OKM AH6 User manual

AH6 Robot Maintenance Manual
Document Version V1.1.2 (19/09/2022) I

Maintenance Manual
AH6 Robot
AH6-0500-0204-2000
AH6-0500-0204-3000
AH6-0600-0204-2000
AH6-0600-0204-3000
AH6-0700-0204-2000
AH6-0700-0204-3000
Version
V1.1.2
Issue Date
19/09/2022
QKM Technology (Dongguan) Co., Ltd.

AH6 Robot Maintenance Manual
Document Version V1.1.2 (19/09/2022) III
Preface
Thank you for purchasing the robot produced by QKM!
This manual describes the instructions to maintain the robot.
Refer to the contents of this manual for maintenance.
Keep this manual properly for future reference.
Overview
This manual provides detailed information on the routine maintenance and safety
inspection of AH3 Robot, as well as the maintenance of mechanical and electrical
components, so that users can better use AH3 Robot. This manual can serve as a reference
for system integrators to design user workstation systems by using our AH3 Robot, and can
also be used to guide system installation, commissioning and maintenance.
Readers
This manual applies to:
Electrical Engineer
Maintenance Engineer
Mechanical Engineer
Technical Support Engineer
Symbols and their meanings
The signs in this document clearly indicate any dangers, warnings, attentions and notes
that may occur while users perform the operations described in this manual; Be sure to
pay attention to the following signs when they appear in this document.

Preface
IV Document Version V1.1.2 (19/09/2022)
The signs in this manual are described in the table below:
Sign
Description
It indicates that a dangerous situation would occur and
cause serious personal injuries or deaths if it is not avoided.
It indicates that a potentially dangerous situation would
occur and cause personal injury or robot damage if it is not
avoided.
It indicates that an unpredictable situation would occur and
cause robot damage, performance degradation, data loss,
etc. if it is not avoided.
It indicates the description of key information and tips of
operation skills.

AH6 Robot Maintenance Manual
Document Version V1.1.2 (19/09/2022) V
Copyright©2022 QKM Technology (Dongguan) Co., Ltd.
All Rights Reserved.
QKM Technology (Dongguan) Co., Ltd. (hereinafter referred to as QKM) owns the patents,
copyrights and other intellectual property rights of this product and its software. Without
the written authorization of QKM, any unit or individual shall not extract or copy the
contents of this document; and shall not directly or indirectly reproduce, manufacture,
process and use this product and related parts.
Notice
The contents of this document are subject to change any time due to product upgrade or
other reasons. QKM reserves the right to change the contents of maintenance and
operation in this manual without prior notice. For the recent information on this product,
please download the latest manual from our official website.
Trademark
is the trademark of QKM Technology (Dongguan) Co., Ltd. QKM has been
granted ownership of this trademark.
Disclaimer
Users need to be careful to maintain and operate the robot in a safe environment. QKM
assumes no obligation and responsibility for incidental or consequential losses arisen
therefrom.
QKM does not assume any direct, indirect, special or incidental loss or liability due to

Preface
VI Document Version V1.1.2 (19/09/2022)
improper use of this product.
QKM Technology (Dongguan) Co., Ltd. (Headquarters)
Tower A, Building 17, Headquarters 1, No. 4 Xinzhu Road, Songshan Lake High-tech
Industrial Development Zone, Dongguan City, Guangdong Province, China
Tel: [phone]
Fax: [phone]-8053
Zip code: 523808
Email: [e-mail]
Website: www.qkmtech.com

AH6 Robot Maintenance Manual
Document Version V1.1.2 (19/09/2022) VII
Version History
Version history contains accumulated information on each update of the
document, and the latest version of the document includes updates in all previous
versions of the document.
Version
Time
Change Content
V1.0.0
03-13-2020
The first version of the document was released.
V1.1.0
05-13-2020
Section 4.3 Replacement and maintenance of
controller fan was deleted.
Section 4.5 Removal and installation of the second
mechanical arm shell was added.
Section 5.3 Replacement and maintenance of
IO-free-distribution PCBA was added.
Section 5.10 Replacement and maintenance of
brake PCBA of the second mechanical arm was
added.
Chapter 5 Description of Electrical Interfaces and
Cable Identification was added.
1. Section 5.1 Description of encoder battery
interfaces and cable identification was

Version History
VIII Document Version V1.1.2 (19/09/2022)
added.
2. Section 5.2 Description of controller
interfaces and cable identification was
added.
3. Section 5.3 Description of
IO-free-distribution PCBA interfaces and
cable identification was added.
4. Section 5.4 Description of surge PCBA
interfaces and cable identification was
added.
5. Section 5.5 Description of filter interfaces
and cable identification was added.
6. Section 5.6 Description of QBUS module
interfaces and cable identification was
added.
7. Section 5.8 Description of 24V switching
power supply interfaces and cable
identification was added.
8. Section 5.10 Description of brake PCBA
interfaces and cable identification was

AH6 Robot Maintenance Manual
Document Version V1.1.2 (19/09/2022) IX
added.
V1.1.1
08-10-2021
The maintenance detection of synchronous belt is
added in Section 2.2.
Corrected IO-free-distribution PCBA diagram in
section 5.3
V1.1.2
19-09-2022
Modify the content of safety shutdown in chapter
1.2.6
Modified the description of encoder battery
maintenance in Section 5.1.

Contents
X Document Version V1.1.2 (19/09/2022)
Contents
Preface...............................................................................................................................III
Version History ................................................................................................................VII
Contents............................................................................................................................X
List of Figure...................................................................................................................XIII
List of Table.....................................................................................................................XV
Chapter 1 Safety Precautions .........................................................................................1
1.1 Safety responsibility...............................................................................................1
1.2 Safety Precautions .................................................................................................2
1.2.1 Precautions for general safety ........................................................................2
1.2.2 Precautions before robot operation...............................................................4
1.2.3 Precautions when operating...........................................................................5
1.2.4 Precautions when a fault occurs.....................................................................6
1.2.5 Precautions during maintenance ...................................................................6
1.2.6 Precautions for safe shutdown.......................................................................8

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1.3 Safety signs.............................................................................................................9
1.4 Waste disposal......................................................................................................10
Chapter 2 Routine Maintenance ...................................................................................11
2.1 Regular maintenance and inspection..................................................................11
2.1.1 Inspection before power-on .........................................................................12
2.1.2 Inspection after power-on ............................................................................14
2.2 Timing belt detection...........................................................................................15
2.2.1 Belt aging and wear reference standard.......................................................15
2.2.2 Transmission belt tension parameters.........................................................17
Chapter 3 Handling of Common Exceptions ................................................................19
Chapter 4 Maintenance of Mechanical Components ...................................................21
4.1 Lubrication of spline screw shaft.........................................................................21
4.2 Removal and installation of upper control cabinet side door panel ..................25
4.3 Removal and installation of upper control cabinet interface panel ...................28
4.4 Removal and installation of base interface panel ...............................................31
4.5 Removal and installation of the second mechanical arm shell ..........................35
Chapter 5 Maintenance of Electrical Components.......................................................40

Contents
XII Document Version V1.1.2 (19/09/2022)
5.1 Replacement and maintenance of encoder battery............................................41
5.2 Replacement and maintenance of controller components................................44
5.3 Replacement and maintenance of IO-free-distribution PCBA ............................48
5.4 Replacement and maintenance of surge protection PCBA.................................51
5.5 Replacement and maintenance of filter..............................................................54
5.6 Replacement and maintenance of QBUS module...............................................56
5.7 Replacement and maintenance of QBUS fuse ....................................................58
5.8 Replacement and maintenance of 24V switching power supply ........................59
5.9 Replacement and maintenance of switching power supply fan assembly ........61
5.10 Replacement and maintenance of brake PCBA in the second mechanical arm
...........................................................................................................................................63
Chapter 6 Technical Services........................................................................................66
6.1 Consulting and services .......................................................................................66

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XIII
List of Figure
Figure 4-1 Special oil brush........................................................................................22
Figure 4-2 Push down spline screw shaft.................................................................... 23
Figure 4-3 Apply lubricating grease............................................................................. 24
Figure 4-4 Push up spline screw shaft.........................................................................24
Figure 4-5 Upper control cabinet side door panel......................................................26
Figure 4-6 Removal of side door panel........................................................................27
Figure 4-7 Installation of side door panel ...................................................................28
Figure 4-8 Upper control cabinet interface panel.......................................................29
Figure 4-9 Removal of upper control cabinet interface panel ....................................30
Figure 4-10 Installation of upper control cabinet interface panel.................................31
Figure 4-11 Base interface panel.................................................................................... 32
Figure 4-12 Removal of base interface panel.................................................................33
Figure 4-13 Installation of base interface panel.............................................................35
Figure 4-14 Second mechanical arm .............................................................................36
Figure 4-15 Removal of the second mechanical arm shell............................................37
Figure 4-16 Connector of system indicator.................................................................... 38
Figure 4-17 Installation of the second mechanical arm shell........................................39

List of Figure
XIV Document Version V1.1.2 (19/09/2022)
Figure 5-1 Encoder battery..........................................................................................42
Figure 5-2 Removal of fastening screws from encoder battery ..................................43
Figure 5-3 Controller....................................................................................................45
Figure 5-4 Removal of fastening screws from controller fixing part........................... 46
Figure 5-5 Removal of fastening screws from controller bottom ...............................46
Figure 5-6 IO-free-distribution PCBA in the base........................................................48
Figure 5-7 Removal of IO-free-distribution PCBA .......................................................49
Figure 5-8 Removal of IO-free-distribution PCBA .......................................................50
Figure 5-9 Surge protection PCBA...............................................................................52
Figure 5-10 Removal of fastening screws....................................................................... 53
Figure 5-11 Filter.............................................................................................................54
Figure 5-12 Removal of fastening screws....................................................................... 55
Figure 5-13 QBUS module..............................................................................................56
Figure 5-14 Removal of fastening screws from QBUS module ......................................57
Figure 5-15 QBUS fuse....................................................................................................59
Figure 5-16 24V switching power supply .......................................................................60
Figure 5-17 Removal of power module..........................................................................61
Figure 5-18 Switching power supply fan assembly .......................................................62
Figure 5-19 Brake PCBA in the second mechanical arm................................................63
Figure 5-20 Removal of brake PCBA from the second mechanical arm........................64

AH6 Robot Maintenance Manual
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List of Table
Table 1-1 Warning signs ....................................................................................................... 9
Table 3-1 Handling of common exceptions...................................................................... 19
Table 4-1 Selection of lubricating grease ......................................................................... 22

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Chapter 1 Safety Precautions
Before starting maintenance on the robot, please read all the following precautions:
1.1 Safety responsibility
The maintenance of the robot system must be performed by safety-trained
personnel.;
Safety-trained personnel are those who have received safety
training (on knowledge, operation, teaching, etc. of industrial
robots, knowledge related to inspection and other operations,
and related laws and regulations) prescribed by local laws and
regulations for workers engaged in services related to industrial
robots.
Do not use the robot illegally. QKM will not be liable for any losses due to
illegal use by users.
Common situations involving illegal use:
beyond specified operating range
unsafe use of electricity

Chapter 1 Safety Precautions
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non-use of additional protective devices
beyond specified environmental requirements
overload
excessive moment of inertia
Do not modify the robot without permission. QKM assumes no responsibility
for any personal injury or machine damage caused by unauthorized changes
to the robot.
QKM is committed to providing safe and reliable information, but does not
assume responsibility for it. Even if all operations are performed in
accordance with the safety instructions, there is no guarantee that the robot
will not cause any personal or property damage.
1.2 Safety Precautions
1.2.1 Precautions for general safety
The robot may be damaged in the case of incomplete safety functions and
protective devices. Do not use the robot when safety functions are disabled or
protective devices are removed.

AH6 Robot Maintenance Manual
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Make sure that there are no other people within the work area of the robot
before operating the robot system.
Do not disassemble the parts that are not described in this manual or perform
maintenance in a different way from that described. Improper disassembly or
maintenance will disable the normal operation of the robot system and may
cause serious safety problems.
Be sure to unplug the power cable when the robot is not used.
Be sure to connect the cable_POWER to the power socket when using the
robot. Do not connect directly to the main power supply from factory.
Be sure to make replacement after turning off the power of the robot and
unplugging the power plug. If the replacement is performed while the power
is on, electric shock or equipment failure may be caused.
Connect the cables properly. Do not place heavy objects on the cables, or
forcibly pull or clamp the cables. Failure to do so may result in cable damage,
disconnection or poor contact, abnormal system operation or electric shock
to personnel.
Do not plug or unplug the cables on the interface panel while the robot is
powered on.

Chapter 1 Safety Precautions
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1.2.2 Precautions before robot operation
Setting up safe area
Understand the safe area before using the robot. Users need to pay full attention to
the safe area during use to avoid accidents caused by neglecting it.
Work area
The work area refers to the range of working area of the robot determined by its
motion trajectories and guaranteed by protective devices.
Protective area
The protective area must be larger than the work area, outside which
protective devices need to be placed for warning and safe use.
Common isolated protective device: safety fence; common safety reminders:
warning sign and slogan.
Dangerous area
The dangerous area includes any position where the robot body and the robot
arms may stay in their motion trajectories, which can be protected by isolated
protective devices to avoid personal injury or property damage.
When the robot stops running, the robot arms will stop in the dangerous area.
Setting emergency stop device
The robot needs to be equipped with an emergency stop device before running. In