90213-1016DED F-Zeroing Motor Replace

KAWASAKI HEAVY INDUSTRIES, LTD. ROBOT DIVISION

90213-1016DED

ZEROING INSTRUCTIONS

MOTOR REPLACEMENT INSTRUCTIONS

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1. Outline of Zeroing

1

Preface

This manual is subject to change without prior notice and without our legal responsibility.

Kawasaki pursues a policy of continuing improvement in design and

specification of the product. The right is therefore, reserved to vary this manual without prior notice.

This manual is copyrighted and all rights are reserved by KHI.

This manual may not, in whole or part, be reproduced in any form or by any means without prior written permission from KHI.

This manual is prepared with the best care but anyway it is impossible to exclude

any misinterpretation by the user or any spelling mistakes. In case of doubts or if the robot behavior is different from that reported in this manual please would you get in touch with the nearest Kawasaki or Kawasaki’s

agent.

KHI cannot anticipate every possible circumstance that might involve a potential

hazard. If a procedure, work method or operating technique not specifically recommended by KHI is used, you must satisfy yourself that it is safe for you and

others. In this case you are completely responsible for eventual damages on human bodies or things.

If you discover physical defects in the manual, KHI will replace the manual at no

charge during 90 days period after you purchased the robot.

If you do not observe warnings and/or cautions to be taken in the manual as described below, it might result in the serious injuries or damages on human

bodies or robots. Therefore you must take extreme care to observe these warnings and cautions.

All rights reserved. Copyright 1999 by KAWASAKI HEAVY INDUSTRIES, LTD.

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[ SYMBOLS ]

Whenever you see the symbols shown below in this manual or on the machine, read and

understand their messages.

This danger symbol identifies special warnings or procedures which, if not strictly observed, will result

in serious injury or death.

This warning symbol identifies special warnings or procedures which, if not strictly observed, could

result in serious injury or death.

[ NOTE ]

This note symbol identifies supplementary information, or to emphasize a point or procedure,

or to give a tip for easier operation.

1. For the confirmation of acceptability and effectiveness of drawings, detailed specification of documents, procedures etc. it shall be still

insufficient. Therefore, if you desire to operate/serve/maintain/adjust/modify, and

to do miscellaneous works, you must pay utmost attentions to them. 2. Those persons who engage with the operation/service of your

system, they must strictly observe all safety regulation at all times. Never replace and/or adjust the inside parts provided in your Robot

system while the power source is being turned ON so as to ensure your own safety.

! DANGER

! WARNING

This caution symbol identifies special instructions or

procedures which, if not correctly followed, may result in injury.

! CAUTION

! WARNING

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This Instru ction Manual describe the Zeroing instructions and Motor replacement

instructions of KAWASAKI ROBOT F Series.

You are recommended to well understand the contents of this Instruction Manual fully, as

well as to look to your own safety for the zeroing work and for the replacement of motors.

For the details of the replacement of motors and the zeroing work in the encoder section,

please refer to separately prepared "H20 Encoder Replacement Instructions".

Those persons who are qualified to engage in the motor replacement work should be restricted to

those who have received the maintenance course in the special education & training program arranged

by our Service Group.

! WARNING

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CONTENTS

1. Outline of Zeroing..................................................................................................... 5

2. How to Preset Encoder............................................................................................ 6

3. Rough Zeroing (1) (All Axes Collectively) .............................................................. 8

4. Rough Zeroing (2) (Each Axis Individually) .........................................................10

5. Accurate Zeroing....................................................................................................12

5.1.Preparation work of accurate zeroing................................................................... 13

5.2. Zeroing of JT2 ..................................................................................................... 15

5.3. Zeroing of JT3 (Except for FS10X, FS30N, FS30L, FS45C, FS45N)................... 17

5.4. Zeroing of JT3 (In case of FS10X, FS30N, FS30L, FS45C, FS45N)................... 19

5.5. Zeroing of JT4 ..................................................................................................... 21

5.6. Zeroing of JT5 ..................................................................................................... 23

5.7. Zeroing of JT6 ..................................................................................................... 25

6. Caution to be Taken at Motor Replacement........................................................28

7. Outline of Motor Replacement..............................................................................29

8. Prior to Replace Motor (Encoder).........................................................................30

9. Summary of Motor Replacement Work................................................................31

10. Works to be carried out Before Replacement of Motors..................................33

11. Replacement Instruction for Motors...................................................................35

11.1. Replacement of 100 W Motor............................................................................ 35

11.2. Replacement of 200 W Motor............................................................................ 37

11.3. Replacement of 475W Motor............................................................................. 39

11.4. Replacement of 1.0 KW Motor........................................................................... 41




12. Adjustment of Timing Belt..................................................................................... 50

Appendix: Figure of Motor Replacement .................................................................... 52

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5


The outline of the zeroing is as shown below:

� Shipping inspection

process of robot

� After replacing motor

Preset of encoder

Accurate zeroing

Rough zeroing

� All axes collectively

� Each axis individually

In case accurate zeroing is carried out, use the following instruments and jigs:

l Digital inclinometer

Mfg. by NIIGATA SEIKI

Levelnic DL-S1

In case of motor replacement, prepare instruments, tools, and grease as follows:

l Dial gauge l Torque wrench

� M4 Hex. wrench

� M5 Hex. wrench

� M6 Hex. wrench

� M8 Hex. wrench

� M10 Hex. wrench

� M12 Hex. wrench

l Grease for H/D

(HARMONIC GREASE 4BNo.2)

l Grease for gear

(SUN LIGHT GREASE No.1)

l Grease contained disulfide

molybdenum(MOLYCOAT etc.)

l Grease for RV reduction unit and

Cyclo reduction unit

(MOLY WHITE RENo.00)

l Zeroing jig(1) l Zeroing jig(2)

l Zeroing jig(4) l Zeroing jig(3)

(plate) Mfg. by KHI (plate) Mfg. by KHI

(Angle) Mfg. by KHI (plate) Mfg. by KHI

l Plus (+) screw driver

(Large, Small)

400mm or more

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2. How to Preset Encoder

6


Controller

l Set to the switches of operation panel as shown below:

Arm

l Press the “AXIS” key and set to the standard posture

(HOME posture) as shown below:

JT3

0 point gauge mark position

JT4


JT1


JT2


At the standard posture, make sure that 0 point gauge

mark of the each axis is coincided accurately.


- +1

�� - +

6

JT5


JT6


Place the “CONTROL

POWER” switch in the

Place the

“HOLD/RUN”

switch in the “RUN”

Place the

“TEACH/REPEAT”

switch in the

Press the

“MOTOR

POWER” switch

Release the

“EMERGENCY

STOP” switch.

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The preset of the encoder is executable on AS software.

Example of preset through keyin g-in on the keyboard:

Referring to AS display on the screen, enter the Preset Command as shown below:

(Example) : Preset of JT1:

For example: For JT1:101

For JT2:102

For JT3:103

For JT4:104

For JT5:105

For JT6:106

For JT7:107

Enter applicable axis No. as shown above.

[[ Encoder rot. counter reset (1st axis) [[.

current angle (deg.mm)? X

Are you sure (Enter 1 to execute)? 1

>

Enter the present arm angle here.

When the arm angle is being set to 0°, enter 0°,

and when it is a certain angle(Ex. 15.4°), enter the value.

After making sure the axis to make preset, enter

the applicable axis No.

! CAUTION

0 1 Z Z 1

Preset

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3. Rough Zeroing (1) (All Axes Collectively)

8


Arm

l Upon completion of encoder preset, keep the robot arm under the standard posture (HOME posture).

This zeroing method is a method through which all robot axes are

changed collectively. When you desire to replace the motor/encoder one by one, do not apply this zeroing method.

Wrist section is a structure that the phenomenon to exert the influence

on zero point of other axes “generation phenomenon” occurs.

! CAUTION

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Controller

l Press the “EMERGENCY STOP” switch and set the “MOTOR POWER” to “OFF”.

l Make rough zeroing with all axes collectively.

ò

JT1 JT2 JT3 JT4 JT5 JT6

set data XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX

cur data XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX

Set current values of all joints as zeroing data? (Enter 1 to set)

l Display present value on screen and confirm.

ò


0.000 0.000 0.000 0.000 0.000 0.000

X[mm] Y[mm] Z[mm] O[deg] A[deg] T[deg]

XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX

Makes sure these values.

If these values are 0, it is OK.

The value displayed

on this line is

presently set up

zeroing set value

The value

displayed on this

line is present

encoder value

In case rough zeroing executes.

In case rough zeroing exits.

O R E Z Z 0

E R E H W

1

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4. Rough Zeroing (2) (Each Axis Individually)

10


Arm

l Match the 0 point on the axis to be matched

by using the arm 0 point gauge mark.

Only through zeroing according to this procedure (rough zeroing of each axis), you can not obtain accurate linear path accuracy and shift amount.

This procedure is prerequisite to the motor encoder replacement instruction described below.

Therefore, surely read also this page when the motor encoder is required to replace.

Wrist section is a structure that the phenomenon to exert the influence on zero point of other axes “generation phenomenon” occurs. Therefore,

! CAUTION

JT3


JT4


JT1


JT2


When the motor is required to replace, if you set the “CONTROL POWER” to “ON” and “MOTOR

POWER” to “ON”, the joint might be out of motion. Therefore, execute the preset without fail.

! CAUTION

JT5


JT6


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Controller


l Operate preset.

+ See “2. How to Preset Encoder”.

l Make rough zeroing of the each axis.

ò

Current angle (deg.mm) ?

ò

ò Encoder value? (Current = xxxxxx, Enter 1 to the current value)

ò

(If stops at halfway, key is only depressed.)

ò

Zeroing value=xxxxxx(268419072-268451840)OK?(Enter 0 to change)

ò

(If re-enter is required, 0 key is only depressed.)

ò

Setting completed.

* In the same way as above make zeroing on JT2∼JT6 one by one.

Example, When JT1 is required to

carry out zeroing enter the axis

No. as “1” after input the ZZERO

O R E Z Z 1

1

0 or

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5. Accurate Zeroing

12

5. Accurate Zeroing

Arm

Remove the cover as a preparation as shown in figure below to put the inclinometer on the robot arm.

And, remove paint, rust, and burr, etc. on the each zeroing jig installing surface enough with the whetstone etc.

JT4 motor

Datum level (B)

Datum level (A)

Datum level (C)

Datum level (D)

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5. Accurate Zeroing

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5. Accurate Zeroing

5.1. Preparation work of accurate zeroing

Controller


Arm

l First, execute rough zeroing described before over all axes. And, match all axes in the state of 0°.

l Install the zeroing jig(1) to the datum level (A) of the lower arm section as shown below. Then place

the inclinometer. Be careful of the inclinometer placing direction.

Accurate zeroing is applied only to JT2 ∼ JT6. For JT1, normally accurate zeroing is not required.

! CAUTION

Once the inclinometer is adjusted by volume control,

never touch and change the adjusted value.

! CAUTION

Level Digital display

Power switch [0-ADJUST] volume HOLD/RUN sel.

0.01/0.001 unit sel.

Measuring

direction

Zeroing jig(1) Inclinometer

- +



Place the

“HOLD/RUN”


Place the

“TEACH/REPEAT”

switch in the

Press the

“MOTOR

POWER” switch

Release the

“EMERGENCY

STOP” switch.

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5. Accurate Zeroing

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5. Accurate Zeroing

Arm

l Next, set the various switches provided to the inclinometer as follows:

Turn the “0-ADJUST” volume control and adjust the digital display is set to 0.00 mm/m.

Power :ON

HOLD/RUN :RUN

! CAUTION

Depending on condition, “0-ADJUST” volume control can not be set to 0. In this case, set the display to a clear and

adequate value; for example, -1.00mm/m.

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5. Accurate Zeroing

15

5. Accurate Zeroing

5.2. Zeroing of JT2

Controller


Arm

l Install the zeroing jig(2) to the datum level(B) of the lower arm section as shown below.

Then place the inclinometer, pay attention not to touch with the “0-ADJUST” volume control.

Be careful of the inclinometer placing direction.

l Press the “AXIS” key provided on the Multi Function Panel, and move JT2.

On this occasion, move JT2 until the inclinometer display may equal to the value set on the datum

level(A) (Standard:0.00).

For example, if the set value at the datum level(A) is 0.00, move the axis until the value at the datum

level(B) becomes 0.00±0.01.

Measuring

direction

Inclinometer Zeroing jig (2)

- +



Place the

“HOLD/RUN”


Place the

“TEACH/REPEAT”

switch in the

Press the

“MOTOR

POWER” switch

Release the

“EMERGENCY

STOP” switch.

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5. Accurate Zeroing

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5. Accurate Zeroing

Controller


l Make zeroing of JT2.

ò

Current angle(deg.mm) ?

ò


ò


ò


* When zeroing value is out of 268419072∼268451840, execute encoder preset again.

ò


ò

Setting completed.

In this way, the zeroing of JT2 has been completed.

O R E Z Z 2

0

1

When you execute the “MOTOR POWER” as “ON”, the

message of “Turn OFF Motor power” is displayed.

or

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5. Accurate Zeroing

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5. Accurate Zeroing

5.3. Zeroing of JT3 (Except for FS10X, FS30N, FS30L, FS45C, FS45N)

Controller


Arm

l Install the zeroing jig(3) to the datum level(C) of the upper arm section as shown below.

Then place the inclinometer, pay attention not to touch with the “0-ADJUST” volume control.




level(A) (Standard : 0.00).

At zeroing, do not move axes except JT3.

(especially JT2).

! CAUTION

Zeroing jig (3)

- +



Place the

“HOLD/RUN”


Place the

“TEACH/REPEAT”

switch in the

Press the

“MOTOR

POWER” switch

Release the

“EMERGENCY

STOP” switch.

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5. Accurate Zeroing

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5. Accurate Zeroing

Controller



ò


ò


ò


ò



ò


ò

Setting completed.


0

1

O R E Z Z 3



or

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5. Accurate Zeroing

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5. Accurate Zeroing

5.4. Zeroing of JT3 (In case of FS10X, FS30N, FS30L, FS45C, FS45N)

Controller


Arm

l Move JT4 at +90°, and make the robot to posture to which does not receive the influence of JT5 easily as

shown below.ê

l Place the zeroing jig(2) on the datum level (D) of the flange surface as shown below.

Then place the inclinometer, pay attention not to touch with the “0-ADJUST” value control.





At zeroing, after matching JT4 to the above posture,

do not move axes except JT3 (especially JT2).

! CAUTION

Zeroing jig (2) +

Move JT4

at +90°



Place the

“HOLD/RUN”


Place the

“TEACH/REPEAT”

switch in the

Press the

“MOTOR

POWER” switch

Release the

“EMERGENCY

STOP” switch.

-

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5. Accurate Zeroing

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5. Accurate Zeroing

Controller



ò


ò


ò


ò



ò


ò

Setting completed.


O R E Z Z 3

0

1



or

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5. Accurate Zeroing

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5. Accurate Zeroing 5.5. Zeroing of JT4

Controller


Arm

l Referring to the figure below, while keeping the standard posture (HOME posture), move JT3 forward at

90° (-90°) and move JT5 upper-ward at 90°(+90°) viewed from rear.

l Place the zeroing jig(1) to the datum level (A) of the lower arm section at the direction as shown above

(clockwise inclination of arm is measured), make zero adjustment by turning “0-ADJUST” value. (If 0

setting is difficult, set adequate value.) Be careful of the inclinometer placing direction. ê l Referring to the figure above, place the zeroing jig (2) on the datum level (D) of the flange surface.

Be careful of the inclinometer placing direction. ê


On this occasion, move JT4 until the

inclinometer display may equal to the value

set on the datum level(A) (Standard : 0.00).

Move JT5

at 90°

Referring to the left figure, if the posture is set

automatically, follow the procedures bellow:

Set to “REPEAT” side. Set to “RUN” side

To axis coincidence accurately, positioning accuracy

range key-in the below:

DO ACCURACY 0.1

Keeping the standard posture (HOME posture), key-in

the below:

DO DRIVE 3, -90 and

- +


! CAUTION

Move JT3

at -90°

- +



Place the

“HOLD/RUN”


Place the

“TEACH/REPEAT”

switch in the

Press the

“MOTOR

POWER” switch

Release the

“EMERGENCY

STOP” switch.

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5. Accurate Zeroing

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5. Accurate Zeroing

Controller



ò


ò


ò


ò



ò


ò

Setting completed.


O R E Z Z 4

0

1



or

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5. Accurate Zeroing

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5. Accurate Zeroing

5.6. Zeroing of JT5

Controller


Arm

Execute the zeroing of JT5 at the robot arm standard posture (HOME posture).

l First, set JT2, JT3 and JT4 to 0°. (You can return posture to 0° by the HOME command.)

ê

l Place the zeroing jig(2) on the datum level (D) of the flange surface as shown below. Then place the

inclinometer, pay attention not to touch with the “0-ADJUST” value control. Be careful of the

inclinometer placing direction.





! CAUTION

- +

Zeroing jig (2)



Place the

“HOLD/RUN”


Place the

“TEACH/REPEAT”

switch in the

Press the

“MOTOR

POWER” switch

Release the

“EMERGENCY

STOP” switch.

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5. Accurate Zeroing

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5. Accurate Zeroing

Controller



ò


ò


ò


ò



ò


ò

Setting completed.


O R E Z Z 5

0

1



or

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5. Accurate Zeroing

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5. Accurate Zeroing

5.7. Zeroing of JT6

Controller


Arm

l Move only JT3 forward at 90° (-90°) in the standard posture (HOME posture).

Referring to the figure below, install the zeroing jig (4) to the wrist flange face (datum level (D) ).

Then place the inclinometer. Be careful of the inclinometer placing direction.


- +

6

On this occasion, move JT6 until the

inclinometer display may equal to the

value set on the datum level (A)

(Standard : 0.00).

Zeroing jig(4)

Move JT3

at -90°

- +

- +

Referring to the left figure, if the posture is set

automatically, follow the procedures bellow:

Set to “REPEAT” side. Set to “RUN” side

To axis coincidence accurately, positioning accuracy

range key-in the below:

DO ACCURACY 0.1

Keeping the standard posture (HOME posture), key-in


! CAUTION



Place the

“HOLD/RUN”


Place the

“TEACH/REPEAT”

switch in the

Press the

“MOTOR

POWER” switch

Release the

“EMERGENCY

STOP” switch.

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5. Accurate Zeroing

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5. Accurate Zeroing

Controller



ò


ò


ò


ò



ò


ò

Setting completed.


O R E Z Z 6

0

1



or

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5. Accurate Zeroing

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5. Accurate Zeroing

Controller

l Completion of all axes accurate zeroing of JT2∼JT6.

l To axis coincidence accura tely, key-in the positioning accuracy range.

l Set the robot to HOME posture (HOME position).

*HOME posture (HOME position) means here the mechanical origin.

l Display the present value on screen and confirm.

ò


0.000 0.000 0.000 0.000 0.000 0.000

X [mm] Y [mm] Z [mm] 0 [deg] A [deg] T [deg]

XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX

Make sure these values.

If these values are 0, it is OK.

Press “MOTOR POWER” switch to “ON”.

M O H O D E

E R E H W

C C A O D U A R C Y . 0 1

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6. Caution to be Taken at Motor Replacement

28

6. Caution to be Taken at Motor Replacement

Prior to start the motor replacement work, pay special attention to the following contents so as to ensure

safety.

! WARNING

! CAUTION

Prior to start the motor replacement work, press the "EMERGENCY

STOP" switch provided in the controller basic operation section without fail.

Then the motor power in the robot system will be turned OFF.

If it is required to change the angle of the specified axis, first turn ON the

motor power. Next, after setting up the specified axis to a desirable posture, again turn

¤ When a motor is required to dismount from the assembly and required to replace with a new one, do not apply excessively strong shocks to

the motor and encoder.

¤ Motors shall be stored safely within the specified ambient temperature and moisture.

¤ For screws which are not necessary for the motor dismounting and

replacement, they must not be removed, as well as for motor covers, they must not be opened.

¤ If the motor is required to connect with the encoder, put the motor

shaft pin into the U-groove of the encoder shaft.

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7. Outline of Motor Replacement

29

7. Outline of Motor Replacement

AC servo motors used mainly in the KAWASAKI Robot System can be divided into two types; one is an

encoder-separable type from the motor section as a unit, and the other is an encoder-unseparable type.

w Small-sized motors of which motor capacity is 100 W, 200 W, 475 W, 1 KW and likes are represented

by a one-piece structure (the motor part and the encoder part are being assembled as a set).

This means that even if either the motor or the encoder has failed, it should be replaced with a new one

as a set.

w Large-sized motors of which motor capacity is 2.1 KW, 3.1 KW, 4.2 KW and likes are represented by

a separable structure (the motor section can be separated into the motor part and the encoder part).

This means that if either the motor or the encoder has failed, it can be replaced with a new one

separately.

w For the replacement of separable-type H20 Model Encoder, please refer to separately prepared “H20

Encoder Replacement Instructions”.

Type Motor

Capacity

FA06N, L, E FC06N

FS06N, L FS10C, N, E

FS10L FA20N FC20N FP20N

FS20C, N

FS30N, L FS45C, N FS10X

100W JT4 JT5 JT6

JT5 JT6

200W JT4 JT5 JT6

475W JT3 JT4 JT5 JT6

JT4

One-piece structure

1.0KW JT1 JT2

JT3

2.1KW JT1 JT2

3.1KW

JT3 JT3 Separable structure

4.2KW JT1 JT2

JT1 JT2

Type Motor Capacity Motor Type Motor Assy P/N

100W P50B05010DCX 50601-1136

200W P50B05020DCX 50601-1143 475W P50B07050DCX 50601-1138

One-piece structure

1.0KW P60B13100HCX 50601-1139 2.1KW P60B13150HCX 50601-1123 3.1KW P60B13200LCX 50601-1125 Separable

structure 4.2KW P80B22450RCX 50601-1121

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8. Prior to Replace Motor (Encoder)

30

8. Prior to Replace Motor (Encoder)

Prior to replace the motor with a new one, first of all, you must make sure whether the present motor is

prerequisite to replace with a new one or not.

In particular, when an encoder-separable motor is used, make sure that the present trouble is not caused by

the failure of the encoder itself.

In other words, only after making sure that the trouble is not caused by the encoder itself, you must start the

motor replacement work.

[ Encoder separable type ]

· Robot motion is abnormal.

· Positioning accuracy is variable.

Check on mechanical

parts and repair/replace

Replace encoder with

a new one.

Even after

replacement,

errors are still

Check on mechanical

parts and repair/replace

Check on surrounding

cables and boards.

Replace motor with a new one.

(One-piece structured small

sized motor should be replaced Errors occur even after replacement.

The trouble might not be caused by the failure of the motor/encoder.

Even though the motor/encoder has replaced with a new one, if the error can not be

removed, the control system is required to check/adjust.

Is oscillation available?

Is abnormal noise

heard?

Is abnormal heat

generated?

Can’t brake be released?

Does brake slip?

Is inside of motor

disconnected?

Are other erroneous causes

observed?

Is rattle found in

mechanics?

Is the encoder value affected by any mechanical interferences?

YES YES

NO NO

YES

NO YES NO

YES NO

YES

NO

YES

NO

YES

NO

YES

NO

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9. Summary of Motor Replacement Work

31


Actually when the motor replacement work is carried out, prepare the measuring instruments, tools, oils &

greases etc. as shown below:

l Dial gauge l Molybdenum disulfide grease l LOCTITE 242

(including MOLYCOAT) l THREE BOND 1212

l SUN LIGHT GREASE No.1 l MOLY WHITE RE No.00

(For Cyclo Reduction Unit/RV Reduction Unit)

l HARMONIC GREASE 4B No.2

l Tools (For H/D)

Motor capacity Torque wrench

100W Torque wrench (M4) for hexagonal-bar attachment: about 150 mm in length

200W Torque wrench (M4) for hexagonal-bar attachment: about 150 mm in length

475W Torque wrench (M5) for hexagonal bar attachment: about 150 mm in length

1.0 KW Torque wrench (M6): for hexagonal bar attachment : about 280mm in length.

2.1 KW

Torque wrench (M10) for hexagonal-bar attachment: about 280 mm in length

3.1 KW Torque wrench (M10) for hexagonal-bar attachment: about 280 mm in length

4.2 KW

Torque wrench (M12) for hexagonal-bar attachment: about 280 mm in length

l Exclusively designed removing jigs and pulley puller (for large-sized motor)

Part No. Applicable Models (Axes)

50514-1010 For FS30N, L (JT1 and 2) For FS45C, N (JT1 and 2) For FS10X (JT1 and 2)

! WARNING

¤ When a motor is required to remove from an assembly, support the arm safely so as to prevent the arm from

dangerous falling.

¤ When a motor is required to replace with a new one, surely turn OFF the "MOTOR POWER" and "CONTROL

POWER" switches.

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Motor replacement work and its confirmation

w Record the robot's present location.

w Set a dial gauge to a place in the forward part of the arm for the axis of which the motor will be replaced. Next, record the values measured by the dial gauge. + See "10. Works to be carried out Before Replacement of Motors".

w If recording disables, preset - zeroing shall be executed after the replacement of the motor without fail.

Motor replacement work

w When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail.

w In order to prevent a robot arm from accidental falling/rotating, the arm must be supported by a crane/forklift truck, or must be put on a support.

w Replace the motor of which capacity may coincide with the applicable model, and with replacement object axes. + See "11. Replacement Instruction for Motors".

Works to be carried out after motor replacement

w First, move the robot arm, until the applicable value may coincide accurately with the value measured by the dial gauge.

w If encoder values can not be recorded successfully, preset and zeroing shall be executed.

Confirmation to be carried out after motor replacement

w Execute repeat run on the program, and make playback the robot motions. Then make sure whether any error/abnormality is observed or not.

w If preset and zeroing have been executed, re-teach the applicable program again.

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10. Works to be carried out Before Replacement of Motors

33


Actually before the motor replacement work is carried out, it is prerequisite to record the robot's present

position.

The recording of the robot's present position is represented by the followings:

w Reading of Encoder Values

w Confirmation of Absolute Position of the Arm at that Time

(Confirmation by using a Dial Gauge)

In this section, how to measure values so as to make sure the arm's absolute position, is explained.

On this occasion, the encoder must be normal and accurate, as well as the display of the encoder values is

precise.

(1) Press the "AXIS" key provided on the Multi Function Panel, and move the robot arm, until an adequate

posture is obtained.

(2) Set the dial gauge to an adequate place (such as to a hand) provided in the forward part from the axis of

which the motor will be replaced.

Set the dial gauge to places shown in the figures (on the next page and the consecutive pages)

(3) Match the value of the dial gauge with 0.

Then keeping this posture, record the encoder values of axis.

(Record as adequate positional variables by executing HERE Command.)

(4) Carry out the motor replacement work in an easily accessable posture.

On this occasion, be careful that the dial gauge position does not move.

! CAUTION

Surfaces on which a dial gauge is required to set shall be

selected to be flat as far as possible. Moreover, the surfaces shall be at right angles to the rotation

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When JT2, 3 and 5 are required to replace When JT1 is required to replace

When JT4 and 6 are required to replace

JT1 JT2

JT3,5

JT4,6

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11. Replacement Instruction for Motors

35


11.1. Replacement of 100 W Motor

Also, see "Figure of Motor Replacement".

Model FA06N, L, E / FC06N / FS06N, L / FS10C, N, E FS10X

Axes JT4 JT5 JT6

JT5 JT6

(1) First, remove the covers from the designated places.

(2) Next, disconnect the connector for motor power cable from the axis of motor to be replaced.

Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from

the assembly. (Cut off "Insulock" provided for the fixing of vinyl sheet to be used for the protection of

connector parts.)

(3) Remove the servo-motor fixing bolts (M4 Hexagon socket head cap bolt - 4 bolts).

Loosen the bolts of the motor bracket for JT5 or 6. And remove the timing belt.

When actually the bolts are required to remove, use a torque wrench for hexagonal-bar attachment

(Length = about 150mm). Be careful that the once removed bolts should not be lost or should not be

dropped into the inner parts of the robot arm during the replacement work.

! WARNING ¤ When a motor is required to replace with a new one, turn OFF the

"MOTOR POWER" switch without fail.

¤ When a motor is required to replace with a new one, do not carelessly make the robot arm fall down or rotate.

To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support by using a crane/forklift truck.

Connector for encoder

Connector for motor power cable

Connector for motor power cable Connector for encoder

M4 Hexagon socket head cap bolt

ò

Pulley

Snap ring

H/D wave generator

M3 Hexagon socket set screw Tightening torque : 1.47N�m (15kgf�cm)

JT5, 6

JT4

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(4) Remove the servo-motor.

(5) i) For JT5 and 6

Remove the snap ring from the end of the removed servo-motor, and remove the pulley.

ii) For JT4

Loosen the hexagon socket set screws from the end of the removed servo-motor, and remove the wave

generator.

(6) Install the once removed pulley or wave generator as specified in item (5) above to the new

servo-motor. In the course of parts installation, be careful not to make a mistake in the selection o f the

direction. First, coat “LOCTITE 242” over the surfaces of the hexagon head socket set screws for the

fixing of the wave generator. Next, tighten the socket set screws firmly.

Tightening torque is 1.47N �m (15kgf�cm).

Coat gear grease (HARMONIC GREASE 4B No.2) over the surface of the wave generator.

(7) Assemble the new servo-motor.

Tightening torque is 3.43 N�m (35kgf�cm).

(8) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as

they were befo re.

(9) Re-install the covers to the designated places as they were before.

! CAUTION

When the pulley or the wave generator is removed, be careful not to give excessively strong forces to the servo-motor.

Refer to “12. Adjustment of Timing Belt” detail for the adjustment

method of timing belt.

[ NOTE ]

! CAUTION

Since the pulley or the wave generator is attached to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its

mounting/dismounting. Straightly mount/dismount the motor.

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11.2. Replacement of 200 W Motor


Model FS10L / FA20N / FC20N / FP20N / FS20C, N

Axis JT4 JT5 JT6





connector parts.)

(3) Remove the servo-motor fixing bolts (M4 Hexagon socket head cap bolt - 4 bolts). When actually the

bolts are required to remove, use a torque wrench for hexagonal bar attachment (Length = about 150 mm).

Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of

the robot arm during the replacement work.





ò

Connector for encoder Connector for motor power cable


Connector for encoder M4 Hexagon socket head cap bolt

Pulley

Snap ring

H/D wave generator Snap ring

JT5, 6

JT4

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(5) i) For JT5 and 6

Remove the snap ring from the end of the removed servo-motor, and remove the pulley.

ii) For JT4

Remove the snap ring from the end of the removed servo-motor, and remove the wave generator.

(6) Install the once removed pulley or wave generator as specified in item (5) above to the new

servo-motor. In the course of parts installation, be careful not to make a mistake in the selection of the

direction.

Coat gear grease (HARMONIC GREASE 4B No.2) over the surface of the wave generator.


Tightening torque is 3.43 N�m (35kgf�cm).

(8) Re-connect the connector for motor power cable and the connector for encoder, and other connectors

as they were before.


! CAUTION

When the pulley or the wave generator is removed, be careful not to give

excessively strong forces to the servo-motor.



[ NOTE ]

! CAUTION

Since the pulley or the wave generator is installed to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its


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11.3. Replacement of 475W Motor


Model FA06N, L, E / FC06N / FS06N, L / FS10C, N, E FS30N,L/FS45C,N FS10X

Axis JT3 JT4,5,6 JT4





connector parts.)


Loosen the bolts of motor bracket for JT5 or 6. And remove the timing belt.


(Length = about 150 mm). Be careful that the once removed bolts should not be lost or should not be


! WARNING

¤ When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail.



ò


Connector for motor power cable M5 Hexagon socket head cap bolt Connector for encoder

Gasket

Input gear

2-M4 Hexagon socket set screw

Tightening torque:3.43N�m(35kgf�cm)

Input gear Snap ring

Pulley Snap ring

JT3 of FA06N, L, E / FC06N

/ FS06N, L / FS10C, N, E

JT4 of FS30N, L / FS45C,

N / FS10X

JT5and 6 of FS30N, L /

FS45C, N

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(5) i) For JT3 of FA06N, L, E / FC06N / FS06N, L / FS10C, N, E

Loosen the fixing screws from the end of the once removed servo-motor, and remove the gear.

At the same time, remove the gasket from the motor mounting face.

ii) For JT4 of FS30N, L / FS45C, N / FS10X

Remove the snap ring from the end of the once removed servo-motor, and remove the input gear.

iii) For JT5 and 6 of FS30N, L /FS45C, N

Remove the snap ring from the end of the once removed servo-motor, and remove the pulley.

(6) Install the once removed gear, gasket or pulley as specified in item (5) above to the new servo-metor.

In the course of parts installation, be careful not to make a mistake in the selection of the gear

direction. First, coat “LOCTITE 242” over the surfaces of the hexagon socket set screws for the

fixing of the gear. Next, tighten the hexagon socket set screws firmly. Tightening torque is

3.43N�m(35kgf�cm). Coat the following gear grease over the surface of the gear.

w Input gear of RV Reduction Unit or Cyclo Reduction Unit ��MOLY WHITE RE No.00


The Tightening torque is 6.86 N�m (70kgf�cm).

(8) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors

as they were before.


! CAUTION

When the gear or the pulley is removed, be careful not to give

excessively strong forces to the servo-motor.



[ NOTE ]

! CAUTION

Since the gear or the pulley is attached to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its


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11.4. Replacement of 1.0 KW Motor


Model FA06N, L, E / FC06N / FS06N, L / FS10C, N, E FS10L / FA20N / FC20N / FP20N / FS20C, N

Axes JT1 JT2

JT3





connector parts.)



(Length = about 280mm). Be careful that the once removed bolts should not be lost or should not be


! WARNING

¤ When a motor is required to replace with a new one, turn OFF the

"MOTOR POWER" switch without fail. ¤ When a motor is required to replace with a new one, do not carelessly

make the robot arm fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on

a supporting table or support by using a crane/forklift truck.




Tightening torque =3.43 N?m (35 kgf?cm)

ò


Gasket

Input gear


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(5) Loosen the hexagon socket set screws from the end of the removed servo-motor, and remove the gear.


(6) Install the once removed gear and gasket as specified in item (5) above to the new servo-motor.

In the course of parts installation, be careful not to make a mistake in the selection of the gear direction.

First, coat “LOCTITE 242” over the surfaces of the hexagon socket set screws for the fixing of the gear.

Next, tighten the hexagon socket set screws firmly.

The tightening torque is 3.43N �m (35kgf�cm).

Coat the following gear grease over the surface of the gear.

• Input gear of Cyclo Reduction Unit .............................MOLY WHITE RE No.00


The tightening torque is 29.4N �m (300kgf�cm).


they were before.


! CAUTION

Since the gear is attached to the motor shaft end, be careful not to apply excessively strong forces to the servo-motor at its mounting/dismounting.

Straightly mount/dismount the motor.

! CAUTION

When the gear is removed, be careful not to give excessively strong

forces to the servo-motor.

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Model FS10L / FA20N / FC20N / FP20N / FS20C, N

Axes JT1 JT2

(1) Remove the encoder cover and disconnect the connector for motor power cable from the axis of motor to

be replaced. Also, disconnect the connector for encoder, as well as disconnect all other connectors to be

required from the assembly.



¤ When a motor is required to replace with a new one, do not carelessly make the robot fall down or rotate. To avoid danger and to ensure

safety, support the robot arm safely on a supporting table or support it by using a crane/forklift truck.

¤ Check to see if the encoder unit itself is repairable or not without fail. The encoder itself is also replaceable.

¤ If the encoder is normal and serviceable, and only the motor is required to

replace with a new one, first, remove the encoder from the motor, and after re-installing the motor, the encoder is required to install to the newly

replaced motor. For the details of mounting/dismounting procedures of




ð

Open here, and

disconnect cable.

Encoder cover

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bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280 mm).




(4) Loosen the hexagon socket set screws from the end of the removed servo-motor, and remove the gear.



In the course of parts installation, be careful not to make a mistake in the selection of the gear direction. First, coat “LOCTITE 242” over the surfaces of the hexagon socket set screws. Next, tighten the socket set screws firmly. The tightening torque is 11.76N�m (120kgf�cm). Coat the following gear over the surface of the gear. • Input gear of Cyclo Reduction Unit��MOLY WHITE RE No.00

(6) Assemble the servo-motor. The tightening torque is 56.84 N�m (580kgf�cm).

(7) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before.

(8) Re-install the encoder cover as they were before.

! CAUTION

Since the gear is attached to the motor shaft end, be careful not to apply

excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

Input gear


! CAUTION

Recommended tightening torque is 0.784 N�m (8 kgf�cm). The nylon washer deforms if the socket head cap bolt of the encoder

cover is tightened too much and the effect of the seal is lost.

! CAUTION When the gear is removed, be careful not to give excessively strong forces to the

servo-motor. Gasket

Tightening torque =11.76 N?m (120 kgf?cm)


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Model FS30N, L / FS45C, N/FS10X Axes JT3

(1) Remove the encoder cover and disconnect the connector for motor power cable from the axis of motor to

be replaced. Also, disconnect the connector for encoder, as well as disconnect all other connectors to be

required from the assembly.



¤ When a motor is required to replace with a new one, do not carelessly make the robot fall down or rotate. To avoid danger and to ensure

safety, support the robot arm safely on a supporting table or support it by using a crane/forklift truck.


¤ If the encoder is normal and serviceable, and only the motor is required to replace with a new one, first, remove the encoder from the motor, and

after re-installing the motor, the encoder is required to install to the newly replaced motor. For the details of mounting/dismounting procedures of

Encoder (Model H20), please refer to separately prepared "H20 Encoder Replacement Instructions".


Encoder cover M4 Hexagon socket head cap bolt

ð


Open here, and

disconnect cable.

ð

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bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280 mm).




(4) Loosen the hexagon socket set screw from the end of the removed servo-motor, and remove the gear.



First, coat "LOCTITE 242" over the surface of hexagon socket head set screw for the fixing gear. Next, tighten the socket set screw firmly. The tightening torque is 11.76N �m (120kgf�cm) Coat the following gear grease over the surface of the gear. • Input gear of RV Reduction Unit ��MOLY WHITE RE No.00

(6) Assemble the servo-motor. The tightening torque is 56.84N�m (580kgf�cm)

(7) Re-connect the connector for motor power cable and the connector for encoder, and all other connectors as they were before.

(8) Re-install the encoder cover as they were before.

M10 Hexagon socket

head cap bolt

! CAUTION

Since the gear is attached to the motor shaft end, be careful not to apply

excessively strong forces to the servo-motor at its mounting/dismounting. Straightly mount/dismount the motor.

! CAUTION

Recommended tightening torque is 0.784 N�m(8 kgf�cm). The nylon washer deforms if the socket head cap bolt of the encoder cover is tightened too much and the effect of the seal is lost.

! CAUTION

When the gear is removed, be careful not to give excessively strong forces to the servo-motor.

Gear

M6 Hexagon socket set screw

Tighteining torque = 11.76 N�m (120kgf�cm)

Gasket

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Model FS30N, L / FS45C, N FS10X

Axes JT1 JT2

JT1 JT2

(1) Remove the encoder cover and disconnect the connector for motor power cable from the axis of motor to be replaced. Also, disconnect the connector for encoder, as well as disconnect all other connectors to be required from the assembly.

! WARNING

¤ When a motor is required to replace with a new one, turn OFF the "MOTOR POWER" switch without fail.

¤ When a motor is required to replace with a new one, do not carelessly make the robot fall down or rotate. To avoid danger and to ensure safety, support the robot arm safely on a supporting table or support it by using a crane/forklift truck.


¤ If the encoder is normal and serviceable, and only the motor is required to replace with a new one, first, remove the encoder from the motor, and after re-installing the motor, the encoder is required to install to the newly replaced motor. For the details of mounting/dismounting procedures of Encoder (Model H20), please refer to separately prepared "H20 Encoder Replacement Instructions".



M4 Hexagon socket

head cap bolt

Connector cover Connector for

motor power cable

Connector

for braking M4 Hexagon socket

head cap bolt

Open here, and

disconnect cable.

M12 Hexagon socket

head cap bolt

encoder cover

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11. Replacement Instruction for Motors (2) Remove the servo-motor fixing bolts (M10 Hexagon socket head cap bolt - 4 bolts). When actually the

bolts are required to remove, use a torque wrench for hexagonal-bar attachment (Length = about 280 mm). Be careful that the once removed bolts should not be lost or should not be dropped into the inner parts of the robot arm during the replacement work.


Since the taper section of the gear is too tight to pull out unless the below mentioned jigs (pulley puller) are used. On the contrary, if you pull out the gear forcibly without using such exclusively designed and specified jigs, the servo-motor might be broken and the motor replacement work becomes very dangerous. Therefore follow the below procedures without fail.

(4) Attach the jigs (rod, pipe and bolt) to the servo -motor. On this occasion, be careful not to apply excessively strong forces to the motor section and the encoder section. Moreover, loosen the center bolt in the Input gear tip by about 5mm.

(5) Attach “Pulley puller” to the jig.

! CAUTION

¤ If the dismount of the servo-motor is difficult, utilize tap for bolt-pulling in the motor flange section (M12 x 4 places).

¤ Be careful that the weight of the servo-motor is very heavy to handle (approx. 30kg).

Bolt

Pipe

Rod

Center bolt

(M10 Hexagon socket head cap bolt)

Input gear

Center bolt

Input gear Approx. 5mm

Loosen the center bolt approx. 5mm in length,

and make sure that the bolt is not pulled out.

This procedures is prerequisite to afford a

safety stopper which is useful when the input

Bar Pulley puller

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(6) Remove the input gear provided in the taper shaft section by using “Pulley puller”.

7) Remove the center bolt. Then remove the input gear.

(8) Coat special grease (Molybdenum disulfide grease) over the surface of the taper shaft section.

After that, install the once removed input gear and center bolt as specified in item(7) above to the new

servo-motor.

(9) Once, tighten the input gear firmly by applying 56.84N �m (580kgf�cm) torque.

After that, remove it again. Re-install the input gear by applying 17.15 N�m (175kgf�cm) torque after coat

“LOCKTITE 242” over the surface of the center bolt.

Grip flat part provided in the input gear with the wrench when tightening. The motor brake might slip.

(10) Assemble the servo-motor. Tightening torque is 98N �m (1000kgf�cm).


they were before.

(12) Re-install encoder cover as they were before.

! CAUTION

While the input gear is being tightened by applying 56.84N�m

(580kgf�cm) of high torque and installed, it might result in unable to take away the input gear from the assembly in the next disassembling work. In

other words, it is necessary once to loosen and to re-tighten the input gear by applying 17.15N�m(175kgf�cm) of low torque.

! CAUTION

When the input gear is too tight to disconnect, if you forcibly disconnect it, be careful that the input gear might be suddenly jump out and might hit

the stopper provided on the center bolt head.

! CAUTION

Recommended tightening torque is 0.784 N�m(8kgf�cm). The nylon washer deforms if the socket head cap bolt of the encoder

cover is tightened too much and the effect of the seal is lost.

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12. Adjustment of Timing Belt

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12. Adjustment of Timing Belt

Adequate tension : Referring to the below figure, when you the center of belt at pressure F[N], to a degree

that the belt deflects about δ mm.

Model Axis Pressure F [N] Deflection δ [mm]

JT5 3.5∼5.0 3.4 FA06N, L, E FC06N FS06N, L FS10C, N, E, X JT6 3.5∼5.0 2.2

JT5 4.0∼5.0 3.6 FS10L FA20N FC20N FP20N FS20C, N

JT6 4.0∼5.0 2.3

JT5 9.5∼12.0 4.9 FS30N, L FS45C, N

JT6 9.5∼12.0 3.3

(1) Rotate 1 turn and loosen the 4 motor bracket mounting

bolts.

(2) Move the motor bracket and adjust the distance

between axes of the pulleys. And make the tension of

the belt suitable as specified below.

(3) Tighten the mounting bolts.

F [N] δ mm

Adjustment procedures:

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Appendix: Figure of Motor Replacement

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l FS Series

Connector for motor

power cable

Connector for

encoder

Motor for JT3

Connector for

encoder

Connector for motor

power cable

Motor for JT2

Connector for

encoder

Connector for

motor power cable Motor for JT1

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Connector for

encoder

Connector for

motor power cable Motor for JT5

Connector for

encoder

Connector for

motor power cable

Motor for JT6

Connector for

encoder

Connector for

motor power cable

Motor for JT4

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90213-1016DED F-Zeroing Motor Replace

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Transcript of 90213-1016DED F-Zeroing Motor Replace