FANUC Robot ARC Mate 100iC
FANUC Robot ARC Mate 100iCe
FANUC Robot M-10iA
FANUC Robot M-10iAe
MECHANICAL UNIT
MAINTENANCE MANUAL
MARMCM10A04081E REV. E
This publication contains proprietary information
of FANUC Robotics America Corporation furnished for
customer use only. No other uses are authorized
without the express written permission of
FANUC Robotics America Corporation.
FANUC Robotics America Corporation
3900 W. Hamlin Road
Rochester Hills, Michigan 48309–3253
B-82755EN/05
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have
a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this
manual.
Copyrights and Trademarks
This new publication contains proprietary information of FANUC Robotics
America Corporation furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics America
Corporation.
The descriptions and specifications contained in this manual were in effect at the
time this manual was approved for printing. FANUC Robotics America
Corporation, hereinafter referred to as FANUC Robotics, reserves the right to
discontinue models at any time or to change specifications or design without
notice and without incurring obligations.
FANUC Robotics manuals present descriptions, specifications, drawings,
schematics, bills of material, parts, connections and/or procedures for installing,
disassembling, connecting, operating and programming FANUC Robotics'
products and/or systems. Such systems consist of robots, extended axes, robot
controllers, application software, the KAREL® programming language,
INSIGHT® vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been trained in one
or more approved FANUC Robotics Training Course(s) be permitted to install,
operate, use, perform procedures on, repair, and/or maintain FANUC Robotics'
products and/or systems and their respective components. Approved training
necessitates that the courses selected be relevant to the type of system installed
and application performed at the customer site.
WARNING
This equipment generates, uses, and can radiate
radiofrequency energy and if not installed and used in
accordance with the instruction manual, may cause
interference to radio communications. As temporarily
permitted by regulation, it has not been tested for
compliance with the limits for Class A computing devices
pursuant to subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such
interference. Operation of the equipment in a residential
area is likely to cause interference, in which case the user,
at his own expense, will be required to take whatever
measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a regularly
scheduled basis at the company's world headquarters in Rochester Hills,
Michigan. For additional information contact
FANUC Robotics America Corporation
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
For customer assistance, including Technical Support, Service, Parts & Part
Repair, and Marketing Requests, contact the Customer Resource Center, 24
hours a day, at 1-800-47-ROBOT (1-800-477-6268). International customers
should call 011-1-248-377-7159.
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
Copyright ©2011 by FANUC Robotics America Corporation
All Rights Reserved
The information illustrated or contained herein is not to be
reproduced, copied, downloaded, translated into another language, published in
any physical or electronic format, including internet, or transmitted in whole or
in part in any way without the prior written consent of FANUC Robotics
America Corporation.
AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®, PalletTool®,
SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® are Registered
Trademarks of FANUC Robotics.
FANUC Robotics reserves all proprietary rights, including but not
limited to trademark and trade name rights, in the following names:
AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™,
AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™,
ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™,
ARC Mate System 5™, ARCWorks Pro™, AssistTool™, AutoNormal™,
AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™,
Center Finder™, Clean Wall™, DualARM™, LR Tool™,
MIG Eye™, MotionParts™, MultiARM™, NoBots™, Paint
Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks
II™, PAINTWorks III™, PalletMate™, PalletMate PC™,
PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™,
Robo Chop™, Robo Spray™, S-420i™, S-430i™, ShapeGen™,
SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR
ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3
Controller™, SYSTEM R-J3iB Controller™, SYSTEM R-J3iC Controller™,
SYSTEM R-30iA Controller™,TCP Mate™, TorchMate™, TripleARM™,
TurboMove™, visLOC™, visPRO-3D™, visTRAC™, WebServer™,
WebTP™, and YagTool™.
•
©FANUC CORPORATION 2011
No part of this manual may be reproduced in any form.
•
All specifications and designs are subject to change without notice.
Patents
One or more of the following U.S. patents might be related to the FANUC
Robotics products described in this manual.
FANUC Robotics America Corporation Patent List
4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 4,942,539 4,984,745
5,238,029 5,239,739 5,272,805 5,293,107 5,293,911 5,331,264 5,367,944
5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687 5,737,218
5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,726 6,059,092
6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621
6,253,799 6,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143
6,378,190 6,385,508 6,425,177 6,477,913 6,490,369 6,518,980 6,540,104
6,541,757 6,560,513 6,569,258 6,612,449 6,703,079 6,705,361 6,726,773
6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,422
7,399,363
FANUC CORPORATION Patent List
4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207
4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,934,504 4,956,594
4,967,125 4,969,109 4,970,370 4,970,448 4,979,127 5,004,968 5,006,035
5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,107,716 5,111,019
5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360
5,292,066 5,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057
5,329,469 5,333,242 5,337,148 5,371,452 5,375,480 5,418,441 5,432,316
5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,461,478 5,463,297
5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,758
5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194
5,552,687 5,558,196 5,561,742 5,570,187 5,570,190 5,572,103 5,581,167
5,582,750 5,587,635 5,600,759 5,608,299 5,608,618 5,624,588 5,630,955
5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,668,628 5,687,295
5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138
5,742,144 5,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135
5,812,408 5,841,257 5,845,053 5,872,894 5,887,122 5,911,892 5,912,540
5,920,678 5,937,143 5,980,082 5,983,744 5,987,591 5,988,850 6,023,044
6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,693
6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898
6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181 6,236,011
6,236,896 6,250,174 6,278,902 6,279,413 6,285,921 6,298,283 6,321,139
6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,377,869 6,382,012
6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979
6,459,958 6,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588
6,680,461 6,696,810 6,728,417 6,763,284 6,772,493 6,845,296 6,853,881
6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 6,970,802 7,038,165
7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,848
7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294
7,181,313 7,280,687 7,283,661 7,291,806 7,299,713 7,315,650 7,324,873
7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,373,220 7,376,488
7,386,367 7,464,623 7,447,615 7,445,260 7,474,939 7,486,816 7,495,192
7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121
Conventions
WARNING
Information appearing under the "WARNING" caption concerns the protection of
personnel. It is boxed and bolded to set it apart from the surrounding text.
CAUTION
Information appearing under the "CAUTION" caption concerns the protection of
equipment, software, and data. It is boxed and bolded to set it apart from the
surrounding text.
Note Information appearing next to NOTE concerns related information or useful hints.
•
Original Instructions
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
• No part of this manual may be reproduced in any form.
• All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
PREFACE
B-82755EN/05
PREFACE
This manual explains the maintenance procedures for the mechanical units of the following robots:
Model name
Mechanical unit
specification No.
FANUC Robot ARC Mate 100iC
(With all axes brakes)
FANUC Robot M-10iA
(With all axes brakes)
FANUC Robot ARC Mate 100iC/6L
(With all axes brakes)
FANUC Robot M-10iA/6L
(With all axes brakes)
FANUC Robot ARC Mate 100iC/10S
(With all axes brakes)
FANUC Robot M-10iA/10S
(With all axes brakes)
FANUC Robot ARC Mate 100iCe (NOTE)
(With J2 and J3-axis brakes)
FANUC Robot M-10iAe (NOTE)
(With J2 and J3-axis brakes)
FANUC Robot ARC Mate 100iCe/6L (NOTE)
(With J2 and J3-axis brakes)
FANUC Robot M-10iAe/6L (NOTE)
(With J2 and J3-axis brakes)
A05B-1221-B201
A05B-1221-B401
A05B-1221-B202
A05B-1221-B402
A05B-1221-B301
A05B-1221-B501
A05B-1221-B302
A05B-1221-B502
Maximum load
3kg or 6kg or 10kg
3kg or 6kg or 10kg
3kg or 6kg
3kg or 6kg
A05B-1221-B601
3kg or 6kg or 10kg
A05B-1221-B602
A05B-1221-B451
3kg or 6kg or 10kg
A05B-1221-B452
3kg or 6kg or 10kg
A05B-1221-B551
3kg or 6kg
A05B-1221-B552
3kg or 6kg
NOTE
These robot can not support Wall & Angle mount.
The label stating the mechanical unit specification number is affixed in the position shown below. Before
reading this manual, determine the specification number of the mechanical unit.
p-1
PREFACE
B-82755EN/05
(2 )
(1)
TYPE
NO.
DATE
(2)
(3)
(4)
WEIGHT
(5) kg
DETAIL A
TYPE
TYPE
NO.
NO.
DATE
DATE
(1 )
(1)
(2)
( 2)
(3)
(3 )
(4 )
( 4)
WEIGHT
WE
IGHT
(5) kg
(5 ) ｋｇ
A
TABLE 1 Position of label indicating mechanical unit specification number
(1)
(2)
(3)
(4)
(5)
CONTENTS
LETTERS
Model name
TYPE
FANUC Robot ARC
Mate 100iC
A05B-1221-B201
FANUC Robot
M-10iA
A05B-1221-B202
FANUC Robot ARC
Mate 100iC/6L
A05B-1221-B301
FANUC Robot
M-10iA/6L
A05B-1221-B302
No.
DATE
WEIGHT kg
(Without controller)
130
A05B-1221-B401
130
A05B-1221-B402
135
A05B-1221-B501
135
A05B-1221-B502
PRINT
FANUC Robot ARC
Mate 100iC/10S
A05B-1221-B601
FANUC Robot
M-10iA/10S
A05B-1221-B602
FANUC Robot ARC
Mate 100iCe
A05B-1221-B451
130
FANUC Robot
M-10iAe
A05B-1221-B452
130
FANUC Robot ARC
Mate 100iCe/6L
A05B-1221-B551
135
FANUC Robot
M-10iAe/6L
A05B-1221-B552
135
PRINT
PRODUCTION
SERIAL NO.
YEAR AND
MONTH
p-2
130
130
PREFACE
B-82755EN/05
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook B-80687EN
All persons who use the FANUC Robot and
system designer must read and understand
thoroughly this handbook
R-30iA
Operator’s Manual
HANDLING TOOL
controller
B-83124EN-2
ARC TOOL
B-83124EN-3
DISPENSE TOOL
B-83124EN-4
ALARM CODE LIST
B-83124EN-6
Maintenance Manual
B-82595EN
B-82595EN-1 (For Europe)
B-82595EN-2 (For RIA)
R-30iA Mate
controller
Operator’s Manual
LR HANDLING TOOL
B-82724EN-1
LR ARC TOOL
B-82724EN-2
ALARM CODE LIST
B-83124EN-6
Maintenance
Manual
B-82725EN
B-82725EN-1 (For Europe)
B-82725EN-2 (For RIA)
FANUC Robot
ARC Mate
100iC, M-10iA
Mechanical
unit
Operator’s manual
B-82754EN
Intended readers:
All persons who use FANUC Robot, system designer
Topics:
Safety items for robot system design, operation, maintenance
Intended readers:
Operator, programmer, maintenance person, system designer
Topics:
Robot functions, operations, programming, setup, interfaces,
alarms
Use:
Robot operation, teaching, system design
Intended readers:
Maintenance person, system designer
Topics:
Installation, connection to peripheral equipment, maintenance
Use:
Installation, start-up, connection, maintenance
Intended readers:
Operator, programmer, maintenance person, system designer
Topics:
Robot functions, operations, programming, setup, interfaces,
alarms
Use:
Robot operation, teaching, system design
Intended readers:
Maintenance person, system designer
Topics:
Installation, connection to peripheral equipment, maintenance
Use:
Installation, start-up, connection, maintenance
Intended readers:
System designer, Maintenance person
Topics:
Installation, connection to the controller, maintenance
Use:
Installation, start-up, connection, maintenance
p-3
SAFETY PRECAUTIONS
Safety
FANUC Robotics is not and does not represent itself as an expert in safety systems,
safety equipment, or the specific safety aspects of your company and/or its work force. It
is the responsibility of the owner, employer, or user to take all necessary steps to
guarantee the safety of all personnel in the workplace.
The appropriate level of safety for your application and installation can be best
determined by safety system professionals. FANUC Robotics therefore, recommends
that each customer consult with such professionals in order to provide a workplace that
allows for the safe application, use, and operation of FANUC Robotics systems.
According to the industry standard ANSI/RIA R15-06, the owner or user is advised to
consult the standards to ensure compliance with its requests for Robotics System design,
usability, operation, maintenance, and service. Additionally, as the owner, employer, or
user of a robotic system, it is your responsibility to arrange for the training of the operator
of a robot system to recognize and respond to known hazards associated with your
robotic system and to be aware of the recommended operating procedures for your
particular application and robot installation.
Ensure that the robot being used is appropriate for the application. Robots used in
classified (hazardous) locations must be certified for this use.
FANUC Robotics therefore, recommends that all personnel who intend to operate,
program, repair, or otherwise use the robotics system be trained in an approved FANUC
Robotics training course and become familiar with the proper operation of the system.
Persons responsible for programming the system–including the design, implementation,
and debugging of application programs–must be familiar with the recommended
programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of safety in the
workplace.
CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION
Safety is essential whenever robots are used. Keep in mind the following factors with
regard to safety:
The safety of people and equipment
Use of safety enhancing devices
Techniques for safe teaching and manual operation of the robot(s)
Techniques for safe automatic operation of the robot(s)
Regular scheduled inspection of the robot and workcell
Proper maintenance of the robot
i
Safety
Keeping People and Equipment Safe
The safety of people is always of primary importance in any situation. However,
equipment must be kept safe, too. When prioritizing how to apply safety to your robotic
system, consider the following:
People
External devices
Robot(s)
Tooling
Workpiece
Using Safety Enhancing Devices
Always give appropriate attention to the work area that surrounds the robot. The safety
of the work area can be enhanced by the installation of some or all of the following
devices:
Safety fences, barriers, or chains
Light curtains
Interlocks
Pressure mats
Floor markings
Warning lights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches
Setting Up a Safe Workcell
A safe workcell is essential to protect people and equipment. Observe the following
guidelines to ensure that the workcell is set up safely. These suggestions are intended to
supplement and not replace existing federal, state, and local laws, regulations, and
guidelines that pertain to safety.
ii
Sponsor your personnel for training in approved FANUC Robotics training course(s)
related to your application. Never permit untrained personnel to operate the robots.
Install a lockout device that uses an access code to prevent unauthorized persons
from operating the robot.
Use anti–tie–down logic to prevent the operator from bypassing safety measures.
Arrange the workcell so the operator faces the workcell and can see what is going on
inside the cell.
Clearly identify the work envelope of each robot in the system with floor markings,
signs, and special barriers. The work envelope is the area defined by the maximum
Safety
motion range of the robot, including any tooling attached to the wrist flange that
extend this range.
Position all controllers outside the robot work envelope.
Never rely on software or firmware based controllers as the primary safety element
unless they comply with applicable current robot safety standards.
Mount an adequate number of EMERGENCY STOP buttons or switches within easy
reach of the operator and at critical points inside and around the outside of the
workcell.
Install flashing lights and/or audible warning devices that activate whenever the robot
is operating, that is, whenever power is applied to the servo drive system. Audible
warning devices shall exceed the ambient noise level at the end–use application.
Wherever possible, install safety fences to protect against unauthorized entry by
personnel into the work envelope.
Install special guarding that prevents the operator from reaching into restricted areas
of the work envelope.
Use interlocks.
Use presence or proximity sensing devices such as light curtains, mats, and
capacitance and vision systems to enhance safety.
Periodically check the safety joints or safety clutches that can be optionally installed
between the robot wrist flange and tooling. If the tooling strikes an object, these
devices dislodge, remove power from the system, and help to minimize damage to
the tooling and robot.
Make sure all external devices are properly filtered, grounded, shielded, and
suppressed to prevent hazardous motion due to the effects of electro–magnetic
interference (EMI), radio frequency interference (RFI), and electro–static discharge
(ESD).
Make provisions for power lockout/tagout at the controller.
Eliminate pinch points. Pinch points are areas where personnel could get trapped
between a moving robot and other equipment.
Provide enough room inside the workcell to permit personnel to teach the robot and
perform maintenance safely.
Program the robot to load and unload material safely.
If high voltage electrostatics are present, be sure to provide appropriate interlocks,
warning, and beacons.
If materials are being applied at dangerously high pressure, provide electrical
interlocks for lockout of material flow and pressure.
Staying Safe While Teaching or Manually Operating the Robot
Advise all personnel who must teach the robot or otherwise manually operate the robot to
observe the following rules:
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.
iii
Safety
Know whether or not you are using an intrinsically safe teach pendant if you are
working in a hazardous environment.
Before teaching, visually inspect the robot and work envelope to make sure that no
potentially hazardous conditions exist. The work envelope is the area defined by the
maximum motion range of the robot. These include tooling attached to the wrist
flange that extends this range.
The area near the robot must be clean and free of oil, water, or debris. Immediately
report unsafe working conditions to the supervisor or safety department.
FANUC Robotics recommends that no one enter the work envelope of a robot that is
on, except for robot teaching operations. However, if you must enter the work
envelope, be sure all safeguards are in place, check the teach pendant DEADMAN
switch for proper operation, and place the robot in teach mode. Take the teach
pendant with you, turn it on, and be prepared to release the DEADMAN switch.
Only the person with the teach pendant should be in the work envelope.
WARNING
Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch,
for any operational convenience. Deactivating a safety device is known to have
resulted in serious injury and death.
Know the path that can be used to escape from a moving robot; make sure the escape
path is never blocked.
Isolate the robot from all remote control signals that can cause motion while data is
being taught.
Test any program being run for the first time in the following manner:
WARNING
Stay outside the robot work envelope whenever a program is being run. Failure to do
so can result in injury.
Using a low motion speed, single step the program for at least one full cycle.
Using a low motion speed, test run the program continuously for at least one
full cycle.
- Using the programmed speed, test run the program continuously for at least
one full cycle.
Make sure all personnel are outside the work envelope before running production.
-
iv
Safety
Staying Safe During Automatic Operation
Advise all personnel who operate the robot during production to observe the following
rules:
Make sure all safety provisions are present and active.
Know the entire workcell area. The workcell includes the robot and its work
envelope, plus the area occupied by all external devices and other equipment with
which the robot interacts.
Understand the complete task the robot is programmed to perform before initiating
automatic operation.
Make sure all personnel are outside the work envelope before operating the robot.
Never enter or allow others to enter the work envelope during automatic operation of
the robot.
Know the location and status of all switches, sensors, and control signals that could
cause the robot to move.
Know where the EMERGENCY STOP buttons are located on both the robot control
and external control devices. Be prepared to press these buttons in an emergency.
Never assume that a program is complete if the robot is not moving. The robot could
be waiting for an input signal that will permit it to continue its activity.
If the robot is running in a pattern, do not assume it will continue to run in the same
pattern.
Never try to stop the robot, or break its motion, with your body. The only way to
stop robot motion immediately is to press an EMERGENCY STOP button located on
the controller panel, teach pendant, or emergency stop stations around the workcell.
Staying Safe During Inspection
When inspecting the robot, be sure to
Turn off power at the controller.
Lock out and tag out the power source at the controller according to the policies of
your plant.
Turn off the compressed air source and relieve the air pressure.
If robot motion is not needed for inspecting the electrical circuits, press the
EMERGENCY STOP button on the operator panel.
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.
If power is needed to check the robot motion or electrical circuits, be prepared to
press the EMERGENCY STOP button, in an emergency.
Be aware that when you remove a servomotor or brake, the associated robot arm will
fall if it is not supported or resting on a hard stop. Support the arm on a solid support
before you release the brake.
v
Safety
Staying Safe During Maintenance
When performing maintenance on your robot system, observe the following rules:
Never enter the work envelope while the robot or a program is in operation.
Before entering the work envelope, visually inspect the workcell to make sure no
potentially hazardous conditions exist.
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.
Consider all or any overlapping work envelopes of adjoining robots when standing in
a work envelope.
Test the teach pendant for proper operation before entering the work envelope.
If it is necessary for you to enter the robot work envelope while power is turned on,
you must be sure that you are in control of the robot. Be sure to take the teach
pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be
prepared to release the DEADMAN switch to turn off servo power to the robot
immediately.
Whenever possible, perform maintenance with the power turned off. Before you
open the controller front panel or enter the work envelope, turn off and lock out the
3–phase power source at the controller.
Be aware that when you remove a servomotor or brake, the associated robot arm will
fall if it is not supported or resting on a hard stop. Support the arm on a solid support
before you release the brake.
WARNING
Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a
power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS
PRESENT at the input side whenever the controller is connected to a power
source. Turning the disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.
vi
Release or block all stored energy. Before working on the pneumatic system, shut
off the system air supply and purge the air lines.
Isolate the robot from all remote control signals. If maintenance must be done when
the power is on, make sure the person inside the work envelope has sole control of
the robot. The teach pendant must be held by this person.
Make sure personnel cannot get trapped between the moving robot and other
equipment. Know the path that can be used to escape from a moving robot. Make
sure the escape route is never blocked.
Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot.
Make sure that such devices do not create pinch points that could trap personnel.
Safety
WARNING
Do not try to remove any mechanical component from the robot before thoroughly
reading and understanding the procedures in the appropriate manual. Doing so can
result in serious personal injury and component destruction.
Be aware that when you remove a servomotor or brake, the associated robot arm will
fall if it is not supported or resting on a hard stop. Support the arm on a solid support
before you release the brake.
When replacing or installing components, make sure dirt and debris do not enter the
system.
Use only specified parts for replacement. To avoid fires and damage to parts in the
controller, never use nonspecified fuses.
Before restarting a robot, make sure no one is inside the work envelope; be sure that
the robot and all external devices are operating normally.
KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE
Certain programming and mechanical measures are useful in keeping the machine tools
and other external devices safe. Some of these measures are outlined below. Make sure
you know all associated measures for safe use of such devices.
Programming Safety Precautions
Implement the following programming safety measures to prevent damage to machine
tools and other external devices.
Back–check limit switches in the workcell to make sure they do not fail.
Implement ‘‘failure routines” in programs that will provide appropriate robot actions
if an external device or another robot in the workcell fails.
Use handshaking protocol to synchronize robot and external device operations.
Program the robot to check the condition of all external devices during an operating
cycle.
Mechanical Safety Precautions
Implement the following mechanical safety measures to prevent damage to machine tools
and other external devices.
Make sure the workcell is clean and free of oil, water, and debris.
Use software limits, limit switches, and mechanical hardstops to prevent undesired
movement of the robot into the work area of machine tools and external devices.
vii
Safety
KEEPING THE ROBOT SAFE
Observe the following operating and programming guidelines to prevent damage to the
robot.
Operating Safety Precautions
The following measures are designed to prevent damage to the robot during operation.
Use a low override speed to increase your control over the robot when jogging the
robot.
Visualize the movement the robot will make before you press the jog keys on the
teach pendant.
Make sure the work envelope is clean and free of oil, water, or debris.
Use circuit breakers to guard against electrical overload.
Programming Safety Precautions
The following safety measures are designed to prevent damage to the robot during
programming:
Establish interference zones to prevent collisions when two or more robots share a
work area.
Make sure that the program ends with the robot near or at the home position.
Be aware of signals or other operations that could trigger operation of tooling
resulting in personal injury or equipment damage.
In dispensing applications, be aware of all safety guidelines with respect to the
dispensing materials.
NOTE: Any deviation from the methods and safety practices described in this manual
must conform to the approved standards of your company. If you have questions, see
your supervisor.
ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT
INSTALLATIONS
Process technicians are sometimes required to enter the paint booth, for example, during
daily or routine calibration or while teaching new paths to a robot. Maintenance
personnel also must work inside the paint booth periodically.
Whenever personnel are working inside the paint booth, ventilation equipment must be
used. Instruction on the proper use of ventilating equipment usually is provided by the
paint shop supervisor.
viii
Safety
Although paint booth hazards have been minimized, potential dangers still exist.
Therefore, today’s highly automated paint booth requires that process and maintenance
personnel have full awareness of the system and its capabilities. They must understand
the interaction that occurs between the vehicle moving along the conveyor and the
robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools.
CAUTION
Ensure that all ground cables remain connected. Never operate the paint robot with
ground provisions disconnected. Otherwise, you could injure personnel or damage
equipment.
Paint robots are operated in three modes:
Teach or manual mode
Automatic mode, including automatic and exercise operation
Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will follow a
predetermined pattern of movements. In teach mode, the process technician teaches
(programs) paint paths using the teach pendant.
In automatic mode, robot operation is initiated at the System Operator Console (SOC) or
Manual Control Panel (MCP), if available, and can be monitored from outside the paint
booth. All personnel must remain outside of the booth or in a designated safe area within
the booth whenever automatic mode is initiated at the SOC or MCP.
In automatic mode, the robots will execute the path movements they were taught during
teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines that require them to
remain in the paint booth, they must stay in a designated safe area.
Paint System Safety Features
Process technicians and maintenance personnel must become totally familiar with the
equipment and its capabilities. To minimize the risk of injury when working near robots
and related equipment, personnel must comply strictly with the procedures in the
manuals.
This section provides information about the safety features that are included in the paint
system and also explains the way the robot interacts with other equipment in the system.
The paint system includes the following safety features:
Most paint booths have red warning beacons that illuminate when the robots are
armed and ready to paint. Your booth might have other kinds of indicators. Learn
what these are.
ix
Safety
Some paint booths have a blue beacon that, when illuminated, indicates that the
electrostatic devices are enabled. Your booth might have other kinds of indicators.
Learn what these are.
EMERGENCY STOP buttons are located on the robot controller and teach pendant.
Become familiar with the locations of all E–STOP buttons.
An intrinsically safe teach pendant is used when teaching in hazardous paint
atmospheres.
A DEADMAN switch is located on each teach pendant. When this switch is held in,
and the teach pendant is on, power is applied to the robot servo system. If the
engaged DEADMAN switch is released or pressed harder during robot operation,
power is removed from the servo system, all axis brakes are applied, and the robot
comes to an EMERGENCY STOP. Safety interlocks within the system might also
E–STOP other robots.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed
robot.
Overtravel by robot axes is prevented by software limits. All of the major and minor
axes are governed by software limits. Limit switches and hardstops also limit travel
by the major axes.
EMERGENCY STOP limit switches and photoelectric eyes might be part of your
system. Limit switches, located on the entrance/exit doors of each booth, will
EMERGENCY STOP all equipment in the booth if a door is opened while the system
is operating in automatic or manual mode. For some systems, signals to these
switches are inactive when the switch on the SOC is in teach mode.
When present, photoelectric eyes are sometimes used to monitor unauthorized
intrusion through the entrance/exit silhouette openings.
System status is monitored by computer. Severe conditions result in automatic
system shutdown.
Staying Safe While Operating the Paint Robot
When you work in or near the paint booth, observe the following rules, in addition to all
rules for safe operation that apply to all robot systems.
WARNING
Observe all safety rules and guidelines to avoid injury.
x
Safety
WARNING
Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch,
for any operational convenience. Deactivating a safety device is known to have
resulted in serious injury and death.
WARNING
Enclosures shall not be opened unless the area is known to be nonhazardous or
all power has been removed from devices within the enclosure. Power shall not be
restored after the enclosure has been opened until all combustible dusts have
been removed from the interior of the enclosure and the enclosure purged. Refer
to the Purge chapter for the required purge time.
Know the work area of the entire paint station (workcell).
Know the work envelope of the robot and hood/deck and door opening devices.
Be aware of overlapping work envelopes of adjacent robots.
Know where all red, mushroom–shaped EMERGENCY STOP buttons are located.
Know the location and status of all switches, sensors, and/or control signals that
might cause the robot, conveyor, and opening devices to move.
Make sure that the work area near the robot is clean and free of water, oil, and debris.
Report unsafe conditions to your supervisor.
Become familiar with the complete task the robot will perform BEFORE starting
automatic mode.
Make sure all personnel are outside the paint booth before you turn on power to the
robot servo system.
Never enter the work envelope or paint booth before you turn off power to the robot
servo system.
Never enter the work envelope during automatic operation unless a safe area has been
designated.
Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.
Remove all metallic objects, such as rings, watches, and belts, before entering a
booth when the electrostatic devices are enabled.
Stay out of areas where you might get trapped between a moving robot, conveyor, or
opening device and another object.
Be aware of signals and/or operations that could result in the triggering of guns or
bells.
Be aware of all safety precautions when dispensing of paint is required.
Follow the procedures described in this manual.
xi
Safety
Special Precautions for Combustible Dusts (Powder Paint)
When the robot is used in a location where combustible dusts are found, such as the
application of powder paint, the following special precautions are required to insure that
there are no combustible dusts inside the robot.
Purge maintenance air should be maintained at all times, even when the robot power
is off. This will insure that dust can not enter the robot.
1.
2.
3.
4.
5.
A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed
to dust when maintenance air is not present, it will be necessary to remove the covers
and clean out any accumulated dust. Do not energize the robot until you have
performed the following steps.
Before covers are removed, the exterior of the robot should be cleaned to remove
accumulated dust.
When cleaning and removing accumulated dust, either on the outside or inside of the
robot, be sure to use methods appropriate for the type of dust that exists. Usually lint
free rags dampened with water are acceptable. Do not use a vacuum cleaner to
remove dust as it can generate static electricity and cause an explosion unless special
precautions are taken.
Thoroughly clean the interior of the robot with a lint free rag to remove any
accumulated dust.
When the dust has been removed, the covers must be replaced immediately.
Immediately after the covers are replaced, run a complete purge cycle. The robot can
now be energized.
Staying Safe While Operating Paint Application Equipment
When you work with paint application equipment, observe the following rules, in
addition to all rules for safe operation that apply to all robot systems.
WARNING
When working with electrostatic paint equipment, follow all national and local codes
as well as all safety guidelines within your organization. Also reference the
following standards: NFPA 33 Standards for Spray Application Using Flammable or
Combustible Materials, and NFPA 70 National Electrical Code.
xii
Grounding: All electrically conductive objects in the spray area must be grounded.
This includes the spray booth, robots, conveyors, workstations, part carriers, hooks,
paint pressure pots, as well as solvent containers. Grounding is defined as the object
or objects shall be electrically connected to ground with a resistance of not more than
1 megohms.
High Voltage: High voltage should only be on during actual spray operations.
Voltage should be off when the painting process is completed. Never leave high
voltage on during a cap cleaning process.
Avoid any accumulation of combustible vapors or coating matter.
Follow all manufacturer recommended cleaning procedures.
Make sure all interlocks are operational.
Safety
No smoking.
Post all warning signs regarding the electrostatic equipment and operation of
electrostatic equipment according to NFPA 33 Standard for Spray Application Using
Flammable or Combustible Material.
Disable all air and paint pressure to bell.
Verify that the lines are not under pressure.
Staying Safe During Maintenance
When you perform maintenance on the painter system, observe the following rules, and
all other maintenance safety rules that apply to all robot installations. Only qualified,
trained service or maintenance personnel should perform repair work on a robot.
Paint robots operate in a potentially explosive environment. Use caution when
working with electric tools.
When a maintenance technician is repairing or adjusting a robot, the work area is
under the control of that technician. All personnel not participating in the
maintenance must stay out of the area.
For some maintenance procedures, station a second person at the control panel within
reach of the EMERGENCY STOP button. This person must understand the robot
and associated potential hazards.
Be sure all covers and inspection plates are in good repair and in place.
Always return the robot to the ‘‘home’’ position before you disarm it.
Never use machine power to aid in removing any component from the robot.
During robot operations, be aware of the robot’s movements. Excess vibration,
unusual sounds, and so forth, can alert you to potential problems.
Whenever possible, turn off the main electrical disconnect before you clean the robot.
When using vinyl resin observe the following:
- Wear eye protection and protective gloves during application and removal.
- Adequate ventilation is required. Overexposure could cause drowsiness or
skin and eye irritation.
- If there is contact with the skin, wash with water.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
When using paint remover observe the following:
- Eye protection, protective rubber gloves, boots, and apron are required
during booth cleaning.
- Adequate ventilation is required. Overexposure could cause drowsiness.
- If there is contact with the skin or eyes, rinse with water for at least 15
minutes. Then seek medical attention as soon as possible.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
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SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral devices installed in a work cell.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1
WORKING PERSON
The personnel can be classified as follows.
Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel
Programmer or teaching operator:
• Operates the robot
• Teaches robot inside the safety fence
Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)
-
An operator cannot work inside the safety fence.
A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc..
To work inside the fence, the person must be trained on proper robot operation.
-
During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following safety
precautions.
-
Use adequate clothing or uniforms during system operation
Wear safety shoes
Use helmet
2
WORKING PERSON SAFETY
Working person safety is the primary safety consideration. Because it is very dangerous to enter the
operating space of the robot during automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration must be made to ensure working
person safety.
(1) Have the robot system working persons attend the training courses held by FANUC.
FANUC provides various training courses. Contact our sales office for details.
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(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is
waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person
safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.
(3) Install a safety fence with a gate so that no working person can enter the work area without passing
through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the
robot is stopped as the safety gate is opened.
The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this
signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of stop
type). For connection, see Fig.2 (a) and Fig.2 (b).
(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such
as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that
stops the robot when a working person enters the work area.
(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the
power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a
padlock.
(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.
RMP
Motor power/brake/signal
EARTH
Safety fence
Interlocking device and safety plug
that are activated if the gate is opened.
Fig.2 (a) Safety Fence and Safety Gate
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SAFETY PRECAUTIONS
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Dual chain
（Note）
Panel board
In case of R-30iA
Terminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2
are provided on the operation box or on the terminal block
of the printed circuit board.
EAS1
EAS11
EAS2
In case of R-30iA Mate
Terminals EAS1,EAS11,EAS2,EAS21 are provided
on the emergency stop board or connector panel.
(in case of Open air type)
EAS21
Termianls FENCE1,FENCE2 are provided
on the emergency stop board.
Single chain
Panel board
Refer to controller maintenance manual for details.
FENCE1
FENCE2
Fig.2 (b) Connection Diagram for Safety Fence
2.1
OPERATOR SAFETY
The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.
(1) If you do not have to operate the robot, turn off the power of the robot controller or press the
EMERGENCY STOP button, and then proceed with necessary work.
(2) Operate the robot system at a location outside of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the
work area unexpectedly and to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.
The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection,
the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of stop type)
when the external EMERGENCY STOP button is pressed. See the diagram below for connection.
Dual chain
External stop button
Panel board
EES1
EES11
EES2
EES21
Single chain
External stop button
（Note）
Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.
In case of R-30iA
EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.
In case of R-30iA Mate
EES1,EES11,EES2,EES21 are on the emergency stop board
or connector panel (in case of Open air type),.
EMGIN1,EMGIN2 are on the emergency stop board.
Refer to the maintenance manual of the controller for details.
Panel board
EMGIN1
EMGIN2
Fig.2.1 Connection Diagram for External Emergency Stop Button
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SAFETY PRECAUTIONS
2.2
B-82755EN/05
SAFETY OF THE PROGRAMMER
While teaching the robot, the operator must enter the work area of the robot. The operator must ensure the
safety of the teach pendant operator especially.
(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating
condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other
conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on
the teach pendant) before entering the area.
(4) The programmer must be extremely careful not to let anyone else enter the robot work area.
Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the
automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence
for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other
people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the
automatic operation mode set, the robot stops as Emergency stop or Control stop (Please refer to "STOP TYPE OF
ROBOT" in SAFETY). After the switch is set to a teach mode, the safety gate is disabled. The programmer should
understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the
safety fence. (In case of R-30iA Mate Controller standard specification, there is no mode switch. The automatic
operation mode and the teach mode is selected by teach pendant enable switch.)
Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and
switch function as follows:
(1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY for
detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the mode switch setting status.
(a)
Automatic operation mode: The DEADMAN switch is disabled.
(b)
Teach mode: Servo power is turned off when the operator releases the DEADMAN switch or when the
operator presses the switch strongly.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iA/ R-30iA Mate employs a 3-position
DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to
its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly,
the robot stops immediately.
The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the
teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should
make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.
The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity
of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the
teach pendant enable switch and the remote condition on the software.
In case of R-30iA Controller or CE or RIA specification of R-30iA Mate Controller
Mode
AUTO
mode
Teach pendant
enable switch
On
Off
Software
remote
condition
Teach pendant
Operator panel
Peripheral device
Local
Remote
Local
Remote
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
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SAFETY PRECAUTIONS
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Mode
Teach pendant
enable switch
On
T1, T2
mode
Off
Software
remote
condition
Teach pendant
Operator panel
Peripheral device
Local
Remote
Local
Remote
Allowed to start
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
In case of standard specification of R-30iA Mate Controller
Teach pendant enable switch
Software remote condition
Teach pendant
Peripheral device
On
Off
Ignored
Local
Remote
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
(5) (Only when R-30iA Controller or CE or RIA specification of R-30iA Mate controller is selected.) To
start the system using the operator’s panel, make certain that nobody is the robot work area and that
there are no abnormal conditions in the robot work area.
(6) When a program is completed, be sure to carry out a test run according to the procedure below.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test run above, execute it in the
automatic operation mode.
(7) While operating the system in the automatic operation mode, the teach pendant operator should leave
the robot work area.
2.3
SAFETY OF THE MAINTENANCE ENGINEER
For the safety of maintenance engineer, pay utmost attention to the following.
(1) During operation, never enter the robot work area.
(2) Except when specifically necessary, turn off the power of the controller while carrying out
maintenance. Lock the power switch, if necessary, so that no other person can turn it on.
(3) If it becomes necessary to enter the robot operation range while the power is on, press the emergency
stop button on the operator panel, or the teach pendant before entering the range. The maintenance
personnel must indicate that maintenance work is in progress and be careful not to allow other people
to operate the robot carelessly.
(4) When disconnecting the pneumatic system, be sure to reduce the supply pressure.
(5) Before the start of teaching, check that the robot and its peripheral devices are all in the normal
operating condition.
(6) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(7) When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers
are working nearby, make certain that their escape path is not obstructed.
(8) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such
as belt conveyor, pay careful attention to its motion.
(9) If necessary, have a worker who is familiar with the robot system stand beside the operator panel and
observe the work being performed. If any danger arises, the worker should be ready to press the
EMERGENCY STOP button at any time.
(10) When replacing or reinstalling components, take care to prevent foreign matter from entering the
system.
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(11) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit
breaker to protect against electric shock.
(12) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in
damage to the components in the controller.
(13) When restarting the robot system after completing maintenance work, make sure in advance that there
is no person in the work area and that the robot and the peripheral devices are not abnormal.
3
3.1
SAFETY OF THE TOOLS AND PERIPHERAL
DEVICES
PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program
to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care
must be taken in programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the
states of all devices in the system and can be stopped according to the states.
3.2
PRECAUTIONS FOR MECHANISM
(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of
grease, water, and dust.
(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.
(3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does
not strike against its peripheral devices or tools.
(4) Observe the following precautions about the mechanical unit cables. When theses attentions are not
kept, unexpected troubles might occur.
•
Use mechanical unit cable that have required user interface.
•
Don’t add user cable or hose to inside of mechanical unit.
•
Please do not obstruct the movement of the mechanical unit cable when cables are added to
outside of mechanical unit.
•
In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a
protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the
cable.
•
Please do not interfere with the other parts of mechanical unit when install equipments in the
robot.
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid
the system construction that power-off stop would be operated routinely. (Refer to bad case example.)
Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or
cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of
stop type.)
(Bad case example)
•
Whenever poor product is generated, a line stops by emergency stop.
•
When alteration was necessary, safety switch is operated by opening safety fence and power-off
stop is executed for the robot during operation.
•
An operator pushes the emergency stop button frequently, and a line stops.
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•
An area sensor or a mat switch connected to safety signal operate routinely and power-off stop is
executed for the robot.
(6) Robot stops urgently when collision detection alarm (SV050) etc. occurs. The frequent urgent stop by
alarm causes the trouble of the robot, too. So remove the causes of the alarm.
4
SAFETY OF THE ROBOT MECHANISM
4.1
PRECAUTIONS IN OPERATION
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can
manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the
jog mode.
4.2
PRECAUTIONS IN PROGRAMMING
(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere
with each other.
(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the
motion so that it starts from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.
4.3
PRECAUTIONS FOR MECHANISMS
(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water,
and dust.
4.4
PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN
EMERGENCY OR ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons trapped in or by the robot), brake release unit can
be used to move the robot axes without drive power.
Please order following unit and cable.
Name
Brake release unit
Robot connection cable
Power cable
Specification
A05B-2450-J350 (Input voltage AC100-115V single phase)
A05B-2450-J351 (Input voltage AC200-240V single phase)
A05B-2525-J047 (5m)
A05B-2525-J048 (10m)
A05B-2525-J010 (5m) (AC100-115V Power plug) (*)
A05B-2525-J011 (10m) (AC100-115V Power plug) (*)
A05B-2450-J364 (5m) (No power plug)
A05B-2450-J365 (10m) (No power plug)
(*) These do not support CE marking.
(2) Please make sure that adequate numbers of brake release units are available and readily accessible for
robot system before installation.
(3) Regarding how to use brake release unit, please refer to Robot controller maintenance manual.
s-9
SAFETY PRECAUTIONS
B-82755EN/05
CAUTION
Robot systems installed without adequate number of brake release units or similar
means are neither in compliance with EN ISO 10218-1 nor with the Machinery
Directive and therefore cannot bear the CE marking.
WARNING
Robot arm would fall down by releasing its brake because of gravity. Therefore, it
is strongly recommended to take adequate measures such as hanging Robot arm
by a crane before releasing a brake.
In case of releasing J2-axis motor brake
Fall down
In case of releasing J3-axis motor brake
Fall down
Fall down
Method of supporting robot arm
Sling
(*)This figure is example of floor mount.
The direction of fall is different
according to the installation angle,so
please support robot appropriately in
consideration of the influence of
gravity.
Fig.4.4 Releasing J2 and J3 motor brake and measures
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SAFETY PRECAUTIONS
5
SAFETY OF THE END EFFECTOR
5.1
PRECAUTIONS IN PROGRAMMING
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay
after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the
end effector.
6
STOP TYPE OF ROBOT
The following three robot stop types exist:
Power-Off Stop (Category 0 following IEC 60204-1)
Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
An alarm is generated and servo power is turned off.
The robot operation is stopped immediately. Execution of the program is paused.
Controlled stop (Category 1 following IEC 60204-1)
The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
An alarm is generated and servo power is turned off.
Hold (Category 2 following IEC 60204-1)
The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
The robot operation is decelerated until it stops. Execution of the program is paused.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.
When the E-Stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or
Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is
different according to the controller type or option configuration.
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SAFETY PRECAUTIONS
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There are the following 3 Stop patterns.
Stop
pattern
A
B
C
P-Stop:
C-Stop:
-:
Mode
E-Stop
button
External
E-Stop
FENCE open
SVOFF input
Servo
disconnect
AUTO
T1
T2
AUTO
T1
T2
AUTO
T1
T2
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
C-Stop
P-Stop
C-Stop
-
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
Power-Off stop
Controlled stop
Not stop
The following table indicates the Stop pattern according to the controller type or option configuration.
R-30iA
Standard
RIA type
(Dual)
R-30iA Mate
RIA
Standard
type
Option
Standard
(Single)
Standard
Stop type set (Stop pattern C)
(A05B-2500-J570)
B (*)
A
A
A
A (**)
A
A
N/A
N/A
C
C
N/A
C
C
CE type
CE
type
(*) R-30iA standard (single) does not have servo disconnect.
(**) R-30iA Mate Standard does not have servo disconnect, and the stop type of SVOFF input is
Power-Off stop.
The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer
"Software version" in operator's manual of controller for the detail of software version screen.
"Stop type set (Stop pattern C)" option
"Stop type set (Stop pattern C)"(A05B-2500-J570) is an optional function. When this option is loaded, the
stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the
stop type is Power-Off stop which is the normal operation of the system.
Alarm
SRVO-001 Operator panel E-stop
SRVO-002 Teach pendant E-stop
SRVO-007 External emergency stops
SRVO-194 Servo disconnect
SRVO-218 Ext.E-stop/Servo Disconnect
SRVO-408 DCS SSO Ext Emergency Stop
SRVO-409 DCS SSO Servo Disconnect
Condition
Operator panel E-stop is pressed.
Teach pendant E-stop is pressed.
External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA controller)
Servo disconnect input (SD4-SD41, SD5-SD51) is open.
(R-30iA controller)
External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA Mate controller)
In DCS Safe I/O connect function, SSO[3] is OFF.
In DCS Safe I/O connect function, SSO[4] is OFF.
Controlled stop is different from Power-Off stop as follows:
In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems
where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized.
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SAFETY PRECAUTIONS
B-82755EN/05
-
The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer the operator's
manual of a particular robot model for the data of stopping distance and stopping time.
This function is available only in CE or RIA type hardware.
When this option is loaded, this function can not be disabled.
The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.
7
WARNING LABEL
(1) Greasing and degreasing label
Fig.7 (a) Greasing and degreasing label
Description
When greasing and degreasing, observe the instructions indicated on this label.
(1) When greasing, be sure to keep the grease outlet open.
(2) Use a manual pump to grease.
(3) Be sure to use specified grease.
CAUTION
See section 2.2 Replacing the Grease and Oil of the Drive Mechanism
(3 years (11,520 hours) checks) for explanations about specified greases, the
amount of grease to be supplied, and the locations of grease and degrease outlets
for individual models.
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SAFETY PRECAUTIONS
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(2) Step-on prohibitive label
Fig.7 (b) Step-on Prohibitive Label
Description
Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may
get hurt if you lose your footing as well.
(3) High-temperature warning label
Fig.7 (c) High-Temperature Warning Label
Description
Be cautious about a section where this label is affixed, as the section generates heat. If you have to
inevitably touch such a section when it is hot, use a protective provision such as heat-resistant gloves.
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B-82755EN/05
SAFETY PRECAUTIONS
(4) Transportation label
300kg
250kg×2
150kg×2
Fig.7 (d) Transportation label
Description
When transporting the robot, observe the instructions indicated on this label.
1) Using a crane
•
Use a crane having a load capacity of 300 kg or greater.
•
Use at least two slings each having a withstand load of 2450 N (250 kgf) or greater. In this case,
please intersect and hang two Slings.
•
Use at least two M10 eyebolts each having a withstand load of 1470 N (150 kgf) or greater.
NOTE
See section 1.1 TRANSPORTATION of operator’s manual for explanations about
the posture a specific model should take when it is transported.
(5) Transportation prohibitive label (When transport equipment option A05B-1221-H072 is specified.)
輸送部材に衝撃を
与えないこと
Do not have impact
on this part
輸送部材にチェーン
などを掛けないこと
Do not chain, pry,
or strap on this part
Fig.7 (e) Transportation prohibitive label
Description
Keep the following in mind when transporting the robot.
(1) Prevent the forks of the forklift from having impact on transport equipment
(2) Do not thread a chain or the like through transport equipment.
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SAFETY PRECAUTIONS
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(6) High current attention label
接触注意
溶接中、内部は高電流が流れます。
DO NOT ACCESS
DURING ENERGIZED HIGH
CURRENT INSIDE
Fig.7 (f) High current attention Label
Description
Do not access during energized high current inside.
(7) Range of motion and payload mark label
Below label is added when CE specification is specified.
-170 deg
(-180 deg)
0 deg
+170 deg
(+180 deg)
J5 axis rotation
center
B
A
Motion range
of J5 axis
rotation center
C
ARC Mate 100iC, M-10iA
ARC Mate 100iCe,M-10iAe
ARC Mate 100iC/6L, M-10iA/6L
ARC Mate 100iCe/6L,M-10iAe/6L
ARC Mate 100iC/10S, M-10iA/10S
D
A
(mm)
B
(mm)
C
(mm)
D
(mm)
MAX. PAYLOAD
(kg)
1720
784
1120
1420
10
1933
996
1333
1632
6
1398
474
798
1098
10
Fig.7 (g) Range of motion and payload mark label
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TABLE OF CONTENTS
B-82755EN/05
TABLE OF CONTENTS
PREFACE ....................................................................................................p-1
SAFETY PRECAUTIONS............................................................................s-1
1
CHECKS AND MAINTENANCE ............................................................. 1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
2
DAILY CHECKS ............................................................................................ 1
FIRST 1-MONTH (320 HOURS) CHECKS .................................................... 4
FIRST 3-MONTH (960 HOURS) CHECKS .................................................... 5
3-MONTH (960 HOURS) CHECKS ............................................................... 9
1-YEAR (3,840 HOURS) CHECKS................................................................ 9
1.5-YEAR CHECKS (5,760 hours)............................................................... 10
2-YEAR CHECKS (7,680 hours).................................................................. 10
3-YEAR (11,520 HOURS) CHECKS............................................................ 10
4-year (13,820 hours) checks ...................................................................... 10
MAINTENANCE TOOLS ............................................................................. 10
PERIODIC MAINTENANCE .................................................................. 15
2.1
2.2
Replacing the Batteries (1 Year (3,840 Hours) or (1.5 Year (5,760 Hours)
Checks) ....................................................................................................... 15
REPLACING THE GREASE AND OIL OF THE DRIVE MECHANISM (3
YEARS (11,520 HOURS) CHECKS) ........................................................... 17
2.2.1
2.2.2
2.2.3
2.2.4
3
TROUBLESHOOTING .......................................................................... 30
3.1
3.2
3.3
4
Grease replacement procedure for the reducer (J1 to J3-axis) ...............................24
Oil replacement procedure for the gearbox (J4 to J6-axis) ....................................24
Procedure for releasing remaining pressure from the grease bath (J1 to J3-axis) ..27
Procedure for releasing oil (J4 to J6-axis)..............................................................28
GENERAL ................................................................................................... 30
FAILURES, CAUSES AND MEASURES ..................................................... 30
BACKLASH MEASUREMENT..................................................................... 38
COMPONENT REPLACEMENT ........................................................... 43
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
FIGURE OF DRIVE MECHANISM .............................................................. 44
REPLACING THE J1-AXIS MOTOR M1 ..................................................... 46
REPLACING THE J1-AXIS REDUCER ....................................................... 48
REPLACING THE J2-AXIS MOTOR M2 ..................................................... 52
REPLACING THE J2-AXIS REDUCER ....................................................... 53
REPLACING THE J3-AXIS MOTOR M3 ..................................................... 56
NOTES OF ATTACHING J3-AXIS MOTOR TO REDUCER........................ 58
REPLACING THE J3-AXIS REDUCER ....................................................... 63
4.9
REPLACING THE J4-AXIS MOTOR M4
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L) ..................... 66
REPLACING THE J4-AXIS MOTOR M4
(ARC Mate 100iC/10S, M-10iA/10S) ........................................................... 68
4.8.1
4.10
J3-axis reducer mounting phase auto adjusting function........................................66
c-1
TABLE OF CONTENTS
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
5
REPLACING THE J4-AXIS GEARBOX
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate
100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L) ................................ 69
REPLACING THE J4-AXIS GEARBOX
(ARC Mate 100iC/10S, M-10iA/10S) ........................................................... 72
REPLACING THE J5-AXIS MOTOR M5 ..................................................... 75
REPLACING THE J6-AXIS MOTOR M6 ..................................................... 77
REPLACING WRIST UNIT .......................................................................... 79
REPLACING THE J2 COVER (OPTION) .................................................... 82
REPLACING THE J4 COVER (OPTION) .................................................... 84
NOTES FOR ASSEMBLING CABLES WITH M/H CONDUIT...................... 85
REPLACING M/H CONDUIT (OPTION) ...................................................... 86
NOTES FOR ASSEMBLING CABLES WITH NO DUST M/H CONDUIT .... 88
REPLACING NO DUST M/H CONDUIT (OPTION) ..................................... 93
REPLACING FLUORIC RESIN RING ......................................................... 97
SEALANT APPLICATION............................................................................ 97
CABLE REPLACEMENT ...................................................................... 99
5.1
5.2
5.3
6
B-82755EN/05
CABLE WIRING......................................................................................... 100
CABLE DRESSING ................................................................................... 101
REPLACING CABLES............................................................................... 110
MASTERING ....................................................................................... 119
6.1
6.2
6.3
6.4
6.5
GENERAL ................................................................................................. 119
REGISTER OF MASTERING POSTURE .................................................. 121
RESETTING ALARMS AND PREPARING FOR MASTERING ................. 122
FIXTURE POSITION MASTER ................................................................. 123
CHECKING THE MASTERING ................................................................. 130
APPENDIX
A
SPARE PARTS LIST .......................................................................... 133
B
CIRCUIT DIAGRAM ............................................................................ 137
C
PERIODIC MAINTENANCE TABLE ................................................... 142
D
MOUNTING BOLT TORQUE LIST ..................................................... 145
E
INSULATION ABOUT ARC WELDING ROBOT................................. 146
E.1
E.2
ABSTRACT................................................................................................ 146
INSULATION AT THE WRIST ................................................................... 146
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1.CHECKS AND MAINTENANCE
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1
CHECKS AND MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter (See the APPENDIX C PERIODIC MAINTENANCE TABLE.).
NOTE
The periodic maintenance procedures described in this chapter assume that the
FANUC robot is used for up to 3840 hours a year. When using the robot beyond
this total operating time, correct the maintenance frequencies shown in this
chapter by calculation in proportion to the difference between the actual
operating time and 3840 hours/year.
1.1
DAILY CHECKS
Clean each part, and visually check component parts for damage before daily system operation. Check the
following items as the occasion demands.
(1) Before turning on power
Item
1
Check items
Oil exudation
Check points
Check there is oil exudation on sealed part of each joint parts.
(Note 1)
Note 1) About exudation of oil
Check items
-
-
Check there is exudation of oil on sealed part of each joint parts.
Oil exudation may be attached (Slightly a loot oil stick) to outside of lip depend on the movement
condition or environment of the circumference. If this oil contents change to a state of dew, it may fail
depend on the movement.
You can prevent oil spot from falling down by wiping the oil contents which is accumulated to under
part of oil seal before operation.
Also, motors may become the high temperature and the internal pressure of grease bath or oil bath may
rise by frequent repetition movement and use in the high temperature environment.
In these cases, you can return internal pressure by releasing grease out let or oil outlet just after
operation of robot. (When opening grease outlet or oil outlet, refer to Section 2.2 and pay attention
grease or oil is not scattered.)
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1.CHECKS AND MAINTENANCE
B-82755EN/05
Oil seal
(J1)
Detail A
C
B
Oil seal
(J2)
Detail B
Oil seal
(J3)
A
Detail C
Fig.1.1 (a) Check parts of main axis
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1.CHECKS AND MAINTENANCE
B-82755EN/05
Oil seal
(J6)
Detail F
Oil seal
(J5)
F
E
Detail E
Oil seal
(J4)
D
Detail D
Fig.1.1 (b) Check parts of wrist axis
Check method
- Insert waste to clearance of each joint which have oil seal and wipe oil. In this time, pay attention not
to press edge of oil seal with waste.
Oil seal
Cleaning area
Pay attention not to press
edge of oil seal with waste.
Fig.1.1 (c) Cleaning method
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1.CHECKS AND MAINTENANCE
B-82755EN/05
When air control set is combined
Item
Check items
Check points
1
Air pressure
2
Lubricator oil mist quantity
3
4
Lubricator oil level
Leakage from hose
5
Drain
Check air pressure using the pressure gauge on the air regulator as
shown in Fig.1.1 (d). If it does not meet the specified pressure of 0.49
to 0.69 MPa (5-7 kgf/cm2), adjust it using the regulator pressure-setting
handle.
Check the drop quantity during wrist or hand motion. If it does not meet
the specified value (1 drop/10-20 sec), adjust it using the lubricator
control knob. Under normal usage, the lubricator becomes empty in
about 10 to 20 days under normal operation.
Check to see that the lubricator level is within the specified level.
Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts,
as required.
Check drain and release it. When quantity of the drain is remarkable,
examine the setting of the air dryer to the air supply side.
Lubricator
Oil inlet
Adjusting knob
Lubricator
mist amount check
Lubricator
Filter
Regulator
pressure
setting handle
Pressure gauge
Fig.1.1 (d) Air control set
(2) After automatic operation
Item
Check items
Check points
1
Vibration, abnormal noises, and
motor heating
Check whether the robot moves along and about the axes smoothly
without unusual vibration or sounds. Also, check whether the
temperatures of the motors are excessively high.
Check to see that the stop positions of the robot have not deviated
from the previous stop positions.
Check whether the peripheral devices operate properly according to
commands from the robot.
Check that the end effector drops within 5 mm when the power is cut.
2
3
4
1.2
Changing repeatability
Peripheral devices for proper
operation
Brakes for each axis
FIRST 1-MONTH (320 HOURS) CHECKS
Check the following items once every one-month (320 hours). Additional inspection areas and times
should be added to the table according to the robot’s working conditions, environment, etc. Then every 3
months thereafter. (See the Section 1.4.)
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1.CHECKS AND MAINTENANCE
B-82755EN/05
Item
Check items
Check points
1
Check the oil gauge of
J4/J5/J6-axis gearbox
2
Confirm the broken of fluoric
resin ring
3
Ventilation portion of controller
OK
Please confirm whether the amount of oil of the oil gauge has come
above the center. Please replenish it in case of the shortage.
When the oil gauge part does not have air moiety, there is it, but this is
not abnormality.
When oil does not enter, the red index moiety of the oil gauge shows
the reflected heat of the light, and the outline of the index moiety is
seen clearly.
When oil enters, it does not show this reflected heat, and the outline of
the index is not clear.
Moreover, please exchange oil when oil discolors due to deterioration
and the character of the oil gauge cannot be read.
Confirm fluoric resin ring is not broken. If it is broken, replace it to new
one.
See Section 1.3. (Note 4)
Check whether the cable connected to the teach pendant and robot is
unevenly twisted.
OK
OK
NG
(Exchange oil)
Fig.1.2 The extent of oil deterioration
1.3
FIRST 3-MONTH (960 HOURS) CHECKS
Check the following items at the first quarterly inspection, then every year thereafter. (See the
Section .1.4.)
Item
Check items
1
Mechanical unit cable and
welding cable
2
Retightening external main bolts
3
Check the mechanical stopper
and adjustable mechanical
stopper
Cleaning and checking each part
4
5
6
Check the end effector (hand)
cable, etc.
Controller cable and robot
connecting cable
Check points
Check whether the jackets of the mechanical unit cables and welding
are damaged. Also, check whether the cables are excessively bent or
unevenly twisted. Check that the connectors of the motors and
connector panels are securely engaged. (NOTE1)
Further, tighten the end-effecter mounting bolts and external main
bolts. (NOTE2)
Check the looseness of mounting bolts of mechanical stopper and
adjustable
mechanical stopper. (NOTE3)
Clean each part (remove chips, etc.) and check component parts for
cracks and flaws. (NOTE4)
Confirm whether there is wound in the cable
Check whether the cable connected to the teach pendant and robot is
unevenly twisted.
Note 1) Inspection points and check items of the mechanical unit cables and
connectors
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1.CHECKS AND MAINTENANCE
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Inspection points of the mechanical unit cables
Check the cable for damage that has been exposed.
Clean it when the spatter adheres.
Fig.1.3 (a) Inspection points of the mechanical unit cables
Inspection points of the connectors
-
Power/brake connectors of the motor exposed externally
Robot connection cables, earth terminal and user cables
Check items
-
Circular connector:
Square connector:
Earth terminal:
Check the connector for looseness by turning it manually.
Check the connector for disengagement of its lever.
Check the connector for looseness.
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1.CHECKS AND MAINTENANCE
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Remove this cover
and check here.
Fig.1.3 (b) Inspection points of connectors
Note 2) Points to be retightened
-
The end effecter mounting bolts, robot installation bolts, and bolts to be removed for inspection need
to be retightened.
The bolts exposed to the outside of the robot need to be retightened.
For the tightening torque, see the recommended bolt tightening torque shown in the Appendix.
A loose prevention agent (adhesive) is applied to some bolts. If the bolts are tightened with greater
than the recommended torque, the loose prevention agent may be removed. So, follow the
recommended tightening torque when retightening them.
-7-
1.CHECKS AND MAINTENANCE
B-82755EN/05
Note 3) Check of mechanical stopper and adjustable mechanical stopper.
-
Check the looseness of stopper mounting bolts. If they are loose, they are needed to be retightened.
J3-axis mechanical stopper B
Spec
Bolt : A97L-0218-0742#M10X20
(Tightening torque 50Nm)
Stopper: A290-7221-X324
J3-axis mechanical stopper
J2-axis mechanical stopper A
J1-axis mechanical stopper B
(When mechanical stopper is specified)
J2-axis mechanical stopper B
Spec
Stopper : A290-7215-X323 (2) Spec
Bolt : A6-BA-16X20
(Tighthening torque 56Nm)
(Tightening torque 56Nm)
J1-axis mechanical stopper A
(When mechanical stopper is specified)
Spec:
Bolt : A6-BA-8X12 (2)
(Tightening torque 37.2Nm)
Stopper : A290-7221-X361
Fig.1.3 (c) Check of mechanical stopper and adjustable mechanical stopper
Note 4) Cleaning
-
-
-
Necessary cleaning points, dust on the flat part, sedimentation of spatters
Clean sediments periodically.
In particular, clean the following points carefully.
Vicinity of the wrist axis and oil seal
→ If chippings or spatters are attached to the oil seal, an oil leak may be caused.
Vicinity of M/H conduit
→ If chipping or spatters are attached to fluoric resin ring, it may shorten life of conduit.
Vicinity of the welding torch and wrist flange
→ The insulation failure occurs when the spatter has collected around the wrist flange or welding
torch, and there is a possibility of damaging the robot mechanism by the welding current. (See
Appendix E)
Check items
Check if the vicinity of the necessary inspection points, wrist part, and J3 arm significantly wears
due to rubbing against the welding cable or hand cable.
Check if there is a trace of a collision around the gun or hand.
Confirm if Fluoric resin ring is broken, if it was broken, replace it to new one. Two years are aims in
an exchange period. If you operate robot with the state that hard mine dust is attached to rotated
part, exchange period may shortens.
Check the reducer or grease bath /oil bath for an oil leak.
→ If oil can be found a day after wiping oil, an oil leak may be caused.
-8-
1.CHECKS AND MAINTENANCE
B-82755EN/05
Fluoric resin ring
(Spec:A290-7221-X571)
Fig.1.3 (d) Cleaning points
1.4
3-MONTH (960 HOURS) CHECKS
Check the following items once every one-month (320 hours).
Item
Check items
1
Check the oil gauge of
J4/J5/J6-axis gearbox
Confirm the broken of fluoric resin
ring
2
3
1.5
Ventilation portion of controller
Check points
(See Section 1.2).
Confirm fluoric resin ring is not broken. If it is broken, replace it to new
one.
See Section 1.3. (Note 4)
(See Section 1.2.)
1-YEAR (3,840 HOURS) CHECKS
Check the following items once every year (3,840 hours).
Item
Check items
1
Mechanical unit cable and
welding cable
Retightening external main bolts
Check the mechanical stopper
and adjustable mechanical
stopper
Cleaning and checking each part
Check the end effector (hand)
cable, etc
2
3
4
5
Check points
(See Section 1.3.)
(See Section 1.3.)
(See Section 1.3.)
(See Section 1.3).
(See Section 1.3.)
-9-
1.CHECKS AND MAINTENANCE
Item
6
B-82755EN/05
Check items
Check points
Replace battery in the mechanical unit. (See Section 2.1.)
Battery (except ARC Mate
100iCe, M-10iAe, ARC Mate
100iCe/6L, M-10iAe/6L)
Controller cable and robot
connecting cable
7
1.6
(See Section 1.3.)
1.5-YEAR CHECKS (5,760 hours)
Check the following item once every 1.5 year (5,760 hours).
Item
1
1.7
Check items
Battery (ARC Mate 100iCe,
M-10iAe, ARC Mate 100iCe/6L,
M-10iAe/6L)
Check points
Replace battery in the mechanical unit. (See Section 7.2.1)
2-YEAR CHECKS (7,680 hours)
Check the following item once every 2 years (7,860 hours).
Item
Check items
Check points
Replacing M/H conduit
/No dust M/H conduit
1
1.8
Replace M/H conduit. (See Section 4.19)
3-YEAR (11,520 HOURS) CHECKS
Check the following items once every 3 years (11,520 hours).
Item
Check items
1
Replacing grease and oil of each
axis reducer and gearbox
1.9
Check points
Replace grease and oil of reducer and gearbox.
See Section 2.2.
4-year (13,820 hours) checks
Check the following items once every 4 years (13,820 hours).
Item
Check items
1
Replace the mechanical unit cable
1.10
Check points
Replace mechanical unit cable. (See Chapter 5.)
MAINTENANCE TOOLS
You should have the following instruments and tools ready for maintenance.
a)
Measuring instruments
Instrument
Condition
Dial gauge
Calipers
1/100mm
150mm
Use
For positioning precision and backlash measurement
- 10 -
1.CHECKS AND MAINTENANCE
B-82755EN/05
b)
Tools
Name
Phillips screwdrivers
Flat-blade screwdrivers
Box wrenches
Hexagonal wrench sets
Torque wrench
Long T wrenches
Adjustable wrenches
Pliers
Long-nose pliers
Cutting pliers
Both-ended wrench
Grease gun
C-ring pliers
Press-fit fixture for J1-axis oil seal
J6 motor wiring detaching tool
Adaptor for J5/J6 axis oiling
Mounting fixture for J3-axis motor
Mounting fixture for J3-axis motor
Mounting fixture for input gear of J3-axis
motor
Mounting fixture for input gear of J3-axis
motor
Mounting fixture for input gear of J3-axis
motor
Flashlight
LOCTITE 242,262,518,7649
Three bond
Oil injection gun
Oil injection nipple with valve
Oil tray with valve
Remarks
(Large, medium, and small sizes)
(Large, medium, and small sizes)
Width across flats 7, 10
Width across flats 2.5, 3, 4, 5, 6, 8, 10, 12 (for replacing parts)
Width across flats 2.5, 3, 4, 5, 6, 8, 10, 17 (for replacing parts)
Width across flats 2.5, 3, 4, 5, 6, 8, 10, 12 (for replacing parts)
(Medium and small sizes)
See Fig.4.3 (d)
A290-7221-X971
A290-7221-X591
A290-7221-Z972 (Fig.1.10 (a))
(For robot which is made before March, 2010)
A290-7221-Z974 (Fig.1.10 (b))
(For ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L,M-10iA/6L
which is made after March, 2010)
A290-7221-X973 (Fig.1.10 (c))
(For ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L,M-10iA/6L
which is made before June, 2009)
A290-7221-X974 (Fig.1.10 (d))
(For ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L,M-10iA/6L
which is made after July, 2009 and before March, 2010)
A290-7221-X976 (Fig.1.10 (e))
(For ARC Mate 100iC/10S,M-10iA/10S)
A05B-1221-K005
A05B-1221-K006
A05B-1221-K007
- 11 -
1.CHECKS AND MAINTENANCE
B-82755EN/05
0.3
(
)
30°
DETAIL A
2 5.5
10
24.5
バリ無き事。
1)NO BURR.
O6
C0
.3
C0
.3
C0
.3
0
0
注）
NOTE)
O 2.8 -0.050
O 6.6 -0.050
O6
A
全周糸面取り。
2)ALL EDGES SOULD BE CHAMFERED
C0.2～C0.5.
DETAIL 詳細
Fig.1.10 (a) Mounting fixture for J3-axis motor A290-7221-Z972
12(二面幅)
WIDTH ACROSS FLAT
M10 (ピッチ1.5)
PITCH
°
135
3.5
R
A
135
°
2
R
19
O 16
O 9.2
+0.1
6
O 7.2 0
0
0.2 O 8.4 -0.1
C0
.2
A
0.4
14
断面 A-A
注）
NOTE)
バリ無き事。
1)NO BURR.
SECTION 断面
全周糸面取り。
2)ALL EDGES SOULD BE CHAMFERED
C0.2～C0.5.
Fig.1.10 (b) Mounting fixture for J3-axis motor A290-7221-Z974
- 12 -
1.CHECKS AND MAINTENANCE
B-82755EN/05
6 6
4- R
15
1
G
)
62
(
r 0.01
P
45
Ｇ
3
A
n 0.01 P
7 9
SECTION B-B
O
R
10
0
94
B
45°
45
+0.01
11
90
O 80 0
O 20
O 78
O 30
G
R
.
C0
5
2- R
3
B
G
1
n 0.01 P
a 0.01 Q
64
R
0.5
Q
8 5
A
SECTION A-A
62
90
15
4-M6 THRU.
EQ.SP.
THRU.
貫通
EQ.SP.
周上等配
RELIEF
逃げ
SECTION 断面
注）
NOTE)
全周糸面取りの事。
ALL EDGES SHOULD BE CHAMFERED
C0.1～C0.5.
Fig.1.10 (c) Mounting fixture for input gear of J3-axis motor A290-7221-X973
6.5
6.5
(
1
G
)
62
15
4R
90
P
94
45
r 0.01
A
G
7
9
3
R
8 5
12
O 80
90
+0.010
0
G
Q
A
O
( 62 )
0
12
n 0.01 P
a 0.01 Q
0.5
1
64
R
R
.5
C0
2-
RELIEF
O 78
G
45
RELIEF
3
O 20
+0.020
R
10
G
O 22 0
O 32
13.15 0
+0.010
n 0.01 P
O 86
O 86
EF
LI
RE
13.15 0
+0.01
O
0
12
SECTION A-A
注）
NOTE)
THRU.
貫通
EQ.SP.
周上等配
RELIEF
逃げ
SECTION 断面
全周糸面取りの事。
ALL EDGES SHOULD BE CHAMFERED
C0.1～C0.5.
Fig.1.10 (d) Mounting fixture for input gear of J3-axis motor A290-7221-X974
- 13 -
( 15 )
1.CHECKS AND MAINTENANCE
B-82755EN/05
6.5
R
1
15
4-
6.5
G
)
65
(
90
P
97
45
r 0.01
A
G
7
9
3
RELIEF
45
+0.010
12
90
O 80 0
G
RELIEF
3
O 78
R
10
O 20
+0.020
O 32
G
O 22 0
2-
R
.5
C0
G
67
A
R
Q
( 65 )
0
12
0.5
8 5
O
n 0.01 P
a 0.01 Q
O 86
16.352 0
+0.010
n 0.01 P
SECTION A-A
THRU.
貫通
EQ.SP.
周上等配
RELIEF
逃げ
SECTION 断面
注）
NOTE)
全周糸面取りの事。
ALL EDGES SHOULD BE CHAMFERED
C0.1～C0.5.
Fig.1.10 (e) Mounting fixture for input gear of J3-axis motor A290-7221-X976
- 14 -
( 15 )
R
1
2.PERIODIC MAINTENANCE
B-82755EN/05
2
PERIODIC MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter.
(See the APPENDIX C PERIODIC MAINTENANCE TABLE.)
2.1
Replacing the Batteries (1 Year (3,840 Hours) or (1.5 Year
(5,760 Hours) Checks)
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced
every 1 year in case of ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L ARC Mate
100iC/10S, M-10iA/10S and 1.5 year in case of ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L,
M-10iAe/6L. Also, use the following procedure to replace when the backup battery voltage drop alarm
occurs.
Procedure of replacing the battery
1
Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.
CAUTION
Be sure to keep the controller power on.
Replacing the batteries with the power supply turned off causes all current
position data to be lost. Therefore, mastering will be required again.
2
3
4
5
Remove the battery case cap. (Fig. 2.1 (a) - (c))
Take out the old batteries from the battery case. In this time, battery can be taken out by pulling the
stick of the center of the battery box.
Insert new batteries into the battery case. Pay attention to the direction of batteries.
Close the battery case cap.
CAUTION
When using a robot with the severe dust/liquid protection option, remove the
cover from the battery case as shown in Fig. 2.1 (b) to replace the battery. After
replacing the battery, reinstall the cover. In this time, please be sure to replace
packing to new one for effects of severe dust/liquid protection.
- 15 -
2.PERIODIC MAINTENANCE
B-82755EN/05
Battery can be taken out
by pulling this stick.
Battery case
Case cap
Battery spec:A98L-0031-0027
(C battery 4pcs)
Fig.2.1 (a) Replacing the battery
Battery cover mounting bolt
M5X10 (4pcs)
Battery cover
Packing for battery cover
A290-7221-Z236
Battery case
Case cap
Battery spec:A98L-0031-0027
(C battery 4pcs)
Fig.2.1 (b) Replacing the battery (When severe dust/liquid protection option is specified)
- 16 -
2.PERIODIC MAINTENANCE
B-82755EN/05
Battery case
Battery spec:A98L-0031-0005
(D battery 4 pcs)
Case cap
Fig.2.2.1 (c) Replacing the battery
(ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)
2.2
REPLACING THE GREASE AND OIL OF THE DRIVE
MECHANISM (3 YEARS (11,520 HOURS) CHECKS)
Replace the grease of the reducers of J1, J2, and J3 axes and oil of the J4/J5/J6-axis gearbox in cycle that
is shorter among every three years and 11,520 hours by using the following procedures.
See table 2.2 (a) for the grease name and the quantity for J1 to J3 axis. See table 2.2 (b) for the oil name
and the quantity for J4 to J6 axis.
Table 2.2 (a) Grease name and amount to be replaced at regular intervals of three years (11,520 hours)
Greasing points
Amount of grease to be applied
Gun tip pressure
Specified grease
J1-axis reducer
J2-axis reducer
J3-axis reducer
785g(872ml)
300g(333ml)
167g(186ml)
0.1MPa or less
(NOTE 1)
Kyodo Yushi
VIGOGREASE RE0
(Specification: A98L-0040-0174)
Table 2.2 (b) Oil name and amount of standard to be replaced at regular intervals of three years
(11,520 hours)
Amount of oil to be applied
Gun tip pressure
Specified oil
Oiling points
(NOTE 2)
J4-axis gearbox
408g(480ml)
J5/J6-axis gearbox
340g(400ml)
0.1MPa or less
(NOTE 1)
- 17 -
Nippon Oil Corporation
BONNOC AX68
(Specification: A98L-0040-0233)
2.PERIODIC MAINTENANCE
B-82755EN/05
NOTE
When using a hand pump, apply grease approximately once per two seconds.
It is not a regulated amount injection. Be sure to confirm the amount of oil with the
oil gauge.
Please supplyl oil until oil level is
3/4 or more ot the total height.
H
Please supply oil until oil level is
3/4 or more ot the total height.
Please pay attention to the posture
of robot when the oig gauge is
comfirmed referring to subection 7.2.2.
Please pay attention to the posture
of robot when the oig gauge is
comfirmed referring to subection 7.2.2.
L
In case of rising sun flag type oil gauge
In case of "H-L" type oil gauge
Fig.2.2 (a) Oil gauge
For grease and oil replacement or replenishment, use the postures indicated below.
Consider relative angle of from posture of floor mount when robot is angle mount.
There is no brake for wrist axes of RC Mate 100iCe, M-10iAe, ARC Mate 100iCe/ 6L, M-10iAe/6L, so
be careful not to drop the axes.
- 18 -
2.PERIODIC MAINTENANCE
B-82755EN/05
Supply position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gearbox
Wrist (using oil pump)
Wrist (not using oil pump)
Wrist (Replenishment)
Wrist (Oil discharge)
Wrist (confirm oiling)
Wrist (Release remaining
pressure)
Table 2.2 (c) Postures for greasing and oiling (Floor mount)
Posture
J1
J2
J3
J4
Arbitrary
Arbitrary
0°
0°
Arbitrary
J5
J6
Arbitrary
Arbitrary
Arbitrary
Arbitrary
0°
180°
18°
18°
90°
-30°
0°
-40°
90°
0°
-70°
0°
0°
20° to 90°
90°
Arbitrary
Table 2.2 (d) Postures for greasing and oiling (Upside-down mount)
Posture
Supply position
J1
J2
J3
J4
J5
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gearbox
Arbitrary
Arbitrary
-90°
0°
Arbitrary
Arbitrary
Arbitrary
Wrist (using oil pump)
-18°
140°
-18°
-90°
Wrist (Replenishment)
-90°
0°
Wrist (Oil discharge)
30°
110°
Wrist (confirm oiling)
180°
0°
20° to 90°
90°
Table 2.2 (e)
Supply position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gearbox
J6
Arbitrary
180°
0°
Wrist (not using oil pump)
Wrist (Release remaining
pressure)
Arbitrary
0°
Arbitrary
Postures for greasing and oiling (-90°wall mount)
Posture
J1
J2
J3
J4
J5
J6
Arbitrary
Arbitrary
90°
0°
Arbitrary
Arbitrary
Arbitrary
Arbitrary
Arbitrary
0°
90°
Wrist (using oil pump)
-72°
-40°
Wrist (not using oil pump)
-72°
90°
Wrist (Replenishment)
0°
0°
Wrist (Oil discharge)
-210°
-70°
Wrist (confirm oiling)
-90°
0°
0° to 70°
90°
Wrist (Release remaining
pressure)
- 19 -
0°
Arbitrary
2.PERIODIC MAINTENANCE
Table 2.2 (f)
Supply position
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis gearbox
B-82755EN/05
Postures for greasing and oiling (+90°wall mount)
Posture
J1
J2
J3
J4
J5
J6
Arbitrary
Arbitrary
-90°
0°
Arbitrary
Arbitrary
Arbitrary
Arbitrary
Arbitrary
0°
-90°
Wrist (using oil pump)
108°
-40°
Wrist (not using oil pump)
108°
90°
Wrist (Replenishment)
180°
0°
Wrist (Oil discharge)
150°
-70°
Wrist (confirm oiling)
90°
0°
110° to 180°
90°
Wrist (Release remaining
pressure)
0°
Arbitrary
Upside-down mount
-90°wall mount
+90°wall mount
Fig.2.2 (b) Installation method
- 20 -
2.PERIODIC MAINTENANCE
B-82755EN/05
Oil gauge
for J4-axis gearbox
A
J4-axis gearbox oil inlet
taper plug R1/8
VIEW A
J1-axis reducer grease outlet
seal bolt M8X10
Fig.2.2 (c) greasing point of reducer and oil supplying points of gearbox (1)
(ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L,ARC Mate 100iCe, M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L)
Oil gauge
for J5/J6-axis gearbox
J2-axis reducer grease inlet
taper plug R1/8
VIEW B
J5/J6-axis gearbox
first oil inlet (when oil pump is used)
Extra low bolt M6X8 & seal washer
J5/J6-axis gearbox
oil outlet
Extra low bolt M8X8
& seal washer
J3-axis reducer grease inlet
seal bolt M6X8 or
bolt M6X10 ＆ seal washer
J3-axis reducer grease outlet
seal bolt M8X10
Refer to the
note of lower right.
J5/J6-axis gearbox
ventilator hole when replacing oil
Extra low bolt M5X8 ＆seal washer
J5/J6-axis gearbox
second oil inlet (When oil pump is not used)
Extra low bolt M6X8
&seal washer
B
J2-axis reducer grease outlet
seal bolt M8X10
Note)
Thre is a case that position of
J3-axis grease outlet is figure below
depending on the time of shippment.
J1-axis reducer grease inlet
taper plug R1/8
J3-axis reducer grease outlet
seal bolt M8X10
Fig.2.2 (d) Greasing point of reducer and oil supplying points of gearbox (2)
ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L,ARC Mate 100iCe, M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L)
- 21 -
2.PERIODIC MAINTENANCE
B-82755EN/05
J4-axis gearbox oil outlet
taper plug R1/8
or
seal bolt M8X10
Fig.2.2 (e) greasing point of reducer and oil supplying points of gearbox (3)
(ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L,ARC Mate 100iCe, M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L)
Oil gauge
for J4-axis gear box
A
A
J4-axis gearbox
oil inlet
taper plug R1/8
J4-axis gearbox
ventilator hole
taper plug R1/8
SECTION A-A
J1-axis reducer grease outlet
seal bolt M8X10
Fig.2.2.1 (f) greasing point of reducer and oil supplying points of gearbox (1)
(ARC Mate 100iC/10S,M-10iA/10S)
- 22 -
2.PERIODIC MAINTENANCE
B-82755EN/05
J5/J6-axis gearbox
oil outlet
Extra low bolt M8X8
& seal washer
J2-axis reducer
grease inlet
taper plug R1/8
VIEW B
J3-axis reducer
grease inlet
bolt M6X10
＆ seal washer
J5/J6-axis gearbox
first oil inlet
(when oil pump is used)
Extra low bolt M6X8
& seal washer
Oil gauge
for J5/J6-axis gearbox
J5/J6-axis gearbox
ventilator hole
when replacing oil
Extra low bolt M5X8
＆seal washer
B
J5/J6-axis gearbox
second oil inlet
(When oil pump is not used)
Extra low bolt M6X8
&seal washer
J3-axis reducer grease outlet
seal bolt M8X10
J2-axis reducer grease outlet
seal bolt M8X10
J1-axis reducer grease inlet
taper plug R1/8
Fig.2.2.1 (g) greasing point of reducer and oil supplying points of gearbox (2)
(ARC Mate 100iC/10S,M-10iA/10S)
J4-axis gearbox oil outlet
seal bolt M8X10
Fig.2.2.1 (h) greasing point of reducer and oil supplying points of gearbox (3)
(ARC Mate 100iC/10S,M-10iA/10S)
- 23 -
2.PERIODIC MAINTENANCE
B-82755EN/05
Table 2.2 Specification of seal bolts, taper plug and seal washer
Parts name
Specification
Seal bolt (M6X8)
Seal bolt (M8X10)
taper plug (R1/8)
seal washer (M5)
seal washer (M6)
seal washer (M8)
2.2.1
A97L-0218-0417#060808
A97L-0218-0417#081010
A97L-0001-0436#1-1D
A30L-0001-0048#5M
A30L-0001-0048#6M
A30L-0001-0048#8M
Grease replacement procedure for the reducer (J1 to J3-axis)
CAUTION
If greasing is performed incorrectly, the internal pressure of the grease bath may
suddenly increase, possibly causing damage to the seal, which would in turn
lead to grease leakage and abnormal operation. When performing greasing,
therefore, observe the following cautions.
1 Before starting to grease, open the grease outlet (remove the seal bolt from
the grease outlet).
2 Supply grease slowly, using a manual pump.
3 Whenever possible, avoid using an air pump, which is powered by the factory
air supply.
If the use of an air pump is unavoidable, supply grease with the pump at a
pressure lower than or equal to the gun tip pressure (see Table 2.2 (a)).
4 Use grease only of the specified type. Grease of a type other than that
specified may damage the reducer or lead to other problems.
5 After greasing, release remaining pressure from the grease bath using the
procedure given in Subsection 2.2.3, and then close the grease outlet.
6 To prevent accidents caused by slipping, completely remove any excess
grease from the floor or robot.
Grease replacement procedure of the J1, J2, J3-axis reducer
1
2
3
4
5
6
Move the robot to the greasing posture described in Table.2.2 (c) to (f).
Turn off the controller power.
Remove the taper plug or seal bolt from grease outlet. (Fig.2.2 (c) to 2.2 (h))
Remove the taper plug or seal bolt from grease inlet and attach grease nipple.
Keep greasing until the new grease pushes out the old grease and comes out from each grease outlet
Release remaining pressure using the procedure given in Subsection 2.2.3.
2.2.2
Oil replacement procedure for the gearbox (J4 to J6-axis)
NOTE
Operation with oil shortage may cause severe damage to gears. Please make
sure the gearbox is always filled with correct amount of oil.
1
2
3
In case of J4-axis, move the robot to the oil-replacing posture described in Table 2.2 (c) to (f). In
case of J5/J6-axis, move the robot to the posture of wrist (oil discharge).
Turn off the controller power.
Put the collection bottle under the oil outlet.
(In case of J4-axis gearbox)
Remove any peripheral equipment, which has been mounted at the J4 oil outlet. In case of ARC
Mate 100iC/10S,M-10iA/10S, remove ventilator hole, too. And remove J4 connector plate
- 24 -
2.PERIODIC MAINTENANCE
B-82755EN/05
4
mounting bolts so that you cans see plug of oil inlet. In this time, pay attention not to cut nylon
band which is attached to mechanical unit cable. There is a case to have to take connector of
user side and air joint off for move the connector panel. Afterwards remove the taper plug of oil
inlet and outlet.
(In case of J5/J6-axis gearbox)
Remove the extra low bolt M8×8 and seal washer.(See Fig.2.2 (c) to (e))
Install the taper plug or extra low bolt and seal washer in the oil outlet after all oil is exhausted.
In case of ARC Mate 100iC/10S,M-10iA/10S, attach taper plug of ventilator hole, too
(In case of J4-axis gearbox)
Firstly, supply oil of 150ml, attach taper plug of oil inlet, in case of ARC Mate
100iC/10S,M-10iA/10S, attach taper plug of ventilator hole, too, make the robot to J3-axis 0º,
remove seal bolt of J4-axis oil outlet, furthermore add oil of 330ml.
When the adapter for oiling (A290-7221-X591) is used, oiling is easy. Install it as shown in
Fig.2.2.2 (b) when you use the oiling adapter. The amounts of oiling are about as many as two
adapters. It takes about five minutes to oil as many as one cup. Attach seal bolt of J4-axis oil
outlet after supplying oil.
(In case of J5/J6-axis gearbox)
1) When oil pump is used
Oil from the J5/J6 axis gearbox first oil inlet (M6) of Fig. 2.2 (d) when you use the oil pump.
At this time, make robot to the posture of wrist (using oil pump). In addition, oil after opening
the oil outlet of the J6 axis crossing roller ring. At this time, stop the M8 oil out once after it
puts it from the M8 oil discharge entrance to going out, make to the posture of wrist
(Replenishment). This time, and add oil from the second oil inlet (M5) with the syringe etc.
Stop it because oil comes out from the oil inlet by about 15ml. Make robot to the posture of
wrist (confirm oiling) at the end and confirm the amount of the oil gauge.
2) When oil pump is not used
Remove the extra low bolt and seal washer of oil inlet and ventilator hole of Fig.2.2 (d), move
the robot posture of wrist (not using oil pump) and add oil. When the adapter for oiling
(A290-7221-X591) is used, oiling is easy. Install it to second oil inlet as shown in Fig.2.2.2 (b)
and add oil when you use the oiling adapter. The amounts of oiling are about as many as two
adapters. It takes about five minutes to oil as many as one cup.
When oil come ventilator hole, remove adapter and move the robot to the posture of wrist
(confirm oiling) and check oil gauge referring to Fig.2.2.2 (c). In case oil level is insufficient,
please fine-tune it by replenishing it with a syringe. Then turn J4-axis 90°and put it back and
confirm height of oil level is 3/4 or more. When oil amount is insufficient, make robot to the
posture of wrist (Replenishment) this time, and add oil from the second oil inlet (M5) with the
syringe etc. Stop it because oil comes out from the oil inlet by about 15ml and close the oil inlet.
Make robot to the posture of wrist (confirm oiling) at the end and confirm the amount of the oil
gauge.
3) When using oil gun
Attach oil injection nipple with valve (A05B-1221-K002) to J5/J6-axis gearbox first oil inlet of
Fig.2.2 (d),(g). Attach oil tray with valve (A05B-1221-K003) to J5/J6-axis gearbox oil outlet
(J6-axis cross roller part). Confirm valve of oil inlet and oil outlet are open referring to
Fig.2.2.2 (d). Supply oil to J5/J6-axis gearbox first oil inlet till oil is come out come from oil
outlet by oil injection gun (A05B-1221-K005). When oil appears from oil outlet, stop
supplying oil and close the valve of oil injection nipple. After that, close the valve of oil tray,
remove tray and close the oil outlet. Then remove oil injection nipple and close the oil inlet.
Make robot to the posture of wrist (Replenishment) this time, and add oil from the second oil
inlet (M5) with the syringe etc. Stop it because oil comes out from the oil inlet by about 15ml
and close the oil inlet. Finally make robot to the posture of wrist (confirm oiling) at the end and
confirm the amount of the oil gauge. Then turn J4-axis 90°and put it back and confirm height
of oil level is 3/4 or more. If oil is sufficient replenish oil with sponge and adjust it.
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2.PERIODIC MAINTENANCE
B-82755EN/05
CAUTION
If supplying oil forcibly when valve is closed, internal pressure of oil bath rise
abnormally and cause oil leak from seal part or oil seal falling out. Be careful
5
Release remaining pressure using the procedure given in Subsection 2.2.4.
If equipment is installed to this surface,
remove it.
Bolt M6X10
J4 connector panel
Bolt M6X10
J4 connector panel
ARC Mate 100iC/10S , M-10iA/10S
ARC Mate 100iC , M-10iA
ARC Mate 100iC/6L , M-10iA/6L
ARC Mate 100iCe , M-10iAe
ARC Mate 100iCe/6L , M-10iAe/6L
Fig.2.2.2 (a) Replacing oil of J4-axis gearbox
Remove this bolt.
J4-axis gearbox
In case of J5/J6-axis
Fig.2.2.2 (b) Oiling adapter
Please supply oil until oil level is
3/4 or more of the total height.
Please supply oil until oil level is
3/4 or more of the total height.
H
L
In case of rising sun flag type oil gauge
In case of "H-L" type oil gauge
Fig.2.2.2 (c) Standard of oil gauge
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2.PERIODIC MAINTENANCE
B-82755EN/05
Oil tray with valve
A05B-1221-K007
White line
Oil injection nipple with valve
A05B-1221-K006
Valve is open
Valve is closed
Oil injection gun
A05B-1221-K005
Fig.2.2.2 (d) Oiling by oil gun
2.2.3
Procedure for releasing remaining pressure from the grease
bath (J1 to J3-axis)
After applying grease, operate the robot as instructed below with the taper plug and seal bolt of the grease
inlet and outlet uncapped to release the remaining pressure within the grease bath. In case of J2-axis, there
are two seal bolts for grease outlet, so uncap both of them.
Attach a recovery bag below the grease inlet and outlet to prevent output grease from splattering.
Operating axis
Grease
replacement part
J1-axis
J1-axis reducer
Axis angle
of 60° or
more
OVR 100%
J2-axis reducer
J3-axis reducer
Arbitrary
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
Arbitrary
Axis angle
of 60° or
more
OVR 100%
Arbitrary
Arbitrary
Axis angle
of 60° or
more
OVR 100%
Arbitrary
If the above operation cannot be performed due to the environment of the robot, prolong the operating
time so that an equivalent operation can be performed. (When the maximum allowable axis angle is 30
- 27 -
2.PERIODIC MAINTENANCE
B-82755EN/05
degrees, perform the twice operation for 20 minutes or more.) After completion of the operation, attach
the taper plug and seal bolts to the grease inlets and outlets. When reusing the taper plug and seal bolts,
be sure to seal them with seal tape.
After replacing grease or oil, grease bath or oil bath may rise if robot is operated again under frequent
inversion movement or high temperature environment. In these cases, you can return internal pressure by
releasing grease out let or oil outlet just after operation of robot. (When opening grease outlet or oil outlet,
refer to Section 2.2 and pay attention grease or oil is not scattered.)
2.2.4
Procedure for releasing oil (J4 to J6-axis)
After replacing oil, please do the following operation to adjust the amount of oil properly.
In case of J4-axis gearbox
Confirm that oil level seen in oil gauge is as per Fig.2.2.2 (c). If confirmed then please operate robot J4
axis during 10 minutes, at 100% override, making 90 degrees motion (or more). Keep oil inlet and oil
outlet closed during this operation. When completed, move the robot posture so that J4-gearbox oil outlet
is right above. (In case of floor mount, J3=0°.) Remaining pressure release at once if upper side of oil
inlet/outlet is opened. When removing oil outlet, please work while covering the oil outlet in wastes so
that oil may protrude.
After operation, confirm whether the oil side of the oil gauge has come above the 3/4 or more of the total
height, add oil from the J4 axis gearbox oil inlet with the syringe etc. when oil is a little. In addition,
attach taper plug of the oil inlet.
Wipe the oil that adheres to the surface of the robot off when confirming it and close the oil inlet/outlet
completely.
In case of J5/J6-axis gearbox
Confirm that oil level seen in oil gauge is as per Fig.2.2.2 (c). If confirmed then please jog robot to the
posture of wrist (Release remaining pressure). Attach extra low bolt and seal washer of the oil inlet but
keep it loose. Operate robot J5 and J6 axis during 10 minutes, at 100% override, making 90 degrees
motion (or more) on both axis. When completed, please jog to the posture of wrist (Replenishment).
Remaining pressure release at once if second oil inlet (M5) is opened.
Confirm that oil level seen in oil gauge is above 3/4 or more of total height. At this time, please rotate the
J4 axis in the direction of +/-, and confirm the thing that the amount of oil doesn't decrease. Move robot
to the posture of wrist (Replenishment) again and add oil from the second oil inlet (M5) with the syringe
etc. when decreasing after operation, attach taper plug of the oil inlet.
Wipe the oil that adheres to the surface of the robot off when confirming it and close the first oil inlet
completely. Be sure to wind seal tape to thread part when taper plug is reused.
When tightening bolts of oil inlet and oil outlet, confirm seal washer is attached before tightening bolts.
Be sure to wind seal tape to thread part when seal tape is reused.
If the above operation cannot be performed due to the environment of the robot, prolong the operating
time so that an equivalent operation can be performed. (When the maximum allowable axis angle is 45
degrees, perform the twice operation for 20 minutes or more.) After completion of the operation, attach
the taper plug to the oil inlets.
After replacing grease or oil, grease bath or oil bath may rise if robot id operated again under frequent
inversion movement or high temperature environment. In these cases, you can return internal pressure by
releasing grease out let or oil outlet just after operation of robot. (When opening grease outlet or oil outlet,
refer to Section 2.2 and pay attention grease or oil is not scattered.)
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2.PERIODIC MAINTENANCE
B-82755EN/05
CAUTION
When reusing seal bolt and taper plug, be sure to seal t thread part with seal
tape.
As for the seal washer, n one side, rubber sticks to the entire and the other side,
rubber sticks to only around hole and rubber sticks is incomplete state, Attach
later face to bolt side. Confirm seal washer by viewing. If it is damaged
obviously, replace it to new one.
See Table 2.2 about specification of seal bolts and seal washer.
- 29 -
3.TROUBLESHOOTING
B-82755EN/05
3
TROUBLESHOOTING
3.1
GENERAL
The source of mechanical unit problems may be difficult to locate because of overlapping causes.
Problems may become further complicated, if they are not corrected properly. Therefore, it is necessary to
keep an accurate record of problems and to take proper corrective actions.
3.2
FAILURES, CAUSES AND MEASURES
Table 3.2 (a) lists the major failures that may occur in the mechanical unit and their probable causes. If
you cannot pinpoint a failure cause or which measures to apply, contact FANUC.
Symptom
Vibration
Noise
Table 3.2 (a) Failures, causes and measures
Description
Cause
-The J1 base lifts off the floor
plate as the robot operates.
-There is a gap between the
J1 base and floor plate.
-A J1 base-retaining bolt is
loose.
-The rack or floor plate
vibrates during operation of
the robot.
-Vibration becomes more
serious when the robot adopts
a specific posture.
-If the operating speed of the
robot is reduced, vibration
stops.
-Vibration is most noticeable
when the robot is accelerating.
-Vibration occurs when two or
more axes operate at the
same time.
[J1 base fastening]
-It is likely that the robot J1
base is not securely fastened to
the floor plate.
-Probable causes are a loose
bolt, an insufficient degree of
surface flatness, or foreign
material caught between the J1
base and floor plate.
-If the robot is not securely
fastened to the floor plate, the
J1 base lifts the floor plate as
the robot operates, allowing the
base and floor plates to strike
each other, which, in turn, leads
to vibration.
[Rack or floor]
-It is likely that the rack or floor
is not sufficiently rigid.
-If the rack or floor is not
sufficiently rigid, reaction from
the robot deforms the rack or
floor, leading to vibration.
[Overload]
-It is likely that the load on the
robot is greater than the
maximum rating.
-It is likely that the robot control
program is too demanding for
the robot hardware.
-It is likely that the
ACCELERATION value is
excessive.
- 30 -
Measure
-If a bolt is loose, apply
LOCTITE and tighten it to the
appropriate torque.
-Adjust the floor plate surface
flatness to within the specified
tolerance.
-If there is any foreign matter
between the J1 base and floor
plate, remove it.
-Reinforce the rack or floor to
make it more rigid.
-If it is impossible to reinforce
the rack or floor, modify the
robot control program; doing so
might reduce the amount of
vibration.
-Check the maximum load that
the robot can handle once
more. If the robot is found to be
overloaded, reduce the load, or
modify the robot control
program.
-Vibration in a specific portion
can be reduced by modifying
the robot control program while
slowing the robot and reducing
its acceleration (to minimize the
influence on the entire cycle
time).
3.TROUBLESHOOTING
B-82755EN/05
Symptom
Description
Cause
Vibration
Noise
(Continued)
-Vibration was first noticed
after the robot collided with an
object or the robot was
overloaded for a long period.
-The grease of the vibrating
axis has not been exchanged
for a long period.
[Broken gear, bearing, or
reducer]
- It is likely that collision or
overload applied an excessive
force on the drive mechanism,
thus damaging the geartooth
surface or rolling surface of a
bearing, or reducer.
- It is likely that prolonged use
of the robot while overloaded
caused fretting of the gear tooth
surface or rolling surface of a
bearing, or reducer due to
resulting metal fatigue.
- It is likely that foreign matter
caught in a gear, bearing, or
within a reducer caused
damage on the gear tooth
surface or rolling surface of the
bearing, or reducer.
- It is likely that, because the
grease has not been changed
for a long period, fretting
occurred on the gear tooth
surface or rolling surface of a
bearing, or reducer due to metal
fatigue.
These factors all generate cyclic
vibration and noise.
- 31 -
Measure
-Operate one axis at a time to
determine which axis is
vibrating.
-Confirm the oil side of the oil
gauge of J4-J6 axis.
Replenish oil when the oil side
has not reached above the half.
-Remove the motor, and
replace the gear, the bearing,
and the reducer. For the spec.
of parts and the method of
replacement, contact FANUC.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
3.TROUBLESHOOTING
B-82755EN/05
Symptom
Description
Cause
Vibration
Noise
(Continued)
-The cause of problem cannot
be identified from examination
of the floor, rack, or
mechanical section.
[Controller, cable, and motor]
-If a failure occurs in a controller
circuit, preventing control
commands from being supplied
to the motor normally, or
preventing motor information
from being sent to the controller
normally, vibration might occur.
-If the Pulsecoder develops a
fault, vibration might occur
because
Information about the motor
position cannot be transferred
to the controller accurately.
-If the motor becomes defective,
vibration might occur because
the motor cannot deliver its
rated performance.
-If a power line in a movable
cable of the mechanical section
has an intermittent break,
vibration might occur because
the motor cannot accurately
respond to commands.
-If a Pulsecoder wire in a
movable part of the mechanical
section has an intermittent
break, vibration might occur
because commands cannot be
sent to the motor accurately.
-If a connection cable between
them has an intermittent break,
vibration might occur.
-If the power cable has an
intermittent break, vibration
might occur.
-If the power source voltage
drops below the rating, vibration
might occur.
-If a robot control parameter is
set to an invalid value, vibration
might occur.
- 32 -
Measure
-Refer to the controller
Maintenance Manual for
troubleshooting related to the
controller and amplifier.
-Replace the Pulsecoder for the
motor of the axis that is
vibrating and check whether the
vibration still occurs.
-Also, replace the motor of the
axis that is vibrating, and check
whether vibration still occurs.
For the method of replacement,
contact FANUC.
-Check that the robot is
supplied with the rated voltage.
-Check whether the sheath of
the power cord is damaged. If
so, replace the power cord, and
check whether vibration still
occurs.
-Check whether the sheath of
the cable connecting the
mechanical section and
controller is damaged. If so,
replace the connection cable,
and check whether vibration still
occurs.
-If vibration occurs only when
the robot assumes a specific
posture, it is likely that a cable
in the mechanical unit is broken.
-Shake the movable part cable
while the robot is at rest, and
check whether an alarm occurs.
If an alarm or any other
abnormal condition occurs,
replace the mechanical unit
cable.
-Check that the robot control
parameter is set to a valid
value. If it is set to an invalid
value, correct it. Contact
FANUC for further information if
necessary.
3.TROUBLESHOOTING
B-82755EN/05
Symptom
Description
Cause
Vibration
Noise
(Continued)
-There is some relationship
between the vibration of the
robot and the operation of a
machine near the robot.
[Noise from a nearby machine]
-If the robot is not grounded
properly, electrical noise is
induced on the grounding wire,
preventing commands from
being transferred accurately,
thus leading to vibration.
-If the robot is grounded at an
unsuitable point, its grounding
potential becomes unstable,
and noise is likely to be induced
on the grounding line, thus
leading to vibration.
-There may be an unusual
sound when using other than
the specified grease.
-Even for the specified grease,
there may be an unusual sound
during operation at low speed
immediately after replacement
or after a long period.
-There is a possibility of grease
or oil has not been exchanged
accurately. The amount of
grease or oil may be
insufficient.
-There is an unusual sound
after replacement of grease.
-There is an unusual sound
after a long period.
-There is an unusual sound
during operation at low speed.
-There is an unusual sound
when operating right
immediately the replacing part,
grease or oil.
- 33 -
Measure
-Connect the grounding wire
firmly to ensure a reliable
ground potential and prevent
extraneous electrical noise.
-Use the specified grease.
-When there is an unusual
sound even for specified
grease, perform operation for
one or two days on an
experiment. Generally, a usual
sound will disappear.
-Stop the robot, and confirm the
damage situation at once.
-Replenish grease or oil when
they are insufficient.
3.TROUBLESHOOTING
Symptom
Rattling
B-82755EN/05
Description
Cause
Measure
-While the robot is not
supplied with power, pushing it
with the hand causes part of
the mechanical unit to wobble.
-There is a gap on the
mounting face of the
mechanical unit.
[Mechanical section coupling
bolt]
-It is likely that overloading or a
collision has loosened a
mounting bolt in the robot
mechanical section.
-Backlash is greater than the
tolerance stated in the
applicable maintenance
manual. (See Section 3.3/)
[Increase in backlash]
-It is likely that excessive force
applied to the drive mechanism,
due to a collision or
overloading, has broken a gear
or the inside of the reducer,
resulting in an increase in the
amount of backlash.
-It is likely that prolonged use
has caused the tooth surfaces
of a gear and the inside of the
reducer to wear out, resulting in
an increase in the amount of
backlash.
-It is likely that prolonged use
without changing the grease
has caused the tooth surfaces
of a gear and the inside of the
reducer to wear out, resulting in
an increase in the amount of
backlash.
-Check that the following bolts
for each axis are tight. If any of
these bolts is loose, apply
LOCTITE and tighten it to the
appropriate torque.
-Motor retaining bolt
-Reducer retaining bolt
-Reducer shaft retaining bolt
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
-Operate one axis at a time to
determine which axis has the
increased backlash.
-Remove the motor, and check
whether any of its gears are
broken. If any gear is broken,
replace it.
-Check whether any other gear
of the drive mechanism is
damage. If there is no damage
gear, replace the reducer.
-If the reducer is broken, or if a
gear tooth is missing, replace
the relevant component. Also,
remove all the grease or oil
from the gearbox and wash the
inside of the gearbox.
-After replacing the gear or
reducer, add an appropriate
amount of grease or oil.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly applying the grease
or oil with a specified type can
help prevent problems.
- 34 -
3.TROUBLESHOOTING
B-82755EN/05
Symptom
Description
Cause
Measure
Motor
overheating
-The ambient temperature of
the installation location
increases, causing the motor
to overheat.
-After a cover was attached to
the motor, the motor
overheated.
-After the robot control
program or the load was
changed, the motor
overheated.
[Ambient temperature]
-It is likely that a rise in the
ambient temperature or
attaching the motor cover
prevented the motor from
releasing heat efficiently, thus
leading to overheating.
[Operating condition]
-It is likely that the robot was
operated with the maximum
average current exceeded.
-After a control parameter was
changed, the motor
overheated.
[Parameter]
-If data input for a workpiece is
invalid, the robot cannot be
accelerated or decelerated
normally, so the average
current increases, leading to
overheating.
[Mechanical section problems]
-It is likely that problems
occurred in the mechanical unit
drive mechanism, thus placing
an excessive load on the motor.
[Motor problems]
-It is likely that a failure of the
motor brake resulted in the
motor running with the brake
applied, thus placing an
excessive load on the motor.
-It is likely that a failure of the
motor prevented it from
delivering its rated performance,
thus causing an excessive
current to flow through the
motor.
-The teach pendant can be
used to monitor the average
current. Check the average
current when the robot control
program is running. The
allowable average current is
specified for the robot according
to its ambient temperature.
Contact FANUC for further
information.
-Relaxing the robot control
program and conditions can
reduce the average current,
thus preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of the
motor well ventilated enables
the motor to release heat
efficiently, thus preventing
overheating. Using a fan to
direct air at the motor is also
effective.
-If there is a source of heat near
the motor, it is advisable to
install shielding to protect the
motor from heat radiation.
-Input an appropriate parameter
as described in CONTROLLER
OPERATOR’S MANUAL.
-Symptom other than stated
above
- 35 -
-Repair the mechanical unit
while referring to the above
descriptions of vibration, noise,
and rattling.
-Check that, when the servo
system is energized, the brake
is released.
If the brake remains applied to
the motor all the time, replace
the motor.
-If the average current falls after
the motor is replaced, it
indicates that the first motor was
faulty.
3.TROUBLESHOOTING
Symptom
Grease oil
leakage
B-82755EN/05
Description
Cause
Measure
-Grease or oil is leaking from
the mechanical unit.
[Poor sealing]
-Probable causes are a crack in
the casting, a broken O-ring, a
damaged oil seal, or a loose
seal bolt.
-A crack in a casting can occur
due to excessive force that
might be caused in collision.
-An O-ring can be damaged if it
is trapped or cut during
disassembling or
re-assembling.
-An oil seal might be damaged if
extraneous dust scratches the
lip of the oil seal.
-A loose seal bolt might allow
grease to leak along the
threads.
-If a crack develops in the
casting, sealant can be used as
a quick-fix to prevent further
grease or oil leakage. However,
the component should be
replaced as soon as possible,
because the crack might
extend.
-O-rings are used in the
locations listed below.
-Motor coupling section
-Reducer (case and shaft)
coupling section
-Connection part of the wrist
-J3 arm coupling section
-Inside the wrist
-Oil seals are used in the
locations stated below.
-Inside the reducer
-Inside the wrist
-Seal bolts are used in the
locations stated below.
-Grease inlet/outlet
-Oil inlet/outlet
-For fix of cover
- 36 -
3.TROUBLESHOOTING
B-82755EN/05
Symptom
Description
Dropping axis -An axis drops because the
brake does not function.
-An axis drops gradually when
it should be at rest.
Cause
Measure
[Brake drive relay and motor]
-It is likely that brake drive relay
contacts are stuck to each other
to keep the brake current
flowing, thus preventing the
brake from operating when the
motor is reenergized.
-It is likely that the brake shoe
has worn out or the brake main
body is damaged, preventing
the brake from operating
efficiently.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
- In case of ARC Mate 100iCe ,
M-10iAe, ARC Mate 100iCe/6L,
M-10iAe/6L brake is not
installed for J1/J4/J5/J6-axes. In
case of J4/J5/J6-axes If you
turn off the controller power at
wait position, robot may move
greatly by weight or exceeds
stroke limit depend on the
posture of robot or wrist load
condition. Adjust the wait
position so that axis does not
move greatly when controller
power is turned off.
-Check whether the brake drive
relay contacts are stuck to each
other. If they are found to be
stuck, replace the relay.
-If the brake shoe is worn out, if
the brake main body is
damaged, or if oil or grease has
entered the motor, replace the
motor.
- J4-axis cable has movable
part .So if robot exceeds stroke
limit, load depends on cable and
it may cause damage of cables .
If robot exceeds stroke limit,
remove plate of back of J4,
return axis to motion range
during checking condition of
cables. If nylon band is cut,
attach new articles. If you
operate robot with nylon band is
cut, it cause damage of cables.
(See Section 6.1).
- 37 -
3.TROUBLESHOOTING
Symptom
B-82755EN/05
Description
Displacement -The robot operates at a point
other than the taught position.
-The repeatability is not within
the tolerance.
-Displacement occurs only in a
specific peripheral unit.
-Displacement occurred after a
parameter was changed.
BZAL alarm
occurred
-BZAL is displayed on the
controller screen
Cause
Measure
[Mechanical section problems]
-If the repeatability is unstable,
probable causes are a failure in
the drive mechanism or a loose
bolt.
-If the repeatability becomes
stable, it is likely that a collision
imposed an excessive load,
leading to slipping on the base
surface or the mating surface of
an arm or reducer.
-It is likely that the Pulsecoder is
abnormal.
[Peripheral unit displacement]
-It is likely that an external force
was applied to the peripheral
unit, thus shifting its position
relative to the robot.
[Parameter]
-It is likely that the mastering
data was rewritten in such a
way that the robot origin was
shifted.
-If the repeatability is unstable,
repair the mechanical section by
referring to the above
descriptions of vibration, noise,
and rattling.
-If the repeatability is stable,
correct the taught program.
Variation will not occur unless
another collision occurs.
-If the Pulsecoder is abnormal,
replace the motor or the
Pulsecoder.
-It is likely that the voltage of the
memory backup battery is low.
- It is likely that the Pulsecoder
cable is defected.
-Correct the setting of the
peripheral unit position.
-Correct the taught program.
-Re-enter the previous
mastering data, which is known
to be correct.
-If correct mastering data is
unavailable, perform mastering
again.
-Replace the battery.
-Replace the cable.
Table 3.2 (b) Allowable drops
At power off
At Power-Off stop
5mm
5mm
NOTE
Each value indicates the amount by which an end effector mounting face may
fall.
3.3
BACKLASH MEASUREMENT
Measurement method
1
2
3
Maintain the robot in a specified posture. (See Fig. 3.3 (b) to (d).)
Apply positive and negative loads to each axis as shown in Fig.3.3 (a).
Remove the loads and measure the displacement.
Measure backlash by applying positive and negative loads to each axis three times. Average the
values measured in the last two measurements for each axis, and use the averages as a measured
backlash for the respective axes.
- 38 -
3.TROUBLESHOOTING
B-82755EN/05
Stop position
0
+10kgf (J1 to J3-axis)
+ 3kgf (J4 to J6-axis)
First step
(Do not measure)
-10kgf (J1 to J3-axis)
- 3kgf (J4 to J6-axis)
+10kgf (J1 to J3-axis)
+ 3kgf (J4 to J6-axis)
-10kgf (J1 to J3-axis)
- 3kgf (J4 to J6-axis)
0kg
L2
L1
+10kgf (J1 to J3-axis)
+ 3kgf (J4 to J6-axis)
-10kgf (J1 to J3-axis)
- 3kgf (J4 to J6-axis)
0kg
Second step
(B2 =L1+ L2)
0kg
Third step
(B3=L3+ L4)
0kg
L3
L4
Fig.3.3 (a) Backlash measurement method
Backlash B is calculated using the following expression: B=
B2 + B3
2
1629 : ARC Mate 100iC, M-10iA
ARC Mate 100iCe, M-10iAe
1300 : ARC Mate 100iC/10S,M-10iA/10S
1760
56
Loading position
Loading positon
Measured position
ARC Mate 100iC, M-10iA
ARC Mate 100iC/10S, M-10iA/10S
ARC Mate 100iCe, M-10iAe
J1 Arbitrary
J2 80°
J3 0°
J4 0°
J5 0°
J6 ±90°
Measured position
ARC Mate 100iC/ 6L, M-10iA/6L
ARC Mate 100iCe/6L, M-10iAe/6L
<J1-axis measured posture>
Fig.3.3 (b) Backlash measured posture (1/3)
- 39 -
3.TROUBLESHOOTING
B-82755EN/05
Measured position
Loading positon
600 : ARC Mate 100iC, M-10iA
ARC Mate 100iCe, M-10iAe
ARC Mate 100iC/6L, M-10iA/6L
ARC Mate 100iCe/6L, M-10iAe/6L
400 : ARC Mate 100iC/10S, M-10iA/10S
J1 Arbitrary
J2 0°
J3 82°
J4 0°
J5 0°
J6 Arbitrary
<J2-axis measured posture>
500
500
Measured
position
Loading
position
Measured
position
J1 Arbitrary
J2 40°
J3 -105°
J4 -90°
J5 90°
J6 0°
Loading
position
ARC Mate 100iC, M-10iA
ARC Mate 100iCe, M-10iAe
J1 Arbitrary
J2 15°
J3 -100°
J4 -90°
J5 90°
J6 0°
ARC Mate 100iC/6L, M-10iA/6L
ARC Mate 100iCe/6L, M-10iAe/6L
500
J1 Arbitrary
J2 40°
J3 -105°
J4 -90°
J5 90°
J6 0°
Measured
position
Loading position
ARC Mate 100iC/10S, M-10iA/10S
<J3-axis measured posture>
Fig.3.3 (c) Backlash measured posture (2/3)
- 40 -
3.TROUBLESHOOTING
B-82755EN/05
mounting position of
magnet stand
Magnet stand
Dial gauge
Loading position
(Loading should be alingned with the
center of J5/J6-axes to avoid
the effect of J5/J6 backlash.)
109
J1 Arbitrary
J2 40°
J3 -90°
J4 -90°
J5 90°
J6 0°
<J4-axis measured position>
115
Loading position
(Loading position should
be loaded in the direction
of the rotation of J6-axis.)
45
Loading position
(Loading position should be aligned
with the center of J6-axis to avoid
the effect of J6 backlash.)
Magnet stand
Dial gauge
Mounting position
of magnet stand
Dial gauge
Mounting position
of magnet stand
Magnet stand
J1 Arbitrary
J2 0°
J3 0°
J4 -90°
J5 90°
J6 0°
J1 Arbitrary
J2 0°
J3 0°
J4 0°
J5 90°
J6 0°
<J6-axis measured posture>
<J5-axis measured posture>
Fig.3.3 (d) Backlash measured posture (3/3)
- 41 -
3.TROUBLESHOOTING
B-82755EN/05
Table.3.3 (a) Permissible backlash value (ARC Mate 100iC, ARC Mate 100iCe)
Angle conversion (arc-min)
Displacement conversion (mm)
Distance between the rotation
center and dial gauge (mm)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50
1.23
2.50
0.33
2.50
0.31
3.00
0.10
3.00
0.04
5.00
0.17
1629
600
500
109
45
115.
Table.3.3 (b) Permissible backlash value (M-10iA, M-10iAe)
Angle conversion (arc-min)
Displacement conversion (mm)
Distance between the rotation
center and dial gauge (mm)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50
1.23
2.50
0.33
2.50
0.31
4.00
0.13
4.00
0.05
6.00
0.20
1629
600
500
109
45
115
Table.3.3 (c) Permissible backlash value (ARC Mate 100iC/6L, ARC Mate 100iCe/6L)
Angle conversion (arc-min)
Displacement conversion (mm)
Distance between the rotation
center and dial gauge (mm)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50
1.27
2.50
0.33
2.50
0.31
3.00
0.10
3.00
0.04
5.00
0.17
1760
600
500
109
45
115
Table.3.3 (d) Permissible backlash value (M-10iA/6L, M-10iAe/6L)
Angle conversion (arc-min)
Displacement conversion (mm
Distance between the rotation
center and dial gauge (mm)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50
1.27
2.50
0.33
2.50
0.31
4.00
0.13
4.00
0.05
6.00
0.20
1760
600
500
109
45
115
Table.3.3 (e) Permissible backlash value (ARC Mate 100iC/10S)
Angle conversion (arc-min)
Displacement conversion (mm
Distance between the rotation
center and dial gauge (mm)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50
0.94
2.50
0.29
2.50
0.36
3.00
0.10
3.00
0.04
5.00
0.17
1300
400
500
109
45
115.5
Table.3.3 (f) Permissible backlash value
Angle conversion (arc-min)
Displacement conversion (mm
Distance between the rotation
center and dial gauge (mm)
(M-10iA/10S)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50
0.94
2.50
0.29
2.50
0.36
4.00
0.13
4.00
0.05
6.00
0.20
1300
400
500
109
45
115.5
NOTE
When measuring backlash under circumstances where the distance between the
rotation center and the dial gauge is different from those in the above table,
make angle and displacement conversions according to the table.
- 42 -
4.COMPONENT REPLACEMENT
B-82755EN/05
4
COMPONENT REPLACEMENT
Once motors, reducers, gearbox and wrist unit are replaced, mastering becomes necessary, perform
mastering according to Section 6 after any of these components is replaced.
NOTE
Be very careful when dismounting and mounting the heavy components that are
listed below.
Component
J3 arm
(See Fig. 4.11 (b), Fig.4.12 (a))
J3 arm
(See Fig. 4.11 (a))
All components from J3-axis reducer to wrist unit
(See Fig. 4.11 (b), Fig.4.12 (b))
All components from J3-axis reducer to wrist unit
(See Fig. 4.11 (b))
All components from J2 arm to wrist unit
(See Fig. 4.5 (b))
All components from J2 arm to wrist unit
(See Fig. 4.5 (b))
All components from J2 base to wrist unit
(See Fig. 4.3 (b))
All components from J2 base to wrist unit
(See Fig. 4.3 (b))
Wrist unit
(See Fig. 4.13 (a))
Model
ARC Mate 100iC, M-10iA
ARC Mate 100iC/10S, M-10iA/10S
ARC Mate 100iCe, M-10iAe
ARC Mate 100iC/6L, M-10iA/6L,
ARC Mate 100iCe/6L, M-10iAe/6L
ARC Mate 100iC, M-10iA,
ARC Mate 100iC/10S, M-10iA/10S,
ARC Mate 100iCe, M-10iAe
ARC Mate 100iC/6L, M-10iA/6L,
ARC Mate 100iCe/6L, M-10iAe/6L
ARC Mate 100iC, M-10iA
ARC Mate 100iC/10S, M-10iA/10S
ARC Mate 100iCe, M-10iAe
ARC Mate 100iC/6L, M-10iA/6L,
ARC Mate 100iCe/6L, M-10iAe/6L
ARC Mate 100iC, M-10iA
ARC Mate 100iC/10S, M-10iA/10S
ARC Mate 100iCe, M-10iAe
ARC Mate 100iC/6L, M-10iA/6L,
ARC Mate 100iCe/6L, M-10iAe/6L
All models
Weight
12.5 kg
14 kg
28 kg
29.5 kg
54 kg
55.5 kg
94.5 kg
96 kg
6kg
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 adhesion 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.
Be sure to wipe the excess LOCTITE after tightening screw.
NOTE
1 Description of [LT242] means LOCTITE 242.
2 Description of [LT262] means LOCTITE 262.
3 Description of [LT518] means LOCTITE 518.
4 Description of [LT675] means LOCTITE 675.
- 43 -
4.COMPONENT REPLACEMENT
4.1
B-82755EN/05
FIGURE OF DRIVE MECHANISM
The drive mechanisms of each axis are shown in the following.
AC servo motor
for J1-axis (M1)
J1-axis reducer
Gear
Fig.4.1 (a) Drive mechanism of J1-axis
J2 arm
J2-axis
reducer
Input gear
J2 base
AC servo motor
for J2-axis (M2)
Fig.4.1 (b) Drive mechanism of J2-axis
- 44 -
4.COMPONENT REPLACEMENT
B-82755EN/05
J3-axis reducer
Input gear
J2 arm
AC servo motor
for J3-axis (M3)
Fig.4.1 (c) Drive mechanism of J3-axis
Gear
Gear
AC servo motor
for J4-axis (M4)
Fig.4.1 (d) Drive mechanism of J4-axis
- 45 -
4.COMPONENT REPLACEMENT
B-82755EN/05
AC servo motor
for J5-axis(M5)
Gear
Gear
Hollow flange
Fig.4.1 (e) Drive mechanism of J5-axis
AC servo motor
for J6-axis(M6)
Drive shaft
Gear
Gear
Gear
Gear
Hollow flange
Fig.4.1 (f) Drive mechanism of J6-axis
4.2
1
2
3
4
5
6
7
8
9
10
11
REPLACING THE J1-AXIS MOTOR M1
Set dial gauges at J1-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the J1-axis motor connector.
Remove the motor mounting bolts (1). Dismount the motor from the J2 base. When dismounting
the motor, be careful of the grease that may drop from the motor if the robot is suspended from a
ceiling or mounted on a wall.
Remove the M10 hexagonal nut (5) from the motor shaft, and pull out the gear (3).
Attach the gear to a new motor (2).
Attach an M10 spring washer (4), apply LOCTITE 242 to the M10 threaded n of the nut (5), and
tighten the M10 nut with a specified torque of [20 Nm].
Replace the O ring (6) with a new one and put it into the J2 base where the J1-axis motor is to be
mounted, and fasten them with bolt (1).
Attach the cable connector to the J1-axis motor.
According to Section 2.2, supply the J1-axis grease bath with the specified grease if grease is
overflowed.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
- 46 -
4.COMPONENT REPLACEMENT
B-82755EN/05
NOTE
If there is a danger that the J1-axis section may fall, for example, because the
robot is installed except floor mount, fix the J1-axis section during replacement
work, for example, by pushing the J1-axis mechanical stopper against the
J1-axis section.
1
2
3
4
5
6
Fig.4.2 Replacing the J1-axis motor
Parts name
1
BOLT
2
MOTOR
3
GEAR
WASHER (Attached to
motor)
NUT (Attached to motor)
O RING
4
5
6
Specification
Q’ty
A6-BA-8X20
A06B-0235-B605 (*1)
A06B-0235-B005#S000 (*2)
A290-7215-X211
4
A6-WB-10S
1
A6-N1-10S
JB-OR1A-G105
1
1
Locking
Torque (N-m)
1
1
LT242
20
(*1) ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S
(*2) ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L
- 47 -
4.COMPONENT REPLACEMENT
4.3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
B-82755EN/05
REPLACING THE J1-AXIS REDUCER
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual to restore
J2 to J6 axes. ( It is set in 0°for all axes when robot is shipped.)
Set dial gauges at J1-axis, and prepare for single axis mastering after replacement.
Put the robot in such a position that the J2 base and the portions above it can be suspended with a
crane or the like (hereafter abbreviated as a crane), and then turn off the controller power. (See Fig.
4.3 (a))
While referencing Section 5.3, pull out the cables below the J2 base from the J1-axis hollow pipe
section toward the upper portion of the J2 base.
While referencing Section 4.2, remove the J1-axis motor from the J2 base.
As shown in Fig. 4.3 (c), remove the bolts (3) that fasten the J2 base to the J1-axis reducer.
While referencing Section 4.3 (b), hoist the J2 base and portions above it slowly.
As shown in Fig. 4.3 (c), remove the O ring (5), bearing, and gear. Bearing rarely left in J2 base. It is
not necessary to remove bearing in this case, when bearing does not rotate smoothly, break oil seal
(12) and remove both oil seal and bearing then replace them to new article.
Remove the bolts (7) that fasten the J1-axis reducer to the J1 base, and dismount the reducer.
Disconnect the pipe.
Replace the O ring (10) with a new one and fit it with the pipe correctly.
Replace the O ring (11) with a new one and attach it to a new reducer, and fasten the reducer to J1
base with (7) bolts (by applying LOCTITE 262 and tightening with a torque of [129 Nm]).
Mount the center gear, bearing (with LOCTITE 675 applied to its outer ring), and O ring (5) to the
reducer. When bearing is broken in this process, replace bearing to new one. When replacing oil seal
(12), press-fit it by using fixture in Fig.4.3 (d).
Fasten the J2 base to the reducer with bolts (3) (by applying LOCTITE 262 and tightening with a
torque of [73.5 Nm]). Be careful not to let the pipe damage the oil seal.
According to Section 4.2, mount the J1-axis motor on the J2 base.
According to Section 5.3, mount the cables.
According to Section 2.2, supply the J1-axis grease bath with the specified grease.
Perform quick mastering, then perform single axis mastering to J1-axis referring to Section 8.4 and
8.5 of operator’s manual.
NOTE
1 Reducer and gear of upper of reducer are can be installed only in combination
below.
(1) Spec of reducer: A97L-0218-0822#33 Gear: A290-7215-X212
(2) Spec of reducer: A97L-0218-0885#33 Gear: A290-7221-Z212
See Fig.4.3 (a) when distinguishing it.
2 When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear (A290-7215-X211) of J1-axis motor shaft, gear
(A290-7215-X212) on J1-axis reducer and bearing (A97L-0001-0192#1400000).
- 48 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Old spec. A97L-0218-0822#33 New spec. A97L-0218-0885#33
Bearing size becomes 6813 from 6814.
Inside diameter shrinks.
Spur gear becomes two steps
from one step.
Contents for change of J1center gear
New spec. A290-7221-Z212
Old spec. A290-7215-X212
40.8
O 70
O 65
45.3
Dimension is changed.
There is no compatibility.
Fig.4.3 (a) Distinction of new and old reducer and gear
- 49 -
4.COMPONENT REPLACEMENT
B-82755EN/05
A
M10 Eyebolt
VIEW A
Mounting position
of eyebolt
Fig.4.3 (b) Sling the J2 base unit
5
6
3
2
1
4
8
7
11
9
10
Fig.4.3 (c) Replacing the J1-axis reducer
Parts name
1
2
3
4
5
6
BOLT
MOTOR
BOLT
O RING
O RING
GEAR
7
BEARING
BOLT
8
J1 REDUCER
9
10
PIPE
O RING
Specifications
Q’ty
A6-BA-8X20
A06B-0235-B605
A6-BA-10X50
JB-OR1A-G105
A290-7207-X342
A290-7215-X212 (*1)
A290-7221-Z212 (*2)
A97L-0001-0192#1400000
A6-BA-12X80
A97L-0218-0822#33 (*1)
A97L-0218-0885#33 (*2)
A290-7215-X215
JB-OR1A-G65
4
1
7
1
1
- 50 -
Locking
Torque (N-m)
LT262
73.5
LT262
129
1
2
6
1
1
1
4.COMPONENT REPLACEMENT
B-82755EN/05
Parts name
11
12
Specifications
O RING
OIL SEAL
Q’ty
A98L-0001-0347#S150
A98L-0040-0047#06009008
Locking
Torque (N-m)
1
1
(*1) Old spec: robot shipped before March, 2010.
(*2) New spec: robot shipped after April, 2010.
J2 base
12
Bearing
Fig.4.3 (d) Replacing the J1-axis reducer
29
7 12
C0
C1
.5
C0
.5
C0
.5
C1
A
SECTION A-A
Fig.4.3 (e) Example of press-fit fixture for oil seal
- 51 -
-0.2
O 82 -0.3
O 60
C1
O 73
O 84
O 89.5 ±0.1
A
4.COMPONENT REPLACEMENT
4.4
1
2
B-82755EN/05
REPLACING THE J2-AXIS MOTOR M2
Set dial gauges at J2-axis, and prepare for single axis mastering after replacement.
Push the J2-axis section against the mechanical stopper, or fix it in such a way that it will not swivel
when the motor is dismounted, for example, by placing it in the direction of gravity.
NOTE
If the J2-axis section is not pushed against the stopper correctly, or it is not
placed in the direction of gravity, there is a danger that the J2-axis section will
swivel when the J2-axis motor is removed.
3
4
5
6
Turn off the controller power.
Remove the J2-axis motor connector.
Remove the motor mounting bolts (1), and dismount the motor from the J2 base.
Remove the bolt (5) that fastens the input gear (4), and dismount the input gear (4). Also, remove
the draw nut from the motor shaft.
Apply LOCTITE 242 to the threaded portion of a draw nut (3) and tighten the draw nut to shaft of
new motor with a torque of [16.7 Nm].
Put the input gear (4) over the draw nut (3), apply LOCTITE 242 to the M6 threaded portion of the
draw nut (3), and tighten the bolt (5) with a torque of [6.8 Nm].
Replace the O ring (6) with a new one and put it into the J2 base portion where the motor is to be
mounted, and fasten the motor to the J2 base with bolts (1). Do not force in the motor. Otherwise,
the input gear may not settle in the correct place, possibly causing vibration (if the input gear is
engaged correctly, the motor will be mounted smoothly).
Attach the cable connector to the J2-axis motor.
According to Section 2.2, supply the J2-axis grease bath with the specified grease.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
7
8
9
10
11
12
5
4
2
3
1
6
Fig.4.4 Replacing J2-axis motor
Parts name
1
2
3
4
5
6
BOLT
MOTOR
DRAW NUT
INPUT GEAR
BOLT
O RING
Specifications
A6-BA-8X20
A06B-0235-B605
A290-7221-X321
A290-7221-X311
A6-BA-5X45
JB-OR1A-G105
Q’ty
4
1
1
1
1
1
- 52 -
Locking
Torque (N-m)
LT242
16.7
LT242
6.8
4.COMPONENT REPLACEMENT
B-82755EN/05
4.5
1
2
3
4
5
6
7
8
9
10
11
12
REPLACING THE J2-AXIS REDUCER
Set dial gauges at J2-axis, and prepare for single axis mastering after replacement.
Put the robot in such a posture that the J2 arm and the components on it can be suspended with a
crane.
Turn off the controller power.
Suspend the J2 arm and the components on it as shown Fig. 4.5 (a) and (b) with a crane so that they
will not drop when the J2 arm is dismounted. (If there is the fixture shown in Fig. 4.5 (b), work
improves. The material must be SS400 or an equivalent. Use the eyebolts delivered with the J2
base when robot is shipped.)
Remove the J2-axis motor as described in Section 4.4 (If the reducer is replaced while the motor is
still mounted, the input gear may be damaged.)
As shown in Fig. 4.5 (c), remove the bolts (1) that fasten the reducer (3) to J2 base, and remove bolts
(2) that fasten the reducer (3) to J2 arm .Be careful not to allow an excessive load to be put on the
cables (because the cables are left attached when the reducer is dismounted).
Replace the O ring (4) with a new one and attach it to a new reducer, insert it into the J2 arm, and
fasten them with bolts (2) (by applying LOCTITE 262 and tightening with a torque of [15.6 Nm]).
Degrease both the J2 base and the J2-axis reducer surfaces that are to meet each other, and as shown
in Fig. 4.5 (d), apply sealant (LOCTITE 518) to the J2-axis reducer on which the J2 base is to be
mounted.
Mount the reducer to the J2 arm with bolts (1) (by applying LOCTITE 262 and tightening with a
torque of [73.5 Nm]).
Mount the J2-axis motor as described in Section 4.4.
According to Section 2.2, supply the J2-axis grease bath with the specified grease.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange input gear (A290-7221-X311) of J2-axis motor shaft.
- 53 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Wind sling to ruggedness part
of tip of wrist.
Wind sling so that sling
goes around J3-axis reducer.
Fig.4.5 (a) Sling the J2 and J3 arms
140
2-M10 THRU
7
50
70
45
4-O7 THRU
130
M10 eyebolts (2pcs)
Fig.4.5 (b) Sling the J2 and J3 arms (When fixture is used)
- 54 -
4.COMPONENT REPLACEMENT
B-82755EN/05
4
シール剤塗布面
SEALANT APPLYING SURFACE
3
2
1
Fig.4.5 (c) Replacing the J2-axis reducer
Parts name
1
2
BOLT
BOLT
3
J2 REDUCER
4
O RING
Specifications
Q’ty
A6-BA-10X20
A6-BA-6X30
A97L-0218-0886#127(*1)
A97L-0218-0886#93 (*2)
JB-OR1A-G130
9
16
1
Locking
LT262
LT262
1
(*1) Except ARC Mate 100iC/10S,M-10iA/6S
(*2) ARC Mate 100iC/10S,M-10iA/6S
Fig.4.5 (d) applying sealant to the J2-axis reducer
NOTE
Refer to Section 4.23 about applying sealant (LOCTITE 518).
- 55 -
Torque (N-m)
73.5
15.6
4.COMPONENT REPLACEMENT
4.6
B-82755EN/05
REPLACING THE J3-AXIS MOTOR M3
NOTE
Fixtures are necessary for replacing J3-axis motor and reducer. See Fig.1.10 (a)
to (e).
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Set dial gauges at J3-axis, and prepare for single axis mastering after replacement.
Place the robot in the posture J2=0º. At this chance, confirm J1 base is fixed to prevent from falling.
Suspend the J3 arm and the components on it as shown Fig. 4.6 (a) with a crane so that they will not
drop when the J2 arm is dismounted
Turn off the controller power.
Remove the connector of a cable leading to the J3-axis motor.
Remove the bolts (1) that fasten the J3-axis motor to the J3 casing, and dismount the motor and
packing (7).
Remove the bolt (6) from the motor shaft, and dismount the input gear (5) and draw nut (4).
Apply LOCTITE 242 to the threaded portion of draw nut (4) and tighten it to the new motor with a
torque of [3.1 Nm].
Put the input gear (5) over the draw nut (4), apply LOCTITE 242 to the M5 threaded portion of the
draw nut (4), and tighten the bolt (6) with a torque of [3.4 Nm]. In this time, be sure to attach key (3),
too. Refer to section 4.8 about mounting input gear to J3-axis motor.
Attach new packing (7), and insert the motor into the reducer. Keep the J3-axis degrease outlet on
the J2 arm side open (see Fig. 2.2 (c)), and look into the outlet to make sure that the input gear has
settled in the correct place. Even one tooth of a shift in engagement can cause vibration. (If the
input gear (5) is engaged correctly, the motor can get in the reducer smoothly.) In this case, if robot
is shipped before March, 2010, please confirm whether attaching the motor to the reducer is
appropriate referring to paragraph 4.8. Please confirm whether the flange of the motor floats, and
install it with the phase that spur gears form a line like figure 4.6 (c) up and down.
Fasten the motor to the J3-axis reducer with bolts (1). Be sure to use a new packing to prevent
grease leakage. Refer to section 4.8 about mounting J3-axis motor to reducer.
Attach the cable connector to the J3-axis motor.
According to Section 2.2, supply the J3-axis grease bath with the specified grease.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
Wind sling to ruggedness part
of tip of wrist.
J2=0°
Fig.4.6 (a) Sling the J3 arm
- 56 -
4.COMPONENT REPLACEMENT
B-82755EN/05
1
2
5
6
3
7
4
Fig.4.6 (b) Replacing the J3-axis motor
Parts name
Specifications
Q’ty
A6-BA-6X14
A06B-0212-B605#S000
4
1
JB-HGKYA-4X13
1
4
BOLT
MOTOR
KEY (Attached to
motor)
DRAW NUT
1
5
INPUT GEAR
6
7
BOLT
PACKING
A290-7221-X421
A290-7221-X411 (*1)
A290-7221-Z411 (*2)
A290-7221-Z415 (*3)
A6-BA-4X55
A98L-0040-0042#03
1
2
3
Locking
Torque (N-m)
LT242
3.1
LT242
3.4
1
1
1
(*1) Old spec robot ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA6L shipped before March,
2010.
(*2) New spec: robot ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA6L shipped after April,
2010 or ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe6L.
(*3) ARC Mate 100iC/10S, M-10iA/10S
- 57 -
4.COMPONENT REPLACEMENT
B-82755EN/05
The old and new reducer is incompatible. See Fig.4.6 (c) when distinguish it.
New spec. A290-7221-Z411
3
Old spec. A290-7221-X411
81.6
84.6
Chamfering size
is different.
Fig.4.6 (c) Distinction of new and old input gear
Assmeble motor so that
spur gear form a line with
this phase.
Fig.4.6 (d) Phase for mounting J3-axis motor to reducer
(Only for robot which is shipped before March, 2010)
4.7
NOTES OF ATTACHING J3-AXIS MOTOR TO REDUCER
1) Procedure of J3 Motor Input Gear Alignment
1
2
3
Apply LOCTITE 242 to thread the Draw Nut (A290-7221-X421) and mount it to the motor shaft by
using torque wrench with regulated torque set at 3.1Nm.
Attach the woodruff key to motor shaft, confirm there is no dust on taper shaft of motor and insert
input gear to motor shaft.
Mount fixture to motor as Fig.4.7 (a) for centering.
- 58 -
4.COMPONENT REPLACEMENT
B-82755EN/05
4
5
Apply LOCTITE 242 to thread and tighten bolt (M4×55) with regulated torque 3.4Nm while
supporting input gear with spanner wrench preventing the input gear from rotating.(to prevent motor
brake slips) If you hear the ratchet sound of the torque wrench then, turn the torque wrench until the
next ratchet sound or until the bolt head is completely past the motor input gear. This completes
setting of the input gear on the motor taper shaft.
Remove the Fixture from the Motor Shaft.
Ｂｏｌｔ
A6-BA-4X55
Tightening torque 3.4 Nm
Fixture A290-7221-X973
LOCTITE
Insert spanner not to
rotate the motor shaft
J3-axis motor input gear
Fixture(*)
Fixture(*)
J3-axis motor
Draw nut
A290-7221-X421
Tightening torque 3.1 Nm
LOCTITE 242
Fixture A290-7221-X974 or
A290-7221-X976
J3-axis motor
Ｂｏｌｔ
A6-BA-4X55
Tightening torque 3.4 Nm
LOCTITE
Fixture(*)
Insert spanner not to
rotate the motor shaft
J3-axis motor input gear
Fixture(*)
J3-axis motor
Draw nut
A290-7221-X421
Tightening torque 3.1 Nm
LOCTITE 242
J3-axis motor
(*) Specification of fixture is differ depend on robot.
1. ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L, M-10iA/6L which is made before March,2010.
A290-7221-X973
2. ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L, M-10iA/6L which is made after April,2010 or
ARC Mate 100iCe,M-10iAe,ARC Mate 100iCe/6L,M-10iAe/6L
A290-7221-X974 (Use them after connecting them.)
3. ARC Mate 100iC/10S,M-10iA/10S
A290-7221-X976 (Use them after connecting them.)
Fig.4.7 (a) Attaching J2-axis and J3-axis motor to reducer
- 59 -
4.COMPONENT REPLACEMENT
B-82755EN/05
There are 3 cases about method of installing J3-axis motor to reducer depend on the shipment time of
robot.
1
Robot which is made before June, 2009
J3-axis reducer grease outlet is made in J3-axis rotation center of J2 arm.
Mount J3-axis motor referring to procedure 2) of this Section.
J3-axis reducer grease outlet
Seal bolt
A97L-0218-0417#081010
Fig.4.7 (b) Robot which is made before June, 2009
2
Robot which is made after July, 2009 and before March, 2010
J3-axis reducer grease outlet is at the position upper than J3-axis rotation center of J2 arm.
Seal bolt is attached to tap for mounting fixture. Mount J3-axis motor referring to procedure 3) of
this Section.
J3-axis reducer grease outlet
Seal bolt
A97L-0218-0417#081010
Seal bolt
A97L-0218-0417#101212
(Note： This is not J3-axis reducer grease outlet.)
Fig.4.7 (c) Robot which is made after July, 2009 and before March, 2010
3
Robot which is made after April, 2010
No fixture is needed while mounting J3-axis motor to reducer.
- 60 -
4.COMPONENT REPLACEMENT
B-82755EN/05
2) Procedure of J3-axis Reducer Alignment
(Robot which is made before June, 2009)
1
2
Mount J3-axis motor that is aligned to J3 casing after attaching packing to motor flange referring to
previous section. Confirm that the Motor Flange is not floating from the attaching surface of the J3
casing from the three sight direction of Fig.4.7 (e). If there is clearance between motor and J3 casing,
input gear is not aligned, insert it again. If you confirm there is no gap, work is completion.
Insert the Fixture (A290-7221-Z972) into the J3 grease outlet as Fig.4.7 (f) until it touches the face
of the bolt. You can judge that it is the good condition in case that the male screw part is not sticking
out of the surface of the counter bore. If input gear is not aligned, the male screw part is sticking out
of the surface of the counterbored hole(2mm) as Fig.4.7 (f).
If the centering is good, the top of the Fixture (A290-7221-Z972) can enter into the hexagon socket
on the bolt head.
Spur gear
Motor shaft
+
Input gear
RV
reducer
(a) Wrong fitting case
(b) Correct fitting
Fig.4.7 (d) Attaching J3-axis motor to reducer
Confirm there is no clearance
in this face.
Fig.4.7 (e) Confirming the mounting of J3-axis motor
- 61 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Centering fixture
A290-7221-Z972
1.5～2.0mm
Centering is performed
Centering is not performed
Fig.4.7 (f) Confirming the gap of the core of J3-axis motor (1/2)
3) Procedure of J3-axis Reducer Alignment
(Robot which is made after July, 2009 and before March, 2010)
1
2
3
4
Remove seal bolt of J3-axis rotation center of J2 arm in Fig.4.7 (c), mount fixture
(A290-7221-Z974) and tighten it well.
Attach J3-axis motor which gear is attached to J3 casing. Attach it so that motor flange surface is
mounted to J3 casing without clearance. (If centering is performed, it is hard to pull out motor. So
try to pull out to confirm it.)
Look the center of fixture which is attached to J2 arm with flashlight and confirm bolt of center gear
is center of fixture. If centering of input gear is performed, center of bolt of input gear accords in
center of hole of fixture. Confirm it referring to Fig.4.7 (g). If centering is not performed, motor is
not mounted to J3 casing.
If it is confirmed, attach seal bolt. If seal bolt is reused, be sure to wind it with seal tape.
- 62 -
4.COMPONENT REPLACEMENT
B-82755EN/05
If centering is performed,
center of bolt of input gear accords
in center of hole of fixture.
If centering is not performed,
center of bolt of input gear does not accord
in center of hole of fixture.
The part which
slips off
The part which
slips off
Detail A
Detail A
Detail A
Centering fixture
A290-7221-Z974
A
Fig.4.7 (g) Confirming the adhering of J3-axis motor (2/2)
4.8
REPLACING THE J3-AXIS REDUCER
NOTE
Fixtures are necessary for replacing J3-axis motor and reducer. See Fig.1.10 (a)
to (e).
1
2
3
4
5
6
7
8
9
Set dial gauges at J3-axis, and prepare for single axis mastering after replacement.
Put the robot in such a posture that the J3-axis section and the components on it can be suspended
with a crane, (If there is the fixture shown in Fig. 4.5 (b), work improves. The material must be
SS400 or an equivalent. Use the eyebolts delivered with the J2 base.)
Turn off the controller power.
While referencing Section 5.3, remove the cable from the J2 arm section. Suspend the J3-axis
section and the components on it with a crane so that they will not drop when the reducer is
dismounted from the J2 arm. This supporting method is common to replacing J2-axis reducer so
reference to section 4.5 for more details. Be careful not to allow an excessive load to be put on the
cable assembly (because the cables are left attached when the reducer is dismounted).
While referencing Section 4.6, dismount the J3-axis motor from the J3 arm unit.
Remove bolts (3) that fasten the J3-axis reducer to the J3 arm dismount the J3 arm that reducer
attaches from the J2 arm.
Remove bolt (1) that fasten J3-axis reducer to J3 casing. In addition, remove J3-axis reducer from J3
casing.
Remove O ring (5) and attach new O ring (5) to the reducer installation part of J2 arm.
Suspend the J3-axis section and the components on it with a crane, and fasten the J2 arm and J3-axis
reducer with bolts (3) (by applying LOCTITE 262 and tightening with a torque of [9.0 Nm]). Please
install it so that the phase of the spur gears form a line like figure 4.6 (c) up and down.
- 63 -
4.COMPONENT REPLACEMENT
10
B-82755EN/05
Degrease both the J3-axis reducer and the J3 casing surfaces that are to meet each other, and as
shown in Fig. 4.8 (c), apply sealant (LOCTITE 518) to the J3-axis reducer surface on which the J3
casing is to be mounted.
While referencing Section 4.6, mount the J3-axis motor on the J3 arm unit. In this case, if robot is
shipped before March, 2010, please confirm whether attaching the motor to the reducer is
appropriate referring to paragraph 4.8.
While referencing Section 5.3, dress the cable into the previous form.
According to Section 2.2, supply the J3-axis grease bath with the specified grease.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
Confirm software version and cope as needed.
11
12
13
14
15
The shipment
time of robot
Before March,
2010.
After April, 2010
Software version
Cope when replacing J3-axis reducer
V7.30P-27 or earlier
V7.40P-06 or earlier
V7.30P-28 or later
V7.40P-07 or later
All
J3-axis reducer mounting phase auto adjusting function is not needed.
Be sure to perform J3-axis reducer mounting phase auto adjusting
function referring to subsection 4.7.1.
J3-axis reducer mounting phase auto adjusting function is not needed.
NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange input gear of J3-axis motor shaft. At this time,
confirm there is no clearance between input gear and J2 arm referring to Section
4.8.
3
1
2
シール剤塗布面
SEALANT APPLYING SURFACE
Parts name
1
2
3
BOLT
ADAPTER
BOLT
4
J3 REDUCER
5
O RING
4
5
Fig.4.8 (a) Replacing the J3 –axis reducer
Specifications
Q’ty
A6-BA-8X25
A290-7221-X422
A6-BA-5X20
A97L-0218-0824#150 (*1)
A97L-0218-0887#150 (*2)
A97L-0218-0887#108 (*3)
JB-OR1A-G130
- 64 -
8
1
12
1
1
Locking
Torque (N-m)
LT262
37.2
LT262
9.0
4.COMPONENT REPLACEMENT
B-82755EN/05
(*1)
Old spec:： ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L which are shipped
before March, 2010
(*2) New spec： ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L which are shipped after
April, 2010 or ARC Mate 100iCe,M-10iAe,ARC Mate 100iCe/6L, M-10iAe/6L.
(*3) ARC Mate 100iC/10S,M-10iA/10S
The old and new reducer is incompatible. See Fig.4.8 (b) when distinguish it.
Old spec. A97L-0218-0824#150 New spec. A97L-0218-0887#150
16-O5.8 Equally spaced
5.7
3
2.7
12-O5.8 Equally spaced
Fig.4.8 (b) Distinction of new and old J3-axis reducer
Fig.4.8 (c) Applying sealant to the J3-axis reducer
NOTE
Refer to Section 4.23 about applying sealant (LOCTITE 518).
- 65 -
4.COMPONENT REPLACEMENT
4.8.1
1
2
3
B-82755EN/05
J3-axis reducer mounting phase auto adjusting function
If H839INIT program and H839RVAT program are not installed to controller, contact FANUC.
Perform H839INIT program.
In H839RVAT program, disturbance torque is measured with J1=J2=J4=J6=0°, J5=-90° and J3
moves between 0° and 40° with override 10%.
Before executing H839RVAT.TP, keep the space so at to move the robot arm without interference
with peripheral. And to avoid the harmful effect by vibration of a robot hand, the position of J5 axis
is set to –90º. Check the interference between a robot arm and a robot hand, too.
Perform H839RVAT program.
4
NOTE
The H839RVAT-related parameter is stored away by SYSMAST.SV. In addition,
a value is listed in inspection certification attached at the time of shipment. After
V7.30P-25, it is necessary to return backup of SYSMAST.SV at the time of the
update of the software.
In addition, contact FANUC about group 2 or later for robots of multiple control.
4.9
1
2
3
4
5
6
7
8
9
10
11
REPLACING THE J4-AXIS MOTOR M4
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L)
Place the robot in a posture of J3 = +180°.
Set dial gauges at J4-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the connector of a cable leading to the J4-axis motor.
As shown in Fig. 4.9, remove the three bolts (1) that fasten the J4-axis motor to the J3 casing, and
dismount the motor.
Remove the bolt (6) that fastens the gear (4) to the motor shaft, and dismount the washer (5), gear
(4) and key (3).
Mount the gear (4) to a new motor, apply LOCTITE 242 to the threaded portion of the motor shaft,
and fasten them with a bolt by tightening with a torque of [1.3 Nm]. (Ensure the specified torque is
achieved otherwise, the J4-axis may get out of place.)
Replace the Packing (7) with a new one and put it in the J3 casing portion where the motor is to be
mounted accurately, and fasten the motor to the J3 casing with bolts (1).
Attach the cable connector to the J4-axis motor.
According to Section 2.2, supply the J4-axis gearbox with the specified oil.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
- 66 -
4.COMPONENT REPLACEMENT
B-82755EN/05
1
2
3
4
5
6
7
Fig.4.9 Replacing the J4-axis motor
Parts name
1
BOLT
2
MOTOR
3
4
5
6
7
KEY
GEAR
WASHER
BOLT
PACKING
Specifications
A97L-0218-0612#051212
A06B-0115-B804 (*1)
A06B-0115-B205#S000 (*2)
JB-HKY-3X3X20B
A290-7221-X412
A290-7210-X532
A6-BA-3X8
A98L-0040-0042#07
Q’ty
Torque (N-m)
1
1
1
1
1
1
(*1) ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L
(*2) ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L
- 67 -
Locking
4
LT675
LT242
1.3
4.COMPONENT REPLACEMENT
4.10
1
2
3
4
5
B-82755EN/05
REPLACING THE J4-AXIS MOTOR M4
(ARC Mate 100iC/10S, M-10iA/10S)
Place the robot in a posture of J3 = +180°.
Set dial gauges at J4-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the connector of a cable leading to the J4-axis motor.
As shown in Fig. 4.10, remove the three bolts (1) that fasten the J4-axis motor to the J3 casing, and
dismount the motor.
Remove the set screw (5) that fastens the gear (4) to the motor shaft, and dismount the gear (4) and
key (3).
Attach key (3) and gear (4) to new motor. Apply LOCTITE 242 to set screw (5) and tighten it with
torque of [0.54 Nm]. (Ensure the specified torque is achieved otherwise, the J4-axis may get out of
place.)
Replace the packing (6) with a new one and put it in the J3 casing portion where the motor is to be
mounted accurately, and fasten the motor to the J3 casing with bolts (1).
Attach the cable connector to the J4-axis motor.
According to Section 2.2, supply the J4-axis gearbox with the specified oil.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
6
7
8
9
10
11
1
2
3
4
5
6
Fig.4.10 Replacing the J4-axis motor
Parts name
1
2
3
4
5
6
BOLT
MOTOR
KEY
GEAR
SET SCREW
PACKING
Specifications
Q’ty
A97L-0218-0612#051212
A06B-0115-B804
JB-HKY-3X3X20B
A290-7221-Z412
A6-SAKT-3X4
A98L-0040-0042#07
4
1
1
1
2
1
- 68 -
Locking
Torque (N-m)
LT675
LT242
0.54
4.COMPONENT REPLACEMENT
B-82755EN/05
4.11
REPLACING THE J4-AXIS GEARBOX
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L,
ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L,
M-10iAe/6L)
Pay attention that specification of J4-axis gearbox is different by time of robot shipment
Before March 2010 (Spec. of mechanical unit: A05B-1221-B201, B202, B301, B302): A05B-1221-K401
After April 2010 (Spec. of mechanical unit: A05B-1221-B401, B402, B451, B452, B501, B502, B551,
B552): A05B-1221-K411
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual to restore
J5 to J6 axes. (It is set in 0º for all axes when robot is shipped.)
Set dial gauges at J3/J4-axes, and prepare for single axis mastering after replacement.
Turn off the controller power.
Pull out all oil of J4-axis gearbox referring to Section 2.2.
Wrap and hang Sling in two places of the J3 arm referring to Fig.4.11 (a) and (b).
Remove the wiring and piping between J3-axis and wrist. When cable installed in M/H conduit or
No dust M/H conduit is removed, refer to Section 4.19 or 4.22.
Referring to section 5.3,remove option cable from J4-axis connector panel.
Referring to section 5.3,remove J3/J4-axis motor connector, clamp part in J3 casing, clamp part in J3
arm and cable of J5/J6-axis motor, and pull out cable from J3 arm unit.
Referring to Section 4.9, remove J4-axis motor.
Remove bolt (1), cover (2) and packing (3).
Remove bolt (4) and pipe B (5).
Remove bolt (6), J3 arm and O ring (7).
Referring to Section 4.6, remove J3-axis motor.
Remove bolt (8) and J4 connector plate (9).
Remove bolt (10) that fasten J3 unit (13) to J2 arm, and remove J3 unit (13) from J2 arm.
Remove adapter (12).
Remove bolt (14) and clamp (15). Then remove bolt (16) and clamp (17).
Remove bolt (18) and pipe A (19). Then remove bolt (20), cover (21) and packing (22).
Please apply parts removed to new J4 axis gearbox by 10 –17. Please spread LOCTITE according to
the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt.
In this time, replace packing (22) to new one. When installing J3 unit to J2 arm, apply LOCTITE
518 to J3-axis reducer referring to Section 4.8.
Do process of 5-9 by opposite procedure. Please spread LOCTITE according to the table of this
paragraph, and tighten by the regulated tightening torque when you install the bolt. In this time,
replace packing (3) and O ring (7) to new one.
Referring to section 5.3,attach cables to J3 arm and J3 casing.
Referring to Section 4.6 and 4.9 attach J3/J4-axis motor. In this time replace packing and seal bolt to
new one.
Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J4 oil outlet.
According to Section 2.2, supply grease to J3-axis reducer with specified grease and supply oil to
J4-axis gearbox with specified oil.
Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J3-axis reducer grease
inlet.
Perform quick mastering and perform single axis mastering to J3 to J4-axis referring to Section 8.4
and 8.5 of operator’s manual.
- 69 -
4.COMPONENT REPLACEMENT
B-82755EN/05
NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear (A290-7221-X412) of J4-axis motor shaft. In
this time, confirm sitting sate of gear referring to section 4.8.
7
2
5
6
4
1
3
Fig.4.11 (a) Replacing the J4-axis gearbox unit (1/4)
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L)
Parts name
1
2
3
4
BOLT
PLATE
PACKING
BOLT
5
PIPE B
6
7
BOLT
O RING
Specifications
Q’ty
A97L-0218-0502#M5X12
A290-7221-X425
A290-7221-X441
A97L-0001-0674#3X35
A290-7221-X430 or A290-7221-X433
(*1),
A290-7221-Z430 or A290-7221-Z433
(*2
A6-BA-6X85
A290-7221-X444
8
1
1
3
Locking
Torque (N-m)
LT242
4.5
LT262
15.7
1
14
1
(*1) ARC Mate 100iC, M-10iA
(*2) ARC Mate 100iC/6L, M-10iA/6L
7
5
6
2
1
4
3
Fig.4.11 (b) Replacing the J4-axis gearbox unit (2/4)
(ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)
- 70 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Parts name
1
2
3
4
5
6
7
BOLT
PLATE
PACKING
BOLT
DUMMY PIPE
BOLT
O RING
Specifications
Q’ty
A6-BA-5X8
A290-7221-Z427
A290-7221-X441
A6-BA-3X30
A290-7221-Z434
A6-BA-6X85
A290-7221-X444
Locking
8
1
1
3
1
14
1
Torque (N-m)
6.8
LT262
15.7
13
11
10
8
12
9
Fig.4.11 (c) Replacing the J4-axis gearbox unit (3/4)
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L
ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)
Parts name
8
BOLT
9
CON.PLATE
10
11
12
BOLT
WASHER
ADAPTER
13
J3 UNIT
Specifications
Q’ty
A6-BA-6X10
Specification is depend on
mechanical unit cable
A6-BA-8X25
A97L-0001-0823#M8H
A290-7221-X422
Specification is depend on
mechanical unit cable
2
- 71 -
Locking
Torque (N-m)
1
8 or 9
8 or 9
1
1
LT262
15.7
4.COMPONENT REPLACEMENT
B-82755EN/05
19
18
15
14
16
17
22
21
20
Fig.4.11 (d) Replacing the J4-axis gearbox unit (4/4)
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L)
14
15
16
17
18
19
20
Parts name
BOLT
CLAMP
BOLT
CLAMP
BOLT
PIPE A
BOLT
21
COVER
22
PACKING
Specifications
A6-BA-4X5
A290-7221-X473
A6-BA-3X6
A290-7221-X474
A6-BA-4X35
A290-7221-X427
A6-BA-5X14
A290-7221-X426 or
A290-7221-Y426
A290-7221-X442
Q’ty
2
1
2
1
2
1
7
Locking
LT262
Torque (N-m)
15.7
1
1
The following service parts are appended to J4-axis gearbox (A05B-1221-K401, A05B-1221-K411) for
maintenance. Please exchange these with the J4-axis gearbox.
Parts name
PACKING
PACKING
BOLT
BOLT
BOLT
WASHER
SEAL BOLT
SEAL BOLT
SEAL WASHER
PACKING
PACKING
O RING
PIN
4.12
1
2
3
Specifications
A98L-0040-0042#03
A98L-0040-0042#07
A6-BA-8X25
A6-BA-5X14
A6-BA-6X10
A97-0001-0823#M8H
A97L-0218-0502#5X10
A97L-0218-0417#081010
A30L-0001-0048#6M
A290-7221-X441
A290-7221-X442
A290-7221-X444
JB-PH-H7A-5X10S45C
Q’ty
1
1
8 or 9
7
1
8 or 9
4
1
1
1
1
1
4
Used place
J3-axis Motor
J4-axis Motor
Between J3 casing and J3-axis reducer
J4-axis Motor mounting part
J3 grease inlet
Between J3 casing and J3-axis reducer
J4-axis Motor
J4 oil outlet
J3 grease inlet
J4-axis hollow part
J4-axis Motor mounting part
Between J3 arm and J3 casing
Z424, Z425
REPLACING THE J4-AXIS GEARBOX
(ARC Mate 100iC/10S, M-10iA/10S)
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual to restore
J5 to J6 axes. (It is set in 0º for all axes when robot is shipped.)
Set dial gauges at J3/J4-axes, and prepare for single axis mastering after replacement.
Turn off the controller power.
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4.COMPONENT REPLACEMENT
B-82755EN/05
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Pull out all oil of J4-axis gearbox referring to Section 2.2.
Wrap and hang Sling in two places of the J3 arm referring to Fig.4.12 (a).
Remove the wiring and piping between J3-axis and wrist. When cable installed in M/H conduit or
No dust M/H conduit is removed, refer to Section 4.19 or 4.22.
Referring to Section 5.3,remove option cable from J4-axis connector panel.
Referring to Section 5.3,remove J3/J4-axis motor connector, clamp part in J3 casing, clamp part in
J3 arm and cable of J5/J6-axis motor, and pull out cable from J3 arm unit.
Referring to Section 4.10, remove J4-axis motor.
Remove bolt (1), cover (2) and packing (3).
Remove bolt (4) and pipe B (5).
Remove bolt (6), J3 arm and O ring (7).
Referring to Section 4.6, remove J3-axis motor.
Remove bolt (8) and J4 connector plate (9).
Remove bolt (10) and plate (11).
Remove bolt (13) that fasten J3 unit (12) to J2 arm, and remove J3 unit (12) from J2 arm.
Remove adapter (14).
Remove bolt (16) and clamp (17). Then remove bolt (18) and clamp (19).
Remove bolt (20) and pipe A (21). Then remove bolt (23), pin (24), cover (25) and packing (26).
Please apply parts removed to new J4 axis gearbox by 10 –19. Please spread LOCTITE according to
the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt.
In this time, replace packing (28) to new one. When installing J3 unit to J2 arm, apply LOCTITE
518 to J3-axis reducer referring to Section 4.8.
Do process of 5-9 by opposite procedure. Please spread LOCTITE according to the table of this
paragraph, and tighten by the regulated tightening torque when you install the bolt. In this time,
replace packing (3) and O ring (7) to new one.
Referring to section 5.3,attach cables to J3 arm and J3 casing.
Referring to Section 4.6 and 4.10 attach J3/J4-axis motor. In this time replace packing and seal bolt
to new one.
Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J4 oil outlet.
According to Section 2.2, supply grease to J3-axis reducer with specified grease and supply oil to
J4-axis gearbox with specified oil.
Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J3-axis reducer grease
inlet.
Perform quick mastering and perform single axis mastering to J3 to J4-axis referring to Section 8.4
and 8.5 of operator’s manual.
NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear (A290-7221-Z412) of J4-axis motor shaft.
7
6
5
2
1
4
3
Fig.4.12 (a) Replacing the J4-axis gearbox unit (ARC Mate 100iC/10S, M-10iA/10S) (1/3)
- 73 -
4.COMPONENT REPLACEMENT
Parts name
1
2
3
4
5
6
7
BOLT
PLATE
PACKING
BOLT
PIPE B
BOLT
O RING
B-82755EN/05
Specifications
Q’ty
Locking
8
1
1
3
1
14
1
LT242
4.5
LT262
15.7
A97L-0218-0502#M5X12
A290-7221-X425
A290-7221-X441
A97L-0001-0674#3X35
A290-7221-X430
A6-BA-6X85
A290-7221-X444
Torque (N-m)
12
10
11
15
14
13
8
9
Fig.4.12 (b) Replacing the J4-axis gearbox unit(ARC Mate 100iC/10S, M-10iA/10S) (2/3)
Parts name
8
9
10
11
12
13
14
15
BOLT
PLATE
BOLT
PLATE
J3 UNIT
BOLT
WASHER
ADAPTER
Specifications
A6-BA-6X10
A290-7221-Z471
A6-BA-6X10
A290-7221-Z472
A290-7221-T413
A6-BA-8X25
A97L-0001-0823#M8H
A290-7221-X422
Q’ty
2
1
1
1
1
9
9
1
- 74 -
Locking
Torque (N-m)
LT262
37.2
4.COMPONENT REPLACEMENT
B-82755EN/05
22
21
20
17
16
18
19
26
24
25
23
Fig.4.12 (c) Replacing the J4-axis gearbox unit (ARC Mate 100iC/10S, M-10iA/10S) (3/3)
Parts name
16
17
18
19
20
21
22
23
24
25
26
BOLT
CLAMP
BOLT
CLAMP
BOLT
PIPE A
PIN
BOLT
PIN
COVER
PACKING
Specifications
Q’ty
A6-BA-4X5
A290-7221-X473
A6-BA-3X6
A290-7221-X474
A6-BA-4X35
A290-7221-X427
JB-PH-H7A-5X10S45C
A6-BA-5X14
JB-PH-H7A-5X10S45C
A290-7221-Z424
A290-7221-X442
2
1
2
1
2
1
2
7
2
1
1
Locking
LT262
Torque (N-m)
15.7
The following service parts are appended to J4-axis gearbox (A05B-1221-K413) for maintenance.
Please exchange these with the J4-axis gearbox.
Parts name
PACKING
PACKING
BOLT
BOLT
WASHER
SEAL BOLT
SEAL BOLT
SEAL BOLT
PACKING
PACKING
O RING
PIN
4.13
Specifications
A98L-0040-0042#03
A98L-0040-0042#07
A6-BA-8X25
A6-BA-5X14
A97L-0001-0823#M8H
A97L-0218-0502#5X10
A97L-0218-0417#081010
A97L-0218-0417#060808
A290-7221-X441
A290-7221-Z442
A290-7221-X444
JB-PH-H7A-5X10S45C
Q’ty
1
1
9
7
9
4
1
1
1
1
1
4
Used place
J3-axis Motor
J4-axis Motor
Between J3 casing and J3-axis reducer
J4-axis Motor mounting part
Between J3 casing and J3-axis reducer
J4-axis Motor
J4 oil outlet
J3 grease inlet
J4-axis hollow part
J4-axis Motor mounting part
Between J3 arm and J3 casing
Z424, Z425
REPLACING THE J5-AXIS MOTOR M5
NOTE
Please exchange it by one when you exchange both J5 and the J6 axis motors.
Otherwise, the balance of pressure collapses, and oil spouts. Moreover, please
open neither oiling entrance nor the oil discharge entrance.
- 75 -
4.COMPONENT REPLACEMENT
1
B-82755EN/05
Place the robot in a posture of J3 = -90°. If it is impossible to make the posture in the on-site
environment, put the collection bottle under the robot.
Set dial gauges at J5-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove seal bolt (1) and J5 motor cover (2).
In case of M-10iA or M-10iA/6L or M-10iA/10S, replace packing (3). (Remove adhesive tape
completely.)
Remove bolt (4) and duct cover (5).
Remove cable of motor.
Remove nylon bands of Pulsecoder line.
Remove seal bolt (6) and plate cover 1 (7).
In case of M-10iA or M-10iA/6L or M-10iA/10S, replace packing (8). (Remove adhesive tape
completely.)
Remove bolt (9) and motor that gears attaches.
Replace motor new one and assemble it by opposite procedure. Refer to Fig.4.13 (b) when motor
(10) is assembled. Please wrap the seal tape when you recycle seal bolt (1), (6). Replace packing (3),
(8) and O ring (16) to new article.
Attach nylon band of Pulsecoder line.
According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
10
9
8
3
12
14
5
7
11
13
4
6
15
16
Fig.4.13 Replacing the J5-axis motor
1
2
3
4
5
Parts name
SEAL BOLT
J5M COVER
PACKING (*1)
BOLT
DUCT COVER
Specifications
A97L-0218-0736#050808
A290-7221-X509
A290-7221-X579
A6-BA-5X45
A290-7221-X506
- 76 -
Number
4
1
1
2
1
Locking
LT262
Torque (N-m)
4.5
9.0
4.COMPONENT REPLACEMENT
B-82755EN/05
6
7
8
9
Parts name
SEAL BOLT
PLATE COVER 1
PACKING (*1)
BOLT
10
MOTOR
11
12
13
14
15
16
SPACER
KEY
GEAR J6-1
WASHER
BOLT
O RING
Specifications
A97L-0218-0736#050808
A290-7221-X561
A290-7221-X581
A6-BA-5X12
A06B-0115-B855#0048 (*2)
A06B-0115-B205#S000 (*3)
A290-7221-X529
JB-HKY-3X3X8A
A290-7221-X511
A290-7210-X532
A97L-0218-0514#M3X8
A98L-0001-0347#S39
Number
2
1
1
3
Locking
Torque (N-m)
4.5
1
1
1
1
1
1
1
LT675
LT242
1.0
(*1) In case of M-10iA, M-10iA/6L, M-10iA/10S
(*2) ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S
(*3) ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L
Fix the motor while gently pressing the motor
against the direction of the arrow.
However, be careful not to press it strongly.
Gear
A290-7221-X591
J5-axis motor
Fig.4.13 (b) Note of assembling J5-axis motor
4.14
REPLACING THE J6-AXIS MOTOR M6
NOTE
Please exchange it by one when you exchange both J5 and the J6 axis motors.
Otherwise, the balance of pressure collapses, and oil spouts. Moreover, please
open neither oiling entrance nor the oil discharge entrance.
1
2
3
4
5
6
7
8
9
10
Place the robot in a posture of J3 = -90°.If it is impossible to make the posture in the on-site
environment, put the collection bottle under the robot.
Set dial gauges at J6-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove seal bolt (1) and plate cover 2 (2).
In case of M-10iA, M-10iA/6L,and M-10iA/10S replace packing (3). (Remove adhesive tape
completely.)
Remove seal bolt (4) and J6 motor cover (5).
In case of M-10iA or M-10iA/6L, M-10iA/10S replace packing (6). (Remove adhesive tape
completely.)
Remove cables of motor.
Remove bolt (7) and motor (8) that gears attaches.
Replace motor new one and assemble it by opposite procedure. Refer to Fig.4.14 (c) when motor
(10) is assembled. Please wrap the seal tape when you recycle seal bolt (1), (4). Replace O ring
- 77 -
4.COMPONENT REPLACEMENT
B-82755EN/05
(14) to new one, too. Please put O ring in the ditch surely. Confirm the gear passes O ring and the
gear has not come in contact with O ring. Apply LOCTITE 675 to key.
According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
11
12
1
2
3
Fig.4.14 (a) Replacing the J6-axis motor (1/2)
8
7
6
5
14
4
9
10
11
12
13
Fig.4.14 (b) Replacing the J6-axis motor (2/2)
Parts name
1
2
SEAL BOLT
PLATE COVER 2
Specifications
A97L-0218-0736#050808
A290-7221-X562
- 78 -
Number
4
1
Locking
Torque (N-m)
4.5
4.COMPONENT REPLACEMENT
B-82755EN/05
Parts name
3
4
5
6
7
PACKING
SEAL BOLT
J6M COVER
PACKING
BOLT
8
MOTOR
9
10
11
12
13
14
SPACER
GEAR J6-1
KEY
BOLT
WASHER
O RING
Specifications
A290-7221-X582
A97L-0218-0735#040808
A290-7221-X505
A290-7221-X575
A6-BA-5X12
A06B-0115-B855#0048 (*2)
A06B-0115-B205#S000 (*3)
A290-7221-X529
A290-7221-X521
JB-HKY-3X3X8A
A97L-0218-0514#M3X8
A290-7210-X532
A98L-0001-0347#S39
Number
Locking
1
4
1
1
3
Torque (N-m)
4.5
1
1
1
1
1
1
1
LT675
LT242
1.0
(*1) In case of M-10iA, M-10iA/6L, M-10iA/10S
(*2) ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S
(*3) ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L
Fix the motor while gently pressing the motor
against the direction of the arrow.
However, be careful not to press it strongly.
Gear
A290-7221-X521
J6-axis motor
Fig.4.14 (c) Note of assembling J6-axis motor
4.15
1
2
3
4
5
6
7
8
9
REPLACING WRIST UNIT
Place the robot in a posture of J3 = -90° and J4 = J5 =0°.
Release all oil of J5/J6 gearbox referring to section 2.2.
Make robot to the posture of J3=5° and J4=±180° while being careful not to move the J5/J6-axes
enough. (If J5/J6-axis are moved without oil, it causes burning of the gear.)
Set dial gauges at J5/J6-axes, and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the J5-axis motor as described in Section 4.13.
Remove seal bolt (1), (3) and wrist unit (2). In this case, it is possible to remove by evenly tightening
the M5 bolt in the pulling out tap two places shown in Fig.4.15 (b).
Remove sealant of sealing face of J3 arm side completely, then clean them by using cleaning agent
and remove grease thoroughly.
Spread three bonds TB1133G (Spec: A98L-0040-0238#0.33KG) or LOCTITE 518 on the uniting
side of the wrist unit and the J3 arm by the thickness of about 1mm referring to Fig.4.13 (c). In this
- 79 -
4.COMPONENT REPLACEMENT
10
11
12
13
14
B-82755EN/05
time, apply three bonds to the hollow part of the counter boring, too. Remove the seal material that
may be seen to the oil bath part as much as possible.
(When using LOCTITE 7649 together)
Five hours are usually necessary because of hardening after applying three bond 1133G or
LOCTITE 518. But if LOCTITE 7649 (accelerator) is used together, it can shorten time. The method
is shown below. Apply sealant (1133G) to J3 arm side (Refer to right figure of Fig.4.15 (c).), then
apply LOCTITE 7649 (Refer to left figure of Fig.4.13 (c).) Insert wrist unit to J3 arm within 2
minutes, and wipe up the overflowed sealant. Apply LOCTITE 7649 to all circumference part of
mating face referring to Fig.4.13 (b). After 30 minutes wipe the LOCTITE 7649 (blue) neatly and
start the oiling process.
Confirm there are two parallelφ5 pins for the positioning on the J3 arm. Then replace wrist unit to
new one and assemble it by opposite procedure. Please wrap the seal tape when you re-use the seal
bolt (1) and (3). Please do not forcibly pull with the bolt and do not fix the wrist unit. The gear might
not enter the drive shaft easily when the wrist unit is installed. And it must enter smoothly and not
forcibly. For this case, the J6 axis motor is removed referring to Section 4.14, and the wrist unit is
installed while rotating the drive shaft by the hand. Please fix the bolt when you confirm the
installation is easily obtained neatly.
Please leave the robot for five hours or more and monitor the firmness the seal sealant material.
(Only when LOCTITE 7649 is not used.)
Referring to Section 4.13, attach J5-axis motor.
According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil.
Perform single axis mastering referring to Section 8.5 of operator’s manual.
NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear (A290-7221-X511) of J5-axis motor shaft and
gear (A290-7221-X521) of J6-axis motor shaft.
O5 parallel pin
1
2
3
Fig.4.15 (a) Replacing the wrist unit
- 80 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Removal tap (M5)
Applying area of
LOCTITE 7649 (accelerator)
(all circumference part including back side)
( 11 )
Fig.4.15 (b) Position of removal tap of wrist unit and LOCTITE 7649 applying area
( 19 )
( 18 )
Apply 1133G to this range of X507.
Apply 1133G to the head of the bolt.
Wrist unit side
J3 arm side
Fig.4.15 (c) Sealant applying area
- 81 -
4.COMPONENT REPLACEMENT
Specifications
Parts name
1
2
3
SEAL BOLT
WRIST ASSY
SEAL BOLT
4.16
1
2
3
4
5
6
B-82755EN/05
A97L-0218-0423#053016
A290-7221-V504
A97L-0218-0423#052016
Numb
er
Locking
4
1
3
REPLACING THE J2 COVER (OPTION)
Remove bolt (1) and washer (2).
Remove J2 cover (3). When replacing only J2 cover, omit the procedure 3 to 5.
Remove bolt (5) and washer (6).
Remove base support (4).
Remove bolt (8) and support (7).
Replace J2 cover (3) to new one, and assemble it by opposite procedure.
3
1
2
Fig.4.16 (a) Replacing J2 cover (1/3)
- 82 -
Torque (N-m)
9.0
9.0
4.COMPONENT REPLACEMENT
B-82755EN/05
4
6
5
Fig.4.16 (b) Replacing J2 cover (2/3)
7
8
Fig.4.16 (c) Replacing J2 cover (3/3)
1
2
3
4
5
6
7
8
Parts name
BOLT
WASHER
J2 COVER
BASE SUPPORT
SEAL BOLT
WASHER
SUPPORT
BOLT
Specifications
A97L-0218-0502#M5X10
A6-WM-5S
A290-7221-X381
A290-7221-X382
A97L-0218-0736#050808
A6-WM-6S
A290-7221-X383
A6-BA-8X12
- 83 -
Number
5
5
1
1
2
2
1
1
Locking
Torque (N-m)
4.COMPONENT REPLACEMENT
4.17
1
2
3
4
5
B-82755EN/05
REPLACING THE J4 COVER (OPTION)
Remove bolt (1) and washer (2).
Remove J4 cover (3). When replacing only J4 cover, omit the procedure 3 and 4.
Remove bolt (5) and support A (4).
Remove bolt (6) and support B (7).
Replace J4 cover (3) to new one, and assemble it by opposite procedure.
1 2
3
Fig.4.17 (a) Replacing J4 cover (1/2)
6
4
7
5
Fig.4.17 (b) Replacing J4 cover (2/2)
Parts name
1
2
3
4
5
6
7
BOLT
WASHER
J4 COVER
SUPPORT A
BOLT
BOLT
SUPPORT B
Specifications
A97L-0218-0502#M5X10
A6-WM-6S
A290-7221-X481
A290-7221-X482
A6-BA-6X10
A6-BA-3X5
A290-7221-X483
- 84 -
Number
4
4
1
1
2
2
1
Locking
Torque (N-m)
4.COMPONENT REPLACEMENT
B-82755EN/05
4.18
2
3
M/H conduit is option to protect hand cable etc. You can prevent cables interference with arm
directly by installing this and can postpone life of cables. Instead conduit is expendable supplies>
replace it regularly.
The cable is clamped at a position 70mm or more away for the wrist side is recommended. A position
30mm or more away is recommended for the J4 back side. In case of M-10iA, adjust the length of the
cable between clamping to 785±5mm. In case of M-10iA/6L, adjust the length of the cable between
clamping to 1005±5mm. Please absorb extra length to Conduit. If cables are not clamped, it cause
broken of cable and conduit, be sure to clamp cables.
The longevity of the cable improves by spreading grease on the surface of the cable in Conduit. Shell
Alvania grease S2 is recommended. In this case, please use the cable with performance that can
endure oil. If grease is not applied, it causes early damage of cables and conduit.
Cable name
End effector cable
Signal line
3DL sensor cable
Power line
Force sensor cable
3DL sensor camera cable
LED lighting cable
Table 4.18 (a) Recommended cables and air tube
Maker
Spec of FANUC
Specifications
Oki cable
co. Ltd
Oki cable
co. Ltd
Oki cable
co. Ltd
Okano
cable co.
Ltd
Hitachi
cable co.
Ltd
Hitachi
cable co.
Ltd
Air tube
SMC
(Cable length between clamp
A66L-0001-0459
0.2mm2
24-core Cable for moving part
2
A66L-0001-0464#1
0.2mm
2-core 4 pairs (8-core) Cable for
moving part
A66L-0001-0401#10
1.25mm2 10-core Cable for moving part
A66L-0001-0178#03P
0.3mm2 2-core 3 pairs (6-core) Cable for
moving part
A66L-0001-0525
2
0.26mm 4-core
0.13mm2 2-core
0.08mm2 2-core
Cable for moving part
A66L-0001-0143
0.2mm2
A97L-0218-0010
TU0604 (Outside diameter=Φ6mm,
Inside diameter=Φ4mm)
6-core Cable for moving part
M-10iA : 785u5mm , M-10iA/6L : 1005u5mm
70 mm
30 mm
Nylon band
Cable , air tube
Rubber tube
Cable clamp position
A
1
NOTES FOR ASSEMBLING CABLES WITH M/H CONDUIT
Greaes applying area (recommended)
Cable clamp position
Fig.4.18 (a) Cable length between clamps
- 85 -
4.COMPONENT REPLACEMENT
Please install circumscription yen of bunches of cables on 30mm or less as shown in figure so that
cables should not rub at the edge of the J6 hollow flange. If filling degree is over , it causes early
damage of conduit.
O
30
3
B-82755EN/05
cable,air tube
Conduit
Fig.4.18 (b) Diameter of cable and air tube in conduit
4
5
6
It is recommended to install protect ring if necessary so that neither cable nor bolt attached to the J6
hollow flange may interfere.
Please roll cables in the rubber seat etc. so as not to damage surfaces of cables by the edge of the
nylon band in the cable clamping part, and bind on that in the nylon band.
When M/H conduit is installed, use by the range limitation of J6 axis range of motion ±190° is
recommended. The longevities of cables shortens when using it exceeding ±190° though it is
possible to use even in range of motion more than this (maximum ±270°).
Table 4.18 (b) Regular exchange cycle
Exchange cycle
J5-axis:±140°
J6-axis:±190°
Cycle that is shorter among 2.4 million cycles
(As one cycle every 30 seconds and four years
NOTE
Please note that it is a standard at the exchange cycle when the cable wire rod
and the air tube of the FANUC recommendation are used. If cable is not
clamped or grease is not applied or filling degree of cable in conduit is over or
robot is operated with fluoric resin ring is broken, it causes early damage of
cables and conduit.
(7) Please examine the structure that the cutting powder etc. Do not invade in Conduit when you specify
M/H conduit and severe dust/liquid protection option simultaneously.
(8) Fluoric resin ring is installed to J6 hollow part and white powder is generated to reduce friction of
rotation. This is not trouble. Fluoric resin ring is expendable supply. (Spec: A290-7221-X571)
Two years are aims in an exchange period. If you operate robot with the state that hard mine dust
is attached to rotated part, exchange period may shortens. If robot is operated with fluoric resin rig is
broken, it causes early damage of conduit.
4.19
REPLACING M/H CONDUIT (OPTION)
(When replacing unit)
1
2
3
Remove all cables, the air tubes, and the cable clamping, etc. that go in M/H conduit.
Remove M4×10 bolts (2pcs) in Fig.4.19 (a) and remove unit of M/H conduit.
Attach new M/H conduit by opposite procedure. In this time, according to Fig.4.19 (a) apply
LOCTITE 242 to internal thread and tighten by regulated torque. Assemble them while paying
attention that circumference of adapter does not interfere inside of out shaft of J6 hollow part.
- 86 -
4.COMPONENT REPLACEMENT
B-82755EN/05
(Otherwise abnormal noise occurs.) Confirm there is a clearance between them. Pay attention that
ring does not protrude from circumference of adapter, too.
Bolt
M4X10(2)
LT242
Fig.4.19 (a) Replacing M/H conduit (1/2)
(When replacing only conduit)
1
2
3
4
5
6
Remove all cables, the air tubes, and the cable clamping, etc. that go in M/H conduit.
Remove M4×10 bolts (2pcs) in Fig.4.19 (a) and remove unit of M/H conduit.
Remove set screw that fix ring.
Sleeve might be attached depending on the shipping time, then remove sleeve.
Remove conduit from adapter.
Attach new M/H conduit by opposite procedure. In this time, according to Fig.4.19 (a), (b) apply
LOCTITE 242 to internal thread and tighten by regulated torque. If you cut conduit, be sure to refer
NOTE in Appendix A. Assemble them while paying attention that circumference of adapter does not
interfere inside of out shaft of J6 hollow part. (Otherwise abnormal noise occurs.) Confirm there is a
clearance between them. Pay attention that ring does not protrude from circumference of adapter,
too.
Sleeve
A97L-0118-0735#RKS-36
(It might be attached
depending on the shipping time.)
Adapter
A290-7221-X631
Bolt
M4X8(3)
Tightening torque 4.5Nm
Plate
A290-7221-X632
LT242
Ring
A290-7221-X633
Set screw
A6-SAKT-3X10(2)
LT242
Conduit
(FANUC spec：
M-10iA , M-10iA/10S : A97L-0118-0734#E36-0062
M-10iA/6L : A97L-0118-0734#E36-0084)
(PMA spec：ESDT-36B)
Fig.4.19 (b) Replacing M/H conduit (2/2)
- 87 -
4.COMPONENT REPLACEMENT
4.20
1
2
3
4
B-82755EN/05
NOTES FOR ASSEMBLING CABLES WITH NO DUST M/H
CONDUIT
M/H conduit is option to protect hand cable etc. You can prevent cables interference with arm
directly by installing this and can postpone life of cables . Instead conduit is expendable supplies>
replace it regularly.
Please prepare rubber bush as figure below. Please make thickness between wrist flange and tip of
rubber bush is 9mm, thickness of rubber bush is 6mm. In case of J3 casing side, please make
thickness between back of J3 casing and tip of rubber bush is 11.4mm and thickness of rubber bush
is 6mm.Make length of cable between rubber bush is 721±5mm (in case of M-10iA) or 941±5mm
(in case of M-10iA/6L) and absorb extra length to Conduit. If cables are not clamped, it cause
broken of cable and conduit, be sure to clamp cables.
The longevity of the cable improves by spreading grease on the surface of the cable in Conduit.
Shell Alvania grease S2 is recommended. In this case, please use the cable with performance that
can endure oil. If grease is not applied, it causes early damage of cables and conduit.
Confirm there is no gap in slit part of rubber bush. If there is a gap, clean degree turn worse. Please
be careful.
Table 4.20 Recommended cables and air tube
Maker
Spec of FANUC
Cable name
End effector cable
Signal line
3DL sensor cable
Power line
Force sensor cable
3DL sensor camera cable
LED lighting cable
Air tube
Oki cable
co. Ltd
Oki cable
co. Ltd
Oki cable
co. Ltd
Okano
cable co.
Ltd
Hitachi
cable co.
Ltd
Hitachi
cable co.
Ltd
SMC
Specifications
A66L-0001-0459
0.2mm2
A66L-0001-0464#1
0.2mm2 2-core 4 pairs (8-core) Cable
for moving part
A66L-0001-0401#10
1.25mm2 10-core Cable for moving part
A66L-0001-0178#03P
0.3mm2 2-core 3 pairs (6-core) Cable
for moving part
A66L-0001-0525
2
0.26mm 4-core
0.13mm2 2-core
0.08mm2 2-core
24-core Cable for moving part
Cable for moving part
A66L-0001-0143
0.2mm2
A97L-0218-0010
TU0604 (Outside diameter=Φ6mm,
Inside diameter=Φ4mm)
6-core Cable for moving part
Clamp length between clamp
M-10iA : 721±5mm
M-10iA/6L : 941±5mm
6
11.4
6
9
Rubber bush
Rubber bush
Grease applying area
Fig.4.20 (a) Cable length between clamp
- 88 -
4.COMPONENT REPLACEMENT
B-82755EN/05
5
Please install circumscription yen of bunches of cables on 30mm or less as shown in figure so that
cables should not rub at the edge of the J6 hollow flange. If filling degree is over, it causes early
damage of cables and conduit.
Conduit
O 30
Cable , air tube
Fig.4.20 (b) Diameter of cable and air tube in conduit
- 89 -
4.COMPONENT REPLACEMENT
Refer to Fig.4.20 (c) about shape of rubber bush and structure of cables in conduit.
Shape of rubber bush of back
of J3 casing side
slit(to go through wire rod)
2mm or more
2mm or more
4-O5
Air tube (O6mm) X 4
O43
O46
7
O3
O7
6
O7
EE (O8mm)
Signal line (O8mm)
Shape of rubber bush of
wrist side
slit(to go through wire rod)
2mm or more
6
O46
O3
Air tube (O6mm) X 4
2mm or more
4-O
5
7
O7
EE (O8mm)
O7
O43
6
B-82755EN/05
Signal line (O8mm)
[Example of four φ6 air tube ,EE(φ8mm) and signal line (φ8mm)]
・Design rubber bush so that diameter of hole is smaller 1mm than air tube and
cable sheet.
・Post air tube and wire rod in dotted line of φ36mm.
・The direction of taper is reversed in case of back of J3 casing side and wrist side.
・Secure the wall thickness more than 2mm between holes.
・Flouring rubber , the hardness between 30 to 50 is recommended.
Fig.4.20 (c) Shape of rubber bush (example)
- 90 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Refer to Fig.4.20 (d) about structure of seal of back of J3 casing.
Example of structure of seal of back
of J3 casing
Base plate mounting bolt
M5×25
(9pcs：Tightening torque 6.0Nm)
Use belleville spring washer.
9
2.4±0.05
Ｒ
0.
Remove bolts which are attached to robot
when it is shipped, and tighten base plate and
plate of back together.
8M
AX
O ring G105
(JIS-B-2401,JIS-B-2406)
A
0
O110H7
O40
O40
O44
Rubber bush
(Flouring rubber
The hardness between
30 to 50)
+0.035
Plate to hold
(Metal which thickness is 2T or more.
SUS or plating metal is recommended.)
Bolt for mounting plate
for holding rubber bush
M4 is recommended,Bolt screw
mating length 1.5d, Equally spaced
(8pcs：Tightening torque 4.5Nm)
6
Base plate
(The board of
aluminium alloy)
32.5
32.5
46
78.5
25
32.5
46
46
7.5
7
39
VIEW A
Fig.4.20 (d) Structure of seal of back of J3 casing
- 91 -
4.COMPONENT REPLACEMENT
8
B-82755EN/05
Refer to Fig.4.20 (e) about structure of seal of wrist.
If wrist is not sealed, dust come from hollow hole. Be sure to seal wrist.
*When you choose material and treatment, take rust protection into account.
*When you choose rubber bush, take weatherability and medicine characteristicresistant into account.
Example of structure of seal of wrist
3
Hand base plate mounting bolt
M4×10(8pcs：Tightening torque 4.5Nm)
Use belleville spring washer.
Refer to section 4.1 about mounting pitch.
4 5
Ｒ０．４ＭＡＸ
O44
O40
O40
O62H7 +0.030
0
A board to hold
(Metal which thickness is 2T or more.
SUS or plating metal is recommended.)
Rubber bush
(Flouring rubber
The hardness between
30 to 50)
3
Robot wrist flange
Sealant applying area
（Recommended sealant:LOCTITE 518)
6
Bolt for mounting plate for
holding rubber bush
M4 is recommended,Bolt screw mating length 1.5d,
Equally spaced
(8pcs：Tightening torque 4.5Nm)
Hand base plate
(The board of
aluminium alloy)
Fig.4.20 (e) Structure of seal of wrist (example)
9
When No dust M/H conduit is installed, use by the range limitation of J6 axis range of motion
±190° is recommended. The longevities of cables shortens when using it exceeding ±190° though it
is possible to use even in range of motion more than this (maximum ±270°). For J5-axis use it
motion range in ±120°. If J5-axis move more than ±120°, it cause break of conduit, be careful.
NOTE
If cable is not clamped or grease is not applied or filling degree of cable in conduit
is over or robot is operated with fluoric resin ring is broken, it causes early
damage of cables and conduit.
10 Specification is ISO class 5 (equal to clean class 100).
- 92 -
4.COMPONENT REPLACEMENT
B-82755EN/05
4.21
REPLACING NO DUST M/H CONDUIT (OPTION)
(When replacing unit)
1
2
3
Remove all cables, the air tubes, and the cable clamping, etc. that go in No dust M/H conduit.
Remove M4×10 bolts (2pcs) and M5×45 bolts (2pcs) in Fig.4.21 (a) and remove unit of M/H
conduit.
Attach new No dust M/H conduit by opposite procedure. In this time, according to Fig.4.21 (a)
apply LOCTITE 242 to internal thread and tighten by regulated torque.
Bolt
A97L-0218-0432#5X45 (2)
LT262
Tightening torque 7Nm
Bolt
A97L-0218-0496#M4X10SC (2)
LT242
Tightening torque 4.5Nm
Fig.4.21 (a) Replacing No dust M/H conduit (1/3)
(When replacing only conduit)
1
2
3
4
5
6
Remove all cables, the air tubes, and the cable clamping, etc. that go in No dust M/H conduit.
Remove bolt M3×8 (8pcs), holder (2pcs), J6 adapter and packing of wrist side.
Remove bolt M3×8 (8pcs), holder (2pcs), J3 adapter and packing of J3 casing side.
Cut conduit referring to note of Appendix A.
Polish conduit with a brush made by nylon.
Attach new No dust M/H conduit by opposite procedure referring to Fig.4.21 (a) to (c). Replace
packing , seal bolt and bolts that LOCTITE is applied. Remove old packing of holder and attach new
packing referring to Fig.4.21 (b). When attaching packing, put it on the oil seal inside the wrist unit
and put J6 adapter on it, and fix them with bolts. Apply LOCTITE 242 and 262 to thread of bolt and
tighten bolts with regulated torque.
- 93 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Holder
A290-7221-X642 (2)
Seal bolt
A97L-0218-0546#030806SC (8)
Tightening torque 2Nm
Holder
A290-7221-X642 (2)
Seal bolt
A97L-0218-0546#030806SC (8)
Tightening torque 2Nm
Wrist side
J3 casing side
Packing B
A290-7221-X642
Packing A
A290-7221-Z641
Attachment packing to holder A290-7221-X642
- 94 -
4.COMPONENT REPLACEMENT
B-82755EN/05
(When attaching No dust M/H conduit to which is ordered after shipment of
robot)
1
2
3
Remove fluoric resin ring referring to Section 4.22.
Remove duct cover and clean the tap hole.
Remove plate cover and clean the tap hole.
Bolt
A6-BA-5X45(2)
Plate cover 1
A290-7221-Z561
Duct cover
A290-7221-X506
Seal bolt
A97L-0218-0736#050808(2)
Fig.4.21 (d) Attach No dust M/H conduit (1/4)
4
Paste packing (A290-7221-X647) to plate cover 1 (A290-7221-X561).
Attach packing while being careful not to
make clearlance between packing.
Plate cover 1
A290-7221-Z561
Packing
A290-7221-X647
Fig.4.21 (e) Attach No dust M/H conduit (2/4)
- 95 -
4.COMPONENT REPLACEMENT
5
B-82755EN/05
Fix plate cover 1 (A290-7221-Z561) with 2 seal bolts. Tightening torque is 4.5Nm. Bend packing
(A290-7221-X647) to have no gap at the corner.
Casting
Packing
A290-7221-X647
A
Be careful
not to make
clearlance
in conrer.
Plate
Seal bolt
A97L-0218-0736#050808SC(2)
(Tightening torque 4.5Nm)
Casting
DETAIL A
Fig.4.21 (f) Attach No dust M/H conduit (3/4)
6
Fix J3 adapter (A290-7221-X643) of no dust M/H conduit to J3 arm. Bolts are 2 RF coating bolts.
Tighten them with tightening torque 9Nm after applying LOCTITE 262 into taps.
Fix J6 adapter (A290-7221-X641) of no dust M/H conduit to J6 housing (A290-7221-X503) pushing
it to the direction of arrow D of Fig.4.21 (g). Then confirm that the gap between J5 adapter
(A290-7221-X502) and J6 adapter (A290-7221-X641) is less than 2.5mm. Bolts are 2 stainless
coating bolts. Washers are 2 stainless washers. Tighten them with tightening torque 4.5Nm after
applying LOCTITE 242 into taps.
7
C
J3 adapter
A290-7221-X643
B
B
Bolt
A97L-0218-0432#5X45(2)
(Tightening torque 9Nm)
LT262
Bolt
A97L-0218-0496#M4X10SC(2)
(Tightening torque 4.5Nm)
Washer
A6-WM-4SUS(2)
D
C J5 adapter
A290-7221-X502
J6 adapter
A290-7221-X641
LT242
SECTION C-C
Fig.4.21 (g) Attach No dust M/H conduit (3/4)
- 96 -
SECTION B-B
2.5or less
4.COMPONENT REPLACEMENT
B-82755EN/05
4.22
1
2
3
4
5
6
REPLACING FLUORIC RESIN RING
Remove the all cable connection of J3 casing.
Remove the plated bolts (2pcs) as shown Fig. 4.22, then remove the end of M/H conduit unit from
J6 hollow part.
Remove the fluoric resin ring using needle-nose pliers and other tool. Be careful not to hurt the J6
housing.
Replace the fluoric resin ring, and insert it to J6 hollow part until the edge of it get in groove inside
of J6 hollow part.
Correct the strained of the fluoric resin ring using the screwdriver and other tool.
Attach the M/H conduit unit and the cable connection of J3 casing. Assemble them while paying
attention that circumference of adapter does not interfere inside of out shaft of J6 hollow part.
(Otherwise abnormal noise occurs.) Confirm there is a clearance between them. In this time, note
that the plated bolts are applied LOCTITE 242 to internal thread and are tightened by regulated
torque. (Refer to Fig.4.22.)
Fluoric resin ring
A290-7221-X571
A
Adapter
A290-7221-X631
Plated bolt
A97L-0218-0496#M4X10TC (2)
Tightening torque 4.5Nm
Applying LOCTITE 242
DETAIL A
Fig.4.22 Replacing fluoric resin ring
4.23
SEALANT APPLICATION
Washing and degreasing the surfaces to be sealed
1
2
3
4
After dismounting the reducer from the arm, apply releasant (LOCTITE Gasket Remover etc.) to the
arm’s surface from which the reducer was dismounted, then wait until the sealant (LOCTITE 518)
becomes softened (for about 10 minutes). Remove the softened sealant from the surface using a
spatula.
Blow air onto the surface to be sealed to remove dust from the tapped holes.
Sufficiently degrease the reducer’s surface to be sealed and the arm’s surface to be sealed, using a
cloth dampened with oil and grease remover. Do not spray oil and grease remover directly onto the
surface.
Polish the arm’s surface to be sealed with an oil stone, and degrease it with removal and cleaner
again.
- 97 -
4.COMPONENT REPLACEMENT
B-82755EN/05
CAUTION
Oil may drip from the inside of the reducer. After degreasing, make sure that no
oil is dripping.
Applying sealant
5
6
Make sure that the reducer and the arm are dry (with no oil and grease remover remaining). If they
are still wet with oil and grease remover, wipe them dry. Always use a new surface of a cloth so that
the grease once wiped up with the cloth will not get on the degreased surface. Make sure that no
ingredient of oil and grease remover is left in the threaded holes or on any other portion. If
ingredient is left, it may prevent stiffening of sealant.
Apply sealant (LOCTITE 518) to the surfaces.
CAUTION
The portions to which sealant is to be applied vary from one axis to another. See
descriptions about reducer replacement for the relevant axes for details.
Assembling
7
8
9
To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as
quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant
was wiped off, apply again.
After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get
closer.
After attaching the reducer, wipe off any excessive sealant that comes out from the sealed section
with a cloth or spatula. Do not use oil and grease remover.
CAUTION
Do not grease or move the reducer before the sealant sets, as it may allow
grease to leak. Before greasing or moving, wait for about at least four hour after
the reducer is mounted.
- 98 -
5.CABLE REPLACEMENT
B-82755EN/05
5
CABLE REPLACEMENT
Replace the welding power cables of the mechanical unit in the cycle that is shorter among every about
two years and 7,680 hours operating. Replace the other cables of the robot in the cycle that is shorter
among every four years and 15,360 hours operating. If a cable is broken or damaged, replace it according
to the procedure described in this chapter.
Cautions in handling the Pulsecoder cable
When transporting, installing, or maintaining the robot, do not detach the Pulsecoder cables carelessly.
The cables are provided with the marking tie shown below. If you detached any cable with the marking
tie, you need to perform mastering for the robot.
Do not detach any connector unless you replace a motor, Pulsecoder, reducer, gearbox or cable.
BATTERY BACKUP
DON'T
DISCONNECT
コネクタ取外不可
Fig.5 Wire mark
If there is a break in or any other damage to a cable, replace the cable according to the procedure
described in this chapter. If the connector of a motor cable is detached, the data about the absolute
position of the robot is lost. Once any of these cables is replaced, perform quick mastering while
referencing Section 8 of operator’s manual. If the data is lost because of a break in a cable, also perform
mastering to calibrate the robot into the previous absolute position.
- 99 -
5.CABLE REPLACEMENT
5.1
B-82755EN/05
CABLE WIRING
Fig.5.1 is the routing of the robot cables. See Chapter 5 of operator’s manual for option cable interface.
K101 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8))
K102 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(Non corresopondence to CE)
K103 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(ARC Mate 100iC , M-10iA)
K111 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8)
:for severe dust/liquid protection option)
(M-10iA)
K121 (M1 to M6 Pulsecoder,power,brake(J2/J3-axis only))
(ARC Mate 100iCe , M-10iAe)
K131 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8))
K132 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(Non corresopondence to CE)
K133 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(ARC Mate 100iC/6L , M-10iA/6L)
K141 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8)
:for severe dust/liquid protection option)
(M-10iA/6L)
K151 (M1 to M6 Pulsecoder,power,brake(J2/J3-axis only))
(ARC Mate 100iCe/6L , M-10iAe/6L)
K161 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8))
K162 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(Non corresopondence to CE)
(ARC Mate 100iC/10S , M-10iA/10S)
K301 Wire feeder cable
K311 User cable (signal)
K312 User cable (power)
K315 User cable (signal usable to force sensor and 3DL sensor)
K321 Welding power cable 38SQ
K323 Welding power cable 60SQ
K331 Earth cable for camera
K351 Camera and 3DL sensor cable
K701 Camera cable (non waterproof type)
K702 Camera cable (waterproof type)
(ARC Mate 100iC , M-10iA,ARC Mate 100iC/6L , M-10iA/6L)
K314 User cable (signal line usable to the 3DL sensor and force sensor)
K331 Earth cable for camera
K703 Camera cable (waterproof type)
(ARC Mate 100iC/10S , M-10iA/10S)
Fig.5.1 Routing of the robot
- 100 -
5.CABLE REPLACEMENT
B-82755EN/05
5.2
CABLE DRESSING
After a cable is replaced individually rather than in a bundle, clamp it with nylon ties (cable ties) at the
specified positions listed in Table 5.2 (a) to (f). Otherwise, the cable might sag or become too tight,
leading to a break in the cable.
Clamp position of Table 5.2 (a) to (g) mean position in Fig.5.2 (a), (b).
Clamp position of inside J1 base
DETAIL B
Clamp position of
pipe of J1-axis reducer
A
C
DETAIL C
Clamp position of J2 base
D
B
SECTION A-A
DETAIL D
A
G
F
Clamp position of
lower side of J2 arm
Clamp position of
J4 connector plate
DETAIL E
Clamp position of
upper side of J2 arm
E
DETAIL G
DETAIL F
Fig.5.2 (a) Clamp position of motor cable
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iCe, M-10iAe)
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5.CABLE REPLACEMENT
B-82755EN/05
Clamp position of inside J1 base
DETAIL I
Clamp position of
pipe of J1-axis reducer
H
J
DETAIL J
J
I
SECTION H-H
K
Clamp position of J2 base
J
DETAIL K
H
N
M
L
Clamp position of
lower side of J2 arm
DETAIL L
Clamp position of
upper side of J2 arm
DETAIL M
DETAIL N
Clamp position of
J4 connector plate
Fig.5.2 (b) Clamp position of motor cable (ARC Mate 100iC/10S, M-10iA/10S)
- 102 -
5.CABLE REPLACEMENT
B-82755EN/05
Table 5.2 (a) Cable pattern diagram (1)
Stamp Cable
No.
Cable pattern diagram
Stamp
Clamp position of inside of J1 base
Clamp position on pipe of J1-axis reducer
Clamp position of J2 base
Clamp position of lower side of J2 arm
+
GB1
-
Clamp position of upper side of J2 arm +
Clamp position of J4 connector plate M 1P
M1P
M3P
M3P
K101
M2P
M2P
M4P
M4P
M5P
M5M
EE
M5BK
EE
M5P
M5M
M5BK
M6P
M6M
M 6BK
M6P
M6M
M6BK
M3M
M3M
M4M
M4BK
M1M
M1BK
M4M
M4BK
M1M
M1BK
M2M
M2M
M2BK
M2BK
- 103 -
K101,
K131,
K161
5.CABLE REPLACEMENT
B-82755EN/05
Table 5.2 (b) Cable pattern diagram (2)
Stamp Cable
No.
Cable pattern diagram
Stamp
Clamp position of inside of J1 base
Clamp position on pipe of J1-axis reducer
Clamp position of J2 base
Clamp positio of lower side of J2 arm
+
GB1
-
Clamp position of upper side of J2 arm +
Clamp position of J4 connector plate M1P
M1P
M3P
M3P
K101
M2P
M2P
M4P
M4P
M5P
M5M
EE
M5BK
EE
M5P
M5M
M5BK
M6P
M6M
M6BK
M6P
M6M
M6BK
M3M
M3M
M4M
M4BK
M1M
M1BK
M4M
M4BK
M1M
M1BK
M2M
M2M
M2BK
M2BK
- 104 -
K102,
K132,
K162
5.CABLE REPLACEMENT
B-82755EN/05
Table 5.2 (c) Cable pattern diagram (3)
Stamp Cable
No.
Cable pattern diagram
Stamp
Clamp position of inside of J1 base
Clamp position on pipe of J1-axis reducer
Clamp position of J2 base
Clamp position of lower side of J2 arm
+
GB1
-
Clamp position of upper side of J2 arm +
Clamp position of J4 connector plate M1P
M1P
M3P
M3P
K101
M2P
M2P
M4P
M4P
M5P
M5M
EE
M5BK
EE
M5P
M5M
M5BK
M6P
M6M
M 6BK
M6P
M6M
M6BK
M3M
M3M
M4M
M4BK
M1M
M1BK
M4M
M4BK
M1M
M1BK
M2M
M2M
M2BK
M2BK
- 105 -
K103,
K133
5.CABLE REPLACEMENT
B-82755EN/05
Table 5.2 (d) Cable pattern diagram (4)
Stamp Cable
No.
Cable pattern diagram
Stamp
Clamp position of inside of J1 base
Clamp position on pipe of J1-axis reducer
Clamp position of J2 base
Clamp position of lower side of J2 arm
+
GB1
-
Clamp position of upper side of J2 arm +
Clamp position of J4 connector plate M1P
M1P
M3P
M3P
K101
M2P
M2P
M4P
M4P
M5P
M5M
EE
M5BK
EE
M5P
M5M
M5BK
M6P
M6M
M6BK
M6P
M6M
M6BK
M3M
M3M
M4M
M4BK
M1M
M1BK
M4M
M4BK
M1M
M1BK
M2M
M2M
M2BK
M2BK
- 106 -
K111,
K141
5.CABLE REPLACEMENT
B-82755EN/05
Table 5.2 (e) Cable pattern diagram (5)
Stamp Cable
No.
Cable pattern diagram
Stamp
Clamp position of inside of J1 base
Clamp position on pipe of J1-axis reducer
Clamp position of J2 base
Clamp position of lower side of J2 arm
+
GB1
-
Clamp position of upper side of J2 arm +
Clamp position of J4 connector plate M1P
M1P
M3P
M3P
K101
M2P
M2P
M 4P
M4P
M5P
EE
M5M
EE
M5P
M5M
M6P
M6M
M6P
M6M
M3M
M3M
M4M
M4M
M1M
M1M
M2M
M2M
M2BK
M2BK
- 107 -
K121,
K151
5.CABLE REPLACEMENT
B-82755EN/05
Table 5.2 (f) Cable pattern diagram (6)
Cable pattern diagram
Stamp
Stamp
Cable
No.
W/F2
K301
AS2
K311
AP2
K312
ASi2
K314
ASi2
K315
K301 W/F1
W/F1
W/F2
Clamp position of
J4 connector plate
AS2
AS1
K311 AS1
Clamp position of
J4 connector plate
Clamp position of
J4 connector plate
AP2
K312 AP1
AP1
Clamp position of
J4 connector plate
K314
ASi1
ASi2
ASi1
ASi2
ASi1
K315 ASi1
Clamp position of
J4 connector plate
Clamp position of
J4 connector plate
Clamp position of
upper side of J2 arm
K321
- 108 -
5.CABLE REPLACEMENT
B-82755EN/05
Table 5.2 (g) Cable pattern diagram (7)
Cable pattern diagram
Stamp
Stamp
Cable
No.
Clamp position of
lower side of J2 arm
Clamp position of
upper side of J2 arm
Clamp position of
J4 connector plate
Clamp position of
J2 base
K323
K331
Clamp position of
J4 connector plate
K351
SEN2
CAM2 K701
CAM1 1221-D301
CAM2 K702
CAM2 K702
Clamp position of
J4 connector plate
CAM2 K703
CAM1
CAM2 K701
Clamp position of
J4 connector plate
CAM1 1221-D302
CAM1
K351
Clamp position of
J4 connector plate
CAM1 1221-D303
CAM1
SEN2
SEN1
2007-T032
SEN1
Clamp positio of lower side
of J2 arm
- 109 -
CAM2 K703
5.CABLE REPLACEMENT
5.3
1)
B-82755EN/05
REPLACING CABLES
Replacing the cable kit
When you have special tool for remove connector of J6-axis, place the robot in a posture of J1 to J4
= 0°
When you don’t have special tool, place the robot in a posture of J1, J2 and J4 =0° and J3=-90°
(Refer to Section 4.14.)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. (It is
set in 0º for all axes when robot is shipped.)
Before replacing cables, turn off the controller power and remove all cables between robot and
controller from the robot.
Cut the nylon band for the J2-/J3-axis cable protection sheet, and remove the cover from the
cable kit. (Refer to Fig.5.3 (a)).
(There is no cable protection sheet for ARC Mate 100iCe,M-10iAe, ARC Mate
100iCe/6L,M-10iAe/6L.)
Remove extra low bolt and button seal bolt, J6 motor cover and J5 motor cover. (Refer to
Fig.5.3 (b)). In case of M-10iA or M-10iA/6L or M-10iA/10S, replace packing. (Remove
adhesive tape completely.)
Remove duct cover and plate cover 1 (Refer to Fig.5.3 (b)). In case of M-10iA or M-10iA/6L
or M-10iA/10S, replace packing. (Remove adhesive tape completely.)
Cut the nylon band of plate cover 1. Remove the earth terminal (M3) of upper side of J5-axis
motor. (Refer to Fig.5.3 (b))
Remove connector of J5/J6-axis motor, when connector of J6-axis motor is removed, use
special tool (A290-7221-X971). If special tool cannot be prepared, remove J6-axis motor
referring to Section 4.14 and remove connector.
Remove earth terminal (M3) above J6-axis motor. (Refer to Fig.5.3 (c))
Remove bolt M5×12 (9pcs), cover, packing (A290-7221-X441). (Refer to Fig.5.3 (e))
(Remove adhesive tape completely.)
Remove bolt M3×35 (3pcs) and pulled out pipe. (Refer to Fig.5.3 (e))
Cut the nylon band of the back of the J6-axis motor.
Remove seal bolt M6×16 (2pcs). (Refer to Fig.5.3 (e))
Remove bolt that fasten clamp (2 places) of J3 casing. Then cut nylon band. (Refer to Fig.5.3
(f))
Pull out cable that is in J3 arm to the J3 casing. When Pulsecoder cable passes between cable
clamps that is read side of J6-axis motor and J3 arm base. Pass it carefully so as not to damage
it by using the space referring to Fig.5.3 (d).
Pull out the cable from the side of the J3 casing. In this time, if power cable and Pulsecoder
cable is pulled beforehand. Work becomes easy.
Remove bolt and J4 connector plate. (Refer to Fig.5.3 (g).) In this time, do not put it into the
state to hang the cable of J4 connector plate. The cable might be hurt.
Remove connector and lead line of J3/J4-axis motor. In this time, do not put it into the state to
hang the cable of J4 connector plate. The cable might be hurt.
Remove cable cover and bolt. (Refer to Fig.5.3 (h)).
Remove connector of J1/J2-axis motor.
Remove M8×10 bolts (4pcs) that fasten J1 connector plate to J1 base and remove J1connector
plate from J1 base (Refer to Fig.5.3 (i)).
Cut the nylon band that fastens rubber boots.
Remove M4×10 bolts (4pcs) that fasten connector housing and bolt M6×10 bolts (2pcs) that
fasten support. (Refer to Fig.5.3 (i)).
Remove connector insert from connector housing and remove connector insert and rubber boot
from J1 connector plate.
Remove the terminal from battery box.
- 110 -
B-82755EN/05
5.CABLE REPLACEMENT
25
26
27
28
29
30
Remove the two earth terminals secured to the J1 base.
Pull out the air tube from the panel union.
When option cable attached, remove them from J1 connector plate and J1 base.
Remove rubber boot from the cable.
Remove the plate, which is attached to support. (Refer to Fig.5.3 (i)).
Pull out cables. When cable pass hollow part of J1-axis reducer, be careful connector insert
don’t caught in it. If cable is pulled forcibly, it causes the disconnection.
Remove plate fixation M8 bolts and the cable. (Refer to Fig.5.3 (k)).
Replace the cable kit to new one .Do 29 to 31 by opposite procedure. Pay attention cable don’t
twist in the J1 base.
Do 23 to 28 by opposite procedure. Pay attention rubber boot come between J1 connector plate
and connector housing.
Do 16 to 22 by opposite procedure. In this time, do not put it into the state to hang the cable of
J4 connector plate. The cable might be hurt.
Do 12 to 15 by opposite procedure. Wind the cable to J3 casing 4 times, and apply shell
Alvania grease S2 referring to Fig.5.3 (f). When reuse seal bolt, be sure to seal them with seal
tape. At this time, please connect it to come to the position in which the head of the nylon band
is shown in Figure 5.3 (f). The cable might be hurt when differing from the shown in the figure
position.
Do 11 by opposite procedure. Clamp cables while pulling it to the J6 motor side at this time. If
pull is insufficient, when the pipe is inserted, cable might be hurt.
Do 9 to 10 by opposite procedure. In this time, be sure to replace packing to new one.
Do 2 to 8 by opposite procedure. In this time, be sure to replace packing to new article. Install
the J2-/J3-axis cable protection sheet onto the cable kit as originally done, and then secure the
cover with nylon band. (Secure the nylon band to such an extent that the cable protection
sheet does not get out of position when the robot operates. If the nylon band is tightened
excessively, the cables in the movable section are confined and the cables can be broken at an
earlier time.)
Perform quick mastering referring Section 8.4 of operator’s manual. If motor is removed,
perform single axis mastering for the axis referring to Section 8.5 of operator’s manual.
31
32
33
34
35
36
37
38
39
2)
Replacing only motor cable
1
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. (It is
set in 0°for all axes when robot is shipped.)
2
Remove cable kit from robot referring to Section (1) of Section 5.3 (1).
3
Replace motor cable to new one and assemble it to cable kit. Clamp cables as the clamping
position that the marking position shown in Figure 5.2 (a) - (f) and in Figure 5.3 (l) is
corresponding. If cable is clamped in not specified position, slack and an impossible pull are
caused in the cable, and it causes the cable disconnection. There are cables that don’t have
marking on all position. First, set the cable with the marking position to a specified position.
The cable without marking is formed along it and do so as not to twist along it.
4
Attach the cable kit onto the robot body. (See (1) of Section 5.3.) Retighten the mounting
bolts.
5
Install the J2/J3-axis cable protection sheet as originally done. (Secure the nylon band to such
an extent that the cable protection sheet does not get out of position when the robot operates.
If the nylon band is tightened excessively, the cables in the movable section are confined and
the cables can be broken at an earlier time.) (There is no cable protection sheet for ARC Mate
100iCe,M-10iAe, ARC Mate 100iCe/6L,M-10iAe/6L.)
6
Perform quick mastering referring Section 8.4 of operator’s manual. If motor is removed,
perform single axis mastering for the axis referring to Section 8.5 of operator’s manual.
3)
Replacing only option cables (K301 etc.)
(There is no option cable for ARC Mate 100iCe,M-10iAe, ARC Mate 100iCe/6L,M-10iAe/6L.)
1
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. (It is
set in 0°for all axes when robot is shipped.)
- 111 -
5.CABLE REPLACEMENT
2
3
4
5
6
7
B-82755EN/05
Cut the nylon band that fastens J2/J3-axis cable protection sheet and remove it from cable kit.
Remove cables that is between J1 base and J4 connector plate from robot referring to (1) of
Section 5.3 and Fig.5.3 (g) to (k)
Replace option cable to new one and fasten it by opposite procedure. Retighten the mounting
bolts.
Clamp cables as the clamping position that the marking position shown in Figure 5.2 (a) - (f)
and in Figure 5.3 (l) is corresponding. If cable is clamped in not specified position, slack and an
impossible pull are caused in the cable, and it causes the cable disconnection. There are cables
that don’t have marking on all position. First, set the cable with the marking position to a
specified position. The cable without marking is formed along it and do so as not to twist along
it.
Install the J2-/J3-axis cable protection sheet as originally done. (Secure the nylon band to
such an extent that the J2/J3-axis cable protection sheet does not get out of position when the
robot operates. If the nylon band is tightened excessively, the cables in the movable section
are confined and the cables can be broken at an earlier time.)
Perform quick mastering referring Section 8.4 of operator’s manual. If motor is removed,
perform single axis mastering for the axis referring to Section 8.5 of operator’s manual.
Cable protection sheet
Cable protection sheet
J
ARC Mate 100iC , M-10iA,
ARC Mate 100iC/6L , M-10iA/6L
ARC Mate 100iC/10S , M-10iA/10S
Fig.5.3 (a) Replacing cable kit (J2/J3-axis cable protection sheet)
- 112 -
5.CABLE REPLACEMENT
B-82755EN/05
Bolt
M5X45 (2)
Tightening torque 9Nm
LT262
Duct cover
Cut nylon band and
remove cable from clamp
of the back side.
Extra low bolt
M5X8 (2)
Tightening torque 4.5Nm
Plate cover 1
Bolt
M3X6
Earth terminal
Packing (*)
A290-7221-X581
Cut nylon band which fix
this cable to the plate
of the interior of J6-axis motor.
Bolt M3X6
Packing (*)
A290-7221-X582
Packing (*)
A290-7221-X575
J5 motor cover
J6 motor cover
Button seal bolt
M4X8(4)
Tightening torque 4.5Nm
Extra low seal bolt
M5X8(4)
Tightening torque 4.5Nm
(*) In case of M-10iA , M-10iA/6L , M-10iA/10S
Fig.5.3 (b) Replacing cable kit (J3 arm part 1)
Earth terminal
Fig.5.3 (c) Replacing cable kit (J3 arm part 2)
- 113 -
5.CABLE REPLACEMENT
B-82755EN/05
Cable clamp
Pulsecoder cable
connector
J3 arm base
Fig.5.3 (d) Replacing cable kit (J3 arm part 3)
Packing
A290-7221-X441
Cover
Bolt M5X12(9)
Apply LOCTITE 242.
Tightening torque : 4.5Nm
Seal bolt
M6X16(2)
Bolt
M3X35(3)
Pipe
Fig.5.3 (e) Replacing cable kit (J3 casing part 1)
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S)
- 114 -
5.CABLE REPLACEMENT
B-82755EN/05
Dummy pipe
Bolt
M3X30 (3)
Packing
A290-7221-X441
Cover
Bolt
M5X8 (9)
Tightening torque 6.8Nm
Seal bolt
M6X16 (2)
Fig.5.3 (f) Replacing cable kit (J3 casing part 1)
(ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)
Marking position
WIND THE CABLE FOUR TIMES.
APPLY SHELL ALVAIA GREASE S2
AFTER ASSEBLING.
Bolt
M4X5(2)
Position of the head
of the nylon band
Position of the head
of the nylon band
Bolt
M3X6(2)
Apply LOCTITE 242.
Clamp
Marking position
Fig.5.3 (g) Replacing cable kit (J3 casing part 2)
- 115 -
5.CABLE REPLACEMENT
B-82755EN/05
Prevent the load from hanging
to the cable which is connected to
J4 connector plate.
Bolt
M6X10
Bolt
M6X10
Bolt
M8X10 (2)
J4 connector panel 2
Bolt
M6X10 (3)
Prevent the load from hanging
to the cable which is connected to
J4 connector plate.
J4 connector panel 1
J4 connector panel
ARC Mate 100iC/10S , M-10iA/10S
ARC Mate 100iC , M-10iA,
ARC Mate 100iC/6L , M-10iA/6L
ARC Mate 100iCe , M-10iAe,
ARC Mate 100iCe/6L , M-10iAe/6L
Fig.5.3 (h) Replacing cable kit (J4 connector plate part)
Cable cover
Bolt
M8X10(2)
Bolt
M6X12(2)
Fig.5.3 (i) Replacing cable kit (J2 base part)
- 116 -
5.CABLE REPLACEMENT
B-82755EN/05
Option cable
Rubber boot(*)
Connector
insert
Plate
J1 connector plate
Bolt
M8X10(4)
Bolt
M4X10(4)
Connector housing
Bolt
M6X10(2)
Support
Air tube
Terminal of
battery box
Bolt
M6X8 (2)
(*)When mechanical unit cable A05B-1221-H202,
H203,H232 or H233 is selected,there is no rubber boot.
-
Tie up with nylon band.
-
+
+
Tightening torque
0.40Nm
Battery box terminal side
Fig.5.3 (j) Replacing cable kit (J1 connector plate part 1)
A
TIE UP END OF RUBBER
TUBE WITH NYLON BAND.
SECTION A-A
A
Fig.5.3 (k) Replacing cable kit (J1 connector plate part 2)
- 117 -
5.CABLE REPLACEMENT
B-82755EN/05
Bolt
M8X10(4)
Apply LOCTITE 262
Plate
Plate
Bolt
M8X12 (4)
Apply LOCTITE 262
J
ARC Mate 100iC , M-10iA,
ARC Mate 100iC/6L , M-10iA/6L
ARC Mate 100iCe , M-10iAe,
ARC Mate 100iCe/6L , M-10iAe/6L
ARC Mate 100iC/10S , M-10iA/10S
Fig.5.3 (l) Replacing cable kit (J2 arm part)
- 118 -
6.MASTERING
B-82755EN/05
6
MASTERING
Mastering is an operation performed to associate the angle of each robot axis with the pulse count value
supplied from the absolute Pulsecoder connected to the corresponding axis motor. To be specific,
mastering is an operation for obtaining the pulse count value corresponding to the zero position.
6.1
GENERAL
The current position of the robot is determined according to the pulse count value supplied from the
Pulsecoder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However,
mastering becomes necessary after:
Motor replacement
Pulsecoder replacement
Reducer replacement
Cable replacement
Batteries for pulse count backup in the mechanical unit have gone dead.
WARNING
Robot data (including mastering data) and Pulsecoder data are backed up by
their respective backup batteries. Data will be lost if the batteries go dead.
Replace the batteries in the control and mechanical units periodically. An alarm
will be issued to warn the user of a low battery voltage.
Mastering method
There are following five methods of mastering.
Table 6.1 Mastering method
Fixture position
mastering
Zero-position
mastering (witness
mark mastering)
Quick mastering
Single axis mastering
Mastering data entry
This is performed using a mastering fixture before the machine is shipped from the
factory.
This is performed with all axes set at the 0-degree position. A zero-position mark
(witness mark) is attached to each robot axis. This mastering is performed with all axes
aligned to their respective witness marks.
This is performed at a user-specified position. The corresponding count value is obtained
from the rotation speed of the Pulsecoder connected to the relevant motor and the
rotation angle within one rotation. Quick mastering uses the fact that the absolute value
of a rotation angle within one rotation will not be lost.
This is performed for one axis at a time. The mastering position for each axis can be
specified by the user. This is useful in performing mastering on a specific axis.
Mastering data is entered directly.
This MAINTENANCE MANUAL describes fixture position mastering that is mainly required during
replacement of parts. For other mastering methods, refer to OPERATOR'S MANUAL.
Once mastering is performed, it is necessary to carry out positioning, or calibration. Positioning is an
operation is which the controller reads the current pulse count value to sense the current position of the
robot.
- 119 -
6.MASTERING
B-82755EN/05
CAUTION
1 If mastering is performed incorrectly, the robot may behave unexpectedly. This is
very dangerous. Therefore, the positioning screen is designed to appear only
when the $MATER_ENB system variable is 1 or 2. After performing positioning,
press F5[DONE] on the positioning screen. The $MASTER_ENB system
variable is reset to 0 automatically, thus hiding the positioning screen.
2 Before mastering is performed, it is recommended that the current mastering
data be backed up.
3 When the motion range is mechanically 360 degrees or more, if any of the axes
(J1-axis and J4-axis) to which the cables are connected is turned one turn in the
correct mastering position, the cables in the mechanical unit are damaged. If the
correct rotation position is not clear because the axis is moved too much during
mastering, remove the connector panel or cover, check the states of the internal
cables, and perform mastering in the correct position. For the checking
procedure, See Fig. 6.1 (a) to 6.1 (c).
Confirm cable is not twisted
when J1=0°.
Bolt
M8X12 (4)
J1 connector panel
Fig.6.1 (a) Confirming the state of cable (J1-axis)
- 120 -
6.MASTERING
B-82755EN/05
Packing (*)
A290-7221-X441
(*) Packing is can not be reused.
If you remove cover, replace
packing to new one.
Bolt
M5X12 (9)
Apply LOCTITE 242.
Tightening torque : 4.5Nm
Confirm cable is wound
four times when
J4=0v.
Plate
Fig.6.1 (b) Confirming the state of cable (J4-axis) (1/2)
Confirm these nylon bands
are attached.
Fig.6.1 (c) Confirming the state of cable (J4-axis) (2/2)
6.2
REGISTER OF MASTERING POSTURE
If the number of soft versions is Edition 24 or earlier of the V7.30
When FIXTURE POSITION MASTER is done for the first time.
It is necessary to input the mastering posture according to the following procedure beforehand.
(It is not necessary when FIXTURE POSITION MASTER is done for the second time or more.)
Procedure
1
2
Press the screen selection key.
Press [0 NEXT] and Select [6 SYSTEM].
- 121 -
6.MASTERING
3
4
5
6
7
8
B-82755EN/05
Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
Place the cursor on $PARAM_GRP, then press [ENTER].
[$MRR_GRP_T] is displayed then press [ENTER].
Place the cursor on $MASTER _POS, then press [ENTER].
Input MASTERING POSTURE in Fig.6.4 (e).
Turn off the power of the controller and turn on it.
(If the power supply of the controller is never turned on again, the value of the mastering posture is
not updated.
6.3
RESETTING ALARMS AND PREPARING FOR
MASTERING
Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and
display the positioning menu.
Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse not established”
Procedure
1
Display the positioning menu by following steps 1 to 6.
1
Press the screen selection key.
2
Press [0 NEXT] and Select [6 SYSTEM].
3
Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4
Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER].
5
Press F1 [TYPE], and select[Master/Cal] from the menu.
6
Select the desired mastering type from the [Master/Cal] menu.
2
To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.
1
Press the MENUS key.
2
Select [0 NEXT] and select [6 SYSTEM].
3
Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4
Place the cursor on F3 RES_PCA, then press F4 [TRUE]. The message “ TRUE” appears and
disappears immediately.
5
Turn off the controller power and on again.
3
To reset the “Servo 075 Pulse not established” alarm, follow steps 1 to 3.
1
When the controller power is switched on again, the message “Servo 075 Pulse not
established ” appears again.
2
Move the axis for which the message mentioned above has appeared till alarm disappears when
press [FAULT RESET] in either direction.
- 122 -
6.MASTERING
B-82755EN/05
6.4
FIXTURE POSITION MASTER
Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the
predetermined fixture position.
Fixture position mastering is accurate because a dedicated mastering fixture is used.
When mastering the robot, arrange the robot to meet the following conditions.
Make the robot mounting base horizontal within 1 mm.
(The overall levelness of the robot mounting surface shall be 1 mm or less.)
Remove the hand and other parts form the wrist.
Set the robot in the condition protected from an external force.
Assembling the fixture base
1
Assemble the fixture base as shown in Fig. 6.4 (a).
Bolt
M5X20 (4)
Mastering fixture B
A290-7221-X952
Plate
Bolt
M5X20 (3)
Plate
Fig.6.4 (a) Assembling the fixture base
- 123 -
6.MASTERING
2
B-82755EN/05
Adjust the dial gauge to 3.00 mm using the calibration block, and tighten it with M5 bolt as shown
in Fig. 6.4 (b). (Do not tighten the bolt too strongly or the dial gauge will be broken.)
Bolt
M5X16 (6)
Plate
Calibration block
E
A
D
B
F
C
Dial gauge
(All dial gauge indicate 3mm
in calibration.)
Assembling method of dial gauge
20 mm
Bolt M5
Clamp
Calibration block
Fig.6.4 (b) Mounting dial gauge
- 124 -
6.MASTERING
B-82755EN/05
3
Mount the fixture to the wrist flange as shown Fig. 6.4 (c).
When assembling pin A290-7221-X955, pay attention to the direction of the pin refer to Fig.6.4 (c).
Bolt
M6X20 (2)
Pin
A290-7221-X955
A290-7221-X956
Assembling pin A290-7221-X955
Robot front
Fig.6.4 (c) Assembling the fixture base
- 125 -
Assemble pin to show
the position of parallel
part of pin and robot
front in figure.
6.MASTERING
4
B-82755EN/05
Assemble the fixture to the wrist flange as shown in Fig. 6.4 (d).
When assembling pin, pay attention the parallel pin turn to radial part of hollow flange. Refer to
Fig.6.4 (d).
Pin
A290-7221-X954
Face for dial gauge
A and B
Face for dial gauge
D and F
Bolt
M4X16 (4)
Mastering fixture A
A290-7221-X951
Face for dial gauge E
Face for dial gauge C
Assemble pin the parallel part of
pin turn to radial part of hollow flange.
Fig.6.4 (d) Assembling the fixture to the wrist flange
- 126 -
6.MASTERING
B-82755EN/05
Mastering
1
2
3
4
Press MENUS.
Press NEXT and select SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
AUTO
SYSTEM Master/Cal
JOINT
TORQUE= [ON]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press‘ENTER’or number key to select.
[TYPE] LOAD RES_PCA
5
DONE
Release brake control, and jog the robot into a posture for mastering.
A to F (see Fig.6.4 (b)) of the fixture attached to the wrist are dial gauges A to F (see Figs.6.4 (d))
and make adjustments so that dial gauges A to F indicate 3 mm. A posture as shown in Fig.6.4 (e)
should be taken. See this figure for reference.
NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.$SV_OFF_ALL: FALSE
$PARAM_GROUP.$SV_OFF_ENB[*]: FALSE (for all axes)
After changing the system variables, switch the controller power off and on
again.
6
Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES.
"MASTER POSITION" shown in Fig. 6.4 (e) is set in this position.
AUTO
SYSTEM Master/Cal
JOINT
TORQUE= [ON]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data:
<0><11808249><3876856>
<9873638><122000309><2000319>
[TYPE] LOAD RES_PCA
- 127 -
DONE
6.MASTERING
7
B-82755EN/05
Select “ 6 CALIBRATE “ and press F4, YES. Mastering will be performed
Alternatively, switch the power off and on again. Switching the power on always causes positioning
to be performed.
AUTO
SYSTEM Master/Cal
JOINT
TORQUE= [ON]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg)
< 0.0000>< 0.0000>< 0.0000>
< 0.0000>< 0.0000>< 0.0000>
[TYPE] LOAD RES_PCA
8
9
DONE
After completing the calibration, press F5 Done.
Return brake control to original setting, and turn off the controller power and on again.
WARNING
Since the axis stroke is not checked during the mastering, be careful to stay
clear of the robot motion.
- 128 -
6.MASTERING
B-82755EN/05
ARC Mate 100iC
M-10iA
ARC Mate 100iCe
M-10iAe
ARC Mate 100iC/6L
M-10iA/6L
ARC Mate 100iCe/6L
M-10iAe/6L
Mastering position
Mastering position
J1
0.00000
J2 22.9302
J3 -94.7411
J4
0.00000
J5 -85.2589
J6 -90.0000
J1 0.00000
J2 55.9747
J3 -118.993
J4 0.00000
J5 -61.0069
J6 -90.0000
ARC Mate 100iC/10S
M-10iA/10S
Mastering position
J1
0.00000
J2
55.6176
J3 -108.076
J4
0.00000
J5 -71.9238
J6 -90.0000
Fig.6.4 (e) Mastering posture
- 129 -
6.MASTERING
6.5
B-82755EN/05
CHECKING THE MASTERING
1
Checking whether mastering has been made correctly
Usually, positioning is performed automatically at power-on. To check whether mastering has
been made correctly, note whether the displayed current position agrees with the actual robot
position. Use the procedure described below:
(1) Reproduce a particular point in a program. Check whether the point agrees with the specified
position.
(2) Set all axes of the robot to their 0-degree (0rad) positions. Check that the zero-degree position
marks indicated in section 8.3 of OPERATOR’S MANUAL are aligned. There is no need to
use any visual aid.
(3) Using fixtures, set the robot to the mastering position in the same way as when performing
mastering. Check that the displayed current position agrees with the actual mastering
position.
If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been
invalidated as a result of an alarm described below 2. Alternatively, the mastering data in system
variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation
error or some other reason.
Compare the data with the values indicated on the supplied data sheet. This system variable is
overwritten whenever mastering is performed. Whenever mastering is performed, record the value
of the system variable on the data sheet.
2
Alarms that may be output during mastering
This section describes those alarms related to Pulsecoders, as well as the actions required to clear
them.
(1) BZAL alarm
This alarm is output if the voltage of the Pulsecoder's backup battery falls to 0 V while the
power to the controller is disconnected. To clear the alarm, fit a new battery, execute the
pulse reset (See Section 6.3.), then turn off the controller power then on again.
Note that, if this alarm occurs, all data originally held by the Pulsecoder will have been lost.
Mastering must be performed again.
(2) BLAL alarm
This alarm is output if the voltage of the Pulsecoder's backup battery has fallen to a level where
backup is no longer possible. If this alarm is output, fit a new battery immediately while
keeping the power turned on. Check whether the current position data is valid, using the
procedure described in 1.
(3) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL, alarms
If any of these alarms is output, contact the FANUC service section. The Pulsecoder may be
defective.
- 130 -
APPENDIX
A
A.SPARE PARTS LIST
APPENDIX
B-82755EN/05
SPARE PARTS LIST
Cable No.
Table A (a) Cables (basic cable)
Specifications
Function
K101
K102
A05B-1221-D001
A05B-1221-D002
K103
K111
A05B-1221-D003
A05B-1221-D011
K121
A05B-1221-D021
K131
K132
A05B-1221-D031
A05B-1221-D032
K133
K141
A05B-1221-D033
A05B-1221-D041
K151
A05B-1221-D051
J1 to J6 MOTOR+EE(RI/OX8)
J1 to J6 MOTOR+EE(RI/OX1)
(Non-correspondence to CE)
J1 to J6 MOTOR+EE(RI/OX1)
J1 to J6 MOTOR+EE(RI/OX8)
(Severe dust/liquid protection option)
J1 to J6 MOTOR
K161
K162
A05B-1221-D061
A05B-1221-D062
J1 to J6 MOTOR+EE(RI/OX8)
J1 to J6 MOTOR+EE(RI/OX1)
Cable No.
Table A (b) Cables (option cable)
Specifications
Function
K301
K311
K312
K315
A660-2006-T755
A660-8016-T454
A660-2007-T053
A66-8017-T649
K321
K323
K331
K351
K701
K702
K314
K331
K703
A660-8040-T023
A660-8040-T024
A660-8016-T828
A660-2007-T032
A05B-1221-D301
A05B-1221-D302
A660-8017-T499
A660-8016-T828
A05B-1221-D303
Axis
J1, J2
J3
J4
J5, J6
J1
J2
J3
J4,J5,J6
J1 to J6 MOTOR+EE(RI/OX8)
J1 to J6 MOTOR +EE(RI/OX1)
(Non-correspondence to CE)
J1 to J6 MOTOR+EE(RI/OX1)
J1 to J6 MOTOR+EE(RI/OX8)
(Severe dust/liquid protection option)
J1 to J6 MOTOR
Specifications
A06B-0235-B605#S000
A06B-0212-B605#S000
A06B-0115-B804
A06B-0115-B855#0048
A06B-0235-B005#S000
A06B-0235-B605#S000
A06B-0212-B605#S000
A06B-0115-B205#S000
Wire feeder power cable
User cable (signal)
User cable (power)
User cable (signal usable to
force sensor and 3DL sensor)
Welding power cable (38SQ)
Welding power cable (60SQ)
Earth cable for camera
Force sensor, 3DV sensor cable
Camera cable (Non-waterproof type)
Camera cable (Waterproof type)
User cable (signal)
Earth cable for camera
Camera cable (Waterproof type)
Table A (c) Motor
Remarks
αiS8/4000
αiS2/5000
βiS0.5/6000
βiSR0.5/6000
αiS8/4000
αiS8/4000
αiS2/5000
βiSR0.5/6000
- 133 -
Model
ARC Mate 100iC
M-10iA
ARC Mate 100iCe
M-10iAe
ARC Mate 100iC/6L
M-10iA/6L
ARC Mate 100iCe/6L
M-10iAe/6L
ARC Mate 100iC/10S
M-10iA/10S
Model
ARC Mate 100iC
M-10iA
ARC Mate 100iC/6L
M-10iA/6L
ARC Mate 100iC/10S
M-10iA/10S
Model
ARC Mate 100iC, M-10iA
ARC Mate 100iC/6L, M-10iA/6L
ARC Mate 100iC/10S, M-10iA/10S
ARC Mate 100iCe, M-10iAe
ARC Mate 100iCe/6L, M-10iAe/6L
A.SPARE PARTS LIST
APPENDIX
Table A (d) Reducer
Remarks
Parts name
Specifications
J1-axis reducer
A97L-0218-0822#33(*1)
A97L-0218-0885$33(*2) (*3)
A97L-0218-0886#127(*1)(*2)
A97L-0218-0886#93 (*3)
A97L-0218-0824#150(*1)
A97L-0218-0887#150(*2)
A97L-0218-0887#108
J2-axis reducer
J3-axis reducer
B-82755EN/05
Model
(*1)
(*2) (*3)
(*1) (*2)
(*3)
(*1)
(*2)
(*3)
(*1) Old spec robot ARC Mate 100iC,M-10iA, ARC Mate 100iC/6L,M-10iA6L shipped before March,
2010.
(*2) New spec: robot ARC Mate 100iC,M-10iA, ARC Mate 100iC/6L,M-10iA6L shipped after April,
2010 or ARC Mate 100iC/10S, M-10iA/10S, ARC Mate 100iCe,M-10iAe,ARC Mate
100iCe/6L,M-10iAe/6L.
(*3) ARC Mate 100iC/10S,M-10iA/10S
NOTE
Specify the following draw nut for the J2, J3-axes reducer.
Parts name
J1-axis gear
Input gear
Input gear
Draw nut
Draw nut
Gear
Gear
Key
Table A (e) Input gear, draw nut, gear and key
Specifications
A290-7215-X211
A290-7221-X311
A290-7221-X411 (*1)
A290-7221-Z411 (*2)
A290-7221-Z415 (*3)
A290-7221-X321
A290-7221-X421
A290-7221-X511
A290-7221-X521
JB-HKY-3X3X8A
Used place
J1-axis Motor
J2-axis Motor
J3-axis Motor
J2-axis Motor
J3-axis Motor
J5-axis Motor
J6-axis Motor
J5, J6-axis Motor
(*1) Old spec robot ARC Mate 100iC,M-10iA, ARC Mate 100iC/6L,M-10iA6L shipped before March,
2010.
(*2) New spec: robot ARC Mate 100iC,M-10iA, ARC Mate 100iC/6L,M-10iA6L shipped after April,
2010 or ARC Mate 100iCe,M-10iAe,ARC Mate 100iCe/6L,M-10iAe/6L.
(*3) ARC Mate 100iC/10S, M-10iA/10S
Parts name
J4-axis gearbox
Wrist unit
Fluoric resin
Table A (f) Other (mechanical unit)
Specifications
Model
ARC Mate 100iC,M-10iA,
ARC Mate 100iC/6L,M-10iA/6L
A05B-1221-K401
Old specification: Robot shipped before March, 2010
ARC Mate 100iC,M-10iA,
ARC Mate 100iC/6L,M-10iA/6L
New specification: Robot shipped after April, 2010
A05B-1221-K411
or ARC Mate 100iCe,M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L
ARC
Mate 100iC/10S,M-10iA/10S
A05B-1221-K413
A290-7221-V504
All models
A290-7221-X571
All models
- 134 -
A.SPARE PARTS LIST
APPENDIX
B-82755EN/05
The following service parts are appended to J4-axis gearbox (A05B-1221-K401, K411, K413) for
maintenance. Please exchange these with the J4-axis gearbox.
Parts name
Packing
Packing
Bolt
Bolt
Washer
Seal bolt
Seal bolt
Seal bolt
Packing
Specifications
Number
A98L-0040-0042#03
A98L-0040-0042#07
A6-BA-8X25
A6-BA-5X14
A97L-0001-0823#M8H
A97L-0218-0502#5X10
A97L-0218-0417#081010
10
A97L-0218-0417#060808
A290-7221-X441
1
1
8 or 9
7
8 or 9
4
A290-7221-X442
1
J4-axis oil outlet
1
1
J3-axis grease inlet
J4-axis Hollow part
J4-axis Motor mounting part
ARC Mate 100iC,M-10iA,
ARC Mate 100iC/6L,M-10iA/6L
J4-axis Motor mounting part
ARC Mate 100iC/10S,M-10iA/10S
Between J3 arm and J3 casing
J4-axis Motor mounting part, J4-axis hollow
part
1
Packing
A290-7221-Z442
O-RING
A290-7221-X444
1
PIN
JB-PH-H7A-5X10S45C
2
Parts name
Table A (g) Battery, grease, oil, and sealant
Specifications
Model
Battery
Grease
A98L-0031-0027
A98L-0040-0174#1.27KG
All Models
All Models
Oil
A98L-0040-0233#0.8L
All Models
Sealant
A98L-0040-0238#0.33KG
All Models
Parts name
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
Parts name
Used place
J3-axis Motor
J4-axis Motor
Between J3 casing and J3-axis reducer
J4-axis Motor mounting part
Between J3 casing and J3-axis reducer
J4-axis Motor
Specifications
A290-7207-X342
A290-7221-X444
A98L-0001-0347#S150
A98L-0001-0347#S39
JB-OR1A-G105
JB-OR1A-G65
Specifications
Packing
Packing
Packing
Packing
Packing
A290-7221-X441
A290-7221-X442
A98L-0040-0042#03
A98L-0040-0042#07
A290-7221-Z236
Packing
Packing
Packing
Packing
A290-7221-X579
A290-7221-X581
A290-7221-X582
A290-7221-X575
Table A (h) O-RING
Model
All Models
All Models
All Models
All Models
All Models
All Models
Table A (i) Packing
Model
All Models
All Models
All Models
All Models
M-10iA, M-10iA/6L
(Severe dust/liquid protection
option)
M-10iA, M-10iA/6L,M-10iA/10S
M-10iA, M-10iA/6L,M-10iA/10S
M-10iA, M-10iA/6L,M-10iA/10S
M-10iA, M-10iA/6L,M-10iA/10S
- 135 -
Remarks
C battery 1.5V (4pcs /per 1 robot)
Kyodo Yushi
VIGOGREASE RE0
JX Nippon Oil & Energy Corporation
BONNOC AX68
Three bond for gearbox
Used place
J1-axis reducer
Wrist- unit
J1-axis reducer
J5, J6-axis Motor (2 places)
J1, J2-axis Motor (2 places)
J1-axis reducer
Used place
J4-axis hollow part
J4-axis motor mounting part
J3-axis Motor
J4-axis Motor
Battery cover
J5 motor cover
Plate cover 1
Plate cover 2
J6 motor cover
A.SPARE PARTS LIST
Parts name
Stopper
Stopper
APPENDIX
B-82755EN/05
Table A (j) Stopper
Specifications
Model
A290-7215-X323
A290-7221-X324
All Models
All Models
Used place
J2-axis
J3-axis
Table A (k) M/H conduit (M-10iA, M-10iA/6L, M-10iA/10S option)
Parts name
M/H conduit
Protection ring
Conduit
Specifications
Model
M-10iA, M-10iA/10S
M-10iA/6L
M-10iA
M-10iA, M-10iA/10S
A05B-1221-J701
A05B-1221-J702
A05B-1221-J711
FANUC Specifications:
A97L-0118-0734#E36-0062
PMA Specifications: ESDT-36B (Note)
FANUC Specifications:
A97L-0118-0734#E36-0084
PMA Specifications: ESDT-36B (Note)
M-10iA/6L
Table A (l) No dust M/H conduit (M-10iA, M-10iA/6L, M-10iA/10S option)
Parts name
M/H conduit
Conduit
Packing A
Packing B
Seal bolt
Specifications
A05B-1221-J721
A05B-1221-J722
FANUC Specifications:
A97L-0118-0734#E36-0062
PMA Specifications: ESDT-36B (Note)
FANUC Specifications:
A97L-0118-0734#E36-0084
PMA Specifications: ESDT-36B (Note)
A290-7221-Z641 (4 pcs/per 1 robot)
A290-7221-Z642 (4 pcs/per 1 robot)
A97L-0218-0546#030806SC (16 pcs/per 1 robot)
Model
M-10iA, M-10iA/10S
M-10iA/6L
M-10iA, M-10iA/10S
M-10iA/6L
M-10iA, M-10iA/6L,M-10iA/10S
NOTE
Please cut it in the convex part when you cut Conduit. The cable might be
damaged in the edge part of Conduit when cutting it in the concave portion.
Good cutting
example
A
DETAIL A
B
Bad cutting
example
DETAIL B
Fig.A Cutting example of conduit
- 136 -
B-82755EN/05
B
APPENDIX
CIRCUIT DIAGRAM
- 137 -
B.CIRCUIT DIAGRAM
B.CIRCUIT DIAGRAM
APPENDIX
B-82755EN/05
A66L-0001-0401#14
(1.25SQ*14C)Φ11.8
A66L-0001-0574
(0.2SQ*6P)Φ7.7
A66L-0001-0532
(0.4SQ*24C)Φ10.6
A66L-0001-0574
(0.2SQ*6P)Φ7.7
J1 CONNECTOR PANEL
RMP
Han 72DD
(2.5SQ 10A)
1 BK(J1) 13 BK(J2) 25 BK(J3) 37 BK(J4) 49 BK(J5) 61 BK(J6)
2
J1U1
14
J2U1
26
15
J2V1
27 J3V1
J3U1
38 (200V) 50
BKC
(0V)
62 (J1,J2,J3,
J4,J5,J6)
3
J1V1
39
J4U1
51
J5U1
63 J6U1
4
J1W1 16 J2W1 28 J3W1 40
J4V1
52
J5V1
64
5
J1G1
6
XROT 18 (OT,A1,A2, 30 XHBK 42 J4G1
17 J2G1 29 J3G1
J6V1
41 J4W1 53 J5W1 65 J6W1
24V
A3,A4)
54 J5G1 66
(SOLDERING)
J6G1
7
RI1
19
RI2
31
RI3
43
RI4
55
RI5
0V
67
(D1,D2)
8
RO1
20
RO2
32
RO3
44
RO4
56
RO5
68
RI6
9
RI7
21
RI8
33
RO7
45
RO8
57 XPPABN 69
RO6
A66L-0001-0574
(0.2SQ*6P)O7.7
5V
5V
5V
0V
0V
0V
10 (A1,A2) 22 (B1,B2) 34 (C1,C2) 46 (A1,A2) 58 (B1,B2) 70 (C1,C2)
11 PRQJ1 23 PRQJ2 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6
12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6
G
A66L-0001-0459
(0.2SQ*24C)Φ8.3
FG
6V
(BT1,BT2,BT3,
BT4,BT5,BT6)
A66L-0001-0464#1
(0.2SQ*4P)Φ6.7
+
A66L-0001-0459
(0.2SQ*24C)Φ8.3
BATTERY
0V
(BT1,BT2,BT3,
BT4,BT5,BT6)
-
:可動部用
MOVABLE
Fig.B (a) Circuit diagram
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S)
- 138 -
B.CIRCUIT DIAGRAM
APPENDIX
B-82755EN/05
J1 MOTOR (αiS8/4000)
IN CASE OF K101,K111,K131,K161
A63L-0001-0648#810SL3SJ
A63L-0001-0653#04A
IN CASE OF K102,K103,K132,K133,K162
MS3108B10SL-3S
J3 MOTOR (αiS2/5000)
M1BK
A BK(J1)
10SL-3P(1.25SQ 13A)
B BKC(J1)
C
M1M
IN CASE OF K101,K111,K131,K161
A63L-0001-0881#1810S
A63L-0001-0881#10C
IN CASE OF K102,K103,K132,K133,K162
A63L-0001-0881#1810S
A J1U1
B J1V1
8 5V(A1)
9
10 0V(A1)
4
5
6
7
M2 BK
A BK(J2)
10SL1(0.3SQ 3A) SG
6V(BT1)
1
XPRQJ1
2
PRQJ1
3 FG
0V(BT1)
M2 M
IN CASE OF K101,K111,K131,K161
A63L-0001-0881#1810S
A63L-0001-0881#10C
IN CASE OF K102,K103,K132,K133,K162
A63L-0001-0881#1810S
A J2U1
B J2V1
8 5V(A2)
9
10 0V(A2)
C
18-10P
C J2W1
D J2G1
M2 P
A63L-0001-0848#B10SL1
A63L-0001-0850
10SL-3P(1.25SQ 13A)
B BKC(J2)
4
5
6
7
A63L-0001-0874
5 BK(J3)
6 BKC(J3)
3 J3W1
4 J3G1
M3 P
A63L-0001-0848#B10SL1
A63L-0001-0850
J2 MOTOR (αiS8/4000)
IN CASE OF K101,K111,K131,K161
A63L-0001-0648#810SL3SJ
A63L-0001-0653#04A
IN CASE OF K102,K103,K132,K133,K162
MS3108B10SL-3S
1 J3U1
2 J3V1
18-10P
C J1W1
D J1G1
M1P
A63L-0001-0848#B10SL1
A63L-0001-0850
M3 M
A63L-0001-0875#SC
10SL1(0.3SQ 3A)
6V(BT2)
1
XPRQJ2
2
PRQJ2
3 FG
0V(BT2)
8 5V(B1)
9
10 0V(B1)
4
5
6
7
10SL1(0.3SQ 3A)
6V(BT3)
1
XPRQJ3
2
PRQJ3
3 FG
0V(BT3)
J4 MOTOR (βiS0.5/6000)
IN CASE OF K101,K103
,K111,K131,K133,K161
A63L-0001-0866#2
A63L-0001-0864#CS
IN CASE OF K102,K132,K162
A63L-0001-0865#2
A63L-0001-0864#CS
1
2 BK(J4)
IN CASE OF K101,K103,K111
,K131,K133,K161
A63L-0001-0866#1
A63L-0001-0864#CS
IN CASE OF K102,K132,K162
A63L-0001-0865#1
A63L-0001-0864#CS
1 J4U1
IN CASE OF K101,K103,K111
,K131,K133
A63L-0001-0848#B10SL1
A63L-0001-0850
IN CASE OF K102,K132
A63L-0001-0848#E10SL1
A63L-0001-0850
8 5V(B2)
9
M4 BK
MOLEX 55619-0401
4
3 BKC(J4)
M4 M
MOLEX 55618-0401
4 J4G1
3 J4W1
2 J4V1
M4 P
10 0V(B2)
4
5
6
7
10SL1(0.3SQ 3A)
6V(BT4)
1
XPRQJ4
2
PRQJ4
3 FG
0V(BT4)
J5 MOTOR (βiSR0.5/6000)
M5 BK
A63L-0001-0865#2
A63L-0001-0864#CS
1 BK(J5)
2 BKC(J5)
M5 M
A63L-0001-0865#1
A63L-0001-0864#CS
1 J5U1
2 J5V1
MOLEX 55618-0401
4 J5G1
3 J5W1
M5 P
A63L-0001-0848#E10SL1
A63L-0001-0850
MOLEX 55619-0401
4
3
8 5V(C1)
9
10 0V(C1)
4
5
6
7
10SL1(0.3SQ 3A)
6V(BT5)
1
XPRQJ5
2
PRQJ5
3 FG
0V(BT5)
J6 MOTOR (βiSR0.5/6000)
PLATE
A290-7221-X431
BUSH
A290-7221-X432
M6 BK
A63L-0001-0865#2
A63L-0001-0864#CS
A660-0001-0586
IN CASE OF K101,K102,K103
A660-0001-0592
IN CASE OF K131,K132,K133
A660-0001-0593
1 BK(J6)
2 BKC(J6)
M6 M
A63L-0001-0865#1
A63L-0001-0864#CS
(0.2SQ*(12C+2P),0.3SQ*12C)
φ4.9*2 + φ5.1*2
MOLEX 55618-0401
4 J6G1
3 J6W1
1 J6U1
2 J6V1
M6 P
A63L-0001-0848#E10SL1
A63L-0001-0850
EE
IN CASE OF K101---ARC Mate 100iC,M-10iA
IN CASE OF K131---ARC Mate 100iC/6L,M-10iA/6L
IN CASE OF K141---ARC Mate 100iC/10S,M-10iA/10S
IN CASE OF K102,K103---ARC Mate 100iC,M-10iA
IN CASE OF K132,K133---ARC Mate 100iC/6L,M-10iA/6L
IN CASE OF K142
---ARC Mate 100iC/10S,M-10iA/10S
1
2
3
4
5
6
7
8
RO1
RO2
RO3
RO4
RO5
RO6
XHBK
0V(D1)
1
2
3
4
5
6
7
8
RO1
RO2
RO3
RO4
RO5
RO6
XHBK
0V(D1)
4
5
6
7
10SL1(0.3SQ 3A)
6V(BT6)
1
XPRQJ6
2
PRQJ6
3 FG
0V(BT6)
ARC Mate 100iC,M-10iA
K101(A05B-1221-D001)---RI/O*8
K102(A05B-1221-D002)---RI/O*1
K103(A05B-1221-D003)---RI/O*1
M-10iA SEVERE DUST/LIQUID PROTECTION
K111(A05B-1221-D011)---RI/O*8
ARC Mate 100iC/6L,M-10iA/6L
K131(A05B-1221-D031)---RI/O*8
K132(A05B-1221-D032)---RI/O*1
K133(A05B-1221-D033)---RI/O*1
A63L-0001-0234#R2424S
9 RI1
10 RI2
11 RI3
12 RI4
13 RI8
14 XPPABN
15 RI5
16 RI6
8 5V(C2)
9
10 0V(C2)
ARC Mate 100iC,M-10iA,
ARC Mate 100iC/6L,M-10iA/6L
ARC Mate 100iC/10S,M-10iA/10S
□ R-30iA/R-30iA Mate
□ FOR CE (STANDARD)
A63L-0001-0234#W1305F
(0.5SQ 5A)Φ3-Φ8
EE
5 +24V(A1)
1 RO1
3 0V(D1)
2 XHBK
4 RI1
EE
IN CASE OF K111--M-10iA SEVERE DUST/LIQUID PROTECTION
IN CASE OF K141--M-10iA/6L SEVERE DUST LIQUID PROTECTION
A63L-0001-0234#W2524F
(0.5SQ 5A)Φ9.6-Φ15
17 24V(A1)
9 RI1
18 24V(A2)
10 RI2
19 24V(A3)
11 RI3
20 24V(A4)
12 RI4
21 RO7
13 RI8
22 RO8
14 XPPABN
23 0V(D1)
15 RI5
24 RI7
16 RI6
MOLEX 55619-0401
4
3
17 24V(A1)
18 24V(A2)
19 24V(A3)
20 24V(A4)
21 RO7
22 RO8
23 RI7
24
M-10iA/6L SEVERE DUST/LIQUID PROTECTION
K141(A05B-1221-D041)---RI/O*8
ARC Mate 100iC/10S,M-10iA/10S
K161(A05B-1221-D061)---RI/O*8
K162(A05B-1221-D062)---RI/O*1
- 139 -
B.CIRCUIT DIAGRAM
APPENDIX
B-82755EN/05
A66L-0001-0401#10
(1.25SQ*10C)φ11.8
A66L-0001-0574
(0.2SQ*6P)φ7.7
A66L-0001-0532
(0.4SQ*24C)φ10.6
A66L-0001-0574
(0.2SQ*6P)φ7.7
J1CONNECTOR PANEL
RMP
J1G1,J2G1
Han 72DD
(2.5SQ 10A)
G J3G1,J4G1
J5G1,J6G1
1
13 BK(J2) 25 BK(J3) 37
49
61
2
J1U1 14 J2U1 26 J3U1 38
50
62
BKC
(J2,J3)
3
J1V1 15 J2V1 27 J3V1 39 J4U1 51 J5U1 63 J6U1
4
J1W1 16 J2W1 28 J3W1 40 J4V1 52 J5V1 64 J6V1
5
J1G1 17 J2G1 29 J3G1 41 J4W1 53 J5W1 65 J6W1
6
18
30
42 J4G1 54 J5G1 66 J6G1
7
19
31
43
55
67
8
20
32
44
56
68
9
21
33
45
57
69
10
(SOLDERING)
A66L-0001-0574
(0.2SQ*6P)φ7.7
5V 22 5V 34 5V 46 0V 58 0V 70 0V
(A1,A2) (B1,B2) (C1,C2) (A1,A2) (B1,B2) (C1,C2)
11 PRQJ1 23 PRQJ2 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6
12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6
G
FG
6V
(BT1,BT2,BT3,
BT4,BT5,BT6)
+
BATTERY
0V
(BT1,BT2,BT3,
BT4,BT5,BT6)
-
Fig.B (b) Circuit diagram
(ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)
- 140 -
B.CIRCUIT DIAGRAM
APPENDIX
B-82755EN/05
J3 MOTOR (αiS2/5000 with BRAKE)
M3 M
J1 MOTOR (αiS8/4000 without BRAKE)
M1 M
A63L-0001-0881#1810S
A J1U1
B J1V1
8 5V(A1)
9
10 0V(A1)
1 J3U1
2 J3V1
A63L-0001-0848#B10SL1
A63L-0001-0850
8 5V(B1)
9
10 0V(B1)
18-10P
10SL1(0.3SQ 3A)
4 6V(BT1)
5 XPRQJ1
6 PRQJ1
7 0V(BT1)
MS3108B10SL-3S
A BK(J2)
M2 M
A63L-0001-0881#1810S
A J2U1
B J2V1
M2 P
A63L-0001-0848#B10SL1
A63L-0001-0850
8 5V(A2)
9
10 0V(A2)
5 BK(J3)
6 BKC(J3)
10SL1(0.3SQ 3A)
4
5
6
7
6V(BT3)
XPRQJ3
PRQJ3
0V(BT3)
1
2
3 FG
1
2
3 FG
J2 MOTOR (αiS8/4000 with BRAKE)
M2 BK
A63L-0001-0874
3 J3W1
4 J3G1
M3 P
C J1W1
D J1G1
M1 P
A63L-0001-0848#B10SL1
A63L-0001-0850
A63L-0001-0875#SC
J4 MOTOR (βiSR0.5/6000 without BRAKE)
10SL-3P(1.25SQ 13A)
B BKC(J2)
C
M4 M
A63L-0001-0865#1
A63L-0001-0864#CS
1 J4U1
2 J4V1
18-10P
C J2W1
D J2G1
M4 P
A63L-0001-0848#E10SL1
A63L-0001-0850
10SL1(0.3SQ 3A)
4 6V(BT2)
5 XPRQJ2
6 PRQJ2
7 0V(BT2)
MOLEX 55618-0401
4 J4G1
3 J4W1
8 5V(B2)
9
10 0V(B2)
1
2
3 FG
10SL1(0.3SQ 3A)
4
5
6
7
6V(BT4)
XPRQJ4
PRQJ4
0V(BT4)
1
2
3 FG
J5 MOTOR (βiSR0.5/6000 without BRAKE)
M5 M
A63L-0001-0865#1
A63L-0001-0864#CS
1 J5U1
2 J5V1
MOLEX 55618-0401
4 J5G1
3 J5W1
M5 P
A63L-0001-0848#E10SL1
A63L-0001-0850
PLATE
A290-7221-X431
BUSH
A290-7221-X432
8 5V(C1)
9
10 0V(C1)
10SL1(0.3SQ 3A)
4
5
6
7
6V(BT5)
XPRQJ5
PRQJ5
0V(BT5)
1
2
3 FG
J6 MOTOR (βiSR0.5/6000 without BRAKE)
A660-0001-0592
[{0.2SQ*(6C+2P)}*2+(0.3SQ*4C+0.2SQ*2C)*2)]
φ4.9*2+φ5.1*2
A63L-0001-0865#1
A63L-0001-0864#CS
M6 M
1 J6U1
2 J6V1
MOLEX 55618-0401
4 J6G1
3 J6W1
M6 P
A63L-0001-0848#E10SL1
A63L-0001-0850
8 5V(C2)
9
10 0V(C2)
ARC Mate 100iCe , M-10iAe
ARC Mate 100iCe/6L , M-10iAe/6L
□R-30iA Mate
□2BK
：可動部用
MOVABLE
K121(A05B-1221-D021) --- without RI /O
K151(A05B-1221-D051) --- without RI/O
- 141 -
10SL1(0.3SQ 3A)
4
5
6
7
6V(BT6)
XPRQJ6
PRQJ6
0V(BT6)
1
2
3 FG
C.PERIODIC MAINTENANCE TABLE
C
APPENDIX
B-82755EN/05
PERIODIC MAINTENANCE TABLE
FANUC Robot ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L
ARC Mate 100iC/10S, M-10iA/10S, ARC Mate 100iCe, M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L Periodic Maintenance Table
Working time (H)
Check
time
Items
1
Check the mechanical cable.
(Damaged or twisted)
Check the motor connector.
(Loosening)
4800
5760
6720
7680
-
○
○
○
0.2H
-
○
○
○
0.2H
-
○
○
○
2.0H
-
○
○
○
5 and adjustable mechanical
0.1H
-
○
○
○
6 Remove spatter and dust etc.
1.0H
-
○
○
○
○
○
○
3 Tighten the end effector bolt.
Tighten the cover and main
4 bolt.
Check the mechanical stopper
stopper
Check the end effector (hand)
Mechanical unit
2
years
0.2H
2
7 cable
Check the oil gauge of J4 to J6
8 axis
0.1H
0.1H
-
Replacing battery. *1
0.1H
-
Replacing battery. *2
0.1H
-
0.5H
872ml
0.5H
333ml
0.5H
186ml
0.5H
400ml
0.5H
400ml
4.0H
-
4.0H
-
●
1.0H
-
●
0.1H
-
19 pendant cable and robot
0.2H
-
20 Cleaning the ventilator
0.2H
-
21 Replacing battery *1
0.1H
-
9
Replacing grease of J1 axis
10 reducer
Replacing grease of J2 axis
11 reducer
Replacing grease of J3 axis
12 reducer
Replacing oil of J4 axis
13 gearbox
Replacing oil of J5 and J6 axis
14 gearbox
Replacing cable of mechanical
15 unit
Replacing cable of Mechanical
16 unit welding power
Replacing M/H conduit/No dust
17 M/H conduit (option)
Check broken of fluoric resin
18 ring.
Check the robot cable, teach
Controller
Oil
First
6
9
1
3
Grease check months months months year
amount 320
960 1920 2880 3840
connecting cable
○
○
○
○
○
○
○
○
●
○
8640
9600 10560
○
○
○
○
○
○
○
○
○
●
●
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
●
○
○
○
○
○
*1 ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L ARC Mate 100iC/10S, M-10iA/10S
*2 ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L
*3 Refer to manual of controller.
*4 ●: requires order of parts
○: doe not requires order of parts
- 142 -
C.PERIODIC MAINTENANCE TABLE
APPENDIX
B-82755EN/05
3
4
5
6
7
8
years
years
years
years
years
years
○
○
○
○
○
1
○
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
○
○
○
○
○
6
○
○
○
○
○
7
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 Item
○
○
○
○
●
○
○
○
○
●
○
○
○
○
●
○
○
○
○
●
○
○
○
8
○
●
9
●
●
●
Overhaul
●
10
●
●
●
●
●
●
12
●
●
13
●
●
14
15
●
○
○
○
○
○
○
●
●
16
●
●
17
●
○
○
○
○
○
○
○
11
○
○
○
○
○
○
○
○
○
○
●
○
○
○
○
○
○
○
○
○
○
○
○
19
○
○
○
○
○
18
○
○
○
20
21
●
- 143 -
D.MOUNTING BOLT TORQUE LIST
D
APPENDIX
B-82755EN/05
MOUNTING BOLT TORQUE LIST
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 adhesion 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.Be sure to wipe the excess LOCTITE after tightening bolt.
Use bolt which strengths are below.
But if it is specified in text, obey it.
Hexagon socket head bolt made by steel
Size is M22 or less : Tensile strength 1200N/mm2 or more
Size is M24 or more : Tensile strength 1000N/mm2 or more
All size of bolt of the plating : Tensile strength 1000N/mm2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm2 or more
If no tightening torque is specified for a bolt, tighten it according to this table.
Recommended bolt tightening torques
Unit: Nm
Hexagon socket head
button bolt
Hexagon socket head
Hexagon bolt
Hexagon socket head
Hexagon socket head
bolt
(steel)
flush bolt
bolt (stainless)
Nominal
(Steel)
Low-head bolt
diameter
(steel)
Tightening torque
Tightening torque
Tightening torque
Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
――――
――――
―――
M3
1.8
1.3
0.76
0.53 ――――
M4
4.0
2.8
1.8
1.3
1.8
1.3
1.7
1.2
M5
7.9
5.6
3.4
2.5
4.0
2.8
3.2
2.3
M6
14
9.6
5.8
4.1
7.9
5.6
5.5
3.8
M8
32
23
14
9.8
14
9.6
13
9.3
M10
66
46
27
19
32
23
26
19
――――
――――
M12
110
78
48
33
45
31
――――
――――
(M14)
180
130
76
53
73
51
――――
――――
M16
270
190
120
82
98
69
――――
――――
(M18)
380
260
160
110
140
96
――――
――――
M20
530
370
230
160
190
130
――――
――――
――――
――――
――――
――――
(M22)
730
510
――――
――――
――――
――――
――――
――――
M24
930
650
――――
――――
――――
――――
――――
――――
(M27)
1400
960
――――
――――
――――
――――
――――
――――
M30
1800
1300
――――
――――
――――
――――
――――
――――
M36
3200
2300
- 144 -
APPENDIX
B-82755EN/05
E
E.1
E.INSULATION ABOUT ARC
WELDING ROBOT
INSULATION ABOUT ARC WELDING
ROBOT
ABSTRACT
The arc welding robot performs welding, using a welding torch attached to its end effector via a bracket.
Because a high welding current flows through the welding torch, the insulation between the end effector
and torch is dualized.
If no due consideration is taken, a poor insulation caused by a pileup of spatter can allow the welding
current to leak into robot mechanical sections, possibly resulting in the motor being damaged or the
sheaths of cables in the mechanical sections melting.
E.2
-
INSULATION AT THE WRIST
Design the insulation between the end effector and welding torch so that no current will leak from
the end effector. Concretely, when fastening the insulating material inserted between the end
effector and torch bracket, use different bolts on the insulation material and torch bracket.
Insert the insulating material between the torch and torch bracket so that the insulation is dualized.
When installing the insulating material, be sure to set the crack in the torch holder away from that
of the insulating material to prevent spatter from getting in the cracks.
Insert the insulating material between the torch and torch bracket so that the insulation is dualized.
When installing the insulating material, be sure to set the crack in the torch holder away from that
of the insulating material to prevent spatter from getting in the cracks.
Allow a sufficient distance (at least 5 mm) at the insulating materials in case a pileup of spatter
should occur.
Even after the insulation is reinforced, it is likely that, if a pileup of spatter grows excessively,
current may leak. Periodically remove spatter when the robot is in service.
- 145 -
INDEX
B-82755EN/05
INDEX
NOTES FOR ASSEMBLING CABLES WITH NO
DUST M/H CONDUIT ..............................................88
NOTES OF ATTACHING J3-AXIS MOTOR TO
REDUCER .................................................................58
<Number>
1.5-YEAR CHECKS (5,760 hours)................................10
1-YEAR (3,840 HOURS) CHECKS ................................9
2-YEAR CHECKS (7,680 hours)...................................10
3-MONTH (960 HOURS) CHECKS ...............................9
3-YEAR (11,520 HOURS) CHECKS ............................10
4-year (13,820 hours) checks .........................................10
<O>
Oil replacement procedure for the gearbox (J4 to
J6-axis) .......................................................................24
<A>
<P>
ABSTRACT.................................................................145
PERIODIC MAINTENANCE .......................................15
PERIODIC MAINTENANCE TABLE .......................142
PREFACE .................................................................... p-1
Procedure for releasing oil (J4 to J6-axis)......................28
Procedure for releasing remaining pressure from the
grease bath (J1 to J3-axis) ..........................................27
<B>
BACKLASH MEASUREMENT ...................................38
<C>
CABLE DRESSING ....................................................101
CABLE REPLACEMENT.............................................99
CABLE WIRING.........................................................100
CHECKING THE MASTERING ................................130
CHECKS AND MAINTENANCE ..................................1
CIRCUIT DIAGRAM..................................................137
COMPONENT REPLACEMENT .................................43
<R>
REGISTER OF MASTERING POSTURE..................121
REPLACING CABLES ...............................................110
REPLACING FLUORIC RESIN RING ........................97
REPLACING M/H CONDUIT (OPTION)....................86
REPLACING NO DUST M/H CONDUIT (OPTION) ..93
Replacing the Batteries (1 Year (3,840 Hours) or (1.5
Year (5,760 Hours) Checks).......................................15
REPLACING THE GREASE AND OIL OF THE
DRIVE MECHANISM (3 YEARS (11,520 HOURS)
CHECKS)...................................................................17
REPLACING THE J1-AXIS MOTOR M1 ...................46
REPLACING THE J1-AXIS REDUCER ......................48
REPLACING THE J2 COVER (OPTION)....................82
REPLACING THE J2-AXIS MOTOR M2 ...................52
REPLACING THE J2-AXIS REDUCER ......................53
REPLACING THE J3-AXIS MOTOR M3 ...................56
REPLACING THE J3-AXIS REDUCER ......................63
REPLACING THE J4 COVER (OPTION)....................84
REPLACING THE J4-AXIS GEARBOX (ARC Mate
100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L,
ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L,
M-10iAe/6L) ..............................................................69
REPLACING THE J4-AXIS GEARBOX (ARC Mate
100iC/10S, M-10iA/10S) ...........................................72
REPLACING THE J4-AXIS MOTOR M4 (ARC Mate
100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L) ..66
REPLACING THE J4-AXIS MOTOR M4 (ARC Mate
100iC/10S, M-10iA/10S) ...........................................68
REPLACING THE J5-AXIS MOTOR M5 ...................75
REPLACING THE J6-AXIS MOTOR M6 ...................77
REPLACING WRIST UNIT .........................................79
RESETTING ALARMS AND PREPARING FOR
MASTERING...........................................................122
<D>
DAILY CHECKS.............................................................1
<F>
FAILURES, CAUSES AND MEASURES....................30
FIGURE OF DRIVE MECHANISM .............................44
FIRST 1-MONTH (320 HOURS) CHECKS ...................4
FIRST 3-MONTH (960 HOURS) CHECKS ...................5
FIXTURE POSITION MASTER.................................123
<G>
GENERAL ..............................................................30,119
Grease replacement procedure for the reducer (J1 to
J3-axis) .......................................................................24
<I>
INSULATION ABOUT ARC WELDING ROBOT ....145
INSULATION AT THE WRIST .................................145
<J>
J3-axis reducer mounting phase auto adjusting function
....................................................................................66
<M>
MAINTENANCE TOOLS.............................................10
MASTERING ..............................................................119
MOUNTING BOLT TORQUE LIST ..........................144
<N>
<S>
NOTES FOR ASSEMBLING CABLES WITH M/H
CONDUIT ..................................................................85
SAFETY PRECAUTIONS ........................................... s-1
SEALANT APPLICATION ..........................................97
i-1
INDEX
B-82755EN/04
SPARE PARTS LIST...................................................133
<T>
TROUBLESHOOTING .................................................30
i-2
REVISION RECORD
B-82755EN/05
REVISION RECORD
Edition
Date
05
May.,2011
04
Jun.,2010
03
Jul., 2009
02
Aug., 2008
01
Mar., 2008
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Contents
Addition of ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L,M-10iAe/6L
Addition of stop type of robot
Change of replacing method of oil of J4-axis
Addition oiling method by oil injection gun
Correction of daily checks.
Correction of errors
Addition of ARC Mate 100iC/10S and M-10iA/10S
Addition of new specification of ARC Mate 100iC,ARC Mate 100iC/6L M-10iA,M-10iA/6L
Addition of replacing method of fluoric resin ring
Correction of errors
Change replacing procedure of J3-axis reducer,J5,J6-axes motor and wrist unit
Addition of replacing method of grease and oil for top mount and angle mount
Addition of No dust M/H conduit
Correction of errors
Addition of M-10iA/6L
Correction of cable replacement
Addition of Method of fixture position master
Correction of errors
r-1
B-82755EN/05
* B - 8 2 7 5 5 E N /
0 5 *
