Delta Robot IP67 Mini Delta Robot IP67 - Omron Removing the plastic bearing from the link ball...

ZX-T Series

Cat. No. I195E-EN-03

Delta Robot IP67Mini Delta Robot IP67

MAINTENANCEMANUAL

Washdown Delta RobotR6Y3 Series

CONTENTS R6Y3Maintenance Manual

T-1

Safety Instructions

1. Safety Information S-1

2. Signal words used in this manual S-2

3. Warning labels S-3

3.1 Warning labels S-33.1.1 Contents of warning label messages S-3

3.1.2 Supplied warning label S-4

3.2 Warning symbols S-4

4. Major precautions for each stage of use S-5

4.1 Precautions for using robots S-5

4.2 Design S-5

4.3 Moving and installation S-6

4.4 Safety measures S-84.4.1 Safety measures S-8

4.4.2 Installing a safety enclosure S-9

4.5 Operation S-104.5.1 Trial operation S-10

4.5.2 Automatic operation S-10

4.5.3 Precautions during operation S-10

4.6 Inspection and maintenance S-114.6.1 Before inspection and maintenance work S-11

4.6.2 Precautions during service work S-12

4.7 Disposal S-12

5. Emergency action when a person is caught by robot S-13

6. Using the robot safely S-14

6.1 Robot protective functions S-14

6.2 Residual risk S-14

6.3 Special training for industrial robot operation S-14

Warranty


T-2

Chapter 1 Overview

1. Overview 1-1

Chapter 2 Attaching, detaching and replacing the cover

1. Detachingorattachingtheα,βandγ-axescovers 2-1

1.1 R6Y3[]110 2-11.1.1 α,βandγ-axescoverremovalprocedure 2-2

1.1.2 α,βandγ-axescoverattachmentprocedure 2-7

1.2 R6Y3[]065 2-131.2.1 α,βandγ-axescoverremovalprocedure 2-14

1.2.2 α,βandγ-axescoverattachmentprocedure 2-17

2. Detachingorattachingtheθ-axiscover 2-22

2.1 θ-axismotorcoverremoval 2-23

2.2 θ-axismotorcoverattachment 2-25

Chapter 3 Periodic inspection

1. Overview 3-1

2. Daily inspection 3-2

3. Monthly inspection 3-3

4. Six-monthinspection 3-4

Chapter 4 Adjusting the origin

1. Adjusting the origin 4-1

1.1 Adjustingtheα,βandγ-axesoriginposition 4-21.1.1 R6Y3[]110 4-2

1.1.2 R6Y3[]065 4-5

1.2 Adjustingtheθ-axisoriginposition(4-axesspecificationonly) 4-8


T-3

Chapter 5 Shaft, movable base and spring cover replacement

1. Shaft, movable base and spring cover replacement procedure 5-1

1.1 Detachingtheshafts,movablebaseandspringcover 5-3

1.2 Attachingtheshafts,movablebaseandspringcovers 5-51.2.1 R6Y30110S03067NJ5,R6Y30065S02067NJ5(3-axesspecification) 5-5

1.2.2 R6Y31110L03067NJ5,R6Y31110H03067NJ5,R6Y31065L02067NJ5,R6Y31065H02067NJ5(4-axesspecification) 5-7

1.2.3 Attachingthespringcover(ReinforcedSpringCovercommonto3-axesand4-axes) 5-10

2. Movable base link ball replacement 5-12

Chapter 6 Spring mechanism replacement

1. Spring mechanism replacement procedure 6-1

1.1 Springmechanismremoval 6-2

1.2 Springmechanismattachment 6-3

Chapter 7 Plastic bearing replacement

1. Plastic bearing replacement procedure 7-1

1.1 Removingtheplasticbearingfromthelinkballslidingpart 7-1

1.2 Attachingtheplasticbearingtothelinkballslidingpart 7-2

1.3 Springmechanismplateplasticbearingremoval 7-3

1.4 Springmechanismplateplasticbearingattachment 7-3

2. Plastic bearing inspection 7-4

Chapter8 θ-axisseal,O-ringreplacement

1. θ-axisseal,O-ringreplacementprocedure 8-1

1.1 θ-axisseal,O-ringremoval 8-1

1.2 θ-axisseal,O-ringattachment 8-3


T-4

Chapter 9 Motor replacement

1. α,βandγ-axesmotorreplacement 9-1

1.1 R6Y3[]110 9-11.1.1 α,βandγ-axesmotorremoval 9-1

1.1.2 α,βandγ-axesmotorattachment 9-4

1.2 R6Y3[]065 9-51.2.1 α,βandγ-axesmotorremoval 9-5

1.2.2 α,βandγ-axesmotorattachment 9-8

2. θ-axismotorreplacement 9-9

2.1 θ-axismotorremoval 9-9

Chapter 10 Speed reduction gear, arm replacement

1. Speed reduction gear replacement precautions 10-1

2. Speed reduction gear and arm replacement procedure 10-2

2.1 R6Y3[]110 10-22.1.1 α,βandγ-axesarmreplacement 10-2

2.1.1.1 Work required after replacing arm link balls 10-4

2.1.1.2 Armharnessreplacement 10-4

2.1.2 α,βandγ-axesspeedreductiongearreplacement 10-6

2.2 R6Y3[]065 10-82.2.1 α,βandγ-axesarmreplacement 10-8

2.2.1.1 Work required after replacing arm link balls 10-10

2.2.1.2 Armharnessreplacement 10-10

2.2.2 α,βandγ-axesspeedreductiongearreplacement 10-12

2.3 θ-axisspeedreductiongearreplacement 10-15

Chapter 11 Option parts replacement

1. Shaft replacement procedure 11-1

1.1 Shaftremoval 11-1

1.2 Shaftattachment 11-3

2. Harness replacement procedure 11-6

2.1 R6Y3[]110 11-6

2.2 R6Y3[]065 11-8

3. Detection connector replacement procedure 11-10


T-5

Chapter 12 Maintenance parts

1. Consumable parts 12-1

2. Basicspecification 12-2

2.1 R6Y3[]110 12-2

2.2 R6Y3[]065 12-3

3. Maintenance parts 12-4

3.1 R6Y3[]110 12-43.1.1 R6Y30110S03067NJ5 BASE 12-4

3.1.2 R6Y31110[]03067NJ5 BASE 12-5

3.1.3 R6Y30110S03067NJ5 AXIS 12-6

3.1.4 R6Y31110[]03067NJ5 AXIS 12-7

3.1.5 R6Y30110S03067NJ5 ARM 12-8

3.1.6 R6Y31110[]03067NJ5 ARM 12-9

3.1.7 R6Y30110S03067NJ5SHAFT 12-10

3.1.8 R6Y31110[]03067NJ5SHAFT 12-11

3.1.9 R6Y31110[]03067NJ5 OPTION 12-12

3.2 R6Y3[]065 12-133.2.1 R6Y30065S02067NJ5 BASE 12-13

3.2.2 R6Y31065[]02067NJ5 BASE 12-14

3.2.3 R6Y30065S02067NJ5 AXIS 12-15

3.2.4 R6Y31065[]02067NJ5 AXIS 12-16

3.2.5 R6Y30065S02067NJ5 ARM 12-17

3.2.6 R6Y31065[]02067NJ5 ARM 12-18

3.2.7 R6Y30065S02067NJ5SHAFT 12-19

3.2.8 R6Y31065[]02067NJ5SHAFT 12-20

3.2.9 R6Y31065[]02067NJ5 OPTION 12-21

3.3 R6Y3[]110,R6Y3[]065θ-axis 12-223.3.1 R6Y30110S03067NJ5,R6Y30065S02067NJ5θ 12-22

3.3.2 R6Y31110L03067NJ5,R6Y31065L02067NJ5θ 12-23

3.3.3 R6Y31110H03067NJ5,R6Y31065H02067NJ5θ 12-25

Contents

1. Safety Information S-1

2. Signal words used in this manual S-2

3. Warning labels S-33.1 Warning labels S-3

3.1.1 Contents of warning label messages S-33.1.2 Supplied warning label S-4

3.2 Warning symbols S-4

4. Major precautions for each stage of use S-54.1 Precautions for using robots S-5

4.2 Design S-5

4.3 Moving and installation S-6

4.4 Safety measures S-8

4.4.1 Safety measures S-84.4.2 Installing a safety enclosure S-9

4.5 Operation S-10

4.5.1 Trial operation S-104.5.2 Automatic operation S-104.5.3 Precautions during operation S-10

4.6 Inspection and maintenance S-11

4.6.1 Before inspection and maintenance work S-114.6.2 Precautions during service work S-12

4.7 Disposal S-12

5. Emergency action when a person is caught by robot S-13

6. Using the robot safely S-146.1 Robot protective functions S-14

6.2 Residual risk S-14

6.3 Special training for industrial robot operation S-14

Safety Instructions

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S-1

1. Safety InformationIndustrialrobotsarehighlyprogrammable,mechanicaldevicesthatprovidealargedegreeoffreedomwhenperformingvariousmanipulativetasks.Tooperatetherobotinsaferandcorrectmanner,strictlyobservethesafetyinstructionsandprecautionsstatedinthis"SafetyInstructions"guide.Failuretotakenecessarysafetymeasuresorincorrecthandlingmayresultintroubleordamagetotherobot,andalsomaycausepersonalinjury(toinstallationpersonnel,robotoperatororservicepersonnel)includingfatalaccidents.

Thesafetyinstructionsandprecautionsdescribedinthe“SafetyInstructions”coveronlytherobot(mechanicalsections).Fordetailsaboutoperationofthecontrollerandsafetyprecautionsassociatedwiththecontrolleroperation,refertotheControllerManual.

Beforeusingthisproduct,readthismanualandrelatedmanualsandtakesafetyprecautionstoensurecorrecthandling. Theprecautionslistedinthismanualrelatetothisproduct.Toensurethesafetyoftheuser’sfinalsystemthatincludesrobots,theusermusttakeappropriatesafetyconsiderations.

Touserobotssafelyandcorrectly,besuretostrictlyobservethesafetyrulesandinstructions.

• Forspecificsafetyinformationandstandards,refertotheapplicablelocalregulationsandcomplywiththe instructions.

• WarninglabelsattachedtotherobotsarewritteninEnglish,Japanese,ChineseandKorean.Thismanualisavailable inEnglishorJapanese(orsomepartsinChinese).Unlesstherobotoperatorsorservicepersonnelunderstand theselanguages,donotpermitthemtohandletherobot.

• CautionsregardingtheofficiallanguageofEUcountries.ForequipmentthatwillbeinstalledinEUcountries,the languageusedforthemanuals,warninglabels,operationscreencharacters,andCEdeclarationsisEnglishonly. WarninglabelsonlyhavepictogramsorelseincludewarningmessagesinEnglish.Inthelattercase,messages inJapaneseorotherlanguagesmightbeadded.

Itisnotpossibletolistallsafetyitemsindetailwithinthelimitedspaceofthismanual.Sopleasenotethatitisessentialthattheuserhaveafullknowledgeofsafetyandalsomakecorrectjudgmentsonsafetyprocedures.

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2. Signal words used in this manualThismanualusesthefollowingsafetyalertsymbolsandsignalwordstoprovidesafetyinstructionsthatmustbeobservedandtodescribehandlingprecautions,prohibitedactions,andcompulsoryactions.Makesureyouunderstandthemeaningofeachsymbolandsignalwordandthenreadthismanual.

DANGER THISINDICATESANIMMEDIATELYHAzARDOUSSITUATIONWHICH,IFNOTAvOIDED,WILLRESULTINDEATHORSERIOUSINJURY.

WARNING THISINDICATESApOTENTIALLYHAzARDOUSSITUATIONWHICH,IFNOTAvOIDED,COULDRESULTINDEATHORSERIOUSINJURY.

CAUTION Thisindicatesapotentiallyhazardoussituationwhich,ifnotavoided,couldresultinminorormoderateinjury,ordamagetotheequipment.

NOTE Explainsthekeypointintheoperationinasimpleandclearmanner.

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3. Warning labelsWarninglabelsareattachedtotherobotbody.Toensurecorrectuse,readthewarninglabelsandcomplywiththeinstructions.

3.1 Warning labels

WARNING IFWARNINgLABELSAREREMOvEDORDIFFICULTTOSEE,THENTHENECESSARYpRECAUTIONSMAYNOTBETAKEN,RESULTINgINANACIDENT. • DONOTREMOvE,ALTERORSTAINTHEWARNINgLABELSONTHEROBOTBODY. • DONOTALLOWWARNINgLABELSTOBEHIDDENBYDEvICESINSTALLEDONTHEROBOTBYTHEUSER. • pROvIDEpROpERLIgHTINgSOTHATTHESYMBOLSANDINSTRUCTIONSONTHEWARNINgLABELSCANBE CLEARLYSEENFROMOUTSIDETHESAFETYENCLOSURE.

3.1.1 Contents of warning label messagesWordmessagesonthedanger,warningandcautionlabelsareconciseandbriefinstructions.Formorespecificinstructions,readandfollowthe"Instructionsonthislabel"describedontherightofeachlabelshownbelow.

1. Warning label 1

DANGER SERIOUSINJURYMAYRESULTFROMCONTACTWITHAMOvINgROBOT. • KEEpOUTSIDEOFTHEROBOTSAFETYENCLOSUREDURINgOpERATION. • pRESSTHEEMERgENCYSTOpBUTTONBEFOREENTERINgTHESAFETYENCLOSURE.

Instructions on this label

• Alwaysinstallasafetyenclosuretokeepallpersonsawayfromtherobotmovementrangeandpreventinjuryfromcontactingthemovingpartoftherobot.

• Installaninterlockthattriggersemergencystopwhenthedoororgateofthesafetyenclosureisopened.

• Thesafetyenclosureshouldbedesignedsothatnoonecanenterinsideexceptfromthedoororgateequippedwithaninterlockdevice.

• Warninglabel1thatcomessuppliedwitharobotshouldbeaffixedtoaneasy-to-seelocationonthedoororgateofthesafetyenclosure.

Potential hazard to human body Seriousinjurymayresultfromcontactwithamovingrobot.

To avoid hazard•Keepoutsideoftherobotsafetyenclosureduringoperation. •presstheemergencystopbuttonbeforeenteringthesafetyenclosure.

2. Warning label 2

WARNING MOvINgpARTSCANpINCHORCRUSHHANDS. KEEpHANDSAWAYFROMTHEMOvABLEpARTSOFTHEROBOT.


Usecautiontopreventhandsandfingersfrombeingpinchedorcrushedbythemovablepartsoftherobotwhentransportingormovingtherobotorduringteaching.

Potential hazard to human body Movingpartscanpinchorcrushhands.

To avoid hazard Keephandsawayfromthemovablepartsoftherobot.

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3. Warning label 3

WARNING IMpROpERINSTALLATIONOROpERATIONMAYCAUSESERIOUSINJURY. BEFOREINSTALLINgOROpERATINgTHEROBOT,READTHEMANUALANDINSTRUCTIONSONTHEWARNINgLABELSANDUNDERSTANDTHECONTENTS.


• Besuretoreadthewarninglabelandthismanualcarefullytomakeyoucompletelyunderstandthecontentsbeforeattemptinginstallationandoperationoftherobot.

• Beforestartingtherobotoperation,evenafteryouhavereadthroughthismanual,readagainthecorrespondingproceduresand"Safetyinstructions"inthismanual.

• Neverinstall,adjust,inspectorservicetherobotinanymannerthatdoesnotcomplywiththeinstructionsinthismanual.

Potential hazard to human body Improper installation or operation may cause serious injury.

To avoid hazardBeforeinstallingoroperatingtherobot,readthemanualandinstructionsonthewarninglabelsandunderstandthecontents.

3.1.2 Supplied warning label

CAUTION Attachthewarninglabelthathasbeenincludedintherobotatshipmenttoalegiblelocationclosetotherobot,suchasentranceofthesafety enclosure.

3.2 Warning symbols

Warningsymbolsshownbelowareattachedtotherobotbodytoalerttheoperatortopotentialhazards.TousetheOMRONrobotsafelyandcorrectlyalwaysfollowtheinstructionsandcautionsindicatedbythesymbols.

1. Electrical shock hazard symbol

WARNING TOUCHINgTHETERMINALBLOCKORCONNECTORMAYCAUSEELECTRICALSHOCK,SOUSECAUTION.

Instructions by this symbol

Thisindicatesahighvoltageispresent. Touchingtheterminalblockorconnectormaycauseelectricalshock.

2. High temperature hazard symbol

WARNING MOTORS,HEATSINKS,ANDREgENERATIvEUNITSBECOMEHOT,SODONOTTOUCHTHEM.

Instructions by this symbol

Thisindicatestheareaaroundthissymbolmaybecomeveryhot. Motors,heatsinks,andregenerativeunitsbecomehotduringandshortlyafteroperation.Toavoidburnsbecarefulnottotouchthosesections.

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4. Major precautions for each stage of useThissectiondescribesmajorprecautionsthatmustbeobservedwhenusingrobots.Besuretocarefullyreadandcomplywithalloftheseprecautionsevenifthereisnoalertsymbolshown.

4.1 Precautions for using robotsgeneralprecautionsforusingrobotsaredescribedbelow.

1. Applications where robots cannot be used

OMRONrobotsaredesignedasgeneral-purposeindustrialequipmentandcannotbeusedfortheapplicationslistedbelow.

DANGER ROBOTSAREDESIgNEDASgENERAL-pURpOSEINDUSTRIALEqUIpMENTANDCANNOTBEUSEDFORTHEFOLLOWINgAppLICATIONS. • INMEDICALEqUIpMENTSYSTEMSWHICHARECRITICALTOHUMANLIFE • INSYSTEMSTHATSIgNIFICANTLYAFFECTSOCIETYANDTHEgENERALpUBLIC • INEqUIpMENTINTENDEDTOCARRYORTRANSpORTpEOpLE • INENvIRONMENTSWHICHARESUBJECTTOvIBRATIONSUCHASONBOARDSHIpSANDvEHICLES.

2. Qualification of operators/workers

Operatorsorpersonswhohandletherobotsuchasforteaching,programming,movementcheck,inspection,adjustment,andrepairmustreceiveappropriatetrainingandalsohavetheskillsneededtoperformthejobcorrectlyandsafely.Theymustreadthemanualcarefullytounderstanditscontentsbeforeattemptingtherobotoperationormaintenance. Tasksrelatedtoindustrialrobots(teaching,programming,movementcheck,inspection,adjustment,repair,etc.)mustbeperformedbyqualifiedpersonswhomeetrequirementsestablishedbylocalregulationsandstandardsforindustrialrobots.

WARNING • THEROBOTMUSTBEOpERATEDONLYBYpERSONSWHOHAvERECEIvEDSAFETYANDOpERATIONTRAININg. OpERATIONBYANUNTRAINEDpERSONISExTREMELYHAzARDOUS. • ADJUSTMENTANDMAINTENANCEBYREMOvINgACOvERREqUIRESpECIALIzEDTECHNICALKNOWLEDgE ANDSKILLS,ANDMAYALSOINvOLvEHAzARDSIFATTEMpTEDBYANUNSKILLEDpERSON.THESETASKS MUSTBEpERFORMEDONLYBYpERSONSWHOHAvEENOUgHABILITYANDqUALIFICATIONSINACCORDANCE WITHLOCALLAWSANDREgULATIONS.FORDETAILEDINFORMATION,pLEASECONTACTYOURDISTRIBUTOR WHEREYOUpURCHASEDTHEpRODUCT.

4.2 Design

1. Restricting the movement range

WARNING SOFTLIMITFUNCTIONISNOTASAFETY-RELATEDFUNCTIONINTENDEDTOpROTECTTHEHUMANBODY. ENSURESAFETYBYINSTALLINgASAFETYENCLOSUREANDSOON.

2. Provide safety measures for end effector (gripper, etc.)

WARNING • ENDEFFECTORSMUSTBEDESIgNEDANDMANUFACTUREDSOTHATTHEYCAUSENOHAzARDS(SUCHASA LOOSEWORKpIECEORLOAD)EvENIFpOWER(ELECTRICITY,AIRpRESSURE,ETC.)ISSHUTOFFORpOWER FLUCTUATIONSOCCUR. • IFTHEOBJECTgRIppEDBYTHEENDEFFECTORMIgHTpOSSIBLYFLYOFFORDROp,THENpROvIDE AppROpRIATESAFETYpROTECTIONTAKINgINTOACCOUNTTHEOBJECTSIzE,WEIgHT,TEMpERATURE,AND CHEMICALpROpERTIES.

3. Provide adequate lighting

provideenoughlightingtoensuresafetyduringwork.

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4. Install an operation status light

WARNING INSTALLASIgNALLIgHT(SIgNALTOWER)ATANEASY-TO-SEEpOSITIONSOTHATTHEOpERATORWILLBEAWAREOFTHEROBOTSTOpSTATUS(TEMpORARILYSTOppED,EMERgENCYSTOp,ERRORSTOp,ETC.).

4.3 Moving and installation

■ Installation environment

1. Do not use in strong magnetic fields

WARNING DONOTUSETHEROBOTNEAREqUIpMENTORINLOCATIONSTHATgENERATESTRONgMAgNETICFIELDS.THEROBOTMAYBREAKDOWNORMALFUNCTIONIFUSEDINSUCHLOCATIONS.

2. Do not use in locations subject to possible electromagnetic interference, etc.

WARNING DONOTUSETHEROBOTINLOCATIONSSUBJECTTOELECTROMAgNETICINTERFERENCE,ELECTROSTATICDISCHARgEORRADIOFREqUENCYINTERFERENCE.THEROBOTMAYMALFUNCTIONIFUSEDINSUCHLOCATIONSCREATINgHAzARDOUSSITUATIONS.

3. Donotuseinlocationsexposedtoflammablegases

WARNING • OMRONROBOTSARENOTDESIgNEDTOBEExpLOSION-pROOF. • DONOTUSETHEROBOTSINLOCATIONSExpOSEDTOExpLOSIvEORINFLAMMABLEgASES,DUSTpARTICLES ORLIqUID.FAILURETOFOLLOWTHISINSTRUCTIONMAYCAUSESERIOUSACCIDENTSINvOLvINgINJURYOR DEATH,ORLEADTOFIRE.

■ Moving

1. Use caution to prevent pinching or crushing of hands or fingers

WARNING KEEpYOURHANDAWAYFROMTHEROBOTINSTALLATIONSURFACEDURINgMOvINg.OTHERWISE,YOURHANDISENTANgLED,CAUSINgSERIOUSpERSONALINJURY.

AsinstructedinWarninglabel2,usecautiontopreventhandsorfingersfrombeingpinchedorcrushedbymovablepartswhentransportingormovingtherobot.Fordetailsonwarninglabels,see"3.Warninglabels"in"Safetyinstructions."

2. Take safety measures when moving the robot

ToensuresafetywhenmovingtheDELTArobot,usetheeyeboltsthatcomewiththerobot. Refertothe"2.3Movingtherobot"inChapter2oftheInstallationManualfordetails.

3. Take measures to prevent the robot from falling

Whenmovingtherobotbyliftingitwithequipmentsuchasahoistorcrane,wearpersonalprotectivegearandbecarefulnottomovetherobotathigherthantherequiredheight.

Makesurethattherearenopersonsonpathsusedformovingtherobot.

WARNING AROBOTFALLINgFROMAHIgHpLACEANDSTRIKINgAWORKERMAYCAUSEDEATHORSERIOUSINJURY.WHENMOvINgTHEROBOT,WEARpERSONALpROTECTIvEgEARSUCHASHELMETSANDMAKESURETHATNOONEISWITHINTHESURROUNDINgAREA.

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■ Installation

1. Protect electrical wiring and hydraulic/pneumatic hoses

Installacoverorsimilaritemtoprotecttheelectricalwiringandhydraulic/pneumatichosesfrompossibledamage.

2. Cautions on arm

Intheinstallationworkorincaseofanemergency,donotholdthearmbyyourhand.Itmaycausemalfunction.

■ Adjustment

1. Adjustment that requires removing a cover

WARNING ADJUSTMENTBYREMOvINgACOvERREqUIRESpECIALIzEDTECHNICALKNOWLEDgEANDSKILLS,ANDMAYALSOINvOLvEHAzARDSIFATEMpTEDBYANUNSKILLEDpERSON.THESETASKSMUSTBEpERFORMEDONLYBYpERSONSWHOHAvEENOUgHABILITYANDqUALIFICATIONSINACORDANCEWITHLOCALLAWSANDREgULATIONS.FORDETAILEDINFORMATION,pLEASECONTACTYOURDISTRIBUTORWHEREYOUpURCHASEDTHEpRODUCT.

■ Wiring

1. Robot cable

Aftercheckingthespecifiedcombinationsoftherobotandcontroller,connecttherobotandcontroller.

2. Wiring safety points

WARNING ALWAYSSHUTOFFALLpHASESOFTHEpOWERSUppLYExTERNALLYBEFORESTARTINgINSTALLATIONORWIRINgWORK.FAILURETODOTHISMAYCAUSEELECTRICALSHOCKORpRODUCTDAMAgE.

CAUTION • Donotapplyexcessiveimpactsorloadstotheconnectorswhenmakingcableconnections.Thismightbendtheconnectorpinsor damagetheinternalpCboard. • Whendisconnectingthecablefromtherobot,donotholdthecableandpullitoutbyhand.Loosenthescrewsontheconnector(if fastenedwiththescrews),andthendisconnectthecable.Tryingtodetachbypullingonthecableitselfmaydamagetheconnectoror cables,andpoorcablecontactwillcausethecontrollerorrobottomalfunction.

3. Precautions for cable routing and installation

CAUTION • Besuretostorethecablesconnectedtotherobotintheductorclampthemsecurelyinplace.Ifthecablesarenotstoredinaconduit orproperlyclamped,excessiveplayormovementormistakenlypullingonthecablemaydamagetheconnectororcables,andpoor cablecontactwillcausethecontrollerorrobottomalfunction. • Donotmodifythecablesanddonotplaceanyheavyobjectsonthem.Handlethemcarefullytoavoiddamage.Damagedcablesmay causemalfunctionorelectricalshock. • Ifthecablesconnectedtothecontrollermaypossiblybecomedamaged,protectthemwithanappropriatecover,etc. • Checkthatthecontrollinesandcommunicationcablesareroutedatagapsufficientlyawayfrommainpowersupplycircuitsand powerlines,etc.Bundlingthemtogetherwithpowerlinesorclosetopowerlinesmaycausefaultyoperationduetonoise.

4. Protective measures against electrical shock

WARNING ALWAYSgROUNDTHEROBOTBODYEARTHTERMINAL.FAILURETODOSOMAYRESULTINELECTRICSHOCK.

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4.4 Safety measures

4.4.1 Safety measures

1. Referring to warning labels and manual

WARNING • BEFORESTARTINgINSTALLATIONOROpERATIONOFTHEROBOT,BESURETOREADTHEWARNINgLABELS ANDTHISMANUAL,ANDCOMpLYWITHTHEINSTRUCTIONS. • NEvERATTEMpTANYREpAIR,pARTSREpLACEMENTANDMODIFICATIONUNLESSDESCRIBEDINTHISMANUAL. THESETASKSREqUIRESpECIALIzEDTECHNICALKNOWLEDgEANDSKILLSANDMAYALSOINvOLvE HAzARDS.pLEASECONTACTYOURDISTRIBUTORFORADvICE.

NOTE Fordetailsonwarninglabels,see"3.Warninglabels"in"Safetyinstructions."

2. Draw up "work instructions" and make the operators/workers understand them

WARNING DECIDEON"WORKINSTRUCTIONS"INCASESWHEREpERSONNELMUSTWORKWITHINTHEROBOTSAFETYENCLOSURETOpERFORMSTARTUpORMAINTENANCEWORK.MAKESURETHEWORKERSCOMpLETELYUNDERSTANDTHESE"WORKINSTRUCTIONS".

Decideon"workinstructions"forthefollowingitemsincaseswherepersonnelmustworkwithintherobotsafetyenclosuretoperformteaching,maintenanceorinspectiontasks.Makesuretheworkerscompletelyunderstandthese"workinstructions".

1.Robotoperatingproceduresneededfortaskssuchasstartupproceduresandhandlingswitches

2.Robotspeedsusedduringtaskssuchasteaching

3.Methodsforworkerstosignaleachotherwhentwoormoreworkersperformtasks

4.Stepsthattheworkershouldtakewhenaproblemoremergencyoccurs

5.Stepstotakeaftertherobothascometoastopwhentheemergencystopdevicewastriggered,includingchecksforcancellingtheproblemorerrorstateandsafetychecksinordertorestarttherobot.

6.Incasesotherthanabove,thefollowingactionsshouldbetakenasneededtopreventhazardoussituationsduetosuddenorunexpectedrobotoperationorfaultyrobotoperationaslistedbelow.

• placeadisplaysignontheoperatorpanel

• Ensurethesafetyofworkersperformingtaskswithintherobotsafetyenclosure

• Clearlyspecifypositionandpostureduringwork Specifyapositionandposturewhereworkercanconstantlycheckrobotmovementsandimmediatelymovetoavoid troubleifanerror/problemoccurs

• Takenoisepreventionmeasures

• Usemethodsforsignalingoperatorsofrelatedequipment

• Usemethodstodecidethatanerrorhasoccurredandidentifythetypeoferror

Implementthe"workinstructions"accordingtothetypeofrobot,installationlocation,andtypeofworktask. Whendrawingupthe"workinstructions",makeanefforttoincludeopinionsfromtheworkersinvolved,equipmentmanufacturertechnicians,andworkplacesafetyconsultants,etc.

3. Take safety measures

DANGER • NEvERENTERTHEROBOTMOvEMENTRANgEWHILETHEROBOTISOpERATINgORTHEMAINpOWERIS TURNEDON.FAILURETOFOLLOWTHISWARNINgMAYCAUSESERIOUSACCIDENTSINvOLvINgINJURYOR DEATH.INSTALLASAFETYENCLOSUREORAgATEINTERLOCKWITHANAREASENSORTOKEEpALLpERSONS AWAYFROMTHEROBOTMOvEMENTRANgE. • WHENITISNECESSARYTOOpERATETHEROBOTWHILEYOUAREWITHINTHEROBOTMOvEMENTRANgE SUCHASFORTEACHINgORMAINTENANCE/INSpECTIONTASKS,BESURETOINSTALLANENABLEDEvICEIN THEExTERNALSAFETYCIRCUITSOTHATYOUCANIMMEDIATELYSTOpTHEROBOTOpERATIONINCASEOFAN ABNORMALORHAzARDOUSCONDITION.ADDITIONALLY,SETTHEROBOTMOvINgSpEEDSOTHATIT COMpLIESWITHTHEROBOTSAFETYSTANDARDS.

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WARNING • DURINgSTARTUpORMAINTENANCETASKS,DISpLAYASIgNSTATINg"WORKINpROgRESS"ONTHE OpERATIONpANELORLOCKTHECOvEROFTHEOpERATIONpANELINORDERTOpREvENTANYONEOTHER THANTHEpERSONFORTHATTASKFROMMISTAKENLYOpERATINgTHESTARTORSELECTORSWITCH. • ALWAYSCONNECTTHEROBOTANDROBOTCONTROLLERINTHECORRECTCOMBINATION.USINgTHEMINAN INCORRECTCOMBINATIONMAYCAUSEFIREORBREAKDOWN.

4. Install brake release circuit

TheDELTArobotisequippedwithabrakereleaseswitchforthemanualteachingormaintenanceinspection. Tousethisbrakereleaseswitch,itisalsonecessarytoinstallabrakereleasecircuitontheuserside. Fordetails,see“4.2Wiringthebrakereleasecableconnector”inChapter2oftheInstallationManual.

WARNING WHENpERFORMINgTHETEACHINgORMAINTENANCEINSpECTIONMANUALLY,INSTALLTHEBRAKERELEASECIRCUITTOENSURETHESAFETY.

5. Install system

Whenconfiguringanautomatedsystemusingarobot,hazardoussituationsaremorelikelytooccurfromtheautomatedsystemthantherobotitself.Sothesystemmanufacturershouldinstallthenecessarysafetymeasuresrequiredfortheindividualsystem.Thesystemmanufacturershouldprovideapropermanualforsafe,correctoperationandservicingofthesystem.

WARNING TOCHECKTHEROBOTCONTROLLEROpERATINgSTATUS,REFERTOTHERELATEDMANUALS.DESIgNANDINSTALLTHESYSTEMINCLUDINgTHEROBOTCONTROLLERSOTHATITWILLALWAYSWORKSAFELY.

6. Do not modify

WARNING NEvERATTEMpTTOMODIFYTHEROBOT.DONOTOpENANYCOvER.DOINgSOMAYCAUSEELECTRICALSHOCK,BREAKDOWN,MALFUNCTION,INJURY,ORFIRE.

4.4.2 Installing a safety enclosureBesuretoinstallasafetyenclosuretokeepanyonefromenteringwithinthemovementrangeoftherobot.Thesafetyenclosurewillpreventtheoperatorandotherpersonsfromcomingincontactwithmovingpartsoftherobotandsuffering injury.

DANGER SERIOUSINJURYMAYRESULTFROMCONTACTWITHAMOvINgROBOT. •KEEpOUTSIDEOFTHEROBOTSAFETYENCLOSUREDURINgOpERATION. •pRESSTHEEMERgENCYSTOpBUTTONBEFOREENTERINgTHESAFETYENCLOSURE.

WARNING • INSTALLANINTERLOCKTHATTRIggERSEMERgENCYSTOpWHENTHEDOORORgATEOFTHESAFETY ENCLOSUREISOpENED. • THESAFETYENCLOSURESHOULDBEDESIgNEDSOTHATNOONECANENTERINSIDEExCEpTFROMTHEDOOR ORgATEEqUIppEDWITHANINTERLOCKDEvICE. • WARNINgLABEL1(SEE"3.WARNINgLABELS"IN"SAFETYINSTRUCTIONS")THATCOMESSUppLIEDWITHA ROBOTSHOULDBEAFFIxEDTOANEASY-TO-SEELOCATIONONTHEDOORORgATEOFTHESAFETY ENCLOSURE.

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4.5 OperationWhenoperatingarobot,ignoringsafetymeasuresandchecksmayleadtoseriousaccidents.Alwaystakethefollowingsafetymeasuresandcheckstoensuresafeoperation.

DANGER CHECKTHEFOLLOWINgpOINTSBEFORESTARTINgROBOTOpERATION. •NOONEISWITHINTHEROBOTSAFETYENCLOSURE. •THEROBOTANDpERIpHERALEqUIpMENTAREINgOODCONDITION.

4.5.1 Trial operationRefertothecontrollermanualaftercarryingoutrobotinstallation,adjustments,inspection,maintenance,or repair.

4.5.2 Automatic operationToperformtheautomaticoperation,followtheinstructionsstatedinthecontrollermanual.

4.5.3 Precautions during operation

1. When the robot is damaged or an abnormal condition occurs

WARNING • IFUNUSUALODORS,NOISEORSMOKEOCCURDURINgOpERATION,IMMEDIATELYTURNOFFpOWERTO pREvENTpOSSIBLEELECTRICALSHOCK,FIREORBREAKDOWN.STOpUSINgTHEROBOTANDCONTACTYOUR DISTRIBUTOR. • IFANYOFTHEFOLLOWINgDAMAgEORABNORMALCONDITIONSOCCURSTHEROBOT,THENCONTINUINgTO OpERATETHEROBOTISDANgEROUS.IMMEDIATELYSTOpUSINgTHEROBOTANDCONTACTYOUR DISTRIBUTOR.

Damage or abnormal condition Type of danger

Damagetomachineharnessorrobotcable Electricalshock,robotmalfunction

Damagetorobotexterior Damaged parts fly off during robot operation

Abnormalrobotoperation(positiondeviation,vibration,etc.) Robot malfunction

α-axis,β-axisorγ-axisbrakemalfunction Shaftormovablebasefallingorrelatedpartflyoff

2. High temperature hazard

WARNING • DONOTTOUCHTHEROBOTDURINgOpERATION.THEROBOTBODYISvERYHOTDURINgOpERATION,SO BURNSMAYOCCURIFYOUTOUCHTHESESECTIONS. • THEMOTORANDSpEEDREDUCTIONgEARCASINgAREvERYHOTSHORTLYAFTEROpERATION,SOBURNSMAY OCCURIFTHESEARETOUCHED.BEFORETOUCHINgTHOSEpARTSFORINSpECTIONSORSERvICINg,TURNOFF THECONTROLLER,WAITFORAWHILEANDCHECKTHATTHEIRTEMpERATUREHASFALLEN.

3. Usecautionwhenreleasingtheα-axis,β-axisorγ-axisbrake

Toreleasethebrake,itisnecessarytoinstallabrakereleasecircuitontheuserside.

WARNING THEα-AXIS,β-AXIS OR γ-AXIS WILLSLIDEDOWNWARDWHENTHEBRAKEISRELEASED,CAUSINgAHAzARDOUS

SITUATION.TAKEADEqUATESAFETYMEASURESBYTAKINgTHEWEIgHTANDSHApEINTOACCOUNT. • BEFORERELEASINgTHEBRAKEAFTERpRESSINgTHEEMERgENCYSTOpBUTTON,pLACEASUppORTUNDER THEα-AXIS,β-AXIS OR γ-AxISSOTHATITWILLNOTSLIDEDOWN. • WHENpERFORMINgTASKS(DIRECTTEACHINg,ETC.)WITHTHEBRAKERELEASED,RELEASETHEBRAKEOF ONLYNECESSARYAxISANDBECAREFULNOTTOLETYOURBODYgETCAUgHTBETWEENTHEMOvABLEBASE ANDTHEINSTALLATIONBASE.

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4. Iftheα-axis,β-axis,γ-axisorθ-axisrotationangleissmall

CAUTION Iftheα-axis,β-axis,γ-axisorθ-axisrotationangleissetsmallerthan5degrees,thenitwillalwaysmovewithinthesameposition,makingitdifficultforaproperoilfilmtoformonthespeedreductiongear,possiblyshorteningitsservicelife.Topreventthis,addarangeofmotionsothateachaxismovesthrougharangeof120degreesormoreabout5timesaday.

4.6 Inspection and maintenanceAlwaysperformdailyandperiodicinspectionsandmakeapre-operationchecktoensuretherearenoproblemswiththerobotandrelatedequipment.Ifaproblemorabnormalityisfound,thenpromptlyrepairitortakeothermeasuresasnecessary.Keeparecordofperiodicinspectionsorrepairsandstorethisrecordforatleast3years.

4.6.1 Before inspection and maintenance work

1. Do not attempt any work or operation unless described in this manual.

Neverattemptanyworkoroperationunlessdescribedinthismanual.

WARNING NEvERATTEMpTINSpECTION,MAINTENANCE,REpAIR,ANDpARTREpLACEMENTUNLESSDESCRIBEDINTHISMANUAL.THESETASKSREqUIRESpECIALIzEDTECHNICALKNOWLEDgEANDSKILLSANDMAYALSOINvOLvEHAzARDS.pLEASEBESURETOCONTACTYOURDISTRIBUTORFORADvICE.

2. Precautions during repair and parts replacement

WARNING IFITISABSOLUTELYREqUIREDTOREpAIRORREpLACEANYpARTOFTHEROBOT,pLEASEBESURETOCONTACTYOURDISTRIBUTORANDFOLLOWTHEINSTRUCTIONSTHEYpROvIDE.INSpECTIONANDMAINTENANCEOFTHEROBOTBYANUNSKILLEDORUNTRAINEDpERSONISExTREMELYHAzARDOUS.

Adjustment,maintenanceandpartsreplacementrequirespecializedtechnicalknowledgeandskills,andalsomayinvolvehazards.Thesetasksmustbeperformedonlybypersonswhohaveenoughabilityandqualificationsrequiredbylocallawsandregulations.

WARNING ADJUSTMENTANDMAINTENANCEBYREMOvINgACOvERREqUIRESpECIALIzEDTECHNICALKNOWLEDgEANDSKILLS,ANDMAYALSOINvOLvEHAzARDSIFATTEMpTEDBYANUNSKILLEDpERSON.FORDETAILEDINFORMATION,pLEASECONTACTYOURDISTRIBUTORWHEREYOUpURCHASEDTHEpRODUCT.

3. Shut off all phases of power supply

WARNING ALWAYSSHUTOFFALLpHASESOFTHEpOWERSUppLYExTERNALLYBEFORECLEANINgTHEROBOTANDCONTROLLERORSECURELYTIgHTENINgTHETERMINALSCREWSETC.FAILURETODOTHISMAYCAUSEELECTRICALSHOCKORpRODUCTDAMAgEORMALFUNCTION.

4. Allow a waiting time after power is shut off (Allow time for temperature and voltage to drop)

WARNING THEMOTORANDSpEEDREDUCTIONgEARCASINgAREvERYHOTSHORTLYAFTEROpERATION,SOBURNSMAYOCCURIFTHEYARETOUCHED.BEFORETOUCHINgTHOSEpARTSFORINSpECTIONSORSERvICINg,TURNOFFTHECONTROLLER,WAITFORAWHILEANDCHECKTHATTHETEMpERATUREHASFALLEN.

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4.6.2 Precautions during service work

1. Precautions when removing a motor

WARNING THEα-AXIS,β-AXIS OR γ-AXIS WILLSLIDEDOWNWARDWHENTHEMOTORISREMOvED,CAUSINgAHAzARDOUS

SITUATION. • TURNOFFTHECONTROLLERANDpLACEASUppORTUNDERTHEα-AXIS,β-AXIS OR γ-AXIS BEFOREREMOvINg

THEMOTOR. • BECAREFULNOTTOLETYOURBODYgETCAUgHTBETWEENTHEMOvABLEBASEANDTHEINSTALLATION BASE.

4.7 DisposalWhendisposingofrobotsandrelateditems,handlethemcarefullyasindustrialwastes.Usethecorrectdisposalmethodincompliancewithyourlocalregulations,orentrustdisposaltoalicensedindustrialwastedisposalcompany.

1. Disposalofpackingboxesandmaterials

Whendisposingofpackingboxesandmaterials,usethecorrectdisposalmethodincompliancewithyourlocalregulations.Wedonotcollectanddisposeoftheusedpackingboxesandmaterials.

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5. Emergency action when a person is caught by robotIfapersoniscaughtinbetweentherobotandmechanicalsection,suchasinstallationbase,usethebrakereleaseswitchontherobotmainunittoreleasetheaxis.

Brake release switch


Astherobotisputintheemergencystopstate,therobotdrivepowerisshutdown.However,theaxiscannotbemovedsincethebrakeisactivated.So,releasethebrake,andthenpushtheaxisbyhandtomoveit.

WARNING THEα-AXIS,β-AXIS OR γ-AxISWILLSLIDEDOWNWARDWHENTHEBRAKEISRELEASED,CAUSINgAHAzARDOUSSITUATION. • BEFORERELEASINgTHEBRAKE,BESURETOpLACEASUppORTUNDERTHEα-AXIS,β-AXIS OR γ-AxISSOTHAT IT WIll NOT SlIDE DOWN. • WHENRELEASINgTHEBRAKE,BECAREFULNOTTOLETYOURBODYgETCAUgHTBETWEENTHEMOvABLE BASEANDTHEINSTALLATIONBASE.

CAUTION Releasethebrakeaxis-by-axis.

NOTE Fordetailsaboutthebrakereleasecableconnector,see“4.2Wiringthebrakereleasecableconnector”inChapter2oftheInstallationManual.

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6. Using the robot safely6.1 Robot protective functions

1. Soft limitsSoftlimitscanbesetoneachaxistolimittheworkingenvelopeinmanual(jog)operationandautomaticoperationafterreturn-to-origin.Theworkingenvelopeisthearealimitedbysoftlimits.

WARNING SOFTLIMITFUNCTIONISNOTASAFETY-RELATEDFUNCTIONINTENDEDTOpROTECTTHEHUMANBODY. ENSURESAFETYBYINSTALLINgASAFETYENCLOSUREANDSOON.

2. α-axis,β-axisorγ-axisbrakesAnelectromagneticbrakeisinstalledontheα-axis,β-axisandγ-axistopreventthemfromslidingdownwardwhentheservoisOFF.

WARNING THEα-AXIS,β-AXIS OR γ-AxISWILLSLIDEDOWNWARDWHENTHEBRAKEISRELEASED,CAUSINgAHAzARDOUSSITUATION.TAKEADEqUATESAFETYMEASURESBYTAKINgTHEWEIgHTANDSHApEINTOACCOUNT. • BEFORERELEASINgTHEBRAKEAFTERpRESSINgTHEEMERgENCYSTOpBUTTON,pLACEASUppORTUNDER THEα-AXIS,β-AXIS OR γ-AxISSOTHATITWILLNOTSLIDEDOWN. • WHENpERFORMINgTASKS(DIRECTTEACHINg,ETC.)WITHTHEBRAKERELEASED,BECAREFULNOTTOLET YOURBODYgETCAUgHTBETWEENTHEMOvABLEBASEANDTHEINSTALLATIONBASE.

6.2 Residual riskToensuresafeandcorrectuseofOMRONrobots,Systemintegratorsand/orendusersimplementthemachinerysafetydesignthatconformstoISO12100. ResidualrisksforOMRONrobotsaredescribedintheDANgERorWARNINginstructionsprovidedineachchapterandsection.So,readthemcarefully.

6.3 Special training for industrial robot operationOperatorsorpersonswhohandletherobotfortaskssuchasforteaching,programming,movementchecks,inspections,adjustments,andrepairsmustreceiveappropriatetrainingandalsohavetheskillsneededtoperformthejobcorrectlyandsafely.Theymustalsoreadthemanualcarefullytounderstanditscontentsbeforeattemptingtherobotoperationormaintenance.

Tasksrelatedtoindustrialrobots(teaching,programming,movementcheck,inspection,adjustment,repair,etc.)mustbeperformedbyqualifiedpersonswhomeetrequirementsestablishedbylocalregulationsandsafetystandardsforindustrial robots.

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Comparison of terms used in this manual with ISO

This manual ISO 10218-1 Note

Maximummovementrange maximumspace Arealimitedbymechanicalstoppers.

Movement range restricted space Arealimitedbymovablemechanicalstoppers.

Working envelope operational space Area limited by software limits.

Within safety enclosure safeguarded space

1

WarrantyForinformationonthewarrantyperiodandterms,pleasecontactourdistributorwhereyoupurchasedtheproduct.

■ This warranty does not cover any failure caused by:

1.Installation,wiring,connectiontoothercontroldevices,operatingmethods,inspectionormaintenancethatdoesnotcomplywithindustrystandardsorinstructionsspecifiedintheOMRONmanual;

2.UsagethatexceededthespecificationsorstandardperformanceshownintheOMRONmanual;

3.productusageotherthanintendedbyOMRON;

4.Storage,operatingconditionsandutilitiesthatareoutsidetherangespecifiedinthemanual;

5.Damageduetoimpropershippingorshippingmethods;

6.Accidentorcollisiondamage;

7.InstallationofotherthangenuineOMRONpartsand/oraccessories;

8.ModificationtooriginalpartsormodificationsnotconformingtostandardspecificationsdesignatedbyOMRON,includingcustomizingperformedbyOMRONincompliancewithdistributororcustomerrequests;

9.pollution,saltdamage,condensation;

10.Firesornaturaldisasterssuchasearthquakes,tsunamis,lightningstrikes,windandflooddamage,etc;

11.BreakdownduetocausesotherthantheabovethatarenotthefaultorresponsibilityofOMRON;

12.Electricalshockwhentheuserinstallstheactuator,etc.onthemovablebaseorendeffectorinthe3-axisspecifications.

■ The following cases are not covered under the warranty:

1.productswhoseserialnumberorproductiondate(month&year)cannotbeverified.

2.Changesinsoftwareorinternaldatasuchasprogramsorpointsthatwerecreatedorchangedbythecustomer.

3.productswhosetroublecannotbereproducedoridentifiedbyOMRON.

4.productsutilized,forexample,inradiologicalequipment,biologicaltestequipmentapplicationsorforotherpurposeswhosewarrantyrepairsarejudgedashazardousbyOMRON.

WARRANTY

OMRON'sexclusivewarrantyisthattheproductsarefreefromdefectsinmaterialsandworkmanshipforaperiod of one year after the date of manufacturing as shown on the product serial number plate.

OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NONINFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUERIMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.

LIMITATIONS OF LIABILITY

OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR COMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE OR STRICT LIABILITY.

InnoeventshalltheresponsibilityofOMRONforanyactexceedtheindividualpriceoftheproductonwhichliability is asserted.

IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION, ABUSE, MISUSE OR INAPPROPIATE MODIFICATION OR REPAIR.

Chapter 1 Overview

Contents

1. Overview 1-1

1-1

1

Ove

rview

1. OverviewWARNING • ADJUSTMENT,MAINTENANCEANDREMOvALOFARMS,SHAFTS,ORTHEθ-AxISASSEMBLYREqUIRE SpECIALIzEDTECHNICALKNOWLEDgEANDSKILLS,ANDALSOMAYINvOLvEHAzARDS.THISWORKMUSTBE CARRIEDOUTBYREFERENCINgTHISMANUALBYSUFFICIENTLYSKILLEDANDqUALIFIEDpERSONNELIN ACCORDANCEWITHTHELAWSANDREgULATIONSOFEACHCOUNTRY. • pLACEACONSpICUOUSSIgNINDICATINgTHEROBOTISBEINgADJUSTED,TOpREvENTOTHERSFROM TOUCHINgTHECONTROLLERSWITCHOROpERATIONpANEL. • IFASAFETYENCLOSUREHASNOTYETBEENpROvIDEDRIgHTAFTERINSTALLATIONOFTHEROBOT,ROpEOFF ORCHAINOFFTHEMOvEMENTRANgEAROUNDTHEMANIpULATORINpLACEOFASAFETYENCLOSURE,AND OBSERvETHEFOLLOWINgpOINTS. 1.USESTABLEpOSTSWHICHWILLNOTFALLOvEREASILY. 2.THEROpEORCHAINSHOULDBEEASILYvISIBLEBYEvERYONEAROUNDTHEROBOT. 3.pLACEACONSpICUOUSSIgNpROHIBITINgTHEOpERATOROROTHERpERSONNELFROMENTERINgTHE MOvEMENTRANgEOFTHEMANIpULATOR. • IFCHECKINgOpERATIONFOLLOWINgADJUSTMENT,REFERTOTHECONTROLLERMANUAL.

CAUTION Useonlythelubricantsspecifiedbyyourdistributors.

Chapter 2 Attaching, detaching and replacing the cover

Contents

1. Detachingorattachingtheα,βandγ-axescovers 2-11.1 R6Y3[]110 2-1

1.1.1 α,βandγ-axescoverremovalprocedure 2-21.1.2 α,βandγ-axescoverattachmentprocedure 2-7

1.2 R6Y3[]065 2-13

1.2.1 α,βandγ-axescoverremovalprocedure 2-141.2.2 α,βandγ-axescoverattachmentprocedure 2-17

2. Detachingorattachingtheθ-axiscover 2-222.1 θ-axismotorcoverremoval 2-23

2.2 θ-axismotorcoverattachment 2-25

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1. Detachingorattachingtheα,βandγ-axescovers1.1 R6Y3[]110

WARNING • IFTHECOvERSAREREMOvEDFORMAINTENANCEWORK,BESURETORETURNTHEMTOTHEIRORIgINAL pOSITIONSUSINgTHEBOLTSUSEDTOSECURETHEM. • IFANYOFTHEBOLTSBECOMELOST,USETHESpECIFIEDBOLTSANDqUANTITIESTOSECURETHECOvERS WHILEREFERRINgTOTHEBELOWpICTURE. • IFTHECOvERSARENOTSECUREDFIRMLY,NOISEMAYOCCUR,THECOvERSMAYDROpANDFLYOUT,HANDS MAYBECOMEENTANgLEDINTHEDRIvEUNITDURINgTEACHINg,ORCOMEINTOCONTACTWITHTHEHOT DRIvEUNIT,CAUSINgBURNS.OBSERvETHESECAUTIONSSTRICTLYTOpREvENTSUCHTROUBLES.

R6Y3[]110

α-axis

β-axis

Bolt

θ-axis

γ-axis

1. Replacement parts

Part Name OMRON Part No. Part No. / Specs Q'ty Remarks

1Motor cover

KDL-M2163-00x 2β,γ-axes,affixedwithelectricshockcaution label

2 KDL-M2163-10x 1 α-axis,warninglabel

3 Seal KDL-M2138-00x 1 Motorcoverattachmentpart(*1)

4 Cover securing bolt 97080-05008 M5,length8 2 (*1)

5 Brakereleaseswitch KDL-M4851-00x 1 (*1)

6 BracketKDL-M1172-00x 1 Motorcoverupperattachment(*1)

KDL-M1173-00x 1 Motorcoverlowerattachment(*1)

7 Bracket securing bolt 91312-04020 M4,length20 4 (*1)

8 Cap KDL-M2165-00x 1 (*1)

9 Boot KDL-M212A-00x 1 (*1)

10 grommetKDL-M212F-00x 1 Encoderintegratedcable(*1)

KDL-M212F-10x 1 (*1)

*1:quantitypercover

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2. Tools to be prepared

Name Part. No. Manufacturer Remarks

Cleaning wipe

Hexwrenchset

Spanner No. 7

1.1.1 α,βandγ-axescoverremovalprocedure

WARNING WHENHANDLINgMOTORS,TAKECARETOAvOIDELECTRICSHOCKORBURNSOWINgTOTHEHEATgENERATEDBYTHEMOTORS.

1 Remove the duct, and then remove the boot and cap.

Duct, boot and cap removalStep 1

Cap

Boot

Cap removal

Boot removal

Duct

NOTE Thebootandcaparemerelyinsertedwhentherobotisshipped.

2 Disconnect the robot cable connector.

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3 Remove the M5 hex bolt from the top of the motor cover.

Bolt removalStep 3

M5 hex bolt

4 Remove the cover a little.grasptherearofthecoverandpullitoutwhileshakingitupanddowntoremovethecoveralittle. About10mmoftherubberwillcomeout(within5mmwhenattached).

Temporarily removed coverStep 4

Cover top temporarily removed

Cover bottom temporarily removed

10mm width

Cover

Pull out a little at a time while shaking up and down.

10mm width

NOTE Theinsideofthecoverwillcatchandsowillnotcomeoffcompletely.

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5 Pull the cover out further.Makeagapbetweenthecoverandbasebypullingthecoveroutfurther.

Temporarily removed coverStep 5

Cover top temporarily removed

Cover bottom temporarily removed

NOTE Thecoverwillcatchatthispointandsowillnotcomeoffcompletely.

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6 Pull out the cover.graspthesidesofthecoverandpushbothsidessothatthebottomdeformsalittletopulloutthecover.Theclipsontheinsideneartheswitchwillcomefree,makingiteasiertopulloutthecoverwithoutitcatching. Themotorconnectorwillcatchontheholeonthesideofthecover,andsothecovershouldbeshiftedtoavoidtheconnector.Theswitchontheinsidewillcatchonthemotorconnector,andsothecovershouldbepulledoutwhiletryingtoavoidtheconnector.

Pull out the cover.Step 6

Internal switch

Slide the cover.

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■ Clip structure

Thecoverclipswillcatchonthestepofthebracketunderthereductiongear. Therearetwosteps,andtheclipscatchonthesecondstep.

Clip construction

Reduction gear

Bracket

Clip construction on inside

Clips

Inside of removed cover

Connection cable


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1.1.2 α,βandγ-axescoverattachmentprocedureAttachthecoverusingtheoppositeoftheprocedureusedforremoval.

WARNING THESAMETYpEOFMOTORCABLEANDENCODERCABLEISUSEDFORTHEα,β,ANDγ-AxES.CONNECTTHECABLESSOTHATTHEYMATCHTHERESpECTIvEAxESATTHECONTROLLER(DRIvER).IFTHECABLESARECONNECTEDINCORRECTLY,THEROBOTWILLNOTOpERATECORRECTLYTORESULTINpOSSIBLEDANgER.

1 Insert the motor cable from smaller hole on the boot with small hole.ThemotorcableconnectorshouldstillbeinsertedfirstevenifusingL-shapedconnectors.

Insert the motor cable.Step 1

Motor cable

Boot

2 Insert the encoder cable and brake release cable (prepared by user) from smaller hole on the boot.

Insert the encoder cable and brake release cable (prepared by user).Step 2

Brake release cable

(prepared by user)

Boot

Encoder cable

CAUTION Theencodercablemustpassthroughtheinsideofthecoverandthereforeasufficientlengthofcableshouldbeinserted.

3 Pull the cover internal cables from the hole with the boot.Ontheoutsideofthecoveristhecap,andthemotorconnectorpartshouldbetheboot.

4 Connect the cover internal switch connector and brake release connector.Storethejointinsidethecover.

Thecableleadingfromthebrakereleaseconnectorshouldbepreparedbytheuser.

Switch connector and brake release connector connectionStep 4

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5 Route the encoder cable.Inserttheencodercableonlythroughtheholeforthemotorconnector,andpullitoutfromtheadjacentcaphole.

Encoder cable routingStep 5

Encoder cable

Encoder cable

Pull out from cap hole side

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6 Temporarily insert the motor cover.Insertthemotorcoversothattheinternalswitchdoesnotinterferewiththemotorconnector. pullthebrakereleasecableandencodercableoutfromthegapnexttothemotorconnector.

Temporary motor cover insertionStep 6

Motor cover

Internal switch

Motor

Pull out from gap.

Cables removed when temporarily inserting cover

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7 Insert the cover so that the rubber on the bottom fits in.Therewillbeagapwhenthecovercatchesonthefirst clip.

GapStep 7

Gap

Gap

Gap at top of cover

Gap at bottom of cover

8 Insert the cover so that the rubber on the top fits in.

Insert the rubber.Step 8

CAUTION Inserttherubberalittleatatime,andavoidtryingtoforceitin.Ifforcedin,therubberwillendupdeformed,makingitdifficulttoattachthemotorcover.

9 Push in the motor cover from the rear.Therubberatthebottomoftheswitchshouldprotrudeapproximately5mm,andtherubberatthetopoftheswitchshouldprotrudeapproximately1mm.

Push in the motor cover.Step 9

Motor cover

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2-11

10 Adjust the motor cover position and then secure with the M5 hex bolt(s).AdjustthemotorcoverpositionandthenscrewintwoM5hexboltstosecure. Ensurethatthemotorcoverhasbeensecurelyattached. ItwillnotbepossibletoinserttheboltsifthemotorcoverpositionandtappingpositionsfortheM5hexbolts are not aligned. Atthistime,donotuseanythreadsealer.

Motor cover attachmentStep 10

M5 hex bolt

11 Attach the robot cable connector.

WARNING CONNECTTHEα,β AND γ-AXES ROBOT CABlES SO THATTHEYMATCHTHERESpECTIvEAxESATTHECONTROLLER(DRIvER).IFTHECABLESARECONNECTEDINCORRECTLY,THEROBOTWILLNOTOpERATECORRECTLYTORESULTINpOSSIBLEDANgER.

12 Attach the boot and cap to the motor cover.

Boot, cap attachmentStep 12

Boot

Push the rubber in completely.

Cap

13 Attach the duct to the robot cable.Inserttherobotcableintothenotchontheduct. Thecablecanbeinsertedeasilybyinsertingathickrodsuchasaflatscrewdriver.

Duct attachmentStep 13

Duct

2

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ching

, de

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hing a

nd re

pla

cing

the c

over

2-12

14 Attach the grommet to the robot cable.

Grommet attachmentStep 14

GrommetBoot

15 Insert the grommet in the boot.

16 Insert the boot in the duct.

Grommet insertionStep 15

Boot insertionStep 16

2

Atta

ching

, de

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hing a

nd re

pla

cing

the c

over

2-13

1.2 R6Y3[]065

WARNING • IFTHECOvERSAREREMOvEDFORMAINTENANCEWORK,BESURETORETURNTHEMTOTHEIRORIgINAL pOSITIONSUSINgTHEBOLTSUSEDTOSECURETHEM. • IFANYOFTHEBOLTSBECOMELOST,USETHESpECIFIEDBOLTSANDqUANTITIESTOSECURETHECOvERS WHILEREFERRINgTOTHEBELOWpICTURE. • IFTHECOvERSARENOTSECUREDFIRMLY,NOISEMAYOCCUR,THECOvERSMAYDROpANDFLYOUT,HANDS MAYBECOMEENTANgLEDINTHEDRIvEUNITDURINgTEACHINg,ORCOMEINTOCONTACTWITHTHEHOT DRIvEUNIT,CAUSINgBURNS.OBSERvETHESECAUTIONSSTRICTLYTOpREvENTSUCHTROUBLES.

CAUTION Theα,β,andγ-axismotorcoverconstructiondoesnotcomplywithIp67,andthereforetheinsideofthecovershouldbecleanedperiodically.ThemotorandspeedreductiongearinsidethecoverdocomplywithIp67.

R6Y3[]065

α-axis

β-axis

Bolt γ-axis

θ-axis



1Motor cover

KDL-M2163-40x 2β,γ-axes,affixedwithelectricshockcaution label

2 KDL-M2163-50x 1 α-axis,warninglabel

3 Seal KDL-M2138-10x 1 Motorcoverattachmentpart(*1)

4 Cover securing bolt 97080-05008 M5,length8 2 (*1)

5 Brakereleaseswitch KDL-M4851-00x 1 (*1)

6 BracketKDL-M1172-00x 1 Motorcoverupperattachment(*1)

KDL-M1193-00x 1 Motorcoverlowerattachment(*1)

7 Bracket securing bolt91312-04010 M4,length10 2 (*1)

91312-04020 M4,length20 2 (*1)

8 Cap KDL-M212A-10x 1 (*1)

9 grommet KDL-M212F-20x 1 (*1)

*1:quantitypercover

2

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nd re

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over

2-14



Cleaning wipe

Hexwrenchset

Spanner No. 7

1.2.1 α,βandγ-axescoverremovalprocedure

WARNING WHENHANDLINgMOTORS,TAKECARETOAvOIDELECTRICSHOCKORBURNSOWINgTOTHEHEATgENERATEDBYTHEMOTORS.

1 Remove the duct and cap. Duct and cap removalStep 1

Cap

Grommet

DuctNOTE Thecapisshippedinthestatethatitisonlyfit.

2 Remove the M5 hex bolt from the top of the motor cover.

NOTE TheM5hexboltcanberemovedeasilybypushinginthemotor cover deeply.

Bolt removalStep 2

Hex bolt

2

Atta

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, de

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nd re

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cing

the c

over

2-15

3 Pull out the cover. Cover pull-outStep 3

Rubber seal


NOTE graduallypulloutthecoversothatthebrakereleaseswitchisnotcaughtinthemotorconnector.

4 Disconnect the robot cable connector.

CAUTION Be careful not to drop any mounting screw as it is small.

Connector disconnectionStep 4

2

Atta

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, de

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hing a

nd re

pla

cing

the c

over

2-16

5 Remove four power cable connector mounting screws from the connector.

Mounting screw removalStep 5

Power cable connector

CAUTION Becarefulnottodropanyscrewyouhaveremovedasitissmall.

6 Pull out the brake release cable, brake cable and encoder cable from the cap in order.

7 Finally, pull out the power cable, from which the screws have been removed. Gradually disconnect the power cable in the orientation shown in the picture.

NOTE Astheinletisnarrow,pulloutthecablebydeformingtheinlet.

Cable pull-out from the capStep 6

Power cable pull-outStep 7

Cap

2

Atta

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, de

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hing a

nd re

pla

cing

the c

over

2-17

1.2.2 α,βandγ-axescoverattachmentprocedureAttachthecoverusingtheoppositeoftheprocedureusedforremoval.

WARNING THESAMETYpEOFMOTORCABLEANDENCODERCABLEISUSEDFORTHEα,β,ANDγ-AxES.CONNECTTHECABLESSOTHATTHEYMATCHTHERESpECTIvEAxESATTHECONTROLLER(DRIvER).IFTHECABLESARECONNECTEDINCORRECTLY,THEROBOTWILLNOTOpERATECORRECTLYTORESULTINpOSSIBLEDANgER.

1 Remove four power cable connector mounting screws from the connector.

CAUTION Becarefulnottodropanyscrewyouhaveremovedasitissmall.

Mounting screw removalStep 1

Power cable connector2 Insert the power cable, from which the screws have been removed, through the hole at the upper portion of the cap. Gradually insert the power cable in the orientation shown in the picture.

NOTE Astheinletisnarrow,pulloutthecablebydeformingtheinlet.

3 Insert the encoder cable, brake cable and brake release cable (prepared by the user) in order.

Power cable insertionStep 2

Cap

Each cable insertionStep 3

2

Atta

ching

, de

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hing a

nd re

pla

cing

the c

over

2-18

4 Pass the cables through the hole outside the motor cover.

NOTE Makesurethattherubbersealisattachedtothecover.

Cables passing through the motor coverStep 4

Rubber seal

Motor cover5 Connect the brake release switch connector.

6 Connect the cable connector to the motor connector.

WARNING CONNECTTHEα,β AND γ-AXES ROBOT CABlES SO THATTHEYMATCHTHERESpECTIvEAxESATTHECONTROLLER(DRIvER).IFTHECABLESARECONNECTEDINCORRECTLY,THEROBOTWILLNOTOpERATECORRECTLYTORESULTINpOSSIBLEDANgER.

Brake release connector connectionStep 5

Brake release connector

Connector connectionStep 6

2

Atta

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, de

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hing a

nd re

pla

cing

the c

over

2-19

7 Attach the motor cover.

CAUTION Attachthemotorcoversothatthebrakereleaseswitchonthemotorcoverdoesnotinterferewiththemotorconnector.

Motor cover attachmentStep 7


8 Insert the motor cover until the stepped portion of the rubber seal.

Motor cover insertion Step 8

2

Atta

ching

, de

tac

hing a

nd re

pla

cing

the c

over

2-20

9 Adjust the motor cover position and then secure with the M5 hex bolt(s).AdjustthemotorcoverpositionandthenscrewintwoM5hexboltstosecure. Ensurethatthemotorcoverhasbeensecurelyattached. ItwillnotbepossibletoinserttheboltsifthemotorcoverpositionandtappingpositionsfortheM5hexbolts are not aligned.

Hex bolt attachmentStep 9

M5 Hex bolt attachment

2

Atta

ching

, de

tac

hing a

nd re

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cing

the c

over

2-21

10 Attach the cap to the motor cover.

NOTE Attachingthecapfromtherearwillensuregoodworkability.

Cap attachmentStep 10

11 Attach the grommet to the robot cables.

12 Attach the duct to the robot cables.Inserttherobotcablesthroughtheslitintheduct.

13 Attach the duct to the cap.

Grommet attachmentStep 11

Grommet

Duct attachmentStep 12

Duct

Cap attachment Step 13

2

Atta

ching

, de

tac

hing a

nd re

pla

cing

the c

over

2-22

2. Detachingorattachingtheθ-axiscoverTodetachthecovers,removetheboltsandscrewsshowninthebelowpicture.

WARNING • IFTHECOvERSAREREMOvEDFORMAINTENANCEWORK,BESURETORETURNTHEMTOTHEIRORIgINAL pOSITIONSUSINgTHEBOLTSUSEDTOSECURETHEM. • IFANYOFTHEBOLTSBECOMELOST,USETHESpECIFIEDBOLTSANDqUANTITIESTOSECURETHECOvERS WHILEREFERRINgTOTHEBELOWpICTURE. • IFTHECOvERSARENOTSECUREDFIRMLY,NOISEMAYOCCUR,THECOvERSMAYDROpANDFLYOUT,HANDS MAYBECOMEENTANgLEDINTHEDRIvEUNITDURINgTEACHINg,ORCOMEINTOCONTACTWITHTHEHOT DRIvEUNIT,CAUSINgBURNS.OBSERvETHESECAUTIONSSTRICTLYTOpREvENTSUCHTROUBLE.

θ-axis

θ-axis motor cover

6 - M4 hex bolt



1 θ-axismotorcover KDL-M182E-00x 1

2θ-axismotorcoverattachmentbolt

90780-04010 M4,length10 6

3 O-ring KN5-M2144-00x 1

4 Washer KDL-M1861-00x 6

5θ-axisharness(coverside)

KDL-M4813-00x 1 Motor cable

6 KDL-M4814-00x 1 Encoder cable

7 θ-axisharnesssecuringbolt 91380-03006 M3,length6 8 Secured to motor cover

8θ-axisharness(motorside)

KDL-M4811-00x 1 Motor cable

9 KDL-M4812-00x 1 Encoder cable

10 Earthbolt 97980-04308 2



Cleaning wipe

phillipsscrewdriver

Hexwrenchset

Spanner No. 7

Threadsealer loctite 241 Henkel Mediumstrengthtype(blue)

2

Atta

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, de

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hing a

nd re

pla

cing

the c

over

2-23

2.1 θ-axismotorcoverremoval

CAUTION Whenremovingtheθ-axismotorcover,firstdisconnecttheharnessfromtheoutsideofthemotorcoverandthenremovethemovablebasefromtheα,βandγ-axisshaftsbeforeproceeding.Thereisariskofbodilyinjuryiftheharnessisdamagedorarobotmalfunctionoccursinsidetherobotmovementrange.Takecarenottocoverthewashersattachedtotheθ-axismotorcover.

1 Remove the M4 hex bolts securing the θ-axis motor cover and movable base.Loosenwithaspannerandthenremove.

M4 hex bolt removalStep 1

Washer

2 Lift the θ-axis motor cover from the movable base.

Inside the motor coverStep 2-4

Encoder cable connectorMotor cable

connector

Earth bolts

3 Disconnect the cable connectors inside the cover.Disconnectthemotorcableconnectorandencodercable connector.

4 Remove the two earth bolts.

5 Remove the θ-axis motor cover.

2

Atta

ching

, de

tac

hing a

nd re

pla

cing

the c

over

2-24

6 Remove the harness from the inside of the θ-axis motor cover (when replacing the harness inside the motor cover).Themotorcableandencodercablewillbothberemoved.

Removethefourlength6M3hexsocketheadboltsfromtheconnectorconnectionontheoutsideoftheθ-axismotorcover,andpulltheharnesstowardtheoutsideofthecover.

Ifreplacingtheharnessinsidethecover,alsoreplacebothoftheconnectorO-rings.

Harness removal (motor cable side)Step 6

Pull toward outside of cover.

O-ring (motor cable side)

Motor side connector

θ-axis motor cover

Harness removal (encoder cable side)Step 6


O-ring (encoder cable side)

2

Atta

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, de

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hing a

nd re

pla

cing

the c

over

2-25

7 Disconnect the motor cable and encoder cable from the θ-axis motor (when replacing the motor, speed reduction gear).

Motor side motor cable, encoder cable removalStep 7

Encoder cable

Motor cable

2.2 θ-axismotorcoverattachmentAttachthecoverusingtheoppositeoftheprocedureusedforremoval.

CAUTION Whenattachingtheθ-axismotorcover,firstdisconnecttheharnessfromtheoutsideofthemotorcoverandthenremovethemovablebasefromtheα,βandγ-axisshaftsbeforeproceeding.Thereisariskofbodilyinjuryiftheharnessisdamagedorarobotmalfunctionoccursinsidetherobotmovement range.

1 Connect the motor cable and encoder cable to the θ-axis motor (when replacing the motor, speed reduction gear). Whenattachingtheθ-axismotorcover,securetheharnesswithcabletiestopreventthemfrommoving.

Motor side motor cable, encoder cable connectionStep 1

Encoder cable

Motor cable

2 Connect the harness (motor side) on the inside of the θ-axis motor cover.Attachtheconnectorsideoftheharnesssothatitisfacingtheoutsideofthecover. Ensurethatthemarkontheconnectorisfacingupward. Ifreplacingtheharnessontheinsideofthecover,fitanO-ringtotheconnector.

Securetheconnectorconnectionontheoutsideoftheθ-axismotorcoverwiththefourlength6M3hexsocketheadbolts.

•Tighteningtorque:2Nm

Harness connection (motor cable side)Step 2


O-ring (motor cable side)

Mark

CAUTION Ifreplacingharnessontheinsideofthecover,itwillnotbepossibletoguaranteewaterproofingpropertiesiftheconnectorO-ringsarenotfitted,andthereforecautionisadvised.

2

Atta

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, de

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hing a

nd re

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cing

the c

over

2-26

3 Connect the cable at the encoder side in the same manner as that described in Step 2.Attachthecableconnectorsothatthemark(groove)is facing upward.

CAUTION Ifreplacingcablesontheinsideofthecover,itwillnotbepossibletoguaranteewaterproofingpropertiesiftheconnectorO-ringsarenotfitted,andthereforecautionisadvised.


Harness connection (encoder cable side)Step 3

Attach connector to outside of cover.

O-ring (encoder cable side)

Encoder cable connector

Motor cable connector

Mark (groove)

2

Atta

ching

, de

tac

hing a

nd re

pla

cing

the c

over

2-27

4 Connect the cable connectors to the inside of the cover.Connectboththemotorcableconnectorandencodercable connector.

Harness routing inside motor coverStep 4-6

Encoder cable connectorMotor cable

connector

O-ring

Cable tie

Earth bolt(Motor side)

Earth bolt(Relay side)

5 Attach the two earth bolts.Atthistime,donotuseanythreadsealer.

WARNING FAILURETOATTACHTHEEARTHBOLTSMAYRESULTINELECTRICSHOCK.

6 Replace the θ-axis motor cover.

CAUTION • Routethecablesontheinsideoftheθ-axismotorcover sothattheydonotcontacttheO-rings.prolongedcontact withtheO-ringsmaycausethemtoshift,leadingtoa possiblelossofwaterproofingproperties. • Donotbendtheharnessexcessively,orapplyexcessive forcewhenreplacingtheθ-axismotorcover.Failureto observethismayresultinharnessdamage.

7 Secure the θ-axis motor cover to the movable base.Attachthewasherstotheθ-axismotorcover,fittheM4hexboltstothewashers,andthentightenwithaspanner.

Washer attachmentStep 7

M4 hex bolt

Chapter 3 Periodic inspection

Contents

1. Overview 3-1

2. Daily inspection 3-2

3. Monthly inspection 3-3

4. Six-monthinspection 3-4

3

Perio

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3-1

1. OverviewDailyandperiodicinspectionoftheOMRONrobotisessentialinordertoensuresafeandefficientoperation.ThischapterdescribestheperiodicinspectionitemsandproceduresfortheR6Y3Seriesrobots.

periodicinspectionincludes:

•Dailyinspection •Monthlyinspection •6-monthinspection

Makesurethatyouthoroughlyunderstanddetailsoftheinspectionandfollowtheproceduresandprecautionsexplainedinthischapter.

WARNING SpECIALIzEDTECHNICALKNOWLEDgEANDSKILLSAREREqUIREDWHENARMS,SHAFTSANDTHEθ-AXIS ASSEMBLYAREDETACHEDTOADJUSTORMAINTAIN.OpERATIONSpERFORMEDBYWORKERSWHODONOTpOSSESSTHESESpECIALKNOWLEDgEANDSKILLSMAYLEADTODANgER.THISWORKMUSTBECARRIEDOUTBYREFERENCINgTHISMANUALBYSUFFICIENTLYSKILLEDANDqUALIFIEDpERSONNELINACCORDANCEWITHTHELAWSANDREgULATIONSOFEACHCOUNTRY.

WARNING • WHENINSpECTIONISREqUIREDINSIDETHESAFETYENCLOSURE,ALWAYSTURNOFFTHECONTROLLERAND ALSOTHEExTERNALSWITCHBOARD. • IFTHEINSpECTIONORMAINTENANCEpROCEDURECALLSFOROpERATIONOFTHEROBOT,STAYOUTSIDETHE SAFETYENCLOSURE. • pLACEASIgNINDICATINgTHEROBOTISBEINgINSpECTED,TOKEEpOTHERSFROMOpERATINgTHE CONTROLLERSWITCHOROpERATIONpANEL. • IFCHECKINgOpERATIONFOLLOWINgINSpECTION,REFERTOTHECONTROLLERMANUAL.

CAUTION Useonlythelubricantsspecifiedbyyourdistributors.

3

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3-2

2. Daily inspectionThefollowingisaninspectionlistthatmustbeperformedeverydaybeforeandafteroperatingtherobot.

■ Inspection to be performed with the controller turned off

Besuretoinspectwithcontrollerpoweroff.

1 Place a sign indicating the robot is being adjusted.placeasignindicatingtherobotisbeinginspected,tokeepothersfromoperatingthecontrollerswitch.

2 Perform the daily inspection.Enterthesafetyenclosureandcheckthefollowingpoints.

Checkpoint Procedure

Robot cable Usercableandwiring

Checkforscratches,dentsandexcessivebendandkinks.(Iftherobotcableisdamaged,contactyourdistributor.)

Regulator,joints,airtube, solenoidvalve,aircylinder

• Checkairpressure.• Checkforairleaks.• Checkdrain.• Checkairfilterforcloggingordamage.

Robotexterior Checkfordamage.(Ifadamageisfound,contactyourdistributor.)

plasticbearing(linkballslidingsurface)• Checkfordeformation,dents.• Checkthatwearamountis0.5mmorless.

plasticbearing(springmechanismplateslidingsurface)

• Checkfordeformation,breakage.(Checkforcracks.)• Checkthatwearamountis0.5mmorless.

Shaft Checkfordeformation.

Spring cover Checkfordamage.(Checkforguideclipbreakage.)

Insidespringcover(spring,plate,etc.)• Checkfordeformation.• Checkthespringtoseeifitisoverstretched.(Normallength:32.5±1mm)• CheckforM3screwlooseness.

θ-axisassemblyseal Checkforanygreaseleakingfromthecoupling.

■ Adjustment and parts replacement

CAUTION • Ifadjustmentorreplacementisdeemednecessaryfollowinginspection,turnoffthecontrollerpowerbeforeenteringthesafety enclosuretocarryoutwork.Ifcheckingoperationafterworkiscomplete,dosoinaccordancewith“■ Inspection to be performed withthecontrollerturnedoff”describedabove. • Ifrobotrepairorpartreplacementisdeemednecessary,contactyourdistributor.Suchrepairandpartreplacementrequires specializedtechnicalknowledge,andmustnotbecarriedoutbytheuser.

3

Perio

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3-3

3. Monthly inspectionThisinspectioniscarriedoutonceamonth.

payattentiontothefollowingifapplyinggreasetotheθ-axisassembly.

WARNING pRECAUTIONSWHENHANDLINggREASE: • INFLAMMATIONMAYOCCURIFTHISgETSINTHEEYES.BEFOREHANDLINgTHEgREASE,WEARYOURSAFETY gOggLESTOENSURETHEgREASEWILLNOTCOMEINCONTACTWITHTHEEYES. • USEFOODgREASE(CASSIDAgREASE,EpS2)WHENUSINgTHEROBOTATFOODpLANTS. • INFLAMMATIONMAYOCCURIFTHEgREASECOMESINTOCONTACTWITHSKIN.BESURETOWEAR pROTECTIvEgLOvESTOpREvENTCONTACTWITHSKIN. • DONOTTAKEORALLYOREAT.(EATINgWILLCAUSEDIARRHEAANDvOMITINg.) • KEEpOUTOFTHEREACHOFCHILDREN. • DONOTHEATTHEgREASEORpLACENEARANOpENFLAMESINCETHISCOULDLEADTOSpARKSANDFIRES. EMERgENCYTREATMENT: • IFTHISgREASEgETSINTHEEYES,WASHLIBERALLYWITHpUREWATERFORABOUT15MINUTESAND CONSULTApHYSICIANFORTREATMENT. • IFTHISgREASECOMESINCONTACTWITHTHESKIN,WASHAWAYCOMpLETELYWITHSOApANDWATER. • IFTAKENINTERNALLY,DONOTINDUCEvOMITINgBUTpROMpTLYCONSULTApHYSICIANFORTREATMENT. DISpOSINgOFgREASEANDTHECONTAINER: • pROpERDISpOSALISCOMpULSORYUNDERFEDERAL,STATEANDLOCALREgULATIONS.TAKEAppROpRIATE MEASURESINCOMpLIANCEWITHLEgALREgULATIONS.


Besuretoperformtheinspectionwithcontrollerpoweroff.

1 Place a sign indicating the robot is being adjusted.placeasignshowingthattherobotisbeinginspected,tokeepothersfromoperatingthecontrollerswitch.

2 Perform the inspection.Enterthesafetyenclosureandcheckthefollowingpoints.


θ-axisassemblyseals(large)(small)

• Checkfordeformation,damageorgreaserun-out.Ifthegreaserunsout,applythegrease.

• Checkifthecomponentmaynotbepickedup(pickupforcelowers).Ifthecomponentisnotpickedup,replacethesealwithanewone.Theleakamountfor30sec.is0.05Mpaorlessinthe0.6Mpa-sealedstate.

• Fordetailsabouthowtoreplacetheseal,refertoChapter8"θ-axisseal,O-ringreplacement".

plasticbearing(linkballslidingpart)

(plateinstallationpart)

Measuretheworn-outamount.Fordetailsabouthowtomeasuretheworn-outamount,see"2.plasticbearinginspection"inChapter7.Replacetheplasticbearingbasedon1500operationhoursor10.8millionoperationcycles.(plateinstallationpartis3timeslongerthanthisreferencevalue.)

Spring cover Checkforlooseness.

CAUTION Whenperformingtheinspection,replacenecessarypartswithnewonesaccordingtotheinspectioncontentsandinspectionreferences. Iftherobotisoperatedcontinuouslywithoutpartreplacement,thismaycausetherobottomalfunction.

3

Perio

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3-4

4. Six-monthinspectionTakethefollowingprecautionswhenperforming6-monthinspection.


Besuretoperformtheinspectionwithcontrollerpoweroff.

1 Place a sign indicating the robot is being adjusted.placeasignshowingthattherobotisbeinginspected,tokeepothersfromoperatingthecontrollerswitch.

2 Perform the inspection.Enterthesafetyenclosureandcheckthefollowingpoints.


Arm Checkfordeformation,damage.

link ball Checkfordamage.

Major robot body bolts and screws (Thoseexposedonoutside)

Checkforloosenessandtightenifnecessary.(Seethebelowtable)

Speed reduction gearCheckthespeedreductiongearforlargenoiseorrattleduringoperation.Iflargenoiseorrattleisfound,replacethespeedreductiongearwhilereferringto"2.Speedreductiongearandarmreplacementprocedure"inChapter10.

Bolt tightening torque

Bolt size Tightening torque (kgfcm) Tightening torque (Nm)

M3 set screw 20 2

M3 20 2

M4 46 4.5

M44-axisspecificationα-axisarmharnessclamp 20 2

M6 156 15.3

M8 380 37

M8 motor mounting bolt 194 19

M10 540 53

M12 1310 128

■ Adjustment and parts replacement

CAUTION • Ifadjustmentorreplacementisdeemednecessaryfollowinginspection,turnoffthecontrollerpowerbeforeenteringthesafety enclosuretocarryoutwork.Ifcheckingoperationafterworkiscomplete,dosoinaccordancewith“■ Inspection to be performed withthecontrollerturnedoff”describedabove. • Ifrobotrepairorpartreplacementisdeemednecessary,contactyourdistributor.Suchrepairandpartreplacementrequires specializedtechnicalknowledge,andmustnotbecarriedoutbytheuser.

Chapter 4 Adjusting the origin

Contents

1. Adjusting the origin 4-11.1 Adjustingtheα,βandγ-axesoriginposition 4-2

1.1.1 R6Y3[]110 4-21.1.2 R6Y3[]065 4-5

1.2 Adjustingtheθ-axisoriginposition(4-axesspecificationonly) 4-8

4

Ad

justing the

orig

in

4-1

1. Adjusting the originTheR6Y3Seriesusesacalibrationtooltomechanicallyadjusttheoriginpositionoftheα,β,γandθ-axes.Besuretoadjusttheoriginpositioninthefollowingcases:

1.Iftheoriginpositionislostafterdisconnectingtherobotcableconnectingthecontrollerwithrobot

2.Iftheoriginpositionislostafterdisconnectingtheθ-axisharnessfromtheθ-axismotorcoverconnectorsandcontrollersiderobot cable connector

3.Ifthemotorisreplaced(samereasonasabove)

4.Ifanyoftheaxisarmsareremoved

CAUTION • Ifanyoftheabovesituationsoccurafterpurchasingtherobot,itisnecessarytoadjusttheoriginposition(s)usingthecalibration tool.(Therobotoriginpositionsareadjustedatthefactory.) • Alwaysusethecalibrationtooltoperformoriginpositionadjustment.Ifadjustedwithoutusingthecalibrationtool,thepositionwill shift,resultinginabnormalrobotoperation,leadingtorobotdamageandpossiblebodilyinjury.

Thismanualdescribestheoriginpositionadjustmentmethodusingthecalibrationtool.


R6Y3[]110


1Origin position jig

KDL-M1501-00x 1 Forα,βandγ-axes

2 KDL-M1501-10x 1 Forθ-axis

R6Y3[]065


1Origin position jig

KDL-M501-30x 1 Forα,βandγ-axes

2 KDL-M501-10x 1 Forθ-axis


Name Part No. Manufacturer Remarks

Cleaning wipe

Hexwrenchset No. 10

4

Ad

justing the

orig

in

4-2

1.1 Adjustingtheα,βandγ-axesoriginposition

1.1.1 R6Y3[]110Theα,βandγ-axesoriginpositionsareshowninthebelowpicture.Adjusteachaxistoitsrespectiveoriginpositionsusingthecalibrationjig.

α, β and γ-axes origin positions

120° 120°

Detailed drawing of installation surface

Do not attach tubing to θ-axis cable.

155

Eyebolts (3 locations)(1067)

120

(46)

25

45

22(6

73) 799

6542

A

4-M5×0.8 depth 8Rc1/8

49

30°45

°

45°

Joint 6

15.7

5±0.

02

5H7 +0.0120 depth 10 View A

P.C.D.31.520 depth 3

4

Ad

justing the

orig

in

4-3

Calibration tool (α, β and γ-axes)

1 Post a sign indicating that the robot is being adjusted.postasignindicatingthattherobotisbeingadjustedtopreventothersfromturningonthecontrollerpower.

2 Enter the safety enclosure.

3 Secure the calibration tool to the base.SecuretheendofthecalibrationtooltothejigattachmentholesonthebasewiththeM12hexsocketheadboltsprovided. ThearmismovedatStep5,andifithitsthecalibrationtoolatthattime,temporarilysecurethetool,movethearmtoapositionabovethetoolatStep5,applythebrake,securethetool,andthenperform Steps 4 and 5.

Securing the calibration toolStep 3

M12 hex socket head bolt

Calibration tool

4 Release the motor brake for α-axis.

CAUTION Whenperformingoriginpositionadjustment,releasethebrakeoneaxisatatime.Neverreleasethebrakeforallthreeaxesatthesametime. Doingsowillresultinadropinoriginpositionaccuracy,leading to malfunctions.

4

Ad

justing the

orig

in

4-4

5 Move the arm slowly until the link ball on the end of the arm contacts the top of the calibration tool.

Position link ball against tool.Step 5

Calibration tool

Calibration tool

Link ball

6 Apply the motor brake for α-axis .

7 Remove the calibration tool from the base.BylooseningtheM12hexsocketheadboltontheendofthecalibrationtool,thetoolcomesawayfromthearmlinkball.Confirmthisandthenremovethecalibration tool.

8 Perform the procedure in Steps 3 to 7 for the γ and β-axes also.

4

Ad

justing the

orig

in

4-5

1.1.2 R6Y3[]065Theα,βandγ-axesoriginpositionsareshowninthebelowpicture.Adjusteachaxistoitsrespectiveoriginpositionsusingthecalibrationjig.

α, β and γ-axes origin positions

Do not attach tubing to θ-axis cable.

120°120°

150

490.

345

90(3

94)

(729)

2017

(27)

Eyebolts (3 locations)

A65

40

50

45°

4-M5x0.8 depth 8

Rc1/8

View A

Joint 6

5H7 +0.0120 depth 10

20 depth 3

15.7

5±0.

02B.C.D. 31.5

4

Ad

justing the

orig

in

4-6

Calibration tool (α, β and γ-axes)



3 Secure the calibration tool to the base.Securethetipofthecalibrationtooltothejigmountingholeinthetopsurfaceofthebasewiththeknobattachedtothecalibrationtool. ThearmismovedatStep5,andifithitsthecalibrationtoolatthattime,temporarilysecurethetool,movethearmtoapositionabovethetoolatStep5,applythebrake,securethetool,andthenperform Steps 4 and 5.

Securing the calibration toolStep 3

KnobKnob

Calibration tool

4 Release the motor brake for α-axis.

CAUTION Whenperformingoriginpositionadjustment,releasethebrakeoneaxisatatime.Neverreleasethebrakeforallthreeaxesatthesametime. Doingsowillresultinadropinoriginpositionaccuracy,leading to malfunctions.

4

Ad

justing the

orig

in

4-7

5 Move the arm slowly until the link ball on the end of the arm contacts the top of the calibration tool.

Position link ball against tool.Step 5

Calibration tool

Calibration tool

Link ball

6 Apply the motor brake for α-axis .

7 Remove the calibration tool from the base.BylooseningtheM12hexsocketheadboltontheendofthecalibrationtool,thetoolcomesawayfromthearmlinkball.Confirmthisandthenremovethecalibration tool.

8 Perform the procedure in Steps 3 to 7 for the γ and β-axes also.

4

Ad

justing the

orig

in

4-8

1.2 Adjustingtheθ-axisoriginposition(4-axesspecificationonly)Theθ-axisoriginpositionreferenceisthepositioninwhichthetoolflangedowelholeisfacingtheα-axis.Theaxisisadjustedtothereferencepositionwhenshippedfromthefactory,however,thepositionmayshiftslightly.Wheninstallingtherobotforthefirsttime,itisnecessarytousethecalibrationtooltoadjusttheoriginposition.

CAUTION Thetoolflangeisfixedon3-axesrobots,andthereforeitisonlynecessarytoattachthemovablebaseinthecorrectdirection. Referto"1.2Attachingtheshafts,movablebase,andspringcovers"inChapter5fordetailsonattachingthemovablebase. Withthe4-axesrobot,itisnecessarytoadjusttheθ-axisoriginpositioninadditiontoattachingthemovablebaseinthecorrectdirection. Theθ-axisoriginpositionshouldgenerallyneverbechanged.Ifchanged,theaxismaynolongermoveintherightdirection.



3 Secure the calibration tool.Theθ-axisoriginpositionisthepositioninwhichthetoolflangedowelholeisfacingtheα-axis.

θ-axis origin position

α-axis

Tool flange

Dowel hole

4 Align the θ-axis calibration tool pin with the tool flange dowel hole.

4

Ad

justing the

orig

in

4-9

5 Use two M5 bolts to secure the calibration tool to the tool flange.

Securing the calibration tool

Knock-pin

Dowel hole

θ-axis calibration tool

Secure at these two points.

θ-axis calibration tool

Chapter 5 Shaft, movable base and spring cover replacement

Contents

1. Shaft, movable base and spring cover replacement procedure 5-11.1 Detaching the shafts, movable base and spring cover 5-3

1.2 Attaching the shafts, movable base and spring covers 5-5

1.2.1 R6Y30110S03067NJ5,R6Y30065S02067NJ5(3-axesspecification) 5-51.2.2 R6Y31110L03067NJ5,R6Y31110H03067NJ5,R6Y31065L02067NJ5,R6Y31065H02067NJ5(4-axesspecification) 5-71.2.3 Attachingthespringcover(ReinforcedSpringCovercommonto3-axesand4-axes) 5-10

2. Movable base link ball replacement 5-12

5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-1

1. Shaft, movable base and spring cover replacement procedure1. Replacement parts


1

Spring cover

KDL-M1542-00x 2 Uppersidecover

1 S02D-MR129-00x 2 Acover(ReinforcedSpringCover)

2 KDL-M1543-00x 2 lower side cover

2 S02D-MR131-00x 2 Bcover(ReinforcedSpringCover)

3 Block S02D-MR126-00x 2Theattachmentpartmayvarydependingontheupperandlowerpositions(ReinforcedSpringCover)

4 Hexsocketheadbolt 91380-03006 8 (ReinforcedSpringCover)

5Plate

S02D-MR127-00x 2 plateA(ReinforcedSpringCover)

5 S02D-MR128-00x 2 plateB(ReinforcedSpringCover)

6 Shaftassembly KDL-M150g-01x 1R6Y3[]110:β,γ-axes(common), α-axis(3-axesspecifications)

(1) Shaftassembly1 KDL-M150H-01x 2

(2)

Cover assembly

KDL-M1540-00x 2

(2) S02D-MR132-00x 1 Reinforced Spring Cover upper portion

(2) S02D-MR132-10x 1 Reinforced Spring Cover lower portion

6 Shaftassembly KDL-M150g-21x 1R6Y3[]065:β,γ-axes(common), α-axis(3-axesspecifications)


(2)

Cover assembly

KDL-M1540-00x 2



7 Shaftassembly KDL-M150g-11x 1R6Y3[]110:α-axis(4-axesspecifications)



(3)

Cover assembly

KDL-M1540-00x 2



7 Shaftassembly KDL-M150g-31x 1R6Y3[]065:α-axis(4-axesspecifications)



(3)

Cover assembly

KDL-M1540-00x 2



5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-2


1 Shaftassembly1 KDL-M150H-01x 1R6Y3[]110:β,γ-axes(common) α-axis(3-axesspecification)

(1) ShaftA KDL-M150A-01x 1

(2) Plastic bearing KDL-M152J-01x 2

1 Shaftassembly1 KDL-M150H-31x 1R6Y3[]065:β,γ-axes(common) α-axis(3-axesspecification)

(1) ShaftA KDL-M150A-20x 1


1 Shaftassembly1 KDL-M150H-11x 1R6Y3[]110:α-axismotorcableside (4-axesspecification)

(1) ShaftA KDL-M150E-02x 1


1 Shaftassembly1 KDL-M150H-41x 1R6Y3[]065:α-axismotorcableside (4-axesspecification)

(1) ShaftA KDL-M150E-10x 1


1 Shaftassembly1 KDL-M150H-21x 1R6Y3[]110:α-axisencodercableside (4-axesspecification)

(1) ShaftA KDL-M150F-02x 1


1 Shaftassembly1 KDL-M150H-51x 1R6Y3[]065:α-axisencodercableside (4-axesspecification)

(1) ShaftA KDL-M150F-10x 1


5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-3

1.1 Detaching the shafts, movable base and spring coverWiththeR6Y31110L03067NJ5,R6Y31110H03067NJ5,R6Y31065L02067NJ5andR6Y31065H02067NJ5(4-axesspecification)robots,theharnessprotrudesfromtheα-axisshaft.Shaft,movablebase,andspringcoverdetachmentisthesameasthatforthe3-axesspecificationrobot.

CAUTION Itisnecessarytoenterthesafetyenclosureinordertodetachorattachtheshafts,movablebase,orspringcovers,andthereforethecontrollerpowermustbeturnedoffbeforehand.



3 Remove the spring covers.Thereareatotalofsixspringcovers:oneatthearm,andoneatthemovablebaseforeachofthethreeaxes. Thereisatopspringcoverandbottomspringcover,withthetopcoverbeingwider. Thespringcoversareheldtogetherwithclipsontheinside. pullthebottomcoverdownatthearmsideandpullthetopcoverupatthemovablebasesidetoremovethespringcover.

Spring cover removalStep 3

Spring cover attachment location

Top cover

Bottom cover

Clip

Arm side

Base side

CAUTION TheReinforcedSpringCoverisattachedinawaydifferentfromthenormalspringcover. FordetailedabouthowtoattachordetachtheReinforcedSpringCover,see"1.2.3Attachingthespringcover(ReinforcedSpringCovercommonto3-axesand4-axes)"inthischapter.

CAUTION Usebothhandswhenremovingthespringcovers.Useonehandforremovalandtheothertostopthebottomcoverfalling. Ifthespringcoverfallsandisdamaged,therobotmayoperate abnormally.

4 Remove the end effector.Referto“6.Attachingtheendeffector”inChapter2oftheinstallationmanualfordetails.

5 Disconnect the air tube from the joint on the user tubing.

CAUTION Donotcarryoutreplacementworkwiththeairtubestillattachedtothejointontheusertubing. Bydoingso,theairtubemaybend.

5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-4

6 Disconnect the θ-axis connection connector of the α-axis arm. (R6Y31110L03067NJ5, R6Y31110H03067NJ5, R6Y31065L02067NJ5 and R6Y31065H02067NJ5 only)Turntheconnector90ºcounterclockwiseandpullitout.

Arm side harnessStep 6

7 Disconnect the harness at the movable base side from the motor cover. (R6Y31110L03067NJ5, R6Y31110H03067NJ5, R6Y31065L02067NJ5 and R6Y31065H02067NJ5 only)Theharnessisdisconnectedbyrotatingtheconnectorasshownwiththearrowonthecableconnectorandthendisconnectingitfromthemotorcover.

Harness removal at movable base sideStep 7

8 Remove the shafts.Removetheshaftsfromthearmandmovablebaselink balls. Whendoingso,thelinkballscanbestretchedbyhandattheendoftheshaftasshowninthepictureontheright. Whenremovingtheshaftsfromthemovablebase,disconnecttheθ-axisrobotcablefromthemotorbeforehand.

CAUTION • Removethespringcoversbeforeremovingtheshafts. Thespringcoversmaybedamagedifworkiscarriedout withoutremovingthem. • Takecarenottopullthespringsontheshaftstoomuch.If stretchedtoofar,thespringsmaynotreturntotheir originalshape,possiblyleadingtoabnormalrobot movement. • WiththeR6Y31110L03067NJ5,R6Y31110H03067NJ5, R6Y31065L02067NJ5andR6Y31065H02067NJ5the harnessisattachedtotheα-axisshaft.Iftheα-axisshaftis removedfromthemovablebasewithoutdisconnecting theθ-axisharnessfromthemotor,thecablewillbepulled andpossiblydamaged,leadingtopotentialdefects. Furthermore,careshouldbetakennottodropthe movable base.

Shaft removalStep 8

Link ball

5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-5

1.2 Attaching the shafts, movable base and spring covers


1.2.1 R6Y30110S03067NJ5,R6Y30065S02067NJ5(3-axesspecification)Thereplacementprocedurefortheshafts,movablebase,andspringcoversisthesameasthatfortheα,βandγ-axes.



3 Attach the shafts.Attachtheshaftswhileensuringtohooktheshaftplasticbearingsontothearmandmovablebaselinkballs.Thelinkballscanbestretchedbyhandattheendoftheshaftasshowninthepicture. Thedepressionontheshaftsforspringcoverattachmentshouldfaceupward. Themovablebaseattachmentdirectionisasshowninthepicture.Referto"1.2Adjustingtheθ-axisoriginposition"inChapter4fordetails.

Shaft attachmentStep 3

Movable base side

Arm side

Link ball

Link ball

α-axis

Depression

Plastic bearing

Encoder cableside

Motor cableside

CAUTION Byattachingtheshaftswithhandsplacedanywhereotherthantheshaftend,thejointbetweentheshaftandshaftendmaydeform,possiblyleadingtomalfunction.Ensuretoplacehandsontheendoftheshaftasshowninthepictureontheright. Takecarenottopullthespringsontheshaftstoomuch. Ifstretchedtoofar,thespringsmaynotreturntotheiroriginalshape,possiblyleadingtomalfunction.

5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-6

4 Attach the spring covers.Thereareatotalofsixspringcovers:oneatthearm,andoneatthemovablebaseforeachofthethreeaxes. Thetopandbottompositionsofthespringcoversarefixed. IftheshaftdirectioniscorrectatStep3,thecoverattachedatthetopwillbewideasshowninthepicture. Thespringcoverscomeasatopandbottomsetwhenshipped.Attachthecoverssothattheysnaptogetherattheguideclips.

Spring cover attachmentStep 4


The top of the spring cover widens.

Spring cover top

Spring cover bottom

Clip


5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-7

1.2.2 R6Y31110L03067NJ5, R6Y31110H03067NJ5, R6Y31065L02067NJ5, R6Y31065H02067NJ5(4-axesspecification)WiththeR6Y31110L03067NJ5,R6Y31110H03067NJ5,R6Y31065L02067NJ5andR6Y31065H02067NJ5(4-axesspecification)robots,theharnessprotrudesfromtheα-axisshaft. Shaft,movablebase,andspringcoverattachmentisthesameasthatforthe3-axesspecificationrobot.



3 Attach the shafts.Attachtheshaftswhileensuringtohooktheshaftplasticbearingsontothearmandmovablebaselinkballs.Thelinkballscanbestretchedbyhandattheendoftheshaftasshowninthepicture. Thedepressionontheshaftsforspringcoverattachmentshouldfaceupward. Themovablebaseattachmentdirectionisasshowninthepicture.Referto"1.2Adjustingtheθ-axisoriginposition"inChapter4fordetails.


Movable base side

Arm side

Link ball

Link ball

α-axis

Depression

Plastic bearing

Encoder cableside

Motor cableside


5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-8

4 Attach the spring covers.Thereareatotalofsixspringcovers:oneatthearm,andoneatthemovablebaseforeachofthethreeaxes. Thetopandbottompositionsofthespringcoversarefixed. IftheshaftdirectioniscorrectatStep3,thecoverattachedatthetopwillbewideasshowninthepicture. Thespringcoverscomeasatopandbottomsetwhenshipped.Attachthecoverssothattheysnaptogetherattheguideclips.



The top of the spring cover widens.

Spring cover top

Spring cover bottom

Clip


5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-9

5 Connect the harness on the arm side.Theconnectortypeofthemotorcableisdifferentfromthatoftheencodercable.Connectthecablessothattheyarenottwistedforcibly. Turntheconnectorclockwisetolockitafterinserted.

Connecting the harness on the arm sideStep 5

Motor cable side Encoder cable side

CAUTION Whenperformingtheoperationwithoutlockingtheconnector,thecablemaycomeoffandhavefaultywiring.

6 Attach the harness at the movable base side to the motor cover.Ensurethatthemovablebaseandα-axisshaftattachmentdirectionsarecorrect. Alignthearrowonthecableconnectorwiththeconnectormarkonthemotorcoverandattach. Attachboththemotorcableandencodercabletotheirrespectiveconnectors.

Harness attachment at movable base sideStep 6

5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-10

1.2.3 Attachingthespringcover(ReinforcedSpringCovercommonto3-axesand4-axes)Theuppercoverattaching(detaching)proceduresmayvaryfromthelowercoverattaching(detaching)procedures.

Upper cover

Lower cover

1 Press-fit the A cover of the upper cover into the spring part from the upper portion.

Upper cover press-fittingStep 1

A cover

Block

B cover

Plate B

CAUTION Iftheshaftisinstalledupsidedown,thecovercannotbeattached.

2 Press-fit the B cover of the upper cover from the lower portion and secure it together with the plate B using the M3 hex socket head bolts.Tighteningtorque:2Nm

Upper cover securingStep 2

5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-11

3 Press-fit the A cover of the lower cover into the spring part from the upper portion.

Lower cover press-fittingStep 3

Plate A

A cover

Block

B cover

CAUTION Iftheshaftisinstalledupsidedown,thecovercannotbeattached.

4 Press-fit the B cover of the lower cover from the lower portion and secure it together with the plate A using the M3 hex socket head bolts.Tighteningtorque:2Nm

CAUTION Detachthecoverinthereverseorderofattachment. • RemovetheM3hexsocketheadboltsfromthelower portiontodetachtheuppercover. • RemovetheM3hexsocketheadboltsfromtheupper portiontodetachthelowercover.

CAUTION HoldthelowerclampboltsoftheuppercoverortheBcoverofthelowercoverbyhandsothatanypartdoesnotdrop.

Lower cover securingStep 4

5

Shaft, m

ovab

le ba

se and

spring

cover repla

cement

5-12

2. Movable base link ball replacementThelinkballattachmentmethodisdescribedbelow. Removethelinkballsusingtheoppositeofthemethodusedforattachment.



1 link ball KDL-M152A-00x 6 Movable base part



Cleaning wipe

Spanner No. 12


1 Apply the thread sealer to the screw part of the link ball thinly.UseHenkelLoctite241(blue).

2 Attach a link ball at six locations on the movable base.

Link ball attachmentStep 2

3 Tighten the link balls with a tool.•Tighteningtorque:20Nm

TighteningStep 3

Chapter 6 Spring mechanism replacement

Contents

1. Spring mechanism replacement procedure 6-11.1 Spring mechanism removal 6-2

1.2 Spring mechanism attachment 6-3

6

Spring

me

cha

nism re

pla

ce

me

nt

6-1

1. Spring mechanism replacement procedure1. Replacement parts

Part Name OMRON Part No. Part No. / Specs Q'ty*1 Remarks

(1) Spring KDL-M152M-00x 2

(2) Plate KDL-M1534-00x 4

(3) Plastic bearing KDL-M152K-00x 4

(4) Plastic block KDL-M153A-00x 2

(5) Screw 98980-03006 M3,length6 4

*1:quantityperaxis



phillipsscrewdriver

6

Spring

me

cha

nism re

pla

ce

me

nt

6-2

1.1 Spring mechanism removal

1 Remove the shaft from the arm and movable base.Referto“Shaft,movablebase,andspringcoverreplacement”inChapter5fordetails.

Shaft removed from arm and movable baseStep 1

Screw

2 Remove the M3 screws at four locations.Byremovingthescrews,thesprings,plateassembly,andplasticblockscomefreeoftheshaft.

Screw removalStep 2

Plastic bearings

3 Remove the springs.performthisprocedureonlywhenreplacingsprings.

4 Remove the press-fit plastic bearings.performthisprocedureonlywhenreplacingplasticbearings. Referto“plasticbearingreplacement”inChapter7for details.

6

Spring

me

cha

nism re

pla

ce

me

nt

6-3

1.2 Spring mechanism attachment

1 Press fit the plastic bearings into the plate.Referto“plasticbearingreplacement”inChapter7for details.

Plastic bearing, plateStep 1

Plastic bearing Plate

CAUTION payattentiontotheattachmentdirection.Itwillnotbepossibletoattachtheshaftiftheplateandplasticbearingdirectionsarenotasshownontheright.

2 Attach the spring.Ensurethattheplatesarebilaterallysymmetrical. Fortwoshafts,twooftheassembliesshownontherightarerequiredatthearmside,andtwoassembliesarerequiredatthemovablebaseside.

Spring attachmentStep 2

Spring

3 Secure the plastic blocks with M3 screws.Asshownontheright,presstheprotrudingpartoftheplasticblockagainsttheprotrudingpartoftheplate,andthensecurewiththescrews. Attachtheplatetotheotherplasticblockattachmentsurfaceontheothersideafterattachingtotheshaft.

Tighteningtorque:40cNm

Securing the plastic blocksStep 3

CAUTION Forceisappliedtotheplasticwhentightening,andthereforecareshouldbetakentoavoidovertightening.

6

Spring

me

cha

nism re

pla

ce

me

nt

6-4

4 Attach the plate and plastic block assembly to the shaft.Inserttheplasticbearingattachedtotheplatesothatitcatchesontheshaftpin.

Assembly attachment locationsStep 4

Pin

Attach the plate and plastic block assembly to one side of the shaft beforehand.

NOTE Theassemblyisattachedatboththearmsideandmovablebaseside;however,theplasticblockdirectionshouldbethesameforboth.

5 Attach the other plate and spring assembly (assembly without plastic block) to the shaft.

Plate and spring assembly attachmentStep 5

Ensure that the plate and plastic block are level.

6 Secure the plastic block with the M3 screws as described in Step 3.Attachsothattheplateandplasticblockarelevel.

7 Attach the plate and plastic block assembly on the opposite of the side already attached using the same procedure described in Steps 3 to 6.

Chapter 7 Plastic bearing replacement

Contents

1. Plastic bearing replacement procedure 7-11.1 Removing the plastic bearing from the link ball sliding part 7-1

1.2 Attaching the plastic bearing to the link ball sliding part 7-2

1.3 Spring mechanism plate plastic bearing removal 7-3

1.4 Spring mechanism plate plastic bearing attachment 7-3

2. Plastic bearing inspection 7-4

7

Plastic

be

aring

rep

lac

em

ent

7-1

1. Plastic bearing replacement procedureCAUTION plasticbearingsareconsumablepartsandshouldthereforebereplacedperiodically.



1 Plastic bearing 1 KDL-M152J-00x 12Replaceifthewearamountis0.5mmor more

2 Plastic bearing 2 KDL-M152K-00x 24Springmechanism(Replaceifthewearamountis0.5mmormore)



Jig KDL-M1501-21x

Jig A KDL-M1116-01x

Jig B KDL-M1117-00x

Hexwrench No. 3

Pliers

1.1 Removing the plastic bearing from the link ball sliding partplasticbearingreplacementguideline:whenamountofwearreaches0.5mm

Whenreplacingplasticbearings,besuretocheckandtakeanoteofthebearingdepth,andperiodicallymeasuretheamount of wear.

1 Install an M4 hex socket head bolt (L20 or more) into the tapping hole in the plastic bearing.

Bolt attachmentStep 2

Bolt

2 Push up the plastic bearing while tightening the M4 hex socket head bolt with a hex wrench.

7

Plastic

be

aring

rep

lac

em

ent

7-2

1.2 Attaching the plastic bearing to the link ball sliding part

1 Fit the plastic bearing installation jig A into the plastic bearing.

Inserting the plastic bearing and jig AStep 2

Jig A

2 Insert the plastic bearing and jig A into the shaft side.

3 Press-fit the plastic bearing using either procedure (1) or (2) shown below.(1)push-intheplasticbearingusingthetoolthatcanpinch,suchasthewaterpumpplierstogetherwiththejigB.

(2)ArrangethejigAonthehorizontalsurfaceandpushitinfromtheoppositesidebyhand.

Pushing in the plastic bearingStep 3

(1) Using water pump pliers

(2) Pushing by hand

Jig A

Jig B

7

Plastic

be

aring

rep

lac

em

ent

7-3

4 Check that the plastic bearing does not protrude.

Plastic bearing attachment condition Step 4

The plastic bearing does not protrude

1.3 Spring mechanism plate plastic bearing removal

1 Push the plate down from above with the protruding part of the plastic bearing facing down.Theplasticbearingwillpopup,allowingittoberemoved. If it still cannot be removed even after poppingup,useaflatscrewdriverorsimilartooltoremove it.

Plastic bearing removalStep 1

Plastic bearing

PlateCAUTION Thebearingispressfitwhenattached,andshouldthereforebe removed using a tool.

1.4 Spring mechanism plate plastic bearing attachment

1 Pay attention to the plastic bearing attachment direction and attach by press fitting.Attachwiththeplasticbearingandplatefacinginthedirectionsshownontheright.

Plastic bearing attachmentStep 1

CAUTION Itwillnotbepossibletoattachthespringcoverifthedirectionisincorrect,resultinginpossiblerobotmalfunction.

7

Plastic

be

aring

rep

lac

em

ent

7-4

2. Plastic bearing inspectionMeasurethewidthofthegapbetweenthetwoshaftjointswithcalipersandsoon.

Thismeasurementincludesthewidthoftwoplasticbearingsofthelinkandfourplasticbearingsoftheplate.

CAUTION • Whenthetotalamountofwearreaches1mmormore,replacetheplasticbearingsofthelink. • Whentheplasticbearingsofthelinkarereplacedatthethirdtime,replacetheplasticbearingsoftheplate.

(Example)Iftheinitialmeasurementvalueis149.50mmandthisvaluehasreached148.50mmduringperiodicmeasurement,replacetheplasticbearings.

Whenreplacingplasticbearings,besuretocheckandtakeanoteofthemeasurementresult,andperiodicallymeasuretheamountofwear.

Measurement method

CAUTION plasticbearingweardebrisprecautions: • Weardebrisremovalisnecessarywhencleaninginfood-relatedindustries. • Weardebrisremovalinindustrialapplicationsshouldbecarriedoutasrequired.

Chapter 8 θ-axisseal,O-ringreplacement

Contents

1. θ-axisseal,O-ringreplacementprocedure 8-11.1 θ-axisseal,O-ringremoval 8-1

1.2 θ-axisseal,O-ringattachment 8-3

8

θ-axis seal, O-ring replacem

ent

8-1

1. θ-axisseal,O-ringreplacementprocedure1. Replacement parts


1 Seal(small) KDL-M219K-00x 1Insideθ-axishousing, small side

2 Seal(large) KDL-M219K-10x 1Insideθ-axishousing, large side

3 O-ring KN5-M2144-00x 1 Housingside

4 O-ring KN6-M1895-00x 1 θ-axismotorcoverside

5 Housing KDL-M1811-00x 1

6 Housingsecuringbolt 91380-04020 M4,length20 6

7 Tool flangeKDL-M1843-00x 1

KDL-M1844-00x 1

8 Tool flange securing bolt 91380-04012 M4,length12 2

9 Tool flange cover KDL-M1816-00x 1 Rubber cover



Cleaning wipe

phillipsscrewdriver

Hexwrenchset


grease EPS2 1g CASSIDA grease Foodgradeoritscompatible

1.1 θ-axisseal,O-ringremovalTheproceduredescribedbelowisfortheR6Y31110L03067NJ5,R6Y31110H03067NJ5,R6Y31065L02067NJ5andR6Y31065H02067NJ5(4-axesspecification).

1 Remove the θ-axis motor cover.Whenremovingtheθ-axismotorcover,firstdisconnecttheθ-axisharnessandthenremovethemovablebasefromtheshaftsbeforeproceeding. Referto"1.2Detachingorattachingtheθ-axiscover"inchapter2fordetails.

2 Remove the O-ring from the groove in the movable base at the motor cover side.

O-ring removalStep 2

8


ent

8-2

3 Remove the tool flange.Removetherubbercover,removetheM4hexsocketheadbolts,andthenremovethetoolflange.

Tool flange removalStep 3

Tool flange

Rubber cover

4 Remove the six length 20 M4 hex socket head bolts from the movable base.Theseboltssecurethemovablebaseandhousing.

5 Remove the housing from the movable base.Thehousingwillstillbeattachedtothemovablebase a little.

M4 hex socket head bolt removalStep 4

Housing removalStep 5

8


ent

8-3

6 Remove the O-ring from the groove on the movable base at the housing side.


7 Remove the two seals from the housing.Thesealscanbeeasilyremovedbyprizingthemfreewithaprecisionflatscrewdriverasshownontheright.

Seal removalStep 7

Seal (large)

Seal (small)

1.2 θ-axisseal,O-ringattachmentFitthesealsusingtheoppositeoftheprocedureusedforremoval.

CAUTION Whenreplacingθ-axisseal,wipeofftheoldgreasestickingtothehousingorθ-axisshaftbeforeattachingtheseal. • Recommendedgrease:CASSIDAgreaseEpS2 Totalgreaseamount:1g

1 Fit the two seals to the housing.Ifunabletoattachthesealsproperlyasshownontheright,attachbypressinginalittle,andensurethatthesealsarenottwisted.

Seal attachmentStep 1

Seal (large)

Seal (small)

8


ent

8-4

2 Apply the recommended grease so that the grooves on the seals (large) and (small) are filled with it.

CAUTION Ifthegreaseapplicationamountissmall,theservicelifeofthesealmaybecomeshorter.

3 Apply a thin layer of the recommended grease to the sliding parts with the seals (large) and (small).

CAUTION Ifthegreaseapplicationamountissmall,theservicelifeofthesealmaybecomeshorter.

4 Attach the O-ring to the groove in the movable base at the housing side.

O-ring attachmentStep 4

Grease applicationStep 2

Grease application


Apply the grease to the slidingpart with the seal (small)

Apply the grease to the slidingpart with the seal (large)

8


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8-5

5 Attach the housing.pushthehousinguntilitisalignedwiththeundersideofthemovablebasesothattheairtubeattachmentportisontheβ-axisside. Afterpushingin,tightenthesixlength20M4hexsocketheadbolts.


Housing attachmentStep 5

These surfaces should be aligned.

CAUTION AttachthehousingwiththehousingsideO-ringattachedtothemovablebasepart.Furthermore,ensurethatthehousingisalignedwiththeundersideofthemovablebase. pickupwillnotbepossibleiftheO-ringhasnotbeenattached,orthehousinghasnotbeenattachedsufficiently.

8


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8-6

6 Install the tool flange.Removegreasefromtheθ-axisshaft(toolflangeattachmentpart). Thetoolflangeisshapedsothatitfitsintotheθ-axisshaftgroove.

Tool flange installationStep 6-7

Degrease this part.

Tool flange

Shaft

Fit into shaft groove.

M4 hex socket head bolts, length 12

7 Attach the tool flange with the two M4 hex socket head bolts.•Tighteningtorque:4.5Nm

CAUTION TightenthetwoM4hexsocketheadboltsevenly. Slippagemayoccurbetweentheθ-axisshaftandsealflangeifoneboltistightenedmorethantheother.

8


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8-7

8 Attach the rubber cover to the tool flange.

Rubber cover attachmentStep 8

Tool flange

Rubber cover

9 Attach the O-ring to the groove in the movable base at the motor side.

10 Attach the θ-axis motor cover.Referto"1.2Detachingorattachingtheθ-axiscover"inchapter2fordetails.

O-ring attachmentStep 9

Chapter 9 Motor replacement

Contents

1. α,βandγ-axesmotorreplacement 9-11.1 R6Y3[]110 9-1

1.1.1 α,βandγ-axesmotorremoval 9-11.1.2 α,βandγ-axesmotorattachment 9-4

1.2 R6Y3[]065 9-5

1.2.1 α,βandγ-axesmotorremoval 9-51.2.2 α,βandγ-axesmotorattachment 9-8

2. θ-axismotorreplacement 9-92.1 θ-axismotorremoval 9-9

9

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9-1

1. α,βandγ-axesmotorreplacement1.1 R6Y3[]110

WARNING IFREpLACINgAMOTORWITHSHAFTS,MOvABLEBASE,ANDARMATTACHED,pLACEASUppORTUNDERTHEMOvABLEBASETOpREvENTITFALLINg.ANDIFREpLACINgAMOTORWITHONLYTHEARMATTACHED,pLACEASUppORTUNDERTHEARMORSTRApITUpWITHSOMESTRINgTOpREvENTITFALLINg.



1 Motor R88M-K1K030T-BS2*2 1000W,200v,withbrake 1 Forα,βandγ-axes

2 Motor securing bolt 91312-08025 M8,length25 4

3 O-ring 90200-03J850 1Attachedtospeedreductiongeargroove

*1:quantityperaxis *2:Forinstallation,removethekey



Cleaning wipe

Hexwrenchset kenko Only No. 6 is 160 mm long


Seal tapeNITOFLONpipeseal No. 95S or its equivalent

NITTODENKO

1.1.1 α,βandγ-axesmotorremoval

NOTE Thesameprocedureisusedtoreplacetheα,βandγ-axesmotors.

1 Post a sign indicating that the robot is being adjusted.postasignindicatingthattherobotisbeingadjustedtopreventothersfromturningonthecontroller power.


3 Remove the motor cover.Referto“1.Detaching,attaching,andreplacing

thecovers”inchapter2fordetails.

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9-2

4 Remove the speed reduction gear cap bolt.Ifthehexsocketheadboltisnotvisibleinsidetheholewhenthecapboltisremoved,releasethemotorbrake,movethearmtoapositionatwhichthehexsocketheadboltbecomesvisible,andthenadjust(ifthearmhasbeenremoved,rotatethespeedreductiongeartoadjusttheposition.)

Cap bolt removalStep 4

Cap bolt

Hex socket head bolt

CAUTION Ifremovingthemotorwiththearmstillattached,itwillfallsuddenlywhenthemotorbrakeisreleased,andmustthereforebesupported.Andifremovingthemotorwiththeshaftsandmovablebasestillattached,themovablebase must be supported to prevent it dropping suddenly.

5 Loosen the M6 hex socket head bolt connecting the speed reduction gear and motor shaft.Tightentheboltwithatorqueof15Nm.

6 Remove the four M8 hex socket head bolts securing the motor to the speed reduction gear.Tightentheboltwithatorqueof19Nm.

CAUTION Takecaretopreventthemotorfallingwhentheboltsareremoved.

Hex socket head bolt removalStep 6

Loosen the M6 hex socket head boltStep 5

9

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9-3

7 Pull the motor from the speed reduction gear to remove.

CAUTION Themotorisrelativelyheavyandshouldthereforebesupportedwithbothhandswhenremoving.

8 Attach the O-ring to the groove in the speed reduction gear (when replacing the O-ring).

Motor removalStep 7


O-ring

9

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9-4

1.1.2 α,βandγ-axesmotorattachmentAttachthemotorsusingtheoppositeoftheprocedureusedforremoval.Whendoingso,thefollowingadditionalproceduresarenecessary.

• Useawasteclothtoremoveanygreasefromthemotorshaftandspeedreductiongearattachmentsurfaces.

• Tomakeiteasiertosecurethemotorshafttothespeedreductiongear,rotatethespeedreductiongearbeforehandsothatthegearhexsocketheadboltisvisiblefromthecapattachmenthole.

• Whenattachingthemotor,fitanO-ringtothespeedreductiongear.

• Attachthemotorwiththeconnectorfacingtotheinside.

• TightentheM8boltofthemotorwithatorqueof19Nm.

• Tightentheclampbetweenthemotorandspeedreductiongearwithatorqueof15Nm(M6).

• Windthesealtapeonthecapbolt.

O-ring attachment

O-ring

Motor attachment direction

Seal tape winding direction

Wind the seal tape two turns in the opposite direction of the screw thread.

9

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9-5

1.2 R6Y3[]065

WARNING IFREpLACINgAMOTORWITHSHAFTS,MOvABLEBASE,ANDARMATTACHED,pLACEASUppORTUNDERTHEMOvABLEBASETOpREvENTITFALLINg.ANDIFREpLACINgAMOTORWITHONLYTHEARMATTACHED,pLACEASUppORTUNDERTHEARMORSTRApITUpWITHSOMESTRINgTOpREvENTITFALLINg.



1 Motor R88M-K40030T-BS2*2 400W,200v,withbrake 1 Forα,βandγ-axes


3 O-ring 90200-01J530 1Attachedtospeedreductiongeargroove

*1:quantityperaxis *2:Forinstallation,removethekey



Cleaning wipe

Hexwrenchset kenko Only No. 4 is 160 mm long


Seal tapeNITOFLONpipeseal No. 95S or its equivalent

NITTODENKO

1.2.1 α,βandγ-axesmotorremoval

NOTE Thesameprocedureisusedtoreplacetheα,βandγ-axesmotors.

1 Post a sign indicating that the robot is being adjusted.postasignindicatingthattherobotisbeingadjustedtopreventothersfromturningonthecontroller power.


3 Remove the motor cover.Referto“1.Detaching,attaching,andreplacing

thecovers”inchapter2fordetails.

9

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9-6

4 Remove the speed reduction gear cap bolt.Ifthehexsocketheadboltisnotvisibleinsidetheholewhenthecapboltisremoved,releasethemotorbrake,movethearmtoapositionatwhichthehexsocketheadboltbecomesvisible,andthenadjust(ifthearmhasbeenremoved,rotatethespeedreductiongeartoadjusttheposition.)

Cap bolt removalStep 4

Cap bolt


CAUTION Ifremovingthemotorwiththearmstillattached,itwillfallsuddenlywhenthemotorbrakeisreleased,andmustthereforebesupported.Andifremovingthemotorwiththeshaftsandmovablebasestillattached,themovablebase must be supported to prevent it dropping suddenly.

5 Loosen the M4 hex socket head bolt connecting the speed reduction gear and motor shaft.Tightentheboltwithatorqueof4.3Nm.

6 Remove the four M4 hex socket head bolts securing the motor to the speed reduction gear.Tightentheboltwithatorqueof2.3Nm.

CAUTION Takecaretopreventthemotorfallingwhentheboltsareremoved.

Hex socket head bolt removalStep 6

Loosen the M4 hex socket head boltStep 5

9

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9-7

7 Pull the motor from the speed reduction gear to remove.

CAUTION Themotorisrelativelyheavyandshouldthereforebesupportedwithbothhandswhenremoving.

8 Attach the O-ring to the groove in the speed reduction gear (when replacing the O-ring).

Motor removalStep 7


O-ring

9

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9-8

1.2.2 α,βandγ-axesmotorattachmentAttachthemotorsusingtheoppositeoftheprocedureusedforremoval.Whendoingso,thefollowingadditionalproceduresarenecessary.

• Useawasteclothtoremoveanygreasefromthemotorshaftandspeedreductiongearattachmentsurfaces.

• Tomakeiteasiertosecurethemotorshafttothespeedreductiongear,rotatethespeedreductiongearbeforehandsothatthegearhexsocketheadboltisvisiblefromthecapattachmenthole.

• Whenattachingthemotor,fitanO-ringtothespeedreductiongear.

• Attachthemotorwiththeconnectorfacingtotheinside.

• TightentheM4boltofthemotorwithatorqueof2.3Nm.

• Tightentheclampbetweenthemotorandspeedreductiongearwithatorqueof4.3Nm(M4).

• Windthesealtapeonthecapbolt.

O-ring attachment

O-ring

Motor attachment direction

Seal tape winding direction

Wind the seal tape two turns in the screw thread direction.

9

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9-9

2. θ-axismotorreplacement1. Replacement parts


1 Motor

R88M-K05030T-S2*1 50W,200v,withoutbrake 1ForR6Y31110L03067NJ5andR6Y31065l02067NJ5

R88M-K10030T-S2*1 100W,200v,withoutbrake 1ForR6Y31110H03067NJ5andR6Y31065H02067NJ5


CommontoR6Y31110L03067NJ5,R6Y31110H03067NJ5,R6Y31065l02067NJ5 and R6Y31065H02067NJ5

*1:Forinstallation,removethekey

2.1 θ-axismotorremovalTheprocedurerequiredtoreplacetheθ-axismotoronlyisdescribedbelow.Referto"2.3θ-axisspeedreductiongearreplacement"inchapter10ifremovingthespeedreductiongearalso.

1 Remove the movable base from the shaft.Refertothe"1.Shaft,movablebase,andspringcoverreplacementprocedure"inchapter5fordetails.

2 Remove the θ-axis motor cover.Refertothe"1.Shaft,movablebase,andspringcoverreplacementprocedure"inchapter5fordetails.

3 Loosen the two speed reduction gear set screws.Removethegasketandthenloosenthesetscrews.

NOTE Ifthesetscrewisnotloosenedsecurely,thespeedreduction gear may be disassembled during motor removal.Itispreferabletoreplacethemotorandspeedreductiongearatthesametime.

Set screw areaStep 3

Gasket

4 Remove the two M4 hex socket head bolts securing the motor to the speed reduction gear.

5 Remove the motor from the speed reduction gear.

Attachthemotorusingtheoppositeoftheprocedureused for removal. Referto"2.3θ-axisspeedreductiongearreplacement"inchapter10fordetails.


Chapter 10 Speed reduction gear, arm replacement

Contents

1. Speed reduction gear replacement precautions 10-1

2. Speed reduction gear and arm replacement procedure 10-22.1 R6Y3[]110 10-2

2.1.1 α,βandγ-axesarmreplacement 10-22.1.2 α,βandγ-axesspeedreductiongearreplacement 10-6

2.2 R6Y3[]065 10-8

2.2.1 α,βandγ-axesarmreplacement 10-82.2.2 α,βandγ-axesspeedreductiongearreplacement 10-12

2.3 θ-axisspeedreductiongearreplacement 10-15

10

Speed reduction gear, arm replacem

ent

10-1

1. Speed reduction gear replacement precautionsSpeedreductiongearreplacementprecautionsaredescribedbelow.Alwaysreadthefollowingreplacementproceduresand precautions before carrying out replacement work.

■ Speed reduction gear replacement precautions

WARNING • THEMOTORANDSpEEDREDUCTIONgEARCASINgWILLBECOMEvERYHOTSHORTLYAFTEROpERATION, RESULTINgINBURNSIFTOUCHED.BEFORETOUCHINgTHESEpARTS,TURNOFFTHECONTROLLER,WAITFORA WHILE,ANDTHENCHECKTHATTHETEMpERATUREHASSUFFICIENTLYFALLEN. DEgREASINgANDWASHINgpRECAUTIONS: • THEEYESMAYBECOMEINFLAMEDIFExpOSEDTOgREASEORDETERgENTONTHEWASTECLOTHUSEDFOR gREASEREMOvAL.BEFOREHANDLINgTHEgREASE,WEARYOURSAFETYgOggLESTOENSURETHEgREASE WILLNOTCOMEINCONTACTWITHTHEEYES. • INFLAMMATIONMAYOCCURIFTHEgREASECOMESINTOCONTACTWITHSKIN.BESURETOWEAR pROTECTIvEgLOvESTOpREvENTCONTACTWITHSKIN. • DONOTTAKEORALLYOREAT.(EATINgWILLCAUSEDIARRHEAANDvOMITINg.) • KEEpOUTOFTHEREACHOFCHILDREN. EMERgENCYTREATMENT: • IFgREASEORDETERgENTSpLATTERSANDgETSINTOTHEEYES,RINSEWITHCLEANWATERFOR15MINUTES ANDTHENCONSULTApHYSICIAN. • IFTHISgREASECOMESINCONTACTWITHTHESKIN,WASHAWAYCOMpLETELYWITHSOApANDWATER. • IFTAKENINTERNALLY,DONOTINDUCEvOMITINgBUTpROMpTLYCONSULTApHYSICIANFORTREATMENT.

CAUTION Aboutthespeedreductiongear • Donotapplystrongforcetoanyofthepartswithahammerandsoon.Furthermore,becarefulnottodropanyoftheparts,asthis mayresultinscratchesordents,leadingtolikelyspeedreductiongeardamage. • Ifthespeedreductiongearisusedinadamagedcondition,itwillnotfunctionatitsspecifiedperformance.Furthermore,usinginthis conditionmayleadtoproblemssuchascompletegearbreak-down. • Thespeedreductiongearwillshiftwhenreplaced,andthereforeitisnecessarytoadjusttheoriginpositionfollowingreplacement.

10


ent

10-2

2. Speed reduction gear and arm replacement procedureThereplacementprocedureandprecautionsforspeedreductiongearsandarmsarelistedbelow. Refertothefollowingtableforbolttighteningtorquevaluesrequiredwhenreplacingspeedreductiongearsorarms.However,pleasefollowtheinstructionsgivenateachreplacementprocedureforthetighteningtorqueappliedtoboltsusedtosecurereductiongearsandarms.OMRONboltsshouldbeused.

■ Bolt tightening torque

Bolt size Tightening torque (kgfcm) Tightening torque (Nm)

M3 set screw 20 2

M3 20 2

M4 46 4.5

M44-axesspecificationα-axisarmharnessclamp 20 2

M4harnessclamp(R6Y3[]065) 20 2

M5harnessmountingbolt(R6Y3[]110) 63 6.2

M5harnessmountingbolt(R6Y3[]065) 20 2

M6 156 15.3

M8 380 37

M10 540 53

M12 1310 128

Recommended"ScrewLock":LOCTITE241(madebyHenkelCorporation)

2.1 R6Y3[]110

2.1.1 α,βandγ-axesarmreplacement

WARNING CARRYOUTREpLACEMENTAFTERREADINg“ATTACHINg,DETACHINgANDREpLACINgTHECOvER”INCHApTER2.

NOTE Thearmreplacementprocedureisthesamefortheα,βandγ-axes.

Therequirementsforα,βandγ-axesarmreplacementareasfollows.



1 Arm assembly 1 KDL-M1520-01x 1 β,γ-axes(common),α-axis(3-axes)

(1) Arm KDL-M1521-01x 1

(2) link ball KDL-M152A-00x 2

(3) Cap KDL-M1561-01x 1

(4) Bolt 1 97080-04006 M4,length6 3

(5) Bolt 2 91312-08020 M8,length20 6

(6) Bolt 3 97080-05008 M5,length8 2

(7) Bolt 4 97080-06008 M6,length8 1

10


ent

10-3


2 Arm assembly 2 KDL-M1520-11x 1 α-axis(4-axes)

(1) Arm KDL-M1521-01x 1


(3) Cap KDL-M1561-01x 1

(4) lower clamp KDL-M1573-00x 2

(5) Bolt 1 91312-04010 M4,length10 2

(6) Bolt 2 97080-04006 M4,length8 1

(7) Bolt 3 91312-08020 M8,length20 6

(8) Harness KDL-M4815-00x 1 θ-axisharness

(9) Bolt 4 KDL-M152N-00x M5,length12 2

(10) Upperclamp KDL-M1574-00x 2

(11) Cable tie $AB80 4

(12) Pin 99480-03008 2

(13) Bolt 5 97080-06008 M6,length8 1

*1:quantityperaxis

2. Required tools


Cleaning wipe

Hexwrenchset

Hexwrench Only No. 6 is 160 mm long

Spanner No. 8


Thearmremovalprocedureisdescribedbelow.Usetheoppositeproceduretoperformarmattachment.



3 Remove the cap (white) from each axis arm.Thehexsocketheadboltattachmentsurfaceisexposedbyremovingthecap.

When cap removed from armStep 3


4 Adjust the arm position (if replacing the speed reduction gear).

5 Remove the length 20 M8 hex socket head bolt used to secure the arm for each axis to its respective speed reduction gear.Tightentheboltswithatighteningtorqueof37Nmwhenattachingthearm.

6 Remove each axis arm.

10


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10-4

2.1.1.1 Work required after replacing arm link balls

Thelinkballattachmentmethodisdescribedhere.


2 Attach a link ball to two locations on each axis arm.Attachtoatotalofsixlocationsontheα,β and γ-axes.

Link ball attachmentStep 2


Tightening with toolStep 3

2.1.1.2 Arm harness replacement



Removing the θ-cable connectorStep 3

Encoder cable sideMotor cable side

3 Turn the θ-cable connector counterclockwise to remove it.

10


ent

10-5

4 Cut the cable ties that clamp the harness and remove the upper portion.

Cutting the cable ties and removing the upper portionStep 4

Clamp (upper)

5 Remove the M5 hex bolts from the harness block.

6 Prepare new harness parts and secure them with the M5 hex bolts.•Tighteningtorque:6.2Nm

7 Install the upper clamp and secure it with two cable ties.

8 Secure excess harness so that it does not interfere with the arm or cover.

Removing the boltsStep 5

Securing the harnessStep 8

10


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10-6

2.1.2 α,βandγ-axesspeedreductiongearreplacement

NOTE Thesameprocedureisusedtoreplacetheα,βandγ-axesspeedreductiongears.

Therequirementsforα,βandγ-axesspeedreductiongearreplacementareasfollows.


Part Name OMRON Part No. Part No. / Specs Q'ty* Remarks

1 Speed reduction gear KDL-M211A-00x 1 Forα,βandγ-axes

2 Speed reduction gear mounting bolt 90112-10J030 M10,length30 4

*1:quantityperaxis

2. Required tools


Cleaning wipe

Hexwrenchset

Screwthreadlockingagent loctite 241 Henkel Medium-strengthtype(blue)

■ Removal



CAUTION Therobotbodyisextremelyheavy,andthereforecareshouldbetakenwhencarryingoutreplacementwork.

3 Remove the relevant axis motor.Referto“1.2.1α,β and γ-axesmotorremoval”inchapter9fordetailsonmotorreplacement.

4 Loosen the bracket hex socket head bolts.Loosenthelength20M4hexsocketheadboltsonthebracketusedtosecurethemotorcoverattachedaboveandbelowthespeedreductiongear. Thespeedreductiongearcanbeeasilyremovedbylooseningthebracket. Removethebracketifstilldifficulttoremovethespeed reduction gear even after loosening.

5 Remove the M10 hex socket head bolts used to secure the speed reduction gear to the base.Tightentheboltswithatighteningtorqueof53Nmwhenreattaching.

Speed reduction gear hex socket head bolt removalStep 5

Loosen the M4 hex socket head boltsStep 4


Bracket

10


ent

10-7

6 Remove the speed reduction gear.Keeptheangleofthespeedreductiongearsteadyandremoveslowlywhilesupportingwithbothhands. Iftheangleisnotkeptsteadyandthespeedreductiongearbecomesstuckonthebase,itwillbedifficulttoremove. Ifthebracketsusedtosecurethemotorcoverattachedaboveandbelowthespeedreductiongearbecomecaught,removethem.

CAUTION Donotapplyexcessiveforcetoremovethespeedreductiongear. Doing so may result in gear malfunction.

■ Attachment

Attachthespeedreductiongearusingtheoppositeofthe procedure used for removal. Attachthespeedreductiongearsothatthecapboltsare ontheoutside.

CAUTION • Thespeedreductiongearisextremelyheavyandshouldthereforebesupportedwithbothhandswhenattaching. • Insertthespeedreductiongearslowlywhileholdingitperpendiculartothebaseatthesameangle.Itwillbedifficulttoinsertthe reductiongearintothebaseifatangle. • Tryagainifunabletoinsertthespeedreductiongearproperly.Usingexcessiveforcetoinsertthegearmaydamageit.

Speed reduction gear attachment condition

The bottom is wider when viewed from the side.

Check the left and right clearances.

Arm side

Motor side

Speed reduction gear removalStep 6

10


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10-8

2.2 R6Y3[]065

2.2.1 α,βandγ-axesarmreplacement


NOTE Thearmreplacementprocedureisthesamefortheα,βandγ-axes.

Therequirementsforα,βandγ-axesarmreplacementareasfollows.



1 Arm assembly 1 KDL-M1520-21x 1 β,γ-axes(common),α-axis(3-axes)

(1) Arm KDL-M1521-10x 1

(2) Shaft KDL-M152F-00x 1


(4) Cap KDL-M1561-10x 1

(5) Bolt 1 97080-04006 M4,length6 5

(6) Bolt 2 91380-06016 M8,length16 6

2 Arm assembly 2 KDL-M1520-31x 1 α-axis(4-axes)

(1) Arm KDL-M1521-10x 1

(2) Shaft KDL-M152F-00x 1


(4) Cap KDL-M1561-10x 1

(5) Bolt 1 91380-06016 M6,length16 6

(6) block KDL-M153E-00x 1

(7) Bolt 2 91380-04030 M4,length30 3

(8) Harness KDL-M4815-00x 1 θ-axisharness

(9) Bolt 3 KDL-M152N-00x M5,length12 2

(10) Clamp KDL-M1573-10x 2

(11) Bolt 4 97080-04020 M4,length20 2

(12) Cable tie $AB80 1

*1:quantityperaxis

2. Required tools


Cleaning wipe

Hexwrenchset

Hexwrench

Spanner No.6,8


10


ent

10-9

Thearmremovalprocedureisdescribedbelow.Usetheoppositeproceduretoperformarmattachment.



3 Remove the cap (white) from each axis arm.Thehexsocketheadboltattachmentsurfaceisexposedbyremovingthecap.

When cap removed from armStep 3

Cap


4 Adjust the arm position (if replacing the speed reduction gear).

5 Remove the length 16 M6 hex socket head bolt used to secure the arm for each axis to its respective speed reduction gear.Tightentheboltswithatighteningtorqueof15Nmwhenattachingthearm.

6 Remove each axis arm.

10


ent

10-10

2.2.1.1 Work required after replacing arm link balls

Thelinkballattachmentmethodisdescribedhere.


2 Attach a link ball to two locations on each axis arm.Attachtoatotalofsixlocationsontheα,β and γ-axes.

Tightening with toolStep 3


2.2.1.2 Arm harness replacement



3 Turn the θ-cable connector counterclockwise to remove it.

Removing the θ-cable connectorStep 3

Encoder cable sideMotor cable side

10


ent

10-11

4 Cut the cable ties that clamp the harness and remove the M4 hex bolts from the clamp.


6 Prepare new harness parts and secure them with the M5 hex bolts.•Tighteningtorque:2Nm

7 Secure the clamp with the M4 hex bolts and use the cable ties to secure the clamp at a position where is 150mm away from the clamp.•Tighteningtorque:2Nm

Cutting the cable ties and removing the M4 bolts from the clampStep 4

Clamp


10


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10-12


2.2.2 α,βandγ-axesspeedreductiongearreplacement

NOTE Thesameprocedureisusedtoreplacetheα,βandγ-axesspeedreductiongears.

Therequirementsforα,βandγ-axesspeedreductiongearreplacementareasfollows.



1 Speed reduction gear KDL-M211A-10x 1 Forα,βandγ-axes

2 Speed reduction gear mounting bolt 91380-08025 M8,length25 4

*1:quantityperaxis

2. Required tools


Cleaning wipe

Hexwrenchset Kenko Only No.6 is 120mm long



10


ent

10-13

■ Removal



CAUTION Therobotbodyisextremelyheavy,andthereforecareshouldbetakenwhencarryingoutreplacementwork.

3 Remove the relevant axis motor.Referto“1.2.1α,β and γ-axesmotorremoval”inchapter9fordetailsonmotorreplacement.

4 Remove the M8 hex socket head bolts used to secure the speed reduction gear to the base.Tightentheboltswithatighteningtorqueof26Nmwhenreattaching.

5 Remove the speed reduction gear.Keeptheangleofthespeedreductiongearsteadyandremoveslowlywhilesupportingwithbothhands. Iftheangleisnotkeptsteadyandthespeedreductiongearbecomesstuckonthebase,itwillbedifficulttoremove.

CAUTION Donotapplyexcessiveforcetoremovethespeedreductiongear. Doing so may result in gear malfunction.

Speed reduction gear hex socket head bolt removalStep 4


10


ent

10-14

■ Attachment

Attachthespeedreductiongearusingtheoppositeofthe procedure used for removal. Attachthespeedreductiongearsothatthecapboltsareontheoutside.

CAUTION • Thespeedreductiongearisextremelyheavyandshouldthereforebesupportedwithbothhandswhenattaching. • Insertthespeedreductiongearslowlywhileholdingitperpendiculartothebaseatthesameangle.Itwillbedifficulttoinsertthe reductiongearintothebaseifatangle. • Tryagainifunabletoinsertthespeedreductiongearproperly.Usingexcessiveforcetoinsertthegearmaydamageit.

Speed reduction gear attachment condition

Check the left and right clearances

Protrusion condition on opposite side

Cap bolt

10


ent

10-15

2.3 θ-axisspeedreductiongearreplacementTherequirementsforθ-axisspeedreductiongearreplacementareasfollows.



1 Speed reduction gear

KDL-M1822-00x 1ForR6Y31110L03067NJ5andR6Y31065l02067NJ5

KDL-M1822-10x 1ForR6Y31110H03067NJ5andR6Y31065H02067NJ5

2 Speed reduction gear mounting bolt 91380-03010 M3,length10 4

CommontoR6Y31110L03067NJ5,R6Y31110H03067NJ5,R6Y31065l02067NJ5 and R6Y31065H02067NJ5

3 θ-axisshaft KDL-M1870-00x 1

4 Shaftsecuringbolt 91380-03008 M3,length8 6

5 Spacer KDL-M1830-00x 1

6 Spacer securing bolt 91380-04008 M4,length8 3

2. Required tools


Cleaning wipe

Hexwrenchset


Spanner

grease EPS2 CASSIDA Foodgradeoritscompatible

Jig Forinstallationofspeedreductiongear

■ Removal



3 Remove the end effector.Referto“6.Attachingtheendeffector”inchapter2oftheinstallationmanualfordetails.


CAUTION Donotcarryoutreplacementworkwiththeairtubestillattachedtothejointontheusertubing.Bydoingso,theairtube may bend.

5 Disconnect the harness from the θ-axis motor cover.Referto"1.Shaft,movablebase,andspringcoverreplacementprocedure"inchapter5fordetails.

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CAUTION Donotcarryoutreplacementworkwiththeharnessstillattachedtotheθ-axismotor.Bydoingso,theharnessmaybe damaged.

6 Remove the movable base from the shafts.Referto"1.Shaft,movablebase,andspringcoverreplacementprocedure"inchapter5fordetails.

7 Remove the θ-axis motor cover.Referto“1.Detaching,attaching,andreplacingthecovers”inchapter2fordetails.

8 Remove the motor cover side O-ring.

9 Remove the tool flange.Referto“1.1θ-axisseal,O-ringremoval”inchapter8 for details.

10 Remove the housing.

11 Remove the O-ring at the housing side.

12 Remove the shaft attached to the speed reduction gear.Insertahexwrenchthroughtheshaftthroughholetopreventtheaxisrotating,andthenremovethesixM3hexsocketheadbolts.

Shaft removalStep 12

13 Remove the spacer.Useaspannertopreventtheaxisrotating,andthenremovethethreeM4hexsocketheadbolts.

Spacer removalStep 13

14 Pull the motor and speed reduction gear assembly from the movable base.RemovethefourM3hexsocketheadboltsfromthespeed reduction gear brackets.

15 Remove the two M4 hex socket head bolts securing the motor to the speed reduction gear.


16 Loosen the two speed reduction gear set screws.

17 Remove the motor from the speed reduction gear.


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■ Attachment

Attachthespeedreductiongearusingtheoppositeoftheprocedureusedforremoval.

1 Attach the motor to the speed reduction gear.

Speed reduction gear attachmentStep 1

2 Attach the two length 14 M4 hex socket head bolts used to secure the motor to the speed reduction gear.•Tighteningtorque:4.5Nm

3 Tighten the two speed reduction gear set screw.•Tighteningtorque:69cNm

Bolt attachmentStep 3

4 Insert the motor and speed reduction gear assembly into the movable base.Ensurethatthemotorconnectorsideisfacingthemovable base α-axisside.

WARNING IFTHEATTACHMENTDIRECTIONISINCORRECT,ITWILLNOTBEpOSSIBLETOpROpERLYEARTHTHEθ-AxISMOTORCOvERWHENATTACHED,RESULTINgINpOSSIBLEELECTRICSHOCK.

Assembly attachmentStep 4

α-axis side

α-axis sideIdentified by 2 punch holes and earth bolt holes.

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5 Temporarily tighten the speed reduction gear to the movable base with the four length 10 M3 hex socket head bolts.

Temporary tighteningStep 5

6 Center the rotational axis.Aligntherotationcenteringjigwiththecenterofthespeedreductiongearaxis. SecuretothemovablebaseattwoofthesixboltlocationswiththeM4bolts,adjusttocentertheθ-axis,andthenfullytightentheboltstemporarilytightenedatStep5.


Aftertightening,removethetwoM4boltsusedtosecurethemovablebase,andthenremovetherotation centering jig.

Rotation centering jig attachmentStep 6

Align centers

Secure to movable base with M4 bolts at 2 locations, and then center

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10-19

7 Install the spacer.Useaspannertopreventtheaxisrotating,andthenattachthethreelength8M4hexsocketheadbolts.

•Tighteningtorque:4.5Nm

Spacer attachmentStep 7

Apply the greaseto the entire surfaceof the spacer thinly

8 Attach the shaft.Insertahexwrenchthroughtheshaftthroughholetopreventtheaxisrotating,andthenattachthesixlength8M3hexsocketheadbolts.

•Tighteningtorque:2Nm(Threadsealerisnot applied)

•Recommendedgrease:CASSIDAgreaseEpS2

9 Apply a thin layer of the recommended grease to the sliding parts with the seals (large) and (small).•Recommendedgrease:CASSIDAgreaseEpS2

Referto“1.2θ-axisseal,O-ringattachment”inchapter8fordetails.

10 Attach the O-ring at the housing side.Referto“1.2θ-axisseal,O-ringattachment”inchapter8fordetails.

11 Attach the housing.Referto“1.2θ-axisseal,O-ringattachment”inchapter8fordetails.



Apply the grease to the slidingpart with the seal (small)

Apply the grease to the slidingpart with the seal (large)

Contents

1. Shaft replacement procedure 11-11.1 Shaft removal 11-1

1.2 Shaft attachment 11-3

2. Harness replacement procedure 11-62.1 R6Y3[]110 11-6

2.2 R6Y3[]065 11-8

3. Detection connector replacement procedure 11-10

Chapter 11 Option parts replacement

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1. Shaft replacement procedure1. Replacement parts


1 Shaft S02D-MR116-00x 1 Fordetection(forR6Y3[]110)

1 Shaft S02D-MR116-20x 1 Fordetection(forR6Y3[]065)

1.1 Shaft removalThedetectioncableshaftislocatedontheleftofeachaxis.Theworkotherthanthedetectionpartconnectorattachmentanddetachmentiscommontoeachaxis.




3 Remove the spring covers.Thereareatotalofsixspringcovers:oneatthearm,andoneatthemovablebaseforeachofthethreeaxes. Thereisatopspringcoverandbottomspringcover,withthetopcoverbeingwider. Thespringcoversareheldtogetherwithclipsontheinside. pullthebottomcoverdownatthearmsideandpullthetopcoverupatthemovablebasesidetoremovethespringcover.

Spring cover removalStep 3


Top cover

Bottom cover

Clip

Arm side

Base side

CAUTION Usebothhandswhenremovingthespringcovers.Useonehandforremovalandtheothertostopthebottomcoverfalling. Ifthespringcoverfallsandisdamaged,therobotmayoperate abnormally.

4 Remove the end effector.Referto“6.Attachingtheendeffector”inchapter2oftheinstallationmanualfordetails.


CAUTION Donotcarryoutreplacementworkwiththeairtubestillattachedtothejointontheusertubing. Bydoingso,theairtubemaybend.

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6 Disconnect the connector of each arm. (The detection cable connector is located on the left.)Turntheconnector90°counterclockwiseandpullitout.

Arm side harnessStep 6

Detection cable connector

7 Hold the wiring on the shaft side and pull it to disconnect the connector.

8 Remove the shafts.Removetheshaftsfromthearmandmovablebaselink balls. Whendoingso,thelinkballscanbestretchedbyhandattheendoftheshaftasshowninthepictureontheright. Whenremovingtheshaftsfromthemovablebase,disconnecttheθ-axisrobotcablefromthemotorbeforehand.

CAUTION • Removethespringcoversbeforeremovingtheshafts. Thespringcoversmaybedamagedifworkiscarriedout withoutremovingthem. • Takecarenottopullthespringsontheshaftstoomuch.If stretchedtoofar,thespringsmaynotreturntotheir originalshape,possiblyleadingtoabnormalrobot movement. • WiththeR6Y31110L03067NJ5and R6Y31110H03067NJ5,R6Y31065L02067NJ5and R6Y31065H02067NJ5theharnessisattachedtothe α-axisshaft.Iftheα-axisshaftisremovedfromthe movablebasewithoutdisconnectingtheθ-axisharness fromthemotor,thecablewillbepulledandpossibly damaged,leadingtopotentialdefects.Furthermore,care shouldbetakennottodropthemovablebase.

Wiring on shaft sideStep 7

Shaft removalStep 8

Link ball

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1.2 Shaft attachmentFordetailsabouthowtoconnecttheθ-axiscable,referto"R6Y31110L03067NJ5,R6Y31110H03067NJ5,R6Y31065L02067NJ5,R6Y31065H02067NJ5(4-axesspecification)"inchapter5. Howtoattachtheshaft,movablebase,andspringcoveristhesameasthestandardspecifications.

NOTE Themovablebasedetectioncableconnectors(3locations)canbeconnectedtoanymatchingconnectors. Asthelengthfromtheshaftisalreadydetermined,connecttheconnectorswhilereferringto"Configurationofdropdetectioncableoption"intheR6Y3SeriesInstallationManual.



3 Attach the shafts.Attachtheshaftswhileensuringtohooktheshaftplasticbearingsontothearmandmovablebaselinkballs.Thelinkballscanbestretchedbyhandattheendoftheshaftasshowninthepicture. Thedepressionontheshaftsforspringcoverattachmentshouldfaceupward. Themovablebaseattachmentdirectionisasshowninthepicture.Referto"1.2Adjustingtheθ-axisoriginposition"inchapter4fordetails.


Movable base side

Arm side

Link ball

Link ball

α-axis

Depression

Plastic bearing


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4 Attach the spring covers.Thereareatotalofsixspringcovers:oneatthearm,andoneatthemovablebaseforeachofthethreeaxes. Thetopandbottompositionsofthespringcoversarefixed. IftheshaftdirectioniscorrectatStep3,thecoverattachedatthetopwillbewideasshowninthepicture below. Thespringcoverscomeasatopandbottomsetwhenshipped.Attachthecoverssothattheysnaptogetherattheguideclips.



The top of the spring cover widens

Spring cover top

Spring cover bottom

Clip

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5 Connect the harness on the arm side.Thedetectioncableconnectorislocatedontheleftofeacharm. Connectthecablessothattheyarenottwistedforcibly. Turntheconnectorclockwisetolockitafterinserted.

Connecting the harness on the arm sideStep 5

Detection cable

CAUTION Whenperformingtheoperationwithoutlockingtheconnector,thecablemaycomeoffandhavefaultywiring.

6 Connect the connector.Inserttheconnectorallthewayinsidesecurelyandattachtherubbercovertoit.

Connecting the connectorStep 6

CAUTION Theencodercableconnectoronthearmsideandthedetectioncableconnectorhavethesameshape. So,theconnectorcanbeinserted,butthewiringsaredifferentfromeachother. Ifnotoperatedcorrectly,checkforincorrectconnections.

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2. Harness replacement procedure2.1 R6Y3[]110


NOTE Theharnessreplacementworkiscommontoeachaxis.

partsandtoolsnecessaryforthereplacementworkareshownbelow.



1 Harness S02D-MR111-00x 1 Forα-axis(encoder+detection)

2 Harness S02D-MR112-00x 1 Forβ-axis(detection+Ø6-airjoint)

3 Harness S02D-MR113-00x 1 Forγ-axis(drivepower+detection)

4 Hexbolt S02D-MR123-00x No.8 2 *quantityperaxis

5 Cable tie $AB80 4

*1:quantityperaxis

2. Required tools


Cleaning wipe


Spanner No.8



3 Turn the detection cable connector counterclockwise to disconnect it.

Disconnecting the detection connectorStep 3

Detection cable

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4 Cut the cable ties that clamp the harness and remove the upper portion.

Cutting the cable ties and removing the upper portionStep 4

Clamp (upper)


6 Prepare new harness parts and secure them with the M5 hex bolts.•Tighteningtorque:6.2Nm

7 Install the upper clamp and secure it with two cable ties.




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2.2 R6Y3[]065


NOTE Theharnessreplacementworkiscommontoeachaxis.

partsandtoolsnecessaryforthereplacementworkareshownbelow.



1 Harness S02D-MR111-00x 1 Forα-axis(encoder+detection)

2 Harness S02D-MR112-00x 1 Forβ-axis(detection+Ø6-airjoint)

3 Harness S02D-MR113-00x 1 Forγ-axis(drivepower+detection)

4 Hexbolt S02D-MR123-00x No.8 2 *quantityperaxis

5 Cable tie $AB80 1

*1:quantityperaxis

2. Required tools


Cleaning wipe


Spanner No.8



3 Turn the detection cable connector counterclockwise to disconnect it.

Disconnecting the detection connectorStep 3

Detection cable

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4 Cut the cable ties that clamp the harness and remove the M4 hex bolts from the clamp.

Cutting the cable ties and removing the M4 bolts from the clampStep 4

Clamp


6 Prepare new harness parts and secure them with the M5 hex bolts.•Tighteningtorque:2Nm

7 Secure the clamp with the M4 hex bolts and use the cable ties to secure the clamp at a position where is 150mm away from the clamp.•Tighteningtorque:2Nm




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3. Detection connector replacement procedureNOTE Theworkotherthanthedetectionpartconnectorattachmentanddetachmentiscommontoeachaxis. payspecialattentiontotheconnectorattachmentorientation.



1 Detection connector S02D-MR109-00x 1

2 Hexbolt 97080-04006 1

2. Required tools


Cleaning wipe


Spanner No.7

Configuration diagram

Movable base (for option)

Detection connector

1 Attach the connector so that it is located on the left when viewed from the front.Tighteningtorque:4.5Nm

Detection connectorStep 1

Connector (left side)

Chapter 12 Maintenance parts

Contents

1. Consumable parts 12-1

2. Basic specification 12-22.1 R6Y3[]110 12-2

2.2 R6Y3[]065 12-3

3. Maintenance parts 12-43.1 R6Y3[]110 12-4

3.1.1 R6Y30110S03067NJ5 BASE 12-43.1.2 R6Y31110[]03067NJ5 BASE 12-53.1.3 R6Y30110S03067NJ5 AXIS 12-63.1.4 R6Y31110[]03067NJ5 AXIS 12-73.1.5 R6Y30110S03067NJ5 ARM 12-83.1.6 R6Y31110[]03067NJ5 ARM 12-93.1.7 R6Y30110S03067NJ5SHAFT 12-103.1.8 R6Y31110[]03067NJ5SHAFT 12-113.1.9 R6Y31110[]03067NJ5 OPTION 12-12

3.2 R6Y3[]065 12-13

3.2.1 R6Y30065S02067NJ5 BASE 12-133.2.2 R6Y31065[]02067NJ5 BASE 12-143.2.3 R6Y30065S02067NJ5 AXIS 12-153.2.4 R6Y31065[]02067NJ5 AXIS 12-163.2.5 R6Y30065S02067NJ5 ARM 12-173.2.6 R6Y31065[]02067NJ5 ARM 12-183.2.7 R6Y30065S02067NJ5SHAFT 12-193.2.8 R6Y31065[]02067NJ5SHAFT 12-203.2.9 R6Y31065[]02067NJ5 OPTION 12-21

3.3 R6Y3[]110,R6Y3[]065θ-axis 12-22

3.3.1 R6Y30110S03067NJ5,R6Y30065S02067NJ5θ 12-223.3.2 R6Y31110L03067NJ5,R6Y31065L02067NJ5θ 12-233.3.3 R6Y31110H03067NJ5,R6Y31065H02067NJ5θ 12-25

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12

1. Consumable parts

Consumable part Q'ty Remarks

KDL-M152J-01x 12 Plastic bearing 1

KDL-M152K-00x 24 Plastic bearing 2

KDL-M219K-00x 1 Seal(insideθ-axishousing,smallside)

KDL-M219K-10x 1 Seal(insideθ-axishousing,largeside)

KDL-M150E-02x 1 R6Y3[]110shaft(α-axismotorcableside,4-axesspecification)

KDL-M150F-02x 1 R6Y3[]110shaft(α-axisencodercableside,4-axesspecification)

KDL-M150E-10x 1 R6Y3[]065shaft(α-axismotorcableside,4-axesspecification)

KDL-M150F-10x 1 R6Y3[]065shaft(α-axisencodercableside,4-axesspecification)

KDL-M211A-00x 3 R6Y3[]110speedreductiongear(α,βandγ-axes)

KDL-M211A-10x 3 R6Y3[]065speedreductiongear(α,βandγ-axes)

KDL-M1822-00x 1 Speedreductiongear(θ-axisforlowinertiamodels)

KDL-M1822-10x 1 Speedreductiongear(θ-axisforhighinertiamodels)

• θ-axissealrecommendedgrease

CASSIDA grease EPS 2

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2. Basic specification2.1 R6Y3[]110

Robot model R6Y30110S03067NJ5 R6Y31110L03067NJ5 R6Y31110H03067NJ5

Working volume

x,Yaxis Stroke Ø1100mm

zaxis Stroke 300mm(max.Ø1100mm)/450mm(centerØ580mm)

θaxis Rotation range ±180°(defaultsetting,itcanbechanged)

Servo motorArm1,2,3 1000W

Rotationalaxis4 50W 100W

Repeatability*1x,Y,zaxis ±0.2mm

θaxis ±0.1°

Maximumpayload 3kg

Maximumthrough-put*2 150 CPM*4

θaxistolerablemomentofinertia*3 0.01kgm2(50W) 0.035kgm2(100W)

Usertubing(outerdiameter) Ø6x1(movabletool)

Travel limit Soft limit

Protection class IP67

Weight 75kg

*1: Thisisthevalueataconstantambienttemperature. *2: With0.1kgpayload.Whenreciprocating305mminhorizontaland25mminverticaldirections. *3: Therearelimitstoaccelerationcoefficientsettings. *4: CpM:Cycleperminutes.Checkthenote2forthecycledefinition.

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2.2 R6Y3[]065

Robot model R6Y30065S02067NJ5 R6Y31065L02067NJ5 R6Y31065H02067NJ5

Working volume

x,Yaxis Stroke Ø650mm

zaxis Stroke 150mm(max.Ø650mm)/250mm(centerØ480mm)

θaxis Rotation range ±180°(defaultsetting,itcanbechanged)

Servo motorArm1,2,3 400W

Rotationalaxis4 50W 100W

Repeatability*1x,Y,zaxis ±0.1mm

θaxis ±0.1°

Maximumpayload 2kg

Maximumthrough-put*2 200 CPM*4

θaxistolerablemomentofinertia*3 0.01kgm2(50W) 0.035kgm2(100W)

Usertubing(outerdiameter) Ø6x1(movabletool)

Travel limit Soft limit

Protection class IP67

Weight 32kg

*1: Thisisthevalueataconstantambienttemperature. *2: With0.1kgpayload.Whenreciprocating305mminhorizontaland25mminverticaldirections. *3: Therearelimitstoaccelerationcoefficientsettings. *4: CpM:Cycleperminutes.Checkthenote2forthecycledefinition.

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3. Maintenance partsCAUTION Thismanualdescribestheparts(partnumbers)whenthemanualispublished.Thepartnumberissubjecttochangewithoutpriornotice.So,besuretocheckthatthepartnumberisthelatestonewhenorderingit.

3.1 R6Y3[]110

3.1.1 R6Y30110S03067NJ5 BASE

A4

A1

A10

A11

A8

A12

A23A16

A2

A17

A7

A4

A13

A24

A18

A6A14

A20

A5A14

A19A9

A3

A22

A21

A15

γ

β

α

No. Part Number Part Name Qty RemarksA1 KDL-M1101-01 BASE,1 1A2 KDL-M1171-00 BRACKET,1 1A3 KDL-M2163-10 COvERASSY 1A4 KDL-M2163-00 COvERASSY 2A5 KDL-M1172-00 BRACKET,2 3A6 KDL-M1173-00 BRACKET,3 3A7 KDL-M111A-00 EYE BOlT 3A8 97080-04010 BOLT,HExAgON 2A9 97080-05008 BOLT,HExAgON 6

A10 KK1-M5184-10 SEAl NAME 1A11 90172-00J040 WASHER,ExTL.TOOTHED 2A12 97602-04308 SCREW,pANHEADW/W 2A13 91380-05014 BOLTHEx.SOCKETHEAD 4A14 91312-04020 BOLT,HEx.SOCKETHEAD 12

A15KDL-M212F-10 COvER,CABLE3 3KDL-M212F-00 COvER,CABLE3 3 ForLtypeconnector

A16 KDL-M211A-00 REDUCTIONgEAR 3A17 90200-03J850 O-RINg 3A18 R88M-K1K030T-BS2 SERvOMOTOR 3A19 KDL-M2138-00 SEAl 3A20 KDL-M4851-00 SW ASSY 3A21 KDL-M212A-00 COvERCABLE1 3A22 KDL-M2165-00 COvER,2 3A23 90112-10J030 BOLTHEx.S.H.:M10x30 12A24 91312-08025 BOLTHEx,SOCKETHEAD 12

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3.1.2 R6Y31110[]03067NJ5 BASE

A4

A1

A10

A11

A8

A12

A23A16

A2

A17

A7

A4

A13 A25

A26

A24

A18

A6A14

A20

A5A14

A19A9

A3

A22

A21

A15

α

β

γ

No. Part Number Part Name Qty RemarksA1 KDL-M1101-01 BASE,1 1A2 KDL-M1171-00 BRACKET,1 1A3 KDL-M2163-10 COvERASSY 1A4 KDL-M2163-00 COvERASSY 2A5 KDL-M1172-00 BRACKET,2 3A6 KDL-M1173-00 BRACKET,3 3A7 KDL-M111A-00 EYE BOlT 3A8 97080-04006 BOLT,HExAgON 6A9 97080-05008 BOLT,HExAgON 6

A10 KK1-M5184-10 SEAl NAME 1A11 90172-00J040 WASHER,ExTL.TOOTHED 2A12 97602-04308 SCREW,pANHEADW/W 2A13 91380-05014 BOLTHEx.SOCKETHEAD 4A14 91312-04020 BOLT,HEx.SOCKETHEAD 12

A15KDL-M212F-10 COvER,CABLE3 3KDL-M212F-00 COvER,CABLE3 3 ForLtypeconnector

A16 KDL-M211A-00 REDUCTIONgEAR 3A17 90200-03J850 O-RINg 3A18 R88M-K1K030T-BS2 SERvOMOTOR 3A19 KDL-M2138-00 SEAl 3A20 KDL-M4851-00 SW ASSY 3A21 KDL-M212A-00 COvERCABLE1 3A22 KDL-M2165-00 COvER,2 3A23 90112-10J030 BOLTHEx.S.H.:M10x30 12A24 91312-08025 BOLTHEx,SOCKETHEAD 12A25 98980-04008 SCREWBINDINgHEAD 1A26 $NK12N NYlON ClIP 1

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3.1.3 R6Y30110S03067NJ5 AXIS

B9

B5

B3

B1

B3

B3

B8

B1

B6

B1

α

β

γ

No. Part Number Part Name Qty RemarksB1 KDL-M1520-01 ARM 1 ASSY 3B3 KDL-M150g-01 ARM,2CARBONASSY. 3B5 KDL-M1800-00 R-AXIS ASSY 1B6 KDL-M1501-00 BRACKETASSY 1 α,βandγ-axesoriginjigB8 KDL-M1501-21 HOLDERSET 1 Plastic bearing replacement jigB9 KDL-M4871-00 CONNECTOR,E/L1 3 Brake release cable connector

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3.1.4 R6Y31110[]03067NJ5 AXIS

B9

B7

B5

B3

B1

B3

B8

B4

B1

B6

B2

α

β

γ

No. Part Number Part Name Qty RemarksB1 KDL-M1520-01 ARM 1 ASSY 2B2 KDL-M1520-11 ARM 1 ASSY 1B3 KDL-M150g-01 ARM,2CARBONASSY. 2B4 KDL-M150g-11 ARM,2CARBONASSY. 1

B5KDL-M1800-10 R-AXIS ASSY 1 R6Y31110l03067NJ5KDL-M1800-20 R-AXIS ASSY 1 R6Y31110H03067NJ5

B6 KDL-M1501-00 BRACKETASSY 1 α,βandγ-axesoriginjigB7 KDL-M1501-10 BRACKETSET 1 θ-axisoriginjigB8 KDL-M1501-21 HOLDERSET 1 Plastic bearing replacement jigB9 KDL-M4871-00 CONNECTOR,E/L1 3 Brake release cable connector

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3.1.5 R6Y30110S03067NJ5 ARM

C12C12

C11

C11

C11

C12

C12

C11

C1

C3

C4

C11

C11

C2

C12

C1

C15

C16C15

C4

C5

C12

C1

C16

C3

C2

C5

α

β

γ

No. Part Number Part Name Qty RemarksC1 KDL-M1521-01 ARM,x 3C2 KDL-M152A-00 JOINT,1 6C3 KDL-M1561-01 CAp,1 3C4 91312-08020 BOLT,HEx.SOCKETHEAD 18C5 97080-04006 BOLT,HExAgON 9

C11 KDL-M150H-01 ARM,CARBONASSY. 6C12 KDL-M1540-00 COvER,ASSY. 6C15 97080-06008 BOLT,HExAgON 3C16 97080-05008 BOLT,HExAgON 6

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3.1.6 R6Y31110[]03067NJ5 ARM

C12C12

C11

C11

C12

C12

C11

C1

C3

C4

C13

C8

C11

C2

C12

C15

C16C15

C4

C5

C14

C12

C18

C1

C3

C6

C9

C17

C2

C10

C5

C7

αβ

γ

No. Part Number Part Name Qty RemarksC1 KDL-M1521-01 ARM,x 3C2 KDL-M152A-00 JOINT,1 6C3 KDL-M1561-01 CAp,1 3C4 91312-08020 BOLT,HEx.SOCKETHEAD 18C5 97080-04006 BOLT,HExAgON 7C6 KDL-M1573-00 CLAMp,1 2C7 KDL-M1574-00 CLAMp,2 2C8 $AB80 TIE 80MM 4C9 99480-03008 pIN,pARALLEL 2

C10 91312-04006 BOLT,HEx.SOCKETHEAD 2C11 KDL-M150H-01 ARM,CARBONASSY. 4C12 KDL-M1540-00 COvER,ASSY. 6C13 KDL-M150H-11 ARM,CARBONASSY. 1C14 KDL-M150H-21 ARM,CARBONASSY. 1C15 97080-06008 BOLT,HExAgON 3C16 97080-05008 BOLT,HExAgON 4C17 KDL-M4815-00 CABLE,TERMINAL5 1C18 KDL-M152N-00 BOlT 2

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12-10

12

3.1.7 R6Y30110S03067NJ5 SHAFT

D2D2

D1

D1

D2

D1

D1

D9

D1

D1

D10

D4

D5D6

D7

D8

α

β

γ

No. Part Number Part Name Qty RemarksD1 KDL-M150A-01 ARM 1 CARBON 6D2 KDL-M152J-01 BEARINg,1 12D4 KDL-M152M-00 SpRINg 12D5 KDL-M1534-00 pLATE,1 24D6 KDL-M152K-00 BEARINg,2 24D7 KDL-M153A-00 BLOCK,1 12D8 KDL-M1542-00 COvER,2 6D9 KDL-M1543-00 COvER,3 6

D10 98980-03006 SCREW,BINDINgHEAD 24

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12-11

12

3.1.8 R6Y31110[]03067NJ5 SHAFT

D2D2

D1

D1

D2

D9

D1

D1

D10

D4

D5

D11

D6

D7

D12

D8

α

β

γ

No. Part Number Part Name Qty RemarksD1 KDL-M150A-01 ARM 1 CARBON 4D2 KDL-M152J-01 BEARINg,1 12D4 KDL-M152M-00 SpRINg 12D5 KDL-M1534-00 pLATE,1 24D6 KDL-M152K-00 BEARINg,2 24D7 KDL-M153A-00 BLOCK,1 12D8 KDL-M1542-00 COvER,2 6D9 KDL-M1543-00 COvER,3 6

D10 98980-03006 SCREW,BINDINgHEAD 24D11 KDL-M150E-02 ARM 2 CARBON 1D12 KDL-M150F-02 ARM 3 CARBON 1

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12-12

12

3.1.9 R6Y31110[]03067NJ5 OPTION

E33

E32

D11

E1

D13

D1

C19

D12

C8

D13

D13

A25

A26

C18

C20C17 C6

C9C10

C5

C7

αβ

γ

No. Part Number Part Name Qty RemarksA25 98980-04008 SCREWBINDINgHEAD 1A26 $NK12N NYlON ClIP 1C5 97080-04006 BOLT,HExAgON 3C6 KDL-M1573-00 CLAMp,1 6C7 KDL-M1574-00 CLAMp,2 6C8 $AB80 TIE 80MM 12C9 99480-03008 pIN,pARALLEL 6

C10 91312-04010 BOlT 6C17 S02D-MR111-00 CABLE,TERMINAL6 1C18 S02D-MR112-00 CABLE,TERMINAL7 1C19 S02D-MR113-00 CABLE,TERMINAL8 1C20 KDL-M152N-00 BOlT 6D1 KDL-M150A-00 ARM 1 CARBON 1D11 KDL-M150E-02 ARM,2CARBON 1D12 KDL-M150F-02 ARM,3CARBON 1D13 S02D-MR116-00 ARM,4CARBON 3E1 S02D-MR108-00 BASE,2 1

E32 S02D-MR109-00 CABLE,TERMINAL9 3E33 97080-04006 BOLT,HExAgON 6

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12-13

12

3.2 R6Y3[]065

3.2.1 R6Y30065S02067NJ5 BASE

A1

A2

A3

A3

A4

A5

A6

A7

A10 A9 A8

A12

A11

A13

A19

A14

A20

A15

A16A21

A18

A17

α

γ

β

No. Part Number Part Name Qty RemarksA1 KDL-M1101-10 BASE,1 1A2 KDL-M2163-50 COvERASSY 1A3 KDL-M2163-40 COvERASSY 2A4 KDL-M1172-00 BRACKET,2 3A5 KDL-M1193-00 STAY,COvER 3A6 KDL-M111A-10 EYE BOlT 3A7 97080-05008 BOLT,HExAgON 6A8 KK1-M5184-10 SEAl NAME 1A9 90172-00J040 WASHER,ExTL.TOOTHED 2

A10 97602-04308 SCREW,pANHEADW/W 2A11 91312-04010 BOLT,HEx.SOCKETHEAD 6A12 91312-04020 BOLT,HEx.SOCKETHEAD 6A13 KDL-M212F-20 COvER,CABLE3 3A14 KDL-M211A-10 REDUCTIONgEAR 3A15 90200-01J530 O-RINg 3A16 R88M-K40030T-BS2 SERvOMOTOR 3A17 KDL-M2138-10 SEAl 3A18 KDL-M4851-00 SW ASSY 3A19 KDL-M212A-10 COvER,CABLE,1 3A20 91380-08025 BOLT,HEx.SOCKETHEAD 12A21 91380-04014 BOLT,HEx.SOCKETHEAD 12

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12-14

12

3.2.2 R6Y31065[]02067NJ5 BASE

A3

A3

A6

A10 A9 A8

A20A14

A15

A16A4

A12

A17

A7

A2

A18

A13

A19

A5

A11

A1

A21

A22 A23 A24

α

γ

β

No. Part Number Part Name Qty RemarksA1 KDL-M1101-10 BASE,1 1A2 KDL-M2163-50 COvERASSY 1A3 KDL-M2163-40 COvERASSY 2A4 KDL-M1172-00 BRACKET,2 3A5 KDL-M1193-00 STAY,COvER 3A6 KDL-M111A-10 EYE BOlT 3A7 97080-05008 BOLT,HExAgON 6A8 KK1-M5184-10 SEAl NAME 1A9 90172-00J040 WASHER,ExTL.TOOTHED 2

A10 97602-04308 SCREW,pANHEADW/W 2A11 91312-04010 BOLT,HEx.SOCKETHEAD 6A12 91312-04020 BOLT,HEx.SOCKETHEAD 6A13 KDL-M212F-20 COvER,CABLE3 3A14 KDL-M211A-10 REDUCTIONgEAR 3A15 90200-01J530 O-RINg 3A16 R88M-K40030T-BS2 SERvOMOTOR 3A17 KDL-M2138-10 SEAl 3A18 KDL-M4851-00 SW ASSY 3A19 KDL-M212A-10 COvER,CABLE,1 3A20 91380-08025 BOLT,HEx.SOCKETHEAD 12A21 91380-04014 BOLT,HEx.SOCKETHEAD 12A22 KAU-M229N-00 ClAMP 1A23 98780-04008 SCREW,FLATHEAD 1A24 $AB80 TIE 80 1

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12-15

12

3.2.3 R6Y30065S02067NJ5 AXIS

β

α

γ

B1

B1

B2

B2

B2

B3

B4B5

B6

B1

No. Part Number Part Name Qty RemarksB1 KDL-M1520-21 ARM 1 ASSY 3B2 KDL-M150g-21 ARM,2CARBONASSY. 3B3 KDL-M1800-00 R-AXIS ASSY 1B4 KDL-M1501-30 BRACKETASSY 1B5 KDL-M1501-21 HOLDERSET 1B6 KDL-M4871-00 CONNECTOR,E/L1 3

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12-16

12

3.2.4 R6Y31065[]02067NJ5 AXIS

B1

B3

B6

B2

B4

B8

B5

B3

B7

B1

α

β

γ

No. Part Number Part Name Qty RemarksB1 KDL-M1520-21 ARM 1 ASSY 2B2 KDL-M1520-31 ARM 1 ASSY 1B3 KDL-M150g-21 ARM,2CARBONASSY. 2B4 KDL-M150g-31 ARM,2CARBONASSY. 1

B5KDL-M1800-10 R-AXIS ASSY 1 R6Y31065l02067NJ5KDL-M1800-20 R-AXIS ASSY 1 R6Y31065H02067NJ5

B6 KDL-M1501-30 BRACKETASSY 1B7 KDL-M1501-21 HOLDERSET 1B8 KDL-M4871-00 CONNECTOR,E/L1 1

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12-17

12

3.2.5 R6Y30065S02067NJ5 ARM

C1

C2

C3

C3

C2C3

C1

C3

C6

C4

C6

C4

C5

C5

C8

C8

C7

C7

C8

C7

C8

C7

α

β

γ

No. Part Number Part Name Qty RemarksC1 KDL-M1521-10 ARM,x 3C2 KDL-M152F-00 JOINT,3 3C3 KDL-M152A-00 JOINT,1 6C4 KDL-M1561-10 CAp,1 3C5 97080-04006 BOLT,HExAgON 15C6 91380-06016 BOLT,HEx.SOCKETHEAD 18C7 KDL-M150H-31 ARM,CARBONASSY. 6C8 KDL-M1540-00 COvER,ASSY. 6

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12-18

12

3.2.6 R6Y31065[]02067NJ5 ARM

C4C6

C1

C5

C13

C16

C13

C15

C14

C3

C2C16C3

C1

C7C8

C4C6

C9

C10

C11

C12

α

γ

β

No. Part Number Part Name Qty RemarksC1 KDL-M1521-10 ARM,x 3C2 KDL-M152F-00 JOINT,3 3C3 KDL-M152A-00 JOINT,1 6C4 KDL-M1561-10 CAp,1 3C5 97080-04006 BOLT,HExAgON 10C6 91380-06016 BOLT,HEx.SOCKETHEAD 18C7 KDL-M1573-10 CLAMp,1 2C8 97080-04020 BOLT,HExAgON 2C9 KDL-M153E-00 BLOCK,2 1

C10 91380-04030 BOLT,HEx.SOCKETHEAD 3C11 KDL-M4815-00 CABLE,TERMINAL5 1C12 KDL-M152N-00 BOlT 2C13 KDL-M150H-31 ARM,CARBONASSY. 4C14 KDL-M150H-41 ARM,CARBONASSY. 1C15 KDL-M150H-51 ARM,CARBONASSY. 1C16 KDL-M1540-00 COvER,ASSY. 6

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12-19

12

3.2.7 R6Y30065S02067NJ5 SHAFT

D1

D2

D3

D4

D5

D6

D9

D7

D8

αβ

γ

No. Part Number Part Name Qty RemarksD1 KDL-M150A-20 ARM 1 CARBON 6D2 KDL-M152J-01 BEARINg,1 12D3 KDL-M152M-00 SpRINg 12D4 KDL-M1534-00 pLATE,1 24D5 KDL-M152K-00 BEARINg,2 24D6 KDL-M153A-00 BLOCK,1 12D7 KDL-M1542-00 COvER,2 6D8 KDL-M1543-00 COvER,3 6D9 98980-03006 SCREW,BINDINgHEAD 24

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12-20

12

3.2.8 R6Y31065[]02067NJ5 SHAFT

D1

D11

D10

D2

D8

D7

D3

D5

D6D9

D4

D1

β

α

γ

No. Part Number Part Name Qty RemarksD1 KDL-M150A-20 ARM 1 CARBON 4D2 KDL-M152J-01 BEARINg,1 12D3 KDL-M152M-00 SpRINg 12D4 KDL-M1534-00 pLATE,1 24D5 KDL-M152K-00 BEARINg,2 24D6 KDL-M153A-00 BLOCK,1 12D7 KDL-M1542-00 COvER,2 6D8 KDL-M1543-00 COvER,3 6D9 98980-03006 SCREW,BINDINgHEAD 24

D10 KDL-M150E-10 ARM 2 CARBON 1D11 KDL-M150F-10 ARM 3 CARBON 1

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12

3.2.9 R6Y31065[]02067NJ5 OPTION

C19

C17

C8C7

A22 A23 A24

C18

D1

D12

E1

D12

D10

D12

D11

E32

E33

C9C10 C20

α

γ

β

No. Part Number Part Name Qty RemarksA22 KAU-M229N-00 ClAMP 3A23 98780-04008 SCREW,FLATHEAD 3A24 $AB80 TIE 80 3C7 KDL-M1573-10 CLAMp,1 6C8 97080-04020 BOLT,HExAgON 6C9 KDL-M153E-00 BLOCK,2 3

C10 91380-04030 BOLT,HEx.SOCKETHEAD 9C17 S02D-MR111-00 CABLE,TERMINAL6 1C18 S02D-MR112-00 CABLE,TERMINAL7 1C19 S02D-MR113-00 CABLE,TERMINAL8 1C20 KDL-M152N-00 BOlT 6D1 KDL-M150A-20 ARM,1CARBON 1

D10 KDL-M150E-10 ARM,2CARBON 1D11 KDL-M150F-10 ARM,3CARBON 1D12 S02D-MR116-00 ARM,4CARBON 3E1 S02D-MR108-00 BASE,2 1

E32 S02D-MR109-00 CABLE,TERMINAL 3E33 97080-04006 BOLT,HExAgON 6

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12-22

12

3.3 R6Y3[]110,R6Y3[]065θ-axis

3.3.1 R6Y30110S03067NJ5,R6Y30065S02067NJ5θ

E7

E3

E1 E2

E6

E4

E5

αβ

γ

No. Part Number Part Name Qty RemarksE1 KDL-M1102-01 BASE,2 1E2 KDL-M152A-00 JOINT,1 6E3 KDL-M181A-01 BRACKET,1 1E4 KDL-M1846-00 pLATE,1 1E5 97080-04010 BOLT,HExAgON 3E6 91380-04012 BOLTHEx.SOCKETHEAD 6E7 $Tl6-01 JOINT 1

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12-23

12

3.3.2 R6Y31110L03067NJ5,R6Y31065L02067NJ5θ

E21

E8

E22

E9

E29

E5

E19

E20

E25

E7

E27

E6

E18

E1 E2

E31

E30

E26

E13

E12

E4

E28E3

E16

E17

E24E15

E14

E10

E24E16

E11

E23

αβ

γ

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12-24

12

No. Part Number Part Name Qty RemarksE1 KDL-M1102-01 BASE,2 1E2 KDL-M152A-00 JOINT,1 6E3 R88M-K05030T-S2 SERvOMOTOR 1E4 KDL-M1822-00 REDUCTIONgEAR 1E5 KDL-M1811-00 HOUSINg,1 1E6 KDL-M1830-00 SPACER 1E7 KDL-M1870-00 SHAFT 1E8 KDL-M1843-00 HOLDER,SHAFT1 1E9 KDL-M1844-00 HOLDER,SHAFT2 1

E10 KDL-M182E-00 COvERRAxIS 1E11 KDL-M1861-00 WASHER 6E12 KDL-M4811-00 CABLE,TERMINAL1 1E13 KDL-M4812-00 CABLE,TERMINAL2 1E14 KDL-M4813-00 CABLE,TERMINAL3 1E15 KDL-M4814-00 CABLE,TERMINAL4 1E16 KDL-M212E-00 COvER,CABLE2 2E17 KN5-M2144-00 ORINg.,3 1E18 KN6-M1895-00 ORINg,1 1E19 KDL-M219K-00 SEAl 1E20 KDL-M219K-10 SEAl 1E21 KDL-M1816-00 COvER,1 1E22 $Tl6-01 JOINT 1E23 97080-04010 BOLT,HExAgON 6E24 91380-03006 BOLTHEx.SOCKETHEAD 8E25 91380-03008 BOLTHEx.SOCKETHEAD 6E26 91380-03010 BOLTHEx.SOCKETHEAD 4E27 91380-04008 BOLTHEx.SOCKETHEAD 3E28 91380-04014 BOLTHEx.SOCKETHEAD 2E29 91380-04012 BOLTHEx.SOCKETHEAD 2E30 91380-04020 BOLTHEx.SOCKETHEAD 6E31 97980-04308 SCREWp/HW/W(+-) 2

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12-25

12

3.3.3 R6Y31110H03067NJ5,R6Y31065H02067NJ5θ

E21

E8

E22

E9

E29

E5

E19

E20

E25

E7

E27

E6

E18

E1 E2

E31

E30

E26

E13

E12

E4

E28E3

E16

E17

E24E15

E14

E10

E24E16

E11

E23

α

β

γ

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12-26

12

No. Part Number Part Name Qty RemarksE1 KDL-M1102-01 BASE,2 1E2 KDL-M152A-00 JOINT,1 6E3 R88M-K10030T-S2 SERvOMOTOR 1E4 KDL-M1822-10 REDUCTIONgEAR 1E5 KDL-M1811-00 HOUSINg,1 1E6 KDL-M1830-00 SPACER 1E7 KDL-M1870-00 SHAFT 1E8 KDL-M1843-00 HOLDER,SHAFT1 1E9 KDL-M1844-00 HOLDER,SHAFT2 1

E10 KDL-M182E-00 COvERRAxIS 1E11 KDL-M1861-00 WASHER 6E12 KDL-M4811-00 CABLE,TERMINAL1 1E13 KDL-M4812-00 CABLE,TERMINAL2 1E14 KDL-M4813-00 CABLE,TERMINAL3 1E15 KDL-M4814-00 CABLE,TERMINAL4 1E16 KDL-M212E-00 COvER,CABLE2 2E17 KN5-M2144-00 ORINg.,3 1E18 KN6-M1895-00 ORINg,1 1E19 KDL-M219K-00 SEAl 1E20 KDL-M219K-10 SEAl 1E21 KDL-M1816-00 COvER,1 1E22 $Tl6-01 JOINT 1E23 97080-04010 BOLT,HExAgON 6E24 91380-03006 BOLTHEx.SOCKETHEAD 8E25 91380-03008 BOLTHEx.SOCKETHEAD 6E26 91380-03010 BOLTHEx.SOCKETHEAD 4E27 91380-04008 BOLTHEx.SOCKETHEAD 3E28 91380-04014 BOLTHEx.SOCKETHEAD 2E29 91380-04012 BOLTHEx.SOCKETHEAD 2E30 91380-04020 BOLTHEx.SOCKETHEAD 6E31 97980-04308 SCREWp/HW/W(+-) 2

Revision history

Amanualrevisioncodeappearsasasuffixtothecatalognumberonthefrontcovermanual.

Cat. No. I195E-EN-03

Revision code

Thefollowingtableoutlinesthechangesmadetothemanualduringeachrevision.

Revision code Date Description

01 June 2013 Original production

01A September 2013 Deltarobotmodelreferenceshavebeenmodified

01B April 2014 Illustrationswerechanged,texterrorswerecorrected

01C May 2014 gearboxboltwasmodified

02 November 2014 InChapter 7, the section "1. plastic bearing replacementprocedure"wasupdatedInChapter10,newsection"2.1.2Armharnessreplacement"was addedNewChapter11"Optionpartsreplacement"wasaddedInChapter12,newsection"3.Maintenanceparts"wasaddedReplacement parts and details of tools to be prepared were addedandchanged,smallerrorswerecorrected

03 August 2015 MiniDeltarobotmodels(R6Y3[]065)wereadded.Newsubchapter"1.2.3Attachingthespringcover(ReinforcedSpringCovercommonto3-axesand4-axes)"wasaddedintoChapter5

Cat. No. I195E-EN-03 Note: Specifications subject to change without notice.

Authorized Distributor:

Printed in Europe

Delta Robot IP67 Mini Delta Robot IP67 - Omron Removing the plastic bearing from the link ball...

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