am100 s6 maintenance manual e

FANUC RoboticsR-J and R-J2 ControllerARC Mate 100/S-6 Mechanical Unit Maintenance Manual

MARAWA10002404E B-80405E/04

This publication contains proprietary information of FANUC RoboticsAmerica, Inc. furnished for customer use only. No other usesare authorized without the express written permission of FANUCRobotics America, Inc.FANUC Robotics America, Inc.3900 W. Hamlin RoadRochester Hills, Michigan 48309–3253

The descriptions and specifications contained in this manual were ineffect at the time this manual was approved for printing. FANUCRobotics America, Inc, hereinafter referred to as FANUCRobotics, reserves the right to discontinue models at any time or tochange specifications or design without notice and without incurringobligations.FANUC Robotics manuals present descriptions, specifications,drawings, schematics, bills of material, parts, connections and/orprocedures for installing, disassembling, connecting, operating andprogramming FANUC Robotics’ products and/or systems. Suchsystems 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 beentrained in one or more approved FANUC Robotics TrainingCourse(s) be permitted to install, operate, use, perform procedureson, repair, and/or maintain FANUC Robotics’ products and/orsystems and their respective components. Approved trainingnecessitates that the courses selected be relevant to the type ofsystem installed and application performed at the customer site.

WARNINGThis equipment generates, uses, and can radiate radiofrequency energy and if not installed and used in accordancewith the instruction manual, may cause interference to radiocommunications. As temporarily permitted by regulation, ithas not been tested for compliance with the limits for Class Acomputing devices pursuant to subpart J of Part 15 of FCCRules, which are designed to provide reasonable protectionagainst such interference. Operation of the equipment in aresidential area is likely to cause interference, in which casethe user, at his own expense, will be required to takewhatever measure may be required to correct theinterference.

FANUC Robotics conducts courses on its systems and products ona regularly scheduled basis at its headquarters in Rochester Hills,Michigan. For additional information contact

FANUC Robotics America, Inc.Training Department3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253www.fanucrobotics.com

Send your comments and suggestions about this manual to:[email protected]

www.fanucrobotics.com

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Copyright �2003 by FANUC Robotics America, Inc.All Rights ReservedThe information illustrated or contained herein is not to bereproduced, copied, translated into another language, or transmittedin whole or in part in any way without the prior written consent ofFANUC Robotics America, Inc.AccuStat�, ArcTool�, DispenseTool�, FANUC LASER DRILL�,KAREL�, INSIGHT�, INSIGHT II�, PaintTool�, PaintWorks�,PalletTool�, SOCKETS�, SOFT PARTS� SpotTool�,TorchMate�, and YagTool� are Registered Trademarks of FANUCRobotics.FANUC Robotics reserves all proprietary rights, including but notlimited 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 System4� ARC Mate System 5� ARCWorks Pro� AssistTool�AutoNormal� AutoTCP� BellTool� BODYWorks� Cal Mate� CellFinder� Center Finder� Clean Wall� CollisionGuard�DispenseTool� F-100� F-200i� FabTool� FANUC LASERDRILL� Flexibell� FlexTool� HandlingTool� HandlingWorks�INSIGHT� INSIGHT II� IntelliTrak� Integrated Process Solution�Intelligent Assist Device� IPC -Integrated Pump Control� IPDIntegral Pneumatic Dispenser� ISA Integral Servo Applicator� ISDIntegral Servo Dispenser� Laser Mate System 3� Laser MateSystem 4� LaserPro� LaserTool� LR Tool� MIG Eye�MotionParts� 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� SOF� PARTS� SpotTool+� SR Mate�SR ShotTool� SureWeld� SYSTEM R-J2 Controller� SYSTEM R-J3 Controller� SYSTEM R-J3iB Controller� TCP Mate�TurboMove� TorchMate� visLOC� visPRO-3D� visTRAC�

WebServer� WebTP� YagTool�

This manual includes information essential to the safety ofpersonnel, equipment, software, and data. This information isindicated by headings and boxes in the text.

WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to set itapart from other text.

Conventions

CAUTIONInformation appearing under CAUTION concerns the protection ofequipment, software, and data. It is boxed to set it apart fromother text.

NOTE Information appearing next to NOTE concerns relatedinformation or useful hints.

Safety-1

FANUC Robotics is not and does not represent itself as an expert insafety systems, safety equipment, or the specific safety aspects ofyour company and/or its work force. It is the responsibility of theowner, employer, or user to take all necessary steps to guaranteethe safety of all personnel in the workplace.The appropriate level of safety for your application and installationcan best be determined by safety system professionals. FANUCRobotics therefore, recommends that each customer consult withsuch professionals in order to provide a workplace that allows forthe safe application, use, and operation of FANUC Robotic systems.According to the industry standard ANSI/RIA R15.06, the owner oruser is advised to consult the standards to ensure compliance withits requests for Robotics System design, usability, operation,maintenance, and service. Additionally, as the owner, employer, oruser of a robotic system, it is your responsibility to arrange for thetraining of the operator of a robot system to recognize and respondto known hazards associated with your robotic system and to beaware of the recommended operating procedures for your particularapplication and robot installation.FANUC Robotics therefore, recommends that all personnel whointend to operate, program, repair, or otherwise use the roboticssystem be trained in an approved FANUC Robotics training courseand become familiar with the proper operation of the system.Persons responsible for programming the system–including thedesign, implementation, and debugging of application programs–must be familiar with the recommended programming proceduresfor your application and robot installation.The following guidelines are provided to emphasize the importanceof safety in the workplace.

Safety-2

Safety is essential whenever robots are used. Keep in mind thefollowing 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

The safety of people is always of primary importance in anysituation. However, equipment must be kept safe, too. Whenprioritizing how to apply safety to your robotic system, consider thefollowing:� People� External devices� Robot(s)� Tooling� Workpiece

Always give appropriate attention to the work area that surroundsthe robot. The safety of the work area can be enhanced by theinstallation 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

A safe workcell is essential to protect people and equipment.Observe the following guidelines to ensure that the workcell is setup safely. These suggestions are intended to supplement and notreplace existing federal, state, and local laws, regulations, andguidelines that pertain to safety.

� Sponsor your personnel for training in approved FANUCRobotics training course(s) related to your application. Neverpermit untrained personnel to operate the robots.

CONSIDERINGSAFETY FOR YOURROBOTINSTALLATION

Keeping People andEquipment Safe

Using SafetyEnhancing Devices

Setting Up a SafeWorkcell

Safety-3

� Install a lockout device that uses an access code to preventunauthorized persons from operating the robot.

� Use anti–tie–down logic to prevent the operator from bypassingsafety measures.

� Arrange the workcell so the operator faces the workcell and cansee what is going on inside the cell.

� Clearly identify the work envelope of each robot in the systemwith floor markings, signs, and special barriers. The workenvelope is the area defined by the maximum motion range ofthe robot, including any tooling attached to the wrist flange thatextend this range.

� Position all controllers outside the robot work envelope.

� Never rely on software as the primary safety element.

� Mount an adequate number of EMERGENCY STOP buttons orswitches within easy reach of the operator and at critical pointsinside and around the outside of the workcell.

� Install flashing lights and/or audible warning devices thatactivate whenever the robot is operating, that is, wheneverpower is applied to the servo drive system. Audible warningdevices shall exceed the ambient noise level at the end–useapplication.

� Wherever possible, install safety fences to protect againstunauthorized entry by personnel into the work envelope.

� Install special guarding that prevents the operator from reachinginto restricted areas of the work envelope.

� Use interlocks.

� Use presence or proximity sensing devices such as lightcurtains, mats, and capacitance and vision systems to enhancesafety.

� Periodically check the safety joints or safety clutches that can beoptionally installed between the robot wrist flange and tooling. Ifthe tooling strikes an object, these devices dislodge, removepower from the system, and help to minimize damage to thetooling and robot.

Safety-4

� Make sure all external devices are properly filtered, grounded,shielded, and suppressed to prevent hazardous motion due tothe effects of electro–magnetic interference (EMI), radiofrequency interference (RFI), and electro–static discharge(ESD).

� Make provisions for power lockout/tagout at the controller.

� Eliminate pinch points. Pinch points are areas where personnelcould get trapped between a moving robot and other equipment.

� Provide enough room inside the workcell to permit personnel toteach the robot and perform maintenance safely.

� Program the robot to load and unload material safely.

� If high voltage electrostatics are present, be sure to provideappropriate interlocks, warning, and beacons.

� If materials are being applied at dangerously high pressure,provide electrical interlocks for lockout of material flow andpressure.

Advise all personnel who must teach the robot or otherwisemanually operate the robot to observe the following rules:

� Never wear watches, rings, neckties, scarves, or loose clothingthat could get caught in moving machinery.

� Know whether or not you are using an intrinsically safe teachpendant if you are working in a hazardous environment.

� Before teaching, visually inspect the robot and work envelope tomake sure that no potentially hazardous conditions exist. Thework envelope is the area defined by the maximum motionrange of the robot. These include tooling attached to the wristflange that extends this range.

� The area near the robot must be clean and free of oil, water, ordebris. Immediately report unsafe working conditions to thesupervisor or safety department.

� FANUC Robotics recommends that no one enter the workenvelope of a robot that is on, except for robot teachingoperations. However, if you must enter the work envelope, besure all safeguards are in place, check the teach pendantDEADMAN switch for proper operation, and place the robot inteach mode. Take the teach pendant with you, turn it on, and beprepared to release the DEADMAN switch. Only the personwith the teach pendant should be in the work envelope.

Staying Safe WhileTeaching or ManuallyOperating the Robot

Safety-5

WARNINGNever 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 inserious 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 causemotion while data is being taught.

� Test any program being run for the first time in the followingmanner:

WARNINGStay outside the robot work envelope whenever a program isbeing run. Failure to do so can result in injury.

- Using a low motion speed, single step the program for atleast one full cycle.

- Using a low motion speed, test run the program continuouslyfor at least one full cycle.

- Using the programmed speed, test run the programcontinuously for at least one full cycle.

� Make sure all personnel are outside the work envelope beforerunning production.

Advise all personnel who operate the robot during production toobserve the following rules:

� Make sure all safety provisions are present and active.

� Know the entire workcell area. The workcell includes the robotand its work envelope, plus the area occupied by all externaldevices and other equipment with which the robot interacts.

� Understand the complete task the robot is programmed toperform before initiating automatic operation.

� Make sure all personnel are outside the work envelope beforeoperating the robot.

Staying Safe DuringAutomatic Operation

Safety-6

� Never enter or allow others to enter the work envelope duringautomatic operation of the robot.

� Know the location and status of all switches, sensors, andcontrol signals that could cause the robot to move.

� Know where the EMERGENCY STOP buttons are located onboth the robot control and external control devices. Be preparedto press these buttons in an emergency.

� Never assume that a program is complete if the robot is notmoving. The robot could be waiting for an input signal that willpermit it to continue activity.

� If the robot is running in a pattern, do not assume it will continueto 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 anEMERGENCY STOP button located on the controller panel,teach pendant, or emergency stop stations around the workcell.

When inspecting the robot, be sure to

� Turn off power at the controller.

� Lock out and tag out the power source at the controlleraccording 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.


� If power is needed to check the robot motion or electricalcircuits, be prepared to press the EMERGENCY STOP button,in an emergency.

� Be aware that when you remove a servomotor or brake, theassociated robot arm will fall if it is not supported or resting on ahard stop. Support the arm on a solid support before yourelease the brake.

When performing maintenance on your robot system, observe thefollowing rules:

Staying Safe DuringInspection

Staying Safe DuringMaintenance

Safety-7

� Never enter the work envelope while the robot or a program is inoperation.

� Before entering the work envelope, visually inspect the workcellto make sure no potentially hazardous conditions exist.


� Consider all or any overlapping work envelopes of adjoiningrobots when standing in a work envelope.

� Test the teach pendant for proper operation before entering thework envelope.

� If it is necessary for you to enter the robot work envelope whilepower is turned on, you must be sure that you are in control ofthe robot. Be sure to take the teach pendant with you, press theDEADMAN switch, and turn the teach pendant on. Be preparedto release the DEADMAN switch to turn off servo power to therobot immediately.

� Whenever possible, perform maintenance with the power turnedoff. Before you open the controller front panel or enter the workenvelope, turn off and lock out the 3–phase power source at thecontroller.


WARNINGLethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful toavoid electrical shock.

HIGH VOLTAGE IS PRESENT at the input side whenever thecontroller is connected to a power source. Turning thedisconnect or circuit breaker to the OFF position removespower from the output side of the device only.

� Release or block all stored energy. Before working on thepneumatic system, shut off the system air supply and purge theair lines.

Safety-8

� Isolate the robot from all remote control signals. If maintenancemust be done when the power is on, make sure the personinside the work envelope has sole control of the robot. Theteach pendant must be held by this person.

� Make sure personnel cannot get trapped between the movingrobot and other equipment. Know the path that can be used toescape from a moving robot. Make sure the escape route isnever blocked.

� Use blocks, mechanical stops, and pins to prevent hazardousmovement by the robot. Make sure that such devices do notcreate pinch points that could trap personnel.

WARNINGDo not try to remove any mechanical component from therobot before thoroughly reading and understanding theprocedures in the appropriate manual. Doing so can result inserious personal injury and component destruction.


� When replacing or installing components, make sure dirt anddebris do not enter the system.

� Use only specified parts for replacement. To avoid fires anddamage to parts in the controller, never use nonspecified fuses.

� Before restarting a robot, make sure no one is inside the workenvelope; be sure that the robot and all external devices areoperating normally.

Certain programming and mechanical measures are useful inkeeping the machine tools and other external devices safe. Someof these measures are outlined below. Make sure you know allassociated measures for safe use of such devices.

Implement the following programming safety measures to preventdamage to machine tools and other external devices.

KEEPING MACHINETOOLS ANDEXTERNALDEVICES SAFE

Programming SafetyPrecautions

Safety-9

� Back–check limit switches in the workcell to make sure they donot fail.

� Implement ‘‘failure routines” in programs that will provideappropriate robot actions if an external device or another robotin the workcell fails.

� Use handshaking protocol to synchronize robot and externaldevice operations.

� Program the robot to check the condition of all external devicesduring an operating cycle.

Implement the following mechanical safety measures to preventdamage to machine tools and other external devices.

� Make sure the workcell is clean and free of oil, water, anddebris.

� Use software limits, limit switches, and mechanical hardstops toprevent undesired movement of the robot into the work area ofmachine tools and external devices.

Observe the following operating and programming guidelines toprevent damage to the robot.

The following measures are designed to prevent damage to therobot during operation.

� Use a low override speed to increase your control over the robotwhen jogging the robot.

� Visualize the movement the robot will make before you pressthe jog keys on the teach pendant.

� Make sure the work envelope is clean and free of oil, water, ordebris.

� Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage tothe robot during programming:

� Establish interference zones to prevent collisions when two ormore robots share a work area.

Mechanical SafetyPrecautions

KEEPING THEROBOT SAFE

Operating SafetyPrecautions

Programming SafetyPrecautions

Safety-10

� Make sure that the program ends with the robot near or at thehome position.

� Be aware of signals or other operations that could triggeroperation of tooling resulting in personal injury or equipmentdamage.

� In dispensing applications, be aware of all safety guidelines withrespect to the dispensing materials.

NOTE Any deviation from the methods and safety practicesdescribed in this manual must conform to the approved standards ofyour company. If you have questions, see your supervisor.

Process technicians are sometimes required to enter the paintbooth, for example, during daily or routine calibration or whileteaching new paths to a robot. Maintenance personal also mustwork inside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilationequipment must be used. Instruction on the proper use ofventilating equipment usually is provided by the paint shopsupervisor.Although paint booth hazards have been minimized, potentialdangers still exist. Therefore, today’s highly automated paint boothrequires that process and maintenance personnel have fullawareness of the system and its capabilities. They mustunderstand the interaction that occurs between the vehicle movingalong the conveyor and the robot(s), hood/deck and door openingdevices, and high–voltage electrostatic tools.Paint robots are operated in three modes:� Teach or manual mode� Automatic mode, including automatic and exercise operation� Diagnostic modeDuring both teach and automatic modes, the robots in the paintbooth will follow a predetermined pattern of movements. In teachmode, the process technician teaches (programs) paint paths usingthe teach pendant.In automatic mode, robot operation is initiated at the SystemOperator Console (SOC) or Manual Control Panel (MCP), ifavailable, and can be monitored from outside the paint booth. Allpersonnel must remain outside of the booth or in a designated safe

ADDITIONALSAFETYCONSIDERATIONSFOR PAINT ROBOTINSTALLATIONS

Safety-11

area within the booth whenever automatic mode is initiated at theSOC or MCP.In automatic mode, the robots will execute the path movements theywere taught during teach mode, but generally at production speeds.When process and maintenance personnel run diagnostic routinesthat require them to remain in the paint booth, they must stay in adesignated safe area.

Process technicians and maintenance personnel must becometotally familiar with the equipment and its capabilities. To minimizethe 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 areincluded in the paint system and also explains the way the robotinteracts with other equipment in the system.The paint system includes the following safety features:

� Most paint booths have red warning beacons that illuminatewhen the robots are armed and ready to paint. Your boothmight have other kinds of indicators. Learn what these are.

� Some paint booths have a blue beacon that, when illuminated,indicates that the electrostatic devices are enabled. Your boothmight have other kinds of indicators. Learn what these are.

� EMERGENCY STOP buttons are located on the robot controllerand teach pendant. Become familiar with the locations of all E–STOP buttons.

� An intrinsically safe teach pendant is used when teaching inhazardous paint atmospheres.

� A DEADMAN switch is located on each teach pendant. When thisswitch is held in, and the teach pendant is on, power is applied to therobot servo system. If the engaged DEADMAN switch is releasedduring robot operation, power is removed from the servo system, allaxis brakes are applied, and the robot comes to an EMERGENCYSTOP. Safety interlocks within the system might also E–STOP otherrobots.

WARNINGAn EMERGENCY STOP will occur if the DEADMAN switch isreleased on a bypassed robot.

Paint System SafetyFeatures

Safety-12

� Overtravel by robot axes is prevented by software limits. All ofthe major and minor axes are governed by software limits. Limitswitches and hardstops also limit travel by the major axes.

� EMERGENCY STOP limit switches and photoelectric eyesmight be part of your system. Limit switches, located on theentrance/exit doors of each booth, will EMERGENCY STOP allequipment in the booth if a door is opened while the system isoperating in automatic or manual mode. For some systems,signals to these switches are inactive when the switch on theSCC is in teach mode.

When present, photoelectric eyes are sometimes used tomonitor unauthorized intrusion through the entrance/exitsilhouette openings.

� System status is monitored by computer. Severe conditionsresult in automatic system shutdown.

When you work in or near the paint booth, observe the followingrules, in addition to all rules for safe operation that apply to all robotsystems.

WARNINGObserve all safety rules and guidelines to avoid injury.

WARNINGNever 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 inserious injury and death.

� Know the work area of the entire paint station (workcell).

� Know the work envelope of the robot and hood/deck and dooropening devices.

� Be aware of overlapping work envelopes of adjacent robots.

� Know where all red, mushroom–shaped EMERGENCY STOPbuttons are located.

Staying Safe WhileOperating the PaintRobot

Safety-13

� Know the location and status of all switches, sensors, and/orcontrol signals that might cause the robot, conveyor, andopening devices to move.

� Make sure that the work area near the robot is clean and free ofwater, oil, and debris. Report unsafe conditions to yoursupervisor.

� Become familiar with the complete task the robot will performBEFORE starting automatic mode.

� Make sure all personnel are outside the paint booth before youturn on power to the robot servo system.

� Never enter the work envelope or paint booth before you turn offpower to the robot servo system.

� Never enter the work envelope during automatic operationunless a safe area has been designated.


� Remove all metallic objects, such as rings, watches, and belts,before entering a booth when the electrostatic devices areenabled.

� Stay out of areas where you might get trapped between amoving robot, conveyor, or opening device and another object.

� Be aware of signals and/or operations that could result in thetriggering of guns or bells.

� Be aware of all safety precautions when dispensing of paint isrequired.

� Follow the procedures described in this manual.

When you work with paint application equipment, observe thefollowing rules, in addition to all rules for safe operation that apply toall robot systems.

WARNINGWhen working with electrostatic paint equipment, follow allnational and local codes as well as all safety guidelineswithin your organization. Also reference the followingstandards: NFPA 33 Standards for Spray Application UsingFlammable or Combustible Materials, and NFPA 70 NationalElectrical Code.

Staying Safe WhileOperating PaintApplication Equipment

Safety-14

� Grounding: All electrically conductive objects in the spray areamust be grounded. This includes the spray booth, robots,conveyors, workstations, part carriers, hooks, paint pressurepots, as well as solvent containers. Grounding is defined as theobject or objects shall be electrically connected to ground with aresistance of not more than 1 megohms.

� High Voltage: High voltage should only be on during actualspray operations. Voltage should be off when the paintingprocess is completed. Never leave high voltage on during a capcleaning process.

� Avoid any accumulation of combustible vapors or coatingmatter.

� Follow all manufacturer recommended cleaning procedures.

� Make sure all interlocks are operational.

� No smoking.

� Post all warning signs regarding the electrostatic equipment andoperation of electrostatic equipment according to NFPA 33Standard for Spray Application Using Flammable orCombustible Material.

� Disable all air and paint pressure to bell.

� Verify that the lines are not under pressure.

When you perform maintenance on the painter system, observe thefollowing rules, and all other maintenance safety rules that apply toall robot installations. Only qualified, trained service or maintenancepersonnel should perform repair work on a robot.

� Paint robots operate in a potentially explosive environment. Usecaution 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. Allpersonnel not participating in the maintenance must stay out ofthe area.

� For some maintenance procedures, station a second person atthe control panel within reach of the EMERGENCY STOPbutton. This person must understand the robot and associatedpotential hazards.

Staying Safe DuringMaintenance

Safety-15

� Be sure all covers and inspection plates are in good repair andin place.

� Always return the robot to the ‘‘home’’ position before youdisarm it.

� Never use machine power to aid in removing any componentfrom the robot.

� During robot operations, be aware of the robot’s movements.Excess vibration, unusual sounds, and so forth, can alert you topotential problems.

� Whenever possible, turn off the main electrical disconnectbefore you clean the robot.

� When using vinyl resin observe the following:

- Wear eye protection and protective gloves during applicationand removal

- Adequate ventilation is required. Overexposure could causedrowsiness or skin and eye irritation.

- If there is contact with the skin, wash with water.

� When using paint remover observe the following:

- Eye protection, protective rubber gloves, boots, and apronare required during booth cleaning.

- Adequate ventilation is required. Overexposure could causedrowsiness.

- If there is contact with the skin or eyes, rinse with water forat least 15 minutes.

B–80405E/04 GENERAL

GENERAL

This manual describes the maintenance and connection of the followingrobot (R-J controller or R–J2 controller) mechanical unit which are Smotor and α motor specifications.Make sure of the specification of mechanical unit when replacing parts.

Mechanical unit of S motor specification [S motor] (R–J controller)

Model Abbreviation Mechanical unit specifications

FANUC Robot ARC Mate 100(J2, J3 axis with brake)

A05B-1207-B201

FANUC Robot ARC Mate 100(All axes with brake)

ARC Mate 100A05B-1207-B601

FANUC Robot S–6(J2, J3 axis with brake)

A05B-1207–B202

FANUC Robot S–6(All axes with brake)

S-6A05B-1207–B602

Mechanical unit of α motor specification [α motor] (R–J or R–J2 controller)

Model Abbreviation Mechanical unit specifications

FANUC Robot ARC Mate 100(J2, J3 axis with brake)

A05B-1207-B251

FANUC Robot ARC Mate 100(All axes with brake)

ARC Mate 100A05B-1207-B651

FANUC Robot S–6(J2, J3 axis with brake)

A05B-1207–B252

FANUC Robot S–6(All axes with brake)

S-6A05B-1207–B652

GENERAL B–80405E/04

For the FANUC Robot series, the following manuals are available:

Safety handbook B–80687EN

All persons who use the FANUC Robotand system designer must read andunderstand thoroughly this handbook.

Intended readers: All persons who use the FANUC Robot, sys-tem designer Topics: Safety items for robot system design, opera-tion, maintenance

R–J controller

Quick manual

HANDLING TOOL B–67994E–2

ARC TOOL B–67994E–3

SEALING TOOL B–67994E–4

Intended readers:Operator, programerTopics: Basic procedures for operating the robotUse: Robot operation, simple teaching

Setup and Operationsmanual

HANDLING TOOLB–67994E–11

ARC TOOL B–67994E–12

SEALING TOOL B–67994E–14

Intended readers: Operator, programer, maintenance person,system designerTopics: Robot functions, operations programing, set-up, interfaces, alarmsUse: Robot operation, teaching, system design

Maintenance manual

B–67995E

Intended readers: Maintenance person, system designerTopics:Installation, connection to peripheral equip-ment maintenanceUse: Installation, start–up, connection, maintenance

R–J2 controller

Setup and Operationsmanual

HANDLING TOOL B–80524EN–11

ARC TOOL B–80524EN–12

SEALING TOOL B–80524EN–14

Intended readers:Operator, programer, maintenance person,system designer Topics:Robot functions, operations, programing, set-up, interfaces, alarmsUse:Robot operation, teaching, system design

Maintenance manual

B–80525E

B–80525E–1(European specification)

Intended readers: Maintenance person, system designer Topics: Installation, connection to peripheral equip-ment, maintenance Use: Installation, start–up, connection, maintenance

Mechanical unit

Maintenance manual

Intended readers:Maintenance person, system designerTopics:Installation, connection to the controller, main-tenanceUse: Installation, start–up, connection, maintenance

FANUC Robot ARC Mate 100/S–6 B–80405E� Arc welding, general–purpose small robot

��

B–80405E/04 GENERAL

The mechanical unit specification numbers are attached at the followingpositions. Therefore, read the description in each section when checking.

The attachment position for the mechanical unit specification number.

Table I LETTERS

No. CONTENTS LETTERS

1 — ARC Mate 100 ARC Mate 100

S–6 S–6

2 TYPE S MOTOR ARC Mate 100 (2BK) A05B–1207–B201SPEC.

S–6 (2BK) A05B–1207–B202

ARC Mate 100 (6BK) A05B–1207–B601

S–6 (6BK) A05B–1207–B602

� MOTOR ARC Mate 100 (2BK) A05B–1207–B251SPEC.

S–6 (2BK) A05B–1207–B252

ARC Mate 100 (6BK) A05B–1207–B651

S–6 (6BK) A05B–1207–B652

3 SERIAL NO. PRINT SERIAL NO.

4 DATE PRINT PRODUCTION YEAR AND MONTH

5 WEIGHT 160

Table of ContentsB–80405E/04

c–1

GENERAL

SAFETY

SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. OPERATOR SAFETY 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. PERIPHERAL DEVICE SAFETY 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. PRECAUTIONS FOR WORK 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 SAFETY SPEED CONTROL 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. SAFETY FOR MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I. MAINTENANCE

1. CONFIGURATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 J1-AXIS DRIVE MECHANISM 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 J2-AXIS DRIVE MECHANISM 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1.5 J5-AXIS AND J6 DRIVE MECHANISM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 MAJOR COMPONENT SPECIFICATIONS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. PREVENTIVE MAINTENANCE 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 DAILY CHECKS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 3–MONTH CHECKS 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 1-YEAR CHECKS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. LUBRICATING CONDITION CHECKS 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 GREASING 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 3-YEAR CHECK 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 REPLACING BATTERY 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TROUBLE SHOOTING 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 GENERAL 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 PROBLEM AND CAUSES 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 REPLACING PARTS AND PERFORMING ADJUSTMENTS 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. ADJUSTING 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 ADJUSTING LIMIT SWITCHES AND DOGS (OPTION) 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5.2 J1-AXIS STROKE MODIFICATION (OPTION) 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 QUICK MASTERING 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 MASTERING USING ZERO DEGREE POSITION 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 MASTERING USING JIG 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 CONFIRMING MASTERING 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 ADJUSTING J5-AXIS SPUR GEAR BACKLASH 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. REPLACING AND ADJUSTING PARTS 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 REPLACING J1 AND J2-AXIS MOTOR 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 REPLACING THE J1-AXIS REDUCER 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 REPLACING THE J2-AXIS REDUCER 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 REPLACING THE J3-AXIS MOTOR 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 REPLACING J3-AXIS REDUCER 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 REPLACING J4-AXIS MOTOR 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 REPLACING THE J4–AXIS REDUCER 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 REPLACING J5-AXIS MOTOR 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 REPLACING THE J5–AXIS GEAR 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 REPLACING J6-AXIS MOTOR, REDUCER 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 RELEASING BRAKE 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. PIPING AND WIRING 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 PIPING 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 WIRING DIAGRAM 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 LIMIT SWITCH INSTALLATION DIAGRAM (OPTION) 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 CABLE INSTALLATION DIAGRAM 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. REPLACING CABLES 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 CABLE CLAMPING 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 REPLACING CABLES 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 REPLACING LIMIT SWITCH (OPTION) 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. OPTIONS 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 COVER OPTION (SPECIFICATION: A05B–1207–J401) 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II. CONNECTION

1. ROBOT INTERFERENCE AREA 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. EQUIPMENT MOUNTING TO ROBOT 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 END EFFECTOR MOUNTING FACE TO WRIST 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 EQUIPMENT MOUNTING FACE 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 LOAD CONDITIONS AT THE WRIST 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 END EFFECTOR AIR PIPE 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 END EFFECTOR I/O SIGNALS (RDI/RDO) 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3. TRANSPORTATION AND INSTALLATION 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 TRANSPORTATION 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 STORAGE 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 INSTALLATION 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 MAINTENANCE AREA 160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 ASSEMBLY DURING INSTALLATION 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 AIR PIPING 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 INSTALLATION SPECIFICATIONS 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIXES

A1. SPARE PARTS LIST 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A2. MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM 179. . . . . . . . . . . . . . . . . . .

I. MAINTENANCE

B–80405E/04 1. CONFIGURATION

19

1 CONFIGURATION

Fig. 1 shows the configuration of the mechanical unit.

Fig. 1 Mechanical unit configuration (ARC Mate100/S-6)

NOTE1. FANUC CALL MOTOR 1–6 (M1–M6) J1–J6MOTOR

EACH.2. 2–BRAKES TYPE:

THE MOTOR FOR J2 AND J3 AXES HAVEBUILT–IN BRAKE. THIS BRAKE IS ON IN THE POWER OFF OR INTHE EMERGENCY STOP.

3. 6–BRAKES TYPE:THE MOTOR FOR ALL AXES (J1, J2, J3, J4, J5AND J6) HAVE BUILT–IN BRAKE. THIS BRAKE ISON IN THE POWER OFF OR IN THE EMERGENCYSTOP.

1. CONFIGURATION B–80405E/04

20

Fig. 1.1 shows the J1-axis drive mechanism.The rotation of the AC servo motor (With/without brake) is deceleratedby the reducer and rotates the J2-axis base. The J2-axis base is supportedby the J1-axis base via the reducer.

J1–axis AC servo motormodel OS (S motor)model αS (α motor)

J2–axis base

Input gear

Reducer

J1–axis base

A

A

Phase A–A

M1

Fig. 1.1 J1-axis drive mechanism (ARC Mate100/S-6)

1.1J1-axis DriveMechanism


21

Fig. 1.2 shows J2-axis drive mechanism. The rotation of the AC servomotor OS is decelerated by the reducer and rotates the J2-axis arm. TheJ2-axis arm is supported by the J2-axis base via the reducer.

J2–axis arm

Input gear

J2–axis AC servo motormodel OS (S motor)model α3 (α motor)

J2–axis base

Reducer

Phase B–B

B

B

M2




22

Fig. 1.3 shows the J3-axis mechanism. The rotation of the AC servomotoris decelerated by the reducer and rotates the J3-axis unit. The J3-axis unitis supported by the J2-axis arm via the reducer.

Hexagonal head(width 11)

Reducer

Cap

J3–axis housing

J3–axis AC servo motormodel 2–OSP (S motor)model α 1 (α motor)

J2–axis arm

Box wrench with ratchet(manual crank)

M3




23

Fig. 1.4 shows the J4-axis drive mechanism. The rotation of the AC servomotor 3–0F is decelerated by the reducer and rotates J3-axis arm.

J3-axis arm is supported by the J3-axis housing via the reducer.

J3–axis housing

Reducer

Center gear

J4–axis AC servo motormodel 3–0F (S motor)model 0.5 (α motor)

Input gear

J3–axis armM4




24

Fig. 1.5 shows the J5-axis and J6–axis drive mechanism. The rotation ofthe AC servomotor is decelerated by the three steps gear of J5–axis androtates the J6-axis unit the rotation of AC servomotor 4–0F is deceleratedby the reducer of J6–axis and rotates the output flange.

J3–axis arm

J5–axis AC servomotor model 4–0F (S motor)model α 0.5 (α motor)

J6–axis AC servomotor model 4–0F (S motor)model α 0.5 (α motor)

J6–axis reducer

Output flange

J5–axis gear (three steps)

M5 M6

Fig. 1.5 J5-axis and J6–axis drive mechanism (ARC Mate100/S-6)

1.5J5-axis and J6 DriveMechanism


25

1) Motor for mechanical unit of S motor specificationsARC Mate 100 (With 2–axis brake) A05B–1207–B201S–6 (With 2–axis brake) A05B–1207–B202

Specifications Axis Remarks

A06B-0313-B075 J1 AC 0S

A06B-0313-B175 J2 AC 0S with brake

A06B-0371-B175 J3 AC 2–0SP with brake

A06B-0369-B156#0003 J4 AC 3-0F

A06B-0367-B156#0004 J5 AC 4-0F

A06B-0367-B156#0004 J6 AC 4-0F

Motor for mechanical unit of S motor specificationsARC Mate 100 (With 6–axis brake) A05B–1207–B601S–6 (With 6–axis brake) A05B–1207–B602




A06B-0371-B175 J3 AC 2-0SP with brake

A06B-0369-B356#0003 J4 AC 3-0F with brake



Motor for mechanical unit of α motor specificationsARC Mate 100 (With 2–axis brake) A05B–1207–B251S–6 (With 2–axis brake) A05B–1207–B252


A06B–0123–B075 J1 α3

A06B–0123–B175 J2 α3 with brake


A06B–0113–B078#0008 J4 α0.5

A06B–0113–B078#0008 J5 α0.5

A06B–0113–B078#0008 J6 α0.5

Motor for mechanical unit of α motor specificationsARC Mate 100 (With 6–axis brake) A05B–1207–B651S–6 (With 6–axis brake) A05B–1207–B652





A06B–0113–B178#0008 J4 α0.5 with brake

A06B–0113–B178#0008 J5 α0.5 with brake

A06B–0113–B178#0008 J6 α0.5 with brake

1.6Major ComponentSpecifications

* Option for changing operation space

* Stopper for with 330° OT

* Stopper for without 330° OT


26

2) Reducer for mechanical unit

S motor specifications α motor specifications

Specifications Axis Specifications Axis

A97L-0118-0930 J1 A97L-0118–0930 J1

A97L-0118-0931 J2 A97L-0118-0931 J2

A97L-0118-0932 J3 A97L-0118-0932 J3

A97L-0118-0933 J4 A290–7207–T403 J4

A97L-0118-0934 J6 A05B–1208–H001 J6

3) Gear for mechanical unit

S motor specifications α motor specifications

Specifications Axis Specifications Axis

A290-7207-X211 J1 A290-7207-X211 J1

A290-7202-X311 J2 A290-7202-X311 J2

A290-7207-X411 J4 A290-7207-Y411 J4

A290-7207-X412 J4 A290-7208-X511 J5

A290-7207-X511 J5 A290-7208-V501 J5

A290-7207-V501 J5 A290-7208–V502 J5

A290-7207-V502 J5 A290-7208–X515 J5

A290-7207-X514 J5

4) CoverSpecifications Remarks

A05B-1207–J401J2–axis motor cover (for floor mount) *Opotion

A290–7207–X403 J3–axis motor cover

5) StopperSpecifications Axis

A290–7207–X227 J1

A290–7207–X226 J1

A290–7207–X321 J1

A290–7207–X347 J1

A290–7207–X327 J2

A290–7207–X333 J3

B–80405E/04 2. PREVENTIVE MAINTENANCE

27

2 PREVENTIVE MAINTENANCE

Optimum performance of the robot can be maintained for a long

time by performing the periodic maintenance procedures pres-

ented in this chapter.

2. PREVENTIVE MAINTENANCE B–80405E/04

28

Clean each part, and visually check component parts for damage beforedaily system operation. Check the following items as the occasiondemands.

a) Before automatic operation

Table 2.1 Daily preventive maintenance checks (1/2)

Item Check items Check points

1 When aircontrol set iscombined.

Air pressure Check air pressure using the pressuregauge on the air regulator as shown inFig. 2.1.

If it does not meet the specified pres-sure of 5-7 kg/cm2, adjust it using theregulator pressure setting handle.

2 Oiler oil mistquantity

Check the drop quantity during wrist orhand motion. If it does not meet thespecified value (1 drop/10 - 20 sec),adjust it using the oiler control knob.Under normal usage the oiler becomesempty in about 10 to 20 days undernormal operation.

3 Oiler oil level Check to see that the oiler level iswithin the specified level shown in Fig.2.1.

4 Leakagefrom hose

Check the joints, tubes, etc. for leaks.

Repair leaks, or replace parts, as re-quired.

5 Cables used in mechanicalunit

Refer to section 8.

6 Vibration, abnormal noises,and motor heating

Check to see that each axis movessmoothly.

7 Changing repeatability Check to see that the stop positions ofthe robot has not deviated from theprevious stop positions.

8 Peripheral devices for properoperation

Check whether the peripheral devicesoperate properly according to com-mands from robot.

9 J2/J3-axis brake Refer to 4.2.

2.1DAILY CHECKS


29

Oil inlet Adjusting knob

Oiler mist amountcheck

Oiler

Regulatorpressure setting handle

FilterPressure gauge

Fig. 2.1 Air control set (option)

b) After automatic operationAfter automatic operation ends, return the robot to the zero point,and turn off the power supply.

Table 2.1 Daily preventive maintenance checks (2/2)


1 Cleaning and checking eachpart

Clean each part and check componentparts for cracks and flaws.

2. PREVENTIVE MAINTENANCE B–80405E/04

30

Check the following items once every 3 monthes. Additional inspectionareas and times should be added to the table according to the robot’sworking conditions, environment, etc.

Table 2.2 Monthly preventive maintenance checks


1 Loose connectors Check that all connectors, including the mo-tor connectors, are secure.

2 Loose bolts Check that all cover mounting bolts and ex-ternal mounting bolts are secure.

3 Removal of dust, etc. Remove any spatter, dust, foreign matter, etc.

2.23–MONTH CHECKS


31

1) Check the following items every year.


1 Lubrication greasing Refer to section 3.1.

2 Changing of battery Refer to section 3.3.

2) 3-year checksCheck the following items once every 3 years.


1 Greasing each axis reducer Refer to section 3.2.

3) Maintenance toolsThe following tools and instruments are required for the maintenanceprocedures contained in this manual.

a) Measuring instrumentsInstruments Accuracy/Tolerance Applications

Dial gauge 1/100 mm Measurement of positioningand backlash.

Slide calipers 150 mm

b) ToolsCross tip (+) screwdrivers: Large, medium, and small sizesFlat tip (-) screwdrivers: Large, medium, and small sizesBox screwdrivers: M3 - M6Hexagonal wrench key sets (metric): M3 - M16Adjustable wrenches: Medium and small sizesPliersCutting pliersCutting nippersDouble and wrenchGrease gunPliers for C-retaining ring

2.31-YEAR CHECKS

3. LUBRICATING CONDITION CHECKS B–80405E/04

32

3 LUBRICATING CONDITION CHECKS

B–80405E/04 3. LUBRICATING CONDITION CHECKS

33

Never perform greasing procedures before turning off power.

1) Apply grease normally every year.2) For the greasing points and the method of greasing, see Fig. 3.1 and

Table 3.1.

Table 3.1 Greasing points (ARC Mate100/S-6)

Item Greasing point Grease Qty Method of greasing

1 J6-axis reducer

Grease SK–3(No.:A98L–0040–0110#2.5KG

50 cc Remove the plugs (PT1/8–2 type) from the J6–axis grease inlet and out-let, attach the J4–axisgrease nipple to theJ6–axis grease inlet, theninject grease. After greas-ing, return the grease nip-ple to the J4–axis greasingpoint, and put the plugs onthe grease inlet and outlet.

2 J4-axis reducer0110#2.5KG

150cc

Remove the plug from thegrease outlet, and injectgrease through the greasenipple attached to thegrease inlet. After greas-ing, plug the grease outlet,and cap the grease nipple.

J3–axis reducer grease nipple

J3–axis reducer airvent for greasing


J2–axis reducer greasenipple

J4–axis reducer air ventfor greasing




J5–axis reducer air vent




RE No. 00

RE No. 00

RE No. 00

RE No. 00

SK–3

SK–3

Fig. 3.1 Greasing points (ARC Mate 100/S–6)

3.1GREASING

3. LUBRICATING CONDITION CHECKS B–80405E/04

34

Change grease for reducers J1, J2, J3 and for gear box of J5 as followsevery 3 years or 20.000 hours. See Fig 3.1 for greasing points.

1 Remove the plugs (PT1/8–2) from the grease outlets for the J1–, J2–,J3–, and J5–axes, as shown in Fig. 3.1.

2 Remove the caps from the grease nipples of the grease inlets for theJ1–, J2–, and J3–axes. Remove the plug from the J5–axis grease inletand mount a grease nipple for other axis inlets on the inlet.

3 Inject the grease specified in Table 3.2 from the grease nipples forJ1–, J2–, J3–, and J5–axes until the old grease is pushed out from theoutlets and this new grease is also pushed out a little.

4 Remove the grease nipples for J1–, J2–, J3–, and J5–axes. Take outabout 5% of the supplied grease so that the grease baths are not full.

5 Mount the grease nipples at the grease inlets for the J1–, J2–, andJ3–axes. Then mount the caps on them.

6 Mount the plugs on the grease outlets for the J1–, J2–, J3–, andJ5–axes and the grease inlet for the J5–axis.

Table 3.2 Grease requiring 3–year changes (ARC Mate 100/S–6)

Grease Qty.Kyodo Yushi

Qty.(cc)

J1-axis reducer 1000

J2-axis reducer Mory–White RE No. 00 1000

J3-axis reducer(Specification:A98L–0040–0119#2KG) 200

J5-axis gear boxA98L–0040–0119#2KG)

250

NOTETake care not to slip on grease. Wipe the grease off the floorand robot structure.

3.23-YEAR CHECK

B–80405E/04 3. LUBRICATING CONDITION CHECKS

35

The data of the zero point of each axis is held by the backup batteries.

The batteries must be replaced every year. They should be replaced asfollows.

1 Turn the power on.Press the EMERGENCY STOP button to inhibit the robot’smotion.

2 Remove the battery case cap.3 Remove the old batteries from the battery case.4 Set the new batteries in the battery case. Take care of the

direction of each battery.5 Remount the battery case cap.

Battery specifications:A98L-0031-0005, 4 alkaline batteries

Battery case Case cap

Fig. 3.3 Replacing batteries (ARC Mate100/S-6)

3.3REPLACING BATTERY

4. TROUBLE SHOOTING B–80405E/04

36

4 TROUBLE SHOOTING

B–80405E/04 4. TROUBLE SHOOTING

37

The source of mechanical unit problems may be difficult to locate becauseof overlapping causes. Problems may become further complicated if theyare not corrected properly. Therefore, it is necessary to keep an accuraterecord of problems and to take proper corrective actions.

4.1GENERAL


38

Table 4.2(a) lists the major failures that may be suffered by the mechanicalunit, together with their causes. Contact us if the cause of a failure cannotbe identified, or the necessary corrective action cannot be determined.

Note, however, that backlash, provided it does not exceed the values listedin Table 4.2(b), is normal. Note also that a drop that does not exceed thevalues indicated in Table 4.2(c) is normal.

Table 4.2(a) Major Failures and Their Causes

Symptom Cause Corrective action Remarks

A BZAL alarm is issued.(Batteries are dead.)

The batteries used for memorybackup are exhausted.

Replace the batteries thenperform quick mastering.

See Section 3.3.See Section 5.3.

The pulse coder signal cable isbroken.

Replace the cable then per-form quick mastering.

See Section 8.2.See Section 5.3.

Positional error. The robot may have hit an object. Make a teaching pointcorrection.

The robot is not firmly secured. Secure the robot firmly. See Section 3.2 of the partexplaining connection.

Peripheral equipment has beenmoved out of position.

Secure the peripheralequipment firmly.

An excessive load has been ap-plied.

Reduce the load.Ensure that the robot is op-erated within its specifiedlimits.

Wrist load: Refer to the specifications.Peripheral equipment: See Section 2.2 of the partexplaining connection.

A specified parameter is incorrect. Correct the parameter. Refer to the instructionmanual.

A cable has broken. Replace the cable. See Section 8.2.

The pulse coder has failed. Replace the motor. See Sections 6.1 through6.10.

The backlash in the mechanicalunit is excessive. (See the description of the rele-vant symptom below.)

Vibration The robot is not secured firmly. Secure the robot firmly. See Section 3.2 of the partexplaining connection.

The floor vibrates (particularlywhen the robot is installed on afloor above ground level.)

Review the location ofinstallation.

An excessive load is applied. Reduce the load.Ensure that the robot is op-erated within its specifiedlimits.

Wrist load: Refer to thespecifications.Peripheral equipment: See Section 2.2 of the partexplaining connection.

The servo system is not correctlyadjusted.

Adjust the servo system. Contact us.

A cable has broken. Replace the cable. See Section 8.2.

A ground connection has not beenmade.

Make the necessary groundconnection.

Refer to the maintenancemanual for the control unit.

A motor is faulty. Replace the motor. See Sections 6.1 through6.10.

An axis board PCB is faulty. Replace the axis boardPCB.

Refer to the maintenancemanual for the control unit.

4.2PROBLEM AND CAUSES


39

Symptom RemarksCorrective actionCause

Vibration A reducer is faulty. Replace the reducer. See Sections 6.2 through6.10.

An incorrect time constant is used. Correct the time constant. Refer to the operator’smanual.

The backlash in the mechanicalunit is excessive. (See the de-scription of the symptom below.)

Mechanical unit back-lash.

A screw or pin is loose. Tighten the screw or pin.(Apply Loctite to the speci-fied area.)

A reducer is faulty. Replace the reducer. See Section 6.2 through6.10.

A gear is not correctly adjusted. Adjust the gear. See Section 5.7.

A gear is worn. Adjust the gear.Replace the gear.

Contact us.

A bearing is worn. Replace the bearing. Contact us.

A part such as a casting has bro-ken.

Replace the broken part. Contact us.

Abnormal sound. Gears and/or reducers requiregreasing.

Apply grease. See Sections 3.1 and 3.2.

Foreign matter has entered a gearor reducer.

Clean the gear or reducer,then apply grease.

See Sections 6.2 through6.10, 3.1, and 3.2.

A gear is not correctly adjusted. Adjust the gear. Contact us.

A gear is worn. Adjust the gear.Replace the gear.

Contact us.

A bearing is worn. Replace the bearing. Contact us.

The servo system is not correctlyadjusted.

Adjust the servo system. Contact us.

Overheating. Gears and/or reducers requiregreasing.

Apply grease. See Sections 3.1 and 3.2.

Grease that does not satisfy thespecifications has been used.

Clean and regrease. See Sections 3.1 and 3.2.

An excessive load is applied. Reduce the load.Ensure that the robot is op-erated within its specifiedlimits.

Wrist load: Refer to the specifications.Peripheral equipment: See Section 2.2 of the partexplaining.

A gear is not correctly adjusted. Adjust the gear. Contact us.

An incorrect time constant is used. Correct the time constant. Refer to the instructionmanual.

The robot arm dropswhen the power is cut.

A motor brake is worn. Replace the motor. See Sections 6.1 through6.10.

Brake relay has burnt out. Replace the relay. Refer to the maintenancemanual for the control unit.

Grease leaks. An O–ring, oil seal, or packing hasdegraded or has been damaged.

Replace the O–ring, oilseal, or packing.

Contact us.

A part such as a casting has bro-ken.

Replace the broken part. Contact us.

A screw is loose. Tighten the screw.


40

Table 4.2(b) Allowable Backlash for Each Axis

J1 J2 J3 J4 J5 J6

Angle (min) 2.5 2.5 2.5 3 6 3

Displacement (mm) 0.93(1291)

0.43(600)

0.38(517)

0.16(200)

0.38(220)

0.16(200)

NOTEA displacement value indicates a rotational backlash withinthe distance (indicated in parentheses) from the center ofthe axis.

Table 4.2(c) Allowable Drop

When power is cut 5 mm

In the event of an emergency stop 5mm


41

Adjustments are necessary whenever a part is replaced.

The table below shows replacement of parts and the required adjustmentitems.

Part to be replaced or function to be changed Adjustment

Replacement of cable (a) Routing of cable

(b) Limit switch

(c) Mastering

Replacement of limit switch(option)

(a) Limit switch and dog adjustment

J1-axis stroke change(option)

(a) Dog mounting position change, limitswitch adjustment

(b) Hard Stop mounting position adjustment

(c) Parameter change

Replacement of batteries(Replace every year)

Replace them keeping power on.

No adjustment is necessary.

4.3REPLACING PARTSAND PERFORMINGADJUSTMENTS

5.ADJUSTING B–80405E/04

42

5 ADJUSTING

Mechanical parts have been adjusted to the optimum condition

at the time of shipment from our company. Therefore, they nor-

mally need not be adjusted by the customer at the time of deliv-

ery.

Adjustment should be made as specified in this section, however,

after a long period of use or after replacing a part.

B–80405E/04 5. ADJUSTING

43

1) Zero point and working limit

Each controlled axis has its own zero point and working limits.Each controlled axis is limited mechanically by dog.When the controlled axis reached its working limit, and trips its limitswitch it is called Over Travel (OT). Over Travel is detected at either endof the axis.The robot is controlled not to work beyond its operating area unless theservo system fails or a system error occurs so that the zero point is lost.Figs. 5.1(a) through 5.1(h) show the zero point, working limits (stroke),OT detection dogs, and mechanical stopper positions for each axis.Adjust each limit switch (Section 8.3) and dog such that an OT alarm isissued at the positions shown in the figures.

Note) The stroke can be changed.

Stroke 330�

+165� –165�

minimum 1�

Stroke end Stroke end

Mechanical stopper

0�

minimum 1�

Fig. 5.1 (a) J1-axis rotation (J1 300°) (ARC Mate100/S-6)

5.1ADJUSTING LIMITSWITCHES AND DOGS(OPTION)


44

Note) When working space is360�, mechanical stopsare not exist.

0�

+180� –180�

minimum 0.5�

minimum 0.5�

–OT +OT Stroke end

360� 0T option specification:A05B–1207–H322

Stroke 360�

Fig. 5.1 (b) J1-axis rotation (Option 360�)(ARC Mate100/S-6)

Note) The motion range is limited by the J3-axis position.

minimum 3�minimum 3�

Storoke240�

Stroke end

Mechanical stopper

Stroke endMechanicalstopper

Fig. 5.1 (c) J2-axis rotation (ARC Mate100/S-6)


45

Note) The motion range is limited by the J2-axis position.

–145�

+180�0�

0�

Stroke 325�

Fig. 5.1 (d) J3-axis rotation (ARC Mate100/S-6)

Note) The J4 axis does not have OT limit switches nor mechanical stops.

Stroke end Stroke end+190� –190�

Fig.5.1 (e) J4-axis wrist rotation (ARC Mate100/S-6)


46

Note) The J5 axis does not have OT limit switches.

Stroke end

Mechanical stopper

Stroke end

Mechanical stopper

minimum 3�

minimum 3�

+140�

–140�

0�

Stroke280�

Fig.5.1 (f) J5-axis wrist rotation (ARC Mate100/S-6)

Note) The J6 axis does not have OT limit switches nor hard stops.

0�

Stroke 540�

+270�–270�

Stroke end Stroke end

Fig.5.1 (g) J6–axis wrist rotation (ARC Mate100/S–6)


47

Note) The allowable range for the relative anglebetween the J2-axis and J3-axis arms isfrom 15° to 165°.

Mechanical stopperOT Stroke end

Minimum 5�

Interference angle 15�

Interference angle 15�

Minimum 5�

Stroke endOT

Mechanical stopper

J3–axis arm

J2–axis arm

Fig.5.1 (h) J2/J3 limit interference angles (ARC Mate100/S-6)


48

It is possible to limit the J1-axis stroke according to the surroundings ofthe robot. The stroke can be changed as shown in Fig. 5.2 (a). It can bechanged according to the OT stroke by changing the dog position or themechanical stop.

The stroke can be changed every 20� at the desired stroke positionbetween –165� to +165�.When the stroke does not include 0�, the stroke must be readjusted to thestandard position when mastering the robot using the jig.J1–axis stroke change option specification (without OT):A05B–1207–J301J1–axis stroke change option specification (with OT): A05B–1207–J302

Note) Standard stroke is from -165� to +165�

Front

Fig.5.2 (a) J1-axis stroke change (ARC Mate100/S-6)

5.2J1-AXIS STROKE MODIFICATION (OPTION)


49

Change the dog and hard stop positions according to the desired stroke

position as shown in Fig. 5.2 (b).

Note) The figure shown the J1-axis base top view.

Limit switch(Rotation side)option

Front

Mechanicalstopper (Rotation side)Example

Mechanical stopper (Fixed side)

Dog (Fixed side)

Limit switch(Rotation side)option

Front

Mechanical stopper (Rotation side)

Mechanical stopper (Fixed side)

Dog (Fixed side)

Example

Fig.5.2 (b) Dog and mechanical stop position change (ARC Mate100/S-6)

1) Changing dog andmechanical stop position


50

After adjusting the dog and mechanical stopper positions, set the system

variables for both J1–axis stroke ends as indicated in Table 5.2.

Parameter number $PARAM GROUP. $LOWERLIMS : J1-axis stroke lower limit

Parameter number $PARAM GROUP. $UPPERLIMS : J1-axis stroke upper limit

Please power off, and perform a cold start after change of the value.

NOTECold start: A type of start operation, where the power is firstturned off, then turned back on. (Cold start is used whenpower failure processing has been disabled.)

If power failure processing is currently enabled (systemvariable $POWERFL is set to true), change the systemvariable $POWERFL to false (power failure processingdisabled). Turn off the power, then turn it on again. Tosubsequently reenable power failure processing, reset thesystem variable $POWERFL to true (power failureprocessing enabled).

2) Changing minimum andmaximum stroke


51

Table 5.2 J1–Axis Stroke Upper and Lower Limits (Changing A Stroke)

Position of eachstroke end

�(Stroke lower limit)$PARAM_GROUP.

$LOWERLIMS

�(Stroke upper limit)$PARAM_GROUP.

$UPPERLIMS

–180� (*1) –180

–165� (standard value) –165

–145� –145

–125� –125

–105� –105

– 85� – 85

– 65� – 65

– 45� – 45

– 25� – 25

– 5� – 5

+ 5� 5

+ 25� 25

+ 45� 45

+ 65� 65

+ 85� 85

+105� 105

+125� 125

+145� 145

+165� (standard value) 165

+180� (*1) 180

*1 �180� is optional. (Specification: A05B–1207–H322)


52

Quick mastering is a method of exact calibration at the original positionwhen the pulse coder battery backup is disconnected, such as when a cableis replaced.

Quick mastering cannot be used when the mechanical phase of the pulsecoder is changed, such as when a motor or reducer is replaced. In sucha case, perform mastering using jigs as described in Section 5.5.

a) Before replacing the cable, note down the mastering data for thesystem variable $DMR_GRP.$MASTER_COUN[1]–[6] (pre-vious mastering data).

b) Replace the cable.c) To release the brake control, set the system variable $PA-

RAM_GROUP.$SV_OFF_ENB to FALSE for all axes, then per-form a cold start. (See Section 5.2(2).)

d) Upon power–up, a BZAL alarm is output. Set the system variable$MCR.$SPC_RESET to true, then perform a cold start.

e) When the power is turned on, the message ”Pulse not established”appears. Rotate each axis through about 10° in the positive (+)or negative (–) direction by joint feed. Then, press the alarm re-lease key to release the message.

f) Move all the axes, by joint feed, to position each axis to the zerodegree mark with an accuracy of �1 mm relative to the arrowmark. (See Fig. 5.3.)

g) Assign the mastering data (noted in step a) for the system vari-able $DMR_GRP.$MASTER_COUN[1]–[6] to the systemvariable for the quick mastering data, $DMR_GRP.$REF_COUN[1]–[6]. Then, enter 0 as the system variable forthe quick mastering reference position data, $DMR_GRP.$REF_POS[1]–[6]. Next, set the quick mastering completionflag $DMR_GRP.$REF_DONE to TRUE. This completes thesetting of the quick mastering reference position at the zero de-gree position for each axis.

h) Press the screen selection key to display the menu. Then, selectSYSTEM. From the system menu, select Master/Cal. If the cal-ibration screen is not displayed, set the system variable $MAS-TER_ENBL to 1.

i) Select 4 QUICK MASTER from the system calibration menu,then press function key F4 (YES). Quick mastering is performed.

j) Teaching and playback are enabled by selecting 6 Master/Calfrom the system calibration menu and pressing function key F4(YES).

k) If brake control has been released, reset the system variable $PA-RAM_GROUP.$SV_OFF_ENB to the previous value for allaxes, then perform a cold start.

l) Finally, as a safeguard against mastering data being rewritten byan operation error, note down the mastering data for the systemvariable $DMR_GRP.$MASTER_COUN.

5.3QUICK MASTERING

1) Mastering procedure (forcable replacement)


53

J5–axis

J6–axis

J4–axis

J3–axis

J4–axis

J2–axis

J1–axis

Fig.5.3 Zero degree position arrow mark for each axis (ARC Mate 100/S–6)


54

Each of the robot’s axes is fitted with arrow marks shown in Fig. 5.3. Theaxis is at the zero degree position if these marks match. If such a markis not at its correct position, it can be mastered as follows.

This operation allows you to roughly master the position. Accuratemastering requires the operation using the mastering jig described in the5.5 section.

a) To release the brake control, set system variable $PA-RAM_GRP.$SV_OFF_ENB for each axis to FALSE, turn off thepower, and perform a cold start. [See 5.2 2)]

b) When a BZAL alarm is output upon power–up, set the systemvariable $MCR.$SPC_RESET to true, then perform a cold start.

c) If the message ”Pulse not established” appears when the poweris turned on, rotate each axis through about 10� in the positive (+)or negative (–) direction by joint feed. Then, press the alarm re-lease key to release the message.

d) Move all axes by joint feed to position each axis to the zero degreemark. (See Fig. 5.3.)

e) Press the screen selection key to display the menu. Then, selectSYSTEM. From the system menu, select Master/Cal. If the cal-ibration screen is not displayed, set the system variable $MAS-TER_ENBL to 1.

f) Select 2 ZERO POSITION MASTER from the system calibra-tion menu, then press function key F4 (YES). Then, masteringis performed. Thus, mastering data acquired from the pulse codercounter is set in the system variable $DMR_GRP. $MAS-TER_COUN, and the system variable $DMR_GRP. $MAS-TER_DONE (mastering completion flag) is set to true.

g) Teaching and playback are enabled by selecting 6 Master/Calfrom the system calibration menu and pressing function key F4(YES).

h) If brake control has been released, reset the system variable $PA-RAM_GRP.$SV_OFF_ENB to the previous value for all axes,then perform a cold start.

i) Finally, as a safeguard against mastering data being rewritten byan operation error, note down the mastering data for the systemvariable $DMR_GRP.$MASTER_COUN. Furthermore, drawarrow marks for zero position calibration with the zero degreeposition attitude, as shown in Fig. 5.3.

To perform mastering for one axis only, perform single–axismastering as described below.The new position data is thus stored only for the target axis, andprevious position data is stored for the other axes.The J2- and J3-axes must be mastered simultaneously becausethey rotate together.

5.4MASTERING USING ZERO DEGREE POSITION

1) Procedure (Mastering ofzero degree position)


55

a) To release brake control, set the system variable $PA-RAM_GROUP.$SV_OFF_ENB to FALSE for all axes, then per-form a cold start. (See Section 5.2 2).)

b) When a BZAL alarm is output upon power–up, set the systemvariable $MCR.$SPC_RESET to true, then perform a cold start.

c) If the message ”Pulse not established” appears when the poweris turned on, rotate each axis through about 10� in the positive(+) or negative (–) direction by joint feed. Then, press the alarmrelease key to release the message.

d) Move the desired axis by joint feed to position the axis to the zerodegree mark. (See Fig. 5.3.)

e) Press the screen selection key to display the menu. Then, selectSYSTEM. From the system menu, select Master/Cal. If the cal-ibration screen is not displayed, set the system variable $MAS-TER_ENBL to 1.

f) Select 3 SINGLE–AXIS MASTER from the system calibrationmenu. Then, the menu for setting each axis appears. Enter 1 inthe (SEL) column of the axis for which mastering is to be per-formed, then enter 0 for the other axes. Enter 0 (for zero degree)in the MASTERING POSITION column. Press function key F5(EXEC) to perform zero degree position mastering for the se-lected axis only.

g) Teaching and playback are enabled by selecting 6 Master/Calfrom the system calibration menu and pressing function key F4(YES).

h) If brake control has been released, reset the system variable $PA-RAM_GRP.$SV_OFF_ENB to its previous value for all axes,then perform cold start.

i) Finally, to safeguard against mastering data being overwritten byan operation error, note down the mastering data for the systemvariable $DMR_GRP.$MASTER_COUN. Furthermore, drawarrow marks for zero position calibration with the zero degreeposition attitude, as shown in Fig. 5.3.

2) Procedure(single–axis mastering)


56

If the present value stored via the APC (Absolute Pulse Coder) and theactual position of each axis are misaligned after a major component of therobot’s mechanical unit has been replaced, mastering is to be carried outto set the robot’s geometric position. (Mastering is executed at J1=0�)The robot has been mastered by the time of the shipment.

Before mastering the robot do the following:� Make the robot’s base level. (1 mm/base)� Remove the wrist hand and related parts.� Do not allow an external force to be applied to the robot.

NOTEThe axis stroke is not checked during mastering. Sufficient care shoud,

therefore, be taken regarding the robot’s axis movement.

1 Assemble the jig base

Assemble mastering jig C to mastering jig B as shown in Fig. 5.5 (a).

Mastering jig CA290–7207–X953

M6X12 (4PCS)Washer M6 (4PCS)

Mastering jig BA290–7207–X952

Fig.5.5 (a) Assembly of jig base (ARC Mate100/S-6)

5.5MASTERING USINGJIG

Assembling themastering jig


57

2 Mounting on robot’s bodyMount the mastering jig B on the J1-axis base using bolts and pins asshown in Fig 5.5 (b).

J1 base A290–7207–X201

Pin A290–7111–X906

M8X20 (2PCS)Pin A290–7111–X906

Fig.5.5. (b) Mounting on robot’s body (ARC Mate100/S-6)

3 Mounting jig on wristPosition the wrist axis such that J4 = J5 = J6 = 0� in manual mode. Asshown in Fig. 5.5(c), mount mastering jig A onto the J6–axis so thatthe cubic section (weight) directls upward.

NOTEWhen using the optional FANUC flange adaptor, first mountthe flange adaptor, and fit the mastering jig onto theadaptor. (Mastering jig A differs from other mastering jigsin shape.)


58

Pin A290–7022–X965

Mastering jig A (For ISO)A290–7207–X951

M6X61(4PCS)Mastering jig A2 (For FANUC)A290–7207–X956

Fig.5.5. (c) Mounting jig on wrist (ARC Mate100/S-6)

1 First execute mastering by using the zero degree position described in

Section 5.4. A temporary coordinate zero point is set in the robot.

2 To release brake control, set system variable $PARAM_GROUP.$SV_OFF_ENB to FALSE for all axes, turn the power off, andperform a cold start. [See 5.2 2)]

3 Set the system variable $DMR_GRP.$MASTER_DONE (masteringcompletion flag) to FALSE to enable each axis to move beyond itsmaximum stroke. While performing joint feed, bear in mind that therobot can move beyond its maximum stroke. Therefore, operate therobot with a smaller teach feedrate override.

4 Using joint feed, move the robot until mastering jig A, mounted ontothe wrist axis, is positioned within mastering jig B mounted on the J1base, as shown in Fig. 5.5(d). The corresponding attitude of the robotis shown in Fig. 5.5(e).

Mastering procedure


59

Mastering jig DA290–7207–X954

M6X12 (2pcs)

Mastering jig EA290–7207–X955

M6X12 (4 pcs)

Fig. 5.5(d) Assembling Mastering Jigs (ARC Mate 100/5–6)

ISO flange

Mastering attitude

J1 = 0�J2 = 85�J3 = –155�J4 = 0�J5 = –25�J6 =0�

Mastering attitude

J1 = 0�J2 = 83.485�J3 = –152.993�J4 = 0�J5 = –27.007�J6 =0�

Mastering Jig Specification: A05B–1207–J052

Mastering Jig Specification: A05B–1207–J053

Flange adaptor (optional)

Fig. 5.5(e) Mastering Attitude (ARC Mate 100/S–6)


60

5 Mount mastering jig D and mastering jig E onto mastering jig B, asshown in Fig. 5.5(d). It is absolutely essential that this step beperformed to prevent the arm from falling when the brake is released.

6 Press and turn the emergency stop button on the teach pendant torelease the lock. The power is disconnected from the motor. Do notpress the alarm release key.

7 [For R–J controller]Press the screen selection key to display the menu. From the menu,select SYSTEM.From the system menu, select Brake Cntrl. Press function key F�,then select function key SHIFT + F3 (REL_ALL) to release the brakeson all axes.[For R–J2 controller]Press the screen selection key to display the menu. From the menu,select SYSTEM.Press the function key F1 (MENU), select Master/Cal. Press SHIFT+ F4 (TORQUE), change the indication from TORQUE=[ON] toTORQUE=[OFF]. Press the RESET key to release the torque on allaxes. (It is equal condition to release the brakes)

8 Install three M8 bolts as shown in Fig. 5.5(f). While tightening thebolts, push mastering jig A, mounted on the wrist, until its oppositesurface is butted against the wall.

9 Check, by viewing through the window, that each of the three surfacesis completely butted against the wall, as shown in Fig. 5.5(g). If notall of the surfaces are fully butted against the walls, loosen the M8bolts, and perform step 7 again.

10 Press the screen selection key to display the menu. Then, selectSYSTEM. From the system menu, select Master/Cal. If thecalibration screen is not displayed, set the system variable$MASTER_ENBL to 1.

11 Select 2 JIG POSITION MASTER from the system calibration menu,then press function key F4 (YES). Then, mastering is performed.Thus, mastering data acquired from the pulse coder counter is set inthe system variable $DMR_ GRP.$MASTER_COUN, and the systemvariable $DMR_ GRP.$MASTER_DONE (mastering completionflag) is set to TRUE.

12 Teaching and playback are enabled by selecting 6 Master/Cal from thesystem calibration menu and pressing function key F4 (YES).

13 Press the screen selection key to display the menu. Then select theSYSTEM.

14 [For R–J controller]From the system menu, select Brake Cntrl. Press function key F�,then select function key SHIFT + F2 (ENG_ALL) to control the brakesof all axes.[For R–J2 controller]From the system menu, press the function key F1 (MENU), selectMaster/Cal. Press SHIFT + F4 (TORQUE), change the indication fromTORQUE=[OFF] to TORQUE=[ON]. Press the RESET key to control the torque of all axes.


61

15 Remove the mastering jig D and E, then release the mastering jig Afrom the mastering jig B with the joint feed. Remove the masteringjig A from the wrist and the mastering jig B from J1 base.

16 After completion of mastering, reset system variable$PARAM_GROUP_. $SV_OFF_ENB to zero.

17 If brake control has been released, reset the system variable$PARAM_GROUP. $SV_OFF_ENB to the previous value for allaxes, then perform cold start. (See Section 5.2 2).)

18 Finally, to safeguard against mastering data being overwritten by anoperation error, note down the mastering data for the system variable$DMR_GRP.$MASTER_COUN [1] to [6].

To perform mastering for a desired axis only, first note down themastering data of the system variable $DMR_GROUP.$MASTER_COUN, then perform mastering for all axes. Once thismastering has been completed, reenter the mastering data for all axesexcept the desired axis. Thus, the new position information for thedesired axis only is stored; the previous position information for theother axes is preserved.

Fig. 5.5(f) Butting Mastering Jig (ARC Mate 100/S–6)


62

Window

Butting surface

Window

Butting surface

Window

Butting surface

Window

Butting surface

Fig. 5.5(g) Mastering Jig Butting Surfaces and Window (ARC Mate 100/S–6)


63

1) Confirming whether mastering is normally done

When turing on the power, the position matching is automaticallydone. To confirm whether this operation has normally finished, checkwhether the present position display coincides with the robot actualposition using one of the following methods.a) Move the axes to 0� by repeat operation, and visually check the

zero degree marks. (It’s shown in Fig. 5.3).b) Position the specified position in repeat operation, and check

whether this position coincides with the programmed position.2) Alarms at positioning

Alarms which may occur at positioning and the action to be taken aredescribed below.a) BZAL alarm

This alarm occurs when the voltage of the pulse coder back-upbattery drops to zero while the controller power is turned off. Ifthis alarm occurs, perform mastering because the data in thecounter is lost.

b) BLAL alarmThis alarm indicates that the voltage of the pulse coder back-upbattery has become tool low to back up the pulse coder. If thisalarm occurs, replace the back-up battery with the system turnedon, and check if the present position data is correct according tothe procedure described in Item 1) above.

c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR,and SPHAL alarmsWhen any of these alarms occur, contact the service engineer.The motor may need to be replaced.

5.6CONFIRMING MASTERING


64

Adjusting J5–axis spur gear backlash (For S motor)If the backlash of the J5–axis exceeds the maximum allowable value(output axis angle of 3 to 6 minutes), backlash adjustment can be madeby following the procedure below. (See Fig. 5.7(a))

1 Position the robot to the attitude, J4 = +90� and J5 = J6 = 0�.2 Remove the eight M4X8 fixing bolts, then remove the J5–axis

gear box cover (A290–7207–X502) from the J3 arm(A290–7207–X402).

Gear 2 assemblyA290–7207–V501

J3 armA290–7207–X402

M4X12 (4 pcs)(Loctite 262)Washer M4 (4 pcs)


Gear J5–4A290–7207–X514

Eccentric punch mark (for reduced back lash)

M4X8 (8 pcs)(Loctite 262)M4 Washer (8 pcs) Packing

A290–7207–X524

M4X10 (6 pcs)(Loctite 262)M4 Washer (6 pcs)

Cover A290–7207–X502

Turn to adjustbacklash.

Fig. 5.7(a) J5–axis gear backlash adjustment (ARC Mate 100/S–6)

3 Loosen the four M4X12 bolts to disengage the gear 2 assembly(A290–7207–V501) from the gear 3 assembly (A290–7207–V502).

4 Remove the six M4X10 bolts. The rotation center axis and gearcenter axis of the gear 3 assembly are not aligned. For this reason,by changing the phase between the gear 3 assembly and the J3arm (with M4X10 bolts used for fixing at 6 of 19 equally spacedpositions along the circumference), the backlash of the gear 3 as-sembly and gear J5–4 can be adjusted. To reduce the backlash,change the mounting phase of the gear 3 assembly, then securethe gear 3 assembly to the J3 arm using six M4X10 bolts.

5 While turning the gear 3 assembly and checking the operation ofthe J5–axis within the stroke (–140� to +140� ), repeat step 4 toreduce the backlash until there is no interference between thegears.

5.7ADJUSTING J5-AXISSPUR GEARBACKLASH

Backlash adjustment ofthe gear 3 assembly andgear J5–4


65

6 To reduce the backlash, position the gear 2 assembly at right

angles to the axis running through the gear 2 and gear 3

assemblies. Then, secure the gear 2 assembly to the J3 arm with

four M4X12 bolts.


8 Check that the backlash of the J5–axis does not exceed the allow-able value (output axis angle of 6 minutes) indicated in Table4.1(b). If the allowable value is exceeded, return to step 3 .

9 Secure the gear box cover of the J5–axis to the J3 arm using eightM4X8 bolts. Also, renew the packing (A290–7207–X524) toprevent grease leakage.

10 Fill the J5–axis gear box with the specified type of grease, accord-ing to the grease replacement procedure described in Section 3.2.

11 Perform mastering according to Sections 5.4 or 5.5.

Backlash adjustment ofthe gear 2 and gear 3assemblies


66

If the backlash of the J5–axis exceeds the maximum allowable value(output axis angle of 3 to 6 minutes), backlash adjustment can be madeby following the procedure below. (See Fig. 5.7(b))

1 Position the robot to the attitude, J4 = +90� and J5 = J6 = 0�.2 Remove the eight M4X8 fixing bolts, then remove the J5–axis

gear box cover (A290–7207–X502) from the J3 arm(A290–7207–X402).


J3 armA290–7208–X402

M5X12 (4 pcs)(Loctite 262)Washer M5 (4 pcs)Plain washer M5(4pcs)


Gear J5–5A290–7208–X515

M4X12 (8 pcs)Washer M4 (8 pcs)

PackingA290–7208–X524

M4X10 (10 pcs)(Loctite 262)Washer M5(10pcs)

Cover A290–7208–X502

Turn to adjustbacklash.

Spring–pinφ5�10 (1pcs)

Fig. 5.7(b) J5–axis gear backlash adjustment (ARC Mate 100/S–6)

3 Loosen the four M5X12 bolts to disengage the gear 2 assembly(A290–7208–V501) from the gear 3 assembly (A290–7208–V502).

4 Remove the ten M5X12 bolts. Rotating the gear 3 assemblyclockwise or counterclockwise around the spring pin (φ5X10)adjusts the backlash between the gear 3 assembly and gear J5–5.Adjust the gear 3 assembly to minimize the backlash, then re-mount it to the J3 arm with the ten M5X12 bolts.


Adjusting J5–axis spurgear backlash (For α motor)

Backlash adjustment ofthe gear 3 assembly andgear J5–4


67

6 To reduce the backlash, position the gear 2 assembly at rightangles to the axis running through the gear 2 and gear 3assemblies. Then, secure the gear 2 assembly to the J3 arm withfour M5X12 bolts.


8 Check that the backlash of the J5–axis does not exceed the allow-able value (output axis angle of 6 minutes) indicated in Table4.1(b). If the allowable value is exceeded, return to step 3 .

9 Secure the gear box cover of the J5–axis to the J3 arm using eightM4X8 bolts. Also, renew the packing (A290–7208–X524) toprevent grease leakage.

10 Fill the J5–axis gear box with the specified type of grease, accord-ing to the grease replacement procedure described in Section 3.2.

11 Perform mastering according to Sections 5.4 or 5.5.

Backlash adjustment ofthe gear 2 and gear 3assemblies

6. REPLACING AND ADJUSTING PARTS B–80405E/04

68

6 REPLACING AND ADJUSTING PARTS

When replacing a part, subsequent adjustment is required.

Parts requiring replacing and their accompanying adjustment

items are listed below.

Replacement parts Adjustment item

Motor (a) Mastering

J1, J2, and J3–axis reducer (a) Mastering

(b) Dog adjustment (*option)

J4 and J6-axis reducer (a) Mastering

J5 axis gear box (a) Mastering

NOTEBe careful when removing and installing the following heavyparts.

Parts Weight (approx.)

J2 Arm–Wrist unit (see Fig. 6.3 (a)) 44 kg

J3 Arm (see Fig. 6.7 (a)) 20 kg

J2 BASE (see Fig. 6.1) 22 kg

B–80405E/04 6. REPLACING AND ADJUSTING PARTS

69

1 Turn off the control unit.2 Remove the connector from the J1–axis motor.3 Remove the four M8X20 motor mounting bolts, then remove the

motor from the J2 base.4 Remove the M10 hexagonal nut from the motor shaft, then pull

out the gear (A290–7207–X211).5 Mount the gear onto a new motor.6 Install an M10 spring washer, then apply Loctite 262 to the M10

screw of the motor. Then, tighten the M10 nut to the specifiedtorque [12.0 Nm (122 kgf–cm)].

7 Check that the O–ring is installed correctly where the motormounts on the J2 base (A290–7207–X301). Then, secure the mo-tor to the J2 base using four M8X20 bolts. Apply Loctite 262 tothe bolts.

8 Fill the J1–axis grease bath with the specified type of grease, asdetailed in Section 3.2.

9 Perform mastering as explained in Chapter 5.

NOTEWhen performing this procedure, ensure that the J1–axisdoes not rotate. When the J1–axis is allowed to rotatebecause of the robot is installed on a slanted plane, preventits rotation by, for example, pushing the J1–axis up againstits mechanical stopper.

1 To prevent its rotation, fix the J2–axis by, for example, pushingit up against its mechanical stopper.

2 Turn off the control unit.3 Remove the connector from the J2–axis motor.4 Remove the four M8X20 motor mounting bolts, then remove the

motor from the J2 base.5 Remove the M10 hexagonal nut from the motor shaft, then pull

out the gear (A290–7207–X311).6 Mount the gear onto a new motor.7 Install an M10 spring washer, then apply Loctite 262 to the M10

screw of the motor. Then, tighten the M10 nut to the specifiedtorque [12.0 Nm (122 kgf–cm)].

8 Check that the O–ring is installed correctly where the mounts onthe J2 base (A290–7207–X301). Then, secure the motor to theJ2 base using four M8X20 bolts. Apply Loctite 262 to the boltthreads.


10 Perform mastering according to Chapter 5.

6.1REPLACING J1 ANDJ2-AXIS MOTOR M1 M2

1) Replacing the J1–axis

motor (Fig.6.1)M1


motor (Fig.6.1)M2


70

J1–axis motor

M8X20 (4 pcs) Loctite 262Washer M8 (4 pcs)

Gear A290–7207–X211

O–ringHexagonal nut M10 Loctite 262 12.0 Nm (122 kgf–cm)Spring washer M10

Hexagonal nut M10 Loctite 262 12.0 Nm (122 kgf–cm)Spring washer M10

O–ring

Gear A290–7207–X311

J2–axis motor


J2 baseA290–7207–X301

M1

M2

Fig.6.1 Replacing J1, J2–axis motor (ARC Mate100/S–6)


71

1 Turn off the control unit.

2 Pull out the cables, running through the pipe of the J1–axis reduc-er, toward the J1–axis connector box as explained in Section 8.2.

3 Remove the J1–axis motor from the J2 base as explained in Sec-tion 6.1.

4 Remove the eight M8X50 bolts securing the J2 base to theJ1–axis reducer, as shown in Fig. 6.2(a).

5 Using a crane, slowly lift the J2 base as explained in Section 5.1of the part explaining connection.

6 Remove the O–ring (large), bearing, and center gear as shown inFig. 6.2(b).

7 Remove the six M12X80 bolts securing the J1–axis reducer to theJ1 base (A290–7207–X201), then remove the reducer.

8 Remove the four M4X10 bolts securing the pipe(A290–7207–X221) to the reducer, then remove the pipe accord-ing to Fig. 6.2(c).

9 Check that the O–ring is installed correctly on the pipe. Then,secure the pipe to a new reducer using four M4X10 bolts. ApplyLoctite 262 to the bolt threads.

10 Mount an O–ring (medium) and O–ring (small) on the reducer.Then, secure the reducer to the J1 base using six M12X80 bolts,tightening them to a torque of 128.4Nm (1310 kgf–cm). ApplyLoctite 262 to the bolt threads.

11 Mount the center gear, bearing (with Loctite RC75 applied to itsexternal ring), and O–ring (large) on the reducer.

12 Secure the J2 base to the reducer using eight M8X50 bolts, tight-ening them to a torque of 37.2 Nm (380 kgf–cm). Apply Loctite262 to the bolt threads. Be careful not to damage the oil seal sur-face with the pipe.

13 Mount the J1–axis motor onto the J2 base as explained in Section6.1.

14 Fill the J1–axis grease bath with the specified type of grease asdetailed in Section 3.2.


6.2REPLACING THEJ1-AXIS REDUCER


72

M4X10 (4 pcs) Loctite 262

M8X50 (8 pcs) Loctite 262 37.2 Nm (380 kgf–cm)Washer M8 (8 pcs)

Cable cover 2A290–7207–X336

ClampA290–7207–X340



ClampA290–7207–X340


ClampA290–7207–X340

M4X10 Loctite 262

ClampA290–7207–X340


Fig.6.2 (a) Replacing J1–axis reducer (ARC Mate100/S–6)


73

O–ring (Large)

J1 reducer center gear

Bearing Loctite RC75 (External ring)


O–ring (medium)

O–ring (small)

J1 base A290–7207–X201

J1–axis reducer

Fig.6.2 (b) Replacing J1–axis reducer (ARC Mate100/S–6)

O–ring

J1–axis reducer


Pipe A290–7207–X221

Fig.6.2 (c) Replacing J1–axis reducer (ARC Mate100/S–6)


74


2 Turn off the control unit.3 Pull out the cables, running through the pipe of the J2–axis reduc-

er, from the J2 arm toward the J2 base as explained in Section 8.2.4 Remove the J2–axis motor from the J2 base as explained in Sec-

tion 6.1.5 Remove the six M10X50 bolts and three M10X20 bolts securing

the J2 arm to the J2–axis reducer as shown in Fig. 6.3(a).6 Using a crane, lift the J2 base and the upper portion, then slowly

pull the J2 arm out sideways.7 Remove the seven M8X75 bolts securing the J2–axis reducer to

the J2 base (A290–7207–X301), then remove the reducer.8 Remove the four M4X10 bolts securing the pipe (A290–7207–

X221) to the reducer, then remove the pipe as shown in Fig.6.3(b).

9 Check that the O–ring is installed correctly on the pipe. Then,secure the pipe to a new reducer using four M4X10 bolts. ApplyLoctite 262 to the bolt threads.

10 Mount the bearing (with Loctite RC75 applied to its externalring) and O–ring on the reducer.

11 Mount the O–ring on the reducer. Then, secure the reducer to theJ2 base using seven M8X75 bolts, tightening them to a torque of37.2 Nm (380 kgf–cm). Apply Loctite 262 to the bolt threads.Be careful not to damage the oil seal surface with the pipe.

12 Secure the J2 arm to the reducer using six M10X50 bolts andthree M10X20 bolts, tightening them to a torque of 73.5 Nm (750kgf–cm). Apply Loctite 262 to the bolt threads.

13 Mount the J2–axis motor to the J2 base as explained in Section6.1.



6.3REPLACING THEJ2-AXIS REDUCER


75

J2–axis reducerBearing Loctite RC75 (External ring)


J2 base A290–7207–X302

J2 base A290–7207–X301

O–ring

M10X50 (6 pcs)N10X20 (3 pcs) Loctite 262 73.5 Nm (750 kgf–cm)Washer M10 (9 pcs)

J2 Arm–Wrist unit



PipeA290–7207–X221

O–ring

J2–axis reducer



76


2 Turn off the control unit.3 Remove the three M6X8 button bolts and two M4X16 bolts, then

remove the J3 cover (A290–7207–X403) from the J3 housing, asshown in Fig. 6.4(a).

4 Disconnect the cable from the J3–axis motor.5 Remove the four M6X16 seal bolts holding the J3–axis motor to

the J3 housing, then remove the motor and its packing.6 Remove the E–ring from the motor shaft, then remove the input

gear and draw bolt.7 Apply Loctite 683 to the screw on a new motor, then tighten the

draw bolt to a torque of 2.9 Nm (30 kgf–cm).8 Mount the input gear onto the motor shaft, then secure it with the

E–ring.9 From the J3 arm side, insert an assembly jig (A05B–1207–J054)

into the J3–axis reducer, as shown in Fig. 6.4(b).10 Mount a new packing (A98L–0040–0042#03), then insert the

motor into the reducer. Check, through the window, that the inputgear is correctly engaged with the reducer gear. If the gear en-gagement is out of line, even by as little as one tooth, vibrationcan occur. Ensure that the motor is inserted correctly.

11 Secure the motor to the J3–axis reducer using four new seal bolts(A97L–0118–0706#M6X16). To prevent grease leakage, newpacking and seal bolts must be used.

12 Attach the cable to the J3–axis motor.13 Fill the J3–axis grease bath with the specified type of grease as

detailed in Section 3.2.14 Mount the J3 cover onto the J3 housing using three M6X8 button

bolts and three M4X16 bolts.15 Perform mastering as explained in Chapter 5.

J3 CoverA290–7207–X403

Button bolt M6X8 (3 pcs)Plain washer M6 (3 pcs)


J3 housingA290–7207–X401 (S motor)A290–7207–Y401 (α motor)

E–ringInput gear

Draw bolt Loctite 683 2.9 Nm (30 kgf–cm)

PackingSeal bolt (4 pcs)Washer M6 (4 pcs)

J3–axis motorM3

Fig.6.4 (a) Replacing J3–axis motor (ARC Mate100/S–6)

6.4REPLACING THEJ3-AXIS MOTOR M3


77

J3–reducer assembly jig Specification: A05B–1207–J054

Window

J2–arm A290–7207–X302

J3–axis motor

Input gear

Gear of reducer

M3

Fig.6.4 (b) Replacing J3–axis motor (ARC Mate100/S–6)


78


2 Turn off the control unit.3 Remove the three M6X8 button bolts and three M4X16 bolts,

then remove the J3 cover (A290–7207–X403) from the J3 hous-ing, as shown in Fig. 6.4 (a).

4 Disconnect the cable from the J3–axis motor.5 Remove the J3–axis motor as explained in Section 6.4.6 Remove the two �8X25 taper pins securing the J2 arm to the

J3–axis reducer, as shown in Fig. 6.5.7 Using a crane, lift the J3 arm. Then, remove the four M8X65

bolts securing the J2 arm to the J3–axis reducer, then remove theJ3–axis reducer from the J2 arm.

8 Remove the ten M6X30 bolts securing the J3–axis reducer to theJ3 housing, then remove the reducer.

9 Secure a new reducer to the J3 housing using ten M6X30 bolts,tightening them to a torque of 15.7 Nm (160 kgf–cm). ApplyLoctite 262 to the bolt threads.

10 Using a crane, lift the J3 arm. Then, secure the J2 arm to the re-ducer using four M8X65 bolts (to which Loctite 262 has been ap-plied) tightened to a torque of 37.2 Nm (380 kgf–cm), and two �8X25 taper pins (with Loctite 242 applied to the taper holes).

11 Mount the J3–axis motor as explained in Section 6.4.12 Attach the cable to the J3–axis motor.13 Fill the J3–axis grease bath with the specified type of grease, as



Taper pins �8X25 Loctite 242

M6X30 (10 pcs) Loctite 262 15.7 Nm (160 kgf–cm)Washer M6 (10 pcs) O–ring (Small)

J3–axis reducerJ3 housing A290–7207–X401 (S motor)A290–7207–Y401 (αmotor)

O–ring(Large)


J2 armA290–7207–X301

Fig.6.5 Replacing J3–axis reducer (ARC Mate100/S–6)

6.5REPLACING J3-AXISREDUCER


79

Replacing J4–axis motor (For S motor)

1 Move the robot to the attitude of J4 = 0� . Maintain this attitudeuntil step 12. (mastering). Note that the cable may break if thiszero degree position is not maintained.



4 Disconnect the cable from the J4–axis motor.5 Remove the four M4X12 bolts securing the J4–axis motor to the

J3 housing (A290–7207–X401), then remove the motor as shownin Fig. 6.6 (a).

6 Remove the M3X12 bolt securing the gear (A290–7207–X411)to the motor shaft, then remove the gear.

7 Mount and secure the gear onto a new motor with an M3X12 bolt,tightening it to a torque of 2.0 Nm (20 kgf–cm). Apply Loctite242 to the bolt threads.

8 Check that the O–ring is installed correctly, then secure the motorto the J3 housing using four M4X12 bolts. Apply Loctite 262 tothe bolt threads.

9 Attach the cable connector to the J4–axis motor.10 Fill the J4–axis grease bath with the specified type of grease, as




M3X12 Loctite 242 2.0 Nm (20 kgf–cm)Washer M3

O–ring

J3–housingA290–7207–X401

J4–axis motor

GearA290–7207–X411

Washer A290–7207–X425

M4

Fig.6.6 (a) Replacing J4–axis motor (ARC Mate100/S–6) S motor specifications

6.6REPLACING J4-AXISMOTOR M4


80

Replacing J4–axis motor (For α motor)

1 Move the robot to the attitude of J4 = 0� . Maintain this attitudeuntil step 12. (mastering). Note that the cable may break if thiszero degree position is not maintained.




J3 housing (A290–7207–X401), then remove the motor as shownin Fig. 6.6 (b).

6 Remove the M3X12 bolt securing the gear (A290–7207–X411)to the motor shaft, then remove the gear.

7 Mount and secure the gear onto a new motor with an M3X12 bolt,tightening it to a torque of 2.0 Nm (20 kgf–cm). Apply Loctite242 to the bolt threads.

8 Install a new packing, then fix the motor to the J3 housing withthe four M5�12 bolts, applying loctite 262. New packing shallbe used to prevent grease leakage.

9 Attach the cable connector to the J4–axis motor.10 Fill the J4–axis grease bath with the specified type of grease, as





Packing

J3–housingA290–7207–Y401

J4–axis motor

GearA290–7207–Y411

Washer A290–7207–X425

M4

Fig.6.6 (b) Replacing J4–axis motor (ARC Mate100/S–6) α motor specifications


81

1 Turn off the control unit.

2 Remove the three M6X8 button bolts and three M4X16 bolts,then remove the J3 cover (A290–7207–X403) from the J3 hous-ing, as shown in Fig. 6.4 (a).

3 Disconnect the cables attached to the connector clamp of the J3housing, as explained in Section 8.2.

4 Remove the sixteen M4X35 bolts securing the J4–axis reducer tothe J3 housing then, while supporting the J3 arm with a crane, re-move the J4–axis reducer from the J3 housing, as shown in Fig.6.7(a).

5 Remove the cables, disconnected in step 3 , and the wrist cablesfrom the J3 housing.

6 Remove the fifteen M4X35 bolts securing the J4–axis reducer tothe J3 arm, then remove the J4–axis reducer from the J3 arm asshown in Fig. 6.7(b).

7 Remove the two bearings and spacer (A290–7207–X424) fromthe reducer.

8 Remove the six M3X8 bolts securing the gear(A290–7207–X412) to the reducer, then remove the gear from thereducer.

9 Secure the gear to a new reducer using six M3X8 bolts, tightenedto a torque of 2.0 Nm (20 kgf–cm). Apply Loctite 242 to the boltthreads.

10 Apply Loctite RC75 to the external rings of the two bearings thenmount the gear, together with the spacer, to the reducer.

11 Check that the O–ring (medium) and O–ring (small) are installedcorrectly. Then, mount the reducer to the J3 arm using fifteenM4X35 bolts, tightened to a torque of 4.6 Nm (47 kgf–cm). Ap-ply Loctite 262 to the bolt threads.

12 Run the wrist cable connectors through the J3 housing, thencheck that the O–ring (big) is installed correctly. Then, secure theJ3 arm to the J3 housing using fifteen M4X35 bolts, tightened toa torque of 4.6 Nm (47 kgf–cm). Apply Loctite 262 to the boltthreads.

13 Connect the wrist cables running through the pipe of the J4–axisreducer as explained in Section 8.2.


15 Mount the J3 cover onto the J3 housing using three M6X8 buttonbolts and three M4X16 bolts.


6.7REPLACING THEJ4–AXIS REDUCER


82


O–ring (Large)

J4–axis reducer

J3 housing A290–7207–X401 (S motor)A290–7207–Y401(α motor)

J3–arm A290–7207–X402(S motor)A290–7208–X402(α motor)


Bearing (2 pcs) Loctite RC75 (External ring)



Gear A290–7207–X412

O–ring (Medium)

O–ring (Small)

SpacerA290–7207–X424

J4 Reducer

J3 armA290–7207–X402 (S motor)A290–7208–X402 (α motor)



83

Replacing J5–axis motor (For S motor)

1 Move the robot to the attitude of J4 = –90� .

2 Turn off the control unit.3 Remove the six M6X15 bolts, then turn the cover

(A290–7207–X503) around the J5–axis until the J5–axis motorcan be lifted out, as shown in Fig. 6.8 (a).


J3 arm, then remove the motor and packing from the J3 arm.6 Remove the M3X12 bolt securing the gear (A290–7207–X511)

to the motor shaft, then remove the gear.7 Secure the gear to a new motor using an M3X12 bolt, tightened

to a torque of 2.0 Nm (20 kgf–cm). Apply Loctite 242 to the boltthreads.

8 Install a new packing (A290–7601–X522), then secure the motorto the J3 arm using four M4X12 bolts. Apply Loctite 262 to thebolt threads. To prevent grease leakage, use a new packing.

9 Connect the J5–axis motor cable.10 Mount a new packing, then fix the J5 cover with the four M6X15

bolts, applying loctite 262. New packing shall be used to preventgrease leakage.



GearA290–7207–X511

Washer A290–7207–X425



J5–axis motorPackingA290–7601–X552

M6X15 (6 pcs) Loctite 262Washer M6 (6 pcs)Cover A290–7207–X503

Packing A290–7207–X525

J3 armA290–7207–X402

Fig.6.8(a) Replacing J5–axis motor for S motor specifications(ARC Mate100/S–6)

6.8REPLACING J5-AXISMOTOR M5


84

Replacing J5–axis motor (For α motor)

1 Move the robot to the attitude of J4 = –90� .

2 Turn off the control unit.3 Remove the six M6X16 bolts,and remove packing

(A290–7208–X525) then turn the cover (A290–7207–X503)around the J5–axis until the J5–axis motor can be lifted out, asshown in Fig. 6.8 (b).


J3 arm, then remove the motor from the J3 arm.6 Remove the M3X12 bolt securing the gear (A290–7208–X511)

to the motor shaft, then remove the gear and the bearing.7 Secure the gear to a new motor using an M3X12 bolt, tightened

to a torque of 2.0 Nm (20 kgf–cm). Apply Loctite 242 to the boltthreads.

8 Check that the O–ring is correctly inserted, then fix the motor tothe J3 arm with the four M5X12 bolts, applying loctite 262.

9 Connect the J5–axis motor cable.10 Mount a new packing, then fix the J5 cover with the four M6 X

16 bolts, applying loctite 262. New packing shall be used to pre-vent grease leakage.



GearA290–7208–X511

WasherA290–7207–X425

M3X12Loctite 2422.0 Nm (20kgf–cm)Washer M3

J3 armA290–7208–X402

M5X12(4pcs)Loctite 262Washer M5(4pcs)

J5–axis motorC–ring

BearingO–ring

M6X16(6pcs)Loctite 262Washer M6(6pcs)

CoverA290–7208–X503PackingA290–7208–X525

M5

Fig.6.8(b) Replacing J5–axis motor for α motor specifications(ARC Mate100/S–6)


85

Replacing J5–axis gear (For S motor )

1 To replace the input gear (A290–7207–X511) of the J5–axismotor, follow the replacement procedure given in Section 6.8.

2 Move the robot to the attitude of J4 = +90� and J5 = J6 = 0� .3 Turn off the control unit.4 Remove the eight M4X8 bolts, cover (A290–7207–X502), and

packing (A290–7207–X524), as shown in Fig. 6.9(a).5 Remove the four M4X12 bolts securing the gear 2 assembly, then

remove the gear 2 assembly from the J3 arm.6 Remove the six M4X10 bolts securing the gear 3 assembly and

the eight M5X20 bolts securing the gear (A290–7207–X514),then remove the gear 3 assembly and gear from the J3 arm. Bypulling out the gear a little, the gear 3 assembly can be removed.

7 Secure a new gear 3 assembly and new gear to the J3 arm (thesemust be fitted together). Secure the gear, together with the J6housing, to the J3 arm using eight M5X20 bolts tightened to atorque of 9.0 Nm (92 kgf–cm). Apply Loctite 262 to the boltthreads. Secure the gear 3 assembly to the J3 arm using sixM4X10 bolts tightened to a torque of 4.6 Nm (47 kgf–cm), as ex-plained in Section 5.7. Apply Loctite 262 to the bolt threads.

8 Secure the gear 2 assembly to the J3 arm using four M4X12 bolts,tightened to a torque of 4.6 Nm (47 kgf–cm), as explained in Sec-tion 5.7. Apply Loctite 262 to the bolt threads.

9 Upon completion of backlash adjustment, as explained in Section5.7, install a new packing, then secure the cover to the J3 arm us-ing eight M4X8 bolts. To prevent grease leakage, use a new pack-ing.





Gear 2 assembleyA290–7207–V501



J3 armA290–7207–X402

GearA290–7207–X514



Cover A290–7207–X502

Fig.6.9(a) Replacing J5 gear for S motor specifications (ARC Mate100/S–6)

6.9REPLACING THEJ5–AXIS GEAR


86

Replacing J5–axis gear (For α motor )

1 To replace the input gear (A290–7207–X511) of the J5–axismotor, follow the replacement procedure given in Section 6.8.

2 Move the robot to the attitude of J4 = +90� and J5 = J6 = 0� .3 Turn off the control unit.4 Remove the eight M4X12 bolts, cover (A290–7208–X502), and

packing (A290–7208–X524), as shown in Fig. 6.9 (b).5 Remove the four M4X12 bolts securing the gear 2 assembly, then

remove the gear 2 assembly from the J3 arm.6 Remove the ten M5X12 bolts securing the gear 3 assembly and

the ten M6X30 bolts securing the gear (A290–7208–X515), thenremove the gear 3 assembly and gear from the J3 arm. By pullingout the gear a little, the gear 3 assembly can be removed.

7 Secure a new gear 3 assembly and new gear to the J3 arm (thesemust be fitted together). Secure the gear, together with the J6housing (A290–7208–X501) to the J3 arm using ten M6X30bolts tightened to a torque of 15.7 Nm (160 kgf–cm). Apply Loc-tite 262 to the bolt threads. Secure the gear 3 assembly to the J3arm using ten M5X12 bolts tightened to a torque of 9.0 Nm (92kgf–cm), as explained in Section 5.7. Apply Loctite 262 to thebolt threads.

8 Secure the gear 2 assembly to the J3 arm using four M5X12 bolts,tightened to a torque of 9.0 Nm (92 kgf–cm), as explained in Sec-tion 5.7. Apply Loctite 262 to the bolt threads.

9 Upon completion of backlash adjustment, as explained in Section5.7, install a new packing, then secure the cover to the J3 arm usingeight M4X12 bolts. To prevent grease leakage, use a new packing.






M5X12 (4 pcs) Loctite 2629.0 Nm (92 kgf–cm)Washer M5 (4 pcs) Plain washer M5(4pcs)


J3 armA290–7207–X402

GearJ5–5A290–7208–X515

M6X30 (10pcs) Loctite 262 15.7 Nm (160 kgf–cm)Washer M6 (10 pcs)Packing

A290–7207–X524Cover A290–7207–X502

Spring pinφ5�10 (1pcs)

Fig.6.9(b) Replacing J5 gear for α motor specifications (ARC Mate100/S–6)


87

Replacing the J6–axis motor

1 Turn off the control unit.2 Remove the four M5X20 bolts and two �5X20 spring pins, then

remove the J6–axis reducer from the J6 housing (A290–7207–X501) as shown in Fig. 6.10(a).

3 Disconnect the cable running through the sheet (A290–7207–X529), as shown in Fig. 8.2(g1).

4 Remove the four M4X12 bolts, then remove the motor from theJ6–axis reducer (harmonic drive), as shown in Fig. 6.10(b).

5 Remove the M3X8 bolt, then remove the reducer wave generatorfrom the motor.

6 Secure the wave generator to the shaft of a new motor, using anM3X8 bolt tightened to a torque of 2.0 Nm (20 kgf–cm). ApplyLoctite 242 to the bolt threads.

7 Mount a new packing, then fix the motor to the reducer with thefour M5X12 bolts, applying loctite 262. New packing shall beused to prevent grease leakage.

8 Reconnect the motor cable, then secure it to the sheet.9 Check that the O–ring is correctly inserted. Fix the reducer and

motor to the J6 housing with the four M5X20 bolts (with a tight-ening torque of 9.0 Nm (92kgf–cm)), applying loctite 262, andtwo �5X20 spring pins.

10 Fill the J6–axis grease bath with the specified grease, as detailedin Section 3.2.


Replacing the J6–axis reducer


remove the J6–axis reducer from the J6 housing (A290–7207–X501) as shown in Fig. 6.10(a).

3 Remove the four M4X12 bolts, then remove the motor from theJ6–axis reducer (harmonic drive) as shown in Fig. 6.10(b).


5 Secure a new wave generator to the shaft of the motor, using anM3X8 bolt tightened to a torque of 2.0 Nm (20 kgf–cm). ApplyLoctite 242 to the bolt threads.

6 Check that the O–ring is installed correctly, then secure the motorto the reducer using four M4X12 bolts. Apply Loctite 262 to thebolt threads.

7 Fix the reducer and motor to the J6 housing with the four M5 X 20bolts (with a tightening torque of 9.0 Nm (92kgf–cm)), applyingloctite 262, and two �5 X 20 spring pins.



6.10REPLACING J6-AXISMOTOR , REDUCERM6


motor and reducer

(For S motor)

M6


88


J6 housingA290–7207–X501

J6–axis motor

Spring pin �5X20 (2 pcs)

Apply sealingagent to thehatched portion.

M6

Fig.6.10 (a) Replacing J6–axis motor and reducer for S motor specifications (ARC Mate100/S–6)



J6–axis motor

O–ring

Wave generator

J6–axis reducer

M6

Fig.6.10 (b) Replacing J6–axis motor and reducer for S motor specifications(ARC Mate100/S–6)


89

Replacing the J6–axis motor


remove the J6–axis reducer from the J6 housing (A290–7208–X501) as shown in Fig. 6.10(c).

3 Disconnect the cable running through the sheet (A290–7208–X529), as shown in Fig. 8.2(g2).

4 Remove the four M5X12 bolts, then remove the motor from theJ6–axis reducer (harmonic drive), as shown in Fig. 6.10(d).


6 Secure the wave generator to the shaft of a new motor, using anM3X8 bolt tightened to a torque of 2.0 Nm (20 kgf–cm). ApplyLoctite 242 to the bolt threads.

7 Mount a new packing, then fix the motor to the reducer with thefour M5X12 bolts, applying loctite 262. New packing shall beused to prevent grease leakage.

8 Reconnect the motor cable, then secure it to the sheet.9 Check that the O–ring is correctly inserted. Fix the reducer and

motor to the J6 housing with the four M5X20 bolts (with a tight-ening torque of 9.0 Nm (92 kgf–cm)), applying loctite 262, andtwo φ5X20 spring pins.



Replacing the J6–axis reducer


remove the J6–axis reducer from the J6 housing (A290–7208–X501) as shown in Fig. 6.10 (c).

3 Remove the four M5X12 bolts, then remove the motor from theJ6–axis reducer (harmonic drive) as shown in Fig. 6.10 (d).


5 Secure a new wave generator to the shaft of the motor, using anM3X8 bolt tightened to a torque of 2.0 Nm (20 kgf–cm). ApplyLoctite 242 to the bolt threads.

6 Install new packing, then secure the motor to the reducer usingfour M5X12 bolts. Apply Loctite 262 to the bolt threads.

7 Confirm that O–ring is positioned correctly and secure the reduc-er with the motor covered by J6 housing using four M5X20 bolts(Loctite 262 applied and tight torque 9.0 Nm (92 kgf–cm)) andtwo spring pins �5X20.




motor and reducer

(For α motor)M6


90

J6 housingA290–7208–X501

J6 axis motor

O ringSpring pin�5X20(2pcs)

M5X20 (4pcs)Loctite 2629.0 Nm (92 kgf–cm)washer M5 (4pcs)

M6

Fig.6.10 (c) Replacing J6–axis motor and reducer for α motor specifications (ARC Mate100/S–6)

M5X12(4pcs)loctite 262washer M5(4pcs)

J6–axis motorPacking

Wave generator

WasherA290–7208–X532

J6–axis reducer

M3X8Loctite 2422.0 Nm (20kgf–cm)washer M3

M6

Fig.6.10 (d) Replacing J6–axis motor and reducer for α motor specifications(ARC Mate100/S–6)


91

It is possible to release a brake when the robot power is down, using “Thebrake release unit (option)”. Then it is possible to change the robotposture which you want. Please observe NOTE 1–3.

NOTE1. When release J2 or J3 motor (M2 or M3) brake, lift

up the robot by crane to that shown in Fig. 6.8.2. When release motor brake, apply a tensile force the

sling enough.3. Don’t release plural brake at the same time.

Fig.6.11 Releasing brake

6.11RELEASING BRAKE

7. PIPING AND WIRING B–80405E/04

92

7 PIPING AND WIRING

B–80405E/04 7. PIPING AND WIRING

93

Fig. 7.1. shows the internal piping diagram of the mechanical unit.

Fig.7.1 Piping diagram (ARC Mate100/S-6)

7.1PIPING


94

Wiring diagram of S motor specifications Wiring diagram of mechanical unit which is S motor specifications for2–axis brake type is shown in Fig. 7.2 (a).Wiring diagram of mechanical unit which is S motor specifications forall–axis brake type is shown in Fig. 7.2 (b).

K101

Controller Mechanical unit

J1–axis motor J2–axis motor J3–axis motor

K108K104(#J2)

J1–axis connector panel

K105(#J1)

K105(#J2) J4–axis motor

(or K112)K102 J6–axis motor

J5–axis motor

K107

K106

Batteries

Panel unionfemale PT3/8

MI

PI

GND

Air (OT Option)

K112:24 pinK102:5 pin


End effector

Fig.7.2 (a) Mechanical unit wiring diagram for 2–axis brake type (ARC Mate100/S6)S motor specifications

7.2WIRING DIAGRAM


95


J1–axis motor J2–axis motor J3–axis motor


Batteries

AirPanel unionfemale PT3/8

(OT Option)

(or K112)K102 J6–axis motor

J5–axis motor

J4–axis motor

MI

PI

GND

K108K104(#J2)

K105(#J1)

K105(#J2)

K101

K107

K106

K103

K112:24 pinK102:5 pin

End effector


Fig.7.2 (b) Mechanical unit wiring diagram for all–axis brake type (ARC Mate100/S6)S motor specifications


96

Wiring diagram of α motor specifications Wiring diagram of mechanical unit which is α motor specifications for2–axis brake type is shown in Fig. 7.2 (c), (d)Wiring diagram of mechanical unit which is α motor specifications forall–axis brake type is shown in Fig. 7.2 (e).

Fig.7.2 (c) Mechanical unit wiring diagram for 2–axis brake type (ARC Mate100/S6) α motor specifications<Cable ass’y specification that this figure is applied to>

A05B–1207–H251A05B–1207–H252A05B–1207–H254A05B–1207–H272A05B–1207–H274A05B–1207–H753A05B–1207–H754


97

Fig.7.2 (d) Mechanical unit wiring diagram for 2–axis brake type (ARC Mate100/S6) α motor specifications<Cable ass’y specification that this figure is applied to>

A05B–1207–H253


98

Fig.7.2 (e) Mechanical unit wiring diagram for all–axis brake type (ARC Mate100/S6) α motor specifications<Cable ass’y specification that this figure is applied to>

A05B–1207–H651A05B–1207–H652A05B–1207–H672A05B–1207–H751A05B–1207–H752A05B–1207–H761


99

Fig. 7.2(e) shows wiring diagram for the MIG EYE cable (A05B–1207–H921)Fig. 7.2(f) shows wiring diagram for the MIG EYE cable (A05B–1207–H922)Fig. 7.2(g) shows wiring diagram for the user cable (A05B–1207–H931)


SEN K136 K132

Panel unionPT3/8 female(for cooling)

Air kitPre-unitAir

Fig.7.2 (e) Wiring diagram for the MIG EYE cable (A05B–1207–H921)


SEN

K131K132


Air kit

Pre-unit

Air

J7M

J7P K133

K135K134

Fig.7.2 (f) Wiring diagram for the MIG EYE cable (A05B–1207–H922)

Controllerfor EE Mechanical unit

K142


Air 2 Panel unionPT3/8 female(for cooling)

EE

Fig.7.2 (g) Wiring diagram for the User cable (A05B–1207–H931)


100

Fig. 7.3. shows the installation diagram for the limit switches.

Option specification (330� OT): A05B–1207–H312Option specification (360� OT): A05B–1207–H322

J3–axis OT limit switch cableK123



Cable K107

SQ3

SQ2

SQ1

Fig.7.3 Limit switch installation diagram (ARC Mate100/S-6)

7.3LIMIT SWITCHINSTALLATIONDIAGRAM (OPTION)


101

Visually check the following:

1) Check whether connecting cables in the robot’s rotational part are dis-torted or bent by the robot rotation.

2) Check whether the routing of the cables connected to the J2 and J3axes is distorted or bent by the elbow motion.

3) Check whether the routing of the cables connected to the end effectoris suitable to the wrist motion or the service motion of the robot.

Fig. 7.4 (a) shows installation diagram for the cables in the mechanicalunit which is S motor specifications.Fig.7.4 (b) shows installation diagram for the cables in the mechanicalunit which is α motor specifications.Fig. 7.4 (c) shows installation diagram for the cables in the mechanicalunit which is CE specifications. When the MIG EYE cable (A05B–1207–H921) is specified, cable K132and K136 are added.When the MIG EYE cable (A05B–1207–H922) is specified, cable K131to K135 are added.When the User cable (A05B–1207–H931) is specified, cable K142 isadded.When the Diecasting cable is specified, the cable within [ ] will be wired.

Fig.7.4(a) Mechanical unit cable installation diagram (ARC Mate100/S-6)S motor specifications

7.4CABLE INSTALLATIONDIAGRAM


102

K114[K104 (#J2)][K230 (#J2)]

K205 (#J2)[K105 (#J2)]

K105 (#J1)[K205 (#J1)]

K104 (#J1)[K108 (#J1)][K230 (#J1)]or K118 [K208]

K101 [K201]K102 (K112)

[K212](K142 When orderthe user cable): A05B–1207–H931

K108

K103[K203] With MIG EYE

A05B–1207–H922(A05B–1207–H921)

K135

K133K132(K132)

K131K134(K136)

Groundcable

Fig.7.4(b) Mechanical unit cable installation diagram (ARC Mate100/S-6)α motor specifications<Cable ass’y specification that this figure is applied to>A05B–1207–H251A05B–1207–H252A05B–1207–H253A05B–1207–H254A05B–1207–H261A05B–1207–H263A05B–1207–H272A05B–1207–H274A05B–1207–H651A05B–1207–H652A05B–1207–H661A05B–1207–H672


103

K205

K214

K105 (#J1)

K204or

K208

K101K102 (K112)(K142 When orderthe user cable): A05B–1207–H931

K108

K103

Fig.7.4(c) Mechanical unit cable installation diagram (ARC Mate100/S-6)α motor specifications [CE specifications]<Cable ass’y specification that this figure is applied to>A05B–1207–H751A05B–1207–H752A05B–1207–H753A05B–1207–H754A05B–1207–H761

8. REPLACING CABLES B–80405E/04

104

8 REPLACING CABLES

A broken or damaged cable should be replaced as specified in

this section. When the pulse coder cable (K102, K112, K103,

K108, K212, K203, K105, K205) connector is removed, the mo-

tor loses its absolute position. Perform the quick mastering (See

5.3) after replacing cables. If the pulse coder cable connector is

disconnected and the motor had losed its absolute position, quick

mastering must be carried out after changing cable.

B–80405E/04 8. REPLACING CABLES

105

When mounting the replaced cables with clamps and tie wraps, clamp itat the positions specified in Table 8.1(a), Table 8.1 (b) and Table 8.1 (c).Unless the cable is clamped at the specified positions, the cable may bebroken due to excessive sag or tention.

Table 8.1(a) Cable clamping positions (ARC Mate100/S-6) (S motor specifications)

Stamp Cable clamping positions Stamp CableNo.


[K201]

[K212]

[K203]

8.1CABLE CLAMPING


106

Table 8.1(b) Cable clamping positions (ARC Mate100/S-6) (α motor specifications)

Stamp Cable clamping positions Stamp Cable No.


RMI

RP1

M1M1

M2M1

M3M

M6M1

M5P1

M6P1

OT

M6M2

M6P2

M4M

M5M1

M6M1

OT

M1P1

M2P1

M3P

M4P

M5P1

M6P1

EE

M5M

M5P

M6M2

M6P2

J1OT

J2OT

J3OT

M6M

M6P

M5M1


107

Table 8.1(b) Cable clamping positions (ARC Mate100/S-6) (α motor specifications) [A05B–1207–H253 is specified]



108

Table 8.1 (c) Extention cable clamping positions

(ARC Mate 100)



109

1 Remove the J3–axis cover (A290–7207–X403) and clamp(A290–7207–X422) from the J3 housing as shown in Fig. 8.2(a1)and Fig. 8.2(b1).

2 Remove the connector cap from the end effector (EE), then re-move the EE connector from the EE plate.

3 Remove the cable K103 relay connector from the connectorclamp (A290–7207–X423), then remove the K101 and K102(K112) connectors from the connector clamp.

4 Remove the cable cover (A290–7207–X334), then cut the nylonbands of the connector clamp and clamp (A290–7207–X421).Then, pull out the cables from the J3 housing (A290–7207–X401).

5 Remove the arm cover (A290–7207–X331) and cover(A290–7207–X330) from the J2 arm as shown in Fig. 8.2(b1) andFig. 8.2(c).

6 Cut the nylon bands of the clamp (A290–7207–X332) and sup-port 22 (A290–7207–X329), then pull out the cables from the J2arm (A290–7207–X302).

7 Remove the two clamps (A290–7207–X340), clamp 12(A290–7207–X323), and clamp 21 (A290–7207–X325) asshown in Fig. 8.2(d).

8 Remove cable cover 1 (A290–7207–X335), cable cover 2(A290–7207–X336), and cable cover 3 (A290–7207–X337).

9 Cut the nylon bands, then pull out the cables, one by one, fromthe inside of the J2–axis reducer.

10 Disconnect the cables connected in cable cover 2, as shown inFig. 8.2(f).

11 Remove the J1–axis connector box from the J1 base, as shown inFig. 8.2(e).

12 Remove clamp 11 (A290–7207–X224) from the J1–axis connec-tor box.

13 Cut the nylon bands of support 11 (A290–7207–X223), then pullout the cables, one by one, from the inside of the J1–axis reducertoward the J1–axis connector box.

14 Remove the cables from the J1–axis connector box.15 Install new cables by reversing the procedure above.Ensure that

the cables are neither too tight nor too slack. Refer to the cableclamp positions, indicated by the marking tapes, as shown in Fig.8.2(a1) through Fig. 8.2(f).

16 Perform quick mastering as explained in Section 5.3.

8.2REPLACING CABLES

1) Replacing cables K101 andK102 (K112) for S motorspecifications


110

1 Remove the J3–axis cover (A290–7207–X403) and clamp(A290–7207–X422) from the J3 housing as shown in Fig. 8.2(a2)and Fig. 8.2(b2).

2 Remove the connector cap from the end effector (EE), then re-move the EE connector from the EE plate.

3 Remove the cable K103 relay connector from the connectorclamp (A290–7207–X447), then remove the K101 and K102(K112) connectors from the connector clamp.

4 Remove the cable cover (A290–7207–X334), then cut the nylonbands of the connector clamp and clamp (A290–7207–X421).Then, pull out the cables from the J3 housing (A290–7207–X401).

5 Remove the arm cover (A290–7207–X331) and cover(A290–7207–X330) from the J2 arm as shown in Fig. 8.2(b2) andFig. 8.2(c).

6 Cut the nylon bands of the clamp (A290–7207–X332) and sup-port 22 (A290–7207–X329), then pull out the cables from the J2arm (A290–7207–X302).

7 Remove the two clamps (A290–7207–X340), clamp 12(A290–7207–X323), and clamp 21 (A290–7207–X325) asshown in Fig. 8.2(d).

8 Remove cable cover 1 (A290–7207–X335), cable cover 2(A290–7207–X336), and cable cover 3 (A290–7207–X337).

9 Cut the nylon bands, then pull out the cables, one by one, fromthe inside of the J2–axis reducer.

10 Disconnect the cables connected in cable cover 2, as shown inFig. 8.2(f).

11 Remove the J1–axis connector box from the J1 base, as shown inFig. 8.2(e).

12 Remove clamp 11 (A290–7207–X224) from the J1–axis connec-tor box.

13 Cut the nylon bands of support 11 (A290–7207–X223), then pullout the cables, one by one, from the inside of the J1–axis reducertoward the J1–axis connector box.

14 Remove the cables from the J1–axis connector box.15 Install new cables by reversing the procedure above.Ensure that

the cables are neither too tight nor too slack. Refer to the cableclamp positions, indicated by the marking tapes, as shown in Fig.8.2(a2) through Fig. 8.2(f).


2) Replacing cables K101 andK102 (K112) for α motorspecifications


111

Nylon band

Marking tape

Arm coverButton boltM8X10 (4 pcs) Clamp

A290–7207–X332

J2 arm A290–7207–X302

Nylon band

Cable cover290–7207–X334


J3 cover A290–7207–X403


Connector clamp

J3 housing

Fig.8.2 (a1) Replacing cable K101, K102 (K112) (ARC Mate100/S–6) S motor specifications

Connector clampA290–7207–X423

Clamp A290–7207–X421

Clamp A290–7207–X422

Button bolt M6X10 (2 pcs)Washer M6 (2 pcs)

EE connectorM3X5 (4 pcs)

Button bolt M6X8 (2 pcs)

Connector cap

EE plateA290–7207–X426 (or X427)

Arm cover A290–7207–X331

Button bolt M8X10 (4 pcs)

J2 arm A290–7207–X302

M4X16 (2 pcs)Washer (2 pcs)


J3 coverA290–7207–X403

J3 housing A290–7207–X401

Fig.8.2 (b1) Replacing cable K101, K102 (K112) (ARC Mate100/S–6) S motor specifications


112

Fig.8.2 (a2) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S–6) α motor specifications

Connector clampA290–7207–X447

ClampA290–7207–X421

J3 housingA290–7207–Y401

ClampA290–7207–X422

Button bolt M6X10(2pcs)Washer M6(2pcs)

EE connector M3X5(4pcs)

Button bolt M6X8(2pcs)

Connector cap

EE plateA290–7207–X426(orX427)

Arm coverA290–7207–X331

Button bolt (4pcs)

J2 armA290–7207–X302

M4X16(2pcs)washerM4(2pcs)

J3 coverA290–7207–X403

Button bolt M6X8(3pcs)plain washer M6(3pcs)

Fig.8.2 (b2) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S–6) α motor specifications


113

Fig. 8.2 (c) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S–6)



M4X10(Loctite 262)

Clamp A290–7207–X340



Clamp A290–7207–X325


Clamp A290–7207–X340

M4X10(Loctite 262)

Clamp 12A290–7207–X323


Fig.8.2 (d) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S–6)


114

Fig.8.2 (e) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S–6)

Nylon band

DETAIL A

Fig.8.2 (f) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S–6)

NOTEIf cable ass’y spec. is A05B–1207–H253, there are no relayconnectors in DETAIL A.


115

1 Remove clamp 12, clamp 21, and cable cover 2 as shown in Fig.8.2(d).

2 Cut the nylon bands, then disconnect the J1M (M1M1) and J1P(M1P1) relay connectors as shown in Fig. 8.2(f).

3 Remove the J1–axis motor connectors, then pull out the cables.4 Install new cables by reversing the procedure above.5 Perform quick mastering as explained in Section 5.3.

1 Remove clamp 12, clamp 21, and cable cover 2 as shown in Fig.8.2(d).

2 Cut the nylon bands, then disconnect the J2M (M2M1) and J2P(M2P1) relay connectors as shown in Fig. 8.2(f).

3 Remove the J2–axis motor connectors, then pull out the cables.4 Install new cables by reversing the procedure above.5 Perform quick mastering as explained in Section 5.3.

1 Remove the J3–axis cover (A290–7207–X403) from the J3 hous-ing, as shown in Fig. 6.4(a).

2 Remove the cable K103 relay connector from the connectorclamp (A290–7207–X423), as shown in Fig. 8.2(a1).

3 Cut the nylon bands of the connector clamp.4 Remove the J5–2 cover from the J3 arm.5 Remove the J5–axis motor cable from clamp J5 (A290–7207–

X526), then pull out cable K103 from the J3 arm.6 Remove clamp J6–1 (A290–7207–X527) from the J5–2 cover

(A290–7207–X503), then cut the nylon bands securing the cable.7 Pull out the J6–axis motor as explained in Section 6.10. Remove

the cable running through the sheet (A290–7207–X529), thenpull out cable K103 from the J6 housing.

8 Pull out cable K103 from the J5–2 cover.9 Install a new K103 cable by reversing the procedure above. The

assembly of the J6–axis reducer is explained in Section 6.10. En-sure that the cables are neither too tight nor too slack. Refer tothe cable clamp positions, indicated by the marking tapes, asshown in Fig. 8.2(g1). Use new packing (A290–7207–X525).


3) Replacing cables K104 (#J1), K108(#J1), K230(#J1), K118, K208, K204,K105 (#J1), K205 (#J1)

4) Replacing cablesK104(#J2), K204 (#J2),K105(#J2), K205 (#J2)K230 (#J2), K114, K205,K214

5) Replacing cables K103 forS motor specifications


116

Details of assembly X529

Nylon bandDamp J5A290–7207–X526

Support A290–7207–X530

J3–arm A290–7207–X402



Clamp A290–7207–X527

M6X15 (6 pcs)Washer (6 pcs)

J5–coverA290–7207–X503Support 2

A290–7207–X531

M4X6 (2 pcs)Washer (2 pcs)Ring

A290–7207–X521

ClampA290–7207–X528

M4X6 (1 pcs)(loctite 262)Washer M4 (1 pcs)Spring pin

�5X20 (2 pcs)

Sheet A290–7207–X529


Nylon bandNylon band


Marking tape

Details of assembly X527 and X528

Nylon band

Fig.8.2 (g1) Replacing cable K101, K102 (K112) S motor specifications

1 Remove the J3–axis cover (A290–7207–X403) from the J3 hous-ing, as shown in Fig. 6.4(a).

2 Remove the cable K103 relay connector from the connectorclamp (A290–7207–X447), as shown in Fig. 8.2(a2).

3 Remove the J5–2 cover from the J3 arm. Refer to Fig. 8.2 (g2).4 Remove the J5–axis motor cable and relay connector of J6 M and

J6 P from clamp J5 (A290–7208– X526), then pull out cableK103 from the J3 arm.

5 Install a new K103 cable by reversing the procedure above. En-sure that the cables are neither too tight nor too slack. Refer tothe cable clamp positions, indicated by the marking tapes, asshown in Fig. 8.2(g2). Use new packing (A290–7208–X525).

6) Replacing cables K103 forα motor specifications


117


1 Remove the J5–2 cover from the J3 arm according to Fig. 8.2(g2).

2 Disconnect the M6M and M6P intermediate connectors from theJ5 clamp (A290–7208–X526), then out the nylon band at theclamp.

3 Remove the J5–2 cover (A290–7208–X503) from the J6–1clamp (A290–7208–X527), then cut the nylon band holding thecable.

4 Pull out the J6–axis motor as explained in Section 6.10. Discon-nect the cable from the sheet (A290–7208–X529).Remove the J6–2 clamp (A290–7208–X528) from the J6 hous-ing, then cut the nylon band holding the cable.

5 Pull out cable K108 from the J6 housing, then pull it out from theJ5–2 cover.

6 Connect a new cable by reversing the above procedure. Section6.10 explains how to mount the J6–axis reducer. When connect-ing the cable, ensure that the cable is neither loose nor stretchedby checking the cable clamp positions, indicated with markingtape as shown in Fig. 8.2 (g2). The packing (A290–7208–X525)shall be replaced with a new one.

7 Perform simplified mastering according to Section 5.3.

7) Replacing cables K108 forα motor specifications


118


Nylon band

SheetA290–7208–X529

Spring pin5X20 (2pcs)

M5X20(4pcs)(loctite 262)Washer M5(4pcs)

M4X8(1pcs)WasherM4(1pcs) Clamp J6–2

A290–7208–X528

RingA290–7208–X521

SupportA290–7208–X530

Clamp J5A290–7208–X526

J3 armA290–7208–X402

M5X20(2pcs)Washer M5(2pcs)

PackingA290–7208–X525

M4X6 (2pcs)Washer M4 (2pcs)

Clamp J6–1A290–7208–X527

M6X16 (6pcs)Washer M6 (6pcs)

J5–2 coverA290–7208–X503

Nylon band Marking tape

Marking tape Nylon band

Details of assembly X527 and X528 Details of assembly X526

Fig.8.2 (g2) Replacing cable K101, K102 (K112) (ARC Mate 100/S–6) α motor specifications


119

When the MIG EYE cable (A05B–1207–H921) is specified, cable K132and K136 are added.Refer to the cable clamp positions, indicated by the marking tapes, asshown in Fig. 8.2 (h1) and Fig. 8.2 (h2).When the MIG EYE cable (A05B–1207–H922) is specified, cable K131to K135 are added.Refer to the cable clamp positions, indicated by the marking tapes, asshown in Fig. 8.2 (i1) and Fig. 8.2 (i2).When the User cable (A05B–1207–H931) is specified, cable K142 isadded.Refer to the cable clamp positions, indicated by the marking tapes, asshown in Fig. 8.2 (j1) and Fig. 8.2 (j2).

Fig. 8.2 (h1) Replacing the MIG EYE cable (A05B–1207–H921) (ARC Mate 100)

8) Replacing additional cables


120

Fig. 8.2 (h2) Replacing the MIG EYE cable (A05B–1207–H921) (ARC Mate 100)


121

Fig. 8.2 (i1) Replacing the MIG EYE cable (A05B–1207–H922) (ARC Mate 100)


122

Fig. 8.2 (i2) Replacing the MIG EYE cable (A05B–1207–H922) (ARC Mate 100)


123

Fig. 8.2 (j1) Replacing the USER cable (A05B–1207–H931) (ARC Mate 100)


124

Fig. 8.2 (j2) Replacing the USER cable (A05B–1207–H931) (ARC Mate 100)


125

1 Remove the LS box (A290–7207–X326) from the J2 base(A290–7207–X301) as shown in Fig. 8.3(a).

2 Remove the J1–axis OT limit switch (A05B–1207–D103) fromthe LS box.

3 Mount the new limit switch, reversing the above procedure.4 Check that the limit switch operates accurately at the overtravel

position.5 Check that the limit switch does not operate within the J1-axis

motion range.

J2 baseA290–7207–X301

PlateA290–7201–X347

LS boxA290–7207–X326

M6X10 (2 pcs)Plain washer M6 (2 pcs)Washer M6 (2 pcs)

M4X25 (2 pcs)Nut lock 1401Plain washer M4 (2 pcs)Washer M4 (2 pcs)

Limit switch (with cable)A05B–1207–D103 SQ1

Fig.8.3 (a) Replacing J1-axis limit switch (ARC Mate100/S-6)

8.3REPLACING LIMITSWITCH (OPTION)1) J1–axis OT limit switch

(A05B–1207–D103)SQ1


126

1 Remove the cover (A290–7207–X330) and support 22 (A290–7207–X329) from the J2 arm (A290–7207–X302) as shown inFig. 8.2(b) and Fig. 8.2(d).

2 Remove the J2–axis OT limit switch (A05B–1207–D104) fromsupport 22.

3 Mount the new limit switch reversing the above procedure.4 Check that the limit switch operates accurately at the overtravel

position.5 Check that the limit switch does not operate within the J2-axis

motion range.

Support A290–7207–X329

Nylon bandM6X10 (2 pcs)Nut lock 1401Plain washer M6 (2 pcs)Washer M6 (2 pcs)

Cover A290–7207–X330

J2 arm A290–7207–X302


Limit switch (with cable)A05B–1207–D104

Button bolt M8X10 (6 pcs)Washer M8 (6 pcs)

SQ2

Fig.8.3 (b) Replacing J2–axis limit switch (ARC Mate100/S–6)

2) J2–axis OT limit switch(A05B–1207–D104)

SQ2


127

1 Remove the arm cover (A290–7207–X331) and clamp(A290–7207–X332) from the J2 arm (A290–7207–X302) by re-ferring to Figs. 8.2 (c) and 8.2 (d).

2 Remove the J3–axis limit switch (A05B–1207–D105) from theclamp.

3 Mount the new limit switch, reversing the above procedure.4 Check that the limit switch operates accurately at the overtravel

position.5 Check that the limit switch does not operate within the J3–axis

motion range.

M4X25 (2 pcs)Nut lock 1401Plain washer M4 (2 pcs)Washer M4 (2 pcs)

M6X10 (2 pcs)Plain washer M6 (2 pcs)Washer M6 (2 pcs)

Clamp A290–7207–X332

Arm cover A290–7207–X331

Button boltM8X10 (4 pcs)

J2 arm A290–7207–X302

Nylon band


J3 coverA290–7207–X403


Plate A290–7201–X347

Limit switch (with cable)A05B–1207–D105 SQ3

Fig.8.3 (c) Replacing J3–axis limit switch (ARC Mate100/S–6)

3) J3–axis OT limit switch(A05B–1207–D105)

SQ3


128

Limit switch relay cable

Nylon band

Fig.8.3 (d) Replacing J2 and J3–axis limit switch (ARC Mate100/S–6)

B–80405E/04 9. OPTIONS

129

9 OPTIONS

9. OPTIONS B–80405E/04

130

Fig. 9.1 shows how to assemble the cover option.

(Assembly)1 Secure the support (A290–7207–X339) to the J2 base

(A290–7207–X301) using four M6X10 bolts.2 Secure the J2 cover (A290–7207–X338) to the support using six

M6X10 button bolts.

To remove the cover, reverse the assembly procedure above.

M6X10 button bolt (6 pcs)

J2 coverA290–7207–X338

When the cover optionis specified

Specification: A05B–1207–J401

SupportA290–7207–X339

J2 baseA290–7207–X301M6X10 (4 pcs)

M6 washer (4 pcs)

Fig. 9.1 Cover Option (ARC Mate 100/S–6)

9.1COVER OPTION(SPECIFICATION:A05B–1207–J401)

II. CONNECTION

B–80405E/04 1. ROBOT INTERFERENCE AREA

133

1 ROBOT INTERFERENCE AREA

Fig. 1(a1), (a2),(a3) and (b) show the external dimensions of the robot.When installing peripheral devices, take care that they do not interferewith the motion of robot body. For installation, use the 4-φ18 hole on thebase. (See 3.2)Fig. 1 (c) and (d1),(d2),(d3) shows the robot operational diagram.

Motion range of J5–axis center

COVER (OPTION)Interference of the rear of the J3–axis

J5–axis center

Fig.1 (a1) Mechanical unit external dimensions (ARC Mate100/S-6) S motor specifications

1. ROBOT INTERFERENCE AREA B–80405E/04

134


Wilthout cover option

Interference of the rear of the J3–axis

J5–axis center

FANUC flange with adaptor

Fig.1 (a2) Mechanical unit external dimensions (ARC Mate100/S-6) α motor specifications

B–80405E/04 1. ROBOT INTERFERENCE AREA

135


Interference of the rear of the J3–axis

FANUC flange with adaptor

J5–axis center

Cover option

Fig.1 (a3) Mechanical unit external dimensions (ARC Mate100/S-6) α motor specifications

1. ROBOT INTERFERENCE AREA B–80405E/04

136

Interference area of the rear of J3–axis



Fig.1 (b) Mechanical unit external dimensions (ARC Mate100/S-6)

B–80405E

/041. R

OB

OT

INT

ER

FE

RE

NC

E A

RE

A

137

Fig.1 (c) O

perational diagram (A

RC

Mate100/S

-6)

1. RO

BO

T IN

TE

RF

ER

EN

CE

AR

EA

B–80405E

/04

138

Fig.1 (d1) O


RC

Mate100/S

-6) S m

otor specifications

B–80405E

/041. R

OB

OT

INT

ER

FE

RE

NC

E A

RE

A

139

*Without α

motor cover (A

05B–1207–J401)

Fig.1 (d2) O


RC

Mate100/S

-6) α m

otor specifications

1. RO

BO

T IN

TE

RF

ER

EN

CE

AR

EA

B–80405E

/04

140

*With cover option (A

05B–1207–J401)

Fig.1 (d3) O


RC

Mate100/S

-6) α m

otor specifications

B–80405E/04 2. EQUIPMENT MOUNTING TO ROBOT

141

2 EQUIPMENT MOUNTING TO ROBOT

2. EQUIPMENT MOUNTING TO ROBOT B–80405E/04

142

Fig. 2.1(a) shows the end effector mounting face at the tip of the wrist. Fit the end effector by using the �50H7 rabbet or the �25H7 rabbet, thenposition the end effector by using the 4–�6H8 reamed holes. Use the4–M6 tapped holes to secure the end effector. Use M6 bolts of a lengththat does not exceed the depth (10 mm) of the tapped holes.

ISO Flange 4–M6 depth 10equally spaced oncircumference � 40

4–�6H8 depth 10equally spaced on cir-cum ference �40

+0.08 0

Fig. 2.1(a) Mounting Surface for End Effector of ISO Flange Type (ARC Mate 100/S–6)

Fig. 2.1(b) shows the end effector mounting face at the tip of the wristused when the FANUC flange adaptor (option specification:A05B–1207–J001) is being used. Fit the end effector by using the �32H8rabbet or the �60H7 rabbet, then position the end effector by using the4–�6H8 reamed holes. Use the 4–M6 tapped holes to secure the endeffector. Use M6 bolts of a length that does not exceed the depth (8 mm)of the tapped holes.

FANUC Flange Adaptor

4–M6 depth 8equally spaced oncircumference � 50

4–�6H8 depth 8equally spaced on cir-cum ference �50

+0.08 0

Fig. 2.1(b) Mounting Surface for End Effector when the FANUC Flange Adaptoris Used (ARC Mate 100/S–6)

2.1END EFFECTORMOUNTING FACETO WRIST

ISO flange type(standard)

FANUC flangeadaptor(option)


143

There are four mounting faces of the equipment for the floor mount typerobot as shown in Fig. 2.2 (a), and four for the upside-down mount typerobot.

NOTE1. When equipment is mounted on equipment mounting

face A, B, C, and D, its center of gravity must be withinthe hatched areas shown in Fig. 2.2(b).

2. The masses of the equipment fitted to the equipmentmounting faces must satisfy all the requirementsbelow.

1) W + A � 6 (kg)

2) W + A + B + C � 18 (kg)

3) W + A + B + C + D � 45 (kg)

W: Mass of the end effector mounting face (kg)A: Mass of equipment mounting face A (kg)B: Mass of equipment mounting face B (kg)C: Mass of equipment mounting face C (kg)D: Mass of equipment mounting face D (kg)

2.2EQUIPMENTMOUNTING FACE


144

Length of J2–axis rotating center

2–M8 depth14Rotating

center of J1–axis

Equipment mounting face D

Length of J2–axis rotating center

Cover interference

Rotating cen-ter of J1–axis

Equipment mounting D (Mounting cover option)

J3 rotatingaxis

4–M6depth10

Equipment mounting face B

2–M6depth8

Equipment mounting A

Rotating cen-ter of J3–axis

3–M6 depth 10

Equipment mounting C

88.5[S motor]87.5[α motor]

240 [S motor]243.5{α motor]

Fig.2.2 (a) Equipment mounting face (ARC Mate100/S–6)


145

Equipment mounting face D

Equipment mounting face B Equipment mounting face A

Equipmentmounting face C

88.5[S motor]87.5[α motor]

Fig.2.2 (b) Positions of the center of gravity on the equipment mounting faces (ARC Mate 100/S–6)


146

Load conditions at the wrist of ARC Mate 100/S–6 is described atTable2.3.The hand or the gun which is installed in the wrist is in accord withfollowing conditions.

Table 2.3 Load conditions at the wrist (ARC Mate 100/S–6)

Allowable moment J4–axis M4 1.6 (kgf⋅m) 15.7 (N⋅m)

J5–axis M5 1.0 (kgf⋅m) 9.8 (N⋅m)

J6–axis M6 0.5 (kgf⋅m) 4.9 (N⋅m)

Allowable inertia J4–axis M4 6.4 (kgf⋅cm⋅s2) 0.63 (kg⋅m2)

J5–axis M5 2.0 (kgf⋅cm⋅s2) 0.20 (kg⋅m2)

J6–axis M6 0.62 (kgf⋅cm⋅s2) 0.061 (kg⋅m2)

2.3LOAD CONDITIONS ATTHE WRIST

Center of J4–axis rotation

Center of J5–axisrotation

Center of J6–axisrotation


147

Following figure 2.3 (a) to (c) show load conditions at the wrist.Use under the range of following graphs.

Load

Distance from the J4–axis to the center of gravity of the load

Fig.2.3 (a) J4–axis load condition (ARC Mate 100/S–6)

Load


Fig.2.3 (b) J5–axis load condition (ARC Mate 100/S–6)

Load


Fig.2.3 (c) J6–axis load condition (ARC Mate 100/S–6)


148

Within the robot’s mechanical unit, an air pipe is provided; its inlet at theJ1–axis connector box, and its outlet at the J3 housing. The piping routeis shown in Fig. 7.1, of the part explaining maintenance. The inlet andoutlet joints of the piping are of the PT3/8 female type. No mating jointsare provided. It is the responsibility of the user to prepare mating jointsthat match tubes to be used.When the User cable (A05B–1207–H931) is specified, two air pipes areprovided.When the MIG EYE cable (A05B–1207–H921, H922) is specified, theair pipe is used only for cooling.

2.4END EFFECTOR AIRPIPE


149

The J3 housing has an end effector connector to enable connection toperipheral equipment. Fig. 2.5(a) and Fig. 2.5(b) show the pinassignment of the end effector connectors. For details, including thesetting of common input signals, refer to the maintenance manual of theR–J controller.Fig. 2.5 (c) shows the pin assignments of the end effector when the Usercable (A05B–1207–H931) is specified.

Mechanical unit (K102)��

End effector

Fig. 2.5(a) End Effector Signal Pin Assignment (ARC Mate 100)

Mechanical unit (K112)

End effector

(When the ARC Mate 100 optional cable is specified)

Fig. 2.5(b) End Effector Signal Pin Assignment (S–6)

2.5END EFFECTOR I/OSIGNALS (RDI/RDO)


150

Fig. 2.5 (c)

Fig. 2.5 (c) shows the pin assignments of the end effector when the Usercable (A05B–1207–H931) specified.

B–80405E/04 3. TRANSPORTATION AND INSTALLATION

151

3 TRANSPORTATION AND INSTALLATION

3. TRANSPORTATION AND INSTALLATION B–80405E/04

152

1 Remove the transit stopper (red) from the J1–axis.2 After turning on the control unit, move the J3–axis, by joint feed,

in the positive (+) direction until the J3–axis transit stopper,shown in box 3.1(a), can be removed.

3 Move the J2–axis, by joint feed, in positive (+) direction, until theJ2–axis transit stopper can be removed.

4 Remove the transit stoppers (red) from the J2–axis and J3–axis.This completes the preparation.

NOTEIf an over travel alarm is issued in step 2 , hold down the shiftkey and press the alarm release key. Then, while stillholding down the shift key, move the J3–axis, by joint feed,in the positive (+) direction until the J3–axis overtravel isreleased.

The robot is transported by lifting. Mount the components for transporta-tion and lift it by attaching a rope to three M12 eye bolts.After installation, remove the components used for transportation and thestop. (Refer to Fig. 3.1(a))The stops for preventing the axes from rotating during shipping arepainted in red. Be sure to remove them before operating the robot.

3.1TRANSPORTATION

1) Preparation prior toinstallation

2) Transportation by crane


153

Crane capacity: min. 300kg

Sling capacity: min. 150 kg

Fig.3.1 (a) Transportation using a crane (ARC Mate100/S-6)


154

The robot can also be transported using a forklift. (Refer to Fig. 3.1 (b))A forklift bracket can be provided as an option. (Option specification:A05B–1207–J051)

(When using a forklift)1 Position the robot to the transit attitude, then turn off the control

unit.2 Disconnect the cables from the J1 base connector panel.3 Fit a transit stopper for the J1–axis to prevent the J1–axis from

rotating.4 Secure forklift brackets to both sides of the J1 base, using three

M10X20 bolts and three M10 plain washers on each side.5 Use the right– and left–hand square holes to transport the robot.6 Remove the right and left forklift brackets.7 Remove the transit stopper from the J1–axis.

Attitude during the shipment

J1: –10�J2: –35�J3: –31�J4: –90�J5: 0�J6: 0�

Stopper for preventing the J1–axis from rotating (remove it after installation)

Forklift

Hexagonal bolt M10X20 (6 pcs)Plain washer M10 (6 pcs)

Forklift bracket (square hole)Specification: A05B–1207–J051

NOTE) 1. Machine weight 160kg

Forklift capacity : min. 300 kg

Fig.3.1 (b) Transportation using a folklift (ARC Mate100/S-6)

3) Transportation by forklift


155

When storage the robot, be sure tot change the attitude of robot to thatshown in Fig. 3.1 (a).

3.2STORAGE


156

Fig. 3.3 (a) shows dimensions of robot base.

Front

(Pin)

J1–axis rotatingcenter

4–�18 through–hole �28 facing, depth 5 (Through hole for foundation bolt)

2–�10H8(Pin–hole for positioning)

+0.022 0

Fig.3.3 (a) Dimensions of robot base (ARC Mate100/S–6)

3.3INSTALLATION


157

Fig. 3.3(b) shows an example of robot installation. Secure an installationplate to the floor using four M20 chemical anchors (strength class: 4.8).Then, secure the robot base to the installation plate using four M16X35bolts (strength class: 12.9).If teaching compatibility is needed when the mechanical unit of the robotis replaced, use the two �10H8 pin holes for positioning.

NOTEIt is the customer’s responsibility to prepare positioningpins, anchor bolts, and the installation plate.

(Pin)

Front

J1–axis rotation center

Installation plate2–�10H

(Pin hole for positioning)

+0.0220

Robot fixing boltsM16X35 (4 pcs)Strength class: 12.9Tightening torque: 313.6 Nm (32 kgf–m)

Chemical anchorM20 (4 pcs)Strength class: 4.8Tightening torque: 186.2Nm (19 kgf–m)

Robot base plate

Installation plate

Fig. 3.3 (b) Example Installation (ARC Mate 100/S–6)


158

Fig. 3.3 (c) shows the outer dimension of the BASE option(A05B–1207–J055). Attached bolt M16X30 (4pcs.), washer M16 (4pcs.)and spring pin φ10X30 (2pcs.) are used to install the robot to the base.

Fig. 3.3 (c) Outer dimension of BASE option (A05B–1207–J055) (ARC Mate 100/S–6)


159

Fig. 3.3 (d) and table 3.3 (d) show force and movement applied to the baseplate during stillness, acceleration or deceleration, and emergency stopstate.

MH

MV

FH

FV

Fig.3.3 (d) Force and moment

Table 3.3 (d) Force and moment

Condition Vertical momentMv [kgfm] (Nm)

Force in vertical direction Fv [kgf] (Nm)

Horizontal moment M [kgfm] (N)

Force in horizontaldirection F [kgf] (N)

During stillness [ 64] ( 627) [205] (2009) [ 0] ( 0) [ 0] ( 0)

During acceleration ordeceleration

[146] (1431) [273] (2675) [ 92] ( 902) [ 97] ( 951)

During emergencystop

[214] (2097) [327] (3205) [122] (1196) [132] (1294)


160

Fig. 3.4 (a) shows the maintenance area.

Maintenance area

Mastering area

Fig.3.4 (a) Maintenance area (ARC Mate100/S-6)

Attitude of robot on mastering is shown in Fig. 3.4(b). Consequently,reserve space for this attitude with J1=0 degree.

Attitude of MasteringJ1=0�J2=85�J3=–155�J4=0�J5=–25�J6=0�

ISO Flange Mastering jig


Attitude of MasteringJ1=0�J2=83.485�J3=–152.993�J4=0�J5=–27.007�J6=0�

Flange Adapter (At installation of option)

Mastering jig


Fig.3.4 (b) Mastering attitude (ARC Mate100/S-6)

3.4MAINTENANCE AREA


161

When laying a cable between a robot controller and a robot body,customers shall prepare a cable duct, etc.

The mechanical unit is shipped with connecting cables unattached (Thecables are connected to the controller.). Connect the cables shown in Fig.3.5 to the connector box of the mechanical unit. When connecting, takecare not to damage the cables.

Fig.3.5 Cable connection board of robot mechanical unit

3.5ASSEMBLY DURINGINSTALLATION


162

Fig. 3.6(a) shows the air piping of a robot.

When the optional air control set is used, an air pipe for connecting themechanical unit and air control set is also provided. To install the aircontrol set, the customer is to prepare an air control set mounting sectionwith tapped holes for mounting, as shown in Fig. 3.6(b).

PT3/8

Air control set (option)Specification: A05B–1302–J011

Straight jointPT3/8

Elbow PT3/8

3–m air hose (Outer diameter: 10 mm, Inner diameter: 6.5 mm)

To be prepared by the customer

Fig.3.6 (a) Air piping (ARC Mate100/S-6)

Fill the oiler of the air control set with turbine oil (#90 to #140) to thespecified level. Preparation of the mounting bolts is the customer’sresponsibility.

4–M6

63

90

Oil inlet Adjustment knob

Oil misting check

Oiler

FilterRegulator pressure setting handle

Pressure gauge

Fig.3.6 (b) Air control set (ARC Mate100/S-6)

3.6AIR PIPING


163

Fig. 3.6 (c) shows the internal piping diagram of the mechanical unit.

Panel unionPT3/8 female

Panel unionPT3/8 female

Fig.3.6 (c) Piping diagram (ARC Mate 100/S–6)


164

Installation condition of the robot is shown in table 3.7.

Table3.7 Installation specifications (ARC Mate100/S-6)

Item Specifications

Type Articulated type

Controlled axes 6 axes (J1, J2, J3, J4, J5, J6)

Reach 1368 mm

Installation Floor, Upside–down (Wall & Angle mount) (Note 1)

Motion range J1 axis 5.76 rad (2.01 rad/sec) 330° (115°/sec) (Note 2)(Maximum speed) J2 axis 4.19 rad (1.92 rad/sec) 240° (110°/sec)

J3 axis 5.67 rad (2.01 rad/sec) 325° (115°/sec)




Max. load capacity at wrist 6 kg

Allowable load J4 axis 15.7 Nm 1.6 kgfmmoment at wrist J5 axis 9.8 Nm 1.0 kgfm

J6 axis 4.9 Nm 0.5 kgfm

Allowable load J4 axis 0.63 kgm2 6.4 kgfcms2

inertia at wrist J5 axis 0.20 kgm2 2.0 kgfcms2

J6 axis 0.061 kgm2 0.62 kgfcms2

Drive method Electric servo drive by AC servo motor

Repeatability �0.1 mm

Weight (Mechanical unit) Approx. 160 kg

Installation environment Ambient temperature: 0 to 45 °CAmbient humidity: Normally 75% RH or less Short term (within one month) Max. 95% RH

Height: Up to 1,000 meters above the sea level requires, no particular provision for attitude.

Vibration : 0.5 G or less

* No dew, nor frost allowed. * No corrosive gas allowed. (Note 3)

Air pressure Pressure 0.49 – 0.69 MPa 5.7 kg/cm2G(Preset pressure 0.49 MPa 5kg/cm2G)

Consumption Maximum peak: 150N/min (Note 4)

NOTE1. Under the installation condition within ( ), the J1–axis motion range and the max. speed

will be limited.2. J1–axis 6.28 rad (360°) rotation is option.3. If a robot is used in an environment with high vibration, dust, or density of cutting oil,

consult the service representative.4. This value indicates the capacity of the air control set. Adjust the air flow to be less than

this value.5. J2 cover is option.

3.7INSTALLATIONSPECIFICATIONS

APPENDIXES

B–80405E/04 A1. SPARE PARTS LIST

167

A1 SPARE PARTS LIST

Table 1 (a) Cable list (ARC Mate100/S-6)

(A1) 2–axis brake (RDI�1, RDO�1) Normal cable : A05B–1207–H201 (For S motor, R–J controller)Extension cable : A05B–1207–H211 (For S motor, R–J controller)

Cable Specifications Remarks

K101 A05B–1207–D101 J1, J2, J3, J4, J5, J6 power

K102 A660–8009–T538 J1, J2, J3, J4, J5, J6 pulse coder,DI/DO

K103 A660–4003–T183 J5 J6, power, pulse coder relay

K104 A660–4003–T184#J2 J2 power relay

K105 A660–2004–T151#J1 J1 pulse coder relay

K105 A660–2004-T151#J2 J1 pulse coder relay

K106 A05B–1207–D102 OT Short circuit

K108 A660–2004–T152 J1 power relay

(B1) 2–axis brake (RDI�8, RDO�8) Normal cable : A05B–1207–H202 (For S motor, R–J controller)




K103 A660–4003–T183 J5, J6 power, pulse coder relay




K106 A05B–1207–D102 OT


Cable list for S motorSpecifications inmechanical unit

A1. SPARE PARTS LIST B–80405E/04

168

(C1) 6–axis brake (RDI�1, RDO�1) Normal cable : A05B–1207–H601 (For S motor, R–J controller)Extension cable : A05B–1207–H611 (For S motor, R–J controller)






K104 A660–4003–T184#J2 J2 poer relay




(D1) 6–axis brake (RDI�8, RDO�8) Normal cable : A05B–1207–H602 (For S motor, R–J controller)










(E1) 2–axis brake (RDI�8, RDO�8) Diecasting cable (option): A05B–1207–H222 (For S motor, R–J controller)











169

(F1) 6–axis brake (RDI�8, RDO�8) Diecasting cable (option): A05B–1207–H622 (For S motor, R–J controller)










(A2) 2–axis brake (RDI�1, RDO�1) Normal cable : A05B–1207–H251(For α motor, R–J controller)Extension cable : A05B–1207–H261(For α motor, R–J controller)


K101 A05B–1207–D106 M1, M2, M3, M4, M5, M6 power

K102 A660–8009–T990 M1, M2, M3, M4, M5, M6 pulsecoder, DI/DO

K103 A660–4003–T287 M5 M6, power, pulse coder relay

K104 A660–4003–T286#J2 M2 power relay

K105 A660–2004–T279#J1 M1 pulse coder relay



K108 A660–2004–T152 M1 power relay

K108 A660–4003–T244 M6 power pulse coder relay

Cable list for � motorspecifications inmechanical unit


170

(B2) 2–axis brake (RDI�8, RDO�8) Normal cable: A05B–1207–H252 (For α motor, R–J controller)




K103 A660–4003–T287 M5, M6 power, pulse coder relay




K106 A05B–1207–D102 OT short circuit


K108 A660–4003–T244 M6 power, pulse coder relay

(C2) 6–axis brake (RDI�1, RDO�1) Normal cable : A05B–1207–H651(For α motor, R–J controller, R–J2 controller)Extension cable : A05B–1207–H661(For α motor, R–J controller, R–J2 controller)












171

(D2) 6–axis brake (RDI�8, RDO�8) Normal cable : A05B–1207–H652(For α motor, R–J controller, R–J2 controller)











(E2) 2–axis brake (RDI�8, RDO�8) Diecasting cable (option): A05B–1207–H272(For α motor, R–J controller)











(F2) 6–axis brake (RDI�8, RDO�8) Diecasting cable (option): A05B–1207–H672(For α motor, R–J controller, R–J2 controller)












172

(A3) 2–axis brake (RDI�1, RDO�1) Normal cable : A05B–1207–H253(For α motor, R–J2 controller)







(B3) 2–axis brake (RDI�1, RDO�1) Extension cable : A05B–1207–H263(For α motor, R–J2 controller)











(C3) 2–axis brake (RDI�8, RDO�8) Normal cable : A05B–1207–H254(For α motor, R–J2 controller)












173

(E3) 2–axis brake (RDI�8, RDO�8) Diecasting cable (option): A05B–1207–H274(For α motor, R–J2 controller)












174

(A4) 2–axis brake (RDI�1, RDO�1) Normal cable : A05B–1207–H753(For α motor, R–J2 controller)







K205 A660–2004–T699 M2 pulse coder relay




(B4) 2–axis brake (RDI�8, RDO�8) Normal cable : A05B–1207–H754(For α motor, R–J2 controller)











Cable list for � motorspecifications inmechanical unit for CE


175

(C4) 6–axis brake (RDI�1, RDO�1) Normal cable : A05B–1207–H751(For α motor, R–J controller, R–J2 controller)Extension cable : A05B–1207–H761 (For α motor, R–J controller, R–J2 controller)











(D4) 6–axis brake (RDI�8, RDO�8) Normal cable : A05B–1207–H752(For α motor, R–J controller, R–J2 controller)












176

(G) Limit switch cable (option): A05B–1207–H312, A05B–1207–H322

(For α motor, S motor, R–J controller, R–J2 controller)


K107 A660–4003–T185 OT relay

K121 A05B–1207–D103 J1 OT with limit switch



(H) TIG welding cable (option): A05B–1207–J101(For internal mechanical unit of ARC Mate 100)(For α motor, S motor, R–J controller, R–J2 controller)


K124 A660–1207–D005 Ground cable

K125 A660–8009–T778 Ground cable

(I1) MIG EYE cable (without ROTATOR) (option): A05B–1207–H921(For α motor, S motor, R–J controller, R–J2 controller)


K136 A660–8009–T818 Sensor cable A

K132 A660–8009–T848 Sensor cable B

� A660–8009–T708#L300R0 Ground cable

(I2) MIG EYE cable (with ROTATOR) (option): A05B–1207–H922(For α motor, S motor, R–J controller, R–J2 controller)


K131 A660–8009–T847 Sensor⋅pulse coder cable A

K132 A660–8009–T848 Sensor cable B

K133 A660–8009–T849 Pulse coder cable B

K134 A660–2004–T221 Power cable A

K135 A660–2004–T222 Power cable B

� A660–8009–T708#L300R0 Ground cable

(J) User cable (option): A05B–1207–H931(For α motor, S motor, R–J controller, R–J2 controller)


K142 A660–2004–T213 User cable

Other cable list inmechanical unit


177

(K) Wire feeder cable (option): A05B–1207–J091/A05B–1207–J092(For α motor, S motor, R–J controller, R–J2 controller)


K141 A660–2004–T251#L7R003 Welder�Robot (7 m):A05B–1207–J091

K141 A660–2004–T251#L14R03 Welder�Robot (14 m):A05B–1207–J092

K143 A660–2004–T214#L600R0 Robot�Wire feeder

TableTable 1 (b1) Motor (ARC Mate100/S–6) (For S motor)

ARC Mate 100 (with 2–axis brake) A05B–1207–B201S–6 (with 2–axis brake) A05B–1207–B202


A06B–0313–B075 J1 AC 0S

A06B–0313–B175 J2 AC 0S brake

A06B–0371–B175 J3 AC 2–0SP brake

A06B–0369–B156#0003 J4 AC 3–0F

A06B–0367–B156#0004 J5 AC 4–0F

A06B–0367–B156#0004 J6 AC 4–0F





A06B–0371–B175 J3 AC 2–0SP brake

A06B–0369–B356#0003 J4 AC 3–0F brake

A06B–0367–B356#0004 J5 AC 4–0F brake

A06B–0367–B356#0004 J6 AC 4–0F brake

Table 1 (b2) Motor (ARC Mate100/S–6) (For α motor)



A06B–0123–B075 J1 α3

A06B–0123–B175 J2 α3 brake

A06B–0371–B175 J3 α1 brake

A06B–0113–B078#0008 J4 α0.5

A06B–0113–B078#0008 J5 α0.5

A06B–0113–B078#0008 J6 α0.5

Motor list for S motorspecifications

Motor list for α motorspecifications


178



A06B–0123–B175 J1 α3 brake

A06B–0123–B175 J2 α3 brake

A06B–0371–B175 J3 α1 brake

A06B–0113–B178#0008 J4 α0.5 brake

A06B–0113–B178#0008 J5 α0.5 brake

A06B–0113–B178#0008 J6 α0.5 brake

Table 1 (c) Cover (ARC Mate100/S–6) *Option

Specifications Remarks

A05B–7202–J401 J2–axis motor cover *

A05B–7202–X403 J3–axis cover

Table 1 (d) Battery (ARC Mate 100/S–6)

Specifications Remarks Qty

A98L–0031–0005 1.5 V size D 4

Table 1 (e) Grease (ARC Mate 100/S–6)

Name Specifications Remarks

Mory–WhiteRE No. 00

A98L–0040–0119#2KG For J1, J2, J3, J5–axis

SK–3 A98L–0040–0110#2.5KG For J4, J6–axis

B–80405E/04A2. MECHANICAL UNIT INTERNAL

CONNECTION DIAGRAM

179

A2 MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM

A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

180

�: moving cable

Fig.2 (a) Internal connection diagram

(AR

C M

ate 100/S–6)

(A05B

–1207–H201) (F

or S m

otor, R–J controller)

(A05B

–1207–H211) (F

or S m


B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

181

�: moving cable

Fig. 2 (b) Internal connection diagram

(AR

C M

ate100/S-6) (A

05B–1207–H

202) (For S

motor, R

–J controller)

A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

182

�: moving cable

Fig.2 (c) Internal connection diagram

(AR

C M

ate 100/S–6)

(A05B

–1207–H601) (F

or S m


(A05B

–1207–H611) (F

or S m


B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

183

�: moving cable

Fig.2 (d) Internal connection diagram

(AR

C M

ate100/S-6) (A

05B–1207–H

602) (For S

motor, R

–J controller)

A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

184

Fig.2 (e) Internal connection diagram

(AR

C M

ate 100/S–6)

(A05B

–1207–H251) (F

or α m


(A05B

–1207–H261) (F

or α m


B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

185

Fig.2 (f) Internal connection diagram

(AR

C M

ate100/S-6) (A

05B–1207–H

252) (For α

motor, R

–J controller)

A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

186

Fig.2 (g) Internal connection diagram

(AR

C M

ate100/S-6)(A

05B–1207–H

651) (For α

motor, R

–J or R–J2 controller)

(A05B

–1207–H661) (F

or α m

otor, R–J or R

–J2 controller)

B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

187

Fig.2 (h) Internal connection diagram

(AR

C M

ate100/S-6) (A

05B–1207–H

652) (For α

motor, R


A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

188

Fig.2 (i) Internal connection diagram

(AR

C M

ate100/S-6)(A

05B–1207–H

253) (For α

motor, R

–J2 controller)

B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

189

Fig.2 (j) Internal connection diagram

(AR

C M

ate100/S-6) (A

05B–1207–H

263) (For α

motor, R

–J2 controller)

A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

190

Fig.2 (k) Internal connection diagram

(AR

C M

ate 100/S–6) (A

05B––1207–H

254) (For

� m

otor, R–J2 controller)

B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

191

Fig. 2 (l–1) Internal connection diagram

(AR

C M

ate 100/S–6) (A

05B–1207–H

753)(F

or �

motor, R

–J2 controller)

A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

192

Fig. 2 (l–2) Internal connection diagram

(AR

C M

ate 100/S–6) (A

05B–1207–H

753)(F

or �

motor, R

–J2 controller)

B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

193

Fig. 2 (m

–1) Internal connection diagram(A

RC

Mate 100/S

–6) (A05B

–1207–H754)

(For

� m


A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

194

Fig. 2 (m


RC

Mate 100/S

–6) (A05B

–1207–H754)

(For

� m


B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

195

Fig. 2 (n–1) Internal connection diagram

(AR

C M

ate 100/S–6) (A

05B–1207–H

751)(F

or �

motor, R


(A05B

–1207–H761)

(For

� m

otor, R–J or R

–J2 controller)

A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

196

Fig. 2 (n–2) Internal connection diagram

(AR

C M

ate 100/S–6) (A

05B–1207–H

751)(F

or �

motor, R


(A05B

–1207–H761)

(For

� m

otor, R–J or R

–J2 controller)

B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

197

Fig. 2 (O


RC

Mate 100/S

–6) (A05B

–1207–H752)

(For

� m

otor, R–J or R

–J2 controller)

A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

198

Fig. 2 (O


RC

Mate 100/S

–6) (A05B

–1207–H752)

(For

� m

otor, R–J or R

–J2 controller)

B–80405E

/04A

2. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL

CO

NN

EC

TIO

N D

IAG

RA

M

199

Fig.2 (p) Internal connection diagram

for MIG

EY

E cable

(A05B

–1207–H921) (A

RC

Mate 100)

(A05B

–1207–H922) (A

RC

Mate 100)

A2. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

LC

ON

NE

CT

ION

DIA

GR

AM

B–80405E

/04

200

Fig.2 (q) Internal connection diagram

for US

ER

cable (A05B

–1207–H931) (A

RC

Mate 100)

IndexB–80405E/04

i–1

�Numbers�1–year checks, 31

3–month checks, 30

3–year check, 34

�A�

Adjusting, 42

Adjusting J5–axis spur gear backlash, 64

Adjusting J5–axis spur gear backlash (For � motor), 66

Adjusting limit switches and dogs (option), 43

Air piping, 162

Assembling the mastering jig, 56

Assembly during installation, 161

�B�

Backlash adjustment of the gear 2 and gear 3 assemblies, 65

�C�

Cable clamping, 105

Cable installation diagram, 101

Configuration, 19

Confirming mastering, 63

Cover option (Specification: A05B–1207–J401), 130

�D�

Daily checks, 28

�E�End effector air pipe, 148

End effector I/O signals (RDI/RDO), 149

End effector mounting face to wrist, 142

Equipment mounting face, 143

Equipment mounting to robot, 141

�G�

Greasing, 33

�I�Installation, 156

Installation specifications, 164

�J�J1–axis drive mechanism, 20

J1–axis stroke modification (option), 48

J2–axis drive mechanism, 21



J5–axis and J6 drive mechanism, 24

�L�Limit switch installation diagram (option), 100

Load conditions at the wrist, 146

Lubricating condition checks, 32

�M�

Maintenance area, 160

Major component specifications, 25

Mastering procedure, 58

Mastering using jig, 56

Mastering using zero degree position, 54

Mechanical unit internal connection diagram, 179

Motor list for � motor specifications, 177

Motor list for S motor specifications, 177

�O�

Operator safety, 6

Options, 129

Other cable list in mechanical unit, 176

�P�Peripheral device safety, 8

Piping, 93

Piping and wiring, 92

Precautions for work, 10

Preventive maintenance, 27

�Q�

Quick mastering, 52

�R�

Releasing brake, 91

Replacing the J2–axis motor, 74

Replacing the J3–axis motor, 76

Replacing and adjusting parts, 68

INDEX B–80405E/04

i–2

Replacing battery, 35

Replacing cables, 104, 109

Replacing J1 and J2–axis motor, 69

Replacing J3–axis reducer, 78

Replacing J4–axis motor, 79

Replacing J5–axis motor, 83

Replacing J6–axis motor, reducer, 87

Replacing limit switch (option), 125

Replacing parts and performing adjustments, 41

Replacing the J1–axis reducer, 71

Replacing the J4–axis reducer, 81

Replacing the J5–axis gear, 85

Robot interference area, 133

�S�Safety for maintenance, 15

Safety precautions, 3

Safety speed control, 13

Spare parts list, 167

Storage, 155

�T�Transportation, 152

Transportation and installation, 151

Troubleshooting, 36

�W�

Wiring diagram, 94

Revision Record

FANUC Robot ARC Mate 100/S–6 MECHANICAL UNIT MAINTENANCE MANUAL (B–80405E)

04 Oct. ’95 � Revisions for CE Marking.

03 Apr., ’95

� Addition of R–J2 controller� Addition of MIG EYE cable and USER cable� Revision of mastering procedure� Deletion of load setting when minimum time control is used.� Addition of outer dimensions of base option.� Addition of option cable list

02 Sep., ’94 � Addition of descriptions for � motor

01 Feb., ’94

Edition Date Contents Edition Date Contents

am100 s6 maintenance manual e

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