Epson C Series Maintenance Manual
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Epson C Series Maintenance Manual

6-axis robots
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6-Axis Robots
C series
Maintenance Manual
Rev.2
EM221R5039F

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Summary of Contents for Epson C Series

  • Page 1 6-Axis Robots C series Maintenance Manual Rev.2 EM221R5039F...
  • Page 3 6-Axis Robots C series Maintenance Manual Rev.2 Copyright © 2021-2022 SEIKO EPSON CORPORATION. All rights reserved. C Series Maintenance Manual Rev.2...
  • Page 4 Contact information is described in “SUPPLIERS” in the first pages of the following manual: Robot System Safety Manual Read this manual first DISPOSAL When disposing this product, dispose in accordance with the laws and regulations of each country. C Series Maintenance Manual Rev.2...
  • Page 5 Please separate used batteries from other waste streams to ensure that it can be recycled in an environmentally sound manner. For more details on available collection facilities please contact your local government office or the retailer where you purchased this product. C Series Maintenance Manual Rev.2...
  • Page 6 Controllers : RC700-A Software : EPSON RC+ 7.0 Ver.7.1.3 or later (C8XL) EPSON RC+ 7.0 Ver.7.1.4 or later (C8, C8L) EPSON RC+ 7.0 Ver.7.2.0 or later (Wall mounting) The C12 series Manipulators can be used with the following combinations of software.
  • Page 7 The manual is primarily intended for people who design robot systems or do programming. RC700 series Maintenance Manual (PDF) C series Maintenance Manual (PDF) (xx: Manipulator series name) This manual describes the details of maintenance etc. The manual is intended for people who perform maintenance.
  • Page 8 EPSON RC+ 7.0 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. C Series Maintenance Manual Rev.2...

  • Page 9: Table Of Contents

    4.2.2 Power Cable ................54 4.2.3 User Cable .................. 57 4.2.4 Color of Cables................57 5. Joint #1 5.1 Joint #1 - Replacing the Motor ..............59 Removal: Joint #1 Motor ................. 59 Installation: Joint #1 Motor ..............61 C Series Maintenance Manual Rev.2...
  • Page 10 Removal: Joint #3 Timing belt .............. 102 Installation: Joint #3 Timing belt ............102 8. Joint #4 8.1 Joint #4 - Replacing the Motor ............. 104 Removal: Joint #4 Motor ............... 104 Installation: Joint #4 Motor ..............106 viii C Series Maintenance Manual Rev.2...
  • Page 11 Removal: Joint #6 Timing belt .............. 145 Installation: Joint #6 Timing belt ............145 10.4 Joint #6 - Replacing the Electromagnetic Brake ........ 146 Removal: Joint #6 Electromagnetic brake ..........146 Installation: Joint #5 Electromagnetic brake ......... 146 C Series Maintenance Manual Rev.2...
  • Page 12 15. Replacing the M/C Cable Removal: M/C cable ................162 Installation: M/C cable ................162 16. Calibration 16.1. Overview ................... 163 16.2. Calibration Procedure ............... 165 17. C4 Maintenance Parts List 18. C4 Option Parts List C Series Maintenance Manual Rev.2...
  • Page 13 3.9.2 M/C Cable Downward ............... 212 3.10 Base Maintenance Cover ..............216 3.11 Connector Plate .................. 218 3.11.1 M/C Cable Backward .............. 218 3.11.2 M/C Cable Downward ............. 222 3.12 Connector Sub Plate ................223 C Series Maintenance Manual Rev.2...
  • Page 14 7.1 Joint #3 - Replacing the Motor ............. 328 7.2 Joint #3 - Replacing the Reduction Gear Unit ........336 7.3 Joint #3 - Replacing the Timing Belt ............ 342 7.4 Joint #3 - Replacing the Electromagnetic Brake ........343 C Series Maintenance Manual Rev.2...
  • Page 15 12.1 Replacing the Control Board 1 ............399 12.2 Replacing the Control Board 2 ............401 13. Replacing the LED Lamp 14. Replacing the M/C Cable 15. Replacing the Fan 16. Calibration 16.1 Overview ..................... 410 16.2 Calibration Procedure ................. 413 C Series Maintenance Manual Rev.2 xiii...
  • Page 16 3.9.1 M/C Cable Backward ..............452 3.9.2 M/C Cable Downward ............... 453 3.10 Base Maintenance Cover ..............455 3.11 Connector Plate .................. 456 3.11.1 M/C Cable Backward .............. 456 3.11.2 M/C Cable Downward ............. 458 C Series Maintenance Manual Rev.2...
  • Page 17 6.1 Joint #2 - Replacing the Motor .............. 540 6.2 Joint #2- Replacing the Reduction Gear Unit ........548 6.3 Joint #2 - Replacing the Timing Belt ............. 555 6.4 Joint #2 - Replacing the Electromagnetic Brake ........556 C Series Maintenance Manual Rev.2...
  • Page 18 11.2 Replacing the Battery Board .............. 622 12. Replacing the Control Board 12.1 Replacing the Control Board 1 ............626 12.2 Replacing the Control Board 2 ............628 13. Replacing the LED Lamp 14. Replacing the M/C Cable C Series Maintenance Manual Rev.2...
  • Page 19 Table of Contents 15. Replacing the Fan 16. Calibration 16.1 Overview ..................... 638 16.2 Calibration Procedure ................. 641 17. C12 Maintenance Parts List 18. C12 Option Parts list C Series Maintenance Manual Rev.2 xvii...
  • 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 23: Safety Maintenance

    ■ 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. C Series Maintenance Manual Rev.2...
  • Page 24 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. ■ When operating maintenance of manipulator, secure about 50 cm of empty space around the manipulator. C Series Maintenance Manual Rev.2...

  • Page 25: General Maintenance

    9 months (2250 h) √ √ 10 months (2500 h) √ 11 months (2750 h) √ 12 months (3000 h) √ √ √ √ 13 months (3250 h) √ √ 20000 h h = hour C Series Maintenance Manual Rev.2...

  • Page 26: Inspection Point

    Check the break operation Joint #1 to 6 break √ √ √ √ √ Check whether unusual Whole √ √ √ √ √ sound or vibration occurs. C Series Maintenance Manual Rev.2...
  • Page 27 If the arm falls when in MOTOR OFF and the brake is not released, contact the supplier. Check that there is no unusual sound or vibration when operating. Check whether unusual sound or vibration occurs. If there is something wrong, contact the supplier. C Series Maintenance Manual Rev.2...

  • Page 28: Overhaul (Parts Replacement)

    Manipulator. NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the parts subject to maintenance (motors, reduction gear units, and timing belts) can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
  • Page 29 The Manipulator operation hours can be checked in [Controller Status Viewer] dialog box- [Motor On Hours]. (1) Select EPSON RC+ menu-[Tools]-[Controller] to open the [Controller Tools] dialog box. (2) Click the <View Controller Status> button to open the [Browse For Folder] dialog box.

  • Page 30: Greasing

    As a rough indication, perform greasing at the same timing as overhaul. 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. C Series Maintenance Manual Rev.2...
  • Page 31 (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 way seated. (6) Pull out the screw inserted in the step (2). M4×15 Plug (4) Grease inlet C Series Maintenance Manual Rev.2...

  • Page 32: Tightening Hexagon Socket Head Bolts

    Bolt hole three and fasten the bolts securely with a hexagonal wrench. Then, use a torque wrench to fasten the bolts with tightening torques shown in the table above. C Series Maintenance Manual Rev.2...

  • Page 33: Layout Of Maintenance Parts

    Electromagnetic brake Joint #6 Timing belt Joint #6 Electromagnetic brake Control Board 2 Joint #5 Motor Joint #4 Motor Joint #4 Reduction gear unit Joint #4 Timing belt Joint #4 Electromagnetic brake Joint #2 Motor C Series Maintenance Manual Rev.2...

  • Page 34: Covers

    Arm #4 side cover Arm #4 side cover Arm #2 side cover Arm #3 Arm #1 top cover bottom cover Connector plate Arm #1 side cover Arm #1 side cover Base bottom cover Connector sub plate C Series Maintenance Manual Rev.2...

  • Page 35: Arm #1 Top Cover

    4-M3×8 (Cross recessed truss 4-M3×8 head small screws) (Cross recessed truss Tightening torque: 0.45±0.1 N·m head small screws) Tightening torque: 0.45±0.1 N·m Arm#1 side cover C Series Maintenance Manual Rev.2...

  • Page 36: Arm #2 Side Cover

    When routing the cables, check the cable locations at removing the cover. Be sure to place the cables back to their original locations. 4-M3×8 (Cross recessed truss head small screws) Tightening torque: 0.45±0.1 N·m Arm#3 head cover C Series Maintenance Manual Rev.2...

  • Page 37: Arm #3 Bottom Cover

    Be sure to place the cables back to their original locations. 6-M3×8 (Cross recessed truss head small screws) Tightening torque: 0.45±0.1 N·m 6-M3×8 (Cross recessed truss head small screws) Tightening torque: Arm #4 side cover 0.45±0.1 N·m C Series Maintenance Manual Rev.2...

  • Page 38: Base Bottom Cover

    When routing the cables, check the cable locations at removing the connector plate. Be sure to place the cables back to their original locations. Connector plate 4-M4×8 (Hexagon socket head cap bolts) Tightening torque: 4.0±0.2 N·m C Series Maintenance Manual Rev.2...

  • Page 39: Connector Sub Plate

    When routing the cables, check the cable locations at removing the user plate. Be sure to place the cables back to their original locations. User plate 2-M3×6 (Hexagon socket head cap bolts) Tightening torque: 2.0±0.1 N·m C Series Maintenance Manual Rev.2...

  • Page 40: Cable Unit

    Improper connection of the connectors may result in improper function of the robot system. CAUTION For details on the connections, refer to the C4 Maintenance 4.2 Connector Pin Assignments. C Series Maintenance Manual Rev.2...
  • Page 41 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. C Series Maintenance Manual Rev.2...

  • Page 42: Removal: Cable Unit

    Connectors: X010, X020, X030, X040, X050, X060, LED, BR010, BR011, BR020, BR030, BR040, BR050, BR060, BT1, X11, X12, X13, X14, X15, X16, XGND, GS01,GS02 Remove the connector connected to the control board 1. Connector: GS01 C Series Maintenance Manual Rev.2...
  • Page 43 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 battery unit will be used again. Be careful not to lose it. C Series Maintenance Manual Rev.2...
  • Page 44 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 C Series Maintenance Manual Rev.2...
  • Page 45 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: 1-M3×8 19. Cut off wire ties of the Arm #3 cable fixing plate. Cable band Coil plate fixing band C Series Maintenance Manual Rev.2...
  • Page 46 Pull out the cables in the order of connector size, from smallest to largest. 22. Pull out the Arm #3 cable unit from the Arm #2. (See an arrow in the photo for pulling direction.) C Series Maintenance Manual Rev.2...
  • Page 47 Hexagon socket head cap bolts: 3-M4×15 (with a plain washer) Arm #3, #4, #5, and #6 lean when the motor is removed. Remove the motor after pushing the Arm to the stopper. Connector D will be used again. Do not lose it. C Series Maintenance Manual Rev.2...
  • Page 48 (See an arrow in the photo for pulling direction.) 35. Remove the Arm #2 cable fixing plate from the cables. The Arm #2 cable fixing plate will be used again. Be careful not to lose it. C Series Maintenance Manual Rev.2...

  • Page 49: Installation: Cable Unit

    : ø17.5 (Length: 280 mm) : 4 g ø25 (Length: 130 mm) : 5 g × 2 ø25 (Length: 130 mm) : 5 g × 2 ø29 (Length: 130 mm) : 5 g ø29 (Length: 130 mm) : 5 g C Series Maintenance Manual Rev.2...
  • Page 50 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 fixing plate with a wire tie. Wire tie: AB100 × 1 Number of turns of spring to fix: 3 turns C Series Maintenance Manual Rev.2...
  • Page 51 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. C Series Maintenance Manual Rev.2...
  • Page 52 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 NOTE  as shown in the photo on the right. C Series Maintenance Manual Rev.2...
  • Page 53 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 Pass the air tubes through the space on the upper side of the spring. C Series Maintenance Manual Rev.2...
  • Page 54 Wire tie: AB150 Mark tube: 46 mm Precautions for cable unit fixation to the plate: Pass the mark tube and the wire tie through the hole of the plate NOTE  as shown in the right photo. C Series Maintenance Manual Rev.2...
  • Page 55 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 C Series Maintenance Manual Rev.2...
  • Page 56 From the Arm #3 cable fixing plate To the ground terminal: 110 mm 100 mm Length of the control board 2 cable passed through the Arm #3: From the Arm #3 to the control board 2 connector: 100 mm Connector: GS02 C Series Maintenance Manual Rev.2...
  • Page 57 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. C Series Maintenance Manual Rev.2...
  • Page 58 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) C Series Maintenance Manual Rev.2...
  • Page 59 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. C Series Maintenance Manual Rev.2...
  • Page 60 37. Fix the cable protection spring (ø25 Length: 130 mm) to the Arm Wire tie: AB100 (2 ties) 38. Temporarily fix the cables to the cable binder. Wire tie: AB150 Mark tube: 21 mm (2 tubes) Mark tube C Series Maintenance Manual Rev.2...
  • Page 61 Hexagon socket head cap bolts: 2-M4×8 Circle (right): X031 ground terminal, X131 ground terminal Circle (left): Ground wire terminal 43. Fix the cable protection spring (ø 25 Length: 130 mm) to the Arm Wire tie: AB100 (2 ties) C Series Maintenance Manual Rev.2...
  • Page 62 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 in the photo on the right. C Series Maintenance Manual Rev.2...
  • Page 63 51. Connect the Joint #2 motor connectors and put them in the Arm #2. Connector: X021, X121, BR021, BT2 52. Fix the ground wires to the Arm #2. Hexagon socket head cap bolts: 2-M4×8 Circle (right): X021 ground terminal, X121 ground terminal Circle (left): ground wire terminal C Series Maintenance Manual Rev.2...
  • Page 64 Tightening torque: 0.45 ± 0.1 N·m Connector: GS01 58. Bind the cable protection spring (ø29, 130 mm) to the base cable fixing plate. Wire tie: AB100 Number of turns of spring to fix: 3 turns C Series Maintenance Manual Rev.2...
  • Page 65 5 mm from the base cable plate. 5 mm 61. Pull the cable out and adjust the plate position. Plate position: 15 mm Fix the cable temporarily fixed by the wire tie. 15 mm C Series Maintenance Manual Rev.2...
  • Page 66 For details, refer to C4 Maintenance: 10.1 Joint #6 – Replacing the Motor, Installation step 6. 70. Apply tension to the Joint #3 motor unit and fix it. For details, refer to C4 Maintenance: 7.1 Joint #3 – Replacing the Motor, Installation step 6. C Series Maintenance Manual Rev.2...
  • Page 67 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. C Series Maintenance Manual Rev.2...

  • Page 68: Connector Pin Assignments

    C4 Maintenance 4. Cable Unit 4.2 Connector Pin Assignments 4.2.1 Signal Cable C Series Maintenance Manual Rev.2...
  • Page 69 C4 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...
  • Page 70 C4 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...
  • Page 71 C4 Maintenance 4. Cable Unit * For specifications without connector X061, BT61, BR061, X161, X72. C Series Maintenance Manual Rev.2...
  • Page 72 C4 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...
  • Page 73 C4 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...

  • Page 74: Power Cable

    C4 Maintenance 4. Cable Unit 4.2.2 Power Cable C Series Maintenance Manual Rev.2...
  • Page 75 C4 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...
  • Page 76 C4 Maintenance 4. Cable Unit * For specifications without connector X061, BT61, BR061, X161, X72. C Series Maintenance Manual Rev.2...

  • Page 77: User Cable

    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 Black White Green Yellow Brown Blue Violet Azure Orange Gray Pink C Series Maintenance Manual Rev.2...

  • Page 78: Joint #1

    The process of aligning the two origins is called “Calibration”. Refer to C4 Maintenance 16. Calibration and follow the steps to perform the calibration. Joint #1 motor Joint #1 reduction gear unit Joint #1 timing belt Joint #1 electromagnetic brake C Series Maintenance Manual Rev.2...

  • Page 79: Joint #1 - Replacing The Motor

    Hexagon socket head cap bolts: 3-M4×20 (with a plain washer) To remove the screw fixed to the rear of the motor unit (B), put a hexagonal wrench through the hole (A) after removing the cap. C Series Maintenance Manual Rev.2...
  • Page 80 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 C Series Maintenance Manual Rev.2...

  • Page 81: Installation: Joint #1 Motor

    Leave 0.5 mm between the electromagnetic brake and the pulley. Refer to the photo for layout of the set screws. Hexagon socket head set screws: 2-M5×10 (with a brass bushing) Tightening torque: 3.9 N·m (40 kgf·cm) t = 0.5 C Series Maintenance Manual Rev.2...
  • Page 82 7. Connect the following connectors. Connectors: X11, X010, BT1, BR011 8. Mount the connector plate. For details, refer to C4 Maintenance: 3. Covers. 9. Calibrate the Joint #1. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 83: Joint #1 - Replacing The Reduction Gear Unit

    For M4 hexagon socket headcap bolts wrench width across flats: 5 mm For M6 hexagon socket headcap bolts Cross-point screwdriver For covers Tools Torque Wrench Spatula For greasing Force gauge For belt tension adjustment For wiping grease Wiping cloth C Series Maintenance Manual Rev.2...

  • Page 84: Removal: Joint #1 Reduction Gear Unit

    Joint #1 timing belt. Hexagon socket head cap bolt: 3-M4×20 5. Remove the pulley 2. Hexagon socket head set screw: 2-M5×10 (with a brass bushing) 6. Remove the flange. Hexagon socket head cap bolt: 4-M4×15 C Series Maintenance Manual Rev.2...
  • Page 85 At this point, remove the bearing first. 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. Wipe grease from the parts while removing them. C Series Maintenance Manual Rev.2...
  • Page 86 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 material if it is attached to the base. C Series Maintenance Manual Rev.2...

  • Page 87: Installation: Joint #1 Reduction Gear Unit

    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: enough to fill in the grooves C Series Maintenance Manual Rev.2...
  • Page 88 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. Grease: SK-1A Grease volume: 40 g C Series Maintenance Manual Rev.2...
  • Page 89 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 the grease may leak.) O-ring O-ring groove O-ring Flange C Series Maintenance Manual Rev.2...
  • Page 90 For details, refer to C4 Maintenance: 5.1 Joint #1 motor, Installation step (6). 17. Mount the connector plate and the base bottom cover. For details, refer to C4 Maintenance: 3. Covers. 18. Calibrate the Joint #1. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 91: Joint #1 - Replacing The Timing Belt

    1. Place the Joint #1 timing belt around the Joint #1 pulley in the back in the photo. 2. Mount the Joint #1 motor unit. For details, refer to C4 Maintenance: 5.1 Joint #1 motor, Installation step (5) to (9). C Series Maintenance Manual Rev.2...

  • Page 92: Joint #1 - Replacing The Electromagnetic Brake

    1. Install the following connector to the connector of the electromagnetic brake. Connector: D (for noise dissipative diode) 2. Mount the Joint #1 motor unit. For details, refer to C4 Maintenance: 5.1 Joint #1 motor, Installation step (2) to (9). C Series Maintenance Manual Rev.2...

  • Page 93: Joint #2

    The process of aligning the two origins is called “Calibration”. Refer to C4 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #2 Timing belt Joint #2 Reduction gear Joint #2 unit Electromagnetic brake Joint #2 Motor C Series Maintenance Manual Rev.2...

  • Page 94: Joint #2 - Replacing The Motor

    To replace the Joint #2 motor, tilt the Arm #2 and press it toward the Arm #1. (See the step (3) When pressing the arm, put a cloth or a similar material between the arms to avoid each arm from contacting. This also protects the arm surfaces and coatings. C Series Maintenance Manual Rev.2...

  • Page 95: Removal: Joint #2 Motor

    If the bolts are removed with the Arm #2 is not tilted, the belt will come off and the Arm #2 will fall. Be sure to tilt the Arm. Hexagon socket head cap bolt: 3-M4×18 (with a plain washer) C Series Maintenance Manual Rev.2...
  • Page 96 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 C Series Maintenance Manual Rev.2...

  • Page 97: Installation: Joint #2 Motor

    Tightening torque: 3.9 N·m (40 kgf·cm) Fix the parts so that the end of the motor shaft and the surface of t = 0.5 mm the pulley become flat. See the photo for positions of the set screws. C Series Maintenance Manual Rev.2...
  • Page 98 Connectors: X121, X021, X62, BR021 8. Mount the Arm #1 cover and the Arm #1 side cover. For details, refer to C4 Maintenance: 3. Covers. 9. Perform the calibration. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 99: Joint #2- Replacing The Reduction Gear Unit

    For M5 hexagon socket set screw wrench width across flats: 3 mm For M4 hexagon socket head cap bolt Cross-point screwdriver For covers Tools Torque wrench Spatula For applying grease Force gauge For belt tension Wiping cloth For wiping grease C Series Maintenance Manual Rev.2...

  • Page 100: Removal: Joint #2 Reduction Gear Unit

    Removing the bolts without supporting the arm may result in the arm falling, bodily CAUTION injury, and/or malfunction of the robot system. C Series Maintenance Manual Rev.2...
  • Page 101 2 as shown in the photo to the shaft and pull out the parts. Remove the wave washer on the Arm #2 hole. The wave washer will be used again. Be careful not to lose it. Wipe grease on the parts while removing them. C Series Maintenance Manual Rev.2...
  • Page 102 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 attached to the Arm #1, and #2, etc. C Series Maintenance Manual Rev.2...

  • Page 103: Installation: Joint #2 Reduction Gear Unit

    After setting it, make sure to confirm that the surfaces of the circular spline and flexspline are matched. 4. Match the screw holes on the cross roller bearing's inner ring and the drilled holes on the circular spline. C Series Maintenance Manual Rev.2...
  • Page 104 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 groove on the installation face of the Arm #2 reduction gear unit. O-ring C Series Maintenance Manual Rev.2...
  • Page 105 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 C Series Maintenance Manual Rev.2...
  • Page 106 For details, refer to C4 Maintenance: 6.1 Joint #2 – Replacing the Motor, Installation steps (10) through (13). 19. Install the removed covers. For details, refer to C4 Maintenance: 3. Covers. 20. Perform the calibration. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 107: Joint #2 - Replacing The Timing Belt

    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). C Series Maintenance Manual Rev.2...

  • Page 108: Joint #2 - Replacing The Electromagnetic Brake

    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). C Series Maintenance Manual Rev.2...

  • Page 109: Joint #3

    The process of aligning the two origins is called “Calibration”. Refer to C4 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #3 motor + Electromagnetic brake Joint #3 Reduction gear unit Joint #3 Timing belt C Series Maintenance Manual Rev.2...

  • Page 110: Joint #3 - Replacing The Motor (With A Brake)

    Put a cloth between the Arm #2 and the Arm #3 so that two arms do not touch each other. Protect arms using cloth, etc. 3. Turn OFF the Controller power. 4. Remove the Arm #2 side cover. For details, refer to C4 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...
  • Page 111 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 plate from the Joint #3 motor. Hexagon socket head cap bolt: 2-M4×12 C Series Maintenance Manual Rev.2...

  • Page 112: Installation: Joint #3 Motor (With A Brake)

    Connector: D 5. Install the motor unit to the Arm #2. Hexagon socket head cap bolts: 2-M4×15 (with a plain washer) Temporarily tighten the screws. Tighten the screws loosely enough to hold the motor unit. C Series Maintenance Manual Rev.2...
  • Page 113 8. Connect the following connectors. Connector: X131, X031, BT3, BR021 9. Install the Arm #2 side cover. For details, refer to C4 Maintenance: 3. Covers. 10. Perform the calibration. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 114: Joint #3 - Replacing The Reduction Gear Unit

    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) through (21). C Series Maintenance Manual Rev.2...
  • Page 115 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. C Series Maintenance Manual Rev.2...
  • Page 116 The parts are greased. Wipe grease while removing the parts. 9. Remove the reduction gear unit from the Arm #3. Hexagon socket set screws: 12-M3×26 The parts are greased. Wipe grease while removing the parts. C Series Maintenance Manual Rev.2...
  • Page 117 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. C Series Maintenance Manual Rev.2...

  • Page 118: Installation: Joint #3 Reduction Gear Unit

    Concave surface Groove Convex surface 3. Set the flexspline with the convex surface facing down. 4. Match the screw holes on the cross roller bearing's inner ring and the drilled holes on the circular spline. C Series Maintenance Manual Rev.2...
  • Page 119 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 the Arm #3 reduction gear unit. O-ring C Series Maintenance Manual Rev.2...
  • Page 120 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 C Series Maintenance Manual Rev.2...
  • Page 121 Replacing the Motor (with a Brake), Installation steps (8) through (11). 19. Install the removed covers. For details, refer toC4 Maintenance: 3. Covers. 20. Perform the calibration. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 122: Joint #3 - Replacing The Timing Belt

    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). C Series Maintenance Manual Rev.2...

  • Page 123: Joint #4

    The process of aligning the two origins is called “Calibration”. Refer to C4 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #4 reduction gear unit Joint #4 motor Joint #4 timing belt Joint #4 electromagnetic brake C Series Maintenance Manual Rev.2...

  • Page 124: Joint #4 - Replacing The Motor

    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) C Series Maintenance Manual Rev.2...
  • Page 125 E : Flat face for drive boss Motor shaft 8. Remove the Joint #4 electromagnetic brake. Hexagon socket set screws: 3-M2.5×10 9. Remove the motor plate from the Joint #4 motor. Hexagon socket head cap bolts: 2-M4×12 C Series Maintenance Manual Rev.2...

  • Page 126: Installation: Joint #4 Motor

    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 Motor shaft C Series Maintenance Manual Rev.2...
  • Page 127 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. C Series Maintenance Manual Rev.2...
  • Page 128 Connectors: X141, X041, BT4, BR041 10. Install the Arm #3 head cover and the Arm #3 bottom cover. For details, refer toC4 Maintenance: 3. Covers. 11. Calibrate the Joint #4. For details, refer toC4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 129: Joint #4 - Replacing The Reduction Gear Unit

    Hexagon socket head cap bolts: 2-M4×8 Joint #4 timing belt 6. Remove the Joint #4 timing belt. 2-M4×5 7. Remove the Joint #4 fitting. 8. Remove the LED lamp. Joint #4 cable fixing plate Joint #4 fittings C Series Maintenance Manual Rev.2...
  • Page 130 The parts are greased. Wipe grease on the parts while removing them. Metal seal 11. Remove the wave generator from the Joint #4 reduction gear unit. The parts are greased. Wipe grease on the parts while removing them. C Series Maintenance Manual Rev.2...
  • Page 131 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 similar material if it is attached to the Arm #3 or other parts. C Series Maintenance Manual Rev.2...

  • Page 132: Installation: Joint #4 Reduction Gear Unit

    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 bearing of the wave generator. Grease: SK-1A 6. Install the O-ring to the Arm #4. O-ring C Series Maintenance Manual Rev.2...
  • Page 133 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. C Series Maintenance Manual Rev.2...
  • Page 134 For details, refer to C4 Maintenance: 9.1 Joint #5 – Replacing the Motor, Installation step (6). 22. Apply tension to the Joint #6 motor unit and fix it. For details, refer to C4 Maintenance: 10.1 Joint #6 – Replacing the Motor, Installation step (6). C Series Maintenance Manual Rev.2...
  • Page 135 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. C Series Maintenance Manual Rev.2...

  • Page 136: Joint #4 - Replacing The 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). C Series Maintenance Manual Rev.2...

  • Page 137: Joint #4 - Replacing The Electromagnetic Brake

    Installation: Joint #4 Electromagnetic brake 1. Mount the Joint #4 electromagnetic brake to the Joint #4 motor unit. For details, refer to C4 Maintenance: 8.1 Joint #4 – Replacing the Motor, Installation steps (2) through (11). C Series Maintenance Manual Rev.2...

  • Page 138: Joint #5

    The process of aligning the two origins is called “Calibration”. Refer to C4 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #5 Reduction gear unit Joint #5 Timing belt Joint #5 motor Joint #5 Electromagnetic brake C Series Maintenance Manual Rev.2...

  • Page 139: Joint #5 - Replacing The Motor

    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) C Series Maintenance Manual Rev.2...
  • Page 140 E : Flat face for drive boss Motor shaft 7. Remove the Joint #5 electromagnetic brake. Hexagon socket set screws: 3-M2.5×10 8. Remove the motor plate from the Joint #5 motor. Hexagon socket head cap bolts: 2-M4×12 C Series Maintenance Manual Rev.2...

  • Page 141: Installation: Joint #5 Motor

    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 Motor shaft C Series Maintenance Manual Rev.2...
  • Page 142 7. Connect the following connectors. Connectors: X052, X152, BT52, BR052 8. Install the Arm #4 side cover. For details, refer to C4 Maintenance: 3. Covers. 9. Perform the calibration. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 143: Joint #5 - Replacing The Reduction Gear Unit

    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) C Series Maintenance Manual Rev.2...
  • Page 144 When installing the gear unit, make sure to use the same number of the shim rings to the same position. Arm #4 plate 9. Remove the Arm #4 plate. Hexagon socket head cap bolts: 6-M3×12 Hexagon socket head cap bolts: 4-M4×10 C Series Maintenance Manual Rev.2...
  • Page 145 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: 7 mm Open-end wrench width for the nut: 8 mm Washer C Series Maintenance Manual Rev.2...
  • Page 146 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 C Series Maintenance Manual Rev.2...

  • Page 147: Installation: Joint #5 Reduction Gear Unit

    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 spline. C Series Maintenance Manual Rev.2...
  • Page 148 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 C Series Maintenance Manual Rev.2...
  • Page 149 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 Arm #4. O-ring C Series Maintenance Manual Rev.2...
  • Page 150 Tightening torque: 2.5 N·m (25 kgf·cm) Arm #4 plate 15. Install the Arm #4 plate. Hexagon socket head cap bolts: 6-M3×12 Tightening torque: 2.5 N·m (25 kgf·cm) Hexagon socket head cap bolts: 4-M4×10 Tightening torque: 4.9 N·m (50 kgf·cm) C Series Maintenance Manual Rev.2...
  • Page 151 Joint #6 timing belt tension = 39.2 N ± 9.8 N (4 kgf ± 1 kgf) Secure the Joint #6 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) C Series Maintenance Manual Rev.2...
  • Page 152 Hexagon socket head cap bolt: 2-M4×15 (with a plain washer) Tightening torque: 4.9 N·m (50 kgf·cm) 24. Install 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. C Series Maintenance Manual Rev.2...

  • Page 153: Joint #5 - Replacing The 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). C Series Maintenance Manual Rev.2...

  • Page 154: Joint #5 - Replacing The Electromagnetic Brake

    Installation: Joint #5 Electromagnetic brake 1. Mount the Joint #5 electromagnetic brake to the Joint #5 motor unit. For details, refer to C4 Maintenance: 9.1 Joint #5 – Replacing the Motor, Installation steps (2) through (9). C Series Maintenance Manual Rev.2...

  • Page 155: Joint #6

    The process of aligning the two origins is called “Calibration”. Refer to C4 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #6 Reduction gear unit Joint #6 Motor Joint #6 electromagnetic brake Joint #6 timing belt C Series Maintenance Manual Rev.2...

  • Page 156: Joint #6 - Replacing The Motor

    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) C Series Maintenance Manual Rev.2...
  • Page 157 E : Flat face for drive boss Motor shaft 7. Remove the Joint #6 electromagnetic brake. Hexagon socket set screws: 3-M2.5×10 8. Remove the motor plate from the Joint #6 motor. Hexagon socket head cap bolts: 2-M4×12 C Series Maintenance Manual Rev.2...

  • Page 158: Installation: Joint #6 Motor

    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 Motor shaft C Series Maintenance Manual Rev.2...
  • Page 159 7. Connect the following connectors. Connectors: X062, X162, BT62, BR062 8. Install the Arm #4 side cover. For details, refer to C4 Maintenance: 3. Covers. 9. Perform the calibration. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 160: Joint #6 - Replacing The Reduction Gear Unit

    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 C Series Maintenance Manual Rev.2...
  • Page 161 The parts are greased. Wipe grease on the parts while removing them. Gear Bolt 10. Remove the wave generator from the Arm #5. The parts are greased. Wipe grease on the parts while removing them. C Series Maintenance Manual Rev.2...
  • Page 162 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 C Series Maintenance Manual Rev.2...

  • Page 163: Installation: Joint #6 Reduction Gear Unit

    Open-end wrench width for the shaft: 5.5 mm Open-end wrench width for the nut: 8 mm 3. Install the O-ring (of the Joint #6 reduction gear unit) to the Arm #5. O-ring 4. Insert the wave generator unit to the Arm #5. C Series Maintenance Manual Rev.2...
  • Page 164 Grease volume: 2 g 9. Install the removed O-ring. O-ring 10. Install the Arm #5 unit to the Arm #4. For details, refer to C4 Maintenance: 9.2 Joint #5 – Replacing the Motor, Installation steps (13) through (25). C Series Maintenance Manual Rev.2...

  • Page 165: Joint #6 - Replacing The 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). C Series Maintenance Manual Rev.2...

  • Page 166: Joint #6 - Replacing The Electromagnetic Brake

    Installation: Joint #5 Electromagnetic brake 1. Mount the Joint #6 electromagnetic 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). C Series Maintenance Manual Rev.2...

  • Page 167: Replacing The Arm #5 O-Ring

    M4×15 or longer Plug 3. Remove the screw. M4×15 or longer If you move the arm with the screw mounted, it may contact Plug with the Manipulator body. Make sure to remove the screw. Arm #5 C Series Maintenance Manual Rev.2...

  • Page 168: Replacing The Battery Unit

    NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the battery can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
  • Page 169 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. C Series Maintenance Manual Rev.2...
  • Page 170 Cut off the wire tie of the plate. Disconnect the connector of one of two batteries. Then, connect the connector of the new battery. Disconnect the connector of the other battery. Then, connect the connector of the new battery. C Series Maintenance Manual Rev.2...
  • Page 171 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 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 172: Replacing The Battery Board

    Cross recessed head screws: 3-M3×8 Disconnect the three connectors from the battery board. Connectors: 2 connectors for the batteries, CN3 Remove the battery board fixed to the Arm #1. Hexagon socket head cap bolts: 2-M3×8 C Series Maintenance Manual Rev.2...

  • Page 173: Installation: Battery Board

    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 C Series Maintenance Manual Rev.2...
  • Page 174 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. C Series Maintenance Manual Rev.2...

  • Page 175: Replacing The Control Board

    Removal: Control board 1 1. Follow C4 Maintenance: 12.2 Replacing the Battery Board Removal steps (1) through (4). Installation: Control board 1 1. Follow C4 Maintenance: 12.2 Replacing the Battery Board Installation steps (11) through (14). C Series Maintenance Manual Rev.2...

  • Page 176: Replacing The Control Board 2

    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 will be used again. Be careful not to lose it. Spacer: 4 spacers Spacer C Series Maintenance Manual Rev.2...

  • Page 177: Installation: Control Board 2

    Move the Manipulator to two or three points (poses) of the registered points. 8. If the Manipulator is out of position, calibrate all the joints and axes. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 178: Replacing The Led Lamp

    LED lamp Name Quantity Note For the part code, refer to the 17. C4 Maintenance Parts LED lamp Maintenance Part List. Tools Cross-point screwdriver For covers C Series Maintenance Manual Rev.2...

  • Page 179: Removal: Led Lamp

    Arm #3 and secure the lamp to the Arm #3. 2. Connect the following connectors. Connector: LED 3. Install the Arm #3 head cover. For details, refer to C4 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...

  • Page 180: Replacing The M/C Cable

    OFF the Controller. The position data will be lost when the cable connector connected to the battery is disconnected. And the EPSON RC+ will display the error message of encoder alarm occurrence when the Controller is turned ON.
  • Page 181 10 m Straight 2216986 R12NZ901E1 M/C cable R12NZ901E2 (flexible, 10 m R12NZ901E3 straight only) 15 m R12NZ901E4 20 m R12NZ901E5 For M4 hexagon Tools Hexagonal wrench (width across flats: 3 mm) socket head cap bolts C Series Maintenance Manual Rev.2...

  • Page 182: Removal: M/C Cable

    6. If the battery connector (BT1*) was disconnected, perform the calibration. For details, refer to C4 Maintenance: 16. Calibration. 7. If the Manipulator is out of position, calibrate all the joints and axes. For details, refer to C4 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 183: Calibration

    Manipulator moves unexpectedly. In EPSON RC+, a coordinate point including the arm pose is defined as “point” and its data is called “point data”.
  • Page 184 For details on Jog & Teach, refer to EPSON RC+ User’s Guide 5.11.1 Robot Manager Command Tools: Robot Manager: Jog and Teach Page. - For details about the basic pose, refer to C Series Manual C4 Manipulator 3.7 Checking NOTE ...

  • Page 185: Calibration Procedure

    Pose data (Point data) prior to the part replacement (motors, reduction 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.
  • Page 186 Be sure to put the key back to the original position after use. 4-1 Prepare the calibration key. A calibration key is secured inside the Arm #1 center cover using the M4 screw. Be careful not to lose the screw. C Series Maintenance Manual Rev.2...
  • Page 187 4-6 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 EPSON calibrate from the menu-[Tool]-[Command Window]. >calpls 0,0,0,0,0,0 * Manipulator does not move. C Series Maintenance Manual Rev.2...
  • Page 188 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 cover. For details, refer to C4 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...
  • Page 189 If accuracy is inadequate, it is necessary to re-calibrate the origin using a different pose (point). You must set the pose (point) again if the Manipulator does not move back to the original position after re-calibration. C Series Maintenance Manual Rev.2...

  • Page 190: C4 Maintenance Parts List

    As a rough indication, perform the overhaul (parts replacement) before reaching 20,000 operation hours of the Manipulator. The operation hours can be checked in [Controller Status Viewer] dialog box - [Motor On Hours]. For details, refer to C4 Maintenance 2.2 Overhaul (Parts Replacement). C Series Maintenance Manual Rev.2...
  • Page 191 Regarding purchase of grease, please contact the following manufacturers. If there is anything unclear, please contact the supplier of your region. Product name Manufacturer Harmonic Grease SK-1A Harmonic Drive Systems Inc. https://www.harmonicdrive.net/ Harmonic Grease SK-2 https://www.chemours.com/en/brands- Krytox®GPL-224 Chemours and-products C Series Maintenance Manual Rev.2...
  • Page 192 − 2165295 − 2165294 − M/C signal cable 10 m 2165293 − (flexible) 15 m 2220937 − 20 m 2220938 − Battery relay cable unit 1653173 − − Radiation Sheet Joint #2 1549699 R13B031905 − C Series Maintenance Manual Rev.2...
  • Page 193 Joint #4, #5, #6 2216068 R13N835011  10.4 Noise Joint #1, #2, #3 2216071 R13N823011 5.4, 6.4, 7.1 dissipative diode LED lamp 2216072 R13N830011 C4-A601** 2216075 R13N820011 C4-A901** 2216076 R13N820021 Cable Unit C4-A601**-UL 2216077 − C4-A901**-UL 2216078 − C Series Maintenance Manual Rev.2...
  • Page 194 R12NZ9003G R12B031923 Base side angled fitting R12NZ900HF R12B031924 Base side fitting R12NZ9003H R12B031925 PS Compatible Plate R12NZ900A5 R12N73L021 (Base Adapter) Adjustable Mechanical Stop R12NZ900L1 R12N73L011 * Refer to each manipulator’s page of C series manual. C Series Maintenance Manual Rev.2...
  • Page 195 C8 Maintenance This volume contains maintenance procedures with safety precautions for C8 series Manipulators.

  • Page 197: Safety Maintenance

    ■ When connecting / replacing the brake release unit or the external short connector, turn OFF the power to the Controller and the brake release unit. Connecting or disconnecting the connector while the power is ON may result in electrical shock. C Series Maintenance Manual Rev.2...
  • Page 198 ■ The Manipulator arms may become hot after the Manipulator operation due to heat generation of the motors. Be careful when performing maintenance. ■ When operating maintenance of manipulator, secure about 50 cm of empty space around the manipulator. C Series Maintenance Manual Rev.2...

  • Page 199: General Maintenance

    9 months (2250 h) √ √ 10 months (2500 h) √ 11 months (2750 h) √ 12 months (3000 h) √ √ √ √ 13 months (3250 h) √ √ 20000 h h = hour C Series Maintenance Manual Rev.2...

  • Page 200: Inspection Point

    Joint #1 to 6 break √ √ √ √ √ Check whether unusual Whole √ √ √ √ √ sound or vibration occurs. Check if the fan is running √ √ √ √ √ (C8-A1401***(C8XL) only) C Series Maintenance Manual Rev.2...
  • Page 201 If there is something wrong, contact the supplier. Check that the fan is running when in MOTOR Check if the fan is running (C8-A1401***(C8XL) only) If the fan is not running when in MOTOR ON, contact the supplier. C Series Maintenance Manual Rev.2...

  • Page 202: Overhaul (Parts Replacement)

    / deceleration in continuous operation) applied on the Manipulator. NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the parts subject to maintenance (motors, reduction gear units, and timing belts) can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
  • Page 203 The Manipulator operation hours can be checked in [Controller Status Viewer] dialog - [Motor On Hours]. (1) Select EPSON RC+ menu-[Tools]-[Controller] to open the [Controller Tools] dialog. (2) Click the <View Controller Status> button to open the [Browse For Folder] dialog.

  • Page 204: Greasing

    As a rough indication, perform greasing at the same timing as overhaul. 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. C Series Maintenance Manual Rev.2...
  • Page 205 Do not use any tool to install and remove the grease nipple and grease line extension jig. NOTE  Always handle them directly by your hand. If the grease nipple or grease line extension jig is installed or removed with a tool such as wrench, they may be damaged. C Series Maintenance Manual Rev.2...

  • Page 206: Joint #1 Reduction Gear Unit (Table Top Mounting)

    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 details, refer to C8 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...

  • Page 207: Joint #1 Reduction Gear Unit (Ceiling Mounting, Wall Mounting)

    8. Apply a thin coat of grease (SK-1A) 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. C Series Maintenance Manual Rev.2...

  • Page 208: Joint #2 Reduction Gear Unit

    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. C Series Maintenance Manual Rev.2...

  • Page 209: Joint #3 Reduction Gear Unit

    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. C Series Maintenance Manual Rev.2...

  • Page 210: Joint #4 Reduction Gear Unit

    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 damaged or deteriorated, replace it with a new one. C Series Maintenance Manual Rev.2...

  • Page 211: Joint #5 Reduction Gear Unit

    4. Remove the grease nipple from the Joint #5 grease inlet. 5. Attach the grease plug to the Joint #5 grease inlet. If the grease plug is damaged or deteriorated, replace it with a new one. C Series Maintenance Manual Rev.2...

  • Page 212: Joint #6 Reduction Gear Unit

    Joint #5 (SK-1A). Remove the grease nipple from the Joint #6 grease inlet. Attach the grease plug to the Joint #6 grease inlet. If the grease plug is damaged or deteriorated, replace it with a new one. C Series Maintenance Manual Rev.2...

  • Page 213: Joint #6 Bevel Gear

    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. Install the Arm #5 grease inlet cover. Hexagon socket head cap bolts: 4-M3×6 Tightening torque: 2.0 ± 0.1 N·m C Series Maintenance Manual Rev.2...

  • Page 214: Tightening Hexagon Socket Head Bolts

    Divide the number of times to fasten the bolts into Bolt hole two or three and fasten the bolts securely with a hexagonal wrench. Then, use a torque wrench to fasten the bolts with tightening torques shown in the table above. C Series Maintenance Manual Rev.2...

  • Page 215: Layout Of Maintenance Parts

    +Electromagnetic brake Joint #6 Motor +Electromagnetic brake Joint #4 Joint #4 Joint #5 Timing belt Reduction gear unit Motor Joint #4 Electromagnetic brake Battery Battery board Control board 2 Control board 1 (Figure: C8-A1401* (C8XL)) C Series Maintenance Manual Rev.2...

  • Page 216: Covers

    ■ 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. C Series Maintenance Manual Rev.2...
  • Page 217 Arm #1 plate Arm #1 side cover center cover Base cover Connector sub plate C8-A1401* (C8XL) only (Figure: C8-A1401* (C8XL)) Cable downward model C8-A1401*B* (C8XL) only Connector plate Connector sub plate Base cover (Figure: C8-A1401*B* (C8XL)) C Series Maintenance Manual Rev.2...
  • Page 218 For M6 For M3 hexagon socket head cap width across flats: 2.5 mm Hexagonal bolts wrench Tools For M4 hexagon socket head cap width across flats: 3 mm bolts Cross-point screwdriver (#2) For cross recessed screws C Series Maintenance Manual Rev.2...

  • Page 219: Arm #1 Center Cover

    Hexagon socket head cap bolts with washer: 5-M4×12 Tightening torque: 4.0 ± 0.2 N·m NOTE 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. C Series Maintenance Manual Rev.2...

  • Page 220: Arm #1 Side Cover

    Hexagon socket head cap bolts with captive washer: 8-M4×12 (one side) Remove the Arm #1 side gasket together. The Arm #1 side covers and Arm #1 side gaskets are NOTE  the same between right and left. C Series Maintenance Manual Rev.2...
  • Page 221 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 shock warning label to the place indicated in the photo. C Series Maintenance Manual Rev.2...

  • Page 222: Arm #2 Side Cover

    Hexagon socket head cap bolts with captive washer: 8-M4×12 (one side) Tightening torque: 4.0±0.2N·m Be careful not to get the gasket and cables caught NOTE  between the cover and the Manipulator. Replace the gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...

  • Page 223: Arm #3 Cover

    4-M4×12 Tightening torque: 4.0 ± 0.2 N·m Be careful not to get the gasket and cables caught between the cover and the NOTE  Manipulator. Replace the gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...

  • Page 224: Arm #3 Maintenance Cover

    Cross recessed truss head small screws: 4-M4×8 P model: Hexagon socket head cap bolts: 4-M4×10 Remove the Arm #3 maintenance gasket together. The gasket has the spacers. NOTE  Be careful not to lose them. C Series Maintenance Manual Rev.2...
  • Page 225 Hexagon socket head cap bolts: 4-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 NOTE  Manipulator. Replace the gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...

  • Page 226: Arm #4 Side Cover

    2. Remove the connectors. RJ45 connector (left): Remove the RJ45 connector from the connector on the cover. F-sensor connector (right): Open the two plastic clips of the connector on the cover and pull out the metallic connector. C Series Maintenance Manual Rev.2...
  • Page 227 Manipulator. Replace the gasket if there are flaws or deteriorations. When replacing the cover, attach the electrical shock warning label and other labels to the places indicated in the photos. C Series Maintenance Manual Rev.2...

  • Page 228: Arm #4 Maintenance Cover (C8Xl Only)

    Cross recessed truss head small screws: 4-M4×10 P model: Hexagon socket head cap bolts: 4-M4×10 Remove the Arm #3 maintenance gasket together. The gasket has the spacers. NOTE  Be careful not to lose them. C Series Maintenance Manual Rev.2...

  • Page 229: Arm #4 Maintenance Cover

    Hexagon socket head cap bolts: 4-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 NOTE  Manipulator. Replace the gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...

  • Page 230: Arm #4 D-Sub Attachment

    Hexagon socket head cap bolts: 2-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. NOTE  Replace the gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...

  • Page 231: Base Cover

    Be careful not to get the gasket and cables caught NOTE  between the cover and the Manipulator. Replace the gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...

  • Page 232: M/C Cable Downward

    Remove the bolts and then remove the base cover. Hexagon socket head cap bolts: 11-M4×10 P model: Remove the base rear gasket together. The gasket has the spacers. Be careful not to lose NOTE  them. C Series Maintenance Manual Rev.2...
  • Page 233 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 NOTE  Manipulator. Replace the gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...
  • Page 234 (See the figure for gasket applying points) Spacer (×11) Gasket Applying point (×11) Base rear gasket Base cover NOTE After applying the liquid gasket, leave the gasket until the liquid gasket becomes  solid and the gasket is fixed. C Series Maintenance Manual Rev.2...
  • Page 235 Install the heat sink. Hexagon socket head cap bolts: 4-M4×15 Tightening torque: 4.0 ± 0.2 N·m Install the fan. For details, refer to C8 Maintenance 15. Replacing the Fan. C Series Maintenance Manual Rev.2...

  • Page 236: Base Maintenance Cover

    Install the base maintenance cover to the Manipulator. (S, C models) Hexagon socket head cap bolts: 6-M4×10 Tightening Torque: 0.9 ± 0.1 N·m NOTE  Be careful not to get the cables caught between the cover and the Manipulator. C Series Maintenance Manual Rev.2...
  • Page 237 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 and the NOTE  Manipulator. Replace the gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...

  • Page 238: Connector Plate

    Remove the bolts and then remove the connector plate. Hexagon socket head cap bolts: 11-M4×10 P model: Remove the base rear gasket together. The gasket has the spacers. Be careful not to lose NOTE  them. C Series Maintenance Manual Rev.2...
  • Page 239 Hexagon socket head cap bolts: 11-M4×10 Tightening torque: 4.0 ± 0.2 N·m NOTE 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. C Series Maintenance Manual Rev.2...
  • Page 240 (See the figure for gasket applying points) Spacer (×11) Gasket Applying point (×11) Base rear gasket Base cover After applying the liquid gasket, leave the gasket until the liquid gasket becomes NOTE  solid and the gasket is fixed. C Series Maintenance Manual Rev.2...
  • Page 241 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. C Series Maintenance Manual Rev.2...

  • Page 242: M/C Cable Downward

    Hexagon socket head cap bolts: 8-M4×10 Tightening Torque: 4.0 ± 0.2 N·m Be careful not to get the gasket and cables caught NOTE  between the cover and the Manipulator. Replace the gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...

  • Page 243: Connector Sub Plate

    P model: Hexagon socket head cap bolts: 4-M4×10 (with a seal washer) NOTE Remove the base sub plate gasket together.  The gasket has the spacers. Be careful not to lose the seal washers and spacers. C Series Maintenance Manual Rev.2...
  • Page 244 Tightening torque: 4.0 ± 0.2 N·m Be careful not to get the gasket and cables caught between the cover and the NOTE  Manipulator. Replace the seal washers and gasket if there are flaws or deteriorations. C Series Maintenance Manual Rev.2...

  • Page 245: Cable Unit

    When routing the cables, observe the cable locations after removing the cover. Be sure to place the cables back to their original locations. C Series Maintenance Manual Rev.2...
  • Page 246 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. C Series Maintenance Manual Rev.2...

  • Page 247: Replacing The Cable Unit (M/C Cable Backward)

    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. C Series Maintenance Manual Rev.2...
  • Page 248 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 the both ends of the connector and pull it out. C Series Maintenance Manual Rev.2...
  • Page 249 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 preventing cable interference. Hexagon socket head cap bolts: 2-M3×6 C Series Maintenance Manual Rev.2...
  • Page 250 17. Disconnect the battery connector. NOTE 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 C Series Maintenance Manual Rev.2...
  • Page 251 Protect the connectors with masking tapes. - To protect the connector’s clips - To avoid adherence of cable grease NOTE Disconnect the connectors one by one in order from the smallest  connector to the largest one. C Series Maintenance Manual Rev.2...
  • Page 252 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. C Series Maintenance Manual Rev.2...
  • Page 253 35. Disconnect the connectors inside the Arm #3. Connectors: X141, X151, X161, BR041, BR051, X041, X71, X72, PS, LED, BT51, BT4 (Hold the clip to remove.) 36. Remove the connector connected to the control board 2. Connector: GS02 C Series Maintenance Manual Rev.2...
  • Page 254 Hexagon socket head cap bolts: 2-M4×10 40. Cut off the wire tie that binds the cable protection coils inside the Arm 41. Disconnect the cables from the Arm #3 side to the Arm #2 side. C Series Maintenance Manual Rev.2...
  • Page 255 44. Remove the Arm #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-M3×6 C Series Maintenance Manual Rev.2...
  • Page 256 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 C Series Maintenance Manual Rev.2...
  • Page 257 D-sub connector D-sub connector fixing plate P model: D-sub connector 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 C Series Maintenance Manual Rev.2...
  • Page 258 C8 Maintenance 4. Cable Unit 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) C Series Maintenance Manual Rev.2...
  • Page 259 The screws and nuts will be used again for fixing the connector. Be careful not to lose them. 4. Disconnect the following connectors to separate the cables. Connectors: X051, X061, X151, X161, XGND, BR051, BR061, BT51, BT61, X71, X72, SW1 C Series Maintenance Manual Rev.2...
  • Page 260 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/yellow) C Series Maintenance Manual Rev.2...
  • Page 261 Silicone tube is provided. Leave out the silicone tube on the Arm #4 side. Pass the following cables through the silicone tube: Ethernet cable, X052/X062 cable, and ground wire (green/yellow) that have been passed from the Arm #3 side. C Series Maintenance Manual Rev.2...
  • Page 262 Use a cable bracket to fix the wrapped silicone sheet. C8XL: Place the silicone tube to the position where it is fixed with a cable bracket. Use a cable bracket to fix the silicone tube. C Series Maintenance Manual Rev.2...
  • Page 263 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 NOTE  Do not to let the cables caught in the attachment. For details, refer to C8 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...
  • Page 264 15. Fix the cable protection plate to the Arm #4. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m NOTE Be careful not to get the cables caught.  It may cause cable breakage. C Series Maintenance Manual Rev.2...
  • Page 265 Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.4 ± 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 C Series Maintenance Manual Rev.2...
  • Page 266 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. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m C Series Maintenance Manual Rev.2...
  • Page 267 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 cover can be installed. C Series Maintenance Manual Rev.2...
  • Page 268 For details, refer to C8 Maintenance: 7.1 Joint #3 - Replacing the Motor, Installation steps (4) and (8). 33. Fix the two ground wire terminals to the Arm #2. Green: Right side Green/yellow: Left side Cross recessed head screws with washer: 2-M4×8 Tightening torque: 0.9 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 269 37. Fix the cables to the Arm #2 cable fixing plate. Check that the silicone tube is not shifted away from the fixed position. Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.4 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 270 Check that the silicone tube is not shifted away from the fixed position. Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.4 ± 0.1 N·m 42. Place a mark at a position 250 mm from the cable bracket (C2). 250 mm C Series Maintenance Manual Rev.2...
  • Page 271 (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. C Series Maintenance Manual Rev.2...
  • Page 272 49. Remove the Arm #1 cable fixing plate fixed temporarily, and fix another cable bracket (C1)-B. Removing Arm #1 cable fixing plate: Hexagon socket head cap bolts: 2-M4×10 Fixing cable bracket (C1)-B: Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.4 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 273 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 side 55. Connect the battery connectors. Connectors: CN3, CN6 C Series Maintenance Manual Rev.2...
  • Page 274 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-M3×6 Tightening torque: 2.0 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 275 66. Install the ground wire plate (M/C cable backward). Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m 67. Install the following connectors according to the marks on the connector plate. RJ45 connector: Ether F-sensor connector: F-sensor C Series Maintenance Manual Rev.2...
  • Page 276 Arm #1 side covers (both sides) Arm #1 center cover Base maintenance cover Connector plate (M/C cable backward) For details, refer to C8 Maintenance: 3. Covers. 72. Perform calibration. For details, refer to C8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 277: Replacing The Cable Unit (M/C Cable Downward)

    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. C Series Maintenance Manual Rev.2...
  • Page 278 X040, LED, GS01, BT1 (Hold the clip to remove.) 8. Disconnect the following connectors. RJ45 connector: Hold the clip to remove. F-sensor connector: Open the clips on the both ends of the connector and pull it out. C Series Maintenance Manual Rev.2...
  • Page 279 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). C Series Maintenance Manual Rev.2...
  • Page 280 7. Install the D-sub connectors according to the marks on the connector plate. 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 C Series Maintenance Manual Rev.2...
  • Page 281 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. Calibration. C Series Maintenance Manual Rev.2...

  • Page 282: Connector Pin Assignment

    C8 Maintenance 4. Cable Unit 4.2 Connector Pin Assignment 4.2.1 Signal Cable C Series Maintenance Manual Rev.2...
  • Page 283 C8 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...
  • Page 284 C8 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...

  • Page 285: Power Cable

    C8 Maintenance 4. Cable Unit 4.2.2 Power Cable C8-A701*** (C8), C8-A901*** (C8L) C Series Maintenance Manual Rev.2...
  • Page 286 C8 Maintenance 4. Cable Unit C8-A1401*** (C8XL) C Series Maintenance Manual Rev.2...
  • Page 287 C8 Maintenance 4. Cable Unit C8-A701*** (C8), C8-A901*** (C8L), C8-A1401*** (C8XL) C Series Maintenance Manual Rev.2...

  • Page 288: User Cable

    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 Black White Green Yellow Brown Blue Violet Azure Orange Gray Pink C Series Maintenance Manual Rev.2...

  • Page 289: Joint #1

    Joint #1 Reduction gear unit Joint #1 Timing belt Joint #1 Motor (Figure: C8-A1401* (C8XL)) Maintenance procedures differ depending on the installation type of the M/C cable. 5.1 M/C Cable Backward (Joint #1) 5.2 M/C Cable Downward (Joint #1) C Series Maintenance Manual Rev.2...

  • Page 290: M/C Cable Backward (Joint #1)

    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. C Series Maintenance Manual Rev.2...
  • Page 291 The heat radiation block, the heat radiation sheet, and the bolts will be used again. Be careful not to  lose them. Be careful not to tear the heat radiation sheet. 5. Remove the brake power supply. Cross recessed head screws with washer: 2-M3×6 C Series Maintenance Manual Rev.2...
  • Page 292 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. C Series Maintenance Manual Rev.2...
  • Page 293 When securing the motor unit loosely, 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. C Series Maintenance Manual Rev.2...
  • Page 294 As the screw is tightened, the Joint #1 motor unit will be pulled and tension will be applied. C8-A1401** (C8XL): Install the heat radiation block For details, refer to the Heat radiation block Installation C Series Maintenance Manual Rev.2...
  • Page 295 7. Mount the connector plate (M/C cable backward). For details, refer to C8 Maintenance: 3. Covers. 8. Mount the base maintenance cover. For details, refer to C8 Maintenance: 3. Covers. 9. Calibrate the Joint #1. For details, refer toC8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 296 3-1 Insert the wire tie under the motor. 3-2 Hold the end of the wire tie. 3-3 While holding the end of the wire tie, push the wire tie to the direction as indicated with the arrow in the photo. C Series Maintenance Manual Rev.2...
  • Page 297 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. NOTE Do not tighten the wire tie too much. It may result in cable  breakage. C Series Maintenance Manual Rev.2...

  • Page 298: Joint #1 - Replacing The Reduction Gear Unit

    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 off. C Series Maintenance Manual Rev.2...
  • Page 299 Ground wire RJ45 connector F-sensor connector 4. Remove the Joint #1 motor unit. For details, refer to C8 Maintenance 5.1.1 Joint #1 – Replacing the Motor Unit (M/C Cable Backward), Removal steps (6) to (7). C Series Maintenance Manual Rev.2...
  • Page 300 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 C Series Maintenance Manual Rev.2...
  • Page 301 Have at least two workers so that one can support the Manipulator while CAUTION the other worker is removing the bolts. 14. Remove the Joint #1 reduction gear unit. Hexagon socket head cap bolts: 12-M6×50 C Series Maintenance Manual Rev.2...
  • Page 302 Manipulator. Be very careful when installing the arm. Have at least two workers so that one can support the Manipulator while the other CAUTION worker is removing the bolts. 3. Connect the grease tube for the Arm #1 side to the fitting. C Series Maintenance Manual Rev.2...
  • Page 303 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 socket head cap bolts: 2-M3×6 Tightening torque: 2.0 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 304 14. Install 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 Backward), Installation steps (6) to (14). C Series Maintenance Manual Rev.2...

  • Page 305: Joint #1 - Replacing The Timing Belt (M/C Cable Backward)

    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. C Series Maintenance Manual Rev.2...
  • Page 306 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 the both ends of the connector and pull it out. C Series Maintenance Manual Rev.2...
  • Page 307 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 NOTE  differ from the photo. Check the positions of the terminals before removing them. C Series Maintenance Manual Rev.2...
  • Page 308 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. C Series Maintenance Manual Rev.2...
  • Page 309 The installation positions of the D-sub cable ground terminals are NOTE  fixed. Make sure to install them to the two screw holes on the backside of the Manipulator (as indicated by arrows in the photo). C Series Maintenance Manual Rev.2...
  • Page 310 11. Install two air tubes in accordance with the indications on the connector plates. Air1: Semitransparent Air2: Blue NOTE  Be careful not to install the air tube of wrong color. 12. Install the connector plate (M/C cable backward). For details, refer to C8 Maintenance: 3 Covers. C Series Maintenance Manual Rev.2...
  • Page 311 C8 Maintenance 5. Joint #1 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. C Series Maintenance Manual Rev.2...

  • Page 312: Joint #1 - Replacing The Electromagnetic Brake

    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. C Series Maintenance Manual Rev.2...
  • Page 313 2. Mount the Joint #1 brake plate to the Joint #1 motor unit. For details, refer to C8 Maintenance: 5.1.1 Joint #1-Replacing the Motor (M/C Cable Backward), Installation steps (4) to (8). NOTE  If you disconnected the connector BT1 in the removal steps, perform calibration. C Series Maintenance Manual Rev.2...

  • Page 314: M/C Cable Downward (Joint #1)

    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. C Series Maintenance Manual Rev.2...
  • Page 315 The heat radiation block, the heat radiation sheet, and the bolts will be used again. Be careful not to NOTE  lose them. Be careful not to tear the heat radiation sheet. Remove the brake power supply. Cross recessed head screws with washer: 2-M3×6 C Series Maintenance Manual Rev.2...
  • Page 316 Hexagon socket head cap bolts: 3-M4×20 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. C Series Maintenance Manual Rev.2...
  • Page 317 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. Calibrate the Joint #1. For details, refer to C8 MMaintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 318: Joint #1 - Replacing The Reduction Gear Unit

    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 off. C Series Maintenance Manual Rev.2...
  • Page 319 P model : 10-M4×8, 2-M3×6 Remove the Joint #1 reduction gear unit. For details, refer to C8 Maintenance 5.1.2 Joint #1 - Replacing the Reduction Gear Unit (M/C Cable Backward), Removal steps (4) to (14). C Series Maintenance Manual Rev.2...
  • Page 320 : 10-M4×8, 2-M3×6 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 steps (4) to (10). C Series Maintenance Manual Rev.2...

  • Page 321: Joint #1 - Replacing The Timing Belt (M/C Cable Downward)

    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. C Series Maintenance Manual Rev.2...
  • Page 322 D-sub connector For details, refer to C8 Maintenance: 5.1.3 Joint #1-Replacing the Timing Belt (M/C Cable Backward), Removal steps (4) to (5), and (7). Remove the brake power supply. Cross recessed head screws with washer: 2-M3×6 C Series Maintenance Manual Rev.2...
  • Page 323 Hexagon socket head cap bolts: 2-M4×12 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). Remove the Joint #1 motor unit. C Series Maintenance Manual Rev.2...
  • Page 324 Install the ground wire to each connector. To connect the ground wire, insert in while holding the connector by hand. 6. Connect the M/C cable connectors. Connector: X11, X12, X14, BR010, BR011, X010, X020, X040, LED, GS01, BT1 C Series Maintenance Manual Rev.2...
  • Page 325 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 details, refer to C8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 326: Joint #1 - Replacing The Electromagnetic Brake

    Removal steps (1) to (6). NOTE  Do not disconnect the connector BT1. If the connector is disconnected, perform calibration. 2. Remove the Joint #1 brake from the brake plate. Hexagon socket head cap bolts: 3-M4×25 C Series Maintenance Manual Rev.2...
  • Page 327 Connector plate (M/C cable downward) Base cover (M/C cable downward) Base maintenance cover For details, refer to C8 Maintenance: 3 Covers. NOTE  If you disconnected the connector BT1 in the removal steps, perform calibration. C Series Maintenance Manual Rev.2...

  • Page 328: Joint #2

    The process of aligning the two origins is called “Calibration”. Refer to C8 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #2 Reduction gear unit Joint #2 Timing belt Joint #2 Motor + Electromagnetic brake (Figure: C8-A1401* (C8XL)) C Series Maintenance Manual Rev.2...

  • Page 329: Joint #2 - Replacing The Motor

    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 off. C Series Maintenance Manual Rev.2...
  • Page 330 The heat dissipation sheet attached to the motor unit will be used again. Be careful not to tear and lose it. C8-A1401** (C8XL) C8-A1401** does not have the heat dissipation block and the heat dissipation sheet, go on to the next step. C Series Maintenance Manual Rev.2...
  • Page 331 ■ 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. WARNING C Series Maintenance Manual Rev.2...
  • Page 332 (D-cut part of the motor shaft × 2) B: Pulley and drive boss screws Do not remove these screws. C: Bushing Pulley Drive boss 11. Remove the Joint #2 electromagnetic brake. Hexagon socket set screws: 2-M6×6 (with a brass bushing) C Series Maintenance Manual Rev.2...
  • Page 333 C8 Maintenance 6. Joint #2 12. Remove the motor plate from the Joint #2 motor. Hexagon socket head cap bolts: 4-M6×20 C Series Maintenance Manual Rev.2...
  • Page 334 If the screw positions are incorrect or the bushing is not set, it NOTE  may cause damage on the side of the brake and may result in the part being unable to be removed. C Series Maintenance Manual Rev.2...
  • Page 335 If the belt is too loose or too tight, it will not have proper tension. Hexagon socket set screws: 3-M5×25 (with a plain washer) C Series Maintenance Manual Rev.2...
  • Page 336 Tension is applied by pushing the set screw (M6×25) with the rubber. 7. Install the brake power supply. Cross recessed head screws with captive washer: 2-M3×6 Tightening torque: 0.45 ± 0.1 N·m 8. Connect the following connectors. Connectors: X121, X021, BT2, BR021 C Series Maintenance Manual Rev.2...
  • Page 337 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. C Series Maintenance Manual Rev.2...

  • Page 338: Joint #2- Replacing The Reduction Gear Unit

    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 off. C Series Maintenance Manual Rev.2...
  • Page 339 The key will be used again. Be careful not to lose it. 6. Pull out the grease tube on the Arm #1 side from the fitting. The grease tube connects between the base and the Arm #1. C Series Maintenance Manual Rev.2...
  • Page 340 Wipe grease on the part while removing it. 9. Remove the reduction gear unit from the Arm #2. Hexagon socket head cap bolts (with plain washer) C8, C8L: 12-M5×40 C8XL: 12-M6×45 Wipe grease on the part while removing it. C Series Maintenance Manual Rev.2...
  • Page 341 C8 Maintenance 6. Joint #2 10. Remove the O-ring from the groove on the Arm #2. Wipe grease on the part while removing it. C Series Maintenance Manual Rev.2...
  • Page 342 Install the reduction gear unit to match the screws and the clearance holes. Grease the inner side of the flexspline. Grease : SK-1A Grease amount : C8, C8L: 55 g C8XL: 102g Insert the wave generator to the reduction gear unit and fix it. C Series Maintenance Manual Rev.2...
  • Page 343 Hexagon socket head cap bolts: 16-M6×35 (with a plain washer) Tightening torque: 18.0 ± 0.9 N·m After fixing the Arm, check that there is no backlash or misalignment on the reduction gear unit by moving the Arm by hand. C Series Maintenance Manual Rev.2...
  • Page 344 For details, refer to C8 Maintenance 11.2 Replacing the Battery Board, Installation steps (2) to (5). 12. Install the Joint #2 timing belt. For details, refer to C8 Maintenance 6.3 Joint #2 – Replacing the Timing Belt, Installation steps (1) to (2). C Series Maintenance Manual Rev.2...

  • Page 345: Joint #2 - Replacing The Timing Belt

    Pass the timing belt to the pulley 2 first, then, place it to the pulley 1. 2. Secure the Joint #2 motor unit. For details, refer to C8 Maintenance: 6.1 Joint #2 – Replacing the Motor, Installation steps (5) to (6) and (10) to (11). C Series Maintenance Manual Rev.2...

  • Page 346: Joint #2 - Replacing The Electromagnetic Brake

    Installation: Joint #2 Electromagnetic brake 1. Mount the Joint #2 electromagnetic brake to the Joint #2 motor unit. For details, refer to C8 Maintenance: 6.1 Joint #2 – Replacing the Motor, Installation steps (2) through (11). C Series Maintenance Manual Rev.2...

  • Page 347: Joint #3

    The process of aligning the two origins is called “Calibration”. Refer to C8 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #3 Reduction gear unit Joint #3 Timing belt Joint #3 Motor + Electromagnetic brake (Figure: C8-A1401* (C8XL)) C Series Maintenance Manual Rev.2...

  • Page 348: Joint #3 - Replacing The Motor

    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. C Series Maintenance Manual Rev.2...
  • Page 349 For details, refer to C8 Maintenance: 3. Covers. 5. Disconnect the following connectors. Connectors: X131, X031, BT3, BR031 (Hold the clip to remove.) NOTE  Be careful not to drop the removed connectors inside the Arm. C Series Maintenance Manual Rev.2...
  • Page 350 ■ 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. WARNING Be sure to do the Removal steps 1 and 2 before loosening the bolts. C Series Maintenance Manual Rev.2...
  • Page 351 Hexagon socket set screws: 2-M5×6 (with a 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 C Series Maintenance Manual Rev.2...
  • Page 352 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 C Series Maintenance Manual Rev.2...
  • Page 353 NOTE 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. C Series Maintenance Manual Rev.2...
  • Page 354 If the belt is too loose or too tight, it will not have proper tension. Hexagon socket set screws: 3-M4×20 (with a plain washer) C Series Maintenance Manual Rev.2...
  • Page 355 8. Connect the following connectors. Connectors: X131, X031, BT3, BR031 9. Install the Arm #2 side cover. For details, refer to C8 Maintenance: 3. Covers. 10. Perform the calibration. For details, refer to C8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 356: Joint #3 - Replacing The Reduction Gear Unit

    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. C Series Maintenance Manual Rev.2...
  • Page 357 CAUTION ■ 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. C Series Maintenance Manual Rev.2...
  • Page 358 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. C Series Maintenance Manual Rev.2...
  • Page 359 Install the reduction gear unit to match the screws and the clearance holes. Grease the inner side of the flexspline. Grease: SK-1A Grease amount: 26 g Insert the wave generator to the reduction gear unit and fix it. C Series Maintenance Manual Rev.2...
  • Page 360 Hexagon socket head cap bolts: 16-M4×25 (with a plain washer) Tightening torque: 5.5 ± 0.2 N·m After fixing the Arm, check that there is no backlash or misalignment on the reduction gear unit by moving the Arm by hand. C Series Maintenance Manual Rev.2...
  • Page 361 10. Install the Joint #3 timing belt. For details, refer to C8 Maintenance 7.3 Joint #2 – Replacing the Timing Belt, Installation steps (1) to (2). C Series Maintenance Manual Rev.2...

  • Page 362: Joint #3 - Replacing The Timing Belt

    Pass 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 C8 Maintenance: 7.1 Joint #3 – Replacing the Motor, Installation steps (5) to (6) and (9) to (10). C Series Maintenance Manual Rev.2...

  • Page 363: Joint #3 - Replacing The Electromagnetic Brake

    Installation: Joint #3 Electromagnetic brake 1. Mount the Joint #3 electromagnetic brake to the Joint #3 motor unit. For details, refer to C8 Maintenance: 7.1 Joint #3 – Replacing the Motor, Installation steps (2) through (10). C Series Maintenance Manual Rev.2...

  • Page 364: Joint #4

    The process of aligning the two origins is called “Calibration”. Refer to C8 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #4 Timing belt Joint #4 Motor Joint #4 Reduction gear unit Joint #4 Electromagnetic brake (Figure: C8-A1401* (C8XL)) C Series Maintenance Manual Rev.2...

  • Page 365: Joint #4 - Replacing The Motor

    The Joints #5 and #6 motors have an identification label for preventing misconnection of the connectors. The label is not necessary for the Joint #4 motor. (There is no connector identification label for the Joint #4.) C Series Maintenance Manual Rev.2...
  • Page 366 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 small plain washer) C Series Maintenance Manual Rev.2...
  • Page 367 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 motor plate from the Joint #4 motor. Hexagon socket head cap bolts: 2-M4×10 C Series Maintenance Manual Rev.2...
  • Page 368 If the screw positions are incorrect or the bushing is not set, it NOTE  may cause damage on the side of the part and may result in the part being unable to be removed. C Series Maintenance Manual Rev.2...
  • Page 369 Joint #4 timing belt tension: 15 to30 N Belt tension meter setting value Weight: 2.5 g/mm width × m span, Width: 6 mm, Span: 61 mm Hexagon socket head cap bolt: 2-M4×15 (with a plain washer) Tightening torque: 4.0 ± 0.2 N·m C Series Maintenance Manual Rev.2...
  • Page 370 10. Install the following cover. Arm #3 cover Arm #3 maintenance cover Arm #2 side cover For details, refer to C8 Maintenance: 3. Covers. 11. Calibrate the Joint #4. For details, refer to C8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 371: Joint #4 - Replacing The 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 status. The brake does not work during replacement. Be careful when performing maintenance work. C Series Maintenance Manual Rev.2...
  • Page 372 To remove all bolts, change the position of the Joint #4 by rotating Hexagon socket head cap bolts: 8-M5×30 C8L: The bolts can be removed from the four through holes on the extension flange of the Arm #4. C Series Maintenance Manual Rev.2...
  • Page 373 The J4 sleeve is attached by gasket and may not be removed easily. If the part cannot be removed, pull the sleeve while rotating it. Handle the sleeve with care since it is thin and easy to deform. C Series Maintenance Manual Rev.2...
  • Page 374 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 C Series Maintenance Manual Rev.2...
  • Page 375 3. Apply grease to the Joint #4 reduction gear unit. Grease: SK-1A Grease amount: 20 g Apply 10g of grease to the wave generator. Apply the remaining 10 g to the inner side of the flexspline as shown in the photo. C Series Maintenance Manual Rev.2...
  • Page 376 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 C Series Maintenance Manual Rev.2...
  • Page 377 For details, refer to Installation steps of C8 Maintenance 9.1 Joint #5 – Replacing the Motor and C8 Maintenance 10.1 Joint #6 – Replacing the Motor. 13. Install the removed covers. For details, refer to C8 Maintenance 3. Covers. 14. Perform the calibration. For details, refer to C8 Maintenance 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 378: Joint #4 - Replacing The Timing Belt

    2. Remove the connectors inside the Arm #3 and the air tube (transparent). Connectors: X71, X72, X041, BR041, BR051, PS, BT4, BT51, X141, X151, X161 3. Remove the cable bracket inside the Arm #3. Hexagon socket head cap bolts: 4-M4×10 C Series Maintenance Manual Rev.2...
  • Page 379 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. C8XL: The cable protection tube is used instead of the cable protection sheet. C Series Maintenance Manual Rev.2...
  • Page 380 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. Remove the Joint #4 timing belt. C Series Maintenance Manual Rev.2...
  • Page 381 5. Wrap the cables inside the Arm #4 with a cable protection sheet and install the Arm #4 cable bracket. C8XL: Install the Arm #4 cable bracket on the cable protection tube. Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.0 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 382 BT4, BT51, X141, X151, X161 10. Connect the ground wire terminals inside the Arm #4 to the Arm #4 cable protection bracket. Cross recessed head screws with captive washer: 2-M4×8 Tightening torque: 0.45 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 383 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. C Series Maintenance Manual Rev.2...

  • Page 384: Joint #4 - Replacing The Electromagnetic Brake

    Installation: Joint #4 Electromagnetic brake 1. Mount the Joint #4 electromagnetic brake to the Joint #4 motor unit. For details, refer to C8 Maintenance: 8.1 Joint #4 – Replacing the Motor, Installation steps (2) through (11). C Series Maintenance Manual Rev.2...

  • Page 385: Joint #5

    The process of aligning the two origins is called “Calibration”. Refer to C8 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #5 Motor + Electromagnetic brake Joint #5, #6 Reduction gear unit set Joint #5 Timing belt (Figure: C8-A1401* (C8XL)) C Series Maintenance Manual Rev.2...

  • Page 386: Joint #5 - Replacing The Motor

    The motors are common for Joints #4, #5, and #6. In order to prevent misconnection of the connectors, attach the label for the motor as shown in the photos. Joint #5 motor Locations of the connector labels X152 X052 BT52 _BT52 C Series Maintenance Manual Rev.2...
  • Page 387 (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. C Series Maintenance Manual Rev.2...
  • Page 388 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 Drive boss Pulley C Series Maintenance Manual Rev.2...
  • Page 389 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 C Series Maintenance Manual Rev.2...
  • Page 390 If the screw positions are incorrect or the bushing is not set, it may NOTE  cause damage on the side of the part and may result in the part being unable to be removed. C Series Maintenance Manual Rev.2...
  • Page 391 - 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. C Series Maintenance Manual Rev.2...
  • Page 392 Be careful not to get the cables caught. It may result in cable  breakage. 11. Install the Arm #4 side cover. For details, refer to C8 Maintenance: 3. Covers. 12. Perform the calibration. For details, refer to C8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 393: Joint #5 - Replacing The 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 status. The brake does not work during replacement. Be careful when performing maintenance work. C Series Maintenance Manual Rev.2...
  • Page 394 Hexagon socket head cap bolts: 8-M5×30 C8L, C8XL: Remove the bolts fixing the Arm #4 extension flange, and remove the Joints #5 and #6 reduction gear unit from the Arm #4 extension part. Hexagon socket head cap bolts: 4-M6×20 C Series Maintenance Manual Rev.2...
  • Page 395 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 with care since it is thin and easy to deform. C Series Maintenance Manual Rev.2...
  • Page 396 Tightening torque: 10.0 ± 0.5 N·m Apply proper tension to the Joint #4 timing belt and fix the Joint #4 motor unit. For details, refer to C8 Maintenance 8.1 Joint #4 – Replacing the Motor, Installation steps (6). C Series Maintenance Manual Rev.2...
  • Page 397 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 For details, refer to Installation steps in C8 Maintenance 4.1 Cable Unit. C Series Maintenance Manual Rev.2...

  • Page 398: Joint #5 - Replacing The Timing Belt

    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. C Series Maintenance Manual Rev.2...

  • Page 399: Joint #5 - Replacing The Electromagnetic Brake

    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. C Series Maintenance Manual Rev.2...
  • Page 400 Installation: Joint #5 Electromagnetic brake 1. Mount the Joint #5 electromagnetic brake to the Joint #5 motor unit. For details, refer to C8 Maintenance: 9.1 Joint #5 – Replacing the Motor, Installation steps (2) through (12). C Series Maintenance Manual Rev.2...

  • Page 401: Joint #6

    The process of aligning the two origins is called “Calibration”. Refer to C8 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joints #5, #6 Reduction gear unit set Joint #6 Timing belt Joint #6 Motor + Electromagnetic brake (Figure: C8-A1401* (C8XL)) C Series Maintenance Manual Rev.2...

  • Page 402: Joint #6 - Replacing The Motor

    The motors are common to Joints #4, #5, and #6. In order to prevent misconnection of the connectors, attach the label for the motor as shown in the photos. Joint #6 motor Locations of the connector labels X162 X062 BT62 _BT62 C Series Maintenance Manual Rev.2...
  • Page 403 6. 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) 7. Remove the Joint #6 motor unit. Hexagon socket head cap bolts: 2-M4×15 (with a plain washer) C Series Maintenance Manual Rev.2...
  • Page 404 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 from the Joint #6 motor. Hexagon socket head cap bolts: 2-M4×10 C Series Maintenance Manual Rev.2...
  • Page 405 If the screw positions are incorrect or the bushing is not set, NOTE  it may cause damage on the side of the part and may result in the part being unable to be removed. C Series Maintenance Manual Rev.2...
  • Page 406 - When you replace 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. C Series Maintenance Manual Rev.2...
  • Page 407 Be careful not to get the cables caught. It may result in cable  breakage. 10. Install the Arm #4 side cover. For details, refer to C8 Maintenance: 3. Covers. 11. Perform the calibration. For details, refer toC8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 408: Joint #6 - Replacing The Reduction Gear Unit (Replacing The Joints #5, #6 Reduction Gear Unit Set)

    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. C Series Maintenance Manual Rev.2...

  • Page 409: Joint #6 - Replacing The Electromagnetic Brake

    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. C Series Maintenance Manual Rev.2...
  • Page 410 Installation: Joint #6 Electromagnetic brake 1. Mount the Joint #6 electromagnetic brake to the Joint #6 motor unit. For details, refer to C8 Maintenance: 10.1 Joint #6 – Replacing the Motor, Installation steps (2) through (11). C Series Maintenance Manual Rev.2...

  • Page 411: Replacing The Battery Unit

    NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the battery can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
  • Page 412 Battery unit (Lithium battery) (Two lithium batteries for replacement) Maintenance Parts Battery board 2173216 Cross-point screwdriver (#2) For cross recessed head screws Tools Hexagonal wrench For M4 hexagon socket head cap bolts (width across flats: 3 mm) C Series Maintenance Manual Rev.2...

  • Page 413: Replacing The Battery Unit (Lithium Battery)

    Connect the two new batteries to the connectors of the battery board which are not connected to anything. Remove the old batteries. Hold the board by hand and pull the battery cable upward to remove the connector. Install the battery to the battery box. C Series Maintenance Manual Rev.2...
  • Page 414 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. C Series Maintenance Manual Rev.2...

  • Page 415: Replacing The Battery Board

    Remove the battery connectors. Hold the board by hand and pull the battery cable upward to NOTE  remove the connector. Remove the plate where the battery box is fixed to. Hexagon socket head cap bolts: 2-M4×10 C Series Maintenance Manual Rev.2...
  • Page 416 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 C Series Maintenance Manual Rev.2...
  • Page 417 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. C Series Maintenance Manual Rev.2...

  • Page 418: Replacing The Control Board

    Control board (1, 2) 2138032 Hexagonal wrench For M4 hexagon socket head cap bolts (width across flats: 3 mm) Tools Spanner For spacers (width across flats: 5.5 mm) Cross-point screwdriver For cross recessed head screws C Series Maintenance Manual Rev.2...

  • Page 419: Replacing The Control Board 1

    Be careful not to drop the screws inside the Manipulator while NOTE  removing them. Remove the control board 1 protection plate. Cross recessed head screws with captive washer: M3×6 It is not necessary to remove the spacer from the plate. C Series Maintenance Manual Rev.2...
  • Page 420 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. If the Manipulator is out of position, calibrate all the joints and axes. For details, refer to C8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 421: Replacing The Control Board 2

    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 C Series Maintenance Manual Rev.2...
  • Page 422 Move the Manipulator to two or three points (poses) of the registered points. 7. If the Manipulator is out of position, calibrate all the joints and axes. For details, refer to C8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...

  • Page 423: Replacing The Led Lamp

    LED lamp (Figure: C8-A1401** (C8XL)) Name Qty. Note 1668127 Maintenance Parts LED lamp (Standard, Clean-room models) Tools Cross-point screwdriver (#2) For cross recessed head screws For Protection model, please contact the supplier of your region. C Series Maintenance Manual Rev.2...
  • Page 424 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. Connector: LED 3. Install the Arm #3 cover. For details, refer to C8 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...
  • Page 425 OFF the Controller. The position data will be lost when the cable connector connected to the battery is disconnected. And the EPSON RC+ will display the error message of encoder alarm occurrence when the Controller is turned ON.
  • Page 426 M/C cable Straight R12NZ900SB 10 m (flexible) L-shaped R12NZ900SF Straight R12NZ900YE 15 m L-shaped R12NZ900YD Straight R12NZ900SC 20 m L-shaped R12NZ900SG Hexagonal wrench Tools For M4 hexagon socket head cap bolts (width across flats: 3 mm) C Series Maintenance Manual Rev.2...
  • Page 427 7. If the battery connector (BT1*) was disconnected, calibrate the Joint #1. For details, refer to C8 Maintenance: 16. Calibration. 8. If the Manipulator is off position, calibrate all the joints and axes. For details, refer to C8 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 428 (Figure: C8-A1401** (C8XL)) Name Qty. Note 2177465 (standard, cleanroom models) Maintenance Part 2178399 (protection model) Tool Cross-point screwdriver For cross recessed head screws C Series Maintenance Manual Rev.2...
  • Page 429 Heat sink side Connect the fan connectors. Install the fan cover. Cross recessed head screws with washer: 4-M4×35 Tightening torque: 0.9 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 430 There are two methods to move the Manipulator during calibration. - Releasing the electromagnetic brake and moving the arms manually. For details, refer to the C Series Manual C8 Manipulator 1.5 How to Move Arms with the Electromagnetic Brake. - Moving the Manipulator using Jog & Teach.
  • Page 431  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.
  • Page 432 For details on Jog & Teach, refer to the following manual. EPSON RC+ User’s Guide 5.11.1 Robot Manager Command Tools: Robot Manager: Jog and Teach Page. - For details about the basic orientation, refer to C Series Manual C8 Manipulator 3.7 NOTE ...
  • Page 433 Jog Motion Setting of the jog motion is required in some calibration procedures. Select EPSON RC+ menu-[Tools]-[Robot Manager] and select the [Jog & Teach] page. The panel, window, and page above are indicated as [Jog & Teach] in the calibration procedures.
  • Page 434 “Brake OFF, *” does not work (* is an axis number to calibrate.), go through the steps (4) and (5) now. Then, [Jog & Teach] panel and “Brake OFF, *” will be available. Move the arm you want to calibrate to the position of the calibration mark. C Series Maintenance Manual Rev.2...
  • Page 435 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. C Series Maintenance Manual Rev.2...
  • Page 436 If accuracy is inadequate, it is necessary to re-calibrate the origin using a different pose (point). You must set the pose (point) again if the Manipulator does not move back to the original position after re-calibration. C Series Maintenance Manual Rev.2...
  • Page 437 As a rough indication, perform the overhaul (parts replacement) before reaching 20,000 operation hours of the Manipulator. The operation hours can be checked in [Controller Status Viewer] dialog - [Motor On Hours]. For details, refer to C8 Maintenance 2.2 Overhaul. C Series Maintenance Manual Rev.2...
  • Page 438 Regarding purchase of grease and other materials, please contact the following manufacturers. If there is anything unclear, please contact the supplier of your region Product name Manufacturer Harmonic Grease SK-1A Harmonic Drive Systems https://www.harmonicdrive.net/ Harmonic Grease SK-2 Inc. https://www.chemours.com/en/brands-and- Chemours Krytox®GPL-224 products 1207B ThreeBond Co.,Ltd https://www.threebond.com LOCTITE641 LOCTITE https://loctite.com/ C Series Maintenance Manual Rev.2...
  • Page 439 Round For Joint #5 1673978 Round 2177465 Standard/Clean-room model Fan (C8XL only) 2178399 Protection model Heat radiation For heat radiation block 1694609 5.1, 5.2 sheet For Motor 1655043 Joint #1, 2 common 5.1, 5.2, 6.2 C Series Maintenance Manual Rev.2...
  • Page 440 1665247 Maintenance gasket 1665248 Sub plate gasket 1665246 Base Installation gasket 1668377 Clean-room model Gasket For Heat sink 1694610 Protection model Seal washer M4 (for sub plate) 1665882 Protection model Air plug For M6 1657011 C Series Maintenance Manual Rev.2...
  • Page 441 R12NZ900LU ø6 straight R12NZ900LV Fittings for customer use ø6 elbow R12NZ900LW Standard user connector kit D-sub R12NZ900LX D-sub R12NZ900LY Waterproof user connector kit Ethernet R12NZ900LZ * Refer to each manipulator’s page of C series manual. C Series Maintenance Manual Rev.2...
  • Page 442 C8 Maintenance 18. C8 Option Parts List C Series Maintenance Manual Rev.2...
  • Page 443 C12 Maintenance This volume contains maintenance procedures with safety precautions for C12 series Manipulators.
  • Page 445 ■ When connecting / replacing the brake release unit or the external short connector, turn OFF the power to the Controller and the brake release unit. Connecting or disconnecting the connector while the power is ON may result in electrical shock. C Series Maintenance Manual Rev.2...
  • Page 446 ■ The Manipulator arms may become hot after the Manipulator operation due to heat generation of the motors. Be careful when performing maintenance. ■ When operating maintenance of manipulator, secure about 50 cm of empty space around the manipulator. C Series Maintenance Manual Rev.2...
  • Page 447 9 months (2250 h) √ √ 10 months (2500 h) √ 11 months (2750 h) √ 12 months (3000 h) √ √ √ √ 13 months (3250 h) √ √ 20000 h h = hour C Series Maintenance Manual Rev.2...
  • Page 448 Joint #1 to 6 break √ √ √ √ √ Check whether unusual Whole √ √ √ √ √ sound or vibration occurs. Check if the fan is running √ √ √ √ √ (C8-A1401***(C8XL) only) C Series Maintenance Manual Rev.2...
  • Page 449 If there is something wrong, contact the supplier. Check that the fan is running when in MOTOR Check if the fan is running (C8-A1401***(C8XL) only) If the fan is not running when in MOTOR ON, contact the supplier. C Series Maintenance Manual Rev.2...
  • Page 450 / deceleration in continuous operation) applied on the Manipulator. NOTE For EPSON RC+ 7.0 the recommended replacement time for the parts subject to  maintenance (motors, reduction gear units, and timing belts) can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
  • Page 451 The Manipulator operation hours can be checked in [Controller Status Viewer] dialog box- [Motor On Hours]. (1) Select EPSON RC+ menu-[Tools]-[Controller] to open the [Controller Tools] dialog box. (2) Click the <View Controller Status> button to open the [Browse For Folder] dialog box.
  • Page 452 As a rough indication, perform greasing at the same timing as overhaul. 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. C Series Maintenance Manual Rev.2...
  • Page 453 Do not use any tool to install and remove the grease nipple and grease line extension jig. NOTE  Always handle them directly by your hand. If the grease nipple or grease line extension jig is installed or removed with a tool such as wrench, they may be damaged. C Series Maintenance Manual Rev.2...
  • Page 454 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 details, refer to C12 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...
  • Page 455 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. C Series Maintenance Manual Rev.2...
  • Page 456 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. C Series Maintenance Manual Rev.2...
  • Page 457 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 damaged or deteriorated, replace it with a new one. C Series Maintenance Manual Rev.2...
  • Page 458 4. Remove the grease nipple from the Joint #5 grease inlet. 5. Attach the grease plug to the Joint #5 grease inlet. If the grease plug is damaged or deteriorated, replace it with a new one. C Series Maintenance Manual Rev.2...
  • Page 459 Joint #5 (SK-1A). Remove the grease nipple from the Joint #6 grease inlet. Attach the grease plug to the Joint #6 grease inlet. If the grease plug is damaged or deteriorated, replace it with a new one. C Series Maintenance Manual Rev.2...
  • Page 460 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. Install the Arm #5 grease inlet cover. Hexagon socket head cap bolts: 4-M3×6 Tightening torque: 2.0 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 461 Divide the number of times to fasten the bolts into Bolt hole two or three and fasten the bolts securely with a hexagonal wrench. Then, use a torque wrench to fasten the bolts with tightening torques shown in the table above. C Series Maintenance Manual Rev.2...
  • Page 462 +Electromagnetic brake Joint #6 Timing belt Joint #6 Motor +Electromagnetic brake Joint #4 Joint #5 Timing belt Joint #4 Reduction gear unit Motor Joint #4 Electromagnetic brake Battery Battery board Control board 2 Control board 1 C Series Maintenance Manual Rev.2...
  • Page 463 Arm #1 side cover Arm #1 maintenance cover Arm #3 maintenance Connector cover Arm #1 plate Arm #1 side cover center cover Base cover Connector sub plate Cable downward model Connector plate Connector sub plate Base cover C Series Maintenance Manual Rev.2...
  • Page 464 For M3 hexagon socket head cap width across flats: 2.5 mm Hexagonal bolts Tools wrench For M4 hexagon socket head cap width across flats: 3 mm bolts Cross-point screwdriver (#2) For cross recessed screws C Series Maintenance Manual Rev.2...
  • Page 465 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 NOTE Be careful not to get the cables caught between the cover and the Manipulator.  C Series Maintenance Manual Rev.2...
  • Page 466 Be careful not to get the cables caught between  the cover and the Manipulator body. When replacing the side cover for the right side of the Arm #1, attach the electrical shock warning label to the place indicated in the photo. C Series Maintenance Manual Rev.2...
  • Page 467 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 NOTE  Be careful not to get the cables caught between the cover and the Manipulator body. C Series Maintenance Manual Rev.2...
  • Page 468 Install the Arm #3 maintenance cover to the Manipulator. Cross recessed truss head small screws: 4-M4×8 Tightening Torque: 0.9 ± 0.1 N·m NOTE  Be careful not to get the cables caught between the cover and the Manipulator body. C Series Maintenance Manual Rev.2...
  • Page 469 2. Remove the connectors. RJ45 connector (left): Remove the RJ45 connector from the connector on the cover. F-sensor connector (right): Open the two plastic clips of the connector on the cover and pull out the metallic connector. C Series Maintenance Manual Rev.2...
  • Page 470 Install the Arm #4 maintenance cover to the Manipulator. Cross recessed truss head small screws: 4-M4×10 Tightening torque: 0.9 ± 0.1 N·m NOTE  Be careful not to get the cables caught between the cover and the Manipulator body. C Series Maintenance Manual Rev.2...
  • Page 471 Hexagon socket head cap bolts: 2-M4×10 Installation Install the D-sub attachment. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m NOTE Be careful not to get the cables caught between the cover and the Manipulator body.  C Series Maintenance Manual Rev.2...
  • Page 472 Install the base cover to the Manipulator. Hexagon socket head cap bolts: 8-M4×10 Tightening Torque: 4.0 ± 0.2 N·m NOTE Be careful not to get the cables caught between the cover and the Manipulator body.  C Series Maintenance Manual Rev.2...
  • Page 473 4. Remove the bolts, and then remove the base cover and the base rear gasket. Hexagon socket head cap bolts: 11-M4×10 NOTE  The gasket has the spacers. Be careful not to lose them. C Series Maintenance Manual Rev.2...
  • Page 474  sink and the base cover. Install the heat sink. Hexagon socket head cap bolts: 4-M4×15 Tightening torque: 4.0 ± 0.2 N·m Install the fan. For details, refer to C12 Maintenance 15. Replacing the Fan. C Series Maintenance Manual Rev.2...
  • Page 475 Install the base maintenance cover to the Manipulator. Hexagon socket head cap bolts: 6-M4×10 Tightening Torque: 0.9 ± 0.1 N·m NOTE  Be careful not to get the cables caught between the cover and the Manipulator body. C Series Maintenance Manual Rev.2...
  • Page 476 4. Remove the bolts, and then remove the connecter plate. and the base rear gasket. Hexagon socket head cap bolts: 11-M4×10 NOTE  The gasket has the spacers. Be careful not to lose them. C Series Maintenance Manual Rev.2...
  • Page 477 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 C12 Maintenance 15. Replacing the Fan. C Series Maintenance Manual Rev.2...
  • Page 478 Remove the bolts and then remove the connector plate. Hexagon socket head cap bolts: 8-M4×10 Installation Install the connector plate to the Manipulator. Hexagon socket head cap bolts: 8-M4×10 Tightening Torque: 4.0 ± 0.2 N·m C Series Maintenance Manual Rev.2...
  • Page 479 Install the connector sub plate to the Manipulator. Hexagon socket head cap bolts: 4-M4×10 Tightening Torque: 4.0 ± 0.2 N·m NOTE  Be careful not to get the cables caught between the cover and the Manipulator body. C Series Maintenance Manual Rev.2...
  • Page 480 When routing the cables, observe the cable locations after removing the cover. Be sure to place the cables back to their original locations. C Series Maintenance Manual Rev.2...
  • Page 481 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. C Series Maintenance Manual Rev.2...
  • Page 482 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. C Series Maintenance Manual Rev.2...
  • Page 483 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 the both ends of the connector and pull it out. C Series Maintenance Manual Rev.2...
  • Page 484 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 interference. Hexagon socket head cap bolts: 2-M3×6 C Series Maintenance Manual Rev.2...
  • Page 485 17. Disconnect the battery connector. NOTE 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 C Series Maintenance Manual Rev.2...
  • Page 486 Protect the connectors with masking tapes. - To protect the connector’s clips - To avoid adherence of cable grease NOTE Disconnect the connectors one by one in order from the smallest  connector to the largest one. C Series Maintenance Manual Rev.2...
  • Page 487 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. C Series Maintenance Manual Rev.2...
  • Page 488 35. Disconnect the connectors inside the Arm #3. Connectors: X141, X151, X161, BR041, BR051, X041, X71, X72, PS, LED, BT51, BT4 (Hold the clip to remove.) 36. Remove the connector connected to the control board 2. Connector: GS02 C Series Maintenance Manual Rev.2...
  • Page 489 Hexagon socket head cap bolts: 2-M4×10 40. Cut off the wire tie that binds the cable protection coils inside the Arm 41. Disconnect the cables from the Arm #3 side to the Arm #2 side. C Series Maintenance Manual Rev.2...
  • Page 490 44. Remove the Arm #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 C Series Maintenance Manual Rev.2...
  • Page 491 C12 Maintenance: 10.1 Joint #6 - Replacing the Motor, Removal steps (4) to (7). The air tube fittings removed together with the Joint #5 motor unit will be used again. Be careful not to lose them. C Series Maintenance Manual Rev.2...
  • Page 492 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) C Series Maintenance Manual Rev.2...
  • Page 493 The screws and nuts will be used again for fixing the connector. Be careful not to lose them. 4. Disconnect the following connectors to separate the cables. Connectors: X051, X061, X151, X161, XGND, BR051, BR061, BT51, BT61, X71, X72, SW1 C Series Maintenance Manual Rev.2...
  • Page 494 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/yellow) C Series Maintenance Manual Rev.2...
  • Page 495 Silicone tube is provided. Leave out the silicone tube on the Arm #4 side. Pass the following cables through the silicone tube: Ethernet cable, X052/X062 cable, and ground wire (green/yellow) that have been passed from the Arm #3 side. C Series Maintenance Manual Rev.2...
  • Page 496 Hold the D-sub connector between the D-sub attachment of the Arm #4 and the D sub connector fixing plate, and fix them with the locking screws removed in step 3 above. (The nuts and washers are not used.) C Series Maintenance Manual Rev.2...
  • Page 497 For details, refer to C12 Maintenance: 9.1 Joint #5 - Replacing the Motor, Installation steps (4) to (8), and C12 Maintenance: 10.1 Joint #6 - Replacing the Motor, Installation steps (4) and (7). NOTE  Use the air tube fittings removed in the cable removal steps again. C Series Maintenance Manual Rev.2...
  • Page 498 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. C Series Maintenance Manual Rev.2...
  • Page 499 Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m NOTE When installing the Arm #3 cable fixing plate, see the picture on  the right side and push the plate to the arrow direction. C Series Maintenance Manual Rev.2...
  • Page 500 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. C Series Maintenance Manual Rev.2...
  • Page 501 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 C Series Maintenance Manual Rev.2...
  • Page 502 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-M4×10 Tightening torque: 4.0 ± 0.2 N·m C Series Maintenance Manual Rev.2...
  • Page 503 41. Fix the cables to the Arm #1. Check that the silicone tube is not shifted away from the fixed position. Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.4 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 504 (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. C Series Maintenance Manual Rev.2...
  • Page 505 49. Remove the Arm #1 cable fixing plate fixed temporarily, and fix another cable bracket (C1)-B. Removing Arm #1 cable fixing plate: Hexagon socket head cap bolts: 2-M4×10 Fixing cable bracket (C1)-B: Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.4 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 506 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 side 55. Connect the battery connectors. Connectors: CN3, CN6 C Series Maintenance Manual Rev.2...
  • Page 507 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 C Series Maintenance Manual Rev.2...
  • Page 508 NOTE 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 Manipulator (indicated with arrows in the photo). C Series Maintenance Manual Rev.2...
  • Page 509 Arm #1 side covers (both sides) Arm #1 center cover Base maintenance cover Connector plate (M/C cable backward) For details, refer to C12 Maintenance: 3. Covers. 72. Perform calibration. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 510 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. C Series Maintenance Manual Rev.2...
  • Page 511 7. Disconnect the cable 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.) 8. Disconnect the following connectors. RJ45 connector (Hold the clip to remove.) C Series Maintenance Manual Rev.2...
  • Page 512 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). C Series Maintenance Manual Rev.2...
  • Page 513 7. Install the D-sub connectors according to the marks on the connector plate. 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 C Series Maintenance Manual Rev.2...
  • Page 514 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. Calibration. C Series Maintenance Manual Rev.2...
  • Page 515 C12 Maintenance 4. Cable Unit 4.2 Connector Pin Assignment 4.2.1 Signal Cable C Series Maintenance Manual Rev.2...
  • Page 516 C12 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...
  • Page 517 C12 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...
  • Page 518 C12 Maintenance 4. Cable Unit 4.2.2 Power Cable C Series Maintenance Manual Rev.2...
  • Page 519 C12 Maintenance 4. Cable Unit C Series Maintenance Manual Rev.2...
  • Page 520 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 Black White Green Yellow Brown Blue Violet Azure Orange Gray Pink C Series Maintenance Manual Rev.2...
  • Page 521 Joint #1 Reduction gear unit Joint #1 Timing belt Joint #1 Motor Maintenance procedures differ depending on the installation type of the M/C cable. 5.1 M/C Cable Backward (Joint #1) 5.2 M/C Cable Downward (Joint #1) C Series Maintenance Manual Rev.2...
  • Page 522 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. C Series Maintenance Manual Rev.2...
  • Page 523 Be careful not to tear the heat radiation sheet. 5. Remove the brake power supply. Cross recessed head screws with washer: 2-M3×6 6. Remove the Joint #1 brake plate from the Joint #1 motor unit. Hexagon socket head cap bolts: 3-M4×20 C Series Maintenance Manual Rev.2...
  • Page 524 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. C Series Maintenance Manual Rev.2...
  • Page 525 When securing the motor unit loosely, 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. C Series Maintenance Manual Rev.2...
  • Page 526 As the screw is tightened, the Joint #1 motor unit will be pulled and tension will be applied. Install the heat radiation block For details, refer to the Heat radiation block Installation C Series Maintenance Manual Rev.2...
  • Page 527 For details, refer to C12 Maintenance: 3. Covers. 8. Mount the base maintenance cover. For details, refer to C12 Maintenance: 3. Covers. 9. Calibrate the Joint #1. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 528 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. C Series Maintenance Manual Rev.2...
  • Page 529 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. NOTE Do not tighten the wire tie too much. It may result in cable  breakage. C Series Maintenance Manual Rev.2...
  • Page 530 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. C Series Maintenance Manual Rev.2...
  • Page 531 Ground wire RJ45 connector F-sensor connector 4. Remove the Joint #1 motor unit. For details, refer to C12 Maintenance 5.1.1 Joint #1 – Replacing the Motor Unit (M/C Cable Backward), Removal steps (6) to (7). C Series Maintenance Manual Rev.2...
  • Page 532 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 C Series Maintenance Manual Rev.2...
  • Page 533 Have at least two workers so that one can support the Manipulator while CAUTION the other worker is removing the bolts. 14. Remove the Joint #1 reduction gear unit. Hexagon socket head cap bolts: 12-M6×50 C Series Maintenance Manual Rev.2...
  • Page 534 Protect the connectors with masking tapes. - To protect the connector’s clips - To avoid adherence of cable grease NOTE Disconnect the cables one by one in order from the largest  connector to the smallest one. C Series Maintenance Manual Rev.2...
  • Page 535 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 socket head cap bolts: 2-M3×6 Tightening torque: 2.0 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 536 14. Install 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 Timing Belt (M/C Cable Backward), Installation steps (6) to (14). C Series Maintenance Manual Rev.2...
  • Page 537 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. C Series Maintenance Manual Rev.2...
  • Page 538 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 the both ends of the connector and pull it out. C Series Maintenance Manual Rev.2...
  • Page 539 Ground wire (green/yellow) terminal (×1) indicated by an arrow Cross recessed head screws with washer: 3-M4×8 NOTE Positions of the ground wire (green/yellow) terminals may  differ from the photo. Check the positions of the terminals before removing them. C Series Maintenance Manual Rev.2...
  • Page 540 Installation: Joint #1 Timing belt (M/C Cable Downward) NOTE When tightening hexagon socket head cap bolts, refer to the 2.4 Tightening Hexagon Socket  Head Cap Bolts. 1. Pass the cables and air tubes to the Joint #1 timing belt. C Series Maintenance Manual Rev.2...
  • Page 541 Make sure to install them to the two screw holes on the backside of the Manipulator (as indicated by arrows in the photo). 6. Mount the ground wire plate (M/C cable backward). Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m C Series Maintenance Manual Rev.2...
  • Page 542 For details, refer to C12 Maintenance: 3 Covers. 13. Install the base maintenance cover. For details, refer to C12 Maintenance: 3 Covers. 14. Calibrate the Joint #1. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 543 Removal steps (1) to (6). NOTE  Do not disconnect the connector BT1. If the connector is disconnected, perform calibration. 2. Remove the Joint #1 brake from the brake plate. Hexagon socket head cap bolts: 3-M4×25 C Series Maintenance Manual Rev.2...
  • Page 544 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). NOTE  If you disconnected the connector BT1 in the removal steps, perform calibration. C Series Maintenance Manual Rev.2...
  • Page 545 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. C Series Maintenance Manual Rev.2...
  • Page 546 The heat radiation block, the heat radiation sheet, and the bolts will be used again. NOTE  Be careful not to lose them. Be careful not to tear the heat radiation sheet. Remove the brake power supply. Cross recessed head screws with washer: 2-M3×6 C Series Maintenance Manual Rev.2...
  • Page 547 Hexagon socket head cap bolts: 3-M4×20 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. C Series Maintenance Manual Rev.2...
  • Page 548 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. Calibrate the Joint #1. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 549 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. C Series Maintenance Manual Rev.2...
  • Page 550 Cross recessed head screws with washer : 9-M4×8, 2-M3×6 Remove the Joint #1 reduction gear unit. For details, refer to C12 Maintenance 5.1.2 Joint #1 - Replacing the Reduction Gear Unit (M/C Cable Backward), Removal steps (4) to (14). C Series Maintenance Manual Rev.2...
  • Page 551 Cross recessed head screws with washer: 9-M4×8, 2-M3×6 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). C Series Maintenance Manual Rev.2...
  • Page 552 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. C Series Maintenance Manual Rev.2...
  • Page 553 D-sub connector For details, refer to C12 Maintenance: 5.1.3 Joint #1-Replacing the Timing Belt (M/C Cable Backward), Removal steps (4) to (5), and (7). Remove the brake power supply. Cross recessed head screws with washer: 2-M3×6 C Series Maintenance Manual Rev.2...
  • Page 554 Hexagon socket head cap bolts: 2-M4×12 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) to (7). Remove the Joint #1 motor unit. C Series Maintenance Manual Rev.2...
  • Page 555 Install the ground wire to each connector. To connect the ground wire, insert in while holding the connector by hand. 6. Connect the M/C cable connectors. Connector: X11, X12, X14, BR010, BR011, X010, X020, X040, LED, GS01, BT1 C Series Maintenance Manual Rev.2...
  • Page 556 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 details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 557 Removal steps (1) to (6). NOTE  Do not disconnect the connector BT1. If the connector is disconnected, perform calibration. 2. Remove the Joint #1 brake from the brake plate. Hexagon socket head cap bolts: 3-M4×25 C Series Maintenance Manual Rev.2...
  • Page 558 Connector plate (M/C cable downward) Base cover (M/C cable downward) Base maintenance cover For details, refer to C12 Maintenance: 3 Covers. NOTE  If you disconnected the connector BT1 in the removal steps, perform calibration. C Series Maintenance Manual Rev.2...
  • Page 559 The process of aligning the two origins is called “Calibration”. Refer to C12 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #2 Reduction gear unit Joint #2 Timing belt Joint #2 Motor + Electromagnetic brake C Series Maintenance Manual Rev.2...
  • Page 560 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. C Series Maintenance Manual Rev.2...
  • Page 561 Manipulator. Be very careful when moving the Manipulator. CAUTION 3. Turn OFF the Controller power. 4. Remove the Arm #1 center cover and the Arm #1 side cover. For details, refer to C12 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...
  • Page 562 ■ 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. WARNING C Series Maintenance Manual Rev.2...
  • Page 563 (D-cut part of the motor shaft × 2) B: Pulley and drive boss screws Do not remove these screws. C: Bushing Pulley Drive boss 10. Remove the Joint #2 electromagnetic brake. Hexagon socket set screws: 2-M6×6 (with a brass bushing) C Series Maintenance Manual Rev.2...
  • Page 564 C12 Maintenance 6. Joint #2 11. Remove the motor plate from the Joint #2 motor. Hexagon socket head cap bolts: 4-M6×20 C Series Maintenance Manual Rev.2...
  • Page 565 If the screw positions are incorrect or the bushing is not set, it NOTE  may cause damage on the side of the brake and may result in the part being unable to be removed. C Series Maintenance Manual Rev.2...
  • Page 566 If the belt is too loose or too tight, it will not have proper tension. Hexagon socket set screws: 3-M5×25 (with a plain washer) C Series Maintenance Manual Rev.2...
  • Page 567 Tension is applied by pushing the set screw (M6×25) with the rubber. 7. Install the brake power supply. Cross recessed head screws with captive washer: 2-M3×6 Tightening torque: 0.45 ± 0.1 N·m 8. Connect the following connectors. Connectors: X121, X021, BT2, BR021 C Series Maintenance Manual Rev.2...
  • Page 568 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. C Series Maintenance Manual Rev.2...
  • Page 569 There is a brass bushing on one of the set screws. Be careful not to lose it. Remove the key from the shaft. The key will be used again. Be careful not to lose it. C Series Maintenance Manual Rev.2...
  • Page 570 If the wave generator unit does not come off easily, set the pulley 2 as shown in the photo to the shaft and pull out the parts. Wipe grease on the part while removing it. C Series Maintenance Manual Rev.2...
  • Page 571 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. C Series Maintenance Manual Rev.2...
  • Page 572 Install the reduction gear unit to match the screws and the clearance holes. Grease the inner side of the flexspline. Grease: SK-1A Grease amount: 102g Insert the wave generator to the reduction gear unit and fix it. C Series Maintenance Manual Rev.2...
  • Page 573 Hexagon socket head cap bolts: 16-M6×35 (with a plain washer) Tightening torque: 18.0 ± 0.9 N·m After fixing the Arm, check that there is no backlash or misalignment on the reduction gear unit by moving the Arm by hand. C Series Maintenance Manual Rev.2...
  • Page 574 For details, refer to C12 Maintenance 11.2 Replacing the Battery Board, Installation steps (2) to (5). 12. Install the Joint #2 timing belt. For details, refer to C12 Maintenance 6.3 Joint #2 – Replacing the Timing Belt, Installation steps (1) to (2). C Series Maintenance Manual Rev.2...
  • Page 575 Pass the timing belt to the pulley 2 first, then, place it to the pulley 1. 2. Secure the Joint #2 motor unit. For details, refer to C12 Maintenance: 6.1 Joint #2 – Replacing the Motor, Installation steps (5) to (6) and (10) to (11). C Series Maintenance Manual Rev.2...
  • Page 576 Installation: Joint #2 Electromagnetic brake 1. Mount the Joint #2 electromagnetic brake to the Joint #2 motor unit. For details, refer to C12 Maintenance: 6.1 Joint #2 – Replacing the Motor, Installation steps (2) through (11). C Series Maintenance Manual Rev.2...
  • Page 577 The process of aligning the two origins is called “Calibration”. Refer to C12 Maintenance 16. Calibration and perform the calibration after the parts replacement. Joint #3 Reduction gear unit Joint #3 Timing belt Joint #3 Motor + Electromagnetic brake C Series Maintenance Manual Rev.2...
  • Page 578 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. C Series Maintenance Manual Rev.2...
  • Page 579 For details, refer to C12 Maintenance: 3. Covers. 5. Disconnect the following connectors. Connector: X131, X031, BT3, BR031 (Hold the clip to remove.) NOTE  Be careful not to drop the removed connectors inside the Arm. C Series Maintenance Manual Rev.2...
  • Page 580 ■ 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. WARNING Be sure to do the Removal steps 1 and 2 before loosening the bolts. C Series Maintenance Manual Rev.2...
  • Page 581 Hexagon socket set screws: 2-M5×6 (with a 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 C Series Maintenance Manual Rev.2...
  • Page 582 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 C Series Maintenance Manual Rev.2...
  • Page 583 NOTE 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. C Series Maintenance Manual Rev.2...
  • Page 584 If the belt is too loose or too tight, it will not have proper tension. Hexagon socket set screws: 3-M4×20 (with a plain washer) C Series Maintenance Manual Rev.2...
  • Page 585 8. Connect the following connectors. Connector: X131, X031, BT3, BR031 9. Install the Arm #2 side cover. For details, refer to C12 Maintenance: 3. Covers. 10. Perform the calibration. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 586 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. C Series Maintenance Manual Rev.2...
  • Page 587 CAUTION ■ 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. C Series Maintenance Manual Rev.2...
  • Page 588 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. C Series Maintenance Manual Rev.2...
  • Page 589 Install the reduction gear unit to match the screws and the clearance holes. Grease the inner side of the flexspline. Grease: SK-1A Grease amount: 26 g Insert the wave generator to the reduction gear unit and fix it. C Series Maintenance Manual Rev.2...
  • Page 590 Hexagon socket head cap bolts: 16-M4×25 (with a plain washer) Tightening torque: 5.5 ± 0.2 N·m After fixing the Arm, check that there is no backlash or misalignment on the reduction gear unit by moving the Arm by hand. C Series Maintenance Manual Rev.2...
  • Page 591 10. Install the Joint #3 timing belt. For details, refer to C12 Maintenance 7.3 Joint #2 – Replacing the Timing Belt, Installation steps (1) to (2). C Series Maintenance Manual Rev.2...
  • Page 592 Pass 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 C12 Maintenance: 7.1 Joint #3 – Replacing the Motor, Installation steps (5) to (6) and (9) to (10). C Series Maintenance Manual Rev.2...
  • Page 593 Installation: Joint #3 Electromagnetic brake 1. Mount the Joint #3 electromagnetic brake to the Joint #3 motor unit. For details, refer to C12 Maintenance: 7.1 Joint #3 – Replacing the Motor, Installation steps (2) through (10). C Series Maintenance Manual Rev.2...
  • Page 594 The process of aligning the two origins is called “Calibration”. Refer to C12 Maintenance: 16. Calibration and perform the calibration after the parts replacement. Joint #4 Timing belt Joint #4 Motor Joint #4 Reduction gear unit Joint #4 Electromagnetic brake C Series Maintenance Manual Rev.2...
  • Page 595 The Joints #5 and #6 motors have an identification label for preventing misconnection of the connectors. The label is not necessary for the Joint #4 motor. (There is no connector identification label for the Joint #4.) C Series Maintenance Manual Rev.2...
  • Page 596 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 small plain washer) C Series Maintenance Manual Rev.2...
  • Page 597 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 motor plate from the Joint #4 motor. Hexagon socket head cap bolts: 2-M4×10 C Series Maintenance Manual Rev.2...
  • Page 598 NOTE 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. C Series Maintenance Manual Rev.2...
  • Page 599 - 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. C Series Maintenance Manual Rev.2...
  • Page 600 10. Install the following cover. Arm #3 cover Arm #3 maintenance cover Arm #2 side cover For details, refer to C12 Maintenance: 3. Covers. 11. Calibrate the Joint #4. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 601 6. Remove the bolts fixing the J4 flange, and remove the Arm #4 from the Arm #3. To remove all bolts, change the position of the Joint #4 by rotating Hexagon socket head cap bolts: 8-M5×30 C Series Maintenance Manual Rev.2...
  • Page 602 The J4 sleeve is attached by gasket and may not be removed easily. If the part cannot be removed, pull the sleeve while rotating it. Handle the sleeve with care since it is thin and easy to deform. C Series Maintenance Manual Rev.2...
  • Page 603 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 C Series Maintenance Manual Rev.2...
  • Page 604 3. Apply grease to the Joint #4 reduction gear unit. Grease: SK-1A Grease amount: 20 g Apply 10g of grease to the wave generator. Apply the remaining 10 g to the inner side of the flexspline as shown in the photo. C Series Maintenance Manual Rev.2...
  • Page 605 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 C Series Maintenance Manual Rev.2...
  • Page 606 For details, refer to Installation steps of C12 Maintenance: 9.1 Joint #5 – Replacing the Motor and C12 Maintenance: 10.1 Joint #6 – Replacing the Motor. 13. Install the removed covers. For details, refer to C12 Maintenance: 3. Covers. 14. Perform the calibration. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 607 2. Remove the connectors inside the Arm #3 and the air tube (transparent). Connectors: X71, X72, X041, BR041, BR051, PS, BT4, BT51, X141, X151, X161 3. Remove the cable bracket inside the Arm #3. Hexagon socket head cap bolts: 4-M4×10 C Series Maintenance Manual Rev.2...
  • Page 608 9. Remove the Arm #4 cable bracket 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. C Series Maintenance Manual Rev.2...
  • Page 609 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. Remove the Joint #4 timing belt. C Series Maintenance Manual Rev.2...
  • Page 610 5. Wrap the cables inside the Arm #4 with a cable protection sheet and install the Arm #4 cable bracket. Install the Arm #4 cable bracket on the cable protection tube. Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.0 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 611 BT4, BT51, X141, X151, X161 10. Connect the ground wire terminals inside the Arm #4 to the Arm #4 cable protection bracket. Cross recessed head screws with captive washer: 2-M4×8 Tightening torque: 0.45 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 612 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. C Series Maintenance Manual Rev.2...
  • Page 613 Installation: Joint #4 Electromagnetic brake 1. Mount the Joint #4 electromagnetic brake to the Joint #4 motor unit. For details, refer to C12 Maintenance: 8.1 Joint #4 – Replacing the Motor, Installation steps (2) through (11). C Series Maintenance Manual Rev.2...
  • Page 614 The process of aligning the two origins is called “Calibration”. Refer to C12 Maintenance: 16. Calibration and perform the calibration after the parts replacement. Joint #5 Motor + Electromagnetic brake Joints #5, #6 Reduction gear unit set Joint #5 Timing belt C Series Maintenance Manual Rev.2...
  • Page 615 The motors are common for Joints #4, #5, and #6. In order to prevent misconnection of the connectors, attach the label for the motor as shown in the photos. Joint #5 motor Locations of the connector labels X152 X052 BT52 _BT52 C Series Maintenance Manual Rev.2...
  • Page 616 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 remove the belt. Hexagon socket head cap bolts: 2-M4×15 (with a plain washer) C Series Maintenance Manual Rev.2...
  • Page 617 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 Drive boss Pulley C Series Maintenance Manual Rev.2...
  • Page 618 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 C Series Maintenance Manual Rev.2...
  • Page 619 If the screw positions are incorrect or the bushing is not set, it may NOTE  cause damage on the side of the part and may result in the part being unable to be removed. C Series Maintenance Manual Rev.2...
  • Page 620 - 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. C Series Maintenance Manual Rev.2...
  • Page 621 Be careful not to get the cables caught. It may result in cable  breakage. 11. Install the Arm #4 side cover. For details, refer to C12 Maintenance: 3. Covers. 12. Perform the calibration. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 622 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. C Series Maintenance Manual Rev.2...
  • Page 623 Remove the bolts fixing the Arm #4 extension flange, and remove the Joints #5 and #6 reduction gear unit from the Arm #4 extension part. Hexagon socket head cap bolts: 4-M6×20 6. Remove the Arm #4 extension flange. Hexagon socket head cap bolts: 12-M3×18 C Series Maintenance Manual Rev.2...
  • Page 624 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 For details, refer to Installation steps in C12 Maintenance: 4.1 Cable Unit. C Series Maintenance Manual Rev.2...
  • Page 625 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. C Series Maintenance Manual Rev.2...
  • Page 626 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. C Series Maintenance Manual Rev.2...
  • Page 627 Installation: Joint #5 Electromagnetic brake 1. Mount the Joint #5 electromagnetic brake to the Joint #5 motor unit. For details, refer to C12 Maintenance: 9.1 Joint #5 – Replacing the Motor, Installation steps (2) through (12). C Series Maintenance Manual Rev.2...
  • Page 628 The process of aligning the two origins is called “Calibration”. Refer to C12 Maintenance: 16. Calibration and perform the calibration after the parts replacement. Joints #5, #6 Reduction gear unit set Joint #6 Timing belt Joint #6 Motor + Electromagnetic brake C Series Maintenance Manual Rev.2...
  • Page 629 The motors are common to Joints #4, #5, and #6. In order to prevent misconnection of the connectors, attach the label for the motor as shown in the photos. Joint #6 motor Locations of the connector labels X162 X062 BT62 _BT62 C Series Maintenance Manual Rev.2...
  • Page 630 6. 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) 7. Remove the Joint #6 motor unit. Hexagon socket head cap bolts: 2-M4×15 (with a plain washer) C Series Maintenance Manual Rev.2...
  • Page 631 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 from the Joint #6 motor. Hexagon socket head cap bolts: 2-M4×10 C Series Maintenance Manual Rev.2...
  • Page 632 NOTE 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. C Series Maintenance Manual Rev.2...
  • Page 633 - When you replace 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. C Series Maintenance Manual Rev.2...
  • Page 634 Be careful not to get the cables caught. It may result in cable  breakage. 10. Install the Arm #4 side cover. For details, refer to C12 Maintenance: 3. Covers. 11. Perform the calibration. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 635 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. C Series Maintenance Manual Rev.2...
  • Page 636 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. C Series Maintenance Manual Rev.2...
  • Page 637 Installation: Joint #6 Electromagnetic brake 1. Mount the Joint #6 electromagnetic brake to the Joint #6 motor unit. For details, refer to C12 Maintenance: 10.1 Joint #6 – Replacing the Motor, Installation steps (2) through (11). C Series Maintenance Manual Rev.2...
  • Page 638 Controller is energized. If warnings of voltage reduction occur, replace the lithium metal battery even if it has not reached the above product life. NOTE For the EPSON RC+ 7.0 the recommended replacement time for the battery can be  checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
  • Page 639 Battery unit (Lithium battery) Maintenance Parts (Two lithium batteries for replacement) Battery board 2173216 Cross-point screwdriver (#2) For cross recessed head screws Tools Hexagonal wrench For M4 hexagon socket head cap bolts (width across flats: 3 mm) C Series Maintenance Manual Rev.2...
  • Page 640 Connect the two new batteries to the connectors of the battery board which are not connected to anything. Remove the old batteries. Hold the board by hand and pull the battery cable upward to remove the connector. Install the battery to the battery box. C Series Maintenance Manual Rev.2...
  • Page 641 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. C Series Maintenance Manual Rev.2...
  • Page 642 Remove the battery connectors. Hold the board by hand and pull the battery cable upward to NOTE  remove the connector. Remove the plate where the battery box is fixed to. Hexagon socket head cap bolts: 2-M4×10 C Series Maintenance Manual Rev.2...
  • Page 643 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 C Series Maintenance Manual Rev.2...
  • Page 644 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. C Series Maintenance Manual Rev.2...
  • Page 645 Control board (1, 2) 2138032 Hexagonal wrench For M4 hexagon socket head cap bolts (width across flats: 3 mm) Tools Spanner For spacers (width across flats: 5.5 mm) Cross-point screwdriver For cross recessed head screws C Series Maintenance Manual Rev.2...
  • Page 646 Be careful not to drop the screws inside the Manipulator while NOTE  removing them. Remove the control board 1 protection plate. Cross recessed head screws with captive washer: M3×6 It is not necessary to remove the spacer from the plate. C Series Maintenance Manual Rev.2...
  • Page 647 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. If the Manipulator is out of position, calibrate all the joints and axes. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 648 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 C Series Maintenance Manual Rev.2...
  • Page 649 Move the Manipulator to two or three points (poses) of the registered points. 7. If the Manipulator is out of position, calibrate all the joints and axes. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 650 Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system. LED lamp Name Qty. Note 1668127 Maintenance Part LED lamp (Standard, Clean-room models) Tool Cross-point screwdriver (#2) For cross recessed head screws C Series Maintenance Manual Rev.2...
  • Page 651 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. Connector: LED 3. Install the Arm #3 cover. For details, refer to C12 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...
  • Page 652 OFF the Controller. The position data will be lost when the cable connector connected to the battery is disconnected. And the EPSON RC+ will display the error message of encoder alarm occurrence when the Controller is turned ON.
  • Page 653 M/C cable Straight R12NZ900SB 10 m (flexible) L-shaped R12NZ900SF Straight R12NZ900YE 15 m L-shaped R12NZ900YD Straight R12NZ900SC 20 m L-shaped R12NZ900SG Hexagonal wrench Tools For M4 hexagon socket head cap bolts (width across flats: 3 mm) C Series Maintenance Manual Rev.2...
  • Page 654 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. Remove the connector sub plate. For details, refer to C12 Maintenance: 3. Covers. C Series Maintenance Manual Rev.2...
  • Page 655 7. If the battery connector (BT1*) was disconnected, calibrate the Joint #1. For details, refer to C12 Maintenance: 16. Calibration. 8. If the Manipulator is off position, calibrate all the joints and axes. For details, refer to C12 Maintenance: 16. Calibration. C Series Maintenance Manual Rev.2...
  • Page 656 Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system. Name Qty. Note Maintenance Part 2177465 Tool Cross-point screwdriver For cross recessed head screws C Series Maintenance Manual Rev.2...
  • Page 657 Heat sink side Connect the fan connectors. Install the fan cover. Cross recessed head screws with washer: 4-M4×35 Tightening torque: 0.9 ± 0.1 N·m C Series Maintenance Manual Rev.2...
  • Page 658 There are two methods to move the Manipulator during calibration. - Releasing the electromagnetic brake and moving the arms manually. For details, refer to the C Series Manual C12 Manipulator 1.5 How to Move Arms with the Electromagnetic Brake. - Moving the Manipulator using Jog & Teach.
  • Page 659  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.
  • Page 660 EPSON RC+ User’s Guide 5.11.1 Robot Manager Command Tools: Robot Manager: Jog and Teach Page. NOTE - For details about the basic orientation, refer to C Series Manual C12 Manipulator 3.7  Checking the Basic orientation. - Whenever possible, calibrate one joint at a time. (Also, replace parts of one joint at a time whenever possible.) If you calibrate the origins for multiple joints simultaneously, it will...
  • Page 661 Pose data (Point data) prior to the part replacement (motors, reduction 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.
  • Page 662 When the joint cannot move to the home position, operate the Manipulator to match the tram mark placed in C Series Manual C12 Manipulator 3.7 Checking the Basic Orientation as accurate as possible. Initialize the encoder when the joint matches the home position or the tram mark.
  • Page 663 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. C Series Maintenance Manual Rev.2...
  • Page 664 If accuracy is inadequate, it is necessary to re-calibrate the origin using a different pose (point). You must set the pose (point) again if the Manipulator does not move back to the original position after re-calibration. C Series Maintenance Manual Rev.2...
  • Page 665 Arm #2 side 1263977 Arm #2 side Joint #3 O ring 1510528 Arm #3 side 1263976 Arm #3 side Joint #4 1520370 Arm #4 side Grease inlet 1657289 Base, Arm #5 2.3, 11 LED lamp 1668127 C Series Maintenance Manual Rev.2...
  • Page 666 Side cover (left) 1655127 Arm #2 Clean-room model Side cover (right) 1674550 Plating cover Arm #3 Cover 1674551 1822065 Side cover (left) Arm #4 1822066 Side cover (right) Gasket Base Gasket For Heat sink 1694610 Clean-room model C Series Maintenance Manual Rev.2...
  • Page 667 Regarding purchase of grease and other materials, please contact the following manufacturers. If there is anything unclear, please contact the supplier of your region Product name Manufacturer Harmonic Grease SK-1A Harmonic Drive Systems Inc. https://www.harmonicdrive.net/ Harmonic Grease SK-2 https://www.chemours.com/en/brands-and- Chemours Krytox®GPL-224 products 1207B ThreeBond Co.,Ltd https://www.threebond.com LOCTITE641 LOCTITE https://loctite.com/ C Series Maintenance Manual Rev.2...
  • Page 668 R12NZ900LU ø6 straight R12NZ900LV Fittings for customer use ø6 elbow R12NZ900LW Standard user connector kit D-sub R12NZ900LX D-sub R12NZ900LY Waterproof user connector kit Ethernet R12NZ900LZ * Refer to each manipulator’s page of C series manual. C Series Maintenance Manual Rev.2...

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