38315294 S 420i Mechanical Unit Maintenance B 80505EN 06

7/21/2019 38315294 S 420i Mechanical Unit Maintenance B 80505EN 06

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(R--J2CONTROLLER)

S-420i

MaintenanceMANUAL


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B--80505E/06 SAFETY PRECAUTIONS

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 theSAFETY HANDBOOK.

D Please use appropriate lighting (e.g. a handy light) for maintenancework. The lighting shall not create new dangerous situations.

D Whenever possible, perform maintenance, inspection and adjustingwith 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 debrisdo 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 gettrappedbetween themoving robot and

other equipment. Know the path that can be used to escape from amoving robot. Make sure the escape route is never blocked.

D If it is necessary to operate the robot during the inspection, pay carefulattention to the robots motion and be sure to press the EMERGENCYSTOP 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 resistantl )


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B--80505E/06SAFETY PRECAUTIONS

3. As speed is increased. the path may vary slightly. Run through theprogram at 5--10% intervals up to 100%.

4. Using the programmed speed, test run the program continuouslyfor 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, ordebris.


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B--80505E/06 PREFACE

PREFACE

This manual describes the maintenance and connection of the following

robot mechanical unit.

Product nameMechanical unit

specificationnumber

Loadcapacity

Remark

FANUC Robot S--420i FFANUC Robot S--420i F/2.85FANUC Robot S--420i WFANUC Robot S--420i SFANUC Robot S--420i LFANUC Robot S--420i RFANUC Robot S--420i R/120

A05B--1313--B201A05B--1313--B281A05B--1313--B203A05B--1313--B241A05B--1313--B261A05B--1313--B401A05B--1313--B402

120kg120kg155kg

80kg75kg

100kg120kg

FANUC Robot S--420i FFANUC Robot S--420i F/2.85FANUC Robot S--420i WFANUC Robot S--420i SFANUC Robot S--420i L

A05B--1318--B201A05B--1318--B281A05B--1318--B203A05B--1318--B241A05B--1318--B261

120kg120kg155kg

80kg75kg

Compact type

FANUC Robot S--420i FFANUC Robot S--420i F/2.85FANUC Robot S--420i WFANUC Robot S--420i W/175

FANUC Robot S--420i W/2.85FANUC Robot S--420i SFANUC Robot S--420i LFANUC Robot S--420i RFANUC Robot S--420i R/120

A05B--1313--B501A05B--1313--B581A05B--1313--B503A05B--1313--B511


120kg120kg155kg175kg

155kg80kg75kg

100kg120kg

With positioning surface

FANUC Robot S--420i FFANUC Robot S--420i F/2.85FANUC Robot S--420i WFANUC Robot S--420i SFANUC Robot S--420i L


120kg120kg155kg

80kg75kg

Compact type


FANUC Robot S--420i F

FANUC Robot S--420i F/2.85FANUC Robot S--420i WFANUC Robot S--420i LFANUC Robot S--420i R

A05B--1313--B701

A05B--1313--B781A05B--1313--B703A05B--1313--B761A05B--1313--B801

120kg

120kg155kg

75kg100kg

Severe dust/liquid

protection(Only remote controller)


FANUC Robot S--420i FFANUC Robot S--420i LFANUC Robot S--420i RFANUC Robot S--420i R/120

A05B--1320--B501A05B--1320--B561A05B--1320--B601A05B--1320--B602

120kg75kg

100kg120kg

High duty type



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B--80505E/06PREFACE

The attachment position for the mechanical unit specification number


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Table Specifications

Item S-420i F S-420iF/2.85

S-420i W S-420iW/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

Motionrange

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)

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)


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)


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)

Maximumspeed

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)


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)


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)


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)


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 Wrist 120kg 120kg 155kg 175kg 155kg 80kg 75kg 100kg 120kgloadcapacity

J3 arm 20kg 20kg 20kg 20kg 20kg 20kg 20kg 20kg 20kg

J2 base 250kg 250kg 250kg 250kg 250kg 250kg 250kg 250kg 250kg

Allowableload

J4 axis 60kgfm(588Nm)

60kgfm(588Nm)

86kgfm(842Nm)

90kgfm(882Nm)

86kgfm(842Nm)

54kgfm(529Nm)

53kgfm(519Nm)

57kgfm(558Nm)

60kgfm(588Nm)

momentat wrist *1


60kgfm(588Nm)

86kgfm(842Nm)

90kgfm(882Nm)

86kgfm(842Nm)

54kgfm(529Nm)

53kgfm(519Nm)

57kgfm(558Nm)

60kgfm(588Nm)


30kgfm(294Nm)

50kgfm(490Nm)

52kgfm(510Nm)

50kgfm(490Nm)

28kgfm(274Nm)

27kgfm(264Nm)

29kgfm(284Nm)

30kgfm(294Nm)

Allowable J4 axis 306kgfcms2 306kgfcms2 486kgfcms2 472kgfcms2 486kgfcms2 376kgfcms2 387kgfcms2 337kgfcms2 306kgfcms2


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B--80505E/06PREFACE

NOTE1 At maximum payload. 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 performanceStandard 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 designerTopics :Safety items for robot system design, operation, maintenance

R--J2 controller Setup and Operationsmanual

SPOT TOOLB--80524E--10

HANDLING TOOLB--80524E--11

SEALING TOOLB--80524E--14

Intended readers :Operator, programer, maintenance person, system designerTopics :Robot functions, operations, programing, setup, interfaces, alarmsUse :Robot operation, teaching, system design

Maintenance manualB--80525E

B--80525E--1(Europeanspecification)

Intended readers :Maintenance person, system designerTopics :Installation, connection to peripheral equipment, maintenanceUse :Installation, start--up, connection, maintenance

Mechanical unit Maintenance manual Intended readers :Maintenance person, system designerTopics :

Installation, connection to the controller, maintenanceUse :installation, start--up, connection, maintenance

FANUC Robot S--420iF/iL/iW/iR/iS B--80505E-- Spot welding, general--purpose large robot

WARNING

MANUALS


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NOTE1 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

in water; ingress of water in quantities causing harmful

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 jetsagainst the enclosure from any 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 splashedagainst the enclosure from any 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

Performance of resistant

chemicals and resistantsolvents


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I MAINTENANCE


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B--80505E/06 1. CONFIGURATIONMAINTENANCE

1 CONFIGURATION

The configuration of the mechanical unit is shown in Fig. 1 (a) to (f).

Fig.1(a) Mechanical unit configuration (S--420iF, W, W/175)


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MAINTENANCE1. CONFIGURATION B--80505E/06

Fig.1(b) Mechanical unit configuration (S--420iF/2.85, S--420iW/2.85)


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Fig.1(d) Mechanical unit configuration (S--420iL)


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Fig.1(f) Mechanical unit configuration (Compact type)


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Fig. 1.1 shows the J1--axis drive mechanism.Rotation of the J1--axis motor (M1)(!22/2000 or M30/3000HV) isinput 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.

Rotation of the J2--axis motor (M2)(!22/2000 or M30/3000HV) is

directly fed to the reducer, and the output moves the J2--axis.Rotation of the J3--axis motor (M3)(!22/2000 or M30/3000HV) is

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 arm

J2--axis arm

1.1J1--AXIS DRIVE

MECHANISM

1.2J2/J3--AXIS DRIVE

MECHANISM


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Fig. 1.2 (b) shows the J2/J3--axis drive mechanism on S--420i compact

type.

Therotation of J3--axis motor is inputted to thereducer viabevel gear. The

output of reducer is linked to J3--axis link 1, and the J3--aixs arm is 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 thereducer through the center gear, and the reducer output directly rotates the

J4--axis (J3--axis arm + wrist unit).

1.3J4--AXIS DRIVEMECHANISM


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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.

1.4J5/J6--AXIS DRIVE

MECHANISM


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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/RA97L--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

J4--axis reducer A97L--0118--0936#70C--36 S--420i F/W/S/L/R

J6--axis reducer A97L--0118--0942#30A--81 S--420i F/S/L/R

A97L--0118--0942#30A--121 S--420i W

3) GearAxis Specifications Model

J1--axis pinion gear A290--7313--X221 S--420i F/W/L/R

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

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

A290--7313--Y404 S--420i W

J4--axis center gear A290--7313--X405 S--420i F/S/L/R

A290--7313--Y405 S--420i W

J5--axis gear 1 assembly A290--7313--V521 S--420i F/S/L/R

A290--7313--V524 S--420i W

1.5MAJOR COMPONENT

SPECIFICATIONS


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B--80505E/06 2. PREVENTIVE MAINTENANCEMAINTENANCE

2 PREVENTIVE MAINTENANCE

Optimum performance of the robot can be maintained for a long time by

performing the periodic maintenance procedures presented in thischapter.

Clean each part, and visually check component parts for damage beforedaily system operation. Check the following items as the occasiondemands.

1) Before turning on power

Item Check items Check points

1When aircontrol set iscombined

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.

2Oiler oil mistquantity

Check the drop quantity during wrist or hand motion. If it does not meet the specifiedvalue (1 drop/10 -- 20 sec), adjust it using the oilercontrol knob. Under normalusagethe 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 fromhose

Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.

Oil inlet Adjusting knob

Oiler mist amount check

2.1DAILY CHECKS


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MAINTENANCE2. PREVENTIVE MAINTENANCE B--80505E/06

Severe dust/liquid protection


1Air pressure Check air pressure using thepressure gauge on theair filterunitas shown in follow-

ing figure. If it does not meet the specified pressure of 0.2!0.05kgf/cm2, adjust itusing 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.

WARNINGFor 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 butalso the oil seals might be broken. Set the air pressure to 0.2!0.05kgf/cm2.


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B--80505E/06 2. PREVENTIVE MAINTENANCEMAINTENANCE

1) Check the following items once every three months. Additionalinspection areas and times should be added to the table according to therobots 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 bentor 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 Cl i h t d i R f t i it

2.23--MONTH CHECKS

2.36--MONTH CHECKS

2.4ANNUAL CHECKS


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MAINTENANCE2. PREVENTIVE MAINTENANCE B--80505E/06

The following tools and instruments are required for the maintenanceprocedures 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 attachedcaution stickers, and pay attention to the air pressure and purge andmaintenance of the air filter. Place them, where the robot operator can seethem easily ; on the front of the R--J2 controller, and the front of operatingbox near the main switch.

2.6MAINTENANCE

TOOLS

2.7CAUTION STICKERSFOR DAILY CHECKS(ONLY SEVEREDUST/LIQUIDPROTECTION)


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B--80505E/06 3. PERIODIC MAINTENANCEMAINTENANCE

3 PERIODIC MAINTENANCE

Replace the grease of the reducers of J1, J2, J3, J4, and J6 axes, and theJ5--axis gear box, every threeyears or 20,000 hours by using thefollowingprocedures.

3.1 Grease for 3--year periodical replacement

Supply position Grease name Quantity

J1--axis reducer 4670 cc (4130g)




J5--axis gear boxyo o yus

Moly white Re no.00 4770 cc (4220g)

J6--axis reducer

.(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.

NOTE1 Be sure to use the procedure described in this manual when

supplying grease at the grease nipple. If an attempt is made

t l ith t l i th tl t th

3.1REPLACING GREASEOF THE DRIVEMECHANISM


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MAINTENANCE3. PERIODIC MAINTENANCE B--80505E/06

Fig.3.1 (a) Replacing grease of J1--axis reducer (S--420iF/W/S/L)

Fi 3 1 (b) R l i f J1 i d (S 420 R)


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(Standard type)

(Compact type)

Fig.3.1 (c) Replacing grease of J2/J3--axis reducer


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Fig.3.1 (d) Replacing grease of J4--axis reducer

Fig.3.1 (e) Replacing grease of J5--axis gear box


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Supply grease to the parts periodically. If the robot is installed in a severeenvironment, apply grease whenever necessary. If water splashes on therobot, apply grease immediately. Fig. 3.2(a), (b) and Table 3.2(a) showgreasing points.Table 3.2 (b) Shows substitute greases.

Table3.2 (a) Greasing points

Positions Grease Amount Method Greasing interval

J1--axis crossroller bearing

40 cc each(2 locations) Supply to the grease nipple

Every 3 years

Balancer 100 cc each(2 locations) Supply to the grease nipple

Every 3 years

Balancer bushingSHELL ALVANIA No. 2(Spec: A97L--0001--0179#2)

10 cc each(4 locations)(S--420iR has 2locations)

Supply to the grease nipple

Every 6 months

J2/J3--axisjoint bearing


Every 3 years

Balancer joint bearing(Only for S--420iR)


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

3.2GREASING


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Fig.3.2 (b) Greasing points (S--420iR)


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The position data of each axis is preserved by the backup battery. Thebattery needs to be periodically replaced every year. Also use thefollowing procedure to replace when the backup battery voltage dropalarm 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.

3.3REPLACING

BATTERY


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Severe dust/liquid protection for the S--420iis used to purge air into thewrist and J3--axis arm. Air filter elements (air filter, and oil mist filter)need to be periodically replaced every year. Use the following procedureto replace the filter element when harsh stains exist.

WARNINGIf 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.

WARNINGWhen air filter and oil mist filter are broken up, it reducesresidual pressure; otherwise you could injure personnel ordamage equipment.

4) Replace thefilterelement as shown in thefollowing figure. Air filtersand oil mist filter are replaced at the same time.

3.4REPLACING FILTER

ELEMENT


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MAINTENANCE4. TROUBLESHOOTING B--80505E/06

4 TROUBLESHOOTING

Thesource of mechanical unit problems may be difficult to locate becauseof overlapping causes.Problems may become furthercomplicated, if theyare not corrected properly. Therefore, it is necessary to keep an accuraterecord of problems and to take proper corrective actions.

Table 4.1 shows the main mechanical unit problems and their causes. Ifa cause of remedy is unclear, please contact this company.

Table4.1 Problems and causes

Symptom Cause Remedy Remarks

The robot does not correctlyreturn to the zero position.

Low voltage of the memorybackup battery

Replace the battery. Refer to section 3.3.

Unusual external start signal Investigate the cause.

Incorrect parameter Revise parameters. Refer to the parameter tablein 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 wasshifted.

Reposition.

Incorrect parameters. Revise parameters. Refer to the parameter tablein Setup and Operationsmanual.

Defective pulse coder cable Replace the cable. Refer to section 8.

APC (Absolute PositionChecker) malfunction.

Replace the motor or thepulse coder.

Refer to sections 6.

Play in mechanical unit. Seebelow.

Vibration The robot is not firmly fas- Re--tighten

4.1GENERAL

4.2PROBLEMS AND

CAUSES


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B--80505E/06 4. TROUBLESHOOTINGMAINTENANCE

Symptom RemarksRemedyCause

There is play.(See Table 4.2 (b).)

Loose screws or pins. Tighten and apply LOCTITEas specified.

Defective reducer. Replace the reducer. Refer to section 6.

There is play. 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 reducerlubrications.

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 thebearings.

Contact the service repre-sentative.

Defective reducer. Replace the reducer. Refer to section 6.Incorrect gear adjustment. Adjust the gears. Refer to section 5.4.

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 theinside of balancer

Lubricate (900 cc) Refer to section 3.2.

Unusual heating Insufficient gear or reducerlubrication.

Lubricate. Refer to section 3.

Specified grease not used. Replace with the specifiedgrease.

Refer to section 3.

Excessive pressure on bear-ings.

Reduce the pressure on thebearings.

Contact the service repre-sentative.

Excessive load. Reduce the load/restrictmovement conditions.

Incorrect gear adjustment. Adjust the gears. Refer to section 5.4.Incorrect time constant. Revise the time constant. Refer to the parameters.

Drops when the power Brake gap too large. Replace the motor. Refer to section 6 and Table*supp y s o

Fused brake drive relay. Replace the relay.. .

Grease leakage Deteriorated O--ring oil seal Replace the O--ring oil seal


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(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 at2nd 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 (B2= L1+ L2)

L2

L1

L3

L4

3rd attempt (B3= L3+ L4)

Fig.4.3 (a) How to measure the backlash

The backlash is calculated as B "B2# B3

2 .

(2) Measuring posture and position.

1 For iF, iF/2.85, iW, iW/175, iW/285, iS, iL,

4.3THE MEASUREMENT

OF THE BACKLASH


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Fig.4.3 (b) Posture for measuring backlash

Table4.3 (b) Position for measuring backlash

Item A B C D E FS--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

M i P t r


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Fig.4.3 (c) Posture for measuring backlash

NOTE

In the case of S--420iR and 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


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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




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MAINTENANCE5. ADJUSTMENTS B--80505E/06

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 makeadjustments at thetime of delivery. However, after fora 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 limitationsD Tooling and fixture interference points

D Cable and hose lengthsThere are three methods used to prevent the robot from going beyondthe necessary motion range. These are

D Axis limit software settingsD Axis limit switches -- optionalD Axis limit hardstops

WARNINGDo not use axis software limits as the only method forrestricting robot motion. Change the hard stops to matchthe software modifications, otherwise injury to personneland damage to equipment can occur.

Axis limitsoftware settingsare upper and lower motion degree

limitations. The limits can be set for all robot axes and will stop robotmotion if the robot is calibrated. If the robot is not calibrated,overtravel limit switches or hardstops are contacted two to threedegrees beyond the software limits. Overtravel switches for axis 1 areavailable as an option.

5.1AXIS LIMITS SETUP

Software Settings


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B--80505E/06 5. ADJUSTMENTSMAINTENANCE

Displays the lower limits of each axis, or the axis limits in a negativedirection.

After you change the axis limits, turn off the controller and then turn iton again so the new settings can be used.

CAUTIONChanging the axis limits will affect the robot work area, and

could change robot motion. Anticipate the effects ofchanging axis limits before changing them; otherwiseunexpected results could occur, such as errors in previouslyrecorded positions.

Lower Limits

Saving Limits


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Zero point and software motion limit are provided for each controlledaxis. The robot cannot exceed the software motion limit unless there isa failure of the system causing loss of zero point position or there is asystem 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.

5.1.1Zero Point Positionand Motion Limit


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Fig.5.1.1 (b) J2--axis (S--420iF/W/S/L)


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Fig.5.1.1 (d) J3--axis (S--420iF/W/S/L)

Fig.5.1.1 (e) J3--axis (S--420iR)


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Fig.5.1.1 (g) J4--axis (S--420iF/W/L/R)

( + 250_)

( -- 250_)


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Fig.5.1.1 (i) J5--axis (S420iF/W/S/L/R)


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Axis limit software settings are upper and lower motion degreelimitations. The limits can be set for all robot axes and will stop robotmotion 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

1234567

89

1111110

00

180.0072.0030.00

300.00130.00360 00

0.00

0.000.00

dgdgdgdgdgdg

mm

mmmm

[ TYPE ]

-70.00-105.00-300.00-130.00-360.00

0.00

0.000.00

-180.00

NOTE

0 indicates the robot does not have these axes.

5 Move the cursor to the axis limit you want to set.

WARNINGDo not depend on axis limit software settings to control themotion range of your robot. Use the axis limit switches or

5.1.2Software Setting

Step


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The J1--axis stroke can be limited depending on the operatingenvironment of the robot. The stroke can be changed by changing thelocations of the dogand mechanical stopper and the settings of themotionlimits using the following procedure.The stroke can be changed every 15 degrees in the upper limit of --135degrees to +180 degrees and the lower limit of --180 degrees to +135degrees.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

5.1.3Hard Stopper and LimitSwitch Setting


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Axis limit switches are overtravel switches that, when tripped, cut powerto the servo motors. These are located 10.5 degrees beyond the softwarelimits. 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 therotating 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. Whenthe 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

theJ1--axis by a jogfeed which goes beyond themotion 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 theRESETkey. Then, while holding on the SHIFT key,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.

5.2ADJUSTING J1--AXIS

LIMIT SWITCH(OPTION)


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When you mastera robot you define the physical location of the robot bysynchronizing the mechanical information with the robots positionalinformation. A robot must be mastered to operate properly. Robots areusually mastered before they leave FANUC However, it is possible thata 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 PositionMaster)

D When mastery is lost due to mechanicaldisassembly or repair.

D When a quick master reference position was notpreviously 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 mechanicaldisassembly or repair.

D When a quick master reference position was notpreviously set.

D Method of choice for S-- and M--series robotswhen 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 quickmaster reference posi-tion

To record mastering data as a reference for futurequick mastering.

Quick mastering To retrieve mastery data that has been stored as aquick master reference position when mastery is lostdue to an electrical or software problem. Do not useif mastery is lost due to mechanical disassembly orrepair.

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

5.3MASTERING

5.3.1General


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When you power up the robot after disconnecting the pulse coder backupbatteries you may see a SRVO--062 BZAL or SRV0--038 Pulse mismatchalarm. Before mastering the robot you must reset the alarm and rotate themotor of each axis that lost battery power to prepare the robot formastering.

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 mismatchalarm.

1 Replace the robot batteries with four new 1.5 volt alkalinebatteries, size D. Observe the direction arrows in the battery boxfor 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 teachpendant.

d Press F1, [TYPE].

e Select Master/Cal. You will see a screen similar to thefollowing.

SYSTEM Master/Cal JOINT 10%

5.3.2Resetting Alarms andPreparing forMastering

Condition

Step


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6 To reset a SRVO--062 alarm when RES_PCA does not appear onthe 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 changeto FALSE.

e If the value does not change to TRUE momentarily,repeatStep 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 onthe operator box.

8 If the SRVO--062 alarm is still present; there is a battery, cable orpulse coder problem. Refer to the SYSTEM R-J2 Controller Series

Electrical Connection and Maintenance Manualfor furtherinformation.

9 If a SRVO--038 alarm is present at this time, repeat step 6 to resetit. It is not necessary to cold start the robot after resetting to clearthis alarm.

10 Rotate each axis that lost battery power by at least one motorrevolution in either direction.

a Jog eachrotary axisat least twenty degrees.

b Jog eachlinear axisat least thirty millimeters.

11 Perform any of the mastering procedures from the MASTER/CAL

ADJUSTMENTS


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When a major part of the robot mechanical unit is replaced and the actualposition of each axis is displaced from the current value stored throughan absolute pulse coder (hereinafter abbreviated as APC), the masteringis executed to set the geometric position of the robot. Mastering has beenperformed 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 P late

B a s e

Plate

BoltsM5X20

BoltsM5X20

5.3.3Mastering to a Fixture(Master PositionMaster)

MAINTENANCE5 ADJUSTMENTS


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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

AB

F

C

D

E20

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).

B 80505E/06 5 ADJUSTMENTSMAINTENANCE


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Fig.5.3.3 (d) Mounting fixture base (S--420iR)

4) Mounting the fixture to the wrist

Mount the fixture to the J6--axis flange as shown in Fig. 5.3.3 (e).

MAINTENANCE5 ADJUSTMENTS B 80505E/06


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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 seea screen similar to thefollowing:


1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER

4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Press ENTER or number key to select.

B--80505E/06 5 ADJUSTMENTSMAINTENANCE


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B 80505E/06 5. ADJUSTMENTSMAINTENANCE

Fig.5.3.3 (f) Mastering attitude (S--420iF, W, W/175)



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C5 JUS S B 80505E/06

Fig.5.3.3 (h) Mastering attitude (S--420iS)



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Fig.5.3.3 (j) Mastering attitude (S--420iR)



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When you master to zero degrees, you position all axes at their zerodegreewitness 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 motorturn. (Procedure 5--2).

1 Using the joint coordinate system, jog each axis of the robot to thezero degree witness mark.

2 Press MENUS.

3 Press SYSTEM.

4 Press F1, [TYPE].


If Master/Cal is not listed on the [TYPE] menu, do thefollowing; otherwise, continue to Step 6.

a Select VARIABLE from the [TYPE] menu.



d Press F1, [TYPE].

e Select Master/Cal. You will see a screen similar to the

following.

5.3.4Zero Degree Mastering

Condition

Step



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[ TYPE ] LOAD RES_PCA

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 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.



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Fig.5.3.4 Zero degree position arrow mark for each axis



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Quick mastering allows you to minimize thetime required to remaster therobot using a reference position you established when the robot wasproperly mastered. You cannot quick master the robot unless you havepreviously recorded this quick master reference position.

Record the quick master reference position when the robot is properlymastered. The best time to record the quick master reference positionis when the robot is still factory-mastered.

If you lose mastery due to an electrical or software problem, you canuse this reference position to master the robot in a minimum amount oftime. If you lose mastery due to mechanical disassembly or repair, youmust master to a fixture or perform zero degree mastering.

Use Procedure 5--4 to record the quick master reference position. UseProcedure 5--5 to quick master the robot.

CAUTION

Record the quick master reference position after the robot isinstalled to preserve the factory mastering settings for futureremastering.

5.3.5Quick Mastering



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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].






d Press F1, [TYPE].


following.


1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER

4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE


Condition



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Procedure 5--5 Quick Mastering the Robot

H The robot has lost mastery due to an electrical or softwareproblem.

NOTEIf 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 robotlost mastery.

H You have cleared any servo faults that prevent you from joggingthe robot.

H You have jogged each axis that has lost mastery at least one motorturn.

1 Jog the robot to the quick master reference position (zero degreeposition).

2 Press MENUS.3 Select SYSTEM.

4 Press F1, [TYPE].





c Press the numeric key 1 and then press ENTER on the teachpendant

Condition



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[ TYPE ] LOAD RES_PCA

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 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]



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You can master a single axis of an S-series robot when mastery was lostdue 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

H You have cleared any servo faults that prevent you from joggingthe robot.

H You have jogged each axis that has lost mastery at least one motorturn. (Procedure 5--2).

1 Using the joint coordinate system, jog the unmastered axis of therobot to the zero degree witness mark.

2 Press MENUS.

3 Select SYSTEM.

4 Press F1, [TYPE].



a Select VARIABLE from the [TYPE] menu.b Move the cursor to $MASTER_ENB.


d Press F1, [TYPE].


following.


1 FIXTURE POSITION MASTER

5.3.6Single Axis Mastering

Condition

Step



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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 unmasteredaxis and press the 0 key.

8 Continuously press and hold the DEADMAN switch and turn theteach pendant ON/OFF switch to ON.

9 Move the cursor to the SEL column for the unmastered axis andpress 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.



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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.)

5.4ADJUSTING J5--AXISBACKLASH

MAINTENANCE6. REPLACING PARTS B--80505E/06


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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 Ma s te ring S e e 5.3

Cable (*) Ma s te ring S e e 5.3

Limit switch (*) Ad ju s tin g , lim it s w it c h S e e 5. 2

* Referto Section 1, item 8 forreplacement of cables and limit switches.

NOTEThe following components are heavy. Be particularly

careful when carrying or assembling them.

Component Weight (approximate)

J1, J2, J3, J4 (M1, M2, M3, M4) 30 kg

Servo motors J 5 (M5) 20 kg

J1--axis 55 kg

Reducers J2-- and J3--axes 50 kg

J4--axis 20 kg

6.1PART REPLACEMENT

AND CORRESPONDINGADJUSTMENT

B--80505E/06 6. REPLACING PARTSMAINTENANCE


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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 boltstogether in order to spread it to the bottom of groove.

Fig.6.1 Standard application of sealant



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1) Replacing J1--axis motor (Fig. 6.2 (a) )1 Turn off the power.

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 aboveprocedure. 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).

6.2REPLACING J1--AXISMOTOR (M1) ANDREDUCER



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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--axisbase.

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

LOCTITE No. 262 to the bolts shown in Fig. 6.2(b). Coatsealant

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).

18 Perform mastering (Refer to section 5 3)


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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 bereplaced, 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 new motor 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.

Usenew motor 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).


6.3REPLACING

J2/J3--AXIS MOTOR(M2/M3) AND

REDUCER



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ii) Compact type (See Fig. 6.3(b))

1 Turn off the power.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 new motor reversing the aboveprocedure.

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).




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Fig.6.3 (c) J2/J3--axis reducer replacing posture (S--420iF/W/S/L)



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Fig.6.3 (d) J2/J3--axis reducer replacing posture (S--420iR)


2) Replacing J3 axis reducer


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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 new reducer reversing the aboveprocedure. Polishthe

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.

Usenew motor mounting sealbolts. (Incase of reusing sealbolts,apply LOCTITE No.242 to them. (Refer to section 6.1)


7 Apply grease to the reducer (Refer to section 3).


Reducer mountingbolts M16 x 140


ii) Compact type (See Fig 6 3(f))


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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 new reducer reversing the aboveprocedure. Polishthereducer 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.


7 Apply grease to the reducer (Refer to section 3).8 Perform mastering (Refer to section 5.3).



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Guide Rods Guide Rods

Fig.6.3 (g) Replacing J2/J3--axis reducer




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3) Replacing J2 axis reducer

i) In case of S--420iF/W/S/L1 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.

WARNINGTHE J2--AXIS MUST BE SET TO ZERO DEGREESBEFORE ATTEMPTING TO REMOVE THE SPRINGBALANCERS. OTHERWISE, INJURY TO PERSONNELMAY 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.

WARNINGLINK 1 IS A COUNTERWEIGHT FOR THE J4--AXIS UNIT.IT MUST BE SECURELY RIGGED BEFORE REMOVING

THE SHAFT OR IT MIGHT FALL. INJURY TOPERSONNEL MAY RESULT.

11 Remove shaft mounting bolts (M12x100 8pcs) and remove the


17 Reassemble the unit by reversing the above procedure. Keep the


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y g p p

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.

Usenew motor mounting sealbolts. (In case of reusing sealbolts,

apply LOCTITE No.242 to them. (Refer to section 6.1)

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 mountingbolts M12 x 60

Fig.6.3 (h) Replacing J2--axis reducer


ii) For the S--420i R


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1 Set the J2--axis arm to --85 and the J3--axis arm to +45 , then turnthe 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).



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Fig.6.3 (j) Replacing J2--axis reducer (S--420iF/W/S/L)


6.4


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1) Replacing J4--axis motor (M4)1 Set the posture of the wrist such thatno loadis 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 new one. 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 face of the super gear.

7 Apply grease to the motor (Refer to section 3).


Fig 6 4 (a) Replacing J4--axis motor (M4)

REPLACING J4--AXIS

MOTOR (M4) ANDJ4--AXIS REDUCER




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1 Remove any load on the robots wrist such as a hand or aworkpiece.


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).

Besureto mount theO- -ringat theappropriateposition.

Pay special attention so as not to scratch the tooth face

of the center gear.

12 Form the cables (Refer to section 8).




6.5


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1 Remove loads from the robots wrist such as a hand andworkpieces. 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 alignment12 x 30

Fig.6.5 Replacing wrist unit

REPLACING WRISTUNIT


6.6


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1) Replacing J5--axis motor (M5)1 Remove loads from the robots wrist such as a hand and

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 Removethe bolt (M12 x 40)formountingthemotor, 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.

Usenew motor mounting sealbolts. (In case of reusing sealbolts,

apply LOCTITE No.242 to them. (Refer to section 6.1)

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.



REPLACING J5--AXISMOTOR (M5) ANDJ5--AXIS REDUCER


2) Replacing J5--axis gear

1 R J5 i (M5) b h i h d


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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. Changethe gasket to a new one, and fix it temporarily with tightening

torque of 1.0--1.6 kgfm. Retighten it after 20--60 minutes 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.



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Fig.6.6 (c) Replacing J5--axis gear


1) Replacing J6 axis motor (M6)

6.7

REPLACING J6 AXIS


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1) Replacing J6--axis motor (M6)1 Remove loads from the robots wrist such as a hand and

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. (Donot

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)formountingthemotor, then remove

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 inputgear. Use new motor mounting sealbolts. (In case of reusing

sealbolts, applyLOCTITE No.242to them. (Refer to section 6.1)

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 notoverstrike)

REPLACING J6--AXISMOTOR (M6) ANDJ6--AXIS REDUCER


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1 Remove loads from the robots wrist such as a hand and


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1 Remove loads from the robot s wrist such as a hand andworkpieces.


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).



LOCTITEGasket EliminatorNo.518

Tool mountingflange

Flange mounting bolts


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 theb b h d bi il

6.8

RELEASING A


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can be released while power is not supplied, enabling the attitude of therobot to be changed arbitrarily.When using the brake release unit, observe the following precautions:

NOTE1 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 from fall.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--420iF/W/S/L)

RELEASING ABRAKE (OPTION)



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Fig.6.8 (c) J2--axis brake releasing (S--420iR)

B--80505E/06 7. PIPING AND WIRINGMAINTENANCE

7PIPING AND WIRING


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7 PIPING AND WIRING

Fig. 7.1 (a) and (b) show the piping diagram of the mechanical unit.7.1

PIPING DIAGRAM

Documents

38315294 S 420i Mechanical Unit Maintenance B 80505EN 06