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FANUC Robot M-900iA/350

FANUC Robot M-900iA/260L


MECHANICAL MANUAL

MAINTENANCE MANUAL
MARMI935009041E REV. D
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 483093253

B-82135EN/05

Before using the Robot, be sure to read the FANUC Robot Safety Manual (B-80687EN) and
understand the content.
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller
labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.

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 Japans Foreign Exchange and
Foreign Trade Law. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual, we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as impossible.

The descriptions and specifications contained in this manual were in


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

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

FANUC Robotics conducts courses on its systems and products on


a regularly scheduled basis at its headquarters in Rochester Hills,
Michigan. For additional information contact
FANUC Robotics America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com

Copyright 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, SOCKETS, SOFT PARTS SpotTool,
TorchMate, and YagTool are Registered Trademarks of FANUC
Robotics.
FANUC Robotics reserves all proprietary rights, including but not
limited to trademark and trade name rights, in the following names:
AccuAir AccuCal AccuChop AccuFlow AccuPath
AccuSeal ARC Mate ARC Mate Sr. ARC Mate System 1
ARC Mate System 2 ARC Mate System 3 ARC Mate System
4 ARC Mate System 5 ARCWorks Pro AssistTool
AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell
Finder Center Finder Clean Wall CollisionGuard
DispenseTool F-100 F-200i FabTool FANUC LASER
DRILL Flexibell FlexTool HandlingTool HandlingWorks
INSIGHT INSIGHT II IntelliTrak Integrated Process Solution
Intelligent Assist Device IPC -Integrated Pump Control IPD
Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD
Integral Servo Dispenser Laser Mate System 3 Laser Mate
System 4 LaserPro LaserTool LR Tool MIG Eye
MotionParts NoBots Paint Stick PaintPro PaintTool 100
PAINTWorks PAINTWorks II PAINTWorks III PalletMate
PalletMate PC PalletTool PC PayloadID RecipTool
RemovalTool Robo Chop Robo Spray S-420i S-430i
ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate
SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM RJ3 Controller SYSTEM R-J3iB Controller TCP Mate
TurboMove TorchMate visLOC visPRO-3D visTRAC
WebServer WebTP YagTool
FANUC LTD 2008

No part of this manual may be reproduced in any form.


All specifications and designs are subject to change without notice.

Conventions

This manual includes information essential to the safety of


personnel, equipment, software, and data. This information is
indicated by headings and boxes in the text.

WARNING

Information appearing under WARNING concerns the


protection of personnel. It is boxed and in bold type to set it
apart from other text.

CAUTION

Information appearing under CAUTION concerns the protection of


equipment, software, and data. It is boxed to set it apart from
other text.

NOTE Information appearing next to NOTE concerns related


information or useful hints.

Safety
FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or
the specific safety aspects of your company and/or its work force. It is the responsibility of the owner,
employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace.
The appropriate level of safety for your application and installation can best be determined by safety
system professionals. FANUC Robotics therefore, recommends that each customer consult with such
professionals in order to provide a workplace that allows for the safe application, use, and operation of
FANUC Robotic systems.
According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the
standards to ensure compliance with its requests for Robotics System design, usability, operation,
maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your
responsibility to arrange for the training of the operator of a robot system to recognize and respond to
known hazards associated with your robotic system and to be aware of the recommended operating
procedures for your particular application and robot installation.
FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair,
or otherwise use the robotics system be trained in an approved FANUC Robotics training course and
become familiar with the proper operation of the system. Persons responsible for programming the
system-including the design, implementation, and debugging of application programs-must be familiar
with the recommended programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of safety in the workplace.

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION


Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:

The safety of people and equipment


Use of safety enhancing devices
Techniques for safe teaching and manual operation of the robot(s)
Techniques for safe automatic operation of the robot(s)
Regular scheduled inspection of the robot and workcell
Proper maintenance of the robot

Keeping People and Equipment Safe


The safety of people is always of primary importance in any situation. However, equipment must be
kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following:

Safety
People
External devices
Robot(s)
Tooling
Workpiece

Using Safety Enhancing Devices


Always give appropriate attention to the work area that surrounds the robot. The safety of the work
area can be enhanced by the installation of some or all of the following devices:

Safety fences, barriers, or chains


Light curtains
Interlocks
Pressure mats
Floor markings
Warning lights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches

Setting Up a Safe Workcell


A safe workcell is essential to protect people and equipment. Observe the following guidelines to
ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace
existing federal, state, and local laws, regulations, and guidelines that pertain to safety.

Sponsor your personnel for training in approved FANUC Robotics training course(s) related to
your application. Never permit untrained personnel to operate the robots.

Install a lockout device that uses an access code to prevent unauthorized persons from operating
the robot.

Use anti-tie-down logic to prevent the operator from bypassing safety measures.
Arrange the workcell so the operator faces the workcell and can see what is going on inside the
cell.

ii

Safety
Clearly identify the work envelope of each robot in the system with floor markings, signs, and
special barriers. The work envelope is the area defined by the maximum motion range of the
robot, including any tooling attached to the wrist flange that extend this range.

Position all controllers outside the robot work envelope.


Never rely on software or firmware based controllers as the primary safety element unless they
comply with applicable current robot safety standards.

Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the
operator and at critical points inside and around the outside of the workcell.

Install flashing lights and/or audible warning devices that activate whenever the robot is
operating, that is, whenever power is applied to the servo drive system. Audible warning devices
shall exceed the ambient noise level at the end-use application.

Wherever possible, install safety fences to protect against unauthorized entry by personnel into
the work envelope.

Install special guarding that prevents the operator from reaching into restricted areas of the
work envelope.

Use interlocks.
Use presence or proximity sensing devices such as light curtains, mats, and capacitance and
vision systems to enhance safety.

Periodically check the safety joints or safety clutches that can be optionally installed between the
robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove
power from the system, and help to minimize damage to the tooling and robot.

Make sure all external devices are properly filtered, grounded, shielded, and suppressed to
prevent hazardous motion due to the effects of electro-magnetic interference (EMI), radio
frequency interference (RFI), and electro-static discharge (ESD).

Make provisions for power lockout/tagout at the controller.


Eliminate pinch points . Pinch points are areas where personnel could get trapped between a
moving robot and other equipment.

Provide enough room inside the workcell to permit personnel to teach the robot and perform
maintenance safely.

Program the robot to load and unload material safely.


If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and
beacons.

If materials are being applied at dangerously high pressure, provide electrical interlocks for
lockout of material flow and pressure.

iii

Safety

Staying Safe While Teaching or Manually Operating the Robot


Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the
following rules:

Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.

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

Before teaching, visually inspect the robot and work envelope to make sure that no potentially
hazardous conditions exist. The work envelope is the area defined by the maximum motion range
of the robot. These include tooling attached to the wrist flange that extends this range.

The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe
working conditions to the supervisor or safety department.

FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for
robot teaching operations. However, if you must enter the work envelope, be sure all safeguards
are in place, check the teach pendant DEADMAN switch for proper operation, and place the
robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the
DEADMAN switch. Only the person with the teach pendant should be in the work envelope.
Warning
Never bypass, strap, or otherwise deactivate a safety device, such as a
limit switch, for any operational convenience. Deactivating a safety
device is known to have resulted in serious injury and death.

Know the path that can be used to escape from a moving robot; make sure the escape path is
never blocked.

Isolate the robot from all remote control signals that can cause motion while data is being taught.
Test any program being run for the first time in the following manner:
Warning
Stay outside the robot work envelope whenever a program is being
run. Failure to do so can result in injury.
Using a low motion speed, single step the program for at least one full cycle.
Using a low motion speed, test run the program continuously for at least one full cycle.
Using the programmed speed, test run the program continuously for at least one full cycle.

Make sure all personnel are outside the work envelope before running production.

iv

Safety

Staying Safe During Automatic Operation


Advise all personnel who operate the robot during production to observe the following rules:

Make sure all safety provisions are present and active.


Know the entire workcell area. The workcell includes the robot and its work envelope, plus the
area occupied by all external devices and other equipment with which the robot interacts.

Understand the complete task the robot is programmed to perform before initiating automatic
operation.

Make sure all personnel are outside the work envelope before operating the robot.
Never enter or allow others to enter the work envelope during automatic operation of the robot.
Know the location and status of all switches, sensors, and control signals that could cause the
robot to move.

Know where the EMERGENCY STOP buttons are located on both the robot control and external
control devices. Be prepared to press these buttons in an emergency.

Never assume that a program is complete if the robot is not moving. The robot could be waiting
for an input signal that will permit it to continue activity.

If the robot is running in a pattern, do not assume it will continue to run in the same pattern.
Never try to stop the robot, or break its motion, with your body. The only way to stop robot
motion immediately is to press an EMERGENCY STOP button located on the controller panel,
teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection


When inspecting the robot, be sure to

Turn off power at the controller.


Lock out and tag out the power source at the controller according to the policies of your plant.
Turn off the compressed air source and relieve the air pressure.
If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY
STOP button on the operator panel.

Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.

If power is needed to check the robot motion or electrical circuits, be prepared to press the
EMERGENCY STOP button, in an emergency.

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

Safety

Staying Safe During Maintenance


When performing maintenance on your robot system, observe the following rules:

Never enter the work envelope while the robot or a program is in operation.
Before entering the work envelope, visually inspect the workcell to make sure no potentially
hazardous conditions exist.

Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.

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

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

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

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

Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is
not supported or resting on a hard stop. Support the arm on a solid support before you release
the brake.
Warning
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to avoid
electrical shock.HIGH VOLTAGE IS PRESENT at the input side
whenever the controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes power from
the output side of the device only.

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

Isolate the robot from all remote control signals. If maintenance must be done when the power
is on, make sure the person inside the work envelope has sole control of the robot. The teach
pendant must be held by this person.

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

Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure
that such devices do not create pinch points that could trap personnel.
Warning
Do not try to remove any mechanical component from the robot
before thoroughly reading and understanding the procedures in the
appropriate manual. Doing so can result in serious personal injury and
component destruction.

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

When replacing or installing components, make sure dirt and debris do not enter the system.
Use only specified parts for replacement. To avoid fires and damage to parts in the controller,
never use nonspecified fuses.

Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and
all external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE


Certain programming and mechanical measures are useful in keeping the machine tools and other
external devices safe. Some of these measures are outlined below. Make sure you know all associated
measures for safe use of such devices.

Programming Safety Precautions


Implement the following programming safety measures to prevent damage to machine tools and
other external devices.

Back-check limit switches in the workcell to make sure they do not fail.
Implement failure routines in programs that will provide appropriate robot actions if an external
device or another robot in the workcell fails.

Use handshaking protocol to synchronize robot and external device operations.


Program the robot to check the condition of all external devices during an operating cycle.

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Safety

Mechanical Safety Precautions


Implement the following mechanical safety measures to prevent damage to machine tools and other
external devices.

Make sure the workcell is clean and free of oil, water, and debris.
Use software limits, limit switches, and mechanical hardstops to prevent undesired movement of
the robot into the work area of machine tools and external devices.

KEEPING THE ROBOT SAFE


Observe the following operating and programming guidelines to prevent damage to the robot.

Operating Safety Precautions


The following measures are designed to prevent damage to the robot during operation.

Use a low override speed to increase your control over the robot when jogging the robot.
Visualize the movement the robot will make before you press the jog keys on the teach pendant.
Make sure the work envelope is clean and free of oil, water, or debris.
Use circuit breakers to guard against electrical overload.

Programming Safety Precautions


The following safety measures are designed to prevent damage to the robot during programming:

Establish interference zones to prevent collisions when two or more robots share a work area.
Make sure that the program ends with the robot near or at the home position.
Be aware of signals or other operations that could trigger operation of tooling resulting in
personal injury or equipment damage.

In dispensing applications, be aware of all safety guidelines with respect to the dispensing
materials.
Note Any deviation from the methods and safety practices described in this manual must conform
to the approved standards of your company. If you have questions, see your supervisor.

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Safety

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT


INSTALLATIONS
Process technicians are sometimes required to enter the paint booth, for example, during daily or
routine calibration or while teaching new paths to a robot. Maintenance personal also must work
inside the paint booth periodically.
Whenever personnel are working inside the paint booth, ventilation equipment must be used.
Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.
Although paint booth hazards have been minimized, potential dangers still exist. Therefore, todays
highly automated paint booth requires that process and maintenance personnel have full awareness of
the system and its capabilities. They must understand the interaction that occurs between the vehicle
moving along the conveyor and the robot(s), hood/deck and door opening devices, and high-voltage
electrostatic tools.
Paint robots are operated in three modes:

Teach or manual mode


Automatic mode, including automatic and exercise operation
Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will follow a predetermined
pattern of movements. In teach mode, the process technician teaches (programs) paint paths using
the teach pendant.
In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual
Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel
must remain outside of the booth or in a designated safe area within the booth whenever automatic
mode is initiated at the SOC or MCP.
In automatic mode, the robots will execute the path movements they were taught during teach mode,
but generally at production speeds.
When process and maintenance personnel run diagnostic routines that require them to remain in the
paint booth, they must stay in a designated safe area.

Paint System Safety Features


Process technicians and maintenance personnel must become totally familiar with the equipment and
its capabilities. To minimize the risk of injury when working near robots and related equipment,
personnel must comply strictly with the procedures in the manuals.

ix

Safety
This section provides information about the safety features that are included in the paint system and
also explains the way the robot interacts with other equipment in the system.
The paint system includes the following safety features:

Most paint booths have red warning beacons that illuminate when the robots are armed and ready
to paint. Your booth might have other kinds of indicators. Learn what these are.

Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic
devices are enabled. Your booth might have other kinds of indicators. Learn what these are.

EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become
familiar with the locations of all E-STOP buttons.

An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres.
A DEADMAN switch is located on each teach pendant. When this switch is held in, and the
teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN
switch is released during robot operation, power is removed from the servo system, all axis
brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within
the system might also E-STOP other robots.
Warning
An EMERGENCY STOP will occur if the DEADMAN switch is released
on a bypassed robot.

Overtravel by robot axes is prevented by software limits. All of the major and minor axes are
governed by software limits. Limit switches and hardstops also limit travel by the major axes.

EMERGENCY STOP limit switches and photoelectric eyes might be part of your system.
Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all
equipment in the booth if a door is opened while the system is operating in automatic or manual
mode. For some systems, signals to these switches are inactive when the switch on the SCC is
in teach mode.When present, photoelectric eyes are sometimes used to monitor unauthorized
intrusion through the entrance/exit silhouette openings.

System status is monitored by computer. Severe conditions result in automatic system shutdown.

Staying Safe While Operating the Paint Robot


When you work in or near the paint booth, observe the following rules, in addition to all rules for
safe operation that apply to all robot systems.
Warning
Observe all safety rules and guidelines to avoid injury.

Safety
Warning
Never bypass, strap, or otherwise deactivate a safety device, such as a
limit switch, for any operational convenience. Deactivating a safety device
is known to have resulted in serious injury and death.
Warning
Enclosures shall not be opened unless the area is know to be
nonhazardous or all power has been removed from devices within the
enclosure. Power shall not be restored after the enclosure has been
opened until all combustible dusts have been removed from the interior
of the enclosure and the enclosure purged. Refer to the Purge chapter
for the required purge time.

Know the work area of the entire paint station (workcell).


Know the work envelope of the robot and hood/deck and door opening devices.
Be aware of overlapping work envelopes of adjacent robots.
Know where all red, mushroom-shaped EMERGENCY STOP buttons are located.
Know the location and status of all switches, sensors, and/or control signals that might cause the
robot, conveyor, and opening devices to move.

Make sure that the work area near the robot is clean and free of water, oil, and debris. Report
unsafe conditions to your supervisor.

Become familiar with the complete task the robot will perform BEFORE starting automatic mode.
Make sure all personnel are outside the paint booth before you turn on power to the robot
servo system.

Never enter the work envelope or paint booth before you turn off power to the robot servo system.
Never enter the work envelope during automatic operation unless a safe area has been designated.
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.

Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the
electrostatic devices are enabled.

Stay out of areas where you might get trapped between a moving robot, conveyor, or opening
device and another object.

Be aware of signals and/or operations that could result in the triggering of guns or bells.
Be aware of all safety precautions when dispensing of paint is required.
Follow the procedures described in this manual.

xi

Safety

Special Precautions for Combustible Dusts (powder paint)


When the robot is used in a location where combustible dusts are found, such as the application of
powder paint, the following special precautions are required to insure that there are no combustible
dusts inside the robot.

Purge maintenance air should be maintained at all times, even when the robot power is off. This
will insure that dust can not enter the robot.

A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dust
when maintenance air is not present, it will be necessary to remove the covers and clean out any
accumulated dust. Do not energize the robot until you have performed the following steps.
1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulated
dust.
2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, be
sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened
with water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate static
electricity and cause an explosion unless special precautions are taken.
3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust.
4. When the dust has been removed, the covers must be replaced immediately.
5. Immediately after the covers are replaced, run a complete purge cycle. The robot can now
be energized.

Staying Safe While Operating Paint Application Equipment


When you work with paint application equipment, observe the following rules, in addition to all rules
for safe operation that apply to all robot systems.
Warning
When working with electrostatic paint equipment, follow all national and
local codes as well as all safety guidelines within your organization.
Also reference the following standards: NFPA 33 Standards for Spray
Application Using Flammable or Combustible Materials , and NFPA 70
National Electrical Code .

Grounding : All electrically conductive objects in the spray area must be grounded. This
includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots,
as well as solvent containers. Grounding is defined as the object or objects shall be electrically
connected to ground with a resistance of not more than 1 megohms.

xii

Safety
High Voltage : High voltage should only be on during actual spray operations. Voltage should be
off when the painting process is completed. Never leave high voltage on during a cap cleaning
process.

Avoid any accumulation of combustible vapors or coating matter.


Follow all manufacturer recommended cleaning procedures.
Make sure all interlocks are operational.
No smoking.
Post all warning signs regarding the electrostatic equipment and operation of electrostatic
equipment according to NFPA 33 Standard for Spray Application Using Flammable or
Combustible Material.

Disable all air and paint pressure to bell.


Verify that the lines are not under pressure.

Staying Safe During Maintenance


When you perform maintenance on the painter system, observe the following rules, and all other
maintenance safety rules that apply to all robot installations. Only qualified, trained service or
maintenance personnel should perform repair work on a robot.

Paint robots operate in a potentially explosive environment. Use caution when working with
electric tools.

When a maintenance technician is repairing or adjusting a robot, the work area is under the control
of that technician. All personnel not participating in the maintenance must stay out of the area.

For some maintenance procedures, station a second person at the control panel within reach
of the EMERGENCY STOP button. This person must understand the robot and associated
potential hazards.

Be sure all covers and inspection plates are in good repair and in place.
Always return the robot to the home position before you disarm it.
Never use machine power to aid in removing any component from the robot.
During robot operations, be aware of the robots movements. Excess vibration, unusual sounds,
and so forth, can alert you to potential problems.

Whenever possible, turn off the main electrical disconnect before you clean the robot.
When using vinyl resin observe the following:
Wear eye protection and protective gloves during application and removal
Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye
irritation.
If there is contact with the skin, wash with water.

xiii

Safety
Follow the Original Equipment Manufacturers Material Safety Data Sheets.

When using paint remover observe the following:


Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.
Adequate ventilation is required. Overexposure could cause drowsiness.
If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then,
seek medical attention as soon as possible.
Follow the Original Equipment Manufacturers Material Safety Data Sheets.

xiv

B-82135EN/05

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety
precautions when operating a robot and its peripheral devices installed
in a work cell.

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SAFETY PRECAUTIONS

1.1

B-82135EN/05

OPERATOR SAFETY
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
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. Equip the gate with an
interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. 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 1,
Class 2, or Class 3).
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.
8. If necessary, install a safety lock so that no one except the operator
in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable
anyone from turning it on when it is locked with a padlock.
9. When adjusting each peripheral device independently, be sure to
turn off the power of the robot.

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SAFETY PRECAUTIONS

Fig. 1.1 (a) Safety Fence and Safety gate (For R-J3iB CONTROLLER)

Fig. 1.1 (b) Safety Fence and Safety (For R-30iA CONTROLLER)

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SAFETY PRECAUTIONS

1.1.1

B-82135EN/05

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 the work area.
3. Install a safety fence with a safety gate to prevent any worker other
than the operator from entering the work area unexpectedly and
also to prevent the worker from entering a dangerous area.
4. Install an EMERGENCY STOP button within the operators 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.

Fig. 1.1.1 (a) Connection Diagram for External Emergency


Stop Switch (For R-J3iB CONTROLLER)

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SAFETY PRECAUTIONS

Fig. 1.1.1 (b) Connection Diagram for External Emergency


Stop Switch (For R-30iA CONTROLLER)

1.1.2

Safety of the Teach Pendant Operator


While teaching the robot, it is necessary for the operator to enter the
work area of the robot. It is particularly necessary to ensure the safety of
the teach pendant operator.
1. Unless it is specifically necessary to enter the robot work area,
carry out all tasks outside the area.
2. Before teaching the robot, check that the robot and its peripheral
devices are all in the normal operating condition.
3. When entering the robot work area and teaching the robot, be sure
to check the location and condition of the safety devices (such as
the EMERGENCY STOP button and the deadmans switch on the
teach pendant).
The teach pendant supplied by FANUC is provided with a teach pendant
enable switch and a deadmans switch in addition to the EMERGENCY
STOP button. The functions of each switch are as follows.
EMERGENCY
STOP button
Deadmans switch
When the enable
switch is on

:
:
:

Pressing this button stops the robot in an


emergency, irrespective to the condition of the
teach pendant enable switch.
The function depends on the state of the teach
pendant enable switch.
Releasing the finger from the deadmans
switch stops the robot in an emergency.

When the enable switch is off-The deadmans switch is ineffective

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SAFETY PRECAUTIONS

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NOTE
The deadmans switch is provided so that the robot
operation can be stopped simply by releasing finger
from the teach pendant in case of emergency.
4. The teach pendant operator should pay careful attention so that no
other workers enter the robot work area.

NOTE
In addition to the above, the teach pendant enable
switch and the deadmans switch also have the
following function. By pressing the deadmans switch
while the enable switch is on, the emergency stop
factor (normally the safety gate) connected to the
controller is invalidated.
In this case, it is possible for an operator to enter the
fence during teach operation without pressing the
EMERGENCY STOP button. In other words, the
system understands that the combined operations of
pressing the teach pendant enable switch and
pressing the deadmans switch indicates the start of
teaching.
The teach pendant operator should be well aware that
the safety gate is not functional under this condition
and bear full responsibility to ensure that no one
enters the fence during teaching.
5. When entering the robot work area, the teach pendant operator
should enable the teach pendant whenever he or she enters the robot
work area. In particular, while the teach pendant enable switch is
off, make certain that no start command is sent to the robot from
any operators panel other than the teach pendant.
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 ON/OFF switch on the Teach pendant and the
three modes switch on the Operators panel and Remote condition on
the software.
Operators
panel three
modes
switch
T1/T2
AUTO
(Except RIA)
AUTO
AUTO

Teach
pendant
ON/OFF switch

Software
remote
condition

Teach
pendant

Operators
panel

Peripheral
devices

On

Independent

Allowed to start

Not allowed

Not allowed

Off
Off

Remote OFF
Remote ON

Not allowed
Not allowed

Allowed to start
Not allowed

Not allowed
Allowed to start

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SAFETY PRECAUTIONS

NOTE
When starting the system using the teach pendant in
the RIA specification, the three modes switch should
be T1/T2.
6. To start the system using the operators box, make certain that
nobody is in the robot work area and that there are no abnormal
conditions in the robot work area.
7. When a program is completed, be sure to carry out a test run
according to the procedure below.
1. Run the program for at least one operation cycle in the single
step mode at low speed.
2. Run the program for at least one operation cycle in the
continuous operation mode at low speed.
3. Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
4. 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.
5. After checking the completeness of the program through the
test run above, execute it in the automatic operation mode.
8. While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.

1.1.3

Safety During Maintenance


For the safety of maintenance personnel, pay utmost attention to the
following.
1. 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.
2. When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
3. Before the start of teaching, check that the robot and its peripheral
devices are all in the normal operating condition.
4. If it is necessary to enter the robot work area for maintenance when
the power is turned on, the worker should indicate that the machine
is being serviced and make certain that no one starts the robot
unexpectedly.
5. Do not operate the robot in the automatic mode while anybody is in
the robot work area.
6. 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.
7. 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.
8. If necessary, have a worker who is familiar with the robot system
stand beside the operators panel and observe the work being
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SAFETY PRECAUTIONS

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performed. If any danger arises, the worker should be ready to press


the EMERGENCY STOP button at any time.
9. When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
10. 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.
11. When replacing parts, be sure to use those specified by FANUC. In
particular, never use fuses or other parts of nonspecified ratings.
They may cause a fire or result in damage to the components in the
controller.

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SAFETY PRECAUTIONS

1.2

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.2.1

Precautions in Programming
1. Use a limit switch or other sensor to detect a dangerous condition
and, if necessary, design the program to stop the robot when the
sensor signal is received.
2. Design the program to stop the robot when an abnormal condition
occurs in any other robots or peripheral devices, even though the
robot itself is normal.
3. For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in programming
so that they do not interfere with each other.
4. Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can 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. Employ a limit switch or mechanical stopper to limit the robot
motion so that the robot does not encounter its peripheral devices or
tools.

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SAFETY PRECAUTIONS

1.3

SAFETY OF THE ROBOT MECHANISM

1.3.1

Precautions in Operation

B-82135EN/05

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 with each other.
2. Be sure to specify the predetermined work origin in a motion
program for the robot and program the motion so that it starts from
the origin and terminates at the origin. Make it possible for the
operator to easily distinguish at a glance that the robot motion has
terminated.

1.3.3

Precautions for Mechanisms


1. Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.

1.3.4

Procedure to move arm without drive power in emergency or


abnormal situations
1. For emergency or abnormal situations (e.g. persons trapped in or by
the robot), brake release unit can be used to move the robot axes
without drive power.
Please order following unit and cable.
Name
Brake release unit
Robot connection
cable
Power cable

Specification
A05B-2450-J350
(Input voltage AC100-115V single phase)
A05B-2450-J351
(Input voltage AC200-240V single phase)
A05B-2450-J360 (5m)
A05B-2450-J361 (10m)
A05B-2525-J010 (5m)
(AC100-150V type)
A05B-2525-J011 (10m) (AC100-150V type)
A05B-2450-J364 (5m)
(AC100-200V type)
A05B-2450-J365 (10m) (AC100-200V type)

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.
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SAFETY PRECAUTIONS

NOTE
Robot systems installed without adequate number of
brake release units or similar means are neither in
compliance with EN ISO 10218-1 nor with the
Machinery Directive and therefore cannot bear the
CE marking.
CAUTION
Robot arm would fall down by releasing its brake
because of gravity. Therefore, it is strongly
recommended to take adequate measures such as
hanging Robot arm by a crane before releasing a
brake.

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SAFETY PRECAUTIONS

In case of releasing J2-axis motor brake

Fall down

B-82135EN/05

In case of releasing J3-axis motor brake

Fall down

Fall down

Method of supporting robot arm


Using M10 tap and eyebolt
sling pcs

Using M12 tap and eyebolt


(sling 2pcs)

(*)This figure is example of floor mount.


The direction of fall is different
according to the installation angle,so
please support robot appropriately in
consideration of the influence of
gravity.

Fig. 1.3.4 Releasing J2 and J3 motor brake and measures

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SAFETY PRECAUTIONS

1.4

SAFETY OF THE END EFFECTOR

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.

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SAFETY PRECAUTIONS

1.5

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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 operators
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 nonspecified 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.

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SAFETY PRECAUTIONS

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1.6

WARNING LABEL
(1) Greasing and degreasing label

Fig. 1.6 (a) Greasing and Degreasing Label

Description
When greasing and degreasing, observe the instructions indicated on
this label.
1. When greasing, be sure to keep the grease outlet open.
2. Use a manual pump to grease.
3. Be sure to use specified grease.

CAUTION
See section I.3.1 REPLACING GREASE OF THE
DRIVE MECHANISM for explanations about specified
greases, the amount of grease to be supplied, and the
locations of grease and degrease outlets for individual
models.

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(2) Step-on prohibitive label

Fig. 1.6 (b) Step-on Prohibitive Label

Description
Do not step on or climb the robot or controller as it may adversely affect
the robot or controller and you may get hurt if you lose your footing as
well.
(3) High-temperature warning label

Fig. 1.6 (c) High-temperature warning label

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

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SAFETY PRECAUTIONS

(4) Transportation label

Fig. 1.6 (d) Transportation label

Description
When transporting the robot, observe the instructions indicated on this
label.
1. Using a forklift
Use a forklift having a load capacity of 3,000 kg or greater.
Keep the total weight of the robot to be transported to within
1,000 kg, because the withstand load of the forklift bracket
(option) is 13,720 N (1,400 kgf).
2. Using a crane
Use a crane having a load capacity of 3,000 kg or greater.
Use at least four slings each having a withstand load of 9,800 N
(1,000 kgf) or greater.
Use at least four eyebolts each having a withstand load of 6,174
N (630 kgf) or greater.

CAUTION
See section II.3.1 TRANSPORTATION for
explanations about the posture a specific model
should take when it is transported.

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(5) Motion range, Max. payload label


When CE specification is specified, following label is added.

+180DEG
-180DEG

0DEG

44

3246

J5-axis rotation center

Motion range
of J5-axis
rotation center

844

2650

MAX. PAYLOAD : 350kg


Fig. 1.6(e) Motion range, max. payload label

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SAFETY PRECAUTIONS

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(6) Transportation prohibitive label


(When transportation equipment option is specified.)

Do not pull eyebolt


sideways

Do not have impact


on this part

Do not chain, pry,


or strap on this part

Fig. 1.6 (f) Transportation prohibitive label

Description
Keep the following in mind when transporting the robot.
1. Do not pull eyebolts sideways.
2. Prevent the forks of the forklift from having impact on
transport equipment.
3. Do not thread a chain or the like through a transport
equipment.

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PREFACE

B-82135EN/05

PREFACE
This manual explains the maintenance and connection procedures for
the following robots:
Model name
FANUC Robot
M-900iA/350
FANUC Robot
M-900iA/260L
FANUC Robot
M-900iA/350
FANUC Robot
M-900iA/260L

Mechanical unit
specification No.

Maximum
load

A05B-1327-B201

350kg

A05B-1327-B203

260kg

A05B-1327-B501

350kg

A05B-1327-B503

260kg

Controller

R-J3iB

R-30iA

CAUTION
Note that the models for the R-J3iB controller and
those for the R-30iA controller partly differ in the
specifications of mechanical unit cables and motors.
The label stating the mechanical unit specification number is affixed
in the position shown below. Before reading this manual, determine
the specification number of the mechanical unit.

p-1

PREFACE

TABLE 1
No.

B-82135EN/05

(1)

CONTENTS

LETTERS

FANUC Robot
M-900iA/350
FANUC Robot
M-900iA/260L
FANUC Robot
M-900iA/350
FANUC Robot
M-900iA/260L

(2)

(3)

(4)

(5)

TYPE

No.

DATE

A05B-1327-B201

PRINT SEAL NO.

PRINT
PRODUCTION
YEAR AND
MONTH

WEIGHT
(Without
controller)
1720kg

A05B-1327-B203

1800kg

A05B-1327-B501

1720kg

A05B-1327-B503

1800kg

Position of label indicating mechanical unit specification number

p-2

PREFACE

B-82135EN/05

Specifications
ITEM
Type
Controlled axes
Installation (NOTE)
Motion range J1-axis
Motion range J2-axis
Motion range J3-axis
Motion range J4-axis
Motion range J5-axis
Motion range J6-axis
Max. Motion speed J1-axis
Max. Motion speed J2-axis
Max. Motion speed J3-axis
Max. Motion speed J4-axis
Max. Motion speed J5-axis
Max. Motion speed J6-axis
Max. Load capacity at wrist
Max. Load capacity at J3 arm
Max. Load capacity at J2 arm
Allowable load moment at wrist J4-axis
Allowable load moment at wrist J5-axis
Allowable load moment at wrist J6-axis
Allowable load inertia at wrist J4-axis
Allowable load inertia at wrist J5-axis
Allowable load inertia at wrist J6-axis
Drive method
Repeatability
Weight
Acoustic noise level (NOTE2)
Installation environment

M-900iA/350

M-900iA/260L

Articulated Type
6 axes (J1, J2, J3, J4, J5, J6)
Floor mount, Upside-down (Angle mount)
360 (6.28rad)
360 (6.28rad)
150 (2.62rad)
150 (2.62rad)
223.4 (3.90rad)
211.28 (3.69rad)
720 (12.57rad)
720 (12.57rad)
250 (4.36rad)
250 (4.36rad)
720 (12.57rad)
720 (12.57rad)
100/s (1.75rad/s)
100/s (1.75rad/s)
95/s (1.66rad/s)
105/s (1.83rad/s)
95/s (1.66rad/s)
95/s (1.66rad/s)
105/s (1.83rad/s)
120/s (2.09rad/s)
105/s (1.83rad/s)
120/s (2.09rad/s)
170/s (2.97rad/s)
200/s (3.49rad/s)
350kg
260kg
25kg
25kg
550kg
550kg
1960N.m (200kgf.m)
1666N.m (170kgf.m)
1960N.m (200kgf.m)
1666N.m (170kgf.m)
891.8N.m (91kgf.m)
715.4N.m (73kgf.m)
235.2kg.m2 (2400kgf.cm.s2)
188.2kg.m2 (1920kgf.cm.s2)
2
2
313.6kg.m2 (3200kgf.cm.s2)
392kg.m (4000kgf.cm.s )
2
2
235.2kg.m (2400kgf.cm.s )
188.2kg.m2 (1920kgf.cm.s2)
2
2
313.6kg.m2 (3200kgf.cm.s2)
392kg.m (4000kgf.cm.s )
2
2
156.8kg.m (1600kgf.cm.s )
117.6kg.m2 (1200kgf.cm.s2)
2
2
225.4kg.m2 (2300kgf.cm.s2)
352.8kg.m (3600kgf.cm.s )
Electric servo drive by AC servo motor
+/- 0.3mm
Approx.1720kg
Approx. 1800kg
76.3dB
Ambient temperature:
0 - 45C
Normally:
Ambient humidity
75%RH or less No dew, nor frost allowed.
Short time (within one month):
Max 95%RH
Height:
Up to 1,000 meters above the sea level requires no
particular provision for attitude.
Vibration:
0.5 (4.9m/s2) or less

NOTE
1 The operation range of the J1-axis and J2-axis are
limited to the installation condition.
2 This value is equivalent continuous A-weighted
sound pressure level, which applied with ISO11201
(EN31201). This value is measured with the
following conditions.
- Maximum load and speed
- Operating mode is AUTO
p-3

PREFACE

B-82135EN/05

RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook
B-80687EN

Intended readers:
All persons who use FANUC Robot, system
designer
All persons who use the FANUC Robot and system Topics:
designer must read and understand thoroughly this Safety items for robot system design, operation,
handbook
maintenance
R-J3iB
Operators manual
Intended readers:
SPOT TOOL
Operator, programmer, maintenance person,
controller
B-81464EN-1
system designer
HANDLING TOOL
Topics:
B-81464EN-2
Robot functions, operations, programming,
SEALING TOOL
setup, interfaces, alarms
B-81464EN-4
Use:
Robot operation, teaching, system design
R-J3iB
Maintenance manual
Intended readers:
B-81465EN
Maintenance person, system designer
controller
B-81465EN-1
Topics:
(For Europe)
Installation,
connection
to
peripheral
equipment, maintenance
Use:
Installation, start-up, connection, maintenance
R-30iA
Operators manual
Intended readers:
SPOT TOOL+
Operator, programmer, maintenance person,
controller
B-82594EN-1
system designer
HANDLING TOOL
Topics:
B-82594EN-2
Robot functions, operations, programming,
DISPENSE TOOL
setup, interfaces, alarms
B-82594EN-4
Use:
SERVO GUN FUNCTION
Robot operation, teaching, system design
B-82634EN
R-30iA
Maintenance manual
Intended readers:
B-82595EN
Maintenance person, system designer
controller
B-82595EN-1
Topics:
(For Europe)
Installation, start-up, connection, maintenance
B-82595EN-2
Use:
(For RIA)
Installation, start-up, connection, maintenance
Mechanical
Maintenance manual
Intended readers:
unit
FANUC Robot M-900iA/350
Maintenance person, system designer
Topics:
FANUC Robot M-900iA/260L
Installation, connection to the controller,
B-82135EN
maintenance
Use:
Installation, start-up, connection, maintenance

p-4

TABLE OF CONTENTS

B-82135EN/05

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

CONFIGURATION .................................................................................. 3
1.1
1.2
1.3
1.4
1.5

PREVENTIVE MAINTENANCE............................................................... 9
2.1
2.2
2.3
2.4
2.5
2.6

J1-AXIS DRIVE MECHANISM....................................................................... 4


J2/J3-AXIS DRIVE MECHANISM .................................................................. 5
J4-AXIS DRIVE MECHANISM....................................................................... 6
J5/J6-AXIS DRIVE MECHANISM .................................................................. 7
MAJOR COMPONENT SPECIFICATI ONS .................................................. 8
DAILY CHECKS .......................................................................................... 10
3-MONTH CHECKS (960 hours) ................................................................. 12
1-YEAR CHECKS (3,840 hours).................................................................. 15
1.5-YEAR CHECKS (5,760 hours)............................................................... 16
3-YEAR CHECKS (11,520 hours)................................................................ 17
MAINTENANCE TOOLS ............................................................................. 18

PERIODIC MAINTENANCE .................................................................. 23


3.1

REPLACING GREASE OF THE DRIVE MECHANISM ............................... 24


3.1.1

Grease Replacement Procedure for the J1-Axis/J2- Axis/J3-Axis and J4-Axis Gear
Box ......................................................................................................................26

3.2
3.3

Grease Replacement Procedure for the Wrist.........................................................26

3.1.3

Procedure for Releasing the Grease Residual Pressure ..........................................27

GREASING POINTS ................................................................................... 29


REPLACING THE BATTERIES ................................................................... 30

TROUBLESHOOTING .......................................................................... 31
4.1
4.2
4.3
4.4

3.1.2

OVERVIEW ................................................................................................. 32
FAILURE AND CAUSE................................................................................ 33
BACKLASH MEASUREMENT..................................................................... 40
COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS .................... 43

ADJUSTMENTS.................................................................................... 44
5.1

AXIS LIMITS SETUP ................................................................................... 45


5.1.1

Zero Point Position and Motion Limit ...................................................................46


c-1

TABLE OF CONTENTS

5.2
5.3

6.6
6.7

5.1.3

Hard Stopper and Limit Switch Setting..................................................................51

ADJUSTING LIMIT SWITCH (OPTION) ...................................................... 57


MASTERING ............................................................................................... 60
5.3.1

General ...................................................................................................................60

5.3.2

Resetting Alarms and Preparing for Mastering ......................................................61

5.3.3

Mastering to a Fixture (Master Position Master) ...................................................62

5.3.4

Zero Degree Mastering...........................................................................................67

5.3.5

Quick Mastering .....................................................................................................69

5.3.6

Single Axis Mastering ............................................................................................71

5.3.7

Mastering Data Entry .............................................................................................74

NOTE FOR PART REPLACEMENT............................................................ 77


REPLACING J1-AXIS MOTOR (M1) AND REDUCER ................................ 78
REPLACING J2-AXIS MOTOR (M2) AND REDUCER ................................ 85
REPLACING J3-AXIS MOTOR (M3) AND REDUCER ................................ 90
REPLACING THE WRIST AXIS MOTORS (M4, M5, AND M6), WRIST UNIT
AND J4 AXIS REDUCER............................................................................. 95
SEALANT APPLICATION............................................................................ 98
REPLACING MOTOR COVERS (OPTION) ................................................ 99
PIPING DIAGRAM..................................................................................... 101
WIRING DIAGRAM.................................................................................... 102

REPLACING CABLES ........................................................................ 105


8.1
8.2
8.3

Software Setting .....................................................................................................50

PIPING AND WIRING ......................................................................... 100


7.1
7.2

5.1.2

REPLACING PARTS ............................................................................ 76


6.1
6.2
6.3
6.4
6.5

B-82135EN/05

CABLE FORMING ..................................................................................... 107


CABLE REPLACEMENT ........................................................................... 112
LIMIT SWITCH REPLACEMENT (OPTION) ............................................. 120

SEVERE DUST/LIQUID PROTECTION OPTION ............................... 124


9.1

9.2

OVERVIEW ............................................................................................... 125


9.1.1

Severe Dust/Liquid Protection Characteristics.....................................................125

9.1.2

Configuration of the Severe Dust/Liquid Protection Option................................126

9.1.3

Notes on Specifying Severe Dust/Liquid Protection Option................................127

REPLACING COMPONENTS OF THE SEVERE DUST/LIQUID


PROTECTION OPTION ............................................................................ 128
9.2.1

Replacing Motor Covers ......................................................................................128

9.2.2

Replacing Cable Covers .......................................................................................130


c-2

TABLE OF CONTENTS

B-82135EN/05

9.2.3

Replacing the Battery and Battery Box Cover .....................................................132

CONNECTION
1

ROBOT INTERFERENCE AREA........................................................ 137


1.1
1.2

MECHANICAL COUPLING TO THE ROBOT..................................... 144


2.1
2.2
2.3
2.4
2.5
2.6

2.7
2.8

External Dimensions.................................................................................. 138


Operation Area .......................................................................................... 140
WRIST LOAD CONDITIONS ..................................................................... 145
LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS ARM ................... 148
MECHANICAL COUPLING OF END EFFECTOR TO WRIST .................. 149
EQUIPMENT MOUNTING FACE .............................................................. 150
OPERATION PERFORMANCE SCREENS............................................... 151
INERTIA LOAD SETTINGS ....................................................................... 154
2.6.1

Setting...................................................................................................................155

2.6.2

Checking the Settings...........................................................................................156

AIR SUPPLY (OPTION) ............................................................................ 158


INTERFACE FOR OPTION CABLE (OPTION) ......................................... 159

TRANSPORTATION AND INSTALLATION ....................................... 176


3.1

TRANSPORTATION.................................................................................. 177
3.1.1

3.2
3.3
3.4
3.5
3.6

Transportation with an End Effector Attached.....................................................184

INSTALLATION ......................................................................................... 185


MAINTENANCE AREA .............................................................................. 189
AIR PIPING (OPTION) .............................................................................. 190
INSTALLATION SPECIFICATIONS .......................................................... 192
STORAGE ................................................................................................. 193

APPENDIX
A

SPARE PARTS LIST .......................................................................... 197

CIRCUIT DIAGRAM ............................................................................ 201

PERIODIC MAINTENANCE TABLE ................................................... 206

MOUNTING BOLT TORQUE LIST ..................................................... 208

c-3

MAINTENANCE

B-82135EN/05

MAINTENANCE

1.CONFIGURATION

CONFIGURATION
The configuration of the mechanical unit is shown in Fig. 1.

Fig. 1 Mechanical unit configuration

-3-

1.CONFIGURATION

1.1

MAINTENANCE

B-82135EN/05

J1-AXIS DRIVE MECHANISM


Fig. 1.1 shows the J1-axis drive mechanism. The rotation of the
J1-axis motor (M1) fastened to the table is input to the reducer
through the center gear, and the output rotates the table.

Fig. 1.1 J1-axis drive mechanism

-4-

B-82135EN/05

1.2

MAINTENANCE

1.CONFIGURATION

J2/J3-AXIS DRIVE MECHANISM


Fig. 1.2 shows the J2/J3-axis drive mechanism. Rotation of the J2-axis
motor (M2) is directly fed to the reducer, and the output moves the
J2-axis arm. Rotation of the J3-axis motor (M3) is directly fed to the
reducer, and the output moves the J3-axis arm via the Link1 and
Link2.

Fig. 1.2 J2/J3-axis drive mechanism

-5-

1.CONFIGURATION

1.3

MAINTENANCE

B-82135EN/05

J4-AXIS DRIVE MECHANISM


Fig. 1.3 shows the J4-axis drive mechanism. Rotation of the J4-axis
motor (M4) is fed to the reducer via the gear and drive shaft, and the
output rotates the J4-axis (all of the wrist unit).

Fig. 1.3 J4-axis drive mechanism

-6-

B-82135EN/05

1.4

MAINTENANCE

1.CONFIGURATION

J5/J6-AXIS DRIVE MECHANISM


Fig. 1.4 shows the J5-axis/J6-axis drive mechanism. The rotation of
the J5-axis motor (M5) is input to the reducer via the gear and drive
shaft, and the output moves the J5-axis. The rotation of the J6-axis
motor (M6) is input to the reducer via the gear and drive shaft, and the
output rotates the J6-axis (wrist flange).

Fig. 1.4 J5/J6-axis drive mechanism

NOTE
All motors incorporate a brake that is applied when
not energized. These brakes are active at power-off
and emergency stop.

-7-

1.CONFIGURATION

1.5

MAINTENANCE

B-82135EN/05

MAJOR COMPONENT SPECIFICATI ONS


Table 1.5 (a) Motor
Motor
Specifications
M1

A06B-0268-B605#S000

M2, M3

A06B-0272-B605#S000

M4, M5, M6

A06B-0238-B605#S000

Model
(30/4000is)
iS30/4000
(40/4000is)
iS40/4000
(12/4000is)
iS12/4000

Axis
J1
J2, J3
J4, J5, J6

Table 1.5 (b) Reducer (M-900iA/350)


Axis

Specifications

J1
J2
J3
J4

A97L-0218-0347#500C-30
A97L-0218-0348#550F-253
A97L-0218-0348#550F-253
A97L-0218-0349#160E-57

Table 1.5 (c) Reducer (M-900iA/260L)


Axis

Specifications

J1
J2
J3
J4

A97L-0218-0347#500C-30
A97L-0218-0348#550F-227
A97L-0218-0348#550F-267
A97L-0218-0349#160E-57

Table 1.5 (d) Wrist Unit


Model Name
M-900iA/350
M-900iA/260L

-8-

Specifications
A290-7327-T501
A290-7327-T503

B-82135EN/05

MAINTENANCE

2.PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained by performing
the periodic maintenance procedures presented in this chapter.

NOTE
The periodic maintenance procedures described in
this chapter assume that the FANUC robot is used
for up to 3840 hours a year. When using the robot
beyond this total operating time, correct the
maintenance frequencies shown in this chapter by
calculation in proportion to the difference between
the actual operating time and 3840 hours/year.

-9-

2.PREVENTIVE MAINTENANCE

2.1

MAINTENANCE

B-82135EN/05

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

Air pressure

Oiler oil mist quantity

Oiler oil level

Leakage from hose

Check points
Check air pressure using the pressure gauge
on the air regulator as shown in Fig. 2.1. If it
does not meet the specified pressure of 0.49
to 0.69 MPa (5-7kgf/cm2), adjust it using the
regulator pressure setting handle.
Check the drop quantity during wrist or hand
motion. If it does not meet the specified value
(1 drop/10-20 sec), adjust it using the oiler
control knob. Under normal usage, the oiler
becomes empty in about 10 to 20 days under
normal operation.
Check to see that the oiler level is within the
specified level shown in Fig. 2.1.
Check the joints, tubes, etc. for leaks. Repair
leaks, or replace parts, as required.

1
2

Oil inlet
Adjusting knob

3
4

Lubricator mist amount check


7
Lubricator
Fig. 2.1 Air control set (option)

- 10 -

5
6

Pressure gauge
Regulator
pressure
handle
Filter

setting

MAINTENANCE

B-82135EN/05

2.PREVENTIVE MAINTENANCE

2. After automatic operation


Item

Check items

Vibration, abnormal
noises, and motor
heating

Changing repeatability

Peripheral devices for


proper operation

Brakes for each axis

- 11 -

Check points
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.

2.PREVENTIVE MAINTENANCE

2.2

MAINTENANCE

B-82135EN/05

3-MONTH CHECKS (960 hours)


1. Check the following items once every about three months (or 960
hours operating). Additional inspection areas and times should be
added to the table according to the robots working conditions,
environment, etc.
Item

Check items

Control unit cable

Ventilation portion of
control unit

Check points
Check whether the cable connected to the
teach pendant is unevenly twisted.
If the ventilation portion of the control unit is
dusty, turn off power and clean the unit.

2. First quarterly inspection Check the following items at the first


quarterly inspection, then every year thereafter.
Item
1

Check items

Check points

Cables used in
mechanical unit

Check whether the jackets of the mechanical


unit cables are damaged. Also, check whether
the cables are excessively bent or unevenly
twisted. Check that the connectors of the
motors and connector panels are securely
engaged. See Section 7.2. (NOTE 1)
Cleaning and checking Clean each part (remove chips, etc.) and
each part
check component parts for cracks and flaws.
(NOTE 2)
Further tightening
Further, tighten the end effector mounting
external main bolts
bolts and external main bolts. (NOTE 3)

NOTE 1) Inspection points and check items of the mechanical unit cables and
connectors
Inspection points of the mechanical unit cables
Fixed part cables likely to interfere with the J1, J2, and J3 movable
parts and peripheral devices For the J1-axis, inspect the cables from
above the J2 base and from the side by removing the metal plate on
the side of the J1 base.
Check items
For cables with a cable cover, open the cover before making the
check.
Check the cables for a sheath break and wear.
If wires of the cable appear, replace it.

- 12 -

B-82135EN/05

MAINTENANCE

2.PREVENTIVE MAINTENANCE

Fig. 2.2 (a) Check items of Mechanical unit cable

Inspection points of the connectors


- Power/brake connectors of the motor exposed externally
- Robot connection cables and user cables, earth terminal
Check items
- Circular connector: Check the connector for looseness by turning
it manually.
- Square connector: Check the connector for disengagement of its
lever.
- Earth terminal:
Check the connector for looseness.

Fig. 2.2 (b) Check items of connector

- 13 -

2.PREVENTIVE MAINTENANCE

MAINTENANCE

B-82135EN/05

NOTE 2) Cleaning
- Necessary cleaning points, dust on the flat part, sedimentation of
spatters
Clean sediments periodically.
In particular, clean the following points carefully.
Vicinity of the wrist axis and oil seal
If chippings or spatters are attached to the oil seal, an oil leak may be
caused.
-

Check if the vicinity of the necessary inspection points, wrist part,


and J3 arm significantly wears due to rubbing against the welding
cable or hand cable.
Check if there is a trace of a collision around the gun or hand.
Check the reducer or grease bath for an oil leak.

If oil can be found a day after wiping oil, an oil leak may be caused.

Fig. 2.2 (c) Cleaning part

NOTE 3) Points to be retightened


-

The end effector 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.

- 14 -

MAINTENANCE

B-82135EN/05

2.3

2.PREVENTIVE MAINTENANCE

1-YEAR CHECKS (3,840 hours)


Check the following items once every about year (or 3,840 hours
operating).
Item
1
2
3

Check items
Cables used in
mechanical unit
Cleaning each parts
and inspection
Tightness of major
external bolts

- 15 -

Check points
(See Section 2.2.)
(See Section 2.2.)
(See Section 2.2.)

2.PREVENTIVE MAINTENANCE

2.4

MAINTENANCE

B-82135EN/05

1.5-YEAR CHECKS (5,760 hours)


Check the following item once every 1.5-year.
Item
1

Check items
Battery

Check points
Replace battery in the mechanical unit. Refer
to Section 3.3.

- 16 -

MAINTENANCE

B-82135EN/05

2.5

2.PREVENTIVE MAINTENANCE

3-YEAR CHECKS (11,520 hours)


Check the following items once every about 3 years (or 11,520 hours
operating).
Item
1

Check items

Check points

Refer to Section 3.1.


Replacing grease of
each axis, reducer and
gear box

- 17 -

2.PREVENTIVE MAINTENANCE

2.6

MAINTENANCE

B-82135EN/05

MAINTENANCE TOOLS
The following tools and instruments are required for the maintenance
procedures contained in this manual.
1. Measuring instruments
Instruments
Dial gauge
accuracy
Slide calipers
Push/pull
tension gauge

Accuracy/Capacity
1/100 mm accuracy
150 mm capacity
98N (10 kgf) accuracy

Applications
Measurement of positioning and
backlash
Measurement of backlash

2. Tools
Cross-point (+) screwdrivers
sizes
Conventional (-) screwdrivers
sizes
Box screw drivers
Hexagonal wrench key sets
(metric)
Adjustable wrenches
Pliers
Cutting pliers
Cutting nippers
Double hexagon offset wrench
Grease gun
Pliers for C-retaining ring
Torque wrench
Gear puller
Spanner
T-shaped hexagonal wrench

- 18 -

: Large, medium, and small

: Large, medium, and small


: M6
: M3 - M20
: Medium and small sizes

: 30x32mm or 32x36mm
(Thickness: 14 mm or less for
stopping J41 gear rotation)
: M8 (Length: 270 mm or more.
Used for wrist axis motor
connection)
M12 (Length: 300 mm or more.
Used for J2 and J3 axis motor
connection)

B-82135EN/05

MAINTENANCE

2.PREVENTIVE MAINTENANCE

3. Special Tools
A290-7324-X921 2PCS
(Guide pin (M12) for J1/J2/J3-axis reducer replacement)
See Fig.2.6 (a).
A290-7324-X922
(Spring pin striking tool for J1-axis reducer replacement)
See Fig.2.6 (b))
A290-7324-X923 2PCS
(Guide pin (M16) for J1/J2/J3-axis reducer replacement)
See Fig.2.6 (c).
A290-7324-X924
(For bearing installation in the J1-axis input gear)
See Fig. 2.6 (d).
A290-7321-X947
(For bearing installation in gear J41)
See Fig. 2.6 (e).
A290-7327-X924
(For oil seal installation in the J2/J3-axis reducer)
See Fig. 2.6 (f).
A290-7327-X910
(Robot hanging tool for J1-axis reducer replacement)
See Fig. 2.6(g).
4. Options (For securing the arm during J2 or J3-axis motor replacement)
For changing the J2-axis operating range: A05B-1327-J032
For changing the J3-axis operating range: A05B-1327-J033

Fig. 2.6 (a) Guide pin (M12) for J1/J2/J3-axis reducer replacement

- 19 -

2.PREVENTIVE MAINTENANCE

MAINTENANCE

Fig. 2.6 (b) Spring pin striking tool for J1-axis reducer replacement

Fig. 2.6 (c) Guide pin (M16) for J1/J2/J3-axis reducer replacement

Fig. 2.6 (d) For bearing installation in the J1-axis input gear

- 20 -

B-82135EN/05

B-82135EN/05

MAINTENANCE

2.PREVENTIVE MAINTENANCE

Fig. 2.6 (e) For installing bearing on gear J41

Fig. 2.6 (f) For installing oil seal to the J2/J3-axis reducer

- 21 -

2.PREVENTIVE MAINTENANCE

MAINTENANCE

Fig. 2.6 (g) Robot hanging tool for J1-axis reducer replacement

- 22 -

B-82135EN/05

B-82135EN/05

MAINTENANCE

PERIODIC MAINTENANCE

- 23 -

3.PERIODIC MAINTENANCE

3.PERIODIC MAINTENANCE

3.1

MAINTENANCE

B-82135EN/05

REPLACING GREASE OF THE DRIVE MECHANISM


Replace the grease of the reducers of J1, J2, and J3 axes, and the
J4-axis gear box, and the wrist, every three years or 11,520 hours by
using the following procedures.

Table 3.1 (a) Grease for 3-year periodical replacement


Quantity
Models
Supply position

M-900iA/350
M-900iA/260L

J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist

Gun tip
pressure

7000g (8000ml)
3000g (3400ml)
2700g (3100ml)
1900g (2200ml)
5000g (5750ml)

Grease name
Kyodo yushi

0.15MPa or less
(NOTE)

VIGOGREASE RE0
Spec. ; A98L-0040-0174

NOTE
When using a hand pump, apply grease approximately
once per 1.5 seconds.
For grease replacement or replenishment, use the attitudes indicated
below.
Table 3.1 (b) Attitudes for greasing
Supply position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist

Attitude
J1

J2

J3

Arbitrary

Arbitrary
0
0
Arbitrary

J4

J5

J6

Arbitrary

Arbitrary

Arbitrary

J4

J5

J6

Arbitrary

Arbitrary

Arbitrary

Arbitrary
0
0
0

For ceiling-hung installation, see Table 3.1 (c).


Table 3.1 (c) Attitudes for greasing (for ceiling-hung installation)
Supply position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box
Wrist

Attitude
J1

J2

J3

Arbitrary
-75

Arbitrary

Arbitrary

+76
-96
0

Arbitrary

- 24 -

180 or

-180

B-82135EN/05

MAINTENANCE

Fig. 3.1 (a) Replacing grease of J1/J2-axis reducer

Fig. 3.1 (b) Replacing grease of J3-axis gear box

- 25 -

3.PERIODIC MAINTENANCE

3.PERIODIC MAINTENANCE

MAINTENANCE

B-82135EN/05

Fig. 3.1 (c) Replacing grease of wrist

3.1.1

Grease Replacement Procedure for the J1-Axis/J2Axis/J3-Axis and J4-Axis Gear Box
1.
2.
3.
4.

Move the robot to the greasing attitude described in Section 3.1.


Turn off the power.
Remove the seal bolt from the grease outlet.
Supply new grease until new grease is output from the grease
outlet.
5. After applying grease, release the residual pressure within the
grease bath as described in the procedure in Section 3.1.3.

3.1.2

Grease Replacement Procedure for the Wrist


1.
2.
3.
4.

Move the robot to the greasing attitude described in Section 3.1.


Turn off the power.
Remove the seal bolt from wrist grease outlet 1 and 2.
Supply new grease through the wrist grease inlet until new grease
is output from wrist grease outlet 1.
5. Attach the seal bolt onto wrist grease outlet 1. When reusing the
seal bolt, be sure to seal the seal bolt with seal tape.
6. Remove the seal bolt from wrist grease outlet 2.
- 26 -

MAINTENANCE

B-82135EN/05

3.PERIODIC MAINTENANCE

7. Supply new grease through the wrist grease inlet until new grease
is output from wrist grease outlet 2.
8. After applying grease, release the residual pressure within the
grease bath as described in the procedure in Section 3.1.3.

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 air supply. Even when
using Table 3.1(a) or less during application of
grease.
4. Use grease only of the specified type. Grease of a
type other than that specified may damage the
reducer or lead to other problems.
5. After applying grease, release the residual pressure
within the grease bath as described in the procedure
in Section 3.1.3.
6. To prevent accidents caused by slipping, completely
remove any excess grease from the floor or robot.

3.1.3

Procedure for Releasing the Grease Residual Pressure


Release the residual pressure as described below.
Attach the recovery bag under the grease inlet and outlet to prevent
drained grease from splattering.

Exchange position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gear box

Wrist

Operation angle
80 or more
90 or more
70 or more
J4=60 or more
J5=120 or more
J6=60 or more
J4=60 or more
J5=120 or more
J6=60 or more

OVR

Operation time

Release position

50%
50%
50%

20minutes
20minutes
20minutes

A
A
A

100%

20minutes

100%

10minutes

For A: Make a run with the grease inlet and outlet open.
For B: Make a run with only the grease outlet open.
For C: Make a run with all of the grease inlets and outlets in the
following figure open.
- 27 -

3.PERIODIC MAINTENANCE

MAINTENANCE

B-82135EN/05

Fig. 3.1.3 Positions to be released when the wrist residual pressure is released

When the above operation is impossible due to ambient conditions,


perform the program operation for a time equivalent to the above.
(When the maximum allowable axis angle is half the specified angle,
run the program for twice the specified time.) Upon completion of the
above operation, attach the grease nipple or the seal bolt to each the
grease inlet and outlet. When reusing the grease nipple and the seal
bolt, be sure to seal it with seal tape.

- 28 -

B-82135EN/05

3.2

3.PERIODIC MAINTENANCE

MAINTENANCE

GREASING POINTS
Fig. 3.2 shows the greasing points. If the robot is installed in a severe
environment, apply grease whenever necessary. If water splashes on
the robot, apply grease immediately. Table 3.2 (b) shows the
substitute table grease. Apply grease every three years or 11,520
hours.
Table 3.2 (a) Greasing points
Greasing
Grease
points
Bearing at
J2/J3-axis
connection

SHELL ALVANIA GREASE S2


(Spec.: A97L-0001-0179#2)

Amount

Way

20 ml each
(2 locations)

Apply grease
from the
grease nipple.

Table 3.2 (b) Substitutes for ALVANIA GREASE S2


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

MOBILACKS GREASE NO.2


VICON NO.2
MULTINOC 2
EPNOC AP-2
EPONEX GREASE NO.2
DYNAMAX NO.2

Fig. 3.2 Greasing Points

- 29 -

3.PERIODIC MAINTENANCE

3.3

MAINTENANCE

B-82135EN/05

REPLACING THE BATTERIES


The position data of each axis is preserved by the backup batteries.
The batteries need to be replaced every 1.5 year. Also, use the
following procedure to replace when the backup battery voltage drop
alarm occurs.
1. Keep the power on. Press the EMERGENCY STOP button to
prohibit the robot motion.

NOTE
Replacing the batteries with the power supply turned
off causes all current position data to be lost.
Therefore, mastering will be required again.
2. Remove the battery case cap.
3. Take out the old batteries from the battery case.
4. Insert new batteries into the battery case. Pay attention to the
direction of batteries.
5. Close the battery case cap.

Fig. 3.3 Replacing Batteries

- 30 -

B-82135EN/05

MAINTENANCE

TROUBLESHOOTING

- 31 -

4.TROUBLESHOOTING

4.TROUBLESHOOTING

4.1

MAINTENANCE

B-82135EN/05

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.

- 32 -

MAINTENANCE

B-82135EN/05

4.2

4.TROUBLESHOOTING

FAILURE AND CAUSE


Table 4.2 lists the major failures that may occur in the mechanical unit
and their probable causes. If you cannot pinpoint a failure cause or
which measures to apply, contact FANUC.

Table 4.2 Failures and Causes


Symptom
Description
Vibration
Noise

- As the robot operates, its base


plate lifts off the floor plate.
- There is a gap between the
base plate and the floor plate.

- The J1 base lifts off the base


plate as the robot operates.
- There is a gap between the J1
base and base plate.
- A J1 base retaining bolt is
loose.

- Apply epoxy to the floor surface


and reinstall the plate.

- Vibration becomes more


serious when the robot adopts a
specific posture.
- If the operating speed of the
robot is reduced, vibration stops.
- Vibration is most noticeable
when the robot is accelerating.
- Vibration occurs when two or
more axes operate at the same
time.

Cause
[Base plate and floor plate
fastening]- It is likely that the
base plate is not securely
fastened to the floor plate
because of poor welding.
- If the base plate is not
securely fastened to the floor
plate, it lifts as the robot
operates, allowing the base and
floor plates to strike each other,
which, in turn, leads to
vibration.
[J1 base fastening]
- It is likely that the robot J1
base is not securely fastened to
the base plate.
- Probable causes are a loose
bolt, an insufficient degree of
surface flatness, or foreign
material caught between the
base plate and floor plate.
- If the robot is not securely
fastened to the base plate, the
J1 base lifts the base plate as
the robot operates, allowing the
base and floor plates to strike
each other, which, in turn, leads
to vibration.
[Rack or floor]
- It is likely that the rack or floor
is not sufficiently rigid.
- If the rack or floor is not
sufficiently rigid, reaction from
the robot deforms the rack or
floor, leading to vibration.
[Overload]
- It is likely that the load on the
robot is greater than the
maximum rating.
- It is likely that the robot
control program is too
demanding for the robot
hardware.
- It is likely that the
ACCELERATION value is
excessive.

- 33 -

Measure
- Re-weld the base plate to the
floor plate.
- If the weld is not strong enough,
increase its width and length.

- If a bolt is loose, apply Loctite


and tighten it to the appropriate
torque.
- Adjust the base plate surface
flatness to within the specified
tolerance.
- If there is any foreign matter
between the J1 base and base
plate, remove it.
- As the robot operates, the rack or
floor on which the robot is
mounted vibrates.

- Reinforce the rack or floor to


make it more rigid.
- If it is impossible to reinforce the
rack or floor, modify the robot
control program; doing so might
reduce the amount of vibration.
- Check the maximum load that
the robot can handle once more. If
the robot is found to be
overloaded, reduce the load, or
modify the robot control program.
- Vibration in a specific portion can
be reduced by modifying the robot
control program while slowing the
robot and reducing its acceleration
(to minimize the influence on the
entire cycle time).

4.TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)

MAINTENANCE

B-82135EN/05

Description

Cause

Measure

- Vibration was first noticed after


the robot collided with an object
or the robot was overloaded for a
long period.
- The grease of the vibrating axis
has not been exchanged for a
long period.

[Broken gear, bearing, or


reducer]
- It is likely that collision or
overload applied an excessive
force on the drive mechanism,
thus damaging the gear tooth
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 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. These factors all
generate cyclic vibration and
noise.

- Operate one axis at a time to


determine which axis is vibrating.
- Remove the motor, and replace
the gear, the bearing, and the
reducer. For the spec. of parts and
the method of replacement,
contact FANUC.
- Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
- Regularly changing the grease
with a specified type can help
prevent problems.

- 34 -

MAINTENANCE

B-82135EN/05

Symptom
Vibration
Noise
(Continued)

4.TROUBLESHOOTING

Description

Cause

Measure

- The cause of problem cannot


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

[Controller, cable, and motor]


- If a failure occurs in a
controller circuit, preventing
control commands from being
supplied to the motor normally,
or preventing motor information
from being sent to the controller
normally, vibration might occur.
- If the pulse coder develops a
fault, vibration might occur
because information about the
motor position cannot be
transferred to the controller
accurately.
- If the motor becomes
defective, vibration might occur
because the motor cannot
deliver its rated performance.
- If a power line in a movable
cable of the mechanical section
has an intermittent break,
vibration might occur because
the motor cannot accurately
respond to commands.
- If a pulse coder wire in a
movable part of the mechanical
section has an intermittent
break, vibration might occur
because commands cannot be
sent to the motor accurately.
- If a connection cable between
them has an intermittent break,
vibration might occur.
- If the power source voltage
drops below the rating,
vibration might occur.
- If a robot control parameter is
set to an invalid value, vibration
might occur.
[Noise from a nearby machine]
- If the robot is not grounded
properly, electrical noise is
induced on the grounding wire,
preventing commands from
being transferred accurately,
thus leading to vibration.
- If the robot is grounded at an
unsuitable point, its grounding
potential becomes unstable,
and noise is likely to be induced
on the grounding line, thus
leading to vibration.

- Refer to the Controller


Maintenance Manual for
troubleshooting related to the
controller and amplifier.
- Replace the pulse coder 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.
- Check that the robot is supplied
with the rated voltage.
- Check whether the sheath of the
power cord is damaged. If so,
replace the power cord, and check
whether vibration still occurs.
- Check whether the sheath of the
cable connecting the mechanical
section and controller is damaged.
If so, replace the connection cable,
and check whether vibration still
occurs.
- If vibration occurs only when the
robot assumes a specific posture,
it is likely that a cable in the
mechanical unit is broken.
- Shake the movable part cable
while the robot is at rest, and
check whether an alarm occurs. If
an alarm or any other abnormal
condition occurs, replace the
mechanical unit cable.
- Check that the robot control
parameter is set to a valid value. If
it is set to an invalid value, correct
it. Contact FANUC for further
information if necessary.

- There is some relationship


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

- 35 -

- Connect the grounding wire firmly


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

4.TROUBLESHOOTING
Symptom

MAINTENANCE

B-82135EN/05

Description

Cause

Measure

Vibration
Noise
(Continued)

- 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.

- 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 usual
sound will disappear.

Rattling

- While the robot is not supplied


with power, pushing it with the
hand causes part of the
mechanical unit to wobble.
- There is a gap on the mounting
face of the mechanical unit.

- There may be an unusual


sound when using other than
the specified grease.
- Even for the specified grease,
there may be an unusual sound
during operation at low speed
immediately after replacement
or after a long period.
[Mechanical section coupling
bolt]
- It is likely that overloading or a
collision has loosened a
mounting bolt in the robot
mechanical section.

- Backlash is greater than the


tolerance stated in the applicable
maintenance manual. (See
Table. 4.3 (b))

[Increase in backlash]
- It is likely that excessive force
applied to the drive
mechanism, due to a collision
or overloading, has broken a
gear or the inside of the
reducer, resulting in an
increase in the amount of
backlash.
- It is likely that prolonged use
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 for backlash.

- 36 -

Check that the following bolts for


each axis are tight. If any of these
bolts is loose, apply Loctite and
tighten it to the appropriate torque.
- Motor retaining bolt
- Reducer retaining bolt
- Reducer shaft retaining bolt
- Base retaining bolt
- Arm retaining bolt
- Casting retaining bolt
- End effector retaining bolt
- Operate one axis at a time to
determine which axis has the
increased backlash.
- Remove the motor, and check
whether any of its gears are
broken. If any gear is broken,
replace it.
- Check whether any other gear of
the drive mechanism is damage. If
there is no damage gear, replace
the reducer.
- If the reducer is broken, or if a
gear tooth is missing, replace the
relevant component. Also, remove
all the grease from the gear box
and wash the inside of the gear
box.
- After replacing the gear or
reducer, add an appropriate
amount of grease.
- Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
- Regularly changing the grease
with a specified type can help
prevent problems.

MAINTENANCE

B-82135EN/05

Symptom
Motor
Overheating

Description

Cause

- The ambient temperature of the


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

[Ambient temperature]
- 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.

- After a control parameter was


changed, the motor overheated.

[Parameter]
- If data input for a workpiece is
invalid, the robot cannot be
accelerated or decelerated
normally, so the average
current increases, leading to
overheating.
[Mechanical section problems]
- It is likely that problems
occurred in the mechanical unit
drive mechanism, thus placing
an excessive load on the
motor.
[Motor problems]
- It is likely that a failure of the
motor brake resulted in the
motor running with the brake
applied, thus placing an
excessive load on the motor.
- It is likely that a failure of the
motor prevented it from
delivering its rated
performance, thus causing an
excessive current to flow
through the motor.

- Symptom other than stated


above

- 37 -

4.TROUBLESHOOTING
Measure
The teach pendant can be used to
monitor the average current.
Check the average current when
the robot control program is
running. The allowable average
current is specified for the robot
according to its ambient
temperature. Contact FANUC for
further information.
- Relaxing the robot control
program and conditions can
reduce the average current, thus
preventing overheating.
- Reducing the ambient
temperature is the most effective
means of preventing overheating.
- Having the surroundings of the
motor well ventilated enables the
motor to release heat efficiently,
thus preventing overheating. Using
a fan to direct air at the motor is
also effective.
- If there is a source of heat near
the motor, it is advisable to install
shielding to protect the motor from
heat radiation.
- Input an appropriate parameter
as described in the controller
operators 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 brake is
released.
- If the brake remains applied to
the motor all the time, replace the
motor.
- If the average current falls after
the motor is replaced, it indicates
that the first motor was faulty.

4.TROUBLESHOOTING
Symptom

MAINTENANCE

Description

Cause

Measure
- If a crack develops in the casting,
sealant can be used as a quick-fix
to prevent further grease leakage.
However, the component should
be replaced as soon as possible,
because the crack might extend.
- O-rings are used in the locations
listed below.
- Motor coupling section
- Reducer (case and shaft)
coupling section
- Wrist coupling section
- J3 arm coupling section
- Inside the wrist
- Oil seals are used in the
locations stated below.
- Inside the reducer
- Inside the wrist
- Seal bolts are used in the
locations stated below.
- Grease drain 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.
- 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.

Grease
Leakage

- Grease is leaking from the


mechanical unit.

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

Dropping
axis

- An axis drops because the


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

[Brake drive relay and motor]


- It is likely that brake drive
relay contacts are stuck to each
other to keep the brake current
flowing, thus preventing the
brake from operating when the
motor is 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.

- 38 -

B-82135EN/05

MAINTENANCE

B-82135EN/05

Symptom
Displacement

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

- Displacement occurs only in a


specific peripheral unit.

- Displacement occurred after a


parameter was changed.

BZAL alarm
occurred

- BZAL is displayed on the


controller screen.

4.TROUBLESHOOTING

Cause

Measure

[Mechanical section problems]


- If the repeatability is unstable,
probable causes are a failure in
the drive mechanism or a loose
bolt.
- If the repeatability becomes
stable, it is likely that a collision
imposed an excessive load,
leading to slipping on the base
surface or the mating surface of
an arm or reducer.
- It is likely that the pulse coder
is abnormal.
[Peripheral unit displacement]
- It is likely that an external
force was applied to the
peripheral unit, thus shifting its
position relative to the robot.
[Parameter]
-It is likely that the mastering
data was rewritten in such a
way that the robot origin was
shifted.
- It is likely that the voltage of
the memory backup battery is
low.
- It is likely that the pulse coder
cable is defected.

- If the repeatability is unstable,


repair the mechanical section by
referring to the above descriptions
of vibration, noise, and rattling.
- If the repeatability is stable,
correct the taught program.
Variation will not occur unless
another collision occurs.
- If the pulse coder is abnormal,
replace the motor or the pulse
coder.

- 39 -

- Correct the setting of the


peripheral unit position.
- Correct the taught program.

- Re-enter the previous mastering


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

4.TROUBLESHOOTING

4.3

MAINTENANCE

B-82135EN/05

BACKLASH MEASUREMENT

Measurement method
1. Maintain the robot in a specified posture. (See Table. 4.3 (a) and
Fig. 4.3 (b).)
2. Apply positive and negative loads to each axis as shown in Fig.4.3
(a).
3. Remove the loads and measure the displacement.
Measure backlash by applying positive and negative loads to each axis
three times. Average the values measured in the last two
measurements for each axis, and use the averages as a measured
backlash for the respective axes.

Stop position
0

+10kg

Firtst step
(Do not measure)

-10kg

+10kg
L1

-10kg
0kg

L2

0kg

+10kg
0kg
L3

-10kg
0kg

Second step
(B2 =L 1+ L2)

Third step
(B3=L 3+ L4)

L4

Fig. 4.3 (a) Backlash Measurement Method

Backlash B is calculated using the following expression:


B=

- 40 -

B2 + B3
2

4.TROUBLESHOOTING

MAINTENANCE

B-82135EN/05

Measurement posture and position


Table 4.3 (a) Backlash Measurement Posture
Posture

Measured axis

J1-axis

J2-axis

J3-axis

J4-axis

J5-axis

J6-axis

J1-axis

Any angle

75

90

J2-axis

Any angle

-90

90

J3-axis

Any angle

42

-90

-90

90

90

J4-axis
J5-axis

Any angle

42

-90

-90

90

90

Any angle

-90

90

90

J6-axis

Any angle

-90

90

When measuring backlash,


press the dial indicator to
the center of the test work
at right angles.

Loading position

Loading position

-axis measurement posture

When measurring backlash,


press the dial indicator to
the center of the test work
at right angles.

Loading position
-axis measurement posture

-axis measurement posture

Fig. 4.3 (b) Backlash Measurement Posture (1/2)

- 41 -

When measuring backlash,


press the dial indicator to
the center of the test work
at right angles.

4.TROUBLESHOOTING

MAINTENANCE

B-82135EN/05

Loading position
-axis measurment posture

When measuring backlash,


press the dial indicator to
the center of the test work
at right angles.

Loading position
When measuring backlash,
press the dial indicator to
the center of the test work
at right angles.

Loading position
When measuring backlash
press the dial indicator to
the center of the test work
at right angles.

-axis measurement posture

-axis measurment posture

Fig. 4.3 (c) Backlash Measurement Posture (2/2)

Permissible backlash values


Table 4.3 (b) Permissible Backlash Value (M-900iA/350)
J1-axis

J2-axis

J3-axis

J4-axis

J5-axis

J6-axis

Angle conversion (arc-min)

2.16

2.00

2.00

2.24

2.55

4.94

Displacement conversion (mm)

1.99

0.73

0.73

0.35

0.39

0.40

Distance between the rotation center and


dial indicator (mm)

3165

1250

1250

530

530

277

J1-axis

J2-axis

J3-axis

J4-axis

J5-axis

J6-axis

Angle conversion (arc-min)

2.16

2.00

2.00

2.24

2.55

4.94

Displacement conversion (mm)

2.35

0.73

0.99

0.42

0.48

0.46

Distance between the rotation center and


dial indicator (mm)

3735

1250

1705

645

645

321

Table 4.3 (c) Permissible Backlash Value (M-900iA/260L)

- 42 -

B-82135EN/05

4.4

MAINTENANCE

4.TROUBLESHOOTING

COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS


Adjustments are needed after a component is replaced. The following
table lists components and the adjustment items that must be made
after their replacement. After replacing a component, make necessary
adjustments according to this table.
Component replacement or
function change
Cable replacement
Change to J1-axis stroke
Battery replacement
(The battery should be replaced once
1.5 years.)

- 43 -

Adjustment item
(a) Cable dressing
(b) Quick mastering
(a) Change to stopper position
(b) Change to parameter
Replace the battery with the
power kept on.
No adjustment is needed.

5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

ADJUSTMENTS
Each part of the mechanical unit is carefully adjusted at the factory
before shipment. Therefore, it is usually unnecessary for the customer
to make adjustments at the time of delivery. However, after a long
period of use or after parts are replaced, adjustments may be required.

- 44 -

B-82135EN/05

5.1

MAINTENANCE

5.ADJUSTMENTS

AXIS LIMITS SETUP


Axis limits define the motion range of the robot. The operating range
of the robot axes can be restricted because of:
- Work area limitations
- Tooling and fixture interference points
- Cable and hose lengths
There are three methods used to prevent the robot from going beyond
the necessary motion range.
These are
- Axis limit software settings (All axes)
- Axis limit hardstops ((J1, J2, J3-axis) optional)
- Axis limit switches ((J1, J2, J3-axis) optional)

CAUTION
1 Changing the movable range of any axis affects the
operation range of the robot. To avoid trouble,
carefully consider a possible effect of the change to
the movable range of each axis in advance.
Otherwise, it is likely that an unexpected condition
occurs; for example, an alarm may occur in a
previous taught position.
2 For the J1, J2, and J3 axes, do not count merely on
software-based limits to the movable range when
changing the movable range of the robot. Use
mechanical stoppers together so that damage to
peripheral equipment and injuries to human bodies
can be avoided. In this case, make the
software-specified limits match the limits based on
the mechanical stoppers.
3 Mechanical stoppers are physical obstacles. The
robot cannot move beyond them. For the J1, J2, and
J3 axes, it is possible to re-position the mechanical
stoppers. For J5-axis, the mechanical stoppers are
fixed. For the J4 and J6 axes, only
software-specified limits are available.
4 For changing J2 and J3 axes interference angles,
only mechanical stoppers are available; a software
specified movable range cannot be changed.
5 Movable mechanical stoppers (J1, J2, and J3 axes)
are deformed in a collision to stop the robot. Once a
stopper is subject to a collision, it can no longer
assure its original strength and, therefore, may not
stop the robot. When this happens, replace it with a
new one.

- 45 -

5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

Upper Limits
Displays the upper limits of each axis, or the axis limits in a positive
direction.

Lower Limits
Displays the lower limits of each axis, or the axis limits in a negative
direction.

5.1.1

Zero Point Position and Motion Limit


Zero point and software motion limit are provided for each controlled
axis. Exceeding the software motion limit of a controlled axis is called
overtravel (OT). Overtravel is detected at both ends of the motion
limit for each axis. The robot cannot exceed the software motion limit
unless there is a failure of the system causing loss of zero point
position or there is a system error.
Fig. 5.1.1 (a) - Fig. 5.1.1 (g) show the zero point and motion limit, LS
detection position, and mechanical stopper position of each axis.

Fig. 5.1.1 (a) J1-axis

- 46 -

B-82135EN/05

MAINTENANCE

Fig. 5.1.1 (b) J2-axis

Fig. 5.1.1 (c) J3-axis

- 47 -

5.ADJUSTMENTS

5.ADJUSTMENTS

MAINTENANCE

Fig. 5.1.1 (d) J2/J3-axis interference angle

- 48 -

B-82135EN/05

B-82135EN/05

MAINTENANCE

Fig. 5.1.1 (e) J4-axis

Fig. 5.1.1 (f) J5-axis

- 49 -

5.ADJUSTMENTS

5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

Fig. 5.1.1 (g) J6-axis

5.1.2

Software Setting
Axis limit software settings are upper and lower motion degree
limitations. The limits can be set for all robot axes and will stop robot
motion if the robot is calibrated.

Procedure Setting Up Axis Limits


Step
1.
2.
3.
4.

Press MENUS.
Select SYSTEM.
Press F1, [TYPE].
Select Axis Limits. You will see a screen similar to the following.

- 50 -

MAINTENANCE

B-82135EN/05

5.ADJUSTMENTS

NOTE
0 indicates the robot does not have these axes.
5. Move the cursor to the axis limit you want to set.

WARNING
Do not depend on J1, J2, and J3 axis limit software
settings to control the motion range of your robot.
Use the axis limit switches or hardstops also;
otherwise, injury to personnel or damage to
equipment could occur.
6. Type the new value using the numeric keys on the teach pendant.
7. Repeat Steps 5 through 6 until you are finished setting the axis
limits.

WARNING
You must turn off the controller and then turn it back
on to use the new information; otherwise, injury to
personnel or damage to equipment could occur.
8. Turn off the controller and then turn it back on again in cold start
mode so the new information can be used.

5.1.3

Hard Stopper and Limit Switch Setting


For the J1-axis, J2-axis and J3-axis, it is possible to re-position
mechanical stoppers. Change the position of the mechanical stoppers
according to the desired movable range. The limit switch-based
movable range can be changed by changing the dog positions. The
dog for the J1 axis is placed in the same position as the mechanical
stopper.
Item

J1-axis
mechanical
stopper,
limit switch
J2-axis
mechanical
stopper

Upper limit
Lower limit
Space between
the upper and
lower limits
Upper limit

Lower limit

Space between
the upper and
lower limits

M-900iA/350

M-900iA/260L

Settable in steps of 7.5 degrees in a range of -135 to +180 degrees


Settable in steps of 7.5 degrees in the range of -180 to +135 degrees
A space of 45 degrees or more is required.

Settable in steps of 15 degrees in the range of -60 to +60 degrees. A


mechanical stopper is also provided at the upper limit +75 degrees of the
standard movable range.
Settable in steps of 15 degrees in the range of -60 to +60 degrees. A
mechanical stopper is also provided at the lower limit -75 degrees of the
standard movable range.
A space of 15 degrees or more is required.

- 51 -

5.ADJUSTMENTS

MAINTENANCE

Item
J2-axis limit
switch

Upper limit
Lower limit

J3-axis (J2+J3)
mechanical
stopper

Space between
the upper and
lower limits
Upper limit

Lower limit

J3-axis (J2+J3)
limit switch

Space between
the upper and
lower limits
Upper limit
Lower limit

Space between
the upper and
lower limits

M-900iA/350

B-82135EN/05

M-900iA/260L

Settable in steps of 15 degrees in the range of -60 to +60 degrees. Also


settable to the upper limit +75 degrees of the standard movable range.
Settable in steps of 15 degrees in the range of -60 to +60 degrees. Also
settable to the lower limit -75 degrees of the standard movable range.
A space of 15 degrees or more is required.

Settable in steps of 15 degrees in the range of -120 to +75 degrees. A


mechanical stopper is also provided at the upper limit +90 degrees of the
standard movable range.
Settable in steps of 15 degrees in the Settable in steps of 15 degrees in the
range of -120 to +75 degrees. A
range of -120 to +75 degrees. A
mechanical stopper is also provided
mechanical stopper is also provided
at the lower limit -121.3 degrees of
at the lower limit -133.4 degrees of
the standard movable range.
the standard movable range.
A space of 15 degrees or more is required.

Settable in steps of 15 degrees in the range of -120 to +75 degrees. Also


settable to the upper limit +90 degrees of the standard movable range.
Settable in steps of 15 degrees in the Settable in steps of 15 degrees in the
range of -120 to +75 degrees. A
range of -120 to +75 degrees. Also
mechanical stopper is also provided
settable to the lower limit - 133.4
at the lower limit -121.3 degrees of
degrees of the standard movable
the standard movable range.
range.
A space of 15 degrees or more is required.

NOTE
If the newly set operation range does not include 0,
it is necessary to change it by zero degree
mastering so that 0 is included.

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B-82135EN/05

MAINTENANCE

Fig. 5.1.3 (a) Mechanical stopper change of J1-axis (option)

- 53 -

5.ADJUSTMENTS

5.ADJUSTMENTS

MAINTENANCE

Fig. 5.1.3 (b) Mechanical stopper change of J2-axis (option)

Fig. 5.1.3 (c) Mechanical stopper change of J3-axis (option)

- 54 -

B-82135EN/05

B-82135EN/05

MAINTENANCE

Fig. 5.1.3 (d) J1-axis dog (option) change

Fig. 5.1.3 (e) J2-axis dog (option) change

- 55 -

5.ADJUSTMENTS

5.ADJUSTMENTS

MAINTENANCE

Fig. 5.1.3 (f) J3-axis dog (option) change

- 56 -

B-82135EN/05

B-82135EN/05

5.2

5.ADJUSTMENTS

MAINTENANCE

ADJUSTING LIMIT SWITCH (OPTION)


Axis limit switches are overtravel switches that, when tripped, cut
power to the servo motors and an operation is stopped. Overtravel
switches for J1-axis, J2-axis and J3-axis and J2/J3 interference angle
are optional.
1. Set the $MOR_GRP.$CAL_DONE system parameter to FALSE.
This disables the motion limit specified by the software. As a
result, the operator can rotate the robot by a jog feed which goes
beyond the motion limit.
2. Loosen the following bolts.
Bolts secure the J1-axis:
Bolts secure the J2-axis:
Bolts secure the J3-axis:
Bolt secure the J2/J3
interference angle:

two M8 x 12
two M4 x 25
two M12 x 20
two M6 x 10
two M12 x 20
two M6 x 10
four M4 x 6

3. Move the limit switch so that the robot activates it at about 0.5
degrees before the stroke end. Step on the dog, and position the
limit switch in such a place that only one of the step-on allowance
indication lines at the tip of the switch is hidden.
4. When the limit switch operates and detects overtravel (OT), the
robot stops, and an error message, OVERTRAVEL, is displayed.
To restart the robot, hold on the SHIFT key and press the RESET
key. Then, while holding on the SHIFT key, move the adjusting
axis off the OT limit switch by jogging in joint mode.
5. Check that the robot also activates the limit switch when the robot
is approx. 0.5 degrees from the opposite stroke end in the same
way as above. If the limit switch does not operate at the position,
adjust the position of the switch again.
6. Set the $MOR_GRP.$CAL_DONE system parameter to TRUE.
7. Turn off the power, and then turn it on again to restart the
controller.

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5.ADJUSTMENTS

MAINTENANCE

Fig. 5.2 (a) Adjusting J1-axis limit switch (option)

Fig. 5.2 (b) Adjusting J2-axis limit switch (option)

- 58 -

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B-82135EN/05

MAINTENANCE

Fig. 5.2 (c) Adjusting J3-axis limit switch (option)

Fig. 5.2 (d) Adjusting J2/J3-axis limit switch (option)

- 59 -

5.ADJUSTMENTS

5.ADJUSTMENTS

5.3

MAINTENANCE

B-82135EN/05

MASTERING
Mastering is an operation performed to associate the angle of each
robot axis with the pulse count value supplied from the absolute pulse
coder connected to the corresponding axis motor. To be specific,
mastering is an operation for obtaining the pulse count value
corresponding to the zero position.

5.3.1

General
The current position of the robot is determined according to the pulse
count value supplied from the pulse coder on each axis. Mastering is
factory-performed. It is unnecessary to perform mastering in daily
operations. However, mastering becomes necessary after:
-

Motor replacement
Pulse coder replacement
Reducer replacement
Cable replacement
Batteries for pulse count backup in the mechanical unit have gone
dead.

CAUTION
Robot data (including mastering data) and pulse
coder data are backed up by their respective backup
batteries. Data will be lost if the batteries go dead.
Replace the batteries in the control and mechanical
units periodically. An alarm will be issued to warn the
user of a low battery voltage.

Mastering method
Table 5.3.1 Types of Mastering
Fixture position mastering
Zero-position mastering (eye
mark mastering)
Quick mastering

Single-axis mastering
Mastering data entry

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.
This is performed at a user-specified position. The corresponding count value is
obtained from the rotation speed of the pulse coder connected to the relevant motor
and the rotation angle within one rotation. Simplified mastering uses the fact that the
absolute value of a rotation angle within one rotation will not be lost.
This is performed for one axis at a time. The mastering position for each axis can be
specified by the user. This is useful in performing mastering on a specific axis.
Mastering data is entered directly.

Once mastering is performed, it is necessary to carry out positioning,


or calibration. Positioning is an operation in which the control unit
reads the current pulse count value to sense the current position of the
robot.
- 60 -

MAINTENANCE

B-82135EN/05

5.ADJUSTMENTS

CAUTION
If mastering is performed incorrectly, the robot may
behave unexpectedly. This is very dangerous.
Therefore, the positioning screen is designed to
appear only when the $MASTER_ENB system
variable is 1 or 2. After performing positioning, press
F5 [DONE] on the positioning screen. The
$MASTER_ENB system variable is reset to 0
automatically, thus hiding the positioning screen.
It is recommended that you back up the current
mastering data before performing mastering.
NOTE
It is recommended that you back up the current
mastering data before performing mastering.

5.3.2

Resetting Alarms and Preparing for Mastering


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

Alarm displayed
Servo 062 BZAL or Servo 075 Pulse mismatch

Procedure Preparing the Robot for Mastering


Step
1. Display the positioning menu by following Steps 1 to Steps 6.
1. Press the screen selection key.
2. Press [0 NEXT] and select [6 SYSTEM].
3. Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4. Place the cursor on $MASTER_ENB, then key in 1 and press
[ENTER].
5. Press F1 [TYPE], and select [Master/Cal] from the menu.
6. Select the desired mastering type from the [Master/Cal] menu.
2. To reset the Servo 062 BZAL alarm, follow Steps 1 to 5.
1. Press the screen selection key.
2. Press [0 NEXT] and select [6 SYSTEM].
3. Press F1 [TYPE], and select [Master/Cal] from the menu.
4. Press the F3 RES_PCA, then press F4 [TRUE].
5. Switch the controller power off and on again.
3. To reset the Servo 075 Pulse mismatch alarm, follow Steps 1 to 3.
1. When the controller power is switched on again, the message
Servo 075 Pulse mismatch appears again.
2. Rotate the axis for which the message mentioned above has
appeared through 10 in either direction.
3. Press [FAULT RESET]. The alarm is reset.
- 61 -

5.ADJUSTMENTS

5.3.3

MAINTENANCE

B-82135EN/05

Mastering to a Fixture (Master Position Master)


Fixture position mastering is performed using a mastering fixture.
This mastering is carried out in the predetermined fixture position.
Fixture position mastering is accurate because a dedicated mastering
fixture is used. Fixture position mastering is factory performed.
It is unnecessary to perform it in daily operations. When mastering the
robot, arrange the robot to meet the following conditions.
-

Make the robot mounting base horizontal. (Set the robot mounting
face so that the levelness of the entire surface is 1 mm or less.)
Remove the hand and other parts from the wrist.
Set the robot in the condition protected from an external force.

1. Assembling the fixture base


Assemble the fixture base as shown in Fig. 5.3.3 (a).
See 2) for the mount of the dial gauges.

Fig. 5.3.3 (a) Assembling fixture base

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B-82135EN/05

MAINTENANCE

5.ADJUSTMENTS

2. Adjust the dial gauge to 3.00 mm using the calibration block, and
tighten it with M5 bolt as shown in Fig. 5.3.3 (b). (Do not tighten
the bolt too strongly or the dial indicator will be broken.)

Fig. 5.3.3 (b) Mounting dial indicator

3. Mount the fixture on the J1-axis base with bolts as shown in Fig.
5.3.3 (c).

Fig. 5.3.3 (c) Mounting fixture base

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5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

4. Mount the fixture to the wrist flange as shown in Fig. 5.3.3 (d).

Fig. 5.3.3 (d) Mounting fixture to wrist

Mastering
1.
2.
3.
4.

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

5. Release brake control, and jog the robot into a posture for
mastering.
See the Fig. 5.3.3 (e) for the mastering posture.
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MAINTENANCE

5.ADJUSTMENTS

NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM GROUP.SV_ OFF_ ENB[*]: FALSE
(For all axes)
After changing the system variables, switch the
control unit power off and on again.
6. Select Fixture Position Master.
7. Press F4, YES. Mastering will be performed automatically.
Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.
8. After positioning is completed, press F5 [DONE].

CAUTION
No check is made on the axis movable range during
mastering. Be very careful when running the robot.
Continuing axis movement may result in the
mechanical stopper being bumped.

Fig. 5.3.3(e) Mastering attitude (M-900iA/350)

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5.ADJUSTMENTS

MAINTENANCE

Fig. 5.3.3 (f) Mastering attitude (M-900iA/260L)

- 66 -

B-82135EN/05

MAINTENANCE

B-82135EN/05

5.3.4

5.ADJUSTMENTS

Zero Degree Mastering


Zero-position mastering (eye mark mastering) is performed with all
axes set at the 0-degree position. A zero-position mark (eye mark) is
attached to each robot axis. This mastering is performed with all axes
set at the 0-degree position using their respective eye marks.
Zero-position mastering involves a visual check. It cannot be so
accurate. It should be used only as a quick-fix method.

Procedure Mastering to Zero Degrees


Step
1.
2.
3.
4.

Press MENUS.
Select NEXT and press SYSTEM.
Press F1, [TYPE].
Select Master/Cal.

5. Release brake control, and jog the robot into a posture for
mastering.

NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM GROUP.SV_ OFF ENB[*]: FALSE (for all
axes)
After changing the system variables, switch the
control unit power off and on again.
6. Select Zero Position Master.
7. Press F4, YES. Mastering will be performed automatically.
Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.

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5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

Table 5.3.4 Attitude with position marks aligned


Axis
Position
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis

Fig. 5.3.4 (a) Zero degree position arrow mark for each axis

- 68 -

0 deg
0 deg
0 deg
0 deg
0 deg
0 deg

MAINTENANCE

B-82135EN/05

5.3.5

5.ADJUSTMENTS

Quick Mastering
Quick mastering is performed at a user-specified position. The
corresponding count value is obtained from the rotation speed of the
pulse coder connected to the relevant motor and the rotation angle
within one rotation. Quick mastering uses the fact that the absolute
value of a rotation angle within one rotation will not be lost.
Quick mastering is factory-performed at the position indicated in
Table. 5.3.4 Do not change the setting unless there is any problem. If
it is impossible to set the robot at the position mentioned above, it is
necessary to re-set the simplified mastering reference position using
the following method. (It would be convenient to set up a marker that
can work in place of the eye mark.)

CAUTION
1. Quick mastering can be used, if the pulse count
value is lost, for example, because a low voltage
has been detected on the backup battery for the
pulse counter.
2. Quick mastering cannot be used, after the pulse
coder is replaced or after the mastering data is lost
from the robot control unit.

Procedure Recording the Quick Master Reference Position


Step
1. Select SYSTEM.
2. Select Master/Cal.

3. Release brake control, and jog the robot to the quick mastering
reference position.
4. Move the cursor to SET QUICK MASTER REF and press
ENTER. Press F4, YES.

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5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

CAUTION
If the robot has lost mastery due to mechanical
disassembly or repair, you cannot perform this
procedure. In this case, master to a fixture or master
to zero degrees to restore robot mastery.

Procedure Quick Mastering


Step
1. Display the Master/Cal screen.

2. Release brake control, and jog the robot to the quick mastering
reference position.

3. Move the cursor to QUICK MASTER and press ENTER. Press F4,
YES. Quick mastering data is memorized.
4. Move the cursor to CALIBRATE and press ENTER. Calibration
is executed. Calibration is executed by power on again.
5. After completing the calibration, press F5 Done.

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MAINTENANCE

B-82135EN/05

5.3.6

5.ADJUSTMENTS

Single Axis Mastering


Single axis mastering is performed for one axis at a time. The
mastering position for each axis can be specified by the user. Single
axis mastering can be used, if mastering data for a specific axis is lost,
for example, because a low voltage has been detected on the pulse
counter backup battery or because the pulse coder has been replaced.

Table 5.3.6 Items Set in Single Axis Mastering


Item
Description
Current position
(Actual axis)
Mastering position (Matra pos)

SEL

ST

- 71 -

The current position of the robot is displayed


for each axis in degree units.
A mastering position is specified for an axis to
be subjected to single axis mastering. It would
be convenient to set to it to the 0 position.
This item is set to 1 for an axis to be
subjected to single axis mastering. Usually, it
is 0.
This item indicates whether single axis
mastering has been completed for the
corresponding axis. It cannot be changed
directly by the user. The value of the item is
reflected in $EACHMST_DON (1 to 9).
0 : Mastering data has been lost. Single axis
mastering is necessary.
1 : Mastering data has been lost.
(Mastering has been performed only for the
other interactive axes.)
Single axis mastering is necessary.
2 : Mastering has been completed.

5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

Procedure Mastering a Single Axis


Step
1. Select SYSTEM.
2. Select Master/Cal.

3. Select 4, Single Axis Master. You will see a screen similar to the
following.

4. Move the cursor to the SEL column for the unmastered axis and
press the numeric key 1. Setting of SEL is available for one or
more axes.
5. Turn off brake control as required, and then jog the robot to the
mastering position.
6. Enter axis data for the mastering position.

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MAINTENANCE

5.ADJUSTMENTS

7. Press F5 [EXEC]. Mastering is performed. Therefore, SEL is reset


to 0, and ST is re-set to 2 or 1.

8. When single axis mastering is completed, press the previous page


key to resume the previous screen.

9. Select [6 CALIBRATE], then press F4 [YES]. Positioning is


performed. Alternatively, switch the power off and on again.
Positioning is performed.
10. After positioning is completed, press F5 [DONE].

- 73 -

5.ADJUSTMENTS

5.3.7

MAINTENANCE

B-82135EN/05

Mastering Data Entry


This function enables mastering data values to be assigned directly to
a system variable. It can be used if mastering data has been lost but the
pulse count is preserved.

Mastering data entry method


Step
1. Press MENUS, then press NEXT and select SYSTEM.
2. Press F1, [TYPE]. Select [Variables]. The system variable screen
appears.

3. Change the mastering data. The mastering data is saved to the


$DMR_GRP.$MASTER_COUN system variable.

4. Select $DMR_GRP.

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MAINTENANCE

5.ADJUSTMENTS

5. Select $MASTER_COUN, and enter the mastering data you have


recorded.

6. Press the PREV key.


7. Set $MASTER_DONE to TRUE.

8. Display the positioning screen, and select [6 CALIBRATE], then


press F4 [YES].
9. After completing calibration, press F5 [DONE].

- 75 -

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

REPLACING PARTS
This section describes the replacement procedures for the major
components of the mechanical section. When replacing mechanical
components, be sure to follow the respective procedures. See Section
8 for how to replace the cables and limit switches.

- 76 -

6.1

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

NOTE FOR PART REPLACEMENT


Once motors, reducers, and gears are replaced, mastering becomes
necessary. Perform mastering according to Section 5.3 after any of
these components are replaced. Be very careful when carrying and
assembling the heavy components listed below.

Table 6.1 Weight of the main parts


Component
Servo motors

Reducers

Weight (approximate)
M1
M2, M3
M4, M5, M6
J1-axis
J2-axis
J3-axis
J4-axis

30kg
35kg
15kg
160kg
95kg
95kg
30kg
90kg
150kg

J2-axis table
J2-axis arm
Link
J3-axis arm

M-900iA/350
M-900iA/260L

115kg
85kg
105kg
110kg

M-900iA/350

365kg

Wrist unit
J3-axis casing-wrist unit
J2-axis arm-wrist unit
J2-axis base-wrist unit

M-900iA/260L

385kg

M-900iA/350

515kg

M-900iA/260L

535kg

M-900iA/350
M-900iA/260L

1195kg
1215kg
180kg

Controller

Remarks

J1 motor is not included.

Link is not included.


J1 motor and J2 table are
not included.

In case of reusing sealbolts for M-900iA, observe following notes


strictly. (If possible, change them to new sealbolts)
1. Apply LOCTITE No.242 to the reusing sealbolts. (However, seal
tape needs to be wound around the seal bolts used as a plug.)
2. Notice the following note.
- Remove excessive bits of sealant on the sealbolt.

NOTE
When applying Loctite to the important bolt tightening
points, make sure that it is applied to the entire
longitudinal portion in the engaging section of the
female threads. If it is applied to the male threads,
the bolts may be loosened because sufficient 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.

- 77 -

6.REPLACING PARTS

6.2

MAINTENANCE

B-82135EN/05

REPLACING J1-AXIS MOTOR (M1) AND REDUCER

1) Replacing J1-axis motor (M1)


Remove
1. Turn off the power.
2. Remove the pulse coder connector cover (2). (The cover turns
together with the bolt, possibly causing damage to the connector.
Hold the cover to prevent it from turning.)
3. Remove three connectors of the motor (1).
4. Remove four motor mounting bolts (4) and then remove the
washers (5).
5. Pull out the motor (1) from the 2 base vertically, while being
careful not to scratch the surface of the gear (7) teeth.
6. Remove the bolt (12) and washer (11) from the shaft of the motor
(1).
7. Pull off the gear (7) with bearing (9), C ring (8,10) from the shaft
of the motor (1).
8. Remove the nut (6) from the shaft.
Assembling
1. Polish the flange surface of the motor (1) using an oil stone.
2. Mount the nut (6) on the shaft of the motor (1).
3. Attach the gear (7) with bearing (9), C ring (8, 10) to the shaft of
the motor (1).
Note)
Before attaching the gear (7) to the motor (1), attach the bearing
(9) and the C rings (8, 10) to the gear (7) by using the fixture
(A290-7324-X924). (See Fig. 6.2 (b))
4. Mount the bolt (12) and the washer (11) on the motor (1).
5. Mount the motor (1) on the 2 base vertically, while being careful
not to scratch the surface of the gear (7) teeth. When mounting,
make sure that the O-ring (13) is in the prescribed place.
6. Attach the four motor mounting bolts (4) and washers (5).
7. Attach the three connectors to the motor (1).
8. Attach the pulse coder connector cover (2).
9. Perform mastering. (See the Section 5.3 for mastering.)

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6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

Name
MOTOR

Specifications
A06B-0268-B605#S000

Qty
1

Loctite

COVER

A290-7324-X101

BOLT

A6-BA-8X12

BOLT

A6-BA-12X30

WASHER

A97L-0001-0823#M12H

NUT

A290-7324-X151

1 LT242

J1 GEAR1

A290-7327-X221

C RING

A6-CJR-45

J1 BEARING A97L-0001-0195#09D000A
1

10

C RING

A6-CJR-45

11

WASHER

A97L-0001-0823#M8H

12

BOLT

A6-BA-8X20

1 LT242

13

O RING

JB-OR1A-G125

Torque N-m (kgf-m)

Fig. 6.2 (a) Replacing J1-axis motor (M1)

- 79 -

118(12)

27.5(2.8)

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

Fig. 6.2 (b) Bearing Presser

2) Replacing J1-axis reducer


Remove

WARNING
The special tools listed below are required to replace
the J1-axis reducer. Be sure to prepare the special
tools.
Name

Specifications

Guide pin
Punch
Guide pin
Adapter
Bolt
Nut
Eyebolt

A290-7324-X921
A290-7324-X922
A290-7324-X923
A290-7327-X910
A6-BA-16x35
A6-N1-20S
JB-BEY-20

Qty
2
1
2
2
12
4
4

1. Remove loads such as the hand and workpiece from the wrist.
2. Ensure that the robot assumes the attitude as J1-axis = 0, J2-axis
= -75, J3-axis = +9, J4-axis = option, J5-axis = 0, J6-axis =
option, then turn off the power.
3. Remove the J1 motor (2) according to the previous item.
4. Detach the cable for connection between the control unit and the
robot, and remove the connector panel from the back of the J1
base (18), then detach the connector.
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MAINTENANCE

6.REPLACING PARTS

5. Remove the cable clamp in the J1 base (18) and the cable clamp
on the table (6) so that the cable is disconnected from the J1 unit
when the unit above the J2-axis base (1) is lifted up.
6. According to Fig. 6.2 (f) and (f), install the hanging fixtures onto
the robot to enable the robot to be hung.
7. Remove the J2-axis base (1) fixing bolt and remove the unit above
the J2-axis base (1) from the table (6) by lifting it up with a crane,
with due attention to the cable.
8. Remove the cable fixing bolt (7) and the washer (8) and then
remove the table (6) and the J1 gear 2 (11) (with the bearing (10)).
9. Remove the reducer mounting bolt (13) and washer (14), then
remove the reducer (16) from the J1 base (18). The J1-axis
reducer and J1 base are positioned with the spring pin (15). So,
remove the J1-axis reducer by using the J1-axis reducer removal
tap.
Assembling
1. Polish the mounting face of the J1 base reducer with an oilstone.
2. After attaching the O-ring (17) to the reducer (16), mount the
reducer onto the J1 base by using the guide pin
(A290-7324-X921), and position the reducer by striking the
spring pin (15) with the punch (A290-7324-X922). Then, fasten
the reducer with the reducer mounting bolt (13) (Apply LT262
and specify the torque.) and washer (14).
3. Apply a sealing agent to the shaft surface of the reducer according
to Section 6.6, SEALANT APPLICATION and Fig. 6.2 (e).
4. Attach the O-ring (12). Before attachment, replace the O-ring with
a new one.
5. Attach the J1 gear 2 (11) (with the bearing (10)).
6. Attach the table (6) and fix it with the table mounting bolt (7)
(with LT262 applied and the torque specified) and washer (8). At
this time, make sure that the oil seal (9) is placed in the specified
position and the lip does not curl up.
7. Place the unit above the J2-axis base onto the table (6) using the
guide pin (A290-7324-X923) with due attention to the cables.
Then, secure J2-axis base with the bolt. See Fig. 6.2 (d) for the
locations where to insert the guide pins.
8. Lay the cables neatly and secure the cable clamp in the J1 base
(18) and the cable clamp on the table (6).
9. Attach the connector to the connector panel on the back of the J1
base (18) and secure it on the robot.
10. Fasten the J1 motor (2) according to the previous item.
11. Connect the cable for connection between the control unit and the
robot.
12. Apply grease (See Section 3.1, REPLACING GREASE OF THE
DRIVE MECHANISM).
13. Perform mastering (See Section 5.3, MASTERING).

- 81 -

6.REPLACING PARTS

MAINTENANCE

Name
1

Specifications

B-82135EN/05

Qty

Loctite

J2 BASE

A290-7327-X301

MOTOR

Fig.6.2(a)

BOLT

Fig.6.2(a)

WASHER

Fig.6.2(a)

O-RING

Fig.6.2(a)

TABLE

A290-7327-X202

BOLT

A6-BA-16X85

19

WASHER

A97L-0001-0823#M16H

19

Torque N-m(kgf-m)

OIL SEAL

A98L-0040-0047#13516514

10

J1 BEARING2

A97L-0001-0192#3200000

11

J1 GEAR2

A290-7327-X222

12

O-RING

A290-7327-X206

13

BOLT

A6-BA-12X95

24

14

WASHER

A97L-0001-0823#M12H

24

15

SPRING PIN

A6-PS-12X30

16

REDUCER

A97L-0218-0347#500C-30

17

O-RING

JB-OR1A-G460

18

J1 BASE

A290-7327-X201

LT262

LT262

Fig. 6.2 (c) Replacing J1-axis reducer

- 82 -

318.5 (32.5)

128.4 (13.1)

B-82135EN/05

MAINTENANCE

Fig. 6.2 (d) Insert location of the guide pins and the spring pins

Fig. 6.2 (e) Replacing J1-axis reducer

- 83 -

6.REPLACING PARTS

6.REPLACING PARTS

MAINTENANCE

Fig. 6.2 (f) Replacing J1-axis reducer (for M-900iA/350)

Fig. 6.2 (g) Replacing J1-axis reducer (for M-900iA/260L)

- 84 -

B-82135EN/05

B-82135EN/05

6.3

MAINTENANCE

6.REPLACING PARTS

REPLACING J2-AXIS MOTOR (M2) AND REDUCER

1) Replacing the J2-axis motor (M2)


Remove
1. Place the robot in the posture shown in Fig. 6.3 (b), and hoist it
using a sling.

WARNING
When its J2-axis motor is removed, its weight, can
cause the J2-axis arm to move extensively unless
the robot is in a specified attitude, resulting in a very
dangerous situation. If it is impossible to keep the
robot in a specified attitude when its J2-axis motor is
replaced, fasten the arm so firmly that it will not
move.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification
can be used to fasten the J2-axis arm. Before
starting to replace the motor, install the stopper and
jog-feed the arm to get it sufficiently close to the
stopper.
2. Turn off the power.
3. Remove the four pulse coder connector cover (2). (The cover
turns together with the bolt, possibly causing damage to the
connector. Hold the cover to prevent it from turning.)
4. Detach the three connectors from the J2-axis motor (1).
5. Remove the four motor mounting seal bolts (4) and washers (5).
6. Pull out the J2-axis motor (1) horizontally, while being careful not
to damage the surface of the gear teeth.
7. Remove the bolt (9) and washer (8), then dismount the input gear
(7), nut (6).
Assembling
1. Polish the flange surface of the J2-axis motor (1) using an oil
stone.
2. Mount the nut (6).
3. Mount and fasten the input gear (7) with bolt (8) and washer (9).
4. Mount the J2-axis motor (1) horizontally, while being careful not
to damage the surface of the gear teeth. Replace the O-ring (10)
with a new one, and put the new O-ring in place.
5. Attach the four motor mounting seal bolts (4) and washers (5).
6. Attach the three connectors to the J2-axis motor (1).
7. Attach the pulse coder connector cover (2)
8. Apply grease.
9. Perform mastering.
- 85 -

6.REPLACING PARTS

MAINTENANCE

Name

Specifications

B-82135EN/05

Qty

MOTOR

A06B-0272-B605#S000

COVER

A290-7324-X101

BOLT

A6-BA-8X12

BOLT

A6-BA-12X25

WASHER

A97L-0001-0823#M12H
M-900iA/350

NUT
M-900iA/260L

Loctite

Torque
N-m (kgf-m)

It is included in the spec. of


INPUT GEAR
A97L-0218-0363#253
It is included in the spec. of
INPUT GEAR
A97L-0218-0363#227

M-900iA/350

A97L-0218-0363#253

M-900iA/260L

A97L-0218-0363#227

1 LT242

INPUT
GEAR

WASHER

A30L-0001-0048#8M

BOLT

A6-BA-8X70

1 LT242

10

O-RING

JB-OR1A-G125

Fig. 6.3 (a) Replacing J2-axis motor (M2)

- 86 -

118 (12)

27.5 (2.8)

MAINTENANCE

B-82135EN/05

6.REPLACING PARTS

Fig.6.3 (b) J2-axis motor (M2) and reducer replacing posture

2) Replacing J2-axis reducer


Disassembling
1. Detach all devices of the wrist flange and place the arm in the
posture shown in Fig. 6.3 (b) and hoist it using a sling.
2. Switch off the power.
3. Detach all of the cables connected to the motor for J2-axis.
4. Remove the J2 motor (1) according to the procedure described in
the previous item.
5. Remove only three sets of bolt (6) and washer (7) that are
separated each other and then insert the guide pins
(A290-7324-X923) instead. After inserting the guide pins, remove
the remaining bolts (6) and washers (7).
6. Remove the bolt (8) and washer (9) and remove the bracket (11).
Since the bracket (11) and J2-axis base (16) are positioned by the
- 87 -

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

spring pin (10), remove them using the bracket extract threaded
holes.
7. Remove the cap (20), grease nipple (19), and pipe (18) from the
reducer (14).
8. Remove only three sets of bolt (12) and washer (13) that are
separated each other and insert the guide pins (A290-7324-X921)
instead. After inserting the guide pins, remove the remaining bolts
(12) and washers (13).
9. Remove the reducer (14).
Assembling
1. Attach the oil seal (5) to a new reducer (14) using the punching
fixture (A290-7324-X924) and then polish the surface on which
the reducer (14) is mounted with oil stone.
2. Attach the O-ring (15) to the reducer (14), lift it up with a crane,
mount it on the J2 base (16) with the guide pins
(A290-7824-X921), and fix it with the bolts (12) (with LT262
applied and the torque specified) and washers (13). At this time,
first insert bolts (12) and washers (13) into the holes in which no
guide pins (A290-7324-X921) are set (A290-7324-X921) and
tighten them. Next, remove the guide pins, insert the bolts (12)
and washers (13) instead, and tighten them.
3. Attach the pipe (18) to the reducer (14) and then attach the grease
nipple (19) and cap (20).
4. Attach the bracket (11) to the reducer (14) with the guide pins
(A290-7824-X923) and secure it with the bolts (6) (with LT262
applied and the torque specified) and washers (7). At this time,
first insert bolts (6) and washers (7) into the holes in which no
guide pins (A290-7324-X923) are set and tighten them. Next,
remove the guide pins, insert the bolts (6) and washers (7) instead,
and tighten them.
5. Adjust the phases of the bracket (11) and J2-axis base (16) with
the crane and make positioning by hitting the spring pin (10) with
the punching (A290-7324-X922). Perform tightening with the bolt
(8) (Applying LT262 and specifying the torque) and washer (9).
6. Mount the J2-axis motor (1) as described above.
7. Connect the cables leading to the J2-axis motor (1) and optional
cables.
8. Apply grease.
9. Perform mastering.

- 88 -

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

Name
1 MOTOR

Specifications

Qty

Fig.6.3(a)

Loctite

2 BOLT

Fig.6.3(a)

3 WASHER

Fig.6.3(a)

4 O-RING

Fig.6.3(a)

5 OIL SEAL

A98L-0040-0185

6 BOLT

A6-BA-16X50

19 LT262

7 WASHER

A97L-0001-0823#M16H

19

8 BOLT

A6-BA-16X40

12 LT262

9 WASHER

A97L-0001-0823#M16H

12

10 SPRING PIN

A6-PS-12X30

11 BRACKET

A290-7327-X306

12 BOLT

A6-BA-12X65

30 LT262

13 WASHER

A97L-0001-0823#M12H

30

14 REDUCER

Torque N-m (kgf-m)

319 (32.5)
319 (32.5)

2
1

M-900iA/350

A97L-0218-0348#550F-253

M-900iA/260L

A97L-0218-0348#550F-227

15 O-RING

JB-OR1A-G340

16 J2 BASE

A290-7327-X301

1
1

17 J2 ARM

A290-7327-X315

18 PIPE

A290-7327-X346

19 GREASE NIPPLE

A97L-0218-0013#A610

20 CAP

A290-7120-X219

Fig. 6.3 (c) Replacing J2-axis reducer

- 89 -

128 (13.1)

6.REPLACING PARTS

6.4

MAINTENANCE

B-82135EN/05

REPLACING J3-AXIS MOTOR (M3) AND REDUCER

1) Replacing J3-axis motor


Disassembling
1. Ensure that the robot assumes the attitude shown in Fig. 6.4 (b)
and hang the robot with a sling.

WARNING
It is very dangerous to remove J3-axis motor when
the robot is not set in the specified posture. This is
because the J3-axis arm may be greatly moved by
gravity. If the robot cannot be set in the specified
posture during replacement of the J3-axis motor, be
sure to fix the arm securely.
<Axis constraint by the operation range modification
option>
An optional stopper for operation range modification
can be used to fasten the J3-axis arm. Before
starting to remove the motor, install the stopper, and
jog-feed the arm to get it sufficiently close to the
stopper.
2. Turn off the power supply.
3. Remove the pulse coder connector cover (2). (At this time, hold
the cover so that it does not rotate. Otherwise, it rotates together
with the bolt, breaking the connector.)
4. Detach the three connectors from the J3-axis motor (1).
5. Remove the four motor mounting seal bolts (4) and washers (5).
6. Pull out the J3-axis motor (1) horizontally, while being careful not
to damage the surface of the gear teeth.
7. Remove the bolt (9) and washer (8), then dismount the input gear
(7), nut (6).
Assembling
1. Polish the flange surface of the J3-axis motor (1) using an oil
stone.
2. Mount the nut (6).
3. Mount the input gear (7) and fasten with bolt (9) and washer (8).
4. Mount the J3-axis motor (1) horizontally, while being careful not
to damage the surface of the gear teeth. Replace the O-ring (10)
with a new one, and put the new O-ring in place.
5. Attach the four motor mounting bolts (4) and washers (5).
6. Attach the three connectors to the J3-axis motor (1).
7. Attach the pulse coder connector cover (2).
8. Apply grease.
9. Perform mastering.

- 90 -

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

Name

Specifications

Qty

MOTOR

A06B-0272-B605#S000

COVER

A290-7324-X101

BOLT

A6-BA-8X12

BOLT

A6-BA-12X25

WASHER

A97L-0001-0823#M12H
M-900iA/350

NUT
M-900iA/260L

Loctite

Torque
N-m (kgf-m)

It is included in the spec. of


INPUT GEAR
A97L-0218-0363#253
It is included in the spec. of
INPUT GEAR
A97L-0218-0363#267

1 LT242

INPUT
GEAR

M-900iA/350

A97L-0218-0363#253

M-900iA/260L

A97L-0218-0363#267

WASHER

A30L-0001-0048#8M

BOLT

A6-BA-8X70

1 LT242

10

O-RING

JB-OR1A-G125

Fig. 6.4 (a) Replacing J3-axis motor (M3)

- 91 -

118 (12)

27.5 (2.8)

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

Fig. 6.4 (b) Changing posture of the J3-axis motor (M3) and reducer

2) Replacing J3-axis reducer


Disassembling
1. Detach all devices of the wrist flange and control the attitude as
shown in Fig. 6.4 (b), then attach the sling to hang the unit.
2. Turn off the power supply.
3. Detach all cables leading to the J3-axis motor.
4. Remove the J3-axis motor (1) as described above.
5. Remove only three sets of bolt (6) and washer (7) that are
separated each other and insert the guide pins (A290-7324-X923)
instead. After inserting the guide pins, remove the remaining bolts
(6) and washers (7).
6. Remove the bolts (8) and washers (9) and remove the bracket (11).
Since the bracket (11) and J2-axis base (16) are positioned by the
spring pin (10), remove them using the bracket extract threaded
holes.
7. Remove the cap (20), grease nipple (19), and pipe (18) from the
reducer (14).
8. Remove only three sets of bolt (12) and washer (18) that are
separated each other and insert the guide pins (A290-7324-X921)
instead. After inserting the guide pins, remove the remaining bolts
(12) and washers (13).
9. Remove the reducer (14).
- 92 -

B-82135EN/05

MAINTENANCE

6.REPLACING PARTS

Assembling
1. Attach the oil seal (5) to a new reducer (14) using the punching
fixture (A290-7324-X924) and then polish the surface on which
the reducer (14) is mounted with oil stone.
2. Attach the new O-ring (15) to the reducer (14), lift it up with a
crane, mount it on the J2 base (16) with the guide pins
(A290-7824-X921), and fix it with the bolts (12) (with LT262
applied and the torque specified) and washers (13). At this time,
first insert bolts (12) and washers (13) into the holes in which no
guide pins (A290-7324-X921) are set and tighten them. Next,
remove the guide pins, insert the bolts (12) and washers (13)
instead, and tighten them.
3. Attach the pipe (18) to the reducer (14) and then attach the grease
nipple (19) and cap (20).
4. Attach the bracket (11) to the reducer (14) with the guide pins
(A290-7324-X923) and secure it with the bolts (6) (with LT262
applied and the torque specified) and washers (7). At this time,
first insert bolts (6) and washers (7) into the holes in which no
guide pins (A290-7324-X923) are set and tighten them. Next,
remove the guide pins, insert the bolts (12) and washers (13)
instead, and tighten them.
5. Adjust the phases of the bracket (11) and J2-axis base (16) with
the crane and make positioning by hitting the spring pin (10) with
the punching (A290-7324-X922). Perform tightening with the bolt
(8) (Applying LT262 and specifying the torque) and washer (9).
6. Mount the J3-axis motor (1) as described above.
7. Attach the cables leading to the J3-axis motor (1) and optional
cables.
8. Apply grease.
9. Perform mastering.

- 93 -

6.REPLACING PARTS

MAINTENANCE

Name
1 MOTOR
2 BOLT

Specifications

B-82135EN/05

Qty

Fig 6.4(a)

3 WASHER
4 O-RING

Fig 6.4(a)

Fig 6.4(a)

5 OIL SEAL
6 BOLT

A98L-0040-0185

A6-BA-16X50

19 LT262

A97L-0001-0823#M16H

19

A6-BA-16X40

12 LT262

9 WASHER
10 SPRING PIN

A97L-0001-0823#M16H

12

11 BRACKET
12 BOLT

A290-7327-X306
A6-BA-12X65

30 LT262

13 WASHER

A97L-0001-0823#M12H

30

14 REDUCER
15 O-RING
16 J2 BASE

A6-PS-12X30

M-900iA/350

Torque
N-m (kgf-m)

Fig 6.4(a)

7 WASHER
8 BOLT

Loctite

319 (32.5)
319 (32.5)

2
1

A97L-0218-0348#550F-253

M-900iA/260L
A97L-0218-0348#550F-267
JB-OR1A-G340
A290-7327-X301

1
1
1

17 LINK

A290-7327-X317

18 PIPE

A290-7327-X346

19 GREASE NIPPLE

A97L-0218-0013#A610

20 CAP

A290-7120-X219

Fig. 6.4 (c) Replacing the J3-axis reducer

- 94 -

128 (13.1)

B-82135EN/05

6.5

MAINTENANCE

6.REPLACING PARTS

REPLACING THE WRIST AXIS MOTORS (M4, M5, AND


M6), WRIST UNIT AND J4 AXIS REDUCER

1) Replacing the Wrist Axis Motors (M4, M5, and M6)


The following describes the procedure for replacing wrist axis motors.
For convenience, the procedure is provided for each of three motors,
but use only the procedure for the motor to be replaced.
Disassembling
1. Place the wrist in a posture in which no load is applied to the wrist
axis.
2. Switch off the power.
3. Detach the three connectors from the motor (8) for J4-axis, the
motor (15) for J5-axis and the motor (1) for J6-axis.
4. Remove the motor mounting bolts (2) and washers (3).
5. Pull out the motor (8), (15) and (1), while being careful not to
damage the surface of the gear teeth.
6. In case of J4-axis motor (8), remove the nut (13) and washer (12),
and dismount the gear J41 (11) (with bearing (10) and C ring (9)).
In case of J5-axis motor (15) remove the nut (18) and washer (17),
and dismount the gear J42 (16). In case of J6-axis, motor (1)
remove the nut (6) and washer (5) and dismount the gear J43 (4).
Assembling
1. Polish the flange surface of the motor (8), (15) and (1) using an oil
stone.
2. In case of J4 motor (8), mount gear J41 (11) (with bearing (10)
and C ring (9)) with the washer (12) and nut (13).
Note) Before attaching the gear J41 (11) to the motor (8), use the
fixture A290-7321-X947 to attach the bearing (10) and Cring (9)
to the gear J41 (11).
In case of J5-axis motor, fasten the gear J42 (16) with the washer
(17) and nut (18).
In case of J6-axis, motor (1) fasten the gear J43 (4) with the
washer (5) and nut (6).
3. Mount the motor (8), (15) and (1), while being careful not to
damage the surface of the gear teeth. When mounting, make sure
that the O-ring (14), (19) and (7) is in the prescribed place. Also,
be sure to orient the motor (1) correctly.
4. Attach the motor mounting bolts (2) and washers (3).
5. Attach the three connectors to the motor (8), (15) and (1).
6. Apply grease.
7. Perform mastering.

NOTE
- When tightening the nut (15), hold the gear (13)
with a 30x32mm or 32x36mm spanner (Thickness
is 14mm or less).
- To install a motor, an M8 T-shaped hexagonal
wrench not shorter than 270mm is required.
- 95 -

6.REPLACING PARTS

MAINTENANCE

Name

Specifications

B-82135EN/05

Qty

MOTOR

A06B-0238-B605#S000

BOLT

A6-BA-8X20

WASHER

A97L-0001-0823#M8H

Loctite

Torque
N-m (kgf-m)

GEAR J61

A290-7327-X425

WASHER

A6-WB-10S

NUT

A6-N1-10X1.25S-M-N1

1 LT242

O-RING

JB-OR1A-G105

MOTOR

A06B-0238-B605#S000

C-RING

A6-CJR-30

10

BEARING

A97L-0218-0428#0600000

11

GEAR J41

12

WASHER

A6-WB-10S

13

NUT

A6-N1-10X1.25S-M-N1

1 LT242

14

O-RING

JB-OR1A-G105

15

MOTOR

A06B-0238-B605#S000

M-900iA/350

A290-7324-X421

M-900iA/260L

A290-7324-Y421

16.7 (1.7)

1
1
16.7 (1.7)

M-900iA/350

A290-7324-X423

M-900iA/260L

A290-7324-Y423

16

GEAR J51

17

WASHER

A6-WB-10S

18

NUT

A6-N1-10X1.25S-M-N1

1 LT242

19

O-RING

JB-OR1A-G105

Fig. 6.5 (a) Replacing the Wrist Axis Motors (M4, M5, M6)

- 96 -

16.7 (1.7)

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

2) Replacing the wrist unit and J4-axis reducer


Disassembling
1. Unload the wrist by removing the hand and any workpiece.
2. Remove the wrist unit mounting bolt (2) and washer (3), and then
dismount the wrist unit.
3. Remove the reducer mounting bolt (5) and washer (6), and then
dismount the reducer (7) from the J3 arm (9).
Assembling
1. Install the O-ring (8) onto the reducer (7).
2. Mount the reducer (7) to the J3 arm (9) and fasten with the
reducer mounting bolt (5) and washer (6).
3. Install the new O-ring (4) in the groove of the end face of the
reducer.
4. Fasten the wrist unit with the wrist unit mounting bolt (2) and
washer (3).
5. Apply grease.
6. Perform mastering.

Name
1

WRIST ASSY

BOLT

3
4

Specifications
M-900iA/350

A290-7327-T501

M-900iA/260L

A290-7327-T503

Qty

Loctite

Torque
N-m (kgf-m)

LT262

73.5 (7.5)

LT262

128.4 (13.1)

A6-BA-10X35

20

WASHER

A97L-0001-0823#M10H

20

O-RING

JB-OR1A-G135

BOLT

A6-BA-12X45

12

WASHER

A97L-0001-0823#M12H

12

REDUCER

A97L-0218-0349#160E-57

O-RING

A98L-0040-0041#271

J3 ARM

M-900iA/350

A290-7327-X402

M-900iA/260L

A290-7327-Y402

Fig. 6.5 (b) Replacing the Wrist Unit and J4 Axis Reducer

- 97 -

6.REPLACING PARTS

6.6

MAINTENANCE

B-82135EN/05

SEALANT APPLICATION

Washing and degreasing the surfaces to be sealed


1. After dismounting the reducer from the arm, apply releasant
(Loctite Gasket Remover) to the arms surface from which the
reducer was dismounted, then wait until the sealant (Loctite 518)
becomes softened (for about 10 minutes). Remove the softened
sealant from the surface using a spatula.
2. Blow air onto the surface to be sealed to remove dust from the
tapped holes.
3. Sufficiently degrease the reducers surface to be sealed and the
arms surface to be sealed, using a cloth dampened with alcohol.
4. Polish the arms surface to be sealed with an oil stone, and
degrease it with alcohol again.

CAUTION
Oil may drip from the inside of the reducer. After
degreasing, make sure that no oil is dripping.

Applying sealant
5. Make sure that the reducer and the arm are dry (with no alcohol
remaining). If they are still wet with alcohol, wipe them dry.
6. Apply sealant (Loctite 518) to the surfaces.

CAUTION
The portions to which sealant is to be applied vary
from one axis to another. See descriptions about
reducer replacement for the relevant axes for
details.

Assembling
7. To prevent dust from sticking to the portions to which sealant was
applied, mount the reducer as quickly as possible after sealant
application. Be careful not to touch the applied sealant. If sealant
was wiped off, apply again.
8. After mounting the reducer, fasten it with bolts and washers
quickly so that the mated surfaces get closer.

CAUTION
Do not grease the reducer before the sealant sets,
as it may allow grease to leak. Before greasing, wait
for about at least one hour after the reducer is
mounted.

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6.7

MAINTENANCE

6.REPLACING PARTS

REPLACING MOTOR COVERS (OPTION)

Replacing the J4-/J5-/J6-axis motor cover


1. Remove the four M6x10 bolts and washers that fasten the motor
cover, and remove the two M12x20 bolts and washers that fasten
the plate, and then remove the motor cover.
2. To mount the motor covers, reverse the above mounting procedure
steps. In this case, however, first attach the bolts, but keep them
loose so that the motor covers can be put in correct place;
After the motor covers are positioned properly, tighten the bolts.

Fig. 6.7 Replacing the J4-/J5-/J6-axis motor covers

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7.PIPING AND WIRING

MAINTENANCE

PIPING AND WIRING

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7.1

7.PIPING AND WIRING

PIPING DIAGRAM
Fig. 7.1 shows the piping diagram of the mechanical unit.

Fig. 7.1 Piping diagram

- 101 -

7.PIPING AND WIRING

7.2

MAINTENANCE

B-82135EN/05

WIRING DIAGRAM
Fig 7.2 (a) shows the wiring diagram of the mechanical unit.

K111
K114
K112
K131
K132
K133
K135
K136
K137
K138
K139
K140

(R-J3iB) or K115 (R-30iA)


(M1 to M6 pulse coder, End effector
(RDI/RDO) or (RI/RO)
(R-J3iB) or K116 (R-30iA)
(M1to M6 pulse coder, End effector
(RDI/RDO) or (RI/RO): SDLP designated)
(M1 to M6 power, brake)
(User cable (signal))
(User cable (power))
(Devicenet (signal))
(I/O unit model B)
(Load axis (pulse coder))
(Load axis (power brake))
(J1/J2/J3OT)
(Devicenet (power supply))
(J2/J3 interference angle OT)

*SDLPSEVERE DUST&LIQUID PROTECTION

Fig. 7.2 (a) Wiring diagram

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MAINTENANCE

Fig. 7.2 (b) Wiring block diagram

- 103 -

7.PIPING AND WIRING

7.PIPING AND WIRING

MAINTENANCE

Fig. 7.2 (c) Connector locations

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8.REPLACING CABLES

MAINTENANCE

REPLACING CABLES
Replace the cables every about four years (or 15,360 hours operating).
When the cable is broken or damaged, or shows signs of wear, replace
it according to this chapter.

Precaution to be observed when handling the pulse coder cable


The pulse coder cable is provided with a marking tie, as shown below,
to warn against disconnecting the cable during transportation,
installation, or maintenance. If the cable with the marking tie is
disconnected, mastering must be performed again. Therefore, do not
disconnect the cable except when replacement of the cable is
necessary.
The J1-axis, J2-axis and J3-axis motors are provided with a pulse
coder connector cover, as shown in Fig. 8 (b), to protect the
connectors. Before removing the connectors for cable replacement or
other purposes, remove the covers. In this case, turning the bolt may
also turn the cover, possibly causing damage to the connector. When
removing the cover, hold it to prevent it from turning.

Fig. 8 (a) Marking tie

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8.REPLACING CABLES

MAINTENANCE

Fig. 8 (b) Pulse coder connector cover

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8.1

8.REPLACING CABLES

CABLE FORMING
When replacing cables, clamp the cable at the position specified in
Table 8.1 (a) to Table 8.1 (c) using a clamp or a nylon band.
Otherwise, cables are loosened or forcedly pulled to cause their
disconnection. Refer to the figures in Section 8.2 for the cable clamp
position not listed in the Table.

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8.REPLACING CABLES

MAINTENANCE

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Table 8.1 (a) CABLE CLAMP

Cable clamping position

Mark

GB1

BATTERY BACKUP
DON'T

M1P K111

DISCONNECT

M2P

BATTERY BACKUP
DON'T

M2P K111

DISCONNECT

DON'T
DISCONNECT

RP1
BATTERY BACKUP

J123OT

K111
(R-J3iB)
or
K115
(R-30iA)

M3P

BATTERY BACKUP

M3P K111

Cable No.

+6V
0V
M1P

Mark

DO N'T

M4P K111

DISCONNECT

BATTERY BACKUP
DO N'T

M5P K111

DISCO NNECT

BATTERY BACKUP
DO N'T

M6P K111

DISCONNECT

M4P
M5P
M6P

EE K111

EE
+6V
0V
M1P

GB1

BATTERY BACKUP
DON'T

M1 P K114

DISCONNECT

M2P

BATTERY BACKUP
DON'T

M2P K114

DISCONNECT

M3P

BATTERY BACKUP
DON'T
DISCONNECT

M3P K114

RP1
BATTERY BACKUP
DO N'T

J123OT

M4P K114

DISCONNECT

BATTERY BACKUP
DO N'T

M5P K114

DISCO NNECT

BATTERY BACKUP
DO N'T

M6P K114

DISCONNECT

M4P
M5P
M6P

EE K114

EE

- 108 -

K114
(R-J3iB)
or
K116
(R-30iA)

8.REPLACING CABLES

MAINTENANCE

B-82135EN/05

Table 8.1 (b) CABLE CLAMP

Mark

Cable clamping position

Mark

M6M
M6BK

M6M K112

M6BK

RM2

M5M K112

M5BK

M4M K112

M4BK

RM1

Cable No.

M3M K112

M3BK

M5M K112
M5BK
M4M
M4BK
M3M
M3BK
M2M
M2BK

M2M K112

M2BK

M1M
M1BK

M1M K1 12

M1BK

AS1

AS2 K131

AS-K131

AP1

AP1 K132
AP-K132

DS3

DS1

DS3
K133

DS1-K133

DS3

DS2

I/O

I/O
I/O-K135

- 109 -

K135

8.REPLACING CABLES

MAINTENANCE

B-82135EN/05

Table 8.1 (c) CABLE CLAMP

Mark

Cable clamping position

Mark

ARP1

Cable No.

ARP2 K136
+6V
0V

ARP-K136
+
-

ARM1

ARM2
ARM-K137

IFOT

COM

NC

IFOTK138

NC

J3OTK138

COM

J123OT
J2OTK138

J3 NC
J3COM
J2 NC
J2COM

J123OT

J1OTK138

COM

NC

J1 NC
J2COM

DP3

DP1

DP3

DP1-K139

DP2

- 110 -

DP2

K138

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8.REPLACING CABLES

MAINTENANCE

Table 8.1 (d) CABLE CLAMP

Mark

Cable clamping position

Mark

Cable No.

3DV

CAM-K143

- 111 -

COM
NC
IFOT

K142 K142

3DV-K142

CAM

IFOT

COM
NC

K140

K140

K143

8.REPLACING CABLES

8.2

MAINTENANCE

B-82135EN/05

CABLE REPLACEMENT
This section describes a procedure for periodically replacing all the
(full-option) mechanical unit cables. If you need to replace a specific
cable (because, for example, it is damaged), do so by referencing this
section. See Section 7.2 for the configuration of the mechanical unit
cables. Cable replacement makes it necessary to perform mastering.
Before attempting replacement, therefore, see Section 5.3.

Replacement procedure
1. Place all the robot axes in their 0-degree position, then set the
control unit power switch to off.
2. Detach, from the connector panel on the rear of the J1-axis base,
the cable leading to the control unit. Remove the connector panel
from the J1 base, and then detach all the cable tubes from the
connector panel. When detaching a RM, RP, AS, AP, ARP, ARM,
DP connector, leave its housing on the connector panel; remove
the inserts together with the cable. If the housing is left on the
cable, the cable cannot be pulled out through the J1 axis piping
(Fig. 8.2 (a)).
3. When the robot has J1-axis limit switches (option), remove the
limit switch for the J1-axis from the plate of the J1-axis base, and
remove the terminal in the switch, then pull out the cable from the
cast through hole (Fig. 8.2 (b)).
4. Remove all connectors from the J1-axis through J6-axis motors.
For the precautions that must be taken, see Precaution to be
observed when handling the pulse coder cable at the beginning of
Chapter 8.
5. When the robot has the J2-axis, J3-axis, and interference angle
limit switches (option), remove the limit switches from the
mounting plate and remove the terminals in the J2-axis and
J3-axis limit switches (Fig. 8.2(c)).
6. When the robot has the DS/DP cable (option), remove the cable
from the J2-axis base connector panel (Fig. 8.2(d)).
7. Run the J2-axis and J3-axis motor and pulse coder cables, J2-axis
and J3-axis limit switch cables (option), and J2-axis DS/DP cables
(option) into the J2 base.
8. Remove the connector panel on the back of the J3-axis casing (Fig.
8.2(e)).
9. Remove the lower plate 1 of the J3-axis casing (Fig. 8.2(e)).
10. Remove the plate 2 that covers the cable on the J2-axis arm (Fig.
8.2(e)).
11. Remove the heat-shrink tubing that covers connectors and remove
the interference angle limit switch cable and the J1-axis, J2-axis,
and J3-axis limit switch cable connectors (Fig.8.2(c)).
12. Remove the plate 3 that secures the cable on the back of the
J2-axis arm (Fig. 8.2(e)).
13. Remove the plate 4 that secures the cable on the top of the J2-axis
base (Fig. 8.2(f)).
14. Remove the plate 5 on the J2-axis base (Fig. 8.2(f)).
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MAINTENANCE

8.REPLACING CABLES

15. Remove the bolts that secure the plate 6 in the J1-axis base, take
out the plate, and remove the bolts of the plate that secures the
cable (Fig. 8.2(g)).
16. Pull out the cable upward from the pipe of the J1-axis.
This completes cable unit detachment from the robot.
17. When replacing a part of the cables, remove the clamp and cover
from the cable unit. Next, cut the cable tie securing the cables, and
then detach the desired cable(s) (Fig. 8.2 (h)).
Install the cable according to the procedure below.
1. Before connecting the cable to the robot, fasten the cable at the
marked position with a cable tie, and install the clamp and cable
cover (Fig. 8.2 (h)).
2. Run the cable from the top of the J2-axis base to the back of
J1-axis base through the J1-axis pipe.
3. Secure the clamp on the plate 6 within the J1-axis base. Securely
bind the cable with the thick cable tie (T120I) attached to the
clamp and fix the plate on the J1-axis base (Fig.8.2 (g)).
4. Install the upper plate 5 of the J2-axis base (Fig. 8.2(f)).
5. Install the upper plate 4 of the J2-axis base, that fixes cables (Fig.
8.2(f)).
6. Install the upper plate 3 of the J2-axis base, that fixes cables (Fig.
8.2(e)).
7. Install the lower plate 1 of the J3-axis casing (Fig. 8.2(e)).
8. Install the connector panel on the back of J3-axis casing (Fig.8.2
(e)).
9. When the robot has the interference angle limit switch (option),
mount it on the mounting plate, run the cable through the casting
hole, connect it to the J1-axis, J2-axis, and J3-axis limit switch
cables with connectors, and cover the connector part with
heat-shrink tubing (Fig. 8.2(c)).
10. Lay the cables straight in the J2-axis arm to relieve mechanical
strain.
11. Install the plate 2 that covers the cable on the back of the J2-axis
arm (Fig. 8.2(e)).
12. Connect all connectors to the J1-axis, J2-axis, and J3-axis motors.
Attach the pulse coder connector covers to the J1-axis, J2-axis,
and J3-axis motors. For notes on this step, refer to Notes on
Using Pulse Coder Cables at the beginning in Chapter 8. In
addition, secure the J3-axis motor cable with a cable tie
considering the routing in the J2 base to prevent interference
during J3 linking.
13. When the robot has the DS/DP cable (option), secure the
connector on the connector panel and secure the connector panel
on the side of the J2 base (Fig. 8.2(d)).
14. When the robot has the J1-axis, J2-axis, and J3-axis limit switches
(option), connect the cable to the limit switch terminal of each
axis and mount the limit switch on the mounting plate (Figs.
8.2(b) and (c)).
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8.REPLACING CABLES

MAINTENANCE

B-82135EN/05

15. Connect the cable and tube to the connector panel on the back of
the J1-axis base. Connect the ground terminal to the J1-axis base,
connect battery terminal to the back of the battery box. Secure the
connector panel on the J1-axis base and connect the cable for
connection with the control unit to the connector panel (Fig.
8.2(a)).
16. Turn on the power. If an alarm is issued at this time, release it
according to Section 5.3.
17. Perform mastering.

Fig. 8.2 (a) Replacing the cable

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MAINTENANCE

Fig. 8.2 (b) Replacing the cable

- 115 -

8.REPLACING CABLES

8.REPLACING CABLES

MAINTENANCE

Fig. 8.2 (c) Replacing the cable

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MAINTENANCE

Fig. 8.2 (d) Replacing the cable

Fig. 8.2 (e) Replacing the cable

- 117 -

8.REPLACING CABLES

8.REPLACING CABLES

MAINTENANCE

Fig. 8.2 (f) Replacing the cable

Fig. 8.2 (g) Replacing the cable

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MAINTENANCE

Fig. 8.2 (h) Replacing the cable

- 119 -

8.REPLACING CABLES

8.REPLACING CABLES

8.3

MAINTENANCE

B-82135EN/05

LIMIT SWITCH REPLACEMENT (OPTION)


This section explains how to replace limit switches. See the cable
replacement procedure for an explanation of how to detach the limit
switch cables.

CAUTION
1 Before limit switch replacement, turn off the power to
the control unit.
2 After a limit switch is installed, be sure to adjust the
limit switch.
1. J1-axis limit switch replacement
1. Remove the limit switch from the plate on the J1-axis base.
2. Cut the cable tie, and detach the cable from the plate.
3. Remove the terminal in the switch, and remove the limit switch
from the cable.
4. Attach a new limit switch to the cable.
5. Install the limit switch on the plate.
6. Fasten the cable to the plate with a cable tie.
2. J2-axis limit switch replacement
1. Cut the cable tie used to prevent the limit switch cable from
slackening.
2. Remove the two plates used to fasten the limit switch to the robot.
3. Remove the limit switch from the plate.
4. Remove the terminal in the switch, and then remove the limit
switch from the cable.
5. Attach a new limit switch to the cable.
6. Install the limit switch on the plate.
7. Install the two plates used for securing the limit switch on the
robot, on the robot.
8. Secure the limit switch cable with a cable tie on the robot to
prevent slack.

CAUTION
1 If the cable slackens, it may contact with robot
components, causing a break. Exercise care to
prevent the slackening cable being contact with
robot components.
2 At some sections on the cable where the clearance
between the cable and the casting is small, sponge
covers are wound for protection. When securing the
cable, make sure that the sponge covers are placed
near the casting.
9. Adjust limit switches.
3. Interference limit switch replacement
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MAINTENANCE

8.REPLACING CABLES

1. Remove the cover plate and cut the cable tie for preventing the
limit switch cable from slacking.
2. Remove the nylon clip.
3. Remove the limit switch from the plate.
4. Remove the heat-shrink tubing, remove the connector for
connection with the J1-axis, J2-axis, and J3-axis limit switch
cables, and then remove the limit switch.
5. Install a new limit switch on the plate.
6. Connect the cable to the J1-axis, J2-axis, and J3-axis limit switch
cable connectors through the casting hole and cover the
connectors with heat-shrink tubing.
7. Secure the cable with the nylon clip.
8. Secure the limit switch cable with a cable tie on the robot to
prevent slack.

CAUTION
1 If the cable slackens, it may contact with robot
components, causing a break. Exercise care to
prevent the slackening cable being contact with
robot components.
2 At some sections on the cable where the clearance
between the cable and the casting is small, sponge
covers are wound for protection. When securing the
cable, make sure that the sponge covers are placed
near the casting.
9. Fasten the cover plate.
10. Adjust limit switches.

- 121 -

8.REPLACING CABLES

MAINTENANCE

Fig. 8.3 (a) Replacing the J1-axis limit switch

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MAINTENANCE

8.REPLACING CABLES

Fig. 8.3 (b) Replacing the J2/J3-axis interference angle limit switch

- 123 -

9.SEVERE DUST/LIQUID
PROTECTION OPTION

MAINTENANCE

B-82135EN/05

SEVERE DUST/LIQUID PROTECTION


OPTION

- 124 -

9.1

9.SEVERE DUST/LIQUID
PROTECTION OPTION

MAINTENANCE

B-82135EN/05

OVERVIEW
The package is intended to improve the Severe dust/Liquid protection
characteristics of the robot so that it can be used in a severe
environment. It is also intended to improve the rust resistance of the
robot so that it can be used for a longer time.

9.1.1

Model

Severe dust/liquid protection


specification

M-900iA/350,260L

A05B-1327-J801

Severe Dust/Liquid Protection Characteristics


The following table lists the IEC529-based Severe dust/Liquid
protection characteristics of the M-900iA.

J3-axis arm and wrist section


Driving unit of the body
Main body

Standard

Severe dust/liquid
protection package

IP67
IP66
IP54

IP67
IP66
IP56

Fig. 9.1.1 Severe dust/Liquid protection characteristics of the M-900iA

- 125 -

9.SEVERE DUST/LIQUID
PROTECTION OPTION

9.1.2

MAINTENANCE

B-82135EN/05

Configuration of the Severe Dust/Liquid Protection Option


The following table lists the major differences between the
M-900iA/350, 260L standard specification and severe dust/liquid
protection package.
Standard
specification
Whole mechanical
unit

Bolts

Bolts Black steel bolt


Black washer

Cover

J3-axis connector
panel EE,
I/O connector

Non-waterproof
connector

Dust-proof/drip-proof enhancement package


Main body

J3-axis arm and wrist section

FR coating bolt
FR coating bolt
Black chrome plated washer
Black chrome plated washer
Stainless bolt
Stainless bolt
Black steel bolt
J1-axis motor cover
J2-axis motor cover
J3-axis motor cover
J4, 5, 6-axis motor cover
Battery box cover
Mechanical unit cable cover (for all exposed cable sections)
Waterproof connector

Fig. 9.1.2 Configuration of the Severe dust/Liquid protection option

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9.1.3

MAINTENANCE

9.SEVERE DUST/LIQUID
PROTECTION OPTION

Notes on Specifying Severe Dust/Liquid Protection Option


1. The liquids below cannot be applied because they may cause
deterioration or corrosion of the rubber parts (such as packings, oil seals,
and O-rings) used in the robot.
1. Organic solvent
2. Chlorine- or gasoline-based cutting fluid.
3. Amine-based cleaning fluid
4. Liquid or solution that includes a corrosive such as an acid or alkali
or causes rust
5. Some other liquid or solution to which nitrile rubber (NBR) does
not have resistance
2. When the robot is used in an environment where a liquid such as water
is dashed over the robot, great attention should be given to drainage
under the J1-axis base. A failure may be caused if the J1-axis base is
kept immersed in water due to poor drainage.

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9.SEVERE DUST/LIQUID
PROTECTION OPTION

MAINTENANCE

9.2

REPLACING COMPONENTS OF THE SEVERE


DUST/LIQUID PROTECTION OPTION

9.2.1

Replacing Motor Covers

B-82135EN/05

Replacing the J1-axis motor cover


1. Remove the bolt (5) that fixes the motor cover (1) to the motor
body and then remove the motor cover.
2. To attach the motor cover, reverse the above procedure.

Replacing the J2- or J3-axis motor cover


1. Remove the bolt (5) that fixes the motor cover (2) to the motor
body, remove the bolt (6) that fixes the motor cover to the bracket,
and then remove the motor cover.
2. To attach the motor cover, reverse the above procedure.

Replacing the J4-, J5-, or J6-axis motor cover


1. Remove the washer (9) and bolt (8) that fix the motor cover (3) to
the J3 casing and plate (4) and then remove the motor cover.
2. Remove the bolt (7) that fixes the plate (4) to the J3 casing and
then remove the plate.
3. To attach the motor cover, reverse the above procedure.

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9.SEVERE DUST/LIQUID
PROTECTION OPTION

MAINTENANCE

B-82135EN/05

3
9
8

4
7

1
5

5
2
2

Name

Specification

Qty

MOTOR COVER

A290-7327-X601

MOTOR COVER

A290-7327-X602

MOTOR COVER

A290-7327-X603

PLATE

A290-7327-X604

BOLT

A6-BA-8X12SUS

BOLT

A6-BA-12X16SUS

BOLT

A6-BA-12X20SUS

BOLT

A6-BA-6X10SUS

WASHER

A6-WM-6S

Fig. 9.2.1 The exchange of the motor cover

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9.SEVERE DUST/LIQUID
PROTECTION OPTION

9.2.2

MAINTENANCE

B-82135EN/05

Replacing Cable Covers


In the severe dust/liquid protection option, the cable cover is put on
exposed cables. When replacing the cables or cable covers, put the
covers as described in Fig. 9.2.2.

NOTE
Arrange the wrinkles at the end of the cable cover
and fix the end to the connector or cable with a
cable tie.
NOTE
When the cable cover is put, the side with the Velcro
strap must face downward or the covering side
(male side) must lie on the covered side correctly to
prevent water from entering the inside of the cover
or being left in the cover.

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Fig. 9.2.2 Attachment of cable covers

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9.SEVERE DUST/LIQUID
PROTECTION OPTION

9.SEVERE DUST/LIQUID
PROTECTION OPTION

9.2.3

MAINTENANCE

B-82135EN/05

Replacing the Battery and Battery Box Cover

Replacing the battery


1. Remove the six SUS bolts (M4 x 10) and remove the plate of
the battery box cover.
2. Replace the battery as described in Section 3.3.
3. Install the plate with the six SUS bolts (M4 x 10).

Replacing the battery box cover


NOTE
When the battery box cover is replaced, the power
must be kept on as in the replacement of the battery
because the battery box needs to be opened. If the
battery is replaced when the power is off, mastering
becomes necessary because current position
information is lost. Press the emergency stop button
to prevent danger during the work.
1. Remove the six SUS bolts (M4 x 10) and then remove the plate of
the battery box cover.
2. Remove the lid of the battery box and then take the battery out of
the box.
3. Remove the four flat head screws (M4 x 12) that fix the battery
box and battery box cover together to the J1-axis connector panel
and then remove the battery box and battery box cover.
4. Remove the battery cable terminal on the rear face of the battery
box and replace the battery box cover.
5. Attach the battery box and battery box cover by reversing the
above procedure.

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MAINTENANCE

Fig. 9.2.3 Replacement of the battery box cover

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9.SEVERE DUST/LIQUID
PROTECTION OPTION

CONNECTION

B-82135EN/05

CONNECTION

1.ROBOT INTERFERENCE AREA

ROBOT INTERFERENCE AREA

- 137 -

1.ROBOT INTERFERENCE AREA

1.1

CONNECTION

B-82135EN/05

External Dimensions
Fig. 1 shows the external dimensions of the robot. When installing
peripheral devices, be careful to clear away any objects that are in the
robots motion path in normal operation. Fig. 1.1 (a) to Fig. 1.2 (a)
show the operation range of the robot.

Fig. 1.1 (a) Mechanical unit operation area (M-900iA/350)

- 138 -

B-82135EN/05

CONNECTION

1.ROBOT INTERFERENCE AREA

Fig. 1.1 (b) Mechanical unit operation area (M-900iA/260L)

- 139 -

1.ROBOT INTERFERENCE AREA

1.2

CONNECTION

Operation Area

Fig. 1.2 (a) Mechanical unit operation area (1/2) (M-900iA/350)

- 140 -

B-82135EN/05

B-82135EN/05

CONNECTION

1.ROBOT INTERFERENCE AREA

Fig. 1.2 (a) Mechanical unit operation area (2/2) (M-900iA/350)

- 141 -

1.ROBOT INTERFERENCE AREA

CONNECTION

Fig. 1.2 (b) Mechanical unit operation area (1/2) (M-900iA/260L)

- 142 -

B-82135EN/05

B-82135EN/05

CONNECTION

1.ROBOT INTERFERENCE AREA

Fig. 1.2 (b) Mechanical unit operation area (2/2) (M-900iA/260L)

- 143 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

MECHANICAL COUPLING TO THE


ROBOT

- 144 -

B-82135EN/05

B-82135EN/05

2.1

CONNECTION

2.MECHANICAL COUPLING TO
THE ROBOT

WRIST LOAD CONDITIONS


Fig. 2.1 (a), (b) contains diagrams that show the wrist load limits.
Apply a load within the region indicated in the graph. Apply the
conditions of the allowable load moment and the allowable load
inertia.

Fig. 2.1 (a) Wrist Load Diagram (M-900iA/350)

NOTE
The FANUC and special flange options cannot be
selected.

- 145 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

Fig. 2.1 (b) Wrist Load Diagram (M-900iA/260L)

NOTE
The FANUC and special flange options cannot be
selected.

- 146 -

CONNECTION

B-82135EN/05

M-900iA/350

M-900iA/260L

350kg

260kg

1960Nm
(200kgfm)
1960Nm
(200kgfm)
891.8Nm
(91kgfm)

1666Nm
(170kgfm)
1666Nm
(170kgfm)
715.4Nm
(73kgfm)

Standard inertia
mode

235.2kgm2
(2400kgfcms2)

188.2kgm
(1920kgfcms2)

High inertia
mode

392kgm2
(4000kgfcms2)

313.6kgm
(3200kgfcms2)

Standard inertia
mode

235.2kgm2
(2400kgfcms2)

188.2kgm
(1920kgfcms2)

High inertia
mode

392kgm2
(4000kgfcms2)

313.6kgm
(3200kgfcms2)

Standard inertia
mode

156.8kgm2
(1600kgfcms2)

117.6kgm
(1200kgfcms2)

High inertia
mode

352.8kgm2
(3600kgfcms2)

225.4kgm
(2300kgfcms2)

Item
Load capacity

At wrist
J4

Allowable load
moment at wrist

J5
J6

J4

Allowable load
inertia at wrist

J5

J6

2.MECHANICAL COUPLING TO
THE ROBOT

- 147 -

2.MECHANICAL COUPLING TO
THE ROBOT

2.2

CONNECTION

B-82135EN/05

LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS ARM


Following shows J2-axis base and J3-axis arm load conditions.
Table 2.2 Installation conditions of loads to be added
Installation site
Loads
Condition
J2-axis base

550kg

J3-axis arm

25kg

The center of gravity must lie within a


radius of 500 mm from the rotation
center of the J1 axis.
J3 axis arm 25kg See Fig. 2.2 for the
positional condition of the center of
gravity.

Fig. 2.2 Load Conditions on J2-Axis Base and J3-Axis Arm

- 148 -

MECHANICAL COUPLING OF END EFFECTOR TO WRIST


Fig. 2.3 (a) and (b) are the diagrams for installing end effectors on the
wrist. To fasten the end effector, first position it with two pin holes at
[D] using fitting [B] or [C], then lock it using screws at [E]. Select
screws and positioning pins of a length that matches the depth of the
tapped and pin holes. Fasten the bolt for fixing the end effector with
following torque: 128.4 6.4 Nm (1310 65kg fcm)
R

2-O12 H7 depth12
O200 Equally spaced [D]

21
7
5.

6-M12 depth 20
O200 Equally spaced [E]

200u0.05

[C]

O 250 h8

145

[B]
+0.040
0

0
-0.072

O 125 H7

145

60

270

SECTION A-A
165

130

Fig. 2.3 (a) End effector mounting face (ISO flange)

2-O12 H7 depth 12
O200 Equally spaced [D]

21
5.7

6-M12 depth 12
O 200 Equally spaced [E]

[C]
0
-0.072

200 u0.05

[B]
+0.040
0

145

60

145

O 125 H7
O 250 h8

2.3

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

295

SECTION A-A
165

130

Fig. 2.3 (b) End effector mounting face (Insulated flange)

NOTE
The FANUC and special flange options cannot be
selected.

- 149 -

2.MECHANICAL COUPLING TO
THE ROBOT

2.4

CONNECTION

B-82135EN/05

EQUIPMENT MOUNTING FACE


As shown in Fig. 2.4 tapped holes are provided to install equipment to
the robot.

CAUTION
Never perform additional machining operation such
as drilling or tapping on the robot body. This can
seriously affect the safety and function of the robot.
NOTE
Note that the use of any threaded holes not shown
in the following figure could injure personnel or
damage equipment.

Fig. 2.4 Equipment mounting faces

- 150 -

CONNECTION

B-82135EN/05

2.5

2.MECHANICAL COUPLING TO
THE ROBOT

OPERATION PERFORMANCE SCREENS


The operation performance screens include the MOTION
PERFORMANCE screen, MOTION PAYLOAD SET screen, and
MOTION ARMLOAD SET screen. These screens are used to specify
payload information and equipment information on the robot.
1.
2.
3.
4.

Click the [MENUS] key to display the screen menu.


Select 6 SYSTEM from the next page.
Click F1 ([TYPE]).
Select MOTION. The MOTION PERFORMANCE screen
appears.

5. Ten different pieces of payload information can be set using


condition No.1 to 10 on this screen. Place the cursor on one of the
numbers, and click F3 (DETAIL). The MOTION PAYLOAD
SET screen appears.

- 151 -

2.MECHANICAL COUPLING TO
THE ROBOT

Center of robot
flange

CONNECTION

X
X

Z
xg (cm)

B-82135EN/05

Iy (kgfcms 2)

mass m(kg)
Center of
gravity

Center of
gravity

Iz (kgfcms2 )
yg (cm)
2

Ix (kgfcms )

zg (cm)

Fig. 2.5 Standard tool coordinate

6. Set the payload, gravity center position, and inertia around the
gravity center on the MOTION PAYLOAD SET screen. The X, Y,
and Z directions displayed on this screen correspond to the
respective standard tool coordinates (with no tool coordinate
system set up). When values are entered, the following message
appears: Path and Cycletime will change. Set it? Respond to the
message with F4 ([YES]) or F5 ([NO]).
7. Clicking F3 ([NUMBER]) will bring you to the MOTION
PAYLOAD SET screen for another condition number. For a
multigroup system, clicking F2 ([GROUP]) will bring you to the
MOTION PAYLOAD SET screen for another group.
8. Click the previous page key to return to the MOTION
PERFORMANCE screen. Click F5 ([SETIND]), and enter the
desired payload setting condition number.
9. On the MOTION PERFORMANCE screen, click F4
([ARMLOAD]) to display the MOTION ARMLOAD SET screen.

10. Specify the weight of the load on the J2 axis base and J3 axis arm
as follows:
ARM LOAD AXIS #1 [kg]:
- 152 -

Weight of the load on the J2 axis


base

B-82135EN/05

CONNECTION

ARM LOAD AXIS #3 [kg]:

2.MECHANICAL COUPLING TO
THE ROBOT

Weight of the load on the J3 axis


arm

The following message appears: Path and Cycletime will change.


Set it? Respond to the message with F4 ([YES]) or F5 ([NO]).
Once the arm payload is set up, the settings are completed by
switching the power off and on again.

- 153 -

2.MECHANICAL COUPLING TO
THE ROBOT

2.6

CONNECTION

B-82135EN/05

INERTIA LOAD SETTINGS


For the M-900iA/350 and 260L, there are two parameter settings
depending on the magnitude of load inertia. (By default, the parameter
settings for the standard inertia mode are made.)

350

Standard inertia mode


235.2kgm2
(2400kgfcms2)

260L

188.2kgm
(1920kgfcms2)

313.6kgm
(3200kgfcms2)

350

235.2kgm2
(2400kgfcms2)

392kgm
(4000kgfcms2)

260L

188.2kgm
(1920kgfcms2)

350
260L

J4-axis

Wrist unit allowable load


inertia

J5-axis

J6-axis

High inertia mode


2
392kgm
(4000kgfcms2)
2

313.6kgm
(3200kgfcms2)

156.8kgm
(1600kgfcms2)

352.8kgm
(3600kgfcms2)

117.6kgm2
(1200kgfcms2)

225.4kgm
(2300kgfcms2)

CAUTION
When a workpiece with inertia exceeding the
allowable inertia for the standard inertia mode is
used in the standard inertia mode, components of
the mechanical unit may be degraded earlier.
Software
system

Software
version

Mechanical unit

V6.10P (7D80)
V6.20P (7D81)
V6.30P (7D82)

92 or earlier
44 or earlier
41 or earlier

All models

V7.10P (7DA0)

All versions

When M-900iA/350 insulated flange


or M-900iA/260L is selected.

Since the high inertia mode is not supported, make use within the
allowable range of the standard inertial mode.
Software
system

Software
version

V6.10P (7D80)
V6.20P (7D81)
V6.30P (7D82)

94 or earlier
46 or earlier
44 or earlier

Mechanical unit

All models

Following the setting method described in Section 2.6.1, make


parameter settings depending on the load. (By default, the parameter
settings for the standard inertia mode are made.)

- 154 -

CONNECTION

B-82135EN/05

Software
system

2.MECHANICAL COUPLING TO
THE ROBOT

Software
version

V6.10P (7D80)
V6.20P (7D81)
V6.30P (7D82)

95 or earlier
47 or earlier
45 or earlier

V7.10P (7DA0)

All versions

V7.20P (7DA1)

All versions

V7.30P (7DA2)

All versions

Mechanical unit

All models
When M-900iA/350 standard flange is
selected.
When M-900iA/350 standard flange
or M-900iA/260L is selected.
M-900iA/350 standard flange or
solution arm is attached or
M-900iA/260L is selected

Parameters are set automatically based on the load settings made in


Section 2.5.

NOTE
With version 19 or later, the settings can also be
used when a solution arm is mounted.
CAUTION
Set the load inertia correctly as described in Section
2.5. When a workpiece with inertia exceeding the
allowable inertia for the standard inertia mode is
used in the standard inertia mode, components of
the mechanical unit may be degraded earlier.

2.6.1

Setting
In the M-900iA/350, when the software edition is:
V6.10P (7D80) and the versions is 93 or 94
V6.20P (7D81) and the versions is 45 or 46
V6.30P (7D82) and the versions is any of 42 to 44
Follow the procedure below to change settings manually.
To make parameter settings, execute the factory-stored setting
program, PAYLD350.PC. This program sets parameters based on the
magnitude of the currently used load inertia of the load settings made
in Section 2.5.
Call the setting program within the operation program. In particular,
when changing the load setting with the PAYLOAD SET command,
execute this program.
[Example of the operation program]
1: PAYLOAD SET [1]
2: CALL PAYLD350 (i)
Enter the robot group number in input parameter i of PAYLD350. If
input parameter i is not specified, set group 1.
- 155 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

Exception processing
In the following cases, exception processing is performed and a
message describing exception processing appears on the user screen
without changing the parameter.
1. When the load setting condition number (1 to 10) on the operation
performance screen is not selected
[User screen display]
Payload number 0 is invalid. (GP: x)
When this message appears, select a load setting condition on the
operation performance screen or set the load setting condition
with the PAYLOAD SET command.
2. When the group specified by input parameter i of PAYLD350 is
not present
[User screen display]
Incorrect group number
When this message appears, specify a correct group number.
3. When the group specified by input parameter i of PAYLD350 is
not M-900iA/350
[User screen display]
This group is not M-900iA/350
When this message appears, specify a correct group number.

2.6.2

Checking the Settings


Settings can be checked on the user screen. To display the user screen,
press the screen selection key and select 9 USER.
[User screen display]
For the standard inertia load setting:
Standard payload set. (GP: x, Payload: y)
For the high inertia load setting:
High payload set. (GP: x, Payload: y)
x indicates the group name for which the parameter was set and y
indicates the load setting number used for evaluation.
To check only the current settings without switching the parameter,
enter the value obtained by adding 100 to the group number in input
parameter i of PAYLD350 and then perform execution. The current
parameter settings of the group are displayed on the user screen.

- 156 -

B-82135EN/05

CONNECTION

2.MECHANICAL COUPLING TO
THE ROBOT

[User screen display]


For the standard inertia load setting:
Standard payload type now (GP: x)
For the high inertia load setting:
High payload type now (GP: x)
x indicates the group number for which the parameter was checked.

- 157 -

2.MECHANICAL COUPLING TO
THE ROBOT

2.7

CONNECTION

B-82135EN/05

AIR SUPPLY (OPTION)


There is an air-pressure supply opening on the side of the J1-axis base
and the front of J3-axis casting. The connector is a Rc1/2 female (ISO).
As couplings are not supplied, it will be necessary to prepare
couplings, which suit to the hose size.

Fig. 2.7 Air-pressure supply connection (option)

- 158 -

B-82135EN/05

2.8

CONNECTION

2.MECHANICAL COUPLING TO
THE ROBOT

INTERFACE FOR OPTION CABLE (OPTION)


Fig. 2.8 (a) to (d) show the position of the end effector interface. End
effector interface (RDI/RDO or RI/RO), I/O Unit-MODEL B interface,
user cable (signal lines, power lines) and device net cable (signal lines,
power lines), camera cable and 3DV sensor cable are prepared as
options.

Fig. 2.8 (a) Interface for Optional cable (Option)

- 159 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

J3-axis casing connector panel (output)


End effector
interface
(RDI/RDO)
or
(RI/RO)

B-82135EN/05

J1-axis connector panel (input)

User cable (signal)


interface
(Air supply)

User cable (power)


interface

User cable(power)
interface

User cable (signal)


interface

(Air supply)

VIEW A

VIEW B

VIEW C

With user cable(signal/power)


J3-axis casing connector panel (output)

J2-axis base connecotr panel (output)

J1-axis connector panel (input)


Devicenet cable
(power) interface

End effector
interface
(RDI/RDO)
or
(RI/RO)

Devicenet cable
(signal) interface
Devicenet cable
(power) interface

Devicenet cable
(signal) interface

(Air supply)

(Air supply)

Devicenet cable
(signal) interface

Deviecnet cable
(power) interface

VIEW A

VIEW D

VIEW C

With devicenet cable (power/signal)


J3-axis casing connector panel (output)

I/OMODEL B

J1-axis connector panel (input)

End effector
interface
(RDI/RDO)
or
(RI/RO)

User cable (power)


interface

I/O UNIT MODEL B


interface
User cable (powerl)
interface

(Air supply)

(Air supply)

VIEW A

VIEW B

VIEW C

With I/O unit model B and User cable(power)

J3-axis casing connector panel (output)

J1-axis connector panel (input)

Additional axis motor


(power,brake)
interface
Additional axis motor
(pulse coder)
interface

End effector
interface
(RDI/RDO)
or
(RI/RO)

Air supply)

Additional axis motor


(power,brake)
interface

Additional axis motor


(pulse coder)
interface
(Air supply)

VIEW A

VIEW B

VIEW C

With additional axis motor cable (pulse coder/power,brake)

Fig. 2.8 (b) Interface for Optional cable 1

- 160 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

J3-axis casing connector panel (output)


End effector
interface
(RDI/RDO)
or
(RI/RO)

J1-axis base connector panel (input)


3DV sensor
interface

User cable (signal)


interface

(Air supply)

User cable (signal)


interface

(Air supply)

3DV sensor
interface

Camera cable
interface

Camera cable
interface

VIEW A

VIEW B

VIEW C

With user cable(signal),camera cable and 3DV sensor

J3-axis casing connector panel (output)

J1-axis base connector panel (input)


User cable (signal)
interface

User cable (power)


interface

(Air supply)

Additional axis motor


(pulse coder)
interface

Camera cable
interface

(Air supply)

Additional axis motor


(pulse coder)
interface

Additional axis motor


(power,brake)
interface
Camera cable
interface

Additional axis motor


(power,brake)
interface

VIEW A

VIEW B

VIEW C

With user cable(signal),camera cable and additional axis motor cable (pulse coder/power,brake)
,without EE

J3-axis casing connector panel (output)

Camera cable
interface

J1-axis base connector panel (input)

User cable (signal)


interface

End effector
interface
(RI/RO)

(Air supply)

User cable (signal)


interface

VIEW A

(Air supply)

Camera cable
interface

VIEW B

VIEW C

With user cable(signal) and camera cable


(*) This interface does't correspond to R-J3iB controller.

Fig. 2.8 (c) Interface for Optional cable 2

- 161 -

2.MECHANICAL COUPLING TO
THE ROBOT

J3-axis casing connector panele (output)


End effector
interface
(RDI/RDO)
or
(RI/RO)

CONNECTION

B-82135EN/05

J1-axis base connector panel (input)

User cable(power)
interface
(Air supply)

User cable (signal)


interface

User cable (power)


interface
User cable (signal)
interface

(Air supply)

VIEW A

VIEW B

VIEW C

With user cable(signal/power)


J3-axis casing connector panele (output)

J1-axis base connector panel (input)

Additional axis motor


(power,brake)
interface
Additional axis motor
(pulse coder)
interface

End effector
interface
(RDI/RDO)
or
(RI/RO)

Air supply)

Additional axis motor


(power,brake)
interface

Additional axis motor


(pulse coder)
interface
(Air supply)

VIEW A

VIEW B

VIEW C

With additional axis motor cable (pulse coder/power,brake)


J3-axis casing connector panele (output)

J1-axis base connector panel (input)

J2-axis base connector panel (output)

(Air supply)

End effector
interface
(RDI/RDO)
or
(RI/RO)

Devicenet cable
(power) interface
Devicenet cable
(power) interface

Devicenet cable
(signal) interface

Devicenet cable
(signal) interface

(Air supply)

Devicenet cable
(power) interface

Devicenet cable
(signal) interface

VIEW A

VIEW C

Withd devicenet cable (signa/power)

Fig. 2.8 (d) Interface for Optional cable 3

- 162 -

VIEW D

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

1. End effector interface (RDI/RDO or RI/RO) (option)


Fig. 2.8 (e), (f), (g), (h) show pin layout for end effector interface
(RDI/RDO or RI/RO).

WARNING
The RDO signal for the R-J3iB controller and the RO
signal for the R-30iA controller are incompatible with
each other because different output formats are
used. For details, refer to the maintenance manuals
for the controllers.
End effector interface(RDI/RDO) (output side)
EE
1
RDO1
5
RDO5
10
RDI2

2
RDO2

6
RDO6

11
RDI3

3
RDO3

7
XHBK

12
RDI4

4
RDO4
8
0V

9
RDI1

14
15
XPPABN RDI5
16
17
18
19
20
RDI6
+24V
+24V
+24V
+24V
21
22
23
24
RDI7
RDO7
RDO8

13
RDI8

XHBK

Controller

End
effector

Prepared by user

:Hand broken

XPPABN:Pneumatic pressure abnormal

Fig. 2.8 (e) Pin layout for end effector interface (RDI/RDO) (option)
(For R-J3iB controller)

End effector interface(RI/RO) (output side)


EE
1
RO1
5
RO5
10
RI2

2
RO2
6
RO6

11
RI3

3
RO3
7
XHBK

8
0V

9
RI1

14
15
XPPABN RI5
16
17
18
19
20
RI6
+24V
+24V
+24V
+24V
21
22
23
24
RI7
0V
RO7
RO8

Controller

12
RI4

4
RO4

End
effector

13
RI8

XHBK

Prepared by user

:Hand broken

XPPABN:Pneumatic pressure abnormal

Fig. 2.8 (f) Pin layout for end effector interface (RDI/RDO) (option)
(For R-30iA controller)

- 163 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

End effector interface (RDI/RDO) (Output)


Han24DD(HARTING)
21
22
23
24

RDO7
RDO8
RDI7

17
18
19
20

+24V
+24V
+24V
+24V

13
14
15
16

RDI8
XPPABN
RDI5
RDI6

9
10
11
12

RDI1
RDI2
RDI3
RDI4

5
6
7
8

RDO5
RDO6
XHBK
0V

1
2
3
4

RDO1
RDO2
RDO3
RDO4

End
effector

XHBK : Hand broken

Please prepare for user.

XPPABN : Pneumatic pressure abnormal

Controller
Fig. 2.8 (g) Pin layout for end effector interface (RDI/RDO)
(When the severe dust/liquid protection package is selected) (Option) (For R-J3iB controller)

End effector interface (RI/RO) (Output)


Han24DD(HARTING)
21
22
23
24

RO7
RDO8
0V
RI7

17
18
19
20

+24V
+24V
+24V
+24V

13
14
15
16

RI8
XPPABN
RI5
RI6

9
10
11
12

RI1
RI2
RI3
RI4

5
6
7
8

RO5
RO6
XHBK
0V

1
2
3
4

RO1
RO2
RO3
RO4

End
effector

XHBK : Hand broken


XPPABN : Pneumatic pressure abnormal

Please prepare for user.

Controller
Fig. 2.8 (h) Pin layout for end effector interface (RI/RO)
(When the severe dust/liquid protection package is selected) (Option) (For R-30iA controller)

- 164 -

B-82135EN/05

CONNECTION

2.MECHANICAL COUPLING TO
THE ROBOT

2. 2. I/O Unit-MODEL B interface (option)


Fig.2.8 (i) show pin layout for I/O Unit-MODEL B interface.

Fig. 2.8 (i) Pin layout for I/O Unit-MODEL B interface (option)

- 165 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

3. User cable (signal line) Interface (option)


Fig. 2.8 (j) shows pin layout for user cable (signal line) interface.
The connector has a code pin for preventing improper insertion.
For cables prepared by user, use this code pin.

Prepared by user

A first pin

Code pin
Fig. 2.8 (j) Pin layout for user cable (signal line) interface and code pin layout (option)

- 166 -

User cable (signal cable) interface code pin


position inlet
User cable (signal cable) interface code pin
position outlet

B-82135EN/05

CONNECTION

2.MECHANICAL COUPLING TO
THE ROBOT

4. User cable (power line) Interface (option)


Fig. 2.8 (k) shows pin layout for user cable (power line) interface.
The connector has a code pin for preventing improper insertion.
For cables prepared by user, use this code pin.

Prepared by user

A first pin

Code pin
Fig. 2.8 (k) Pin layout for user cable (power line) interface and code pin layout (option)

- 167 -

User cable (signal cable) interface code pin


position inlet
User cable (signal cable) interface code pin
position outlet

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

5. DeviceNet cable (signal line) interface (option)


Fig. 2.8 (l) shows pin layout for DeviceNet cable (signal line)
interface.

Fig. 2.8 (l) Pin layout for DeviceNet cable (signal line) interface (option)

6. DeviceNet cable (power line) interface (option)


Fig. 2.8 (m) shows pin layout for DeviceNet cable (power line)
interface.

Fig. 2.8 (m) Pin layout for DeviceNet cable (power line) interface (option)

- 168 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

7. Additional axis motor cable (pulse coder cable) interface


(optional)
Fig. 2.8 (n) shows the pin layout of the additional axis motor cable
(pulse coder cable) interface.
The connector has a code pin for preventing improper insertion.

Additional axis motor cable (pulsecoder) interface (outlet)

FEMALE TYPE Han24DD (HARTING)


17
18
19
20

21
22
23
24

13
14
15
16

9 +5V(A1)
10 +5V(A2)
11
12 +6V(BT1)

5
6
7
8

1
2
3
0V(BT1) 4

0V(A1)
0V(A2)

Additional
axis motor

SPD1
XSPD1
PRQJ1
XPRQJ1

Additional axis motor cable (pulsecoder) interface (inlet)

MALE TYPE Han24DD (HARTING)

Controller
1
2
3
4

SPD1
XSPD1
PRQJ1
XPRQJ1

5
6
7
8

0V(A1)
0V(A2)

9 +5V(A1) 13
10 +5V(A2) 14
11
15
16
12

17
18
19
20

+6V(BT1)

21
22
23
24

0V(BT1)

Battery
box

Code pin
First pin

First pin

Code pin
Additional axis motor cable (pulsecoder) interface
code pin position (inlet)

Additional axis motor cable (pulsecoder) interface


code pin position (outlet)

Fig. 2.8 (n) Pin Layout of the Additional Axis Motor Cable (Pulse Coder Cable)
Interface and Layout Position of the Code Pin (Optional)

- 169 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

8. Additional axis motor cable (power and brake cables) interface


(optional)
Fig. 2.8 (o) shows the pin layout of the additional axis motor cable
(power and brake cables) interface.
The connector has a code pin for preventing improper insertion.

Additional axis motor cable (pulsecoder) interface (outlet)

FEMALE TYPE Han24DD (HARTING)


21
22
23
24

17
18
19
20

13
14
15
16

9 +5V(A1)
10 +5V(A2)
11
12 +6V(BT1)

5
6
7
8

1
2
3
0V(BT1) 4

0V(A1)
0V(A2)

Additional
axis motor

SPD1
XSPD1
PRQJ1
XPRQJ1

Additional axis motor cable (pulsecoder) interface (inlet)

MALE TYPE Han24DD (HARTING)

Controller
1
2
3
4

SPD1
XSPD1
PRQJ1
XPRQJ1

5
6
7
8

0V(A1)
0V(A2)

9 +5V(A1) 13
10 +5V(A2) 14
11
15
16
12

17
18
19
20

+6V(BT1)

21
22
23
24

0V(BT1)

Battery
box

Code pin
First pin

First pin

Code pin
Additional axis motor cable (pulsecoder) interface
code pin position (inlet)

Additional axis motor cable (pulsecoder) interface


code pin position (outlet)

Fig. 2.8 (o) Pin Layout of the Additional Axis Motor Cable (Power and Brake Cables)
Interface and Layout Position of the Code Pin (Optional)

- 170 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

Connector Specifications
Table 2.8 (a) Connector specifications (Mechanical unit side)
Cable
Input side (J1-axis base)
RDO/RDO or
RI/RO
I/O

Output side (J3-axis casing)

JMWR2524F

JMWR2516F

AS
(Signal)

Housing
Insert
Contact
Code pin

09 30 006 0301
09 16 024 3001(Han 24DD M)
09 15 000 6103
09 30 000 9901

Housing
Insert
Contact
Code pin

09 30 006 0301
09 16 024 3101(Han 24DD F)
09 15 000 6203
09 30 000 9901

AP
(Power)

Housing
Insert
Contact
Code pin

09 20 010 0301
09 21 015 3001(Han 15D M)
09 15 000 6101
09 30 000 9901

Housing
Insert
Contact
Code pin

09 20 010 0301
09 21 015 3101(Han 15D F)
09 15 000 6201
09 30 000 9901

Housing
Insert
Contact
Guide pin
Bush

09 30 006 0301
09 16 024 3101(Han 24DD F)
09 15 000 6204
09 33 000 9908
09 33 000 9909

RDI/RDO or
RI/RO
When the
severe
dust/liquid
protection
package is
selected

- 171 -

Manu.
Fujikura
Ltd

Harting

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

Table 2.8 (b) Connector specifications (User side)


Cable
Input side (J1-axis base)
RDI/RDO or
RI/RO

I/O

Hood
Select
one

AS
(Signal)

Insert
Contact
Select
one
Clamp
Select
one

AP
(Power)

Hood
Select
one
Insert
Contact
Select
one

Clamp
Select
one
Code pin

B-82135EN/05

Output side (J3-axis casing)


JMSP2524M
Straight (Appendix)
(FANUC specification:
A63L-0001-0234#S2524M)
JMLP2524M
Angle
JMSP2516M
Straight (Appendix)
JMLP2516M
Angle

09 30 006 1540 Side entry


1541
0542
0543
1440 Top entry
1441
0442
0443
09 16 024 3101(Han 24DD F)
09 15 000 6204 AWG 26-22
6203 AWG 20
6205 AWG 18
6202 AWG 18
6201 AWG 16
6206 AWG 14
09 00 000 5083
5086
5090
5094

Hood

The same

Insert

09 16 024 3001(Han 24DD M)


09 15 000 6104
AWG 26-22
6103
AWG 20
6105
AWG 18
6102
AWG 18
6101
AWG 16
6106
AWG 14

Contact

Clamp

The same

Hood

The same

Insert

09 21 015 3001(Han 15D M)


09 15 000 6104
AWG 26-22
6103
AWG 20
6105
AWG 18
6102
AWG 18
6101
AWG 16
6106
AWG 14

Manu.

Fujikura
Ltd

Harting

etc
09 20 010 1541 Side entry
0540
0541
1440 Top entry
0440
0441
09 21 015 3101(Han 15D F)
09 15 000 6204 AWG 26-22
6203 AWG 20
6205 AWG 18
6202 AWG 18
6201 AWG 16
6206 AWG 14

Contact

09 00 000 5083
5086
5090
5094

Clamp

The same

etc
09 30 000 9901

Code pin

- 172 -

09 30 000 9901

Harting

CONNECTION

B-82135EN/05

Table 2.8 (b) Connector specifications (User side) (continued)


Cable
Input side (J1 base)

Hood

RDI/RDO or
RI/RO
Severe
dust/liquid
protection
cables which
are
corresponded
is specified

Insert

Contact

Clamp

Guide
pin
Bush

2.MECHANICAL COUPLING TO
THE ROBOT

Output side (J3 casing)


09 30 006 1540
Side entry
1541
0542
0543
1440(Appendix) Top entry
(FANUC specification:
A63L-0001-0453#06B1440)
1441
0442
0443
09 16 024 3001(Han 24DD M)
(Appendix)
(FANUC specification:
A63L-0001-0453#24DDM)
09 15 000 6104(Appendix) AWG 26-22
(FANUC specification:
A63L-0001-0453#CA6140)
6103
AWG 20
6105
AWG 18
6102
AWG 18
6101
AWG 16
6106
AWG 14
09 00 000 5083(Appendix)
5086
5090
5094 etc
09 33 000 9908(Appendix)
(FANUC specification:
A63L-0001-0453#A-9908)
09 33 000 9909(Appendix)
(FANUC specification:
A63L-0001-0453#A-9909)

Manu.

Harting

NOTE
For details, such as the dimensions, of the parts
listed above, refer to the related catalogs offered by
the respective manufacturers, or contact FANUC.

- 173 -

2.MECHANICAL COUPLING TO
THE ROBOT

CONNECTION

B-82135EN/05

Table 2.8 (c) Connector specifications (DeviceNet cable) (Mechanical unit side)
Cable
Input side (J1-axis base)
Output side
Manu.
(J2-axis
Manu.
base)
DS
(Signal line)

84854-9101

DP
(Power line)

Housing
Insert
Contact

MOLEX 84854-9100
JAPAN
CO., LTD.
09 30 006 0301(Han 6E)
09 32 010 3001(Han 10EE M)
09 33 000 6104

Harting

84854-9102

Output side
(J3-axis
casing)

Manu.

MOLEX 84854-9100
JAPAN
CO., LTD.

MOLEX
JAPAN
CO., LTD.

MOLEX 84854-9102
JAPAN
CO., LTD.

MOLEX
JAPAN
CO., LTD.

Table 2.8 (d) Connector specifications (DeviceNet cable, on the user equipment side)
Cable
Input side (J1-axis base)
Output side
Manu.
Manu.
(J2-axis base)

Output side
(J3-axis casing)

Manu.

DS
(Signal
line)

MINI connector for use on the device net


5-pin FEMALE
CM03A-R5P-P-2

Fujikura MINI connector for Fujikura


use on the device Ltd
Ltd
net,
5-pin male
CM03A-R5P-P-2

MINI connector for Fujikura


use on the device Ltd
net,
5-pin male
CM03A-R5P-P-2

DP
(Power
line)

Hood

Harting

MINI connector for Fujikura


use on the device Ltd
net,
4-pin male
CM03A-PR4S-P-2

MINI connector for Fujikura


use on the device Ltd
net,
4-pin male
CM03A-PR4S-P-2

09 30 006 1540(Han 6E) Side entry


1541
Select
0542
one
0543
1440
Top entry 1441
0442
0443
Insert

09 32 010 3101(Han 10EE F)

Contact 09 33 000 6220


6214
6205
6204
6202
6207

AWG20
AWG18
AWG18
AWG16
AWG14
AWG12

Clamp 09 00 000 5083


5086
Select
5090
one
5094 etc

- 174 -

CONNECTION

B-82135EN/05

2.MECHANICAL COUPLING TO
THE ROBOT

Table 2.8 (e) Connector specifications (Additional axis motor cable, Mechanical unit side)
Cable
Input side (J1-axis base)
Output side (J3-axis casing)
ARP
(Pulse code
line)

Housing
Insert
Contact
Code pin

09 30 006 0301
09 16 024 3001(Han 24DD M)
09 15 000 6103
09 30 000 9901

Housing
Insert
Contact
Code pin

09 30 006 0301
09 16 024 3101(Han 24DD F)
09 15 000 6203
09 30 000 9901

ARM
(Power brake
line)

Housing
Insert
Contact
Code pin

09 20 010 0301
09 21 015 3001(Han 15D M)
09 15 000 6101
09 30 000 9901

Housing
Insert
Contact
Code pin

09 20 010 0301
09 21 015 3101(Han 15D F)
09 15 000 6201
09 30 000 9901

- 175 -

Manu.

Harting

3.TRANSPORTATION AND INSTALLATION

CONNECTION

B-82135EN/05

TRANSPORTATION AND INSTALLATION

- 176 -

B-82135EN/05

3.1

CONNECTION

3.TRANSPORTATION AND INSTALLATION

TRANSPORTATION
CAUTION
When hoisting or lowering the robot with a crane or
forklift, move it slowly with great care. When placing
the robot on the floor, exercise care to prevent the
installation surface of the robot from striking the floor
strongly.
1. Transportation using a crane the robot can be transported by
lifting it. When transporting the robot, be sure to change the
attitude of the robot to that shown in Fig. 3.1 (a), (b) and lift by
attaching slings to the four M20 eyebolts.

CAUTION
When lifting the robot, take notice so that the motor,
connectors, or cables of the robot are not scratched
by slings.
2. Transportation using a forklift the robots can also be transported
using a forklift (refer to Fig.3.1 (c), (d)). Transport materials are
available as an option.

NOTE
Detach the end effectors and base plate before
transporting the robot. If the robot must necessarily
be transported with the base plate attached, take the
following precautions:
- If the end effectors and base plate are attached, the
center of gravity of the entire robot changes. When
lifting the robot, be extremely careful to keep the
robot in balance.
- The end effectors may oscillate due to, for example,
vibrations during transportation, possibly
overloading the robot. Fasten the end effectors
securely referring to subsection 3.1.1.
- If the base plate is attached, lift the base plate
instead of the robot.
CAUTION
Use the forklift transport bracket only when carrying
the robot with a forklift. Do not use the forklift
transport bracket for other transport means. Do not
use the transport bracket for fastening the robot.
Before transporting the robot with the transport
brackets, check the fastening bolts of the brackets
for looseness. Tighten the loose bolts, if any.
- 177 -

3.TRANSPORTATION AND INSTALLATION

CONNECTION

Fig. 3.1 (a) Transportation using a crane (M-900iA/350)

- 178 -

B-82135EN/05

B-82135EN/05

CONNECTION

3.TRANSPORTATION AND INSTALLATION

Fig. 3.1 (b) Transportation using a crane (M-900iA/260L)

- 179 -

3.TRANSPORTATION AND INSTALLATION

CONNECTION

Fig. 3.1 (c) Transportation using a forklift (M-900iA/350)

- 180 -

B-82135EN/05

B-82135EN/05

CONNECTION

3.TRANSPORTATION AND INSTALLATION

Fig. 3.1 (d) Transportation using a forklift (M-900iA/260L)

CAUTION
Exercise care to prevent the fork of the forklift from
striking transport equipments strongly.

- 181 -

3.TRANSPORTATION AND INSTALLATION

CONNECTION

Fig. 3.1 (e) Eyebolt installation location

- 182 -

B-82135EN/05

B-82135EN/05

CONNECTION

3.TRANSPORTATION AND INSTALLATION

Fig. 3.1 (f) Transport equipment installation location

- 183 -

3.TRANSPORTATION AND INSTALLATION

3.1.1

CONNECTION

B-82135EN/05

Transportation with an End Effector Attached


When transporting a robot with an end effector such as a welding gun
or hand attached, secure the arm with wood. If the arm is not secured,
the end effector may oscillate for a cause such as vibration during
transportation, thus imposing a large impact load on the reducer of the
robot and damaging the reducer at an earlier stage.

Woods

Pallet
Woods

Fig. 3.1.1 Example of securing the arm during transportation when an end effector is attached

- 184 -

CONNECTION

B-82135EN/05

3.2

3.TRANSPORTATION AND INSTALLATION

INSTALLATION
Fig. 3.2 (a) shows the robot base dimensions. Fig. 3.2 (b) shows actual
examples of robot installations. In Fig. 3.2 (b), the floor plate is
imbedded in concrete and fastened with twelve M20 (strength
classification 4.8) chemical anchors. Also, fasten the base plate to the
robot base using eight M20x60 bolts (strength classification 12.9).
Next, position the robot, and weld the base plate to the floor plate.
(Foot length is 10 to 15mm.)
(The base plate is prepared as an option.)
Avoid placing any object in front of the robot on the mounting face to
facilitate the installation of the mastering fixture, as shown in Fig. 3.2
(a). (The shaded portion)
Fig. 3.2 (c) and Table 3.2 (a), (b) show the force and moment applied
to the base plate at the time of emergency stop. Table 3.2(c) indicates
the coasting time and distance consumed from the pressing of the
emergency stop button until the robot stops.

Fig. 3.2 (a) Dimensions of the robot base

- 185 -

3.TRANSPORTATION AND INSTALLATION

CONNECTION

B-82135EN/05

Fig. 3.2 (b) Actual installation example

NOTE
The strength of the chemical anchor depends on the concrete strength. See the
design guideline of the manufacturer for the execution of the chemical anchor and
consider the safety ratio sufficiently before use.
NOTE
1. Parts to be provided by the customer:
Robot mounting bolts:
Chemical anchors:
Base plates:
Floor plate:

M20 x 60 (strength classification 12.9


M20 (strength classification 4.8)
Thickness 32t
Thickness 32t

8pcs.
12pcs.
4pcs.
1pcs.

2. Installation work (welding, anchoring, etc.) is repaired by the customer.


3. If the robot is operated with any combination other than stated above, it is likely
to be damaged.
- 186 -

CONNECTION

B-82135EN/05

3.TRANSPORTATION AND INSTALLATION

Table 3.2 (a) Force and moment during emergency stop


Model
Vertical moment
Force in vertical
MV [kNm (kgfm)]
direction
FV [kN (kgf)]
M-900iA/350
84.28(8600)
53.90(5500)
M-900iA/260L
94.08(9600)
53.90(5500)

Horizontal moment
MH [kNm (kgfm)]

Force in horizontal
direction
FH [kN (kgf)]

25.48(2600)
34.30(3500)

32.34(3300)
34.30(3500)

Table 3.2 (b) Force and moment applied during acceleration or deceleration
Horizontal moment
Model
Vertical moment
Force in vertical
MH [kNm (kgfm)]
MV [kNm (kgfm)]
direction
FV [kN (kgf)]
M-900iA/350
34.3(3500)
35.28(3600)
9.8(1000)
M-900iA/260L
34.3(3500)
33.32(3400)
11.76(1200)
Table 3.2(c) Coasting time and distance when emergency stop
Model
J1-axis
M-900iA/350
M-900iA/260L

Coasting time [msec]


Coasting distance [deg] (rad)
Coasting time [msec]
Coasting distance [deg] (rad)

* Override : 100%
* Max. payload, and max. inertia posture

- 187 -

739
36.1 (0.63)
754
33.3 (0.58)

Force in horizontal
direction
FH [kN (kgf)]
12.34(1300)
11.76(1200)

J2-axis

J3-axis

260
13.9 (0.24)
193
10.5 (0.18)

251
10.8 (0.19)
373
15.6 (0.27)

3.TRANSPORTATION AND INSTALLATION

CONNECTION

Fig. 3.2 (c) Force to the base plate

- 188 -

B-82135EN/05

B-82135EN/05

3.3

CONNECTION

3.TRANSPORTATION AND INSTALLATION

MAINTENANCE AREA
Fig. 3.3 shows the maintenance area of the mechanical unit. In
mastering, it needs to take the posture in item 5.3.3 of Chapter I. Be
sure to leave enough room for the robot to be mastered.

Fig. 3.3 Maintenance area

- 189 -

3.TRANSPORTATION AND INSTALLATION

3.4

CONNECTION

B-82135EN/05

AIR PIPING (OPTION)


Fig. 3.4 (a) shows how to connect air hose to the robot. If the air
control set is specified as an option, the air hose between the
mechanical unit and the air control set is provided. Mount the air
control set using the information in Fig. 3.4 (b).

Fig. 3.4 (a) Air piping Option

- 190 -

B-82135EN/05

CONNECTION

3.TRANSPORTATION AND INSTALLATION

Air control set


Fill the oiler having three air components to the specified level with
turbine oil #90 to #140. The machine tool builder is required to
prepare mounting bolts.

Fig. 3.4 (b) Air control set Option

- 191 -

3.TRANSPORTATION AND INSTALLATION

3.5

B-82135EN/05

INSTALLATION SPECIFICATIONS

Table 3.5 Installation specifications


Items
Pressure
Air pressure
Air flow
Weight of mechanical unit
Allowable ambient temperature
Allowable ambient humidity
Atmosphere
Vibration

CONNECTION

Specifications
2
0.490.69MPa(57kgf/cm )
2
Set pressure 0.49MPa(5kgf/cm )
3
(Note 1)
Max. Peak 150Nl/min (0.15Nm /min)
M-900iA/350
Approx.1720kg
M-900iA/260L
Approx.1800kg
045
Usual: Less than 75%RH
Short period (in one month): Max. 95%RH or less (Condensation free)
Free of corrosive gases.
(Note 2)
Less than 0.5G(4.9m/s2)

CAUTION
1. This value indicates the maximum capacity of the air
control set. Adjust the air flow to be less than this
value.
2. Contact the service representative, if the robot is to
be used in an environment or a place subjected to
severe vibrations, heavy dust, cutting oil splash and
or other foreign substances.

- 192 -

CONNECTION

B-82135EN/05

3.6

3.TRANSPORTATION AND INSTALLATION

STORAGE
To store the robot, set it to the same attitude as that used for
transportation. (See II- 3.1)

- 193 -

APPENDIX

A.SPARE PARTS LIST

APPENDIX

B-82135EN/05

SPARE PARTS LIST

Table A (a) Cables (Standard: CE)


No.

Specification

Function

K111

A660-8015-T036

J1J6 PULSECODER +EE

K115

A660-8015-T875

J1J6 PULSECODER +EE (R-30iA)

K114

A660-8015-T144

J1J6 PULSECODER +EE


(SDLP) (R-J3iB)

K116

A660-8015-T876

J1J6 PULSECODER +EE


(SDLP) (R-30iA)

K112
Table A (b) Cables (Option cable: CE)
No.

A660-8015-T037

J1J6 POWER

Specification

Function

K131

A660-8015-T039

AS (USER/SIGNAL)

K132

A660-8015-T040

AP (USER/POWER)

K133

A660-4004-T372

DNS (SIGNAL)

K135

A05B-1327-D001

I/O

K136

A660-8015-T041

ARP

K137

A660-8015-T042

ARM

K138

A660-8015-T043

J123 OT

K139

A660-4004-T376

DNP (POWER)

K140

A05B-1327-D002

J2/J3 Interference angle OT

K142

A660-8015-T161

3DV

K143

A05B-1327-D003#A

CAMERA

Table A (c) Motor


Axis
J1

Specification
A06B-0268-B605#S000

Remarks
(Model 30/4000is)
Model iS30/4000

J2, J3

A06B-0272-B605#S000

(Model 40/4000is)
Model iS40/4000

J4, J5, J6

A06B-0238-B605#S000

(Model 12/4000is)
Model iS12/4000

- 197 -

(R-J3iB)

A.SPARE PARTS LIST

APPENDIX

Table A (d) Reducer


Axis name

Specification

J1
J2
J3
J4

B-82135EN/05

Model

A97L-0218-0347#500C-30

M-900iA/350,260L

A97L-0218-0348#550F-253

M-900iA/350

A97L-0218-0348#550F-227

M-900iA/260L

A97L-0218-0348#550F-253

M-900iA/350

A97L-0218-0348#550F-267

M-900iA/260L

A97L-0218-0349#160E-57

M-900iA/350, 260L

Table A (e) Gear


Name

Specification

Model

J1-axis spur gear

A290-7327-X221

M-900iA/350, 260L

J1-axis bearing 1

A97L-0001-0195#09D000A

M-900iA/350, 260L

J1-axis C-ring

A6-CJR-45

M-900iA/350,260L

J1-axis center gear

A290-7327-X222

M-900iA/350,260L

J1-axis bearing 2

A97L-0001-0192#3200000

M-900iA/350,260L

J2-axis input gear

A97L-0218-0363#253

M-900iA/350

A97L-0218-0363#227

M-900iA/260L

A97L-0218-0363#253

M-900iA/350

A97L-0218-0363#267

M-900iA/260L

A290-7324-X421

M-900iA/350

A290-7324-Y421

M-900iA/260L

J4-axis bearing

A97L-0218-0428#0600000

M-900iA/350,260L

J4-axis C-ring

A6-CJR-30

M-900iA/350,260L

J5-axis spur gear

A290-7324-X423

M-900iA/350

A290-7324-Y423

M-900iA/260L

A290-7327-X425

M-900iA/350,260L

J3-axis input gear


J4-axis spur gear

J6-axis spur gear

- 198 -

B-82135EN/05

Table A (f) Other (Mechanical unit)


Name

A.SPARE PARTS LIST

APPENDIX

Specification

Model

A290-7327-T501

M-900iA/350

A290-7327-T503

M-900iA/260L

Shaft assembly (link)

A290-7327-V321

M-900iA/350,260L

J3 arm assembly

A290-7327-V401

M-900iA/350

A290-7327-V403

M-900iA/260L

Wrist unit

Table A (g) Battery and grease


Name

Specification

Remarks

Battery

A98L-0031-0005

1.5V, size D

Grease

A98L-0040-0174#16KG

Kyodo Yushi
VIGOGREASE RE0

Grease
Table A (h) O-ring
Name

A97L-0001-0179#2

Shell Alvania GREASE S2

Specification

Location

O-ring

JB-OR1A-G125

J1 to J3-axis motor

O-ring

JB-OR1A-G105

J4 to J6-axis motor

O-ring

JB-OR1A-G460

O-ring

A290-7327-X206

O-ring

JB-OR1A-G340

O-ring

A98L-0040-0041#271

O-ring

JB-OR1A-G135

O-ring

JB-OR1A-G210

O-ring

JB-OR1A-G135

O-ring

JB-OR1A-G135

- 199 -

J1-axis reducer
J2/J3-axis reducer
J4-axis reducer

J3-axis arm assembly


Wrist assembly

A.SPARE PARTS LIST

APPENDIX

Table A (i) Mechanical Stopper


Name

B-82135EN/05

Specification

Collar

A290-7324-X214

Bush

A97L-0218-0484#3125

Bolt

A6-BA-24X80

Washer

A6-WM-24S

Stopper

A290-7327-X215

Plate

A290-7327-X216

Stopper J2A

A290-7324-X361

Location
For J1-axi

Common plus side to the J2-axis and


the J3-axis

Stopper J2B

A290-7324-X362

Common minus side to the J2-axis and


the J3-axis

Stopper J3C

A290-7324-Y362

M-900iA/260L
Minus side of the J3-axis
Specific to the stroke end position

- 200 -

B-82135EN/05

APPENDIX

CIRCUIT DIAGRAM

- 201 -

B.CIRCUIT DIAGRAM

B.CIRCUIT DIAGRAM

APPENDIX

Fig. B (a) Circuit Diagram (R-J3iB controller)

- 202 -

B-82135EN/05

B-82135EN/05

APPENDIX

- 203 -

B.CIRCUIT DIAGRAM

B.CIRCUIT DIAGRAM

APPENDIX

Fig. B (b) Circuit Diagram (R-30iA controller)

- 204 -

B-82135EN/05

B-82135EN/05

APPENDIX

- 205 -

B.CIRCUIT DIAGRAM

C.PERIODIC MAINTENANCE TABLE

APPENDIX

B-82135EN/05

PERIODIC MAINTENANCE TABLE

FANUC Robot M-900iA/350 and 260L Periodic Maintenance Table


Items

Working time (H) Check Oil First


3
6
9
1
time Grease check months months months year
Amount 320
960
1920 2880 3840

5760

6720

2
years
7680

8640

9600

10560

3
12480 13440 14400
years
11520

Check the mechanical cable


(damaged or twisted)

0.2H

Check the motor connector


2
(loosening)

0.2H

Tighten the end effector


bolt

0.2H

Tighten the cover and main


bolt

2.0H

Remove spatter and dust


etc

1.0H

0.1H

6 Replacing battery

Mechanical unit

4800

Replacing
grease
J1-axis reducer

of

Replacing
grease
J2-axis reducer

of

Replacing
grease
9
J3-axis reducer

of

10

Replacing
grease
J4-axis gear box

of

11

Replacing grease of wrist


5750ml
* 1.0H
(J5/J6) axis reducer

* 1.0H 8000ml

* 0.5H 3400ml

* 0.5H 3100ml

* 0.5H 2200ml

12

Greasing Points

13
14
15 Greasing to J2/J3 bearing *

0.1H

20ml

each

16

Control unit

17
18

Replacing cable of
mechanical unit

4.0H

19

Check the robot cable and


teach pendant cable

0.2H

20 Cleaning the ventilator

0.2H

21 Check the source voltage *

0.2H

* 0.1H

22 Replacing battery

*: Refer to this manual or the controller maintenance manual.


:Requires exchange of parts
:Does not require exchange of parts
- 206 -

C.PERIODIC MAINTENANCE TABLE

APPENDIX

B-82135EN/05

4
16320 17280 18240 5 years 20160 21120 22080 6 years 24000 24960 25920 7 years 27840 28800 29760 8 years
years
19200
23040
26880
30720
15360

Overhaul

- 207 -

D.MOUNTING BOLT TORQUE LIST

APPENDIX

B-82135EN/05

MOUNTING BOLT TORQUE LIST


NOTE
When applying Loctite to the important bolt tightening
points, make sure that it is applied to the entire
longitudinal portion in the engaging section of the
female threads. If it is applied to the male threads, the
bolts may be loosened because sufficient 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.

- 208 -

APPENDIX

B-82135EN/05

D.MOUNTING BOLT TORQUE LIST

If no tightening torque is specified for a bolt, tighten it according to this


table.
Recommended bolt tightening torques

Nominal
diameter

M3
M4
M5
M6
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
M36

Hexagon socket head bolt


(Steel in strength category 12.9)

Hexagon socket head bolt


(stainless)

Tightening torque
Upper limit
Lower limit

Tightening torque
Upper limit
Lower limit

1.8(18)
4.0(41)
7.9(81)
14(140)
32(330)
66(670)
110(1150)
180(1850)
270(2800)
380(3900)
530(5400)
730(7450)
930(9500)
1400(14000)
1800(18500)
3200(33000)

1.3(13)
2.8(29)
5.6(57)
9.6(98)
23(230)
46(470)
78(800)
130(1300)
190(1900)
260(2700)
370(3800)
510(5200)
650(6600)
960(9800)
1300(13000)
2300(23000)

0.76(7.7)
1.8(18)
3.4(35)
5.8(60)
14(145)
27(280)
48(490)
76(780)
120 (1200)
160(1650)
230(2300)
-

- 209 -

0.53(5.4)
1.3(13)
2.5(25)
4.1(42)
9.8(100)
19(195)
33(340)
53(545)
82(840)
110(1150)
160(1600)
-

Unit: Nm (kgf-cm)
Hexagon socket head boss
bolt
Hexagon socket head flush
bolt (steel in strength
category 12.9)
Tightening torque
Upper limit
Lower limit
1.8(18)
4.0(41)
7.9(81)
14(140)
32(330)
-

1.3(13)
2.8(29)
5.6(57)
9.6(98)
23(230)
-

INDEX

B-82135EN/05

INDEX
<Number>

<I>

1.5-YEAR CHECKS (5,760 hours)................................. 16

INERTIA LOAD SETTINGS....................................... 154

1-YEAR CHECKS (3,840 hours).................................... 15

INSTALLATION ......................................................... 185

3-MONTH CHECKS (960 hours)................................... 12

INSTALLATION SPECIFICATIONS ......................... 192

3-YEAR CHECKS (11,520 hours).................................. 17

INTERFACE FOR OPTION CABLE (OPTION) ........ 159

<A>

<J>

ADJUSTING LIMIT SWITCH (OPTION)..................... 57

J1-AXIS DRIVE MECHANISM ...................................... 4

ADJUSTMENTS ............................................................ 44

J2/J3-AXIS DRIVE MECHANISM ................................. 5

AIR PIPING (OPTION)................................................ 190

J4-AXIS DRIVE MECHANISM ...................................... 6

AIR SUPPLY (OPTION).............................................. 158

J5/J6-AXIS DRIVE MECHANISM ................................. 7

AXIS LIMITS SETUP .................................................... 45

<L>

<B>

LIMIT SWITCH REPLACEMENT (OPTION) ........... 120

BACKLASH MEASUREMENT .................................... 40

LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS


ARM ............................................................................. 148

<C>

<M>

CABLE FORMING ...................................................... 107


CABLE REPLACEMENT............................................ 112

MAINTENANCE AREA ............................................. 189

Checking the Settings.................................................... 156

MAINTENANCE TOOLS ............................................. 18

CIRCUIT DIAGRAM................................................... 201

MAJOR COMPONENT SPECIFICATI ONS.................. 8

COMPONENT REPLACEMENT AND ADJUSTMENT

MASTERING ................................................................. 60

ITEMS............................................................................. 43

Mastering Data Entry...................................................... 74

CONFIGURATION ..........................................................3

Mastering to a Fixture (Master Position Master) ............ 62

Configuration of the Severe Dust/Liquid Protection Option

MECHANICAL COUPLING OF END EFFECTOR TO

...................................................................................... 126

WRIST.......................................................................... 149
MECHANICAL COUPLING TO THE ROBOT.......... 144

<D>

MOUNTING BOLT TORQUE LIST ........................... 208

DAILY CHECKS............................................................ 10

<N>

<E>

NOTE FOR PART REPLACEMENT ............................ 77

EQUIPMENT MOUNTING FACE .............................. 150

Notes on Specifying Severe Dust/Liquid Protection Option

External Dimensions ..................................................... 138

...................................................................................... 127

<F>

<O>

FAILURE AND CAUSE ................................................ 33

Operation Area.............................................................. 140

<G>

OPERATION PERFORMANCE SCREENS ............... 151


OVERVIEW ............................................................ 32,125

General............................................................................ 60
Grease Replacement Procedure for the J1-Axis/J2-

<P>

Axis/J3-Axis and J4-Axis Gear Box ............................... 26

PERIODIC MAINTENANCE ........................................ 23

Grease Replacement Procedure for the Wrist.................. 26

PERIODIC MAINTENANCE TABLE ........................ 206

GREASING POINTS...................................................... 29

PIPING AND WIRING ................................................ 100

<H>

PIPING DIAGRAM...................................................... 101


PREFACE...................................................................... p-1

Hard Stopper and Limit Switch Setting........................... 51

i-1

INDEX

B-82135EN/05

<Z>

PREVENTIVE MAINTENANCE ....................................9

Zero Degree Mastering ................................................... 67

Procedure for Releasing the Grease Residual Pressure ... 27

Zero Point Position and Motion Limit ............................ 46

<Q>
Quick Mastering.............................................................. 69

<R>
Replacing Cable Covers ................................................ 130
REPLACING CABLES ................................................ 105
REPLACING COMPONENTS OF THE SEVERE
DUST/LIQUID PROTECTION OPTION .................... 128
REPLACING GREASE OF THE DRIVE MECHANISM
........................................................................................ 24
REPLACING J1-AXIS MOTOR (M1) AND REDUCER78
REPLACING J2-AXIS MOTOR (M2) AND REDUCER85
REPLACING J3-AXIS MOTOR (M3) AND REDUCER90
Replacing Motor Covers ............................................... 128
REPLACING MOTOR COVERS (OPTION) ................ 99
REPLACING PARTS ..................................................... 76
REPLACING THE BATTERIES ................................... 30
Replacing the Battery and Battery Box Cover .............. 132
REPLACING THE WRIST AXIS MOTORS (M4, M5,
AND M6), WRIST UNIT AND J4 AXIS REDUCER.... 95
Resetting Alarms and Preparing for Mastering ............... 61
ROBOT INTERFERENCE AREA ............................... 137

<S>
SAFETY PRECAUTIONS ............................................ s-1
SEALANT APPLICATION............................................ 98
Setting ........................................................................... 155
Severe Dust/Liquid Protection Characteristics.............. 125
SEVERE DUST/LIQUID PROTECTION OPTION..... 124
Single Axis Mastering..................................................... 71
Software Setting .............................................................. 50
SPARE PARTS LIST.................................................... 197
STORAGE .................................................................... 193

<T>
TRANSPORTATION ................................................... 177
TRANSPORTATION AND INSTALLATION............ 176
Transportation with an End Effector Attached.............. 184
TROUBLESHOOTING .................................................. 31

<W>
WIRING DIAGRAM .................................................... 102
WRIST LOAD CONDITIONS ..................................... 145

i-2

May, 2007

Jul., 2006

Sep., 2004

Date

03

02

01

Edition

04

Contents

Addition of the M-900iA/260L


Addition of the panel board for the R-J3iC
Addition of a model that supports the R-J3iC
Correction of the trouble shooting table
Addition of a procedure for releasing the residual
pressure of the grease bath
- Correction of a description of the severe dust/liquid
protection package
- Addition of an alert during transport

- Change the name of controller


(From R-J3iC to R-30iA)
- Add the note of the transportation equipments
- Change of the Section 2.2 3-month checks
- Change of the installation
- Correction of errors

Edition

05

Date

Dec.,
2007

Contents

- Addition of a procedure to move arms in emergency


or abnormal situations
- Addition of notes to transportation with an end
effector attached
- Addition of coasting time and distance when
emergency stop
- Addition of sensor cables for Severe Dust/Liquid
Protection Option
- Correction of errors

FANUC Robot M-900iA/350/260L MECHANICAL UNIT MAINTENANCE MANUAL (B-82135EN)

Revision Record