S-420i Mechanical Unit Maintenance [B-80505EN_06]

( R-- J 2 CONTROLLER )

S-420i

Maintenance MANUAL

B - 8 0505E N / 06E FANUC LTD , 1996

Uwe Stolzenbach

B--80505E/06 SAFETY PRECAUTIONS

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SAFETY PRECAUTIONS

IMPORTANT!Before operating, servicing or in any other way handling therobot, 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 maintenance

work. The lighting shall not create new dangerous situations.D Whenever possible, perform maintenance, inspection and adjusting

with the power function off.D When replacing parts, be sure to use those specified by FANUC.D When replacing or installing components, make sure dirt and debris

do not enter the system.D Be aware that when you remove a servomotor or brake, the associated

axis will fall if it is not supported or resting on a hard stop.D Make sure personnel cannot get trapped between the moving robot and

other equipment. Know the path that can be used to escape from 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 robot’s 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 controllerIf touching is unavoidable, wear protective garments (heat resistantgloves, etc.).

D Do not try to remove any mechanical component from the robot beforethoroughly reading and undestanding the procedures in the manual.Doing so can result in serious personal injury and componentdestruction.

D After replacement, be sure to fix all removed parts that includescrews.

D The motor and reducer are heavy. Be careful when replacing.D After replacing parts or performing adjustment, be sure to test

operation according to the following procedure.1. Using a low motion speed, single step the program for at least one

full cycle.2. Using a low motion speed, test run the program continuously for

at least one full cycle.

B--80505E/06SAFETY PRECAUTIONS

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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, or

debris.

B--80505E/06 PREFACE

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PREFACE

This manual describes the maintenance and connection of the followingrobot 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

120kg120kg155kg80kg75kg

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


Compact type

FANUC Robot S--420i FFANUC Robot S--420i F/2.85FANUC Robot S--420i WFANUC Robot S--420i W/175FANUC 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--B511A05B--1313--B521A05B--1313--B541A05B--1313--B561A05B--1313--B601A05B--1313--B602

120kg120kg155kg175kg155kg80kg75kg

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



Compact type


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


120kg120kg155kg75kg

100kg

Severe dust/liquidprotection(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


The mechanical unit specification numbers are attached at the followingpositions. Therefore, read the description in each section when checking.

B--80505E/06PREFACE

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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)g

J2 axis 142°(2.48rad)

142°(2.48rad)

142°(2.48rad)

142°(2.48rad)

142°(2.48rad)

142°(2.48rad)

142°(2.48rad)

123°(2.15rad)

123°(2.15rad)

J3 axis 135°(2.36rad)

135°(2.36rad)

135°(2.36rad)

135°(2.36rad)

135°(2.36rad)

135°(2.36rad)

135°(2.36rad)

106°(1.85rad)

106°(1.85rad)

J4 axis 600°(10.47rad)

600°(10.47rad)

600°(10.47rad)

600°(10.47rad)

600°(10.47rad)

480°(8.38rad)

600°(10.47rad)

600°(10.47rad)

600°(10.47rad)

J5 axis 260°(4.54rad)

260°(4.54rad)

260°(4.54rad)

260°(4.54rad)

260°(4.54rad)

260°(4.54rad)

260°(4.54rad)

260°(4.54rad)

260°(4.54rad)

J6 axis 720°(12.57rad)

720°(12.52rad)

720°(12.57rad)

720°(12.57rad)

720°(12.52rad)

720°(12.57rad)

720°(12.57rad)

720°(12.57rad)

720°(12.57rad)

Maximumspeed

J1 axis 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)


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)


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)


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)


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)

Maximumload

Wrist 120kg 120kg 155kg 175kg 155kg 80kg 75kg 100kg 120kgloadcapacity J3 arm 20kg 20kg 20kg 20kg 20kg 20kg 20kg 20kg 20kgcapacity

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

Allowableload

t

J4 axis 60kgfm(588Nm)

60kgfm(588Nm)

86kgfm(842Nm)

90kgfm(882Nm)

86kgfm(842Nm)

54kgfm(529Nm)

53kgfm(519Nm)

57kgfm(558Nm)

60kgfm(588Nm)

momentat wrist *1 J5 axis 60kgfm

(588Nm)60kgfm(588Nm)

86kgfm(842Nm)

90kgfm(882Nm)

86kgfm(842Nm)

54kgfm(529Nm)

53kgfm(519Nm)

57kgfm(558Nm)

60kgfm(588Nm)

J6 axis 30kgfm(294Nm)

30kgfm(294Nm)

50kgfm(490Nm)

52kgfm(510Nm)

50kgfm(490Nm)

28kgfm(274Nm)

27kgfm(264Nm)

29kgfm(284Nm)

30kgfm(294Nm)

Allowableload iner-ti t i t

J4 axis 306kgfcms2

(30.0kgm2)306kgfcms2








(30.0kgm2)tia at wrist*1 J5 axis 306kgfcms2









(30.0kgm2)

J6 axis 77kgfcms2

(7.5kgm2)77kgfcms2

(7.5kgm2)164kgfcms2




(9.8kgm2)104kgfcms2

(10.1kgm2)86kgfcms2

(8.4kgm2)77kgfcms2

(7.5kgm2)

Max. weld force 500kg

Repeatability 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm 0.4mm

Weight *2 1500kg 1600kg 1500kg 1600kg 1600kg 1500kg 1600kg 1700kg 1700kg

Installation condition Ambient temperature : 0 to 45°CHumidity : Normal 75% RH or less

Short period (One month or less) 95% RH or less (No dew, nor frost allowed)Vibration : 0.5G (4.9m/s2) or less

NOTEThe direction of weld reaction force should always bethrough the cross point of J4, J5 and J6 axes.

B--80505E/06PREFACE

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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 handbookB--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

WARNING1 For S--420i of severe dust/liquid protection, set up the regulated air--pressure.

Otherwise, not only the sufficient performance of dust proof/water proof can’t be obtained butalso the oil seals may be broken. It must be set the air pressure to 0.20.05kgf/cm2.

2 Prepare the dry air for purge line, removed water. The air filter only remove garbage and oilfrom air flows, can’t remove water and vapor. Moist air will damage to the robot.

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 harmfuleffects shall not be possible when the enclosure istemporarily immersed in water under standardizedconditions of pressure”

-- Formal definition of IP55.5=”dust protected; ingress of dust is not totally prevented

but dust shall not penetrate in a quantity to interferewith satisfactory operation of the apparatus or toimpair safety”

5=”protected against water jets; water projected in jetsagainst the enclosure from any direction shall have noharmful effects”

-- Formal definition of IP54.5=’dust protected; ingress of dust is not totally prevented

but dust shall not penetrate in a quantity to interferewith satisfactory operation of the apparatus or toimpair safety”

4=”protected against splashing water; water splashedagainst the enclosure from any direction shall have noharmful effects”

2 ”Severe dust/liquid protection” in not retrofittable.

The following materials can’t use the robot, severe dust/liquid protection model,

because they will harm rubber parts (packings, oil seals O--rings).

1) Organic solvents

Aromatic hydrocarbon

Petroleum hydrocarbon, ether

2) Coolant for machine tools

3) Other liquid or solution, that they will harm NBR.

Performance of resistantchemicals and resistantsolvents

I MAINTENANCE

B--80505E/06 1. CONFIGURATIONMAINTENANCE

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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)

MAINTENANCE1. CONFIGURATION B--80505E/06

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

Fig.1(c) Mechanical unit configuration (S--420iS)


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

Fig.1(e) Mechanical unit configuration (S--420iR)


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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)(α22/2000 or αM30/3000HV) 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)(α22/2000 or αM30/3000HV)

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)(α22/2000 or αM30/3000HV) isdirectly fed to the reducer, and the output moves the J2--axis.

Rotation of the J3--axis motor (M3)(α22/2000 or αM30/3000HV) isdirectly fed to the reducer. The reducer output is coupled to the J3--axislink 1 and moves the J3--axis arm via the J3--axis link 2.

J3--axis link 2

J3--axis link 1

J3--axis arm

J2--axis arm

J2 motor(M2)(α22/2000 orαM30/3000HV)

J2--axis reducer

J3--axis reducer

J3 motor(M3)(α22/2000 orαM30/3000HV)

Fig.1.2(a) J2/J3--axis drive mechanism

1.1J1--AXIS DRIVEMECHANISM

1.2J2/J3--AXIS DRIVEMECHANISM


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Fig. 1.2 (b) shows the J2/J3--axis drive mechanism on S--420i compacttype.The rotation of J3--axis motor is inputted to the reducer via bevel gear. Theoutput of reducer is linked to J3--axis link 1, and the J3--aixs arm is movedvia the J3--axis link 2.At the same time, the rotation of J2--axis motor is inputted to the reducervia 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)(α22/1500) is transmitted to thereducer through the center gear, and the reducer output directly rotates theJ4--axis (J3--axis arm + wrist unit).

J4--axis reducer(Hollow shaft)

Fig.1.3 J4--axis drive mechanism

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)(α12/2000) is reduced with four gearsand fed to rotate the J6--axis unit. This causes J5--axis to rotate (wristbending).

Rotation of the J6--axis motor (M6)(αM6/300) is directly fed to thereducer and rotates the wrist flange.

Fig.1.4 J5/J6--axis drive mechanism

NOTEAn electrically released brake is incorporated in the motors for all axes (J1, J2, J3, J4, J5, andJ6 axes) and applies at power off or in an emergency stop.

1.4J5/J6--AXIS DRIVEMECHANISM


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1) MotorMotor Specifications Model Axis Remark

M1 A06B--0147--B675 α 22/2000 J1

A06B--0186--B675#0011 α M30/3000HV High duty

M2 A06B--0147--B675 α 22/2000 J2

A06B--0186--B675#0011 α M30/3000HV High duty

M3 A06B--0147--B675 α 22/2000 J3

A06B--0186--B675#0011 α M30/3000HV S--420iW/2.85

M4 A06B--0146--B675 α 22/1500 J4

M5 A06B--0142--B675#0006 α 12/2000 J5

M6 A06B--0162--B675#0006 α M6/3000 J6

2) ReducerAxis Specifications Model

J1--axis reducer A97L--0118--0939#250C--35 S--420i F/W/S/L/R

J2--axis reducer A97L--0118--0940#250A--118 S--420i F/S/L

A97L--0118--0940#250A--129 S--420i W/R

A97L--0118--0940#250A--141 S--420i R/120

J3--axis reducer A97L--0118--0941#250A--129 S--420i F/S/L/R

A97L--0118--0941#250A--141 S--420i F2.85/R120

A97L--0118--0941#250A--171 S--420i W


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

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

3) GearAxis Specifications Model

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

A290--7313--Y221 S--420i S

A290--7313--Z221 S--420i R/120 F/2.85, W/2.85

J1--axis center gear A290--7313--X222 S--420i F/W/L/Rg

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/Rp g

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

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

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

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

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


A290--7313--V525 S--420i W


A290--7313--V526 S--420i W

J5--axis gear 4 A290--7313--X508 S--420i F/S/L/Rg

A290--7313--Y508 S--420i W

J2/J3 gear box assembly A290--7313--V351 S--420i F/W/S/L (Compact type)

4) OthersItem Specifications Model

Wrist unit(St d d d l)

A290--7313--T501 S--420i F/S/L/R(Standard model) A290--7313--T503 S--420i W

Wrist unit(S d t/li id t ti )

A290--7313--T511 S--420i F/L/R(Severe dust/liquid protection) A290--7313--T513 S--420i W

1.5MAJOR COMPONENTSPECIFICATIONS

B--80505E/06 2. PREVENTIVE MAINTENANCEMAINTENANCE

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2 PREVENTIVE MAINTENANCE

Optimum performance of the robot can be maintained for a long time byperforming 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/cm2 (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 oiler control knob. Under normal usagethe 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

Oiler

Pressure gauge

Regulator pressure setting handleFilter

Fig.2.1 Air control set

2.1DAILY CHECKS

MAINTENANCE2. PREVENTIVE MAINTENANCE B--80505E/06

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Severe dust/liquid protection


1Air pressure Check air pressure using the pressure gauge on the air filter unit as shown in follow-

ing figure. If it does not meet the specified pressure of 0.20.05kgf/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 followingitem.

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 0.20.05kgf/cm2.

2) After automatic operation

5Vibration, abnormal noises,and motor heating

Check whether the robot moves along and about the axes smoothly without unusualvibration or sounds. Also check whether the temparature of the motors are exces-sively high.

6 Changing repeatability Check to see that the stop positions of the robot has not deviated from the previousstop positions.

7 Peripheral devices for properoperation

Check whether the peripheral devices operate properly according to commandsfrom the robot.

8 Brakes for each axis Check that the end effector drops within 0.2 mm when the power is cut.

B--80505E/06 2. PREVENTIVE MAINTENANCEMAINTENANCE

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1) Check the following items once every three months. Additionalinspection areas and times should be added to the table according to therobot’s working conditions, environment, etc.


1 Control unit cable Check whether the cable connected to the teach pendant is unevenlytwisted.

2 Ventilation portion of control unit If the ventilation portion of the control unit is dusty, tum off power andclean the unit.

2) First quarterly inspectionCheck the following items at the first quarterly inspection, then everyyear thereafter.


4 Cables used in mechanical unit Check whether the jackets of the mechanical unit cables are damaged.Also check whether the cables are excessively bent or unevenly twisted.Check that the connectors of the motors and connector panels are se-curely engaged.See section 7.2.

5 Cleaning and checking each part Clean each part (remove chips, etc.) and check component parts forcracks and flaws.

6 Further tightening external mainbolts Further tighten the end--effecter mounting bolts and external main bolts.

Check the following item once every six months.


1 Greasing balancer bushing Grease to the balancer bushing. Refer to item 3.2.

Check the following items once every year.


1 Battery Replace battery in the mechanical unit. Refer to 3.3.

2 Cables used in mechanical unit Refer to previous item.

3 Cleaning each parts and inspec-tion

Refer to previous item.

4 Tightness of major external bolts Refer to previous item.

5 Greasing of balancer joint bearing Supply grease to the bearing (only for the S--420i R).(See Section 3.2.)

6 Filter element Replace filter elements in the air filter unit. Refer to 3.4.

Check the following items once every 3 years.


1 Replacing grease of each axis, re-ducer and gear box

Refer to item 3.1

2 Greasing to cross--roller bearing Grease to the required positions. Refer to item 3.2.

2.23--MONTH CHECKS

2.36--MONTH CHECKS

2.4ANNUAL CHECKS

2.53--YEAR CHECKS

MAINTENANCE2. PREVENTIVE MAINTENANCE B--80505E/06

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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) ToolsCross--point(+)screwdrivers : Large, medium, and small sizesConventional(--)screwdrivers : Large, medium, and small sizesHexagonal wrench key sets : M3 -- M16(metric)Adjustable wrenches : Medium and small sizesPliersCutting pliersCutting nippersDouble hexagon offset wrenchGrease gunPliers for C--retaining ringTorque wrenchDial 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.

2.6MAINTENANCETOOLS

2.7CAUTION STICKERSFOR DAILY CHECKS(ONLY SEVEREDUST/LIQUIDPROTECTION)

B--80505E/06 3. PERIODIC MAINTENANCEMAINTENANCE

15

3 PERIODIC MAINTENANCE

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

3.1 Grease for 3--year periodical replacement

Supply position Grease name Quantity

J1--axis reducer 4670 cc (4130g)



J4--axis reducerKyodo yushi

900 cc (800g)

J5--axis gear boxKyodo yushi

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

J6--axis reducerMoly white Re no.00

(Spec.: A98L--0040--0119) 370 cc (330g)

J2--axis reducer and gear box(Compact type)

2600 cc (2300g)

J3--axis reducer and gear box(Compact type)

2600 cc (2300g)

1) Replacing procedure of grease to the reducer and the gear box1 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 madeto supply grease without unplugging the grease outlet, theseal may be broken, and grease leakage may result.

2 Check for grease leakage due to the broken seal if one of thefollowing occurs when supplying new grease at the greaseinlet:. Old grease is slow in coming out of the grease outlet.. Very little old grease comes out of the grease outlet.

3 To prevent accidents caused by slipping, completelyremove any excess grease from the floor or robot.

3.1REPLACING GREASEOF THE DRIVEMECHANISM

MAINTENANCE3. PERIODIC MAINTENANCE B--80505E/06

16

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

Fig.3.1 (b) Replacing grease of J1--axis reducer (S--420iR)


17

(Standard type)

(Compact type)

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


18

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

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

Fig.3.1 (f) Replacing grease of J6--axis reducer


19

When replacing or supplying grease, orient the robot as shown in Fig 3.1(g). For the S--420i R, position the robot to the zero--degree attitude.

Fig.3.1 (g) Greasing posture (S--420iF/W/S/L)


20

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

20 cc each(2 locations) Supply to the grease nipple Every 3 years

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

20 cc each(2 locations) Supply to the grease nipple Every year

Table3.2 (b) Substitutes for ALVANIA NO.2

MOBIL OIL MOBILACK GREASE NO.2 NIPPON OIL EPNOC NO.2

ESSO STANDARD VICON NO.2 IDEMITSU KOHSAN DAPHNE COLONEX GREASE NO.2

MITSUBISHI DIAMOND MULTIPURPOSE GREASE NO.2 COSMO OIL LIMAX NO.2

Fig.3.2 (a) Greasing points (S--420iF/W/S/L)

3.2GREASING


21

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


22

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 toprohibit the robot motion.Replacing the battery with the power supply turned off causes allcurrent position data to be lost. Therefore, mastering will berequired again.

2 Remove the battery case cap.3 Take out the old batteries from the battery case.4 Insert new batteries into the battery case.

Pay attention to the direction of batteries.5 Close the battery case cap.

Fig.3.3 Replacing Battery

3.3REPLACINGBATTERY


23

Severe dust/liquid protection for the S--420i is 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.

NOTEBe sure to shut off the primary valve.

3) Check that the air filter’s 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 the filter element as shown in the following figure. Air filtersand oil mist filter are replaced at the same time.

Fig.3.4 Replacing Battery

3.4REPLACING FILTERELEMENT

MAINTENANCE4. TROUBLESHOOTING B--80505E/06

24

4 TROUBLESHOOTING

The source of mechanical unit problems may be difficult to locate becauseof overlapping causes. Problems may become further complicated, 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 Operationsmanual.

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-tened.

Re--tighten.

Floor vibration. (especiallywhen installed above the firstfloor)

Investigate the installationlocation.

Incorrect servo adjustment. Adjust the servo. Contact the service repre-sentative.

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

Not grounded. Connect to ground.

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

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

Incorrect time constant Revise the time constant Refer to the parameters.

Play in mechanical units. Seebelow.

4.1GENERAL

4.2PROBLEMS ANDCAUSES

B--80505E/06 4. TROUBLESHOOTINGMAINTENANCE

25

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.(See Table 4 2 )

Incorrect gear adjustment. Adjust the gears. Refer to section 5.4.(See Table 4.2.) Worn gears. Replace the gears. Refer to section 6.

Worn bearings. Replace the bearings. Contact the service repre-sentative.

Cracked casting, etc. Replace cracked parts. Contact the service repre-sentative.

Unusual noise Insufficient gear or 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 powersupply is off

Brake gap too large. Replace the motor. Refer to section 6 and Table4 3 (*)supply is off

Fused brake drive relay. Replace the relay.4.3 (*).

Grease leakage Deteriorated O--ring, oil sealor packing.

Replace the O--ring, oil sealor packing.

Cracked casting, etc. Replace cracked parts. Contact the service repre-sentative.

Loose screws. Tighten.

(*) Refer to the maintenance manual of the controller.


26

(1) Method1 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 Position0

+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,

Table4.3 (a) Posture for measuring backlash

Measuringaxis

Postureaxis

J2 J3 J4 J5 J6

J1 70_ 0_ ------ ------ ------

J2 0_ 0_ ------ --90_ ------

J3 50_ --90_ --90_ --90_ 90_

J4 50_ --90_ 90_ 90_ --90_

J5 70_ 0_ 90_ 90_ --180_

J6 70_ 0_ 90_ 90_ --90_

4.3THE MEASUREMENTOF THE BACKLASH


27

Fig.4.3 (b) Posture for measuring backlash

Table4.3 (b) Position for measuring backlash

Item A B C D E F

S--420iF 2193 1190 1300 233 233 250

S--420iW 2193 1190 1300 251 251 323

S--420iW/175 2193 1190 1300 220 220 298

S--420iW/2.85 2655 1190 1752 251 251 323

S--420iS 2043 1190 1150 377 377 350

S--420iL 2795 1190 1902 408 408 360

S--420iF/2.85 2655 1190 1752 233 233 250

2 For iR,iR/120

Table4.3 (c) Posture for measuring backlash

Measuringaxis

Postureaxis

J2 J3 J4 J5 J6

J1 0_ 30_ ------ ------ ------

J2 ------ ------ ------ ------ ------

J3 --20_ 0_ ------ ------ ------

J4 --20_ 0_ --90_ 90_ --90_

J5 --30_ 0_ 180_ 30_ 0_

J6 --30_ 0_ --90_ 30_ 0_


28

Fig.4.3 (c) Posture for measuring backlash

NOTEIn the case of S--420iR and iR/120, the backlash of J2 can’tmeasure. Because the gravity acts on the direction of J2,constantly.

(3) Allowable backlash tolerances

Table4.3 (d) Allowable backlash tolerances (S--420iF)

J1 J2 J3 J4 J5 J6

Angle conversion (arc--min) 3.1 1.45 0.89 11.98 4.79 14.18

Displacement conversion (mm) 1.98 0.5 0.33 1.51 0.6 1.03

Distance (mm) 2193 1190 1300 433 433 250

Table4.3 (e) Allowable backlash tolerances (S--420iW)

J1 J2 J3 J4 J5 J6



Distance (mm) 2193 1190 1300 451 451 323


29

Table4.3 (f) Allowable backlash tolerances (S--420iW/175)

J1 J2 J3 J4 J5 J6



Distance (mm) 2193 1190 1300 440 440 298

Table4.3 (g) Allowable backlash tolerances (S--420iW/2.85)

J1 J2 J3 J4 J5 J6



Distance (mm) 2655 1190 1752 451 451 323

Table4.3 (h) Allowable backlash tolerances (S--420iS)

J1 J2 J3 J4 J5 J6

Angle conversion (arc--min) 3.34 1.45 1 6.74 2.7 7.24


Distance (mm) 2043 1190 1150 577 577 350

Table4.3 (i) Allowable backlash tolerances (S--420iL)

J1 J2 J3 J4 J5 J6


Displacement conversion (mm) 1.94 0.5 0.33 1.5 0.6 1

Distance (mm) 2795 1190 1902 608 608 360

Table4.3 (j) Allowable backlash tolerances (S--420iF/2.85)

J1 J2 J3 J4 J5 J6



Distance (mm) 2655 1190 1752 433 433 250

Table4.3 (k) Allowable backlash tolerances (S--420iR,iR/120)

J1 J2 J3 J4 J5 J6

Angle conversion (arc--min) 2.21 ------ 0.98 14.37 4.79 11.35

Displacement conversion (mm) 2 ------ 0.5 1.81 0.6 0.83

Distance (mm) 3113 ------ 1752 496 496 288

MAINTENANCE5. ADJUSTMENTS B--80505E/06

30

5 ADJUSTMENTS

Each part of the mechanical unit is carefully adjusted at the factory beforeshipment. Therefore it is usually unnecessary for the customer to makeadjustments at the time of delivery. However, after for a long period of useor after parts are replaced, adjustments may be required.

Axis limits define the motion range of the robot. The operating range ofthe robot axes can be restricted because of:D Work area limitationsD Tooling and fixture interference pointsD Cable and hose lengths

There 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 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. 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.

Axis limit switches are overtravel switches that, when tripped, cutpower to the servo motors. These are located about 0.5 degreesbeyond the software limits. Overtravel switches for J1--axis areavailable as an option.

Axis limit hardstops are physical barriers that are located two or threedegrees beyond the overtravel limit switch or software setting on thethree major axes. The robot cannot move beyond a hardstop.

Setting the axis limits software settings changes the motion range ofthe robot. The axis limit screen displays the current upper and loweraxis limits, for each robot axis, in degrees.

Displays the upper limits of each axis, or the axis limits in a positivedirection.

5.1AXIS LIMITS SETUP

Software Settings

Limit Switches

Hardstops

Upper Limits

B--80505E/06 5. ADJUSTMENTSMAINTENANCE

31

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, andcould 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


32

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 calledovertravel (OT). Overtravel is detected at both ends of J1--axis by anoptional adjustable OT switch. Overtravel is not detected on any otheraxis.

The total travel (stroke) of J1--axis through J5--axis beyond the softwaremotion limit is restricted by a mechanical stopper. A mechanical stopperis not provided for J6--axis.

Fig.5.1.1 (a) -- (j) show the zero point and motion limit OT detectionposition, and mechanical stopper position of each axis.

Fig.5.1.1 (a) J1--axis (S--420iF/W/S/L/R)

5.1.1Zero Point Positionand Motion Limit


33

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

Fig.5.1.1 (c) J2--axis (S--420iR)


34

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

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

Fig.5.1.1 (f) J2/J3--axis interference angle (S--420iF/W/S/L/R)


35

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

( + 250_)

( -- 250_)

Fig.5.1.1 (h) J4--axis (S--420iS)


36

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

Fig.5.1.1 (j) J6--axis (S--420iF/W/S/L/R)


37

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 UPPER1/16

123456789

111111000

180.0072.0030.00

300.00130.00360 00

0.000.000.00

dgdgdgdgdgdgmmmmmm

[ TYPE ]

-70.00-105.00-300.00-130.00-360.00

0.000.000.00

-180.00

NOTE0 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 orhardstops also; otherwise injury to personnel or damage toequipment could occur.

6 Type the new value using the numeric keys on the teach pendant.

7 Repeat Steps 5 through 6 until you are finished setting the axislimits.

WARNINGYou must turn off the controller and then turn it back on touse the new information; otherwise injury to personnel ordamage to equipment could occur.

8 Turn off the controller and then turn it back on again so the newinformation can be used.

5.1.2Software Setting

Step


38

The J1--axis stroke can be limited depending on the operatingenvironment of the robot. The stroke can be changed by changing thelocations of the dog and mechanical stopper and the settings of the motionlimits 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 stopperChange the dog position and the mechanical position as shown in Figs.5.1.3 (a), (b) to match with a desired stroke position.

Fig.5.1.3 (a) Mechanical stopper locations

Fig.5.1.3 (b) Dog (option) locations

5.1.3Hard Stopper and LimitSwitch Setting


39

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 pivotingdog mounted on a bracket bolted to the rotating J1--axis table. SeeFigure 5.2. Use these steps to adjust the OT switch.The J1--axis stroke may be limited by moving the mechanicalstoppers and OT limit switch dog. Refer to Section 5.3. Whenthe J1--axis stroke is to be limited, a second mechanical stopperand dog must be used.1 Set the $MOR_GRP.$CAL_DONE system parameter to

FALSE. This disables the motion limit specified by thesoftware. As a result, the operator can rotate the robot aroundthe J1--axis by a jog feed which goes beyond the motion limit.

2 Press the emergency stop button to stop the robot moving.3 Loosen the two M6×8 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”, isdisplayed. To restart the robot, hold on the SHIFT key andpress the RESET key. Then, while holding on the SHIFT key,move the J1--axis off the OT limit switch by jogging in jointmode.

6 Check that the robot also activates the limit switch when therobot is approx. 0.5 degrees from the opposite stroke end inthe same way as above. If the limit switch does not operateat the position, adjust the position of the switch again.

7 Set the $MOR_GRP.$CAL_DONE system parameter toTRUE.

8 Turn off the power, then turn it on again to restart thecontroller.

Fig.5.2 Adjusting J1--axis OT (option)

5.2ADJUSTING J1--AXISLIMIT SWITCH(OPTION)


40

When you master a robot you define the physical location of the robot bysynchronizing the mechanical information with the robot’s 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 Table5.3.1 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 extremeprecision 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 haverecorded a reference position. You cannot quick master a robot unless thereference position was taught before mastering was lost.

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

5.3MASTERING

5.3.1General


41

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 formastering.

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 thefollowing; 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%

[ TYPE ] LOAD RES_PCA

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

Press ’ENTER’ or number key to select.

DONE

5.3.2Resetting Alarms andPreparing forMastering

Condition

Step


42

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 SeriesElectrical Connection and Maintenance Manual for 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 each rotary axis at least twenty degrees.

b Jog each linear axis at least thirty millimeters.

11 Perform any of the mastering procedures from the MASTER/CALmenu.


43

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 followingconditions.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.

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

1) Assembling the fixture baseAssemble the fixture base as shown in Fig. 5.3.3 (a).

ADAPTOR Plate

Base

Plate

BoltsM5X20

BoltsM5X20

Note) The shape of the adapter plate varies with the model.

Fig.5.3.3 (a) Assembling fixture base

5.3.3Mastering to a Fixture(Master PositionMaster)


44

2) Mount the dial gauges.Adjust the dial gauge to 3.00 mm using the calibration block, andtighten it with M5 bolt as shown in Fig. 5.3.3 (b). (Do not tighten thebolt 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).

Fig.5.3.3 (c) Mounting fixture base (S--420iF/W/S/L)


45

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

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

Fig.5.3.3 (e) Mounting fixture to wrist


46

5) To release the brake control, set the system variable$PARAM_GROUP.$SV_OFF_ALL to false. Then set systemvariable $PARAM_GROUP.$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 usinga fixture is to be performed. (See Fig. 5.3.3 (f) to (j).) When joggingthe robot, be careful not to hit the wrist of the robot onto the masteringfixture.

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 axisto the mastering fixture position, jog the robot in a direction in whichthe dial indicator reading decreases to prevent an error caused by axisbacklash.

8) Press MENUS.9) Select SYSTEM.10)Press F1, [TYPE].11)Select Master/Cal.

If Master/Cal is not listed on the [TYPE] menu, do the following;otherwise, continue to Step 12.a) Select VARIABLE from the [TYPE] menu.b) Move the cursor to $MASTER_ENB.c) Press the numeric key “1” and then press ENTER on the teach

pendant.d) Press F1, [TYPE].e) Select Master/Cal. You will see a screen similar to the following:





DONE

12)Select Master Position Master.13)Press F4, YES. Mastering will be performed automatically.14)Select Calibrate.15)Press F4, YES.16)To re-enable brake control, set system variable

$PARAM_GROUP.$SV_OFF_ALL to true. Then set systemvariable $PARAM_GROUP.$SV_OFF_ENB for each axis to true.

17)Turn off the power, and power on.


47

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

Fig.5.3.3 (g) Mastering attitude (S--420iF, 2.85, W/2.85)


48

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

Fig.5.3.3 (i) Mastering attitude (S--420iL)


49

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


50

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 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 each axis of the robot to thezero degree witness mark.

2 Press MENUS.

3 Press SYSTEM.

4 Press F1, [TYPE].






d Press F1, [TYPE].


5.3.4Zero Degree Mastering

Condition

Step


51





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 degJ2--axis 0 deg --15 degJ3--axis 0 deg +15 degJ4--axis 0 deg 0 degJ5--axis 0 deg 0 degJ6--axis 0 deg 0 deg

NOTEFor the S--420i R, the attitude assumed by aligning theposition marks differs from the zero--degree attitude.


52

Fig.5.3.4 Zero degree position arrow mark for each axis


53

Quick mastering allows you to minimize the time required to remaster 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.

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

5.3.5Quick Mastering


54

Procedure 5--4 Recording the Quick Master Reference Position

H The robot is properly mastered.

1 Align the witness marks on the robot. This is the zero position,which will be the quick master reference position. .

2 Press MENUS.

3 Select SYSTEM.

4 Press F1, [TYPE].






d Press F1, [TYPE].






DONE

6 Move the cursor to SET QUICK MASTER REF and pressENTER.

7 Press F4, YES.

Condition

Set quick master ref? [NO]


55

Procedure 5--5 Quick Mastering the Robot

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

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

H The quick master reference position was recorded before the robotlost mastery.


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].






d Press F1, [TYPE].


Condition


56





DONE

6 Move the cursor to QUICK MASTER and press ENTER.

7 Press F4, YES.

8 Move the cursor to CALIBRATE and press ENTER

9 Press F4, YES.

Quick master? [NO]


57

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






d Press F1, [TYPE].






6 Select 4, Single Axis Master. You will see a screen similar to thefollowing.

5.3.6Single Axis Mastering

Condition

Step


58

SINGLE AXIS MASTER JOINT 10%

[ TYPE ] GROUP EXEC

ACTUAL POS (MSTR POS) (SEL) [ST]J1 0.000 ( 0.000) (0) [2]J2 3.514 ( 35.000) (0) [0]J3 -7.164 (-100.000) (0) [2]J4 -357.366 ( 0.000) (0) [2]J5 -1.275 ( -80.000) (0) [2]J6 4.571 ( 0.000) (0) [2]E1 0.000 ( 0.000) (0) [0]E2 0.000 ( 0.000) (0) [0]E3 0.000 ( 0.000) (0) [0]

1/9

7 Move the cursor to the MSTR POS column for the 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.


59

When the backlash of the J5--axis exceeds the tolerance (six minutes),listed in Table 4.2, adjust the backlash as described below.

1) Adjusting the backlash of the gear 1 and gear 2 assembliesa) Position a lever type dial test indicator on the notched portion of

the U nut of the gear 1 assembly and secure the indicator. (Makethe measurement at a point 36 mm from the center of rotation ofthe gear 1 assembly.)

b) While holding the gear 2 assembly still, measure the play in thegear 1 assembly.

c) Change the thickness of the spacers used with each assembly toadjust the backlash to within 0 to 0.15 mm. (The J5--axis musthave 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 ata point 136 mm from the center of rotation of the gear 4assembly.)

b) While holding the gear 2 assembly still, measure the play in thegear 4 assembly.

c) Adjust the position of the gear 3 assembly so that the backlashwithin 0 to 0.10 mm. (The J5--axis must have some backlash.)

Fig.5.4 Adjusting J5--axis 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 correspondingadjustment. After replacing a part, perform the appropriateadjustment, as listed below.

Table 6.1 Parts to be Replaced and Adjustment Items

Parts to be replaced Adjustment Method

Motor, reducer, gear Mastering See 5.3

Wrist unit Mastering See 5.3

Cable (*) Mastering See 5.3

Limit switch (*) Adjusting, limit switch See 5.2

* Refer to Section 1, item 8 for replacement of cables and limit switches.

NOTEThe following components are heavy. Be particularlycareful when carrying or assembling them.

Component Weight (approximate)

Servo motorsJ1, J2, J3, J4 (M1, M2, M3, M4) 30 kg

Servo motorsJ5 (M5) 20 kg

J1--axis 55 kg

Reducers J2-- and J3--axes 50 kg

J4--axis 20 kg

J1--axis table 60 kg

J1--axis holder 30 kg

J1--axis cross roller bearing 30 kg

J2--axis arm 90 kg

Balancer (S--420 iF/W/S/L) 45 kg

J3--axis link 1 285 kg

Wrist unit 100 kg

J2--J6--axis unit (See Fig. 6.2 (b).) 1100 kg

J4--J6--axis unit (See Fig. 6.3 (j).) 300 kg

Balancer (S--420 iR) 100 kg

J3--axis link 1 (with add. weight) 345 kg

Controller (i--cabinet) 100 kg

J2/J3 gear box (Compact type) 25 kg

6.1PART REPLACEMENTAND CORRESPONDINGADJUSTMENT

B--80505E/06 6. REPLACING PARTSMAINTENANCE

61

In case of reusing sealbolts for S--420i, observe following notes strictly.(If possible, change them to new sealbolts)1) Apply LOCTITE to the sealbolts.2) Notice the following 3 notes.

a) Remove excessive bits of sealant on the sealbolt. (Not necessaryto remove sealant which is fixed tightly.)

b) The length of application is 2d (d : diameter of the bolt) from thetip 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


62

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 (M12×35) and then remove

the motor.4 Remove the nut and gear in order.5 Replace the motor, and remount a new motor reversing above

procedure. Polish the motor flange with oil stone. ApplyLOCTITE No. 242 to the thread of the nut. Be careful not todamage the tooth surface of the spur gear. Install an O ringcorrectly.

6 Perform mastering (Refer to section 5.3).

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

6.2REPLACING J1--AXISMOTOR (M1) ANDREDUCER


63

2) Replacing J1--axis reducer (Fig. 6.2 (b) )1 Turn off the power.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--axisunit. (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 removethe table.

10 Remove the holder mounting bolts (M12×45 12 pcs) and removethe holder.

11 Remove the center gear.12 Remove the reducer mounting bolts (M16×110 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. ApplyLOCTITE No. 262 to the bolts shown in Fig. 6.2 (b). Coat sealantenough 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).


64

Fig.6.2 (b) Replacing J1--axis reducer


65

1) Replacing the J2/J3--axis motor (M2/M3)i) Standard type (See Fig. 6.3(a))

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).) (For S--420iR, suspend it asshown in Fig. 6.3(d).)

3 Remove the connectors.4 Remove the mounting bolts (M12×40) of the motor to be

replaced, and remove the motor to be replaced.5 Remove the nut, the input gear and the draw bolt in order.6 Replace the motor, and remount a 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.Use new 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).8 Perform mastering (Refer to section 5.3).

Fig.6.3 (a) Replacing J2/J3--axis motor (M2/M3)

6.3REPLACINGJ2/J3--AXIS MOTOR(M2/M3) ANDREDUCER


66

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 (M12×35) 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 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.Be careful not to damage the tooth surface of the input gear.

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

Fig.6.3 (b) Replacing J2/J3--axis motor (Compact type)


67

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


68

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


69

2) Replacing J3--axis reduceri) 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 (M12×60 16 pcs), and then

the bracket.4 Remove the reducer mounting bolts (M16×140 3 pcs) and taper

pin (φ16×60 3 pcs).5 Remove and replace the reducer.6 Remount a new reducer reversing the above procedure. Polish the

reducer mounting surface and the motor flange mounting surfaceusing 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.⋅Use new 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 Apply grease to the reducer (Refer to section 3).8 Perform mastering (Refer to section 5.3).

Reducer mountingbolts M16 x 140

Fig.6.3 (e) Replacing J3--axis reducer


70

ii) Compact type (See Fig. 6.3(f))1 Turn off the power supply.2 Remove J3--axis motor (M3) following the above procedure.3 Remove the gear box mounting bolts (M12×60 8 pcs, M12×50

8 pcs)4 Remove the reducer mounting bolts (M16×140 3 pcs) and taper

pin (φ16×60 3 pcs).5 Remove and replace the reducer.6 Remount a new reducer reversing the above procedure. Polish the

reducer mounting surface and the motor flange mounting surfaceusing 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.⋅Be careful not to damage the tooth surface of the input gear.


Fig.6.3 (f) Replacing J3--axis reducer (Compact type)


71

Guide Rods Guide Rods

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


72

3) Replacing J2--axis reduceri) In case of S--420iF/W/S/L

1 Position the J2--axis to 0 degrees.2 Turn off the power.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 connectionsection, then remove the balancer.

6 Remove the bolts (M8x25 6pcs) from the lower part of the link1/link 2 connection section, then remove the shaft.

7 Remove (M10x110 16pcs) bolts from the J2/J3--axis connectionsection, 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 thefront 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 REMOVINGTHE SHAFT OR IT MIGHT FALL. INJURY TOPERSONNEL MAY RESULT.

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

12 Remove link 1.13 Again suspend the J2--axis arm with a rope. Remove the

(M12x60) bracket mounting bolts and bracket with the J2--axisset to 0 degrees.

14 Remove the reduction--unit mounting bolts (M16x50 6pcs andM10x35 18pcs). Insert guide rods, threaded M12, into thebracketmounting bolt holes and withdraw the reduction unit, as shownin Fig.6.3 (g).

15 Separate the J2--axis arm from the robot.16 Replace the reduction unit.


73

17 Reassemble the unit by reversing the above procedure. Keep thefollowing points in mind.Polish the surface where the reduction unit is mounted, as wellas the motor flange, with an oilstone. Apply Loctite No. 262 tothe bolts specified in Fig. 6.3. (h), (i).Mount the O--ring in the specified position.Use new 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


74

ii) For the S--420i R1 Set the J2--axis arm to --85 and the J3--axis arm to +45 , then turn

the power off.2 Perform steps 3 and 4 in (i).3 Remove the four balancer securing bolts (M12x40) and C--ring,

then remove the balancer.4 Perform step 6 in (i).5 Remove the U--shaped nut and bearing, then remove the housing

from the shaft.6 Perform steps 7 to 12 in (i). (Fig. 6.3 (k))7 Support the J2--axis with a rope, set the J2--axis arm to --85 , then

remove the bracket.8 Perform steps 14 to 19 in (i).

Fig.6.3 (i) Replacing J2--axis reducer (Compact type)


75

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

Fig.6.3 (k) Replacing J2--axis reducer (S--420iR)


76

1) Replacing J4--axis motor (M4)1 Set the posture of the wrist such that no load is applied to the wrist

axis.2 Turn off the power.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 LocktiteNo. 242 to the threaded portion of the motor shaft.Be sure to mount the O- -ring at the appropriateposition. Pay special attention so as not to scratch thetooth face of the super gear.

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


6.4REPLACING J4--AXISMOTOR (M4) ANDJ4--AXIS REDUCER


77

2) Replacing J4--axis reducer1 Remove any load on the robot’s wrist such as a hand or a

workpiece.2 Turn off the power.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 removeburrs. Apply Loctite No. 262 to the bolts shown in Fig. 6.4(b).Be sure to mount the O- -ring at the appropriate position.Pay special attention so as not to scratch the tooth faceof the center gear.

12 Form the cables (Refer to section 8).13 Apply grease to the reducer (Refer to section 3).14 Perform mastering (Refer to section 5.3).



78

1 Remove loads from the robot’s wrist such as a hand andworkpieces. Support the wrist with a crane.

2 Turn off the power.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.6 Perform mastering (Refer to section 5.3).

Spring pin for alignmentφ12 x 30

Fig.6.5 Replacing wrist unit

6.5REPLACING WRISTUNIT


79

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

workpieces.2 Turn off the power.3 Remove the J5--axis cover, the connector of the J5--axis motor

(M5), then the plate. Cut the nylon cable tie. (See Section 8.2,”Replacing the Cables.”)

4 Remove the bolt (M12 x 40) for mounting the motor, then removethe 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.Use new 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.





80

2) Replacing J5--axis gear1 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 gear3 and remove gear 3 assembly. (Fig.6.6 (c))

6 Remove eight J5--axis gear 2 mounting bolts (M6 x 16) and thegear 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 tighteningtorque of 1.0--1.6 kgfm. Retighten it after 20--60minutes with1.6kgfm. Use new gear4 mounting sealbolts. (In case of reusingsealbolts, apply LOCTITE No.262 to them. (Refer to section 6.1))

10 Refill with grease.

Gasket

J5--axis gear 1assembly

Cover mountingbolts M6x16(M6 x 40 for S--420iW)



81

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


82

1) Replacing J6--axis motor (M6)1 Remove loads from the robot’s 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. (Do not

remove plate and Teflon sheet attached to the J5--axis cover 2).5 Remove rubber block mounting bolts and take out the cable.6 Remove four bolts (M8×22) for mounting themotor, 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. ApplyLocktite No. 242 to the threaded portion of the motor shaft.Be sure to mount the O--ring at the appropriate position. Payspecial attention so as not to scratch the tooth face of the inputgear. Use new motor mounting sealbolts. (In case of reusingsealbolts, apply LOCTITE No.242 to them. (Refer to section6.1)Fasten two bolts (M4 x 60) of the rubber block, so that the endsprotrude 2.5mm through the plate.

9 Apply grease to the reducer (Refer to section 3).10 Perform cable forming (See section 8).11 Perform mastering (Refer to section 5.4).

(Do notoverstrike)

Washer




83

Fig.6.7 (b) Replacing J6--axis motor


84

2) Replacing J6--axis reducer1 Remove loads from the robot’s wrist such as a hand and

workpieces.2 Turn off the power.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 appropriateposition. Pay special attention so as not to scratch the tooth faceof the center gear. Apply Loctite gasket eliminator No. 518 to theflange mounting face of the reducer. Apply Loctite No. 262 to thebolts shown in Fig. 6.7 (c).


LOCTITEGasket EliminatorNo.518

Tool mountingflange

Flange mounting bolts

Fig.6.7 (c) Replacing J6--axis reducer


85

By using the optional brake release unit, the motor brake for each a axiscan 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)

Fig.6.8 (b) J3--axis brake releasing (S--420iF/W/S/L)

6.8RELEASING ABRAKE (OPTION)


86

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

Fig.6.8 (d) J3--axis brake releasing (S--420iR)

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

87

7 PIPING AND WIRING

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

Fig.7.1 (a) Piping diagram

7.1PIPING DIAGRAM

MAINTENANCE7. PIPING AND WIRING B--80505E/06

88

Fig.7.1 (b) Piping diagram for purge air (for severe dust/liquid protection)


89

Fig. 7.2 (a) to (t) show the wiring diagram of the mechanical unit.

Fig.7.2 (a) Wiring diagram (schematics) in mechanical unit (S--420iF, W, W/175, integrated type)

7.2WIRING DIAGRAM


90

K524 (Devicenet (Signal)) [option]K525 (Devicenet (Power)) [option]

Fig.7.2 (b) Wiring diagram (schematics) in mechanical unit (S--420iF, W, W/175, Remote type)

Fig.7.2 (c) Wiring diagram (schematics) in mechanical unit (S--420iF/2.85, S--420iW/2.85 Integrated type)


91


Fig.7.2 (d) Wiring diagram (schematics) in mechanical unit (S--420iF/2.85, S--420iW/2.85, Remote type)

Fig.7.2 (e) Wiring diagram (schematics) in mechanical unit (S--420iS, Integrated type)


92


Fig.7.2 (f) Wiring diagram (schematics) in mechanical unit (S--420iS, Remote type)

Fig.7.2 (g) Wiring diagram (schematics) in mechanical unit (S--420iL, Integrated type)


93


Fig.7.2 (h) Wiring diagram (schematics) in mechanical unit (S--420iL, Remote type)

Fig.7.2 (i) Wiring diagram (schematics) in mechanical unit (S--420iR)


94

Fig.7.2 (j) Wiring diagram (block) in mechanical unit (S--420iF, W, W/175, Integrated type)


95

Fig.7.2 (k) Wiring diagram (block) in mechanical unit (S--420iF, W, W/175, Remote type)


96

Fig.7.2 (l) Wiring diagram (block) in mechanical unit (S--420iF/2.85, W/2.85, Integrated type)


97

Fig.7.2 (m) Wiring diagram (block) in mechanical unit (S--420iF/2.85, W/2.85, Remote type)


98

Fig.7.2 (n) Wiring diagram (block) in mechanical unit (S--420iS, Integrated type)


99

Fig.7.2 (o) Wiring diagram (block) in mechanical unit (S--420iS, Remote type)


100

Fig.7.2 (p) Wiring diagram (block) in mechanical unit (S--420iL, Integrated type)


101

Fig.7.2 (q) Wiring diagram (block) in mechanical unit (S--420iL, Remote type)


102

Fig.7.2 (r) Wiring diagram (block) in mechanical unit (S--420iR)


103

(AS2, AP2, EE,I/O, AIR2, DS3, DP3)

(DS2, DP2)

(AS1, AP1, AIR1, DS1, DP1)

Fig.7.2 (s) Connector locations


104

S--420i F2.85/W2.85/R

(AS1, AP1, AIR1, DS1, DP1)

Fig.7.2 (t) Connector locations

B--80505E/06 8. REPLACING CABLEMAINTENANCE

105

8 REPLACING CABLE

Replace the cable every four years. When the cable is broken or damaged,or shows signs of wear, replace it according to this chapter.

Precautions to be observed when handling the pulse coder cableThe pulse coder cable is provided with a marking tie, as shown below, towarn against disconnecting the cable during transportation, installation,or maintenance. If the cable with the marking tie is disconnected,mastering must be performed again. Therefore, do not disconnect thecable except when replacement of the cable is necessary.

MARKING TIE

BATTERY BACKUPDON’T

DISCONNECT

MAINTENANCE8. REPLACING CABLE B--80505E/06

106

Fig. 8.1 (a) to (g) shows the cable clamp position.

When replacing cables, clamp the cable at the position specified in Figure8.1 (a) to (g) using a clamp or a nylon band. Otherwise, cables areloosened or forcedly pulled to cause their disconnection. Refer to thefigures in section 8.2 for the cable clamp position not listed in the Table.

Table8.1 (a) Cable clamp position

8.1CABLE FORMING


107

Table8.1 (b) Cable clamp position


108

Table8.1 (c) Cable clamp posiiton


109

Table8.1 (d) Cable clamp posiiton


110

Table8.1 (e) Cable clamp posiiton


111

Table8.1 (f) Cable clamp posiiton


112

Table8.1 (g) Cable clamp posiiton


113

Table8.1 (h) Cable clamp posiiton

MARK CABLE CLAMPING POSITION MARK CABLE No.

DS 1

DS 3

DS 2

K524

DP 1

DP 3

DP 2

K525


114

This section describes the procedure for replacing all cables duringroutine cable replacement for the mechanical unit.

To replace one or a few damaged cables only, refer to this section toreplace them.The cables in the mechanical unit consist of those for the basic axes (J1to J4 axes) and those for the wrist section (J5 and J6 axes). They can bedivided into two parts at the connector section of the J3--axis arm. (SeeFig. 7.2)

WARNINGRemoving the cables will cause loss of mastering data, somastering must be performed once the cables have beenreplaced. (When the pulse coder cable is not to be replaced,mastering is not required.) Before replacing the cables, referto Item 5.7, ”Quick Mastering.”Perform cable replacement with each axis at the zero degreemark.

Cable replacement procedure1) Replacing the cables for the basic axes

1 Turn off the power. Remove the side cover of the controller, thendisconnect all cables. Separate the controller from the robot.(For the S--420i F/W/S/L having a separate control unit or theS--420i R, disconnect the cables (except those for the mechanicalunit) from the connector panel, remove the connector panel, thendisconnect the mechanical unit cables.)

2 Disconnect the cables from the J1-- to J4--axis motors. (M1 toM4)

3 Remove the optional connector panel, then remove theconnectors and air tube. (See Fig. 8.2 (a) (b) (c).)

4 Remove the plate from the J1--axis base. Draw the plate out of thebase and remove its clamps and cable ties. (See Fig. 8.2 (d).)

5 Remove the two plates from the J2--axis base. Remove theclamps and cable ties from the plates, then remove the cable track.(See Fig. 8.2 (e).)(For the S--420i R, remove the cover from the J2 angle base, thenremove the clamp and cable tie. See Fig. 8.2 (f).)

6 Remove the cable track and cover from the J2--axis arm. Cut thecable ties. (See Fig. 8.2 (g).)

7 Draw the plate, together with the cables, out of the cast hole inthe upper part of the J2--axis arm. Remove the clamps and cableties. (See Fig. 8.2 (h).)

8 Remove all plates, clamps, and cable ties from the J3--axis casing.9 Remove the two covers from the J3--axis arm. Cut the cable ties

and remove all connectors. Also, remove the plates. (Fig. 8.2(i).)

10 Draw the grommet out of the J3--axis casing, then remove thecables.

2) Replacing the cables for the wrist section

8.2REPLACING THECABLES


115

11 Perform step 9 described above.12 Remove the J6--axis cover. Remove all connectors. (See Fig. 6.7

(a).)13 Remove the J6--axis motor cover and rubber block. Draw out the

cables.(See Fig. 6.7 (a).)14 Remove the J5--axis cover, then remove the supprt mounted on

the J5--axis cover. (See Fig. 8.2 (j).)15 Cut the cable ties for the support, then remove the cables.16 Remove the clamps, cable ties, plates and grommet, as shown in

Fig. 8.2 (j).17 Draw the cables out of the robot. Open the lid of the cable track

with a screwdriver and draw the cables out of the track. (See Fig.8.2 (k).). Replace the cables.

18 Assemble the cables by reversing the above procedure. Arrangethe cables correctly and clamp them at the correct positions. (SeeFigs. 8.1 (a) to (e), and 8.2 (a) to (k).)

19 Perform mastering. (See 5.3 through 5.4)

Fig.8.2 (a) Replacing the cable


116

Fig.8.2 (b) Replacing the cable (Severe dust/liquid protection)

J1 BASE PANEL (INPUT) J3 CASING PANEL (OUTPUT)

User cable (signal)interface

User cable (power)interface

Air supply

DeviceNet cable(signal) interface

DeviceNet cable(power) interface

Air supply DeviceNet cable(power) interface


End effectorinterface (RDI/RDO)

I/O unit modelBinterface

J2 BASE PANEL (OUTPUT)

Fig.8.2 (c) Replacing the cable (With DeviceNet Cable)


117

Fig.8.2 (d) Replacing the cable

(DS)

(DP)

(DP)

(DS)

(DP)

(DS)

Fig.8.2 (e) Replacing the cable


118

Fig.8.2 (f) Replacing the cable

(DS)(DP) (DS)(DP)

Fig.8.2 (g) Replacing the cable


119

Fig.8.2 (h) Replacing the cable


120

S420i F2.85/W2.85/R

Fig.8.2 (i) Replacing the cable


121

Fig.8.2 (j) Replacing the cable

Fig.8.2 (k) Replacing the cable


122

1) Remove the limit--switch box, then remove the limit switch from thebox.

2) Disconnect the cable from the limit switch.3) Open the side cover of the controller. Disconnect the limit--switch

cable.If the remote controller is employed, remove the connector plate atthe base of robot. Disconnect the limit switch cable at back side of P1connector.

4) Remove the side cover of the J1--axis. Draw out the cable. Replacethe limit switch with a new one.

5) Reassemble the unit by reversing the above procedure.6) Adjust the limit switch. (See item 5.2)

Fig.8.3 J1--axis limit switch mounting diagram

8.3REPLACING THEOPTIONAL J1--AXISLIMIT SWITCH(OPTION)

II CONNECTION

B--80505E/06 1. ROBOT INTERFERENCE AREACONNECTION

125

1 ROBOT INTERFERENCE AREA

Fig. 1 (a), (d), (g), (j) and (m) shows the external dimensions of the robot.Fig. (b), (e), (h) and (k) shows the external dimensions of the compacttype robot.When installing peripheral devices, be careful to clear away any objectsthat are in the robot’s motion path in normal operation. Fig. (c), (f), (i),(l) and (n) shows operation range of the robot.

NOTEIf an adjacent type controller is used, when the robot movesalong the J3 axis in the positive direction, the gap betweenlink 1 and the controller becomes small, and an object likea tool or part (if placed on the controller) may be caughtbetween link 1 and the controller, leading to damage to thecontroller. Be careful when starting the robot. (See part P inthe figure.)

CONNECTION1. ROBOT INTERFERENCE AREA B--80505E/06

126

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

NOTERestrict the robot’s operation to avoid hitting the adjacent type controller. (shading)If |J1|≧115_ and J2≧ --5_, the robot is not allowed to move into the area for which the followingexpression is satisfied:

J3+3/10×J2 ≧ --66.5_


127

Fig.1 (b) Mechanical unit external dimensions (S--420iF/W Compact type)

NOTEIf |J1|≧ 115_ and J2≧ --5_, the robot is not allowed to moveinto the area for which the following expression is satisfied:

J3+3/10×J2 ≧ --66.5_


128

(Note) Figures A to H show posture at positions A to H shown in Fig. 1 (a), (b).

Fig.1 (c) Mechanical unit stroke limits


129

Fig.1 (d) Mechanical unit external dimensions (S--420iF/2.85, S--420iW/2.85)

NOTERestrict the robot’s operation to avoid hitting the adjacenttype controller (shading)If |J1| ≧ 115_ and J2 ≧ --20_, the robot is not allowed tomove into the area for which the following expression issatisfied:

J3+J2/2 ≧ --60_


130

Fig.1 (e) Mechanical unit external dimensions (S--420iF/2.85 Compact type)


J3+J2/2 ≧ --60_


131

(Note) Figures A to H show posture at positions A to H shown in Fig.1 (d), (e).

Fig.1 (f) Mechanical unit stroke limits (S--420iF/2.85, S420iW/2.85)


132

Fig.1 (g) Mechanical unit external dimensions (S--420iS)

NOTERestrict the robot’s operation to avoid hitting the adjacenttype controller (shading)If |J1|≧ 115_ and J2 ≧ 5_, the robot is not allowed to moveinto the area for which the following expression is satisfied:

J3+J2/5 ≧ --74_


133

Fig.1 (h) Mechanical unit external dimensions (S--420iS Compact type)

NOTERestrict the robot’s operation to avoid hitting the adjacenttype controller (shading)If |J1|≧ 115_ and J2 ≧ 5_, the robot is not allowed to moveinto the area for which the following expression is satisfied:

J3+J2/5 ≧ --74_


134

(Note) A to H correspond to the points of Fig.1 (g), (h).

Fig.1 (i) Mechanical unit stroke limits (S--420iS)


135

Fig.1 (j) Mechanical unit external dimensions (S--420iL)

NOTERestrict the robot’s operation to avoid hitting the adjacenttype controller (shading)If |J1| ≧ 115_ and J2 ≧ --20_ , the robot is not allowed tomove into the area for which the following expression issatisfied:

J3+J2/2 ≧ --60_


136

Fig.1 (k) Mechanical unit external dimensions (S--420iL Compact type)


J3+J2/2 ≧ --60_


137

(Note) A to H correspond to the points of Fig.1 (j), (k).

Fig.1 (l) Mechanical unit stroke limits (S--420iL)


138

Fig.1 (m) Mechanical unit external dimensions (S--420iR)

NOTERestrict the robot’s operation (shading)If --61_ ≦ J3 ≦ --41_, the robot is not allowed to move intothe area for which the following expression is satisfied:J2 ≧ --1.6×J3--94.6_


139

(Note) A to H correspond to the points of Fig.1 (m).

Fig.1 (n) Mechanical unit stroke limits (S--420iR)

CONNECTION2. MECHANICAL COUPLING TO

THE ROBOT B--80505E/06

140

2 MECHANICAL COUPLING TO THE ROBOT

B--80505E/062. MECHANICAL COUPLING TO

THE ROBOTCONNECTION

141

Fig. 2.1 (a), (b) is a diagram to limit loads applied to the wrist. Apply aload within the region indicated in the graph.

Fig.2.1 (a) Wrist Load Diagram (S--420iF/S/L/R)

2.1WRIST LOADCONDITIONS



142

Fig.2.1 (b) Wrist Load Diagram (S--420iW, W/175)


THE ROBOTCONNECTION

143

Fig. 2.7 shows J2--axis base and J3--axis arm load conditions. Keep theload below the loads shown in Table 2.2 and Fig. 2.2 (a), (b).

Table2.2 Installation condition of loads to be added

Installation site Loads Condition

J2--axis base 250kgWithin radius of 500mm from the center of rotation

of J1--axis

J3- -axis arm 20kg Within 500mm to the wrist direction from the cen-ter of J3- -axis

Fig.2.2(a) Load Conditions on J2--axis base and J3--axis arm (S--420iF/W/S/L)

2.2LOAD CONDITIONSON J2--AXIS BASEAND J3--AXIS ARM



144

Fig.2.2(b) Load Conditions on J2--axis base and J3--axis arm (S--420iR)


THE ROBOTCONNECTION

145

Fig. 2.3 is the diagram for installing end effectors on the wrist. Install theend effector using a 60 mmφH7 spigot. Using the standard flange as anexample, position using a dowel pin with 2--φ10H7 reamed holes andfasten using 6--M10 bolts with 6--M10 tapped holes. Take intoconsideration the depth of tapped and reamed holes when selecting theM10 bolts and positioning dowel pins. (Refer to the diagram for theoptional dimensions.)

6--M10 tap depth 20Equally spaced onφF circumference

2--0G depth 20Equally spaced onφF circumference204 for insulating flange

Standard flange Special flange ISO flange Insulating flange

A Ø60H7 A Ø76G7 A Ø80H7 A Ø80H7B Ø110h7 B Ø108f8 B Ø160h8 B Ø160h8C 6 C 10 C 90.15 C 8F Ø90 F Ø92 F Ø125 F Ø125G Ø10H7 G Ø9H7 G Ø10H7 G Ø10H7

+0.03000

--0.035

+0.0150

+0.040+0.010--0.036--0.090

+0.0150

+0.0350

0--0.063

+0.0150

+0.0350

0--0.063

+0.0150

+0.30

Fig.2.3 End effector mounting face

2.3MECHANICALCOUPLING OF ENDEFFECTOR TOWRIST



146

As shown in Fig. 2.4 (a) to (e), tapped holes are provided to installequipment to the robot.

Note)These taps can’t be usedfor compact type robot.

Note)

Fig.2.4 (a) Equipment mounting surfaces (S--420iF, W, W/175)

NOTE1 For using threaded holes of equipment mounting face. (only severe dust/liquid protection) S--420i

for severe dust/liquid protection is used purge air into wrist and J3 arm. Because it keeps airtightchamber, equipment mounting face threaded holes, of J3 arm, are used SUS bolts and sealingwashers. When the customers set equipment on J3 arm using these threaded holes (M10), it willbe used coated sealing blots or sealing washers. It will reduce leakage from J3 arm.

2 For S--420i R, severe dust/liquid protection, it fills M12 threaded holes, that is side of anglebase, with M12 sus bolts. Don’t drive the robot in severe dust/liquid environment.

WARNINGIncomplete leakage measure ments on these taps will make air flow and noise increase, and itwill cause low pressure and will break down the robot low pressure.

2.4EQUIPMENTMOUNTING FACE


THE ROBOTCONNECTION

147

2--2--

2--

Fig.2.4 (b) Equipment mounting surfaces (S--420iF/2.85, S420iW/2.85)

2--

2--2--

2--

Fig.2.4 (c) Equipment mounting surfaces (S--420iS)



148

2--

2-- 2--

2--

Fig.2.4 (d) Equipment mounting surfaces (S--420iL)


THE ROBOTCONNECTION

149

Fig.2.4 (e) Equipment mounting surfaces (S--420iR)



150

When using the turbo move option, set the load masses (including themass of the hand), wrist axis load moment values, and load inertia values.

Set each load by setting the system variables listed below. Then, turn offand on the power to use the new information.1 Load mass at wrist

Set the same values (in kg) for both of $PARAM_GROUP.$PAYLOAD and $GROUP. $PAYLOAD.[Example of input]$PARAM_GROUP. $PAYLOAD : 120$GROUP. PAYLOAD : 120

2 Wrist axis load momentSet a load moment (kgf--m) (an integer) to $PARAM_GROUP.$AXISMOMENT.[Example of input]When load moment is as follows;J4--axis load moment 60 kgf--mJ5--axis load moment 60 kgf--mJ6--axis load moment 30 kgf--mSet system variables as below :J4--axis load moment $PARAM_GROUP.$AXISMOMENT[4] : 60J5--axis load moment $PARAM_GROUP.$AXISMOMENT[5] : 60J6--axis load moment $PARAM_GROUP.$AXISMOMENT[6] : 30

3 Wrist axis load inertiaSet a load inertia (kgf--cm--s2) (an integer) to $PARAM_GROUP.$AXIS INERTIA.[Example of input]When load inertia is as follows;J4--axis load inertia 306 kgf--cm--s2

J5--axis load inertia 306 kgf--cm--s2

J6--axis load inertia 76 kgf--cm--s2

Set system variables as below:J4--axis load inertia $PARAM_GROUP.$AXIS INERTIA[4] : 306J5--axis load inertia $PARAM_GROUP.$AXIS INERTIA[5] : 306J6--axis load inertia $PARAM_GROUP.$AXIS INERTIA[6] : 76

4 Load mass at J3--axis arm and J2--axis base.Set a load mass (kg) to $PARAM_GROUP.$ARM_LOAD.[Example of input]$PARAM_GROUP. $ARM_LOAD [1] : 20 (for load at J3--axisarm.)$PARAM_GROUP. $ARM_LOAD [2] : 250 (for load at J2--axisbase.)

2.5SETTING OF SYSTEMVARIABLES FORTURBO MOVE


THE ROBOTCONNECTION

151

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

Fig.2.6 Air--pressure supply connection (option)

2.6AIR SUPPLY(OPTION)



152

Fig. 2.7 show the posiiton of the end effecter interface. End effecterinterface (RDI/RDO), I/O Unit--MODEL B interface and user cable(signal lines, power lines) and devicenet cable (signal lines, power lines)are prepared as options.

Fig.2.7 (a) Interface for End Effecter (Option)

2.7INTERFACE FOREND EFFECTER(OPTION)


THE ROBOTCONNECTION

153

Fig.2.7 (b) Layout of interface for Option cable (Severe dust/liquid protection)



154

User cable(signal) interface

View A

DeviceNet cable (power) interface


J3 CASING PANEL (OUTPUT)

End effector interface(RDI/RDO)

I/O unit modelB interface

(Air supply)

User cable(power) interface

(Air supply)

User cable (signal) interface


User cable (power) interface

J1 BASE PANEL (INPUT)

DeviceNet cable (signal)interface

Detail B

J2 BASE PANEL (OUTPUT)



View C

Fig.2.7 (c) Layout of interface for Option cable (With devicenet cable)


THE ROBOTCONNECTION

155

(1) End effector interface (RDI/RDO) (Option)Fig. 2.7 (d) shows pin layout for end effector interface (RDI/RDO).

*

Fig.2.7 (d) Pin layout for end effector interface (RDI/RDO)

(2) I/O Unit--MODEL B interface (Option)Fig. 2.7 (e) shows pin layout for I/O Unit--MODEL B interface.

*

Fig.2.7 (e) Pin layout for I/O Unit--MODEL B interface (option)

(3) End effector interface (RDI/RDO) (Option) (Severe dust/liquidprotection)Fig. 2.7 (f) shows pin layout for end effector interface (RDI/RDO).

Fig.2.7 (f) Pin layout for end effector interface (RDI/RDO)(Severe dust/liquid protection)



156

(4) I/O Unit--MODEL B interface (Option)Fig. 2.7 (g) shows pin layout for I/O Unit--MODEL B interface.

Fig.2.7 (g) Pin layout for I/O Unit--MODEL B interface (option)(Severe dust/liquid protection)

(5) User cable (signal line) Interface (option)Fig. 2.7 (h) shows pin layout for user cable (signal line) interface.

AS

approx. AWG21

Fig.2.7 (h) Pin layout for user cable (signal line) interface (option)


THE ROBOTCONNECTION

157

(6) User cable (power line) Interface (option)Fig. 2.7 (i) shows pin layout for user cable (power line) interface.

AP

approx. AWG17

Fig.2.7 (i) Pin layout for user cable (power line) interface (option)

(7) User cable(for aux. axis, signal line) interface (option)Fig. 2.7 (j) shows pin layout for user cable (for aux. axis, signal line)interface.(This interface is applied in case of using A05B--2351--J310 or J311)

(Separately prepared)

Fig.2.7 (j) Pin layout for user cable (for aux. axis, singnal line) interface(option)

NOTEA05B--2351--J310 and J312 include a signal cable and twopower cables for aux. axis control.



158

(8) User cable(for aux. axis, power line) interface(option )Fig. 2.7 (k) shows pin layout for user cable (for aux. axis, power line)interface.

(Separately prepared)

Fig.2.7 (k) Pin layout for user cable (for aux. axis, power line) interface (option)

NOTE1 A05B--2351--J310 and J312 include a signal cable and two

power cables for aux. axis control.2 In case of using the user cable (Power), it is necessary to

select the End Effector whose Continuous Rating Currentis 10.4 A rms. If FANUC servo motor is used, following tableshows the available.

Motor Model Continuous RatingCurrent (A rms)

Motor Model Continuous RatingCurrent (A rms)

α 0.5/3000 2.8 α 3/3000 4.6

α 1/3000 2.2 α 6/2000 5.6

α 2/2000 2.2 α 6/3000 10.0

α 2/3000 2.9 α 12/2000 8.8


THE ROBOTCONNECTION

159

(9) DeviceNet cable (signal line) interface (option)Fig 2.7 (l) shows pin layout for DeviceNet cable (signal line)interface.

Fig.2.7 (l) Pin layout for DeviceNet cable (signal line) interface (option)

(10) DeviceNet cable (power line) interface (option)Fig 2.7 (m) shows pin layout for DeviceNet cable (power line)interface.

Fig.2.7 (m) Pin layout for DeviceNet cable (power line) interface (option)



160

Table2.7 (a) Connector specifications (Machine side) (S--420iF/W/S/L/R)

Cable Input side (J1 base) Output side (J3 casing) Manu.

RDI/RDO JMWR2524FDDK

I/O JMWR2516FDDK

AS(Signal)

HousingInsertContact

09 30 006 030109 16 024 3001 (Han 24DD M)09 15 000 6103


09 30 006 030109 16 024 3101 (Han 24DD F)09 15 000 6203

HartingAP

(Power)HousingInsertContact

09 20 010 030109 21 015 3001 (Han 15D M)09 15 000 6103


09 20 010 030109 21 015 3101 (Han 15D F)09 15 000 6203

Harting

AS foraux. axis(Signal)


09 30 006 0301 (Han 6E)09 16 024 3001 (Han24DD M)09 15 000 6103 (S1--S4)09 15 000 6104 (S5--S8)


09 30 006 0301 (Han 6E)09 16 024 3001 (Han24DD F)09 15 000 6203 (S1--S4)09 15 000 6204 (S5--S10)

Harting

Table2.7 (b) Connector specifications (User side) (S--420iF/W/S/L/R)

Cable Input side (J1 base) Output side (J3 casing)

RDI/RDO JMSP2524M Streight (Appendix)JMLP2524M Angle

I/O JMSP2516M Streight (Appendix)JMLP2524M Angle

Food 09 30 006 1540 Side1541 entry054205431440 Top1441 entry04420443

Food

← The same

AS Insert 09 16 024 3101 (Han 24DD F) Insert 09 16 024 3001 (Han 24DD M)

(Signal) Contact 09 15 000 6204 appox. AWG 26--226203 AWG 206202 AWG 186201 AWG 166206 AWG 14

Contact 09 15 000 6104 appox. AWG 26--226103 AWG 206102 AWG 186101 AWG 166106 AWG 14

Clamp 09 00 000 5083508650905094 etc.

Clamp

← The same

Food 09 20 010 1541 Side0540 entry05411440 Top0440 entry0441

Food

← The same

APInsert 09 21 015 3101 (Han 15D F) Insert 09 21 015 3001 (Han 15D M)

AP

(Power)Contact 09 15 000 6220 appox.AWG 20

6205 AWG 186204 AWG 166202 AWG 146207 AWG 12

Contact 09 15 000 6120 appox.AWG 206105 AWG 186104 AWG 166102 AWG 146107 AWG 12

Clamp 09 00 000 5083508650905094 etc.

Clamp

← The same


THE ROBOTCONNECTION

161

Table2.7 (c) Connector specifications (Severe dust/liquid protection) (Machine side)


RDI/RDO_________

housingInsertContact

09 03 006 030109 16 024 3101 (Han 24DD F)09 15 000 6203

I/O_________

housingInsertContact

09 20 010 030109 21 015 3101 (Han 15D F)09 15 000 6202

Table2.7 (d) Appended connector (Severe dust/liquid protection) (Machine side)


RDI/RDO

_________

HoodInsertContactClamp

09 30 006 144009 16 024 3101 (Han 24DD M)09 15 000 6104152D (PG13.5)

I/O

_________

HoodInsertContactClamp

09 20 010 144009 21 015 3101 (Han 15D M)09 15 000 6102, 6103, 6104152D9 (PG13.5)

Table2.7 (e) Connector specifications (device net cable) (Mechine side) (S--420iF/W/S/L)

Cablename

Input side(J1--axis base) Manufacturer

Output side(J2--axis base) Manufacturer

Output side(J3--axis casing) Manufacturer

DS(signal line)

84854--9101 MOLEXJAPAN CO.,LTD.



DP(power line)


09 30 006 0301(Han 6E)

09 32 010 3001(Han 10EE M)

09 33 00 6104

HARTINGElektronikCo., Ltd.





162

Table2.7 (f) Connector specifications (device net cable, on the user equipment side) (S--420iF/W/S/L)

Cable nameInput side

(J1--axis base)Manufac-

turerOutput side

(J2--axis base)Output side

(J3--axis casing)

DS(signal line)

MINI connector for use on the device net5--pin, female 1

MINI connector for useon the device net

5--pin, male


5--pin, male

DP(power line)

Hood Selectjust one.

09 30 006 1540 (Han 6E) Side1541 entry054205431440 Top1441 entry04420443

HARTINGElectronikCo., Ltd.


4--pin, male


4--pin, male

Insert 09 32 010 3101 (Han 10 EE F)

Contact 09 33 000 6220 AWG206214 AWG186205 AWG186204 AWG166202 AWG146207 AWG12

ClampSelect justone.

09 00 000 5083508650905094

Many other types are available.

B--80505E/063. TRANSPORTATION AND

INSTALLATIONCONNECTION

163

3 TRANSPORTATION AND INSTALLATION

1) Transportation using a craneThe robot can be transported by lifting it. When transporting therobot, be sure to change the attitude of the robot to that shown in Fig.3.1 (a), (c) and lift by attaching ropes to the four M20 eyebolts.

2) Transportation using a forkliftThe robots can also be transported using a forklift (Refer to Fig. 3.1(a), (c)). Transport materials are available as an option.

NOTEAlways attach the transportation equipment whentransporting the S--420i R. Otherwise, the robot is likely tofall forward.

3.1TRANSPORTATION

CONNECTION3. TRANSPORTATION AND

INSTALLATION B--80505E/06

164

iF, iW, iW/175 : 2053.3iS : 1917.3iF/2.85iW/2.85 : 2462.9iL : 2598.9

Fig.3.1 (a) Transportation using a crane (S--420iF/W/S/L)



165

Fig.3.1 (b) Transportation using a forklift (S--420iF/W/S/L)



166

Fig.3.1 (c) Transportation using a crane (S--420iR)

Fig.3.1 (d) Transportation using a forklift (S--420iR)



167

Fig.3.1 (e) Mechanical interface for eyebolt and transport equipment



168

Proper shipping and handling methods will help preserve the operationalusefulness of the robotic equipment. Robots are handled many timesfrom manufacturing to final installation at the plant. All individualsinvolved with handling this robotic equipment should be aware of theproper methods which must be used. Special items for considerationinclude:

D Lifting with a fork truck (pg. 160)D Overhead Crane Lifting (pg. 160)D Type of Transportation Truck to SpecifyD Shipping Skids and Base Plates (pg. 162)D Proper/Improper Securing to a Truck Deck (pg. 165, 166)D Shipping with Tooling Attached (pg. 164)

Fork truck considerations:When using a fork truck to lift the robot, be sure that the forks are set wideenough to slide into the center of the lifting pockets. Never use forkswhich are set too narrow or too wide for this feature. Using improperlyset forks can cause crowding of the castings and could potentially damagethem. The proper fork spacing is 41” between forklift pocket centers (or1,042mm).

Overhead crane lifting:Many facilities use overhead cranes to move machinery into position.FANUC provides lifting eyebolts at the base of the robot for this purpose.To prevent damage to the upper arm components, a spreader bar isrecommended.

Vehicle transportation:When robots must be transported on highways, it is imperative that theselected truck be equipped with “air ride” suspension. This type ofsuspension provides the most protection to the equipment from roadshocks and damage.

Shipping skids and base plates:FANUC ships robots on skids designed for the purpose of properlyhandling the equipment. When robots are placed into systems, they areremoved from these skids and generally placed on steel floor plates.These plates are then secured to the floor. In cases where this operationoccurs at the plant, the skids may be discarded. In instances where therobots are incorporated into systems away from the plant (majority ofcases), the skids must be saved. Upon completion of the system runoff,the robots (without baseplates) should be placed back onto the shippingskids for transportation to the plant.

3.2ROBOTTRANSPORTATIONCONSIDERATIONS



169

Securing robots to the vehicle:After the robots are placed onto the shipping skids, they can be loadedonto the truck. Proper securing of the robots involves chaining theshipping skid to the truck deck. Under NO circumstances should chains(or other securing devices) be attached to the robot. This practice cancause irreparable damage to the robotic equipment.

Shipping with tooling attached:FANUC always recommends that heavy tooling be removed from therobot arm prior to shipping. There are instances where tooling can be lefton the robot. These include medium/light weight tools, and short distancemoves. In these cases, the tooling could be left on the robot, but armblocking is required. The robot should be placed into the shippingposition and blocked with wood supports between the arm and lowercasting. The blocking could be secured with plastic banding which willprevent marring.



170

TransportEquipment

TransportEquipment

Shipping skid

Fig.3.2 (a) Robot Mounted on Proper Shipping Skid

FANUC ships S-420i robots to customers on special shipping skids.Usually these are made of steel, but on certain models, wood skids areused. S-420i robots should only be shipped using these skids. Under nocircumstances should the robot be shipped without these skids. Robotsshould NOT be shipped with steel mounting plates attached.



171

After a robot is ready for shipment, it must be placed into the shippingposition. This position places the robot directly over the shipping skidwhich helps prevent damage from improper handling.

Fig.3.2 (b) Shipping Position of Robot



172

FANUC recommends that all tooling be removed from the robot wristprior to shipment. In some cases where robots will be transported overa short distance, the tooling can remain mounted to the robot wrist. If therobot is to be shipped with the tooling mounted, it is imperative that theupper arm is blocked to reduce shipping damages.

Heavy Tooling

Blocking

Fig.3.2 (c) Shipping Robot with Tooling (Special Considerations)



173

To properly transport a robot, it must be mounted to a skid. This robotskid must be secured to the truck deck. Chains or straps are not to beattached to any aspect of the robot arm.

Shipping Skid

Chains or Straps

Truck Deck

Truck Deck

Fig.3.2 (d) Proper Robot Securing to Truck



174

Under NO circumstances are chains or straps to be run through the forklift pockets. This method can cause structural damage to the robotmechanical unit and/or peripherals which have been mounted to them.

Chains or Straps

Never chain through fork pockets

Fig.3.2 (e) Improper Robot Securing to Truck



175

Fig. 3.3 (a) shows the robot base dimensions. Fig. 3.3 (b) shows an actualexample of robot installation. The floor plate should be embedded inconcrete and fastened with chemical anchors. Also fasten the base plateto the robot base using M20 x 60 bolts (strength classification 12.9). Next,position the robot and weld the base plate to the floor plate.

Fig. 3.3 (c) shows another example of the robot installation for S--420iR.The floor plate should be either welded to the frame or fastended witheight M20 x 60 bolts (strength classification 12.9). Also fasten the baseplate to the robot base using four M20 x 60 bolts (strength classification12.9) and four M16 x 60 bolts (strength classification 12.9) with plainwashers. Next, position the robot and weld the base plate to the floor plate.

Avoid placing any object in front of the robot on the mounting surface tofacilitate the installation of the mastering fixture, as shown in Fig. 3.3 (a).Fig. 3.3 (d) and table 3.3 show force and movement applied to the baseplate during emergency stop state.

Fig.3.3 (a) Installation hole dimensions of the robot base

NOTE1 Parts to be provided by the customer:i) S--420iF/W/S/L

Robot mounting bolts : M20 x 60 (strength classification 12.9) 4pcs.Chemical anchors : M20 (strength classification 4.8) 8pcs.Base plates : thickness 32 3pcs.Floor plate : thickness 32

ii) S--420iRRobot mounting bolts : M16 x 60 (strength classification 12.9) 4pcs.

: M20 x 60 (strength classification 12.9) 4pcs.(12pcs.)

Plain washers : M16 4pcs.Base plates : thickness 32 3pcs.Floor plate : thickness 32Frame

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

3 S--420i severe dust/liquid protection, installation.When the robots work in the environment, using water or liquid, completedraining must need. Incomplete draining will make robot break down.

3.3INSTALLATION



176

Fig.3.3 (b) Actual installation example (S--420iF/W/S/L)



177

Fig.3.3 (c) Actual installation example (S--420iR)



178

Fig.3.3 (d) Force and moment during emergency stop

Table3.3 Force and moment during emergency stop

Model Vertical momentMV [kgm]

Force in verticaldirectionFV [kg]

Horizontal momentMH [kgm]

Force in horizontaldirectionFH [kg]

S--420i F 4500 3200 1900 1900

S--420i F/2.85 5100 3200 2100 1800

S--420i W 4600 3200 2000 1900

S--420i W/175 4900 3400 2400 2000

S--420i W/2.85 5600 3500 2500 2100

S--420i S 3600 2900 1000 1300

S--420i L 5200 3200 2200 1800

S--420i R 6800 3700 3600 2700

S--420i R/120 6700 3600 3400 2500



179

Fig. 3.4 (a), (b) shows the maintenance area of the mechanical unit. Inmastering, it needs to take the posture of Fig. 5.3.3 (f)~(j) of Chapter I.Keep the enough space for taking the posture.

Fig.3.4 (a) Maintenance area (S--420iF/W/S/L)

Fig.3.4 (b) Maintenance area (S--420iR)

3.4MAINTENANCEAREA



180

Fig. 3.5 (a) shows how to connect air hose to the robot. If the air controlset is specified as an option, the air hose between the mechanical unit andthe air control set is provided. Mount the air control set using theinformation in Fig. 3.5 (b).

Fig.3.5 (a) Air piping Option

NOTEPipe used in the mechanical unit has an outer diameter of12 mm and an inner diameter of 8 mm. You can use adifferent size pipe outside the mechanical unit.

Fill the oiler having three air components to the specified level withturbine oil #90 to #140. The machine tool builder is required to preparemounting bolts.

Fig.3.5 (b)Air control set Option

3.5AIR PIPING



181

Following figure shows how to connect air tube to the robot. The air tubebetween the mechanical unit and air filter unit is provided. If the air tubeis extended, use hard tube, because pressure drop is reduced.

Specification of air filter unit and element

Name Specifications

Air filter unit A97L--0218--0016

Element set for replacing A97L--0218--0016#EL

3.6PURGE AIR PIPING(FOR SEVEREDUST/LIQUIDPROTECTION)



182

Table3.7 Installation specifications

Items Specifications

Airpressure

Pressure 5 -- 7 kgf/cm2, 0.49 -- 0.69 Mpa (Set pressure 5 kgf/cm2, 0.49 MPa)

Air flow Max. peak 150 Nl/min, 0.15 Nm3/min (Note 1)

Weight of mechanicalunit

Approx. 1500 kg (including controller)→ S--420iF/W/S

1600 kg (including Controller)→ S--420iF/2.85W/175, W/2.85 iL

1700 kg → S--420iR, R/120

Allowable ambienttemperature

0 -- 45°C

Allowable ambienthumidity

Usual: Less than 75% RHShort period (in one month): Max. 98% RH or less

Condensation free

Atmosphere Free of corrosive gases (Note 2)

Vibration Less than 0.5 G, 4.9 m/s2

NOTE1 This value indicates the maximum capacity of the air control

set.Adjust the air flow to be less than this value.

2 Contact the service representative, if the robot is to be usedin an environment or a place subjected to severe vibrations,heavy dust, cutting oil splash and or other foreignsubstances.

To store the robot, set it to the same attitude as that used for transportation(See Fig. 3.1 (a) and (b)) and store it on a level surface.

3.7INSTALLATIONSPECIFICATIONS

3.8STORAGE

APPENDIX

NOTE2)

NOTE2)

B--80505E/06 A. SPARE PARTS LISTAPPENDIX

185

A SPARE PARTS LIST

TableA (a) Cables (for the basic axes)

No. Specifications Function Applicable models

K121 A660--8010--T136A660--8010--T136#C M1 to M6 PULCO S--420i F/W/L

with a integratedK122 A660--4003--T305

A660--4003--T305#C M1 to M6 POWERwith a integratedcontrol unit

K123 A660--8010--T223A660--8010--T223#C M1 to M6 PULCO, EE

S 420i F/W/LK124 A660--8010--T224

A660--8010--T224#C M1 to M6 PULCOS--420i F/W/Lwith a remotecontrol unit

K125 A660--4003--T319A660--4003--T319#C M1 to M6 POWER

control unit

K131 A660--8010--T148 M1 to M6 PULCO, EEK132 A660--4003--T313 M1 to M6 POWER S--420i R, R/120K136 A660--8010--T220 M1 to M6 PULCO

S 420i R, R/120

K141 A660--8010--T133A660--8010--T133#C M1 to M6 PULCO S--420i S




S 420i SK144 A660--8010--T422

A660--8010--T422#C M1 to M6 PULCOS--420i Swith a remotecontrol unit


control unit

K161 A660--4003--T297 EXTENSIONS 420i L

K162 A660--4003--T298 EXTENSIONS--420i L

K181 A660--8011--T005A660--8011--T005#C M1 to M6 PULCO S--420i F/2.85

S--420i W/2.85


S 420i W/2.85with a integratedcontrol unit


S--420i F/2.85

K184 A660--8011--T007A660--8011--T007#C M1 to M6 PULCO

S--420i F/2.85S--420i W/2.85with a remote


t a e otecontrol unit

NOTE1 “-- #C” cables are used for compact type mechanical unit.

2 Cable K161, K162 conform to CE Marking.

APPENDIXA. SPARE PARTS LIST B--80505E/06

186

TableA (b) Cables (for the basic axes : CE Marking)


K221 A660--8011--T017A660--8011--T017#C M1 to M6 PULCO S--420i F/W/L




S 420i F/W/LK224 A660--8011--T019

A660--8011--T019#C M1 to M6 PULCOS--420i F/W/Lwith a remotecontrol unit


control unit

K231 A660--8011--T020 M1 to M6 PULCO, EEK232 A660--4003--T383 M1 to M6 POWER S--420i R, R/120K236 A660--8011--T021 M1 to M6 PULCO

S 420i R, R/120

K241 A660--8011--T022A660--8011--T022#C M1 to M6 PULCO S--420i S




S 420i SK244 A660--8011--T024

A660--8011--T024#C M1 to M6 PULCOS--420i Swith a remotecontrol unit


control unit

K281 A660--8011--T028A660--8011--T028#C M1 to M6 PULCO S--420i F/2.85

S--420i W/2.85


S 420i W/2.85with a integratedcontrol unit


S--420i F/2.85

K284 A660--8011--T030A660--8011--T030#C M1 to M6 PULCO

S--420i F/2.85S--420i W/2.85with a remote


t a e otecontrol unit

NOTE“-- #C” cables are used for compact type mechanical unit.

TableA (c) Cables (for the basic axes : Severe dust/liquid protection)


K323 A660--8011--T944 M1 to M6 PULCO, EE S--420i F/W/L

K331 A660--8012--T001 M1 to M6 PULCO, EE S--420i R

NOTEFor the remote controller type, the M1 to M6 POWER cableis the same as for the CE Mark.


187

TableA (d) Cables (for the wrist)


K108 A660--2004--T285 M6P COUPLINGK109 A660--4003--T283 M6MBK COUPLING S--420i F/W/S/L/RK110 A660--4003--T450 EXTENSION

S 420i F/W/S/L/R

NOTEWrist cables conform to CE Marking.

TableA (e) Cables (optional)


K111 A660--2004--T203 EE (RDI/RDO) Integrated typeK112 A660--2004--T204 AS (UER/SIGNAL)

S 420i F/W/S/LK113 A660--2004--T205 AP (USER/POWER)

S--420i F/W/S/L

K114 A660--8009--T796 J1 OT Integrated typeK115 A660--8010--T218 J1 OT Remote type

K119 A660--2004--T325 I/O (STANDARD) S--420i F/W/S/Lwith a integrated

K120 A660--4003--T328 I/O (SPECIAL)with a integratedcontrol unit

K128 A05B--1313--D001 I/O (STANDARD) S--420i F/W/S/Lwith a remote

K129 A05B--1313--D003 I/O (SPECIAL)with a remotecontrol unit

K133 A660--2004--T330 AS (UER/SIGNAL)K134 A660--2004--T345 AP (USER/POWER)

S 420i RK138 A05B--1313--D002 I/O (STANDARD)

S--420i R

K139 A05B--1313--D004 I/O (SPECIAL)K524 A660--4003--T585 DEVICENET (SIGNAL)

S 420i F/W/S/LK525 A660--4003--T586 DEVICENET (POWER)

S--420i F/W/S/L

TableA (f) Cables (optional : Severe dust/liquid protection)


K329 A05B--1313--D023 I/O (SPECIAL) S--420i F/W/L

K339 A05B--1313--D024 I/O (SPECIAL) S--420i R

NOTE5)

NOTE5)


188

TableA (g) Cables (optional : CE Marking)


K211 A660--2004--T809 EE (RDI/RDO) Integrated typeK212 A660--2004--T804 AS (UER/SIGNAL)

S 420i F/W/S/LK213 A660--2004--T805 AP (USER/POWER)

S--420i F/W/S/L

K219 A660--2004--T817 I/O (STANDARD) S--420i F/W/S/Lwith a integrated

K220 A660--4003--T476 I/O (SPECIAL)with a integratedcontrol unit

K228 A05B--1313--D011 I/O (STANDARD) S--420i F/W/S/Lwith a remote

K229 A05B--1313--D013 I/O (SPECIAL)with a remotecontrol unit

K233 A660--2004--T807 AS (UER/SIGNAL)K234 A660--2004--T808 AP (USER/POWER)

S 420i RK238 A05B--1313--D012 I/O (STANDARD)

S--420i R

K239 A05B--1313--D014 I/O (SPECIAL)

TableA (h) Motors

Name (Axis) Specifications Remarks

M1, M2, M3 (J1, J2,J3) A06B--0147--B675 α 22/2000M4 (J4) A06B--0146--B675 α 22/1500M5 (J5) A06B--0142--B675#0006 α 12/2000M6 (J6) A06B--0162--B175#0006 α M6/3000

TableA (i) For High duty (M4 to M6 are common)


M1, M2, (J1, J2) A06B--0186--B675#0011 α M30/3000HVM3 (J3) A06B--0147--B675 α 22/2000

TableA (j) For S--420iW/2.85 (M4 to M6 are common)


M1, M2, (J1, J2) A06B--0147--B675 α 22/2000M3 (J3) A06B--0186--B675#0011 α M30/3000HV

NOTEThe specification of the motor for J5 and J6 axismanufactured before August 1995 areJ5 AXIS : A06B--0142--B675#0003J6 AXIS : A06B--0162--B175#0003

There are two pulse--coder cable which correspond to eachmotor.#0003 : K107 (A660--4003--T233)#0006 : K110 (A660--4003--T450)

When you change the motor (#0003), you must prepare thecable--K110 and new motor (#0006).

NOTE6)


189

TableA (k) Reducer

Name Specifications Applicable models

J1--axis reducer A97L--0118--0939#250C--35 S--420i F/W/S/L/RA97L--0118--0940#250A--118 S--420i F/S/L

J2--axis reducer A97L--0118--0940#250A--129 S--420i W/RJ2 axis reducerA97L--0118--0940#250A--141 S--420i R/120A97L--0118--0941#250A--129 S--420i F/S/L/R

J3--axis reducer A97L--0118--0941#250A--171 S--420i WJ3 axis reducerA97L--0118--0941#250A--141 S--420i F2.85/R120


J6 axis reducerA97L--0118--0942#30A--81 S--420i F/S/L/R

J6--axis reducerA97L--0118--0942#30A--121 S--420i W

TableA (l) Gear


A290--7313--X221 S--420i F/W/L/R

J1--axisA290--7313--Y221 S--420i S

J1--axispinion gear

A290--7313--Z221S--420i R/120S--420i F/2.85S--420i W/2.85

A290--7313--X222 S--420i F/W/L/R

J1--axisA290--7313--Y222 S--420i S

J1--axiscenter gear

A290--7313--Z222S--420i R/120S--420i F/2.85S--420i W/2.85

J2/J3 gearboxassembly A290--7313--V351

J2/J3 gear Aassembly A290--7313--V352 S--420i F/W/S/L

Compact typeJ2/J3 gear B

assembly A290--7313--V353

Compact type

J4--axis A290--7313--X404 S--420i F/S/L/RJ4 axispinion gear A290--7313--Y404 S--420i W

J4--axis A290--7313--X405 S--420i F/S/L/RJ4 axiscenter gear A290--7313--Y405 S--420i W

J5--axisgear 1

A290--7313--V521 S--420i F/S/L/Rgear 1

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

J5--axisgear 2

A290--7313--V522 S--420i F/S/L/Rgear 2

assembly A290--7313--V525 S--420i W

J5--axisgear 3

A290--7313--V523 S--420i F/S/L/Rgear 3

assembly A290--7313--V526 S--420i W

J5--axis A290--7313--X508 S--420i F/S/L/RJ5 axisgear 4 A290--7313--Y508 S--420i W

NOTEV351 includes V352, V353 and the other parts.


190

TableA (m) Others (mechanical unit)


Balancer A05B--1313--V301 S--420i F/W/S/LBalancer A05B--1313--V311 S--420i RWrist unit A290--7313--V501 S--420i F/S/L/RWrist unit A290--7313--V503 S--420i W

Shaft assembly A290--7313--V321 S--420i F/W/S/L/RJ3--axis arm assembly A290--7313--V401 S--420i F/W/LJ3--axis arm assembly A290--7313--V441 S--420i SJ3--axis arm assembly A290--7313--V461 S--420i L/RJ3--axis arm assembly A290--7313--V471 S--420i R

Cable track A97L--0218--0608#27 S--420i F/W/S/L/R

TableA (n) Others (mechanical unit) for severe dust/liquid protection


Balancer A290--7313--V302 S--420i F/W/LBalancer A290--7313--V312 S--420i RWrist unit A290--7313--V551 S--420i F/L/RWrist unit A290--7313--V553 S--420i W

J3--axis arm assembly A290--7313--V411 S--420i F/W/LJ3--axis arm assembly A290--7313--V472 S--420i R

Extended arm assembly A290--7313--V462 S--420i L/R

TableA (o) Battery and grease


Battery A98L--0031--0005 1.5 V, size DGrease A98L--0040--0119#2KG Kyodo Yushi

Moly--white RE No.00Grease A97L--0001--0179#2 Shell Alvania No.2

TableA (p) O--rings

Name Specifications Location

O--ring JB--ORIA--G125 M1 to M5O--ring A98L--0001--0347#S115 M6O--ring A98L--0040--0041#280 J1--axis reducerO--ring JB--ORIA--G135 J1--axis reducerO--ring JB--ORIA--G210 J1--axis reducerO--ring JB--ORIA--G290 J1--axis reducerO--ring JB--ORIA--G270 J2/J3--axis reducerO--ring A98L--0040--0041#176 J3--axis reducerO--ring A98L--0001--0347#S70 J4--axis reducerO--ring JB--ORIA--G115 J4--axis reducerO--ring A98L--0040--0041#165 J4--axis reducerO--ring A98L--0040--0041#173 J4--axis reducer

B--80505E/06 B. CONNECTION DIAGRAMAPPENDIX

191

B CONNECTION DIAGRAM

AP

PE

ND

IXB

.CO

NN

EC

TIO

ND

IAG

RA

MB

--80505E/06

192

Fig

.B.1

Intern

alCo

nn

ection

Diag

ram(S

--420iF,W,W

/175,Integ

ratedtyp

e)

B--80505E

/06B

.CO

NN

EC

TIO

ND

IAG

RA

MA

PP

EN

DIX

193

Fig

.B.2

Intern

alCo

nn

ection

Diag

ram(S

--420iF,W,W

/175,Rem

ote

type)

AP

PE

ND

IXB

.CO

NN

EC

TIO

ND

IAG

RA

MB

--80505E/06

194

Fig

.B.3

Intern

alCo

nn

ection

Diag

ram(S

--420iF/2.85,W

/2.85,Integ

ratedtyp

e)

B--80505E

/06B

.CO

NN

EC

TIO

ND

IAG

RA

MA

PP

EN

DIX

195

Fig

.B.4

Intern

alCo

nn

ection

Diag

ram(S

--420iF/2.85,W

/2.85,Rem

ote

type)

AP

PE

ND

IXB

.CO

NN

EC

TIO

ND

IAG

RA

MB

--80505E/06

196

Fig

.B.5

Intern

alCo

nn

ection

Diag

ram(S

--420iS,in

tegrated

type)

B--80505E

/06B

.CO

NN

EC

TIO

ND

IAG

RA

MA

PP

EN

DIX

197

Fig

.B.6

Intern

alCo

nn

ection

Diag

ram(S

--420iS,R

emo

tetyp

e)

AP

PE

ND

IXB

.CO

NN

EC

TIO

ND

IAG

RA

MB

--80505E/06

198

Fig

.B.7

Intern

alCo

nn

ection

Diag

ram(S

--420iL,In

tegrated

type)

B--80505E

/06B

.CO

NN

EC

TIO

ND

IAG

RA

MA

PP

EN

DIX

199

Fig

.B.8

Intern

alCo

nn

ection

Diag

ram(S

--420iL,R

emo

tetyp

e)

AP

PE

ND

IXB

.CO

NN

EC

TIO

ND

IAG

RA

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B--80505E/06 Table of Contents

c--1

SAFETY PRECAUTIONS s--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

I MAINTENANCE

1. CONFIGURATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 J1--AXIS DRIVE MECHANISM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 J2/J3--AXIS DRIVE MECHANISM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 J4--AXIS DRIVE MECHANISM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 J5/J6--AXIS DRIVE MECHANISM 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 MAJOR COMPONENT SPECIFICATIONS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. PREVENTIVE MAINTENANCE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 DAILY CHECKS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 3--MONTH CHECKS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 6--MONTH CHECKS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 ANNUAL CHECKS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 3--YEAR CHECKS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 MAINTENANCE TOOLS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 CAUTION STICKERS FOR DAILY CHECKS(ONLY SEVERE DUST/LIQUID PROTECTION) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. PERIODIC MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 REPLACING GREASE OF THE DRIVE MECHANISM 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 GREASING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 REPLACING BATTERY 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 REPLACING FILTER ELEMENT 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TROUBLESHOOTING 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 GENERAL 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 PROBLEMS AND CAUSES 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 THE MEASUREMENT OF THE BACKLASH 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. ADJUSTMENTS 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 AXIS LIMITS SETUP 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Zero Point Position and Motion Limit 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1.2 Software Setting 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1.3 Hard Stopper and Limit Switch Setting 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 ADJUSTING J1--AXIS LIMIT SWITCH (OPTION) 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 MASTERING 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.1 General 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.2 Resetting Alarms and Preparing for Mastering 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.3 Mastering to a Fixture (Master Position Master) 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.4 Zero Degree Mastering 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.5 Quick Mastering 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.6 Single Axis Mastering 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B--80505E/06Table of Contents

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5.4 ADJUSTING J5--AXIS BACKLASH 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. REPLACING PARTS 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 PART REPLACEMENT AND CORRESPONDING ADJUSTMENT 60. . . . . . . . . . . . . . . . . . . . . . .

6.2 REPLACING J1--AXIS MOTOR (M1) AND REDUCER 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 REPLACING J2/J3--AXIS MOTOR (M2/M3) AND REDUCER 65. . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 REPLACING J4--AXIS MOTOR (M4) AND J4--AXIS REDUCER 76. . . . . . . . . . . . . . . . . . . . . . . . .

6.5 REPLACING WRIST UNIT 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



6.8 RELEASING A BRAKE (OPTION) 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. PIPING AND WIRING 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 PIPING DIAGRAM 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 WIRING DIAGRAM 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. REPLACING CABLE 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1 CABLE FORMING 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 REPLACING THE CABLES 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 REPLACING THE OPTIONAL J1--AXIS LIMIT SWITCH (OPTION) 122. . . . . . . . . . . . . . . . . . . . .

II CONNECTION

1. ROBOT INTERFERENCE AREA 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. MECHANICAL COUPLING TO THE ROBOT 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 WRIST LOAD CONDITIONS 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 LOAD CONDITIONS ON J2--AXIS BASE AND J3--AXIS ARM 143. . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 MECHANICAL COUPLING OF END EFFECTOR TO WRIST 145. . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 EQUIPMENT MOUNTING FACE 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 SETTING OF SYSTEM VARIABLES FOR TURBO MOVE 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 AIR SUPPLY (OPTION) 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 INTERFACE FOR END EFFECTER (OPTION) 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. TRANSPORTATION AND INSTALLATION 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 TRANSPORTATION 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 ROBOT TRANSPORTATION CONSIDERATIONS 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 INSTALLATION 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 MAINTENANCE AREA 179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 AIR PIPING 180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 PURGE AIR PIPING (FOR SEVERE DUST/LIQUID PROTECTION) 181. . . . . . . . . . . . . . . . . . . . .

3.7 INSTALLATION SPECIFICATIONS 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 STORAGE 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B--80505E/06 Table of Contents

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APPENDIX

A. SPARE PARTS LIST 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. CONNECTION DIAGRAM 191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. PERIODIC MAINTENANCE TABLE 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IndexB--80505E/06

i--1

[Numbers]3--month Checks, 13

3--year Checks, 13

6--month Checks, 13

[A]Adjusting J1--axis Limit Switch (Option), 39

Adjusting J5--axis Backlash, 59

Adjustments, 30

Air Piping, 180

Air Supply (Option), 151

Annual Checks, 13

Axis Limits Setup, 30

[C]Cable Forming, 106

Caution Stickers for Daily Checks (Only Severe Dust/Liquid Protection), 14

Configuration, 3

Connection Diagram, 191

[D]Daily Checks, 11

[E]Equipment Mounting Face, 146

[G]Greasing, 20

[H]Hard Stopper and Limit Switch Setting, 38

[I]Installation, 168, 175

Installation Specifications, 182

Interface for End Effecter (Option), 152

[J]J1--axis Drive Mechanism, 7

J2/J3--axis Drive Mechanism, 7

J4--axis Drive Mechanism, 8

J5/J6--axis Drive Mechanism, 9

[L]Load Conditions on J2--axis Base and J3--axis Arm,

143

[M]Maintenance Area, 179

Maintenance Tools, 14

Major Component Specifications, 10

Mastering, 40

Mastering to a Fixture (Master Position Master), 43

Mechanical Coupling of End Effector to Wrist, 145

Mechanical Coupling to the Robot, 140

[P]Part Replacement and Corresponding Adjustment, 60

Periodic Maintenance, 15

Periodic Maintenance Table, 201

Piping and Wiring, 87

Piping Diagram, 87

Preventive Maintenance, 11

Problems and Causes, 24

Purge Air Piping (for Severe Dust/Liquid Protection),181

[Q]Quick Mastering, 53

[R]Releasing A Breake (Option), 85

Replacing Battery, 22

Replacing Cable, 105

Replacing Filter Element, 23

Replacing Grease of the Drive Mechanism, 15

Replacing J1--axis Motor (M1) and Reducer, 62

Index B--80505E/06

i--2

Replacing J2/J3--axis Motor (M2/M3) and Reducer, 65

Replacing J4--axis Motor (M4) and J4--axis Reducer,76



Replacing Parts, 60

Replacing the Cables, 114

Replacing the Optional J1--axis Limit Switch(Option), 122

Replacing Wrist Unit, 78

Resetting Alarms and Preparing for Mastering, 41

Robot Interference Area, 125

[S]Setting of System Variables for Turbo Move, 150

Single Axis Mastering, 57

Software Setting, 37

Spare Parts List, 185

Storage, 182

[T]The Measurement of the Backlash, 26

Transportation, 163

Transportation and Installation, 163

Troubleshooting, 24

[W]Wiring Diagram, 89

Wrist Load Conditions, 141

[Z]Zero Degree Mastering, 50

Zero Point Position and Motion Limit, 32

Revision Record

FANUC Robot S--420i F/W/S/L/R MECHANICAL UNIT MAINTENANCE MANUAL (B--80505E)

05 Dec.,’95S Additional descriptions for CE markingS Additional descriptions for compact typeS Modification of base loading data

04 Aug.,’95S Robot transportation consideration is added in II--Chapter 3.S Correction of errors.

03 Apr., ’95 Additional descriptions of S--420 iF/2.85

02 Feb., ’95 Additional descriptions of S--420 iW/iS/iL/iR

01 Aug., ’94 06 Dec., ’97S Additional descriptions for severe dust/liquid protectionS Modification of the backlashS Correction of errors.

Revision Date Contents Revision Date Contents

Documents

S-420i Mechanical Unit Maintenance [B-80505EN_06]