B-82545EN/02 MAINTENANCE 2.

PREVENTIVE MAINTENANCE

2 PREVENTIVE MAINTENANCE
Daily inspection, periodic inspection, and periodic maintenance can
keep the performance of the positioner stable for a long period of time.

NOTE
The annual operating time of the 1-axis servo
positioner is assumed to be 3840 hours.
When using the positioner beyond this annual
operating time, correct the maintenance frequency
in this chapter, which is determined on assumption
that the positioner is used for 3860 hours per year,
and perform maintenance as appropriate.

-5-
2.PREVENTIVE MAINTENANCE MAINTENANCE B-82545EN/02

2.1 DAILY INSPECTION

Clean and maintain each robot component during everyday system

operations. At the same time, check the components to see if there is a
crack or break in them. Also check and maintain the following items as
required.

a) Before automatic operation

No. Inspection item Inspection procedure
1 Pneumatic Make a pneumatic pressure check,
pressure check using the three-piece pneumatic
option shown in Fig. 2.1.
If the measured pneumatic
pressure does not fall in the range
between 0.5 and 0.7 MPa (5 and 7
kg/cm2), make adjustments, using
the regulator pressure setting
handle.
2 Check on the Put the pneumatic pressure system
For
amount of oil in operation and check the amount
machines
mist of oil dripping. If the measured
with a
amount of oil dripping does not
three-piece
meet the rating (one drop/10 to 20
pneumatic
seconds), make adjustments, using
option
the oil adjustment knob. The oiler
becomes empty after 10 to 20 days
of normal operation.
3 Check on the Check to see if the amount of oil in
amount of oil the three-piece option is within the
rated level shown in Fig. 2.1.
4 Check for Check to see if a joint or hose leaks.
leakage from the If you find a problem, tighten the
piping joint or replace any defective
component.
5 Whether cables are abnormal See Chapter 8.
Mechanical unit
6 Battery voltage check Make sure that when the power is
turned on, the BLAL alarm has not
been raised. If the BLAL alarm has
been raised, replace the battery as
directed in Section 3.4.
7 Whether there is any abnormal Check that each axis is running
vibration, noise, or heat smoothly.
generation in motors
8 Whether there is a change to Check to see if there is any
positioning precision displacement from the previous
position and there are variations in
the stop position.

-6-
B-82545EN/02 MAINTENANCE 2.PREVENTIVE MAINTENANCE

No. Inspection item Inspection procedure

9 Reliable operation of peripheral Check to see if the machine
equipment operates exactly according to
directions from the robot and
peripheral equipment.
10 Check on the operation of the See Section 4.2.
brake.

Fig. 2.1 Three-piece pneumatic option

b) After automatic operation

Once you are finished with automatic operation, bring the
positioner to its reference position, and turn it off.
No. Inspection item Inspection procedure
1 Component cleaning Clean and maintain each component. At the
and inspection same time, check the components to see if
there is a crack or break in them.

-7-
2.PREVENTIVE MAINTENANCE MAINTENANCE B-82545EN/02

2.2 QUARTERLY INSPECTION

Inspect the following items at regular intervals of about three months.

Increase the locations and the frequency of inspection if necessary (or
960 hours operating).
No. Inspection item Inspection procedure
1 Loose connector Check that the motor connectors or other
connectors are not loose.
2 Loose bolt Check that the cover retaining bolts or
external bolts are not loose. In particular,
check the following three points.
1 axis positioner, Follower unit base fixing
bolts
Bolts fixing jigs to the flange surface
motor cover retaining bolts
3 Debris removal Remove any spatter, debris, and dust from
the mechanical unit.

2.3 ONE-AND HALF-YEAR PERIODIC INSPECTION

(5,760 hours)

Perform the following inspection/maintenance item at regular intervals

of about one year and half (or 5,760 hours operating).
No. Inspection item Inspection procedure
1 Battery replacement Replace the battery in the mechanical
unit. (See Section 3.3.)

2.4 THREE-YEAR PERIODIC INSPECTION (11,520 hours)

Perform the following inspection/maintenauce item at regular intervals
of three year.
No. Inspection item Inspection procedure
1 Grease replacement See Section 3.1.

-8-
B-82545EN/02 MAINTENANCE 2.PREVENTIVE MAINTENANCE

2.5 MAINTENANCE TOOLS

You should have the following instruments and tools ready for
maintenance.

a) Measuring instruments
Instrument Condition Use
Dial gauge 1/100mm For positioning precision and
backlash measurement
Calipers 150mm

b) Tools
Phillips screwdrivers (large, medium, and small sizes)
Flat-blade screwdrivers (large, medium, and small sizes)
Box wrenches (M3 to M6)
Allen wrenches (M3 to M20)
Torque wrench See Table 2.6.
Long T wrenches (M5, M6 and M8)
Adjustable wrenches (medium and small sizes)
Pliers
Long-nose pliers
Cutting pliers
Both-ended wrench
Grease gun
C-ring pliers
Flashlight
Seal tape
Loctite No. 242, 262, 675
Sling
Gear puller

NOTE
Prepare torque wrenches that enable the torque
values indicated in Table 2.5 to be set.

NOTE
When applying LOCTITE to the important bolt
tightening points, make sure that it is applied to the
entire longitudinal portion in the engaging section of
the female threads. If it is applied to the male
threads, the bolts may be loosened because
sufficient effects cannot be obtained. Remove the
dust within the bolts and taps and wipe oil off the
engaging section. Make sure that there is no
solvent in the taps.

-9-
2.PREVENTIVE MAINTENANCE MAINTENANCE B-82545EN/02

Table 2.5
Bolt size Torque setting value
M3 1.3 Nm (13 kgfcm)
M4 4 Nm (41 kgfcm)
M5 9 Nm (92 kgfcm)
M6 15.6 Nm (159 kgfcm)
M8 37.2 Nm (380 kgfcm)
M10 73.5 Nm (750 kgfcm)
M12 128.4 Nm (1310 kgfcm)
M14 204.8 Nm (2090 kgfcm)
M16 318.5 Nm (3121 kgfcm)

- 10 -
B-82545EN/02 MAINTENANCE 3.PERIODIC MAINTENANCE

3 PERIODIC MAINTENANCE

- 11 -
3.PERIODIC MAINTENANCE MAINTENANCE B-82545EN/02

3.1 GREASE REPLACEMENT

The grease for the reducers needs to be replaced every three years or
11,520 hours in the procedure shown below. For greasing points, see
Figs. 3.1 (a) and (b).

<1> Remove the seal bolts and plugs of the grease outlets shown in
Figs. 3.1(a) and (b).
<2> Attach the grease nipple supplied with the positioner.
<3> Apply the grease specified in Table 3.1(a) and (b) until the old
grease is replaced and the new grease is output from the grease
outlets. Use grease outlet 1 shown in Figs. 3.1 (a) and (b). Only
when grease outlet 1 cannot be used due to the installation state of
the jig, use grease outlet 2. At this time, confirm that the same
amount of the old grease as that of applied grease has been output
to prevent the grease bath from overflowing.
<4> After applying grease, release the residual pressure in the grease
bath as instructed by the procedure in Section 3.2.

CAUTION
When reusing a grease nipple once used, wind
sealing tape around the screw.

Table 3.1 (a) Grease to be replaced at regular intervals of three years

(11,520 hours) (300kg load capacity)
Specified grease Amount of grease Positioner
Gun tip
to be applied posture when
Kyodo Yushi
pressure
greased
Reducer VIGOGREASE RE0 About 980 ml 0.1 MPa or less Grease outlet 1
(Specification: (NOTE) is used : 0q
A98L-0040-0174) Grease outlet 2
is used : free
NOTE When using a hand pump, apply grease approximately once per
two seconds.
Table 3.1 (b) Grease to be replaced at regular intervals of three years
(11,520 hours) (1000kg load capacity)
Specified grease Amount of grease Positioner
Gun tip
to be applied posture when
Kyodo Yushi
pressure
greased
Reducer VIGOGREASE RE0 About 5500 ml 0.15 MPa or Grease outlet 1
(Specification: less is used : 0q
A98L-0040-0174) (NOTE) Grease outlet 2
is used : free
NOTE When using a hand pump, apply grease approximately twice per
three seconds.

- 12 -
B-82545EN/02 MAINTENANCE 3.PERIODIC MAINTENANCE

Seal bolt for grease outlet 1

ឃ⢽ญ㪈㩷䉲䊷䊦䊗䊦䊃
Seal bolt for grease outlet 2
ឃ⢽ญ㪉䇭䉲䊷䊦䊗䊦䊃

Plug for grease inlet

⛎⢽ญ䇭ၒᩖ

Fig. 3.1 (a) Grease inlet and outlet ( 300kg load capacity)

Seal bolt for grease outlet 2

ឃ⢽ญ㪉䇭䉲䊷䊦䊗䊦䊃
Seal boltឃ⢽ญ㪈㩷䉲䊷䊦䊗䊦䊃
for grease outlet 1

Plug for grease inlet

⛎⢽ญ䇭ၒᩖ

Fig. 3.1 (b) Grease inlet and outlet ( 1000kg load capacity)

- 13 -
3.PERIODIC MAINTENANCE MAINTENANCE B-82545EN/02

CAUTION
If you grease incorrectly, the pressure in the grease
bath will increase, leading to a broken seal, which will
eventually cause grease leakage or malfunction.
When greasing, be sure to follow the cautions stated
below.
1 Before starting greasing, open the grease outlets
(remove bolts and the like from the grease outlets).
2 Using a manual greasing pump, grease gently and
slowly.
3 Avoid using a pneumatic pump driven from a factory
pneumatic line as much as possible.
Even when using a of Table 3.1 (a) and (b) less
during application of grease.
4 Be sure to use the specified grease. Otherwise,
damage to reducers or a similar abnormality may
occur.
5 After applying grease, release the residual pressure
within the grease bath as described in the
procedure in Section 3.2.
6 Wipe off any grease from the floor and positioner
completely, so no one will slip on it.

3.2 PROCEDURE FOR RELEASING THE GREASE RESIDUAL

PRESSURE

After applying grease, to release residual pressure from the grease bath,
perform a repetitive operation with a motion angle of at least 60 degrees
and OVR100% for 10 minutes or more while leaving the grease inlets
and outlets open.
Under the grease inlets and outlets, attach bags for collecting grease so
that grease does not spatter when it comes out of the inlets or outlets.
If the above operation cannot be performed due to the environment of
the positioner, prolong the operating time so that an equivalent
operation can be performed. (If only a motion angle of 30 degrees can
be set, perform an operation for 20 minutes or more.) After completion
of the operation, attach the plugs and seal bolts to the grease inlets and
outlets. When reusing the plugs and seal bolts, be sure to seal them with
seal tape.

- 14 -
B-82545EN/02 MAINTENANCE 3.PERIODIC MAINTENANCE

3.3 BATTERY REPLACEMENT

A backup battery is used to keep the reference-position data for the

positioner.
The battery needs to be replaced at regular intervals of one year and half.
Follow this procedure for battery replacement.

This section describes the battery replacement procedure to follow

when the HARTING connector option is selected. Replace the battery
on the controller side when the HARTING connector option is not
selected.

1) Keep the power turned on.

Press the EMERGENCY STOP button of the robot to keep robot
and positioner from moving.

CAUTION
Be sure to turn on the power. If the battery is
replaced when the power is off, the current position
information is lost, so that mastering becomes
necessary.

2) Uncap the battery case.

3) Take out the battery from the battery case.
4) Insert a new battery into the battery case while paying attention to
the polarity of the battery.
5) Cap the battery case.

Fig. 3.3 (a) Battery replacement 1

- 15 -
3.PERIODIC MAINTENANCE MAINTENANCE B-82545EN/02

Cap

Battery case Battery specifications: A98L-0031-0005

(1.5V size-D 4 pcs)

Fig. 3.3 (b) Battery replacement 2

- 16 -