AM-100iD Maintenance Manual [B-83945EN 03]

< Robot ARC Mate 100+D < Robot M-10+D MECHANICAL UNIT MAINTENANCE MANUAL B-83945EN/03 © FANUC CORPORATION, 2018 • Original Instructions Thank you very much for purchasing FANUC Robot. Before using the Robot, be sure to read the "FANUC Robot series SAFETY HANDBOOK (B-80687EN)" and understand the content. • No part of this manual may be reproduced in any form. • All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law”. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual, we endeavor to include all pertinent matters. There are, however, a very large number of operations that must not or cannot be performed, and if the manual contained them all, it would be enormous in volume. It is, therefore, requested to assume that any operations that are not explicitly described as being possible are "not possible". SAFETY PRECAUTIONS B-83945EN/03 SAFETY PRECAUTIONS This chapter describes the precautions which must be followed to enable the safe use of the robot. Before using the robot, be sure to read this chapter thoroughly. For detailed functions of the robot operation, read the relevant operator's manual to understand fully its specification. For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral equipment installed in a work cell. For safe use of FANUC robots, you must read and follow the instructions in “FANUC Robot series SAFETY HANDBOOK (B-80687EN)”. 1 PERSONNEL Personnel can be classified as follows. Operator: • Turns the robot controller power ON/OFF • Starts the robot program from operator panel Programmer or Teaching operator: • Operates the robot • Teaches the robot inside the safeguarded space Maintenance technician: • Operates the robot • Teaches the robot inside the safeguarded space • Performs maintenance (repair, adjustment, replacement) - - The operator is not allowed to work in the safeguarded space. The programmer or teaching operator and maintenance technician are allowed to work in the safeguarded space. Works carried out in the safeguarded space include transportation, installation, teaching, adjustment, and maintenance. To work inside the safeguarded space, the person must be trained on proper robot operation. Table 1 (a) lists the work outside the safeguarded space. In this table, the symbol “{” means the work allowed to be carried out by the specified personnel. Table 1 (a) List of work outside the Safeguarded Space Programmer or Operator Teaching operator { Turn power ON/OFF to Robot controller Select operating mode (AUTO/T1/T2) Select remote/local mode Select robot program with teach pendant Select robot program with external device Start robot program with operator’s panel Start robot program with teach pendant Reset alarm with operator’s panel Reset alarm with teach pendant Set data on teach pendant { s-1 { { { { { { { { { { Maintenance technician { { { { { { { { { { SAFETY PRECAUTIONS B-83945EN/03 Operator Teaching with teach pendant Emergency stop with operator’s panel Emergency stop with teach pendant Operator’s panel maintenance Teach pendant maintenance Programmer or Teaching operator Maintenance technician { { { { { { { { { { During robot operation, programming and maintenance, the operator, programmer, teaching operator and maintenance technician take care of their safety using at least the following safety protectors. • • • Use clothes, uniform, overall adequate for the work Safety shoes Helmet 2 DEFINITION OF SAFETY NOTATIONS To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on safety with "Warning" or "Caution" according to its severity. Read the contents of each "Warning", "Caution" before attempting to use the robot. Symbol Definitions WARNING Used if hazard resulting in the death or serious injury of the user will be expected to occur if he or she fails to follow the approved procedure. Used if a hazard resulting in the minor or moderate injury of the user, or equipment damage may be expected to occur if he or she fails to follow the approved procedure. Used if a supplementary explanation not related to any of WARNING and CAUTION is to be indicated. CAUTION NOTE s-2 SAFETY PRECAUTIONS B-83945EN/03 3 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN EMERGENCY OR ABNORMAL SITUATIONS (1) For emergency or abnormal situations (e.g. persons trapped in or sandwiched by the robot), brake release unit can be used to move the robot axes without drive power. Please order following unit and cable. Name Brake release unit Robot connection cable Power cable Specification A05B-2450-J350 (Input voltage AC100-115V single phase) A05B-2450-J351 (Input voltage AC200-240V single phase) A05B-2525-J047 ( 5m) A05B-2525-J048(10m) A05B-2525-J010 ( 5m) (AC100-115V Power plug) (*) A05B-2525-J011(10m) (AC100-115V Power plug) (*) A05B-2450-J364 ( 5m) (AC100-115V or AC200-240V No power plug) A05B-2450-J365(10m) (AC100-115V or AC200-240V No power plug) (*) These do not support CE marking. (2) Please make sure that adequate numbers of brake release units are available and readily accessible for robot system before installation. (3) Regarding how to use brake release unit, please refer to Robot controller maintenance manual. CAUTION Robot systems installed without adequate number of brake release units or similar means are neither in compliance with EN ISO 10218-1 nor with the Machinery Directive and therefore cannot bear the CE marking. WARNING Robot arm would fall down by releasing its brake because of gravity. Therefore, it is strongly recommended to take adequate measures such as supporting the robot arm by a crane before releasing a brake. s-3 SAFETY PRECAUTIONS B-83945EN/03 In case of releasing the J2-axis motor brake J2軸モータブレーキを解除する場合 Fall落下 down In J3軸モータブレーキを解除する場合 case of releasing the J3-axis motor brake Fall落下 down Fall落下 down Method ofアーム支持方法 supporting the robot arm Sling スリング (*) This figure is an example of floor mount. 図は床置き設置時の例です。 (*)direction The of fall is different according 設置角度によっては落下方向が異なり to theますので重力の影響を考慮し適切に支 installation angle, so support えてください。 the robot appropriately in consideration of the influence of the gravity. Fig. 3 (a) Releasing J2 and J3 motor brake and measures s-4 SAFETY PRECAUTIONS B-83945EN/03 4 (1) WARNING & CAUTION LABEL Greasing and degreasing label 1) 必ず排脂口を開けて給脂して下さい。Ｏｐｅｎｔｈｅｇｒｅａｓｅｏｕｔｌｅｔａｔｇｒｅａｓｉｎｇ． 1) 必ず排脂口を開けて給脂してください。 Be sure to oｐｅｎｔｈｅｇｒｅａｓｅｏｕｔｌｅｔａｔｇｒｅａｓｉｎｇ．必须在排脂口打开的状态下供脂。必须在排脂口打开的状态下供脂。 2) 手動式ポンプを使用して給脂を行って下さい。 2) 手動式ポンプを使用して給脂してください。Ｕｓｅａｈａｎｄｐｕｍｐａｔｇｒｅａｓｉｎｇ. 请使用手动式供脂泵进行供脂。Ｕｓｅａｈａｎｄｐｕｍｐａｔｇｒｅａｓｉｎｇ． 3）必ず指定グリースを使用してください。 Be sure to uｓｅｄｅｓｉｇｎａｔｅｄｇｒｅａｓｅ. 必须使用指定的润滑脂。请使用手动式供脂泵进行供脂。 3）必ず指定グリスを使用して下さい。Ｕｓｅｄｅｓｉｇｎａｔｅｄｇｒｅａｓｅａｔｇｒｅａｓｉｎｇ．必须使用指定的润滑脂。 Except ARC Mate 100iD/16S, M-10iD/16S ARC Mate 100iD/16S, M-10iD/16S Fig. 4 (a) Greasing and degreasing label Description When greasing and degreasing, observe the instructions indicated on this label. (1) Open the grease outlet at greasing. (2) Use a hand pump at greasing. (3) Use designated grease at greasing. CAUTION See Section 2.2 Maintenance for explanations about specified greases, the amount of grease to be supplied, and the locations of grease and degrease outlets for individual models. (2) Step-on prohibitive label Fig. 4 (b) Step-on prohibitive label Description Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well. s-5 SAFETY PRECAUTIONS (3) B-83945EN/03 High-temperature warning label Fig. 4 (c) 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. (4) Transportation label 300kg 250kg×2 150kg×2 Except ARC Mate 100iD/16S, M-10iD/16S ARC Mate 100iD/16S, M-10iD/16S Fig. 4 (d) Transportation label Description When transporting the robot, observe the instructions indicated on this label. The above label indicates the following: Using a crane • Use a crane with a load capacity of 300kg or greater. • Use two slings with each load capacity of 250 kg or greater, sling the robot as shown Chapter 1 of operator’s manual. • Use two M10 eyebolts with each load capacity of 1470 N (150 kgf) or greater. CAUTION See Section 1.1 TRANSPORTATION of the mechanical unit operator’s manual (B-83944EN) for explanations about the posture a specific model should take when it is transported. s-6 SAFETY PRECAUTIONS B-83945EN/03 (5) High current attention label 接触注意溶接中、内部は高電流が流れます。 DO NOT ACCESS DURING ENERGIZED HIGH CURRENT INSIDE 禁止触摸焊接时内部有大电流。 Fig. 4 (e) High current attention Label Description Do not access during energized high current inside. (6) Operating space and payload label Below label is added when CE specification is specified. Except ARC Mate 100iD/16S, M-10iD/16S ARC Mate 100iD/16S, M-10iD/16S Fig. 4 (f) Operating space and payload label s-7 PREFACE B-83945EN/03 PREFACE This manual explains the maintenance procedures for the mechanical units of the following robots: Model name FANUC Robot ARC Mate 100iD FANUC Robot ARC Mate 100iD FANUC Robot M-10iD/12 FANUC Robot M-10iD/12 FANUC Robot ARC Mate 100iD/10L FANUC Robot M-10iD/10L FANUC Robot ARC Mate 100iD/16S FANUC Robot M-10iD/16S FANUC Robot ARC Mate 100iD/8L FANUC Robot M-10iD/8L Mechanical unit specification No. A05B-1227-B201 A05B-1227-B221 A05B-1227-B251 A05B-1227-B271 A05B-1227-B202 A05B-1227-B222 A05B-1227-B252 A05B-1227-B272 A05B-1227-B301 A05B-1227-B321 A05B-1227-B302 A05B-1227-B322 A05B-1227-B421 A05B-1227-B422 A05B-1227-B521 A05B-1227-B522 p-1 Maximum load Remarks 12kg With all axes brakes 12kg With J2 to J5 axes brakes 12kg With all axes brakes 12kg With J2 to J5 axes brakes 10kg With all axes brakes 10kg With all axes brakes 16kg 16kg 8kg 8kg With all axes brakes With all axes brakes With all axes brakes With all axes brakes PREFACE B-83945EN/03 The label stating the mechanical unit specification number is affixed in the position shown below. Before reading this manual, verify the specification number of the mechanical unit. (1) TYPE NO. DATE WEIGHT (2) (3) (4) (5) kg (1) TYPE NO. DAT E WEIGHT (2) (3) (4) (5) kg Position of label indicating mechanical unit specification number TABLE 1) CONTENTS (1) (2) (3) (4) (5) Model name TYPE No. DATE WEIGHT kg (Without controller) FANUC Robot ARC Mate 100iD FANUC Robot ARC Mate 100iD FANUC Robot M-10iD/12 FANUC Robot M-10iD/12 LETTERS FANUC Robot ARC Mate 100iD/10L FANUC Robot M-10iD/10L FANUC Robot ARC Mate 100iD/16S FANUC Robot M-10iD/16S FANUC Robot ARC Mate 100iD/8L FANUC Robot M-10iD/8L A05B-1227-B201 A05B-1227-B221 A05B-1227-B251 A05B-1227-B271 A05B-1227-B202 A05B-1227-B222 A05B-1227-B252 A05B-1227-B272 A05B-1227-B301 A05B-1227-B321 A05B-1227-B302 A05B-1227-B322 145 145 145 145 SERIAL NO. IS PRINTED PRODUCTION YEAR AND MONTH ARE PRINTED 150 150 A05B-1227-B421 140 A05B-1227-B422 140 A05B-1227-B521 180 A05B-1227-B522 180 p-2 PREFACE B-83945EN/03 RELATED MANUALS For the FANUC Robot series, the following manuals are available: SAFETY HANDBOOK B-80687EN All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook Intended readers: Operator, system designer Topics: Safety items for robot system design, operation, maintenance Intended readers: Operator, programmer, maintenance technician, system designer Topics: Robot functions, operations, programming, setup, interfaces, alarms Use: Robot operation, teaching, system design R-30iB Plus/ OPERATOR’S MANUAL R-30iB Mate Plus (Basic Operation) controller B-83284EN OPERATOR’S MANUAL (Alarm Code List) B-83284EN-1 OPERATOR’S MANUAL (Optional Function) B-83284EN-2 ARC WELDING FUNCTION OPERATOR’S MANUAL B-83284EN-3 Spot WELDING FUNCTION OPERATOR’S MANUAL B-83284EN-4 DISPENSE FUNCTION OPERATOR’S MANUAL B-83284EN-5 MAINTENANCE MANUAL R-30iB Plus : B-83195EN R-30iB Mate Plus: B-83525EN FANUC Robot ARC Mate 100iD M-10iD Mechanical unit Intended readers: Maintenance technician, system designer Topics: Installation, start-up, connection, maintenance Use: Installation, start-up, connection, maintenance Intended readers: System designer, Maintenance technician Topics: Installation, connection to the controller, maintenance Use: Installation, start-up, connection, maintenance Operator’s manual B-83944EN This manual uses following terms. Name Terms in this manual Connection cable between robot and controller Robot mechanical unit Robot connection cable Mechanical unit p-3 TABLE OF CONTENTS B-83945EN/03 TABLE OF CONTENTS SAFETY PRECAUTIONS............................................................................s-1 PREFACE ....................................................................................................p-1 1 CHECKS AND MAINTENANCE ............................................................. 1 1.1 PERIODIC MAINTENANCE .......................................................................... 1 1.1.1 1.1.2 1.2 CHECK POINTS............................................................................................ 4 1.2.1 1.2.2 1.2.3 1.2.4 1.3 2 2.2 MAINTENANCE TOOLS ............................................................................... 9 REPLACING THE BATTERIES (1 YEAR (3840 HOURS) CHECKS) ............................................................ 12 REPLACING THE GREASE AND OIL OF THE DRIVE MECHANISM (3 YEARS (11520 HOURS) CHECKS) ........................................................ 13 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 Grease Replacement Procedure for the Reducer (J2/J3-axis).................................13 Procedure for Releasing Remaining Pressure from the Grease Bath (J2/J3-axis)..16 Oil Replacement Procedure for the J1-axis Gearbox .............................................16 Oil Replacement Procedure for the J4-axis Gearbox .............................................19 Oil Replacement Procedure for the J5/J6- axis Gearbox (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L) ....................22 Oil Replacement Procedure for the J5/J6- axis Gearbox (ARC Mate 100iD/16S, M-10iD/16S) ...................................................................25 Procedure for Releasing Remaining Pressure from the Oil Bath (J1/J4/J5/J6-axis)28 TROUBLESHOOTING .......................................................................... 29 3.1 3.2 4 Confirmation of Oil Seepage....................................................................................4 Confirmation of the Air Control Set (option)...........................................................5 Check the Mechanical Unit Cables and Connectors ................................................6 Check of Fixed Mechanical Stopper and Adjustable Mechanical Stopper ..............8 CHECKS AND MAINTENANCE ........................................................... 12 2.1 3 Daily Checks ............................................................................................................1 Periodic Checks and Maintenance............................................................................2 TROUBLESHOOTING................................................................................. 29 BACKLASH MEASUREMENT..................................................................... 38 REPLACING PARTS ............................................................................ 42 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 DRIVE MECHANISM................................................................................... 43 REPLACING THE J1-AXIS MOTOR (M1) ................................................... 45 REPLACING THE J1 UNIT.......................................................................... 46 REPLACING THE J2-AXIS MOTOR (M2) ................................................... 49 REPLACING THE J2-AXIS REDUCER ....................................................... 50 REPLACING THE J3-AXIS MOTOR (M3) ................................................... 53 REPLACING THE J3-AXIS REDUCER ....................................................... 55 NOTES OF ATTACHING THE GEAR TO THE J3-AXIS REDUCER........... 58 REPLACING THE J4-AXIS MOTOR (M4) ................................................... 59 c-1 TABLE OF CONTENTS 4.10 4.11 4.12 4.13 4.14 5 REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L)................ 60 REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iD/16S, M-10iD/16S)........................................................... 62 REPLACING THE J5/J6-AXIS MOTOR (M5, M6) (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L)................ 64 REPLACING THE J5/J6-AXIS MOTOR (M5, M6) (ARC Mate 100iD/16S, M-10iD/16S)........................................................... 67 REPLACING THE J5/J6-AXIS GEARBOX (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L)................ 69 4.15 REPLACING THE J5/J6-AXIS GEARBOX 4.16 4.17 4.18 4.19 (ARC Mate 100iD/16S, M-10iD/16S)........................................................... 71 REPLACING THE J3 ARM UNIT................................................................. 74 REPLACING THE J2 COVER (OPTION) .................................................... 75 REPLACING THE J3 COVER (OPTION) .................................................... 76 REPLACING THE M/H CONDUIT (OPTION) .............................................. 77 REPLACING CABLES .......................................................................... 79 5.1 5.2 5.3 5.4 6 B-83945EN/03 CABLE WIRING........................................................................................... 80 CABLE DRESSING ..................................................................................... 81 REPLACING THE J1 TO J4 CABLE............................................................ 88 REPLACING S J5 AND J6 CABLES ........................................................... 94 MASTERING ......................................................................................... 98 6.1 6.2 6.3 6.4 6.5 OVERVIEW ................................................................................................. 98 RESETTING ALARMS AND PREPARING FOR MASTERING ................. 101 FIXTURE POSITION MASTER ................................................................. 102 SINGLE AXIS MASTERING (FOR PARTS REPLACING)......................... 107 VERIFYING MASTERING ......................................................................... 110 APPENDIX A MAINTENANCE PARTS ..................................................................... 113 B MECHANICAL UNIT CIRCUIT DIAGRAM.......................................... 117 C PERIODIC MAINTENANCE TABLE ................................................... 124 D STRENGTH OF BOLT AND BOLT TORQUE LIST............................ 126 E INSULATION ABOUT ARC WELDING ROBOT................................. 127 E.1 E.2 INSULATION AT THE WRIST ................................................................... 127 INSULATION AT THE ADDITIONAL AXIS ................................................ 128 c-2 1. CHECKS AND MAINTENANCE B-83945EN/03 1 CHECKS AND MAINTENANCE Optimum performance of the robot can be maintained by performing the checks and maintenance procedures presented in this chapter. (See the APPENDIX C PERIODIC MAINTENANCE TABLE.) NOTE The periodic maintenance procedures described in this chapter assume that the FANUC robot is used for up to 3840 hours a year. In cases where robot use exceeds 3840 hours/year, adjust the given maintenance frequencies accordingly. The ratio of actual operation time/year vs. the 3840 hours/year should be used to calculate the new (higher) frequencies. For example, when using the robot 7680 hours a year with a recommended maintenance interval of 3 years or 11520 hours, use the following calculation to determine the maintenance frequency: 3 years / 2 = perform maintenance every 1.5 years. 1.1 PERIODIC MAINTENANCE 1.1.1 Daily Checks Clean each part, and visually check component parts for damage before daily system operation. Check the following items when necessary. Check items Oil seepage Air control set Vibration, abnormal noises Positioning accuracy Peripheral equipment for proper operation Brakes for each axis Warnings Check points and management Check to see if there is oil on the sealed part of each joint. If there is an oil seepage, clean it. ⇒”1.2.1 Confirmation of Oil Seepage” ( When air control set is used) ⇒”1.2.2 Confirmation of the Air Control Set” Check whether vibration or abnormal noises occur. When vibration or abnormal noises occur, perform measures referring to the following section: ⇒”3.1 TROUBLESHOOTING”(symptom : Vibration, Noise) Check that the taught positions of the robot have not deviated from the previously taught positions. If displacement occurs, perform the measures as described in the following section: ⇒”3.1 TROUBLESHOOTING”(symptom : Displacement) Check whether the peripheral equipment operate properly according to commands from the robot and the peripheral equipment. Check that the end effector drops 5 mm or less when the servo power is turned off. If the end effector (hand) drops more than the prescribed amount, perform the measures as described in the following section: ⇒”3.1 TROUBLESHOOTING”(symptom : Dropping axis) Check whether unexpected warnings occur in the alarm screen on the teach pendant. If unexpected warnings occur, perform the measures as described in the following manual: ⇒”CONTROLLER OPERATOR’S MANUAL (Alarm Code List)(B-83284EN-1)” -1- 1. CHECKS AND MAINTENANCE 1.1.2 B-83945EN/03 Periodic Checks and Maintenance Check the following items at the intervals recommended below based on the period or the accumulated operating time, whichever comes first. (○ : Item needs to be performed.) Check and maintenance intervals (Period, Accumulated operating time) 1 3 1 month months year 320h 960h 3840h ○ ○ Cleaning the controller ventilation system Check for external damage or peeling paint Only 1st check ○ ○ ○ Check for water ○ Only 1st check ○ ○ Only 1st check ○ ○ Only 1st check ○ ○ Only 1st check ○ Only 1st check 2 3 4 years years years 7680h 11520h 15360h Check and maintenance item ○ Check for damages to the teach pendant cable, the operation box connection cable or the robot connection cable Check for damage to the mechanical unit cable (movable part) and welding cable Check for damage to the end effector (hand) cable Check the connection of each axis motor and other exposed connectors Retightening the end effector mounting bolts Check points, management and maintenance method Confirm the controller ventilation system is not dusty. If dust has accumulated, remove it. Check whether the robot has external damage or peeling paint due to the interference with the peripheral equipment. If an interference occurs, eliminate the cause. Also, if the external damage is serious, and causes a problem in which the robot will not operate, replace the damaged parts. Check whether the robot is subjected to water or cutting oils. If water is found, remove the cause and wipe off the liquid. Check whether the cable connected to the teach pendant, operation box and robot are unevenly twisted or damaged. If damage is found, replace the damaged cables. Observe the movable part of the mechanical unit cable and welding cable, and check for damage. Also, check whether the cables are excessively bent or unevenly twisted. ⇒”1.2.3 Check the Mechanical Unit Cables and Connectors” Check whether the end effector cables are unevenly twisted or damaged. If damage is found, replace the damaged cables. Check the connection of each axis motor and other exposed connectors. ⇒”1.2.3 Check the Mechanical Unit Cables and Connectors” Retighten the end effector mounting bolts. Refer to the following section for tightening torque information: ⇒”4.1 END EFFECTOR INSTALLATION TO WRIST of the mechanical unit operator’s manual (B-84944EN)” -2- Periodic maintenance table No. 20 1 2 19 3 4 5 6 1. CHECKS AND MAINTENANCE B-83945EN/03 Check and maintenance intervals (Period, Accumulated operating time) 1 3 1 month months year 320h 960h 3840h ○ 2 3 4 years years years 7680h 11520h 15360h ○ Check and maintenance item Retightening the external main bolts Only 1st check ○ ○ Check the fixed mechanical stopper and the adjustable mechanical stopper Only 1st check ○ ○ Clean spatters, sawdust and dust Only 1st check ○ Replacing the mechanical unit batteries ○ ○ ○ ○ ○ Replacing cable of Mechanical unit welding power Replacing the grease and oil of J2, J3- axis reducer and J1. J4 to J6-axis gearbox Replacing the mechanical unit cable Replacing the Material handling (M/H) conduit Replacing the controller batteries Check points, management and maintenance method Retighten the robot installation bolts, bolts to be removed for inspection, and bolts exposed to the outside. Refer to the recommended bolt tightening torque guidelines at the end of the manual. An adhesive to prevent bolts from loosening is applied to some bolts. If the bolts are tightened with greater than the recommended torque, the adhesive might be removed. Therefore, follow the recommended bolt tightening torque guidelines when retightening the bolts. Check that there is no evidence of a collision on the fixed mechanical stopper, the adjustable mechanical stopper, and check that the stopper mounting bolts are not loose. ⇒”1.2.4 Check of Fixed Mechanical Stopper and Adjustable Mechanical Stopper” Check that spatters, sawdust, or dust does not exist on the robot main body. If dust has accumulated, remove it. Especially, clean the robot movable parts well (each joint, J1 base inside and surroundings, around the welding torch, conduit part, wrist axis hollow part) Insulation failure might occur when the spatter has collected around the wrist flange or welding torch, and there is a possibility of damaging the robot mechanism by the welding current. (See Appendix C) Replace the mechanical unit batteries. Regardless of operating time, replace batteries at 1 year. ⇒”2.1 REPLACING THE BATTERIES” Replace the cable of Mechanical unit welding. ⇒”5 REPLACING CABLES” Replace the grease and oil of each axis reducer and gearbox. ⇒”2.2 REPLACING THE GREASE AND OIL OF THE DRIVE MECHANISM” Replace the mechanical unit cable. ⇒”5 REPLACING CABLES” Replace the Material handling (M/H) conduit ⇒”4.15 REPLACING M/H CONDUIT” Replace the controller batteries. Regardless of operating time, replace batteries at 4 years. ⇒Chapter 7 Replacing batteries of R-30iB/R-30iB Plus CONTROLLER MAINTENANCE MANUAL (B-83195EN) or R-30iB Mate/R-30iB Mate Plus CONTROLLER MAINTENANCE MANUAL (B-83525EN)” -3- Periodic maintenance table No. 7 8 9 10 17 11 to 15 16 18 21 1. CHECKS AND MAINTENANCE B-83945EN/03 1.2 CHECK POINTS 1.2.1 Confirmation of Oil Seepage Check items Check there is oil on sealed part of each joint parts. If there is oil seepage, clean them. Oil seal オイルシール (J3) Oil seal オイルシール (J6) (J6) G D F 詳細DD Detail Oil seal オイルシール (J5) (J5) Oil seal オイルシール (J2) (J2) C Detail 詳細GG E Detail 詳細CC Detail 詳細FF オイルシール Oil seal (J1) (J1) Oil seal オイルシール (J4) (J4) A Detail 詳細A A 詳細 EE Detail B Detail 詳細 BB Fig. 1.2.1 (a) Check parts of oil seepage Management x Oil might accumulate on the outside of the seal lip depending on the movement condition or environment of the axis. If the oil viscosity changes, the oil might drip depending on the axis movement. To prevent oil spots, be sure to wipe away any accumulated oil under the axis components in Fig. 1.2.1 (a) before you operate the robot. x In case of oil seepage, please consider replacing the grease and the oil altogether. This replacement potentially can help improve the seepage situation. x Also, motors might become hot and the internal pressure of the grease bath or oil bath may increase by frequent repetitive movement and use in high temperature environments. In these cases, normal internal can be restored by venting the grease outlet. (When opening the grease outlet of J2 and J3-axis, refer to Subsection 2.2 and ensure that grease is not expelled onto the machine or tooling. When opening the oil outlet of J1 and J4 to J6-axis, put a oil pan under the oil outlet or place the oil outlet at the upper side.) WARNING Hot grease might eject suddenly when you open the grease outlet. Attach bags for collecting grease, and use appropriate protective equipment such as heat-resistant gloves, protective glasses, a face shield, or a body suit if necessary. x If you must wipe oil frequently, and opening the grease outlet does not stop the seepage, perform the measures below. ⇒”3.1 TROUBLESHOOTING”(symptom : Grease leakage, Oil leakage) -4- 1. CHECKS AND MAINTENANCE B-83945EN/03 1.2.2 Confirmation of the Air Control Set (option) When an air control set is used, check the items below. Item Check items 1 Air pressure 2 Lubricator oil mist quantity 3 Lubricator oil level 4 Leakage from hose 5 Drain Check points Check the air pressure using the pressure gauge on the air regulator as shown in Fig. 1.2.2 (a). 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 number of oil drops during operation. If it does not meet the specified value (1 drop/10-20 sec), adjust it using the lubricator control knob. Under normal usage, the lubricator will be empty in about 10 to 20 days. Check to see that the air control set oil level is within the specified level. Check the joints, tubes, etc. for leaks. Retighten the joints or replace parts, as required. Check the drain and release it. If the quantity of the drained liquid is significant, examine the setting of the air dryer on the air supply side. Handle for lubricator adjustment ルブリケータ調整ハンドルルブリケータオイル滴下量確認 Lubricator oil drop amount check Pressure gauge 圧力計 Lubricator oil inlet ルブリケータ給油口 Lubricator ルブリケータ Air filter エアフィルタ Regulator pressure レギュレータ setting handle 圧力設定ハンドル Drain port ドレインポート Fig. 1.2.2 (a) Air control set (option) -5- 1. CHECKS AND MAINTENANCE 1.2.3 B-83945EN/03 Check the Mechanical Unit Cables and Connectors Inspection points of the mechanical unit cables and welding cables Check the cables for visible damage that has been exposed. Closely inspect movable parts. Clean any spatter that might be found. Fig. 1.2.3 (a) Inspection points of the mechanical unit cables -6- 1. CHECKS AND MAINTENANCE B-83945EN/03 Inspection points of the connectors x Power/brake connectors of the motor exposed externally x Robot connection cables, earth terminal and user cables Check items x Circular connector: Check the connector for tightness by turning it manually. x Square connector: Check the connector for engagement of its lever. x Earth/Ground terminal: Check the terminal for tightness. Fig. 1.2.3 (b) Connector Inspection points -7- 1. CHECKS AND MAINTENANCE 1.2.4 x x x B-83945EN/03 Check of Fixed Mechanical Stopper and Adjustable Mechanical Stopper Check that there is no evidence of a collision on the fixed mechanical stopper and the adjustable mechanical stopper. If there is evidence of a collision on the stopper, replace the parts. Check the tightness of the stopper mounting bolts. If they are loose, retighten them. Be sure to check the tightness of the mounting bolts of the J1-axis swing stopper. Refer to Section 6.2 of the mechanical unit operator’s manual (B-83944EN) for details regarding the adjustable mechanical stopper. J3-axis mechanical stopper B J3軸機械式ストッパB Spec.: 仕様 Bolt : A6-BA-10X16 ボルト : A6-BA-10X16 J3軸機械式ストッパA J3-axis mechanical stopper A J2-axis mechanical stopper B J2軸機械式ストッパB Spec.: Bolt仕様 : A6-BA-16X30 ボルト : A6-BA-16X30 J2-axis mechanical stopper A J2軸機械式ストッパA J1-axis mechanical stopper A J1軸機械式ストッパA (When J1-axis (機械式ストッパ指定時) mechanical stopper is specified) A J1-axis mechanical J1軸機械式ストッパB stopper B (機械式ストッパ指定時) (When J1-axis mechanical stopper is specified) 仕様 Spec.: ストッパ : A290-7227-X367 Stopper : A290-7227-X367 ボルト : A6-BA-8X16 Bolt :A6-BA-8X16 56Nm) (締め付けトルク (Tightening torque 56Nm) Detail 詳細AA Fig. 1.2.4 (a) Check of fixed mechanical stopper and adjustable mechanical stopper -8- 1. CHECKS AND MAINTENANCE B-83945EN/03 1.3 MAINTENANCE TOOLS You should have the following instruments and tools ready for maintenance. a) b) Measuring instruments Instrument Condition Dial gauge Vernier calipers 1/100mm 150mm Use For positioning precision and backlash measurement Tools Name Cross-head screwdriver Straight-head screwdriver Nut driver Hexagonal wrench sets Torque wrench Long T wrenches Adjustable wrenches Pliers Long-nose pliers Cutting pliers Both-ended wrench Grease gun Vacuum cleaner C-ring pliers J1/J2/J3-axis reducer rigging fixture Mounting fixture for gear of J3-axis motor Adapter Flashlight LOCTITE 243,263,518,675 Three bond TB1133G Oil injection gun Oil injection nipple with valve Oil tray with valve J3 arm maintenance fixture kit Wrench Wrench Remarks (Large, medium, and small sizes) (Large, medium, and small sizes) Width across flats 7, 10 (for grease nipple) Width across flats 2.5, 3, 4, 5, 6, 8, 10, 12 (for replacing parts) Width across flats 2.5, 3, 4, 5, 6, 8, 10, 12 (for replacing parts) Width across flats 2.5, 3, 4, 5, 6, 8, 10, 12 (for replacing parts) (Medium and small sizes) A290-7227-X940 (Fig.1.3 (a)) A290-7227-X971 (Fig.1.3 (b)) A290-7227-X972 (Fig. 1.3 (c)) A98L-0040-0238 A05B-1221-K005 A05B-1224-K006 A05B-1227-K007 A05B-1227-K901 A05B-1227-K008 (For replacing the J1 unit) A05B-1227-K009 (For replacing the J1 unit) -9- 1. CHECKS AND MAINTENANCE B-83945EN/03 208 7.7 46.8 139.5 135 65 C2 118 44.3 13.5 0 76 13 46.2 37 50 刻印"J1" MARK 16 45 3-M12 THRU 刻印"J2" MARK 刻印"J3" MARK THRU 4-O6.6 THRU 65 質量 WEIGHT 貫通 2- 13 C3 2.15Kg A290-7227-X940 Fig. 1.3 (a) J1/J2/J3-axis reducer rigging fixture 6.5 ( 15 1 G ) 70 4R 6.5 108 r 0.01 90 P G 45 7 9 A R RELIEF 0 .5 8 5 R 12 .5 C0 2R G Q A ( 70 ) O ( 15 ) 0 12 n 0.01 P a 0.01 Q 78 90 G O 80 0 +0.010 45 RELIEF 3 O 20 O 78 G R 11.4 3 +0.020 O 22 0 O 86 O 32 14 0 +0.010 n 0.01 P SECTION A-A RELIEF 逃げ SECTION 断面 A290-7227-X971 Fig. 1.3 (b) Mounting fixture for gear of J3-axis motor - 10 - 1 1. CHECKS AND MAINTENANCE B-83945EN/03 ( -0.025 X C0 .3 .3 C0 C0 .5 A G G G ) O 22 -0.035 .5 C0 O 14 0 O 7.1 0 .5 C0 +0.010 10.6 G +0.010 13.6 a 0.01 X SECTION A-A 逃げ RELIEF A a 0.01 X 注） NOTE) 1)バリ無きこと。 NO BURR. 2)全周糸面取りのこと。(C0.2～C0.3) ALL EDGE SHOULD BE CHAMFERED C0.2～C0.3. 3)寸法は表面処理後のものとする Dimension is for after surface treatment. SECTION 断面 A290-7227-X972 Fig. 1.3 (c) Mounting fixture for gear of J3-axis motor - 11 - 2. CHECKS AND MAINTENANCE 2 2.1 B-83945EN/03 CHECKS AND MAINTENANCE REPLACING THE BATTERIES (1 YEAR (3840 HOURS) CHECKS) The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every year. Also, use the following procedure to replace when the backup battery voltage drop alarm occurs. Procedure for replacing the battery 1 Press the EMERGENCY STOP button to prohibit the robot motion. CAUTION Be sure to keep controller power turned on. Replacing the batteries with the power turned off causes all current position data to be lost. Therefore, mastering will be required again. 2 3 4 5 Remove the battery case cap. (Fig. 2.1 (a)) If it cannot be removed, tap it on its side with a plastic hammer to loosen the cap before you remove it. Take out the old batteries from the battery case. At this time, the battery can be taken out by pulling the stick in the center of the battery box. Insert new batteries into the battery case. Pay attention to the direction of the batteries. Close the battery case cap. Battery can be taken out この棒を引っ張ると by pulling this stick バッテリが取り出せます。 Battery case バッテリケース Battery spec. :A98L-0031-0027 バッテリ仕様:A98L-0031-0027 (C battery 4 pcs) (単二アルカリ電池 4本) Fig. 2.1 (a) Replacing the battery - 12 - Case cap ケースキャップ 2. CHECKS AND MAINTENANCE B-83945EN/03 2.2 REPLACING THE GREASE AND OIL OF THE DRIVE MECHANISM (3 YEARS (11520 HOURS) CHECKS) According to below, replace the grease and the oil of the reducers of J2 and J3-axes and the J1, J4/J5/J6-axis gearbox at the intervals based on every 3 years or 11520 hours, whichever comes first. Upside-down mount 天吊設置の場合 wall mount -90°-90º 壁掛け設置の場合 +90º mount 掛けwall 設置の場合 +90°壁 Fig. 2.2 (a) Installation method 2.2.1 1 2 3 4 5 6 Grease Replacement Procedure for the Reducer (J2/J3-axis) CAUTION Failure to supply grease correctly may cause an increase of the internal pressure of the grease bath. Such pressure increase will then damage the seal, which in turn leads to grease leakage and abnormal robot operation. When performing greasing, therefore, observe the following precautions. Before starting to grease, remove the seal bolt of the grease outlet to allow the grease to come out. Supply grease slowly, using a manual pump. (once per two seconds) Whenever possible, avoid using an air pump, which is 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 2.2.1 (a)). Use grease only of the specified type. Grease of a type other than that specified may damage the reducer or lead to other problems. After greasing, release remaining pressure from the grease bath using the procedure given in Subsection 2.2.2, and then close the grease outlet. To prevent slipping accidents and catching fire, completely remove any excess grease from the floor or robot. - 13 - 2. CHECKS AND MAINTENANCE B-83945EN/03 Table 2.2.1 (a) Grease name and amount to be replaced at regular intervals of three years (11520 hours) Amount of grease to be Greasing points Gun tip pressure Specified grease applied Kyodo Yushi 250ｇ(280ml) J2-axis reducer VIGOGREASE RE0 0.1MPa or less (NOTE) (Specification: 200ｇ(220ml) J3-axis reducer A98L-0040-0174) NOTE When a manual pump is used for greasing, the standard rate is one pumping cycles per two seconds. WARNING Hot grease might eject suddenly when you open the grease outlet. Attach bags for collecting grease, and use appropriate protective equipment such as heat-resistant gloves, protective glasses, a face shield, or a body suit if necessary. For grease replacement or replenishment, use the Postures indicated below. Consider relative angle of from posture of floor mount when robot is angle mount. Table 2.2.1 (b) Grease supplying posture (J2/J3-axis reducer) Posture Grease supplying position J1 J2 J3 J4 J5 Floor mount 0° J2-axis reducer Upside-down -90° grease supplying mount Arbitrary Wall mount -90º 90° posture Wall mount +90º -90° Arbitrary Arbitrary Arbitrary Floor mount 0° 0° J3-axis reducer Upside-down 0° 180° grease supplying mount Wall mount -90º 0° 0° posture Wall mount +90º 0° 0° - 14 - J6 Arbitrary 2. CHECKS AND MAINTENANCE B-83945EN/03 1 2 3 4 5 6 Move the robot to the greasing Posture described in Table 2.2.1 (b). Turn off controller power. Remove the bolt and the seal washer from grease outlet. (Fig. 2.2.1 (a)) Remove the bolt and the seal washer from grease inlet and attach grease nipple. Keep greasing until the new grease pushes out the old grease and comes out from each grease outlet. Release remaining pressure using the procedure given in Subsection 2.2.2. J3-axis reducer grease inlet J3軸減速機給脂口ボルトM6X10 シールワッシャ Bolt M6 x10 & +seal washer J3-axis reducer grease outlet J3軸減速機排脂口 Bolt M6 x10 & seal washer ボルトM6X10 + シールワッシャ J2-axis reducer grease inlet J2軸減速機給脂口 Bolt M6 x10 &+seal washer ボルトM6X10 シールワッシャ J2-axis reducer grease outlet J2軸減速機排脂口 Bolt M6 x10 &+seal washer ボルトM6X10 シールワッシャ Fig. 2.2.1 (a) Greasing point of J2/J3-axis reducer Table 2.2.1 (c) Specification of taper plug and seal washer Parts name Specification taper plug seal washer (R1/8) (M6) A97L-0001-0436#1-1D A30L-0001-0048#6M - 15 - 2. CHECKS AND MAINTENANCE 2.2.2 B-83945EN/03 Procedure for Releasing Remaining Pressure from the Grease Bath (J2/J3-axis) After applying grease, operate the robot more than 10 minutes as instructed below with the taper plug and seal bolt of the grease inlet and outlet uncapped to release the remaining pressure within the grease bath. Attach a recovery bag below the grease inlet and outlet to prevent output grease from splattering. Operating axis Grease replacement part J2-axis reducer J3-axis reducer J1-axis J2-axis Arbitrary Axis angle of 60° or more OVR 100% Arbitrary J3-axis J4-axis J5-axis J6-axis Arbitrary Axis angle of 60° or more OVR 100% Arbitrary If the above operation cannot be performed due to the environment of the robot, adjust the operating time according to the operating angle. (When the maximum allowable axis angle is 30 degrees, perform the twice operation for 20 minutes or more.) If you grease multiple axes, you can exercise multiple axes at the same time. After completion of the operation, attach the taper plug and seal bolts to the grease inlets and outlets. When reusing the seal bolts, be sure to seal them with seal tape. After replacing grease or oil, the internal pressure of the grease bath or oil bath may rise if the robot is operated again under frequent inversion movement or a high temperature environment. In these cases, you can return to normal internal pressure by releasing the grease outlet or oil outlet just after robot operation. (When opening grease outlet or oil outlet, be sure that grease or oil is not spattered.) 2.2.3 Oil Replacement Procedure for the J1-axis Gearbox CAUTION 1 There is severe risk of gear damage in case robot is operated with oil shortage. Please make sure the gearbox is always filled with correct amount of oil. 2 Failure to supply oil correctly may cause damage to the seal, which would in turn lead to oil leakage and abnormal operation. When performing oiling, therefore, observe the following cautions. (1) Use specified oil. Use of non-approved oil may damage the reducer or lead to other problems. (2) After oiling, release remaining pressure from the grease bath using the procedure given in Subsection 2.2.6, and then close the grease outlet. (3) To prevent slipping accidents and catching fire, completely remove any excess oil from the floor or robot. Table 2.2.3 (a) Oil name and amount of oiling of standard to be replaced at regular intervals of three years (11520 hours) Amount of oil to be Gun tip pressure Specified oil Oiling points applied NOTE) JXTG Nippon Oil & Energy 2040ｇ(2400ml) Corporation (except +90º wall mount) BONNOC AX68 J1-axis gearbox 0.1MPa or less 1360ｇ(1600ml) (Specification: (+90º wall mount) A98L-0040-0233) - 16 - 2. CHECKS AND MAINTENANCE B-83945EN/03 NOTE 1 In case of +90º wall mount, 800 ml remains at oil drainage in the J1 gearbox, so oil supply amount is 1600 ml. The total amount of oil is 2400ml. 2 It is not a regulated amount injection. For oil replacement or replenishment, use the arbitrary postures. BB テーパプラグ R1/8 taper plug R1/8 CC テーパプラグ R1/8 taper plug R1/8 AA テーパプラグ R1/8 taper plug R1/8 Fig. 2.2.3 (a) Greasing point of J1-axis gearbox Table 2.2.3 (b) Oiling points A B Installation Floor mount Upside-down mount Wall mount -90º Wall mount +90º Oil inlet/outlet Ventilator hole Oil inlet Oil inlet Parts name Ventilator hole Oil inlet/outlet Oil outlet Ventilator hole Table 2.2.3 (c) Specification of taper plugs Specification taper plug (R1/8) A97L-0001-0436#2-1D - 17 - C Ventilator hole Oil outlet 2. CHECKS AND MAINTENANCE B-83945EN/03 Exhausting oil method 1 2 Turn off controller power. Put the oil pan under the oil outlet. Then remove the plug or the seal bolt of the oil inlet/outlet and ventilator hole, and discharge the oil. Oiling method Supply oil according to the description below. 1 2 3 Install oil injection nipple with a valve (A05B-1224-K006) to oil inlet. Install the oil tray with a valve (A05B-1227-K007) to the J1-axis gearbox ventilator hole. Confirm the valve is open, according to Fig.2.2.3 (b), supply oil by using oil injection gun (A05B-1221-K005). In this time, install adapter for keeping of oiling posture. (It is appendix of A05B-1224-K006). except +90º wall mount If oil comes out to oil tray from ventilator hole, stop supplying oil, close the valve of the oil injection nipple, then remove the oil gun. +90º wall mount Supply 1600ml oil, then stop the valve of the oil injection nipple, then remove the oil gun. 4 5 6 Attach seal bolt to the ventilator hole. Replace seal bolt by new one. When reusing it, be sure to wind it with seal tape. Remove the oil injection nipple, attach the taper plug to oil inlet. In this time, oil may drop. Set the oil pan under it and attach the seal bolts immediately. Replace the taper plug by new one. When reusing it, be sure to wind it with seal tape. Release the remaining pressure using the procedure given in Subsection 2.2.7. CAUTION If supplying oil forcibly when valve is closed, internal pressure of oil bath rise abnormally and cause oil leak from seal part or oil seal falling out. Be careful. Adapter for holding oiling posture 給油姿勢保持アダプタ (Appendix of A05B-1224-K006) （A05B-1224-K006に添付） Oil tray with a valve バルブ付オイル受け皿 A05B-1227-K007 A05B-1227-K007 Oil injection nipple with a valve バルブ付オイル注入ニップル A05B-1224-K006 A05B-1224-K006 Oil オイル注入ガン injection gun A05B-1221-K005 A05B-1221-K005 Fig. 2.2.3 (b) Oil injection by oil gun (oiling of J1-axis gearbox) - 18 - 2. CHECKS AND MAINTENANCE B-83945EN/03 2.2.4 Oil Replacement Procedure for the J4-axis Gearbox CAUTION 1 There is severe risk of gear damage in case robot is operated with oil shortage. Please make sure the gearbox is always filled with correct amount of oil. 2 Failure to supply oil correctly may cause damage to the seal, which would in turn lead to oil leakage and abnormal operation. When performing oiling, therefore, observe the following cautions. (1) Use specified oil. Use of non-approved oil may damage the reducer or lead to other problems. (2) After oiling, release remaining pressure from the grease bath using the procedure given in Subsection 2.2.6, and then close the grease outlet. (3) To prevent slipping accidents and catching fire, completely remove any excess oil from the floor or robot. Table 2.2.4 (a) Oil name and amount of oiling of standard to be replaced at regular intervals of three years (11520 hours) Amount of oil to be applied NOTE) Oiling points 670ｇ(790ml) J4-axis gearbox NOTE) Gun tip pressure Specified oil 0.1MPa or less JXTG Nippon Oil & Energy Corporation BONNOC AX68 (Specification: A98L-0040-0233) It is not a regulated amount injection. For oil replacement or replenishment, use the Postures indicated below. Consider relative angle of from posture of floor mount when robot is angle mount. Supply position J4-axis gearbox Table 2.2.4 (b) Oiling posture (J4-axis gearbox) Posture J1 J2 J3 J4 Floor mount Upside-down mount Wall mount -90° Wall mount +90° Arbitrary Arbitrary 0° - 19 - 0° 180° -90° 90° Arbitrary J5 J6 Arbitrary Arbitrary 2. CHECKS AND MAINTENANCE B-83945EN/03 J4-axis gearbox ventilator hole J4軸ギヤボックス空気抜き穴 taperテーパプラグ plug R1/8 R1/8 J4-axis gearbox oil inlet & outlet J4軸ギヤボックス給排油口 taper plug R1/8 テーパプラグ R1/8 Fig. 2.2.4 (a) Greasing point of J4-axis gearbox Table 2.2.4 (c) Specification of taper plugs Parts name Specification taper plug (R1/8) A97L-0001-0436#1-1D Exhausting oil method 1 2 3 Move the robot to the oil discharge Posture for J4-axis gearbox described in Table 2.2.4 (b). Turn off controller power. Put the oil pan under the oil outlet. Then remove the plug or the seal bolt of the oil inlet/outlet and ventilator hole, and discharge the oil. (See Fig. 2.2.4 (b).) - 20 - 2. CHECKS AND MAINTENANCE B-83945EN/03 Oiling method Supply oil according to the description below. 1 2 3 4 5 6 Install oil injection nipple with a valve (A05B-1224-K006) to oil inlet. Install the oil tray with a valve (A05B-1227-K007) to the J4-axis gearbox ventilator hole. Confirm the valve is open, according to Fig. 2.2.4 (b), supply oil by using oil injection gun (A05B-1221-K005). In this time, install adapter for keeping of oiling posture. (It is appendix of A05B-1224-K006). If oil comes out to oil tray from ventilator hole, stop supplying oil, close the valve of the oil injection nipple, then remove the oil gun. Attach seal bolt to the ventilator hole. Replace seal bolt by new one. When reusing taper plugs, be sure to wind it with seal tape. Remove the oil injection nipple, attach the taper plug to oil inlet. In this time, oil may drop. Set the oil pan under it and attach the seal bolts immediately. Replace the taper plug by new one. When reusing taper plugs, be sure to wind it with seal tape. Release the remaining pressure using the procedure given in Subsection 2.2.7. CAUTION If supplying oil forcibly when valve is closed, internal pressure of oil bath rise abnormally and cause oil leak from seal part or oil seal falling out. Be careful. Oil tray with a valve バルブ付オイル受け皿 A05B-1227-K007 A05B-1227-K007 Oil injection gun オイル注入ガン A05B-1221-K005 A05B-1221-K005 Oil injection nipple with a valve バルブ付オイル注入ニップル A05B-1224-K006 A05B-1224-K006 Adapter for holding oiling posture 給油姿勢保持アダプタ (Appendix of A05B-1224-K006) （A05B-1224-K006に添付） White白線 line Valve is open Valve is closed バルブが開いた状態バルブが閉じた状態 Fig. 2.2.4 (b) Oil injection by oil gun (oiling of J4-axis gearbox) - 21 - 2. CHECKS AND MAINTENANCE 2.2.5 B-83945EN/03 Oil Replacement Procedure for the J5/J6- axis Gearbox (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L) CAUTION 1 There is severe risk of gear damage in case robot is operated with oil shortage. Please make sure the gearbox is always filled with correct amount of oil. 2 Failure to supply oil correctly may cause damage to the seal, which would in turn lead to oil leakage and abnormal operation. When performing oiling, therefore, observe the following cautions. (1) Use specified oil. Use of non-approved oil may damage the reducer or lead to other problems. (2) After oiling, release remaining pressure from the grease bath using the procedure given in Subsection 2.2.7, and then close the grease outlet. (3) To prevent slipping accidents and catching fire, completely remove any excess oil from the floor or robot. Oiling points Table 2.2.5 (a) Oil name and amount of oiling of standard to be replaced at regular intervals of three years (11520 hours) Amount of oil to be applied Gun tip Specified oil (total capacity of the oil bath) pressure NOTE) J5/J6-axis gearbox NOTE) 280g(330ml) 0.1MPa or less JXTG Nippon Oil & Energy Corporation BONNOC AX68 (Specification: A98L-0040-0233) It is not a regulated amount injection. For oil replacement or replenishment, use the Postures indicated below. Consider relative angle of from posture of floor mount when robot is angle mount. Oiling points J5/J6-axis gearbox J5/J6-axis gearbox releasing remaining pressure Table 2.2.5 (b) Oiling posture (J5/J6-axis gearbox) Posture J1 J2 J3 J4 Floor mount Upside-down mount Wall mount -90° Wall mount +90° Floor mount Upside-down mount Wall mount -90° Wall mount +90° Arbitrary 0° Arbitrary Arbitrary 0° 0° 0° 0° 180° 90° 90° 20° to 90° 0° 180° -90° -20° to -90° -90° 0° to 70° 110° to 180° 90° -90° J5 J6 0° Arbitrary Arbitrary Arbitrary (NOTE) Choose the one of the posture taken easily when there is two or more posture. - 22 - 2. CHECKS AND MAINTENANCE B-83945EN/03 Exhausting oil method 1 2 3 4 5 Move the robot to the posture of J5/J6-axis gearbox described in Table 2.2.5 (b). Turn off controller power. Put the oil pan under the oil outlet. Remove two bolts and washer of oil outlet. Then remove the taper plug of the oil inlet. (See Fig. 2.2.5 (a)) In this time, if you remove bolt of oil inlet firstly, you can prevent spilling oil on surroundings. Install the bolt and the seal washer to the oil outlet (lower side) after all oil is exhausted. J5/J6-axis gearbox oil outlet (upper side) J5/J6軸ギヤボックス排油口 (上側) ボルトM6X8 シールワッシャ Bolt M6 x8 &+ seal washer J5/J6-axis gearbox oil outlet (lower side) J5/J6軸ギヤボックス排油口 (下側) Bolt M6 x8 &+ seal washer ボルトM6X8 シールワッシャ J5/J6-axis gearbox oil inlet J5/J6軸ギヤボックス給油口テーパプラグR1/8 taper plug R1/8 Fig. 2.2.5 (a) Oil inlet and outlet Table 2.2.5 (c) Specification of seal washer and taper plug Parts name Specification Seal washer (M6) Taper plug (R1/8) A30L-0001-0048#6M A97L-0001-0436#1-1D - 23 - 2. CHECKS AND MAINTENANCE B-83945EN/03 Injecting oil method (1) Install oil injection nipple with valve (A05B-1224-K006) to oil inlet (Fig.2.2.5 (c)) referring to Fig.2.2.5 (b). (2) Confirm valve of oil inlet and oil outlet are open referring to Fig.2.2.5 (b). Supply oil to J5/J6-axis gearbox by oil injection gun (A05B-1221-K005). If oil comes out in oil tray from oil outlet (upper side), stop supplying oil, close the valve oil injection nipple, and remove oil gun (3) Attach the bolt and the seal washer to oil outlet (upper side). (4) Remove the oil injection nipple with a valve, attach the taper plug to the oil inlet. In this time, oil may drop. Set a oil pan under the oil inlet and attach the taper plug immediately. Replace the taper plug with a new one. When reusing it, wind it with seal tape. (5) Release the remaining pressure using the procedure given in Subsection 2.2.7. CAUTION If supplying oil forcibly when valve is closed, internal pressure of oil bath rise abnormally and cause oil leak from seal part or oil seal falling out. Be careful. Oil injection gun オイル注入ガン A05B-1221-K005 A05B-1221-K005 Oil injection nipple with a valve バルブ付オイル注入ニップル A05B-1224-K006 A05B-1224-K006 White line 白線 Valve is open Valve is closed バルブが開いた状態バルブが閉じた状態 Fig. 2.2.5 (b) Oil injection by oil gun Fig. 2.2.5 (c) Oil injection nipple with valve (A05B-1224-K006) - 24 - 2. CHECKS AND MAINTENANCE B-83945EN/03 2.2.6 Oil Replacement Procedure for the J5/J6- axis Gearbox (ARC Mate 100iD/16S, M-10iD/16S) CAUTION 1 There is severe risk of gear damage in case robot is operated with oil shortage. Please make sure the gearbox is always filled with correct amount of oil. 2 Failure to supply oil correctly may cause damage to the seal, which would in turn lead to oil leakage and abnormal operation. When performing oiling, therefore, observe the following cautions. (1) Use specified oil. Use of non-approved oil may damage the reducer or lead to other problems. (2) After oiling, release remaining pressure from the grease bath using the procedure given in Subsection 2.2.7, and then close the grease outlet. (3) To prevent slipping accidents and catching fire, completely remove any excess oil from the floor or robot. Oiling points Table 2.2.6 (a) Oil name and amount of oiling of standard to be replaced at regular intervals of three years (11520 hours) Amount of oil to be applied Gun tip Specified oil (total capacity of the oil bath) pressure NOTE) J5/J6-axis gearbox NOTE) 680g(800ml) 0.1MPa or less JXTG Nippon Oil & Energy Corporation BONNOC AX68 (Specification: A98L-0040-0233) It is not a regulated amount injection. For oil replacement or replenishment, use the Postures indicated below. Consider relative angle of from posture of floor mount when robot is angle mount. Oiling points J5/J6-axis gearbox J5/J6-axis gearbox releasing remaining pressure Table 2.2.6 (b) Oiling posture (J5/J6-axis gearbox) Posture J1 J2 J3 J4 Floor mount Upside-down mount Wall mount -90° Wall mount +90° Floor mount Upside-down mount Wall mount -90° Wall mount +90° Arbitrary 0° Arbitrary Arbitrary 0° 0° 0° 0° 180° -90° 90° 0° 0° 0° -90° 0° 90° -90° 90° -90° -90° J5 J6 0° Arbitrary Arbitrary Arbitrary (NOTE) Choose the one of the posture taken easily when there is two or more posture. - 25 - 2. CHECKS AND MAINTENANCE B-83945EN/03 Exhausting oil method 1 2 3 4 5 Move the robot to the posture of J5/J6-axis gearbox described in Table 2.2.6 (b). Turn off controller power. Put the oil pan under the oil outlet. Remove two bolts and washer of oil outlet. Then remove the taper plug of the oil inlet. (See Fig. 2.2.6 (a)) In this time, if you remove bolt of oil inlet firstly, you can prevent spilling oil on surroundings. Install the bolt and the seal washer to the oil outlet (lower side) after all oil is exhausted. J5/J6-axis gearbox oil outlet (upper side) J5/J6軸ギヤボックス排油口 (上側) Bolt M8 x10 & seal washer ボルトM8X10 + シールワッシャ J5/J6-axis gearbox oil outlet (lower side) J5/J6軸ギヤボックス排油口 (下側) Bolt M8 x10 & seal washer ボルトM8X10 + シールワッシャ J5/J6-axis gearbox oil inlet J5/J6軸ギヤボックス給油口 Bolt M8 x 10 & seal washer ボルトM8X10 + シールワッシャ Fig. 2.2.6 (a) Oil inlet and outlet Table 2.2.6 (c) Specification of seal washer Parts name Specification Seal washer (M8) A30L-0001-0048#8M Injecting oil method (1) Install oil injection nipple with valve (A05B-1224-K006) to oil inlet (Fig.2.2.6 (c)) referring to Fig.2.2.6 (b). (2) Confirm valve of oil inlet and oil outlet are open referring to Fig.2.2.6 (b). Supply oil to J5/J6-axis gearbox by oil injection gun (A05B-1221-K005). If oil comes out from oil outlet (upper side), stop supplying oil, close the valve oil injection nipple, and remove oil gun (3) Attach the bolt and the seal washer to oil outlet (upper side). (4) Remove the oil injection nipple with a valve, attach the taper plug to the oil inlet. In this time, oil may drop. Set a oil pan under the oil inlet and attach the taper plug immediately. Replace the taper plug with a new one. When reusing it, wind it with seal tape. (5) Release the remaining pressure using the procedure given in Subsection 2.2.7. CAUTION If supplying oil forcibly when valve is closed, internal pressure of oil bath rise abnormally and cause oil leak from seal part or oil seal falling out. Be careful. - 26 - 2. CHECKS AND MAINTENANCE B-83945EN/03 Oil injection gun オイル注入ガン A05B-1221-K005 A05B-1221-K005 Oil adapter 給油アダプタ A290-7228-X568 A290-7228-X568 A Oil injection nipple with a valve バルブ付オイル注入ニップル A05B-1224-K006 A05B-1224-K006 Detail 詳細 AA White白線 line Valve is open バルブが開いた状態 Valve is closed バルブが閉じた状態 Fig. 2.2.6 (b) Oil injection by oil gun Fig. 2.2.6 (c) Oil injection nipple with valve (A05B-1224-K006) - 27 - 2. CHECKS AND MAINTENANCE 2.2.7 B-83945EN/03 Procedure for Releasing Remaining Pressure from the Oil Bath (J1/J4/J5/J6-axis) After replacing oil, please do the following operation to adjust the amount of oil properly. In case of J1-axis gearbox Operate robot J1 axis during 10 minutes or more, at 100% override, making 90 degrees motion (or more). Keep the taper plug attached during this operation. Remaining pressure release at once if the ventilator hole is opened. After operation, wipe the oil that adheres to the surface of the robot off when confirming it and close the oil inlet/outlet completely. In case of J4-axis gearbox If confirmed then please operate robot J4 axis during 10 minutes or more, at 100% override, making 90 degrees motion (or more). Keep the taper plugs attached during this operation. When completed, move the robot posture so that J4-gearbox oil outlet is right above. (In case of floor mount, J3=0°.)Remaining pressure release at once if oil inlet/outlet is opened. After operation, wipe the oil that adheres to the surface of the robot off when confirming it and close the oil inlet/outlet completely. In case of J5/J6-axis gearbox Move the robot to posture for releasing the remaining pressure. Operate robot J5 and J6 axis during 10 minutes or more, at 100% override, making 90 degrees motion (or more) on both axis. When completed, move the robot posture so that the oil outlets is right above. (In case of floor mount, J3=0° and J4=-90º.) Remaining pressure release at once if one of oil outlet is opened. (Be careful that oil is not spattered when opening the oil outlet.) Wipe the oil that adheres to the surface of the robot off when confirming it and tighten bolts of oil inlet completely. If the above operation cannot be performed due to the environment of the robot, adjust the operating time according to the operating angle. (When the maximum allowable axis angle is 45 degrees, perform the twice operation for 20 minutes or more.) After completion of the operation, attach the taper plug to the oil inlets. When you supply grease or oil to plural axes, you can run the plural axes at the same time. After replacing grease or oil, the internal pressure of the grease bath or oil bath may rise if the robot is operated again under frequent inversion movement or a high temperature environment. In these cases, you can return to normal internal pressure by releasing the grease outlet or oil outlet just after robot operation. (When opening grease outlet or oil outlet, be sure that grease or oil is not spattered.) CAUTION When reusing seal bolt and taper plug, be sure to seal the thread part with seal tape. As for the seal washer, In one side, rubber sticks to the entire and the other side, rubber sticks to only around hole and rubber sticks is incomplete state, Attach later face to bolt side. Confirm seal washer by viewing. If it is damaged obviously, replace it by new one. See Table 2.2.5 (c) and Table 2.2.6 (c) about specification of seal bolts and seal washer. - 28 - 3. TROUBLESHOOTING B-83945EN/03 3 TROUBLESHOOTING The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems may become further complicated, if they are not corrected properly. Therefore, you must keep an accurate record of problems and to take proper corrective actions. 3.1 TROUBLESHOOTING Table 3.1 (a) shows the major troubleshooting symptoms that may occur in the mechanical unit and their probable causes. If you cannot pinpoint a failure cause or which measures to take, contact your local FANUC representative. For troubleshooting except the mechanical unit, refer to “CONTROLLER MAINTENANCE MANUAL (B-83195EN etc.)” and Alarm Code List (B-83284EN-1). Symptom Vibration Noise Table 3.1 (a) Troubleshooting Cause The J1 base lifts off the floor [J1 base fastening] It is likely that the robot J1 plate as the robot operates. base is not securely There is a gap between the fastened to the floor plate. J1 base and floor plate. Probable causes are a A J1 base retaining bolt is loose bolt, an insufficient loose. degree of surface flatness, or contamination caught between the J1 base and floor plate. If the robot is not securely fastened to the floor plate, the J1 base lifts the floor plate as the robot operates, allowing the base and floor plates to strike each other, which, in turn, leads to vibration. [Rack or floor] The rack or floor plate It is likely that the rack or vibrates during operation of floor is not sufficiently rigid. the robot. If the rack or floor is not sufficiently rigid, reaction from the robot deforms the rack or floor, leading to vibration. Description - - - 29 - - - - - Measure If a bolt is loose, apply LOCTITE and tighten it to the appropriate torque. Adjust the floor plate surface flatness to within the specified tolerance. If there is any contamination, remove it. Reinforce the rack or floor to make it more rigid. If it is impossible to reinforce the rack or floor, modify the robot control program; doing so might reduce the amount of vibration. 3. TROUBLESHOOTING Symptom Vibration Noise (Continued) Description - - - - - - - - Vibration becomes more serious when the robot adopts a specific posture. If the operating speed of the robot is reduced, vibration stops. Vibration is most noticeable when the robot is accelerating. Vibration occurs when two or more axes operate at the same time. Vibration was first noticed after the robot collided with an object or the robot was overloaded for a long period. The grease or oil of the vibrating axis has not been replaced for a long period. There is vibration or unusual sound just after replacing grease or oil or parts. Periodic vibration and noise occur. B-83945EN/03 Cause [Overload] It is likely that the load on the robot is greater than the maximum rating. It is likely that the robot control program is too demanding for the robot hardware. It is likely that the ACCELERATION value is excessive. [Gear, bearing, or reducer] It is likely that collision or overload applied an excessive force on the drive mechanism, thus damaging the tooth surface or rolling contact surface of a bearing, or reducer. Prolonged overloaded use may cause fretting fatigue on the gear tooth surface or the rolling surface of bearing and reducer. It is likely that contamination caught in a gear, bearing, or within a reducer caused damage on the tooth surface or rolling contact surface of the bearing, or reducer. It is likely that contamination caught in a gear, bearing, or within a reducer caused vibration. - It is likely that, because the grease has not been replaced for a long period, fretting occurred on the gear tooth surface or rolling surface of a bearing, or reducer due to metal fatigue. There is a possibility of grease or oil has not been replaced accurately. The amount of grease or oil may be insufficient. - 30 - - - - - - - - Measure Check the maximum load that the robot can handle once more. If the robot is found to be overloaded, reduce the load, or modify the robot control program. Vibration in a specific portion can be reduced by modifying the robot control program while slowing the robot and reducing its acceleration (to minimize the influence on the entire cycle time)． Operate one axis at a time to determine which axis is vibrating. Remove the motor, and replace the gear, the bearing, and the reducer. For the spec. of parts and the method of replacement, contact your local FANUC representative. 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. Supplying the specified grease or oil at the recommended interval will prevent problems 3. TROUBLESHOOTING B-83945EN/03 Symptom Vibration Noise (Continued) Description - The cause of problem cannot be identified from examination of the floor, rack, or mechanical section. Cause [Controller, cable, and motor] If a failure occurs in a controller circuit, preventing control commands from being supplied to the motor normally, or preventing motor information from being sent to the controller normally, vibration might occur. Pulsecoder defect may be the cause of the vibration as the motor cannot propagate the accurate position to the controller. If the motor becomes defective, vibration might occur because the motor cannot deliver its rated performance. If a power line in a movable cable of the mechanical unit has an intermittent break, vibration might occur because the motor cannot accurately respond to commands. If a Pulsecoder wire in a movable part of the mechanical unit has an intermittent break, vibration might occur because commands cannot be sent to the motor accurately. If a connection cable between the mechanical unit and the controller has an intermittent break, vibration might occur. If the power supply cable is about to be snapped, vibration might occur. If the power source voltage drops below the rating, vibration might occur. It may vibrate when the invalid value parameter was set. - 31 - - - - - - - - - Measure Refer to the Controller Maintenance Manual for troubleshooting related to the controller and amplifier. Replace the motor of the axis that is vibrating, and check whether vibration still occurs. To replace the motor, Contact your local FANUC representative. If vibration occurs only when the robot assumes a specific posture, it is likely that a cable in the mechanical unit is broken. Shake the movable part cable while the robot is at rest, and check whether an alarm occurs. If an alarm or any other abnormal condition occurs, replace the mechanical unit cable. Check whether the jacket of the cable connecting the mechanical unit and controller is damaged. If so, replace the connection cable, and check whether vibration still occurs. Check whether the jacket of the power cable is damaged. If so, replace the power cable, and check whether vibration still occurs. Check that the robot is supplied with the rated voltage. Check that the robot control parameter is set to a valid value. If it is set to an invalid value, correct them. Contact your local FANUC representative for further information if necessary. 3. TROUBLESHOOTING Symptom Vibration Noise (Continued) B-83945EN/03 Description Cause Measure - There is some relationship between the vibration of the robot and the operation of a machine near the robot. [Noise from a nearby machine] If the robot is not grounded properly, electrical noise is induced on the grounding wire, preventing commands from being transferred accurately, thus leading to vibration. If the robot is grounded at an unsuitable point, its grounding potential becomes unstable, and noise is likely to be induced on the grounding line, thus leading to vibration. - Connect the grounding wire firmly to ensure a reliable ground potential and prevent extraneous electrical noise. - There is an unusual sound after replacement of grease. There is an unusual sound after a long period. There is an unusual sound during operation at low speed. - There may be an unusual sound when using other than the specified grease. Even for the specified grease, there may be an unusual sound during operation at low speed immediately after replacement or after a long period. - Use the specified grease. When there is an abnormal noise even when using the specified grease, operate for one or two days as an experiment. Generally, any abnormal noise will disappear. - There is an unusual sound when operating right immediately the replacing part, grease or oil. - There is a possibility of Grease or oil has not been replaced accurately. The amount of grease or oil may be insufficient. - Stop the robot, and confirm the damage situation at once. Replenish grease or oil when they are insufficient. - The movement speed of robot is not constant - Sludge may be generated by the deterioration of the oil, and it may be attached to bearing etc. - Perform running and destroy the sludge. Then replace oil. - - - 32 - 3. TROUBLESHOOTING B-83945EN/03 Symptom Rattling - - - Description Cause While the robot is not supplied with power, pushing it with the hand causes part of the mechanical unit to wobble. There is a gap on the mounting face of the mechanical unit. [Mechanical section coupling bolt] It is likely that overloading or a collision has loosened a mounting bolt in the robot mechanical section. - Measure Backlash is greater than the allowance stated in the applicable maintenance manual. (See Section 3.2.) [Increase in backlash] It is likely that excessive force applied to the drive mechanism, due to a collision or overloading, has broken a gear or the inside of the reducer, resulting in an increase in the amount of backlash. It is likely that prolonged use has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash. It is likely that prolonged use without changing the grease has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash. - - - - - - - - 33 - Check that the following bolts for each axis are tight. If any of these bolts is loose, apply LOCTITE and tighten it to the appropriate torque. Motor retaining bolt Reducer retaining bolt Reducer shaft retaining bolt Base retaining bolt Arm retaining bolt Casting retaining bolt End effector retaining bolt Operate one axis individually to determine which axis has the increased backlash. Remove the motor, and check whether any of its gears are broken. If any gear is broken, replace it. Check whether any other gear of the drive mechanism is damaged. If there are no damaged gears, replace the reducer. If the reducer is broken, or if a gear tooth is missing, replace the relevant component. Also, remove all the grease or oil from the gearbox and wash the inside of the gearbox. After replacing the gear or reducer, add an appropriate amount of grease or oil. Using the robot within its maximum rating prevents problems with the drive mechanism. Regularly applying the grease or oil with a specified type can help prevent problems. 3. TROUBLESHOOTING Symptom Motor overheating B-83945EN/03 Description - - - The ambient temperature of the installation location increases, causing the motor to overheat. After a cover was attached to the motor, the motor overheated. After the robot control program or the load was changed, the motor overheated. Cause [Ambient temperature] It is likely that the motor overheated along with the ambient temperature rose, and could not release heat. [Operating condition] It is likely that the overcurrent above the specified permissive average current. Measure - - - - - - After a robot control parameter (load setting etc.) was changed, the motor overheated. - Symptom other than stated above [Parameter] If data input for a workpiece is invalid, the robot cannot be accelerated or decelerated normally, so the average current increases, leading to overheat. [Mechanical section problems] It is likely that problems occurred in the mechanical unit drive mechanism, thus placing an excessive load on the motor. [Motor problems] It is likely that a failure of the motor brake resulted in the motor running with the brake applied, thus placing an excessive load on the motor. It is likely that a failure of the motor prevented it from delivering its rated performance, thus causing an excessive current to flow through the motor. - 34 - - - - - Reducing the ambient temperature is the most effective means of preventing overheat. Having the surroundings of the motor well ventilated enables the motor to release heat efficiently, thus preventing overheat. If there is a source of heat near, it is advisable to install shielding to protect the motor from heat radiation. Relaxing the robot control program and load condition is effective to reduce the average current. Thus, prevent overheat. The teach pendant can monitor the average current. Check the average current when the robot control program launched. As for load setting, Input an appropriate parameter referring to Section 4.3 of the mechanical unit operator’s manual (B-83944EN). Repair the mechanical unit while referring to the above descriptions of vibration, noise, and rattling. Check that, when the servo system is energized, the brake is released. If the brake remains applied to the motor all the time, replace the motor. If the average current falls after the motor is replaced, it indicates that the first motor was faulty. 3. TROUBLESHOOTING B-83945EN/03 Symptom Grease leakage Oil leakage Description - Grease or oil is leaking from the mechanical unit. Cause [Poor sealing] Probable causes are a crack in the casting, a broken O-ring, a damaged oil seal, or a loose seal bolt. A crack in a casting can occur due to excessive force that might be caused in collision. An O-ring can be damaged if it is trapped or cut during disassembling or re-assembling. An oil seal might be damaged if extraneous dust scratches the lip of the oil seal. A loose seal bolt or a taper plug might allow grease to leak along the threads. - - - - Dropping axis - An axis drops because the brake does not function. An axis drops gradually when it should be at rest. [Brake drive relay and motor] It is likely that brake drive relay contacts are stuck to each other to keep the brake current flowing, thus preventing the brake from operating when the motor is reenergized. It is likely that the brake shoe has worn out or the brake main body is damaged, preventing the brake from operating efficiently. It is likely that oil or grease has entered the motor, causing the brake to slip. - 35 - - - - Measure If a crack develops in the casting, sealant can be used as a quick-fix to prevent further grease or oil leakage. However, the component should be replaced as soon as possible, because the crack might extend. O-rings are used in the locations listed below. Motor coupling section Reducer (case and shaft) coupling section Wrist connection section J3 arm coupling section Inside the wrist Oil seals are used in the locations stated below. Inside the reducer Inside the wrist Seal bolts and taper plugs are used in the locations stated below. Grease inlet or outlet Oil inlet or outlet Cover fixation Check whether the brake drive relay contacts are stuck to each other. If they are found to be stuck, replace the relay. If the brake shoe is worn out, if the brake main body is damaged, or if oil or grease has entered the motor, replace the motor. J4-axis cable has movable part .So if robot exceeds stroke limit, load depends on cable and it may cause damage of cables. If robot exceeds stroke limit, remove plate of back of J4, return axis to motion range during checking condition of cables. (See Section 6.1). 3. TROUBLESHOOTING Symptom Displacement Description - - - - CLALM alarm occurred. Move error excess alarm occurred. - The robot operates at a point other than the taught position. The repeatability is not within the tolerance. Displacement occurs only in specific peripheral equipment. Displacement occurred after a parameter was changed. Ambient temperature of the robot installation location is low, CLALM alarm is displayed on the teach pendant screen. Ambient temperature of the robot installation position is low, “Move error excess” alarm is displayed on the teach pendant screen. B-83945EN/03 Cause [Mechanical section problems] If the repeatability is unstable, probable causes are a failure in the drive mechanism or a loose bolt. If the repeatability becomes stable, it is likely that a collision imposed an excessive load, leading to slipping on the base surface or the mating surface of an arm or reducer. It is likely that the Pulsecoder is faulty. [Peripheral equipment displacement] It is likely that an external force was applied to the peripheral equipment, thus shifting its position relative to the robot. [Parameter] It is likely that the mastering data was rewritten in such a way that the robot origin was shifted. [Peripheral temperature] When the robot is used in a low temperature environment that is near to 0ºC, or the robot is not operated for a long time in an environment that is less than 0ºC, there will be a large viscous resistance of the drive train immediately after starting which will cause the alarm. - 36 - Measure - - - - - - - - If the repeatability is unstable, repair the mechanical section by referring to the above descriptions of vibration, noise, and rattling. If the repeatability is stable, correct the taught program. The problem will not occur unless another collision occurs. If the Pulsecoder is faulty, replace the motor. Correct the setting of the peripheral equipment position. Correct the taught program. Re-enter the previous mastering data, which is known to be correct. If correct mastering data is unavailable, perform mastering again. Perform a warm up operation or a low speed operation for several minutes. 3. TROUBLESHOOTING B-83945EN/03 Symptom CLALM alarm occurred. Move error excess alarm occurred. - - BZAL alarm occurred - Description Cause After changing the motion program or the load condition, the CLALM alarm is displayed. After changing the motion program or the load condition, the “Move error excess” alarm is displayed. None of the symptoms stated above are the problem. BZAL is displayed on the teach pendant screen - It is likely that a robot collision occurred. [Overload] It is likely that load exceeded the permissible value. It is likely that the motion program is too severe for the robot. x Excessive motion due to a large “ACC (value)”. x Tight motion such as reverse motion using “CNT”. x Linear motion occurs near singularity point where axes revolve in high speed. It is likely the vibration occurred. - It is likely that rated voltage is not supplied due to the voltage drop. It is likely that the voltage of the memory backup battery is low. It is likely that the Pulsecoder cable is defective. Measure - - - - - - - If a robot collision has occurred, press the [RESET] key while pressing the [SHIFT] key. Then, jog the robot in the opposite direction while pressing the [SHIFT] key. Check the motion program. Check the permissible value of the robot payload. If the load exceeds the permissible value, reduce the load or change the motion program. Consider minimizing the influence on cycle time by reducing the speed or acceleration, and changing the motion program. Check that the load setting is performed correctly. Refer to the Symptoms: Vibration, Noise section of this troubleshooting for more information. Check that the robot is supplied with the proper rated voltage. Replace the battery. Replace the cable. Table 3.1 (b) End effector mounting face allowable drops At power off At emergency stop 5mm 5mm NOTE Each value indicates the amount by which an end effector mounting face may fall. - 37 - 3. TROUBLESHOOTING 3.2 B-83945EN/03 BACKLASH MEASUREMENT Measurement method 1 2 3 Put the robot in a specified posture. (See Fig. 3.2 (b) to (d).) Apply positive and negative loads to each axis as shown in Fig. 3.2 (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. Stop position 0 +10kgf (J1 to J3-axis) + 3kgf (J4 to J6-axis) First step (Do not measure) -10kgf (J1 to J3-axis) - 3kgf (J4 to J6-axis) +10kgf (J1 to J3-axis) + 3kgf (J4 to J6-axis) -10kgf (J1 to J3-axis) - 3kgf (J4 to J6-axis) 0kg L2 -10kgf (J1 to J3-axis) - 3kgf (J4 to J6-axis) 0kg L1 Second step (B2 =L1+ L2) 0kg +10kgf (J1 to J3-axis) + 3kgf (J4 to J6-axis) 0kg L3 Third step (B3=L3+ L4) L4 Fig. 3.2 (a) Backlash measurement method Backlash B is calculated using the following expression: B= - 38 - B2 + B3 2 3. TROUBLESHOOTING B-83945EN/03 Loading position 負荷をかける位置 Loading position 負荷をかける位置 J1 J1任意 Arbitrary J2 J2 80° 80º J3 0° J3 0º J4 J4 0° 0º J5 0° J5 0º J6 90° 1615 J6 ±90º Measured 測定位置 position <J1-axis measuring posture> <J1軸測定姿勢> Measured 測定位置 position Loading position 負荷をかける位置 640 550 Measured position 測定位置 J1 J1 Arbitrary 任意 J2 0° 0º J2 J3 71°71º J3 J4 0° 0º J4 J5 0° 0º J5 Loading position J6 0° 0º負荷をかける位置 J6 <J2-axis measuring posture> <J3-axis measuring posture> <J3軸測定姿勢> <J2軸測定姿勢> Fig. 3.2 (b) Backlash measured posture (1/3) CAUTION Please be careful so that the robot does not collide with the floor. - 39 - J1 任意 J1 Arbitrary J2 40° 40º J2 J3 -110° J3 -110º J4 -90° J4 -90º J5 90° J5 J6 0° 90º J6 0º 3. TROUBLESHOOTING B-83945EN/03 J1 Arbitrary 任意 J2 J1 40º J2 40° J3 J3 -90° -90º J4 J4 90° 90º J5 J5 -90° -90º J6 J6 -90° -90º Loading position 負荷をかける位置測定位置 position Measured 95 95 <J4-axis<J4軸測定姿勢> measuring posture> A Loading position 負荷をかける位置 Loading position 負荷をかける位置 62 ※J6のバックラッシの影響を (Loading should be aligtned 受けない様にJ6の回転中心に負荷を掛けること In the direction of the rotation of the rotation of J6-axis) 測定位置 position Measured Detail 詳細AA 任意 J1J1 Arbitrary J2J2 0° 0º J3J3 0° 0º 90° J4J4 90º J5 90° J5J6 -90° 90º J6 -90º <J5-axis<J5軸測定姿勢> measuring posture> Fig. 3.2 (c) Backlash measured posture (2/3) CAUTION Please be careful so that the robot does not collide with the floor. - 40 - 3. TROUBLESHOOTING B-83945EN/03 B Loading position 負荷をかける位置 Measured 測定位置 position 100 任意 J1J1 Arbitrary J2J2 0° 0º J3J3 0° 0º J4J4 0° 0º J5J5 90°90º J6J6 0° 0º Detail 詳細BB <J6-axis <J6軸測定姿勢> measuring posture> Fig. 3.2 (d) Backlash measured posture (3/3) Angle conversion (arc-min) Displacement conversion (mm) Distance between the rotation center and dial gauge (mm) Table 3.2 (a) Backlash allowance J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis 2.50 1.17 2.50 0.47 2.50 0.40 4.00 0.11 4.00 0.07 4.00 0.12 1615 640 550 95 62 100 NOTE When measuring backlash in cases where the distance between the rotation center and the dial gauge is different from those in the above table, make angle and displacement conversions according to the table. - 41 - 4. REPLACING PARTS 4 B-83945EN/03 REPLACING PARTS Once motors, reducers, gearbox and wrist unit are replaced, mastering becomes necessary, perform mastering according to Chapter 6 after any of these parts are replaced. NOTE 1 Be very careful when dismounting and mounting the heavy components that are listed below. 2 This Chapter assumes that robot is floor mount. If other installation is adopted, consider relative angle of from posture of floor mount. Part Mass (approximate) J1 unit (See Fig. 4.3 (a)) J2 base to wrist unit (See Fig. 4.3 (b)) All components from J2 arm to wrist unit (The J2-axis reducer is not included) (See Fig. 4.5 (b)) All components from J3 casing to wrist unit (See Fig. 4.7 (b)) J3 arm unit (See Fig. 4.10 (a), Fig. 4.16 (a)) J5/J6-axis gear box (See Fig. 4.13 (a), Fig. 4.14 (a)) 60kg 90 kg 55 kg 25 kg 10 kg 5 kg NOTE 1 When applying LOCTITE to a part, spread the LOCTITE on the entire length area of the engaging part of the female thread. If applied to the male threads, poor adhesion can occur potentially loosening the bolt. Clean the bolts and the threaded holes and wipe off the oil on the engaging section. Make sure that there is no solvent left in the threaded holes. In this case, remove all the excess LOCTITE when you are finished screwing the bolts into the threaded holes. 2 Description of [LT243] means LOCTITE 243. 3 Description of [LT263] means LOCTITE 263. 4 Description of [LT518] means LOCTITE 518. 5 Description of [LT675] means LOCTITE 675. - 42 - 4. REPLACING PARTS B-83945EN/03 4.1 DRIVE MECHANISM The drive mechanisms of each axis are shown in the following. ギヤ Gear AC servo motor J1軸モータ (M1) for J1-axis (M1) ギヤ Gear Fig. 4.1 (a) Drive mechanism of J1-axis J2アーム J2 arm J2軸減速機 J2-axis reducer J2 base J2ベース AC servo motor J2軸モータ (M2) for J2-axis (M2) Gear ギヤ Fig. 4.1 (b) Drive mechanism of J2-axis J3-axis reducer J3軸減速機 J3 arm J3アーム Gear ギヤ AC servo motor J3軸モータ for J3-axis (M3) (M3) Fig. 4.1 (c) Drive mechanism of J3-axis - 43 - 4. REPLACING PARTS B-83945EN/03 ギヤ Gear Gear ギヤ J4軸モータ AC servo motor(M4) for J4-axis (M4) Fig. 4.1 (d) Drive mechanism of J4-axis Gear ギヤ Drive shaft ドライブシャフト AC servo motor(M5) J5軸モータ for J5-axis (M5) Gear ギヤ Gear ギヤ Fig. 4.1 (e) Drive mechanism of J5-axis AC servo motor J6軸モータ (M6) for J6-axis (M6) Gear ギヤ Gear ギヤ Hollow flange 中空フランジ Gear ギヤ Fig. 4.1 (f) Drive mechanism of J6-axis - 44 - 4. REPLACING PARTS B-83945EN/03 4.2 1 2 3 4 5 6 7 8 9 10 11 12 REPLACING THE J1-AXIS MOTOR (M1) Set a dial gauge at the J1-axis, and prepare for single axis mastering after replacement. Refer to Section 6.4. Turn off controller power. Pull out oil of the J1-axis gearbox referring to Section 2.2. Remove the J1-axis motor connector. Remove the motor mounting bolts (1). Dismount the motor (2) from the J1 base. Loosen the M10 hexagonal nut (5) from the motor shaft, remove the gear (3) from the taper surface, and pull out it with the hexagonal nut (5) and the washer (4). Attach the gear (3) to a new motor (2). Attach an M10 spring washer (4), apply LOCTITE 243 to the M10 threaded n of the nut (5), and tighten the M10 nut with a specified torque of [20 Nm]. Replace the O-ring (6) by a new one and put it into the J1 base where the J1-axis motor is to be mounted, and fasten them with bolt (1). Connect cable connectors to the J1-axis motor. According to Section 2.2, supply the J1-axis gearbox with the specified oil. Perform single axis mastering. Refer to Section 6.4. NOTE If there is a danger that the J1-axis section may rotate, fix the J1-axis section during replacement work, for example, by pushing the J1-axis mechanical stopper against the J1-axis section. 6 5 4 3 2 1 Fig. 4.2 (a) Replacing the J1-axis motor Parts name 1 BOLT 2 MOTOR 3 GEAR WASHER (Attached to motor) NUT (Attached to motor) O-RING 4 5 6 Specification Q’ty A6-BA-8X20 With brake A06B-2235-B605 Without brake A06B-2235-B005 A290-7227-X211 3 A6-WB-10S-M-NI 1 A6-N1-10X1.25S-M-NI JB-OR1A-G105 1 1 - 45 - Locking Torque (N-m) LT243 20 1 1 4. REPLACING PARTS 4.3 B-83945EN/03 REPLACING THE J1 UNIT NOTE Wrenches A05B-1227-K008 and A05B-1227-K009 are necessary for replacing the J1 unit. 1 2 3 4 5 6 7 8 9 10 Set a dial gauge at the J1-axis, and prepare for single axis mastering after replacement. Refer to Section 6.4. Set the Quick Master Reference Position. Refer to the QUICK MASTERING sections of the mechanical unit Operator’s Manual (B-83944EN). (All the axes are set to 0º before shipment.) Put the robot in such a position that the J2 base and the portions above it can be suspended with a crane or the like (hereafter abbreviated as a crane), and then turn off controller power. (See Fig. 4.3 (a)) While referencing Section 5.3, pull out the cables below the J3 casing from the J1 connector panel. As shown in Fig. 4.3 (b), remove the bolts (1) that fasten the J2 base to the J1 unit (2) using the wrench (A05B-1227-K009). While referencing Section 4.3 (a), hoist the J2 base and portions above it slowly. Replace the J1 unit (2) by new one using the wrench (A05B-1227-K008). Then assemble it in the reversed sequence. According to Section 5.3 mount the cables. According to Section 2.2, supply the J1-axis gearbox with the specified oil. Perform quick mastering and perform single axis mastering of J1-axis. Refer to the QUICK MASTERING section of the mechanical unit operator’s Manual (B-83944EN) and Section 6.4 of this manual. - 46 - 4. REPLACING PARTS B-83945EN/03 Position for hanging the J2 base J2ベース吊上げ時の姿勢 Rigging fixture 吊治具 A290-7227-X940 A290-7227-X940 Bolts ボルト M8 x 25 (4) J1: 0° J2:-30° J3:-45° J4: 0° J5:-55° J6: 0° M6X25 (4) M12 M12eyebolt アイボルト A290-7227-X940 A290-7227-X940 (Refer to Section 1.3) (1.3節参照) (Position for J1) (J1の場合の位置) When the fixture is used 治具を使用する場合 Eyebolt Mounting アイボルト position 取り付け位置 M10 eyebolt (M10) アイボルト A View 矢視 AA When the fixture is not used 治具を使用しない場合 Fig. 4.3 (a) Sling the J2 base unit - 47 - 4. REPLACING PARTS B-83945EN/03 1 2 Fig. 4.3 (b) Replacing the J1 unit Parts name 1 2 BOLT J1 UNIT Specifications A6-BA-12X25 With brake A290-7227-T221 Without brake A290-7227-T271 - 48 - Q’ty Locking Torque (N-m) 12 LT263 128 1 4. REPLACING PARTS B-83945EN/03 4.4 1 REPLACING THE J2-AXIS MOTOR (M2) Set a dial gauge at the J2-axis, and prepare for single axis mastering after replacement. Refer to Section 6.4. Push the J2-axis section against the mechanical stopper, or refer to Fig .4.5 (a), fix it in such a way that it will not swivel when the motor is dismounted. 2 NOTE If the J2-axis section is not pushed against the stopper correctly, or it is not placed in the direction of gravity, there is a danger that the J2-axis section will swivel when the J2-axis motor is removed. 3 4 5 6 7 8 9 10 11 12 13 14 Turn off controller power. When the J2 cover (option) is attached, remove it referring to Section 4.17. Remove the J2-axis motor connector. Remove the motor mounting bolts (1), and dismount the motor from the J2 base. Loosen the bolt (5) that fastens the gear (4), and dismount the gear (4) and the bolt (5). Also, remove the draw nut (3) from the motor shaft. Apply LOCTITE 243 to the threaded portion of the new motor (2) shaft and tighten the draw nut to shaft of new motor (2) with a torque of [20.0 Nm]. Put the gear (4) over the draw nut (3), apply LOCTITE 243 to the M5 threaded portion of the draw nut (3), and tighten the bolt (5) with a torque of [6.8 Nm]. Replace the O-ring (6) with a new one and put it into the J2 base portion where the motor is to be mounted, and fasten the motor to the J2 base with bolts (1). Do not force in the motor. Otherwise, the gear may not settle in the correct place, possibly causing vibration (if the gear is engaged correctly, the motor will be mounted smoothly). Connect cable connectors to the J2-axis motor. When the J2 cover (option) was attached, attach it referring to Section 4.17. According to Section 2.2, supply the J2-axis reducer with the specified grease. Perform single axis mastering. Refer to Section 6.4. 6 5 4 3 2 1 Fig. 4.4 (a) Replacing the J2-axis motor 1 2 3 4 5 6 Parts name BOLT MOTOR DRAW NUT GEAR BOLT O-RING Specifications A6-BA-8X20 A06B-2235-B605 A290-7221-X321 A290-7227-X311 A6-BA-5X45 JB-OR1A-G115 - 49 - Q’ty 4 1 1 1 1 1 Locking Torque (N-m) 28 LT243 20.0 LT243 6.8 4. REPLACING PARTS 4.5 1 2 3 4 5 6 7 8 9 10 11 12 13 B-83945EN/03 REPLACING THE J2-AXIS REDUCER Set a dial gauge at the J2-axis, and prepare for single axis mastering after replacement. Refer to Section 6.4. Put the robot in such a posture that the J2 arm and the components on it can be suspended with a crane. Turn off controller power. Suspend the J2 arm and the components on it as shown Fig. 4.5 (a) with a crane so that they will not drop when the J2 arm is dismounted. (If there is the fixture shown in Fig. 4.5 (a), work improves. Use the eyebolts delivered with the J2 base when robot is shipped.) Remove the J2-axis motor as described in Section 4.4. (If the reducer is replaced while the motor is still mounted, the gear may be damaged.) Suction the grease with a vacuum cleaner to prevent grease from splattering. Remove the bolts (1) that fasten the reducer (4) to J2 base and remove bolts (2) that fasten the reducer (4) to J2 arm .Be careful not to allow an excessive load to be put on the cables (because the cables are left attached when the reducer is dismounted). Insert new O-ring (5) to the J2 arm reducer mounting part referring to Fig. 4.5 (c), then insert the new reducer (4), and fasten them with bolts (3) (by applying LOCTITE 263 and tightening with a torque of [15.6 Nm]). Degrease both the J2 base and the J2-axis reducer surfaces that are to meet each other, and as shown in Fig. 4.5 (c), install the O-ring (3) into the reducer groove. Mount the reducer to the J2 base with bolts (1) (by applying LOCTITE 263 and tightening with a torque of [73.5 Nm]) then fix the J2 arm. Mount the J2-axis motor as described in Section 4.4. According to Section 2.2, supply the J2-axis reducer with the specified grease. Perform single axis mastering. Refer to Section 6.4. NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear of J2-axis motor shaft. - 50 - 4. REPLACING PARTS B-83945EN/03 A290-7227-X940 A290-7227-X940 (See Section 1.3) (1.3節参照) M12 eyebolt M12 アイボルト Wind a sling to the ruggedness 手首先端の凹凸部分に partスリングを巻きつけること of the writ tip Wind a sling so that the sling goes around J3軸減速機を一周するよう the J3-axis reducer にスリングを巻きつけること Rigging fixture 吊治具 A290-7227-X940 A290-7227-X940 Bolt ボルト M8 x 25(4) (4) M6X25 (Position for J2) (J2の場合の位置) J2=-45° J3= 0° J2=-45° J3= 0° When fixture is not used 治具を使用しない場合 When fixture is used 治具を使用する場合 Fig. 4.5 (a) Sling to the J2 and the J3 arm 5 4 3 2 1 Fig. 4.5 (b) Replacing the J2-axis reducer Parts name 1 2 3 4 5 BOLT BOLT O-RING REDUCER O-RING Specifications Q’ty Locking Torque (N-m) A6-BA-10X20 A6-BA-6X22 JB-OR1A-G110 A97L-0318-0239#430Z-126 A98L-0040-0041#050 12 18 1 1 1 LT263 LT263 73.5 15.6 - 51 - 4. REPLACING PARTS B-83945EN/03 O-ring (5) (5) Oリング O-ring (3) (3) Oリング J2J2アーム側 arm side J2J2ベース側 base side Fig. 4.5 (c) Inserting position of the O-ring (5) - 52 - 4. REPLACING PARTS B-83945EN/03 4.6 REPLACING THE J3-AXIS MOTOR (M3) NOTE Fixtures are necessary for replacing J3-axis motor and reducer. See Section1.3. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Set a dial gauge at the J3-axis, and prepare for single axis mastering after replacement. Refer to Section 6.4. Place the robot in the posture J2=0°. At this chance, confirm J1 base is fixed to prevent from falling. Put the robot in such a posture that the J3-axis section and the components on it can be suspended with a crane, (If there is the fixture shown in Fig. 4.6 (a), work improves.) Turn off controller power. When the J3 cover (option) is attached, remove it referring to Section 4.18. Remove the connector of a cable leading to the J3-axis motor. Remove the bolts (1) that fasten the J3-axis motor to the J3 casing, and dismount the motor (2) and gasket (7). Remove the bolt (6) from the motor shaft, and dismount the gear (5) and draw nut (4). Apply LOCTITE 243 to the threaded portion of draw nut (4) and tighten it to the new motor with a torque of [3.1 Nm]. Put the gear (5) over the draw nut (4), apply LOCTITE 243 to the M5 threaded portion of the draw nut (4), and tighten the bolt (6) with a torque of [3.4 Nm]. In this time, be sure to attach key (3), too. Refer to Section 4.8 about mounting gear to J3-axis motor. Attach new gasket (7), and insert the motor into the reducer. Keep the J3-axis degrease outlet on the J2 arm side open (see Fig. 2.2.1 (a)), and look into the outlet to make sure that the gear has settled in the correct place. Even one tooth of a shift in engagement can cause vibration. (If the gear (5) is engaged correctly, the motor can get in the reducer smoothly.) Fasten the motor to the J3-axis reducer with bolts (1). Be sure to use a new gasket to prevent grease leakage. Refer to Section 4.7 about mounting J3-axis motor to reducer. Connect cable connectors to the J3-axis motor. When the J3 cover (option) was attached, attach it referring to Section 4.18. According to Section 2.2, supply the J3-axis reducer with the specified grease. Perform single axis mastering. Refer to Section 6.4. M12 アイボルト M12 eyebolt A290-7227-X940 A290-7227-X940 (See(1.3節参照) Section 1.3) (Position for J3) (J3の場合の位置) Rigging fixture A290-7227-X940 吊治具 A290-7227-X940 Bolt ボルト M6 x 25 M6X25 (4) (4) Wind a sling to 手首先端の凹凸部分にスリングを巻きつけること the ruggedness part of the writ tip 治具を使用する場合 When fixture is used When fixture is not used 治具を使用しない場合 Fig. 4.6 (a) Hanging method of the J3 arm - 53 - 4. REPLACING PARTS B-83945EN/03 7 6 2 5 3 4 1 Fig. 4.6 (b) Replacing the J3-axis motor Parts name 1 2 3 4 5 6 7 BOLT MOTOR KEY DRAW NUT GEAR BOLT GASKET Specifications A6-BA-6X16 A06B-2212-B605 Motor appendix A290-7221-X421 A290-7227-X411 A6-BA-4X70 A98L-0040-0042#03 Q’ty 4 1 1 1 1 1 1 - 54 - Locking Torque (N-m) 10.0 LT243 3.1 LT243 3.4 4. REPLACING PARTS B-83945EN/03 4.7 REPLACING THE J3-AXIS REDUCER NOTE Fixtures are necessary for replacing the J3-axis reducer. See Section 1.3. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Set a dial gauge at the J3-axis, and prepare for single axis mastering after replacement. Refer to Section 6.4. Put the robot in such a posture that the J3-axis section and the components on it can be suspended with a crane, (If there is the fixture shown in Fig. 4.7 (a), work improves.) Turn off controller power. While referencing Section 5.3, remove the cable from the J2 arm section. While referencing Fig. 4.7 (a), suspend the J3-axis section and the components on it with a crane so that they will not drop when the reducer is dismounted from the J2 arm. Be careful not to allow an excessive load to be put on the cable assembly (because the cables are left attached when the reducer is dismounted). While referencing Section 4.6, dismount the J3-axis motor from the J3 arm unit. (If the reducer is replaced while the motor is still mounted, the gear may be damaged.) Suction the grease with a vacuum cleaner to prevent grease from splattering. Remove bolts (3) which fix the J3-axis reducer (4) on the J3 casing, then remove the J3-axis reducer (3) from the J3 casing. As shown in Fig. 4.7 (b), suspend the J3-axis section and the components on it with a crane, then remove the bolts (3) which fix the J3-axis reducer (4) on the J2 arm, then remove the J3-axis reducer from the J2 arm. Attach new O-ring (5) on the groove of the J3-axis reducer referring to Fig. 4.7 (c). Attach the J3-axis reducer on the J2 arm with bolts (3) (by applying LOCTITE 263 and tightening with a torque of [10.8Nm]) and fix it. Degrease both the J3-axis reducer and the J3 casing surfaces that are to meet each other, then attach the O-ring (2) on the J3-axis reducer (4), then fix the J3 casing on the J2 arm with bolts (1). (by applying LOCTITE 263 and tightening with a torque of [73.5Nm]) While referencing Section 4.6, mount the J3-axis motor on the J3 arm unit. . While referencing Section 5.3, dress the cable into the previous form. According to Section 2.2, supply the J3-axis grease bath with the specified grease. Perform single axis mastering. Refer to Section 6.4. NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear of J3-axis motor shaft. In this time, confirm sitting sate of gear referring to Section 4.8. - 55 - 4. REPLACING PARTS M12 eyebolt M12 アイボルト B-83945EN/03 A290-7227-X940 A290-7227-X940 (See Section 1.3) (1.3節参照) (Position for J3) (J3の場合の位置) Rigging fixture A290-7227-X940 吊治具 A290-7227-X940 Bolt ボルト M8 x 25(4)(4) M6X25 手首先端の凹凸部分に Wind a sling to the スリングを巻きつけること ruggedness part of the writ tip When fixture is not used 治具を使用しない場合 When fixture is used 治具を使用する場合 Fig. 4.7 (a) Hanging method of the J3 arm - 56 - 4. REPLACING PARTS B-83945EN/03 5 4 2 J3 casing J3ケーシング 3 1 J2 arm J2アーム Fig. 4.7 (b) Replacing the J3 –axis reducer Parts name 1 2 3 4 5 BOLT O-RING BOLT REDUCER O-RING Specifications Q’ty Locking Torque (N-m) A6-BA-10X30 A98L-0040-0041#153 A6-BA-5X20 A97L-0318-0240#265Z-145 A98L-0040-0041#046 9 1 18 1 1 LT263 LT518 LT263 73.5 10.8 O-ring (5) (5) Oリング O-ring (2) Oリング (2) J2 arm side J2アーム側 J3 casing side J3ケーシング側 Fig. 4.7 (c) Inserting position of the O-ring - 57 - 4. REPLACING PARTS B-83945EN/03 4.8 NOTES OF ATTACHING THE GEAR TO THE J3-AXIS REDUCER 1 Apply LOCTITE 243 to thread the Draw Nut (A290-7227-X411) and mount it to the motor shaft by using torque wrench with regulated torque set at 3.1Nm. Attach the woodruff key to motor shaft, confirm there is no dust on taper shaft of motor and insert gear to motor shaft. Mount fixture to motor as Fig.4.8 (a) for centering. While referencing Fig. 4.8 (a), apply LOCTITE 243 to thread and tighten bolt (M4 x 70) with regulated torque 3.4Nm while supporting gear with spanner wrench preventing the gear from rotating.(to prevent motor brake slips) If you hear the ratchet sound of the torque wrench then, turn the torque wrench until the next ratchet sound or until the bolt head is completely past the motor gear. This completes setting of the gear on the motor taper shaft. Remove the Fixture from the Motor Shaft. 2 3 4 5 Fixture 治具 A290-7227-X972 A290-7227-X972 Fixture 治具 A290-7227-X971 A290-7227-X971 Insert a spanner ギヤ回り止めのため、 to prevent the モンキスパナなど gear from rotating を差し込んで支持する。 Bolt ボルト A6-BA-4X70 A6-BA-4X70 Tightening torque 締付トルク 3.4 Nm 3.4Nm LOCTITE 243 ロックタイト243塗布 J3-axis motor gear J3軸モータギヤ Draw nut ドローナット A290-7227-X411 A290-7227-X411 Tightening torque 締付トルク 3.1 Nm 3.1Nm ロックタイト243 LOCTITE 243 Fixture 治具 A290-7227-X971 A290-7227-X971 J3-axis motor J3軸モータ J3-axis motor J3軸モータ Fig. 4.8 (a) Attaching the gear on the J3-axis motor - 58 - 4. REPLACING PARTS B-83945EN/03 4.9 1 2 3 4 5 6 7 8 9 10 11 12 13 REPLACING THE J4-AXIS MOTOR (M4) Pull out oil of J4-axis gearbox referring to Subsection 2.2.4. Set a dial gauge at the J4-axis, and prepare for single axis mastering after replacement. Refer to Section 6.4. Turn off controller power. Remove bolts (1), and then remove the J4 cover (2) and the gasket (3). Remove the connector of a cable leading to the J4-axis motor. As shown in Fig. 4.9 (a), remove the three bolts (4) that fasten the J4-axis motor to the J3 casing, and dismount the motor (5). Remove the bolt (9) that fastens the gear (7) to the motor shaft, and dismount the washer (8), gear (7) and key (6). Mount the gear (7) to a new motor, apply LOCTITE 243 to the threaded portion of the motor shaft, and fasten them with a bolt by tightening with a torque of [1.3 Nm]. (Ensure the specified torque is achieved otherwise, the J4-axis may get out of place.) Replace the gasket (10) with a new one and put it in the J3 casing portion where the motor is to be mounted accurately, and fasten the motor to the J3 casing with bolts (4). Attach the J4 cover (2) and the gasket (3) with bolts (1). Connect cable connectors to the J4-axis motor. According to Section 2.2.4, supply the J4-axis gearbox with the specified oil. Perform single axis mastering. Refer to Section 6.4. 9 10 8 7 6 5 4 3 2 1 Fig. 4.9 (a) Replacing the J4-axis motor Parts name 1 2 3 4 5 6 7 8 9 10 BOLT J4 COVER GASKET SEAL BOLT MOTOR KEY GEAR WASHER BOLT GASKET Specifications A97L-0218-0496#M5X16BC A290-7227-X482 A290-7227-X447 A97L-0218-0621#051616 A06B-0114-B855#0048 A97L-0118-0402#3X3X12BQ A290-7227-X412 A290-7210-X532 A6-BA-3X8 A98L-0040-0042#07 - 59 - Q’ty 5 1 1 4 1 1 1 1 1 1 Locking Torque (N-m) 5.6 6.8 LT675 LT243 1.3 4. REPLACING PARTS 4.10 1 B-83945EN/03 REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L) Set dial gauges at the J3/J4-axes, and prepare for single axis mastering after replacement. Refer to Section 6.4. Set the Quick Master Reference Position. Refer to the QUICK MASTERING sections of the mechanical unit Operator’s Manual (B-83944EN). (All the axes are set to 0º before shipment.) Turn off controller power. Pull out all oil of J4-axis gearbox referring to Section 2.2. Wrap and hang Sling in two places of the J3 arm referring to Fig.4.10 (a). Referring to Section 5.3, remove the wiring and piping between J3-axis and wrist. When cable installed in M/H conduit is removed, refer to Section 4.19. Remove option cables from the J3 casing. Referring to Section 4.9, remove J4-axis motor. Remove bolts (1), the J3 arm and the O-ring (2). 2 3 4 5 6 7 8 9 2 1 Fig. 4.10 (a) Replacing the J4-axis gearbox unit (1/2) Parts name 1 2 10 11 12 13 14 BOLT O-RING Specifications A6-BA-6X115 A290-7227-X444 Q’ty Locking Torque (N-m) 9 1 LT263 15.6 When the J3 cover (option) is attached, remove it referring to Section 4.18. Referring to Section 4.6, remove J3-axis motor. Remove bolts (6) which fix the J4-axis gearbox (7) on the J2 arm, then remove the J4-axis gearbox (7) from the J3-axis reducer. Remove bolts (3), the J4 cover (4) and J4-axis motor with gear referring to Section 4.9. Attach the removed motor on the new J4-axis gearbox. In this time, replace gaskets by new articles. - 60 - 4. REPLACING PARTS B-83945EN/03 7 5 8 4 3 6 Fig. 4.10 (b) Replacing the J4-axis gearbox unit (2/2) Parts name 3 4 5 6 7 8 15 16 17 18 19 20 21 22 BOLT J4 COVER GASKET BOLT J4-AXIS GEARBOX O-RING Specifications Q’ty A97L-0218-0496#M5X16BC A290-7227-X482 A290-7227-X447 A6-BA-10X30 A05B-1227-K421 A98L-0040-0041#153 5 1 1 9 1 1 Locking Torque (N-m) 5.6 LT263 73.5 LT518 Attach the new J4-axis gearbox on the J2 arm. Please spread LOCTITE according to the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt. Apply LOCTITE 518 on the new O-ring (8), and then install it to the J3-axis reducer. Then attach the J3-axis reducer on the J4-axis gearbox (7) with bolts (6). Referring to Section 4.6 and 4.9 attach J3/J4-axis motor. In this time replace gasket and seal bolt to new one. When the J3 cover (option) was attached, attach it referring to Section 4.18. Referring to Section 5.3 and 5.4, attach cables to the J3 arm and the J3 casing. According to Section 2.2, supply grease to J3-axis reducer with specified grease and supply oil to J4-axis gearbox with specified oil. Attach the J4 cover (4) and the gasket (5). In this time, replace the gasket by new one. Perform quick mastering and perform single axis mastering of J3 and J4-axis. Refer to the QUICK MASTERING section of the mechanical unit operator’s Manual (B-83944EN) and Section 6.4 of this manual. NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear (A290-7227-X412) of J4-axis motor shaft. The following service parts are appended to J4-axis gearbox (A05B-1227-K421) for maintenance. Please replace these with the J4-axis gearbox. Parts name GASKET GASKET BOLT BOLT SEAL BOLT TAPER PLUG SEAL WASHER GASKET GASKET Specifications Q’ty A98L-0040-0042#03 A98L-0040-0042#07 A6-BA-10X30 A6-BA-6X8 A97L-0218-0621#051616 A97L-0001-0436#2-1D A30L-0001-0048#6M A290-7227-X441 A290-7227-X443 1 1 9 1 4 1 1 1 1 - 61 - Used place J3-axis motor J4-axis motor J3-axis reducer to J3 casing J3-axis grease inlet J4 -axis moto J4-axis oil inlet/outlet J3-axis grease inlet J3 casing backside J3 casing pipe 4. REPLACING PARTS 4.11 1 B-83945EN/03 REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iD/16S, M-10iD/16S) Set dial gauges at the J3/J4-axes, and prepare for single axis mastering after replacement. Refer to Section 6.4. Set the Quick Master Reference Position. Refer to the QUICK MASTERING sections of the mechanical unit Operator’s Manual (B-83944EN). (All the axes are set to 0º before shipment.) Turn off controller power. Pull out all oil of J4-axis gearbox referring to Section 2.2. Wrap and hang slings in two places of the J3 arm referring to Fig.4.10 (a). Referring to Section 5.3, remove the wiring and piping between J3-axis and wrist. When cable installed in M/H conduit is removed, refer to Section 4.19. Remove option cables from the J3 casing. Referring to Section 4.9, remove the J4-axis motor. Remove bolts (1), the J3 arm and the O-ring (2). 2 3 4 5 6 7 8 9 2 1 Fig. 4.11 (a) Replacing the J4-axis gearbox unit (1/2) Parts name 1 2 10 11 12 13 14 BOLT O-RING Specifications A6-BA-6X115 A290-7227-X444 Q’ty Locking Torque (N-m) 9 1 LT263 15.6 When the J3 cover (option) is attached, remove it referring to Section 4.18. Referring to Section 4.6, remove J3-axis motor. Remove bolts (6) which fix the J4-axis gearbox (7) on the J2 arm, then remove the J4-axis gearbox (7) from the J3-axis reducer. Remove bolts (3), the J4 cover (4) and J4-axis motor with gear referring to Section 4.9. Attach the removed motor on the new J4-axis gearbox. In this time, replace gaskets by new articles. - 62 - 4. REPLACING PARTS B-83945EN/03 7 8 5 4 3 6 Fig. 4.11 (b) Replacing the J4-axis gearbox unit (2/2) Parts name 3 4 5 6 7 8 15 16 17 18 19 20 21 22 BOLT J4 COVER GASKET BOLT J4-AXIS GEARBOX O-RING Specifications Q’ty A97L-0218-0496#M5X16BC A290-7227-X482 A290-7227-X447 A6-BA-10X30 A05B-1227-K441 A98L-0040-0041#153 5 1 1 9 1 1 Locking Torque (N-m) 5.6 LT263 73.5 LT518 Attach the new J4-axis gearbox on the J2 arm. Please spread LOCTITE according to the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt. Apply LOCTITE 518 on the new O-ring (8), and then install it to the J3-axis reducer. Then attach the J3-axis reducer on the J4-axis gearbox (7) with bolts (6). Referring to Section 4.6 and 4.9 attach J3/J4-axis motor. In this time replace gasket and seal bolt to new one. When the J3 cover (option) was attached, attach it referring to Section 4.18. Referring to Section 5.3 and 5.4, attach cables to the J3 arm and the J3 casing. According to Section 2.2, supply grease to J3-axis reducer with specified grease and supply oil to J4-axis gearbox with specified oil. Attach the J4 cover (4) and the gasket (5). In this time, replace the gasket by new one. Perform quick mastering and perform single axis mastering of J3 and J4-axis. Refer to the QUICK MASTERING section of the mechanical unit operator’s Manual (B-83944EN) and Section 6.4 of this manual. NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, replace the gear (A290-7227-X412) of J4-axis motor shaft. - 63 - 4. REPLACING PARTS B-83945EN/03 The following service parts are appended to J4-axis gearbox (A05B-1227-K441) for maintenance. Please replace these with the J4-axis gearbox. Parts name GASKET GASKET BOLT BOLT SEAL BOLT TAPER PLUG SEAL WASHER GASKET GASKET 4.12 Specifications Q’ty A98L-0040-0042#03 A98L-0040-0042#07 A6-BA-10X30 A6-BA-6X8 A97L-0218-0621#051616 A97L-0001-0436#2-1D A30L-0001-0048#6M A290-7227-X441 A290-7227-X443 1 1 9 1 4 1 1 1 1 Used place J3-axis motor J4-axis motor J3-axis reducer to J3 casing J3-axis grease inlet J4 -axis motor J4-axis oil inlet/outlet J3-axis grease inlet J3 casing backside J3 casing pipe REPLACING THE J5/J6-AXIS MOTOR (M5, M6) (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L) NOTE 1 If you remove only one of the motors (J5 or J6) you will not have to drain the oil from the J5/J6-axis gearbox. However, the J5/J6 gearbox will drain automatically if both motors and drain plugs are removed at one time. Remove J5 and J6 motors, only one at a time. Replace motor prior to removing other one. This enables you to do so without loosening the oil in the arm. All drain and fill plugs must remain sealed in position. (Note: J3 must be at -90 degrees for this to work properly) 2 Since J5-axis moves according to J6-axis, mastering for both of the J5-axis and the J6-axis is necessary when replacing the J5-axis motor. 1 2 3 4 5 6 7 8 9 10 11 12 Place the robot in a posture of J3 = -90°. If it is impossible to make the posture in the on-site environment, put the collection bottle under the robot. Set dial gauges at the J5/J6-axes, and prepare for single axis mastering after replacement. Refer to Section 6.4. Turn off controller power. Remove bolts (1), and then remove the J3 arm cover (2). Remove the cables which are attached on the motor. Remove bolt (4) and motor (5) that gear (7) attaches. Remove bolt (10) and motor (11) that gear (13) attaches. Replace motor new one and assemble it applying the steps above in reverse sequence. Replace the O-ring (9) or (15) by new article. Apply LOCTITE 675 on the key. In case of the J5-axis motor, When assembling the motor (5) with bolts (4), adjust the backlash of the gear (7) and the gear (A290-7227-X512) referring to Fig. 4.12 (b). In case of the J6-axis motor, When assembling the motor (11) with bolts (10), adjust the backlash of the gear (13) and the gear (A290-7227-X522) referring to Fig. 4.12 (c). According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil. Perform single axis mastering for J5/J6-axis. Refer to Section 6.4. - 64 - 4. REPLACING PARTS B-83945EN/03 11 10 3 12 13 4 6 7 5 2 14 15 8 9 J6 J5 1 Fig. 4.12 (a) Replacing the J5/J6-axis motor Parts name Specifications Q’ty 1 2 3 4 5 6 7 8 9 10 BOLT J3 ARM COVER GASKET BOLT MOTOR KEY GEAR BOLT O-RING BOLT 6 1 1 3 1 1 1 1 1 3 11 MOTOR A97L-0218-0496#M5X12BC A290-7227-X504 A290-7227-X562 A6-BA-5X12 A06B-0114-B855#0048 A97L-0118-0402#3X3X12BQ A290-7227-X511 A6-BA-3X25 JB-OR1A-G45 A6-BA-5X12 With brake A06B-0114-B855#0048 12 13 14 15 KEY GEAR BOLT O-RING Without brake A06B-0114-B205#0048 A97L-0118-0402#3X3X12BQ A290-7227-X511 A6-BA-3X25 JB-OR1A-G45 - 65 - Locking Torque (N-m ) LT675 LT243 2.0 1 1 1 1 1 LT675 LT243 2.0 4. REPLACING PARTS B-83945EN/03 Gear ギヤ A290-7227-X512 A290-7227-X512 A A When assembling the motor (5), fix it during pushing it toward the arrow モータ(5)を組み付ける際、モータ(5)を矢印方向へ 18Nの力で押し付けながら固定してください。 direction with force of 18N. その際ボルト(4)は均等に少しずつ締め付け、 At this chance, equally tighten bolts (4) モータ(5)が傾かないように注意してください。 little by little , prevent the motor (5) inclines. 5 7 Gear ギヤ A290-7227-X512 A290-7227-X512 7 5 4 断面A-A Section A-A Fig. 4.12 (b) Assembling the J5-axis motor モータ(11)を組み付ける際、モータ(11)を矢印方向 When assembling the motor (11), fix へ13Nの力で押し付けながら固定してください。 it during pushing it toward the arrow その際ボルト(10)は均等に少しずつ締め付け、 direction with force of 13N. モータ(11)が傾かないように注意してください。 At this chance, equally tighten bolts (10) little by little , prevent the motor (11) inclines. A 11 13 A 10 Gear ギヤ A290-7227-X522 A290-7227-X522 13 11 断面 A-A Gear Section A-A ギヤ A290-7227-X522 A290-7227-X522 Fig. 4.12 (c) Assembling the J6-axis motor - 66 - 4. REPLACING PARTS B-83945EN/03 4.13 REPLACING THE J5/J6-AXIS MOTOR (M5, M6) (ARC Mate 100iD/16S, M-10iD/16S) NOTE 1 If you remove only one of the motors (J5 or J6) you will not have to drain the oil from the J5/J6-axis gearbox. However, the J5/J6 gearbox will drain automatically if both motors and drain plugs are removed at one time. Remove J5 and J6 motors, only one at a time. Replace motor prior to removing other one. This enables you to do so without loosening the oil in the arm. All drain and fill plugs must remain sealed in position. (Note: J3 must be at -90 degrees for this to work properly) 2 Since J6-axis moves according to J5-axis, mastering for both of the J5-axis and the J6-axis is necessary when replacing the J5-axis motor. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Place the robot in a posture of J3 = -90°. If it is impossible to make the posture in the on-site environment, put the collection bottle under the robot. Set dial gauges at the J5/J6-axes, and prepare for single axis mastering after replacement. Refer to Section 6.4. Turn off controller power. Remove bolts (1), and then remove the J3 arm cover (2). Remove the cables which are attached on the motor. Remove bolt (4) and motor (5) that gear (7) attaches. Remove the bearing (8) from the gear (7). Remove the bolt (10) and the set screw (9), then remove the gear (7) from the motor (5). Replace motor (5) by new one and assemble it applying the steps above in reverse sequence. Replace the O-ring (11) by new article. Apply LOCTITE 675 on the key. Remove bolt (12) and motor (13) that gear (15) and other parts attaches. Remove the bearing (16) from the gear (15). Remove the bolt (18) and the set screw (17), then remove the gear (15) from the motor (13). Replace motor (13) by new one and assemble it applying the steps above in reverse sequence. Replace the O-ring (19) by new article. Apply LOCTITE 675 on the key. According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil. Perform single axis mastering for J5/J6-axis. Refer to Section 6.4. - 67 - 4. REPLACING PARTS B-83945EN/03 19 13 5 6 7 12 8 10 11 15 16 18 14 17 3 2 9 4 1 Fig. 4.13 (a) Replacing the J5/J6-axis motor Parts name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 BOLT J3 ARM COVER GASKET BOLT MOTOR KEY GEAR BEARING SET SCREW BOLT O-RING BOLT MOTOR KEY GEAR BEARING SET SCREW BOLT O-RING Specifications A97L-0218-0496#M5X12BC A290-7227-X505 A290-7227-X564 A6-BA-5X12 A06B-0115-B855#0048 A97L-0118-0402#3X3X12BQ A290-7228-X511 A97L-0001-0193#0400000 A6-SAKT-3X3 A6-BA-3X30 JB-OR1A-G45 A6-BA-5X12 A06B-0114-B855#0048 A97L-0118-0402#3X3X12BQ A290-7228-X511 A97L-0001-0193#0400000 A6-SAKT-3X3 A6-BA-3X30 JB-OR1A-G45 - 68 - Q’ty 6 1 1 3 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 Locking Torque (N-m) 5.6 LT675 LT243 LT243 0.69 2.0 LT675 LT243 LT243 0.69 2.0 4. REPLACING PARTS B-83945EN/03 4.14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 REPLACING THE J5/J6-AXIS GEARBOX (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L) Place the robot in a posture of J3 = -90° and J4 = J5 =0°. Remove the end effector, the M/H conduit, etc. Refer to Section 4.19 about removing of the M/H conduit. Release all oil of J5/J6 gearbox referring to Section 2.2. Set dial gauges at the J5/J6-axes, and prepare for single axis mastering after replacement. Refer to Section 6.4. Turn off controller power. Remove the J6-axis motor as described in Section 4.12. Remove bolts (1) and (4), and then remove the J5/J6-axis gearbox (2) and the gasket (3). When using the fixture (A05B-1227-K901), attach the plate with two M5 bolts referring to Fig. 4.14 (c). Confirm there is 1 parallel φ5 pins for the positioning on the J3 arm. Then replace the J5/J6-axis gearbox (2) by new one and assemble it applying the procedure in reverse sequence. At this chance, remove the gasket (3) by new one. When mounting the J5/J6-axis gearbox (2) with bolts (1) and (4) in case of not using the fixture, refer to Fig. 4.14 (b), adjust the backlash of the gear (A290-7227-X513) and the gear (A290-7227-X514). When using the fixture (A05B-1227-K911), put the J3 arm to the arrow direction. Turn the plunger till it touches the wrist, then twist it 540° in that state. Mount the J6-axis motor as described in Section 4.12. When using the fixture (A05B-1227-K911), remove the fixture from the robot. According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil. Perform single axis mastering for J5/J6-axis. Refer to Section 6.4. NOTE 1 Remaining oil in the J5/J6-axis gearbox may drop when removing the wrist unit. 2 When adjusting backlash, pushing force is 25N. Be careful to the pushing force and direction. If pushing force is insufficient, it may cause large backlash. If pushing force is too large, it may cause vibration or premature failure. 4 3 2 平行ピン pin pararrel 1 Fig. 4.14 (a) Replacing the J5/J6-axis gearbox - 69 - 4. REPLACING PARTS 1 2 3 4 B-83945EN/03 Parts name BOLT J5/J6-AXIS GEARBOX GASKET BOLT Specifications A97L-0218-0496#M6X16BC A290-7227-V525 A290-7227-Y561 A97L-0218-0496#M6X25BC Q’ty 5 1 1 4 Locking LT263 Torque (N-m ) 15.6 LT263 15.6 When assembling the wrist unit (2), connect the手首ユニット(2)を組み付ける際、手首ユニット(2)とJ3 wrist unit (2) and the J3 arm with φ5 parallel. J3 arm J3アームアームをφ5平行ピンで接続し、φ5平行ピンを回転 Make the φ5 parralel pin as rotation axis,] 軸として手首ユニット(2)を矢印方向へ25Nの力で押し付けながら固定してください。 direction with force of 25N. その際ボルト(1)、(4)は均等に少しずつ締め付け、 At 手首ユニット(2)が傾かないように注意してください。 this chance, equally tighten bolts (1) and (4) fix the wrist unit during pushing it toward the arrow little by little , prevent the wrist unit (2) inclines. Gear ギヤ A290-7227-X513 A290-7227-X513 Gear ギヤ A290-7227-X513 A290-7227-X513 φ5 O Parallel pin 5 平行ピン φ5OParallel pin 5 平行ピン Gearギヤ A290-7227-X514 A290-7227-X514 2 2 Fig. 4.14 (b) Assembling the J5/J6-axis gearbox Plateプレート A290-7227-X901 A290‐7227‐X901 Bolt ボルト M5 x 16 (2) (2) M5X16 Plunger プランジャ Fig. 4.14 (c) Assembling the J5/J6-axis gearbox (when using the A05B-1227-K911) - 70 - 4. REPLACING PARTS B-83945EN/03 4.15 REPLACING THE J5/J6-AXIS GEARBOX (ARC Mate 100iD/16S, M-10iD/16S) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Place the robot in a posture of J3 = -90° and J4 = J5 =0°. Remove the end effector, the M/H conduit, etc. Refer to Section 4.19 about removing of the M/H conduit. Release all oil of J5/J6 gearbox referring to Section 2.2. Set dial gauges at the J5/J6-axes, and prepare for single axis mastering after replacement. Refer to Section 6.4. Turn off controller power. Remove the J6-axis motor as described in Section 4.13. Remove bolts (1) and (4), and then remove the J5/J6-axis gearbox (2) and the gasket (3). When using the fixture (A05B-1228-K901), attach the bracket with two M5 bolts with referring to Fig. 4.15 (c). Attach the new J5/J6-axis gearbox (2) by the reversed sequence. In this time, replace the gasket (3) by new one. All nine bolts (1), (4) until those contact the surface, then loosen those 90º. Put the J5/J6-axis gearbox to the arrow direction with referring to Fig. 4.15 (b). When using the fixture, put the J3 arm to the arrow direction. Turn the plunger till it touches the wrist, then twist it 540º in that state. When not using the fixture put the J5/J6-axis gearbox to the arrow direction. Tighten bolts until those hit the surface, the loosen 20º. Perform this procedure. In A→B→C→D→ E order one by one. Refer to Fig. 4.15 (d). Final Tighten all bolts in A→B→C→D→E→F→G→H→I order with referring to Fig. 4.15 (d). Mount the J6-axis motor as described in Section 4.13. Adjust backlash using a dial gauge. When using the fixture (A05B-1228-K901), remove the fixture from the robot. According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil. Perform single axis mastering for J5/J6-axis. Refer to Section 6.4. NOTE 1 Remaining oil in the J5/J6-axis gearbox may drop when removing the J5/J6-axis gearbox. 2 When adjusting backlash, be careful to the pushing force and direction. If pushing force is insufficient, it may cause large backlash. If pushing force is too large, it may cause vibration or premature failure. - 71 - 4. REPLACING PARTS B-83945EN/03 4 2 3 1 Fig. 4.15 (a) Replacing the J5/J6-axis gearbox Parts name 1 2 3 4 BOLT J5/J6-AXIS GEARBOX GASKET BOLT Specifications Q’ty Locking Torque (N-m ) A97L-0218-0496#M6X25BC 5 LT263 15.6 A290-7228-V505 1 A290-7228-X561 A97L-0218-0496#M6X25BC 1 4 LT263 15.6 J3 arm J3アーム When assembling the J5/J6-axis gearbox (2), connect the J5/J6-axis gearbox (2) and the J3 arm with the 手首ユニット(2)を組み付ける際、手首ユニット(2)とJ3 アームをカラーで接続し、カラーを回転軸として collar. 手首ユニット(2)を矢印方向へ25Nの力で押し Make the collar as rotation axis,fix the wrist unit during 付けながら固定してください。その際ボルト(1)、(4)は均等に少しずつ締め付け、 pushing it toward the arrow direction with force of 25N. 手首ユニット(2)が傾かないように注意してください。 At this chance, equally tighten bolts (1) and (4) little by little , prevent the wrist unit (2) inclines. Collar カラー 2 2 Fig. 4.15 (b) Assembling the J5/J6-axis gearbox - 72 - 4. REPLACING PARTS B-83945EN/03 Bracket ブラケット A290-7228-X911 A290-7228-X911 回転軸 Rotation axis Bolt ボルト (2) M5 M5X12 x 12 (2) Stop pin ストップピンプランジャ Plunger Fig. 4.15 (c) Assembling the J5/J6-axis gearbox (when using the A05B-1228-K901) D B G E H F I A C Wrist unit side 手首ユニット側 J3 arm side J3アーム側 Fig. 4.15 (d) Tightening order of the bolts - 73 - 4. REPLACING PARTS 4.16 1 B-83945EN/03 REPLACING THE J3 ARM UNIT Set a dial gauge at the J5/J6-axis, and prepare for single axis mastering after replacement. Refer to Section 6.4. Set the Quick Master Reference Position. Refer to the QUICK MASTERING sections of the mechanical unit Operator’s Manual (B-83944EN). (All the axes are set to 0º before shipment.) Turn off controller power. Pull out all oil of J4-axis gearbox referring to Section 2.2. Wrap and hang Sling in two places of the J3 arm referring to Fig.4.16 (a). Referring to Section 5.3, remove the wiring and piping between J3-axis and wrist. When cable installed in M/H conduit is removed, refer to Section 4.19. Remove option cables from the J3 casing. Referring to Section 4.9, remove J4-axis motor. Remove bolts (1), the J3 arm and the O-ring (2). Attach the new J3 arm unit (3) and the new O-ring (2). According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil. Perform single axis mastering for J5/J6-axis. Refer to Section 6.4. 2 3 4 5 6 7 8 9 10 11 12 3 2 1 Fig.4.16 (a) Replacing the J3 arm unit Parts name 1 2 BOLT O-RING 3 J3 ARM Specifications A6-BA-6X115 A290-7227-X444 A05B-1227-K521#12 (*1) A05B-1227-K521#LG (*2) A05B-1227-K541 (*3) Q’ty Locking Torque (N-m ) 9 1 LT263 15.6 1 (*1) ARC Mate 100iD, M-10iD/12 (*2) ARC Mate 100iD/10L/8L, M-10iD/10L/8L (*3) ARC Mate 100iD/16S, M-10iD/16S - 74 - 4. REPLACING PARTS B-83945EN/03 4.17 1 2 3 REPLACING THE J2 COVER (OPTION) Remove bolts (1) and washers (2). Remove the J2 cover (3). Replace J2 cover (3) by new one. For its assembly, please apply the steps above in reverse sequence 1 2 3 Fig. 4.17 (a) Replacing the J2 cover Parts name 1 2 3 BOLT WASHER J2 COVER Specifications Q’ty A97L-0218-0502#M6X12 A97L-0318-0430#06012516 A290-7227-X381 3 3 1 - 75 - Locking Torque (N-m) 4. REPLACING PARTS 4.18 1 2 3 B-83945EN/03 REPLACING THE J3 COVER (OPTION) Remove bolts (1), (3) and washers (2), (4). Remove the J3 cover (5). Replace the J3 cover (5) by new one. For its assembly, please apply the steps above in reverse sequence 1 2 5 4 3 Fig. 4.18 (a) Replacing the J3 cover Parts name 1 2 3 4 5 BOLT WASHER BOLT WASHER J3 COVER Specifications Q’ty A97L-0218-0502#M8X12 A97L-0318-0430#08018016 A97L-0218-0502#M6X12 A97L-0318-0430#06012516 A290-7227-X481 2 2 1 1 1 - 76 - Locking Torque (N-m) 4. REPLACING PARTS B-83945EN/03 4.19 REPLACING THE M/H CONDUIT (OPTION) (When replacing the unit) 1 2 3 Remove all cables, the air tubes, and the cable clamping, etc. that go in M/H conduit. Remove M4 x 10 bolts (2 pcs) in Fig. 4.19 (a) and remove unit of M/H conduit. Attach new M/H conduit applying reverse sequence. In this time, according to Fig. 4.19 (a) apply LOCTITE 243 to internal thread and tighten by regulated torque. Assemble them while paying attention that circumference of adapter does not interfere inside of out shaft of J6 hollow part. (Otherwise abnormal noise occurs.) Confirm there is a clearance between them. Pay attention that ring does not protrude from circumference of adapter, too. 1 Fig. 4.19 (a) Replacing the M/H conduit (1/2) Parts name 1 BOLT Specifications Q’ty Locking Torque (N-m) A97L-0218-0496#M4X10TC 2 LT243 4.5 - 77 - 4. REPLACING PARTS B-83945EN/03 (When replacing only the conduit) 1 2 3 4 5 Remove all cables, the air tubes, and the cable clamping, etc. that go in M/H conduit. Remove M4 x 10 bolts (2 pcs) in Fig. 4.19 (a) and remove unit of the M/H conduit. Remove set screws that fix the ring. Remove the conduit from the adapter. Attach new M/H conduit applying reverse sequence. In this time, according to Fig. 4.19 (b) apply LOCTITE 243 to internal thread and tighten by regulated torque. If you cut conduit, be sure to refer NOTE in Appendix A. Assemble them while paying attention that circumference of adapter does not interfere inside of out shaft of J6 hollow part. (Otherwise abnormal noise occurs.) Confirm there is a clearance between them. Pay attention that the ring does not protrude from circumference of adapter, too. A A Plate A290-7227-X632 プレート A290-7227-X632 Bolt Conduit M-10iD/12 : A98L-0040-0331#42M-0062 M-10iD/10L : A98L-0040-0331#42M-0082 コンジット M-10iD/8L : M-10 A98L-0040-0331#42M-0102 iD/12 A98L-0040-0331#42M-0062 M-10iD/7L A98L-0040-0331#42M-0082 M-10iD/16S : A98L-0040-0331#42M-0062 ボルト A97L-0218-0496#M4X10TC (2) LT243 A97L-0218-0496#M4X10TC(2) LT243 (締め付けトルク 4.5Nm) Tightening torque 4.5Nm Ring A290-7227-X633 リング Set screw A290-7227-X633 A6-SAKT-3X14SUS (2) セットスクリュー A6-SAKT-3X14SUS (2) Tightening 75cNm) torque 75cNm (締め付けトルク LT243 LT243 アダプタ A290-7227-X631 ボルト Adapter A97L-0218-0496#M4X8TC (3)LT243 (締め付けトルク 4.5Nm) A290-7227-X631 Bolt A97L-0218-0496#M4X8TC (3) LT243 Tightening torque 4.5Nm B Section A-A 断面A-A 詳細B Detail B Fig. 4.19 (b) Replacing the M/H conduit (2/2) - 78 - 5. REPLACING CABLES B-83945EN/03 5 REPLACING CABLES Replace the welding power cables every two years or 7680 hours, whichever comes first. Replace the other cables every four years or 15360 hours, whichever comes first. If a cable is broken or damaged, replace it according to the procedure described in this chapter. Cautions in handling the Pulsecoder cable When transporting, installing, or maintaining the robot, do not detach the Pulsecoder cables carelessly. The cables are provided with the marking tie shown below. If you detached any cable with the marking tie, you need to perform mastering for the robot. Do not detach any connector unless you replace a motor, Pulsecoder, reducer, gearbox or cable. BATTERY BACKUP DON'T DISCONNECT コネクタ取外不可 Fig. 5 (a) Wire mark If there is a break in or any other damage to a cable, replace the cable according to the procedure described in this chapter. If the connector of a motor cable is detached, the data about the absolute position of the robot is lost. Once any of these cables is replaced, perform quick mastering while referencing Chapter 8 of the Operator’s Manual. If the data is lost because of a break in a cable, also perform mastering to calibrate the robot into the previous absolute position. - 79 - 5. REPLACING CABLES 5.1 B-83945EN/03 CABLE WIRING Fig. 5.1 (a) is the routing of the robot cables. See Chapter 5 of the mechanical unit operator’s manual (B-83944EN) for option cable interface. K102 M6 Pulsecoder,power,brake) K102(M5, (M5、M6 パルスコーダ、パワー、ブレーキ) K104 M6 Pulsecoder,power,brake (J5-axis)) K104(M5, (M5、M6 パルスコーダ、パワー、ブレーキ (J6軸)) (M1 to M6 Pulsecoder,power,brake) (RI/RO*1)) K101 (M1～M6K101 パルスコーダ、パワー、ブレーキ、EE (M1 to M6 Pulsecoder,power,brake (J2 to J5-axis). (RI/RO*1)) EE(RI/RO*1)) K103 (M1～M6K103 パルスコーダ、パワー、ブレーキ (J2～J5軸)、EE (M1 to M6 Pulsecoder,power,brake, (RI/RO*8)) EE(RI/RO*8)) K105 (M1～M6K105 パルスコーダ、パワー、ブレーキ、EE K108 (M1 to M6 Pulsecoder,power,brake, EE(RI/RO*8)) For severe dust/lquid protection option K301 (FANUC製ワイヤ送給装置ケーブル) K301 Wire feeder cable for FANUC K302 (リンカーン製ワイヤ送給装置ケーブル) K302 Wire feeder cable for LINCOLN K303 (ダイヘン製ワイヤ送給装置ケーブル) K303 Wire feeder cable for DAIHEN K304 (溶接パワーケーブル) K304 Welding power cable K305 (カメラケーブル) K305 Camera cable K306 (ユーザケーブル(力センサ・立体センサ対応信号線) K306 User cable (signal usable to force sensor K307 (イーサネットケーブル (信号線)) and 3D Laser Vision senro) K308 (イーサネットケーブル (信号線)用アース) K307 Ethernet cable (signal) K308 Earth for Etherner cable (singal) Fig. 5.1 (a) Routing of the robot - 80 - 5. REPLACING CABLES B-83945EN/03 5.2 CABLE DRESSING After a cable is replaced individually rather than in a bundle, clamp it with cable ties (cable ties) at the specified positions listed in Table 5.2 (a) to (f). Otherwise, the cable might sag or become too tight, leading to a break in the cable. Clamp position of Table 5.2 (a) to (f) mean position in Fig.5.2 (a). Clamp position 2 J3ケーシング of J3 casing クランプ位置2 Clamp position of J2 arm J2アーム上部クランプ位置 upper side Clamp position 1 of J3 casing J3ケーシングクランプ位置1 Clamp position of J2 arm J2アーム下部クランプ位置 lower side Clamp position 1 of J2 base J2ベースクランプ位置1 ClampJ2ベースクランプ位置2 position 2 of J2 base Clamp position in J1 J1ベース内クランプ位置 base Fig. 5.2 (a) Clamp position of motor cable 1 to 7 in Table 5.2 (a) to (e) imply below clamp position. 1 Clamp position of inside of the J1 base 2 Clamp position 1 of the J2 base 3 Clamp position 2 of the J2 base 4 Clamp position of lower side of the J2 arm 5 Clamp position of upper side of the J2 arm 6 Clamp position 1 of J3 casing 7 Clamp position 2 of J3 casing - 81 - 5. REPLACING CABLES B-83945EN/03 Table 5.2 (a) Cable pattern diagram (1) Cable Stamp 捺印ケーブル番号 No. Cable pattern diagram ケーブル模式図 Stamp 捺印 1 2 3 + GB1 M1 P - M1P BA TTER Y BA CKUP D ON'T DIS CONN ECT R l NŽ ^æŠO s Â 4 M2P M2P BA TTER Y BA CKUP D ON'T DIS CONN ECT 5 R l NŽ ^æŠO s Â 6 M3P 7 M3P BA TTER Y BA CKUP D ON'T DIS CONN ECT R l NŽ ^æŠO s Â M4P RMP M4P BATTE RY B ACKU P DON 'T DISCO NNEC T K101 Rl N ^ŽæŠO s Â M56 M56 BAT TERY BAC KUP DO N'T DIS CONN ECT R l N ^ŽæŠO s Â M3M M3M M4M M4BK M4BK EE M4M EE M1M M1M M1BK M2M M1BK M2M M2BK M2BK - 82 - K101 K105 5. REPLACING CABLES B-83945EN/03 Table 5.2 (b) Cable pattern diagram (2) Cable Stamp 捺印ケーブル番号 No. Cable pattern diagram ケーブル模式図 Stamp 捺印 M5P BATTERY BACKUP DON'T M5P DISCONNECT R l N ^Žæ ŠO s Â M6P BATTERY BACKUP M6P DON'T DISCONNECT M56 K102 M56 R l N ^Žæ ŠO s Â M6M M6M K102 M6BK M5M M5BK - 83 - M6BK M5M M5BK 5. REPLACING CABLES B-83945EN/03 Table 5.2 (c) Cable pattern diagram (3) Stamp 捺印 Cable pattern diagram ケーブル模式図 Stamp 捺印 Cable ケーブル番号 No. 1 2 3 + GB1 M1P - M1P BA TTER Y BA CKUP D ON'T DI SCON NECT R l N ^ŽæŠO s Â 4 M2P M2P BA TTER Y BA CKUP D ON'T DI SCON NECT 5 R l N ^ŽæŠO s Â 6 M3P 7 M3P BA TTER Y BA CKUP D ON'T DI SCON NECT R l N ^ŽæŠO s Â M4P RMP M4P BATT ERY BACK UP DON 'T DISC ONNE CT K101 R l N ^ŽæŠO s Â M56 M56 BAT TERY BAC KUP DO N'T DIS CONN ECT R l NŽ ^æŠO s Â M3M M3M M4M M4BK M4BK EE M4M EE M1M M1M M2M M2M M2BK M2BK - 84 - K103 5. REPLACING CABLES B-83945EN/03 Table 5.2 (d) Cable pattern diagram (4) ケーブル Stamp 捺印 Cable 番号 No. Cable pattern diagram ケーブル模式図 Stamp 捺印 M5P BATTERY BACKUP DON'T M5P DISCONNECT R l N ^Žæ ŠO s Â M6P BATTERY BACKUP M6P DON'T DISCONNECT M56 K102 M56 R l N ^Žæ ŠO s Â M6M M6M K104 M5M M5BK - 85 - M5M M5BK 5. REPLACING CABLES B-83945EN/03 Table 5.2 (e) Cable pattern diagram (5) Cable Stamp 捺印ケーブル番号 No. Cable pattern diagram ケーブル模式図 Stamp 捺印 1 2 3 + GB1 M1P - M1P B ATTER Y BA CKUP D ON'T D ISCON NECT R l N ^Žæ ŠO s Â 4 M2P M2P B ATTER Y BA CKUP D ON'T D ISCON NECT 5 R l N ^Žæ ŠO s Â 6 M3P 7 M3P B ATTER Y BA CKUP D ON'T D ISCON NECT R l N ^Žæ ŠO s Â M4P RMP M4P BATT ERY BACK UP DO N'T DISC ONNE CT K101 R l N ^Žæ ŠO s Â M56 M56 BA TTER Y BA CKUP D ON'T DI SCON NECT R l N ^Žæ ŠO s Â M3M M3M M4M M4BK M4BK EE M4M EE M1 M M1M M1BK M2M M1BK M2M M2BK M2BK - 86 - K108 5. REPLACING CABLES B-83945EN/03 Table 5.2 (f) Cable pattern diagram (6) Cable Stamp 捺印ケーブル番号 No. Cable pattern diagram ケーブル模式図 Stamp 捺印 1 23456 7 W/F2 K302 W/F1 W/F1 K301 W/F2 K302 K303 1 2 3 4 5 6 7 W/P2 CAM2 K305 CAM2 K305 CAM1 K306 ASi1 ASi1 3 4 5 6 (without (捺印 stamp) なし) ASi2 K306 ES2 K307 7 ES2 ES1 2 K307 ES1 1 ASi2 CAM1 K304 K304 W/P1 W/P1 W/P2 K308 - 87 - 5. REPLACING CABLES 5.3 1 2 3 4 B-83945EN/03 REPLACING THE J1 TO J4 CABLE Place the robot in a posture of J1 to J4 = 0° Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the mechanical unit Operator’s Manual (B-83944EN). (The Quick Master Reference is set with all axes at 0º before shipment.) Before replacing cables, turn off controller power and remove all cables between robot and controller from the robot. Remove bolts M5 x 16 (5), then remove the J4 cover. Gasket ガスケット A290-7227-X447 A290-7227-X447 J4 cover J4カバー Bolt ボルト M5 x 16 (5) M5X16 (5) Fig. 5.3 (a) Replacing cable kit - 88 - 5. REPLACING CABLES B-83945EN/03 5 6 7 Remove cable from the J1 to J4-axis motors. Remove the cable from the connectors of the cable on the J3 casing. (See Fig. 5.3 (b)) Remove bolts M6 x 12 and the washer, and then pull out cable with the clamp from the robot. (See Fig. 5.3 (b)) A A Bolt ボルト M6M6X12(2) x 12 (2) Bolt ボルト M6 x 12 M6X12 Washer ワッシャ Tie M56 with cable ties M56をケーブルタイで縛ること。 (when assembling) (組み付け時) Section A-A 断面 A-A Fig. 5.3 (b) Replacing cable kit - 89 - 5. REPLACING CABLES 8 B-83945EN/03 Remove bolts M6 x12 which fix the clamps of the J2 arm upper side and lower side. Then remove the cable kit from the J2 arm. (Refer to Fig. 5.3 (c)) Bolt ボルト M6 x 12 (2) M6X12(2) Apply LOCTITE 263 (when assembling) ロックタイト263塗布のこと (組み付け時) Bolt ボルト M6 x 12 (2) M6X12(2) Apply LOCTITE 263 (when assembling) ロックタイト263塗布のこと (組み付け時) Fig. 5.3 (c) Replacing cable kit - 90 - 5. REPLACING CABLES B-83945EN/03 9 Remove bolts M6 x 12 which fix the clamps of the J2 base (2 places). Then remove the cable kit from the J2 base. (Refer to Fig. 5.3 (d)) Bolt ボルト M6 x 12 (2) M6X12(2) Apply LOCTITE 263 (when(組み付け時) assembling) ロックタイト263塗布のこと Cable tie ケーブルタイ Bolt ボルト M6 x 12 (2) M6X12(2) Apply LOCTITE 263 ロックタイト263塗布のこと (組み付け時) (when assembling) Fig. 5.3 (d) Replacing cable kit - 91 - 5. REPLACING CABLES 10 11 12 13 14 B-83945EN/03 Remove bolts M6 x 12 (4 pcs) which fix the J1 connector plate to the J1 base. Then remove the J1 connector plate from the J1 base. (See Fig. 5.3 (e)) Remove bolts M4 x 10 (2 pcs), then remove the battery box. Remove the terminal from the battery box. Remove the earth terminal (2 places) which is fixed to the J1 base. If option cables are attached, remove those from the J1 connector plate and the J1 base. Washer ワッシャ(2)(2) Bolt ボルト M6 x 12 (2) M6X12 (2) J1 connector plate J1分線板 Bolt ボルト M6 x 12 (4) M6X12 (4) Earth terminal アース端子 Bolt ボルト M4 x 10 (2) M4X10 (2) Battery box バッテリボックス - Tie up with cable ties. ケーブルタイで固定のこと。 - + + Tightening torque 0.50Nm 締め付けトルク 0.50Nm Battery box terminal side バッテリボックス端子面 Fig. 5.3 (e) Replacing cable kit 15 16 17 Pull out whole of the cable kit from the J1 connector plate position. Assemble the cable in the reversed sequence. Perform quick mastering. Refer to the QUICK MASTERING section of the mechanical unit Operator’s Manual (B-83944EN). - 92 - 5. REPLACING CABLES B-83945EN/03 18 When the welding cable is specified, remove bolts, washes and the nut, then disassemble the terminal part. When assembling, wind the acetate tape as Fig. 5.3 (f). A B B A Wind the acetate tape toアセテートテープを巻き insulate the terminal 端子部を絶縁すること。 part. Washer ワッシャ W/P 2 W/P 1 Section A-A 断面 A-A Terminal 端子 A97L-0218-0737 A97L-0218-0737 Bolts M4M4X10(2) x 10 (2) ボルト Washers ワッシャ (2) (2) Nut ナットワッシャ Washer Bolt M8 x 25 ボルトM8X25 Washer ワッシャ Section B-B 断面 B-B Fig. 5.3 (f) Replacing cable kit - 93 - 5. REPLACING CABLES 5.4 1 2 3 B-83945EN/03 REPLACING S J5 AND J6 CABLES Place the robot in a posture of J4 = 0° Set the Quick Master Reference Position. Refer to the QUICK MASTERING section of the mechanical unit Operator’s Manual (B-83944EN). (The Quick Master Reference is set with all axes at 0º before shipment.) Remove bolts M5 x 12 (6), then remove the J3 arm cover. ガスケット Gasket A290-7227-X562 A290-7227-X562 J3J3アームカバー arm cover Bolt ボルト M5 x 12(6)(6) M5X12 Fig. 5.4 (a) Replacing cable kit (J3 arm part 1) 4 Remove bolts which fix clamp in the J3 arm, then remove the cable from the motor. Slack cable as well as shape of U to direction 板金と同じ方向にケーブルをU字にたるませること(矢印参照) of (組み付け時) plate. (refer to arrow) (When assembling) C C Section B-B 断面 B-B Two cable shold be slacked to 2本のケーブルは互い違いのU字とすること。 (組み付け時) different direction. (When assembling) Bolt ボルト M3M3X6 x6 Bolt ボルト M5M5X8(2) x 8 (2) B B TieM5M,M5P,M6M,M6Pをケーブルタイで縛ること。 up M5M, M5P, M6M, M6P with cable ties (組み付け時) (when assembling) Bolt ボルト M5X8(2) M5 x 8 (2) Section 断面C-C C-C Fig. 5.4 (b) Replacing cable kit (J3 arm part 2) (ARC Mate 100iD, M-10iD/12) - 94 - 5. REPLACING CABLES B-83945EN/03 Slack cable as well as shape of U to direction 板金と同じ方向にケーブルをU字にたるませること(矢印参照) of （組付け時） plate. (refer to arrow) (When assembling) 2本のケーブルは互い違いのU字とすること。 Two cable shold be slacked to different direction. (When assembling) Section 断面 A-A A-A Bolt ボルト M3 x 6 M3X6 Boltボルト M5 M5X8(2) x 8 (2) A A Tie up M5P, M5M,M5BK, M6P, M6M, M6BK with M5P,M5M,M5BK,M6P,M6M,M6BKをケーブルタイで縛ること。 cable ties (when assembling) Fig. 5.4 (c) Replacing cable kit (J3 arm part 2) (ARC Mate 100iD/10L, M-10iD/10L) Slack cable as well as shape of U to direction of plate. (refer to arrow) 板金と同じ方向にケーブルをU字にたるませること(矢印参照) (When assembling) B B 断面 A-AA-A Section 2本のケーブルは互い違いのU字とすること。 Two cable shold be slacked to different direction. (When assembling) Bolt ボルト M5X8(2) M5 x 8 (2) Section 断面B-B B-B Boltボルト M3 xM3X6 6 Bolt M5ボルト x 8 (2) M5X8(2) A A Bolt ボルト M3 xM3X6 6 Bolt Tie up M5M, M5P, M6M, M6P with cable ties ボルト M5M,M5P,M6M,M6Pをケーブルタイで縛ること。 M5 x 8M5X8(2) (2) (when assembling) Bolt ボルト M5X8(2) M5 x 8 (2) Fig. 5.4 (d) Replacing cable kit (J3 arm part 2) (ARC Mate 100iD/16S, M-10iD/16S) - 95 - 5. REPLACING CABLES B-83945EN/03 Slack cable as well as shape of U to direction 板金と同じ方向にケーブルをU字にたるませること(矢印参照) of plate. (refer to arrow) (When assembling) Section A-A 断面 A-A Two cable shold be slacked to 2本のケーブルは互い違いのU字とすること。 different direction. (When assembling) Bolt M3 x 6 ボルト M3X6 ボルト Bolt M5X8(2) M5 x 8 (2) A A Tie up M5P, M5M,M5BK, M6P, M6M, M6BK M5P,M5M,M5BK,M6P,M6M,M6BKをケーブルタイで縛ること。 with cable ties (when assembling) Fig. 5.4 (e) Replacing cable kit (J3 arm part 2) (ARC Mate 100iD/8L, M-10iD/8L) 5 6 Remove bolts M4 x 8 (4), then remove the pipe. Remove bolts M6 x 16 (7), then remove the plate. Gasket ガスケット A290-7227-X441 A290-7227-X441 Plate プレート Bolt M6ボルト x 16 (7) M6X16 (7) Gasket A290-7227-X443 ガスケット A290-7227-X443 Plate パイプ Bolt M4 x 8 (4) ボルト M4X8 (4) Fig. 5.4 (f) Replacing cable kit (J3 casing 1) 7 Remove bolts M3 x 8 (4) on the J3 casing backside. - 96 - 5. REPLACING CABLES B-83945EN/03 A A Boltボルト M3M3X8(4) x 8 (4) Tie up M56 with cable ties M56をケーブルタイで縛ること。 (組み付け時) (when assembling) Section A-A 断面 A-A Fig. 5.4 (g) Replacing cable kit (J3 casing 2) 8 Push the connector from the lower side so that the connector tab is pressed in the J3 casing, and then remove the cables from the connector. Wrist side 手首側 Tab 爪 Fig. 5.4 (h) Replacing cable kit (J3 casing connector) 9 10 11 Pull out cables from the J3 casing lower side and the J3 arm side to the J3 casing side. Assemble the cable in the reversed sequence. Perform quick mastering. Refer to the QUICK MASTERING section of the mechanical unit Operator’s Manual (B-83944EN). - 97 - 6. MASTERING 6 B-83945EN/03 MASTERING Mastering associates the angle of each robot axis with the pulse count value supplied from the absolute Pulsecoder connected to the corresponding axis motor. To be specific, mastering is an operation for obtaining the pulse count value; corresponding to the zero position. CAUTION 1 In case of ARC Mate 100iD, M-10iD series, mastering is performed with gravity compensation function enabled in our factory before shipment. Please refer to Chapter 11 of Controller optional function operator’s manual (B-83284EN-2) for details of the gravity compensation function. 2 In case of performing mastering with gravity compensation is enabled, if load setting (See Section 4.3 of the mechanical unit operator’s manual (B-83944EN)) is not correct, it will influence the precision of the mastering. 6.1 OVERVIEW The current position of the robot is determined according to the pulse count value supplied from the Pulsecoder on each axis. Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However, mastering becomes necessary after: Motor replacement Pulsecoder replacement Reducer replacement Cable replacement Batteries for pulse count backup in the mechanical unit have gone dead. WARNING Robot data (including mastering data) and Pulsecoder data are backed up by their respective backup batteries. Data will be lost if the batteries die. Replace the batteries in the controller and mechanical units periodically. An alarm will alert you when battery voltage is low. - 98 - 6. MASTERING B-83945EN/03 Mastering method Table 6.1 (a) describes the following mastering methods. Table 6.1 (a) Mastering method Fixture position mastering Zero-position mastering (witness mark mastering) Quick mastering Quick mastering for single axis Single axis mastering Mastering data entry Mastering performed before shipping using the mastering fixture. . Mastering performed with all axes set at the 0-degree position. A zero-position mark (witness mark) is attached to each robot axis. This mastering is performed with all axes aligned to their respective witness marks. Mastering performed at a user-specified position. The corresponding count value is obtained from the rotation count of the Pulsecoder 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. (All axes at the same time) Mastering performed at a user-specified position for one axis. The corresponding count value is obtained from the rotation count of the Pulsecoder 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. Mastering performed for one axis at a time. The mastering position for each axis can be specified by the user. This is useful when performing mastering on a specific axis. Enter the Mastering data directly. This MAINTENANCE MANUAL describes fixture position mastering and single axis mastering those are mainly required during replacement of parts. For other mastering methods, refer to the OPERATOR'S MANUAL. Once mastering is performed, you must carry out positioning (calibration). Positioning is an operation in which the controller reads the pulse count value to sense the current position of the robot. CAUTION 1 If mastering is performed incorrectly, the robot may behave unexpectedly. This is very dangerous. So, the Master/Cal screen is designed to appear only when the $MASTER_ENB system variable is 1 or 2. After performing positioning, press F5 [DONE] on the Master/Cal screen. The $MASTER_ENB system variable is reset to 0 automatically, thus hiding the Master/Cal screen. 2 Before mastering is performed, it is recommended that the current mastering data be backed up. 3 When the motion range is mechanically 360 degrees or more, turning any of the axes (J1-axis and J4-axis) to which the cables are connected one turn in the correct mastering position will damage the cables in the mechanical unit. If the correct rotation position is not clear because the axis is moved too much during mastering, remove the connector panel or cover, check the states of the internal cables, and perform mastering in the correct position. For the checking procedure, see Fig. 6.1 (a) and (b). - 99 - 6. MASTERING B-83945EN/03 J1=0 vの時 Check that the cables are ケーブルが捻れていないか not twisted with the 確認してください J1-axis placed in 0º J1 connector panel J1分線盤 Bolt ボルト M6X10 (4) M6 x10 (4) Fig. 6.1 (a) Confirming the state of cable (J1-axis) Gasket (*) ガスケット(*) A290-7227-X441 A290-7227-X441 Gasket cannot be reused. (*)ガスケットは再利用できません。プレートを外した際はガスケット Replace it when removing the plate. を新品に交換してください。 Check that the cables are プレート Plate J4=0 vの時 with the not twisted ケーブルが4周巻いてある J4-axis placed in 0º 状態か確認してください Fig. 6.1 (b) Confirming the state of cable (J4-axis) - 100 - Bolt ボルト M6 x16 M6X16 (7) (7) tightening torque 締付けトルク 4.5Nm 4.5Nm ロックタイト243塗布 Apply LOCTITE 243 6. MASTERING B-83945EN/03 6.2 RESETTING ALARMS AND PREPARING FOR MASTERING Before performing mastering because a motor has been replaced, it is necessary to release the relevant alarm and display the positioning menu. Alarm displayed “SRVO-062 BZAL” or “SRVO-075 Pulse not established” Procedure 1 Display the positioning menu by following the steps 1 to 6. 1 Press the [MENU] key. 2 Press [0 NEXT] and select [6 SYSTEM]. 3 Press F1 ([TYPE]), and select [Variable] from the menu. 4 Place the cursor on $MASTER_ENB, then key in “1” and press the [ENTER] key. 5 Press F1 ([TYPE]), and select [Master/Cal] from the menu. 6 Select the desired mastering type from the [Master/Cal] menu. 2 To reset the “SRVO-062 BZAL” alarm, follow steps 1 to 5. 1 Press the [MENU] key. 2 Press [0 NEXT] and select [6 SYSTEM]. 3 Press F1 ([TYPE]), and select [Master/Cal] from the menu. 4 Press F3 ([RES_PCA]), then press F4 ([YES]). 5 Cycle power of the controller. 3 To reset the “SRVO-075 Pulse not established” alarm, follow the steps 1 to 2. 1 After cycling controller power, the message “SRVO-075 Pulse not established” appears again. 2 Move the axis for which the message mentioned above has appeared in either direction till the alarm disappears when you press the [RESET] key. - 101 - 6. MASTERING 6.3 B-83945EN/03 FIXTURE POSITION MASTER Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the predetermined fixture position. Fixture position mastering is accurate because a dedicated mastering fixture is used. When mastering the robot, arrange the robot to meet the following conditions. Make the robot mounting base horizontal. (The overall levelness of the robot mounting surface shall be 1 mm or less.) Remove the hand and other parts form the wrist. Set the robot in the condition protected from an external force. Assembling the fixture base 1 Assemble the fixture base as shown in Fig. 6.3 (a). Bolt ボルト M5 x 20 (4) M5X20 (4) Plate プレート A290-7221-X953 A290-7221-X953 Mastering fixture B マスタリング治具B A290-7227-X952 A290-7227-X952 Bolt ボルト M5 x 20 (3) M5X20 (3) Plate プレート A290-7221-X957 A290-7221-X957 Fig. 6.3 (a) Assembling the fixture base - 102 - 6. MASTERING B-83945EN/03 2 Adjust the dial gauge to 3.00 mm using the calibration block, and tighten it with M5 bolt as shown in Fig. 6.3 (b). (Do not tighten the bolt too strongly or the dial gauge will be broken.) 較正ブロック Calibration block Bolt ボルト M5X16 M5 x 16(6) (6) プレート Plate E A B F C ダイヤルゲージ Dial gauge (全てのダイヤルゲージが較正ブロック突き当て時に (All dial gauge indicate 3mm in calibration.) 目盛りの読みが3mmになるよう調整) Assembling method of the dial gauge ダイヤルゲージの組付け方 20 mm ボルトM5 Bolt M5 クランプ Clamp 較正ブロック Calibration block Fig. 6.3 (b) Mounting dial gauge 3 Remove the cover that protects the fixture mounting face of the J1 base. (Upon the completion of mastering, attach this cover to the original position.) Mount the fixture to the J1 base as shown Fig. 6.3 (c). When assembling pin A290-7329-X093, pay attention to the direction of the pin refer to Fig.6.3 (c). Pin ピン A290-7329-X092 A290-7329-X092 A290-7329-X093 A290-7329-X093 Bolt ボルト M6X20 M6 x 20(2)(2) Diamond locating ダイヤピンの向き pin direction ロボット Robot 正面 front Fig. 6.3 (c) Assembling the fixture base - 103 - 6. MASTERING 4 B-83945EN/03 Assemble the fixture to the wrist flange as shown in Fig. 6.3 (d). When assembling the diamond locating pin, pay attention the parallel pin turn to radial part of hollow flange. Refer to Fig. 6.3 (d). Face for the dial ダイヤルゲージ gauges D and F D,Fを当てる面 Bolt ボルト M4X12 M4 x 12(4)(4) Mastering fixture A マスタリング治具A A290-7227-X951 A290-7227-X951 Face for the dial ダイヤルゲージA,Bを gauges A and B 当てる面 Face for the dial ダイヤルゲージCを gauge C 当てる面 Face for the dial ダイヤルゲージE gauge E を当てる面ピン Pin A290-7227-X953 A290-7227-X953 Diamond locating pin direction ダイヤピンの向き Wrist center 手首中心 Fig. 6.3 (d) Assembling the fixture to the wrist flange Mastering 1 2 3 4 Press the [MENU] key to display the screen menu. Select [0 NEXT] and press [6 SYSTEM]. Press F1 [TYPE]. Then select [Variables] from the menu. If $DMR_GRP[group].$GRAV_MAST=1, set the gravity compensation to enabled, if it is 0, set the gravity compensation to disabled. In addition release the brake control. NOTE Gravity compensation can be set to enabled/disabled by setting the system variables as follows: $PARAM_GROUP[group].$SV_DMY_LNK[8] : FALSE(disabled) or TRUE (enabled) 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, cycle power of the controller. (Mastering can be performed without setting of gravity compensation. However, it will affect precision.) 5 If mastering is performed with gravity compensation is enabled, Set the wrist side fixture payload as the following table. Refer to “4.3 LOAD SETTING” of operator’s manual (B-83944EN). PAYLOAD PAYLOAD CENTER X PAYLOAD CENTER Y PAYLOAD CENTER Z PAYLOAD INERTIA X PAYLOAD INERTIA Y PAYLOAD INERTIA Z [kg] [cm] [cm] [cm] [kgfcms2] [kgfcms2] [kgfcms2] - 104 - 2.45 -2.01 0.52 1.24 0.05 0.04 0.08 6. MASTERING B-83945EN/03 6 7 8 9 Press the [MENU] key to show screen menu. Press [0 NEXT] and select [6 SYSTEM]. Press F1 [TYPE] to show screen switch menu. Select Master/Cal. Master/Cal screen will be displayed. SYSTEM Master/Cal AUTO JOINT 10 % TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS 5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Press 'ENTER' or number key to select. [ TYPE ] 10 11 LOAD RES_PCA DONE Jog the robot into a posture for mastering. A to F (see Fig. 6.3 (b)) of the fixture attached to the wrist are dial gauges A to F (see Fig. 6.3 (d)) and make adjustments so that dial gauges A to F indicate 3 mm. The posture as shown in Fig. 6.3 (e) should be used. See this figure for reference. Select “1 FIXTURE POSITION MASTER” and Press F4, YES. "MASTER POSITION" shown in Fig. 6.3 (e) is set in this position. SYSTEM Master/Cal AUTO JOINT 10 % TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS 5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <12200039> <2000319> [ TYPE ] LOAD RES_PCA DONE 12 Select “7 CALIBRATE“ and press F4 [YES]. Position arrangement will be performed. Alternatively, cycle power of the controller to perform position arrangement. SYSTEM Master/Cal AUTO JOINT 10 % TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS 5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <0.000><46.4556><-107.057> <0.000><-72.9430><-90.000> - 105 - 6. MASTERING 13 B-83945EN/03 After positioning has completed, press F5 [DONE]. DONE F5 14 15 Return the setting of the gravity compensation. Return brake control to the original setting, and cycle power of the controller. CAUTION No check is made on the axis movable range during mastering. Be very careful when running the robot. Continuing axis movement may result in the mechanical stopper being bumped. ARC Mate 100iD/12 M-10iD/12 ARC Mate 100iD/10L M-10iD/10L Mastering position Mastering position マスタリング角度マスタリング角度 J1 0.00000 J2 46.4556 J3 -107.057 J4 0.00000 J5 -72.9430 J6 -90.0000 J1 0.00000 J2 19.1043 J3 -87.40583 J4 0.00000 J5 -92.59417 J6 -90.0000 ARC Mate 100iD/16S M-10iD/16S ARC Mate 100iD/8L M-10iD/8L Mastering position マスタリング角度 Mastering position マスタリング角度 J1 0.00000 J2 48.9977 J3 -96.7975 J4 0.00000 J5 -83.2025 J6 -90.0000 J1 0.00000 J2 15.4674 J3 -88.6438 J4 0.00000 J5 -91.3562 J6 -90.0000 Fig. 6.3 (e) Mastering posture - 106 - 6. MASTERING B-83945EN/03 6.4 SINGLE AXIS MASTERING (FOR PARTS REPLACING) Single axis mastering is performed for one axis at a time. The mastering position for each axis can be specified by the user. Perform single axis mastering when parts are replaced. NOTE There is a possibility that you cannot perform the procedure in this section due to the backlash or the motor failure. In that case, contact your local FANUC representative. SINGLE AXIS MASTER J1 J2 J3 J4 J5 J6 E1 E2 E3 ACTUAL POS 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 AUTO (MSTR POS) ( 0.000) 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( ( 0.000) ( 0.000) ( 0.000) JOINT 10% 1/9 (SEL) [ST] (0) [2] (0) [2] (0) [2] (0) [2] (0) [2] (0) [0] (0) [0] (0) [0] (0) [0] EXEC Item Current position (ACTUAL AXIS) Mastering position (MSTR POS) SEL ST Table 6.4 (a) Items set in single axis mastering Description The current position of the robot is displayed for each axis in degree units. A mastering position is specified for an axis to be subjected to single axis mastering. It would be convenient if it is set to 0 degree 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. Procedure of Single axis mastering 1 2 3 4 Press the [MENU] key to display the screen menu. Select [0 NEXT] and press [6 SYSTEM]. Press F1 [TYPE]. Then select [Variables] from the menu. If $DMR_GRP[group].$GRAV_MAST=1, set the gravity compensation to enabled, if it is 0, set the gravity compensation to disabled. In addition release the brake control. NOTE Gravity compensation can be set to enabled/disabled by setting the system variables as follows: $PARAM_GROUP[group].$SV_DMY_LNK[8] : FALSE(disabled) or TRUE (enabled) 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, cycle power of the controller. (Mastering can be performed without setting of gravity compensation. However, it will affect precision.) - 107 - 6. MASTERING 5 B-83945EN/03 Prepare a mark (witness mark, scribe mark, point for check or temporarily set dial gauge)for single axis mastering before parts replacing, then record all axis position of this posture. * The reproducibility after replacing parts varies depending on the mark’s accuracy. * When you can use a dial gauge, set the dial gauge as shown in the figure, then record the scale reading of the dial gauge and the angle of the axis. Fig. 6.4 (a) Setting of the dial gauge 6 7 8 9 10 Move the robot to the posture when the parts are replaced, so replace the parts. After replacing parts, move the robot the marked position in step 5. At this time, move the axis except the replaced axis correctly, match the replaced axis to the marked positon (in case of the dial gauge : scale reading). Clear an alarm that occurs as described in Section 6.2. Then prepare for the mastering. Select [6 SYSTEM]. Select [Master/Cal]. The positioning screen will be displayed. SYSTEM Master/Cal AUTO JOINT 10 % TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS 5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Press 'ENTER' or number key to select. [ TYPE ] 11 LOAD RES_PCA DONE Select [5 SINGLE AXIS MASTER]. The following screen will be displayed. SINGLE AXIS MASTER J1 J2 J3 J4 J5 J6 E1 E2 E3 ACTUAL POS 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 AUTO (MSTR POS) 0.000) ( 0.000) ( ( 0.000) 0.000) ( 0.000) ( 0.000) ( ( 0.000) ( 0.000) ( 0.000) JO INT 10% 1/9 (SEL) [ST] (0) [2] (0) [2] (0) [2] (0) [2] (0) [2] (0) [0] (0) [0] (0) [0] (0) [0] EXEC - 108 - 6. MASTERING B-83945EN/03 12 13 14 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. Input the position data (recorded position in step 5) of the axis mastering is done. Press F5 [EXEC]. Mastering is performed. So, [SEL] is reset to 0, and [ST] is re-set to 2 or 1. SINGLE AXIS MASTER J1 J2 J3 J4 J5 J6 E1 E2 E3 ACTUAL POS 0.000 0.000 0.000 0.000 0.000 90.000 0.000 0.000 0.000 AUTO (MSTR POS) 0.000) ( ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) JOINT 10% 6/9 (SEL) [ST] (0) [2] (0) [2] (0) [2] (0) [2] (0) [2] (1) [0] (0) [0] (0) [0] (0) [0] EXEC 15 When single axis mastering is completed, press the [PREV] key to resume the previous screen. SYSTEM Master/Cal AUTO JOINT 10 % TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS 5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Press 'ENTER' or number key to select. [ TYPE ] 16 17 LOAD RES_PCA DONE Select [7 CALIBRATE], then press F4 [YES]. Positioning is performed. Alternatively, turn off the controller power and on again. Positioning is performed. After positioning is completed, press F5 [DONE]. DONE F5 18 19 Return the setting of the gravity compensation. Return brake control to original setting, and cycle power of the controller. - 109 - 6. MASTERING 6.5 B-83945EN/03 VERIFYING MASTERING 1 How to verify that the robot is mastered properly: Usually, positioning is performed automatically when the power is turned on. To check whether mastering has been performed correctly, examine if the current displayed position meets the actual robot position by using the procedure described below: (1) Reproduce a particular point in a program. Check whether the point agrees with the specified position. (2) Set all axes of the robot to their 0-degree (0 rad) positions. Check that the zero-degree position marks indicated in ZERO POSITION MASTERRING Section of OPERATOR’S MANUAL are aligned. There is no need to use a visual aid. (3) Using fixtures, set the robot to the mastering position in the same way as when performing mastering. Check that the displayed current position agrees with the actual mastering position. If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been invalidated as a result of an alarm described in 2 in this section. Alternatively, the mastering data in system variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation error or some other reason. Compare the data with the values indicated on the supplied data sheet. This system variable is overwritten whenever mastering is performed. Whenever mastering is performed, record the value of the system variable on the data sheet. 2 Alarm type displayed during mastering and their solution method: (1) BZAL alarm This alarm is displayed if the Pulsecoder's backup battery voltage decreases to 0 V while the power to the controller is disconnected. Furthermore, if the Pulsecoder connector is removed for cable replacement, etc. this alarm is displayed as the voltage decreases to 0. Confirm if the alarm will disappear by performing a pulse reset (See Section 6.2.). Then, cycle power of the controller to check if the alarm disappears or not. The battery may be drained if the alarm is still displayed. Perform a pulse reset, and turn off and on the controller power after replacing the battery. Note that, if this alarm is displayed, all the original data held by the Pulsecoder will be lost. Mastering is required. (2) BLAL alarm This alarm is displayed if the voltage of the Pulsecoder's backup battery has fallen to a level where backup is no longer possible. If this alarm is displayed, replace the battery with a new one immediately while keeping the power turned on. Check whether the current position data is valid, using the procedure described in 1 in this section. (3) Alarm notification like CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL may have trouble with Pulsecoder, contact your local FANUC representative. - 110 - APPENDIX APPENDIX B-83945EN/03 A MAINTENANCE PARTS Cable No. Specifications K101 A660-8020-T704#12 K101 A660-8020-T704#SH K101 A660-8020-T704#EL K102 K102 K102 K102 K103 A660-8020-T705#12 A660-8020-T705#LG A660-8020-T705#SH A660-8020-T705#EL A660-8020-T706#12 K104 A660-8020-T707#12 K105 A660-8020-T841#12 K108 Cable No. A660-8021-T503#12 Specifications K301 K302 K303 K304 K304 K304 K305 A660-2008-T370#12 A660-2008-T371#12 A660-2008-T372#12 A660-8040-T051#12H A660-8040-T051#12L A660-8040-T051#12D A05B-1227-D001#12 K306 A660-8020-T934#12 K307 K308 A660-2008-T373#12 A660-8020-T935 Axis J1, J2 J1 J3 J4 J5 J6 A. MAINTENANCE PARTS Specifications A06B-2235-B605 A06B-2235-B005 A06B-2212-B605 A06B-0114-B855#0048 A06B-0114-B855#0048 A06B-0114-B855#0048 A06B-0114-B205#0048 Table A (a) Cables (basic cable) Function J1 to J6 MOTOR+EE(RI/O x 1) (For 6 axes brake type) J1 to J6 MOTOR+EE(RI/O x 1) (For 6 axes brake type) J1 to J6 MOTOR+EE(RI/O x 1) (For 6 axes brake type) Wrist cable (For 6 axes brake type) Wrist cable (For 6 axes brake type) Wrist cable (For 6 axes brake type) Wrist cable (For 6 axes brake type) J1 to J6 MOTOR+EE(RI/O x 1) (For 4 axes brake type) Wrist cable (For 4 axes brake type) J1 to J6 MOTOR+EE(RI/O x 8) (For 6 axes brake type) J1 to J6 MOTOR+EE(RI/O x 8) (For 6 axes brake type) (For severe dust/liquid protection option) Table A (b) Cables (option cable) Function Wire feeder power cable for FANUC Wire feeder power cable for LINCOLN Wire feeder power cable for DAIHEN Welding power cable for FANUC (60SQ) Welding power cable for LINCOLN (60SQ) Welding power cable for DAIHEN (60SQ) Camera cable User cable (signal usable to force sensor and 3D Laser Vision sensor) Ethernet cable (signal) Earth Ethernet cable (signal) Table A (c) Motor Remarks αiS8/4000-B (with brake) αiS8/4000-B (without brake) αiS2/5000-B βiSR0.4/6000 βiSR0.4/6000 βiSR0.4/6000 (with brake) βiSR0.4/6000 (without brake) - 113 - Models ARC Mate 100iD, ARC Mate 100iD/10L, M-10iD/12/10L ARC Mate 100iD/16S, M-10iD/12/16S ARC Mate 100iD/8L M-10iD/8L ARC Mate 100iD M-10iD/12 ARC Mate 100iD/10L M-10iD/10L ARC Mate 100iD/16S M-10iD/16S ARC Mate 100iD/8L M-10iD/8L All models ARC Mate 100iD, ARC Mate 100iD/10L, M-10iD/12/10L Models All models Models All models A. MAINTENANCE PARTS APPENDIX Table A (d) Reducer Specifications Parts name J2-axis reducer J3-axis reducer B-83945EN/03 A97L-0318-0239#430Z-126 A97L-0318-0240#265Z-145 NOTE Specify the following draw nut for the J2, J3-axes reducer. Parts name Table A (e) Gear, draw nut, gear and key Specifications Location of use J1-axis gear J2-axis gear J3-axis gear Draw nut Draw nut A290-7227-X211 A290-7227-X311 A290-7227-X411 A290-7221-X311 A290-7221-X421 J1-axis motor J2-axis motor J3-axis motor J2-axis motor J3-axis motor Gear A290-7227-X412 J4-axis motor Gear A290-7227-X511 J5, J6-axis motor (2 pcs/per 1 robot) Gear A290-7228-X511 Key A97L-0118-0402#3X3X12BNQ J5, J6-axis motor (2 pcs/per 1 robot) J5, J6-axis motor pcs/per 1 robot) Table A (f) Other (mechanical unit) Specifications Parts name J1 unit With brake Without brake J4-axis gearbox A05B-1227-K421 J4-axis gearbox A05B-1227-K441 J5/J6-axis gearbox A290-7227-V525 J5/J6-axis gearbox A290-7228-V505 J3 arm unit A05B-1227-K521#12 J3 arm unit A05B-1227-K521#LG J3 arm unit A05B-1227-K541 A290-7227-T221 A290-7227-T271 Models All models ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L ARC Mate 100iD/16S, M-10iD/16S All models Models All models ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L ARC Mate 100iD/16S, M-10iD/16S ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L ARC Mate 100iD/16S, M-10iD/16S ARC Mate 100iD M-10iD/12 ARC Mate 100iD/10L/8L M-10iD/10L/8L ARC Mate 100iD/16S M-10iD/16S - 114 - A. MAINTENANCE PARTS APPENDIX B-83945EN/03 The following service parts are appended to J4-axis gearbox (A05B-1227-K421, K441) for maintenance. Please exchange these with the J4-axis gearbox. Parts name GASKET GASKET BOLT BOLT SEAL BOLT TAPER PLUG SEAL WASHER GASKET GASKET Parts name Specifications A98L-0040-0042#03 A98L-0040-0042#07 A6-BA-10X30 A6-BA-6X8 A97L-0218-0621#051616 A97L-0001-0436#2-1D A30L-0001-0048#6M A290-7227-X441 A290-7227-X443 Q’ty 1 1 9 1 4 1 1 1 1 Used place J3-axis motor J4-axis motor J3-axis reducer to J3 casing J3-axis grease inlet J4 -axis moto J4-axis oil inlet/outlet J3-axis grease inlet J3 casing backside J3 casing pipe Table A (g) Battery, grease, oil, and sealant Specifications Remark Battery A98L-0031-0027 Grease A98L-0040-0174#16KG Oil A98L-0040-0233#20L C battery 1.5V (4pcs/ per 1 robot) Kyodo Yushi VIGOGREASE RE0 Refer to Section 2.2 for required grease amount. JX Nippon Oil & Energy Corporation BONNOC AX68 Refer to Section 2.2 for required grease amount. Table A (h) O-ring Parts name O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring Specifications JB-OR1A-G105 JB-OR1A-G115 JB-OR1A-G110 A98L-0040-0041#050 A98L-0040-0041#153 A98L-0040-0041#046 A290-7227-X444 JB-OR1A-G45 Parts name Specifications Gasket Gasket Gasket Gasket A98L-0040-0042#03 A290-7227-X447 A98L-0040-0042#07 A290-7227-Y561 Parts name Stopper J1-axis motor J2-axis motor J2-axis reducer J2-axis reducer J3 -axis reducer J3-axis reducer J3 arm to J3 casing J5, J6-axismotor (2 pcs) Table A (i) Gasket Location of use J3-axis motor J4 cover J4-axis motor J5/J6-AXIS GEARBOX Specifications A290-7215-X323 Location of use Models All Models All Models All Models All Models Table A (j) Stopper Used place J2-axis Models All Models Table A (k) M/H conduit (M-10iD/12/10L/16S/8L option) Parts name M/H conduit Conduit Specifications A05B-1227-J701#12 A05B-1227-J701#LG A05B-1227-J701#SH A05B-1227-J701#EL FANUC Specifications: A97L-0118-0734#E36-0062 (NOTE) REIKU Specifications: PU R B-4219 FANUC Specifications: A97L-0118-0734#E36-0082 (NOTE) REIKU Specifications: PU R B-4219 FANUC Specifications: A97L-0118-0734#E36-0102 (NOTE) REIKU Specifications: PU R B-4219 - 115 - Models M-10iD/12 M-10iD/10L M-10iD/16S M-10iD/8L M-10iD/12/16S M-10iD/10L M-10iD/8L A. MAINTENANCE PARTS Parts name Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt APPENDIX Table A (l) Bolt Specifications A6-BA-12X25 A6-BA-5X45 A6-BA-10X20 A6-BA-6X22 A6-BA-5X45 A6-BA-10X30 A6-BA-5X20 A6-BA-3X8 A6-BA-6X115 A6-BA-3X25 A97L-0218-0496#M6X16BC A97L-0218-0496#M6X25BC B-83945EN/03 Qty. 12 1 12 18 1 9 18 1 9 2 5 4 Location of use J1 unit to J2 base J2-axis motor J2 base to J2-axis reducer J2 -axis reducer J3-axis motor J3 casing to J3-axis reducer J3 -axis reducer J4-axis motor J3 arm to J3 casing J5/J6-axis motor Wrist unit to J3 arm Wrist unit to J3 arm NOTE 1 When a bolt with instructions to apply Loctite is removed, it is recommended to replace it with the new one. In case that a washer is attached, replace it at the same time. 2 Please cut it in the convex part when you cut Conduit. The cable might be damaged in the edge part of Conduit when cutting it in the concave portion. Good cutting example A DETAIL A B Bad cutting example DETAIL B Fig. A (a) Cutting example of conduit - 116 - B-83945EN/03 B APPENDIX B. MECHANICAL UNIT CIRCUIT DIAGRAM MECHANICAL UNIT CIRCUIT DIAGRAM - 117 - B. MECHANICAL UNIT CIRCUIT DIAGRAM APPENDIX BASIC AXIS CABLE ARC Mate 100iD, M-10iD/12 ARC Mate 100iD/10L, M-10iD/10L K101(A660-8020-T704#12)---RI/O*1 K105(A660-8020-T841#12)---RI/O*8 B-83945EN/03 J1 MOTOR (αiS8/4000) A63L-0002-0128#810SL3SJ M1BK 10SL-3P(1.25SQ 13A) A BK(J1) C B BKC(J1) M1M ARC Mate 100iD/8L, M-10iD/8L K101(A660-8020-T704#EL)---RI/O*1 K105(A660-8020-T841#EL)---RI/O*8 A66L-0001-0771 (1.25SQ*6C)Φ8.8 A63L-0001-0648#81810SB ARC Mate 100iD/16S, M-10iD/16S K101(A660-8020-T704#SH)---RI/O*1 K105(A660-8020-T841#SH)---RI/O*8 A66L-0001-0770 （0.2SQ*3P）Φ6.9 A63L-0001-0848#B10SL1 A63L-0001-0850 18-10P C J1W1 D J1G1 A J1U1 B J1V1 M1P 8 9 4 5 6 7 5V(J1) 10 0V(J1) 10SL1(0.3SQ 3A) 6V(BT1) 1 XPRQJ1 2 PRQJ1 3 FG 0V(BT1) J2 MOTOR (αiS8/4000) A66L-0001-0771 （1.25SQ*6C）Φ8.8 A63L-0002-0128#810SL3SJ M2BK 10SL-3P(1.25SQ 13A) A BK(J2) C B BKC(J2) M2M A63L-0001-0648#81810SB A J2U1 B J2V1 M2P A63L-0001-0848#B10SL1 A63L-0001-0850 A66L-0001-0770 （0.2SQ*3P）Φ6.9 8 9 18-10P C J2W1 D J2G1 10SL1(0.3SQ 3A) 6V(BT2) 1 XPRQJ2 2 6 PRQJ2 3 FG 7 0V(BT2) 4 5 5V(J2) 10 0V(J2) J1 CONNECTOR PANEL Han 72DD (2.5SQ 10A) RMP 1 BK(J1) 13 BK(J2) 25 BK(J3) 37 BK(J4) 49 BK(J5) 61 BK(J6) BKC 2 J1U1 14 J2U1 26 J3U1 38 (200V) 50 (0V) 3 J1V1 15 J2V1 27 J3V1 39 J4U1 51 J5U1 63 J6U1 4 J1W1 16 J2W1 28 J3W1 40 J4V1 52 J5V1 64 J6V1 5 62 (J1,J2,J3, J4,J5,J6) J1G1 17 J2G1 29 J3G1 41 J4W1 53 J5W1 65 J6W1 24VF 6 XROT 18 (OT,A1,A2, 30 XHBK 42 J4G1 54 J5G1 66 J6G1 7 RI1 19 RI2 31 8 RO1 20 RO2 9 RI7 21 RI8 A3,A4) 5V 10 (J1,J2) 22 0V (A1,A2) RI4 55 RI5 67 44 RO4 56 RO5 68 RI6 45 RO8 RI9 69 57 (XPPABN) RO6 RI3 43 32 RO3 33 RO7 A63L-0002-0244#J32 A63L-0002-0244#T32SK A63L-0002-0066#CTM M56 A66L-0001-0769 （0.2SQ*12P,0.2SQ*24C,0.4SQ*24C)Φ19.0 A63L-0002-0244#P32 A63L-0002-0244#R32SK A63L-0002-0066#CRM BUSH A290-7227-X491 NUT A290-7227-X492 D8 J6W1 D7 D6 J6U1 D5 C8 C7 J6V1 C6 C5 BK(J6) C4 B8 J5W1 B7 B6 J5U1 B5 A8 A7 J5V1 A6 A5 BK(J5) A4 D4 D2 0V 6V D1 (BT5,BT6) (BT5,BT6) C3 J6G1 C2 0V 5V (J5,J6) C1 (J5,J6) B3 B2 XPQRJ6 B1 PRQJ6 BKC D3 (J5,J6) B4 J5G1 A3 A2 XPRQJ5 A1 PRQJ5 FG PACKING A290-7227-X493 0V 0V 5V 34 5V 46 0V 58 (J1,J2) (J3,J4) 70 (J5,J6) (J3,J4) (J5,J6) 11 PRQJ1 23 PRQJ2 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6 12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6 G FG IN CASE OF K101 1 RO1 6V (BT1,BT2,BT3, BT4,BT5,BT6) 3 0V(A1) 2 XHBK 4 RI1 5 24VF(A1) + BATTERY 0V (BT1,BT2,BT3, BT4,BT5,BT6) A63L-0001-0234#W1305F (0.5SQ 5A)Φ3-Φ8 EE EE IN CASE OF K105 1 2 3 4 5 6 7 8 RO1 RO2 RO3 RO4 RO5 RO6 XHBK 0V(A1) A63L-0001-0234#W2524F (0.5SQ 5A)Φ9.6-Φ15 17 24VF(A1) 9 RI1 18 24VF(A2) 10 RI2 11 RI3 19 24VF(A3) 12 RI4 20 24VF(A4) 13 RI8 21 RO7 14 RI(XPPABN) 22 RO8 15 RI5 23 0V(A2) 16 RI6 24 RI7 :可動部用 MOVABLE Fig. B (a) Mechanical unit circuit diagram (Basic cable 6-axes brake type) - 118 - B. MECHANICAL UNIT CIRCUIT DIAGRAM APPENDIX B-83945EN/03 J3 MOTOR (αiS2/5000) M3M A63L-0001-0875#SC 1 J3U1 2 J3V1 A63L-0001-0848#B10SL1 A63L-0001-0850 8 5V(J3) 9 10 0V(J3) A63L-0001-0874 5 BK(J3) 6 BKC(J3) 3 J3W1 4 J3G1 M3P 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT3) 1 XPRQJ3 2 PRQJ3 3 FG 0V(BT3) J4 MOTOR (βiSR0.4/6000) M4BK A63L-0001-0865#2 A63L-0001-0864#CS 1 BK(J4) 2 BKC(J4) M4M A63L-0001-0865#1 A63L-0001-0864#CS 1 J4U1 MOLEX 55618-0401 4 J4G1 3 J4W1 2 J4V1 M4P A63L-0001-0848#E10SL1 A63L-0001-0850 MOLEX 55619-0401 4 3 8 5V(J4) 9 10 0V(J4) CABLE CLAMP A63L-0002-0178#2052DP13 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT4) 1 XPRQJ4 2 PRQJ4 3 FG 0V(BT4) J5 MOTOR (βiSR0.4/6000) M5BK A63L-0001-0865#2 A63L-0001-0864#CS A66L-0001-0287#030RDXWH （0.3SQ*6P） 1 BK(J5) 2 BKC(J5) M5M A63L-0001-0865#1 A63L-0001-0864#CS 1 J5U1 2 J5V1 MOLEX 55618-0401 4 J5G1 3 J5W1 M5P A63L-0001-0848#E10SL1 A63L-0001-0850 MOLEX 55619-0401 4 3 8 5V(J5) 9 10 0V(J5) 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT5) 1 XPRQJ5 2 PRQJ5 3 FG 0V(BT5) J6 MOTOR (βiSR0.4/6000) M6BK A63L-0001-0865#2 A63L-0001-0864#CS 1 BK(J6) 2 BKC(J6) M6M A63L-0001-0865#1 A63L-0001-0864#CS 1 J6U1 2 J6V1 MOLEX 55618-0401 4 J6G1 3 J6W1 M6P A66L-0001-0287#020BUXWH （0.2SQ*8P） A63L-0001-0848#E10SL1 A63L-0001-0850 MOLEX 55619-0401 4 3 8 5V(J6) 9 10 0V(J6) 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT6) 1 XPRQJ6 2 PRQJ6 3 FG 0V(BT6) WRIST CABLE ARC Mate 100iD, M-10iD/12 K102(A660-8020-T705#12) ARC Mate 100iD/10L, M-10iD/10L K102(A660-8020-T705#LG) ARC Mate 100iD/8L, M-10iD/8L K102(A660-8020-T705#EL) ARC Mate 100iD/16S, M-10iD/16S K102(A660-8020-T705#SH) - 119 - ARC Mate 100iD, M-10iD/12 ARC Mate 100iD/10L, M-10iD/10L ARC Mate 100iD/8L, M-10iD/8L ARC Mate 100iD/16S, M-10iD/16S 6BK B. MECHANICAL UNIT CIRCUIT DIAGRAM APPENDIX B-83945EN/03 J1 MOTOR (αiS8/4000) BASIC AXIS CABLE ARC Mate 100iD, M-10iD/12 K103(A660-8020-T706#12)---RI/O*1 M1M A66L-0001-0771 (1.25SQ*6C)Φ8.8 A63L-0001-0648#81810SB A66L-0001-0770 （0.2SQ*3P）Φ6.9 A63L-0001-0848#B10SL1 A63L-0001-0850 A J1U1 B J1V1 18-10P C J1W1 D J1G1 M1P 8 9 4 5 6 7 5V(J1) 10 0V(J1) 10SL1(0.3SQ 3A) 6V(BT1) 1 XPRQJ1 2 PRQJ1 3 FG 0V(BT1) J2 MOTOR (αiS8/4000) A66L-0001-0771 （1.25SQ*6C）Φ8.8 A63L-0002-0128#810SL3SJ M2BK 10SL-3P(1.25SQ 13A) A BK(J2) C B BKC(J2) M2M A J2U1 B J2V1 A63L-0001-0648#81810SB M2P A66L-0001-0770 （0.2SQ*3P）Φ6.9 A63L-0001-0848#B10SL1 A63L-0001-0850 8 9 18-10P C J2W1 D J2G1 10SL1(0.3SQ 3A) 6V(BT2) 1 XPRQJ2 2 6 PRQJ2 3 FG 7 0V(BT2) 4 5 5V(J2) 10 0V(J2) J1 CONNECTOR PANEL Han 72DD (2.5SQ 10A) RMP 1 BK(J1) 13 BK(J2) 25 BK(J3) 37 BK(J4) 49 BK(J5) 61 BK(J6) J1U1 14 J2U1 26 J3U1 3 J1V1 39 J4U1 51 J5U1 63 J6U1 4 J1W1 16 J2W1 28 J3W1 40 J4V1 52 J5V1 64 J6V1 15 J2V1 27 J3V1 38 (200V) 50 (0V) BKC 2 62 (J1,J2,J3, J4,J5,J6) 5 J1G1 17 J2G1 6 XROT 18 (OT,A1,A2, 30 XHBK 42 J4G1 54 J5G1 66 J6G1 7 RI1 19 RI2 31 RI3 43 RI4 55 RI5 0V 67 (A1,A2) 8 RO1 20 RO2 32 RO3 44 RO4 56 RO5 68 RI6 57 (XPPABN) 69 RO6 9 29 J3G1 41 J4W1 53 J5W1 65 J6W1 24VF A3,A4) RI7 21 RI8 33 RO7 45 RO8 RI9 A63L-0002-0244#J32 A63L-0002-0244#T32SK A63L-0002-0066#CTM M56 A66L-0001-0769 （0.2SQ*12P,0.2SQ*24C,0.4SQ*24C)Φ19.0 A63L-0002-0244#P32 A63L-0002-0244#R32SK A63L-0002-0066#CRM BUSH A290-7227-X491 NUT A290-7227-X492 D8 J6W1 D7 D6 J6U1 D5 C8 C7 J6V1 C6 C5 BK(J6) C4 D4 B8 J5W1 B7 B6 J5U1 B5 A8 A7 J5V1 A6 A5 BK(J5) A4 BKC D3 (J5,J6) C3 J6G1 B4 J5G1 0V 6V D1 (BT5,BT6) (BT5,BT6) C2 0V 5V (J5,J6) C1 (J5,J6) B2 XPQRJ6 B1 PRQJ6 B3 A3 D2 FG A2 XPRQJ5 A1 PRQJ5 PACKING A290-7227-X493 0V 5V 5V 34 5V 46 58 0V 70 0V 10 (J1,J2) 22 (J3,J4) (J1,J2) (J3,J4) (J5,J6) (J5,J6) 11 PRQJ1 23 PRQJ2 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6 12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6 G FG A63L-0001-0234#W1305F (0.5SQ 5A)Φ3-Φ8 EE 1 RO1 6V (BT1,BT2,BT3, BT4,BT5,BT6) 3 0V(A1) 2 XHBK 5 24VF(A1) 4 RI1 + BATTERY 0V (BT1,BT2,BT3, BT4,BT5,BT6) - :可動部用 MOVABLE Fig. B (b) Mechanical unit circuit diagram (Basic cable 4-axes brake type) - 120 - B. MECHANICAL UNIT CIRCUIT DIAGRAM APPENDIX B-83945EN/03 J3 MOTOR (αiS2/5000) M3M A63L-0001-0875#SC 1 J3U1 2 J3V1 A63L-0001-0874 5 BK(J3) 6 BKC(J3) 3 J3W1 4 J3G1 M3P A63L-0001-0848#B10SL1 A63L-0001-0850 10SL1(0.3SQ 3A) 6V(BT3) 1 XPRQJ3 2 PRQJ3 3 FG 0V(BT3) 4 5 6 7 8 5V(J3) 9 10 0V(J3) J4 MOTOR (βiSR0.4/6000) A63L-0001-0865#2 A63L-0001-0864#CS A63L-0001-0865#1 A63L-0001-0864#CS M4BK 1 BK(J4) 2 BKC(J4) M4M 1 J4U1 2 J4V1 8 9 5V(J4) MOLEX 55619-0401 4 3 4 3 MOLEX 55618-0401 J4G1 J4W1 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT4) 1 XPRQJ4 2 PRQJ4 3 FG 0V(BT4) M4P A63L-0001-0848#E10SL1 A63L-0001-0850 10 0V(J4) CABLE CLAMP A63L-0002-0178#2052DP13 J5 MOTOR (βiSR0.4/6000) M5BK A63L-0001-0865#2 A63L-0001-0864#CS A66L-0001-0287#030RDXWH （0.3SQ*6P） 1 BK(J5) 2 BKC(J5) M5M A63L-0001-0865#1 A63L-0001-0864#CS 1 J5U1 2 J5V1 MOLEX 55618-0401 4 J5G1 3 J5W1 M5P A63L-0001-0848#E10SL1 A63L-0001-0850 MOLEX 55619-0401 4 3 8 5V(J5) 9 10 0V(J5) 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT5) 1 XPRQJ5 2 PRQJ5 3 FG 0V(BT5) J6 MOTOR (βiSR0.4/6000) M6M A63L-0001-0865#1 A63L-0001-0864#CS 1 J6U1 2 J6V1 MOLEX 55618-0401 4 J6G1 3 J6W1 M6P A66L-0001-0287#020BUXWH （0.2SQ*8P） A63L-0001-0848#E10SL1 A63L-0001-0850 8 5V(J6) 9 10 0V(J6) 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT6) 1 XPRQJ6 2 PRQJ6 3 FG 0V(BT6) WRIST CABLE ARC Mate 100iD, M-10iD/12 K104(A660-8020-T707#12) ARC Mate 100iD, M-10iD/12 4BK - 121 - B. MECHANICAL UNIT CIRCUIT DIAGRAM APPENDIX B-83945EN/03 BASIC AXIS CABLE WITH SDLP A05B-1227-H223#** ARC Mate 100iD, M-10iD/12 ARC Mate 100iD/10L, M-10iD/10L K108(A660-8021-T503#12)---RI/O*8 A66L-0001-0723 （1.25SQ*6C）Φ8.8 ARC Mate 100iD/8L, M-10iD/8L K108(A660-8021-T503#EL)---RI/O*8 A66L-0001-0771 (1.25SQ*6C)Φ8.8 A63L-0001-0648#81810SB A66L-0001-0770 （0.2SQ*3P）Φ6.9 A63L-0001-0848#B10SL1 A63L-0001-0850 J1 MOTOR (αiS8/4000) A63L-0002-0128#810SL3SJ M1BK 10SL-3P(1.25SQ 13A) A BK(J1) C B BKC(J1) M1M 18-10P C J1W1 D J1G1 A J1U1 B J1V1 M1P 8 9 5V(J1) 10 0V(J1) 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT1) 1 XPRQJ1 2 PRQJ1 3 FG 0V(BT1) J2 MOTOR (αiS8/4000) A66L-0001-0723 （1.25SQ*6C）Φ8.8 A63L-0002-0128#810SL3SJ M2BK 10SL-3P(1.25SQ 13A) A BK(J2) C B BKC(J2) M2M A66L-0001-0771 （1.25SQ*6C）Φ8.8 A63L-0001-0648#81810SB A66L-0001-0770 （0.2SQ*3P）Φ6.9 A63L-0001-0848#B10SL1 A63L-0001-0850 A J2U1 B J2V1 18-10P C J2W1 D J2G1 M2P 8 9 5V(J2) 10 0V(J2) 10SL1(0.3SQ 3A) 6V(BT2) 1 XPRQJ2 2 6 PRQJ2 3 FG 7 0V(BT2) 4 5 A66L-0001-0532 (0.5SQ*24C)Φ10.6 A66L-0001-0770 （0.2SQ*3P）Φ6.9 CON. BOX A290-7227-X681 PLATE A290-7227-X683 A66L-0001-0400#2 (0.5SQ*6P,0.2SQ*4P)Φ12.1 J1 CONNECTOR PANEL Han 72DD (2.5SQ 10A) RMP 1 BK(J1) 13 BK(J2) 25 BK(J3) 37 BK(J4) 49 BK(J5) 61 BK(J6) 2 J1U1 14 J2U1 26 J3U1 38 (200V) 50 3 J1V1 15 J2V1 (0V) 27 J3V1 39 J4U1 51 J5U1 BKC 62 (J1,J2,J3, J4,J5,J6) 4 J1W1 16 J2W1 28 J3W1 40 5 J1G1 17 J2G1 29 J3G1 41 J4W1 53 J5W1 65 J6W1 6 XROT 18 (OT,A1,A2, 30 XHBK 42 J4G1 54 J5G1 66 J6G1 7 RI1 19 RI2 8 RO1 20 RO2 9 RI7 21 RI8 J4V1 52 J5V1 64 J6V1 24VF A3,A4) 5V 10 (J1,J2) 22 31 RI4 55 RI5 0V 67 (A1,A2) 44 RO4 56 RO5 68 RI6 45 RO8 RI9 69 57 (XPPABN) RO6 RI3 43 32 RO3 33 RO7 EE 63 J6U1 1 RO1 2 RO2 3 RO3 4 RO4 5 RO5 6 RO6 7 XHBK 8 0V(A1) (SOLDERING OR CRIMPING) A66L-0001-0769 （0.2SQ*12P,0.2SQ*24C,0.4SQ*24C)Φ19.0 A63L-0001-0463#R2424S (0.5SQ 5A)Φ9.6-Φ15 17 24VF(A1) 9 RI1 10 RI2 18 24VF(A2) 19 24VF(A3) 11 RI3 12 RI4 20 24VF(A4) 13 RI8 21 RO7 14 RI9(XPPABN) 22 RO8 15 RI5 23 RI7 16 RI6 24 A63L-0002-0244#J32 A63L-0002-0244#T32SK A63L-0002-0066#CTM M56 5V 34 5V 46 0V 58 0V 70 0V (J1,J2) (J3,J4) (J5,J6) (J3,J4) (J5,J6) D8 J6W1 D7 D6 J6U1 D5 11 PRQJ1 23 PRQJ2 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6 C8 C7 J6V1 C6 C5 BK(J6) C4 12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6 B8 J5W1 B7 B6 J5U1 B5 A8 A7 J5V1 A6 A5 BK(J5) A4 G 6V (BT1,BT2,BT3, BT4,BT5,BT6) + BATTERY 0V (BT1,BT2,BT3, BT4,BT5,BT6) - FG A66L-0001-0400#2 (0.5SQ*6P,0.2SQ*4P)Φ12.1 D2 0V 6V D1 (BT5,BT6) (BT5,BT6) C3 J6G1 C2 0V 5V (J5,J6) C1 (J5,J6) B3 B2 XPQRJ6 B1 PRQJ6 D4 BKC D3 (J5,J6) B4 J5G1 A3 A63L-0002-0244#P32 A63L-0002-0244#R32SK A63L-0002-0066#CRM A63L-0002-0066#CR2L BUSH A290-7227-X494 NUT A290-7227-X492 A66L-0001-0163#5 (1.25SQ*5C)Φ7.7) CABLE CLAMP A63L-0002-0178#1650DP9 :可動部用 MOVABLE Fig. B (c) Mechanical unit circuit diagram (Basic cable 6-axes brake type) (severe dust/liquid protection option) - 122 - FG A2 XPRQJ5 A1 PRQJ5 PACKING A290-7227-X493 APPENDIX B-83945EN/03 J3 MOTOR (αiS2/5000) M3M A63L-0001-0875#SC 1 J3U1 2 J3V1 A63L-0001-0848#B10SL1 A63L-0001-0850 8 5V(J3) 9 10 0V(J3) A63L-0001-0874 5 BK(J3) 6 BKC(J3) 3 J3W1 4 J3G1 M3P 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT3) 1 XPRQJ3 2 PRQJ3 3 FG 0V(BT3) J4 MOTOR (βiSR0.4/6000) M4BK A63L-0001-0865#2 A63L-0001-0864#CS 1 BK(J4) 2 BKC(J4) M4M A63L-0001-0865#1 A63L-0001-0864#CS 1 J4U1 2 J4V1 8 9 5V(J4) CABLE CLAMP A63L-0002-0178#2052DP13 4 3 MOLEX 55618-0401 J4G1 J4W1 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT4) 1 XPRQJ4 2 PRQJ4 3 FG 0V(BT4) M4P A63L-0001-0848#E10SL1 A63L-0001-0850 10 0V(J4) MOLEX 55619-0401 4 3 J5 MOTOR (βiSR0.4/6000) A63L-0001-0865#2 A63L-0001-0864#CS A66L-0001-0287#030RDXWH （0.3SQ*6P） A63L-0001-0865#1 A63L-0001-0864#CS M5BK 1 BK(J5) 2 BKC(J5) M5M 1 J5U1 2 J5V1 MOLEX 55618-0401 4 J5G1 3 J5W1 M5P A63L-0001-0848#E10SL1 A63L-0001-0850 MOLEX 55619-0401 4 3 8 5V(J5) 9 10 0V(J5) 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT5) 1 XPRQJ5 2 PRQJ5 3 FG 0V(BT5) J6 MOTOR (βiSR0.4/6000) A63L-0001-0865#2 A63L-0001-0864#CS A63L-0001-0865#1 A63L-0001-0864#CS A66L-0001-0287#020BUXWH （0.2SQ*8P） M6BK 1 BK(J6) 2 BKC(J6) M6M MOLEX 55618-0401 4 J6G1 3 J6W1 1 J6U1 2 J6V1 M6P A63L-0001-0848#E10SL1 A63L-0001-0850 WRIST CABLE ARC Mate 100iD, M-10iD/12 K102(A660-8020-T705#12) MOLEX 55619-0401 4 3 8 5V(J6) 9 10 0V(J6) 4 5 6 7 10SL1(0.3SQ 3A) 6V(BT6) 1 XPRQJ6 2 PRQJ6 3 FG 0V(BT6) ARC Mate 100iD, M-10iD/12 ARC Mate 100iD/10L, M-10iD/10L ARC Mate 100iD/8L, M-10iD/8L 6BK ARC Mate 100iD/10L, M-10iD/10L K102(A660-8020-T705#LG) ARC Mate 100iD/8L, M-10iD/8L K102(A660-8020-T705#EL) - 123 - B. MECHANICAL UNIT CIRCUIT DIAGRAM C. PERIODIC MAINTENANCE TABLE APPENDIX C B-83945EN/03 PERIODIC MAINTENANCE TABLE FANUC Robot ARC Mate 100iD, ARC Mate 100iD/10L/8L/16S, M-10iD/12/10L/8L/16S Periodic Maintenance Table Accumulated operating Check time (H) time Items - ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2 Check for water 0.1H - ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 0.1H - ○ ○ ○ 0.1H - ○ ○ ○ 0.1H - ○ ○ ○ 6 Tighten the end effector bolt 0.1H - ○ ○ ○ 1.0H - ○ ○ ○ 0.1H - ○ ○ ○ ○ ○ ○ ● ● ○ ○ ○ Mechanical unit Tighten the cover and main 7 bolt Check the fixed mechanical 8 stopper and adjustable mechanical stopper Remove spatter and dust 9 etc. 10 Replacing battery *3 Replacing oil of J1 axis 11 gearbox Controller 18 Replacing the M/H conduit *4 *5 *6 *7 1.0H 0.1H - 0.5H 2400ml (*4) 1600ml (*5) 0.5H 280ml 0.5H 220ml 0.5H 790ml 0.5H 330ml (*6) 800ml (*7) 4.0H - 4.0H - ● 1.0H - ● Check the robot cable, teach 19 pendant cable and robot 0.2H connecting cable Cleaning the controller 20 ventilation system 0.2H 21 Replacing battery *1 *3 *3 7680 8640 9600 10560 0.1H Replacing grease of J2 axis 12 reducer Replacing grease of J3 axis 13 reducer Replacing oil of J4 axis 14 gearbox Replacing oil of J5 and J6 15 axis gearbox Replacing cable of 16 mechanical unit Replacing Mechanical unit 17 welding power cable *2 2 years Check for external 1 damage or peeling paint Check the mechanical cable 3 and welding power cable (Damaged or twisted) Check the end effector 4 (hand) cable Check the motor connector. 5 (Loosening) *1 Oil 3 First 6 9 1 Grease check months months months year amount 320 960 1920 2880 3840 4800 5760 6720 0.1H ○ - ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ - Refer to “REPLACING UNITS Chapter of MAINTENANCE ” of the following manuals. R-30iB/R-30iB Plus CONTROLLER MAINTENANCE MANUAL (B-83195EN), R-30iB Mate/R-30iB Mate Plus CONTROLLER MAINTENANCE MANUAL (B-83525EN) ●: requires order of parts ○: does not require order of parts Regardless of the operating time, replace the mechanical unit batteries at 1 year, replace controller batteries at 4 years. except +90º wall mount +90º wall mount ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L ARC Mate 100iD/16S, M-10iD/16S - 124 - APPENDIX B-83945EN/03 C. PERIODIC MAINTENANCE TABLE 3 4 5 6 7 8 years years years years years years Item 11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 1 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2 ○ ○ ○ ○ 3 ○ ○ ○ ○ ○ 4 ○ ○ ○ ○ ○ 5 ○ ○ ○ ○ ○ 6 ○ ○ ○ ○ ○ 7 ○ ○ ○ ○ ○ 8 ○ ○ ○ ○ ○ 9 ● ● ● ● ● 10 Overhaul ○ ● ● ● ● 12 ● ● 13 ● ● 14 ● ● 15 ● ○ ○ 16 ● ● 17 ● ● 18 ○ ○ ○ ○ 11 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ● ○ ○ ○ ○ ○ ○ 19 ○ ○ ○ 20 21 - 125 - D. STRENGTH OF BOLT AND BOLT TORQUE LIST D APPENDIX B-83945EN/03 STRENGTH OF BOLT AND BOLT TORQUE LIST NOTE When applying LOCTITE to a part, spread the LOCTITE on the entire length of the engaging part of the female thread. If applied to the male threads, poor adhesion can occur, potentially loosening the bolt. Clean the bolts and the threaded holes and wipe off any oil on the engaging section. Make sure that there is no solvent left in the threaded holes. When finished, remove all the excess LOCTITE when you are finished screwing the bolts into the threaded holes. Use the following strength bolts. Comply with any bolt specification instructions. Hexagon socket head bolt made of steel: Size M22 or less: Tensile strength 1200N/mm2 or more Size M24 or more: Tensile strength 1000N/mm2 or more All size plating bolt: Tensile strength 1000N/mm2 or more Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc.) Tensile strength 400N/mm2 or more Refer to the following tables if the bolts tightening torque are not specified. Recommended bolt tightening torques Unit: Nm Hexagon socket head button bolt Hexagon socket head Hexagon bolt Hexagon socket head Hexagon socket head bolt (steel) flush bolt bolt (stainless steel) Nominal (steel) Low-head bolt diameter (steel) Tightening torque Tightening torque Tightening torque Tightening torque Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit ―――― ―――― ―――― ――― M3 1.8 1.3 0.76 0.53 M4 4.0 2.8 1.8 1.3 1.8 1.3 1.7 1.2 M5 7.9 5.6 3.4 2.5 4.0 2.8 3.2 2.3 M6 14 9.6 5.8 4.1 7.9 5.6 5.5 3.8 M8 32 23 14 9.8 14 9.6 13 9.3 M10 66 46 27 19 32 23 26 19 ―――― ―――― M12 110 78 48 33 45 31 ―――― ―――― (M14) 180 130 76 53 73 51 ―――― ―――― M16 270 190 120 82 98 69 ―――― ―――― (M18) 380 260 160 110 140 96 ―――― ―――― M20 530 370 230 160 190 130 ―――― ―――― ―――― ―――― ―――― ―――― (M22) 730 510 ―――― ―――― ―――― ―――― ―――― ―――― M24 930 650 ―――― ―――― ―――― ―――― ―――― ―――― (M27) 1400 960 ―――― ―――― ―――― ―――― ―――― ―――― M30 1800 1300 ―――― ―――― ―――― ―――― ―――― ―――― M36 3200 2300 - 126 - APPENDIX B-83945EN/03 E E. INSULATION ABOUT ARC WELDING ROBOT INSULATION ABOUT ARC WELDING ROBOT The arc welding robot performs welding, using a welding torch attached to its end effector mounting face via a bracket. Because a high welding current flows through the welding torch, the insulating material must not permit bolting directly from the welding torch bracket to mounting face plate. If no due consideration is taken, a poor insulation caused by a pileup of spatter can allow the welding current to leak into robot mechanical units, possibly damaging the motor or melting the mechanical unit cable jackets. E.1 INSULATION AT THE WRIST Please be careful to the following contents. - - - Insulate the end effector mounting surface. Insulation material which is inserted between the end effector mounting surface and the welding torch bracket must be different, and bolt them separately referring to Fig. E.1 (a). Insert the insulating material between the torch bracket and faceplate to ensure the two are electrically isolated. When installing the insulating material, be sure to set the crack in the torch holder away from that of the insulating material to prevent spatter from getting in the cracks. Allow a sufficient distance (at least 5 mm) at the insulating materials in case a pileup of spatter should occur. 5mm5mm以上 or more Torch bracket トーチブラケットトーチ Torch ロボット手首 Robot wrist Insulation material 絶縁部材固定ボルト mounting bolts Torch bracket mounting bolts トーチブラケット固定ボルト Bad 悪い例 example Insulation 絶縁部材 material (ベークライト等) (bakelite etc.) Fig. E.1 (a) Insulation at the wrist - Even after the insulation is reinforced, it is likely that, if a pileup of spatter grows excessively, current may leak. Periodically remove the spatter. - 127 - E. INSULATION ABOUT ARC WELDING ROBOT E.2 APPENDIX B-83945EN/03 INSULATION AT THE ADDITIONAL AXIS If welding fixtures are installed to the additional axis, Perform insulation against between welding fixtures and the additional axis to prevent welding electric current intrusion. If the follower unit is used, perform insulation against between welding fixtures and follower unit to prevent welding electric current intrusion into the housing. Points that need 絶縁必要箇所 the insulation Fig. E.2 (a) Insulation at the additional axis - 128 - INDEX B-83945EN/03 INDEX <B> <P> BACKLASH MEASUREMENT ...................................38 Periodic Checks and Maintenance ...................................2 PERIODIC MAINTENANCE .........................................1 PERIODIC MAINTENANCE TABLE .......................124 PREFACE .................................................................... p-1 Procedure for Releasing Remaining Pressure from the Grease Bath (J2/J3-axis) ..............................16 Procedure for Releasing Remaining Pressure from the Oil Bath (J1/J4/J5/J6-axis) ...........................28 <C> CABLE DRESSING ......................................................81 CABLE WIRING...........................................................80 Check of Fixed Mechanical Stopper and Adjustable Mechanical Stopper....................................8 CHECK POINTS .............................................................4 Check the Mechanical Unit Cables and Connectors....................................................................6 CHECKS AND MAINTENANCE .............................1,12 Confirmation of Oil Seepage............................................4 Confirmation of the Air Control Set (option)...................5 <R> REPLACING CABLES .................................................79 REPLACING PARTS....................................................42 REPLACING S J5 AND J6 CABLES ...........................94 REPLACING THE BATTERIES (1 YEAR (3840 HOURS) CHECKS).........................................12 REPLACING THE GREASE AND OIL OF THE DRIVE MECHANISM (3 YEARS (11520 HOURS) CHECKS) ...................................................13 REPLACING THE J1 TO J4 CABLE ...........................88 REPLACING THE J1 UNIT..........................................46 REPLACING THE J1-AXIS MOTOR (M1) .................45 REPLACING THE J2 COVER (OPTION)....................75 REPLACING THE J2-AXIS MOTOR (M2) .................49 REPLACING THE J2-AXIS REDUCER ......................50 REPLACING THE J3 ARM UNIT................................74 REPLACING THE J3 COVER (OPTION)....................76 REPLACING THE J3-AXIS MOTOR (M3) .................53 REPLACING THE J3-AXIS REDUCER ......................55 REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L)....................................................60 REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iD/16S, M-10iD/16S) ..................................62 REPLACING THE J4-AXIS MOTOR (M4) .................59 REPLACING THE J5/J6-AXIS GEARBOX (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L)....................................................69 <D> Daily Checks ....................................................................1 DRIVE MECHANISM ..................................................43 <F> FIXTURE POSITION MASTER.................................102 <G> Grease Replacement Procedure for the Reducer (J2/J3-axis) .................................................................13 <I> INSULATION ABOUT ARC WELDING ROBOT ....................................................................127 INSULATION AT THE ADDITIONAL AXIS...........128 INSULATION AT THE WRIST .................................127 <M> MAINTENANCE PARTS ...........................................113 MAINTENANCE TOOLS...............................................9 MASTERING ................................................................98 MECHANICAL UNIT CIRCUIT DIAGRAM ............117 <N> REPLACING THE J5/J6-AXIS GEARBOX (ARC Mate 100iD/16S, NOTES OF ATTACHING THE GEAR TO THE J3-AXIS REDUCER ..................................................58 M-10iD/16S) ..............................................................71 REPLACING THE J5/J6-AXIS MOTOR (M5, M6) (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L)...........................64 REPLACING THE J5/J6-AXIS MOTOR (M5, M6) (ARC Mate 100iD/16S, M-10iD/16S)................67 REPLACING THE M/H CONDUIT (OPTION) ...........77 RESETTING ALARMS AND PREPARING FOR MASTERING..................................................101 <O> Oil Replacement Procedure for the J1-axis Gearbox ......................................................................16 Oil Replacement Procedure for the J4-axis Gearbox ......................................................................19 Oil Replacement Procedure for the J5/J6- axis Gearbox (ARC Mate 100iD, ARC Mate 100iD/10L/8L, M-10iD/12/10L/8L)...........................22 Oil Replacement Procedure for the J5/J6- axis Gearbox (ARC Mate 100iD/16S, M-10iD/16S) ....................................................................................25 OVERVIEW ..................................................................98 <S> SAFETY PRECAUTIONS ........................................... s-1 SINGLE AXIS MASTERING (FOR PARTS REPLACING) ..........................................................107 i-1 INDEX B-83945EN/03 STRENGTH OF BOLT AND BOLT TORQUE LIST .........................................................................126 <T> TROUBLESHOOTING .................................................29 <V> VERIFYING MASTERING ........................................110 i-2 REVISION RECORD B-83945EN/03 REVISION RECORD Edition 03 02 01 Date Contents ・ Addition of ARC Mate 100iD/16S, M-10iD/16S Dec., 2020 ・ Correction of errors ・ Addition of ARC Mate 100iD/8L, M-10iD/8L and new spec. (A05B-1227-B221, B222, B271, Feb., 2020 B272, B321, B322) ・ Correction of errors Oct, 2018 r-1 B-83945EN/03 * B - 8 3 9 4 5 E N / 0 3 *

AM-100iD Maintenance Manual [B-83945EN 03]

Похожие документы

Разделы

Поддержка

AM-100iD Maintenance Manual [B-83945EN 03]

Похожие документы

Добавить этот документ в коллекции

Добавить этот документ в сохраненные

Предложите, как улучшить StudyLib