ArcMate 120 Mechaical Unit Mantenance

FANUC Robotics
R-J and R-J2 Controller

ARC Mate 120/S-12
Mechanical Unit Maintenance Manual
MARAWAS1208403E
B-80485E/03
This publication contains proprietary information of FANUC Robotics
America, Inc. furnished for customer use only. No other uses
are authorized without the express written permission of FANUC
Robotics America, Inc.
FANUC Robotics America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 483093253
The descriptions and specifications contained in this manual were in
effect at the time this manual was approved for printing. FANUC
Robotics America, Inc, hereinafter referred to as FANUC
Robotics, reserves the right to discontinue models at any time or to
change specifications or design without notice and without incurring
obligations.
FANUC Robotics manuals present descriptions, specifications,
drawings, schematics, bills of material, parts, connections and/or
procedures for installing, disassembling, connecting, operating and
programming FANUC Robotics products and/or systems. Such
systems consist of robots, extended axes, robot controllers,
application software, the KAREL programming language,
INSIGHT vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been
trained in one or more approved FANUC Robotics Training
Course(s) be permitted to install, operate, use, perform procedures
on, repair, and/or maintain FANUC Robotics products and/or
systems and their respective components. Approved training
necessitates that the courses selected be relevant to the type of
system installed and application performed at the customer site.
WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in accordance
with the instruction manual, may cause interference to radio
communications. As temporarily permitted by regulation, it
has not been tested for compliance with the limits for Class A
computing devices pursuant to subpart J of Part 15 of FCC
Rules, which are designed to provide reasonable protection
against such interference. Operation of the equipment in a
residential area is likely to cause interference, in which case
the user, at his own expense, will be required to take
whatever measure may be required to correct the
interference.
FANUC Robotics conducts courses on its systems and products on
a regularly scheduled basis at its headquarters in Rochester Hills,
Michigan. For additional information contact
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
Copyright 2003 by FANUC Robotics America, Inc.
All Rights Reserved
The information illustrated or contained herein is not to be
reproduced, copied, translated into another language, or transmitted
in whole or in part in any way without the prior written consent of
AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,
KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,
PalletTool, SOCKETS, SOFT PARTS SpotTool,
TorchMate, and YagTool are Registered Trademarks of FANUC
Robotics.
FANUC Robotics reserves all proprietary rights, including but not
limited to trademark and trade name rights, in the following names:
AccuAir AccuCal AccuChop AccuFlow AccuPath
AccuSeal ARC Mate ARC Mate Sr. ARC Mate System 1
ARC Mate System 2 ARC Mate System 3 ARC Mate System
4 ARC Mate System 5 ARCWorks Pro AssistTool
AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell
Finder Center Finder Clean Wall CollisionGuard
DispenseTool F-100 F-200i FabTool FANUC LASER
DRILL Flexibell FlexTool HandlingTool HandlingWorks
INSIGHT INSIGHT II IntelliTrak Integrated Process Solution
Intelligent Assist Device IPC -Integrated Pump Control IPD
Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD
Integral Servo Dispenser Laser Mate System 3 Laser Mate
System 4 LaserPro LaserTool LR Tool MIG Eye
MotionParts NoBots Paint Stick PaintPro PaintTool 100
PAINTWorks PAINTWorks II PAINTWorks III PalletMate
PalletMate PC PalletTool PC PayloadID RecipTool
RemovalTool Robo Chop Robo Spray S-420i S-430i
ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate
SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM R-
J3 Controller SYSTEM R-J3iB Controller TCP Mate
TurboMove TorchMate visLOC visPRO-3D visTRAC
WebServer WebTP YagTool
This manual includes information essential to the safety of
personnel, equipment, software, and data. This information is
indicated by headings and boxes in the text.
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set it
apart from other text.
Conventions
CAUTION
Information appearing under CAUTION concerns the protection of
equipment, software, and data. It is boxed to set it apart from
other text.

NOTE Information appearing next to NOTE concerns related
information or useful hints.
Safety-1
FANUC Robotics is not and does not represent itself as an expert in
safety systems, safety equipment, or the specific safety aspects of
your company and/or its work force. It is the responsibility of the
owner, employer, or user to take all necessary steps to guarantee
the safety of all personnel in the workplace.
The appropriate level of safety for your application and installation
can best be determined by safety system professionals. FANUC
Robotics therefore, recommends that each customer consult with
such professionals in order to provide a workplace that allows for
the safe application, use, and operation of FANUC Robotic systems.
According to the industry standard ANSI/RIA R15.06, the owner or
user is advised to consult the standards to ensure compliance with
its requests for Robotics System design, usability, operation,
maintenance, and service. Additionally, as the owner, employer, or
user of a robotic system, it is your responsibility to arrange for the
training of the operator of a robot system to recognize and respond
to known hazards associated with your robotic system and to be
aware of the recommended operating procedures for your particular
application and robot installation.
FANUC Robotics therefore, recommends that all personnel who
intend to operate, program, repair, or otherwise use the robotics
system be trained in an approved FANUC Robotics training course
and become familiar with the proper operation of the system.
Persons responsible for programming the systemincluding the
design, implementation, and debugging of application programs
must be familiar with the recommended programming procedures
for your application and robot installation.
The following guidelines are provided to emphasize the importance
of safety in the workplace.
Safety-2
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
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
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
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.
CONSIDERING
SAFETY FOR YOUR
ROBOT
INSTALLATION
Keeping People and
Equipment Safe
Using Safety
Enhancing Devices
Setting Up a Safe
Workcell
Safety-3
Install a lockout device that uses an access code to prevent
unauthorized persons from operating the robot.
Use antitiedown logic to prevent the operator from bypassing
safety measures.
Arrange the workcell so the operator faces the workcell and can
see what is going on inside the cell.
Clearly identify the work envelope of each robot in the system
with floor markings, signs, and special barriers. The work
envelope is the area defined by the maximum motion range of
the robot, including any tooling attached to the wrist flange that
extend this range.
Position all controllers outside the robot work envelope.
Never rely on software as the primary safety element.
Mount an adequate number of EMERGENCY STOP buttons or
switches within easy reach of the operator and at critical points
inside and around the outside of the workcell.
Install flashing lights and/or audible warning devices that
activate whenever the robot is operating, that is, whenever
power is applied to the servo drive system. Audible warning
devices shall exceed the ambient noise level at the enduse
application.
Wherever possible, install safety fences to protect against
unauthorized entry by personnel into the work envelope.
Install special guarding that prevents the operator from reaching
into restricted areas of the work envelope.
Use interlocks.
Use presence or proximity sensing devices such as light
curtains, mats, and capacitance and vision systems to enhance
safety.
Periodically check the safety joints or safety clutches that can be
optionally installed between the robot wrist flange and tooling. If
the tooling strikes an object, these devices dislodge, remove
power from the system, and help to minimize damage to the
tooling and robot.
Safety-4
Make sure all external devices are properly filtered, grounded,
shielded, and suppressed to prevent hazardous motion due to
the effects of electromagnetic interference (EMI), radio
frequency interference (RFI), and electrostatic discharge
(ESD).
Make provisions for power lockout/tagout at the controller.
Eliminate pinch points. Pinch points are areas where personnel
could get trapped between a moving robot and other equipment.
Provide enough room inside the workcell to permit personnel to
teach the robot and perform maintenance safely.
Program the robot to load and unload material safely.
If high voltage electrostatics are present, be sure to provide
appropriate interlocks, warning, and beacons.
If materials are being applied at dangerously high pressure,
provide electrical interlocks for lockout of material flow and
pressure.
Advise all personnel who must teach the robot or otherwise
manually operate the robot to observe the following rules:
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
Know whether or not you are using an intrinsically safe teach
pendant if you are working in a hazardous environment.
Before teaching, visually inspect the robot and work envelope to
make sure that no potentially hazardous conditions exist. The
work envelope is the area defined by the maximum motion
range of the robot. These include tooling attached to the wrist
flange that extends this range.
The area near the robot must be clean and free of oil, water, or
debris. Immediately report unsafe working conditions to the
supervisor or safety department.
FANUC Robotics recommends that no one enter the work
envelope of a robot that is on, except for robot teaching
operations. However, if you must enter the work envelope, be
sure all safeguards are in place, check the teach pendant
DEADMAN switch for proper operation, and place the robot in
teach mode. Take the teach pendant with you, turn it on, and be
prepared to release the DEADMAN switch. Only the person
with the teach pendant should be in the work envelope.
Staying Safe While
Teaching or Manually
Operating the Robot
Safety-5

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

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

WARNING
Stay outside the robot work envelope whenever a program is
being run. Failure to do so can result in injury.
- Using a low motion speed, single step the program for at
least one full cycle.
- Using a low motion speed, test run the program continuously
for at least one full cycle.
- Using the programmed speed, test run the program
continuously for at least one full cycle.
Make sure all personnel are outside the work envelope before
running production.
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.
Staying Safe During
Automatic Operation
Safety-6
Never enter or allow others to enter the work envelope during
automatic operation of the robot.
Know the location and status of all switches, sensors, and
control signals that could cause the robot to move.
Know where the EMERGENCY STOP buttons are located on
both the robot control and external control devices. Be prepared
to press these buttons in an emergency.
Never assume that a program is complete if the robot is not
moving. The robot could be waiting for an input signal that will
permit it to continue activity.
If the robot is running in a pattern, do not assume it will continue
to run in the same pattern.
Never try to stop the robot, or break its motion, with your body.
The only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel,
teach pendant, or emergency stop stations around the workcell.
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.
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.
When performing maintenance on your robot system, observe the
following rules:
Staying Safe During
Inspection
Staying Safe During
Maintenance
Safety-7
Never enter the work envelope while the robot or a program is in
operation.
Before entering the work envelope, visually inspect the workcell
to make sure no potentially hazardous conditions exist.
Consider all or any overlapping work envelopes of adjoining
robots when standing in a work envelope.
Test the teach pendant for proper operation before entering the
work envelope.
If it is necessary for you to enter the robot work envelope while
power is turned on, you must be sure that you are in control of
the robot. Be sure to take the teach pendant with you, press the
DEADMAN switch, and turn the teach pendant on. Be prepared
to release the DEADMAN switch to turn off servo power to the
robot immediately.
Whenever possible, perform maintenance with the power turned
off. Before you open the controller front panel or enter the work
envelope, turn off and lock out the 3phase power source at the
controller.
release the brake.
WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
HIGH VOLTAGE IS PRESENT at the input side whenever the
controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.
Release or block all stored energy. Before working on the
pneumatic system, shut off the system air supply and purge the
air lines.
Safety-8
Isolate the robot from all remote control signals. If maintenance
must be done when the power is on, make sure the person
inside the work envelope has sole control of the robot. The
teach pendant must be held by this person.
Make sure personnel cannot get trapped between the moving
robot and other equipment. Know the path that can be used to
escape from a moving robot. Make sure the escape route is
never blocked.
Use blocks, mechanical stops, and pins to prevent hazardous
movement by the robot. Make sure that such devices do not
create pinch points that could trap personnel.

WARNING
Do not try to remove any mechanical component from the
robot before thoroughly reading and understanding the
procedures in the appropriate manual. Doing so can result in
serious personal injury and component destruction.
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.
Certain programming and mechanical measures are useful in
keeping the machine tools and other external devices safe. Some
of these measures are outlined below. Make sure you know all
associated measures for safe use of such devices.
Implement the following programming safety measures to prevent
damage to machine tools and other external devices.
KEEPING MACHINE
TOOLS AND
EXTERNAL
DEVICES SAFE
Programming Safety
Precautions
Safety-9
Backcheck limit switches in the workcell to make sure they do
not fail.
Implement failure routines in programs that will provide
appropriate robot actions if an external device or another robot
in the workcell fails.
Use handshaking protocol to synchronize robot and external
device operations.
Program the robot to check the condition of all external devices
during an operating cycle.
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.
Observe the following operating and programming guidelines to
prevent damage to the robot.
The following measures are designed to prevent damage to the
robot during operation.
Use a low override speed to increase your control over the robot
when jogging the robot.
Visualize the movement the robot will make before you press
the jog keys on the teach pendant.
Make sure the work envelope is clean and free of oil, water, or
debris.
Use circuit breakers to guard against electrical overload.
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.
Mechanical Safety
Precautions
KEEPING THE
ROBOT SAFE
Operating Safety
Precautions
Programming Safety
Precautions
Safety-10
Make sure that the program ends with the robot near or at the
home position.
Be aware of signals or other operations that could trigger
operation of tooling resulting in personal injury or equipment
damage.
In dispensing applications, be aware of all safety guidelines with
respect to the dispensing materials.
NOTE Any deviation from the methods and safety practices
described in this manual must conform to the approved standards of
your company. If you have questions, see your supervisor.
Process technicians are sometimes required to enter the paint
booth, for example, during daily or routine calibration or while
teaching new paths to a robot. Maintenance personal also must
work inside the paint booth periodically.
Whenever personnel are working inside the paint booth, ventilation
equipment must be used. Instruction on the proper use of
ventilating equipment usually is provided by the paint shop
supervisor.
Although paint booth hazards have been minimized, potential
dangers still exist. Therefore, todays highly automated paint booth
requires that process and maintenance personnel have full
awareness of the system and its capabilities. They must
understand the interaction that occurs between the vehicle moving
along the conveyor and the robot(s), hood/deck and door opening
devices, and highvoltage electrostatic tools.
Paint robots are operated in three modes:
Teach or manual mode
Automatic mode, including automatic and exercise operation
Diagnostic mode
During both teach and automatic modes, the robots in the paint
booth will follow a predetermined pattern of movements. In teach
mode, the process technician teaches (programs) paint paths using
the teach pendant.
In automatic mode, robot operation is initiated at the System
Operator Console (SOC) or Manual Control Panel (MCP), if
available, and can be monitored from outside the paint booth. All
personnel must remain outside of the booth or in a designated safe
ADDITIONAL
SAFETY
CONSIDERATIONS
FOR PAINT ROBOT
INSTALLATIONS
Safety-11
area within the booth whenever automatic mode is initiated at the
SOC or MCP.
In automatic mode, the robots will execute the path movements they
were taught during teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines
that require them to remain in the paint booth, they must stay in a
designated safe area.
Process technicians and maintenance personnel must become
totally familiar with the equipment and its capabilities. To minimize
the risk of injury when working near robots and related equipment,
personnel must comply strictly with the procedures in the manuals.
This section provides information about the safety features that are
included in the paint system and also explains the way the robot
interacts with other equipment in the system.
The paint system includes the following safety features:
Most paint booths have red warning beacons that illuminate
when the robots are armed and ready to paint. Your booth
might have other kinds of indicators. Learn what these are.
Some paint booths have a blue beacon that, when illuminated,
indicates that the electrostatic devices are enabled. Your booth
might have other kinds of indicators. Learn what these are.
EMERGENCY STOP buttons are located on the robot controller
and teach pendant. Become familiar with the locations of all E
STOP buttons.
An intrinsically safe teach pendant is used when teaching in
hazardous paint atmospheres.
A DEADMAN switch is located on each teach pendant. When this
switch is held in, and the teach pendant is on, power is applied to the
robot servo system. If the engaged DEADMAN switch is released
during robot operation, power is removed from the servo system, all
axis brakes are applied, and the robot comes to an EMERGENCY
STOP. Safety interlocks within the system might also ESTOP other
robots.

WARNING
An EMERGENCY STOP will occur if the DEADMAN switch is
released on a bypassed robot.
Paint System Safety
Features
Safety-12
Overtravel by robot axes is prevented by software limits. All of
the major and minor axes are governed by software limits. Limit
switches and hardstops also limit travel by the major axes.
EMERGENCY STOP limit switches and photoelectric eyes
might be part of your system. Limit switches, located on the
entrance/exit doors of each booth, will EMERGENCY STOP all
equipment in the booth if a door is opened while the system is
operating in automatic or manual mode. For some systems,
signals to these switches are inactive when the switch on the
SCC is in teach mode.
When present, photoelectric eyes are sometimes used to
monitor unauthorized intrusion through the entrance/exit
silhouette openings.
System status is monitored by computer. Severe conditions
result in automatic system shutdown.
When you work in or near the paint booth, observe the following
rules, in addition to all rules for safe operation that apply to all robot
systems.
WARNING
Observe all safety rules and guidelines to avoid injury.

WARNING
Never bypass, strap, or otherwise deactivate a safety device,
such as a limit switch, for any operational convenience.
Deactivating a safety device is known to have resulted in
serious injury and death.
Know the work area of the entire paint station (workcell).
Know the work envelope of the robot and hood/deck and door
opening devices.
Be aware of overlapping work envelopes of adjacent robots.
Know where all red, mushroomshaped EMERGENCY STOP
buttons are located.
Staying Safe While
Operating the Paint
Robot
Safety-13
Know the location and status of all switches, sensors, and/or
control signals that might cause the robot, conveyor, and
opening devices to move.
Make sure that the work area near the robot is clean and free of
water, oil, and debris. Report unsafe conditions to your
supervisor.
Become familiar with the complete task the robot will perform
BEFORE starting automatic mode.
Make sure all personnel are outside the paint booth before you
turn on power to the robot servo system.
Never enter the work envelope or paint booth before you turn off
power to the robot servo system.
Never enter the work envelope during automatic operation
unless a safe area has been designated.
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.
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.
Staying Safe While
Operating Paint
Application Equipment
Safety-14
Grounding: All electrically conductive objects in the spray area
must be grounded. This includes the spray booth, robots,
conveyors, workstations, part carriers, hooks, paint pressure
pots, as well as solvent containers. Grounding is defined as the
object or objects shall be electrically connected to ground with a
resistance of not more than 1 megohms.
High Voltage: High voltage should only be on during actual
spray operations. Voltage should be off when the painting
process is completed. Never leave high voltage on during a cap
cleaning process.
Avoid any accumulation of combustible vapors or coating
matter.
Follow all manufacturer recommended cleaning procedures.
Make sure all interlocks are operational.
No smoking.
Post all warning signs regarding the electrostatic equipment and
operation of electrostatic equipment according to NFPA 33
Standard for Spray Application Using Flammable or
Combustible Material.
Disable all air and paint pressure to bell.
Verify that the lines are not under pressure.
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.
Staying Safe During
Maintenance
Safety-15
Be sure all covers and inspection plates are in good repair and
in place.
Always return the robot to the home position before you
disarm it.
Never use machine power to aid in removing any component
from the robot.
During robot operations, be aware of the robots movements.
Excess vibration, unusual sounds, and so forth, can alert you to
potential problems.
Whenever possible, turn off the main electrical disconnect
before you clean the robot.
When using vinyl resin observe the following:
- Wear eye protection and protective gloves during application
and removal
- Adequate ventilation is required. Overexposure could cause
drowsiness or skin and eye irritation.
- If there is contact with the skin, wash with water.
When using paint remover observe the following:
- Eye protection, protective rubber gloves, boots, and apron
are required during booth cleaning.
- Adequate ventilation is required. Overexposure could cause
drowsiness.
- If there is contact with the skin or eyes, rinse with water for
at least 15 minutes.
B80485E/03 GENERAL
GENERAL
This manual describes the maintenance and connection of the following
robot (RJ controller or RJ2 controller) mechanical units.
Make sure of the specification of mechanical unit when replacing parts.
Model Abbreviation
Mechanical unit
specifications
FANUC Robot ARC
Mate 120
(All axes with brake)
ARC Mate 120 A05B-1208-B201
FANUC Robot
S12
(All axes with brake)
S-12 A05B-1208-B202
Table 1(a) Specification of ARC Mate 120 / S12
Item Specification
Type Articulated type
Controlled axes 6 axes (J1, J2, J3, J4, J5, J6)
J1-axis
(rotation)
-165 to +165 (135/sec)
-2.88rad to +2.88rad (2.36rad/sec) Note 1
Motion range
(Maximum
J2-axis
(rotation)
-105 to +165 (120/sec)
-1.83rad to +2.88rad (2.09rad/sec)
(Maximum
speed) J3-axis
(rotation)
-190 to +300 (135/sec)
J4-axis
(wrist rotation)
-190 to +190 (240/sec)
J5-axis
(wrist swing)
-140 to +140 (240/sec)
J6-axis
(wrist rotation)
-270 to +270 (400/sec)
Maximum load capacity at
wrist
12kg
Installation Floor mount, upside-down mount,
(wall mount, angle mount) Note 2
Drive method Electric servo drive by AC servo motor
Feedback method Fully electric absolute position detection system
Repeatability "0.1mm
Mastering fixture Option
Air control set Option
Forklift bracket Option
Weight (Mechanical unit) About 230kg
Height Up to 1000 meters above the sea level requires, no
particular provision for attitude
Acoustic noise level Note3 70 dB or less
EMI Complied with EN55011
GENERAL B80485E/03
NOTE
1. 360 or 6.28rad rotation of J1axis is an option.
2. Motion range of J1axis and J2axis is limited when the
robot is wallmounted or anglemounted.
3 This value is equivalent continuous Aweighted sound
pressure level which applied with prEN31201.
This value is measured with the following conditions.
S Maximum load and speed
S Operating mode is AUTO
B80485E/03 GENERAL
For the FANUC Robot series, the following manuals are available:
SAFETY HANDBOOK
B-80687EN
All persons who use the FANUC Robot
and system designer must read and un
derstand thoroughly this handbook.
Intended readers:
All persons who use the FANUC Robot,
system designer
Topics:
Safety items for robot system design, op
eration, maintenance
R-J controller Quick manual
HANDLING TOOL
B-67994E-2
ARC TOOL
B-67994E-3
SEALING TOOL
B-67994E-4
Intended readers:
Operator, programer
Topics:
Basic procedures for operating the robot
Use:
Robot operation, simple teaching
Setup and Operations
manual
HANDLING TOOL
B-67994E-11
ARC TOOL
B-67994E-12
SEALING TOOL
B-67994E-14
Intended readers:
Operator, programer, maintenance person,
system designer
Topics:
Robot functions, operations, programing,
setup, interfaces, alarms
Use:
Robot operation, teaching system design
Maintenance manual
B-67995E
Intended readers:
Maintenance person, system designer
Topics:
Installation, connection to peripheral
equipment, maintenance
Use:
Installation, start-up, connection, mainte
nance
R-J2 controller Setup and Operations
manual
HANDLING TOOL
B-80524EN-11
ARC TOOL
B-80524EN-12
SEALING TOOL
B-80524EN-14
Intended readers:
Operator, programer, maintenance person,
system designer
Topics:
Robot functions, operations, programing ,
setup, interfaces alarms
Use:
Robot operation, teaching system design
Maintenance manual
B-80525E
B-80525E-1
(European
specification)
Intended readers:
Topics:
Installation, connection to peripheral
equipment, maintenance
Use:
nance
Mechanical unit Maintenance manual Intended readers:
Topics:
Installation, connection to the controller,
maintenance
Use:
nance
FANUC Robot ARC Mate 120/S12 B80485E
S Arc welding, generalpurpose small robot
Related manuals
GENERAL B80485E/03
The mechanical unit specification numbers are attached at the following
positions. Therefore, read the description in each section when checking.

The attachment position for the mechanical unit specification number.
Table I Letters
No. Contents Letters
NAME ARC Mate 120 ARC Mate 120
S-12 S-12
TYPE ARC Mate 120 A05B-1208-B201
S-12 A05B-1208-B202
SERIAL No. PRINT SERIAL No.
DATE PRINT PRODUCTION YEAR AND MONTH
WEIGHT 230
Table of Contents
B80485E/03
c1
GENERAL
SAFETY
SAFETY PRECAUTIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. OPERATOR SAFETY 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. PERIPHERAL DEVICE SAFETY 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. PRECAUTIONS FOR WORK 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Safety Speed Control 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. SAFETY FOR MAINTENANCE 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I. MAINTENANCE
1. CONFIGURATION 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 J1-axis Drive Mechanism 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 J2-axis Drive Mechanism 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 J5-axis and J6axis Drive Mechanism 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Major Component Specifications 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. PREVENTIVE MAINTENANCE 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Daily Checks 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 3month Checks 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 1-year Checks 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 3year Checks 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Maintenance Tools 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. LUBRICATING CONDITION CHECKS 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Greasing 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 3-year Check 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Replacing Battery 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. TROUBLESHOOTING 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Problem and Causes 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Replacing Parts and Performing Adjustments 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. ADJUSTING 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Adjusting Limit Switches and Dogs (Option) 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
B80485E/03
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5.2 J1-axis stroke modification (option) 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Quick Mastering 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Mastering Using Zero Degree Position 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Mastering Using Jig 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Confirming Mastering 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Adjusting J5-axis Spur Gear backlash 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. REPLACING AND ADJUSTING PARTS 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Replacing J1 and J2-axis Motor M1 , M2 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Replacing J1-Axis Reducer 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Replacing J2-Axis Reducer 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Replacing J3-Axis Motor M3 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Replacing J3-axis Reducer 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Replacing J4-axis Motor M4 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Replacing J4Axis Reducer 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 Replacing J5-axis Motor M5 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9 Replacing J5Axis Gear 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10 Replacing J6-axis Motor, Reducer M6 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.11 Releasing Brake 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. PIPING AND WIRING 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Piping 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Wiring Diagram 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Limit Switch (Option) Installation diagram 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Cable Installation Diagram 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. REPLACING CABLES 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Cable Clamping 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Replacing Cables 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Replacing Limit Switch(Option) 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. OPTIONS 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Cover Option (Specification: A05B1208J401) 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II. CONNECTION
1. ROBOT INTERFERENCE AREA 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. EQUIPMENT MOUNTING TO ROBOT 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 End Effector Mounting Face to Wrist 117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Equipment Mounting Face 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 End Effector Air Pipe 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 End Effector I/O Signals (RDI/RDO) 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Wrist Load Specifications 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
B80485E/03
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3. TRANSPORTATION AND INSTALLATION 127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Transportation 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Storage 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Installation 132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Maintenance Area 136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Assembly During Installation 137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Air Piping 138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Installation specifications 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPENDIX
A. SPARE PARTS LIST 145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM 149 . . . . . . . . . . . . . . . . . . . .
I. MAINTENANCE
B80485E/03 1. CONFIGURATION
23

1
CONFIGURATION
Fig. 1 shows the configuration of the mechanical unit.
Fig. 1 Mechanical unit configuration (ARC Mate120/S-12)
NOTE
1. FANUC call motor 1 to 6 (M1 to M6) J1 to J6 motor
each.
2. The motor for all axes (J1, J2, J3, J4, J5 and J6) have
builtin brake this brake is on in the power off or in the
emargency stop.
1. CONFIGURATION B80485E/03
24
Fig. 1.1 shows the J1-axis drive mechanism.
The rotation of the AC servo motor M9 is decelerated by the reducer and
rotates the J2-axis base. The J2-axis base is supported by the J1-axis base
via the reducer.
J1axis AC servo motor
model M9
J2axis base
Input gear
Reducer
J1axis base
A
A
Phase AA
M1
Fig. 1.1 J1-axis drive mechanism (ARC Mate120/S-12)
Fig. 1.2 shows J2-axis drive mechanism. The rotation of the AC servo
motor M9 is decelerated by the reducer and rotates the J2-axis arm. The
J2-axis arm is supported by the J2-axis base via the reducer.
J2axis arm
Input gear
J2axis AC servo
motor model M9
J2axis base
Reducer
Phase BB
B
B
M2
1.1
J1-axis Drive
Mechanism
1.2
J2-axis Drive
Mechanism
25
Fig. 1.3 shows the J3-axis mechanism. The rotation of the AC servomotor
2 is decelerated by the reducer and rotates the J3-axis unit. The J3-axis
unit is supported by the J2-axis arm via the reducer.
Reducer
J3axis housing
model a2
J2axis arm
Input gear
J3axis cover
M3
Fig. 1.4 shows the J4-axis drive mechanism. The rotation of the AC servo
motor 1 is decelerated by the reducer and rotates J3-axis arm.
J3-axis arm is supported by the J3-axis housing via the reducer.
J3axis housing
Reducer
Center gear
model a1
Input gear
J3axis arm
M4
1.3
J3-axis Drive
Mechanism
1.4
J4-axis Drive
Mechanism
1. CONFIGURATION B80485E/03
26
Fig. 1.5 shows the J5-axis and J6axis drive mechanism. The rotation of
the AC servomotor 0.5 is decelerated by the three steps gear of J5axis
and rotates the J6-axis unit. The rotation of AC servomotor 0.5 is
decelerated by the reducer of J6axis and rotates the output flange.
J3axis arm
J5axis AC servomotor
a 0.5
J6axis AC servomotor a
0.5
J6axis reducer
Output flange
J5axis gear (three steps)
M6
M5
Fig. 1.5 J5-axis and J6axis drive mechanism (ARC Mate120/S-12)
1.5
J5-axis and J6axis
Drive Mechanism
*Option for changing
operation space
27
1) Motor
ARC Mate 120 (With all axes brake) A05B1208B201
S12 (With all axes brake) A05B1208B202
Specifications Axis Remarks
A06B0163B175 J1 M9 with brake
A06B0163B175 J2 M9 with brake
A06B0373B175 J3 2 with brake
A06B0371B175 J4 1 with brake
A06B0113B178#0008 J5 0.5 with brake
A06B0113B178#0008 J6 0.5 with brake
2) Reducer
Specifications Axis
A97L01180948 J1
A97L01180949 J2
A97L01180950 J3
A97L7208T402 J4
A97L1208H001 J6
3) Gear
Specification Axis
A2907208X211 J1, J2
A2907208X212 J1, J2
A2907208X411 J3
A2907208X412 J3
A2907208X413 J4
A2907208X414 J4
A2907208X511 J5
A2907208V515 J5
A2907208V501 J5
A2907208V502 J5
4) Cover
Specifications Remarks
A05B1208J401
J2axis motor cover
(for floor mount)
*Option
A2907208X403 J3axis motor cover
5) Stopper
Specifications Axis
A2907208X224 J1
A2907208X225 J1
A2907208X337 J1
A2907208X329 J2
A2907208X331 J2
1.6
Major Component
Specifications
2. PREVENTIVE MAINTENANCE
B80485E/03
28
2
PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained for a long
time by performing the periodic maintenance procedures pres-
ented in this chapter.
B80485E/03
29
Clean each part, and visually check component parts for damage before
daily system operation. Check the following items as the occasion
demands.
a) Before automatic operation
Table 2.1 Daily preventive maintenance checks (1/2)
Item Check items Check points
1 When air
control set is
combined.
Air pressure Check air pressure using the pressure
gauge on the air regulator as shown in
Fig. 2.1.
If it does not meet the specified pres-
sure of 5-7 kg/cm
2
, adjust it using the
regulator pressure setting handle.
2 Oiler oil mist
quantity
Check the drop quantity during wrist or
hand motion. If it does not meet the
specified value (1 drop/10 - 20 sec),
adjust it using the oiler control knob.
Under normal usage the oiler becomes
empty in about 10 to 20 days under
normal operation.
3 Oiler oil level Check to see that the oiler level is
within the specified level shown in Fig.
2.1.
4 Leakage
from hose
Check the joints, tubes, etc. for leaks.
Repair leaks, or replace parts, as re-
quired.
5 Cables used in mechanical
unit
Refer to section 8.
6 Vibration, abnormal noises,
and motor heating
Check to see that each axis moves
smoothly.
7 Changing repeatability Check to see that the stop positions of
the robot has not deviated from the
previous stop positions.
8 Peripheral devices for proper
operation
Check whether the peripheral devices
operate properly according to com-
mands from robot.
9 J2/J3-axis brake Refer to 4.2.
2.1
Daily Checks
B80485E/03
30
Oil inlet Adjusting knob
Oiler mist amount
check
Oiler
Regulator
pressure
setting handle
Filter
Pressure gauge
Fig. 2.1 Air control set (option)
b) After automatic operation
After automatic operation ends, return the robot to the zero point,
and turn off the power supply.
Table 2.1 Daily preventive maintenance checks (2/2)
1 Cleaning and checking each
part
Clean each part and check component
parts for cracks and flaws.
B80485E/03
31
Check the following items once every 3 monthes. Additional inspection
areas and times should be added to the table according to the robots
working conditions, environment, etc.
Table 2.2 Monthly preventive maintenance checks
1 Loose connectors Check that all connectors, including the mo-
tor connectors, are secure.
2 Loose bolts Check that all cover mounting bolts and ex-
ternal mounting bolts are secure.
3 Removal of dust, etc. Remove any spatter, dust, foreign matter, etc.
Check the following items every year.
1 Lubrication greasing Refer to section 3.1.
2 Changing of battery Refer to section 3.3.
Check the following items once every 3 years.
1 Greasing each axis reducer Refer to section 3.2.
The following tools and instruments are required for the maintenance
procedures contained in this manual.
a) Measuring instruments
Instruments Accuracy/Tolerance Applications
Dial gauge 1/100 mm Measurement of positioning
and backlash.
Slide calipers 150 mm
b) Tools
Cross tip (+) screwdrivers: Large, medium, and small sizes
Flat tip (-) screwdrivers: Large, medium, and small sizes
Box screwdrivers: M3 - M6
Hexagonal wrench key sets (metric): M3 - M16
Adjustable wrenches: Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Double wrench
Grease gun
Pliers for C-retaining ring
Flashlight
2.2
3month Checks
2.3
1-year Checks
2.4
3year Checks
2.5
Maintenance Tools
3. LUBRICATING CONDITION CHECKS B80485E/03
32
3
LUBRICATING CONDITION CHECKS
B80485E/03 3. LUBRICATING CONDITION CHECKS
33
Never perform greasing procedures before turning off power.
1) Apply grease normally every year.
2) For the greasing points and the method of greasing, see Fig. 3.1 and
Table 3.1.
Table 3.1 Greasing points (ARC Mate120/S-12)
Item Greasing point Grease Qty. Method of greasing
1 J6-axis reducer
Grease SK3
(No.:
A98L0040
0110#1KG
10 cc Remove the plugs (PT
1/82 type) from the J6
axis grease inlet and out-
let, attach the J4axis
grease nipple to the
J6axis grease inlet, then
inject grease. After greas-
ing, return the grease nip-
ple to the J4axis greasing
point, and put the plugs on
the grease inlet and outlet.
2 J4-axis reducer
0110#1KG
20 cc Remove the plug from the
grease outlet, and inject
grease through the grease
nipple attached to the
grease inlet. After greas-
ing, plug the grease outlet,
and cap the grease nipple.
J3axis reducer grease nipple
J3axis reducer air
vent for greasing
J2axis reducer
airvent for greasing
J2axis reducer grease
nipple
J4axis reducer air vent
for greasing
J6axis
reducer airvent for greasing
(feed grease at assembling)
for greasing
J5axis reducer air
vent
for greasing
RE No. 00
RE No. 00
RE No. 00
RE No. 00
SK3
SK3
Fig. 3.1 Greasing points (ARC Mate 120/S12)
3.1
Greasing
3. LUBRICATING CONDITION CHECKS B80485E/03
34
Change grease for reducers J1, J2, J3 and for gear box of J5 as follows
every 3 years or 20.000 hours. See Fig 3.1 for greasing points.
1 Remove the plugs (PT1/82) from the grease outlets for the J1, J2,
J3, and J5axes, as shown in Fig. 3.1.
2 Remove the caps from the grease nipples of the grease inlets for the
J1, J2, and J3axes. Remove the plug from the J5axis grease inlet
and mount a grease nipple for other axis inlets on the inlet.
3 Inject the grease specified in Table 3.2 from the grease nipples for
J1, J2, J3, and J5axes until the old grease is pushed out from the
outlets and this new grease is also pushed out a little.
4 Remove the grease nipples for J1, J2, J3, and J5axes. Take out
about 5% of the supplied grease so that the grease baths are not full.
5 Mount the grease nipples at the grease inlets for the J1, J2, and
J3axes. Then mount the caps on them.
6 Mount the plugs on the grease outlets for the J1, J2, J3, and
J5axes and the grease inlet for the J5axis.
Table 3.2 Grease requiring 3year changes (ARC Mate 120/S12)
Grease
Qty.
Kyodo Yushi
Qty.
(cc)
J1-axis reducer 1600
J2-axis reducer
MoryWhite RE No. 00
1600
J3-axis reducer
(Specification:
A98L00400119#2.7KG)
520
J5-axis gear box
A98L00400119#2.7KG)
250
NOTE
1. Take care not to slip on grease. Wipe the grease off
the floor and robot structure.
3.2
3-year Check
B80485E/03 3. LUBRICATING CONDITION CHECKS
35
The data of the zero point of each axis is held by the backup batteries.
The batteries must be replaced every year. They should be replaced as
follows.
Turn the power on.
Press the EMERGENCY STOP button to inhibit the robots
motion.
Remove the battery case cap.
Remove the old batteries from the battery case.
Set the new batteries in the battery case. Take care of the
direction of each battery.
Remount the battery case cap.
Fig. 3.3 Replacing batteries (ARC Mate120/S-12)
3.3
Replacing Battery
4. TROUBLESHOOTING B80485E/03
36
4
TROUBLESHOOTING
B80485E/03 4. TROUBLESHOOTING
37
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.
4.1
General
38
Table 4.2(a) lists the major failures that may be suffered by the mechanical
unit, together with their causes. Contact us if the cause of a failure cannot
be identified, or the necessary corrective action cannot be determined.
Note, however, that backlash, provided it does not exceed the values listed
in Table 4.2(b), is normal. Note also that a drop that does not exceed the
values indicated in Table 4.2(c) is normal.
Table 4.2(a) Major Failures and Their Causes
Symptom Cause Corrective action Remarks
A BZAL alarm is issued.
(Batteries are dead.)
The batteries used for memory
backup are exhausted.
Replace the batteries then
perform quick mastering.
See Section 3.3.
See Section 5.3.
The pulse coder signal cable is
broken.
Replace the cable then per-
form quick mastering.
See Section 8.2.
See Section 5.3.
Positional error. The robot may have hit an object. Make a teaching point
correction.
The robot is not firmly secured. Secure the robot firmly. See Section 3.2 of the part
explaining connection.
Peripheral equipment has been
moved out of position.
Secure the peripheral
equipment firmly.
An excessive load has been ap-
plied.
Reduce the load.
Ensure that the robot is op-
erated within its specified
limits.
Wrist load:
Refer to the specifications.
Peripheral equipment:
See Section 2.2 of the part
A specified parameter is incorrect. Correct the parameter. Refer to the instruction
manual.
A cable has broken. Replace the cable. See Section 8.2.
The pulse coder has failed. Replace the motor. See Sections 6.1 through
6.10.
The backlash in the mechanical
unit is excessive.
(See the description of the rele-
vant symptom below.)
Vibration The robot is not secured firmly. Secure the robot firmly. See Section 3.2 of the part
The floor vibrates (particularly
when the robot is installed on a
floor above ground level.)
Review the location of
installation.
An excessive load is applied. Reduce the load.
limits.
Wrist load: Refer to the
specifications.
The servo system is not correctly
adjusted.
Adjust the servo system. Contact us.
A cable has broken. Replace the cable. See Section 8.2.
A ground connection has not been
made.
Make the necessary ground
connection.
Refer to the maintenance
manual for the control unit.
A motor is faulty. Replace the motor. See Sections 6.1 through
6.10.
An axis board PCB is faulty. Replace the axis board
PCB.
Refer to the maintenance
4.2
Problem and Causes
39
Symptom Remarks Corrective action Cause
Vibration A reducer is faulty. Replace the reducer. See Sections 6.2 through
6.10.
An incorrect time constant is used. Correct the time constant. Refer to the operators
manual.
The backlash in the mechanical
unit is excessive. (See the de-
scription of the symptom below.)
Mechanical unit back-
lash.
A screw or pin is loose. Tighten the screw or pin.
(Apply Loctite to the speci-
fied area.)
A reducer is faulty. Replace the reducer. See Section 6.2 through
6.10.
A gear is not correctly adjusted. Adjust the gear. See Section 5.7.
A gear is worn. Adjust the gear.
Replace the gear.
Contact us.
A bearing is worn. Replace the bearing. Contact us.
A part such as a casting has bro-
ken.
Replace the broken part. Contact us.
Abnormal sound. Gears and/or reducers require
greasing.
Apply grease. See Sections 3.1 and 3.2.
Foreign matter has entered a gear
or reducer.
Clean the gear or reducer,
then apply grease.
See Sections 6.2 through
6.10, 3.1, and 3.2.
A gear is not correctly adjusted. Adjust the gear. Contact us.
A gear is worn. Adjust the gear.
Replace the gear.
Contact us.
A bearing is worn. Replace the bearing. Contact us.
The servo system is not correctly
adjusted.
Adjust the servo system. Contact us.
Overheating. Gears and/or reducers require
greasing.
Apply grease. See Sections 3.1 and 3.2.
Grease that does not satisfy the
specifications has been used.
Clean and regrease. See Sections 3.1 and 3.2.
An excessive load is applied. Reduce the load.
limits.
Wrist load:
Refer to the specifications.
explaining.
A gear is not correctly adjusted. Adjust the gear. Contact us.
An incorrect time constant is used. Correct the time constant. Refer to the instruction
manual.
The robot arm drops
when the power is cut.
A motor brake is worn. Replace the motor. See Sections 6.1 through
6.10.
Brake relay has burnt out. Replace the relay. Refer to the maintenance
Grease leaks. An Oring, oil seal, or packing has
degraded or has been damaged.
Replace the Oring, oil
seal, or packing.
Contact us.
A part such as a casting has bro-
ken.
Replace the broken part. Contact us.
A screw is loose. Tighten the screw.
40
Table 4.2(b) Allowable Backlash for Each Axis
J1 J2 J3 J4 J5 J6
Angle (min) 2.5 2.5 2.5 3 5 3
Displacement (mm) 1.16
(1595)
0.40
(550)
0.44
(600)
0.17
(200)
0.29
(200)
0.17
(200)
NOTE
A displacement value indicates a rotational backlash within
the distance (indicated in parentheses) from the center of
the axis.
Table 4.2(c) Allowable Drop
When power is cut 5 mm
In the event of an emergency stop 5 mm
41
Adjustments are necessary whenever a part is replaced.
The table below shows replacement of parts and the required adjustment
items.
Part to be replaced or
function to be changed
Adjustment
Replacement of cable (a) Routing of cable
(b) Limit switch
(c) Mastering
Replacement of limit switch
(option)
(a) Limit switch and dog adjustment
J1axis stroke change
(option)
(a) Dog mounting position change, limit
switch adjustment
(b) Hard Stop mounting position adjustment
(c) Parameter change
Replacement of batteries
(Replace every year)
Replace them keeping power on.
No adjustment is necessary.
4.3
Replacing Parts and
Performing
Adjustments
5. ADJUSTING B80485E/03
42
5
ADJUSTING
Mechanical parts have been adjusted to the optimum condition
at the time of shipment from our company. Therefore, they nor-
mally need not be adjusted by the customer at the time of deliv-
ery.
Adjustment should be made as specified in this section, however,
after a long period of use or after replacing a part.
B80485E/03 5. ADJUSTING
43
1) Zero point and working limit
Each controlled axis has its own zero point and working limits.
Each controlled axis is limited mechanically by dog.
When the controlled axis reached its working limit, and trips its limit
switch it is called Over Travel (OT). Over Travel is detected at both ends
of the axis.
The robot is controlled not to work beyond its operating area unless the
servo system fails or a system error occurs so that the zero point is lost.
Figs. 5.1(a) through 5.1(h) show the zero point, working limits (stroke),
OT detection dogs, and mechanical stopper positions for each axis.
Adjust each limit switch (Section 8.3) and dog such that an OT alarm is
issued at the positions shown in the figures.
Fig. 5.1 (a) J1-axis rotation (J1 300_) (ARC Mate120/S-12)
5.1
Adjusting Limit
Switches and Dogs
(Option)
44
Fig. 5.1 (b) J1-axis rotation (Option 360_)(ARC Mate120/S-12)
Fig. 5.1 (c) J2-axis rotation (ARC Mate120/S-12)
45
Note) The motion range is limited
by the J2-axis position.
+300_
190_
0_
Stroke 490_
Fig. 5.1 (d) J3-axis rotation (ARC Mate120/S-12)
Note) The J4 axis does not have OT limit switches nor mechanical stops.
Stroke end Stroke end
+190_ 190_
Storoke 380
Fig.5.1 (e) J4-axis wrist rotation (ARC Mate120/S-12)
46
Note) The J5 axis does not have
OT limit switches.
Stroke end
Mechanical stopper
Stroke end
Mechanical stopper
minimum 3_
minimum 3_
+140_
140_
0_
Stroke
280_
Fig.5.1 (f) J5-axis wrist rotation (ARC Mate120/S-12)
Note) The J6 axis does not have OT limit switches nor hard stops.
0_
Stroke
540_
+270_ 270_
Stroke end Stroke end
Fig.5.1 (g) J6axis wrist rotation (ARC Mate120/S12)
47
Fig.5.1 (h) J2/J3 limit interference angles (ARC Mate120/S-12)
48
It is possible to limit the J1-axis stroke according to the surroundings of
the robot. The stroke can be changed as shown in Fig. 5.2 (a). It can be
changed according to the OT stroke by changing the dog position or the
mechanical stop.
The stroke can be changed every 22.5_ at the desired stroke position
between 165_ to +165_.
When the stroke does not include 0_, the stroke must be readjusted to the
standard position when mastering the robot using the jig.
J1axis stroke change option specification (without OT):
A05B1208J301
J1axis stroke change option specification (with OT): A05B1208J302
Note) Standard stroke is from -165_ to +165_
Front
Fig.5.2 (a) J1-axis stroke change (ARC Mate120/S-12)
5.2
J1-axis stroke
modification (Option)
49
Change the dog and hard stop positions according to the desired stroke
position as shown in Fig. 5.2 (b).
Note) The figure shown the J1-axis base top view.
Limit switch
(Rotation side)
option
Front
Mechanical
stopper
(Rotation side)
Example
Mechanical stopper
(Fixed side)
Dog (Fixed side)
Limit switch
(Rotation side)
option
Front
Mechanical stopper
(Rotation side)
Mechanical stopper
(Fixed side)
Dog (Fixed side)
Example
Fig.5.2 (b) Dog and mechanical stop position change (ARC Mate120/S-12)
1) Changing dog and
mechanical stop position
50
After adjusting the dog and mechanical stopper positions, set the system
variables for both J1axis stroke ends as indicated in Table 5.2.
Parameter number $PARAM GROUP. $LOWERLIMS :
J1-axis stroke lower limit
Parameter number $PARAM GROUP. $UPPERLIMS :
J1-axis stroke upper limit
Please power off, and perform a cold start after change of the value.
NOTE
Cold start: A type of start operation, where the power is first
turned off, then turned back on. (Cold start is used when
power failure processing has been disabled.)
If power failure processing is currently enabled (system
variable $POWERFL is set to true), change the system
variable $POWERFL to false (power failure processing
disabled). Turn off the power, then turn it on again. To
subsequently reenable power failure processing, reset the
system variable $POWERFL to true (power failure
processing enabled).
2) Changing minimum and
maximum stroke
51
Table 5.2 J1Axis Stroke Upper and Lower Limits (Changing A Stroke)
Position of each
stroke end
(Stroke lower limit)
$PARAM_GROUP.
$LOWERLIMS
(Stroke upper limit)
$PARAM_GROUP.
$UPPERLIMS
180_ (*1) 180
165_ (standard value) 165
142.5_ 142.5
120_ 120
105_ 105
97.5_ 97.5
75_ 75
52.5_ 52.5
30_ 30
7.5_ 7.5
+ 7.5_ 7.5
+ 30_ 30
+ 52.5_ 52.5
+ 75_ 75
+ 97.5_ 97.5
+105_ 105
+120_ 120
+142.5_ 142.5
+165_ (standard value) 165
+180_ (*1) 180
*1 "180_ is optional. (Specification: A05B1208H322)
52
Quick mastering is a method of exact calibration at the original position
when the pulse coder battery backup is disconnected, such as when a cable
is replaced.
Quick mastering cannot be used when the mechanical phase of the pulse
coder is changed, such as when a motor or reducer is replaced. In such
a case, perform mastering using jigs as described in Section 5.5.
a) Before replacing the cable, note down the mastering data for the
system variable $DMR_GRP.$MASTER_COUN[1][6] (pre-
vious mastering data).
b) Replace the cable.
c) To release the brake control, set the system variable $PA-
RAM_GROUP.$SV_OFF_ENB to FALSE for all axes, then per-
form a cold start. (See Section 5.2(2).)
d) Upon powerup, a BZAL alarm is output. Set the system variable
$MCR.$SPC_RESET to TRUE, then perform a cold start.
e) When the power is turned on, the message Pulse not established
appears. Rotate each axis through about 10 in the positive (+)
or negative () direction by joint feed. Then, press the alarm re-
lease key to release the message.
f) Move all the axes, by joint feed, to position each axis to the zero
degree mark with an accuracy of "1 mm relative to the arrow
mark. (See Fig. 5.3.)
g) Assign the mastering data (noted in step a)) for the system
variable $DMR_GRP.$MASTER_COUN[1][6] to the system
variable for the quick mastering data, $DMR_GRP.
$REF_COUN [1][6]. Then, enter 0 as the system variable for
the quick mastering reference position data, $DMR_GRP.
$REF_POS [1][6]. Next, set the quick mastering completion
flag $DMR_GRP.$REF_DONE to TRUE. This completes the
setting of the quick mastering reference position at the zero de-
gree position for each axis.
h) Press the screen selection key to display the menu. Then, select
SYSTEM. From the system menu, select Master/Cal. If the cal-
ibration screen is not displayed, set the system variable $MAS-
TER_ENBL to 1.
i) Select 4 QUICK MASTER from the system calibration menu,
then press function key F4 (YES). Quick mastering is performed.
j) Teaching and playback are enabled by selecting 6 Master/Cal
from the system calibration menu and pressing function key F4
(YES).
k) If brake control has been released, reset the system variable $PA-
RAM_GROUP.$SV_OFF_ENB to the previous value for all
axes, then perform a cold start.
l) Note down the mastering data for the system variable
$DMR_GRP.$MASTER_COUN.
5.3
Quick Mastering
1) Mastering procedure (for
cable replacement)
53
J5axis
J6axis
J4axis J3axis
J2axis
J1axis
Fig.5.3 Zero degree position arrow mark for each axis (ARC Mate 120/S12)
54
Each of the robots axes is fitted with arrow marks shown in Fig. 5.3. The
axis is at the zero degree position if these marks match. If such a mark
is not at its correct position, it can be mastered as follows.
This operation allows you to roughly master the position. Accurate
mastering requires the operation using the mastering jig described in the
5.5 section.
a) To release the brake control, set system variable $PA-
RAM_GRP.$SV_OFF_ENB for each axis to FALSE, turn off the
power, and perform a cold start. [See 5.2 2)]
b) When a BZAL alarm is output upon powerup, set the system
variable $MCR.$SPC_RESET to TRUE, then perform a cold
start.
c) If the message Pulse not established appears when the power
is turned on, rotate each axis through about 10_ in the positive (+)
or negative () direction by joint feed. Then, press the alarm re-
lease key to release the message.
d) Move all axes by joint feed to position each axis to the zero degree
mark. (See Fig. 5.3.)
e) Press the screen selection key to display the menu. Then, select
TER_ENBL to 1.
f) Select 2 ZERO POSITION MASTER from the system calibra-
tion menu, then press function key F4 (YES). Then, mastering
is performed. Thus, mastering data acquired from the pulse coder
counter is set in the system variable $DMR_GRP.MAS-
TER_COUN, and the system variable $DMR_GRP.MAS-
TER_DONE (mastering completion flag) is set to true.
g) Teaching and playback are enabled by selecting 6 Master/Cal
(YES).
h) If brake control has been released, reset the system variable $PA-
RAM_GROUP.$SV_OFF_ENB to the previous value for all
axes, then perform a cold start.
i) Finally, as a safeguard against mastering data being rewritten by
an operation error, note down the mastering data for the system
variable $DMR_GRP.$MASTER_COUN. Furthermore, draw
arrow marks for zero position calibration with the zero degree
position attitude, as shown in Fig. 5.3.
To perform mastering for one axis only, perform singleaxis
mastering as described below.
The new position data is thus stored only for the target axis, and
previous position data is stored for the other axes.
The J2- and J3-axes must be mastered simultaneously because
they rotate together.
5.4
Mastering Using Zero
Degree Position
1) Procedure (Mastering of
zero degree position)
55
a) To release brake control, set the system variable $PA-
RAM_GROUP.$SV_OFF_ENB to FALSE for all axes, then
perform a cold start. (See Section 5.2 2).)
b) When a BZAL alarm is output upon powerup, set the system
variable $MCR.$SPC_RESET to true, then perform a cold start.
c) If the message Pulse not established appears when the power
is turned on, rotate each axis through about 10_ in the positive
(+) or negative () direction by joint feed. Then, press the alarm
release key to release the message.
d) Move the desired axis by joint feed to position the axis to the zero
degree mark. (See Fig. 5.3.)
e) Press the screen selection key to display the menu. Then, select
TER_ENBL to 1.
f) Select 3 SINGLEAXIS MASTER from the system calibration
menu. Then, the menu for setting each axis appears. Enter 1 in
the (SEL) column of the axis for which mastering is to be per-
formed, then enter 0 for the other axes. Enter 0 (for zero degree)
in the MASTERING POSITION column. Press function key F5
(EXEC) to perform zero degree position mastering for the se-
lected axis only.
g) Teaching and playback are enabled by selecting 6 Master/Cal
(YES).
h) If brake control has been released, reset the system variable $PA-
RAM_GROUP.$SV_OFF_ENB to its previous value for all
axes, then perform cold start.
i) Finally, to safeguard against mastering data being overwritten by
an operation error, note down the mastering data for the system
variable $DMR_GRP.$MASTER_COUN. Furthermore, draw
arrow marks for zero position calibration with the zero degree
position attitude, as shown in Fig. 5.3.
2) Procedure(singleaxis
mastering)
56
If the present value stored via the APC (Absolute Pulse Coder) and the
actual position of each axis are misaligned after a major component of the
robots mechanical unit has been replaced, mastering is to be carried out
to set the robots geometric position. (Mastering is executed at J1=0_)
The robot has been mastered by the time of the shipment.
Before mastering the robot do the following:
Make the robots base level. (1 mm/base)
Remove the wrist hand and related parts.
Do not allow an external force to be applied to the robot.
NOTE
The axis stroke is not checked during mastering. Sufficient
care shoud, therefore, be taken regarding the robots axis
movement.
1 Assembling the jig base
Assemble mastering jig Y to mastering jig X as shown in Fig. 5.5 (a)
Mastering jig Y
A2907208X954
M6X12 (4PCS)
Washer M6 (4PCS)
Mastering jig X
A2907208X953
Fig.5.5. (a) Assembly of jig base (ARC Mate120/S-12)
5.5
Mastering Using Jig
Assembling the
mastering jig
57
2 Mounting on robots body
Mount the mastering jig X on the J1-axis base using bolts and pins as
shown in Fig 5.5 (b).
J1 base
A2907208X201
Pin
A2907111X906
M8X20 (2PCS)
Pin
A2907111X906
Mastering jig X
A2907208X953
Fig.5.5. (b) Mounting on robots body (ARC Mate120/S-12)
3 Mounting jig on wrist
Position the wrist axis such that J4 = J5 = J6 = 0_ in manual mode.
As shown in Fig. 5.5(c), mount mastering jig A onto the J6axis so that
the cubic section (weight) directls upward.
NOTE
When using the optional FANUC flange adaptor, first mount
the flange adaptor, and fit the mastering jig onto the
adaptor. (Mastering jig A differs from other mastering jigs
in shape.)
58
Pin
A2907022X965
Mastering jig A (For ISO)
A2907207X951
M6X61(4PCS)
Mastering jig A2 (For FANUC)
A2907207X956
Fig.5.5. (c) Mounting jig on wrist (ARC Mate120/S-12)
1 First execute mastering by using the zero degree position described in
Section 5.4. A temporary coordinate zero point is set in the robot.
2 To release brake control, set system variable $PARAM_GROUP.
$SV_OFF_ENB to FALSE for all axes, turn the power off, and
perform a cold start. [See 5.2 2)]
3 Using joint feed, move the robot until mastering jig A, mounted onto
the wrist axis, is positioned within mastering jig X mounted on the J1
base, as shown in Fig. 5.5(d). The corresponding attitude of the robot
is shown in Fig. 5.5(e).
Mastering jig Z
A2907208X955
M6X14 (4pcs)
M6X14 (4 pcs)
Mastering jig W
A2907208X956
Fig. 5.5(d) Assembling Mastering Jigs (ARC Mate 120/S12)
Mastering procedure
59
Mastering Jig
Specification:
A05B1208J053
ISO flange
Mastering attitude
J1 = 0_
J2 = 91.523_
J3 = 157.396_
J4 = 0_
J5 = 22.670_
J6 =0_
Mastering attitude
J1 = 0_
J2 = 90.347_
J3 = 155.586_
J4 = 0_
J5 = 24.480_
J6 =0_
Mastering Jig
Specification:
A05B1208J052
Flange adaptor
(option)
Fig. 5.5(e) Mastering Attitude (ARC Mate 120/S12)
60
4 Mount mastering jig Z and mastering jig W onto mastering jig X, as
shown in Fig. 5.5(d). It is absolutely essential that this step be
performed to prevent the arm from falling when the brake is released.
5 Press and turn the emergency stop button on the teach pendant to
release the lock. The power is disconnected from the motor. Do not
press the alarm release key.
6 Press the screen selection key to display the menu. From the menu,
select SYSTEM. From the system menu, select Brake Cntrl. Press
function key F, then select function key F3 (RELALL) to release
the brakes on all axes.
7 [For RJ controller]
Press the screen selection key to display the menu. From the menu,
function key F, then select function key SHIFT )F3 (REL_ALL)
to release the brakes on all axes.
[For RJ2 controller]
Press the screen selection key to display the menu. From the menu,
select SYSTEM. Press the function key F1(MENU), select
Master/Cal. Press SHIFT + F4 (TORQUE), change the indication
from TORQUE=[ON] to TORQUE=[OFF].
Press the RESET key to release the torque on all axes.
(It is equal condition to release the brakes)
8 Check, by viewing through the window, that each of the three surfaces
is completely butted against the wall, as shown in Fig. 5.5(g). If not
all of the surfaces are fully butted against the walls, loosen the M8
bolts, and perform step 7 again.
9 Press the screen selection key to display the menu. Then, select
SYSTEM. From the system menu, select Master/Cal. If the
calibration screen is not displayed, set the system variable
$MASTER_ENBL to 1.
10 Select 2 JIG POSITION MASTER from the system calibration menu,
then press function key F4 (YES). Then, mastering is performed.
Thus, mastering data acquired from the pulse coder counter is set in
the system variable $DMR_GRP. $MASTER_COUN, and the system
variable $DMR_ GRP.MASTER_DONE (mastering completion flag)
is set to TRUE.
11 Teaching and playback are enabled by selecting 6 Master/Cal from the
system calibration menu and pressing function key F4 (YES).
12 Press the screen selection key to display the menu. From the menu,
function key F, then select function key F2 (ENGALL) to control
the brakes of all axes. Then, press the alarm release key.
13 [For RJ controller]
From the system menu, select Brake Cntrl. Press function key F,
then select function key SHIFT ) F2 (ENG_ALL) to control the
brakes of all axes.
[For RJ2 controller]
From the system menu, press the function key F1 (MENU), select
Master/Cal. Press SHIFT ) F4 (TORQUE), change the indication
from TORQUE=[OFF] to TORQUE=[ON]. Press the RESET key to
control the torque of all axes.
14 Finally, to safeguard against mastering data being overwritten by an
operation error, note down the mastering data for the system variable
$DMR_GRP.$MASTER_COUN. Furthermore, draw arrow marks
for zero position calibration with the zero degree position attitude, as
shown in Fig. 5.3.
61
To perform mastering for a desired axis only, first note down the
mastering data of the system variable $DMR_GROUP.
$MASTER_COUN, then perform mastering for all axes. Once this
mastering has been completed, reenter the mastering data for all axes
except the desired axis. Thus, the new position information for the
desired axis only is stored; the previous position information for the
other axes is preserved.
Fig. 5.5(f) Butting Mastering Jig (ARC Mate 120/S12)
Window
Butting surface
Window
Butting
surface
Window
Butting surface
Window
Butting surface
Fig. 5.5(g) Mastering Jig Butting Surfaces and Window (ARC Mate 120/S12)
62
1) Confirming whether mastering is normally done
When turing on the power, the position matching is automatically
done. To confirm whether this operation has normally finished, check
whether the present position display coincides with the robot actual
position using one of the following methods.
a) Move the axes to 0_ by repeat operation, and visually check the
zero degree marks. (Its shown in Fig. 5.3).
b) Position the specified position in repeat operation, and check
whether this position coincides with the programmed position.
2) Alarms at positioning
Alarms which may occur at positioning and the action to be taken are
described below.
a) BZAL alarm
This alarm occurs when the voltage of the pulse coder back-up
battery drops to zero while the controller power is turned off. If
this alarm occurs, perform mastering because the data in the
counter is lost.
b) BLAL alarm
This alarm indicates that the voltage of the pulse coder back-up
battery has become tool low to back up the pulse coder. If this
alarm occurs, replace the back-up battery with the system turned
on, and check if the present position data is correct according to
the procedure described in Item 1) above.
c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR,
and SPHAL alarms
When any of these alarms occur, contact the service engineer.
The motor may need to be replaced.
5.6
Confirming Mastering
63
If the backlash of the J5axis exceeds the maximum allowable value
(output axis angle of 3 to 6 minutes) shown in table 4.2(b), backlash
adjustment can be made by following the procedure below. (See Fig. 5.7.)
1 Position the robot to the attitude, J4 = +90_ and J5 = J6 = 0_.
2 Remove the twelve M4X8 fixing bolts, then remove the J5axis
gear box cover (A2907208X502) from the J3 arm
(A2907208X402).
Gear 2 assembly
A2907208V501
J3 arm
A2907208X402
M5X12 (4 pcs)
(Loctite 262)
Washer M5 (4 pcs)
Plane washer M5 (4pcs)
Gear 3 assembly
A2907208V502
Gear J55
A2907208X515
M4X12 (8 pcs)
M4 Washer (8 pcs)
Packing
A2907208X524
M5X12 (10 pcs)
(Loctite 262)
M5 Washer (10 pcs)
Cover
A2907208X502
Turn to adjust
backlash.
Spring pin
f5X10
(1 pcs)
Fig. 5.7 J5axis gear backlash adjustment (ARC Mate 120/S12)
3 Loosen the four M412 bolts to disengage the gear 2 assembly
(A2907208V501) from the gear 3 assembly (A2907208
V502).
4 Remove the ten M52 bolts. The rotation center axis and gear
center axis of the gear 3 assembly are not aligned. Rotate the gear
3 assembly about the spring pin (f510) as its center, and the
backlash between the gear 3 assembly and the gear J55. To re-
duce the backlash, change the mounting phase of the gear 3 as-
sembly, then secure the gear 3 assembly to the J3 arm using six
M4X10 bolts.
5 While turning the gear 3 assembly and checking the operation of
the J5axis within the stroke (140_ to +140_ ), repeat step 4 to
reduce the backlash until there is no interference between the
gears.
5.7
Adjusting J5-axis Spur
Gear backlash
Backlash adjustment of
the gear 3 assembly and
gear J55
64
6 To reduce the backlash, position the gear 2 assembly at right
angles to the axis running through the gear 2 and gear 3 assem-
blies. Then, secure the gear 2 assembly to the J3 arm with four
M512 bolts.
7 While turning the gear 2 assembly and checking the operation of
the J5axis within the stroke (140_ to +140_ ), repeat step 6 to
reduce the backlash until there is no interference between the
gears.
8 Check that the backlash of the J5axis does not exceed the allow-
able value (output axis angle of 5 minutes) indicated in Table
4.2(b). If the allowable value is exceeded, return to step 3 .
9 Secure the gear box cover of the J5axis to the J3 arm using eight
M4X8 bolts. Also, renew the packing (A2907207X524) to
prevent grease leakage.
10 Fill the J5axis gear box with the specified type of grease, accord-
ing to the grease replacement procedure described in Section 3.2.
11 Perform mastering according to Sections 5.4 or 5.5.
Backlash adjustment of
the gear 2 and gear 3
assemblies
B80485E/03 6. REPLACING AND ADJUSTING PARTS
65
6
REPLACING AND ADJUSTING PARTS
When replacing a part, subsequent adjustment is required.
Parts requiring replacing and their accompanying adjustment
items are listed below.
Replacement parts Adjustment item
Motor (a) Mastering
J1, J2, and J3axis reducer (a) Mastering
(b) Dog adjustment (*option)
J4 and J6-axis reducer (a) Mastering
J5 axis gear box (a) Mastering
NOTE
Be careful when removing and installing the following heavy
parts.
Parts Weight (approx.)
J2 ArmWrist unit (see Fig. 6.3 (a)) 59 kg
J3 Arm (see Fig. 6.7 (a)) 20 kg
J2 Base (see Fig. 6.1) 32 kg
6. REPLACING AND ADJUSTING PARTS B80485E/03
66
1 Turn off the control unit.
2 Remove the connector from the J1axis motor.
3 Remove the four M8X20 motor mounting bolts, then remove the
motor from the J2 base.
4 Remove the M10 hexagonal nut from the motor shaft, then pull
out the gear (A2907208X211) and the bearing.
5 Remove the C ring, exchange the bearing and secure it to the gear
using the C ring.
6 Mount the gear onto a new motor.
7 Install an M10 spring washer, then apply Loctite 262 to the M10
screw of the motor. Then, tighten the M10 nut to the specified
torque [12.0 Nm (122 kgfcm)].
8 Check that the Oring is installed correctly where the motor
mounts on the J2 base (A2907208X301). Then, secure the mo-
tor to the J2 base using four M8X20 bolts. Apply Loctite 262 to
the bolts.
9 Fill the J1axis grease bath with the specified type of grease, as
detailed in Section 3.2.
10 Perform mastering as explained in Chapter 5.
NOTE
When performing this procedure, ensure that the J1axis
does not rotate. When the J1axis is allowed to rotate
because of the robot is installed on a slanted plane, prevent
its rotation by, for example, pushing the J1axis up against
its mechanical stopper.
1 To prevent its rotation, fix the J2axis by, for example, pushing
it up against its mechanical stopper.
3 Remove the connector from the J2axis motor.
4 Remove the four M825 motor mounting bolts, then remove the
motor from the J2 base.
5 Remove the M10 hexagonal nut from the motor shaft, then pull
out the gear (A2907208X211) and the bearing.
6 Remove the C ring, exchange the bearing and secure it to the gear
using the C ring.
7 Mount the gear onto a new motor.
8 Install an M10 spring washer, then apply Loctite 262 to the M10
screw of the motor. Then, tighten the M10 nut to the specified
torque [12.0 Nm (122 kgfcm)].
6.1
Replacing J1 and
J2-axis Motor M1 M2
1) Replacing the J1axis
motor (Fig.6.1) M1
motor (Fig.6.1) M2
67
9 Check that the Oring is installed correctly where the motor
mounts on the J2 base (A2907208X301). Then, secure the mo-
tor to the J2 base using four M8X25 bolts. Apply Loctite 262 to
the bolt threads.
11 Perform mastering according to Chapter 5.
J1axis motor
M8X25 (4 pcs)
Loctite 262
Washer M8 (4 pcs)
Gear A2907208X211
Oring
Hexagonal nut M10
Loctite 262
12.0 Nm (122 kgfcm)
Spring washer M10
Cring
Bearing
J2axis motor
M8X25 (4 pcs)
Loctite 262
Washer M8 (4 pcs)
J2 base
A2907208X301
Gear A2907208X211
Oring
Hexagonal nut M10
Loctite 262
12.0 Nm (122 kgfcm)
Spring washer M10
Bearing
Cring
M1
M2
Fig.6.1 Replacing J1, J2axis motor (ARC Mate120/S12)
68
2 Pull out the cables, running through the pipe of the J1axis reduc-
er, toward the J1axis connector box as explained in Section 8.2.
3 Remove the J1axis motor from the J2 base as explained in Sec-
tion 6.1.
4 Remove the eleven M11X65 bolts securing the J2 base to the
J1axis reducer, as shown in Fig. 6.2(a).
5 Using a crane, slowly lift the J2 base as explained in Section 5.1
of the part explaining connection.
6 Remove the Oring (large), bearing, and center gear as shown in
Fig. 6.2(b).
7 Remove the six M14X85 bolts securing the J1axis reducer to the
J1 base (A2907208X201), then remove the reducer.
8 Remove the three M6X25 bolts securing the pipe (A2907208
X221) to the reducer, then remove the pipe according to Fig.
6.2(c).
9 Check that the Oring is installed correctly on the pipe. Then,
secure the pipe to a new reducer using four M6X25 bolts. Apply
Loctite 262 to the bolt threads.
10 Mount an Oring (medium) and Oring (small) on the reducer.
Then, secure the reducer to the J1 base using six M14X85 bolts,
tightening them to a torque of 204.8 Nm (2090 kgfcm). Apply
11 Mount the center gear, bearing (with Loctite RC75 applied to its),
and Oring (large) on the reducer.
12 Secure the J2 base to the reducer using eleven M10X65 bolts,
Loctite 262 to the bolt threads. Be careful not to damage the oil
seal surface with the pipe.
13 Mount the J1axis motor onto the J2 base as explained in Section
6.1.
14 Fill the J1axis grease bath with the specified type of grease as
6.2
Replacing J1-Axis
Reducer
69
M4X10
Loctite 262
M10X65 (11 pcs)
Loctite 262
73.5 Nm (750 kgfcm)
Washer M10 (11 pcs)
Cable cover 2
A2907208X333
Clamp
A2907208X336
Cable cover 2
A2907208X334
M6X20 (2 pcs)
Washer M6 (2 pcs)
Clamp
A2907207X325
Cable cover 3
A2907208X335
Clamp
A2907208X336
M4X10
Loctite 262
Clamp
A2907208X341
M6X20 (2 pcs)
Washer M6 (2 pcs)
Fig.6.2 (a) Replacing J1axis reducer (ARC Mate120/S12)
70
Oring (Large)
J1 reducer center gear
Bearing
Loctite RC75 (External ring)
M14X85 (6 pcs)
Loctite 262
204.8 Nm (2090 kgfcm)
Washer M14 (6 pcs)
Oring (medium)
Oring (small)
J1 base
A2907208X201
J1axis reducer
Fig.6.2 (b) Replacing J1axis reducer (ARC Mate120/S12)
Oring
J1axis reducer
M6X25 (3 pcs)
Loctite 262
Washer M6 (3 pcs)
Pipe
A2907208X221
Fig.6.2 (c) Replacing J1axis reducer (ARC Mate120/S12)
71
3 Pull out the cables, running through the pipe of the J2axis reduc-
er, from the J2 arm toward the J2 base as explained in Section 8.2.
4 Remove the J2axis motor from the J2 base as explained in Sec-
tion 6.1.
5 Remove the six M12X85 bolts and three M12X30 bolts securing
the J2 arm to the J2axis reducer as shown in Fig. 6.3(a).
6 Using a crane, lift the J2 base and the upper portion, then slowly
pull the J2 arm out sideways.
7 Remove Oring (large), bearing and center gear as shown in
Fig.6.3(a).
8 Remove the twelve M10X80 bolts securing the J2axis reducer
to the J2 base (A2907208X301), then remove the reducer.
9 Remove the three M6X25 bolts securing the pipe (A2907208
X221) to the reducer, then remove the pipe as shown in Fig.
6.3(b).
10 Check that the Oring is installed correctly on the pipe. Then,
secure the pipe to a new reducer using three M6X25 bolts. Apply
11 Mount center gear, the bearing (with Loctite RC75 applied to its
outside diameter) and Oring on the reducer.
12 Mount the Oring on the reducer. Then, secure the reducer to the
J2 base using twelve M10X80 bolts, tightening them to a torque
of 73.5 Nm (750 kgfcm). Apply Loctite 262 to the bolt threads.
Be careful not to damage the oil seal surface with the pipe.
13 Secure the J2 arm to the reducer using six M12X85 bolts and
three M12X30 bolts, tightening them to a torque of 128.4 Nm
(1310 kgfcm). Apply Loctite 262 to the bolt threads.
14 Mount the J2axis motor to the J2 base as explained in Section
6.1.
6.3
Replacing J2-Axis
Reducer
72
J2axis reducer
Bearing
Loctite RC75 (External ring)
M10X80 (12 pcs)
Loctite 262
73.5 Nm (750 kgfcm)
Washer M10 (12 pcs)
J2 arm
A2907208X302
J2 base
A2907208X301
M12X30 (3 pcs)
N12X85 (6 pcs)
Loctite 262
128.4 Nm (1310 kgfcm)
Washer M12 (9 pcs)
Oring
Gear
A2907208X212
J2 ArmWrist unit
M6X25 (3 pcs)
Loctite 262
Washer M6 (3 pcs)
Pipe
A2907207X221
Oring
J2axis reducer
73
3 Remove the twelve M6X10 button bolts, then remove the J3 cov-
er (A2907208X403) from the J3 housing, as shown in Fig. 6.4.
4 Disconnect the cable from the J3axis motor.
5 Remove the four M6X16 seal bolts holding the J3axis motor to
the J3 housing, then remove the motor.
6 Remove the hexagon M6 nut from the motor shaft, then remove
the gear (A2907208X411).
7 Install gear to the new motor.
8 Mount on M6 spring washer, apply Loctite 262 to the M6 screw
on a new motor, then tighten the draw bolt to a torque of 2.9 Nm
(30 kgfcm).
9 Confirm that Oring is inserted correctly to the position of motor
that mounts J3 housing (A2907208X401). Secure the motor
to the J3axis housing using four M616 bolts (apply loctite
262)
10 Attach the cable to the J3axis motor.
11 Fill the J3axis grease bath with the specified type of grease as
12 Mount the J3 cover onto the J3 housing using twelve M6X10 but-
ton bolts.
J3 Cover
A2907208X403
Button bolt M6X10 (12 pcs)
Washer M6 (12 pcs)
Plain washer M6 (12 pcs)
M6X16 (4 pcs)
Loctite 262
Washer M6 (4 pcs)
J3 housing
A2907208X401
Oring
Gear
A2907208X411
Heagon nut M6
Loctite 262
2.9 Nm (30 kgfcm)
Spring Washer M6
J3axis motor
M3
Fig.6.4 Replacing J3axis motor (ARC Mate120/S12)
6.4
Replacing J3-Axis
Motor
M3
74
3 Remove the twelve M6X10 button bolts , then remove the J3 cov-
5 Remove the J3axis motor as explained in Section 6.4.
6 Using a crane, lift the J3 arm. Then, remove the six M8X80 bolts
and two M825 bolt securing the J2 arm to the J3axis reducer,
then remove the J3axis reducer from the J2 arm.
7 Remove the ten M665 bolts securing the J3axis reducer to the
J3 housing, then remove the reducer.
8 Secure a new reducer to the J3 housing using ten M6X65 bolts,
9 Using a crane, lift the J3 arm. Then, secure the J2 arm to the re-
ducer using six M880 bolts and two M825 bolts (to which
Loctite 262 has been applied) tightened to a torque of 37.2 Nm
(380 kgfcm), and two f8X25 taper pins (with Loctite 242 ap-
plied to the taper holes).
10 Mount the J3axis motor as explained in Section 6.4.
11 Attach the cable to the J3axis motor.
13 Mount the J3 cover onto the J3 housing using twelve M610
button bolts and three M410 bolts.
Bearing
Loctite RC75
(EXternal ring)
M8X25 (2 pcs)
M8X80 (6 pcs)
Loctite 262
37.2 Nm (380 kgfcm)
Washer M8 (8 pcs)
J3axis reducer
J3 housing
A2907208X401
Oring (Large)
M6X65 10 pcs)
Loctite 262
15.7 Nm (160 kgfcm)
Washer M6 (10 pcs)
J2 arm
A2907208X301
Gear
A2907208X212
Fig.6.5 Replacing J3axis reducer (ARC Mate120/S12)
6.5
Replacing J3-axis
Reducer
75
1 Move the robot to the attitude of J4 = 0_ . Maintain this attitude
until step 12. (mastering). Note that the cable may break if this
zero degree position is not maintained.
3 Remove the twelve M610 button bolts, then remove the J3
cover (A2907208X403) from the J3 housing, as shown in Fig.
6.4.
5 Remove the four M6X16 bolts securing the J4axis motor to the
J3 housing (A2907208X401), then remove the motor as shown
in Fig. 6.6.
6 Remove a hexagon nut at the motor shaft and pull out the gear
(A2907208X411).
7 Mount and secure the gear onto a new motor.
8 Mount on M6 spring washer and apply loctite 262 to the M6 bolt
thread. Then tighten M6 nut with a torque of 2.9 Nm (30kgfcm).
9 Check that the Oring is installed correctly, on the J3 housing
(A2907208X401) at the place where the motor is mounted.
Then secure the motor to the J3 housing using four M616 bolts.
Apply Loctite 262 to the bolt threads.
10 Attach the cable connector to the J4axis motor.
button bolts.
M6X16 (4 pcs)
Loctite 262
Washer M6 (4 pcs)
Hexagon nut M6
Loctite 262
2.9 Nm (30 kgfcm)
Spring washer M6
Oring
J3housing
A2907208X401
J4axis
motor
Gear
A2907208X413
M4
6.6
Replacing J4-axis
Motor
M4
76
2 Remove the twelve M610 button bolts,then remove the J3 cov-
3 Disconnect the cables attached to the connector clamp of the J3
housing, as explained in Section 8.2.
4 Remove the fifteen M4X35 bolts securing the J4axis reducer to
the J3 housing then, while supporting the J3 arm with a crane, re-
move the J4axis reducer from the J3 housing, as shown in Fig.
6.7(a).
5 Remove the cables, disconnected in step 3 , and the wrist cables
from the J3 housing.
6 Remove the sixteen M4X35 bolts securing the J4axis reducer to
the J3 arm, then remove the J4axis reducer from the J3 arm as
shown in Fig. 6.7(b).
7 Remove the two bearings and spacer (A2907207X424) from
the reducer.
8 Remove the six M3X8 bolts securing the gear (A2907208
X414) to the reducer, then remove the gear from the reducer.
9 Secure the gear to a new reducer using six M3X8 bolts, tightened
to a torque of 2.0 Nm (20 kgfcm). Apply Loctite 242 to the bolt
threads.
10 Apply Loctite RC75 to the external rings of the two bearings then
mount the gear, together with the spacer, to the reducer.
11 Check that the Oring (medium) and Oring (small) are installed
correctly. Then, mount the reducer to the J3 arm using sixteen
M4X35 bolts, tightened to a torque of 4.6 Nm (47 kgfcm). Ap-
ply Loctite 262 to the bolt threads.
12 Run the wrist cable connectors through the J3 housing, then
check that the Oring (large) is installed correctly. Then, secure
the J3 arm to the J3 housing using fifteen M4X35 bolts, tightened
threads.
13 Connect the wrist cables running through the pipe of the J4axis
reducer as explained in Section 8.2.
button bolts.
6.7
Replacing J4Axis
Reducer
77
M4X35 (15 pcs)
Loctite 262
4.6 Nm (47 kgfcm)
Washer M4 (15 pcs)
Oring (Large)
J4axis reducer
J3 housing
A2907207X401
J3arm
A2907208X402
Bearing (2 pcs)
Loctite RC75
(External ring)
M4X35 (16 pcs)
Loctite 262
4.6 Nm (47 kgfcm)
Washer M4 (16 pcs)
M3X8 (6 pcs)
Loctite 262
2.0 Nm (20 kgfcm)
Washer M3 (6 pcs)
Gear
A2907208X414
Oring (Medium)
Oring (Small)
Spacer
A2907207X424
J4
Reducer
J3 arm
A2907208X402
78
1 Move the robot to the attitude of J4 = 90_ .
3 Remove the six M615 bolts, remove the packing (A290
7208X525), then turn the J5 cover (A2907208X503) around
the J5axis until the J5axis motor can be lifted out, as shown in
Fig. 6.8.
5 Remove the four M512 bolts securing the J5axis motor to the
J3 arm, then remove the motor from the J3 arm.
6 Remove the M3X12 bolt securing the gear (A2907208X511)
to the motor shaft, then remove the gear and bearing.
7 Secure the gear to a new motor using an M312 bolt, tightened
threads.
8 Confirm the O ring is installed correctly, then secure the motor
to the J3 arm using four M512 bolts. Apply Loctite 262 to the
bolt threads.
9 Connect the J5axis motor cable.
10 Install a new packing and secure the J5 cover with four M616
bolts. Apply loctite 262 to the bolt threads.
Gear
A2907208X511
Washer
A2907207X425
M5X12 (4 pcs)
Loctite 262
Washer M5 (4 pcs)
M3X12
Loctite 242
2.0 Nm (20 kgfcm)
Washer M3
J5axis motor
M6X16 (6 pcs)
Loctite 262
Washer M6 (6 pcs)
Cover
A2907208X503
Packing
A2907208X525
J3 arm
A2907208X402
Cring
Bearing
Oring
M5
6.8
Replacing J5-axis
Motor
M5
79
1 To replace the input gear (A2907208X511) of the J5axis
motor, follow the replacement procedure given in Section 6.8.
2 Move the robot to the attitude of J4 = +90_ and J5 = J6 = 0_ .
4 Remove the eight M412 bolts, cover (A2907208X502), and
packing (A2907208X524), as shown in Fig. 6.9.
5 Remove the four M512 bolts securing the gear 2 assembly,
then remove the gear 2 assembly from the J3 arm.
6 Remove the ten M512 bolts securing the gear 3 assembly and the
ten M630 bolts securing the gear (A2907208X515), then re-
move the gear 3 assembly and the gear from the J3 arm. By pulling
out the gear a little, the gear 3 assembly can be removed.
7 Secure a new gear 3 assembly and new gear to the J3 arm (these
must be fitted together). Secure the gear, together with the J6
housing(A2907208X501), to the J3 arm using ten M630
bolts tightened to a torque of 15.7 Nm (160 kgfcm). Apply Loc-
tite 262 to the bolt threads. Secure the gear 3 assembly to the J3
arm using ten M512 bolts tightened to a torque of 9.0 Nm (92
kgfcm), as explained in Section 5.7. Apply Loctite 262 to the
bolt threads.
8 Secure the gear 2 assembly to the J3 arm using four M512
bolts, tightened to a torque of 9.0 Nm (92 kgfcm), as explained
in Section 5.7. Apply Loctite 262 to the bolt threads.
9 Upon completion of backlash adjustment, as explained in Section
5.7, install a new packing, then secure the cover to the J3 arm us-
ing eight M412 bolts. To prevent grease leakage, use a new
packing.
M4X 12 (8 pcs)
Washer M4 (8 pcs)
M5X12 (10pcs)
Loctite 262
9.0 Nm (92 kgfcm)
Washer M5 (10 pcs)
Gear 2 assembly
A2907208V501
M5X12 (4 pcs)
Loctite 262
9.0 Nm (92 kgfcm)
Washer M5 (4 pcs)
Plain washer M5 (4pcs)
Gear 3 assembly
A2907208V502
J3 arm
A2907208X402
Gear J55
A2907208X515
M6X30 (10 pcs)
Loctite 262
15.7 Nm (160 kgfcm)
Washer M6 (10 pcs) Packing
A2907208X524
Cover
A2907208X502
Spring pin
f5X10 (1 pcs)
Fig.6.9 Replacing J5 gear (ARC Mate120/S12)
6.9
Replacing J5Axis
Gear
80
2 Remove the four M5X20 bolts and two f5X20 spring pins, then
remove the J6axis reducer from the J6 housing (A2907208
X501) as shown in Fig. 6.10(a).
3 Disconnect the cable running through the sheet (A2907208
X529), as shown in Fig. 8.2(g).
4 Remove the four M4X12 bolts, then remove the motor and a
packing from the J6axis reducer (harmonic drive), as shown in
Fig. 6.10(b).
5 Remove the M3X8 bolt, then remove the reducer wave generator
from the motor.
6 Secure the wave generator to the shaft of a new motor, using an
M3X8 bolt tightened to a torque of 2.0 Nm (20 kgfcm). Apply
7 Install a new packing and secure the motor to the reducer using
four M512 bolts. Apply loctite 262 to the bolt threads.
8 Reconnect the motor cable, then secure it to the sheet.
9 Check that the Oring is installed correctly, then secure the motor
with the reducer to the J6 housing using four M520 bolts with
a torque of 9.0 Nm (92kgfcm) and two f520 spring pins. Ap-
10 Fill the J6axis grease bath with the specified grease, as detailed
in Section 3.2.
2 Remove the four M520 bolts and two f5X20 spring pins, then
remove the J6axis reducer from the J6 housing (A2907208
X501) as shown in Fig. 6.10(a).
3 Remove the four M512 bolts, then remove the motor and a
packing from the J6axis reducer (harmonic drive) as shown in
Fig. 6.10(a).
4 Remove the M3X8 bolt, then remove the reducer wave generator
from the motor.
5 Secure a new wave generator to the shaft of the motor, using an
M3X8 bolt tightened to a torque of 2.0 Nm (20 kgfcm). Apply
6 Install a new packing and secure the motor to the reducer using
four M512 bolts. Apply loctite 242 to the bolt heads.
7 Check that the Oring is installed correctly, then secure the motor
with the reducer to the J6 housing using four M520 bolts with
a torque of 9.0 Nm (92 kgfcm) and two f520 spring pins. Ap-
8 Fill the J6axis grease bath with the specified grease, as detailed
in Section 3.2.
6.10
Replacing J6-axis
Motor, Reducer
M6
motor
M6
reducer
81
M5X20 (4 pcs)
Loctite 262
9.0 Nm (92 kgfcm)
Washer M5 (4 pcs)
J6 housing
A2907208X501
J6axis motor
Spring pin
f5X20 (2 pcs)
Oring
M6
Fig.6.10 (a) Replacing J6axis motor and reducer (ARC Mate120/S12)
M5X12 (4 pcs)
Loctite 262
Washer M5 (4 pcs)
M3X8
Loctite 242
2.0 Nm (20 kgfcm)
Washer M3
J6axis motor
Packing
Wave generator
J6axis reducer
Washer
A2907208X532
M6
Fig.6.10 (b) Replacing J6axis motor and reducer (ARC Mate120/S12)
82
It is possible to release a brake when the robot power is down, using The
brake release unit (option). Then it is possible to change the robot
posture which you want.
Please observe NOTE 13.
NOTE
1. When release J2 or J3 motor (M2 or M3) brake, lift
up the robot by crane to that shown in Fig. 6.8.
2. When release motor brake, apply a tensile force the
sling enough.
3. Dont release plural brake at the same time.
Fig. 6.11 Releasing brake
6.11
Releasing Brake
B80485E/03 7. PIPING AND WIRING
83
7
PIPING AND WIRING
7. PIPING AND WIRING B80485E/03
84
Fig. 7.1. shows the internal piping diagram of the mechanical unit.
Fig.7.1 Piping diagram (ARC Mate120/S-12)
7.1
Piping
85
Wiring diagrams of mechanical unit are shown in Fig. 7.2 (a) and 7.2 (b).
Fig.7.2 (a) Mechanical unit wiring diagram (A05B1208H201)
Fig. 7.2 (a) Mechanical unit wiring diagram (A05B1208H211)
Fig. 7.2 (a) Mechanical unit wiring diagram (A05B1208H301)
7.2
Wiring Diagram
86
Fig.7.2 (b) Mechanical unit wiring diagram (A05B1208H202)
Fig. 7.2 (b) Mechanical unit wiring diagram (A05B1208H222)
Fig. 7.2 (b) Mechanical unit wiring diagram (A05B1208H302)
87
Fig. 7.2 (c) shows wiring diagram for the MIG EYE cable (A05B1208
H921).
Fig. 7.2 (d) shows wiring diagram for the MIG EYE cable (A05B1208
H922).
Fig. 7.2 (c) Wiring diagram for the MIG EYE cable (A05B1208H921)
Fig. 7.2 (d) Wiring diagram for the MIG EYE cable (A05B1208H922)
88
Fig. 7.3. shows the installation diagram for the limit switches.
Option specification (330_ OT): A05B1208H312
Option specification (360_ OT): A05B1208H322
J3axis OT limit switch cable
K123
K122
K121
Cable
K107
SQ3
SQ2
SQ1
Fig.7.3 Limit switch installation diagram (ARC Mate120/S-12)
7.3
Limit Switch (Option)
Installation Diagram
89
Visually check the following:
1) Check whether connecting cables in the robots rotational part are dis-
torted or bent by the robot rotation.
2) Check whether the routing of the cables connected to the J2 and J3
axes is distorted or bent by the elbow motion.
3) Check whether the routing of the cables connected to the end effector
is suitable to the wrist motion or the service motion of the robot.
Fig. 7.4 (a) shows installation diagram for the cables in the mechanical
unit.
When the Diecasting cable (A05B1208H222) specified, the cable
within [ ] will be wired.
FIg. 7.4 (b) shows installation diagram for the cables in the mechanical
unit which is CE specifications.
Fig.7.4 (a) Mechanical unit cable installation diagram (ARC Mate120/S-12)
7.4
Cable Installation
Diagram
90
Fig. 7.4 (b) Mechanical unit cable installation diagram
FIg. 7.4 (b) (ARC Mate 120/S12) [CE specifications]
<Cable assy specification that this figure is applied to>
A05B1208H301
A05B1208H302
B80485E/03 8. REPLACING CABLES
91
8
REPLACING CABLES
A broken or damaged cable should be replaced as specified in
this section. When the pulse coder cable (K102, K202, K112,
K103, K108, K205) connector is removed, the motor loses its ab-
solute position. Perform the quick mastering (See 5.3) after re-
placing cables. If the pulse coder cable connector is discon-
nected and the motor had losed its absolute position, quick
mastering must be carried out after changing cable.
8. REPLACING CABLES B80485E/03
92
When mounting the replaced cables with clamps and tie wraps, clamp it
at the positions specified in Table 8.1 (a), Table 8.1 (b). Unless the cable
is clamped at the specified positions, the cable may be broken due to
excessive sag or tention.
Table 8.1 (a) Cable clamping positions (ARC Mate120/S-12)
8.1
Cable Clamping
93
Table 8.1 (b) Extension cable clamping positions (ARC Mate 120)
94
1 Remove the J3axis cover (A2907208X403) from the J3 hous-
ing (A2907208X401) as shown in Fig. 8.2(a).
2 For K102, remove the connector cap from the end effector (EE),
then remove the EE connector from the EE plate.(See Fig.8.2(b)).
3 Remove the cable K103 relay connector from the connector
clamp (A2907208X424), then remove the K101 (K201) and
K102 (K112) (K202) connectors from the connector clamp.
4 Cut the nylon bands at the connector clamp and the support.
Then, pull out the cables from the J3 housing (A2907207
X401).
5 Remove the arm cover (A2907208X326) and cover
(A2907208X325) from the J2 arm (A2907208X302) as
shown in Fig. 8.2(c) and Fig. 8.2(d).
6 Cut the nylon bands of the clamp (A2907208X324) and sup-
port 22 (A2907208X323), then pull out the cables from the J2
arm.
7 Remove the two clamps (A2907208X336), clamp 12
(A2907208X341), and clamp 21 (A2907207X325) as
shown in Fig. 8.2(e).
8 Remove cable cover 1 (A2907208X333), cable cover 2
(A2907207X334), and cable cover 3 (A2907207X335).
9 Cut the nylon bands at support 12 (A2907208X321) and sup-
port 21 (A2907208X322), then pull out the cables, one by one,
from the inside of the J2axis reducer (Refer to Fig. 8.2 (f)).
10 Disconnect the J1axis connector box from J1 base
(A2907208X201) , as shown in Fig. 8.2(g).
11 Remove clamp 11 (A2907208X228) from the J1axis connec-
tor box.
12 Cut the nylon bands of support 11 (A2907208X223), then pull
out the cables, one by one, from the inside of the J1axis reducer
toward the J1axis connector box.
13 Remove the cables from the J1axis connector box.
14 Install new cables by reversing the procedure above.Ensure that
the cables are neither too tight nor too slack. Refer to the cable
clamp positions, indicated by the marking tapes, as shown in Fig.
8.2(a) through Fig. 8.2(g).
15 Perform quick mastering as explained in Section 5.3.
8.2
Replacing Cables
1) Replacing cable K101
(K201) and K102 (K112)
(K202)
95
Nylon band
J2 arm
A2907208X302
Nylon band
J3 cover
A2907208X403
Washer M6 (12 pcs)
Connector clamp
A2907208X424
Support
A2907208X424
J3 housing
A2907208X401
Support
A2907208X422
Fig.8.2 (a) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S12)
EE connector
M3X5 (4 pcs)
Nylon band
Connector cap
EE plate
A2907208X427 (or X426)
EE relay connector (K112)
Support
A2907208X422
J3 housing
A2907208X401
Fig.8.2 (b) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S12)
96
Fig. 8.2 (c) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S12)
Fig. 8.2 (d) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S12)
97
Cable cover 1
A2907208X333
M10X65 (11 pcs)
(Loctite 262)
Washer M10 (11 pcs)
M4X10
(Loctite 262)
Clamp
A2907208X336
Cable cover 2
A2907208X334
M6X20 (2 pcs)
Washer M6 (2 pcs)
Clamp
A2907207X325
Cable cover 3
A2907208X335
Clamp
A2907208X336
M4X10
(Loctite 262)
Clamp
A2907208X341
M6X20 (2 pcs)
Washer M6 (2 pcs)
Fig.8.2 (e) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S12)
Fig.8.2 (f) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S12)
98
J1 base
A2907208X201
Clamp 11
A2907208X288
J1axis connector box
M6X10 (2 pcs)
Washer M6 (2pcs)
M8X10 (4 pcs)
M6X20 (2 pcs)
Washer M6 (2pcs)
Support 11
A2907208X223
Fig.8.2 (g) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S12)
1 Remove J3 axis cover (A2907208X403) from the J3 housing
(A2907208X401).
2 Disconnect the K104(#J3) and K105(#J3) relay connectors from
the connector clamp (A2907208X424) as shown in Fig. 8.2(a).
3 Cut nylon band at connector clamp.
4 Remove the J1axis motor connectors, then pull out the cables.
5 Install new cables by reversing the procedure above.
1 Remove J3 axis cover (A2907208X403) from the J3 housing
(A2907208X401).
2 Disconnect the K104(#J4) [K204] and K105 (#J4) [K205] relay
connectors from the connector clamp (A2907208X424) as
shown in Fig. 8.2(a).
3 Cut nylon band at connector clamp.
4 Remove the J4axis motor connectors, then pull out the cables.
5 Install new cables by reversing the procedure above.
2) Replacing cable
K104(#J3),and K105(#J3)
3) Replacing cable K104(#J4)
[K204] and K105(#J4)
[K205]
99
1 Remove the J3axis cover (A2907208X403) from the J3 hous-
ing (A2907208X401), as shown in Fig. 8.2(a).
2 Remove the cable K103 relay connector from the connector
clamp (A2907208X424), as shown in Fig. 8.2(a) and cut the
nylon bands of the connector clamp.
3 Remove the J52 cover from the J3 arm as shown in Fig.8.2(h).
4 Remove the J5axis motor cable connector and M6M, M6P relay
connector from clamp J5 (A2907208X526), then pull out cable
K103 from the J3 arm.
5 Install a new K103 cable by reversing the procedure above. En-
sure that the cables are neither too tight nor too slack. Refer to
the cable clamp positions, indicated by the marking tapes, as
shown in Fig. 8.2(g).
Install a new packing (A2907208X525) to prevent grease from
leakage.
1 Remove the J52 cover from the J3 arm (see Fig. 8.2 (h)).
2 Remove relay connector M6M and M6P from the clamp J5
(A2907208X526) and cut off the nylon band.
3 Remove the clamp J61 (A2907208X527) from the J52 cov-
er (A2907208X503) and cut off the nylon band.
4 Take out J6axis motor, referring to item 6.10. Remove the cable
relayed at the sheet (A2907208X529), remove the clamp J62
(A2907208X528) from the J6 housing, and cut off the nylon
band.
5 Extract cable K108 from the J6 housing, then from the J52 cov-
er.
6 Install a new K108 cable by reversing the procedure above. En-
sure that the cables are neither too tight nor too slack. Refer to
the cable clamp positions, indicated by the marking tapes, as
shown in Fig. 8.2(g).
Install a new packing (A2907208X525) to prevent grease from
leakage.
1 Remove the connector cap of EE (end effector) and EE connector
from the EE plate. (see Fig. 8.2 (b)).
2 Pull out the relay connector of cable K109 from the support
(A2907208X422).
3 Install a new cable by reversing the procedure above.
100
Marking tape
Details of assembly X527 and X528
Nylon band
Details of assembly X529
Nylon band
Clamp J5
A2907208X526
J3arm
A2907208X402
M5X20 (2 pcs)
Washer M5 (2 pcs)
Packing
A2907208X525
Clamp J61
A2907208X527
M6X16 (6 pcs)
Washer M6 (6 pcs)
J52cover
A2907208X503
Support
A2907208X530
Ring
A2907208X521
Clamp J62
A2907208X528
M4X8 (1 pcs)
Washer M4 (1 pcs)
Spring pin
f5X20 (2 pcs)
Sheet
A2907208X529
M5X20 (4 pcs)
(Loctite 262)
Washer M5 (4 pcs)
M4X6 (2 pcs)
Washer M4 (2 pcs)
Details of assembly X526
Nylon band Marking tape
M5M
M5P
Fig.8.2 (h) Replacing cable K103, K108
101
When the MIG EYE cable (A05B1208H921) is specified, cable K132
is added.
Refer to the cable clamp positions, indicated by the marking tapes, as
shown in Fig. 8.2 (i1) and Fig. 8.2 (i2).
When the MIG EYE cable (A05B1208H922) is specified, cable K131
to K133 are added.
Refer to the cable clamp position, indicated by the marking tapes, as
shown in Fig. 8.2 (j1) and Fig. 8.2 (j2).
Fig. 8.2 (i1) Replacing the MIG EYE cable (A05B1208H921) (ARC Mate 120)
7) Replacing additional cable
102
Fig. 8.2 (i2) Replacing the MIG EYE cable (A05B1208H921) (ARC Mate 120)
103
Fig. 8.2 (j1) Replacing the MIG EYE cable (A05B1208H922) (ARC Mate 120)
104
Fig. 8.2 (j2) Replacing the MIG EYE cable (A05B1208H922) (ARC Mate 120)
105
1 Remove the LS box (A2907208X338) from the J2 base
(A2907208X301) as shown in Fig. 8.3(a).
2 Remove the J1axis OT limit switch (A05B1208D103) from
the LS box.
3 Remove a connector relayed in the cable cover 2 and cut the nylon
band at the clamp (A2907208X340).
4 Take out the bush from J2 base and pull out the cable.
5 Mount the new limit switch, reversing the above procedure.
6 Check that the limit switch operates accurately at the overtravel
position.
7 Check that the limit switch does not operate within the J1-axis
motion range.
J2 base
A2907208X301
Plate
A2907201X347
LS box
A2907208X338
M6X10 (2 pcs)
Washer M6 (2 pcs)
M4X25 (2 pcs)
Nut lock 1401
Washer M4 (2 pcs)
Limit switch (with cable)
A05B1208D103
Clamp
A2907208X340
Bush
Nylon band
SQ1
Fig.8.3 (a) Replacing J1-axis limit switch (ARC Mate120/S-12)
8.3
Replacing Limit
Switch(Option)
1) J1axis OT limit switch
(A05B1208D103) SQ1
106
1 Remove the LS plate (A2907208X327) from the J2 arm
(A2907208X302) as shown in Fig. 8.2(b) .
2 Remove the relay connector in J2 arm as shown in Fig.8.3 (b).
LS plate..
4 Pull out the bush from the J2 arm and extract the cable.
5 Mount the new limit switch reversing the above procedure.
position.
7 Check that the limit switch does not operate within the J2-axis
motion range.
M4X25 (2 pcs)
Nut lock 1401
Washer M4 (2 pcs)
Bush
A05B1208D104
Plate
A2907201X347
LS plate
A2907208X327
M6X10 (2 pcs)
Plain washer M6
(2 pcs)
Washer M6
(2 pcs)
SQ2
Fig.8.3 (b) Replacing J2axis limit switch (ARC Mate120/S12)
(A05B1208D104) SQ2
107
1 Remove the LS plate (A2907208X328) from J2 arm
(A2907208X302) as shown in Fig.8.3 (c).
2 Remove relay connector in J2 arm, referring to Fig. 8.2(b).
the LS plate.
4 Remove bush from J2 arm and pull out cable.
5 Mount the new limit switch, reversing the above procedure.
position.
7 Check that the limit switch does not operate within the J3axis
motion range.
M4X25 (2 pcs)
Nut lock 1401
Washer M4 (2 pcs)
M6X10 (2 pcs)
Washer M6 (2 pcs)
Bush
Plate
A2907201X347
A05B1208D105
LS Plate
A2907208X328
SQ3
Fig.8.3 (c) Replacing J3axis limit switch (ARC Mate120/S12)
(A05B1208D105) SQ3
108
Limit switch relay cable
A6604003T242
Nylon
band
Fig.8.3 (d) Replacing J2 and J3axis limit switch (ARC Mate120/S12)
B80485E/03
9. OPTIONS
109
9
OPTIONS
9. OPTIONS
B80485E/03
110
Fig. 9.1 shows how to assemble the cover option.
(Assembly)
1 Secure the support (A2907208X339) to the J2 base
(A2907208X301) using four M6X10 bolts.
2 Secure the J2 cover (A2907208X303) to the support using six
M6X10 button bolts.
To remove the cover, reverse the assembly procedure above.
M6X10 button bolt (6 pcs)
J2 cover
A2907208X303
When the cover option
is specified
Specification:
A05B1208J401
Support
A2907208X339
J2 base
A2907208X301
M6X10 (4 pcs)
M6 washer (4 pcs)
Fig. 9.1 Cover Option (ARC Mate 120/S12)
9.1
Cover Option
(Specification:
A05B1208J401)
II. CONNECTION
B80485E/03 1. ROBOT INTERFERENCE AREA
113
1
ROBOT INTERFERENCE AREA
Fig. 1(a) and (b) show the external dimensions of the robot. Fig. 1 (e)
shows the external dimensions of the robot with MIG EYE. When
installing peripheral devices, take care that they do not interfere with the
motion of robot body. For installation, use the 4-18 hole on the base.
(See 3.2)
Fig. 1 (c) and (d) shows the robot operational diagram.
Fig. 1 (f) and (g) shows the robot operational diagram with MIG EYE.
Motion range of J5axis center
COVER
(OPTION)
With FANUC Flange adaptor
J5axis center
Fig.1 (a) Mechanical unit external dimensions (ARC Mate120/S-12)
1. ROBOT INTERFERENCE AREA B80485E/03
114
J2axis rotation
interference area
Motion range of
J5axis center
Fig.1 (b) Mechanical unit external dimensions (ARC Mate120/S-12)
B
8
0
4
8
5
E
/
0
3
1
.

R
O
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T

I
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T
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5
F
i
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.
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(
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r
a
t
i
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l

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t
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-
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.

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(
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e
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0
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-
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B80485E/03 1. ROBOT INTERFERENCE AREA
117
Fig. 1 (e) Mechanical unit external dimensions (ARC Mate 120/S12 with MIG EYE)
1
.

R
O
B
O
T

I
N
T
E
R
F
E
R
E
N
C
E

A
R
E
A
B
8
0
4
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0
3
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.
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(
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.

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9
F
i
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.
1

(
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i
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)
2. EQUIPMENT MOUNTING TO ROBOT B80485E/03
120
2
EQUIPMENT MOUNTING TO ROBOT
B80485E/03 2. EQUIPMENT MOUNTING TO ROBOT
121
Fig. 2.1(a) shows the end effector mounting face at the tip of the wrist.
Fit the end effector by using the f50H7 rabbet or the f25H7 rabbet, then
position the end effector by using the 4f6H8 reamed holes. Use the
4M6 tapped holes to secure the end effector. Use M6 bolts of a length
that does not exceed the depth (10 mm) of the tapped holes.
ISO Flange
4M6 depth 10
equally spaced on
circumference f 40
4f6H7
equally spaced on
circum ference f40
+0.012
0
depth 10
Fig. 2.1(a) Mounting Surface for End Effector of ISO Flange Type
(ARC Mate 120/S12)
Fig. 2.1(b) shows the end effector mounting face at the tip of the wrist
used when the FANUC flange adaptor (option specification:
A05B1207J001) is being used. Fit the end effector by using the f32H8
rabbet or the f60H7 rabbet, then position the end effector by using the
4f6H8 reamed holes. Use the 4M6 tapped holes to secure the end
effector. Use M6 bolts of a length that does not exceed the depth (8 mm)
of the tapped holes.
FANUC Flange Adaptor
4M6 depth 8
equally spaced on
circumference f 50
4f6H8
equally spaced on
circumference f 50
+0.018
0
depth 8
Fig. 2.1(b) Mounting Surface for End Effector when the FANUC Flange
Adaptor is Used (ARC Mate 120/S12)
2.1
End Effector
Mounting Face to
Wrist
ISO flange type
(standard)
FANUC flange
adaptor(option)
122
There are four mounting faces of the equipment for the floor mount type
robot as shown in Fig. 2.2 (a), and four for the upside-down mount type
robot.
NOTE
1. When equipment is mounted on equipment
mounting face A, B, C, and D, its center of gravity
must be within the hatched areas shown in Fig.
2.2(b).
2. The masses of the equipment fitted to the
equipment mounting faces must satisfy all the
requirements below.
1) W + A v 12 (kg)
2) W + A + B + C v 32 (kg)
3) W + A + B + C + D v 72 (kg)
W: Mass of the end effector mounting face (kg)
A: Mass of equipment mounting face A (kg)
B: Mass of equipment mounting face B (kg)
C: Mass of equipment mounting face C (kg)
D: Mass of equipment mounting face D (kg)
2.2
Equipment Mounting
Face
123
2M8 through hole
Rotating
center
of J1axis
Equipment mounting face D
Cover interference
Rotating cen-
ter of J1axis
Equipment mounting D (Mounting cover option)
4M6
depth 10
Equipment mounting
face B
2M6
depth 8
Equipment mounting A
Equipment mounting C
3M6
depth 10
Fig.2.2 (a) Equipment mounting face (ARC Mate120/S12)
124
Equipment mounting face D
Equipment mounting face B
Equipment mounting face A
Equipment
mounting face C
Fig.2.2 (b) Positions of the center of gravity on the equipment mounting faces (ARC Mate 120/S12)
125
Within the robots mechanical unit, an air pipe is provided; its inlet at the
J1axis connector box, and its outlet at the J3 housing. The piping route
is shown in Fig. 7.1, of the part explaining maintenance. The inlet and
outlet joints of the piping are of the PT3/8 female type. No mating joints
are provided. It is the responsibility of the user to prepare mating joints
that match tubes to be used.
2.3
End Effector Air Pipe
126
The J3 housing has an end effector connector to enable connection to
peripheral equipment. Fig. 2.4(a) and Fig. 2.4(b) show the pin
assignment of the end effector connectors. For details, including the
setting of common input signals, refer to the maintenance manual of the
RJ, RJ2 controller.
Mechanical unit (K102)
EE
End
effector
Fig. 2.4(a) End Effector Signal Pin Assignment (A05B1208H201)
Fjig. 2.4(a) End Effector Signal Pin Assignment (A05B1208H211)
Fjig. 2.4(a) End Effector Signal Pin Assignment (A05B1208H301)
Mechanical unit (K112, K202)
End
effector
Fig. 2.4(b) End Effector Signal Pin Assignment (A05B1208H202)
2.4
End Effector I/O
Signals (RDI/RDO)
127
Fig. 2.4 (c)
Fig. 2.4 (c) shows the pin assignments of the end effector.
128
Table 2.5 lists wrist load specifications.
The conditions given in the table should be strictly adhered to when
attaching the end effector to the wrist.
Table2.5 Wrist load (ARC Mate 120 / S12)
Allowable moment of J4 axis M
4
2.8 kgfm
27 Nm
5
2.0 kgfm
20 Nm
6
1.2 kgfm
12 Nm
Allowable inertia of J4 axis J
4
7.7 kgfcms
2
0.75 kgm
2
5
4.9 kgfcms
2
0.48 kgm
2
6
0.78 kgfcms
2
0.077 kgm
2
NOTE
The values given for the load specifications are those for the conditions at the center of rotation.
2.5
Wrist Load
Specifications
129
Fig. 2.5 (a) to Fig. 2.5 (c) show the wrist load specifications. Load
specifications are given to ensure that parameter values come within the
range shown in the plot below.
Fig 2.5 (a) J4axis load condition (ARC Mate 120 / S12)
Fig 2.5 (b) J5axis load condition (ARC Mate 120 / S12)
130
Fig 2.5 (c) J6axis load condition (ARC Mate 120 / S12)
B80485E/03 3. TRANSPORTATION AND INSTALLATION
131
3
TRANSPORTATION AND INSTALLATION
3. TRANSPORTATION AND INSTALLATION B80485E/03
132
1 Remove the transit stopper (red) from the J1axis.
2 After turning on the control unit, move the J3axis, by joint feed,
in the positive (+) direction until the J3axis transit stopper,
shown in box 3.1(a), can be removed.
3 Move the J2axis, by joint feed, in positive (+) direction, until
the J2axis transit stopper can be removed.
4 Remove the transit stoppers (red) from the J2axis and J3axis.
This completes the preparation.
NOTE
If an over travel alarm is issued in step 2 , hold down the shift
key and press the alarm release key. Then, while still
holding down the shift key, move the J3axis, by joint feed,
in the positive (+) direction until the J3axis overtravel is
released.
The robot is transported by lifting. Mount the components for transporta-
tion and lift it by attaching a rope to three M12 eye bolts.
After installation, remove the components used for transportation and the
stop. (Refer to Fig. 3.1(a))
The stops for preventing the axes from rotating during shipping are
painted in red. Be sure to remove them before operating the robot.
3.1
Transportation
1) Preparation prior to
installation
2) Transportation by crane
133
Fig.3.1 (a) Transportation using a crane (ARC Mate120/S-12)
The robot can also be transported using a forklift. (Refer to Fig. 3.1 (b))
A forklift bracket can be provided as an option. (Option specification:
A05B1208J051)
(When using a forklift)
1 Position the robot to the transit attitude, then turn off the control
unit.
2 Disconnect the cables from the J1 base connector panel.
3 Fit a transit stopper for the J1axis to prevent the J1axis from
rotating.
4 Secure forklift brackets to both sides of the J1 base, using from
M1230 bolts and four M12 plain washers on each side.
5 Use the right and lefthand square holes to transport the robot.
6 Remove the right and left forklift brackets.
7 Remove the transit stopper from the J1axis.
3) Transportation by forklift
134
Fig.3.1 (b) Transportation using a folklift (ARC Mate120/S-12)
135
When storage the robot, be sure to change the attitude of the robot to that
shown in Fig.3.1.
3.2
Storage
136
Fig. 3.3 (a) shows dimensions of robot base.
Front
(Pin)
J1axis rotating
center
4f18 throughhole
f28 facing, depth 5
(Through hole for foundation bolt)
2f10H8
(Pinhole for positioning)
+0.022
0
Fig.3.3 (a) Dimensions of robot base (ARC Mate120/S12)
3.3
Installation
137
Fig. 3.3(b) shows an example of robot installation. Secure an installation
plate to the floor using four M20 chemical anchors (strength class: 4.8).
Then, secure the robot base to the installation plate using four M16X35
bolts (strength class: 12.9).
If teaching compatibility is needed when the mechanical unit of the robot
is replaced, use the two f10H8 pin holes for positioning.
NOTE
It is the customers responsibility to prepare positioning
pins, anchor bolts, and the installation plate.
(Pin)
Front
J1axis
rotation
center
Installation plate
2f10H8
(Pin hole for positioning)
+0.022
0
Robot fixing bolts
M16X35 (4 pcs)
Strength class: 12.9
Tightening torque:
313.6 Nm (32 kgfm)
Chemical anchor
M20 (4 pcs)
Strength class: 4.8
Tightening torque:
186.2 Nm (19 kgfm)
Robot base plate
Installation plate
Fig. 3.3(b) Example Installation (ARC Mate 120/S12)
138
Fig. 3.3 (c) shows the outer dimension the BASE option (A05B1208
J055). Attached bolt M16X30 (4 pcs.), washer M16 (4 pcs.) and spring
pin f10X30 (2 pcs.) are used to install the robot to the base.
Fig. 3.3 (c) Outer dimension of BASE option (A05B1208J055) (ARC Mate 120/S12)
139
Fig. 3.3 (d) and Table 3.3 (d) show force and moment applied to the base
plate during stillness, acceleration or deceleration, and emergency stop
state.
Fig. 3.3 (d) Force and moment
Table 3.3 (d) Force and moment
Condition Vertical
moment
Mv [kgfm]
(Nm)
Force in
vertical
direction
Fv [kgf] (N)
Horizontal
moment
M [kgfm]
(Nm)
Force in
horizontal
direction
F [kgf] (N)
During stillness [ 92] ( 902) [302] (2960) [ 0] ( 0) [ 0] ( 0)
During accel
eration or de
celeration
[259] (2538) [414] (4057) [177] (1735) [168] (1646)
celeration
During Emer
gency stop
[411] (4028) [529] (5184) [200] (1960) [181] (1774)
140
Fig. 3.4 (a) shows the maintenance area.
Maintenance area
Mastering area
Fig.3.4 (a) Maintenance area (ARC Mate120/S-12)
Attitude of robot on mastering is shown in Fig. 3.4(b). Consequently,
reserve space for this attitude with J1=0 degree.
Mastering Jig
Specification:
A05B1208J053
ISO flange
Mastering attitude
J1 = 0_
J2 = 91.523_
J3 = 157.396_
J4 = 0_
J5 = 22.670_
J6 =0_
Mastering attitude
J1 = 0_
J2 = 90.347_
J3 = 155.586_
J4 = 0_
J5 = 24.480_
J6 =0_
Mastering Jig
Specification:
A05B1208J052
Flange adaptor
(optional)
Fig.3.4 (b) Mastering attitude (ARC Mate120/S-12)
3.4
Maintenance Area
141
When laying a cable between a robot controller and a robot body,
customers shall prepare a cable duct, etc.
The mechanical unit is shipped with connecting cables unattached (The
cables are connected to the controller.). Connect the cables shown in Fig.
3.5 to the connector box of the mechanical unit. When connecting, take
care not to damage the cables.
Connector box of
mechanical unit
Power line cable
Signal cable Earth cable
M8X10
Fig.3.5 Cable connection board of robot mechanical unit
(ARC Mate 120/S12)
3.5
Assembly During
Installation
142
Fig. 3.6(a) shows the air piping of a robot.
When the optional air control set is used, an air pipe for connecting the
mechanical unit and air control set is also provided. To install the air
control set, the customer is to prepare an air control set mounting section
with tapped holes for mounting, as shown in Fig. 3.6(b).
PT3/8
Air control set (option)
Specification: A05B1302J011
Straight joint
PT3/8
Elbow
PT3/8
3m air hose
(Outer diameter: 10 mm, Inner diameter: 6.5 mm)
To be prepared by the customer
Fig.3.6 (a) Air piping (ARC Mate120/S-12)
Fill the oiler of the air control set with turbine oil (#90 to #140) to the
specified level. Preparation of the mounting bolts is the customers
responsibility.
4M6
63
90
Oil inlet
Adjustment knob
Oil misting check
Oiler
Filter
Regulator
pressure
setting handle
Pressure gauge
Fig.3.6 (b) Air control set (ARC Mate120/S-12)
3.6
Air Piping
143
Fig. 3.6 (c) shows the internal piping diagram of the mechanical unit.
Fig. 3.6 (c) Piping diagram (ARC Mate 120/S12)
144
Installation condition of the robot is shown in table 3.7.
Table3.7 Installation specifications (ARC Mate120/S-12)
Item Specifications
Type Articulated type
Controlled axes 6 axes (J1, J2, J3, J4, J5, J6)
Reach 1605 mm
Installation Floor, Upsidedown (Wall & Angle mount)
(Note 1)
Motion
range
J1 axis 5.76 rad (2.36 rad/sec) 330 (135 /sec)
(Note 2)
(Maximum
speed)
J2 axis 4.63 rad (2.09 rad/sec) 265 (120/sec)
Max. load capacity at wrist 12 kg
Allowable J4 axis 27 Nm 2.8 kgfm
load
moment at
J5 axis 20 Nm 2.0 kgfm
moment at
wrist J6 axis 12 Nm 1.2 kgfm
Allowable J4 axis 0.75 kgm
2
7.7 kgfcms
2
load inertia
at wrist
J5 axis 0.48 kgm
2
4.9 kgfcms
2
at wrist
J6 axis 0.077 kgm
2
0.78 kgfcms
2
Drive method Electric servo drive by AC servo motor
Repeatability "0.1 mm
Weight (Mechanical unit) Approx. 230 kg
Installation environment Ambient temperature: 0 45 C
Ambient humidity:
Normally 75% RH or less
Short term (within one month)
Max. 95% RH
Height: Up to 1,000 meters above the sea level
requires, no particular provision for attitude.
Vibration: 0.5 G or less
*No dew, nor frost allowed.
*No corrosive gas allowed. (Note 3)
Air pressure Pressure 0.49 0.69 MPa 57 kg/cm
2
G
(Preset pressure 0.49 MPa 5 kg/cm
2
G)
Consumption Maximum peak: 150Nl/min (Note 4)
3.7
Installation
specifications
145
NOTE
1. Under the installation condition within (), the J1axis
motion range and the max. speed will be limited.
2. J1axis 6.28 rad (360) rotation is option.
3. If a robot is used in an environment with high
vibration, dust, or density of cutting oil, consult the
service representative.
4. This value indicates the capacity of the air control
set. Adjust the air flow to be less than this value.
5. J2 cover is option.
APPENDIX
B80485E/03 A. SPARE PARTS LIST
145
A
SPARE PARTS LIST
Table 1 (a) Cable list (ARC Mate120/S-12)
(A) 6axis brake (RDIX1, RDOX1) Nomal Cable: A05B1208H201
Cable Specifications Remarks
K101 A05B1208D101 M1, M2, M3, M4, M5, M6 power
K102 A6608009T850 M1, M2, M3, M4, M5, M6 pulse
coder, DI/DO
K103 A6604003T241 M5 M6, power, pulse coder relay
K104 A6604003T243#J3 M3 power relay
K204 A6604003T410 M4 power relay
K105 A6602004T223#J3 M3 pulse coder relay
K205 A6602004-T700 M4 pulse coder relay
K106 A05B1207D102 OT Short circuit
K108 A6604003T244 M6 power ,pulse coder
(B) 6axis brake (RDIX8, RDOX8) Nomal Cable: A05B1208H202
K112 A6608009T851 M1, M2, M3, M4, M5, M6 pulse
coder, DI/DO
K103 A6604003T241 M5, M6 power, pulse coder relay
K205 A6602004T700 M4 pulse coder relay
K106 A05B1207D102 OT short circuit
K108 A6604003T244 M6 power ,pulse coder relay
K109 A6604003T245 EE relay
A. SPARE PARTS LIST B80485E/03
146
(C) 6axis brake (RDIX1, RDOX1) Extension Cable: A05B1208H211
K102 A6608009T850 M1, M2, M3, M4, M5, M6 pulse
coder, DI/DO
K108 A6604003T244 M6 power, pulse coder relay
(D) 6axis brake (RDIX8, RDOX8) Diecasting Cable: A05B1208H222
K201 A05B1208D201 J1, J2, J3, J4, J5, J6 power
K202 A6608010T128 J1, J2, J3, J4, J5, J6 pulse coder,
DI/DO
K103 A6604003T241 J5, J6 power, pulse coder relay
A6604003T243#J3 J3 power relay
K104
A6604003T243#J4 J4 power relay
K105 A6602004T223#J3 J3 pulse coder relay
K105 A6602004T223#J4 J4 pulse coder relay
K106 A05B1207D102 OT short circuit
K108 A6604003T244 J6 power, pulse coder relay
K109 A6604003T245 EE relay
(E) 6axis brake (RDIX1, RDOX1) Normal cable (for CE):
A05B1208H301
K102 A6608009T850 M1, M2, M3, M4, M5, M6 pulse
coder, DI/DO
B80485E/03 A. SPARE PARTS LIST
147
(F) 6axis brake (RDIX8, RDOX8) Normal cable (for CE):
A05B1208H302
K112 A6608009T851 M1, M2, M3, M4, M5, M6 pulse
coder, DI/DO
K109 A6604003T245 EE relay
(G) Limit switch cable (option)
K107 A6604003T242 OT relay
K121 A05B1208D103 J1 OT limit switch
(H) MIG EYE cable (without ROTATOR) (option): A05B1208H921
K132 A6608010T939 Sensor cable
A6608009T708#L300R0 Ground cable
(I)MIG EYE cable (with ROTATOR) (option): A05B1208H922
K131 A6602004T638 Power cable
K132 A6608010T939 Sensor cable
K133 A6608010T940 Pulse coder cable
A6608009T708#L300R0 Ground cable
A. SPARE PARTS LIST B80485E/03
148
Table 1 (b) Motor (ARC Mate 120/S12)
ARC Mate 120 A05B1208B201
S12 A05B1208B202
Specifications Axis Remarks
A06B0163B175 J1 a M9 with brake
A06B0163B175 J2 a M9 with brake
A06B0373B175 J3 a 2 with brake
A06B0371B175 J4 a 1 with brake
A06B113B178#0008 J5 a 0.5 with brake
A06B113B178#0008 J6 a 0.5 with brake
Table 1 (c) Cover (ARC Mate 120/S12)
Specifications Remarks
A05B7208J401 J2axis motor cover (option)
A05B7208X403 J3axis cover
Table 1 (d) Battery (ARC Mate 120/S12)
Specifications Remarks Qty.
A98L00310005 1.5 V size D 4
Table 1 (e) Grease (ARC Mate 120/S12)
Name Specification Remarks
MoryWhite
RE No. 00
A98L00400119#2.7KG For J1, J2, J3, J5axis
SK3 A98L00400110#1KG For J4, J6axis
B80485E/03 B. MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM
149
B
MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM
B
.

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l

c
o
n
n
e
c
t
i
o
n

d
i
a
g
r
a
m

(
A
R
C

M
a
t
e
1
2
0
/
S
-
1
2
)

(
A
0
5
B
1
2
0
8
H
3
0
2
)
B
.

M
E
C
H
A
N
I
C
A
L

U
N
I
T

I
N
T
E
R
N
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M
B
8
0
4
8
5
E
/
0
3
1
5
8
F
i
g
.

2

(
g
)

I
n
t
e
r
n
a
l

c
o
n
n
e
c
t
i
o
n

d
i
a
g
r
a
m

(
A
R
C

M
a
t
e
1
2
0
/
S
-
1
2
)

(
A
0
5
B
1
2
0
8
H
9
2
1
)
F
i
g
.

2

(
g
)

I
n
t
e
r
n
a
l

c
o
n
n
e
c
t
i
o
n

d
i
a
g
r
a
m

(
A
R
C

M
a
t
e
1
2
0
/
S
-
1
2
)

(
A
0
5
B
1
2
0
8
H
9
2
2
)
Index
B62764EN/01
i1
Numbers
1year checks, 27
3month checks, 27
3year check, 30
3year checks, 27
A
Adjusting, 38
Adjusting J5axis bevel gear backlash, 59
Adjusting limit switches and dogs (Option), 39
Air piping, 138
Assembly during installation, 137
C
Cable clamping, 88
Cable installation diagram, 85
Configuration, 19
Confirming mastering, 58
Cover option (Specification: A05B1208J401), 106
D
Daily checks, 25
E
End effector air pipe, 121
End effector I/O signals (RDI/RDO), 122
End effector mounting face to wrist, 117
Equipment mounting face, 118
Equipment mounting to robot, 116
G
Greasing, 29
I
Installation, 132
Installation specifications, 140
J
J1axis drive mechanism, 20
J1axis stroke modification (option), 44
J5axis and J6axis Drive Mechanism, 22
L
Limit switch (option) installation diagram, 84
Lubricating condition checks, 28
M
Maintenance area, 136
Maintenance tools, 27
Major Component Specifications, 23
Mastering using jig, 52
Mastering using zero degree position, 50
Mechanical unit internal connection diagram, 149
O
Operator safety, 6
Options, 105
P
Peripheral device safety, 8
Piping, 80
Piping and wiring, 79
Precautions for work, 10
Preventive maintenance, 24
Problem and causes, 34
Q
Quick mastering, 48
R
Releasing brake, 78
Replacing and adjusting parts, 61
Replacing battery, 31
Replacing cables, 87, 90
Replacing J1 and J2axis motor M1 , M2 , 62
Replacing J1Axis reducer, 64
Replacing J2axis reducer, 67
Replacing J3axis motor M3 , 69
INDEX
B62764EN/01
i2
Replacing J5axis gear, 75
Replacing J6axis motor, reducer M6 , 76
Replacing limit switch, 101
Replacing parts and performing adjustments, 37
Robot interference area, 109
S
Safety for maintenance, 15
Safety precautions, 3
Safety speed control, 13
Spare parts list, 145
Storage, 131
T
Transportation, 128
Transportation and installation, 127
Troubleshooting, 32
W
Wiring Diagram, 81
Wrist load specifications, 124
Revision Record
FANUC Robot ARC Mate 120/S12 MAINTENANCE MANUAL (B80485E)
03 Dec., 95 @Addition of descriptions for CE marking.
02 Feb., 95
@RJ2 controller was added.
@Mastering procedure was changed.
@MIG EYE cable and user cable were added.
@Load setting for minimum time control was deleted.
@Diecasting cable list was added.
01 Aug., 94
Edition Date Contents Edition Date Contents

ArcMate 120 Mechaical Unit Mantenance

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ArcMate 120 Mechaical Unit Mantenance

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FANUC Robotics

R-J and R-J2 Controller

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