M410_700.pdf

5/19/2018

M410_700.pdf-slidepdf.com

FANUC RobotM-410iB/700 MECHANICAL UNIT

MAINTENANCE MANUAL MARMCM41701091E REV. A 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

http://slidepdf.com/reader/full/m410700pdf

1/127

5/19/2018


The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics America, hereinafter referred to astime FANUC reserves the right toInc, discontinue models at any or to Robotics, change specifications or design without notice and without incurring obligations. FANUC Robotics manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC Robotics’ products and/or systems. Such systems consist of robots, extended axes, robot controllers, application software, the KAREL programming language, INSIGHT vision equipment, and special tools. FANUC Robotics recommends that only persons who have been trained in one or more approved FANUC Robotics Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintain FANUC Robotics’ products and/or systems and their respective components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.

WARNING This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measure may be required to correct the interference.

FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at its headquarters in Rochester Hills, http://slidepdf.com/reader/full/m410700pdf Michigan. For additional information contact FANUC Robotics America, Inc.

2/127

5/19/2018


Copyright 2008 by FANUC Robotics America, Inc. All Rights Reserved

The information illustrated or contained herein is not to be reproduced, copied, downloaded, translated into another language, published in any physical or electronic format, including internet, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics America, Inc. AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL, KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks, 







PalletTool SOFT PARTS SpotTool , of FANUC TorchMate , ,SOCKETS and YagTool,  are Registered Trademarks Robotics. FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuAir  AccuCal AccuChop AccuFlow AccuPath AccuSeal ARC Mate ARC Mate Sr.  ARC Mate System 1  ARC Mate System 2 ARC Mate System 3 ARC Mate System 4 ARC Mate System 5 ARCWorks Pro AssistTool AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell Finder  Center Finder  Clean Wall CollisionGuard DispenseTool  F-100 F-200i FabTool FANUC LASER DRILL Flexibell FlexTool HandlingTool HandlingWorks INSIGHT INSIGHT II IntelliTrak Integrated Process Solution Intelligent Assist Device IPC -Integrated Pump Control IPD Integral Pneumatic Dispenser  ISA Integral Servo Applicator  ISD Integral Servo Dispenser  Laser Mate System 3  Laser Mate System 4 LaserPro LaserTool LR Tool MIG Eye MotionParts  NoBots Paint Stick PaintPro PaintTool 100 PAINTWorks  PAINTWorks II PAINTWorks III PalletMate PalletMate PC PalletTool PC PayloadID RecipTool RemovalTool  Robo Chop Robo Spray S-420i S-430i ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate SR ShotTool SureWeld SYSTEM R-J2 Controller  SYSTEM RJ3 Controller  SYSTEM R-J3iB Controller  TCP Mate TurboMove TorchMate visLOC visPRO-3D visTRAC WebServer  WebTP YagTool http://slidepdf.com/reader/full/m410700pdf

FANUC LTD 2008

3/127

5/19/2018


Conventions This manual includes information essential to the safety of personnel, software, data. indicated byequipment, headings and boxesand in the text.This information is

WARNING

Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.

CAUTION Information appearing under CAUTION concerns the protection of equipment, software, and data. It is boxed to set it apart from other text.

NOTE Information appearing next to NOTE concerns related information or useful hints.


4/127

5/19/2018


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 http://slidepdf.com/reader/full/m410700pdf

the country from where the product is re-exported. Furthermore, the product may also be

5/127

5/19/2018



6/127

5/19/2018


Safety FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for your application and installation can best be determined by safety system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotic systems. According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation. 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)

http://slidepdf.com/reader/full/m410700pdf • Regular

scheduled inspection of the robot and workcell

7/127

5/19/2018


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 • Light

fences, barriers, or chains

curtains

• Interlocks • Pressure • Floor

mats

markings

• Warning

lights stops

• Mechanical

• EMERGENCY • DEADMAN

STOP buttons

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. http://slidepdf.com/reader/full/m410700pdf •

Sponsor your personnel for training in approved FANUC Robotics training course(s) related to

8/127

5/19/2018


Safety

• 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 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.

http://slidepdf.com/reader/full/m410700pdf •

If materials are being applied at dangerously high pressure provide electrical interlocks for

9/127

5/19/2018


Safety

Staying Safe While Teaching or Manually Operating the Robot Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules: • Never

wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.

• Know

whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment.

•

Before teaching, visually inspect the robot and work sure that no potentially hazardous conditions exist. The work envelope is theenvelope to area definedmake 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 • Test

the robot from all remote control signals that can cause motion while data is being taught.

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. http://slidepdf.com/reader/full/m410700pdf — Using a low motion speed, single

step the program for at least one full cycle.

10/127

5/19/2018


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 that athat program is complete if the robot is not moving. The robot could be waiting for an assume input signal will permit it to continue activity. • If

the robot is running in a pattern, do not assume it will continue to run in the same pattern.

• Never

try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection When inspecting the robot, be sure to • Turn

off power at the controller.

• Lock

out and tag out the power source at the controller according to the policies of your plant.

• •

Turn off the compressed air source and relieve the air pressure. If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel.

• Never



11/127

5/19/2018


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


• Consider

all or any overlapping work envelopes of adjoining robots when standing in a work envelope.

• Test

the teach pendant for proper operation before entering the work envelope.

• If

it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately.

• Whenever

possible, perform maintenance with the power turned off. Before you open the controller front panel or enter the work envelope, turn off and lock out the 3-phase power source at the controller.

• Be aware that

an applicator bell cup can continue to spin at a very high speed even if the robot is idle. Use protective gloves or disable bearing air and turbine air before servicing these items.

• Be

aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.

Warning Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only. • Release

or block all stored energy. Before working on the pneumatic system, shut off the system air supply and purge the air lines.


I l t th

b tf

ll

t

t l i

l If

i t

tb d

h

th

12/127

5/19/2018

M410_700.pdf-slidepdf.com Safety

• Make sure personnel

cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked.

• Use

blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel.

Warning Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction. • Be

aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.

• When • Use

replacing or installing components, make sure dirt and debris do not enter the system.

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 thedevices. following programming safety measures to prevent damage to machine tools and other external • 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. http://slidepdf.com/reader/full/m410700pdf

13/127

5/19/2018 Safety


Mechanical Safety Precautions Implement the following mechanical safety measures to prevent damage to machine tools and other external devices. • Make sure the workcell

is clean and free of oil, water, and debris.

• Use

software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.

KEEPING THE ROBOT SAFE Observe the following operating and programming guidelines to prevent damage to the robot.

Operating Safety Precautions The following measures are designed to prevent damage to the robot during operation. • Use

a low override speed to increase your control over the robot when jogging the robot.

• Visualize

the movement the robot will make before you press the jog keys on the teach pendant.

• Make sure the work • Use

envelope is clean and free of oil, water, or debris.

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 • Make

prevent collisions when two or more robots share a work area.

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.


14/127

5/19/2018


B-82335EN/01

SAFETY PRECAUTIONS

1

SAFETY PRECAUTIONS

1.1

OPERATOR SAFETY

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.

Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure operator safety. (1) Have the robot system operators 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 operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no operator can enter the work area without passing through the gate. Install an interlock switch, 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 interlock signal 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.1.1. (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 an operator enters the work area.


15/127

5/19/2018


SAFETY PRECAUTIONS

B-82335EN/01

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.

Safety fence Limit switch operate when the gate is opened.

Fig. 1.1(a) Safety Fence and Safety Gate Dual chain

Panel board EAS1 EAS11 EAS2 EAS21

Single chain http://slidepdf.com/reader/full/m410700pdf

16/127

5/19/2018


B-82335EN/01

1.1.1

SAFETY PRECAUTIONS

Operator Safety

The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. (1) If it is not necessary for the robot to operate, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work. (2) Operate the robot system at a location outside of the safety fence (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and to prevent the worker from entering a dangerous area. (4) Install an EMERGENCY STOP button within the operator’s reach.

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection. Dual chain External stop button

Panel board EES1 EES11 EES2 EES21

Single chain

Panel board EMGIN1 EMGIN2 http://slidepdf.com/reader/full/m410700pdf

17/127

5/19/2018


SAFETY PRECAUTIONS

B-82335EN/01

(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating (3) Ifcondition. it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on the teach pendant) before entering the area. (4) The programmer must be extremely careful not to let anyone else enter the robot work area.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot enters the emergency stop state. After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence. 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) Automatic operation mode: The DEADMAN switch is disabled. (b) Teach mode: Causes an emergency stop when the operator releases the DEADMAN switch or when the operator presses the switch strongly. Note) The DEADMAN switch is provided to place the robot in the emergency stop state when the operator releases the teach pendant or presses the pendant strongly in case of emergency. The R-J3iC employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly, the robot enters the emergency stop state. The operator’s intention of starting teaching is determined by the control unit 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 could operate in such conditions and be responsible in carrying out tasks safely. The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the teach pendant enable switch and the remote condition on the software. http://slidepdf.com/reader/full/m410700pdf

18/127

5/19/2018 B-82335EN/01


SAFETY PRECAUTIONS

(5) To start the system using the operator’s panel, make certain that nobody is the robot work area and that no abnormal conditions the to robot work (6) there Whenare a program is completed, beinsure carry out aarea. 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 s 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 teach pendant operator should leave the robot work area.

1.1.3

Safety durin g 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 it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed. (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 a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time. (10) When replacing or reinstalling components, take care to prevent foreign matter from entering 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.


19/127

5/19/2018


SAFETY PRECAUTIONS

B-82335EN/01

(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or devices, even itself is normal. (3) peripheral For a system in which thethough robot the androbot its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.

1.2.2

Precautions for Mechanism

(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust. (2) Use mechanical unit cable that have required user interface. Please do not obstruct the movement of the mechanical unit cable when cables are added. (Please never tie an external cable to the mechanical unit cable by using the nylon band etc.) Moreover, please do not interfere with the mechanical unit cable when equipment is installed in the robot. If these precautions are not observed, there is a possibility that the mechanical unit cable is disconnected and the trouble not anticipated occurs. (3) 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.

1.3

SAFETY OF THE ROBOT MECHANISM

1.3.1

Precaution s 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.

1.3.2

Precautions in Programming

(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere withsure each (2) Be toother. specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

1.3.3

Precautions for Mechanisms


20/127

5/19/2018


B-82335EN/01

cable

SAFETY PRECAUTIONS A05B-2450-J361 (10m), (except A cabinet integrated controller type)

Power cable

A05B-2525-J045 (5m), ( A cabinet integrated controller type) A05B-2525-J046 (10m), ( A cabinet integrated controller type) A05B-2525-J010 (5m) (AC100-115V Power plug) (*) A05B-2525-J011 (10m) (AC100-115V Power plug) (*) A05B-2450-J364 (5m) (No power plug) A05B-2450-J365 (10m) (No power plug)

(*) These do not support CE marking. (2) Please make sure that adequate numbers of brake release units are available and readily accessible for robot system before installation. (3) Regarding how to use brake release unit, please refer to Robot controller maintenance manual.

NOTE Robot systems installed without adequate number of brake release units or similar means are not in compliance with EN ISO 10218-1 nor with the Machinery Directive and therefore cannot bear the CE marking. CAUTION Robot arm would fall down by releasing its brake because of gravity. Especially because spring balancer and counter balancer are used for J2-axis, it is hard to predict J2-arm and J3-arm movement by the condition of Robot attitude and end effecter. Therefore, it is strongly recommended to take adequate measures such as hanging Robot arm by a crane before releasing a brake. In case of releasing motor brake

Method of supporting arm

Use M12 eyebolt (Sling 1pcs)

Arm

？


lever block(2pcs) Slint(2pcs)

？ Motion is


21/127

5/19/2018


SAFETY PRECAUTIONS

In case of releasing motor brake

B-82335EN/01

Method of supporting arm

？ Use M12 eyebolt (Sling 1pcs)

？ Counter balancer


Arm

？

0

Motion is Unpredictable.

0

Use M12 eyebolt (including opposite side 2pcs) Sling(2pcs)

？ Fig. 1.3.4(b) Releasing J3 mo tor brake and measures


22/127

5/19/2018


B-82335EN/01

SAFETY PRECAUTIONS

SAFETY OF THE END EFFECTOR

1.4

1.4.1

Precautions in Programming

(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. (2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

1.5

SAFETY IN MAINTENANCE

(1) Never enter the robot work area while the robot is operating. Turn off the power before entering the robot work area for inspection and maintenance. (2) If it is necessary to enter the robot work area with the power turned on, first press the EMERGENCY STOP button on the operator’s box. (3) When replacing or reinstalling components, take care to prevent foreign matter from entering the system. When replacing the parts in the pneumatic system, be sure to reduce the pressure in the piping to zero by turning the pressure control on the air regulator. (4) When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and turn off the circuit breaker to protect against electric shock. (5) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in damage to the components in the controller. (6) Before restarting the robot, be sure to check that no one is in the robot work area and that the robot and its peripheral devices are all in the normal operating state.

1.6

WARNING LABEL

(1) Greasing and degreasing label


23/127

5/19/2018


SAFETY PRECAUTIONS

B-82335EN/01

CAUTION See section 2.3 ″ PERIODIC MAINTENANCE for explanations about specified greases, the amount of grease to be supplied, and the locations of grease and degrease outlets for individual models.

(2) Disassembly prohibitive label

Fig. 1.6 (b) Disassembly Prohib itive Label

Description Do not disassemble the balance unit. It is very dangerous because a spring is loaded in it. (3) Step-on prohibitive label


24/127

5/19/2018


B-82335EN/01

SAFETY PRECAUTIONS

(4) High-temperature warning label

Fig. 1.6 (d) High-temperature warni ng l abel

Description Be cautious about a section where this label is affixed, as the section generates heat. If you have to inevitably touch such a section when it is hot, use a protective provision such as heat-resistant gloves. (5) Transportation label

>3000kg

<1000kg X4

>3000kg

>1000kg X4 >950kg X2

Fig. 1.6 (e) Transport ation l abel http://slidepdf.com/reader/full/m410700pdf

25/127

5/19/2018


SAFETY PRECAUTIONS

B-82335EN/01

CAUTION See section II.1.1 TRANSPORTATION of operator’s manual for explanations about the posture a specific model should take when it is transported. (6) Putting weight label 1 ボルトM12X40(4本)とワッシャ(4枚)を外し、

2

200kg

2

オモリを外して下さい。 Remove the bolts(M12X40(4pcs)), the washers(4pcs), and remove the weight. で外したボルト・ワッシャにて、オモリをリンクに固定して下さい。締付トルクは96Nmです。 Fix the weight to link by bolts and washers removed in Tightening torque is 96Nm. 3

オモリ WEIGHT

リンク LINK

アイボルト4本を外して下さい。 Remove the eye bolts(4pcs).

1

3

(

)

ロボット設置時、本図に従ってオモリを付け直して下さい。 At installation,put the weight according with this procedure.

Fig. 1.6 (f) Putti ng w eight Label

Description After installation of robot, observe the instructions indicated on this label. 1) Remove the bolts(M12×40(4pcs)),the washers(4pcs), and remove the weight. 2) Fix the weight to link by bolts and washers removed in tightening torque in 96Nm 3) Remove eyebolts (4pcs).


26/127

5/19/2018


B-82335EN/01

SAFETY PRECAUTIONS

(7) Balancer replacement label

170kg

J2=7～26 (DEG)

Fig. 1.6 (g) Balancer Replacement Label

Description When replacing the balancer, observe the instructions indicated on this label. When replacing the balancer, keep the J2 axis at between 7° and 26°. • • Weight of balancer is 170kg. (8) Transportation prohibitive label


27/127

5/19/2018


SAFETY PRECAUTIONS

B-82335EN/01

(9) Range of motion and payload mark label Below label is added when CE specification is specified.

+180DEG -180DEG

0DEG

The wrist tip rotation center B

Motion area of the writs tip rotation center

A

M- 410 iB/160 M-410iB/300 M-410iB/450 M-410iB/700

C

A

B

C

MAX. PAYLOAD

(mm) 3 14 3 3143 3130 3143

(mm) 2880 2880 2696 2870

(mm) 78 78 238 88

(kg) 160 300 450 700

Fig.1.6 (i) Range of moti on and paylo ad mark label


28/127

5/19/2018


PREFACE

B-82335EN/01

PREFACE This manual explains the operation for the mechanical units of the following robots: Model name

Mechanical un it specification No.

Maximum load

FANUC Robot M-410iB/700

A05B-1042-B201

700kg

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.

(1) (2)

TYPE

NO. DATE

(3) (4)

TOTAL WEIGHT WITH CONTROLLER : TOTAL WEIGHT WITHOUT CONTROLLER:

kg kg

(5) (6)

OSHINO-MURA. YAMANASHI PREF.JAPAN

TABLE 1) (1)

(2)


(3)

(4)

(5)

(6) 29/127

5/19/2018


PREFACE

B-82335EN/01

RELATED MANUALS For the FANUC Robot series, the following manuals are available: Safety handbook B-80687EN Intended readers: All persons who use the FANUC Robot All persons who use FANUC Robot, system designer and system designer must read and Topics: understand thoroughly this handbook Safety items for robot system design, operation, maintenance R-30i A Setup and Operations Intended readers: controller manual Operator, programmer, maintenance person, system designer Topics: HANDLING TOOL B-82594EN-2

Robot functions, operations, programming, setup, interfaces, alarms Use: Robot operation, teaching, system design

Maintenance manual B-82595EN

Intended readers: Maintenance person, system designer Topics: Installation, connection to peripheral equipment, maintenance Use: Installation, start-up, connection, maintenance

B-82595EN-1 (For Europe) B-82595EN-2 (For RIA) Mechanical unit

Operator’s manual FANUC Robot M-410iB/700 B-82334EN

Intended readers: System designer, Maintenance person Topics: Installation, connection to controller, maintenance Use: Installation, start-up, connection, maintenance


30/127

5/19/2018


TABLE OF CONTENTS

B-82335EN/01

TABLE OF CONTENTS SAFETY PRECAUTIONS............................................................................s-1 PREFACE ....................................................................................................p-1 1

2

CHECKS AND MAINTENANCE .............................................................1 1.1

DAILY CHECKS ............................................................................................ 1

1.2 1.3 1.4 1.5 1.6 1.7

1-MONTH (320 HOURS) CHECKS ............................................................... 2 3-MONTH (960 HOURS) CHECKS ............................................................... 2 1-YEAR (3,840 HOURS) CHECKS................................................................ 5 1.5-YEAR (5,760 HOURS) CHECKS............................................................. 5 3-YEAR (11,520 HOURS) CHECKS.............................................................. 6 MAINTENANCE TOOLS ............................................................................... 6

PERIODIC MAINTENANCE .................................................................... 2.1 GREASING TO BALANCER BUSH (1.5 YEAR CHECKS (3,840HOURS)) 9 2.2 2.3 2.4

GREASING TO BEARING (3 YEAR CHECKS (11,520HOURS)).................. 9 REPLACING THE BATTERIES (1.5 YEAR CHECKS) ................................ 12 REPLACING THE GREASE OF THE DRIVE MECHANISM (3 YEARS (11,520 HOURS) CHECKS) .......................................................14 PROCEDURE FOR RELEASING RESIDUAL PRESSURE FROM THE GREASE BATH ........................................................................................... 17

3

TROUBLESHOOTING ..........................................................................18 3.1 3.2 3.3

4

OVERVIEW .................................................................................................18 FAILURES, CAUSES AND MEASURES..................................................... 18 BACKLASH MEASUREMENT..................................................................... 25

COMPONENT REPLACEMENT AND ADJ USTMENTS....................... 28 4.1 4.2 4.3 4.4 4.5

FIGURE OF DRIVE MECHANISM ..............................................................29 REPLACING THE J1-AXIS MOTOR M1 .....................................................31 REPLACING THE J1-AXIS REDUCER ....................................................... 34 REPLACING THE J2-AXIS MOTOR M2 .....................................................37 REPLACING THE J2-AXIS REDUCER ....................................................... 39


31/127

5/19/2018 TABLE

OF CONTENTS

M410_700.pdf-slidepdf.com B-82335EN/01

6.1

GENERAL ...................................................................................................74

6.2 6.3

RESETTING ALARMS AND PREPARING FOR MASTERING ................... 75 FIXTURE POSITION MASTER ...................................................................75

PPENDIX

A

SPARE PARTS LIST ............................................................................83

B

CIRCUIT DIAGRAM ..............................................................................85

C

PERIODIC MAINTENANCE TABL E ..................................................... 90

D

BOLT TIGHTENING TORQUE TAB LE.................................................92


32/127

5/19/2018 B-82335EN/01

1

M410_700.pdf -slidepdf.com 1.CHECKS AND MAINTENANCE

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 When air control set is combined Item

Check items

1

Air pressure

2

Oiler oil mist quantity

3 4

Oiler oil level Leakage from hose

Check poi nts 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 0.49 to 0.69 MPa (5-7 kgf/cm 2), adjust it using the regulator pressure-setting handle. Check the drop quantity during wrist or hand motion. If it does not meet the specified value (1 drop/10-20 sec), adjust it using the oiler control knob. Under normal usage, the oiler becomes empty in about 10 to 20 days under normal operation. Check to see that the oiler level is within the specified level. Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.

Oil inlet

Adjusting knob

Lubricator mist amount check http://slidepdf.com/reader/full/m410700pdf

33/127

5/19/2018 1.CHECKS

AND MAINTENANCE

M410_700.pdf-slidepdf.com B-82335EN/01

(2) After automatic operation Item

Check items

1

Vibration, abnormal noises, and motor heating Changing repeatability Peripheral devices for proper operation Brakes for each axis

2 3 4

1.2

Check poi nts 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. Check to see that the stop positions of the robot have not deviated from the previous stop positions. Check whether the peripheral devices operate properly according to commands from the robot. Check that the end effector drops within 0.2 mm when the power is cut.

1-MONTH (320 HOURS) CHECKS

Check the following items once every one-month (320 hours). Additional inspection areas and times should be added to the table according to the robot’s working conditions, environment, etc. (1) 1-month (320 hours) check Item 1

1.3

Check items Control unit cable and robot connecting cable

Check poin ts Check whether the cable connected to the teach pendant and robot is unevenly twisted.

3-MONTH (960 HOURS) CHECKS

Check the following items once every three months (960 hours). Additional inspection areas and times should be added to the table according to the robot’s working conditions, environment, etc. (1) 3-month (960 hours) checks Item 1 2

Check items Control unit cable Ventilation portion of control unit

Check poin ts (See section 1.2.) If the ventilation portion of the control unit is dusty, turn off power and clean the unit.

Check the following items at the first quarterly inspection, then every year thereafter. (See the Section.1.4.) (2) First quarterly inspection (960 hours) Item

Check items


Check poi nts

34/127

1.CHECKS AND MAINTENANCE M410_700.pdf -slidepdf.com

B-82335EN/01 5/19/2018

NOTE 1) Inspection point s and check items of the mechanical unit cables and connectors Inspection points of the mechanical unit cables Movable parts of J1, the upper side and lower side of link for wrist posture maintenance of rear side of J2 arm, movable part in uniting part of J2 to J3 and J3 to J4 and fixed department cable who interferes easily in peripherals

Check it ems For cables with a cable cover, open the cover before making the check. Check the cables for a sheath break and wear. If wires of the cable appear, replace it.

Remove the cover.

Fig 1.3(a) Check items o f Mechanical uni t cable

Inspection poi nts of the connectors -

Power/brake connectors of the motor exposed externally. Robot connection cables, user cables and earth terminal.


35/127

1.CHECKS 5/19/2018

AND MAINTENANCE

RM2

RM1

B-82335EN/01 M410_700.pdf-slidepdf.com

RP1

AIR11

AIR21

AS1

In case of type remote controller

Fig 1.3(b) Check items of connector

NOTE 2) Cleanin g Necessary cleaning points, dust on the flat part, sedimentation of spatters Clean sediments periodically. In particular, clean the following points carefully. 1) Vicinity of the balancer rod and shaft →

2)

If chippings or spatters are attached to the bushing, abnormal wear may be caused.

Vicinity of the wrist axis and oil seal →

If chippings or spatters are attached to the oil seal, an oil leak may be occurred. -

Check if the vicinity of the necessary inspection points, wrist part, and J3 arm significantly wears due to rubbing against the hand cable. Check if there is a trace of a collision around the hand. Check the reducer or grease bath for an oil leak.


36/127

1.CHECKS AND MAINTENANCE M410_700.pdf -slidepdf.com

B-82335EN/01 5/19/2018

Fig.1.3(c) Cleanin g p art

NOTE 3) -

Point s to be retig htened

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.

-

1-YEAR (3,840 HOURS) CHECKS

1.4 Check the following items once every year (3,840 hours). Item 1

Check items Greasing balancer shaft


Check poi nts Grease balancer shaft. (See Section 2.1)

37/127

1.CHECKS AND MAINTENANCE

B-82335EN/01

5/19/2018

1.6


3-YEAR (11,520 HOURS) CHECKS

Check the following items once every 3 years (11,520 hours). Item

Check items

1

Check poin ts

Replacing grease of each axis reducer Grease of bearing

2

1.7

Replace grease of reducer and gearbox. (See Section 2.3.) Supply grease to each connection of bearing. (See Section 2.1)

MAINTENANCE TOOLS

The following tools and instruments are required for the maintenance procedures contained in this manual. 1)

Measuring instruments

Instruments Dial gauge accuracy

Accuracy/Capacity 1/100 mm accuracy

Applications Measurement of positioning and backlash

Slide calipers Push/pull tension gauge

150 mm capacity 98N (10 kgf) accuracy

Measurement of backlash

2) Tools Cross-point (+) screwdrivers: Conventional (-) screwdrivers: Box screwdrivers: Hexagonal wrench key sets: T-shaped hexagonal wrench: Torque wrenches for hexagonal: Monkey spanner: Monkey spanner torque: Socket wrenches: Socket torque wrenches:

G

Large, medium, and small sizes Large, medium, and small sizes M6 (Grease nipple) M3 - M20 (metric) M6 For M8, M10, M12, M16 bolts socket head bolts (those usable for the torque settings listed in Table 1.7 (a)) Medium and small sizes 8 mm and 24 mm wide across wrenches flats (those usable for the torque settings listed in Table 1.7 (b)) M10 (Width across flats 17mm for J4 input gear). M33 (Width across flats 50mm for balancer). (Those usable for the torque settings listed in Table 1.7 (c))

ll


38/127


B-82335EN/01

5/19/2018


Table 1.7 (a) Torque setti ngs (torque wrenches for hexagonal socket head bolts) Nominal diameter

Torque setting

M8 M10 M12 M16

27.5N-m(2.8kgfm) 73.5N-m(75kgfm) 128N-m(13.1kgfm) 319N-m(32.5kgf-m) Table 1.7 (b) Torque settings (adjustable-end torque wrenches)

Width across flats

Torque setting

24 41

118N–m (12kgf–m) 118N–m (12kgf–m) Table 1.7 (c) Torque setting s (socket torq ue wrenches)

Nominal diameter M33

Torque setting 31.9N-m(32.5kgf-m)

Fig. 1.7 (a) Guide pi n (M12) for J1/J2/J3-axis reducer r eplacement


39/127


B-82335EN/01

5/19/2018


Fig. 1.7 (c) Guid e pin (M16) for J1/J2/J3-axis redu cer replacement 20

12 u0.1

7 4

13.5

O

1 . 0 0 -

6 9

O

5 5

O

6 7

O

4 - C 1

2-M8 DP10 LEAD HOLE NOT THRU

Fig. 1.7(d) For in stalli ng oi l seal to the J2/J3-axis redu cer


40/127

2.PERIODIC MAINTENANCE

B-82335EN/01

5/19/2018

2 2.1


PERIODIC MAINTENANCE GREASING TO BALANCER BUSH (1.5 YEAR CHECKS (3,840HOURS)) GREASING TO BEARING (3 YEAR CHECKS (11,520HOURS))

Be sure to supply grease to the machine at the timing (cumulative operation time or period whichever earlier) specified in Table 2.1 (a), (b). Adjust the greasing timing if your robot is installed in an adverse environment. Supply grease immediately if water is splashed to the robot. Fig 2.1(a) indicates the greasing point of balancer bush. In this time, move robot posture to J3=-16 to –126 . Fig.2.1 (b) to (d) indicate the greasing point of bearing part. When greasing to bearing of J3-axis arm connection part, remove seal bolt in Fig.2.1 (b) before greasing. º

º

When the seal bolt is reused, be sure to seal it with seal tape. See Table 2.3(b) about posture for greasing. Table 2.1 (a) Greasing the Balancer Bush Recommended grease

Amount of grease

Greasing interval

Showa Shell Sekiyu K. K. SHELL ALVANIA GREASE S2 (Spec.: A97L-0001-0179#2)

10 ml for each (two points)

In the cycle that is shorter among 1 year and 3,840 hours.

Supply posi tion

Table 2.1 (b) Greasing of the bearing part Amo un t o f Greasing Recommended grease grease method

J3 arm connecting position bearing greasing point

Showa Shell Sekiyu K. K.

J3-axis base cross roller bearing connecting position

SHELL ALVANIA GREASE S2 (Spec.: A97L-0001-0179#2)

Wrist connecting position bearing

20ml (Two points)

20ml

Supply grease through a grease nipple.

Cumulative operation time (duration)

In the cycle that is shorter among 3 years and 11,520 hours.

10ml (Two points)

NOTE After grease is supplied old grease is pushed out from the bearing's rotating http://slidepdf.com/reader/full/m410700pdf

41/127


B-82335EN/01

5/19/2018


Table 2.1 (c) Substitutes for Shell ALVANIA GREASE S2 Maker

Grease name

MOBIL OIL ESSO STANDARD NIPPON OIL CORPORATION NIPPON OIL CORPORATION IDEMITSU KOHSAN COSMO OIL

MOBILACKS GREASE NO.2 VICON NO.2 NIPPON MITSUBISHI MULTINOC 2 EPNOC AP-2 EPONEX GREASE NO.2 DYNAMAX NO.2

Grease nipple inlet of balancer bush grease

Fig.2.1 (a) Greasing for b alancer bush (2 poi nts)

Seal bolt M6X8 at the bearing grease outlet for connectiong J3-axis arm Grease nipple at the bearing greasing point for connectiong J3-axis arm


42/127


B-82335EN/01

5/19/2018


1 2

CAUTION Before greasing, remove the stopper or seal bolt at the grease outlet. Apply grease slowly with a manual pump.

Grease nipple at the cross roller bearing greasing points for connection J3-axis base

Fig.2.1 (c) Greasing fo r cross r oller bearin g J3-axis base

Grease nipple at the bearing greasing points for connecting wrist

Fig.2.1 (d) Greasing for bearing wrist connection (2 points)


43/127

2.PERIODIC MAINTENANCE 5/19/2018

2.2

B-82335EN/01


REPLACING THE BATTERIES (1.5 YEAR CHECKS)

The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every 1.5 years. Also, use the following procedure to replace when the backup battery voltage drop alarm occurs. 1

Keep the power on. Press the EMERGENCY STOP button to prohibit 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 3 4 5

Remove the battery case cap. (Fig.2.2) Take out the old batteries from the battery case. Insert new batteries into the battery case. Pay attention to the direction of batteries. Close the battery case cap.


44/127


B-82335EN/01

5/19/2018


Position of battery

RM2

RM1

RP1

AIR11

AIR21

AS1

Integrated controller type

Battery case

Remote controller type

Case cap Battery spec:A98L-0031-0005 (D battery 4pcs) Fig.2.2


Replacing Batteries

45/127


B-82335EN/01

5/19/2018


2.3

REPLACING THE GREASE OF THE DRIVE MECHANISM (3 YEARS (11,520 HOURS) CHECKS)

Replace the grease of the reducers of J1, J2, J3, and J4 axes in the cycle that is shorter among every three years and 11,520 hours by using the following procedures. Table 2.3 (a) Grease for 3-year (11,520 hours) p eriodi cal r eplacement Models

Supply posi tion

Grease name

J1-axis reducer M-410iB/700

J3-axis reducer J4-axis reducer

NOTE

7400g (8370ml)

Kyodo yushi VIGOGREASE RE0 Spec.: A98L-0040-0174

J2-axis reducer

Gun tip pressure

Quantity

2800g (3170ml)

0.15 MPa or less (NOTE)

2600g (2940ml) 950g (1080ml)

When using a hand pump, apply grease approximately once per 1.5 seconds.

For grease replacement or replenishment, use the attitudes indicated below. Table 2.3 (b) Attitu des for gr easing Robot

Att it ud e

Supply position

J1

J1-axis reducer M-410iB/700

0

J2

°

J3-axis reducer

Arbitrary 0

J2-axis reducer Arbitrary

J4-axis reducer

J3 Arbitrary

Arbitrary

°

-44 to 40

J4

°

Arbitrary

-16

Arbitrary

°

Arbitrary

0

°

NOTE In a high-duty environment where, for example, a cooling unit (fan) is used, grease must be replaced every half the specified standard period.


46/127

B-82335EN/01

5/19/2018

2.PERIODIC MAINTENANCE M410_700.pdf-slidepdf.com

CAUTION If greasing is performed incorrectly, the internal pressure of the grease bath may suddenly increase, possibly causing damage to the seal, which would in turn lead to grease leakage and abnormal operation. When performing greasing, therefore, observe the following cautions. 1 Before starting to grease, open the grease outlet (remove the plug or bolt from the grease outlet). 2 Supply grease slowly without applying excessive force, using a manual pump. 3 Whenever possible, avoid using a compressed-air pump, powered by the factory

4 5 6 7

air supply. Even when using a compressed-air pump unavoidably, set the gun tip pressure (see Table 2.3 (a).) to0.15MPa or less during application of grease. Use grease only of the specified type. Grease of a type other than that specified may damage the reducer or lead to other problems. After applying grease, release the residual pressure within the grease bath as described in the procedure in Section 2.4. To prevent accidents caused by slipping, completely remove any excess grease from the floor or robot. If no old grease is pushed out from the grease outlet soon or if only an extremely small amount of old grease is pushed out when new grease is supplied into the grease inlet, it is likely that grease is leaking because of a damaged sealing or a similar break.

Grease replacement procedure for the J1-axis, J2-axis, J3-axis, and J4-axis reduc ers CAUTION Be careful not to confuse the grease inlet of the J4-axis reducer with the grease inlet of the wrist link bearing in Fig. 2.1 (d) of Section 2.1 because they are close to each other. 1 2

Move the robot to the greasing attitude described in Table 2.3(a). Turn off the power.

3 4 5

Remove the seal bolt shown the Fig. 2.3 (a) to (d) from the grease outlet. Supply new grease until new grease is output from the grease outlet. After applying grease, release the residual pressure within the grease bath as described in the procedure in Section 2.4.


47/127


B-82335EN/01

5/19/2018


J2-axis reducer grease inlet grease nipple

J2-axis reducer grease outlet taper plug Rc3/8

Fig.2.3 (b)

Replacing grease of J2-axis reducer

J3-axis reducer grease outlet taper plug Rc1/4

SECTION A-A

A J3-axis reducer grease inlet grease inlet

A

Fig.2.3 (c) Replacin g gr ease of J3-axis redu cer


48/127


B 82335EN/01

5/19/2018

2.4


PROCEDURE FOR RELEASING RESIDUAL PRESSURE FROM THE GREASE BATH

To release the residual pressure in the grease bath after applying grease, operate the robot for 20 minutes or more as described in the table below with the grease nipple of the grease inlet and the taper plug or seal bolt of the grease outlet left open for the J1-axis reducer and J4-axis reducer, and the taper plug of the grease outlet left open for the J2-axis reducer and J3-axis reducer. Attach the reclaim bags under the grease inlet and grease outlet to prevent spilled grease from splattering. Operating axis Grease replacement part

J1-axis

J1-axis reducer

Axis angle of 80° or more OVR 50%

J2-axis reducer

Arbitrary

J2-axis

J3-axis

J4-axis

Arbitrary Axis angle of 90° or more

Arbitrary

OVR 50%

J3-axis reducer

Axis angle of 60° or more OVR 100%

Arbitrary

J4-axis reducer

Arbitrary

Arbitrary Axis angle of 60° or more OVR 100%

If the above operations cannot be performed due to local circumstances, the same count operation is necessary. (When only an axis angle of 30 ° can be set instead of 60 °, perform the operation for 40 minutes, which is double the specified time of 20 minutes.) When multiple axes are greased at the same time, the axes can be run at the same time. After the above operation is performed, attach the grease nipple to the grease inlet and the seal bolt to the grease outlet. When the seal bolt, taper plug or grease nipple is reused, be sure to seal it with seal tape.


3.TROUBLESHOOTING

49/127 B-82335EN/01

5/19/2018

3 3.1


TROUBLESHOOTING OVERVIEW

The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from many interrelated factors. If you fail to take the correct measures, the failure may be aggravated. 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 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 Failures, causes and measures Symptom

Descriptio n

Cause

Measure

Vibration Noise

-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

-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 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 that, in turn, lead to vibration. [Rack or floor]

between the J1 base and floor plate, remove it.

-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

make it more rigid. -If it is impossible to reinforce the rack or floor, modify the robot control program; doing so might reduce the amount of vibration

-Apply epoxy to the floor surface plate.

and

re-install

the

-Reinforce the rack or floor to

http://slidepdf.com/reader/full/m410700pdf B-82335EN/01

50/127

3.TROUBLESHOOTING

5/19/2018Symptom

Measure -slidepdf.com M410_700.pdf

Descriptio n

Cause

Vibration

-Vibration was first noticed

[Broken gear, bearing, or reducer]

-Operate one axis at a time to

Noise (Continued)

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.

- It is likely that collision or overload applied an excessive force on the drive mechanism, thus damaging the geartooth surface or rolling surface of a bearing, or reducer. - It is likely that prolonged use of the robot while overloaded caused fretting of the gear tooth surface or rolling surface of a bearing, or reducer due to resulting metal fatigue. - It is likely that foreign matter caught in a gear, bearing, or within a reducer caused damage on the gear tooth surface or rolling surface of the bearing, or reducer. - It is likely that, because the grease

determine which axis is vibrating. - Find the source of the vibration while referring to the drive mechanism drawing of each axis given in the related maintenance manual. -Remove the motor, and check whether there are any fretting on a gear tooth surface. If any fretting is found, replace the gear. Note) Even a small amount of damage on a gear tooth surface can generate a large amount of noise. Therefore,

has not been changed for a long period, fretting occurred on the gear tooth surface or rolling surface of a bearing, or reducer due to metal fatigue.

it is necessary to check each gear tooth surface carefully. -Check whether any other gear in the drive mechanism is abnormal. If all the gears are found to be satisfactory, the reducer must be replaced. -If there is foreign, matter

These factors all generate cyclic vibration and noise.

caught in a gear, or if a gear tooth is missing, replace the gear. 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. -If nothing changes after a gear or reducer is replaced, it is likely that a bearing is damaged. -Using the robot within its


3.TROUBLESHOOTING

51/127 B-82335EN/01

5/19/2018Symptom

Descriptio n

Cause

Vibration

-The cause of problem cannot

[Controller, cable, and motor]

Measure -slidepdf.com M410_700.pdf -Refer

Noise (Continued)

be identified from examination of the floor, rack, or mechanical section.

-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

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

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.

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

-If a connection cable between them has an intermittent break, vibration might occur. -If a power cable 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.

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

to

the

controller


52/127

3.TROUBLESHOOTING

5/19/2018Symptom

Descriptio n

Cause

Vibration

-There is some relationship

[Noise from a nearby machine]

Noise (Continued)

between the vibration of the robot and the operation of a machine near the robot.

-If the robot is not grounded properly, electrical noise is induced on the grounding wire, preventing commands from being transferred accurately, thus leading to vibration. -If the robot is grounded at an unsuitable point, its grounding potential becomes unstable, and noise is likely to be induced on the grounding line, thus leading to vibration. -There may be an unusual sound when using other than the specified grease. -Even for the specified grease, there may be an unusual sound during operation at low speed

firmly to ensure a reliable ground potential and prevent extraneous electrical noise.

usual sound will disappear.

-There is an unusual sound when operating right immediately the replacing part, grease.

immediately after replacement or after a long period. -There is a possibility of grease has not been exchanged accurately. The amount of refueling may be insufficient.

-While the robot is not supplied with power, pushing

[Mechanical section coupling bolt] -It is likely that overloading or a

it with the hand causes part of the mechanical unit to wobble. -There is a gap on the mounting surface of the mechanical unit.

collision has loosened a mounting bolt in the robot mechanical section.

-There is an unusual sound after replacement of grease. -There is an unusual sound after a long period. -There is an unusual sound during operation at low speed.

Rattling

Measure -slidepdf.com M410_700.pdf -Connect the grounding wire

-Use the specified grease. -When there is an unusual sound even for specified grease, perform operation for one or two days on an experiment. Generally, a

-Stop the robot, and confirm the damage situation at once. -Replenish grease when they are insufficient. -Check that the following bolts for each axis are tight. If any of these bolts is loose, apply Loctite and tighten it to the appropriate torque. -Motor retaining bolt -Reducer retaining bolt -Reducer shaft retaining bolt -Base retaining bolt -Arm retaining bolt -Casting retaining bolt -End effecter retaining bolt


3.TROUBLESHOOTING

53/127 B-82335EN/01

Symptom

Descriptio n

Cause

Rattling

-Backlash is greater than the

[Increase in backlash]

(Continued)

tolerance stated in the applicable maintenance manual. (See Section 3.3.)

-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.

5/19/2018

Measure


-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 -Afterbox. replacing the gear or reducer, add an appropriate amount of grease. -Using the robot within its maximum rating prevents problems with the drive mechanism. -Regularly changing the grease with a specified type can help prevent problems.


3.TROUBLESHOOTING

54/127

Symptom

Descripti on

Cause

Motor

-The ambient temperature of

[Ambient temperature]

overheating

the installation location increases, causing the motor to overheat. -After a cover was attached to the motor, the motor overheated. -After the robot control program or the load was changed, the motor overheated.

-It is likely that a rise in the ambient temperature or attaching the motor cover prevented the motor from releasing heat efficiently, thus leading to overheating. [Operating condition] -It is likely that the robot was operated with the maximum average current exceeded.

5/19/2018

Measure


The teach pendant can be

used to monitor the average current. Check the average current when the robot control program is running. The allowable average current is specified for the robot according to its ambient temperature. Contact FANUC for further information. -Relaxing the robot control program and conditions can reduce the average current, thus preventing overheating. -Reducing the ambient temperature is the most effective means of preventing overheating. -Having the surroundings of the motor well ventilated enables the motor to release heat efficiently, thus preventing overheating. Using a fan to direct air at the motor is also effective. -If there is a source of heat near the motor, it is advisable

-After a control parameter was changed, the motor overheated.

-Symptom other than stated above

[Parameter] -If data input for a workpiece is invalid, the robot cannot be accelerated or decelerated normally, so the average current increases, leading to overheating. [Mechanical section problems] -It is likely that problems occurred in the mechanical unit drive mechanism, thus placing an excessive load on the motor. [Motor problems]


3.TROUBLESHOOTING

to install shielding to protect the motor from heat radiation. -Input an appropriate parameter as described in CONTROLLER OPERATOR’S MANUAL.

-Repair the mechanical unit while referring to the above descriptions of vibration, noise, and rattling. -Check that, when the servo system is energized, the

B-82335EN/01

55/127

Symptom

Descripti on

Cause

Grease

-Grease is leaking from the

[Poor sealing]

leakage

mechanical unit.

-Probable causes are a crack in the casting, a broken O-ring, a damaged oil seal, or a loose seal bolt. -A crack in a casting can occur due to excessive force that might be caused in collision. -An O-ring can be damaged if it is trapped or cut during disassembling or re-assembling. -An oil seal might be damaged if extraneous dust scratches the lip of the oil seal. -A loose seal bolt might allow grease to leak along the threads. -Problems with the grease nipple or threads.

casting, sealant can be used as a quick-fix to prevent further grease leakage. However, the component should be replaced as soon as possible, because the crack might extend. -O-rings are used in the locations listed below. -Motor coupling section -Reducer (case and shaft) coupling section -Link 1 connection part -Oil seals are used in the locations stated below. -Inside the reducer -Inside the wrist

[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

-Seal bolts are used in the locations stated below. -Grease drain outlet -Replace the grease nipple. -Check whether the brake drive relay contacts are stuck to each other. If they are found to be stuck, replace the relay.

5/19/2018

Dropping axis

Displacement

-An axis drops because the brake does not function. -An axis drops gradually when it should be at rest.

-The robot operates at a point other than the taught position. -The repeatability is not within the tolerance.

-If a crack develops in the

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.

-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.

[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

-If the repeatability is unstable, repair the mechanical section by referring to the above descriptions of vibration, noise and rattling


Measure


3.TROUBLESHOOTING

56/127

Symptom

Descripti on

Cause

Displacement

-Displacement occurred after

[Parameter]

(Continued)

a parameter was changed.

-It is likely that the mastering data was rewritten in such a way that the robot origin was shifted.

5/19/2018

BZAL alarm -BZAL is displayed on the occurred controller screen

3.3

Measure


-The voltage of the memory backup battery may be low. -The pulsecoder cable may be broken.

-Re-enter

the

previous

mastering data, which is known to be correct. -If correct mastering data is unavailable, perform mastering again. -Replace the battery. -Replace the cable.

BA CKLASH MEASUREMENT

Measurement m ethod 1. 2. 3.

Maintain the robot in a specified posture. (See Table 3.3.) Apply positive and negative loads to each axis as shown in Fig. 3.3 (a). Remove the loads and measure the displacement.

Calculate the backlash using the following expression.


3.TROUBLESHOOTING

B-82335EN/01

57/127

5/19/2018


Measured position Measured position 3130 Load position

Load position

J1 arbitrary J2 81° J3 -10° J4 -90°

J1 arbitrary J2 0° J3 -58° J4 0°

Measured position Load position

3 2 9

Load position

J1 arbitrary J2 41° J3 -90°


J1 arbitrary J2 30° J3 -66°

3.TROUBLESHOOTING

58/127

TOLERANCE VALUE OF BACKL ASH 5/19/2018


Measured axis

Table.3.3 Measurement postu re and tol erance value of backlash Tolerance Posture value J1-axi s J2-axi s J3-axi s J4-axi s (arc-min)

J1-axis

Arbitrary

81

J2-axis

Arbitrary

0

J3-axis

Arbitrary

41

J4-axis

Arbitrary

30

-10

-90

-58

0

-90

0

-66

-10

°

°

°

°

°

°

°

°

°

°

°

°

Tolerance value (mm)

2.2

2.00

2

0.78

2

0.83

2.3

0.21

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 angle and displacement conversions according to the table.

http://slidepdf.com/reader/full/m410700pdf 4.COMPONENT REPLACEMENT AND ADJUSTMENTS

B-82335EN/01

59/127

5/19/2018


4

COMPONENT REPLACEMENT AND ADJUSTMENTS

Adjustments are needed after a component is replaced. The following table lists components and the adjustment items that must be made after the components are replaced. After replacing a component, make necessary adjustments according to this table. Replacement component

Adjustment item

Motor

Mastering

Reducers Wrist –axis unit

NOTE Be very careful when dismounting and mounting the heavy components that are listed below. Component Servo motor

Reducer

Weight J1-axis

30

J2, J3-axis

35

J4-axis

10

J1-axis

165

J2, J3-axis

95

J4-axis

20

Bracket (J2, J3-axis motor mounting face)

35

Wrist-axis unit

90

Unit which is above J2-axis base (except balancer unit)(See Fig.4.3 (a))

1500

Balancer unit

170

NOTE When applying Loctite to the important bolt tightening points, make sure that it is applied longitudinal portion in the of the female threads.toIf the it is entire applied to the male threads, theengaging bolts maysection be loosened because sufficient effects cannot be obtained. Remove the dust within the bolts and taps and wipe oil off the engaging section. Make sure that there is no solvent in the taps. Be sure to wipe the overflowed Loctite after tightening screw.

http://slidepdf.com/reader/full/m410700pdf B-82335EN/01 4.COMPONENT

REPLACEMENT AND ADJUSTMENTS

60/127

4.1

5/19/2018

FIGURE OF DRIVE MECHANISM


The drive mechanisms of each axis are shown in the following.

J2 BASE

J1 REDUCER

J1 BASE

GEAR 1

GEAR 2

J1 MOTOR(M1)

Fig. 4.1(a) Drive mechanism of J1-axis

J2 ARM

INPUT GEAR

J2 MOTOR(M2)

4.COMPONENT REPLACEMENT AND ADJUSTMENTS http://slidepdf.com/reader/full/m410700pdf

B-82335EN/01

61/127

5/19/2018


LINK 2

J3 MOTOR(M3)

LINK 1

J3 REDUCER

INPUT GEAR

J2 BASE Fig. 4.1(c) Drive mechanism of J3-axis

J4 MOTOR(M4)

GEAR1

GEAR2

J4 BASE

B-82335EN/01 4.COMPONENT http://slidepdf.com/reader/full/m410700pdf

REPLACEMENT AND ADJUSTMENTS

62/127

4.2

5/19/2018

1. 2.

・・・

・

3. 4. 5.

6. 7. 8. 9.

10. 11. 12. 13. 14. 15.

REPLACING THE J1-AXIS MOTOR M1


Turn off the power of the controller. (Only integrated controller type) To provide space in which the J1-axis motor can be removed, shift the location of the control unit by following the procedure below (see Fig. 4.2 (a)). Remove the bolts (two M6 ×10) from the connector plate, and dismount it. Remove the bolt (M10×16) from the cable clamp, and dismount the cable clamp. Remove the bolts (two M10 ×20 bolts and two M10×16) from the control unit retaining plate, and dismount it. Shift the control unit to a location shown in Fig. 4.2 (a). Remove bolt (3) and pulsecoder connector cover (4). (At this time, hold the cover so that it does not rotate. Otherwise, it rotates together with the bolt, breaking the connector.) Remove connectors from the J1-axis motor. Prepare to wipe off grease that will come out from the grease bath when the J1-axis motor is dismounted from the robot. In case of integrated controller type, also cover the control unit with a cloth to protect it from grease drips. The J1-axis motor is heavy. To support the motor during removal of it, place a jack or other lifting tool under the motor in advance. Remove four motor securing bolts (1). Remove the J1-axis motor from the J1-axis base. Take care not to soil the transformer with grease. Polish the flange surface of the new J1-axis motor (5) using an oil stone. Take off the gear (6) of the shaft leader of the motor, and change a gear to a new motor. In this time, apply Loctite No.518 to nut and attach gear to nut by specified torque (118Nm(12kgfm)) (see Fig.4.2(c)) Attach new motor to J1-base.In this time, replace O-ring to new one. Attach connector to J1-axis motor. (Only integrated controller type) Put back the control unit which moved. Attach bolt (3) and pulsecoder connector cover (4). According to Section 2.3, supply the J1-axis grease bath with the specified grease. Perform mastering referring to Section 6 of this manual or Section 8 of operator’s manual.


B-82335EN/01

63/127

5/19/2018


Cable clamp Bolt M10X16

Connector plate Bolt M6X10 Move controller to this position.

Plate for mounting controller unit M10X20 M10X16 Washer

Robot front Fig.4.2 (a) Replacing J1-axis mot or (1/3)

B-82335EN/01

4.COMPONENT REPLACEMENT AND ADJUSTMENTS


64/127

5/19/2018


8

7 6

5

3

2 4 1

Fig.4.2 (b) Replacing J1-axis moto r (2/3)

Apply Loctite NO.518 to part.

Gear

Motor shaft



B-82335EN/01

65/127

4.3

REPLACING THE J1-AXIS REDUCER

5/19/2018


1. 2. 3.

Control the robot posture so that J1 to J4-axis are set to 0 degrees or less, and turn off the power. Remove the balancer according to Section 4.11 REPLACING THE BALANCER. Take out all cables, which are laid between the J1-axis base and J2-axis base, from the hollow section of the J1-axis reducer by pulling them toward the J2-axis base side (see Section 5.3). 4. Prepare to wipe off grease that will come out from the grease bath when the J1-axis motor is dismounted. In case of integrated controller type, also cover the control unit with a cloth to protect it from grease drips. 5. Remove the J1-axis motor referring to Section 4.2. 6. Hang the robot by using sling and lever block according to Fig.4.3 (a). 7. Remove the grease tube of J1-axis reducer. 8. Remove the J1-axis reducer mounting bolts (1) and washer (2), and separate the units that are above the J2-axis base from the J1-axis reducer. 9. Remove the J1-axis reducer mounting bolts (7) and washer (8) and, dismount the J1-axis reducer from the J1-axis base. 10. Dismount the gear (11) to which bearing (12) is attached from the J1-axis reducer. 11. Remove bolt (3), washer (4) and pipe (5) from reducer. 12. Replace reducer to new one, and assemble it by opposite procedure. ・ Polish the reducer mounting surface and the J2 base mounting surface with an oilstone. ・ Replace O-ring to new one and attach it in right position. ・ Be careful not to damage the surface of the gear teeth. ・ Change it that a bolt with Loctite tight application instructions and the clamping torque instructions and the washer are as new as possible. ・ When bearing (12) is broken or it is attached to J1-axis reducer and can’t be removed, replace it to new one. 13. Assemble cables according to section 5.3. 14. According to Section 2.3, supply the J1axis grease bath with the specified grease. 15. Perform mastering referring to Section 6 of this manual or Section 8 of operator’s manual.

B-82335EN/01



66/127

Lever block 5/19/2018


Wind sling to J3 arm this way.

J3 arm Put slings through the omission hole of the casting in this way.

1 2

SECTION A-A

Fig. 4.3 (a) Hanging meth od o f J2 base unit



B-82335EN/01

67/127

3 5/19/2018


4 5

7

6

8

9

10

12

11

Fig. 4.3 (b) Replacing t he J1-axis reducer

Parts name 1

BOLT

2 3 4

Specifications

Number

A6-BA-16X50

18

WASHER

A97L-0001-0823#M16H

18

BOLT

A6-BA-6X16

8

WASHER

A97L 0001 0823#M6H

8

B-82335EN/01

Locking LT262

Torque (N-m) 319(32.5)



68/127

4.4 5/19/2018

1.

REPLACING THE J2-AXIS MOTOR M2 Turn off the power of the controller.


WARNING

If you try to remove the J2-axis motor without fastening the J2 arm first, the J2 arm may move, posing a serious danger to you (the arm may fall in the direction of gravity or rise, depending on the load condition and posture). Fasten the arm so that it does not move. 2. 3.

Support robot as Fig.4.4 (a). Remove bolt (4) and pulsecoder connector cover (5). (At this time, hold the cover so that it does not rotate. Otherwise, it rotates together with the bolt, breaking the connector.) Remove connectors from the J2-axis motor. Remove the four motor mounting bolts (1), washers (2) and J3-axis motor (3) .In this time, pull out the J2-axis motor (3) horizontally, while being careful not to damage the surface of the gear teeth. Remove the bolt (9) and seal washer (8) that fasten input gear (7) and remove input gear (7). Then

4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14.

dismount draw nut (6)ofwhich fixed in motor shaft. Polish thethe flange surface the new J2-axis motor (3) using an oil stone. Apply Loctite No.242 to screw part of draw nut (6) and attach nut (6) to motor shaft by specified torque [118Nm]. Attach input gear (7) above draw nut (6) and attach the bolt (9) and seal washer (8) by specified torque [27.5Nm]. Replace O-ring (10) to new one and attach it J2 base mounting part just in a correct position. Then attach motor to J2 base by bolt (1) and washer (2). In this time, avoid push the motor forcibly. A spar gear might be damaged. Attach connector to J2-axis motor. Attach bolt (4) and pulsecoder connector cover (5). According to Section 2.3, supply the J2-axis grease bath with the specified grease. Perform mastering referring to Section 6 of this manual or Section 8 of operator’s manual.

TIP

Before removing the motor, loosen all the four mounting bolts and try to turn the motor byinhand. If a force acts onwhether the motor cause the motor to be turned strongly one direction, check thetoarm is correctly fastened, without removing the bolts.


B-82335EN/01

69/127

5/19/2018

Use eyebolt (SlingM12 1pcs)



0

Fig.4.4 (a) Supporting method when replacing J2-axis motor and reducer

1 2

3

6

10

7

8


B-82335EN/01


Parts name

Specifications

70/127

Number

Locking

Torque (N-m)

1

BOLT

A6-BA-12X25

4

2 3

WASHER MOTOR

A97L-0001-0823#M12H A06B-0272-B605#S000

4 1

4

BOLT

A6-BA-8X12

1

5

COVER

A290-7324-X101

1

6

DRAW NUT

Included in INPUT GEAR

1

7

INPUT GEAR

A97L-0218-0363#253

1

8

WASHER

A30L-0001-0048#8SUS

1

9

BOLT

A6-BA-8X70

1

10

O-RING

JB-OR1A-G125

1

5/19/2018

4.5


LT242

118(12)

LT242

27.5(2.8)


Replacement p rocedure 1. 2. 3. 4. 5.

6. 7. 8.

9.

Turn off the power of the controller. Support robot as Fig.4.4 (a). Remove the J2-axis motor referring to Section 4.4. Using a vacuum cleaner, drain grease from the J2-axis reducer through the hole in which the J2-axis motor was before dismounted. Remove only three sets of bolt (3) and washer (4) that are separated each other and insert the guide pins (A290-7324-X923) instead. After inserting the guide pins, remove the remaining bolts (3) and washers (4). Remove the bolts (1) and washers (2) and remove the bracket (5). Since the bracket (5) and J2-axis base are positioned by the spring pin (6), remove them using the bracket extract threaded holes. Remove the cap (12), grease nipple (13), and shaft (14) from the reducer (10). Remove only three sets of bolt (7) and washer (8) that are separated each other and insert the guide pins (A290-7324-X921) instead. After inserting the guide pins, remove the remaining bolts (7) and washers (8). Remove the reducer (10).

As sembli ng 1.

Attach the oil seal (9) to a new reducer (10) using the punching fixture (A290-7324-X924) and then polish the surface on which the reducer (10) is mounted with oil stone.

2.

Attach the new O-ring (11) to the reducer (10), lift it up with a crane, mount it on the J2 arm with the guide pins (A290-7324-X921), and fix it with the bolts (7) (with Loctite No.262 applied and the torque specified) and washers (8). At this time, first insert bolts (7) and washers (8) into the holes in which no guide pins (A290-7324-X921) are set and tighten them. Next, remove the guide pins, insert the bolts (7) and washers (8) instead and tighten them


B-82335EN/01

71/127

10 5/19/2018

13 12

2 1


7 8

3 4 6 5

11 14 9

Fig. 4.5 (b) Replacing t he J2-axis reducer

1

Parts name BOLT

Specifications A6-BA-16X40

2

WASHER

A97L-0001-0823#M16H

3

BOLT

A6-BA-16X50

4

WASHER

A97L-0001-0823#M16H

5

BRACKET

A290-7327-X306

6

SPRING PIN

A6-PS-12X30

7

BOLT

A6-BA-12X65

8 9

WASHER OIL SEAL

A97L-0001-0823#M12H A97L-0040-0185

10

RV REDUCER

A97L-0218-0348#550F-253

1

11

O-RING

JB-OR1A-G340

1

12

CAP

A290-7120-X219

1

B-82335EN/01

Number 12 12 19 19 1 2 30

Locking LT262 LT262

319(32.5)

LT262

128(13.1)

30 1



4.6

Torque (N-m) 319(32.5)


72/127

5/19/20181.

Turn off the power of the controller.


WARNING If you try to remove the J3-axis motor without fastening the J3 arm first, the J3 arm may move, posing a serious danger to you (the arm may fall in the direction of gravity or rise, depending on the load condition and posture). Fasten the arm so that it does not move. 2. 3.

Support robot as Fig.4.6 (a). Remove bolt (4) and pulsecoder connector cover (5). (At this time, hold the cover so that it does not rotate. Otherwise, it rotates together with the bolt, breaking the connector.) Remove connectors from the J3-axis motor. Remove the four motor mounting bolts (1), washers (2) and J3-axis motor (3) .In this time, pull out the J3-axis motor (3) horizontally, while being careful not to damage the surface of the gear teeth. Remove the bolt (9) and seal washer (8) that fasten input gear (7) and remove input gear (7). Then

4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14.

dismount draw nut (6), fixed in motor shaft. Polish thethe flange surface ofwhich the new J3-axis motor (3) using an oil stone. Apply Loctite No.242 to screw part of draw nut (6) and attach nut (6) to motor shaft by specified torque [118Nm]. Attach input gear (7) above draw nut (6) and attach the bolt (9) and seal washer (8) by specified torque [27.5Nm]. Replace O-ring (10) to new one and attach it J2 base mounting part just in a correct position. Then attach motor to J2 base by bolt (1) and washer (2). In this time, avoid push the motor forcibly. A spar gear might be damaged. Attach connector to J3-axis motor. Attach bolt (4) and pulsecoder connector cover (5). According to Section 2.3, supply the J3-axis grease bath with the specified grease. Perform mastering referring to Section 6 of this manual or Section 8 of operator’s manual.

TIP Before removing the motor, loosen all the four mounting bolts and try to turn the motor by hand. If a force acts on the motor to cause the motor to be turned strongly in one direction, check whether the arm is correctly fastened, without removing the bolts.


B-82335EN/01

73/127

5/19/2018




A 0

DETAIL A

Fig.4.6 (a) Supporting method when replacing J3-axis motor and reducer

9 8

7

1


B-82335EN/01


Parts name

1

2

BOLT

Specifications

A6-BA-12X25

Number 4

Locking

Torque (N-m)

74/127

1

BOLT

A6 BA 12X25

4

2 3

WASHER MOTOR

A97L-0001-0823#M12H A06B-0272-B605#S000

4 1

4

BOLT

A6-BA-8X12

1

5

COVER

A290-7324-X101

1

6

DRAW NUT

Included in INPUT GEAR

1

7

INPUT GEAR

A98L-0218-0363#353

1

8

WASHER

A30L-0001-0048#8SUS

1

9

BOLT

A6-BA-8X70

1

10

O-RING

JB-OR1A-G125

1

5/19/2018

4.7


LT242

118(12)

LT242

27.5(2.8)


Replacement p rocedure 1. 2. 3. 4. 5.

6. 7. 8. 9.

Turn off the power of the controller. Support robot as Fig.4.6 (a). Remove the J3-axis motor referring to Section 4.6. Using a vacuum cleaner, drain grease from the J3-axis reducer through the hole in which the J3-axis motor was before dismounted. Remove only three sets of bolt (3) and washer (4) that are separated each other and insert the guide pins (A290-7324-X923) instead. After inserting the guide pins, remove the remaining bolts (3) and washers (4). Remove the bolts (1) and washers (2) and remove the bracket (5). Since the bracket (5) and J2-axis base are positioned by the spring pin (6), remove them using the bracket extract threaded holes. Remove the cap (12), grease nipple (13), and shaft (14) from the reducer (10). Remove only three sets of bolt (7) and washer (8) that are separated each other and insert the guide pins (A290-7324-X921) instead. After inserting the guide pins, remove the remaining bolts (7) and washers (8). Remove the reducer (10).

As sembli ng 1.

Attach the oil seal (9) to a new reducer (10) using the punching fixture (A290-7324-X924) and then polish the surface on which the reducer (10) is mounted with oil stone.

2.

Attach the new O-ring (11) to the reducer (10), lift it up with a crane, mount it on the J2 arm with the guide pins (A290-7324-X921), and fix it with the bolts (7) (with Loctite No.262 applied and the torque specified) and washers (8). At this time, first insert bolts (7) and washers (8) into the holes in which no guide pins (A290-7324-X921) are set and tighten them. Next, remove the guide pins, insert the bolts (7) and washers (8) instead and tighten them


B-82335EN/01

5

75/127

10 7 4 M410_700.pdf -slidepdf.com 3

5/19/2018

8

12

1 2 13 14

11

6

9

Fig. 4.7 Replacing the J3-axis reducer Parts name

Specifications

Number

1

BOLT

A6-BA-16X40

12

2

WASHER

A97L-0001-0823#M16H

12

3

BOLT

A6-BA-16X50

19

4

WASHER

A97L-0001-0823#M16H

19

5

BRACKET

A290-7327-X306

6 7

SPRING PIN BOLT

A6-PS-12X30 A6-BA-12X65

2 30

8

WASHER

A97L-0001-0823#M12H

30

9

OIL SEAL

A97L-0040-0185

1

10

RV REDUCER

A97L-0218-0348#550F-253

1

11

O-RING

JB-OR1A-G340

1

12 13

CAP GREASE NIPPLE

A290-7120-X219 A97L-0218-0013#A610

1 1

14

SHAFT

A290-7327-X346

1

B-82335EN/01

Torque (N-m) 319(32.5)

LT262

319(32.5)

LT262

128(13.1)

1



4.8

Locking LT262


76/127

1. 2. 3. 4.

5/19/2018

5. ・・・・・・

6. 7.

Turn off the power of the controller. M410_700.pdf-slidepdf.com Remove connectors from the J4-axis motor. Remove motor mounting bolt (1) and washer (2), then remove motor (3). Remove a nut (6) from the end of the motor shaft, holding the gear with a wrench so that the motor shaft will not turn. Then, remove the gear from the motor. Replace motor to new one, assemble it by opposite procedure Polish the motor mounting surface with an oilstone. Apply Loctite No. 242 (blue) to the thread of the motor. Take care not to apply Loctite to the tapered part of the shaft. Tighten the nut with a regulated torque, holding the gear with a wrench. Replace O-ring to new one and mount it just in a correct position. Take care not to damage any tooth flank of the gear. Replace each removed washer with a new one if possible. According to Section 2.3, supply the J4-axis grease bath with the specified grease. Perform mastering referring to Section 6 of this manual or Section 8 of operator’s manual.

1 2 3

4 5 6 7


4.9


B-82335EN/01

77/127

1. 2. 3. 4.

Turn off the power of the controller. M410_700.pdf-slidepdf.com Remove the hand and workpiece from the wrist. Remove the J4-axis motor referring to Section 4.8. Remove bolt (8) and washer (9) and remove the reducer which gear and wrist flange is attached from the wrist. Prepare to wipe off grease that will come out from the grease bath when the reducer is dismounted. Remove wrist flange mounting bolts (1) and washer (2) and remove wrist flange (3) from reducer. Remove pipe mounting bolt (4), washer (5) and remove pipe from reducer. And remove gear (12).

5/19/2018

5. 6. 7. 8.

Replace the reducer (11). Assemble the by opposite procedure. ・Replace O-ring (10), (13) to new one. 9. Attach the J4-axis motor referring to Section 4.8. 10. According to Section 2.3, supply the J4-axis grease bath with the specified grease. 11. Perform mastering referring to Section 6 of this manual or Section 8 of operator’s manual.

13 12 11

B-82335EN/01


Parts name Specifications http://slidepdf.com/reader/full/m410700pdf 1

BOLT

9 8

A6-BA-12X30

Number 12

Locking LT262

Torque (N-m) 128(13.1)

78/127

2

WASHER

A97L-0001-0823#M12H

FLANGE

A290-7042-X553

1

BOLT

A6-BA-6X20

3

5

WASHER

A97L-0001-0823#M6H

3

6

PIPE

A290-7039-X512

1

7

O-RING

A98L-0001-0347#S70

1

8

BOLT

A6-BA-10X85

14

9 10

WASHER O-RING

A97L-0001-0823#M10H JB-OR1A-G25

14 1

11

RV REDUCER

A97L-0218-0806#120C-36

1

12

GEAR J32

A290-7125-X422

1

13

O-RING

A98L-0040-0041#173

1

5/19/2018 3 4

4.10

12 M410_700.pdf-slidepdf.com

LT262

73.5(75)

REPLACING WRIST AXIS UNIT

This part describes the procedure for replacing only the J4-axis reducer.

To replace only the J4-axis

reducer, see Section 4.9. 1. 2. 3. ・・・・・

4. 5. 6. 7. 8.

Turn off the power of the controller. Unload hands or workpiece from the wrist, place the workbench or the like under the wrist unit, and secure the wrist unit. Remove the J3-axis link from the wrist unit by following the steps below. Remove bolt (1) and cover (2). Remove bolt (3) of the both side of J3-axis link. Remove link (4). Remove bolt (5) and washer (6). Remove shaft assy (7) from J3-axis link (4). Remove shaft assy (7) from wrist axis unit. Remove bolt (8) and plate (9). Remove bearing nut (10) from shaft (14). Remove nylons ring (11). Remove bolt (12) and washer (13) and remove shaft (14) which bearing is attached to from

wrist-axis unit. 9. Do procedure 5-8 for wrist-axis unit and J3-axis arm connecting part. (Fig.4.10(c)) 10. Change the wrist flange in new wrist axis unit from old one. 11. Assemble new wrist axis unit by opposite procedure, and tighten the bearing nuts removed in step 6 with a rotation start forth of 17 6 N to 21 6 N (1 8 kgf to 2 2 kgf) (see Fig 4 10 (d))


B-82335EN/01


79/127

3

1

5/19/2018


2 4 6 7

5

Fig. 4.10 (a) Replacing t he wri st-axis un it (1/4)

B-82335EN/01



80/127

5/19/2018


22 18

21

17 16 20 19

Fig. 4.10 (c) Replacing the w rist -axis uni t (3/4)

4.COMPONENT REPLACEMENT AND ADJUSTMENTS Specifications

http://slidepdf.com/reader/full/m410700pdf Parts name

Numbe r

B-82335EN/01

Locki ng

Torque (N-m)

81/127

1

BOLT

A6 BA 6X10

4

2

COVER

A290-7042-X404

1

3

BOLT

A6-BA-6X12

2

4 5

LINK BOLT

A290-7042-X403 A6-BA-8X25

1 8

6

WASHER

A97L-0001-0823#M8H

8

7

SHAFT ASSY

A290-7042-V401

1

8

BOLT

A6-BA-6X10

4

9

PLATE

A290-7041-X522

1

10 11

BEARING NUT NYLOS RING

A97L-0118-0441#AN16SSRY A97L-0118-0436#32016XAV

1 1

12

BOLT

A6-BA-10X100

6

13

WASHER

A97L-0001-0823#M10H

6

14

SHAFT

A290-7041-X503

1

15

BEARING

A97L-0089-0001#HR16XJ

1

16

BOLT

A6-BA-6X10

4

17

PLATE

A290-7041-X522

1

18 19

NYLOS RING BOLT

A97L-0118-0436#32016XAV A6-BA-10X90

1 6

20

WASHER

A97L-0001-0823#M10H

6

21

SHAFT

A290-7041-X502

1

22

BEARING

A97L-0089-0001#HR16XJ

1

5/19/2018

4.11


REPLACING BALANCER

Replacement p rocedure 1. 2. 3. 4. 5. 6.

Place the robot in the posture for the replacement of J2=7° Remove bolt (1) and cover (2), loosen U nut (3) and remove it. Place the robot in the posture for the replacement of J2=26°and J3= -92° Turn off the power of the controller. Attach two M12 eyebolts to the balancer, and hoist it with a crane. Remove bolt (4).

7. 8. 9.

Remove bolt (5), washer and shaft assy (7). Remove bolt (8) and shaft (9) of both sides. Attach a U nut (3) in order that the rod of the balancer does not come off, and then hoist the balancer.

B-82335EN/01

8.


Supply grease to the grease nipple attached to the shaft (9) (see Section 2.1, “GREASING TO BALANCER BUSH”).


82/127

5/19/2018


Eyebolt (M12)

Fig. 4.11(a) Replacing the balancer (1/4)

8 9

3 8 9


2 1

B-82335EN/01

83/127

5/19/2018


Remove 4 bolts of outside.

Fig. 4.11(c) Replacing the balancer (3/4)

6 5 7

A 4 DETAIL A Fig. 4.11(d) Replacing the b alancer (4/4)

WARNING Never disassemble the balancer. The balancer contains a large compressed spring. If the balancer is disassembled without using a special fixture, the internal spring will extend, and can expose you to danger. When replacing the balancer, be sure to replace the balancer assembly. NOTE To attach the U-nut (3), mount the M33 socket with a diagonal side length of 50 mm on a torque wrench and perform tightening

B-82335EN/01

4.12


REPLACING THE J1-AXIS PENDULUM STOPPER


84/127

1. 2. 3. 4.

Remove bolt (1) and washer (2). Remove plate (3) Remove pin (5) and stopper (4). Assemble them by opposite procedure.

5/19/2018


1 3

2 4 5

Fig. 4.12 Replacin g the J1-axis pendulu m stop per Parts name

Specifications

1 2

BOLT WASHER

A6-BA-12X30 A97L-0001-0823#M12H

4 4

3

PLATE

A290-7039-X213

1

4

STOPPER

A290-7039-V201

1

5

PIN

A290-7037-X202

1

5.REPLACING CABLES

5

Number


REPLACING CABLES

Locking

Torque (N-m)

B-82335EN/01

85/127

5/19/2018Replace

the cables in the cycle that is shorter among every four years and 15,360 hours. When the cable M410_700.pdf -slidepdf.com is broken or damaged, or shows signs of wear, replace it according to this chapter.

Precaution s to be observed when handlin g the puls ecoder 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. The J1-axis to J3-axis motors are provided with a pulsecoder connector cover, as shown in Fig. 5 (b), to protect the connectors. Before removing the connectors for cable replacement or other purposes, remove the covers. In this case, turning the bolt may also turn the cover, possibly causing damage to the connector. When removing the cover, hold it to prevent it from turning.

Fig. 5 (a) Marking Tie

Pulsecoder connector cover (J2-axis)

5.REPLACING CABLES

B-82335EN/01

5.1

Pulsecoder connector cover (J3-axis)

CABLE FORMING


86/127

When replacing cables, clamp the cable at the position specified in Fig.5.1 (a) to (b) using a clamp or a nylon band. Otherwise, cables can be loosened or pulled by force to cause their disconnection. Refer to 5/19/2018 M410_700.pdf-slidepdf.com the figures in section 5.3 for the cable clamp. Then Fig.5.1(c) to (i) show the marking position of cables. If you need to replace a specific cable (because, for example, it is damaged), do so by adopting the appropriate procedures. Clamp of tip of J3-axis arm

AS2

AIR22

AIR12

EE

SECTION B-B' Clamp of wrist unit Clamp in J2 base

B

B

Clamp of tip of J3-axis arm Clamp of J3-axis link base

SECTION A-A'

Clamp in J3-axis arm

Clamp of J2-axis link

A

A'

Clamp of side of J2 base

Clamp below J1 base

5.REPLACING CABLES Clamp of tip of J3-axis arm http://slidepdf.com/reader/full/m410700pdf

B-82335EN/01

87/127

AS2 AIR22

AIR12

5/19/2018


EE

SECTION B-B' Clamp of wrist unit B

Clamp in J2 base

B'

Clamp of tip of J3-axis arm Clamp of J3-axis link base

SECTION A-A'

Clamp in J3 arm

Clamp of J2-axis link

A

A'

Clamp of sied of J2 base Clamp of outlet of J1-axis connector plate

Clamp below J1 base

Fig.5.1 (b) Fix position of cable (remote controller type)

B-82335EN/01


5.REPLACING CABLES

88/127

5/19/2018


(SQ1) (FAN)

EE

FASTEN THE CABLES WITH NYLON BAND AT IMPORTANT POINTS. GB1

(M5M) (*When A05B-1042-H204 is specified) M4M

M1P

M3M

M4P M23P

A

Clamp of draw out point of controller

M1M

M2M

Note 1)Match the marking position to the center of the spong Note 2)Don't pull out the stopping of the unused part.

SECTION AA'(SCALE 1/2) A'

Fig.5.1(c) Figure of cable clamp (integrated controller type)

NOTE Fig.5.1(c) and Fig.5.1 to (i) show the sectionA05B-1042-H204 of cable clamp ofisthe mechanical unit cable (e) A05B-1042-H202.When specified, pay attention that M45P and M5M is formed instead of M4Pand AIR2.

5.REPLACING CABLES

B-82335EN/01 M2M


EE M4P

M3M

M23P

89/127

M4M

5/19/2018

M1M

Q

M1P (SQ1)

(FAN) L

L' RM2

RM1

M410_700.pdf -slidepdf.com NYLON BAND（2 locations）

NYLON BAND

RP1

AIR11 AIR21

AS1

T'

T

P

EE

M4P

SECTION TT'

EARTH CABLE (FROM RP1)

Q' SECTION LL'

J1OT

M 4 M 5 B K

J 1 O T

EARTH CABLE (FROM RM2)

EARTH CABLE (FROM RM1)

NYLON BAND SECTION QQ'

VIEW P

Fig.5.1 (d) Figure of cable clamp (remote cont rol ler type)

5.REPLACING CABLES

B-82335EN/01

http://slidepdf.com/reader/full/m410700pdf M 3 M

P 3 M

E L B A . C N

90/127 T A E

M 1 R I A

5/19/2018

2 R I A

P 4 M

E E

M 4 S A M

6 3 3 X p m a l c

P 3 M , M 3

o T

1 R I A 2 R I A

M 4 M S A

M

' D

D

' C C N O I T C E S

' C

D N A B N O L Y N H T I W E T A L P O T P U . L E 0 I 3 T T

O N I O T I I T A S O T P O R O W H T E T N E I W O I S 6 T A 3 C 3 E X R I O D T T P F U E L E I O T T

P 4 M

M 4 M

' D D N O I T C E S

P 4 M

E E

P 2 M , M 2 M

N O I T I S O P G N I K R A M

2 R I A

1 R I A

E E

P 4 M

M 3 M

M 2 M P 3 2 M

D N A B O N L Y N H T I W E T A L P

e s a b 1 J w o l e b p m a l C

O T P U . L E 0 I 3 T T

M 2 M

5 3 3 X 2 4 0 7 p 0 m 9 a l 2 C A

P 2 M

' B C

S A


1 R I A

2 R I A

B

M 4 M

E S O H E H . T T N O I T O N J I E T H N T . I S O N E J R B U U E T T H T T R ' I T N A H O G D G I , N A E I R M K T I S T T O S N ) H S I U H O e P t D o ) T ) N 1 2

' B B N O I T C E S

e s a b 2 J n i p m a l C

） D N A B N O L Y N O W T F O R E T N E C （ N O I T I S O P G N I K R A M

' A

1 R I A

2 R I A

E E

M 4 M

M 3 M

M 2 M

P 4 M P 3 2 M

S A

' A A N O I T C E S

6 1 2

d e i f i c

4 5 4 4 7 7 T T -

B # 2 7 8 T -

X 2 4 0 7 p 0 m 9 a l 2

5.REPLACING CABLES

B-82335EN/01

' N N N O I T C E

http://slidepdf.com/reader/full/m410700pdf 1 R I A

2 R I

M E 4 E M S P 4 M

A

S

O W T E H N T O I F T O I ) S R D O E N

4 2 4 X 2 4

91/127

A

5/19/2018 1 R I A

M E 4 E M S P A 4

2 R I A

M E 4 E M S P 4 A M

1 R I A

M E 4 E M S P A 4 M

2 R I A

1 R I A 2 R I A

1 R I A 2 R I A

M E 4 E M S P 4 A M

M E 4 E M S P A 4 M

D N A B N O L Y N H T I W E T A L P O T P U L E 0 I 3 T T

' K K N O I T C E S

e s a b

' J J N I O T C E S

' I I N O I T C E S

N

M

' L L N O I T C E S

H T I W R E V O C E L B A C D . N L A 0 3 E T L B D A N C A B P U N O E L I Y T N

L

' L

K

' K

J

' J

I

' I

k n i l 3 J f o p m a l C

. G N I W A R E D R A S P A 4 ' M I D I N N A O I M C T 4 M E S F O M O N R O F I T D I E S G O N P A H E C H X T E


H

G

1 R I A 2 R I A

1 R I A 2 R I A

P 4 M

E E M 4 S M A

P 4 M

E E M 4 S M A

1 R I A 2 R I A

P 4 M

M 4 M

E E S A

' ' ' ' 1 2 2 1 D D E E 2 1 2 1 E D E D N N N N O O O O I I I I T T T T C C C C E E E E S S S S

F 2 E H T I W R E V O C E L B A C D . N L A 0 3 E T L B D A N C A B P U N O E L I Y T N

' ' ' C P F C P F N N N O O O I I I T T T C C C E E E S S S

' ' G B B G N N O O I I T T C C E E S S

H T I W R E V O C E L B

1 E

2 D

N O I T I S

P T A N B G E N C N I O K E L R H Y A T N M (

m r a s i x a ' 3 N J n i ' p M m a l C

M

2 R I A

1 R I A

' M M N O I T C E S

' H

0 7 0 9 2 A

p m a l C


1 5 3 X r 1 e 4 v o 0 c 7 -

5 1 4

X 1 4 7 0 0 9 2 A

) D N A B N O L Y N O W T E H N T O I F T O I S R O E P T N G E N C I K E R H A T M (

) 2 ( 0 1 4 X 0 6 7 - A p 0 t B m 9 l a 2 6 l o A C B A

f o e d i s r e p p u f o p m a l C

6 1 ) 2 4 ( X 0 - 1 1 X 4 6 0 7 - A p 0 t B m 9 l a 2 6 l o C A B A


' F

1 D

' 1 D ' C

B

' B

A

' A

e T b A L p P O m T a P l U L C E 0 I 3 T T


E C E L I B B G U A A T C M R I . R D A S E R E H A P L ) T W E B E A O E A T G T K C O ) ) N 1 2

3 4 3

E D I S 1 5 R 3 E X W O F L O

D

N H T . k A L n B ' I 0 i 1 W 3 l N E E T O L B D 2 L A N J Y N C A B H P T U N w O I E L o W I Y l T N E

C

. G N R I E P H S M T E A O L L K C O N T I N R E D W H E W S R U E E V P T O A E C T S

k n i l 2 J

G

' 2 D

0 9 2 A

6 1 4 X 1

'

' 2 E

e l b a C

E D I S 1 5 R 3 E X P P F U O

p m a l C

E D I S 0 5 R 3 E X P P F U O

X 1 4 0 7 p 0 m 9 a 2 l C A

3 4 3 X 1 4 0 7 p 0 m 9 a 2 l C A

6 1 4 X 1 4 0

) 2 ( 0 1 X 6 7 - A p 0 t B m 9 l a 2 o 6 l C A B A

5.REPLACING CABLES

B-82335EN/01

Clamp in J2 base


92/127

5/19/2018

AS

C


M4M

EE AIR2

C

M4P

M4M

AIR2

AS

EE

AIR1

AIR1

M3M

M4P

M3P

M3M

M23P

M2M

SECTION BB'(SCALE 1/2)

SECTION A-A'

SECTION CC'(SCALE 1/2)

AS AIR2 M4M

AIR1

EE M4P

M3M M2M

M23P

SECTION DD'(SCALE 1/2)

A

A'

M1P M1M

M1M

BATTERY (SQ1)

M1P (SQ1)

H202指定時

H206指定時

D'

SECTION EE'(SCALE 1/2) D E

E'

MARKING POSITIO OF Clamp below J1 base (THE CENTER OF THE TWO NYLON BAND) Clamp in pedestal

Fig.5.1 (g) Figure of cabl e clamp (Below J 1 base and i n J2 base)

5.REPLACING CABLES

B-82335EN/01

AIR2


AIR1 M4P

M4M AS EE

93/127

5/19/2018

M410_700.pdf-slidepdf.com SECTION AA' (SCALE 1/1)

H

A'

B

I

B'

A

AIR1 AIR2

M4M M4P

EE AS

SECTION BB' (SCALE 1/1)

Fig.5.1 (h) Figure of cable clamp (Clamp in J3 arm)

5.REPLACING CABLES

B-82335EN/01 DO NOT USE NYLON BAND HERE.

http://slidepdf.com/reader/full/m410700pdf MARKING POSIITON (THE CENTER OF THE TWO NYLON BAND)

D

MARKING POSIITON (THE CENTER OF THE TWO NYLON BAND)

CLAMP OF WRIST UNIT E

F

G

94/127

NYLON BAND FOR AIR HOSE

5/19/2018


D'

AIR2

M4M

M4P

F'

G'

AIR2

AIR2

AIR2 M4P

E'

M4P

M4M M4P

M4M

M4M

EE AS EE AS

AIR1

SECTION DD' (SCALE 1/1)

EE

EE

AS

AS

SECTION EE' (SCALE 1/1)

AIR1

AIR1

AIR1

SECTION FF' (SCALE 1/1)

SECTION GG' (SCALE 1/1)

AS2

EE MARKING POSITION

AIR22

AIR12 EE

MARKING POSIITON (THE CENTER OF THE TWO NYLON BAND)

SET 凸 SIDE OF AIR HOSE TO BOTTOM DIRECTION(HATCHING AREA) 凸side

Fig.5.1 (i) Figure of cable clamp (J3 arm to wrist unit)

Fig 5 1 (j) to (l) imply clamp position below

5.REPLACING CABLES

Stamp

B-82335EN/01

Cable pattern diagram


Cable

Stamp NO.

95/127

GB1

+

GB1-K101

5/19/2018


-

② M3P-K101

BATTERYBACKUP DON'T

M3P

DISCONNECT

コネクタ取外不可

③

J1OT

④

②

①

J1OT

M2P-K101

BATTERYBACKUP DON'T

M2P

DISCONNECT

①

CRF8


4 8 . 0 1

M1P-K101

② ① ③ ④ ⑤⑥⑦⑧⑨

BATTERYBACKUP DO N'T

⑩ ⑪

M1P

DISCONNECT


K101

⑫

EE

EE-K101

M4P-K101

BATTERY

M4P

BACKUP

DON'T DISCONNECT


M3M M3M-K102

CNJ3A CNGA CNGC CNR88 CNJ1A CNJ2A CNJ4

N C

M3BK

A G N C

C G N C

M2M-K102

3 4 7 0 8 0 4 T

CNJ1B

A 1 J N C

③ ②

④ ①

A 2 J N C

①

③ ④

②

M2BK

B 3 J N C

B G N C

③ ⑤ ⑥

M1M-K102

② ④ ⑩ ⑦⑧

⑫

M1BK

M4M-K102

⑨ M4BK

M2BK K102

4 J N C

M1M M1BK M4M M4BK

B

5.REPLACING CABLES

B-82335EN/01

Stamp

M2M

8 8 R R C

①

CNJ3B CNGB

M3BK

A 3 J



Cable

Stamp NO.

96/127

+

5/19/2018

GB1


GB1-K103

-

② M3P-K103

BATTERYBACKUP DON'T

M3P

DISCONNECT


③

②

J1OT

①

④

J1OT

M2P-K103

BATTERYBACKUP DON'T

M2P

DISCONNECT


①

CRF8 ② ①

⑩ ⑪ ③④ ⑤⑥⑦⑧⑨

M1P-K103

BATTERYBACKUP

M1P

DON'T DISCONNECT


K103

⑫

EE

EE-K103

M4P K103

BATTERYBACKUP DON 'T

M4P

DISCONNECT


M5P K103

M3M

M3M-K104

CNJ3A CNGA CNGC CNR88

M3BK A 3 J N C

A G N C

C G N C

M2M-K104

4 4 7 0 0 8 4 T

8 8 R R C

④

CNJ1A CNJ2A

①

①

A 2 J N

② ③ ④

③

②

A 1 J N C

C

CNJ4 CNJ5 CNJ3B CNGB

M3BK M2M

M2BK

K104

4 J N C

① ③

5 J N C

B 3 J N C

M1M-K104

② ④

⑤

B G N C

⑥

⑧⑨

⑩ ⑫

M1BK

M4M-K104

5.REPLACING CABLES

M2BK

M1M M1BK M4M

B-82335EN/01


Stamp

http://slidepdf.com/reader/full/m410700pdf ③

Cable

Stamp NO.

97/127

②

5/19/2018

④ ⑤ ⑥

⑦

⑧ ⑨

⑩


⑫

* # * * * T 6 0 0 2

AS1

AS2 K105

AS2-K105

AS1-K105

M3P-K201

BATTERYBACKUP DON'T DISCONNECT


②③

④

M2P-K201

BATTERYBACKUP DON'T

M3P M2P

DISCONNECT


GB1 +

-

GB1

RP1

M1P-K201

DON'T DISCONNECT


⑤

② ③④

⑥⑦

M1P

BATTERY BACKUP

⑧ ⑨

⑩ ⑪ ⑫

K201

EE

EE-K201

T O 1 J

M4P-K201

M4P M2M

BATTERY BACKUP DON'T DISCONNECT


② ③

M2M-K202

④

RM2

M2BK

M2BK

② M1M-K202

M1M M1BK K202

M1BK

M3M-K202

5.REPLACING CABLES

B-82335EN/01

5.2

M3M

CABLE REPLACEMENT


This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables. If you need to replace a specific cable (because, for example, it is damaged), do so by adopting the

98/127

appropriate procedures. See section 5.1 for the configuration of the mechanical unit cables. Cable makes it necessary to perform mastering. Before attempting replacement, therefore, see M410_700.pdf -slidepdf.com section 6 MASTERING.

5/19/2018replacement

Replacement proc edure (integrated cont roll er type) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15.

Turn the power off, then disconnect all cable connectors to the robot main body from the controller (Fig. 5.2 (a)). Remove the cable clamp (Fig. 5.2 (b)) on the rear of the controller. Detach the metal plate from the controller exit, then detach the two metal plates securing the rubber clamp (Fig.5.2 (b)). Release cables from a rubber clamp. Pull all cables connected to the robot main body out of the controller (Fig. 5.2 (b)). Remove the air hoses and AS cable from the frame connecting plate (Fig. 5.2 (b)). Remove the cover sheet metal from the battery box, and detach the battery cable terminals from the terminal all board the connectors rear of the battery (see Fig. 5.2J1-axis. (b)). Remove the on cable from thebox motors for the Remove the bolt from the cable clamp in the lower section of the J1-axis base, and dismount the cable clamp in the J2-axis base, then pull the cables out of the J2-axis base (see Fig. 5.2 (c)). Remove all the cable connectors from the motors for the J2- to J4-axes. Remove the wrist EE plate from the wrist and then remove the cable, air hose, and AS cable from the wrist EE plate. Remove the bolts of the cable clamp for the tip of J3-axis arm and J4-axis casing (see Fig. 5.2 (e)). In addition, cut nylon band, which fix these cables to clamp and remove cable from metal of clamp. (These metal of clamp are reused.) Remove the Teflon seat attached to the cable near the wrist link. (The removed Teflon seat is attached again after the old cable is replaced.) Remove the bolts for cable clamps within the J3-axis arm (see Fig. 5.2 (d)). Draw the cable fixing sponge within the J3-axis arm from the through hole on the J3 arm (see Fig. 5.2 (d)). Remove the plate of the J3-axis base section, and remove the bolts for the cable clamp attached to the J3-axis base section (see Fig. 5.2 (c)). Remove the bolts for the cable clamp attached to the J2-axis link section. Remove metal between

clamp of upper side and lower side. (See Fig. 5.2 (c)). 16. Remove the bolts for the cable clamp attached to the J2-axis base. (See Fig. 5.2 (c)). 17. Pull out wrist side cable from J3-axis hollow part to J2 arm side. 18. Remove cable from robot.

5.REPLACING CABLES

B-82335EN/01

Replacement proc edure (remote cont roller t ype) 1.

Turn the power off, and then disconnect all cable connectors to the back of robot pedestal from the controller (Fig. 5.2 (f)).


99/127

2. 3.

5/19/2018

4. 5. 6.

7. 8.

9.

Remove air hoses and AS cable from the panel (Fig. 5.2 (f)). Remove the connector plate. Since the internal cable is fixed, care must be taken so that the internal M410_700.pdf-slidepdf.com cable is not strongly yanked (see Fig. 5.2 (g)). Remove the battery cable and earth cable. Cut the nylon band that clamp J1OT connector and connection of connector. Remove screws fastening the connector inserts (Fig. 5.2 (g)). Remove the connector housing, and dismount the connector insert from the housing. Also, dismount the plate retaining the cable from the connector plate. Then cut off the nylon tie clamping the cable to the plate, and dismount the plate (see Fig. 5.2 (h)). Follow the cable replacement steps 7 to 28 of the integrated controller type. Temporarily fasten the cable to the cable retaining plate with a nylon band, and also temporarily fasten the cable retaining plate to the connector box. Pull the cable into the connector box so that the cable does not sag, then fasten it with a nylon tie (see Fig. 5.2 (i)). Attach a new connector housing to the connector plate. Remove the cable retaining plate from the connector box, and attach it to the connector plate (see Fig. 5.2 (h)).

10. Install the cable by following steps 1 to 6 in reverse. Connect the air hose so that it matches the markings on the pedestal connector panel and wrist connector plate. 11 Turn the power on. Clear an alarm that occurs as described in Section 6.2. 12 Perform mastering referring to Section 6 of this manual or Section 8 of operator’s manual.

5.REPLACING CABLES

B-82335EN/01

CNJ3

CNJ6


CNJ5 CNJ4

Robot M-410iB/700 (R-30iA Controller)

CNJ2

100/127

CNG

CNJ1

5/19/2018

Motor power J1M M410_700.pdf-slidepdf.com J2M J3M J4M

Pulsecoder RI/RO HBK,ROT BRAKE

CRF8 CRR88 Robot M-410iB/700 ・Detail of the cable connection for servo amplifier R-30iA (Servo amplifier)

(R-30iA Controller)

CNJ1A CRF8 CNJ1B CRR88

CNJ2A CNJ2B

CNJ4 CNJ3A CNGC

CNJ3B

CNGB Pulsecoder (Pulsecoder,RI/RO, XHBK,XROT)

CNGA

BRAKE

5.REPLACING CABLES

B-82335EN/01

Battery box

Battery box cover http://slidepdf.com/reader/full/m410700pdf

BATTERY BOX (TERMINAL SIDE)

-

+

101/127

Bolt M6X10 (4)

5/19/2018

TIE UP WITH NYLON BAND. M410_700.pdf -slidepdf.com GB1

Cable clamp Phillips machine screw M4X10 (4) Controller exist metal plate Air hose AS cable Connector plate

Phillips machine screw M4X12 (2) Rubber clamp securing metal plate Phillops machine screw M4X12 (2) Rubber clamp

Fig.5.2 (b) Cable replacement (integrated co ntro ller typ e) J3 link base mounting bolt M6X10 (4)

J2 link mounting bolt M6X10 (4)

Metal between J2 link

Clamp of J2 link mounting bolt M6X10 (4)

Clamp on J2 base mounting bolt M6X10 (4) (Apply Loctite No.242.)

5.REPLACING CABLES

B-82335EN/01

Temporary end position of plate A (Use one M6 bolt.) Plate A in temporary position

http://slidepdf.com/reader/full/m410700pdf Bolt M12X35 Cable mounting sponge Plate A in J3 arm G

102/127

5/19/2018

Clamp of tip of J3 arm M410_700.pdf -slidepdf.com

H

AS2 AIR22

AIR12 EE

Plate B J

Clamp of hollow part of J3 arm mounting bolt M6X10 (3) Last mounting position of Plate A and B

Teflon tape

Fig.5.2 (d) Cable replacement

Clamp of tip of J3 arm mounting bolt M8X12 (2) Clamp of wrist unit mounting bolt M8X12 (2)

Wrist EE plate

J4 casing

5.REPLACING CABLES


B-82335EN/01

103/127

5/19/2018


Robot connection cable from controller

Option cable interface

Fig.5.2 (f) Cable replacement (Remote type co ntro ller)

Connector plate mounting bolt M6X10

Connector plate

Connector plate mounting bolt M6X16

RP1 Insert mounting screw （each ４pcs）

M E E 6 4 ｎａ H

RM1 M E E 6 4 ｎａ H

RM2

B-82335EN/01


5.REPLACING CABLES

104/127

Connector 5/19/2018plate

M410_700.pdf-slidepdf.com Plate mounting bolt

M6X10

Cable mounting plate

BATTERY BOX (TERMINAL SIDE)

Housing mounting bolt M4X10 -

+

TIE UP WITH NYLON BAND. GB1

Fig.5.2 (h) Cable replacement (Remote typ e contr oll er)

B

Connector plate Cable mountinig plate

6.MASTERING

6

B-82335EN/01

MASTERING


Mastering is an operation performed to associate the angle of each robot axis with the pulse count value

105/127

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.

5/19/2018


6.1

GENERAL

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 m ethod There are following five methods of mastering. Table 6.1 Masterin g metho ds

Fixture position mastering Zero-position mastering (eye mark mastering) Quick mastering

B-82335EN/01

This is performed using a mastering fixture before the machine is shipped from the factory. This is performed with all axes set at the 0-degree position. A zero-position mark (eye mark) is attached to each robot axis. This mastering is performed with all axes aligned to their respective eye marks.position. The corresponding count value is This is performed at a user-specified obtained from the rotation speed of the pulsecoder connected to the relevant motor and the rotation angle within one rotation. Quick mastering uses the fact that the absolute value of a rotation angle within one rotation will not be lost

6.MASTERING

CAUTION

If mastering is performed incorrectly, the robot may behave unexpectedly. This is very dangerous. Therefore, the positioning screen is designed to appear only http://slidepdf.com/reader/full/m410700pdf when the $MATER_ENB system variable is 1 or 2. After performing positioning, press F5 [DONE] on the positioning screen. The $MASTER_ENB system

106/127

variable is reset to 0 automatically, thus hiding the positioning screen. 5/19/2018


CAUTION

Before mastering is performed, it is recommended that the current mastering data be backed up.

6.2

RESETTING ALARMS AND PREPARING FOR MASTERING

Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and display the positioning menu.

Al arm dis pl ayed

“Servo 062 BZAL” or “Servo 075 Pulse mismatch”

Procedure 1.

Display the positioning menu by following steps 1 to 6. 1. Press the screen selection key. 2. Press [0 NEXT] and Select [6 SYSTEM]. 3. Press F1 [TYPE], and select [SYSTEM Variable] from the menu. 4. 5. 6.

2.

To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5. 1. Press the MENUS key. 2. Select [0 NEXT] and select [6 SYSTEM]. 3. Press F1 [TYPE], and select [SYSTEM Variable] from the menu. 4. 5.

3.

Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER]. Press F1 [TYPE], and select [Mater/Cal] from the menu. Select the desired mastering type from the [Master/Cal] menu.

Place the cursor on F3 RES_PCA, then press F4 [TRUE]. Switch the controller power off and on again.

To reset the “Servo 075 Pulse mismatch” alarm, follow steps 1 to 3. h h ll i i h d i h

6.MASTERING -

i

h

B-82335EN/01

Remove the hand and other parts form the wrist. Set the robot in the condition protected from an external force.

http://slidepdf.com/reader/full/m410700pdf As sembl in g t he fix ture b ase

1.

l

Assemble the fixture base as shown in Fig. 6.3(a).

107/127

Bolt M6×20

5/19/2018

M410_700.pdf -slidepdf.com Base

Plate

Plate

Bolt M6×20 Fig.6.3 (a) Assemblin g th e fixtu re base

2.

Attach the fixture base to the robot as shown in Fig. 6.3 (b).

Dia pin Parallel pin

B-82335EN/01

3.

6.MASTERING

As shown in Fig. 6.3 (c), set the dial gauge to a reading of 3.00 mm, using a calibration block, and fasten it with an M5 bolt.

CAUTION http://slidepdf.com/reader/full/m410700pdf

Do not fasten the M5 bolt too firmly, because the dial gauge might break.

108/127

5/19/2018


Bolt M5×10

Calibration block

Fig.6.3 (c) Attaching a di al gauge

6.MASTERING 4.

B-82335EN/01

Attach the fixture to the wrist as shown in Fig. 6.3 (d). Dia pin


109/127 Adapter

Bolt M12X20 (4)

5/19/2018


A

Parallel pin

Pay attention to the direction of dia pin.

DETAIL A

B

DETAIL C

B

C SECTION B-B

Fig.6.3 (d) Attaching the f ixture to the wrist

Mastering 1. 2. 3. 4.

Press MENUS. Press NEXT and select SYSTEM. Press F1, [TYPE]. Select Mater/Cal.

AUTO SYSTEM Master/Cal

B-82335EN/01

5.

JOINT

1%

TORQUE = [ON ]

6.MASTERING

Release brake control, and jog the robot into a posture for mastering. A to E (see Fig. 6.4 (b)) of the fixture attached to the wrist are dial gauges A to E (see Figs. 6.4 (d)) and make adjustments so that dial gauges A to E indicate 3 mm. A posture as shown in Fig. 6.4 (e) should be taken. See this figure for reference.


NOTE

110/127

5/19/2018

6.

Brake control can be released by setting the system variables as follows: M410_700.pdf-slidepdf.com $PARAM_GROUP.$SV_OFF_ALL: FALSE $PARAM_GROUP.$SV_OFF_ENB[*]: FALSE (for all axes) After changing the system variables, switch the control unit power off and on again. Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES. "MASTER POSITION" shown in Figs. 6.4 (e) is set in this position. AUTO SYSTEM Master/Cal

JOINT

1%

TORQUE = [ON ] 1 FIXTURE

POSITION MASTER

2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <0> <0>

[ TYPE ]

LOAD

RES_PCA

DONE

6.MASTERING 7.

B-82335EN/01

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.

http://slidepdf.com/reader/full/m410700pdf SYSTEM Master/Cal

AUTO JOINT

1%

111/127

TORQUE = [ON ] 1 FIXTURE POSITION MASTER

5/19/2018


2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <

0.0000> <

0.0000> <

0.0000>

<

0.0000> <

0.0000> <

0.0000>

[ TYPE ]

8.

LOAD RES_PCA

DONE

After positioning is completed, press F5 [DONE].

WARNING

Since the axis stroke is not checked during the mastering, be careful to stay clear of the robot motion.


112/127

5/19/2018


APPENDIX


113/127

5/19/2018


B-82335EN/01

A

APPENDIX

A.SPARE PARTS LIST

SPARE PARTS LIST Table A (a) Cables


Cable

Specificati on

Functi on

Remark

114/127

A660-8016-T672

J1

～

K102

A660-4004-T873

J1

～

K103

A660-8016-T673

J1

～

K104

A660-4004-T874

J1

～

K201

A660-8016-T744

J1

～

K101 5/19/2018

J4 PULSECODER+EE


J4 POWER


J5 PULSECODER+EE J5 POWER J4 PULSECODER+EE


～

K202 K105

A660-8016-T745 A660-2006-T872#A

J1 J4 POWER AS

K105

A660-2006-T872#B

AS


K708

A660-8012-T572

Zipper tube


K106

A660-8014-T737

OT cable


Table A (b) Motor Axi s

Specif ic ati on

Remark iS30/4000

J1 J2, J3

A06B-0268-B605#S000 A06B-0272-B605#S000

α

J4

A06B-0235-B605#S000

αi

S40/4000

αi

S8/4000

Table A (c) Reducer Axi s

Specif ic ati on

J1

A97L-0218-0265/450C-37

J2, J3

A97L-0218-0348/550F-253

J4

A97L-0218-0806/120C-36

Remark

Table A (d) Gear Name

Specificatio n

Remark

Gear

A290-7042-X221

J1-axis reducer

Input gear kit

A97L-0218-0363#253

J2, J3-axis reducer

Gear J41

A290-7042-X511

J4-axis reducer

Name

Table A (e) Mechanical stop per Specificatio n

Stopper assy

A290-7039-V201

J1-axis

Stopper

A290-7041-X312

J1-axis

A.SPARE PARTS LIST

Remark

APPENDIX

B-82335EN/01

Table A (g) Oil seal Name Oil seal

Specificatio n A98L-0040-0185

Remark J2, J3-axis reducer

Table A (h) Others (Mechanical un it)


Name

Specificatio n

Remark

115/127

5/19/2018

Balancer

A290-7042-V301

Wrist unit

A05B-1042-K501


Table A (i) Battery and grease Name

Specificatio n

Battery Grease

A98L-0031-0005 A98L-0040-0174#13KG

Grease

A97L-0001-0179#2

B-82335EN/01

B

APPENDIX

Remark Size D 1.5V Kyodo Yushi VIGOGREASE RE0 SHELL ALVANIA GREASE S2

B.CIRCUIT DIAGRAM

CIRCUIT DIAGRAM


116/127

5/19/2018


B.CIRCUIT DIAGRAM

APPENDIX

B-82335EN/01

CONTROLLER

CNJ1A

0721#3HASKX

J1U1 J1V1 3 J1W1 1

0726#031KSX 0727#ASM(3)

http://slidepdf.com/reader/full/m410700pdf 2

CNJ1B 1 2

J1U1 J1V1

0721#3HASKX

0726#031KSX 0727#ASM(3)

K102 A660-4004-T873

K104 A660-4004-T874 (SERVO HAND OPTION)

117/127

3

J1W1

CNJ2A

0721#3HASKX

0726#031KSX 0727#ASM(3)

J2U1 J2V1 3 J2W1 1 2

5/19/2018

CNJ2B

0721#3HASKX

2

CNJ3A

0721#3HASKX 0726#031KSX 0727#ASM(3)

J3U1 J3V1 3 J3W1 1 2

CNJ3B 1 J3U1 2 3


0726#031KSX 0727#ASM(3)

J2U1 J2V1 3 J2W1 1

0721#3HASKX

0726#031KSX 0727#ASM(3)

J3V1 J3W1

CNJ4

0984#H03SSX

0996#031KSX 0997#ASL(3)

J4U J4V 3 J4W 1 2

CNJ5

0984#H03SSX

0996#031KSX 0997#ASL(3)

J5U J5V 3 J5W 1 2

CNJ6

0984#H03SSX

(J6U) (J6V) 3 (J6W) 1 2

CNGA 1 2 3

0721#3HASKY

0726#031KSY 0727#ASM(3)

J1G1 J2G1 J3G1

CNGB 1

J1G1

2 3

J2G1 J3G1

0721#3HASKY

CNGC

0726#031KSY 0727#ASM(3)

0984#H03SSY

0996#031KSY 0997#ASL(2)

J4G J5G 3 (J6G) 1 2

CRR88

D3200M(YY)

A1 BK(J1),BK(J2) B1 BKCOM1(J1,J2) A2 BK(J3) B2 BKCOM1(J3) A3 BK(J4),BK(J5),(BK(J6)) B3 BKCOM1(J4,J5,(J6))

CRF8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

A63L-0002-0008#H48S

A XPRQJ1 XPRQJ2 XPRQJ3 XPRQJ4 XPRQJ5 (XPRQJ6)

B PRQJ1 PRQJ2 PRQJ3 PRQJ4 PRQJ5 (PRQJ6)

RI 1 RI 3 RI 5 RI 7 XPPABN RO 2 RO 4 RO 6 RO 8

RI 2 RI 4 RI 6 RI 8 RO 1 RO 3 RO 5 RO 7 XHBK XROT 0V(G1,G2)

+24V(A1,A2,A3,A4,A5) +24VIN(A1,A2,A3,A 4,A5)

B-82335EN/01

C +5V(A1,A2) +5V(A3,A4) +5V(B1,B2) +5V(B3,B4) +5V(C1) (+5V) 0V(A1,A2) 0V(A3,A4) 0V(B1,B2) 0V(B3,B4) 0V(C1) (0V)

APPENDIX

A66L-0001-0401#30

0648#82222SD

0749#12A1

0848#A10SL1 0850(8)


B.CIRCUIT DIAGRAM

J1 MOTOR (αiS30/4000)

M1M

http://slidepdf.com/reader/full/m410700pdf J1U1 A66L-0001-0464#1

K101 A660-8016-T672

22-22P(8.0SQ 46A)

A

C J1W1

B J1V1

D

M1P

J1G1 10SL1(0.3SQ 3A)

0648#82222SD

0749#12A1


M2M

22-22P(8.0SQ 46A)

A J2U1

C J2W1

B J2V1

D J2G1

118/127

8 9 10

+6V(BT1) XPRQJ1 PRQJ1 0V(BT1) 7 0V(A2) 4

+5V(A1) +5V(A2) 0V(A1)

5 6

0648#810SL3SJ 0653#04AC

5/19/2018

M1BK A

0848#A10SL1 0850(8)

1 2 3

10SL-3P(1.25SQ 13A) B BKCOM1(J1) C

BK(J1)

M2P

10SL1(0.3SQ 3A)

+5V(A3) +5V(A4) 10 0V(A3) 8

DRAIN

9

+6V(BT2) XPRQJ2 6 PRQJ2 0V(BT2) 7 0V(A4) 4

1

5

2

DRAIN M410_700.pdf-slidepdf.com 0648#810SL3SJ 0653#04AC

M2BK A

3

10SL-3P(1.25SQ 13A)

BK(J2)

B BKCOM1(J2) C

J3 MOTOR (αiS40/4000) M3M 22-22P(8.0SQ 46A)

0648#82222SD

0749#12A1

A66L-0001-0401#30

A J3U1

C J3W1

B J3V1

D J3G1

M3P

0848#A10SL1 0850(8)

10SL1(0.3SQ 3A)

+5V(B1) +5V(B2) 10 0V(B1) 8 9

0648#810SL3SJ 0653#04AC

+6V(BT3) XPRQJ3 6 PRQJ3 0V(BT3) 7 0V(B2) 4 5

M3BK A

BK(J3)

1 2 3

DRAIN


A66L-0001-0401#30 A66L-0001-0464#2


0881#1810S 0881#10C

M4M

22-22P(8.0SQ 46A)

A J4U B J4V

A66L-0001-0401#10

M4P

0848#B10SL1 0850(8)

10SL1(0.3SQ 3A)

+5V(B3) +5V(B4) 10 0V(B3) 8 9

A66L-0001-0464#2

C J4W D J4G

0648#810SL3SJ 0653#04AC

A66L-0001-0459

+6V(BT4) XPRQJ4 6 PRQJ4 0V(BT4) 7 0V(B4) 4 5

M4BK A

A66L-0001-0459

M5M

J5U J5V C J5W A

B

BK(J4)

1 2 3

DRAIN


20-15S(3.5SQ 23A) D BK(J5) F E BKCOM1(J5) G J5G

A66L-0001-0163#5

GB1 +6V(BT1,BT2,BT3, BT4,BT5)

M5P A

+

PRQJ5

B XPRQJ5 C

16S-1S(1.25SQ 13A) D +5V(C1) F +6V(BT5) E 0V(C1) G 0V(BT5)

SG

BATTERY

-

END EFFECTOR INTERFACE

0V(BT1,BT2,BT3, BT4,BT5)

ZIPPER TUBE

AS1

K708 A660-8012-T572

6

S1 S2 S3 S4 S5 S6

7 8

S7 S8

1 2 3 4 5

9 10 11 12 13 14

2

A63L-0001-0234#W2524M

3

(0.5SQ 5A)Φ9.6-Φ15

4

S9 S10 S11 S12 S13 S14

15 16

1

S15 S16

18 19 20 21 22 17

23 24

S17 S18 S19 S20 S21 S22

5 6 7 8

RO 1 RO 2 RO 3 RO 4 RO 5 RO 6 XHBK 0V(G1)

S23 S24

3 4

K105

5

A660-2006-T872#A

6 7

APPENDIX

J1 CONNECTOR BOX


M TYPE

Han 46EE (4.0SQ 16A)

11 12 13 14 15 16

RI 1 RI 2 RI 3 RI 4 RI 8 XPPABN RI 5 RI 6

17

+24V(A2)

+24VIN(A2)

18

+24V(A3)

+24VIN(A3)

19

+24V(A4)

+24VIN(A4)

20

+24V(A5)

+24VIN(A5)

RO 7 RO 8 23 0V(G2) 24 RI 7 21 22

A63L-0001-0234#R2524FX

AS2 2

B.CIRCUIT DIAGRAM

(0.5SQ 5A)Φ9.6-Φ15 9 10

USER INTERFACE/SIGNAL (OPTION) 1

RM2

A63L-0001-0234#R2524F

EE

USER INTERFACE/SIGNAL (OPTION)

S1 S2 S3 S4 S5 S6 S7

(0.5SQ 5A)Φ9.6-Φ15

12 13 14

S9 S10 S11 S12 S13 S14 15 S15 9

10 11

21 22 17

18

19 20

23

S17 S18 S19 S20 S21 S22 S23

B-82335EN/01

119/127

17 J2V1 18 J3V1 19 J3V1 20 21 22 23 24 J1W1 25 J1W1 26 J2W1 27 J2W1 28 J3W1 29 J3W1 30 31

1 2 J1U1 3 J1U1 4 J2U1 5 J2U1 6 J3U1 7 J3U1 8 9 10 11 12 13 14 J1V1 15 J1V1 16 J2V1

5/19/2018

RM1

32 33 34 35 J1G1 36 J1G1 37 J2G1 38 J2G1 39 J3G1 40 J3G1 41 42 43 44 45 46

M TYPE

1 17 J2V1 2 J1U1 18 J3V1 19 J3V1 3 J1U1 4 J2U1 20 J4V 5 J2U1 21 J5V 6 J3U1 22 7 J3U1 23 BK(J2) 8 J4U 24 J1W1 9 J5U 25 J1W1 10 26 J2W1 11 BK(J1) 27 J2W1 BKCOM1(J1,J2) 28 J3W1 12 BKCOM1(J3,J4,J5) 29 J3W1 13 14 J1V1 30 J4W 15 J1V1 31 J5W 16 J2V1

K202 A660-8016-T745

K204

A66L-0001-0401#30

A660-8016-T823 M410_700.pdf -slidepdf.com (SERVO HAND OPTION)

A66L-0001-0464#1

Han 46EE (4.0SQ 16A) 32 33 BK(J3) 34 35 J1G 36 J1G 37 J2G 38 J2G 39 J3G 40 J3G 41 J4G 42 J5G 43 44 BK(J4) 45 BK(J5) 46

GB1 +6V(BT1,BT2,BT3, BT4,BT5)

+

BATTERY

0V(BT1,BT2,BT3, BT4,BT5)

RP1

M TYPE

1 RI1 2 RI7 3 RO1 4 RO7 5 +5V(A1,A2,A3,A4) 6 PRQJ1 7 XPRQJ1 8 RI2 9 RI8 10 RO2 11 RO8 12 +5V (B1,B2,B3,B 4) 13 PRQJ2 14 XPRQJ2

15 RI3 16 XPPABN 17 RO3 18 +24V(A1,A2,A3,A4) 19 +5V(C1) 20 PRQJ3 21 XPRQJ3 22 RI4 23 XHBK 24 RO4 25 0V(D1,D2) 26 0V (A1,A 2,A 3,A 4) 27 PRQJ4 28 XPRQJ4

Han 42DD (2.5SQ 10A) 29 RI5 30 XROT 31 RO5 32 33 0V(B1,B2,B3,B4) 34 PRQJ5 35 XPRQJ5 36 RI6 37 +24E(OT) 38 RO6 39 40 0V(C1) 41 42

K201 A660-8016-T744

031KSFY


031KSY 1 +24EOT 2 XROT 3

USER INTERFACE/SIGNAL (OPTION) AS1 1 2 3 4 5 6 7 8

B-82335EN/01


APPENDIX

S1 S2 S3 S4 S5 S6 S7 S8

9 10

A63L-0001-0234#W2524M (0.5SQ 5A)Φ9.6-Φ15 17 S17 S9 18 S18 S10

15 16 11 12 13 14

S11 S12 S13 S14 S15 S16

23 24 19 20 21 22

S19 S20 S21 S22 S23 S24

B.CIRCUIT DIAGRAM

120/127

0648#82222SD 0749#12A1


M1M A

5/19/2018

B 0848#A10SL1 0850(8)

J1U1 J1V1

C

D

M1P 8 9 10

+5V(A1) +5V(A2) 0V(A1)

0648#810SL3SJ 0653#04AC

4 5 6 7

M1BK A

BK(J1)


0648#82222SD 0749#12A1

22-22P(8.0SQ 46A) J1W1 J1G1

M2M

22-22P(8.0SQ 46A)

J2U1 J2W1 M410_700.pdf -slidepdf.com J2V1 J2G1

10SL1(0.3SQ 3A) +6V(BT1) 1 XPRQJ1 2 PRQJ1 3 DRAIN 0V(BT1)

A

C

B

D

M2P

0848#A10SL1 0850(8)

+5V(A3) +5V(A4) 10 0V(A3) 8 9

0V(A2) 10SL-3P(1.25SQ 13A)

0648#810SL3SJ 0653#04AC

5 6 7

B BKCOM1(J1) C

M2BK A BK(J2)

10SL1(0.3SQ 3A) +6V(BT2) 1 XPRQJ2 2 PRQJ2 3 DRAIN 0V(BT2) 0V(A4) 10SL-3P(1.25SQ 13A)

B BKCOM1(J2) C


0648#82222SD 0749#12A1

A66L-0001-0401#30

4

M3M A B

J3U1 J3V1

C D

M3P

0848#A10SL1 0850(8)

+5V(B1) +5V(B2) 10 0V(B1) 8 9

0648#810SL3SJ 0653#04AC

4 5 6 7

22-22P(8.0SQ 46A) J3W1 J3G1

10SL1(0.3SQ 3A) +6V(BT3) 1 XPRQJ3 2 PRQJ3 3 DRAIN 0V(BT3) 0V(B2)

M3BK A

BK(J3)


A66L-0001-0401#30

A66L-0001-0464#2


0881#1810S 0881#10C

M4M A B

+5V(B3) +5V(B4) 10 0V(B3) 8 9

A66L-0001-0464#2

0648#810SL3SJ 0653#04AC

D

4 5 6 7

A66L-0001-0459

K105

C

M4P

0848#B10SL1 0850(8)

A66L-0001-0401#10

J4U J4V

22-22P(8.0SQ 46A) J4W J4G

10SL1(0.3SQ 3A) +6V(BT4) 1 XPRQJ4 2 PRQJ4 3 DRAIN 0V(BT4) 0V(B4)

M4BK A

A66L-0001-0459

BK(J4)


A660-2006-T872#B

M5M A B C

20-15S(3.5S Q 23A) D BK(J5) F E BKCOM1(J5) G J5G

J5U J5V J5W

M5P

16S-1S(1.25SQ 13A)

A PRQJ5

D

B XPRQJ5

E

C

+5V(C1) 0V(C1)

F G

+6V(BT5) 0V(BT5)

SG

END EFFECTOR INTERFACE A63L-0001-0234#R2524F

EE

6

RO1 RO2 RO3 RO4 RO5 RO6

7 8

XHBK 0V(D1)

1 2 3 4 5

11 12 13 14 9

10

15 16

(0.5SQ 5A)Φ9.6-Φ15 17 +24V(A1) RI1 18 +24V(A2) RI2 19 +24V(A3) RI3 20 +24V(A4) RI4 21 RO7 RI8 XPPABN 22 RO8

RI5 RI6

23 24

0V(D2) RI7

USER INTERFACE/SIGNAL (OPTION) AS2 1 2 3

C.PERIODIC MAINTENANCE TABLE

C

S1 S2 S3

A63L-0001-0234#R2524FX 9 10 11

(0.5SQ 5A)Φ9.6-Φ15 17 S17 S9 18 S18 S10 19 S19 S11

APPENDIX

B-82335EN/01

PERIODIC MAINTENANCE TABLE


FANUC Robot M-410iB/700

Periodic Maintenance Table

121/127

5/19/2018


Working time (H) Items Check the mechanical cable. (damaged or twisted)

3

Check time

6

9

1

First Grease check months months months year amount 320 960 1920 2880 3840

2 years 4800

5760

6720

7680

0.2H

―

○

○

○

2 (loosening)

0.2H

―

○

○

○

3 Tighten the end effector bolt.

0.2H

―

○

○

○

2.0H

―

○

○

○

5 Remove spatter and dust etc.

1.0H

―

○

○

○

6 Check the hand cable

0.1H

○

○

○

7 Replacing battery.

0.1H

―

1.2H

8370ml

0.6H

3170ml

0.6H

2940ml

0.4H

1080ml

0.5H

10ml each

0.1H

20ml each

14 cross roller bearing*1

0.1H

20ml

greasing 15 Apply parts of wrist *1 to (2connection locations)

0.1H

10ml each

4.0H

―

1

Check the motor connector.

4

t i n u l a c i n a h c e M

Tighten the cover and main bolt.

Replacing grease of J1 axis

8 reducer *1


9 reducer *1


10 reducer *1


11 reducer *1

Greasing to balancer bush*1(2

12 location)

Apply greasing to bearing of

13 J3-axis arm connection*1 (2 location) Apply greasing to the J3-axis

Replacing cable of mechanical

16 unit *

●

B-82335EN/01


APPENDIX

●

8640

9600 10560

●

C.PERIODIC MAINTENANCE TABLE

122/127

5/19/2018


3

4

5

6

7

8

years

years

years

years

years

years

11520 12480 13440 14400 15360 16320 17280 18240 19200

20160

21120

22080

23040

24000

24960

25920

26880 27840 28800 29760 30720

Item

○

○

○

○

○

1

○

○

○

○

○

2

○

○

○

○

○

3

○

○

○

○

○

4

○

○

○

○

○

5

○

○

○

○

○

6

●

●

●

●

7

●

●

8

●

●

9

●

●

●

●

●

●

●

l u a h r e v O

●

●

10 11 12

●

●

13

●

●

14

●

●

15

○

●

○

○

○

○

16 ○

○

○

○

○

D.BOLT TIGHTENING TORQUE TABLE

D

○

○

○

○

○

○

○

○

○

APPENDIX

○

17

B-82335EN/01

BOLT TIGHTENING TORQUE TABLE

NOTE When applying Loctite to the important bolt tightening points, make sure that it is http://slidepdf.com/reader/full/m410700pdf applied to the entire longitudinal portion in the engaging section of the female

123/127

5/19/2018

threads. If it is applied to the male threads, the bolts may be loosened because sufficient effects cannot be obtained. Remove the dustM410_700.pdf within the bolts and taps -slidepdf.com and wipe oil off the engaging section. Make sure that there is no solvent in the taps. Be sure to wipe the overflowed Loctite after tightening screw.

Those bolts for which no tightening torque is specified must be tightened according to the following table. Unit : Nm (kgf cm)

Table D Recommended Bolt Tighteni ng Torques

Nominal diameter

Hexagon socket head bolt (Steel: st rength rating of 12.9)

Hexagon socket head bolt (Stainless)

Hexagon socket head pan bolt Hexagon socket head countersunk bolt

Tightening torque

Tightening torque

(Steel: strength rating of 12.9) Tightening torque

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 M12

66(670) 110(1150)

46(470) 78(800)

27(280) 48(490)

19(195) 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)

230(2300)

M20

530(5400)

370(3800)

(M22)

730(7450)

510(5200) ⎯⎯⎯⎯⎯

M24

930(9500)

650(6600) ⎯⎯⎯⎯⎯

(M27) M30

1400(14000) 1800(18500)

940(9800) 1300(13000) ⎯⎯⎯⎯⎯

M36

3200(33000)

2300(23000) ⎯⎯⎯⎯⎯

⎯⎯⎯⎯⎯

B-82335EN/01

160(1600)

⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯

32(330)

⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯

23(230)

⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯

INDEX

INDEX 1.5-YEAR (5,760 HOURS) CHECKS.............................5 1-MONTH (320 HOURS) CHECKS ...............................2 http://slidepdf.com/reader/full/m410700pdf 1-YEAR (3,840 HOURS) CHECKS................................5

REPLACING THE J1-AXIS PENDULUM STOPPER.53 REPLACING THE J1-AXIS REDUCER ......................34 REPLACING THE J2-AXIS MOTOR M2....................37 REPLACING THE J2-AXIS REDUCER ......................39 REPLACING THE J3-AXIS MOTOR M3....................41

124/127

3-MONTH (960 HOURS) CHECKS ...............................2 3-YEAR (11,520 HOURS) CHECKS..............................6 5/19/2018 BACKLASH MEASUREMENT ...................................25 BOLT TIGHTENING TORQUE TABLE ..................... 92 CABLE FORMING .......................................................55 CABLE REPLACEMENT.............................................67 CHECKS AND MAINTENANCE ..................................1 CIRCUIT DIAGRAM....................................................85 COMPONENT REPLACEMENT AND ADJUSTMENTS .......................................................................................28

REPLACING THE J3-AXIS REDUCER ......................43 REPLACING THE J4-AXIS MOTOR M4....................45 M410_700.pdf-slidepdf.com REPLACING THE J4-AXIS REDUCER ......................46 REPLACING WRIST AXIS UNIT ...............................47 RESETTING ALARMS AND PREPARING FOR MASTERING ................................................................75 SAFETY PRECAUTIONS ........................................... s-1 SPARE PARTS LIST.....................................................83 TROUBLESHOOTING .................................................18

DAILY CHECKS.............................................................1 FAILURES, CAUSES AND MEASURES....................18 FIGURE OF DRIVE MECHANISM.............................29 FIXTURE POSITION MASTER...................................75 GENERAL.....................................................................74 GREASING TO BALANCER BUSH (1.5 YEAR CHECKS (3,840HOURS)) GREASING TO BEARING (3 YEAR CHECKS (11,520HOURS)) .................................9 MAINTENANCE TOOLS...............................................6

MASTERING ................................................................ 74 OVERVIEW .................................................................. 18


125/127

5/19/2018


Rev is i o n Rec o r d

FANUC Robot M-410iB/700 MECHANICAL UNIT MAINTENANCE MANUAL (B-82335EN)


126/127

5/19/2018


01

Nov.,2008

Edition

D at e

Contents


Edition

D at e

Contents

127/127

M410_700.pdf

Recommend Documents