arcmate 120 mechaical unit mantenance

FANUC RoboticsR-J and R-J2 ControllerARC Mate 120/S-12 Mechanical Unit Maintenance Manual

MARAWAS1208403E B-80485E/03

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

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

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

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

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

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

www.fanucrobotics.com

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Copyright �2003 by FANUC Robotics America, Inc.All Rights ReservedThe information illustrated or contained herein is not to bereproduced, copied, translated into another language, or transmittedin whole or in part in any way without the prior written consent ofFANUC Robotics America, Inc.AccuStat�, ArcTool�, DispenseTool�, FANUC LASER DRILL�,KAREL�, INSIGHT�, INSIGHT II�, PaintTool�, PaintWorks�,PalletTool�, SOCKETS�, SOFT PARTS� SpotTool�,TorchMate�, and YagTool� are Registered Trademarks of FANUCRobotics.FANUC Robotics reserves all proprietary rights, including but notlimited to trademark and trade name rights, in the following names:AccuAir� AccuCal� AccuChop� AccuFlow� AccuPath�AccuSeal� ARC Mate� ARC Mate Sr. � ARC Mate System 1�ARC Mate System 2� ARC Mate System 3� ARC Mate System4� ARC Mate System 5� ARCWorks Pro� AssistTool�AutoNormal� AutoTCP� BellTool� BODYWorks� Cal Mate� CellFinder� Center Finder� Clean Wall� CollisionGuard�DispenseTool� F-100� F-200i� FabTool� FANUC LASERDRILL� Flexibell� FlexTool� HandlingTool� HandlingWorks�INSIGHT� INSIGHT II� IntelliTrak� Integrated Process Solution�Intelligent Assist Device� IPC -Integrated Pump Control� IPDIntegral Pneumatic Dispenser� ISA Integral Servo Applicator� ISDIntegral Servo Dispenser� Laser Mate System 3� Laser MateSystem 4� LaserPro� LaserTool� LR Tool� MIG Eye�MotionParts� NoBots� Paint Stick� PaintPro� PaintTool 100�PAINTWorks� PAINTWorks II� PAINTWorks III� PalletMate�PalletMate PC� PalletTool PC� PayloadID� RecipTool�RemovalTool� Robo Chop� Robo Spray� S-420i� S-430i�ShapeGen� SoftFloat� SOF� PARTS� SpotTool+� SR Mate�SR ShotTool� SureWeld� SYSTEM R-J2 Controller� SYSTEM R-J3 Controller� SYSTEM R-J3iB Controller� TCP Mate�TurboMove� TorchMate� visLOC� visPRO-3D� visTRAC�

WebServer� WebTP� YagTool�

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

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

Conventions

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

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

Safety-1

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

Safety-2

Safety is essential whenever robots are used. Keep in mind thefollowing factors with regard to safety:

� The safety of people and equipment� Use of safety enhancing devices� Techniques for safe teaching and manual operation of the

robot(s)� Techniques for safe automatic operation of the robot(s)� Regular scheduled inspection of the robot and workcell� Proper maintenance of the robot

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

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

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

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

CONSIDERINGSAFETY FOR YOURROBOTINSTALLATION

Keeping People andEquipment Safe

Using SafetyEnhancing Devices

Setting Up a SafeWorkcell

Safety-3

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

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

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

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

� Position all controllers outside the robot work envelope.

� Never rely on software as the primary safety element.

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

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

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

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

� Use interlocks.

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

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

Safety-4

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

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

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

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

� Program the robot to load and unload material safely.

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

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

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

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

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

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

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

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

Staying Safe WhileTeaching or ManuallyOperating the Robot

Safety-5

WARNINGNever bypass, strap, or otherwise deactivate a safety device,such as a limit switch, for any operational convenience.Deactivating a safety device is known to have resulted inserious injury and death.

� Know the path that can be used to escape from a moving robot;make sure the escape path is never blocked.

� Isolate the robot from all remote control signals that can causemotion while data is being taught.

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

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

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

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

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

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

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

� Make sure all safety provisions are present and active.

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

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

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

Staying Safe DuringAutomatic Operation

Safety-6

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

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

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

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

� If the robot is running in a pattern, do not assume it will continueto run in the same pattern.

� Never try to stop the robot, or break its motion, with your body.The only way to stop robot motion immediately is to press anEMERGENCY STOP button located on the controller panel,teach pendant, or emergency stop stations around the workcell.

When inspecting the robot, be sure to

� Turn off power at the controller.

� Lock out and tag out the power source at the controlleraccording to the policies of your plant.

� Turn off the compressed air source and relieve the air pressure.

� If robot motion is not needed for inspecting the electrical circuits,press the EMERGENCY STOP button on the operator panel.


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

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

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

Staying Safe DuringInspection

Staying Safe DuringMaintenance

Safety-7

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

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


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

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

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

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


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

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

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

Safety-8

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

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

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

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


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

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

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

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

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

KEEPING MACHINETOOLS ANDEXTERNALDEVICES SAFE

Programming SafetyPrecautions

Safety-9

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

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

� Use handshaking protocol to synchronize robot and externaldevice operations.

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

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

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

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

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

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

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

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

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

� Use circuit breakers to guard against electrical overload.

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

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

Mechanical SafetyPrecautions

KEEPING THEROBOT SAFE

Operating SafetyPrecautions

Programming SafetyPrecautions

Safety-10

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

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

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

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

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

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

ADDITIONALSAFETYCONSIDERATIONSFOR PAINT ROBOTINSTALLATIONS

Safety-11

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

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

This section provides information about the safety features that areincluded in the paint system and also explains the way the robotinteracts with other equipment in the system.The paint system includes the following safety features:

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

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

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

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

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

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

Paint System SafetyFeatures

Safety-12

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

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

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

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

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

WARNINGObserve all safety rules and guidelines to avoid injury.

WARNINGNever bypass, strap, or otherwise deactivate a safety device,such as a limit switch, for any operational convenience.Deactivating a safety device is known to have resulted inserious injury and death.

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

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

� Be aware of overlapping work envelopes of adjacent robots.

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

Staying Safe WhileOperating the PaintRobot

Safety-13

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

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

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

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

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

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


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

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

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

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

� Follow the procedures described in this manual.

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

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

Staying Safe WhileOperating PaintApplication Equipment

Safety-14

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

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

� Avoid any accumulation of combustible vapors or coatingmatter.

� Follow all manufacturer recommended cleaning procedures.

� Make sure all interlocks are operational.

� No smoking.

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

� Disable all air and paint pressure to bell.

� Verify that the lines are not under pressure.

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

� Paint robots operate in a potentially explosive environment. Usecaution when working with electric tools.

� When a maintenance technician is repairing or adjusting a robot,the work area is under the control of that technician. Allpersonnel not participating in the maintenance must stay out ofthe area.

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

Staying Safe DuringMaintenance

Safety-15

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

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

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

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

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

� When using vinyl resin observe the following:

- Wear eye protection and protective gloves during applicationand removal

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

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

� When using paint remover observe the following:

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

- Adequate ventilation is required. Overexposure could causedrowsiness.

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

B–80485E/03 GENERAL

GENERAL

This manual describes the maintenance and connection of the followingrobot (R–J controller or R–J2 controller) mechanical units.Make sure of the specification of mechanical unit when replacing parts.

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FANUC Robot ARCMate 120(All axes with brake)

ARC Mate 120 A05B-1208-B201

FANUC Robot S–12(All axes with brake)

S-12 A05B-1208-B202

Table 1(a) Specification of ARC Mate 120 / S–12

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B–80485E/03 GENERAL

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GENERAL B–80485E/03

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

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The attachment position for the mechanical unit specification number.

Table I Letters

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Table of ContentsB–80485E/03

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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 J6–axis Drive Mechanism 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Major Component Specifications 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. PREVENTIVE MAINTENANCE 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Daily Checks 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 3–month Checks 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 1-year Checks 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 3–year 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 J4–Axis Reducer 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Replacing J5-axis Motor M5 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 Replacing J5–Axis 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: A05B–1208–J401) 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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

B–80485E/03 1. CONFIGURATION

23

1 CONFIGURATION

Fig. 1 shows the configuration of the mechanical unit.

Fig. 1 Mechanical unit configuration (ARC Mate120/S-12)

NOTE1. 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

built–in brake this brake is on in the power off or in theemargency stop.

1. CONFIGURATION B–80485E/03

24

Fig. 1.1 shows the J1-axis drive mechanism.

The rotation of the AC servo motor αM9 is decelerated by the reducer androtates the J2-axis base. The J2-axis base is supported by the J1-axis basevia the reducer.

J1–axis AC servo motormodel αM9

J2–axis base

Input gear

ReducerJ1–axis base

A

A

Phase A–A

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 servomotor αM9 is decelerated by the reducer and rotates the J2-axis arm. TheJ2-axis arm is supported by the J2-axis base via the reducer.

J2–axis arm

Input gear

J2–axis AC servomotor model αM9

J2–axis base

Reducer

Phase B–B

B

B

M2


1.1J1-axis DriveMechanism



25

Fig. 1.3 shows the J3-axis mechanism. The rotation of the AC servomotorα2 is decelerated by the reducer and rotates the J3-axis unit. The J3-axisunit is supported by the J2-axis arm via the reducer.

Reducer

J3–axis housing

J3–axis AC servo motormodel �2

J2–axis arm

Input gear

J3–axis cover

M3


Fig. 1.4 shows the J4-axis drive mechanism. The rotation of the AC servomotor α1 is decelerated by the reducer and rotates J3-axis arm.

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

J3–axis housingReducer

Center gear

J4–axis AC servo motormodel �1

Input gear

J3–axis arm

M4




1. CONFIGURATION B–80485E/03

26

Fig. 1.5 shows the J5-axis and J6–axis drive mechanism. The rotation ofthe AC servomotor α0.5 is decelerated by the three steps gear of J5–axisand rotates the J6-axis unit. The rotation of AC servomotor α0.5 isdecelerated by the reducer of J6–axis and rotates the output flange.

J3–axis arm

J5–axis AC servomotor� 0.5

J6–axis AC servomotor �0.5

J6–axis reducer

Output flange

J5–axis gear (three steps)

M6

M5

Fig. 1.5 J5-axis and J6–axis drive mechanism (ARC Mate120/S-12)

1.5J5-axis and J6–axis Drive Mechanism

*Option for changing operation space


27

1) MotorARC Mate 120 (With all axes brake) A05B–1208–B201S–12 (With all axes brake) A05B–1208–B202

Specifications Axis Remarks

A06B–0163–B175 J1 αM9 with brake

A06B–0163–B175 J2 αM9 with brake

A06B–0373–B175 J3 α2 with brake

A06B–0371–B175 J4 α1 with brake

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

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

2) ReducerSpecifications Axis

A97L–0118–0948 J1

A97L–0118–0949 J2

A97L–0118–0950 J3

A97L–7208–T402 J4

A97L–1208–H001 J6

3) GearSpecification Axis

A290–7208–X211 J1, J2

A290–7208–X212 J1, J2

A290–7208–X411 J3

A290–7208–X412 J3

A290–7208–X413 J4

A290–7208–X414 J4

A290–7208–X511 J5

A290–7208–V515 J5

A290–7208–V501 J5

A290–7208–V502 J5

4) CoverSpecifications Remarks

A05B–1208–J401J2–axis motor cover (for floor mount) *Option

A290–7208–X403 J3–axis motor cover

5) StopperSpecifications Axis

A290–7208–X224 J1

A290–7208–X225 J1

A290–7208–X337 J1

A290–7208–X329 J2

A290–7208–X331 J2

1.6Major ComponentSpecifications

2. PREVENTIVE MAINTENANCE B–80485E/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.

B–80485E/03 2. PREVENTIVE MAINTENANCE

29

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

a) Before automatic operation

Table 2.1 Daily preventive maintenance checks (1/2)

Item Check items Check points

1 When aircontrol set iscombined.

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

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

2 Oiler oil mistquantity

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

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

4 Leakagefrom hose

Check the joints, tubes, etc. for leaks.

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

5 Cables used in mechanicalunit

Refer to section 8.

6 Vibration, abnormal noises,and motor heating

Check to see that each axis movessmoothly.

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

8 Peripheral devices for properoperation

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

9 J2/J3-axis brake Refer to 4.2.

2.1Daily Checks

2. PREVENTIVE MAINTENANCE B–80485E/03

30

Oil inlet Adjusting knob

Oiler mist amountcheck

Oiler

Regulatorpressure setting handle

FilterPressure gauge

Fig. 2.1 Air control set (option)

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

Table 2.1 Daily preventive maintenance checks (2/2)


1 Cleaning and checking eachpart

Clean each part and check componentparts for cracks and flaws.

B–80485E/03 2. PREVENTIVE MAINTENANCE

31

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

Table 2.2 Monthly preventive maintenance checks


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

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

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

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 maintenanceprocedures contained in this manual.

a) Measuring instrumentsInstruments Accuracy/Tolerance Applications

Dial gauge 1/100 mm Measurement of positioningand backlash.

Slide calipers 150 mm

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

2.23–month Checks

2.31-year Checks

2.43–year Checks

2.5Maintenance Tools

3. LUBRICATING CONDITION CHECKS B–80485E/03

32

3 LUBRICATING CONDITION CHECKS

B–80485E/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 SK–3(No.:A98L–0040–0110#1KG

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

2 J4-axis reducer0110#1KG

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

J3–axis reducer grease nipple

J3–axis reducer airvent for greasing

J2–axis reducer airvent for greasing

J2–axis reducer greasenipple

J4–axis reducer air ventfor greasing J6–axis

reducer airvent for greasing(feed grease at assembling)

J5–axis reducer air ventfor greasing

J5–axis reducer airvent



J1–axis reducer air ventfor greasing

RE No. 00

RE No. 00

RE No. 00

RE No. 00

SK–3

SK–3

Fig. 3.1 Greasing points (ARC Mate 120/S–12)

3.1Greasing

3. LUBRICATING CONDITION CHECKS B–80485E/03

34

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

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

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

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

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

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

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

Table 3.2 Grease requiring 3–year changes (ARC Mate 120/S–12)

Grease Qty.Kyodo Yushi

Qty.(cc)

J1-axis reducer 1600

J2-axis reducer Mory–White RE No. 00 1600

J3-axis reducer(Specification:A98L–0040–0119#2.7KG) 520

J5-axis gear boxA98L–0040–0119#2.7KG)

250

NOTE1. Take care not to slip on grease. Wipe the grease off

the floor and robot structure.

3.23-year Check

B–80485E/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 asfollows.� Turn the power on.

Press the EMERGENCY STOP button to inhibit the robot’smotion.

� 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)

3.3Replacing Battery

4. TROUBLESHOOTING B–80485E/03

36

4 TROUBLESHOOTING

B–80485E/03 4. TROUBLESHOOTING

37

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

4.1General


38

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

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

Table 4.2(a) Major Failures and Their Causes

Symptom Cause Corrective action Remarks

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

The batteries used for memorybackup are exhausted.

Replace the batteries thenperform quick mastering.

See Section 3.3.See Section 5.3.

The pulse coder signal cable isbroken.

Replace the cable then per-form quick mastering.

See Section 8.2.See Section 5.3.

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

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

Peripheral equipment has beenmoved out of position.

Secure the peripheralequipment firmly.

An excessive load has been ap-plied.

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

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

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

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

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

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

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

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

Review the location ofinstallation.

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

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

The servo system is not correctlyadjusted.

Adjust the servo system. Contact us.

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

A ground connection has not beenmade.

Make the necessary groundconnection.

Refer to the maintenancemanual for the control unit.

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

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

Refer to the maintenancemanual for the control unit.

4.2Problem and Causes


39

Symptom RemarksCorrective actionCause

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

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

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

Mechanical unit back-lash.

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

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

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

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

Contact us.

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

A part such as a casting has bro-ken.

Replace the broken part. Contact us.

Abnormal sound. Gears and/or reducers requiregreasing.

Apply grease. See Sections 3.1 and 3.2.

Foreign matter has entered a gearor reducer.

Clean the gear or reducer,then apply grease.

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

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

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

Contact us.

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

The servo system is not correctlyadjusted.

Adjust the servo system. Contact us.

Overheating. Gears and/or reducers requiregreasing.

Apply grease. See Sections 3.1 and 3.2.

Grease that does not satisfy thespecifications has been used.

Clean and regrease. See Sections 3.1 and 3.2.

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

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

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

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

The robot arm dropswhen the power is cut.

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

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

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

Replace the O–ring, oilseal, or packing.

Contact us.

A part such as a casting has bro-ken.

Replace the broken part. Contact us.

A screw is loose. Tighten the screw.


40

Table 4.2(b) Allowable Backlash for Each Axis

J1 J2 J3 J4 J5 J6

Angle (min) 2.5 2.5 2.5 3 5 3

Displacement (mm) 1.16(1595)

0.40(550)

0.44(600)

0.17(200)

0.29(200)

0.17(200)

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

Table 4.2(c) Allowable Drop

When power is cut 5 mm

In the event of an emergency stop 5 mm


41

Adjustments are necessary whenever a part is replaced.

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

Part to be replaced or function to be changed Adjustment

Replacement of cable (a) Routing of cable

(b) Limit switch

(c) Mastering

��

�� (a) Limit switch and dog adjustment

��

�� (a) Dog mounting position change, limit

switch adjustment

(b) Hard Stop mounting position adjustment

(c) Parameter change

��

��Replace them keeping power on.

No adjustment is necessary.

4.3Replacing Parts andPerformingAdjustments

5. ADJUSTING B–80485E/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.

B–80485E/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 limitswitch it is called Over Travel (OT). Over Travel is detected at both endsof the axis.The robot is controlled not to work beyond its operating area unless theservo system fails or a system error occurs so that the zero point is lost.Figs. 5.1(a) through 5.1(h) show the zero point, working limits (stroke),OT detection dogs, and mechanical stopper positions for each axis.Adjust each limit switch (Section 8.3) and dog such that an OT alarm isissued at the positions shown in the figures.

Fig. 5.1 (a) J1-axis rotation (J1 300�) (ARC Mate120/S-12)

5.1Adjusting LimitSwitches 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 haveOT limit switches.

Stroke end

Mechanical stopper

Stroke end

Mechanical stopper

minimum 3�

minimum 3�

+140�

–140�

0�

Stroke280�

Fig.5.1 (f) J5-axis wrist rotation (ARC 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) J6–axis wrist rotation (ARC Mate120/S–12)


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

The stroke can be changed every 22.5� at the desired stroke positionbetween –165� to +165�.When the stroke does not include 0�, the stroke must be readjusted to thestandard position when mastering the robot using the jig.J1–axis stroke change option specification (without OT):A05B–1208–J301J1–axis stroke change option specification (with OT): A05B–1208–J302

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

Front

Fig.5.2 (a) J1-axis stroke change (ARC Mate120/S-12)

5.2J1-axis strokemodification (Option)


49

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

position as shown in Fig. 5.2 (b).

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

Limit switch(Rotation side)option

Front

Mechanicalstopper (Rotation side)

Example

Mechanical stopper (Fixed side)

Dog (Fixed side)

Limit switch(Rotation side)option

Front

Mechanical stopper (Rotation side)

Mechanical stopper (Fixed side)

Dog (Fixed side)

Example

Fig.5.2 (b) Dog and mechanical stop position change (ARC Mate120/S-12)

1) Changing dog andmechanical stop position


50

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

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

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

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

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

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

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

2) Changing minimum andmaximum stroke


51

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

Position of eachstroke end

�(Stroke lower limit)$PARAM_GROUP.

$LOWERLIMS

�(Stroke upper limit)$PARAM_GROUP.

$UPPERLIMS

–180� (*1) –180

–165� (standard value) –165

–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: A05B–1208–H322)


52

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

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

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

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

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

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

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

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

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

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

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

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

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

l) Note down the mastering data for the system variable$DMR_GRP.$MASTER_COUN.

5.3Quick Mastering

1) Mastering procedure (forcable replacement)


53

J5–axis

J6–axis

J4–axis J3–axis

J2–axis

J1–axis

Fig.5.3 Zero degree position arrow mark for each axis (ARC Mate 120/S–12)


54

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

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

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

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

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

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

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

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

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

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

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

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

5.4Mastering Using ZeroDegree Position

1) Procedure (Mastering ofzero degree position)


55

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

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

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

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

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

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

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

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

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

2) Procedure(single–axismastering)


56

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

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

NOTEThe axis stroke is not checked during mastering. Sufficientcare shoud, therefore, be taken regarding the robot’s axismovement.

1 Assembling the jig base

Assemble mastering jig Y to mastering jig X as shown in Fig. 5.5 (a)

Mastering jig YA290–7208–X954

M6X12 (4PCS)Washer M6 (4PCS)

Mastering jig XA290–7208–X953

Fig.5.5. (a) Assembly of jig base (ARC Mate120/S-12)

5.5Mastering Using Jig

Assembling themastering jig


57

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

J1 base A290–7208–X201

Pin A290–7111–X906

M8X20 (2PCS)Pin A290–7111–X906

Mastering jig XA290–7208–X953

Fig.5.5. (b) Mounting on robot’s body (ARC Mate120/S-12)

3 Mounting jig on wristPosition 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 J6–axis so thatthe cubic section (weight) directls upward.

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


58

Pin A290–7022–X965

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

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

Fig.5.5. (c) Mounting jig on wrist (ARC 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, andperform a cold start. [See 5.2 2)]

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

Mastering jig ZA290–7208–X955

M6X14 (4pcs)

M6X14 (4 pcs)

Mastering jig WA290–7208–X956

Fig. 5.5(d) Assembling Mastering Jigs (ARC Mate 120/S–12)

Mastering procedure


59

Mastering Jig Specification: A05B–1208–J053

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�


Flange adaptor (option)

Fig. 5.5(e) Mastering Attitude (ARC Mate 120/S–12)


60

4 Mount mastering jig Z and mastering jig W onto mastering jig X, asshown in Fig. 5.5(d). It is absolutely essential that this step beperformed to prevent the arm from falling when the brake is released.

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

6 Press the screen selection key to display the menu. From the menu,select SYSTEM. From the system menu, select Brake Cntrl. Pressfunction key F�, then select function key F3 (REL–ALL) to releasethe brakes on all axes.

7 [For R–J controller]Press the screen selection key to display the menu. From the menu,select SYSTEM. From the system menu, select Brake Cntrl. Pressfunction key F�, then select function key SHIFT �F3 (REL_ALL)to release the brakes on all axes.[For R–J2 controller]Press the screen selection key to display the menu. From the menu,select SYSTEM. Press the function key F1(MENU), selectMaster/Cal. Press SHIFT + F4 (TORQUE), change the indicationfrom 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 surfacesis completely butted against the wall, as shown in Fig. 5.5(g). If notall of the surfaces are fully butted against the walls, loosen the M8bolts, and perform step 7 again.

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

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 inthe system variable $DMR_GRP. $MASTER_COUN, and the systemvariable $DMR_ GRP.MASTER_DONE (mastering completion flag)is set to TRUE.

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

12 Press the screen selection key to display the menu. From the menu,select SYSTEM. From the system menu, select Brake Cntrl. Pressfunction key F�, then select function key F2 (ENG–ALL) to controlthe brakes of all axes. Then, press the alarm release key.

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

14 Finally, to safeguard against mastering data being overwritten by anoperation error, note down the mastering data for the system variable$DMR_GRP.$MASTER_COUN. Furthermore, draw arrow marksfor zero position calibration with the zero degree position attitude, asshown in Fig. 5.3.


61

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

Fig. 5.5(f) Butting Mastering Jig (ARC Mate 120/S–12)

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/S–12)


62

1) Confirming whether mastering is normally done

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

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

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

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

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

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

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

5.6Confirming Mastering


63

If the backlash of the J5–axis exceeds the maximum allowable value(output axis angle of 3 to 6 minutes) shown in table 4.2(b), backlashadjustment 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 J5–axis

gear box cover (A290–7208–X502) from the J3 arm(A290–7208–X402).

Gear 2 assemblyA290–7208–V501

J3 armA290–7208–X402

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


Gear J5–5A290–7208–X515

M4X12 (8 pcs)M4 Washer (8 pcs) Packing

A290–7208–X524

M5X12 (10 pcs)(Loctite 262)M5 Washer (10 pcs)

Cover A290–7208–X502

Turn to adjustbacklash.

Spring pin�5X10 (1 pcs)

Fig. 5.7 J5–axis gear backlash adjustment (ARC Mate 120/S–12)

3 Loosen the four M4�12 bolts to disengage the gear 2 assembly(A290–7208–V501) from the gear 3 assembly (A290–7208–V502).

4 Remove the ten M5�2 bolts. The rotation center axis and gearcenter axis of the gear 3 assembly are not aligned. Rotate the gear3 assembly about the spring pin (�5�10) as its center, and thebacklash between the gear 3 assembly and the gear J5–5. 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 sixM4X10 bolts.

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

5.7Adjusting J5-axis SpurGear backlash

Backlash adjustment ofthe gear 3 assembly andgear J5–5


64

6 To reduce the backlash, position the gear 2 assembly at rightangles to the axis running through the gear 2 and gear 3 assem-blies. Then, secure the gear 2 assembly to the J3 arm with fourM5�12 bolts.

7 While turning the gear 2 assembly and checking the operation ofthe J5–axis within the stroke (–140� to +140� ), repeat step 6 toreduce the backlash until there is no interference between thegears.

8 Check that the backlash of the J5–axis does not exceed the allow-able value (output axis angle of 5 minutes) indicated in Table4.2(b). If the allowable value is exceeded, return to step 3 .

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

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

11 Perform mastering according to Sections 5.4 or 5.5.

Backlash adjustment ofthe gear 2 and gear 3assemblies

B–80485E/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 J3–axis reducer (a) Mastering

(b) Dog adjustment (*option)

J4 and J6-axis reducer (a) Mastering

J5 axis gear box (a) Mastering

NOTEBe careful when removing and installing the following heavyparts.

Parts Weight (approx.)

J2 Arm–Wrist unit (see Fig. 6.3 (a)) 59 kg

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

J2 Base (see Fig. 6.1) 32 kg

6. REPLACING AND ADJUSTING PARTS B–80485E/03

66

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

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

out the gear (A290–7208–X211) 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 specifiedtorque [12.0 Nm (122 kgf–cm)].

8 Check that the O–ring is installed correctly where the motormounts on the J2 base (A290–7208–X301). Then, secure the mo-tor to the J2 base using four M8X20 bolts. Apply Loctite 262 tothe bolts.

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

10 Perform mastering as explained in Chapter 5.

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

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

2 Turn off the control unit.3 Remove the connector from the J2–axis motor.4 Remove the four M8�25 motor mounting bolts, then remove the

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

out the gear (A290–7208–X211) 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 specifiedtorque [12.0 Nm (122 kgf–cm)].

6.1Replacing J1 andJ2-axis Motor M1 M2

1) Replacing the J1–axismotor (Fig.6.1)M1

2) Replacing the J1–axismotor (Fig.6.1)M2


67

9 Check that the O–ring is installed correctly where the motormounts on the J2 base (A290–7208–X301). Then, secure the mo-tor to the J2 base using four M8X25 bolts. Apply Loctite 262 tothe bolt threads.


11 Perform mastering according to Chapter 5.

J1–axis motor

M8X25 (4 pcs) Loctite 262Washer M8 (4 pcs)

Gear A290–7208–X211

O–ring

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

C–ringBearing

J2–axis motorM8X25 (4 pcs) Loctite 262Washer M8 (4 pcs)

J2 baseA290–7208–X301

Gear A290–7208–X211O–ring

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

BearingC–ring

M1

M2

Fig.6.1 Replacing J1, J2–axis motor (ARC Mate120/S–12)


68

1 Turn off the control unit.

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

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

4 Remove the eleven M11X65 bolts securing the J2 base to theJ1–axis reducer, as shown in Fig. 6.2(a).

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

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

7 Remove the six M14X85 bolts securing the J1–axis reducer to theJ1 base (A290–7208–X201), then remove the reducer.

8 Remove the three M6X25 bolts securing the pipe (A290–7208–X221) to the reducer, then remove the pipe according to Fig.6.2(c).

9 Check that the O–ring is installed correctly on the pipe. Then,secure the pipe to a new reducer using four M6X25 bolts. ApplyLoctite 262 to the bolt threads.

10 Mount an O–ring (medium) and O–ring (small) on the reducer.Then, secure the reducer to the J1 base using six M14X85 bolts,tightening them to a torque of 204.8 Nm (2090 kgf–cm). ApplyLoctite 262 to the bolt threads.

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

12 Secure the J2 base to the reducer using eleven M10X65 bolts,tightening them to a torque of 73.5 Nm (750 kgf–cm). ApplyLoctite 262 to the bolt threads. Be careful not to damage the oilseal surface with the pipe.

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

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


6.2Replacing J1-Axis Reducer


69

M4X10 Loctite 262

M10X65 (11 pcs) Loctite 262 73.5 Nm (750 kgf–cm)Washer M10 (11 pcs)

Cable cover 2A290–7208–X333

ClampA290–7208–X336


M6X20 (2 pcs)Washer M6 (2 pcs)

ClampA290–7207–X325


ClampA290–7208–X336

M4X10 Loctite 262

ClampA290–7208–X341


Fig.6.2 (a) Replacing J1–axis reducer (ARC Mate120/S–12)


70

O–ring (Large)

J1 reducer center gear

Bearing Loctite RC75 (External ring)


O–ring (medium)

O–ring (small)

J1 base A290–7208–X201

J1–axis reducer

Fig.6.2 (b) Replacing J1–axis reducer (ARC Mate120/S–12)

O–ring

J1–axis reducer


Pipe A290–7208–X221

Fig.6.2 (c) Replacing J1–axis reducer (ARC Mate120/S–12)


71


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

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

tion 6.1.5 Remove the six M12X85 bolts and three M12X30 bolts securing

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

pull the J2 arm out sideways.7 Remove O–ring (large), bearing and center gear as shown in

Fig.6.3(a).8 Remove the twelve M10X80 bolts securing the J2–axis reducer

to the J2 base (A290–7208–X301), then remove the reducer.9 Remove the three M6X25 bolts securing the pipe (A290–7208–

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

10 Check that the O–ring is installed correctly on the pipe. Then,secure the pipe to a new reducer using three M6X25 bolts. ApplyLoctite 262 to the bolt threads.

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

12 Mount the O–ring on the reducer. Then, secure the reducer to theJ2 base using twelve M10X80 bolts, tightening them to a torqueof 73.5 Nm (750 kgf–cm). 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 andthree M12X30 bolts, tightening them to a torque of 128.4 Nm(1310 kgf–cm). Apply Loctite 262 to the bolt threads.

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



6.3Replacing J2-Axis Reducer


72

J2–axis reducer

Bearing Loctite RC75 (External ring)


J2 arm A290–7208–X302

J2 base A290–7208–X301

M12X30 (3 pcs)N12X85 (6 pcs) Loctite 262 128.4 Nm (1310 kgf–cm)Washer M12 (9 pcs)

O–ring

GearA290–7208–X212

J2 Arm–Wrist unit



PipeA290–7207–X221

O–ring

J2–axis reducer



73


2 Turn off the control unit.3 Remove the twelve M6X10 button bolts, then remove the J3 cov-

er (A290–7208–X403) from the J3 housing, as shown in Fig. 6.4.4 Disconnect the cable from the J3–axis motor.5 Remove the four M6X16 seal bolts holding the J3–axis motor to

the J3 housing, then remove the motor.6 Remove the hexagon M6 nut from the motor shaft, then remove

the gear (A290–7208–X411).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 kgf–cm).

9 Confirm that O–ring is inserted correctly to the position of motorthat mounts J3 housing (A290–7208–X401). Secure the motorto the J3–axis housing using four M6�16 bolts (apply loctite262)

10 Attach the cable to the J3–axis motor.11 Fill the J3–axis grease bath with the specified type of grease as

detailed in Section 3.2.12 Mount the J3 cover onto the J3 housing using twelve M6X10 but-

ton bolts.13 Perform mastering as explained in Chapter 5.

J3 CoverA290–7208–X403

Button bolt M6X10 (12 pcs)Washer M6 (12 pcs)Plain washer M6 (12 pcs)


J3 housingA290–7208–X401

O–ring

Gear A290–7208–X411

Heagon nut M6 Loctite 262 2.9 Nm (30 kgf–cm)Spring Washer M6

J3–axis motorM3

Fig.6.4 Replacing J3–axis motor (ARC Mate120/S–12)

6.4Replacing J3-Axis Motor M3


74


2 Turn off the control unit.3 Remove the twelve M6X10 button bolts , then remove the J3 cov-

er (A290–7208–X403) from the J3 housing, as shown in Fig. 6.4.4 Disconnect the cable from the J3–axis motor.5 Remove the J3–axis motor as explained in Section 6.4.6 Using a crane, lift the J3 arm. Then, remove the six M8X80 bolts

and two M8�25 bolt securing the J2 arm to the J3–axis reducer,then remove the J3–axis reducer from the J2 arm.

7 Remove the ten M6�65 bolts securing the J3–axis reducer to theJ3 housing, then remove the reducer.

8 Secure a new reducer to the J3 housing using ten M6X65 bolts,tightening them to a torque of 15.7 Nm (160 kgf–cm). ApplyLoctite 262 to the bolt threads.

9 Using a crane, lift the J3 arm. Then, secure the J2 arm to the re-ducer using six M8�80 bolts and two M8�25 bolts (to whichLoctite 262 has been applied) tightened to a torque of 37.2 Nm(380 kgf–cm), and two �8X25 taper pins (with Loctite 242 ap-plied to the taper holes).

10 Mount the J3–axis motor as explained in Section 6.4.11 Attach the cable to the J3–axis motor.12 Fill the J3–axis grease bath with the specified type of grease, as

detailed in Section 3.2.13 Mount the J3 cover onto the J3 housing using twelve M6�10

button bolts and three M4�10 bolts.14 Perform mastering as explained in Chapter 5.

Bearing Loctite RC75(EXternal ring)

M8X25 (2 pcs)M8X80 (6 pcs) Loctite 262 37.2 Nm (380 kgf–cm)Washer M8 (8 pcs)

J3–axis reducer

J3 housing A290–7208–X401

O–ring (Large)

M6X65 10 pcs) Loctite 262 15.7 Nm (160 kgf–cm)Washer M6 (10 pcs)

J2 armA290–7208–X301

GearA290–7208–X212

Fig.6.5 Replacing J3–axis reducer (ARC Mate120/S–12)

6.5Replacing J3-axisReducer


75

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

2 Turn off the control unit.3 Remove the twelve M6�10 button bolts, then remove the J3

cover (A290–7208–X403) from the J3 housing, as shown in Fig.6.4.

4 Disconnect the cable from the J4–axis motor.5 Remove the four M6X16 bolts securing the J4–axis motor to the

J3 housing (A290–7208–X401), then remove the motor as shownin Fig. 6.6.

6 Remove a hexagon nut at the motor shaft and pull out the gear(A290–7208–X411).

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 (30kgf–cm).9 Check that the O–ring is installed correctly, on the J3 housing

(A290–7208–X401) at the place where the motor is mounted.Then secure the motor to the J3 housing using four M6�16 bolts.Apply Loctite 262 to the bolt threads.

10 Attach the cable connector to the J4–axis motor.11 Fill the J4–axis grease bath with the specified type of grease, as

detailed in Section 3.1.12 Mount the J3 cover onto the J3 housing using twelve M6�10

button bolts.13 Perform mastering as explained in Chapter 5.


Hexagon nut M6 Loctite 262 2.9 Nm (30 kgf–cm)Spring washer M6

O–ring

J3–housingA290–7208–X401

J4–axis motor

GearA290–7208–X413

M4


6.6Replacing J4-axisMotor M4


76

1 Turn off the control unit.

2 Remove the twelve M6�10 button bolts,then remove the J3 cov-er (A290–7208–X403) from the J3 housing, as shown in Fig. 6.4.

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

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

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

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

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

8 Remove the six M3X8 bolts securing the gear (A290–7208–X414) to the reducer, then remove the gear from the reducer.

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

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

11 Check that the O–ring (medium) and O–ring (small) are installedcorrectly. Then, mount the reducer to the J3 arm using sixteenM4X35 bolts, tightened to a torque of 4.6 Nm (47 kgf–cm). Ap-ply Loctite 262 to the bolt threads.

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

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


15 Mount the J3 cover onto the J3 housing using twelve M6�10button bolts.


6.7Replacing J4–Axis Reducer


77


O–ring (Large)

J4–axis reducer


J3–arm A290–7208–X402


Bearing (2 pcs) Loctite RC75 (External ring)



Gear A290–7208–X414

O–ring (Medium)

O–ring (Small)

SpacerA290–7207–X424

J4 Reducer

J3 armA290–7208–X402



78

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

2 Turn off the control unit.3 Remove the six M6�15 bolts, remove the packing (A290–

7208–X525), then turn the J5 cover (A290–7208–X503) aroundthe J5–axis until the J5–axis motor can be lifted out, as shown inFig. 6.8.

4 Disconnect the cable from the J5–axis motor.5 Remove the four M5�12 bolts securing the J5–axis motor to the

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

to the motor shaft, then remove the gear and bearing.7 Secure the gear to a new motor using an M3�12 bolt, tightened

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

8 Confirm the O ring is installed correctly, then secure the motorto the J3 arm using four M5�12 bolts. Apply Loctite 262 to thebolt threads.

9 Connect the J5–axis motor cable.10 Install a new packing and secure the J5 cover with four M6�16

bolts. Apply loctite 262 to the bolt threads.11 Fill the J5–axis grease bath with the specified type of grease, as

detailed in Section 3.2.12 Perform mastering as explained in Chapter 5.

GearA290–7208–X511

Washer A290–7207–X425


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

J5–axis motor


Cover A290–7208–X503Packing A290–7208–X525

J3 armA290–7208–X402

C–ring

BearingO–ring

M5


6.8Replacing J5-axisMotor M5


79

1 To replace the input gear (A290–7208–X511) of the J5–axismotor, follow the replacement procedure given in Section 6.8.

2 Move the robot to the attitude of J4 = +90� and J5 = J6 = 0� .3 Turn off the control unit.4 Remove the eight M4�12 bolts, cover (A290–7208–X502), and

packing (A290–7208–X524), as shown in Fig. 6.9.5 Remove the four M5�12 bolts securing the gear 2 assembly,

then remove the gear 2 assembly from the J3 arm.6 Remove the ten M5�12 bolts securing the gear 3 assembly and the

ten M6�30 bolts securing the gear (A290–7208–X515), then re-move the gear 3 assembly and the gear from the J3 arm. By pullingout the gear a little, the gear 3 assembly can be removed.

7 Secure a new gear 3 assembly and new gear to the J3 arm (thesemust be fitted together). Secure the gear, together with the J6housing(A290–7208–X501), to the J3 arm using ten M6�30bolts tightened to a torque of 15.7 Nm (160 kgf–cm). Apply Loc-tite 262 to the bolt threads. Secure the gear 3 assembly to the J3arm using ten M5�12 bolts tightened to a torque of 9.0 Nm (92kgf–cm), as explained in Section 5.7. Apply Loctite 262 to thebolt threads.

8 Secure the gear 2 assembly to the J3 arm using four M5�12bolts, tightened to a torque of 9.0 Nm (92 kgf–cm), as explainedin Section 5.7. Apply Loctite 262 to the bolt threads.

9 Upon completion of backlash adjustment, as explained in Section5.7, install a new packing, then secure the cover to the J3 arm us-ing eight M4�12 bolts. To prevent grease leakage, use a newpacking.



M4X 12 (8 pcs)Washer M4 (8 pcs)

M5X12 (10pcs) Loctite 262 9.0 Nm (92 kgf–cm)Washer M5 (10 pcs)

Gear 2 assemblyA290–7208–V501M5X12 (4 pcs)

Loctite 262 9.0 Nm (92 kgf–cm)Washer M5 (4 pcs) Plain washer M5 (4pcs)


J3 armA290–7208–X402

Gear J5–5A290–7208–X515

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

A290–7208–X524Cover A290–7208–X502

Spring pin �5X10 (1 pcs)

Fig.6.9 Replacing J5 gear (ARC Mate120/S–12)

6.9Replacing J5–Axis Gear


80

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

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

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

4 Remove the four M4X12 bolts, then remove the motor and apacking from the J6–axis reducer (harmonic drive), as shown inFig. 6.10(b).

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

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

7 Install a new packing and secure the motor to the reducer usingfour M5�12 bolts. Apply loctite 262 to the bolt threads.

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

with the reducer to the J6 housing using four M5�20 bolts witha torque of 9.0 Nm (92kgf–cm) and two �5�20 spring pins. Ap-ply Loctite 262 to the bolt threads.

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


1 Turn off the control unit.2 Remove the four M5�20 bolts and two �5X20 spring pins, then

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

3 Remove the four M5�12 bolts, then remove the motor and apacking from the J6–axis reducer (harmonic drive) as shown inFig. 6.10(a).

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

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

6 Install a new packing and secure the motor to the reducer usingfour M5�12 bolts. Apply loctite 242 to the bolt heads.

7 Check that the O–ring is installed correctly, then secure the motorwith the reducer to the J6 housing using four M5�20 bolts witha torque of 9.0 Nm (92 kgf–cm) and two �5�20 spring pins. Ap-ply Loctite 262 to the bolt threads.

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

6.10Replacing J6-axisMotor, Reducer M6

1) Replacing the J6–axismotor M6

2) Replacing the J6–axisreducer


81




J6–axis motor


O–ring

M6

Fig.6.10 (a) Replacing J6–axis motor and reducer (ARC Mate120/S–12)


M3X8 Loctite 242 2.0 Nm (20 kgf–cm)Washer M3

J6–axis motorPacking

Wave generator

J6–axis reducer

Washer A290–7208–X532

M6

Fig.6.10 (b) Replacing J6–axis motor and reducer (ARC Mate120/S–12)


82

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

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

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

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

Fig. 6.11 Releasing brake

6.11Releasing Brake

B–80485E/03 7. PIPING AND WIRING

83

7 PIPING AND WIRING

7. PIPING AND WIRING B–80485E/03

84

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

Fig.7.1 Piping diagram (ARC Mate120/S-12)

7.1Piping


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 (A05B–1208–H201) Fig. 7.2 (a) Mechanical unit wiring diagram (A05B–1208–H211) Fig. 7.2 (a) Mechanical unit wiring diagram (A05B–1208–H301)

7.2Wiring Diagram


86

Fig.7.2 (b) Mechanical unit wiring diagram (A05B–1208–H202)Fig. 7.2 (b) Mechanical unit wiring diagram (A05B–1208–H222)Fig. 7.2 (b) Mechanical unit wiring diagram (A05B–1208–H302)


87

Fig. 7.2 (c) shows wiring diagram for the MIG EYE cable (A05B–1208–H921).Fig. 7.2 (d) shows wiring diagram for the MIG EYE cable (A05B–1208–H922).

Fig. 7.2 (c) Wiring diagram for the MIG EYE cable (A05B–1208–H921)

Fig. 7.2 (d) Wiring diagram for the MIG EYE cable (A05B–1208–H922)


88

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

Option specification (330� OT): A05B–1208–H312Option specification (360� OT): A05B–1208–H322

J3–axis OT limit switch cableK123



Cable K107

SQ3

SQ2

SQ1

Fig.7.3 Limit switch installation diagram (ARC Mate120/S-12)

7.3Limit Switch (Option)Installation Diagram


89

Visually check the following:

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

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

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

Fig. 7.4 (a) shows installation diagram for the cables in the mechanicalunit.When the Diecasting cable (A05B–1208–H222) specified, the cablewithin [ ] will be wired.FIg. 7.4 (b) shows installation diagram for the cables in the mechanicalunit which is CE specifications.

Fig.7.4 (a) Mechanical unit cable installation diagram (ARC Mate120/S-12)

7.4Cable InstallationDiagram


90

Fig. 7.4 (b) Mechanical unit cable installation diagramFIg. 7.4 (b) (ARC Mate 120/S–12) [CE specifications]

<Cable ass’y specification that this figure is applied to> A05B–1208–H301A05B–1208–H302

B–80485E/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 B–80485E/03

92

When mounting the replaced cables with clamps and tie wraps, clamp itat the positions specified in Table 8.1 (a), Table 8.1 (b). Unless the cableis clamped at the specified positions, the cable may be broken due toexcessive sag or tention.

Table 8.1 (a) Cable clamping positions (ARC Mate120/S-12)

8.1Cable Clamping


93

Table 8.1 (b) Extension cable clamping positions (ARC Mate 120)


94

1 Remove the J3–axis cover (A290–7208–X403) from the J3 hous-ing (A290–7208–X401) 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 connectorclamp (A290–7208–X424), then remove the K101 (K201) andK102 (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 (A290–7207–X401).

5 Remove the arm cover (A290–7208–X326) and cover(A290–7208–X325) from the J2 arm (A290–7208–X302) asshown in Fig. 8.2(c) and Fig. 8.2(d).

6 Cut the nylon bands of the clamp (A290–7208–X324) and sup-port 22 (A290–7208–X323), then pull out the cables from the J2arm.

7 Remove the two clamps (A290–7208–X336), clamp 12(A290–7208–X341), and clamp 21 (A290–7207–X325) asshown in Fig. 8.2(e).

8 Remove cable cover 1 (A290–7208–X333), cable cover 2(A290–7207–X334), and cable cover 3 (A290–7207–X335).

9 Cut the nylon bands at support 12 (A290–7208–X321) and sup-port 21 (A290–7208–X322), then pull out the cables, one by one,from the inside of the J2–axis reducer (Refer to Fig. 8.2 (f)).

10 Disconnect the J1–axis connector box from J1 base(A290–7208–X201) , as shown in Fig. 8.2(g).

11 Remove clamp 11 (A290–7208–X228) from the J1–axis connec-tor box.

12 Cut the nylon bands of support 11 (A290–7208–X223), then pullout the cables, one by one, from the inside of the J1–axis reducertoward the J1–axis connector box.

13 Remove the cables from the J1–axis 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 cableclamp 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.

8.2Replacing Cables

1) Replacing cable K101(K201) and K102 (K112)(K202)


95

Nylon band

J2 arm A290–7208–X302

Nylon band

J3 cover A290–7208–X403

Button bolt M6X8 (12 pcs)Plain washer M6 (12 pcs)Washer M6 (12 pcs)

Connector clampA290–7208–X424

SupportA290–7208–X424



Fig.8.2 (a) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S–12)

EE connectorM3X5 (4 pcs)

Nylon band

Connector cap

EE plateA290–7208–X427 (or X426)

EE relay connector (K112)

Button bolt M4X6 (4 pcs)



Fig.8.2 (b) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S–12)


96

Fig. 8.2 (c) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S–12)

Fig. 8.2 (d) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S–12)


97


M10X65 (11 pcs)(Loctite 262)Washer M10 (11 pcs)

M4X10(Loctite 262)

Clamp A290–7208–X336



Clamp A290–7207–X325


Clamp A290–7208–X336

M4X10(Loctite 262)

Clamp A290–7208–X341


Fig.8.2 (e) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S–12)

Fig.8.2 (f) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S–12)


98

J1 base A290–7208–X201

Clamp 11A290–7208–X288

J1–axis connector box

M6X10 (2 pcs)Washer M6 (2pcs)

M8X10 (4 pcs)

M6X20 (2 pcs)Washer M6 (2pcs)

Support 11A290–7208–X223

Fig.8.2 (g) Replacing cable K101 (K201) and K102 (K112) (K202) (ARC Mate120/S–12)

1 Remove J3 axis cover (A290–7208–X403) from the J3 housing(A290–7208–X401).

2 Disconnect the K104(#J3) and K105(#J3) relay connectors fromthe connector clamp (A290–7208–X424) as shown in Fig. 8.2(a).

3 Cut nylon band at connector clamp.4 Remove the J1–axis motor connectors, then pull out the cables.5 Install new cables by reversing the procedure above.6 Perform quick mastering as explained in Section 5.3.

1 Remove J3 axis cover (A290–7208–X403) from the J3 housing(A290–7208–X401).

2 Disconnect the K104(#J4) [K204] and K105 (#J4) [K205] relayconnectors from the connector clamp (A290–7208–X424) asshown in Fig. 8.2(a).

3 Cut nylon band at connector clamp.4 Remove the J4–axis motor connectors, then pull out the cables.5 Install new cables by reversing the procedure above.6 Perform quick mastering as explained in Section 5.3.

2) Replacing cableK104(#J3),and K105(#J3)

3) Replacing cable K104(#J4)[K204] and K105(#J4)[K205]


99

1 Remove the J3–axis cover (A290–7208–X403) from the J3 hous-ing (A290–7208–X401), as shown in Fig. 8.2(a).

2 Remove the cable K103 relay connector from the connectorclamp (A290–7208–X424), as shown in Fig. 8.2(a) and cut thenylon bands of the connector clamp.

3 Remove the J5–2 cover from the J3 arm as shown in Fig.8.2(h).4 Remove the J5–axis motor cable connector and M6M, M6P relay

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

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


1 Remove the J5–2 cover from the J3 arm (see Fig. 8.2 (h)).2 Remove relay connector M6M and M6P from the clamp J5

(A290–7208–X526) and cut off the nylon band.3 Remove the clamp J6–1 (A290–7208–X527) from the J5–2 cov-

er (A290–7208–X503) and cut off the nylon band.4 Take out J6–axis motor, referring to item 6.10. Remove the cable

relayed at the sheet (A290–7208–X529), remove the clamp J6–2(A290–7208–X528) from the J6 housing, and cut off the nylonband.

5 Extract cable K108 from the J6 housing, then from the J5–2 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 tothe cable clamp positions, indicated by the marking tapes, asshown in Fig. 8.2(g).Install a new packing (A290–7208–X525) to prevent grease fromleakage.


1 Remove the connector cap of EE (end effector) and EE connectorfrom the EE plate. (see Fig. 8.2 (b)).

2 Pull out the relay connector of cable K109 from the support(A290–7208–X422).

3 Install a new cable by reversing the procedure above.

4) Replacing cable K103




100

Marking tape

Details of assembly X527 and X528

Nylon band

Details of assembly X529

Nylon band

Clamp J5A290–7208–X526 J3–arm

A290–7208–X402


Packing A290–7208–X525

Clamp J6–1 A290–7208–X527


J5–2coverA290–7208–X503


RingA290–7208–X521

Clamp J6–2A290–7208–X528



Sheet A290–7208–X529

M5X20 (4 pcs)(Loctite 262)Washer M5 (4 pcs)


Details of assembly X526

Nylon bandMarking tape

M5M M5P

Fig.8.2 (h) Replacing cable K103, K108


101

When the MIG EYE cable (A05B–1208–H921) is specified, cable K132is added. Refer to the cable clamp positions, indicated by the marking tapes, asshown in Fig. 8.2 (i1) and Fig. 8.2 (i2). When the MIG EYE cable (A05B–1208–H922) is specified, cable K131to K133 are added. Refer to the cable clamp position, indicated by the marking tapes, asshown in Fig. 8.2 (j1) and Fig. 8.2 (j2).

Fig. 8.2 (i1) Replacing the MIG EYE cable (A05B–1208–H921) (ARC Mate 120)

7) Replacing additional cable


102

Fig. 8.2 (i2) Replacing the MIG EYE cable (A05B–1208–H921) (ARC Mate 120)


103

Fig. 8.2 (j1) Replacing the MIG EYE cable (A05B–1208–H922) (ARC Mate 120)


104

Fig. 8.2 (j2) Replacing the MIG EYE cable (A05B–1208–H922) (ARC Mate 120)


105

1 Remove the LS box (A290–7208–X338) from the J2 base(A290–7208–X301) as shown in Fig. 8.3(a).

2 Remove the J1–axis OT limit switch (A05B–1208–D103) fromthe LS box.

3 Remove a connector relayed in the cable cover 2 and cut the nylonband at the clamp (A290–7208–X340).

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 baseA290–7208–X301

PlateA290–7201–X347

LS boxA290–7208–X338

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

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

Limit switch (with cable)A05B–1208–D103

Clamp A290–7208–X340

Bush

Nylon band

SQ1

Fig.8.3 (a) Replacing J1-axis limit switch (ARC Mate120/S-12)

8.3Replacing LimitSwitch(Option)1) J1–axis OT limit switch

(A05B–1208–D103) SQ1


106

1 Remove the LS plate (A290–7208–X327) from the J2 arm(A290–7208–X302) as shown in Fig. 8.2(b) .

2 Remove the relay connector in J2 arm as shown in Fig.8.3 (b).3 Remove the J2–axis OT limit switch (A05B–1208–D104) from

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.6 Check that the limit switch operates accurately at the overtravel

position.7 Check that the limit switch does not operate within the J2-axis

motion range.


Bush


PlateA290–7201–X347

LS plateA290–7208–X327

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

SQ2

Fig.8.3 (b) Replacing J2–axis limit switch (ARC Mate120/S–12)

2) J2–axis OT limit switch(A05B–1208–D104) SQ2


107

1 Remove the LS plate (A290–7208–X328) from J2 arm(A290–7208–X302) as shown in Fig.8.3 (c).

2 Remove relay connector in J2 arm, referring to Fig. 8.2(b).3 Remove the J3–axis OT limit switch (A05B–1207–D105) from

the LS plate.4 Remove bush from J2 arm and pull out 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 J3–axis

motion range.


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

Bush

Plate A290–7201–X347


LS Plate A290–7208–X328

SQ3

Fig.8.3 (c) Replacing J3–axis limit switch (ARC Mate120/S–12)

3) J3–axis OT limit switch(A05B–1208–D105) SQ3


108

Limit switch relay cableA660–4003–T242

Nylon band

Fig.8.3 (d) Replacing J2 and J3–axis limit switch (ARC Mate120/S–12)

B–80485E/03 9. OPTIONS

109

9 OPTIONS

9. OPTIONS B–80485E/03

110

Fig. 9.1 shows how to assemble the cover option.

(Assembly)1 Secure the support (A290–7208–X339) to the J2 base

(A290–7208–X301) using four M6X10 bolts.2 Secure the J2 cover (A290–7208–X303) to the support using six

M6X10 button bolts.

To remove the cover, reverse the assembly procedure above.

M6X10 button bolt (6 pcs)Plain washer M6 (6 pcs)

J2 coverA290–7208–X303

When the cover optionis specified

Specification: A05B–1208–J401


J2 baseA290–7208–X301

M6X10 (4 pcs)M6 washer (4 pcs)

Fig. 9.1 Cover Option (ARC Mate 120/S–12)

9.1Cover Option(Specification:A05B–1208–J401)

II. CONNECTION

B–80485E/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. Wheninstalling peripheral devices, take care that they do not interfere with themotion of robot body. For installation, use the 4-φ18 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 J5–axis center

COVER (OPTION)

With FANUC Flange adaptor

J5–axis center

Fig.1 (a) Mechanical unit external dimensions (ARC Mate120/S-12)

1. ROBOT INTERFERENCE AREA B–80485E/03

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J2–axis rotation interference area

Motion range of J5–axis center

Fig.1 (b) Mechanical unit external dimensions (ARC Mate120/S-12)

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B–80485E/03 1. ROBOT INTERFERENCE AREA

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Fig. 1 (e) Mechanical unit external dimensions (ARC Mate 120/S–12 with MIG EYE)

1. RO

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.1 (f) Op

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Fig

.1 (g) O

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2. EQUIPMENT MOUNTING TO ROBOT B–80485E/03

120

2 EQUIPMENT MOUNTING TO ROBOT

B–80485E/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 �50H7 rabbet or the �25H7 rabbet, thenposition the end effector by using the 4–�6H8 reamed holes. Use the4–M6 tapped holes to secure the end effector. Use M6 bolts of a lengththat does not exceed the depth (10 mm) of the tapped holes.

ISO Flange 4–M6 depth 10equally spaced oncircumference � 40

4–�6H7equally spaced oncircum ference �40

+0.0120 depth 10

Fig. 2.1(a) Mounting Surface for End Effector of ISO Flange Type (ARC Mate 120/S–12)

Fig. 2.1(b) shows the end effector mounting face at the tip of the wristused when the FANUC flange adaptor (option specification:A05B–1207–J001) is being used. Fit the end effector by using the �32H8rabbet or the �60H7 rabbet, then position the end effector by using the4–�6H8 reamed holes. Use the 4–M6 tapped holes to secure the endeffector. Use M6 bolts of a length that does not exceed the depth (8 mm)of the tapped holes.

FANUC Flange Adaptor

4–M6 depth 8equally spaced oncircumference � 50

4–�6H8equally spaced oncircumference � 50

+0.0180 depth 8

Fig. 2.1(b) Mounting Surface for End Effector when the FANUC FlangeAdaptor is Used (ARC Mate 120/S–12)

2.1End EffectorMounting Face toWrist

ISO flange type(standard)

FANUC flangeadaptor(option)


122

There are four mounting faces of the equipment for the floor mount typerobot as shown in Fig. 2.2 (a), and four for the upside-down mount typerobot.

NOTE1. When equipment is mounted on equipment

mounting face A, B, C, and D, its center of gravitymust be within the hatched areas shown in Fig.2.2(b).

2. The masses of the equipment fitted to theequipment mounting faces must satisfy all therequirements below.

1) W + A � 12 (kg)

2) W + A + B + C � 32 (kg)

3) W + A + B + C + D � 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)

2.2Equipment MountingFace


123

2–M8 through hole

Rotatingcenter of J1–axis

Equipment mounting face D

Cover interference

Rotating cen-ter of J1–axis

Equipment mounting D (Mounting cover option)

4–M6depth 10

Equipment mountingface B

2–M6depth 8

Equipment mounting A

Equipment mounting C

3–M6depth 10

Fig.2.2 (a) Equipment mounting face (ARC Mate120/S–12)


124

Equipment mounting face D

Equipment mounting face B Equipment mounting face A

Equipmentmounting face C

Fig.2.2 (b) Positions of the center of gravity on the equipment mounting faces (ARC Mate 120/S–12)


125

Within the robot’s mechanical unit, an air pipe is provided; its inlet at theJ1–axis connector box, and its outlet at the J3 housing. The piping routeis shown in Fig. 7.1, of the part explaining maintenance. The inlet andoutlet joints of the piping are of the PT3/8 female type. No mating jointsare provided. It is the responsibility of the user to prepare mating jointsthat match tubes to be used.

2.3End Effector Air Pipe


126

The J3 housing has an end effector connector to enable connection toperipheral equipment. Fig. 2.4(a) and Fig. 2.4(b) show the pinassignment of the end effector connectors. For details, including thesetting of common input signals, refer to the maintenance manual of theR–J, RJ–2 controller.

Mechanical unit (K102)��

End effector

Fig. 2.4(a) End Effector Signal Pin Assignment (A05B–1208–H201)Fjig. 2.4(a) End Effector Signal Pin Assignment (A05B–1208–H211)Fjig. 2.4(a) End Effector Signal Pin Assignment (A05B–1208–H301)

Mechanical unit (K112, K202)

End effector

Fig. 2.4(b) End Effector Signal Pin Assignment (A05B–1208–H202)Fig. 2.4(b) End Effector Signal Pin Assignment (A05B–1208–H222)Fig. 2.4(b) End Effector Signal Pin Assignment (A05B–1208–H302)

2.4End Effector I/OSignals (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 whenattaching the end effector to the wrist.

Table2.5 Wrist load (ARC Mate 120 / S–12)

�� ⋅��⋅

�� ⋅��⋅

�� ⋅��⋅

�� ⋅ ⋅��⋅�

�� !�� ⋅ ⋅��⋅�

�� ⋅ ⋅��⋅�

NOTEThe values given for the load specifications are those for the conditions at the center of rotation.

2.5Wrist Load Specifications


129

Fig. 2.5 (a) to Fig. 2.5 (c) show the wrist load specifications. Loadspecifications are given to ensure that parameter values come within therange shown in the plot below.

Fig 2.5 (a) J4–axis load condition (ARC Mate 120 / S–12)

Fig 2.5 (b) J5–axis load condition (ARC Mate 120 / S–12)


130

Fig 2.5 (c) J6–axis load condition (ARC Mate 120 / S–12)

B–80485E/03 3. TRANSPORTATION AND INSTALLATION

131

3 TRANSPORTATION AND INSTALLATION

3. TRANSPORTATION AND INSTALLATION B–80485E/03

132

1 Remove the transit stopper (red) from the J1–axis.2 After turning on the control unit, move the J3–axis, by joint feed,

in the positive (+) direction until the J3–axis transit stopper,shown in box 3.1(a), can be removed.

3 Move the J2–axis, by joint feed, in positive (+) direction, untilthe J2–axis transit stopper can be removed.

4 Remove the transit stoppers (red) from the J2–axis and J3–axis.This completes the preparation.

NOTEIf an over travel alarm is issued in step 2 , hold down the shiftkey and press the alarm release key. Then, while stillholding down the shift key, move the J3–axis, by joint feed,in the positive (+) direction until the J3–axis overtravel isreleased.

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

3.1Transportation

1) Preparation prior toinstallation

2) Transportation by crane


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:A05B–1208–J051)

(When using a forklift)1 Position the robot to the transit attitude, then turn off the control

unit.2 Disconnect the cables from the J1 base connector panel.3 Fit a transit stopper for the J1–axis to prevent the J1–axis from

rotating.4 Secure forklift brackets to both sides of the J1 base, using from

M12�30 bolts and four M12 plain washers on each side.5 Use the right– and left–hand square holes to transport the robot.6 Remove the right and left forklift brackets.7 Remove the transit stopper from the J1–axis.

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 thatshown in Fig.3.1.

3.2Storage


136

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

Front

(Pin)

J1–axis rotatingcenter

4–�18 through–hole �28 facing, depth 5 (Through hole for foundation bolt)

2–�10H8(Pin–hole for positioning)

+0.0220

Fig.3.3 (a) Dimensions of robot base (ARC Mate120/S–12)

3.3Installation


137

Fig. 3.3(b) shows an example of robot installation. Secure an installationplate to the floor using four M20 chemical anchors (strength class: 4.8).Then, secure the robot base to the installation plate using four M16X35bolts (strength class: 12.9).If teaching compatibility is needed when the mechanical unit of the robotis replaced, use the two �10H8 pin holes for positioning.

NOTEIt is the customer’s responsibility to prepare positioningpins, anchor bolts, and the installation plate.

(Pin)

Front

J1–axis rotation center

Installation plate2–�10H8(Pin hole for positioning)

+0.022

0

Robot fixing boltsM16X35 (4 pcs)Strength class: 12.9Tightening torque: 313.6 Nm (32 kgf–m)

Chemical anchorM20 (4 pcs)Strength class: 4.8Tightening torque: 186.2 Nm (19 kgf–m)

Robot base plate

Installation plate

Fig. 3.3(b) Example Installation (ARC Mate 120/S–12)


138

Fig. 3.3 (c) shows the outer dimension the BASE option (A05B–1208–J055). Attached bolt M16X30 (4 pcs.), washer M16 (4 pcs.) and springpin �10X30 (2 pcs.) are used to install the robot to the base.

Fig. 3.3 (c) Outer dimension of BASE option (A05B–1208–J055) (ARC Mate 120/S–12)


139

Fig. 3.3 (d) and Table 3.3 (d) show force and moment applied to the baseplate during stillness, acceleration or deceleration, and emergency stopstate.

Fig. 3.3 (d) Force and moment

Table 3.3 (d) Force and moment

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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.


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�


Flange adaptor (optional)

Fig.3.4 (b) Mastering attitude (ARC Mate120/S-12)

3.4Maintenance 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 (Thecables are connected to the controller.). Connect the cables shown in Fig.3.5 to the connector box of the mechanical unit. When connecting, takecare not to damage the cables.

Connector box ofmechanical unit

Power line cableSignal cable Earth cable

M8X10

Fig.3.5 Cable connection board of robot mechanical unit(ARC Mate 120/S–12)

3.5Assembly DuringInstallation


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 themechanical unit and air control set is also provided. To install the aircontrol set, the customer is to prepare an air control set mounting sectionwith tapped holes for mounting, as shown in Fig. 3.6(b).

PT3/8

Air control set (option)Specification: A05B–1302–J011

Straight jointPT3/8

Elbow PT3/8

3–m air hose (Outer diameter: 10 mm, Inner diameter: 6.5 mm)

To be prepared by the customer

Fig.3.6 (a) Air piping (ARC Mate120/S-12)

Fill the oiler of the air control set with turbine oil (#90 to #140) to thespecified level. Preparation of the mounting bolts is the customer’sresponsibility.

4–M6

63

90

Oil inlet Adjustment knob

Oil misting check

Oiler

FilterRegulator pressure setting handle

Pressure gauge

Fig.3.6 (b) Air control set (ARC Mate120/S-12)

3.6Air Piping


143

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

Fig. 3.6 (c) Piping diagram (ARC Mate 120/S–12)


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, Upside–down (Wall & Angle mount)

(Note 1)

Motionrange

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)

J3 axis 8.55 rad (2.36 rad/sec) 490° (135°/sec)




Max. load capacity at wrist 12 kg

Allowable J4 axis 27 Nm 2.8 kgfmload

moment at J5 axis 20 Nm 2.0 kgfmmoment atwrist J6 axis 12 Nm 1.2 kgfm

Allowable J4 axis 0.75 kgm2 7.7 kgfcms2

load inertiaat wrist J5 axis 0.48 kgm2 4.9 kgfcms2at wrist

J6 axis 0.077 kgm2 0.78 kgfcms2

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 °CAmbient humidity: Normally 75% RH or less Short term (within one month)

Max. 95% RHHeight: Up to 1,000 meters above the sea levelrequires, no particular provision for attitude. Vibration: 0.5 G or less *No dew, nor frost allowed. *No corrosive gas allowed. (Note 3)

Air pressure Pressure 0.49 – 0.69 MPa 5–7 kg/cm2G(Preset pressure 0.49 MPa 5 kg/cm2G)

Consumption Maximum peak: 150Nl/min (Note 4)

3.7Installationspecifications


145

NOTE1. Under the installation condition within (), the J1–axis

motion range and the max. speed will be limited.2. J1–axis 6.28 rad (360°) rotation is option.3. If a robot is used in an environment with high

vibration, dust, or density of cutting oil, consult theservice representative.

4. This value indicates the capacity of the air controlset. Adjust the air flow to be less than this value.

5. J2 cover is option.

APPENDIX

B–80485E/03 A. SPARE PARTS LIST

145

A SPARE PARTS LIST

Table 1 (a) Cable list (ARC Mate120/S-12)

(A) 6–axis brake (RDIX1, RDOX1) Nomal Cable: A05B–1208–H201

Cable Specifications Remarks

K101 A05B–1208–D101 M1, M2, M3, M4, M5, M6 power

K102 A660–8009–T850 M1, M2, M3, M4, M5, M6 pulsecoder, DI/DO

K103 A660–4003–T241 M5 M6, power, pulse coder relay

K104 A660–4003–T243#J3 M3 power relay

K204 A660–4003–T410 M4 power relay

K105 A660–2004–T223#J3 M3 pulse coder relay

K205 A660–2004-T700 M4 pulse coder relay

K106 A05B–1207–D102 OT Short circuit

K108 A660–4003–T244 M6 power ,pulse coder

(B) 6–axis brake (RDIX8, RDOX8) Nomal Cable: A05B–1208–H202




K103 A660–4003–T241 M5, M6 power, pulse coder relay




K205 A660–2004–T700 M4 pulse coder relay

K106 A05B–1207–D102 OT short circuit

K108 A660–4003–T244 M6 power ,pulse coder relay

K109 A660–4003–T245 EE relay

A. SPARE PARTS LIST B–80485E/03

146

(C) 6–axis brake (RDIX1, RDOX1) Extension Cable: A05B–1208–H211










K108 A660–4003–T244 M6 power, pulse coder relay

(D) 6–axis brake (RDIX8, RDOX8) Diecasting Cable: A05B–1208–H222


K201 A05B–1208–D201 J1, J2, J3, J4, J5, J6 power

K202 A660–8010–T128 J1, J2, J3, J4, J5, J6 pulse coder,DI/DO

K103 A660–4003–T241 J5, J6 power, pulse coder relay

A660–4003–T243#J3 J3 power relayK104

A660–4003–T243#J4 J4 power relay

K105 A660–2004–T223#J3 J3 pulse coder relay

K105 A660–2004–T223#J4 J4 pulse coder relay

K106 A05B–1207–D102 OT short circuit

K108 A660–4003–T244 J6 power, pulse coder relay

K109 A660–4003–T245 EE relay

(E) 6–axis brake (RDIX1, RDOX1) Normal cable (for CE): A05B–1208–H301











B–80485E/03 A. SPARE PARTS LIST

147

(F) 6–axis brake (RDIX8, RDOX8) Normal cable (for CE): A05B–1208–H302











K109 A660–4003–T245 EE relay

(G) Limit switch cable (option)


K107 A660–4003–T242 OT relay

K121 A05B–1208–D103 J1 OT limit switch



(H) MIG EYE cable (without ROTATOR) (option): A05B–1208–H921


K132 A660–8010–T939 Sensor cable

— A660–8009–T708#L300R0 Ground cable

(I)MIG EYE cable (with ROTATOR) (option): A05B–1208–H922


K131 A660–2004–T638 Power cable

K132 A660–8010–T939 Sensor cable

K133 A660–8010–T940 Pulse coder cable

— A660–8009–T708#L300R0 Ground cable

A. SPARE PARTS LIST B–80485E/03

148

Table 1 (b) Motor (ARC Mate 120/S–12)

ARC Mate 120 A05B–1208–B201S–12 A05B–1208–B202

Specifications Axis Remarks

A06B–0163–B175 J1 � M9 with brake

A06B–0163–B175 J2 � M9 with brake

A06B–0373–B175 J3 � 2 with brake

A06B–0371–B175 J4 � 1 with brake

A06B–113–B178#0008 J5 � 0.5 with brake

A06B–113–B178#0008 J6 � 0.5 with brake

Table 1 (c) Cover (ARC Mate 120/S–12)

Specifications Remarks

A05B–7208–J401 J2–axis motor cover (option)

A05B–7208–X403 J3–axis cover

Table 1 (d) Battery (ARC Mate 120/S–12)

Specifications Remarks Qty.

A98L–0031–0005 1.5 V size D 4

Table 1 (e) Grease (ARC Mate 120/S–12)

Name Specification Remarks

Mory–WhiteRE No. 00

A98L–0040–0119#2.7KG For J1, J2, J3, J5–axis

SK–3 A98L–0040–0110#1KG For J4, J6–axis

B–80485E/03 B. MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM

149

B MECHANICAL UNIT INTERNAL CONNECTION DIAGRAM

B. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

L CO

NN

EC

TIO

N D

IAG

RA

MB

–80485E/03

150

Fig

. 2 (a) Intern

al con

nectio

n d

iagram

(AR

C M

ate120/S-12) (A

05B–1208–H

201)

B–80485E

/03B

. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL C

ON

NE

CT

ION

DIA

GR

AM

151

Fig

. 2 (b) In

ternal co

nn

ection

diag

ram (A

RC

Mate120/S

-12) (A05B

–1208–H202)

B. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

L CO

NN

EC

TIO

N D

IAG

RA

MB

–80485E/03

152

Fig

. 2 (c) Intern

al con

nectio

n d

iagram

(AR

C M

ate120/S-12) (A

05B–1208–H

211)

B–80485E

/03B

. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL C

ON

NE

CT

ION

DIA

GR

AM

153

Fig

. 2 (d) In

ternal co

nn

ection

diag

ram (A

RC

Mate120/S

-12) (A05B

–1208–H222)

B. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

L CO

NN

EC

TIO

N D

IAG

RA

MB

–80485E/03

154

Fig

. 2 (e–1) Intern

al con

nectio

n d

iagram

(AR

C M

ate120/S-12) (A

05B–1208–H

301)

B–80485E

/03B

. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL C

ON

NE

CT

ION

DIA

GR

AM

155

Fig

. 2 (e–2) Intern

al con

nectio

n d

iagram

(AR

C M

ate120/S-12) (A

05B–1208–H

301)

B. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

L CO

NN

EC

TIO

N D

IAG

RA

MB

–80485E/03

156

Fig

. 2 (f–1) Intern

al con

nectio

n d

iagram

(AR

C M

ate120/S-12) (A

05B–1208–H

302)

B–80485E

/03B

. ME

CH

AN

ICA

L UN

IT IN

TE

RN

AL C

ON

NE

CT

ION

DIA

GR

AM

157

Fig

. 2 (f–2) Intern

al con

nectio

n d

iagram

(AR

C M

ate120/S-12) (A

05B–1208–H

302)

B. M

EC

HA

NIC

AL U

NIT

INT

ER

NA

L CO

NN

EC

TIO

N D

IAG

RA

MB

–80485E/03

158

Fig

. 2 (g) In

ternal co

nn

ection

diag

ram (A

RC

Mate120/S

-12) (A05B

–1208–H921)

Fig

. 2 (g) In

ternal co

nn

ection

diag

ram (A

RC

Mate120/S

-12) (A05B

–1208–H922)

IndexB–62764EN/01

i–1

�Numbers�1–year checks, 27

3–month checks, 27

3–year check, 30

3–year checks, 27

�A�

Adjusting, 38

Adjusting J5–axis 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: A05B–1208–J401), 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�J1–axis drive mechanism, 20

J1–axis stroke modification (option), 44

J2–axis drive mechanism, 20



J5–axis and J6–axis 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 J2–axis motor M1 , M2 , 62

Replacing J1–Axis reducer, 64

Replacing J2–axis reducer, 67

Replacing J3–axis motor M3 , 69




INDEX B–62764EN/01

i–2

Replacing J5–axis gear, 75


Replacing J6–axis 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/S–12 MAINTENANCE MANUAL (B–80485E)

03 Dec., ’95 �Addition of descriptions for CE marking.

02 Feb., ’95

�R–J2 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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