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FANUC Robot LR Mate 200iC
FANUC Robot ARC Mate 50iC
Mechanical Unit
MAINTENANCE MANUAL
MARMTLR2012071E REV. C
This publication contains proprietary information of FANUC Robotics America, Inc. furnished for customer
use only. No other uses are authorized without the express written permission of
FANUC Robotics America, Inc.
FANUC Robotics America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
B-82585EN/03
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.
Copyrights and Trademarks
This new publication contains proprietary information of FANUC Robotics America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics America, Inc.
The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics America, Inc, hereinafter referred to as FANUC Robotics, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations.
FANUC Robotics manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC Robotics' products and/or systems. Such systems consist of robots, extended axes, robot controllers, application software, the KAREL® programming language, INSIGHT® vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been trained in one or more approved FANUC Robotics Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintain FANUC Robotics' products and/or systems and their respective components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.
WARNING
This equipment generates, uses, and can radiate radiofrequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at the company's world headquarters in Rochester Hills, Michigan. For additional information contact
FANUC Robotics America, Inc. Training Department 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253 www.fanucrobotics.com
For customer assistance, including Technical Support, Service, Parts & Part Repair, and Marketing Requests, contact the Customer Resource Center, 24 hours a day, at 1-800-47-ROBOT (1-800-477-6268). International customers should call 011-1-248-377-7159.
Send your comments and suggestions about this manual to: [email protected]
Copyright ©2010 by FANUC Robotics America, Inc. All Rights Reserved
The information illustrated or contained herein is not to be
reproduced, copied, downloaded, translated into another language, published in any physical or electronic format, including internet, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics America, Inc.
AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®,PalletTool®,
SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® are Registered
Trademarks of FANUC Robotics.
FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names:
AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™, AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™, ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™, ARC Mate System 5™, ARCWorks Pro™, AssistTool™, AutoNormal™, AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™, Center Finder™, Clean Wall™, DualARM™, LR Tool™, MIG Eye™, MotionParts™, MultiARM™, NoBots™, Paint Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks II™, PAINTWorks III™, PalletMate™, PalletMate PC™, PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™, Robo Chop™, Robo Spray™, S-420i™, S-430i™, ShapeGen™, SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3 Controller™, SYSTEM R-J3iB Controller™, SYSTEM R-J3iC Controller™, SYSTEM R-30iA Controller™,TCP Mate™, TorchMate™, TripleARM™, TurboMove™, visLOC™, visPRO-3D™, visTRAC™, WebServer™, WebTP™, and YagTool™.
©FANUC LTD 2010
! No part of this manual may be reproduced in any form.
! All specifications and designs are subject to change without notice.
Patents
One or more of the following U.S. patents might be related to the FANUC Robotics products described in this manual.
FRA Patent List 4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 4,942,539 4,984,745 5,238,029 5,239,739 5,272,805 5,293,107 5,293,911 5,331,264 5,367,944 5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687 5,737,218 5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,726 6,059,092 6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621 6,253,799 6,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143 6,378,190 6,385,508 6,425,177 6,477,913 6,490,369 6,518,980 6,540,104 6,541,757 6,560,513 6,569,258 6,612,449 6,703,079 6,705,361 6,726,773 6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,422 7,399,363
FANUC LTD Patent List
4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207 4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,934,504 4,956,594 4,967,125 4,969,109 4,970,370 4,970,448 4,979,127 5,004,968 5,006,035 5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,107,716 5,111,019 5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360 5,292,066 5,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057 5,329,469 5,333,242 5,337,148 5,371,452 5,375,480 5,418,441 5,432,316 5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,461,478 5,463,297 5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,758 5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194 5,552,687 5,558,196 5,561,742 5,570,187 5,570,190 5,572,103 5,581,167 5,582,750 5,587,635 5,600,759 5,608,299 5,608,618 5,624,588 5,630,955 5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,668,628 5,687,295 5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138 5,742,144 5,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135 5,812,408 5,841,257 5,845,053 5,872,894 5,887,122 5,911,892 5,912,540 5,920,678 5,937,143 5,980,082 5,983,744 5,987,591 5,988,850 6,023,044 6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,693 6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898 6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181 6,236,011 6,236,896 6,250,174 6,278,902 6,279,413 6,285,921 6,298,283 6,321,139 6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,377,869 6,382,012 6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979 6,459,958 6,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588 6,680,461 6,696,810 6,728,417 6,763,284 6,772,493 6,845,296 6,853,881 6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 6,970,802 7,038,165 7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,848 7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294 7,181,313 7,280,687 7,283,661 7,291,806 7,299,713 7,315,650 7,324,873 7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,373,220 7,376,488 7,386,367 7,464,623 7,447,615 7,445,260 7,474,939 7,486,816 7,495,192 7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121
Conventions
WARNING
Information appearing under the "WARNING" caption concerns the protection of personnel. It is boxed and bolded to set it apart from the surrounding text.
CAUTION
Information appearing under the "CAUTION" caption concerns the protection of equipment, software, and data. It is boxed and bolded to set it apart from the surrounding text.
Note Information appearing next to NOTE concerns related information or useful hints.
! Original Instructions
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (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 have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
Safety
i
FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace.
The appropriate level of safety for your application and installation can be best determined by safety system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotics systems.
According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation.
Ensure that the robot being used is appropriate for the application. Robots used in classified (hazardous) locations must be certified for this use.
FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC Robotics training course and become familiar with the proper operation of the system. Persons responsible for programming the system–including the design, implementation, and debugging of application programs–must be familiar with the recommended programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of safety in the workplace.
CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION
Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:
! The safety of people and equipment
! Use of safety enhancing devices
! Techniques for safe teaching and manual operation of the robot(s)
! Techniques for safe automatic operation of the robot(s)
! Regular scheduled inspection of the robot and workcell
! Proper maintenance of the robot
Safety
Keeping People and Equipment Safe
The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following:
! People
! External devices
! Robot(s)
! Tooling
! Workpiece
Using Safety Enhancing Devices
Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices:
! Safety fences, barriers, or chains
! Light curtains
! Interlocks
! Pressure mats
! Floor markings
! Warning lights
! Mechanical stops
! EMERGENCY STOP buttons
! DEADMAN switches
Setting Up a Safe Workcell
A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal, state, and local laws, regulations, and guidelines that pertain to safety.
! Sponsor your personnel for training in approved FANUC Robotics training course(s) related to your application. Never permit untrained personnel to operate the robots.
! Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot.
! Use anti–tie–down logic to prevent the operator from bypassing safety measures.
! Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell.
! Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work envelope is the area defined by the maximum
ii
Safety
motion range of the robot, including any tooling attached to the wrist flange that extend this range.
! Position all controllers outside the robot work envelope.
! Never rely on software or firmware based controllers as the primary safety element unless they comply with applicable current robot safety standards.
! Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell.
! Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the end–use application.
! Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope.
! Install special guarding that prevents the operator from reaching into restricted areas of the work envelope.
! Use interlocks.
! Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety.
! Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot.
! Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electro–magnetic interference (EMI), radio frequency interference (RFI), and electro–static discharge (ESD).
! Make provisions for power lockout/tagout at the controller.
! Eliminate pinch points. Pinch points are areas where personnel could get trapped between a moving robot and other equipment.
! Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely.
! Program the robot to load and unload material safely.
! If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons.
! If materials are being applied at dangerously high pressure, provide electrical interlocks for lockout of material flow and pressure.
Staying Safe While Teaching or Manually Operating the Robot
Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules:
! Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.
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Safety
! Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment.
! Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range.
! The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department.
! FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope.
WARNING
Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.
! Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked.
! Isolate the robot from all remote control signals that can cause motion while data is being taught.
! Test any program being run for the first time in the following manner:
WARNING
Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury.
! Using a low motion speed, single step the program for at least one full cycle.
! Using a low motion speed, test run the program continuously for at least one full cycle.
! Using the programmed speed, test run the program continuously for at least one full cycle.
! Make sure all personnel are outside the work envelope before running production.
iv
Safety
Staying Safe During Automatic Operation
Advise all personnel who operate the robot during production to observe the following rules:
! Make sure all safety provisions are present and active.
! Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external devices and other equipment with which the robot interacts.
! Understand the complete task the robot is programmed to perform before initiating automatic operation.
! Make sure all personnel are outside the work envelope before operating the robot.
! Never enter or allow others to enter the work envelope during automatic operation of the robot.
! Know the location and status of all switches, sensors, and control signals that could cause the robot to move.
! Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared to press these buttons in an emergency.
! Never assume that a program is complete if the robot is not moving. The robot could be waiting for an input signal that will permit it to continue its activity.
! If the robot is running in a pattern, do not assume it will continue to run in the same pattern.
! Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.
Staying Safe During Inspection
When inspecting the robot, be sure to
! Turn off power at the controller.
! Lock out and tag out the power source at the controller according to the policies of your plant.
! Turn off the compressed air source and relieve the air pressure.
! If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel.
! Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.
! If power is needed to check the robot motion or electrical circuits, be prepared to press the EMERGENCY STOP button, in an emergency.
! Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
v
Safety
Staying Safe During Maintenance
When performing maintenance on your robot system, observe the following rules:
! Never enter the work envelope while the robot or a program is in operation.
! Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist.
! Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.
! Consider all or any overlapping work envelopes of adjoining robots when standing in a work envelope.
! Test the teach pendant for proper operation before entering the work envelope.
! If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately.
! Whenever possible, perform maintenance with the power turned off. Before you open the controller front panel or enter the work envelope, turn off and lock out the 3–phase power source at the controller.
! Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
! Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
WARNING
Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only.
! Release or block all stored energy. Before working on the pneumatic system, shut off the system air supply and purge the air lines.
! Isolate the robot from all remote control signals. If maintenance must be done when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this person.
! Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked.
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Safety
! Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel.
WARNING
Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction.
! Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
! When replacing or installing components, make sure dirt and debris do not enter the system.
! Use only specified parts for replacement. To avoid fires and damage to parts in the controller, never use nonspecified fuses.
! Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices are operating normally.
KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE
Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices.
Programming Safety Precautions
Implement the following programming safety measures to prevent damage to machine tools and other external devices.
! Back–check limit switches in the workcell to make sure they do not fail.
! Implement ‘‘failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails.
! Use handshaking protocol to synchronize robot and external device operations.
! Program the robot to check the condition of all external devices during an operating cycle.
Mechanical Safety Precautions
Implement the following mechanical safety measures to prevent damage to machine tools and other external devices.
! Make sure the workcell is clean and free of oil, water, and debris.
! Use software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.
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Safety
KEEPING THE ROBOT SAFE
Observe the following operating and programming guidelines to prevent damage to the robot.
Operating Safety Precautions
The following measures are designed to prevent damage to the robot during operation.
! Use a low override speed to increase your control over the robot when jogging the robot.
! Visualize the movement the robot will make before you press the jog keys on the teach pendant.
! Make sure the work envelope is clean and free of oil, water, or debris.
! Use circuit breakers to guard against electrical overload.
Programming Safety Precautions
The following safety measures are designed to prevent damage to the robot during programming:
! Establish interference zones to prevent collisions when two or more robots share a work area.
! Make sure that the program ends with the robot near or at the home position.
! Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage.
! In dispensing applications, be aware of all safety guidelines with respect to the dispensing materials.
NOTE: Any deviation from the methods and safety practices described in this manual must conform to the approved standards of your company. If you have questions, see your supervisor.
ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS
Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personnel also must work inside the paint booth periodically.
Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.
Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand
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Safety
the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools.
CAUTION
Ensure that all ground cables remain connected. Never operate the paint robot with ground provisions disconnected. Otherwise, you could injure personnel or damage equipment.
Paint robots are operated in three modes:
! Teach or manual mode
! Automatic mode, including automatic and exercise operation
! Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant.
In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe area within the booth whenever automatic mode is initiated at the SOC or MCP.
In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.
Paint System Safety Features
Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals.
This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system.
The paint system includes the following safety features:
! Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are.
! Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are.
! EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E–STOP buttons.
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Safety
! An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres.
! A DEADMAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN switch is released or pressed harder during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also E–STOP other robots.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed robot.
! Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. Limit switches and hardstops also limit travel by the major axes.
! EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SOC is in teach mode.
! When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings.
! System status is monitored by computer. Severe conditions result in automatic system shutdown.
Staying Safe While Operating the Paint Robot
When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.
WARNING
Observe all safety rules and guidelines to avoid injury.
WARNING
Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.
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Safety
WARNING
Enclosures shall not be opened unless the area is known to be nonhazardous or all power has been removed from devices within the enclosure. Power shall not be restored after the enclosure has been opened until all combustible dusts have been removed from the interior of the enclosure and the enclosure purged. Refer to the Purge chapter for the required purge time.
! Know the work area of the entire paint station (workcell).
! Know the work envelope of the robot and hood/deck and door opening devices.
! Be aware of overlapping work envelopes of adjacent robots.
! Know where all red, mushroom–shaped EMERGENCY STOP buttons are located.
! Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move.
! Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor.
! Become familiar with the complete task the robot will perform BEFORE starting automatic mode.
! Make sure all personnel are outside the paint booth before you turn on power to the robot servo system.
! Never enter the work envelope or paint booth before you turn off power to the robot servo system.
! Never enter the work envelope during automatic operation unless a safe area has been designated.
! Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.
! Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic devices are enabled.
! Stay out of areas where you might get trapped between a moving robot, conveyor, or opening device and another object.
! Be aware of signals and/or operations that could result in the triggering of guns or bells.
! Be aware of all safety precautions when dispensing of paint is required.
! Follow the procedures described in this manual.
Special Precautions for Combustible Dusts (Powder Paint)
When the robot is used in a location where combustible dusts are found, such as the application of powder paint, the following special precautions are required to insure that there are no combustible dusts inside the robot.
! Purge maintenance air should be maintained at all times, even when the robot power is off. This will insure that dust can not enter the robot.
xi
Safety
! posednot present, it will be necessary to remove the covers
f the
h water are acceptable. Do not use a vacuum cleaner to special
can
Stayin
hen you work with paint application equipment, observe the following rules, in o all rules for safe operation that apply to all robot systems.
A purge cycle will not remove accumulated dusts. Therefore, if the robot is exto dust when maintenance air is and clean out any accumulated dust. Do not energize the robot until you have performed the following steps.
! Before covers are removed, the exterior of the robot should be cleaned to remove accumulated dust.
! When cleaning and removing accumulated dust, either on the outside or inside orobot, be sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened witremove dust as it can generate static electricity and cause an explosion unlessprecautions are taken.
! Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust.
! When the dust has been removed, the covers must be replaced immediately.
! Immediately after the covers are replaced, run a complete purge cycle. The robotnow be energized.
g Safe While Operating Paint Application Equipment
Waddition t
WARNING
When working with electrostatic paint equipment, follow all national and local codesas well as all safety guidelines within your organization. Also reference the following s nCombustib
ta dards: NFPA 33 Standards for Spray Application Using Flammable or le Materials, and NFPA 70 National Electrical Code.
!
pots, as well as solvent containers. Grounding is defined as the object e than
! e on during actual spray operations. r leave high
tter.
nufacturer recommended cleaning procedures.
eration of A 33 Standard for Spray Application Using
Disable all air and paint pressure to bell.
! Verify that the lines are not under pressure.
Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressureor objects shall be electrically connected to ground with a resistance of not mor1 megohms.
High Voltage: High voltage should only bVoltage should be off when the painting process is completed. Nevevoltage on during a cap cleaning process.
a! Avoid any accumulation of combustible vapors or coating m
! Follow all ma
! Make sure all interlocks are operational.
! No smoking.
! Post all warning signs regarding the electrostatic equipment and opelectrostatic equipment according to NFPFlammable or Combustible Material.
!
xii
Safety
xiii
Stayin
d,
!
!
the robot
isconnect before you clean the robot.
uld cause drowsiness or
rer’s Material Safety Data Sheets.
.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheet
g Safe During Maintenance
When you perform maintenance on the painter system, observe the following rules, an oall ther maintenance safety rules that apply to all robot installations. Only qualified
trained service or maintenance personnel should perform repair work on a robot.
! Paint robots operate in a potentially explosive environment. Use caution when working with electric tools.
When a maintenance technician is repairing or adjusting a robot, the work area isunder the control of that technician. All personnel not participating in the maintenance must stay out of the area.
For some maintenance procedures, station a second person at the control panel within reach of the EMERGENCY STOP button. This person must understandand associated potential hazards.
! Be sure all covers and inspection plates are in good repair and in place.
! Always return the robot to the ‘‘home’’ position before you disarm it.
! Never use machine power to aid in removing any component from the robot.
! During robot operations, be aware of the robot’s movements. Excess vibration, unusual sounds, and so forth, can alert you to potential problems.
! Whenever possible, turn off the main electrical d
! When using vinyl resin observe the following:
- Wear eye protection and protective gloves during application and removal.
- Adequate ventilation is required. Overexposure coskin and eye irritation.
- If there is contact with the skin, wash with water.
- Follow the Original Equipment Manufactu
! When using paint remover observe the following:
- Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.
- Adequate ventilation is required. Overexposure could cause drowsiness
- If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then seek medical attention as soon as possible.
B-82585EN/03 SAFETY PRECAUTIONS
s-1
1 SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell. In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1.1 WORKING PERSON
The personnel can be classified as follows.
Operator:! Power ON/OFF for robot controller
! Start of robot program with operator’s panel Programmer or teaching operator: ! Operate for Robot
! Teaching inside safety fence Maintenance engineer: ! Operate for Robot
! Teaching inside safety fence
! Maintenance (adjustment, replacement)
- An operator cannot work inside the safety fence. - A programmer, Teaching operator and maintenance engineer can work inside the safety fence. The
workings inside safety fence are lifting, setting, teaching, adjusting, maintenance, etc. - To work inside the fence, the person must be trained for the robot.
Table 1 lists the workings of outside the fence. In this table, the symbol “!“ means the working allowed to be carried out by the personnel.
In operating, programming and maintenance, the programmer, teaching operator and maintenance engineer take care of their safety using the following safety protectors, for example.
! Use adequate clothes, uniform, overall for operation
! Put on the safety shoes
! Use helmet
1.2 WORKING PERSON SAFETY
Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety.
(1) Have the robot system working person attend the training courses held by FANUC.
FANUC provides various training courses. Contact our sales office for details.
(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working
SAFETY PRECAUTIONS B-82585EN/03
s-2
person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.
(3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened.
The controller is designed to receive this interlocking device of the door switch. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.2 (a),(b).
(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when a working person enters the work area.
(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.
(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.
!"#"$%"&&'($)"&*(+#,'
-.!/0
1&$'2,"(3*4'5)('*+&4*6+7'$8*9,:;*$<+$*+2'*+($)5+$'4)7*$<'*;+$'*)6*"9'&'4=
Fig.1.2 Safety fence and safety gate
B-82585EN/03 SAFETY PRECAUTIONS
s-3
>+&',*#"+24
*-.?@
*-.?@@
*-.?A
*-.?A@
>+&',*#"+24
*B-C%-@
*B-C%-A
D:+,*(<+)&
?)&;,'*(<+)&
EC"$'F/'2G)&+,6*-.?@H-.?@@H-.?AH-.?A@*"2*B-C%-@HB-C%-A+2'*92"5)4'4*"&*$<'*"9'2+$)"&*#"I*"2*"&*$<'*$'2G)&+,*#,"(3"7*$<'*92)&$'4*()2(:)$*#"+24=!'7'2*$"*("&$2",,'2*G+)&$'&+&('*G+&:+,*7"2*4'$+),6=
Single chain is in case of standard controller. Dual chain is in case of Open air controller.
NOTE Please drop the power supply of the robot control system at once when the
worker is placed by the robot by any chance or it is confined, push the robot arm directly, change posture, and liberate the worker.
1.2.1 Operator Safety
The operator is a person who operates the robot system. In this sense, a worker who operates power on/off of the robot system or the teach pendant is also a operator. The operator can’t operate inside a safety fence. (1) Operate the robot system at a location outside of the safety fence. (2) If it is not necessary for the robot to operate, turn off the power of the robot controller or press the
EMERGENCY STOP button, and then proceed with necessary work. (3) Install an EMERGENCY STOP button within the general person’s reach.
The robot controller is designed to be able to connect to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.
SAFETY PRECAUTIONS B-82585EN/03
s-4
D:+,*(<+)&
?)&;,'*(<+)&
EC"$'F%"&&'($"*--?@+&4*--?@@H--?A*+&4*--?A@*"2*-JK1C@+&4*-JK1CA=
1&*(+6'*"7*!LMN).--?@H--?@@H--?AH--?A@*"2*-JK1C@H-JK1CA*+2'*"&*$<'*9+&',*#"+24=
1&*(+6'*"7*!LMN).*J+$'--?@H--?@@H--?AH--?A@O+2'*"&*$<'*'G'2;'&(8*6$"9*#"+24*"2*("&&'($"29+&',*P)&*(+6'*"7*Q9'&*+)2*$89'RH=-JK1C@H-JK1CAO+2'*"&*$<'*'G'2;'&(8*6$"9*#"+24=
!'7'2*$"*$<'*G+)&$'&+&('*G+&:+,*"7*$<'*("&$2",,'2*7"2*4'$+),6=
-I$'2&+,*6$"9*#:$$"&
>+&',*#"+24
*-JK1C@
*-JK1CA
>+&',*#"+24
*--?@
*--?@@
*--?A
*--?A@
-I$'2&+,*6$"9*#:$$"&
Fig.1.2.1 Circuit diagram for external emergency stop button
Single chain is in case of standard controller. Dual chain is in case of Open air controller.
1.2.2 Safety of the Teaching Operator
While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teaching operator.
(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal
operating condition. (3) When entering the robot work area and teaching the robot, be sure to check the location and
condition of the safety devices (such as the EMERGENCY STOP button and the DEADMAN switch on the teach pendant).
(4) The teaching operator should pay careful attention so that no other workers enter the robot work area.
B-82585EN/03 SAFETY PRECAUTIONS
s-5
Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button.These button and switch function as follows: (1) Emergency stop button: Causes an emergency stop when pressed. (2) DEADMAN switch: Functions differently depending on the mode switch setting status.
(a) When the switch is set to the enable position: An emergency stop is made by releasing the DEADMAN switch.
(b) When the switch is set to the disable position: The DEADMAN switch is disabled.
The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot can operate in such conditions and be responsible in carrying out tasks safely.
The teach pendant and peripheral device interface each send a robot start signal. However, the validity of each signal changes depending on the teach pendant enable switch and the remote condition of the software.
Table 1.2.2(a) STANDARD
Teach pendant enable
switch
Software remote
condition Teach pendant Peripheral device
On Ignored Allowed to start Not allowed
Local Not allowed Not allowed Off
Remote Not allowed Allowed to start
Table 1.2.2(b) CE/RIA
Mode Teach pendant
enable switch
Software remote
condition Teach pendant Operator panel Peripheral device
Local Not allowed Not allowed Not allowed On
Remote Not allowed Not allowed Not allowed
Local Not allowed Allowed to start Not allowed AUTO mode
OffRemote Not allowed Not allowed Allowed to start
Local Allowed to start Not allowed Not allowed On
Remote Allowed to start Not allowed Not allowed
Local Not allowed Not allowed Not allowed T1, T2 mode
OffRemote Not allowed Not allowed Not allowed
(5) (When CE or RIA specification is selected.) To start the system using the operator’s panel, make certain that nobody is the robot work area and that there are no abnormal conditions in the robot work area.
(6) When a program is completed, be sure to carry out a test run according to the procedure below. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low
speed.(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test run above, execute it in the
automatic operation mode. (7) While operating the system in the automatic operation mode, the teaching operator should leave the
robot work area.
SAFETY PRECAUTIONS B-82585EN/03
s-6
1.2.3 Safety During Maintenance
For the safety of maintenance personnel, pay utmost attention to the following.
(1) During operation, never enter the robot work area. (2) Except when specifically necessary, turn off the power of the controller while carrying out
maintenance. Lock the power switch, if necessary, so that no other person can turn it on. (3) If it becomes necessary to enter the robot operation range while the power is on, press the
emergency stop button on the operator panel, or the teach pendant before entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly.
(4) When disconnecting the pneumatic system, be sure to reduce the supply pressure. (5) Before the start of teaching, check that the robot and its peripheral devices are all in the normal
operating condition. (6) Do not operate the robot in the automatic mode while anybody is in the robot work area. (7) When you maintain the robot alongside a wall or instrument, or when multiple workers are working
nearby, make certain that their escape path is not obstructed. (8) When a tool is mounted on the robot, or when any moving device other than the robot is installed,
such as belt conveyor, pay careful attention to its motion. (9) If necessary, have trained worker who knows the robot system well stand beside the operator panel,
and observe the operation. In case any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time.
(10) During replacing or reinstalling components, Take care not to let foreign matter enter the system. (11) When handling each unit or printed circuit board in the controller during inspection, turn off the
circuit breaker to protect against electric shock. (12) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or
result in damage to the components in the controller. (13) When restarting the robot system after completing maintenance work, make sure in advance that
there is no person in the work area and that the robot and the peripheral devices are not abnormal.
1.3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES
1.3.1 Precautions in Programming
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can stop them according to the their states.
1.3.2 Precautions for Mechanism
(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust.
(2) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does not strike against its peripheral devices or tools.
(3) Observe the following precautions about the mechanical unit cables. When theses attentions are not kept, unexpected troubles might occur.
! Use mechanical unit cable that have required user interface.
B-82585EN/03 SAFETY PRECAUTIONS
s-7
! Don"t add user cable or hose to inside of mechanical unit.
! Please do not obstruct the movement of the mechanical unit cable when cables are added to outside
of mechanical unit.
! In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a
protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable.
! Please do not interfere with the other parts of mechanical unit when install equipments in the robot.
1.4 SAFETY OF THE ROBOT MECHANISM
1.4.1 Precautions in Operation
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.
1.4.2 Precautions in Programming
(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other.
(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.
1.4.3 Precautions for Mechanisms
(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water, and dust.
1.5 SAFETY OF THE END EFFECTOR
1.5.1 Precautions in Programming
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.
SAFETY PRECAUTIONS B-82585EN/03
s-8
1.6 WARNING LABEL
(1) Transportation attention label 1
500kg
80kg!4
100kg!4
Fig. 1.6 (a) Transportation attention label 1
Description1) Use a crane having a load capacity of 500 kg or greater. 2) Use at least four slings each having a withstand load of 980 N (100 kgf) or greater. 3) Use at least four eyebolts each having a withstand load of 784 N (80 kgf) or greater.
(2) Transportation attention label 2
ST
UVWXYZ[\]^_`ab
UVWXYZc^defghijab
%.k/1QC
DQ*CQ/*>kll*-mnQl/??1D-o.m?=
!-JQp-*-m-nQl/?Hn-BQ!-*k?-
Fig.1.6 (b) Transportation attention label 2
B-82585EN/03 SAFETY PRECAUTIONS
s-9
DescriptionKeep the following in mind about eyebolt.
1) Don’t pull eyebolt side ways. 2) Remove eyebolt before use.
(3) Greasing attention label (When grease applying kit: A05B-1139-K021 is specified.)
ST
qrstuvrwZxyjzu{|}~Z���vrwZ�fe�^d��`�
~�s��}ZA=�GG�ib@((�vrw���i�
��.�1? ����.JQkC/
vrw����./*K!-?1CK
Please knead a tube and makegrease soft before supply greaseto cylinder.
When you give a plunger 2.5mmpush, 1cc grease is injected.
�
�
�
�
J1J2J3J4J5J6
M((P�GGR
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A((P�GGR
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.M�NLMNM@LN@MN
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Fig.1.6 (c) Greasing attention label
DescriptionKeep the following in mind about grease applying kit.
1) Please knead a tube and make grease soft before supply grease to cylinder. 2) When you give a plunger 2.5mm push, 1ml grease is injected.
(4) Range of motion and payload mark label
Below label is added when CE specification is specified.
SAFETY PRECAUTIONS B-82585EN/03
s-10
0deg -180deg+180deg
J5-AXISROTATION CENTER
MOTION RANGEOF J5-AXISROTATION CENTER
STANDARDLONG ARM
959 228 704 5131147 393 892 742
MAX.PAYLOAD:5kg
UNIT:mm
AB
C D
A B C D
Fig.1.6 (d) Range of motion and payload mark label
B-82585EN/03 PREFACE
p-1
PREFACE
This manual explains maintenance procedures for the mechanical units of the following robots:
Model name Mechanical unit
specification No.
Maximum
loadRemarks
FANUC Robot LR Mate 200iC A05B-1139-B2013-axes brake type Non-severe dust/liquid protection specification
FANUC Robot LR Mate 200iC A05B-1139-B2026-axes brake type Non-severe dust/liquid protection specification
FANUC Robot LR Mate 200iC A05B-1139-B2033-axes brake type severe dust/liquid protection specification
FANUC Robot LR Mate 200iC A05B-1139-B2046-axes brake type severe dust/liquid protection specification
A05B-1139-B2116-axes brake type Non-severe dust/liquid protection specification
FANUC Robot LR Mate 200iC/5L
A05B-1139-B2126-axes brake type severe dust/liquid protection specification
A05B-1139-B2136-axes brake type Clean class 100 (ISO class 5)
specificationFANUC Robot LR Mate 200iC/5LC
A05B-1139-B2146-axes brake type Clean class 10 (ISO class 4)
specification
A05B-1139-B2216-axes brake type Clean class 100 (ISO class 5) specification
FANUC Robot LR Mate 200iC/5C
A05B-1139-B2226-axes brake type Clean class 10 (ISO class 4) specification
FANUC Robot LR Mate 200iC/5WP A05B-1139-B2316-axes brake type Washing specification
A05B-1139-B1013-axes brake type Non-severe dust/liquid protection specification
A05B-1139-B102
5-axes brake type Non-severe dust/liquid protection specification
A05B-1139-B1033-axes brake type severe dust/liquid protection specification
A05B-1139-B1045-axes brake type severe dust/liquid protection specification
A05B-1139-B107
3-axes brake type Non-severe dust/liquid protection specification!(High spped wrist)
A05B-1139-B108
5-axes brake type Non-severe dust/liquid protection specification!(High spped wrist)
FANUC Robot LR Mate 200iC/5H
A05B-1139-B109
5kg
3-axes brake type severe dust/liquid protection specification!(High spped wrist)
PREFACE B-82585EN/03
p-2
Model name Mechanical unit
specification No.
Maximum
loadRemarks
FANUC Robot LR Mate 200iC/5H A05B-1139-B110
5-axes brake type severe dust/liquid protection specification!(High spped wrist)
A05B-1139-B1053-axes brake type (2nd food specification)
FANUC Robot LR Mate 200iC/5F
A05B-1139-B1065-axes brake type (2nd food specification)
A05B-1139-B2513-axes brake type Non-severe dust/liquid protection specification
A05B-1139-B2526-axes brake type Non-severe dust/liquid protection specification
A05B-1139-B2533-axes brake type severe dust/liquid protection specification
FANUC Robot ARC Mate 50iC
A05B-1139-B2546-axes brake type severe dust/liquid protection specification
A05B-1139-B2616-axes brake type Non-severe dust/liquid protection specification
FANUC Robot ARC Mate 50iC/5L
A05B-1139-B2626-axes brake type severe dust/liquid protection specification
NOTE The following abbreviations are used herein. STANDARD : LR Mate 200iC, ARC Mate 50iC 5L : LR Mate 200iC/5L, ARC Mate 50iC/5L 5LC : LR Mate 200iC/5LC 5C : LR Mate 200iC/5C 5WP : LR Mate 200iC/5WP 5H : LR Mate 200iC/5H 5F : LR Mate 200iC/5F
The label stating the mechanical unit specification number is affixed in the position shown below. Before reading this manual, determine the specification number of the mechanical unit.
OSHINO-MURA.YAMANASHI PREF.JAPAN
(3)
(2)
(4)
(1)
WEIGHT‚‹‚‡(5)
TYPENO.DATE
Position of label indicating mechanical unit specification number
B-82585EN/03 PREFACE
p-3
TABLE 1"
(1) (2) (3) (4) (5)
CONTENTS - TYPE No. DATE WEIGHT
(Without controller)
A05B-1139-B201
A05B-1139-B202
A05B-1139-B203
FANUC Robot
LR Mate 200iC
A05B-1139-B204
27kg
A05B-1139-B211FANUC Robot LR
Mate 200iC/5L A05B-1139-B212
A05B-1139-B213FANUC Robot LR
Mate 200iC/5LC A05B-1139-B214
29kg
A05B-1139-B221FANUC Robot LR
Mate 200iC/5C A05B-1139-B222
FANUC Robot LR
Mate 200iC/5WPA05B-1139-B231
27kg
A05B-1139-B101
A05B-1139-B102
A05B-1139-B103
A05B-1139-B104
A05B-1139-B107
A05B-1139-B108
A05B-1139-B109
FANUC Robot
LR Mate 200iC/5H
A05B-1139-B110
A05B-1139-B105FANUC Robot
LR Mate 200iC/5F A05B-1139-B106
26kg
A05B-1139-B251
A05B-1139-B252
A05B-1139-B253ARC Mate 50iC
A05B-1139-B254
27kg
A05B-1139-B261
LETTERS
ARC Mate 50iC/5LA05B-1139-B262
SERIAL NO.
PRODUCTION
YEAR AND
MONTH
29kg
Positon of label indicating mechanical unit specification number
PREFACE B-82585EN/03
p-4
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 :
All persons who use FANUC Robot, system designer
Topics :
Safety items for robot system design, operation, maintenance
R-30iA Mate
controller
Operations manual
LR HANDLING TOOL
B-82724EN-1
ALARM CODE LIST
B-82594EN-6
ALARM CODE LIST
(for series 7DA4/7DA5)
B-83124EN-6
Intended readers :
Operator, programmer, maintenance person, system designer
Topics :
Robot functions, operations, programming, setup, interfaces, alarms
Use :
Robot operation, teaching, system design
Maintenancemanual
Standard:
B-82725EN
B-82725EN-1
(For Europe)
B-82725EN-2
(For RIA)
Open air type:
B-82965EN
B-82965EN-1
(For Europe and RIA )
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to peripheral equipment, maintenance
Use :
Installation, start-up, connection, maintenance
Mechanical
unit
Operator’s manual
FANUC Robot
LR Mate 200iCB-82584EN
Intended readers:
System designer, Maintenance person
Topics:
Installation, connection to controller, maintenance
Use:
Installation, start-up, connection, maintenance
B-82585EN/03 TABLE OF CONTENTS
c - 1
TABLE OF CONTENTS
1 SAFETY PRECAUTIONS.....................................................................s-1
PREFACE....................................................................................................p-1
1 CHECKS AND MAINTENANCE .............................................................1 1.1 DAILY CHECKS ............................................................................................ 1
1.2 FIRST 1-MONTH (320 hours operating) CHECK .......................................... 3
1.3 FIRST 3-MONTH (960 hours) CHECKS........................................................ 3
1.4 3-MONTH (960 hours) CHECKS ................................................................... 5
1.5 1-YEAR (3,840 hours) CHECKS.................................................................... 5
1.6 1.5-YEAR (5,760 hours) CHECKS................................................................. 5 1.7 2-YEAR (7,680 hours) CHECKS (LR Mate 200iC /5WP,5F) 4-YEAR (15,360
hours) CHECKS (LR Mate 200iC, LR Mate 200iC/5L , /5C, /5LC, /5H) ........ 6
1.8 MAINTENANCE TOOLS ............................................................................... 6
2 PERIODIC MAINTENANCE....................................................................8 2.1 REPLACING THE BATTERIES
(1-YEAR CHECKS (battery built-in type))
(1.5-YEAR CHECKS (external battery type))................................................. 8
2.2 REPLENISH THE GREASE OF THE DRIVE MECHANISM
(4 years (11,520 hours) checks) .................................................................. 10 2.2.1 Grease supply procedure of the J1-axis reducer.....................................................12 2.2.2 Grease supply procedure of the J2-axis reducer.....................................................13 2.2.3 Grease supply procedure of the J3-axis reducer.....................................................14 2.2.4 Grease supply procedure of the J4-axis reducer.....................................................15 2.2.5 Grease supply procedure of the J5/J6-axis reducer ................................................16
3 TROUBLESHOOTING ..........................................................................17 3.1 OVERVIEW ................................................................................................. 17
3.2 FAILURES, CAUSES AND MEASURES..................................................... 17
3.3 BACKLASH MEASUREMENT..................................................................... 23
4 REPLACING PARTS ............................................................................27 4.1 FIGURE OF DRIVE MECHANISM .............................................................. 28
4.2 REPLACING J1-AXIS MOTOR.................................................................... 30
4.3 REPLACING J1-AXIS REDUCER ............................................................... 32
4.4 REPLACING J2-AXIS MOTOR.................................................................... 37
4.5 REPLACING J2-AXIS REDUCER ............................................................... 40
4.6 REPLACING J3-AXIS MOTOR.................................................................... 45
4.7 REPLACING J3-AXIS REDUCER ............................................................... 47
4.8 REPLACING J4-AXIS MOTOR.................................................................... 49
4.9 REPLACING J4-AXIS REDUCER ............................................................... 51
4.10 REPLACING J5-AXIS MOTOR.................................................................... 54
4.11 REPLACING J5-AXIS REDUCER ............................................................... 56
4.12 REPLACING J6-AXIS MOTOR.................................................................... 59
4.13 REPLACING WRIST UNIT .......................................................................... 61
TABLE OF CONTENTS B-82585EN/03
c - 2
4.14 REPLACING J6-AXIS REDUCER ............................................................... 63
4.15 REPLACING J3 BELT ................................................................................. 65
4.16 REPLACING J5/J6 BELT ............................................................................ 66
4.17 REPLACING SOLENOID VALVE................................................................ 68
4.18 SEALANT APPLICATION............................................................................ 70
5 REPLACING CABLES..........................................................................71 5.1 CABLE WIRING........................................................................................... 71
5.2 CABLE FORMING....................................................................................... 73
5.3 CABLE AND AIR TUBE REPLACEMENT ................................................... 76 5.3.1 Replacing Cable K101 and Air tube (Connector plate to J2 base) .........................76 5.3.2 Replacing Cable K106, K107, K108 and Air tube (J2 base to J3 casing)..............82 5.3.3 Replacing Cable K102, K103, K104, K105, K109, K110, K111, K112, K113.....88 5.3.4 Replacing Cable K104............................................................................................89 5.3.5 Replacing Air Tube ................................................................................................89
6 ADJUSTMENTS....................................................................................97 6.1 ADJUSTING TENSION OF BELT................................................................ 97
6.2 MASTERING ............................................................................................... 98 6.2.1 Resetting Alarms and Preparing for Mastering ....................................................100 6.2.2 Fixture Position Master ........................................................................................100
6.3 CHECKING THE MASTERING ................................................................. 105
APPENDIX
A SPARE PARTS LIST ..........................................................................109
B CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM .............................116
C PERIODIC MAINTENANCE TABLE ...................................................134
D MOUNTING BOLT TORQUE LIST .....................................................142
E INSULATION ABOUT ARC WELDING ROBOT.................................143 E.1 ABSTRACT................................................................................................ 143
E.2 INSULATION AT THE WRIST................................................................... 143
B-82585EN/03 1.CHECKS AND MAINTENANCE
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1 CHECKS AND MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter.
(See the APPENDIX A 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. When using the robot beyond this total operating time, correct the maintenance frequencies shown in this chapter by calculation in proportion to the difference between the actual operating time and 3840 hours/year.!
1.1 DAILY CHECKS
Clean each part, and visually check component parts for damage before daily system operation. Check the
following items as the occasion demands.
(1) Before turning on power
Item Check items Check points
1 Air pressure Check air pressure using the pressure gauge on the air
regulator as shown in Fig.1.1.If it does not meet the
specified pressure of 0.49MPa (5 kg/cm2), adjust it using the
regulator pressure setting handle.
2 Leakage from hose Check the joints, tubes, etc. for leaks.
Repair leaks, or replace parts, as required.
3
When air control set is
provided.
Drain Check drain and release it. When quantity of the drain is
remarkable, examine the setting of the air dryer to the air
supply side.
4
Supply pressure
Check the supply pressure using the air purge kit shown in Fig.1.1 (b). If it does not meet the specified pressure of 10 KPa (0.1
kgf/cm2), adjust it using the regulator pressure setting
handle.
5 Dryer Check whether the color of the dew point checker is blue. When it is not blue, identify the cause and replace the dryer. Maintenance for air purge kit, refer to the operator’s
manual attached kit.
6
When air purge kit is provided.
Drain Check drain, When quantity of the drain is remarkable, examine the setting of the air dryer to the air supply side.
7 Vibration, abnormal noises and motor
heating
Check whether each axis moves smoothly
8 Changing repeatability Check whether the stop positions of the robot have not
deviated from the previous stop positions.
9 Peripheral devices for proper operation Check whether the peripheral devices operate properly
according to commands from robot.
10 Each axis brake Refer to 3.2.
11 Cleaning and checking each part Clean each part (remove chips, etc.) and check component
parts for cracks and flaws. (NOTE 1)
1.CHECKS AND MAINTENANCE B-82585EN/03
- 2 -
Pressure gauge
Pressure
Adjusting Knob
Rc1/4
AIR SUPPLY
Rc1/4 AIR OUTLET
2-6.5!16.5
Length round hole
Fig.1.1 (a) Air control set
!
"
!
"
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1234556#-'+7&"/%-)&7/8#
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Fig.1.1 (b) Air purge kit (option)
(2) After turning on power
Item Check items Check points
1
Vibration, abnormal noises, and
motor heating
Check whether the robot moves along and about the axes smoothly
without unusual vibration or sounds. Also, check whether the
temperatures of the motors are excessively high.
2Changing repeatability Check to see that the stop positions of the robot have not deviated
from the previous stop positions.
3Peripheral devices for proper
operation
Check whether the peripheral devices operate properly according to
commands from the robot.
4 Brakes for each axis Check that the end effector drops within 2 mm when the power is cut.
(Note 1) Cleaning
- Necessary cleaning points, dust on the flat part, sedimentation of spatters
Clean sediments periodically.
In particular, clean the following points carefully.
B-82585EN/03 1.CHECKS AND MAINTENANCE
- 3 -
Vicinity of the wrist axis and oil seal
! If chippings or spatters are attached to the oil seal, an oil leak may be caused.
- Check if the vicinity of the necessary inspection points, wrist part, and J3 arm significantly wears
due to rubbing against the welding cable or hand cable.
- Check if there is a trace of a collision around the hand.
- Check the reducer or grease bath for an oil leak.
! If oil can be found a day after wiping oil, an oil leak may be caused.
Vicinity of the welding torch and wrist flange (When ARC welding application is specified.)
! The insulation failure occurs when the spatter has collected around the wrist flange or welding,
and there is a possibility of damaging the robot mechanism by the welding current. (See Appendix
E)
Fig 1.1 (c) Cleaning part
1.2 FIRST 1-MONTH (320 hours operating) CHECK
Check the following items after the first one-month operation (or 320 hours operating). then every 3
months or 960 hours. (See the Section 1.4.)
Item Check items Check points
1 Ventilation portion of controller If the ventilation portion of the controller is dusty, turn off the
power and clean the unit.
1.3 FIRST 3-MONTH (960 hours) CHECKS
Check the following items at the first quarterly inspection, then every year or 3,840 hours thereafter. (See
the Section 1.5.)
Item Check items Check points
1 Connector used in mechanical unit Check that the connectors of the connector panels are securely
engaged. (NOTE 2)
2 Retightening external main bolts Tighten the end-effecter mounting bolts and external main bolts.
(NOTE 3)
1.CHECKS AND MAINTENANCE B-82585EN/03
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Item Check items Check points
3 Check the mechanical stopper and
adjustable mechanical stopper
Check the spring ping of J1-axis mechanical stopper is not
transformed, if it is transformed, replace it to new one.
Check the looseness of J3-axis stopper mounting bolts. If they are
loose, they are needed to be retightened. (NOTE 4)
4 Check the application cable Confirm whether there is wound in the cable.
5 Controller cable and robot
connecting cable
Check whether the cable connected to the teach pendant and robot
is unevenly twisted.
(NOTE 2) Inspection points of the connectors
- Robot connection cables, earth terminal and user cables
Check items - Circular connector: Check the connector for looseness by turning it manually.
- Square connector: Check the connector for disengagement of its lever.
- Earth terminal: Check the terminal for looseness by turning.
Fig 1.3 (a) Check items of connector
(NOTE 3) Points to be retightened
- The end effecter mounting bolts, robot installation bolts, and bolts to be removed for inspection need
to be retightened.
- The bolts exposed to the outside of the robot need to be retightened.
For the tightening torque, see the recommended bolt tightening torque shown in the Appendix.
A loose prevention agent (adhesive) is applied to some bolts. If the bolts are tightened with greater
than the recommended torque, the loose prevention agent may be removed. So, follow the
recommended tightening torque when retightening them.
B-82585EN/03 1.CHECKS AND MAINTENANCE
- 5 -
(NOTE 4) Check of mechanical stopper and adjustable mechanical stopper. - Check the spring ping of J1-axis mechanical stopper is not transformed, if it is transformed, replace
it to new one.
Check the looseness of J3-axis stopper mounting bolts. If they are loose, they are needed to be
retightened.
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FLOTUSR&929Fig.1.3 (b) Check of mechanical stopper.
1.4 3-MONTH (960 hours) CHECKS
Check the following items in the cycle that is shorter between every 3 moths or 960 hours.
Item Check items Check points
1 Ventilation portion of controller (See Section 1.2)
1.5 1-YEAR (3,840 hours) CHECKS
Check the following items in the cycle that is shorter between once every year or 3,840 hours.
Item Check items Check points
1 Tightness of major external bolts (See Section 1.3)
2 Retightening external main bolts (See Section 1.3)
3 Check the mechanical stopper. (See Section 1.3)
4 Check the application cable (See Section 1.3)
5 Battery (battery built-in type) Replace battery in the mechanical unit. (See Section 2.1)
6 Controller cable and robot
connecting cable
(See Section 1.3)
1.6 1.5-YEAR (5,760 hours) CHECKS
Check the following items about once in the cycle that is shorter between every 1.5 year and 5,760 hours.
1.CHECKS AND MAINTENANCE B-82585EN/03
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Item Check items Check points
1 Battery (external battery type) Replace battery in the mechanical unit. (See Section 2.1)
1.7 2-YEAR (7,680 hours) CHECKS (LR Mate 200iC /5WP,5F)
4-YEAR (15,360 hours) CHECKS (LR Mate 200iC, LR Mate
200iC/5L , /5C, /5LC, /5H)
In case of except LR Mate 200iC/5H,5F, Check the following items in the cycle that is shorter among
every four years and 15,360 hours.
In case of LR Mate 200iC/5H,5F, Check the following items in the cycle that is shorter among every two
years and 7,680 hours.
Item Check items Check points
1 Greasing of reducers of each axis
(Except LR Mate 200iC/5F)
Specified grease
Harmonic grease 4BNo.2
Spec:A98L-0040-0230#2KG
Greasing kit
(tube of grease plus injector)
Spec:A05B-1139-K021
Tube of grease (80 g)
Spec:A05B-1139-K022
Do not use Harmonic grease SK-3 or unspecified grease.
Greasing of reducers of each axis
(LR Mate 200iC/5F)
Specified grease
NOK
Klubersynth UH1 14-1600
Spec:A98L-0040-0218
Greasing kit
(tube of grease plus injector)
Spec:A05B-1139-K023
Tube of grease (80 g)
Spec:A05B-1139-K024
Do not use not specified grease.
1.8 MAINTENANCE TOOLS
The following tools and instruments are required for the maintenance procedures contained in this
manual.
(a) Measuring instruments
Instrument Specifications Vendor Manufacturer model No. Application
Tension meter A97L-0218-0700 Mitsuboshi Belting Ltd.DOCTOR TENSION
TYPE-"
Adjustment of belt
tension
Instruments Accuracy/Tolerance Applications
Dial gauge accuracy 1/100 mm Measurement of positioning and backlash
Slide calipers 150 mm
B-82585EN/03 1.CHECKS AND MAINTENANCE
- 7 -
(b) Tools
"Torque wrench
"Cross tip (+) screwdrivers
Large, medium, and small sizes
"Flat tip (–) screwdrivers
Large, medium, and small sizes
"Box driver Width across flats&7 (for grease nipple)
"Hex-head wrench set Width across flats&2.5, 3, 4 (for replacing parts)
"Monkey wrench Middle, little
"Pincers
"Radio pincers
"Nippers
"Glasses wrench
"Pliers for C–retaining ring
"LOCTITE 242#262#518#638
"Grease applying kit
(Except LR Mate 200iC/5F) A05B-1139-K021
(LR Mate 200iC/5F) A05B-1139-K023
(It is options that grease (80g) for the grease greasing
with the injection syringe and the tube makes a set.)
"$grease in tube (80g)
(Except LR Mate 200iC/5F) A05B-1139-K022
(LR Mate 200iC/5F) A05B-1139-K024
OM
Fig 1.8 example of cylinder
2.PERIODIC MAINTENANCE B-82585EN/03
- 8 -
2 PERIODIC MAINTENANCE
2.1 REPLACING THE BATTERIES
(1-YEAR CHECKS (battery built-in type))
(1.5-YEAR CHECKS (external battery type))
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every 1 year in case of battery built-in J1 base type 1.5 years in case of external battery type. Also, use the following procedure to replace when the backup battery voltage drop alarm occurs.
Procedure of replacing the battery (battery built-in type)
1 Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.
CAUTION Replacing the batteries with the power supply turned off causes all current
position data to be lost. Therefore, mastering will be required again.!
2 When battery box cover is attached, remove the battery case cap. (Fig. 2.1 (a)) 3 Loosen the plate screw, take out the lid of the battery box, and replace battery. Battery can be taken
out by pulling the stick, which is center of the battery box. 4 Assemble them by the opposite procedure. Pay attention to the direction of batteries. Please
exchange packing absolutely when severe dust/liquid protection specification or 5LC,5WP,5C,5F is selected.
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Fig.2.1 (a) Replacing the battery (battery built-in type)
B-82585EN/03 2.PERIODIC MAINTENANCE
- 9 -
Procedure of replacing the battery (external battery type)
1 Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.
CAUTION Be sure to keep the power on. Replacing the batteries with the power supply turned off causes all current
position data to be lost. Therefore, mastering will be required again.!
2 Remove the battery case cap. (Fig. 2.1 (b)) 3 Take out the old batteries from the battery case. 3 Insert new batteries into the battery case. Pay attention to the direction of batteries. 4 Close the battery case cap.
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Fig.2.1 (b) Replacing the battery (external battery type)
Fig 2.1 (c) shows the external size of external battery box. When the battery box needs to be built into the control unit or other internal units, refer to the outer dimensions shown in Fig.2.1 (c) The battery box can be fixed by using M4 flat–head screws. (The bolts do not come with the system.) A maximum of six terminals can be attached to the backplane of the battery box.
2.PERIODIC MAINTENANCE B-82585EN/03
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Fig.2.1 (c) Outer dimensions of the battery box
2.2 REPLENISH THE GREASE OF THE DRIVE MECHANISM
(4 years (11,520 hours) checks)
In case of except 5WP or 5F, supply the grease of the reducers every four years or 15,360 hours by using the following procedures. In case of 5WP or 5F, supply the grease of the reducers every two years or 7,680 hours by using the following procedures. For the grease name and quantity, see the table 2.2 (a).
B-82585EN/03 2.PERIODIC MAINTENANCE
- 11 -
Table 2.2 (a) Grease for 4-year periodical greasing
Greasing points Greasing amount Specified grease
J1-axis reducer 2.7g(3ml)
J2-axis reducer 2.7g(3ml)
J3-axis reducer 1.8g(2ml)
J4-axis reducer 1.8g(2ml)
J5-axis reducer 1.8g(2ml)
J6-axis reducer 1.8g(2ml)
Except 5F
Harmonic grease 4BNo.2
Spec: A98L-0040-0230
5F
NOK
Klubersynth UH1 14-1600
Spec: A98L-0040-0218
For grease replacement, use the postures indicated below.
Table 2.2 (b) Postures for greasing
Posture Supply position
J1 J2 J3 J4 J5 J6
J1-axis reducer -90° 90°
J2-axis reducer
J3-axis reducer
J4-axis reducer
J5-axis reducer
J6-axis reducer
Arbitrary ArbitraryArbitrary Arbitrary Arbitrary Arbitrary
CAUTION The following maintenance kits are prepared for the grease greasing. Greasing kit (except LR Mate 200iC/5F): A05B-1139-K021 (This a set of greasing syringe and grease in tube. (80g)) Greasing kit (LR Mate 200iC/5F): A05B-1139-K023 (This a set of greasing syringe and grease in tube. (80g)) Grease in tube(except LR Mate 200iC/5F): A05B-1139-K022 Grease in tube(LR Mate 200iC/5F): A05B-1139-K024
There is no J6-axis for LR Mate 200iC/5H or 5F.!
NOTE If greasing is performed incorrectly, the internal pressure of the grease bath may
suddenly increase, possibly causing damage to the seal, which would in turn lead to grease leakage and abnormal operation. When performing greasing, therefore, observe the following cautions.
1 In case of J1-axis and J3-axis, before starting to grease, open the grease outlet (remove the seal bolt from the grease outlet).
2 Use grease only of the specified type. Grease of a type other than that specified may damage the reducer or lead to other problems. Do no use Harmonic grease SK-3
3 To prevent accidents caused by slipping, completely remove any excess grease from the floor or robot.
4 Please fill a necessary amount to the injection syringe after softening grease in the tube massaging it by the hand when you use the grease greasing kit. Please install the nozzle in the point of the injection syringe. Please remove the nozzle and do the cap when you do not use the injection syringe.
2.PERIODIC MAINTENANCE B-82585EN/03
- 12 -
2.2.1 Grease supply procedure of the J1-axis reducer
1 Move the robot to the posture of J1=-90° and J2=90°. 2 Turn off the controller power. 3 Remove the bolt/seal bolt (1) and cover U (3). In case of 5LC,5C .5F, remove washer(2), too. In case
of packing is attached, remove packing (4), too. Then remove cover (5). 4 Remove seal bolt of two places referring to fig.2.2.1. 5 Supply regulated amount grease through the grease inlet by using injection syringe. Pay attention
that grease inlet differs in case of floor mount and top mount. At this time, note that grease might come out from the side not used.
6 Assemble parts in the opposite procedure. In case of packing is attached, be sure to replace packing. ! ! When reusing the seal bolt, be sure to seal it with seal tape.
In case of 5F, fill gap between plate and article of cast metal with SEALANT 4588 (CLEAR).
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Fig. 2.2.1 Supply grease of the J1-axis reducer
Name Specification Amount Loctite Torque N-m (kgf-cm)
BOLT A6-BA-4X8
SEAL BOLT A97L-0218-0546#040808BC(*1) 4.5 N-m (46kgf-cm)
SEAL BOLT A97L-0218-0546#040808EN(*2) 4.5 N-m (46kgf-cm)
SEAL BOLT A97L-0218-0546#041010EN(*6) 4.5 N-m (46kgf-cm)
1
BOLT A97L-0218-0546#040808S(*3)
4
2.0 N-m (20kgf-cm)
2 WASHER A290-7139-Y234(*3) (*5) 4
A290-7139-X332(*4)
A290-7139-Y332(*5)
A290-7139-Z332(*6) 3 COVER U
A290-7139-Z371(*3)
1
4 PACKING A290-7139-X356(*7) 1
5 COVER A290-7139-X347 1
(*1) When severe dust/liquid protection specification of Standard,5L,5H is specified. (*2) When 5LC,5WP 5C is specified.
B-82585EN/03 2.PERIODIC MAINTENANCE
- 13 -
(*3) When 5F is specified. (*4) When Standard, 5L,5H is specified. (*5) When 5LC,5C is specified. (*6) When 5WP is specified. (*7) When severe dust/liquid protection specification of Standard, 5L,5H or 5LC,5WP 5C is specified.
2.2.2 Grease supply procedure of the J2-axis reducer
1 Turn off the controller power. 2 Remove the seal bolt (1) and remove cover S (2) and packing (4). In case of 5F, remove collar
(3),too. In this time, wipe the grease. Supply grease through the grease inlet by using injection syringe. Be sure to spread it to round in the gear because a regulated amount is a standard.
3 Attach cover S (2) and packing (4). In this time, note the installation phase. Be sure to replace packing. When reusing the seal bolt, be sure to seal it with seal tape.
(
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Fig. 2.2.2 Supply grease of the J2-axis reducer
Name Specification Amount Loctite Torque N-m (kgf-cm)
SEAL BOLT A97L-0218-0738#040808BC(*1) 2.0 N-m (46kgf-cm)
SEAL BOLT A97L-0218-0738#040808EN(*2) 2.0 N-m (46kgf-cm) 1
SEAL BOLT A97L-0218-0738#041010S(*3)
4
2.0 N-m (46kgf-cm)
A290-7139-X309(*4) 2 COVER S
A290-7139-Y309(*3)1
3 COLLAR A290-7139-Z372 (*3) 1
4 PACKING A290-7139-X351 1
(*1) When Standard,5L,5H is specified. (*2) When 5LC,5WP,5C is specified. (*3) When 5F is specified. (*4) When except 5F is specified.
2.PERIODIC MAINTENANCE B-82585EN/03
- 14 -
2.2.3 Grease supply procedure of the J3-axis reducer
1 Turn off the controller power. 2 Remove the bolt/seal bolt (1) and J2 arm cover (3). In case of 5F, remove washer (2),too. In case of
packing is attached, remove packing (4), too.
3 Supply regulated amount grease through the grease inlet by using injection syringe. Please use
arbitrary one as a greasing inlet. Please note that grease might come out immediately after in the greasing or the greasing. Please note greasing excessively even in that case.
4 Attach J2 arm cover. In case of packing is attached. Be sure to replace packing of. When reusing the seal bolt, be sure to seal it with seal tape.
^/,"@%?9>=AQ#=>'>="?=96Q87=8?="79E678
./C
)
Fig. 2.2.3 Supply grease of the J3-axis reducer
Name Specification Amount Loctite Torque N-m (kgf-cm)
BOLT A97L-0218-0504#M4X10(*1) 3 2.0 N-m (20kgf-cm)
SEAL BOLT A97L-0218-0496#M4X12BC(*2) 4.5 N-m (46kgf-cm)
SEAL BOLT A97L-0218-0496#M4X12EN(*3) 4.5 N-m (46kgf-cm) 1
BOLT A6-B-4X12SUS(*4)
8
2 WASHER A290-7139-Y234(*4)(*5) 8
A290-7139-X306 (*1)
A290-7139-X308 (*2)
A290-7139-Y308 (*5)
A290-7139-Z308 (*6)
3 J2 ARM COVER
A290-7139-Z368 (*3)
1
4 PACKING A290-7139-X355 (*7) 1
(*1) When not severe dust/liquid protection specification of Standard ,5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When 5LC,5C is specified. (*5) When 5WP is specified. (*6) When 5F is specified. (*7) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C is specified.
B-82585EN/03 2.PERIODIC MAINTENANCE
- 15 -
2.2.4 Grease supply procedure of the J4-axis reducer
NOTE Fig. 2.2.4 is an example of standard type. In case of 5H or 5F, refer to Subsection 2.2.5.
1 Turn off the controller power.
2 Remove the bolt/seal bolt (1) and J3 cover (3). In case of 5LC,5C,5F, remove washer (2),too. In case
of packing is attached, remove packing (4), too.
3 Supply regulated amount grease through the grease inlet by using injection syringe. Please note that
grease might come out immediately after in the greasing or the greasing. Please note greasing excessively even in that case.
4 Attach J3 cover. In this time, be sure to replace packing when it is attached. When reusing the seal bolt, be sure to seal it with seal tape.
^C,"@%?9>=AQ#=>'>="?=96Q87=8?="79E678
. C/
)
Fig. 2.2.4 Supply grease of the J4-axis reducer
Name Specification Amount Loctite Torque N-m (kgf-cm)
BOLT A97L-0218-0504#M4X10(*1) 3 2.0 N-m (20kgf-cm)
PLATED BOLT A97L-0218-0496#M4X12BC(*2) 2.0 N-m (20kgf-cm)
PLATED BOLT A97L-0218-0496#M4X12EN(*3) 2.0 N-m (20kgf-cm) 1
BOLT A6-B-4X12SUS(*6)
6
2 WASHER A290-7139-Y234(*4) (*6) 6
2.PERIODIC MAINTENANCE B-82585EN/03
- 16 -
Name Specification Amount Loctite Torque N-m (kgf-cm)
A290-7139-X404(*1) 1
A290-7139-X406 (*2) 1
A290-7139-Y406 (*4) 1 3 J3 COVER
A290-7139-Z406 (*5) 1
4 PACKING A290-7139-X451 (*6) 1
(*1) When severe dust/liquid protection specification of Standard,5L,5H is specified. (*2) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP 5C is specified. (*4) When 5LC,5C is specified. (*5) When 5WP is specified. (*6) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP 5C is specified.
2.2.5 Grease supply procedure of the J5/J6-axis reducer
NOTE Fig. 2.2.5 is an example of standard type. In case of 5H,5F type, read J5/J6 as J4/J5.
1 Turn off the controller power. 2 Supply regulated amount grease through the grease inlet by using injection syringe. Please note
that grease might come out immediately after in the greasing or the greasing. Please note greasing excessively even in that case.
^1,"@%?9>=AQ#=>9'>="?=9%&7=8?="79E678
^`,"@%?9>=AQ#=>9'>="?=9%&7=8?="79E678
Fig. 2.2.5 Supply grease of the J5/J6-axis reducer (Standard,5L,5H,5LC,5WP,5C)
Replacing grease of the J4/J5-axis reducer (5H,5F)
B-82585EN/03 3.TROUBLESHOOTING
- 17 -
3 TROUBLESHOOTING
3.1 OVERVIEW
The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from many interrelated factors. If you fail to take the correct measures, the failure may be aggravated. Therefore, it is necessary to analyze the symptoms of the failure precisely so that the true cause can be found.
3.2 FAILURES, CAUSES AND MEASURES
Table 3.2(a) lists the major failures that may occur in the mechanical unit and their probable causes. If you cannot pinpoint a failure cause or which measures to apply, contact FANUC.
Table 3.2 (a) Failures, causes and measures
Symptom Description Cause Measure
-The J1 base lifts off the floor
plate as the robot operates.
-There is a gap between the
J1 base and floor plate.
-A J1 base retaining bolt is
loose.
[J1 base fastening]
-It is likely that the robot J1 base is
not securely fastened to the floor
plate.
-Probable causes are a loose bolt,
an insufficient degree of surface
flatness, or foreign material caught
between the floor plate and floor
plate.
-If the robot is not securely fastened
to the floor plate, the J1 base lifts
the floor plate as the robot operates,
allowing the base and floor plates to
strike each other, which, in turn,
leads to vibration.
-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 foreign matter
between the J1 base and
floor plate, remove it.
-Apply epoxy to the floor
surface and re-install the
plate.
[Rack or floor]
-It is likely that the rack or floor is not
sufficiently rigid.
-If the rack or floor is not sufficiently
rigid, reaction from the robot
deforms the rack or floor, leading to
vibration.
-Reinforce the rack or floor to
make it more rigid.
-If reinforcing the rack or floor
is impossible, modify the
robot control program; doing
so might reduce the amount
of vibration.
Vibration
Noise
-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.
[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.
-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).
3.TROUBLESHOOTING B-82585EN/03
- 18 -
Symptom Description Cause Measure
Vibration
Noise
(Continued)
-Vibration was first noticed
after the robot collided with
an object or the robot was
overloaded for a long period.
-The grease of the vibrating
axis has not been
exchanged for a long period.
[Broken 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.
- It is likely that prolonged use of the
robot while overloaded caused
fretting of the tooth surface or rolling
contact surface of a bearing, or
reducer due to resulting metal
fatigue.
- It is likely that foreign matter
caught in a gear, bearing, or within a
reducer caused damage on the
tooth surface or rolling contact
surface of the bearing, or reducer.
- It is likely that, because the grease
has not been changed for a long
period, fretting occurred on the tooth
surface or rolling contact surface of
a bearing, or reducer due to metal
fatigue.
These factors all generate cyclic
vibration and noise.
-Operate one axis at a time to
determine which axis is
vibrating.
-Remove the motor, and
replace the gear, the bearing,
and the reducer. For the
spec. of parts and the method
of replacement, contact
FANUC.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the
grease with a specified type
can help prevent problems.
B-82585EN/03 3.TROUBLESHOOTING
- 19 -
Symptom Description Cause Measure
Vibration -The cause of problem
cannot be identified from
examination of the floor,
rack, or mechanical section.
[Controller, cable, and motor]
-If a failure occurs in a controller
circuit, preventing control commands
from being supplied to the motor
normally, or preventing motor
information from being sent to the
controller normally, vibration might
occur.
-If the pulsecoder develops a fault,
vibration might occur because
information about the motor position
cannot be transferred to the
controller accurately.
-If the motor becomes defective,
vibration might occur because the
motor cannot deliver its rated
performance.
-If a power line in a movable cable of
the mechanical section has an
intermittent break, vibration might
occur because the motor cannot
accurately respond to commands.
-If a pulsecoder wire in a movable
part of the mechanical section has
an intermittent break, vibration might
occur because commands cannot
be sent to the motor accurately.
-If a connection cable between them
has an intermittent break, vibration
might occur.
-If the power cable between them
has an intermittent break, vibration
might occur.
-If the power source voltage drops
below the rating, vibration might
occur.
-If a robot control parameter is set to
an invalid value, vibration might
occur.
-There is a possibility that the belt
has been damaged about the
allophone of the axis of the belt
drive.
-Refer to the Controller
Maintenance Manual for
troubleshooting related to the
controller and amplifier.
-Replace the pulsecoder for
the motor of the axis that is
vibrating, and check whether
the vibration still occurs.
-Also, replace the motor of
the axis that is vibrating, and
check whether vibration still
occurs. For the method of
replacement, contact FANUC.
-Check that the robot is
supplied with the rated
voltage.
-Check whether the sheath of
the power cord is damaged. If
so, replace the power cord,
and check whether vibration
still occurs.
-Check whether the sheath of
the cable connecting the
mechanical section and
controller is damaged. If so,
replace the connection cable,
and check whether vibration
still occurs.
-If vibration occurs only when
the robot assumes a specific
posture, it is likely that a
cable in the mechanical unit
is broken.
-Shake the movable part
cable while the robot is at
rest, and check whether an
alarm occurs. If an alarm or
any other abnormal condition
occurs, replace the
mechanical unit cable.
-Check that the robot control
parameter is set to a valid
value. If it is set to an invalid
value, correct it. Contact
FANUC for further information
if necessary.
-Please exchange it if
watching the cover is opened,
an internal belt is confirmed,
and damage is shown.
3.TROUBLESHOOTING B-82585EN/03
- 20 -
Symptom Description Cause Measure
Vibration
Noise
(Continued)
-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.
-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.
-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
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
Rattling
-Backlash is greater than the
tolerance stated in the
applicable maintenance
manual. (See Section 3.3.)
[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.
-Operate one axis at a time to
determine which axis has the
increased backlash.
-Remove the motor, and
check whether any of its
gears are broken. If any gear
is broken, replace it.
-Check whether any other
gear of the drive mechanism
is damage. If there is no
damage gear, replace the
reducer.
-If the reducer is broken, or if
a gear tooth is missing,
replace the relevant
component. Also, remove all
the grease from the gear box
and wash the inside of the
gear box.
-After replacing the gear or
reducer, add an appropriate
amount of grease.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly applying the
grease with a specified type
can help prevent problems.
B-82585EN/03 3.TROUBLESHOOTING
- 21 -
Symptom Description Cause Measure
-The ambient temperature of
the installation location
increases, causing the motor
to overheat.
-After the robot control
program or the load was
changed, the motor
overheated.
[Ambient temperature]
-It is likely that a rise in the ambient
temperature prevented the motor
from releasing heat efficiently, thus
leading to overheating.
[Operating condition]
-It is likely that the robot was
operated with the maximum average
current exceeded.
-The teach pendant can be
used to monitor the average
current. Check the average
current when the robot control
program is running. The
allowable average current is
specified for the robot
according to its ambient
temperature. Contact FANUC
for further information.
-Relaxing the robot control
program and conditions can
reduce the average current,
thus preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of
the robot well ventilated
enables the robot to release
heat efficiently, thus
preventing overheating. Using
a fan to direct air at the motor
is also effective.
-If there is a source of heat
near the motor, it is advisable
to install shielding to protect
the motor from heat radiation.
-After a control parameter
was changed, the motor
overheated.
[Parameter]
-If data input for a workpiece is
invalid, the robot cannot be
accelerated or decelerated normally,
so the average current increases,
leading to overheating.
-Input an appropriate
parameter as described in
CONTROLLER
OPERATOR’S MANUAL.
Motor
overheating
-Symptom other than stated
above
[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.
-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-82585EN/03
- 22 -
Symptom Description Cause Measure
Grease
leakage
-Grease is leaking from the
mechanical unit.
[Poor sealing]
-Probable causes are a crack in the
casting, a broken O-ring, a damaged
oil seal, or a loose seal bolt.
-A crack in a casting can occur due
to excessive force that might be
caused in collision.
-An O-ring can be damaged if it is
trapped or cut during disassembling
or re-assembling.
-An oil seal might be damaged if
extraneous dust scratches the lip of
the oil seal.
-A loose seal bolt might allow grease
to leak along the threads.
-If a crack develops in the
casting, sealant can be used
as a quick-fix to prevent
further grease leakage.
However, the component
should be replaced as soon
as possible, because the
crack might extend.
-O-rings are used in the
locations listed below.
-Motor coupling section
-Reducer coupling section
-Wrist coupling section
-J3 arm coupling section
-Inside the wrist
-Oil seals are used in the
locations stated below.
-Inside the reducer
-Inside the wrist
-Seal bolts are used in the
locations stated below.
-Grease drain inlet and
outlet
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 deenergized.
-It is likely that the brake shoe has
worn out or the brake main body is
damaged, preventing the brake from
operating efficiently.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
-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.
-The robot operates at a
point other than the taught
position.
-The repeatability is not
within the tolerance.
[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
abnormal.
-If the repeatability is
unstable, repair the
mechanical section by
referring to the above
descriptions of vibration,
noise, and rattling.
-If the repeatability is stable,
correct the taught program.
Variation will not occur unless
another collision occurs.
-If the pulsecoder is
abnormal, replace the motor
or the pulsecoder.
Displace
ment
-Displacement occurs only in
a specific peripheral unit.
[Peripheral unit displacement]
-It is likely that an external force was
applied to the peripheral unit, thus
shifting its position relative to the
robot.
-Correct the setting of the
peripheral unit position.
-Correct the taught program.
B-82585EN/03 3.TROUBLESHOOTING
- 23 -
Symptom Description Cause Measure
Displace
ment
-Displacement occurred after
a parameter was changed.
[Parameter]
-It is likely that the mastering data
was rewritten in such a way that the
robot origin was shifted.
-Re-enter the previous
mastering data, which is
known to be correct.
-If correct mastering data is
unavailable, perform
mastering again.
BZAL alarm
occurred
-BZAL is displayed on the
controller screen
- It is likely that the voltage of the
memory backup battery is low.
- It is likely that the pulsecoder cable
is defected.
-Replace the battery.
-Replace the cable.
Table 3.2 (b) Allowable drops
At power off 2 mm
At emergency stop 2 mm
NOTE Each value indicates the amount by which an end effector mounting surface may
fall.
3.3 BACKLASH MEASUREMENT
Measurement method 1 Maintain the robot in a specified posture. (See Table 3.3.) 2 Apply positive and negative loads to each axis as shown in Fig.3.3 (a). 3 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.
!"#$%
!"#$%
!"#$%
&
'"#$%
()*+,+*-.).*/
'"#$%
'"#$%
0
0
0
0
1.2)-),-)3+45*,/*),637-8239
&#$%
&#$%
&#$%
&#$
(3:*/;,-)3+4<,=0,!,0,9> >?
@A.2;,-)3+4<,=0,!,0,9" B"
?
>
"
B
Fig. 3.3 (a) Backlash measurement method
Backlash B is calculated using the following expression:
3.TROUBLESHOOTING B-82585EN/03
- 24 -
B=2
BB32
!
Table 3.3(a) Backlash measurement posture, position and permissible value
Measurement
axisJ1-axis J2-axis J3-axis J4-axis J5-axis J6-axis Measurement position
J1-axis Arbitrary 90° 0° 0° 0° 90° Rotation center of J5-axis
J2-axis Arbitrary 0° 90° 0° 0° 0° Rotation center of J3-axis
of J2 arm
J3-axis Arbitrary 90° -90° 0° 0° 180° Rotation center of J5-axis
J4-axis Arbitrary 0° 90° 0° -90° 90° 100mm from rotation
center of J4-axis
J5-axis Arbitrary 90° 0° 0° -90° 0° or 180° 206mm from rotation
center of J5-axis
J6-axis Arbitrary 90° 0° 0° -90° 90° or -90° 100mm from rotation
center of J6-axis
Table 3.3(b) Distance at axis and measurement position and permissible value for backlash
Measured
axis
Distance at axis and measurement position
(mm)Permissible value (mm)
LR Mate 200iC,
LR Mate 200iC/5C,
5WP,5H,5F
LR Mate 200iC/5L,5LC
LR Mate 200iC,
LR Mate 200iC/5C,
5WP,5H,5F
LR Mate 200iC/5L,5LC
J1-axis 695 (except 5F)
702.5 (5F)
885 0.40 0.51
J2-axis 300 400 0.17 0.23
J3-axis 320 410 0.19 0.24
J4-axis 100 100 0.16 0.16
J5-axis 180 180 0.18 0.18
J6-axis 100 100 0.15 0.15
NOTE In case of 5H,5F type, read J5/J6 as J4/J5.
NOTE When measuring backlash under circumstances where the distance between the
rotation center and the dial indicator is different from those in the above table, make displacement conversions according to the table.
C37-82363/),+*-.).*/4D*)7).*/,:3/)32,*%,EF'7G.-9
0*7;./$,+*-.).*/
?&&
HIF,,,4()7/;72;JFKJFLMJFN9O&>PF,4F19QQF,4F0JF0K9
Fig.3.3 (b) Backlash measurement position of J1-axis
B-82585EN/03 3.TROUBLESHOOTING
- 25 -
C37-82363/),+*-.).*/
0*7;./$+*-.).*/
"&&,4()7/;72;JFKJFLMJFNJF19
B&&,4F0JF0K9
Fig.3.3 (c) Backlash measurement position of J2-axis
C37-82363/)+*-.).*/
0*7;./$,+*-.).*/
?&&
?&&
">&,4()7/;72;JFKJFLMJFNJF19
B?&,4F0JF0K9
Fig.3.3 (d) Backlash measurement position of J3-axis
3.TROUBLESHOOTING B-82585EN/03
- 26 -
C37-82363/),+*-.).*/
?&&
0*7;./$,+*-.).*/
D*)7).*/,:3/)32,*%EB'7G.-,4EH'7G.-9
Fig.3.3 (e) Backlash measurement position of J4-axis
0*7;./$,+*-.).*/
C37-82363/)+*-.).*/
?&&
?Q&
?&&
Fig.3.3 (f) Backlash measurement position of J5-axis
?&&
C37-82363/),+*-.).*/
0*7;./$,+*-.).*/
Fig.3.3 (g) Backlash measurement position of J6-axis
B-82585EN/03 4.REPLACING PARTS
- 27 -
4 REPLACING PARTS
! When replacing a part, subsequent adjustment is required.
! When removing or mounting a motor, apply force in the direction of the shaft only. If excessive force is applied in any other direction, the motor and/or reducer may be damaged.
! If a motor and associated parts to be assembled incur a phase mismatch, assembly might prove impossible. Carefully check the state of the parts before removing them.
! Assemble a new O–ring and packing for seal securing after you exchange parts for spec of seal.
CAUTION The packing must not be reused. To maintain dust and drip preventive effects,
replace the old packing with new ones and then perform assembly.
! To secure the performance of the seal, replace seal bolt to new one after replacing parts as much as possible. If preparing it is impossible, peel off the sealant, spread LOCTITE on the internal thread, and recycle.
NOTEWhen applying LOCTITE to the important bolt tightening points, make sure that it is applied to the entire longitudinal portion in the engaging section of the female threads. If it is applied to the male threads, the bolts may be loosened because sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps and wipe oil off the engaging section. Make sure that there is no solvent in the taps.Be sure to wipe the excess LOCTITE after tightening screw.
! When tightening a bolt, always observe the tightening torque, if specified those bolts for which no tightening torque is specified must be tightened according to the table of APPENDIX.
! Assemble the reducer to the vertical direction as much as possible when you assemble it.
! When installing bolt to reducer, make the applying order a corner and tighten uniformly.
! When applying LOCTITE 518 to reducer, pay attention LOCTITE doesn’t enter inside the reducer.
! Spread it after softening grease mixing it when you do not softly spread grease easily.
NOTE When replacing parts of 5F, apply the edible grease Klubersynth UH1 14-31 to
the O-ring, oil seal, and V-seal of the parts. (See Section 1.8.) Be careful not to apply the Klubersynth UH1 14-1600, which is for reducers.
NOTE The following abbreviations are used herein. STANDARD : LR Mate 200iC !"ARC Mate"50iC
5L : LR Mate 200iC/5L !"ARC Mate 50iC#5L
5LC : LR Mate 200iC/5LC 5C : LR Mate 200iC/5C 5WP : LR Mate 200iC/5WP 5H : LR Mate 200iC/5H
4.REPLACING PARTS B-82585EN/03
- 28 -
4.1 FIGURE OF DRIVE MECHANISM
The drive mechanisms of each axis are shown in the following.
CAUTION When robot is 5H or 5F,please read J5/J6 as J4/J5.
!"#$%&'
!(#$%&'
!(#%)*&#+',-.'+/012213#&0%456
7*7'
8151+#/8(6#41+#!(#%)*&
*97-5#:'%+
1-57-5#:'%+
Fig. 4.1 (a) Drive mechanism of J1-axis
B-82585EN/03 4.REPLACING PARTS
- 29 -
!"#$%&
!"#'$()
&*+*%#,&"-#.*%#!"#$/0(
!"#$/0(#%)123)%
Fig. 4.1 (b) Drive mechanism of J2-axis
!"#$%&
!4#5*2(067
!4#$/0(#%)123)%
!4#$/0(#0682+#8299:
!4#$/0(#*2+82+#8299:
')9+
&*+*%#,&4-#.*%#!4#$/0(
Fig. 4.1 (c) Drive mechanism of J3-axis
4.REPLACING PARTS B-82585EN/03
- 30 -
&*+*%#,&;-#.*%#!;#$/0(
!4#5*2(067
!;#$/0(#0682+#7)$%
!;#$/0(#*2+82+#7)$%
808)
!;#$/0(#%)123)%
!4#$%&
Fig. 4.1 (d) Drive mechanism of J4-axis
!4#$%&
&*+*%#,&<-#.*%#!<#$/0(
&*+*%#,&=-#.*%#!=#$/0(
!<#$/0(#0682+#8299:
!=#$/0(#0682+#8299:
')9+
')9+
!<#$/0(#*2+82+#8299:
!<#$/0(#%)123)%
!=#$/0(#*2+82+#7)$%
!=#$/0(#%)123)%
!=#$/0(#0682+#7)$%
!=#5*2(067
!=#$/0(#*2+82+#8299:
Fig. 4.1 (e) Drive mechanism of J5/J6-axis
4.2 REPLACING J1-AXIS MOTOR
Replacing procedure 1 Move the robot posture to J1=-90° and J2=90°. 2 Remove robot from floor plate, and turn off the controller power. 3 Make it to posture in which the motor (2) can be removed.
B-82585EN/03 4.REPLACING PARTS
- 31 -
4 When severe dust/liquid protection specification of Standard, 5L,5H or 5LC,5WP,5C,5F is specified, remove plated bolt/bolt (12), cover B (11) and packing (13). (When not severe dust/liquid protection specification of Standard,5L,5H is specified, there are not.)
5 Remove bolt (1) and motor (2). In this time, note that grease may go out. 6 Remove cable K101 from motor (2). 7 Wipe the grease of the gear (6) off. In this time, pay attention not to damage the tooth side. 8 Remove O-ring (3) and seal bolt (4), and remove washer plate (5), gear (6), holder (7), O-ring (8)
and key (9) sequentially. 9 Assemble it in the opposite procedure after exchanging Motor, packing and O-ring for the new
article. In this time, pay attention to the following.
! When motor is attached, confirm the thing that the oil seal is at the position, and note that the lip cannot be turned over.
! Spread grease on surroundings about the gear. 10 Perform single axis mastering referring to Section 8.5 of operator’s manual.
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Fig. 4.2 Replacing J1-axis motor
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
1 BOLT A6-BA-5X20 4 5.6Nm (57kgfcm)
2 MOTOR A06B-0116-B855#0048 1
3 O-RING A98L-0001-0347#S46 1
4 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
5 WASHER PLATE A290-7139-X231 1
A290-7139-X211 (*1) 1 6 GEAR J1-1
A290-7139-X213 (*2) 1
7 HOLDER A290-7139-X221 1
8 O-RING A98L-0001-0347#S46 1
9 KEY JB-HKY-3X3X12B 1
10 OIL SEAL A98L-0040-0223#01001805 1
A290-7139-X233 (*3) 1 11 COVER B
A290-7139-Y233 (*4) 1
PLATED BOLT A97L-0218-0496#M4X8BC (*3) 10 4.5Nm (46kgfcm)
PLATED BOLT A97L-0218-0496#M4X8EN (*4) 10 4.5Nm (46kgfcm) 12
BOLT A6-B-4X8SUS (*6) 10 2.0Nm (20kgfcm)
13 PACKING A290-7139-X252 (*5) 1
4.REPLACING PARTS B-82585EN/03
- 32 -
(*1) When Standard,5C,5WP,5H,5F is specified. (*2 )When 5L,5LC is specified. (*3) When severe dust/liquid protection specification of Standard,5L,5H is specified. (*4) When 5LC,5WP,5C is specified. (*5) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified. (*6 )When 5F is specified.
4.3 REPLACING J1-AXIS REDUCER
Replacing procedure 1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set
in 0° for all axes when robot is shipped.) 2 Turn off the controller power. 3 Remove cover B (When severe dust/liquid protection specification of Standard, 5L,5H or
5LC,5WP,5C,5F is specified.) and J1 motor referring to Section 4.2 (The gear need not be removed.) 4 Remove bolt/plated bolt (6), In case of 5LC,5C,5F, remove washer (7). And remove J2 base cover
(8). When packing is attached, remove packing (20), too. 5 Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106, K107 and
K108 referring to Fig.5.3.1 (b) in Chapter 5. 6 Remove bolt/seal bolt (1). In case of 5F, remove washer (2). And remove cover U (3). When
packing is attached, remove packing (19), too. 7 Pull out cable K101 to the J1 base side. In this time, pull out the cable after it pushes into the pipe on
the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relayed connector caught.
8 Remove bolt (4), (5) and remove J1 base (18) by using tap for pulled out. In this time, pay attention that there is a possibility that grease goes out. (Refer to Fig.4.3 (d))
9 Wipe the grease of the gear (14) off. In this time, do not damage the tooth side. 10 Remove bolt/seal bolt (15) and reducer (11). 11 Remove seal bolt (13) and gear (14). 12 Assemble the gear (14) to wave generator (12) of the new reducer (11). 13 Keep the horizontal and install a new main body of the reducer in J2 base. In this time, be sure to put
O-ring (8) after it exchanges it for the new article. 14 Fill grease to the reducer. It is total 19ml greasing in inside of reducer, gear and bearing of wave
generator.15 When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified,
spread the sealant on the reducer referring to Fig.4.3 (b). 16 Attach new wave generator (12) to the reducer. In this time, be sure to put wave washer (9). 17 Phase to reducer and assemble J1 base (17) referring to Fig.4.2 (c). In this time, be sure to put O-ring
(16). Assemble bolt (5) after previously assembling all bolt (4). 18 Put J1 motor, cable and cover in the reverse order of 3-7. In case of 5F, fill gap between plate and
article of cast metal with SEALANT 4588 (CLEAR).
CAUTION Do not apply grease to the O-ring (16). Otherwise, hardening of sealant is
prevented, causing a grease leak.
19 Pass the cable K101 through J2 base side, and connect it with the relay connector. In this time, pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relayed connector caught.
20 Attach J2 base cover (8) by bolt/plated bolt (6).In case of 5LC,5C,5F attach washer (7). When packing is attached, replace packing (20) to new one, and attach it.
21 Attach J1 motor referring to Section 4.2.
B-82585EN/03 4.REPLACING PARTS
- 33 -
22 When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified, attach cover B.
23 Attach robot to floor plate. 24 Perform quick mastering and perform single axis mastering for J1-axis referring to Section 8.4 and
8.5 of operator’s manual.
NOTE When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear of J1-axis motor shaft.
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Fig. 4.3 (a) Replacing J1-axis reducer
4.REPLACING PARTS B-82585EN/03
- 34 -
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
BOLT A6-BA-4X8 (*1) 4
SEAL BOLT A97L-0218-0546#040808BC(*2) 4 4.5Nm (46kgfcm)
SEAL BOLT A97L-0218-0546#040808EN(*3) 4 4.5Nm (46kgfcm)
SEAL BOLT A97L-0218-0546#041010EN(*6) 4 4.5Nm (46kgfcm)
1
BOLT A97L-0218-0760#040808S (*8) 4 2.0Nm (20kgfcm)
2 WASHER A290-7139-Y234 (*8) 4
A290-7139-X332 (*4) 1
A290-7139-Y332 (*5) 1
A290-7139-Z332 (*6) 1 3 COVER U
A290-7139-Z371 (*8) 1
4 BOLT A6-BA-4X12 7 4.5Nm (46kgfcm)
5 BOLT A6-BA-4X20 9 4.5Nm (46kgfcm)
BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm)6
BOLT A6-B-4X12SUS (*8) 8 2.0Nm (20kgfcm)
7 WASHER A290-7139-Y234 (*5) (*8) 8
A290-7139-X305 (*1) 1
A290-7139-X307 (*2) 1
A290-7139-Y307 (*5) 1
A290-7139-Z307 (*6) 1
8 J2 BASE COVER
A290-7139-Z367 (*8) 1
9 O-RING (Attached to J1 REDUCER) 1
10 WAVE-WASHER (Attached to J1 REDUCER) 1
A97L-0218-0812#80(*4) 1
A97L-0218-0812#80C(*3) 1 11 J1 REDUCER
A97L-0218-0812#80F(*8) 1
12WAVE
GENERATOR (Attached to J1 REDUCER) 1
13 SEAL BOLT A97L-0218-0423#030505 6
14 GEAR J1-2 A290-7139-X212 1
BOLT A6-BA-4X30(*1) 12 5.4Nm (55kgfcm)
SEAL BOLT A97L-0218-0546#043016BC(*2) 12 5.4Nm (55kgfcm)15
SEAL BOLT A97L-0218-0546#043016EN(*3) (*8) 12 5.4Nm (55kgfcm)
16 O-RING (Attached to J1 REDUCER) 1
17 J1 RING A290-7139-X241 1
A290-7139-X201 (*4) 1
A290-7139-Y201 (*5) 1
A290-7139-Z201 (*6) 1 18 J1 BASE
A290-7139-Z261 (*8) 1
19 PACKING A290-7139-X356 (*7) (*8) 1
20 PACKING A290-7139-X354 (*7) (*8) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When Standard, 5L,5H is specified. (*5) When 5LC,5C is specified. (*6) When 5WP is specified. (*7) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C is specified. (*8) When 5F is specified.
B-82585EN/03 4.REPLACING PARTS
- 35 -
$889:#9*3+0+)#<>@#+*##+5)############8$%+*.#+5)#!>#'$()#(01)E1*6F+#82+#9*3+0+)#06(01)#+5)#%)123)%E
Fig. 4.3 (b) Range to J1-axis reducer of sealant spreading
(When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate
200iC/5LC,5WP,5C,5F is specified.)
4.REPLACING PARTS B-82585EN/03
- 36 -
&;/"D
&;/>"
Fig. 4.3 (c) Assembled phase of J1-axis reducer
&;#GHI#JKL#IMNNOP#KMG,"#INHQOR-
Fig. 4.3 (d) Position of taps for pulled out to remove J1 base.
B-82585EN/03 4.REPLACING PARTS
- 37 -
4.4 REPLACING J2-AXIS MOTOR
Replacing procedure 1 Turn off the controller power. 2 Remove bolt/plated bolt (1). In case of 5LC,5C,5F, remove washer (2). And remove J2 base cover
(3). When packing is attached, remove packing (20), too. 3 Cut the nylon band, which connect cable and clamp (5). 4 Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106, K107 and
K108 referring to Fig.5.3.1 (b) in Chapter 5. 5 Remove bolt (4) and clamp (5). 6 Remove seal bolt (6) and support (7). When packing is attached, remove packing (21), too. 7 Remove seal bolt (8). In case of 5F, remove collar (9). And remove cover S (10), packing (22). In
this time, pay attention that grease may go out. 8 Remove seal bolt (11), washer (12), collar (13),wave generator (19), O-ring (18), key (17) and
Motor (15) to which shaft (16) attaches.
CAUTION When the motor is removed, the arm moves downward by its weight. Hold the
arm so that the arm does not collide with any other objects. 9 Remove cable K102 and K103 from motor (15). 10 Assemble it in the opposite procedure after exchanging Motor, O-ring, packing and shaft (17) for the
new article. In this time, pay attention to the following.
! Spread LOCTITE 638 referring to Fig.4.4 (b) when you apply shaft(16).
!" Be sure to attach wave generator (21) after attaching motor (15). Spread grease inside of reducer before assembling it.
! Pay attention the phase when you apply the cover S (10) referring to Fig.4.4 (c).
11 Perform single axis mastering referring to Section 8.5 of operator’s manual.
4.REPLACING PARTS B-82585EN/03
- 38 -
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Fig. 4.4 (a) Replacing J2-axis motor
B-82585EN/03 4.REPLACING PARTS
- 39 -
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm) 1
BOLT A6-B-4X12SUS (*8) 8 2.0Nm (20kgfcm)
2 WASHER A290-7139-Y234 (*4) (*8) 8
A290-7139-X305 (*1) 1
A290-7139-X307 (*2) 1
A290-7139-Y307 (*4) 1
A290-7139-Z307 (*5) 1
3 J2 BASE COVER
A290-7139-Z367 (*8) 1
4 BOLT A6-BA-4X8 2
5 CLAMP J2-1 A290-7139-X333 1
6 SEAL BOLT A97L-0218-0423#041212 7 4.5Nm (46kgfcm)
A290-7139-X303 (*6) 1
A290-7139-Y303 (*4) 1
A290-7139-Z303 (*5) 1 7 SUPPORT
A290-7139-Z363 (*8) 1
A97L-0218-0595#040808BC(*6) 4 2.0Nm (20kgfcm)
A97L-0218-0595#040808EN(*3) 4 2.0Nm (20kgfcm) 8 SEAL BOLT
A97L-0218-0760#041010S(*8) 4 1.3Nm (13kgfcm)
9 COLLAR A290-7139-Z372 (*8) 4
A290-7139-X309(*6) 1
A290-7139-Y309(*4) 1
A290-7139-Z309(*5) 1 10 COVER S
A290-7139-Z369(*8) 1
11 SEAL BOLT A97L-0218-0423#031616 1 1.3Nm (13kgfcm)
12 WASHER A290-7210-X532 1
13 COLLAR A97L-0218-0763#410 1
14 SEAL BOLT A97L-0218-0423#051212 4 5.6Nm (57kgfcm)
15 MOTOR A06B-0116-B855#0048 1
16 SHAFT A290-7139-X322 1 LT638
17 KEY JB-HKY-3X3X12B 1
18 O RING JB-OR1A-G45 1
19WAVE
GENERATOR (Attached to J2 REDUCER) 1
20 PACKING A290-7139-X354 (*7) 1
21 PACKING A290-7139-X352 (*7) 1
22 PACKING A290-7139-X351 (*7) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When 5LC,5C is specified. (*5) When 5WP is specified. (*6) When Standard, 5L,5H is specified. (*7) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified. (*8) 5F is specified.
4.REPLACING PARTS B-82585EN/03
- 40 -
(ILOHP#SLOHRO#KT#GUO#VTRVPO#PVHWOGOLEE
B0)C#$
$
$
Fig. 4.4 (b) Apply LOCTITE 638 to shaft
6*+)-#8$:#$++)6+0*6#+*##########+5)#$(()&'9)1#85$()E
Fig. 4.4 (c) Assembled phase of cover S
4.5 REPLACING J2-AXIS REDUCER
Replacing procedure 1 Turn off the controller power. 2 Remove the robot from floor plate and knock down it sidewise." (Because you must reassemble
reducer in a horizontal state.) 3 Remove bolt/plated bolt (1). In case of 5LC,5C,5F, remove washer (2). And remove J2 base cover
(3). When packing is attached, remove packing (25), too.
B-82585EN/03 4.REPLACING PARTS
- 41 -
4 Remove the connector that relays cable K101 and cable K102, K103, K104, K105, K106, K107 and K108 referring to Fig.5.3.1 (b) in Chapter 5.
5 Remove bolt (5) and clamp (4). 6 Cut the nylon band, which connect cable and clamp (4). 7 Remove bolt (6) and support (7). When packing is attached, remove packing (26), too. 8 Remove seal bolt (8), in case of 5F remove collar (9), then remove cover S (10) and packing (11). In
this time, pay attention that there is a possibility that grease goes out. 9 Remove seal bolt (12), washer (13) and wave generator (14). 10 Remove seal bolt (19), motor (18) and O-ring (20), (21). 11 Remove bolt/seal bolt (15) and J2 arm (17) to which reducer (24) is attached. 12 Remove bolt (22) and remove reducer (24) from J2 arm (17). 13 Exchange reducer, O-ring, packing (when severe dust/liquid protection is specified) for new parts in
the following order. 14 Attach new reducer to the J2 arm (17) by using bolt/seal bolt (22). When severe dust/liquid
protection specification of Standard, 5L,5H or 5LC,5WP,5C,5F is specified, spread the sealant on the reducer referring to Fig.4.5 (b).
CAUTION Do not apply grease to the O-ring (23). Otherwise, hardening of sealant is
prevented, causing a grease leak.
15 Attach J2 motor (18) to the J2 arm. Be sure to make the decelerator the horizontal about the procedure of 16 and 17.
16 Attach J2 base (16) to the reducer (24) by using bolt/seal bolt (15). In this time, be sure to put O-ring (23).
17 Fill grease to the reducer. It is total 26ml greasing in inside of reducer, gear and bearing of wave generator.
18 Attach wave generator (14) to the J2 base (16). 19 Attach cover S (10). In this time, pay attention to the phase referring to Fig.4.4 (c). 20 Attach support (7) by using seal bolt (6). When packing is attached, be sure to replace packing (26)
to new one and attach there. 21 Fix cable to the clamp (4) by using nylon band, attach support (7) by using bolt (5) 22 Attach J2 base cover (3) by using bolt/plated bolt (1). In case of 5LC,5C,5F, attach washer (2), too.
In this time, be sure to replace packing (25) to new one and attach there. 23 Attach robot to floor plate. 24 Perform quick mastering and perform single axis mastering for J2-axis referring to Section 8.4 and
8.5 of operator’s manual.
NOTE When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear of J2-axis motor shaft.
4.REPLACING PARTS B-82585EN/03
- 42 -
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Fig. 4.5 (a) Replacing J2-axis reducer
B-82585EN/03 4.REPLACING PARTS
- 43 -
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm) 1
BOLT A6-B-4X12SUS(*11) 8 2.0Nm (20kgfcm)
2 WASHER A290-7139-Y234 (*4)(*11) 8
A290-7139-X305 (*1) 1
A290-7139-X307 (*2) 1
A290-7139-Y307 (*4) 1
A290-7139-Z307 (*5) 1
3 J2 BASE COVER
A290-7139-Z367 (*11) 1
4 CLAMP J2-1 A290-7139-X333 1
5 BOLT A6-BA-4X8 2
6 SEAL BOLT A97L-0218-0423#041212 7 4.5Nm (46kgfcm)
A290-7139-X303 (*6) 1
A290-7139-Y303 (*4) 1
A290-7139-Z303 (*5) 1 7 SUPPORT
A290-7139-Z363 (*12) 1
SEAL BOLT A97L-0218-0595#040808BC(*6) 4 2.0Nm (20kgfcm)
SEAL BOLT A97L-0218-0595#040808EN(*3) 4 2.0Nm (20kgfcm) 8
SEAL BOLT A97L-0218-0760#041010S (*11) 4 1.3Nm (13kgfcm)
9 COLLAR A290-7139-Z372 (*11) 4
A290-7139-X309(*6) 1
A290-7139-Y309(*4) 1
A290-7139-Z309(*5) 1 10 COVER S
A290-7139-Z369(*11) 1
11 PACKING A290-7139-X351 1
12 SEAL BOLT A97L-0218-0423#031616 1 1.3Nm (13kgfcm)
13 WASHER A290-7210-X532 1
14 WAVE GENERATOR (Attached to J2 REDUCER) 1
15 BOLT A6-BA-4X20 16
A290-7139-X301 (*6) 1
A290-7139-Y301 (*4) 1
A290-7139-Z301 (*5) 1
A290-7139-Y361 (*13) 1
16 J2 BASE
A290-7139-Z361 (*11) 1
A290-7139-X302 (*7) 1
A290-7139-X310(*8) 1
A290-7139-Y302 (*8) 1
A290-7139-Y310(*9) 1
A290-7139-Z302 (*10) 1
A290-7139-Y362 (*14) 1
A290-7139-Y363 (*15) 1
17 J2 ARM
A290-7139-Z362 (*11) 1
18 MOTOR A06B-0116-B855#0048 1
19 SEAL BOLT A97L-0218-0423#051212 4 5.6Nm (57kgfcm)
20 O RING JB-OR1A-G45 1
21 O RING (Attached to J2 REDUCER) 1
BOLT A6-BA-4X35 (*1) 12 5.4Nm (55kgfcm)
SEAL BOLT A97L-0218-0546#043516BC(*2) 12 5.4Nm (55kgfcm) 22
SEAL BOLT A97L-0218-0546#043516EN(*3) (*11) 12 5.4Nm (55kgfcm)
23 O RING (Attached to J2 REDUCER) 1
4.REPLACING PARTS B-82585EN/03
- 44 -
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
A97L-0218-0813#120(*10) 1
A97L-0218-0813#120C(*3) 1 24 J2 REDUCER
A97L-0218-0813#120F (*11) 1
25 PACKING A290-7139-X354 (*10) (*11) 1
26 PACKING A290-7139-X352 (*10) (*11) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When 5LC,5C is specified. (*5) When 5WP is specified. (*6) When Standard, 5H,5L is specified. (*7) When Standard, 5H is specified. (*8) When 5C is specified. (*9) When 5LC is specified. (*10) When severe dust/liquid protection specification of Standard,5L,5H or LR Mate
200iC/5LC,5WP,5C is specified.
(*11) When 5F is specified. (*12) When 5C clean class 100, 5LC clean class 100 is specified. (*13) When 5C clean class 10, 5LC clean class 10 is specified. (*14) When 5C clean class 10 is specified. (*15) When 5LC clean class 10 is specified.
$889:#9*3+0+)#<>@#+*##+5)############8$%+*.#+5)#3*B)%#(#(01)E
1*6F+#82+#9*3+0+)#06(01)#+5)#%)123)%E
Fig. 4.5 (b) Range to J2-axis reducer of sealant spreading
(When severe dust/liquid protection specification of
LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C,5F is specified.)
B-82585EN/03 4.REPLACING PARTS
- 45 -
4.6 REPLACING J3-AXIS MOTOR
Replacing procedure 1 Turn off the controller power. 2 Remove bolt/plated bolt (4). In case of 5LC,5C,5F, remove washer (5), too. And remove J2 arm
cover (6). When packing is attached, remove packing (16), too. 3 Loosen a bolt (8) a little and lower the tension of the belt and remove belt (7).
CAUTION When removing the belt, put the part beyond the J3 housing on a workbench to
prevent the arm from dropping
4 According to Subsection 5.3.1, remove J2 base cover and relay of cable K101 and air tube. (Referring to Fig.5.3.1 (a), (b))
5 According to Subsection 5.3.1, remove clamp J2-1 and cut the nylon band, which connect cable and air tube to clamp. (Referring to Fig.5.3.1 (b))
6 Remove seal bolt (1). In case of 5F, remove collar (2), And remove guide arm (3). Do not add power forcibly when you remove guide arm. When packing is attached, remove packing (15), too. Pay attention that the load doesn’t rest upon cable and air tube so that an upper cable and the air tube may work from guide arm without removing.
7 Remove clamp J2-2 referring to Fig.5.3.2 (e) of Subsection 5.3.2 (You don’t have to cut nylon band.)
8 Pull lower cable from guide arm from J2 base to guide arm. In this time, pull out the cable after it pushes into the robot on the tip of the part of the relayed
connector and it passes it. 9 Remove bolt (14) and motor (13). 10 Remove seal bolt (9), washer plate (10) and pulley (11). 11 Remove cable K104 and K105 from motor (13). 12 Assemble it in the opposite procedure after exchanging motor and packing for the new article. In this
time, pay attention to the following.
! Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
! When installing guide arm, assemble it horizontally so as not to damage oil seal. 13 Perform single axis mastering referring to Section 8.5 of operator’s manual.
4.REPLACING PARTS B-82585EN/03
- 46 -
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Fig. 4.6 Replacing J3-axis motor
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
A97L-0218-0423#051616 (*1) 4 5.6Nm (57kgfcm)
A97L-0218-0546#051616BC(*2) 4 5.6Nm (57kgfcm)
A97L-0218-0546#051616EN(*3) 4 5.6Nm (57kgfcm) 1 SEAL BOLT
A97L-0218-0546#052016EN(*8) 4 5.6Nm (57kgfcm)
2 COLLAR A290-7139-Z373 (*8) 4
A290-7139-X304 (*4) 1
A290-7139-Y304 (*5) 1
A290-7139-Z304 (*6) 1 3 GUIDE ARM
A290-7139-Z364 (*8) 1
BOLT A97L-0218-0504#M4X10 (*1) 3 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm) 4
BOLT A6-B-4X12SUS(*8) 8
5 WASHER A290-7139-Y234 (*5) (*8) 8
A290-7139-X306 (*4) 1
A290-7139-X308 (*2) 1
A290-7139-Y308 (*5) 1
A290-7139-Z308 (*6) 1
6 J2 ARM COVER
A290-7139-Z368 (*8) 1
7 BELT A98L-0040-0190#007-098 1
8 BOLT A97L-0218-0504#M5X12 3 5.6Nm (57kgfcm)
9 SEAL BOLT A97L-0218-0423#030606 3
10 WASHER PLATE A290-7139-X231 1
11 PULLEY A290-7139-X311 1
12 KEY JB-HKY-3X3X12B 1
13 MOTOR A06B-0115-B855#0048 1
14 BOLT A6-BA-5X12 4 5.6Nm (57kgfcm)
15 PACKING A290-7139-X353 (*7) 1
16 PACKING A290-7139-X355 (*7) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard,5L,5H is specified.
B-82585EN/03 4.REPLACING PARTS
- 47 -
(*3) When 5LC,5WP,5C is specified. (*4) When Standard,5H,5Lis specified (*5) When 5LC,5C is specified. (*6) When 5WP is specified. (*7) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP 5C,5F is specified. (*8) When 5F is specified.
4.7 REPLACING J3-AXIS REDUCER
Replacing procedure 1 Turn off the controller power. 2 Remove guide arm referring to Section 4.6. 3 Remove J2 arm cover and belt referring to Section 4.6.
CAUTION When removing the belt, put the part beyond the J3 housing on a workbench to
prevent the arm from dropping
4 Remove seal bolt (1), washer (2) and pulley (3). 5 Remove bolt (4) and J2 arm to which reducer (8) is attached. Note that grease may go out. 6 Remove bolt/seal bolt (6) and reducer (8). 7 Replace reducer to new one and install to J3 arm unit horizontally. In this time, put wave washer
(10) and O-ring (9). 8 Fill grease to the reducer. It is total 10ml greasing in inside of reducer, gear and bearing of wave
generator9 Attach wave generator (7) to reducer. 10 When packing is attached, spread sealant to the reducer referring to Fig.4.7 (b) 11 Attach J3 arm unit to which reducer attach to the J2 arm. In this time, be sure to put O-ring (11).
CAUTION Do not apply grease to the O-ring (11). Otherwise, hardening of sealant is
prevented, causing a grease leak.
12 Install pulley (3) and belt. 13 Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. 14 Install J2 arm cover referring to Section 4.6. 15 Perform quick mastering and perform single axis mastering to J3-axis referring to chapter 8 of
operator’s manual.
4.REPLACING PARTS B-82585EN/03
- 48 -
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Fig. 4.7 (a) Replacing J3-axis reducer
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
1 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)
2 WASHER A290-7210-X532 1
3 PULLEY A290-7139-X312 1
4 BOLT A6-BA-3X16 16 2.0Nm (20kgfcm)
5 KEY (Attached to J3 REDUCER) 1
BOLT A6-BA-3X25 (*1) 12 2.0Nm (20kgfcm)
SEAL BOLT A97L-0218-0546#032504BC(*2) 12 2.0Nm (20kgfcm) 6
SEAL BOLT A97L-0218-0546#032504EN(*3) 12 2.0Nm (20kgfcm)
7WAVE
GENERATOR (Attached to J3 REDUCER) 1
A97L-0218-0814#100 (*4) 1
A97L-0218-0814#100C (*3) 1 8 J3 REDUCER
A97L-0218-0814#100F (*9) 1
9 O-RING (Attached to J3 REDUCER) 1
10 WAVE WASHER (Attached to J3 REDUCER) 1
11 O-RING (Attached to J3 REDUCER) 1
A290-7139-X401 (*4) 1
A290-7139-Y401 (*7) 1
A290-7139-Z401 (*6) 1
12 J3 HOUSING
A290-7139-Y461 (*8) 1
B-82585EN/03 4.REPLACING PARTS
- 49 -
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
A290-7139-Z461 (*9) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When Standard, 5H,5L is specified (*5) When 5LC,5C is specified. (*6) When 5WP is specified. (*7) When 5C clean class 100, 5LC clean class 100 is specified. (*8) When 5C clean class 10, 5LC clean class 10 is specified. (*9) When 5F is specified.
$889:#9*3+0+)#<>@#+*##+5)############8$%+*.#+5)#8299):#(01)E1*6F+#82+#9*3+0+)#06(01)#+5)#%)123)%E
Fig. 4.7 (b) Range to J3-axis reducer of sealant spreading (When severe dust/liquid protection specification
of LR Mate 200iC, LR Mate 200iC/5L or LR Mate 200iC/5C,5LC,5WP,5F is specified)
4.8 REPLACING J4-AXIS MOTOR
Replacing procedure
CAUTION This section is for standard type. This mechanical part doesn't exist in 5H or 5F.
If you replace J4-axis motor of 5H or 5F, refer to Section 4.10
1 Turn off the controller power. 2 Remove bolt/plated bolt (1). In case of 5LC or 5C,remove washer (2). And remove J3 cover (3).
When" packing is attached, remove packing (14), too. 3 Remove bolt (13), motor (12) and O-ring (4). Note that grease may go out.
4.REPLACING PARTS B-82585EN/03
- 50 -
CAUTIONWhen the motor is removed, the J3 arm can be rotated. Do as the J3arm is put on the stand so that the arm should not collide with surroundings.
4 Wipe the grease of the gear (7) off. In this time, pay attention not to damage the tooth side. 5 Remove cable K107 and K109 from motor (12). 6 Remove seal bolt (5), washer plate (6), gear (7), key (8), holder (9) and O-ring (10). 7 Assemble it in the opposite procedure after exchanging motor-ring and packing for the new article.
! Confirm the thing that the oil seal (11) is at the position, and note that the lip cannot be turned over.
! Spread grease on surroundings of the gear. 8 Perform single axis mastering referring to Section 8.5 of operator’s manual.
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Fig. 4.8 Replacing J4-axis motor
Parts Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
BOLT A97L-0218-0504#M4X10 (*1) 4 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 6 2.0Nm (20kgfcm)1
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 6 2.0Nm (20kgfcm)
2 WASHER A290-7139-Y234 (*5) 6
A290-7139-X404 (*4) 1
A290-7139-X406 (*2) 1
A290-7139-Y406 (*5) 1 3 J3 COVER
A290-7139-Z406 (*6) 1
4 O-RING A98L-0001-0347#S46 1
5 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
6 WASHER PLATE A290-7139-X231 1
7 GEAR J4-1 A290-7139-X411 1
8 KEY JB-HKY-3X3X12B 1
9 HOLDER A290-7139-X221 1
10 O-RING A98L-0001-0347#S46 1
11 OIL SEAL A98L-0040-0223#01001805 1
No brake A06B-0114-B205#0048 12 MOTOR
With brake A06B-0114-B855#0048 1
13 BOLT A6-BA-5X20 4 5.6Nm (57kgfcm)
14 PACKING A290-7139-X451 (*7) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L is specified. (*2) When severe dust/liquid protection specification of Standard, 5L is specified. (*3) When 5LC,5WP,5C is specified. (*4) When Standard, 5Lis specified
B-82585EN/03 4.REPLACING PARTS
- 51 -
(*5) When 5LC,5C is specified. (*6) When 5WP is specified. (*7) When severe dust/liquid protection specification of Standard,5L or 5C,5LC,5WP is specified
4.9 REPLACING J4-AXIS REDUCER
Replacing procedure
CAUTION This section is for standard type. This mechanical part doesn't exist in 5H or 5F.
If you replace J4-axis reducer of 5H or 5F, refer to Section 4.11.
1 Turn off the controller power. 2 Remove J3 arm cover, relay connector and air tube referring to Section 4.10. 3 Remove J3 cover and cut the nylon band, which connect cable to clamp (2) referring to Section 4.8. 4 Pull out the cable of the J3 arm to the J3 casing side through the pipe. In this time, pull out the cable
after it pushes into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relayed connector caught.
5 Remove bolt (1) and clamp (2). 6 Remove bolt (3), (4) and J3 arm (13). Pay attention not to damage oil seal (8). Note that there is a
possibility that grease goes out. 7 Wipe the grease of the gear (12) off. In this time, pay attention not to damage the tooth side. 8 Remove bolt/plated bolt (6) and reducer (10). 9 Remove seal bolt (5) and pipe (9). 10 Remove seal bolt (7) and gear (12). 11 Assemble it in the opposite procedure after exchanging reducer for the new article.
! When installing reducer, spread grease on teeth of Wave generator, and be sure to install O-ring (11). (In case of J4-axis reducer, wave generator is assembled in reducer when it is shipped.) Also, pay attention to the phase of bolts referring to Fig.4.9(c).
! Spread grease on surroundings of the gear.
! When installing reducer to J3 casing apply bolt (3) after applying all bolt (4).
! When installing J3 arm, confirm the thing that the oil seal (8) is at the position, and note that the lip cannot be turned over.
! When severe dust/liquid protection specification of Standard, 5L or 5C,5LC,5WP is specified, spread sealant to the each part referring to Fig.4.9 (b).
CAUTION Do not apply grease to the O-ring (11). Otherwise, hardening of sealant is
prevented, causing a grease leak.
12 Perform quick mastering and perform single axis mastering for J4-axis referring to chapter 8 of operator’s manual.
NOTE When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear of J4-axis motor shaft.
4.REPLACING PARTS B-82585EN/03
- 52 -
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Fig. 4.9 (a) Replacing J4-axis reducer
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
1 BOLT A6-BA-4X8 1
2 CLAMP J4-1 A290-7139-X432 2
3 BOLT A6-BA-3X30 4 2.0Nm (20kgfcm)
4 BOLT A6-BA-3X35 10 2.0Nm (20kgfcm)
5 SEAL BOLT A97L-0218-0423#030606 4 1.3Nm (13kgfcm)
BOLT A6-BA-3X25 (*1) 9 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M3X25BC (*2) 9 2.0Nm (20kgfcm) 6
PLATED BOLT A97L-0218-0496#M3X25EN (*3) 9 2.0Nm (20kgfcm)
7 SEAL BOLT A97L-0218-0423#030505 6 1.3Nm (13kgfcm)
8 OIL SEAL A98L-0040-0049#02603707 1
9 PIPE A290-7139-X421 1
A97L-0218-0815#80(*4) 1 LT518 10 J4 REDUCER
A97L-0218-0815#80C(*3) 1 LT518
11 O-RING (Attached to J4 REDUCER) 1
12 GEAR J4-2 A290-7139-X412 1
A290-7139-X402 (*4) 1
A290-7139-Y402 (*5) 1
A290-7139-Y462 (*7) 1 13 J3 ARM 1
A290-7139-Z402 (*6) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L is specified. (*2) When severe dust/liquid protection specification of Standard, 5L is specified. (*3) When 5LC,5WP,5C is specified. (*4) When Standard, 5Lis specified (*5) When 5LC,5C clean class 100 is specified. (*6) When 5WP is specified. (*7) When 5LC,5C clean class 10 is specified.
B-82585EN/03 4.REPLACING PARTS
- 53 -
$
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8VIO
$IINYVTS#HLOH#KJ#9+<>@
,Z>-(O[OLO#PMRG\NV]MVP#ILKGOQGVKT#RIOQVJVQHGVKT#KJ#####9%#&HGO#"DDV3^9%#&HGO#"DDV3\<9^#####$%3#&HGO#<DV3^$%3#&HGO#<DV3\<9#KL#####9%#&HGO#"DDV3\<3^<93^<C8
_!4#QHRVTS#RVPO#KJ#LOPMQOL,Z>-_808)_!4#QHRVTS#RVPO#KJ#!4#HLW##$IINY#9*3+0+)#<>@#GK#GUO############KL##############IHLG#,Z>-
(O[OLO#PMRG\NV]MVP#ILKGOQGVKT#RIOQVJVQHGVKT#KJ9%#&HGO#"DDV3^$%3#&HGO#<DV3#KL9%#&HGO#"DDV3\<3^<C8
(O[OLO#PMRG\NV]MVP#ILKGOQGVKT#RIOQVJVQHGVKT#KJ9%#&HGO#"DDV3\<9^$%3#&HGO#<DV3\<9KL#9%#&HGO#"DDV3\<93
Fig. 4.9 (b) Spread range of sealant
,&4/4<-
&4/4D,;-
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Fig. 4.9 (c) Assembled phase of J4-axis reducer
4.REPLACING PARTS B-82585EN/03
- 54 -
4.10 REPLACING J5-AXIS MOTOR
Replacing procedure
CAUTION This mechanism becomes J4 axis in 5H or 5F. When you replace part of 5H or
5F, read J5/J6 as J4/J5.
1 Turn off the controller power. 2 Remove bolt/plated bolt (1). In case of 5LC,5C,5F, remove washer (2).And remove J3 arm cover (3).
When packing is attached, remove packing (14), too. 3 Remove bolt/plated bolt (4) . In case of 5LC,5C,5F, remove washer (5).And remove J3 arm cover
(6). When packing is attached, remove packing (15), too. 4 Loosen a bolt (7) a little and lower the tension of the belt (8) and remove belt (8). Remove the bolt
(16) when you do not remove the belt easily. 5 Pull cable from upper side of J5-axis motor and remove all relay connector.
CAUTION When the belt is removed, the wrist moves to bellow side. Do as the wrist is put on the
stand so that the wrist should not collide with surroundings.
6 Remove bolt (7) and motor (13). 7 Remove cable K110, K111 from motor (13). 8 Remove seal bolt (9), washer (10), motor pulley (11) and key (12). 9 Assemble it in the opposite procedure after exchanging motor and packing for the new article.
!" Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
!" In case of 5F, pay attention to assemble J3 arm cover mounting bolts referring to Fig.4.10 (c). 10 Perform single axis mastering referring to Section 8.5 of operator’s manual. In this time, perform not
only J5-axis but also J6-axis.
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Fig. 4.10 (a) Replacing J5-axis motor
B-82585EN/03 4.REPLACING PARTS
- 55 -
+)6(0*6#$1!2(+067'*9+
>=
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$=X'X;/>"(2(#,;-
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Fig. 4.10 (c) J3 arm cover mounting bolts (LR Mate 200iC/5F)
Parts Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 4.5Nm (46kgfcm)
1
BOLT A6-B-4X12SUS (*7) 4 2.0Nm (20kgfcm)
4.REPLACING PARTS B-82585EN/03
- 56 -
Parts Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
A6-B-4X18SUS (*7) 7 2.0Nm (20kgfcm)
2 WASHER A290-7139-Y234 (*4)(*7) 11
A290-7139-X405 (*1) 1
A290-7139-X407 (*2) 1
A290-7139-Y407 (*4) 1
A290-7139-Z407 (*5) 1
3 J3 ARM COVER
A290-7139-Z467 (*7) 1
BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 4.5Nm (46kgfcm)
A6-B-4X12SUS (*7) 4
4
BOLT A6-B-4X14SUS (*7) 7
5 WASHER A290-7139-Y234 (*4)(*7) 11
A290-7139-X405 (*1) 1
A290-7139-X407 (*2) 1
A290-7139-Y407 (*4) 1
A290-7139-Z407 (*5) 1
6 J3 ARM COVER
A290-7139-Z467 (*7) 1
7 BOLT A97L-0218-0504#M5X12 3 5.6Nm (57kgfcm)
8 BELT A98L-0040-0227#006-152 1
9 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)
10 WASHER A290-7210-X532 1
11 MOTOR PULLEY A290-7139-X413 1
12 KEY A97L-0118-0402#3X3X6BN 1 LT242
With brake A06B-0117-B855#0049 1 13 MOTOR
No brake A06B-0117-B205#0049 1
14 PACKING A290-7139-X454 (*6) 1
15 PACKING A290-7139-X454 (*6) 1
16 BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
(*1) When not severe dust/liquid protection specification of Standard,5L is specified. (*2) When severe dust/liquid protection specification of Standard,5L is specified. (*3) When 5LC,5WP,5C is specified. (*4) When 5LC,5C is specified. (*5) When 5WP is specified. (*6) When severe dust/liquid protection specification of Standard, 5L or 5C,5LC,5WP,5F is specified (*7) When 5F is specified.
4.11 REPLACING J5-AXIS REDUCER
Replacing procedure
CAUTION This mechanism becomes J4 axis in 5H or 5F.When you replace part of 5H or
5F, read J5/J6 as J4/J5.
1 Turn off the controller power. 2 Remove both side of J3-arm cover referring to Section 4.10. 3 Remove belt (1) referring to Section 4.10. 4 Pull out cable from upper side of J5-axis motor and remove all relay of cable.
B-82585EN/03 4.REPLACING PARTS
- 57 -
CAUTION When the belt is removed, the wrist moves to bellow side. Do as the wrist is put on the
stand so that the wrist should not collide with surroundings.
5 Remove seal bolt (2), washer plate (3) and pulley (4). 6 Remove key (6) and bolt (7). 7 Remove seal bolt (8) and J3 arm (9). When packing is attached, remove packing (16), too. In this
time, pay attention not to damage oil seal (5). Pay attention that grease may go out, too. 8 Remove relay of cable K112, K113 and K106, K107. 9 Remove bolt/plated bolt (10) and remove reducer (13). 10 Replace reducer and packing to new one, and assemble robot by opposite procedure. In this time,
pay attention below.
! Fill grease to the reducer. It is total 7ml greasing in inside of reducer, gear and bearing of wave generator and install it horizontally. Be sure to install O-ring (11) and (14) and wave washer (15).
! Apply grease to the lip of the Oil seal (5)
! Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
! When severe dust/liquid protection specification of Standard, 5L,5H or 5C,5LC,5WP,5F is specified, spread sealant to the reducer referring to Fig.4.11 (b).
CAUTION Do not apply grease to the O-ring (11). Otherwise, hardening of sealant is
prevented, causing a grease leak.
11 Perform single axis mastering to J5-axis and J6-axis referring to chapter 8 of operator’s manual.
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Fig. 4.11 (a) Replacing J5-axis reducer
4.REPLACING PARTS B-82585EN/03
- 58 -
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
1 BELT A98L-0040-0227#006-152 1
2 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
3 WASHER PLATE A290-7139-X231 1
4 PULLEY A290-7139-X414 1
5 OIL SEAL A98L-0040-0223#01001805 1
6 KEY JB-HKY-3X3X6B 1
7 BOLT A6-BA-3X8 12 2.0Nm (20kgfcm)
8 SEAL BOLT A97L-0218-0423#041616 7 4.5Nm (46kgfcm)
A290-7139-X403 (*1) 1
A290-7139-Y403 (*2) 1
A290-7139-Z403 (*3) 1
A290-7139-Y463 (*9) 1
9 J3 ARM 2
A290-7139-Z463 (*10) 1
BOLT A6-BA-3X22 (*4) 9 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M3X22BC (*5) 9 2.0Nm (20kgfcm) 10
PLATED BOLT A97L-0218-0496#M3X22EN (*6) 9 2.0Nm (20kgfcm)
11 O-RING (Attached to J5 REDUCER) 1
12WAVE
GENERATOR (Attached to J5 REDUCER) 1
A97L-0218-0816#50(*1) 1
A97L-0218-0816#50C(*6) 1 13 J5 REDUCER
A97L-0218-0816#50F(*10) 1
14 O-RING (Attached to J5 REDUCER) 1
15 WAVE WASHER (Attached to J5 REDUCER) 1
16 PACKING A290-7139-X453 (*7) (*10) 1
(*1) When Standard, 5L,5H is specified. (*2 )When 5LC,5C is specified. (*3) When 5WP is specified. (*4) When not severe dust/liquid protection specification of Standard, 5L,5H (*5) When severe dust/liquid protection specification of Standard,5L,5H (*6) When 5LC,5WP,5C is specified. (*7) When severe dust/liquid protection specification of Standard, 5L,5H or 5LC,5WP 5C is specified. (*8) When 5C clean class 100 or 5LC clean class 100 is specified. (*9) When 5C clean class 10 or 5LC clean class 10 is specified. (*10) When 5F is specified.
B-82585EN/03 4.REPLACING PARTS
- 59 -
$889:#9*3+0+)#<>@#+*#########*.#*X%067,>>-#(01)E
1*6F+#82+#9*3+0+)#06(01)#+5)#%)123)%E
Fig. 4.11 (b) Spread range of sealant to J5-reducer (When severe dust/liquid protection specification of LR
Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C,5F is specified.)
4.12 REPLACING J6-AXIS MOTOR
Replacing procedure
CAUTION This mechanism becomes J5 axis in 5H or 5F.When you replace part of 5H or
5F,read J6 as J5. 1 Turn off the controller power. 2 Remove both side of J3 arm cover of J3 arm referring to Section 4.10. 3 Loosen tension adjusting bolt and lower tension and remove belt (1) referring to Fig. 6.1.1 (b).
Loose the bolt (9) and remove pulley if it is difficult to remove the belt.
CAUTIONWhen the belt (1) is removed, the wrist moves to bellow side. Do as the wrist is put on the stand so that the wrist should not collide with surroundings.
4 Loosen bolt (2) and lower tension and remove belt (3).
CAUTIONWhen the belt (3) is removed, the wrist become rotatable, When end effector is attached, fix it so that the wrist should not collide with surroundings.
5 Remove bolt (2) motor (8). 6 Remove cable K112, K113 from motor (8). 7 Remove seal bolt (4), washer (5), motor pulley (6) and key (7). 8 Assemble it in the opposite procedure after exchanging motor and packing for the new article.
! Adjust the tension of the belt referring to Section 6.1 after the installation of the belt
4.REPLACING PARTS B-82585EN/03
- 60 -
9 Perform single axis mastering referring to Section 8.5 of operator’s manual. In this time, perform not only J6-axis but also J5-axis.
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Fig. 4.12 (a) Replacing J6-axis motor
+)6(0*6#$1!2(+067'*9+ +)6(0*6#$1!2(+067
'*9+?
B0)C#$ B0)C#'Fig. 4.12 (b) Replacing J6-axis motor
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
1 BELT A98L-0040-0227#006-152 1
2FLANGE
SOCKET BOLT A97L-0218-0504#M5X12 3
3 BELT A98L-0040-0227#006-100 1
4 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)
B-82585EN/03 4.REPLACING PARTS
- 61 -
5 WASHER A290-7210-X532 1
6MOTOR
PULLEYA290-7139-X413 1
7 KEY JB-HKY-3X3X6B 1
No brake A06B-0117-B205#00498 MOTOR
With brake A06B-0117-B855#00491
9 BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
4.13 REPLACING WRIST UNIT
Replacing procedure
CAUTION If you replace unit of 5H or 5F, read J5/J6 as J4/J5.
1 Turn off the controller power. 2 Replacing both side of J3 arm cover of J3 arm referring to Section 4.10. 3 Remove belt (1), (8) referring to Section 4.12.
CAUTIONWhen the belt (1), (8) is removed, the wrist moves to bellow side or rotate. Do as the wrist is put on the stand so that the wrist should not collide with surroundings.
4 Remove seal bolt (9), washer (10), pulley (11) and key (12). 5 Remove seal bolt (13) and J3 arm (14). When packing is attached, remove packing (21), too. 6 Remove relay of cable K112, K113 of J6-axis motor and cable K107 and K108. 7 Remove seal bolt (2), washer plate (3) and pulley (4). 8 Remove bolt (7), wrist unit (20) and key (5). In this time, pay attention not to damage oil seal (6).
Pay attention that grease may go out, too. 9 Remove bolt/plated bolt (19) and J5-axis reducer (16). 10 Replace wrist unit to new one and attach it. Attach reducer horizontally after apply greasing to gear
of reducer. In this time, be sure to replace wave washer (15), O-ring (17), (18), too. Apply grease to the lip of the oil seal (6).
11 Assemble it in the reverse order of 3-8. 12 Adjust belt referring to Section 6.1. 13 Install J3 arm cover. 14 Perform single axis mastering referring to Section 8.5 of operator’s manual. In this time, perform not
only J6-axis but also J5-axis.
4.REPLACING PARTS B-82585EN/03
- 62 -
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Fig. 4.13 Replacing wrist unit
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
1 BELT A98L-0040-0227#006-152 1
2 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm)
3 WASHER PLATE A290-7139-X231 1
4 PULLEY A290-7139-X414 1
5 KEY JB-HKY-3X3X6B 1
6 OIL SEAL A98L-0040-0223#01001805 1
7 BOLT A6-BA-3X8 12 2.0Nm (20kgfcm)
8 BELT A98L-0040-0227#006-100 1
9 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm)
10 WASHER A290-7210-X532 1
11 MOTOR PULLEY A290-7139-X413 1
12 KEY JB-HKY-3X3X6B 1
13 SEAL BOLT A97L-0218-0423#041616 7 4.5Nm (46kgfcm)
A290-7139-X403 (*1) 1
A290-7139-Y403 (*8) 1
A290-7139-Z403 (*3) 1
A290-7139-Y463 (*9) 1
14 J3 ARM 2
A290-7139-Z463 (*10) 1
15 WAVE WASHER (Attached to J5 REDUCER) 1
A97L-0218-0816#50(*1) 1
A97L-0218-0816#50C(*4) 1 16 J5 REDUCER
A97L-0218-0816#50F(*10) 1
17 O-RING (Attached to J5 REDUCER) 1
18 O-RING (Attached to J5 REDUCER) 1
B-82585EN/03 4.REPLACING PARTS
- 63 -
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
BOLT A6-BA-3X22 (*5) (*11) 9 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M3X22BC (*6) (*12) 9 2.0Nm (20kgfcm) 19
PLATED BOLT A97L-0218-0496#M3X22EN (*4) 9 2.0Nm (20kgfcm)
A290-7139-V502 (*5)(*6) 1
A290-7139-V521 (*2) 1
A290-7139-V531 (*3) 1
A290-7139-V503 (*10) 1
20 WRIST ASS’Y
A290-7139-V505 (*11)(*12) 1
21 PACKING A290-7139-X453 (*7) 1
(*1) When Standard, 5L,5H is specified. (*2) When 5LC,5C is specified. (*3) When 5WP is specified. (*4) When 5LC,5WP,5C is specified. (*5) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*6) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*7) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP 5C,5F is specified. (*8) When 5C clean class 100 or 5LC clean class 100 is specified. (*9) When 5C clean class 10 or 5LC clean class 10 is specified. (*10) When 5F is specified. (*11) When not severe dust/liquid protection specification of 5H high speed wrist is specified. (*12) When severe dust/liquid protection specification of 5H high speed wrist is specified.
4.14 REPLACING J6-AXIS REDUCER
Replacing procedure
CAUTION This mechanism becomes J5 axis in 5H or 5F.When you replace part of 5H or
5F,read J6 as J5.
1 Make to posture that J6 turns to the right under and turn off the controller power as shown in Fig.4.14 (a).
2 Remove bolt (1) and reducer. 3 Remove seal bolt (3), washer (4) and wave generator (5). 4 Remove O-ring (6). 5 Apply greasing to bearing of wave generator (5) to which attach new reducer and install to the robot. 6 Greasing total 6ml inside and gear of reducer (2) and wave generator by using the injection syringe. 7 Install new reducer (2) to the robot. In this time, replace O-ring (6) to new one, too. 8 Perform single axis mastering referring to Section 8.5 of operator’s manual. In this time, perform not
only J6-axis but also J5-axis.
4.REPLACING PARTS B-82585EN/03
- 64 -
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Fig. 4.14 (a) Replacing J6-axis reducer
&4/"<
Fig. 4.14 (b) Assembling phase of J6-axis reducer
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
BOLT A6-BA-3X25 (*1) 8 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M3X25BC (*2) 8 2.0Nm (20kgfcm) 1
PLATED BOLT A97L-0218-0496#M3X25EN (*3) 8 2.0Nm (20kgfcm)
A97L-0218-0817#50(*4) 1
A97L-0218-0817#50C(*3) 1
A97L-0218-0817#30 (*5) 1 2 REDUCER
A97L-0218-0817#30F (*6) 1
3 SEAL BOLT A97L-0218-0432#030808 1 1.3Nm (13kgfcm)
B-82585EN/03 4.REPLACING PARTS
- 65 -
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
4 WASHER A290-7210-X532 1
5WAVE
GENERATOR (ATTACHED TO J6 REDUCER) 1
6 O RING (ATTACHED TO J6 REDUCER) 1 2.0Nm (20kgfcm)
(*1) When not severe dust/liquid protection specification of Standard,5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard,5L,5H is specified. (*3) When 5LC,5WP 5C is specified. (*4) When Standard, 5H,5L is specified. (*5) When 5H high speed wrist is specified. (*6) When 5F is specified.
4.15 REPLACING J3 BELT
Replacing procedure 1 Turn off the controller power. 2 Remove bolt/plated bolt (1). In case of 5LC,5C,5F, remove washer (2). And remove J2 arm cover
(3). When packing is attached, remove packing (4), too. 3 Loosen tension adjusting bolt and lower tension and remove belt (5) referring to Fig.4.15.
CAUTION When removing the belt (5), put the part beyond the J3 housing on a workbench
to prevent the arm from dropping.
4 Replace belt and packing to new one and do the opposite procedure. In this time, pay attention below.
! Adjust the tension of the belt referring to Section 6.1 after the installation of the belt. 5 Perform single axis mastering referring to Section 8.5 of operator’s manual.
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"
Fig. 4.15 Replacing J3 belt
4.REPLACING PARTS B-82585EN/03
- 66 -
Parts Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC(*2) 8 4.5Nm (46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN(*3) 8 4.5Nm (46kgfcm) 1
BOLT A6-B-4X12SUS(*7) 8 2.0Nm (20kgfcm)
2 WASHER A290-7139-Y234 (*4) (*7) 8
A290-7139-X306 (*1) 1
A290-7139-X308 (*2) 1
A290-7139-Y308 (*4) 1
A290-7139-Z308 (*5) 1
3 J2 ARM COVER
A290-7139-Z368 (*7) 1
4 PACKING A290-7139-X355 (*6) 1
5 BELT A98L-0040-0190#007-098 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When 5LC,5C is specified. (*5) When 5WP is specified. (*6) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified. (*7) When 5F is specified.
4.16 REPLACING J5/J6 BELT
Replacing procedure
CAUTIONWhen replacing 5H or 5F,please read J5/J6 as J4/J5.
1 Turn off the controller power. 2 Remove bolt/plated bolt (1). In case of 5LC,5C,5F , remove washer (2). And remove J3 arm cover
(3). When packing is attached, remove packing (4), too. 3 Remove bolt/plated bolt (5).In case of 5LC,5C,5F , remove washer (6). And remove J3 arm cover
(7). When packing is attached, remove packing (8), too. 4 In case of replacing J5 belt, loosen tension adjusting bolt and lower tension and remove belt
referring to Fig.6.1.1 (b). In case of replacing J6 belt, loosen tension adjusting bolt and lower tension and remove belt
referring to Fig.6.1.1 (c).
CAUTIONWhen the belt (9) is removed, the wrist moves to bellow side or rotate. Do as the wrist is put on the stand so That the wrist should not collide with surroundings.
CAUTIONWhen the belt (10) is removed, the wrist become possible to rotate. When end effector is attached, fix it so that the wrist should not collide with surroundings.
5 Replace belt and packing to new one and do the opposite procedure. In this time, pay attention below.
! Adjust the tension of the belt referring to Section 6.1 after the installation of the belt.
! In case of 5F, pay attention to assemble J3 arm cover mounting bolts referring to Fig.4.16 (b).
B-82585EN/03 4.REPLACING PARTS
- 67 -
6 Perform single axis mastering referring to Section 8.5 of operator’s manual. In this time, perform not only J5-axis but also J6-axis when replacing J5 belt.
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=Fig. 4.16 (a) Replacing J5/J6 belt
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 4.5Nm (46kgfcm)
A6-B-4X12SUS(*7) 4 2.0Nm (20kgfcm)
1
BOLT A6-B-4X18SUS(*7) 7 2.0Nm (20kgfcm)
2 WASHER A290-7139-Y234 (*4) (*7) 11
A290-7139-X405 (*1) 1
A290-7139-X407 (*2) 1
A290-7139-Y407 (*4) 1
A290-7139-Z407 (*5) 1
3 J3 ARM COVER
A290-7139-Z467 (*7) 1
4 PACKING A290-7139-X454 (*6) 1
BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm) 5
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 4.5Nm (46kgfcm)
6 WASHER A290-7139-Y234 (*4) (*7) 11
A290-7139-X405 (*1) 1
A290-7139-X407 (*2) 1
A290-7139-Y407 (*4) 1
A290-7139-Z407 (*5) 1
7 J3 ARM COVER
A290-7139-Z467 (*7) 1
4.REPLACING PARTS B-82585EN/03
- 68 -
Parts Name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
8 PACKING A290-7139-X454 (*6) 1
9 BELT A98L-0040-0227#006-152 1
10 BELT A98L-0040-0227#006-100 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When 5LC,5C is specified. (*5) When 5WP is specified. (*6) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified. (*7) When 5F is specified.
$=X'X;/>"(2(#,;-
$=X'X;/>"(2(#,;-
$=X'X;/>;(2(#,A-
$=X'X;/>@(2(#,A-
Fig. 4.16 (b) J3 arm cover mounting bolts (LR Mate 200iC/5F)
4.17 REPLACING SOLENOID VALVE
Replacing procedure 1 Make J3-axis to posture in which SV PLATE is removed easily. 2 Turn off the controller power. 3 Remove bolt (1), (4) , in case of 5LC,5C,5F remove washer (2),(5).And remove SV PLATE (3).
When packing is attached, remove packing (5), too. 4 Remove relay of air tube and take solenoid valve out. 5 Replace solenoid valve and packing to new one, and do the opposite procedure.
In case of 5F, fill gap between plate and article of cast metal with SEALANT 4588 (CLEAR).
B-82585EN/03 4.REPLACING PARTS
- 69 -
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Fig. 4.17 Replacing Solenoid valve
Parts Name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
BOLT A6-BA-4X8 (*1) 4
PLATED BOLT A97L-0218-0546#040808BC(*2) 4 4.0Nm (40kgfcm)
PLATED BOLT A97L-0218-0546#040808EN(*3) 4 4.5Nm (45kgfcm)
PLATED BOLT A97L-0218-0546#041010EN(*4) 4 4.5Nm (45kgfcm)
1
PLATED BOLT A97L-0218-0760#040808S (*6) 4 2.0Nm (20kgfcm)
2 WASHER A290-7139-Y234 (*3)(*6) 4
A290-7139-X433 (*1)(*2) 1
A290-7139-Y433 (*3) 1
A290-7139-Z433 (*4) 1 3 SV PLATE
A290-7139-Z471 (*6) 1
BOLT A6-BA-4X8 (*1) 2
PLATED BOLT A97L-0218-0546#040808BC(*2) 2 4.0Nm (45kgfcm)
PLATED BOLT A97L-0218-0546#040808EN(*3) 2
PLATED BOLT A97L-0218-0546#041010EN(*4) 2
4
PLATED BOLT A97L-0218-0760#040808S (*6) 2 2.0Nm (20kgfcm)
5 WASHER A290-7139-Y234 (*6) 2
6SOL VALVE
A97L-0218-0113#D3R or
A97L-0218-0113#D3 or
A97L-0218-0113#D2 or
A97L-0218-0113#D1
1
7 PACKING A290-7139-X452 (*5) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5C is specified. (*4) When 5WP is specified. (*5) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified. (*6) When 5F is specified.
4.REPLACING PARTS B-82585EN/03
- 70 -
4.18 SEALANT APPLICATION
Washing and degreasing the surfaces to be sealed 1 After dismounting the reducer from the arm, apply releasant (LOCTITE Gasket Remover) to the
arm’s surface from which the reducer was dismounted, then wait until the sealant (LOCTITE 518) becomes softened (for about 10 minutes). Remove the softened sealant from the surface using a spatula.
2 Blow air onto the surface to be sealed to remove dust from the tapped holes. 3 Sufficiently degrease the reducer’s surface to be sealed and the arm’s surface to be sealed, using a
cloth dampened with alcohol. 4 Polish the arm’s surface to be sealed with an oil stone, and degrease it with alcohol again.
CAUTION Oil may drip from the inside of the reducer. After degreasing, make sure that no
oil is dripping.
Applying sealant 5 Make sure that the reducer and the arm is dry (with no alcohol remaining). If they are still wet with
alcohol, wipe them dry. 6 Apply sealant (LOCTITE 518) to the surfaces.
CAUTION The portions to which sealant is to be applied vary from one axis to another. See
descriptions about reducer replacement for the relevant axes for details.
Assembling7 To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as
quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant was wiped off, apply again.
8 After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get closer.
B-82585EN/03 5.REPLACING CABLES
- 71 -
5 REPLACING CABLES
Replace the cables every four years (15,360 hours). When the cable is broken or damaged or shows signs of wear, replace it according to this chapter.
Precautions to be observed when handling the pulsecoder cable The pulsecoder cable is provided with a marking tie, as shown below, to warn against disconnecting the cable during transportation, installation, or maintenance. If the cable with the marking tie is disconnected, mastering must be performed again. Therefore, do not disconnect the cable except when replacement of the motor, the pulsecoder, the reducer, and the cable are necessary.
!"##$%&'!"()*+
,-./#
,01(-..$(#
23456789
Fig. 5 marking label
5.1 CABLE WIRING
Followings are the routing of the robot cables.
5.REPLACING CABLES B-82585EN/03
- 72 -
!"#"$%&'()*+',)-./0,123.4)5./6
!"#7$*7',)-./6!"#8$*7',123.4)5./6
!"#9$*8',)-./6!"#:$*8',123.4)5./6
!"#+$*9'()'*+',)-./6!"#;$*9'()'*+',123.4)5./6
!"#<$=>6
!"#?$*9',)-./6
!""#$*:',)-./6!"""$*:',123.4)5./6
!""7$*+',)-./6!""8$*+',123.4)5./6
!""9$@A5'.BB.4()/6
Fig.5.1 (a) Routing of the robot cables (Standard,5L,5LC,5C,5WP)
B-82585EN/03 5.REPLACING CABLES
- 73 -
!"#"$%&'()'*:',)-./0',123.4)5./6
!"#7$*7',)-./6!"#8$*7',123.4)5./6
!"#9$*8',)-./6!"#:$*8',123.4)5./6
!"#+$*9'()'*:',)-./6!"#;$*9'()'*:',123.4)5./6
!"#<$=>6
!""#$*9',)-./6!"""$*9',123.4)5./6
!""7$*:',)-./6!""8$*:',123.4)5./6
!""9$@A5'.BB.4()/6
Fig. 5.1 (b) Routing of the robot cables (5H,5F)
5.2 CABLE FORMING
When replacing cables, clamp the cable at the position specified in Fig.5.2 (a) to (d) using a clamp or a nylon band. Otherwise, cables can be loosened or pulled by force to cause their disconnection. Refer to the Fig.5.2 (a) to (e) for the cable clamp.
5.REPLACING CABLES B-82585EN/03
- 74 -
!"#$
!"!
!"!%&$%'(
!)!%&$%%'
!)!
!(!%&$%'*
!(!
''2345'6789
'',01( -..$ (#'''',- ./#
!"##$% &'!" () *+
:;+<')<=>
:;+
+,-
+,%&$%'.
!()/!%&$%'/
!(!%
!)!%
!/!%
''2345'6789
'', 01(-.. $(#
''' ',-./#
!"# #$%&'! "()*+
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:?+
!/!%&$%%-
!/!
' '2345'6789
'',01(-. .$(#' ''',-./ #
! "##$%&' !"()*+
''2345'6789'',01(-. .$(#
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Fig.5.2 (a) Cable externals chart of Mechanical unit (Standard 3-axes brake type)
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F2GK,*7L7
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Fig.5.2 (b) Cable externals chart of Mechanical unit
(Standard, 5L,5LC,5C,5WP 6-axes brake type)
B-82585EN/03 5.REPLACING CABLES
- 75 -
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Fig.5.2 (c) Cable externals chart of Mechanical unit (5WP)
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Fig.5.2 (d) Cable externals chart of Mechanical unit (5H,5F 3-axes brake type)
5.REPLACING CABLES B-82585EN/03
- 76 -
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Fig.5.2 (e) Cable externals chart of Mechanical unit (5H,5F 5-axes brake type)
5.3 CABLE AND AIR TUBE REPLACEMENT
This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables. See Section 5.1 for the configuration of the mechanical unit cables. You must perform mastering after cable replacement. Refer to Chapter 6 MASTERING or chapter 8 OPERATOR’S MANUAL in advance. (If pulsecoder cable is not replaced, mastering is not necessary.)
5.3.1 Replacing Cable K101 and Air tube (Connector plate to J2
base)
Replacing procedure 1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set
in 0° for all axes when robot is shipped.) 2 Turn off the controller power and remove cable of controller side from connector plate of back of
J1-axis.3 Remove robot from floor plate, knock down the robot sidewise. 4 Remove J2 base cover (3) referring to Fig.5.3.1 (a). 5 Remove all relay of cable K102, K103, K104, K105, K106, K107, K108 and K101.Remove relay of
air tube similarly. (In case of 5C,5LC there are two white air tube and one black air tube, In case of other models there is one white air tube and one black air tube.)
6 Remove bolt (5). In case of 5C,5LC,5F remove washer (6). And remove cover U (7). When packing is attached, remove packing (8), too.
7 If necessary, remove cover B. (See Fig.5.3.1 (c)) 8 Cut the nylon band which connect cable and air tube to clamp J1-2 referring to Fig.5.2.1(d). 9 Cut the nylon band of battery box terminal and remove cable.
B-82585EN/03 5.REPLACING CABLES
- 77 -
10 Remove connector plate. 11 Pull cable and air tube in J2 base to J1 base side. In this time pull out the cable after it pushes into
the pipe on the tip of the part of the relayed connector and it passes. 12 Replace cable and air tube for the new article and assemble them by opposite procedure. When
packing is attached, be sure to replace packing to new one. 13 Perform quick mastering referring to Section 8.4 of operator’s manual.
"89
:;<
7+
Fig.5.3.1 (a) Remove the J2 base cover
Parts name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm(20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm(46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 8 4.5Nm(46kgfcm) 1
BOLT A6-B-4X12SUS (*7) 8 2.0Nm(20kgfcm)
2 WASHER A290-7139-Y234 (*4) (*7) 8
A290-7139-X305 (*1) 1
A290-7139-X307 (*2) 1
A290-7139-Y307 (*4) 1
A290-7139-Z307 (*5) 1
3 J2 BASE COVER
A290-7139-Z367 (*7) 1
4 PACKING A290-7139-X354 (*6) 1
A6-BA-4X8 (*1) 4
A97L-0218-0546#040808BC(*2) 4
A97L-0218-0546#040808EN(*3) 4 5 BOLT
A97L-0218-0760#040808S (*7) 4
6 WASHER A290-7139-Y234 (*4) (*7) 4
7 COVER U A290-7139-X332 1
8 PACKING A290-7139-X356 (*6) 1
(*1) When not severe dust/liquid protection specification of Standard,5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified.
5.REPLACING CABLES B-82585EN/03
- 78 -
(*4) When 5LC,5C is specified. (*5) When 5WP is specified. (*6) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified. (*7) When 5F is specified.
FGJ2.'!"#:
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S
D
D
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SQ='7$WXQP@6
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EGA.2'1AI)A
Fig.5.3.1 (b) Replace the cable in J2 base
B-82585EN/03 5.REPLACING CABLES
- 79 -
FGJ2.'!"#:
FGJ2.'!"#9
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O@FPQ>R'YLY
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Y
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@VP$O9'WXQP@6
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Z
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Fig.5.3.1 (c) Replace the cable in J2 base (5L,5LC)
5.REPLACING CABLES B-82585EN/03
- 80 -
"78
Fig.5.3.1 (d) Remove the cover B (When only severe dust/liquid protection specification is specified)
When severe dust/liquid protection specification of Standard, 5L,5H or 5LC,5WP,5C,5F is specified.
Parts name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
PLATED BOLT A97L-0218-0496#M4X8BC(*1) 10 4.5Nm(46kgfcm)
PLATED BOLT A97L-0218-0496#M4X8EN(*2) 10 4.5Nm(46kgfcm) 1
BOLT A6-B-4X8SUS (*3) 10 2.0Nm(20kgfcm)
A290-7139-X233 (*1) 1 2 COVER B
A290-7139-Y233 (*2) 1
3 PACKING A290-7139-X252 1
(*1) When severe dust/liquid protection specification of Standard , 5L,5H is specified. (*2) When 5LC,5WP,5C,5F is specified. (*3) When 5F is specified.
B-82585EN/03 5.REPLACING CABLES
- 81 -
SQ='"$DTSF!6
SQ='7$WXQP@6
E123.4)5./'2IA.$DTU@VWXQP@6
E)-./'2IA.$=@YVWXQP@6
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$=@YVWXQP@6
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F
Fig.5.3.1 (e) Replace the cable in J1 base
R>_"',IA
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8
9: 7
Fig.5.3.1 (f) Replace the parts of connector plate
5.REPLACING CABLES B-82585EN/03
- 82 -
Parts name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
BOLT A6-BA-4X10(*1) 4 2.0Nm(20kgfcm)
PLATED BOLT A97L-0218-0496#M4X10BC (*2) 4 4.5Nm(46kgfcm)1
PLATED BOLT A97L-0218-0496#M4X10EN (*3) 4 4.5Nm(46kgfcm)
2 WASHER A290-7139-Y234 (*8) 4
3 BOLT A6-BA-4X8 4 LT242
A290-7139-X233 (*4) 1
A290-7139-Y233 (*5) 1
A290-7139-Z233 (*6) 1 4 CON.PLATE
A290-7139-Z271 (*8) 1
5 PACKING A290-7139-X251 (*7) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When Standard, 5L,5H is specified. (*5) When 5LC,5C is specified. (*6) When 5WP is specified. (*7) When severe dust/liquid protection specification of Standard,,5L,5H or 5LC,5WP,5C,5F is specified. (*8) When 5F is specified.
E)-./'2IA.$=@YVWXQP@6
E123.4)5./'2IA.$DTU@VWXQP@6
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Fig.5.3.1 (g) Clamp of J1 base
5.3.2 Replacing Cable K106, K107, K108 and Air tube (J2 base to J3
casing)
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. ( It is set in 0° for all axes when robot is shipped.)
2 Turn off the controller power and remove cable of controller side from connector plate of back of J1-axis.
3 Remove the J3 arm cover which is in view of in front of the robot, it is left referring to Fig.5.3.2 (a). 4 When packing is attached, remove packing, too. 5 Drag cable to remove the relay easily. 6 Remove relay of K106 and K110, K112. Remove relay of K107 and K111, K113. 7 Cut the nylon band, which connect cable to clamp J4-2 referring to Fig.5.3.2 (c). 8 Remove J3 cover referring to Fig.5.3.2 (d). 9 Remove air tube of six in diameter which color is black and white that has come from J2 base to J3
casing.10 When packing is attached, remove packing, too. 11 Cut the nylon band, which connect cable to clamp J4-1 referring to Fig.5.3.2 (e). 12 Pull out the cable of the J3 arm to the J3 casing side. In this time, pull out the cable after it pushes
into the pipe on the tip of the part of the relayed connector and it passes. 13 Remove relay of cable K106 and K109. (In case of 5H or 5F,there is no K109.) 14 Cut the nylon band, which connect cable and air tube to clamp J3-2 referring to Fig.5.3.2 (e). 15 Remove J2 base cover referring to Section 4.4.
B-82585EN/03 5.REPLACING CABLES
- 83 -
16 When packing is attached, remove packing, too. 17 Cut the nylon band, which connect cable and air tube to clamp J2-2 referring to Fig.5.3.2 (e). 18 Remove relay to K101 and air tube. 19 Remove clamp J2-1 from J2 base referring to Fig.5.3.1 (b). 20 Remove guide arm. 21 When packing is attached, remove packing. 22 Remove clamp J3-1 from guide arm. 23 Drag the cable from the upper side and the lower side of the guide arm. In this time, drag it after it
passes it on the tip of the part of the connector. 24 Cut the nylon band which connect cable and air tube to clamp J3-1 and sheet referring to Fig.5.3.2
(h) and (i). 25 Replace cable and air tube for the new article and assemble them by opposite procedure. When
packing is attached, be sure to replace packing to new one. In case of 5F, pay attention to assemble J3 arm cover mounting bolts referring to Fig.5.3.2 (b).
26 Perform quick mastering referring to Section 8.4 of operator’s manual.
"
8
9
7
Fig.5.3.2 (a) Remove the J2 arm cover
Parts name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
BOLT A97L-0218-0504#M4x10(*1) 3 2.0Nm(20kgfcm)
PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm(46kgfcm)
PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 4.5Nm(46kgfcm)
A6-B-4X12SUS (*7) 4 2.0Nm(20kgfcm)
1
BOLT A6-B-4X14SUS (*7) 7 2.0Nm(20kgfcm)
2 WASHER A290-7139-Y234 (*4)(*7) 11
A290-7139-X405 (*1) 1
A290-7139-X407 (*2) 1
A290-7139-Y407 (*4) 1
A290-7139-Z407 (*5) 1
3 J3 ARM COVER
A290-7139-Z467 (*7) 1
4 PACKING A290-7139-X454 (*6) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When 5LC,5C is specified.
5.REPLACING CABLES B-82585EN/03
- 84 -
(*5) When 5WP is specified. (*6) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified. (*7) When 5F is specified.
S+LDL9V"7OUO'$96 S+LDL9V"9OUO'$;6
Fig.5.3.2 (b) J3 arm cover mounting bolts (5F)
FSDT@
eDTSF!
f=@Y
gDTU@h
`@TT>W
iN=@@R
jkFT@S=
l>=SRN@mnopqpr
R`T>R'DSRY
Y@PSQT'Y
stuvwxSI/'(1J.
F
F
O@FPQ>R'FLF
Y
ywxzFGJ2.
{|p}'*9L7S7?#L;"8?LV889
CS=!QRN
mnopqprR`T>R'DSRY
mnopqprR`T>R'DSRY
Fig.5.3.2 (c) Clamp of J3 arm part
B-82585EN/03 5.REPLACING CABLES
- 85 -
"
8
97
Fig.5.3.2 (d) Remove the J3 cover
Parts name Specifications Q’ty LOCTITE Torque N-m
(kgf-cm)
BOLT A97L-0218-0504#M4X10(*1) 4 2.0Nm(20kgfcm)
PLATED BOLT A97L-0218-0417#M4X12BC (*2) 6 4.5Nm(46kgfcm)
PLATED BOLT A97L-0218-0417#M4X12EN (*3) 6 4.5Nm(46kgfcm) 1
BOLT A6-B-4X12SUS (*7) 6 2.0Nm(20kgfcm)
2 WASHER A290-7139-Y234 (*4) (*7) 6
A290-7139-X404 (*1) 1
A290-7139-X406 (*2) 1
A290-7139-Y406 (*4) 1
A290-7139-Z406 (*5) 1
3 J3 COVER
A290-7139-Z466 (*7) 1
4 PACKING A290-7139-X451 (*6) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When 5LC,5C is specified. (*5) When 5WP is specified. (*6) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified. (*7) When 5F is specified.
5.REPLACING CABLES B-82585EN/03
- 86 -
8S$FT@S=6$~76
Y
Y
SQ=7$WXQP@6SQ="$DTSF!6
E123.4)5./'2IA.$DTU@VWXQP@6
E)-./'2IA.$=@YVWXQP@6
R`T>R'DSRY
R`T>R'DSRY
E>W@='TQR@$=@YVWXQP@6
E123.4)5./'2IA.$DTU@VWXQP@6
"S$=@Y6$~96
"D$DTU@6$~96
8D$>=SRN@6$~:6
SQ="$DTSF!6$~"6
7S$`@TT>W6$~86
7D$N=@@R6$~86
FGJ2.
SI/'(1J.$O+�76
SI/'(1J.$O8_"<�;6
R`T>R'DSRY
SI/'(1J.$O8_"<�;6
R`T>R'DSRY
Y@PSQT'Z
Z
Y@PSQT'@
@
O@FPQ>R'YLY
{|p}*9L"S7?#L;"8?LV987
$~6'=.B./'()'PGJ2.':_8_
Fig.5.3.2 (d) Cable clamp in parts of J3 casing
N
N
FSDT@'!"#8FSDT@'!"#:
FSDT@'!"#7FSDT@'!"#9
Y@PSQT'X
O@FPQ>R'NLN
XF2GK,'*7L7S7?#L;"8?LV889
Fig.5.3.2 (e) Cable clamp in J3 casing part
B-82585EN/03 5.REPLACING CABLES
- 87 -
"
8
:9
7
Fig.5.3.2 (f) Remove the guide arm
Parts name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
SEAL BOLT A97L-0218-0423#051616 (*1) 4 5.6Nm(57kgfcm)
SEAL BOLT A97L-0218-0546#051616BC(*2) 4 5.6Nm(57kgfcm)
SEAL BOLT A97L-0218-0546#051616EN(*3) 4 5.6Nm(57kgfcm) 1
SEAL BOLT A97L-0218-0760#052016EN (*9) 4 5.6Nm(57kgfcm)
2 COLLAR A290-7139-Z373 (*9) 4
A290-7139-X304 (*4) 1
A290-7139-Y304 (*5) 1
A290-7139-Z304 (*6) 1
A290-7139-Y304 (*8) 1
3 GUIDE ARM
A290-7139-Z364 (*9) 1
4 BOLT A6-BA-4X8 2
5 PACKING A290-7139-X353 (*7) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard, 5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When Standard, 5L,5H is specified. (*5) When 5LC,5C is specified. (*6) When 5WP is specified. (*7) When severe dust/liquid protection specification of Standard,5L,5H or 5LC,5WP,5C,5F is specified. (*8) When 5C clean class 10 or 5LC clean class 10 is specified (*9) When 5F is specified.
Table 5.3.2' Air tube
(*1)H001,H002,H003,H004,H005,H006,H007,H008,H011,H012,H013,H014,H016,H017,H018,H022,H023,H026,
H032,H033,H034,H035 is specified
(*2) H004,H005,H014,H015,H034,H035 is specified
(*3) H003,H004,H005,H008,H013,H014,H015,H018,H023,H024,H033,H034,H035 is specified
(*4)H002,H003,H004,H005,H007,H008,H012,H013,H014,H017,H018,H022,H023,H032,H033,H034,H035 is
specified
(*5) H001,H006,H011,H016,H026 is specified
5.REPLACING CABLES B-82585EN/03
- 88 -
(*1) H002,H003,H004,H005,H012,H013,H014,H017,H018,H022,H023,H032,H033 is specified
(*2) H004,H005,H014,H015 is specified
(*3) H003,H004,H005,H013,H014,H015,H018,H023,H024,H033 is specified
SQ='"$DTSF!6
SQ='7$WXQP@6
FSDT@�!"#+
FSDT@'!"#;FSDT@'!"#<
mnopqprR`T>R'DSRYmnopqpr
R`T>R'DSRY
mnopqprR`T>R'DSRY
�w�p���������SY*UOP'PX@'CS=!QRN_
�w�OX@@P
{|p}'*8L"S7?#L;:7"LV88:
{|p}*7L7FTSCE'*7L7S7?#L;"8?LV889'$"6
mnopqprR`T>R'DSRY
mnopqprR`T>R'DSRY
8���w�p�PXQ=Y'CS=!QRN
7���w�p�O@F>RY'CS=!QRN
Fig.5.3.2 (g) Cable clamp inside the guide arm (Except 5LC,5C)
mnopqprR`T>R'DSRY�w�
OX@@P
{|p}'*8L"FTSCE'*8L"S7?#L;"8?LV88:'$"6
SQ='"$O9'DTSF!6
SQ='7$+O'WXQP@6
mnopqprR`T>R'DSRYmnopqpr
R`T>R'DSRY
�w�p���������SY*UOP'PX@'CS=!QRN_
{|p}'*7L7FTSCES7?#L;"8?LV889
mnopqprR`T>R'DSRY
mnopqprR`T>R'DSRY
8���w�p�PXQ=Y'CS=!QRN
7���w�p�O@F>RY'CS=!QRN
FSDT@'!"#+
FSDT@'!"#;FSDT@'!"#<
@VP$O9'WXQP@6
Fig.5.3.2 (h) Cable clamp inside the guide arm (5C,5LC)
5.3.3 Replacing Cable K102, K103, K104, K105, K109, K110, K111,
K112, K113
1 Turn off the controller power. 2 (In case of except 5H or 5F)
In case of cable K102 and K103, remove J2-axis motor, In case of cable K104 and K105, remove J3-axis motor. In case of cable K109, remove J4-axis motor. In case of cable K110 or K111, remove J5-axis motor. In case of cable K112 or K113, remove J6-axis motor. See section 4 about replacing procedure of motor.
B-82585EN/03 5.REPLACING CABLES
- 89 -
(In case of 5H or 5F) In case of cable K102 and K103 remove J2-axis motor, In case of cable K104 and K105, remove J3-axis motor. In case of cable K110 or K111, remove J4-axis motor. In case of cable K112 or K113, remove J5-axis motor. See section 4 about replacing procedure of motor.
3 Replace cable to new one and assemble it by opposite procedure. 4 Install motor referring to Chapter 4. 5 In case of replacing K103 or K104 or K105 or K109 or K111 or K112 or K113, perform single axis
mastering referring to Section 8.4 of operator’s manual.
5.3.4 Replacing Cable K104
1 Turn off the controller power. 2 Remove J3 arm cover. (See Fig.5.3.2 (a)) 3 Remove nut on J3 arm. 4 Remove relay of K107 and cable K114. 5 Replace cable to new one, and assemble it by opposite procedure. Spread LOCTITE referring to Fig.5.3.4 and tighten nut with the specified torque. When packing is
attached, be sure to replace packing.
FGJ2.'!""9
R1('$S((G4\.5'()''!""96PI^\(.AIA^'()/d1.�8_#RK'$8"]^B4K6
TP7+7
/.2GH'()'4GJ2.'!"#;
Fig.5.3.4 Replace the cable K114
5.3.5 Replacing Air Tube
Replacing procedure of air tube between connector plate to J2 base
1 See section 5.3.1.
Replacing procedure of air tube between J2 base to J3 casing
1 See section 5.3.2.
5.REPLACING CABLES B-82585EN/03
- 90 -
Replacing procedure of air tube between J3 casing to J3 arm
1 Turn off the controller power. 2 Remove J3 arm cover. (See Fig.5.3.2 (a)) 3 Remove air tube from panel union on J3 motor. 4 Cut the nylon band, which connects air tube to clamp J4-2. 5 Remove J3 cover. (See Fig.5.3.2 (c)) 6 Cut the nylon band which connects air tube to clamp J4-1. 7 Remove the cover of solenoid valve (See Fig.5.3.5 (h)) 8 Drag air tube from the part removed by 7. 9 Replace air tube to new one, and install them by opposite procedure. When packing is attached , be
sure to replace packing.
:;#
7?#
:<#
8##
SQ='7$�'WXQP@6
SQ='"$e'DTSF!6
�'*7�w�'''''*7'JG3.
���'''''''''''''''�F)AA.4()/',GA.2
Fig.5.3.5 (a) Marking of air tube (connector plate to J2 base)(Standard,5L,5WP,5H,5F)
:;#
7?#
:<#
8##
SQ='7$�+'�'WXQP@6
SQ='"$�9'e'DTSF!6
@VP$�9'��WXQP@6
7?#
:;#
�'*7�w�'''''*7'JG3.
���'''''''''''''''�F)AA.4()/',GA.2
Fig.5.3.5 (b) Marking of air tube (connector plate to J2 base)(5C,5LC)
B-82585EN/03 5.REPLACING CABLES
- 91 -
�'*7�w�''''*7'JG3.
*8yw�p�'�*8'4G3IA^
SQ='7$�'WXQP@6
SQ='"$e'DTSF!6
89#
:;#
?"#
;##
7?#
7?#
Fig.5.3.5 (c) Marking of air tube (J2 base to J3 casing) (Standard,5WP,5H)
SQ='7$�'WXQP@6
SQ='"$e'DTSF!6
89#
:;#
"#"#
<##
8?#
8?#
*8yw�p�'�*8'4G3IA^
�'*7�w�''''*7'JG3.
Fig.5.3.5 (d) Marking of air tube (J2 base to J3 casing) (5L)
SQ='7$�+'�WXQP@6
SQ='"$�9'e'DTSF!6
89#
:;#
"#"#
<##
@VP$�9'�'WXQP@6
89#
<##
8?#
8?#
8?#
*8yw�p�'�*8'4G3IA^
�'*7�w�''''*7'JG3.
Fig.5.3.5 (e) Marking of air tube (J2 base to J3 casing) (5LC)
5.REPLACING CABLES B-82585EN/03
- 92 -
SQ='7$�+'�WXQP@6
SQ='"$�9'e'DTSF!6
89#
:;#
?"#
;##
@VP$�9'�'WXQP@6
89#
;##
7?#
7?#
7?#
*8yw�p�'�*8'4G3IA^
�'*7�w�''''*7'JG3.
Fig.5.3.5 (f) Marking of air tube (J2 base to J3 casing) (5C)
E21^
EGA.2'1AI)A
=@Y
$~96
DTU@
$~96
DTSF!
$~"6
`@TT>W
$~86
N=@@R
$~86
FT@S=
$~76
>=SRN@
$~76
D
D
FGJ2.
DTSF! =@Y
DTU@`@TT>W
N=@@R
FT@S=
>=SRN@
RH2)A'JGA5
��{��w��!@`'YQ=@FPQ>R
Y@PSQT'S
Y@PSQT'F O@FPQ>R'DLD
F
S
F2GK,'*9L7S7?#L;"8?LV889
$~6=.B./'()'(GJ2.':_8_
CG/]IA^
RH2)A'JGA5
RH2)A'JGA5
)/
WXQP@
$~:6
Fig.5.3.5 (g) Remove the air tube in J3 arm
B-82585EN/03 5.REPLACING CABLES
- 93 -
"
8
:+
7
9
Fig.5.3.2 (h) Remove the cover of solenoid valve part
Parts name Specifications Q’ty LOCTITE Torque N-m (kgf-cm)
BOLT A6-BA-4X8 (*1) 4
SEAL BOLT A97L-0218-0546#040808BC(*2) 4 4.5Nm(46kgfcm)
SEAL BOLT A97L-0218-0546#040808EN(*3) 4 4.5Nm(46kgfcm) 1
PLATED BOLT A97L-0218-0760#040808S (*8) 3 2.0Nm(20kgfcm)
2 WASHER A290-7139-Y234 (*5) (*8) 3
BOLT A6-BA-4X8 (*1) 2
SEAL BOLT A97L-0218-0546#040808BC(*2) 2 4.5Nm(46kgfcm)
SEAL BOLT A97L-0218-0546#040808EN(*3) 2 4.5Nm(46kgfcm) 3
PLATED BOLT A97L-0218-0760#040808S (*8) 3 2.0Nm(20kgfcm)
4 WASHER A290-7139-Y234 (*5) (*8) 3
A290-7139-X433 (*4) 1
A290-7139-Y433 (*5) 1
A290-7139-Z433 (*6) 1 5 SV PLATE
A290-7139-Z471 (*8) 1
6 PACKING A290-7139-X452 (*7) 1
(*1) When not severe dust/liquid protection specification of Standard, 5L,5H is specified. (*2) When severe dust/liquid protection specification of Standard,5L,5H is specified. (*3) When 5LC,5WP,5C is specified. (*4) When Standard, 5L,5H is specified. (*5) When 5LC,5C is specified. (*6) When 5WP is specified. (*7) When severe dust/liquid protection specification of Standard, 5L,5H or 5LC,5WP,5C,5F is specified. (*8) When 5F is specified.
5.REPLACING CABLES B-82585EN/03
- 94 -
SI/'(1J.'$=.56
SI/'(1J.'$D2G4]6
SI/'(1J.'$>/GA^.6
SI/'(1J.'$N/..A6
SI/'(1J.'$D21.6SI/'(1J.'$=.56
SI/'(1J.'$`.22)-6
SI/'(1J.'$F2.G/6
SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6EGA.2'1AI)A
SI/'(1J.'$D2G4]6
SI/'(1J.'$N/..A6
SI/'(1J.'$D21.6
SI/'(1J.'$`.22)-6
SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6
EGA.2'1AI)A
SI/'(1J.'$D2G4]6
SI/'(1J.'$D21.6SI/'(1J.'$=.56
SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6EGA.2'1AI)A
SI/'(1J.O)2.A)I5'MG2M.S?;TL#7"<L#""8�Y"
SI/'(1J.O)2.A)I5'MG2M.S?;TL#7"<L#""8�Y7'$"6
SI/'(1J.O)2.A)I5'MG2M.S?;TL#7"<L#""8�Y8='$"6$X##:0X#":'I3'3,.4IBI.56S?;TL#7"<L#""8�Y8$"6$X##90X#"9'I3'3,.4IBI.56
X##70X#87'I3'3,.4IBI.5
X##80X#"80X#88'I3'3,.4IBI.5
X##90X##:0X#"90X#":'I3'3,.4IBI.5
EGA.2'1AI)A
SI/'(1J.'$D2G4]6SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6
SI/'(1J.'$W\I(.6
X##"0X##+'I3'3,.4IBI.5
Fig.5.3.5 (i) Remove the air tube of solenoid valve part (Standard,5WP,5H)
B-82585EN/03 5.REPLACING CABLES
- 95 -
SI/'(1J.'$D2G4]6
SI/'(1J.'$N/..A6
SI/'(1J.'$D21.6SI/'(1J.$=.56
SI/'(1J.$`.22)-6
SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6EGA.2'1AI)A
SI/'(1J.'$D2G4]6
SI/'(1J.$D21.6SI/'(1J.'$=.56
SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6EGA.2'1AI)A
O)2.A)I5'MG2M.S?;TL#7"<L#""8�Y"'$"6
SI/'(1J.
O)2.A)I5'MG2M.S?;TL#7"<L#""8�Y7'$"6
SI/'(1J.
EGA.2'1AI)A
SI/'(1J.
EGA.2'1AI)A
SI/'(1J.
SI/'(1J.'$D2G4]6
SI/'(1J.'$N/..A6
SI/'(1J.'$D21.6SI/'(1J.'$=.56
SI/'(1J.'$`.22)-6
SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6EGA.2'1AI)A
O)2.A)I5'MG2M.S?;TL#7"<L#""8�Y8$"6
SI/'(1J.
EGA.2'1AI)A
SI/'(1J.
SI/'(1J.'$F2.G/6 SI/'(1J.'$>/GA^.6
X#"<0X#78'I3'3,.4IBI.5
X#";0X#77'I3'3,.4IBI.5
X#79'I3'3,.4IBI.5
EGA.2'1AI)A
SI/'(1J.'$D2G4]6SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6
SI/'(1J.'$W\I(.6
X#7+'I3'3,.4IBI.5
Fig.5.3.5 (j) Remove the air tube of solenoid valve part (5C,5LC)
5.REPLACING CABLES B-82585EN/03
- 96 -
SI/'(1J.'$D2G4]6
SI/'(1J.'$N/..A6
SI/'(1J.'$D21.6SI/'(1J.'$=.56
SI/'(1J.'$`.22)-6
SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6EGA.2'1AI)A
SI/'(1J.'$D2G4]6
SI/'(1J.'$=.56SI/'(1J.'$=.56
SI/'(1J.'$D2G4]6
SI/'(1J.'$W\I(.6EGA.2'1AI)A
SI/'(1J.
O)2.A)I5'MG2M.S?;TL#7"<L#""8�Y"'$"6
SI/'(1J.
O)2.A)I5'MG2M.S?;TL#7"<L#""8�Y7'$"6
X##<'I3'3,.4IBI.5
X##;'I3'3,.4IBI.5
Fig.5.3.5 (k) Remove the air tube of solenoid valve part (5F)
B-82585EN/03 6.ADJUSTMENTS
- 97 -
6 ADJUSTMENTS
Each part of the mechanical units of a robot is set to the best condition before the robot is shipped to the customer. The customer does not need to make adjustments on the robot when it is delivered.
6.1 ADJUSTING TENSION OF BELT
Please use the following tension meters for the tension adjustment of the belt.
Instrument Specifications Vendor Manufacturer model No. Application
Tension meter A97L-0218-0700 Mitsuboshi Belting Ltd. DOCTOR TENSION TYPE-!Adjustment of belt
tension
1 Place the robot in the posture to avoid uneven belt tension.
(recommended posture: J3=80!.J5="90!)
2 Remove the bolt and arm cover (refer to Chapter 5). 3 When packing is attached, remove packing, too. 4 Adjust it so that it may loosen tension-adjusting bolts and the tension may reach a regulated value. 5 Attach arm cover. When packing is attached, be sure to replace packing to new one. In this time,
tighten the bolt with the specified torque.
!"#$%&#'()*+$!%#,'-&.!
Fig. 6.1 (a) Adjusting tension of J3 belt
Table. 6.1 (a) Measurement condition of J3 belt
BELT TENSION new belt : 73"5N
reused belt : 60"5N
MASS 0.0367kg
WIDTH 7mm
SPAN 175mm
NOTE This is example of LR Mate 200iC. In case of LR Mate 200iC/5H,5F, please read
J5/J6 as J4/J5.
6.ADJUSTMENTS B-82585EN/03
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NOTE The tension of the belt deteriorates slowly, but this is a normal phenomenon.
If belt is adjusted frequently. it shorten the life of belt, please don’t adjust belt except case of replacing motor, reducer etc.
!"#$%&#()*+$!%#,'-&.!
Fig. 6.1 (b) Adjusting tension of J5 belt
!"#$%&#()*+$!%#,'-&.!
Fig. 6.1 (c) Adjusting tension of J6 belt
Table 6.1 (b) Measurement condition of J5 belt
BELT TENSION new belt : 24.5"2.5N
reused belt : 18.5"2.5N
MASS 0.0171kg
WIDTH 6mm
SPAN 180mm
Table 6.1 (c) Measurement condition of J6 belt
BELT TENSION new belt : 24.5"2.5N
reused belt : 18.5"2.5N
MASS 0.0171kg
WIDTH 6mm
SPAN 110mm
6.2 MASTERING
Mastering is an operation performed to associate 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.
B-82585EN/03 6.ADJUSTMENTS
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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 go dead. Replace the batteries in the control and mechanical units periodically. An alarm will be issued to warn the user of a low battery voltage.
Mastering method There are following five methods of mastering.
Fixture position mastering This is performed using a mastering fixture before the machine is shipped
from the factory.
Zero-position mastering (witness
mark mastering)
This is 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.
Quick mastering This is performed at a user-specified position. The corresponding count
value is obtained from the rotation speed of the pulsecoder connected to the
relevant motor and the rotation angel within one rotation. Quick mastering
uses the fact that the absolute value of a rotation angel within one rotation
will not be lost.
One-axis mastering This is performed for one axis at a time. The mastering position for each axis
can be specified by the user. This is useful in performing mastering on a
specific axis.
Mastering data entry Mastering data is entered directly.
This MAINTENANCE MANUAL describes fixture position mastering that is mainly required during replacement of parts. For other mastering methods, refer to OPERATOR’S MANUAL.
Once mastering is performed, you must carry out positioning, or calibration. Positioning is an operation is which the controller reads the current pulse count value to sense the current position of the robot.
CAUTION If mastering is performed incorrectly, the robot may behave unexpectedly. This is
very dangerous. Therefore, the positioning screen is designed to appear only when the $MASTER_ENB system variable is 1 or 2. After performing positioning, press F5 [DONE] on the positioning screen. The $MASTER_ENB system variable is reset to 0 automatically, thus hiding the positioning screen.
CAUTION It is recommended that the current mastering data be backed up before
mastering is performed.
6.ADJUSTMENTS B-82585EN/03
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6.2.1 Resetting Alarms and Preparing for Mastering
Before performing mastering because a motor is replaced, you must release the relevant alarm and display the positioning menu.
Alarm displayed “Servo 062 BZAL” or “Servo 075 Pulse mismatch”
Procedure1 Display the positioning menu by following steps 1 to 6.
1 Press the screen selection key. 2 Press [0 NEXT] and Select [6 SYSTEM]. 3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu. 4 Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER]. 5 Press F1 [TYPE], and select [Master/Cal] from the menu. 6 Select the desired mastering type from the [Master/Cal] menu.
2 To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5. 1 Press the screen selection key. 2 Press [0 NEXT] and Select [6 SYSTEM]. 3 Press F1 [TYPE], and select [Master/Cal] from the menu. 4 Press the F3 [RES_PCA], then press F4 [TRUE]. 5 Turn off the controller power and on again.
3 To reset the “Servo 075 Pulse mismatch” alarm, follow steps 1 to 3. 1 When the controller power is switched on again, the message “Servo 075 Pulse mismatch”
appears again. 2 Rotate the axis for which the message mentioned above has appeared through 10 degrees in
either direction. 3 Press [FAULT RESET]. The alarm is reset.
6.2.2 Fixture Position Master
Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the predetermined fixture position. Fixture position mastering is accurate because a dedicated mastering fixture is used. When mastering the robot, arrange the robot to meet the following conditions.
! Make the robot mounting base horizontal within 1 mm. (Set the robot mounting face so that the levelness of the entire surface is 1 mm or less.)
! Remove the hand and other parts form the wrist.
! Set the robot in the condition protected from an external force.
Assembling the fixture base 1 Assemble the fixture base as shown in Fig. 6.2.2 (a).
B-82585EN/03 6.ADJUSTMENTS
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/0123'456789
/0123456789
/:15;4<6789
=%#(5>;?@2A>?1>2<
=%#(5>;?@2A>?1>2A
=.(!"(5>;?@2A@?1>25
=.(!"(5>;?@2A@?1>2A
B%1!+C"'-($"'((5>;?@2A>?1>22
B%1!+C"'-($"'-(5>;?@2A>?1>25
Fig. 6.2.2 (a) Assembling the fixture base
2 Mount the fixture on the J1 base with bolts as shown in Fig.6.2.2 (b)
/:1504<6789
=%#(5>;?@2A>?1>2<
=%#(5>;?@2A>?1>2A
Fig. 6.2.2 (b) Mounting dial indicator
3 Mount the fixture to the wrist flange as shown Fig.6.2.2 (c). By using the calibration block, adjust the dial gage needle to 3.00 mm and fasten it with M-5 bolt. (In case of LR Mate 200iC/5H,5F, the
dial gage No.3 is not necessary to adjust.)
NOTE The dial gauge could be damaged if the bolt is fastened too tight.
6.ADJUSTMENTS B-82585EN/03
- 102 -
#&D0
#&D<
#&D3
#&DA
#&D5
#&D2
B%1!+C"'E(5>;?@2A>?1>2@
B%1!+C"'-(5>;?@2A2?1>3<
B%1!+C"'((5>;?@2A>?1>23
B%1!+C"')(5>;?@2A0?1>33
E(.%-C(!%&#'-.&EF
-&.!'/0
E.(/=
GHI'JH'K88LMNOL'PQKR'RKSRL
4T9'%U'7K8L'HV'.C'/KJL'5;;QEW0G'HX'0B'Y'#&DA'Q8'UHJ'S8LPD
Fig. 6.2.2 (c) Mounting the wrist fixture
4 Assemble the fixture to the wrist flange as shown in Fig. 6.2.2 (d).
/01234<6789
=%#(5>;?@2A;?1>33
Fig. 6.2.2 (d) Assembling the fixture to the wrist flange
B-82585EN/03 6.ADJUSTMENTS
- 103 -
Mastering1 Press MENUS. 2 Press NEXT and select SYSTEM. 3 Press F1, [TYPE]. 4 Select Mater/Cal.
SYSTEM Master/Cal JOINT 10%
1 FIXTURE POSITION MASTER 2 ZERO POSTIION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALLIBRATE
Press ‘ ENTER ‘ or number key to select.
[ TYPE ] LOAD RES_PCA DONE
5 Release brake control, and jog the robot into a posture for mastering.
NOTE Brake control can be released by setting the system variables as follows: $PARAM_GROUP.$SV_OFF_ALL: FALSE $PARAM_GROUP.$SV_OFF_ENB[*]: FALSE (for all axes) After changing the system variables, switch the controller power off and on
again.
To prevent an error from occurring due to axis backlash at this time, ensure that the dial gage needle is adjusted to a specified position in the decreasing direction. If the needle is adjusted in the reverse direction, start all over again.
(In case of LR Mate 200iC, LR Mate 200iC/5L,5LC,5C,5WP)
1) Move the robot gradually so that dial gages No.1 through No. 6 shown in Fig.6.2.2 (c) touch the points indicated by arrows No. 1 through No. 6 shown in Fig.6.2.2 (e).
2) Move the J6 axis so that dial gages No.1 and No.2 indicate same value. 3) Set the corresponding value of dial gauges No.4 and No.5 and move the J1–axis and the J4–axis so
that the dial gauge No.3 may show 3.00mm. When the value of dial gauge No.1 and No.2 deviates, modify it to make correspond.
4) Move the J2, J3, and J5 axes so that dial gages No.2, No.3 and No.4 indicate 3.00 mm. 5) After the operations above, check that all dial gages indicate 3.00 mm.
(In case of LR Mate 200iC/5H,5F)
1) Move the robot gradually so that dial gages No.1, No.2, No.4, No.5 and No.6 shown in Fig.6.2.2 (c) touch the points indicated by arrows No.1, No.2, No.4, No.5 and No.6 shown in Fig.6.2.2 (e). (Dial gauge No.3 is not used.)
2) Move the J5 axis so that dial gages No.1 and No.2 indicate same value. 3) Move the J1 axis so that dial gages No.4 and No.5 indicate same value. 4) Move the J2, J3, and J4 axes so that dial gages No. 1,No.5, No.6 indicate 3.00 mm. 5) After the operations above, check that all dial gages indicate 3.00 mm.
6 Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES. “MASTER POSITION” shown in Figs. 6.2.2(e) is set in this position.
6.ADJUSTMENTS B-82585EN/03
- 104 -
7 Select “ 6 CALIBRATE “ and press F4, YES. Mastering will be performed. Alternatively, switch the power off and on again. Switching the power on always causes positioning to be performed.
8 After positioning is completed, press F5 [DONE]. 9 Return brake control to original setting, and switch the controller power off and on again.
WARNING Since the axis stroke is not checked during the mastering, be careful to stay
clear of the robot motion.
(1%$
'*2
'*5
'*A
'*<
'*0
'*3
=&$%!%&#>;'''''PLR
'32D225'''PLR?:0D>30''PLR
;'''''PLR
?><D;A0'PLR
;'''''PLR
/($!"C%#,'=&$%!%&#
#&D2#&D5
#&D3
#&DA4T9 #&D0
#&D<
.C'/KJL'5;;QEY
.C'/KJL'5;;QEW0Z=Y0E(CE'/KJL'0;QE
(1%$
'*2
'*5
'*A
'*<
'*0
=&$%!%&#>;'''''PLR
'32D225'''PLR?:0D>30''PLR
?><D;A0'PLR
;'''''PLR
/($!"C%#,'=&$%!%&#.C'/KJL'5;;QEW0G
4T9'%U'7K8L'HV'.C'/KJL'5;;QEW0G'HX'0B'Y''''#&DA'Q8'UHJ'S8LPD
(1%$
'*2
'*5
'*A
'*<
'*0
=&$%!%&#>;'''''PLR
'0>D3:<'''PLR?:0D<''''''PLR
?><D3''''''PLR
;'''''PLR
/($!"C%#,'=&$%!%&#.C'/KJL'5;;QEW0B
Fig. 6.2.2 (e) Mastering position (LR Mate 200iC, LR Mate 200iC/5WP,5C,5H,5F,ARC Mate 50iC)
B-82585EN/03 6.ADJUSTMENTS
- 105 -
(1%$
'*2
'*5
'*A
'*<
'*0
'*3
=&$%!%&#
'05D2<@'''PLR
/($!"C%#,'=&$%!%&#.C'/KJL'5;;QEW0.Y0.E(CE'/KJL'0;QEW0.
#&D2#&D5
#&D3
#&DA
#&D<
#&D0
'?><D5:<'''PLR
';'''PLR
'?:0D@23'''PLR
';''PLR
'>;'''PLR
Fig. 6.2.2 (f) Mastering position (LR Mate 200iC/5L,5LC,ARC Mate 50iC/5L)
6.3 CHECKING THE MASTERING
1 Checking whether mastering has been made correctly Usually, positioning is performed automatically at power-on. To check whether mastering has
been made correctly, note whether the displayed current position agrees with the actual robot position. Use 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 (0rad) positions. Check that the zero-degree position marks indicated in Fig. 8.2 of OPERATOR’S MANUAL are aligned. There is no need to use any 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 6.2.1. Alternatively, the mastering data in system
6.ADJUSTMENTS B-82585EN/03
- 106 -
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 Alarms that may be output during mastering and remedy for it (1) BZAL alarm This alarm is output if the voltage of the pulsecoder's backup battery falls to 0 V while the
power to the controller is disconnected. Also, if pulsecoder connector is removed for replacing cables etc. this alarm is output because voltage becomes to 0. To clear the alarm, fit a new battery, execute the pulse reset (See section 6.2.), then turn the power off then on again# andconfirm alarm is not output.
Battery might be weak if you can’t reset alarm, then replace battery to new one , perform pulse reset , turn off and on the controller power.Note that, if this alarm occurs, all data originally held by the pulsecoder will have been lost. Mastering must be performed again.
(2) BLAL alarm This alarm is output if the voltage of the pulsecoder's backup battery has fallen to a level where
backup is no longer possible. If this alarm is output, fit a new battery immediately while keeping the power turned on. Check whether the current position data is valid, using the procedure described in 1.
(3) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL, alarms Contact the FANUC because the pulsecoder may be defective.
APPENDIX
B-82585EN03 APPENDIX A.SPARE PARTS LIST
- 109 -
A SPARE PARTS LIST
Table A (a) List of Basic cable (Specifications of Standard,5WP,5C)
Name Specifications Remarks
A660-8016-T285 RMP(Standard,5C)K101
A660-8016-T495 RMP(5WP)
K102 A660-4004-T706 J2 power
K103 A660-2006-T657 J2 pulsecoder
K104 A660-4004-T707 J3 power
K105 A660-2006-T658 J3 pulsecoder
K106 A660-4004-T708 Relay of J4, J5, J6 power
K107 A660-4004-T709
J4 pulsecoder
Relay of J5, J6 pulsecoder
Relay of end effector
K108 A660-2006-T659 Relay of YV
K109A660-2006-T660 (3-axis brake type)
A660-4004-T710 (6-axis brake type)
J4 power
K110A660-2006-T661 (3-axis brake type)
A660-4004-T711 (6-axis brake type)
J5 power
K111 A660-2006-T662 J5 pulsecoder
K112A660-2006-T663 (3-axis brake type)
A660-4004-T712 (6-axis brake type)
J6 power
K113 A660-2006-T664 J6 pulsecoder
K114 A660-2006-T665 End effector
K131 A660-8016-T498#L5R003 External battery cable
(When external battery option is selected)
Table A (b) List of Basic cable (Specifications of 5L,5LC)
Name Specifications Remarks
K101 A660-8016-T285 RMP
K102 A660-4004-T822 J2 power
K103 A660-2006-T789 J2 pulsecoder
K104 A660-4004-T823 J3 power
K105 A660-2006-T790 J3 pulsecoder
K106 A660-4004-T824 Relay of J4, J5, J6 power
K107 A660-4004-T825
J4 pulsecoder
Relay of J5, J6 pulsecoder
Relay of end effector
K108 A660-2006-T791 Relay of YV
K109 A660-4004-T710 J4 power
K110 A660-2006-T711 J5 power
K111 A660-2006-T662 J5 pulsecoder
K112 A660-4004-T712 J6 power
K113 A660-2006-T664 J6 pulsecoder
K114 A660-2006-T665 End effector
K131 A660-8016-T498#L5R003 External battery cable
(When external battery option is selected)
A.SPARE PARTS LIST APPENDIX B-82585EN/03
- 110 -
Table A (c) List of Basic cable (5H,5F)
Name Specifications Remarks
K101 A660-8016-T285 RMP
K102 A660-4004-T706 J2 power
K103 A660-2006-T657 J2 pulsecoder
K104 A660-4004-T707 J3 power
K105 A660-2006-T658 J3 pulsecoder
K106 A660-4004-T810 Relay of J4, J5 power
K107 A660-4004-T811 Relay of J4, J5 pulsecoder
Relay of end effector
K108 A660-2006-T659 Relay of YV
K110A660-2006-T771 (3-axis brake type)
A660-4004-T812 (5-axis brake type)
J4 power
K111 A660-2006-T772 J4 pulsecoder
K112A660-2006-T773 (3-axis brake type)
A660-4004-T813 (5-axis brake type)
J5 power
K113 A660-2006-T774 J5 pulsecoder
K114 A660-2006-T665 End effector
K131 A660-8016-T498#L5R003 External battery cable
(When external battery option is selected)
Table A (d) Motor (Standard, 5L,5LC,5WP,5C)
Name Specifications Remarks
!iSR1/6000(*) A06B-0116-B855#0048 J1, J2-axis
!iSR0.5/6000 A06B-0115-B855#0048 J3-axis
!iSR0.4/4000 A06B-0114-B205#0048 J4-axis (3-axis brake type)
!iSR0.4/4000 A06B-0114-B855#0048 J4-axis(6-axis brake type)
!iSR0.2/4000 A06B-0117-B205#0049 J5,J6-axis(3-axis brake type)
!iSR0.2/4000 A06B-0117-B855#0049 J5,J6-axis(6-axis brake type)
(*) When J2-axis motor is replaced, please order shaft “A290-7139-X322” at the same time.
Table A (e) Motor (5H,5F)
Name Specifications Remarks
!iSR1/6000(*) A06B-0116-B855#0048 J1,J2-axis
!iSR0.5/6000 A06B-0115-B855#0048 J3-axis
!iSR0.2/4000 A06B-0117-B205#0049 J4,J5-axis(3-axis brake type)
!iSR0.2/4000 A06B-0117-B855#0049 J4,J5-axis(6-axis brake type)
(*) When J2-axis motor is replaced, please order shaft “A290-7139-X322” at the same time.
Table A (f) Reducer
Name Specifications Remarks
Harmonic drive A97L-0218-0812#80 J1-axis(Standard.5L,5H)
Harmonic drive A97L-0218-0812#80C J1-axis(5C,5LC,5WP)
Harmonic drive A97L-0218-0812#80F J1-axis(5F)
Harmonic drive A97L-0218-0813#120 J1-axis(Standard.5L,5H)
Harmonic drive A97L-0218-0813#120C J2-axis(5C,5LC,5WP)
Harmonic drive A97L-0218-0813#120F J2-axis(5F)
Harmonic drive A97L-0218-0814#100 J3-axis(Standard.5L,5H)
Harmonic drive A97L-0218-0814#100C J3-axis(5C,5LC,5WP)
Harmonic drive A97L-0218-0814#100F J3-axis(5F)
Harmonic drive A97L-0218-0815#80 J4-axis(Standard,5L)
Harmonic drive A97L-0218-0815#80C J4-axis(5C,5LC,5WP)
Harmonic drive A97L-0218-0816#50 J5-axis(Standard.5L), J4-axis(5H)
Harmonic drive A97L-0218-0816#50C J5-axis(5C,5LC,5WP)
B-82585EN03 APPENDIX A.SPARE PARTS LIST
- 111 -
Name Specifications Remarks
Harmonic drive A97L-0218-0816#50F J4-axis(5F)
Harmonic drive A97L-0218-0817#50 J6-axis(Standard.5L), J5-axis(5H)
Harmonic drive A97L-0218-0817#50C J6-axis(5C,5LC,5WP)
Harmonic drive A97L-0218-0817#30 J5-axis (5H High speed wrist)
Harmonic drive A97L-0218-0817#30F J5-axis(5F)
NOTE When arranging in the reducer machine unit, the waving generator is built into
the main body of the reducer machine beforehand as for J4-axis of Standard,5L,5LC,5WP or 5C reducer. As for other reducers, the waving generator is separated from the main body of the reducer machine.
Table A (g) Gear
Name Specifications Remarks
A290-7139-X211 J1-axis(Standard,5WP,5C,5H,5F) GEAR J1-1
A290-7139-X213 J1-axis(5L,5LC)
GEAR J1-2 A290-7139-X212 J1-axis
GEAR J4-1 A290-7139-X411 J4-axis(Standard,5L,5LC,5WP,5C)
GEAR J4-2 A290-7139-X412 J4-axis(Standard,5L,5LC,5WP,5C)
Table A (h) Pulley, shaft, key
Name Specifications Remarks
Pulley A290-7139-X311 J3-axis
Pulley A290-7139-X312 J3-axis
Pulley A290-7139-X414 J5-axis(Standard,5L,5LC,5WP,5C)
J4-axis(5H,5F)
Pulley A290-7139-X415 J6-axis(Standard,5L,5LC,5WP,5C)
J5-axis(5H,5F)
Motor pulley A290-7139-X413J5,J6-axis(Standard,5L,5LC,5WP,5C)
J4,J5-axis(5H,5F)
Shaft A290-7139-X322 J2-axis
Key JB-HKY-3X3X12B Motor, pulley, gear
Key JB-HKY-3X3X6B Motor, pulley, gear
Table A (i) Bearing, belt
Name Specifications Remarks
Bearing A97L-0001-0192#08Z000A J1-axis reducer
Bearing A97L-0218-0596 J4-axis reducer
(Standard.5L,5LC,5WP,5C)
Belt A98L-0040-0190#007-098 J3-axis motor
Belt A98L-0040-0227#006-100 J5-axis motor (Standard.5L,5LC,5WP,5C)
J4-axis motor (5H,5F)
Belt A98L-0040-0227#006-152 J6-axis motor (Standard.5L,5LC,5WP,5C)
J5-axis motor (5H,5F)
Table A (j) Packing(When severe dust/liquid protection specification of
standard,5L,5H or 5WP,5C,5LC is specified)
Name Specifications Remarks
Packing A290-7139-X251 Connector plate
Packing A290-7139-X252 Cover B
Packing A290-7139-X253 Battery box
Packing (*) A290-7139-X351 Cover S
A.SPARE PARTS LIST APPENDIX B-82585EN/03
- 112 -
Name Specifications Remarks
Packing A290-7139-X352 Support
Packing A290-7139-X353 Guide arm
Packing A290-7139-X354 J2 base cover
Packing A290-7139-X355 J2 arm over
Packing A290-7139-X356 Cover U
Packing A290-7139-X451 J3 base cover
Packing A290-7139-X452 SV plate
Packing A290-7139-X453 J3 arm
Packing A290-7139-X454 J3 arm cover (2pcs/1 machines)
(*) This packing is attached when non-severe dust/liquid protection specification of Standard,5L,5H
Table A (k) Oil seal, O-RING
Name Specifications Remarks
Oil seal A98L-0040-0223#01001805J1, J4-axis motor (Standard,5L,5LC,5WP,5C)
J1-axis motor (5H,5F)
Oil seal A98L-0040-0049#02603707 J4-axis reducer (Standard,5L,5LC5WP,5C)
Oil seal A98L-0040-0223#01001805J5-axis reducer (Standard,5L,5LC5WP,5C)
J4-axis reducer (5H,5F)
O-RING A98L-0001-0347#S46 J1, J4-axis motor (Standard,5L,5LC5WP,5C)
J1-axis motor (5H,5F)
O-RING A98L-0001-0347#S35 J1-axis reducer
O-RING JB-OR1A-G45 J2-axis motor
Table A (l) Seal bolt! (Not serve dust/liquid protection specification of standard,5L,5H)
Name Specifications Remarks
Seal bolt A97L-0218-0417#040505
J3, J4, J5, J6 grease inlet 5pcs per 1 robot
(Standard,5L)
J3, J4, J5 grease inlet 4pcs per 1 robot (5H)
Seal bolt A97L-0218-0417#060606 J1 grease outlet
Seal bolt A97L-0218-0423#030606 J4-axis reducer 4pcs per 1 robot (except 5H)
Seal bolt A97L-0218-0423#051212 J2-axis motor 4pcs per 1 robot
Seal bolt A97L-0218-0595#040808BC J2-axis reducer 4pcs per 1 robot
Table A (m) Seal bolt! (Serve dust/liquid protection specification of standard,5L,5H)
Name Specifications Remarks
Seal bolt A97L-0218-0417#040505
J3, J4, J5, J6 grease inlet 5pcs per 1 robot
(Standard,5L)
J3, J4, J5 grease inlet 4pcs per 1 robot (5H)
Seal bolt A97L-0218-0417#060606 J1 grease outlet
Seal bolt A97L-0218-0423#030606 J4-axis reducer 4pcs per 1 robot (except 5H)
Seal bolt A97L-0218-0423#051212 J2-axis motor 4pcs per 1 robot
Seal bolt A97L-0218-0546#032516BC J2-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0546#040808BC Cover U, solenoid valve plate 8pcs per 1 robot
Seal bolt A97L-0218-0546#043016BC J1-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0546#043516BC J2-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0595#040808BC J2-axis reducer 4pcs per 1 robot
Table A (n) Seal bolt! (5LC,5C)
Name Specifications Remarks
Seal bolt A97L-0218-0417#040505 J3, J4, grease inlet 3pcs per 1 robot
Seal bolt A97L-0218-0417#040505S J5, J6, grease inlet 2pcs per 1 robot
Seal bolt A97L-0218-0417#060606 J1 grease inlet! 1pcs per 1 robot
Seal bolt A97L-0218-0417#060606S J1 grease inlet! 1pcs per 1 robot
B-82585EN03 APPENDIX A.SPARE PARTS LIST
- 113 -
Name Specifications Remarks
Seal bolt A97L-0218-0423#030606 J4-axis reducer 4pcs per 1 robot
Seal bolt A97L-0218-0423#051212 J2-axis motor 4pcs per 1 robot
Seal bolt A97L-0218-0546#032516EN J2-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0546#040808EN Cover U, solenoid valve plate 8pcs per 1 robot
Seal bolt A97L-0218-0546#043016EN J1-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0546#043516EN J2-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0595#040808EN J2-axis reducer 4pcs per 1 robot
Table A (o) Seal bolt! (5WP)
Name Specifications Remarks
Seal bolt A97L-0218-0417#040505 J3, J4, grease inlet 3pcs per 1 robot
Seal bolt A97L-0218-0417#040505S J5, J6, grease inlet 2pcs per 1 robot
Seal bolt A97L-0218-0417#060606 J1 grease inlet! 1pcs per 1 robot
Seal bolt A97L-0218-0417#060606S J1 grease inlet! 1pcs per 1 robot
Seal bolt A97L-0218-0423#030606 J4-axis reducer 4pcs per 1 robot
Seal bolt A97L-0218-0423#051212 J2-axis motor 4pcs per 1 robot
Seal bolt A97L-0218-0546#032516EN J2-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0546#041010ENCover U, solenoid valve plate 8pcs per 1
robot
Seal bolt A97L-0218-0546#043016EN J1-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0546#043516EN J2-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0595#040808EN J2-axis reducer 4pcs per 1 robot
Table A (p) Seal bolt! (5F)
Name Specifications Remarks
Seal bolt A97L-0218-0417#040505 J3 grease inlet 2pcs per 1 robot
Seal bolt A97L-0218-0417#060606 J1 grease outlet! 2pcs per 1 robot
Seal bolt A97L-0218-0423#051212 J2-axis motor 4pcs per 1 robot
Seal bolt A97L-0218-0539#040606S J4, J5, grease inlet 2pcs per 1 robot
Seal bolt A97L-0218-0546#032504EN J3-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0546#043016EN J1-axis reducer 12pcs per 1 robot
Seal bolt A97L-0218-0595#043516EN J2-axis reducer
Seal bolt A97L-0218-0760#040808SCover U, solenoid valve plate 8pcs per 1
robot
Seal bolt A97L-0218-0760#041010S Cover 2 4pcs per 1 robot
Table A (q) Spring pin, Stopper, Wrist unit, Sheet
Name Specifications Remarks
Spring pin A6-PS-5X18S J3 Stopper
A290-7139-X441 J3 Stopper! (except 5C,5LC) Stopper
A290-7139-Y441 J3 Stopper! (5C,5LC)
A290-7139-V502
J6-axis reducer is included
(Standard,5L)
J5-axis reducer is included
(5H)
A290-7139-V503J5-axis reducer is included (5F)
A290-7139-V505J5-axis reducer is included
(5H High speed wrist )
A290-7139-V521J6-axis reducer is included
(5C,5LC)
Wrist unit
A290-7139-V531J6-axis reducer is included
(5WP)
A.SPARE PARTS LIST APPENDIX B-82585EN/03
- 114 -
A290-7139-X345 J2-axis motor(Standard,5WP,5C,5H) Sheet
A290-7139-X349 J2-axis motor(5L,5LC)
Table A (r) Air tube (Standard,5WP,5C,5H)
Name Specifications Remarks
Air tube A97L-0218-0114#ABL580R06mm BLACK AIR1
Connector plate to J2base
Air tube A97L-0218-0010#AAL580R04mm BLACK AIR1 (5C)
Connector plate to J2base
Air tube A97L-0218-0114#BBL570R06mm WHITE AIR2
Connector plate to J2base
Air tube A97L-0218-0010#BAL570R04mm WHITE EXT(5C)
Connector plate to J2base
Air tube A97L-0218-0114#ABL700R06mm BLACK AIR1
J2 base to J3 casing
Air tube A97L-0218-0010#AAL700R04mm BLACK AIR1 (5C)
J2 base to J3 casing
Air tube A97L-0218-0114#BBL910R06mm WHITE AIR2
J2 base to J3 casing
Air tube A97L-0218-0010#BAL700R04mm WHITE EXT(5C)
J2 base to J3 casing
Air tube
(H002,H003,H004,H005,
H007,H008)
A97L-0218-0010#BAL150R0
4mm WHITE EXHAUST
J3 casing
Air tube
(H002,H003,H004,H005,
H007,H008,H022,H023,
H024,H032,H033)
A97L-0218-0010#AFL855R0
3.18mm BLACK AIR1
J3 casing to J3 arm
Air tube
(H002,H003,H004,H005,
H007,H008,H022,H023,
H024,H032,H033)
A97L-0218-0010#CFL745R0
3.18mm RED A1
J3 casing to J3 arm
Air tube
(H002,H003,H004,H005,
H007,H008,H022,H023,
H024,H032,H033)
A97L-0218-0010#DFL745R0
3.18mm BLUE B1
J3 casing to J3 arm
Air tube
(H003,H004,H005,H008,
H023,H024,H033)
A97L-0218-0010#EFL745R0
3.18mm YELLOW A2
J3 casing to J3 arm
Air tube
(H003,H004,H005,H008,
H023,H024,H033)
A97L-0218-0010#FFL745R0
3.18mm GREEN B2
J3 casing to J3 arm
Air tube
(H004,H005,H024)A97L-0218-0010#GFL745R0
3.18mm CLEAR A3
J3 casing to J3 arm
Air tube
(H004,H005,H024)A97L-0218-0010#HFL745R0
3.18mm ORANGE B3
J3 casing to J3 arm
Table A (s)! Air tube (5L,5LC)
Name Specifications Remarks
Air tube A97L-0218-0114#ABL580R06mm BLACK AIR1 (5L)
Connector plate"J2 base
Air tube A97L-0218-0010#AAL580R04mm BLACK AIR1 (5C)
Connector plate"J2 base
Air tube A97L-0218-0114#BBL570R06mm WHITE AIR2
Connector plate"J2 base
B-82585EN03 APPENDIX A.SPARE PARTS LIST
- 115 -
Name Specifications Remarks
Air tube A97L-0218-0010#BAL570R04mm WHITE EXT(5C)
Connector plate"J2 base
Air tube A97L-0218-0114#ABL800R06mm BLACK AIR1 (5L)
J2 base"J3 casing
Air tube A97L-0218-0010#AAL800R04mm BLACK AIR1 (5C)
J2 base"J3 casing
Air tube A97L-0218-0114#BBL1R0136mm WHITE AIR2
J2 base"J3 casing
Air tube A97L-0218-0010#BAL800R04mm WHITE EXT(5C)
J2 base"J3 casing
Air tube A97L-0218-0010#BAL150R0
4mm WHITE EXHAUST
J3 casing
Air tube
(H012,H013,H014,H015,
H017,H018)
A97L-0218-0010#AFL945R0
3.18mm BLACK AIR1
J3 casing to J3 arm
Air tube
(H012,H013,H014,H015,
H017,H018)
A97L-0218-0010#CFL835R0
3.18mm RED A1
J3 casing to J3 arm
Air tube
(H012,H013,H014,H015,
H017,H018)
A97L-0218-0010#DFL835R0
3.18mm BLUE B1
J3 casing to J3 arm
Air tube
(H013,H014,H015,H018)A97L-0218-0010#EFL835R0
3.18mm YELLOW A2
J3 casing to J3 arm
Air tube
(H013,H014,H015,H018)A97L-0218-0010#FFL835R0
3.18mm GREEN B2
J3 casing to J3 arm
Air tube
(H014,H015)A97L-0218-0010#GFL835R0
3.18mm CLEAR A3
J3 casing to J3 arm
Air tube
(H014,H015)A97L-0218-0010#HFL835R0
3.18mm ORANGE B3
J3 casing to J3 arm
Table A (t) Solenoid valve (Either the following is installed by the option specification)
(except H001,H006,H011, H016 and H026)
Name Specifications Remarks
Solenoid valve A97L-0218-0113#D1 Double solenoidX1 (2 positionX1)
Solenoid valve A97L-0218-0113#D2 Double solenoidX2 (2 positionX2)
Solenoid valve A97L-0218-0113#D3 Double solenoidX3 (2 positionX3)
Solenoid valve A97L-0218-0113#D3RDouble solenoidX3
(2 positonX2, 3 positionX1)
Table A (u) Battery
Name Specifications Remarks
Battery A98L-0031-0027 C battery/1.5V 4pcs/ per 1 robot
(When battery built-in option is selected)
Battery A98L-0031-0005 D battery/1.5V 4pcs/ per 1 robot
(When external battery option is selected)
Table A (v) Grease
Name Specifications Remarks
Grease A98L-0040-0230
Greasing kit A05B-1139-K021
Grease in tube A05B-1139-K022
Harmonic grease 4BNo.2
(Except 5F)
Grease A98L-0040-0218
Greasing kit A05B-1139-K023
Grease in tube A05B-1139-K024
Klubersynth UH1 14-1600
(5F)
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM APPENDIX B-82585EN/03
- 116 -
B CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
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B-82585EN03 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
- 117 -
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B-82585EN03 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
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B-82585EN03 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
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B-82585EN03 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
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B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM APPENDIX B-82585EN/03
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B-82585EN03 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
- 127 -
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Fig. B (g) CIRCUIT DIAGRAM (LR Mate 200iC/5H,5F 3-axes brake type)
B-82585EN03 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
- 129 -
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Fig. B(h) CIRCUIT DIAGRAM (LR Mate 200iC/5H,5F 5-axes brake type)
B-82585EN03 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
- 131 -
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9F5L09>?;F5=9F5,0
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9F5K09F580>?-;F5=
.5.0 6&"*/,-7.
6&"*+,-7..5D0
9&8;-'=
+D)EF59&8;>75=
>#
>'>0
958;-'=
9D)EF59"8;>75=
!#
!'!0
9F2K09F2L0
20
9F2,09F280
#'
.2.
>?-;F2=209>?;F2=
#'
.2>?
#'0
9&8;>72=@
9D)EF2+D)EF29"8;>72=
"52
9&8;-0=958;-0=
0&C1
.2D
F29.:7:)9;ST4)&J'U"&&&=
!0!'!#
9"8;>72=9D)EF2958;-0=
>0>'>#
9&8;>72=+D)EF29&8;-0=
.2D0 6&"*/-7.
!0!'!#
9F2L9>?;F2=9F2,
>0>'>#
9F2K9F28>?-;F2=
.2.0 6&"*+-7.
!" >"!5 >5!2 >2
!0!'!#
9):09):'
>0>'>#
9&8;30=9&8;3'=
/8' 60'*+-7.
4:$3G:B*98!$83!C@$%&'01%&00#(*0
!&5>%00#C%A&&'<A&&@
!" >"!5 >5!2 9):2 >2 &8;32=
!0!'!#
9):09):'9):#
>0>'>#
9&8;30=9&8;3'=&8;3#=
/8' 60'*+-7.
4:$3G:B*98!$83!C@$%&'01%&00#(*'
!&5>%00#C%A&&#<A&&1 WXYZ/*[$\;Q<&
"#$%&'($)**+,538$93:-3/01
B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM APPENDIX B-82585EN/03
- 132 -
!"#!"$
!"#
!"$
%#&'())*'+(,&-./+*01!&#
%#&'())*'+(,&-./+*01!&$
%2&/,3
1)&'/4*&(5&*6'*-+&78$$%2&'/49):;6</=4+&-(,+
>1)&'/4*&(5&78$$%#&'())*'+(,&-./+*;6</=4+&-(,+
Fig.! B(i)! Air pressure diagram
(Double solenoid valve"1 A05B-1139-H002,H007,H012,H017,H022,H032 is specified)
!"#!"$!"2!"?
!"?
!"#!"2
!"$
%#&'())*'+(,&-./+*01!&#
%#&'())*'+(,&-./+*01!&$
%2&/,3
1)&'/4*&(5&*6'*-+&78$$%2&'/49):;6</=4+&-(,+
>1)&'/4*&(5&78$2%#&'())*'+(,&-./+*;6</=4+&-(,+
Fig.! B(j)! Air pressure diagram
(Double solenoid valve"2 A05B-1139-H003,H008,H013,H018,H023,H033 is specified)
B-82585EN03 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM
- 133 -
!"$!"2!"?!"@!"A !"#
!"?
!"#!"2
!"$
!"@
!"A
%2&'/49):;6</=4+&-(,+
%#&'())*'+(,&-./+*01!&$
%#&'())*'+(,&-./+*01!&#
%2&/,3
Fig.! B(k) Air pressure diagram
(Double solenoid valve"3 A05B-1139-H004,H014,H024 is specified)
!"$ !"#!"2!"?!"@!"A
!"A
!"@
!"?
!"#!"2
!"$
%#&'())*'+(,&-./+*01!&$
%#&'())*'+(,&-./+*01!&#
%2&'/49):;6</=4+&-(,+
%2&/,3
Fig.! B(l)! Air pressure diagram
(Double solenoid valve"3R A05B-1139-H005,H015 is specified)
C.PERIODIC MAINTENANCE TABLE APPENDIX B-82585EN/03
- 134 -
C PERIODIC MAINTENANCE TABLE
FANUC Robot LR Mate 200iC, LR Mate 200iC/5C, /5L, /5LC
ARC Mate 50iC,ARC Mate 50iC/5L ! ! Periodic Maintenance Table
Working time (H)
Items
Check time
Greaseamount
First check320
3
months
960
6
months
1920
9
months
2880
1
years
3840 4800 5760 6720
2
years
7680 8640 9600 10560
1Check the! exposedconnector.(loosening)
0.2H " # # #
2 Tighten the end effector bolt. 0.2H " # # #
3Tighten the cover and main bolt.
2.0H " # # #
4Check the mechanical stopper.
0.1H " # # #
5 Remove spatter and dust etc. 1.0H " # # # # # # # # # # #
6Check hand cable and external battery cable (option)
0.1H " # # #
Replacing battery. (if built-in batteries are specified)
0.1H " $ $
7Replacing battery. (if external batteries are specified)
0.1H " $
8 Greasing the reducers. 0.5H 14ml
Mechanic
al unit
9Replacing cable of mechanical unit *1
4.0H "
10Check the robot cable and teach pendant cable
0.2H " # # #
11 Cleaning the ventilator 0.2H " # # # # # # # # # # #
Contr
olle
r
12 Replacing battery *1 0.1H "
*1 Refer to manual of controller. *2 $: requires order of parts
#: does not require order of parts
B-82585EN/03 APPENDIX C.PERIODIC MAINTENANCE TABLE
- 135 -
3
years
11520! 12480! 13440! 14400!
4
years
15360! 16320! 17280! 18240!
5
years
19200 20160 21120 22080
6
years
23040 24000 24960 25920
7
years
26880! 27840! 28800! 29760
8
years
30720 Item
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 1
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 2
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 3
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 4
#! #! #! #! #! # #! #! # # # # # # # # #! #! #! # 5
#! #! # # #! 6
$! ! ! ! $! ! ! ! $ ! ! ! $ ! ! ! $! ! ! !
$! ! ! ! ! $! ! ! ! ! ! $ ! ! ! ! ! $! !
7
! ! ! ! $! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 8
! ! ! ! $! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 9
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 10
#! #! #! #! #! # #! #! # # # # # # # # #! #! #! # 11
! ! ! ! $! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !
%&'()*+,!
12
C.PERIODIC MAINTENANCE TABLE APPENDIX B-82585EN/03
- 136 -
FANUC Robot LR Mate 200iC/5WP Periodic Maintenance Table
Working time (H)
Items
Check time
Greaseamount
First check320
3
months
960
6
months
1920
9
months
2880
1
years
3840 4800 5760 6720
2
years
7680 8640 9600 10560
1Check the! exposedconnector.(loosening)
0.2H " # # #
2 Tighten the end effector bolt. 0.2H " # # #
3 Tighten the cover and main bolt. 2.0H " # # #
4 Check the mechanical stopper. 0.1H " # # #
5 Remove spatter and dust etc. 1.0H " # # # # # # # # # # #
6Check hand cable and external battery cable (option)
0.1H " # # #
7Replacing battery.(external battery)
0.1H " $
8 Greasing the reducers. 0.5H 14ml $
Mechanic
al unit
9Replacing cable of mechanical unit *
4.0H "
10Check the robot cable and teach pendant cable
0.2H " # # #
11 Cleaning the ventilator 0.2H " # # # # # # # # # # #
Contr
olle
r
12 Replacing battery *1 0.1H "
*1 Refer to manual of controller. *2 $: requires order of parts
#: does not require order of parts
B-82585EN/03 APPENDIX C.PERIODIC MAINTENANCE TABLE
- 137 -
3years
11520! 12480! 13440! 14400!
4years
15360! Item
#! ! ! ! 1
#! ! ! ! 2
#! ! ! ! 3
#! ! ! ! 4
#! #! #! #! 5
#! 6
$! ! ! ! 7
! ! ! ! 8
! ! ! ! 9
#! ! ! ! 10
#! #! #! #! 11
! ! ! !
%&'()*+,!
12
C.PERIODIC MAINTENANCE TABLE APPENDIX B-82585EN/03
- 138 -
FANUC Robot LR Mate 200iC/5H Periodic Maintenance Table
Working time (H)
Items
Check time
Greaseamount
First check320
3
months
960
6
months
1920
9
months
2880
1
years
3840 4800 5760 6720
2
years
7680 8640 9600 10560
1Check the! exposedconnector.(loosening)
0.2H " # # #
2 Tighten the end effector bolt. 0.2H " # # #
3Tighten the cover and main bolt.
2.0H " # # #
4Check the mechanical stopper.
0.1H " # # #
5 Remove spatter and dust etc. 1.0H " # # # # # # # # # # #
6Check hand cable and external battery cable (option)
0.1H " # # #
Replacing battery. (if built-in batteries are specified)
0.1H " $ $
7Replacing battery. (if external batteries are specified)
0.1H " $
8 Greasing the reducers. 0.5H 12ml
Mechanic
al unit
9Replacing cable of mechanical unit *
4.0H "
10Check the robot cable and teach pendant cable
0.2H " # # #
11 Cleaning the ventilator 0.2H " # # # # # # # # # # #
Contr
olle
r
12 Replacing battery *1 0.1H "
*1 Refer to manual of controller. *2 $: requires order of parts
#: does not require order of parts
B-82585EN/03 APPENDIX C.PERIODIC MAINTENANCE TABLE
- 139 -
3
years
11520! 12480! 13440! 14400!
4
years
15360! 16320! 17280! 18240!
5
years
19200 20160 21120 22080
6
years
23040 24000 24960 25920
7
years
26880! 27840! 28800! 29760
8
years
30720 Item
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 1
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 2
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 3
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 4
#! #! #! #! #! # #! #! # # # # # # # # #! #! #! # 5
#! #! # # #! 6
$! ! ! ! $! ! ! ! $ ! ! ! $ ! ! ! $! ! ! !
$! ! ! ! ! $! ! ! ! ! ! $ ! ! ! ! ! $! !
7
! ! ! ! $! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 8
! ! ! ! $! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 9
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 10
#! #! #! #! #! # #! #! # # # # # # # # #! #! #! # 11
! ! ! ! $! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !%&'()*+,!
12
C.PERIODIC MAINTENANCE TABLE APPENDIX B-82585EN/03
- 140 -
FANUC Robot LR Mate 200iC/5F Periodic Maintenance Table
Working time (H)
Items
Check time
Greaseamount
First check320
3
months
960
6
months
1920
9
months
2880
1
years
3840 4800 5760 6720
2
years
7680 8640 9600 10560
1Check the! exposedconnector.(loosening)
0.2H " # # #
2 Tighten the end effector bolt. 0.2H " # # #
3Tighten the cover and main bolt.
2.0H " # # #
4Check the mechanical stopper.
0.1H " # # #
5 Remove spatter and dust etc. 1.0H " # # # # # # # # # # #
6Check hand cable and external battery cable (option)
0.1H " # # #
7 Replacing battery. 0.1H " $ $
8 Greasing the reducers. 0.5H 12ml
Mechanic
al unit
9Replacing cable of mechanical unit *
4.0H "
10Check the robot cable and teach pendant cable
0.2H " # # #
11 Cleaning the ventilator 0.2H " # # # # # # # # # # #
Contr
olle
r
12 Replacing battery *1 0.1H "
*1 Refer to manual of controller. *2 $: requires order of parts
#: does not require order of parts
B-82585EN/03 APPENDIX C.PERIODIC MAINTENANCE TABLE
- 141 -
3
years
11520! 12480! 13440! 14400!
4
years
15360! 16320! 17280! 18240!
5
years
19200 20160 21120 22080
6
years
23040 24000 24960 25920
7
years
26880! 27840! 28800! 29760
8
years
30720 Item
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 1
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 2
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 3
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 4
#! #! #! #! #! # #! #! # # # # # # # # #! #! #! # 5
#! #! # # #! 6
$! ! ! ! $! ! ! ! $ ! ! ! $ ! ! ! $! ! ! ! 7
! ! ! ! $! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 8
! ! ! ! $! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! 9
#! ! ! ! #! ! ! ! # ! ! ! # ! ! ! #! ! ! ! 10
#! #! #! #! #! # #! #! # # # # # # # # #! #! #! # 11
! ! ! ! $! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !
%&'()*+,!
12
D.MOUNTING BOLT TORQUE LIST APPENDIX B-82585EN/03
- 142 -
D MOUNTING BOLT TORQUE LIST
NOTE When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female threads. If it is applied to the male threads, the bolts may be loosened because sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps and wipe oil off the engaging section. Make sure that there is no solvent in the taps.Be sure to wipe the excess LOCTITE after tightening screw.
If no tightening torque is specified for a bolt, tighten it according to this table.
Recommended bolt tightening torques Unit: Nm (kgf-cm)
Hexagon socket head bolt
(Steel in strength category 12.9)
Hexagon socket head bolt
(stainless)
Hexagon socket head boss
bolt
Hexagon socket head flush
bolt (steel in strength category
12.9)
Tightening torque Tightening torque Tightening torque
Nominal
diameter
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
M3 1.8(18) 1.3(13) 0.76(7.7) 0.53(5.4) - -
M4 4.0(41) 2.8(29) 1.8(18) 1.3(13) 1.8(18) 1.3(13)
M5 7.9(81) 5.6(57) 3.4(35) 2.5(25) 4.0(41) 2.8(29)
M6 14(140) 9.6(98) 5.8(60) 4.1(42) 7.9(81) 5.6(57)
M8 32(330) 23(230) 14(145) 9.8(100) 14(140) 9.6(98)
M10 66(670) 46(470) 27(280) 19(195) 32(330) 23(230)
M12 110(1150) 78(800) 48(490) 33(340) - -
(M14) 180(1850) 130(1300) 76(780) 53(545) - -
M16 270(2800) 190(1900) 120 (1200) 82(840) - -
(M18) 380(3900) 260(2700) 160(1650) 110(1150) - -
M20 530(5400) 370(3800) 230(2300) 160(1600) - -
(M22) 730(7450) 510(5200) - - - -
M24 930(9500) 650(6600) - - - -
(M27) 1400(14000) 960(9800) - - - -
M30 1800(18500) 1300(13000) - - - -
M36 3200(33000) 2300(23000) - - - -
B-82585EN/03 APPENDIX E.INSULATION ABOUT ARC WELDING ROBOT
- 143 -
E INSULATION ABOUT ARC WELDING ROBOT
E.1 ABSTRACT
The arc welding robot performs welding, using a welding torch attached to its end effector via a bracket. Because a high welding current flows through the welding torch, the insulation between the end effector and torch is dualized. 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 sections, possibly resulting in the motor being damaged or the sheaths of cables in the mechanical sections melting.
E.2 INSULATION AT THE WRIST
- Design the insulation between the end effector and welding torch so that no current will leak from the end effector. Concretely, when fastening the insulating material inserted between the end effector and torch bracket, use different bolts on the insulation material and torch bracket. - Insert the insulating material between the torch and torch bracket so that the insulation is dualized. 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. - Insert the insulating material between the torch and torch bracket so that the insulation is dualized. 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. - Even after the insulation is reinforced, it is likely that, if a pileup of spatter grows excessively, current may leak. Periodically remove spatter when the robot is in service.
B-82585EN/03 INDEX
i-1
INDEX
<Number>
1.5-YEAR (5,760 hours) CHECKS..................................5
1-YEAR (3,840 hours) CHECKS.....................................5
2-YEAR (7,680 hours) CHECKS (LR Mate 200iC
/5WP,5F) 4-YEAR (15,360 hours) CHECKS (LR
Mate 200iC, LR Mate 200iC/5L , /5C, /5LC, /5H) ......6
3-MONTH (960 hours) CHECKS....................................5
<A>
ABSTRACT.................................................................143
ADJUSTING TENSION OF BELT...............................97
ADJUSTMENTS ...........................................................97
<B>
BACKLASH MEASUREMENT ...................................23
<C>
CABLE AND AIR TUBE REPLACEMENT ................76
CABLE FORMING .......................................................73
CABLE WIRING...........................................................71
CHECKING THE MASTERING ................................105
CHECKS AND MAINTENANCE ..................................1
CIRCUIT DIAGRAM, AIR PRESSURE DIAGRAM.116
<D>
DAILY CHECKS.............................................................1
<F>
FAILURES, CAUSES AND MEASURES....................17
FIGURE OF DRIVE MECHANISM.............................28
FIRST 1-MONTH (320 hours operating) CHECK ..........3
FIRST 3-MONTH (960 hours) CHECKS ........................3
Fixture Position Master ................................................100
<G>
Grease supply procedure of the J1-axis reducer.............12
Grease supply procedure of the J2-axis reducer.............13
Grease supply procedure of the J3-axis reducer.............14
Grease supply procedure of the J4-axis reducer.............15
Grease supply procedure of the J5/J6-axis reducer ........16
<I>
INSULATION ABOUT ARC WELDING ROBOT ....143
INSULATION AT THE WRIST .................................143
<M>
MAINTENANCE TOOLS...............................................6
MASTERING ................................................................98
MOUNTING BOLT TORQUE LIST ..........................142
<O>
OVERVIEW ..................................................................17
<P>
PERIODIC MAINTENANCE .........................................8
PERIODIC MAINTENANCE TABLE .......................134
PREFACE.................................................................... p-1
<R>
Replacing Air Tube........................................................89
Replacing Cable K101 and Air tube (Connector plate to
J2 base).......................................................................76
Replacing Cable K102, K103, K104, K105, K109,
K110, K111, K112, K113...........................................88
Replacing Cable K104 ...................................................89
Replacing Cable K106, K107, K108 and Air tube (J2
base to J3 casing)........................................................82
REPLACING CABLES.................................................71
REPLACING J1-AXIS MOTOR...................................30
REPLACING J1-AXIS REDUCER...............................32
REPLACING J2-AXIS MOTOR...................................37
REPLACING J2-AXIS REDUCER...............................40
REPLACING J3 BELT..................................................65
REPLACING J3-AXIS MOTOR...................................45
REPLACING J3-AXIS REDUCER...............................47
REPLACING J4-AXIS MOTOR...................................49
REPLACING J4-AXIS REDUCER...............................51
REPLACING J5/J6 BELT .............................................66
REPLACING J5-AXIS MOTOR...................................54
REPLACING J5-AXIS REDUCER...............................56
REPLACING J6-AXIS MOTOR...................................59
REPLACING J6-AXIS REDUCER...............................63
REPLACING PARTS....................................................27
REPLACING SOLENOID VALVE ..............................68
REPLACING THE BATTERIES (1-YEAR CHECKS
(battery built-in type)) (1.5-YEAR CHECKS
(external battery type)) .................................................8
REPLACING WRIST UNIT .........................................61
REPLENISH THE GREASE OF THE DRIVE
MECHANISM (4 years (11,520 hours) checks) ........10
Resetting Alarms and Preparing for Mastering ............100
<S>
SAFETY PRECAUTIONS ........................................... s-1
SEALANT APPLICATION ..........................................70
SPARE PARTS LIST ..................................................109
<T>
TROUBLESHOOTING.................................................17
Revision Record!
FANUC Robot LR Mate 200iC ,ARC Mate 50iC MECHANICAL UNIT MAINTENANCE MANUAL (B-82585EN)
03 Dec,2009
! Addition of LR Mate 200iC/5H(high speed wrist) ,5F and ARC Mate 50iC, ARC Mate 50iC/5L
!Change of adjusting value of belt
!Correction of errors
02 Feb.,2008
!"Addition of LR Mate 200iC/5L,5LC,5WP,5C
!"Addition of Air pressure diagram
!"Correction of errors
01 Nov., 2007
Edition Date Contents Edition Date Contents
B-82585EN/03
* B - 8 2 5 8 5 E N / 0 3 *