manual mecanico m900

FANUC Robot M-900iA/350FANUC Robot M-900iA/260L

MECHANICAL MANUAL

MAINTENANCE MANUAL

MARMI935009041E REV. DThis publication contains proprietary information of FANUC Robotics America, Inc. furnished for

customer use only. No other uses are authorized without the express written permission of

FANUC Robotics America, Inc.

FANUC Robotics America, Inc.3900 W. Hamlin Road

Rochester Hills, Michigan 483093253

B-82135EN/05

Before using the Robot, be sure to read the FANUC Robot Safety Manual (B-80687EN) and understand the content. This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual. 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 manual are controlled based on Japans Foreign Exchange and Foreign Trade Law. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual, we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as impossible.

The descriptions and specifications contained in this manual were ineffect at the time this manual was approved for printing. FANUCRobotics America, Inc, hereinafter referred to as FANUC Robotics,reserves the right to discontinue models at any time or to changespecifications or design without notice and without incurringobligations.FANUC Robotics manuals present descriptions, specifications,drawings, schematics, bills of material, parts, connections and/orprocedures for installing, disassembling, connecting, operating andprogramming FANUC Robotics products and/or systems. Suchsystems consist of robots, extended axes, robot controllers,application software, the KAREL programming language,INSIGHT vision equipment, and special tools.FANUC Robotics recommends that only persons who have beentrained in one or more approved FANUC Robotics TrainingCourse(s) be permitted to install, operate, use, perform procedureson, repair, and/or maintain FANUC Robotics products and/orsystems and their respective components. Approved trainingnecessitates that the courses selected be relevant to the type ofsystem installed and application performed at the customer site.

WARNINGThis equipment generates, uses, and can radiate radiofrequency energy and if not installed and used in accordancewith the instruction manual, may cause interference to radiocommunications. As temporarily permitted by regulation, ithas not been tested for compliance with the limits for Class Acomputing devices pursuant to subpart J of Part 15 of FCCRules, which are designed to provide reasonable protectionagainst such interference. Operation of the equipment in aresidential area is likely to cause interference, in which casethe user, at his own expense, will be required to takewhatever measure may be required to correct theinterference.

FANUC Robotics conducts courses on its systems and products ona regularly scheduled basis at its headquarters in Rochester Hills,Michigan. For additional information contact

FANUC Robotics America, Inc.Training Department3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253www.fanucrobotics.com

Send your comments and suggestions about this manual to:[email protected]

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Copyright 2008 by FANUC Robotics America, Inc.All Rights ReservedThe information illustrated or contained herein is not to bereproduced, copied, downloaded, translated into another language,published in any physical or electronic format, including internet, ortransmitted in whole or in part in any way without the prior writtenconsent of FANUC Robotics America, Inc.

AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,PalletTool, SOCKETS, SOFT PARTS SpotTool,TorchMate, and YagTool are Registered Trademarks of FANUCRobotics.FANUC Robotics reserves all proprietary rights, including but notlimited to trademark and trade name rights, in the following names:AccuAir AccuCal AccuChop AccuFlow AccuPathAccuSeal ARC Mate ARC Mate Sr. ARC Mate System 1ARC Mate System 2 ARC Mate System 3 ARC Mate System4 ARC Mate System 5 ARCWorks Pro AssistToolAutoNormal AutoTCP BellTool BODYWorks Cal Mate CellFinder Center Finder Clean Wall CollisionGuardDispenseTool F-100 F-200i FabTool FANUC LASERDRILL Flexibell FlexTool HandlingTool HandlingWorksINSIGHT INSIGHT II IntelliTrak Integrated Process SolutionIntelligent Assist Device IPC -Integrated Pump Control IPDIntegral Pneumatic Dispenser ISA Integral Servo Applicator ISDIntegral Servo Dispenser Laser Mate System 3 Laser MateSystem 4 LaserPro LaserTool LR Tool MIG EyeMotionParts NoBots Paint Stick PaintPro PaintTool 100PAINTWorks PAINTWorks II PAINTWorks III PalletMatePalletMate PC PalletTool PC PayloadID RecipToolRemovalTool Robo Chop Robo Spray S-420i S-430iShapeGen SoftFloat SOF PARTS SpotTool+ SR MateSR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM R-J3 Controller SYSTEM R-J3iB Controller TCP MateTurboMove TorchMate visLOC visPRO-3D visTRACWebServer WebTP YagTool

FANUC LTD 2008

No part of this manual may be reproduced in any form. All specifications and designs are subject to change without notice.

This manual includes information essential to the safety ofpersonnel, equipment, software, and data. This information isindicated by headings and boxes in the text.

WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to set itapart from other text.

CAUTIONInformation appearing under CAUTION concerns the protection ofequipment, software, and data. It is boxed to set it apart fromother text.

NOTE Information appearing next to NOTE concerns relatedinformation or useful hints.

Conventions

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SafetyFANUCRobotics is not and does not represent itself as an expert in safety systems, safety equipment, orthe specific safety aspects of your company and/or its work force. It is the responsibility of the owner,employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace.

The appropriate level of safety for your application and installation can best be determined by safetysystem professionals. FANUC Robotics therefore, recommends that each customer consult with suchprofessionals in order to provide a workplace that allows for the safe application, use, and operation ofFANUC Robotic systems.

According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult thestandards to ensure compliance with its requests for Robotics System design, usability, operation,maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is yourresponsibility to arrange for the training of the operator of a robot system to recognize and respond toknown hazards associated with your robotic system and to be aware of the recommended operatingprocedures for your particular application and robot installation.

FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair,or otherwise use the robotics system be trained in an approved FANUC Robotics training course andbecome familiar with the proper operation of the system. Persons responsible for programming thesystem-including the design, implementation, and debugging of application programs-must be familiarwith the recommended programming procedures for your application and robot installation.

The following guidelines are provided to emphasize the importance of safety in the workplace.

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:

The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot

Keeping People and Equipment Safe

The safety of people is always of primary importance in any situation. However, equipment must bekept safe, too. When prioritizing how to apply safety to your robotic system, consider the following:

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Safety

People External devices Robot(s) Tooling Workpiece

Using Safety Enhancing Devices

Always give appropriate attention to the work area that surrounds the robot. The safety of the workarea can be enhanced by the installation of some or all of the following devices:

Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEADMAN switches

Setting Up a Safe Workcell

A safe workcell is essential to protect people and equipment. Observe the following guidelines toensure that the workcell is set up safely. These suggestions are intended to supplement and not replaceexisting federal, state, and local laws, regulations, and guidelines that pertain to safety.

Sponsor your personnel for training in approved FANUC Robotics training course(s) related toyour application. Never permit untrained personnel to operate the robots.

Install a lockout device that uses an access code to prevent unauthorized persons from operatingthe robot.

Use anti-tie-down logic to prevent the operator from bypassing safety measures. Arrange the workcell so the operator faces the workcell and can see what is going on inside thecell.

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Safety

Clearly identify the work envelope of each robot in the system with floor markings, signs, andspecial barriers. The work envelope is the area defined by the maximum motion range of therobot, including any tooling attached to the wrist flange that extend this range.

Position all controllers outside the robot work envelope. Never rely on software or firmware based controllers as the primary safety element unless theycomply with applicable current robot safety standards.

Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of theoperator and at critical points inside and around the outside of the workcell.

Install flashing lights and/or audible warning devices that activate whenever the robot isoperating, that is, whenever power is applied to the servo drive system. Audible warning devicesshall exceed the ambient noise level at the end-use application.

Wherever possible, install safety fences to protect against unauthorized entry by personnel intothe work envelope.

Install special guarding that prevents the operator from reaching into restricted areas of thework envelope.

Use interlocks. Use presence or proximity sensing devices such as light curtains, mats, and capacitance andvision systems to enhance safety.

Periodically check the safety joints or safety clutches that can be optionally installed between therobot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, removepower from the system, and help to minimize damage to the tooling and robot.

Make sure all external devices are properly filtered, grounded, shielded, and suppressed toprevent hazardous motion due to the effects of electro-magnetic interference (EMI), radiofrequency interference (RFI), and electro-static discharge (ESD).

Make provisions for power lockout/tagout at the controller. Eliminate pinch points . Pinch points are areas where personnel could get trapped between amoving robot and other equipment.

Provide enough room inside the workcell to permit personnel to teach the robot and performmaintenance safely.

Program the robot to load and unload material safely. If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, andbeacons.

If materials are being applied at dangerously high pressure, provide electrical interlocks forlockout of material flow and pressure.

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Safety

Staying Safe While Teaching or Manually Operating the Robot

Advise all personnel who must teach the robot or otherwise manually operate the robot to observe thefollowing rules:

Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in movingmachinery.

Know whether or not you are using an intrinsically safe teach pendant if you are working ina hazardous environment.

Before teaching, visually inspect the robot and work envelope to make sure that no potentiallyhazardous conditions exist. The work envelope is the area defined by the maximum motion rangeof the robot. These include tooling attached to the wrist flange that extends this range.

The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafeworking conditions to the supervisor or safety department.

FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except forrobot teaching operations. However, if you must enter the work envelope, be sure all safeguardsare in place, check the teach pendant DEADMAN switch for proper operation, and place therobot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release theDEADMAN switch. Only the person with the teach pendant should be in the work envelope.

Warning

Never bypass, strap, or otherwise deactivate a safety device, such as alimit switch, for any operational convenience. Deactivating a safetydevice is known to have resulted in serious injury and death.

Know the path that can be used to escape from a moving robot; make sure the escape path isnever blocked.

Isolate the robot from all remote control signals that can cause motion while data is being taught. Test any program being run for the first time in the following manner:

Warning

Stay outside the robot work envelope whenever a program is beingrun. Failure to do so can result in injury.

Using a low motion speed, single step the program for at least one full cycle.

Using a low motion speed, test run the program continuously for at least one full cycle.

Using the programmed speed, test run the program continuously for at least one full cycle.

Make sure all personnel are outside the work envelope before running production.

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Safety

Staying Safe During Automatic Operation

Advise all personnel who operate the robot during production to observe the following rules:

Make sure all safety provisions are present and active. Know the entire workcell area. The workcell includes the robot and its work envelope, plus thearea occupied by all external devices and other equipment with which the robot interacts.

Understand the complete task the robot is programmed to perform before initiating automaticoperation.

Make sure all personnel are outside the work envelope before operating the robot. Never enter or allow others to enter the work envelope during automatic operation of the robot. Know the location and status of all switches, sensors, and control signals that could cause therobot to move.

Know where the EMERGENCY STOP buttons are located on both the robot control and externalcontrol devices. Be prepared to press these buttons in an emergency.

Never assume that a program is complete if the robot is not moving. The robot could be waitingfor an input signal that will permit it to continue activity.

If the robot is running in a pattern, do not assume it will continue to run in the same pattern. Never try to stop the robot, or break its motion, with your body. The only way to stop robotmotion immediately is to press an EMERGENCY STOP button located on the controller panel,teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection

When inspecting the robot, be sure to

Turn off power at the controller. Lock out and tag out the power source at the controller according to the policies of your plant. Turn off the compressed air source and relieve the air pressure. If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCYSTOP button on the operator panel.


If power is needed to check the robot motion or electrical circuits, be prepared to press theEMERGENCY STOP button, in an emergency.

Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it isnot supported or resting on a hard stop. Support the arm on a solid support before you releasethe brake.

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Safety

Staying Safe During Maintenance

When performing maintenance on your robot system, observe the following rules:

Never enter the work envelope while the robot or a program is in operation. Before entering the work envelope, visually inspect the workcell to make sure no potentiallyhazardous conditions exist.


Consider all or any overlapping work envelopes of adjoining robots when standing in a workenvelope.

Test the teach pendant for proper operation before entering the work envelope. If it is necessary for you to enter the robot work envelope while power is turned on, you must besure that you are in control of the robot. Be sure to take the teach pendant with you, press theDEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switchto turn off servo power to the robot immediately.

Whenever possible, perform maintenance with the power turned off. Before you open thecontroller front panel or enter the work envelope, turn off and lock out the 3-phase power sourceat the controller.

Be aware that an applicator bell cup can continue to spin at a very high speed even if the robot isidle. Use protective gloves or disable bearing air and turbine air before servicing these items.


Warning

Lethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful to avoidelectrical shock.HIGH VOLTAGE IS PRESENT at the input sidewhenever the controller is connected to a power source. Turning thedisconnect or circuit breaker to the OFF position removes power fromthe output side of the device only.

Release or block all stored energy. Before working on the pneumatic system, shut off the systemair supply and purge the air lines.

Isolate the robot from all remote control signals. If maintenance must be done when the poweris on, make sure the person inside the work envelope has sole control of the robot. The teachpendant must be held by this person.

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Safety

Make sure personnel cannot get trapped between the moving robot and other equipment. Knowthe path that can be used to escape from a moving robot. Make sure the escape route is neverblocked.

Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make surethat such devices do not create pinch points that could trap personnel.

Warning

Do not try to remove any mechanical component from the robotbefore thoroughly reading and understanding the procedures in theappropriate manual. Doing so can result in serious personal injury andcomponent destruction.


When replacing or installing components, make sure dirt and debris do not enter the system. Use only specified parts for replacement. To avoid fires and damage to parts in the controller,never use nonspecified fuses.

Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot andall external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Certain programming and mechanical measures are useful in keeping the machine tools and otherexternal devices safe. Some of these measures are outlined below. Make sure you know all associatedmeasures for safe use of such devices.

Programming Safety Precautions

Implement the following programming safety measures to prevent damage to machine tools andother external devices.

Back-check limit switches in the workcell to make sure they do not fail. Implement failure routines in programs that will provide appropriate robot actions if an externaldevice or another robot in the workcell fails.

Use handshaking protocol to synchronize robot and external device operations. Program the robot to check the condition of all external devices during an operating cycle.

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Safety

Mechanical Safety Precautions

Implement the following mechanical safety measures to prevent damage to machine tools and otherexternal devices.

Make sure the workcell is clean and free of oil, water, and debris. Use software limits, limit switches, and mechanical hardstops to prevent undesired movement ofthe robot into the work area of machine tools and external devices.

KEEPING THE ROBOT SAFE

Observe the following operating and programming guidelines to prevent damage to the robot.

Operating Safety Precautions

The following measures are designed to prevent damage to the robot during operation.

Use a low override speed to increase your control over the robot when jogging the robot. Visualize the movement the robot will make before you press the jog keys on the teach pendant. Make sure the work envelope is clean and free of oil, water, or debris. Use circuit breakers to guard against electrical overload.

Programming Safety Precautions

The following safety measures are designed to prevent damage to the robot during programming:

Establish interference zones to prevent collisions when two or more robots share a work area. Make sure that the program ends with the robot near or at the home position. Be aware of signals or other operations that could trigger operation of tooling resulting inpersonal injury or equipment damage.

In dispensing applications, be aware of all safety guidelines with respect to the dispensingmaterials.

Note Any deviation from the methods and safety practices described in this manual must conformto the approved standards of your company. If you have questions, see your supervisor.

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Safety

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOTINSTALLATIONS

Process technicians are sometimes required to enter the paint booth, for example, during daily orroutine calibration or while teaching new paths to a robot. Maintenance personal also must workinside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilation equipment must be used.Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.

Although paint booth hazards have been minimized, potential dangers still exist. Therefore, todayshighly automated paint booth requires that process and maintenance personnel have full awareness ofthe system and its capabilities. They must understand the interaction that occurs between the vehiclemoving along the conveyor and the robot(s), hood/deck and door opening devices, and high-voltageelectrostatic tools.

Paint robots are operated in three modes:

Teach or manual mode Automatic mode, including automatic and exercise operation Diagnostic mode

During both teach and automatic modes, the robots in the paint booth will follow a predeterminedpattern of movements. In teach mode, the process technician teaches (programs) paint paths usingthe teach pendant.

In automatic mode, robot operation is initiated at the System Operator Console (SOC) or ManualControl Panel (MCP), if available, and can be monitored from outside the paint booth. All personnelmust remain outside of the booth or in a designated safe area within the booth whenever automaticmode is initiated at the SOC or MCP.

In automatic mode, the robots will execute the path movements they were taught during teach mode,but generally at production speeds.

When process and maintenance personnel run diagnostic routines that require them to remain in thepaint booth, they must stay in a designated safe area.

Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the equipment andits capabilities. To minimize the risk of injury when working near robots and related equipment,personnel must comply strictly with the procedures in the manuals.

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Safety

This section provides information about the safety features that are included in the paint system andalso explains the way the robot interacts with other equipment in the system.

The paint system includes the following safety features:

Most paint booths have red warning beacons that illuminate when the robots are armed and readyto paint. Your booth might have other kinds of indicators. Learn what these are.

Some paint booths have a blue beacon that, when illuminated, indicates that the electrostaticdevices are enabled. Your booth might have other kinds of indicators. Learn what these are.

EMERGENCY STOP buttons are located on the robot controller and teach pendant. Becomefamiliar with the locations of all E-STOP buttons.

An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres. A DEADMAN switch is located on each teach pendant. When this switch is held in, and theteach pendant is on, power is applied to the robot servo system. If the engaged DEADMANswitch is released during robot operation, power is removed from the servo system, all axisbrakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks withinthe system might also E-STOP other robots.

Warning

An EMERGENCY STOP will occur if the DEADMAN switch is releasedon a bypassed robot.

Overtravel by robot axes is prevented by software limits. All of the major and minor axes aregoverned by software limits. Limit switches and hardstops also limit travel by the major axes.

EMERGENCY STOP limit switches and photoelectric eyes might be part of your system.Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP allequipment in the booth if a door is opened while the system is operating in automatic or manualmode. For some systems, signals to these switches are inactive when the switch on the SCC isin teach mode.When present, photoelectric eyes are sometimes used to monitor unauthorizedintrusion through the entrance/exit silhouette openings.

System status is monitored by computer. Severe conditions result in automatic system shutdown.

Staying Safe While Operating the Paint Robot

When you work in or near the paint booth, observe the following rules, in addition to all rules forsafe operation that apply to all robot systems.

Warning

Observe all safety rules and guidelines to avoid injury.

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Safety

Warning

Never bypass, strap, or otherwise deactivate a safety device, such as alimit switch, for any operational convenience. Deactivating a safety deviceis known to have resulted in serious injury and death.

Warning

Enclosures shall not be opened unless the area is know to benonhazardous or all power has been removed from devices within theenclosure. Power shall not be restored after the enclosure has beenopened until all combustible dusts have been removed from the interiorof the enclosure and the enclosure purged. Refer to the Purge chapterfor the required purge time.

Know the work area of the entire paint station (workcell). Know the work envelope of the robot and hood/deck and door opening devices. Be aware of overlapping work envelopes of adjacent robots. Know where all red, mushroom-shaped EMERGENCY STOP buttons are located. Know the location and status of all switches, sensors, and/or control signals that might cause therobot, conveyor, and opening devices to move.

Make sure that the work area near the robot is clean and free of water, oil, and debris. Reportunsafe conditions to your supervisor.

Become familiar with the complete task the robot will perform BEFORE starting automatic mode. Make sure all personnel are outside the paint booth before you turn on power to the robotservo system.

Never enter the work envelope or paint booth before you turn off power to the robot servo system. Never enter the work envelope during automatic operation unless a safe area has been designated. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in movingmachinery.

Remove all metallic objects, such as rings, watches, and belts, before entering a booth when theelectrostatic devices are enabled.

Stay out of areas where you might get trapped between a moving robot, conveyor, or openingdevice and another object.

Be aware of signals and/or operations that could result in the triggering of guns or bells. Be aware of all safety precautions when dispensing of paint is required. Follow the procedures described in this manual.

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Safety

Special Precautions for Combustible Dusts (powder paint)

When the robot is used in a location where combustible dusts are found, such as the application ofpowder paint, the following special precautions are required to insure that there are no combustibledusts inside the robot.

Purge maintenance air should be maintained at all times, even when the robot power is off. Thiswill insure that dust can not enter the robot.

A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dustwhen maintenance air is not present, it will be necessary to remove the covers and clean out anyaccumulated dust. Do not energize the robot until you have performed the following steps.

1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulateddust.

2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, besure to use methods appropriate for the type of dust that exists. Usually lint free rags dampenedwith water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate staticelectricity and cause an explosion unless special precautions are taken.

3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust.

4. When the dust has been removed, the covers must be replaced immediately.

5. Immediately after the covers are replaced, run a complete purge cycle. The robot can nowbe energized.

Staying Safe While Operating Paint Application Equipment

When you work with paint application equipment, observe the following rules, in addition to all rulesfor safe operation that apply to all robot systems.

Warning

When working with electrostatic paint equipment, follow all national andlocal codes as well as all safety guidelines within your organization.Also reference the following standards: NFPA 33 Standards for SprayApplication Using Flammable or Combustible Materials , and NFPA 70National Electrical Code .

Grounding : All electrically conductive objects in the spray area must be grounded. Thisincludes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots,as well as solvent containers. Grounding is defined as the object or objects shall be electricallyconnected to ground with a resistance of not more than 1 megohms.

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Safety

High Voltage : High voltage should only be on during actual spray operations. Voltage should beoff when the painting process is completed. Never leave high voltage on during a cap cleaningprocess.

Avoid any accumulation of combustible vapors or coating matter. Follow all manufacturer recommended cleaning procedures. Make sure all interlocks are operational. No smoking. Post all warning signs regarding the electrostatic equipment and operation of electrostaticequipment according to NFPA 33 Standard for Spray Application Using Flammable orCombustible Material.

Disable all air and paint pressure to bell. Verify that the lines are not under pressure.

Staying Safe During Maintenance

When you perform maintenance on the painter system, observe the following rules, and all othermaintenance safety rules that apply to all robot installations. Only qualified, trained service ormaintenance personnel should perform repair work on a robot.

Paint robots operate in a potentially explosive environment. Use caution when working withelectric tools.

When a maintenance technician is repairing or adjusting a robot, the work area is under the controlof that technician. All personnel not participating in the maintenance must stay out of the area.

For some maintenance procedures, station a second person at the control panel within reachof the EMERGENCY STOP button. This person must understand the robot and associatedpotential hazards.

Be sure all covers and inspection plates are in good repair and in place. Always return the robot to the home position before you disarm it. Never use machine power to aid in removing any component from the robot. During robot operations, be aware of the robots movements. Excess vibration, unusual sounds,and so forth, can alert you to potential problems.

Whenever possible, turn off the main electrical disconnect before you clean the robot. When using vinyl resin observe the following: Wear eye protection and protective gloves during application and removal

Adequate ventilation is required. Overexposure could cause drowsiness or skin and eyeirritation.

If there is contact with the skin, wash with water.

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Safety

Follow the Original Equipment Manufacturers Material Safety Data Sheets.

When using paint remover observe the following: Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.

Adequate ventilation is required. Overexposure could cause drowsiness.

If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then,seek medical attention as soon as possible.

Follow the Original Equipment Manufacturers Material Safety Data Sheets.

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B-82135EN/05 SAFETY PRECAUTIONS

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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.

SAFETY PRECAUTIONS B-82135EN/05

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1.1 OPERATOR SAFETY Operator 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 general safety precautions. Careful consideration must be made to ensure operator safety. 1. Have the robot system operators attend the training courses held by

FANUC.

FANUC provides various training courses. Contact our sales office for details.

2. Even when the robot is stationary, it is possible that the robot is still

ready to move state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.

3. Install a safety fence with a gate so that no operator can enter the work area without passing through the gate. Equip the gate with an interlock that stops the robot when the gate is opened.

The controller is designed to receive this interlock signal. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1.

4. Provide the peripheral devices with appropriate grounding (Class 1,

Class 2, or Class 3). 5. Try to install the peripheral devices outside the work area. 6. Draw an outline on the floor, clearly indicating the range of the

robot motion, including the tools such as a hand. 7. Install a mat switch or photoelectric switch on the floor with an

interlock to a visual or aural alarm that stops the robot when an operator enters the work area.

8. If necessary, install a safety lock so that no one except the operator in charge can turn on the power of the robot.

The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

9. When adjusting each peripheral device independently, be sure to

turn off the power of the robot.


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Fig. 1.1 (a) Safety Fence and Safety gate (For R-J3iB CONTROLLER)

Fig. 1.1 (b) Safety Fence and Safety (For R-30iA CONTROLLER)


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1.1.1 Operator Safety The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. 1. If it is not necessary for the robot to operate, turn off the power of

the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work.

2. Operate the robot system at a location outside the work area. 3. Install a safety fence with a safety gate to prevent any worker other

than the operator from entering the work area unexpectedly and also to prevent the worker from entering a dangerous area.

4. Install an EMERGENCY STOP button within the operators reach.

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

Fig. 1.1.1 (a) Connection Diagram for External Emergency

Stop Switch (For R-J3iB CONTROLLER)


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Fig. 1.1.1 (b) Connection Diagram for External Emergency

Stop Switch (For R-30iA CONTROLLER)

1.1.2 Safety of the Teach Pendant 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 teach pendant operator. 1. Unless it is specifically necessary to enter the robot work area,

carry out all tasks outside the area. 2. Before teaching the robot, check that the robot and its peripheral

devices are all in the normal operating condition. 3. When entering the robot work area and teaching the robot, be sure

to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the deadmans switch on the teach pendant).

The teach pendant supplied by FANUC is provided with a teach pendant enable switch and a deadmans switch in addition to the EMERGENCY STOP button. The functions of each switch are as follows. EMERGENCY STOP button

: Pressing this button stops the robot in an emergency, irrespective to the condition of the teach pendant enable switch.

Deadmans switch : The function depends on the state of the teach pendant enable switch. When the enable switch is on

: Releasing the finger from the deadmans switch stops the robot in an emergency.

When the enable switch is off-The deadmans switch is ineffective


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NOTE The deadmans switch is provided so that the robot

operation can be stopped simply by releasing finger from the teach pendant in case of emergency.

4. The teach pendant operator should pay careful attention so that no

other workers enter the robot work area.

NOTE In addition to the above, the teach pendant enable

switch and the deadmans switch also have the following function. By pressing the deadmans switch while the enable switch is on, the emergency stop factor (normally the safety gate) connected to the controller is invalidated.

In this case, it is possible for an operator to enter the fence during teach operation without pressing the EMERGENCY STOP button. In other words, the system understands that the combined operations of pressing the teach pendant enable switch and pressing the deadmans switch indicates the start of teaching.

The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching.

5. When entering the robot work area, the teach pendant operator

should enable the teach pendant whenever he or she enters the robot work area. In particular, while the teach pendant enable switch is off, make certain that no start command is sent to the robot from any operators panel other than the teach pendant.

The teach pendant, operator panel, and peripheral device interface send each robot start signal. However, the validity of each signal changes as follows depending on the ON/OFF switch on the Teach pendant and the three modes switch on the Operators panel and Remote condition on the software.

Operators panel three

modes switch

Teach pendant

ON/OFF switch

Software remote

condition

Teach pendant

Operators panel

Peripheral devices

T1/T2 AUTO

(Except RIA) On Independent Allowed to start Not allowed Not allowed

AUTO Off Remote OFF Not allowed Allowed to start Not allowed AUTO Off Remote ON Not allowed Not allowed Allowed to start


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NOTE When starting the system using the teach pendant in

the RIA specification, the three modes switch should be T1/T2.

6. To start the system using the operators box, make certain that

nobody is in the robot work area and that there are no abnormal conditions in the robot work area.

7. When a program is completed, be sure to carry out a test run according to the procedure below. 1. Run the program for at least one operation cycle in the single

step mode at low speed. 2. Run the program for at least one operation cycle in the

continuous operation mode at low speed. 3. Run the program for one operation cycle in the continuous

operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing.

4. Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble.

5. After checking the completeness of the program through the test run above, execute it in the automatic operation mode.

8. While operating the system in the automatic operation mode, the teach pendant operator should leave the robot work area.

1.1.3 Safety During Maintenance

For the safety of maintenance personnel, pay utmost attention to the following. 1. Except when specifically necessary, turn off the power of the

controller while carrying out maintenance. Lock the power switch, if necessary, so that no other person can turn it on.

2. When disconnecting the pneumatic system, be sure to reduce the supply pressure.

3. Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition.

4. If it is necessary to enter the robot work area for maintenance when the power is turned on, the worker should indicate that the machine is being serviced and make certain that no one starts the robot unexpectedly.

5. Do not operate the robot in the automatic mode while anybody is in the robot work area.

6. When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed.

7. When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful attention to its motion.

8. If necessary, have a worker who is familiar with the robot system stand beside the operators panel and observe the work being


s-8

performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time.

9. When replacing or reinstalling components, take care to prevent foreign matter from entering the system.

10. When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and turn off the circuit breaker to protect against electric shock.

11. When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of nonspecified ratings. They may cause a fire or result in damage to the components in the controller.


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1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.2.1 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 program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal.

3. For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other.

4. Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.

1.2.2 Precautions for Mechanism

1. Keep the component cells of the robot system clean, and operate the

robot in an environment free of grease, water, and dust. 2. Employ a limit switch or mechanical stopper to limit the robot

motion so that the robot does not encounter its peripheral devices or tools.


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1.3 SAFETY OF THE ROBOT MECHANISM

1.3.1 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 in advance what

motion the robot will perform in the jog mode.

1.3.2 Precautions in Programming 1. When the work areas of robots overlap, make certain that the

motions of the robots do not interfere with each other. 2. Be sure to specify the predetermined work origin in a motion

program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

1.3.3 Precautions for Mechanisms

1. Keep the work area of the robot clean, and operate the robot in an

environment free of grease, water, and dust.

1.3.4 Procedure to move arm without drive power in emergency or abnormal situations

1. For emergency or abnormal situations (e.g. persons trapped in or by

the robot), brake release unit can be used to move the robot axes without drive power. Please order following unit and cable.

Name Specification

Brake release unit

A05B-2450-J350 (Input voltage AC100-115V single phase) A05B-2450-J351 (Input voltage AC200-240V single phase)

Robot connection cable

A05B-2450-J360 (5m) A05B-2450-J361 (10m)

Power cable

A05B-2525-J010 (5m) (AC100-150V type) A05B-2525-J011 (10m) (AC100-150V type) A05B-2450-J364 (5m) (AC100-200V type) A05B-2450-J365 (10m) (AC100-200V type)

2. Please make sure that adequate numbers of brake release units are

available and readily accessible for robot system before installation.

3. Regarding how to use brake release unit, please refer to Robot controller maintenance manual.


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NOTE Robot systems installed without adequate number of

brake release units or similar means are neither in compliance with EN ISO 10218-1 nor with the Machinery Directive and therefore cannot bear the CE marking.

CAUTION Robot arm would fall down by releasing its brake

because of gravity. Therefore, it is strongly recommended to take adequate measures such as hanging Robot arm by a crane before releasing a brake.


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In case of releasing J2-axis motor brake

Fall down

Method of supporting robot arm

Using M10 tap and eyeboltsling pcs

Using M12 tap and eyebolt(sling 2pcs)

(*)This figure is example of floor mount. The direction of fall is different according to the installation angle,so please support robot appropriately in consideration of the influence of gravity.

Fall down Fall down

In case of releasing J3-axis motor brake

Fig. 1.3.4 Releasing J2 and J3 motor brake and measures


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1.4 SAFETY OF THE END EFFECTOR

1.4.1 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. Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.


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1.5 SAFETY IN MAINTENANCE 1. Never enter the robot work area while the robot is operating. Turn

off the power before entering the robot work area for inspection and maintenance.

2. If it is necessary to enter the robot work area with the power turned on, first press the EMERGENCY STOP button on the operators box.

3. When replacing or reinstalling components, take care to prevent foreign matter from entering the system. When replacing the parts in the pneumatic system, be sure to reduce the pressure in the piping to zero by turning the pressure control on the air regulator.

4. When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and turn off the circuit breaker to protect against electric shock.

5. When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of nonspecified ratings. They may cause a fire or result in damage to the components in the controller.

6. Before restarting the robot, be sure to check that no one is in the robot work area and that the robot and its peripheral devices are all in the normal operating state.


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1.6 WARNING LABEL (1) Greasing and degreasing label

Fig. 1.6 (a) Greasing and Degreasing Label

Description

When greasing and degreasing, observe the instructions indicated on this label.

1. When greasing, be sure to keep the grease outlet open. 2. Use a manual pump to grease. 3. Be sure to use specified grease.

CAUTION

See section I.3.1 REPLACING GREASE OF THE DRIVE MECHANISM for explanations about specified greases, the amount of grease to be supplied, and the locations of grease and degrease outlets for individual models.


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(2) Step-on prohibitive label

Fig. 1.6 (b) Step-on Prohibitive Label

Description

Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well. (3) High-temperature warning label

Fig. 1.6 (c) High-temperature warning label

Description Be cautious about a section where this label is affixed, as the section generates heat. If you have to inevitably touch such a section when it is hot, use a protective provision such as heat resistant gloves.


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(4) Transportation label

Fig. 1.6 (d) Transportation label

Description

When transporting the robot, observe the instructions indicated on this label. 1. Using a forklift Use a forklift having a load capacity of 3,000 kg or greater. Keep the total weight of the robot to be transported to within

1,000 kg, because the withstand load of the forklift bracket (option) is 13,720 N (1,400 kgf).

2. Using a crane Use a crane having a load capacity of 3,000 kg or greater. Use at least four slings each having a withstand load of 9,800 N

(1,000 kgf) or greater. Use at least four eyebolts each having a withstand load of 6,174

N (630 kgf) or greater.

CAUTION See section II.3.1 TRANSPORTATION for

explanations about the posture a specific model should take when it is transported.


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(5) Motion range, Max. payload label When CE specification is specified, following label is added.

0DEG-180DEG+180DEG

MAX. PAYLOAD : 350kg

Motion rangeof J5-axisrotation center

J5-axis rotation center

26508444432

46

Fig. 1.6(e) Motion range, max. payload label


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(6) Transportation prohibitive label (When transportation equipment option is specified.)

Do not pull eyeboltsideways

Do not have impacton this part

Do not chain, pry,or strap on this part

Fig. 1.6 (f) Transportation prohibitive label

Description

Keep the following in mind when transporting the robot.

1. Do not pull eyebolts sideways. 2. Prevent the forks of the forklift from having impact on

transport equipment. 3. Do not thread a chain or the like through a transport

equipment.

B-82135EN/05 PREFACE

p-1

PREFACE This manual explains the maintenance and connection procedures for the following robots:

Model name Mechanical unit specification No.

Maximum load

Controller

FANUC Robot M-900iA/350 A05B-1327-B201 350kg

FANUC Robot M-900iA/260L A05B-1327-B203 260kg

R-J3iB

FANUC Robot M-900iA/350 A05B-1327-B501 350kg

FANUC Robot M-900iA/260L A05B-1327-B503 260kg

R-30iA

CAUTION

Note that the models for the R-J3iB controller and those for the R-30iA controller partly differ in the specifications of mechanical unit cables and motors.

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.

PREFACE B-82135EN/05

p-2

TABLE 1 No. (1) (2) (3) (4) (5)

CONTENTS TYPE No. DATE WEIGHT (Without

controller) FANUC Robot M-900iA/350

A05B-1327-B201 1720kg

FANUC Robot M-900iA/260L

A05B-1327-B203 1800kg

FANUC Robot M-900iA/350

A05B-1327-B501 1720kg

LETTERS

FANUC Robot M-900iA/260L

A05B-1327-B503

PRINT SEAL NO. PRINT PRODUCTION

YEAR AND MONTH

1800kg

Position of label indicating mechanical unit specification number

B-82135EN/05 PREFACE

p-3

Specifications ITEM M-900iA/350 M-900iA/260L

Type Articulated Type Controlled axes 6 axes (J1, J2, J3, J4, J5, J6) Installation (NOTE) Floor mount, Upside-down (Angle mount) Motion range J1-axis 360 (6.28rad) 360 (6.28rad) Motion range J2-axis 150 (2.62rad) 150 (2.62rad) Motion range J3-axis 223.4 (3.90rad) 211.28 (3.69rad) Motion range J4-axis 720 (12.57rad) 720 (12.57rad) Motion range J5-axis 250 (4.36rad) 250 (4.36rad) Motion range J6-axis 720 (12.57rad) 720 (12.57rad) Max. Motion speed J1-axis 100/s (1.75rad/s) 100/s (1.75rad/s) Max. Motion speed J2-axis 95/s (1.66rad/s) 105/s (1.83rad/s) Max. Motion speed J3-axis 95/s (1.66rad/s) 95/s (1.66rad/s) Max. Motion speed J4-axis 105/s (1.83rad/s) 120/s (2.09rad/s) Max. Motion speed J5-axis 105/s (1.83rad/s) 120/s (2.09rad/s) Max. Motion speed J6-axis 170/s (2.97rad/s) 200/s (3.49rad/s) Max. Load capacity at wrist 350kg 260kg Max. Load capacity at J3 arm 25kg 25kg Max. Load capacity at J2 arm 550kg 550kg Allowable load moment at wrist J4-axis 1960N.m (200kgf.m) 1666N.m (170kgf.m) Allowable load moment at wrist J5-axis 1960N.m (200kgf.m) 1666N.m (170kgf.m) Allowable load moment at wrist J6-axis 891.8N.m (91kgf.m) 715.4N.m (73kgf.m)

235.2kg.m2 (2400kgf.cm.s2) 188.2kg.m2 (1920kgf.cm.s2) Allowable load inertia at wrist J4-axis 392kg.m2 (4000kgf.cm.s2) 313.6kg.m2 (3200kgf.cm.s2)

235.2kg.m2 (2400kgf.cm.s2) 188.2kg.m2 (1920kgf.cm.s2) Allowable load inertia at wrist J5-axis 392kg.m2 (4000kgf.cm.s2) 313.6kg.m2 (3200kgf.cm.s2)

156.8kg.m2 (1600kgf.cm.s2) 117.6kg.m2 (1200kgf.cm.s2) Allowable load inertia at wrist J6-axis 352.8kg.m2 (3600kgf.cm.s2) 225.4kg.m2 (2300kgf.cm.s2)

Drive method Electric servo drive by AC servo motor Repeatability +/- 0.3mm Weight Approx.1720kg Approx. 1800kg Acoustic noise level (NOTE2) 76.3dB

Ambient temperature: 0 - 45C Ambient humidity

Normally: 75%RH or less No dew, nor frost allowed.

Short time (within one month): Max 95%RH

Height:

Up to 1,000 meters above the sea level requires no particular provision for attitude.

Installation environment

Vibration: 0.5 (4.9m/s2) or less

NOTE 1 The operation range of the J1-axis and J2-axis are

limited to the installation condition. 2 This value is equivalent continuous A-weighted

sound pressure level, which applied with ISO11201 (EN31201). This value is measured with the following conditions.

- Maximum load and speed - Operating mode is AUTO

PREFACE B-82135EN/05

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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 designer Topics: Safety items for robot system design, operation, maintenance

R-J3iB controller

Operators manual SPOT TOOL B-81464EN-1 HANDLING TOOL B-81464EN-2 SEALING TOOL B-81464EN-4

Intended readers: Operator, programmer, maintenance person, system designer Topics: Robot functions, operations, programming, setup, interfaces, alarms Use: Robot operation, teaching, system design

R-J3iB controller

Maintenance manual B-81465EN B-81465EN-1 (For Europe)

Intended readers: Maintenance person, system designer Topics: Installation, connection to peripheral equipment, maintenance Use: Installation, start-up, connection, maintenance

R-30iA controller

Operators manual SPOT TOOL+ B-82594EN-1 HANDLING TOOL B-82594EN-2 DISPENSE TOOL B-82594EN-4 SERVO GUN FUNCTION B-82634EN

Intended readers: Operator, programmer, maintenance person, system designer Topics: Robot functions, operations, programming, setup, interfaces, alarms Use: Robot operation, teaching, system design

R-30iA controller

Maintenance manual B-82595EN B-82595EN-1 (For Europe) B-82595EN-2 (For RIA)

Intended readers: Maintenance person, system designer Topics: Installation, start-up, connection, maintenance Use: Installation, start-up, connection, maintenance

Mechanical unit

Maintenance manual FANUC Robot M-900iA/350 FANUC Robot M-900iA/260L B-82135EN

Intended readers: Maintenance person, system designer Topics: Installation, connection to the controller, maintenance Use: Installation, start-up, connection, maintenance

B-82135EN/05 TABLE OF CONTENTS

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TABLE OF CONTENTS SAFETY PRECAUTIONS............................................................................s-1 PREFACE....................................................................................................p-1

MAINTENANCE

1 CONFIGURATION ..................................................................................3 1.1 J1-AXIS DRIVE MECHANISM....................................................................... 4 1.2 J2/J3-AXIS DRIVE MECHANISM.................................................................. 5 1.3 J4-AXIS DRIVE MECHANISM....................................................................... 6 1.4 J5/J6-AXIS DRIVE MECHANISM.................................................................. 7 1.5 MAJOR COMPONENT SPECIFICATI ONS .................................................. 8

2 PREVENTIVE MAINTENANCE...............................................................9 2.1 DAILY CHECKS .......................................................................................... 10 2.2 3-MONTH CHECKS (960 hours) ................................................................. 12 2.3 1-YEAR CHECKS (3,840 hours).................................................................. 15 2.4 1.5-YEAR CHECKS (5,760 hours)............................................................... 16 2.5 3-YEAR CHECKS (11,520 hours)................................................................ 17 2.6 MAINTENANCE TOOLS ............................................................................. 18

3 PERIODIC MAINTENANCE..................................................................23 3.1 REPLACING GREASE OF THE DRIVE MECHANISM ............................... 24

3.1.1 Grease Replacement Procedure for the J1-Axis/J2- Axis/J3-Axis and J4-Axis Gear Box ......................................................................................................................26

3.1.2 Grease Replacement Procedure for the Wrist.........................................................26 3.1.3 Procedure for Releasing the Grease Residual Pressure ..........................................27

3.2 GREASING POINTS ................................................................................... 29 3.3 REPLACING THE BATTERIES................................................................... 30

4 TROUBLESHOOTING ..........................................................................31 4.1 OVERVIEW ................................................................................................. 32 4.2 FAILURE AND CAUSE................................................................................ 33 4.3 BACKLASH MEASUREMENT..................................................................... 40 4.4 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS .................... 43

5 ADJUSTMENTS....................................................................................44 5.1 AXIS LIMITS SETUP................................................................................... 45

5.1.1 Zero Point Position and Motion Limit ...................................................................46

TABLE OF CONTENTS B-82135EN/05

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5.1.2 Software Setting .....................................................................................................50 5.1.3 Hard Stopper and Limit Switch Setting..................................................................51

5.2 ADJUSTING LIMIT SWITCH (OPTION) ...................................................... 57 5.3 MASTERING ............................................................................................... 60

5.3.1 General ...................................................................................................................60 5.3.2 Resetting Alarms and Preparing for Mastering ......................................................61 5.3.3 Mastering to a Fixture (Master Position Master) ...................................................62 5.3.4 Zero Degree Mastering...........................................................................................67 5.3.5 Quick Mastering .....................................................................................................69 5.3.6 Single Axis Mastering ............................................................................................71 5.3.7 Mastering Data Entry .............................................................................................74

6 REPLACING PARTS ............................................................................76 6.1 NOTE FOR PART REPLACEMENT............................................................ 77 6.2 REPLACING J1-AXIS MOTOR (M1) AND REDUCER ................................ 78 6.3 REPLACING J2-AXIS MOTOR (M2) AND REDUCER ................................ 85 6.4 REPLACING J3-AXIS MOTOR (M3) AND REDUCER ................................ 90 6.5 REPLACING THE WRIST AXIS MOTORS (M4, M5, AND M6), WRIST UNIT

AND J4 AXIS REDUCER............................................................................. 95 6.6 SEALANT APPLICATION............................................................................ 98 6.7 REPLACING MOTOR COVERS (OPTION) ................................................ 99

7 PIPING AND WIRING .........................................................................100 7.1 PIPING DIAGRAM..................................................................................... 101 7.2 WIRING DIAGRAM.................................................................................... 102

8 REPLACING CABLES........................................................................105 8.1 CABLE FORMING..................................................................................... 107 8.2 CABLE REPLACEMENT ........................................................................... 112 8.3 LIMIT SWITCH REPLACEMENT (OPTION) ............................................. 120

9 SEVERE DUST/LIQUID PROTECTION OPTION ...............................124 9.1 OVERVIEW ............................................................................................... 125

9.1.1 Severe Dust/Liquid Protection Characteristics.....................................................125 9.1.2 Configuration of the Severe Dust/Liquid Protection Option................................126 9.1.3 Notes on Specifying Severe Dust/Liquid Protection Option................................127

9.2 REPLACING COMPONENTS OF THE SEVERE DUST/LIQUID PROTECTION OPTION ............................................................................ 128 9.2.1 Replacing Motor Covers ......................................................................................128 9.2.2 Replacing Cable Covers .......................................................................................130

B-82135EN/05 TABLE OF CONTENTS

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9.2.3 Replacing the Battery and Battery Box Cover .....................................................132

CONNECTION

1 ROBOT INTERFERENCE AREA........................................................137 1.1 External Dimensions.................................................................................. 138 1.2 Operation Area .......................................................................................... 140

2 MECHANICAL COUPLING TO THE ROBOT.....................................144 2.1 WRIST LOAD CONDITIONS..................................................................... 145 2.2 LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS ARM................... 148 2.3 MECHANICAL COUPLING OF END EFFECTOR TO WRIST .................. 149 2.4 EQUIPMENT MOUNTING FACE .............................................................. 150 2.5 OPERATION PERFORMANCE SCREENS............................................... 151 2.6 INERTIA LOAD SETTINGS....................................................................... 154

2.6.1 Setting...................................................................................................................155 2.6.2 Checking the Settings...........................................................................................156

2.7 AIR SUPPLY (OPTION) ............................................................................ 158 2.8 INTERFACE FOR OPTION CABLE (OPTION) ......................................... 159

3 TRANSPORTATION AND INSTALLATION .......................................176 3.1 TRANSPORTATION.................................................................................. 177

3.1.1 Transportation with an End Effector Attached.....................................................184 3.2 INSTALLATION ......................................................................................... 185 3.3 MAINTENANCE AREA.............................................................................. 189 3.4 AIR PIPING (OPTION) .............................................................................. 190 3.5 INSTALLATION SPECIFICATIONS .......................................................... 192 3.6 STORAGE ................................................................................................. 193

APPENDIX

A SPARE PARTS LIST ..........................................................................197 B CIRCUIT DIAGRAM ............................................................................201 C PERIODIC MAINTENANCE TABLE ...................................................206 D MOUNTING BOLT TORQUE LIST .....................................................208

MAINTENANCE

B-82135EN/05 MAINTENANCE 1.CONFIGURATION

- 3 -

1 CONFIGURATION The configuration of the mechanical unit is shown in Fig. 1.

Fig. 1 Mechanical unit configuration

1.CONFIGURATION MAINTENANCE B-82135EN/05

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1.1 J1-AXIS DRIVE MECHANISM Fig. 1.1 shows the J1-axis drive mechanism. The rotation of the J1-axis motor (M1) fastened to the table is input to the reducer through the center gear, and the output rotates the table.

Fig. 1.1 J1-axis drive mechanism


- 5 -

1.2 J2/J3-AXIS DRIVE MECHANISM Fig. 1.2 shows the J2/J3-axis drive mechanism. Rotation of the J2-axis motor (M2) is directly fed to the reducer, and the output moves the J2-axis arm. Rotation of the J3-axis motor (M3) is directly fed to the reducer, and the output moves the J3-axis arm via the Link1 and Link2.

Fig. 1.2 J2/J3-axis drive mechanism


- 6 -

1.3 J4-AXIS DRIVE MECHANISM Fig. 1.3 shows the J4-axis drive mechanism. Rotation of the J4-axis motor (M4) is fed to the reducer via the gear and drive shaft, and the output rotates the J4-axis (all of the wrist unit).

Fig. 1.3 J4-axis drive mechanism


- 7 -

1.4 J5/J6-AXIS DRIVE MECHANISM Fig. 1.4 shows the J5-axis/J6-axis drive mechanism. The rotation of the J5-axis motor (M5) is input to the reducer via the gear and drive shaft, and the output moves the J5-axis. The rotation of the J6-axis motor (M6) is input to the reducer via the gear and drive shaft, and the output rotates the J6-axis (wrist flange).

Fig. 1.4 J5/J6-axis drive mechanism

NOTE All motors incorporate a brake that is applied when

not energized. These brakes are active at power-off and emergency stop.


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1.5 MAJOR COMPONENT SPECIFICATI ONS Table 1.5 (a) Motor

Motor Specifications Model Axis M1 A06B-0268-B605#S000 (30/4000is)

iS30/4000 J1

M2, M3 A06B-0272-B605#S000 (40/4000is) iS40/4000

J2, J3

M4, M5, M6 A06B-0238-B605#S000 (12/4000is) iS12/4000

J4, J5, J6

Table 1.5 (b) Reducer (M-900iA/350)

Axis Specifications J1 A97L-0218-0347#500C-30 J2 A97L-0218-0348#550F-253 J3 A97L-0218-0348#550F-253 J4 A97L-0218-0349#160E-57

Table 1.5 (c) Reducer (M-900iA/260L)

Axis Specifications J1 A97L-0218-0347#500C-30 J2 A97L-0218-0348#550F-227 J3 A97L-0218-0348#550F-267 J4 A97L-0218-0349#160E-57

Table 1.5 (d) Wrist Unit

Model Name Specifications M-900iA/350 A290-7327-T501 M-900iA/260L A290-7327-T503

B-82135EN/05 MAINTENANCE 2.PREVENTIVE MAINTENANCE

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2 PREVENTIVE MAINTENANCE Optimum performance of the robot can be maintained by performing the periodic maintenance procedures presented in this chapter.

NOTE The periodic maintenance procedures described in

this chapter assume that the FANUC robot is used for up to 3840 hours a year. When using the robot beyond this total operating time, correct the maintenance frequencies shown in this chapter by calculation in proportion to the difference between the actual operating time and 3840 hours/year.

2.PREVENTIVE MAINTENANCE MAINTENANCE B-82135EN/05

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2.1 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 When air control set is combined

Item Check items Check points

1 Air pressure Check air pressure using the pressure gauge on the air regulator as shown in Fig. 2.1. If it does not meet the specified pressure of 0.49 to 0.69 MPa (5-7kgf/cm2), adjust it using the regulator pressure setting handle.

2 Oiler oil mist quantity Check the drop quantity during wrist or hand motion. If it does not meet the specified value (1 drop/10-20 sec), adjust it using the oiler control knob. Under normal usage, the oiler becomes empty in about 10 to 20 days under normal operation.

3 Oiler oil level Check to see that the oiler level is within the specified level shown in Fig. 2.1.

4 Leakage from hose Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.

1 Oil inlet 5 Pressure gauge 2 Adjusting knob 6 Regulator pressure setting

handle 3 Lubricator mist amount check 7 Filter 4 Lubricator

Fig. 2.1 Air control set (option)


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2. After automatic operation

Item Check items Check points 1 Vibration, abnormal

noises, and motor heating

Check whether the robot moves along and about the axes smoothly without unusual vibration or sounds. Also, check whether the temperatures of the motors are excessively high.

2 Changing repeatability Check to see that the stop positions of the robot have not deviated from the previous stop positions.

3 Peripheral devices for proper operation

Check whether the peripheral devices operate properly according to commands from the robot.

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


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2.2 3-MONTH CHECKS (960 hours) 1. Check the following items once every about three months (or 960

hours operating). Additional inspection areas and times should be added to the table according to the robots working conditions, environment, etc.


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

2 Ventilation portion of control unit

If the ventilation portion of the control unit is dusty, turn off power and clean the unit.

2. First quarterly inspection Check the following items at the first

quarterly inspection, then every year thereafter. Item Check items Check points

1 Cables used in mechanical unit

Check whether the jackets of the mechanical unit cables are damaged. Also, check whether the cables are excessively bent or unevenly twisted. Check that the connectors of the motors and connector panels are securely engaged. See Section 7.2. (NOTE 1)

2 Cleaning and checking each part

Clean each part (remove chips, etc.) and check component parts for cracks and flaws. (NOTE 2)

3 Further tightening external main bolts

Further, tighten the end effector mounting bolts and external main bolts. (NOTE 3)

NOTE 1) Inspection points and check items of the mechanical unit cables and

connectors Inspection points of the mechanical unit cables Fixed part cables likely to interfere with the J1, J2, and J3 movable parts and peripheral devices For the J1-axis, inspect the cables from above the J2 base and from the side by removing the metal plate on the side of the J1 base. Check items For cables with a cable cover, open the cover before making the check. Check the cables for a sheath break and wear. If wires of the cable appear, replace it.


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Fig. 2.2 (a) Check items of Mechanical unit cable

Inspection points of the connectors - Power/brake connectors of the motor exposed externally - Robot connection cables and user cables, earth terminal Check items - Circular connector: Check the connector for looseness by turning

it manually. - Square connector: Check the connector for disengagement of its

lever. - Earth terminal: Check the connector for looseness.

Fig. 2.2 (b) Check items of connector


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NOTE 2) 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 spatters are attached to the oil seal, an oil leak may be caused. - Check if the vicinity of the necessary inspection points, wrist part,

and J3 arm significantly wears due to rubbing against the welding cable or hand cable.

- Check if there is a trace of a collision around the gun or hand. - Check the reducer or grease bath for an oil leak. If oil can be found a day after wiping oil, an oil leak may be caused.

Fig. 2.2 (c) Cleaning part

NOTE 3) Points to be retightened

- The end effector mounting bolts, robot installation bolts, and bolts to be removed for inspection need to be retightened.

- The bolts exposed to the outside of the robot need to be retightened.

For the tightening torque, see the recommended bolt tightening torque shown in the Appendix. A loose prevention agent (adhesive) is applied to some bolts. If the bolts are tightened with greater than the recommended torque, the loose prevention agent may be removed. So, follow the recommended tightening torque when retightening them.


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2.3 1-YEAR CHECKS (3,840 hours) Check the following items once every about year (or 3,840 hours operating). Item Check items Check points

1 Cables used in mechanical unit

(See Section 2.2.)

2 Cleaning each parts and inspection

(See Section 2.2.)

3 Tightness of major external bolts

(See Section 2.2.)


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2.4 1.5-YEAR CHECKS (5,760 hours) Check the following item once every 1.5-year.


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


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2.5 3-YEAR CHECKS (11,520 hours) Check the following items once every about 3 years (or 11,520 hours operating). Item Check items Check points

1 Replacing grease of each axis, reducer and gear box

Refer to Section 3.1.


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2.6 MAINTENANCE TOOLS The following tools and instruments are required for the maintenance procedures contained in this manual.

1. Measuring instruments

Instruments Accuracy/Capacity Applications Dial gauge accuracy

1/100 mm accuracy Measurement of positioning and backlash

Slide calipers 150 mm capacity Push/pull tension gauge

98N (10 kgf) accuracy Measurement of backlash

2. Tools

Cross-point (+) screwdrivers sizes

: Large, medium, and small

Conventional (-) screwdrivers sizes

: Large, medium, and small

Box screw drivers : M6 Hexagonal wrench key sets (metric)

: M3 - M20

Adjustable wrenches : Medium and small sizes Pliers Cutting pliers Cutting nippers Double hexagon offset wrench Grease gun Pliers for C-retaining ring Torque wrench Gear puller Spanner : 30x32mm or 32x36mm

(Thickness: 14 mm or less for stopping J41 gear rotation)

T-shaped hexagonal wrench : M8 (Length: 270 mm or more. Used for wrist axis motor connection) M12 (Length: 300 mm or more. Used for J2 and J3 axis motor connection)


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3. Special Tools A290-7324-X921 2PCS (Guide pin (M12) for J1/J2/J3-axis reducer replacement) See Fig.2.6 (a). A290-7324-X922 (Spring pin striking tool for J1-axis reducer replacement) See Fig.2.6 (b)) A290-7324-X923 2PCS (Guide pin (M16) for J1/J2/J3-axis reducer replacement) See Fig.2.6 (c). A290-7324-X924 (For bearing installation in the J1-axis input gear) See Fig. 2.6 (d). A290-7321-X947 (For bearing installation in gear J41) See Fig. 2.6 (e). A290-7327-X924 (For oil seal installation in the J2/J3-axis reducer) See Fig. 2.6 (f). A290-7327-X910 (Robot hanging tool for J1-axis reducer replacement) See Fig. 2.6(g).

4. Options (For securing the arm during J2 or J3-axis motor replacement) For changing the J2-axis operating range: A05B-1327-J032 For changing the J3-axis operating range: A05B-1327-J033

Fig. 2.6 (a) Guide pin (M12) for J1/J2/J3-axis reducer replacement


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Fig. 2.6 (b) Spring pin striking tool for J1-axis reducer replacement

Fig. 2.6 (c) Guide pin (M16) for J1/J2/J3-axis reducer replacement

Fig. 2.6 (d) For bearing installation in the J1-axis input gear


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Fig. 2.6 (e) For installing bearing on gear J41

Fig. 2.6 (f) For installing oil seal to the J2/J3-axis reducer


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Fig. 2.6 (g) Robot hanging tool for J1-axis reducer replacement

B-82135EN/05 MAINTENANCE 3.PERIODIC MAINTENANCE

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3 PERIODIC MAINTENANCE

3.PERIODIC MAINTENANCE MAINTENANCE B-82135EN/05

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3.1 REPLACING GREASE OF THE DRIVE MECHANISM Replace the grease of the reducers of J1, J2, and J3 axes, and the J4-axis gear box, and the wrist, every three years or 11,520 hours by using the following procedures.

Table 3.1 (a) Grease for 3-year periodical replacement

Models Supply position Quantity Gun tip pressure Grease name

J1-axis reducer 7000g (8000ml) J2-axis reducer 3000g (3400ml) J3-axis reducer 2700g (3100ml) J4-axis gear box 1900g (2200ml)

M-900iA/350 M-900iA/260L

Wrist 5000g (5750ml)

0.15MPa or less(NOTE)

Kyodo yushi

VIGOGREASE RE0 Spec. ; A98L-0040-0174

NOTE When using a hand pump, apply grease approximately

once per 1.5 seconds. For grease replacement or replenishment, use the attitudes indicated below.

Table 3.1 (b) Attitudes for greasing Attitude Supply position

J1 J2 J3 J4 J5 J6 J1-axis reducer Arbitrary J2-axis reducer 0

Arbitrary

J3-axis reducer 0 0 J4-axis gear box 0

Arbitrary Arbitrary Arbitrary

Wrist

Arbitrary

Arbitrary 0 0 0 0

For ceiling-hung installation, see Table 3.1 (c).

Table 3.1 (c) Attitudes for greasing (for ceiling-hung installation) Attitude Supply position

J1 J2 J3 J4 J5 J6 J1-axis reducer Arbitrary J2-axis reducer -75

Arbitrary

J3-axis reducer +76 J4-axis gear box -96

Arbitrary Arbitrary Arbitrary

Wrist

Arbitrary Arbitrary

0 180 or -180 0 0


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Fig. 3.1 (a) Replacing grease of J1/J2-axis reducer

Fig. 3.1 (b) Replacing grease of J3-axis gear box

3.PERIODIC MAINTENANCE MAINTENANCE B-82135EN/05

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Fig. 3.1 (c) Replacing grease of wrist

3.1.1 Grease Replacement Procedure for the J1-Axis/J2-

Axis/J3-Axis and J4-Axis Gear Box 1. Move the robot to the greasing attitude described in Section 3.1. 2. Turn off the power. 3. Remove the seal bolt from the grease outlet. 4. Supply new grease until new grease is output from the grease

outlet. 5. After applying grease, release the residual pressure within the

grease bath as described in the procedure in Section 3.1.3.

3.1.2 Grease Replacement Procedure for the Wrist 1. Move the robot to the greasing attitude described in Section 3.1. 2. Turn off the power. 3. Remove the seal bolt from wrist grease outlet 1 and 2. 4. Supply new grease through the wrist grease inlet until new grease

is output from wrist grease outlet 1. 5. Attach the seal bolt onto wrist grease outlet 1. When reusing the

seal bolt, be sure to seal the seal bolt with seal tape. 6. Remove the seal bolt from wrist grease outlet 2.


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7. Supply new grease through the wrist grease inlet until new grease is output from wrist grease outlet 2.

8. After applying grease, release the residual pressure within the grease bath as described in the procedure in Section 3.1.3.

CAUTION 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, observe the following cautions.

1. Before starting to grease, open the grease outlet (remove the plug or bolt from the grease outlet).

2. Supply grease slowly without applying excessive force, using a manual pump.

3. Whenever possible, avoid using a compressed-air pump, powered by the factory air supply. Even when using Table 3.1(a) or less during application of grease.

4. Use grease only of the specified type. Grease of a type other than that specified may damage the reducer or lead to other problems.

5. After applying grease, release the residual pressure within the grease bath as described in the procedure in Section 3.1.3.

6. To prevent accidents caused by slipping, completely remove any excess grease from the floor or robot.

3.1.3 Procedure for Releasing the Grease Residual Pressure

Release the residual pressure as described below. Attach the recovery bag under the grease inlet and outlet to prevent drained grease from splattering.

Exchange position Operation angle OVR Operation time Release positionJ1-axis reducer 80 or more 50% 20minutes A J2-axis reducer 90 or more 50% 20minutes A J3-axis reducer 70 or more 50% 20minutes A

J4-axis gear box J4=60 or more J5=

manual mecanico m900

Documents

fanuc robot safety manual

instruction manual

export license

reexport regulations

robot controllers

900ia350fanuc robot

fanucrobotics america

government of japan