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    FANUC Robot seriesMAINTENANCE MANUALB--81595EN/01LR Mate 100i B

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    B--81595EN/01GENERALp--1GENERALThis manual describes the maintenance and connection procedures for therobots listed below.ModelAbbreviationMechanical unitspecificationsFANUC Robot LR Mate100i B(J2, J3 axes with brake)LR Mate 100i BA05B--1137--B201FANUC Robot LR Mate100i B(All axes with brake)LR M...

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    GENERALB--81595EN/01p--2Position of specification number of mechanical unit

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    B--81595EN/01GENERALp--3ItemSpecificationsTypeArticulated typeControlled axes5 axes (J1,J2,J3,J4,J5)InstallationFloor, Upside--downLoad capacity5kgNOTE1Motion rangeNOTE 2J1 AXIS ROTATION320° (5.59 rad)NOTE 2J2 AXIS ROTATION185° (3.23 rad)J3 AXIS ROTATION365° (6.37 rad)J4 AXIS WRIST SWING240° ...

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    GENERALB--81595EN/01p--4NOTE1 When a load of 5 kg is imposed, the wrist is oriented only downward in the neighborhood of thetop of the operation area (with a reach of 600 mm or more).2 Mutual angle with J2--axis: 0 to138.2°.3 Definition of IP codeDefinition of IP656= Dust--tight : Dust does n...

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    Table of ContentsB--81595EN/01c--1GENERALP--1..................................................................SAFETY PRECAUTIONS1. SAFETY PRECAUTIONS3......................................................1.1OPERATOR SAFETY4..............................................................1.1.1Operat...

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    B--81595EN/01TABLE OF CONTENTSc--24.2PROBLEMS AND CAUSES36........................................................4.3REPLACING PARTS AND PERFORMING ADJUSTMENTS38.............................5. ADJUSTING39...............................................................5.1BACKLASH ADJUSTMENT OF THE ...

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    B--81595EN/01TABLE OF CONTENTSc--31.2DETAILS OF THE OPERATING AREA103.............................................2. MECHANICAL COUPLING TO THE ROBOT104..................................2.1WRIST LOAD CONDITIONS105.....................................................2.2INSTALLING THE END EFFECTOR ...

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    SAFETY PRECAUTIONS

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    B--81595EN/011. SAFETY PRECAUTIONSSAFETY PRECAUTIONS31 SAFETY PRECAUTIONSFor the safety of the operator and the system, follow all safety precautionswhen operating a robot and its peripheral devices installed in a work cell.

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    1. SAFETY PRECAUTIONSB--81595EN/01SAFETY PRECAUTIONS4Operator safety is the primary safety consideration. Because it is verydangerous to enter the operating space of the robot during automaticoperation, adequate safety precautions must be observed.The following lists the general safety precaution...

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    B--81595EN/011. SAFETY PRECAUTIONSSAFETY PRECAUTIONS5(9) When adjusting each peripheral device independently, be sure to turnoff the power of the robot.Safety gate which executes with opening the door.Fig.1.1 Safety Fence and Safety Gate

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    1. SAFETY PRECAUTIONSB--81595EN/01SAFETY PRECAUTIONS6The operator is a person who operates the robot system. In this sense, aworker who operates the teach pendant is also an operator. However, thissection does not apply to teach pendant operators.(1) If it is not necessary for the robot to operat...

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    B--81595EN/011. SAFETY PRECAUTIONSSAFETY PRECAUTIONS7While teaching the robot, it is necessary for the operator to enter the workarea of the robot. It is particularly necessary to ensure the safety of theteach pendant operator.(1) Unless it is specifically necessary to enter the robot work area, ...

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    1. SAFETY PRECAUTIONSB--81595EN/01SAFETY PRECAUTIONS8(5) When entering the robot work area, the teach pendant operator shouldenable the teach pendant whenever he or she enters the robot workarea. In particular, while the teach pendant enable switch is off, makecertain that no start command is sen...

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    B--81595EN/011. SAFETY PRECAUTIONSSAFETY PRECAUTIONS9For the safety of maintenance personnel, pay utmost attention to thefollowing.(1) Except when specifically necessary, turn off the power of thecontroller while carrying out maintenance. Lock the power switch,if necessary, so that no other perso...

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    1. SAFETY PRECAUTIONSB--81595EN/01SAFETY PRECAUTIONS10(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 sensorsignal is received.(2) Design the program to stop the robot when an abnormal conditionoccurs in any ot...

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    B--81595EN/011. SAFETY PRECAUTIONSSAFETY PRECAUTIONS11(1) When operating the robot in the jog mode, set it at an appropriatespeed so that the operator can manage the robot in any eventuality.(2) Before pressing the jog key, be sure you know in advance whatmotion the robot will perform in the jog ...

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    1. SAFETY PRECAUTIONSB--81595EN/01SAFETY PRECAUTIONS12(1) To control the pneumatic, hydraulic and electric actuators, carefullyconsider the necessary time delay after issuing each control commandup to actual motion and ensure safe control.(2) Provide the end effector with a limit switch, and cont...

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    B--81595EN/011. SAFETY PRECAUTIONSSAFETY PRECAUTIONS13(1) Never enter the robot work area while the robot is operating. Turn offthe power before entering the robot work area for inspection andmaintenance.(2) If it is necessary to enter the robot work area with the power turnedon, first press the ...

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    1. SAFETY PRECAUTIONSB--81595EN/01SAFETY PRECAUTIONS14Do not step on or climb the robot or controller as it may adversely affectthe robot or controller and you may get hurt if you lose your footing aswell.(1) Step--on prohibitive labelFig.1.6 (a) Step--on Prohibitive LabelBe cautious about a sect...

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    B--81595EN/011. SAFETY PRECAUTIONSSAFETY PRECAUTIONS15A high voltage is applied to the places where this label is attached.Before starting maintenance, turn the power to the control unit off, thenturn the circuit breaker off to avoid electric shock hazards. Be careful withservo amplifier and othe...

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    I. MAINTENANCE

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    MAINTENANCEB--81595EN/011. CONFIGURATION191CONFIGURATIONFig.1 shows the configuration of the mechanical unit.J2 baseJ1 baseAC servo motor for J1--axisAC servo motor for J2--axisJ2 armWrist unitJ3 armAC servo motor for J5--axisAC servo motor for J4--axisAC servo motor for J3--axisFig.1 Mechanical ...

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    MAINTENANCE1. CONFIGURATIONB--81595EN/0120Fig.1.1 shows the J1--axis drive mechanism.The rotation of the AC servo motor is decelerated by the reducer via thecenter gear and the decelerated rotation rotates the J2--axis base. TheJ2--axis base is supported by the J1--axis base via the J1 axis reduc...

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    MAINTENANCEB--81595EN/011. CONFIGURATION21Fig.1.3 shows the J3--axis drive mechanism. The rotation of the AC servomotor is decelerated by the reducer and rotates the J3--axis arm via thegear. The J3--axis arm is supported by the J2--axis arm via the gear andthe bearing.J3 armBearingGearJ2 armGear...

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    MAINTENANCE1. CONFIGURATIONB--81595EN/0122Fig.1.5 shows the J5--axis drive mechanism. The rotation of the AC servomotor is decelerated by the reducer and rotates the output flange.J5 reducerOutput flangeMotor for J5--axisFig.1.5 J5--axis drive mechanism1.5J5--AXIS DRIVEMECHANISM

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    MAINTENANCEB--81595EN/011. CONFIGURATION23(a) When 2 axes break type is A05B--1137--B201.SpecificationsAxisRemarksA06B--0115--B075#0008J1βM0.5/4000A06B--0115--B275#0008J2βM0.5/4000 with brakeA06B--0115--B275#0008J3βM0.5/4000 with brakeA06B--0114--B075#0008J4βM0.4/4000A06B--0114--B075#0008J5β...

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    MAINTENANCE2. PREVENTIVE MAINTENANCEB--81595EN/01242PREVENTIVE MAINTENANCEOptimum perfomance of the robot can be maintained for a long time byperforming the periodic maintenance procedures presented in thischapter.NOTEThe FANUC robot assumes a yearly run time of 3840 hours.If you use the robot mo...

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    MAINTENANCEB--81595EN/012. PREVENTIVE MAINTENANCE25Clean each part, and visually check component parts for damage beforedaily system operation.Check the following items as the occasion demands.a) Before automatic operationItemCheck itemsCheck points1When aircontrol set isprovided.Air pressureChec...

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    MAINTENANCE2. PREVENTIVE MAINTENANCEB--81595EN/0126Check 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.ItemCheck itemsCheck points1Loose boltCheck if the cover mounting ...

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    MAINTENANCEB--81595EN/012. PREVENTIVE MAINTENANCE27The following tools and instruments are required for the maintenanceprocedures contained in this manual.a) Measuring instrumentsInstrumentsAccuracy/ToleranceApplicationsDial gauge1/100 mmMeasurement of positioningand backlash.Slide calipers150 mm...

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    MAINTENANCE3. PERIODIC MAINTENANCEB--81595EN/01283PERIODIC MAINTENANCE

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    MAINTENANCEB--81595EN/013. PERIODIC MAINTENANCE29NOTEIncorrect greasing rapidly increases the pressure in the greasebus. This may cause the seal to be damaged, resulting in agrease leak or operation failure.When greasing the robot, note the following points:1 Remove the grease outlet (The plug or...

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    MAINTENANCE3. PERIODIC MAINTENANCEB--81595EN/0130Table 3.1 (a) Greasing points (LR Mate 100)Greasing pointGreaseQtyJ1--axis reducerHarmonic greaseSK 3(N t )30ccJ2--axis reducerSK--3(Note)20ccJ3--axis gear box100ccJ4--axis gear box380ccJ5--axis reducer5ccNOTEFANUC specification number for SK--3 ha...

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    MAINTENANCEB--81595EN/013. PERIODIC MAINTENANCE31J4 gear box bleed holeM6×6 (Seal bolt)J3 gear box greasing pointM6×6 (Seal bolt)J3 gear box bleed holeM6×6 (Seal bolt)J4 gear box greasing pointM6×6 (Seal bolt)J2 reducer bleed holeM6×8 (Seal bolt)J2 reducer greasing pointJ1 reducer greasing p...

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    MAINTENANCE3. PERIODIC MAINTENANCEB--81595EN/0132The memory holding the position data of each axis is backed up bybatteries.Replace the backup batteries according to the schedule described inSection NO TAG.Also, replace the backup batteries when the BLAL alarm is output toindicate that the voltag...

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    MAINTENANCEB--81595EN/013. PERIODIC MAINTENANCE33BoltBattery caseBatteries(4 pieces, D size, 1.5V)Case capFig.3.2 Replacing batteries

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    MAINTENANCE4. TROUBLESHOOTINGB--81595EN/01344 TROUBLESHOOTING

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    MAINTENANCEB--81595EN/014. TROUBLESHOOTING35The source of mechanical unit problems might be difficult to locatebecause of overlapping causes.Problems might become furthercomplicated if they are not corrected properly. Therefore, it is necessaryto keep an accurate record of problems and to take pr...

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    MAINTENANCE4. TROUBLESHOOTINGB--81595EN/0136Major problems in the mechanical unit and their probable causes are listedbelow:Contact FANUC, if the cause of a failure or the action to be taken cannotbe determined.Table 4.2 (a) Problems and causesSymptomCauseActionRemarksBZAL alarmoccursThe voltage ...

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    MAINTENANCEB--81595EN/014. TROUBLESHOOTING37SymptomRemarksActionCauseAbnormaldInsufficient greasing for a gear or reducerFeed grease.See section 3.1.soundForeign matter caught in a gear orreducerClean the gear and reducerthen feed grease.See sections 6.2 through6.*, and section 3.1.Gear adjustmen...

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    MAINTENANCE4. TROUBLESHOOTINGB--81595EN/0138Adjustments are necessary whenever a part is replaced.The table below shows replacement of parts and the required adjustmentitems.Parts to be replaced orfunctions to be changedAdjustmentReplacement of cable(a) Routing of cable(b) Quick MasteringReplacem...

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    MAINTENANCEB--81595EN/015. ADJUSTING395ADJUSTINGMechanical parts have been adjusted to the optimum condition at the timeof shipment. Therefore, adjustment by the customer is normally notneeded at the time of delivery.Adjustment should be made as specified in this section, however, after along per...

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    MAINTENANCE5. ADJUSTINGB--81595EN/01401 Preparation for adjustment1) Remove bolt (2), and remove packing (3) and J4 gear box cover (1).At this time, grease can drip. Use care.2) Before making a backlash adjustment, clean off grease from theinside of the gear box so that the gear and bolt can be v...

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    MAINTENANCEB--81595EN/015. ADJUSTING41No.NameSpecificationsQ’tyLOCTITETorque N-m (kgf-m)1G.B. COVER 2A290-7137-X40412BOLTA97L-0218-0496#M5X12ZN83G.B. PACKING 2A290-7137-X42814BOLTA6-BA-5X104 LT2625.6 (57)5GEAR W3 ASS’YA290-7137-V40216SEAL BOLTA97L-0218-0495#05101045.6 (57)7GEAR W2 ASS’YA290...

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    MAINTENANCE5. ADJUSTINGB--81595EN/0142Mastering is an operation performed to associate the angle of each robot axiswith the pulse count value supplied from the absolute pulse coder connectedto the corresponding axis motor. To be specific, mastering is an operation forobtaining the pulse count val...

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    MAINTENANCEB--81595EN/015. ADJUSTING43Before performing mastering because a motor is replaced, it is necessaryto release the relevant alarm and display the positioning menu.“Servo 062 BZAL” or “Servo 075 Pulse mismatch”1To reset the ”Servo 062 BZAL” alarm, follow steps 1 to 7.1Press M...

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    MAINTENANCE5. ADJUSTINGB--81595EN/0144Jig position mastering is performed using a mastering jig. This masteringis carried out in the predetermined jig position.Jig position mastering is accurate because a dedicated mastering jig isused. Jig position mastering is factory--performed. It is unnecess...

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    MAINTENANCEB--81595EN/015. ADJUSTING452) Mount the fixture on the J1--axis base with bolts as shown inFig.5.2.3(b).M8×16 (2 pieces)φ6 Positioning pin (2 pieces)Fig.5.2.3 (b) Mounting fixture base

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    MAINTENANCE5. ADJUSTINGB--81595EN/01463) Mount the wrist fixture as shown in Fig.5.2.3 (c).Adjust the dial gauge to 3.00 mm using the calibration block, andtighten it with M5 bolt as shown in Fig.5.2.3 (c). (Do not tighten thebolt too strongly or the dial indicator will be broken.)M5×16 (Four)Bo...

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    MAINTENANCEB--81595EN/015. ADJUSTING474) Mounting the fixture to the wristMount the fixture to the wrist flange as shown in Fig.5.2.3 (d).φ5 Positioning pinM5×16Fig.5.2.3 (d) Mounting fixture to wrist

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    MAINTENANCE5. ADJUSTINGB--81595EN/01481) Press MENUS.2) Press NEXT and select SYSTEM.3) Press F1, [TYPE].4) Select Master/Cal.SYSTEM Master/CalJOINT 10%[ TYPE ]LOADRES_PCA1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATEPress ’ENT...

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    MAINTENANCEB--81595EN/015. ADJUSTING49NOTENo check is made on the axis movable range duringmastering. Be very careful when running the robot.Continuing axis movement may result in the mechanicalstopper being bumped.

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    MAINTENANCE5. ADJUSTINGB--81595EN/0150Mastering positionAxisPositionFig.5.2.3 (e) Mastering attitude

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    MAINTENANCEB--81595EN/015. ADJUSTING51Zero--position mastering (eye mark mastering) is performed with all axesset at the 0--degree position. A zero--position mark (eye mark) is attachedto each robot axis. This mastering is performed with all axes set at the0--degree position using their respectiv...

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    MAINTENANCE5. ADJUSTINGB--81595EN/0152Marking J4Marking J3Marking J2Marking J1Reamed holeThe J5--axis zero degree posi-tion has not been attached yet,when the unit leaves the factory.The J5--axis is in the zero de-gree position when the outputflange and the reamed hole ispositioned, as shown in t...

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    MAINTENANCEB--81595EN/015. ADJUSTING53Simplified mastering is performed at a user--specified position. Thecorresponding count value is obtained from the rotation speed of the pulsecoder connected to the relevant motor and the rotation angle within onerotation. Simplified mastering uses the fact t...

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    MAINTENANCE5. ADJUSTINGB--81595EN/01541Display the Master/Cal screen.SYSTEM Master/CalJOINT 10%[ TYPE ]LOADRES_PCA1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATEPress ’ENTER’ or number key to select.DONE2Release brake control,...

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    MAINTENANCEB--81595EN/015. ADJUSTING55Single axis mastering is performed for one axis at a time. The masteringposition for each axis can be specified by the user.Single axis mastering can be used, if mastering data for a specific axis islost, for example, because a low voltage has been detected o...

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    MAINTENANCE5. ADJUSTINGB--81595EN/01561Select SYSTEM.2Select Master/Cal.SYSTEM Master/CalJOINT 10%[ TYPE ]LOADRES_PCA1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATEPress ’ENTER’ or number key to select.3Select 4, Single Axis M...

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    MAINTENANCEB--81595EN/015. ADJUSTING577Press F5 [EXEC]. Mastering is performed. So, SEL is reset to 0, andST is re--setto2or 1.SINGLE AXIS MASTERJOINT 30%GROUPEXEC1/9GROUPEXECF5ACTUAL AXIS(MATR POS)(SEL)[ST]J125.255(0.000)(0)[2]J225.550(0.000)(0)[2]J3-50.000(0.000)(0)[2]J412.500(0.000)(0)[2]J50.0...

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    MAINTENANCE5. ADJUSTINGB--81595EN/0158This function enables mastering data values to be assigned directly to asystem variable. It can be used if mastering data has been lost but the pulsecount is preserved.1Press MENUS, then press NEXT and select SYSTEM.2Press F1, [TYPE]. Select [Variables]. The ...

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    MAINTENANCEB--81595EN/015. ADJUSTING59Usually, positioning is performed automatically when the power is turnedon. To check if mastering is completed correctly, check that the currentposition indication matches the actual robot position according to theprocedure below.(a) Replay a particular point...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/01606 REPLACING PARTS-- When replacing a part, subsequent adjustment is required.-- Parts requiring replacing and their accompanying adjustment itemsare listed in item 4.3.-- When tightening a bolt, always observe the tightening torque, ifspecified.-- Packi...

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    MAINTENANCEB--81595EN/016. REPLACING PARTS611 Change the robot attitude to allow J2 cover U (1) to be removed.2 Remove bolt (3), then remove J2 cover U (1).3 Remove bolt (4), then remove J2 cover S (5) (to detach the motorconnector).4 Detach the connector attached to motor (8).5 Remove bolt (7), ...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/0162Fig.6.1 Replacing J1--axis motor

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    MAINTENANCEB--81595EN/016. REPLACING PARTS631 Detach the cabling according to Chapter 8.2 Remove the J1 motor according to Section 6.1. (The gear need not beremoved.)3 Remove bolt (1), then remove the J2 base. At this time, grease candrip. Use care.4 Clean the grease paths of center gear (3) and ...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/0164J2 BaseOil sealJ1 BaseJ1 Redacer outletFig.6.2 Replacing J1--axis reducer

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    MAINTENANCEB--81595EN/016. REPLACING PARTS651 Change the robot attitude to allow J2 cover U (1) to be removed.2 Remove bolt (2), then remove J2 cover U (1) (to detach the motorconnector).3 Remove bolt (5), then remove J2 cover S (4).4 Detach the connector attached to motor (8).5 Remove bolt (7), ...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/0166Fig.6.3 Replacing J2--axis motor

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    MAINTENANCEB--81595EN/016. REPLACING PARTS671 Move the robot to an attitude of J2 = 90° and J3 = 0°. The other axesmay take arbitrary attitudes.2 Detach the cabling up to clamp J2--1 according to Chapter 8.3 Remove bolt (1), then remove washer plate (2) and the J2 arm.4 Remove bolt (4), then re...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/0168Clamp J2--1J2 reduceroutletJ2 armFig.6.4 Replacing J2--axis reducer

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    MAINTENANCEB--81595EN/016. REPLACING PARTS691 Remove bolt (1), then remove J3 cover R (2).2 Remove bolt (4), then remove packing (6) and motor (5).NOTEWhen the motor is removed, the arm moves downward byits weight. Hold the arm so that the arm does not collide withany other objects.3 Detach the c...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/0170Wave generatorGreasefilling areaFig.6.5 Replacing J3--axis motor

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    MAINTENANCEB--81595EN/016. REPLACING PARTS711 Detach the cabling up to J3 clamp 2 according to Chapter 8.2 Remove J3 ring (1).3 Remove bolt (2) and washer plate (3), then remove the J3 arm.4 Remove bolt (5), then remove packing (6) and gear box cover (4).5 Clean off grease from the inside of the ...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/0172NameSpecificationsQ’tyLOCTITETorque N-m (kgf-m)1J3 RINGA290-7137-X42312BOLTA6-BA-5×168 LT2625.6 (57)3WASHER PLATE J3A290-7137-X32614G.B. COVER 1A290-7137-X40215BOLTA97L-0218-0496#M5×20ZN105.6 (57)6G.B. PAKING 1A290-7137-X42717PINJB-PH-H7A-5×12S45C-...

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    MAINTENANCEB--81595EN/016. REPLACING PARTS73J3 arm sideJ2 arm sideJ3 armJ3 housingCircularsplineFlangeFlexsplineFor pin (7)J2 armClamp J2--2Tap forgear (14)Tap for crossroller (16)Tap for circularsplineFig.6.6 (a) Replacing J3 gear box

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    MAINTENANCE6. REPLACING PARTSB--81595EN/0174Grease filling areaLoctite No.518 applying areaFig.6.6 (b) Grease filling area and loctite 518 applying area

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    MAINTENANCEB--81595EN/016. REPLACING PARTS751 Remove bolt (2), then remove J3 cover R (1).2 Remove bolt (4), then remove motor (5) and O--ring (6).NOTEWhen the motor is removed, the arm moves downward byits weight. Hold the arm so that the arm does not collide withany other objects.3 Remove bolt ...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/0176Fig.6.7 Replacing J4--axis motor

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    MAINTENANCEB--81595EN/016. REPLACING PARTS771 Remove bolt (2), then remove J4 gear box cover (1). At this time,grease can drip. Use care.2 Clean off grease from the inside of gear box so that the gear and boltcan be viewed.NOTEWhen the motor is removed, the arm moves downward byits weight. Hold t...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/01781 Detach the cabling up to wrist clamp 1 according to Chapter 8.2 Remove bolt (1), then remove J3 housing (2) and packing (3).3 Remove gear (6) according to Section 6.8.4 Remove the J5 housing.5 Remove bolt (5), then remove cross roller (4).6 Install ne...

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    MAINTENANCEB--81595EN/016. REPLACING PARTS79Wrist clamp 1J5 housingLoctite 518 applyingareaFig.6.9 Replacing J4--axis cross roller

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    MAINTENANCE6. REPLACING PARTSB--81595EN/01801 Remove bolt (1), then remove pin (4), packing (3), and adapter (2).2 Detach the connector attached to motor (7).3 Remove bolt (8), then remove packing (6) and motor (7).4 Remove setscrew (5), then remove the wave generator.5 Using a new motor and pack...

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    MAINTENANCEB--81595EN/016. REPLACING PARTS811 Remove bolt (1), then remove pin (6), packing (8), and adapter (4).2 Detach the connector attached to motor (9).3 Remove bolt (10), then remove packing (8) and motor (9).4 Remove setscrew (7), then remove the wave generator.5 Remove bolt (2), then rem...

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    MAINTENANCE6. REPLACING PARTSB--81595EN/01821 Remove bolt (1), then remove J3 cover R (2).2 Remove the magnetic solenoid valve.3 Remove bolt (6) and the air tube, then remove magnetic solenoid valve(5).4 By reversing the procedure above, assemble a new magnetic solenoidvalve and packing.Relay Con...

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    MAINTENANCEB--81595EN/016. REPLACING PARTS831 After dismounting the gear or the cross roller, apply releasant (LoctiteGasket Remover) to the arm’s surface from which the reducer wasdismounted, then wait until the sealant (Loctite 518) becomessoftened (for about 10 minutes). Remove the softened ...

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    MAINTENANCE7. PIPING AND WIRINGB--81595EN/01847 PIPING AND WIRING

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    B--81595EN/017. PIPING AND WIRINGMAINTENANCE85Fig.7.1 shows the piping diagram of the mechanical unit.Solenoid valve (option)M5 Depth5(Air outlet for user)Air pressure inkt PT1/4AIR1 (Air for user)AIR2(Air for solenoid valve)Fig. 7.1 Piping diagram7.1PIPING DIAGRAM

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    MAINTENANCE7. PIPING AND WIRINGB--81595EN/0186Fig.7.2 shows the wiring diagram of the mechanical unit.Solenoid valve (option)Fig. 7.2 Wiring diagram7.2WIRING DIAGRAM

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    B--81595EN/018. REPLACING CABLESMAINTENANCE878 REPLACING CABLESReplace the cables every four years. When the cable is broken ordamaged, 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...

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    MAINTENANCE8. REPLACING CABLESB--81595EN/0188Fig.8.1 shows the cable clamp position.When replacing cables, clamp the cable at the position specified in Figure8.1 using a clamp or a nylon band. Otherwise, cables are loosened orforcedly pulled to cause their disconnection. Refer to the figures inse...

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    B--81595EN/018. REPLACING CABLESMAINTENANCE89(1) Detaching the cable in the J3 and J5 housings1 Move the robot to an attitude of 0° for all axes, then turn off thepower to the control unit.2 Remove bolts (2) and (5), then remove J3 cover R (1), J3 cover F(4).3 Remove bolt (14), then remove wrist...

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    MAINTENANCE8. REPLACING CABLESB--81595EN/0190(White)(Black)RelayConnectorRelay ConnectorJ5 MotorFig. 8.2.1(a) Replacing cable in J3 and J5 housings

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    B--81595EN/018. REPLACING CABLESMAINTENANCE91(2) Detaching the cable in the J2 arm1 Remove bolt (2), then remove J2 arm cover (1).2 Remove bolt (5), then remove clamp J2--2 (4). Cut the cable tie.3 Pull out the cable from within the J3 housing.NameSpecificationsQ’tyLOCTITETorque N-m (kgf-m)1J2 ...

  • Page 97

    MAINTENANCE8. REPLACING CABLESB--81595EN/0192(3) Detaching the cable in the J1 and J2 bases1 Remove bolts (1) and (4), then remove J2 cover S (5) and J2 coverU (2).2 Remove bolt (7), then remove J2--1 (8). Cut the cable tie.3 Pull out the cable from the J2 arm.4 Detach the connector attached to m...

  • Page 98

    B--81595EN/018. REPLACING CABLESMAINTENANCE93(White)(White)(Black)Signal Cable(Red× White)J2BasePower Cable(Blue× White)(Black)(White)Signal Cable(Red× White)Power Cable(Blue× White)(Black)(White)(Black)Signal Cable(Red× White)Power Cable(Blue× White)Nylon bandFig. 8.2.1(c) Replacing cable ...

  • Page 99

    MAINTENANCE8. REPLACING CABLESB--81595EN/0194Apply the loctite No.242 along thecircumference of the screw.Note(White)(Black)Signal Cable(Red× White)Power Cable(Blue× White)Air tube markingJ1 sideJ2 to J5 sideFig. 8.2.1(d) Replacing cable in J1 base(4) Installing the cable1 By reversing the proc...

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    B--81595EN/018. REPLACING CABLESMAINTENANCE951 Remove bolt (2), then remove J3 cover F (1) and packing (3).2 Remove bolt (4), then remove the J3 housing and packing (5).3 Replace cables K102 and K103.4 Using a new packing, install the cables by reversing the procedureabove.NameSpecificationsQ’t...

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    MAINTENANCE8. REPLACING CABLESB--81595EN/0196J3 housingFig. 8.2.2 Replacing cables K102 and K103

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    B--81595EN/018. REPLACING CABLESMAINTENANCE971 Remove bolt (2), then remove J3 cover F (1) and packing (3).2 Replace cable K104.3 Using a new packing, install cable K104 by reversing the procedureabove.NameSpecificationsQ’tyLOCTITETorque N-m (kgf-m)1J3 COVER FA290--7137--X40512BOLTA97L--0218--0...

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    MAINTENANCE8. REPLACING CABLESB--81595EN/01981 Replace cable K105 according to Section 6.12, “REPLACINGMAGNETIC SOLENOID VALVE”.8.2.4Replacing Cable K105

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    II. CONNECTION

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    CONNECTIONB--81595EN/011.OPERATING AREA1011OPERATING AREA

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    CONNECTION1. OPERATING AREAB--81595EN/01102Fig.1.1 shows the operating area and the dimensions of the robot. Caremust be taken not to put obstructions in the operating area of a robot wheninstalling peripheral equipment.Motion range of J4-axisrotation centerJ4-axis rotation centerJ4-axis rotation...

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    CONNECTIONB--81595EN/011.OPERATING AREA103Fig.1.2 illustrates the details of the operating area of the robot.Fig.1.2 Operating area of the robot1.2DETAILS OF THEOPERATING AREA

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    CONNECTION2. MECHANICAL COUPLING TOTHE ROBOTB--81595EN/011042 MECHANICAL COUPLING TO THE ROBOT

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    CONNECTIONB--81595EN/012. MECHANICAL COUPLINGTO THE ROBOT105Fig.2.1 is diagrams to limit loads applied to the wrist. Apply a load withinthe region indicated in the graph.Fig.2.1 Wrist Load Diagram2.1WRIST LOADCONDITIONS

  • Page 110

    CONNECTION2. MECHANICAL COUPLING TOTHE ROBOTB--81595EN/01106Fig.2.2 shows the end effector mounting face at the tip of the wrist. Fitthe end effector to the wrist using aφ20H7 orφ40h7 engagement, positionthe effector using aφ5H7 reamed hole, and fix the effector to the wristusing 4--M5 tapped ...

  • Page 111

    CONNECTIONB--81595EN/012. MECHANICAL COUPLINGTO THE ROBOT107Fig. 2.3 shows the attachment tap positions for clamping the hand cableand air tube.NOTEThe clamping parts should be prepared by the customer.NOTEThe tightening torque of bolts and other fastening parts forthe taps must not exceed 5.6 Nm...

  • Page 112

    CONNECTION2. MECHANICAL COUPLING TOTHE ROBOTB--81595EN/01108It is possible to make an effective use of the robot by setting payloadconditions such as the weight, moment, and inertia of the hands and otherobjects attached to the wrist section of the robot appropriately.The motion performance scree...

  • Page 113

    CONNECTIONB--81595EN/012. MECHANICAL COUPLINGTO THE ROBOT1096Set the payload, gravity center position, and inertia around thegravity center on the MOTION PAYLOAD SET screen. The X, Y,and Z directions displayed on this screen correspond to therespective standard tool coordinates (with no tool coor...

  • Page 114

    CONNECTION2. MECHANICAL COUPLING TOTHE ROBOTB--81595EN/01110Optional solenoid valves can be mounted as shown in Tables 2.5 (a) and(b). Plugs are inserted in all the ports used for supplying air before therobot is shipped. To use the air circuit, you must remove the plugs andconnect the couplings ...

  • Page 115

    CONNECTIONB--81595EN/012. MECHANICAL COUPLINGTO THE ROBOT111solenoid valve outletDP6DP6DP6DP6DP6solenoid valve (option)DP5Air outlet for userAir inletAIR2 (Air for solenoid valve)AIR1 (Air for user)Fig.2.5 Supplying air

  • Page 116

    CONNECTION2. MECHANICAL COUPLING TOTHE ROBOTB--81595EN/01112Fig. 2.6 shows the location and pin layout of the signal interface for theend effector.NOTEThe connector to be plugged into the interface and the cableattached to that connector should be prepared by thecustomer.NOTEWhen the robot is shi...

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    CONNECTIONB--81595EN/012. MECHANICAL COUPLINGTO THE ROBOT113CapPlug connector(to be prepared by the customer)Fig.2.6 Signal interface for end effector

  • Page 118

    CONNECTION3. TRANSPORTATION ANDINSTALLATIONB--81595EN/011143 TRANSPORTATION AND INSTALLATION

  • Page 119

    CONNECTIONB--81595EN/013. TRANSPORTATION ANDINSTALLATION115While transporting the robot, the robot posture must be set as shownbelow. To mount and install the robot safely and to prevent rotation, alifting device is available as an optional unit.NOTEWhen the J1 motor does not have a brake, instal...

  • Page 120

    CONNECTION3. TRANSPORTATION ANDINSTALLATIONB--81595EN/01116NOTE1 After installing the robot, remove the transport members.2 The robot cannot stand independently.For transportation, the robot is secured to afall--protection plate. If the fall--protection plate is removed, the robot will fall. So, ...

  • Page 121

    CONNECTIONB--81595EN/013. TRANSPORTATION ANDINSTALLATION117Fig.3.2 (a) shows the base of the robot.Move the robot on the base until the robot touches three referencesurfaces. Then, firmly secure the robot to the base with four M10 bolts.NOTEThe tightening torque must not exceed 46 Nm (470 kgfm).F...

  • Page 122

    CONNECTION3. TRANSPORTATION ANDINSTALLATIONB--81595EN/01118Fig.3.2 (b) Force and moment of J1 baseTable 3.2 Force and moment of J1 baseConditionBending momentMV [kgfm] (Nm)Force in verticaldirectionFV [kgf] (N)Twisting momentMH [kgfm] (Nm)Force in horizontaldirectionFH [kgf] (N)During stillness[1...

  • Page 123

    CONNECTIONB--81595EN/013. TRANSPORTATION ANDINSTALLATION119Table 3.3 shows the installation conditions of the robot.Table 3.3 Installation conditionsItemDescriptionAirSupply0.49MPa (5kg/cm2)Maximuminstanta-neousdemand120Nℓ/minWeight ofmechanical unitApprox. 38kgAmbienttemperature0°Cto45°CRela...

  • Page 124

    CONNECTION3. TRANSPORTATION ANDINSTALLATIONB--81595EN/01120Fig.3.4 shows the layout of maintenance area.Maintenance spaceFig.3.4 Maintenance area3.4MAINTENANCEAREA

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    CONNECTIONB--81595EN/013. TRANSPORTATION ANDINSTALLATION121Fig.3.5 shows the connection of a pneumatic tube with the robot.In addition, air control set is available as un optional unit.NOTEThe air control set option is not allailable on a clean type.Pneumatic tubeDry airFilter and regulatorPneuma...

  • Page 126

    CONNECTION3. TRANSPORTATION ANDINSTALLATIONB--81595EN/01122To store the robot, set it to the same attitude as that used for transportation.(See I-- 3.1)3.6STORAGE

  • Page 127

    APPENDIX

  • Page 128

    B--81595EN/01A. SPARE PARTS LIST FORTHE MECHANICAL UNITOF LR Mate 100iBAPPENDIX125ASPAREPARTSLISTFORTHEMECHANICALUNITOFLR Mate 100iBTable A (a) CableNameSpecificationRemarksCable K101A660--8014--T355 (2BK)A660--8014--T356 (5BK)Main cableCable K102A660--4004--T142J3 PowerCable K103A660--2005--T684...

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    APPENDIXA. SPARE PARTS LIST FORTHE MECHANICAL UNITOF LR Mate 100iBB--81595EN/01126Table A (c) ReducerNameSpecificationRemarksHarmonic driveA97L--0218--0296#80J1axisHarmonic driveA97L--0218--0297#80J2axisHarmonic driveA97L--0218--0298#100J3axisHarmonic driveA97L--0218--0299#50J5axisTable A (d) Bea...

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    B--81595EN/01A. SPARE PARTS LIST FORTHE MECHANICAL UNITOF LR Mate 100iBAPPENDIX127Table A (g) CoverNameSpecificationRemarksJ2 cover UA290--7137--X303J2 base upperJ2 cover SA290--7137--X304J2 base sideJ3 cover RA290--7137--X406J3 housing rear coverTable A (h) Cable protectorNameSpecificationRemark...

  • Page 131

    APPENDIXA. SPARE PARTS LIST FORTHE MECHANICAL UNITOF LR Mate 100iBB--81595EN/01128Table A (k) Undesirable--environment packageNameSpecificationRemarksPacking J1--BA290--7137--X224J1 back face coverPacking J1--CA290--7137--X225J1 connector panelPacking J2--UA290--7137--X327J2 base upper coverPacki...

  • Page 132

    B--81595EN/01A. SPARE PARTS LIST FORTHE MECHANICAL UNITOF LR Mate 100iBAPPENDIX129Table A (o) Battery and greaseNameSpecificationRemarksBatteryA98L--0031--0005Size D 1/1.5VGreaseA98L--0040--0110#1KGHarmonic grease SK--3

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    APPENDIXB. MECHANICAL UNIT CIRCUITDIAGRAMB--81595EN/01130BMECHANICALUNITCIRCUITDIAGRAM

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    B--81595EN/01B. MECHANICAL UNIT CIRCUITDIAGRAMAPPENDIX131

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    APPENDIXB. MECHANICAL UNIT CIRCUITDIAGRAMB--81595EN/01132

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    B--81595EN/01B. MECHANICAL UNIT CIRCUITDIAGRAMAPPENDIX133

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    APPENDIXB. MECHANICAL UNIT CIRCUITDIAGRAMB--81595EN/01134

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    B--81595EN/01B. MECHANICAL UNIT CIRCUITDIAGRAMAPPENDIX135

  • Page 139

    APPENDIXC. PERIODIC MAINTENANCE TABLEB--81595EN/01136CPERIODICMAINTENANCETABLETYPE4 Periodic Maintenance TableChecktimegreaseamountFirstcheck3203months9606months19209months28801year38404800576067202years768086409600105603years115201248013440144001Check themechanical cable0.2H--fffff f f f ff ffff...

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    B--81595EN/01C. PERIODIC MAINTENANCE TABLEAPPENDIX1374years153601632017280182405years1920020160 21120220806years2304024000 24960259207years268802784028800297608years30720fffff f f fff f ffffffffff f f fff f ffffffffff f f fff f ffffffffff f f fff f fffffFFFFfffff f f fff f fffffFFFFF F F FFF F FF...

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    APPENDIXD. BOLT TIGHTENINGTORQUE TABLEB--81595EN/01138DBOLTTIGHTENINGTORQUETABLEThose bolts for which no tightening torque is specified must be tightenedaccording to the following table.Table D Recommended Bolt Tightening TorquesUnit : Nm (kgf·cm)NominaldiameterHexagon socket head bolt(Steel : s...

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    IndexB--81595EN/01i--1[Numbers]1.5--year checks, 261--year Checks, 263--month Checks, 26[A]Adjusting, 39Adjusting J4--axis Timing Belt Tension, 40[C]Cable Forming, 88Configuration, 19[D]Daily Checks, 25Details of the Operating Area, 103[G]Greasing, 29[I]Installating the Robot, 117Installation Con...

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    IndexB--81595EN/01i--2Wrist Load Conditions, 105[Z]Zero Degree Mastering, 51

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    Revision RecordFANUC Robot series LR Mate 100i B MAINTENANCE MANUAL (B--81595EN)01Oct., 2001EditionDateContentsEditionDateContents

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