the inside of
the gear box.
- After replacing the gear or
reducer, add an appropriate
amount of grease.
- If nothing changes after a gear or
reducer is replaced, it is likely
that a bearing is damaged.
- Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
- Regularly changing the grease
with a specified type can help
prevent problems.
- 44 -
MAINTENANCE
B-81455EN/08
Symptom
Vibration
Noise
(Continued)
Description
Cause
4. TROUBLESHOOTING
Measure
- Refer to the R-J3iB Controller
- The cause of problem cannot be [Controller, cable, and motor]
Maintenance Manual for
identified from examination of the - If a failure occurs in a controller
troubleshooting related to the
circuit, preventing control
floor, rack, or mechanical
controller and amplifier.
commands from being supplied
section.
- Replace the pulse coder for the
to the motor normally, or
motor of the axis that is vibrating,
preventing motor information
and check whether the vibration
from being sent to the controller
still occurs.
normally, vibration might occur.
- Also, replace the motor of the
- If the pulse coder develops a
axis that is vibrating, and check
fault, vibration might occur
whether vibration still occurs.
because information about the
- Check that the robot is supplied
motor position cannot be
with the rated voltage.
transferred to the controller
- Check whether the sheath of the
accurately.
power cord is damaged. If so,
- If the motor becomes defective,
replace the power cord, and
vibration might occur because
the motor cannot deliver its rated check whether vibration still
occurs.
performance.
- If a power line in a movable cable - Check whether the sheath of the
of the mechanical section has an cable connecting the mechanical
section and controller is
intermittent break, vibration
damaged. If so, replace the
might occur because the motor
connection cable, and check
cannot accurately respond to
whether vibration still occurs.
commands.
- If a pulse coder wire in a movable - If vibration occurs only when the
robot assumes a specific
part of the mechanical section
posture, it is likely that a cable in
has an intermittent break,
the mechanical unit is broken.
vibration might occur because
commands cannot be sent to the - Shake the movable part cable
while the robot is at rest, and
motor accurately.
check whether an alarm occurs.
- If a connection cable between
If an alarm or any other abnormal
them has an intermittent break,
condition occurs, replace the
vibration might occur.
- If the power source voltage drops mechanical unit cable.
below the rating, vibration might - Check that the robot control
parameter is set to a valid value.
occur.
- If a robot control parameter is set If it is set to an invalid value,
correct it. Contact FANUC for
to an invalid value, vibration
further information if necessary.
might occur.
- Connect the grounding wire
[Noise from a nearby machine]
- There is some relationship
firmly to ensure a reliable ground
between the vibration of the robot - If the robot is not grounded
potential and prevent extraneous
properly, electrical noise is
and the operation of a machine
electrical noise.
induced on the grounding wire,
near the robot.
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.
- 45 -
4. TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)
Rattling
MAINTENANCE
Description
Cause
B-81455EN/08
Measure
- There is an unusual sound after - There may be an unusual sound - Use the specified grease.
- When there is an unusual sound
when using other than the
replacement of grease.
even for specified grease,
- There is an unusual sound after a specified grease.
perform operation for one or two
- Even for the specified grease,
long period of time.
days on an experiment.
- There is an unusual sound during there may be an unusual sound
Generally, an usual sound will
during operation at low speed
operation at low speed.
immediately after replacement or disappear.
after a long period of time.
[Mechanical section coupling bolt] Check that the following bolts for
- While the robot is not supplied
each axis are tight. If any of these
- It is likely that overloading or a
with power, pushing it with the
bolts is loose, apply loctite and
collision has loosened a
hand causes part of the
tighten it to the appropriate torque.
mounting bolt in the robot
mechanical unit to wobble.
- Motor retaining bolt
mechanical section.
- There is a gap on the mounting
- Reducer retaining bolt
surface of the mechanical unit.
- Reducer shaft retaining bolt
- Base retaining bolt
- Arm retaining bolt
- Casting retaining bolt
- End effecter retaining bolt
- Operate one axis at a time to
[Increase in backlash]
- Backlash is greater than the
determine which axis has the
tolerance stated in the applicable - It is likely that excessive force
increased backlash.
applied to the drive mechanism,
maintenance manual.
due to a collision or overloading, - Remove the motor, and check
has broken a gear or the inside of whether any of its gears are
broken. If any gear is broken,
the reducer, resulting in an
replace it.
increase in the amount of
- Check whether any other gear of
backlash.
the drive mechanism is damage.
- It is likely that prolonged use
without changing the grease has If there is no damage gear,
replace the reducer.
caused the tooth surfaces of a
- If the reducer is broken, or if a
gear and the inside of the
gear tooth is missing, replace the
reducer to wear out, resulting in
relevant component. Also,
an increase in the amount of
remove all the grease from the
backlash.
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.
- 46 -
MAINTENANCE
B-81455EN/08
Symptom
Motor
overheating
Description
Cause
- The ambient temperature of the [Ambient temperature]
- It is likely that a rise in the
installation location increases,
ambient temperature or
causing the motor to overheat.
- After a cover was attached to the attaching the motor cover
prevented the motor from
motor, the motor overheated.
- After the robot control program or releasing heat efficiently, thus
the load was changed, the motor leading to overheating.
[Operating condition]
overheated.
- It is likely that the robot was
operated with the maximum
average current exceeded.
4. TROUBLESHOOTING
Measure
The teach pendant can be used to
monitor the average current.
Check the average current when
the robot control program is
running. The allowable average
current is specified for the robot
according to its ambient
temperature. Contact FANUC for
further information.
- Relaxing the robot control
program and conditions can
reduce the average current, thus
preventing overheating.
- Reducing the ambient
temperature is the most effective
means of preventing
overheating.
- Having the surroundings of the
motor well ventilated enables the
motor to release heat efficiently,
thus preventing overheating.
Using a fan to direct air at the
motor is also effective.
- If there is a source of heat near
the motor, it is advisable to install
shielding to protect the motor
from heat radiation.
- Input an appropriate parameter
as described in the manual.
- After a control parameter was
[Parameter]
changed, the motor overheated. - If data input for a workpiece is
invalid, the robot cannot be
accelerated or decelerated
normally, so the average current
increases, leading to
overheating.
Repair the mechanical unit while
- Symptom other than stated
[Mechanical section problems]
above
- It is likely that problems occurred referring to the above descriptions
of vibration, noise, and rattling.
in the mechanical unit drive
- Check that, when the servo
mechanism, thus placing an
system is energized, the brake is
excessive load on the motor.
released.
[Motor problems]
- If the brake remains applied to
- It is likely that a failure of the
motor brake resulted in the motor the motor all the time, replace the
motor.
running with the brake applied,
- If the average current falls after
thus placing an excessive load
the motor is replaced, it indicates
on the motor.
that the first motor was faulty.
- 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.
- 47 -
4. TROUBLESHOOTING
Symptom
MAINTENANCE
Description
Cause
B-81455EN/08
Measure
- If a crack develops in the casting,
[Poor sealing]
sealant can be used as a
- Probable causes are a crack in
quick-fix to prevent further
the casting, a broken O-ring, a
damaged oil seal, or a loose seal grease leakage. However, the
component should be replaced
bolt.
as soon as possible, because the
- A crack in a casting can occur
due to excessive force that might crack might extend.
- O-rings are used in the locations
be caused in collision.
- An O-ring can be damaged if it is listed below.
- Motor coupling section
trapped or cut during
disassembling or re-assembling. - Reducer (case and shaft)
coupling section
- An oil seal might be damaged if
extraneous dust scratches the lip - Wrist coupling section
- J3 arm coupling section
of the oil seal.
- Inside the wrist
- A loose seal bolt might allow
grease to leak along the threads. - Oil seals are used in the locations
stated below.
- Problems with the grease nipple
- J1 axis cable pipe joint
or threads.
- Inside the reducer
- Inside the wrist
- Seal bolts are used in the
locations stated below. Refer to
the relevant parts manual for
detailed descriptions of their
replacement.
- J2 and J3-axis motor mounting
section
- Grease drain outlet
- Check whether the brake drive
Dropping axis - An axis drops because the brake [Brake drive relay and motor]
relay contacts are stuck to each
- It is likely that brake drive relay
does not function.
other, as explained in the
contacts are stuck to each other
- An axis drops gradually when it
to keep the brake current flowing, relevant manual. If they are
should be at rest.
found to be stuck, replace the
thus preventing the brake from
relay.
operating when the motor is
- If the brake shoe is worn out, if
deenergized.
- It is likely that the brake shoe has the brake main body is damaged,
worn out or the brake main body or if oil or grease has entered the
motor, replace the motor.
is damaged, preventing the
brake from operating efficiently.
- It is likely that oil or grease has
entered the motor, causing the
brake to slip.
- If the repeatability is unstable,
[Mechanical section problems]
Displacement - The robot operates at a point
repair the mechanical section by
- If the repeatability is unstable,
other than the taught position.
referring to the above
- The repeatability is not within the probable causes are a failure in
descriptions of vibration, noise,
the drive mechanism or a loose
tolerance.
and rattling.
bolt.
- If the repeatability is stable,
- If the repeatability becomes
correct the taught program.
stable it is likely that a collision
Variation will not occur unless
imposed an excessive load,
another collision occurs.
leading to slipping on the base
surface or the mating surface of
an arm or reducer.
Grease
leakage
- Grease is leaking from the
mechanical unit.
- 48 -
MAINTENANCE
B-81455EN/08
Symptom
Description
Displacement - Displacement occurs only in a
(Continued)
specific peripheral unit.
- Displacement occurred after a
parameter was changed.
BZAL alarm
occured
- BZAL is displayed on the
controller screen.
Cause
4. TROUBLESHOOTING
Measure
- Correct the setting of the
[Peripheral unit displacement]
peripheral unit position.
- It is likely that an external force
- Correct the taught program.
was applied to the peripheral
unit, thus shifting its position
relative to the robot.
- Re-enter the previous mastering
[Parameter]
- It is likely that the mastering data data, which is known to be
correct.
was rewritten in such a way that
- If correct mastering data is
the robot origin was shifted.
unavailable, perform mastering
again.
- Replace the battery.
- The voltage of the memory
- Replace the cable.
backup battery is low.
- The pulse coder cable is
defected.
- 49 -
4. TROUBLESHOOTING
4.3
MAINTENANCE
B-81455EN/08
BACKLASH MEASUREMENT
Measurement method
1.
2.
3.
Maintain the robot in a specified posture. (See Table 4.3 (a),(b)
and Fig. 4.3 (b),(c).)
Apply positive and negative loads to each axis as shown in Fig. 4.3
(a).
Remove the loads and measure the displacement.
Measure backlash by applying positive and negative loads to each axis
three times. Average the values measured in the last two measurements
for each axis,
and use the averages as a measured backlash for the respective axes.
Fig.4.3 (a) Backlash Measurement Method
Backlash B is calculated using the following expression:
B2＋B3
B＝
2
- 50 -
B-81455EN/08
4. TROUBLESHOOTING
MAINTENANCE
Measurement posture and position
• R-2000iA/165F, 200F, 200FO, 210F, 165CF, 125L and 130U
Table 4.3 (a) Backlash Measurement Posture
(R-2000iA/165F, 200F, 200FO, 210F, 165CF, 125L, 130U)
Measured
axis
J1
J1
Any angle
J2
Any angle
Any angle
J3 165F,
200F,
200FO,
210F,
130U
165CF Any angle
125L
(Any angle)
Any angle
J4 165F,
200F,
200FO,
210F,
165CF,
130U
125L
(Any angle)
J5
Any angle
J6
Any angle
J2
Posture
J3
J4
J5
J6
75°
0°
40°
0°
82°
-90°
0°
0°
-90°
0°
0°
90°
90°
0°
90°
40°
(40°)
40°
-90°
(-90°)
-90°
-90°
(-90°)
-90°
90°
(90°)
90°
-90°
(90°)
90°
(40°)
0°
0°
(-90°)
0°
0°
(-90°)
-90°
0°
(90°)
90°
-90°
(90°)
90°
90°
NOTE
NOTE
NOTE
When the R-2000iA/125L is set to a posture (J3 at
-90° in which no gravity is applied to the J3 and J4
axes, the robot wrist interferes with the J1 base
ground side. Therefore, backlashes for the J3 and
J4 axes cannot be measured, unless sufficient
operating space is provided in the lower area ahead
of the robot, for example, by installing the robot on
the pedestal.
- 51 -
4. TROUBLESHOOTING
MAINTENANCE
B-81455EN/08
Fig.4.3 (b) Backlash Measurement Posture (R-2000iA/165F, 200F, 200FO, 210F, 165CF, 125L and 130U) (1/2)
- 52 -
B-81455EN/08
MAINTENANCE
4. TROUBLESHOOTING
Fig.4.3 (b) Backlash Measurement Posture (R-2000iA/165F, 200F, 200FO, 210F, 165CF, 125L and 130U) (2/2)
- 53 -
4. TROUBLESHOOTING
MAINTENANCE
B-81455EN/08
• R-2000iA/165R, 200R and 100P
Table 4.3 (b) Backlash Measurement Posture
(R-2000iA/165R, 200R and 100P)
Measured
axis
J1
J2
J3
J4
J5
J6
J1
J2
Posture
J3
J4
J5
J6
Any angle
––
Any angle
Any angle
Any angle
Any angle
15°
–
-30°
30°
65°
65°
60°
–
0°
0°
-90°
-90°
0°
–
0°
90°
90°
-90°
90°
–
90°
90°
90°
90°
0°
–
-90°
-90°
-90°
0°
NOTE
NOTE
When the R-2000iA/165R, 200R or 100P is used,
backlash for the J2 axis cannot be measured
because the balancer force or gravity is always
applied to the J2 axis.
- 54 -
B-81455EN/08
MAINTENANCE
4. TROUBLESHOOTING
Fig.4.3 (c) Backlash Measurement Posture (R-2000iA/165R and 200R) (1/2)
- 55 -
4. TROUBLESHOOTING
MAINTENANCE
Fig.4.3 (c) Backlash Measurement Posture (R-2000iA/165R and 200R) (2/2)
- 56 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
4. TROUBLESHOOTING
Fig.4.3 (d) Backlash Measurement Posture (R-2000iA/100P) (1/2)
- 57 -
4. TROUBLESHOOTING
MAINTENANCE
Fig.4.3 (d) Backlash Measurement Posture (R-2000iA/100P) (2/2)
- 58 -
B-81455EN/08
4. TROUBLESHOOTING
MAINTENANCE
B-81455EN/08
Permissible backlash values
Table 4.3 (c) Permissible Backlash Value (R-2000iA/165F)
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.37
Displacement conversion (mm) 2.15
Distance between the rotation
3118
center and dial indicator (mm)
2.00
0.63
2.00
0.74
2.30
0.35
3.06
0.46
6.41
0.56
1075
1280
519
519
301
Table 4.3 (d) Permissible Backlash Value (R-2000iA/200F)
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.37
Displacement conversion (mm) 2.09
Distance between the rotation
3033
center and dial indicator (mm)
2.00
0.63
2.00
0.65
2.28
0.38
2.86
0.48
4.91
0.53
1075
1110
572
572
370
Table 4.3 (e) Permissible Backlash Value (R-2000iA/200FO/130U)
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.37
Displacement conversion (mm) 2.21
Distance between the rotation
3200
center and dial indicator (mm)
2.00
0.63
2.00
0.65
2.28
0.38
2.86
0.48
4.91
0.53
1075
1110
572
572
370
Table 4.3 (f) Permissible Backlash Value (R-2000iA/210F)
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.37
Displacement conversion (mm) 2.19
Distance between the rotation
3178
center and dial indicator (mm)
2.00
0.63
2.00
0.74
2.28
0.36
2.99
0.48
5.49
0.59
1075
1280
548
548
370
Table 4.3 (g) Permissible Backlash Value (R-2000iA/165R)
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.37
Displacement conversion (mm) 2.35
Distance between the rotation
3402
center and dial indicator (mm)
–
–
2.00
1.03
2.30
0.35
3.06
0.46
6.41
0.56
–
1768
519
519
301
Table 4.3 (h) Permissible Backlash Value (R-2000iA/200R)
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.37
Displacement conversion (mm) 2.29
Distance between the rotation
3328
center and dial indicator (mm)
–
–
2.00
0.98
2.28
0.38
2.86
0.48
4.91
0.53
–
1682
572
572
370
Table 4.3 (i) Permissible Backlash Value (R-2000iA/100P)
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.37
Displacement conversion (mm) 2.83
Distance between the rotation
4101
center and dial indicator (mm)
–
–
2.00
1.50
2.28
0.59
2.99
0.77
5.49
1.49
–
2575
885
885
935
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4. TROUBLESHOOTING
MAINTENANCE
B-81455EN/08
Table 4.3 (j) Permissible Backlash Value (R-2000iA/165CF)
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.40
Displacement conversion (mm) 1.33
Distance between the rotation
1912
center and dial indicator (mm)
2.00
0.32
2.00
0.52
2.14
0.32
3.28
0.49
7.28
0.62
550
887
513
513
294
Table 4.3 (k) Permissible Backlash Value (R-2000iA/125L)
J1
J2
J3
J4
J5
J6
Angle conversion (arc-min)
2.37
Displacement conversion (mm) 2.32
Distance between the rotation
3368
center and dial indicator (mm)
2.00
0.63
2.00
0.95
2.32
0.28
3.39
0.41
8.27
0.72
1075
1635
412
412
299
NOTE
When the R-2000iA/165R, 200R or 100P is used,
backlash for the J2 axis cannot be measured
because the balancer force or gravity is always
applied in the operating direction of the J2 axis.
- 60 -
B-81455EN/08
5
MAINTENANCE
5. ADJUSTMENTS
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 a long period
of use or after parts are replaced, adjustments may be required.
- 61 -
5. ADJUSTMENTS
5.1
MAINTENANCE
B-81455EN/08
AXIS LIMITS SETUP
Axis limits define the motion range of the robot. The operating range of
the robot axes can be restricted because of:
•
Work area limitations
•
Tooling and fixture interference points
•
Cable and hose lengths
There are three methods used to prevent the robot from going beyond
the necessary motion range. These are
•
Axis limit software settings (All axes)
•
Axis limit hardstops ((J1, J2, J3 axis) optional)
•
Axis limit switches ((J1, J2, J3 axis) optional)
NOTE
1 Changing the movable range of any axis affects the
operation range of the robot. To avoid trouble,
carefully consider a possible effect of the change to
the movable range of each axis in advance.
Otherwise, it is likely that an unexpected condition
occurs; for example, an alarm may occur in a
previous taught position.
2 For the J1, J2, and J3 axes, do not count merely on
software-based limits to the movable range when
changing the movable range of the robot. Use
mechanical stoppers together so that damage to
peripheral equipment and injuries to human bodies
can be avoided. In this case, make the
software-specified limits match the limits based on
the mechanical stoppers.
3 Mechanical stoppers are physical obstacles. The
robot cannot move beyond them. For the J1, J2, and
J3 axes, it is possible to re-position the mechanical
stoppers. For J5 axis, the mechanical stoppers are
fixed. For the J4 and J6 axes, only
software-specified limits are available.
4 For changing J2 and J3 axes interference angles,
only mechanical stoppers are available; a
software-specified movable range cannot be
changed.
5 Movable mechanical stoppers (J1, J2, and J3 axes)
are deformed in a collision to stop the robot. Once a
stopper is subject to a collision, it can no longer
assure its original strength and, therefore, may not
stop the robot. When this happens, replace it with a
new one.
Upper Limits
- 62 -
MAINTENANCE
B-81455EN/08
5. ADJUSTMENTS
Displays the upper limits of each axis, or the axis limits in a positive
direction.
Lower Limits
Displays the lower limits of each axis, or the axis limits in a negative
direction.
5.1.1
Zero Point Position and Motion Limit
Zero point and software motion limit are provided for each controlled
axis. The robot cannot exceed the software motion limit unless there is
a failure of the system causing loss of zero point position or there is a
system error.
Exceeding the software motion limit of a controlled axis is called
overtravel (OT). Overtravel is detected at both ends of the motion limit
for each axis.
Fig.5.1.1 (a) - (m) show the zero point and motion limit, LS detection
position, and mechanical stopper position of each axis.
Fig.5.1.1 (a) J1-axis (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
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5. ADJUSTMENTS
MAINTENANCE
Fig.5.1.1 (b) J1-axis (R-2000iA/165CF)
Fig.5.1.1 (c) J2-axis (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
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B-81455EN/08
B-81455EN/08
MAINTENANCE
Fig.5.1.1 (d) J2-axis (R-2000iA/165R, 200R and 100P)
Fig.5.1.1 (e) J2-axis (R-2000iA/165CF)
- 65 -
5. ADJUSTMENTS
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Fig.5.1.1 (f) J3-axis (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
Fig.5.1.1 (g) J3-axis (R-2000iA/165R, 200R and 100P)
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B-81455EN/08
MAINTENANCE
5. ADJUSTMENTS
Fig.5.1.1 (h) J3-axis (R-2000iA/165CF)
Fig.5.1.1 (i) J2/J3-axis interference angle
(R-2000iA/165F, 200F, 210F, 200FO, 165R, 200R, 100P, 125L and 130U)
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5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Fig.5.1.1 (j) J2/J3-axis interference angle (R-2000iA/165CF)
Fig.5.1.1 (k) J4-axis
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B-81455EN/08
5. ADJUSTMENTS
MAINTENANCE
Fig.5.1.1 (l) J5-axis
Fig.5.1.1 (m) J6-axis
- 69 -
5. ADJUSTMENTS
5.1.2
MAINTENANCE
B-81455EN/08
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.
NOTE
0 indicates the robot does not have these axes.
5
Move the cursor to the axis limit you want to set.
WARNING
Do not depend on J1, J2, and J3 axis limit software
settings to control the motion range of your robot.
Use the axis limit switches or hardstops also;
otherwise injury to personnel or damage to
equipment could occur.
6
7
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.
WARNING
You must turn off the controller and then turn it back
on to use the new information; otherwise injury to
personnel or damage to equipment could occur.
8
Turn off the controller and then turn it back on again so the new
information can be used.
- 70 -
MAINTENANCE
B-81455EN/08
5.1.3
5. ADJUSTMENTS
Hard Stopper and Limit Switch Setting
For the J1, J2, and J3 axes, it is possible to re-position mechanical
stoppers. Change the position of the mechanical stoppers according to
the desired movable range. The limit switch-based movable range can
be changed by changing the dog positions as shown in Figures 5.1.3 (a),
(b), and (c). The dog for the J1 axis is placed in the same position as the
mechanical stopper.
Item
J1 axis mechanical Upper limit
stopper, limit switch Lower limit
Space between the
upper and lower limits
J2 axis mechanical Upper limit
stopper
Lower limit
J2 axis limit switch
Space between the
upper and lower limits
Upper limit
Lower limit
J3 axis (J2+J3)
mechanical stopper
Space between the
upper and lower limits
Upper limit
Lower limit
Space between the
upper and lower limits
J3 axis (J2+J3) limit Upper limit
switch
Lower limit
Space between the
upper and lower limits
R-2000iA/165F/210F/125L
R-2000iA/200F/200FO/130U
Settable in steps of 7.5° degrees in a range of -112.5° to +180° degrees
Settable in steps of 7.5° degrees in the range of -180° to +112.5° degrees
A space of 67.5° degrees or more is required.
Settable in steps of 15° degrees in the range of -45° to +60° degrees. A
mechanical stopper is also provided at the upper limit +75° degrees of the
standard movable range.
Settable in steps of 15° degrees in the range of -45° to +60° degrees. A
mechanical stopper is also provided at the lower limit -60° degrees of the
standard movable range.
A space of 15° degrees or more is required.
Settable in steps of 15° degrees in the range of -45° to +60° degrees. Also
settable to the upper limit +75° degrees of the standard movable range.
Settable in steps of 15° degrees in the range of -45° to +60° degrees. Also
settable to the lower limit -60° degrees of the standard movable range.
A space of 15° degrees or more is required.
Settable in steps of 15° degrees in the range of -45° to +180° degrees. A
mechanical stopper is also provided at the upper limit +195° degrees of
the standard movable range.
Settable in steps of 15° degrees in Settable in steps of 15° degrees in
the range of -60° to +150° degrees. the range of -60° to +150° degrees.
A mechanical stopper is also
A mechanical stopper is also
provided at the lower limit -79°
provided at the lower limit -76°
degrees of the standard movable
degrees of the standard movable
range.
range.
A space of 30° degrees or more is required.
Settable in steps of 15° degrees in the range of -45° to +180° degrees.
Also settable to the upper limit +195° degrees of the standard movable
range.
Settable in steps of 15° degrees in Settable in steps of 15° degrees in
the range of -75° to +165° degrees. the range of -75° to +165° degrees.
Also settable to the lower limit -79° Also settable to the lower limit -76°
degrees of the standard movable
degrees of the standard movable
range.
range.
A space of 30° degrees or more is required.
NOTE
If the newly set operation range does not include 0°, it
is necessary to change it by zero degree mastering so
that 0° is included.
- 71 -
5. ADJUSTMENTS
MAINTENANCE
Item
J1 axis mechanical Upper limit
stopper, limit switch Lower limit
Space between the
upper and lower limits
J2 axis mechanical Upper limit
stopper
Lower limit
J2 axis limit switch
Space between the
upper and lower limits
Upper limit
Lower limit
J3 axis (J2+J3)
mechanical stopper
Space between the
upper and lower limits
Upper limit
Lower limit
Space between the
upper and lower limits
J3 axis (J2+J3) limit Upper limit
switch
Lower limit
Space between the
upper and lower limits
B-81455EN/08
R-2000iA/165R and 100P
R-2000iA/200R
Settable in steps of 7.5° degrees in a range of -112.5° to +180° degrees
Settable in steps of 7.5° degrees in the range of -180° to +112.5° degrees
A space of 67.5° degrees or more is required.
Settable in steps of 15° degrees in the range of -105° to +45° degrees. A
mechanical stopper is also provided at the upper limit +75° degrees of the
standard movable range.
Settable in steps of 15° degrees in the range of -105° to +45° degrees. A
mechanical stopper is also provided at the lower limit -60° degrees of the
standard movable range.
A space of 15° degrees or more is required.
Settable in steps of 15° degrees in the range of -105° to +60° degrees.
Also settable to the upper limit +65° degrees of the standard movable
range.
Settable in steps of 15° degrees in the range of -105° to +45° degrees.
Also settable to the lower limit -120° degrees of the standard movable
range.
A space of 15° degrees or more is required.
Settable in steps of 15° degrees in the range of -45° to +180° degrees. A
mechanical stopper is also provided at the upper limit +195° degrees of
the standard movable range.
Settable in steps of 15° degrees in Settable in steps of 15° degrees in
the range of -60° to +150° degrees. the range of -60° to +150° degrees.
A mechanical stopper is also
A mechanical stopper is also
provided at the lower limit -79°
provided at the lower limit -76°
degrees of the standard movable
degrees of the standard movable
range.
range.
A space of 30° degrees or more is required.
Settable in steps of 15° degrees in the range of -45° to +180° degrees.
Also settable to the upper limit +195° degrees of the standard movable
range.
Settable in steps of 15° degrees in Settable in steps of 15° degrees in
the range of -75° to +165° degrees. the range of -75° to +165° degrees.
Also settable to the lower limit -79° Also settable to the lower limit -76°
degrees of the standard movable
degrees of the standard movable
range.
range.
A space of 30° degrees or more is required.
NOTE
If the newly set operation range does not include 0°,
it is necessary to change it by zero degree
mastering so that 0° is included.
- 72 -
MAINTENANCE
B-81455EN/08
Item
J1 axis mechanical Upper limit
stopper, limit switch Lower limit
Spacing between the
upper limit and lower
limit
J2 axis mechanical Upper limit
stopper
Lower limit
J2 axis limit switch
Spacing between the
upper limit and lower
limit
Upper limit
Lower limit
J3 axis (J2+J3)
mechanical stopper
Spacing between the
upper limit and lower
limit
Upper limit
Lower limit
Spacing between the
upper limit and lower
limit
J3 axis (J2+J3) limit Upper limit
switch
Lower limit
Spacing between the
upper limit and lower
limit
5. ADJUSTMENTS
R-2000iA/165CF
Settable in steps of 7.5° in the range -127.5° to +180° .
Settable in steps of 7.5° in the range -180° to +127.5° .
Requires a space of 52.5° or more.
Settable in steps of 15° in the range -45° to +90° . A mechanical stopper
also exists at the upper limit, +110° , of the standard movable range.
Settable in steps of 15° in the range -30° to +105° . A mechanical stopper
also exists at the lower limit, -55° , of the standard movable range.
Requires a space of 30° or more.
Settable in steps of 15° in the range -45° to +105° . A limit switch can also
be set at the upper limit, +110° , of the standard movable range.
Settable in steps of 15° in the range -45° to +105° . A limit switch can also
be set at the lower limit, -55° , of the standard movable range.
Requires a space of 30° or more.
Settable in steps of 15° in the range -75° to +105° . A mechanical stopper
also exists at the upper limit, +120° , of the standard movable range.
Settable in steps of 15° in the range -60° to +120° . A mechanical stopper
also exists at the lower limit, -75° , of the standard movable range.
Requires a space of 30° or more.
Settable in steps of 15° in the range -75° to +105° . A limit switch can also
be set at the upper limit, +120° , of the standard movable range.
Settable in steps of 15° in the range -60° to +120° . A limit switch can also
be set at the lower limit, -75° , of the standard movable range.
Requires a space of 15° or more.
NOTE
If the newly set operation range does not include 0°,
it is necessary to change it by zero degree
mastering so that 0° is included.
- 73 -
5. ADJUSTMENTS
MAINTENANCE
Fig.5.1.3 (a) Mechanical stopper locations of J1-axis (option)
- 74 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
5. ADJUSTMENTS
Fig.5.1.3 (b) J1-Axis Mechanical Stopper (Stopper Specification for each Model)
- 75 -
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Fig.5.1.3 (c) Mechanical stopper locations of J2-axis (option) (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 76 -
B-81455EN/08
MAINTENANCE
5. ADJUSTMENTS
Fig.5.1.3 (d) Mechanical stopper locations of J2-axis (option) (R-2000iA/165R, 200R and 100P)
Fig.5.1.3 (e) Mechanical stopper locations of J2-axis (option) (R-2000iA/165CF)
- 77 -
5. ADJUSTMENTS
MAINTENANCE
Fig.5.1.3 (f) Mechanical stopper locations of J3-axis (option)
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L, 130U)
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B-81455EN/08
B-81455EN/08
MAINTENANCE
5. ADJUSTMENTS
Fig.5.1.3 (g) Mechanical stopper locations of J3-axis (Robot model and stopper)
- 79 -
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Fig.5.1.3 (h) Mechanical stopper locations of J3-axis (option) (R-2000iA/165CF)
Fig.5.1.3 (i) J1-axis dog (option) locations
Fig.5.1.3 (j) J2-axis dog (option) location (R-2000iA/165F, 200F, 200FO, 210F, 125L, 130U)
- 80 -
B-81455EN/08
MAINTENANCE
5. ADJUSTMENTS
Fig.5.1.3 (k) J2-axis dog (option) location (R-2000iA/165R, 200R and 100P)
Fig.5.1.3 (l) J2-axis dog (option) location (R-2000iA/165CF)
- 81 -
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Fig.5.1.3 (m) J3-axis dog (option) location (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.5.1.3 (n) J3-axis dog (option) location (R-2000iA/165CF)
- 82 -
B-81455EN/08
5.2
MAINTENANCE
5. ADJUSTMENTS
ADJUSTING LIMIT SWITCH (OPTION)
Axis limit switches are overtravel switches that, when tripped, cut
power to the servo motors and an operation is stopped. Overtravel
switches for J1-axis, J2-axis and J3-axis are optional.
1
Set the $MOR_GRP.$CAL_DONE system parameter to FALSE.
This disables the motion limit specified by the software. As a
result, the operator can rotate the robot by a jog feed which goes
beyond the motion limit.
2
Loosen the following bolts.
For R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P,
125L, 130U
Bolts secure the J1-axis : two M8×12
two M4×25
Bolts secure the J2-axis : two M6×10
two M4×25
Bolts secure the J3-axis : two M6×10
two M4×25
For R-2000iA/165CF
Bolts secure the J1-axis : two M6×8
two M4×25
Bolts secure the J2-axis : two M8×12
two M4×25
Bolts secure the J3-axis : two M6×12
two M4×25
3
Move the limit switch so that the robot activates it at about 0.5
degrees before the stroke end. Step on the dog, and position the
limit switch in such a place that only one of the step-on allowance
indication lines at the tip of the switch is hidden.
4
When the limit switch operates and detects overtravel (OT), the
robot stops, and an error message, “OVERTRAVEL”, is displayed.
To restart the robot, hold on the SHIFT key and press the RESET
key. Then, while holding on the SHIFT key, move the adjusting
axis off the OT limit switch by jogging in joint mode.
5
Check that the robot also activates the limit switch when the robot
is approx. 0.5 degrees from the opposite stroke end in the same
way as above. If the limit switch does not operate at the position,
adjust the position of the switch again.
6
Set the $MOR_GRP.$CAL_DONE system parameter to TRUE.
7
Turn off the power, then turn it on again to restart the controller.
- 83 -
5. ADJUSTMENTS
MAINTENANCE
Fig.5.2 (a) Adjusting J1-axis limit switch (option)
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.5.2 (b) Adjusting J1-axis limit switch (option) (R-2000iA/165CF)
- 84 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
Fig.5.2 (c) Adjusting J2-axis limit switch (option)
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.5.2 (d) Adjusting J2-axis limit switch (option) (R-2000iA/165CF)
- 85 -
5. ADJUSTMENTS
5. ADJUSTMENTS
MAINTENANCE
Fig.5.2 (e) Adjusting J3-axis limit switch (option)
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.5.2 (f) Adjusting J3-axis limit switch (option) (R-2000iA/165CF)
- 86 -
B-81455EN/08
MAINTENANCE
B-81455EN/08
5.3
5. 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.
5.3.1
General
The current position of the robot is determined according to the pulse
count value supplied from the pulse coder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering
in daily operations. However, mastering becomes necessary after:
•
Motor replacement.
•
Pulse coder replacement.
•
Reducer replacement.
•
Cable replacement.
•
Batteries for pulse count backup in the mechanical unit have gone
dead.
NOTE
Robot data (including mastering data) and pulse
coder data are backed up by their respective backup
batteries. Data will be lost if the batteries go dead.
Replace the batteries in the control and mechanical
units periodically. An alarm will be issued to warn
the user of a low battery voltage.
Mastering method
Table 5.3.1 Types of Mastering
Jig position mastering
Zero-position
mastering
(eye mark mastering)
Quick mastering
Single-axis mastering
Mastering data entry
- 87 -
This is performed using a mastering jig 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.
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.
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 is entered directly.
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Once mastering is performed, it is necessary to carry out positioning, or
calibration. Positioning is an operation in which the control unit reads
the current pulse count value to sense the current position of the robot.
NOTE
If mastering is performed incorrectly, the robot may
behave unexpectedly. This is very dangerous. So,
the positioning screen is designed to appear only
when the $MASTER_ENB system variable is 1 or 2.
After performing positioning, press F5 [DONE] on
the positioning screen. The $MASTER_ENB system
variable is reset to 0 automatically, thus hiding the
positioning screen.
5.3.2
Resetting Alarms and Preparing for Mastering
Before performing mastering because a motor is replaced, it is
necessary to release the relevant alarm and display the positioning
menu.
Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse mismatch”
Procedure Preparing the Robot for Mastering
Step
1
2
3
Display the positioning menu by following steps 1 to 6.
1
Press MENUS.
2
Press NEXT and select [SYSTEM].
3
Press F1 [TYPE], and select [SYSTEM Variables] from the
menu.
4
Place the cursor on $MASTER_ENB, then key in “1” and
press [ENTER].
5
Press F1 [TYPE], and select [Master/Cal] from the menu.
6
Select the desired mastering type from the [Master/Cal]
menu.
To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.
1
Press MENUS.
2
Press [ONEXT] and select [6SYSTEM].
3
Press F1 [TYPE], and select [SYSTEM Variables] from the
menu.
4
Place the cursor on F3 RES_PCA, then press F4 [TRUE].
The message “TRUE” appears and disappears immediately.
5
Switch the controller power off and on again.
To reset the “Servo 075 Pulse mismatch” alarm, follow steps 1 to 3.
1
When the controller power is switched on again, the message
“Servo 075 Pulse mismatch” appears again.
2
Rotate the axis for which the message mentioned above has
appeared through 10 in either direction.
3
Press [FAULT RESET]. The alarm is reset.
- 88 -
MAINTENANCE
B-81455EN/08
5.3.3
5. ADJUSTMENTS
Mastering to a Fixture (Master Position Master)
Jig position mastering is performed using a mastering jig. This
mastering is carried out in the predetermined jig position.
Jig position mastering is accurate because a dedicated mastering jig is
used. Jig position mastering is factory-performed. It is unnecessary to
perform it in daily operations.
When mastering the robot, arrange the robot to meet the following
conditions.
•
Make the robot mounting base horizontal within 1 mm.
•
Remove the hand and other parts from the wrist.
•
Set the robot in the condition protected from an external force.
1)
Assembling the fixture base
Assemble the fixture base as shown in Fig.5.3.3 (a) to Fig.5.3.3
(c).
Fig.5.3.3 (a) Assembling fixture base
(R-2000iA/165F, 200F, 200FO, 210F, 165CF, 125L and 130U)
Fig.5.3.3 (b) Assembling fixture base (R-2000iA/165R)
- 89 -
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Fig.5.3.3 (c) Assembling fixture base (R-2000iA/200R, 100P)
2)
Mount the dial gauges.
Adjust the dial gauge to 3.00 mm using the calibration block, and
tighten it with M5 bolt as shown in Fig.5.3.3 (d). (Do not tighten
the bolt too strongly or the dial indicator will be broken.)
Fig.5.3.3 (d) Mounting dial indicator
- 90 -
MAINTENANCE
B-81455EN/08
3)
5. ADJUSTMENTS
Mount the fixture on the J1-axis base with bolts as shown in
Fig.5.3.3 (e) to Fig.5.3.3 (g).
Fig.5.3.3 (e) Mounting fixture base (R-2000iA/165F, 200F, 200FO, 210F, 165CF, 125L and 130U)
Fig.5.3.3 (f) Mounting fixture base (R-2000iA/165R)
- 91 -
5. ADJUSTMENTS
MAINTENANCE
Fig.5.3.3 (g) Mounting fixture base (R-2000iA/200R, 100P)
- 92 -
B-81455EN/08
MAINTENANCE
B-81455EN/08
4)
5. ADJUSTMENTS
Mounting the fixture to the wrist
Mount the fixture to the wrist flange as shown in Fig.5.3.3 (h) to
Fig.5.3.3 (l).
Fig.5.3.3 (h) Mounting fixture to wrist (R-2000iA/165F, 210F and 125L)
NOTE
Before mounting the fixture to the wrist of the
R-2000iA/165F, 210F or 125L, detach the FANUC
flange adapter and special flange adapter.
If the adapters remain attached, mastering cannot
be performed in a correct posture.
- 93 -
5. ADJUSTMENTS
MAINTENANCE
Fig.5.3.3 (i) Mounting fixture to wrist (R-2000iA/200F, 200FO, 130U)
Fig.5.3.3 (j) Mounting fixture to wrist (R-2000iA/165R, 100P)
- 94 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
5. ADJUSTMENTS
NOTE
Before mounting the fixture to the wrist of the
R-2000iA/165R, 100P, detach the FANUC flange
adapter and special flange adapter.
If the adapters remain attached, mastering cannot
be performed in a correct posture.
Fig.5.3.3 (k) Mounting fixture to wrist (R-2000iA/200R)
- 95 -
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Fig.5.3.3 (l) Mounting fixture to wrist (R-2000iA/165CF)
Mastering
1)
2)
3)
4)
Press MENUS.
Press NEXT and select SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
LOAD
- 96 -
RES_PCA
DONE
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
5)
Release brake control, and jog the robot into a posture for
mastering.
See the Fig. 5.3.3 (m) to the Fig. 5.3.3 (t) for the mastering
posture.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM_GROUP.SV_OFF_ENB[*]: FALSE
(for all axes)
After changing the system variables, switch the
control unit power off and on again.
6)
Select Fixture Position Master.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE
POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>
[ TYPE ]
LOAD
- 97 -
RES_PCA
DONE
5. ADJUSTMENTS
MAINTENANCE
7)
B-81455EN/08
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.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000> <
0.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
[ TYPE ]
8)
LOAD
RES_PCA
DONE
After positioning is completed, press F5 [DONE].
NOTE
No check is made on the axis movable range during
mastering. Be very careful when running the robot.
Continuing axis movement may result in the
mechanical stopper being bumped.
- 98 -
B-81455EN/08
MAINTENANCE
Fig.5.3.3 (m) Mastering attitude (R-2000iA/165F)
Fig.5.3.3 (n) Mastering attitude (R-2000iA/200F, 200FO, 130U)
- 99 -
5. ADJUSTMENTS
5. ADJUSTMENTS
MAINTENANCE
INSULATED FLANGE
MASTERING POSITION
AXIS
POSITION
J1
0
DEG
J2
+24.9086 DEG
J3
-93.3974 DEG
J4
J5
J6
0
STANDARD FLANGE
MASTERING POSITION
DEG
-86.6026 DEG
0
DEG
Fig.5.3.3 (o) Mastering attitude (R-2000iA/210F)
Fig.5.3.3 (p) Mastering attitude (R-2000iA/165R)
- 100 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
Fig.5.3.3 (q) Mastering attitude (R-2000iA/200R)
Fig.5.3.3 (r) Mastering attitude (R-2000iA/100P)
- 101 -
5. ADJUSTMENTS
5. ADJUSTMENTS
MAINTENANCE
Fig.5.3.3 (s) Mastering attitude (R-2000iA/165CF)
Fig.5.3.3 (t) Mastering attitude (R-2000iA/125L)
- 102 -
B-81455EN/08
5.3.4
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Zero Position 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 Position
Step
1
2
3
4
Press MENUS.
Select NEXT and press SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
5
LOAD
RES_PCA
DONE
Release brake control, and jog the robot into a posture for
mastering.
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.
- 103 -
5. ADJUSTMENTS
MAINTENANCE
6
B-81455EN/08
Select Zero Position Master.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE
POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>
[ TYPE ]
7
LOAD
RES_PCA
DONE
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.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000> <
0.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
[ TYPE ]
LOAD
- 104 -
RES_PCA
DONE
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
Table 5.3.4 Attitude with position marks aligned
Axis
Position
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
0 deg
0 deg
0 deg
0 deg
0 deg
0 deg
J5-axis
J3-axis
J6-axis
J4-axis
J2-axis
J1-axis
Vernier mark
J1-axis
J2-axis
J2-axis
J3-axis
Scribing mark
J4-axis
J5-axis
J6-axis
Fig.5.3.4 (a) Zero degree position arrow mark for each axis (R-2000iA/165F and 125L)
- 105 -
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
J5-axis
J6-axis
J4-axis
J3-axis
J2-axis
J1-axis
Vernier mark
J1-axis
J2-axis
J2-axis
J3-axis
Scribing mark
J4-axis
J5-axis
J6-axis
Fig.5.3.4 (b) Zero degree position arrow mark for each axis (R-2000iA/200F, 200FO, 130U)
- 106 -
B-81455EN/08
MAINTENANCE
5. ADJUSTMENTS
Fig.5.3.4 (c) Zero degree position arrow mark for each axis (R-2000iA/210F)
- 107 -
5. ADJUSTMENTS
MAINTENANCE
Fig.5.3.4 (d) Zero degree position arrow mark for each axis (R-2000iA/165R)
- 108 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
5. ADJUSTMENTS
Fig.5.3.4 (e) Zero degree position arrow mark for each axis (R-2000iA/200R)
- 109 -
5. ADJUSTMENTS
MAINTENANCE
Fig.5.3.4 (f) Zero degree position arrow mark for each axis (R-2000iA/100P)
- 110 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
5. ADJUSTMENTS
Fig.5.3.4 (g) Zero degree position arrow mark for each axis (R-2000iA/165CF)
- 111 -
5. ADJUSTMENTS
5.3.5
MAINTENANCE
B-81455EN/08
Quick Mastering
Quick mastering is performed at a user-specified position. The
corresponding count value is obtained from the rotation speed of the
pulse coder connected to the relevant motor and the rotation angle
within one rotation. Quick mastering uses the fact that the absolute
value of a rotation angle within one rotation will not be lost.
Quick mastering is factory-performed at the position indicated in Table
5.3.4. Do not change the setting unless there is any problem.
If it is impossible to set the robot at the position mentioned above, it is
necessary to re-set the quick mastering reference position using the
following method. (It would be convenient to set up a marker that can
work in place of the eye mark.)
NOTE
1 Quick mastering can be used, if the pulse count
value is lost, for example, because a low voltage has
been detected on the backup battery for the pulse
counter.
2 Quick mastering cannot be used, after the pulse
coder is replaced or after the mastering data is lost
from the robot control unit.
Procedure Recording the Quick Master Reference Position
Step
1
2
Select SYSTEM.
Select Master/Cal.
3
Release brake control, and jog the robot to the quick mastering
reference position.
Move the cursor to SET QUICK MASTER REF and press
ENTER. Press F4, YES.
4
- 112 -
MAINTENANCE
B-81455EN/08
5. ADJUSTMENTS
NOTE
If the robot has lost mastery due to mechanical
disassembly or repair, you cannot perform this
procedure. In this case, master to a fixture or
master to zero degrees to restore robot mastery.
Procedure Quick Mastering
Step
1
Display the Master/Cal screen.
2
Release brake control, and jog the robot to the quick mastering
reference position.
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.
3
4
5
- 113 -
5. ADJUSTMENTS
5.3.6
MAINTENANCE
B-81455EN/08
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.
Item
Table 5.3.6 Items Set in Single Axis Mastering
Description
Current position
(Actual axis)
Mastering position
(Matra pos)
SEL
ST
- 114 -
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-81455EN/08
5. 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
- 115 -
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
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
- 116 -
MAINTENANCE
B-81455EN/08
5.3.7
5. 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
Press MENUS, then press NEXT and select SYSTEM.
Press F1, [TYPE]. Select [Variables]. The system variable screen
appears.
3
Change the mastering data.
The mastering data is saved to the $DMR_GRP.$MASTER_COUN
system variable.
4
Select $DMR_GRP.
- 117 -
5. ADJUSTMENTS
MAINTENANCE
B-81455EN/08
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
- 118 -
B-81455EN/08
6
MAINTENANCE
6. REPLACING PARTS
REPLACING PARTS
This section describes the replacement procedures for the major
components of the mechanical section. When replacing mechanical
components, be sure to follow the respective procedures. See Section 8
for how to replace the cables and limit switches.
- 119 -
6. REPLACING PARTS
6.1
MAINTENANCE
B-81455EN/08
NOTE FOR PART REPLACEMENT
Once motors, reducers, and gears are replaced, mastering becomes
necessary. Perform mastering according to Section 5.3 after any of
these components is replaced.
Be very careful when carrying and assembling the heavy components
listed below.
Table 6.1 Weight of the main parts
Weight
Component
Remarks
(approximate)
M1, M2, M3
30kg
Servo motors
M4, M5, M6
10kg
165F, 200F,
200FO, 210F,
165R, 200R,
110kg
J1-axis
100P, 125L,
130U
165CF
80kg
Reducers J2-axis
70kg
165F, 200F,
200FO, 165R,
200R, 100P,
50kg
J3-axis
125L, 130U,
165CF
210F
55kg
Reducers J4-axis
15kg
J2 table
165CF
75kg
165F, 200F,
200FO, 210F,
130kg
125L, 130U
J2-axis arm
165R, 200R,
135kg
100P
165CF
100kg
165F, 200F,
200FO, 210F,
120kg
Balancer
125L
165R, 200R,
300kg
100P
165F, 165R,
50kg
125L
200F, 200FO,
Wrist unit
210F, 200R,
80kg
100P, 130U
165CF
55kg
165F
830kg
200F
860kg
210F
875kg
200FO, 130U
930kg
J1-axis motor and the
J2-axis base-wrist
balancer are not
165R
960kg
unit
included.
200R
990kg
100P
1015kg
125L
850kg
165CF
710kg
- 120 -
B-81455EN/08
6. REPLACING PARTS
MAINTENANCE
Component
J2-axis arm-wrist
unit
J3-axis casing-wrist
unit
Controller
165F
200F, 200FO,
130U
210F
165R
200R
100P
125L
165CF
165F, 165R
200F, 200FO,
200R, 130U
210F
100P
125L
165CF
Weight
(approximate)
460kg
Remarks
490kg
505kg
465kg
495kg
520kg
480kg
370kg
290kg
J2-axis reducer is not
included.
320kg
330kg
345kg
310kg
270kg
180kg
In case of reusing sealbolts for R-2000iA, observe following notes
strictly. (If possible, change them to new sealbolts)
1) Apply LOCTITE No.242 when reusing sealbolts.
(However, seal tape needs to be wound around the seal bolts used
as a plug.)
2) Notice the following 3 notes.
a) Remove excessive bits of sealant on the sealbolt.
b) The length of application is 2d (d : diameter of the bolt) from
the tip of the bolt, and spread it evenly around it.
c) Spread LOCTITE No.242 on the entire threaded portion and
rub the 2 bolts together in order to spread it to the bottom of
the groove.
Fig.6.1 Standard application of LOCTITE No.242
- 121 -
6. REPLACING PARTS
6.2
MAINTENANCE
B-81455EN/08
REPLACING J1-AXIS MOTOR (M1) AND REDUCER
1) Replacing J1-axis motor (M1)
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Remove
1
Turn off the power.
2
(In the case of R-2000iA/165F, 200F, 200FO, 210F, 165R,
200R, 125L, 130U)
Remove the pulse coder connector cover (2). (The cover
turns together with the bolt, possibly causing damage to the
connector. Hold the cover to prevent it from turning.)
(In the case of R-2000iA/100P)
Remove the fan. (See the section 6.6)
3
Remove three connectors of the motor (1).
4
Remove three motor mounting bolts (4) and then remove the
washers (5).
5
Pull out the motor (1) from the 2 base vertically, while being
careful not to scratch the surface of the gear (7) teeth.
6
Remove the bolt (12) and washer (11) from the shaft of the
motor (1).
7
Pull off the gear (7) with bearing (9), C ring (8, 10) from the
shaft of the motor (1).
8
Remove the nut (6) from the shaft.
Assembling
1
Polish the flange surface of the motor (1) using an oil stone.
2
Mount the nut (6) on the shaft of the motor (1).
3
Attach the gear (7) with bearing (9), C ring (8, 10) to the shaft
of the motor (1).
Note) Before attaching the gear (7) to the motor (1), attach
the bearing (9) and the C rings (8, 10) to the gear (7)
by using the jig (A290-7324-X924). (See Fig.6.2 (b).)
4
Mount the bolt (12) and the washer (11) on the motor (1).
5
Mount the motor (1) on the 2 base vertically, while being
careful not to scratch the surface of the gear (7) teeth.
Replace the O-ring (13) to the new one and mount the O-ring
(13) in the prescribed place.
6
Attach the three motor mounting bolts (4) and washers (5).
7
Attach the three connectors to the motor (1).
8
(In the case of R-2000iA/165F, 200F, 200FO, 210F, 165R,
200R, 125L, 130U)
Attach the pulse coder connector cover (2).
(In the case of R-2000iA/100P)
Attach the fan. (See the section 6.6)
9
Perform mastering. (See the section 5.3 for mastering.)
- 122 -
B-81455EN/08
6. REPLACING PARTS
MAINTENANCE
Fig.6.2 (a) Replacing J1-axis motor (M1)
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Parts list of replacing J1-axis motor
Name
Specifications
1 MOTOR
2 COVER
3 BOLT
4 BOLT
5 WASHER
6 NUT
A06B-0267-B605#S000
A290-7324-X101
A6-BA-8×12
A6-BA-12×30
A97L-0001-0823#M12H
It is included in the spec of INPUT GEAR
A97L-0218-0285#205
7 INPUT GEAR
A97L-0218-0285#205
8 C RING
A6-CJR-45
9 BEARING
A97L-0001-0196#09Z000A
10 C RING
A6-CJR-45
11 WASHER
A97L-0001-0823#M8H
12 BOLT
A6-BA-8×60
13 O RING
JB-OR1A-G125
14 (*) SEAL
A98L-0004-0771#A12TP
(*) This is for 130U only. The seal is included in A06B-0267-B605#S000.
- 123 -
Q’ty
1
1
1
3
3
1
1
1
1
1
1
1
1
1
Loctite
Torque N·m (kgf·m)
LT242
118 (12)
LT242
27.5 (2.8)
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Fig.6.2 (b) Bearing Pressure
2) Replacing J1-axis motor (M1) (R-2000iA/165CF)
Remove
1
Turn off the power.
2
Remove the pulse coder connector cover (2). (The cover
turns together with the bolt, possibly causing damage to the
connector. Hold the cover to prevent it from turning.)
3
Remove tree connectors of the motor (1).
4
Remove four motor mounting bolts (4) and then remove the
washer (5).
5
Pull out the motor (1) from the J1 base vertically, while being
careful not to scratch the surface of the gear teeth.
6
Remove the nut (9) and washer (8) from the shaft of the
motor (1).
7
Pull off the gear (7) from the shaft of the motor (1).
Assembling
1
Grind the flange surface of the motor (1) using an oil stone.
2
Mount the gear (7) and new seal (6) on the shaft of the motor
(1). (The seal is included in A06B-0267-B605#S000 motor.)
3
Attach the nut (9) and washer (8) to the motor (1).
4
Mount the motor (1) on the J1 base vertically, while being
careful not to scratch the surface of the gear teeth. Replace
the O-ring (10) to the new one and mount the O-ring (10) in
the prescribed place.
5
Attach the four motor mounting bolts (4) and washers (5).
- 124 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
6
7
8
Attach the three connectors to the motor (1).
Attach the pulse coder connector cover (2).
Perform mastering. (See Section 5.3 MASTERING.)
Fig.6.2 (c) Replacing J1-axis motor (M1) (R-2000iA/165CF)
R-2000iA/165CF
Name
1 MOTOR
2 COVER
3 BOLT
4 BOLT
5 WASHER
6 SEAL
7 J1 GEAR 1
8 WASHER
9 NUT
10 O RING
Specifications
A06B-0267-B605#S000
A290-7324-X101
A6-BA-8×12
A6-BA-12×30
A97L-0001-0823#M12H
A98L-0004-0771#A12TP
A290-7321-X221
A97L-0001-0610#20
A6-N1-20X1.5S-M-NI
JB-OR1A-G125
Q’ty
1
1
1
4
4
1
1
1
1
1
- 125 -
Loctite
LT242
Torque N·m (kgf·m)
118 (12)
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
3) Replacing J1-axis reducer
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Remove
WARNING
The special tools listed below are required to
replace the J1-axis reducer. Be sure to prepare the
special tools. If the robot is hung without using the
special tools, the robot can fall.
Contact FANUC for information about the tools for
hanging the R-2000iA/165R, 200R and 100P.
For R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L, 130U
Name
Guide pin
Punch
Guide pin
Specification
A290-7324-X921
A290-7324-X922
A290-7324-X923
Q’ty
2
1
2
For hanging R-2000iA/165F, 200F, 200FO, 210F, 125L, 130U
Block
Adapter 1
Adapter 2
Plate
Bolt
Bolt
Bolt
1
2
A290-7324-X925
A290-7324-X926
A290-7324-X927
A290-7324-X928
A6-BA-8 40
A6-BA-12 45
A6-BA-12 65
4
1
1
1
6
10
6
Remove loads such as the hand and workpiece from the
wrist.
Remove the balancer according to Section 6.7,
“REPLACING THE BALANCER”.
NOTE
No balancer is provided for the R-2000iA/130U.
3
4
5
(In the case of R-2000iA/165F, 200F, 200FO, 210F, 125L
and 130U)
While maintaining the attitude (J2=0°) for balancer
replacement, remove the two bolts for mounting the J2 base
immediately under the J2 arm beforehand. (See Fig.6.2 (d).)
(In the case of R-2000iA/165F, 200F, 200FO, 210F, 125L
and 130U)
Ensure that the robot assumes the attitude shown in Fig.6.2
(e).
(J2=-40°, J3=-30°)
(In the case of R-2000iA/165R, 200R and 100P)
For the postures of 165R and 200R, consult FANUC service
representative.
Turn off the power.
- 126 -
MAINTENANCE
B-81455EN/08
6
7
8
9
10
11
12
6. REPLACING PARTS
Remove the J1-axis motor according to the previous item.
Detach the cable for connection between the control unit and
the robot, and remove the connector panel from the back of
the J1 base, then detach the connector.
Remove the J1 base cable clamp and the J2 base cable clamp,
then pull out the cable from the center pipe toward the J2
base.
Remove the bolt (5), then remove the plate (4).
Remove the bolt (10) and washer (9), then remove the spacer
(6), plate (7), and stopper (8).
(For R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
According to Fig.6.2 (e), install the hanging jigs onto the
robot to enable the robot to be hung.
When attaching the plate (X928), remove the clamp plate
(X326).
(For the R-2000iA/165R, 200R and 100P)
For the attitude of the 165R, 200R or 100P contact FANUC.
Remove the J2 base mounting bolt (1) and washer (2), and
hang the main robot unit for separation from the J1 unit. At
this time, be careful not to damage the oil seal (11).
The J2 base and J1-axis reducer are positioned with the
spring pin (3). Be careful when handing the robot.
Remove the reducer mounting bolt (12) and washer (13),
then remove the reducer (15) from the J1 base.
The J1-axis reducer and J1 base are positioned with the
spring pin (14). So, remove the J1-axis reducer by using the
J1-axis reducer removal tap.
Assembling
1
Polish the mounting surface of the J1 base reducer (15) with
an oilstone.
2
After attaching the O-ring (16) to the reducer (15), mount the
reducer onto the J1 base by using the guide pin
(A290-7324-X921) (according to Fig.6.2 (g), (i)), and
position the reducer by striking the spring pin (14) with the
punch (A290-7324-X922). Then, fasten the reducer with the
reducer mounting bolt (12) and washer (13).
At this time, ensure that the gear of the reducer is not
damaged by interfering with the center pipe (17).
3
Apply a sealing agent to the shaft surface of the reducer
according to Section 6.8, “SEALANT APPLICATION” and
Fig.6.2 (j).
4
Place the main robot unit on the J1 unit by using the guide pin
(A290-7324-X923). (See Fig.6.2 (h), (i).)
Then, perform positioning by striking the spring pin (3) with
the punch (A290-7324-X922), then perform fastening with
the J2 base mounting bolt (1) and washer (2). At this time,
check that the oil seal (11) is installed in position, and ensure
that the lip is not turned up when the robot is installed.
5
Install the plate (4), spacer (6), plate (7), and stopper (8) in
position.
- 127 -
6. REPLACING PARTS
MAINTENANCE
6
7
8
9
10
11
B-81455EN/08
Lay the cables neatly, and fasten the J1 base clamp and J2
base clamp.
Fasten the J1-axis motor according to the previous item.
Attach the connector onto the connector panel on the back of
the J1 base, then attach the cable for connection between the
control unit and the robot.
Mount the balancer onto the robot according to Section 6.7,
“REPLACING THE BALANCER”.
Apply grease. (See Section 3.1, “REPLACING GREASE
ON THE DRIVE MECHANISM”.)
Perform mastering. (See Section 5.3, “MASTERING”.)
Fig.6.2 (d) Replacing J1-axis reducer
(R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
Fig.6.2 (e) Replacing J1-axis reducer (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 128 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Fig.6.2 (f) Replacing J1-axis reducer
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Parts list of replacing J1-axis reducer
Name
1 BOLT
2 WASHER
3 SPRING PIN
4 PLATE
5 BOLT
6 SPACER
7 PLATE
8 STOPPER
9 WASHER
10 BOLT
11 OIL SEAL
12 BOLT
13 WASHER
14 SPRING PIN
15 REDUCER
16 O RING
17 PIPE
18 BOLT
19 WASHER
20 O RING
Specifications
A6-BA-16×55
A97L-0001-0823#M16H
A6-PS-12×30
A290-7324-X321
A6-BA-6×10
A290-7324-X218
A290-7324-X217
165F, 200F, 125L
165R, 200FO, 210F, 200R, 100P, 130U
A97L-0001-0823#M12H
A6-BA-12×50
A98L-0040-0047#12515514
A6-BA-12×55
A97L-0001-0823#M12H
A6-PS-12×30
A97L-0218-0355#320C-205
JB-OR1A-G415
A290-7324-X231
A6-BA-6×16
A97L-0001-0823#M6H
JB-OR1A-G125
- 129 -
Q’ty
A290-7324-X215
A290-7324-Y215
11
11
1
1
2
1
1
1
1
4
4
1
16
16
1
1
1
1
4
4
1
LT262
Torque N·m
(kgf·m)
318 (32.5)
LT262
128 (13.1)
Loctite
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Fig.6.2 (g) Replacing J1-axis reducer
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.6.2 (h) Replacing J1-axis reducer
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
- 130 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Insert
ガイドピン2本(A290-7324-X921)
two guide pins (A290-7324-X921) into
はこの円周上のネジ穴のいずれかに対角に挿入する事
any
diagonal pair on this circumference.
ガイドピン2本(A290-7324-X921)
Insert
two guide pins (A290-7324-X921) into
はこの円周上の穴のいずれかに対角に挿入する事
any
diagonal pair on this circumference.
ガイドピン2本(A290-7324-X921)
Insert
two guide pins (A290-7324-X921) into
はこの円周上の穴のいずれかに対角に挿入する事
any
diagonal pair on this circumference.
スプリングピンはこのリーマ穴に
Insert the spring pin into this reamer bore.
挿入する事
J1-axis base
J1軸ベース
J1-axis
reducer
J1軸減速機
J2-axis base
J2軸ベース
Fig.6.2 (i) Insertion positions of the guide pins and spring pin
Fig.6.2 (j) Replacing J1-axis reducer (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
- 131 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
4) Replacing J1-axis reducer (R-2000iA/165CF)
Remove
1
2
3
4
5
6
7
8
9
10
Place the robot in a transportation posture.
Turn off the power.
Remove J1-axis motor.
Detach the cable for connection between the control unit and
robot, and remove the J1 base rear-surface connector panel,
then dismount the connector.
Remove the J1 base cable clamp, J1 base side-surface
connector panel, and J1 base cable clamp so that the cable
can be pulled out from the J1 unit when the robot main body
is hoisted.
Remove the J1 mounting bolt (1) and washer (2), and hoist
the robot main body while being careful not to damage the
cable, then detach the cable from the J1 unit.
Remove the table mounting bolt (3) and washer (4), then
dismount the table (5).
Remove the bearing (7) and center gear (8).
Remove the reducer mounting bolt (9) and washer (10), then
dismount the reducer (12) from the J1 base.
Remove the pipe mounting bolt (16) and washer (15), then
dismount the pipe (14) from the reducer (12).
Assembling
1
Mount and fasten the pipe (14) to the reducer (12) with the
pipe mounting bolt (16) and washer (15). Replace the O-ring
(13) to the new one and mounnt the O-ring (13) in the
prescribed place.
2
Add loctite. (See the section 6.8 and Fig.6.2 (k))
3
Mount and fasten the reducer (12) to the J1 base with the
reducer mounting bolts (9) and washers (10). Replace the
O-ring (11) to the new one and mount the O-ring (13) in the
correct place.
4
Attach the center gear (8) and bearing (7).
5
Mount and fasten the table (5) with the table mounting bolt
(3) and washer (4). When fastening, make sure that the Oil
seal (6) is in the prescribed place.
6
Place the robot main body on the J1 unit while being careful
not to damage the cable, and fasten it with the J1 base
mounting bolt (1) and washer (2).
7
Fix the J1 base cable clamp, J1 base side-surface connector
panel, and J1 base clamp, while setting the cable in an
appropriate form.
8
Attach the connector to the J1 base rear-surface connector
panel, and fasten the robot. Attach the cable connecting the
control section and robot.
9
Fasten the motor by following the procedure described
above.
10 Apply grease.
11 Perform mastering. (See Section 5.3 MASTERING.)
- 132 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Fig.6.2 (k) Replacing J1-axis reducer (R-2000iA/165CF)
Name
1 BOLT
2 WASHER
3 BOLT
4 WASHER
5 TABLE
6 OIL SEAL
7 BEARING
8 J1 GEAR 2
9 BOLT
10 WASHER
11 O RING
12 REDUCER
13 O RING
14 PIPE
15 WASHER
16 BOLT
Specifications
A6-BA-12×75
A97L-0001-0823#M12H
A6-BA-12×85
A97L-0001-0823#M12H
A290-7321-X202
A98L-0040-0047#12515514
A97L-0001-0192#3000000
A290-7321-X222
A6-BA-18×145
A97L-0001-0823#M18H
A98L-0040-0041#281
A97L-0218-0237#320C-35
JB-OR1A-G135
A290-7321-X231
A97L-0001-0823#M6H
A6-BA-6×16
Q’ty
16
16
15
15
1
1
1
1
9
9
1
1
1
1
4
4
- 133 -
Loctite
Torque N·m
(kgf·m)
LT262
128.4 (13.1)
LT262
441 (45)
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
NOTE
Apply beads of sealant (Loctite 518) 2 mm wide
along the bold line with no gap.
Fig.6.2 (l) Replacing J1-axis reducer (R-2000iA/165CF)
- 134 -
MAINTENANCE
B-81455EN/08
6.3
6. REPLACING PARTS
REPLACING J2-AXIS MOTOR (M2) AND REDUCER
1) Replacing the J2-axis motor (M2)
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Remove
1
Place the motor in the posture shown in Figure 6.3 (b), (c)
and hoist it using a sling.
WARNING
When its J2-axis motor is removed, its weight, in
conjunction with the righting moment of its balancer,
can cause the J2-axis arm to move extensively
unless the robot is in a specified attitude, resulting in
a very dangerous situation. (To be specific, the arm
may drop in the gravity direction or rise up
depending on the status of the load and the attitude
of the robot.) If it is impossible to keep the robot in a
specified attitude when its J2-axis motor is replaced,
fasten the arm so firmly that it will not move.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification
can be used to fasten the J2-axis arm. Before
starting to replace the motor, install the stopper and
jog-feed the arm to get it sufficiently close to the
stopper; however, a minimum constraint angle of
this option is 15 so it is impossible to simultaneously
keep the arm from dropping and rising. If it is
unknown how the arm will behave when the J2-axis
motor is removed, use a crane and the stopper to
keep the arm, respectively, from dropping and
rising.
2
3
4
5
6
Turn off the power.
Detach the three connectors from the J2-axis motor (1).
(In the case of R-2000iA/165F, 200F, 200FO, 210F, 165R,
200R, 125L, 130U)
Remove the pulse coder connector cover (2). (The cover
turns together with the bolt, possibly causing damage to the
connector. Hold the cover to prevent it from turning.)
(In the case of R-2000iA/100P)
Remove the fan. (See the section 6.6)
Remove the four motor mounting seal bolts (4) and washers
(5).
Pull out the J2-axis motor (1) horizontally, while being
careful not to damage the surface of the gear teeth.
- 135 -
6. REPLACING PARTS
MAINTENANCE
7
B-81455EN/08
Remove the bolt (8) and washer (9), then dismount the input
gear (7), nut (6).
Assembling
1
Polish the flange surface of the J2-axis motor (1) using an oil
stone. Attach the new seal (11). (The seal is included in
A06B-0267-B605#S000 motor.)
2
Mount the nut (6).
3
Mount and fasten the input gear (7) with bolt (8) and washer
(9).
4
Mount the J2-axis motor (1) horizontally, while being careful
not to damage the surface of the gear teeth. Replace the
O-ring (10) to the new one and mount the O-ring (10) in the
prescribed place.
5
Attach the four motor mounting seal bolts (4) and washers
(5).
6
Attach the three connectors to the J2-axis motor (1).
7
(In the case of R-2000iA/165F, 200F, 200FO, 210F, 165R,
200R, 125L, 130U)
Attach the pulse coder connector cover (2).
(In the case of R-2000iA/100P)
Attach the fan. (See the section 6.6)
8
Apply grease.
9
Perform mastering. (See Section 5.3 MASTERING.)
- 136 -
B-81455EN/08
6. REPLACING PARTS
MAINTENANCE
Note that when the R-2000iA/165R,
200R or 100P is used, the motor
connector is pulled out in a different
direction.
Fig.6.3 (a) Replacing J2-axis motor (M2) (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Parts list for replacing J2-axis motor (M2)
Name
Specifications
1 MOTOR
A06B-0267-B605#S000
A290-7324-X101
2 COVER
A6-BA-8×12
3 BOLT
4 SEAL BOLT
A97L-0118-0706#M12 30
5 WASHER
A97L-0001-0823#M12H
6 NUT
165F
INPUT GEAR
125L
A97L-0218-0379#210
INPUT GEAR
200F
200FO A97L-0218-0379#257
210F
200R
100P
130U
165R
INPUT GEAR
A97L-0218-0379#231
7 INPUT GEAR
165F
A97L-0218-0379#210
125L
A97L-0218-0379#257
200F
200FO
210F
200R
100P
130U
165R
A97L-0218-0379#231
8 BOLT
A6-BA-8×55
9 SEAL WASHER
A30L-0001-0048#8M
10 O RING
JB-OR1A-G125
11 SEAL
A98L-0004-0771#A12TP
- 137 -
Q’ty
1
1
1
4
4
1
Loctite
Torque N·m (kgf·m)
LT242
118 (12)
LT242
27.5 (2.8)
1
1
1
1
1
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Fig.6.3 (b) J2-axis motor (M2) and reducer replacing posture (R-2000iA/165F, 200F, 210F, 200FO, 125L and 130U)
- 138 -
B-81455EN/08
MAINTENANCE
6. REPLACING PARTS
Fig.6.3 (c) J2-axis motor (M2) and reducer replacing posture (R-2000iA/165R, 200R and 100P)
- 139 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
2) Replacing the J2-axis motor (M2) (R-2000iA/165CF)
Remove
1
Place the motor in the posture shown in Figure 6.3 (e), and
hoist it using a sling.
2
Turn off the power.
3
Detach the three connectors from the motor (1).
4
Remove the four motor mounting seal bolts (2) and washers
(3).
5
Pull out the motor (1) horizontally, while being careful not to
damage the surface of the gear teeth.
6
Remove the nut (7) and washer (6), then dismount the input
gear (5), draw bolt (4).
Assembling
1
Polish the flange surface of the motor (1) using an oil stone.
2
Attach the new seal (9). (The seal is included in
A06B-0267-B605#S000 motor.)
3
Mount the draw bolt (4).
4
Mount and fasten the input gear (5) with washer (6) and nut
(7).
5
Mount the motor (1) horizontally, while being careful not to
damage the surface of the gear teeth. Replace the O-ring (8)
to the new one and mount the O-ring (8) in the prescribed
place.
6
Attach the four motor mounting seal bolts (2) and washers
(3).
7
Attach the three connectors to the motor (1).
8
Apply grease.
9
Perform mastering. (See Section 5.3 MASTERING.)
- 140 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Fig.6.3 (d) Replacing J2-axis motor (M2) (R-2000iA/165CF)
Name
Specifications
1 MOTOR
2 BOLT
3 WASHER
4 DRAW BOLT
5 INPUT GEAR
6 WASHER
7 NUT
8 O RING
9 SEAL
A06B-0267-B605#S000
A97L-0118-0706#M12×30
A97L-0001-0823#M12H
It is included in A97L-0218-0245#210
A97L-0218-0245#210
A6-WB-10S
A6-N1-10S
JB-OR1A-G125
A98L-0004-0771#A12TP
Q’ty
1
4
4
1
1
1
1
1
1
Loctite
Torque N·m (kgf·m)
LT242
118 (12)
LT242
26.5 (2.7)
Fig.6.3 (e) J2-axis motor (M2) and reducer replacing posture (R-2000iA/165CF)
- 141 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
3) Replacing J2-axis reducer
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Disassembling
Common tool for replacing the J2-axis reducer
Name
Specification
Guide pin
Guide pin
1
2
3
4
Q’ty
A290-7324-X921
A290-7324-X923
1
1
Place the arm in the posture shown in Figure 6.3 (b) and (c),
and hoist it using a sling.
Switch off the power.
Detach all of the cables connected to the J3 through J6-axis
motors and option cables, and pull out the cables to the
outside of the J2 base.
For the 100P, remove the fan of the J3 motor before
removing the cables. (See Section 6.6, “REPLACING
FANS”.)
Remove the balancer (1) according to Section 6.7,
“REPLACING THE BALANCER”.
NOTE
No balancer is provided for the R-2000iA/130U.
5
Remove the J2-axis motor (2) according to the procedure
described in the previous item.
WARNING
If the balance is left installed on the robot when the
J2-axis motor is removed, the weight of the robot, in
conjunction with the righting moment of its balancer,
can cause the J2-axis arm to move extensively,
resulting in a very dangerous situation. Before
starting to remove the J2-axis motor, be sure to
remove the balancer and sling the arm, using a
crane.
6
7
Remove the J2 arm mounting bolts (5) and (7) and washers
(6) and (8), then remove the J2 arm (4) by using a guide pin
as shown in Fig.6.3 (g). At this time, apply a sufficient
tension to the spring.
Remove the reducer mounting bolt (12) and washer (13),
dismount the reducer (11) using a guide pin.
- 142 -
MAINTENANCE
B-81455EN/08
6. REPLACING PARTS
Assembling
1
By using a guide pin (A290-7324-X921, A290-7324-X923)
as shown in Fig.6.3 (g), install a new reducer (11) with the
bolt (12) and washer (13). At this time, replace the O-ring
(14) to the new one, and mount the O-ring (14) in the
prescribed place.
2
Apply a sealing agent to the reducer. (See Section 6.8,
“SEALANT APPLICATION”.)
3
Replace the O-ring (9) and the O-ring (10) to the new one and
attach those O-ring to the J2 arm.
CAUTION
Do not apply grease to the O-ring (9). Applying
grease can prevent sealant from hardening, thus
allowing the grease to leak. If it is difficult to fasten
the O-ring, apply a small amount of sealant to the
O-ring, and attach the O-ring to the O-ring groove in
the J2 arm.
4
By using a guide pin, fasten the J2 arm (4) to the reducer (11)
with the bolts (5) and (7) and washers (6) and (8). At this
time, check that the O-ring (9) and ring (10) are installed in
position.
CAUTION
When installing the J2 arm, bring the arm into close
contact with the mating component in one operation
so that the sealant is not wiped away. Check that
the O-ring is installed in the correct location and that
no sealant has been wiped away.
5
6
7
8
9
Mount the J2-axis motor (2) according to the procedure
described earlier.
Mount the balancer (1) according to Section 6.7,
“REPLACING THE BALANCER”.
Attach the cables for connection to the J3 through J6-axis
motors and the option cables.
In the case of 100P, attach the fan of J3 motor. (See the
section 6.6)
Apply grease.
Perform mastering. (See Section 5.3 MASTERING.)
- 143 -
6. REPLACING PARTS
Name
1 BALANCER ASSY
2 MOTOR
3 O RING
4 J2 ARM
5 BOLT
6 WASHER
7 BOLT
8 WASHER
9 O RING
10 RING
11 REDUCER
12 BOLT
13 WASHER
14 O RING
MAINTENANCE
Specifications
A290-7324-V301
165F
200F
125L
200FO A290-7324-V302
210F
A290-7324-V303
165R
A290-7324-V311
200R
100P
A06B-0267-B605#S000
JB-OR1A-G125
165F
A290-7324-X315
200F
200FO
125L
30U
210F
A290-7324-X314
165R
A290-7324-Y315
200R
100P
A6-BA-16×55
A97L-0001-0823#M16H
A6-BA-12×45
A97L-0001-0823#M12H
A98L-0001-0347#S265
A290-7324-X316
165F
A97L-0218-0370#450E-210
125L
200F
A97L-0218-0370#450E-257
200FO
210F
200R
100P
130U
165R
A97L-0218-0370#450E-231
A6-BA-12×60
A97L-0001-0823#M12H
JB-OR1A-G300
B-81455EN/08
Q’ty
1
Loctite
Torque N·m (kgf·m)
1
1
1
6
6
21
21
1
1
1
24
24
1
LT262
319 (32.5)
LT262
128 (13.1)
LT262
128 (13.1)
Fig.6.3 (f) Replacing J2-axis reducer (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
- 144 -
B-81455EN/08
MAINTENANCE
Fig.6.3 (g) Using the guide pin
- 145 -
6. REPLACING PARTS
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
4) Replacing J2-axis reducer (R-2000iA/165CF)
Disassembling
Common tool for replacing the J2-axis reducer
Name
Specification
Guide pin
Guide pin
1
2
3
4
5
A290-7324-X921
A290-7324-X923
Q’ty
1
1
Posture the robot as shown in Fig.6.3 (e), then hang it with a
sling.
Turn off the power.
Remove the J2 arm mounting bolts (3 and 5), remove the
washers (4 and 6), and remove the J2 arm (7) with the guide
pin as shown in Fig.6.3 (g). At this time, apply a sufficient
tension to the sling.
Remove the motor (1) as described above.
Remove the reducer mounting bolt (8) and the washer (9),
then remove the reducer (10) by using a guide pin as shown
in Fig.6.3 (g).
Assembling
1
Mount a new reducer (10) with the reducer mounting bolt (8)
and washer (9) by using the guide pin as shown in Fig.6.3 (g).
At this time, replace the O-ring (11) to the new one and
mount the O-ring (11) in the appropriate place.
2
Secure the motor (1) as described before.
3
Apply a sealing agent to the reducer. (See Section 6.8,
“SEALANT APPLICATION”.)
4
Replace the O-ring (13) and the O-ring (12) to the new one
and attach those O-ring to the J2 arm.
CAUTION
Do not apply grease to the O-ring (13). Applying
grease can prevent sealant from hardening, thus
allowing the grease to leak. If it is difficult to fasten
the O-ring, apply a small amount of sealant to the
O-ring, and attach the O-ring to the O-ring groove in
the J2 arm.
5
Secure the J2 arm to the reducer (10) with the J2 arm
mounting bolts (3) (5) and washers (4) (6). At this time,
ensure that the O-ring (13) and ring (12) are attached in the
appropriate places.
- 146 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
CAUTION
When installing the J2 arm, bring the arm into close
contact with the mating component in one operation
so that the sealant is not wiped away. Check that
the O-ring is installed in the correct location and that
no sealant has been wiped away.
6
7
Name
1 MOTOR
2 O RING
3 BOLT
4 WASHER
5 BOLT
6 WASHER
7 J2 ARM
8 BOLT
9 WASHER
10 REDUCER
11 O RING
12 PLATE
13 O RING
Apply grease.
Perform mastering. (See Section 5.3 MASTERING.)
Specifications
Q’ty
A06B-0267-B605#S000
JB-OR1A-G125
A6-BA-16×55
A97L-0001-0823#M16H
A6-BA-12×45
A97L-0001-0823#M12H
A290-7321-X314
A6-BA-12×55
A97L-0001-0823#M12H
A97L-0218-0238#450E-210
JB-OR1A-G300
A290-7321-X316
A98L-0001-0347#S265
1
1
6
6
21
21
1
24
24
1
1
1
1
Loctite
LT262
318.5 (32.5)
LT262
128.4 (13.1)
LT262
128.4 (13.1)
Fig.6.3 (h) Replacing J2-axis reducer (R-2000iA/165CF)
- 147 -
Torque N·m (kgf·m)
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
NOTE
Apply sealant (Loctite 518) to the section indicated
(shown above).
Fig.6.3 (i) Replacing J2-axis reducer (R-2000iA/165CF)
- 148 -
MAINTENANCE
B-81455EN/08
6.4
6. REPLACING PARTS
REPLACING J3-AXIS MOTOR (M3) AND REDUCER
1) Replacing J3-axis motor
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Disassembling
1
Ensure that the robot assumes the attitude shown in Fig.6.4
(e) and 6.4 (f), and hang the robot with a sling.
CAUTION
If the J3-axis arm is not slung in a specified manner
when the J3-axis motor is removed, the arm may
drop, resulting in a very dangerous situation.
If it is impossible to sling the J3-axis arm in a
specified manner, fasten
it so that it will not move.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification
can be used to fasten the J3-axis arm. Before
starting to remove the motor, install the stopper in
the dropping direction, and jog-feed the arm to get it
sufficiently close to the stopper.
2
3
4
5
Turn off the power supply.
In the case of 100P, remove the fan. (See the section 6.6)
Detach the three connectors from the J3-axis motor (1).
Remove the four motor mounting seal bolts (2) and washers
(3).
NOTE
To install the J3-axis motor, an M12 T-shaped
hexagonal wrench not shorter than 320 mm is
required.
6
7
Pull out the J3-axis motor (1) horizontally, while being
careful not to damage the surface of the gear teeth.
Remove the bolt (6) and washer (7), then dismount the input
gear (5), nut (4) and seal (9).
Assembling
1
Polish the flange surface of the J3-axis motor (1) using an oil
stone. (The seal is included in A06B-0267-B605#S000
motor.)
2
Attach the new seal (9).
3
Mount the nut (4).
4
Mount and fasten the input gear (5) with bolt (6) and nut (7).
5
Mount the J3-axis motor (1) horizontally, while being careful
not to damage the surface of the gear teeth. Replace the
- 149 -
6. REPLACING PARTS
MAINTENANCE
6
7
8
9
10
B-81455EN/08
O-ring (8) to the new one and mount the O-ring (8) in the
prescribed place.
Attach the four motor mounting seal bolts (2) and washers
(3).
Attach the three connectors to the J3-axis motor (1).
In the case of 100P, attach the fan. (See the section 6.6)
Apply grease.
Perform mastering. (See Section 5.3 MASTERING.)
- 150 -
B-81455EN/08
Name
1 MOTOR
2 SEAL BOLT
3 WASHER
4 NUT
5 INPUT GEAR
6 BOLT
7 WASHER
8 O RING
9 SEAL
6. REPLACING PARTS
MAINTENANCE
Specifications
Q’ty
A06B-0267-B605#S000
A97L-0118-0706#M12X30
A97L-0001-0823#M12H
165F
It is included in INPUT GEAR
165R
A97L-0218-0380#201
100P
125L
200F
It is included in INPUT GEAR
200FO A97L-0218-0380#219
200R
130U
210F
It is included in INPUT GEAR
A97L-0218-0381#236
165F
A97L-0218-0380#201 1
165R
100P
125L
200F
A97L-0218-0380#219
200FO
200R
130U
210F
A97L-0218-0381#236
165F
A6-BA-8×50
200F
200FO
165R
200R
100P
125L
130U
210F
A6-BA-8×60
A30L-0001-0048#8M
JB-OR1A-G125
A98L-0004-0771#A12TP
1
4
4
1
Loctite
Torque N·m (kgf·m)
LT242
118 (12)
1
LT242
27.5 (2.8)
1
1
1
Fig.6.4 (a) Replacing J3-axis moter (M3) (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
- 151 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
2) Replacing the J3-axis reducer (R-2000iA/165CF)
Disassembling
1
Control the attitude as shown in Fig.6.4 (g), then attach the
sling to hang the unit.
2
Turn off the power supply.
3
Detach the three connectors from the motor (1).
4
Remove the four motor mounting seal bolts (2) and washers
(3).
5
Pull out the motor (1) horizontally, while being careful not to
damage the surface of the gear teeth.
6
Remove the nut (6) and washer (7), then dismount the input
gear (5), draw bolt (4).
Assembling
1
Polish the flange surface of the motor (1) using an oil stone.
2
Attach the new seal (9).
(The seal is included in
A06B-0267-B605#S000 motor.)
3
Mount the draw bolt (4).
4
Mount and fasten the input gear (5) with washer (7) and nut
(6).
5
Mount the motor (1) horizontally, while being careful not to
damage the surface of the gear teeth. Replace the O-ring (8)
to the new one and mount the O-ring (8) in the prescribed
place.
6
Attach the four motor mounting seal bolts (2) and washers
(3).
7
Attach the three connectors to the motor (1).
8
Apply grease.
9
Perform mastering. (See Section 5.3 MASTERING.)
NOTE
To install the J3-axis motor (1), an M12 T-shaped
hexagonal wrench not shorter than 370 mm is
required.
- 152 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Name
1 MOTOR
2 BOLT
3 WASHER
4 DRAW BOLT
5 INPUT GEAR
6 WASHER
7 NUT
8 O RING
9 SEAL
Specifications
Q’ty
A06B-0267-B605#S000
A97L-0118-0706#M12X30
A97L-0001-0823#M12H
It is included in
A97L-0218-0227#190
A97L-0218-0227#190
A6-WB-10S
A6-N1-10S
JB-OR1A-G125
A98L-0004-0771#A12TP
1
4
4
1
1
1
1
1
1
Loctite
LT242
118 (12)
LT242
26.5 (2.7)
Fig.6.4 (b) Replacing J3-axis moter (R-2000iA/165CF)
- 153 -
Torque N·m (kgf·m)
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
3) Replacing the J3 axis reducer
Disassembling
Common tool for replacing the J3-axis reducer
Name
Specification
Guide pin
Guide pin
1
A290-7324-X921
A290-7324-X923
Q’ty
1
1
Place the reducer in the location of Fig.6.4 (e) to Fig.6.4 (g),
and hoist it using a sling.
WARNING
If the J3-axis arm is not slung in a specified manner
when the J3-axis motor is removed, the arm may
drop, resulting in a very dangerous situation.
If it is impossible to sling the J3-axis arm in a
specified manner, fasten it so that it will not move.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification
can be used to fasten the J3-axis arm. Before
starting to remove the motor, install the stopper in
the dropping direction, and jog-feed the J3-axis arm
to get it sufficiently close to the stopper.
2
3
4
5
6
7
Switch off the power.
For the 100P, remove the fan of the J3 motor before
removing the cables. (See Section 6.6, “REPLACING
FANS”.)
Detach the cables leading to the J3 to J6-axis motors, and all
option cables, then pull out them from the J2 arm.
Dismount the J3-axis motor (1) by the procedure described
above.
Remove the J2 arm mounting bolts (3) and (5) and washers
(4) and (6), then remove the J3-axis unit by using the guide
pin (A290-7324-X921, A290-7324-X923) as shown in
Fig.6.4 (h). At this time, apply a sufficient tension to the
sling. (See Fig.6.4 (c) and ig.6.4 (d).)
Remove the reducer mounting bolt (10) and washer (11),
then dismount the reducer (9) with using the guide pin.
NOTE
When installing the J3 axis reducer, attach an M12
hexagonal socket (with a tip not shorter than 70 mm)
to a torque wrench, and tighten the bolt.
- 154 -
MAINTENANCE
B-81455EN/08
6. REPLACING PARTS
Assembling
1
By using a guide pin as shown in Fig.6.4 (h), install a new
reducer (9) with the bolt (10) and washer (11). At this time,
replace the O-ring (12) to the new one and mount the O-ring
(12) in the prescribed place. (See Fig.6.4 (c) and ig.6.4 (d).)
2
Apply a sealing agent to the reducer. (See Section 6.8,
“SEALANT APPLICATION”.)
3
Replace the O-ring (7) and the O-ring (8) to the new one and
attach the O-ring to the J2 arm (13).
CAUTION
Do not apply grease to the O-ring (7). Applying
grease can prevent sealant from hardening, thus
allowing the grease to leak. If it is difficult to fasten
the O-ring, apply a small amount of sealant to the
O-ring, and attach the O-ring to the O-ring groove in
the J2 arm.
4
By using a guide pin, fasten the J3-axis unit to the J2 arm (13)
with the bolts (3) and (5) and washers (4) and (6). At this
time, check that the O-ring (7) and ring (8) are installed in
position.
CAUTION
When installing the J3-axis unit, bring the arm into
close contact with the mating component in one
operation so that the sealant is not wiped away.
Check that the O-ring is installed in the correct
location and that no sealant has been wiped away.
5
6
7
8
Fix the J3-axis motor (1) by the procedure described above.
Attach the cable leading to the J3 to J6-axis motors and
option cables.
Apply grease.
Perform mastering. (See Section 5.3 MASTERING.)
- 155 -
6. REPLACING PARTS
MAINTENANCE
Fig.6.4 (c) (1/2) Replacing the J3 Axis Reducer
(R-2000iA/165F, 200F, 200FO, 165R, 200R, 100P, 125L, 130U and 165CF)
- 156 -
B-81455EN/08
B-81455EN/08
6. REPLACING PARTS
MAINTENANCE
Parts list for replacing J3-axis reducer (R-2000iA/165F, 200F, 200FO, 165R, 200R, 100P, 125L and 130U)
Name
Specifications
Q’ty
Loctite
Torque N·m (kgf·m)
1 MOTOR
A06B-0267-B605#S000
1
2 O RING
JB-OR1A-G125
1
3 BOLT (NOTE)
A6-BA-10×35 (February 2004 and earlier)
18
LT262
73.5 (7.5)
A6-BA-10×45 (March 2004 and later)
4 WASHER
A97L-0001-0823#M10H
18
5 BOLT (NOTE)
A6-BA-16×45 (Except March 2004)
6
LT262
318 (32.5)
A6-BA-16×55 (March 2004)
6 WASHER
A97L-0001-0823#M16H
6
7 O RING
A98L-0001-0347#S240
1
8 RING
A290-7324-X317
1
9 REDUCER
165F
A97L-0218-0371#320E-201
1
165R
100P
125L
200F
A97L-0218-0371#320E-219
200FO
200R
130U
10 BOLT
A6-BA-12×50
16
LT262
128 (13.1)
11 WASHER
A97L-0001-0823#M12H
16
12 O RING
JB-OR1A-G2701
1
13 J2 ARM
A290-7324-X315
1
Note: The bolt length changes depending on the shipment time. When replacing the reducer, confirm that the length of the
removed bolts is the same as that of new ones.
(R-2000iA/165R, 200R, 100P)
Name
Specifications
1 MOTOR
A06B-0267-B605#S000
2 O RING
JB-OR1A-G125
3 BOLT
A6-BA-10×35
4 WASHER
A97L-0001-0823#M10H
5 BOLT
A6-BA-16×45
6 WASHER
A97L-0001-0823#M16H
7 O RING
A98L-0001-0347#S240
8 RING
A290-7324-X317
9 REDUCER
165R
A97L-0218-0371#320E-201
100P
200R
A97L-0218-0371#320E-219
10 BOLT
A6-BA-12×50
11 WASHER
A97L-0001-0823#M12H
12 O RING
JB-OR1A-G270
13 J2 ARM
A290-7324-X315
(R-2000iA/165CF)
Name
1 MOTOR
2 O RING
3 BOLT
4 WASHER
5 BOLT
6 WASHER
7 O RING
8 RING
9 REDUCER
10 BOLT
11 WASHER
12 O RING
13 J2 ARM
Q’ty
1
1
18
18
6
6
1
1
1
16
16
1
1
Loctite
Torque N·m (kgf·m)
LT262
73.5 (7.5)
LT262
318 (32.5)
LT262
128 (13.1)
Specifications
Q’ty
Loctite
Torque N·m (kgf·m)
A06B-0267-B605#S000
1
JB-OR1A-G125
1
A6-BA-10×35
18
LT262
73.5 (7.5)
A97L-0001-0823#M10H
18
A6-BA-16×45
6
LT262
318 (32.5)
A97L-0001-0823#M16H
6
A98L-0001-0347#S240
1
A290-7321-X317
1
A97L-0218-0239#320E-190
1
A6-BA-12×50
16
LT262
128 (13.1)
A97L-0001-0823#M12H
16
JB-OR1A-G270
1
A290-7321-X314
1
Fig.6.4 (c) (2/2) Replacing the J3 Axis Reducer
(R-2000iA/165F, 200F, 200FO, 165R, 200R, 100P, 125L, 130U and 165CF)
- 157 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
(R-2000iA/210F)
Name
1 MOTOR
2 O RING
3 BOLT
4 WASHER
5 BOLT
6 WASHER
7 O RING
8 RING
9 REDUCER
10 BOLT
11 WASHER
12 O RING
13 J2 ARM
Specifications
Q’ty
A06B-0267-B605#S000
JB-OR1A-G125
A6-BA-12×40
A97L-0001-0823#M12H
A6-BA-16×45
A97L-0001-0823#M16H
A98L-0040-0041#178
A290-7324-Z317
A97L-0218-0372#410F-236
A6-BA-12×60
A97L-0001-0823#M12H
JB-OR1A-G280
A290-7324-X314
1
1
18
18
6
6
1
1
1
23
23
1
1
Loctite
LT262
128 (13.1)
LT262
318 (32.5)
LT262
128 (13.1)
Fig.6.4 (d) Replacing J3-axis reducer (R-2000iA/210F)
- 158 -
Torque N·m (kgf·m)
B-81455EN/08
MAINTENANCE
6. REPLACING PARTS
Fig.6.4 (e) Replacement Posture of the J3 Axis Reducer (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 159 -
6. REPLACING PARTS
MAINTENANCE
Fig.6.4 (f) Replacement Posture of the J3 Axis Reducer (R-2000iA/165R, 200R and 100P)
- 160 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
6. REPLACING PARTS
Fig.6.4 (g) Replacement Posture of the J3 Axis Reducer (R-2000iA/165CF)
- 161 -
6. REPLACING PARTS
MAINTENANCE
Fig.6.4 (h) Using of guide pin
- 162 -
B-81455EN/08
B-81455EN/08
6.5
MAINTENANCE
6. REPLACING PARTS
REPLACING THE WRIST AXIS MOTORS (M4, M5, AND M6),
WRIST UNIT, AND J4 AXIS REDUCER
1) Replacing the Wrist Axis Motors (M4, M5, and M6)
Disassembling
1
Place the wrist in a posture in which no load is applied to the
wrist axis.
2
Switch off the power.
3
Detach the three connectors from the motor (1).
4
Remove the three motor mounting bolts (2) and washers (3).
5
Pull out the motor (1), while being careful not to damage the
surface of the gear teeth.
6
In case of J4-axis motor, remove the nut (12) and washer (7),
and dismount the gear (11) [with bearing (10) and C ring (9)].
In case of J5-axis motor or J6-axis motor remove the nut (8)
and washer (7), and dismount the gear (6).
Assembling
1
Polish the flange surface of the motor (1) using an oil stone.
2
In case of J4-axis motor, attach seal (5) and mount gear (11)
[with bearing (10) and C ring (9)] with the washer (7) and nut
(12).
Note) Before attaching the gear (11) to the motor (1), use the
jig A290-7321-X947 to attach the bearing (10) and
C-ring (9) to the gear (11). (The seal is included in
A06B-0267-B605#S000 motor.)
In case of J5-axis motor or J6-axis motor attach seal (5) and
fasten the gear (6) with the washer (7) and nut (8).
3
Mount the motor (1), while being careful not to damage the
surface of the gear teeth. Replace the O-ring (4) to the new
one and mount the O-ring (4) in the prescribed place. Also be
sure to orient the motor (1) correctly.
4
Attach the three motor mounting bolts (2) and washers (3).
5
Attach the three connectors to the motor (1).
6
Apply grease.
7
Perform mastering.
NOTE
– When tightening the nut (12), hold the gear (11) with
a 30×32mm or 32×36mm spanner (Thickness is
14mm or less.
– To install a motor, an M8 T-shaped hexagonal
wrench not shorter than 300mm is required.
- 163 -
6. REPLACING PARTS
MAINTENANCE
Fig.6.5 (a) Replacing the Wrist Axis Motors (M4, M5, M6)
- 164 -
B-81455EN/08
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
R-2000iA/165F, 200F, 200FO, 165R, 200R, 125L and 130U
Name
1
2
3
4
5
6
MOTOR
BOLT
WASHER
O RING
SEAL (*)
GEAR J51
GEAR J61
7
8
9
10
11
WASHER
NUT
C RING
BEARING
GEAR J41
12 NUT
Specifications
Q’ty
A06B-0235-B605#S000
A6-BA-8×20
A97L-0001-0823#M8H
JB-OR1A-G105
A98L-0004-0771#A03TP
A290-7324-X423
165F
A290-7324-X425
165R
125L
200F
A290-7324-Z425
200FO
200R
130U
A97L-0001-0610#10
A6-N1-10X1.25S-M-N1
A6-CJR-30
A97L-0218-0428#0600000
165F
A290-7324-X421
165R
200F
A290-7324-Z421
200FO
200R
130U
125L
A290-7324-Y421
A290-7321-X409
3
9
9
3
3
1
1
3
2
1
1
1
1
Loctite
Torque N·m (kgf·m)
LT242
16.7 (1.7)
LT242
16.7 (1.7)
R-2000iA/210F, 100P
Name
1
2
3
4
5
6
7
8
9
10
11
12
MOTOR
BOLT
WASHER
O RING
SEAL
GEAR J51
GEAR J61
WASHER
NUT
C RING
BEARING
GEAR J41
NUT
Specifications
Q’ty
A06B-0235-B605#S000
A6-BA-8×20
A97L-0001-0823#M8H
JB-OR1A-G105
A98L-0004-0771#A03TP
A290-7324-Z423
A290-7324-X425
A97L-0001-0610#10
A6-N1-10×1.25S-M-N1
A6-CJR-30
A97L-0218-0428#0600000
A290-7324-Z421
A290-7321-X409
3
9
9
3
3
1
1
3
2
1
1
1
1
- 165 -
Loctite
Torque N·m (kgf·m)
LT242
16.7 (1.7)
LT242
16.7 (1.7)
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
R-2000iA/165CF
Name
1
2
3
4
5
6
7
8
9
10
11
12
MOTOR
BOLT
WASHER
O RING
SEAL
GEAR J51
GEAR J61
WASHER
NUT
C RING
BEARING
GEAR J41
NUT
Specifications
Q’ty
A06B-0235-B605#S000
A6-BA-8×20
A97L-0001-0823#M8H
JB-OR1A-G105
A98L-0004-0771#A03TP
A290-7321-Y423
A290-7321-Y425
A97L-0001-0610#10
A6-N1-10×1.25S-M-N1
A6-CJR-30
A97L-0218-0428#0600000
A290-7321-Y421
A290-7321-X409
3
9
9
3
3
1
1
3
2
1
1
1
1
- 166 -
Loctite
Torque N·m (kgf·m)
LT242
16.7 (1.7)
LT242
16.7 (1.7)
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
2) Replacing the wrist unit and J4 axis reducer
(R-2000iA/165F, 165R and 125L)
Disassembling
1
Unload the wrist by removing the hand and any workpiece.
2
Remove the wrist unit mounting bolt (1) and washer (2), then
dismount the wrist unit.
3
Remove the reducer mounting bolt (4) and washer (5), then
dismount the reducer (6) from the J3 arm.
Assembling
1
Replace the O-ring (7) to the new one and install the O-ring
(7) onto the reducer (6).
2
Mount and fasten the reducer (6) to the J3 arm with the
reducer mounting bolt (4) and washer (5).
3
Replace the O-ring (3) to the new one and install the O-ring
(3) in the groove of the end face of the reducer.
Fasten the wrist unit with the wrist unit mounting bolt (1) and
washer (2).
4
Apply grease.
5
Perform mastering. (See Section 5.3 MASTERING.)
Name
1 BOLT
2 WASHER
3 O RING
4 BOLT
5 WASHER
6 REDUCER
7 O RING
Specifications
A6-BA-10×35
A97L-0001-0823#M10H
JB-OR1A-G135
A6-BA-8×35
A97L-0001-0823#M8H
A97L-0218-0281#70F-45
A98L-0040-0041#260
Q’ty
12
12
1
16
16
1
1
Loctite
Torque N·m (kgf·m)
LT262
73.5 (7.5)
LT262
37.2 (3.8)
Fig.6.5 (b) Replacing the Wrist Unit and J4 Axis Reducer (R-2000iA/165F, 165R and 125L)
- 167 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
3) Replacing the wrist unit and J4-axis reducer
(R-2000iA/200F, 200FO, 200R and 130U)
Disassembling
1
Remove the load, such as the hand and workpiece, from the
wrist.
2
Remove the wrist unit mounting bolt (1) and washer (2), then
remove the wrist unit.
3
Remove the adapter mounting bolt (4) and washer (5), then
remove the adapter (6).
4
Remove the reducer mounting bolt (8) and washer (9), then
remove the reducer (10) from the J3 arm.
Assembling
1
Replace the O-ring (11) to the new one and attach the O-ring
(11) to the groove in the reducer (10) end face.
2
Mount the reducer (10) on the J3 arm, and fasten them with
the reducer mounting bolt (8) and washer (9).
3
Replace the O-ring (7) to the new one and attach the O-ring
(7) to the groove in the adapter (6) end face (on the reducer
side).
4
Fasten the adapter (6) with the adapter mounting bolt (4) and
washer (5).
5
Replace the O-ring (3) to the new one and attach the O-ring
(3) to the groove in the adapter (6) end face (on the wrist
side).
6
Fasten the wrist unit with the wrist unit mounting bolt (1) and
washer (2).
7
Apply grease.
8
Perform mastering. (See Section 5.3 MASTERING.)
- 168 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Name
1 BOLT
2 WASHER
3 O RING
4 BOLT
5 WASHER
6 ADAPTER
7 O RING
8 BOLT
9 WASHER
10 REDUCER
11 O RING
Specifications
A6-BA-8×35
A97L-0001-0823#M8H
A98L-0040-0041#166
A6-BA-12×25
A97L-0001-0823#M12H
A290-7321-Z411
A98L-0040-0041#167
A6-BA-10×35
A97L-0001-0823#M10H
A97L-0218-0249#110E-46
JB-ORIA-G190
Q’ty
18
18
1
12
12
1
1
12
12
1
1
Loctite
Torque N·m (kgf·m)
LT262
37.2 (3.8)
LT262
128.4 (13.1)
LT262
73.5 (7.5)
Fig.6.5 (c) Replacing the wrist unit and J4-axis reducer (R-2000iA/200F, 200FO, 200R and 130U)
- 169 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
4) Replacing the wrist unit and J4 axis reducer (R-2000iA/210F, 100P)
Disassembling
1
Unload the wrist by removing the hand and any workpiece.
2
Remove the wrist unit mounting bolt (1) and washer (2), then
dismount the wrist unit.
3
Remove the reducer mounting bolt (4) and washer (5), then
dismount the reducer (6) from the J3 arm.
Assembling
1
Replace the O-ring (7) to the new one and install the O-ring
(7) onto the groove of the end face of the reducer (6).
2
Mount and fasten the reducer (6) to the J3 arm with the
reducer mounting bolt (4) and washer (5).
3
Replace the O-ring (3) to the new one and install the O-ring
(3) in the wrist unit.
4
Add loctite. (See the section 6.8)
5
Fasten the wrist unit with the wrist unit mounting bolt (1) and
washer (2).
6
Apply grease.
7
Perform mastering. (See Seciton 5.3 MASTERING.)
- 170 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
(R-2000iA/210F)
Name
1 BOLT
2 WASHER
3 O RING
4 BOLT
5 WASHER
6 REDUCER
7 O RING
Specifications
A6-BA-8×40
A97L-0001-0823#M8H
A290-7302-X552
A6-BA-10×35
A97L-0001-0823#M10H
A97L-0218-0342#110E-46
JB-ORIA-G190
Q’ty
24
24
1
12
12
1
1
Loctite
Torque N·m (kgf·m)
LT262
37.2 (3.8)
LT262
73.5 (7.5)
Fig.6.5 (d) Replacing the wrist unit and J4-axis reducer (R-2000iA/210F, 100P)
- 171 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
5) Replacing the wrist unit and J4 axis reducer (R-2000iA/165CF)
Disassembling
1
Unload the wrist by removing the hand and any workpiece.
2
Remove the wrist unit mounting bolt (1) and washer (2), then
dismount the wrist unit.
3
Remove the adapter mounting bolt (5) and washer (6), then
dismount the adapter (4).
4
Remove the reducer mounting bolt (8) and washer (9), then
dismount the reducer (7) from the adapter (11).
Assembling
1
Add loctite. (See the section 6.8)
2
Fasten the reducer (7) to the adapter (11) with the reducer
mounting bolt (8) and washer (9). Replace the O-ring (10) to
the new one and mount the O-ring (10) in the prescribed
place.
3
Mount and fasten the adapter (4) with the adapter mounting
bolt (5) and washer (6).
4
Mount and fasten the wrist unit with wrist unit mounting bolt
(1) and washer (2). Replace the O-ring (3) to the new one
and mount the O-ring (3) in the prescribed place.
5
Apply grease.
6
Perform mastering. (See Section 5.3 MASTERING.)
- 172 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Name
1 BOLT
2 WASHER
3 O RING
4 ADAPTER
5 BOLT
6 WASHER
7 REDUCER
8 BOLT
9 WASHER
10 O RING
11 ADAPTER
Specifications
A6-BA-8×30
A97L-0001-0823#M8H
A98L-0001-0347#S125
A290-7321-X413
A6-BA-8×20
A97L-0001-0823#M8H
A97L-0218-0240#80E-37
A6-BA-8×30
A97L-0001-0823#M8H
A290-7302-X552
A290-7321-X412
Q’ty
16
16
1
1
18
18
1
16
16
1
1
Loctite
Torque N·m (kgf·m)
LT262
37.2 (3.8)
LT262
37.2 (3.8)
LT262
37.2 (3.8)
Fig.6.5 (e) Replacing the Wrist Unit and J4 Axis Reducer (R-2000iA/165CF)
- 173 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
NOTE
Degrease the surface to be sealed, and apply
sealant (Loctite 518) to the portion indicated
(shown above).
Especially for the portions A, sealant should be
applied with no gap.
Fig.6.5 (f) Replacing the Wrist Unit and J4 Axis Reducer (R-2000iA/165CF)
- 174 -
MAINTENANCE
B-81455EN/08
6.6
6. REPLACING PARTS
REPLACING FANS
The R-2000iA/100P is equipped with cooling fans for the J1, J2, and
J3-axis motors. The procedure for replacing the fans is the same for all
axes. The following example describes the procedure for the J2-axis.
Disassembling
1
Turn off the power.
2
Remove the grounding cable from the fan body.
3
Remove the fan cable.
4
Remove bolts 1, washers 2, and fan assembly 3.
At this time, be careful not to break the pulse coder connector
of the motor.
Assembling
1
Mount fan assembly 3 and secure it with bolts 1 and washers
2.
At this time, be careful not to break the pulse coder connector
of the motor.
2
Connect the fan cable.
3
Connect the grounding cable to the fan body.
- 175 -
6. REPLACING PARTS
Name
1 BOLT
2 WASHER
3 FAN ASSY
MAINTENANCE
Specifications
B-81455EN/08
Q’ty
A6-BA-8×12
A6-WM-8S
A290-7324-V602
2
2
1
Fig.6.6 Replacing the fan
- 176 -
Loctite
Torque N·m (kgf·m)
B-81455EN/08
6.7
MAINTENANCE
6. REPLACING PARTS
REPLACING THE BALANCER
Disassembling
1
Orient the robot to allow replacement of the J2-axis motor
(M2) and reducer.
2
Turn off the power.
3
(In the case of R-2000iA/165F, 200F, 200FO, 210F and
125L)
Remove the button head bolt (1), and attach M8 and M12
eyebolts to the balancer, then lift the balancer with a crane.
(In the case of R-2000iA/165R, 200R and 100P)
Attach four eyebolts (M12) to the balancer, then lift the
balancer at four points with a crane.
4
Remove the bolt (2) and cover (3), and loosen the U nut (4)
so that no tension is applied to the balancer.
5
Remove the bolt (5) and washer (6), then pull out the shaft
assembly (7).
6
Remove the bolt (8) and washer (9), then remove the shaft
(10).
7
Lift the balancer assembly (12).
Assembling
1
Insert the shaft (10) so that the through tap is placed
horizontally, then install the bolt (8) and washer (9).
2
Insert the shaft assembly (7), then install the bolt (5) and
washer (6).
3
Tighten the U nut (4) by a specified torque, then fasten the
cover (3) with the mounting bolt (2).
4
(In the case of R-2000iA/165F, 200F, 200FO, 210F and
125L)
Remove the eyebolt (M12, M8), then install the button head
bolt (1).
(In the case of R-2000iA/165R, 200R and 100P)
Remove the eyebolt (M12).
5
Supply grease to the grease nipple attached to the shaft.
WARNING
Never disassemble the balancer. The balancer
contains a large compressed spring. If the balancer
is disassembled without using a special jig, the
internal spring will extend, and can expose you to
danger. When replacing the balancer, be sure to
replace the balancer assembly.
- 177 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
NOTE
When tightening the U nut (4), use a torque wrench
with a socket for a M33 or M42 nut.
Width across flats
M33 : 50mm
M42 : 65mm
Name
Specifications
1 BUTTON BOLT
2 BOLT
3 COVER
4 U NUT
5 BOLT
6 WASHER
7 SHAFT ASSY
8 BOLT
9 WASHER
10 SHAFT
11 GREASE NIPPLE
12 BALANCER ASS’Y
A97L-0080-0007#M12X20
A6-BA-6×10
A290-7324-X391
A97L-0001-0660#BMN133
A6-BA-6×20
A97L-0001-0823#M6H
A290-7324-V351
A6-BA-8×20
A97L-0001-0823#M8H
A290-7324-X382
A97L-0218-0013#A610
165F A290-7324-V301
200F
125L
210F A290-7324-V303
Q’ty
1
2
1
1
4
4
1
8
8
2
2
1
Loctite
Torque N·m (kgf·m)
319 (32.5)
Fig.6.7 (a) Replacing the balancer (R-2000iA/165F, 200F, 210F and 125L)
- 178 -
6. REPLACING PARTS
MAINTENANCE
B-81455EN/08
Name
1 BUTTON BOLT
2 BOLT
3 COVER
4 U NUT
5 BOLT
6 WASHER
7 SHAFT ASSY
8 BOLT
9 WASHER
10 SHAFT
11 GREASE NIPPLE
12 BALANCER ASS’Y
Specifications
A97L-0080-0007#M12 20
A6-BA-6×10
A290-7324-X391
A97L-0001-0660#BMN133
A6-BA-6×20
A97L-0001-0823#M6H
A290-7324-V351
A6-BA-8×20
A97L-0001-0823#M8H
A290-7324-X382
A97L-0218-0013#A610
A290-7324-V302
Q’ty
Loctite
1
2
1
1
4
4
1
8
8
2
2
1
Fig.6.7 (b) Replacing the balancer (R-2000iA/200FO)
- 179 -
Torque N·m (kgf·m)
319 (32.5)
6. REPLACING PARTS
Name
MAINTENANCE
Specifications
2 BOLT
3 COVER
4 U NUT
5 BOLT
6 WASHER
7 SHAFT ASSY
8 BOLT
9 WASHER
10 SHAFT
11 GREASE NIPPLE
12 BALANCER ASSY
A6-BA-6×10
A290-7324-Y391
A97L-0001-0660#BMN142
A6-BA-12×35
A97L-0001-0823#M12H
A290-7324-V361
A6-BA-8×20
A97L-0001-0823#M8H
A290-7324-Y382
A97L-0218-0013#A610
A290-7324-V311
B-81455EN/08
Q’ty
2
1
1
8
8
1
8
8
2
2
1
Loctite
Torque N·m (kgf·m)
319 (32.5)
Fig.6.7 (c) Replacing the balancer (R-2000iA/165R, 200R and 100P)
- 180 -
MAINTENANCE
B-81455EN/08
6.8
6. REPLACING PARTS
SEALANT APPLICATION
Washing and degreasing the surfaces to be sealed
1
2
3
4
After dismounting the reducer from the arm, apply releasant
(Loctite Gasket Remover) to the arm’s surface from which the
reducer was dismounted, then wait until the sealant (Loctite 518)
becomes softened (for about 10 minutes). Remove the softened
sealant from the surface using a spatula.
Blow air onto the surface to be sealed to remove dust from the
tapped holes.
Sufficiently degrease the reducer’s surface to be sealed and the
arm’s surface to be sealed, using a cloth dampened with alcohol.
Polish the arm's surface to be sealed with an oil stone, and
degrease it with alcohol again.
NOTE
Oil may drip from the inside of the reducer. After
degreasing, make sure that no oil is dripping.
Applying sealant
5
6
Make sure that the reducer and the arm are dry (with no alcohol
remaining). If they are still wet with alcohol, wipe them dry.
Apply sealant (Loctite 518) to the surfaces.
NOTE
The portions to which sealant is to be applied vary
from one axis to another. See descriptions about
reducer replacement for the relevant axes for
details.
Assembling
7
8
To prevent dust from sticking to the portions to which sealant was
applied, mount the reducer as quickly as possible after sealant
application. Be careful not to touch the applied sealant. If sealant
was wiped off, apply again.
After mounting the reducer, fasten it with bolts and washers
quickly so that the mated surfaces get closer.
NOTE
Do not grease the reducer before the sealant sets,
as it may allow grease to leak. Before greasing, wait
for about at least one hour after the reducer is
mounted.
- 181 -
6. REPLACING PARTS
6.9
MAINTENANCE
B-81455EN/08
REPLACING MOTOR COVERS (OPTION)
Replacing the J1-/J2-axis motor cover
1
2
Remove the M8×12 bolts (three for the J1-axis and two for the
J2-axis) and washers that fasten the motor cover to the motor, then
remove the motor cover.
To mount the motor cover, reverse the above mounting procedure
steps.
Fig.6.9 (a) Replacing the J1-/J2-axis motor cover (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 182 -
MAINTENANCE
B-81455EN/08
6. REPLACING PARTS
Fig.6.9 (b) Replacing the J1-/J2-axis motor cover
(R-2000iA/165R, 200R) (For severe dust/liquid protection option)
Replacing the J3-/J4-/J5-/J6-axis motor cover
1
2
3
Remove the seven M6×10 bolts and washers that fasten the lower
motor cover, then remove the motor cover. If there is no motor
cover, go to step 2.
Remove the four M6×10 bolts that fasten the upper motor cover to
the J3-axis casing, the M6×12 bolt that fastens the motor cover
together with the cable clamp metal, and the related washers, then
remove the motor cover.
To mount the motor covers, reverse the above mounting procedure
steps. In this case, however, first attach the bolts, but keep them
loose so that the motor covers can be put in correct place;
otherwise the upper motor cover tap may be destroyed. After the
motor covers are positioned properly, tighten the bolts.
Fig.6.9 (c) Replacing the J3-/J4-/J5-/J6-axis motor covers
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 125L and 130U)
- 183 -
7. PIPING AND WIRING
7
MAINTENANCE
PIPING AND WIRING
- 184 -
B-81455EN/08
MAINTENANCE
B-81455EN/08
7.1
7. PIPING AND WIRING
PIPING DIAGRAM
Fig.7.1 shows the piping diagram of the mechanical unit.
Fig.7.1 (a) Piping diagram (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 185 -
7. PIPING AND WIRING
MAINTENANCE
Fig.7.1 (b) Piping diagram (R-2000iA/165R, 200R and 100P)
- 186 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
Fig.7.1 (c) Piping diagram (R-2000iA/165CF)
- 187 -
7. PIPING AND WIRING
7. PIPING AND WIRING
7.2
MAINTENANCE
WIRING DIAGRAM
Fig.7.2 shows the wiring diagram of the mechanical unit.
Fig.7.2 (a) Wiring diagram (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 188 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
Fig.7.2 (b) Wiring diagram (R-2000iA/165R, 200R and 100P)
- 189 -
7. PIPING AND WIRING
7. PIPING AND WIRING
MAINTENANCE
Fig.7.2 (c) Wiring diagram (R-2000iA/165CF)
- 190 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
7. PIPING AND WIRING
Fig.7.2 (d) Wiring diagram block (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 191 -
7. PIPING AND WIRING
MAINTENANCE
Fig.7.2 (e) Wiring diagram block (R-2000iA/165R and 200R)
- 192 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
Fig.7.2 (f) Wiring diagram block (R-2000iA/100P)
- 193 -
7. PIPING AND WIRING
7. PIPING AND WIRING
MAINTENANCE
Fig.7.2 (g) Wiring diagram block (R-2000iA/165CF)
- 194 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
7. PIPING AND WIRING
Fig.7.2 (h) Connector locations (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 195 -
7. PIPING AND WIRING
MAINTENANCE
Fig.7.2 (i) Connector locations (R-2000iA/165R and 200R)
Fig.7.2 (j) Connector locations (R-2000iA/100P)
- 196 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
Fig.7.2 (k) Connector locations (R-2000iA/165CF)
- 197 -
7. PIPING AND WIRING
8. REPLACING CABLES
8
MAINTENANCE
B-81455EN/08
REPLACING CABLES
Replace the cables every four years. When the cable is broken or
damaged, or shows signs of wear, replace it according to this chapter.
Precautions to be observed when handling the pulse coder cable
The pulse coder cable is provided with a marking tie, as shown below,
to warn against disconnecting the cable during transportation,
installation, or maintenance. If the cable with the marking tie is
disconnected, mastering must be performed again. Therefore, do not
disconnect the cable except when replacement of the cable is necessary.
The J1-axis and J2-axis motors are provided with a pulse coder
connector cover, as shown in Fig.8 (b), to protect the connectors.
Before removing the connectors for cable replacement or other
purposes, remove the covers. In this case, turning the bolt may also turn
the cover, possibly causing damage to the connector. When removing
the cover, hold it to prevent it from turning.
Fig.8 (a) Marking Tie
- 198 -
B-81455EN/08
MAINTENANCE
8. REPLACING CABLES
Fig.8 (b) Pulse coder connector cover
- 199 -
8. REPLACING CABLES
8.1
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CABLE FORMING
When replacing cables, clamp the cable at the position specified in
Table 8.1 (a) to (o) using a clamp or a nylon band. Otherwise, cables are
loosened or forcedly pulled to cause their disconnection. Refer to the
figures in section 8.2 for the cable clamp position not listed in the Table.
Table 8.1 (a) CABLE CLAMP (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
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Table 8.1 (b) CABLE CLAMP (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
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Table 8.1 (c) CABLE CLAMP (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
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Table 8.1 (d) CABLE CLAMP (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
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Table 8.1 (e) CABLE CLAMP (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
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Table 8.1 (f) CABLE CLAMP (R-2000iA/165R, 200R and 100P)
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Table 8.1 (g) CABLE CLAMP (R-2000iA/165R, 200R and 100P)
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Table 8.1 (h) CABLE CLAMP (R-2000iA/165R, 200R and 100P)
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Table 8.1 (i) CABLE CLAMP (R-2000iA/165R, 200R and 100P)
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Table 8.1 (j) CABLE CLAMP (R-2000iA/165R, 200R and 100P)
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Table 8.1 (k) CABLE CLAMP (R-2000iA/100P)
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Table 8.1 (l) CABLE CLAMP (R-2000iA/165CF)
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Table 8.1 (m) CABLE CLAMP (R-2000iA/165CF)
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Table 8.1 (n) CABLE CLAMP (R-2000iA/165CF)
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Table 8.1 (o) CABLE CLAMP (R-2000iA/165CF)
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8.2
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8. REPLACING CABLES
CABLE REPLACEMENT
This section describes a procedure for periodically replacing all the
(full-option) mechanical unit cables.
If you need to replace a specific cable (because, for example, it is
damaged), do so by referencing this section. See Section 7.2 for the
configuration of the mechanical unit cables.
Cable replacement makes it necessary to perform mastering. Before
attempting replacement, therefore, see Section 5.3.
• Replacement procedure (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
(1) Place all the robot axes in their 0-degree position, then set the
control unit power switch to off.
(2) Detach, from the connector panel on the rear of the robot, the cable
leading to the control unit. Remove the connector panel from the
J1 base, then detach all the cable tubes from the connector panel.
When detaching a HARTING connector, leave its housing on the
connector panel; remove the inserts together with the cable. If the
housing is left on the cable, the cable cannot be pulled out through
the J1 axis piping. (Fig.8.2 (a))
(3) When the robot has limit switches (option), remove the limit
switch for the J1-axis from the plate of the J1-axis base, and
remove the terminal in the switch, then pull out the cable from the
cast through hole. (Fig.8.2 (b))
(4) Remove all connectors from the J1-axis through J6-axis motors.
For the precautions that must be taken, see “Precautions to be
observed when handling the pulse coder cable” at the beginning of
Chapter 8.
(5) Remove the cover plate attached to the J2-axis base. If a DS/DP
cable (option) is connected, remove the cable from the connector
panel jointly secured to the cover plate. (Fig.8.2 (d))
(6) The upper part of the J1-axis has a plate for clamping the cable.
The plate is fastened to the J2-axis base. Remove the bolt and
cable cover attached to the plate, then drop the cable in the pipe.
(Fig.8.2 (f))
(7) Remove and pull out the plate from within the J1-axis base as
much as possible, then remove the bolt fastening the clamp.
(Fig.8.2 (i))
(8) Pull out the cable upward from the pipe of the J1-axis.
This completes cable detachment from the J1-axis base.
(9) Remove the plate fastening the cable under the balancer.
Moreover, remove the bolts fastening the left plate of the J2-axis
base, and pull out the cable to the lower side of the J2-axis arm by
running the cable under the balancer. (Fig.8.2 (j))
(10) Remove the cover plate of the J2-axis arm. Then, remove the bolts
fastening the plate of the J2-axis arm. (Fig.8.2 (l))
(11) If the robot has limit switches (option), remove the limit switches
for the J2-axis and J3-axis from the plate of the J2-axis arm, and
remove the terminals in the switches, then pull out the cables from
the cast through hole of the J2-axis arm. (Fig.8.2 (m))
This completes cable detachment from the J2-axis base and J2-axis arm.
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(12) Remove the bolts securing the left plate of the J3-axis casing.
(Fig.8.2 (o))
(13) Remove the connector panel from the front of the J3-axis casing,
then detach the cables and tubes from the connector panel.
(Fig.8.2 (q))
(14) Remove the bolts fastening the right plate of the J3-axis casing.
(Fig.8.2 (r))
This completes cable unit detachment from the robot.
(15) When replacing a part of the cables, remove the clamp and cable
cover from the cable unit. Next, cut the cable tie securing the
cables, then detach the desired cable(s). (Fig.8.2 (t))
Install the cable according to the procedure below.
(1) Before connecting the cable to the robot, fasten the cable at the
marked position with a cable tie, and install the clamp and cable
cover. (Fig.8.2 (t))
(2) Fasten the cable unit to the J2-axis arm with the bolts. When a
limit switch is used, run the cable through the cast through hole of
the J2-axis arm, and connect the switch terminal for the J2-axis
and J3-axis, then install the switch onto the plate of the J2-axis arm.
Pull out any excess cable toward the J2-axis arm cover, then bind
the excess cable with the main cable by using a cable tie. Next,
install the cover plate on the J2-axis arm. (Fig.8.2 (l), (m))
(3) Pull out the cable toward the back of the robot by running the cable
under the balancer. Then, fasten the left plate of the J2-axis base
and the plate under the balancer. Be careful to lay the cable so that
mechanical strain is not caused between the plate under the
balancer and the cable. (Fig.8.2 (j))
CAUTION
Do not use bolts to forcibly pull the plate under the
balancer. Otherwise, the plate is deformed, causing
interference with the balancer and a break in the
cable.
(4) Fasten the plate to the left and right sides of the J3-axis casing.
Then, connect the cables and tubes to the connector panel on the
front of the J3-axis casing, then fasten the connector panel to the
J3-axis casing. Lay neatly the cables run on the J3-axis casing,
and fasten the cables to the tie mount on the J3 casing. (Fig.8.2 (o),
(q), (r))
(5) Run the cable through the J1-axis pipe from the top of the J2-axis
base, then pull out the cable toward the back of the J1-axis base.
(6) Fasten the clamp onto the plate in the J1-axis base. Bind tightly
the cables with a thick cable tie (T120I) running through the clamp,
then fasten the plate to the J1-axis base. (Fig.8.2 (i))
(7) Fasten the clamp and cable cover to the plate at the top of the
J1-axis. Bind tightly the cables with a thick cable tie (T120I)
running through the clamp, then fasten the plate to the J2-axis base.
(Fig.8.2 (f))
(8) Fasten the cover plate to the J2-axis base. If a DS/DP cable
(option) is used, fasten the connector onto the connector panel,
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then fasten the connector panel together with the cover plate.
(Fig.8.2 (d))
(9) Attach all connectors to the J1-axis through J6-axis motors. Make
sure that the pulse coder connector covers are attached to the
J1-axis and J2-axis motors.
(10) When the robot has limit switches (option), run the cable through
the cast through hole of the J1-axis base, then connect the cable to
the terminal in the switch. Next, fasten the switch to the plate on
the J1-axis base. (Fig.8.2 (b))
(11) Connect the cables and tubes to the connector panel on the back of
the robot. Connect the ground terminal to the J1-axis base, then
connect the battery terminal to the back of the battery box. Next,
fasten the connector panel to the J1-axis base, then connect the
cable used for connection with the control unit to the connector
panel. (Fig.8.2 (a))
(12) Turn on the power. If an alarm is issued at this time, release it
according to Section 5.3.
(13) Perform mastering.
• Replacement procedure (R-2000iA/165R, 200R and 100P)
(1) Place all the robot axes in their 0-degree position, then set the
control unit power switch to off.
(2) Detach, from the connector panel on the rear of the robot, the cable
leading to the control unit. Remove the connector panel from the
J1 base, then detach all the cable tubes from the connector panel.
When detaching a HARTING connector, leave its housing on the
connector panel; remove the inserts together with the cable. If the
housing is left on the cable, the cable cannot be pulled out through
the J1 axis piping. (Fig.8.2 (a))
(3) When the robot has limit switches (option), remove the limit
switch for the J1-axis from the plate of the J1-axis base, and
remove the terminal in the switch, then pull out the cable from the
cast through hole. (Fig.8.2 (b))
(4) In the case of 100P remove the fan cable of J1, J2 and J3-axis and
the fan. (See the section 6.6) Remove all connectors from the
J1-axis through J6-axis motors. For the precautions that must be
taken, see “Precautions to be observed when handling the pulse
coder cable” at the beginning of Chapter 8.
(5) Remove the cover plate attached to the J2-axis base. If a DS/DP
cable (option) is connected, remove the cable from the connector
panel. (Fig.8.2 (e))
(6) The upper part of the J1-axis has a plate for clamping the cable.
The plate is fastened to the J2-axis base. Remove the bolt and
cable cover attached to the plate, then drop the cable in the pipe.
(Fig.8.2 (g))
(7) Remove and pull out the plate from within the J1-axis base as
much as possible, then remove the bolt fastening the clamp.
(Fig.8.2 (i))
(8) Pull out the cable upward from the pipe of the J1-axis.
This completes cable detachment from the J1-axis base.
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(9) Remove the left plate of the J2-axis base, and the protective plate
under the balancer. Run the cable under the balancer, toward the
J2-axis arm side of the J2-axis base. (Fig.8.2 (k))
(10) Remove the cover plate of the J2-axis arm. Then, remove the bolts
fastening the plate of the J2-axis arm. (Fig.8.2 (l))
(11) If the robot has limit switches (option), remove the limit switches
for the J2-axis and J3-axis from the plate of the J2-axis arm, and
remove the terminals in the switches, then pull out the cables from
the cast through hole of the J2-axis arm. (Fig.8.2 (m))
This completes cable detachment from the J2-axis base and J2-axis arm.
(12) Remove the bolts securing the left plate of the J3-axis casing.
(Fig.8.2 (o))
(13) Remove the connector panel from the front of the J3-axis casing,
then detach the cables and tubes from the connector panel.
(Fig.8.2 (q))
(14) Remove the bolts fastening the right plate of the J3-axis casing.
(Fig.8.2 (r))
This completes cable unit detachment from the robot.
(15) When replacing a part of the cables, remove the clamp and cable
cover from the cable unit. Next, cut the cable tie securing the
cables, then detach the desired cable(s). (Fig.8.2 (u))
Install the cable according to the procedure below.
(1) Before connecting the cable to the robot, fasten the cable at the
marked position with a cable tie, and install the clamp and cable
cover. (Fig.8.2 (u))
(2) Fasten the cable unit to the J2-axis arm with the bolts. When a
limit switch is used, run the cable through the cast through hole of
the J2-axis arm, and connect the switch terminal for the J2-axis
and J3-axis, then install the switch onto the plate of the J2-axis arm.
Pull out any excess cable toward the J2-axis arm cover, then bind
the excess cable with the main cable by using a cable tie. Next,
install the cover plate on the J2-axis arm. (Fig.8.2 (l), (m))
(3) Run the cable under the balancer, toward the J1-axis motor side of
the J2-axis base. Then, fasten the left plate of the J2-axis base.
Pay particular attention to cabling so that strain is not caused on
the cable. To prevent interference between the balancer and cable,
mount the protective plate, then fasten the cable to the plate with
cable ties. (Fig.8.2 (k))
(4) Fasten the plate to the left and right sides of the J3-axis casing.
Then, connect the cables and tubes to the connector panel on the
front of the J3-axis casing, then fasten the connector panel to the
J3-axis casing. Lay neatly the cables run on the J3-axis casing,
and fasten the cables to the tie mount on the J3 casing. (Fig.8.2 (o),
(q), (r))
(5) Run the cable through the J1-axis pipe from the top of the J2-axis
base, then pull out the cable toward the back of the J1-axis base.
(6) Fasten the clamp onto the plate in the J1-axis base. Bind tightly
the cables with a thick cable tie (T120I) running through the clamp,
then fasten the plate to the J1-axis base. (Fig.8.2 (i))
(7) Fasten the clamp and cable cover to the plate at the top of the
J1-axis. Bind tightly the cables with a thick cable tie (T120I)
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running through the clamp, then fasten the plate to the J2-axis base.
(Fig.8.2 (g))
(8) Fasten the cover plate to the J2-axis base. If a DS/DP cable
(option) is used, fasten the connector onto the connector panel.
(Fig.8.2 (e))
(9) Attach all connectors to the J1-axis through J6-axis motors. Make
sure that the pulse coder connector covers are attached to the
J1-axis and J2-axis motors.
In the case of 100P attach the fan cable of the J1, J2 and J3-axis
and the fan.
(10) When the robot has limit switches (option), run the cable through
the cast through hole of the J1-axis base, then connect the cable to
the terminal in the switch. Next, fasten the switch to the plate on
the J1-axis base. (Fig.8.2 (b))
(11) Connect the cables and tubes to the connector panel on the back of
the robot. Connect the ground terminal to the J1-axis base, then
connect the battery terminal to the back of the battery box. Next,
fasten the connector panel to the J1-axis base, then connect the
cable used for connection with the control unit to the connector
panel. (Fig.8.2 (a))
(12) Turn on the power. If an alarm is issued at this time, release it
according to Section 5.3.
(13) Perform mastering.
• Replacement procedure (R-2000iA/165CF)
(1) Place all the robot axes in their 0-degree position, then set the
control unit power switch to off.
(2) Detach, from the connector panel on the rear of the robot, the cable
leading to the control unit. Remove the connector panel from the
J1 base, then detach all the cable from the connector panel. When
detaching a HARTING connector, leave its housing on the
connector panel; remove the inserts together with the cable. If the
housing is left on the cable, the cable cannot be pulled out through
the J1 axis piping. (Fig.8.2 (c))
(3) Remove the connector panel from the J1-axis base side, then
remove the connector and tube.
(4) When the robot has limit switches (option), remove the limit
switch for the J1-axis from the plate of the J1-axis base, and
remove the cable from the terminal in the switch.
(5) Remove all connectors from the J1-axis through J6-axis motors.
For the precautions that must be taken, see “Precautions to be
observed when handling the pulse coder cable” at the beginning of
Chapter 8.
(6) If a DS/DP cable (option) is connected, remove the connector
secured to the J2-axis base.
(7) The upper part of the J1-axis has a plate for clamping the cable.
The plate is fastened to the J2-axis base. Remove the bolt and
cable cover attached to the plate, then drop the cable in the pipe.
(Fig.8.2 (h))
(8) Remove and pull out the plate from within the J1-axis base as
much as possible, then remove the bolt fastening the clamp.
(Fig.8.2 (i))
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(9) Pull out the cable upward from the pipe of the J1-axis.
This completes cable detachment from the J1-axis base.
(10) Remove the bolts fastening the left plate of the J2-axis base, then
pull out the plate toward the outside of the J2-axis base. (Fig.8.2
(n))
(11) Remove the plate fastening the cable to the J2-axis arm. (Fig.8.2
(n))
(12) If the robot has limit switches (option), remove the limit switches
for the J2-axis and J3-axis from the plate of the J2-axis arm, and
remove the terminals in the switches, then pull out the cables from
the cast through hole of the J2-axis arm.
This completes cable detachment from the J2-axis base and J2-axis arm.
(13) Remove the bolts securing the left plate of the J3-axis casing.
(Fig.8.2 (p))
(14) Remove the connector box from the right side front of the J3-axis
casing, then detach the cables and tubes from the connector box.
(Fig.8.2 (s))
This completes cable unit detachment from the robot.
(15) When replacing a part of the cables, remove the clamp and cable
cover from the cable unit. Next, cut the cable tie securing the
cables, then detach the desired cable(s). (Fig.8.2 (v))
Install the cable according to the procedure below.
(1) Before connecting the cable to the robot, fasten the cable at the
marked position with a cable tie, and install the clamp and cable
cover. (Fig.8.2 (v))
(2) Fasten the cable unit to the J2-axis arm with the bolts. When a
limit switch is used, run the cable through the cast through hole of
the J2-axis arm, and connect the switch terminal for the J2-axis
and J3-axis, then install the switch onto the plate of the J2-axis arm.
Pull out any excess cable toward the J2-axis arm cover, then bind
the excess cable with the main cable by using a cable tie. Next,
install the cover plate on the J2-axis arm. (Fig.8.2 (n))
(3) Fasten the left plate of the J2-axis base.
(4) Fasten the plate to the left side of the J3-axis casing. Then,
connect the cables and tubes to the connector box on the right of
the J3-axis casing, then fasten the connector box to the J3-axis
casing. (Fig.8.2 (p), (s))
(5) Run the cable through the J1-axis pipe from the top of the J2-axis
base, then pull out the cable toward the back of the J1-axis base.
(6) Fasten the clamp onto the plate in the J1-axis base. Fasten the
plate to the J1-axis base. (Fig.8.2 (i))
(7) Fasten the plate to the J2-axis base at the top of the J1-axis.
(Fig.8.2 (h))
(8) If a DS/DP cable (option) is used, fasten the connector onto the
connector panel, then fasten the connector panel to the J2-axis
base.
(9) Attach all connectors to the J1-axis through J6-axis motors.
(10) When the robot has limit switches (option), connect the cable to
the terminal in the switch. Next, fasten the switch to the plate on
the J1-axis base.
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(11) Connect the cables and tubes to the connector panel on the side of
the J1-axis base, then connect the connector panel to the J1-axis
base.
(12) Connect the cable to the connector panel on the back of the robot.
Connect the ground terminal to the back of the battery box. Next,
fasten the connector panel to the J1-axis base, then connect the
cable used for connection with the control unit to the connector
panel. (Fig.8.2 (c))
(13) Turn on the power. If an alarm is issued at this time, release it
according to Section 5.3.
(14) Perform mastering.
Fig.8.2 (a) Replacing the cable (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
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Fig.8.2 (b) Replacing the cable (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
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Fig.8.2 (c) Replacing the cable (R-2000iA/165CF)
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8. REPLACING CABLES
MAINTENANCE
Fig.8.2 (d) Replacing the cable (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
Fig.8.2 (e) Replacing the cable (R-2000iA/165R, 200R and 100P)
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Fig.8.2 (f) Replacing the cable (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
Fig.8.2 (g) Replacing the cable (R-2000iA/165R, 200R and 100P)
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Fig.8.2 (h) Replacing the cable (R-2000iA/165CF)
Fig.8.2 (i) Replacing the cable
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Fig.8.2 (j) Replacing the cable
(R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
Fig.8.2 (k) Replacing the cable (R-2000iA/165R, 200R and 100P)
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Fig.8.2 (l) Replacing the cable
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
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Fig.8.2 (m) Replacing the cable
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.8.2 (n) Replacing the cable (R-2000iA/165CF)
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Fig.8.2 (o) Replacing the cable
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.8.2 (p) Replacing the cable (R-2000iA/165CF)
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Fig.8.2 (q) Replacing the cable
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.8.2 (r) Replacing the cable
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
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Fig.8.2 (s) Replacing the cable (R-2000iA/165CF)
Fig.8.2 (t) Replacing the cable (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
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Fig.8.2 (u) Replacing the cable (R-2000iA/165R, 200R and 100P)
Fig.8.2 (v) Replacing the cable (R-2000iA/165CF)
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8.3
MAINTENANCE
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LIMIT SWITCH REPLACEMENT (OPTION)
This section explains how to replace limit switches.
See the cable replacement procedure for an explanation of how to
detach the limit switch cables.
NOTE
1 Before limit switch replacement, turn off the power
to the control unit.
2 After a limit switch is installed, be sure to adjust the
limit switch.
1.
J1-axis limit switch replacement
(1) Remove the limit switch from the plate on the J1-axis base.
(2) Cut the cable tie, and detach the cable from the plate.
(3) Remove the terminal in the switch, and remove the limit
switch from the cable.
(4) Attach a new limit switch to the cable.
(5) Install the limit switch on the plate.
(6) Fasten the cable to the plate with a cable tie.
2.
J2-axis limit switch replacement (R-2000iA/165F, 200F, 200FO,
210F, 165R, 200R, 100P, 125L and 130U)
(1) Remove the cover plate of the J2-axis arm, then cut the cable
tie used to prevent the limit switch cable from slackening.
(2) Remove the plate of the J2-axis arm used to fasten the limit
switch.
(3) Remove the limit switch from the plate.
(4) Remove the terminal in the switch, then remove the limit
switch from the cable.
(5) Attach a new limit switch to the cable.
(6) Install the limit switch on the plate.
(7) Install the plate on the J2-axis arm.
(8) Pull the limit switch cable slackening in the J2-axis arm
toward the cover of the J2-axis arm, then tie the cable to the
cables for the mechanical section.
NOTE
1 If a cable is slackening, the cable can rub against
the casting and can break as the robot moves.
Ensure that the cable does not slacken to rub
against the casting.
2 At some sections on the cable (J2: one section, J3:
two sections) where the clearance between the
cable and the casting is small, sponge covers are
wound for protection. When securing the cable,
make sure that the sponge covers are placed near
the casting shown in the figure.
- 234 -
MAINTENANCE
B-81455EN/08
3.
4.
8. REPLACING CABLES
(9) Fasten the cover plate to the J2-axis arm.
Finally, adjust all limit switches.
(10) Now adjust all limit switches.
J2-axis limit switch replacement (R-2000iA/165CF)
(1) Remove the plate on which the J2-axis limit switch is
mounted.
(2) Remove the J2-axis limit switch from the plate.
(3) Detach the cable from the limit switch.
(4) Attach a new limit switch to the cable.
(5) Mount the limit switch on the plate.
(6) Fasten the plate to the J2-axis base.
(7) Fasten the cable to the J2-axis base with the plate.
J3-axis limit switch replacement (R-2000iA/165CF)
(1) Remove the cable tied plate of the J2-axis arm, then cut the
cable tie used to prevent the limit switch cable from
slackening.
(2) Remove the plate of the J2-axis arm used to fasten the limit
switch.
(3) Remove the limit switch from the plate.
(4) Remove the terminal in the switch, then remove the limit
switch from the cable.
(5) Attach a new limit switch to the cable.
(6) Install the limit switch on the plate.
(7) Install the plate on the J2-axis arm.
(8) Pull the limit switch cable slackening in the J2-axis arm
toward the outside of the J2-axis arm, then tie the cable to the
cables for the mechanical section.
NOTE
1 If a cable is slackening, the cable can rub against
the casting and can break as the robot moves.
Ensure that the cable does not slacken to rub
against the casting.
2 At some sections on the cable where the clearance
between the cable and the casting is small, sponge
covers are wound for protection. When securing the
cable, make sure that the sponge covers are placed
near the casting shown in the figure.
(9) Fasten the cable tied plate to the J2-axis arm.
(10) Finally, adjust all limit switches.
- 235 -
8. REPLACING CABLES
MAINTENANCE
Fig.8.3 (a) Replacing the J1-axis limit switch
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
Fig.8.3 (b) Replacing the J2/J3-axis limit switch
(R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
- 236 -
B-81455EN/08
B-81455EN/08
MAINTENANCE
Fig.8.3 (c) Replacing the limit switch (R-2000iA/165CF)
- 237 -
8. REPLACING CABLES
9. SEVERE DUST/LIQUID
PROTECTION PACKAGE
9
MAINTENANCE
SEVERE DUST/LIQUID
PACKAGE
- 238 -
B-81455EN/08
PROTECTION
B-81455EN/08
9.1
9. SEVERE DUST/LIQUID
PROTECTION PACKAGE
MAINTENANCE
SEVERE DUST/LIQUID PROTECTION PACKAGE
(OPTION)
The package is intended to improve the Severe dust/Liquid protection
characteristics of the robot so that it can be used in a severe
environment. It is also intended to improve the rust resistance of the
robot so that it can be used for a longer time.
Model
R-2000iA/165F, 125L
R-2000iA/200F
R-2000iA/210F
R-2000iA/165R
R-2000iA/200R
9.1.1
Severe dust/liquid protection option specification
A05B-1324-J801
A05B-1324-J802
A05B-1324-J806
A05B-1324-J803
A05B-1324-J804
Severe Dust/Liquid Protection Characteristics
The following table lists the IEC529-based Severe dust/Liquid
protection characteristics of the R-2000iA.
J3-axis arm and wrist section
Drive unit of the main body
Main body
Standard
Severe dust/liquid protection
package
IP67
IP67
IP54
IP67
IP67
IP55
Fig.9.1.1 Severe dust/Liquid protection characteristics of the R-2000iA
- 239 -
9. SEVERE DUST/LIQUID
PROTECTION PACKAGE
9.1.2
MAINTENANCE
B-81455EN/08
Configuration of the Severe Dust/Liquid Protection Package
The following table lists the major differences between the R-2000iA
standard specification and severe dust/liquid protection package.
Standard specification
Overall mechanism
section
Bolt and washer
Black oxide-finished steel
bolt
Black oxide-finished
washer
Cover
J3-axis connector board Non-waterproof
EE (I/O) connectors
connector
Others
Severe dust/liquid protection package
J3-axis arm and
Main body
wrist section
FR-coated bolt
FR-coated bolt
Black chromate-treated washer Black chromate-treated washer
Stainless bolt
Stainless bolt
Black oxide-finished steel bolt
J1-axis motor cover
J2-axis motor cover
J3-axis motor covers (upper and lower)
Battery box cover
Covers for intra-mechanical section cables (for all otherwise
exposed cable portions)
Connectors are made waterproof by means of a conversion cable.
A gasket is added to the J3-axis connector board.
Fig.9.1.2 Configuration of the severe dust/liquid protection package
- 240 -
B-81455EN/08
9.1.3
MAINTENANCE
9. SEVERE DUST/LIQUID
PROTECTION PACKAGE
Cautions for Specifying the Severe Dust/Liquid Protection
Package
(1) The following fluids are unusable on the robot because they may
deteriorate or erode the rubber components (such as gaskets, oil
seals, and O-rings) of the robot.
(a) Organic solvent
(b) Chlorine- or gasoline-type cutting fluid
(c) Amine cleaning agent
(d) Corrosive fluid (such as acid or alkaline) and fluid or solvent
that can cause rust
(e) Fluid or solvent to which nitrile rubber (NBR) is not resistant
(2) If the robot is installed in an environment in which water or any
other fluid may be splashed to the robot, be sure to drain the fluid
from under the J1-axis base. If the J1-axis base is kept in water or
any other fluid, the robot could become defective.
- 241 -
9. SEVERE DUST/LIQUID
PROTECTION PACKAGE
MAINTENANCE
9.2
REPLACING SEVERE DUST/LIQUID PROTECTION
PACKAGE COMPONENTS
9.2.1
Replacing Motor Covers
B-81455EN/08
Replace motor covers as required according to Section 6.8. Ensure that
all bolts are stainless.
9.2.2
Replacing Cable Covers
Cable covers are attached to all otherwise exposed cables in the
undesirable-environment option. After a cable or cable cover is
replaced, mount the cover as shown in Fig.9.2.2.
NOTE
Fasten a cable cover end to a connector or cable
with a nylon tie while gathering wrinkles in the cable
cover end neatly.
NOTE
Mount each cable cover in such a manner that the Magic Tape (Velcro tape) on it is
downward or that its covering side (male side) laps over the other side from above,
so as to keep water from getting or lingering in the cover.
- 242 -
B-81455EN/08
MAINTENANCE
9. SEVERE DUST/LIQUID
PROTECTION PACKAGE
Fig.9.2.2 (a) Mounting the cable cover (R-2000iA/165F, 200F and 210F)
- 243 -
9. SEVERE DUST/LIQUID
PROTECTION PACKAGE
MAINTENANCE
Fig.9.2.2 (b) Mounting the cable cover (R-2000iA/165R, 200R)
- 244 -
B-81455EN/08
MAINTENANCE
B-81455EN/08
9.2.3
9. SEVERE DUST/LIQUID
PROTECTION PACKAGE
Replacing the Batteries and Battery Box Cover
Replacing the batteries
1. Remove the six SUS bolts (M4×10), then the battery box cover
plate.
2. Replace the batteries according to Section 3.3.
3. Mount the battery box cover plate with the six SUS bolts
(M4×10).
Replacing the battery box cover
NOTE
When the battery box cover is replaced, the power
must be kept on in the same manner as for the
batteries, because the battery box will be opened. If
the battery box cover is replaced while the power is
off, the current position information will be lost,
resulting in mastering becoming necessary. Keep
the emergency stop button held down for safety
purposes when replacing the battery box cover.
1.
2.
3.
4.
5.
Remove the six SUS bolts (M4×10), then the battery box cover
plate.
Remove the lid of the battery box, and take out the batteries.
Remove the four M4×12 flush bolts that fasten the battery box and
battery box cover together to the J1-axis connector board, then
remove the battery box and battery box cover.
Remove the battery cable terminals from the rear of the battery
box, and replace the battery box.
Reverse the above steps to mount the battery box and battery box
cover.
Fig.9.2.3 Replacing the battery box cover
- 245 -
9. SEVERE DUST/LIQUID
PROTECTION PACKAGE
9.2.4
MAINTENANCE
B-81455EN/08
Replacing the EE (I/O) Cable
1.
2.
3.
4.
5.
6.
7.
Remove the J3-axis connector board from the J3-axis casing.
Remove the HARTING connector housing and insert from the
connector board.
Remove the EE (I/O) conversion cable from the standard
round-type connector, and take it out.
Replace the EE (I/O) conversion cable, put a rubber boot between
the connector board and the HARTING connector housing, and
fasten the housing to the connector board.
Attach the EE (I/O) conversion cable to the standard round-type
connector, and fasten the HARTING connector insert to the
housing.
Close the opening of the rubber boot at the cable sheath, using two
nylon ties. Also bundle the excess portion of the cable with a
nylon tie so that the round-type connector will not move within the
J3-axis casing.
Fasten the connector board to the J3-axis casing.
Fig.9.2.4 Replacing the EE (I/O) cable
- 246 -
II. CONNECTION
B-81455EN/08
1
CONNECTION
1. ROBOT INTERFERENCE AREA
ROBOT INTERFERENCE AREA
- 249 -
1. ROBOT INTERFERENCE AREA
1.1
CONNECTION
B-81455EN/08
EXTERNAL DIMENSION
Fig.1.1 (a) to (j) show the external dimensions of the robot.
When installing peripheral devices, be careful to clear away any objects
that are in the robot's motion path in normal operation.
Fig.1.1 (a) Mechanical unit operation area (R-2000iA/165F)
- 250 -
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.1 (b) Mechanical unit operation area (R-2000iA/200F)
- 251 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.1 (c) Mechanical unit operation area (R-2000iA/200FO)
- 252 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.1 (d) Mechanical unit operation area (R-2000iA/210F)
- 253 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.1 (e) Mechanical unit operation area (R-2000iA/165R)
- 254 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.1 (f) Mechanical unit operation area (R-2000iA/200R)
- 255 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.1 (g) Mechanical unit operation area (R-2000iA/100P)
- 256 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.1 (h) Mechanical unit operation area (R-2000iA/165CF)
- 257 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.1 (i) Mechanical unit operation area (R-2000iA/125L)
- 258 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.1 (j) Mechanical unit operation area (R-2000iA/130U)
- 259 -
1. ROBOT INTERFERENCE AREA
1.2
CONNECTION
OPERATION AREA
Fig.1.2 (a) to (j) show the operation area of the robot.
Fig.1.2 (a) Mechanical unit operation area (R-2000iA/165F) (1/2)
- 260 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (a) Mechanical unit operation area (R-2000iA/165F) (2/2)
- 261 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.2 (b) Mechanical unit operation area (R-2000iA/200F) (1/2)
- 262 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (b) Mechanical unit operation area (R-2000iA/200F) (2/2)
- 263 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.2 (c) Interference area (R-2000iA/200FO) (1/2)
- 264 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (c) Interference area (R-2000iA/200FO) (2/2)
- 265 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.2 (d) Mechanical unit operation area (R-2000iA/210F) (1/2)
- 266 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (d) Mechanical unit operation area (R-2000iA/210F) (2/2)
- 267 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.2 (e) Mechanical unit operation area (R-2000iA/165R) (1/2)
- 268 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (e) Mechanical unit operation area (R-2000iA/165R) (2/2)
- 269 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.2 (f) Mechanical unit operation area (R-2000iA/200R) (1/2)
- 270 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (f) Mechanical unit operation area (R-2000iA/200R) (2/2)
- 271 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.2 (g) Mechanical unit operation area (R-2000iA/100P) (1/2)
- 272 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (g) Mechanical unit operation area (R-2000iA/100P) (2/2)
- 273 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.2 (h) Mechanical unit operation area (R-2000iA/165CF) (1/2)
- 274 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (h) Mechanical unit operation area (R-2000iA/165CF) (2/2)
- 275 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.2 (i) Mechanical unit operation area (R-2000iA/125L) (1/2)
- 276 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (i) Mechanical unit operation area (R-2000iA/125L) (2/2)
- 277 -
1. ROBOT INTERFERENCE AREA
CONNECTION
Fig.1.2 (j) Mechanical unit operation area (R-2000iA/130U) (1/2)
- 278 -
B-81455EN/08
B-81455EN/08
CONNECTION
1. ROBOT INTERFERENCE AREA
Fig.1.2 (j) Mechanical unit operation area (R-2000iA/130U) (2/2)
- 279 -
2. MECHANICAL COUPLING TO
THE ROBOT
2
CONNECTION
MECHANICAL
ROBOT
COUPLING
- 280 -
B-81455EN/08
TO
THE
B-81455EN/08
2.1
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
WRIST LOAD CONDITIONS
Fig.2.1 (a) to (w) are diagrams to limit loads applied to the wrist. Apply
a load within the region indicated in the graph.
Fig.2.1 (a) Wrist Load Diagram (ISO Flange) (R-2000iA/165F and 165R)
- 281 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Fig.2.1 (b) Wrist Load Diagram (FANUC/Special Flange Mounting Bolt 10 pcs) (R-2000iA/165F and 165R)
- 282 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (c) Wrist Load Diagram (FANUC/Special Flange Mounting Bolt 6 pcs) (R-2000iA/165F and 165R)
- 283 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.1 (d) Wrist Load Diagram (Insulated ISO Flange) (R-2000iA/165F, 165R)
- 284 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (e) Wrist Load Diagram (ISO flange and FANUC/Special Flange Mounting Bolt 10 pcs)
(R-2000iA/200F, 200FO and 200R)
- 285 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Fig.2.1 (f) Wrist Load Diagram (FANUC/Special Flange Mounting Bolt 6 pcs) (R-2000iA/200F, 200FO and 200R)
- 286 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (g) Wrist Load Diagram (Insulated ISO Flange) (R-2000iA/200F, 200FO and 200R)
- 287 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.1 (h) Wrist Load Diagram (ISO Flange) (R-2000iA/210F)
- 288 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (i) Wrist Load Diagram (FANUC/Special Flange Mounting Bolt 10 pcs) (R-2000iA/210F)
- 289 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Fig.2.1 (j) Wrist Load Diagram (FANUC/Special Flange Mounting Bolt 6 pcs) (R-2000iA/210F)
- 290 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (k) Wrist Load Diagram (Insulated ISO Flange) (R-2000iA/210F)
- 291 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.1 (l) Wrist Load Diagram (ISO Flange) (R-2000iA/100P)
- 292 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (m) Wrist Load Diagram (FANUC/Special Flange Mounting Bolt 10pcs) (R-2000iA/100P)
- 293 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Fig.2.1 (n) Wrist Load Diagram (FANUC/Special Flange Mounting Bolt 6pcs) (R-2000iA/100P)
- 294 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (o) Wrist Load Diagram (Insulated ISO Flange) (R-2000iA/100P)
- 295 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.1 (p) Wrist Load Diagram (ISO Flange) (R-2000iA/165CF)
- 296 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (q) Wrist Load Diagram (FANUC/Special Flange) (R-2000iA/165CF)
- 297 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.1 (r) Wrist Load Diagram (Insulated ISO Flange) (R-2000iA/165CF)
- 298 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (s) Wrist Load Diagram (ISO Flange) (R-2000iA/125L)
- 299 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.1 (t) Wrist Load Diagram (FANUC/Special Flange) (R-2000iA/125L)
- 300 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (u) Wrist Load Diagram (Insulated ISO Flange) (R-2000iA/125L)
- 301 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.1 (v) Wrist Load Diagram (ISO Flange and FANUC/Special flange) (R-2000iA/130U)
- 302 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.1 (w) Wrist Load Diagram (Insulated ISO Flange) (R-2000iA/130U)
- 303 -
2. MECHANICAL COUPLING TO
THE ROBOT
2.2
CONNECTION
B-81455EN/08
LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS ARM
Following shows J2-axis base and J3-axis arm load conditions.
Table 2.2 Installation condition of loads to be added
Installation site
Models
Loads
Condition
J2 axis base
All models
550kg
J3 axis arm
R-2000iA/165F,
200F, 200FO,
210F, 165R,
100P, 130U
R-2000iA/200R
R-2000iA/165CF
25kg
R-2000iA/125L
20kg
–
25kg
The center of gravity must lie
within a radius of 500mm from
the rotation center of the J1
axis.
See Fig.2.2 (a),(b),and (c) for
the positional condition of the
center of gravity.
–
See Fig.2.2 (e) for the
positional condition of the
center of gravity.
See Fig.2.2 (f) for the
positional condition of the
center of gravity.
CAUTION
If the J3 arm rotates backwards, its load might
interfere with the J2 balancer. Be very careful,
therefore, when rotating the J3 arm backwards.
- 304 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.2 (a) Load Conditions on J2-Axis Base and J3-axis Arm (R-2000iA/165F, 210F)
- 305 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Fig.2.2 (b) Load Conditions on J2-Axis Base and J3-axis Arm (R-2000iA/200F, 200FO, 130U)
- 306 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.2 (c) Load Conditions on J2-Axis Base and J3-axis Arm (R-2000iA/165R, 100P)
- 307 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.2 (d) Load Conditions on J2-Axis Base and J3-axis Arm (R-2000iA/200R)
- 308 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.2 (e) Load Conditions on J2-Axis Base and J3-axis Arm (R-2000iA/165CF)
- 309 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.2 (f) Load Conditions on J2-Axis Base and J3-axis Arm (R-2000iA/125L)
- 310 -
B-81455EN/08
B-81455EN/08
2.3
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
MECHANICAL COUPLING OF END EFFECTOR TO WRIST
Fig.2.3 (a) to (l) are the diagrams for installing end effectors on the
wrist. To fasten the end effector, first position it with two pin holes at G
using fitting A or B, then lock it using screws at D. Select screws and
positioning pins of a length that matches the depth of the tapped and pin
holes. Fasten the bolt for fixing the end effector with following torque.
73.5±3.4 Nm (750±35kg fcm)
Fig.2.3 (a) End effector mounting face (ISO flange) (R-2000iA/165F, 165R and 125L)
- 311 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Fig.2.3 (b) End effector mounting face (FANUC/Special flange) (R-2000iA/165F, 165R and 125L)
CAUTION
When a FANUC flange or special flange is used, use
ten bolts to install an end effector.
When only six bolts are used as for an ISO flange,
such use is allowed within the allowable load range
shown in Fig.2.1 (c).
- 312 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.3 (c) End effector mounting face (Insulated ISO flange) (R-2000iA/165F, 165R and 125L)
- 313 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Fig.2.3 (d) End effector mounting face (ISO flange) (R-2000iA/200F, 200FO, 200R and 130U)
CAUTION
There are 10 tapped holes on the flange surface. To
mount the end effector, use only six tapped holes
arranged evenly on a circle.
- 314 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.3 (e) End effector mounting face (FANUC/Special flange) (R-2000iA/200F, 200FO, 200R and 130U)
CAUTION
When a FANUC flange or special flange is used, use
ten bolts to install an end effector.
When only six bolts are used as for an ISO flange,
such use is allowed within the allowable load range
shown in Fig.2.1 (f).
- 315 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Fig.2.3 (f) End effector mounting face (Insulated flange) (R-2000iA/200F, 200FO, 200R and 130U)
- 316 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.3 (g) End effector mounting face (ISO flange) (R-2000iA/210F and 100P)
- 317 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Fig.2.3 (h) End effector mounting face (FANUC/Special flange) (R-2000iA/210F and 100P)
CAUTION
When a FANUC flange or special flange is used, use
ten bolts to install an end effector.
When only six bolts are used as for an ISO flange,
such use is allowed within the allowable load range
shown in Fig.2.1 (j).
- 318 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
2-φG depth H
Fig.2.3 (i) End effector mounting face (Insulated ISO flange) (R-2000iA/210F and 100P)
- 319 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.3 (j) End effector mounting face (ISO flange) (R-2000iA/165CF)
- 320 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.3 (k) End effector mounting face (FANUC/Special flange) (R-2000iA/165CF)
- 321 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.3 (l) End effector mounting face (Insulated ISO flange) (R-2000iA/165CF)
- 322 -
B-81455EN/08
CONNECTION
B-81455EN/08
2.4
2. MECHANICAL COUPLING TO
THE ROBOT
INSTALLING A FANUC/SPECIAL FLANGE ADAPTER
(R-2000iA/165F, 210F, 165R AND 125L)
Fig.2.4 shows the method of installing a standard flange adapter and
special flange adapter (R-2000iA/165F, 210F, 165R and 125L).
(1) Press the pin into the adapter. At this time, apply Loctite No. 601
to the fitting surface.
(2) Attach the adapter to the robot by using six M10×20 bolts. At this
time, apply Loctite No. 262 to the screw, and tighten the screw by
the following torque:
73.5±3.4 Nm (750±35kg fcm)
Fig.2.4 Installing a FANUC/Special flange adapter
(R-2000iA/165F, 210F, 165R and 125L)
Name
Specifications
1
ADAPTER
2
3
4
BOLT
WASHER
PIN
A290-7324-X551 (STANDARD)
A290-7324-X552 (SPECIAL)
A6-BA-10X20
A97L-0001-0823#M10H
JB-PH-H7A-10X18S45C
- 323 -
Q’ty LOCTITE
Torque
(Nm)
1
6
6
1
LT262
LT601
73.5
2. MECHANICAL COUPLING TO
THE ROBOT
2.5
CONNECTION
B-81455EN/08
EQUIPMENT MOUNTING FACE
As shown in Fig.2.5 (a) to (h) tapped holes are provided to install
equipment to the robot.
CAUTION
Never perform additional machining operation such
as drilling or tapping on the robot body. This can
seriously affect the safety and function of the robot.
NOTE
Note that the use of a tapped hole not shown in the
following figure is not assured.
- 324 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.5 (a) Equipment mounting surfaces (R-2000iA/165F, 210F)
- 325 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.5 (b) Equipment mounting surfaces (R-2000iA/200F)
- 326 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.5 (c) Equipment mounting surfaces (R-2000iA/200FO, 130U)
- 327 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.5 (d) Equipment mounting surfaces (R-2000iA/165R)
- 328 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.5 (e) Equipment mounting surfaces (R-2000iA/200R)
- 329 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.5 (f) Equipment mounting surfaces (R-2000iA/100P)
- 330 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.5 (g) Equipment mounting surfaces (R-2000iA/165CF)
- 331 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.5 (h) Equipment mounting surfaces (R-2000iA/125L)
- 332 -
B-81455EN/08
CONNECTION
B-81455EN/08
2.6
2. MECHANICAL COUPLING TO
THE ROBOT
SETTING SYSTEM VARIABLES FOR MINIMUM CYCLE
CONTROL
It is possible to make an effective use of the robot by setting payload
conditions such as the weight, moment, and inertia of the hands and
other objects attached to the wrist section, J3 axis arm, J2 axis base of
the robot appropriately.
•
Wrist axis payload moment
Assign the following system variables with integers (in kgf-m)
representing the moment of the wrist section payload.
[Example of setting system variables]
$PARAM_GROUP.$AXISMOMENT[4]:
94 (J4 axis payload moment)
$PARAM_GROUP.$AXISMOMENT[5]:
94 (J5 axis payload moment)
$PARAM_GROUP.$AXISMOMENT[6]:
47 (J6 axis payload moment)
•
Wrist axis payload inertia
Assign the following system variables with integers (in kgf-cm-s2)
representing the inertia of the wrist arm payload.
[Example of setting system variables]
$PARAM_GROUP.$AXISINERTIA[4]:
800 (J4 axis payload inertia)
$PARAM_GROUP.$AXISINERTIA[5]:
800 (J5 axis payload inertia)
$PARAM_GROUP.$AXISINERTIA[6]:
410 (J6 axis payload inertia)
•
Weight of the load on the J3 axis arm and J2 axis base
Assign the following system variables with integers (in kg)
representing the weight of the load on the J3 axis arm and J2 axis
base.
[Example of setting system variables]
$PARAM_GROUP.$ARM_LOAD[1]:
25 (J3 axis arm load weight)
$PARAM_GROUP.$ARM_LOAD[2]:
550 (J2 axis base load weight)
Motion performance screens
The motion performance screens include the MOTION
PERFORMANCE screen, MOTION PAYLOAD SET screen, and
MOTION ARMLOAD SET screen. These screens are used to specify
payload information and equipment information on the robot.
1
Click the [MENUS] key to display the screen menu.
2
Select “6 SYSTEM” from the next page.
3
Click F1 ([TYPE]).
- 333 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
4
Select “MOTION.”
appears.
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.
6
Set the payload, gravity center position, and inertia around the
gravity center on the MOTION PAYLOAD SET screen. The X, Y,
and Z directions displayed on this screen correspond to the
respective standard tool coordinates (with no tool coordinate
system set up). When values are entered, the following message
appears: “Path and Cycletime will change. Set it?” Respond to
the message with F4 ([YES]) or F5 ([NO]).
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.
7
- 334 -
The MOTION PERFORMANCE screen
CONNECTION
B-81455EN/08
8
9
10
2. MECHANICAL COUPLING TO
THE ROBOT
Click the previous page key to return to the MOTION
PERFORMANCE screen. Click F5 ([SETIND]), and enter the
desired payload setting condition number.
On the MOTION PERFORMANCE screen, click F4
([ARMLOAD]) to display the MOTION ARMLOAD SET screen.
Specify the weight of the load on the J2 axis base and J3 axis arm
as follows:
ARM LOAD AXIS #1 [kg]: Weight of the load on the J2 axis base
ARM LOAD AXIS #3 [kg]: Weight of the load on the J3 axis arm
The following message appears: “Path and Cycletime will change.
Set it?” Respond to the message with F4 ([YES]) or F5 ([NO]).
Once the arm payload is set up, the settings are completed by
switching the power off and on again.
- 335 -
2. MECHANICAL COUPLING TO
THE ROBOT
2.7
CONNECTION
B-81455EN/08
SETTING THE LOAD INERTIA (R-2000iA/200FO, 210F)
There are two different parameter settings for the R-2000iA/200FO,
210F according to the amplitude of the load inertia.
(The
factory-shipped parameter setting is for standard inertia mode.)
200FO
J4-axis
210F
200FO
Allowable load
inertia at wrist
J5-axis
210F
200FO
J6-axis
210F
Standard
nertia mode
High
inertia mode
117.6kg·m2
(1200kgf·cm·s2)
141.1kg·m2
(1440kgf·cm·s2)
117.6kg·m2
(1200kgf·cm·s2)
141.1kg·m2
(1440kgf·cm·s2)
58.8kg·m2
(600kgf·cm·s2)
78.4kg·m2
(800kgf·cm·s2)
215.6kg·m
(2200kgf·cm·s2)
2
215.6kg·m
(2200kgf·cm·s2)
2
215.6kg·m
(2200kgf·cm·s2)
2
215.6kg·m
(2200kgf·cm·s2)
2
196.0kg·m
(2000kgf·cm·s2)
2
196.0kg·m
(2000kgf·cm·s2)
2
Be sure to make parameter settings appropriate for the load, as
described in this section.
NOTE
If a workpiece having inertia that exceeds the
allowable inertia in standard inertia mode is used in
that mode, parts of the mechanical unit may
deteriorate earlier.
To set parameters, execute setting program FO_PAYLD.PC (For
200FO) and PAYLD210PC (For 210F) that is stored in advance. Of the
load settings made in Section 2.6, this program sets parameters based on
the magnitude of the load inertia currently selected.
- 336 -
CONNECTION
B-81455EN/08
2. MECHANICAL COUPLING TO
THE ROBOT
When the software version is : V6.10P (7D80) : Version 95 and later
V6.20P (7D81) : Version 47 and later
V6.30P (7D82) : Version 45 and later
The parameters are automatically set according to the load settings
made in Section 2.6.
CAUTION
Set the load inertia correctly as described in Section
2.6.
If a workpiece with inertia exceeding the allowable
inertia in the standard inertia mode is used in the
mode, parts of the mechanical unit may degrade
earlier.
When the software version is : V6.10P (7D80) : Version 94 and earlier
V6.20P (7D81) : Version 46 and earlier
V6.30P (7D82) : Version 44 and earlier
Set the parameters based on the load, as described later.
(Parameter settings appropriate for the standard inertia mode are made
before shipment.)
CAUTION
If a workpiece with 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 the parameters, execute the setting program (FO_PAYLD.PC for
the 200FO or PAYLD210.PC for the 210F) installed before shipment.
This program sets the parameters based on the currently-used load
inertia of the load settings made in Section 2.6.
•
Setting method
The setting program is called in program.
In particular, when load settings are switched with PAYLOAD
instruction, execute this program.
[Example of program]
(For 200FO)
1 : PAYLOAD [1]
2 : CALL FO_PAYLD (i)
(For 210F)
1 : PAYLOAD [1]
2 : CALL PAYLD 210 (i)
For input parameter i of FO_PAYLD (PAYLD 210), specify the
group number of the robot. When input parameter i is omitted, the
setting of group 1 is done.
- 337 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
•
B-81455EN/08
Checking the settings
Executing the setting program displays the settings made on the
user screen. To display the user screen, press the MENUS key and
then select “9 USER.”
[Information displayed on the user screen]
For standard inertia load settings : Standard payload set.
(GP: x, Payload: y)
For high inertia load settings
: High payload set.
(GP: x, Payload: y)
x represents the group number for which the parameter was set. y
represents the load setting number used for evaluation.
When checking the current settings only without switching
parameters, specify the group number added by 100 for input
parameter i of FO_PAYLD (PAYLD 210) and then execute the
program. This displays the current parameter settings of the group
on the user screen.
[Information displayed on the user screen]
For standard inertia load settings : Standard payload
type now (GP: x)
For high inertia load settings
: High payload
type now (GP: x)
x represents the group number whose parameter was checked.
•
Exception processing
In the following cases, exception processing is performed.
Parameters are not changed and a message describing the
exception processing appears on the user screen.
1
When none of load setting condition numbers (Nos. 1 to 10)
is selected
[Information displayed on the user screen]
Payload number 0 is invalid. (GP: x)
When this message appears, select the load setting condition
on the motion performance screen or set the load setting
condition with the PAYLOAD instruction.
2
When the group specified by input parameter i of
FO_PAYLD (PAYLD 210) does not exist
[Information displayed on the user screen]
Incorrect group number
When this message appears, specify the correct group
number.
3
When the group specified by input parameter i of
FO_PAYLD (PAYLD 210) is not R-2000iA/200FO (210F)
[Information displayed on the user screen]
This group is not R-2000iA/200FO (210F)
When this message appears, specify the correct group
number.
- 338 -
B-81455EN/08
2.8
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
AIR SUPPLY (OPTION)
There is an air-pressure supply opening on the side of the J1-axis base
and the front of J3-axis casting. The connector is a Rc1/2 female (ISO).
As coupling are not supplied, it will be necessary to prepare couplings
which suit to the hose size.
Fig.2.8 (a) Air-pressure supply connection (option) (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 339 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.8 (b) Air-pressure supply connection (option) (R-2000iA/165R, 200R and 100P)
- 340 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.8 (c) Air-pressure supply connection (option) (R-2000iA/165CF)
- 341 -
2. MECHANICAL COUPLING TO
THE ROBOT
2.9
CONNECTION
B-81455EN/08
INTERFACE FOR OPTION CABLE (OPTION)
Fig.2.9 (a) to (e) show the position of the end effecter interface. End
effecter interface (RDI/RDO), I/O Unit-MODEL B interface and user
cable (signal lines, power lines) and DeviceNet cable (signal lines,
power lines) are prepared as options.
Fig.2.9 (a) Interface for Optional cable (Option) (R-2000iA/165F, 200F, 200FO, 210F, 125L and 130U)
- 342 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.9 (b) Interface for Optional cable (Option) (R-2000iA/165R, 200R and 100P)
- 343 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.9 (c) Interface for Optional cable (Option) (R-2000iA/165CF)
- 344 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
Fig.2.9 (d) Layout of interface for Option cable (R-2000iA/165F, 200F, 200FO, 210F, 165R, 200R, 100P, 125L and 130U)
- 345 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
Fig.2.9 (e) Layout of interface for Option cable (R-2000iA/165CF)
- 346 -
B-81455EN/08
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
(1) End effector interface (RDI/RDO) (Option)
Fig.2.9 (f) and (g) show pin layout for end effector interface
(RDI/RDO).
Fig.2.9 (f) Pin layout for end effector interface (RDI/RDO)
Fig.2.9 (g) Pin layout for end effector interface (RDI/RDO) (Severe dust/liquid protection package)
- 347 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
(2) I/O Unit-MODEL B interface (Option)
Fig.2.9 (h) and (i) show pin layout for I/O Unit-MODEL B
interface.
Fig.2.9 (h) Pin layout for I/O Unit-MODEL B interface (option)
Fig.2.9 (i) Pin layout for I/O Unit-MODEL B interface (Severe dust/liquid protection package) (option)
- 348 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
(3) User cable (signal line) Interface (option)
Fig.2.9 (j) shows pin layout for user cable (signal line) interface.
The connector has a code pin for preventing improper insertion.
For cables prepared by the user, use this code pin.
Fig.2.9 (j) Pin layout for user cable (signal line) interface and code pin layout (option)
- 349 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
(4) User cable (power line) Interface (option)
Fig.2.9 (k) shows pin layout for user cable (power line) interface.
The connector has a code pin for preventing improper insertion.
For cables prepared by the user, use this code pin.
Fig.2.9 (k) Pin layout for user cable (power line) interface and code pin layout (option)
- 350 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
(5) DeviceNet cable (signal line) interface (option)
Fig.2.9 (l) shows pin layout for DeviceNet cable (signal line)
interface.
Fig.2.9 (l) Pin layout for DeviceNet cable (signal line) interface (option)
(6) DeviceNet cable (power line) interface (option)
Fig.2.9 (m) shows pin layout for DeviceNet cable (power line)
interface.
Fig.2.9 (m) Pin layout for DeviceNet cable (power line) interface (option)
- 351 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
(7) Additional axis motor cable (pulse coder cable) interface
(optional)
Fig.2.9 (n) shows the pin layout of the additional axis motor cable
(pulse coder cable) interface.
The connector has a code pin for preventing improper insertion.
Fig.2.9 (n) Pin Layout of the Additional Axis Motor Cable (Pulse Coder Cable)
Interface and Layout Position of the Code Pin (Optional)
- 352 -
B-81455EN/08
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT
(8) Additional axis motor cable (power and brake cables) interface
(optional)
Fig.2.9 (o) shows the pin layout of the additional axis motor cable
(power and brake cables) interface.
The connector has a code pin for preventing improper insertion.
Fig.2.9 (o) Pin Layout of the Additional Axis Motor Cable (Power and Brake Cables)
Interface and Layout Position of the Code Pin (Optional)
- 353 -
2. MECHANICAL COUPLING TO
THE ROBOT
CONNECTION
B-81455EN/08
Table 2.9 (a) Connector specifications (Mechanical unit side)
Cable
RDI/RDO
I/O
AS
(Signal)
AP
(Power)
Housing
Insert
Contact
Code pin
Housing
Insert
Contact
Code pin
Input side (J1 base)
–––––––––
–––––––––
09 30 006 0301
09 16 024 3001 (Han 24DD M)
09 15 000 6103
09 30 000 9901
09 20 010 0301
09 21 015 3001 (Han 15D M)
09 15 000 6103
09 30 000 9901
Housing
Insert
Contact
Code pin
Housing
Nsert
Contact
Code pin
Output side (J3 casing)
JMWR2524F
JMWR2516F
09 30 006 0301
09 16 024 3101 (Han 24DD F)
09 15 000 6203
09 30 000 9901
09 20 010 0301
09 21 015 3101 (Han 15D F)
09 15 000 6203
09 30 000 9901
Manu.
Fujikura
Harting
Table 2.9 (b) Connector specifications (User side)
Input side (J1 base)
RDI/RDO
–––––––––
I/O
–––––––––
Hood
Select
one
AS (Signal)
Insert
Contact
Select
one
Clamp
Select
one
Code pin
Hood
Select
one
AP
(Power)
Insert
Contact
Select
one
Clamp
Select
one
Code pin
09 30 006 1540
Side
1541
entry
0542
0543
1440
Top
1441
entry
0442
0443
09 16 024 3101 (Han 24DD F)
09 15 000 6204 appox. AWG 26-22
6203
AWG 20
6205
AWG 18
6202
AWG 18
6201
AWG 16
6206
AWG 14
09 00 000 5083
5086
5090
5094
etc.
09 30 000 9901
09 20 010 1541
Side
0540
entry
0541
1440
Top
0440
entry
0441
09 21 015 3101 (Han 15D F)
09 15 000 6204 appox AWG 26-22
6203
AWG 20
6205
AWG 18
6202
AWG 18
6201
AWG 16
6206
AWG 14
09 00 000 5083
5086
5090
5094
etc.
09 30 000 9901
Output side (J3 casing)
JMSP2524M Straight (Appendix)
(FANUC spec. : A63L-0001-0234#S2524M)
JMLP2524M Angle
JMSP2516M Straight (Appendix)
(FANUC spec. : A63L-0001-0234#S2516M)
JMLP2516M Angle
Hood
Manu.
Fujikura
← The same
Insert
Contact
09 16 024 3001 (Han 24DD M)
09 15 000 6104 appox. AWG 26-22
6103
AWG 20
6105
AWG 18
6102
AWG 18
6101
AWG 16
6106
AWG 14
Clamp
← The same
Harting
Code pin
Hood
09 30 000 9901
← The same
Insert
Contact
09 21 015 3001 (Han 15D M)
09 15 000 6104 appox. AWG 26-22
6103
AWG 20
6105
AWG 18
6102
AWG 18
6101
AWG 16
6106
AWG 14
Clamp
← The same
Code pin
- 354 -
09 30 000 9901
CONNECTION
B-81455EN/08
2. MECHANICAL COUPLING TO
THE ROBOT
NOTE
For details, such as the dimensions, of the parts listed above, refer to the related
catalogs offered by the respective manufacturers, or contact FANUC.
Table 2.9 (c) Connector specifications (DeviceNet cable) (Mechanical unit side)
Input side
Cable name
(J1-axis base)
84854-9101
DS
(signal line)
Housing
Insert
Contact
DP
(power line)
09 30 006 0301
(Han 6E)
09 32 010 3001
(Han 10EE M)
09 33 00 6104
Manufacturer
MOLEX
JAPAN CO.,
LTD.
HARTING
Electronik Co.,
Ltd.
Output side
(J2-axis base)
84854-9100
84854-9102
Manufacturer
MOLEX
JAPAN CO.,
LTD.
MOLEX
JAPAN CO.,
LTD.
Output side
Manufacturer
(J3-axis casing)
84854-9100
MOLEX
JAPAN CO.,
LTD.
84854-9102
MOLEX
JAPAN CO.,
LTD.
Table 2.9 (d) Connector specifications (DeviceNet cable, on the user equipment side)
Input side
(J1-axis base)
Cable name
MINI connector for use on the device net
5-pin, female 1
DS
(signal line)
Hood
09 30 006 1540 (Han 6E) Side
Select
1541
entry
just one.
0542
Output side
Manufac(J2-axis
turer
base)
MOLEX
84854-9000 MOLEX
JAPAN CO.,
JAPAN CO.,
LTD.
LTD.
HARTING
84854-9151 MOLEX
Electronik
JAPAN CO.,
Co., Ltd.
LTD.
Manufacturer
Output side
(J3-axis
casing)
84854-9000
84854-9151
Manufacurer
MOLEX
JAPAN CO.,
LTD.
MOLEX
JAPAN CO.,
LTD.
0543
1440
Top
1441
entry
0442
0443
Insert
09 32 010 3101 (Han 10 EE F)
DP
Contact 09 33 000 6220
AWG20
(power line)
6214
AWG18
6205
AWG18
6204
AWG16
6202
AWG14
6207
AWG12
Clamp
09 00 000 5083
Select
5086
just one.
5090
5094
Many other types are available.
Table 2.9 (e) Connector specifications (Additional axis motor cable, Mechanical unit side)
Cable
ARP
(Pulse coder line)
AP
(Power brake line)
Housing
Insert
Contact
Code pin
Housing
Insert
Contact
Code pin
Input side (J1-axis base)
09 30 006 0301
09 16 024 3001 (Han 24DD M)
09 15 000 6103
09 30 000 9901
09 20 010 0301
09 21 015 3001 (Han 15D M)
09 15 000 6101
09 30 000 9901
- 355 -
Output side (J3-axis casing)
09 30 006 0301
Housing
09 16 024 3101 (Han 24DD F)
Insert
09 15 000 6203
Contact
09 30 000 9901
Code pin
09 20 010 0301
Housing
09 21 015 3101 (Han 15D F)
Insert
09 15 000 6203
Contact
09 30 000 9901
Code pin
Manu.
Harting
3. TRANSPORTATION AND
INSTALLATION
3
CONNECTION
B-81455EN/08
TRANSPORTATION AND INSTALLATION
- 356 -
CONNECTION
B-81455EN/08
3.1
3. TRANSPORTATION AND
INSTALLATION
TRANSPORTATION
CAUTION
When hoisting or lowering the robot with a crane or
forklift, move it slowly with great care. When
placing the robot on the floor, exercise care to
prevent the installation surface of the robot from
striking the floor strongly.
1)
Transportation using a crane
The robot can be transported by lifting it. When transporting the
robot, be sure to change the attitude of the robot to that shown in
Fig.3.1 (a) to (i) and lift by attaching slings to the four M20
eyebolts.
NOTE
When lifting the robot, take notice so that the motor,
connectors, or cables of the robot are not scratched
by slings.
2)
Transportation using a forklift
The robots can also be transported using a forklift (Refer to Fig.3.1
(j) to (r)). Transport materials are available as an option.
WARNING
Be sure to use transport materials. Otherwise, the
R-2000iA/165R, 200R and 100P would fall down
toward the front.
WARNING
When an end effector and peripherals are installed
on a robot, the center of gravity of the robot changes
and the robot might become unstable while being
transported.
If the robot becomes unstable, remove the tooling
and place the robot into the transportation position.
This will position the unit center of gravity correctly.
It is recommended to transport the end effector and
peripherals separately from the robot.
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.
- 357 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
Fig.3.1 (a) Transportation using a crane (R-2000iA/165F)
- 358 -
B-81455EN/08
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.1 (b) Transportation using a crane (R-2000iA/200F)
- 359 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
Fig.3.1 (c) Transportation using a crane (R-2000iA/200FO, 130U)
- 360 -
B-81455EN/08
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.1 (d) Transportation using a crane (R-2000iA/210F)
- 361 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
Fig.3.1 (e) Transportation using a crane (R-2000iA/165R)
- 362 -
B-81455EN/08
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.1 (f) Transportation using a crane (R-2000iA/200R)
- 363 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
Fig.3.1 (g) Transportation using a crane (R-2000iA/100P)
- 364 -
B-81455EN/08
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.1 (h) Transportation using a crane (R-2000iA/165CF)
- 365 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
Fig.3.1 (i) Transportation using a crane (R-2000iA/125L)
- 366 -
B-81455EN/08
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.1 (j) Transportation using a forklift (R-2000iA/165F)
Fig.3.1 (k) Transportation using a forklift (R-2000iA/200F)
CAUTION
Exercise care to prevent the fork of the forklift from
striking transport members strongly.
- 367 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B-81455EN/08
Fig.3.1 (l) Transportation using a forklift (R-2000iA/200FO, 130U)
Fig.3.1 (m) Transportation using a forklift (R-2000iA/210F)
CAUTION
Exercise care to prevent the fork of the forklift from
striking transport members strongly.
- 368 -
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.1 (n) Transportation using a forklift (R-2000iA/165R)
- 369 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B-81455EN/08
Fig.3.1 (o) Transportation using a forklift (R-2000iA/200R)
CAUTION
Exercise care to prevent the fork of the forklift from
striking transport members strongly.
- 370 -
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.1 (p) Transportation using a forklift (R-2000iA/100P)
- 371 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B-81455EN/08
Fig.3.1 (q) Transportation using a forklift (R-2000iA/165CF)
CAUTION
Exercise care to prevent the fork of the forklift from
striking transport members strongly.
- 372 -
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.1 (r) Transportation using a forklift (R-2000iA/125L)
CAUTION
Exercise care to prevent the fork of the forklift from
striking transport members strongly.
- 373 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B-81455EN/08
Fig.3.1 (s) Mechanical interface for eyebolt and transport equipment
WARNING
Be sure to use transport materials. Otherwise, the
R-2000iA/165R, 200R and 100P would fall down
toward the front.
- 374 -
CONNECTION
B-81455EN/08
3.2
3. TRANSPORTATION AND
INSTALLATION
INSTALLATION
Fig.3.2 (a) shows the robot base dimensions. Fig.3.2 (b) to (d) show
actual examples of robot installations.
In Fig.3.2 (b), the floor plate is imbedded in concrete and fastened with
eight M20 (strength classification 4.8) chemical anchors. Also fasten
the base plate to the robot base using eight M20×60 bolts (strength
classification 12.9). Next, position the robot, and weld the base plate to
the floor plate. (Foot length is 10 to 15mm.) (The base plate is prepared
as an option.)
In Fig.3.2 (c), the floor plate is not imbedded in concrete. It is fastened
with eight M20 (strength classification 4.8) chemical anchors, and the
inclination of the floor plate is adjusted by four set screws. The robot
base is brought against three 20mm dia. Straight pins inserted into the
base to position the robot base, and the robot base is fastened to the
floor plate using three M20×60 bolts (strength classification 12.9).
Fig.3.2 (d) is the same as Fig.3.2 (c) except that straight pins for
contacting the robot base are not used.
Avoid placing any object in front of the robot on the mounting surface
to facilitate the installation of the mastering fixture, as shown in Fig.3.2
(a).
CAUTION
For the R-2000iA/165R, 200R or 100P the
mastering fixture is below the J1 base mounting
face. Install the robot so that the mastering fixture
does not interfere with the mounting face, as
described in Subsection 5.3.3, “Fixture Position
Mastering.”.
Fig.3.2 (e) and Table 3.2 show the force and moment applied to the base
plate at the time of emergency stop.
- 375 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
Fig.3.2 (a) Dimensions of the robot base
- 376 -
B-81455EN/08
B-81455EN/08
CONNECTION
Fig.3.2 (b) Actual installation example
- 377 -
3. TRANSPORTATION AND
INSTALLATION
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
Fig.3.2 (c) Actual installation example
- 378 -
B-81455EN/08
B-81455EN/08
CONNECTION
Fig.3.2 (d) Actual installation example
- 379 -
3. TRANSPORTATION AND
INSTALLATION
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B-81455EN/08
NOTE
1 Parts to be provided by the customer:
Robot mounting bolts : M20×60 (strength classification 12.9) 8pcs.
Chemical anchors
: M20 (strength classification 4.8)
8pcs.
Base plates
: thickness 32t
4pcs.
Floor plate
: thickness 32t
1pcs.
Set screw
: M20
4pcs.
Nut
: M20
4pcs.
Straight pin
: φ20
3pcs.
2 Installation work (welding, anchoring, etc.) is prepared by the customer.
3 If the robot is operated with any combination other than stated above, it is likely to be
damaged.
Table 3.2 Force and moment during emergency stop
Model
Vertical moment
MV [kNm (kgfm)]
Force in vertical
direction
FV [kN (kgf)]
Horizontal moment
MH [kNm (kgfm)]
Force in horizontal
direction
FH [kN (kgf)]
R-2000iA/165F
R-2000iA/200F
R-2000iA/200FO
R-2000iA/210F
R-2000iA/165R
R-2000iA/200R
R-2000iA/100P
R-2000iA/165CF
R-2000iA/125L
R-2000iA/130U
60.76 (6200)
66.64 (6800)
71.54 (7300)
70.56 (7200)
73.50 (7500)
78.40 (8000)
77.42 (7900)
31.36 (3200)
60.76 (6200)
56.84 (5800)
35.28 (3600)
38.22 (3900)
39.20 (4000)
38.22 (3900)
38.22 (3900)
40.18 (4100)
38.22 (3900)
29.40 (3000)
35.28 (3600)
35.28 (3600)
24.50 (2500)
25.48 (2600)
25.48 (2600)
25.48 (2600)
25.48 (2600)
25.48 (2600)
25.48 (2600)
17.64 (1800)
24.50 (2500)
24.50 (2500)
25.48 (2600)
26.46 (2700)
26.46 (2700)
26.46 (2700)
26.46 (2700)
26.46 (2700)
25.48 (2600)
17.64 (1800)
24.50 (2500)
23.52 (2400)
- 380 -
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.2 (e) Force and moment during Emergency Stop
- 381 -
3. TRANSPORTATION AND
INSTALLATION
3.3
CONNECTION
B-81455EN/08
MAINTENANCE AREA
Fig.3.3 shows the maintenance area of the mechanical unit. In
mastering, it needs to take the posture of Fig. of Chapter I. Be sure to
leave enough room for the robot to be mastered.
Fig.3.3 (a) Maintenance area (R-2000iA/165F, 200F, 210F and 125L)
- 382 -
B-81455EN/08
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
Fig.3.3 (b) Maintenance area (R-2000iA/200FO, 130U)
Fig.3.3 (c) Maintenance area (R-2000iA/165R, 200R and 100P)
- 383 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
Fig.3.3 (d) Maintenance area (R-2000iA/165CF)
- 384 -
B-81455EN/08
B-81455EN/08
3.4
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
AIR PIPING (OPTION)
Fig.3.4 (a) shows how to connect air hose to the robot. If the air control
set is specified as an option, the air hose between the mechanical unit
and the air control set is provided. Mount the air control set using the
information in Fig.3.4 (b).
Fig.3.4 (a) Air piping Option
- 385 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B-81455EN/08
Air control set
Fill the oiler having three air components to the specified level with
turbine oil #90 to #140. The machine tool builder is required to prepare
mounting bolts.
Fig.3.4 (b) Air control set Option
- 386 -
3.5
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B-81455EN/08
INSTALLATION SPECIFICATIONS
Items
Air
pressure
Table 3.5 Installation specifications
Specifications
Pressure
Air flow
Weight of mechanical
unit
Allowable ambient
temperature
Allowable ambient
humidity
Atmosphere
Vibration
0.49 to 0.69 MPa (5 to 7 kgf/cm2)
(Set pressure 0.49 MPa (5 kgf/cm2))
Max. peak 150 Nl/min, 0.15 Nm3/min (Upper Note)
R-2000iA/165F
Approx. 1210 kg
R-2000iA/200F
Approx. 1240 kg
R-2000iA/200FO
Approx. 1310 kg
R-2000iA/210F
Approx. 1270 kg
R-2000iA/165R
Approx. 1540 kg
R-2000iA/200R
Approx. 1570 kg
R-2000iA/100P
Approx. 1630 kg
R-2000iA/165CF
Approx. 1050 kg
R-2000iA/125L
Approx. 1230 kg
R-2000iA/130U
Approx. 1210 kg
0 to 45°C
Usual: Less than 75% RH
Short period (in one month): Max. 95% RH or less
Condensation free
Free of corrosive gases (Lower Note)
Less than 0.5 G, 4.9 m/s2
NOTE
This value indicates the maximum capacity of the air
control set.
Adjust the air flow to be less than this value.
- 387 -
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B-81455EN/08
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.
If the robot is used especially in an adverse
environment stated below, grease the balancer as
required.
• Dusty environment; for example, an application in
which the robot is used to handle tiles or bricks.
• Environment full of spatters developed in spot
welding; for example, an application in which
welding spatters deposit and accumulate on and
around the balancer
In addition, if the robot is used in a special
environment stated below, use a robot jacket or
some other means to protect the balancer support
part (which joins with the J2 arm and J2 base) and
rod sliding part.
• Environment where glass abrasive powders and
others are used; for example, an application in
which the robot or balancer is subjected to
splashes of powders in handling and other
operations during glass abrasion.
• Environment where metal powders are used; for
example, an application in which the robot or
balancer is subjected to splashes of powders in
handling and other operations during metal
working.
- 388 -
CONNECTION
B-81455EN/08
3.6
3. TRANSPORTATION AND
INSTALLATION
STORAGE
To store the robot, set it to the same attitude as that used for
transportation. (See II- 3.1)
- 389 -
APPENDIX
APPENDIX
B-81455EN/08
A
A. SPARE PARTS LIST
SPARE PARTS LIST
No.
Table A (a) Cables (Standard)
Specification
Function
K111 A660-8013-T914
K112 A660-8013-T915
K111 A660-8013-T914#L
K112 A660-8013-T915#L
K117 A660-8014-T386
K118 A660-8014-T387
K251 A660-8014-T009
K115 A660-8014-T269
No.
J1 to J6 PULSECODER+EE
J1 to J6 POWER
J1 to J6 PULSECODER+EE
J1 to J6 POWER
J1 to J6 PULSECODER+EE
J1 to J6 POWER
J1 to J6 PULSECODER+EE
J1 to J6 POWER
Table A (b) Cables (Standard : CE)
Specification
Function
K511 A660-8013-T920
K512 A660-8013-T921
K511 A660-8013-T920#L
K512 A660-8013-T921#L
K517 A660-8014-T397
K518 A660-8014-T398
K516 A660-8014-T359
K515 A660-8014-T266
- 393 -
J1 to J6 PULSECODER+EE
J1 to J6 POWER
J1 to J6 PULSECODER+EE
J1 to J6 POWER
J1 to J6 PULSECODER+EE
J1 to J6 POWER
J1 to J6 PULSECODER+EE
J1 to J6 POWER
Models
R-2000iA/165F,
200F, 210F, 125L
R-2000iA/200FO
R-2000iA/165R,
200R, 100P
R-2000iA/165CF
Models
R-2000iA/165F,
200F, 210F, 125L
R-2000iA/200FO,
130U
R-2000iA/165R,
200R, 100P
R-2000iA/165CF
A. SPARE PARTS LIST
APPENDIX
No.
B-81455EN/08
Table A (c) Cables (Option cable)
Specification
Function
K131 A660-8013-T916
K132 A660-8013-T917
K133 A660-4004-T014
K134 A660-4004-T015
K135 A05B-1324-D001
K136 A660-8013-T918
K138 A660-8014-T077
K139 A660-8014-T078
K131 A660-8013-T916#L
K132 A660-8013-T917#L
K133 A660-4004-T014#L
K134 A660-4004-T015#L
K135 A05B-1324-D001#L
K136 A660-8013-T918#L
K138 A660-8014-T077#L
K139 A660-8014-T078#L
K148 A660-8014-T389
K149 A660-8014-T390
K150 A660-8014-T391
K151 A660-8014-T392
K152 A05B-1324-D007
K153 A660-8014-T393
K155 A660-8014-T394
K156 A660-8014-T395
K158 A05B-1324-D039
K164 A05B-1324-D040
K143 A660-8014-T364
K144 A660-8014-T365
K273 A660-4003-T939
K274 A660-4003-T940
K291 A05B-1321-D017
K282 A660-8013-T449
- 394 -
AS (USER/SIGNAL)
AP (USER/POWER)
DNS (SIGNAL)
DNP (POWER)
I/O
J123 OT
ARP
ARM
AS (USER/SIGNAL)
AP (USER/POWER)
DNS (SIGNAL)
DNP (POWER)
I/O
J123 OT
ARP
ARM
AS (USER/SIGNAL)
AP (USER/POWER)
DNS (SIGNAL)
DNP (POWER)
I/O
J123 OT
ARP
ARM
FAN CABLE
FAN CABLE
AS (USER/SIGNAL)
AP (USER/POWER)
DNS (SIGNAL)
DNP (POWER)
I/O
J123 OT
Models
R-2000iA/165F,
200F, 210F, 125L
R-2000iA/200FO,
130U
R-2000iA/165R,
200R, 100P
R-2000iA/100P
R-2000iA/165CF
A. SPARE PARTS LIST
APPENDIX
B-81455EN/08
Table A (d) Cables (Option cable : CE)
Specification
Function
Models
R-2000iA/165F,
K531 A660-8013-T922
AS (USER/SIGNAL)
200F, 210F, 125L
K532 A660-8013-T923
AP (USER/POWER)
No.
K533 A660-4004-T016
K534 A660-4004-T017
K535 A05B-1324-D002
K136 A660-8013-T918
K538 A660-8014-T079
K539 A660-8014-T080
K531 A660-8013-T922#L
K532 A660-8013-T923#L
K533 A660-4004-T016#L
K534 A660-4004-T017#L
K535 A05B-1324-D002#L
K136 A660-8013-T918#L
K538 A660-8014-T079#L
K539 A660-8014-T080#L
K548 A660-8014-T400
K549 A660-8014-T401
K550 A660-8014-T402
K551 A660-8014-T403
K552 A05B-1324-D008
K153 A660-8014-T393
K555 A660-8014-T404
K556 A660-8014-T405
K536 A660-8014-T366
K546 A660-8014-T367
K542 A660-4004-T149
K543 A660-4004-T150
K281 A05B-1321-D006
K282 A660-8013-T449
K544 A660-8014-T362
K545 A660-8014-T363
DNS (SIGNAL)
DNP (POWER)
I/O
J123 OT
ARP
ARM
AS (USER/SIGNAL)
AP (USER/POWER)
DNS (SIGNAL)
DNP (POWER)
I/O
J123 OT
ARP
ARM
AS (USER/SIGNAL)
AP (USER/POWER)
DNS (SIGNAL)
DNP (POWER)
I/O
J123 OT
ARP
ARM
AS (USER/SIGNAL)
AP (USER/POWER)
DNS (SIGNAL)
DNP (POWER)
I/O
J123 OT
ARP
ARM
R-2000iA/200FO,
130U
R-2000iA/165R,
200R, 100P
R-2000iA/165CF
Table A (e) Motor
Axis
Specification
Remarks
Model αiS30/3000
J1, J2, J3 A06B-0267-B605#S000
(Model α30/3000is)
Model αiS8/4000
J4, J5, J6 A06B-0235-B605#S000
(Model α8/4000is)
Table A (f) Motor seal
Specification
Models
R-2000iA/165CF,
130U
J1
A98L-0004-0771#A12TP
J2, J3
A98L-0004-0771#A12TP
All models
J4, J5, J6 A98L-0004-0771#A03TP
All models
Axis
- 395 -
A. SPARE PARTS LIST
APPENDIX
Name
J1-axis
reducer
J2-axis
reducer
J3-axis
reducer
J4-axis
reducer
B-81455EN/08
Table A (g) Reducer
Specification
Models
A97L-0218-0355#320C-205 R-2000iA/165F, 200F, 200FO,
210F, 165R, 200R, 100P, 125L,
130U
R-2000iA/165CF
A97L-0218-0237#320C-35
A97L-0218-0370#450E-210 R-2000iA/165F, 125L
A97L-0218-0370#450E-231 R-2000iA/165R
A97L-0218-0370#450E-257 R-2000iA/200F, 200FO, 210F,
200R, 100P, 130U
A97L-0218-0238#450E-210 R-2000iA/165CF
A97L-0218-0371#320E-201 R-2000iA/165F, 165R, 100P, 125L
A97L-0218-0371#320E-219 R-2000iA/200F, 200FO, 200R,
130U
A97L-0218-0372#410F-236 R-2000iA/210F
A97L-0218-0239#320E-190 R-2000iA/165CF
R-2000iA/165F, 165R, 125L
A97L-0218-0281#70F-45
R-2000iA/200F, 200FO, 200R,
A97L-0218-0249#110E-46
130U
R-2000iA/210F, 100P
A97L-0218-0341#110E-46
R-2000iA/165CF
A97L-0218-0240#80E-37
NOTE
1 Draw nut is not included in the J2, J3 reducer except
165CF specification.
2 When the J5 or J6-axis reducer is broken, replace
the wrist unit.
- 396 -
APPENDIX
B-81455EN/08
A. SPARE PARTS LIST
Table A (h) Gear
Specification
Models
R-2000iA/165F, 200F, 200FO,
J1-axis
A97L-0218-0285#205
210F, 165R, 200R, 100P, 125L,
input gear
J1-axis
A97L-0001-0196#09Z000A 130U
bearing
J1-axis
A6-CJR-45
C-ring
R-2000iA/165CF
J1-axis
A290-7321-X221
spur gear
R-2000iA/165CF
A290-7321-X222
J1-axis
center
gear
J1-axis
A97L-0001-0192#3000000
bearing
R-2000iA/165F, 125L
J2-axis
A97L-0218-0379#210
input gear A97L-0218-0379#231
R-2000iA/165R
R-2000iA/200F, 200FO, 210F,
A97L-0218-0379#257
200R, 100P, 130U
R-2000iA/165CF
A97L-0218-0245#210
R-2000iA/165F, 165R, 100P, 125L
J3-axis
A97L-0218-0380#201
input gear A97L-0218-0380#219
R-2000iA/200F, 200FO, 200R,
130U
R-2000iA/210F
A97L-0218-0381#236
R-2000iA/165CF
A97L-0218-0227#190
R-2000iA/165F, 165R
J4-axis
A290-7324-X421
spur gear A290-7324-Y421
R-2000iA/125L
R-2000iA/200F, 200FO, 210F,
A290-7324-Z421
200R, 100P, 130U
R-2000iA/165CF
A290-7321-Y421
J4-axis
A97L-0218-0428#0600000 All models
bearing
J4-axis
A6-CJR-30
C-ring
R-2000iA/165F, 200F, 200FO,
J5-axis
A290-7324-X423
spur gear
165R, 200R, 125L, 130U
R-2000iA/210F, 100P
A290-7324-Z423
R-2000iA/165CF
A290-7321-Y423
R-2000iA/165F, 210F, 165R, 100P,
J6-axis
A290-7324-X425
spur gear
125L
R-2000iA/200F, 200FO, 200R,
A290-7324-Z425
130U
R-2000iA/165CF
A290-7321-Y425
Name
NOTE
Nut (A-290-7324-X151 : Common to J2 and J3
except 165CF) is not included in J2, J3 input gear
except 165CF.
- 397 -
A. SPARE PARTS LIST
APPENDIX
B-81455EN/08
Table A (i) Other (Mechanical unit)
Specification
Models
R-2000iA/165F, 200F, 125L
Balancer A290-7324-V301
R-2000iA/200FO
A290-7324-V302
R-2000iA/210F
A290-7324-V303
R-2000iA/165R, 200R, 100P
A290-7324-V311
R-2000iA/165F, 165R
Wrist unit A290-7324-T503
R-2000iA/125L
A290-7324-T563
R-2000iA/200F, 200FO, 200R,
A290-7321-T505
130U
R-2000iA/210F, 100P
A290-7324-T515
R-2000iA/165CF
A290-7321-T503
R-2000iA/165F, 165R
J3 arm
A290-7324-V403
assembly A290-7324-V405
R-2000iA/200F, 200FO, 200R,
130U
R-2000iA/210F
A290-7324-V415
R-2000iA/100P
A290-7324-V431
R-2000iA/125L
A290-7324-V463
R-2000iA/165CF
A290-7321-V441
R-2000iA/100P
Fan
A290-7324-V602
Name
Name
Table A (j) Battery and grease
Specification
Application models
Remarks
Battery A98L-0031-0005
All models
1.5V, size D
Kyodo Yushi
Grease A98L-0040-0174#12.8KG R-2000iA/165CF
VIGO GREASE
A98L-0040-0174#16KG R-2000iA/165F,
RE 0
165R, 125L
R-2000iA/200F,
A98L-0040-0174#17KG
200FO, 210F, 200R,
100P, 130U
Grease A97L-0001-0179#2
All models
Shell Alvania No.2
- 398 -
A. SPARE PARTS LIST
APPENDIX
B-81455EN/08
Name
Table A (k) O-ring
Specification
Models
O-ring
JB-OR1A-G125
All models
O-ring
JB-OR1A-G105
All models
O-ring
JB-OR1A-G415
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
R-2000iA/165F, 200F,
200FO, 210F, 165R,
200R, 100P, 125L, 130U
R-2000iA/165CF
A98L-0040-0041#281
JB-OR1A-G135
JB-OR1A-G300
All models
A98L-0001-0347#S265
R-2000iA/165F, 200F,
JB-OR1A-G270
A98L-0001-0347#S240 200FO, 165R, 200R,
100P, 125L, 130U, 165CF
R-2000iA/210F
JB-OR1A-G280
A98L-0040-0041#178
A98L-0040-0041#260 R-2000iA/165F, 165R,
125L
JB-OR1A-G135
R-2000iA/200F, 200FO,
JB-OR1A-G190
A98L-0040-0041#167 200R, 130U
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
A98L-0040-0041#166
R-2000iA/210F, 100P
A290-7302-X552
JB-OR1A-G190
R-2000iA/165CF
A290-7302-X552
A98L-0001-0347#S125
JB-OR1A-G210
All models
R-2000iA/165F, 165R,
JB-OR1A-G135
125L
A98L-0040-0041#166 R-2000iA/200F, 200FO,
200R, 130U
R-2000iA/210F, 100P
A290-7302-X552
A98L-0001-0347#S125 R-2000iA/165CF
R-2000iA/165F, 165R,
JB-OR1A-G135
125L
A98L-0040-0041#166 R-2000iA/200F, 200FO,
200R, 130U
R-2000iA/210F, 100P
A290-7302-X552
A98L-0001-0347#S125 R-2000iA/165CF
- 399 -
Location
J1 to J3-axis
motor
J4 to J6-axis
motor
J1-axis
reducer
J2-axis
reducer
J3-axis
reducer
J4-axis
reducer
J3 arm
assembly
Wrist
assembly
A. SPARE PARTS LIST
APPENDIX
Name
Collar
Stopper
Bush
Bolt
Washer
Stopper 2
Stopper
J2A
Stopper
J2A
Stopper
J2B
Plate
Stopper
J3A
Table A (l) Mechanical stopper
Specification
Models
Location
R-2000iA/165F, 200F,
For J1-axis
A290-7324-X214
200FO, 210F, 165R, 200R,
100P, 125L, 130U
R-2000iA/165F, 200F, 125L
A290-7324-X215
R-2000iA/210F, 165R,
A290-7324-Y215
200R, 200FO, 100P, 130U
A290-7324-Z215
A97L-0218-0484#3125 R-2000iA/165F, 200F,
200FO, 210F, 165R, 200R,
A6-BA-24 80
100P, 125L, 130U
A6-WM-24S
A290-7321-X461
R-2000iA/165CF
R-2000iA/165F, 200F,
200FO, 210F, 125L, 130U
R-2000iA/165R, 200R,
100P
R-2000iA/165F, 200F,
200FO, 210F, 165R, 200R,
100P, 125L, 130U
R-2000iA/165CF
R-2000iA/165F, 200F,
200FO, 125L, 130U
R-2000iA/165R, 200R,
100P
R-2000iA/210F
R-2000iA/165F, 125L
R-2000iA/165R, 100P
R-2000iA/200F, 200FO,
130U
R-2000iA/200R
R-2000iA/210F
R-2000iA/165F, 210F,
165R, 100P, 125L
R-2000iA/200F, 200FO,
200R, 130U
R-2000iA/200F, 200FO,
200R, 130U
R-2000iA/165CF
A290-7321-X462
R-2000iA/165CF
A290-7321-X215
A290-7324-X341
A290-7324-Y341
A290-7324-X342
A290-7321-Y345
A290-7324-X461
A290-7324-Y461
Stopper
J3B
Stopper
A290-7324-X466
A290-7324-X462
A290-7324-Y462
A290-7324-Z462
A290-7324-Z465
A290-7324-X467
A290-7324-X343
A290-7324-Z343
Stopper
J3A
Stopper
J3B
B-81455EN/08
- 400 -
For J2-axis
plus side
For J2-axis
plus side
For J2-axis
minus side
For J2-axis
For J3-axis
plus side
For J3-axis
minus side
For J3-axis
For J3-axis
plus side
For J3-axis
minus side
For J3-axis
plus side
For J3-axis
minus side
B-81455EN/08
B
APPENDIX
CONNECTION DIAGRAM
- 401 -
B. CONNECTION DIAGRAM
B. CONNECTION DIAGRAM
APPENDIX
Fig.B (a) Connection Diagram (R-2000iA/165F, 200F, 210F, 125L)
- 402 -
B-81455EN/08
B-81455EN/08
APPENDIX
- 403 -
B. CONNECTION DIAGRAM
B. CONNECTION DIAGRAM
APPENDIX
Fig.B (b) Connection Diagram (R-2000iA/200FO and 130U)
- 404 -
B-81455EN/08
B-81455EN/08
APPENDIX
- 405 -
B. CONNECTION DIAGRAM
B. CONNECTION DIAGRAM
APPENDIX
Fig.B (c) Connection Diagram (R-2000iA/165R and 200R)
- 406 -
B-81455EN/08
B-81455EN/08
APPENDIX
- 407 -
B. CONNECTION DIAGRAM
B. CONNECTION DIAGRAM
APPENDIX
Fig.B (d) Connection Diagram (R-2000iA/100P)
- 408 -
B-81455EN/08
B-81455EN/08
APPENDIX
- 409 -
B. CONNECTION DIAGRAM
B. CONNECTION DIAGRAM
APPENDIX
Fig.B (e) Connection Diagram (R-2000iA/165CF)
- 410 -
B-81455EN/08
B-81455EN/08
APPENDIX
- 411 -
B. CONNECTION DIAGRAM
C. PERIODIC MAINTENANCE TABLE
C
APPENDIX
B-81455EN/08
PERIODIC MAINTENANCE TABLE
FANUC Robot R-2000iA/165F, 165R, 125L
PERIODIC MAINTENANCE TABLE
- 412 -
B-81455EN/08
APPENDIX
- 413 -
C. PERIODIC MAINTENANCE TABLE
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-81455EN/08
FANUC Robot R-2000iA/200F, 200FO, 200R, 130U
PERIODIC MAINTENANCE TABLE
- 414 -
B-81455EN/08
APPENDIX
- 415 -
C. PERIODIC MAINTENANCE TABLE
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-81455EN/08
FANUC Robot R-2000iA/210F
PERIODIC MAINTENANCE TABLE
- 416 -
B-81455EN/08
APPENDIX
- 417 -
C. PERIODIC MAINTENANCE TABLE
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-81455EN/08
FANUC Robot R-2000iA/100P
PERIODIC MAINTENANCE TABLE
- 418 -
B-81455EN/08
APPENDIX
- 419 -
C. PERIODIC MAINTENANCE TABLE
C. PERIODIC MAINTENANCE TABLE
APPENDIX
B-81455EN/08
FANUC Robot R-2000iA/165CF
PERIODIC MAINTENANCE TABLE
- 420 -
B-81455EN/08
APPENDIX
- 421 -
C. PERIODIC MAINTENANCE TABLE
D. BOLT TIGHTENING TORQUE TABLE
D
APPENDIX
B-81455EN/08
BOLT TIGHTENING TORQUE TABLE
Those bolts for which no tightening torque is specified must be
tightened according to the following table.
Table D Recommended Bolt Tightening Torques
Nominal
diameter
M3
M4
M5
M6
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
M36
Unit : Nm (kgf·cm)
Hexagon socket head pan bolt
Hexagon socket head
countersunk bolt
(Steel : strength rating of 12.9)
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
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)






1.8(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)
46(470)
78(800)
130(1300)
190(1900)
260(2700)
370(3800)
510(5200)
650(6600)
940(9800)
1300(13000)
2300(23000)
- 422 -
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)






1.3(13)
2.8(29)
5.6(57)
9.6(98)
23(230)










INDEX
B-81455EN/08
INDEX
Number
F
1.5-YEAR (5,760 HOURS) CHECKS ...........22
FAILURE AND CAUSE ...............................43
1-YEAR (3,840 HOURS) CHECKS ..............22
G
3-MONTH (960 HOURS) CHECKS .............18
General ..........................................................87
3-YEAR (11,520 HOURS) CHECKS ............22
Grease Replacement Procedure for the
A
J1-Axis/J2-Axis/J3-Axis and J4-Axis Gear
ADJUSTING LIMIT SWITCH (OPTION) ...83
Box .............................................................31
ADJUSTMENTS...........................................61
Grease Replacement Procedure for the Wrist
AIR PIPING (OPTION) ..............................385
(R-2000iA/165F, 210F, 165R, 100P and
AIR SUPPLY (OPTION).............................339
125L) ..........................................................31
Attitude for Greasing....................................32
Grease Replacement Procedure for the Wrist
AXIS LIMITS SETUP...................................62
(R-2000iA/200F, 200FO, 200R, 165CF and
130U)..........................................................31
B
GREASING OF THE BALANCER SHAFT.38
BACKLASH MEASUREMENT ...................50
H
BOLT TIGHTENING TORQUE TABLE ...422
Hard Stopper and Limit Switch Setting ......71
C
I
CABLE FORMING .....................................200
CABLE REPLACEMENT...........................215
INSTALLATION.........................................375
Cautions for Specifying the Severe
INSTALLATION SPECIFICATIONS........387
Dust/Liquid Protection Package .............241
INSTALLING A FANUC/SPECIAL FLANGE
CONFIGURATION........................................ 3
ADAPTER (R-2000iA/165F, 210F, 165R
Configuration of the Severe Dust/Liquid
AND 125L)...............................................323
INTERFACE FOR OPTION CABLE
Protection Package..................................240
(OPTION).................................................342
CONNECTION DIAGRAM ........................401
D
J
DAILY CHECKS...........................................16
J1-AXIS DRIVE MECHANISM .....................6
J2-AXIS DRIVE MECHANISM .....................7
E
J3-AXIS DRIVE MECHANISM .....................8
EQUIPMENT MOUNTING FACE ............324
J4-AXIS DRIVE MECHANISM .....................9
EXTERNAL DIMENSION .........................250
J5/J6-AXIS DRIVE MECHANISM ..............10
i-1
INDEX
B-81455EN/08
L
R
LIMIT SWITCH REPLACEMENT (OPTION)
Replacing Cable Covers ..............................242
..................................................................234
REPLACING CABLES ...............................198
LOAD CONDITIONS ON J2-AXIS BASE
REPLACING FANS....................................175
AND J3-AXIS ARM .................................304
REPLACING J1-AXIS MOTOR (M1) AND
REDUCER ...............................................122
M
REPLACING J2-AXIS MOTOR (M2) AND
MAINTENANCE AREA .............................382
REDUCER ...............................................135
MAINTENANCE TOOLS.............................23
REPLACING J3-AXIS MOTOR (M3) AND
MAJOR COMPONENT SPECIFICATIONS
REDUCER ...............................................149
....................................................................11
Replacing Motor Covers..............................242
MASTERING ................................................87
REPLACING MOTOR COVERS (OPTION)
Mastering Data Entry ................................117
..................................................................182
Mastering to a Fixture (Master Position
REPLACING PARTS..................................119
Master).......................................................89
REPLACING SEVERE DUST/LIQUID
MECHANICAL COUPLING OF END
PROTECTION PACKAGE COMPONENTS
EFFECTOR TO WRIST ..........................311
..................................................................242
MECHANICAL COUPLING TO THE ROBOT
REPLACING THE BALANCER ................177
..................................................................280
REPLACING THE BATTERIES..................39
Replacing the Batteries and Battery Box
N
Cover ........................................................245
NOTE FOR PART REPLACEMENT .........120
Replacing the EE (I/O) Cable .....................246
O
REPLACING THE GREASE OF THE DRIVE
OPERATION AREA....................................260
MECHANISM............................................30
OVERVIEW...................................................42
REPLACING THE WRIST AXIS MOTORS
(M4, M5, AND M6), WRIST UNIT, AND J4
P
AXIS REDUCER .....................................163
PERIODIC MAINTENANCE.......................29
Resetting Alarms and Preparing for
PERIODIC MAINTENANCE TABLE .......412
Mastering...................................................88
PIPING AND WIRING ...............................184
ROBOT INTERFERENCE AREA..............249
PIPING DIAGRAM.....................................185
S
PREVENTIVE MAINTENANCE.................15
SEALANT APPLICATION.........................181
Procedure for Releasing Residual Pressure
SETTING SYSTEM VARIABLES FOR
from the Grease Bath................................36
MINIMUM CYCLE CONTROL..............333
Q
SETTING THE LOAD INERTIA
Quick Mastering .........................................112
(R-2000iA/200FO, 210F) .........................336
i-2
INDEX
B-81455EN/08
Severe Dust/Liquid Protection Characteristics
TRANSPORTATION AND INSTALLATION
..................................................................239
..................................................................356
TROUBLESHOOTING.................................41
SEVERE DUST/LIQUID PROTECTION
PACKAGE ...............................................238
W
SEVERE DUST/LIQUID PROTECTION
WIRING DIAGRAM ...................................188
PACKAGE (OPTION) .............................239
WRIST LOAD CONDITIONS ....................281
Single Axis Mastering.................................114
Software Setting ...........................................70
Z
SPARE PARTS LIST ..................................393
Zero Point Position and Motion Limit .........63
STORAGE ...................................................389
Zero Position Mastering .............................103
T
TRANSPORTATION ..................................357
i-3
Feb.,2001
Date
01
Edition
Contents
07
• Addition of R-2000iA/200F description
Jul.,2001 • Additional options of undesirable-environment
and motor cover
02
Edition
06
08
• Addition of R-2000iA/165R, 200R, 165CF and
125L
Nov.,2001
Apr.,2003 • Addition of R-2000iA/200FO
04
03
Aug.,2003 • Addition of R-2000iA/130U
05
Date
Contents
Mar.,2004 • Addition of R-2000iA/210F
Mar.,2005 • Addition of R-2000iA/100P
• Addition of notes for preventive maintenance
• Addition of releasing residual pressure of grease
Apr.,2007 bath
• Addition of notes for transportation
• Correction of errors
FANUC Robot R-2000iA MAINTENANCE MANUAL (B-81455EN)
Revision Record