S 420i Mechanical Unit Maintenance B 80505EN 06

(R--J2CONTROLLER)
S-420i
MaintenanceMANUAL
B- 80505EN/ 06
E FANUC LTD, 1996
B--80505E/06 SAFETY PRECAUTIONS
s--1
SAFETY PRECAUTIONS
IMPORTANT!
Before operating, servicing or in any other way handling the
robot, the FANUC Robot SAFETY HANDBOOK
(B--80687E) must be thoroughly studied.
Consider the following notes in addition to the items described in the
SAFETY HANDBOOK.
D Please use appropriate lighting (e.g. a handy light) for maintenance
work. The lighting shall not create new dangerous situations.
D Whenever possible, perform maintenance, inspection and adjusting
with the power function off.
D When replacing parts, be sure to use those specified by FANUC.
D When replacing or installing components, make sure dirt and debris
do not enter the system.
D Be aware that when you remove a servomotor or brake, the associated
axis will fall if it is not supported or resting on a hard stop.
D 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.
D If it is necessary to operate the robot during the inspection, pay careful
attention to the robots motion and be sure to press the EMERGENCY
STOP button immediately when necessary.
D Be careful not to slip during maintenance by spilling grease.
D Do not climb on the robot.
D Be careful when touching the hot parts below.
(1) Servo motor (CAUTION LABEL fixed)
(2) Inside of controller
If touching is unavoidable, wear protective garments (heat resistant
gloves, etc.).
D Do not try to remove any mechanical component fromthe robot before
thoroughly reading and undestanding the procedures in the manual.
Doing so can result in serious personal injury and component
destruction.
D After replacement, be sure to fix all removed parts that include
screws.
D The motor and reducer are heavy. Be careful when replacing.
D After replacing parts or performing adjustment, be sure to test
operation according to the following procedure.
1. Using a low motion speed, single step the program for at least one
full cycle.
2. Using a low motion speed, test run the program continuously for
at least one full cycle.
B--80505E/06 SAFETY PRECAUTIONS
s--2
3. As speed is increased. the path may vary slightly. Run through the
program at 5--10% intervals up to 100%.
4. Using the programmed speed, test run the program continuously
for at least one full cycle.
Make sure all personnel are outside the fence before test running.
D After maintenance work, the robot must be clean of oil, water, or
debris.
B--80505E/06 PREFACE
p--1
PREFACE
This manual describes the maintenance and connection of the following
robot mechanical unit.
Product name
Mechanical unit
specification
number
Load
capacity
Remark
FANUC Robot S--420i F
FANUC Robot S--420i F/2.85
FANUC Robot S--420i W
FANUC Robot S--420i S
FANUC Robot S--420i L
FANUC Robot S--420i R
FANUC Robot S--420i R/120
A05B--1313--B201
A05B--1313--B281
A05B--1313--B203
A05B--1313--B241
A05B--1313--B261
A05B--1313--B401
A05B--1313--B402
120kg
120kg
155kg
80kg
75kg
100kg
120kg
A05B--1318--B201
A05B--1318--B281
A05B--1318--B203
A05B--1318--B241
A05B--1318--B261
120kg
120kg
155kg
80kg
75kg
Compact type
FANUC Robot S--420i W/175
FANUC Robot S--420i W/2.85
A05B--1313--B501
A05B--1313--B581
A05B--1313--B503
A05B--1313--B511
A05B--1313--B521
A05B--1313--B541
A05B--1313--B561
A05B--1313--B601
A05B--1313--B602
120kg
120kg
155kg
175kg
155kg
80kg
75kg
100kg
120kg
With positioning surface
A05B--1318--B701
A05B--1318--B781
A05B--1318--B703
A05B--1318--B741
A05B--1318--B761
120kg
120kg
155kg
80kg
75kg
Compact type
A05B--1313--B701
A05B--1313--B781
A05B--1313--B703
A05B--1313--B761
A05B--1313--B801
120kg
120kg
155kg
75kg
100kg
Severe dust/liquid
protection
(Only remote controller)
A05B--1320--B501
A05B--1320--B561
A05B--1320--B601
A05B--1320--B602
120kg
75kg
100kg
120kg
High duty type
The mechanical unit specification numbers are attached at the following
positions. Therefore, read the description in each section when checking.
p--2
The attachment position for the mechanical unit specification number
p--3
Table Specifications
Item S-420i F S-420iF/
2.85
S-420i W S-420i
W/175
S-420iW/
2.85
S-420i S S-420i L S-420i R S-420i R/120
Type Articulated type
Controlled axes 6 axes (J1, J2, J3, J4, J5, J6)
Reach 2.4 m 2.85 m 2.4 m 2.4 m 2.85 m 2.25m 3.0m 3.1m
Installation Floor mount Rack mount
Motion
range
J1 axis 360
(6.28rad)
360
(6.28rad)
360
(6.28rad)
360
(6.28rad)
360
(6.28rad)
360
(6.28rad)
360
(6.28rad)
360
(6.28rad)
360
(6.28rad) g
J2 axis 142
(2.48rad)
142
(2.48rad)
142
(2.48rad)
142
(2.48rad)
142
(2.48rad)
142
(2.48rad)
142
(2.48rad)
123
(2.15rad)
123
(2.15rad)
J3 axis 135
(2.36rad)
135
(2.36rad)
135
(2.36rad)
135
(2.36rad)
135
(2.36rad)
135
(2.36rad)
135
(2.36rad)
106
(1.85rad)
106
(1.85rad)
J4 axis 600
(10.47rad)
600
(10.47rad)
600
(10.47rad)
600
(10.47rad)
600
(10.47rad)
480
(8.38rad)
600
(10.47rad)
600
(10.47rad)
600
(10.47rad)
J5 axis 260
(4.54rad)
260
(4.54rad)
260
(4.54rad)
260
(4.54rad)
260
(4.54rad)
260
(4.54rad)
260
(4.54rad)
260
(4.54rad)
260
(4.54rad)
J6 axis 720
(12.57rad)
720
(12.52rad)
720
(12.57rad)
720
(12.57rad)
720
(12.52rad)
720
(12.57rad)
720
(12.57rad)
720
(12.57rad)
720
(12.57rad)
Maximum
speed
J1 axis 100/sec
(1.75rad/
sec)
90/sec
(1.57rad/
sec)
90/sec
(1.57rad/
sec)
90/sec
(1.57rad/
sec)
90/sec
(1.57rad/
sec)
70/sec
(1.22rad/
sec)
100/sec
(1.75rad/
sec)
100/sec
(1.75rad/
sec)
90/sec
(1.57rad/
sec)
J2 axis 110
(1.92rad/
sec)
100
(1.75rad/
sec)
100
(1.75rad/
sec)
100
(1.75rad/
sec)
100
(1.75rad/
sec)
110
(1.92rad/
sec)
110
(1.92rad/
sec)
100
(1.75rad/
sec)
90
(1.57rad/
sec)
J3 axis 100
(1.75rad/
sec)
90
(1.57rad/
sec)
75
(1.31rad/
sec)
75
(1.31rad/
sec)
75
(1.31rad/
sec)
100
(1.75rad/
sec)
100
(1.75rad/
sec)
100
(1.75rad/
sec)
90
(1.57rad/
sec)
J4 axis 210
(3.67rad/
sec)
210
(3.67rad/
sec)
140
(2.44rad/
sec)
140
(2.44rad/
sec)
140
(2.44rad/
sec)
210
(3.67rad/
sec)
210
(3.67rad/
sec)
210
(3.67rad/
sec)
210
(3.67rad/
sec)
J5 axis 150
(2.62rad/
sec)
150
(2.62rad/
sec)
110
(1.92rad/
sec)
110
(1.92rad/
sec)
110
(1.92rad/
sec)
150
(2.62rad/
sec)
150
(2.62rad/
sec)
150
(2.62rad/
sec)
150
(2.62rad/
sec)
J6 axis 210
(3.67rad/
sec)
210
(3.67rad/
sec)
140
(2.44rad/
sec)
140
(2.44rad/
sec)
140
(2.44rad/
sec)
210
(3.67rad/
sec)
210
(3.67rad/
sec)
210
(3.67rad/
sec)
210
(3.67rad/
sec)
Maximum
load
Wrist 120kg 120kg 155kg 175kg 155kg 80kg 75kg 100kg 120kg
load
capacity
J3 arm 20kg 20kg 20kg 20kg 20kg 20kg 20kg 20kg 20kg
capacity
J2 base 250kg 250kg 250kg 250kg 250kg 250kg 250kg 250kg 250kg
Allowable
load
t
J4 axis 60kgfm
(588Nm)
60kgfm
(588Nm)
86kgfm
(842Nm)
90kgfm
(882Nm)
86kgfm
(842Nm)
54kgfm
(529Nm)
53kgfm
(519Nm)
57kgfm
(558Nm)
60kgfm
(588Nm)
moment
at wrist *1
J5 axis 60kgfm
(588Nm)
60kgfm
(588Nm)
86kgfm
(842Nm)
90kgfm
(882Nm)
86kgfm
(842Nm)
54kgfm
(529Nm)
53kgfm
(519Nm)
57kgfm
(558Nm)
60kgfm
(588Nm)
J6 axis 30kgfm
(294Nm)
30kgfm
(294Nm)
50kgfm
(490Nm)
52kgfm
(510Nm)
50kgfm
(490Nm)
28kgfm
(274Nm)
27kgfm
(264Nm)
29kgfm
(284Nm)
30kgfm
(294Nm)
Allowable
load iner-
ti t i t
J4 axis 306kgfcms
2
(30.0kgm
2
)
306kgfcms
2
(30.0kgm
2
)
486kgfcms
2
(47.6kgm
2
)
472kgfcms
2
(46.3kgm
2
)
486kgfcms
2
(47.6kgm
2
)
376kgfcms
2
(36.8kgm
2
)
387kgfcms
2
(37.9kgm
2
)
337kgfcms
2
(33.0kgm
2
)
306kgfcms
2
(30.0kgm
2
)
tia at wrist
*1
J5 axis 306kgfcms
2
(30.0kgm
2
)
306kgfcms
2
(30.0kgm
2
)
486kgfcms
2
(47.6kgm
2
)
472kgfcms
2
(46.3kgm
2
)
486kgfcms
2
(47.6kgm
2
)
376kgfcms
2
(36.8kgm
2
)
387kgfcms
2
(37.9kgm
2
)
337kgfcms
2
(33.0kgm
2
)
306kgfcms
2
(30.0kgm
2
)
J6 axis 77kgfcms
2
(7.5kgm
2
)
77kgfcms
2
(7.5kgm
2
)
164kgfcms
2
(16.1kgm
2
)
158kgfcms
2
(15.5kgm
2
)
164kgfcms
2
(16.1kgm
2
)
100kgfcms
2
(9.8kgm
2
)
104kgfcms
2
(10.1kgm
2
)
86kgfcms
2
(8.4kgm
2
)
77kgfcms
2
(7.5kgm
2
)
Max. weld force 500kg
Repeatability !0.4mm !0.4mm !0.4mm !0.4mm !0.4mm !0.4mm !0.4mm !0.4mm !0.4mm
Weight *2 1500kg 1600kg 1500kg 1600kg 1600kg 1500kg 1600kg 1700kg 1700kg
Installation condition Ambient temperature : 0 to 45C
Humidity : Normal 75% RH or less
Short period (One month or less) 95% RH or less (No dew, nor frost allowed)
Vibration : 0.5G (4.9m/s
2
) or less
NOTE
The direction of weld reaction force should always be
through the cross point of J4, J5 and J6 axes.
p--4
NOTE
1 At maximumpayload. Allowable load moment and inertia at
wrist are changed by load.
2 Including Controller (i F/i W/i S/i L), Not including controller
(i R, i R/120)
Table of dust proof water proof performance
Standard model Severe dust/liquid protection
Wrist + J3 arm IP55 IP67
Other part IP54 IP55
For the FANUC Robot series, the following manuals are available:
Safety handbook
B--80687E
All persons who use the FANUC Robot and system de-
signer must read and understand thoroughly this handbook
Intended readers :
All persons who use FANUC Robot, system designer
Topics :
Safety items for robot system design, operation, maintenance
R--J2 controller Setup and Operations
manual
SPOT TOOL
B--80524E--10
HANDLING TOOL
B--80524E--11
SEALING TOOL
B--80524E--14
Intended readers :
Operator, programer, maintenance person, system designer
Topics :
Robot functions, operations, programing, setup, interfaces, alarms
Use :
Robot operation, teaching, system design
Maintenance manual
B--80525E
B--80525E--1
(European
specification)
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to peripheral equipment, maintenance
Use :
Installation, start--up, connection, maintenance
Mechanical unit Maintenance manual Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to the controller, maintenance
Use :
installation, start--up, connection, maintenance
FANUC Robot S--420iF/iL/iW/iR/iS B--80505E
-- Spot welding, general--purpose large robot
WARNING
1 For S--420i of severe dust/liquid protection, set up the regulated air--pressure.
Otherwise, not only the sufficient performance of dust proof/water proof cant be obtained but
also the oil seals may be broken. It must be set the air pressure to 0.2!0.05kgf/cm
2
.
2 Prepare the dry air for purge line, removed water. The air filter only remove garbage and oil
from air flows, cant remove water and vapor. Moist air will damage to the robot.
MANUALS
p--5
NOTE
1 Definitions of the IP protection levels.
-- Formal definition of IP67.
6=dust--tight; no ingress of dust
7=protected against the effects of temporary immersion
inwater; ingress of water inquantities causingharmful
effects shall not be possible when the enclosure is
temporarily immersed in water under standardized
conditions of pressure
5=dust protected; ingress of dust is not totally prevented
but dust shall not penetrate in a quantity to interfere
with satisfactory operation of the apparatus or to
impair safety
5=protected against water jets; water projected in jets
against the enclosure fromany direction shall have no
harmful effects
5=dust protected; ingress of dust is not totally prevented
but dust shall not penetrate in a quantity to interfere
with satisfactory operation of the apparatus or to
impair safety
4=protected against splashing water; water splashed
against the enclosure fromany direction shall have no
harmful effects
2 Severe dust/liquid protection in not retrofittable.
The following materials cant use the robot, severe dust/liquid protection model,
because they will harm rubber parts (packings, oil seals O--rings).
1) Organic solvents
Aromatic hydrocarbon
Petroleum hydrocarbon, ether
2) Coolant for machine tools
3) Other liquid or solution, that they will harm NBR.
Performance of resistant
chemicals and resistant
solvents
I MAINTENANCE
B--80505E/06 1. CONFIGURATION MAINTENANCE
3
1
CONFIGURATION
The configuration of the mechanical unit is shown in Fig. 1 (a) to (f).
Fig.1(a) Mechanical unit configuration (S--420i F, W, W/175)
MAINTENANCE 1. CONFIGURATION B--80505E/06
4
Fig.1(b) Mechanical unit configuration (S--420i F/2.85, S--420i W/2.85)
Fig.1(c) Mechanical unit configuration (S--420i S)
5
Fig.1(d) Mechanical unit configuration (S--420i L)
Fig.1(e) Mechanical unit configuration (S--420i R)
6
Fig.1(f) Mechanical unit configuration (Compact type)
7
Fig. 1.1 shows the J1--axis drive mechanism.
Rotation of the J1--axis motor (M1)(!22/2000 or M30/3000HV) is
input to the reducer via the center gear, and the output rotates the table.
The table is held to the base via a cross roller bearing.
J1 motor (M1)
(22/2000 or M30/3000HV)
Fig.1.1 J1--axis drive mechanism
Fig. 1.2 (a) shows the J2/J3--axis drive mechanism.
directly fed to the reducer, and the output moves the J2--axis.
directly fed to the reducer. The reducer output is coupled to the J3--axis
link 1 and moves the J3--axis arm via the J3--axis link 2.
J3--axis link 2
J3--axis link 1
J3--axis arm
J2--axis arm
J2 motor
(M2)(!22/2000 or
M30/3000HV)
J2--axis reducer
J3--axis reducer
J3 motor
(M3)(!22/2000 or
M30/3000HV)
Fig.1.2(a) J2/J3--axis drive mechanism
1.1
J1--AXIS DRIVE
MECHANISM
1.2
J2/J3--AXIS DRIVE
MECHANISM
8
Fig. 1.2 (b) shows the J2/J3--axis drive mechanism on S--420i compact
type.
The rotation of J3--axis motor is inputted to the reducer via bevel gear. The
output of reducer is linked to J3--axis link 1, and the J3--aixs armis moved
via the J3--axis link 2.
At the same time, the rotation of J2--axis motor is inputted to the reducer
via the bevel gear, and the reducer output moves the J2--axis arm.
Fig.1.2(b) J2/J3--axis drive mechanism (Compact type)
Fig. 1.3 shows the J4--axis drive mechanism.
Rotation of the J4--axis motor (M4)(!22/1500) is transmitted to the
reducer through the center gear, and the reducer output directly rotates the
J4--axis (J3--axis arm + wrist unit).
J4--axis reducer
(Hollow shaft)
Fig.1.3 J4--axis drive mechanism
1.3
J4--AXIS DRIVE
MECHANISM
9
Fig. 1.4 shows the J5/J6--axis drive mechanism.
Rotation of the J5--axis motor (M5)(!12/2000) is reduced with four gears
and fed to rotate the J6--axis unit. This causes J5--axis to rotate (wrist
bending).
Rotation of the J6--axis motor (M6)(!M6/300) is directly fed to the
reducer and rotates the wrist flange.
Fig.1.4 J5/J6--axis drive mechanism
NOTE
An electrically released brake is incorporated in the motors for all axes (J1, J2, J3, J4, J5, and
J6 axes) and applies at power off or in an emergency stop.
1.4
J5/J6--AXIS DRIVE
MECHANISM
10
1) Motor
Motor Specifications Model Axis Remark
M1 A06B--0147--B675 22/2000 J1
A06B--0186--B675#0011 M30/3000HV High duty
M2 A06B--0147--B675 22/2000 J2
A06B--0186--B675#0011 M30/3000HV High duty
M3 A06B--0147--B675 22/2000 J3
A06B--0186--B675#0011 M30/3000HV S--420iW/2.85
M4 A06B--0146--B675 22/1500 J4
M5 A06B--0142--B675#0006 12/2000 J5
M6 A06B--0162--B675#0006 M6/3000 J6
2) Reducer
Axis Specifications Model
J1--axis reducer A97L--0118--0939#250C--35 S--420i F/W/S/L/R
J2--axis reducer A97L--0118--0940#250A--118 S--420i F/S/L
A97L--0118--0940#250A--129 S--420i W/R
A97L--0118--0940#250A--141 S--420i R/120
J3--axis reducer A97L--0118--0941#250A--129 S--420i F/S/L/R
A97L--0118--0941#250A--141 S--420i F2.85/R120
A97L--0118--0941#250A--171 S--420i W
J6--axis reducer A97L--0118--0942#30A--81 S--420i F/S/L/R
A97L--0118--0942#30A--121 S--420i W
3) Gear
Axis Specifications Model
J1--axis pinion gear A290--7313--X221 S--420i F/W/L/R p g
A290--7313--Y221 S--420i S
A290--7313--Z221 S--420i R/120 F/2.85, W/2.85
J1--axis center gear A290--7313--X222 S--420i F/W/L/R g
A290--7313--Y222 S--420i S
A290--7313--Z222 S--420i R/120 F/2.85, W/2.85
J4--axis pinion gear A290--7313--X404 S--420i F/S/L/R p g
A290--7313--Y404 S--420i W
J4--axis center gear A290--7313--X405 S--420i F/S/L/R g
A290--7313--Y405 S--420i W
J5--axis gear 1 assembly A290--7313--V521 S--420i F/S/L/R g y
A290--7313--V524 S--420i W
A290--7313--V525 S--420i W
A290--7313--V526 S--420i W
J5--axis gear 4 A290--7313--X508 S--420i F/S/L/R g
A290--7313--Y508 S--420i W
J2/J3 gear box assembly A290--7313--V351 S--420i F/W/S/L (Compact type)
4) Others
Item Specifications Model
Wrist unit
(St d d d l)
A290--7313--T501 S--420i F/S/L/R
(Standard model)
A290--7313--T503 S--420i W
Wrist unit
(S d t/li id t ti )
A290--7313--T511 S--420i F/L/R
(Severe dust/liquid protection)
A290--7313--T513 S--420i W
1.5
MAJOR COMPONENT
SPECIFICATIONS
B--80505E/06 2. PREVENTIVE MAINTENANCE MAINTENANCE
11
2
PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained for a long time by
performing the periodic maintenance procedures presented in this
chapter.
Clean each part, and visually check component parts for damage before
daily system operation. Check the following items as the occasion
demands.
1) Before turning on power
Item Check items Check points
1
When air
control set is
combined
Air pressure 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 5 -- 7 kgf/cm
2
(0.49 to 0.69 MPa),
adjust it using the regulator pressure setting handle.
2
Oiler oil mist
quantity
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.
3 Oiler oil level Check to see that the oiler level is within the specified level shown in Fig. 2.1.
4
Leakage from
hose
Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.
Oil inlet Adjusting knob
Oiler mist amount check
Oiler
Pressure gauge
Regulator pressure setting handle
Filter
Fig.2.1 Air control set
2.1
DAILY CHECKS
MAINTENANCE 2. PREVENTIVE MAINTENANCE B--80505E/06
12
Severe dust/liquid protection
1
Air pressure Check air pressure using the pressure gauge on the air filter unit as shown in follow-
ing figure. If it does not meet the specified pressure of 0.2!0.05kgf/cm
2
, adjust it
using the regurator pressure setting handle.
2
Stains of filter elements Check to see element. If it has harsh stains, change elements. Refer to following
item.
3 Leakage from horse Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.
WARNING
For severe dust/liquid protection of the S--420i, set up the regulated air--pressure.
Otherwise, not only the sufficient performance of dust proof/water proof cannot be obtained but
also the oil seals might be broken. Set the air pressure to 0.2!0.05kgf/cm
2
.
2) After automatic operation
5
Vibration, abnormal noises,
and motor heating
Check whether the robot moves along and about the axes smoothly without unusual
vibration or sounds. Also check whether the temparature of the motors are exces-
sively high.
6
Changing repeatability Check to see that the stop positions of the robot has not deviated from the previous
stop positions.
7
Peripheral devices for proper
operation
Check whether the peripheral devices operate properly according to commands
from the robot.
8 Brakes for each axis Check that the end effector drops within 0.2 mm when the power is cut.
B--80505E/06 2. PREVENTIVE MAINTENANCE MAINTENANCE
13
1) Check the following items once every three months. Additional
inspection areas and times should be added to the table according to the
robots working conditions, environment, etc.
1
Control unit cable Check whether the cable connected to the teach pendant is unevenly
twisted.
2
Ventilation portion of control unit If the ventilation portion of the control unit is dusty, tum off power and
clean the unit.
2) First quarterly inspection
Check the following items at the first quarterly inspection, then every
year thereafter.
4 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 se-
curely engaged.See section 7.2.
5 Cleaning and checking each part
Clean each part (remove chips, etc.) and check component parts for
cracks and flaws.
6
Further tightening external main
bolts
Further tighten the end--effecter mounting bolts and external main bolts.
Check the following item once every six months.
1 Greasing balancer bushing Grease to the balancer bushing. Refer to item 3.2.
Check the following items once every year.
1 Battery Replace battery in the mechanical unit. Refer to 3.3.
2 Cables used in mechanical unit Refer to previous item.
3 Cleaning each parts and inspec-
tion
Refer to previous item.
4 Tightness of major external bolts Refer to previous item.
5 Greasing of balancer joint bearing Supply grease to the bearing (only for the S--420i R).
(See Section 3.2.)
6 Filter element Replace filter elements in the air filter unit. Refer to 3.4.
Check the following items once every 3 years.
1 Replacing grease of each axis, re-
ducer and gear box
Refer to item 3.1
2 Greasing to cross--roller bearing Grease to the required positions. Refer to item 3.2.
2.2
3--MONTH CHECKS
2.3
6--MONTH CHECKS
2.4
ANNUAL CHECKS
2.5
3--YEAR CHECKS
MAINTENANCE 2. PREVENTIVE MAINTENANCE B--80505E/06
14
The following tools and instruments are required for the maintenance
procedures contained in this manual.
1) Measuring instruments
Instruments Accuracy/Tolerance Applications
Dialgauge accuracy 1/100 mm Measurement of positioning and backlash
Slide calipers 150 mm
Push/pull tension gauge 10 kgf (98N) Measurement of backlash
2) Tools
Cross--point(+)screwdrivers : Large, medium, and small sizes
Conventional(--)screwdrivers : Large, medium, and small sizes
Hexagonal wrench key sets : M3 -- M16
(metric)
Adjustable wrenches : Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Double hexagon offset wrench
Grease gun
Pliers for C--retaining ring
Torque wrench
Dial indicator and base
For severe dust/liquid protection of the S--420i, follow the attached
caution stickers, and pay attention to the air pressure and purge and
maintenance of the air filter. Place them, where the robot operator can see
themeasily ; on the front of the R--J2 controller, and the front of operating
box near the main switch.
2.6
MAINTENANCE
TOOLS
2.7
CAUTION STICKERS
FOR DAILY CHECKS
(ONLY SEVERE
DUST/LIQUID
PROTECTION)
B--80505E/06 3. PERIODIC MAINTENANCE MAINTENANCE
15
3
PERIODIC MAINTENANCE
Replace the grease of the reducers of J1, J2, J3, J4, and J6 axes, and the
J5--axis gear box, every three years or 20,000 hours by using thefollowing
procedures.
3.1 Grease for 3--year periodical replacement
Supply position Grease name Quantity
J1--axis reducer 4670 cc (4130g)
J4--axis reducer
Kyodo yushi
900 cc (800g)
J5--axis gear box
Kyodo yushi
Moly white Re no.00
4770 cc (4220g)
J6--axis reducer
Moly white Re no.00
(Spec.: A98L--0040--0119)
370 cc (330g)
J2--axis reducer and gear box
(Compact type)
2600 cc (2300g)
J3--axis reducer and gear box
(Compact type)
2600 cc (2300g)
1) Replacing procedure of grease to the reducer and the gear box
1 Turn off the power.
2 Remove the grease outlet plug. Also remove the ventilation
plug for J5--axis.
3 Apply new grease from the grease inlet until it comes out
from the grease outlet.
4 Remount the plug at the grease outlet.
NOTE
1 Be sure to use the procedure described in this manual when
supplying grease at the grease nipple. If an attempt is made
to supply grease without unplugging the grease outlet, the
seal may be broken, and grease leakage may result.
2 Check for grease leakage due to the broken seal if one of the
following occurs when supplying new grease at the grease
inlet:
. Old grease is slow in coming out of the grease outlet.
. Very little old grease comes out of the grease outlet.
3 To prevent accidents caused by slipping, completely
remove any excess grease from the floor or robot.
3.1
REPLACING GREASE
OF THE DRIVE
MECHANISM
MAINTENANCE 3. PERIODIC MAINTENANCE B--80505E/06
16
Fig.3.1 (a) Replacing grease of J1--axis reducer (S--420i F/W/S/L)
Fig.3.1 (b) Replacing grease of J1--axis reducer (S--420i R)
17
(Standard type)
(Compact type)
Fig.3.1 (c) Replacing grease of J2/J3--axis reducer
18
Fig.3.1 (d) Replacing grease of J4--axis reducer
Fig.3.1 (e) Replacing grease of J5--axis gear box
Fig.3.1 (f) Replacing grease of J6--axis reducer
19
When replacing or supplying grease, orient the robot as shown in Fig 3.1
(g). For the S--420i R, position the robot to the zero--degree attitude.
Fig.3.1 (g) Greasing posture (S--420i F/W/S/L)
20
Supply grease to the parts periodically. If the robot is installed in a severe
environment, apply grease whenever necessary. If water splashes on the
robot, apply grease immediately. Fig. 3.2(a), (b) and Table 3.2(a) show
greasing points.
Table 3.2 (b) Shows substitute greases.
Table3.2 (a) Greasing points
Positions Grease Amount Method Greasing interval
J1--axis cross
roller bearing
40 cc each
(2 locations)
Supply to the grease nipple
Every 3 years
Balancer 100 cc each
(2 locations)
Every 3 years
Balancer bushing
SHELL ALVANIA No. 2
(Spec: A97L--0001--0179#2)
10 cc each
(4 locations)
(S--420iR has 2
locations)
Every 6 months
J2/J3--axis
joint bearing
20 cc each
(2 locations)
Every 3 years
Balancer joint bearing
(Only for S--420iR)
20 cc each
(2 locations)
Every year
Table3.2 (b) Substitutes for ALVANIA NO.2
MOBIL OIL MOBILACK GREASE NO.2 NIPPON OIL EPNOC NO.2
ESSO STANDARD VICON NO.2 IDEMITSU KOHSAN DAPHNE COLONEX GREASE NO.2
MITSUBISHI DIAMOND MULTIPURPOSE GREASE NO.2 COSMO OIL LIMAX NO.2
Fig.3.2 (a) Greasing points (S--420i F/W/S/L)
3.2
GREASING
21
Fig.3.2 (b) Greasing points (S--420i R)
22
The position data of each axis is preserved by the backup battery. The
battery needs to be periodically replaced every 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.
Replacing the battery 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 Battery
3.3
REPLACING
BATTERY
23
Severe dust/liquid protection for the S--420i is used to purge air into the
wrist and J3--axis arm. Air filter elements (air filter, and oil mist filter)
need to be periodically replaced every year. Use the following procedure
to replace the filter element when harsh stains exist.
WARNING
If harsh stains exist on the filter element, it cannot hold oil,
and will make flowing oil and mist.
1) Turn off the power.
2) Shut off the purge air.
NOTE
Be sure to shut off the primary valve.
3) Check that the air filters gauge indicated zero.
WARNING
When air filter and oil mist filter are broken up, it reduces
residual pressure; otherwise you could injure personnel or
damage equipment.
4) Replace the filter element as shown in the following figure. Air filters
and oil mist filter are replaced at the same time.
Fig.3.4 Replacing Battery
3.4
REPLACING FILTER
ELEMENT
MAINTENANCE 4. TROUBLESHOOTING B--80505E/06
24
4
TROUBLESHOOTING
The source of mechanical unit problems may be difficult to locate because
of overlapping causes. Problems may become further complicated, if they
are not corrected properly. Therefore, it is necessary to keep an accurate
record of problems and to take proper corrective actions.
Table 4.1 shows the main mechanical unit problems and their causes. If
a cause of remedy is unclear, please contact this company.
Table4.1 Problems and causes
Symptom Cause Remedy Remarks
The robot does not correctly
return to the zero position.
Low voltage of the memory
backup battery
Replace the battery. Refer to section 3.3.
Unusual external start signal Investigate the cause.
Incorrect parameter Revise parameters. Refer to the parameter table
in Setup and Operations
manual.
Position offset The robot has been hit. Revise the teaching points.
The robot is not firmly fas-
tened.
Re--tighten.
Peripheral device was
shifted.
Reposition.
Incorrect parameters. Revise parameters. Refer to the parameter table
in Setup and Operations
manual.
Defective pulse coder cable Replace the cable. Refer to section 8.
APC (Absolute Position
Checker) malfunction.
Replace the motor or the
pulse coder.
Refer to sections 6.
Play in mechanical unit. See
below.
Vibration The robot is not firmly fas-
tened.
Re--tighten.
Floor vibration. (especially
when installed above the first
floor)
Investigate the installation
location.
Incorrect servo adjustment. Adjust the servo. Contact the service repre-
sentative.
Defective cable. Replace the cable. Refer to section 8.
Not grounded. Connect to ground.
Defective motor. Replace the motor. Refer to section 6.
Defective reducer. Replace the reducer. Refer to sections 6.
Incorrect time constant Revise the time constant Refer to the parameters.
Play in mechanical units. See
below.
4.1
GENERAL
4.2
PROBLEMS AND
CAUSES
B--80505E/06 4. TROUBLESHOOTING MAINTENANCE
25
Symptom Remarks Remedy Cause
There is play.
(See Table 4.2 (b).)
Loose screws or pins. Tighten and apply LOCTITE
as specified.
Defective reducer. Replace the reducer. Refer to section 6.
There is play.
(See Table 4 2 )
Incorrect gear adjustment. Adjust the gears. Refer to section 5.4.
(See Table 4.2.)
Worn gears. Replace the gears. Refer to section 6.
Worn bearings. Replace the bearings. Contact the service repre-
sentative.
Cracked casting, etc. Replace cracked parts. Contact the service repre-
sentative.
Unusual noise Insufficient gear or reducer
lubrications.
Lubricate. Refer to section 3.
Foreign matter in gears or re-
ducer.
Clean and lubricate. Refer to section 3.
Excessive pressure on bear-
ings.
Reduce the pressure on the
bearings.
Contact the service repre-
sentative.
Defective reducer. Replace the reducer. Refer to section 6.
Worn gears. Replace the gears. Refer to section 6.
Worn bearings. Replace the bearings. Contact the service repre-
sentative.
Incorrect servo adjustment. Adjust the servo. Contact the service repre-
sentative.
Insufficient lubrication to the
inside of balancer
Lubricate (900 cc) Refer to section 3.2.
Unusual heating Insufficient gear or reducer
lubrication.
Lubricate. Refer to section 3.
Specified grease not used. Replace with the specified
grease.
Refer to section 3.
Excessive pressure on bear-
ings.
Reduce the pressure on the
bearings.
Contact the service repre-
sentative.
Excessive load. Reduce the load/restrict
movement conditions.
Incorrect time constant. Revise the time constant. Refer to the parameters.
Drops when the power
supply is off
Brake gap too large. Replace the motor. Refer to section 6 and Table
4 3 (*) supply is off
Fused brake drive relay. Replace the relay.
4.3 (*).
Grease leakage Deteriorated O--ring, oil seal
or packing.
Replace the O--ring, oil seal
or packing.
Cracked casting, etc. Replace cracked parts. Contact the service repre-
sentative.
Loose screws. Tighten.
(*) Refer to the maintenance manual of the controller.
26
(1) Method
1 Move the robot to the designated posture(Refer to table 4.3(a),
and Fig 4.3 (b) ).
2 Release the brake control (Refer P85).
3 Apply pressure on each axis as Fig 4.3 (a).
4 Measure the moving distance.
Apply pressure on each axis 3 times, and measure the moving distance at
2nd and 3rd attempt. The backlash is calculated by the average of them.
Home Position
0
+10kg
--10kg
+10kg
+10kg
--10kg
--10kg
1st attempt (Dont measure)
2nd attempt (B
2
= L
1
+ L
2
)
L
2
L
1
L
3
L
4
3rd attempt (B
3
= L
3
+ L
4
)
Fig.4.3 (a) How to measure the backlash
The backlash is calculated as B "
B
2
#B
3
2
.
(2) Measuring posture and position.
1 For iF, iF/2.85, iW, iW/175, iW/285, iS, iL,
Table4.3 (a) Posture for measuring backlash
Measuring
axis
Posture
axis
J2 J3 J4 J5 J6
J1 70_ 0_ ------ ------ ------
J2 0_ 0_ ------ --90_ ------
J3 50_ --90_ --90_ --90_ 90_
J4 50_ --90_ 90_ 90_ --90_
J5 70_ 0_ 90_ 90_ --180_
J6 70_ 0_ 90_ 90_ --90_
4.3
THE MEASUREMENT
OF THE BACKLASH
27
Fig.4.3 (b) Posture for measuring backlash
Table4.3 (b) Position for measuring backlash
Item A B C D E F
S--420iF 2193 1190 1300 233 233 250
S--420iW 2193 1190 1300 251 251 323
S--420iW/175 2193 1190 1300 220 220 298
S--420iW/2.85 2655 1190 1752 251 251 323
S--420iS 2043 1190 1150 377 377 350
S--420iL 2795 1190 1902 408 408 360
S--420iF/2.85 2655 1190 1752 233 233 250
2 For iR,iR/120
Table4.3 (c) Posture for measuring backlash
Measuring
axis
Posture
axis
J2 J3 J4 J5 J6
J1 0_ 30_ ------ ------ ------
J2 ------ ------ ------ ------ ------
J3 --20_ 0_ ------ ------ ------
J4 --20_ 0_ --90_ 90_ --90_
J5 --30_ 0_ 180_ 30_ 0_
J6 --30_ 0_ --90_ 30_ 0_
28
Fig.4.3 (c) Posture for measuring backlash
NOTE
In the case of S--420iRand iR/120, the backlash of J2 cant
measure. Because the gravity acts on the direction of J2,
constantly.
(3) Allowable backlash tolerances
Table4.3 (d) Allowable backlash tolerances (S--420iF)
J1 J2 J3 J4 J5 J6
Angle conversion (arc--min) 3.1 1.45 0.89 11.98 4.79 14.18
Displacement conversion (mm) 1.98 0.5 0.33 1.51 0.6 1.03
Distance (mm) 2193 1190 1300 433 433 250
Table4.3 (e) Allowable backlash tolerances (S--420iW)
J1 J2 J3 J4 J5 J6
Distance (mm) 2193 1190 1300 451 451 323
29
Table4.3 (f) Allowable backlash tolerances (S--420iW/175)
J1 J2 J3 J4 J5 J6
Distance (mm) 2193 1190 1300 440 440 298
Table4.3 (g) Allowable backlash tolerances (S--420iW/2.85)
J1 J2 J3 J4 J5 J6
Distance (mm) 2655 1190 1752 451 451 323
Table4.3 (h) Allowable backlash tolerances (S--420iS)
J1 J2 J3 J4 J5 J6
Angle conversion (arc--min) 3.34 1.45 1 6.74 2.7 7.24
Distance (mm) 2043 1190 1150 577 577 350
Table4.3 (i) Allowable backlash tolerances (S--420iL)
J1 J2 J3 J4 J5 J6
Displacement conversion (mm) 1.94 0.5 0.33 1.5 0.6 1
Distance (mm) 2795 1190 1902 608 608 360
Table4.3 (j) Allowable backlash tolerances (S--420iF/2.85)
J1 J2 J3 J4 J5 J6
Distance (mm) 2655 1190 1752 433 433 250
Table4.3 (k) Allowable backlash tolerances (S--420iR,iR/120)
J1 J2 J3 J4 J5 J6
Angle conversion (arc--min) 2.21 ------ 0.98 14.37 4.79 11.35
Displacement conversion (mm) 2 ------ 0.5 1.81 0.6 0.83
Distance (mm) 3113 ------ 1752 496 496 288
MAINTENANCE 5. ADJUSTMENTS B--80505E/06
30
5
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 for a long period of use
or after parts are replaced, adjustments may be required.
Axis limits define the motion range of the robot. The operating range of
the robot axes can be restricted because of:
D Work area limitations
D Tooling and fixture interference points
D Cable and hose lengths
There are three methods used to prevent the robot from going beyond
the necessary motion range. These are
D Axis limit software settings
D Axis limit switches -- optional
D Axis limit hardstops
WARNING
Do not use axis software limits as the only method for
restricting robot motion. Change the hard stops to match
the software modifications, otherwise injury to personnel
and damage to equipment can occur.
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. If the robot is not calibrated,
overtravel limit switches or hardstops are contacted two to three
degrees beyond the software limits. Overtravel switches for axis 1 are
available as an option.
Axis limit switches are overtravel switches that, when tripped, cut
power to the servo motors. These are located about 0.5 degrees
beyond the software limits. Overtravel switches for J1--axis are
available as an option.
Axis limit hardstops are physical barriers that are located two or three
degrees beyond the overtravel limit switch or software setting on the
three major axes. The robot cannot move beyond a hardstop.
Setting the axis limits software settings changes the motion range of
the robot. The axis limit screen displays the current upper and lower
axis limits, for each robot axis, in degrees.
Displays the upper limits of each axis, or the axis limits in a positive
direction.
5.1
AXIS LIMITS SETUP
Software Settings
Limit Switches
Hardstops
Upper Limits
B--80505E/06 5. ADJUSTMENTS MAINTENANCE
31
Displays the lower limits of each axis, or the axis limits in a negative
direction.
After you change the axis limits, turn off the controller and then turn it
on again so the new settings can be used.
CAUTION
Changing the axis limits will affect the robot work area, and
could change robot motion. Anticipate the effects of
changing axis limits before changing them; otherwise
unexpected results could occur, such as errors in previously
recorded positions.
Lower Limits
Saving Limits
32
Zero point and software motion limit are provided for each controlled
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.
Exceeding the software motion limit of a controlled axis is called
overtravel (OT). Overtravel is detected at both ends of J1--axis by an
optional adjustable OT switch. Overtravel is not detected on any other
axis.
The total travel (stroke) of J1--axis through J5--axis beyond the software
motion limit is restricted by a mechanical stopper. A mechanical stopper
is not provided for J6--axis.
Fig.5.1.1 (a) -- (j) show the zero point and motion limit OT detection
position, and mechanical stopper position of each axis.
Fig.5.1.1 (a) J1--axis (S--420i F/W/S/L/R)
5.1.1
Zero Point Position
and Motion Limit
33
Fig.5.1.1 (b) J2--axis (S--420i F/W/S/L)
Fig.5.1.1 (c) J2--axis (S--420i R)
34
Fig.5.1.1 (d) J3--axis (S--420i F/W/S/L)
Fig.5.1.1 (e) J3--axis (S--420i R)
Fig.5.1.1 (f) J2/J3--axis interference angle (S--420i F/W/S/L/R)
35
Fig.5.1.1 (g) J4--axis (S--420i F/W/L/R)
( + 250_)
( -- 250_)
Fig.5.1.1 (h) J4--axis (S--420i S)
36
Fig.5.1.1 (i) J5--axis (S420i F/W/S/L/R)
Fig.5.1.1 (j) J6--axis (S--420i F/W/S/L/R)
37
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.
Use Procedure 5--1 to set up axis limits.
Procedure 5--1 Setting Up Axis Limits
1 Press MENUS.
2 Select SYSTEM.
3 Press F1, [TYPE].
4 Select Axis Limits. You will see a screen similar to the following.
System Axis Limits JOINT 100%
AXIS GROUP LOWER UPPER
1/16
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
0
0
0
180.00
72.00
30.00
300.00
130.00
360 00
0.00
0.00
0.00
dg
dg
dg
dg
dg
dg
mm
mm
mm
[ TYPE ]
-70.00
-105.00
-300.00
-130.00
-360.00
0.00
0.00
0.00
-180.00
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 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 so the new
information can be used.
5.1.2
Software Setting
Step
38
The J1--axis stroke can be limited depending on the operating
environment of the robot. The stroke can be changed by changing the
locations of the dog and mechanical stopper and the settings of the motion
limits using the following procedure.
The stroke can be changed every 15 degrees in the upper limit of --135
degrees to +180 degrees and the lower limit of --180 degrees to +135
degrees.
If mastering position (0 degree) does not exist within the changed stroke,
the stroke must be reset so that it contains 0 degree position.
Changing the dog position and the mechanical stopper
Change the dog position and the mechanical position as shown in Figs.
5.1.3 (a), (b) to match with a desired stroke position.
Fig.5.1.3 (a) Mechanical stopper locations
Fig.5.1.3 (b) Dog (option) locations
5.1.3
Hard Stopper and Limit
Switch Setting
39
Axis limit switches are overtravel switches that, when tripped, cut power
to the servo motors. These are located 10.5 degrees beyond the software
limits. Overtravel switches for axis 1 are available as an option.
The optional J1--axis OT limit switch is actuated by a pivoting
dog mounted on a bracket bolted to the rotating J1--axis table. See
Figure 5.2. Use these steps to adjust the OT switch.
The J1--axis stroke may be limited by moving the mechanical
stoppers and OT limit switch dog. Refer to Section 5.3. When
the J1--axis stroke is to be limited, a second mechanical stopper
and dog must be used.
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 around
the J1--axis by a jog feed which goes beyond the motion limit.
2 Press the emergency stop button to stop the robot moving.
3 Loosen the two M68 bolts and the two M4X25 bolts that
secure the J1--axis limit switch.
4 Move the limit switch so that the robot activates it at about
0.5 degrees before the stroke end around the J1--axis.
5 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 RESETkey. Then, while holding on the SHIFTkey,
move the J1--axis off the OT limit switch by jogging in joint
mode.
6 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.
7 Set the $MOR_GRP.$CAL_DONE system parameter to
TRUE.
8 Turn off the power, then turn it on again to restart the
controller.
Fig.5.2 Adjusting J1--axis OT (option)
5.2
ADJUSTING J1--AXIS
LIMIT SWITCH
(OPTION)
40
When you master a robot you define the physical location of the robot by
synchronizing the mechanical information with the robots positional
information. A robot must be mastered to operate properly. Robots are
usually mastered before they leave FANUC However, it is possible that
a robot might lose its mastering data and require to be remastered.
You can master the robot using several different methods. Refer to Table
5.3.1 to select the method that best meets your needs.
Table5.3.1 Mastering Methods
Mastering Method When to Use
Mastering to a fixture
(Master Position
Master)
D When mastery is lost due to mechanical
disassembly or repair.
D When a quick master reference position was not
previously set.
D Method of choice for P--and A--series robots.
Used for S-- and M--series robots when extreme
precision is required.
mastering to zero de-
grees
D When mastery is lost due to mechanical
disassembly or repair.
D When a quick master reference position was not
previously set.
D Method of choice for S-- and M--series robots
when extreme precision is not required.
Single axis mastering When mastery was lost due to mechanical disas-
sembly or repair of a single axis (usually due to mo-
tor replacement).
Recording the quick
master reference posi-
tion
To record mastering data as a reference for future
quick mastering.
Quick mastering To retrieve mastery data that has been stored as a
quick master reference position when mastery is lost
due to an electrical or software problem. Do not use
if mastery is lost due to mechanical disassembly or
repair.
Quick mastering is a convenient way to master an robot after you have
recorded a reference position. You cannot quick master a robot unless the
reference position was taught before mastering was lost.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
5.3
MASTERING
5.3.1
General
41
When you power up the robot after disconnecting the pulse coder backup
batteries you may see a SRVO--062 BZAL or SRV0--038 Pulse mismatch
alarm. Before mastering the robot you must reset the alarmand rotate the
motor of each axis that lost battery power to prepare the robot for
mastering.
Use Procedure 5--2 to reset these alarms and prepare the robot for
mastering.
Procedure 5--2 Preparing the Robot for Mastering
H You see a SRVO--062 BZAL or SRVO--038 Servo mismatch
alarm.
1 Replace the robot batteries with four new 1.5 volt alkaline
batteries, size D. Observe the direction arrows in the battery box
for proper orientation of the batteries.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the
following; otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key 1 and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
e Select Master/Cal. You will see a screen similar to the
following.
SYSTEM Master/Cal JOINT 10%
[ TYPE ] LOAD RES_PCA
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press ENTER or number key to select.
DONE
5.3.2
Resetting Alarms and
Preparing for
Mastering
Condition
Step
42
6 To reset a SRVO--062 alarm when RES_PCA does not appear on
the Master/Cal menu, do the following:
a Press F1, [TYPE].
b Select Variables.
c Move the cursor to $MCR and press ENTER.
d Move the cursor to $SPC_RESET and press F4, TRUE.
The value will change to TRUE momentarily, and will then change
to FALSE.
e If the value does not change to TRUE momentarily, repeat
Step 6.
f Press RESET on the operator box.
7 Perform a cold start.
a Turn off the robot.
b Press and hold the FAULT RESET button on the operator box.
c While still pressing FAULT RESET, press the ON button on
the operator box.
8 If the SRVO--062 alarm is still present; there is a battery, cable or
pulse coder problem. Refer to the SYSTEM R-J2 Controller Series
Electrical Connection and Maintenance Manual for further
information.
9 If a SRVO--038 alarm is present at this time, repeat step 6 to reset
it. It is not necessary to cold start the robot after resetting to clear
this alarm.
10 Rotate each axis that lost battery power by at least one motor
revolution in either direction.
a Jog each rotary axis at least twenty degrees.
b Jog each linear axis at least thirty millimeters.
11 Perform any of the mastering procedures from the MASTER/CAL
menu.
43
When a major part of the robot mechanical unit is replaced and the actual
position of each axis is displaced from the current value stored through
an absolute pulse coder (hereinafter abbreviated as APC), the mastering
is executed to set the geometric position of the robot. Mastering has been
performed before shipment.
When mastering the robot, arrange the robot to meet the following
conditions.
D Make the robot mounting base horizontal within 1 mm.
D Remove the hand and other parts from the wrist.
D Set the robot in the condition protected from an external force.
D Have the appropriate mastering fixture for your robot.
D Clear any servo faults that prevent you from jogging the robot.
D Jog each axis that has lost mastery at least one motor turn.
NOTE
Since the axis stroke is not checked during the mastering,
be careful to stay clear of the robot motion.
1) Assembling the fixture base
Assemble the fixture base as shown in Fig. 5.3.3 (a).
ADAPTOR Plate
Base
Plate
Bolts
M5X20
Bolts
M5X20
Note) The shape of the adapter plate varies with the model.
Fig.5.3.3 (a) Assembling fixture base
5.3.3
Mastering to a Fixture
(Master Position
Master)
44
2) Mount the dial gauges.
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.)
0
3
Calibration block
M5 bolt
A
B
F
C
D
E
20
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), (d).
Fig.5.3.3 (c) Mounting fixture base (S--420i F/W/S/L)
45
Fig.5.3.3 (d) Mounting fixture base (S--420i R)
4) Mounting the fixture to the wrist
Mount the fixture to the J6--axis flange as shown in Fig. 5.3.3 (e).
Fig.5.3.3 (e) Mounting fixture to wrist
46
5) To release the brake control, set the system variable
$PARAM_GROUP.$SV_OFF_ALL to false. Then set system
variable $PARAM_GROUP.$SV_OFF_ENB for each axis to false,
turn off the power, and power on.
6) Jog each axis to a calibration point or near it where calibration using
a fixture is to be performed. (See Fig. 5.3.3 (f) to (j).) When jogging
the robot, be careful not to hit the wrist of the robot onto the mastering
fixture.
7) Jog the robot slowly until the dial indicators A to F shown in Fig.
5.3.3 (b) meet arrows A to F shown in Fig. 5.3.3(e).To set each axis
to the mastering fixture position, jog the robot in a direction in which
the dial indicator reading decreases to prevent an error caused by axis
backlash.
8) Press MENUS.
9) Select SYSTEM.
10)Press F1, [TYPE].
11)Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 12.
a) Select VARIABLE from the [TYPE] menu.
b) Move the cursor to $MASTER_ENB.
c) Press the numeric key 1 and then press ENTER on the teach
pendant.
d) Press F1, [TYPE].
e) Select Master/Cal. You will see a screen similar to the following:
3 QUICK MASTER
6 CALIBRATE
DONE
12)Select Master Position Master.
13)Press F4, YES. Mastering will be performed automatically.
14)Select Calibrate.
15)Press F4, YES.
16)To re-enable brake control, set system variable
$PARAM_GROUP.$SV_OFF_ALL to true. Then set system
variable $PARAM_GROUP.$SV_OFF_ENB for each axis to true.
17)Turn off the power, and power on.
47
Fig.5.3.3 (f) Mastering attitude (S--420i F, W, W/175)
Fig.5.3.3 (g) Mastering attitude (S--420i F, 2.85, W/2.85)
48
Fig.5.3.3 (h) Mastering attitude (S--420i S)
Fig.5.3.3 (i) Mastering attitude (S--420i L)
49
Fig.5.3.3 (j) Mastering attitude (S--420i R)
50
When you master to zero degrees, you position all axes at their zerodegree
witness marks and record the zero degree position.
Use Procedure 5--3 to master to zero degrees.
Procedure 5--3 Mastering to Zero Degrees
H You have cleared any servo faults that prevent you from jogging
the robot.
H You have jogged each axis that has lost mastery at least one motor
turn. (Procedure 5--2).
1 Using the joint coordinate system, jog each axis of the robot to the
zero degree witness mark.
2 Press MENUS.
3 Press SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
following.
5.3.4
Zero Degree Mastering
Condition
Step
51
3 QUICK MASTER
6 CALIBRATE
DONE
6 Select Zero Position Master.
7 Press F4, YES. Mastering will be performed automatically.
8 Select Calibrate.
9 Press F4, YES.
Table5.3.4 Attitude with position marks aligned
Axis S--420iF/W/S/L S--420iR
J1--axis 0 deg 0 deg
J2--axis 0 deg --15 deg
J3--axis 0 deg +15 deg
NOTE
For the S--420i R, the attitude assumed by aligning the
position marks differs from the zero--degree attitude.
52
Fig.5.3.4 Zero degree position arrow mark for each axis
53
Quick mastering allows you to minimize the time required to remaster the
robot using a reference position you established when the robot was
properly mastered. You cannot quick master the robot unless you have
previously recorded this quick master reference position.
Record the quick master reference position when the robot is properly
mastered. The best time to record the quick master reference position
is when the robot is still factory-mastered.
If you lose mastery due to an electrical or software problem, you can
use this reference position to master the robot in a minimum amount of
time. If you lose mastery due to mechanical disassembly or repair, you
must master to a fixture or perform zero degree mastering.
Use Procedure 5--4 to record the quick master reference position. Use
Procedure 5--5 to quick master the robot.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
5.3.5
Quick Mastering
54
Procedure 5--4 Recording the Quick Master Reference Position
H The robot is properly mastered.
1 Align the witness marks on the robot. This is the zero position,
which will be the quick master reference position. .
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
following.
3 QUICK MASTER
6 CALIBRATE
DONE
6 Move the cursor to SET QUICK MASTER REF and press
ENTER.
7 Press F4, YES.
Condition
Set quick master ref? [NO]
55
Procedure 5--5 Quick Mastering the Robot
H The robot has lost mastery due to an electrical or software
problem.
NOTE
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.
H The quick master reference position was recorded before the robot
lost mastery.
the robot.
turn.
1 Jog the robot to the quick master reference position (zero degree
position).
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
following.
Condition
56
3 QUICK MASTER
6 CALIBRATE
DONE
6 Move the cursor to QUICK MASTER and press ENTER.
7 Press F4, YES.
8 Move the cursor to CALIBRATE and press ENTER
9 Press F4, YES.
Quick master? [NO]
57
You can master a single axis of an S-series robot when mastery was lost
due to mechanical disassembly or repair of a single axis.
Use Procedure 5--6 to master a single axis.
Procedure 5--6 Mastering a Single Axis
the robot.
turn. (Procedure 5--2).
1 Using the joint coordinate system, jog the unmastered axis of the
robot to the zero degree witness mark.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
following.
3 QUICK MASTER
6 CALIBRATE
6 Select 4, Single Axis Master. You will see a screen similar to the
following.
5.3.6
Single Axis Mastering
Condition
Step
58
SINGLE AXIS MASTER JOINT 10%
[ TYPE ] GROUP EXEC
ACTUAL POS (MSTR POS) (SEL) [ST]
J1 0.000 ( 0.000) (0) [2]
J2 3.514 ( 35.000) (0) [0]
J3 -7.164 (-100.000) (0) [2]
J4 -357.366 ( 0.000) (0) [2]
J5 -1.275 ( -80.000) (0) [2]
J6 4.571 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [0]
E2 0.000 ( 0.000) (0) [0]
E3 0.000 ( 0.000) (0) [0]
1/9
7 Move the cursor to the MSTR POS column for the unmastered
axis and press the 0 key.
8 Continuously press and hold the DEADMAN switch and turn the
teach pendant ON/OFF switch to ON.
9 Move the cursor to the SEL column for the unmastered axis and
press the numeric key 1.
10 Press ENTER.
11 Press F5, EXEC. Mastering will be performed automatically.
12 Press PREV.
13 Select Calibrate.
14 Press F4, YES.
59
When the backlash of the J5--axis exceeds the tolerance (six minutes),
listed in Table 4.2, adjust the backlash as described below.
1) Adjusting the backlash of the gear 1 and gear 2 assemblies
a) Position a lever type dial test indicator on the notched portion of
the U nut of the gear 1 assembly and secure the indicator. (Make
the measurement at a point 36 mm from the center of rotation of
the gear 1 assembly.)
b) While holding the gear 2 assembly still, measure the play in the
gear 1 assembly.
c) Change the thickness of the spacers used with each assembly to
adjust the backlash to within 0 to 0.15 mm. (The J5--axis must
have some backlash.)
2) Adjusting the backlash of the gear 2, 3, and 4 assemblies.
a) Position a lever type dial indicator on the tooth surface of the gear
4 assembly and secure the indicator. (Make the measurement at
a point 136 mm from the center of rotation of the gear 4
assembly.)
b) While holding the gear 2 assembly still, measure the play in the
gear 4 assembly.
c) Adjust the position of the gear 3 assembly so that the backlash
within 0 to 0.10 mm. (The J5--axis must have some backlash.)
Fig.5.4 Adjusting J5--axis Backlash
5.4
ADJUSTING J5--AXIS
BACKLASH
MAINTENANCE 6. REPLACING PARTS B--80505E/06
60
6
REPLACING PARTS
Replace the main parts of the mechanical unit as described below.
1) When a part is replaced, the corresponding adjustment must be made.
Table 6.1 lists those parts that can be replaced and the corresponding
adjustment. After replacing a part, perform the appropriate
adjustment, as listed below.
Table 6.1 Parts to be Replaced and Adjustment Items
Parts to be replaced Adjustment Method
Motor, reducer, gear Mastering See 5.3
Wrist unit Mastering See 5.3
Cable (*) Mastering See 5.3
Limit switch (*) Adjusting, limit switch See 5.2
* Refer to Section 1, item8 for replacement of cables andlimit switches.
NOTE
The following components are heavy. Be particularly
careful when carrying or assembling them.
Component Weight (approximate)
Servo motors
J1, J2, J3, J4 (M1, M2, M3, M4) 30 kg
Servo motors
J5 (M5) 20 kg
J1--axis 55 kg
Reducers J2-- and J3--axes 50 kg
J4--axis 20 kg
J1--axis table 60 kg
J1--axis holder 30 kg
J1--axis cross roller bearing 30 kg
J2--axis arm 90 kg
Balancer (S--420 iF/W/S/L) 45 kg
J3--axis link 1 285 kg
Wrist unit 100 kg
J2--J6--axis unit (See Fig. 6.2 (b).) 1100 kg
J4--J6--axis unit (See Fig. 6.3 (j).) 300 kg
Balancer (S--420 iR) 100 kg
J3--axis link 1 (with add. weight) 345 kg
Controller (i--cabinet) 100 kg
J2/J3 gear box (Compact type) 25 kg
6.1
PART REPLACEMENT
AND CORRESPONDING
ADJUSTMENT
B--80505E/06 6. REPLACING PARTS MAINTENANCE
61
In case of reusing sealbolts for S--420i, observe following notes strictly.
(If possible, change them to new sealbolts)
1) Apply LOCTITE to the sealbolts.
2) Notice the following 3 notes.
a) Remove excessive bits of sealant on the sealbolt. (Not necessary
to remove sealant which is fixed tightly.)
b) The length of application is 2d (d : diameter of the bolt) from the
tip of the bolt, and spread it evenly around it.
c) Spread LOCTITE on whole threaded portion and rubbing 2 bolts
together in order to spread it to the bottom of groove.
Fig.6.1 Standard application of sealant
62
1) Replacing J1--axis motor (Fig. 6.2 (a) )
2 Remove the J1--axis motor connectors. (For the S--420i R,
remove the cover from the J2 angle base.)
3 Remove four motor mounting bolts (M1235) and then remove
the motor.
4 Remove the nut and gear in order.
5 Replace the motor, and remount a new motor reversing above
procedure. Polish the motor flange with oil stone. Apply
LOCTITE No. 242 to the thread of the nut. Be careful not to
damage the tooth surface of the spur gear. Install an O ring
correctly.
6 Perform mastering (Refer to section 5.3).
Fig.6.2 (a) Replacing J1--axis motor (M1)
6.2
REPLACING J1--AXIS
MOTOR (M1) AND
REDUCER
63
2) Replacing J1--axis reducer (Fig. 6.2 (b) )
2 Remove J1--axis motor (M1) by the above procedure.
3 When equipped with integrated controller, open the side cover of
the controller and disconnect the cables.
4 Remove the controller mounting bolts (M10 x 30 2pcs and M10
x 35 2 pcs) and remove the controller.
5 Remove the cables and air tubes from the connector box (option)
at the side of J1--axis base and remove the grease supply tube.
6 Remove two M8 x 12 bolts in the J1--axis base and extract a plate
with a cable halfway.
7 Remove a cable clamp and nylon band attached to the plate and
draw out the plate from J1--axis base.
8 Remove J2--base mounting bolts (M12 x 35 12 pcs) and lift up
the robot body taking care of the cable to separate the J1--axis
unit. (For the S--420i R, remove the 9 bolts (M12x35) and 3 bolts
(M12x80) securing the J2 angle base.)
9 Remove the table mounting bolts (M12 x 70 13 pcs) and remove
the table.
10 Remove the holder mounting bolts (M1245 12 pcs) and remove
the holder.
11 Remove the center gear.
12 Remove the reducer mounting bolts (M16110 9 pcs) and
remove the reducer with cross roller bearing from the J1--axis
base.
13 Remove the cross roller bearing and the pipe from the reducer.
14 Replace the reducer.
15 Reassemble by reversing the above procedure. Polish the reducer
and motor flange mounting surfaces using an oil stone. Apply
LOCTITENo. 262 to the bolts shown in Fig. 6.2 (b). Coat sealant
enough to the connections between the bolts and the J1 base.
Install O ring at a correct position.
Be careful not to damage the tooth surface of the center gear.
16 Form the cables (Refer to section 8).
17 Lubricate with grease (Refer to section 3).
64
Fig.6.2 (b) Replacing J1--axis reducer
65
1) Replacing the J2/J3--axis motor (M2/M3)
i) Standard type (See Fig. 6.3(a))
2 Suspend the J3--axis arm with a rope. Also, suspend the J3--axis
link for safety. (See Fig. 6.3(c).) (For S--420iR, suspend it as
shown in Fig. 6.3(d).)
3 Remove the connectors.
4 Remove the mounting bolts (M1240) of the motor to be
replaced, and remove the motor to be replaced.
5 Remove the nut, the input gear and the draw bolt in order.
6 Replace the motor, and remount a newmotor reversing the above
procedure.
Polish the motor flange with an oil stone. Apply LOCTITE No.
242 to the draw bolt and the motor thread.
Mount the O--ring correctly.
Use newmotor mounting sealbolts. (In case of reusing sealbolts,
apply LOCTITE No.242 to them. (Refer to section 6.1)
Be careful not to damage the tooth surface of the input gear.
7 Replenish the grease (Refer to section 3).
Fig.6.3 (a) Replacing J2/J3--axis motor (M2/M3)
6.3
REPLACING
J2/J3--AXIS MOTOR
(M2/M3) AND
REDUCER
66
ii) Compact type (See Fig. 6.3(b))
2 Suspend the J3--axis arm with a rope. Also, suspend the J3--axis
link for safety. (See Fig. 6.3(c).)
3 Remove the connectors.
4 Remove the mounting bolts (M1235) of the motor to be
replaced, and remove the motor to be replaced.
5 Remove the draw bolt and input spline in order.
6 Replace the motor, and remount a newmotor reversing the above
procedure.
Polish the motor flange with an oil stone. Apply LOCTITE No.
242 to the draw bolt and the motor thread.
Mount the O--ring correctly.
7 Replenish the grease (Refer to section 3).
Fig.6.3 (b) Replacing J2/J3--axis motor (Compact type)
67
Fig.6.3 (c) J2/J3--axis reducer replacing posture (S--420i F/W/S/L)
68
Fig.6.3 (d) J2/J3--axis reducer replacing posture (S--420i R)
69
2) Replacing J3--axis reducer
i) Standard type (See Fig. 6.3(e))
1 Turn off the power supply.
2 Remove J3--axis motor (M3) following the above procedure.
3 Remove the bracket mounting bolts (M1260 16 pcs), and then
the bracket.
4 Remove the reducer mounting bolts (M16140 3 pcs) and taper
pin (1660 3 pcs).
5 Remove and replace the reducer.
6 Remount a newreducer reversing the above procedure. Polish the
reducer mounting surface and the motor flange mounting surface
using an oil--stone.
Apply LOCTITE No. 262 to the bolts shown in Fig. 6.3 (e).
Apply LOCTITE No. 242 to the taper pins removed in the step 4,
and insert the pins after reaming.
Take care to use the O--ring at the specified position.
7 Apply grease to the reducer (Refer to section 3).
Reducer mounting
bolts M16 x 140
Fig.6.3 (e) Replacing J3--axis reducer
70
ii) Compact type (See Fig. 6.3(f))
1 Turn off the power supply.
2 Remove J3--axis motor (M3) following the above procedure.
3 Remove the gear box mounting bolts (M1260 8 pcs, M1250
8 pcs)
4 Remove the reducer mounting bolts (M16140 3 pcs) and taper
pin (1660 3 pcs).
5 Remove and replace the reducer.
6 Remount a newreducer reversing the above procedure. Polish the
reducer mounting surface and the motor flange mounting surface
using an oil--stone.
Apply LOCTITE No. 262 to the bolts shown in Fig. 6.3 (f).
Apply LOCTITE No. 242 to the taper pins removed in the step 4,
and insert the pins after reaming.
Take care to use the O--ring at the specified position.
Fig.6.3 (f) Replacing J3--axis reducer (Compact type)
71
Guide Rods Guide Rods
Fig.6.3 (g) Replacing J2/J3--axis reducer
72
i) In case of S--420iF/W/S/L
1 Position the J2--axis to 0 degrees.
3 Remove the cables, threaded through the connection section of
the J3--axis arm into the cable track, from the mechanical unit.
(See item 8.)
4 Suspend the J3--axis arm with a rope.
WARNING
THE J2--AXIS MUST BE SET TO ZERO DEGREES
BEFORE ATTEMPTING TO REMOVE THE SPRING
BALANCERS. OTHERWISE, INJURY TO PERSONNEL
MAY RESULT.
5 Remove the C ring from the shaft of the J2/J3--axis connection
section, then remove the balancer.
6 Remove the bolts (M8x25 6pcs) from the lower part of the link
1/link 2 connection section, then remove the shaft.
7 Remove (M10x110 16pcs) bolts from the J2/J3--axis connection
section, then remove the shaft.
8 Remove the J4--axis unit and link 2 from the robot. (See Fig. 6.3
(j).)
9 Suspend the J2--axis arm with a rope. Remove the J2--axis motor
(M2) as described previously. Butt the J2--axis arm against the
front stopper.
10 Suspend link 1 with a rope. Remove the J3--axis motor (M3),
bracket or gear box (compact type) and reduction unit.
WARNING
LINK 1 IS A COUNTERWEIGHT FOR THE J4--AXIS UNIT.
IT MUST BE SECURELY RIGGED BEFORE REMOVING
THE SHAFT OR IT MIGHT FALL. INJURY TO
PERSONNEL MAY RESULT.
11 Remove shaft mounting bolts (M12x100 8pcs) and remove the
shaft.
12 Remove link 1.
13 Again suspend the J2--axis arm with a rope. Remove the
(M12x60) bracket mounting bolts and bracket with the J2--axis
set to 0 degrees.
14 Remove the reduction--unit mounting bolts (M16x50 6pcs and
M10x35 18pcs). Insert guide rods, threaded M12, into thebracket
mounting bolt holes and withdraw the reduction unit, as shown
in Fig.6.3 (g).
15 Separate the J2--axis arm from the robot.
16 Replace the reduction unit.
73
17 Reassemble the unit by reversing the above procedure. Keep the
following points in mind.
Polish the surface where the reduction unit is mounted, as well
as the motor flange, with an oilstone. Apply Loctite No. 262 to
the bolts specified in Fig. 6.3. (h), (i).
Mount the O--ring in the specified position.
Be careful not to scratch the teeth surfaces of the input gear.
Arrange the cables correctly. (See item 8.)
18 Perform regreasing. (See item 3.)
19 Perform mastering. (See item 5.3.)
Bracket mounting
bolts M12 x 60
Fig.6.3 (h) Replacing J2--axis reducer
74
ii) For the S--420i R
1 Set the J2--axis arm to --85 and the J3--axis arm to +45 , then turn
the power off.
2 Perform steps 3 and 4 in (i).
3 Remove the four balancer securing bolts (M12x40) and C--ring,
then remove the balancer.
4 Perform step 6 in (i).
5 Remove the U--shaped nut and bearing, then remove the housing
from the shaft.
6 Perform steps 7 to 12 in (i). (Fig. 6.3 (k))
7 Support the J2--axis with a rope, set the J2--axis arm to --85 , then
remove the bracket.
8 Perform steps 14 to 19 in (i).
Fig.6.3 (i) Replacing J2--axis reducer (Compact type)
75
Fig.6.3 (j) Replacing J2--axis reducer (S--420i F/W/S/L)
Fig.6.3 (k) Replacing J2--axis reducer (S--420i R)
76
1) Replacing J4--axis motor (M4)
1 Set the posture of the wrist such that no load is applied to the wrist
axis.
3 Remove the connector.
4 Remove four bolts (M12 x 40 2pcs, M12 x 55 2pcs) for mounting
the motor, then the motor.
5 Remove the nut and take out the center gear.
6 Replace the motor with a newone. And reassemble it in a reverse
order. Also replace the O--ring (as a precaution). Apply Locktite
No. 242 to the threaded portion of the motor shaft.
Be sure to mount the O- -ring at the appropriate
position. Pay special attention so as not to scratch the
tooth faceof thesuper gear.
7 Apply grease to the motor (Refer to section 3).
6.4
REPLACING J4--AXIS
MOTOR (M4) AND
J4--AXIS REDUCER
77
1 Remove any load on the robots wrist such as a hand or a
workpiece.
3 Remove the plate, a grommet and cable ties (See Fig. 6.4(b)).
4 Remove the plate of the J3--axis arm, remove all the connectors,
cable ties and the plates. Pull out the cables from J3--axis arm.
Refer to Fig.8.2 (g) to (i)
5 Remove the J4--axis motor (M4) by the procedure shown above.
6 Remove six gear box mounting bolts (M10 x 50) and, then the
gear box.
7 Remove the center gear.
8 Support the J3--axis arm with a crane. Remove J3--axis arm
mounting mounting bolts (M14 x 95 6 pcs), then J3--axis arm.
9 Remove the reducer mounting bolts (M10 x 30), and remove the
reducer.
10 Replace the reducer.
11 Reassemble the removed components. Polish the surface on
which the reducer is to be mounted with an oilstone to remove
burrs. Apply Loctite No. 262 to the bolts shown in Fig. 6.4(b).
Besuretomount theO- -ringat theappropriateposition.
Pay special attention so as not to scratch the tooth face
of thecenter gear.
12 Form the cables (Refer to section 8).
78
1 Remove loads from the robots wrist such as a hand and
workpieces. Support the wrist with a crane.
3 Remove the J3--axis arm plate, then remove the connectors, cut
the cable ties and the plates. Refer to Fig.8.2 (h), (i).
4 Remove the wrist unit mounting bolts (M12 x 35 8 pcs) and the
wrist unit.
5 Replace the wrist unit with a new one. Reassemble the removed
components.
Spring pin for alignment
12 x 30
Fig.6.5 Replacing wrist unit
6.5
REPLACING WRIST
UNIT
79
workpieces.
3 Remove the J5--axis cover, the connector of the J5--axis motor
(M5), then the plate. Cut the nylon cable tie. (See Section 8.2,
Replacing the Cables.)
4 Remove the bolt (M12 x 40) for mounting the motor, then remove
the motor.
5 Remove the draw bolt and spline from the motor shaft.
6 Replace the motor with a new one. Also replace the O--ring (as
a precaution). Reassemble the removed components.
Be sure to mount the O--ring at the appropriate position.
Fasten the excess part of the cable to the plate with a nylon tie.
See 8.2 for an explanation of how to lay the cable.
6.6
REPLACING J5--AXIS
MOTOR (M5) AND
J5--AXIS REDUCER
80
2) Replacing J5--axis gear
1 Remove J5--axis motor (M5) by the previous method.
2 Remove drain plugs from the J5--axis cover and drain grease.
3 Remove four gear 1 assembly bolts (M6 x 16) and remove the
gear 1 assembly. (Fig.6.6 (b))
4 Remove ten J5--axis cover mounting bolts (M6 x 16) (M6 x 40
for S--420iW), two spring pins (6 dia. x 20) gasket and the cover.
(Fig.6.6 (b))
5 Remove six gear 3 assembly bolts (M12 x 30) while rotating gear
3 and remove gear 3 assembly. (Fig.6.6 (c))
6 Remove eight J5--axis gear 2 mounting bolts (M6 x 16) and the
gear 2 assembly.
7 Remove sixteen J5--axis gear 4 assembly seal bolts (M10 x 50)
and gear 4 (Do not re--use the seal volts.)
8 Change the gear.
9 Adjust backlash and assemble it in the reverse order (See 5.4).
Apply Loctite No. 262 to the bolts shown in the figure. Change
the gasket to a new one, and fix it temporarily with tightening
torque of 1.0--1.6 kgfm. Retighten it after 20--60minutes with1.6
kgfm. Use new gear4 mounting sealbolts. (In case of reusing
sealbolts, apply LOCTITE No.262 to them. (Refer to section 6.1))
10 Refill with grease.
Gasket
J5--axis gear 1
assembly
Cover mounting
bolts M6x16
(M6 x 40 for S--420iW)
81
Fig.6.6 (c) Replacing J5--axis gear
82
workpieces.
2 Turn off the power at the position of J5=--90 degrees.
3 Remove the cover, motor cover and cable connectors.
4 Remove J5--axis cover 2, a plate, a grommet and a clamp. (Do not
remove plate and Teflon sheet attached to the J5--axis cover 2).
5 Remove rubber block mounting bolts and take out the cable.
6 Remove four bolts (M822) for mounting themotor, thenremove
the motor.
7 Remove the nut, input gear and the draw bolt.
8 Replace the motor with a new one. Reassemble the removed
components. Polish the motor flange with oil stone. Apply
Locktite No. 242 to the threaded portion of the motor shaft.
Be sure to mount the O--ring at the appropriate position. Pay
special attention so as not to scratch the tooth face of the input
gear. Use new motor mounting sealbolts. (In case of reusing
sealbolts, apply LOCTITENo.242 to them. (Refer to section6.1)
Fasten two bolts (M4 x 60) of the rubber block, so that the ends
protrude 2.5mm through the plate.
10 Perform cable forming (See section 8).
(Do not
overstrike)
Washer
6.7
REPLACING J6--AXIS
MOTOR (M6) AND
J6--AXIS REDUCER
83
Fig.6.7 (b) Replacing J6--axis motor
84
workpieces.
3 Remove the flange mounting bolts (M14 x 25 4pcs and M6 x 20
4pcs) and the wrist flange.
4 Remove eight bolts (M8 x 40) for mounting the reducer, then
remove the reducer.
5 Replace the reducer with a new one. Reassemble the removed
components. Be sure to mount the O--ring at the appropriate
position. Pay special attention so as not to scratch the tooth face
of the center gear. Apply Loctite gasket eliminator No. 518 to the
flange mounting face of the reducer. Apply Loctite No. 262 to the
bolts shown in Fig. 6.7 (c).
LOCTITE
Gasket Eliminator
No.518
Tool mounting
flange
Flange mounting bolts
Fig.6.7 (c) Replacing J6--axis reducer
85
By using the optional brake release unit, the motor brake for each a axis
can be released while power is not supplied, enabling the attitude of the
robot to be changed arbitrarily.
When using the brake release unit, observe the following precautions:
NOTE
1 When releasing the brake of the J2-- or J3--axis motor, support
the robot using a crane, as shown in Fig. 6.8 (a) to (d).
2 When releasing the brake of the J4--, J5--, or J6--axis motor,
support the end effector using a crane, to prevent it fromfall.
3 Before releasing a brake, apply sufficient tension to the sling.
4 Do not release the brake for two or more axes
simultaneously.
Fig.6.8 (a) J2--axis brake releasing (S--420i F/W/S/L)
Fig.6.8 (b) J3--axis brake releasing (S--420i F/W/S/L)
6.8
RELEASING A
BRAKE (OPTION)
86
Fig.6.8 (c) J2--axis brake releasing (S--420i R)
Fig.6.8 (d) J3--axis brake releasing (S--420i R)
B--80505E/06 7. PIPING AND WIRING MAINTENANCE
87
7
PIPING AND WIRING
Fig. 7.1 (a) and (b) show the piping diagram of the mechanical unit.
Fig.7.1 (a) Piping diagram
7.1
PIPING DIAGRAM
MAINTENANCE 7. PIPING AND WIRING B--80505E/06
88
Fig.7.1 (b) Piping diagram for purge air (for severe dust/liquid protection)
89
Fig. 7.2 (a) to (t) show the wiring diagram of the mechanical unit.
Fig.7.2 (a) Wiring diagram (schematics) in mechanical unit (S--420i F, W, W/175, integrated type)
7.2
WIRING DIAGRAM
90
K524 (Devicenet (Signal)) [option]
K525 (Devicenet (Power)) [option]
Fig.7.2 (b) Wiring diagram (schematics) in mechanical unit (S--420i F, W, W/175, Remote type)
Fig.7.2 (c) Wiring diagram (schematics) in mechanical unit (S--420i F/2.85, S--420i W/2.85 Integrated type)
91
Fig.7.2 (d) Wiring diagram (schematics) in mechanical unit (S--420i F/2.85, S--420i W/2.85, Remote type)
Fig.7.2 (e) Wiring diagram (schematics) in mechanical unit (S--420i S, Integrated type)
92
Fig.7.2 (f) Wiring diagram (schematics) in mechanical unit (S--420i S, Remote type)
Fig.7.2 (g) Wiring diagram (schematics) in mechanical unit (S--420i L, Integrated type)
93
Fig.7.2 (h) Wiring diagram (schematics) in mechanical unit (S--420i L, Remote type)
Fig.7.2 (i) Wiring diagram (schematics) in mechanical unit (S--420i R)
94
Fig.7.2 (j) Wiring diagram (block) in mechanical unit (S--420i F, W, W/175, Integrated type)
95
Fig.7.2 (k) Wiring diagram (block) in mechanical unit (S--420i F, W, W/175, Remote type)
96
Fig.7.2 (l) Wiring diagram (block) in mechanical unit (S--420i F/2.85, W/2.85, Integrated type)
97
Fig.7.2 (m) Wiring diagram (block) in mechanical unit (S--420i F/2.85, W/2.85, Remote type)
98
Fig.7.2 (n) Wiring diagram (block) in mechanical unit (S--420i S, Integrated type)
99
Fig.7.2 (o) Wiring diagram (block) in mechanical unit (S--420i S, Remote type)
100
Fig.7.2 (p) Wiring diagram (block) in mechanical unit (S--420i L, Integrated type)
101
Fig.7.2 (q) Wiring diagram (block) in mechanical unit (S--420i L, Remote type)
102
Fig.7.2 (r) Wiring diagram (block) in mechanical unit (S--420i R)
103
(AS2, AP2, EE,
I/O, AIR2, DS3, DP3)
(DS2, DP2)
(AS1, AP1, AIR1, DS1, DP1)
Fig.7.2 (s) Connector locations
104
S--420i F2.85/W2.85/R
(AS1, AP1, AIR1, DS1, DP1)
Fig.7.2 (t) Connector locations
B--80505E/06 8. REPLACING CABLE MAINTENANCE
105
8
REPLACING CABLE
Replace the cable every four years. When the cable is broken or damaged,
or shows signs of wear, replace it according to this chapter.
Precautions to be observed when handling the 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.
MARKING TIE
BATTERY BACKUP
DONT
DISCONNECT
MAINTENANCE 8. REPLACING CABLE B--80505E/06
106
Fig. 8.1 (a) to (g) shows the cable clamp position.
When replacing cables, clamp the cable at the position specified in Figure
8.1 (a) to (g) 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.
Table8.1 (a) Cable clamp position
8.1
CABLE FORMING
107
Table8.1 (b) Cable clamp position
108
Table8.1 (c) Cable clamp posiiton
109
Table8.1 (d) Cable clamp posiiton
110
Table8.1 (e) Cable clamp posiiton
111
Table8.1 (f) Cable clamp posiiton
112
Table8.1 (g) Cable clamp posiiton
113
Table8.1 (h) Cable clamp posiiton
MARK CABLE CLAMPING POSITION MARK CABLE No.
DS 1
DS 3
DS 2
K524
DP 1
DP 3
DP 2
K525
114
This section describes the procedure for replacing all cables during
routine cable replacement for the mechanical unit.
To replace one or a few damaged cables only, refer to this section to
replace them.
The cables in the mechanical unit consist of those for the basic axes (J1
to J4 axes) and those for the wrist section (J5 and J6 axes). They can be
divided into two parts at the connector section of the J3--axis arm. (See
Fig. 7.2)
WARNING
Removing the cables will cause loss of mastering data, so
mastering must be performed once the cables have been
replaced. (When the pulse coder cable is not to be replaced,
mastering is not required.) Before replacing the cables, refer
to Item 5.7, Quick Mastering.
Perform cable replacement with each axis at the zero degree
mark.
Cable replacement procedure
1) Replacing the cables for the basic axes
1 Turn off the power. Remove the side cover of the controller, then
disconnect all cables. Separate the controller from the robot.
(For the S--420i F/W/S/L having a separate control unit or the
S--420i R, disconnect the cables (except those for the mechanical
unit) from the connector panel, remove the connector panel, then
disconnect the mechanical unit cables.)
2 Disconnect the cables from the J1-- to J4--axis motors. (M1 to
M4)
3 Remove the optional connector panel, then remove the
connectors and air tube. (See Fig. 8.2 (a) (b) (c).)
4 Remove the plate fromthe J1--axis base. Drawthe plate out of the
base and remove its clamps and cable ties. (See Fig. 8.2 (d).)
5 Remove the two plates from the J2--axis base. Remove the
clamps and cable ties fromthe plates, then remove the cabletrack.
(See Fig. 8.2 (e).)
(For the S--420i R, remove the cover from the J2 angle base, then
remove the clamp and cable tie. See Fig. 8.2 (f).)
6 Remove the cable track and cover from the J2--axis arm. Cut the
cable ties. (See Fig. 8.2 (g).)
7 Draw the plate, together with the cables, out of the cast hole in
the upper part of the J2--axis arm. Remove the clamps and cable
ties. (See Fig. 8.2 (h).)
8 Remove all plates, clamps, and cable ties fromthe J3--axis casing.
9 Remove the two covers from the J3--axis arm. Cut the cable ties
and remove all connectors. Also, remove the plates. (Fig. 8.2
(i).)
10 Draw the grommet out of the J3--axis casing, then remove the
cables.
2) Replacing the cables for the wrist section
8.2
REPLACING THE
CABLES
115
11 Perform step 9 described above.
12 Remove the J6--axis cover. Remove all connectors. (See Fig. 6.7
(a).)
13 Remove the J6--axis motor cover and rubber block. Drawout the
cables.(See Fig. 6.7 (a).)
14 Remove the J5--axis cover, then remove the supprt mounted on
the J5--axis cover. (See Fig. 8.2 (j).)
15 Cut the cable ties for the support, then remove the cables.
16 Remove the clamps, cable ties, plates and grommet, as shown in
Fig. 8.2 (j).
17 Draw the cables out of the robot. Open the lid of the cable track
with a screwdriver and drawthe cables out of the track. (See Fig.
8.2 (k).). Replace the cables.
18 Assemble the cables by reversing the above procedure. Arrange
the cables correctly and clamp themat the correct positions. (See
Figs. 8.1 (a) to (e), and 8.2 (a) to (k).)
19 Perform mastering. (See 5.3 through 5.4)
Fig.8.2 (a) Replacing the cable
116
Fig.8.2 (b) Replacing the cable (Severe dust/liquid protection)
J1 BASE PANEL (INPUT) J3 CASING PANEL (OUTPUT)
User cable (signal)
interface
User cable (power)
interface
Air supply
DeviceNet cable
(signal) interface
DeviceNet cable
(power) interface
Air supply
DeviceNet cable
(power) interface
DeviceNet cable
(signal) interface
End effector
interface (RDI/RDO)
I/O unit model
Binterface
J2 BASE PANEL (OUTPUT)
Fig.8.2 (c) Replacing the cable (With DeviceNet Cable)
117
Fig.8.2 (d) Replacing the cable
(DS)
(DP)
(DP)
(DS)
(DP)
(DS)
Fig.8.2 (e) Replacing the cable
118
Fig.8.2 (f) Replacing the cable
(DS)
(DP)
(DS)
(DP)
Fig.8.2 (g) Replacing the cable
119
Fig.8.2 (h) Replacing the cable
120
S420i F2.85/W2.85/R
Fig.8.2 (i) Replacing the cable
121
Fig.8.2 (j) Replacing the cable
Fig.8.2 (k) Replacing the cable
122
1) Remove the limit--switch box, then remove the limit switch from the
box.
2) Disconnect the cable from the limit switch.
3) Open the side cover of the controller. Disconnect the limit--switch
cable.
If the remote controller is employed, remove the connector plate at
the base of robot. Disconnect the limit switch cable at back side of P1
connector.
4) Remove the side cover of the J1--axis. Draw out the cable. Replace
the limit switch with a new one.
5) Reassemble the unit by reversing the above procedure.
6) Adjust the limit switch. (See item 5.2)
Fig.8.3 J1--axis limit switch mounting diagram
8.3
REPLACING THE
OPTIONAL J1--AXIS
LIMIT SWITCH
(OPTION)
II CONNECTION
B--80505E/06 1. ROBOT INTERFERENCE AREA CONNECTION
125
1
ROBOT INTERFERENCE AREA
Fig. 1 (a), (d), (g), (j) and (m) shows the external dimensions of the robot.
Fig. (b), (e), (h) and (k) shows the external dimensions of the compact
type robot.
When installing peripheral devices, be careful to clear away any objects
that are in the robots motion path in normal operation. Fig. (c), (f), (i),
(l) and (n) shows operation range of the robot.
NOTE
If an adjacent type controller is used, when the robot moves
along the J3 axis in the positive direction, the gap between
link 1 and the controller becomes small, and an object like
a tool or part (if placed on the controller) may be caught
between link 1 and the controller, leading to damage to the
controller. Be careful when starting the robot. (See part P in
the figure.)
CONNECTION 1. ROBOT INTERFERENCE AREA B--80505E/06
126
Fig.1 (a) Mechanical unit external dimensions (S--420i F, W, W/175)
NOTE
Restrict the robots operation to avoid hitting the adjacent type controller. (shading)
If |J1| $115_ andJ2 $--5_, therobot is not allowedto moveinto thearea for which thefollowing
expression is satisfied:
J3+3/10%J2 $--66.5_
127
Fig.1 (b) Mechanical unit external dimensions (S--420i F/W Compact type)
NOTE
If |J1| $115_ and J2$--5_, the robot is not allowed tomove
into the area for which the following expression is satisfied:
J3+3/10%J2 $--66.5_
128
(Note) Figures Ato Hshowposture at positions A to H shown in Fig. 1 (a), (b).
Fig.1 (c) Mechanical unit stroke limits
129
Fig.1 (d) Mechanical unit external dimensions (S--420i F/2.85, S--420i W/2.85)
NOTE
Restrict the robots operation to avoid hitting the adjacent
type controller (shading)
If |J1| $ 115_ and J2 $ --20_, the robot is not allowed to
move into the area for which the following expression is
satisfied:
J3+J2/2 $--60_
130
Fig.1 (e) Mechanical unit external dimensions (S--420i F/2.85 Compact type)
NOTE
satisfied:
J3+J2/2 $--60_
131
(Note) Figures Ato Hshowposture at positions Ato Hshown in Fig.1 (d), (e).
Fig.1 (f) Mechanical unit stroke limits (S--420i F/2.85, S420i W/2.85)
132
Fig.1 (g) Mechanical unit external dimensions (S--420i S)
NOTE
If |J1| $115_ and J2 $5_, the robot is not allowed to move
J3+J2/5 $--74_
133
Fig.1 (h) Mechanical unit external dimensions (S--420i S Compact type)
NOTE
If |J1| $115_ and J2 $5_, the robot is not allowed to move
J3+J2/5 $--74_
134
(Note) A to H correspond to the points of Fig.1 (g), (h).
Fig.1 (i) Mechanical unit stroke limits (S--420i S)
135
Fig.1 (j) Mechanical unit external dimensions (S--420i L)
NOTE
If |J1| $ 115_ and J2 $ --20_ , the robot is not allowed to
satisfied:
J3+J2/2 $--60_
136
Fig.1 (k) Mechanical unit external dimensions (S--420i L Compact type)
NOTE
satisfied:
J3+J2/2 $--60_
137
(Note) A to H correspond to the points of Fig.1 (j), (k).
Fig.1 (l) Mechanical unit stroke limits (S--420i L)
138
Fig.1 (m) Mechanical unit external dimensions (S--420i R)
NOTE
Restrict the robots operation (shading)
If --61_ &J3 &--41_, the robot is not allowed to move into
the area for which the following expression is satisfied:
J2 $--1.6%J3--94.6_
139
(Note) A to H correspond to the points of Fig.1 (m).
Fig.1 (n) Mechanical unit stroke limits (S--420i R)
CONNECTION
2. MECHANICAL COUPLING TO
THE ROBOT B--80505E/06
140
2
MECHANICAL COUPLING TO THE ROBOT
B--80505E/06
THE ROBOT CONNECTION
141
Fig. 2.1 (a), (b) is a diagram to limit loads applied to the wrist. Apply a
load within the region indicated in the graph.
Fig.2.1 (a) Wrist Load Diagram (S--420i F/S/L/R)
2.1
WRIST LOAD
CONDITIONS
CONNECTION
142
Fig.2.1 (b) Wrist Load Diagram (S--420i W, W/175)
B--80505E/06
143
Fig. 2.7 shows J2--axis base and J3--axis arm load conditions. Keep the
load below the loads shown in Table 2.2 and Fig. 2.2 (a), (b).
Table2.2 Installation condition of loads to be added
Installation site Loads Condition
J2--axis base 250kg
Within radius of 500mm from the center of rotation
of J1--axis
J3- -axis arm 20kg
Within 500mm to the wrist direction from the cen-
ter of J3- -axis
Fig.2.2(a) Load Conditions on J2--axis base and J3--axis arm (S--420i F/W/S/L)
2.2
LOAD CONDITIONS
ON J2--AXIS BASE
AND J3--AXIS ARM
CONNECTION
144
Fig.2.2(b) Load Conditions on J2--axis base and J3--axis arm (S--420i R)
B--80505E/06
145
Fig. 2.3 is the diagram for installing end effectors on the wrist. Install the
end effector using a 60 mmH7 spigot. Using the standard flange as an
example, position using a dowel pin with 2--10H7 reamed holes and
fasten using 6--M10 bolts with 6--M10 tapped holes. Take into
consideration the depth of tapped and reamed holes when selecting the
M10 bolts and positioning dowel pins. (Refer to the diagram for the
optional dimensions.)
6--M10 tap depth 20
Equally spaced on
"F circumference
2--0G depth 20
Equally spaced on
"F circumference
204 for insulating flange
Standard flange Special flange ISO flange Insulating flange
A 60H7 A 76G7 A 80H7 A 80H7
B 110h7 B 108f8 B 160h8 B 160h8
C 6 C 10 C 9!0.15 C 8
F 90 F 92 F 125 F 125
G 10H7 G 9H7 G 10H7 G 10H7
+0.030
0
0
--0.035
+0.015
0
+0.040
+0.010
--0.036
--0.090
+0.015
0
+0.035
0
0
--0.063
+0.015
0
+0.035
0
0
--0.063
+0.015
0
+0.3
0
Fig.2.3 End effector mounting face
2.3
MECHANICAL
COUPLING OF END
EFFECTOR TO
WRIST
CONNECTION
146
As shown in Fig. 2.4 (a) to (e), tapped holes are provided to install
equipment to the robot.
Note)
These taps cant be used
for compact type robot.
Note)
Fig.2.4 (a) Equipment mounting surfaces (S--420i F, W, W/175)
NOTE
1 For using threaded holes of equipment mounting face. (only severe dust/liquid protection) S--420i
for severe dust/liquid protection is used purge air into wrist and J3 arm. Because it keeps airtight
chamber, equipment mounting face threaded holes, of J3 arm, are used SUS bolts and sealing
washers. When the customers set equipment on J3 armusing these threaded holes (M10), it will
be used coated sealing blots or sealing washers. It will reduce leakage from J3 arm.
2 For S--420i R, severe dust/liquid protection, it fills M12 threaded holes, that is side of angle
base, with M12 sus bolts. Dont drive the robot in severe dust/liquid environment.
WARNING
Incomplete leakage measure ments on these taps will make air flow and noise increase, and it
will cause low pressure and will break down the robot low pressure.
2.4
EQUIPMENT
MOUNTING FACE
B--80505E/06
147
2--
2--
2--
Fig.2.4 (b) Equipment mounting surfaces (S--420i F/2.85, S420i W/2.85)
2--
2--
2--
2--
Fig.2.4 (c) Equipment mounting surfaces (S--420i S)
CONNECTION
148
2--
2--
2--
2--
Fig.2.4 (d) Equipment mounting surfaces (S--420i L)
B--80505E/06
149
Fig.2.4 (e) Equipment mounting surfaces (S--420i R)
CONNECTION
150
When using the turbo move option, set the load masses (including the
mass of the hand), wrist axis load moment values, and load inertia values.
Set each load by setting the system variables listed below. Then, turn off
and on the power to use the new information.
1 Load mass at wrist
Set the same values (in kg) for both of $PARAM_GROUP.
$PAYLOAD and $GROUP. $PAYLOAD.
[Example of input]
$PARAM_GROUP. $PAYLOAD : 120
$GROUP. PAYLOAD : 120
2 Wrist axis load moment
Set a load moment (kgf--m) (an integer) to $PARAM_GROUP.
$AXISMOMENT.
[Example of input]
When load moment is as follows;
J4--axis load moment 60 kgf--m
Set system variables as below :
J4--axis load moment $PARAM_GROUP.$AXISMOMENT[4] : 60
3 Wrist axis load inertia
Set a load inertia (kgf--cm--s
2
) (an integer) to $PARAM_GROUP.
$AXIS INERTIA.
[Example of input]
When load inertia is as follows;
J4--axis load inertia 306 kgf--cm--s
2
2
2
Set system variables as below:
J4--axis load inertia $PARAM_GROUP.$AXIS INERTIA[4] : 306
4 Load mass at J3--axis arm and J2--axis base.
Set a load mass (kg) to $PARAM_GROUP.$ARM_LOAD.
[Example of input]
$PARAM_GROUP. $ARM_LOAD [1] : 20 (for load at J3--axis
arm.)
$PARAM_GROUP. $ARM_LOAD [2] : 250 (for load at J2--axis
base.)
2.5
SETTING OF SYSTEM
VARIABLES FOR
TURBO MOVE
B--80505E/06
151
There is an air--pressure supply opening on the side of the J3--axis base
and the rear of J3--axis casting. The connector is a Rc1/2 female (ISO).
As coupling are not supplied, it will be necessary to prepare couplings
which suit to the hose size.
Fig.2.6 Air--pressure supply connection (option)
2.6
AIR SUPPLY
(OPTION)
CONNECTION
152
Fig. 2.7 show the posiiton of the end effecter interface. End effecter
interface (RDI/RDO), I/O Unit--MODEL B interface and user cable
(signal lines, power lines) and devicenet cable (signal lines, power lines)
are prepared as options.
Fig.2.7 (a) Interface for End Effecter (Option)
2.7
INTERFACE FOR
END EFFECTER
(OPTION)
B--80505E/06
153
Fig.2.7 (b) Layout of interface for Option cable (Severe dust/liquid protection)
CONNECTION
154
User cable
(signal) interface
View A
DeviceNet cable (power) interface
DeviceNet cable
(signal) interface
J3 CASING PANEL (OUTPUT)
End effector interface
(RDI/RDO)
I/O unit model
B interface
(Air supply)
User cable
(power) interface
(Air supply)
User cable (signal) interface
DeviceNet cable
(power) interface
User cable (power) interface
J1 BASE PANEL (INPUT)
DeviceNet cable (signal)
interface
Detail B
J2 BASE PANEL (OUTPUT)
DeviceNet cable
(signal) interface
DeviceNet cable
(power) interface
View C
Fig.2.7 (c) Layout of interface for Option cable (With devicenet cable)
B--80505E/06
155
(1) End effector interface (RDI/RDO) (Option)
Fig. 2.7 (d) shows pin layout for end effector interface (RDI/RDO).
*
Fig.2.7 (d) Pin layout for end effector interface (RDI/RDO)
(2) I/O Unit--MODEL B interface (Option)
Fig. 2.7 (e) shows pin layout for I/O Unit--MODEL B interface.
*
Fig.2.7 (e) Pin layout for I/O Unit--MODEL B interface (option)
(3) End effector interface (RDI/RDO) (Option) (Severe dust/liquid
protection)
Fig. 2.7 (f) shows pin layout for end effector interface (RDI/RDO).
Fig.2.7 (f) Pin layout for end effector interface (RDI/RDO)
CONNECTION
156
(4) I/O Unit--MODEL B interface (Option)
Fig. 2.7 (g) shows pin layout for I/O Unit--MODEL B interface.
Fig.2.7 (g) Pin layout for I/O Unit--MODEL B interface (option)
(5) User cable (signal line) Interface (option)
Fig. 2.7 (h) shows pin layout for user cable (signal line) interface.
AS
approx. AWG21
Fig.2.7 (h) Pin layout for user cable (signal line) interface (option)
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157
(6) User cable (power line) Interface (option)
Fig. 2.7 (i) shows pin layout for user cable (power line) interface.
AP
approx. AWG17
Fig.2.7 (i) Pin layout for user cable (power line) interface (option)
(7) User cable(for aux. axis, signal line) interface (option)
Fig. 2.7 (j) shows pin layout for user cable (for aux. axis, signal line)
interface.
(This interface is applied in case of using A05B--2351--J310 or J311)
(Separately prepared)
Fig.2.7 (j) Pin layout for user cable (for aux. axis, singnal line) interface(option)
NOTE
A05B--2351--J310 and J312 include a signal cable and two
power cables for aux. axis control.
CONNECTION
158
(8) User cable(for aux. axis, power line) interface(option )
Fig. 2.7 (k) shows pin layout for user cable (for aux. axis, power line)
interface.
(Separately prepared)
Fig.2.7 (k) Pin layout for user cable (for aux. axis, power line) interface (option)
NOTE
1 A05B--2351--J310 and J312 include a signal cable and two
power cables for aux. axis control.
2 In case of using the user cable (Power), it is necessary to
select the End Effector whose Continuous Rating Current
is 10.4 A rms. If FANUCservo motor is used, following table
shows the available.
Motor Model Continuous Rating
Current (A rms)
Motor Model Continuous Rating
Current (A rms)
0.5/3000 2.8 3/3000 4.6
1/3000 2.2 6/2000 5.6
2/2000 2.2 6/3000 10.0
2/3000 2.9 12/2000 8.8
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159
(9) DeviceNet cable (signal line) interface (option)
Fig 2.7 (l) shows pin layout for DeviceNet cable (signal line)
interface.
Fig.2.7 (l) Pin layout for DeviceNet cable (signal line) interface (option)
(10) DeviceNet cable (power line) interface (option)
Fig 2.7 (m) shows pin layout for DeviceNet cable (power line)
interface.
Fig.2.7 (m) Pin layout for DeviceNet cable (power line) interface (option)
CONNECTION
160
Table2.7 (a) Connector specifications (Machine side) (S--420i F/W/S/L/R)
Cable Input side (J1 base) Output side (J3 casing) Manu.
RDI/RDO JMWR2524F
DDK
I/O JMWR2516F
DDK
AS
(Signal)
Housing
Insert
Contact
09 30 006 0301
09 16 024 3001 (Han 24DD M)
09 15 000 6103
Housing
Insert
Contact
09 30 006 0301
09 16 024 3101 (Han 24DD F)
09 15 000 6203
Harting
AP
(Power)
Housing
Insert
Contact
09 20 010 0301
09 21 015 3001 (Han 15D M)
09 15 000 6103
Housing
Insert
Contact
09 20 010 0301
09 21 015 3101 (Han 15D F)
09 15 000 6203
Harting
AS for
aux. axis
(Signal)
Housing
Insert
Contact
09 30 006 0301 (Han 6E)
09 16 024 3001 (Han24DD M)
09 15 000 6103 (S1--S4)
09 15 000 6104 (S5--S8)
Housing
Insert
Contact
09 30 006 0301 (Han 6E)
09 16 024 3001 (Han24DD F)
09 15 000 6203 (S1--S4)
09 15 000 6204 (S5--S10)
Harting
Table2.7 (b) Connector specifications (User side) (S--420i F/W/S/L/R)
Cable Input side (J1 base) Output side (J3 casing)
RDI/RDO JMSP2524M Streight (Appendix)
JMLP2524M Angle
I/O JMSP2516M Streight (Appendix)
JMLP2524M Angle
Food 09 30 006 1540 Side
1541 entry
0542
0543
1440 Top
1441 entry
0442
0443
Food
'The same
AS Insert 09 16 024 3101 (Han 24DD F) Insert 09 16 024 3001 (Han 24DD M)
(Signal) Contact 09 15 000 6204 appox. AWG 26--22
6203 AWG 20
6202 AWG 18
6201 AWG 16
6206 AWG 14
Contact 09 15 000 6104 appox. AWG 26--22
6103 AWG 20
6102 AWG 18
6101 AWG 16
6106 AWG 14
Clamp 09 00 000 5083
5086
5090
5094 etc.
Clamp
'The same
Food 09 20 010 1541 Side
0540 entry
0541
1440 Top
0440 entry
0441
Food
'The same
AP
Insert 09 21 015 3101 (Han 15D F) Insert 09 21 015 3001 (Han 15D M)
AP
(Power)
Contact 09 15 000 6220 appox. AWG 20
6205 AWG 18
6204 AWG 16
6202 AWG 14
6207 AWG 12
Contact 09 15 000 6120 appox. AWG 20
6105 AWG 18
6104 AWG 16
6102 AWG 14
6107 AWG 12
Clamp 09 00 000 5083
5086
5090
5094 etc.
Clamp
'The same
B--80505E/06
161
Table2.7 (c) Connector specifications (Severe dust/liquid protection) (Machine side)
RDI/RDO
_________
housing
Insert
Contact
09 03 006 0301
09 16 024 3101 (Han 24DD F)
09 15 000 6203
I/O
_________
housing
Insert
Contact
09 20 010 0301
09 21 015 3101 (Han 15D F)
09 15 000 6202
Table2.7 (d) Appended connector (Severe dust/liquid protection) (Machine side)
RDI/RDO
_________
Hood
Insert
Contact
Clamp
09 30 006 1440
09 16 024 3101 (Han 24DD M)
09 15 000 6104
152D (PG13.5)
I/O
_________
Hood
Insert
Contact
Clamp
09 20 010 1440
09 21 015 3101 (Han 15D M)
09 15 000 6102, 6103, 6104
152D9 (PG13.5)
Table2.7 (e) Connector specifications (device net cable) (Mechine side) (S--420i F/W/S/L)
Cable
name
Input side
(J1--axis base)
Manufacturer
Output side
(J2--axis base)
Manufacturer
Output side
(J3--axis casing)
Manufacturer
DS
(signal line)
84854--9101 MOLEX
JAPAN CO.,
LTD.
84854--9100 MOLEX
JAPAN CO.,
LTD.
84854--9100 MOLEX
JAPAN CO.,
LTD.
DP
(power line)
Housing
Insert
Contact
09 30 006 0301
(Han 6E)
09 32 010 3001
(Han 10EEM)
09 33 00 6104
HARTING
Elektronik
Co., Ltd.
84854--9102 MOLEX
JAPAN CO.,
LTD.
84854--9102 MOLEX
JAPAN CO.,
LTD.
CONNECTION
162
Table2.7 (f) Connector specifications (device net cable, on the user equipment side) (S--420i F/W/S/L)
Cable name
Input side
(J1--axis base)
Manufac-
turer
Output side
(J2--axis base)
Output side
(J3--axis casing)
DS
(signal line)
MINI connector for use on the device net
5--pin, female 1
MINI connector for use
on the device net
5--pin, male
on the device net
5--pin, male
DP
(power line)
Hood Select
just one.
09 30 006 1540 (Han 6E) Side
1541 entry
0542
0543
1440 Top
1441 entry
0442
0443
HARTING
Electronik
Co., Ltd.
on the device net
4--pin, male
on the device net
4--pin, male
Insert 09 32 010 3101 (Han 10 EE F)
Contact 09 33 000 6220 AWG20
6214 AWG18
6205 AWG18
6204 AWG16
6202 AWG14
6207 AWG12
Clamp
Select just
one.
09 00 000 5083
5086
5090
5094
Many other types are available.
B--80505E/06
3. TRANSPORTATION AND
INSTALLATION CONNECTION
163
3
TRANSPORTATION AND INSTALLATION
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), (c) and lift by attaching ropes to the four M20 eyebolts.
2) Transportation using a forklift
The robots can also be transported using a forklift (Refer to Fig. 3.1
(a), (c)). Transport materials are available as an option.
NOTE
Always attach the transportation equipment when
transporting the S--420i R. Otherwise, the robot is likely to
fall forward.
3.1
TRANSPORTATION
CONNECTION
INSTALLATION B--80505E/06
164
iF, iW, iW/175 : 2053.3
iS : 1917.3
iF/2.85
iW/2.85 : 2462.9
iL : 2598.9
Fig.3.1 (a) Transportation using a crane (S--420i F/W/S/L)
B--80505E/06
165
Fig.3.1 (b) Transportation using a forklift (S--420i F/W/S/L)
CONNECTION
166
Fig.3.1 (c) Transportation using a crane (S--420i R)
Fig.3.1 (d) Transportation using a forklift (S--420i R)
B--80505E/06
167
Fig.3.1 (e) Mechanical interface for eyebolt and transport equipment
CONNECTION
168
Proper shipping and handling methods will help preserve the operational
usefulness of the robotic equipment. Robots are handled many times
from manufacturing to final installation at the plant. All individuals
involved with handling this robotic equipment should be aware of the
proper methods which must be used. Special items for consideration
include:
D Lifting with a fork truck (pg. 160)
D Overhead Crane Lifting (pg. 160)
D Type of Transportation Truck to Specify
D Shipping Skids and Base Plates (pg. 162)
D Proper/Improper Securing to a Truck Deck (pg. 165, 166)
D Shipping with Tooling Attached (pg. 164)
Fork truck considerations:
When using a fork truck to lift the robot, be sure that the forks are set wide
enough to slide into the center of the lifting pockets. Never use forks
which are set too narrow or too wide for this feature. Using improperly
set forks can cause crowding of the castings and could potentially damage
them. The proper fork spacing is 41 between forklift pocket centers (or
1,042mm).
Overhead crane lifting:
Many facilities use overhead cranes to move machinery into position.
FANUC provides lifting eyebolts at the base of the robot for this purpose.
To prevent damage to the upper arm components, a spreader bar is
recommended.
Vehicle transportation:
When robots must be transported on highways, it is imperative that the
selected truck be equipped with air ride suspension. This type of
suspension provides the most protection to the equipment from road
shocks and damage.
Shipping skids and base plates:
FANUC ships robots on skids designed for the purpose of properly
handling the equipment. When robots are placed into systems, they are
removed from these skids and generally placed on steel floor plates.
These plates are then secured to the floor. In cases where this operation
occurs at the plant, the skids may be discarded. In instances where the
robots are incorporated into systems away from the plant (majority of
cases), the skids must be saved. Upon completion of the system runoff,
the robots (without baseplates) should be placed back onto the shipping
skids for transportation to the plant.
3.2
ROBOT
TRANSPORTATION
CONSIDERATIONS
B--80505E/06
169
Securing robots to the vehicle:
After the robots are placed onto the shipping skids, they can be loaded
onto the truck. Proper securing of the robots involves chaining the
shipping skid to the truck deck. Under NO circumstances should chains
(or other securing devices) be attached to the robot. This practice can
cause irreparable damage to the robotic equipment.
Shipping with tooling attached:
FANUC always recommends that heavy tooling be removed from the
robot arm prior to shipping. There are instances where tooling can be left
on the robot. These include medium/light weight tools, and short distance
moves. In these cases, the tooling could be left on the robot, but arm
blocking is required. The robot should be placed into the shipping
position and blocked with wood supports between the arm and lower
casting. The blocking could be secured with plastic banding which will
prevent marring.
CONNECTION
170
Transport
Equipment
Transport
Equipment
Shipping skid
Fig.3.2 (a) Robot Mounted on Proper Shipping Skid
FANUC ships S-420i robots to customers on special shipping skids.
Usually these are made of steel, but on certain models, wood skids are
used. S-420i robots should only be shipped using these skids. Under no
circumstances should the robot be shipped without these skids. Robots
should NOT be shipped with steel mounting plates attached.
B--80505E/06
171
After a robot is ready for shipment, it must be placed into the shipping
position. This position places the robot directly over the shipping skid
which helps prevent damage from improper handling.
Fig.3.2 (b) Shipping Position of Robot
CONNECTION
172
FANUC recommends that all tooling be removed from the robot wrist
prior to shipment. In some cases where robots will be transported over
a short distance, the tooling can remain mounted to the robot wrist. If the
robot is to be shipped with the tooling mounted, it is imperative that the
upper arm is blocked to reduce shipping damages.
Heavy Tooling
Blocking
Fig.3.2 (c) Shipping Robot with Tooling (Special Considerations)
B--80505E/06
173
To properly transport a robot, it must be mounted to a skid. This robot
skid must be secured to the truck deck. Chains or straps are not to be
attached to any aspect of the robot arm.
Shipping Skid
Chains or Straps
Truck Deck
Truck Deck
Fig.3.2 (d) Proper Robot Securing to Truck
CONNECTION
174
Under NO circumstances are chains or straps to be run through the fork
lift pockets. This method can cause structural damage to the robot
mechanical unit and/or peripherals which have been mounted to them.
Chains or Straps
Never chain through fork pockets
Fig.3.2 (e) Improper Robot Securing to Truck
B--80505E/06
175
Fig. 3.3 (a) shows the robot base dimensions. Fig. 3.3 (b) shows an actual
example of robot installation. The floor plate should be embedded in
concrete and fastened with chemical anchors. Also fasten the base plate
to the robot base using M20 x 60 bolts (strength classification 12.9). Next,
position the robot and weld the base plate to the floor plate.
Fig. 3.3 (c) shows another example of the robot installation for S--420iR.
The floor plate should be either welded to the frame or fastended with
eight M20 x 60 bolts (strength classification 12.9). Also fasten the base
plate to the robot base using four M20 x 60 bolts (strength classification
12.9) and four M16 x 60 bolts (strength classification 12.9) with plain
washers. Next, position the robot and weld the base plate to the floor plate.
Avoid placing any object in front of the robot on the mounting surface to
facilitate the installation of the mastering fixture, as shown in Fig. 3.3 (a).
Fig. 3.3 (d) and table 3.3 show force and movement applied to the base
plate during emergency stop state.
Fig.3.3 (a) Installation hole dimensions of the robot base
NOTE
1 Parts to be provided by the customer:
i) S--420iF/W/S/L
Robot mounting bolts : M20 x 60 (strength classification 12.9) 4pcs.
Chemical anchors : M20 (strength classification 4.8) 8pcs.
Base plates : thickness 32 3pcs.
Floor plate : thickness 32
ii) S--420iR
Robot mounting bolts : M16 x 60 (strength classification 12.9) 4pcs.
: M20 x 60 (strength classification 12.9) 4pcs.
(12pcs.)
Plain washers : M16 4pcs.
Base plates : thickness 32 3pcs.
Floor plate : thickness 32
Frame
2 Installation work (welding, anchoring, etc.) is prepared by the customer.
3 S--420i severe dust/liquid protection, installation.
When the robots work in the environment, using water or liquid, complete
draining must need. Incomplete draining will make robot break down.
3.3
INSTALLATION
CONNECTION
176
Fig.3.3 (b) Actual installation example (S--420i F/W/S/L)
B--80505E/06
177
Fig.3.3 (c) Actual installation example (S--420i R)
CONNECTION
178
Fig.3.3 (d) Force and moment during emergency stop
Table3.3 Force and moment during emergency stop
Model
Vertical moment
M
V
[kgm]
Force in vertical
direction
F
V
[kg]
Horizontal moment
M
H
[kgm]
Force in horizontal
direction
F
H
[kg]
S--420i F 4500 3200 1900 1900
S--420i F/2.85 5100 3200 2100 1800
S--420i W 4600 3200 2000 1900
S--420i W/175 4900 3400 2400 2000
S--420i W/2.85 5600 3500 2500 2100
S--420i S 3600 2900 1000 1300
S--420i L 5200 3200 2200 1800
S--420i R 6800 3700 3600 2700
S--420i R/120 6700 3600 3400 2500
B--80505E/06
179
Fig. 3.4 (a), (b) shows the maintenance area of the mechanical unit. In
mastering, it needs to take the posture of Fig. 5.3.3 (f)((j) of Chapter I.
Keep the enough space for taking the posture.
Fig.3.4 (a) Maintenance area (S--420i F/W/S/L)
Fig.3.4 (b) Maintenance area (S--420i R)
3.4
MAINTENANCE
AREA
CONNECTION
180
Fig. 3.5 (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. 3.5 (b).
Fig.3.5 (a) Air piping Option
NOTE
Pipe used in the mechanical unit has an outer diameter of
12 mm and an inner diameter of 8 mm. You can use a
different size pipe outside the mechanical unit.
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.3.5 (b)Air control set Option
3.5
AIR PIPING
B--80505E/06
181
Following figure shows howto connect air tube to the robot. The air tube
between the mechanical unit and air filter unit is provided. If the air tube
is extended, use hard tube, because pressure drop is reduced.
Specification of air filter unit and element
Name Specifications
Air filter unit A97L--0218--0016
Element set for replacing A97L--0218--0016#EL
3.6
PURGE AIR PIPING
(FOR SEVERE
DUST/LIQUID
PROTECTION)
CONNECTION
182
Table3.7 Installation specifications
Items Specifications
Air
pressure
Pressure 5 -- 7 kgf/cm
2
, 0.49 -- 0.69 Mpa (Set pressure 5 kgf/
cm
2
, 0.49 MPa)
Air flow Max. peak 150 Nl/min, 0.15 Nm
3
/min (Note 1)
Weight of mechanical
unit
Approx. 1500 kg (including controller)
)S--420iF/W/S
1600 kg (including Controller)
)S--420iF/2.85W/175, W/2.85 iL
1700 kg )S--420iR, R/120
Allowable ambient
temperature
0 -- 45C
Allowable ambient
humidity
Usual: Less than 75% RH
Short period (in one month): Max. 98% RH or less
Condensation free
Atmosphere Free of corrosive gases (Note 2)
Vibration Less than 0.5 G, 4.9 m/s
2
NOTE
1 This value indicates the maximumcapacity 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.
To store the robot, set it to the same attitude as that used for transportation
(See Fig. 3.1 (a) and (b)) and store it on a level surface.
3.7
INSTALLATION
SPECIFICATIONS
3.8
STORAGE
APPENDIX
NOTE2)
NOTE2)
B--80505E/06 A. SPARE PARTS LIST APPENDIX
185
A
SPARE PARTS LIST
TableA (a) Cables (for the basic axes)
No. Specifications Function Applicable models
K121
A660--8010--T136
A660--8010--T136#C
M1 to M6 PULCO
S--420i F/W/L
with a integrated
K122
A660--4003--T305
A660--4003--T305#C
M1 to M6 POWER
with a integrated
control unit
K123
A660--8010--T223
A660--8010--T223#C
M1 to M6 PULCO, EE
S 420i F/W/L
K124
A660--8010--T224
A660--8010--T224#C
M1 to M6 PULCO
S--420i F/W/L
with a remote
control unit
K125
A660--4003--T319
A660--4003--T319#C
M1 to M6 POWER
control unit
K131 A660--8010--T148 M1 to M6 PULCO, EE
K132 A660--4003--T313 M1 to M6 POWER S--420i R, R/120
K136 A660--8010--T220 M1 to M6 PULCO
S 420i R, R/120
K141
A660--8010--T133
A660--8010--T133#C
M1 to M6 PULCO
S--420i S
with a integrated
K142
A660--4003--T304
A660--4003--T304#C
M1 to M6 POWER
with a integrated
control unit
K143
A660--8010--T421
A660--8010--T421#C
M1 to M6 PULCO, EE
S 420i S
K144
A660--8010--T422
A660--8010--T422#C
M1 to M6 PULCO
S--420i S
with a remote
control unit
K145
A660--4003--T332
A660--4003--T332#C
M1 to M6 POWER
control unit
K161 A660--4003--T297 EXTENSION
S 420i L
K162 A660--4003--T298 EXTENSION
S--420i L
K181
A660--8011--T005
A660--8011--T005#C
M1 to M6 PULCO
S--420i F/2.85
S--420i W/2.85
K182
A660--4003--T377
A660--4003--T337#C
M1 to M6 POWER
S 420i W/2.85
with a integrated
control unit
K183
A660--8011--T006
A660--8011--T006#C
M1 to M6 PULCO, EE
S--420i F/2.85
K184
A660--8011--T007
A660--8011--T007#C
M1 to M6 PULCO
S--420i F/2.85
S--420i W/2.85
with a remote
K185
A660--4003--T378
A660--4003--T378#C
M1 to M6 POWER
t a e ote
control unit
NOTE
1 -- #C cables are used for compact type mechanical unit.
2 Cable K161, K162 conform to CE Marking.
APPENDIX A. SPARE PARTS LIST B--80505E/06
186
TableA (b) Cables (for the basic axes : CE Marking)
K221
A660--8011--T017
A660--8011--T017#C
M1 to M6 PULCO
S--420i F/W/L
with a integrated
K222
A660--4003--T381
A660--4003--T381#C
M1 to M6 POWER
with a integrated
control unit
K223
A660--8011--T018
A660--8011--T018#C
M1 to M6 PULCO, EE
S 420i F/W/L
K224
A660--8011--T019
A660--8011--T019#C
M1 to M6 PULCO
S--420i F/W/L
with a remote
control unit
K225
A660--4003--T382
A660--4003--T382#C
M1 to M6 POWER
control unit
K231 A660--8011--T020 M1 to M6 PULCO, EE
K232 A660--4003--T383 M1 to M6 POWER S--420i R, R/120
K236 A660--8011--T021 M1 to M6 PULCO
S 420i R, R/120
K241
A660--8011--T022
A660--8011--T022#C
M1 to M6 PULCO
S--420i S
with a integrated
K242
A660--4003--T384
A660--4003--T384#C
M1 to M6 POWER
with a integrated
control unit
K243
A660--8011--T023
A660--8011--T023#C
M1 to M6 PULCO, EE
S 420i S
K244
A660--8011--T024
A660--8011--T024#C
M1 to M6 PULCO
S--420i S
with a remote
control unit
K245
A660--4003--T385
A660--4003--T385#C
M1 to M6 POWER
control unit
K281
A660--8011--T028
A660--8011--T028#C
M1 to M6 PULCO
S--420i F/2.85
S--420i W/2.85
K282
A660--4003--T386
A660--4003--T386#C
M1 to M6 POWER
S 420i W/2.85
with a integrated
control unit
K283
A660--8011--T029
A660--8011--T029#C
M1 to M6 PULCO, EE
S--420i F/2.85
K284
A660--8011--T030
A660--8011--T030#C
M1 to M6 PULCO
S--420i F/2.85
S--420i W/2.85
with a remote
K285
A660--4003--T387
A660--4003--T387#C
M1 to M6 POWER
t a e ote
control unit
NOTE
-- #C cables are used for compact type mechanical unit.
TableA (c) Cables (for the basic axes : Severe dust/liquid protection)
K323 A660--8011--T944 M1 to M6 PULCO, EE S--420i F/W/L
K331 A660--8012--T001 M1 to M6 PULCO, EE S--420i R
NOTE
For the remote controller type, the M1 to M6 POWERcable
is the same as for the CE Mark.
187
TableA (d) Cables (for the wrist)
K108 A660--2004--T285 M6P COUPLING
K109 A660--4003--T283 M6MBK COUPLING S--420i F/W/S/L/R
K110 A660--4003--T450 EXTENSION
S 420i F/W/S/L/R
NOTE
Wrist cables conform to CE Marking.
TableA (e) Cables (optional)
K111 A660--2004--T203 EE (RDI/RDO) Integrated type
K112 A660--2004--T204 AS (UER/SIGNAL)
S 420i F/W/S/L
K113 A660--2004--T205 AP (USER/POWER)
S--420i F/W/S/L
K114 A660--8009--T796 J1 OT Integrated type
K115 A660--8010--T218 J1 OT Remote type
K119 A660--2004--T325 I/O (STANDARD)
S--420i F/W/S/L
with a integrated
K120 A660--4003--T328 I/O (SPECIAL)
with a integrated
control unit
K128 A05B--1313--D001 I/O (STANDARD)
S--420i F/W/S/L
with a remote
K129 A05B--1313--D003 I/O (SPECIAL)
with a remote
control unit
K133 A660--2004--T330 AS (UER/SIGNAL)
K134 A660--2004--T345 AP (USER/POWER)
S 420i R
K138 A05B--1313--D002 I/O (STANDARD)
S--420i R
K139 A05B--1313--D004 I/O (SPECIAL)
K524 A660--4003--T585 DEVICENET (SIGNAL)
S 420i F/W/S/L
K525 A660--4003--T586 DEVICENET (POWER)
S--420i F/W/S/L
TableA (f) Cables (optional : Severe dust/liquid protection)
K329 A05B--1313--D023 I/O (SPECIAL) S--420i F/W/L
K339 A05B--1313--D024 I/O (SPECIAL) S--420i R
NOTE5)
NOTE5)
188
TableA (g) Cables (optional : CE Marking)
K211 A660--2004--T809 EE (RDI/RDO) Integrated type
K212 A660--2004--T804 AS (UER/SIGNAL)
S 420i F/W/S/L
K213 A660--2004--T805 AP (USER/POWER)
S--420i F/W/S/L
K219 A660--2004--T817 I/O (STANDARD)
S--420i F/W/S/L
with a integrated
K220 A660--4003--T476 I/O (SPECIAL)
with a integrated
control unit
K228 A05B--1313--D011 I/O (STANDARD)
S--420i F/W/S/L
with a remote
K229 A05B--1313--D013 I/O (SPECIAL)
with a remote
control unit
K233 A660--2004--T807 AS (UER/SIGNAL)
K234 A660--2004--T808 AP (USER/POWER)
S 420i R
K238 A05B--1313--D012 I/O (STANDARD)
S--420i R
K239 A05B--1313--D014 I/O (SPECIAL)
TableA (h) Motors
Name (Axis) Specifications Remarks
M1, M2, M3 (J1, J2,J3) A06B--0147--B675 22/2000
M4 (J4) A06B--0146--B675 22/1500
M5 (J5) A06B--0142--B675#0006 12/2000
M6 (J6) A06B--0162--B175#0006 M6/3000
TableA (i) For High duty (M4 to M6 are common)
M1, M2, (J1, J2) A06B--0186--B675#0011 M30/3000HV
M3 (J3) A06B--0147--B675 22/2000
TableA (j) For S--420i W/2.85 (M4 to M6 are common)
M1, M2, (J1, J2) A06B--0147--B675 22/2000
M3 (J3) A06B--0186--B675#0011 M30/3000HV
NOTE
The specification of the motor for J5 and J6 axis
manufactured before August 1995 are
J5 AXIS : A06B--0142--B675#0003
J6 AXIS : A06B--0162--B175#0003
There are two pulse--coder cable which correspond to each
motor.
#0003 : K107 (A660--4003--T233)
#0006 : K110 (A660--4003--T450)
When you change the motor (#0003), you must prepare the
cable--K110 and new motor (#0006).
NOTE6)
189
TableA (k) Reducer
Name Specifications Applicable models
A97L--0118--0940#250A--118 S--420i F/S/L
J2--axis reducer A97L--0118--0940#250A--129 S--420i W/R J2 axis reducer
A97L--0118--0940#250A--141 S--420i R/120
A97L--0118--0941#250A--129 S--420i F/S/L/R
J3--axis reducer A97L--0118--0941#250A--171 S--420i W J3 axis reducer
A97L--0118--0941#250A--141 S--420i F2.85/R120
J6 axis reducer
A97L--0118--0942#30A--81 S--420i F/S/L/R
J6--axis reducer
A97L--0118--0942#30A--121 S--420i W
TableA (l) Gear
A290--7313--X221 S--420i F/W/L/R
J1--axis
A290--7313--Y221 S--420i S
J1--axis
pinion gear
A290--7313--Z221
S--420i R/120
S--420i F/2.85
S--420i W/2.85
A290--7313--X222 S--420i F/W/L/R
J1--axis
A290--7313--Y222 S--420i S
J1--axis
center gear
A290--7313--Z222
S--420i R/120
S--420i F/2.85
S--420i W/2.85
J2/J3 gearbox
assembly
A290--7313--V351
J2/J3 gear A
assembly
A290--7313--V352
S--420i F/W/S/L
Compact type
J2/J3 gear B
assembly
A290--7313--V353
Compact type
J4--axis
A290--7313--X404 S--420i F/S/L/R
J4 axis
pinion gear A290--7313--Y404 S--420i W
J4--axis
A290--7313--X405 S--420i F/S/L/R
J4 axis
center gear A290--7313--Y405 S--420i W
J5--axis
gear 1
A290--7313--V521 S--420i F/S/L/R
gear 1
assembly
A290--7313--V524 S--420i W
J5--axis
gear 2
A290--7313--V522 S--420i F/S/L/R
gear 2
assembly
A290--7313--V525 S--420i W
J5--axis
gear 3
A290--7313--V523 S--420i F/S/L/R
gear 3
assembly
A290--7313--V526 S--420i W
J5--axis
A290--7313--X508 S--420i F/S/L/R
J5 axis
gear 4 A290--7313--Y508 S--420i W
NOTE
V351 includes V352, V353 and the other parts.
190
TableA (m) Others (mechanical unit)
Balancer A05B--1313--V301 S--420i F/W/S/L
Balancer A05B--1313--V311 S--420i R
Wrist unit A290--7313--V501 S--420i F/S/L/R
Wrist unit A290--7313--V503 S--420i W
Shaft assembly A290--7313--V321 S--420i F/W/S/L/R
J3--axis arm assembly A290--7313--V401 S--420i F/W/L
J3--axis arm assembly A290--7313--V441 S--420i S
J3--axis arm assembly A290--7313--V461 S--420i L/R
J3--axis arm assembly A290--7313--V471 S--420i R
Cable track A97L--0218--0608#27 S--420i F/W/S/L/R
TableA (n) Others (mechanical unit) for severe dust/liquid protection
Balancer A290--7313--V302 S--420i F/W/L
Balancer A290--7313--V312 S--420i R
Wrist unit A290--7313--V551 S--420i F/L/R
Wrist unit A290--7313--V553 S--420i W
J3--axis arm assembly A290--7313--V411 S--420i F/W/L
J3--axis arm assembly A290--7313--V472 S--420i R
Extended arm assembly A290--7313--V462 S--420i L/R
TableA (o) Battery and grease
Battery A98L--0031--0005 1.5 V, size D
Grease A98L--0040--0119#2KG Kyodo Yushi
Moly--white RE No.00
Grease A97L--0001--0179#2 Shell Alvania No.2
TableA (p) O--rings
Name Specifications Location
O--ring JB--ORIA--G125 M1 to M5
O--ring A98L--0001--0347#S115 M6
O--ring A98L--0040--0041#280 J1--axis reducer
O--ring JB--ORIA--G135 J1--axis reducer
O--ring JB--ORIA--G270 J2/J3--axis reducer
O--ring A98L--0001--0347#S70 J4--axis reducer
B--80505E/06 B. CONNECTION DIAGRAM APPENDIX
191
B
CONNECTION DIAGRAM
A
P
P
E
N
D
I
X
B
.
C
O
N
N
E
C
T
I
O
N
D
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A
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A
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B
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C
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A
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A
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A
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9
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A
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C
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A
B
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A
P
P
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1
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F
B--80505E/06 Table of Contents
c--1
SAFETY PRECAUTIONS s--1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREFACE p--1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I MAINTENANCE
1. CONFIGURATION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 J1--AXIS DRIVE MECHANISM 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 J2/J3--AXIS DRIVE MECHANISM 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 J4--AXIS DRIVE MECHANISM 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 J5/J6--AXIS DRIVE MECHANISM 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 MAJOR COMPONENT SPECIFICATIONS 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. PREVENTIVE MAINTENANCE 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 DAILY CHECKS 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 3--MONTH CHECKS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 6--MONTH CHECKS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 ANNUAL CHECKS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 3--YEAR CHECKS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 MAINTENANCE TOOLS 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 CAUTION STICKERS FOR DAILY CHECKS
(ONLY SEVERE DUST/LIQUID PROTECTION) 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. PERIODIC MAINTENANCE 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 REPLACING GREASE OF THE DRIVE MECHANISM 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 GREASING 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 REPLACING BATTERY 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 REPLACING FILTER ELEMENT 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. TROUBLESHOOTING 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 GENERAL 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 PROBLEMS AND CAUSES 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 THE MEASUREMENT OF THE BACKLASH 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. ADJUSTMENTS 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 AXIS LIMITS SETUP 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 Zero Point Position and Motion Limit 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.2 Software Setting 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.3 Hard Stopper and Limit Switch Setting 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 ADJUSTING J1--AXIS LIMIT SWITCH (OPTION) 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 MASTERING 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 General 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2 Resetting Alarms and Preparing for Mastering 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.3 Mastering to a Fixture (Master Position Master) 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.4 Zero Degree Mastering 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.5 Quick Mastering 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.6 Single Axis Mastering 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--2
5.4 ADJUSTING J5--AXIS BACKLASH 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. REPLACING PARTS 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 PART REPLACEMENT AND CORRESPONDING ADJUSTMENT 60 . . . . . . . . . . . . . . . . . . . . . . .
6.2 REPLACING J1--AXIS MOTOR (M1) AND REDUCER 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 REPLACING J2/J3--AXIS MOTOR (M2/M3) AND REDUCER 65 . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 REPLACING J4--AXIS MOTOR (M4) AND J4--AXIS REDUCER 76 . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 REPLACING WRIST UNIT 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 RELEASING A BRAKE (OPTION) 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. PIPING AND WIRING 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 PIPING DIAGRAM 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 WIRING DIAGRAM 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. REPLACING CABLE 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 CABLE FORMING 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 REPLACING THE CABLES 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 REPLACING THE OPTIONAL J1--AXIS LIMIT SWITCH (OPTION) 122 . . . . . . . . . . . . . . . . . . . . .
II CONNECTION
1. ROBOT INTERFERENCE AREA 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. MECHANICAL COUPLING TO THE ROBOT 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 WRIST LOAD CONDITIONS 141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 LOAD CONDITIONS ON J2--AXIS BASE AND J3--AXIS ARM 143 . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 MECHANICAL COUPLING OF END EFFECTOR TO WRIST 145 . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 EQUIPMENT MOUNTING FACE 146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 SETTING OF SYSTEM VARIABLES FOR TURBO MOVE 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 AIR SUPPLY (OPTION) 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 INTERFACE FOR END EFFECTER (OPTION) 152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. TRANSPORTATION AND INSTALLATION 163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 TRANSPORTATION 163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 ROBOT TRANSPORTATION CONSIDERATIONS 168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 INSTALLATION 175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 MAINTENANCE AREA 179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 AIR PIPING 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 PURGE AIR PIPING (FOR SEVERE DUST/LIQUID PROTECTION) 181 . . . . . . . . . . . . . . . . . . . . .
3.7 INSTALLATION SPECIFICATIONS 182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 STORAGE 182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--3
APPENDIX
A. SPARE PARTS LIST 185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. CONNECTION DIAGRAM 191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. PERIODIC MAINTENANCE TABLE 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index
B--80505E/06
i--1
[Numbers]
3--month Checks, 13
3--year Checks, 13
6--month Checks, 13
[A]
Adjusting J1--axis Limit Switch (Option), 39
Adjusting J5--axis Backlash, 59
Adjustments, 30
Air Piping, 180
Air Supply (Option), 151
Annual Checks, 13
Axis Limits Setup, 30
[C]
Cable Forming, 106
Caution Stickers for Daily Checks (Only Severe Dust/
Liquid Protection), 14
Configuration, 3
Connection Diagram, 191
[D]
Daily Checks, 11
[E]
Equipment Mounting Face, 146
[G]
Greasing, 20
[H]
Hard Stopper and Limit Switch Setting, 38
[I]
Installation, 168, 175
Installation Specifications, 182
Interface for End Effecter (Option), 152
[J]
J1--axis Drive Mechanism, 7
J2/J3--axis Drive Mechanism, 7
J4--axis Drive Mechanism, 8
J5/J6--axis Drive Mechanism, 9
[L]
Load Conditions on J2--axis Base and J3--axis Arm,
143
[M]
Maintenance Area, 179
Maintenance Tools, 14
Major Component Specifications, 10
Mastering, 40
Mastering to a Fixture (Master Position Master), 43
Mechanical Coupling of End Effector to Wrist, 145
Mechanical Coupling to the Robot, 140
[P]
Part Replacement and Corresponding Adjustment, 60
Periodic Maintenance, 15
Periodic Maintenance Table, 201
Piping and Wiring, 87
Piping Diagram, 87
Preventive Maintenance, 11
Problems and Causes, 24
Purge Air Piping (for Severe Dust/Liquid Protection),
181
[Q]
Quick Mastering, 53
[R]
Releasing A Breake (Option), 85
Replacing Battery, 22
Replacing Cable, 105
Replacing Filter Element, 23
Replacing Grease of the Drive Mechanism, 15
Replacing J1--axis Motor (M1) and Reducer, 62
Index
B--80505E/06
i--2
Replacing J2/J3--axis Motor (M2/M3) and Reducer, 65
Replacing J4--axis Motor (M4) and J4--axis Reducer,
76
79
82
Replacing Parts, 60
Replacing the Cables, 114
Replacing the Optional J1--axis Limit Switch
(Option), 122
Replacing Wrist Unit, 78
Resetting Alarms and Preparing for Mastering, 41
Robot Interference Area, 125
[S]
Setting of System Variables for Turbo Move, 150
Single Axis Mastering, 57
Software Setting, 37
Spare Parts List, 185
Storage, 182
[T]
The Measurement of the Backlash, 26
Transportation, 163
Transportation and Installation, 163
Troubleshooting, 24
[W]
Wiring Diagram, 89
Wrist Load Conditions, 141
[Z]
Zero Degree Mastering, 50
Zero Point Position and Motion Limit, 32
Revision Record
FANUC Robot S--420i F/W/S/L/R MECHANICAL UNIT MAINTENANCE MANUAL (B--80505E)
05 Dec.,95
S Additional descriptions for CE marking
S Additional descriptions for compact type
S Modification of base loading data
04 Aug.,95
S Robot transportation consideration is added in II--Chapter 3.
S Correction of errors.
03 Apr., 95 Additional descriptions of S--420 iF/2.85
02 Feb., 95 Additional descriptions of S--420 iW/iS/iL/iR
01 Aug., 94 06 Dec., 97
S Additional descriptions for severe dust/liquid protection
S Modification of the backlash
S Correction of errors.
Revision Date Contents Revision Date Contents

S 420i Mechanical Unit Maintenance B 80505EN 06

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