90205 1140DEF b series inspection maintenance manual

Tài liệu hướng dẫn sử dụng robot Kawasaki, cách kiểm tra hoạt động robot, bảo trì robot. Mô tả đầy đủ trạng thái và các lỗi của robot trong quá trình làm việc và cách xử lý các lỗi. User guide of Kawasaki robots, how to check robot operation, and maintenance of robots. Fully describe the status and errors of the robot in the process of working and how to handle the error.

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Kawasaki Heavy Industries, Ltd.

Inspection & Maintenance

Manual

B Series

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B Series

Kawasaki Robot Inspection and Maintenance Manual

PREFACE

This manual describes inspection and maintenance procedures for Kawasaki Robot B Series

Read and understand the contents of this manual and the safety manuals thoroughly, and strictlyobserve all rules for safety before proceeding with any operation

Never proceed with any operation until you understand the contents of this manual completely Kawasaki is not responsible for any accidents and/or damages resulting from operations/

maintenance based on only a limited reading or limited understanding of some parts of this manual

1 This manual does not constitute a guarantee of the systems in which the robot is utilized Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems relating to industrial property rights as a result of using the system

2 It is recommended that all personnel assigned for activation of operation, teaching,

maintenance or inspection of the robot attend the necessary education/training course(s) prepared by Kawasaki, before assuming their responsibilities

3 Kawasaki reserves the right to change, revise, or update this manual without prior notice

4 This manual may not, in whole or in part, be reprinted or copied without the prior written consent of Kawasaki

5 Store this manual with care and keep it available for use at any time If the robot is

reinstalled or moved to a different site or sold off to a different user, attach this manual to the

BX100S, BX100N, BX100L, BX130X, BX165N, BX165LBX200L, BX250L, BX300L, BT165L, BT200LThis manual is applicable to the following robot arms

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B Series

SYMBOLS

The items that require special attention in this manual are designated with the following symbols

Ensure proper and safe operation of the robot and prevent physical injury or property damages by complying with the safety matters given in the boxes with these symbols

Denotes precautions regarding robot specification, handling, teaching, operation, and maintenance

[ NOTE ]

Failure to comply with indicated matters can result

in imminent injury or death

DANGER

Failure to comply with indicated matters may possibly lead to injury or death

WARNING

Failure to comply with indicated matters may lead

to physical injury and/or mechanical damage

CAUTION

1 The accuracy and effectiveness of the diagrams, procedures, and detail

explanations given in this manual cannot be confirmed with absolute

certainty Accordingly, it is necessary to give one’s fullest attention when

using this manual to perform any work Should any unexplained

questions or problems arise, please contact Kawasaki

2 Safety related contents described in this manual apply to each individual

work and not to all robot work In order to perform every work in safety,

read and fully understand the safety manual, all pertinent laws, regulations and related materials as well as all the safety explanations described in

each chapter, and prepare safety measures suitable for actual work

WARNING

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B Series

Preface 1

Symbols 2

1.0 Precautions 5

2.0 Items of Maintenance & Inspection 14

3.0 Details of Daily Check 18

4.0 Grease Replacement for Reduction Units 19

4.1 JT1 Reduction Unit 20

5.0 Check of Timing Belt 38

5.1 Check Procedure 40

5.2 Readjustment Procedure 40

5.3 Replacement Procedure (Unused Items) 41

6.0 Check of Motor Brake Torque 42

7.0 Check of Internal Machine Cables and Tubes 43

8.0 Check of Gas Spring 44

8.1 Check of Gas Pressure 45

8.2 Gas Replenishment 49

8.3 Gas Discharging 51

8.4 Check of Rod Section 53

9.0 Grease Replenishment for Balancer Bearing 55

CONTENTS

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B Series

11.0 Retightening 57

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B Series 1 PrecautionsKawasaki Robot Inspection and Maintenance Manual

1.0 PRECAUTIONS

Prior to starting maintenance on a Kawasaki robot, pay attention to the following matters to ensure safety

1 Prior to starting maintenance, turn OFF the controller power switch and the

external power switch for shutting off power supply to the robot controller

Display signs indicating clearly “Inspection and maintenance in progress”, and lockout/tagout the external power switch to prevent accidents of electric shock, etc caused when personnel accidentally turns ON the power

2 If changing the joint angle is required for grease replenishment, etc., first, turn

ON the motor power Then, set the arm to the specified pose Be careful not to

be caught by or between any moving parts of the arm due to careless approach to the arm at this time After moving the arm to the desired pose, turn OFF the

controller and external power Display signs indicating clearly “Inspection and maintenance in progress”, and lockout/tagout the external power switch before starting maintenance

3 Some arm parts may be very hot after continuous operations, depending on

ambient temperature when conducting maintenance immediately after the

continuous operations Be sure the arm has cooled before starting any work Handling hot machine parts is extremely dangerous and may result in injury,

burns, etc

4 Warning labels are affixed to the arm to identify areas with possibility of electric shock, high temperature or pinching, so check these areas beforehand See the next pages for the warning labels and their positions

WARNING

1 Do not apply excessive force to the robot arm while robot is not operating

Applying excessive force may result in a shortened service life and/or damage to

parts or the brake mechanisms in the joints

2 Use only Kawasaki designated greases and other lubricants

3 For replenishing and replacing grease, use manual type grease gun

4 When using air pump type grease gun, reduce air pressure on the supply side to 0.26 Mpa (2.5 kgf/cm2) or lower by a regulator, etc and apply grease using grease pump P3L (manu by Macnaught, pump ratio 50:1, part No.:50154-0349) (When using all other grease pump models/brands, contact Kawasaki before using.)

CAUTION

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Hazardous places for high temperature and electric shock (BX100S, BX100N)

Hazardous place for high temperature Hazardous place for electric shock

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Hazardous places for high temperature and electric shock (BX100L, BX130X, BX165N, BX165L, BX200L)

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Hazardous places for high temperature and electric shock (BX250L, BX300L)

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Hazardous places for high temperature and electric shock (BT165L, BT200L)

Hazardous place for electric shock

Hazardous place for high temperature

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Hazardous places for pinching (BX100S, BX100N)

Hazardous place for pinching

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Hazardous places for pinching (BX100L, BX130X, BX165N, BX165L, BX200L)

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Hazardous places for pinching (BX250L, BX300L)

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Hazardous places for pinching (BT165L, BT200L)

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B Series 2 Items of Maintenance & InspectionKawasaki Robot Inspection and Maintenance Manual

2.0 ITEMS OF MAINTENANCE & INSPECTION

For robot maintenance & inspection, there are daily checks, routine inspections (every 5000 hoursand 10000 hours) and overhaul

This manual describes items to be maintained and inspected, as well as inspection methods and adjustment methods These items are very important for using the robot successfully for a long time in a stable condition Thus, conduct the following maintenance and inspections without fail

Maintenance periodItems

DailyInspection

Every 5000hours

Every 10000hours

40000hours

ReferencePageExterior of robot

Robot movement & abnormal noises

Positioning accuracy of robot

Grease replenishment for reduction

units

19-37

Check of internal machine cables

and tubes

43

Grease replenishment for balancer

If the maintenance is not made as specified, it may result in a shortened service life of robot and it may require unexpected number of replacement parts at

overhaul (approx every 40000 hours) In addition, it is recommended to

replace seal parts such as oil seal in overhaul Upon reaching the 40000-hour

overhaul period, contact your nearest Kawasaki service center

CAUTION

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1 Inspection items for BX100S and BX100N

Every 10000 hoursGrease replacement for reduction units

Check of timing beltsCheck of internal machine cables and tubes

Battery replacement on 1HG board

*

* Figure of internal machine

Sheet

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2 Inspection items for BX100L, BX130X, BX165N, BX165L, BX200L, BT165L andBT200L

Every 5000 hoursCheck of gas spring

Grease replenishment for balancer bearings

*

* Figure of internal machine

Sheet

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3 Inspection items for BX250L and BX300L

Every 5000 hoursCheck of gas spring

Grease replenishment for balancer bearings

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B Series 3 Details of Daily CheckKawasaki Robot Inspection and Maintenance Manual

3.0 DETAILS OF DAILY CHECK

When daily maintenance and inspection of the Kawasaki robot is required, see the table below

parts, due to interference etc., especially wrist section

1 Remove the cause of interference, etc

twisting, damage, etc on the cables, hoses and other component parts connected with the tool

1 Remove the cause of trouble

by readjusting the clamps, etc

1 Check the lubrication level

2 Check if any abnormality is observed in the driving system

3 If the backlash has increased and thus resulted in vibration, contact nearest Kawasaki service center

2 If the backlash has increased and thus resulted in vibration, contact nearest Kawasaki service center

(Emergency, Deadman, Safety Fence switches, etc.) can be operated normally

1 Check switches and wiring for problems and remove the cause

If the above abnormalities cannot be corrected by mechanical troubleshooting, contact Kawasaki for control system inspection and adjustment

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B Series 4 Grease Replacement for Reduction UnitsKawasaki Robot Inspection and Maintenance Manual

4.0 GREASE REPLACEMENT FOR REDUCTION UNITS

[ NOTE ]Use a hexagonal wrench or a torque wrench with hexagonal-bar

attachment whose size is shown below for mounting/removing a plug

1 Prior to replacing/replenishing the grease and oil, turn OFF the controller

and external power switches Display signs indicating clearly “Inspection

and maintenance in progress” and lockout/tagout the external power switch

to prevent personnel from accidentally turning ON the power

2 Prior to replacing or replenishing the grease, remove the plug from drain

port without fail If grease is replenished without removing the drain plug, internal pressure increase by replenishing the grease may damage the sealing

or cause grease to flow into the motor

WARNING

1 When replacing/replenishing grease, maintain the specified refill level; do not apply too much grease

2 Use a hand-pump type grease gun to replace or replenish the grease

3 When using air pump type grease gun, reduce air pressure on the supply side

to 0.26 Mpa (2.5 kgf/cm2) or lower by a regulator, etc and apply grease using grease pump P3L (manu by Macnaught, pump ratio 50:1, part

No.:50154-0349) (When using all other grease pump models/brands,

contact Kawasaki before using.)

4 When replenishing grease, do not connect a long hose for drainage to the

drain port directly, or grease may not drain smoothly and may leak out

resulting in seal’s inside out or coming off due to increased pressure by

replenishing

5 Observe the latest MSDS of the grease before grease replenishment

6 When replacing/replenishing grease, prepare a container and rags in advance

to catch the spilled grease The grease might leak from filler port and drain port

CAUTION

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Drain port

Filler port Filler port

Drain port

4.1 JT1 REDUCTION UNIT

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Procedure

1 Remove the plug (R1/4) from the filler port and attach the grease replenishment jig with grease nipple (R1/4) shown in the above figure

2 Put a container for drained grease and remove the plug (R3/8) from the drain port

3 Supply specified amount of grease from the filler port until only new grease comes out

4 Return the plug to the drain port (temporary joint)

5 Remove the grease nipple from the filler port

6 Measure the amount of drained grease (volume or mass)

7 Adjust the amount of grease so that the amount of grease supplied and that of grease drained are the same

When the amounts of grease supplied and drained are the same, move to 8

When the amount of grease supplied is smaller than that of grease drained, move to a

When the amount of grease supplied is larger than that of grease drained, move to d

[When the amount of grease supplied is smaller than that of grease drained]

a Remove the plug from the drain port and attach a grease nipple (R3/8)

b Add grease from the drain port (Amount of grease to be added = Amount of grease drained - Amount of grease supplied) If the grease comes out from the filler port

before the grease of specified amount has been replenished, attach the plug to the filler port and move JT1 in Teach mode Then, remove the plug from the filler port and replenish the grease from the drain port

c Move to 8

[When the amount of grease supplied is larger than that of grease drained]

d Remove the plug from the drain port and drain the grease (Amount of grease to be drained = Amount of grease supplied - Amount of grease drained) If the grease does not come out from the drain port spontaneously, move JT1 in Teach mode or connect a

The pressure in the grease bath may be increased due to the influence of

temperature change, etc and grease may be disgorged Cover each port with a

rag, etc so that grease may not spatter when removing the plug

[ NOTE ]

1 The amounts of grease should be the same in supply and drainage To check

the amounts, catch the drained grease with bag or container without fail

2 Keep the difference between supplied amount and drained amount within ±5 %

of the specified supply amount (BX250L/BX300L: ±320 cc, Other than

BX250L/BX300L: ±190 cc)

[ NOTE ]

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8 Move the axis backwards and forwards individually 2 or 3 times in teach mode after the grease replenishment

9 Return the plug* to the filler port

10 Remove the plug or the grease nipple from the drain port and return the plug*

11 Wipe away any grease around the filler and drain ports with the rag

NOTE* Grease port plugs are coated with sealant To prevent grease leakage, it is

recommended to use sealant tape when returning the plug or to replace the plugs with new ones at every grease replacement

Too much pressure damages seal structure in the grease bath

The pressure of regulator applied should be 20 kPa or less

CAUTION

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Drain port Filler port

BX100S, BX100N, BX100L, BX130X, BX165N, BX165L, BX200L, BT165L, BT200L

BX250L, BX300L

Read WARNING and CAUTION in 4.0 before starting operation

WARNING

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Procedure

1 Move the robot so that the JT2 becomes 0°, and then turn OFF the power

2 Remove the plug (R1/4) from the filler port and attach a grease nipple (R1/4)

b Add grease from the drain port (Amount of grease to be added = Amount of grease drained - Amount of grease supplied) If the grease comes out from the filler port before the specified amount of grease has been replenished, attach the plug to the filler port and move JT2 in Teach mode Then, remove the plug from the filler port and replenish the grease from the drain port

c Move to 9

temperature change, etc and grease may be disgorged Cover each port with a

rag, etc so that grease may not spatter when removing the plug

[ NOTE ]

1 The amounts of grease should be the same in supply and drainage To check the amounts, catch the drained grease with bag or container without fail

of the specified supply amount (±100 cc)

[ NOTE ]

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d Remove the plug from the drain port and drain the grease (Amount of grease to be drained = Amount of grease supplied - Amount of grease drained)

If the grease does not come out from the drain port spontaneously, move JT2 in Teach mode or connect a regulator to the filler port and apply pressure by air until the grease comes out Do not apply additional pressure once the grease starts coming out

CAUTION

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BT200L

BX250L, BX300L

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b Add grease from the drain port (Amount of grease to be added = Amount of grease drained - Amount of grease supplied) If the grease comes out from the filler port before the specified amount of grease has been replenished, attach the plug to the filler port and move JT3 in Teach mode Then, remove the plug from the filler port and replenish the grease from the drain port

c Move to 9

temperature change, etc and grease may be disgorged Cover each port with

a rag, etc so that grease may not spatter when removing the plug

[ NOTE ]

of the specified supply amount (BX100S/BX100N: ±70 cc, Other than

BX100S/BX100N: ±100 cc)

[ NOTE ]

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d Remove the plug from the drain port and drain the grease (Amount of grease to be drained = Amount of grease supplied - Amount of grease drained) If the grease does not come out from the drain port spontaneously, move JT3 in Teach mode or connect a regulator to the filler port and apply pressure by air until the grease comes out Do not apply additional pressure once the grease starts coming out

CAUTION

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4.4 JT4 REDUCTION UNIT

BX100S, BX100N, BX100L, BX130X

BX165N, BX165L, BX200L, BT165L

Procedure

1 Remove the plastic covers

2 Move the robot so that the forearm takes a horizontal posture, and then turn OFF the power

3 Remove the plug (R1/4) from the filler port and attach a grease nipple (R1/4)

temperature change, etc and grease may be disgorged Cover each port with

a rag, etc so that grease may not spatter when removing the plug

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b Add grease from the drain port (Amount of grease to be added = Amount of grease drained - Amount of grease supplied) If the grease comes out from the filler port

before the specified amount of grease has been replenished, attach the plug to the filler port and move JT4 in Teach mode Then, remove the plug from the filler port and replenish the grease from the drain port

c Move to 10

d Remove the plug from the drain port and drain the grease (Amount of grease to be drained = Amount of grease supplied - Amount of grease drained) If the grease does not come out from the drain port spontaneously, move JT4 in Teach mode or connect a regulator to the filler port and apply pressure by air until the grease comes out Do not apply additional pressure once the grease starts coming out

Regulator set

Part No

49154-0007

CAUTION

of the specified supply amount (BX250L/BX300L: ±120 cc, Other than

BX250L/BX300L: ±50 cc)

[ NOTE ]

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