FS06L with deviation err. and motor overload

[aslack]

Our painting robot, an FS06L on a D+ controller, got some of its hoses tangled around axis 5 earlier in the week. Ever since then, we've been getting E1124: "Deviation error of JT5" and E1028: "JT5 motor overload", maybe 2 or 3 times a day. If I just Reset the error and then start the robot back up, it (usually) immediately faults again for the same error. The fix we've been using has been to Reset the error, go into teach mode and then jog axis 5 a small amount. Sometimes this jog is smooth, and sometimes it is very jerky, but just a small move seems to work. Going back into repeat mode and restarting puts it right back into service for another few hours. My guess is the RV drive got messed up with the hoses and it's locking up.

We've got a Kawasaki technician coming in this afternoon, but I was wondering if there's anything I can do in the meantime. I've tried to record a few trends of JT5 but of course it never threw the errors while I was recording.

[aslack]

Just FYI: it turned out that there was a loose screw floating around inside the JT5 casting! It was sitting right in plain sight when we took the cover off, pretty obviously the cause of our problem.

The common cause for E1124 and E1028 is "mechanical binding" for anyone that ever has these errors.

[tony gast]

where did the screw come from..........mmm.....

[aslack]

It actually belonged to one of the air fittings that is located on the top of the JT5 casting. Oddly enough, we had the robot shipped without those ports, even though that isn't a standard option. It seems that when they removed the ports, they just removed the internal connections and then replaced the coverplate with a blank. Probably the screw got dropped down in there and the guys doing the work forgot to fish it out.

[rdixiemiller]

 I had the sae issue with an FS-030-L. Had an air fitting get dropped into the arm.