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MOTOR REPLACEMENT INSTRUCTIONS

ZEROING INSTRUCTIONS

KAWASAKI HEAVY INDUSTRIES, LTD. ROBOT DIVISION

90213-1016DED

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N

1. Outline of Zeroing

Preface

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
This manual is subject to change without prior notice and without our legal responsibility. Kawasaki pursues a policy of continuing improvement in design and specification of the product. The right is therefore, reserved to vary this manual without prior notice. This manual is copyrighted and all rights are reserved by KHI. This manual may not, in whole or part, be reproduced in any form or by any means without prior written permission from KHI. This manual is prepared with the best care but anyway it is impossible to exclude any misinterpretation by the user or any spelling mistakes. In case of doubts or if the robot behavior is different from that reported in this manual please would you get in touch with the nearest Kawasaki or Kawasakis agent. KHI cannot anticipate every possible circumstance that might involve a potential hazard. If a procedure, work method or operating technique not specifically recommended by KHI is used, you must satisfy yourself that it is safe for you and others. In this case you are completely responsible for eventual damages on human bodies or things. If you discover physical defects in the manual, KHI will replace the manual at no charge during 90 days period after you purchased the robot. If you do not observe warnings and/or cautions to be taken in the manual as described below, it might result in the serious injuries or damages on human bodies or robots. Therefore you must take extreme care to observe these warnings and cautions.
All rights reserved. Copyright 1999 by KAWASAKI HEAVY INDUSTRIES, LTD.

WARNING

1. For the confirmation of acceptability and effectiveness of drawings, detailed specification of documents, procedures etc. it shall be still

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
to do miscellaneous works, you must pay utmost attentions to them. 2. Those persons who engage with the operation/service of your system, they must strictly observe all safety regulation at all times. Never replace and/or adjust the inside parts provided in your Robot system while the power source is being turned ON so as to ensure your own safety.

insufficient. Therefore, if you desire to operate/serve/maintain/adjust/modify, and

[ SYMBOLS ]

Whenever you see the symbols shown below in this manual or on the machine, read and understand their messages.

DANGER

This danger symbol identifies special warnings or procedures which, if not strictly observed, will result in serious injury or death.

WARNING

This warning symbol identifies special warnings or procedures which, if not strictly observed, could result in serious injury or death.

CAUTION

This caution symbol identifies special instructions or

procedures which, if not correctly followed, may result in injury. [ NOTE ]

This note symbol identifies supplementary information, or to emphasize a point or procedure, or to give a tip for easier operation.

1. Outline of Zeroing

This Instru ction Manual describe the Zeroing instructions and Motor replacement instructions of KAWASAKI ROBOT F Series.

You are recommended to well understand the contents of this Instruction Manual fully, as

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
well as to look to your own safety for the zeroing work and for the replacement of motors. For the details of the replacement of motors and the zeroing work in the encoder section, please refer to separately prepared "H20 Encoder Replacement Instructions".

WARNING

Those persons who are qualified to engage in the motor replacement work should be restricted to those who have received the maintenance course in the special education & training program arranged by our Service Group.

CONTENTS
1. Outline of Zeroing..................................................................................................... 5 2. How to Preset Encoder............................................................................................ 6

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
3. Rough Zeroing (1) (All Axes Collectively) .............................................................. 8 4. Rough Zeroing (2) (Each Axis Individually) .........................................................10 5. Accurate Zeroing....................................................................................................12
5.1.Preparation work of accurate zeroing................................................................... 13 5.2. Zeroing of JT2 ..................................................................................................... 15 5.3. Zeroing of JT3 (Except for FS10X, FS30N, FS30L, FS45C, FS45N)................... 17 5.4. Zeroing of JT3 (In case of FS10X, FS30N, FS30L, FS45C, FS45N)................... 19 5.5. Zeroing of JT4 ..................................................................................................... 21 5.6. Zeroing of JT5 ..................................................................................................... 23 5.7. Zeroing of JT6 ..................................................................................................... 25

6. Caution to be Taken at Motor Replacement........................................................28 7. Outline of Motor Replacement..............................................................................29 8. Prior to Replace Motor (Encoder).........................................................................30 9. Summary of Motor Replacement Work................................................................31 10. Works to be carried out Before Replacement of Motors..................................33 11. Replacement Instruction for Motors...................................................................35
11.1. Replacement of 100 W Motor............................................................................ 35 11.2. Replacement of 200 W Motor............................................................................ 37 11.3. Replacement of 475W Motor............................................................................. 39 11.4. Replacement of 1.0 KW Motor........................................................................... 41 11.5. Replacement of 2.1 KW Motor........................................................................... 43 11.6. Replacement of 3.1 KW Motor........................................................................... 45 11.7. Replacement of 4.2 KW Motor........................................................................... 47 12. Adjustment of Timing Belt..................................................................................... 50 Appendix: Figure of Motor Replacement .................................................................... 52

1. Outline of Zeroing

1. Outline of Zeroing
The outline of the zeroing is as shown below:

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Shipping inspection process of robot Preset of encoder After replacing motor Rough zeroing All axes collectively Each axis individually Accurate zeroing In case accurate zeroing is carried out, use the following instruments and jigs: l Zeroing jig(1) l Zeroing jig(2) l Digital inclinometer (plate) Mfg. by KHI (plate) Mfg. by KHI l Zeroing jig(3) l Zeroing jig(4) Mfg. by NIIGATA SEIKI Levelnic DL -S1 (plate) Mfg. by KHI (Angle) Mfg. by KHI In case of motor replacement, prepare instruments, tools, and grease as follows: l Torque wrench l Grease contained disulfide l Dial gauge molybdenum(MOLYCOAT etc.) l Grease for gear (SUN LIGHT GREASE No.1) l Grease for H/D
400mm or more

M 4 Hex. wrench M 5 Hex. wrench M 6 Hex. wrench M 8 Hex. wrench M10 Hex. wrench M12 Hex. wrench

(HARMONIC GREASE 4BNo.2)

l Grease for RV reduction unit and Cyclo reduction unit (MOLY WHITE RENo.00) l Plus (+) screw driver (Large, Small)

2. How to Preset Encoder

2. How to Preset Encoder


Controller l Set to the switches of operation panel as shown below:

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Place the CONTROL Release the Press the Place the Place the TEACH/REPEAT POWER switch in the EMERGENCY MOTOR STOP switch. POWER switch switch in the HOLD/RUN switch in the RUN Arm l Press the AXIS key and set to the standard posture (HOME posture) as shown below: JT6 0 point gauge mark position
1

JT5

0 point gauge mark position JT4

0 point gauge mark position

JT3

0 point gauge mark position JT2

0 point gauge mark position

JT1

0 point gauge mark position

At the standard posture, make sure that 0 point gauge mark of the each axis is coincided accurately. 0 point gauge mark position

2. How to Preset Encoder

2. How to Preset Encoder

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
The preset of the encoder is executable on AS software. Example of preset through keyin g-in on the keyboard: Referring to AS display on the screen, enter the Preset Command as shown below: (Example) : Preset of JT1:

Preset

For example: For JT1:101 For JT2:102 For JT3:103 For JT4:104 For JT5:105 For JT6:106 For JT7:107

Enter applicable axis No. as shown above.

[[ Encoder rot. counter reset (1st axis) [[ . current angle (deg.mm)? X >

Are you sure (Enter 1 to execute)? 1

Enter the present arm angle here.

When the arm angle is being set to 0, enter 0 ,

and when it is a certain angle(Ex. 15.4), enter the value.

CAUTION

After making sure the axis to make preset, enter the applicable axis No.

3. Rough Zeroing (1) (All Axes Collectively)

3. Rough Zeroing (1) (All Axes Collectively)


!

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
This zeroing method is a method through which all robot axes are changed collectively. When you desire to replace the motor/encoder one by one, do not apply this zeroing method. Wris t section is a structure that the phenomenon to exert the influence on zero point of other axes generation phenomenon occurs.
Arm l Upon completion of encoder preset, keep the robot arm under the standard posture (HOME posture). 8

CAUTION

3. Rough Zeroing (1) (All Axes Collectively)

3. Rough Zeroing (1) (All Axes Collectively)

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Controller l Press the EMERGENCY STOP switch and set the MOTOR POWER to OFF. l Make rough zeroing with all axes collectively.

JT1

JT2

JT3

JT4

JT5

JT6

set data XXXXXX

XXXXXX XXXXXX

XXXXXX XXXXXX

XXXXXX XXXXXX

XXXXXX XXXXXX XXXXXX XXXXXX

The value displayed on this line is

cur data XXXXXX

Set current values of all joints as zeroing data? (Enter 1 to set)

presently set up

zeroing set value

The value

In case rough zeroing executes.

In case rough zeroing exits.

displayed on this line is present encoder value

l Display present value on screen and confirm.

JT1

JT2

JT3

JT4

JT5

JT6

0.000

0.000

0.000

0.000

0.000

0.000

X[mm]

Y[mm]

Z[mm]

O[deg]

A[deg]

T[deg]

XXXXXX XXXXXX XXXXXX

XXXXXX XXXXXX XXXXXX

Makes sure these values.

If these values are 0, it is OK.

4. Rough Zeroing (2) (Each Axis Individually)

4. Rough Zeroing (2) (Each Axis Individually)


!

CAUTION

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Only through zeroing according to this procedure (rough zeroing of each axis), you can not obtain accurate linear path accuracy and shift amount. This procedure is prerequisite to the motor encoder replacement instruction described below. Therefore, surely read also this page when the motor encoder is required to replace. Wrist section is a structure that the phenomenon to exert the influence on zero point of other axes generation phenomenon occurs. Therefore,
Arm l Match the 0 point on the axis to be matched by using the arm 0 point gauge mark. JT6 0 point gauge mark position JT5 0 point gauge mark position JT4 0 point gauge mark position JT3 0 point gauge mark position JT2 0 point gauge mark position JT1 0 point gauge mark position

CAUTION

When the motor is required to replace, if you set the CONTROL POWER to ON and MOTOR POWER to ON, the joint might be out of motion. Therefore, execute the preset without fail.

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4. Rough Zeroing (2) (Each Axis Individually)

4. Rough Zeroing (2) (Each Axis Individually)

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Controller l Press the EMERGENCY STOP switch and set the MOTOR POWER to OFF. l Operate preset.

+ See 2. How to Preset Encoder.

l Make rough zeroing of the each axis.

Example, When JT1 is required to carry out zeroing enter the axis

Current angle (deg.mm) ?

No. as 1 after input the ZZERO

or

Encoder value? (Current = xxxxxx, Enter 1 to the current value)

( If stops at halfway,

key is only depressed.)

Zeroing value=xxxxxx(268419072-268451840)OK?(Enter 0 to change)

( If re-enter is required, 0 key is only depressed.)

Setting completed.

* In the same way as above make zeroing on JT2 JT6 one by one.

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5. Accurate Zeroing

5. Accurate Zeroing
Arm

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Remove the cover as a preparation as shown in figure below to put the inclinometer on the robot arm. And, remove paint, rust, and burr, etc. on the each zeroing jig installing surface enough with the whetstone etc. Datum level (D) Datum level (B) Datum level (C) Datum level (A) JT4 motor 12

5. Accurate Zeroing

5. Accurate Zeroing
5.1. Preparation work of accurate zeroing

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Accurate zeroing is applied only to JT2 JT6. For JT1, normally accurate zeroing is not required.
Controller l Set to the switches of operation panel as shown below: Place the CONTROL Release the Press the Place the Place the POWER switch in the EMERGENCY MOTOR STOP switch. POWER switch switch in the TEACH/REPEAT HOLD/RUN switch in the RUN Arm l First, execute rough zeroing described before over all axes. And, match all axes in the state of 0. the inclinometer. Be careful of the inclinometer placing direction. Level l Install the zeroing jig(1) to the datum level (A) of the lower arm section as shown below. Then place Digital display Measuring direction

CAUTION

Inclinometer Zeroing jig(1)

Power switch HOLD/RUN sel.

[0-ADJUST] volume

0.01/0.001 unit sel.

CAUTION

Once the inclinometer is adjusted by volume control,

never touch and change the adjusted value.

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5. Accurate Zeroing

5. Accurate Zeroing

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Arm l Next, set the various switches provided to the inclinometer as follows: Power :ON HOLD/RUN :RUN Turn the 0-ADJUST volume control and adjust the digital display is set to 0.00 mm/m.

CAUTION

Depending on condition, 0-ADJUST volume control can not be set to 0. In this case, set the display to a clear and adequate value; for example, -1.00mm/m.

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5. Accurate Zeroing

5. Accurate Zeroing
5.2. Zeroing of JT2

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Controller l Set to the switches of operation panel as shown below: Place the CONTROL Release the Press the Place the Place the TEACH/REPEAT POWER switch in the EMERGENCY MOTOR STOP switch. POWER switch switch in the HOLD/RUN switch in the RUN Arm l Install the zeroing jig(2) to the datum level(B) of the lower arm section as shown below. Then place the inclinometer, pay attention not to touch with the 0-ADJUST volume control. Be careful of the inclinometer placing direction. Measuring direction

Zeroing jig (2)

Inclinometer

l Press the AXIS key provided on the Multi Function Panel, and move JT2.

On this occasion, move JT2 until the inclinometer display may equal to the value set on the datum level(A) (Standard:0.00).

For example, if the set value at the datum level(A) is 0.00, move the axis until the value at the datum level(B) becomes 0.00 0.01.

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5. Accurate Zeroing

5. Accurate Zeroing

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Controller l Press the EMERGENCY STOP switch and set the MOTOR POWER to OFF. When you ex ecute the MOTOR POWER as ON, the message of Turn OFF Motor power is displayed. l Make zeroing of JT2.


or

Current angle(deg.mm) ?

Encoder value? (Current = xxxxxx, Enter 1 to the current value)

(If stops at halfway,

key is only depressed.)

Zeroing value=xxxxxx(268419072-268451840)OK?(Enter 0 to change)

* When zeroing value is out of 268419072268451840, execute encoder preset again.

( If re-enter is required, 0 key is only depressed.)

Setting completed.

In this way, the zeroing of JT2 has been completed.

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5. Accurate Zeroing

5. Accurate Zeroing
5.3. Zeroing of JT3 (Except for FS10X, FS30N, FS30L, FS45C, FS45N)

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Set to the switches of operation panel as shown below: Place the CONTROL Release the Press the Place the Place the TEACH/REPEAT POWER switch in the EMERGENCY MOTOR STOP switch. POWER switch switch in the HOLD/RUN switch in the RUN Arm l Install the zeroing jig(3) to the datum level(C) of the upper arm section as shown below. Then place the inclinometer, pay attention not to touch with the 0-ADJUST volume control. Be careful of the inclinometer placing direction.

Controller

Zeroing jig (3)

l Press the AXIS key provided on the Multi Function Panel, and move JT3.

On this occasion, move JT3 until the inclinometer display may equal to the value set on the datum level(A) (Standard : 0.00).

CAUTION

At zeroing, do not move axes except JT3. (especially JT2).

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5. Accurate Zeroing

5. Accurate Zeroing
Controller

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Press the EMERGENCY STOP switch and set the MOTOR POWER to OFF. When you execute the MOTOR POWER as ON, the message of Turn OFF Motor power is displayed. l Make zeroing of JT3.

Current angle (deg.mm) ?

or

Encoder value? (Current = xxxxxx, Enter 1 to the current value)

(If stops at halfway,

key is only depressed.)

Zeroing value=xxxxxx(268419072-268451840)OK?(Enter 0 to change)

* When zeroing value is out of 268419072268451840, execute encoder preset again.

(If re-enter is required, 0 key is only depressed.)

Setting completed.

In this way, the zeroing of JT3 has been completed.

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5. Accurate Zeroing

5. Accurate Zeroing
5.4. Zeroing of JT3 (In case of FS10X, FS30N, FS30L, FS45C, FS45N)

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Set to the switches of operation panel as shown below: Place the CONTROL Release the Press the Place the Place the TEACH/REPEAT POWER switch in the EMERGENCY MOTOR STOP switch. POWER switch switch in the HOLD/RUN switch in the RUN Arm l Move JT4 at +90, and make the robot to posture to which does not receive the influence of JT5 easily as shown below. l Place the zeroing jig(2) on the datum level (D) of the flange surface as shown below. Then place the inclinometer, pay attention not to touch with the 0-ADJUST value control. Be careful of the inclinometer placing direction.

Controller

Zeroing jig (2)

Move JT4 at +90

l Press the AXIS key provided on the Multi Function Panel, and move JT3.

On this occasion, move JT3 until the inclinometer display may equal to the value set on the datum level(A) (Standard : 0.00).

CAUTION

At zeroing, after matching JT4 to the above posture, do not move axes except JT3 (especially JT2).
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5. Accurate Zeroing

5. Accurate Zeroing
Controller

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Press the EMERGENCY STOP switch and set the MOTOR POWER to OFF. When you execute the MOTOR POWER as ON, the message of Turn OFF Motor power is displayed. l Make zeroing of JT3.

Current angle (deg.mm) ?

or

Encoder value? (Current = xxxxxx, Enter 1 to the current value)

( If stops at halfway,

key is only depressed.)

Zeroing value=xxxxxx(268419072-268451840)OK?(Enter 0 to change)

* When zeroing value is out of 268419072 268451840, execute encoder preset again.

(If re-enter is required, 0 key is only depressed.)

Setting completed.

In this way, the zeroing of JT3 has been completed.

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5. Accurate Zeroing

5. Accurate Zeroing
5.5. Zeroing of JT4
Controller

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Place the CONTROL Release the Press the Place the Place the TEACH/REPEAT POWER switch in the EMERGENCY MOTOR STOP switch. POWER switch switch in the HOLD/RUN switch in the RUN Arm l Referring to the figure below, while keeping the standard posture (HOME posture), move JT3 forward at 90 (-90) and move JT5 upper-ward at 90(+90) viewed from rear. Move JT3 at -90

l Set to the switches of operation panel as shown below:

Referring to the left figure, if the posture is set automatically, follow the procedures bellow:

Move JT5 at 90

Set to REPEAT side. Set to RUN side

To axis coincidence accurately, positioning accuracy range key-in the below: DO ACCURACY 0.1

Keeping the standard posture (HOME posture), key-in the below:

DO DRIVE 3, -90

and

l Place the zeroing jig(1) to the datum level (A) of the lower arm section at the direction as shown above

(clockwise inclination of arm is measured), make zero adjustment by turning 0-ADJUST value. (If 0 setting is difficult, set adequate value.) Be careful of the inclinometer placing direction.

l Referring to the figure above, place the zeroing jig (2) on the datum level (D) of the flange surface. Be careful of the inclinometer placing direction.

l Press the AXIS key provided on the Multi Function Panel, and move JT4.

On this occasion, move JT4 until the inclinometer display may equal to the value set on the datum level(A) (Standard : 0.00).

CAUTION

At zeroing, do not move axes except JT4.

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5. Accurate Zeroing

5. Accurate Zeroing

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Controller l Press the EMERGENCY STOP switch and set the MOTOR POWER to OFF. When you execute the MOTOR POWER as ON, the message of Turn OFF Motor power is displayed. l Make zeroing of JT4.

Current angle (deg.mm) ?

or

Encoder value? (Current = xxxxxx, Enter 1 to the current value)

( If stops at halfway,

key is only depressed.)

Zeroing value=xxxxxx(268419072-268451840)OK?(Enter 0 to c hange)

* When zeroing value is out of 268419072 268451840, execute encoder preset again.

(If re-enter is required, 0 key is only depressed.)

Setting completed.

In this way, the zeroing of JT4 has been completed.

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5. Accurate Zeroing

5. Accurate Zeroing
5.6. Zeroing of JT5

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Set to the switches of operation panel as shown below: Place the CONTROL Release the Press the Place the Place the TEACH/REPEAT POWER switch in the EMERGENCY MOTOR STOP switch. POWER switch switch in the HOLD/RUN switch in the RUN Arm Execute the zeroing of JT5 at the robot arm standard posture (HOME posture). l First, set JT2, JT3 and JT4 to 0. (You can return posture to 0 by the HOME command.)

Controller

l Place the zeroing jig(2) on the datum level (D) of the flange surface as shown below. Then place the

inclinometer, pay attention not to touch with the 0-ADJUST value control. Be careful of the inclinometer placing direction.

Zeroing jig (2)

l Press the AXIS key provided on the Multi Function Panel, and move JT5.

On this occasion, move JT5 until the inclinometer display may equal to the value set on the datum level(A) (Standard : 0.00).

CAUTION

At zeroing, do not move axes except JT5.

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5. Accurate Zeroing

5. Accurate Zeroing
Controller

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Press the EMERGENCY STOP switch and set the MOTOR POWER to OFF. When you execute the MOTOR POWER as ON, the message of Turn OFF Motor power is displayed. l Make zeroing of JT5.


or

Current angle (deg.mm) ?

Encoder value? (Current = xxxxxx, Enter 1 to the current value)

( If stops at halfway,

key is only depressed.)

Zeroing value=xxxxxx(268419072-268451840)OK?(Enter 0 to change)

* When zeroing value is out of 268419072 268451840, execute encoder preset again.

(If re-enter is required, 0 key is only depressed.)

Setting completed.

In this way, the zeroing of JT5 has been completed.

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5. Accurate Zeroing

5. Accurate Zeroing
5.7. Zeroing of JT6

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Set to the switches of operation panel as shown below: Place the CONTROL Release the Press the Place the Place the TEACH/REPEAT POWER switch in the EMERGENCY MOTOR STOP switch. POWER switch switch in the HOLD/RUN switch in the RUN Arm l Move only JT3 forward at 90 (-90) in the standard posture (HOME posture). Then place the inclinometer. Be careful of the inclinometer placing direction. Referring to the figure below, install the zeroing jig (4) to the wrist flange face (datum level (D) ). Referring to the left figure, if the posture is set automatically, follow the procedures bellow: Move JT3 at -90

Controller

Zeroing jig(4)

Set to REPEAT side. Set to RUN side

To axis coincidence accurately, positioning accuracy range key-in the below: DO ACCURACY 0.1

Keeping the standard posture (HOME posture), key-in

l Press the AXIS key provided on the Multi Function Panel, and move JT6.

CAUTION

On this occasion, move JT6 until the

At zeroing, do not move axes except JT6.

inclinometer display may equal to the value set on the datum level (A) (Standard : 0.00).

25

5. Accurate Zeroing

5. Accurate Zeroing
Controller

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Press the EMERGENCY STOP switch and set the MOTOR POWER to OFF. When you execute the MOTOR POWER as ON, the message of Turn OFF Motor power is displayed. l Make zeroing of JT6.

Current angle (deg.mm) ?

or

Encoder value? (Current = xxxxxx, Enter 1 to the current value)

(If stops at halfway,

key is only depressed.)

Zeroing value=xxxxxx(268419072-268451840)OK?(Enter 0 to change)

* When zeroing value is out of 268419072 268451840, execute encoder preset again.

( If re-enter is required, 0 key is only depressed.)

Setting completed.

In this way, the zeroing of JT6 has been completed.

26

5. Accurate Zeroing

5. Accurate Zeroing
Controller

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Completion of all axes accurate zeroing of JT2 JT6. Press MOTOR POWER switch to ON. l To axis coincidence accura tely, key-in the positioning accuracy range.

l Set the robot to HOME posture (HOME position).

*HOME posture (HOME position) means here the mechanical origin.

l Display the present value on screen and confirm.

JT1

JT2

JT3

JT4

JT5

JT6

0.000

0.000

0.000

0.000

0.000

0.000

X [mm]

Y [mm]

Z [mm]

0 [deg]

A [deg]

T [deg]

XXXXXX

XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX

Make sure these values.

If these values are 0, it is OK.

27

6. Caution to be Taken at Motor Replacement

6. Caution to be Taken at Motor Replacement


Prior to start the motor replacement work, pay special attention to the following contents so as to ensure safety.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
!

WARNING

Prior to start the motor replacement work, press the "EMERGENCY

STOP" switch provided in the controller basic operation section without fail. Then the motor power in the robot system will be turned OFF.

If it is required to change the angle of the specified axis, first turn ON the

motor power. Next, after setting up the specified axis to a desirable posture, again turn

CAUTION

When a motor is required to dismount from the assembly and required to replace with a new one, do not apply excessively strong shocks to the motor and encoder.

Motors shall be stored safely within the specified ambient temperature and moisture. For screws which are not necessary for the motor dismounting and

replacement, they must not be removed, as well as for motor covers, they must not be opened.

If the motor is required to connect with the encoder, put the motor shaft pin into the U-groove of the encoder shaft.

28

7. Outline of Motor Replacement

7. Outline of Motor Replacement


AC servo motors used mainly in the KAWASAKI Robot System can be divided into two types; one is an encoder-separable type from the motor section as a unit, and the other is an encoder-unseparable type.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
w Small-sized motors of which motor capacity is 100 W, 200 W, 475 W, 1 KW and likes are represented by a one-piece structure (the motor part and the encoder part are being assembled as a set). This means that even if either the motor or the encoder has failed, it should be replaced with a new one as a set. w Large-sized motors of which motor capacity is 2.1 KW, 3.1 KW, 4.2 KW and likes are represented by a separable structure (the motor section can be separated into the motor part and the encoder part). This means that if either the motor or the encoder has failed, it can be replaced with a new one separately. w For the replacement of separable-type H20 Model Encoder, please refer to separately prepared H20 Encoder Replacement Instructions.
Type Motor Capacity FA06N, L, E FC06N FS06N, L FS10C, N, E FS10L FA20N FC20N FP20N FS20C, N FS30N, L FS45C, N FS10X

100W

JT4 JT5 JT6

JT5 JT6

One-piece structure

200W

JT4 JT5 JT6

475W

JT3 JT1 JT2

JT4 JT5 JT6

JT4

1.0KW 2.1KW 3.1KW 4.2KW

JT3 JT1 JT2

Separable structure

JT3 JT1 JT2

JT3 JT1 JT2

Type

Motor Capacity

Motor Type

Motor Assy P/N

100W 200W 475W

P50B05010DCX P50B05020DCX P50B07050DCX P60B13100HCX P60B13150HCX P60B13200LCX

50601-1136 50601-1143 50601-1138 50601-1139 50601-1123 50601-1125 50601-1121

One-piece structure

Separable structure

1.0KW 2.1KW 3.1KW 4.2KW

P80B22450RCX

29

8. Prior to Replace Motor (Encoder)

8. Prior to Replace Motor (Encoder)


Prior to re place the motor with a new one, first of all, you must make sure whether the present motor is prerequisite to replace with a new one or not.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
In particular, when an encoder-separable motor is used, make sure that the present trouble is not caused by the failure of the encoder itself. In other words, only after making sure that the trouble is not caused by the encoder itself, you must start the motor replacement work. [ Encoder separable type ] Robot motion is abnormal. Positioning accuracy is variable. Is oscillation available? YES Is rattle found in mechanics? YES Check on mechanical parts and repair/replace NO Is abnormal noise heard? NO YES Is NO abnormal heat generated? NO YES Is the encoder value affected by any mechanical interferences? YES NO Replace encoder with a new one. Cant brake be released? Even after YES Check on mechanical replacement, parts and repair/replace errors are still NO Does brake slip? YES Check on surrounding cables and boards. NO Is inside of motor disconnected? NO YES Replace motor with a new one. (One-piece structured Are other erroneous causes observed? NO YES small sized motor should be replaced Errors occur even after replacement. The trouble might not be caused by the failure of the motor/encoder. Even though the motor/encoder has replaced with a new one, if the error can not be removed, the control system is required to check/adjust. 30

9. Summary of Motor Replacement Work

9. Summary of Motor Replacement Work


Actually when the motor replacement work is carried out, prepare the measuring instruments, tools, oils & greases etc. as shown below:

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
l Dial gauge l Molybdenum disulfide grease (including MOLYCOAT) l LOCTITE 242 l THREE BOND 1212 l SUN LIGHT GREASE No.1 l MOLY WHITE RE No.00 (For Cyclo Reduction Unit/RV Reduction Unit) l HARMONIC GREASE 4B No.2 (For H/D) l Tools Motor capacity 100W 200W 475W Torque wrench 1.0 KW 2.1 KW 3.1 KW 4.2 KW Torque wrench (M4) for hexagonal-bar attachment: about 150 mm in length Torque wrench (M4) for hexagonal-bar attachment: about 150 mm in length Torque wrench (M5) for hexagonal bar attachment: about 150 mm in length Torque wrench (M6): for hexagonal bar attachment : about 280mm in length. Torque wrench (M10) for hexagonal-bar attachment: about 280 mm in length Torque wrench (M10) for hexagonal-bar attachment: about 280 mm in length Torque wrench (M12) for hexagonal-bar attachment: about 280 mm in length l Exclusively designed removing jigs and pulley puller (for large-sized motor) Part No. Applicable Models (Axes) 50514-1010 For FS30N, L (JT1 and 2) For FS45C, N (JT1 and 2) For FS10X (JT1 and 2)

WARNING

When a motor is required to remove from an assembly, support the arm safely so as to prevent the arm from dangerous falling. When a motor is required to replace with a new one, surely turn OFF the "MOTOR POWER" and "CONTROL POWER" switches.

31

9. Summary of Motor Replacement Work

9. Summary of Motor Replacement Work


Motor replacement work and its confirmation

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
w Record the robot's present location. w Set a dial gauge to a place in the forward part of the arm for the axis of which the motor will be replaced. Next, record the values measured by the dial gauge. + See "10. Works to be carried out Before Replacement of Motors". w If recording disables, preset - zeroing shall be executed after the replacement of the motor without fail. Motor replacement work w When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail. w In order to prevent a robot arm from accidental falling/rotating, the arm must be supported by a crane/forklift truck, or must be put on a support. w Replace the motor of which capacity may coincide with the applicable model, and with replacement object axes. + See "11. Replacement Instruction for Motors". Works to be carried out after motor replacement w First, move the robot arm, until the applicable value may coincide accurately with the value measured by the dial gauge. w If encoder values can not be recorded successfully, preset and zeroing shall be executed. Confirmation to be carried out after motor replacement w Execute repeat run on the program, and make playback the robot motions. Then make sure whether any error/abnormality is observed or not. w If preset and zeroing have been executed, re-teach the applicable program again. 32

10. Works to be carried out Before Replacement of Motors

10. Works to be carried out Before Replacement of Motors


Actually before the motor replacement work is carried out, it is prerequisite to record the robot's present position.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
The recording of the robot's present position is represented by the followings:

w Reading of Encoder Values

w Confirmation of Absolute Position of the Arm at that Time (Confirmation by using a Dial Gauge)

In this section, how to measure values so as to make sure the arm's absolute position, is explained.

On this occasion, the encoder must be normal and accurate, as well as the display of the encoder values is precise.

(1) Press the "AXIS" key provided on the Multi Function Panel, and move the robot arm, until an adequate posture is obtained.

(2) Set the dial gauge to an adequate place (such as to a hand) provided in the forward part from the axis of which the motor will be replaced.

Set the dial gauge to places shown in the figures (on the next page and the consecutive pages)

CAUTION

Surfaces on which a dial gauge is required to set shall be

selected to be flat as far as possible. Moreover, the surfaces shall be at right angles to the rotation of the axis of a motor to be replaced.

(3) Match the value of the dial gauge with 0.

Then keeping this posture, record the encoder values of axis.

(Record as adequate positional variables by executing HERE Command.)

(4) Carry out the motor replacement work in an easily accessable posture.

On this occasion, be careful that the dial gauge position does not move.

33

10. Works to be carried out Before Replacement of Motors

10. Works to be carried out Before Replacement of Motors


When JT1 is required to replace When JT2, 3 and 5 are required to replace

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
JT3,5 JT2 JT1 When JT4 and 6 are required to replace JT4,6 34

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


!
When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail.

WARNING

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
When a motor is required to replace with a new one, do not carelessly make the robot arm fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support by using a crane/forklift truck.

11.1. Replacement of 100 W Motor


Also, see "Figure of Motor Replacement". Model A xes

FA06N, L, E / FC06N / FS06N, L / FS10C, N, E JT4 JT5 JT6

FS10X JT5 JT6

(1) First, remove the covers from the designated places.

(2) Next, disconnect the connector for motor power cable from the axis of motor to be replaced.

Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly. (Cut off "Insulock" provided for the fixing of vinyl sheet to be used for the protection of connector parts.) Connector for encoder

Connector for motor power cable

(3) Remove the servo-motor fixing bolts (M4 Hexagon socket head cap bolt - 4 bolts). Loosen the bolts of the motor bracket for JT5 or 6. And remove the timing belt.

When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 150mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work.

Connector for encoder Connector for motor power cable

M4 Hexagon socket head cap bolt

H/D wave generator

Pulley JT4 JT5, 6 Snap ring 35 M3 Hexagon socket set screw Tightening torque : 1.47Nm (15kgfcm)

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


(4) Remove the servo-motor.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Since the pulley or the wave generator is attached to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.
(5) i) For JT5 and 6 ii) For JT4 Remove the snap ring from the end of the removed servo-motor, and remove the pulley. Loosen the hexagon socket set screws from the end of the removed servo-motor, and remove the wave generator.

CAUTION

CAUTION

When the pulley or the wave generator is removed, be careful not to give excessively strong forces to the servo-motor.

(6) Install the once removed pulley or wave generator as specified in item (5) above to the new

servo-motor. In the course of parts installation, be careful not to make a mistake in the selection o f the direction. First, coat LOCTITE 242 over the surfaces of the hexagon head socket set screws for the fixing of the wave generator. Next, tighten the socket set screws firmly. Tightening torque is 1.47N m (15kgfcm).

Coat gear grease (HARMONIC GREASE 4B No.2) over the surface of the wave generator.

(7) Assemble the new servo-motor.

Tightening torque is 3.43 N m (35kgf cm).

[ NOTE ]

Refer to 12. Adjustment of Timing Belt detail for the adjustment method of timing belt.

(8) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were befo re.

(9) Re-install the covers to the designated places as they were before.

36

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


!
When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail.

WARNING

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
When a motor is required to replace with a new one, do not carelessly make the robot arm fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support by using a crane/forklift truck.

11.2. Replacement of 200 W Motor


Also, see "Figure of Motor Replacement". Model Axis

FS10L / FA20N / FC20N / FP20N / FS20C, N JT4 JT5 JT6

(1) First, remove the covers from the designated places.

(2) Next, disconnect the connector for motor power cable from the axis of motor to be replaced.

Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly. (Cut off "Insulock" provided for the fixing of vinyl sheet to be used for the protection of connector parts.)

Connector for motor power cable

Connector for encoder

(3) Remove the servo-motor fixing bolts (M4 Hexagon socket head cap bolt - 4 bolts). When actually the

bolts are required to remove, use a torque wrench for hexagonal bar attachment (Length = about 150 mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work. Connector for encoder

M4 Hexagon socket head cap bolt

Connector for motor power cable

JT5, 6

Pulley H/D wave generator Snap ring Snap ring

JT4

37

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


(4) Remove the servo-motor.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Since the pulley or the wave generator is installed to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.
(5) i) For JT5 and 6 ii) For JT4 Remove the snap ring from the end of the removed servo-motor, and remove the pulley. Remove the snap ring from the end of the removed servo-motor, and remove the wave generator.

CAUTION

CAUTION

When the pulley or the wave generator is removed, be careful not to give excessively strong forces to the servo -motor.

(6) Install the once removed pulley or wave generator as specified in item (5) above to the new

servo-motor. In the course of parts installation, be careful not to make a mistake in the selection of the direction.

Coat gear grease (HARMONIC GREASE 4B No.2) over the surface of the wave generator.

(7) Assemble the new servo-motor.

Tightening torque is 3.43 N m (35kgf cm).

[ NOTE ]

Refer to 12. Adjustment of Timing Belt detail for the adjustment method of timing belt.

(8) Re-connect the connector for motor power cable and the connector for encoder, and other connectors as they were before.

(9) Re-install the covers to the designated places as they were before.

38

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


!

WARNING

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
When a motor is required to replace with a new one, do not carelessly make the robot arm fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support by using a crane/forklift truck.

When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail.

11.3. Replacement of 475W Motor


Also, see "Figure of Motor Replacement". Model Axis

FA06N, L, E / FC06N / FS06N, L / FS10C, N, E JT3

FS30N,L/FS45C,N JT4,5,6

FS10X JT4

(1) First, remove the covers from the designated places.

(2) Next, disconnect the connector for motor power cable from the axis of motor to be replaced.

Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly. (Cut off "Insulock" provided for the fixing of vinyl sheet to be used for the protection of connector parts.)

Connector for motor power cable

Connector for encoder

(3) Remove the servo-motor fixing bolts (M5 Hexagon socket head cap bolt - 4 bolts). Loosen the bolts of motor bracket for JT5 or 6. And remove the timing belt.

When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 150 mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work. JT4 of FS30N, L / FS45C, N / FS10X

Connector for encoder Connector for motor power cable

M5 Hexagon socket head cap bolt

JT3 of FA06N, L, E / FC06N / FS06N, L / FS10C, N, E Gasket Input gear

Input gear Snap ring 2-M4 Hexagon socket set screw 39 Tightening torque:3.43Nm(35kgfcm)

Pulley Snap ring

JT5and 6 of FS30N, L / FS45C, N

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


(4) Remove the servo-motor.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Since the gear or the pulley is attached to the motor shaft end, be careful not to apply excessively strong forces to the servo -motor at its mounting/dismounting. Straightly mount/dismount the motor.
(5) i) For JT3 of FA06N, L, E / FC06N / FS06N, L / FS10C, N, E Loosen the fixing screws from the end of the once removed servo-motor, and remove the gear. At the same time, remove the gasket from the motor mounting face. ii) For JT4 of FS30N, L / FS45C, N / FS10X Remove the snap ring from the end of the once removed servo-motor, and remove the input gear. iii) For JT5 and 6 of FS30N, L /FS45C, N Remove the snap ring from the end of the once removed servo-motor, and remove the pulley.

CAUTION

CAUTION

When the gear or the pulley is removed, be careful not to give excessively strong forces to the servo -motor.

(6) Install the once removed gear, gasket or pulley as specified in item (5) above to the new servo-metor. In the course of parts installation, be careful not to make a mistake in the selection of the gear

direction. First, coat LOCTITE 242 over the surfaces of the hexagon socket set screws for the fixing of the gear. Next, tighten the hexagon socket set screws firmly. Tightening torque is 3.43N m(35kgfcm). Coat the following gear grease over the surface of the gear. w Input gear of RV Reduction Unit or Cyclo Reduction Unit MOLY WHITE RE No.00

(7) Assemble the new servo-motor.

The Tightening torque is 6.86 N m (70kgf cm).

[ NOTE ]

Refer to 12. Adjustment of Timing Belt detail for the adjustment method of timing belt.

(8) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before.

(9) Re-install the covers to the designated places as they were before.

40

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


!

WARNING

When a motor is required to replace with a new one, turn OFF the

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
"MOTOR POWER" switch without fail. When a motor is required to replace with a new one, do not carelessly make the robot arm fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support by using a crane/forklift truck.

11.4. Replacement of 1.0 KW Motor


Also, see "Figure of Motor Replacement". Model A xes

FA06N, L, E / FC06N / FS06N, L / FS10C, N, E JT1 JT2

FS10L / FA20N / FC20N / FP20N / FS20C, N JT3

(1) First, remove the covers from the designated places.

(2) Next, disconnect the connector for motor power cable from the axis of motor to be replaced.

Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly. (Cut off "Insulock" provided for the fixing of vinyl sheet to be used for the protection of connector parts.)

Connector for motor power cable

Connector for encoder

(3) Remove the servo-motor fixing bolts (M8 Hexagon socket head cap bolt - 4 bolts).

When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work. Connector for encoder

M8 Hexagon socket head cap bolt

Connector for motor power cable

Input gear

Gasket 2-M4 Hexagon socket set screw Tightening torque =3.43 N ?m (35 kgf? cm) 41

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


(4) Remove the servo-motor.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
!

CAUTION

Since the gear is attached to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

(5) Loosen the hexagon socket set screws from the end of the removed servo-motor, and remove the gear. At the same time, remove the gasket from the motor mounting face.

CAUTION

When the gear is removed, be careful not to give excessively strong forces to the servo -motor.

(6) Install the once removed gear and gasket as specified in item (5) above to the new servo-motor.

In the course of parts installation, be careful not to make a mistake in the selection of the gear direction.

First, coat LOCTITE 242 over the surfaces of the hexagon socket set screws for the fixing of the gear. Next, tighten the hexagon socket set screws firmly. The tightening torque is 3.43N m (35kgfcm).

Coat the following gear grease over the surface of the gear.

Input gear of Cyclo Reduction Unit .............................MOLY WHIT E RE No.00

(7) Assemble the new servo-motor.

The tightening torque is 29.4N m (300kgfcm).

(8) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before.

(9) Re-install the covers to the designated places as they were before.

42

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


!
When a motor is required to replace with a new one, turn OFF the

WARNING

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
"MOTOR POWER" switch without fail. When a motor is required to replace with a new one, do not carelessly make the robot fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support it by using a crane/forklift truck. Check to see if the encoder unit itself is repairable or not without fail. The encoder itself is also replaceable. replace with a new one, first, remove the encoder from the motor, and after re-installing the motor, the encoder is required to install to the newly replaced motor. For the details of mounting/dismounting procedures of If the encoder is normal and serviceable, and only the motor is required to

11.5. Replacement of 2.1 KW Motor


Also, see "Figure of Motor Replacement". Model A xes

FS10L / FA20N / FC20N / FP20N / FS20C, N JT1 JT2

(1) Remove the encoder cover and disconnect the connector for motor power cable from the axis of motor to be replaced. Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly.

Connector for encoder

Open here, and

disconnect cable.

Connector for motor power cable

Encoder cover

M4 Hexagon socket head cap bolt

43

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


(2) Remove the servo-motor fixing bolts (M10 Hexagon socket head cap bolt - 4 bolts). When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280 mm).

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work. (3) Remove the servo-motor.

CAUTION

Since the gear is attached to the motor shaft end, be careful not to apply

excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

(4) Loosen the hexagon socket set screws from the end of the removed servo-motor, and remove the gear. At the same time, remove the gasket from the motor mounting face.
M10 Hexagon socket head cap bolt

CAUTION

When the gear is removed, be careful not to give excessively strong forces to the servo-motor.

Input gear

Gasket

2-M6 Hexagon socket set screw

Tightening torque =11.76 N? m (120 kgf?cm)

(5) Install the once removed gear and gasket as specified in item (4) above to the new servo-motor. In the course of parts installation, be careful not to make a mistake in the selection of the gear direction. First, coat LOCTITE 242 over the surfaces of the hexagon socket set screws. Next, tighten the socket set screws firmly. The tightening torque is 11.76N m (120kgfcm). Coat the following gear over the surface of the gear. Input gear of Cyclo Reduction Unit MOLY WHITE RE No.00 (6) Assemble the servo-motor. The tightening torque is 56.84 N m (580kgfcm). (7) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before. (8) Re-install the encoder cover as they were before.

CAUTION

Recommended tightening torque is 0.784 Nm (8 kgfcm). The nylon washer deforms if the socket head cap bolt of the encoder cover is tightened too much and the effect of the seal is lost.

44

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


!
When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail.

WARNING

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
When a motor is required to replace with a new one, do not carelessly make the robot fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support it by using a crane/forklift truck. Check to see if the encoder unit itself is repairable or not without fail. The encoder itself is also replaceable. If the encoder is normal an d serviceable, and only the motor is required to replace with a new one, first, remove the encoder from the motor, and after re-installing the motor, the encoder is required to install to the newly replaced motor. For the details of mounting/dismounting procedures of Encoder (Model H20), please refer to separately prepared "H20 Encoder Replacement Instructions".

11.6. Replacement of 3.1 KW Motor


Also, see "Figure of Motor Replacement". Model Axes

FS30N, L / FS45C, N/FS10X JT3

(1) Remove the encoder cover and disconnect the connector for motor power cable from the axis of motor to be replaced. Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly.

Connector for encoder

Open here, and

disconnect cable.

Connector for motor power cable

Encoder cover

M4 Hexagon socket head cap bolt

45

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


(2) Remove the servo-motor fixing bolts (M10 Hexagon socket head cap bolt - 4 bolts). When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280 mm).

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work. (3) Remove the servo-motor.

CAUTION

Since the gear is attached to the motor shaft end, be careful not to apply

excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

Gasket

M10 Hexagon socket head cap bolt

Gear

M6 Hexagon socket set screw

Tighteining torque = 11.76 N m (120kgfcm) (4) Loosen the hexagon socket set screw from the end of the removed servo-motor, and remove the gear. At the same time, remove the gasket from the motor mounting face.

CAUTION

When the gear is removed, be careful not to give excessively strong forces to the servo-motor.

(5) Install the once removed gear and gasket as specified in item (4) above to the new servo-motor. First, coat "LOCTITE 242" over the surface of hexagon socket head set screw for the fixing gear. Next, tighten the socket set screw firmly. The tightening torque is 11.76N m (120kgfcm) Coat the following gear grease over the surface of the gear. Input gear of RV Reduction Unit MOLY WHITE RE No.00 (6) Assemble the servo-motor. The tightening torque is 56.84N m (580kgfcm) (7) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before. (8) Re-install the encoder cover as they were before.

CAUTION

Recommended tightening torque is 0.784 Nm(8 kgfcm). The nylon washer deforms if the socket head cap bolt of the encoder cover is tightened too much and the effect of the seal is lost.

46

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


!

WARNING

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
11.7. Replacement of 4.2 KW Motor
Also, see "Figure of Motor Replacement". Model Axes FS30N, L / FS45C, N JT1 JT2 FS10X JT1 JT2 (1) Remove the encoder cover and disconnect the connector for motor power cable from the axis of motor to be replaced. Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly. Connector for encoder encoder cover Open here, and disconnect cable. M12 Hexagon socket head cap bolt M4 Hexagon socket head cap bolt Connector for motor power cable Connector cover Connector for motor power cable Connector M4 Hexagon socket head cap bolt for braking 47

When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch with out fail. When a motor is required to replace with a new one, do not carelessly make the robot fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support it by using a crane/forklift truck. Check to see if the encoder unit itself is repairable or not without fail. The encoder itself is also replaceable. If the encoder is normal and serviceable, and only the motor is required to replace with a new one, first, remove the encoder from the motor, and after re -installing the motor, the encoder is required to install to the newly replaced motor. For the details of mounting/dismounting procedures of Encoder (Model H20), please refer to separately prepared "H20 Encoder Replacement Instructions".

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


(2) Remove the servo-motor fixing bolts (M10 Hexagon socket head cap bolt - 4 bolts). When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280 mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work. (3) Remove the servo-motor.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
!

CAUTION

If the dismount of the servo-motor is difficult, utilize tap for bolt-pulling in the motor flange section (M12 x 4 places). Be careful that the weight of the servo-motor is very heavy to handle (approx. 30kg).

Since the taper section of the gear is too tight to pull out unless the below mentioned jigs (pulley puller) are used. On the contrary, if you pull out the gear forcibly without using such exclusively designed and specified jigs, the servo-motor might be broken and the motor replacement work becomes very dangerous. Therefore follow the below procedures without fail. (4) Attach the jigs (rod, pipe and bolt) to the servo -motor. On this occasion, be careful not to apply excessively strong forces to the motor section and the encoder section. Moreover, loosen the center bolt in the Input gear tip by about 5mm. Approx. 5mm Input gear

Center bolt

Rod

Bolt

Loosen the center bolt approx. 5mm in length, and make sure that the bolt is not pulled out.

Pipe

Input gear

Center bolt

This procedures is prerequisite to afford a stopper which is useful when the input

(M10 Hexagon socket head cap bolt)safety

(5) Attach Pulley puller to the jig.

Bar

Pulley puller

48

11. Replacement Instruction for Motors

11. Replacement Instruction for Motors


(6) Remove the input gear provided in the taper shaft section by using Pulley puller.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
When the input gear is too tight to disconnect, if you forcibly disconnect it, be careful that the input gear might be suddenly jump out and might hit the stopper provided on the center bolt head.
7) Remove the center bolt. Then remove the input gear. (8) Coat special grease (Molybdenum disulfide grease) over the surface of the taper shaft section. After that, install the once removed input gear and center bolt as specified in item(7) above to the new servo-motor. (9) Once, tighten the input gear firmly by applying 56.84N m (580kgfcm) torque. After that, remove it again. Re-install the input gear by applying 17.15 Nm (175kgfcm) torque after coat LOCKTITE 242 over the surface of the center bolt. Grip flat part provided in the input gear with the wrench when tightening. The motor brake might slip.

CAUTION

CAUTION

While the input gear is being tightened by applying 56.84Nm

(580kgfcm) of high torque and installed, it might result in unable to take away the input gear from the assembly in the next disassembling work. In other words, it is necessary once to loosen and to re-tighten the input gear by applying 17.15Nm(175kgfcm) of low torque.

(10) Assemble the servo-motor. Tightening torque is 98N m (1000kgfcm).

(11) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before.

(12) Re-install encoder cover as they were before.

CAUTION

Recommended tightening torque is 0.784 Nm(8kgfcm). The nylon washer deforms if the socket head cap bolt of the encoder cover is tightened too much and the effect of the seal is lost.

49

12. Adjustment of Timing Belt

12. Adjustment of Timing Belt


Adequate tension : Referring to the below figure, when you the center of belt at pressure F[N], to a degree that the belt deflects about mm.

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
F [N] Adjustment procedures: mm (1) Rotate 1 turn and loosen the 4 motor bracket mounting bolts. (2) Move the motor bracket and adjust the distance between axes of the pulleys. And make the tension of the belt suitable as specified below. (3) Tighten the mounting bolts. Model Axis Pressure F [N] 3.55.0 3.55.0 4.05.0 4.05.0 Deflection [mm] 3.4 FA06N, L, E FC06N FS06N, L FS10C, N, E, X FS10L FA20N FC20N FP20N FS20C, N JT5 JT6 2.2 JT5 3.6 JT6 2.3 JT5 9.512.0 9.512.0 4.9 FS30N, L FS45C, N JT6 3.3 50

51

.
MEMO

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N

Appendix: Figure of Motor Replacement

Appendix: Figure of Motor Replacement


l
FS Series
Connector for motor power cable

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Connector for encoder Motor for JT3 Connector for motor power cable Connector for encoder Motor for JT2 Connector for encoder Connector for Motor for JT1 motor power cable 52

Appendix: Figure of Motor Replacement

Appendix: Figure of Motor Replacement

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N
Motor for JT6 Connector for encoder Connector for encoder Connector for Connector for motor power cable motor power cable Motor for JT5 Connector for motor power cable Connector for encoder Motor for JT4 53

54

.
MEMO

IN T N EN O D T E C IN D O TE F PY N OR R D C IG ED U H FO ST TE D O R M D PR E O IN R R CU TE E M D FE EN D RE T IS N TR C IB E O U N TI L O Y N