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    FANUC > LR Mate 200*CMECHANICAL UNITMAINTENANCE MANUAL B-82585EN/02

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    Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content. • No part of this manual may be reproduced in any form. • All specifications and designs are subject to change without notice. The products in this man...

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    B-82585EN/02 SAFETY PRECAUTIONS s-1 1 SAFETY PRECAUTIONS For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell. In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”. 1.1 WORKIN...

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    SAFETY PRECAUTIONS B-82585EN/02 s-2 Table 1 List of workings outside the fence OperatorProgrammer or Teaching operator Maintenance engineer Power ON/OFF for Robot controller Select operating mode (AUTO, T1, T2) Select Remote/Local mode Select robot program with teach pendant Sele...

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    B-82585EN/02 SAFETY PRECAUTIONS s-3 1.2 WORKING PERSON SAFETY Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the gen...

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    SAFETY PRECAUTIONS B-82585EN/02 s-4 (9) When adjusting each peripheral device independently, be sure to turn off the power of the robot. Fig.1.2 Safety fence and safety gate E-stop board FENCE1 FENCE11 NOTE Terminal FENCE1 and terminal FENCE11 are on the PC board in the E-stop unit. ...

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    B-82585EN/02 SAFETY PRECAUTIONS s-5 1.2.1 General Person Safety The general person is a person who operates the robot system. In this sense, a worker who operates power on/off of the robot system or the teach pendant is also a general person. The general person can’t operate inside a safety ...

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    SAFETY PRECAUTIONS B-82585EN/02 s-6 1.2.2 Safety of the Teaching Operator While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teaching operator. (1) Unless it is specifically necessary to en...

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    B-82585EN/02 SAFETY PRECAUTIONS s-7 Table 1.2.2(b) CE/RIA Mode Teach pendant enable switch Software remote condition Teach pendant Operator panel Peripheral deviceLocal Not allowed Not allowed Not allowed On Remote Not allowed Not allowed Not allowed Local Not allowed Allowed to start Not allow...

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    SAFETY PRECAUTIONS B-82585EN/02 s-8 1.2.3 Safety During Maintenance For the safety of maintenance personnel, pay utmost attention to the following. (1) During operation, never enter the robot work area. (2) Except when specifically necessary, turn off the power of the controller while carryi...

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    B-82585EN/02 SAFETY PRECAUTIONS s-9 1.3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 1.3.1 Precautions in Programming (1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received. (2) Design the...

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    SAFETY PRECAUTIONS B-82585EN/02 s-10 1.4 SAFETY OF THE ROBOT MECHANISM 1.4.1 Precautions in Operation (1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality. (2) Before pressing the jog key, be sure you know i...

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    B-82585EN/02 SAFETY PRECAUTIONS s-11 1.5 SAFETY OF THE END EFFECTOR 1.5.1 Precautions in Programming (1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. (2) ...

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    SAFETY PRECAUTIONS B-82585EN/02 s-12 1.6 WARNING LABEL (1) Transportation attention label 1 500kg80kg 4100kg 4 Fig. 1.6(a) Transportation attention label 1 Description 1) Use a crane having a load capacity of 500 kg or greater. 2) Use at least four slings each having a withstand load of 980 ...

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    B-82585EN/02 SAFETY PRECAUTIONS s-13 (2) Transportation attention label 2 注意アイボルトを横引きしないことアイボルトを外してから使用することCAUTIONDO NOT PULL EYBOLTSSIDEWAYS.REMOVE EYEBOLTS,BEFORE USE Fig.1.6 (b) Transportation attention label 2 Description Ke...

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    SAFETY PRECAUTIONS B-82585EN/02 s-14 (3) Greasing attention label (When grease applying kit: A05B-1139-K021 is specified.) 注意シリンダにグリスを入れる前にチューブを揉んでグリスを柔らかくして下さい。ブランジャーを2.5mm押すと1ccのグリスが出...

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    B-82585EN/02 SAFETY PRECAUTIONS s-15 (4) Range of motion and payload mark label Below label is added when CE specification is specified. 0deg-180deg+180degJ5-AXISROTATION CENTERMOTION RANGEOF J5-AXISROTATION CENTERSTANDARDLONG ARM959 228 704 5131147 393 892 742MAX.PAYLOAD:5kgUNIT:mmABCDABCD Fi...

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    B-82585EN/02 PREFACE p-1 PREFACE This manual explains the maintenance and connection procedures for the mechanical units of the following robots: Model name Mechanical unit specification No. Maximum load Remarks FANUC Robot LR Mate 200iC A05B-1139-B201 3-axes brake type Non-severe dust/liquid ...

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    PREFACE B-82585EN/02 p-2 The label stating the mechanical unit specification number is affixed in the position shown below. Before reading this manual, determine the specification number of the mechanical unit. OSHINO-MURA.YAMANASHI PREF.JAPAN(3)(2)(4)(1)WEIGHT‚‹‚‡(5)TYPENO.DATE TAB...

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    B-82585EN/02 PREFACE p-3 RELATED MANUALS For the FANUC Robot series, the following manuals are available: Safety handbook B-80687EN All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook Intended readers: All persons who use FANUC Robot, system...

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    B-82585EN/02 TABLE OF CONTENTS c - 1 TABLE OF CONTENTS SAFETY PRECAUTIONS............................................................................s-1 PREFACE....................................................................................................p-1 1 CHECKS AND MAINTENANCE .........

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    TABLE OF CONTENTS B-82585EN/02 c - 2 4.6 REPLACING J3-AXIS MOTOR.................................................................... 57 4.7 REPLACING J3-AXIS REDUCER ............................................................... 59 4.8 REPLACING J4-AXIS MOTOR......................................

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    B-82585EN/02 1.CHECKS AND MAINTENANCE - 1 - 1 CHECKS AND MAINTENANCE Optimum performance of the robot can be maintained by performing the periodic maintenance procedures presented in this chapter. (See the APPENDIX A PERIODIC MAINTENANCE TABLE.) NOTE The periodic maintenance procedures descri...

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    1.CHECKS AND MAINTENANCE B-82585EN/02 - 2 - 1.1 DAILY CHECKS Clean each part, and visually check component parts for damage before daily system operation. Check the following items as the occasion demands. (1) Before turning on power Item Check items Check points 1 Air pressure Check air press...

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    B-82585EN/02 1.CHECKS AND MAINTENANCE - 3 - OSOSPressure gaugePressure adjustment knob2-7x11Length round holeAir outlet(O6 Air tube)Air inlet(O10 air tube)Pneumaticair outletDry airPneumatic tubeFilter and regulatorDew point checkerDryer unit Fig.1.1(b) Air purge kit (option) (2) After turning...

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    1.CHECKS AND MAINTENANCE B-82585EN/02 - 4 - (Note 1) Cleaning - Necessary cleaning points, dust on the flat part, sedimentation of spatters Clean sediments periodically. In particular, clean the following points carefully. Vicinity of the wrist axis and oil seal → If chippings or spatte...

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    B-82585EN/02 1.CHECKS AND MAINTENANCE - 5 - 1.2 First 1-Month (320 hours operating) Check Check the following items after the first one-month operation (or 320 hours operating) First 1-month check ItemCheck items Check points 1 Control unit cable and robot connecting cable Check whether the ...

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    1.CHECKS AND MAINTENANCE B-82585EN/02 - 6 - (NOTE 2) Inspection points of the connectors - Robot connection cables, earth terminal and user cables Check items - Circular connector: Check the connector for looseness by turning it manually. - Square connector: Check the connector for disengagem...

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    B-82585EN/02 1.CHECKS AND MAINTENANCE - 7 - 1.4 1-year (3,840 hours) checks Check the following items about once every year (3,840 hours). ItemCheck items Check points 1 Tightness of major external bolts (See Section 1.3) 2 Tightness of major external bolts (See Section 1.3) 3 Battery (battery...

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    1.CHECKS AND MAINTENANCE B-82585EN/02 - 8 - 1.6 2-year (7,680 hours) checks (LR Mate 200iC /5WP) 4-year (15,360 hours) checks (LR Mate 200iC, LR Mate 200iC/5L , /5C, /5LC, /5H) Check the following items in the cycle that is shorter among every four years and 15,360 hours. ItemCheck itmes Che...

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    B-82585EN/02 1.CHECKS AND MAINTENANCE - 9 - 1.7 MAINTENANCE TOOLS The following tools and instruments are required for the maintenance procedures contained in this manual. (a) Measuring instruments Instrument Specifications Vendor Manufacturer model No. Application Tension meter A97L-0218-070...

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    1.CHECKS AND MAINTENANCE B-82585EN/02 - 10 - O5 Fig 1.7 example of cylinder

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    B-82585EN/02 2.PERIODIC MAINTENANCE - 11 - 2 PERIODIC MAINTENANCE

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    2.PERIODIC MAINTENANCE B-82585EN/02 - 12 - 2.1 REPLACING THE BATTERIES (1-YEAR CHECKS (battery built-in type)) (1.5-YEAR CHECKS (external battery type)) The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every 1 year in case of battery built-i...

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    B-82585EN/02 2.PERIODIC MAINTENANCE - 13 - Procedure of replacing the battery (external battery type) 1 Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion. CAUTION Be sure to keep the power on. Replacing the batteries with the power supply turned off causes all...

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    2.PERIODIC MAINTENANCE B-82585EN/02 - 14 - Fig 2.1(c) shows the external size of external battery box. When the battery box needs to be built into the control unit or other internal units, refer to the outer dimensions shown in Fig.2.1(c) The battery box can be fixed by using M4 flat–head scre...

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    B-82585EN/02 2.PERIODIC MAINTENANCE - 15 - 2.2 REPLENISH THE GREASE OF THE DRIVE MECHANISM (4 years (11,520 hours) checks) Replacing the grease of the reducers every four years or 15,360 hours by using the following procedures. For the grease name and quantity, see the table 2.2 (a). Table 2.2...

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    2.PERIODIC MAINTENANCE B-82585EN/02 - 16 - NOTE If greasing is performed incorrectly, the internal pressure of the grease bath may suddenly increase, possibly causing damage to the seal, which would in turn lead to grease leakage and abnormal operation. When performing greasing, therefore, ob...

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    B-82585EN/02 2.PERIODIC MAINTENANCE - 17 - 2.2.1 Grease replacement procedure of the J1-axis reducer 1 Move the robot to the attitude of J1=-90° and J2=90°. 2 Turn off the power. 3 Remove the bolt/seal bolt (1) and cover U (2). In case of packing is attached, remove packing (3), too. 4 Remove...

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    2.PERIODIC MAINTENANCE B-82585EN/02 - 18 - 2.2.2 Grease replacement procedure of the J2-axis reducer 1 Turn off the power. 2 Remove the seal bolt (1), (2) and remove cover S (3) and packing (4). Supply grease through the grease inlet by using injection syringe. Be sure to spread it to round in ...

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    B-82585EN/02 2.PERIODIC MAINTENANCE - 19 - 2.2.3 Grease replacement procedure of the J3-axis reducer 1 Turn off the power. 2 Remove the bolt/seal bolt (1) and J2 arm cover (2). In case of packing is attached, remove packing (3), too. 3 Supply regulated amount grease through the grease inlet b...

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    2.PERIODIC MAINTENANCE B-82585EN/02 - 20 - 2.2.4 Grease replacement procedure of the J4-axis reducer NOTE Fig. 2.2.4 is an example of standard type. In case of 5H type, read J5/J6 as J4/J5. 1 Turn off the power. 2 Remove the bolt/seal bolt (1) and J3 cover (2). In case of packing is attac...

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    B-82585EN/02 2.PERIODIC MAINTENANCE - 21 - Name Specification AmountLoctite Torque N-m (kgf-cm) BOLT A97L-0218-0504#M4X10 3 2.0 N-m (20kgf-cm) PLATED BOLT A97L-0218-0496#M4X12BC(*1) 6 2.0 N-m (20kgf-cm) 1 PLATED BOLT A97L-0218-0496#M4X12EN(*2) 6 2.0 N-m (20kgf-cm) A290-7139-X404 1 A290-713...

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    2.PERIODIC MAINTENANCE B-82585EN/02 - 22 - 2.2.5 Grease replacement procedure of the J5/J6-axis reducer NOTE Fig. 2.2.5 is an example of standard type. In case of 5H type, read J5/J6 as J4/J5. 1 Turn off the power. 2 Supply regulated amount grease through the grease inlet by using inject...

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    B-82585EN/02 3.TROUBLESHOOTING - 23 - 3 TROUBLESHOOTING

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    3.TROUBLESHOOTING B-82585EN/02 - 24 - 3.1 OVERVIEW The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from many interrelated factors. If you fail to take the correct measures, the failure may be aggravated. Therefore, it is necessary to analyz...

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    B-82585EN/02 3.TROUBLESHOOTING - 25 - 3.2 FAILURES, CAUSES AND MEASURES Table 3.2 lists the major failures that may occur in the mechanical unit and their probable causes. If you cannot pinpoint a failure cause or which measures to apply, contact FANUC. Table 3.2 (a) Failures, causes and measu...

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    3.TROUBLESHOOTING B-82585EN/02 - 26 - Symptom Description Cause Measure Vibration Noise (Continued) -Vibration was first noticed after the robot collided with an object or the robot was overloaded for a long period. -The grease of the vibrating axis has not been exchanged for a long period. [Bro...

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    B-82585EN/02 3.TROUBLESHOOTING - 27 - Symptom Description Cause Measure Vibration Noise (Continued) -The cause of problem cannot be identified from examination of the floor, rack, or mechanical section. [Controller, cable, and motor] -If a failure occurs in a controller circuit, preventing contr...

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    3.TROUBLESHOOTING B-82585EN/02 - 28 - Symptom Description Cause Measure Vibration -There is some relationship between the vibration of the robot and the operation of a machine near the robot. [Noise from a nearby machine] -If the robot is not grounded properly, electrical noise is induced on the...

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    B-82585EN/02 3.TROUBLESHOOTING - 29 - Symptom Description Cause Measure -The ambient temperature of the installation location increases, causing the motor to overheat. -After the robot control program or the load was changed, the motor overheated. [Ambient temperature] -It is likely that a rise ...

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    3.TROUBLESHOOTING B-82585EN/02 - 30 - Symptom Description Cause Measure Grease -Grease is leaking from the mechanical unit. [Poor sealing] -Probable causes are a crack in the casting, a broken O-ring, a damaged oil seal, or a loose seal bolt. -A crack in a casting can occur due to excessive forc...

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    B-82585EN/02 3.TROUBLESHOOTING - 31 - Symptom Description Cause Measure -The robot operates at a point other than the taught position. -The repeatability is not within the tolerance. [Mechanical section problems] -If the repeatability is unstable, probable causes are a failure in the drive mecha...

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    3.TROUBLESHOOTING B-82585EN/02 - 32 - 3.3 BACKLASH MEASUREMENT Measurement method 1 Maintain the robot in a specified posture. (See Table 3.3.) 2 Apply positive and negative loads to each axis as shown in Fig.3.3 (a). 3 Remove the loads and measure the displacement. Measure backlash by applyin...

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    B-82585EN/02 3.TROUBLESHOOTING - 33 - Table 3.3(a) Backlash measurement posture, position and permissible value Measurement axis J1-axis J2-axis J3-axis J4-axis J5-axis J6-axisMeasurement position J1-axis Arbitrary 90° 0° 0° 0° 90° Rotation center of J5-axis J2-axis Arbitrary 0° 90° 0...

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    3.TROUBLESHOOTING B-82585EN/02 - 34 - MeasurementpositionLoadingposition Fig.3.3(c) Backlash measurement position of J2-axis MeasurementpositionLoadingposition100100 Fig.3.3 (d) Backlash measurement position of J3-axis

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    B-82585EN/02 3.TROUBLESHOOTING - 35 - Measurement position100Loading positionRotation center ofJ4-axis (J6-axis) Fig.3.3 (e) Backlash measurement position of J4-axis LoadingpositionMeasurementposition100100 Fig.3.3 (f) Backlash measurement position of J5-axis 100Measurement positionLoading pos...

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    4.REPLACING PARTS B-82585EN/02 - 36 - 4 REPLACING PARTS – When replacing a part, subsequent adjustment is required. – When removing or mounting a motor, apply force in the direction of the shaft only. If excessive force is applied in any other direction, the motor and/or reducer may be dama...

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    B-82585EN/02 4.REPLACING PARTS - 37 - NOTE The following abbreviations are used herein. STANDARD : LR Mate 200iC 5L : LR Mate 200iC/5L 5LC : LR Mate 200iC/5LC 5C : LR Mate 200iC/5C 5WP : LR Mate 200iC/5WP 5H : LR Mate 200iC/5H

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    4.REPLACING PARTS B-82585EN/02 - 38 - 4.1 FIGURE OF DRIVE MECHANISM The drive mechanisms of each axis are shown in the following. CAUTION When robot is 5H,please read J5/J6 as J4/J5. J2 AXIS BASEJ1 AXIS BASEJ1 AXIS REDUCER(HOLLOW SHAFT)PIPEMOTOR (M1) FOR J1 AXISINPUT GEAROUTPUT GEAR Fig. 4...

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    B-82585EN/02 4.REPLACING PARTS - 39 - J2 AXIS ARMJ2 AXIS BASEMOTOR (M2) FOR J2 AXISJ2 AXIS REDUCER Fig. 4.1 (b) Drive mechanism of J2-axis J2 AXIS ARMJ3 AXIS HOUSINGJ3 AXIS REDUCERJ3 AXIS INPUT PULLYJ3 AXIS OUTPUT PULLYBELTMOTOR (M3) FOR J3 AXIS Fig. 4.1 (c) Drive mechanism of J3-axis

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    4.REPLACING PARTS B-82585EN/02 - 40 - MOTOR (M4) FOR J4 AXISJ3 AXIS HOUSINGJ4 AXIS INPUT GEARJ4 AXIS OUTPUT GEARPIPEJ4 AIXS REDUCERJ3 AIXS ARM Fig. 4.1 (d) Drive mechanism of J4-axis J3 AIXS ARMMOTOR (M5) FOR J5 AXISMOTOR (M5) FOR J5 AXISJ5 AXIS INPUT PULLYJ6 AXIS INPUT PULLYBELTBELTJ5 AXIS OUT...

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    B-82585EN/02 4.REPLACING PARTS - 41 - 4.2 REPLACING J1-AXIS MOTOR Replacing procedure 1 Move the robot posture to J1=90° and J2=-90°. 2 Remove robot from floor plate, and turn off the power of the controller. 3 Make it to posture in which the motor (2) can be removed. 4 When severe dust/liqui...

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    4.REPLACING PARTS B-82585EN/02 - 42 - A111213987365421VIEW A10 Fig. 4.2 Replacing J1-axis motor Parts Name Specifications NumberLoctite Torque N-m (kgf-cm)1 BOLT A6-BA-5X20 4 2 MOTOR A06B-0116-B855#0048 1 3 O-RING A98L-0001-0347#S46 1 4 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm) ...

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    B-82585EN/02 4.REPLACING PARTS - 43 - 4.3 REPLACING J1-AXIS REDUCER Replacing procedure 1 Turn off the power of the controller. 2 Remove cover B (When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified.) and J1 motor referr...

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    4.REPLACING PARTS B-82585EN/02 - 44 - 18 Pass the cable K101 through J2 base side, and connect it with the relay connector. In this time, pull out the cable after it pushes into the pipe on the tip of the part of the relayed connector and it passes it. Do not pull it out forcibly with the relaye...

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    B-82585EN/02 4.REPLACING PARTS - 45 - 19121843891015165671711121413 Fig. 4.3 (a) Replacing J1-axis reducer

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    4.REPLACING PARTS B-82585EN/02 - 46 - Parts Name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A6-BA-4X8(*1) 4 SEAL BOLT A97L-0218-0546#040808BC(*2) 4 4.5Nm (46kgfcm) 1 SEAL BOLT A97L-0218-0546#040808EN(*3) 4 4.5Nm (46kgfcm) 2 COVER U A290-7139-X332 1 3 BOLT A6-BA-4X12 7 4.5Nm (4...

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    B-82585EN/02 4.REPLACING PARTS - 47 - APPLY LOCTITE 518 TO THE PARTOF THE J1 BASE SIDE.DON'T PUT LOCTITE INSIDE THE REDUCER. Fig. 4.3 (b) Range to J1-axis reducer of sealant spreading (When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 2...

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    4.REPLACING PARTS B-82585EN/02 - 48 - M4X20M4X12 Fig. 4.3 (c) Assembled phase of J1-axis reducer M4 tap for pulled out (2 places) Fig. 4.3 (d) Position of taps for pulled out to remove J1 base.

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    B-82585EN/02 4.REPLACING PARTS - 49 - 4.4 REPLACING J2-AXIS MOTOR Replacing procedure 1 Turn off the power of the controller. 2 Remove bolt/plated bolt (1) and J2 base cover (2). When packing is attached, remove packing (19), too. 3 Remove sponge (3). 4 Cut the nylon band, which connect cable a...

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    4.REPLACING PARTS B-82585EN/02 - 50 - 123456789101112131415161820211719 Fig. 4.4(a) Replacing J2-axis motor

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    B-82585EN/02 4.REPLACING PARTS - 51 - Parts Name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm) 1 PLATED BOLT A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm) A290-7139-X305(*1) 1 A290-...

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    4.REPLACING PARTS B-82585EN/02 - 52 - Spread grease on the inside diameter..VIEW AAA Fig. 4.4(b) Apply Loctite 638 to shaft 注)取付位相に注意のことNOTE) PAY ATTENTION TO THE ASSEMBLED PHASEA97L-0218-0738#040808BC(LR Mate 200iC,LR Mate 200iC/5L,5H)A97L-0218-0738#040808EN(LR...

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    B-82585EN/02 4.REPLACING PARTS - 53 - 4.5 REPLACING J2-AXIS REDUCER Replacing procedure 1 Turn off the power of the controller. 2 Remove the robot from floor plate and knock down it sidewise. 3 Remove bolt/plated bolt (1), J2 base cover (2) and sponge (3). When packing is attached, remove packi...

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    4.REPLACING PARTS B-82585EN/02 - 54 - 22 Attach J2 base cover (2) by using bolt/plated bolt (1). In this time, put sponge (3) without forgetting, be sure to replace packing (25) to new one and attach there. 23 Attach robot to floor plate. 24 Perform mastering (See sub section 6.2 and refer to s...

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    B-82585EN/02 4.REPLACING PARTS - 55 - Parts Name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm) 1 PLATED BOLT A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm) A290-7139-X305(*1) 1 A290-...

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    4.REPLACING PARTS B-82585EN/02 - 56 - (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is spec...

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    B-82585EN/02 4.REPLACING PARTS - 57 - 4.6 REPLACING J3-AXIS MOTOR Replacing procedure 1 Turn off the power of the controller. 2 Remove bolt/plated bolt (3) and J2 arm cover (4). When packing is attached, remove packing (14), too. 3 Loosen a bolt (6) a little and lower the tension of the belt (5...

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    4.REPLACING PARTS B-82585EN/02 - 58 - 123 4567891013121114VIEW Fig. 4.6 Replacing J3-axis motor Parts Name Specifications Number Loctite Torque N-m (kgf-cm)A97L-0218-0423#051616(*1) 4 5.6Nm (57kgfcm) A97L-0218-0546#051616BC(*2) 4 5.6Nm (57kgfcm) 1 SEAL BOLT A97L-0218-0546#051616EN(*3) 4 5.6...

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    B-82585EN/02 4.REPLACING PARTS - 59 - 4.7 REPLACING J3-AXIS REDUCER Replacing procedure 1 Turn off the power of the controller. 2 Remove guide arm referring to Section 4.6. 3 Remove J2 arm cover and belt referring to section 4.6. CAUTION When removing the belt, put the part beyond the J3 h...

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    4.REPLACING PARTS B-82585EN/02 - 60 - 123456781091211 Fig. 4.7(a) Replacing J3-axis reducer

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    B-82585EN/02 4.REPLACING PARTS - 61 - Parts Name Specifications Number Loctite Torque N-m (kgf-cm)1 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm) 2 WASHER A290-7210-X532 1 3 PULLEY A290-7139-X312 1 4 BOLT A6-BA-3X16 16 2.0Nm (20kgfcm) 5 KEY (Attached to J3 REDUCER) 1 BOLT A6-BA-3X25...

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    4.REPLACING PARTS B-82585EN/02 - 62 - 4.8 REPLACING J4-AXIS MOTOR Replacing procedure CAUTION This section is for standard type. This mechanical part does't exist in 5H. If you replace J4-axis motor of 5H, refer to Section 4.10 1 Turn off the power of the controller. 2 Remove bolt/plated bol...

  • Page 87

    B-82585EN/02 4.REPLACING PARTS - 63 - Parts Name Specifications Number LoctiteTorque N-m (kgf-cm)BOLT A97L-0218-0504#M4X10 (*1) 4 2.0Nm (20kgfcm) PLATED BOLT A97L-0218-0496#M4X12BC (*2) 6 2.0Nm (20kgfcm) 1 PLATED BOLT A97L-0218-0496#M4X12EN (*3) 6 2.0Nm (20kgfcm) A290-7139-X404 (*4) 1 A290...

  • Page 88

    4.REPLACING PARTS B-82585EN/02 - 64 - 4.9 REPLACING J4-AXIS REDUCER Replacing procedure CAUTION This section is for standard type. This mechanical part does't exist in 5H. If you replace J4-axis reducer of 5H, refer to Section 4.11. 1 Turn off the power of the controller. 2 Remove J3 arm co...

  • Page 89

    B-82585EN/02 4.REPLACING PARTS - 65 - 124356 78910 111312 Fig. 4.9(a) Replacing J4-axis reducer Parts Name Specifications Number Loctite Torque N-m (kgf-cm)1 BOLT A6-BA-4X8 1 2 CLAMP J4-1 A290-7139-X432 2 3 BOLT A6-BA-3X30 4 2.0Nm (20kgfcm) 4 BOLT A6-BA-3X35 10 2.0Nm (20kgfcm) 5 SEAL BOL...

  • Page 90

    4.REPLACING PARTS B-82585EN/02 - 66 - AASECTION A-APipeApplying area of LT518(*1)Severe dust/liquid protection specification of LR Mate 200iC,LR Mate 200iC/5L,5H or LR Mate 200iC/5C,5LC,5WP・J3 casing side of reducer(*1)・PIPE・J3 casing side of J3 arm Apply Loctite 518 to the ...

  • Page 91

    B-82585EN/02 4.REPLACING PARTS - 67 - (M3X35)M3X30(4)M3X35(10) Fig. 4.9(c) Spread range of sealant

  • Page 92

    4.REPLACING PARTS B-82585EN/02 - 68 - 4.10 REPLACING J5-AXIS MOTOR Replacing procedure CAUTION This mechanism becomes J4 axis in 5H. When you replace part of 5H, read J5/J6 as J4/J5. 1 Turn off the power of the controller. 2 Remove bolt/plated bolt (1) and J3 arm cover (2). When packing is a...

  • Page 93

    B-82585EN/02 4.REPLACING PARTS - 69 - 12345678910111213A Fig. 4.10(a) Replacing J5-axis motor TENSION ADJUSTINGBOLT14VIEW A Fig. 4.10(b) Replacing J5-axis motor

  • Page 94

    4.REPLACING PARTS B-82585EN/02 - 70 - Parts Name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm) 1 PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 4.5Nm (46kgfcm) A290-7139-X405(*1) 1 A29...

  • Page 95

    B-82585EN/02 4.REPLACING PARTS - 71 - 4.11 REPLACING J5-AXIS REDUCER Replacing procedure CAUTION This mechanism becomes J4 axis in 5H.When you replace part of 5H, read J5/J6 as J4/J5. 1 Turn off the power of the controller. 2 Remove both side of J3-arm cover referring to Section 4.10. 3 Rem...

  • Page 96

    4.REPLACING PARTS B-82585EN/02 - 72 - 12347689101112131415165 Fig. 4.11(a) Replacing J5-axis reducer Parts Name Specifications Number Loctite Torque N-m (kgf-cm)1 BELT A98L-0040-0227#006-152 1 2 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm) 3 WASHER PLATE A290-7139-X231 1 4 PULLEY A29...

  • Page 97

    B-82585EN/02 4.REPLACING PARTS - 73 - (*2 )When LR Mate 200iC/5LC,5C is specified. (*3) When LR Mate 200iC/5WP is specified. (*4) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H (*5) When severe dust/liquid protection specification of LR Mate 200iC, LR ...

  • Page 98

    4.REPLACING PARTS B-82585EN/02 - 74 - 4.12 REPLACING J6-AXIS MOTOR Replacing procedure CAUTION This mechanism becomes J5 axis in 5H.When you replace part of 5H,read J6 as J5. 1 Turn off the power of the controller. 2 Remove both side of J3 arm cover of J3 arm. 3 Loosen tension adjusting bol...

  • Page 99

    B-82585EN/02 4.REPLACING PARTS - 75 - 12384567BA Fig. 4.12(a) Replacing J6-axis motor TENSION ADJUSTINGBOLTTENSION ADJUSTINGBOLT9VIEW AVIEW B Fig. 4.12(b) Replacing J6-axis motor

  • Page 100

    4.REPLACING PARTS B-82585EN/02 - 76 - Parts Name Specifications Number Loctite Torque N-m (kgf-cm)1 BELT A98L-0040-0227#006-152 1 2 FLANGE SOCKET BOLT A97L-0218-0504#M5X12 3 3 BELT A98L-0040-0227#006-100 1 4 SEAL BOLT A97L-0218-0423#030606 1 1.3Nm (13kgfcm) 5 WASHER A290-7210-X532 1 6 ...

  • Page 101

    B-82585EN/02 4.REPLACING PARTS - 77 - 4.13 REPLACING WRIST UNIT Replacing procedure CAUTION If you replace unit of 5H, read J5/J6 as J4/J5. 1 Turn off the power of the controller. 2 Replacing both side of J3 arm cover of J3 arm referring to Section 4.10. 3 Remove belt (1), (8) referring to ...

  • Page 102

    4.REPLACING PARTS B-82585EN/02 - 78 - 125634717191816152114138209101112 Fig. 4.13 Replacing wrist unit

  • Page 103

    B-82585EN/02 4.REPLACING PARTS - 79 - Parts Name Specifications Number Loctite Torque N-m (kgf-cm)1 BELT A98L-0040-0227#006-152 1 2 SEAL BOLT A97L-0218-0423#030606 3 1.3Nm (13kgfcm) 3 WASHER PLATE A290-7139-X23 1 1 4 PULLEY A290-7139-X414 1 5 KEY JB-HKY-3X3X6B 1 6 OIL SEAL A98L-0040-02...

  • Page 104

    4.REPLACING PARTS B-82585EN/02 - 80 - 4.14 REPLACING J6-AXIS REDUCER Replacing procedure CAUTION This mechanism becomes J5 axis in 5H.When you replace part of 5H,read J6 as J5. 1 Make to posture that J6 turns to the right under and turn off the power of the controller as shown in Fig.4.14 (...

  • Page 105

    B-82585EN/02 4.REPLACING PARTS - 81 - M3X25 Fig. 4.14(b) Assembling phase of J6-axis reducer Parts Name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A6-BA-3X25 (*1) 8 2.0Nm (20kgfcm) PLATED BOLT A97L-0218-0496#M3X25BC (*2) 8 2.0Nm (20kgfcm) 1 PLATED BOLT A97L-0218-0496#M3X25EN (*3) ...

  • Page 106

    4.REPLACING PARTS B-82585EN/02 - 82 - 4.15 REPLACING J3 BELT Replacing procedure 1 Turn off the power of the controller. 2 Remove blot/plated bolt (1) and J2 arm cover (2). When packing is attached, remove packing (3), too. 3 Loosen tension adjusting bolt and lower tension and remove belt (4) r...

  • Page 107

    B-82585EN/02 4.REPLACING PARTS - 83 - Parts Name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm (46kgfcm) 1 PLATED BOLT A97L-0218-0496#M4X12EN (*3) 8 4.5Nm (46kgfcm) A290-7139-X306(*1) 1 A290-...

  • Page 108

    4.REPLACING PARTS B-82585EN/02 - 84 - 4.16 REPLACING J5/J6 BELT Replacing procedure CAUTION When replacing 5H,please read J5/J6 as J4/J5. 1 Turn off the power of the controller. 2 Remove bolt/plated bolt (1) and J3 arm cover (2). When packing is attached, remove packing (3), too. 3 Remove bol...

  • Page 109

    B-82585EN/02 4.REPLACING PARTS - 85 - 12374568 Fig. 4.16 Replacing J5/J6 belt Parts Name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm (20kgfcm) PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm (46kgfcm) 1 PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 4...

  • Page 110

    4.REPLACING PARTS B-82585EN/02 - 86 - 4.17 REPLACING SOLENOID VALVE Replacing procedure 1 Make J3-axis to posture in which SV PLATE is removed easily. 2 Turn off the power of the controller. 3 Remove bolt (1), (3) and SV PLATE (2). When severe dust/liquid protection specification is specified, ...

  • Page 111

    B-82585EN/02 4.REPLACING PARTS - 87 - Parts Name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A6-BA-4X8(*1) 4 PLATED BOLT A97L-0218-0546#040808BC(*2) 4 PLATED BOLT A97L-0218-0546#040808EN(*3) 4 1 PLATED BOLT A97L-0218-0546#041010EN(*4) 4 A290-7139-X433 1 A290-7139-Y433(*3) 1 ...

  • Page 112

    4.REPLACING PARTS B-82585EN/02 - 88 - 4.18 SEALANT APPLICATION Washing and degreasing the surfaces to be sealed 1 After dismounting the reducer from the arm, apply releasant (Loctite Gasket Remover) to the arm’s surface from which the reducer was dismounted, then wait until the sealant (Locti...

  • Page 113

    B-82585EN/02 5.REPLACING CABLES - 89 - 5 REPLACING CABLES Replace the cables every four years (15,360 hours). When the cable is broken or damaged or shows signs of wear, replace it according to this chapter. Precautions to be observed when handling the pulse coder cable The pulse coder cable ...

  • Page 114

    5.REPLACING CABLES B-82585EN/02 - 90 - 5.1 CABLE WIRING Followings are the routing of the robot cables. K101(J1 toJ6 power,pulse coder)K102(J2 power)K103(J2 pulse coder)K104(J3 power)K105(J3 pulse coder)K106(J4 to J6 power)K107(J4 to J6 pulse coder)K108(RO)K109(J4 power)K110(J5 power)K111(...

  • Page 115

    B-82585EN/02 5.REPLACING CABLES - 91 - K101(J1 to J5 power pulse coder)K102(J2 power)K103(J2 pulse coder)K104(J3 power)K105(J3 pulse coder)K106(J4 to J5 power)K107(J4 to J5 pulse coder)K108(RO)K110(J4 power)K111(J4 pulse coder)K112(J5 power)K113(J5 pulse coder)K114(End effector) Fig. 5.1 (b)...

  • Page 116

    5.REPLACING CABLES B-82585EN/02 - 92 - 5.2 CABLE FORMING When replacing cables, clamp the cable at the position specified in Fig.5.2 (a) to (d) using a clamp or a nylon band. Otherwise, cables can be loosened or pulled by force to cause their disconnection. Refer to the Fig.5.2 (a) to (d) for t...

  • Page 117

    B-82585EN/02 5.REPLACING CABLES - 93 - M3BKM3MM3M1 K104M5M1 K110M5MM4M1 K109M4MYV2YV1 K108M456M1 K106M4M1M5M1M6M1M6M1 K112M6MM2M1 K102M2MM2BKK101K102K104K106K103K105K113K108K109K110K112K107M1MM1BKM2MM2BKM3MM3BKK111M5PM6PM4MM5MM6MM3PM4PM2PEEEE1 K114K114EEConnector platerelay in J2 baserelay in J3...

  • Page 118

    5.REPLACING CABLES B-82585EN/02 - 94 - M3BKM3MM3M1 K104M5M1 K110M5MM4M1 K109M4MYV2YV1 K108M2M1 K102M2MM2BKK101K102K104K106K103K105K113K108K110K112K107M1MM1BKM2MM2BKM3MM3BKK111M4PM5PM4MM5MM3PM2PEEEE1 K114K114EEConncetor platerelay in J2 baserelay in J3 armrelay in J3 armClampJ4-2ClampJ4-1ClampJ4-...

  • Page 119

    B-82585EN/02 5.REPLACING CABLES - 95 - 5.3 CABLE AND AIR TUBE REPLACEMENT This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables. See section 5.1 for the configuration of the mechanical unit cables. It is necessary to perform after cable repla...

  • Page 120

    5.REPLACING CABLES B-82585EN/02 - 96 - 1234567 Fig.5.3.1 (a) Remove the J2 base cover Parts name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A97L-0218-0504#M4X10(*1) 3 2.0Nm(20kgfcm) PLATED BOLT A97L-0218-0496#M4X12BC (*2) 8 4.5Nm(46kgfcm) 1 PLATED BOLT A97L-0218-0496#M4X12EN (*3) ...

  • Page 121

    B-82585EN/02 5.REPLACING CABLES - 97 - パルスコーダ線Pulsecoder line(BLUEXWHITE)AABB継手Panel unionケーブル K105Cable K105ケーブル K104Cable K104ケーブル K103Cable K103ケーブル K102Cable K102AIR 1(BLACK)AIR 1(BLACK)AIR 2(WHITE)AIR 2(WHITE)パワー線Power line(REDXWHITE...

  • Page 122

    5.REPLACING CABLES B-82585EN/02 - 98 - AIR 1(O4 BLACK)AIR 2(O6 WHITE)パルスコーダ線Pulsecoder line(BLUEXWHITE)パワー線Power line(REDXWHITE)M2M1M3M1M456M1M2P1M3P1M456PEE1YV1EXT(O4 WHITE)DETAIL Fケーブル K103Cable K103ケーブル K102Cable K102SECTION D-Dケーブル K105Cable K105...

  • Page 123

    B-82585EN/02 5.REPLACING CABLES - 99 - 123 Fig.5.3.1(d) Remove the cover B (When only severe dust/liquid protection specification is specified) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H or LR Mate 200iC/5LC,5WP,5C is specified. Parts name Specificat...

  • Page 124

    5.REPLACING CABLES B-82585EN/02 - 100 - AIR 1(BLACK)AIR 2(WHITE)パルスコーダ線Pulsecoder line(BLUEXWHITE)パワー線Power line(REDXWHITE)ナイロンバンドNylon bandマーキングを合わせること。ADJUST THE MARKING.AIR 1(BLACK)AIR 2(WHITE)DETAIL CCバッテリボックス端...

  • Page 125

    B-82585EN/02 5.REPLACING CABLES - 101 - Parts name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A6-BA-4X10(*1) 4 2.0Nm(20kgfcm) PLATED BOLT A97L-0218-0496#M4X10BC (*2) 4 4.5Nm(46kgfcm) 1 PLATED BOLT A97L-0218-0496#M4X10EN (*3) 4 4.5Nm(46kgfcm) 2 BOLT A6-BA-4X8 4 LT242 A290-7139-X23...

  • Page 126

    5.REPLACING CABLES B-82585EN/02 - 102 - 5.3.2 REPLAING CABLE K106, K107, K108 and Air tube (J2 base to J3 casing) 1 Turn off the power of the controller and remove cable of controller side from connector plate of back of J1-axis. 2 Remove the J3 arm cover which is in view of in front of the rob...

  • Page 127

    B-82585EN/02 5.REPLACING CABLES - 103 - 123 Fig.5.3.2 (a) Remove the J2 arm cover Parts name Specifications Number Loctite Torque N-m (kgf-cm)BOLT A97L-0218-0504#M4x10(*1) 3 2.0Nm(20kgfcm) PLATED BOLT A97L-0218-0496#M4X12BC (*2) 11 4.5Nm(46kgfcm) 1 PLATED BOLT A97L-0218-0496#M4X12EN (*3) 11 ...

  • Page 128

    5.REPLACING CABLES B-82585EN/02 - 104 - CABLE黒BLACK赤RED青BLUE黄YELLOW緑GREEN透明CLEAR橙ORANGEナイロンバンドNYLON BANDDETAIL DエアチューブAir tubeCCSECTION C-CDケーブルCableクランプ J4-2A290-7139-X334MARKINGナイロンバンドNYLON BANDナイロンバンドNYLON B...

  • Page 129

    B-82585EN/02 5.REPLACING CABLES - 105 - Parts name Specifications Number Loctite Torque N-m (kgf-cm) BOLT A97L-0218-0504#M4X10(*1) 4 2.0Nm(20kgfcm) PLATED BOLT A97L-0218-0417#M4X12BC (*2) 6 4.5Nm(46kgfcm) 1 PLATED BOLT A97L-0218-0417#M4X12EN (*3) 6 4.5Nm(46kgfcm) A290-7139-X404 (*1) 1 A290...

  • Page 130

    5.REPLACING CABLES B-82585EN/02 - 106 - GGCABLE K103CABLE K105CABLE K102CABLE K104DETAIL HSECTION G-GHClamp J2-2A290-7139-X334 Fig.5.3.2 (e) Cable clamp in J3 casing part 1243 Fig.5.3.2 (f) Remove the guide arm Parts name Specifications Number Loctite Torque N-m (kgf-cm)SEAL BOLT A97L-0218-042...

  • Page 131

    B-82585EN/02 5.REPLACING CABLES - 107 - (*1) When not severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*2) When severe dust/liquid protection specification of LR Mate 200iC, LR Mate 200iC/5L,5H is specified. (*3) When LR Mate 200iC/5LC,5WP,5C is sp...

  • Page 132

    5.REPLACING CABLES B-82585EN/02 - 108 - 5.3.3 REPLAING CABLE K102, K103, K104, K105, K109, K110, K111, K112, K113 1 Turn off the power of the controller. 2 (In case of except LR Mate 200iC/5H) In case of cable K102 and K103, remove J2-axis motor, In case of cable K104 and K105, remove J3-axis m...

  • Page 133

    B-82585EN/02 5.REPLACING CABLES - 109 - 5.3.4 REPLAING CABLE K104 1 Turn off the power of the controller. 2 Remove J3 arm cover. (See Fig.5.3.2 (a)) 3 Remove nut on J3 arm. 4 Remove relay of K107 and cable K114. 5 Replace cable to new one, and assemble it by opposite procedure. Spread Loctite r...

  • Page 134

    5.REPLACING CABLES B-82585EN/02 - 110 - 5.3.5 REPLAING AIR TUBE Replacing procedure of air tube between connector plate to J2 base 1 See section 5.3.1. Replacing procedure of air tube between J2 base to J3 casing 1 See section 5.3.2. Replacing procedure of air tube between J3 casing to J3 a...

  • Page 135

    B-82585EN/02 5.REPLACING CABLES - 111 - 570290580300AIR 2(白 WHITE)AIR 1(黒 BLACK)→ J2ベース J2 base分線盤 ←Connector panel Fig.5.3.5 (a) Marking of air tube (connector plate to J2 base)( LR Mate 200iC, LR Mate 200iC/5L,5WP,5H) 570290580300AIR 2(φ6 白 WHITE)AIR 1...

  • Page 136

    5.REPLACING CABLES B-82585EN/02 - 112 - AIR 2(白 WHITE)AIR 1(黒 BLACK)3405701010800390390J3ケーシング ←J3 casing→ J2ベース J2 base Fig.5.3.5 (d) Marking of air tube (J2 base to J3 casing) ( LR Mate 200iC/5L) AIR 2(φ6 白WHITE)AIR 1(φ4 黒 BLACK)340570910700EXT(φ4 白 WHITE)3...

  • Page 137

    B-82585EN/02 5.REPLACING CABLES - 113 - プラグPlug継手Panel union赤RED(*1)青BLUE(*1)黒BLACK(*1)黄YELLOW(*3)緑GREEN(*3)透明CLEAR(*2)橙ORANGE(*2)A05B-1139-BBCABLE黒BLACK赤RED青BLUE黄YELLOW緑GREEN透明CLEAR橙ORANGEナイロンバンドNYLON BANDコネクタキー向きKEY DIRECT...

  • Page 138

    5.REPLACING CABLES B-82585EN/02 - 114 - Parts name Specifications NumberLoctite Torque N-m (kgf-cm)BOLT A6-BA-4X8(*1) 4 SEAL BOLT A97L-0218-0546#040808BC(*2) 4 4.5Nm(46kgfcm) 1 SEAL BOLT A97L-0218-0546#040808EN(*3) 4 4.5Nm(46kgfcm) BOLT A6-BA-4X8(*1) 2 SEAL BOLT A97L-0218-0546#040808BC(*2...

  • Page 139

    B-82585EN/02 5.REPLACING CABLES - 115 - エアチューブ(黒)Air tube (Black)エアチューブ(オレンジAir tube (Orange)エアチューブ(緑)Air tube (Green)エアチューブ(青)Air tube (Blue)エアチューブ(赤)Air tube (Red)エアチューブ(黄色)Air tube (Yellow)エアチュ...

  • Page 140

    5.REPLACING CABLES B-82585EN/02 - 116 - エアチューブ(黒)Air tube (Black)エアチューブ(緑)Air tube (Green)エアチューブ(青)Air tube (Blue)エアチューブ(赤)Air tube(Red)エアチューブ(黄)Air tube(Yellow)エアチューブ(黒)Air tube (Black)エアチューブ(白)Air...

  • Page 141

    B-82585EN/02 6.ADJUSTMENTS - 117 - 6 ADJUSTMENTS Each part of the mechanical units of a robot is set to the best condition before the robot is shipped to the customer. The customer does not need to make adjustments on the robot when it is delivered.

  • Page 142

    6.ADJUSTMENTS B-82585EN/02 - 118 - 6.1 ADJUSTING TENSION OF BELT Please use the following tension meters for the tension adjustment of the belt. Instrument Specifications Vendor Manufacturer model No. Application Tension meter A97L-0218-0700 Mitsuboshi Belting Ltd.DOCTOR TENSION TYPE- Adjustme...

  • Page 143

    B-82585EN/02 6.ADJUSTMENTS - 119 - TENSIONADJUSTING BOLT Fig. 6.1(b) Adjusting tension of J5 belt TENSIONADJUSTING BOLT Fig. 6.1(c) Adjusting tension of J6 belt Table 6.1(b) Measurement condition of J5 belt BELT TENSION 27.5 2.5N MASS 0.0171kg WIDTH 6mm SPAN 180mm Table 6.1(c) Measurement c...

  • Page 144

    6.ADJUSTMENTS B-82585EN/02 - 120 - 6.2 MASTERING Mastering is an operation performed to associate the angle of each robot axis with the pulse count value supplied from the absolute pulse coder connected to the corresponding axis motor. To be specific, mastering is an operation for obtaining th...

  • Page 145

    B-82585EN/02 6.ADJUSTMENTS - 121 - This MAINTENANCE MANUAL describes fixture position mastering that is mainly required during replacement of parts. For other mastering methods, refer to OPERATOR’S MANUAL. Once mastering is performed, it is necessary to carry out positioning, or calibration....

  • Page 146

    6.ADJUSTMENTS B-82585EN/02 - 122 - 1 When the controller power is switched on again, the message “Servo 075 Pulse mismatch” appears again. 2 Rotate the axis for which the message mentioned above has appeared through 10 degrees in either direction. 3 Press [FAULT RESET]. The alarm is reset. ...

  • Page 147

    B-82585EN/02 6.ADJUSTMENTS - 123 - 2 Mount the fixture on the J1–axis base with bolts as shown in Fig.6.2.2 (b) M8X25(4pcs)PINA290-7139-X914PINA290-7139-X913 Fig. 6.2.2 (b) Mounting dial indicator 3 Mount the fixture to the wrist flange as shown Fig.6.2.2 (c). By using the calibration block,...

  • Page 148

    6.ADJUSTMENTS B-82585EN/02 - 124 - NO.5NO.4NO.6NO.3NO.2NO.1FIXTURE CA290-7139-X917FIXTURE BA290-7131-X964FIXTURE AA290-7139-X916FIXTURE DA290-7135-X966CALIBRATION BLOCKBOLT M5CLAMPHow to assemble diag gauge Fig. 6.2.2 (c) Mounting the wrist fixture 4 Assemble the fixture to the wrist flange as...

  • Page 149

    B-82585EN/02 6.ADJUSTMENTS - 125 - Mastering 1 Press MENUS. 2 Press NEXT and select SYSTEM. 3 Press F1, [TYPE]. 4 Select Mater/Cal. SYSTEM Master/Cal JOINT 10% 1 FIXTURE POSITION MASTER 2 ZERO POSTIION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALLIBRATE Press ...

  • Page 150

    6.ADJUSTMENTS B-82585EN/02 - 126 - (In case of LR Mate 200iC/5H) 1) Move the robot gradually so that dial gages No.1, No.2, No.4, No.5 and No.6 shown in Fig.6.2.2 (c) touch the points indicated by arrows No.1, No.2, No.4, No.5 and No.6 shown in Fig.6.2.2 (e). (Dial gauge No.3 is not used.) 2) Mo...

  • Page 151

    B-82585EN/02 6.ADJUSTMENTS - 127 - AXIS J1 J2 J3 J4 J5 J6POSITION90 deg 61.112 deg-85.965 deg0 deg-94.035 deg0 degMASTERING POSITIONNO.1NO.2NO.6NO.3(*)NO.5NO.4LR Mate 200iC,LR Mate 200iC/5WP,5CAXIS J1 J2 J3 J4 J5POSITION90 deg 61.112 deg-85.965 deg-94.035 deg0 degMASTER...

  • Page 152

    6.ADJUSTMENTS B-82585EN/02 - 128 - AXIS J1 J2 J3 J4 J5 J6POSITION 52.147 degMASTERING POSITIONLR Mate 200iC/5L,5LCNO.1NO.2NO.6NO.3NO.4NO.5 -94.284 deg 0 deg -85.716 deg 0 deg 90 deg Fig. 6.2.2 (f) Mastering posture (LR Mate 200iC/5L,5LC)

  • Page 153

    APPENDIX

  • Page 154

  • Page 155

    B-82585EN/02 APPENDIX A.SPARE PARTS LIST - 131 - A SPARE PARTS LIST Table A (a1) List of Basic cable (Specifications of Standard,5WP,5C) Name Specifications Remarks A660-8016-T285 RMP(Standard,5C) K101 A660-8016-T495 RMP(5WP) K102 A660-4004-T706 J2 power K103 A660-2006-T657 J2 pulse coder K104 ...

  • Page 156

    A.SPARE PARTS LIST APPENDIX B-82585EN/02 - - 132Table A (a2) List of Basic cable (Specifications of 5L,5LC) Name Specifications Remarks K101 A660-8016-T285 RMP K102 A660-4004-T822 J2 power K103 A660-2006-T789 J2 pulsecoder K104 A660-4004-T823 J3 power K105 A660-2006-T790 J3 pulsecoder K106 A6...

  • Page 157

    B-82585EN/02 APPENDIX A.SPARE PARTS LIST - - 133 Table A (b1) Motor (Standard, 5L,5LC,5WP,5C) Name Specifications Remarks βiSR1/6000 A06B-0116-B855#0048 J1, J2-axis βiSR0.5/6000 A06B-0115-B855#0048 J3-axis βiSR0.4/4000 A06B-0114-B205#0048 J4-axis (3-axis brake type) βiSR0.4/4000 A06B-011...

  • Page 158

    A.SPARE PARTS LIST APPENDIX B-82585EN/02 - - 134Table A (c) Reducer Name Specifications Remarks Harmonic drive A97L-0218-0812#80 J1-axis(Standard.5L,5H) Harmonic drive A97L-0218-0812#80C J1-axis(5C,5LC,5WP) Harmonic drive A97L-0218-0813#120 J1-axis(Standard.5L,5H) Harmonic drive A97L-0218-08...

  • Page 159

    B-82585EN/02 APPENDIX A.SPARE PARTS LIST - - 135Table A (f) Bearing, belt Name Specifications Remarks Bearing A97L-0001-0192#08Z000A J1-axis reducer Bearing A97L-0218-0596 J4-axis reducer(Standard.5L,5LC,5WP,5C) Belt A98L-0040-0190#007-098 J3-axis motor Belt A98L-0040-0227#006-100 J5-axis m...

  • Page 160

    A.SPARE PARTS LIST APPENDIX B-82585EN/02 - - 136Table A (i) Seal bolt Name Specifications Remarks J 1, J3, J4, J5, J6-axis motor J2, J3, J5-axis reducer Wrist unit, J4 pipe Standard,5L,5LC,5WP,5CSeal bolt A97L-0218-0423#030606 J 1, J3, J4, J5-axis motor J2, J3, J4-axis reducer Wrist unit 5H...

  • Page 161

    B-82585EN/02 APPENDIX A.SPARE PARTS LIST - - 137Table A (j) Spring pin, Stopper, Wrist unit, Sheet Name Specifications Remarks Spring pin A6-PS-5X18S J3 Stopper Stopper A290-7139-X441 J3Stopper A290-7139-V501 J6-axis reducer is included (Standard,5L not severe dust/liquid protection specific...

  • Page 162

    A.SPARE PARTS LIST APPENDIX B-82585EN/02 - - 138Table A (k) Air tube (Standard,5WP,5C,5H) Name Specifications Remarks Air tube A97L-0218-0114#ABL640R0 6mm BLACK AIR1 Connector plate to J2base Air tube A97L-0218-0010#AAL580R0 4mm BLACK AIR1 (5C) Connector plate to J2base Air tube A97L-0218...

  • Page 163

    B-82585EN/02 APPENDIX A.SPARE PARTS LIST - - 139Table A (k2) Air tube(5L,5LC) Name Specifications Remarks Air tube A97L-0218-0114#ABL580R0 6mm BLACK AIR1(5L) Connector plate J2 base Air tube A97L-0218-0010#AAL580R0 4mm BLACK AIR1 (5C) Connector plate J2 base Air tube A97L-0218-0114#BBL57...

  • Page 164

    A.SPARE PARTS LIST APPENDIX B-82585EN/02 - - 140Table A (l) Solenoid valve (Either the following is installed by the option specification) (except H001,H006,H011and H016) Name Specifications Remarks Solenoid valve A97L-0218-0113#D1 Double solenoidX1(2 positionX1) Solenoid valve A97L-0218-0113...

  • Page 165

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 141 - B CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM

  • Page 166

    B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM APPENDIX B-82585EN/02 - 142 - - Fig. B (a) CIRCUIT DIAGRM (LR Mate 200iC 3-axes brake type)

  • Page 167

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 143 - LR Mate 200iC (3BK)

  • Page 168

    B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM APPENDIX B-82585EN/02 - 144 - - Fig.B(b) Circuit diagram (LR Mate 200iC 6-axes brake type When H301 is specified) (LR Mate 200iC/5C When H321 is specified)

  • Page 169

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 145 - LR Mate 200iC (6BK)LR Mate 200iC/5C

  • Page 170

    B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM APPENDIX B-82585EN/02 - 146 - - Fig.B(c) Circuit diagram (LR Mate 200iC 6-axes brake type When H302 is specified)

  • Page 171

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 147 -

  • Page 172

    B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM APPENDIX B-82585EN/02 - 148 - - Fig.B(d) Circuit diagram (LR Mate 200iC 6-axes brake type When H006 is specified) (LR Mate 200iC/5C H006 is specified)

  • Page 173

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 149 -

  • Page 174

    B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM APPENDIX B-82585EN/02 - 150 - - Fig.B(e) Circuit diagram (LR Mate 200iC/5L)

  • Page 175

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 151 - LR Mate 200iC/5L

  • Page 176

    B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM APPENDIX B-82585EN/02 - 152 - - Fig.B(f) Circuit diagram (LR Mate 200iC/5WP)

  • Page 177

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 153 - LR Mate 200iC/5WP

  • Page 178

    B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM APPENDIX B-82585EN/02 - 154 - - Fig. B(g) CIRCUIT DIAGRAM (LR Mate 200iC/5H 3-axes brake type)

  • Page 179

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 155 - LR Mate 200iC/5H (3BK)

  • Page 180

    B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM APPENDIX B-82585EN/02 - 156 - - Fig. B(h) CIRCUIT DIAGRAM (LR Mate 200iC/5H 6-axes brake type)

  • Page 181

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 157 - LR Mate 200iC/5H (5BK)

  • Page 182

    B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM APPENDIX B-82585EN/02 - 158 - RO1RO2RO1RO2J1 connector plateAIR 1J1 connector plateAIR 2J3 armJ3 casingExhaust port Fig. B(i) Air pressure diagram (Double solenoid valve 1 A05B-1139-H002,H012,H017,H022,H032 is specified) RO1RO2RO3RO4RO4RO1RO3RO2...

  • Page 183

    B-82585EN02 APPENDIX B.CIRCUIT DIAGRAM, AIR PRESSURE DIAGRM - 159 - RO2RO3RO4RO5RO6RO1RO4RO1RO3RO2RO5RO6J3 casingExhaust portJ1 connector plateAIR 2J1 connector plateAIR 1J3 arm Fig. B(k) Air pressure diagram (Double solenoid valve 3 A05B-1139-H004,H014,H024 is specified) RO2RO1RO3RO4RO5RO...

  • Page 184

    C.PERIODIC MAINTENANCE TABLE APPENDIX B-82585EN/02 - 160 - C PERIODIC MAINTENANCE TABLE FANUC Robot LR Mate 200iC, LR Mate 200iC/5C, /5L, /5LC Periodic Maintenance Table Working time (H) Items Check time Oil Grease amountFirst check3203 months9606 months19209 months28801 years384048005760 ...

  • Page 185

    B-82585EN/02 APPENDIX C.PERIODIC MAINTENANCE TABLE - 161 - 3 years 11520 12480 13440 14400 4 years 15360 16320 17280 18240 5 years19200 20160 21120 220806 years23040 24000 24960 259207 years 26880 27840 28800 297608 years30720 Item○ ○ ○ ○ ○ 1○ ○ ○ ○ ○...

  • Page 186

    C.PERIODIC MAINTENANCE TABLE APPENDIX B-82585EN/02 - 162 - FANUC Robot LR Mate 200iC/5WP Periodic Maintenance Table Working time (H) Items Check time Oil Grease amountFirst check3203 months9606 months19209 months28801 years384048005760 6720 2 years 7680 86409600 1056...

  • Page 187

    B-82585EN/02 APPENDIX C.PERIODIC MAINTENANCE TABLE - 163 - 3 years 11520 12480 13440 14400 4 years 15360 Item ○ 1○ 2○ 3○ ○ ○ ○ 4● 5 6 7○ ○ ○ ○ 8○ ○ ○ ○ 9○ ○ 10 Overhaul 11

  • Page 188

    C.PERIODIC MAINTENANCE TABLE APPENDIX B-82585EN/02 - 164 - FANUC Robot LR Mate 200iC/5H Periodic Maintenance Table Working time (H) Items Check time Oil Grease amountFirst check3203 months9606 months19209 months28801 years384048005760 6720 2 years 7680 86409600 105601 Check ...

  • Page 189

    B-82585EN/02 APPENDIX C.PERIODIC MAINTENANCE TABLE - 165 - 3 years 11520 12480 13440 14400 4 years 15360 16320 17280 18240 5 years19200 20160 21120 220806 years23040 24000 24960 259207 years 26880 27840 28800 297608 years30720 Item○ ○ ○ ○ ○ 1○ ○ ○ ○ ○...

  • Page 190

    D.MOUNTING BOLT TORQUE LIST APPENDIX B-82585EN/02 - 166 - D MOUNTING BOLT TORQUE LIST NOTE When applying Loctite to the important bolt tightening points, make sure that it is applied to the entire longitudinal portion in the engaging section of the female threads. If it is applied to the male t...

  • Page 191

    B-82585EN/02 APPENDIX D.MOUNTING BOLT TORQUE LIST - 167 - If no tightening torque is specified for a bolt, tighten it according to this table. Recommended bolt tightening torques Unit: Nm (kgf-cm) Hexagon socket head bolt (Steel in strength category 12.9)Hexagon socket head bolt (stainless) Hex...

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    B-82585EN/02 INDEX i-1 INDEX<Number> 1.5-year (5,760 hours) checks ...........................................7 1-year (3,840 hours) checks ..............................................7 2-year (7,680 hours) checks (LR Mate 200iC /5WP) 4-year (15,360 hours) checks (LR Mate 200iC, LR Mate...

  • Page 194

    INDEX B-82585EN/02 i-2 REPLENISH THE GREASE OF THE DRIVE MECHANISM (4 years (11,520 hours) checks) .............15 RESETTING ALARMS AND PREPARING FOR MASTERING.......................................................121 <S> SAFETY PRECAUTIONS ............................................ s-1 ...

  • Page 195

    Revision RecordFANUC Robot LR Mate 200iC MECHANICAL UNIT MAINTENANCE MANUAL (B-82585EN) 02 Feb.,2008Addition of LR Mate 200iC/5L,5LC,5WP,5C Addition of Air pressure diagram Revice 01 Nov., 2007 Edition Date Contents Edition Date Contents

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