FANUC Robotics R-J and R-J2 Controller ARC Mate 100/S-6 Mechanical Unit Maintenance Manual MARAWA10002404E

B-80405E/04
This publication contains proprietary information of FANUC Robotics America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics America, Inc. FANUC Robotics America, Inc. 3900 W. Hamlin Road Rochester Hills, Michigan 483093253

The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics America, Inc, hereinafter referred to as FANUC Robotics, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations. FANUC Robotics manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC Robotics products and/or systems. Such systems consist of robots, extended axes, robot controllers, application software, the KAREL programming language, INSIGHT vision equipment, and special tools. FANUC Robotics recommends that only persons who have been trained in one or more approved FANUC Robotics Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintain FANUC Robotics products and/or systems and their respective components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.

WARNING This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measure may be required to correct the interference. FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at its headquarters in Rochester Hills, Michigan. For additional information contact FANUC Robotics America, Inc. Training Department 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253 www.fanucrobotics.com Send your comments and suggestions about this manual to: [email protected]

Copyright 2003 by FANUC Robotics America, Inc. All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, translated into another language, or transmitted in whole or in part in any way without the prior written consent of FANUC 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 FANUC Robotics. FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuAir AccuCal AccuChop AccuFlow AccuPath AccuSeal ARC Mate ARC Mate Sr. ARC Mate System 1 ARC Mate System 2 ARC Mate System 3 ARC Mate System 4 ARC Mate System 5 ARCWorks Pro AssistTool AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell Finder Center Finder Clean Wall CollisionGuard DispenseTool F-100 F-200i FabTool FANUC LASER DRILL Flexibell FlexTool HandlingTool HandlingWorks INSIGHT INSIGHT II IntelliTrak Integrated Process Solution Intelligent Assist Device IPC -Integrated Pump Control IPD Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD Integral Servo Dispenser Laser Mate System 3 Laser Mate System 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 RJ3 Controller SYSTEM R-J3iB Controller TCP Mate TurboMove TorchMate visLOC visPRO-3D visTRAC WebServer WebTP YagTool

Conventions

This manual includes information essential to the safety of personnel, equipment, software, and data. This information is indicated by headings and boxes in the text. WARNING Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.

CAUTION Information appearing under CAUTION concerns the protection of equipment, software, and data. It is boxed to set it apart from other text.

NOTE Information appearing next to NOTE concerns related information or useful hints.

Safety-1 FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for your application and installation can best be determined by safety system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotic systems. According to the industry standard ANSI/RIA R15.06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation. FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC Robotics training course and become familiar with the proper operation of the system. Persons responsible for programming the systemincluding the design, implementation, and debugging of application programs must be familiar with the recommended programming procedures for your application and robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace.

Safety-2

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety: The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot

Keeping People and Equipment Safe

The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following: People External devices Robot(s) Tooling Workpiece

Using Safety Enhancing Devices

Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices: Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEADMAN switches

Setting Up a Safe Workcell

A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal, state, and local laws, regulations, and guidelines that pertain to safety. Sponsor your personnel for training in approved FANUC Robotics training course(s) related to your application. Never permit untrained personnel to operate the robots.

Safety-3 Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot. Use antitiedown logic to prevent the operator from bypassing safety measures. Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell. Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work envelope is the area defined by the maximum motion range of the robot, including any tooling attached to the wrist flange that extend this range. Position all controllers outside the robot work envelope. Never rely on software as the primary safety element. Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell. Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the enduse application. Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope. Install special guarding that prevents the operator from reaching into restricted areas of the work envelope. Use interlocks. Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety. Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot.

Safety-4 Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electromagnetic interference (EMI), radio frequency interference (RFI), and electrostatic discharge (ESD). Make provisions for power lockout/tagout at the controller. Eliminate pinch points. Pinch points are areas where personnel could get trapped between a moving robot and other equipment. Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely. Program the robot to load and unload material safely. If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons. If materials are being applied at dangerously high pressure, provide electrical interlocks for lockout of material flow and pressure.

Staying Safe While Teaching or Manually Operating the Robot

Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules: Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment. Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range. The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department. FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope.

Safety-5

WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.

Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked. Isolate the robot from all remote control signals that can cause motion while data is being taught. Test any program being run for the first time in the following manner: WARNING Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury.

Using a low motion speed, single step the program for at least one full cycle. - Using a low motion speed, test run the program continuously for at least one full cycle. - Using the programmed speed, test run the program continuously for at least one full cycle. Make sure all personnel are outside the work envelope before running production.

Staying Safe During Automatic Operation

Advise all personnel who operate the robot during production to observe the following rules: Make sure all safety provisions are present and active. Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external devices and other equipment with which the robot interacts. Understand the complete task the robot is programmed to perform before initiating automatic operation. Make sure all personnel are outside the work envelope before operating the robot.

Safety-6 Never enter or allow others to enter the work envelope during automatic operation of the robot. Know the location and status of all switches, sensors, and control signals that could cause the robot to move. Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared to press these buttons in an emergency. Never assume that a program is complete if the robot is not moving. The robot could be waiting for an input signal that will permit it to continue activity. If the robot is running in a pattern, do not assume it will continue to run in the same pattern. Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection

When inspecting the robot, be sure to Turn off power at the controller. Lock out and tag out the power source at the controller according to the policies of your plant. Turn off the compressed air source and relieve the air pressure. If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. If power is needed to check the robot motion or electrical circuits, be prepared to press the EMERGENCY STOP button, in an emergency. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.

Staying Safe During Maintenance

When performing maintenance on your robot system, observe the following rules:

Safety-7 Never enter the work envelope while the robot or a program is in operation. Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Consider all or any overlapping work envelopes of adjoining robots when standing in a work envelope. Test the teach pendant for proper operation before entering the work envelope. If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately. Whenever possible, perform maintenance with the power turned off. Before you open the controller front panel or enter the work envelope, turn off and lock out the 3phase power source at the controller. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only.

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

Safety-8 Isolate the robot from all remote control signals. If maintenance must be done when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this person. Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked. Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel.

WARNING Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. When replacing or installing components, make sure dirt and debris do not enter the system. Use only specified parts for replacement. To avoid fires and damage to parts in the controller, never use nonspecified fuses. Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Programming Safety Precautions

Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices.

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

Safety-9 Backcheck limit switches in the workcell to make sure they do not fail. Implement failure routines in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails. Use handshaking protocol to synchronize robot and external device operations. Program the robot to check the condition of all external devices during an operating cycle.

Mechanical Safety Precautions

Implement the following mechanical safety measures to prevent damage to machine tools and other external devices. Make sure the workcell is clean and free of oil, water, and debris. Use software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.

KEEPING THE ROBOT SAFE

Operating Safety Precautions

Observe the following operating and programming guidelines to prevent damage to the robot. The following measures are designed to prevent damage to the robot during operation. Use a low override speed to increase your control over the robot when jogging the robot. Visualize the movement the robot will make before you press the jog keys on the teach pendant. Make sure the work envelope is clean and free of oil, water, or debris. Use circuit breakers to guard against electrical overload.

Programming Safety Precautions

The following safety measures are designed to prevent damage to the robot during programming: Establish interference zones to prevent collisions when two or more robots share a work area.

Safety-10 Make sure that the program ends with the robot near or at the home position. Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage. In dispensing applications, be aware of all safety guidelines with respect to the dispensing materials.

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

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS

Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personal also must work inside the paint booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor. Although paint booth hazards have been minimized, potential dangers still exist. Therefore, todays highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and highvoltage electrostatic tools. Paint robots are operated in three modes: Teach or manual mode Automatic mode, including automatic and exercise operation Diagnostic mode During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe

Safety-11 area within the booth whenever automatic mode is initiated at the SOC or MCP. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.

Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features: Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are. Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are. EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E STOP buttons. An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres. A DEADMAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN switch is released during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also ESTOP other robots. WARNING An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed robot.

Safety-12 Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. Limit switches and hardstops also limit travel by the major axes. EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SCC is in teach mode. When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings. System status is monitored by computer. Severe conditions result in automatic system shutdown.

Staying Safe While Operating the Paint Robot

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

WARNING Observe all safety rules and guidelines to avoid injury.

WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.

Know the work area of the entire paint station (workcell). Know the work envelope of the robot and hood/deck and door opening devices. Be aware of overlapping work envelopes of adjacent robots. Know where all red, mushroomshaped EMERGENCY STOP buttons are located.

Safety-13 Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move. Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor. Become familiar with the complete task the robot will perform BEFORE starting automatic mode. Make sure all personnel are outside the paint booth before you turn on power to the robot servo system. Never enter the work envelope or paint booth before you turn off power to the robot servo system. Never enter the work envelope during automatic operation unless a safe area has been designated. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic devices are enabled. Stay out of areas where you might get trapped between a moving robot, conveyor, or opening device and another object. Be aware of signals and/or operations that could result in the triggering of guns or bells. Be aware of all safety precautions when dispensing of paint is required. Follow the procedures described in this manual.

Staying Safe While Operating Paint Application Equipment

When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. WARNING When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials, and NFPA 70 National Electrical Code.

Safety-14

Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms. High Voltage: High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process. Avoid any accumulation of combustible vapors or coating matter. Follow all manufacturer recommended cleaning procedures. Make sure all interlocks are operational. No smoking. Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material. Disable all air and paint pressure to bell. Verify that the lines are not under pressure.

Staying Safe During Maintenance

When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot. Paint robots operate in a potentially explosive environment. Use caution when working with electric tools. When a maintenance technician is repairing or adjusting a robot, the work area is under the control of that technician. All personnel not participating in the maintenance must stay out of the area. For some maintenance procedures, station a second person at the control panel within reach of the EMERGENCY STOP button. This person must understand the robot and associated potential hazards.

Safety-15 Be sure all covers and inspection plates are in good repair and in place. Always return the robot to the home position before you disarm it. Never use machine power to aid in removing any component from the robot. During robot operations, be aware of the robots movements. Excess vibration, unusual sounds, and so forth, can alert you to potential problems. Whenever possible, turn off the main electrical disconnect before you clean the robot. When using vinyl resin observe the following:

Wear eye protection and protective gloves during application and removal Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye irritation. If there is contact with the skin, wash with water.

When using paint remover observe the following:

Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning. Adequate ventilation is required. Overexposure could cause drowsiness. If there is contact with the skin or eyes, rinse with water for at least 15 minutes.

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GENERAL

GENERAL
This manual describes the maintenance and connection of the following robot (R-J controller or RJ2 controller) mechanical unit which are S motor and motor specifications. Make sure of the specification of mechanical unit when replacing parts.
Mechanical unit of S motor specification [S motor] (RJ controller) Model FANUC Robot ARC Mate 100 (J2, J3 axis with brake) FANUC Robot ARC Mate 100 (All axes with brake) FANUC Robot S6 (J2, J3 axis with brake) FANUC Robot S6 (All axes with brake) Abbreviation Mechanical unit specifications A05B-1207-B201 ARC Mate 100 A05B-1207-B601 A05B-1207B202 S-6 A05B-1207B602

Mechanical unit of motor specification [ motor] (RJ or RJ2 controller) Model FANUC Robot ARC Mate 100 (J2, J3 axis with brake) FANUC Robot ARC Mate 100 (All axes with brake) FANUC Robot S6 (J2, J3 axis with brake) FANUC Robot S6 (All axes with brake) Abbreviation Mechanical unit specifications A05B-1207-B251 ARC Mate 100 A05B-1207-B651 A05B-1207B252 S-6 A05B-1207B652

GENERAL

B80405E/04

Related Manuals

For the FANUC Robot series, the following manuals are available:
Safety handbook B80687EN All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook. RJ controller Quick manual HANDLING TOOL B67994E2 ARC TOOL B67994E3 SEALING TOOL B67994E4 Setup and Operations manual HANDLING TOOL B67994E1 1 ARC TOOL B67994E12 SEALING TOOL B67994E14 Maintenance manual B67995E Intended readers: All persons who use the FANUC Robot, system designer Topics: Safety items for robot system design, operation, maintenance Intended readers: Operator, programer Topics: Basic procedures for operating the robot Use: Robot operation, simple teaching

Intended readers: Operator, programer, maintenance person, system designer Topics: Robot functions, operations programing, setup, interfaces, alarms Use: Robot operation, teaching, system design Intended readers: Maintenance person, system designer Topics: Installation, connection to peripheral equipment maintenance Use: Installation, startup, connection, maintenance Intended readers: Operator, programer, maintenance person, system designer Topics: Robot functions, operations, programing, setup, interfaces, alarms Use: Robot operation, teaching, system design Intended readers: Maintenance person, system designer Topics: Installation, connection to peripheral equipment, maintenance Use: Installation, startup, connection, maintenance Intended readers: Maintenance person, system designer Topics: Installation, connection to the controller, maintenance Use: Installation, startup, connection, maintenance B80405E

RJ2 controller

Setup and Operations manual HANDLING TOOL B80524EN1 1 ARC TOOL B80524EN12 SEALING TOOL B80524EN14 Maintenance manual B80525E B80525E1 (European specification)

Mechanical unit

Maintenance manual

FANUC Robot ARC Mate 100/S6 D Arc welding, generalpurpose small robot

B80405E/04

GENERAL

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

The attachment position for the mechanical unit specification number.

Table I LETTERS No. 1 CONTENTS ARC Mate 100 S6 2 TYPE S MOTOR SPEC. ARC Mate 100 (2BK) S6 (2BK) ARC Mate 100 (6BK) S6 (6BK) a MOTOR SPEC. ARC Mate 100 (2BK) S6 (2BK) ARC Mate 100 (6BK) S6 (6BK) 3 4 5 SERIAL NO. DATE WEIGHT LETTERS ARC Mate 100 S6 A05B1207B201 A05B1207B202 A05B1207B601 A05B1207B602 A05B1207B251 A05B1207B252 A05B1207B651 A05B1207B652 PRINT SERIAL NO. PRINT PRODUCTION YEAR AND MONTH 160

B80405E/04

Table of Contents

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 1.2 1.3 1.4 1.5 1.6 J1-AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J2-AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J3-AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J4-AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J5-AXIS AND J6 DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAJOR COMPONENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 21 22 23 24 25

2. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 2.2 2.3 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3MONTH CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1-YEAR CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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

3.1 3.2 3.3 GREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3-YEAR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1 4.2 4.3 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 PROBLEM AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 REPLACING PARTS AND PERFORMING ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5. ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1 ADJUSTING LIMIT SWITCHES AND DOGS (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 c1

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5.2 5.3 5.4 5.5 5.6 5.7

J1-AXIS STROKE MODIFICATION (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QUICK MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTERING USING ZERO DEGREE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTERING USING JIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONFIRMING MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING J5-AXIS SPUR GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 52 54 56 63 64

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

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 REPLACING J1 AND J2-AXIS MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE J1-AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE J2-AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE J3-AXIS MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING J3-AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING J4-AXIS MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE J4AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING J5-AXIS MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE J5AXIS GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING J6-AXIS MOTOR, REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELEASING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 71 74 76 78 79 81 83 85 87 91

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

7.1 7.2 7.3 7.4 PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 LIMIT SWITCH INSTALLATION DIAGRAM (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 CABLE INSTALLATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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

8.1 8.2 8.3 CABLE CLAMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 REPLACING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 REPLACING LIMIT SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

9. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.1 COVER OPTION (SPECIFICATION: A05B1207J401) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

II. CONNECTION
1. ROBOT INTERFERENCE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 2. EQUIPMENT MOUNTING TO ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.1 2.2 2.3 2.4 2.5 END EFFECTOR MOUNTING FACE TO WRIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIPMENT MOUNTING FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOAD CONDITIONS AT THE WRIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . END EFFECTOR AIR PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . END EFFECTOR I/O SIGNALS (RDI/RDO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c2 142 143 146 148 149

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

3.1 3.2 3.3 3.4 3.5 3.6 3.7 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY DURING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 155 156 160 161 162 164

APPENDIXES
A1. SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 A2. MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . 179

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1. CONFIGURATION

CONFIGURATION

Fig. 1 shows the configuration of the mechanical unit.

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

NOTE 1. FANUC CALL MOTOR 16 (M1M6) J1J6MOTOR EACH. 2. 2BRAKES TYPE: THE MOTOR FOR J2 AND J3 AXES HAVE BUILTIN BRAKE. THIS BRAKE IS ON IN THE POWER OFF OR IN THE EMERGENCY STOP. 3. 6BRAKES TYPE: THE MOTOR FOR ALL AXES (J1, J2, J3, J4, J5 AND J6) HAVE BUILTIN BRAKE. THIS BRAKE IS ON IN THE POWER OFF OR IN THE EMERGENCY STOP.

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1.1
J1-axis Drive Mechanism

Fig. 1.1 shows the J1-axis drive mechanism. The rotation of the AC servo motor (With/without brake) is decelerated by the reducer and rotates the J2-axis base. The J2-axis base is supported by the J1-axis base via the reducer.
J1axis AC servo motor M1 model OS (S motor) model S ( motor)

J2axis base A

Input gear Reducer J1axis base Phase AA

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

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1. CONFIGURATION

1.2
J2-axis Drive Mechanism

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

J2axis arm Input gear

J2axis AC servo motor model OS (S motor) model 3 ( motor) M2 J2axis base B Reducer

Phase BB

Fig. 1.2 J2-axis drive mechanism (ARC Mate100/S-6)

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1.3
J3-axis Drive Mechanism

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

J3axis housing Reducer Hexagonal head (width 11) Cap

Box wrench with ratchet (manual crank)

J3axis AC servo motor model 2OSP (S motor) model 1 ( motor) M3 J2axis arm

Fig. 1.3 J3-axis drive mechanism (ARC Mate100/S-6)

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1. CONFIGURATION

1.4
J4-axis Drive Mechanism

Fig. 1.4 shows the J4-axis drive mechanism. The rotation of the AC servo motor 30F is decelerated by the reducer and rotates J3-axis arm. J3-axis arm is supported by the J3-axis housing via the reducer.

J3axis housing Reducer

Center gear

Input gear J4axis AC servo motor M4 model 30F (S motor) model 0.5 ( motor) J3axis arm

Fig. 1.4 J4-axis drive mechanism (ARC Mate100/S-6)

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1.5
J5-axis and J6 Drive Mechanism

Fig. 1.5 shows the J5-axis and J6axis drive mechanism. The rotation of the AC servomotor is decelerated by the three steps gear of J5axis and rotates the J6-axis unit the rotation of AC servomotor 40F is decelerated by the reducer of J6axis and rotates the output flange.

J5axis AC servomotor M5 model 40F (S motor) model 0.5 ( motor)

J6axis AC servomotor model 40F (S motor) model 0.5 ( motor)

M6

J6axis reducer

Output flange J3axis arm J5axis gear (three steps)

Fig. 1.5 J5-axis and J6axis drive mechanism (ARC Mate100/S-6)

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1. CONFIGURATION

1.6
Major Component Specifications
1) Motor for mechanical unit of S motor specifications ARC Mate 100 (With 2axis brake) A05B1207B201 S6 (With 2axis brake) A05B1207B202
Specifications A06B-0313-B075 A06B-0313-B175 A06B-0371-B175 A06B-0369-B156#0003 A06B-0367-B156#0004 A06B-0367-B156#0004 Axis J1 J2 J3 J4 J5 J6 AC 0S AC 0S with brake AC 20SP with brake AC 3-0F AC 4-0F AC 4-0F Remarks

Motor for mechanical unit of S motor specifications ARC Mate 100 (With 6axis brake) A05B1207B601 S6 (With 6axis brake) A05B1207B602
Specifications A06B-0313-B175 A06B-0313-B175 A06B-0371-B175 A06B-0369-B356#0003 A06B-0367-B356#0004 A06B-0367-B356#0004 Axis J1 J2 J3 J4 J5 J6 Remarks AC 0S with brake AC 0S with brake AC 2-0SP with brake AC 3-0F with brake AC 4-0F with brake AC 4-0F with brake

Motor for mechanical unit of motor specifications ARC Mate 100 (With 2axis brake) A05B1207B251 S6 (With 2axis brake) A05B1207B252
Specifications A06B0123B075 A06B0123B175 A06B0371B175 A06B0113B078#0008 A06B0113B078#0008 A06B0113B078#0008 Axis J1 J2 J3 J4 J5 J6 3 3 with brake 1 with brake 0.5 0.5 0.5 Remarks

Motor for mechanical unit of motor specifications ARC Mate 100 (With 6axis brake) A05B1207B651 S6 (With 6axis brake) A05B1207B652
Specifications A06B0123B175 A06B0123B175 A06B0371B175 A06B0113B178#0008 A06B0113B178#0008 A06B0113B178#0008 Axis J1 J2 J3 J4 J5 J6 Remarks 3 with brake 3 with brake 1 with brake 0.5 with brake 0.5 with brake 0.5 with brake

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2) Reducer for mechanical unit

S motor specifications
Specifications A97L-0118-0930 A97L-0118-0931 A97L-0118-0932 A97L-0118-0933 A97L-0118-0934 Axis J1 J2 J3 J4 J6

motor specifications
Specifications A97L-01180930 A97L-0118-0931 A97L-0118-0932 A2907207T403 A05B1208H001 Axis J1 J2 J3 J4 J6

3) Gear for mechanical unit

S motor specifications
Specifications A290-7207-X211 A290-7202-X311 A290-7207-X411 A290-7207-X412 A290-7207-X511 A290-7207-V501 A290-7207-V502 A290-7207-X514 Axis J1 J2 J4 J4 J5 J5 J5 J5

motor specifications
Specifications A290-7207-X211 A290-7202-X311 A290-7207-Y411 A290-7208-X511 A290-7208-V501 A290-7208V502 A290-7208X515 Axis J1 J2 J4 J5 J5 J5 J5

4) Cover
Specifications A05B-1207J401 A2907207X403 Remarks J2axis motor cover (for floor mount) *Opotion J3axis motor cover

5) Stopper
Specifications A2907207X227 A2907207X226 A2907207X321 A2907207X347 A2907207X327 A2907207X333 Axis J1 J1 J1 J1 J2 J3 * Option for changing operation space * Stopper for with 330 OT * Stopper for without 330 OT

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2. PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE

Optimum performance of the robot can be maintained for a long time by performing the periodic maintenance procedures presented in this chapter.

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2.1
DAILY CHECKS

Clean each part, and visually check component parts for damage before daily system operation. Check the following items as the occasion demands.

a) Before automatic operation

Table 2.1 Daily preventive maintenance checks (1/2) Item 1 Check items When air control set is combined. Air pressure Check points Check air pressure using the pressure gauge on the air regulator as shown in Fig. 2.1. If it does not meet the specified pressure of 5-7 kg/cm2, adjust it using the regulator pressure setting handle. 2 Oiler oil mist quantity Check the drop quantity during wrist or hand motion. If it does not meet the specified value (1 drop/10 - 20 sec), adjust it using the oiler control knob. Under normal usage the oiler becomes empty in about 10 to 20 days under normal operation. Check to see that the oiler level is within the specified level shown in Fig. 2.1. Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required. Refer to section 8. Check to see that each axis moves smoothly. Check to see that the stop positions of the robot has not deviated from the previous stop positions. Check whether the peripheral devices operate properly according to commands from robot. Refer to 4.2.

Oiler oil level

Leakage from hose Cables used in mechanical unit Vibration, abnormal noises, and motor heating Changing repeatability

5 6 7

Peripheral devices for proper operation J2/J3-axis brake

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2. PREVENTIVE MAINTENANCE

Oil inlet

Adjusting knob Oiler mist amount check

Oiler Regulator Pressure gauge pressure setting handle Fig. 2.1 Air control set (option)

Filter

b) After automatic operation After 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) Item 1 Check items Cleaning and checking each part Check points Clean each part and check component parts for cracks and flaws.

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2.2
3MONTH CHECKS

Check the following items once every 3 monthes. Additional inspection areas and times should be added to the table according to the robots working conditions, environment, etc.
Table 2.2 Monthly preventive maintenance checks Item 1 2 3 Check items Loose connectors Loose bolts Removal of dust, etc. Check points Check that all connectors, including the motor connectors, are secure. Check that all cover mounting bolts and external mounting bolts are secure. Remove any spatter, dust, foreign matter, etc.

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2.3
1-YEAR CHECKS

1) Check the following items every year.

Item 1 2 Check items Lubrication greasing Changing of battery Check points Refer to section 3.1. Refer to section 3.3.

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

Item 1 Check items Greasing each axis reducer Check points Refer to section 3.2.

3) Maintenance tools The following tools and instruments are required for the maintenance procedures contained in this manual. a) Measuring instruments
Instruments Dial gauge Slide calipers Accuracy/Tolerance 1/100 mm 150 mm Applications Measurement of positioning and backlash.

b) Tools Cross tip (+) screwdrivers: Large, medium, and small sizes Flat tip (-) screwdrivers: Large, medium, and small sizes Box screwdrivers: M3 - M6 Hexagonal wrench key sets (metric): M3 - M16 Adjustable wrenches: Medium and small sizes Pliers Cutting pliers Cutting nippers Double and wrench Grease gun Pliers for C-retaining ring

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LUBRICATING CONDITION CHECKS

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3. LUBRICATING CONDITION CHECKS

3.1
GREASING

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 1 Greasing point J6-axis reducer Grease Qty Method of greasing

Grease SK3 (No.: A98L0040 0110#2.5KG 2 J4-axis reducer

50 cc Remove the plugs (PT 1/82 type) from the J6 axis grease inlet and outlet, attach the J4axis grease nipple to the J6axis grease inlet, then inject grease. After greasing, return the grease nipple to the J4axis greasing point, and put the plugs on the grease inlet and outlet. 150 cc Remove the plug from the grease outlet, and inject grease through the grease nipple attached to the grease inlet. After greasing, plug the grease outlet, and cap the grease nipple.

J6axis reducer air vent for greasing SK3 J3axis reducer grease nipple RE No. 00 J4axis reducer air vent for greasing

J3axis reducer air vent for greasing

J6axis reducer airvent for greasing J5axis reducer air vent for greasing

J2axis reducer airvent for greasing

J2axis reducer grease nipple

RE No. 00

J5axis reducer air vent RE No. 00 J4axis reducer grease nipple SK3

J1axis reducer grease nipple RE No. 00 J1axis reducer air vent for greasing

Fig. 3.1 Greasing points (ARC Mate 100/S6)

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3.2
3-YEAR CHECK

Change grease for reducers J1, J2, J3 and for gear box of J5 as follows every 3 years or 20.000 hours. See Fig 3.1 for greasing points. 1 Remove the plugs (PT1/82) from the grease outlets for the J1, J2, J3, and J5axes, as shown in Fig. 3.1. 2 Remove the caps from the grease nipples of the grease inlets for the J1, J2, and J3axes. Remove the plug from the J5axis grease inlet and mount a grease nipple for other axis inlets on the inlet. 3 Inject the grease specified in Table 3.2 from the grease nipples for J1, J2, J3, and J5axes until the old grease is pushed out from the outlets and this new grease is also pushed out a little. 4 Remove the grease nipples for J1, J2, J3, and J5axes. Take out about 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, and J3axes. Then mount the caps on them. 6 Mount the plugs on the grease outlets for the J1, J2, J3, and J5axes and the grease inlet for the J5axis.
Table 3.2 Grease requiring 3year changes (ARC Mate 100/S6) Grease Kyodo Yushi J1-axis reducer J2-axis reducer J3-axis reducer J5-axis gear box MoryWhite RE No. 00 (Specification: A98L00400119#2KG) Qty. (cc) 1000 1000 200 250

NOTE Take care not to slip on grease. Wipe the grease off the floor and robot structure.

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3.3
REPLACING BATTERY

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 as follows. 1 Turn the power on. Press the EMERGENCY STOP button to inhibit the robots motion. 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 case

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

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

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TROUBLE SHOOTING

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4.1
GENERAL

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

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4.2
PROBLEM AND CAUSES

Table 4.2(a) lists the major failures that may be suffered by the mechanical unit, together with their causes. Contact us if the cause of a failure cannot be identified, or the necessary corrective action cannot be determined. Note, however, that backlash, provided it does not exceed the values listed in Table 4.2(b), is normal. Note also that a drop that does not exceed the values indicated in Table 4.2(c) is normal.
Table 4.2(a) Major Failures and Their Causes

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

Cause The batteries used for memory backup are exhausted. The pulse coder signal cable is broken.

Corrective action Replace the batteries then perform quick mastering. Replace the cable then perform quick mastering. Make a teaching point correction. Secure the robot firmly. Secure the peripheral equipment firmly. Reduce the load. Ensure that the robot is operated within its specified limits. Correct the parameter. Replace the cable. Replace the motor.

Remarks See Section 3.3. See Section 5.3. See Section 8.2. See Section 5.3.

Positional error.

The robot may have hit an object. The robot is not firmly secured. Peripheral equipment has been moved out of position. An excessive load has been applied.

See Section 3.2 of the part explaining connection.

Wrist load: Refer to the specifications. Peripheral equipment: See Section 2.2 of the part explaining connection. Refer to the instruction manual. See Section 8.2. See Sections 6.1 through 6.10.

A specified parameter is incorrect. A cable has broken. The pulse coder has failed. The backlash in the mechanical unit is excessive. (See the description of the relevant symptom below.) Vibration The robot is not secured firmly. The floor vibrates (particularly when the robot is installed on a floor above ground level.) An excessive load is applied.

Secure the robot firmly. Review the location of installation. Reduce the load. Ensure that the robot is operated within its specified limits. Adjust the servo system. Replace the cable.

See Section 3.2 of the part explaining connection.

Wrist load: Refer to the specifications. Peripheral equipment: See Section 2.2 of the part explaining connection. Contact us. See Section 8.2.

The servo system is not correctly adjusted. A cable has broken.

A ground connection has not been Make the necessary ground Refer to the maintenance made. connection. manual for the control unit. A motor is faulty. An axis board PCB is faulty. Replace the motor. Replace the axis board PCB. See Sections 6.1 through 6.10. Refer to the maintenance manual for the control unit.

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Symptom Vibration

Cause A reducer is faulty.

Corrective action Replace the reducer.

Remarks See Sections 6.2 through 6.10. Refer to the operators manual.

An incorrect time constant is used. Correct the time constant. The backlash in the mechanical unit is excessive. (See the description of the symptom below.) Mechanical unit backlash. A screw or pin is loose. Tighten the screw or pin. (Apply Loctite to the specified area.) Replace the reducer. Adjust the gear. Adjust the gear. Replace the gear. Replace the bearing. Replace the broken part. Apply grease. Clean the gear or reducer, then apply grease. Adjust the gear. Adjust the gear. Replace the gear. Replace the bearing. Adjust the servo system. Apply grease. Clean and regrease. Reduce the load. Ensure that the robot is operated within its specified limits. Adjust the gear.

A reducer is faulty. A gear is not correctly adjusted. A gear is worn. A bearing is worn. A part such as a casting has broken. Abnormal sound. Gears and/or reducers require greasing. Foreign matter has entered a gear or reducer. A gear is not correctly adjusted. A gear is worn. A bearing is worn. The servo system is not correctly adjusted. Overheating. Gears and/or reducers require greasing. Grease that does not satisfy the specifications has been used. An excessive load is applied.

See Section 6.2 through 6.10. See Section 5.7. Contact us. Contact us. Contact us. See Sections 3.1 and 3.2. See Sections 6.2 through 6.10, 3.1, and 3.2. Contact us. Contact us. Contact us. Contact us. See Sections 3.1 and 3.2. See Sections 3.1 and 3.2. Wrist load: Refer to the specifications. Peripheral equipment: See Section 2.2 of the part explaining. Contact us. Refer to the instruction manual. See Sections 6.1 through 6.10. Refer to the maintenance manual for the control unit. Contact us. Contact us.

A gear is not correctly adjusted.

An incorrect time constant is used. Correct the time constant. The robot arm drops when the power is cut. A motor brake is worn. Brake relay has burnt out. Grease leaks. An Oring, oil seal, or packing has degraded or has been damaged. A part such as a casting has broken. A screw is loose. Replace the motor. Replace the relay. Replace the Oring, oil seal, or packing. Replace the broken part. Tighten the screw.

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Table 4.2(b) Allowable Backlash for Each Axis J1 Angle (min) Displacement (mm) 2.5 0.93 (1291) J2 2.5 0.43 (600) J3 2.5 0.38 (517) J4 3 0.16 (200) J5 6 0.38 (220) J6 3 0.16 (200)

NOTE A displacement value indicates a rotational backlash within the distance (indicated in parentheses) from the center of the axis.

Table 4.2(c) Allowable Drop When power is cut In the event of an emergency stop 5 mm 5mm

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4.3
REPLACING PARTS AND PERFORMING ADJUSTMENTS

Adjustments are necessary whenever a part is replaced. The table below shows replacement of parts and the required adjustment items.

Part to be replaced or function to be changed Replacement of cable (b) Limit switch (c) Mastering Replacement of limit switch (option) J1-axis stroke change (option)

Adjustment (a) Routing of cable

(a) Limit switch and dog adjustment (a) Dog mounting position change, limit switch 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.

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ADJUSTING

Mechanical parts have been adjusted to the optimum condition at the time of shipment from our company. Therefore, they normally need not be adjusted by the customer at the time of delivery. Adjustment should be made as specified in this section, however, after a long period of use or after replacing a part.

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5. ADJUSTING

5.1
ADJUSTING LIMIT SWITCHES AND DOGS (OPTION)

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 limit switch it is called Over Travel (OT). Over Travel is detected at either end of the axis. The robot is controlled not to work beyond its operating area unless the servo 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 is issued at the positions shown in the figures.
Note) The stroke can be changed.

0_ Stroke 330_

+165_

165_

minimum 1_

minimum 1_

Stroke end

Stroke end

Mechanical stopper

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

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0_ 360_ 0T option specification: A05B1207H322

Stroke 360_

+180_

180_

minimum 0.5_ minimum 0.5_ OT +OT

Note) When working space is 360_, mechanical stops are not exist.

Stroke end

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

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

Storoke 240_

minimum 3_ Stroke end Mechanical stopper minimum 3_

Stroke end Mechanical stopper

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

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

0_ Stroke 325_

0_ +180_

145_

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

+190_ Stroke end

190_ Stroke end

Note) The J4 axis does not have OT limit switches nor mechanical stops. Fig.5.1 (e) J4-axis wrist rotation (ARC Mate100/S-6)

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minimum 3_ Stroke end Mechanical stopper +140_ Stroke 280_

0_

Mechanical stopper Stroke end

140_

minimum 3_ Note) The J5 axis does not have OT limit switches. Fig.5.1 (f) J5-axis wrist rotation (ARC Mate100/S-6)

0_ Stroke 540_

270_ Stroke end

+270_ Stroke end

Note) The J6 axis does not have OT limit switches nor hard stops. Fig.5.1 (g) J6axis wrist rotation (ARC Mate100/S6)

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Mechanical stopper OT Stroke end Minimum 5_

Interference angle 15_ J3axis arm J2axis arm

Interference angle 15_ Minimum 5_

Stroke end OT Mechanical stopper Note) The allowable range for the relative angle between the J2-axis and J3-axis arms is from 15 to 165.

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

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5.2
J1-AXIS STROKE MODIFICATION (OPTION)

It is possible to limit the J1-axis stroke according to the surroundings of the robot. The stroke can be changed as shown in Fig. 5.2 (a). It can be changed according to the OT stroke by changing the dog position or the mechanical stop. The stroke can be changed every 20_ at the desired stroke position between 165_ to +165_. When the stroke does not include 0_, the stroke must be readjusted to the standard position when mastering the robot using the jig. J1axis stroke change option specification (without OT): A05B1207J301 J1axis stroke change option specification (with OT): A05B1207J302

Front

Note) Standard stroke is from -165_ to +165_ Fig.5.2 (a) J1-axis stroke change (ARC Mate100/S-6)

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1) Changing dog and mechanical stop position

Change the dog and hard stop positions according to the desired stroke position as shown in Fig. 5.2 (b).

Limit switch (Rotation side) option

Front Mechanical stopper (Rotation side)

Example

Mechanical stopper (Fixed side) Dog (Fixed side)

Limit switch (Rotation side) option

Front

Example

Mechanical stopper (Rotation side) Mechanical stopper (Fixed side) Dog (Fixed side)

Note) The figure shown the J1-axis base top view. Fig.5.2 (b) Dog and mechanical stop position change (ARC Mate100/S-6)

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2) Changing minimum and maximum stroke

After adjusting the dog and mechanical stopper positions, set the system variables for both J1axis 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. NOTE Cold start: A type of start operation, where the power is first turned off, then turned back on. (Cold start is used when power failure processing has been disabled.) If power failure processing is currently enabled (system variable $POWERFL is set to true), change the system variable $POWERFL to false (power failure processing disabled). Turn off the power, then turn it on again. To subsequently reenable power failure processing, reset the system variable $POWERFL to true (power failure processing enabled).

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Table 5.2 J1Axis Stroke Upper and Lower Limits (Changing A Stroke) Position of each stroke end 180_ (*1) 165_ (standard value) 145_ 125_ 105_ 85_ 65_ 45_ 25_ + 5_ 5_
(Stroke lower limit) $PARAM_GROUP. $LOWERLIMS 180 165 145 125 105 85 65 45 25 5 5 25 45 65 85 105 125 145 165 180 (Stroke upper limit) $PARAM_GROUP. $UPPERLIMS

+ 25_ + 45_ + 65_ + 85_ +105_ +125_ +145_ +165_ (standard value) +180_ (*1) *1 "180_ is optional. (Specification: A05B1207H322)

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5.3
QUICK MASTERING

Quick mastering is a method of exact calibration at the original position when the pulse coder battery backup is disconnected, such as when a cable is replaced. Quick mastering cannot be used when the mechanical phase of the pulse coder is changed, such as when a motor or reducer is replaced. In such a case, perform mastering using jigs as described in Section 5.5.

1) Mastering procedure (for cable replacement)

a) Before replacing the cable, note down the mastering data for the system variable $DMR_GRP.$MASTER_COUN[1][6] (previous mastering data). b) Replace the cable. c) To release the brake control, set the system variable $PARAM_GROUP.$SV_OFF_ENB to FALSE for all axes, then perform a cold start. (See Section 5.2(2).) d) Upon powerup, 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 release key to release the message. f) Move all the axes, by joint feed, to position each axis to the zero degree mark with an accuracy of "1 mm relative to the arrow mark. (See Fig. 5.3.) g) Assign the mastering data (noted in step a) for the system variable $DMR_GRP.$MASTER_COUN[1][6] to the system variable for the quick mastering data, $DMR_GRP. $REF_COUN[1][6]. Then, enter 0 as the system variable for the quick mastering reference position data, $DMR_GRP. $REF_POS[1][6]. Next, set the quick mastering completion flag $DMR_GRP.$REF_DONE to TRUE. This completes the setting of the quick mastering reference position at the zero degree position for each axis. h) Press the screen selection key to display the menu. Then, select SYSTEM. From the system menu, select Master/Cal. If the calibration screen is not displayed, set the system variable $MASTER_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/Cal from the system calibration menu and pressing function key F4 (YES). k) If brake control has been released, reset the system variable $PARAM_GROUP.$SV_OFF_ENB to the previous value for all axes, then perform a cold start. l) Finally, as a safeguard against mastering data being rewritten by an operation error, note down the mastering data for the system variable $DMR_GRP.$MASTER_COUN.

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J5axis

J4axis J6axis J4axis J3axis J2axis

J1axis

Fig.5.3 Zero degree position arrow mark for each axis (ARC Mate 100/S6)

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5.4
MASTERING USING ZERO DEGREE POSITION
1) Procedure (Mastering of zero degree position)

Each of the robots axes is fitted with arrow marks shown in Fig. 5.3. The axis is at the zero degree position if these marks match. If such a mark is not at its correct position, it can be mastered as follows. This operation allows you to roughly master the position. Accurate mastering requires the operation using the mastering jig described in the 5.5 section.

a) To release the brake control, set system variable $PARAM_GRP.$SV_OFF_ENB for each axis to FALSE, turn off the power, and perform a cold start. [See 5.2 2)] b) When a BZAL alarm is output upon powerup, set the system variable $MCR.$SPC_RESET to true, then perform a cold start. c) If the message Pulse not established appears when the power is turned on, rotate each axis through about 10_ in the positive (+) or negative () direction by joint feed. Then, press the alarm release key to release the message. d) Move all axes by joint feed to position each axis to the zero degree mark. (See Fig. 5.3.) e) Press the screen selection key to display the menu. Then, select SYSTEM. From the system menu, select Master/Cal. If the calibration screen is not displayed, set the system variable $MASTER_ENBL to 1. f) Select 2 ZERO 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 in the system variable $DMR_GRP. $MASTER_COUN, and the system variable $DMR_GRP. $MASTER_DONE (mastering completion flag) is set to true. g) Teaching and playback are enabled by selecting 6 Master/Cal from the system calibration menu and pressing function key F4 (YES). h) If brake control has been released, reset the system variable $PARAM_GRP.$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 by an operation error, note down the mastering data for the system variable $DMR_GRP.$MASTER_COUN. Furthermore, draw arrow marks for zero position calibration with the zero degree position attitude, as shown in Fig. 5.3. To perform mastering for one axis only, perform singleaxis mastering as described below. The new position data is thus stored only for the target axis, and previous position data is stored for the other axes. The J2- and J3-axes must be mastered simultaneously because they rotate together.

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2) Procedure (singleaxis mastering)

a) To release brake control, set the system variable $PARAM_GROUP.$SV_OFF_ENB to FALSE for all axes, then perform a cold start. (See Section 5.2 2).) b) When a BZAL alarm is output upon powerup, set the system variable $MCR.$SPC_RESET to true, then perform a cold start. c) If the message Pulse not established appears when the power is turned on, rotate each axis through about 10_ in the positive (+) or negative () direction by joint feed. Then, press the alarm release key to release the message. d) Move the desired axis by joint feed to position the axis to the zero degree mark. (See Fig. 5.3.) e) Press the screen selection key to display the menu. Then, select SYSTEM. From the system menu, select Master/Cal. If the calibration screen is not displayed, set the system variable $MASTER_ENBL to 1. f) Select 3 SINGLEAXIS MASTER from the system calibration menu. Then, the menu for setting each axis appears. Enter 1 in the (SEL) column of the axis for which mastering is to be performed, 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 selected axis only. g) Teaching and playback are enabled by selecting 6 Master/Cal from the system calibration menu and pressing function key F4 (YES). h) If brake control has been released, reset the system variable $PARAM_GRP.$SV_OFF_ENB to its previous value for all axes, then perform cold start. i) Finally, to safeguard against mastering data being overwritten by an operation error, note down the mastering data for the system variable $DMR_GRP.$MASTER_COUN. Furthermore, draw arrow marks for zero position calibration with the zero degree position attitude, as shown in Fig. 5.3.

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5.5
MASTERING USING JIG

If the present value stored via the APC (Absolute Pulse Coder) and the actual position of each axis are misaligned after a major component of the robots mechanical unit has been replaced, mastering is to be carried out to set the robots 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: D Make the robots base level. (1 mm/base) D Remove the wrist hand and related parts. D Do not allow an external force to be applied to the robot. NOTE
The axis stroke is not checked during mastering. Sufficient care shoud, therefore, be taken regarding the robots axis movement.

Assembling the mastering jig

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

Mastering jig C A2907207X953

M6X12 (4PCS) Washer M6 (4PCS)

Mastering jig B A2907207X952

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

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2 Mounting on robots body Mount the mastering jig B on the J1-axis base using bolts and pins as shown in Fig 5.5 (b).
J1 base A2907207X201

Pin A2907111X906

M8X20 (2PCS) Pin A2907111X906 Fig.5.5. (b) Mounting on robots body (ARC Mate100/S-6)

3 Mounting jig on wrist Position the wrist axis such that J4 = J5 = J6 = 0_ in manual mode. As shown in Fig. 5.5(c), mount mastering jig A onto the J6axis so that the cubic section (weight) directls upward. NOTE When using the optional FANUC flange adaptor, first mount the flange adaptor, and fit the mastering jig onto the adaptor. (Mastering jig A differs from other mastering jigs in shape.)

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Pin A2907022X965

Mastering jig A (For ISO) A2907207X951 Mastering jig A2 (For FANUC) A2907207X956 M6X61(4PCS)

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

Mastering procedure

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, and perform a cold start. [See 5.2 2)] 3 Set the system variable $DMR_GRP.$MASTER_DONE (mastering completion flag) to FALSE to enable each axis to move beyond its maximum stroke. While performing joint feed, bear in mind that the robot can move beyond its maximum stroke. Therefore, operate the robot with a smaller teach feedrate override. 4 Using joint feed, move the robot until mastering jig A, mounted onto the wrist axis, is positioned within mastering jig B mounted on the J1 base, as shown in Fig. 5.5(d). The corresponding attitude of the robot is shown in Fig. 5.5(e).

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Mastering jig D A2907207X954

M6X12 (2pcs)

Mastering jig E A2907207X955 M6X12 (4 pcs) Fig. 5.5(d) Assembling Mastering Jigs (ARC Mate 100/56)

Mastering attitude J1 = 0_ J2 = 85_ J3 = 155_ J4 = 0_ J5 = 25_ J6 =0_

ISO flange

Mastering Jig Specification: A05B1207J052

Mastering attitude J1 = 0_ J2 = 83.485_ J3 = 152.993_ J4 = 0_ J5 = 27.007_ J6 =0_

Flange adaptor (optional)

Mastering Jig Specification: A05B1207J053

Fig. 5.5(e) Mastering Attitude (ARC Mate 100/S6)

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5 Mount mastering jig D and mastering jig E onto mastering jig B, as shown in Fig. 5.5(d). It is absolutely essential that this step be performed to prevent the arm from falling when the brake is released. 6 Press and turn the emergency stop button on the teach pendant to release the lock. The power is disconnected from the motor. Do not press the alarm release key. 7 [For RJ 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 brakes on all axes. [For RJ2 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] to TORQUE=[OFF]. Press the RESET key to release the torque on all axes. (It is equal condition to release the brakes) 8 Install three M8 bolts as shown in Fig. 5.5(f). While tightening the bolts, push mastering jig A, mounted on the wrist, until its opposite surface is butted against the wall. 9 Check, by viewing through the window, that each of the three surfaces is completely butted against the wall, as shown in Fig. 5.5(g). If not all of the surfaces are fully butted against the walls, loosen the M8 bolts, and perform step 7 again. 10 Press the screen selection key to display the menu. Then, select SYSTEM. From the system menu, select Master/Cal. If the calibration 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 in the system variable $DMR_ GRP.$MASTER_COUN, and the system variable $DMR_ GRP.$MASTER_DONE (mastering completion flag) is set to TRUE. 12 Teaching and playback are enabled by selecting 6 Master/Cal from the system calibration menu and pressing function key F4 (YES). 13 Press the screen selection key to display the menu. Then select the SYSTEM. 14 [For RJ controller] From the system menu, select Brake Cntrl. Press function key F, then select function key SHIFT + F2 (ENG_ALL) to control the brakes of all axes. [For RJ2 controller] From the system menu, press the function key F1 (MENU), select Master/Cal. Press SHIFT + F4 (TORQUE), change the indication from TORQUE=[OFF] to TORQUE=[ON]. Press the RESET key to control the torque of all axes.

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15 Remove the mastering jig D and E, then release the mastering jig A from the mastering jig B with the joint feed. Remove the mastering jig 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 all axes, then perform cold start. (See Section 5.2 2).) 18 Finally, to safeguard against mastering data being overwritten by an operation 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 the mastering data of the system variable $DMR_GROUP. $MASTER_COUN, then perform mastering for all axes. Once this mastering has been completed, reenter the mastering data for all axes except the desired axis. Thus, the new position information for the desired axis only is stored; the previous position information for the other axes is preserved.

Fig. 5.5(f) Butting Mastering Jig (ARC Mate 100/S6)

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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/S6)

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5.6
CONFIRMING MASTERING

1) Confirming whether mastering is normally done When turing on the power, the position matching is automatically done. To confirm whether this operation has normally finished, check whether the present position display coincides with the robot actual position using one of the following methods. a) Move the axes to 0_ by repeat operation, and visually check the zero degree marks. (Its 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 are described below. a) BZAL alarm This alarm occurs when the voltage of the pulse coder back-up battery drops to zero while the controller power is turned off. If this alarm occurs, perform mastering because the data in the counter is lost. b) BLAL alarm This alarm indicates that the voltage of the pulse coder back-up battery has become tool low to back up the pulse coder. If this alarm occurs, replace the back-up battery with the system turned on, and check if the present position data is correct according to the procedure described in Item 1) above. c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL alarms When any of these alarms occur, contact the service engineer. The motor may need to be replaced.

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5.7
ADJUSTING J5-AXIS SPUR GEAR BACKLASH

Adjusting J5axis spur gear backlash (For S motor) If the backlash of the J5axis exceeds the maximum allowable value (output axis angle of 3 to 6 minutes), backlash adjustment can be made by following the procedure below. (See Fig. 5.7(a)) 1 2 Position the robot to the attitude, J4 = +90_ and J5 = J6 = 0_. Remove the eight M4X8 fixing bolts, then remove the J5axis gear box cover (A2907207X502) from the J3 arm (A2907207X402).
Gear 2 assembly A2907207V501 M4X12 (4 pcs) (Loctite 262) Washer M4 (4 pcs) Gear 3 assembly A2907207V502 J3 arm A2907207X402

Gear J54 A2907207X514

Eccentric punch mark (for reduced back lash) Turn to adjust backlash.

M4X10 (6 pcs) M4X8 (8 pcs) (Loctite 262) (Loctite 262) M4 Washer (6 pcs) M4 Washer (8 pcs) Packing A2907207X524 Cover A2907207X502

Fig. 5.7(a) J5axis gear backlash adjustment (ARC Mate 100/S6)

Backlash adjustment of the gear 3 assembly and gear J54

Loosen the four M4X12 bolts to disengage the gear 2 assembly (A2907207V501) from the gear 3 assembly (A2907207 V502). Remove the six M4X10 bolts. The rotation center axis and gear center axis of the gear 3 assembly are not aligned. For this reason, by changing the phase between the gear 3 assembly and the J3 arm (with M4X10 bolts used for fixing at 6 of 19 equally spaced positions along the circumference), the backlash of the gear 3 assembly and gear J54 can be adjusted. To reduce the backlash, change the mounting phase of the gear 3 assembly, then secure the gear 3 assembly to the J3 arm using six M4X10 bolts. While turning the gear 3 assembly and checking the operation of the J5axis within the stroke (140_ to +140_ ), repeat step 4 to reduce the backlash until there is no interference between the gears.

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5. ADJUSTING

Backlash adjustment of the gear 2 and gear 3 assemblies

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.

While turning the gear 2 assembly and checking the operation of the J5axis within the stroke (140_ to +140_ ), repeat step 6 to reduce the backlash until there is no interference between the gears. 8 Check that the backlash of the J5axis does not exceed the allowable value (output axis angle of 6 minutes) indicated in Table 4.1(b). If the allowable value is exceeded, return to step 3 . 9 Secure the gear box cover of the J5axis to the J3 arm using eight M4X8 bolts. Also, renew the packing (A2907207X524) to prevent grease leakage. 10 Fill the J5axis gear box with the specified type of grease, according to the grease replacement procedure described in Section 3.2. 11 Perform mastering according to Sections 5.4 or 5.5.

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Adjusting J5axis spur gear backlash (For motor)

If the backlash of the J5axis exceeds the maximum allowable value (output axis angle of 3 to 6 minutes), backlash adjustment can be made by following the procedure below. (See Fig. 5.7(b)) 1 2 Position the robot to the attitude, J4 = +90_ and J5 = J6 = 0_. Remove the eight M4X8 fixing bolts, then remove the J5axis gear box cover (A2907207X502) from the J3 arm (A2907207X402).
M5X12 (4 pcs) Gear 2 assembly (Loctite 262) A2907208V501 Washer M5 (4 pcs) Plain washer M5 (4pcs) Gear 3 assembly A2907208V502 M4X10 (10 pcs) (Loctite 262) Washer M5(10pcs) Gear J55 A2907208X515 Springpin 5 10 (1pcs) M4X12 (8 pcs) Washer M4 (8 pcs) Packing A2907208X524 Cover A2907208X502
Turn to adjust backlash.

J3 arm A2907208X402

Fig. 5.7(b) J5axis gear backlash adjustment (ARC Mate 100/S6)

Backlash adjustment of the gear 3 assembly and gear J54

Loosen the four M5X12 bolts to disengage the gear 2 assembly (A2907208V501) from the gear 3 assembly (A2907208 V502). Remove the ten M5X12 bolts. Rotating the gear 3 assembly clockwise or counterclockwise around the spring pin (5X10) adjusts the backlash between the gear 3 assembly and gear J55. Adjust the gear 3 assembly to minimize the backlash, then remount it to the J3 arm with the ten M5X12 bolts. While turning the gear 3 assembly and checking the operation of the J5axis within the stroke (140_ to +140_ ), repeat step 4 to reduce the backlash until there is no interference between the gears.

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5. ADJUSTING

Backlash adjustment of the gear 2 and gear 3 assemblies

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 M5X12 bolts. 7 While turning the gear 2 assembly and checking the operation of the J5axis within the stroke (140_ to +140_ ), repeat step 6 to reduce the backlash until there is no interference between the gears. 8 Check that the backlash of the J5axis does not exceed the allowable value (output axis angle of 6 minutes) indicated in Table 4.1(b). If the allowable value is exceeded, return to step 3 . 9 Secure the gear box cover of the J5axis to the J3 arm using eight M4X8 bolts. Also, renew the packing (A2907208X524) to prevent grease leakage. 10 Fill the J5axis gear box with the specified type of grease, according to the grease replacement procedure described in Section 3.2. 11 Perform mastering according to Sections 5.4 or 5.5.

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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 Motor J1, J2, and J3axis reducer J4 and J6-axis reducer J5 axis gear box Adjustment item (a) Mastering (a) Mastering (b) Dog adjustment (*option) (a) Mastering (a) Mastering

NOTE Be careful when removing and installing the following heavy parts.

Parts J2 ArmWrist unit (see Fig. 6.3 (a)) J3 Arm (see Fig. 6.7 (a)) J2 BASE (see Fig. 6.1)

Weight (approx.) 44 kg 20 kg 22 kg

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6.1
REPLACING J1 AND J2-AXIS MOTOR M1 M2
1) Replacing the J1axis motor M1 (Fig.6.1)

1 2 3 4 5 6

8 9

Turn off the control unit. Remove the connector from the J1axis motor. Remove the four M8X20 motor mounting bolts, then remove the motor from the J2 base. Remove the M10 hexagonal nut from the motor shaft, then pull out the gear (A2907207X211). Mount the gear onto a new motor. Install an M10 spring washer, then apply Loctite 262 to the M10 screw of the motor. Then, tighten the M10 nut to the specified torque [12.0 Nm (122 kgfcm)]. Check that the Oring is installed correctly where the motor mounts on the J2 base (A2907207X301). Then, secure the motor to the J2 base using four M8X20 bolts. Apply Loctite 262 to the bolts. Fill the J1axis grease bath with the specified type of grease, as detailed in Section 3.2. Perform mastering as explained in Chapter 5.

NOTE When performing this procedure, ensure that the J1axis does not rotate. When the J1axis is allowed to rotate because of the robot is installed on a slanted plane, prevent its rotation by, for example, pushing the J1axis up against its mechanical stopper.
2) Replacing the J2axis motor M2 (Fig.6.1)

To prevent its rotation, fix the J2axis by, for example, pushing it up against its mechanical stopper. 2 Turn off the control unit. 3 Remove the connector from the J2axis 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 (A2907207X311). 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 specified torque [12.0 Nm (122 kgfcm)]. 8 Check that the Oring is installed correctly where the mounts on the J2 base (A2907207X301). Then, secure the motor to the J2 base using four M8X20 bolts. Apply Loctite 262 to the bolt threads. 9 Fill the J2axis grease bath with the specified type of grease, as detailed in Section 3.2. 10 Perform mastering according to Chapter 5.

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J1axis motor M8X20 (4 pcs) Loctite 262 Washer M8 (4 pcs)

M1

Gear A2907207X211 Hexagonal nut M10 Oring Loctite 262 12.0 Nm (122 kgfcm) Spring washer M10 Hexagonal nut M10 Loctite 262 12.0 Nm (122 kgfcm) Spring washer M10 Oring Gear A2907207X311

J2 base A2907207X301

M8X20 (4 pcs) Loctite 262 J2axis motor Washer M8 (4 pcs)

M2

Fig.6.1 Replacing J1, J2axis motor (ARC Mate100/S6)

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6.2
REPLACING THE J1-AXIS REDUCER

1 2 3 4 5 6 7 8

Turn off the control unit. Pull out the cables, running through the pipe of the J1axis reducer, toward the J1axis connector box as explained in Section 8.2. Remove the J1axis motor from the J2 base as explained in Section 6.1. Remove the eight M8X50 bolts securing the J2 base to the J1axis reducer, as shown in Fig. 6.2(a). Using a crane, slowly lift the J2 base as explained in Section 5.1 of the part explaining connection. Remove the Oring (large), bearing, and center gear as shown in Fig. 6.2(b). Remove the six M12X80 bolts securing the J1axis reducer to the J1 base (A2907207X201), then remove the reducer. Remove the four M4X10 bolts securing the pipe (A2907207X221) to the reducer, then remove the pipe according to Fig. 6.2(c). Check that the Oring is installed correctly on the pipe. Then, secure the pipe to a new reducer using four M4X10 bolts. Apply Loctite 262 to the bolt threads. Mount an Oring (medium) and Oring (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 kgfcm). Apply Loctite 262 to the bolt threads. Mount the center gear, bearing (with Loctite RC75 applied to its external ring), and Oring (large) on the reducer. Secure the J2 base to the reducer using eight M8X50 bolts, tightening them to a torque of 37.2 Nm (380 kgfcm). Apply Loctite 262 to the bolt threads. Be careful not to damage the oil seal surface with the pipe. Mount the J1axis motor onto the J2 base as explained in Section 6.1. Fill the J1axis grease bath with the specified type of grease as detailed in Section 3.2. Perform mastering as explained in Chapter 5.

10

11 12

13 14 15

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M8X50 (8 pcs) Loctite 262 37.2 Nm (380 kgfcm) Washer M8 (8 pcs) Cable cover 2 A2907207X336

M4X10 (4 pcs) Loctite 262 Clamp A2907207X340 M6X16 (2 pcs) Washer M4 (2 pcs) Clamp A2907207X340 M4X10 Loctite 262

Clamp A2907207X340 M6X16 (2 pcs) Washer M4 (2 pcs) Clamp Cable cover 2 A2907207X340 A2907207X336 Cable cover 3 A2907207X337

Fig.6.2 (a) Replacing J1axis reducer (ARC Mate100/S6)

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Oring (Large) Bearing Loctite RC75 (External ring) J1 reducer center gear M12X80 (6 pcs) Loctite 262 128.4 Nm (1310 kgfcm) Washer M12 (6 pcs) J1axis reducer

Oring (medium) Oring (small)

J1 base A2907207X201

Fig.6.2 (b) Replacing J1axis reducer (ARC Mate100/S6)

J1axis reducer

Oring

Pipe A2907207X221 M4X10 (4 pcs) Loctite 262 Washer M4 (4 pcs)

Fig.6.2 (c) Replacing J1axis reducer (ARC Mate100/S6)

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6.3
REPLACING THE J2-AXIS REDUCER

1 2 3 4 5 6 7 8

To prevent its rotation, fix the J2axis by, for example, pushing it up against its mechanical stopper. Turn off the control unit. Pull out the cables, running through the pipe of the J2axis reducer, from the J2 arm toward the J2 base as explained in Section 8.2. Remove the J2axis motor from the J2 base as explained in Section 6.1. Remove the six M10X50 bolts and three M10X20 bolts securing the J2 arm to the J2axis reducer as shown in Fig. 6.3(a). Using a crane, lift the J2 base and the upper portion, then slowly pull the J2 arm out sideways. Remove the seven M8X75 bolts securing the J2axis reducer to the J2 base (A2907207X301), then remove the reducer. Remove the four M4X10 bolts securing the pipe (A2907207 X221) to the reducer, then remove the pipe as shown in Fig. 6.3(b). Check that the Oring is installed correctly on the pipe. Then, secure the pipe to a new reducer using four M4X10 bolts. Apply Loctite 262 to the bolt threads. Mount the bearing (with Loctite RC75 applied to its external ring) and Oring on the reducer. Mount the Oring on the reducer. Then, secure the reducer to the J2 base using seven M8X75 bolts, tightening them to a torque of 37.2 Nm (380 kgfcm). Apply Loctite 262 to the bolt threads. Be careful not to damage the oil seal surface with the pipe. Secure the J2 arm to the reducer using six M10X50 bolts and three M10X20 bolts, tightening them to a torque of 73.5 Nm (750 kgfcm). Apply Loctite 262 to the bolt threads. Mount the J2axis motor to the J2 base as explained in Section 6.1. Fill the J2axis grease bath with the specified type of grease, as detailed in Section 3.2. Perform mastering as explained in Chapter 5.

10 11

12

13 14 15

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J2 ArmWrist unit

Bearing Loctite RC75 (External ring) Oring

J2 base A2907207X302 J2axis reducer

M10X50 (6 pcs) N10X20 (3 pcs) Loctite 262 73.5 Nm (750 kgfcm) Washer M10 (9 pcs) M8X75 (7 pcs) Loctite 262 37.2 Nm (380 kgfcm) Washer M8 (7 pcs)

J2 base A2907207X301

Fig.6.3 (a) Replacing J2axis reducer (ARC Mate100/S6)

M4X10 (4 pcs) Loctite 262 Washer M4 (4 pcs) Pipe A2907207X221 Oring J2axis reducer

Fig.6.3 (b) Replacing J2axis reducer (ARC Mate100/S6)

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6.4
REPLACING THE J3-AXIS MOTOR M3

1 2 3

To prevent its rotation, fix the J3axis by, for example, pushing it up against its mechanical stopper. Turn off the control unit. Remove the three M6X8 button bolts and two M4X16 bolts, then remove the J3 cover (A2907207X403) from the J3 housing, as shown in Fig. 6.4(a). Disconnect the cable from the J3axis motor. Remove the four M6X16 seal bolts holding the J3axis motor to the J3 housing, then remove the motor and its packing. Remove the Ering from the motor shaft, then remove the input gear and draw bolt. Apply Loctite 683 to the screw on a new motor, then tighten the draw bolt to a torque of 2.9 Nm (30 kgfcm). Mount the input gear onto the motor shaft, then secure it with the Ering. From the J3 arm side, insert an assembly jig (A05B1207J054) into the J3axis reducer, as shown in Fig. 6.4(b). Mount a new packing (A98L00400042#03), then insert the motor into the reducer. Check, through the window, that the input gear is correctly engaged with the reducer gear. If the gear engagement is out of line, even by as little as one tooth, vibration can occur. Ensure that the motor is inserted correctly. Secure the motor to the J3axis reducer using four new seal bolts (A97L01180706#M6X16). To prevent grease leakage, new packing and seal bolts must be used. Attach the cable to the J3axis motor. Fill the J3axis grease bath with the specified type of grease as detailed in Section 3.2. Mount the J3 cover onto the J3 housing using three M6X8 button bolts and three M4X16 bolts. Perform mastering as explained in Chapter 5.
Button bolt M6X8 (3 pcs) Plain washer M6 (3 pcs) M4X16 (2 pcs) Washer M4 (2 pcs) J3 housing A2907207X401 (S motor) A2907207Y401 ( motor)

4 5 6 7 8 9 10

11

12 13 14 15

J3 Cover A2907207X403

Draw bolt Loctite 683 2.9 Nm (30 kgfcm) Packing Seal bolt (4 pcs) Washer M6 (4 pcs)

J3axis motor
M3

Input gear

Ering

Fig.6.4 (a) Replacing J3axis motor (ARC Mate100/S6)

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J3axis motor
M3

J3reducer assembly jig Specification: A05B1207J054 Input gear Window

J2arm A2907207X302 Gear of reducer Fig.6.4 (b) Replacing J3axis motor (ARC Mate100/S6)

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6.5
REPLACING J3-AXIS REDUCER

1 2 3

To prevent its rotation, fix the J3axis by, for example, pushing it up against its mechanical stopper. Turn off the control unit. Remove the three M6X8 button bolts and three M4X16 bolts, then remove the J3 cover (A2907207X403) from the J3 housing, as shown in Fig. 6.4 (a). Disconnect the cable from the J3axis motor. Remove the J3axis motor as explained in Section 6.4. Remove the two f8X25 taper pins securing the J2 arm to the J3axis reducer, as shown in Fig. 6.5. Using a crane, lift the J3 arm. Then, remove the four M8X65 bolts securing the J2 arm to the J3axis reducer, then remove the J3axis reducer from the J2 arm. Remove the ten M6X30 bolts securing the J3axis reducer to the J3 housing, then remove the reducer. Secure a new reducer to the J3 housing using ten M6X30 bolts, tightening them to a torque of 15.7 Nm (160 kgfcm). Apply Loctite 262 to the bolt threads. Using a crane, lift the J3 arm. Then, secure the J2 arm to the reducer using four M8X65 bolts (to which Loctite 262 has been applied) tightened to a torque of 37.2 Nm (380 kgfcm), and two f8X25 taper pins (with Loctite 242 applied to the taper holes). Mount the J3axis motor as explained in Section 6.4. Attach the cable to the J3axis motor. Fill the J3axis grease bath with the specified type of grease, as detailed in Section 3.2. Mount the J3 cover onto the J3 housing using three M6X8 button bolts and three M4X16 bolts. Perform mastering as explained in Chapter 5.

4 5 6 7

8 9

10

11 12 13 14 15

J3 housing A2907207X401 (S motor) A2907207Y401 (motor) Oring (Large)

M6X30 (10 pcs) Taper pins f8X25 Loctite 262 Loctite 242 15.7 Nm (160 kgfcm) Washer M6 (10 pcs) Oring (Small) J3axis reducer

M8X65 (4 pcs) Loctite 262 37.2 Nm (380 kgfcm) Washer M8 (4 pcs) J2 arm A2907207X301

Fig.6.5 Replacing J3axis reducer (ARC Mate100/S6)

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6.6
REPLACING J4-AXIS MOTOR M4

Replacing J4axis motor (For S motor) 1 Move the robot to the attitude of J4 = 0_ . Maintain this attitude until step 12. (mastering). Note that the cable may break if this zero degree position is not maintained.

Turn off the control unit. Remove the three M6X8 button bolts and three M4X16 bolts, then remove the J3 cover (A2907207X403) from the J3 housing, as shown in Fig. 6.4 (a). 4 Disconnect the cable from the J4axis motor. 5 Remove the four M4X12 bolts securing the J4axis motor to the J3 housing (A2907207X401), then remove the motor as shown in Fig. 6.6 (a). 6 Remove the M3X12 bolt securing the gear (A2907207X411) 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 kgfcm). Apply Loctite 242 to the bolt threads. 8 Check that the Oring is installed correctly, then secure the motor to the J3 housing using four M4X12 bolts. Apply Loctite 262 to the bolt threads. 9 Attach the cable connector to the J4axis motor. 10 Fill the J4axis grease bath with the specified type of grease, as detailed in Section 3.1. 11 Mount the J3 cover onto the J3 housing using three M6X8 button bolts and three M4X16 bolts. 12 Perform mastering as explained in Chapter 5.
M4X12 (4 pcs) Loctite 262 Washer M4 (4 pcs) Oring J4axis motor
M4

2 3

J3housing A2907207X401

Gear A2907207X411 Washer A2907207X425 M3X12 Loctite 242 2.0 Nm (20 kgfcm) Washer M3

Fig.6.6 (a) Replacing J4axis motor (ARC Mate100/S6) S motor specifications

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Replacing J4axis motor (For motor) 1 Move the robot to the attitude of J4 = 0_ . Maintain this attitude until step 12. (mastering). Note that the cable may break if this zero degree position is not maintained.

Turn off the control unit. Remove the three M6X8 button bolts and three M4X16 bolts, then remove the J3 cover (A2907207X403) from the J3 housing, as shown in Fig. 6.4 (a). 4 Disconnect the cable from the J4axis motor. 5 Remove the four M4X12 bolts securing the J4axis motor to the J3 housing (A2907207X401), then remove the motor as shown in Fig. 6.6 (b). 6 Remove the M3X12 bolt securing the gear (A2907207X411) 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 kgfcm). Apply Loctite 242 to the bolt threads. 8 Install a new packing, then fix the motor to the J3 housing with the four M5 12 bolts, applying loctite 262. New packing shall be used to prevent grease leakage. 9 Attach the cable connector to the J4axis motor. 10 Fill the J4axis grease bath with the specified type of grease, as detailed in Section 3.1. 11 Mount the J3 cover onto the J3 housing using three M6X8 button bolts and three M4X16 bolts. 12 Perform mastering as explained in Chapter 5.
M5X12 (4 pcs) Loctite 262 Washer M5 (4 pcs) J4axis motor
M4

2 3

J3housing A2907207Y401

Packing

Gear A2907207Y411 Washer A2907207X425 M3X12 Loctite 242 2.0 Nm (20 kgfcm) Washer M3 Fig.6.6 (b) Replacing J4axis motor (ARC Mate100/S6) motor specifications

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6.7
REPLACING THE J4AXIS REDUCER

1 2

Turn off the control unit. Remove the three M6X8 button bolts and three M4X16 bolts, then remove the J3 cover (A2907207X403) from the J3 housing, as shown in Fig. 6.4 (a). Disconnect the cables attached to the connector clamp of the J3 housing, as explained in Section 8.2. Remove the sixteen M4X35 bolts securing the J4axis reducer to the J3 housing then, while supporting the J3 arm with a crane, remove the J4axis reducer from the J3 housing, as shown in Fig. 6.7(a). Remove the cables, disconnected in step 3 , and the wrist cables from the J3 housing. Remove the fifteen M4X35 bolts securing the J4axis reducer to the J3 arm, then remove the J4axis reducer from the J3 arm as shown in Fig. 6.7(b). Remove the two bearings and spacer (A2907207X424) from the reducer. Remove the six M3X8 bolts securing the gear (A2907207X412) to the reducer, then remove the gear from the reducer. Secure the gear to a new reducer using six M3X8 bolts, tightened to a torque of 2.0 Nm (20 kgfcm). Apply Loctite 242 to the bolt threads. Apply Loctite RC75 to the external rings of the two bearings then mount the gear, together with the spacer, to the reducer. Check that the Oring (medium) and Oring (small) are installed correctly. Then, mount the reducer to the J3 arm using fifteen M4X35 bolts, tightened to a torque of 4.6 Nm (47 kgfcm). Apply Loctite 262 to the bolt threads. Run the wrist cable connectors through the J3 housing, then check that the Oring (big) is installed correctly. Then, secure the J3 arm to the J3 housing using fifteen M4X35 bolts, tightened to a torque of 4.6 Nm (47 kgfcm). Apply Loctite 262 to the bolt threads. Connect the wrist cables running through the pipe of the J4axis reducer as explained in Section 8.2. Fill the J4axis grease bath with the specified type of grease, as detailed in Section 3.1. Mount the J3 cover onto the J3 housing using three M6X8 button bolts and three M4X16 bolts. Perform mastering as explained in Chapter 5.

3 4

5 6

7 8

10 11

12

13 14 15 16

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Oring (Large) J4axis reducer J3arm A2907207X402 (S motor) A2907208X402 ( motor)

M4X35 (16 pcs) Loctite 262 4.6 Nm (47 kgfcm) Washer M4 (16 pcs) J3 housing A2907207X401 (S motor) A2907207Y401( motor) Fig.6.7 (a) Replacing J4axis reducer (ARC Mate100/S6)

Bearing (2 pcs) Loctite RC75 (External ring)

M3X8 (6 pcs) Loctite 262 2.0 Nm (20 kgfcm) Washer M3 (6 pcs) Gear A2907207X412 Oring (Medium) Oring (Small)

M4X35 (15 pcs) Loctite 262 4.6 Nm (47 kgfcm) Washer M4 (15 pcs) J4 Reducer Spacer A2907207X424 J3 arm A2907207X402 (S motor) A2907208X402 ( motor) Fig.6.7 (b) Replacing J4axis reducer (ARC Mate100/S6)

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6.8
REPLACING J5-AXIS MOTOR M5

Replacing J5axis motor (For S motor) 1 2 3 Move the robot to the attitude of J4 = 90_ .

Turn off the control unit. Remove the six M6X15 bolts, then turn the cover (A2907207X503) around the J5axis until the J5axis motor can be lifted out, as shown in Fig. 6.8 (a). 4 Disconnect the cable from the J5axis motor. 5 Remove the four M4X12 bolts securing the J5axis motor to the J3 arm, then remove the motor and packing from the J3 arm. 6 Remove the M3X12 bolt securing the gear (A2907207X511) 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 kgfcm). Apply Loctite 242 to the bolt threads. 8 Install a new packing (A2907601X522), then secure the motor to the J3 arm using four M4X12 bolts. Apply Loctite 262 to the bolt threads. To prevent grease leakage, use a new packing. 9 Connect the J5axis 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 prevent grease leakage. 11 Fill the J5axis grease bath with the specified type of grease, as detailed in Section 3.2. 12 Perform mastering as explained in Chapter 5.
M4X12 (4 pcs) Gear A2907207X511 Loctite 262 Washer Washer M4 (4 pcs) A2907207X425 M3X12 Loctite 242 2.0 Nm (20 kgfcm) Washer M3

J5axis motor Packing A2907601X552 M6X15 (6 pcs) Loctite 262 Washer M6 (6 pcs) Cover A2907207X503 Packing A2907207X525

J3 arm A2907207X402

Fig.6.8(a)

Replacing J5axis motor for S motor specifications (ARC Mate100/S6)

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Replacing J5axis motor (For motor) 1 2 3 Move the robot to the attitude of J4 = 90_ .

Turn off the control unit. Remove the six M6X16 bolts,and remove packing (A2907208X525) then turn the cover (A2907207X503) around the J5axis until the J5axis motor can be lifted out, as shown in Fig. 6.8 (b). 4 Disconnect the cable from the J5axis motor. 5 Remove the four M5X12 bolts securing the J5axis motor to the J3 arm, then remove the motor from the J3 arm. 6 Remove the M3X12 bolt securing the gear (A2907208X511) 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 kgfcm). Apply Loctite 242 to the bolt threads. 8 Check that the Oring is correctly inserted, then fix the motor to the J3 arm with the four M5X12 bolts, applying loctite 262. 9 Connect the J5axis 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 prevent grease leakage. 11 Fill the J5axis grease bath with the specified type of grease, as detailed in Section 3.2. 12 Perform mastering as explained in Chapter 5.

Washer A2907207X425 M3X12 Loctite 242 2.0 Nm (20kgfcm) Washer M3

Gear A2907208X511

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

J5axis motor M5 Cring Oring Bearing

J3 arm A2907208X402

M6X16(6pcs) Loctite 262 Washer M6(6pcs) Cover A2907208X503 Packing A2907208X525

Fig.6.8(b)

Replacing J5axis motor for motor specifications (ARC Mate100/S6)

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6.9
REPLACING THE J5AXIS GEAR

Replacing J5axis gear (For S motor ) To replace the input gear (A2907207X511) of the J5axis motor, 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 (A2907207X502), and packing (A2907207X524), 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 (A2907207X514), then remove the gear 3 assembly and gear from the J3 arm. By pulling 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 (these must be fitted together). Secure the gear, together with the J6 housing, to the J3 arm using eight M5X20 bolts tightened to a torque of 9.0 Nm (92 kgfcm). Apply Loctite 262 to the bolt threads. Secure the gear 3 assembly to the J3 arm using six M4X10 bolts tightened to a torque of 4.6 Nm (47 kgfcm), as explained 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 kgfcm), as explained in Section 5.7. Apply Loctite 262 to the bolt threads. 9 Upon completion of backlash adjustment, as explained in Section 5.7, install a new packing, then secure the cover to the J3 arm using eight M4X8 bolts. To prevent grease leakage, use a new packing. 10 Fill the J5axis grease bath with the specified type of grease, as detailed in Section 3.2. 11 Perform mastering as explained in Chapter 5.
Gear 2 assembley A2907207V501 M4X12 (4 pcs) Loctite 262 4.6 Nm (47 kgfcm) Washer M4 (4 pcs) Gear 3 assembly A2907207V502 J3 arm A2907207X402

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

Cover A2907207X502

Gear A2907207X514 M5X20 (8 pcs) Loctite 262 M4X10 (6 pcs) 9.0 Nm (92 kgfcm) Loctite 262 Washer M5 (8 pcs) 4.6 Nm (47 kgfcm) Washer M4 (6 pcs) Packing A2907207X524

Fig.6.9(a) Replacing J5 gear for S motor specifications (ARC Mate100/S6)

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Replacing J5axis gear (For motor ) To replace the input gear (A2907207X511) of the J5axis motor, 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 (A2907208X502), and packing (A2907208X524), 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 (A2907208X515), then remove the gear 3 assembly and gear from the J3 arm. By pulling 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 (these must be fitted together). Secure the gear, together with the J6 housing (A2907208X501) to the J3 arm using ten M6X30 bolts tightened to a torque of 15.7 Nm (160 kgfcm). Apply Loctite 262 to the bolt threads. Secure the gear 3 assembly to the J3 arm using ten M5X12 bolts tightened to a torque of 9.0 Nm (92 kgfcm), as explained in Section 5.7. Apply Loctite 262 to the bolt threads. 8 Secure the gear 2 assembly to the J3 arm using four M5X12 bolts, tightened to a torque of 9.0 Nm (92 kgfcm), as explained in Section 5.7. Apply Loctite 262 to the bolt threads. 9 Upon completion of backlash adjustment, as explained in Section 5.7, install a new packing, then secure the cover to the J3 arm using eight M4X12 bolts. To prevent grease leakage, use a new packing. 10 Fill the J5axis grease bath with the specified type of grease, as detailed in Section 3.2. 11 Perform mastering as explained in Chapter 5.
M5X12 (4 pcs) Loctite 262 9.0 Nm (92 kgfcm) Washer M5 (4 pcs) Plain washer M5 (4pcs) Gear 2 assembly A2907208V501 J3 arm A2907207X402

Gear 3 assembly A2907208V502 M5X12 (10 pcs) Loctite 262 9.0 Nm (92 kgfcm) Washer M5 (10 pcs)

GearJ55 A2907208X515 M6X30 (10pcs) Spring pin 5 10 (1pcs) Loctite 262 15.7 Nm (160 kgfcm) Packing Washer M6 (10 pcs) A2907207X524 Cover A2907207X502

M4X12 (8 pcs) Washer M4 (8 pcs)

Fig.6.9(b) Replacing J5 gear for motor specifications (ARC Mate100/S6)

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6.10
REPLACING J6-AXIS MOTOR M6 , REDUCER
1) Replacing the J6axis motor M6 and reducer (For S motor)

Replacing the J6axis motor 1 2 Turn off the control unit. Remove the four M5X20 bolts and two f5X20 spring pins, then remove the J6axis reducer from the J6 housing (A2907207 X501) as shown in Fig. 6.10(a). 3 Disconnect the cable running through the sheet (A2907207 X529), as shown in Fig. 8.2(g1). 4 Remove the four M4X12 bolts, then remove the motor from the J6axis reducer (harmonic drive), as shown in Fig. 6.10(b). 5 Remove the M3X8 bolt, then remove the reducer wave generator from the motor. 6 Secure the wave generator to the shaft of a new motor, using an M3X8 bolt tightened to a torque of 2.0 Nm (20 kgfcm). Apply Loctite 242 to the bolt threads. 7 Mount a new packing, then fix the motor to the reducer with the four M5X12 bolts, applying loctite 262. New packing shall be used to prevent grease leakage. 8 Reconnect the motor cable, then secure it to the sheet. 9 Check that the Oring is correctly inserted. Fix the reducer and motor to the J6 housing with the four M5X20 bolts (with a tightening torque of 9.0 Nm (92kgfcm)), applying loctite 262, and two f5X20 spring pins. 10 Fill the J6axis grease bath with the specified grease, as detailed in Section 3.2. 11 Perform mastering as explained in Chapter 5. Replacing the J6axis reducer 1 2 Turn off the control unit. Remove the four M5X20 bolts and two f5X20 spring pins, then remove the J6axis reducer from the J6 housing (A2907207 X501) as shown in Fig. 6.10(a). Remove the four M4X12 bolts, then remove the motor from the J6axis reducer (harmonic drive) as shown in Fig. 6.10(b). Remove the M3X8 bolt, then remove the reducer wave generator from the motor. Secure a new wave generator to the shaft of the motor, using an M3X8 bolt tightened to a torque of 2.0 Nm (20 kgfcm). Apply Loctite 242 to the bolt threads. Check that the Oring is installed correctly, then secure the motor to the reducer using four M4X12 bolts. Apply Loctite 262 to the bolt threads. Fix the reducer and motor to the J6 housing with the four M5 X 20 bolts (with a tightening torque of 9.0 Nm (92kgfcm)), applying loctite 262, and two f5 X 20 spring pins. Fill the J6axis grease bath with the specified grease, as detailed in Section 3.2. Perform mastering as explained in Chapter 5.

3 4 5

8 9

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J6 housing A2907207X501

J6axis motor Apply sealing agent to the hatched portion.

M6

M5X20 (4 pcs) Loctite 262 9.0 Nm (92 kgfcm) Washer M5 (4 pcs)

Spring pin f5X20 (2 pcs) Fig.6.10 (a) Replacing J6axis motor and reducer for S motor specifications (ARC Mate100/S6)

M4X12 (4 pcs) Loctite 262 Washer M4 (4 pcs) M3X8 Loctite 242 2.0 Nm (20 kgfcm) Washer M3

J6axis motor
M6

Oring Wave generator J6axis reducer

Fig.6.10 (b) Replacing J6axis motor and reducer for S motor specifications (ARC Mate100/S6)

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2) Replacing the J6axis motor M6 and reducer (For motor)

Replacing the J6axis motor 1 2 Turn off the control unit. Remove the four M5X20 bolts and two f5X20 spring pins, then remove the J6axis reducer from the J6 housing (A2907208 X501) as shown in Fig. 6.10(c). 3 Disconnect the cable running through the sheet (A2907208 X529), as shown in Fig. 8.2(g2). 4 Remove the four M5X12 bolts, then remove the motor from the J6axis reducer (harmonic drive), as shown in Fig. 6.10(d). 5 Remove the M3X8 bolt, then remove the reducer wave generator from the motor. 6 Secure the wave generator to the shaft of a new motor, using an M3X8 bolt tightened to a torque of 2.0 Nm (20 kgfcm). Apply Loctite 242 to the bolt threads. 7 Mount a new packing, then fix the motor to the reducer with the four M5X12 bolts, applying loctite 262. New packing shall be used to prevent grease leakage. 8 Reconnect the motor cable, then secure it to the sheet. 9 Check that the Oring is correctly inserted. Fix the reducer and motor to the J6 housing with the four M5X20 bolts (with a tightening torque of 9.0 Nm (92 kgfcm)), applying loctite 262, and two 5X20 spring pins. 10 Fill the J6axis grease bath with the specified grease, as detailed in Section 3.2. 11 Perform mastering as explained in Chapter 5. Replacing the J6axis reducer 1 2 Turn off the control unit. Remove the four M5X20 bolts and two f5X20 spring pins, then remove the J6axis reducer from the J6 housing (A2907208 X501) as shown in Fig. 6.10 (c). Remove the four M5X12 bolts, then remove the motor from the J6axis reducer (harmonic drive) as shown in Fig. 6.10 (d). Remove the M3X8 bolt, then remove the reducer wave generator from the motor. Secure a new wave generator to the shaft of the motor, using an M3X8 bolt tightened to a torque of 2.0 Nm (20 kgfcm). Apply Loctite 242 to the bolt threads. Install new packing, then secure the motor to the reducer using four M5X12 bolts. Apply Loctite 262 to the bolt threads. Confirm that Oring is positioned correctly and secure the reducer with the motor covered by J6 housing using four M5X20 bolts (Loctite 262 applied and tight torque 9.0 Nm (92 kgfcm)) and two spring pins f5X20. Fill the J6axis grease bath with the specified grease, as detailed in Section 3.2. Perform mastering as explained in Chapter 5.

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6 7

8 9

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J6 housing A2907208X501

J6 axis motor M6 M5X20 (4pcs) Loctite 262 9.0 Nm (92 kgfcm) washer M5 (4pcs)

O ring Spring pin f5X20(2pcs) Fig.6.10 (c) Replacing J6axis motor and reducer for motor specifications (ARC Mate100/S6)

M5X12(4pcs) loctite 262 washer M5(4pcs) M3X8 Loctite 242 2.0 Nm (20kgfcm) washer M3 J6axis motor Packing M6 Wave generator Washer A2907208X532 J6axis reducer

Fig.6.10 (d) Replacing J6axis motor and reducer for motor specifications (ARC Mate100/S6)

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6.11
RELEASING BRAKE

It is possible to release a brake when the robot power is down, using The brake release unit (option). Then it is possible to change the robot posture which you want. Please observe NOTE 13. NOTE 1. 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. Dont release plural brake at the same time.

Fig.6.11 Releasing brake

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PIPING AND WIRING

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7.1
PIPING

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

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

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7.2
WIRING DIAGRAM

Wiring diagram of S motor specifications Wiring diagram of mechanical unit which is S motor specifications for 2axis brake type is shown in Fig. 7.2 (a). Wiring diagram of mechanical unit which is S motor specifications for allaxis brake type is shown in Fig. 7.2 (b).

Controller

Mechanical unit J1axis motor J2axis motor J3axis motor

K108 J1axis connector panel MI

K104 (#J2) K105 (#J1)

K105 (#J2)

J4axis motor

K101

J5axis motor

PI

Batteries

(or K112) K102

J6axis motor

GND K106 Air Panel union female PT3/8

K107

K112:24 pin K102:5 pin End effector (OT Option) Panel union female PT3/8

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

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Controller

Mechanical unit J1axis motor J2axis motor J3axis motor

K108 J1axis connector panel MI

K104 (#J2) K105 (#J1)

K105 (#J2)

J4axis motor

K101

J5axis motor

PI

K103 Batteries (or K112) K102 K107 J6axis motor K112:24 pin K102:5 pin End effector (OT Option) Panel union female PT3/8

GND K106 Panel union female PT3/8 Air

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

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Wiring diagram of motor specifications Wiring diagram of mechanical unit which is motor specifications for 2axis brake type is shown in Fig. 7.2 (c), (d) Wiring diagram of mechanical unit which is motor specifications for allaxis brake type is shown in Fig. 7.2 (e).

Fig.7.2 (c) Mechanical unit wiring diagram for 2axis brake type (ARC Mate100/S6) motor specifications <Cable assy specification that this figure is applied to> A05B1207H251 A05B1207H252 A05B1207H254 A05B1207H272 A05B1207H274 A05B1207H753 A05B1207H754

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Fig.7.2 (d) Mechanical unit wiring diagram for 2axis brake type (ARC Mate100/S6) motor specifications <Cable assy specification that this figure is applied to> A05B1207H253

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Fig.7.2 (e) Mechanical unit wiring diagram for allaxis brake type (ARC Mate100/S6) motor specifications <Cable assy specification that this figure is applied to> A05B1207H651 A05B1207H652 A05B1207H672 A05B1207H751 A05B1207H752 A05B1207H761

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Fig. 7.2(e) shows wiring diagram for the MIG EYE cable (A05B1207H921) Fig. 7.2(f) shows wiring diagram for the MIG EYE cable (A05B1207H922) Fig. 7.2(g) shows wiring diagram for the user cable (A05B1207H931)
Controller

Mechanical unit

SEN

K136

K132

Panel union PT3/8 female (for cooling)

Air kit

Air

Pre-unit

Fig.7.2 (e) Wiring diagram for the MIG EYE cable (A05B1207H921)

Controller SEN

Mechanical unit

K132 K131 J7P J7M Panel union PT3/8 female (for cooling) Air kit Air K134 K133 K135 Pre-unit

Fig.7.2 (f) Wiring diagram for the MIG EYE cable (A05B1207H922)

Controller for EE

Mechanical unit

K142 EE

Panel union PT3/8 female (for cooling)

Air 2

Panel union PT3/8 female (for cooling)

Fig.7.2 (g) Wiring diagram for the User cable (A05B1207H931)

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7.3
LIMIT SWITCH INSTALLATION DIAGRAM (OPTION)

Fig. 7.3. shows the installation diagram for the limit switches. Option specification (330_ OT): A05B1207H312 Option specification (360_ OT): A05B1207H322

J3axis OT limit switch cable K123 SQ3 Cable K107 J2axis OT limit switch cable K122 SQ2

J1axis OT limit switch cable K121 SQ1

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

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7.4
CABLE INSTALLATION DIAGRAM

Visually check the following: 1) Check whether connecting cables in the robots rotational part are distorted or bent by the robot rotation. 2) Check whether the routing of the cables connected to the J2 and J3 axes is distorted or bent by the elbow motion. 3) Check whether the routing of the cables connected to the end effector is suitable to the wrist motion or the service motion of the robot. Fig. 7.4 (a) shows installation diagram for the cables in the mechanical unit which is S motor specifications. Fig.7.4 (b) shows installation diagram for the cables in the mechanical unit which is motor specifications. Fig. 7.4 (c) shows installation diagram for the cables in the mechanical unit which is CE specifications. When the MIG EYE cable (A05B1207H921) is specified, cable K132 and K136 are added. When the MIG EYE cable (A05B1207H922) is specified, cable K131 to K135 are added. When the User cable (A05B1207H931) is specified, cable K142 is added. 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

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K114 [K104 (#J2)] [K230 (#J2)] K205 (#J2) [K105 (#J2)]

K108

K105 (#J1) [K205 (#J1)] K104 (#J1) [K108 (#J1)] [K230 (#J1)] or K118 [K208]

K103 [K203] With MIG EYE A05B1207H922 (A05B1207H921)

Ground cable

K135 K133 K132 (K132) K131 K134 K101 [K201] (K136) K102 (K112) [K212] (K142 When order the user cable) : A05B1207H931

Fig.7.4(b) Mechanical unit cable installation diagram (ARC Mate100/S-6) motor specifications <Cable assy specification that this figure is applied to> A05B1207H251 A05B1207H252 A05B1207H253 A05B1207H254 A05B1207H261 A05B1207H263 A05B1207H272 A05B1207H274 A05B1207H651 A05B1207H652 A05B1207H661 A05B1207H672

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K205 K214

K108

K103 K105 (#J1) K204 or K208

K101 K102 (K112) (K142 When order the user cable) : A05B1207H931

Fig.7.4(c) Mechanical unit cable installation diagram (ARC Mate100/S-6) motor specifications [CE specifications] <Cable assy specification that this figure is applied to> A05B1207H751 A05B1207H752 A05B1207H753 A05B1207H754 A05B1207H761

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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 motor 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.

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8.1
CABLE CLAMPING

When mounting the replaced cables with clamps and tie wraps, clamp it at 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 be broken 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]

J1axis connector panel

[K203]

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

Stamp Cable clamping positions
Stamp Cable No.

M1M1 M2M1 M3M

RMI
M4M M5M1 M6M1 OT M1P1 M2P1

RP1

M3P M4P

M5P1

M6P1

J1axis connector panel

EE

M5M1 M6M1 M5P1 M6P1

M5M M5P M6M2 M6P2

J1OT

OT
J2OT

J3OT

M6M2 M6P2

M6M M6P

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Table 8.1(b) Cable clamping positions (ARC Mate100/S-6) ( motor specifications) [A05B1207H253 is specified]
Stamp Cable clamping positions
Stamp Cable No.

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Table 8.1 (c) Extention cable clamping positions (ARC Mate 100)
Stamp

Cable clamping positions

Stamp Cable No.

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8.2
REPLACING CABLES
1) Replacing cables K101 and K102 (K112) for S motor specifications

2 3

8 9 10 11 12 13

14 15

16

Remove the J3axis cover (A2907207X403) and clamp (A2907207X422) from the J3 housing as shown in Fig. 8.2(a1) and Fig. 8.2(b1). Remove the connector cap from the end effector (EE), then remove the EE connector from the EE plate. Remove the cable K103 relay connector from the connector clamp (A2907207X423), then remove the K101 and K102 (K112) connectors from the connector clamp. Remove the cable cover (A2907207X334), then cut the nylon bands of the connector clamp and clamp (A2907207X421). Then, pull out the cables from the J3 housing (A2907207 X401). Remove the arm cover (A2907207X331) and cover (A2907207X330) from the J2 arm as shown in Fig. 8.2(b1) and Fig. 8.2(c). Cut the nylon bands of the clamp (A2907207X332) and support 22 (A2907207X329), then pull out the cables from the J2 arm (A2907207X302). Remove the two clamps (A2907207X340), clamp 12 (A2907207X323), and clamp 21 (A2907207X325) as shown in Fig. 8.2(d). Remove cable cover 1 (A2907207X335), cable cover 2 (A2907207X336), and cable cover 3 (A2907207X337). Cut the nylon bands, then pull out the cables, one by one, from the inside of the J2axis reducer. Disconnect the cables connected in cable cover 2, as shown in Fig. 8.2(f). Remove the J1axis connector box from the J1 base, as shown in Fig. 8.2(e). Remove clamp 11 (A2907207X224) from the J1axis connector box. Cut the nylon bands of support 11 (A2907207X223), then pull out the cables, one by one, from the inside of the J1axis reducer toward the J1axis connector box. Remove the cables from the J1axis connector box. Install new cables by reversing the procedure above.Ensure that the cables are neither too tight nor too slack. Refer to the cable clamp positions, indicated by the marking tapes, as shown in Fig. 8.2(a1) through Fig. 8.2(f). Perform quick mastering as explained in Section 5.3.

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2) Replacing cables K101 and K102 (K112) for motor specifications

2 3

8 9 10 11 12 13

14 15

16

Remove the J3axis cover (A2907207X403) and clamp (A2907207X422) from the J3 housing as shown in Fig. 8.2(a2) and Fig. 8.2(b2). Remove the connector cap from the end effector (EE), then remove the EE connector from the EE plate. Remove the cable K103 relay connector from the connector clamp (A2907207X447), then remove the K101 and K102 (K112) connectors from the connector clamp. Remove the cable cover (A2907207X334), then cut the nylon bands of the connector clamp and clamp (A2907207X421). Then, pull out the cables from the J3 housing (A2907207 X401). Remove the arm cover (A2907207X331) and cover (A2907207X330) from the J2 arm as shown in Fig. 8.2(b2) and Fig. 8.2(c). Cut the nylon bands of the clamp (A2907207X332) and support 22 (A2907207X329), then pull out the cables from the J2 arm (A2907207X302). Remove the two clamps (A2907207X340), clamp 12 (A2907207X323), and clamp 21 (A2907207X325) as shown in Fig. 8.2(d). Remove cable cover 1 (A2907207X335), cable cover 2 (A2907207X336), and cable cover 3 (A2907207X337). Cut the nylon bands, then pull out the cables, one by one, from the inside of the J2axis reducer. Disconnect the cables connected in cable cover 2, as shown in Fig. 8.2(f). Remove the J1axis connector box from the J1 base, as shown in Fig. 8.2(e). Remove clamp 11 (A2907207X224) from the J1axis connector box. Cut the nylon bands of support 11 (A2907207X223), then pull out the cables, one by one, from the inside of the J1axis reducer toward the J1axis connector box. Remove the cables from the J1axis connector box. Install new cables by reversing the procedure above.Ensure that the cables are neither too tight nor too slack. Refer to the cable clamp positions, indicated by the marking tapes, as shown in Fig. 8.2(a2) through Fig. 8.2(f). Perform quick mastering as explained in Section 5.3.

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J3 housing

Nylon band

Connector clamp

Marking tape

M4X16 (2 pcs) Washer M4 (2 pcs) Cable cover 2907207X334 Nylon band J2 arm A2907207X302 Clamp A2907207X332 Button bolt M6X8 (3 pcs) Plain washer M6 (3 pcs) J3 cover A2907207X403

Arm cover

Button bolt M8X10 (4 pcs)

Fig.8.2 (a1) Replacing cable K101, K102 (K112) (ARC Mate100/S6) S motor specifications

Connector clamp A2907207X423 Clamp A2907207X421 Clamp A2907207X422 Button bolt M6X10 (2 pcs) Washer M6 (2 pcs) EE connector M3X5 (4 pcs) Button bolt M6X8 (2 pcs)

J3 housing A2907207X401

M4X16 (2 pcs) Washer (2 pcs) Connector cap EE plate A2907207X426 (or X427) Button bolt M6X8 (3 pcs) Plain washer M6 (3 pcs) J3 cover A2907207X403

J2 arm A2907207X302

Button bolt M8X10 (4 pcs) Arm cover A2907207X331 Fig.8.2 (b1) Replacing cable K101, K102 (K112) (ARC Mate100/S6) S motor specifications

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Fig.8.2 (a2) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S6) motor specifications

Connector clamp A2907207X447 Clamp A2907207X421 Clamp A2907207X422

J3 housing A2907207Y401

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

EE connector M3X5(4pcs) Button bolt M6X8(2pcs) M4X16(2pcs) washer M4(2pcs) Connector cap EE plate A2907207X426(orX427) Button bolt (4pcs) Arm cover A2907207X331 Fig.8.2 (b2) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S6) motor specifications Button bolt M6X8 (3pcs) plain washer M6 (3pcs) J3 cover A2907207X403

J2 arm A2907207X302

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Fig. 8.2 (c) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S6)

Cable cover 1 A2907207X335 M8X50 (8 pcs) (Loctite 262) Washer M8 (8 pcs)

M4X10 (Loctite 262) Clamp A2907207X340 M16X16 (2 pcs) Washer M4 (2 pcs) Clamp 12 A2907207X323 M4X10 (Loctite 262)

Clamp A2907207X340 M6X16 (2 pcs) Washer M4 (2 pcs) Clamp Cable cover 2 A2907207X325 A2907207X336 Cable cover 3 A2907207X337

Fig.8.2 (d) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S6)

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Fig.8.2 (e) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S6)

DETAIL A

Nylon band

Fig.8.2 (f) Replacing cable K101, K102 (K112) (K212) (ARC Mate100/S6)

NOTE If cable assy spec. is A05B1207H253, there are no relay connectors in DETAIL A.

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

1 2 3 4 5

Remove clamp 12, clamp 21, and cable cover 2 as shown in Fig. 8.2(d). Cut the nylon bands, then disconnect the J1M (M1M1) and J1P (M1P1) relay connectors as shown in Fig. 8.2(f). Remove the J1axis motor connectors, then pull out the cables. Install new cables by reversing the procedure above. Perform quick mastering as explained in Section 5.3.

4) Replacing cables K104(#J2), K204 (#J2), K105(#J2), K205 (#J2) K230 (#J2), K114, K205, K214

1 2 3 4 5

Remove clamp 12, clamp 21, and cable cover 2 as shown in Fig. 8.2(d). Cut the nylon bands, then disconnect the J2M (M2M1) and J2P (M2P1) relay connectors as shown in Fig. 8.2(f). Remove the J2axis motor connectors, then pull out the cables. Install new cables by reversing the procedure above. Perform quick mastering as explained in Section 5.3.

5) Replacing cables K103 for S motor specifications

Remove the J3axis cover (A2907207X403) from the J3 housing, as shown in Fig. 6.4(a). 2 Remove the cable K103 relay connector from the connector clamp (A2907207X423), as shown in Fig. 8.2(a1). 3 Cut the nylon bands of the connector clamp. 4 Remove the J52 cover from the J3 arm. 5 Remove the J5axis motor cable from clamp J5 (A2907207 X526), then pull out cable K103 from the J3 arm. 6 Remove clamp J61 (A2907207X527) from the J52 cover (A2907207X503), then cut the nylon bands securing the cable. 7 Pull out the J6axis motor as explained in Section 6.10. Remove the cable running through the sheet (A2907207X529), then pull out cable K103 from the J6 housing. 8 Pull out cable K103 from the J52 cover. 9 Install a new K103 cable by reversing the procedure above. The assembly of the J6axis reducer is explained in Section 6.10. Ensure that the cables are neither too tight nor too slack. Refer to the cable clamp positions, indicated by the marking tapes, as shown in Fig. 8.2(g1). Use new packing (A2907207X525). 10 Perform quick mastering as explained in Section 5.3.

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Details of assembly X529 Nylon band Damp J5 A2907207X526 Support A2907207X530 M5X20 (2 pcs) Washer M5 (2 pcs) Packing A2907207X525 Clamp A2907207X527 J3arm A2907207X402

Sheet A2907207X529 M5X20 (4 pcs) (Loctite 262) Washer M5 (4 pcs) M4X6 (2 pcs) Ring Washer (2 pcs) A2907207X521 Spring pin f5X20 (2 pcs) M4X6 (1 pcs) Clamp (loctite 262) A2907207X528 Washer M4 (1 pcs)

J5cover A2907207X503 Support 2 A2907207X531

M6X15 (6 pcs) Washer (6 pcs)

Nylon band Nylon band Nylon band

Marking tape

Details of assembly X526 Details of assembly X527 and X528

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

6) Replacing cables K103 for motor specifications

1 2 3 4

Remove the J3axis cover (A2907207X403) from the J3 housing, as shown in Fig. 6.4(a). Remove the cable K103 relay connector from the connector clamp (A2907207X447), as shown in Fig. 8.2(a2). Remove the J52 cover from the J3 arm. Refer to Fig. 8.2 (g2). Remove the J5axis motor cable and relay connector of J6 M and J6 P from clamp J5 (A2907208 X526), then pull out cable K103 from the J3 arm. Install a new K103 cable by reversing the procedure above. Ensure that the cables are neither too tight nor too slack. Refer to the cable clamp positions, indicated by the marking tapes, as shown in Fig. 8.2(g2). Use new packing (A2907208X525).
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6
7) Replacing cables K108 for motor specifications

Perform quick mastering as explained in Section 5.3. Remove the J52 cover from the J3 arm according to Fig. 8.2 (g2). Disconnect the M6M and M6P intermediate connectors from the J5 clamp (A2907208X526), then out the nylon band at the clamp. Remove the J52 cover (A2907208X503) from the J61 clamp (A2907208X527), then cut the nylon band holding the cable. Pull out the J6axis motor as explained in Section 6.10. Disconnect the cable from the sheet (A2907208X529). Remove the J62 clamp (A2907208X528) from the J6 housing, then cut the nylon band holding the cable. Pull out cable K108 from the J6 housing, then pull it out from the J52 cover. Connect a new cable by reversing the above procedure. Section 6.10 explains how to mount the J6axis reducer. When connecting the cable, ensure that the cable is neither loose nor stretched by checking the cable clamp positions, indicated with marking tape as shown in Fig. 8.2 (g2). The packing (A2907208X525) shall be replaced with a new one. Perform simplified mastering according to Section 5.3.

1 2

5 6

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Details of assembly X529

Nylon band

Clamp J5 A2907208X526

J3 arm A2907208X402 M5X20(2pcs) Washer M5(2pcs) Packing A2907208X525 M4X6 (2pcs) Washer M4 (2pcs) Clamp J61 A2907208X527

Sheet A2907208X529 Spring pin 5X20 (2pcs)

Ring A2907208X521 M4X8(1pcs) M6X16 (6pcs) Washer Washer M6 (6pcs) Clamp J62 M4(1pcs) A2907208X528 J52 cover A2907208X503 M5X20(4pcs) Support (loctite 262) A2907208X530 Washer M5(4pcs)

Nylon band

Marking tape

Marking tape Details of assembly X527 and X528

Nylon band

Details of assembly X526

Fig.8.2 (g2) Replacing cable K101, K102 (K112) (ARC Mate 100/S6) motor specifications

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8) Replacing additional cables

When the MIG EYE cable (A05B1207H921) is specified, cable K132 and K136 are added. Refer to the cable clamp positions, indicated by the marking tapes, as shown in Fig. 8.2 (h1) and Fig. 8.2 (h2). When the MIG EYE cable (A05B1207H922) is specified, cable K131 to K135 are added. Refer to the cable clamp positions, indicated by the marking tapes, as shown in Fig. 8.2 (i1) and Fig. 8.2 (i2). When the User cable (A05B1207H931) is specified, cable K142 is added. Refer to the cable clamp positions, indicated by the marking tapes, as shown in Fig. 8.2 (j1) and Fig. 8.2 (j2).

Fig. 8.2 (h1) Replacing the MIG EYE cable (A05B1207H921) (ARC Mate 100)

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Fig. 8.2 (h2) Replacing the MIG EYE cable (A05B1207H921) (ARC Mate 100)

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Fig. 8.2 (i1) Replacing the MIG EYE cable (A05B1207H922) (ARC Mate 100)

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Fig. 8.2 (i2) Replacing the MIG EYE cable (A05B1207H922) (ARC Mate 100)

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Fig. 8.2 (j1) Replacing the USER cable (A05B1207H931) (ARC Mate 100)

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Fig. 8.2 (j2) Replacing the USER cable (A05B1207H931) (ARC Mate 100)

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8.3
REPLACING LIMIT SWITCH (OPTION)
1) J1axis OT limit switch (A05B1207D103)
SQ1

1 2 3 4 5

Remove the LS box (A2907207X326) from the J2 base (A2907207X301) as shown in Fig. 8.3(a). Remove the J1axis OT limit switch (A05B1207D103) from the LS box. Mount the new limit switch, reversing the above procedure. Check that the limit switch operates accurately at the overtravel position. Check that the limit switch does not operate within the J1-axis motion range.

J2 base A2907207X301

Plate A2907201X347 LS box A2907207X326 Limit switch (with cable) A05B1207D103 SQ1 M6X10 (2 pcs) Plain washer M6 (2 pcs) Washer M6 (2 pcs) M4X25 (2 pcs) Nut lock 1401 Plain washer M4 (2 pcs) Washer M4 (2 pcs)

Fig.8.3 (a) Replacing J1-axis limit switch (ARC Mate100/S-6)

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2) J2axis OT limit switch (A05B1207D104)

SQ2

2 3 4 5

Remove the cover (A2907207X330) and support 22 (A290 7207X329) from the J2 arm (A2907207X302) as shown in Fig. 8.2(b) and Fig. 8.2(d). Remove the J2axis OT limit switch (A05B1207D104) from support 22. Mount the new limit switch reversing the above procedure. Check that the limit switch operates accurately at the overtravel position. Check that the limit switch does not operate within the J2-axis motion range.

Support A2907207X329 M6X10 (2 pcs) Nut lock 1401 Plain washer M6 (2 pcs) Washer M6 (2 pcs) Nylon band

Cover A2907207X330 Button bolt M8X10 (6 pcs) Washer M8 (6 pcs) J2 arm A2907207X302

M4X25 (2 pcs) Washer M4 (2 pcs) Limit switch (with cable) A05B1207D104

SQ2

Fig.8.3 (b) Replacing J2axis limit switch (ARC Mate100/S6)

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3) J3axis OT limit switch (A05B1207D105)

SQ3

2 3 4 5

Remove the arm cover (A2907207X331) and clamp (A2907207X332) from the J2 arm (A2907207X302) by referring to Figs. 8.2 (c) and 8.2 (d). Remove the J3axis limit switch (A05B1207D105) from the clamp. Mount the new limit switch, reversing the above procedure. Check that the limit switch operates accurately at the overtravel position. Check that the limit switch does not operate within the J3axis motion range.

M4X25 (2 pcs) Nut lock 1401 Plain washer M4 (2 pcs) Washer M4 (2 pcs)

Limit switch (with cable) A05B1207D105 SQ3 Plate A2907201X347

M6X10 (2 pcs) Plain washer M6 (2 pcs) Washer M6 (2 pcs) Clamp A2907207X332

M4X16 (2 pcs) Washer M4 (2 pcs) Nylon band Button bolt M6X8 (3 pcs) Plain washer M6 (3 pcs) J3 cover A2907207X403 J2 arm A2907207X302

Arm cover A2907207X331

Button bolt M8X10 (4 pcs)

Fig.8.3 (c) Replacing J3axis limit switch (ARC Mate100/S6)

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Limit switch relay cable

Nylon band

Fig.8.3 (d) Replacing J2 and J3axis limit switch (ARC Mate100/S6)

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9. OPTIONS

OPTIONS

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9.1
COVER OPTION (SPECIFICATION: A05B1207J401)

Fig. 9.1 shows how to assemble the cover option. (Assembly) 1 Secure the support (A2907207X339) to the J2 base (A2907207X301) using four M6X10 bolts. 2 Secure the J2 cover (A2907207X338) to the support using six M6X10 button bolts. To remove the cover, reverse the assembly procedure above.

M6X10 button bolt (6 pcs)

J2 cover A2907207X338

When the cover option is specified Specification: A05B1207J401 Support A2907207X339

M6X10 (4 pcs) M6 washer (4 pcs) Fig. 9.1 Cover Option (ARC Mate 100/S6)

J2 base A2907207X301

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1. ROBOT INTERFERENCE AREA

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 interfere with the motion of robot body. For installation, use the 4-18 hole on the base. (See 3.2) Fig. 1 (c) and (d1),(d2),(d3) shows the robot operational diagram.
Motion range of J5axis center

J5axis center

COVER (OPTION) Interference of the rear of the J3axis

Fig.1 (a1) Mechanical unit external dimensions (ARC Mate100/S-6) S motor specifications

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FANUC flange with adaptor Motion range of J5axis center

Interference of the rear of the J3axis J5axis center

Wilthout cover option

Fig.1 (a2) Mechanical unit external dimensions (ARC Mate100/S-6) motor specifications

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FANUC flange with adaptor

Motion range of J5axis center Interference of the rear of the J3axis J5axis center

Cover option

Fig.1 (a3) Mechanical unit external dimensions (ARC Mate100/S-6) motor specifications

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Interference area of the rear of J3axis

Motion range of J3axis center

Motion range of J5axis center

Fig.1 (b) Mechanical unit external dimensions (ARC Mate100/S-6)

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1. ROBOT INTERFERENCE AREA

Fig.1 (c) Operational diagram (ARC Mate100/S-6)

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Fig.1 (d1) Operational diagram (ARC Mate100/S-6) S motor specifications

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1. ROBOT INTERFERENCE AREA

*Without motor cover (A05B1207J401) Fig.1 (d2) Operational diagram (ARC Mate100/S-6) motor specifications

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*With cover option (A05B1207J401) Fig.1 (d3) Operational diagram (ARC Mate100/S-6) motor specifications

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EQUIPMENT MOUNTING TO ROBOT

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2.1 END EFFECTOR MOUNTING FACE TO WRIST

ISO flange type (standard)

Fig. 2.1(a) shows the end effector mounting face at the tip of the wrist. Fit the end effector by using the f50H7 rabbet or the f25H7 rabbet, then position the end effector by using the 4f6H8 reamed holes. Use the 4M6 tapped holes to secure the end effector. Use M6 bolts of a length that does not exceed the depth (10 mm) of the tapped holes.
ISO Flange 4M6 depth 10 equally spaced on circumference f 40

4f6H8+0.08 depth 10 0 equally spaced on circum ference f40 Fig. 2.1(a) Mounting Surface for End Effector of ISO Flange Type (ARC Mate 100/S6)

FANUC flange adaptor(option)

Fig. 2.1(b) shows the end effector mounting face at the tip of the wrist used when the FANUC flange adaptor (option specification: A05B1207J001) is being used. Fit the end effector by using the f32H8 rabbet or the f60H7 rabbet, then position the end effector by using the 4f6H8 reamed holes. Use the 4M6 tapped holes to secure the end effector. Use M6 bolts of a length that does not exceed the depth (8 mm) of the tapped holes.
FANUC Flange Adaptor

4M6 depth 8 equally spaced on circumference f 50 4f6H8+0.08 depth 8 0 equally spaced on circum ference f50 Fig. 2.1(b) Mounting Surface for End Effector when the FANUC Flange Adaptor is Used (ARC Mate 100/S6)

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2.2
EQUIPMENT MOUNTING FACE

There are four mounting faces of the equipment for the floor mount type robot as shown in Fig. 2.2 (a), and four for the upside-down mount type robot. NOTE 1. When equipment is mounted on equipment mounting face A, B, C, and D, its center of gravity must be within the hatched areas shown in Fig. 2.2(b). 2. The masses of the equipment fitted to the equipment mounting faces must satisfy all the requirements below. 1) 2) 3) W+A v 6 (kg) v 18 (kg) v 45 (kg)

W+A+B+C

W+A+B+C+D W: A: B: C: D: Mass Mass Mass Mass Mass of of of of of

the end effector mounting face (kg) equipment mounting face A (kg) equipment mounting face B (kg) equipment mounting face C (kg) equipment mounting face D (kg)

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Length of J2axis rotating center

88.5[S motor] 87.5[ motor]

4M6 depth 10

J3 rotating axis

Equipment mounting face B

2M8 depth 14 Rotating center of J1axis

Equipment mounting face D

240 [S motor] 243.5{ motor]

2M6 depth 8

Length of J2axis rotating center Equipment mounting A

Rotating center of J3axis

Cover interference

Rotating center of J1axis

3M6 depth 10

Equipment mounting D (Mounting cover option)

Equipment mounting C

Fig.2.2 (a) Equipment mounting face (ARC Mate100/S6)

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Equipment mounting face D Equipment mounting face B Equipment mounting face A Equipment mounting face C

88.5[S motor] 87.5[ motor]

Fig.2.2 (b) Positions of the center of gravity on the equipment mounting faces (ARC Mate 100/S6)

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2.3
LOAD CONDITIONS AT THE WRIST

Load conditions at the wrist of ARC Mate 100/S6 is described at Table2.3. The hand or the gun which is installed in the wrist is in accord with following conditions.
Table 2.3 Load conditions at the wrist (ARC Mate 100/S6) Allowable moment J4axis M4 J5axis M5 J6axis M6 Allowable inertia J4axis M4 J5axis M5 J6axis M6 1.6 (kgfm) 1.0 (kgfm) 0.5 (kgfm) 6.4 (kgfcms2) 2.0 (kgfcms2) 0.62 (kgfcms2) 15.7 (Nm) 9.8 (Nm) 4.9 (Nm) 0.63 (kgm2) 0.20 (kgm2) 0.061 (kgm2)

Center of J4axis rotation

Center of J6axis rotation

Center of J5axis rotation

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Following figure 2.3 (a) to (c) show load conditions at the wrist. Use under the range of following graphs.
Load

Distance from the J4axis to the center of gravity of the load

Fig.2.3 (a) J4axis load condition (ARC Mate 100/S6) Load

Distance from the J5axis to the center of gravity of the load

Fig.2.3 (b) J5axis load condition (ARC Mate 100/S6)

Load

Distance from the J6axis to the center of gravity of the load

Fig.2.3 (c) J6axis load condition (ARC Mate 100/S6)

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2.4
END EFFECTOR AIR PIPE

Within the robots mechanical unit, an air pipe is provided; its inlet at the J1axis connector box, and its outlet at the J3 housing. The piping route is shown in Fig. 7.1, of the part explaining maintenance. The inlet and outlet joints of the piping are of the PT3/8 female type. No mating joints are provided. It is the responsibility of the user to prepare mating joints that match tubes to be used. When the User cable (A05B1207H931) is specified, two air pipes are provided. When the MIG EYE cable (A05B1207H921, H922) is specified, the air pipe is used only for cooling.

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

The J3 housing has an end effector connector to enable connection to peripheral equipment. Fig. 2.5(a) and Fig. 2.5(b) show the pin assignment of the end effector connectors. For details, including the setting of common input signals, refer to the maintenance manual of the RJ controller. Fig. 2.5 (c) shows the pin assignments of the end effector when the User cable (A05B1207H931) is specified.

Mechanical unit (K102) EE 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 (S6)

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Fig. 2.5 (c)

Fig. 2.5 (c) shows the pin assignments of the end effector when the User cable (A05B1207H931) specified.

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TRANSPORTATION AND INSTALLATION

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3.1
TRANSPORTATION
1) Preparation prior to installation

1 2

3 4

Remove the transit stopper (red) from the J1axis. After turning on the control unit, move the J3axis, by joint feed, in the positive (+) direction until the J3axis transit stopper, shown in box 3.1(a), can be removed. Move the J2axis, by joint feed, in positive (+) direction, until the J2axis transit stopper can be removed. Remove the transit stoppers (red) from the J2axis and J3axis. This completes the preparation.

NOTE If an over travel alarm is issued in step 2 , hold down the shift key and press the alarm release key. Then, while still holding down the shift key, move the J3axis, by joint feed, in the positive (+) direction until the J3axis overtravel is released.
2) Transportation by crane

The robot is transported by lifting. Mount the components for transportation and lift it by attaching a rope to three M12 eye bolts. After installation, remove the components used for transportation and the stop. (Refer to Fig. 3.1(a)) The stops for preventing the axes from rotating during shipping are painted in red. Be sure to remove them before operating the robot.

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Crane capacity: min. 300kg

Sling capacity: min. 150 kg

Fig.3.1 (a) Transportation using a crane (ARC Mate100/S-6)

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3) Transportation by forklift

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: A05B1207J051) (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 J1axis to prevent the J1axis 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 lefthand square holes to transport the robot. 6 Remove the right and left forklift brackets. 7 Remove the transit stopper from the J1axis.
NOTE) 1. Machine weight 160kg Attitude during the shipment J1: J2: J3: J4: J5: J6: 10_ 35_ 31_ 90_ 0_ 0_

Stopper for preventing the J1axis from rotating (remove it after installation)

Forklift Forklift capacity : min. 300 kg Forklift bracket (square hole) Specification: A05B1207J051 Hexagonal bolt M10X20 (6 pcs) Plain washer M10 (6 pcs)

Fig.3.1 (b) Transportation using a folklift (ARC Mate100/S-6)

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3.2
STORAGE

When storage the robot, be sure tot change the attitude of robot to that shown in Fig. 3.1 (a).

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3.3
INSTALLATION

Fig. 3.3 (a) shows dimensions of robot base.

(Pin)

Front

J1axis rotating center

2f10H8 0 (Pinhole for positioning)

+0.022

4f18 throughhole f28 facing, depth 5 (Through hole for foundation bolt)

Fig.3.3 (a) Dimensions of robot base (ARC Mate100/S6)

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Fig. 3.3(b) shows an example of robot installation. Secure an installation plate to the floor using four M20 chemical anchors (strength class: 4.8). Then, secure the robot base to the installation plate using four M16X35 bolts (strength class: 12.9). If teaching compatibility is needed when the mechanical unit of the robot is replaced, use the two f10H8 pin holes for positioning. NOTE It is the customers responsibility to prepare positioning pins, anchor bolts, and the installation plate.

(Pin)

Front J1axis rotation center

2f10H +0.022 0 (Pin hole for positioning) Robot fixing bolts M16X35 (4 pcs) Strength class: 12.9 Tightening torque: 313.6 Nm (32 kgfm) Chemical anchor M20 (4 pcs) Strength class: 4.8 Tightening torque: 186.2Nm (19 kgfm) Installation plate

Installation plate

Robot base plate

Fig. 3.3 (b) Example Installation (ARC Mate 100/S6)

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Fig. 3.3 (c) shows the outer dimension of the BASE option (A05B1207J055). Attached bolt M16X30 (4pcs.), washer M16 (4pcs.) and spring pin 10X30 (2pcs.) are used to install the robot to the base.

Fig. 3.3 (c) Outer dimension of BASE option (A05B1207J055) (ARC Mate 100/S6)

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Fig. 3.3 (d) and table 3.3 (d) show force and movement applied to the base plate during stillness, acceleration or deceleration, and emergency stop state.

MH MV FV

FH

Fig.3.3 (d) Force and moment

Table 3.3 (d) Force and moment Condition Vertical moment Mv [kgfm] (Nm) Force in vertical direction Fv [kgf] (Nm) [205] [273] [327] (2009) (2675) (3205) Horizontal moment M [kgfm] (N) Force in horizontal direction F [kgf] (N) [ 0] ( 0)

During stillness During acceleration or deceleration During emergency stop

[ 64] [146] [214]

( 627) (1431) (2097)

0]

0)

[ 92] [122]

( 902) (1196)

[ 97] [132]

( 951) (1294)

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3.4
MAINTENANCE AREA

Fig. 3.4 (a) shows the maintenance area.

Mastering area Maintenance 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 Mastering J1=0_ J2=85_ J3=155_ J4=0_ ISO Flange Mastering jig J5=25_ J6=0_ Specification: A05B1207J052

Flange Adapter (At installation of option)

Mastering jig

Attitude of Mastering J1=0_ J2=83.485_ J3=152.993_ J4=0_ J5=27.007_ J6=0_

Specification: A05B1207J053 Fig.3.4 (b) Mastering attitude (ARC Mate100/S-6)

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3.5
ASSEMBLY DURING INSTALLATION

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 (The cables are connected to the controller.). Connect the cables shown in Fig. 3.5 to the connector box of the mechanical unit. When connecting, take care not to damage the cables.

Fig.3.5 Cable connection board of robot mechanical unit

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3.6
AIR PIPING

Fig. 3.6(a) shows the air piping of a robot. When the optional air control set is used, an air pipe for connecting the mechanical unit and air control set is also provided. To install the air control set, the customer is to prepare an air control set mounting section with tapped holes for mounting, as shown in Fig. 3.6(b).

Air control set (option) Specification: A05B1302J011

Straight joint PT3/8

Elbow PT3/8

PT3/8

To be prepared by the customer 3m air hose (Outer diameter: 10 mm, Inner diameter: 6.5 mm) 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 the specified level. Preparation of the mounting bolts is the customers responsibility.
Oil inlet Adjustment knob Oil misting check 4M6

Oiler Pressure gauge Regulator pressure setting handle 63

90

Filter

Fig.3.6 (b) Air control set (ARC Mate100/S-6)

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Fig. 3.6 (c) shows the internal piping diagram of the mechanical unit.

Panel union PT3/8 female

Panel union PT3/8 female

Fig.3.6 (c) Piping diagram (ARC Mate 100/S6)

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3.7
INSTALLATION SPECIFICATIONS
Item Type Controlled axes Reach Installation Motion range (Maximum speed) J1 axis J2 axis J3 axis J4 axis J5 axis J6 axis Max. load capacity at wrist Allowable load moment at wrist J4 axis J5 axis J6 axis Allowable load inertia at wrist J4 axis J5 axis J6 axis Drive method Repeatability Weight (Mechanical unit) Installation environment

Installation condition of the robot is shown in table 3.7.

Table3.7 Installation specifications (ARC Mate100/S-6) Specifications Articulated type 6 axes (J1, J2, J3, J4, J5, J6) 1368 mm Floor, Upsidedown (Wall & Angle mount) 5.76 rad (2.01 rad/sec) 4.19 rad (1.92 rad/sec) 5.67 rad (2.01 rad/sec) 6.63 rad (4.19 rad/sec) 4.89 rad (4.19 rad/sec) 9.43 rad (6.98 rad/sec) 6 kg 15.7 Nm 9.8 Nm 4.9 Nm 0.63 kgm2 0.20 kgm2 0.061 kgm2 "0.1 mm Approx. 160 kg Ambient temperature: 0 to 45 C Ambient 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) 1.6 kgfm 1.0 kgfm 0.5 kgfm 6.4 kgfcms2 2.0 kgfcms2 0.62 kgfcms2 330 (115/sec) 240 (110/sec) 325 (115/sec) 380 (240/sec) 280 (240/sec) 540 (400/sec) (Note 1) (Note 2)

Electric servo drive by AC servo motor

Air pressure

Pressure Consumption

0.49 0.69 MPa (Preset pressure 0.49

5.7 kg/cm2G MPa 5kg/cm2G) (Note 4)

Maximum peak: 150N/min

NOTE 1. Under the installation condition within ( ), the J1axis motion range and the max. speed will be limited. 2. J1axis 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.

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A1. SPARE PARTS LIST

A1

SPARE PARTS LIST

Cable list for S motor Specifications in mechanical unit

Table 1 (a) Cable list (ARC Mate100/S-6)

(A1) 2axis brake (RDI 1, RDO 1) Normal cable : A05B1207H201 (For S motor, RJ controller) Extension cable : A05B1207H211 (For S motor, RJ controller)
Cable K101 K102 K103 K104 K105 K105 K106 K108 Specifications A05B1207D101 A6608009T538 A6604003T183 A6604003T184#J2 A6602004T151#J1 A6602004-T151#J2 A05B1207D102 A6602004T152 Remarks J1, J2, J3, J4, J5, J6 power J1, J2, J3, J4, J5, J6 pulse coder, DI/DO J5 J6, power, pulse coder relay J2 power relay J1 pulse coder relay J1 pulse coder relay OT Short circuit J1 power relay

(B1) 2axis brake (RDI 8, RDO 8) Normal cable : A05B1207H202 (For S motor, RJ controller)
Cable K101 K102 K103 K104 K105 K105 K106 K108 Specifications A05B1203D101 A6608009T539 A6604003T183 A6604003T183#J2 A6602004T151#J1 A6602004T151#J2 A05B1207D102 A6602004T152 Remarks J1, J2, J3, J4, J5, J6 power J1, J2, J3, J4, J5, J6 pulse coder, DI/DO J5, J6 power, pulse coder relay J2 power relay J1 pulse coder relay J2 pulse coder relay OT J1 power relay

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(C1) 6axis brake (RDI 1, RDO 1) Normal cable : A05B1207H601 (For S motor, RJ controller) Extension cable : A05B1207H611 (For S motor, RJ controller)
Cable K101 K102 K103 K104 K104 K105 K105 K106 Specifications A05B1207D101 A6608009T538 A6604003T183 A6604003T184#J1 A6604003T184#J2 A6602004T151#J1 A6602004T151#J2 A05B1207D102 Remarks J1, J2, J3, J4, J5, J6 power J1, J2, J3, J4, J5, J6 pulse coder, DI/DO J5, J6 power, pulse coder relay J1 power relay J2 poer relay J1 pulse coder relay J2 pulse coder relay OT Short circuit

(D1) 6axis brake (RDI 8, RDO 8) Normal cable : A05B1207H602 (For S motor, RJ controller)
Cable K101 K102 K103 K104 K104 K105 K105 K106 Specifications A05B1207D101 A6608009T539 A6604003T183 A6604003T184#J1 A6604003T184#J2 A6602004T151#J1 A6602004T151#J2 A05B1207D102 Remarks J1, J2, J3, J4, J5, J6 power J1, J2, J3, J4, J5, J6 pulse coder, DI/DO J5, J6 power, pulse coder relay J1 power relay J2 power relay J1 pulse coder relay J2 pulse coder relay OT Short circuit

(E1) 2axis brake (RDI 8, RDO 8) Diecasting cable (option): A05B1207H222 (For S motor, RJ controller)
Cable K201 K212 K203 K208 K230 K205 K205 K106 Specifications A05B1207D201 A6608009T821 A6604003T239 A6602004T216 A6604003T240#J2 A6602004T215#J1 A6602004T215#J2 A05B1207D102 Remarks J1, J2, J3, J4, J5, J6 power J1, J2, J3, J4, J5, J6 pulse coder, DI/DO J5, J6 power, pulse coder relay J1 power relay J2 power relay J1 pulse coder relay J2 pulse coder relay OT Short circuit

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(F1) 6axis brake (RDI 8, RDO 8) Diecasting cable (option): A05B1207H622 (For S motor, RJ controller)
Cable K201 K212 K203 K230 K230 K205 K205 K106 Specifications A05B1207D201 A6608009T821 A6604003T239 A6604003T240#J1 A6604003T240#J2 A6602004T215#J1 A6602004T215#J2 A05B1207D102 Remarks J1, J2, J3, J4, J5, J6 power J1, J2, J3, J4, J5, J6 pulse coder, DI/DO J5, J6 power, pulse coder relay J1 power relay J2 power relay J1 pulse coder relay J2 pulse coder relay OT Short circuit

Cable list for a motor specifications in mechanical unit

(A2) 2axis brake (RDI 1, RDO 1) Normal cable : A05B1207H251 (For motor, RJ controller) Extension cable : A05B1207H261 (For motor, RJ controller)
Cable K101 K102 K103 K104 K105 K105 K106 K108 K108 Specifications A05B1207D106 A6608009T990 A6604003T287 A6604003T286#J2 A6602004T279#J1 A6602004T279#J2 A05B1207D102 A6602004T152 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5 M6, power, pulse coder relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M1 power relay M6 power pulse coder relay

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(B2) 2axis brake (RDI 8, RDO 8) Normal cable: A05B1207H252 (For motor, RJ controller)
Cable K101 K102 K103 K104 K105 K105 K106 K108 K108 Specifications A05B1207D106 A6608009T991 A6604003T287 A6604003T286#J2 A6602004T279#J1 A6602004T279#J2 A05B1207D102 A6602004T152 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5, M6 power, pulse coder relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT short circuit M1 power relay M6 power, pulse coder relay

(C2) 6axis brake (RDI 1, RDO 1) Normal cable : A05B1207H651 (For motor, RJ controller, RJ2 controller) Extension cable : A05B1207H661 (For motor, RJ controller, RJ2 controller)
Cable K101 K102 K103 K104 K104 K105 K105 K106 K108 Specifications A05B1207D106 A6608009T990 A6604003T287 A6604003T286#J1 A6604003T286#J2 A6602004T279#J1 A6602004T279#J2 A05B1207D102 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5, M6 power, pulse coder relay M1 power relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M6 power pulse coder relay

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(D2) 6axis brake (RDI 8, RDO 8) Normal cable : A05B1207H652 (For motor, RJ controller, RJ2 controller)
Cable K101 K102 K103 K104 K104 K105 K105 K106 K108 Specifications A05B1207D106 A6608009T991 A6604003T287 A6604003T286#J1 A6604003T286#J2 A6602004T279#J1 A6602004T279#J2 A05B1207D102 A6604003T224 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5, M6 power, pulse coder relay M1 power relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M6 power pulse coder relay

(E2) 2axis brake (RDI 8, RDO 8) Diecasting cable (option): A05B1207H272 (For motor, RJ controller)
Cable K201 K212 K203 K208 K230 K205 K205 K106 K108 Specifications A05B1207D206 A6608010T040 A6604003T289 A6602004T216 A6604003T290#J2 A6602004T290#J1 A6602004T290#J2 A05B1207D102 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5, M6 power, pulse coder relay M1 power relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M6 power, pulse coder relay

(F2) 6axis brake (RDI 8, RDO 8) Diecasting cable (option): A05B1207H672 (For motor, RJ controller, RJ2 controller)
Cable K201 K212 K203 K230 K230 K205 K205 K106 K108 Specifications A05B1207D206 A6608010T040 A6604003T289 A6604003T290#J1 A6604003T290#J2 A6602004T290#J1 A6602004T290#J2 A05B1207D102 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5, M6 power, pulse coder relay M1 power relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M6 power, pulse coder relay

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(A3) 2axis brake (RDI 1, RDO 1) Normal cable : A05B1207H253 (For motor, RJ2 controller)
Cable K101 K102 K103 K106 K108 Specifications A05B1207D108 A6608011T322 A6604003T287 A05B1207D102 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5, M6 power, pulse coder relay OT Short circuit M6 power, pulse coder relay

(B3) 2axis brake (RDI 1, RDO 1) Extension cable : A05B1207H263 (For motor, RJ2 controller)
Cable K101 K102 K103 K104 K105 K105 K106 K108 K108 Specifications A05B1207D107 A6608009T990 A6604003T287 A6604003T286#J2 A6602004T279#J1 A6602004T279#J2 A05B1207D102 A6602004T152 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5, M6 power, pulse coder relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M1 power relay M6 power, pulse coder relay

(C3) 2axis brake (RDI 8, RDO 8) Normal cable : A05B1207H254 (For motor, RJ2 controller)
Cable K101 K102 K103 K104 K105 K105 K106 K108 K108 Specifications A05B1207D107 A6608009T991 A6604003T287 A6604003T286#J2 A6602004T279#J1 A6602004T279#J2 A05B1207D102 A6602004T152 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5, M6 power, pulse coder relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M1 power relay M6 power, pulse coder relay

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(E3) 2axis brake (RDI 8, RDO 8) Diecasting cable (option): A05B1207H274 (For motor, RJ2 controller)
Cable K201 K212 K203 K208 K230 K205 K205 K106 K108 Specifications A05B1207D207 A6608010T040 A6604003T289 A6602004T216 A6604003T290#J2 A6602004T290#J1 A6602004T290#J2 A05B1207D102 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5, M6 power, pulse coder relay M1 power relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M6 power, pulse coder relay

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Cable list for a motor specifications in mechanical unit for CE

(A4) 2axis brake (RDI 1, RDO 1) Normal cable : A05B1207H753 (For motor, RJ2 controller)
Cable K101 K102 K103 K214 K105 K205 K106 K108 K208 Specifications A05B1207D107 A6608009T990 A6604003T287 A6604003T405 A6602004T279#J1 A6602004T699 A05B1207D102 A6604003T244 A6602004T691 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5 M6, power, pulse coder relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M6 power, pulse coder relay M1 power relay

(B4) 2axis brake (RDI 8, RDO 8) Normal cable : A05B1207H754 (For motor, RJ2 controller)
Cable K101 K112 K103 K214 K105 K205 K106 K108 K208 Specifications A05B1207D107 A6608009T991 A6604003T287 A6604003T405 A6602004T279#J1 A6602004T699 A05B1207D102 A6604003T244 A6602004T691 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5 M6, power, pulse coder relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M6 power, pulse coder relay M1 power relay

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(C4) 6axis brake (RDI 1, RDO 1) Normal cable : A05B1207H751 (For motor, RJ controller, RJ2 controller) Extension cable : A05B1207H761 (For motor, RJ controller, RJ2 controller)
Cable K101 K102 K103 K204 K214 K105 K205 K106 K108 Specifications A05B1207D106 A6608009T990 A6604003T287 A6604003T414 A6604003T405 A6602004T279#J1 A6602004T699 A05B1207D102 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5 M6, power, pulse coder relay M1 power relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M6 power, pulse coder relay

(D4) 6axis brake (RDI 8, RDO 8) Normal cable : A05B1207H752 (For motor, RJ controller, RJ2 controller)
Cable K101 K112 K103 K204 K214 K105 K205 K106 K108 Specifications A05B1207D106 A6608009T991 A6604003T287 A6604003T414 A6604003T405 A6602004T279#J1 A6602004T699 A05B1207D102 A6604003T244 Remarks M1, M2, M3, M4, M5, M6 power M1, M2, M3, M4, M5, M6 pulse coder, DI/DO M5 M6, power, pulse coder relay M1 power relay M2 power relay M1 pulse coder relay M2 pulse coder relay OT Short circuit M6 power, pulse coder relay

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Other cable list in mechanical unit

(G) Limit switch cable (option): A05B1207H312, A05B1207H322 (For motor, S motor, RJ controller, RJ2 controller)
Cable K107 K121 K122 K123 Specifications A6604003T185 A05B1207D103 A05B1207D104 A05B1207D105 OT relay J1 OT with limit switch J2 OT with limit switch J3 OT with limit switch Remarks

(H) TIG welding cable (option): A05B1207J101 (For internal mechanical unit of ARC Mate 100) (For motor, S motor, RJ controller, RJ2 controller)
Cable K124 K125 Specifications A6601207D005 A6608009T778 Remarks Ground cable Ground cable

(I1) MIG EYE cable (without ROTATOR) (option): A05B1207H921 (For motor, S motor, RJ controller, RJ2 controller)
Cable K136 K132 Specifications A6608009T818 A6608009T848 A6608009T708#L300R0 Remarks Sensor cable A Sensor cable B Ground cable

(I2) MIG EYE cable (with ROTATOR) (option): A05B1207H922 (For motor, S motor, RJ controller, RJ2 controller)
Cable K131 K132 K133 K134 K135 Specifications A6608009T847 A6608009T848 A6608009T849 A6602004T221 A6602004T222 A6608009T708#L300R0 Remarks Sensorpulse coder cable A Sensor cable B Pulse coder cable B Power cable A Power cable B Ground cable

(J) User cable (option): A05B1207H931 (For motor, S motor, RJ controller, RJ2 controller)
Cable K142 Specifications A6602004T213 User cable Remarks

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(K) Wire feeder cable (option): A05B1207J091/A05B1207J092 (For motor, S motor, RJ controller, RJ2 controller)
Cable K141 K141 K143 Specifications A6602004T251#L7R003 A6602004T251#L14R03 A6602004T214#L600R0 Remarks WelderXRobot (7 m): A05B1207J091 WelderXRobot (14 m): A05B1207J092 RobotXWire feeder

Motor list for S motor specifications

TableTable 1 (b1) Motor (ARC Mate100/S6) (For S motor)

ARC Mate 100 (with 2axis brake) A05B1207B201 S6 (with 2axis brake) A05B1207B202
Specifications A06B0313B075 A06B0313B175 A06B0371B175 A06B0369B156#0003 A06B0367B156#0004 A06B0367B156#0004 Axis J1 J2 J3 J4 J5 J6 AC 0S AC 0S brake AC 20SP brake AC 30F AC 40F AC 40F Remarks

ARC Mate 100 (with 6axis brake) A05B1207B601 S6 (with 6axis brake) A05B1207B602
Specifications A06B0313B175 A06B0313B175 A06B0371B175 A06B0369B356#0003 A06B0367B356#0004 A06B0367B356#0004 Axis J1 J2 J3 J4 J5 J6 Remarks AC 0S brake AC 0S brake AC 20SP brake AC 30F brake AC 40F brake AC 40F brake

Motor list for motor specifications

Table 1 (b2) Motor (ARC Mate100/S6) (For motor)

ARC Mate 100 (with 2axis brake) A05B1207B251 S6 (with 2axis brake) A05B1207B252
Specifications A06B0123B075 A06B0123B175 A06B0371B175 A06B0113B078#0008 A06B0113B078#0008 A06B0113B078#0008 Axis J1 J2 J3 J4 J5 J6 3 3 brake 1 brake 0.5 0.5 0.5 Remarks

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ARC Mate 100 (with 6axis brake) A05B1207B651 S6 (with 6axis brake) A05B1207B652
Specifications A06B0123B175 A06B0123B175 A06B0371B175 A06B0113B178#0008 A06B0113B178#0008 A06B0113B178#0008 Axis J1 J2 J3 J4 J5 J6 3 brake 3 brake 1 brake 0.5 brake 0.5 brake 0.5 brake Remarks

Table 1 (c) Cover (ARC Mate100/S6) *Option Specifications A05B7202J401 A05B7202X403 Remarks J2axis motor cover * J3axis cover

Table 1 (d) Battery (ARC Mate 100/S6) Specifications A98L00310005 Remarks 1.5 V size D Qty 4

Table 1 (e) Grease (ARC Mate 100/S6) Name MoryWhite RE No. 00 SK3 Specifications A98L00400119#2KG Remarks For J1, J2, J3, J5axis

A98L00400110#2.5KG For J4, J6axis

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A2. MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM

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MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM

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Fig.2 (a) Internal connection diagram (ARC Mate 100/S6) (A05B1207H201) (For S motor, RJ controller) (A05B1207H211) (For S motor, RJ controller)

180

f : moving cable

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A2. MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM

Fig. 2 (b) Internal connection diagram (ARC Mate100/S-6) (A05B1207H202) (For S motor, RJ controller)

181

f : moving cable

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Fig.2 (c) Internal connection diagram (ARC Mate 100/S6) (A05B1207H601) (For S motor, RJ controller) (A05B1207H611) (For S motor, RJ controller)

182

f : moving cable

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A2. MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM

Fig.2 (d) Internal connection diagram (ARC Mate100/S-6) (A05B1207H602) (For S motor, RJ controller)

183

f : moving cable

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Fig.2 (e) Internal connection diagram (ARC Mate 100/S6) (A05B1207H251) (For motor, RJ controller) (A05B1207H261) (For motor, RJ controller)

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Fig.2 (f) Internal connection diagram (ARC Mate100/S-6) (A05B1207H252) (For motor, RJ controller)

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Fig.2 (g) Internal connection diagram (ARC Mate100/S-6) (A05B1207H651) (For motor, RJ or RJ2 controller) (A05B1207H661) (For motor, RJ or RJ2 controller)

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Fig.2 (h) Internal connection diagram (ARC Mate100/S-6) (A05B1207H652) (For motor, RJ or RJ2 controller)

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Fig.2 (i) Internal connection diagram (ARC Mate100/S-6) (A05B1207H253) (For motor, RJ2 controller)

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Fig.2 (j) Internal connection diagram (ARC Mate100/S-6) (A05B1207H263) (For motor, RJ2 controller)

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Fig.2 (k) Internal connection diagram (ARC Mate 100/S6) (A05B1207H254) (For a motor, RJ2 controller)

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Fig. 2 (l1) Internal connection diagram (ARC Mate 100/S6) (A05B1207H753) (For a motor, RJ2 controller)

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Fig. 2 (l2) Internal connection diagram (ARC Mate 100/S6) (A05B1207H753) (For a motor, RJ2 controller)

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Fig. 2 (m1) Internal connection diagram (ARC Mate 100/S6) (A05B1207H754) (For a motor, RJ2 controller)

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Fig. 2 (m2) Internal connection diagram (ARC Mate 100/S6) (A05B1207H754) (For a motor, RJ2 controller)

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Fig. 2 (n1) Internal connection diagram (ARC Mate 100/S6) (A05B1207H751) (For a motor, RJ or RJ2 controller) (A05B1207H761) (For a motor, RJ or RJ2 controller)

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Fig. 2 (n2) Internal connection diagram (ARC Mate 100/S6) (A05B1207H751) (For a motor, RJ or RJ2 controller) (A05B1207H761) (For a motor, RJ or RJ2 controller)

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Fig. 2 (O1) Internal connection diagram (ARC Mate 100/S6) (A05B1207H752) (For a motor, RJ or RJ2 controller)

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Fig. 2 (O2) Internal connection diagram (ARC Mate 100/S6) (A05B1207H752) (For a motor, RJ or RJ2 controller)

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Fig.2 (p) Internal connection diagram for MIG EYE cable (A05B1207H921) (ARC Mate 100) (A05B1207H922) (ARC Mate 100)

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Fig.2 (q) Internal connection diagram for USER cable (A05B1207H931) (ARC Mate 100)

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Index
J
J1axis drive mechanism, 20 J1axis stroke modification (option), 48 J2axis drive mechanism, 21 J3axis drive mechanism, 22 J4axis drive mechanism, 23

Numbers
1year checks, 31 3month checks, 30 3year check, 34

A
Adjusting, 42 Adjusting J5axis spur gear backlash, 64 Adjusting J5axis spur gear backlash (For a motor), 66 Adjusting limit switches and dogs (option), 43 Air piping, 162 Assembling the mastering jig, 56 Assembly during installation, 161

J5axis and J6 drive mechanism, 24

L
Limit switch installation diagram (option), 100 Load conditions at the wrist, 146 Lubricating condition checks, 32

M B
Backlash adjustment of the gear 2 and gear 3 assemblies, 65 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 a motor specifications, 177 Motor list for S motor specifications, 177

C
Cable clamping, 105 Cable installation diagram, 101 Configuration, 19 Confirming mastering, 63 Cover option (Specification: A05B1207J401), 130

O
Operator safety, 6 Options, 129 Other cable list in mechanical unit, 176

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

P
Peripheral device safety, 8 Piping, 93 Piping and wiring, 92 Precautions for work, 10 Preventive maintenance, 27

Q G
Greasing, 33 Quick mastering, 52

R I
Installation, 156 Installation specifications, 164 Releasing brake, 91 Replacing the J2axis motor, 74 Replacing the J3axis motor, 76 Replacing and adjusting parts, 68

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Replacing battery, 35 Replacing cables, 104, 109 Replacing J1 and J2axis motor, 69 Replacing J3axis reducer, 78 Replacing J4axis motor, 79 Replacing J5axis motor, 83 Replacing J6axis motor, reducer, 87 Replacing limit switch (option), 125 Replacing parts and performing adjustments, 41 Replacing the J1axis reducer, 71 Replacing the J4axis reducer, 81 Replacing the J5axis gear, 85 Robot interference area, 133

Safety precautions, 3 Safety speed control, 13 Spare parts list, 167 Storage, 155

T
Transportation, 152 Transportation and installation, 151 Troubleshooting, 36

S
Safety for maintenance, 15

W
Wiring diagram, 94

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Revision Record FANUC Robot ARC Mate 100/S6 MECHANICAL UNIT MAINTENANCE MANUAL (B80405E)

04

Oct. 95

D Revisions for CE Marking.

03

Apr., 95

D D D D D D

Addition of RJ2 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

D Addition of descriptions for a motor

01

Feb., 94

Edition

Date

Contents

Edition

Date

Contents