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C4 Maintenance 1. Safety Maintenance

C Series Maintenance Manual Rev.2

3

1. Safety Maintenance

Please read this chapter, this manual, and other relevant manuals carefully to understand
safe maintenance procedures before performing any maintenance.

Only authorized personnel who have taken maintenance training held by the manufacturer

or dealer should be allowed to perform the robot maintenance.

WARNING

■

Do not remove any parts unless otherwise instructed by this manual. Follow the

maintenance procedure strictly as described. Improper removal of parts or

improper maintenance may cause not only malfunction of the robot system but

serious safety problems.

■

If you have not received training, keep away from the Manipulator while the power

is ON. Do not enter the operating area while the power is ON. Entering the

operating area with the power ON is extremely hazardous and may cause serious

safety problems as the Manipulator may move even it seems to be stopped.

■

When you check the operation of the Manipulator after replacing parts, be sure to

check it while you are outside of the safeguarded area. Checking the operation

of the Manipulator while you are inside of the safeguarded area may cause serious

safety problems as the Manipulator may move unexpectedly.

■

Before operating the robot system, make sure that both the Emergency Stop

switches and safeguard switch function properly. Operating the robot system

when the switches do not function properly is extremely hazardous and may result

in serious bodily injury and/or serious damage to the robot system as the switches

cannot fulfill their intended functions in an emergency.

WARNING

■

To shut off power to the robot system, disconnect the power plug from the power

source. Be sure to connect the AC power cable to a power receptacle.

DO NOT connect it directly to a factory power source.

■

Before performing any replacement procedure, turn OFF the Controller and

related equipment, and then disconnect the power plug from the power source.

Performing any replacement procedure with the power ON is extremely hazardous

and may result in electric shock and/or malfunction of the robot system.

■

When connecting / replacing the brake release unit or the external short

connector, turn OFF the power to the Controller and the brake release unit.

Inserting and removing the connector while the power is ON may result in

electrical shock.

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Summary of Contents for C Series

Page 1: ...Rev 2 EM221R5039F 6 Axis Robots C series Maintenance Manual ...

Page 2: ...Manipulator manual C4 series Maintenance Manual Rev 2 ...

Page 3: ...C Series Maintenance Manual Rev 2 i 6 Axis Robots C series Maintenance Manual Rev 2 Copyright 2021 2022 SEIKO EPSON CORPORATION All rights reserved ...

Page 4: ...es possible dangers and consequences that we can foresee Be sure to comply with safety precautions on this manual to use our robot system safety and correctly TRADEMARKS Microsoft Windows and Windows logo are either registered trademarks or trademarks of Microsoft Corporation in the United States and or other countries Other brand and product names are trademarks or registered trademarks of the re...

Page 5: ...iler where you purchased this product Use of the chemical symbols Pb Cd or Hg indicates if these metals are used in the battery This information only applies to customers in the European Union according to DIRECTIVE 2006 66 EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and accumulators and repealing Directive 91 157 EEC and l...

Page 6: ...0 Ver 7 2 0 or later Wall mounting The C12 series Manipulators can be used with the following combinations of software Controllers RC700 A Software EPSON RC 7 0 Ver 7 4 6 or later Setting by Using Software EPSON RC This manual contains setup procedures using the software Those sections are indicated by the symbol on the left Turning ON OFF Controller When you see the instruction Turn ON OFF the Co...

Page 7: ...ls from unpacking to operation Daily inspection of the controller Controller specifications and basic functions C series Manual PDF This manual describes the specifications and functions of the Manipulator The manual is primarily intended for people who design robot systems Technical information functions specifications etc required for the Manipulator installation and design Daily inspection of t...

Page 8: ...0 User s Guide PDF This manual describes general information about program development software EPSON RC 7 0 SPEL Language Reference PDF This manual describes the robot programming language SPEL Other Manual PDF Manuals for each option are available ...

Page 9: ...14 3 1 Arm 1 Top Cover 15 3 2 Arm 1 Side Cover 15 3 3 Arm 2 Side Cover 16 3 4 Arm 3 Head Cover 16 3 5 Arm 3 Bottom Cover 17 3 6 Arm 4 side cover 17 3 7 Base Bottom Cover 18 3 8 Connector Plate 18 3 9 Connector Sub Plate 19 3 10 User Plate 19 4 Cable Unit 20 4 1 Replacing the Cable Unit 20 Removal Cable unit 22 Installation Cable unit 29 4 2 Connector Pin Assignments 48 4 2 1 Signal Cable 48 4 2 2 ...

Page 10: ...Reduction gear unit 80 Installation Joint 2 Reduction gear unit 83 6 3 Joint 2 Replacing the Timing Belt 87 Removal Joint 2 Timing belt 87 Installation Joint 2 Timing belt 87 6 4 Joint 2 Replacing the Electromagnetic Brake 88 Removal Joint 2 Electromagnetic brake 88 Installation Joint 2 Electromagnetic brake 88 7 Joint 3 89 7 1 Joint 3 Replacing the Motor with a Brake 90 Removal Joint 3 Motor with...

Page 11: ...eduction gear unit 123 Installation Joint 5 Reduction gear unit 127 9 3 Joint 5 Replacing the Timing Belt 133 Removal Joint 5 Timing belt 133 Installation Joint 5 Timing belt 133 9 4 Joint 5 Replacing the Electromagnetic Brake 134 Removal Joint 5 Electromagnetic brake 134 Installation Joint 5 Electromagnetic brake 134 10 Joint 6 135 10 1 Joint 6 Replacing the Motor 136 Removal Joint 6 Motor 136 In...

Page 12: ...3 13 Replacing the Control Board 155 13 1 Replacing the Control Board 1 155 Removal Control board 1 155 Installation Control board 1 155 13 2 Replacing the Control Board 2 156 Removal Control board 2 156 Installation Control board 2 157 14 Replacing the LED Lamp 158 Removal LED lamp 159 Installation LED lamp 159 15 Replacing the M C Cable 160 Removal M C cable 162 Installation M C cable 162 16 Cal...

Page 13: ... 2 3 5 Joint 4 Reduction Gear Unit 190 2 3 6 Joint 5 Reduction Gear Unit 191 2 3 7 Joint 6 Reduction Gear Unit 192 2 3 8 Joint 6 Bevel Gear 193 2 4 Tightening Hexagon Socket Head Bolts 194 2 5 Layout of Maintenance Parts 195 3 Covers 196 3 1 Arm 1 Center Cover 199 3 2 Arm 1 Side Cover 200 3 3 Arm 2 Side Cover 202 3 4 Arm 3 Cover 203 3 5 Arm 3 Maintenance Cover 204 3 6 Arm 4 Side Cover 206 3 7 Arm ...

Page 14: ...ckward 285 5 1 4 Joint 1 Replacing the Electromagnetic Brake M C Cable Backward 292 5 2 M C Cable Downward Joint 1 294 5 2 1 Joint 1 Replacing the Motor M C Cable Downward 294 5 2 2 Joint 1 Replacing the Reduction Gear Unit M C Cable Downward 298 5 2 3 Joint 1 Replacing the Timing Belt M C Cable Downward 301 5 2 4 Joint 1 Replacing the Electromagnetic Brake M C Cable Downward 306 6 Joint 2 308 6 1...

Page 15: ...he Electromagnetic Brake 379 10 Joint 6 381 10 1 Joint 6 Replacing the Motor 382 10 2 Joint 6 Replacing the Reduction Gear Unit Replacing the Joints 5 6 Reduction Gear Unit Set 388 10 3 Joint 6 Replacing the Timing Belt 388 10 4 Joint 6 Replacing the Electromagnetic Brake 389 11 Replacing the Battery Unit 391 11 1 Replacing the Battery Unit Lithium Battery 393 11 2 Replacing the Battery Board 395 ...

Page 16: ...nit 436 2 3 4 Joint 4 Reduction Gear Unit 437 2 3 5 Joint 5 Reduction Gear Unit 438 2 3 6 Joint 6 Reduction Gear Unit 439 2 3 7 Joint 6 Bevel Gear 440 2 4 Tightening Hexagon Socket Head Bolts 441 2 5 Layout of Maintenance Parts 442 3 Covers 443 3 1 Arm 1 Center Cover 445 3 2 Arm 1 Side Cover 446 3 3 Arm 2 Side Cover 447 3 4 Arm 3 Cover 447 3 5 Arm 3 Maintenance Cover 448 3 6 Arm 4 Side Cover 449 3...

Page 17: ...1 Replacing the Reduction Gear Unit M C Cable Backward 510 5 1 3 Joint 1 Replacing the Timing Belt M C Cable Backward 517 5 1 4 Joint 1 Replacing the Electromagnetic Brake M C Cable Backward 523 5 2 M C Cable Downward Joint 1 525 5 2 1 Joint 1 Replacing the Motor M C Cable Downward 525 5 2 2 Joint 1 Replacing the Reduction Gear Unit M C Cable Downward 529 5 2 3 Joint 1 Replacing the Timing Belt M ...

Page 18: ...g the Reduction Gear Unit Replacing the Joint 5 6 Reduction Gear Unit Set 602 9 3 Joint 5 Replacing the Timing Belt 605 9 4 Joint 5 Replacing the Electromagnetic Brake 606 10 Joint 6 608 10 1 Joint 6 Replacing the Motor 609 10 2 Joint 6 Replacing the Reduction Gear Unit Replacing the Joints 5 6 Reduction Gear Unit Set 615 10 3 Joint 6 Replacing the Timing Belt 615 10 4 Joint 6 Replacing the Electr...

Page 19: ... of Contents C Series Maintenance Manual Rev 2 xvii 15 Replacing the Fan 636 16 Calibration 638 16 1 Overview 638 16 2 Calibration Procedure 641 17 C12 Maintenance Parts List 645 18 C12 Option Parts list 648 ...

Page 20: ...Table of Contents xviii C Series Maintenance Manual Rev 2 ...

Page 21: ...C4 Maintenance This volume contains maintenance procedures with safety precautions for C4 series Manipulators ...

Page 22: ......

Page 23: ...uarded area Checking the operation of the Manipulator while you are inside of the safeguarded area may cause serious safety problems as the Manipulator may move unexpectedly Before operating the robot system make sure that both the Emergency Stop switches and safeguard switch function properly Operating the robot system when the switches do not function properly is extremely hazardous and may resu...

Page 24: ... extremely hazardous and may result in electric shock and or improper function of the robot system If the Manipulator is operated without connecting the brake release unit or the external short connector the brakes cannot be released and it may cause damage on them After using the brake release unit be sure to connect the external short connector to the Manipulator or check connection of the conne...

Page 25: ...e stages daily monthly quarterly biannual and annual The inspection points are added every stage If the Manipulator is operated for 250 hours or longer per month the inspection points must be added every 250 hours 750 hours 1500 hours and 3000 hours operation Inspection Point Daily inspection Monthly inspection Quarterly inspection Biannual inspection Annual inspection Overhaul replacement 1 month...

Page 26: ...s on Manipulator on the connector plates etc Visually check for external defects Clean up if necessary External appearance of Manipulator External cables Check for bends or improper location Repair or place it properly if necessary Safeguard etc Check either the external short connector or the brake release unit connector is connected The external short connector on the back side of the Manipulato...

Page 27: ...an up if necessary Check the appearance of the cable and if it is scratched check that there is no cable disconnection Check for bends or improper location Repair or place it properly if necessary Check that the safeguard etc are located properly If the location is improper place it properly Check either the external short connector or the brake release unit connector is connected Check whether ex...

Page 28: ...erhaul the parts parts replacement The time between overhauls is 20 000 operation hours of the Manipulator as a rough indication However it may vary depending on usage condition and degree of the load such as when operated with the maximum motion speed and maximum acceleration deceleration in continuous operation applied on the Manipulator For the EPSON RC 7 0 Ver 7 2 x or later firmware Ver 7 2 x...

Page 29: ...Click the View Controller Status button to open the Browse For Folder dialog box 3 Select the folder where the information is stored 4 Click OK to view the Controller Status Viewer dialog box 5 Select Robot from the tree menu on the left side For the parts subject to overhaul refer to C4 Maintenance 17 C4 Maintenance Parts List For details of replacement of each part refer to each section Please c...

Page 30: ...on your skin follow the instructions below If grease gets into your eyes Flush them thoroughly with clean water and then see a doctor immediately If grease gets into your mouth If swallowed do not induce vomiting See a doctor immediately If grease just gets into your mouth wash out your mouth with water thoroughly If grease gets on your skin Wash the area thoroughly with soap and water Greasing pa...

Page 31: ...ction you can unplug the plug easily 2 Insert the screw into the screw part M4 depth 5 of the plug Screw M4 length 15 mm or more easy to unplug 3 Hold the screw inserted in the step 2 and unplug the plug 4 Apply the grease Grease SK 2 Grease amount 2 g 5 Insert the plug unplugged in the step 3 to the original position To prevent the grease leaking or unplugging be sure to insert the plug all the w...

Page 32: ...g Torque See below for the set screw M3 2 0 0 1 N m 21 1 kgf cm Set Screw Tightening Torque M4 4 0 0 2 N m 41 2 kgf cm M4 2 4 0 1 N m 26 1 kgf cm M5 8 0 0 4 N m 82 4 kgf cm M5 3 9 0 2 N m 40 2 kgf cm M6 13 0 0 6 N m 133 6 kgf cm M8 32 0 1 6 N m 326 16 kgf cm M10 58 0 2 9 N m 590 30 kgf cm M12 100 0 5 0 N m 1 020 51 kgf cm It is recommended to fasten the bolts aligned on a circumference in a crissc...

Page 33: ...le Joint 1 Reduction gear unit Joint 2 Electromagnetic brake Joint 2 Timing belt Joint 3 Electromagnetic brake Joint 3 Timing belt Joint 5 Electromagnetic brake Joint 5 Timing belt Joint 6 Motor Joint 5 Motor Joint 6 Electromagnetic brake Joint 6 Timing belt Joint 4 Reduction gear unit Joint 4 Motor Joint 2 Motor Joint 3 Motor Joint 4 Electromagnetic brake Joint 4 Timing belt Battery Top Control b...

Page 34: ... OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system Be careful not to get any foreign substances in the Manipulator connectors and pins during maintenance Turning ON the power to the robot system when an...

Page 35: ... M3 8 Cross recessed truss head small screws Tightening torque 0 45 0 1 N m Arm 1 top cover 3 2 Arm 1 Side Cover CAUTION When mounting the cover be careful not to get the cables caught in it or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock ...

Page 36: ...rm 2 side cover 4 M3 8 Cross recessed truss head small screws Tightening torque 0 45 0 1 N m 4 M3 8 Cross recessed truss head small screws Tightening torque 0 45 0 1 N m 3 4 Arm 3 Head Cover CAUTION When mounting the cover be careful not to get the cables caught in it or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or c...

Page 37: ...o the position where you can remove the cover easily Arm 3 bottom cover 4 M3 5 Cross recessed truss head small screws Tightening torque 0 6 0 1 N m 3 6 Arm 4 side cover CAUTION When mounting the cover be careful not to get the cables caught in it or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These a...

Page 38: ... using our attached screws or equivalent ones Base bottom cover 4 M3 5 cross recessed flat head machine screws Tightening torque 0 6 0 1 N m 3 8 Connector Plate CAUTION Do not remove the connector plate forcibly Removing the connector plate forcibly may result in damage to the cables disconnection and or contact failure Damaged cables disconnection or contact failure is extremely hazardous and may...

Page 39: ...te Be sure to place the cables back to their original locations Connector sub plate 4 M4 8 Hexagon socket head cap bolts Tightening torque 4 0 0 2 N m 3 10 User Plate CAUTION Do not remove the connector plate forcibly It may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system...

Page 40: ...nce Turning ON the power to the robot system when any foreign substances exist in them is extremely hazardous and may result in electric shock and or malfunction of the robot system Be sure to connect the cables properly Do not allow unnecessary strain on the cables Do not put heavy objects on the cables Do not bend or pull the cables forcibly Unnecessary strain on the cables may result in damage ...

Page 41: ...If swallowed do not induce vomiting See a doctor immediately If grease just gets into your mouth wash out your mouth with water thoroughly If grease gets on your skin Wash the area thoroughly with soap and water Name Quantity Note Maintenance Parts Cable unit for C4 A601 1 For part code refer to the 17 C4 Maintenance Part List for C4 A901 1 for C4 A601 UL 1 for C4 A901 UL 1 Battery relay cable uni...

Page 42: ...ad cover Arm 3 bottom cover Arm 2 side cover Both sides Arm 1 side cover Both sides Arm 1 top cover Connector plate When removing the user plate and the connector plate remove the following parts together D sub 9 pin connector D sub 15 pin connector Air tube 4 4 Disconnect the connectors inside the base Connectors X010 X020 X030 X040 X050 X060 LED BR010 BR011 BR020 BR030 BR040 BR050 BR060 BT1 X11 ...

Page 43: ...ery board Hexagon socket head cap bolts 2 M3 8 9 Remove the battery unit Hexagon socket head cap bolts 2 M4 8 The battery unit and battery relay cable will be used again Be careful not to lose them If you are replacing the battery relay cable follow the step 10 10 If replacing the battery relay cable Remove the connectors connected to the battery Connectors 2 connectors for the batteries BT The ba...

Page 44: ...1 X061 LED BR041 BR051 BR061 BT4 BT51 BT61 X141 X151 X161 XGND GS02 X72 X061 BR061 BT61 and X161 may not be existed 13 Remove the Arm 4 cable fixing plate with the ground wires from the Arm 4 Hexagon socket head cap bolts 2 M4 8 The Arm 4 cable fixing plate will be used again Be careful not to lose it 14 Remove the connectors inside the Arm 4 Connectors X052 X152 BT52 BR052 X062 X162 BT62 BR062 ...

Page 45: ... M4 15 with a plain washer 17 Cut off the following bands from the Arm 4 cable fixing plate Cable band Coil plate fixing band 18 Remove the following parts from the Arm 3 Arm 3 cable fixing plate circle Hexagon socket head cap bolts 2 M4 8 Ground wire fixing bolts triangle Hexagon socket head cap bolts 2 M4 8 Control board 2 square Hexagon socket head cap bolt 1 M4 10 Hexagon socket head cap bolt ...

Page 46: ... See an arrow in the photo for pulling direction Joint 5 motor cable and brake cable Joint 6 motor cable brake cable Cable for installed wire for customer use Connector X051 X061 X151 X161 XGND BR051 BR061 BT51 BT61 X061 X161 BR061 and BT61 may not be existed When pulling out the cables carefully treat cables and connectors to prevent damage to them Pull out the cables in the order of connector si...

Page 47: ... cap bolts 2 M4 8 26 Remove the Arm 2 cable fixing plate Hexagon socket head cap bolts 2 M4 8 It is not necessary to remove the fixing bolts completely Remaining the bolts on the Arm 2 makes it easy to mount the cable unit Pull out the cables from the Arm 1 27 Cut off the binding tie of the Arm 1 28 Remove two ground wires Hexagon socket head cap bolts 2 M4 8 29 Disconnect the connectors of the Jo...

Page 48: ...l not to lose it Base cable fixing plate Hexagon socket head cap bolt 2 M4 8 Ground wire Hexagon socket head cap bolt 4 M4 8 33 Cut off the wire tie of the base cable fixing plate The base cable fixing plate will be used again Be careful not to lose it 34 Pull out the cables in the Arm 2 and the base from the Arm 1 See an arrow in the photo for pulling direction 35 Remove the Arm 2 cable fixing pl...

Page 49: ...61 X151 X161 XGND BR051 BR061 BT51 BT61 X71 X72 SW1 This operation is not necessary if the cable unit is separated from the beginning 3 Cut the mark tube into following length 68 mm 2 for fixing the J1 wire tie 65 mm for fixing the J2 wire tie 23 mm 2 for fixing the J2 wire tie 21 mm 2 for fixing the J3 wire tie 57 mm 2 for fixing the J3 wire tie 46 mm for fixing the J4 wire tie 4 Grease the insid...

Page 50: ...e tie through the hole of the plate as shown in the photo on the right When installing the cable unit place the plate the air tube and the cables as shown in the photo on the right example and then fix the plate and the cable unit with a wire tie Cable Air tube Plate 6 Insert the cable unit with the cable protection spring ø 17 5 from the Arm 4 7 Wrap the end of the spring to the Arm 4 cable fixin...

Page 51: ...e cable protection spring ø 29 from the Arm 1 to the base side Connectors to be passed through to the base X12 X020 X030 X13 X040 X050 X060 X14 X15 X16 XGND BR011 BR010 BT1 BR020 BR030 BR040 BR050 BR060 LED SW1 GS01 GS02 9 Pull the wrapped cables from the Arm 2 10 Pass the cable unit to the Arm 3 ...

Page 52: ...m of the Arm 2 to the Arm 3 cable fixing plate Wire tie AB100 Number of turns of spring to fix 3 turns 13 Temporally bind two cables Wire tie AB150 2 Mark tube 57 mm 2 Temporarily bind the cables so that their position can be adjusted later Precautions for cable unit fixation to the plate Pass the mark tube and the wire tie through the hole of the plate as shown in the photo on the right NOTE ...

Page 53: ... plate and the cable unit with a wire tie Air tube Plate Cable 14 Fix the cable protection spring ø17 5 to the Arm 3 cable fixing plate Wire tie AB100 Number of turns of spring to fix 3 turns 15 Pass the four air tubes and the ground wire of the cable unit through the cable protection spring ø 17 5 and pull them out from the Arm 4 Pass the air tubes through the space on the upper side of the sprin...

Page 54: ... the plate Place the silicone sheet on the plate as shown in the photo on the right example Fix the wire tie at the center of the silicone sheet 17 Temporarily fix the Arm 4 cable fixing plate to the Arm 4 Hexagon socket head cap bolt 2 M4 10 18 Temporarily bind the cables coming from the Arm 4 Wire tie AB150 Mark tube 46 mm Precautions for cable unit fixation to the plate Pass the mark tube and t...

Page 55: ...bles as shown in the right photo example and then fix the plate and the cable unit with a wire tie Plate Air tube Cables 19 Disconnect the D sub connector to the user plate installation part 20 Install the D sub connector to the user plate 21 Temporarily fix the Arm 3 cable fixing plate to the Arm 3 Hexagon socket head cap bolt 2 M4 8 ...

Page 56: ...ed 60 mm Length of the cable passed through the Arm 3 From the Arm 3 cable fixing plate to each connector 50 mm Connector X141 X151 X161 XGND X041 X051 X061 BR041 BR051 BR061 LED BT4 BT51 BT61 X71 X72 X161 X061 BR061 BT61 and X72 may not be existed 50 mm Air tube length From the Arm 3 to the air tube 30 mm 30 mm Ground wire length From the Arm 3 cable fixing plate To the ground terminal 110 mm 110...

Page 57: ...xing plate and tighten the temporarily fixed screws Adjust orientation of terminals as shown in the photo Circle right Ground terminal user wire s ground terminal Circle left X052 X062 ground terminal X152 X162 ground terminal 25 Fix the cables temporarily fixed to the Arm 3 cable fixing plate 26 Install the D sub connector to the user plate Be careful of the direction of the user plate ...

Page 58: ...plate to the Arm 4 Hexagon socket head cap bolt 2 M3 6 29 Fix the Joint 5 motor unit to the Arm 4 temporarily and place the Joint 5 timing belt on the pulleys Hexagon socket head cap bolts 2 M4 15 with a plain washer 30 Fix the Joint 6 motor unit to the Arm 4 temporarily and place the Joint 5 timing belt on the pulleys Hexagon socket head cap bolts 2 M4 15 with a plain washer ...

Page 59: ...s Connectors X052 X062 X152 X162 BR052 BR062 BT52 BT62 32 Put the connected connectors in the Arm 4 33 Connect the connectors inside the Arm 3 Hexagon socket head cap bolts 2 M4 8 Connectors X71 X72 X041 X051 X061 LED BR041 BR051 BR061 BT4 BT51 BT61 X141 X151 X161 XGND X72 X061 BR061 BT61 and X161 may not be existed ...

Page 60: ...t X061 ground terminal X041 ground terminal Use X051 ground terminal if X061 is not existed Install the following ground terminals to the parts marked with triangles Hexagon socket head cap bolt 2 M4 8 Triangle right X141 ground terminal Triangle left Ground wire terminal Adjust the orientation of terminals as shown in the photo on the right M4 M3 36 Put the cables temporarily fixed to the Arm 3 c...

Page 61: ...e pulleys Hexagon socket head cap bolts 2 M4 15 with a plain washer Pass the cables to the left side of the motor s rear side as shown in the photo Motor rear 41 Connect the Joint 3 motor connectors and put them in the Arm 2 Connectors X031 X131 BR031 BT3 42 Fix two ground wires to the Arm 2 Hexagon socket head cap bolts 2 M4 8 Circle right X031 ground terminal X131 ground terminal Circle left Gro...

Page 62: ... on the right and fix the cable temporarily fixed by the wire tie Pushing depth 6 mm 46 Fix the cable protection spring ø25 130 mm to the Arm 1 cable fixing plate Wire tie AB100 2 ties Number of turns of spring to fix 3 turns 47 Temporarily fix the cables to the Arm 1 cable fixing plate Wire tie AB150 2 ties Mark tube 68 mm 2 tubes Set the heads of the wire ties to the side of the cables as shown ...

Page 63: ...gh the hole of the plate as shown in the photo on the right When installing the cable unit place the plate the air tube and the cables as shown in the photo on the right example and then fix the plate and the cable unit with a wire tie Cable Air tube Plate 50 Temporarily fix the Joint 2 motor unit to the Arm 1 and place the Joint 2 timing belt to the pulleys Hexagon socket head cap bolts 3 M4 15 w...

Page 64: ...able Install the connectors to the battery unit Connector BT 2 connectors The connectors can be installed on either side 56 Install the connectors to the battery board Connector 2 connectors for the batteries BT CN1 BT CN2 CN3 Wire tie AB100 57 Install the control board 1 to the Arm 1 and connect the connector Cross recessed head screws 3 M3 8 Tightening torque 0 45 0 1 N m Connector GS01 58 Bind ...

Page 65: ...ies Precautions for cable unit fixation to the plate When installing the cable unit place the plate the air tube and the cables as shown in the photo on the right example and then fix the plate and the cable unit with a wire tie Air tube Plate Cable Fix the cables with the wire ties so that the silicone sheet projects 5 mm from the base cable plate 5 mm 61 Pull the cable out and adjust the plate p...

Page 66: ...e of the base 70 mm 65 Insert the air tubes to the air tube fitting on the connector plate 66 Connect the connectors to the M C cable Connector X010 X020 X030 X040 X050 X060 LED BR010 BR011 BR020 BR030 BR040 BR050 BR060 BT1 X11 X12 X13 X14 X15 X16 XGND GS01 GS02 67 Connect the D sub 9 pin connector and the D sub 15 pin connector to the connector plate 68 Apply tension to the Joint 5 motor unit and...

Page 67: ...ntenance 6 1 Joint 2 Replacing the Motor Installation step 6 72 Mount the following covers and plates Arm 3 head cover Arm 3 bottom cover Arm 2 side cover Both sides Arm 1 side cover Both sides Arm 1 top cover Connector plate For details refer to C4 Maintenance 3 Covers 73 Perform the calibration For details refer to C4 Maintenance 16 Calibration ...

Page 68: ...C4 Maintenance 4 Cable Unit 48 C Series Maintenance Manual Rev 2 4 2 Connector Pin Assignments 4 2 1 Signal Cable ...

Page 69: ...C4 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 49 ...

Page 70: ...C4 Maintenance 4 Cable Unit 50 C Series Maintenance Manual Rev 2 ...

Page 71: ...C4 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 51 For specifications without connector X061 BT61 BR061 X161 X72 ...

Page 72: ...C4 Maintenance 4 Cable Unit 52 C Series Maintenance Manual Rev 2 ...

Page 73: ...C4 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 53 ...

Page 74: ...C4 Maintenance 4 Cable Unit 54 C Series Maintenance Manual Rev 2 4 2 2 Power Cable ...

Page 75: ...C4 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 55 ...

Page 76: ...C4 Maintenance 4 Cable Unit 56 C Series Maintenance Manual Rev 2 For specifications without connector X061 BT61 BR061 X161 X72 ...

Page 77: ... connector X061 BT61 BR061 X161 X72 4 2 4 Color of Cables The following table shows the codes and cable colors indicated in the pin assignments 4 2 1 Signal Cable 4 2 2 Power Cable 4 2 3 User Cable Code Cable color B Black W White R Red G Green Y Yellow BR Brown L Blue V Violet A Azure O Orange GL Gray P Pink ...

Page 78: ...sconnect the power plug from the power source Performing any work while connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life of the motors and encoder and or damage them Neve...

Page 79: ... flats 4 mm 1 For M5 hexagon socket head cap bolts Cross point screwdriver 1 For covers Torque wrench 1 Force gauge 1 For belt tension adjustment Removal Joint 1 Motor 1 Turn ON the Controller 2 Remove the connector plate For details refer to C4 Maintenance 3 Covers 3 Disconnect the connectors Connector X11 X010 BT1 BR011 Hold the clip to remove 4 Remove the Joint 1 motor unit from the base Hexago...

Page 80: ... with a brass bushing Pulley and the motor shaft Hexagon socket head set screws 2 M5 10 with a brass bushing There is a brass bushing on one of the set screws fixing the drive boss and the pulley 1 Be careful not to lose it 6 Remove the electromagnetic brake of the Joint 1 Hexagon socket head set screw 1 M5 8 7 Remove the motor plate from the Joint 1 motor Hexagon socket head cap bolts 4 M5 15 ...

Page 81: ...ce of the electromagnetic brake to the set screw side Be careful not to cut the cable by getting it caught between the brake and the plate Secure the set screw while pressing the electromagnetic brake to the motor plate Hexagon socket head set screw 1 M5 8 Tightening torque 3 9 N m 40 kgf cm Flat surface 3 Install the drive boss and the pulley 1 to the Joint 1 motor unit Fix the drive boss and the...

Page 82: ...he unit is secured too loose or too tight the belt will not have proper tension 6 Apply proper tension to the Joint 1 motor unit and secure it Pass a suitable cord or a string insulation lock to the drilled hole on the motor plate Pull the cord using a force gauge or a similar tool to apply specified tension Joint 1 timing belt tension 78 4 N 9 8 N 8 kgf 1 kgf Apply proper tension to the Joint 1 m...

Page 83: ...eplace these parts and accessories all together as a set Reduction gear unit Wave generator Flexspline Circular spline Accessory Spacer Grip ring only for Specification type 1 For details refer to C4 Maintenance 17 C4 Maintenance Parts List It is recommended to replace the O ring when replacing the reduction gear unit Name Quantity Note Maintenance Parts Joint 1 reduction gear unit 1 1687022 Joint...

Page 84: ...ers are removing the bolts Removing the bolts without supporting the arm may result in the arm falling bodily injury and or malfunction of the robot system 3 Remove the connector plate and the base bottom cover For details refer to C4 Maintenance 3 Covers 4 Loosen the set screws of the Joint 1 motor unit and remove the Joint 1 timing belt Hexagon socket head cap bolt 3 M4 20 5 Remove the pulley 2 ...

Page 85: ...wave generator unit from the reduction gear unit Wipe grease from the parts while removing them If it is difficult to remove the wave generator unit install the removed pulley 2 to the shaft and pull the parts together 9 Remove the wave generator from the shaft Hexagon socket head set screws 2 M5 6 with a brass bushing At this point remove the bearing first The bearing will be used again Be carefu...

Page 86: ...enly and remove the circular spline 11 Remove the flexspline from the base Hexagon socket head cap bolt 6 M6 15 12 Remove the friction plate EKagrip between the flexspline installation surface and the flexspline This step is not necessary for the Manipulator with a serial number C40E004191 or later since a friction plate EKagrip is not included in the part 13 Wipe grease using a cloth or similar m...

Page 87: ...tion gear unit package and check if it contains the parts below Specification type 1 Specification type 2 2 Place the friction plate EKagrip on the end face of the shaft to match the screw holes This step is not necessary for the specification type 2 since the friction plate EKagrip is not included in the part 3 Apply grease all over the tooth flank of the flexspline Grease SK 1 Grease amount enou...

Page 88: ...0 kgf cm Install the flexspline to match the air escapement holes of the flex spline with these of the spacer Flexspline Spacer 5 Apply grease all over the tooth flank of the circular spline Grease SK 1A Grease amount enough to fill the grooves 6 Install the circular spline Hexagon socket head cap bolt 16 M4 20 Tightening torque 4 9 N m 50 kgf cm 7 Apply grease to the inside of the flexspline Grea...

Page 89: ...m 40 kgf cm When installing the part press the wave generator all the way in and fix the set screw to the D cut face of the shaft Insert the brass bushing to the end of the other set screw 10 Install the bearing 11 Install the assembled wave generator unit to the reduction gear unit 12 Put the O ring into the groove on the flange Carefully assemble the parts to avoid damaging the O ring Otherwise ...

Page 90: ... cm Align the end of the shaft with the side of the pulley 15 Loosely secure the Joint 1 motor unit Make sure that the motor unit can be moved by hand and it does not tilt when being pulled If the unit is secured too loose or too tight the belt will not have proper tension 16 Mount the Joint 1 motor unit For details refer to C4 Maintenance 5 1 Joint 1 motor Installation step 6 17 Mount the connect...

Page 91: ...wrench 1 Force gauge 1 For belt tension adjustment Removal Joint 1 Timing belt 1 Remove the Joint 1 motor unit For details refer to C4 Maintenance 5 1 Joint 1 motor Removal step 1 to 4 2 Remove the Joint 1 timing belt Work process is common between C4 A601 and C4 A901 Installation Joint 1 Timing belt 1 Place the Joint 1 timing belt around the Joint 1 pulley in the back in the photo 2 Mount the Joi...

Page 92: ... head cap bolt Torque wrench 1 Force gauge 1 For belt tension adjustment Removal Joint 1 Electromagnetic brake 1 Remove the Joint 1 electromagnetic brake from the Joint 1 motor unit For details refer to C4 Maintenance 5 1 Joint 1 motor Removal step 1 to 6 2 Remove the following connector Connector D for noise dissipative diode Installation Joint 1 Electromagnetic brake 1 Install the following conn...

Page 93: ...placement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement It may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and canno...

Page 94: ...s 4 mm 1 For M5 hexagon socket head cap bolt Cross point screwdriver 1 For covers Torque wrench 1 Cloth 1 For pressing arms Force gauge 1 For belt tension The brake is mounted on the Joint 2 to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status However the brake does not work during replacement To replace the Joint 2 motor tilt the Arm ...

Page 95: ...that two arms do not touch each other Protect arms using a cloth etc Tilt the Arm 2 4 Turn OFF the Controller power 5 Disconnect the following connectors Connector X121 X021 X62 BR021 Hold the clip to remove 6 Tilt the Arm 2 and remove the Joint 2 motor unit and the belt from the Arm 1 If the bolts are removed with the Arm 2 is not tilted the belt will come off and theArm 2 will fall Be sure to ti...

Page 96: ...t set screws 2 M5 6 with a brass bushing Pulley and the motor shaft Hexagon socket set screws 2 M5 10 with a brass bushing There is a brass bushing on one of the set screws fixing the driving boss and the pulley Be careful not to lose it 8 Remove the Joint 2 electromagnetic brake Hexagon socket set screw 1 M5 8 9 Remove the motor plate from the Joint 2 motor Hexagon socket head cap bolts 4 M5 15 ...

Page 97: ... careful not to cut the brake wire by getting it caught between the brake and the motor plate Press the brake toward the motor plate and tighten the set screw Hexagon socket set screw 1 M5 8 Tightening torque 3 9 N m 40 kgf cm Flat surface 3 Mount the drive boss and the pulley 1 to the Joint 2 motor unit Put the end faces of the brake boss and the pulley 1 together and fix them Hexagon socket set ...

Page 98: ...the screw for tension adjustment to the motor plate Screw M4 30 or longer recommended length Pass a suitable cord or a string insulation lock to the screw Pull the cord using a force gauge or a similar tool to apply specified tension Joint 2 timing belt tension 78 4 N 9 8 N 8 kgf 1 kgf Apply tension by pressing toward the A surface in the figure and secure the motor unit Pulley 2 Timing belt A Hex...

Page 99: ...sory O ring 2 For details refer to C4 Maintenance 17 C4 Maintenance Parts List It is recommended replacing the O ring for Joint 2 when replacing the reduction gear unit Name Quantity Note Maintenance Parts Joint 2 reduction gear unit 1 1687023 Joint 2 O ring 1 1510528 Tools Hexagonal wrench width across flats 2 5 mm 1 For M3 hexagon socket head cap bolt For M5 hexagon socket set screw width across...

Page 100: ... 6 3 Joint 2 Replacing the Motor Removal steps 1 through 4 Pulley 1 Timing belt Pulley 2 3 Remove the cable unit For details refer to C4 Maintenance 4 1 Replacing the Cable Unit removal steps 9 through 26 4 Pull out the cables from the Arm 1 5 Turn the Manipulator laterally with the motor pulley facing down CAUTION When turning the Manipulator laterally there must be two or more people to work on ...

Page 101: ...on socket head cap bolts 16 M4 30 By removing the screws theArm 2 3 4 5 and 6 end effector can be separated Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts Wipe grease on the parts while removing them 9 Remove the wave generator from the reduction gear unit If the wave generator unit does not come off easily set the pulley 2 as shown i...

Page 102: ...se it There is a brass bushing on one of the set screws Be careful not to lose it Wipe grease on the parts while removing them Bearing 11 Remove the reduction gear unit from the Arm 2 Hexagon socket head cap bolt 12 M4 30 Wipe grease on the parts while removing them 12 Remove the O ring Wipe grease on the parts while removing them O ring 13 Wipe grease using a cloth or a similar material if it is ...

Page 103: ... bearing unit Circular spline Wave generator CAUTION Do not adjust the bolts securing the flexspline and the cross roller bearing If the bolts are adjusted it requires centering of the parts by the reduction gear unit manufacturer 2 Set the O rings to the grooves on both faces of the circular spline Make sure to fit the rings completely Convex surface Concave surface Convex surface Groove Concave ...

Page 104: ...rator and install the wave generator to the shaft Hexagon socket set screw 2 M5 6 with a brass bushing Tightening torque 3 9 N m 40 kgf cm When installing the wave generator push it to the end and set the set screws on the shaft s flat face For the other set screw set the brass bushing to the end 7 Install the removed bearing to the shaft Bearing 8 Set the O ring to the groove on the installation ...

Page 105: ...tion face of the Arm 2 reduction gear unit has clearance holes Install the reduction gear unit to match the screws and the clearance holes Bolts Holes 10 Grease the inner side of the flexspline Grease SK 1A Grease amount 30 g 11 Set the wave washer to the position where the Arm 2 bearing will be set 12 Insert the wave generator to the reduction gear unit and fix it Wave washer ...

Page 106: ...the end of the shaft and the side of the pulley and then fix them 15 Turn the Arm to the opposite side and install the Arm 1 plate Hexagon socket head cap bolts 6 M4 12 Tightening torque 4 9 N m 50 kgf cm After installing the plate move the arm to make sure that there is no errors Arm 1 plate 16 Install the cable unit For details refer to C4 Maintenance 4 1 Replacing the Cable Unit installation st...

Page 107: ... from the pulley 2 This procedure is common in C4 A601 and C4 A901 Installation Joint 2 Timing belt 1 Place the Joint 2 timing belt to the pulley 1 and the pulley 2 of the Joint 2 Place the timing belt to the pulley 2 first Then place the timing belt to the pulley 1 2 Secure the Joint 2 motor unit For details refer to C4 Maintenance 6 1 Joint 2 Replacing the Motor Installation steps 6 8 and 9 Name...

Page 108: ...e electromagnetic brake connector Connector D for noise dissipative diode 2 Assemble the Joint 2 electromagnetic brake and mount the motor unit For details refer to C4 Maintenance 6 1 Joint 2 Replacing the Motor Installation steps 2 through 9 Name Quantity Note Maintenance Parts Joint 2 electromagnetic brake 1 For the part code refer to the 17 C4 Maintenance Part List Noise dissipative diode 1 Too...

Page 109: ...rocedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be...

Page 110: ... coatings Removal Joint 3 Motor with a brake 1 Turn ON the Controller power 2 Tilt the Arm 3 Put a cloth between theArm 2 and theArm 3 so that two arms do not touch each other Protect arms using cloth etc Tilt Arm 3 3 Turn OFF the Controller power 4 Remove the Arm 2 side cover For details refer to C4 Maintenance 3 Covers Name Quantity Note Maintenance Parts AC servo motor 150 W with a brake 1 For ...

Page 111: ...plain washer 7 Remove the connector for the noise dissipative diode Connector D The noise dissipative diode will be used again Be careful not to lose it 8 Remove the Joint 3 pulley 1 from the Joint 3 motor unit Hexagon socket set screws 2 M4 8 with a brass bushing There is a brass bushing in one of the set screw fixing the drive boss and the pulley Be careful not to lose it 9 Remove the motor plat...

Page 112: ...ulley 1 to the Joint 3 motor unit Hexagon socket set screw 2 M4 8 with a brass bushing Tightening torque 2 5 N m 25 kgf cm Set the set screw to the flat face of the motor shaft For the other set screw set the brass bushing to the end Join the end of the motor shaft and the side of the pulley and then fix them 3 Fix the motor cable to the motor Wire tie AB200 30mm to 35mm Wire t 4 Install the remov...

Page 113: ...tor unit and fix it Install the screw for tension adjustment to the motor plate Screw M4 40 or longer recommended length Pass a suitable cord or a string insulation lock to the screw Pull the cord using a force gauge or a similar tool to apply specified tension Joint 3 timing belt tension 68 6 N 9 8 N 7 kgf 1 kgf Secure the Joint 3 motor unit by applying tention Hexagon socket head cap bolt 2 M4 1...

Page 114: ...de cover User plate When removing the user plate remove the following parts from the plate D sub 9 pin connector 4 air tubes For details refer to C4 Maintenance 3 Covers 2 Remove the Joint 3 timing belt For details refer to C4 Maintenance 7 3 Joint 3 Replacing the Motor Removal steps 1 through 3 3 Remove the cable unit For details refer to C4 Maintenance 4 1 Replacing the Cable Unit steps 9 throug...

Page 115: ...et set screws 2 M4 8 with a brass bushing 6 Remove the screws securing the reduction gear unit Hexagon socket head cap bolts 16 M3 20 By removing the screws Arm 3 4 5 and 6 end effector can be separated Have at least two workers so that one can support the Manipulator while the other worker is removing the screws The parts are greased Wipe grease while removing the parts ...

Page 116: ...reful not to lose it The parts are greased Wipe grease while removing the parts 8 Remove the wave generator from the shaft Hexagon socket set screws 2 M4 5 with a brass bushing Remove the bearing The bearing will be used again Be careful not to lose it There is a brass bushing on one of the set screws Be careful not to lose it The parts are greased Wipe grease while removing the parts 9 Remove the...

Page 117: ...int 3 C Series Maintenance Manual Rev 2 97 10 Remove the O ring The parts are greased Wipe grease while removing the parts O ring 11 Wipe grease using a cloth or a similar material if it is attached to the Arm 2 and 3 etc ...

Page 118: ...to the fitting parts O ring Flexspline Cross roller bearing unit Circular spline Wave generator CAUTION Do not adjust the bolts securing the flexspline and the cross roller bearing If the bolts are adjusted it requires centering of the parts by the reduction gear unit manufacturer 2 Set the O rings to the grooves on the both faces of the circular spline Make sure to fit the rings completely Convex...

Page 119: ...ve generator and install it to the shaft Hexagon socket set screws 2 M4 5 with a brass bushing Tightening torque 2 5 N m 25 kgf cm When installing the wave generator push it to the end and set the set screws on the shaft s flat face For the other set screw set the brass bushing to the end 7 Install the removed bearing to the shaft 8 Set the O ring to the O ring groove on the installation face of t...

Page 120: ...ation face of the Arm 3 reduction gear unit has clearance holes Install the reduction gear unit to match the screws and the clearance holes Bolts Holes 10 Grease the inner side of the flexspline Grease SK 1A Grease amount 20 g 11 Set the wave washer to the position where the Arm 3 bearing will be set 12 Insert the wave generator to the reduction gear unit and fix it Wave washer ...

Page 121: ...e side of the pulley and then fix them 15 Install the Arm 2 plate Hexagon socket head cap bolts 5 M4 12 Tightening torque 4 9 N m 50 kgf cm Arm 2 plate 16 Install the cable unit For details refer to C4 Maintenance 4 1 Replacing the Cable Unit Installation steps 5 through 39 and through 62 to 63 17 Place the Joint 3 timing belt to the pulley 1 and the pulley 2 of the Joint 3 18 Secure the Joint 3 m...

Page 122: ...allation Joint 3 Timing belt 1 Place the Joint 3 timing belt to the pulley 1 and the pulley 2 of the Joint 3 Place the timing belt to the pulley 2 first Then place the timing belt to the pulley 1 2 Secure the Joint 3 motor unit For details refer to C4 Maintenance 7 1 Joint 3 Replacing the Motor with a Brake Installation steps 6 8 and 9 Name Quantity Note Maintenance Parts Timing belt Joint 3 of C4...

Page 123: ...cement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and c...

Page 124: ...lip to remove 4 Remove the plate of the control board For details refer to C4 Maintenance 13 2 Joint 2 Replacing the Motor Installation steps 3 through 5 5 Remove the Joint 4 motor unit from the Arm 3 Hexagon socket head cap bolts 2 M4 15 with a small plain washer Name Quantity Note Maintenance Parts AC servo motor 50 W 1 For the part code refer to the 17 C4 Maintenance Part List Tools Hexagonal w...

Page 125: ...ft fixing Hexagon socket set screws 2 M3 8 with a brass bushing There is a brass bushing in one of the set screw fixing the drive boss and the pulley Be careful not to lose it Pulley Motor shaft Drive boss A Pulley and motor shaft fixing screws B Pulley and drive boss fixing screws C Bushing D Flat face for motor shaft E Flat face for drive boss A A B C C B D E 8 Remove the Joint 4 electromagnetic...

Page 126: ...s 3 M2 5 10 Be careful of the direction of the Joint 4 electromagnetic brake wiring See the photo 3 Mount the drive boss and the pulley 1 to the Joint 4 motor unit Put the end faces of the drive boss and the pulley 1 together Hexagon socket set screws 2 M3 8 with a brass bushing Set the pulley 1 and the motor shaft Leave 0 5 mm for the electromagnetic brake Hexagon socket set screws 2 M3 8 with a ...

Page 127: ...r unit inside the Arm 4 Place the timing belt around the pulley 1 and pulley 2 Hexagon socket head cap bolts 2 M4 15 Check that the teeth of the timing belt engage with these of the pulley When securing the motor unit temporarily make sure that the motor unit can be moved by hand and it does not tilt when being pulled If the unit is secured too loose or too tight the belt will not have proper tens...

Page 128: ...imilar tool and apply specified tension to fix the motor unit Joint 4 timing belt tension 39 2 N 9 8 N 4 kgf 1 kgf Hexagon socket head cap bolt 2 M4 15 with a plain washer Tightening torque 4 9 N m 50 kgf cm Force gauge 8 Install the control board 2 For details refer to C4 Maintenance 13 2 Replacing the Control Board 2 Installation steps 2 through 4 9 Connect the following connectors Connectors X1...

Page 129: ... 1 For covers Torque wrench 1 Spatula 1 For applying grease Force gauge 1 For belt tension adjustment Wiping cloth 1 For wiping grease Removal Joint 4 Reduction gear unit 1 Remove the Joint 4 motor unit from the Arm 3 For details refer to C4 Maintenance 8 1 Joint 4 Replacing the Motor Installation steps 1 through 5 2 Remove the Joint 5 motor unit from the Arm 4 For details refer to C4 Maintenance ...

Page 130: ... M3 6 with a spring washer and a plain bushing The bearing will be used again Be careful not to lose it 10 Remove the Joint 4 reduction gear unit flange Hexagon socket head cap bolts 3 M3 8 When removing the flange remove the two bearings and the metal seal together The parts will be used again Be careful not to lose it The parts are greased Wipe grease on the parts while removing them Metal seal ...

Page 131: ... longer The parts are greased Wipe grease on the parts while removing them 13 Remove the flexspline Hexagon socket head cap bolts 12 M3 10 Since the flexspline turns when removing the screws and is difficult to remove hold the Arm 4 by two workers as shown in the figure The parts are greased Wipe grease on the parts while removing them 14 Remove the O rings O ring 15 Wipe grease using a cloth or a...

Page 132: ...arts on the right 2 Grease the tooth surface of the circular spline to fill the groove Grease SK 1A Grease amount About to fill the tooth grooves of the circular spline 3 Grease the tooth surface of the flexspline to fill the groove Grease SK 1A Grease amount About to fill the tooth grooves of the flexspline 4 Grease the inner side of the flexspline Grease SK 1A Grease amount 10 g 5 Grease the bea...

Page 133: ...ket head cap bolts 12 M3 10 Tightening torque 2 5 N m 25 kgf cm Be careful of the direction of the circular spline See the figure M3 screw position Mark 8 Install the flexspline Hexagon socket head cap bolts 12 M3 10 Tightening torque 2 5 N m 25 kgf cm 9 Set the bearing to the wave generator and install it to the flexspline 10 Install the metal seal ...

Page 134: ...nt 4 timing belt 2 M4 5 17 Install the Joint 4 motor unit For details refer to C4 Maintenance 8 1 Joint 4 Replacing the Motor Installation step 6 18 Install the Joint 5 motor unit For details refer to C4 Maintenance 9 1 Joint 5 Replacing the Motor Installation steps 4 through 5 19 Install the Joint 6 motor unit For details refer to C4 Maintenance 10 1 Joint 6 Replacing the Motor Installation steps...

Page 135: ...it and fix it For details refer to C4 Maintenance 8 1 Joint 4 Replacing the Motor Installation step 7 24 Install the Arm 3 head cover the Arm 3 bottom cover and the Arm 4 side cover For details refer to C4 Maintenance 3 Covers 25 Perform the calibration For details refer to C4 Maintenance 16 Calibration ...

Page 136: ... timing belt Installation Joint 4 Timing belt 1 Place the Joint 4 timing belt around the Joint 4 pulley 2 2 Install the Joint 4 motor unit For details refer to C4 Maintenance 8 1 Joint 4 Replacing the Motor Installation steps 6 through 11 Name Quantity Note Maintenance Parts Joint 4 timing belt 1 1593699 Tools Hexagonal wrench width across flats 3 mm 1 For M4 hexagon socket head cap bolts Cross po...

Page 137: ...ake to the Joint 4 motor unit For details refer to C4 Maintenance 8 1 Joint 4 Replacing the Motor Installation steps 2 through 11 Name Quantity Note Maintenance Parts Joint 4 electromagnetic brake 1 For the part code refer to the 17 C4 Maintenance Part List Tools Hexagonal wrench width across flats 1 5 mm 1 For M3 hexagon socket set screws width across flats 2 mm 1 For M2 5 hexagon socket head cap...

Page 138: ...dure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be use...

Page 139: ...ollowing connectors Connectors X052 X152 BT52 BR052 4 Loosen the bolts securing the Joint 5 motor unit and remove the belt Hexagon socket head cap bolts 2 M4 15 with a plain washer 5 Remove the Joint 5 motor unit Hexagon socket head cap bolts 2 M4 15 with a plain washer Name Quantity Note Maintenance Parts AC servo motor 50 W 1 For the part code refer to 17 C4 Maintenance Part Code Tools Hexagonal...

Page 140: ...et set screws 2 M3 8 with a brass bushing There is a brass bushing in one of the set screws fixing the drive boss and the pulley Be careful not to lose it Pulley Motor shaft Drive boss A Pulley and motor shaft fixing screws B Pulley and drive boss fixing screws C Bushing D Flat face for motor shaft E Flat face for drive boss A A B C C B D E 7 Remove the Joint 5 electromagnetic brake Hexagon socket...

Page 141: ...s 3 M2 5 10 Be careful of the direction of the Joint 5 electromagnetic brake wiring See the photo Electromagnetic brake wiring 3 Mount the drive boss and the pulley 1 to the Joint 5 motor unit Set the drive boss and the pulley 1 so that their surfaces become flat Hexagon socket set screws 2 M3 8 with a brass bushing Fix the pulley 1 and the motor shaft Leave 0 5 mm for the electromagnetic brake He...

Page 142: ...g pulled If the unit is secured too loose or too tight the belt will not have proper tension 6 Apply tension to the Joint 5 motor unit and fix it Joint 5 Timing belt tension 39 2 N 9 8 N 4 kgf 1 kgf Secure the Joint 5 motor unit by applying tension Hexagon socket head cap bolts 2 M4 15 with a plain washer Tightening torque 4 9 N m 50 kgf cm 7 Connect the following connectors Connectors X052 X152 B...

Page 143: ...nd remove the Joint 5 timing belt 6 315 mm Hexagon socket head cap bolts 2 M4 15 with a plain washer 4 Loosen the set screws of the Joint 6 motor unit and remove the Joint 6 timing belt 6 324 mm Hexagon socket head cap bolts 2 M4 15 with a plain washer Name Quantity Note Maintenance Parts Joint 5 reduction gear unit 1 1539260 Tools Hexagonal wrench width across flats 1 5 mm 1 For M3 hexagon socket...

Page 144: ...e is a brass bushing in one of the set screws Be careful not to lose it Pulley 2 7 Remove the bearing retainer plate Hexagon socket head cap bolts 4 M3 6 8 Pull out the gear unit If it is difficult to remove the gear unit install the removed pulley 2 to the shaft and remove the parts The bearing of the gear unit has shim rings Check the position and the number of the shim rings When installing the...

Page 145: ...hoto on the right O ring 13 Remove the wave generator from the reduction gear unit If it is difficult to remove the wave generator unit install the removed pulley 2 to the shaft and remove the parts When removing the wave generator the bearing on the end of the shaft comes off together Do not lose the bearing The parts are greased Wipe grease on the parts while removing them 14 Remove the wave gen...

Page 146: ...pline fixing bolts Hexagon socket head cap bolts 3 M2 10 Flexspline fixing bolts Hexagon socket head cap bolts 6 M3 8 The parts are greased Wipe grease on the parts while removing them 16 Remove the circular spline and the flexspline The parts are greased Wipe grease on the parts while removing them 17 Remove the O ring of the housing O ring ...

Page 147: ... 1 Unpack the new reduction gear unit package and check if it contains the parts on the right Wave generator Flexspline Circular spline 2 Grease all over the tooth surface of the flexspline Grease SK 2 Grease amount About to fill the tooth groove of the flexspline 3 Grease all over the tooth surface of the circular spline Grease SK 2 Grease amount About to fill the tooth groove of the circular spl...

Page 148: ...e O ring of the Joint 5 reduction gear unit to the housing O ring 6 Install the flexspline so that the hole on the inner side can match the bearing s outer ring Hexagon socket head cap bolts 6 M3 8 Tightening torque 2 5 N m 25 kgf cm Bearing outer ring 7 Install the circular spline Hexagon socket head cap bolts 3 M2 10 ...

Page 149: ...ut and the wave generator Set an open end wrench to the shaft and turn the nut Open end wrench width for the shaft 7 mm Open end wrench width for the nut 8 mm Nut Washer 10 Grease the bearing of the wave generator Grease SK 2 Grease amount About to fill space between the balls 11 Insert the wave generator to the reduction gear unit 12 Install the O ring of the Joint 5 reduction gear unit to the Ar...

Page 150: ...ng then tighten the screws Return the key to its original position after tightening the screws Key The key is on the Arm 1 under the Arm 1 upper cover Hexagon socket head cap bolts M3 6 14 Install the Joint 6 flange unit Hexagon socket head cap bolt 6 M3 15 Tightening torque 2 5 N m 25 kgf cm 15 Install the Arm 4 plate Hexagon socket head cap bolts 6 M3 12 Tightening torque 2 5 N m 25 kgf cm Hexag...

Page 151: ...set screw insert the brass bushing to the end Pulley 2 large 19 Place the Joint 6 timing belt 6 324 mm to the Pulley 1 and 2 and fix it temporarily Check that the teeth of the timing belt engage with these of the pulley Pulley 2 Pulley 1 When securing the motor unit temporarily make sure that the motor unit can be moved by hand and it does not tilt when being pulled If the unit is secured too loos...

Page 152: ...lley 1 Timing belt When securing the motor unit temporarily make sure that the motor unit can be moved by hand and it does not tilt when being pulled If the unit is secured too loose or too tight the belt will not have proper tension 23 Apply tension to the Joint 5 motor unit and fix it Joint 5 timing belt tension 39 2 N 9 8 N 4 kgf 1 kgf Secure the Joint 5 motor unit by applying tension Hexagon s...

Page 153: ...ain washer 4 Remove the Joint 5 timing belt Installation Joint 5 Timing belt 1 Place the Joint 5 timing belt to the pulley 1 and the pulley 2 of the Joint 5 2 Secure the Joint 5 motor unit For details refer to C4 Maintenance 9 1 Joint 5 Replacing the Motor Installation steps 5 6 8 and 9 Name Quantity Note Maintenance Parts Joint 5 timing belt 315 mm 1 1599367 Tools Hexagonal wrench width across fl...

Page 154: ...e Joint 5 motor unit For details refer to C4 Maintenance 9 1 Joint 5 Replacing the Motor Installation steps 2 through 9 Name Quantity Note Maintenance Parts Joint 5 electromagnetic brake 1 For the part code refer to the 17 C4 Maintenance Part List Tools Hexagonal wrench width across flats 1 5 mm 1 For M3 hexagon socket set screws Hexagonal wrench width across flats 2 mm 1 For M2 5 hexagon socket h...

Page 155: ...edure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be us...

Page 156: ...llowing connectors Connectors X062 X162 BT62 BR062 4 Loosen the bolts securing the Joint 6 motor unit and remove the belts Hexagon socket head cap bolts 2 M4 15 with a plain washer 5 Remove the Joint 6 motor unit Hexagon socket head cap bolts 2 M4 15 with a plain washer Name Quantity Note Maintenance Parts AC servo motor 50 W 1 For the part code refer to the 17 C4 Maintenance Part Code Tools Hexag...

Page 157: ...screws 2 M3 8 with a brass bushing There is a brass bushing in one of the set screws fixing the drive boss and the pulley Be careful not to lose it Pulley Motor shaft Drive boss A Pulley and motor shaft fixing screws B Pulley and drive boss fixing screws C Bushing D Flat face for motor shaft E Flat face for drive boss A A B C C B D E 7 Remove the Joint 6 electromagnetic brake Hexagon socket set sc...

Page 158: ...s 3 M2 5 10 Be careful of the direction of the Joint 6 electromagnetic brake wiring See the figure Electromagnetic brake wiring 3 Mount the drive boss and the pulley 1 to the Joint 6 motor unit Set the drive boss and the pulley 1 so that their surfaces become flat Hexagon socket set screws 2 M3 8 with a brass bushing Set the pulley 1 and the motor shaft Leave 0 5 mm for the electromagnetic brake H...

Page 159: ...g pulled If the unit is secured too loose or too tight the belt will not have proper tension 6 Apply tension to the Joint 6 motor unit and fix it Joint 6 timing belt tension 39 2 N 9 8 N 4 kgf 1 kgf Secure the Joint 6 motor unit by applying tention Hexagon socket head cap bolts 2 M4 15 with a plain washer Tightening torque 4 9 N m 50 kgf cm 7 Connect the following connectors Connectors X062 X162 B...

Page 160: ... 4 plate which was removed in the step 4 For the O ring of the Arm 5 see the photo on the right The O ring will be used again Be careful not to lose it O ring 5 Remove the Joint 6 flange Hexagon socket head cap bolts 7 M3 6 Name Quantity Note Maintenance Parts Joint 6 reduction gear unit 1 1539261 Tools Hexagonal wrench width across flats 1 5 mm 1 For M3 hexagon socket set screws For M2 hexagon so...

Page 161: ...e Arm 5 plug Set the screw to the plug and pull out Recommended screw length M4 15 mm or longer The parts are greased Wipe grease on the parts while removing them 9 Remove the gear Remove the bearing Set the open end wrench to the nut on the Joint 6 reduction gear unit Insert the tool to the hole where the plug was and then turn the screw to remove Hexagon socket head cap bolt 1 M3 8 with a plain ...

Page 162: ...haft has a bearing remove it The bearing will be used again Be careful not to lose it There is a washer between the nut and the wave generator Be careful not to lose it The parts are greased Wipe grease on the parts while removing them Open end wrench width for the shaft 5 5 mm Open end wrench width for the nut 8 mm ...

Page 163: ...and check if it contains the parts on the right 2 Install the wave generator to the shaft Insert the washer between the nut and the wave generator Set the open end wrench to the nut and D cut part black circle in the figure and turn the nut Open end wrench width for the shaft 5 5 mm Open end wrench width for the nut 8 mm Washer 3 Install the O ring of the Joint 6 reduction gear unit to the Arm 5 O...

Page 164: ...p bolts 6 M3 28 Tightening torque 2 5 N m 25 kgf cm There is a bearing on the back side of the flexspline If you removed the bearing during the removal steps install the bearing first and install the Joint 6 reduction gear unit to the Arm 5 7 Install the Joint 6 flange Hexagon socket head cap bolts 7 M3 6 Tightening torque 2 5 N m 25 kgf cm 8 Inject grease to the gear and insert the plug to the en...

Page 165: ...a plain washer 4 Remove the Joint 6 timing belt Installation Joint 6 Timing belt 1 Place the Joint 6 timing belt around the pulley 1 and 2 of the Joint 6 2 Secure the Joint 6 motor unit For details refer to C4 Maintenance 10 1 Joint 6 Replacing the Motor Installation steps 5 6 8 and 9 Name Quantity Note Maintenance Parts Joint 6 timing belt 324 mm 1 1593701 Tools Hexagonal wrench width across flat...

Page 166: ...magnetic brake to the Joint 6 motor unit For details refer to C4 Maintenance 10 1 Joint 6 Replacing the Motor Installation steps 2 through 9 Name Quantity Note Maintenance Parts Joint 6 electromagnetic brake 1 For part code refer to the 17 C4 Maintenance Part code Tools Hexagonal wrench width across flats 1 5 mm 1 For M3 hexagon socket set screws width across flats 2 mm 1 For M2 5 hexagon socket h...

Page 167: ...ntroller power M4 15 or longer Arm 5 Plug 4 Insert a screw to the plug M4 15 or longer Plug 5 While holding the screw disconnect the plug 6 Remove the O ring from the plug O ring Plug Screw Installation Arm 5 O ring 1 Install the O ring to the plug O ring Plug Screw 2 Insert the plug to the Arm 5 Push the plug to the stopper at the end Plug M4 15 or longer Plug 3 Remove the screw If you move the a...

Page 168: ...batteries improperly Exposing to fire Forcing discharge Deforming by pressure Short circuit Polarity Positive Negative Heating 85 C or more Soldering the terminal of the lithium battery directly When disposing the battery consult with the professional disposal services or comply with the local regulation Make sure that the battery terminal is insulated even for a used buttery If the terminal conta...

Page 169: ...trol board 1 Bottom Battery board Battery lithium battery Note The battery relay cable unit is reusable If the cable or the connector clip is broken during replacement of the cable unit and battery replace the cable unit For details on the replacement refer to Removal step 10 and Installation step 55 in C4 Maintenance 4 Cable Unit Name Quantity Note Maintenance Parts Battery unit Lithium battery 1...

Page 170: ...he L shaped plate on the Arm 1 and remove the plate Hexagon socket head cap bolts 2 M4 8 Be careful not to disconnect the battery connector If you removed all the batteries before connecting the new ones the calibration data will be deleted and you will need to perform calibration Follow the steps below to remove the lithium batteries 4 Cut off the wire tie of the plate 5 Disconnect the connector ...

Page 171: ...t head cap bolts 2 M4 8 9 Install the Arm 1 upper cover For details refer to C4 Maintenance 3 Covers 10 Turn ON the Controller power 11 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three points poses of the registered points 12 If the Manipulator is out of position calibrate all the joints and axes For details refer to C4 Maint...

Page 172: ...ter replacing the parts The process of aligning the two origins is called Calibration Refer to C4 Maintenance 16 Calibration and perform the calibration after the parts replacement Removal Battery board 1 Turn OFF the Controller power 2 Remove the Arm 1 upper cover For details refer to C4 Maintenance 3 Covers 3 Disconnect the connector from the control board 1 Connector GS01 4 Remove the control b...

Page 173: ...t Head Cap Bolts 1 Install the battery board to the Arm 1 Hexagon socket head cap bolts 2 M3 8 Tightening torque 0 7 0 05 N m 2 Connect the connectors to the battery board 3 Install the control board 1 Cross recessed head screws 3 M3 8 Tightening torque 0 45 0 1 N m Be careful of the direction of the control board 1 See the photo 4 Install the connector to the control board 1 Connector GS01 NOTE ...

Page 174: ... For details refer to C4 Maintenance 3 Covers 6 Turn ON the Controller power 7 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three points poses of the registered points 8 Perform the calibration For details refer to C4 Maintenance 16 Calibration ...

Page 175: ...cement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system Always use the control board designated by us Control board 1 Control board 2 13 1 Replacing the Control Board 1 Removal Control b...

Page 176: ...nd wire fixed to the plate Hexagon socket head cap bolts 2 M4 5 4 Remove the connector connected to the control board 2 Connector GS02 5 Remove the plate fixed to the Arm 3 Hexagon socket head cap bolt M4 10 Hexagon socket head cap bolt M3 8 M4 M3 6 Remove the control board 2 fixed to the plate Cross recessed head screw 4 M3 8 There is a spacer between the plate and the control board 2 The spacer ...

Page 177: ...e plate with the control board 2 to the Arm 3 Hexagon socket head cap bolt M4 10 Hexagon socket head cap bolt M3 8 M4 M3 3 Connect the connector to the control board 2 Connector GS02 4 Install the removed ground wire to the plate Hexagon socket head cap bolt 2 M4 5 5 Install the Arm 3 head cover For details refer to C4 Maintenance 3 Covers 6 Turn ON the Controller power 7 Check operation to see if...

Page 178: ...em To shut off power to the robot system disconnect the power plug from the power source Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power...

Page 179: ... the Arm 3 head cover Connector LED 4 Remove the LED lamp from the Arm 3 Turn the resin nut securing the LED lamp in the Arm 3 counter clockwise Resin nut Installation LED lamp 1 Install the LED lamp to the Arm 3 Detach the resin nut from the LED lamp and pass the lamp through the Arm 3 Turn the nut clockwise from the inside of the Arm 3 and secure the lamp to the Arm 3 2 Connect the following con...

Page 180: ...re with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION When disconnecting the connectors during the replacement of the cable unit be sure to reconnect the connectors to their proper positions by referring to the connector pin assignments Improper connection of the connectors may result in improper function of the robot system For...

Page 181: ...2 5 m Straight 1 2216980 L shaped 1 2216980 10 m Straight 1 2216981 L shaped 1 2217094 15 m Straight 1 2216982 L shaped 1 2217095 20 m Straight 1 2216983 L shaped 1 2217096 M C cable UL specification 3 m Straight 1 2216984 5 m Straight 1 2216985 10 m Straight 1 2216986 M C cable flexible straight only 3 m 1 R12NZ901E1 5 m 1 R12NZ901E2 10 m 1 R12NZ901E3 15 m 1 R12NZ901E4 20 m 1 R12NZ901E5 Tools Hex...

Page 182: ...isconnect the battery connector BT1 Otherwise you will need to calibrate Installation M C cable 1 Connect the connectors of the new M C cable to these of the cable unit Connect the connectors with the same number 2 Install the connector sub plate to the connector plate For details refer to C4 Maintenance 3 Covers 3 Connect the following connectors to the Controller Power cable connector Signal cab...

Page 183: ...perator However operating the robot system while someone is inside the safeguarded area is extremely hazardous and may result in serious safety problems in case that the Manipulator moves unexpectedly In EPSON RC a coordinate point including the arm pose is defined as point and its data is called point data There are two methods to move the Manipulator during calibration Releasing the electromagne...

Page 184: ... one joint at a time whenever possible If you calibrate the origins for multiple joints simultaneously it will be more difficult to verify their origins and obtain the origin correct positions However joint 5 cannot be calibrated alone due to the structure of the Manipulator Make sure you calibrate joint 5 and 6 at the same time Calibration Flowchart 4 Calibration Yes Start 1 Basic Pose Confirmati...

Page 185: ...ction gear unit or belt is necessary for the calibration Verify the recorded pulse values of the basic pose obtained in the Setup C Series Manual C4 Manipulator 3 7 Checking the Basic orientation 2 Part Replacement Replace parts as instructed in this manual Be careful not to injure yourself or damage parts during part replacement 3 Encoder Initialization Turn ON the Controller while all joints are...

Page 186: ... the encoder initialization refer to the procedure indicated above When the origin of the Joint 5 is calibrated the Joint 6 will be out of position Due to the structure of the Manipulator any offset in the position of the Joint 5 affects the Joint 6 Calibrate the origin of the Joint 6 together when calibrating the Joint 5 4 Calibration For Joint 5 For Joint 3 For Joint 2 For Joint 1 Position of gr...

Page 187: ...t this point if the key cannot be set completely the arm s is not in the origin Move the arm until the key can be set completely The key will be broken if you move any arm with the key in the groove Do not move arm s once its position is fixed EPSON RC 4 4 Reset the encoder Execute one of the following commands to reset the encoder of the joint you want to calibrate from the menu Tool Command Wind...

Page 188: ...Joint 2 calib 2 Joint 3 calib 3 Joint 4 calib 4 Joint 5 calib 5 6 Joint 6 calib 6 Move the arm to several points to check if the arm moves to the original positions properly Teach points if fine adjustment is necessary 4 8 All joints are calibrated Put the calibration key back to the original position in the Arm 1 and secure it with the screw Hexagon socket head cap bolt 1 M3 6 4 9 Mount the Arm 1...

Page 189: ...itions Select the Joint jog mode from Jog Teach to operate in the jog motion Enter the command below in the command window and execute it Execute the command below in the menu Tools Command Window calpls ppls P1 1 ppls P1 2 ppls P1 3 ppls P1 4 ppls P1 5 ppls P1 6 The Manipulator will not move Perform the calibration Input one of the following commands according to the joint being calibrated Joint ...

Page 190: ...ree parts When replacing the reduction gear unit be sure to replace these parts all together as a set Waveform generator The waveform generator consists of an ellipsoidal cam and ball bearings on outer circumference The inner ring of the bearings is secured to the cam while the outer ring is capable of flexible deformation through the ball bearings Circular spline Flexspline Waveform generator Fle...

Page 191: ...m 1 3 2138032 R13B040502 13 O ring Joint 1 1480857 R13B031223 5 2 Joint 2 1510528 R13B031242 6 2 Joint 3 1520370 R13B031243 7 2 Joint 4 1520372 R13B031244 8 2 Arm 3 4 1520371 R13B031245 Arm 5 1520374 R13B031247 For plug 11 Regarding purchase of grease Due to the chemicals regulations of individual countries the UN GHS we are requesting our customers to purchase grease required for maintenance from...

Page 192: ...6988 2150707 R13N824051 L shaped 2217098 2169358 R13NZ910F1 10 m Straight 2216989 2155586 R13N824061 L shaped 2217099 2169359 R13NZ910F2 15 m Straight 2216990 2185612 L shaped 2217100 2185620 20 m Straight 2216991 2185496 L shaped 2217101 2185621 M C power cable UL specification 3 m Straight 2216992 2181813 5 m Straight 2216993 2181914 10 m Straight 2216994 2181915 M C signal cable 3 m 2216995 215...

Page 193: ...ame Code Old Code Note Reference Overhaul Motor Joint 1 2 2150748 R13N807011 400 W 5 1 6 1 Joint 3 2209414 150 W Electromagnetic brake 7 1 Joint 4 5 6 2149265 R13N807031 50 W 8 1 9 1 10 1 Electromagnetic brake Joint 1 2 1605914 R13N835021 5 4 6 4 Joint 4 5 6 1605913 R13N835011 8 4 9 4 10 4 Noise dissipative diode Joint 1 2 3 2167709 R13N823011 5 4 6 4 7 1 LED lamp 1605919 R13N830011 14 Cable Unit ...

Page 194: ...rake release unit Main unit only R12NZ900M2 R12B120803 For Europe R12NZ900KV R12B120804 For U S Japan Camera plate unit R12NZ9003F R12B031922 6 2 PS compatible plate R12NZ9003G R12B031923 6 3 Base side angled fitting R12NZ900HF R12B031924 6 4 Base side fitting R12NZ9003H R12B031925 6 5 PS Compatible Plate Base Adapter R12NZ900A5 R12N73L021 6 6 Adjustable Mechanical Stop R12NZ900L1 R12N73L011 6 7 R...

Page 195: ...C8 Maintenance This volume contains maintenance procedures with safety precautions for C8 series Manipulators ...

Page 196: ......

Page 197: ...rded area Checking the operation of the Manipulator while you are inside of the safeguarded area may cause serious safety problems as the Manipulator may move unexpectedly Before operating the robot system make sure that both the Emergency Stop switches and safeguard switch function properly Operating the robot system when the switches do not function properly is extremely hazardous and may result...

Page 198: ...unction of the robot system If the Manipulator is operated without connecting the brake release unit or the external short connector the brakes cannot be released and it may cause damage on them After using the brake release unit be sure to connect the external short connector to the Manipulator or check connection of the connector for the brake release unit The Manipulator arms may become hot aft...

Page 199: ...ve stages daily monthly quarterly biannual and annual The inspection points are added every stage If the Manipulator is operated for 250 hours or longer per month the inspection points must be added every 250 hours 750 hours 1500 hours and 3000 hours operation Inspection Point Daily inspection Monthly inspection Quarterly inspection Biannual inspection Annual inspection Overhaul replacement 1 mont...

Page 200: ...onnector plates etc Visually check for external defects Clean up if necessary External appearance of Manipulator External cables Check for bends or improper location Repair or place it properly if necessary Safeguard etc Check either the external short connector or the brake release unit connector is connected The external short connector on the back side of the Manipulator or the brake release un...

Page 201: ...o cable disconnection Check for bends or improper location Repair or place it properly if necessary Check that the safeguard etc are located properly If the location is improper place it properly Check either the external short connector or the brake release unit connector is connected Check whether external short connector or break release connector is connected When neither is connected connect ...

Page 202: ...verhaul the parts parts replacement The time between overhauls is 20 000 operation hours of the Manipulator as a rough indication However it may vary depending on usage condition and degree of the load such as when operated with the maximum motion speed and maximum acceleration deceleration in continuous operation applied on the Manipulator For the EPSON RC 7 0 Ver 7 2 x or later firmware Ver 7 2 ...

Page 203: ...2 Click the View Controller Status button to open the Browse For Folder dialog 3 Select the folder where the information is stored 4 Click OK to view the Controller Status Viewer dialog 5 Select Robot from the tree menu on the left side For the parts subject to overhaul refer to C8 Maintenance 17 Maintenance Parts List For details of replacement of each part refer to each section Please contact th...

Page 204: ...lot of time and money will be required for the repairs If grease gets into your eyes mouth or on your skin follow the instructions below If grease gets into your eyes Flush them thoroughly with clean water and then see a doctor immediately If grease gets into your mouth If swallowed do not induce vomiting See a doctor immediately If grease just gets into your mouth wash out your mouth with water t...

Page 205: ...et head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Flat head screwdriver 1 For grease plug Before greasing move the Manipulator so that the grease inlet is not directed down Do not remove the grease plug while the grease inlet is directed down Otherwise the oil content separated from the grease may leak out Do not use any tool to install and remove the grease nipple and g...

Page 206: ...Joint 1 grease inlet located inside the Arm 1 3 Attach the grease nipple to the Joint 1 grease inlet 4 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 11g 5 Remove the grease nipple from the Joint 1 grease inlet 6 Attach the grease plug to the Joint 1 grease inlet If the grease plug is damaged or deteriorated replace it with a new one 7 Install the Arm 1 side cov...

Page 207: ...ne extension jig and grease nipple to the Joint 1 grease inlet 5 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 11g 6 Remove the grease nipple and grease line extension jig from the Joint 1 grease inlet 7 Attach the grease plug to the Joint 1 grease inlet If the grease plug is damaged or deteriorated replace it with a new one 8 Apply a thin coat of grease SK 1A ...

Page 208: ...Greasing 1 Remove the grease plug from the Joint 2 grease inlet of the Arm 1 2 Attach the grease nipple to the Joint 2 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 6g C8 C8L 12g C8XL 4 Remove the grease nipple from the Joint 2 grease inlet 5 Attach the grease plug to the Joint 2 grease inlet If the grease plug is damaged or deteriorated replace ...

Page 209: ...int 3 grease inlet of the Arm 2 2 Attach the grease nipple to the Joint 3 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 3g 4 Remove the grease nipple from the Joint 3 grease inlet 5 Attach the grease plug to the Joint 3 grease inlet If the grease plug is damaged or deteriorated replace it with a new one ...

Page 210: ...ug attaching hole located near the label with 4 printed is the Joint 4 grease inlet The grease inlet position differs depending on the model Carefully identify the correct position 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 2g 4 Remove the grease nipple from the Joint 4 grease inlet 5 Attach the grease plug to the Joint 4 grease inlet If the grease plug is...

Page 211: ...le located near the label with 5 printed is the Joint 5 grease inlet Be careful not to confuse it with the Joint 6 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 1g Be careful not to mix with the grease used in the Joint 6 SK 2 4 Remove the grease nipple from the Joint 5 grease inlet 5 Attach the grease plug to the Joint 5 grease inlet If the grea...

Page 212: ...e located near the label with 6 printed is the Joint 6 grease inlet Be careful not to confuse it with the Joint 5 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 2 Grease amount 0 5g Be careful not to mix with the grease used in the Joint 5 SK 1A 4 Remove the grease nipple from the Joint 6 grease inlet 5 Attach the grease plug to the Joint 6 grease inlet If the gre...

Page 213: ... groove 3 Apply grease to the mating surface of the bevel gear inside the Arm 5 Grease SK 2 Grease amount 2g 4 Apply a thin coat of grease SK 2 to the O ring Fit the O ring into the base groove Do not allow the O ring to come out of the groove If the O ring is swollen damaged or deteriorated replace it with a new one 5 Install the Arm 5 grease inlet cover Hexagon socket head cap bolts 4 M3 6 Tight...

Page 214: ...below for the set screw M3 2 0 0 1 N m 21 1 kgf cm Set Screw Tightening Torque M4 4 0 0 2 N m 41 2 kgf cm M4 2 4 0 1 N m 26 1 kgf cm M5 8 0 0 4 N m 82 4 kgf cm M5 3 9 0 2 N m 40 2 kgf cm M6 13 0 0 6 N m 133 6 kgf cm M6 8 0 0 4 N m 82 4 kgf cm M8 32 0 1 6 N m 326 16 kgf cm M10 58 0 2 9 N m 590 30 kgf cm M12 100 0 5 0 N m 1 020 51 kgf cm It is recommended to fasten the bolts aligned on a circumferen...

Page 215: ...ng belt Joint 1 Reduction gear unit Joint 3 Reduction gear unit Joint 3 Motor Electromagnetic brake Joint 3 Timing belt LED lamp Joint 5 Motor Electromagnetic brake Joint 5 Timing belt Joint 6 Motor Electromagnetic brake Joint 6 Timing belt Joint 5 6 Reduction Gear Unit Set Joint 4 Electromagnetic brake Joint 4 Motor Joint 4 Reduction gear unit Joint 4 Timing belt Battery board Battery Control boa...

Page 216: ...function of the robot system To shut off power to the robot system disconnect the power plug from the power source Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacemen...

Page 217: ...er cover Base cover Arm 3 maintenance cover Arm 4 D sub attachment Arm 4 side cover Arm 2 side cover Arm 1 side cover Arm 2 side cover Arm 1 side cover Arm 4 maintenance cover Arm 1 maintenance cover Figure C8 A1401 C8XL Fan C8 A1401 C8XL only Cable downward model Connector plate Connector sub plate Fan C8 A1401 B C8XL only Figure C8 A1401 B C8XL Base cover ...

Page 218: ...ket Arm 1 Center gasket 1 1665238 Protection model Side gasket 2 1665240 Arm 2 Side gasket 2 1665241 Arm 3 Cover gasket 1 1665242 Maintenance gasket 1 1665254 Arm 4 Side gasket 2 1665243 Maintenance gasket 1 1665257 D sub attachment gasket 1 1665255 Base Rear gasket 1 1665244 Bottom gasket 1 1665247 Maintenance gasket 1 1665248 Sub plate gasket 1 1665246 Installation gasket 1 1668377 Gasket For he...

Page 219: ...al locations Removal Remove the screws and then remove the Arm 1 center cover S C models Cross recessed truss head small screws 5 M4 10 P model Hexagon socket head cap bolts with captive washer 5 M4 12 Remove the Arm 1 center gasket together Installation S C models Install the Arm 1 center cover to the Manipulator Cross recessed truss head small screws 5 M4 10 Tightening torque 0 9 0 1 N m P model...

Page 220: ...and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal Remove the screws and then remove the Arm 1 side cover S C models Cross recessed truss head small screws 4 M4 10 one side P model Hexagon socket head cap bolts with captive washer 8...

Page 221: ...e on the Arm 1 side cover Install the Arm 1 side cover to the Manipulator Hexagon socket head cap bolts with captive washer 8 M4 12 one side Tightening torque 4 0 0 2 N m Be careful not to get the gasket and cables caught between the cover and the Manipulator Replace the gasket if there are flaws or deteriorations When replacing the side cover for the right side of the Arm 1 attach the electrical ...

Page 222: ...ide cover S C models Cross recessed truss head small screws 4 M4 10 one side P model Hexagon socket head cap bolts with captive washer 8 M4 12 one side Remove the Arm 2 side gasket together Note that the Arm 2 side covers and Arm 2 side gaskets are different between right and left Installation S C models Install the Arm 2 side cover to the Manipulator Cross recessed truss head small screws 4 M4 10...

Page 223: ...ocations Removal Remove the screws and then remove the Arm 3 head cover S C models Cross recessed truss head small screws 4 M4 10 P model Hexagon socket head cap bolts with captive washer 4 M4 12 Remove the Arm 3 gasket together Installation S C models Install the Arm 3 cover to the Manipulator Cross recessed truss head small screws 4 M4 10 Tightening torque 0 9 0 1 N m P model Install the gasket ...

Page 224: ...ock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal 1 Before removing the Arm 3 maintenance cover move the arm to the position where you can remove the cover easily 2 Remove the screws and then remove the Arm 3 maintenance cover S C models Cross recessed truss h...

Page 225: ...Arm 3 maintenance gasket Install the Arm 3 maintenance gasket to the Arm 3 maintenance cover See the figure for gasket applying points Arm 3 maintenance gasket Gasket applying point 4 Spacer 4 Arm 3 maintenance cover After applying the liquid gasket leave the gasket until the liquid gasket becomes solid and the gasket is fixed 3 Install the Arm 3 maintenance cover to the Manipulator Hexagon socket...

Page 226: ...e cable locations at removing the cover Be sure to place the cables back to their original locations Removal 1 Remove the screws and then remove the Arm 4 side cover S C models Cross recessed truss head small screws 7 M4 10 one side P model Hexagon socket head cap bolts with captive washer 7 M4 12 one side Remove the Arm 4 side gasket together The Arm 4 side cover and Arm 4 side gasket are the sam...

Page 227: ...mall screws 7 M4 10 one side Tightening torque 0 9 0 1 N m P model Install the Arm 4 side gasket to the grove on the Arm 4 side cover Install the Arm 4 cover to the Manipulator Cross recessed truss head small screws 7 M4 12 one side Tightening torque 4 0 0 2 N m Be careful not to get the gasket and cables caught between the cover and the Manipulator Replace the gasket if there are flaws or deterio...

Page 228: ...ic shock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal 1 Before removing theArm 4 maintenance cover move the arm to the position where you can remove the cover easily 2 Remove the screws and then remove the Arm 4 maintenance cover S C models Cross recessed tru...

Page 229: ... Arm 4 maintenance gasket Install the Arm 4 maintenance gasket to the Arm 4 maintenance cover See the figure for gasket applying points Arm 4 maintenance gasket Gasket applying point 4 Spacer 4 Arm 4 maintenance cover After applying the liquid gasket leave the gasket until the liquid gasket becomes solid and the gasket is fixed 3 Install the Arm 4 maintenance cover to the Manipulator Hexagon socke...

Page 230: ...mely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the D sub attachment Be sure to place the cables back to their original locations Removal Remove the screws and then remove the D sub attachment Hexagon socket head cap bolts 2 M4 10 P model Remove the D sub attachment gasket together Installati...

Page 231: ...s located on the bottom face of the base Removal Remove the bolts and then remove the base cover Hexagon socket head cap bolts 8 M4 10 P model Remove the base bottom gasket together Installation S C models Install the base cover to the Manipulator Hexagon socket head cap bolts 8 M4 10 Tightening Torque 4 0 0 2 N m P model Install the gasket to the grove on the base bottom face and then install the...

Page 232: ...hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations The base cover of the M C cable downward model is located on the backside of the base C8 A701 B C8 C8 A901 B C8L Removal Remove the bolts and then remove the base cover Hexagon so...

Page 233: ...t 11 places 2 Apply the liquid gasket to the base rear gasket Install the base rear gasket to the base cover See the figure for gasket applying points Base rear gasket Gasket Applying point 11 Spacer 11 Base cover After applying the liquid gasket leave the gasket until the liquid gasket becomes solid and the gasket is fixed 3 Install the base cover to the Manipulator Hexagon socket head cap bolts ...

Page 234: ...ts and then remove the base cover and the base rear gasket Hexagon socket head cap bolts 11 M4 10 The gasket has the spacers Be careful not to lose them C8 A1401 B C8XL Installation 1 Install the spacers to the holes on the gasket 11 places 2 Apply the liquid gasket to the base rear gasket Install the base rear gasket to the base cover See the figure for gasket applying points Base rear gasket Gas...

Page 235: ...t the gasket and cables caught between the cover and the Manipulator Replace the gasket if there are flaws or deteriorations For cleanroom and protection models install the gasket between the heat sink and the base cover 4 Install the heat sink Hexagon socket head cap bolts 4 M4 15 Tightening torque 4 0 0 2 N m 5 Install the fan For details refer to C8 Maintenance 15 Replacing the Fan NOTE NOTE ...

Page 236: ...routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal Remove the screws and then remove the base maintenance cover S C models Cross recessed truss head small screws 6 M4 10 P model Hexagon socket head cap bolts 6 M4 10 Remove the base maintenance gasket together The gasket has the spacers Be careful not to lose them ...

Page 237: ...lying points Base maintenance gasket Gasket applying point 6 Spacer 6 Base maintenance plate After applying the liquid gasket leave the gasket until the liquid gasket becomes solid and the gasket is fixed 3 Install the base maintenance cover to the Manipulator Hexagon socket head cap bolts 6 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the gasket and cables caught between the cover an...

Page 238: ... or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the connector plate Be sure to place the cables back to their original locations C8...

Page 239: ...laces 2 Apply the liquid gasket to the base rear gasket Install the base rear gasket to the connector plate See the figure for gasket applying points Base rear gasket Gasket Applying point 11 Spacer 11 Connector plate After applying the liquid gasket leave the gasket until the liquid gasket becomes solid and the gasket is fixed 3 Install the connector plate to the Manipulator Hexagon socket head c...

Page 240: ...ts and then remove the connecter plate and the base rear gasket Hexagon socket head cap bolts 11 M4 10 The gasket has the spacers Be careful not to lose them C8 A1401 C8XL Installation 1 Install the spacers to the holes on the gasket 11 places 2 Apply the liquid gasket to the base rear gasket Install the base rear gasket to the base cover See the figure for gasket applying points Base rear gasket ...

Page 241: ...t the gasket and cables caught between the cover and the Manipulator Replace the gasket if there are flaws or deteriorations For cleanroom and protection models install the gasket between the heat sink and the connector plate 4 Install the heat sink Hexagon socket head cap bolts 4 M4 15 Tightening torque 4 0 0 2 N m 5 Install the fan For details refer to C8 Maintenance 15 Replacing the Fan NOTE NO...

Page 242: ...ck and or improper function of the robot system When routing the cables check the cable locations at removing the connector plate Be sure to place the cables back to their original locations Removal Remove the bolts and then remove the connector plate Hexagon socket head cap bolts 8 M4 10 P model Remove the base bottom gasket together Installation S C models Install the connector plate to the Mani...

Page 243: ...oper function of the robot system When installing the connector sub plate be careful not to get the cables caught in it or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables ch...

Page 244: ...e gasket Install the base sub plate gasket to the connector sub plate See the figure for gasket applying points Sub plate gasket Gasket applying point 4 Spacer 4 Connector sub plate After applying the liquid gasket leave the gasket until the liquid gasket becomes solid and the gasket is fixed 3 Install the connector sub plate to the Manipulator Hexagon socket head cap bolts 4 M4 10 with a seal was...

Page 245: ...result in electric shock and or malfunction of the robot system Be careful not to get any foreign substances in the Manipulator connectors and pins during maintenance Turning ON the power to the robot system when any foreign substances exist in them is extremely hazardous and may result in electric shock and or malfunction of the robot system Be sure to connect the cables properly Do not allow unn...

Page 246: ...protective gear including a mask protective goggles and oil resistant gloves If alcohol or adhesive gets on your skin wash the area thoroughly with soap and water If alcohol or adhesive gets into your eyes or mouth flush your eyes or wash out your mouth with clean water thoroughly and then see a doctor immediately Wear protective gear including a mask protective goggles and oil resistant gloves du...

Page 247: ...ub connector Long nose pliers 1 For removing an air tube Nippers 1 For cutting a wire tie Cross point screwdriver 2 1 For cross recessed head screws Torque rench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use this jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own we...

Page 248: ...3 maintenance cover Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base maintenance cover Connector plate M C cable backward 4 Remove the two air tubes inside the base 5 Remove the two D sub connectors 6 Disconnect the cables from the base and disconnect the following connectors Connectors X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 Hold the clip to remove 7 D...

Page 249: ...odel 10 M4 8 2 M3 6 10 Remove the brake power supply Cross recessed head screws with washer 2 M3 6 11 Disconnect the following cables through the opening of the base D sub cable Ground wire RJ45 connector F sensor connector 12 Remove the Joint 1 motor unit For details refer to C8 Maintenance 5 1 1 Joint 1 Replacing the Motor M C Cable Backward Removal steps 6 and 7 13 Remove the plate for preventi...

Page 250: ...et Hexagon socket head cap bolts 2 M3 6 15 Remove the Joint 1 timing belt 16 Remove the battery from the battery box 17 Disconnect the battery connector Hold the board by hand and pull up the battery cable to disconnect the connector 18 Remove the plate to which the battery board is fixed Hexagon socket head cap bolts 2 M4 10 NOTE ...

Page 251: ...al steps 1 to 3 and 5 to 9 22 Cut off the wire tie that binds the cables inside the Arm 1 and remove the connector connected to the control board 1 Connector GS01 23 Remove the Joint 1 cable fixing plate Arm 1 side Hexagon socket head cap bolts 2 M4 10 24 Disconnect the internal cables from the base side to the Arm 1 side Protect the connectors with masking tapes To protect the connector s clips T...

Page 252: ...emove the Arm 1 cable brackets C2 and S2 one each and cable protection tube Hexagon socket head cap bolts 2 M3 6 C2 2 M4 10 S2 27 Remove the Arm 2 cable bracket C2 and cable protection tube Hexagon socket head cap bolts 2 M3 6 28 Remove the Arm 2 cable fixing plate Hexagon socket head cap bolts 2 M4 10 29 Cut off the wire tie that binds the cable protection coils inside the Arm 2 ...

Page 253: ...kets C3A and S3 Hexagon socket head cap bolts 2 M4 8 C3A 2 M4 8 S3 33 Remove the two air tubes inside the Arm 3 Remove the air tube fittings from the air tubes The air tube fittings will be used again Be careful not to lose them 34 Remove the two ground wire terminals from the Arm 3 Cross recessed head screws with washer 2 M4 8 35 Disconnect the connectors inside the Arm 3 Connectors X141 X151 X16...

Page 254: ...gon socket head cap bolts 2 M4 10 38 Remove the Arm 3 cable bracket C3B Hexagon socket head cap bolts 2 M3 6 39 Remove the Arm 3 cable fixing plate 1 Hexagon socket head cap bolts 2 M4 10 40 Cut off the wire tie that binds the cable protection coils inside theArm 3 41 Disconnect the cables from the Arm 3 side to the Arm 2 side ...

Page 255: ... first cover the connectors with a plastic bag Then pass the cable unit through the arm 43 Remove the Arm 3 cable fixing plate 2 Hexagon socket head cap bolts 2 M4 10 44 Remove theArm 3 cable bracket C4 and the cable protection sheet Hexagon socket head cap bolts 2 M3 6 C8XL Remove the cable bracket C4 and the cable protection sheet at the Arm 4 maintenance cover Hexagon socket head cap bolts 2 M3...

Page 256: ...6 Cut off the wire tie that binds the cables of the Arm 4 47 Loosen the bolts that fix the cable protection plate attached on the Arm 4 and disconnect the cables Hexagon socket head cap bolts 2 M4 10 48 Remove the ground wire terminals from the cable protection plate Cross recessed head screws with washer 4 M4 8 ...

Page 257: ...oved together with the Joint 5 motor unit will be used again Be careful not to lose them 50 Remove the Arm 4 D sub attachment Hexagon socket head cap bolts 2 M4 10 For details refer to C8 Maintenance 3 Covers 51 Remove the following parts from the Arm 4 D sub attachment S C models D sub connector D sub connector fixing plate P model D sub connector 52 Remove the Arm 4 cable fixing plate Hexagon so...

Page 258: ...ntenance 4 Cable Unit 238 C Series Maintenance Manual Rev 2 54 Disconnect the following cables that have no relays from the Arm 4 side to the Arm 3 side Ethernet cable X052 X062 cable Ground wire green yellow ...

Page 259: ...25 mm 120 mm F sensor connector housing 2 pieces Silicon sheet 3 sheets 25 mm 120 mm 2 Remove the Ethernet cable from the connector Protect the cable ends with masking tapes to prevent the clip from damage 3 Remove the locking screws and nuts of the D sub connector The screws and nuts will be used again for fixing the connector Be careful not to lose them 4 Disconnect the following connectors to s...

Page 260: ... 190 mm from the connector end Air tube 210 mm from the end 130 mm 6 Pass the separated cable unit base side from theArm 2 to theArm 1 To protect the connectors and facilitate the work first cover the connectors with a plastic bag Then pass the cable unit through the arm Pass the following cables that have no relays through the arm to the Arm 3 side Ethernet cable X052 X062 cable Ground wire green...

Page 261: ...rm 3 side Insert the connectors through the braid tube as shown in the photo and fix the tube with the wire tie so that connectors are not to be pulled out Then pull the braid tube from the Arm 4 side while pushing the cables from the Arm 3 side to pass the cables through See the photo 8 Pass the separated cable unit Arm 4 side from theArm 4 to theArm 3 C8 C8L No silicone tube is provided C8XL Sil...

Page 262: ... arrow in the photo 9 Install the cable fixing plate to the Arm 4 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 10 Use a cable bracket C4 to fix the cables Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 4 0 1 N m C8 C8L Wrap the cables with the attached silicone sheet Use a cable bracket to fix the wrapped silicone sheet C8XL Place the silicone tube to the position ...

Page 263: ...fixing plate and fix them with the locking screws removed in step 3 above The nuts and washers are not used P model No D sub connector fixing plate is provided The D sub connector has screw holes Fix the D sub connector using the locking screws removed in step 3 above 12 Install the D sub attachment to the Arm 4 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m Do not to let the ...

Page 264: ...r is installed incorrectly and no cable is caught between components For details refer to C8 Maintenance 9 1 Joint 5 Replacing the Motor Installation steps 4 to 8 and C8 Maintenance 10 1 Joint 6 Replacing the Motor Installation steps 4 and 7 Use the air tube fittings removed in the cable removal steps again 14 Mount the brake power supply to the plate Mount the power so that the cables are directe...

Page 265: ...3g C8L approximately 6g Divide the above grease into halves and apply each half from the Arm 4 side and the Arm 3 side respectively Pay attention so that the grease does not get into the cable fixing area in the Arm 3 and connectors 18 Use a cable bracket C4 to fix the cables to the Arm 3 cable fixing plate 2 Wrap the cables with the attached silicone sheet Use a cable bracket to fix the wrapped s...

Page 266: ...ad cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 22 Use a cable bracket C3B to fix the cables Place the two air tubes at the bottom part of the cables Place the silicone tube to the position where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 4 0 1 N m 23 Install the control board 2 fixing plate to the Arm 3...

Page 267: ...X71 X72 PS LED BT51 BT4 Hold the clip to remove 26 Install the two ground wire terminals to the Arm 3 Green yellow Left side Green Right side Cross recessed head screws with washer 2 M4 8 Tightening torque 0 9 0 1 N m 27 Use air tube fittings elbows to connect air tubes of the same color Remove the air tube fittings from the old cables to use them again Adjust the connector protrusion so that the ...

Page 268: ...g The cables can be pushed up even after fixing the cables 30 Push up the whole cables by 10 mm to the direction indicated with the arrow in the photo to allow for some space 31 Fix the cables to the Arm 2 by fixing the cable brackets C3A Check that the silicone tube is not shifted away from the fixed position Hexagon socket head cap bolts 2 M4 8 Tightening torque 4 0 0 2 N m 32 Install the Joint ...

Page 269: ...to the position where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube temporarily Hexagon socket head cap bolts 2 M3 6 Rough guide of temporary fixing The cables can be pushed up even after fixing the cables 36 Install the Arm 2 cable fixing plate to the Arm 2 After fitting the two U shaped grooves to the fixing bolts tighten the bolts Hexagon socket head cap bolts 2 ...

Page 270: ...cket Use a cable bracket to fix the silicone tube temporarily Hexagon socket head cap bolts 2 M3 6 Rough guide of temporary fixing The cables can be pushed up even after fixing the cables 40 Push up the whole cables by 10 mm to the direction indicated with the arrow in the photo to allow for some space 41 Fix the cables to the Arm 1 Check that the silicone tube is not shifted away from the fixed p...

Page 271: ...he X021 X121 BR021 and CN3 cables place a mark at a position 160 mm from the connector respectively 45 Use cable brackets C1 to fix the cables to the Arm 1 cable fixing plate temporarily 2 positions Temporarily fix the silicone tube by aligning its end to the mark Hexagon socket head cap bolts 4 M3 6 Rough guide of temporary fixing The cables can be pushed up even after fixing the cables ...

Page 272: ...BR021 and CN3 connectors should reach the end face of the Arm 1 when they are pulled out The cables should not be too long 47 Place a mark on the cables at the sleeve outlet on the base side 48 Fix the cable bracket C1 A on the near side so that the cable positions do not change Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 4 0 1 N m 49 Remove the Arm 1 cable fixing plate fixed temporar...

Page 273: ... the Arm 1 cable fixing plate to the Arm 1 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 52 Install the connector GS01 to the control board 1 53 Install the Joint 2 motor and connect the connector For details refer to C8 Maintenance 6 1 Joint 2 Replacing the Motor Installation steps 4 and 9 54 Fix the two ground wire terminals to the Arm 2 Green Right side Green yellow Left s...

Page 274: ...to the battery box 59 Pass the Joint 1 timing belt through the cable 60 Use cable brackets C1 to fix the cables to the base cable fixing plate Wrap the cables with the attached silicone sheet Use a cable bracket to fix the wrapped silicone sheet Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 0 0 1 N m 61 Install the plate for preventing cable interference Hexagon socket head cap bolts 2 ...

Page 275: ...ews with washer 2 M3 6 Tightening torque 0 45 0 1 N m 65 Install the ground wire terminals to the plate Cross recessed head screws with washer S C models 9 M4 8 2 M3 6 P model 10 M4 8 2 M3 6 Tightening torque 0 9 0 1 N m M4 8 0 45 0 1 N m M3 6 The installation positions of the D sub cable ground terminals are predetermined Make sure to install them to the two screw holes on the backside of the Man...

Page 276: ...er With round terminal D sub 70 Install the two air tubes according to the marks on the connector plate Air1 Clear Air2 Blue Install the air tube with the correct color 71 Install the covers and plate indicated below Arm 4 side covers both sides Arm 4 maintenance cover C8XL only Arm 3 cover Arm 3 maintenance cover Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base ma...

Page 277: ...D Sub connector Long nose pliers 1 For removing an air tube Nippers 1 For cutting a wire tie Cross point screwdriver 2 1 For cross recessed head screws Torque rench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use this jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own...

Page 278: ...e the covers and plate indicated below Arm 4 side covers both sides Arm 4 maintenance cover C8XL only Arm 3 cover Arm 3 maintenance cover Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base cover M C cable downward Base maintenance cover Connector plate M C cable downward For details refer to C8 Maintenance 3 Covers 5 Remove the two air tubes in the base 6 Remove the ...

Page 279: ...rews with washer S C models 9 M4 8 2 M3 6 P model 10 M4 8 2 M3 6 10 Remove the brake power supply Cross recessed head screws with washer 2 M3 6 11 The subsequent steps are the same as those for the M C cable backward For details refer to C8 Maintenance 4 1 1 Replacing the Cable Unit M C Cable Backward Removal steps 13 to 54 ...

Page 280: ...The cables should be located in the direction as shown in the photo See the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 4 Install the ground wire terminals to the plate Cross recessed head screws with washer S C models 9 M4 8 2 M3 6 P model 10 M4 8 2 M3 6 Tightening torque 0 9 0 1 N m M4 8 0 45 0 1 N m M3 6 5 Install the following connectors according to the ...

Page 281: ...he following covers and plate Arm 4 side covers both sides Arm 4 maintenance cover C8XL only Arm 3 cover Arm 3 maintenance cover Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base cover M C cable downward Base maintenance cover Connector plate M C cable downward For details refer to C8 Maintenance 3 Covers 10 Perform calibration For details refer to C8 Maintenance 16...

Page 282: ...C8 Maintenance 4 Cable Unit 262 C Series Maintenance Manual Rev 2 4 2 Connector Pin Assignment 4 2 1 Signal Cable ...

Page 283: ...C8 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 263 ...

Page 284: ...C8 Maintenance 4 Cable Unit 264 C Series Maintenance Manual Rev 2 ...

Page 285: ...C8 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 265 4 2 2 Power Cable C8 A701 C8 C8 A901 C8L ...

Page 286: ...C8 Maintenance 4 Cable Unit 266 C Series Maintenance Manual Rev 2 C8 A1401 C8XL ...

Page 287: ...C8 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 267 C8 A701 C8 C8 A901 C8L C8 A1401 C8XL ...

Page 288: ...able 4 2 4 Color of Cables The following table shows the codes and cable colors indicated in the pin assignments 4 2 1 Signal Cable 4 2 2 Power Cable 4 2 3 User Cable Code Cable color B Black W White R Red G Green Y Yellow BR Brown L Blue V Violet A Azure O Orange GL Gray P Pink ...

Page 289: ...ng the AC power cable to a factory power source is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and encoder Disassembled motor and encoder will cause a ...

Page 290: ...For M5 hexagon socket head cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Nippers 1 For cutting the wire tie Pliers 1 For tightening the wire tie Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs ...

Page 291: ...ng only the brake do not disconnect the connector BT1 If the connector is disconnected perform calibration C8 A701 C8 C8 A901 C8L C8 A1401 C8XL Remove the heat radiation block 1 Remove the wire tie and the bolts to remove the heat radiation block Hexagon socket head cap bolts M5 15 Wire tie AB350 2 Remove the heat radiation sheet between the heat radiation block and the motor C8 A1401 C8XL The hea...

Page 292: ... the Joint 1 brake plate from the Joint 1 motor unit Hexagon socket head cap bolts 3 M4 20 7 Remove the Joint 1 motor unit from the base Hexagon socket head cap bolts 3 M6 30 with a plain washer Be careful not to tear and lose the heat radiation sheet attached to the motor ...

Page 293: ...e Manipulator is operated without the heat radiation sheet the motor generates heat and the error may occur If the heat radiation sheet has the protection film remove the film Pass the pulley 1 of the Joint 1 motor unit to the Joint 1 timing belt and loosely secure it to the base Hexagon socket head cap bolts 3 M6 30 with a plain washer Make sure that the gear grooves of the timing belt are fit in...

Page 294: ...lower limit Vibration abnormal noise or reduction in life of the parts may occur if the value exceeds the upper limit When you replace with a new belt belt extends and the belt tension may decrease in the initial stage Make sure to operate the robot two to three days and check the belt tension again When using the belt tension tensile jig maintenance part Fix the belt tension tensile jig for J1 J2...

Page 295: ...ing the brake If the J1 brake positioning jig cannot be inserted all the way the motor and the brake core may be misaligned In such a case use the brake release unit option part to release the brake and then align the brake Correct Wrong 5 Install the brake power supply to the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross ...

Page 296: ... has the protection film remove the film Image of the protection film 2 Fix the upper part of the heat radiation block to the Joint 1 motor plate with the bolts Hexagon socket head cap bolts M5 15 Tightening torque 4 0 0 2 N m 3 Fix the lower part of the heat radiation block to the motor with the wire tie Wire tie AB350 3 1 Insert the wire tie under the motor 3 2 Hold the end of the wire tie 3 3 W...

Page 297: ...277 3 4 Wrap the wire tie around the motor 3 5 Tighten the wire tie to hold the heat radiation sheet firmly Make sure that the heat radiation sheet sticks out of the heat radiation block Do not tighten the wire tie too much It may result in cable breakage NOTE ...

Page 298: ...er 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig and J1 brake positioning jig are assembly jigs Use the jigs when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the...

Page 299: ...o that at least one of them can support the arm while the others are removing the bolts Removing the bolts without supporting the arm may result in the arm falling bodily injury and or malfunction of the robot system 1 Remove the following parts Connector plate Connector Cable grounding plate Brake power supply For details refer to C8 Maintenance 5 1 3 Joint 1 Replacing the Timing Belt M C Cable B...

Page 300: ...cable bracket C1 Hexagon socket head cap bolts 2 M3 6 7 Remove the Joint 1 timing belt 8 Remove the Joint 2 motor unit For details refer to C8 Maintenance 6 1 Joint 2 Replacing the Motor Removal steps 1 to 9 9 Remove the Joint 1 cable fixing plate Arm 1 side Hexagon socket head cap bolts 2 M4 10 10 Remove the connector connected to the control board 1 Connector GS01 ...

Page 301: ... Pull out the grease tube between the base and the Arm 1 on the Arm 1 side from the fitting 13 Remove the Arm 1 from the base Hexagon socket head cap bolts 15 M6 30 with a plain washer CAUTION By removing the bolts the Arm 1 2 3 4 5 and 6 end effector can be separated There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when remov...

Page 302: ...e reduction gear unit has clearance holes Install the reduction gear unit to match the screws and the clearance holes 2 Install the Arm 1 to the base Hexagon socket head cap bolts 15 M6 30 with a plain washer Tightening torque 18 0 0 9 N m CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when installing the arm Have at...

Page 303: ...the cables 5 Connect the connector to the control board 1 Connector GS01 6 Install the Joint 1 cable bracket Arm 1 side Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 7 Install the Joint 2 motor unit For details refer to C8 Maintenance 6 1 Joint 2 Replacing the Motor Installation steps 4 to 9 8 Pass the cables and the air tube inside the Joint 1 timing belt 9 Mount the base ca...

Page 304: ...t of the base D sub cable Ground wire RJ45 connector F sensor connector 13 Connect the ground wires Cross recessed head screws with washer S C models 9 M4 8 2 M3 6 P model 10 M4 8 2 M3 6 Tightening torque 0 9 0 1N m M4 8 0 45 0 1 N m M3 6 The ground terminals of the D sub cables have fixed installation positions Install them to the two screw holes Photo indicated by the arrows 14 Install the follo...

Page 305: ...ss flats 4 mm 1 For M5 hexagon socket head cap bolt width across flats 5 mm 1 For M6 hexagon socket head cap bolt Box wrench width across flats 5 mm 1 For D Sub connector Long nose pliers 1 For removing the air tube Cross point screwdriver 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positio...

Page 306: ...M C cable backward For details refer to C8 Maintenance 3 Covers 4 Remove two air tubes inside the base 5 Remove two D sub connectors 6 Disconnect the cables from the base and disconnect the connectors Connector X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 Hold the clip to remove 7 Disconnect the following connectors RJ45 connector Hold the clip to remove F sensor connector Open the clips on...

Page 307: ...crews with washer 2 M3 6 9 Remove the ground wire plate M C cable backward Hexagon socket head cap bolts 2 M4 10 10 Remove the following ground wire terminals D sub cable ground wire terminals 2 Ground wire green yellow terminal 1 indicated by an arrow Cross recessed head screws with washer 3 M4 8 Positions of the ground wire green yellow terminals may differ from the photo Check the positions of ...

Page 308: ...able Ground wire RJ45 connector F sensor connector 12 Remove the Joint 1 motor unit For details refer to C8 Maintenance 5 1 1 Joint 1 Replacing the Motor M C Cable Backward Removal steps 6 to 7 13 Remove the Joint 1 cable fixing plate Hexagon socket head cap bolts 2 M3 6 Do not remove the base cable bracket C1 14 Remove the Joint 1 timing belt ...

Page 309: ...placing the Motor M C Cable Backward Installation steps 1 to 4 4 Disconnect the following parts from the hole inside the base to the upper side of the base D sub cable Ground wire RJ45 connector F sensor connector 5 Install the terminals of the D sub cable ground wire and ground wire green yellow D sub cable ground wire terminals 2 indicated by arrows Ground wire green yellow terminal 1 Cross rece...

Page 310: ... sensor connector F sensor Install the ground wire to each connector To connect the ground wire insert it while holding the connector by hand 9 Connect the M C cable connectors Connector X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 10 Install the D sub connectors in accordance with the indications on the connector plates Left D sub for brake release with a wire marker SW1 B release Right D ...

Page 311: ...ance 5 Joint 1 C Series Maintenance Manual Rev 2 291 13 Install the base maintenance cover For details refer to C8 Maintenance 3 Covers 14 Calibrate the Joint 1 For details refer to C8 Maintenance 16 Calibration ...

Page 312: ...flats 3 mm 1 For M4 hexagon socket head cap bolt Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs in relevant maintenance steps The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the mo...

Page 313: ...ad cap bolts 3 M4 25 Installation Joint 1 Electromagnetic brake M C Cable Backward When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts 1 Install the Joint 1 brake to the brake plate Hexagon socket head cap bolts 3 M4 25 Tightening torque 4 0 0 2 N m Be careful of the assembly direction of the Joint 1 electromagnetic brake See the photo 2 Mount th...

Page 314: ...mm 1 For M5 hexagon socket head cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Nippers 1 For cutting the wire tie Pliers 1 For tightening the wire tie Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use these ...

Page 315: ... to C8 Maintenance 3 Covers 4 Disconnect the cables from the base and disconnect the following connectors Connector X11 X010 BT1 BR011 Hold the clip to remove When only replacing the brake do not disconnect the connector BT1 If the connector is disconnected perform calibration C8 A701 C8 C8 A901 C8L C8 A1401 C8XL Remove the heat radiation block 1 Remove the wire tie and the bolts to remove the hea...

Page 316: ... the Joint 1 brake plate from the Joint 1 motor unit Hexagon socket head cap bolts 3 M4 20 7 Remove the Joint 1 motor unit from the base Hexagon socket head cap bolts 3 M6 30 with a plain washer Be careful not to tear and lose the heat radiation sheet attached to the motor ...

Page 317: ...e plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 3 Connect the following connectors Connector X11 X010 BT1 BR011 4 Install the following covers Connector plate M C cable downward Base cover M C cable downward Base maintenance cover For details refer to C...

Page 318: ...river 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig and J1 brake positioning jig are assembly jigs Use the jigs when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or ...

Page 319: ...ing the Arm 1 there must be two or more people to work on it so that at least one of them can support the arm while the others are removing the bolts Removing the bolts without supporting the arm may result in the arm falling bodily injury and or malfunction of the robot system 1 Remove the following parts Connector plate Connector Brake power supply For details refer to C8 Maintenance 5 2 3 Joint...

Page 320: ...nt 1 Replacing the Reduction Gear Unit M C Cable Backward Installation steps 1 to 11 2 Install the ground terminals to the plate Cross recessed head screws with washer S C models 9 M4 8 2 M3 6 P model 10 M4 8 2 M3 6 3 Install the following parts Connector plate Connector Brake power supply For details refer to C8 Maintenance 5 2 3 Joint 1 Replacing the Timing Belt M C Cable Downward Installation s...

Page 321: ...n socket head cap bolt width across flats 5 mm 1 For M6 hexagon socket head cap bolt Box wrench width across flats 5 mm 1 For D Sub connector Long nose pliers 1 For removing the air tube Cross point screwdriver 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Us...

Page 322: ...malfunction of the robot system 3 Remove the following covers Base maintenance cover Base cover M C cable downward Connector plate M C cable downward For details refer to C8 Maintenance 3 Covers 4 Disconnect the cables from the base and disconnect the following connectors Connector X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 Hold the clip to remove 5 Disconnect the following parts Air tube...

Page 323: ...3 7 Remove the ground wire plate M C cable downward Hexagon socket head cap bolts 2 M4 12 8 Remove the Joint 1 motor unit For details refer to C8 Maintenance 5 1 1 Joint 1 Replacing the Motor M C cable backward Removal steps 6 to 7 9 Remove the Joint 1 motor unit ...

Page 324: ...ghtening torque 4 0 0 2 N m 4 Install the brake power supply to the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 5 Connect the following connectors in accordance with the indications on the connector plates RJ45 connector Ether F sensor connector F sen...

Page 325: ...e marker with a round terminal D sub 8 Install two air tubes in accordance with the indications on the connector plates Air1 Semitransparent Air2 Blue Be careful not to install the air tube of wrong color 9 Install the following covers Connector plate M C cable downward Base cover M C cable downward Base maintenance cover For details refer to C8 Maintenance 3 Covers 10 Calibrate the Joint 1 For de...

Page 326: ...mbly jig Use the jig in relevant maintenance steps The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Removal Joint 1 Electromagnetic brake M C Cable Downward 1 Remove the Joint 1 brake plate from the Joint 1 moto...

Page 327: ...int 1 motor unit For details refer to C8 Maintenance 5 1 1 Joint 1 Replacing the Motor M C Cable Backward Installation step 4 3 Install the brake power supply to the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 4 Connect the M C cable connectors Connec...

Page 328: ...ent procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement It may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be u...

Page 329: ...auge 0 5 mm 2 For pulley position adjustment Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be c...

Page 330: ...ved Therefore release the brake and tilt the Arm 2 in advance Put a cloth between the Arm 1 and Arm 2 so that the arms do not touch each other EPSON RC Command brake off 2 CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when moving the Manipulator 3 Turn OFF the Controller power 4 Remove the Arm 1 center cover and the...

Page 331: ...supply Cross recessed head screws with captive washer 2 M3 6 8 Loosen the bolts securing the Joint 2 motor unit and remove the belt Hexagon socket head cap bolts 3 M5 25 with a plain washer WARNING Loosening the bolts while the Arm 2 is not bent may cause the belt come off and the Arm 2 falls down and it is extremely hazardous Be sure to do the Removal steps 1 and 2 before loosening the bolts ...

Page 332: ...and the motor shaft A Hexagon socket set screws 2 M5 12 Do not remove the pulley and drive boss screws B in the figure There is a brass bushing on one of the set screws If you removed the screws B be careful not to lose the brass bushing A Pulley and motor shaft screws D cut part of the motor shaft 2 B Pulley and drive boss screws Do not remove these screws C Bushing Pulley Drive boss A A C B B 11...

Page 333: ...C8 Maintenance 6 Joint 2 C Series Maintenance Manual Rev 2 313 12 Remove the motor plate from the Joint 2 motor Hexagon socket head cap bolts 4 M6 20 ...

Page 334: ...tromagnetic brake to the Joint 2 motor unit Hexagon socket set screws 2 M6 6 with a brass bushing Tightening torque 6 0 0 4 N m Be careful of the assembly direction of the Joint 2 electromagnetic brake See the photo Fix the set screws while pressing the electromagnetic brake to the motor plate The brass bushing is not necessary for the screw for the flat surface D cut Set the bushing to the other ...

Page 335: ... then fix them Hexagon socket set screws 2 M5 8 with a brass bushing Tightening torque 3 9 0 2 N m If the screw positions are incorrect or the bushing is not set it may cause damage on the side of the part and may result in the part being unable to be removed Set the set screws to the positions indicated in the right figure A Pulley and motor shaft screws D cut part of the motor shaft 2 B Pulley a...

Page 336: ...in life of the parts may occur if the value exceeds the upper limit When you replace with a new belt belt extends and the belt tension may decrease in the initial stage Make sure to operate the robot two to three days and check the belt tension again When using the belt tension tensile jig maintenance part Fix the belt tension tensile jig for J1 J2 and J3 with the screws 2 M4 35 and push the rubbe...

Page 337: ...Arm 1 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m C8 A1401 C8XL C8 A1401 does not have the heat dissipation block and the heat dissipation sheet go on to the next step 10 Mount the Arm 1 cover and the Arm 1 side cover For details refer to C8 Maintenance 3 Covers 11 Perform calibration For details refer to C8 Maintenance 16 Calibration ...

Page 338: ...nt screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 0 5 mm 2 For adjusting the pulley position Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own we...

Page 339: ... the Battery Board Removal steps 3 to 6 3 Remove the battery box Countersunk screws 2 M3 8 4 Arm 1 side arm fixing bolts Hexagon socket head cap bolts 8 M6 25 with a plain washer 5 Remove the Joint 2 pulley 2 from the Joint 2 shaft Hexagon socket set screws 2 M5 10 There is a brass bushing on one of the set screws Be careful not to lose it C8XL Remove the key from the shaft The key will be used ag...

Page 340: ...careful when removing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts The Arms are connected by the internal cables When replacing the parts place the removed arm while not applying load on the cables It may result in cable disconnection 8 Remove the wave generator from the reduction gear unit If the wave generator unit does no...

Page 341: ...C8 Maintenance 6 Joint 2 C Series Maintenance Manual Rev 2 321 10 Remove the O ring from the groove on the Arm 2 Wipe grease on the part while removing it ...

Page 342: ...s swollen damaged or deteriorated replace it with a new one 2 Install the reduction gear unit to the Arm 2 C8 C8L Hexagon socket head cap bolts 12 M5 40 Tightening torque 10 0 0 5 N m C8XL Hexagon socket head cap bolts 12 M6 45 Tightening torque 18 0 0 9 N m Installation face of the Arm 2 reduction gear unit has clearance holes Install the reduction gear unit to match the screws and the clearance ...

Page 343: ...8 M6 2 5 with a plain washer CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when installing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts 7 Fix the Arm 2 C8 C8L Hexagon socket head cap bolts 16 M5 30 with a plain washer Tightening torque 10 0 0 ...

Page 344: ...L Set the key to the shaft and insert the pulley 2 while aligning to the key groove The brass bushing is not necessary for the screw for the flat surface Set the bushing to the other screw and then fix the screw If the screw positions are incorrect or the bushing is not set it may cause damage on the side of the brake and may result in the part being unable to be removed 10 Install the battery box...

Page 345: ... not work during replacement Be careful when performing maintenance work When removing the Joint 2 motor tilt the Arm 2 and press it against the Arm 1 Reference C8 Maintenance 6 1 Joint 2 Replacing the Motor Removal step 2 When pressing the arm put a piece of cloth or a similar material between the arms to avoid contacting each other This protects the arm surfaces from scratching and paint peeling...

Page 346: ...sting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work When removing the Joint 2 motor tilt the Arm 2 and press it against the Arm 1 Reference C8 Maintenance 6 1 Joint 2 Replacing the Motor Removal ...

Page 347: ...ith the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be used agai...

Page 348: ...on adjustment Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintena...

Page 349: ...brake Tilt the Arm 3 and push it against the Arm 2 The Arm 3 falls by its weight when the Joint 3 motor unit is removed Therefore release the brake and tilt the Arm 3 in advance EPSON RC Command brake off 3 CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when moving the Manipulator Put a cloth between the Arm 2 and Ar...

Page 350: ... 2 M3 6 7 Loosen the bolts securing the Joint 3 motor unit and remove the belt Hexagon socket head cap bolts 3 M4 20 with a plain washer WARNING Loosening the bolts while the Arm 3 is not bent may cause the belt come off and the Arm 3 falls down and it is extremely hazardous Be sure to do the Removal steps 1 and 2 before loosening the bolts ...

Page 351: ...rom above A in the figure Pulley and motor shaft screws A Hexagon socket set screws 2 M5 12 Do not remove the pulley and drive boss screws B in the figure There is a brass bushing on one of the set screws If you removed the screws B be careful not to lose the brass bushing Pulley and drive boss screws B Hexagon socket set screws 2 M5 6 with a brass bushing A Pulley and motor shaft screws D cut par...

Page 352: ...ual Rev 2 10 Remove the Joint 3 electromagnetic brake Hexagon socket set screws 2 M5 10 with a brass bushing The screws have a brass bushing Be careful not to lose them 11 Remove the motor plate from the Joint 3 motor Hexagon socket head cap bolts 4 M5 15 ...

Page 353: ...socket set screws 2 M5 10 with a brass bushing Tightening torque 3 9 0 2 N m Be careful of the assembly direction of the Joint 3 electromagnetic brake See the photo Fix the set screws while pressing the electromagnetic brake to the motor plate The brass bushing is not necessary for the screw for the flat surface D cut Set the bushing to the other screw and then fix the screw If the screw positions...

Page 354: ... then fix them Hexagon socket set screw 2 M5 6 with a brass bushing Tightening torque 3 9 0 2 N m Set the set screws to the positions indicated in the right figure A Pulley and motor shaft screws D cut part of the motor shaft 2 B Pulley and drive boss screws Do not remove these screws C Bushing Pulley Drive boss A A C B B If the screw positions are incorrect or the bushing is not set it may cause ...

Page 355: ...ou replace with a new belt belt extends and the belt tension may decrease in the initial stage Make sure to operate the robot two to three days and check the belt tension again When using the belt tension tensile jig maintenance part Fix the belt tension tensile jig for J1 J2 J3 with the screws 2 M4 35 and push the rubber against the pulley Tension is applied by pushing the set screw M6 25 with th...

Page 356: ...s recessed head screws Torque wrench 1 For tightening torque control Feeler gauge 0 5 mm 2 For adjusting the pulley position Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power i...

Page 357: ... 3 Hexagon socket head cap bolts 16 M4 25 with a plain washer Remove a wave washer on the Arm 1 side The wave washer will be used again Be careful not to lose it Wipe grease on the parts while removing them CAUTION By removing the bolts the Arm 2 side arm the Arm 3 4 5 and 6 end effector can be separated There is a possibility of hands and fingers being caught and or damage or malfunction to the M...

Page 358: ...sily set the pulley 2 as shown in the photo to the shaft and pull out the parts Wipe grease on the wave generator while removing it 6 Remove the reduction gear unit from the Arm 3 Hexagon socket head cap bolts 12 M4 30 Wipe grease on the reduction gear unit while removing it 7 Remove the O ring from the groove on the Arm 3 Wipe grease on the O ring while removing it ...

Page 359: ...he O ring to come out of the groove If the O ring is swollen damaged or deteriorated replace it with a new one 2 Install the reduction gear unit to the Arm 3 Hexagon socket head cap bolts 12 M4 30 Tightening torque 5 5 0 2 N m Installation face of the Arm 3 reduction gear unit has clearance holes Install the reduction gear unit to match the screws and the clearance holes 3 Grease the inner side of...

Page 360: ...ve washer to the Arm 2 Hexagon socket head cap bolts 6 M5 20 with a plain washer CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when installing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts 7 Fix the Arm 3 Hexagon socket head cap bolts 16 M4 25 ...

Page 361: ...ening torque 3 9 0 2 N m Insert the pulley 2 so that one of the set screws is at the flat face of the shaft The brass bushing is not necessary for the screw for the flat surface Set the bushing to the other screw and then fix the screw If the screw positions are incorrect or the bushing is not set it may cause damage on the side of the brake and may result in the part being unable to be removed 10...

Page 362: ... work during replacement Be careful when performing maintenance work When removing the Joint 3 motor tilt the Arm 2 and press it against the Arm 2 Reference C8 Maintenance 7 1 Joint 3 Replacing the Motor Removal step 2 When pressing the arm put a piece of cloth or a similar material between the arms to avoid contacting each other This protects the arm surfaces from scratching and paint peeling off...

Page 363: ...is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work When removing the Joint 3 motor tilt the Arm 2 and press it against the Arm 2 Reference C8 Maintenance 7 1 Joint 3 Replacing the Motor Removal step 2 When pressing the arm ...

Page 364: ...edure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be us...

Page 365: ...rews Feeler gauge 0 5 mm 2 For pulley position adjustment Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing m...

Page 366: ... to C8 Maintenance 3 Covers 3 Pull out the cables from theArm 3 and disconnect the following connectors Connector X141 X041 BT4 BR041 Hold the clip to remove 4 Remove the brake power supply Cross recessed head screws with captive washer 2 M3 6 5 Remove the cable bracket Hexagon socket head cap bolts 2 M4 10 6 Remove the Joint 4 motor unit from the Arm 3 Hexagon socket head cap bolts 2 M4 15 with a...

Page 367: ...haft screws Hexagon socket set screws 2 M4 4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley Be careful not to lose it A Pulley and motor shaft screws B Pulley and drive boss screws C Bushing Pulley Drive boss A A C B 8 Remove the Joint 4 electromagnetic brake Hexagon socket set screws 3 M3 15 with a spacer Be careful not to lose the spacers 9 Remove the moto...

Page 368: ...of the direction of the Joint 4 electromagnetic brake wire See the photo Electromagnetic brake wire 3 Mount the drive boss and the pulley 1 to the Joint 4 motor unit Fix the drive boss and the motor shaft There is an uneven part for the feeler gauge 0 5 mm on the boss Use the uneven part to leave 0 5 mm space If there is no space the parts may chafe while the motor is driving and it may result in ...

Page 369: ...e screw 4 Put the Joint 4 motor unit inside the Arm 4 5 Pass the timing belt around the pulley 1 and pulley 2 and temporarily fix it Hexagon socket head cap bolts 2 M4 15 with a washer Check that the teeth of the timing belt engage with these of the pulley As a rough guide of temporary fixing check that the motor unit can be moved by hand and it does not tilt when being pulled If the belt is too l...

Page 370: ...le jig for J4 J5 and J6 against the Arm 3 as shown in the photo Insert the screw to the through hole at the center and fix it lightly to the hole for the belt tension tensile jig Hexagon socket head cap bolt M4 15 Tension is applied as the Joint 4 motor unit is stretched by tightening the screw 7 Install the plate for fixing the cables Hexagon socket head cap bolts 2 M4 10 8 Install the brake powe...

Page 371: ...ap bolts width across flats 4 mm 1 For M5 hexagon socket head cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to pr...

Page 372: ... Motor 4 Remove the cables passing through the Arm 4 as shown in the photo For details refer to the Removal steps in C8 Maintenance 4 1 Cable Unit 5 Loosen the fixing bolts of the Joint 4 motor plate and remove the belt Do not remove the Joint 4 motor Hexagon socket head cap bolts 2 M4 15 with a small plain washer 6 Remove the bolts fixing the J4 flange and remove the Arm 4 from the Arm 3 To remov...

Page 373: ...asily insert a tool in a gap between the J4 flange and the Arm and remove the wave generator little by little Be careful not to damage the parts 9 Remove the Joint 4 reduction gear unit Hexagon socket head cap bolts 12 M3 28 10 Remove the J4 sleeve holder Then remove the J4 sleeve Hexagon socket head cap bolts 4 M3 6 The J4 sleeve is attached by gasket and may not be removed easily If the part can...

Page 374: ...ve the bolts of the bearing holder on the pulley Hexagon socket head cap bolts 3 M3 8 with a plain washer 12 Remove the pulley from the pulley spacer Hexagon socket set screws 2 M4 4 13 Remove the pulley spacer from the wave generator Hexagon socket head cap bolts 4 M3 8 ...

Page 375: ...n for the reduction gear unit Fit the J4 sleeve and install the J4 sleeve holder Hexagon socket head cap bolts 4 M3 6 Tightening torque 2 0 0 1 N m 2 Install the O ring to the O ring groove Install the Joint 4 reduction gear unit Hexagon socket head cap bolts 12 M3 28 Tightening torque 2 4 0 1 N m 3 Apply grease to the Joint 4 reduction gear unit Grease SK 1A Grease amount 20 g Apply 10g of grease...

Page 376: ...it to the O ring groove on the Joint 4 reduction gear unit Then install the J4 flange Hexagon socket head cap bolts 16 M3 20 Tightening torque 2 4 0 1 N m 6 Fix the pulley spacer to the wave generator of the Joint 4 reduction gear unit Hexagon socket head cap bolts 4 M3 8 Tightening torque 2 0 0 1 N m 7 Fix the J4 pulley to the J4 pulley spacer Hexagon socket set screws 2 M4 4 ...

Page 377: ...agon socket head cap bolts 8 M5 30 Tightening torque 10 0 0 5 N m 10 Install the Joint 4 timing belt with a proper tension For details refer to C8 Maintenance 8 1 Joint 4 Replacing the Motor Installation steps 5 and 6 11 Pass the cables to the Arm 4 For details refer to Installation steps in C8 Maintenance 4 1 Cable Unit 12 Install the Joint 5 and 6 motors For details refer to Installation steps o...

Page 378: ...r passing the cables Braid tube 600 mm or longer 1 For passing the cables The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Removal ...

Page 379: ... 10 7 Remove the green yellow ground wire and the green ground wire connected to X052 and X062 from the cable protection plate Cross recessed head screws with captive washer 2 M4 8 Positions of the ground wire terminals may differ from the photo Check which connector the terminal is connected to 8 Remove the following connectors Connector X052 X062 9 Remove the Arm 4 cable bracket and the cable pr...

Page 380: ...racket and the cable protection sheet Hexagon socket head cap bolts 2 M3 6 The Arm 4 cable bracket and cable protection sheet will be used again Be careful not to lose them 13 Pull the following parts from the Arm 4 to the Arm 3 LAN cable X052 and X062 cables Ground wire Air tube blue Protect the connectors with masking tapes To protect the connector s clips To avoid adherence of cable grease 14 R...

Page 381: ...h the wire tie so that connectors are not to be pulled out Then pull the braid tube from the Arm 4 side while pushing the cables from the Arm 3 side to pass the cables through See the photo Pulling the cables forcibly may cause falling off or breakage of the connectors and disconnection of the cables If it is difficult to pass the cables pass the cables one by one in the following order X052 and X...

Page 382: ...rque 4 0 0 2 N m 8 Install the brake power supply to the plate Install the brake power supply so that the cable is facing to the left Cross recessed head screws with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 9 Connect the connectors inside the Arm 3 and the air tube transparent Connector X71 X72 X041 BR041 BR051 PS BT4 BT51 X141 X151 X161 10 Connect the ground wire terminals inside the ...

Page 383: ... to the Arm 4 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the cables caught It may cause cable breakage 13 Install the air tube blue to the fitting 14 Install the following covers Arm 3 cover Arm 3 maintenance cover Arm 4 side cover Arm 4 maintenance cover C8XL only For details refer to C8 Maintenance 3 Covers NOTE ...

Page 384: ...ch joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work The electromagnetic brakes are common for Joints 4 5 and 6 The Joints 5 and 6 electromagnetic brakes have an identification label for preventing misconnection of the connectors The label i...

Page 385: ... the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be used again A...

Page 386: ...ontrol Spanner width across flats 8 mm 1 For air tube fitting Feeler gauge 0 5 mm 2 For adjusting the drive boss position Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The bra...

Page 387: ... the screws fixing the cable protection bracket on the Arm 4 and pull out the cables Hexagon socket head cap bolts 2 M4 10 4 Remove the brake power supply connected to the connector BR052 from the plate Cross recessed head screw with captive washer 2 M3 6 5 Disconnect the following connectors Connector X052 X152 BT52 BR052 6 Remove the air tube fitting located in the front of the Joint 5 motor uni...

Page 388: ...lain washer 9 Remove the Joint 5 pulley 1 and the drive boss from the motor shaft of the Joint 5 motor unit Pulley 1 and drive boss screws Hexagon socket set screws 2 M4 4 with a brass bushing Drive boss and motor shaft screws Hexagon socket set screws 2 M4 4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley Be careful not to lose it A Pulley and motor shaft sc...

Page 389: ...enance Manual Rev 2 369 10 Remove the Joint 5 electromagnetic brake Hexagon socket head cap bolts 3 M3 15 with a spacer Be careful not to lose the spacers 11 Remove the motor plate from the Joint 5 motor Hexagon socket head cap bolts 2 M4 10 ...

Page 390: ...he assembly direction of the Joint 5 electromagnetic brake wiring See the photo Electromagnetic brake wiring 3 Mount the drive boss and the pulley 1 to the Joint 5 motor unit Fix the drive boss and the motor shaft There is an uneven part for the feeler gauge 0 5 mm on the boss Use the uneven part to leave 0 5 mm space If there is no space the parts may chafe while the motor is driving and it may r...

Page 391: ...d pulley 2 and fix it temporarily Make sure that the teeth of the timing belt engage with these of the pulley As a rough guide of temporary fixing check that the motor unit can be moved by hand and it does not tilt when being pulled If the belt is too loose or too tight it will not have proper tension 6 Apply tension to the Joint 5 timing belt and fix the Joint 5 motor unit Joint 5 Timing belt ten...

Page 392: ...It may cause air leakage due to screw breakage or gasket deformation Fitting is too loose It may cause loose screws and air leakage 8 Connect the following connectors Connectors X052 X152 BT52 BR052 9 Install the brake power supply to the plate Cross recessed head screw with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 10 Fix the cable protection bracket to the Arm 4 Hexagon socket head ca...

Page 393: ...dth across flats 2 5 mm 1 For M3 hexagon socket head cap bolts width across flats 3 mm 1 For M4 hexagon socket head cap bolts width across flats 4 mm 1 For M5 hexagon socket head cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Spanner width across flats 8 mm 1 For air f...

Page 394: ...own in the photo For details refer to the Removal steps in C8 Maintenance 4 1 Cable Unit 5 Remove the Joints 5 6 reduction gear unit C8 Loosen the fixing bolts of the Joint 4 motor plate and remove the belt Do not remove the Joint 4 motor Hexagon socket head cap bolts 2 M4 15 with a small plain washer Remove the bolts fixing the J4 flange and remove the Joints 5 and 6 reduction gear unit with the ...

Page 395: ...tion Gear Unit C8L C8XL Remove the Arm 4 extension flange C8XL does not have the J4 sleeve on the Arm 4 Hexagon socket head cap bolts 12 M3 18 7 C8 C8L First remove the J4 sleeve holder Then remove the J4 sleeve Hexagon socket head cap bolts 4 M3 6 The J4 sleeve is adhered with gasket and may not be removed easily If the part cannot be removed pull the sleeve while rotating it Handle the sleeve wi...

Page 396: ...ning torque 2 0 0 1 N m 2 C8 Install the Joint 4 reduction gear unit For details refer to Installation steps in C8 Maintenance 8 2 Joint 4 Replacing the Reduction Gear Unit C8L C8XL Install the Arm 4 extension flange C8XL does not have the sleeve Hexagon socket head cap bolts 12 M3 18 Tightening torque 2 4 0 1 N m 3 Install the Joints 5 and 6 reduction gear unit C8 Install the J4 flange to the Arm...

Page 397: ...earing mating part indicated by a yellow mark in the right photo Adhesive Loctite641 Hexagon socket head cap bolts 4 M6 20 Tightening torque 13 0 0 6 N m 4 Pass the cables to the Arm 4 Connect all the connectors inside the Arm 3 and bind them together Fix the cables inside the Arm 4 and connect the D sub to the Arm 4 For details refer to Installation steps in C8 Maintenance 4 1 Cable Unit ...

Page 398: ...ty Note Maintenance Parts Joint 5 timing belt 330 mm 1 1655932 Belt tensile jig 1 1674582 Tools Hexagonal wrench width across flats 3 mm 1 For M4 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension...

Page 399: ... Electromagnetic brake 1 2172928 Common for Joints 4 5 6 Belt tensile jig 1 1674582 Tools Hexagonal wrench width across flats 2 mm 1 For M4 hexagon socket set screws width across flats 2 5 mm 1 For M3 hexagon socket head cap bolts width across flats 3 mm 1 For M4 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control S...

Page 400: ...able blue orange BR053 is connected at the time of shipment Before attaching the label disconnect the connector One side of BR052 and BR053 have the same shape Identify the connectors by color Removal Joint 5 Electromagnetic brake 1 Remove the Joint 5 electromagnetic brake For details refer to C8 Maintenance 9 1 Joint 5 Replacing the Motor Removal steps 1 through 10 Installation Joint 5 Electromag...

Page 401: ... the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be used again A...

Page 402: ... head screws Feeler gauge 0 5 mm 2 For adjusting the drive boss position Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful wh...

Page 403: ...et head cap bolts 2 M4 10 4 Remove the brake power supply connected to the connector BR062 from the protection plate Cross recessed head screw with captive washer 2 M3 6 5 Pull out the cables from the Arm 4 and disconnect the following connectors Connectors X062 X162 BT62 BR062 6 Loosen the bolts securing the Joint 6 motor unit and remove the belts Hexagon socket head cap bolts 2 M4 15 with a plai...

Page 404: ...crews Hexagon socket set bolts 2 M4 4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley Be careful not to lose it A Pulley and motor shaft screws B Pulley and drive boss screws C Bushing Pulley Drive boss A A C B 9 Remove the Joint 6 electromagnetic brake Hexagon socket set bolts 3 M3 15 with a spacer Be careful not to lose the spacers 10 Remove the motor plate...

Page 405: ...e assembly direction of the Joint 5 electromagnetic brake wiring See the photo Electromagnetic brake wiring 3 Mount the drive boss and the pulley 1 to the Joint 6 motor unit Fix the drive boss and the motor shaft There is an uneven part for the feeler gauge 0 5 mm on the boss Use the uneven part to leave 0 5 mm space If there is no space the parts may chafe while the motor is driving and it may re...

Page 406: ...ngage with these of the pulley As a rough guide of temporary fixing check that the motor unit can be moved by hand and it does not tilt when being pulled If the belt is too loose or too tight it will not have proper tension 6 Apply tension to the Joint 6 timing belt and fix the Joint 6 motor unit Joint 6 timing belt tension 15 to 30 N Belt tension meter setting value Weight 2 5 g mm width m span W...

Page 407: ...lowing connectors Connectors X062 X162 BT62 BR062 8 Install the brake power supply to the plate Cross recessed head screw with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 9 Fix the cable protection plate to the Arm 4 Hexagon socket head cap bolt 2 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the cables caught It may result in cable breakage 10 Install the Arm 4 side cover For...

Page 408: ...air fittings Feeler gauge 0 5 mm 2 For drive boss position adjustment Belt tension meter 1 Refer Unitta U 505 For details of the replacement procedure refer to C8 Maintenance 9 2 Joint 5 Replacing the Reduction Gear Unit Replacing the Joints 5 6 Reduction Gear Unit The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the mot...

Page 409: ...omagnetic Brake Name Qty Note Maintenance Parts Electromagnetic brake 1 2172928 Common to Joints 4 5 6 Belt tensile jig 1 1674582 Tools Hexagonal wrench width across flats 2 mm 1 For M4 hexagon socket set screws width across flats 2 5 mm 1 For M3 hexagon socket head cap bolts width across flats 3 mm 1 For M4 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws F...

Page 410: ...ble blue orange BR063 is connected at the time of shipment Before attaching the label disconnect the connector One side of BR062 and BR063 have the same shape Identify the connectors by color Removal Joint 6 Electromagnetic brake 1 Remove the Joint 6 electromagnetic brake For details refer to C8 Maintenance 10 1 Joint 6 Replacing the Motor Removal steps 1 through 9 Installation Joint 6 Electromagn...

Page 411: ...ecting batteries improperly Exposing to fire Forcing discharge Deforming by pressure Short circuit Polarity Positive Negative Heating 85 C or more Soldering the terminal of the lithium battery directly When disposing the battery consult with the professional disposal services or comply with the local regulation Make sure that the battery terminal is insulated even for a used buttery If the termina...

Page 412: ... from the originals after replaced the battery Designated parts must be used for the lithium battery and battery board Be careful of the battery polarity to connect it correctly Battery board Battery Figure C8 A1401 C8XL Name Qty Note Maintenance Parts Battery unit Lithium battery 1 2172925 Two lithium batteries for replacement Battery board 1 2173216 Tools Cross point screwdriver 2 1 For cross re...

Page 413: ...battery box If you removed all the batteries before connecting the new ones the calibration data will be deleted and you will need to perform calibration Follow the steps below to remove the lithium batteries 4 Connect the two new batteries to the connectors of the battery board which are not connected to anything 5 Remove the old batteries Hold the board by hand and pull the battery cable upward ...

Page 414: ...Maintenance 3 Covers 8 Turn ON the Controller power 9 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three points poses of the registered points 10 If the Manipulator is out of position calibrate all the joints and axes For details refer to C8 Maintenance 16 Calibration ...

Page 415: ...cessary to match these origins after replacing the parts The process of aligning the two origins is called Calibration Refer to C8 Maintenance 16 Calibration and perform the calibration after the parts replacement Removal Battery board 1 Turn OFF the Controller power 2 Remove the Arm 1 side cover For details refer to C8 Maintenance 3 Covers 3 Remove the battery from the battery box 4 Remove the ba...

Page 416: ...xed to the plate Cross recessed head screws 3 M3 6 Installation Battery board When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts 1 Install the battery board to the plate Cross recessed head screws 3 M3 6 Tightening torque 0 45 0 1 N m 2 Connect the connectors to the battery board Connector CN3 CN6 NOTE ...

Page 417: ...ry board is installed to Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 4 Connect the battery connectors 5 Install the battery to the battery box 6 Install the Arm 1 side cover For details refer to C8 Maintenance 3 Covers 7 Perform the calibration For details refer to C8 Maintenance 16 Calibration ...

Page 418: ...re to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot sy...

Page 419: ...er to C8 Maintenance 3 Covers 3 Remove the connector connected to the control board 1 Connector GS01 4 Remove the control board 1 fixed to the Arm 1 Cross recessed head screws 3 M3 8 Be careful not to drop the screws inside the Manipulator while removing them 5 Remove the control board 1 protection plate Cross recessed head screws with captive washer M3 6 It is not necessary to remove the spacer f...

Page 420: ...cessed head screws 3 M3 8 Tightening torque 0 45 0 1 N m Be careful not to drop the screws inside the Manipulator while removing them 3 Connect the connector to the control board 1 Connector GS01 4 Install the Arm 1 center cover For details refer to C8 Maintenance 3 Covers 5 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three po...

Page 421: ...oard 2 1 Turn OFF the Controller power 2 Remove the Arm 3 cover For details refer to C8 Maintenance 3 Covers 3 Remove the connector connected to the control board 2 Connector GS02 4 Remove the plate fixed to the Arm 3 Hexagon socket head cap bolts 2 M4 10 5 Remove the control board 2 fixed to the plate Cross recessed head screws 4 M3 8 ...

Page 422: ... photo 2 Install the plate with the control board 2 to the Arm 3 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 3 Connect the connector to the control board 2 Connector GS02 4 Install the Arm 3 cover For details refer to C8 Maintenance 3 Covers 5 Turn ON the Controller power 6 Check operation to see if the Manipulator s position and posture are out of position Move the Manipul...

Page 423: ...m disconnect the power plug from the power source Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may resu...

Page 424: ...ED is under the Arm 3 cover Connector LED 4 Remove the LED lamp from the Arm 3 Turn the plastic nut securing the LED lamp in the Arm 3 counterclockwise Plastic nut Installation LED lamp 1 Install the LED lamp to the Arm 3 Remove the plastic nut from the LED lamp Pass the lamp from the inside of the Arm 3 Turn the nut clockwise and secure the lamp to the Arm 3 2 Connect the following connector Conn...

Page 425: ...acement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION When disconnecting the connectors during the replacement of the cable unit be sure to reconnect the connectors to their proper positions Improper connection of the connectors may result in improper function of the robot system For details on the connections ple...

Page 426: ... R12NZ900S7 15 m Straight 1 R12NZ900YC L shaped 1 R12NZ900YB 20 m Straight 1 R12NZ900S4 L shaped 1 R12NZ900S8 M C cable flexible 3 m Straight 1 R12NZ900S9 L shaped 1 R12NZ900SD 5 m Straight 1 R12NZ900SA L shaped 1 R12NZ900SE 10 m Straight 1 R12NZ900SB L shaped 1 R12NZ900SF 15 m Straight 1 R12NZ900YE L shaped 1 R12NZ900YD 20 m Straight 1 R12NZ900SC L shaped 1 R12NZ900SG Tools Hexagonal wrench width...

Page 427: ... plate For details refer to C8 Maintenance 3 Covers Installation M C cable 1 Install the connector sub plate For details refer to C8 Maintenance 3 Covers 2 Connect the connectors of the new M C cable to these of the cable unit Connector X11 X12 X14 BR010 X010 X020 X040 LED GS01 3 Install the connector plate For details refer to C8 Maintenance 3 Covers 4 Connect the following connectors to the Cont...

Page 428: ...r to the robot system disconnect the power plug from the power source Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely ha...

Page 429: ...ews be sure to support the cover 2 Remove the fan cover 3 Remove the fan connectors 4 Remove the fan Installation Fan 1 Install the fan Be careful of the installation direction of the fan The arrow on the fan indicated with the arrow in the photo should point the heat sink and the cables should come to the upper side of the fan Heat sink side 2 Connect the fan connectors 3 Install the fan cover Cr...

Page 430: ...perator However operating the robot system while someone is inside the safeguarded area is extremely hazardous and may result in serious safety problems in case that the Manipulator moves unexpectedly In EPSON RC a coordinate point including the arm pose is defined as point and its data is called point data There are two methods to move the Manipulator during calibration Releasing the electromagne...

Page 431: ... result in Manipulator malfunction When the home positions of the Joints 1 and 4 are uncertain check torsion of the internal cables The home positions are where the Manipulator has the internal cables not twisted at the basic orientation described in C Series Manual C8 Manipulator 3 7 Checking the Basic orientation Torsion of the internal cables can be checked by removing the following covers Join...

Page 432: ...place parts of one joint at a time whenever possible If you calibrate the origins for multiple joints simultaneously it will be more difficult to verify their origins and obtain the origin correct positions However joint 5 cannot be calibrated alone due to the structure of the Manipulator Make sure you calibrate joint 5 and 6 at the same time Calibration Flowchart 4 Calibration Yes Start 1 Basic P...

Page 433: ...motors reduction gear unit or belt is necessary for the calibration Verify the recorded pulse values of the basic pose obtained in the Setup Operation 3 7 Checking the Basic orientation 2 Part Replacement Replace parts as instructed in this manual Be careful not to injure yourself or damage parts during part replacement 3 Encoder Initialization Turn ON the Controller while all joints are in the mo...

Page 434: ...fer to the procedure indicated above When the origin of the Joint 5 is calibrated the Joint 6 will be out of position Due to the structure of the Manipulator any offset in the position of the Joint 5 affects the Joint 6 Calibrate the origin of the Joint 6 together when calibrating the Joint 5 4 Calibration Calibration marks of each joint Figure C8 A1401 C8XL EPSON RC 4 1 Move the arm you want to c...

Page 435: ...N RC 4 4 Input the command in the Command window and execute it Execute one of the following commands to reset the encoder of the joint you want to calibrate from the menu Tool Command Window calpls 0 0 0 0 0 0 Manipulator does not move EPSON RC 4 5 Perform the calibration Execute one of the following commands to reset the encoder of the joint you want to calibrate from the menu Tool Command Windo...

Page 436: ...itions Select the Joint jog mode from Jog Teach to operate in the jog motion Enter the command below in the command window and execute it Execute the command below in the menu Tools Command Window calpls ppls P1 1 ppls P1 2 ppls P1 3 ppls P1 4 ppls P1 5 ppls P1 6 The Manipulator will not move Perform the calibration Input one of the following commands according to the joint being calibrated Joint ...

Page 437: ...y 5 1 4 5 2 4 6 4 Joint 3 2172927 7 4 Joints 4 5 6 2172928 8 4 9 4 10 4 J1 brake positioning jig 1675081 Assembly tool 5 1 4 5 2 4 Timing belt Joint 1 C8 1655928 Width 20 mm 560mm 5 1 3 5 2 3 C8L 1655929 580mm C8XL 1655930 595 mm Joint 2 C8 1655920 Width 14 mm 475mm 6 3 C8L 1655924 485mm C8XL 1655927 540 mm Joint 3 C8 1655915 Width 10 mm 471 mm 7 3 C8L 1655918 480 mm C8XL 1655919 501 mm Joint 4 16...

Page 438: ...te Reference Grease Joints 1 2 3 4 5 SK 1A For purchasing grease liquid gasket and adhesive please contact the supplier of your region 2 3 5 1 2 5 2 2 7 2 8 2 9 2 Joint 6 Bevel gear SK 2 2 3 10 2 Cable GPL 224 4 Liquid gasket For protection model 1207B 3 Adhesive LOCTITE641 8 2 9 2 Grease up kit 1674592 Set of grease gun nipple an extension tool 2 3 Grease plug 1656158 2 3 Regarding purchase of gr...

Page 439: ...ble flexible 3 m Straight R12NZ900S9 L shaped R12NZ900SD 5 m Straight R12NZ900SA L shaped R12NZ900SE 10 m Straight R12NZ900SB L shaped R12NZ900SF 15 m Straight R12NZ900YE L shaped R12NZ900YD 20 m Straight R12NZ900SC L shaped R12NZ900SG Cable unit C8 2172929 Standard Clean room model 4 2172932 Protection model C8L 2172930 Standard Clean room model 2172933 Protection model C8XL 2172931 Standard Clea...

Page 440: ...Side cover left 1655127 Side cover right 1674550 Arm 3 Cover 1674551 Arm 4 Side cover 1674553 Gasket Arm 1 Center gasket 1665238 Protection model 3 Side gasket 1665240 Arm 2 Side gasket 1665241 Arm 3 Cover gasket 1665242 Maintenance gasket 1665254 Arm 4 Side gasket 1665243 Maintenance gasket 1665257 D sub attachment gasket 1665255 Base Rear gasket 1665244 Bottom gasket 1665247 Maintenance gasket 1...

Page 441: ... release unit Camera plate unit R12NZ9003F Common to C3 and C4 Old Code R12B031922 6 2 Tool adapter ISO flange R12NZ900LQ 6 3 Adjustable mechanical stop J1 R12NZ900LR 6 4 C8 C8L_J2 R12NZ900N6 C8XL_J2 R12NZ900LT J3 R12NZ900LU Fittings for customer use ø6 straight R12NZ900LV 6 5 ø6 elbow R12NZ900LW Standard user connector kit D sub R12NZ900LX Waterproof user connector kit D sub R12NZ900LY Ethernet R...

Page 442: ...C8 Maintenance 18 C8 Option Parts List 422 C Series Maintenance Manual Rev 2 ...

Page 443: ...C12 Maintenance This volume contains maintenance procedures with safety precautions for C12 series Manipulators ...

Page 444: ......

Page 445: ...arded area Checking the operation of the Manipulator while you are inside of the safeguarded area may cause serious safety problems as the Manipulator may move unexpectedly Before operating the robot system make sure that both the Emergency Stop switches and safeguard switch function properly Operating the robot system when the switches do not function properly is extremely hazardous and may resul...

Page 446: ...unction of the robot system If the Manipulator is operated without connecting the brake release unit or the external short connector the brakes cannot be released and it may cause damage on them After using the brake release unit be sure to connect the external short connector to the Manipulator or check connection of the connector for the brake release unit The Manipulator arms may become hot aft...

Page 447: ...ve stages daily monthly quarterly biannual and annual The inspection points are added every stage If the Manipulator is operated for 250 hours or longer per month the inspection points must be added every 250 hours 750 hours 1500 hours and 3000 hours operation Inspection Point Daily inspection Monthly inspection Quarterly inspection Biannual inspection Annual inspection Overhaul replacement 1 mont...

Page 448: ...connector plates etc Visually check for external defects Clean up if necessary External appearance of Manipulator External cables Check for bends or improper location Repair or place it properly if necessary Safeguard etc Check either the external short connector or the brake release unit connector is connected The external short connector on the back side of the Manipulator or the brake release u...

Page 449: ...o cable disconnection Check for bends or improper location Repair or place it properly if necessary Check that the safeguard etc are located properly If the location is improper place it properly Check either the external short connector or the brake release unit connector is connected Check whether external short connector or break release connector is connected When neither is connected connect ...

Page 450: ...rm it is recommended to overhaul the parts parts replacement The time between overhauls is 20 000 operation hours of the Manipulator as a rough indication However it may vary depending on usage condition and degree of the load such as when operated with the maximum motion speed and maximum acceleration deceleration in continuous operation applied on the Manipulator For EPSON RC 7 0 the recommended...

Page 451: ...2 Click the View Controller Status button to open the Browse For Folder dialog box 3 Select the folder where the information is stored 4 Click OK to view the Controller Status Viewer dialog box 5 Select Robot from the tree menu on the left side For the parts subject to overhaul refer to C12 Maintenance 17 Maintenance Parts List For details of replacement of each part refer to each section Please c...

Page 452: ...ey will be required for the repairs If grease gets into your eyes mouth or on your skin follow the instructions below If grease gets into your eyes Flush them thoroughly with clean water and then see a doctor immediately If grease gets into your mouth If swallowed do not induce vomiting See a doctor immediately If grease just gets into your mouth wash out your mouth with water thoroughly If grease...

Page 453: ... head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Flat head screwdriver 1 For grease plug Before greasing move the Manipulator so that the grease inlet is not directed down Do not remove the grease plug while the grease inlet is directed down Otherwise the oil content separated from the grease may leak out Do not use any tool to install and remove the grease nipple and gre...

Page 454: ...rease inlet located inside the Arm 1 3 Attach the grease nipple to the Joint 1 grease inlet 4 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 11g 5 Remove the grease nipple from the Joint 1 grease inlet 6 Attach the grease plug to the Joint 1 grease inlet If the grease plug is damaged or deteriorated replace it with a new one 7 Install the Arm 1 side cover For de...

Page 455: ...int 2 grease inlet of the Arm 1 2 Attach the grease nipple to the Joint 2 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 12g 4 Remove the grease nipple from the Joint 2 grease inlet 5 Attach the grease plug to the Joint 2 grease inlet If the grease plug is damaged or deteriorated replace it with a new one ...

Page 456: ...int 3 grease inlet of the Arm 2 2 Attach the grease nipple to the Joint 3 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 3g 4 Remove the grease nipple from the Joint 3 grease inlet 5 Attach the grease plug to the Joint 3 grease inlet If the grease plug is damaged or deteriorated replace it with a new one ...

Page 457: ...lug attaching hole located near the label with 4 printed is the Joint 4 grease inlet The grease inlet position differs depending on the model Carefully identify the correct position 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 2g 4 Remove the grease nipple from the Joint 4 grease inlet 5 Attach the grease plug to the Joint 4 grease inlet If the grease plug i...

Page 458: ...ole located near the label with 5 printed is the Joint 5 grease inlet Be careful not to confuse it with the Joint 6 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 1A Grease amount 1g Be careful not to mix with the grease used in the Joint 6 SK 2 4 Remove the grease nipple from the Joint 5 grease inlet 5 Attach the grease plug to the Joint 5 grease inlet If the gre...

Page 459: ...le located near the label with 6 printed is the Joint 6 grease inlet Be careful not to confuse it with the Joint 5 grease inlet 3 Inject grease from the grease nipple using a grease gun Grease SK 2 Grease amount 0 5g Be careful not to mix with the grease used in the Joint 5 SK 1A 4 Remove the grease nipple from the Joint 6 grease inlet 5 Attach the grease plug to the Joint 6 grease inlet If the gr...

Page 460: ...e groove 3 Apply grease to the mating surface of the bevel gear inside the Arm 5 Grease SK 2 Grease amount 2g 4 Apply a thin coat of grease SK 2 to the O ring Fit the O ring into the base groove Do not allow the O ring to come out of the groove If the O ring is swollen damaged or deteriorated replace it with a new one 5 Install the Arm 5 grease inlet cover Hexagon socket head cap bolts 4 M3 6 Tigh...

Page 461: ...below for the set screw M3 2 0 0 1 N m 21 1 kgf cm Set Screw Tightening Torque M4 4 0 0 2 N m 41 2 kgf cm M4 2 4 0 1 N m 26 1 kgf cm M5 8 0 0 4 N m 82 4 kgf cm M5 3 9 0 2 N m 40 2 kgf cm M6 13 0 0 6 N m 133 6 kgf cm M6 8 0 0 4 N m 82 4 kgf cm M8 32 0 1 6 N m 326 16 kgf cm M10 58 0 2 9 N m 590 30 kgf cm M12 100 0 5 0 N m 1 020 51 kgf cm It is recommended to fasten the bolts aligned on a circumferen...

Page 462: ...int 1 Timing belt Joint 1 Reduction gear unit Joint 3 Reduction gear unit Joint 3 Motor Electromagnetic brake Joint 3 Timing belt LED lamp Joint 5 Motor Electromagnetic brake Joint 5 Timing belt Joint 6 Motor Electromagnetic brake Joint 6 Timing belt Joints 5 6 Reduction Gear Unit Set Joint 4 Electromagnetic brake Joint 4 Motor Joint 4 Reduction gear unit Joint 4 Timing belt Battery board Battery ...

Page 463: ...elated equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system Be careful not to get any foreign substances in the Manipulator connectors and pins during maintenance Turning ON the power to the robot system when any foreign substances exis...

Page 464: ...4 Side cover left 1 1822063 Side cover right 1 1822064 Arm 1 Side cover 2 1674548 Cleanroom model Plating cover Arm 2 Side cover left 1 1655127 Side cover right 1 1674550 Arm 3 Cover 1 1674551 Arm 4 Side cover left 1 1822065 Side cover right 1 1822066 Gasket Base Gasket for heat sink 1 1694610 Cleanroom model Tools Hexagonal wrench width across flats 2 5 mm 1 For M3 hexagon socket head cap bolts w...

Page 465: ...d may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal Remove the screws and then remove the Arm 1 center cover Cross recessed truss head small screws 5 M4 10 Installation Install the Arm 1 center cover to the Manipulator Cross recessed t...

Page 466: ... routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal Remove the screws and then remove the Arm 1 side cover Cross recessed truss head small screws 4 M4 10 one side Installation Install the Arm 1 side cover to the Manipulator Cross recessed truss head small screws 4 M4 10 one side Tightening torque 0 9 0 1 N m Be ca...

Page 467: ...the Manipulator Cross recessed truss head small screws 4 M4 10 one side Tightening torque 0 9 0 1 N m Be careful not to get the cables caught between the cover and the Manipulator body 3 4 Arm 3 Cover CAUTION When mounting the cover be careful not to get the cables caught in it or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnectio...

Page 468: ...e robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal 1 Before removing the Arm 3 maintenance cover move the arm to the position where you can remove the cover easily 2 Remove the screws and then remove the Arm 3 maintenance cover Cross recessed truss head small screws 4 M4 8 Installation Install ...

Page 469: ...oper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal 1 Remove the screws and then remove the Arm 4 side cover Cross recessed truss head small screws 7 M4 10 one side The Arm 4 side cover andArm 4 side are the same between right and left 2 Remove the connectors RJ45 connector le...

Page 470: ...e cables caught in it or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original l...

Page 471: ...orcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the D sub attachment Be sure to place the cables back to their original locations Removal Remove t...

Page 472: ...ric shock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations The base cover of the M C cable backward model is located on the bottom face of the base Removal Remove the bolts and then remove the base cover Hexagon socket head cap bolts 8 M4 10 Installation Install the base...

Page 473: ...cables check the cable locations at removing the cover Be sure to place the cables back to their original locations The base cover of the M C cable downward model is located on the backside of the base Removal 1 Remove the fan For details refer to C12 Maintenance 15 Replacing the Fan 2 Remove the bolts on the heat sink Hexagon socket head cap bolts 4 M4 15 3 Remove the heat sink For cleanroom mode...

Page 474: ... until the liquid gasket becomes solid and the gasket is fixed 3 Install the base cover to the Manipulator Hexagon socket head cap bolts 11 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the gasket and cables caught between the cover and the Manipulator body Replace the gasket if there are flaws or deteriorations For cleanroom model install the gasket between the heat sink and the base ...

Page 475: ...nd may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the cover Be sure to place the cables back to their original locations Removal Remove the screws and then remove the base maintenance cover Cross recessed truss head small screws 6 M4 10 Installation Install the base maintenance cover to the Manipulator Hexagon...

Page 476: ... disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the connector plate Be sure to place the cables back to their original locations Removal 1 Remove the fan For details refer to C12 Maintenance 15 Replacing the Fan 2 Remove the bolts on the he...

Page 477: ...l the liquid gasket becomes solid and the gasket is fixed 3 Install the connecter plate to the Manipulator Hexagon socket head cap bolts 11 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the gasket and cables caught between the cover and the Manipulator body Replace the gasket if there are flaws or deteriorations For cleanroom model install the gasket between the heat sink and the conne...

Page 478: ...them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing the connector plate Be sure to place the cables back to their original locations Removal Rem...

Page 479: ...n installing the connector sub plate be careful not to get the cables caught in it or bend them forcibly to push into the cover Unnecessary strain on cables may result in damage to the cables disconnection and or contact failure These are extremely hazardous and may result in electric shock and or improper function of the robot system When routing the cables check the cable locations at removing t...

Page 480: ... result in electric shock and or malfunction of the robot system Be careful not to get any foreign substances in the Manipulator connectors and pins during maintenance Turning ON the power to the robot system when any foreign substances exist in them is extremely hazardous and may result in electric shock and or malfunction of the robot system Be sure to connect the cables properly Do not allow un...

Page 481: ... protective gear including a mask protective goggles and oil resistant gloves If alcohol or adhesive gets on your skin wash the area thoroughly with soap and water If alcohol or adhesive gets into your eyes or mouth flush your eyes or wash out your mouth with clean water thoroughly and then see a doctor immediately Wear protective gear including a mask protective goggles and oil resistant gloves d...

Page 482: ...r cross recessed head screws Torque rench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use this jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful ...

Page 483: ...intenance cover Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base maintenance cover Connector plate M C cable backward 4 Remove the two air tubes inside the base 5 Remove the two D sub connectors 6 Disconnect the cables from the base and disconnect the following connectors Connectors X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 Hold the clip to remove 7 Disco...

Page 484: ... 6 10 Remove the brake power supply Cross recessed head screws with washer 2 M3 6 11 Disconnect the following cables through the opening of the base D sub cable Ground wire RJ45 connector F sensor connector 12 Remove the Joint 1 motor unit For details refer to C12 Maintenance 5 1 1 Joint 1 Replacing the Motor M C Cable Backward Removal steps 6 and 7 13 Remove the plate for preventing cable interfe...

Page 485: ...et Hexagon socket head cap bolts 2 M3 6 15 Remove the Joint 1 timing belt 16 Remove the battery from the battery box 17 Disconnect the battery connector Hold the board by hand and pull up the battery cable to disconnect the connector 18 Remove the plate to which the battery board is fixed Hexagon socket head cap bolts 2 M4 10 NOTE ...

Page 486: ...val steps 1 to 3 and 5 to 9 22 Cut off the wire tie that binds the cables inside the Arm 1 and remove the connector connected to the control board 1 Connector GS01 23 Remove the Joint 1 cable fixing plate Arm 1 side Hexagon socket head cap bolts 2 M4 10 24 Disconnect the internal cables from the base side to the Arm 1 side Protect the connectors with masking tapes To protect the connector s clips ...

Page 487: ...emove the Arm 1 cable brackets C2 and S2 one each and cable protection tube Hexagon socket head cap bolts 2 M3 6 C2 2 M4 10 S2 27 Remove the Arm 2 cable bracket C2 and cable protection tube Hexagon socket head cap bolts 2 M3 6 28 Remove the Arm 2 cable fixing plate Hexagon socket head cap bolts 2 M4 10 29 Cut off the wire tie that binds the cable protection coils inside the Arm 2 ...

Page 488: ...ckets C3A and S3 Hexagon socket head cap bolts 2 M4 8 C3A 2 M4 8 S3 33 Remove the two air tubes inside the Arm 3 Remove the air tube fittings from the air tubes The air tube fittings will be used again Be careful not to lose them 34 Remove the two ground wire terminals from the Arm 3 Cross recessed head screws with washer 2 M4 8 35 Disconnect the connectors inside the Arm 3 Connectors X141 X151 X1...

Page 489: ...gon socket head cap bolts 2 M4 10 38 Remove the Arm 3 cable bracket C3B Hexagon socket head cap bolts 2 M3 6 39 Remove the Arm 3 cable fixing plate 1 Hexagon socket head cap bolts 2 M4 10 40 Cut off the wire tie that binds the cable protection coils inside theArm 3 41 Disconnect the cables from the Arm 3 side to the Arm 2 side ...

Page 490: ...ork first cover the connectors with a plastic bag Then pass the cable unit through the arm 43 Remove the Arm 3 cable fixing plate 2 Hexagon socket head cap bolts 2 M4 10 44 Remove theArm 3 cable bracket C4 and the cable protection sheet Hexagon socket head cap bolts 2 M3 6 Remove the cable bracket C4 and the cable protection sheet at the Arm 4 maintenance cover Hexagon socket head cap bolts 2 M3 6...

Page 491: ...es Hexagon socket head cap bolts 2 M4 10 48 Remove the ground wire terminals from the cable protection plate Cross recessed head screws with washer 4 M4 8 49 Remove the Joints 5 and 6 motor units For details refer to C12 Maintenance 9 1 Joint 5 Replacing the Motor Removal steps 4 to 8 and C12 Maintenance 10 1 Joint 6 Replacing the Motor Removal steps 4 to 7 The air tube fittings removed together w...

Page 492: ...move the following parts from the Arm 4 D sub attachment D sub connector D sub connector fixing plate 52 Remove the Arm 4 cable fixing plate Hexagon socket head cap bolts 2 M4 10 53 Remove the cable bracket C4 Hexagon socket head cap bolts 2 M3 6 54 Disconnect the following cables that have no relays from the Arm 4 side to the Arm 3 side Ethernet cable X052 X062 cable Ground wire green yellow ...

Page 493: ... 25 mm 120 mm F sensor connector housing 2 pieces Silicon sheet 3 sheets 25 mm 120 mm 2 Remove the Ethernet cable from the connector Protect the cable ends with masking tapes to prevent the clip from damage 3 Remove the locking screws and nuts of the D sub connector The screws and nuts will be used again for fixing the connector Be careful not to lose them 4 Disconnect the following connectors to ...

Page 494: ...s 190 mm from the connector end Air tube 210 mm from the end 130 mm 6 Pass the separated cable unit base side from theArm 2 to theArm 1 To protect the connectors and facilitate the work first cover the connectors with a plastic bag Then pass the cable unit through the arm Pass the following cables that have no relays through the arm to the Arm 3 side Ethernet cable X052 X062 cable Ground wire gree...

Page 495: ...the connectors through the braid tube as shown in the photo and fix the tube with the wire tie so that connectors are not to be pulled out Then pull the braid tube from the Arm 4 side while pushing the cables from the Arm 3 side to pass the cables through See the photo 8 Pass the separated cable unit Arm 4 side from theArm 4 to theArm 3 Silicone tube is provided Leave out the silicone tube on the ...

Page 496: ...2 M4 10 Tightening torque 4 0 0 2 N m 10 Use a cable bracket C4 to fix the cables Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 4 0 1 N m Place the silicone tube to the position where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube 11 Install the D sub connector to the D sub attachment of the Arm 4 D sub connector fixing plate is provided Hold the D sub con...

Page 497: ... the near side Lower photo Joint 6 motor side Place the other cables and the air tube clear on the front side Fix the cables by binding them with a wire tie INSULOC AB150 or equivalent inserted through the hole of the cable fixing plate so that the cables do not interfere with the Joint 6 motor pulley Pay attention so that no connector is installed incorrectly and no cable is caught between compon...

Page 498: ...4 10 Tightening torque 4 0 0 2 N m Be careful not to get the cables caught It may cause cable breakage 16 Fix the cables to the Arm 4 maintenance cover using a cable bracket C4 Wrap the cables with the attached silicone sheet Use a cable bracket to fix the wrapped silicone sheet Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 4 0 1 N m 17 Apply grease to the cables in the sleeve Grease Kr...

Page 499: ...0 1 N m 19 Install the Arm 3 cable fixing plate 2 to the Arm 3 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 20 Use the cable protection spring to bind cables at the Arm 3 cable fixing plate 1 Type of wire tie AB100 Number of wire ties 4 21 Install the Arm 3 cable fixing plate 1 to the Arm 3 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m When installing t...

Page 500: ... plate to the Arm 3 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 24 Connect the connector to the control board 2 Connector GS02 25 Connect the cable connectors inside the Arm 3 Connectors X141 X151 X161 BR041 BR051 X041 X71 X72 PS LED BT51 BT4 Hold the clip to remove 26 Install the two ground wire terminals to the Arm 3 Green yellow Left side Green Right side Cross recessed ...

Page 501: ...be to the position where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube temporarily Hexagon socket head cap bolts 2 M4 8 Rough guide of temporary fixing The cables can be pushed up even after fixing the cables 30 Push up the whole cables by 10 mm to the direction indicated with the arrow in the photo to allow for some space 31 Fix the cables to the Arm 2 by fixing th...

Page 502: ... wire ties 4 Be careful of the orientation of the Arm 2 cable fixing plate The side with two U shaped grooves should be placed down 35 Use cable brackets C2 to fix the cables to the Arm 2 cable fixing plate temporarily Place the silicone tube to the position where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube temporarily Hexagon socket head cap bolts 2 M3 6 Rough gu...

Page 503: ... brackets C2 to fix the cables to the Arm 2 temporarily Place the silicone tube to the position where it is fixed with a cable bracket Use a cable bracket to fix the silicone tube temporarily Hexagon socket head cap bolts 2 M3 6 Rough guide of temporary fixing The cables can be pushed up even after fixing the cables 40 Push up the whole cables by 10 mm to the direction indicated with the arrow in ...

Page 504: ... 130 mm from the connector 44 For the X021 X121 BR021 and CN3 cables place a mark at a position 160 mm from the connector respectively 45 Use cable brackets C1 to fix the cables to the Arm 1 cable fixing plate temporarily 2 positions Temporarily fix the silicone tube by aligning its end to the mark Hexagon socket head cap bolts 4 M3 6 Rough guide of temporary fixing The cables can be pushed up eve...

Page 505: ... BR021 and CN3 connectors should reach the end face of the Arm 1 when they are pulled out The cables should not be too long 47 Place a mark on the cables at the sleeve outlet on the base side 48 Fix the cable bracket C1 A on the near side so that the cable positions do not change Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 4 0 1 N m 49 Remove the Arm 1 cable fixing plate fixed tempora...

Page 506: ... the Arm 1 cable fixing plate to the Arm 1 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 52 Install the connector GS01 to the control board 1 53 Install the Joint 2 motor and connect the connector For details refer to C12 Maintenance 6 1 Joint 2 Replacing the Motor Installation steps 4 and 9 54 Fix the two ground wire terminals to the Arm 2 Green Right side Green yellow Left ...

Page 507: ... N m 57 Connect the battery connectors 58 Install the battery to the battery box 59 Pass the Joint 1 timing belt through the cable 60 Use cable brackets C1 to fix the cables to the base cable fixing plate Wrap the cables with the attached silicone sheet Use a cable bracket to fix the wrapped silicone sheet Hexagon socket head cap bolts 2 M3 6 Tightening torque 2 0 0 1 N m ...

Page 508: ... cable Ground wire RJ45 connector F sensor connector 64 Install the brake power supply to the plate The cables should be located in the direction as shown in the photo See the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 65 Install the ground wire terminals to the plate Cross recessed head screws with washer 9 M4 8 2 M3 6 Tightening torque 0 9 0 1N m M4 8 0 45...

Page 509: ... Left D sub connector for brake release with a wire marker SW1 B release Right D sub connector for user wiring without a wire marker With round terminal D sub 70 Install the two air tubes according to the marks on the connector plate Air1 Clear Air2 Blue Install the air tube with the correct color 71 Install the covers and plate indicated below Arm 4 side covers both sides Arm 4 maintenance cover ...

Page 510: ...r cross recessed head screws Torque rench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use this jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful ...

Page 511: ... and or malfunction of the robot system 4 Remove the covers and plate indicated below Arm 4 side covers both sides Arm 4 maintenance cover Arm 3 cover Arm 3 maintenance cover Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base cover M C cable downward Base maintenance cover Connector plate M C cable downward For details refer to C12 Maintenance 3 Covers 5 Remove the t...

Page 512: ...t 9 Remove the ground wire terminals Cross recessed head screws with washer 9 M4 8 2 M3 6 10 Remove the brake power supply Cross recessed head screws with washer 2 M3 6 11 The subsequent steps are the same as those for the M C cable backward For details refer to C12 Maintenance 4 1 1 Replacing the Cable Unit M C Cable Backward Removal steps 13 to 54 ...

Page 513: ...upply to the plate The cables should be located in the direction as shown in the photo See the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1N m 4 Install the ground wire terminals to the plate Cross recessed head screws with washer 9 M4 8 2 M3 6 Tightening torque 0 9 0 1N m M4 8 0 45 0 1 N m M3 6 5 Install the following connectors according to the marks on the conn...

Page 514: ...all the following covers and plate Arm 4 side covers both sides Arm 4 maintenance cover Arm 3 cover Arm 3 maintenance cover Arm 2 side covers both sides Arm 1 side covers both sides Arm 1 center cover Base cover M C cable downward Base maintenance cover Connector plate M C cable downward For details refer to C12 Maintenance 3 Covers 10 Perform calibration For details refer to C12 Maintenance 16 Ca...

Page 515: ...C12 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 495 4 2 Connector Pin Assignment 4 2 1 Signal Cable ...

Page 516: ...C12 Maintenance 4 Cable Unit 496 C Series Maintenance Manual Rev 2 ...

Page 517: ...C12 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 497 ...

Page 518: ...C12 Maintenance 4 Cable Unit 498 C Series Maintenance Manual Rev 2 4 2 2 Power Cable ...

Page 519: ...C12 Maintenance 4 Cable Unit C Series Maintenance Manual Rev 2 499 ...

Page 520: ...Cable 4 2 4 Color of Cables The following table shows the codes and cable colors indicated in the pin assignments 4 2 1 Signal Cable 4 2 2 Power Cable 4 2 3 User Cable Code Cable color B Black W White R Red G Green Y Yellow BR Brown L Blue V Violet A Azure O Orange GL Gray P Pink ...

Page 521: ...le connecting the AC power cable to a factory power source is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement procedures The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and encoder Disassembled motor and encoder wi...

Page 522: ...ead cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Nippers 1 For cutting the wire tie Pliers 1 For tightening the wire tie Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs in relevant maintenance...

Page 523: ...t disconnect the connector BT1 If the connector is disconnected perform calibration Remove the heat radiation block 1 Remove the wire tie and the bolts to remove the heat radiation block Hexagon socket head cap bolts M5 15 Wire tie AB350 2 Remove the heat radiation sheet between the heat radiation block and the motor The heat radiation block the heat radiation sheet and the bolts will be used agai...

Page 524: ...t 1 504 C Series Maintenance Manual Rev 2 7 Remove the Joint 1 motor unit from the base Hexagon socket head cap bolts 3 M6 30 with a plain washer Be careful not to tear and lose the heat radiation sheet attached to the motor ...

Page 525: ...he Manipulator is operated without the heat radiation sheet the motor generates heat and the error may occur If the heat radiation sheet has the protection film remove the film Pass the pulley 1 of the Joint 1 motor unit to the Joint 1 timing belt and loosely secure it to the base Hexagon socket head cap bolts 3 M6 30 with a plain washer Make sure that the gear grooves of the timing belt are fit i...

Page 526: ...low the lower limit Vibration abnormal noise or reduction in life of the parts may occur if the value exceeds the upper limit When you replace with a new belt belt extends and the belt tension may decrease in the initial stage Make sure to operate the robot two to three days and check the belt tension again When using the belt tension tensile jig maintenance part Fix the belt tension tensile jig f...

Page 527: ...ng the brake If the J1 brake positioning jig cannot be inserted all the way the motor and the brake core may be misaligned In such a case use the brake release unit option part to release the brake and then align the brake Correct Wrong 5 Install the brake power supply to the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross r...

Page 528: ...without the heat radiation sheet the motor generates heat and the error may occur If the heat radiation sheet has the protection film remove the film Image of the protection film 2 Fix the upper part of the heat radiation block to the Joint 1 motor plate with the bolts Hexagon socket head cap bolts M5 15 Tightening torque 4 0 0 2 N m 3 Fix the lower part of the heat radiation block to the motor wi...

Page 529: ...e tie to the direction as indicated with the arrow in the photo 3 4 Wrap the wire tie around the motor 3 5 Tighten the wire tie to hold the heat radiation sheet firmly Make sure that the heat radiation sheet sticks out of the heat radiation block Do not tighten the wire tie too much It may result in cable breakage NOTE ...

Page 530: ...ad screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig and J1 brake positioning jig are assembly jigs Use the jigs when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The bra...

Page 531: ...e to work on it so that at least one of them can support the arm while the others are removing the bolts Removing the bolts without supporting the arm may result in the arm falling bodily injury and or malfunction of the robot system 1 Remove the following parts Connector plate Connector Cable grounding plate Brake power supply For details refer to C12 Maintenance 5 1 3 Joint 1 Replacing the Timin...

Page 532: ...cable bracket C1 Hexagon socket head cap bolts 2 M3 6 7 Remove the Joint 1 timing belt 8 Remove the Joint 2 motor unit For details refer to C12 Maintenance 6 1 Joint 2 Replacing the Motor Removal steps 1 to 9 9 Remove the Joint 1 cable fixing plate Arm 1 side Hexagon socket head cap bolts 2 M4 10 10 Remove the connector connected to the control board 1 Connector GS01 ...

Page 533: ...2 Pull out the grease tube between the base and the Arm 1 on the Arm 1 side from the fitting 13 Remove the Arm 1 from the base Hexagon socket head cap bolts 15 M6 30 with a plain washer CAUTION By removing the bolts the Arm 1 2 3 4 5 and 6 end effector can be separated There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when remo...

Page 534: ... Arm 1 to the base Hexagon socket head cap bolts 15 M6 30 with a plain washer Tightening torque 18 0 0 9 N m CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when installing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts 3 Connect the grease tube f...

Page 535: ... socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 7 Install the Joint 2 motor unit For details refer to C12 Maintenance 6 1 Joint 2 Replacing the Motor Installation steps 4 to 9 8 Pass the cables and the air tube inside the Joint 1 timing belt 9 Mount the base cable bracket C1 Wrap the cables with the attached silicone sheet Use a cable bracket to fix the wrapped silicone sheet Hexagon ...

Page 536: ... to the upper part of the base D sub cable Ground wire RJ45 connector F sensor connector 13 Connect the ground wires Cross recessed head screws with washer 9 M4 8 2 M3 6 Tightening torque 0 9 0 1N m M4 8 0 45 0 1 N m M3 6 The ground terminals of the D sub cables have fixed installation positions Install them to the two screw holes Photo indicated by the arrows 14 Install the following parts Connec...

Page 537: ...et head cap bolt width across flats 5 mm 1 For M6 hexagon socket head cap bolt Box wrench width across flats 5 mm 1 For D Sub connector Long nose pliers 1 For removing the air tube Cross point screwdriver 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use thes...

Page 538: ... M C cable backward For details refer to C12 Maintenance 3 Covers 4 Remove two air tubes inside the base 5 Remove two D sub connectors 6 Disconnect the cables from the base and disconnect the connectors Connector X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 Hold the clip to remove 7 Disconnect the following connectors RJ45 connector Hold the clip to remove F sensor connector Open the clips ...

Page 539: ...crews with washer 2 M3 6 9 Remove the ground wire plate M C cable backward Hexagon socket head cap bolts 2 M4 10 10 Remove the following ground wire terminals D sub cable ground wire terminals 2 Ground wire green yellow terminal 1 indicated by an arrow Cross recessed head screws with washer 3 M4 8 Positions of the ground wire green yellow terminals may differ from the photo Check the positions of ...

Page 540: ...aintenance 5 1 1 Joint 1 Replacing the Motor M C Cable Backward Removal steps 6 to 7 13 Remove the Joint 1 cable fixing plate Hexagon socket head cap bolts 2 M3 6 Do not remove the base cable bracket C1 14 Remove the Joint 1 timing belt Installation Joint 1 Timing belt M C Cable Downward When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts 1 Pass ...

Page 541: ...cable Ground wire RJ45 connector F sensor connector 5 Install the terminals of the D sub cable ground wire and ground wire green yellow D sub cable ground wire terminals 2 indicated by arrows Ground wire green yellow terminal 1 Cross recessed head screws with washer 3 M4 8 Tightening torque 0 9 0 1 N m The installation positions of the D sub cable ground terminals are fixed Make sure to install th...

Page 542: ...nd 9 Connect the M C cable connectors Connector X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 10 Install the D sub connectors in accordance with the indications on the connector plates Left D sub for brake release with a wire marker SW1 B release Right D sub for user wiring no wire marker with a round terminal D sub 11 Install two air tubes in accordance with the indications on the connector...

Page 543: ...ssembly jigs Use these jigs in relevant maintenance steps The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Removal Joint 1 Electromagnetic brake M C Cable Backward 1 Remove the Joint 1 electromagnetic brake from...

Page 544: ...nt 1 brake to the brake plate Hexagon socket head cap bolts 3 M4 25 Tightening torque 4 0 0 2 N m Be careful of the assembly direction of the Joint 1 electromagnetic brake See the photo 2 Mount the Joint 1 brake plate to the Joint 1 motor unit For details refer to C12 Maintenance 5 1 1 Joint 1 Replacing the Motor M C Cable Backward Installation steps 4 to 8 If you disconnected the connector BT1 in...

Page 545: ... head cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Nippers 1 For cutting the wire tie Pliers 1 For tightening the wire tie Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs in relevant maintenan...

Page 546: ...downward For details refer to C12 Maintenance 3 Covers 4 Disconnect the cables from the base and disconnect the following connectors Connector X11 X010 BT1 BR011 Hold the clip to remove When only replacing the brake do not disconnect the connector BT1 If the connector is disconnected perform calibration Remove the heat radiation block 1 Remove the wire tie and the bolts to remove the heat radiatio...

Page 547: ... the Joint 1 brake plate from the Joint 1 motor unit Hexagon socket head cap bolts 3 M4 20 7 Remove the Joint 1 motor unit from the base Hexagon socket head cap bolts 3 M6 30 with a plain washer Be careful not to tear and lose the heat radiation sheet attached to the motor ...

Page 548: ...the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 3 Connect the following connectors Connector X11 X010 BT1 BR011 4 Install the following covers Connector plate M C cable downward Base cover M C cable downward Base maintenance cover For details refer to...

Page 549: ...ad screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig and J1 brake positioning jig are assembly jigs Use the jigs when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The bra...

Page 550: ... motor When removing the Arm 1 there must be two or more people to work on it so that at least one of them can support the arm while the others are removing the bolts Removing the bolts without supporting the arm may result in the arm falling bodily injury and or malfunction of the robot system 1 Remove the following parts Connector plate Connector Brake power supply For details refer to C12 Maint...

Page 551: ...tenance 5 1 2 Joint 1 Replacing the Reduction Gear Unit M C Cable Backward Installation steps 1 to 11 2 Install the ground terminals to the plate Cross recessed head screws with washer 9 M4 8 2 M3 6 3 Install the following parts Connector plate Connector Brake power supply For details refer to C12 Maintenance 5 2 3 Joint 1 Replacing the Timing Belt M C Cable Downward Installation steps 4 to 10 ...

Page 552: ...ats 5 mm 1 For M6 hexagon socket head cap bolt Box wrench width across flats 5 mm 1 For D Sub connector Long nose pliers 1 For removing the air tube Cross point screwdriver 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig and J1 brake positioning jig are assembly jigs Use these jigs in relevant maintenance s...

Page 553: ...alfunction of the robot system 3 Remove the following covers Base maintenance cover Base cover M C cable downward Connector plate M C cable downward For details refer to C12 Maintenance 3 Covers 4 Disconnect the cables from the base and disconnect the following connectors Connector X11 X12 X14 BR010 BR011 X010 X020 X040 LED GS01 BT1 Hold the clip to remove 5 Disconnect the following parts Air tube...

Page 554: ...2 7 Remove the ground wire plate M C cable downward Hexagon socket head cap bolts 2 M4 12 8 Remove the Joint 1 motor unit For details refer to C12 Maintenance 5 1 1 Joint 1 Replacing the Motor M C cable backward Removal steps 6 to 7 9 Remove the Joint 1 motor unit ...

Page 555: ... downward Hexagon socket head cap bolts 2 M4 12 Tightening torque 4 0 0 2 N m 4 Install the brake power supply to the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 5 Connect the following connectors in accordance with the indications on the connector pl...

Page 556: ...e marker with a round terminal D sub 8 Install two air tubes in accordance with the indications on the connector plates Air1 Semitransparent Air2 Blue Be careful not to install the air tube of wrong color 9 Install the following covers Connector plate M C cable downward Base cover M C cable downward Base maintenance cover For details refer to C12 Maintenance 3 Covers 10 Calibrate the Joint 1 For d...

Page 557: ...embly jig Use the jig in relevant maintenance steps The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Removal Joint 1 Electromagnetic brake M C Cable Downward 1 Remove the Joint 1 brake plate from the Joint 1 mot...

Page 558: ...nt 1 motor unit For details refer to C12 Maintenance 5 1 1 Joint 1 Replacing the Motor M C Cable Backward Installation step 4 3 Install the brake power supply to the plate Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo Cross recessed head screws with washer 2 M3 6 Tightening torque 0 45 0 1 N m 4 Connect the M C cable connectors Connec...

Page 559: ...y replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement It may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and c...

Page 560: ...auge 0 5 mm 2 For pulley position adjustment Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be c...

Page 561: ...ng the motor 1 Turn ON the Controller power 2 Release the Joint 2 brake Tilt the Arm 2 and push it against the Arm 1 The Arm 2 falls by its weight when the Joint 2 motor unit is removed Therefore release the brake and tilt the Arm 2 in advance Put a cloth between the Arm 1 and Arm 2 so that the arms do not touch each other EPSON RC Command brake off 2 CAUTION There is a possibility of hands and fi...

Page 562: ...supply Cross recessed head screws with captive washer 2 M3 6 7 Loosen the bolts securing the Joint 2 motor unit and remove the belt Hexagon socket head cap bolts 3 M5 25 with a plain washer WARNING Loosening the bolts while the Arm 2 is not bent may cause the belt come off and the Arm 2 falls down and it is extremely hazardous Be sure to do the Removal steps 1 and 2 before loosening the bolts ...

Page 563: ...and the motor shaft A Hexagon socket set screws 2 M5 12 Do not remove the pulley and drive boss screws B in the figure There is a brass bushing on one of the set screws If you removed the screws B be careful not to lose the brass bushing A Pulley and motor shaft screws D cut part of the motor shaft 2 B Pulley and drive boss screws Do not remove these screws C Bushing Pulley Drive boss A A C B B 10...

Page 564: ...C12 Maintenance 6 Joint 2 544 C Series Maintenance Manual Rev 2 11 Remove the motor plate from the Joint 2 motor Hexagon socket head cap bolts 4 M6 20 ...

Page 565: ...ctromagnetic brake to the Joint 2 motor unit Hexagon socket set screws 2 M6 6 with a brass bushing Tightening torque 6 0 0 4 N m Be careful of the assembly direction of the Joint 2 electromagnetic brake See the photo Fix the set screws while pressing the electromagnetic brake to the motor plate The brass bushing is not necessary for the screw for the flat surface D cut Set the bushing to the other...

Page 566: ... then fix them Hexagon socket set screws 2 M5 8 with a brass bushing Tightening torque 3 9 0 2 N m If the screw positions are incorrect or the bushing is not set it may cause damage on the side of the part and may result in the part being unable to be removed Set the set screws to the positions indicated in the right figure A Pulley and motor shaft screws D cut part of the motor shaft 2 B Pulley a...

Page 567: ...in life of the parts may occur if the value exceeds the upper limit When you replace with a new belt belt extends and the belt tension may decrease in the initial stage Make sure to operate the robot two to three days and check the belt tension again When using the belt tension tensile jig maintenance part Fix the belt tension tensile jig for J1 J2 and J3 with the screws 2 M4 35 and push the rubbe...

Page 568: ...et head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 0 5 mm 2 For adjusting the pulley position Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from...

Page 569: ...y connector For details refer to C12 Maintenance 11 2 Replacing the Battery Board Removal steps 3 to 6 3 Remove the battery box Countersunk screws 2 M3 8 4 Arm 1 side arm fixing bolts Hexagon socket head cap bolts 8 M6 25 with a plain washer 5 Remove the Joint 2 pulley 2 from the Joint 2 shaft Hexagon socket set screws 2 M5 10 There is a brass bushing on one of the set screws Be careful not to los...

Page 570: ...or can be separated There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when removing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts The Arms are connected by the internal cables When replacing the parts place the removed arm while not applying load on the ca...

Page 571: ...ual Rev 2 551 9 Remove the reduction gear unit from the Arm 2 Hexagon socket head cap bolts with plain washer 12 M6 45 Wipe grease on the part while removing it 10 Remove the O ring from the groove on the Arm 2 Wipe grease on the part while removing it ...

Page 572: ...e O ring to come out of the groove If the O ring is swollen damaged or deteriorated replace it with a new one 2 Install the reduction gear unit to the Arm 2 Hexagon socket head cap bolts 12 M6 45 Tightening torque 18 0 0 9 N m Installation face of the Arm 2 reduction gear unit has clearance holes Install the reduction gear unit to match the screws and the clearance holes 3 Grease the inner side of...

Page 573: ... washer to the Arm 1 Hexagon socket head cap bolts 8 M6 2 5 with a plain washer CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when installing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts 7 Fix the Arm 2 Hexagon socket head cap bolts 16 M6 35 w...

Page 574: ...essary for the screw for the flat surface Set the bushing to the other screw and then fix the screw If the screw positions are incorrect or the bushing is not set it may cause damage on the side of the brake and may result in the part being unable to be removed 10 Install the battery box Countersunk screws 2 M3 8 Tightening torque 0 45 0 1 N m 11 Install the following parts Battery Battery board B...

Page 575: ...ful when performing maintenance work When removing the Joint 2 motor tilt the Arm 2 and press it against the Arm 1 Reference C12 Maintenance 6 1 Joint 2 Replacing the Motor Removal step 2 When pressing the arm put a piece of cloth or a similar material between the arms to avoid contacting each other This protects the arm surfaces from scratching and paint peeling off Removal Joint 2 Timing belt 1 ...

Page 576: ...sting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work When removing the Joint 2 motor tilt the Arm 2 and press it against the Arm 1 Reference C12 Maintenance 6 1 Joint 2 Replacing the Motor Removal...

Page 577: ...rocedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be...

Page 578: ...on adjustment Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintena...

Page 579: ... brake Tilt the Arm 3 and push it against the Arm 2 The Arm 3 falls by its weight when the Joint 3 motor unit is removed Therefore release the brake and tilt the Arm 3 in advance EPSON RC Command brake off 3 CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when moving the Manipulator Put a cloth between the Arm 2 and A...

Page 580: ...r 2 M3 6 7 Loosen the bolts securing the Joint 3 motor unit and remove the belt Hexagon socket head cap bolts 3 M4 20 with a plain washer WARNING Loosening the bolts while the Arm 3 is not bent may cause the belt come off and the Arm 3 falls down and it is extremely hazardous Be sure to do the Removal steps 1 and 2 before loosening the bolts ...

Page 581: ...rom above A in the figure Pulley and motor shaft screws A Hexagon socket set screws 2 M5 12 Do not remove the pulley and drive boss screws B in the figure There is a brass bushing on one of the set screws If you removed the screws B be careful not to lose the brass bushing Pulley and drive boss screws B Hexagon socket set screws 2 M5 6 with a brass bushing A Pulley and motor shaft screws D cut par...

Page 582: ...ual Rev 2 10 Remove the Joint 3 electromagnetic brake Hexagon socket set screws 2 M5 10 with a brass bushing The screws have a brass bushing Be careful not to lose them 11 Remove the motor plate from the Joint 3 motor Hexagon socket head cap bolts 4 M5 15 ...

Page 583: ...omagnetic brake to the Joint 3 motor unit Hexagon socket set screws 2 M5 10 with a brass bushing Tightening torque 3 9 0 2 N m Be careful of the assembly direction of the Joint 3 electromagnetic brake See the photo Fix the set screws while pressing the electromagnetic brake to the motor plate The brass bushing is not necessary for the screw for the flat surface D cut Set the bushing to the other s...

Page 584: ...d then fix them Hexagon socket set screw 2 M5 6 with a brass bushing Tightening torque 3 9 0 2 N m Set the set screws to the positions indicated in the right figure A Pulley and motor shaft screws D cut part of the motor shaft 2 B Pulley and drive boss screws Do not remove these screws C Bushing Pulley Drive boss A A C B B If the screw positions are incorrect or the bushing is not set it may cause...

Page 585: ...e with a new belt belt may stretch and the belt tension will decrease in the initial stage of operation Make sure to operate the robot two to three days and check the belt tension again When using the belt tension tensile jig maintenance part Fix the belt tension tensile jig for J1 J2 J3 with the screws 2 M4 35 and push the rubber against the pulley Tension is applied by pushing the set screw M6 2...

Page 586: ...Torque wrench 1 For tightening torque control Feeler gauge 0 5 mm 2 For adjusting the pulley position Belt tension meter 1 Refer Unitta U 505 Cloth cushioning 1 For pressing arms The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is O...

Page 587: ...n socket head cap bolts 16 M4 25 with a plain washer Remove a wave washer on the Arm 1 side The wave washer will be used again Be careful not to lose it Wipe grease on the parts while removing them CAUTION By removing the bolts the Arm 2 side arm the Arm 3 4 5 and 6 end effector can be separated There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulato...

Page 588: ...asily set the pulley 2 as shown in the photo to the shaft and pull out the parts Wipe grease on the wave generator while removing it 6 Remove the reduction gear unit from the Arm 3 Hexagon socket head cap bolts 12 M4 30 Wipe grease on the reduction gear unit while removing it 7 Remove the O ring from the groove on the Arm 3 Wipe grease on the O ring while removing it ...

Page 589: ...he O ring to come out of the groove If the O ring is swollen damaged or deteriorated replace it with a new one 2 Install the reduction gear unit to the Arm 3 Hexagon socket head cap bolts 12 M4 30 Tightening torque 5 5 0 2 N m Installation face of the Arm 3 reduction gear unit has clearance holes Install the reduction gear unit to match the screws and the clearance holes 3 Grease the inner side of...

Page 590: ...ve washer to the Arm 2 Hexagon socket head cap bolts 6 M5 20 with a plain washer CAUTION There is a possibility of hands and fingers being caught and or damage or malfunction to the Manipulator Be very careful when installing the arm Have at least two workers so that one can support the Manipulator while the other worker is removing the bolts 7 Fix the Arm 3 Hexagon socket head cap bolts 16 M4 25 ...

Page 591: ...ue 3 9 0 2 N m Insert the pulley 2 so that one of the set screws is at the flat face of the shaft The brass bushing is not necessary for the screw for the flat surface Set the bushing to the other screw and then fix the screw If the screw positions are incorrect or the bushing is not set it may cause damage on the side of the brake and may result in the part being unable to be removed 10 Install t...

Page 592: ...hen performing maintenance work When removing the Joint 3 motor tilt the Arm 2 and press it against the Arm 2 Reference C12 Maintenance 7 1 Joint 3 Replacing the Motor Removal step 2 When pressing the arm put a piece of cloth or a similar material between the arms to avoid contacting each other This protects the arm surfaces from scratching and paint peeling off Removal Joint 3 Timing belt 1 Follo...

Page 593: ...s mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work When removing the Joint 3 motor tilt the Arm 2 and press it against the Arm 2 Reference C12 Maintenance 7 1 Joint 3 Replacing the Motor Removal step 2 When pressing the arm ...

Page 594: ...cement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and c...

Page 595: ...crews Feeler gauge 0 5 mm 2 For pulley position adjustment Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing ...

Page 596: ...to C12 Maintenance 3 Covers 3 Pull out the cables from the Arm 3 and disconnect the following connectors Connector X141 X041 BT4 BR041 Hold the clip to remove 4 Remove the brake power supply Cross recessed head screws with captive washer 2 M3 6 5 Remove the cable bracket Hexagon socket head cap bolts 2 M4 10 6 Remove the Joint 4 motor unit from the Arm 3 Hexagon socket head cap bolts 2 M4 15 with ...

Page 597: ...haft screws Hexagon socket set screws 2 M4 4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley Be careful not to lose it A Pulley and motor shaft screws B Pulley and drive boss screws C Bushing Pulley Drive boss A A C B 8 Remove the Joint 4 electromagnetic brake Hexagon socket set screws 3 M3 15 with a spacer Be careful not to lose the spacers 9 Remove the moto...

Page 598: ...l of the direction of the Joint 4 electromagnetic brake wire See the photo Electromagnetic brake wire 3 Mount the drive boss and the pulley 1 to the Joint 4 motor unit Fix the drive boss and the motor shaft There is an uneven part for the feeler gauge 0 5 mm on the boss Use the uneven part to leave 0 5 mm space If there is no space the parts may chafe while the motor is driving and it may result i...

Page 599: ...hat the teeth of the timing belt engage with these of the pulley As a rough guide of temporary fixing check that the motor unit can be moved by hand and it does not tilt when being pulled If the belt is too loose or too tight it will not have proper tension 6 Apply tension to the Joint 4 timing belt and fix the Joint 4 motor unit Joint 4 timing belt tension 15 to30 N Belt tension meter setting val...

Page 600: ...ad cap bolt M4 15 Tension is applied as the Joint 4 motor unit is stretched by tightening the screw 7 Install the plate for fixing the cables Hexagon socket head cap bolts 2 M4 10 8 Install the brake power supply to the plate Install the brake power supply so that the cable is facing downward Cross recessed head screw with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 9 Connect the followin...

Page 601: ...own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Removal Joint 4 Reduction gear unit 1 Turn OFF the Controller power 2 Remove the Arm 4 side cover and Arm 3 cover For details refer to C12 Maintenance 3 Covers 3 Remove the Joints 5 and 6 motors For details refer to the Removal steps in C12 ...

Page 602: ...asily insert a tool in a gap between the J4 flange and the Arm and remove the wave generator little by little Be careful not to damage the parts 9 Remove the Joint 4 reduction gear unit Hexagon socket head cap bolts 12 M3 28 10 Remove the J4 sleeve holder Then remove the J4 sleeve Hexagon socket head cap bolts 4 M3 6 The J4 sleeve is attached by gasket and may not be removed easily If the part can...

Page 603: ...ove the bolts of the bearing holder on the pulley Hexagon socket head cap bolts 3 M3 8 with a plain washer 12 Remove the pulley from the pulley spacer Hexagon socket set screws 2 M4 4 13 Remove the pulley spacer from the wave generator Hexagon socket head cap bolts 4 M3 8 ...

Page 604: ...n for the reduction gear unit Fit the J4 sleeve and install the J4 sleeve holder Hexagon socket head cap bolts 4 M3 6 Tightening torque 2 0 0 1 N m 2 Install the O ring to the O ring groove Install the Joint 4 reduction gear unit Hexagon socket head cap bolts 12 M3 28 Tightening torque 2 4 0 1 N m 3 Apply grease to the Joint 4 reduction gear unit Grease SK 1A Grease amount 20 g Apply 10g of grease...

Page 605: ...it to the O ring groove on the Joint 4 reduction gear unit Then install the J4 flange Hexagon socket head cap bolts 16 M3 20 Tightening torque 2 4 0 1 N m 6 Fix the pulley spacer to the wave generator of the Joint 4 reduction gear unit Hexagon socket head cap bolts 4 M3 8 Tightening torque 2 0 0 1 N m 7 Fix the J4 pulley to the J4 pulley spacer Hexagon socket set screws 2 M4 4 ...

Page 606: ...n socket head cap bolts 8 M5 30 Tightening torque 10 0 0 5 N m 10 Install the Joint 4 timing belt with a proper tension For details refer to C12 Maintenance 8 1 Joint 4 Replacing the Motor Installation steps 5 and 6 11 Pass the cables to the Arm 4 For details refer to Installation steps in C12 Maintenance 4 1 Cable Unit 12 Install the Joints 5 and 6 motors For details refer to Installation steps o...

Page 607: ...r passing the cables Braid tube 600 mm or longer 1 For passing the cables The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work Removal ...

Page 608: ...Arm 4 Hexagon socket head cap bolts 2 M4 10 7 Remove the green yellow ground wire and the green ground wire connected to X052 and X062 from the cable protection plate Cross recessed head screws with captive washer 2 M4 8 Positions of the ground wire terminals may differ from the photo Check which connector the terminal is connected to 8 Remove the following connectors Connector X052 X062 9 Remove ...

Page 609: ...et and the cable protection sheet Hexagon socket head cap bolts 2 M3 6 The Arm 4 cable bracket and cable protection sheet will be used again Be careful not to lose them 13 Pull the following parts from the Arm 4 to the Arm 3 LAN cable X052 and X062 cables Ground wire Air tube blue Protect the connectors with masking tapes To protect the connector s clips To avoid adherence of cable grease 14 Remov...

Page 610: ...be with the wire tie so that connectors are not to be pulled out Then pull the braid tube from the Arm 4 side while pushing the cables from the Arm 3 side to pass the cables through See the photo Pulling the cables forcibly may cause falling off or breakage of the connectors and disconnection of the cables If it is difficult to pass the cables pass the cables one by one in the following order X052...

Page 611: ...torque 4 0 0 2 N m 8 Install the brake power supply to the plate Install the brake power supply so that the cable is facing downward Cross recessed head screws with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 9 Connect the connectors inside the Arm 3 and the air tube transparent Connector X71 X72 X041 BR041 BR051 PS BT4 BT51 X141 X151 X161 10 Connect the ground wire terminals inside the A...

Page 612: ...acket to the Arm 4 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the cables caught It may cause cable breakage 13 Install the air tube blue to the fitting 14 Install the following covers Arm 3 cover Arm 3 maintenance cover Arm 4 side cover Arm 4 maintenance cover For details refer to C12 Maintenance 3 Covers NOTE ...

Page 613: ...h joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when performing maintenance work The electromagnetic brakes are common for Joints 4 5 and 6 The Joints 5 and 6 electromagnetic brakes have an identification label for preventing misconnection of the connectors The label is...

Page 614: ...edure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be us...

Page 615: ...control Spanner width across flats 8 mm 1 For air tube fitting Feeler gauge 0 5 mm 2 For adjusting the drive boss position Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The br...

Page 616: ...out the cables Hexagon socket head cap bolts 2 M4 10 4 Remove the brake power supply for the brake connected to the connector BR052 from the plate Cross recessed head screw with captive washer 2 M3 6 5 Disconnect the following connectors Connector X052 X152 BT52 BR052 6 Remove the air tube fitting located in the front of the Joint 5 motor unit 7 Loosen the screws fixing the Joint 5 motor unit and ...

Page 617: ...m the motor shaft of the Joint 5 motor unit Pulley 1 and drive boss screws Hexagon socket set screws 2 M4 4 with a brass bushing Drive boss and motor shaft screws Hexagon socket set screws 2 M4 4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley Be careful not to lose it A Pulley and motor shaft screws B Pulley and drive boss screws C Bushing Pulley Drive boss ...

Page 618: ...aintenance Manual Rev 2 10 Remove the Joint 5 electromagnetic brake Hexagon socket head cap bolts 3 M3 15 with a spacer Be careful not to lose the spacers 11 Remove the motor plate from the Joint 5 motor Hexagon socket head cap bolts 2 M4 10 ...

Page 619: ... the assembly direction of the Joint 5 electromagnetic brake wiring See the photo Electromagnetic brake wiring 3 Mount the drive boss and the pulley 1 to the Joint 5 motor unit Fix the drive boss and the motor shaft There is an uneven part for the feeler gauge 0 5 mm on the boss Use the uneven part to leave 0 5 mm space If there is no space the parts may chafe while the motor is driving and it may...

Page 620: ...d pulley 2 and fix it temporarily Make sure that the teeth of the timing belt engage with these of the pulley As a rough guide of temporary fixing check that the motor unit can be moved by hand and it does not tilt when being pulled If the belt is too loose or too tight it will not have proper tension 6 Apply tension to the Joint 5 timing belt and fix the Joint 5 motor unit Joint 5 Timing belt ten...

Page 621: ...ay cause air leakage due to screw breakage or gasket deformation Fitting is too loose It may cause loose screws and air leakage 8 Connect the following connectors Connectors X052 X152 BT52 BR052 9 Install the power supply of the brake to the plate Cross recessed head screw with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 10 Fix the cable protection bracket to the Arm 4 Hexagon socket head...

Page 622: ...ead cap bolts width across flats 3 mm 1 For M4 hexagon socket head cap bolts width across flats 4 mm 1 For M5 hexagon socket head cap bolts width across flats 5 mm 1 For M6 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Spanner width across flats 8 mm 1 For air fittings Feeler gauge 0 5 mm 2 For drive boss posi...

Page 623: ...nance 9 1 Joint 5 Replacing the Motor and C12 Maintenance 10 1 Joint 6 Replacing the Motor 4 Remove the cables passing through the Arm 4 as shown in the photo For details refer to the Removal steps in C12 Maintenance 4 1 Cable Unit 5 Remove the Joints 5 6 reduction gear unit Remove the bolts fixing the Arm 4 extension flange and remove the Joints 5 and 6 reduction gear unit from the Arm 4 extensio...

Page 624: ... cap bolts 12 M3 18 Tightening torque 2 4 0 1 N m 2 Install the Joint 5 and 6 reduction gear unit Install the Arm 4 extension flange to the Arm 4 extension part Hexagon socket head cap bolts 4 M6 20 Tightening torque 13 0 0 6 N m 3 Pass the cables to the Arm 4 Connect all the connectors inside the Arm 3 and bind them together Fix the cables inside the Arm 4 and connect the D sub to the Arm 4 For d...

Page 625: ... Qty Note Maintenance Parts Joint 5 timing belt 330 mm 1 1655932 Belt tensile jig 1 1674582 Tools Hexagonal wrench width across flats 3 mm 1 For M4 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tensi...

Page 626: ...ts Electromagnetic brake 1 2172928 Common for Joints 4 5 6 Belt tensile jig 1 1674582 Tools Hexagonal wrench width across flats 2 mm 1 For M4 hexagon socket set screws width across flats 2 5 mm 1 For M3 hexagon socket head cap bolts width across flats 3 mm 1 For M4 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws Torque wrench 1 For tightening torque control...

Page 627: ...ble blue orange BR053 is connected at the time of shipment Before attaching the label disconnect the connector One side of BR052 and BR053 have the same shape Identify the connectors by color Removal Joint 5 Electromagnetic brake 1 Remove the Joint 5 electromagnetic brake For details refer to C12 Maintenance 9 1 Joint 5 Replacing the Motor Removal steps 1 through 10 Installation Joint 5 Electromag...

Page 628: ...cedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION Be careful not to apply excessive shock to the motor shaft during replacement The shock may shorten the life of the motors and encoder and or damage them Never disassemble the motor and the encoder Disassembled motor and encoder will cause a positional gap and cannot be u...

Page 629: ...ssed head screws Feeler gauge 2 For adjusting the drive boss position Belt tension meter 1 Refer Unitta U 505 The belt tensile jig is an assembly jig Use the jig when adjusting belt tension The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF status The brake does not work during replacement Be careful when ...

Page 630: ...d cap bolts 2 M4 10 4 Remove the brake power supply for the brake connected to the connector BR062 from the protection plate Cross recessed head screw with captive washer 2 M3 6 5 Pull out the cables from the Arm 4 and disconnect the following connectors Connectors X062 X162 BT62 BR062 6 Loosen the bolts securing the Joint 6 motor unit and remove the belts Hexagon socket head cap bolts 2 M4 15 wit...

Page 631: ...crews Hexagon socket set bolts 2 M4 4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley Be careful not to lose it A Pulley and motor shaft screws B Pulley and drive boss screws C Bushing Pulley Drive boss A A C B 9 Remove the Joint 6 electromagnetic brake Hexagon socket set bolts 3 M3 15 with a spacer Be careful not to lose the spacers 10 Remove the motor plate...

Page 632: ... the assembly direction of the Joint 5 electromagnetic brake wiring See the photo Electromagnetic brake wiring 3 Mount the drive boss and the pulley 1 to the Joint 6 motor unit Fix the drive boss and the motor shaft There is an uneven part for the feeler gauge 0 5 mm on the boss Use the uneven part to leave 0 5 mm space If there is no space the parts may chafe while the motor is driving and it may...

Page 633: ...gage with these of the pulley As a rough guide of temporary fixing check that the motor unit can be moved by hand and it does not tilt when being pulled If the belt is too loose or too tight it will not have proper tension 6 Apply tension to the Joint 6 timing belt and fix the Joint 6 motor unit Joint 6 timing belt tension 15 to 30 N m Belt tension meter setting value Weight 2 5 g mm width m span ...

Page 634: ...owing connectors Connectors X062 X162 BT62 BR062 8 Install the brake power supply to the plate Cross recessed head screw with captive washer 2 M3 6 Tightening torque 0 45 0 1 N m 9 Fix the cable protection plate to the Arm 4 Hexagon socket head cap bolt 2 M4 10 Tightening torque 4 0 0 2 N m Be careful not to get the cables caught It may result in cable breakage 10 Install the Arm 4 side cover For ...

Page 635: ...gs Feeler gauge 0 5 mm 2 For drive boss position adjustment Belt tension meter 1 Refer Unitta U 505 For details of the replacement procedure refer to C12 Maintenance 9 2 Joint 5 Replacing the Reduction Gear Unit Replacing the Joints 5 6 Reduction Gear Unit The brake is mounted on each joint to prevent the arm from lowering due to its own weight while the Controller power is OFF or the motor is OFF...

Page 636: ...romagnetic Brake Name Qty Note Maintenance Parts Electromagnetic brake 1 2172928 Common to Joints 4 5 6 Belt tensile jig 1 1674582 Tools Hexagonal wrench width across flats 2 mm 1 For M4 hexagon socket set screws width across flats 2 5 mm 1 For M3 hexagon socket head cap bolts width across flats 3 mm 1 For M4 hexagon socket head cap bolts Cross point screwdriver 2 1 For cross recessed head screws ...

Page 637: ...ble blue orange BR063 is connected at the time of shipment Before attaching the label disconnect the connector One side of BR062 and BR063 have the same shape Identify the connectors by color Removal Joint 6 Electromagnetic brake 1 Remove the Joint 6 electromagnetic brake For details refer to C12 Maintenance 10 1 Joint 6 Replacing the Motor Removal steps 1 through 9 Installation Joint 6 Electromag...

Page 638: ...charge Disassembling Connecting batteries improperly Exposing to fire Forcing discharge Deforming by pressure Short circuit Polarity Positive Negative Heating 85 C or more Soldering the terminal of the lithium battery directly When disposing the battery consult with the professional disposal services or comply with the local regulation Make sure that the battery terminal is insulated even for a us...

Page 639: ...ition moves from the originals after replaced the battery Designated parts must be used for the lithium battery and battery board Be careful of the battery polarity to connect it correctly Battery board Battery Name Qty Note Maintenance Parts Battery unit Lithium battery 1 2172925 Two lithium batteries for replacement Battery board 1 2173216 Tools Cross point screwdriver 2 1 For cross recessed hea...

Page 640: ... battery box If you removed all the batteries before connecting the new ones the calibration data will be deleted and you will need to perform calibration Follow the steps below to remove the lithium batteries 4 Connect the two new batteries to the connectors of the battery board which are not connected to anything 5 Remove the old batteries Hold the board by hand and pull the battery cable upward...

Page 641: ... Maintenance 3 Covers 8 Turn ON the Controller power 9 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three points poses of the registered points 10 If the Manipulator is out of position calibrate all the joints and axes For details refer to C12 Maintenance 16 Calibration ...

Page 642: ...cessary to match these origins after replacing the parts The process of aligning the two origins is called Calibration Refer to C12 Maintenance 16 Calibration and perform the calibration after the parts replacement Removal Battery board 1 Turn OFF the Controller power 2 Remove the Arm 1 side cover For details refer to C12 Maintenance 3 Covers 3 Remove the battery from the battery box 4 Remove the ...

Page 643: ...ixed to the plate Cross recessed head screws 3 M3 6 Installation Battery board When tightening hexagon socket head cap bolts refer to the 2 4 Tightening Hexagon Socket Head Cap Bolts 1 Install the battery board to the plate Cross recessed head screws 3 M3 6 Tightening torque 0 45 0 1 N m 2 Connect the connectors to the battery board Connector CN3 CN6 NOTE ...

Page 644: ...ry board is installed to Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 4 Connect the battery connectors 5 Install the battery to the battery box 6 Install the Arm 1 side cover For details refer to C12 Maintenance 3 Covers 7 Perform the calibration For details refer to C12 Maintenance 16 Calibration ...

Page 645: ...ource Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of t...

Page 646: ...er to C12 Maintenance 3 Covers 3 Remove the connector connected to the control board 1 Connector GS01 4 Remove the control board 1 fixed to the Arm 1 Cross recessed head screws 3 M3 8 Be careful not to drop the screws inside the Manipulator while removing them 5 Remove the control board 1 protection plate Cross recessed head screws with captive washer M3 6 It is not necessary to remove the spacer ...

Page 647: ...cessed head screws 3 M3 8 Tightening torque 0 45 0 1 N m Be careful not to drop the screws inside the Manipulator while removing them 3 Connect the connector to the control board 1 Connector GS01 4 Install the Arm 1 center cover For details refer to C12 Maintenance 3 Covers 5 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three p...

Page 648: ...oard 2 1 Turn OFF the Controller power 2 Remove the Arm 3 cover For details refer to C12 Maintenance 3 Covers 3 Remove the connector connected to the control board 2 Connector GS02 4 Remove the plate fixed to the Arm 3 Hexagon socket head cap bolts 2 M4 10 5 Remove the control board 2 fixed to the plate Cross recessed head screws 4 M3 8 ...

Page 649: ... photo 2 Install the plate with the control board 2 to the Arm 3 Hexagon socket head cap bolts 2 M4 10 Tightening torque 4 0 0 2 N m 3 Connect the connector to the control board 2 Connector GS02 4 Install the Arm 3 cover For details refer to C12 Maintenance 3 Covers 5 Turn ON the Controller power 6 Check operation to see if the Manipulator s position and posture are out of position Move the Manipu...

Page 650: ... system To shut off power to the robot system disconnect the power plug from the power source Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedure with the ...

Page 651: ...LED is under the Arm 3 cover Connector LED 4 Remove the LED lamp from the Arm 3 Turn the plastic nut securing the LED lamp in the Arm 3 counterclockwise Plastic nut Installation LED lamp 1 Install the LED lamp to the Arm 3 Remove the plastic nut from the LED lamp Pass the lamp from the inside of the Arm 3 Turn the nut clockwise and secure the lamp to the Arm 3 2 Connect the following connector Con...

Page 652: ...ng any replacement procedure with the power ON is extremely hazardous and may result in electric shock and or malfunction of the robot system CAUTION When disconnecting the connectors during the replacement of the cable unit be sure to reconnect the connectors to their proper positions Improper connection of the connectors may result in improper function of the robot system For details on the conn...

Page 653: ... R12NZ900S7 15 m Straight 1 R12NZ900YC L shaped 1 R12NZ900YB 20 m Straight 1 R12NZ900S4 L shaped 1 R12NZ900S8 M C cable flexible 3 m Straight 1 R12NZ900S9 L shaped 1 R12NZ900SD 5 m Straight 1 R12NZ900SA L shaped 1 R12NZ900SE 10 m Straight 1 R12NZ900SB L shaped 1 R12NZ900SF 15 m Straight 1 R12NZ900YE L shaped 1 R12NZ900YD 20 m Straight 1 R12NZ900SC L shaped 1 R12NZ900SG Tools Hexagonal wrench width...

Page 654: ...r to C12 Maintenance 3 Covers Do not pull the connector plate forcibly Do not disconnect the M C cable from the connector plate 4 Remove the connectors Connectors X11 X12 X14 BR010 X010 X020 X040 LED GS01 Each connector is numbered and has a different shape Do not disconnect the battery connector BT1 Otherwise calibration will be required For details refer to C12 Maintenance 16 Calibration 5 Remov...

Page 655: ... C12 Maintenance 3 Covers 4 Connect the following connectors to the Controller Power cable connector Signal cable connector 5 Turn ON the Controller power 6 Check operation to see if the Manipulator s position and posture are out of position Move the Manipulator to two or three points poses of the registered points 7 If the battery connector BT1 was disconnected calibrate the Joint 1 For details r...

Page 656: ...of the robot system To shut off power to the robot system disconnect the power plug from the power source Be sure to connect the AC power cable to a power receptacle DO NOT connect it directly to a factory power source Before performing any replacement procedure turn OFF the Controller and related equipment and then disconnect the power plug from the power source Performing any replacement procedu...

Page 657: ...rews be sure to support the cover 2 Remove the fan cover 3 Remove the fan connectors 4 Remove the fan Installation Fan 1 Install the fan Be careful of the installation direction of the fan The arrow on the fan indicated with the arrow in the photo should point the heat sink and the cables should come to the upper side of the fan Heat sink side 2 Connect the fan connectors 3 Install the fan cover C...

Page 658: ...perator However operating the robot system while someone is inside the safeguarded area is extremely hazardous and may result in serious safety problems in case that the Manipulator moves unexpectedly In EPSON RC a coordinate point including the arm pose is defined as point and its data is called point data There are two methods to move the Manipulator during calibration Releasing the electromagne...

Page 659: ... result in Manipulator malfunction When the home positions of the Joints 1 and 4 are uncertain check torsion of the internal cables The home positions are where the Manipulator has the internal cables not twisted at the basic orientation described in C Series Manual C12 Manipulator 3 7 Checking the Basic orientation Torsion of the internal cables can be checked by removing the following covers Joi...

Page 660: ...eplace parts of one joint at a time whenever possible If you calibrate the origins for multiple joints simultaneously it will be more difficult to verify their origins and obtain the origin correct positions However joint 5 cannot be calibrated alone due to the structure of the Manipulator Make sure you calibrate joint 5 and 6 at the same time Calibration Flowchart 4 Calibration Yes Start 1 Basic ...

Page 661: ...eduction gear unit or belt is necessary for the calibration Verify the recorded pulse values of the basic pose obtained in the C Series Manual C12 Manipulator 3 7 Checking the Basic orientation 2 Part Replacement Replace parts as instructed in this manual Be careful not to injure yourself or damage parts during part replacement 3 Encoder Initialization Turn ON the Controller while all joints are i...

Page 662: ...r initialization refer to the procedure indicated above When the origin of the Joint 5 is calibrated the Joint 6 will be out of position Due to the structure of the Manipulator any offset in the position of the Joint 5 affects the Joint 6 Calibrate the origin of the Joint 6 together when calibrating the Joint 5 4 Calibration Calibration marks of each joint EPSON RC 4 1 Move the arm you want to cal...

Page 663: ...ON RC 4 4 Input the command in the Command window and execute it Execute one of the following commands to reset the encoder of the joint you want to calibrate from the menu Tool Command Window calpls 0 0 0 0 0 0 Manipulator does not move EPSON RC 4 5 Perform the calibration Execute one of the following commands to reset the encoder of the joint you want to calibrate from the menu Tool Command Wind...

Page 664: ...itions Select the Joint jog mode from Jog Teach to operate in the jog motion Enter the command below in the command window and execute it Execute the command below in the menu Tools Command Window calpls ppls P1 1 ppls P1 2 ppls P1 3 ppls P1 4 ppls P1 5 ppls P1 6 The Manipulator will not move Perform the calibration Input one of the following commands according to the joint being calibrated Joint ...

Page 665: ...th 20 mm 595 mm 5 1 3 5 2 3 Joint 2 1655927 Width 14 mm 540 mm 6 3 Joint 3 1655919 Width 10 mm 501 mm 7 3 Joint 4 1655931 Width 6 mm 243 mm 8 3 Joint 5 1655932 330 mm 9 3 Joint 6 1655933 339 mm 10 3 Belt tensile jig 1674582 Assembly tool 5 6 7 8 9 10 Battery unit 2172925 2 lithium batteries for replacement 11 1 Battery board 2173216 11 2 Grease 3 Joints 1 2 3 4 5 SK 1A For purchasing grease liquid...

Page 666: ... 4 AB150 1675754 1 bag 100 pcs white AB350 1697428 1 bag 50 pcs white 5 1 5 2 Felt sheet For Arm 3 1673981 Square 8 For Arm 3 maintenance cover 1673980 Square 8 For Joint 4 1673979 Round 8 For Joint 5 1673978 Round 9 Fan 2177465 15 Heat radiation sheet For heat radiation block 1694609 5 1 5 2 For Motor 1655043 Joint 1 2 common 5 1 5 2 6 2 Cover Arm 1 Center cover 1675435 Metal cover Common to Stan...

Page 667: ... shaped metal body with gear teeth around the outer circumference of the opening Circular spline A rigid ring shaped body with gear teeth on the inner circumference The circular spline has two more teeth than the flexspline does The splines are greased Be sure to keep the grease from being attaching to the clothes 3 Regarding purchase of grease liquid gasket and adhesive Due to the chemicals regul...

Page 668: ...900N7 For brake release unit Camera plate unit R12NZ9003F Common to C3 C4 C8 Old Code R12B031922 6 2 Tool adapter ISO flange R12NZ900LQ 6 3 Adjustable mechanical stop J1 R12NZ900LR 6 4 J2 R12NZ900LT J3 R12NZ900LU Fittings for customer use ø6 straight R12NZ900LV 6 5 ø6 elbow R12NZ900LW Standard user connector kit D sub R12NZ900LX Waterproof user connector kit D sub R12NZ900LY Ethernet R12NZ900LZ Re...

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