fanuc arc mate 100iB Maintenance Manual

FANUC Robot ARC Mate 100i MODEL B FANUC Robot M-6i MODEL B

MAINTENANCE MANUAL

B--81545EN/01

B--81545EN/01	PREFACE

PREFACE

This manual explains the maintenance and connection procedures for the mechanical units (R--J3i controller) of the following robots. Before replacing the purts, determine the specification number of the mechanical unit.:

Model name

FANUC Robot ARC Mate 100i MODEL B

(With J2 and J3--axis brake)

FANUC Robot ARC Mate 100i MODEL B

(With all axes brake)

FANUC Robot M--6i MODEL B (With J2 and J3--axis brake)

FANUC Robot M--6i MODEL B (With all axes brake)

	Abbreviation	Mechanical unit
		specification No.
		A05B--1215--B201
	ARC Mate 100i
	MODEL B
		A05B--1215--B601
		A05B--1215--B202
	M--6i MODEL B
		A05B--1215--B602

		PREFACE						B--81545EN/01

	No.	(1)
	CONTENTS	MODEL
		FANUC Robot ARC Mate 100i
		MODEL B (2--axis brake)
		FANUC Robot ARC Mate 100i
	LETTERS	MODEL B (6--axis brake)
		FANUC Robot M--6i MODEL B
		(2--axis brake)
		FANUC Robot M--6i MODEL B
		(6--axis brake)

	(2)	(3)	(4)	(5)
	TYPE	No.	DATE	WEIGHT
				(Without controller)
	A05B--1215--B201			184 kg
	A05B--1215--B601	PRINT	PRINT	138 kg
		SERIAL	PRODUCTION
			YEAR AND
	A05B--1215--B201	NO.		184 kg
			MONTH
	A05B--1215--B601			138 kg

B--81545EN/01	PREFACE

Specification

Item
Type
Controlled axes
Installation
Motion range	J1 axis rotation
(Maximum speed)	J2 axis rotation
	J3 axis rotation
	J4 axis wrist rotation
	J5 axis wrist swing
	J6 axis wrist rotation
Maximum speed	J1 axis
	J2 axis
	J3 axis
	J4 axis
	J5 axis
	J6 axis
Max. load capacity at wrist
Max. load capacity on J3 catting
Allowable load moment at wrist	J4 axis
	J5 axis
	J6 axis
Allowable load inertia at wrist	J4 axis
	J5 axis
	J6 axis
Drive method
Repeatability
Weight of mechanical unit

Installation environment

R--2000i/165F

Articulated type

6 axes (J1, J2, J3, J4, J5, J6)

Floor, Upside--dowm (Wall & Angle mount) (Note 1) 340° (5.93rad)

250° (4.36rad)

315° (5.60rad)

380° (6.63rad)

280° (4.89rad)

720° (12.57rad)

150°/s (2.62rad/s)

160°/s (2.79rad/s)

170°/s (2.97rad/s)

400°/s (6.98rad/s)

400°/s (6.98rad/s)

500°/s (8.73rad/s) 6kg

12kg 15.7N·m (1.8kgf·m) 9.8N·m (1.0kgf·m) 5.9N·m (0.5kgf·m)

0.63kg·m2 (6.4kgf·cm·s2) 0.22kg·m2 (2.2kgf·cm·s2)

0.061kg·m2 (0.62kgf·cm·s2) Electric servo drive by AC servo motor

0.06mm

	134kg (2--axis brake type)
	138kg (6--axis brake type)
Ambient temperature : 0 -- 45°C
Ambient humidity	: Normally :75%RH or less
	: Short time 95%RH or less
	(within 1 month)
	(No dew or frost allowed)
Vibration	: 0.5G (4.9m/s2) or less

NOTE

1 Under the installation condition within ( ), the J1 and J2 axis motion range will be limited.

PREFACE	B--81545EN/01

Dust--proof/waterproof performance of M--6i B

Normal specification

Wrist+J3 arm	IP67
Other part	IP54

NOTE

Definition of IP code Definition of IP 67

6=Dust--tight

7=Protection from water immersion Definition of IP 54

5=Dust--protected

4=Protection from splashing water

Performance of resistant chemicals and resistant solvents

(1)(1) The robot (including severe dust/liquid protection model) cannot be used with the following liquids because there is feat that rubber parts (packing, oil seal, O ring etc.) will corrode.

(a)Organic solvcnts

(b)Coolant including chlorine / gasoline

(c)Acid, alkali and liquid causing rust

(d)Other liquids or solutions, that will harm NBR

(2)When the robots work in the environment, using water or liquid, complete draining of J1 base must be done. Incomplete draining of J1 base will make the robot break down.

B--81545EN/01	PREFACE

RELATED MANUALS		For the FANUC Robot series, the following manuals are available:
Safety handbook B--80687EN			Intended readers :
			All persons who use FANUC Robot, system designer
All persons who use the FANUC Robot and system de-			Topics :
signer must read and understand thoroughly this handbook			Safety items for robot system design, operation, maintenance
R--J3i MODEL B controller	Setup and Operations		Intended readers :
	manual		Operator, programmer, maintenance person, system designer
			Topics :
	SPOT TOOL		Robot functions, operations, programming, setup, interfaces, alarms
		B--81464EN--1	Use :
	HANDLING TOOL		Robot operation, teaching, system design
		B--81464EN--2
	ARC TOOL
		B--81464EN--3
	SEALING TOOL
		B--81464EN--4
	Maintenance manual		Intended readers :
		B--81465EN	Maintenance person, system designer
			Topics :
		B--81465EN--1	Installation, connection to peripheral equipment, maintenance
		(European	Use :
		specification)	Installation, start--up, connection, maintenance
Mechanical unit	Maintenance manual		Intended readers :
	FANUC Robot ARC Mate		Maintenance person, system designer
	100i B		Topics :
	M--6i B		Installation, connection to the controller, maintenance
	B--81545EN		Use :
			installation, start--up, connection, maintenance

B--81545EN/01

Table of Contents

I. MAINTENANCE

1. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1	J1--AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4
1.2	J2--AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
1.3	J3--AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
1.4	J4--AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
1.5	J5-- AND J6--AXIS DRIVE MECHANISMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
1.6	SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS . . . . . . . . . . . . . . . . .	9

2. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1	DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
2.2	QUARTERLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14
2.3	YEARLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
2.4	ONE-- AND HALF--YEAR PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
2.5	THREE--YEAR PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
2.6	MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18

3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1 GREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.2 GREASE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3.3 BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

4.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.2 TROUBLES AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.3 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1	REFERENCE POSITION AND MOVING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	33
5.2	SIMPLIFIED MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	37
5.3	MASTERING BY ZERO POSITION MARK ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	39
5.4	JIG--BASED MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41
5.5	CONFIRMING MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
5.6	J5--AXIS GEAR BACKLASH ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	48
5.7	BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	50

6. COMPONENT REPLACEMENT AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.1	REPLACING THE J1--AXIS MOTOR M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	53
6.2	REPLACING THE J1--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	55
6.3	REPLACING THE J2--AXIS MOTOR M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	57
6.4	REPLACING THE J2--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	59
6.5	REPLACING THE J3--AXIS MOTOR M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	62
6.6	REPLACING THE J3--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	64

TABLE OF CONTENTS		B--81545EN/01
6.7	REPLACING THE J4--AXIS MOTOR M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . 66
6.8	REPLACING THE J4--AXIS GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . 67
6.9	REPLACING THE J5--AXIS MOTOR M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . 69
6.10	REPLACING THE J5--AXIS GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . 71
6.11	REPLACING THE J6--AXIS MOTOR M6 AND REDUCER . . . . . . . . . . . . . . . . . . . .	. . . . . . . . 73

7. PIPING AND WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

7.1 PIPING DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 7.2 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 7.3 CABLE MOUNTING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

8. CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

8.1 CABLE DRESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 8.2 REPLACING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

9. COVER OPTION REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

9.1	REPLACING THE J2 COVER OPTION (A05B--1210--J401) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
9.2	REPLACING THE J4 COVER OPTION (A05B--1210--J402) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92
10. M--6i PACKAGES WITH REINFORCED DUST--PROOF AND
DRIP--PROOF CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		93

10.1DUST--PROOF AND DRIP--PROOF PERFORMANCE OF THE PACKAGES WITH

REINFORCED DUST--PROOF AND DRIP--PROOF CHARACTERISTICS . . . . . . . . . . . . . . . . . .

94

10.2CONFIGURATION OF THE PACKAGES WITH REINFORCED DUST--PROOF AND

DRIP--PROOF CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95

10.3CAUTIONS IN SELECTING THE PACKAGES WITH REINFORCED DUST--PROOF

AND DRIP--PROOF CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97

10.4REPLACING THE COMPONENTS OF THE PACKAGES WITH REINFORCED DUST--PROOF

AND DRIP--PROOF CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98

II. CONNECTION

1. ROBOT OUTLINE DRAWING AND OPERATION AREA DIAGRAM . . . . . . . . . . . . . 103

1.1 OUTLINE DRAWING AND OPERATION AREA DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

2. MOUNTING DEVICES ON THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

2.1	WRIST SECTION END EFFECTOR MOUNTING SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . .	108
2.2	DEVICE MOUNTING SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109
2.3	SETTING THE SYSTEM VARIABLES FOR SHORTEST--TIME CONTROL . . . . . . . . . . . . . . .	111
2.4	WRIST LOAD CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	114
2.5	END EFFECTOR AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115
2.6	END EFFECTOR INPUT SIGNALS (RDI/RDO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	116
2.7	CONNECTOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	117

B--81545EN/01	TABLE OF CONTENTS

3. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 3.2 STORING THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 3.3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 3.4 MAINTENANCE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 3.5 ASSEMBLING THE ROBOT FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 3.6 AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 3.7 INSTALLATION CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

APPENDIX

A. SPARE PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 B. INTRA--MECHANICAL UNIT CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . 139 C. PERIODIC INSPECTION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 D. BOLT MOUNTING TORQUE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

I. MAINTENANCE

B--81545EN/01	MAINTENANCE	1. CONFIGURATION

1 CONFIGURATION

Fig. 1 shows the configuration of the mechanical unit.

AC servo motor for J4--axis (M4)

AC servo motor for J3--axis (M3)

AC servo motor for J1--axis (M1)

J3--axis arm

AC servo motor for J5--axis (M5)

AC servo motor for J6--axis (M6)

Wrist unit

J3--axis casing

J2--axis arm

AC servo motor for J2--axis (M2)

J2--axis base

J1--axis base

Fig 1 Mechanical unit configuration

1. CONFIGURATION	MAINTENANCE	B--81545EN/01

1.1

J1--AXIS DRIVE MECHANISM

Fig. 1.1 shows the J1--axis drive mechanism.

The J1--axis drive mechanism is configured in such a way that the J2--axis base is rotated by reducing the rotation speed of an AC servo motor with a reducer.

The J2--axis base is supported on the J1--axis base through the reducer.

J1--axis AC servo motor

J2--axis base

J1--axis reducer

J1--axis base

Fig 1.1 J1--axis drive mechanism

B--81545EN/01	MAINTENANCE	1. CONFIGURATION

1.2

J2--AXIS DRIVE MECHANISM

Fig. 1.2 shows the J2--axis drive mechanism. The J2--axis drive mechanism is configured in such a way that the J2--axis arm is rotated by reducing the rotation speed of an AC servo motor with a reducer.

The J2--axis arm is supported on the J2--axis base through the reducer.

J2--axis AC servo motor	J2--axis arm
J2--axis base
	J2--axis reducer

Fig 1.2 J2--axis drive mechanism

1. CONFIGURATION	MAINTENANCE	B--81545EN/01

1.3

J3--AXIS DRIVE MECHANISM

Fig. 1.3 shows the J3--axis drive mechanism. The J3--axis drive mechanism is configured in such a way that the J3--axis casing is rotated by reducing the rotation speed of an AC servo motor with a reducer.

The J3--axis casing is supported on the J2--axis arm through the reducer.

J3--axis reducer

J3--axis AC servo motor

J3--axis casing

J2--axis arm

Fig 1.3 J3--axis drive mechanism

B--81545EN/01	MAINTENANCE	1. CONFIGURATION

1.4

J4--AXIS DRIVE MECHANISM

Fig. 1.4 shows the J4--axis drive mechanism. The J4--axis drive mechanism is configured in such a way that the J3--axis arm is rotated by reducing the rotation speed of an AC servo motor with a two--stage gear.

J3--axis arm

Final gear

Second gear

J3--axis casing

Input gear

J4--axis AC servo motor

Fig 1.4 J4--axis drive mechanism

1. CONFIGURATION	MAINTENANCE	B--81545EN/01

1.5

J5-- AND J6--AXIS DRIVE MECHANISMS

Fig. 1.5 shows the J5-- and J6--axis drive mechanisms. The J5--axis drive mechanism is configured in such a way that the J6--axis unit is rotated by reducing the rotation speed of an AC servo motor with a three--stage gear. The J6--axis drive mechanism is configured in such a way that the output flange is rotated by reducing the rotation speed of an AC servo motor with a reducer.

J5--axis AC servo motor	J6--axis unit	J6--axis AC servo motor
		Output flange
Input gear
Second gear	Final gear	J6--axis reducer
	Third gear

Fig 1.5 J5-- and J6--axis drive mechanisms

B--81545EN/01	MAINTENANCE	1. CONFIGURATION

1.6

SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS

1)Motors

ARC Mate 100i MODEL B

(two--axis, equipped with a brake): A05B--1215--B201

M--6i MODEL B

(two--axis, equipped with a brake): A05B--1215--B202

Specification	Axis		Remark
A06B-0223-B005	J1	α 4/4000i
A06B-0223-B605	J2	α 4/4000i	Equipped with a brake
A06B-0202-B605	J3	α 1/5000i	Equipped with a brake
A06B-0202-B005	J4	α 1/5000i
A06B-0115-B075#0008	J5	β M0.5/4000
A06B-0114-B075#0008	J6	β M0.4/4000

ARC Mate 100i MODEL B
(six--axis, equipped with a brake): A05B--				1215	--B601
M--6i MODEL B
(six--axis, equipped with a brake): A05B--				1215--	B602
Specification		Axis			Remark
A06B-0223-B605		J1	α 4/4000i		Equipped with a brake
A06B-0223-B605		J2	α 4/4000i		Equipped with a brake
A06B-0202-B605		J3	α 1/5000i		Equipped with a brake
A06B-0202-B605		J4	α 1/5000i		Equipped with a brake
A06B-0115-B275#0008		J5	β M0.5/4000
			Equipped with a brake
A06B-0114-B275#0008		J6	β M0.4/4000
			Equipped with a brake
2) Reducers
Specification		Axis
A97L-0218-0288#33		J1
A97L-0218-0289#153		J2
A97L-0218-0295#161		J3
A97L-0218-0224		J6
3) J4--axis gearbox
Specification		Axis
A05B-1215-K401		J4

1. CONFIGURATION MAINTENANCE B--81545EN/01

4) Gears

	Specification	Axis
	A290-7215-X511	J5
	A290-7215-V501	J5
	A290-7215-V502	J5
	A290-7215-X514	J5

5) Stoppers

	Specification	Axis
	A290-7215-X241	J1	Note) 330° stopper
	A290-7215-X323	J2
	A290-7215-X324	J3

B--81545EN/01	MAINTENANCE	2. PREVENTIVE MAINTENANCE

2 PREVENTIVE MAINTENANCE

Performing daily inspection, periodic inspection, and maintenance can keep the performance of robots in a stable state for a long period.

2. PREVENTIVE MAINTENANCE	MAINTENANCE	B--81545EN/01

2.1

DAILY INSPECTION

Clean and maintain each component of robots during everyday system operations. At the same time, check the components to see if there is a crack or break in them. Also check and maintain the following items as required.

a) Before automatic operation

No.	Inspection item		Inspection procedure
1		Pneumatic pressure	Make a pneumatic pressure
		check	check, using the three--piece
			pneumatic option shown in Fig.
			2.1.
			If the measured pneumatic pres-
			sure does not fall in the range
			between 0.5 and 0.7 MPa (5 and
			7 kg/cm2), make adjustments,
			using the regulator pressure set-
			ting handle.
2		Check on the amount of	Put the pneumatic pressure sys-
		oil mist	tem in operation and check the
	For		amount of oil dripping. If the
	machines		measured amount of oil dripping
	with a		does not meet the rating (one
	three--piece		drop/10 to 20 seconds), make
	pneumatic		adjustments, using the oil ad-
	option		justment knob. The oiler be-
			comes empty after 10 to 20 days
			of normal operation.
3		Check on the amount of	Check to see if the amount of oil
		oil	in the three--piece option is with-
			in the rated level shown in Fig.
			2.1.
4		Check for leakage from	Check to see if a joint or hose
		the piping	leaks.
			If you find a problem, tighten the
			joint or replace any defective
			component.

5Whether cables are abnormal Mechanical unit

6Battery voltage check

See Chapter 8.

Make sure that when the power is turned on, the BLAL alarm has not been raised. If the BLAL alarm has been raised, replace the battery as directed in Section 3.3.

7	Whether there is any abnormal vibra-	Check that each axis is running
	tion, noise, or heat generation in motors	smoothly.
8	Whether there is a change to positioning	Check to see if there is any dis-
	precision	placement from the previous
		position and there are variations
		in the stop position.

B--81545EN/01		MAINTENANCE	2. PREVENTIVE MAINTENANCE
No.		Inspection item		Inspection procedure

9Reliable operation of peripheral equipment

Check to see if the machine operates exactly according to directions from the robot and peripheral equipment.

10 Check on the operation of the J2-- and See Section 4.2. J3--axis brakes.

Oiler’s oil inlet				Oiler adjustment knob
								Check oiler’s oil level

	Oiler
Filter	Pressure gauge
	Regulator pressure setting handle

Fig 2.1 Three--piece pneumatic option

b)After automatic operation

Once you are finished with automatic operation, bring the robot to its reference position, and turn it off.

	No.	Inspection item	Inspection procedure
	1	Component cleaning	Clean and maintain each component. At the
		and inspection	same time, check the components to see if
			there is a crack or break in them.

2. PREVENTIVE MAINTENANCE	MAINTENANCE	B--81545EN/01

2.2

QUARTERLY INSPECTION

Inspect the following items at regular intervals of three months. Increase the locations and the frequency of inspection if the conditions under which the robot is used and the environment in which it runs require so.

	No.	Inspection item	Inspection procedure
	1	Loose connector	Check that the motor connectors or other con-
			nectors are not loose.
	2	Loose bolt	Check that the cover retaining bolts or external
			bolts are not loose.
	3	Debris removal	Remove any spatter, debris, and dust from the
			mechanical unit.

B--81545EN/01	MAINTENANCE	2. PREVENTIVE MAINTENANCE

2.3

YEARLY INSPECTION

Inspect the following item at regular intervals of one year.

	No.	Inspection item	Inspection procedure
	1	Greasing	See Section 3.1.

2. PREVENTIVE MAINTENANCE	MAINTENANCE	B--81545EN/01

2.4

ONE-- AND HALF--YEAR PERIODIC INSPECTION

Perform the following inspection/maintenance item at regular intervals of one year and half.

	No.	Inspection item	Inspection procedure
	1	Battery replacement	Replace the battery in the mechanical unit.
			(See Section 3.3.)

B--81545EN/01	MAINTENANCE	2. PREVENTIVE MAINTENANCE

2.5

THREE--YEAR PERIODIC INSPECTION

	No.	Inspection item	Inspection procedure
	1	Grease replacement	See Section 3.2.

2. PREVENTIVE MAINTENANCE	MAINTENANCE	B--81545EN/01

2.6

MAINTENANCE TOOLS

You should have the following instruments and tools ready for maintenance.

a)	Measuring instruments
	Instrument		Condition			Use
Dial gauge			1/100mm		For positioning precision and backlash
					measurement
Calipers			150mm
b)	Tools
	Phillips screwdrivers			(large, medium, and small sizes)
	Flat--blade screwdrivers			(large, medium, and small sizes)
	Box wrenches			(M3 to M6)
	Allen wrenches			(M3 to M16)
	Torque wrench
	Long T wrenches			(M5 and M6)
	Adjustable wrenches			(medium and small sizes)
	Pliers

Long--nose pliers

Cutting pliers

Both--ended wrench

Grease gun

C--ring pliers

Flashlight

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3 PERIODIC MAINTENANCE

3. PERIODIC MAINTENANCE	MAINTENANCE	B--81545EN/01

3.1

GREASING

When greasing the robot, keep its power turned off.

i)Roughly speaking, replenish the robot with grease once a year.

ii)See Fig. 3.1 and Table 3.1 for greasing points and the method.

Table. 3.1 Greasing points

		Greasing	Specified	Amount	Greasing method
	No.			of
		point	grease	grease
	1	J6--axis	Mori White	40cc	J6--axis grease inlet and out-
		reducer	RE No.00		let, and attach the supplied
			(Specification:		grease nipple to the grease in-
			A97L-0040-0119)		let. After greasing, remove the
					grease nipple, and attach the
					flat--head bolts and sealing
					washers to the grease inlet
					and outlet.

CAUTION

If you grease incorrectly, the pressure in the grease bath may increase steeply, leading to a broken seal, which will eventually cause grease leakage or malfunction.

When greasing, be sure to follow the cautions stated in Section 3.2.

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Grease nipple at the grease inlet for the J3-axis reducer

Seal bolt at the grease outlet for the J1-axis reducer

Grease nipple at the grease inlet for the J4-axis reducer

Low head bolt and seal washer at the grease outlet for the J5-axis reducer

Low head bolt and seal washer at the grease outlet for the J6-axis reducer

Low head bolt and seal washer at the grease outlet for the J4-axis reducer

Low head bolt and

seal washer at the grease outlet for the J6-axis reducer

Low head bolt and seal washer at the grease inlet for the J5-axis reducer

Grease nipple at the grease inlet for the J2-axis reducer

Grease nipple at the grease outlet for the J1-axis reducer

Seal bolt at the grease outlet for the J3-axis reducer

Seal bolt at the grease outlet for the

J2-axis reducer (2 locations)

Fig 3.1 Greasing points

3. PERIODIC MAINTENANCE	MAINTENANCE	B--81545EN/01

3.2

GREASE REPLACEMENT

Follow the procedure stated below to replace the grease in the J1--, J2--, and J3--axis reducers and the J4-- and J5--axis gearboxes once every three years or after 11,520 hours of operation. See Fig. 3.1 for greasing points.

1)Remove the seal bolts from the J1--, J2--, and J3--axis grease outlets shown in Fig. 3.1. Also remove the flat--bolts and sealing washers

from the J4-- and J5--axis grease outlets.

2)Uncap the grease nipples at the J1--, J2--, J3--, and J4--axis grease inlets. Remove the flat--head bolt from the J5--axis grease inlet and attach the supplied grease nipple to the J5--axis grease inlet.

3)Supply the grease specified in Table 3.2 to the J1--, J2--, and J3--axis reducers, and J4-- and J5--axis gearboxes through their respective grease nipples. Keep greasing until the new grease pushes out the old grease and comes out from each grease outlet. Ensure that the amount of the newly supplied grease equals the amount of the drained grease so that the grease bath will not become full.

4)Wind sealing tape around the J1--, J2--, and J3--axis seal bolts you removed, and attach them to the respective grease outlets.

5)Attach the J4-- and J5--axis flat--head bolts and the J4-- and J5--axis sealing washers to the respective grease inlets and outlets.

Table. 3.2 Grease to be replaced at regular intervals of three years

J1--axis reducer

J2--axis reducer

J3--axis reducer

J4--axis gearbox

J5--axis gearbox

Specified grease	Amount of	Robot pos-
	grease to be	ture when
Kyodo Yushi	applied (cc)	greased

Mori White RE No.00 (Specification: A98L-0040-0119#2.4KG)

About 1100	--
About 570	--
About 300	--
About 700	--
About 400	J4=+90°