CMA Dishmachines GR Series User manual

GR Painting Robot Series
Mechanical Maintenance Manual
Version No.：ZL-GR6150-002-V1
Issue Date：January 2020
The copyright is reserved for CMA (WUHU) Robotics Company Limited
For customer use only and any unauthorized use of this manual is strictly prohibited
CMA (WUHU) Robotics Company Limited
No.96, East Wanchun Road, Jiujiang Economic Development District, Wuhu, Anhui Province
TEL：[phone]
CMA
CMA (WUHU) Robotics Company Limited
Supplier of Intelligent Painting Robots

ZL-GR6150-002-V1 Mechanical Maintenance Manual
CMA (WUHU) Robotics Company Limited
Statement
Thank you for purchasing the painting robots designed by CMA (WUHU) Robotics Company Limited
(CMA, in short). The contents stated in the manual are directly related to your safety, lawful rights and
responsibilities. Please ensure to read through the manual and correctly set the operation parameters before
use. Any operation that does not strictly follow the instructions or the warnings of the manual might lead to
physical injury or property damage. All rights for explanation are reserved by CMA.
This manual is intended for technical reference only which makes no warranty to the entire application
of the robot system. Therefore, CMA accepts no responsibility for any accident, damage or industrial
copyright dispute that follows the use of the application system. It is strongly recommended that all the
professionals involved in operation, teaching, maintenance, and inspection should take CMA special training
before being authorized to use the robots.
Copyright and Brand name
The copyright of the manual is fully reserved by CMA and is intended for CMA users only. Neither can
the manual be reproduced nor should it be revealed to a third party without the written consent of CMA.
The manual should be well kept during the life circle of the robot. An optional copy can be ordered from
CMA if the original one is damaged or lost. The address of the new owner is required to be reported to CMA
if the robot is resold or transferred.
This manual is an indispensable part of the whole manual collection and all the professionals involved
in operation, teaching, maintenance, and inspection are required take CMA special training on the knowledge
instructed by the following manuals:
ZL-GR-001-V1：Safety Manual for GR Painting Robot Series
ZL-GR-002-V1：Maintenance Manual for GR Painting Robot Series
ZL-GR-003-V1：Explosion Protection Manual for GR Painting Robot Series
ZL-GR-004-V1：Remote Assistance Manual for GR Painting Robot Series
ZL-GR-005-V1：IO Communication Instruction Manual for GR Painting Robot Series
ZL-GR-006-V1：Program Editor Instruction Manual for GR Painting Robot Series
ZL-GR6150-001-V1：Installation and Connection Instruction Manual for GR6150 Robot
ZL-GR6150-002-V1：Mechanical Maintenance Manual for GR6150 Robot
ZL-GR6150-003-V1：Electrical Maintenance Manual for GR6150 Robot
ZL-GR6150-004-V1：Electrical Schematic Diagram for GR6150 Robot
All rights reserved by CMA. The manual and the relevant manuals are subject to change without prior
notice for the purpose of product improvement, specification change or instruction update. Please visit the
following website for the latest updates: www.cmarobot.com.cn.

ZL-GR6150-002-V1 Mechanical Maintenance Manual
CMA (WUHU) Robotics Company Limited
About the Manual
The target readers of the manual include professionals involved in robot operation, maintenance and
technical service.
This manual intends to explain the mechanical maintenance during use for all the GR6150 painting
robots designed by CMA.
In order to effectively draw the attention of the users of the manual to a specific subject or aspect, the
following symbols will be used, each with the following meanings.
Safety precautions in this manual are classified into four categories, “danger”, “caution”, “attention” and
“important” respectively.
Danger
Danger! This warning means death might occur, if an operation is not properly
performed.
Caution
Caution! This warning means death or server physical injury might occur, if an
operation is not properly performed.
Attention
Attention! This warning means minor physical injury or minor material damage
may occur, if an operation is not properly performed.
Important
Important! This warning means special attention should be paid to a certain
operation.
Warnings titled by “attention” might also lead to severe consequence in different cases. Therefore it is
strongly recommended that anything titled by “attention” should be handled with extreme caution.
Please read the manual and the files attached carefully and master all the required knowledge about
the robot and the safety instructions before use.
A cover or safety shied is taken out only for the purpose of illustration. Please ensure to restore
the cover or safety shield before any operation.
The figures and photos contained in this manual are for the purpose of illustration only and they
might be different from the product purchased.
The manual is subject to change without prior notice for the purpose of product improvement,
specification change and instruction update.
The manual will be reissued and a new version number will be specified if the contents are

ZL-GR6150-002-V1 Mechanical Maintenance Manual
CMA (WUHU) Robotics Company Limited
renewed.
If you need to order the manual due to damage, loss, etc., please contact our agent or the
nearest sales office on the back cover of the manual, and order according to the data number on the
cover.
CMA is not responsible for any consequence caused by any unauthorized modification or
change of the robot.

ZL-GR6150-002-V1 Mechanical Maintenance Manual
CMA (WUHU) Robotics Company Limited
Content
Chapter One: Safety.....................................................................................................................................................1
1.1 Instruction for Safe Use of Robots............................................................................................................... 1
1.1.1 Safety Precautions during Adjustment,Operation,Mainteance........................................................ 1
1.1.2 Safety Countermeasures of Robot Body.......................................................................................... 3
1.2 Shift,Transfer, and Sale of Robots................................................................................................................7
1.3 Abandonment of Robots............................................................................................................................... 7
Chapter Two: Basic Description...................................................................................................................................9
2.1 Robot System Composition.......................................................................................................................... 9
2.2 Unpacking Check..........................................................................................................................................9
2.3 Machine Body Nameplate.......................................................................................................................... 11
2.4 Body Part Composition and Identification of Each Axis...........................................................................13
2.5 Robot Axis Range Limit and Home Position.............................................................................................13
2.6 Robot Performance Parameters.................................................................................................................. 16
2.7 Allowable Value of Wirst Payload..............................................................................................................18
2.7.1 Allowable Weight...........................................................................................................................18
2.7.2 Allowable Maximum of Static Payload Torque.............................................................................18
2.7.3 Allowable Maximum of Moment of Inertia...................................................................................19
2.7.4 Allowable Payload Curve Diagram................................................................................................19
Chapter Three: Handling and Installation.................................................................................................................. 20
3.1 Robot Handling...........................................................................................................................................20
3.1.1 Handling Precautions......................................................................................................................20
3.1.2 Handling Method............................................................................................................................20
3.2 Robot Installation........................................................................................................................................22
3.2.1 Setting of Safety Fence...................................................................................................................22
3.2.2 Robot Installation Method..............................................................................................................22
3.2.3 Ground Mounting........................................................................................................................... 23
3.2.4 Supporter Installation..................................................................................................................... 24
3.2.5 Wall-mounted/ Suspended Installation.......................................................................................... 24
3.3 Installation Site and Environment.............................................................................................................. 25
3.4 Intergrated Application Installation Interface.............................................................................................26
3.4.1 Tool installation at the End of the Robot Wrist.....................................................................................26
3.4.2 Other Auxiliary Interfaces...................................................................................................................... 28
Chapter Four: Overhaul and Maintenance.................................................................................................................32
4.1 Preventive Maintenance..............................................................................................................................31
4.1.1 Daily Inspection..............................................................................................................................31
4.1.2 Quarterly Inspection....................................................................................................................... 31
4.1.3 Annual Inspection...........................................................................................................................32
4.1.4 Inspect Every Two Years............................................................................................................... 32
4.2 Overhaul of Main Bolts.............................................................................................................................. 32
4.3 Lubricant Inspection................................................................................................................................... 33
4.4 Change the Lubricant..................................................................................................................................34

ZL-GR6150-002-V1 Mechanical Maintenance Manual
CMA (WUHU) Robotics Company Limited
4.4.1 The Oil Supply Quantity of Lubricant........................................................................................... 34
4.4.2 Space Orientation of Lubrication................................................................................................... 34
4.4.3 Lubricant Replacement Steps for J1~J4 Axis Reducer and Wrist Parts........................................34
4.4.4 Release the Residual Pressure in Lubricating Oil Cavity.............................................................. 37
4.5 Robot Maintenance and Use Area..............................................................................................................37
4.6 Home Position Calibration......................................................................................................................... 38
4.6.1 Home Position Calibration Method................................................................................................38
4.6.2 Mechanical Home Position Calibration of Each Axis................................................................... 39
Appendix....................................................................................................................................................................42
ATightening Torque Table of Screws............................................................................................................... 41
BBackup List..................................................................................................................................................... 41

ZL-GR6150-002-V1 Mechanical Maintenance Manual
CMA (WUHU) Robotics Company Limited
1
Chapter One Safety
1.1 Instructions for Safe Use of Robots
Before performing installation, operation, maintenance, and overhaul operations, please be sure to read this
manual and other attached documents thoroughly and use this product correctly. Please fully grasp the equipment
knowledge, safety information and all precautions before using this product. This manual uses the following
symbols to indicate their importance.
1.1.1 Safety Precautions during Adjustment, Operation, Maintenance, etc.
（1）Operators must wear work clothes, safety helmets, safety shoes, etc.
（2）When turning on the power, make sure that there are no workers within the robot's operating range.
（3）The power must be cut off before entering the robot's range of motion for work.
（4）When overhaul, maintenance and other operations must be carried out under the power-on state, two persons
should work in a team at this time. One person maintains a posture that can immediately press the emergency stop
button, while the other person is within the robot's range of motion, staying vigilant and working quickly. In
addition, you should confirm the retreat path before proceeding.
（5）The load on the wrist and the robot arm must be controlled within the allowable carrying weight and torque.
If the allowable carrying weight and torque regulations are not observed, it will lead to abnormal action or
premature damage of mechanical components.
（6）It is forbidden to disassemble and work on parts not covered in the maintenance manual.
The robot is equipped with various self-diagnostic functions and abnormality detection functions, so that it
can stop safely even if an abnormality occurs. Even so, accidents caused by robots still occur from time to time.
Danger
It means that if the handling is wrong, it will cause the user's death or serious injury, and
the situation is very dangerous.
Warning
It indicates a situation that will cause death or serious injury to the user if the handling is
incorrect.
Attention
It indicates a situation that will cause minor injuries or property damage to the user if the
handling is incorrect.

ZL-GR6150-002-V1 Mechanical Maintenance Manual
CMA (WUHU) Robotics Company Limited
2
The above-mentioned accidents were all caused by the same reasons as "ignorance of safety operation
procedures" and "no idea that the robot would move suddenly". In other words, they are all accidents caused by
man-made unsafe behaviors such as "temporary negligence" and "failure to follow the prescribed steps."
"Emergency situations" make it too late for operators to implement "emergency stop", "flee" and other
behaviors to avoid the accident, which may lead to major accidents. "Emergency situations" generally have the
following types.
（1）Low-speed action suddenly becomes high-speed action.
（2）Other operators performed the operation.
（3）A different program was started due to an abnormality or program error in the peripheral equipment.
（4）Abnormal operation due to noise, malfunction, defect, etc.
（5）Misoperation.
（6）Originally planned to regenerate at low speed to perform the action, but it performed the high-speed action.
（7）The work pieces transported by the robot fall and scatter.
（8）When the work piece is in the stopped state of clamping and interlocking standby, it suddenly loses control.
（9）The next or behind robot performed the action.
The above are only some examples, and there are many forms of "emergency situations". In most cases, it is
impossible to "stop" or "escape" a robot that moves suddenly, so the following best countermeasures should be
implemented to avoid such accidents.
Danger
Most robot accidents are as follows:
1、The automatic operation was performed without confirming whether there is
anyone in the robot's motion range.
2、It enters the robot's motion range in the automatic operation state, and the robot
starts suddenly during the operation.
3、You just notice the robot in front of you, ignoring the others.
Danger
Be careful and approach the robot cautiously.
Danger
When the robot is not in use, measures such as "press the emergency stop button"
and "cut off the power" should be taken to prevent the robot from moving.

ZL-GR6150-002-V1 Mechanical Maintenance Manual
CMA (WUHU) Robotics Company Limited
3
In order to comply with these principles, it is necessary to fully understand the following precautions
and follow them.
1.1.2 Safety Countermeasures of Robot Body
Attention
The design of the robot should remove unnecessary protrusions or sharp parts, use
materials that adapt to the working environment, and adopt a fail-safe protection
structure that is not prone to damage or accidents during operation. In addition, it
should be equipped with misoperation detection stop function and emergency stop
function when the robot is in use, as well as interlocking function to prevent the
danger of the robot when the peripheral equipment is abnormal, so as to ensure
safe operation.
Warning
The main body of the robot is a multi-joint manipulator structure, and the angle of
each joint in the movement is constantly changing.
When you must approach the robot for teaching and other tasks, be careful not to
get caught by the joints. Because there are mechanical stops at the action ends of
the axis 1、2 and 3, which has a high risk of being clamped, so special attention
should be paid to it.
In addition, if the servo motor is removed or the brake is released, the robot arm
may fall due to its own weight or move in an uncertain direction. Therefore,
measures to prevent falling must be implemented, and the surrounding safety
conditions must be confirmed before operation.
Attention
When installing the attached machine on the end effector and the mechanical arm,
the size and quantity of screws specified in this book should be strictly observed,
and the torque wrench should be used to tighten according to the specified torque.
Unspecified tightening and imperfect methods will loosen the screws and cause
major accidents.
Danger
During the operation of the robot, please configure a monitor (the third party) who
can immediately press the emergency stop button to monitor the safety status.
Danger
During the operation of the robot, the operation should be carried out in a state
where the emergency stop button can be pressed immediately.

ZL-GR6150-002-V1 Mechanical Maintenance Manual
CMA (WUHU) Robotics Company Limited
4
Attention
When designing and manufacturing the end effector, it is controlled within the
allowable payload range of the robot wrist.
Attention
The fail-safe protection structure should be adopted, even if the power supply or
compressed air supply of the end effector is cut off, the installation object will not
be released or fly out, and the corner or protruding part should be treated to
prevent damage to people and objects.
Attention
The fail-safe protection structure should be adopted, even if the power supply or
compressed air supply of the end effector is cut off, the installation object will not
be released or fly out, and the corner or protruding part should be treated to
prevent damage to people and objects.
Attention
It is strictly forbidden to supply power, compressed air, and welding cooling water
outside the specifications, which will affect the performance of the robot and cause
abnormal operations, malfunctions, damage and other dangerous situations.
Attention
Although electromagnetic interference is related to its type or intensity, there is no
perfect countermeasure with current technology.
When the robot is in operation or when the power is on, the operation precautions
and regulations should be followed. Due to electromagnetic waves, other noises, and
substrate defects, the recorded data will be lost.
Therefore, please back up programs or frequently used data to an external storage
medium such as a Compact flash card.
Attention
In a large-scale system, multiple operators are involved in the work. When it is
necessary to talk at a distance, the intention should be correctly conveyed by means
of gestures, etc.
Factors such as noise in the environment can make it impossible to convey the
meaning correctly and cause accidents.