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FANUC Robot ARC Mate 100iC

FANUC Robot ARC Mate 100iCe


FANUC Robot M-10iA
FANUC Robot M-10iAe

MECHANICAL UNIT
MAINTENANCE MANUAL
MARMCM10A04081E REV. E
This publication contains proprietary information
of FANUC Robotics America Corporation furnished for
customer use only. No other uses are authorized
without the express written permission of
FANUC Robotics America Corporation.

FANUC Robotics America Corporation


3900 W. Hamlin Road
Rochester Hills, Michigan 48309–3253

B-82755EN/05
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have
a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this
manual.

Copyrights and Trademarks


This new publication contains proprietary information of FANUC Robotics
America Corporation furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics America
Corporation.

The descriptions and specifications contained in this manual were in effect at the
time this manual was approved for printing. FANUC Robotics America
Corporation, hereinafter referred to as FANUC Robotics, reserves the right to
discontinue models at any time or to change specifications or design without
notice and without incurring obligations.

FANUC Robotics manuals present descriptions, specifications, drawings,


schematics, bills of material, parts, connections and/or procedures for installing,
disassembling, connecting, operating and programming FANUC Robotics'
products and/or systems. Such systems consist of robots, extended axes, robot
controllers, application software, the KAREL® programming language,
INSIGHT® vision equipment, and special tools.

FANUC Robotics recommends that only persons who have been trained in one
or more approved FANUC Robotics Training Course(s) be permitted to install,
operate, use, perform procedures on, repair, and/or maintain FANUC Robotics'
products and/or systems and their respective components. Approved training
necessitates that the courses selected be relevant to the type of system installed
and application performed at the customer site.

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

For customer assistance, including Technical Support, Service, Parts & Part
Repair, and Marketing Requests, contact the Customer Resource Center, 24
hours a day, at 1-800-47-ROBOT (1-800-477-6268). International customers
should call 011-1-248-377-7159.

Send your comments and suggestions about this manual to:


product.documentation@fanucrobotics.com

Copyright ©2011 by FANUC Robotics America Corporation


All Rights Reserved

The information illustrated or contained herein is not to be


reproduced, copied, downloaded, translated into another language, published in
any physical or electronic format, including internet, or transmitted in whole or
in part in any way without the prior written consent of FANUC Robotics
America Corporation.

AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®, PalletTool®,


SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® are Registered
Trademarks of FANUC Robotics.

FANUC Robotics reserves all proprietary rights, including but not


limited to trademark and trade name rights, in the following names:

AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™,


AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™,
ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™,
ARC Mate System 5™, ARCWorks Pro™, AssistTool™, AutoNormal™,
AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™,
Center Finder™, Clean Wall™, DualARM™, LR Tool™,
MIG Eye™, MotionParts™, MultiARM™, NoBots™, Paint
Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks
II™, PAINTWorks III™, PalletMate™, PalletMate PC™,
PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™,
Robo Chop™, Robo Spray™, S-420i™, S-430i™, ShapeGen™,
SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR
ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3
Controller™, SYSTEM R-J3iB Controller™, SYSTEM R-J3iC Controller™,
SYSTEM R-30iA Controller™,TCP Mate™, TorchMate™, TripleARM™,
TurboMove™, visLOC™, visPRO-3D™, visTRAC™, WebServer™,
WebTP™, and YagTool™.

©FANUC CORPORATION 2011


• No part of this manual may be reproduced in any form.
• All specifications and designs are subject to change without notice.
Patents

One or more of the following U.S. patents might be related to the FANUC
Robotics products described in this manual.

FANUC Robotics America Corporation Patent List


4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 4,942,539 4,984,745
5,238,029 5,239,739 5,272,805 5,293,107 5,293,911 5,331,264 5,367,944
5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687 5,737,218
5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,726 6,059,092
6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621
6,253,799 6,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143
6,378,190 6,385,508 6,425,177 6,477,913 6,490,369 6,518,980 6,540,104
6,541,757 6,560,513 6,569,258 6,612,449 6,703,079 6,705,361 6,726,773
6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,422
7,399,363

FANUC CORPORATION Patent List


4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207
4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,934,504 4,956,594
4,967,125 4,969,109 4,970,370 4,970,448 4,979,127 5,004,968 5,006,035
5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,107,716 5,111,019
5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360
5,292,066 5,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057
5,329,469 5,333,242 5,337,148 5,371,452 5,375,480 5,418,441 5,432,316
5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,461,478 5,463,297
5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,758
5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194
5,552,687 5,558,196 5,561,742 5,570,187 5,570,190 5,572,103 5,581,167
5,582,750 5,587,635 5,600,759 5,608,299 5,608,618 5,624,588 5,630,955
5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,668,628 5,687,295
5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138
5,742,144 5,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135
5,812,408 5,841,257 5,845,053 5,872,894 5,887,122 5,911,892 5,912,540
5,920,678 5,937,143 5,980,082 5,983,744 5,987,591 5,988,850 6,023,044
6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,693
6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898
6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181 6,236,011
6,236,896 6,250,174 6,278,902 6,279,413 6,285,921 6,298,283 6,321,139
6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,377,869 6,382,012
6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979
6,459,958 6,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588
6,680,461 6,696,810 6,728,417 6,763,284 6,772,493 6,845,296 6,853,881
6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 6,970,802 7,038,165
7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,848
7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294
7,181,313 7,280,687 7,283,661 7,291,806 7,299,713 7,315,650 7,324,873
7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,373,220 7,376,488
7,386,367 7,464,623 7,447,615 7,445,260 7,474,939 7,486,816 7,495,192
7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121
Conventions

WARNING
Information appearing under the "WARNING" caption concerns the protection of
personnel. It is boxed and bolded to set it apart from the surrounding text.

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

Note Information appearing next to NOTE concerns related information or useful hints.
• Original Instructions

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.

• No part of this manual may be reproduced in any form.


• All specifications and designs are subject to change without notice.

The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.

In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
B-82755EN/05 PREFACE

PREFACE
This manual explains the maintenance procedures for the mechanical units of the following robots:

Model name Mechanical unit Maximum load


specification No.
FANUC Robot ARC Mate 100iC A05B-1221-B201
3kg or 6kg or 10kg
(With all axes brakes) A05B-1221-B401
FANUC Robot M-10iA A05B-1221-B202
3kg or 6kg or 10kg
(With all axes brakes) A05B-1221-B402
FANUC Robot ARC Mate 100iC/6L A05B-1221-B301
3kg or 6kg
(With all axes brakes) A05B-1221-B501
FANUC Robot M-10iA/6L A05B-1221-B302
3kg or 6kg
(With all axes brakes) A05B-1221-B502
FANUC Robot ARC Mate 100iC/10S
A05B-1221-B601
(With all axes brakes)
3kg or 6kg or 10kg
FANUC Robot M-10iA/10S
A05B-1221-B602
(With all axes brakes)
FANUC Robot ARC Mate 100iCe (NOTE)
A05B-1221-B451 3kg or 6kg or 10kg
(With J2 and J3-axis brakes)
FANUC Robot M-10iAe (NOTE)
A05B-1221-B452 3kg or 6kg or 10kg
(With J2 and J3-axis brakes)
FANUC Robot ARC Mate 100iCe/6L (NOTE)
A05B-1221-B551 3kg or 6kg
(With J2 and J3-axis brakes)
FANUC Robot M-10iAe/6L (NOTE)
A05B-1221-B552 3kg or 6kg
(With J2 and J3-axis brakes)

NOTE
These robot can not support Wall & Angle mount.

The label stating the mechanical unit specification number is affixed in the position shown below. Before
reading this manual, determine the specification number of the mechanical unit.

p-1
PREFACE B-82755EN/05

(2 )

(1)

TYPE (2)
NO. (3) WEIGHT
DATE (4) (5) kg

DETAIL A TYPE
TYPE
NO.
NO.
DATE
DATE
(3)
(3 )
(4 )
( 4)
(1 )
(1)
(2)
( 2)
WEIGHT
WE IGHT
(5) kg
(5 ) kg

TABLE 1 Position of label indicating mechanical unit specification number


(1) (2) (3) (4) (5)
WEIGHT kg
CONTENTS Model name TYPE No. DATE
(Without controller)
FANUC Robot ARC A05B-1221-B201
130
Mate 100iC A05B-1221-B401
FANUC Robot A05B-1221-B202
130
M-10iA A05B-1221-B402
FANUC Robot ARC A05B-1221-B301
135
Mate 100iC/6L A05B-1221-B501
FANUC Robot A05B-1221-B302
135
M-10iA/6L A05B-1221-B502
FANUC Robot ARC PRINT
A05B-1221-B601 130
LETTERS Mate 100iC/10S PRINT PRODUCTION
FANUC Robot SERIAL NO. YEAR AND
A05B-1221-B602 MONTH 130
M-10iA/10S
FANUC Robot ARC
A05B-1221-B451 130
Mate 100iCe
FANUC Robot
A05B-1221-B452 130
M-10iAe
FANUC Robot ARC
A05B-1221-B551 135
Mate 100iCe/6L
FANUC Robot
A05B-1221-B552 135
M-10iAe/6L

p-2
B-82755EN/05 PREFACE

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

Safety handbook B-80687EN Intended readers:


All persons who use the FANUC Robot and All persons who use FANUC Robot, system designer
system designer must read and understand Topics:
thoroughly this handbook Safety items for robot system design, operation, maintenance
R-30iA Operator’s Manual Intended readers:
controller HANDLING TOOL Operator, programmer, maintenance person, system designer
B-83124EN-2 Topics:
ARC TOOL Robot functions, operations, programming, setup, interfaces,
B-83124EN-3 alarms
DISPENSE TOOL Use:
B-83124EN-4 Robot operation, teaching, system design
ALARM CODE LIST
B-83124EN-6
Maintenance Manual Intended readers:
B-82595EN Maintenance person, system designer
B-82595EN-1 (For Europe) Topics:
B-82595EN-2 (For RIA) Installation, connection to peripheral equipment, maintenance
Use:
Installation, start-up, connection, maintenance
R-30iA Mate Operator’s Manual Intended readers:
controller LR HANDLING TOOL Operator, programmer, maintenance person, system designer
B-82724EN-1 Topics:
LR ARC TOOL Robot functions, operations, programming, setup, interfaces,
B-82724EN-2 alarms
ALARM CODE LIST Use:
B-83124EN-6 Robot operation, teaching, system design
Maintenance Intended readers:
Manual Maintenance person, system designer
B-82725EN Topics:
B-82725EN-1 (For Europe) Installation, connection to peripheral equipment, maintenance
B-82725EN-2 (For RIA) Use:
Installation, start-up, connection, maintenance
FANUC Robot Operator’s manual Intended readers:
ARC Mate B-82754EN System designer, Maintenance person
100iC, M-10iA Topics:
Mechanical Installation, connection to the controller, maintenance
unit Use:
Installation, start-up, connection, maintenance

p-3
SAFETY PRECAUTIONS
Safety
FANUC Robotics is not and does not represent itself as an expert in safety systems,
safety equipment, or the specific safety aspects of your company and/or its work force. It
is the responsibility of the owner, employer, or user to take all necessary steps to
guarantee the safety of all personnel in the workplace.

The appropriate level of safety for your application and installation can be best
determined by safety system professionals. FANUC Robotics therefore, recommends
that each customer consult with such professionals in order to provide a workplace that
allows for the safe application, use, and operation of FANUC Robotics systems.

According to the industry standard ANSI/RIA R15-06, the owner or user is advised to
consult the standards to ensure compliance with its requests for Robotics System design,
usability, operation, maintenance, and service. Additionally, as the owner, employer, or
user of a robotic system, it is your responsibility to arrange for the training of the operator
of a robot system to recognize and respond to known hazards associated with your
robotic system and to be aware of the recommended operating procedures for your
particular application and robot installation.

Ensure that the robot being used is appropriate for the application. Robots used in
classified (hazardous) locations must be certified for this use.

FANUC Robotics therefore, recommends that all personnel who intend to operate,
program, repair, or otherwise use the robotics system be trained in an approved FANUC
Robotics training course and become familiar with the proper operation of the system.
Persons responsible for programming the system–including the design, implementation,
and debugging of application programs–must be familiar with the recommended
programming procedures for your application and robot installation.

The following guidelines are provided to emphasize the importance of safety in the
workplace.

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION


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

i
Safety

Keeping People and Equipment Safe

The safety of people is always of primary importance in any situation. However,


equipment must be kept safe, too. When prioritizing how to apply safety to your robotic
system, consider the following:
 People
 External devices
 Robot(s)
 Tooling
 Workpiece

Using Safety Enhancing Devices

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

Setting Up a Safe Workcell

A safe workcell is essential to protect people and equipment. Observe the following
guidelines to ensure that the workcell is set up safely. These suggestions are intended to
supplement and not replace existing federal, state, and local laws, regulations, and
guidelines that pertain to safety.

 Sponsor your personnel for training in approved FANUC Robotics training course(s)
related to your application. Never permit untrained personnel to operate the robots.
 Install a lockout device that uses an access code to prevent unauthorized persons
from operating the robot.
 Use anti–tie–down logic to prevent the operator from bypassing safety measures.
 Arrange the workcell so the operator faces the workcell and can see what is going on
inside the cell.
 Clearly identify the work envelope of each robot in the system with floor markings,
signs, and special barriers. The work envelope is the area defined by the maximum

ii
Safety

motion range of the robot, including any tooling attached to the wrist flange that
extend this range.
 Position all controllers outside the robot work envelope.
 Never rely on software or firmware based controllers as the primary safety element
unless they comply with applicable current robot safety standards.
 Mount an adequate number of EMERGENCY STOP buttons or switches within easy
reach of the operator and at critical points inside and around the outside of the
workcell.
 Install flashing lights and/or audible warning devices that activate whenever the robot
is operating, that is, whenever power is applied to the servo drive system. Audible
warning devices shall exceed the ambient noise level at the end–use application.
 Wherever possible, install safety fences to protect against unauthorized entry by
personnel into the work envelope.
 Install special guarding that prevents the operator from reaching into restricted areas
of the work envelope.
 Use interlocks.
 Use presence or proximity sensing devices such as light curtains, mats, and
capacitance and vision systems to enhance safety.
 Periodically check the safety joints or safety clutches that can be optionally installed
between the robot wrist flange and tooling. If the tooling strikes an object, these
devices dislodge, remove power from the system, and help to minimize damage to
the tooling and robot.
 Make sure all external devices are properly filtered, grounded, shielded, and
suppressed to prevent hazardous motion due to the effects of electro–magnetic
interference (EMI), radio frequency interference (RFI), and electro–static discharge
(ESD).
 Make provisions for power lockout/tagout at the controller.
 Eliminate pinch points. Pinch points are areas where personnel could get trapped
between a moving robot and other equipment.
 Provide enough room inside the workcell to permit personnel to teach the robot and
perform maintenance safely.
 Program the robot to load and unload material safely.
 If high voltage electrostatics are present, be sure to provide appropriate interlocks,
warning, and beacons.
 If materials are being applied at dangerously high pressure, provide electrical
interlocks for lockout of material flow and pressure.

Staying Safe While Teaching or Manually Operating the Robot

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

 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.

iii
Safety

 Know whether or not you are using an intrinsically safe teach pendant if you are
working in a hazardous environment.
 Before teaching, visually inspect the robot and work envelope to make sure that no
potentially hazardous conditions exist. The work envelope is the area defined by the
maximum motion range of the robot. These include tooling attached to the wrist
flange that extends this range.
 The area near the robot must be clean and free of oil, water, or debris. Immediately
report unsafe working conditions to the supervisor or safety department.
 FANUC Robotics recommends that no one enter the work envelope of a robot that is
on, except for robot teaching operations. However, if you must enter the work
envelope, be sure all safeguards are in place, check the teach pendant DEADMAN
switch for proper operation, and place the robot in teach mode. Take the teach
pendant with you, turn it on, and be prepared to release the DEADMAN switch.
Only the person with the teach pendant should be in the work envelope.

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

 Know the path that can be used to escape from a moving robot; make sure the escape
path is never blocked.
 Isolate the robot from all remote control signals that can cause motion while data is
being taught.
 Test any program being run for the first time in the following manner:

WARNING
Stay outside the robot work envelope whenever a program is being run. Failure to do
so can result in injury.

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

iv
Safety

Staying Safe During Automatic Operation

Advise all personnel who operate the robot during production to observe the following
rules:
 Make sure all safety provisions are present and active.
 Know the entire workcell area. The workcell includes the robot and its work
envelope, plus the area occupied by all external devices and other equipment with
which the robot interacts.
 Understand the complete task the robot is programmed to perform before initiating
automatic operation.
 Make sure all personnel are outside the work envelope before operating the robot.
 Never enter or allow others to enter the work envelope during automatic operation of
the robot.
 Know the location and status of all switches, sensors, and control signals that could
cause the robot to move.
 Know where the EMERGENCY STOP buttons are located on both the robot control
and external control devices. Be prepared to press these buttons in an emergency.
 Never assume that a program is complete if the robot is not moving. The robot could
be waiting for an input signal that will permit it to continue its activity.
 If the robot is running in a pattern, do not assume it will continue to run in the same
pattern.
 Never try to stop the robot, or break its motion, with your body. The only way to
stop robot motion immediately is to press an EMERGENCY STOP button located on
the controller panel, teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection

When inspecting the robot, be sure to


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

v
Safety

Staying Safe During Maintenance

When performing maintenance on your robot system, observe the following rules:
 Never enter the work envelope while the robot or a program is in operation.
 Before entering the work envelope, visually inspect the workcell to make sure no
potentially hazardous conditions exist.
 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught
in moving machinery.
 Consider all or any overlapping work envelopes of adjoining robots when standing in
a work envelope.
 Test the teach pendant for proper operation before entering the work envelope.
 If it is necessary for you to enter the robot work envelope while power is turned on,
you must be sure that you are in control of the robot. Be sure to take the teach
pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be
prepared to release the DEADMAN switch to turn off servo power to the robot
immediately.
 Whenever possible, perform maintenance with the power turned off. Before you
open the controller front panel or enter the work envelope, turn off and lock out the
3–phase power source at the controller.
 Be aware that when you remove a servomotor or brake, the associated robot arm will
fall if it is not supported or resting on a hard stop. Support the arm on a solid support
before you release the brake.

WARNING
Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a
power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS
PRESENT at the input side whenever the controller is connected to a power
source. Turning the disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.

 Release or block all stored energy. Before working on the pneumatic system, shut
off the system air supply and purge the air lines.
 Isolate the robot from all remote control signals. If maintenance must be done when
the power is on, make sure the person inside the work envelope has sole control of
the robot. The teach pendant must be held by this person.
 Make sure personnel cannot get trapped between the moving robot and other
equipment. Know the path that can be used to escape from a moving robot. Make
sure the escape route is never blocked.
 Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot.
Make sure that such devices do not create pinch points that could trap personnel.

vi
Safety

WARNING
Do not try to remove any mechanical component from the robot before thoroughly
reading and understanding the procedures in the appropriate manual. Doing so can
result in serious personal injury and component destruction.

 Be aware that when you remove a servomotor or brake, the associated robot arm will
fall if it is not supported or resting on a hard stop. Support the arm on a solid support
before you release the brake.
 When replacing or installing components, make sure dirt and debris do not enter the
system.
 Use only specified parts for replacement. To avoid fires and damage to parts in the
controller, never use nonspecified fuses.
 Before restarting a robot, make sure no one is inside the work envelope; be sure that
the robot and all external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE


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

Programming Safety Precautions

Implement the following programming safety measures to prevent damage to machine


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

Mechanical Safety Precautions

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

vii
Safety

KEEPING THE ROBOT SAFE


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

Operating Safety Precautions

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

Programming Safety Precautions

The following safety measures are designed to prevent damage to the robot during
programming:
 Establish interference zones to prevent collisions when two or more robots share a
work area.
 Make sure that the program ends with the robot near or at the home position.
 Be aware of signals or other operations that could trigger operation of tooling
resulting in personal injury or equipment damage.
 In dispensing applications, be aware of all safety guidelines with respect to the
dispensing materials.

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

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT


INSTALLATIONS
Process technicians are sometimes required to enter the paint booth, for example, during
daily or routine calibration or while teaching new paths to a robot. Maintenance
personnel also must work inside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilation equipment must be
used. Instruction on the proper use of ventilating equipment usually is provided by the
paint shop supervisor.

viii
Safety

Although paint booth hazards have been minimized, potential dangers still exist.
Therefore, today’s highly automated paint booth requires that process and maintenance
personnel have full awareness of the system and its capabilities. They must understand
the interaction that occurs between the vehicle moving along the conveyor and the
robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools.

CAUTION
Ensure that all ground cables remain connected. Never operate the paint robot with
ground provisions disconnected. Otherwise, you could injure personnel or damage
equipment.

Paint robots are operated in three modes:


 Teach or manual mode
 Automatic mode, including automatic and exercise operation
 Diagnostic mode

During both teach and automatic modes, the robots in the paint booth will follow a
predetermined pattern of movements. In teach mode, the process technician teaches
(programs) paint paths using the teach pendant.

In automatic mode, robot operation is initiated at the System Operator Console (SOC) or
Manual Control Panel (MCP), if available, and can be monitored from outside the paint
booth. All personnel must remain outside of the booth or in a designated safe area within
the booth whenever automatic mode is initiated at the SOC or MCP.

In automatic mode, the robots will execute the path movements they were taught during
teach mode, but generally at production speeds.

When process and maintenance personnel run diagnostic routines that require them to
remain in the paint booth, they must stay in a designated safe area.

Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the
equipment and its capabilities. To minimize the risk of injury when working near robots
and related equipment, personnel must comply strictly with the procedures in the
manuals.

This section provides information about the safety features that are included in the paint
system and also explains the way the robot interacts with other equipment in the system.

The paint system includes the following safety features:


 Most paint booths have red warning beacons that illuminate when the robots are
armed and ready to paint. Your booth might have other kinds of indicators. Learn
what these are.

ix
Safety

 Some paint booths have a blue beacon that, when illuminated, indicates that the
electrostatic devices are enabled. Your booth might have other kinds of indicators.
Learn what these are.
 EMERGENCY STOP buttons are located on the robot controller and teach pendant.
Become familiar with the locations of all E–STOP buttons.
 An intrinsically safe teach pendant is used when teaching in hazardous paint
atmospheres.
 A DEADMAN switch is located on each teach pendant. When this switch is held in,
and the teach pendant is on, power is applied to the robot servo system. If the
engaged DEADMAN switch is released or pressed harder during robot operation,
power is removed from the servo system, all axis brakes are applied, and the robot
comes to an EMERGENCY STOP. Safety interlocks within the system might also
E–STOP other robots.

WARNING
An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed
robot.

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

Staying Safe While Operating the Paint Robot

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

WARNING
Observe all safety rules and guidelines to avoid injury.

x
Safety

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

WARNING
Enclosures shall not be opened unless the area is known to be nonhazardous or
all power has been removed from devices within the enclosure. Power shall not be
restored after the enclosure has been opened until all combustible dusts have
been removed from the interior of the enclosure and the enclosure purged. Refer
to the Purge chapter for the required purge time.

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


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

xi
Safety

Special Precautions for Combustible Dusts (Powder Paint)


When the robot is used in a location where combustible dusts are found, such as the
application of powder paint, the following special precautions are required to insure that
there are no combustible dusts inside the robot.
 Purge maintenance air should be maintained at all times, even when the robot power
is off. This will insure that dust can not enter the robot.
 A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed
to dust when maintenance air is not present, it will be necessary to remove the covers
and clean out any accumulated dust. Do not energize the robot until you have
performed the following steps.
1. Before covers are removed, the exterior of the robot should be cleaned to remove
accumulated dust.
2. When cleaning and removing accumulated dust, either on the outside or inside of the
robot, be sure to use methods appropriate for the type of dust that exists. Usually lint
free rags dampened with water are acceptable. Do not use a vacuum cleaner to
remove dust as it can generate static electricity and cause an explosion unless special
precautions are taken.
3. Thoroughly clean the interior of the robot with a lint free rag to remove any
accumulated dust.
4. When the dust has been removed, the covers must be replaced immediately.
5. Immediately after the covers are replaced, run a complete purge cycle. The robot can
now be energized.

Staying Safe While Operating Paint Application Equipment


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

WARNING
When working with electrostatic paint equipment, follow all national and local codes
as well as all safety guidelines within your organization. Also reference the
following standards: NFPA 33 Standards for Spray Application Using Flammable or
Combustible Materials, and NFPA 70 National Electrical Code.
 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.

xii
Safety

 No smoking.
 Post all warning signs regarding the electrostatic equipment and operation of
electrostatic equipment according to NFPA 33 Standard for Spray Application Using
Flammable or Combustible Material.
 Disable all air and paint pressure to bell.
 Verify that the lines are not under pressure.

Staying Safe During Maintenance

When you perform maintenance on the painter system, observe the following rules, and
all other maintenance safety rules that apply to all robot installations. Only qualified,
trained service or maintenance personnel should perform repair work on a robot.
 Paint robots operate in a potentially explosive environment. Use caution when
working with electric tools.
 When a maintenance technician is repairing or adjusting a robot, the work area is
under the control of that technician. All personnel not participating in the
maintenance must stay out of the area.
 For some maintenance procedures, station a second person at the control panel within
reach of the EMERGENCY STOP button. This person must understand the robot
and associated potential hazards.
 Be sure all covers and inspection plates are in good repair and in place.
 Always return the robot to the ‘‘home’’ position before you disarm it.
 Never use machine power to aid in removing any component from the robot.
 During robot operations, be aware of the robot’s movements. Excess vibration,
unusual sounds, and so forth, can alert you to potential problems.
 Whenever possible, turn off the main electrical disconnect before you clean the robot.
 When using vinyl resin observe the following:
- Wear eye protection and protective gloves during application and removal.
- Adequate ventilation is required. Overexposure could cause drowsiness or
skin and eye irritation.
- If there is contact with the skin, wash with water.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
 When using paint remover observe the following:
- Eye protection, protective rubber gloves, boots, and apron are required
during booth cleaning.
- Adequate ventilation is required. Overexposure could cause drowsiness.
- If there is contact with the skin or eyes, rinse with water for at least 15
minutes. Then seek medical attention as soon as possible.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

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B-82755EN/05 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral devices installed in a work cell.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.

1 WORKING PERSON
The personnel can be classified as follows.

Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel

Programmer or teaching operator:


• Operates the robot
• Teaches robot inside the safety fence

Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)

- An operator cannot work inside the safety fence.


- A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc..
- To work inside the fence, the person must be trained on proper robot operation.

During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following safety
precautions.

- Use adequate clothing or uniforms during system operation


- Wear safety shoes
- Use helmet

2 WORKING PERSON SAFETY


Working person safety is the primary safety consideration. Because it is very dangerous to enter the
operating space of the robot during automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration must be made to ensure working
person safety.

(1) Have the robot system working persons attend the training courses held by FANUC.

FANUC provides various training courses. Contact our sales office for details.

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SAFETY PRECAUTIONS B-82755EN/05

(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is
waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person
safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.
(3) Install a safety fence with a gate so that no working person can enter the work area without passing
through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the
robot is stopped as the safety gate is opened.

The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this
signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of stop
type). For connection, see Fig.2 (a) and Fig.2 (b).

(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such
as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that
stops the robot when a working person enters the work area.
(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the
power of the robot.

The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a
padlock.

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.

RMP
Motor power/brake/signal

EARTH

Safety fence

Interlocking device and safety plug


that are activated if the gate is opened.
Fig.2 (a) Safety Fence and Safety Gate

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B-82755EN/05 SAFETY PRECAUTIONS

Dual chain
Panel board (Note)

EAS1 In case of R-30iA


Terminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2
EAS11 are provided on the operation box or on the terminal block
of the printed circuit board.
EAS2
In case of R-30iA Mate
EAS21 Terminals EAS1,EAS11,EAS2,EAS21 are provided
on the emergency stop board or connector panel.
(in case of Open air type)

Termianls FENCE1,FENCE2 are provided


on the emergency stop board.
Single chain
Panel board
Refer to controller maintenance manual for details.
FENCE1

FENCE2

Fig.2 (b) Connection Diagram for Safety Fence

2.1 OPERATOR SAFETY


The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.

(1) If you do not have to operate the robot, turn off the power of the robot controller or press the
EMERGENCY STOP button, and then proceed with necessary work.
(2) Operate the robot system at a location outside of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the
work area unexpectedly and to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection,
the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of stop type)
when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

Dual chain
External stop button
Panel board
EES1
(Note)
EES11 Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.

EES2 In case of R-30iA


EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.
EES21
In case of R-30iA Mate
EES1,EES11,EES2,EES21 are on the emergency stop board
or connector panel (in case of Open air type),.
Single chain EMGIN1,EMGIN2 are on the emergency stop board.
External stop button Refer to the maintenance manual of the controller for details.
Panel board
EMGIN1
EMGIN2

Fig.2.1 Connection Diagram for External Emergency Stop Button

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SAFETY PRECAUTIONS B-82755EN/05

2.2 SAFETY OF THE PROGRAMMER


While teaching the robot, the operator must enter the work area of the robot. The operator must ensure the
safety of the teach pendant operator especially.

(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating
condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other
conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on
the teach pendant) before entering the area.
(4) The programmer must be extremely careful not to let anyone else enter the robot work area.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the
automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence
for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other
people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the
automatic operation mode set, the robot stops as Emergency stop or Control stop (Please refer to "STOP TYPE OF
ROBOT" in SAFETY). After the switch is set to a teach mode, the safety gate is disabled. The programmer should
understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the
safety fence. (In case of R-30iA Mate Controller standard specification, there is no mode switch. The automatic
operation mode and the teach mode is selected by teach pendant enable switch.)

Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and
switch function as follows:
(1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY for
detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the mode switch setting status.
(a) Automatic operation mode: The DEADMAN switch is disabled.
(b) Teach mode: Servo power is turned off when the operator releases the DEADMAN switch or when the
operator presses the switch strongly.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iA/ R-30iA Mate employs a 3-position
DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to
its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly,
the robot stops immediately.

The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the
teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should
make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity
of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the
teach pendant enable switch and the remote condition on the software.

In case of R-30iA Controller or CE or RIA specification of R-30iA Mate Controller


Software
Teach pendant
Mode remote Teach pendant Operator panel Peripheral device
enable switch
condition
Local Not allowed Not allowed Not allowed
On
AUTO Remote Not allowed Not allowed Not allowed
mode Local Not allowed Allowed to start Not allowed
Off
Remote Not allowed Not allowed Allowed to start

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B-82755EN/05 SAFETY PRECAUTIONS

Software
Teach pendant
Mode remote Teach pendant Operator panel Peripheral device
enable switch
condition
Local Allowed to start Not allowed Not allowed
On
T1, T2 Remote Allowed to start Not allowed Not allowed
mode Local Not allowed Not allowed Not allowed
Off
Remote Not allowed Not allowed Not allowed

In case of standard specification of R-30iA Mate Controller


Teach pendant enable switch Software remote condition Teach pendant Peripheral device
On Ignored Allowed to start Not allowed
Off Local Not allowed Not allowed
Remote Not allowed Allowed to start

(5) (Only when R-30iA Controller or CE or RIA specification of R-30iA Mate controller is selected.) To
start the system using the operator’s panel, make certain that nobody is the robot work area and that
there are no abnormal conditions in the robot work area.
(6) When a program is completed, be sure to carry out a test run according to the procedure below.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test run above, execute it in the
automatic operation mode.
(7) While operating the system in the automatic operation mode, the teach pendant operator should leave
the robot work area.

2.3 SAFETY OF THE MAINTENANCE ENGINEER


For the safety of maintenance engineer, pay utmost attention to the following.

(1) During operation, never enter the robot work area.


(2) Except when specifically necessary, turn off the power of the controller while carrying out
maintenance. Lock the power switch, if necessary, so that no other person can turn it on.
(3) If it becomes necessary to enter the robot operation range while the power is on, press the emergency
stop button on the operator panel, or the teach pendant before entering the range. The maintenance
personnel must indicate that maintenance work is in progress and be careful not to allow other people
to operate the robot carelessly.
(4) When disconnecting the pneumatic system, be sure to reduce the supply pressure.
(5) Before the start of teaching, check that the robot and its peripheral devices are all in the normal
operating condition.
(6) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(7) When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers
are working nearby, make certain that their escape path is not obstructed.
(8) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such
as belt conveyor, pay careful attention to its motion.
(9) If necessary, have a worker who is familiar with the robot system stand beside the operator panel and
observe the work being performed. If any danger arises, the worker should be ready to press the
EMERGENCY STOP button at any time.
(10) When replacing or reinstalling components, take care to prevent foreign matter from entering the
system.

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SAFETY PRECAUTIONS B-82755EN/05

(11) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit
breaker to protect against electric shock.
(12) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in
damage to the components in the controller.
(13) When restarting the robot system after completing maintenance work, make sure in advance that there
is no person in the work area and that the robot and the peripheral devices are not abnormal.

3 SAFETY OF THE TOOLS AND PERIPHERAL


DEVICES
3.1 PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program
to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care
must be taken in programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the
states of all devices in the system and can be stopped according to the states.

3.2 PRECAUTIONS FOR MECHANISM


(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of
grease, water, and dust.
(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.
(3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does
not strike against its peripheral devices or tools.
(4) Observe the following precautions about the mechanical unit cables. When theses attentions are not
kept, unexpected troubles might occur.
• Use mechanical unit cable that have required user interface.
• Don’t add user cable or hose to inside of mechanical unit.
• Please do not obstruct the movement of the mechanical unit cable when cables are added to
outside of mechanical unit.
• In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a
protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the
cable.
• Please do not interfere with the other parts of mechanical unit when install equipments in the
robot.
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid
the system construction that power-off stop would be operated routinely. (Refer to bad case example.)
Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or
cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of
stop type.)
(Bad case example)
• Whenever poor product is generated, a line stops by emergency stop.
• When alteration was necessary, safety switch is operated by opening safety fence and power-off
stop is executed for the robot during operation.
• An operator pushes the emergency stop button frequently, and a line stops.
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B-82755EN/05 SAFETY PRECAUTIONS

• An area sensor or a mat switch connected to safety signal operate routinely and power-off stop is
executed for the robot.
(6) Robot stops urgently when collision detection alarm (SV050) etc. occurs. The frequent urgent stop by
alarm causes the trouble of the robot, too. So remove the causes of the alarm.

4 SAFETY OF THE ROBOT MECHANISM


4.1 PRECAUTIONS IN OPERATION
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can
manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the
jog mode.

4.2 PRECAUTIONS IN PROGRAMMING


(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere
with each other.
(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the
motion so that it starts from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

4.3 PRECAUTIONS FOR MECHANISMS


(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water,
and dust.

4.4 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN


EMERGENCY OR ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons trapped in or by the robot), brake release unit can
be used to move the robot axes without drive power.
Please order following unit and cable.

Name Specification
A05B-2450-J350 (Input voltage AC100-115V single phase)
Brake release unit
A05B-2450-J351 (Input voltage AC200-240V single phase)
A05B-2525-J047 (5m)
Robot connection cable
A05B-2525-J048 (10m)
A05B-2525-J010 (5m) (AC100-115V Power plug) (*)
A05B-2525-J011 (10m) (AC100-115V Power plug) (*)
Power cable
A05B-2450-J364 (5m) (No power plug)
A05B-2450-J365 (10m) (No power plug)
(*) These do not support CE marking.

(2) Please make sure that adequate numbers of brake release units are available and readily accessible for
robot system before installation.
(3) Regarding how to use brake release unit, please refer to Robot controller maintenance manual.

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SAFETY PRECAUTIONS B-82755EN/05

CAUTION
Robot systems installed without adequate number of brake release units or similar
means are neither in compliance with EN ISO 10218-1 nor with the Machinery
Directive and therefore cannot bear the CE marking.

WARNING
Robot arm would fall down by releasing its brake because of gravity. Therefore, it
is strongly recommended to take adequate measures such as hanging Robot arm
by a crane before releasing a brake.

In case of releasing J2-axis motor brake In case of releasing J3-axis motor brake

Fall down Fall down


Fall down

Method of supporting robot arm

Sling

(*)This figure is example of floor mount.


The direction of fall is different
according to the installation angle,so
please support robot appropriately in
consideration of the influence of
gravity.

Fig.4.4 Releasing J2 and J3 motor brake and measures

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B-82755EN/05 SAFETY PRECAUTIONS

5 SAFETY OF THE END EFFECTOR


5.1 PRECAUTIONS IN PROGRAMMING
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay
after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the
end effector.

6 STOP TYPE OF ROBOT


The following three robot stop types exist:

Power-Off Stop (Category 0 following IEC 60204-1)


Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
- An alarm is generated and servo power is turned off.
- The robot operation is stopped immediately. Execution of the program is paused.

Controlled stop (Category 1 following IEC 60204-1)


The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
- The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
- An alarm is generated and servo power is turned off.

Hold (Category 2 following IEC 60204-1)


The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
- The robot operation is decelerated until it stops. Execution of the program is paused.

WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.

When the E-Stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or
Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is
different according to the controller type or option configuration.

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SAFETY PRECAUTIONS B-82755EN/05

There are the following 3 Stop patterns.

Stop E-Stop External Servo


Mode FENCE open SVOFF input
pattern button E-Stop disconnect
AUTO P-Stop P-Stop C-Stop C-Stop P-Stop
A T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
AUTO P-Stop P-Stop P-Stop P-Stop P-Stop
B T1 P-Stop P-Stop - P-Stop P-Stop
T2 P-Stop P-Stop - P-Stop P-Stop
AUTO C-Stop C-Stop C-Stop C-Stop C-Stop
C T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
P-Stop: Power-Off stop
C-Stop: Controlled stop
-: Not stop

The following table indicates the Stop pattern according to the controller type or option configuration.

R-30iA R-30iA Mate


Option Standard Standard RIA CE
RIA type CE type Standard
(Single) (Dual) type type
Standard B (*) A A A A (**) A A
Stop type set (Stop pattern C)
N/A N/A C C N/A C C
(A05B-2500-J570)
(*) R-30iA standard (single) does not have servo disconnect.
(**) R-30iA Mate Standard does not have servo disconnect, and the stop type of SVOFF input is
Power-Off stop.

The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer
"Software version" in operator's manual of controller for the detail of software version screen.

"Stop type set (Stop pattern C)" option


"Stop type set (Stop pattern C)"(A05B-2500-J570) is an optional function. When this option is loaded, the
stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the
stop type is Power-Off stop which is the normal operation of the system.

Alarm Condition
SRVO-001 Operator panel E-stop Operator panel E-stop is pressed.
SRVO-002 Teach pendant E-stop Teach pendant E-stop is pressed.
SRVO-007 External emergency stops External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA controller)
SRVO-194 Servo disconnect Servo disconnect input (SD4-SD41, SD5-SD51) is open.
(R-30iA controller)
SRVO-218 Ext.E-stop/Servo Disconnect External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA Mate controller)
SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF.
SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.

Controlled stop is different from Power-Off stop as follows:


- In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
- In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems
where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized.
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B-82755EN/05 SAFETY PRECAUTIONS

- The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer the operator's
manual of a particular robot model for the data of stopping distance and stopping time.

This function is available only in CE or RIA type hardware.

When this option is loaded, this function can not be disabled.

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.

7 WARNING LABEL
(1) Greasing and degreasing label

Fig.7 (a) Greasing and degreasing label

Description
When greasing and degreasing, observe the instructions indicated on this label.

(1) When greasing, be sure to keep the grease outlet open.


(2) Use a manual pump to grease.
(3) Be sure to use specified grease.

CAUTION
See section 2.2 Replacing the Grease and Oil of the Drive Mechanism
(3 years (11,520 hours) checks) for explanations about specified greases, the
amount of grease to be supplied, and the locations of grease and degrease outlets
for individual models.

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SAFETY PRECAUTIONS B-82755EN/05

(2) Step-on prohibitive label

Fig.7 (b) Step-on Prohibitive Label

Description
Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may
get hurt if you lose your footing as well.

(3) High-temperature warning label

Fig.7 (c) High-Temperature Warning Label

Description
Be cautious about a section where this label is affixed, as the section generates heat. If you have to
inevitably touch such a section when it is hot, use a protective provision such as heat-resistant gloves.

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B-82755EN/05 SAFETY PRECAUTIONS

(4) Transportation label

300kg
250kg×2

150kg×2

Fig.7 (d) Transportation label

Description
When transporting the robot, observe the instructions indicated on this label.
1) Using a crane
• Use a crane having a load capacity of 300 kg or greater.
• Use at least two slings each having a withstand load of 2450 N (250 kgf) or greater. In this case,
please intersect and hang two Slings.
• Use at least two M10 eyebolts each having a withstand load of 1470 N (150 kgf) or greater.

NOTE
See section 1.1 TRANSPORTATION of operator’s manual for explanations about
the posture a specific model should take when it is transported.

(5) Transportation prohibitive label (When transport equipment option A05B-1221-H072 is specified.)

輸送部材に衝撃を 輸送部材にチェーン
与えないこと などを掛けないこと
Do not have impact Do not chain, pry,
on this part or strap on this part

Fig.7 (e) Transportation prohibitive label

Description
Keep the following in mind when transporting the robot.

(1) Prevent the forks of the forklift from having impact on transport equipment
(2) Do not thread a chain or the like through transport equipment.
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SAFETY PRECAUTIONS B-82755EN/05

(6) High current attention label

接触注意
溶接中、内部は高電流が流れます。
DO NOT ACCESS
DURING ENERGIZED HIGH
CURRENT INSIDE

Fig.7 (f) High current attention Label

Description
Do not access during energized high current inside.

(7) Range of motion and payload mark label


Below label is added when CE specification is specified.

-170 deg (-180 deg)


0 deg

+170 deg (+180 deg)

J5 axis rotation
center

Motion range
of J5 axis
rotation center
A
B

C D
A B C D MAX. PAYLOAD
(mm) (mm) (mm) (mm) (kg)
ARC Mate 100iC, M-10iA
ARC Mate 100iCe,M-10iAe 1720 784 1120 1420 10
ARC Mate 100iC/6L, M-10iA/6L 1933 996 1333 1632 6
ARC Mate 100iCe/6L,M-10iAe/6L
ARC Mate 100iC/10S, M-10iA/10S 1398 474 798 1098 10

Fig.7 (g) Range of motion and payload mark label

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B-82755EN/05 TABLE OF CONTENTS

TABLE OF CONTENTS
PREFACE ....................................................................................................p-1
SAFETY PRECAUTIONS............................................................................s-1
1 CHECKS AND MAINTENANCE ............................................................. 1
1.1 DAILY CHECKS ............................................................................................ 1
1.2 FIRST 1-MONTH (320 HOURS) CHECKS .................................................... 4
1.3 FIRST 3-MONTH (960 HOURS) CHECKS .................................................... 5
1.4 3-MONTH (960 HOURS) CHECKS ............................................................... 9
1.5 1-YEAR (3,840 HOURS) CHECKS................................................................ 9
1.6 1.5-YEAR CHECKS (5,760 hours)............................................................... 10
1.7 2-YEAR CHECKS (7,680 hours).................................................................. 10
1.8 3-YEAR (11,520 HOURS) CHECKS............................................................ 10
1.9 4-year (13,820 hours) checks ...................................................................... 10
1.10 MAINTENANCE TOOLS ............................................................................. 10
2 PERIODIC MAINTENANCE .................................................................. 15
2.1 Replacing the Batteries (1 Year (3,840 Hours) or (1.5 Year (5,760 Hours)
Checks) ....................................................................................................... 15
2.2 REPLACING THE GREASE AND OIL OF THE DRIVE MECHANISM (3
YEARS (11,520 HOURS) CHECKS) ........................................................... 17
2.2.1 Grease replacement procedure for the reducer (J1 to J3-axis) ...............................24
2.2.2 Oil replacement procedure for the gearbox (J4 to J6-axis) ....................................24
2.2.3 Procedure for releasing remaining pressure from the grease bath (J1 to J3-axis) ..27
2.2.4 Procedure for releasing oil (J4 to J6-axis)..............................................................28

3 TROUBLESHOOTING .......................................................................... 30
3.1 GENERAL ................................................................................................... 30
3.2 FAILURES, CAUSES AND MEASURES ..................................................... 30
3.3 BACKLASH MEASUREMENT..................................................................... 38
4 COMPONENT REPLACEMENT ........................................................... 43
4.1 FIGURE OF DRIVE MECHANISM .............................................................. 44
4.2 REPLACING THE J1-AXIS MOTOR M1 ..................................................... 46
4.3 REPLACING THE J1-AXIS REDUCER ....................................................... 48
4.4 REPLACING THE J2-AXIS MOTOR M2 ..................................................... 52
4.5 REPLACING THE J2-AXIS REDUCER ....................................................... 53
4.6 REPLACING THE J3-AXIS MOTOR M3 ..................................................... 56
4.7 NOTES OF ATTACHING J3-AXIS MOTOR TO REDUCER........................ 58
4.8 REPLACING THE J3-AXIS REDUCER ....................................................... 63
4.8.1 J3-axis reducer mounting phase auto adjusting function........................................66
4.9 REPLACING THE J4-AXIS MOTOR M4
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L) ..................... 66
4.10 REPLACING THE J4-AXIS MOTOR M4
(ARC Mate 100iC/10S, M-10iA/10S) ........................................................... 68

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TABLE OF CONTENTS B-82755EN/05

4.11 REPLACING THE J4-AXIS GEARBOX


(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate
100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L) ................................ 69
4.12 REPLACING THE J4-AXIS GEARBOX
(ARC Mate 100iC/10S, M-10iA/10S) ........................................................... 72
4.13 REPLACING THE J5-AXIS MOTOR M5 ..................................................... 75
4.14 REPLACING THE J6-AXIS MOTOR M6 ..................................................... 77
4.15 REPLACING WRIST UNIT .......................................................................... 79
4.16 REPLACING THE J2 COVER (OPTION) .................................................... 82
4.17 REPLACING THE J4 COVER (OPTION) .................................................... 84
4.18 NOTES FOR ASSEMBLING CABLES WITH M/H CONDUIT...................... 85
4.19 REPLACING M/H CONDUIT (OPTION) ...................................................... 86
4.20 NOTES FOR ASSEMBLING CABLES WITH NO DUST M/H CONDUIT .... 88
4.21 REPLACING NO DUST M/H CONDUIT (OPTION) ..................................... 93
4.22 REPLACING FLUORIC RESIN RING ......................................................... 97
4.23 SEALANT APPLICATION............................................................................ 97
5 CABLE REPLACEMENT ...................................................................... 99
5.1 CABLE WIRING......................................................................................... 100
5.2 CABLE DRESSING ................................................................................... 101
5.3 REPLACING CABLES............................................................................... 110
6 MASTERING ....................................................................................... 119
6.1 GENERAL ................................................................................................. 119
6.2 REGISTER OF MASTERING POSTURE .................................................. 121
6.3 RESETTING ALARMS AND PREPARING FOR MASTERING ................. 122
6.4 FIXTURE POSITION MASTER ................................................................. 123
6.5 CHECKING THE MASTERING ................................................................. 130

APPENDIX
A SPARE PARTS LIST .......................................................................... 133
B CIRCUIT DIAGRAM ............................................................................ 137
C PERIODIC MAINTENANCE TABLE ................................................... 142
D MOUNTING BOLT TORQUE LIST ..................................................... 145
E INSULATION ABOUT ARC WELDING ROBOT................................. 146
E.1 ABSTRACT................................................................................................ 146
E.2 INSULATION AT THE WRIST ................................................................... 146

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B-82755EN/05 1.CHECKS AND MAINTENANCE

1 CHECKS AND MAINTENANCE


Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter (See the APPENDIX C PERIODIC MAINTENANCE TABLE.).

NOTE
The periodic maintenance procedures described in this chapter assume that the
FANUC robot is used for up to 3840 hours a year. When using the robot beyond
this total operating time, correct the maintenance frequencies shown in this
chapter by calculation in proportion to the difference between the actual
operating time and 3840 hours/year.

1.1 DAILY CHECKS


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

(1) Before turning on power


Item Check items Check points
1 Oil exudation Check there is oil exudation on sealed part of each joint parts.
(Note 1)

Note 1) About exudation of oil

Check items
- Check there is exudation of oil on sealed part of each joint parts.
- Oil exudation may be attached (Slightly a loot oil stick) to outside of lip depend on the movement
condition or environment of the circumference. If this oil contents change to a state of dew, it may fail
depend on the movement.
You can prevent oil spot from falling down by wiping the oil contents which is accumulated to under
part of oil seal before operation.
- Also, motors may become the high temperature and the internal pressure of grease bath or oil bath may
rise by frequent repetition movement and use in the high temperature environment.
In these cases, you can return internal pressure by releasing grease out let or oil outlet just after
operation of robot. (When opening grease outlet or oil outlet, refer to Section 2.2 and pay attention
grease or oil is not scattered.)

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1.CHECKS AND MAINTENANCE B-82755EN/05

Oil seal
(J1)

Detail A
C Oil seal
(J2)

B
Detail B

Oil seal
(J3)
A
Detail C
Fig.1.1 (a) Check parts of main axis

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B-82755EN/05 1.CHECKS AND MAINTENANCE

Oil seal
(J6)

Detail F
Oil seal
F (J5)

Detail E

Oil seal
D (J4)

Detail D
Fig.1.1 (b) Check parts of wrist axis

Check method
- Insert waste to clearance of each joint which have oil seal and wipe oil. In this time, pay attention not
to press edge of oil seal with waste.

Oil seal

Cleaning area

Pay attention not to press


edge of oil seal with waste.
Fig.1.1 (c) Cleaning method

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1.CHECKS AND MAINTENANCE B-82755EN/05

When air control set is combined


Item Check items Check points
1 Air pressure Check air pressure using the pressure gauge on the air regulator as
shown in Fig.1.1 (d). If it does not meet the specified pressure of 0.49
to 0.69 MPa (5-7 kgf/cm2), adjust it using the regulator pressure-setting
handle.
2 Lubricator 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 lubricator
control knob. Under normal usage, the lubricator becomes empty in
about 10 to 20 days under normal operation.
3 Lubricator oil level Check to see that the lubricator level is within the specified level.
4 Leakage from hose Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts,
as required.
5 Drain Check drain and release it. When quantity of the drain is remarkable,
examine the setting of the air dryer to the air supply side.

Lubricator Adjusting knob


Oil inlet

Lubricator
mist amount check

Lubricator

Regulator Pressure gauge


Filter
pressure
setting handle

Fig.1.1 (d) Air control set

(2) After automatic operation


Item Check items Check points
Vibration, abnormal noises, and Check whether the robot moves along and about the axes smoothly
1 motor heating without unusual vibration or sounds. Also, check whether the
temperatures of the motors are excessively high.
Changing repeatability Check to see that the stop positions of the robot have not deviated
2
from the previous stop positions.
Peripheral devices for proper Check whether the peripheral devices operate properly according to
3
operation commands from the robot.
4 Brakes for each axis Check that the end effector drops within 5 mm when the power is cut.

1.2 FIRST 1-MONTH (320 HOURS) CHECKS


Check the following items once every one-month (320 hours). Additional inspection areas and times
should be added to the table according to the robot’s working conditions, environment, etc. Then every 3
months thereafter. (See the Section 1.4.)

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B-82755EN/05 1.CHECKS AND MAINTENANCE

Item Check items Check points


1 Check the oil gauge of Please confirm whether the amount of oil of the oil gauge has come
J4/J5/J6-axis gearbox above the center. Please replenish it in case of the shortage.
When the oil gauge part does not have air moiety, there is it, but this is
not abnormality.
When oil does not enter, the red index moiety of the oil gauge shows
the reflected heat of the light, and the outline of the index moiety is
seen clearly.
When oil enters, it does not show this reflected heat, and the outline of
the index is not clear.
Moreover, please exchange oil when oil discolors due to deterioration
and the character of the oil gauge cannot be read.
2 Confirm the broken of fluoric Confirm fluoric resin ring is not broken. If it is broken, replace it to new
resin ring one.
See Section 1.3. (Note 4)
3 Ventilation portion of controller Check whether the cable connected to the teach pendant and robot is
unevenly twisted.

OK OK OK NG
(Exchange oil)
Fig.1.2 The extent of oil deterioration

1.3 FIRST 3-MONTH (960 HOURS) CHECKS


Check the following items at the first quarterly inspection, then every year thereafter. (See the
Section .1.4.)

Item Check items Check points


1 Mechanical unit cable and Check whether the jackets of the mechanical unit cables and welding
welding cable are damaged. Also, check whether the cables are excessively bent or
unevenly twisted. Check that the connectors of the motors and
connector panels are securely engaged. (NOTE1)
2 Retightening external main bolts Further, tighten the end-effecter mounting bolts and external main
bolts. (NOTE2)
3 Check the mechanical stopper Check the looseness of mounting bolts of mechanical stopper and
and adjustable mechanical adjustable
stopper mechanical stopper. (NOTE3)
4 Cleaning and checking each part Clean each part (remove chips, etc.) and check component parts for
cracks and flaws. (NOTE4)
5 Check the end effector (hand) Confirm whether there is wound in the cable
cable, etc.
6 Controller cable and robot Check whether the cable connected to the teach pendant and robot is
connecting cable unevenly twisted.

Note 1) Inspection points and check items of the mechanical unit cables and
connectors

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1.CHECKS AND MAINTENANCE B-82755EN/05

Inspection points of the mechanical unit cables


Check the cable for damage that has been exposed.
Clean it when the spatter adheres.

Fig.1.3 (a) Inspection points of the mechanical unit cables

Inspection points of the connectors


- Power/brake connectors of the motor exposed externally
- Robot connection cables, earth terminal and user cables

Check items
- Circular connector: Check the connector for looseness by turning it manually.
- Square connector: Check the connector for disengagement of its lever.
- Earth terminal: Check the connector for looseness.

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B-82755EN/05 1.CHECKS AND MAINTENANCE

Remove this cover


and check here.

Fig.1.3 (b) Inspection points of connectors

Note 2) Points to be retightened


- The end effecter mounting bolts, robot installation bolts, and bolts to be removed for inspection need
to be retightened.
- The bolts exposed to the outside of the robot need to be retightened.
For the tightening torque, see the recommended bolt tightening torque shown in the Appendix.
A loose prevention agent (adhesive) is applied to some bolts. If the bolts are tightened with greater
than the recommended torque, the loose prevention agent may be removed. So, follow the
recommended tightening torque when retightening them.

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1.CHECKS AND MAINTENANCE B-82755EN/05

Note 3) Check of mechanical stopper and adjustable mechanical stopper.


- Check the looseness of stopper mounting bolts. If they are loose, they are needed to be retightened.

J3-axis mechanical stopper B

Spec
Bolt : A97L-0218-0742#M10X20
(Tightening torque 50Nm)
Stopper: A290-7221-X324 J3-axis mechanical stopper

J2-axis mechanical stopper A

J1-axis mechanical stopper B


J2-axis mechanical stopper B (When mechanical stopper is specified)
Spec
Stopper : A290-7215-X323 (2) Spec J1-axis mechanical stopper A
(Tighthening torque 56Nm) Bolt : A6-BA-16X20 (When mechanical stopper is specified)
(Tightening torque 56Nm)
Spec:
Bolt : A6-BA-8X12 (2)
(Tightening torque 37.2Nm)
Stopper : A290-7221-X361

Fig.1.3 (c) Check of mechanical stopper and adjustable mechanical stopper

Note 4) Cleaning
- Necessary cleaning points, dust on the flat part, sedimentation of spatters
Clean sediments periodically.
In particular, clean the following points carefully.
Vicinity of the wrist axis and oil seal
→ If chippings or spatters are attached to the oil seal, an oil leak may be caused.
Vicinity of M/H conduit
→ If chipping or spatters are attached to fluoric resin ring, it may shorten life of conduit.
Vicinity of the welding torch and wrist flange
→ The insulation failure occurs when the spatter has collected around the wrist flange or welding
torch, and there is a possibility of damaging the robot mechanism by the welding current. (See
Appendix E)

- Check items
- Check if the vicinity of the necessary inspection points, wrist part, and J3 arm significantly wears
due to rubbing against the welding cable or hand cable.
- Check if there is a trace of a collision around the gun or hand.
- Confirm if Fluoric resin ring is broken, if it was broken, replace it to new one. Two years are aims in
an exchange period. If you operate robot with the state that hard mine dust is attached to rotated
part, exchange period may shortens.
- Check the reducer or grease bath /oil bath for an oil leak.
→ If oil can be found a day after wiping oil, an oil leak may be caused.

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B-82755EN/05 1.CHECKS AND MAINTENANCE

Fluoric resin ring


(Spec:A290-7221-X571)

Fig.1.3 (d) Cleaning points

1.4 3-MONTH (960 HOURS) CHECKS


Check the following items once every one-month (320 hours).

Item Check items Check points


1 Check the oil gauge of (See Section 1.2).
J4/J5/J6-axis gearbox
2 Confirm the broken of fluoric resin Confirm fluoric resin ring is not broken. If it is broken, replace it to new
ring one.
See Section 1.3. (Note 4)
3 Ventilation portion of controller (See Section 1.2.)

1.5 1-YEAR (3,840 HOURS) CHECKS


Check the following items once every year (3,840 hours).

Item Check items Check points


1 Mechanical unit cable and (See Section 1.3.)
welding cable
2 Retightening external main bolts (See Section 1.3.)
3 Check the mechanical stopper (See Section 1.3.)
and adjustable mechanical
stopper
4 Cleaning and checking each part (See Section 1.3).
5 Check the end effector (hand) (See Section 1.3.)
cable, etc

-9-
1.CHECKS AND MAINTENANCE B-82755EN/05

Item Check items Check points


6 Battery (except ARC Mate Replace battery in the mechanical unit. (See Section 2.1.)
100iCe, M-10iAe, ARC Mate
100iCe/6L, M-10iAe/6L)
7 Controller cable and robot (See Section 1.3.)
connecting cable

1.6 1.5-YEAR CHECKS (5,760 hours)


Check the following item once every 1.5 year (5,760 hours).

Item Check items Check points


Battery (ARC Mate 100iCe, Replace battery in the mechanical unit. (See Section 7.2.1)
1 M-10iAe, ARC Mate 100iCe/6L,
M-10iAe/6L)

1.7 2-YEAR CHECKS (7,680 hours)


Check the following item once every 2 years (7,860 hours).

Item Check items Check points


Replacing M/H conduit Replace M/H conduit. (See Section 4.19)
1
/No dust M/H conduit

1.8 3-YEAR (11,520 HOURS) CHECKS


Check the following items once every 3 years (11,520 hours).

Item Check items Check points


1 Replacing grease and oil of each Replace grease and oil of reducer and gearbox.
axis reducer and gearbox See Section 2.2.

1.9 4-year (13,820 hours) checks


Check the following items once every 4 years (13,820 hours).

Item Check items Check points


1 Replace the mechanical unit cable Replace mechanical unit cable. (See Chapter 5.)

1.10 MAINTENANCE TOOLS


You should have the following instruments and tools ready for maintenance.

a) Measuring instruments
Instrument Condition Use
Dial gauge 1/100mm For positioning precision and backlash measurement
Calipers 150mm

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B-82755EN/05 1.CHECKS AND MAINTENANCE
b) Tools
Name Remarks
Phillips screwdrivers (Large, medium, and small sizes)
Flat-blade screwdrivers (Large, medium, and small sizes)
Box wrenches Width across flats 7, 10
Hexagonal wrench sets Width across flats 2.5, 3, 4, 5, 6, 8, 10, 12 (for replacing parts)
Torque wrench Width across flats 2.5, 3, 4, 5, 6, 8, 10, 17 (for replacing parts)
Long T wrenches Width across flats 2.5, 3, 4, 5, 6, 8, 10, 12 (for replacing parts)
Adjustable wrenches (Medium and small sizes)
Pliers
Long-nose pliers
Cutting pliers
Both-ended wrench
Grease gun
C-ring pliers
Press-fit fixture for J1-axis oil seal See Fig.4.3 (d)
J6 motor wiring detaching tool A290-7221-X971
Adaptor for J5/J6 axis oiling A290-7221-X591
Mounting fixture for J3-axis motor A290-7221-Z972 (Fig.1.10 (a))
(For robot which is made before March, 2010)
Mounting fixture for J3-axis motor A290-7221-Z974 (Fig.1.10 (b))
(For ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L,M-10iA/6L
which is made after March, 2010)
Mounting fixture for input gear of J3-axis A290-7221-X973 (Fig.1.10 (c))
motor (For ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L,M-10iA/6L
which is made before June, 2009)
Mounting fixture for input gear of J3-axis A290-7221-X974 (Fig.1.10 (d))
motor (For ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L,M-10iA/6L
which is made after July, 2009 and before March, 2010)
Mounting fixture for input gear of J3-axis A290-7221-X976 (Fig.1.10 (e))
motor (For ARC Mate 100iC/10S,M-10iA/10S)
Flashlight
LOCTITE 242,262,518,7649
Three bond
Oil injection gun A05B-1221-K005
Oil injection nipple with valve A05B-1221-K006
Oil tray with valve A05B-1221-K007

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1.CHECKS AND MAINTENANCE B-82755EN/05

0.3

( )

30°
DETAIL A
2 5.5 10 24.5

A
O6

O6
C0
.3
C0
.3
.3
-0.050

-0.050

注) C0
0

NOTE)
O 6.6

O 2.8

バリ無き事。
1)NO BURR.

全周糸面取り。
2)ALL EDGES SOULD BE CHAMFERED DETAIL 詳細
C0.2~C0.5.

Fig.1.10 (a) Mounting fixture for J3-axis motor A290-7221-Z972

M10 (ピッチ1.5) 12(二面幅)


PITCH WIDTH ACROSS FLAT

° 135 6
A 135 °
3.5 2
-0.1

+0.1
0

O 9.2
O 16
0.2 O 8.4

O 7.2
.2

0.4
C0

R
R

19 14
A
断面 A-A
注)
NOTE)
バリ無き事。
1)NO BURR.
SECTION 断面
全周糸面取り。
2)ALL EDGES SOULD BE CHAMFERED
C0.2~C0.5.

Fig.1.10 (b) Mounting fixture for J3-axis motor A290-7221-Z974

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B-82755EN/05 1.CHECKS AND MAINTENANCE
6 6

4- R
1

15
G
( )

62
r 0.01
94
P
45

0
10

R
3 A SECTION B-B

O
n 0.01 P
7 9 0
12
O
+0.01
0
13.15

RE
LI

B
45
EF

45°
+0.01
0
O 86
O 30

O 20
O 78

90

G
O 80

11
B
5

2- R
3

.
C0
R

1
64 0.5 8 5 Q
a 0.01 Q

R
n 0.01 P

A 62 15
90

SECTION A-A 4-M6 THRU.


EQ.SP.

THRU. 貫通
注) EQ.SP. 周上等配
NOTE) RELIEF 逃げ
SECTION 断面
全周糸面取りの事。
ALL EDGES SHOULD BE CHAMFERED
C0.1~C0.5.

Fig.1.10 (c) Mounting fixture for input gear of J3-axis motor A290-7221-X973

6.5 6.5

4- G
R
1
( )
15
62

90
P
94 45
r 0.01

A
G

7 9
n 0.01 P
+0.010
0
13.15

10 R RELIEF
45

G
+0.020

+0.010
O 86

O 32

O 20
O 78
0

G
90
O 22

O 80

12

RELIEF
3

.5
2-

C0
R

R
1

0.5
R
a 0.01 Q
n 0.01 P

64 8 5 Q
A ( 62 ) ( 15 )
O
12

SECTION A-A
0

注)
NOTE) THRU. 貫通
EQ.SP. 周上等配
全周糸面取りの事。 RELIEF 逃げ
ALL EDGES SHOULD BE CHAMFERED SECTION 断面
C0.1~C0.5.

Fig.1.10 (d) Mounting fixture for input gear of J3-axis motor A290-7221-X974
- 13 -
1.CHECKS AND MAINTENANCE B-82755EN/05

6.5 6.5

4-
R
1

15
G
( )

65
90
P
97 45
r 0.01

A
G

7 9
n 0.01 P
+0.010
0
16.352

10 R RELIEF

45
3

G
+0.020

+0.010

G
O 86
O 32

O 20
O 78

90
O 22

O 80

12
RELIEF 2-
3

.5 R
C0 1
R

67 8 5
a 0.01 Q
n 0.01 P

Q
A ( 65 ) ( 15 )

O
0.5

12
0
R

SECTION A-A
注) THRU. 貫通
NOTE) EQ.SP. 周上等配
RELIEF 逃げ
全周糸面取りの事。 SECTION 断面
ALL EDGES SHOULD BE CHAMFERED
C0.1~C0.5.

Fig.1.10 (e) Mounting fixture for input gear of J3-axis motor A290-7221-X976

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B-82755EN/05 2.PERIODIC MAINTENANCE

2 PERIODIC MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter.
(See the APPENDIX C PERIODIC MAINTENANCE TABLE.)

2.1 Replacing the Batteries (1 Year (3,840 Hours) or (1.5 Year


(5,760 Hours) Checks)
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced
every 1 year in case of ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L ARC Mate
100iC/10S, M-10iA/10S and 1.5 year in case of ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L,
M-10iAe/6L. Also, use the following procedure to replace when the backup battery voltage drop alarm
occurs.

Procedure of replacing the battery


1 Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.

CAUTION
Be sure to keep the controller power on.
Replacing the batteries with the power supply turned off causes all current
position data to be lost. Therefore, mastering will be required again.

2 Remove the battery case cap. (Fig. 2.1 (a) - (c))


3 Take out the old batteries from the battery case. In this time, battery can be taken out by pulling the
stick of the center of the battery box.
4 Insert new batteries into the battery case. Pay attention to the direction of batteries.
5 Close the battery case cap.

CAUTION
When using a robot with the severe dust/liquid protection option, remove the
cover from the battery case as shown in Fig. 2.1 (b) to replace the battery. After
replacing the battery, reinstall the cover. In this time, please be sure to replace
packing to new one for effects of severe dust/liquid protection.

- 15 -
2.PERIODIC MAINTENANCE B-82755EN/05

Battery can be taken out


by pulling this stick.

Case cap
Battery case Battery spec:A98L-0031-0027
(C battery 4pcs)

Fig.2.1 (a) Replacing the battery

Battery cover mounting bolt


M5X10 (4pcs)

Battery cover
Packing for battery cover
A290-7221-Z236

Case cap
Battery case Battery spec:A98L-0031-0027
(C battery 4pcs)
Fig.2.1 (b) Replacing the battery (When severe dust/liquid protection option is specified)

- 16 -
B-82755EN/05 2.PERIODIC MAINTENANCE

Battery case Battery spec:A98L-0031-0005 Case cap


(D battery 4 pcs)

Fig.2.2.1 (c) Replacing the battery


(ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)

2.2 REPLACING THE GREASE AND OIL OF THE DRIVE


MECHANISM (3 YEARS (11,520 HOURS) CHECKS)
Replace the grease of the reducers of J1, J2, and J3 axes and oil of the J4/J5/J6-axis gearbox in cycle that
is shorter among every three years and 11,520 hours by using the following procedures.
See table 2.2 (a) for the grease name and the quantity for J1 to J3 axis. See table 2.2 (b) for the oil name
and the quantity for J4 to J6 axis.

Table 2.2 (a) Grease name and amount to be replaced at regular intervals of three years (11,520 hours)
Greasing points Amount of grease to be applied Gun tip pressure Specified grease
J1-axis reducer 785g(872ml) Kyodo Yushi
0.1MPa or less
J2-axis reducer 300g(333ml) VIGOGREASE RE0
(NOTE 1)
J3-axis reducer 167g(186ml) (Specification: A98L-0040-0174)

Table 2.2 (b) Oil name and amount of standard to be replaced at regular intervals of three years
(11,520 hours)
Amount of oil to be applied
Oiling points Gun tip pressure Specified oil
(NOTE 2)
J4-axis gearbox 408g(480ml) Nippon Oil Corporation
0.1MPa or less
BONNOC AX68
J5/J6-axis gearbox 340g(400ml) (NOTE 1)
(Specification: A98L-0040-0233)

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2.PERIODIC MAINTENANCE B-82755EN/05

NOTE
When using a hand pump, apply grease approximately once per two seconds.
It is not a regulated amount injection. Be sure to confirm the amount of oil with the
oil gauge.

Please supplyl oil until oil level is Please supply oil until oil level is
3/4 or more ot the total height. H 3/4 or more ot the total height.

Please pay attention to the posture Please pay attention to the posture
of robot when the oig gauge is of robot when the oig gauge is
comfirmed referring to subection 7.2.2. comfirmed referring to subection 7.2.2.
L

In case of rising sun flag type oil gauge In case of "H-L" type oil gauge

Fig.2.2 (a) Oil gauge

For grease and oil replacement or replenishment, use the postures indicated below.
Consider relative angle of from posture of floor mount when robot is angle mount.
There is no brake for wrist axes of RC Mate 100iCe, M-10iAe, ARC Mate 100iCe/ 6L, M-10iAe/6L, so
be careful not to drop the axes.

- 18 -
B-82755EN/05 2.PERIODIC MAINTENANCE
Table 2.2 (c) Postures for greasing and oiling (Floor mount)
Posture
Supply position
J1 J2 J3 J4 J5 J6
J1-axis reducer Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary
J2-axis reducer 0°
J3-axis reducer 0° 0°
J4-axis gearbox Arbitrary 180°
Wrist (using oil pump) 18° -40°
Wrist (not using oil pump) 18° 90°
Wrist (Replenishment) 90° 0° 0°
Wrist (Oil discharge) -30° -70°
Wrist (confirm oiling) 0° 0°
Wrist (Release remaining
20° to 90° 90° Arbitrary
pressure)

Table 2.2 (d) Postures for greasing and oiling (Upside-down mount)
Posture
Supply position
J1 J2 J3 J4 J5 J6
J1-axis reducer Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary
J2-axis reducer -90°
J3-axis reducer 0° 180°
J4-axis gearbox Arbitrary 0°
Wrist (using oil pump) -18° 140°
Wrist (not using oil pump) -18° -90°
Wrist (Replenishment) -90° 0° 0°
Wrist (Oil discharge) 30° 110°
Wrist (confirm oiling) 180° 0°
Wrist (Release remaining
20° to 90° 90° Arbitrary
pressure)

Table 2.2 (e) Postures for greasing and oiling (-90°wall mount)
Posture
Supply position
J1 J2 J3 J4 J5 J6
J1-axis reducer Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary
J2-axis reducer 90°
J3-axis reducer 0° 0°
J4-axis gearbox Arbitrary 90°
Wrist (using oil pump) -72° -40°
Wrist (not using oil pump) -72° 90°
Wrist (Replenishment) 0° 0° 0°
Wrist (Oil discharge) -210° -70°
Wrist (confirm oiling) -90° 0°
Wrist (Release remaining
0° to 70° 90° Arbitrary
pressure)

- 19 -
2.PERIODIC MAINTENANCE B-82755EN/05

Table 2.2 (f) Postures for greasing and oiling (+90°wall mount)
Posture
Supply position
J1 J2 J3 J4 J5 J6
J1-axis reducer Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary Arbitrary
J2-axis reducer -90°
J3-axis reducer 0° 0°
J4-axis gearbox Arbitrary -90°
Wrist (using oil pump) 108° -40°
Wrist (not using oil pump) 108° 90°
Wrist (Replenishment) 180° 0° 0°
Wrist (Oil discharge) 150° -70°
Wrist (confirm oiling) 90° 0°
Wrist (Release remaining
110° to 180° 90° Arbitrary
pressure)

Upside-down mount

+90°wall mount -90°wall mount


Fig.2.2 (b) Installation method

- 20 -
B-82755EN/05 2.PERIODIC MAINTENANCE

Oil gauge
for J4-axis gearbox

J4-axis gearbox oil inlet


taper plug R1/8

VIEW A

J1-axis reducer grease outlet


seal bolt M8X10

Fig.2.2 (c) greasing point of reducer and oil supplying points of gearbox (1)
(ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L,ARC Mate 100iCe, M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L)

Oil gauge
for J5/J6-axis gearbox
J2-axis reducer grease inlet J5/J6-axis gearbox
taper plug R1/8 first oil inlet (when oil pump is used)
VIEW B J5/J6-axis gearbox
Extra low bolt M6X8 & seal washer oil outlet
Extra low bolt M8X8
& seal washer
J3-axis reducer grease inlet
seal bolt M6X8 or
bolt M6X10 & seal washer

J3-axis reducer grease outlet


seal bolt M8X10 J5/J6-axis gearbox
Refer to the ventilator hole when replacing oil
note of lower right. Extra low bolt M5X8 &seal washer

J5/J6-axis gearbox
B second oil inlet (When oil pump is not used)
Extra low bolt M6X8
&seal washer

J2-axis reducer grease outlet


seal bolt M8X10
Note)
Thre is a case that position of
J3-axis grease outlet is figure below
depending on the time of shippment.
J1-axis reducer grease inlet
taper plug R1/8

J3-axis reducer grease outlet


seal bolt M8X10

Fig.2.2 (d) Greasing point of reducer and oil supplying points of gearbox (2)
ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L,ARC Mate 100iCe, M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L)
- 21 -
2.PERIODIC MAINTENANCE B-82755EN/05

J4-axis gearbox oil outlet


taper plug R1/8
or
seal bolt M8X10
Fig.2.2 (e) greasing point of reducer and oil supplying points of gearbox (3)
(ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L,ARC Mate 100iCe, M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L)

Oil gauge
for J4-axis gear box

A A

J4-axis gearbox
oil inlet
taper plug R1/8
J4-axis gearbox
ventilator hole
taper plug R1/8

SECTION A-A

J1-axis reducer grease outlet


seal bolt M8X10

Fig.2.2.1 (f) greasing point of reducer and oil supplying points of gearbox (1)
(ARC Mate 100iC/10S,M-10iA/10S)

- 22 -
B-82755EN/05 2.PERIODIC MAINTENANCE

J5/J6-axis gearbox
oil outlet
J2-axis reducer Extra low bolt M8X8
grease inlet & seal washer
taper plug R1/8
Oil gauge
VIEW B for J5/J6-axis gearbox
J5/J6-axis gearbox
first oil inlet
(when oil pump is used)
Extra low bolt M6X8
& seal washer

J5/J6-axis gearbox
ventilator hole
when replacing oil
Extra low bolt M5X8
J3-axis reducer &seal washer
B
grease inlet
bolt M6X10 J5/J6-axis gearbox
& seal washer second oil inlet
(When oil pump is not used)
Extra low bolt M6X8
&seal washer
J3-axis reducer grease outlet
seal bolt M8X10

J2-axis reducer grease outlet


seal bolt M8X10

J1-axis reducer grease inlet


taper plug R1/8

Fig.2.2.1 (g) greasing point of reducer and oil supplying points of gearbox (2)
(ARC Mate 100iC/10S,M-10iA/10S)

J4-axis gearbox oil outlet


seal bolt M8X10
Fig.2.2.1 (h) greasing point of reducer and oil supplying points of gearbox (3)
(ARC Mate 100iC/10S,M-10iA/10S)

- 23 -
2.PERIODIC MAINTENANCE B-82755EN/05

Table 2.2 Specification of seal bolts, taper plug and seal washer
Parts name Specification
Seal bolt (M6X8) A97L-0218-0417#060808
Seal bolt (M8X10) A97L-0218-0417#081010
taper plug (R1/8) A97L-0001-0436#1-1D
seal washer (M5) A30L-0001-0048#5M
seal washer (M6) A30L-0001-0048#6M
seal washer (M8) A30L-0001-0048#8M

2.2.1 Grease replacement procedure for the reducer (J1 to J3-axis)


CAUTION
If greasing is performed incorrectly, the internal pressure of the grease bath may
suddenly increase, possibly causing damage to the seal, which would in turn
lead to grease leakage and abnormal operation. When performing greasing,
therefore, observe the following cautions.
1 Before starting to grease, open the grease outlet (remove the seal bolt from
the grease outlet).
2 Supply grease slowly, using a manual pump.
3 Whenever possible, avoid using an air pump, which is powered by the factory
air supply.
If the use of an air pump is unavoidable, supply grease with the pump at a
pressure lower than or equal to the gun tip pressure (see Table 2.2 (a)).
4 Use grease only of the specified type. Grease of a type other than that
specified may damage the reducer or lead to other problems.
5 After greasing, release remaining pressure from the grease bath using the
procedure given in Subsection 2.2.3, and then close the grease outlet.
6 To prevent accidents caused by slipping, completely remove any excess
grease from the floor or robot.

Grease replacement procedure of the J1, J2, J3-axis reducer


1 Move the robot to the greasing posture described in Table.2.2 (c) to (f).
2 Turn off the controller power.
3 Remove the taper plug or seal bolt from grease outlet. (Fig.2.2 (c) to 2.2 (h))
4 Remove the taper plug or seal bolt from grease inlet and attach grease nipple.
5 Keep greasing until the new grease pushes out the old grease and comes out from each grease outlet
6 Release remaining pressure using the procedure given in Subsection 2.2.3.

2.2.2 Oil replacement procedure for the gearbox (J4 to J6-axis)


NOTE
Operation with oil shortage may cause severe damage to gears. Please make
sure the gearbox is always filled with correct amount of oil.

1 In case of J4-axis, move the robot to the oil-replacing posture described in Table 2.2 (c) to (f). In
case of J5/J6-axis, move the robot to the posture of wrist (oil discharge).
2 Turn off the controller power.
3 Put the collection bottle under the oil outlet.
(In case of J4-axis gearbox)
Remove any peripheral equipment, which has been mounted at the J4 oil outlet. In case of ARC
Mate 100iC/10S,M-10iA/10S, remove ventilator hole, too. And remove J4 connector plate
- 24 -
B-82755EN/05 2.PERIODIC MAINTENANCE
mounting bolts so that you cans see plug of oil inlet. In this time, pay attention not to cut nylon
band which is attached to mechanical unit cable. There is a case to have to take connector of
user side and air joint off for move the connector panel. Afterwards remove the taper plug of oil
inlet and outlet.
(In case of J5/J6-axis gearbox)
Remove the extra low bolt M8×8 and seal washer.(See Fig.2.2 (c) to (e))
4 Install the taper plug or extra low bolt and seal washer in the oil outlet after all oil is exhausted.
In case of ARC Mate 100iC/10S,M-10iA/10S, attach taper plug of ventilator hole, too
(In case of J4-axis gearbox)
Firstly, supply oil of 150ml, attach taper plug of oil inlet, in case of ARC Mate
100iC/10S,M-10iA/10S, attach taper plug of ventilator hole, too, make the robot to J3-axis 0º,
remove seal bolt of J4-axis oil outlet, furthermore add oil of 330ml.
When the adapter for oiling (A290-7221-X591) is used, oiling is easy. Install it as shown in
Fig.2.2.2 (b) when you use the oiling adapter. The amounts of oiling are about as many as two
adapters. It takes about five minutes to oil as many as one cup. Attach seal bolt of J4-axis oil
outlet after supplying oil.
(In case of J5/J6-axis gearbox)
1) When oil pump is used
Oil from the J5/J6 axis gearbox first oil inlet (M6) of Fig. 2.2 (d) when you use the oil pump.
At this time, make robot to the posture of wrist (using oil pump). In addition, oil after opening
the oil outlet of the J6 axis crossing roller ring. At this time, stop the M8 oil out once after it
puts it from the M8 oil discharge entrance to going out, make to the posture of wrist
(Replenishment). This time, and add oil from the second oil inlet (M5) with the syringe etc.
Stop it because oil comes out from the oil inlet by about 15ml. Make robot to the posture of
wrist (confirm oiling) at the end and confirm the amount of the oil gauge.

2) When oil pump is not used


Remove the extra low bolt and seal washer of oil inlet and ventilator hole of Fig.2.2 (d), move
the robot posture of wrist (not using oil pump) and add oil. When the adapter for oiling
(A290-7221-X591) is used, oiling is easy. Install it to second oil inlet as shown in Fig.2.2.2 (b)
and add oil when you use the oiling adapter. The amounts of oiling are about as many as two
adapters. It takes about five minutes to oil as many as one cup.
When oil come ventilator hole, remove adapter and move the robot to the posture of wrist
(confirm oiling) and check oil gauge referring to Fig.2.2.2 (c). In case oil level is insufficient,
please fine-tune it by replenishing it with a syringe. Then turn J4-axis 90°and put it back and
confirm height of oil level is 3/4 or more. When oil amount is insufficient, make robot to the
posture of wrist (Replenishment) this time, and add oil from the second oil inlet (M5) with the
syringe etc. Stop it because oil comes out from the oil inlet by about 15ml and close the oil inlet.
Make robot to the posture of wrist (confirm oiling) at the end and confirm the amount of the oil
gauge.

3) When using oil gun


Attach oil injection nipple with valve (A05B-1221-K002) to J5/J6-axis gearbox first oil inlet of
Fig.2.2 (d),(g). Attach oil tray with valve (A05B-1221-K003) to J5/J6-axis gearbox oil outlet
(J6-axis cross roller part). Confirm valve of oil inlet and oil outlet are open referring to
Fig.2.2.2 (d). Supply oil to J5/J6-axis gearbox first oil inlet till oil is come out come from oil
outlet by oil injection gun (A05B-1221-K005). When oil appears from oil outlet, stop
supplying oil and close the valve of oil injection nipple. After that, close the valve of oil tray,
remove tray and close the oil outlet. Then remove oil injection nipple and close the oil inlet.
Make robot to the posture of wrist (Replenishment) this time, and add oil from the second oil
inlet (M5) with the syringe etc. Stop it because oil comes out from the oil inlet by about 15ml
and close the oil inlet. Finally make robot to the posture of wrist (confirm oiling) at the end and
confirm the amount of the oil gauge. Then turn J4-axis 90°and put it back and confirm height
of oil level is 3/4 or more. If oil is sufficient replenish oil with sponge and adjust it.
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2.PERIODIC MAINTENANCE B-82755EN/05

CAUTION
If supplying oil forcibly when valve is closed, internal pressure of oil bath rise
abnormally and cause oil leak from seal part or oil seal falling out. Be careful

5 Release remaining pressure using the procedure given in Subsection 2.2.4.


If equipment is installed to this surface,
remove it.

Bolt M6X10

J4 connector panel
Bolt M6X10

J4 connector panel
ARC Mate 100iC , M-10iA ARC Mate 100iC/10S , M-10iA/10S
ARC Mate 100iC/6L , M-10iA/6L
ARC Mate 100iCe , M-10iAe
ARC Mate 100iCe/6L , M-10iAe/6L

Fig.2.2.2 (a) Replacing oil of J4-axis gearbox

Remove this bolt.

J4-axis gearbox In case of J5/J6-axis

Fig.2.2.2 (b) Oiling adapter

Please supply oil until oil level is Please supply oil until oil level is
3/4 or more of the total height. 3/4 or more of the total height.

In case of rising sun flag type oil gauge In case of "H-L" type oil gauge

Fig.2.2.2 (c) Standard of oil gauge


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B-82755EN/05 2.PERIODIC MAINTENANCE

Oil tray with valve


A05B-1221-K007

White line

Oil injection nipple with valve


A05B-1221-K006

Valve is open Valve is closed

Oil injection gun


A05B-1221-K005

Fig.2.2.2 (d) Oiling by oil gun

2.2.3 Procedure for releasing remaining pressure from the grease


bath (J1 to J3-axis)
After applying grease, operate the robot as instructed below with the taper plug and seal bolt of the grease
inlet and outlet uncapped to release the remaining pressure within the grease bath. In case of J2-axis, there
are two seal bolts for grease outlet, so uncap both of them.
Attach a recovery bag below the grease inlet and outlet to prevent output grease from splattering.

Operating axis
Grease J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis
replacement part
Axis angle
of 60° or
J1-axis reducer more Arbitrary
OVR 100%
Axis angle
of 60° or
J2-axis reducer Arbitrary more Arbitrary
OVR 100%
Axis angle
of 60° or
J3-axis reducer Arbitrary more Arbitrary
OVR 100%

If the above operation cannot be performed due to the environment of the robot, prolong the operating
time so that an equivalent operation can be performed. (When the maximum allowable axis angle is 30
- 27 -
2.PERIODIC MAINTENANCE B-82755EN/05

degrees, perform the twice operation for 20 minutes or more.) After completion of the operation, attach
the taper plug and seal bolts to the grease inlets and outlets. When reusing the taper plug and seal bolts,
be sure to seal them with seal tape.

After replacing grease or oil, grease bath or oil bath may rise if robot is operated again under frequent
inversion movement or high temperature environment. In these cases, you can return internal pressure by
releasing grease out let or oil outlet just after operation of robot. (When opening grease outlet or oil outlet,
refer to Section 2.2 and pay attention grease or oil is not scattered.)

2.2.4 Procedure for releasing oil (J4 to J6-axis)


After replacing oil, please do the following operation to adjust the amount of oil properly.

In case of J4-axis gearbox


Confirm that oil level seen in oil gauge is as per Fig.2.2.2 (c). If confirmed then please operate robot J4
axis during 10 minutes, at 100% override, making 90 degrees motion (or more). Keep oil inlet and oil
outlet closed during this operation. When completed, move the robot posture so that J4-gearbox oil outlet
is right above. (In case of floor mount, J3=0°.) Remaining pressure release at once if upper side of oil
inlet/outlet is opened. When removing oil outlet, please work while covering the oil outlet in wastes so
that oil may protrude.
After operation, confirm whether the oil side of the oil gauge has come above the 3/4 or more of the total
height, add oil from the J4 axis gearbox oil inlet with the syringe etc. when oil is a little. In addition,
attach taper plug of the oil inlet.
Wipe the oil that adheres to the surface of the robot off when confirming it and close the oil inlet/outlet
completely.

In case of J5/J6-axis gearbox


Confirm that oil level seen in oil gauge is as per Fig.2.2.2 (c). If confirmed then please jog robot to the
posture of wrist (Release remaining pressure). Attach extra low bolt and seal washer of the oil inlet but
keep it loose. Operate robot J5 and J6 axis during 10 minutes, at 100% override, making 90 degrees
motion (or more) on both axis. When completed, please jog to the posture of wrist (Replenishment).
Remaining pressure release at once if second oil inlet (M5) is opened.
Confirm that oil level seen in oil gauge is above 3/4 or more of total height. At this time, please rotate the
J4 axis in the direction of +/-, and confirm the thing that the amount of oil doesn't decrease. Move robot
to the posture of wrist (Replenishment) again and add oil from the second oil inlet (M5) with the syringe
etc. when decreasing after operation, attach taper plug of the oil inlet.
Wipe the oil that adheres to the surface of the robot off when confirming it and close the first oil inlet
completely. Be sure to wind seal tape to thread part when taper plug is reused.
When tightening bolts of oil inlet and oil outlet, confirm seal washer is attached before tightening bolts.
Be sure to wind seal tape to thread part when seal tape is reused.
If the above operation cannot be performed due to the environment of the robot, prolong the operating
time so that an equivalent operation can be performed. (When the maximum allowable axis angle is 45
degrees, perform the twice operation for 20 minutes or more.) After completion of the operation, attach
the taper plug to the oil inlets.

After replacing grease or oil, grease bath or oil bath may rise if robot id operated again under frequent
inversion movement or high temperature environment. In these cases, you can return internal pressure by
releasing grease out let or oil outlet just after operation of robot. (When opening grease outlet or oil outlet,
refer to Section 2.2 and pay attention grease or oil is not scattered.)

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B-82755EN/05 2.PERIODIC MAINTENANCE

CAUTION
When reusing seal bolt and taper plug, be sure to seal t thread part with seal
tape.
As for the seal washer, n one side, rubber sticks to the entire and the other side,
rubber sticks to only around hole and rubber sticks is incomplete state, Attach
later face to bolt side. Confirm seal washer by viewing. If it is damaged
obviously, replace it to new one.
See Table 2.2 about specification of seal bolts and seal washer.

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3.TROUBLESHOOTING B-82755EN/05

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

3.2 FAILURES, CAUSES AND MEASURES


Table 3.2 (a) lists the major failures that may occur in the mechanical unit and their probable causes. If
you cannot pinpoint a failure cause or which measures to apply, contact FANUC.

Table 3.2 (a) Failures, causes and measures


Symptom Description Cause Measure
Vibration -The J1 base lifts off the floor [J1 base fastening] -If a bolt is loose, apply
Noise plate as the robot operates. -It is likely that the robot J1 LOCTITE and tighten it to the
-There is a gap between the base is not securely fastened to appropriate torque.
J1 base and floor plate. the floor plate. -Adjust the floor plate surface
-A J1 base-retaining bolt is -Probable causes are a loose flatness to within the specified
loose. bolt, an insufficient degree of tolerance.
surface flatness, or foreign -If there is any foreign matter
material caught between the J1 between the J1 base and floor
base and floor plate. plate, remove it.
-If the robot is not securely
fastened to the floor plate, the
J1 base lifts the floor plate as
the robot operates, allowing the
base and floor plates to strike
each other, which, in turn, leads
to vibration.
-The rack or floor plate [Rack or floor] -Reinforce the rack or floor to
vibrates during operation of -It is likely that the rack or floor make it more rigid.
the robot. is not sufficiently rigid. -If it is impossible to reinforce
-If the rack or floor is not the rack or floor, modify the
sufficiently rigid, reaction from robot control program; doing so
the robot deforms the rack or might reduce the amount of
floor, leading to vibration. vibration.
-Vibration becomes more [Overload] -Check the maximum load that
serious when the robot adopts -It is likely that the load on the the robot can handle once
a specific posture. robot is greater than the more. If the robot is found to be
-If the operating speed of the maximum rating. overloaded, reduce the load, or
robot is reduced, vibration -It is likely that the robot control modify the robot control
stops. program is too demanding for program.
-Vibration is most noticeable the robot hardware. -Vibration in a specific portion
when the robot is accelerating. -It is likely that the can be reduced by modifying
-Vibration occurs when two or ACCELERATION value is the robot control program while
more axes operate at the excessive. slowing the robot and reducing
same time. its acceleration (to minimize the
influence on the entire cycle
time).

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B-82755EN/05 3.TROUBLESHOOTING

Symptom Description Cause Measure


Vibration -Vibration was first noticed [Broken gear, bearing, or -Operate one axis at a time to
Noise after the robot collided with an reducer] determine which axis is
(Continued) object or the robot was - It is likely that collision or vibrating.
overloaded for a long period. overload applied an excessive -Confirm the oil side of the oil
-The grease of the vibrating force on the drive mechanism, gauge of J4-J6 axis.
axis has not been exchanged thus damaging the geartooth Replenish oil when the oil side
for a long period. surface or rolling surface of a has not reached above the half.
bearing, or reducer. -Remove the motor, and
- It is likely that prolonged use replace the gear, the bearing,
of the robot while overloaded and the reducer. For the spec.
caused fretting of the gear tooth of parts and the method of
surface or rolling surface of a replacement, contact FANUC.
bearing, or reducer due to -Using the robot within its
resulting metal fatigue. maximum rating prevents
- It is likely that foreign matter problems with the drive
caught in a gear, bearing, or mechanism.
within a reducer caused -Regularly changing the grease
damage on the gear tooth with a specified type can help
surface or rolling surface of the prevent problems.
bearing, or reducer.
- It is likely that, because the
grease has not been changed
for a long period, fretting
occurred on the gear tooth
surface or rolling surface of a
bearing, or reducer due to metal
fatigue.

These factors all generate cyclic


vibration and noise.

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3.TROUBLESHOOTING B-82755EN/05

Symptom Description Cause Measure


Vibration -The cause of problem cannot [Controller, cable, and motor] -Refer to the controller
Noise be identified from examination -If a failure occurs in a controller Maintenance Manual for
(Continued) of the floor, rack, or circuit, preventing control troubleshooting related to the
mechanical section. commands from being supplied controller and amplifier.
to the motor normally, or -Replace the Pulsecoder for the
preventing motor information motor of the axis that is
from being sent to the controller vibrating and check whether the
normally, vibration might occur. vibration still occurs.
-If the Pulsecoder develops a -Also, replace the motor of the
fault, vibration might occur axis that is vibrating, and check
because whether vibration still occurs.
Information about the motor For the method of replacement,
position cannot be transferred contact FANUC.
to the controller accurately. -Check that the robot is
-If the motor becomes defective, supplied with the rated voltage.
vibration might occur because -Check whether the sheath of
the motor cannot deliver its the power cord is damaged. If
rated performance. so, replace the power cord, and
-If a power line in a movable check whether vibration still
cable of the mechanical section occurs.
has an intermittent break, -Check whether the sheath of
vibration might occur because the cable connecting the
the motor cannot accurately mechanical section and
respond to commands. controller is damaged. If so,
-If a Pulsecoder wire in a replace the connection cable,
movable part of the mechanical and check whether vibration still
section has an intermittent occurs.
break, vibration might occur -If vibration occurs only when
because commands cannot be the robot assumes a specific
sent to the motor accurately. posture, it is likely that a cable
-If a connection cable between in the mechanical unit is broken.
them has an intermittent break, -Shake the movable part cable
vibration might occur. while the robot is at rest, and
-If the power cable has an check whether an alarm occurs.
intermittent break, vibration If an alarm or any other
might occur. abnormal condition occurs,
-If the power source voltage replace the mechanical unit
drops below the rating, vibration cable.
might occur. -Check that the robot control
-If a robot control parameter is parameter is set to a valid
set to an invalid value, vibration value. If it is set to an invalid
might occur. value, correct it. Contact
FANUC for further information if
necessary.

- 32 -
B-82755EN/05 3.TROUBLESHOOTING

Symptom Description Cause Measure


Vibration -There is some relationship [Noise from a nearby machine] -Connect the grounding wire
Noise between the vibration of the -If the robot is not grounded firmly to ensure a reliable
(Continued) robot and the operation of a properly, electrical noise is ground potential and prevent
machine near the robot. induced on the grounding wire, extraneous electrical noise.
preventing commands from
being transferred accurately,
thus leading to vibration.
-If the robot is grounded at an
unsuitable point, its grounding
potential becomes unstable,
and noise is likely to be induced
on the grounding line, thus
leading to vibration.
-There is an unusual sound -There may be an unusual -Use the specified grease.
after replacement of grease. sound when using other than -When there is an unusual
-There is an unusual sound the specified grease. sound even for specified
after a long period. -Even for the specified grease, grease, perform operation for
-There is an unusual sound there may be an unusual sound one or two days on an
during operation at low speed. during operation at low speed experiment. Generally, a usual
immediately after replacement sound will disappear.
or after a long period.
-There is an unusual sound -There is a possibility of grease -Stop the robot, and confirm the
when operating right or oil has not been exchanged damage situation at once.
immediately the replacing part, accurately. The amount of -Replenish grease or oil when
grease or oil. grease or oil may be they are insufficient.
insufficient.

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3.TROUBLESHOOTING B-82755EN/05

Symptom Description Cause Measure


Rattling -While the robot is not [Mechanical section coupling -Check that the following bolts
supplied with power, pushing it bolt] for each axis are tight. If any of
with the hand causes part of -It is likely that overloading or a these bolts is loose, apply
the mechanical unit to wobble. collision has loosened a LOCTITE and tighten it to the
-There is a gap on the mounting bolt in the robot appropriate torque.
mounting face of the mechanical section. -Motor retaining bolt
mechanical unit. -Reducer retaining bolt
-Reducer shaft retaining bolt
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
-Backlash is greater than the [Increase in backlash] -Operate one axis at a time to
tolerance stated in the -It is likely that excessive force determine which axis has the
applicable maintenance applied to the drive mechanism, increased backlash.
manual. (See Section 3.3/) due to a collision or -Remove the motor, and check
overloading, has broken a gear whether any of its gears are
or the inside of the reducer, broken. If any gear is broken,
resulting in an increase in the replace it.
amount of backlash. -Check whether any other gear
-It is likely that prolonged use of the drive mechanism is
has caused the tooth surfaces damage. If there is no damage
of a gear and the inside of the gear, replace the reducer.
reducer to wear out, resulting in -If the reducer is broken, or if a
an increase in the amount of gear tooth is missing, replace
backlash. the relevant component. Also,
-It is likely that prolonged use remove all the grease or oil
without changing the grease from the gearbox and wash the
has caused the tooth surfaces inside of the gearbox.
of a gear and the inside of the -After replacing the gear or
reducer to wear out, resulting in reducer, add an appropriate
an increase in the amount of amount of grease or oil.
backlash. -Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly applying the grease
or oil with a specified type can
help prevent problems.

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B-82755EN/05 3.TROUBLESHOOTING

Symptom Description Cause Measure


Motor -The ambient temperature of [Ambient temperature] -The teach pendant can be
overheating the installation location -It is likely that a rise in the used to monitor the average
increases, causing the motor ambient temperature or current. Check the average
to overheat. attaching the motor cover current when the robot control
-After a cover was attached to prevented the motor from program is running. The
the motor, the motor releasing heat efficiently, thus allowable average current is
overheated. leading to overheating. specified for the robot according
-After the robot control [Operating condition] to its ambient temperature.
program or the load was -It is likely that the robot was Contact FANUC for further
changed, the motor operated with the maximum information.
overheated. average current exceeded. -Relaxing the robot control
program and conditions can
reduce the average current,
thus preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of the
motor well ventilated enables
the motor to release heat
efficiently, thus preventing
overheating. Using a fan to
direct air at the motor is also
effective.
-If there is a source of heat near
the motor, it is advisable to
install shielding to protect the
motor from heat radiation.
-After a control parameter was [Parameter] -Input an appropriate parameter
changed, the motor -If data input for a workpiece is as described in CONTROLLER
overheated. invalid, the robot cannot be OPERATOR’S MANUAL.
accelerated or decelerated
normally, so the average
current increases, leading to
overheating.
-Symptom other than stated [Mechanical section problems] -Repair the mechanical unit
above -It is likely that problems while referring to the above
occurred in the mechanical unit descriptions of vibration, noise,
drive mechanism, thus placing and rattling.
an excessive load on the motor. -Check that, when the servo
[Motor problems] system is energized, the brake
-It is likely that a failure of the is released.
motor brake resulted in the If the brake remains applied to
motor running with the brake the motor all the time, replace
applied, thus placing an the motor.
excessive load on the motor. -If the average current falls after
-It is likely that a failure of the the motor is replaced, it
motor prevented it from indicates that the first motor was
delivering its rated performance, faulty.
thus causing an excessive
current to flow through the
motor.

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3.TROUBLESHOOTING B-82755EN/05

Symptom Description Cause Measure


Grease oil -Grease or oil is leaking from [Poor sealing] -If a crack develops in the
leakage the mechanical unit. -Probable causes are a crack in casting, sealant can be used as
the casting, a broken O-ring, a a quick-fix to prevent further
damaged oil seal, or a loose grease or oil leakage. However,
seal bolt. the component should be
-A crack in a casting can occur replaced as soon as possible,
due to excessive force that because the crack might
might be caused in collision. extend.
-An O-ring can be damaged if it -O-rings are used in the
is trapped or cut during locations listed below.
disassembling or -Motor coupling section
re-assembling. -Reducer (case and shaft)
-An oil seal might be damaged if coupling section
extraneous dust scratches the -Connection part of the wrist
lip of the oil seal. -J3 arm coupling section
-A loose seal bolt might allow -Inside the wrist
grease to leak along the -Oil seals are used in the
threads. locations stated below.
-Inside the reducer
-Inside the wrist
-Seal bolts are used in the
locations stated below.
-Grease inlet/outlet
-Oil inlet/outlet
-For fix of cover

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B-82755EN/05 3.TROUBLESHOOTING

Symptom Description Cause Measure


Dropping axis -An axis drops because the [Brake drive relay and motor] -Check whether the brake drive
brake does not function. -It is likely that brake drive relay relay contacts are stuck to each
-An axis drops gradually when contacts are stuck to each other other. If they are found to be
it should be at rest. to keep the brake current stuck, replace the relay.
flowing, thus preventing the -If the brake shoe is worn out, if
brake from operating when the the brake main body is
motor is reenergized. damaged, or if oil or grease has
-It is likely that the brake shoe entered the motor, replace the
has worn out or the brake main motor.
body is damaged, preventing - J4-axis cable has movable
the brake from operating part .So if robot exceeds stroke
efficiently. limit, load depends on cable and
-It is likely that oil or grease has it may cause damage of cables .
entered the motor, causing the If robot exceeds stroke limit,
brake to slip. remove plate of back of J4,
- In case of ARC Mate 100iCe , return axis to motion range
M-10iAe, ARC Mate 100iCe/6L, during checking condition of
M-10iAe/6L brake is not cables. If nylon band is cut,
installed for J1/J4/J5/J6-axes. In attach new articles. If you
case of J4/J5/J6-axes If you operate robot with nylon band is
turn off the controller power at cut, it cause damage of cables.
wait position, robot may move (See Section 6.1).
greatly by weight or exceeds
stroke limit depend on the
posture of robot or wrist load
condition. Adjust the wait
position so that axis does not
move greatly when controller
power is turned off.

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3.TROUBLESHOOTING B-82755EN/05

Symptom Description Cause Measure


Displacement -The robot operates at a point [Mechanical section problems] -If the repeatability is unstable,
other than the taught position. -If the repeatability is unstable, repair the mechanical section by
-The repeatability is not within probable causes are a failure in referring to the above
the tolerance. the drive mechanism or a loose descriptions of vibration, noise,
bolt. and rattling.
-If the repeatability becomes -If the repeatability is stable,
stable, it is likely that a collision correct the taught program.
imposed an excessive load, Variation will not occur unless
leading to slipping on the base another collision occurs.
surface or the mating surface of -If the Pulsecoder is abnormal,
an arm or reducer. replace the motor or the
-It is likely that the Pulsecoder is Pulsecoder.
abnormal.
-Displacement occurs only in a [Peripheral unit displacement] -Correct the setting of the
specific peripheral unit. -It is likely that an external force peripheral unit position.
was applied to the peripheral -Correct the taught program.
unit, thus shifting its position
relative to the robot.
-Displacement occurred after a [Parameter] -Re-enter the previous
parameter was changed. -It is likely that the mastering mastering data, which is known
data was rewritten in such a to be correct.
way that the robot origin was -If correct mastering data is
shifted. unavailable, perform mastering
again.
BZAL alarm -BZAL is displayed on the -It is likely that the voltage of the -Replace the battery.
occurred controller screen memory backup battery is low. -Replace the cable.
- It is likely that the Pulsecoder
cable is defected.

Table 3.2 (b) Allowable drops


At power off 5mm
At Power-Off stop 5mm

NOTE
Each value indicates the amount by which an end effector mounting face may
fall.

3.3 BACKLASH MEASUREMENT


Measurement method
1 Maintain the robot in a specified posture. (See Fig. 3.3 (b) to (d).)
2 Apply positive and negative loads to each axis as shown in Fig.3.3 (a).
3 Remove the loads and measure the displacement.

Measure backlash by applying positive and negative loads to each axis three times. Average the
values measured in the last two measurements for each axis, and use the averages as a measured
backlash for the respective axes.

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B-82755EN/05 3.TROUBLESHOOTING

Stop position
0

+10kgf (J1 to J3-axis)


+ 3kgf (J4 to J6-axis)

-10kgf (J1 to J3-axis) First step


- 3kgf (J4 to J6-axis) (Do not measure)
+10kgf (J1 to J3-axis)
+ 3kgf (J4 to J6-axis)

-10kgf (J1 to J3-axis) 0kg Second step


L1
- 3kgf (J4 to J6-axis) (B2 =L1+ L2)
0kg +10kgf (J1 to J3-axis)
L2
+ 3kgf (J4 to J6-axis)
0kg Third step
-10kgf (J1 to J3-axis) L3 (B3=L3+ L4)
- 3kgf (J4 to J6-axis)
0kg
L4

Fig.3.3 (a) Backlash measurement method

B2 + B3
Backlash B is calculated using the following expression: B=
2

1629 : ARC Mate 100iC, M-10iA


ARC Mate 100iCe, M-10iAe
1300 : ARC Mate 100iC/10S,M-10iA/10S 1760

56
Loading positon Loading position

Measured position Measured position


J1 Arbitrary
J2  80°
J3 0°
J4 0°
J5 0°
ARC Mate 100iC, M-10iA J6 ±90° ARC Mate 100iC/ 6L, M-10iA/6L
ARC Mate 100iC/10S, M-10iA/10S ARC Mate 100iCe/6L, M-10iAe/6L
ARC Mate 100iCe, M-10iAe
<J1-axis measured posture>

Fig.3.3 (b) Backlash measured posture (1/3)

- 39 -
3.TROUBLESHOOTING B-82755EN/05

Measured position
Loading positon
600 : ARC Mate 100iC, M-10iA
ARC Mate 100iCe, M-10iAe
ARC Mate 100iC/6L, M-10iA/6L
ARC Mate 100iCe/6L, M-10iAe/6L

400 : ARC Mate 100iC/10S, M-10iA/10S

J1 Arbitrary
J2  0°
J3 82°
J4 0°
J5 0°
J6 Arbitrary

<J2-axis measured posture>

Loading
500

position
500

Measured Measured
position position J1 Arbitrary
J2  15°
J1 Arbitrary J3 -100°
J2  40° J4 -90°
Loading J3 -105° J5 90°
position J4 -90° J6 0°
ARC Mate 100iC, M-10iA J5 90° ARC Mate 100iC/6L, M-10iA/6L
J6 0°
ARC Mate 100iCe, M-10iAe ARC Mate 100iCe/6L, M-10iAe/6L
500

J1 Arbitrary
Measured J2  40°
position J3 -105°
J4 -90°
J5 90°
J6 0°
Loading position
ARC Mate 100iC/10S, M-10iA/10S
<J3-axis measured posture>
Fig.3.3 (c) Backlash measured posture (2/3)

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B-82755EN/05 3.TROUBLESHOOTING

Magnet stand mounting position of


magnet stand
Dial gauge
Loading position
(Loading should be alingned with the
center of J5/J6-axes to avoid
the effect of J5/J6 backlash.)
109
J1 Arbitrary
J2  40°
J3 -90°
J4 -90°
J5 90°
J6 0°

<J4-axis measured position>


115
Loading position Loading position
(Loading position should be aligned (Loading position should
with the center of J6-axis to avoid be loaded in the direction
the effect of J6 backlash.) of the rotation of J6-axis.)
45

Magnet stand

Dial gauge

Mounting position
of magnet stand

Dial gauge

Mounting position
of magnet stand
Magnet stand

J1 Arbitrary
J2  0° J1 Arbitrary
J3 0° J2  0°
J4 -90° J3 0°
J5 90° J4 0°
J6 0° J5 90°
J6 0°

<J5-axis measured posture> <J6-axis measured posture>

Fig.3.3 (d) Backlash measured posture (3/3)

- 41 -
3.TROUBLESHOOTING B-82755EN/05

Table.3.3 (a) Permissible backlash value (ARC Mate 100iC, ARC Mate 100iCe)
J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis
Angle conversion (arc-min) 2.50 2.50 2.50 3.00 3.00 5.00
Displacement conversion (mm) 1.23 0.33 0.31 0.10 0.04 0.17
Distance between the rotation
1629 600 500 109 45 115.
center and dial gauge (mm)

Table.3.3 (b) Permissible backlash value (M-10iA, M-10iAe)


J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis
Angle conversion (arc-min) 2.50 2.50 2.50 4.00 4.00 6.00
Displacement conversion (mm) 1.23 0.33 0.31 0.13 0.05 0.20
Distance between the rotation
1629 600 500 109 45 115
center and dial gauge (mm)

Table.3.3 (c) Permissible backlash value (ARC Mate 100iC/6L, ARC Mate 100iCe/6L)
J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis
Angle conversion (arc-min) 2.50 2.50 2.50 3.00 3.00 5.00
Displacement conversion (mm) 1.27 0.33 0.31 0.10 0.04 0.17
Distance between the rotation
1760 600 500 109 45 115
center and dial gauge (mm)

Table.3.3 (d) Permissible backlash value (M-10iA/6L, M-10iAe/6L)


J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis
Angle conversion (arc-min) 2.50 2.50 2.50 4.00 4.00 6.00
Displacement conversion (mm 1.27 0.33 0.31 0.13 0.05 0.20
Distance between the rotation
1760 600 500 109 45 115
center and dial gauge (mm)

Table.3.3 (e) Permissible backlash value (ARC Mate 100iC/10S)


J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis
Angle conversion (arc-min) 2.50 2.50 2.50 3.00 3.00 5.00
Displacement conversion (mm 0.94 0.29 0.36 0.10 0.04 0.17
Distance between the rotation
1300 400 500 109 45 115.5
center and dial gauge (mm)

Table.3.3 (f) Permissible backlash value (M-10iA/10S)


J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis
Angle conversion (arc-min) 2.50 2.50 2.50 4.00 4.00 6.00
Displacement conversion (mm 0.94 0.29 0.36 0.13 0.05 0.20
Distance between the rotation
1300 400 500 109 45 115.5
center and dial gauge (mm)

NOTE
When measuring backlash under circumstances where the distance between the
rotation center and the dial gauge is different from those in the above table,
make angle and displacement conversions according to the table.

- 42 -
B-82755EN/05 4.COMPONENT REPLACEMENT

4 COMPONENT REPLACEMENT
Once motors, reducers, gearbox and wrist unit are replaced, mastering becomes necessary, perform
mastering according to Section 6 after any of these components is replaced.

NOTE
Be very careful when dismounting and mounting the heavy components that are
listed below.

Component Model Weight


J3 arm ARC Mate 100iC, M-10iA 12.5 kg
(See Fig. 4.11 (b), Fig.4.12 (a)) ARC Mate 100iC/10S, M-10iA/10S
ARC Mate 100iCe, M-10iAe
J3 arm ARC Mate 100iC/6L, M-10iA/6L, 14 kg
(See Fig. 4.11 (a)) ARC Mate 100iCe/6L, M-10iAe/6L
All components from J3-axis reducer to wrist unit ARC Mate 100iC, M-10iA, 28 kg
(See Fig. 4.11 (b), Fig.4.12 (b)) ARC Mate 100iC/10S, M-10iA/10S,
ARC Mate 100iCe, M-10iAe
All components from J3-axis reducer to wrist unit ARC Mate 100iC/6L, M-10iA/6L, 29.5 kg
(See Fig. 4.11 (b)) ARC Mate 100iCe/6L, M-10iAe/6L
All components from J2 arm to wrist unit ARC Mate 100iC, M-10iA 54 kg
(See Fig. 4.5 (b)) ARC Mate 100iC/10S, M-10iA/10S
ARC Mate 100iCe, M-10iAe
All components from J2 arm to wrist unit ARC Mate 100iC/6L, M-10iA/6L, 55.5 kg
(See Fig. 4.5 (b)) ARC Mate 100iCe/6L, M-10iAe/6L
All components from J2 base to wrist unit ARC Mate 100iC, M-10iA 94.5 kg
(See Fig. 4.3 (b)) ARC Mate 100iC/10S, M-10iA/10S
ARC Mate 100iCe, M-10iAe
All components from J2 base to wrist unit ARC Mate 100iC/6L, M-10iA/6L, 96 kg
(See Fig. 4.3 (b)) ARC Mate 100iCe/6L, M-10iAe/6L
Wrist unit All models 6kg
(See Fig. 4.13 (a))

NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and
taps and wipe oil off the engaging section. Make sure that there is no solvent in
the taps.
Be sure to wipe the excess LOCTITE after tightening screw.

NOTE
1 Description of [LT242] means LOCTITE 242.
2 Description of [LT262] means LOCTITE 262.
3 Description of [LT518] means LOCTITE 518.
4 Description of [LT675] means LOCTITE 675.

- 43 -
4.COMPONENT REPLACEMENT B-82755EN/05

4.1 FIGURE OF DRIVE MECHANISM


The drive mechanisms of each axis are shown in the following.

AC servo motor
for J1-axis (M1)

J1-axis reducer

Gear
Fig.4.1 (a) Drive mechanism of J1-axis

J2 arm

Input gear J2-axis


reducer J2 base

AC servo motor
for J2-axis (M2)

Fig.4.1 (b) Drive mechanism of J2-axis

- 44 -
B-82755EN/05 4.COMPONENT REPLACEMENT

J3-axis reducer
Input gear

J2 arm

AC servo motor
for J3-axis (M3)
Fig.4.1 (c) Drive mechanism of J3-axis

Gear

Gear

AC servo motor
for J4-axis (M4)

Fig.4.1 (d) Drive mechanism of J4-axis

- 45 -
4.COMPONENT REPLACEMENT B-82755EN/05

AC servo motor
for J5-axis(M5)

Gear

Gear

Hollow flange

Fig.4.1 (e) Drive mechanism of J5-axis

AC servo motor
for J6-axis(M6) Drive shaft
Gear
Gear Gear

Gear

Hollow flange

Fig.4.1 (f) Drive mechanism of J6-axis

4.2 REPLACING THE J1-AXIS MOTOR M1


1 Set dial gauges at J1-axis, and prepare for single axis mastering after replacement.
2 Turn off the controller power.
3 Remove the J1-axis motor connector.
4 Remove the motor mounting bolts (1). Dismount the motor from the J2 base. When dismounting
the motor, be careful of the grease that may drop from the motor if the robot is suspended from a
ceiling or mounted on a wall.
5 Remove the M10 hexagonal nut (5) from the motor shaft, and pull out the gear (3).
6 Attach the gear to a new motor (2).
7 Attach an M10 spring washer (4), apply LOCTITE 242 to the M10 threaded n of the nut (5), and
tighten the M10 nut with a specified torque of [20 Nm].
8 Replace the O ring (6) with a new one and put it into the J2 base where the J1-axis motor is to be
mounted, and fasten them with bolt (1).
9 Attach the cable connector to the J1-axis motor.
10 According to Section 2.2, supply the J1-axis grease bath with the specified grease if grease is
overflowed.
11 Perform single axis mastering referring to Section 8.5 of operator’s manual.

- 46 -
B-82755EN/05 4.COMPONENT REPLACEMENT

NOTE
If there is a danger that the J1-axis section may fall, for example, because the
robot is installed except floor mount, fix the J1-axis section during replacement
work, for example, by pushing the J1-axis mechanical stopper against the
J1-axis section.

1
2

3
4
5
6

Fig.4.2 Replacing the J1-axis motor

Parts name Specification Q’ty Locking Torque (N-m)


1 BOLT A6-BA-8X20 4
A06B-0235-B605 (*1)
2 MOTOR 1
A06B-0235-B005#S000 (*2)
3 GEAR A290-7215-X211 1
WASHER (Attached to
4 A6-WB-10S 1
motor)
5 NUT (Attached to motor) A6-N1-10S 1 LT242 20
6 O RING JB-OR1A-G105 1
(*1) ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S
(*2) ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L

- 47 -
4.COMPONENT REPLACEMENT B-82755EN/05

4.3 REPLACING THE J1-AXIS REDUCER


1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual to restore
J2 to J6 axes. ( It is set in 0°for all axes when robot is shipped.)
2 Set dial gauges at J1-axis, and prepare for single axis mastering after replacement.
3 Put the robot in such a position that the J2 base and the portions above it can be suspended with a
crane or the like (hereafter abbreviated as a crane), and then turn off the controller power. (See Fig.
4.3 (a))
4 While referencing Section 5.3, pull out the cables below the J2 base from the J1-axis hollow pipe
section toward the upper portion of the J2 base.
5 While referencing Section 4.2, remove the J1-axis motor from the J2 base.
6 As shown in Fig. 4.3 (c), remove the bolts (3) that fasten the J2 base to the J1-axis reducer.
7 While referencing Section 4.3 (b), hoist the J2 base and portions above it slowly.
8 As shown in Fig. 4.3 (c), remove the O ring (5), bearing, and gear. Bearing rarely left in J2 base. It is
not necessary to remove bearing in this case, when bearing does not rotate smoothly, break oil seal
(12) and remove both oil seal and bearing then replace them to new article.
9 Remove the bolts (7) that fasten the J1-axis reducer to the J1 base, and dismount the reducer.
10 Disconnect the pipe.
11 Replace the O ring (10) with a new one and fit it with the pipe correctly.
12 Replace the O ring (11) with a new one and attach it to a new reducer, and fasten the reducer to J1
base with (7) bolts (by applying LOCTITE 262 and tightening with a torque of [129 Nm]).
13 Mount the center gear, bearing (with LOCTITE 675 applied to its outer ring), and O ring (5) to the
reducer. When bearing is broken in this process, replace bearing to new one. When replacing oil seal
(12), press-fit it by using fixture in Fig.4.3 (d).
14 Fasten the J2 base to the reducer with bolts (3) (by applying LOCTITE 262 and tightening with a
torque of [73.5 Nm]). Be careful not to let the pipe damage the oil seal.
15 According to Section 4.2, mount the J1-axis motor on the J2 base.
16 According to Section 5.3, mount the cables.
17 According to Section 2.2, supply the J1-axis grease bath with the specified grease.
18 Perform quick mastering, then perform single axis mastering to J1-axis referring to Section 8.4 and
8.5 of operator’s manual.

NOTE
1 Reducer and gear of upper of reducer are can be installed only in combination
below.
(1) Spec of reducer: A97L-0218-0822#33 Gear: A290-7215-X212
(2) Spec of reducer: A97L-0218-0885#33 Gear: A290-7221-Z212
See Fig.4.3 (a) when distinguishing it.
2 When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear (A290-7215-X211) of J1-axis motor shaft, gear
(A290-7215-X212) on J1-axis reducer and bearing (A97L-0001-0192#1400000).

- 48 -
B-82755EN/05 4.COMPONENT REPLACEMENT

Old spec. A97L-0218-0822#33 New spec. A97L-0218-0885#33


Bearing size becomes 6813 from 6814.
Inside diameter shrinks.

Spur gear becomes two steps


from one step.

Contents for change of J1center gear


Old spec. A290-7215-X212 New spec. A290-7221-Z212
40.8 45.3

O 65
O 70

Dimension is changed.
There is no compatibility.

Fig.4.3 (a) Distinction of new and old reducer and gear

- 49 -
4.COMPONENT REPLACEMENT B-82755EN/05

A
Mounting position
M10 Eyebolt of eyebolt
VIEW A

Fig.4.3 (b) Sling the J2 base unit

5
3 8 11
6
2 4 7 9
1

10

Fig.4.3 (c) Replacing the J1-axis reducer

Parts name Specifications Q’ty Locking Torque (N-m)


1 BOLT A6-BA-8X20 4
2 MOTOR A06B-0235-B605 1
3 BOLT A6-BA-10X50 7 LT262 73.5
4 O RING JB-OR1A-G105 1
5 O RING A290-7207-X342 1
A290-7215-X212 (*1)
GEAR 1
6 A290-7221-Z212 (*2)
BEARING A97L-0001-0192#1400000 2
7 BOLT A6-BA-12X80 6 LT262 129
A97L-0218-0822#33 (*1)
8 J1 REDUCER 1
A97L-0218-0885#33 (*2)
9 PIPE A290-7215-X215 1
10 O RING JB-OR1A-G65 1

- 50 -
B-82755EN/05 4.COMPONENT REPLACEMENT

Parts name Specifications Q’ty Locking Torque (N-m)


11 O RING A98L-0001-0347#S150 1
12 OIL SEAL A98L-0040-0047#06009008 1
(*1) Old spec: robot shipped before March, 2010.
(*2) New spec: robot shipped after April, 2010.

J2 base
12

Bearing
Fig.4.3 (d) Replacing the J1-axis reducer

29

A 7 12
C1
O 89.5 ±0.1

-0.2
-0.3
O 84
O 73

O 60
O 82

C1
C0
.5

C1
.5
.5
C0
C0

A
SECTION A-A
Fig.4.3 (e) Example of press-fit fixture for oil seal

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4.COMPONENT REPLACEMENT B-82755EN/05

4.4 REPLACING THE J2-AXIS MOTOR M2


1 Set dial gauges at J2-axis, and prepare for single axis mastering after replacement.
2 Push the J2-axis section against the mechanical stopper, or fix it in such a way that it will not swivel
when the motor is dismounted, for example, by placing it in the direction of gravity.

NOTE
If the J2-axis section is not pushed against the stopper correctly, or it is not
placed in the direction of gravity, there is a danger that the J2-axis section will
swivel when the J2-axis motor is removed.

3 Turn off the controller power.


4 Remove the J2-axis motor connector.
5 Remove the motor mounting bolts (1), and dismount the motor from the J2 base.
6 Remove the bolt (5) that fastens the input gear (4), and dismount the input gear (4). Also, remove
the draw nut from the motor shaft.
7 Apply LOCTITE 242 to the threaded portion of a draw nut (3) and tighten the draw nut to shaft of
new motor with a torque of [16.7 Nm].
8 Put the input gear (4) over the draw nut (3), apply LOCTITE 242 to the M6 threaded portion of the
draw nut (3), and tighten the bolt (5) with a torque of [6.8 Nm].
9 Replace the O ring (6) with a new one and put it into the J2 base portion where the motor is to be
mounted, and fasten the motor to the J2 base with bolts (1). Do not force in the motor. Otherwise,
the input gear may not settle in the correct place, possibly causing vibration (if the input gear is
engaged correctly, the motor will be mounted smoothly).
10 Attach the cable connector to the J2-axis motor.
11 According to Section 2.2, supply the J2-axis grease bath with the specified grease.
12 Perform single axis mastering referring to Section 8.5 of operator’s manual.

5 4 2 1
3

Fig.4.4 Replacing J2-axis motor

Parts name Specifications Q’ty Locking Torque (N-m)


1 BOLT A6-BA-8X20 4
2 MOTOR A06B-0235-B605 1
3 DRAW NUT A290-7221-X321 1 LT242 16.7
4 INPUT GEAR A290-7221-X311 1
5 BOLT A6-BA-5X45 1 LT242 6.8
6 O RING JB-OR1A-G105 1

- 52 -
B-82755EN/05 4.COMPONENT REPLACEMENT

4.5 REPLACING THE J2-AXIS REDUCER


1 Set dial gauges at J2-axis, and prepare for single axis mastering after replacement.
2 Put the robot in such a posture that the J2 arm and the components on it can be suspended with a
crane.
3 Turn off the controller power.
4 Suspend the J2 arm and the components on it as shown Fig. 4.5 (a) and (b) with a crane so that they
will not drop when the J2 arm is dismounted. (If there is the fixture shown in Fig. 4.5 (b), work
improves. The material must be SS400 or an equivalent. Use the eyebolts delivered with the J2
base when robot is shipped.)
5 Remove the J2-axis motor as described in Section 4.4 (If the reducer is replaced while the motor is
still mounted, the input gear may be damaged.)
6 As shown in Fig. 4.5 (c), remove the bolts (1) that fasten the reducer (3) to J2 base, and remove bolts
(2) that fasten the reducer (3) to J2 arm .Be careful not to allow an excessive load to be put on the
cables (because the cables are left attached when the reducer is dismounted).
7 Replace the O ring (4) with a new one and attach it to a new reducer, insert it into the J2 arm, and
fasten them with bolts (2) (by applying LOCTITE 262 and tightening with a torque of [15.6 Nm]).
8 Degrease both the J2 base and the J2-axis reducer surfaces that are to meet each other, and as shown
in Fig. 4.5 (d), apply sealant (LOCTITE 518) to the J2-axis reducer on which the J2 base is to be
mounted.
9 Mount the reducer to the J2 arm with bolts (1) (by applying LOCTITE 262 and tightening with a
torque of [73.5 Nm]).
10 Mount the J2-axis motor as described in Section 4.4.
11 According to Section 2.2, supply the J2-axis grease bath with the specified grease.
12 Perform single axis mastering referring to Section 8.5 of operator’s manual.

NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange input gear (A290-7221-X311) of J2-axis motor shaft.

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4.COMPONENT REPLACEMENT B-82755EN/05

Wind sling to ruggedness part


of tip of wrist.
Wind sling so that sling
goes around J3-axis reducer.

Fig.4.5 (a) Sling the J2 and J3 arms

140
2-M10 THRU
45 7
70
50

4-O7 THRU
130
M10 eyebolts (2pcs)

Fig.4.5 (b) Sling the J2 and J3 arms (When fixture is used)

- 54 -
B-82755EN/05 4.COMPONENT REPLACEMENT

4 3
シール剤塗布面
SEALANT APPLYING SURFACE

2
1

Fig.4.5 (c) Replacing the J2-axis reducer

Parts name Specifications Q’ty Locking Torque (N-m)


1 BOLT A6-BA-10X20 9 LT262 73.5
2 BOLT A6-BA-6X30 16 LT262 15.6
A97L-0218-0886#127(*1) 1
3 J2 REDUCER
A97L-0218-0886#93 (*2)
4 O RING JB-OR1A-G130 1
(*1) Except ARC Mate 100iC/10S,M-10iA/6S
(*2) ARC Mate 100iC/10S,M-10iA/6S

Fig.4.5 (d) applying sealant to the J2-axis reducer

NOTE
Refer to Section 4.23 about applying sealant (LOCTITE 518).

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4.COMPONENT REPLACEMENT B-82755EN/05

4.6 REPLACING THE J3-AXIS MOTOR M3


NOTE
Fixtures are necessary for replacing J3-axis motor and reducer. See Fig.1.10 (a)
to (e).

1 Set dial gauges at J3-axis, and prepare for single axis mastering after replacement.
2 Place the robot in the posture J2=0º. At this chance, confirm J1 base is fixed to prevent from falling.
3 Suspend the J3 arm and the components on it as shown Fig. 4.6 (a) with a crane so that they will not
drop when the J2 arm is dismounted
4 Turn off the controller power.
5 Remove the connector of a cable leading to the J3-axis motor.
6 Remove the bolts (1) that fasten the J3-axis motor to the J3 casing, and dismount the motor and
packing (7).
7 Remove the bolt (6) from the motor shaft, and dismount the input gear (5) and draw nut (4).
8 Apply LOCTITE 242 to the threaded portion of draw nut (4) and tighten it to the new motor with a
torque of [3.1 Nm].
9 Put the input gear (5) over the draw nut (4), apply LOCTITE 242 to the M5 threaded portion of the
draw nut (4), and tighten the bolt (6) with a torque of [3.4 Nm]. In this time, be sure to attach key (3),
too. Refer to section 4.8 about mounting input gear to J3-axis motor.
10 Attach new packing (7), and insert the motor into the reducer. Keep the J3-axis degrease outlet on
the J2 arm side open (see Fig. 2.2 (c)), and look into the outlet to make sure that the input gear has
settled in the correct place. Even one tooth of a shift in engagement can cause vibration. (If the
input gear (5) is engaged correctly, the motor can get in the reducer smoothly.) In this case, if robot
is shipped before March, 2010, please confirm whether attaching the motor to the reducer is
appropriate referring to paragraph 4.8. Please confirm whether the flange of the motor floats, and
install it with the phase that spur gears form a line like figure 4.6 (c) up and down.
11 Fasten the motor to the J3-axis reducer with bolts (1). Be sure to use a new packing to prevent
grease leakage. Refer to section 4.8 about mounting J3-axis motor to reducer.
12 Attach the cable connector to the J3-axis motor.
13 According to Section 2.2, supply the J3-axis grease bath with the specified grease.
14 Perform single axis mastering referring to Section 8.5 of operator’s manual.

Wind sling to ruggedness part


of tip of wrist.

J2=0°

Fig.4.6 (a) Sling the J3 arm


- 56 -
B-82755EN/05 4.COMPONENT REPLACEMENT

1
2 5

6
3 7
4

Fig.4.6 (b) Replacing the J3-axis motor

Parts name Specifications Q’ty Locking Torque (N-m)


1 BOLT A6-BA-6X14 4
2 MOTOR A06B-0212-B605#S000 1
KEY (Attached to
3 JB-HGKYA-4X13 1
motor)
4 DRAW NUT A290-7221-X421 1 LT242 3.1
A290-7221-X411 (*1)
5 INPUT GEAR A290-7221-Z411 (*2) 1
A290-7221-Z415 (*3)
6 BOLT A6-BA-4X55 1 LT242 3.4
7 PACKING A98L-0040-0042#03 1
(*1) Old spec robot ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA6L shipped before March,
2010.
(*2) New spec: robot ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA6L shipped after April,
2010 or ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe6L.
(*3) ARC Mate 100iC/10S, M-10iA/10S

- 57 -
4.COMPONENT REPLACEMENT B-82755EN/05

The old and new reducer is incompatible. See Fig.4.6 (c) when distinguish it.

Old spec. A290-7221-X411 New spec. A290-7221-Z411

3
Chamfering size
is different.

84.6
81.6

Fig.4.6 (c) Distinction of new and old input gear

Assmeble motor so that


spur gear form a line with
this phase.

Fig.4.6 (d) Phase for mounting J3-axis motor to reducer


(Only for robot which is shipped before March, 2010)

4.7 NOTES OF ATTACHING J3-AXIS MOTOR TO REDUCER


1) Procedure of J3 Motor Input Gear Alignment
1 Apply LOCTITE 242 to thread the Draw Nut (A290-7221-X421) and mount it to the motor shaft by
using torque wrench with regulated torque set at 3.1Nm.
2 Attach the woodruff key to motor shaft, confirm there is no dust on taper shaft of motor and insert
input gear to motor shaft.
3 Mount fixture to motor as Fig.4.7 (a) for centering.

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B-82755EN/05 4.COMPONENT REPLACEMENT

4 Apply LOCTITE 242 to thread and tighten bolt (M4×55) with regulated torque 3.4Nm while
supporting input gear with spanner wrench preventing the input gear from rotating.(to prevent motor
brake slips) If you hear the ratchet sound of the torque wrench then, turn the torque wrench until the
next ratchet sound or until the bolt head is completely past the motor input gear. This completes
setting of the input gear on the motor taper shaft.
5 Remove the Fixture from the Motor Shaft.
Bolt
A6-BA-4X55
Fixture A290-7221-X973 Tightening torque 3.4 Nm
LOCTITE

Insert spanner not to


J3-axis motor input gear
rotate the motor shaft

Fixture(*)

Fixture(*)

J3-axis motor

Draw nut J3-axis motor


A290-7221-X421
Tightening torque 3.1 Nm Bolt
Fixture A290-7221-X974 or LOCTITE 242 A6-BA-4X55
    A290-7221-X976 Tightening torque 3.4 Nm
LOCTITE
Fixture(*)
Insert spanner not to
rotate the motor shaft J3-axis motor input gear

Fixture(*)

J3-axis motor

Draw nut
A290-7221-X421 J3-axis motor
Tightening torque 3.1 Nm
LOCTITE 242

(*) Specification of fixture is differ depend on robot.


1. ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L, M-10iA/6L which is made before March,2010.
A290-7221-X973
2. ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L, M-10iA/6L which is made after April,2010 or
ARC Mate 100iCe,M-10iAe,ARC Mate 100iCe/6L,M-10iAe/6L
A290-7221-X974 (Use them after connecting them.)
3. ARC Mate 100iC/10S,M-10iA/10S
 A290-7221-X976 (Use them after connecting them.)
Fig.4.7 (a) Attaching J2-axis and J3-axis motor to reducer
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4.COMPONENT REPLACEMENT B-82755EN/05

There are 3 cases about method of installing J3-axis motor to reducer depend on the shipment time of
robot.

1 Robot which is made before June, 2009


J3-axis reducer grease outlet is made in J3-axis rotation center of J2 arm.
Mount J3-axis motor referring to procedure 2) of this Section.

J3-axis reducer grease outlet


Seal bolt
A97L-0218-0417#081010

Fig.4.7 (b) Robot which is made before June, 2009

2 Robot which is made after July, 2009 and before March, 2010
J3-axis reducer grease outlet is at the position upper than J3-axis rotation center of J2 arm.
Seal bolt is attached to tap for mounting fixture. Mount J3-axis motor referring to procedure 3) of
this Section.

J3-axis reducer grease outlet


Seal bolt
A97L-0218-0417#081010

Seal bolt
A97L-0218-0417#101212

(Note: This is not J3-axis reducer grease outlet.)

Fig.4.7 (c) Robot which is made after July, 2009 and before March, 2010

3 Robot which is made after April, 2010


No fixture is needed while mounting J3-axis motor to reducer.

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B-82755EN/05 4.COMPONENT REPLACEMENT

2) Procedure of J3-axis Reducer Alignment


(Robot which is made before June, 2009)
1 Mount J3-axis motor that is aligned to J3 casing after attaching packing to motor flange referring to
previous section. Confirm that the Motor Flange is not floating from the attaching surface of the J3
casing from the three sight direction of Fig.4.7 (e). If there is clearance between motor and J3 casing,
input gear is not aligned, insert it again. If you confirm there is no gap, work is completion.
2 Insert the Fixture (A290-7221-Z972) into the J3 grease outlet as Fig.4.7 (f) until it touches the face
of the bolt. You can judge that it is the good condition in case that the male screw part is not sticking
out of the surface of the counter bore. If input gear is not aligned, the male screw part is sticking out
of the surface of the counterbored hole(2mm) as Fig.4.7 (f).

If the centering is good, the top of the Fixture (A290-7221-Z972) can enter into the hexagon socket
on the bolt head.

Spur gear
Motor shaft
+
Input gear

RV
reducer

(a) Wrong fitting case (b) Correct fitting


Fig.4.7 (d) Attaching J3-axis motor to reducer

Confirm there is no clearance


in this face.
Fig.4.7 (e) Confirming the mounting of J3-axis motor

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4.COMPONENT REPLACEMENT B-82755EN/05

Centering fixture
A290-7221-Z972
1.5~2.0mm

Centering is performed Centering is not performed


Fig.4.7 (f) Confirming the gap of the core of J3-axis motor (1/2)

3) Procedure of J3-axis Reducer Alignment


(Robot which is made after July, 2009 and before March, 2010)
1 Remove seal bolt of J3-axis rotation center of J2 arm in Fig.4.7 (c), mount fixture
(A290-7221-Z974) and tighten it well.
2 Attach J3-axis motor which gear is attached to J3 casing. Attach it so that motor flange surface is
mounted to J3 casing without clearance. (If centering is performed, it is hard to pull out motor. So
try to pull out to confirm it.)
3 Look the center of fixture which is attached to J2 arm with flashlight and confirm bolt of center gear
is center of fixture. If centering of input gear is performed, center of bolt of input gear accords in
center of hole of fixture. Confirm it referring to Fig.4.7 (g). If centering is not performed, motor is
not mounted to J3 casing.
4 If it is confirmed, attach seal bolt. If seal bolt is reused, be sure to wind it with seal tape.

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B-82755EN/05 4.COMPONENT REPLACEMENT

If centering is performed,
center of bolt of input gear accords
in center of hole of fixture.
If centering is not performed,
center of bolt of input gear does not accord
in center of hole of fixture.

The part which The part which


slips off slips off

Detail A Detail A Detail A

Centering fixture
A290-7221-Z974

Fig.4.7 (g) Confirming the adhering of J3-axis motor (2/2)

4.8 REPLACING THE J3-AXIS REDUCER


NOTE
Fixtures are necessary for replacing J3-axis motor and reducer. See Fig.1.10 (a)
to (e).

1 Set dial gauges at J3-axis, and prepare for single axis mastering after replacement.
2 Put the robot in such a posture that the J3-axis section and the components on it can be suspended
with a crane, (If there is the fixture shown in Fig. 4.5 (b), work improves. The material must be
SS400 or an equivalent. Use the eyebolts delivered with the J2 base.)
3 Turn off the controller power.
4 While referencing Section 5.3, remove the cable from the J2 arm section. Suspend the J3-axis
section and the components on it with a crane so that they will not drop when the reducer is
dismounted from the J2 arm. This supporting method is common to replacing J2-axis reducer so
reference to section 4.5 for more details. Be careful not to allow an excessive load to be put on the
cable assembly (because the cables are left attached when the reducer is dismounted).
5 While referencing Section 4.6, dismount the J3-axis motor from the J3 arm unit.
6 Remove bolts (3) that fasten the J3-axis reducer to the J3 arm dismount the J3 arm that reducer
attaches from the J2 arm.
7 Remove bolt (1) that fasten J3-axis reducer to J3 casing. In addition, remove J3-axis reducer from J3
casing.
8 Remove O ring (5) and attach new O ring (5) to the reducer installation part of J2 arm.
9 Suspend the J3-axis section and the components on it with a crane, and fasten the J2 arm and J3-axis
reducer with bolts (3) (by applying LOCTITE 262 and tightening with a torque of [9.0 Nm]). Please
install it so that the phase of the spur gears form a line like figure 4.6 (c) up and down.

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4.COMPONENT REPLACEMENT B-82755EN/05

10 Degrease both the J3-axis reducer and the J3 casing surfaces that are to meet each other, and as
shown in Fig. 4.8 (c), apply sealant (LOCTITE 518) to the J3-axis reducer surface on which the J3
casing is to be mounted.
11 While referencing Section 4.6, mount the J3-axis motor on the J3 arm unit. In this case, if robot is
shipped before March, 2010, please confirm whether attaching the motor to the reducer is
appropriate referring to paragraph 4.8.
12 While referencing Section 5.3, dress the cable into the previous form.
13 According to Section 2.2, supply the J3-axis grease bath with the specified grease.
14 Perform single axis mastering referring to Section 8.5 of operator’s manual.
15 Confirm software version and cope as needed.

The shipment
Software version Cope when replacing J3-axis reducer
time of robot
Before March, V7.30P-27 or earlier J3-axis reducer mounting phase auto adjusting function is not needed.
2010. V7.40P-06 or earlier
V7.30P-28 or later Be sure to perform J3-axis reducer mounting phase auto adjusting
V7.40P-07 or later function referring to subsection 4.7.1.
After April, 2010 All J3-axis reducer mounting phase auto adjusting function is not needed.

NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange input gear of J3-axis motor shaft. At this time,
confirm there is no clearance between input gear and J2 arm referring to Section
4.8.

1
2
4
シール剤塗布面 5
SEALANT APPLYING SURFACE
Fig.4.8 (a) Replacing the J3 –axis reducer
Parts name Specifications Q’ty Locking Torque (N-m)
1 BOLT A6-BA-8X25 8 LT262 37.2
2 ADAPTER A290-7221-X422 1
3 BOLT A6-BA-5X20 12 LT262 9.0
A97L-0218-0824#150 (*1)
4 J3 REDUCER A97L-0218-0887#150 (*2) 1
A97L-0218-0887#108 (*3)
5 O RING JB-OR1A-G130 1
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B-82755EN/05 4.COMPONENT REPLACEMENT

(*1) Old spec:: ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L which are shipped
before March, 2010
(*2) New spec: ARC Mate 100iC,M-10iA,ARC Mate 100iC/6L,M-10iA/6L which are shipped after
April, 2010 or ARC Mate 100iCe,M-10iAe,ARC Mate 100iCe/6L, M-10iAe/6L.
(*3) ARC Mate 100iC/10S,M-10iA/10S

The old and new reducer is incompatible. See Fig.4.8 (b) when distinguish it.
Old spec. A97L-0218-0824#150 New spec. A97L-0218-0887#150
16-O5.8 Equally spaced
12-O5.8 Equally spaced
2.7

5.7
Fig.4.8 (b) Distinction of new and old J3-axis reducer

Fig.4.8 (c) Applying sealant to the J3-axis reducer

NOTE
Refer to Section 4.23 about applying sealant (LOCTITE 518).

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4.COMPONENT REPLACEMENT B-82755EN/05

4.8.1 J3-axis reducer mounting phase auto adjusting function


1 If H839INIT program and H839RVAT program are not installed to controller, contact FANUC.
2 Perform H839INIT program.
3 In H839RVAT program, disturbance torque is measured with J1=J2=J4=J6=0°, J5=-90° and J3
moves between 0° and 40° with override 10%.
Before executing H839RVAT.TP, keep the space so at to move the robot arm without interference
with peripheral. And to avoid the harmful effect by vibration of a robot hand, the position of J5 axis
is set to –90º. Check the interference between a robot arm and a robot hand, too.
4 Perform H839RVAT program.

NOTE
The H839RVAT-related parameter is stored away by SYSMAST.SV. In addition,
a value is listed in inspection certification attached at the time of shipment. After
V7.30P-25, it is necessary to return backup of SYSMAST.SV at the time of the
update of the software.
In addition, contact FANUC about group 2 or later for robots of multiple control.

4.9 REPLACING THE J4-AXIS MOTOR M4


(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L)
1 Place the robot in a posture of J3 = +180°.
2 Set dial gauges at J4-axis, and prepare for single axis mastering after replacement.
3 Turn off the controller power.
4 Remove the connector of a cable leading to the J4-axis motor.
5 As shown in Fig. 4.9, remove the three bolts (1) that fasten the J4-axis motor to the J3 casing, and
dismount the motor.
6 Remove the bolt (6) that fastens the gear (4) to the motor shaft, and dismount the washer (5), gear
(4) and key (3).
7 Mount the gear (4) to a new motor, apply LOCTITE 242 to the threaded portion of the motor shaft,
and fasten them with a bolt by tightening with a torque of [1.3 Nm]. (Ensure the specified torque is
achieved otherwise, the J4-axis may get out of place.)
8 Replace the Packing (7) with a new one and put it in the J3 casing portion where the motor is to be
mounted accurately, and fasten the motor to the J3 casing with bolts (1).
9 Attach the cable connector to the J4-axis motor.
10 According to Section 2.2, supply the J4-axis gearbox with the specified oil.
11 Perform single axis mastering referring to Section 8.5 of operator’s manual.

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B-82755EN/05 4.COMPONENT REPLACEMENT

3
4
5
6
7

Fig.4.9 Replacing the J4-axis motor

Parts name Specifications Q’ty Locking Torque (N-m)


1 BOLT A97L-0218-0612#051212 4
A06B-0115-B804 (*1)
2 MOTOR 1
A06B-0115-B205#S000 (*2)
3 KEY JB-HKY-3X3X20B 1 LT675
4 GEAR A290-7221-X412 1
5 WASHER A290-7210-X532 1
6 BOLT A6-BA-3X8 1 LT242 1.3
7 PACKING A98L-0040-0042#07 1
(*1) ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L
(*2) ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L

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4.COMPONENT REPLACEMENT B-82755EN/05

4.10 REPLACING THE J4-AXIS MOTOR M4


(ARC Mate 100iC/10S, M-10iA/10S)
1 Place the robot in a posture of J3 = +180°.
2 Set dial gauges at J4-axis, and prepare for single axis mastering after replacement.
3 Turn off the controller power.
4 Remove the connector of a cable leading to the J4-axis motor.
5 As shown in Fig. 4.10, remove the three bolts (1) that fasten the J4-axis motor to the J3 casing, and
dismount the motor.
6 Remove the set screw (5) that fastens the gear (4) to the motor shaft, and dismount the gear (4) and
key (3).
7 Attach key (3) and gear (4) to new motor. Apply LOCTITE 242 to set screw (5) and tighten it with
torque of [0.54 Nm]. (Ensure the specified torque is achieved otherwise, the J4-axis may get out of
place.)
8 Replace the packing (6) with a new one and put it in the J3 casing portion where the motor is to be
mounted accurately, and fasten the motor to the J3 casing with bolts (1).
9 Attach the cable connector to the J4-axis motor.
10 According to Section 2.2, supply the J4-axis gearbox with the specified oil.
11 Perform single axis mastering referring to Section 8.5 of operator’s manual.

3
4
5
6

Fig.4.10 Replacing the J4-axis motor

Parts name Specifications Q’ty Locking Torque (N-m)


1 BOLT A97L-0218-0612#051212 4
2 MOTOR A06B-0115-B804 1
3 KEY JB-HKY-3X3X20B 1 LT675
4 GEAR A290-7221-Z412 1
5 SET SCREW A6-SAKT-3X4 2 LT242 0.54
6 PACKING A98L-0040-0042#07 1

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B-82755EN/05 4.COMPONENT REPLACEMENT

4.11 REPLACING THE J4-AXIS GEARBOX


(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L,
ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L,
M-10iAe/6L)
Pay attention that specification of J4-axis gearbox is different by time of robot shipment
Before March 2010 (Spec. of mechanical unit: A05B-1221-B201, B202, B301, B302): A05B-1221-K401
After April 2010 (Spec. of mechanical unit: A05B-1221-B401, B402, B451, B452, B501, B502, B551,
B552): A05B-1221-K411

1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual to restore
J5 to J6 axes. (It is set in 0º for all axes when robot is shipped.)
2 Set dial gauges at J3/J4-axes, and prepare for single axis mastering after replacement.
3 Turn off the controller power.
4 Pull out all oil of J4-axis gearbox referring to Section 2.2.
5 Wrap and hang Sling in two places of the J3 arm referring to Fig.4.11 (a) and (b).
6 Remove the wiring and piping between J3-axis and wrist. When cable installed in M/H conduit or
No dust M/H conduit is removed, refer to Section 4.19 or 4.22.
7 Referring to section 5.3,remove option cable from J4-axis connector panel.
8 Referring to section 5.3,remove J3/J4-axis motor connector, clamp part in J3 casing, clamp part in J3
arm and cable of J5/J6-axis motor, and pull out cable from J3 arm unit.
9 Referring to Section 4.9, remove J4-axis motor.
10 Remove bolt (1), cover (2) and packing (3).
11 Remove bolt (4) and pipe B (5).
12 Remove bolt (6), J3 arm and O ring (7).
13 Referring to Section 4.6, remove J3-axis motor.
14 Remove bolt (8) and J4 connector plate (9).
15 Remove bolt (10) that fasten J3 unit (13) to J2 arm, and remove J3 unit (13) from J2 arm.
16 Remove adapter (12).
17 Remove bolt (14) and clamp (15). Then remove bolt (16) and clamp (17).
18 Remove bolt (18) and pipe A (19). Then remove bolt (20), cover (21) and packing (22).
19 Please apply parts removed to new J4 axis gearbox by 10 –17. Please spread LOCTITE according to
the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt.
In this time, replace packing (22) to new one. When installing J3 unit to J2 arm, apply LOCTITE
518 to J3-axis reducer referring to Section 4.8.
20 Do process of 5-9 by opposite procedure. Please spread LOCTITE according to the table of this
paragraph, and tighten by the regulated tightening torque when you install the bolt. In this time,
replace packing (3) and O ring (7) to new one.
21 Referring to section 5.3,attach cables to J3 arm and J3 casing.
22 Referring to Section 4.6 and 4.9 attach J3/J4-axis motor. In this time replace packing and seal bolt to
new one.
23 Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J4 oil outlet.
24 According to Section 2.2, supply grease to J3-axis reducer with specified grease and supply oil to
J4-axis gearbox with specified oil.
25 Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J3-axis reducer grease
inlet.
26 Perform quick mastering and perform single axis mastering to J3 to J4-axis referring to Section 8.4
and 8.5 of operator’s manual.

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4.COMPONENT REPLACEMENT B-82755EN/05

NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear (A290-7221-X412) of J4-axis motor shaft. In
this time, confirm sitting sate of gear referring to section 4.8.

2
7 5 4
6 1

Fig.4.11 (a) Replacing the J4-axis gearbox unit (1/4)


(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L)

Parts name Specifications Q’ty Locking Torque (N-m)


1 BOLT A97L-0218-0502#M5X12 8 LT242 4.5
2 PLATE A290-7221-X425 1
3 PACKING A290-7221-X441 1
4 BOLT A97L-0001-0674#3X35 3
A290-7221-X430 or A290-7221-X433
(*1),
5 PIPE B 1
A290-7221-Z430 or A290-7221-Z433
(*2
6 BOLT A6-BA-6X85 14 LT262 15.7
7 O RING A290-7221-X444 1
(*1) ARC Mate 100iC, M-10iA
(*2) ARC Mate 100iC/6L, M-10iA/6L

5 2
7 4 1
6

Fig.4.11 (b) Replacing the J4-axis gearbox unit (2/4)


(ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)
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B-82755EN/05 4.COMPONENT REPLACEMENT

Parts name Specifications Q’ty Locking Torque (N-m)


1 BOLT A6-BA-5X8 8 6.8
2 PLATE A290-7221-Z427 1
3 PACKING A290-7221-X441 1
4 BOLT A6-BA-3X30 3
5 DUMMY PIPE A290-7221-Z434 1
6 BOLT A6-BA-6X85 14 LT262 15.7
7 O RING A290-7221-X444 1

13

11
10

12 8
9

Fig.4.11 (c) Replacing the J4-axis gearbox unit (3/4)


(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L
ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)

Parts name Specifications Q’ty Locking Torque (N-m)


8 BOLT A6-BA-6X10 2
Specification is depend on
9 CON.PLATE 1
mechanical unit cable
10 BOLT A6-BA-8X25 8 or 9 LT262 15.7
11 WASHER A97L-0001-0823#M8H 8 or 9
12 ADAPTER A290-7221-X422 1
Specification is depend on
13 J3 UNIT 1
mechanical unit cable

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4.COMPONENT REPLACEMENT B-82755EN/05

19
18
15
14

16
17
22

21
20
Fig.4.11 (d) Replacing the J4-axis gearbox unit (4/4)
(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L)

Parts name Specifications Q’ty Locking Torque (N-m)


14 BOLT A6-BA-4X5 2
15 CLAMP A290-7221-X473 1
16 BOLT A6-BA-3X6 2 LT262 15.7
17 CLAMP A290-7221-X474 1
18 BOLT A6-BA-4X35 2
19 PIPE A A290-7221-X427 1
20 BOLT A6-BA-5X14 7
A290-7221-X426 or
21 COVER 1
A290-7221-Y426
22 PACKING A290-7221-X442 1

The following service parts are appended to J4-axis gearbox (A05B-1221-K401, A05B-1221-K411) for
maintenance. Please exchange these with the J4-axis gearbox.
Parts name Specifications Q’ty Used place
PACKING A98L-0040-0042#03 1 J3-axis Motor
PACKING A98L-0040-0042#07 1 J4-axis Motor
BOLT A6-BA-8X25 8 or 9 Between J3 casing and J3-axis reducer
BOLT A6-BA-5X14 7 J4-axis Motor mounting part
BOLT A6-BA-6X10 1 J3 grease inlet
WASHER A97-0001-0823#M8H 8 or 9 Between J3 casing and J3-axis reducer
SEAL BOLT A97L-0218-0502#5X10 4 J4-axis Motor
SEAL BOLT A97L-0218-0417#081010 1 J4 oil outlet
SEAL WASHER A30L-0001-0048#6M 1 J3 grease inlet
PACKING A290-7221-X441 1 J4-axis hollow part
PACKING A290-7221-X442 1 J4-axis Motor mounting part
O RING A290-7221-X444 1 Between J3 arm and J3 casing
PIN JB-PH-H7A-5X10S45C 4 Z424, Z425

4.12 REPLACING THE J4-AXIS GEARBOX


(ARC Mate 100iC/10S, M-10iA/10S)
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual to restore
J5 to J6 axes. (It is set in 0º for all axes when robot is shipped.)
2 Set dial gauges at J3/J4-axes, and prepare for single axis mastering after replacement.
3 Turn off the controller power.
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B-82755EN/05 4.COMPONENT REPLACEMENT
4 Pull out all oil of J4-axis gearbox referring to Section 2.2.
5 Wrap and hang Sling in two places of the J3 arm referring to Fig.4.12 (a).
6 Remove the wiring and piping between J3-axis and wrist. When cable installed in M/H conduit or
No dust M/H conduit is removed, refer to Section 4.19 or 4.22.
7 Referring to Section 5.3,remove option cable from J4-axis connector panel.
8 Referring to Section 5.3,remove J3/J4-axis motor connector, clamp part in J3 casing, clamp part in
J3 arm and cable of J5/J6-axis motor, and pull out cable from J3 arm unit.
9 Referring to Section 4.10, remove J4-axis motor.
10 Remove bolt (1), cover (2) and packing (3).
11 Remove bolt (4) and pipe B (5).
12 Remove bolt (6), J3 arm and O ring (7).
13 Referring to Section 4.6, remove J3-axis motor.
14 Remove bolt (8) and J4 connector plate (9).
15 Remove bolt (10) and plate (11).
16 Remove bolt (13) that fasten J3 unit (12) to J2 arm, and remove J3 unit (12) from J2 arm.
17 Remove adapter (14).
18 Remove bolt (16) and clamp (17). Then remove bolt (18) and clamp (19).
19 Remove bolt (20) and pipe A (21). Then remove bolt (23), pin (24), cover (25) and packing (26).
20 Please apply parts removed to new J4 axis gearbox by 10 –19. Please spread LOCTITE according to
the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt.
In this time, replace packing (28) to new one. When installing J3 unit to J2 arm, apply LOCTITE
518 to J3-axis reducer referring to Section 4.8.
21 Do process of 5-9 by opposite procedure. Please spread LOCTITE according to the table of this
paragraph, and tighten by the regulated tightening torque when you install the bolt. In this time,
replace packing (3) and O ring (7) to new one.
22 Referring to section 5.3,attach cables to J3 arm and J3 casing.
23 Referring to Section 4.6 and 4.10 attach J3/J4-axis motor. In this time replace packing and seal bolt
to new one.
24 Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J4 oil outlet.
25 According to Section 2.2, supply grease to J3-axis reducer with specified grease and supply oil to
J4-axis gearbox with specified oil.
26 Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J3-axis reducer grease
inlet.
27 Perform quick mastering and perform single axis mastering to J3 to J4-axis referring to Section 8.4
and 8.5 of operator’s manual.

NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear (A290-7221-Z412) of J4-axis motor shaft.

7
6
5 2
4
1

Fig.4.12 (a) Replacing the J4-axis gearbox unit (ARC Mate 100iC/10S, M-10iA/10S) (1/3)

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4.COMPONENT REPLACEMENT B-82755EN/05

Parts name Specifications Q’ty Locking Torque (N-m)


1 BOLT A97L-0218-0502#M5X12 8 LT242 4.5
2 PLATE A290-7221-X425 1
3 PACKING A290-7221-X441 1
4 BOLT A97L-0001-0674#3X35 3
5 PIPE B A290-7221-X430 1
6 BOLT A6-BA-6X85 14 LT262 15.7
7 O RING A290-7221-X444 1

12

10 11

15

13
14
8
9

Fig.4.12 (b) Replacing the J4-axis gearbox unit(ARC Mate 100iC/10S, M-10iA/10S) (2/3)

Parts name Specifications Q’ty Locking Torque (N-m)


8 BOLT A6-BA-6X10 2
9 PLATE A290-7221-Z471 1
10 BOLT A6-BA-6X10 1
11 PLATE A290-7221-Z472 1
12 J3 UNIT A290-7221-T413 1
13 BOLT A6-BA-8X25 9 LT262 37.2
14 WASHER A97L-0001-0823#M8H 9
15 ADAPTER A290-7221-X422 1

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B-82755EN/05 4.COMPONENT REPLACEMENT

22
21
20
17

16
18
26 19
24
25

23
Fig.4.12 (c) Replacing the J4-axis gearbox unit (ARC Mate 100iC/10S, M-10iA/10S) (3/3)

Parts name Specifications Q’ty Locking Torque (N-m)


16 BOLT A6-BA-4X5 2
17 CLAMP A290-7221-X473 1
18 BOLT A6-BA-3X6 2 LT262 15.7
19 CLAMP A290-7221-X474 1
20 BOLT A6-BA-4X35 2
21 PIPE A A290-7221-X427 1
22 PIN JB-PH-H7A-5X10S45C 2
23 BOLT A6-BA-5X14 7
24 PIN JB-PH-H7A-5X10S45C 2
25 COVER A290-7221-Z424 1
26 PACKING A290-7221-X442 1

The following service parts are appended to J4-axis gearbox (A05B-1221-K413) for maintenance.
Please exchange these with the J4-axis gearbox.
Parts name Specifications Q’ty Used place
PACKING A98L-0040-0042#03 1 J3-axis Motor
PACKING A98L-0040-0042#07 1 J4-axis Motor
BOLT A6-BA-8X25 9 Between J3 casing and J3-axis reducer
BOLT A6-BA-5X14 7 J4-axis Motor mounting part
WASHER A97L-0001-0823#M8H 9 Between J3 casing and J3-axis reducer
SEAL BOLT A97L-0218-0502#5X10 4 J4-axis Motor
SEAL BOLT A97L-0218-0417#081010 1 J4 oil outlet
SEAL BOLT A97L-0218-0417#060808 1 J3 grease inlet
PACKING A290-7221-X441 1 J4-axis hollow part
PACKING A290-7221-Z442 1 J4-axis Motor mounting part
O RING A290-7221-X444 1 Between J3 arm and J3 casing
PIN JB-PH-H7A-5X10S45C 4 Z424, Z425

4.13 REPLACING THE J5-AXIS MOTOR M5


NOTE
Please exchange it by one when you exchange both J5 and the J6 axis motors.
Otherwise, the balance of pressure collapses, and oil spouts. Moreover, please
open neither oiling entrance nor the oil discharge entrance.

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4.COMPONENT REPLACEMENT B-82755EN/05

1 Place the robot in a posture of J3 = -90°. If it is impossible to make the posture in the on-site
environment, put the collection bottle under the robot.
2 Set dial gauges at J5-axis, and prepare for single axis mastering after replacement.
3 Turn off the controller power.
4 Remove seal bolt (1) and J5 motor cover (2).
5 In case of M-10iA or M-10iA/6L or M-10iA/10S, replace packing (3). (Remove adhesive tape
completely.)
6 Remove bolt (4) and duct cover (5).
7 Remove cable of motor.
8 Remove nylon bands of Pulsecoder line.
9 Remove seal bolt (6) and plate cover 1 (7).
10 In case of M-10iA or M-10iA/6L or M-10iA/10S, replace packing (8). (Remove adhesive tape
completely.)
11 Remove bolt (9) and motor that gears attaches.
12 Replace motor new one and assemble it by opposite procedure. Refer to Fig.4.13 (b) when motor
(10) is assembled. Please wrap the seal tape when you recycle seal bolt (1), (6). Replace packing (3),
(8) and O ring (16) to new article.
13 Attach nylon band of Pulsecoder line.
14 According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil.
15 Perform single axis mastering referring to Section 8.5 of operator’s manual.

10
9 7 5
1 2 3 8 4

12 11
6
13
14
15

16

Fig.4.13 Replacing the J5-axis motor

Parts name Specifications Number Locking Torque (N-m)


1 SEAL BOLT A97L-0218-0736#050808 4 4.5
2 J5M COVER A290-7221-X509 1
3 PACKING (*1) A290-7221-X579 1
4 BOLT A6-BA-5X45 2 LT262 9.0
5 DUCT COVER A290-7221-X506 1

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B-82755EN/05 4.COMPONENT REPLACEMENT

Parts name Specifications Number Locking Torque (N-m)


6 SEAL BOLT A97L-0218-0736#050808 2 4.5
7 PLATE COVER 1 A290-7221-X561 1
8 PACKING (*1) A290-7221-X581 1
9 BOLT A6-BA-5X12 3
A06B-0115-B855#0048 (*2)
10 MOTOR 1
A06B-0115-B205#S000 (*3)
11 SPACER A290-7221-X529 1
12 KEY JB-HKY-3X3X8A 1 LT675
13 GEAR J6-1 A290-7221-X511 1
14 WASHER A290-7210-X532 1
15 BOLT A97L-0218-0514#M3X8 1 LT242 1.0
16 O RING A98L-0001-0347#S39 1
(*1) In case of M-10iA, M-10iA/6L, M-10iA/10S
(*2) ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S
(*3) ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L
Fix the motor while gently pressing the motor
against the direction of the arrow.
However, be careful not to press it strongly.

Gear
A290-7221-X591

J5-axis motor

Fig.4.13 (b) Note of assembling J5-axis motor

4.14 REPLACING THE J6-AXIS MOTOR M6


NOTE
Please exchange it by one when you exchange both J5 and the J6 axis motors.
Otherwise, the balance of pressure collapses, and oil spouts. Moreover, please
open neither oiling entrance nor the oil discharge entrance.

1 Place the robot in a posture of J3 = -90°.If it is impossible to make the posture in the on-site
environment, put the collection bottle under the robot.
2 Set dial gauges at J6-axis, and prepare for single axis mastering after replacement.
3 Turn off the controller power.
4 Remove seal bolt (1) and plate cover 2 (2).
5 In case of M-10iA, M-10iA/6L,and M-10iA/10S replace packing (3). (Remove adhesive tape
completely.)
6 Remove seal bolt (4) and J6 motor cover (5).
7 In case of M-10iA or M-10iA/6L, M-10iA/10S replace packing (6). (Remove adhesive tape
completely.)
8 Remove cables of motor.
9 Remove bolt (7) and motor (8) that gears attaches.
10 Replace motor new one and assemble it by opposite procedure. Refer to Fig.4.14 (c) when motor
(10) is assembled. Please wrap the seal tape when you recycle seal bolt (1), (4). Replace O ring
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4.COMPONENT REPLACEMENT B-82755EN/05

(14) to new one, too. Please put O ring in the ditch surely. Confirm the gear passes O ring and the
gear has not come in contact with O ring. Apply LOCTITE 675 to key.
11 According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil.
12 Perform single axis mastering referring to Section 8.5 of operator’s manual.

Fig.4.14 (a) Replacing the J6-axis motor (1/2)

8
7
6
5
14

10 9
4
11
12 13
Fig.4.14 (b) Replacing the J6-axis motor (2/2)

Parts name Specifications Number Locking Torque (N-m)


1 SEAL BOLT A97L-0218-0736#050808 4 4.5
2 PLATE COVER 2 A290-7221-X562 1

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B-82755EN/05 4.COMPONENT REPLACEMENT

Parts name Specifications Number Locking Torque (N-m)


3 PACKING A290-7221-X582 1
4 SEAL BOLT A97L-0218-0735#040808 4 4.5
5 J6M COVER A290-7221-X505 1
6 PACKING A290-7221-X575 1
7 BOLT A6-BA-5X12 3
A06B-0115-B855#0048 (*2)
8 MOTOR 1
A06B-0115-B205#S000 (*3)
9 SPACER A290-7221-X529 1
10 GEAR J6-1 A290-7221-X521 1
11 KEY JB-HKY-3X3X8A 1 LT675
12 BOLT A97L-0218-0514#M3X8 1 LT242 1.0
13 WASHER A290-7210-X532 1
14 O RING A98L-0001-0347#S39 1
(*1) In case of M-10iA, M-10iA/6L, M-10iA/10S
(*2) ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S
(*3) ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L

Fix the motor while gently pressing the motor


against the direction of the arrow.
However, be careful not to press it strongly.

Gear
A290-7221-X521

J6-axis motor

Fig.4.14 (c) Note of assembling J6-axis motor

4.15 REPLACING WRIST UNIT


1 Place the robot in a posture of J3 = -90° and J4 = J5 =0°.
2 Release all oil of J5/J6 gearbox referring to section 2.2.
3 Make robot to the posture of J3=5° and J4=±180° while being careful not to move the J5/J6-axes
enough. (If J5/J6-axis are moved without oil, it causes burning of the gear.)
4 Set dial gauges at J5/J6-axes, and prepare for single axis mastering after replacement.
5 Turn off the controller power.
6 Remove the J5-axis motor as described in Section 4.13.
7 Remove seal bolt (1), (3) and wrist unit (2). In this case, it is possible to remove by evenly tightening
the M5 bolt in the pulling out tap two places shown in Fig.4.15 (b).
8 Remove sealant of sealing face of J3 arm side completely, then clean them by using cleaning agent
and remove grease thoroughly.
9 Spread three bonds TB1133G (Spec: A98L-0040-0238#0.33KG) or LOCTITE 518 on the uniting
side of the wrist unit and the J3 arm by the thickness of about 1mm referring to Fig.4.13 (c). In this
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4.COMPONENT REPLACEMENT B-82755EN/05

time, apply three bonds to the hollow part of the counter boring, too. Remove the seal material that
may be seen to the oil bath part as much as possible.
(When using LOCTITE 7649 together)
Five hours are usually necessary because of hardening after applying three bond 1133G or
LOCTITE 518. But if LOCTITE 7649 (accelerator) is used together, it can shorten time. The method
is shown below. Apply sealant (1133G) to J3 arm side (Refer to right figure of Fig.4.15 (c).), then
apply LOCTITE 7649 (Refer to left figure of Fig.4.13 (c).) Insert wrist unit to J3 arm within 2
minutes, and wipe up the overflowed sealant. Apply LOCTITE 7649 to all circumference part of
mating face referring to Fig.4.13 (b). After 30 minutes wipe the LOCTITE 7649 (blue) neatly and
start the oiling process.
10 Confirm there are two parallelφ5 pins for the positioning on the J3 arm. Then replace wrist unit to
new one and assemble it by opposite procedure. Please wrap the seal tape when you re-use the seal
bolt (1) and (3). Please do not forcibly pull with the bolt and do not fix the wrist unit. The gear might
not enter the drive shaft easily when the wrist unit is installed. And it must enter smoothly and not
forcibly. For this case, the J6 axis motor is removed referring to Section 4.14, and the wrist unit is
installed while rotating the drive shaft by the hand. Please fix the bolt when you confirm the
installation is easily obtained neatly.
11 Please leave the robot for five hours or more and monitor the firmness the seal sealant material.
(Only when LOCTITE 7649 is not used.)
12 Referring to Section 4.13, attach J5-axis motor.
13 According to Section 2.2, supply the J5/J6-axis gearbox with the specified oil.
14 Perform single axis mastering referring to Section 8.5 of operator’s manual.

NOTE
When the influence of the damaged pieces generated from broken reducer is
concerned about, exchange gear (A290-7221-X511) of J5-axis motor shaft and
gear (A290-7221-X521) of J6-axis motor shaft.

O5 parallel pin
1

3
Fig.4.15 (a) Replacing the wrist unit

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B-82755EN/05 4.COMPONENT REPLACEMENT

Removal tap (M5)

Applying area of
LOCTITE 7649 (accelerator)
(all circumference part including back side)

Fig.4.15 (b) Position of removal tap of wrist unit and LOCTITE 7649 applying area
( 11 )

( 19 ) ( 18 )

Apply 1133G to this range of X507.


Apply 1133G to the head of the bolt.

Wrist unit side J3 arm side


Fig.4.15 (c) Sealant applying area

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4.COMPONENT REPLACEMENT B-82755EN/05

Specifications Numb Locking Torque (N-m)


Parts name
er
1 SEAL BOLT A97L-0218-0423#053016 4 9.0
2 WRIST ASSY A290-7221-V504 1
3 SEAL BOLT A97L-0218-0423#052016 3 9.0

4.16 REPLACING THE J2 COVER (OPTION)


1 Remove bolt (1) and washer (2).
2 Remove J2 cover (3). When replacing only J2 cover, omit the procedure 3 to 5.
3 Remove bolt (5) and washer (6).
4 Remove base support (4).
5 Remove bolt (8) and support (7).
6 Replace J2 cover (3) to new one, and assemble it by opposite procedure.

3 1
2

Fig.4.16 (a) Replacing J2 cover (1/3)

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B-82755EN/05 4.COMPONENT REPLACEMENT

4
6
5

Fig.4.16 (b) Replacing J2 cover (2/3)

7 8

Fig.4.16 (c) Replacing J2 cover (3/3)

Parts name Specifications Number Locking Torque (N-m)


1 BOLT A97L-0218-0502#M5X10 5
2 WASHER A6-WM-5S 5
3 J2 COVER A290-7221-X381 1
4 BASE SUPPORT A290-7221-X382 1
5 SEAL BOLT A97L-0218-0736#050808 2
6 WASHER A6-WM-6S 2
7 SUPPORT A290-7221-X383 1
8 BOLT A6-BA-8X12 1

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4.COMPONENT REPLACEMENT B-82755EN/05

4.17 REPLACING THE J4 COVER (OPTION)


1 Remove bolt (1) and washer (2).
2 Remove J4 cover (3). When replacing only J4 cover, omit the procedure 3 and 4.
3 Remove bolt (5) and support A (4).
4 Remove bolt (6) and support B (7).
5 Replace J4 cover (3) to new one, and assemble it by opposite procedure.

1 2 3

Fig.4.17 (a) Replacing J4 cover (1/2)

7 4
6 5

Fig.4.17 (b) Replacing J4 cover (2/2)

Parts name Specifications Number Locking Torque (N-m)


1 BOLT A97L-0218-0502#M5X10 4
2 WASHER A6-WM-6S 4
3 J4 COVER A290-7221-X481 1
4 SUPPORT A A290-7221-X482 1
5 BOLT A6-BA-6X10 2
6 BOLT A6-BA-3X5 2
7 SUPPORT B A290-7221-X483 1

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B-82755EN/05 4.COMPONENT REPLACEMENT

4.18 NOTES FOR ASSEMBLING CABLES WITH M/H CONDUIT


1 M/H conduit is option to protect hand cable etc. You can prevent cables interference with arm
directly by installing this and can postpone life of cables. Instead conduit is expendable supplies>
replace it regularly.
2 The cable is clamped at a position 70mm or more away for the wrist side is recommended. A position
30mm or more away is recommended for the J4 back side. In case of M-10iA, adjust the length of the
cable between clamping to 785±5mm. In case of M-10iA/6L, adjust the length of the cable between
clamping to 1005±5mm. Please absorb extra length to Conduit. If cables are not clamped, it cause
broken of cable and conduit, be sure to clamp cables.
3 The longevity of the cable improves by spreading grease on the surface of the cable in Conduit. Shell
Alvania grease S2 is recommended. In this case, please use the cable with performance that can
endure oil. If grease is not applied, it causes early damage of cables and conduit.

Table 4.18 (a) Recommended cables and air tube


Cable name Maker Spec of FANUC Specifications
Oki cable
End effector cable A66L-0001-0459 0.2mm2 24-core Cable for moving part
co. Ltd
2
Signal line Oki cable 0.2mm 2-core 4 pairs (8-core) Cable for
A66L-0001-0464#1
3DL sensor cable co. Ltd moving part
Oki cable
Power line A66L-0001-0401#10 1.25mm2 10-core Cable for moving part
co. Ltd
Okano
0.3mm2 2-core 3 pairs (6-core) Cable for
Force sensor cable cable co. A66L-0001-0178#03P
moving part
Ltd
2
Hitachi 0.26mm 4-core
3DL sensor camera cable cable co. A66L-0001-0525 0.13mm2 2-core
Ltd 0.08mm2 2-core Cable for moving part
Hitachi
LED lighting cable cable co. A66L-0001-0143 0.2mm2 6-core Cable for moving part
Ltd
TU0604 (Outside diameter=Φ6mm,
Air tube SMC A97L-0218-0010
Inside diameter=Φ4mm)

(Cable length between clamp M-10iA : 785u5mm , M-10iA/6L : 1005u5mm

70 mm 30 mm Nylon band
Cable , air tube

Rubber tube

Cable clamp position


A

Greaes applying area (recommended)


Cable clamp position

Fig.4.18 (a) Cable length between clamps

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4.COMPONENT REPLACEMENT B-82755EN/05

3 Please install circumscription yen of bunches of cables on 30mm or less as shown in figure so that
cables should not rub at the edge of the J6 hollow flange. If filling degree is over , it causes early
damage of conduit.

30
O
cable,air tube

Conduit
Fig.4.18 (b) Diameter of cable and air tube in conduit

4 It is recommended to install protect ring if necessary so that neither cable nor bolt attached to the J6
hollow flange may interfere.
5 Please roll cables in the rubber seat etc. so as not to damage surfaces of cables by the edge of the
nylon band in the cable clamping part, and bind on that in the nylon band.
6 When M/H conduit is installed, use by the range limitation of J6 axis range of motion ±190° is
recommended. The longevities of cables shortens when using it exceeding ±190° though it is
possible to use even in range of motion more than this (maximum ±270°).

Table 4.18 (b) Regular exchange cycle


Exchange cycle
J5-axis:±140° Cycle that is shorter among 2.4 million cycles
J6-axis:±190° (As one cycle every 30 seconds and four years

NOTE
Please note that it is a standard at the exchange cycle when the cable wire rod
and the air tube of the FANUC recommendation are used. If cable is not
clamped or grease is not applied or filling degree of cable in conduit is over or
robot is operated with fluoric resin ring is broken, it causes early damage of
cables and conduit.

(7) Please examine the structure that the cutting powder etc. Do not invade in Conduit when you specify
M/H conduit and severe dust/liquid protection option simultaneously.
(8) Fluoric resin ring is installed to J6 hollow part and white powder is generated to reduce friction of
rotation. This is not trouble. Fluoric resin ring is expendable supply. (Spec: A290-7221-X571)
Two years are aims in an exchange period. If you operate robot with the state that hard mine dust
is attached to rotated part, exchange period may shortens. If robot is operated with fluoric resin rig is
broken, it causes early damage of conduit.

4.19 REPLACING M/H CONDUIT (OPTION)


(When replacing unit)
1 Remove all cables, the air tubes, and the cable clamping, etc. that go in M/H conduit.
2 Remove M4×10 bolts (2pcs) in Fig.4.19 (a) and remove unit of M/H conduit.
3 Attach new M/H conduit by opposite procedure. In this time, according to Fig.4.19 (a) apply
LOCTITE 242 to internal thread and tighten by regulated torque. Assemble them while paying
attention that circumference of adapter does not interfere inside of out shaft of J6 hollow part.

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B-82755EN/05 4.COMPONENT REPLACEMENT
(Otherwise abnormal noise occurs.) Confirm there is a clearance between them. Pay attention that
ring does not protrude from circumference of adapter, too.

Bolt
M4X10(2)
LT242

Fig.4.19 (a) Replacing M/H conduit (1/2)

(When replacing only conduit)


1 Remove all cables, the air tubes, and the cable clamping, etc. that go in M/H conduit.
2 Remove M4×10 bolts (2pcs) in Fig.4.19 (a) and remove unit of M/H conduit.
3 Remove set screw that fix ring.
4 Sleeve might be attached depending on the shipping time, then remove sleeve.
5 Remove conduit from adapter.
6 Attach new M/H conduit by opposite procedure. In this time, according to Fig.4.19 (a), (b) apply
LOCTITE 242 to internal thread and tighten by regulated torque. If you cut conduit, be sure to refer
NOTE in Appendix A. Assemble them while paying attention that circumference of adapter does not
interfere inside of out shaft of J6 hollow part. (Otherwise abnormal noise occurs.) Confirm there is a
clearance between them. Pay attention that ring does not protrude from circumference of adapter,
too.

Adapter
A290-7221-X631
Sleeve Plate
Bolt
A97L-0118-0735#RKS-36 A290-7221-X632
M4X8(3)
(It might be attached Tightening torque 4.5Nm
LT242
Ring
depending on the shipping time.) A290-7221-X633
Set screw
A6-SAKT-3X10(2)
LT242

Conduit
(FANUC spec:
M-10iA , M-10iA/10S : A97L-0118-0734#E36-0062
M-10iA/6L : A97L-0118-0734#E36-0084)
(PMA spec:ESDT-36B)

Fig.4.19 (b) Replacing M/H conduit (2/2)

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4.COMPONENT REPLACEMENT B-82755EN/05

4.20 NOTES FOR ASSEMBLING CABLES WITH NO DUST M/H


CONDUIT
1 M/H conduit is option to protect hand cable etc. You can prevent cables interference with arm
directly by installing this and can postpone life of cables . Instead conduit is expendable supplies>
replace it regularly.
2 Please prepare rubber bush as figure below. Please make thickness between wrist flange and tip of
rubber bush is 9mm, thickness of rubber bush is 6mm. In case of J3 casing side, please make
thickness between back of J3 casing and tip of rubber bush is 11.4mm and thickness of rubber bush
is 6mm.Make length of cable between rubber bush is 721±5mm (in case of M-10iA) or 941±5mm
(in case of M-10iA/6L) and absorb extra length to Conduit. If cables are not clamped, it cause
broken of cable and conduit, be sure to clamp cables.
3 The longevity of the cable improves by spreading grease on the surface of the cable in Conduit.
Shell Alvania grease S2 is recommended. In this case, please use the cable with performance that
can endure oil. If grease is not applied, it causes early damage of cables and conduit.
4 Confirm there is no gap in slit part of rubber bush. If there is a gap, clean degree turn worse. Please
be careful.

Table 4.20 Recommended cables and air tube


Cable name Maker Spec of FANUC Specifications
Oki cable
End effector cable A66L-0001-0459 0.2mm2 24-core Cable for moving part
co. Ltd
Signal line Oki cable 0.2mm2 2-core 4 pairs (8-core) Cable
A66L-0001-0464#1
3DL sensor cable co. Ltd for moving part
Oki cable
Power line A66L-0001-0401#10 1.25mm2 10-core Cable for moving part
co. Ltd
Okano
0.3mm2 2-core 3 pairs (6-core) Cable
Force sensor cable cable co. A66L-0001-0178#03P
for moving part
Ltd
2
Hitachi 0.26mm 4-core
3DL sensor camera cable cable co. A66L-0001-0525 0.13mm2 2-core
Ltd 0.08mm2 2-core Cable for moving part
Hitachi
LED lighting cable cable co. A66L-0001-0143 0.2mm2 6-core Cable for moving part
Ltd
TU0604 (Outside diameter=Φ6mm,
Air tube SMC A97L-0218-0010
Inside diameter=Φ4mm)

Clamp length between clamp


M-10iA : 721±5mm
M-10iA/6L : 941±5mm
6 6
11.4
9

Rubber bush
Rubber bush

Grease applying area

Fig.4.20 (a) Cable length between clamp

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B-82755EN/05 4.COMPONENT REPLACEMENT
5 Please install circumscription yen of bunches of cables on 30mm or less as shown in figure so that
cables should not rub at the edge of the J6 hollow flange. If filling degree is over, it causes early
damage of cables and conduit.

Conduit
O 30

Cable , air tube

Fig.4.20 (b) Diameter of cable and air tube in conduit

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4.COMPONENT REPLACEMENT B-82755EN/05

6 Refer to Fig.4.20 (c) about shape of rubber bush and structure of cables in conduit.

Shape of rubber bush of back slit(to go through wire rod)


of J3 casing side
2mm or more
7
Air tube (O6mm) X 4

4-O5

2mm or more
O46

O43

6 O7
O3
EE (O8mm)
O7

Signal line (O8mm)

Shape of rubber bush of


wrist side slit(to go through wire rod)
2mm or more
7
Air tube (O6mm) X 4
5
4-O

2mm or more

O3
6
O43

O46

O7

EE (O8mm)
O7

Signal line (O8mm)

[Example of four φ6 air tube ,EE(φ8mm) and signal line (φ8mm)]


・Design rubber bush so that diameter of hole is smaller 1mm than air tube and
cable sheet.
・Post air tube and wire rod in dotted line of φ36mm.
・The direction of taper is reversed in case of back of J3 casing side and wrist side.
・Secure the wall thickness more than 2mm between holes.
・Flouring rubber , the hardness between 30 to 50 is recommended.

Fig.4.20 (c) Shape of rubber bush (example)

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B-82755EN/05 4.COMPONENT REPLACEMENT
7 Refer to Fig.4.20 (d) about structure of seal of back of J3 casing.

Example of structure of seal of back


of J3 casing

Base plate mounting bolt


M5×25
(9pcs:Tightening torque 6.0Nm)
Use belleville spring washer.
Remove bolts which are attached to robot 9 2.4±0.05
when it is shipped, and tighten base plate and


plate of back together.

0.
8M
AX
O ring G105
(JIS-B-2401,JIS-B-2406)

Plate to hold
(Metal which thickness is 2T or more.
SUS or plating metal is recommended.)

+0.035
Rubber bush

O110H7 0
(Flouring rubber
O44
O40
The hardness between

O40
30 to 50)
A
Bolt for mounting plate
for holding rubber bush
M4 is recommended,Bolt screw
mating length 1.5d, Equally spaced
(8pcs:Tightening torque 4.5Nm)

Base plate 6
(The board of
aluminium alloy)

46 32.5 32.5 46
46
32.5
25

78.5
7.5

39

VIEW A
Fig.4.20 (d) Structure of seal of back of J3 casing
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4.COMPONENT REPLACEMENT B-82755EN/05

8 Refer to Fig.4.20 (e) about structure of seal of wrist.


If wrist is not sealed, dust come from hollow hole. Be sure to seal wrist.

*When you choose material and treatment, take rust protection into account.
*When you choose rubber bush, take weatherability and medicine characteristic-
Example of structure of seal of wrist resistant into account.

Hand base plate mounting bolt


3 4 5 M4×10(8pcs:Tightening torque 4.5Nm)
R0.4MAX Use belleville spring washer.
Refer to section 4.1 about mounting pitch.

A board to hold
(Metal which thickness is 2T or more.
SUS or plating metal is recommended.)
O40
+0.030
0

O40

O44
O62H7

Rubber bush
(Flouring rubber
The hardness between
30 to 50)

Bolt for mounting plate for


holding rubber bush
3 6 M4 is recommended,Bolt screw mating length 1.5d,
Robot wrist flange
Equally spaced
(8pcs:Tightening torque 4.5Nm)
Sealant applying area
(Recommended sealant:LOCTITE 518) Hand base plate
(The board of
aluminium alloy)

Fig.4.20 (e) Structure of seal of wrist (example)

9 When No dust M/H conduit is installed, use by the range limitation of J6 axis range of motion
±190° is recommended. The longevities of cables shortens when using it exceeding ±190° though it
is possible to use even in range of motion more than this (maximum ±270°). For J5-axis use it
motion range in ±120°. If J5-axis move more than ±120°, it cause break of conduit, be careful.

NOTE
If cable is not clamped or grease is not applied or filling degree of cable in conduit
is over or robot is operated with fluoric resin ring is broken, it causes early
damage of cables and conduit.

10 Specification is ISO class 5 (equal to clean class 100).

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B-82755EN/05 4.COMPONENT REPLACEMENT

4.21 REPLACING NO DUST M/H CONDUIT (OPTION)


(When replacing unit)
1 Remove all cables, the air tubes, and the cable clamping, etc. that go in No dust M/H conduit.
2 Remove M4×10 bolts (2pcs) and M5×45 bolts (2pcs) in Fig.4.21 (a) and remove unit of M/H
conduit.
3 Attach new No dust M/H conduit by opposite procedure. In this time, according to Fig.4.21 (a)
apply LOCTITE 242 to internal thread and tighten by regulated torque.

Bolt
A97L-0218-0432#5X45 (2)
LT262
Tightening torque 7Nm

Bolt
A97L-0218-0496#M4X10SC (2)
LT242
Tightening torque 4.5Nm
Fig.4.21 (a) Replacing No dust M/H conduit (1/3)

(When replacing only conduit)


1 Remove all cables, the air tubes, and the cable clamping, etc. that go in No dust M/H conduit.
2 Remove bolt M3×8 (8pcs), holder (2pcs), J6 adapter and packing of wrist side.
3 Remove bolt M3×8 (8pcs), holder (2pcs), J3 adapter and packing of J3 casing side.
4 Cut conduit referring to note of Appendix A.
5 Polish conduit with a brush made by nylon.
6 Attach new No dust M/H conduit by opposite procedure referring to Fig.4.21 (a) to (c). Replace
packing , seal bolt and bolts that LOCTITE is applied. Remove old packing of holder and attach new
packing referring to Fig.4.21 (b). When attaching packing, put it on the oil seal inside the wrist unit
and put J6 adapter on it, and fix them with bolts. Apply LOCTITE 242 and 262 to thread of bolt and
tighten bolts with regulated torque.

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4.COMPONENT REPLACEMENT B-82755EN/05

Holder
A290-7221-X642 (2)
Seal bolt
A97L-0218-0546#030806SC (8)
Tightening torque 2Nm

Holder
A290-7221-X642 (2)
Seal bolt
A97L-0218-0546#030806SC (8)
Tightening torque 2Nm

Wrist side J3 casing side

Packing B
A290-7221-X642

Packing A
A290-7221-Z641

Attachment packing to holder A290-7221-X642

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B-82755EN/05 4.COMPONENT REPLACEMENT

(When attaching No dust M/H conduit to which is ordered after shipment of


robot)
1 Remove fluoric resin ring referring to Section 4.22.
2 Remove duct cover and clean the tap hole.
3 Remove plate cover and clean the tap hole.

Bolt
A6-BA-5X45(2)
Duct cover
Plate cover 1
A290-7221-X506
A290-7221-Z561

Seal bolt
A97L-0218-0736#050808(2)

Fig.4.21 (d) Attach No dust M/H conduit (1/4)

4 Paste packing (A290-7221-X647) to plate cover 1 (A290-7221-X561).

Attach packing while being careful not to


make clearlance between packing.

Plate cover 1
A290-7221-Z561

Packing
A290-7221-X647

Fig.4.21 (e) Attach No dust M/H conduit (2/4)

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4.COMPONENT REPLACEMENT B-82755EN/05

5 Fix plate cover 1 (A290-7221-Z561) with 2 seal bolts. Tightening torque is 4.5Nm. Bend packing
(A290-7221-X647) to have no gap at the corner.

Casting Packing
A290-7221-X647

A
Be careful
not to make
clearlance
in conrer.

Plate

Seal bolt
A97L-0218-0736#050808SC(2) Casting
(Tightening torque 4.5Nm)
DETAIL A
Fig.4.21 (f) Attach No dust M/H conduit (3/4)

6 Fix J3 adapter (A290-7221-X643) of no dust M/H conduit to J3 arm. Bolts are 2 RF coating bolts.
Tighten them with tightening torque 9Nm after applying LOCTITE 262 into taps.
7 Fix J6 adapter (A290-7221-X641) of no dust M/H conduit to J6 housing (A290-7221-X503) pushing
it to the direction of arrow D of Fig.4.21 (g). Then confirm that the gap between J5 adapter
(A290-7221-X502) and J6 adapter (A290-7221-X641) is less than 2.5mm. Bolts are 2 stainless
coating bolts. Washers are 2 stainless washers. Tighten them with tightening torque 4.5Nm after
applying LOCTITE 242 into taps.

Bolt
A97L-0218-0432#5X45(2) D
J3 adapter (Tightening torque 9Nm) C J5 adapter
B A290-7221-X643
LT262
C A290-7221-X502

B Bolt SECTION B-B


A97L-0218-0496#M4X10SC(2) J6 adapter
(Tightening torque 4.5Nm) A290-7221-X641
Washer 2.5or less
A6-WM-4SUS(2)
LT242

SECTION C-C

Fig.4.21 (g) Attach No dust M/H conduit (3/4)

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B-82755EN/05 4.COMPONENT REPLACEMENT

4.22 REPLACING FLUORIC RESIN RING


1 Remove the all cable connection of J3 casing.
2 Remove the plated bolts (2pcs) as shown Fig. 4.22, then remove the end of M/H conduit unit from
J6 hollow part.
3 Remove the fluoric resin ring using needle-nose pliers and other tool. Be careful not to hurt the J6
housing.
4 Replace the fluoric resin ring, and insert it to J6 hollow part until the edge of it get in groove inside
of J6 hollow part.
5 Correct the strained of the fluoric resin ring using the screwdriver and other tool.
6 Attach the M/H conduit unit and the cable connection of J3 casing. Assemble them while paying
attention that circumference of adapter does not interfere inside of out shaft of J6 hollow part.
(Otherwise abnormal noise occurs.) Confirm there is a clearance between them. In this time, note
that the plated bolts are applied LOCTITE 242 to internal thread and are tightened by regulated
torque. (Refer to Fig.4.22.)

Fluoric resin ring A


A290-7221-X571
Adapter
A290-7221-X631

Plated bolt
A97L-0218-0496#M4X10TC (2)
Tightening torque 4.5Nm
Applying LOCTITE 242

DETAIL A

Fig.4.22 Replacing fluoric resin ring

4.23 SEALANT APPLICATION


Washing and degreasing the surfaces to be sealed
1 After dismounting the reducer from the arm, apply releasant (LOCTITE Gasket Remover etc.) to the
arm’s surface from which the reducer was dismounted, then wait until the sealant (LOCTITE 518)
becomes softened (for about 10 minutes). Remove the softened sealant from the surface using a
spatula.
2 Blow air onto the surface to be sealed to remove dust from the tapped holes.
3 Sufficiently degrease the reducer’s surface to be sealed and the arm’s surface to be sealed, using a
cloth dampened with oil and grease remover. Do not spray oil and grease remover directly onto the
surface.
4 Polish the arm’s surface to be sealed with an oil stone, and degrease it with removal and cleaner
again.

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4.COMPONENT REPLACEMENT B-82755EN/05

CAUTION
Oil may drip from the inside of the reducer. After degreasing, make sure that no
oil is dripping.

Applying sealant
5 Make sure that the reducer and the arm are dry (with no oil and grease remover remaining). If they
are still wet with oil and grease remover, wipe them dry. Always use a new surface of a cloth so that
the grease once wiped up with the cloth will not get on the degreased surface. Make sure that no
ingredient of oil and grease remover is left in the threaded holes or on any other portion. If
ingredient is left, it may prevent stiffening of sealant.
6 Apply sealant (LOCTITE 518) to the surfaces.

CAUTION
The portions to which sealant is to be applied vary from one axis to another. See
descriptions about reducer replacement for the relevant axes for details.

Assembling
7 To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as
quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant
was wiped off, apply again.
8 After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get
closer.
9 After attaching the reducer, wipe off any excessive sealant that comes out from the sealed section
with a cloth or spatula. Do not use oil and grease remover.

CAUTION
Do not grease or move the reducer before the sealant sets, as it may allow
grease to leak. Before greasing or moving, wait for about at least four hour after
the reducer is mounted.

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B-82755EN/05 5.CABLE REPLACEMENT

5 CABLE REPLACEMENT
Replace the welding power cables of the mechanical unit in the cycle that is shorter among every about
two years and 7,680 hours operating. Replace the other cables of the robot in the cycle that is shorter
among every four years and 15,360 hours operating. If a cable is broken or damaged, replace it according
to the procedure described in this chapter.

Cautions in handling the Pulsecoder cable


When transporting, installing, or maintaining the robot, do not detach the Pulsecoder cables carelessly.
The cables are provided with the marking tie shown below. If you detached any cable with the marking
tie, you need to perform mastering for the robot.
Do not detach any connector unless you replace a motor, Pulsecoder, reducer, gearbox or cable.

BATTERY BACKUP

DON'T

DISCONNECT

コネクタ取外不可

Fig.5 Wire mark

If there is a break in or any other damage to a cable, replace the cable according to the procedure
described in this chapter. If the connector of a motor cable is detached, the data about the absolute
position of the robot is lost. Once any of these cables is replaced, perform quick mastering while
referencing Section 8 of operator’s manual. If the data is lost because of a break in a cable, also perform
mastering to calibrate the robot into the previous absolute position.

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5.CABLE REPLACEMENT B-82755EN/05

5.1 CABLE WIRING


Fig.5.1 is the routing of the robot cables. See Chapter 5 of operator’s manual for option cable interface.

K101 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8))


K102 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(Non corresopondence to CE)
K103 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(ARC Mate 100iC , M-10iA)

K111 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8)


:for severe dust/liquid protection option)
(M-10iA)

K121 (M1 to M6 Pulsecoder,power,brake(J2/J3-axis only))


(ARC Mate 100iCe , M-10iAe)

K131 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8))


K132 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(Non corresopondence to CE)
K133 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(ARC Mate 100iC/6L , M-10iA/6L)

K141 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8)


:for severe dust/liquid protection option)
(M-10iA/6L)

K151 (M1 to M6 Pulsecoder,power,brake(J2/J3-axis only))


(ARC Mate 100iCe/6L , M-10iAe/6L)

K161 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*8))


K162 (M1 to M6 Pulsecoder,power,brake,end effector (RI/RO*1))
(Non corresopondence to CE)
(ARC Mate 100iC/10S , M-10iA/10S)

K301 Wire feeder cable


K311 User cable (signal)
K312 User cable (power)
K315 User cable (signal usable to force sensor and 3DL sensor)
K321 Welding power cable 38SQ
K323 Welding power cable 60SQ
K331 Earth cable for camera
K351 Camera and 3DL sensor cable
K701 Camera cable (non waterproof type)
K702 Camera cable (waterproof type)
(ARC Mate 100iC , M-10iA,ARC Mate 100iC/6L , M-10iA/6L)

K314 User cable (signal line usable to the 3DL sensor and force sensor)
K331 Earth cable for camera
K703 Camera cable (waterproof type)
(ARC Mate 100iC/10S , M-10iA/10S)

Fig.5.1 Routing of the robot

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B-82755EN/05 5.CABLE REPLACEMENT

5.2 CABLE DRESSING


After a cable is replaced individually rather than in a bundle, clamp it with nylon ties (cable ties) at the
specified positions listed in Table 5.2 (a) to (f). Otherwise, the cable might sag or become too tight,
leading to a break in the cable.

Clamp position of Table 5.2 (a) to (g) mean position in Fig.5.2 (a), (b).

Clamp position of inside J1 base

DETAIL B
Clamp position of
pipe of J1-axis reducer

A
C DETAIL C
Clamp position of J2 base
D

B
DETAIL D
SECTION A-A
A

G
Clamp position of
lower side of J2 arm
F Clamp position of
J4 connector plate

DETAIL E
Clamp position of
E upper side of J2 arm
DETAIL G

DETAIL F

Fig.5.2 (a) Clamp position of motor cable


(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iCe, M-10iAe)

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5.CABLE REPLACEMENT B-82755EN/05

Clamp position of inside J1 base

DETAIL I
Clamp position of
H pipe of J1-axis reducer

J
DETAIL J
J

K Clamp position of J2 base

I J

SECTION H-H DETAIL K


H

N
Clamp position of
M lower side of J2 arm
DETAIL L
L Clamp position of
upper side of J2 arm

DETAIL M

Clamp position of
DETAIL N J4 connector plate

Fig.5.2 (b) Clamp position of motor cable (ARC Mate 100iC/10S, M-10iA/10S)

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B-82755EN/05 5.CABLE REPLACEMENT
Table 5.2 (a) Cable pattern diagram (1)

Stamp Cable pattern diagram Stamp Cable


No.

Clamp position of inside of J1 base


Clamp position on pipe of J1-axis reducer
Clamp position of J2 base
Clamp position of lower side of J2 arm
+

-
Clamp position of upper side of J2 arm +
GB1

Clamp position of J4 connector plate -


M1P

M 1P
M2P

M2P
K101

M3P

M3P
M4P
M4P

M5P
M5P
M5M
M5M

M5BK
M5BK
EE K101,
EE

M6P K131,
M6P

M6M K161
M6M

M6BK
M 6BK

M3M
M3M

M4M
M4M

M4BK
M4BK

M1M
M1M

M1BK
M1BK
M2M

M2M
M2BK

M2BK

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5.CABLE REPLACEMENT B-82755EN/05

Table 5.2 (b) Cable pattern diagram (2)

Stamp Cable pattern diagram Stamp Cable


No.

Clamp position of inside of J1 base


Clamp position on pipe of J1-axis reducer
Clamp position of J2 base
Clamp positio of lower side of J2 arm
+

-
Clamp position of upper side of J2 arm +
GB1

Clamp position of J4 connector plate -


M1P

M1P
M2P

M2P
K101

M3P

M3P
M4P
M4P

M5P
M5P
M5M
M5M

EE
M5BK
M5BK K102,
K132,
EE

M6P
M6P

K162
M6M
M6M

M6BK
M6BK

M3M
M3M

M4M
M4M

M4BK
M4BK

M1M
M1M

M1BK
M1BK
M2M

M2M
M2BK

M2BK

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B-82755EN/05 5.CABLE REPLACEMENT
Table 5.2 (c) Cable pattern diagram (3)

Stamp Cable pattern diagram Stamp Cable


No.

Clamp position of inside of J1 base

Clamp position on pipe of J1-axis reducer


Clamp position of J2 base
Clamp position of lower side of J2 arm
+
-
Clamp position of upper side of J2 arm +
GB1

Clamp position of J4 connector plate -


M1P

M1P
M2P

M2P
K101

M3P

M3P
M4P
M4P

M5P
M5P
M5M
M5M

M5BK
M5BK K103,
EE K133
EE

M6P
M6P

M6M
M6M

M6BK
M 6BK

M3M
M3M

M4M
M4M

M4BK
M4BK

M1M
M1M

M1BK
M1BK
M2M

M2M
M2BK

M2BK

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5.CABLE REPLACEMENT B-82755EN/05

Table 5.2 (d) Cable pattern diagram (4)

Stamp Cable pattern diagram Stamp Cable


No.

Clamp position of inside of J1 base


Clamp position on pipe of J1-axis reducer
Clamp position of J2 base
Clamp position of lower side of J2 arm
+
-
Clamp position of upper side of J2 arm +
GB1

Clamp position of J4 connector plate -


M1P

M1P
M2P

M2P
K101

M3P

M3P
M4P
M4P

M5P
M5P
M5M
M5M

M5BK
M5BK K111,
EE
K141
EE

M6P
M6P

M6M
M6M

M6BK
M6BK

M3M
M3M

M4M
M4M

M4BK
M4BK

M1M
M1M

M1BK
M1BK
M2M

M2M
M2BK

M2BK

- 106 -
B-82755EN/05 5.CABLE REPLACEMENT
Table 5.2 (e) Cable pattern diagram (5)

Stamp Cable pattern diagram Stamp Cable


No.

Clamp position of inside of J1 base


Clamp position on pipe of J1-axis reducer
Clamp position of J2 base
Clamp position of lower side of J2 arm
+
-
Clamp position of upper side of J2 arm +
GB1

Clamp position of J4 connector plate -


M1P

M1P
M2P

M2P
K101

M3P

M3P
M 4P
M4P

M5P
M5P
M5M
M5M

EE K121,
EE

M6P K151
M6P

M6M
M6M

M3M
M3M

M4M
M4M

M1M
M1M
M2M

M2M
M2BK

M2BK

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5.CABLE REPLACEMENT B-82755EN/05

Table 5.2 (f) Cable pattern diagram (6)

Cable
Stamp Cable pattern diagram Stamp No.

Clamp position of
J4 connector plate

W/F1 W/F2 K301

W/F2
K301 W/F1

Clamp position of
J4 connector plate
AS1 AS2 K311
K311 AS1

AS2
Clamp position of
J4 connector plate

AP1 AP2 K312


AP2
K312 AP1

Clamp position of
J4 connector plate
ASi1 ASi2 K314
ASi2
K314
ASi1

Clamp position of
J4 connector plate
ASi1 ASi2 K315
K315 ASi1

ASi2

Clamp position of
J4 connector plate
Clamp position of
upper side of J2 arm

K321

- 108 -
B-82755EN/05 5.CABLE REPLACEMENT
Table 5.2 (g) Cable pattern diagram (7)

Cable
Stamp Cable pattern diagram Stamp No.

Clamp position of
lower side of J2 arm
Clamp position of
Clamp position of upper side of J2 arm
J2 base
Clamp position of
J4 connector plate

K323

K331

Clamp position of
J4 connector plate

SEN1 SEN2 K351


2007-T032
SEN1

K351
SEN2

Clamp position of
J4 connector plate
CAM1 1221-D301

CAM2 K701

CAM1 CAM2 K701


Clamp position of
J4 connector plate
CAM1 1221-D302

CAM2 K702

CAM1 CAM2 K702

Clamp position of
J4 connector plate
CAM1 1221-D303

CAM2 K703

CAM1 CAM2 K703

Clamp positio of lower side


of J2 arm

- 109 -
5.CABLE REPLACEMENT B-82755EN/05

5.3 REPLACING CABLES


1) Replacing the cable kit
When you have special tool for remove connector of J6-axis, place the robot in a posture of J1 to J4
= 0°
When you don’t have special tool, place the robot in a posture of J1, J2 and J4 =0° and J3=-90°
(Refer to Section 4.14.)

1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. (It is
set in 0º for all axes when robot is shipped.)
2 Before replacing cables, turn off the controller power and remove all cables between robot and
controller from the robot.
3 Cut the nylon band for the J2-/J3-axis cable protection sheet, and remove the cover from the
cable kit. (Refer to Fig.5.3 (a)).
(There is no cable protection sheet for ARC Mate 100iCe,M-10iAe, ARC Mate
100iCe/6L,M-10iAe/6L.)
4 Remove extra low bolt and button seal bolt, J6 motor cover and J5 motor cover. (Refer to
Fig.5.3 (b)). In case of M-10iA or M-10iA/6L or M-10iA/10S, replace packing. (Remove
adhesive tape completely.)
5 Remove duct cover and plate cover 1 (Refer to Fig.5.3 (b)). In case of M-10iA or M-10iA/6L
or M-10iA/10S, replace packing. (Remove adhesive tape completely.)
6 Cut the nylon band of plate cover 1. Remove the earth terminal (M3) of upper side of J5-axis
motor. (Refer to Fig.5.3 (b))
7 Remove connector of J5/J6-axis motor, when connector of J6-axis motor is removed, use
special tool (A290-7221-X971). If special tool cannot be prepared, remove J6-axis motor
referring to Section 4.14 and remove connector.
8 Remove earth terminal (M3) above J6-axis motor. (Refer to Fig.5.3 (c))
9 Remove bolt M5×12 (9pcs), cover, packing (A290-7221-X441). (Refer to Fig.5.3 (e))
(Remove adhesive tape completely.)
10 Remove bolt M3×35 (3pcs) and pulled out pipe. (Refer to Fig.5.3 (e))
11 Cut the nylon band of the back of the J6-axis motor.
12 Remove seal bolt M6×16 (2pcs). (Refer to Fig.5.3 (e))
13 Remove bolt that fasten clamp (2 places) of J3 casing. Then cut nylon band. (Refer to Fig.5.3
(f))
14 Pull out cable that is in J3 arm to the J3 casing. When Pulsecoder cable passes between cable
clamps that is read side of J6-axis motor and J3 arm base. Pass it carefully so as not to damage
it by using the space referring to Fig.5.3 (d).
15 Pull out the cable from the side of the J3 casing. In this time, if power cable and Pulsecoder
cable is pulled beforehand. Work becomes easy.
16 Remove bolt and J4 connector plate. (Refer to Fig.5.3 (g).) In this time, do not put it into the
state to hang the cable of J4 connector plate. The cable might be hurt.
17 Remove connector and lead line of J3/J4-axis motor. In this time, do not put it into the state to
hang the cable of J4 connector plate. The cable might be hurt.
18 Remove cable cover and bolt. (Refer to Fig.5.3 (h)).
19 Remove connector of J1/J2-axis motor.
20 Remove M8×10 bolts (4pcs) that fasten J1 connector plate to J1 base and remove J1connector
plate from J1 base (Refer to Fig.5.3 (i)).
21 Cut the nylon band that fastens rubber boots.
22 Remove M4×10 bolts (4pcs) that fasten connector housing and bolt M6×10 bolts (2pcs) that
fasten support. (Refer to Fig.5.3 (i)).
23 Remove connector insert from connector housing and remove connector insert and rubber boot
from J1 connector plate.
24 Remove the terminal from battery box.
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B-82755EN/05 5.CABLE REPLACEMENT
25 Remove the two earth terminals secured to the J1 base.
26 Pull out the air tube from the panel union.
27 When option cable attached, remove them from J1 connector plate and J1 base.
28 Remove rubber boot from the cable.
29 Remove the plate, which is attached to support. (Refer to Fig.5.3 (i)).
30 Pull out cables. When cable pass hollow part of J1-axis reducer, be careful connector insert
don’t caught in it. If cable is pulled forcibly, it causes the disconnection.
31 Remove plate fixation M8 bolts and the cable. (Refer to Fig.5.3 (k)).
32 Replace the cable kit to new one .Do 29 to 31 by opposite procedure. Pay attention cable don’t
twist in the J1 base.
33 Do 23 to 28 by opposite procedure. Pay attention rubber boot come between J1 connector plate
and connector housing.
34 Do 16 to 22 by opposite procedure. In this time, do not put it into the state to hang the cable of
J4 connector plate. The cable might be hurt.
35 Do 12 to 15 by opposite procedure. Wind the cable to J3 casing 4 times, and apply shell
Alvania grease S2 referring to Fig.5.3 (f). When reuse seal bolt, be sure to seal them with seal
tape. At this time, please connect it to come to the position in which the head of the nylon band
is shown in Figure 5.3 (f). The cable might be hurt when differing from the shown in the figure
position.
36 Do 11 by opposite procedure. Clamp cables while pulling it to the J6 motor side at this time. If
pull is insufficient, when the pipe is inserted, cable might be hurt.
37 Do 9 to 10 by opposite procedure. In this time, be sure to replace packing to new one.
38 Do 2 to 8 by opposite procedure. In this time, be sure to replace packing to new article. Install
the J2-/J3-axis cable protection sheet onto the cable kit as originally done, and then secure the
cover with nylon band. (Secure the nylon band to such an extent that the cable protection
sheet does not get out of position when the robot operates. If the nylon band is tightened
excessively, the cables in the movable section are confined and the cables can be broken at an
earlier time.)
39 Perform quick mastering referring Section 8.4 of operator’s manual. If motor is removed,
perform single axis mastering for the axis referring to Section 8.5 of operator’s manual.

2) Replacing only motor cable


1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. (It is
set in 0°for all axes when robot is shipped.)
2 Remove cable kit from robot referring to Section (1) of Section 5.3 (1).
3 Replace motor cable to new one and assemble it to cable kit. Clamp cables as the clamping
position that the marking position shown in Figure 5.2 (a) - (f) and in Figure 5.3 (l) is
corresponding. If cable is clamped in not specified position, slack and an impossible pull are
caused in the cable, and it causes the cable disconnection. There are cables that don’t have
marking on all position. First, set the cable with the marking position to a specified position.
The cable without marking is formed along it and do so as not to twist along it.
4 Attach the cable kit onto the robot body. (See (1) of Section 5.3.) Retighten the mounting
bolts.
5 Install the J2/J3-axis cable protection sheet as originally done. (Secure the nylon band to such
an extent that the cable protection sheet does not get out of position when the robot operates.
If the nylon band is tightened excessively, the cables in the movable section are confined and
the cables can be broken at an earlier time.) (There is no cable protection sheet for ARC Mate
100iCe,M-10iAe, ARC Mate 100iCe/6L,M-10iAe/6L.)
6 Perform quick mastering referring Section 8.4 of operator’s manual. If motor is removed,
perform single axis mastering for the axis referring to Section 8.5 of operator’s manual.

3) Replacing only option cables (K301 etc.)


(There is no option cable for ARC Mate 100iCe,M-10iAe, ARC Mate 100iCe/6L,M-10iAe/6L.)
1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. (It is
set in 0°for all axes when robot is shipped.)
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5.CABLE REPLACEMENT B-82755EN/05

2 Cut the nylon band that fastens J2/J3-axis cable protection sheet and remove it from cable kit.
3 Remove cables that is between J1 base and J4 connector plate from robot referring to (1) of
Section 5.3 and Fig.5.3 (g) to (k)
4 Replace option cable to new one and fasten it by opposite procedure. Retighten the mounting
bolts.
5 Clamp cables as the clamping position that the marking position shown in Figure 5.2 (a) - (f)
and in Figure 5.3 (l) is corresponding. If cable is clamped in not specified position, slack and an
impossible pull are caused in the cable, and it causes the cable disconnection. There are cables
that don’t have marking on all position. First, set the cable with the marking position to a
specified position. The cable without marking is formed along it and do so as not to twist along
it.
6 Install the J2-/J3-axis cable protection sheet as originally done. (Secure the nylon band to
such an extent that the J2/J3-axis cable protection sheet does not get out of position when the
robot operates. If the nylon band is tightened excessively, the cables in the movable section
are confined and the cables can be broken at an earlier time.)
7 Perform quick mastering referring Section 8.4 of operator’s manual. If motor is removed,
perform single axis mastering for the axis referring to Section 8.5 of operator’s manual.

Cable protection sheet


Cable protection sheet

ARC Mate 100iC , M-10iA, ARC Mate 100iC/10S , M-10iA/10S


ARC Mate 100iC/6L , M-10iA/6L

Fig.5.3 (a) Replacing cable kit (J2/J3-axis cable protection sheet)

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B-82755EN/05 5.CABLE REPLACEMENT

Bolt
M5X45 (2)
Tightening torque 9Nm
LT262

Duct cover

Cut nylon band and Extra low bolt


remove cable from clamp M5X8 (2)
of the back side. Tightening torque 4.5Nm
Plate cover 1
Bolt
M3X6 Packing (*)
Earth terminal A290-7221-X581

Cut nylon band which fix


this cable to the plate
of the interior of J6-axis motor.

Bolt M3X6
Packing (*)
Packing (*) A290-7221-X582
A290-7221-X575

J6 motor cover J5 motor cover

Button seal bolt


M4X8(4) Extra low seal bolt
Tightening torque 4.5Nm M5X8(4)
Tightening torque 4.5Nm

(*) In case of M-10iA , M-10iA/6L , M-10iA/10S


Fig.5.3 (b) Replacing cable kit (J3 arm part 1)

Earth terminal

Fig.5.3 (c) Replacing cable kit (J3 arm part 2)

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5.CABLE REPLACEMENT B-82755EN/05

Cable clamp

Pulsecoder cable
connector

J3 arm base
Fig.5.3 (d) Replacing cable kit (J3 arm part 3)

Packing
A290-7221-X441
Cover
Bolt M5X12(9)
Apply LOCTITE 242.
Tightening torque : 4.5Nm
Seal bolt
M6X16(2)
Bolt
M3X35(3)

Pipe

Fig.5.3 (e) Replacing cable kit (J3 casing part 1)


(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S)

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B-82755EN/05 5.CABLE REPLACEMENT

Dummy pipe

Bolt
M3X30 (3)

Packing
A290-7221-X441

Cover

Bolt
M5X8 (9) Seal bolt
Tightening torque 6.8Nm M6X16 (2)

Fig.5.3 (f) Replacing cable kit (J3 casing part 1)


(ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)

Marking position
WIND THE CABLE FOUR TIMES.
APPLY SHELL ALVAIA GREASE S2
AFTER ASSEBLING.

Bolt
Position of the head M4X5(2)
of the nylon band

Position of the head


of the nylon band

Bolt
M3X6(2)
Apply LOCTITE 242.

Clamp

Marking position

Fig.5.3 (g) Replacing cable kit (J3 casing part 2)

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5.CABLE REPLACEMENT B-82755EN/05

Prevent the load from hanging


to the cable which is connected to
J4 connector plate.

Bolt Bolt J4 connector panel 2


M6X10 Bolt
M6X10 M8X10 (2)

Prevent the load from hanging Bolt


to the cable which is connected to M6X10 (3)
J4 connector plate.

J4 connector panel 1
J4 connector panel

ARC Mate 100iC , M-10iA, ARC Mate 100iC/10S , M-10iA/10S


ARC Mate 100iC/6L , M-10iA/6L
ARC Mate 100iCe , M-10iAe,
ARC Mate 100iCe/6L , M-10iAe/6L

Fig.5.3 (h) Replacing cable kit (J4 connector plate part)

Cable cover

Bolt
M8X10(2)

Bolt
M6X12(2)

Fig.5.3 (i) Replacing cable kit (J2 base part)

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B-82755EN/05 5.CABLE REPLACEMENT

Option cable

Rubber boot(*)
Connector
insert
Plate
J1 connector plate

Bolt
M8X10(4)
Bolt
M4X10(4)
Connector housing
Bolt
M6X10(2) Support
Terminal of
Air tube battery box Bolt
M6X8 (2)

(*)When mechanical unit cable A05B-1221-H202,


H203,H232 or H233 is selected,there is no rubber boot.

Tie up with nylon band.

- +

+
-

Tightening torque
0.40Nm
Battery box terminal side

Fig.5.3 (j) Replacing cable kit (J1 connector plate part 1)

TIE UP END OF RUBBER


TUBE WITH NYLON BAND.

SECTION A-A A

Fig.5.3 (k) Replacing cable kit (J1 connector plate part 2)

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5.CABLE REPLACEMENT B-82755EN/05

Bolt
M8X10(4)
Apply LOCTITE 262

Plate Plate

Bolt
M8X12 (4)
Apply LOCTITE 262

ARC Mate 100iC , M-10iA, ARC Mate 100iC/10S , M-10iA/10S


ARC Mate 100iC/6L , M-10iA/6L
ARC Mate 100iCe , M-10iAe,
ARC Mate 100iCe/6L , M-10iAe/6L

Fig.5.3 (l) Replacing cable kit (J2 arm part)

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B-82755EN/05 6.MASTERING

6 MASTERING
Mastering is an operation performed to associate the angle of each robot axis with the pulse count value
supplied from the absolute Pulsecoder connected to the corresponding axis motor. To be specific,
mastering is an operation for obtaining the pulse count value corresponding to the zero position.

6.1 GENERAL
The current position of the robot is determined according to the pulse count value supplied from the
Pulsecoder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However,
mastering becomes necessary after:
- Motor replacement
- Pulsecoder replacement
- Reducer replacement
- Cable replacement
- Batteries for pulse count backup in the mechanical unit have gone dead.

WARNING
Robot data (including mastering data) and Pulsecoder data are backed up by
their respective backup batteries. Data will be lost if the batteries go dead.
Replace the batteries in the control and mechanical units periodically. An alarm
will be issued to warn the user of a low battery voltage.

Mastering method
There are following five methods of mastering.

Table 6.1 Mastering method


Fixture position This is performed using a mastering fixture before the machine is shipped from the
mastering factory.
Zero-position This is performed with all axes set at the 0-degree position. A zero-position mark
mastering (witness (witness mark) is attached to each robot axis. This mastering is performed with all axes
mark mastering) aligned to their respective witness marks.
Quick mastering This is performed at a user-specified position. The corresponding count value is obtained
from the rotation speed of the Pulsecoder connected to the relevant motor and the
rotation angle within one rotation. Quick mastering uses the fact that the absolute value
of a rotation angle within one rotation will not be lost.
Single axis mastering This is performed for one axis at a time. The mastering position for each axis can be
specified by the user. This is useful in performing mastering on a specific axis.
Mastering data entry Mastering data is entered directly.

This MAINTENANCE MANUAL describes fixture position mastering that is mainly required during
replacement of parts. For other mastering methods, refer to OPERATOR'S MANUAL.

Once mastering is performed, it is necessary to carry out positioning, or calibration. Positioning is an


operation is which the controller reads the current pulse count value to sense the current position of the
robot.

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6.MASTERING B-82755EN/05

CAUTION
1 If mastering is performed incorrectly, the robot may behave unexpectedly. This is
very dangerous. Therefore, the positioning screen is designed to appear only
when the $MATER_ENB system variable is 1 or 2. After performing positioning,
press F5[DONE] on the positioning screen. The $MASTER_ENB system
variable is reset to 0 automatically, thus hiding the positioning screen.
2 Before mastering is performed, it is recommended that the current mastering
data be backed up.
3 When the motion range is mechanically 360 degrees or more, if any of the axes
(J1-axis and J4-axis) to which the cables are connected is turned one turn in the
correct mastering position, the cables in the mechanical unit are damaged. If the
correct rotation position is not clear because the axis is moved too much during
mastering, remove the connector panel or cover, check the states of the internal
cables, and perform mastering in the correct position. For the checking
procedure, See Fig. 6.1 (a) to 6.1 (c).

Confirm cable is not twisted


when J1=0°.
Bolt
M8X12 (4)

J1 connector panel

Fig.6.1 (a) Confirming the state of cable (J1-axis)

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B-82755EN/05 6.MASTERING

Packing (*)
A290-7221-X441
(*) Packing is can not be reused.
If you remove cover, replace
packing to new one.

Bolt
M5X12 (9)
Confirm cable is wound Apply LOCTITE 242.
four times when Tightening torque : 4.5Nm
J4=0v.
Plate

Fig.6.1 (b) Confirming the state of cable (J4-axis) (1/2)

Confirm these nylon bands


are attached.

Fig.6.1 (c) Confirming the state of cable (J4-axis) (2/2)

6.2 REGISTER OF MASTERING POSTURE


If the number of soft versions is Edition 24 or earlier of the V7.30
When FIXTURE POSITION MASTER is done for the first time.
It is necessary to input the mastering posture according to the following procedure beforehand.
(It is not necessary when FIXTURE POSITION MASTER is done for the second time or more.)

Procedure
1 Press the screen selection key.
2 Press [0 NEXT] and Select [6 SYSTEM].
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6.MASTERING B-82755EN/05

3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu.


4 Place the cursor on $PARAM_GRP, then press [ENTER].
5 [$MRR_GRP_T] is displayed then press [ENTER].
6 Place the cursor on $MASTER _POS, then press [ENTER].
7 Input MASTERING POSTURE in Fig.6.4 (e).
8 Turn off the power of the controller and turn on it.
(If the power supply of the controller is never turned on again, the value of the mastering posture is
not updated.

6.3 RESETTING ALARMS AND PREPARING FOR


MASTERING
Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and
display the positioning menu.

Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse not established”

Procedure
1 Display the positioning menu by following steps 1 to 6.
1 Press the screen selection key.
2 Press [0 NEXT] and Select [6 SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4 Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER].
5 Press F1 [TYPE], and select[Master/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal] menu.

2 To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.


1 Press the MENUS key.
2 Select [0 NEXT] and select [6 SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4 Place the cursor on F3 RES_PCA, then press F4 [TRUE]. The message “ TRUE” appears and
disappears immediately.
5 Turn off the controller power and on again.

3 To reset the “Servo 075 Pulse not established” alarm, follow steps 1 to 3.
1 When the controller power is switched on again, the message “Servo 075 Pulse not
established ” appears again.
2 Move the axis for which the message mentioned above has appeared till alarm disappears when
press [FAULT RESET] in either direction.

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B-82755EN/05 6.MASTERING

6.4 FIXTURE POSITION MASTER


Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the
predetermined fixture position.
Fixture position mastering is accurate because a dedicated mastering fixture is used.
When mastering the robot, arrange the robot to meet the following conditions.
- Make the robot mounting base horizontal within 1 mm.
(The overall levelness of the robot mounting surface shall be 1 mm or less.)
- Remove the hand and other parts form the wrist.
- Set the robot in the condition protected from an external force.

Assembling the fixture base


1 Assemble the fixture base as shown in Fig. 6.4 (a).

Bolt
M5X20 (4)

Mastering fixture B
A290-7221-X952

Plate

Bolt
M5X20 (3)

Plate

Fig.6.4 (a) Assembling the fixture base

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6.MASTERING B-82755EN/05

2 Adjust the dial gauge to 3.00 mm using the calibration block, and tighten it with M5 bolt as shown
in Fig. 6.4 (b). (Do not tighten the bolt too strongly or the dial gauge will be broken.)

Bolt
Calibration block M5X16 (6)
Plate
E
A

B D F

C
Dial gauge
(All dial gauge indicate 3mm
in calibration.)

Assembling method of dial gauge

Bolt M5
20 mm

Clamp

Calibration block

Fig.6.4 (b) Mounting dial gauge

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B-82755EN/05 6.MASTERING
3 Mount the fixture to the wrist flange as shown Fig. 6.4 (c).
When assembling pin A290-7221-X955, pay attention to the direction of the pin refer to Fig.6.4 (c).

Bolt
M6X20 (2)

Pin
A290-7221-X955
A290-7221-X956

Assembling pin A290-7221-X955

Assemble pin to show


the position of parallel
Robot front part of pin and robot
front in figure.

Fig.6.4 (c) Assembling the fixture base

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6.MASTERING B-82755EN/05

4 Assemble the fixture to the wrist flange as shown in Fig. 6.4 (d).
When assembling pin, pay attention the parallel pin turn to radial part of hollow flange. Refer to
Fig.6.4 (d).

Pin
A290-7221-X954
Face for dial gauge Bolt
D and F M4X16 (4)
Face for dial gauge Mastering fixture A
A and B A290-7221-X951

Face for dial gauge E


Face for dial gauge C

Assemble pin the parallel part of


pin turn to radial part of hollow flange.

Fig.6.4 (d) Assembling the fixture to the wrist flange

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B-82755EN/05 6.MASTERING

Mastering
1 Press MENUS.
2 Press NEXT and select SYSTEM.
3 Press F1, [TYPE].
4 Select Master/Cal.

AUTO
SYSTEM Master/Cal JOINT
TORQUE= [ON]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Press‘ENTER’or number key to select.

[TYPE] LOAD RES_PCA DONE

5 Release brake control, and jog the robot into a posture for mastering.
A to F (see Fig.6.4 (b)) of the fixture attached to the wrist are dial gauges A to F (see Figs.6.4 (d))
and make adjustments so that dial gauges A to F indicate 3 mm. A posture as shown in Fig.6.4 (e)
should be taken. See this figure for reference.

NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.$SV_OFF_ALL: FALSE
$PARAM_GROUP.$SV_OFF_ENB[*]: FALSE (for all axes)
After changing the system variables, switch the controller power off and on
again.

6 Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES.


"MASTER POSITION" shown in Fig. 6.4 (e) is set in this position.

AUTO
SYSTEM Master/Cal JOINT
TORQUE= [ON]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data:
<0><11808249><3876856>
<9873638><122000309><2000319>

[TYPE] LOAD RES_PCA DONE

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6.MASTERING B-82755EN/05

7 Select “ 6 CALIBRATE “ and press F4, YES. Mastering will be performed


Alternatively, switch the power off and on again. Switching the power on always causes positioning
to be performed.
AUTO
SYSTEM Master/Cal JOINT
TORQUE= [ON]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg)
< 0.0000>< 0.0000>< 0.0000>
< 0.0000>< 0.0000>< 0.0000>

[TYPE] LOAD RES_PCA DONE

8 After completing the calibration, press F5 Done.


9 Return brake control to original setting, and turn off the controller power and on again.

WARNING
Since the axis stroke is not checked during the mastering, be careful to stay
clear of the robot motion.

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B-82755EN/05 6.MASTERING

ARC Mate 100iC ARC Mate 100iC/6L


M-10iA M-10iA/6L
ARC Mate 100iCe ARC Mate 100iCe/6L
M-10iAe M-10iAe/6L

Mastering position Mastering position


J1 0.00000
J1 0.00000 J2 22.9302
J2 55.9747 J3 -94.7411
J3 -118.993 J4 0.00000
J4 0.00000 J5 -85.2589
J5 -61.0069 J6 -90.0000
J6 -90.0000

ARC Mate 100iC/10S


M-10iA/10S

Mastering position
J1 0.00000
J2 55.6176
J3 -108.076
J4 0.00000
J5 -71.9238
J6 -90.0000

Fig.6.4 (e) Mastering posture

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6.MASTERING B-82755EN/05

6.5 CHECKING THE MASTERING


1 Checking whether mastering has been made correctly
Usually, positioning is performed automatically at power-on. To check whether mastering has
been made correctly, note whether the displayed current position agrees with the actual robot
position. Use the procedure described below:
(1) Reproduce a particular point in a program. Check whether the point agrees with the specified
position.
(2) Set all axes of the robot to their 0-degree (0rad) positions. Check that the zero-degree position
marks indicated in section 8.3 of OPERATOR’S MANUAL are aligned. There is no need to
use any visual aid.
(3) Using fixtures, set the robot to the mastering position in the same way as when performing
mastering. Check that the displayed current position agrees with the actual mastering
position.
If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been
invalidated as a result of an alarm described below 2. Alternatively, the mastering data in system
variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation
error or some other reason.
Compare the data with the values indicated on the supplied data sheet. This system variable is
overwritten whenever mastering is performed. Whenever mastering is performed, record the value
of the system variable on the data sheet.

2 Alarms that may be output during mastering


This section describes those alarms related to Pulsecoders, as well as the actions required to clear
them.
(1) BZAL alarm
This alarm is output if the voltage of the Pulsecoder's backup battery falls to 0 V while the
power to the controller is disconnected. To clear the alarm, fit a new battery, execute the
pulse reset (See Section 6.3.), then turn off the controller power then on again.
Note that, if this alarm occurs, all data originally held by the Pulsecoder will have been lost.
Mastering must be performed again.
(2) BLAL alarm
This alarm is output if the voltage of the Pulsecoder's backup battery has fallen to a level where
backup is no longer possible. If this alarm is output, fit a new battery immediately while
keeping the power turned on. Check whether the current position data is valid, using the
procedure described in 1.
(3) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL, alarms
If any of these alarms is output, contact the FANUC service section. The Pulsecoder may be
defective.

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APPENDIX
B-82755EN/05 APPENDIX A.SPARE PARTS LIST

A SPARE PARTS LIST


Table A (a) Cables (basic cable)
Cable No. Specifications Function Model
K101 A05B-1221-D001 J1 to J6 MOTOR+EE(RI/OX8) ARC Mate 100iC
K102 A05B-1221-D002 J1 to J6 MOTOR +EE(RI/OX1) M-10iA
(Non-correspondence to CE)
K103 A05B-1221-D003 J1 to J6 MOTOR+EE(RI/OX1)
K111 A05B-1221-D011 J1 to J6 MOTOR+EE(RI/OX8)
(Severe dust/liquid protection option)
K121 A05B-1221-D021 J1 to J6 MOTOR ARC Mate 100iCe
M-10iAe
K131 A05B-1221-D031 J1 to J6 MOTOR+EE(RI/OX8) ARC Mate 100iC/6L
K132 A05B-1221-D032 J1 to J6 MOTOR+EE(RI/OX1) M-10iA/6L
(Non-correspondence to CE)
K133 A05B-1221-D033 J1 to J6 MOTOR+EE(RI/OX1)
K141 A05B-1221-D041 J1 to J6 MOTOR+EE(RI/OX8)
(Severe dust/liquid protection option)
K151 A05B-1221-D051 J1 to J6 MOTOR ARC Mate 100iCe/6L
M-10iAe/6L
K161 A05B-1221-D061 J1 to J6 MOTOR+EE(RI/OX8) ARC Mate 100iC/10S
K162 A05B-1221-D062 J1 to J6 MOTOR+EE(RI/OX1) M-10iA/10S

Table A (b) Cables (option cable)


Cable No. Specifications Function Model
K301 A660-2006-T755 Wire feeder power cable ARC Mate 100iC
K311 A660-8016-T454 User cable (signal) M-10iA
K312 A660-2007-T053 User cable (power) ARC Mate 100iC/6L
K315 A66-8017-T649 User cable (signal usable to M-10iA/6L
force sensor and 3DL sensor)
K321 A660-8040-T023 Welding power cable (38SQ)
K323 A660-8040-T024 Welding power cable (60SQ)
K331 A660-8016-T828 Earth cable for camera
K351 A660-2007-T032 Force sensor, 3DV sensor cable
K701 A05B-1221-D301 Camera cable (Non-waterproof type)
K702 A05B-1221-D302 Camera cable (Waterproof type)
K314 A660-8017-T499 User cable (signal) ARC Mate 100iC/10S
K331 A660-8016-T828 Earth cable for camera M-10iA/10S
K703 A05B-1221-D303 Camera cable (Waterproof type)

Table A (c) Motor


Axis Specifications Remarks Model
J1, J2 A06B-0235-B605#S000 αiS8/4000 ARC Mate 100iC, M-10iA
J3 A06B-0212-B605#S000 αiS2/5000 ARC Mate 100iC/6L, M-10iA/6L
J4 A06B-0115-B804 βiS0.5/6000 ARC Mate 100iC/10S, M-10iA/10S
J5, J6 A06B-0115-B855#0048 βiSR0.5/6000
J1 A06B-0235-B005#S000 αiS8/4000 ARC Mate 100iCe, M-10iAe
J2 A06B-0235-B605#S000 αiS8/4000 ARC Mate 100iCe/6L, M-10iAe/6L
J3 A06B-0212-B605#S000 αiS2/5000
J4,J5,J6 A06B-0115-B205#S000 βiSR0.5/6000

- 133 -
A.SPARE PARTS LIST APPENDIX B-82755EN/05

Table A (d) Reducer


Parts name Specifications Remarks Model
J1-axis reducer A97L-0218-0822#33(*1) (*1)
A97L-0218-0885$33(*2) (*3) (*2) (*3)
J2-axis reducer A97L-0218-0886#127(*1)(*2) (*1) (*2)
A97L-0218-0886#93 (*3) (*3)
J3-axis reducer A97L-0218-0824#150(*1) (*1)
A97L-0218-0887#150(*2) (*2)
A97L-0218-0887#108 (*3)
(*1) Old spec robot ARC Mate 100iC,M-10iA, ARC Mate 100iC/6L,M-10iA6L shipped before March,
2010.
(*2) New spec: robot ARC Mate 100iC,M-10iA, ARC Mate 100iC/6L,M-10iA6L shipped after April,
2010 or ARC Mate 100iC/10S, M-10iA/10S, ARC Mate 100iCe,M-10iAe,ARC Mate
100iCe/6L,M-10iAe/6L.
(*3) ARC Mate 100iC/10S,M-10iA/10S

NOTE
Specify the following draw nut for the J2, J3-axes reducer.

Table A (e) Input gear, draw nut, gear and key


Parts name Specifications Used place
J1-axis gear A290-7215-X211 J1-axis Motor
Input gear A290-7221-X311 J2-axis Motor
A290-7221-X411 (*1)
Input gear A290-7221-Z411 (*2) J3-axis Motor
A290-7221-Z415 (*3)
Draw nut A290-7221-X321 J2-axis Motor
Draw nut A290-7221-X421 J3-axis Motor
Gear A290-7221-X511 J5-axis Motor
Gear A290-7221-X521 J6-axis Motor
Key JB-HKY-3X3X8A J5, J6-axis Motor
(*1) Old spec robot ARC Mate 100iC,M-10iA, ARC Mate 100iC/6L,M-10iA6L shipped before March,
2010.
(*2) New spec: robot ARC Mate 100iC,M-10iA, ARC Mate 100iC/6L,M-10iA6L shipped after April,
2010 or ARC Mate 100iCe,M-10iAe,ARC Mate 100iCe/6L,M-10iAe/6L.
(*3) ARC Mate 100iC/10S, M-10iA/10S

Table A (f) Other (mechanical unit)


Parts name Specifications Model
ARC Mate 100iC,M-10iA,
A05B-1221-K401 ARC Mate 100iC/6L,M-10iA/6L
Old specification: Robot shipped before March, 2010
ARC Mate 100iC,M-10iA,
J4-axis gearbox ARC Mate 100iC/6L,M-10iA/6L
A05B-1221-K411 New specification: Robot shipped after April, 2010
or ARC Mate 100iCe,M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L
A05B-1221-K413 ARC Mate 100iC/10S,M-10iA/10S
Wrist unit A290-7221-V504 All models
Fluoric resin A290-7221-X571 All models

- 134 -
B-82755EN/05 APPENDIX A.SPARE PARTS LIST
The following service parts are appended to J4-axis gearbox (A05B-1221-K401, K411, K413) for
maintenance. Please exchange these with the J4-axis gearbox.
Parts name Specifications Number Used place
Packing A98L-0040-0042#03 1 J3-axis Motor
Packing A98L-0040-0042#07 1 J4-axis Motor
Bolt A6-BA-8X25 8 or 9 Between J3 casing and J3-axis reducer
Bolt A6-BA-5X14 7 J4-axis Motor mounting part
Washer A97L-0001-0823#M8H 8 or 9 Between J3 casing and J3-axis reducer
Seal bolt A97L-0218-0502#5X10 4 J4-axis Motor
A97L-0218-0417#081010
Seal bolt 1 J4-axis oil outlet
10
Seal bolt A97L-0218-0417#060808 1 J3-axis grease inlet
Packing A290-7221-X441 1 J4-axis Hollow part
J4-axis Motor mounting part
A290-7221-X442 1 ARC Mate 100iC,M-10iA,
Packing ARC Mate 100iC/6L,M-10iA/6L
J4-axis Motor mounting part
A290-7221-Z442
ARC Mate 100iC/10S,M-10iA/10S
O-RING A290-7221-X444 1 Between J3 arm and J3 casing
J4-axis Motor mounting part, J4-axis hollow
PIN JB-PH-H7A-5X10S45C 2
part

Table A (g) Battery, grease, oil, and sealant


Parts name Specifications Model Remarks
Battery A98L-0031-0027 All Models C battery 1.5V (4pcs /per 1 robot)
Grease A98L-0040-0174#1.27KG All Models Kyodo Yushi
VIGOGREASE RE0
Oil A98L-0040-0233#0.8L All Models JX Nippon Oil & Energy Corporation
BONNOC AX68
Sealant A98L-0040-0238#0.33KG All Models Three bond for gearbox

Table A (h) O-RING


Parts name Specifications Model Used place
O-RING A290-7207-X342 All Models J1-axis reducer
O-RING A290-7221-X444 All Models Wrist- unit
O-RING A98L-0001-0347#S150 All Models J1-axis reducer
O-RING A98L-0001-0347#S39 All Models J5, J6-axis Motor (2 places)
O-RING JB-OR1A-G105 All Models J1, J2-axis Motor (2 places)
O-RING JB-OR1A-G65 All Models J1-axis reducer

Table A (i) Packing


Parts name Specifications Model Used place
Packing A290-7221-X441 All Models J4-axis hollow part
Packing A290-7221-X442 All Models J4-axis motor mounting part
Packing A98L-0040-0042#03 All Models J3-axis Motor
Packing A98L-0040-0042#07 All Models J4-axis Motor
Packing A290-7221-Z236 M-10iA, M-10iA/6L Battery cover
(Severe dust/liquid protection
option)
Packing A290-7221-X579 M-10iA, M-10iA/6L,M-10iA/10S J5 motor cover
Packing A290-7221-X581 M-10iA, M-10iA/6L,M-10iA/10S Plate cover 1
Packing A290-7221-X582 M-10iA, M-10iA/6L,M-10iA/10S Plate cover 2
Packing A290-7221-X575 M-10iA, M-10iA/6L,M-10iA/10S J6 motor cover

- 135 -
A.SPARE PARTS LIST APPENDIX B-82755EN/05

Table A (j) Stopper


Parts name Specifications Model Used place
Stopper A290-7215-X323 All Models J2-axis
Stopper A290-7221-X324 All Models J3-axis

Table A (k) M/H conduit (M-10iA, M-10iA/6L, M-10iA/10S option)


Parts name Specifications Model
M/H conduit A05B-1221-J701 M-10iA, M-10iA/10S
A05B-1221-J702 M-10iA/6L
Protection ring A05B-1221-J711 M-10iA
Conduit FANUC Specifications: M-10iA, M-10iA/10S
A97L-0118-0734#E36-0062
PMA Specifications: ESDT-36B (Note)
FANUC Specifications: M-10iA/6L
A97L-0118-0734#E36-0084
PMA Specifications: ESDT-36B (Note)

Table A (l) No dust M/H conduit (M-10iA, M-10iA/6L, M-10iA/10S option)


Parts name Specifications Model
M/H conduit A05B-1221-J721 M-10iA, M-10iA/10S
A05B-1221-J722 M-10iA/6L
Conduit FANUC Specifications: M-10iA, M-10iA/10S
A97L-0118-0734#E36-0062
PMA Specifications: ESDT-36B (Note)
FANUC Specifications: M-10iA/6L
A97L-0118-0734#E36-0084
PMA Specifications: ESDT-36B (Note)
Packing A A290-7221-Z641 (4 pcs/per 1 robot) M-10iA, M-10iA/6L,M-10iA/10S
Packing B A290-7221-Z642 (4 pcs/per 1 robot)
Seal bolt A97L-0218-0546#030806SC (16 pcs/per 1 robot)

NOTE
Please cut it in the convex part when you cut Conduit. The cable might be
damaged in the edge part of Conduit when cutting it in the concave portion.

A Good cutting
example

DETAIL A

B
Bad cutting
example
DETAIL B
Fig.A Cutting example of conduit
- 136 -
B-82755EN/05 APPENDIX B.CIRCUIT DIAGRAM

B CIRCUIT DIAGRAM

- 137 -
B.CIRCUIT DIAGRAM APPENDIX B-82755EN/05

A66L-0001-0401#14
(1.25SQ*14C)Φ11.8

A66L-0001-0574
(0.2SQ*6P)Φ7.7

A66L-0001-0532
(0.4SQ*24C)Φ10.6

A66L-0001-0574
(0.2SQ*6P)Φ7.7

J1 CONNECTOR PANEL
RMP Han 72DD
(2.5SQ 10A)

1 BK(J1) 13 BK(J2) 25 BK(J3) 37 BK(J4) 49 BK(J5) 61 BK(J6)


BKC
2 J1U1 14 J2U1 26 J3U1 38 (200V) 50 (0V) 62 (J1,J2,J3,
J4,J5,J6)

3 J1V1 15 J2V1 27 J3V1 39 J4U1 51 J5U1 63 J6U1

4 J1W1 16 J2W1 28 J3W1 40 J4V1 52 J5V1 64 J6V1

5 J1G1 17 J2G1 29 J3G1 41 J4W1 53 J5W1 65 J6W1


24V
6 XROT 18 (OT,A1,A2, 30 XHBK 42 J4G1 54 J5G1 66 J6G1 (SOLDERING)
A3,A4)

7 RI1 19 RI2 31 RI3 43 RI4 55 RI5 67 0V


(D1,D2)

8 RO1 20 RO2 32 RO3 44 RO4 56 RO5 68 RI6


A66L-0001-0574
(0.2SQ*6P)O7.7
9 RI7 21 RI8 33 RO7 45 RO8 57 XPPABN 69 RO6

5V 5V 5V 0V 0V 0V
10 (A1,A2) 22 (B1,B2) 34 (C1,C2) 46 (A1,A2) 58 (B1,B2) 70 (C1,C2)

11 PRQJ1 23 PRQJ2 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6

12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6


A66L-0001-0459
G FG (0.2SQ*24C)Φ8.3

6V
A66L-0001-0464#1
(BT1,BT2,BT3, (0.2SQ*4P)Φ6.7
BT4,BT5,BT6)
+
A66L-0001-0459
BATTERY (0.2SQ*24C)Φ8.3

0V
(BT1,BT2,BT3,
-
BT4,BT5,BT6)

:可動部用
MOVABLE

Fig.B (a) Circuit diagram


(ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iC/10S, M-10iA/10S)

- 138 -
B-82755EN/05 APPENDIX B.CIRCUIT DIAGRAM

J1 MOTOR (αiS8/4000) J3 MOTOR (αiS2/5000)


IN CASE OF K101,K111,K131,K161
A63L-0001-0648#810SL3SJ M1BK 10SL-3P(1.25SQ 13A) M3 M A63L-0001-0874
A63L-0001-0653#04A
A BK(J1) B BKC(J1) C A63L-0001-0875#SC 1 J3U1 3 J3W1 5 BK(J3)
IN CASE OF K102,K103,K132,K133,K162
MS3108B10SL-3S 2 J3V1 4 J3G1 6 BKC(J3)
IN CASE OF K101,K111,K131,K161 M1M 18-10P M3 P
A63L-0001-0881#1810S 10SL1(0.3SQ 3A)
A63L-0001-0881#10C A J1U1 C J1W1
IN CASE OF K102,K103,K132,K133,K162 B J1V1 D J1G1 A63L-0001-0848#B10SL1 4 6V(BT3)
8 5V(B1) 1
A63L-0001-0881#1810S A63L-0001-0850 5 XPRQJ3
9 2
6 PRQJ3
M1P 10SL1(0.3SQ 3A) SG 10 0V(B1)
7 0V(BT3)
3 FG
A63L-0001-0848#B10SL1 4 6V(BT1)
8 5V(A1) 1
A63L-0001-0850 5 XPRQJ1
9 2
6 PRQJ1
10 0V(A1)
7 0V(BT1)
3 FG J4 MOTOR (βiS0.5/6000)
IN CASE OF K101,K103
,K111,K131,K133,K161
A63L-0001-0866#2
M4 BK MOLEX 55619-0401
A63L-0001-0864#CS 1 4
J2 MOTOR (αiS8/4000) IN CASE OF K102,K132,K162 2 BK(J4) 3 BKC(J4)
A63L-0001-0865#2
IN CASE OF K101,K111,K131,K161
A63L-0001-0648#810SL3SJ M2 BK 10SL-3P(1.25SQ 13A)
A63L-0001-0864#CS
A63L-0001-0653#04A IN CASE OF K101,K103,K111
A BK(J2) B BKC(J2) C
IN CASE OF K102,K103,K132,K133,K162
MS3108B10SL-3S
,K131,K133,K161 M4 M MOLEX 55618-0401
A63L-0001-0866#1
A63L-0001-0864#CS 1 J4U1 4 J4G1
IN CASE OF K101,K111,K131,K161
A63L-0001-0881#1810S
M2 M 18-10P IN CASE OF K102,K132,K162
A63L-0001-0865#1
2 J4V1 3 J4W1
A63L-0001-0881#10C A J2U1 C J2W1 A63L-0001-0864#CS
IN CASE OF K102,K103,K132,K133,K162
A63L-0001-0881#1810S
B J2V1 D J2G1 IN CASE OF K101,K103,K111 M4 P 10SL1(0.3SQ 3A)
,K131,K133 4 6V(BT4)
A63L-0001-0848#B10SL1 8 5V(B2) 1
M2 P 10SL1(0.3SQ 3A) A63L-0001-0850
9
5 XPRQJ4
2
IN CASE OF K102,K132 6 PRQJ4
4 6V(BT2) A63L-0001-0848#E10SL1 10 0V(B2) 3 FG
A63L-0001-0848#B10SL1 8 5V(A2) 1 7 0V(BT4)
A63L-0001-0850 5 XPRQJ2 A63L-0001-0850
9 2
6 PRQJ2 3 FG
10 0V(A2)
7 0V(BT2)

J5 MOTOR (βiSR0.5/6000)
A63L-0001-0865#2 M5 BK MOLEX 55619-0401
A63L-0001-0864#CS 1 BK(J5) 4
2 BKC(J5) 3

A63L-0001-0865#1 M5 M MOLEX 55618-0401


A63L-0001-0864#CS 1 J5U1 4 J5G1
2 J5V1 3 J5W1

M5 P 10SL1(0.3SQ 3A)
A63L-0001-0848#E10SL1 4 6V(BT5)
8 5V(C1) 1
A63L-0001-0850 5 XPRQJ5
9 2
6 PRQJ5
10 0V(C1) 3 FG
7 0V(BT5)

J6 MOTOR (βiSR0.5/6000)
A63L-0001-0865#2 M6 BK MOLEX 55619-0401
A63L-0001-0864#CS 1 BK(J6) 4
A660-0001-0586
IN CASE OF K101,K102,K103 2 BKC(J6) 3
A660-0001-0592
PLATE
IN CASE OF K131,K132,K133
A290-7221-X431 A660-0001-0593 A63L-0001-0865#1 M6 M MOLEX 55618-0401
BUSH (0.2SQ*(12C+2P),0.3SQ*12C)
A63L-0001-0864#CS 1 J6U1 4 J6G1
A290-7221-X432 φ4.9*2 + φ5.1*2
2 J6V1 3 J6W1

M6 P 10SL1(0.3SQ 3A)
A63L-0001-0848#E10SL1 4 6V(BT6)
8 5V(C2) 1
A63L-0001-0850 5 XPRQJ6
9 2
6 PRQJ6
A63L-0001-0234#W2524F 10 0V(C2) 3 FG
7 0V(BT6)
EE (0.5SQ 5A)Φ9.6-Φ15
IN CASE OF K101---ARC Mate 100iC,M-10iA 1 RO1 9 RI1 17 24V(A1)
IN CASE OF K131---ARC Mate 100iC/6L,M-10iA/6L 2 RO2 10 RI2 18 24V(A2)
IN CASE OF K141---ARC Mate 100iC/10S,M-10iA/10S 3 RO3 11 RI3 19 24V(A3) ARC Mate 100iC,M-10iA,
4 RO4 12 RI4 20 24V(A4) ARC Mate 100iC/6L,M-10iA/6L
5 RO5 13 RI8 21 RO7
6 RO6 14 XPPABN 22 RO8 ARC Mate 100iC/10S,M-10iA/10S
7 XHBK 15 RI5 23 0V(D1) □ R-30iA/R-30iA Mate
8 0V(D1) 16 RI6 24 RI7 □ FOR CE (STANDARD)

ARC Mate 100iC,M-10iA


K101(A05B-1221-D001)---RI/O*8
A63L-0001-0234#W1305F
K102(A05B-1221-D002)---RI/O*1
EE (0.5SQ 5A)Φ3-Φ8
K103(A05B-1221-D003)---RI/O*1
IN CASE OF K102,K103---ARC Mate 100iC,M-10iA 1 RO1 3 0V(D1) 5 +24V(A1)
IN CASE OF K132,K133---ARC Mate 100iC/6L,M-10iA/6L 2 XHBK 4 RI1
IN CASE OF K142 ---ARC Mate 100iC/10S,M-10iA/10S M-10iA SEVERE DUST/LIQUID PROTECTION
K111(A05B-1221-D011)---RI/O*8

A63L-0001-0234#R2424S ARC Mate 100iC/6L,M-10iA/6L


EE K131(A05B-1221-D031)---RI/O*8
1 RO1 9 RI1 17 24V(A1) K132(A05B-1221-D032)---RI/O*1
2 RO2 10 RI2 18 24V(A2) K133(A05B-1221-D033)---RI/O*1
3 RO3 11 RI3 19 24V(A3)
4 RO4 12 RI4 20 24V(A4)
IN CASE OF K111--- 5 RO5 13 RI8 21 RO7 M-10iA/6L SEVERE DUST/LIQUID PROTECTION
M-10iA SEVERE DUST/LIQUID PROTECTION 6 RO6 14 XPPABN 22 RO8 K141(A05B-1221-D041)---RI/O*8
IN CASE OF K141--- 7 XHBK 15 RI5 23 RI7
M-10iA/6L SEVERE DUST LIQUID PROTECTION
8 0V(D1) 16 RI6 24 ARC Mate 100iC/10S,M-10iA/10S
K161(A05B-1221-D061)---RI/O*8
K162(A05B-1221-D062)---RI/O*1

- 139 -
B.CIRCUIT DIAGRAM APPENDIX B-82755EN/05

A66L-0001-0401#10
(1.25SQ*10C)φ11.8

A66L-0001-0574
(0.2SQ*6P)φ7.7

A66L-0001-0532
(0.4SQ*24C)φ10.6

A66L-0001-0574
(0.2SQ*6P)φ7.7

J1CONNECTOR PANEL
RMP J1G1,J2G1
G J3G1,J4G1 Han 72DD
J5G1,J6G1 (2.5SQ 10A)

1 13 BK(J2) 25 BK(J3) 37 49 61

2 J1U1 14 J2U1 26 J3U1 38 50 62


BKC
(J2,J3)
3 J1V1 15 J2V1 27 J3V1 39 J4U1 51 J5U1 63 J6U1

4 J1W1 16 J2W1 28 J3W1 40 J4V1 52 J5V1 64 J6V1

5 J1G1 17 J2G1 29 J3G1 41 J4W1 53 J5W1 65 J6W1


(SOLDERING)
6 18 30 42 J4G1 54 J5G1 66 J6G1

7 19 31 43 55 67

8 20 32 44 56 68
A66L-0001-0574
(0.2SQ*6P)φ7.7
9 21 33 45 57 69

10
5V 22 5V 34 5V 46 0V 58 0V 70 0V
(A1,A2) (B1,B2) (C1,C2) (A1,A2) (B1,B2) (C1,C2)
11 PRQJ1 23 PRQJ2 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6

12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6

G FG

6V
(BT1,BT2,BT3,
BT4,BT5,BT6)
+
BATTERY
0V
(BT1,BT2,BT3,
-
BT4,BT5,BT6)

Fig.B (b) Circuit diagram


(ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)

- 140 -
B-82755EN/05 APPENDIX B.CIRCUIT DIAGRAM

J3 MOTOR (αiS2/5000 with BRAKE)

J1 MOTOR (αiS8/4000 without BRAKE) M3 M A63L-0001-0874


A63L-0001-0875#SC 1 J3U1 3 J3W1 5 BK(J3)
2 J3V1 4 J3G1 6 BKC(J3)
M1 M 18-10P
M3 P 10SL1(0.3SQ 3A)
A63L-0001-0881#1810S A J1U1 C J1W1
B J1V1 D J1G1 A63L-0001-0848#B10SL1 4 6V(BT3)
A63L-0001-0850 8 5V(B1) 5 XPRQJ3 1
9 2
6 PRQJ3
M1 P 10SL1(0.3SQ 3A) 10 0V(B1)
7 0V(BT3)
3 FG
A63L-0001-0848#B10SL1 4 6V(BT1)
A63L-0001-0850 8 5V(A1) 1
5 XPRQJ1
9 2
6 PRQJ1
10 0V(A1) 3 FG
7 0V(BT1)

J2 MOTOR (αiS8/4000 with BRAKE) J4 MOTOR (βiSR0.5/6000 without BRAKE)


MS3108B10SL-3S M2 BK 10SL-3P(1.25SQ 13A)
A BK(J2) B BKC(J2) C M4 M MOLEX 55618-0401
A63L-0001-0865#1
A63L-0001-0864#CS 1 J4U1 4 J4G1
M2 M 18-10P 2 J4V1 3 J4W1
A63L-0001-0881#1810S A J2U1 C J2W1
B J2V1 D J2G1 M4 P 10SL1(0.3SQ 3A)
A63L-0001-0848#E10SL1
8 5V(B2) 4 6V(BT4) 1
M2 P 10SL1(0.3SQ 3A) A63L-0001-0850
9
5 XPRQJ4 2
A63L-0001-0848#B10SL1 4 6V(BT2) 6 PRQJ4
8 5V(A2) 1 10 0V(B2) 3 FG
A63L-0001-0850 5 XPRQJ2 7 0V(BT4)
9 2
6 PRQJ2
10 0V(A2) 3 FG
7 0V(BT2)

J5 MOTOR (βiSR0.5/6000 without BRAKE)

A63L-0001-0865#1 M5 M MOLEX 55618-0401


A63L-0001-0864#CS 1 J5U1 4 J5G1
2 J5V1 3 J5W1

M5 P 10SL1(0.3SQ 3A)
A63L-0001-0848#E10SL1 4 6V(BT5)
A63L-0001-0850 8 5V(C1) 1
5 XPRQJ5
9 2
6 PRQJ5
10 0V(C1) 3 FG
7 0V(BT5)

J6 MOTOR (βiSR0.5/6000 without BRAKE)


A660-0001-0592
[{0.2SQ*(6C+2P)}*2+(0.3SQ*4C+0.2SQ*2C)*2)]
φ4.9*2+φ5.1*2
PLATE A63L-0001-0865#1 M6 M MOLEX 55618-0401
A290-7221-X431 A63L-0001-0864#CS
BUSH 1 J6U1 4 J6G1
A290-7221-X432 2 J6V1 3 J6W1

M6 P 10SL1(0.3SQ 3A)
A63L-0001-0848#E10SL1 4 6V(BT6)
A63L-0001-0850 8 5V(C2) 1
5 XPRQJ6
9 2
6 PRQJ6
10 0V(C2) 3 FG
7 0V(BT6)

ARC Mate 100iCe , M-10iAe


:可動部用 ARC Mate 100iCe/6L , M-10iAe/6L
 MOVABLE □R-30iA Mate
□2BK

K121(A05B-1221-D021) --- without RI /O


K151(A05B-1221-D051) --- without RI/O

- 141 -
C.PERIODIC MAINTENANCE TABLE APPENDIX B-82755EN/05

C PERIODIC MAINTENANCE TABLE


FANUC Robot ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L
ARC Mate 100iC/10S, M-10iA/10S, ARC Mate 100iCe, M-10iAe,
ARC Mate 100iCe/6L, M-10iAe/6L Periodic Maintenance Table

Working time (H) Check Oil First


3 6 9 1 2
time Grease check months months months year years
amount 320 960 1920 2880 3840 4800 5760 6720 7680 8640 9600 10560
Items
Check the mechanical cable.
1 (Damaged or twisted)
0.2H - ○ ○ ○
Check the motor connector.
2 (Loosening)
0.2H - ○ ○ ○

3 Tighten the end effector bolt. 0.2H - ○ ○ ○


Tighten the cover and main
4 bolt. 2.0H - ○ ○ ○
Check the mechanical stopper
5 and adjustable mechanical 0.1H - ○ ○ ○
stopper
6 Remove spatter and dust etc. 1.0H - ○ ○ ○
Check the end effector (hand)
7 cable 0.1H ○ ○ ○
Mechanical unit

Check the oil gauge of J4 to J6


8 axis 0.1H - ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Replacing battery. *1 0.1H - ● ●


9
Replacing battery. *2 0.1H - ●
Replacing grease of J1 axis
10 reducer 0.5H 872ml

Replacing grease of J2 axis


11 reducer 0.5H 333ml

Replacing grease of J3 axis


12 reducer 0.5H 186ml

Replacing oil of J4 axis


13 gearbox 0.5H 400ml

Replacing oil of J5 and J6 axis


14 gearbox 0.5H 400ml

Replacing cable of mechanical


15 unit 4.0H -
Replacing cable of Mechanical
16 unit welding power 4.0H - ●
Replacing M/H conduit/No dust
17 M/H conduit (option) 1.0H - ●
Check broken of fluoric resin
18 ring. 0.1H - ○ ○ ○ ○ ○ ○ ○ ○ ● ○ ○ ○
Check the robot cable, teach
19 pendant cable and robot 0.2H - ○ ○ ○
Controller

connecting cable
20 Cleaning the ventilator 0.2H - ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

21 Replacing battery *1 0.1H -

*1 ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L ARC Mate 100iC/10S, M-10iA/10S
*2 ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L
*3 Refer to manual of controller.
*4 ●: requires order of parts
○: doe not requires order of parts

- 142 -
B-82755EN/05 APPENDIX C.PERIODIC MAINTENANCE TABLE

3 4 5 6 7 8
years years years years years years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 Item

○ ○ ○ ○ ○ 1

○ ○ ○ ○ ○ 2

○ ○ ○ ○ ○ 3

○ ○ ○ ○ ○ 4

○ ○ ○ ○ ○ 5

○ ○ ○ ○ ○ 6

○ ○ ○ ○ ○ 7

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 8

● ● ● ● ●
9
● ● ● ●

Overhaul
● ● 10

● ● 11

● ● 12

● ● 13

● ● 14

● 15

● ● 16

● ● 17

○ ○ ○ ○ ● ○ ○ ○ ○ ○ ○ ○ ● ○ ○ ○ ○ ○ ○ ○ 18

○ ○ ○ ○ ○ 19

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 20

● 21

- 143 -
D.MOUNTING BOLT TORQUE LIST APPENDIX B-82755EN/05

D MOUNTING BOLT TORQUE LIST


NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps
and wipe oil off the engaging section. Make sure that there is no solvent in the
taps.Be sure to wipe the excess LOCTITE after tightening bolt.
Use bolt which strengths are below.
But if it is specified in text, obey it.
Hexagon socket head bolt made by steel
Size is M22 or less : Tensile strength 1200N/mm2 or more
Size is M24 or more : Tensile strength 1000N/mm2 or more
All size of bolt of the plating : Tensile strength 1000N/mm2 or more

Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm2 or more

If no tightening torque is specified for a bolt, tighten it according to this table.


Recommended bolt tightening torques Unit: Nm
Hexagon socket head
button bolt
Hexagon socket head
Hexagon socket head Hexagon socket head Hexagon bolt
bolt
Nominal bolt (stainless) flush bolt (steel)
(Steel)
diameter Low-head bolt
(steel)
Tightening torque Tightening torque Tightening torque Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
M3 1.8 1.3 0.76 0.53 ―――― ―――― ―――― ―――
M4 4.0 2.8 1.8 1.3 1.8 1.3 1.7 1.2
M5 7.9 5.6 3.4 2.5 4.0 2.8 3.2 2.3
M6 14 9.6 5.8 4.1 7.9 5.6 5.5 3.8
M8 32 23 14 9.8 14 9.6 13 9.3
M10 66 46 27 19 32 23 26 19
M12 110 78 48 33 ―――― ―――― 45 31
(M14) 180 130 76 53 ―――― ―――― 73 51
M16 270 190 120 82 ―――― ―――― 98 69
(M18) 380 260 160 110 ―――― ―――― 140 96
M20 530 370 230 160 ―――― ―――― 190 130
(M22) 730 510 ―――― ―――― ―――― ―――― ―――― ――――
M24 930 650 ―――― ―――― ―――― ―――― ―――― ――――
(M27) 1400 960 ―――― ―――― ―――― ―――― ―――― ――――
M30 1800 1300 ―――― ―――― ―――― ―――― ―――― ――――
M36 3200 2300 ―――― ―――― ―――― ―――― ―――― ――――

- 144 -
E.INSULATION ABOUT ARC
B-82755EN/05 APPENDIX WELDING ROBOT

E INSULATION ABOUT ARC WELDING


ROBOT
E.1 ABSTRACT
The arc welding robot performs welding, using a welding torch attached to its end effector via a bracket.
Because a high welding current flows through the welding torch, the insulation between the end effector
and torch is dualized.
If no due consideration is taken, a poor insulation caused by a pileup of spatter can allow the welding
current to leak into robot mechanical sections, possibly resulting in the motor being damaged or the
sheaths of cables in the mechanical sections melting.

E.2 INSULATION AT THE WRIST


- Design the insulation between the end effector and welding torch so that no current will leak from
the end effector. Concretely, when fastening the insulating material inserted between the end
effector and torch bracket, use different bolts on the insulation material and torch bracket.
- Insert the insulating material between the torch and torch bracket so that the insulation is dualized.
When installing the insulating material, be sure to set the crack in the torch holder away from that
of the insulating material to prevent spatter from getting in the cracks.
- Insert the insulating material between the torch and torch bracket so that the insulation is dualized.
When installing the insulating material, be sure to set the crack in the torch holder away from that
of the insulating material to prevent spatter from getting in the cracks.
- Allow a sufficient distance (at least 5 mm) at the insulating materials in case a pileup of spatter
should occur.
- Even after the insulation is reinforced, it is likely that, if a pileup of spatter grows excessively,
current may leak. Periodically remove spatter when the robot is in service.

- 145 -
B-82755EN/05 INDEX

INDEX
NOTES FOR ASSEMBLING CABLES WITH NO
<Number> DUST M/H CONDUIT ..............................................88
1.5-YEAR CHECKS (5,760 hours)................................10 NOTES OF ATTACHING J3-AXIS MOTOR TO
1-YEAR (3,840 HOURS) CHECKS ................................9 REDUCER .................................................................58
2-YEAR CHECKS (7,680 hours)...................................10
3-MONTH (960 HOURS) CHECKS ...............................9 <O>
3-YEAR (11,520 HOURS) CHECKS ............................10 Oil replacement procedure for the gearbox (J4 to
4-year (13,820 hours) checks .........................................10 J6-axis) .......................................................................24

<A> <P>
ABSTRACT.................................................................145 PERIODIC MAINTENANCE .......................................15
PERIODIC MAINTENANCE TABLE .......................142
<B> PREFACE .................................................................... p-1
BACKLASH MEASUREMENT ...................................38 Procedure for releasing oil (J4 to J6-axis)......................28
Procedure for releasing remaining pressure from the
<C> grease bath (J1 to J3-axis) ..........................................27
CABLE DRESSING ....................................................101
CABLE REPLACEMENT.............................................99 <R>
CABLE WIRING.........................................................100 REGISTER OF MASTERING POSTURE..................121
CHECKING THE MASTERING ................................130 REPLACING CABLES ...............................................110
CHECKS AND MAINTENANCE ..................................1 REPLACING FLUORIC RESIN RING ........................97
CIRCUIT DIAGRAM..................................................137 REPLACING M/H CONDUIT (OPTION)....................86
COMPONENT REPLACEMENT .................................43 REPLACING NO DUST M/H CONDUIT (OPTION) ..93
Replacing the Batteries (1 Year (3,840 Hours) or (1.5
<D> Year (5,760 Hours) Checks).......................................15
DAILY CHECKS.............................................................1 REPLACING THE GREASE AND OIL OF THE
DRIVE MECHANISM (3 YEARS (11,520 HOURS)
<F> CHECKS)...................................................................17
FAILURES, CAUSES AND MEASURES....................30 REPLACING THE J1-AXIS MOTOR M1 ...................46
FIGURE OF DRIVE MECHANISM .............................44 REPLACING THE J1-AXIS REDUCER ......................48
FIRST 1-MONTH (320 HOURS) CHECKS ...................4 REPLACING THE J2 COVER (OPTION)....................82
FIRST 3-MONTH (960 HOURS) CHECKS ...................5 REPLACING THE J2-AXIS MOTOR M2 ...................52
FIXTURE POSITION MASTER.................................123 REPLACING THE J2-AXIS REDUCER ......................53
REPLACING THE J3-AXIS MOTOR M3 ...................56
<G> REPLACING THE J3-AXIS REDUCER ......................63
GENERAL ..............................................................30,119
REPLACING THE J4 COVER (OPTION)....................84
Grease replacement procedure for the reducer (J1 to
REPLACING THE J4-AXIS GEARBOX (ARC Mate
J3-axis) .......................................................................24 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L,
ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L,
<I>
M-10iAe/6L) ..............................................................69
INSULATION ABOUT ARC WELDING ROBOT ....145
REPLACING THE J4-AXIS GEARBOX (ARC Mate
INSULATION AT THE WRIST .................................145
100iC/10S, M-10iA/10S) ...........................................72
REPLACING THE J4-AXIS MOTOR M4 (ARC Mate
<J>
100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L) ..66
J3-axis reducer mounting phase auto adjusting function
REPLACING THE J4-AXIS MOTOR M4 (ARC Mate
....................................................................................66
100iC/10S, M-10iA/10S) ...........................................68
<M> REPLACING THE J5-AXIS MOTOR M5 ...................75
MAINTENANCE TOOLS.............................................10 REPLACING THE J6-AXIS MOTOR M6 ...................77
MASTERING ..............................................................119 REPLACING WRIST UNIT .........................................79
MOUNTING BOLT TORQUE LIST ..........................144 RESETTING ALARMS AND PREPARING FOR
MASTERING...........................................................122
<N>
NOTES FOR ASSEMBLING CABLES WITH M/H <S>
CONDUIT ..................................................................85 SAFETY PRECAUTIONS ........................................... s-1
SEALANT APPLICATION ..........................................97

i-1
INDEX B-82755EN/04

SPARE PARTS LIST...................................................133

<T>
TROUBLESHOOTING .................................................30

i-2
B-82755EN/05 REVISION RECORD

REVISION RECORD
Edition Date Contents
• Addition of ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L,M-10iAe/6L
• Addition of stop type of robot
• Change of replacing method of oil of J4-axis
05 May.,2011
• Addition oiling method by oil injection gun
• Correction of daily checks.
• Correction of errors
• Addition of ARC Mate 100iC/10S and M-10iA/10S
• Addition of new specification of ARC Mate 100iC,ARC Mate 100iC/6L M-10iA,M-10iA/6L
04 Jun.,2010
• Addition of replacing method of fluoric resin ring
• Correction of errors
• Change replacing procedure of J3-axis reducer,J5,J6-axes motor and wrist unit
• Addition of replacing method of grease and oil for top mount and angle mount
03 Jul., 2009
• Addition of No dust M/H conduit
• Correction of errors
• Addition of M-10iA/6L
• Correction of cable replacement
02 Aug., 2008
• Addition of Method of fixture position master
• Correction of errors
01 Mar., 2008

r-1
B-82755EN/05

* B - 8 2 7 5 5 E N / 0 5 *