Page 1 6-Axis Robots C8 series MANIPULATOR MANUAL Rev.13 EM208R4413F...
Page 4 FOREWORD Thank you for purchasing our robot products. This manual contains the information necessary for the correct use of the manipulator. Please carefully read this manual and other related manuals before installing the robot system. Keep this manual handy for easy access at all times. WARRANTY The robot and its optional parts are shipped to our customers only after being subjected to the strictest quality controls, tests, and inspections to certify its compliance with our high...
Page 5 TRADEMARKS Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries. Other brand and product names are trademarks or registered trademarks of the respective holders. NOTICE No part of this manual may be copied or reproduced without authorization. The contents of this manual are subject to change without notice.
Page 6 Regarding battery disposal The crossed out wheeled bin label that can be found on your product indicates that this product and incorporated batteries should not be disposed of via the normal household waste stream. To prevent possible harm to the environment or human health please separate this product and its batteries from other waste streams to ensure that it can be recycled in an environmentally sound manner.
Page 7 C8 Manipulators can be used with the following combinations of Controllers and software. Controller : 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) Setting by Software This manual contains setup procedures using the software.
Page 8 C8 Rev.13...
Page 9: Table Of Contents
Table of Contents Setup & Operation 1. Safety 1.1 Conventions....................3 1.2 Design and Installation Safety ..............4 1.3 Operation Safety ..................5 1.4 Emergency Stop ..................7 1.5 How to Move Arms with the Electromagnetic Brake ......9 1.5.1 Moving the Arm using the brake release unit ......10 1.5.2 Moving the Arm using the software ..........10 1.6 Precaution for Operation in Low Power Status ........10 1.7 Warning Labels ..................
Page 10 Table of Contents 4. End Effectors 4.1 Attaching an End Effector ..............46 4.2 Attaching Camera and Air Valves ............46 4.3 WEIGHT and INERTIA Settings ............48 4.3.1 WEIGHT setting ............... 50 4.3.2 INERTIA setting ................ 54 4.4 Precautions for Auto Acceleration/Deceleration ........59 5.
Page 11 Table of Contents Maintenance 1. Safety Maintenance 2. General Maintenance 2.1 Maintenance Inspection ...............86 2.1.1 Schedule for Maintenance Inspection ........86 2.1.2 Inspection Point ................87 2.2 Overhaul (Parts Replacement) .............89 2.3 Greasing ....................91 2.3.1 Joint #1 Reduction Gear Unit (Table Top Mounting) ....93 2.3.2 Joint #1 Reduction Gear Unit (Ceiling Mounting, Wall mounting) ..........94 2.3.3 Joint #2 Reduction Gear Unit ...........95...
Page 12 Table of Contents 4. Cable Unit 4.1 Replacing the Cable Unit ..............132 4.1.1 Replacing the Cable Unit (M/C Cable Backward) ....134 4.1.2 Replacing the Cable Unit (M/C Cable Downward) ....164 4.2 Connector Pin Assignment ..............169 4.2.1 Signal Cable ................169 4.2.2 Power Cable ................
Page 13 Table of Contents 9. Joint #5 9.1 Joint #5 - Replacing the Motor ............274 9.2 Joint #5 - Replacing the Reduction Gear Unit (Replacing the Joint #5, #6 Reduction Gear Unit Set) ..... 281 9.3 Joint #5 - Replacing the Timing Belt ..........287 9.4 Joint #5 - Replacing the Electromagnetic Brake .......
Page 14 Table of Contents C8 Rev.13...
Page 15: Setup & Operation
Setup & Operation This volume contains information for setup and operation of the Manipulators. Please read this volume thoroughly before setting up and operating the Manipulators.
Page 17: Safety
Setup & Operation 1. Safety 1. Safety Installation and transportation of the Manipulators and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes. Please read this manual and other related manuals before installing the robot system or before connecting cables.
Page 18: Design And Installation Safety
The following items are safety precautions for design personnel: ■ Personnel who design and/or construct the robot system with this product must read the Safety chapter in the EPSON RC+ User’s Guide. Designing and/or constructing the robot system without understanding the safety requirements is extremely hazardous, and may result in serious bodily injury and/or severe equipment damage to the robot system.
Page 19: Operation Safety
Setup & Operation 1. Safety 1.3 Operation Safety The following items are safety precautions for qualified Operator personnel: ■ Please carefully read the Safety-related Requirements in the Safety chapter of the Safety and Installation manual. Operating the robot system without understanding the safety requirements is extremely hazardous and may result in serious bodily injury and/or severe equipment damage to the robot system.
Page 20 Setup & Operation 1. Safety ■ Whenever possible, only one person should operate the robot system. If it is necessary to operate the robot system with more than one person, ensure that all people involved communicate with each other as to what they are doing and take all necessary safety precautions.
Page 21: Emergency Stop
Setup & Operation 1. Safety 1.4 Emergency Stop If the Manipulator moves abnormally during operation, immediately press the Emergency Stop switch. Pressing the Emergency Stop switch immediately changes the Manipulator to deceleration motion and stops it at the maximum deceleration speed. However, avoid pressing the Emergency Stop switch unnecessarily while the Manipulator is running normally.
Page 22 Setup & Operation 1. Safety For details of the Safeguard system, refer to the following manuals. EPSON RC+ User’s Guide 2. Safety - Installation and Design Precautions - Safeguard System Safety and Installation 2.6 Connection to EMERGENCY Connector To check brake problems, refer to the following manuals.
Page 23: How To Move Arms With The Electromagnetic Brake
Setup & Operation 1. Safety 1.5 How to Move Arms with the Electromagnetic Brake There are two methods to release the electromagnetic brake. Follow either method to release the electromagnetic brake and move the arms manually. 1.5.1 Moving the arm using the brake release unit Follow the method when you just unpack the delivered boxes or when the Controller does not start up yet.
Page 24: Moving The Arm Using The Brake Release Unit
Setup & Operation 1. Safety 1.5.1 Moving the Arm using the brake release unit The C8 series has the Brake Release Unit as an option. For details, refer to Setup & Option: 6 Options. 1.5.2 Moving the Arm using the software ■...
Page 25: Warning Labels
Setup & Operation 1. Safety 1.7 Warning Labels The Manipulator has the following warning labels. The warning labels are attached around the locations where specific dangers exist. Be sure to comply with descriptions and warnings on the labels to operate and maintain the Manipulator safely.
Page 26 Setup & Operation 1. Safety Location Warning Label NOTE You may get your hand or fingers caught when bringing your hand close to moving parts. Location Warning Label Note Location Label Be careful not to burn yourself. Location of Labels Top View Cable Downward model Bottom View...
Page 27: Specifications
Setup & Operation 2. Specifications 2. Specifications 2.1 Features of Manipulators Speed & Accuracy Increased productivity by balanced, best-in class fast and accurate operation. High-speed, low-oscillation, and high-precision positioning by our technology even in heavy weight transportation. Average cycle time (300 mm) 1 kg 5 kg 8 kg...
Page 28: Model Number
Setup & Operation 2. Specifications 2.2 Model Number C8 – A 14 0 1 S □ □ □ UL specification : UL compliant □ : Non UL compliant Mounting type □ : Table Top mounting : Ceiling mounting : Wall mounting M/C cable installation direction □...
Page 29: Part Names And Motion Range Of Each Arm
Setup & Operation 2. Specifications 2.3 Part Names and Motion Range of Each Arm LED Lamp (This lamp lights up Upper Arm (Arms #3 to #6) while the motors are ON.) Arm #4 Joint #4 Arm #3 Arm #6 Joint #6 Joint #3 Joint #5 Arm #5...
Page 30 Setup & Operation 2. Specifications Cable backward model Ethernet cable F-sensor connector cable connector User cable connector Standard-model : Cover (15-pin D-sub connector) Clean-room model : Exhaust port For ø12 mm pneumatic tube Power cable Signal cable For ø6 mm pneumatic tubes (Air1, Air2) Cable downward model Standard-model...
Page 31: Outer Dimensions
Setup & Operation 2. Specifications 2.4 Outer Dimensions [Unit: mm] 2.4.1 C8-A701*** (C8) C8 Rev.13...
Page 32: C8-A901*** (C8L)
Setup & Operation 2. Specifications 2.4.2 C8-A901*** (C8L) C8 Rev.13...
Page 33: C8-A1401*** (C8Xl)
Setup & Operation 2. Specifications 2.4.3 C8-A1401*** (C8XL) C8 Rev.13...
Page 34: Standard Motion Range
Setup & Operation 2. Specifications 2.5 Standard Motion Range 2.5.1 C8-A701*** (C8) [Unit: mm] Top View P point* Arm #1 0 pulse position Motion range of P point* Front View Lateral View Arm #2 Arms #4, #6 0 pulse position 0 pulse position P point* Arms #3, #5...
Page 35: C8-A901*** (C8L)
Setup & Operation 2. Specifications 2.5.2 C8-A901*** (C8L) [Unit: mm] Top View Arm #1 P point* 0 pulse position Motion range of P point* Front View Lateral View Arm #2 Arms #4, #6 0 pulse position 0 pulse position P point* Arms #3, #5 0 pulse position Motion range of P point*...
Page 36: C8-A1401*** (C8Xl)
Setup & Operation 2. Specifications 2.5.3 C8-A1401*** (C8XL) [Unit: mm] Top View P point* Arm #1 0 pulse position Motion range of P point* Front View Lateral View Arm #2 Arms #4, #6 0 pulse position 0 pulse position P point* Arms #3, #5 0 pulse position Motion range of P point*...
Page 37: Specifications
Setup & Operation 2. Specifications 2.6 Specifications 2.6.1 Specifications table Item Specification Model Number C8-A701*** C8-A901*** C8-A1401*** Model Name C8XL Mounting type Table Top mounting, Ceiling mounting, Wall mounting Standard Weight 49 kg (108 lbs.) 52 kg (115 lbs.) 62 kg (137 lbs.) Cleanroom &...
Page 38 Setup & Operation 2. Specifications Item Specification Model Number C8-A701*** C8-A901*** C8-A1401*** Model Name C8XL Joint #4 0.47 kg·m Allowable moment of Joint #5 0.47 kg·m inertia (GD2/4) Joint #6 0.15 kg·m 15 wires (D-sub) Installed wire for customer use 8 pin (RJ45) Cat 5e or equivalent 6 pin (for Force Sensor) Installed pneumatic tube for customer use...
Page 39 Setup & Operation 2. Specifications *7: Conditions of Manipulator at measurement are as follows: Operating conditions: Under rated load, 6 arms simultaneous motion, maximum speed, maximum acceleration/deceleration, and duty 50% for C8/ C8L, 30% for C8XL. Measurement point: 1000 mm apart from the rear of Manipulator *8: The exhaust system in the Cleanroom-model Manipulator draws air from the base interior and arm cover interior.
Page 40 Setup & Operation 2. Specifications *10: In general use, Accel setting 100 is the optimum setting that maintains the balance of acceleration and vibration when positioning. Although values larger than 100 can be set to Accel, it is recommended to minimize the use of large values to necessary motions since operating the Manipulator continuously with the large Accel setting may shorten the product life remarkably.
Page 41 For US/JP(power supply voltage 100 V, short connector included) Short connector for the brake release box *1: When using the brake release box with C8 series, it is necessary to connect the short connector to the M/C power cable or connect the M/C power cable with the Controller.
Page 42: How To Set The Model
The custom specifications may require a different configuration procedure; check the custom specifications number (MT***) and contact the supplier of your region if necessary. The Manipulator model can be set from software. Refer to the chapter Robot Configuration in the EPSON RC+ User’s Guide. C8 Rev.13...
Page 43: Environment And Installation
Setup & Operation 3. Environment and Installation 3. Environment and Installation Installation and transportation of robots and robotic equipment shall be performed by qualified personnel and should conform to all national and local codes. 3.1 Environmental Conditions A suitable environment is essential for the robot system to function properly and safely. Be sure to install the robot system in an environment that meets the following conditions: Item Conditions...
Page 44 Setup & Operation 3. Environment and Installation Do not use the Manipulator under conditions where it can be exposed to water or any other corrosive liquid (including water). *2 Any contaminants that can deteriorate sealing performance of nitrile rubber oil sealing, O-rings, packing seals and liquid gasket should be avoided.
Page 45: Unpacking, Transportation, And Relocation
Setup & Operation 3. Environment and Installation 3.2 Unpacking, Transportation, and Relocation Using a cart or similar equipment, transport the Manipulator in the same conditions as it was delivered. Observe the following when unpacking the Manipulator. The installation shall be made by qualified installation personnel and should conform to all national and local codes.
Page 46 Setup & Operation 3. Environment and Installation When condensation occurs on the Manipulator during transport or storage, turn ON the power only after the condensation dries. When using the Manipulator for the robot system again after long-term storage, perform a test run to verify that the Manipulator works properly.
Page 47 Setup & Operation 3. Environment and Installation Using Eyebolt Check that the eyebolts are securely fastened before carrying the Manipulator. After transporting the Manipulator, remove the eyebolts and keep them for future use. The eyebolts (accessory, 2 pcs) and wire must be strong enough to withstand the weight (See the figures below).
Page 48: Mounting Dimensions
Setup & Operation 3. Environment and Installation 3.3 Mounting Dimensions Mounting Area Be sure to have the following space available in addition to the space for mounting the Manipulator, Controller, and peripheral equipment. Space for teaching points Space for maintenance and inspections (for installing jigs) Space for cables The minimum bend radius of the power cable is 90 mm.
Page 49 Setup & Operation 3. Environment and Installation C8-A901** (C8L) C8 Rev.13...
Page 50: Cable Downward Model
Setup & Operation 3. Environment and Installation C8-A1401** (C8XL) 3.3.2 Cable Downward Model The following part differs from the cable backward model. C8-A701*B* (C8), C8-A901*B* (C8L) C8-A1401*B* (C8XL) C8 Rev.13...
Page 51: Installation
■ To ensure safety, a safeguard must be installed for the robot system. For details on the safeguard, refer to the Installation and Design Precautions in the Safety chapter of the EPSON RC+ User’s Guide. ■ Install the Manipulator in a location with sufficient space so that a tool or a work piece does not touch a wall or a safeguard when the Manipulator extends its arm fully while holding a work piece.
Page 52 Setup & Operation 3. Environment and Installation Base table A base table for anchoring the Manipulator is not supplied. Please make or obtain the base table for your Manipulator. The shape and size of the base table differ depending on the intended use of the robot system.
Page 53 Setup & Operation 3. Environment and Installation For environmental conditions regarding space when placing the Controller on the base table, NOTE  refer to the Robot Controller manual. When using the Manipulator in the cleanroom, follow the steps below before the installation. (1) Unpack the Manipulator outside of the cleanroom.
Page 54: Connecting The Cables
Setup & Operation 3. Environment and Installation 3.5 Connecting the Cables ■ Before performing any replacement procedure, turn OFF the Controller and related equipment, and then disconnect the power plug from the power source. Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system.
Page 55 Setup & Operation 3. Environment and Installation Cleanroom-model Manipulator For the Cleanroom-model, an exhaust system is necessary. For details, refer to Setup & Operation: 2.6 Specifications. Protection-model Manipulator For the Protection-model, also make sure to follow the following precautions. ■ When operating the Manipulator under special environmental conditions (adverse conditions with dust and oily smoke), do not place the Controller in the same condition since the Controller does not comply with IP67.
Page 56: User Wires And Pneumatic Tubes
Setup & Operation 3. Environment and Installation 3.6 User Wires and Pneumatic Tubes ■ Only authorized or certified personnel should be allowed to perform wiring. Wiring by unauthorized or uncertified personnel may result in bodily injury and/or malfunction of the robot system. CAUTION User electrical wires and pneumatic tubes are contained in the cable unit.
Page 57: Electrical Wires
Setup & Operation 3. Environment and Installation Electrical wires Specifications of the user wires D-sub 15-pin Allowable Nominal Rated Voltage Wires Note Current Sectional Area AC/DC30 V 0.106 mm Shielded Pins with the same number, indicated on the connectors on both ends of the cables, are connected.
Page 58: Pneumatic Tubes
Setup & Operation 3. Environment and Installation Pneumatic tubes Max. Usable Pneumatic Pressure Pneumatic Tubes Outer Diameter × Inner Diameter 0.59 MPa (6 kgf/cm : 86 psi) ø6 mm × ø4 mm Standard model, Cleanroom model The elbow fitting is attached on the Arm #4 at the time of shipment. The part can be replaced with the straight fitting (accessory) according to application.
Page 59: Checking The Basic Orientation
Setup & Operation 3. Environment and Installation 3.7 Checking the Basic orientation After parts have been replaced (motors, reduction gear units, belts, etc.), the Manipulator cannot operate properly because a gap exists between the origin positions stored in each motor and these stored in the Controller. The process to compensate the position gap is called “Calibration”.
Page 60: End Effectors
Setup & Operation 4. End Effectors 4. End Effectors 4.1 Attaching an End Effector Create an end effector for your Manipulator. Flange dimensions of the wrist attached to the end of Arm #6 is as below. ■ If you use an end effector equipped with a gripper or chuck, connect wires and/or pneumatic tubes properly so that the gripper does not release the work piece when the power to the robot system is turned OFF.
Page 61 Setup & Operation 4. End Effectors C8-A701*** (C8) C8-A901*** (C8L) [Unit: mm] Arm #5 Arm #3 Deck Deck Arm #5 Arm #3 Deck Deck Rotation Center of the Upper Arm Rotation Center of the Upper Arm C8-A1401*** (C8XL) Arm #5 Deck Arm #3 Deck Rotation Center of the Upper Arm...
Page 62: Weight And Inertia Settings
The allowable load for C8 series Manipulators is 8 kg at the maximum. Due to the limitations of the moment and inertia moment shown in the table below, the load (end effector weight + work piece weight) should also meet these conditions.
Page 63 Setup & Operation 4. End Effectors The moment M (Nm) and inertia moment I (kgm ) when the volume of the load (end effector + work piece) is small can be obtained by the following formula. M (Nm) = m(kg) × L (m) × g (m/s I (kgm ) = m(kg) ×...
Page 64: Weight Setting
Manipulator, and/or shorten the life cycle of parts/mechanisms. The acceptable weight capacity (end effector and work piece) for C8 series Manipulators is as follows: Rated...
Page 65 Setup & Operation 4. End Effectors Load on the Manipulator Mounting location of the load C8-A701*** (C8) Load on the fore end of Arm #6 Arm #5 Deck Arm #3 Deck C8-A901*** (C8L) Load on the fore end of Arm #6 Arm #5 Deck Arm #3 Deck C8-A1401*** (C8XL)
Page 66 Setup & Operation 4. End Effectors Calculate the Weight parameter by using the formula below and enter the value. Weight Parameter Formula Weight parameter = M : Load on the fore end of Arm #6 (kg) : Equivalent weight of the Arm #3 deck (kg) : Equivalent weight of the Arm #5 deck (kg) )²/ (L)²...
Page 67 Setup & Operation 4. End Effectors Automatic speed setting by Weight parameter The percentages in the graphs are based on the speed at rated weight (3 kg) as 100%. C8-A701***(C8) Acceleration / Deceleration Speed (kg) Weight Parameter C8-A901***(C8L) Acceleration / Deceleration Speed (kg) Weight Parameter...
Page 68: Inertia Setting
CAUTION cause errors, excessive shock, insufficient function of the Manipulator, and/or shorten the life of parts/mechanisms. The acceptable inertia moment of load for C8 series Manipulators is 0.03 kgm nominal rating and 0.15 kgm maximum. Change the setting of the inertia moment according to the inertia moment of the load using the INERTIA command.
Page 69 Manipulator, and/or shorten the life cycle of parts/mechanisms. The acceptable eccentric quantity of the load for C8 series Manipulators is 50 mm at nominal rating and 300 mm at maximum. When the eccentric quantity of the load exceeds the rating, change the setting of eccentric quantity parameter using the INERTIA command.
Page 70 Setup & Operation 4. End Effectors Automatic acceleration/deceleration setting by INERTIA (eccentric quantity) Automatic setting by inertia moment setting (common to C8 series) 0.05 0.10 0.15 (kg·m ) Inertia moment The percentage in the graph is based on the acceleration/ deceleration at rated eccentricity (0.03 kg·m...
Page 71 Setup & Operation 4. End Effectors Calculating the Inertia Moment Refer to the following example formulas to calculate the inertia moment of the load (end effector with work piece). The inertia moment of the entire load is calculated by the sum of (a), (b), and (c). Rotation Center End Effector (a) Work Piece (b)
Page 72 Setup & Operation 4. End Effectors (c) Inertia moment of a sphere Sphere’s Center of Gravity Rotation Center + m × L C8 Rev.13...
Page 73: Precautions For Auto Acceleration/Deceleration
Setup & Operation 4. End Effectors 4.4 Precautions for Auto Acceleration/Deceleration The speed and acceleration/deceleration of the Manipulator motion are automatically optimized according to the values of WEIGHT and INERTIA and the Manipulator’s postures. WEIGHT Setting The speed and acceleration/deceleration of the Manipulator are controlled according to the load weight set by the WEIGHT command.
Page 74: Motion Range
Manipulator does not move. The pulse range can be set in [Tools]-[Robot manager]-[Range] panel. EPSON You may also execute the Range command from the [Command Window]. C8 Rev.13...
Page 75: Max. Pulse Range Of Joint #1
Setup & Operation 5. Motion Range 5.1.1 Max. Pulse Range of Joint #1 Pulse values in counterclockwise direction are positive (+) and values in clockwise direction are negative (-). - direction Arm #1 0 pulse position + direction C8-A701*** (C8) C8-A901*** (C8L) C8-A1401*** (C8XL) Angle (°)
Page 76: Max. Pulse Range Of Joint #3
5.1.4 Max. Pulse Range of Joint #4 From the angle of arm end, clockwise pulse values are positive (+) and counterclockwise pulse values are negative (-). The max. pulse range of the Arm #4 is common to C8 series Manipulators.
Page 77: Max. Pulse Range Of Joint #5
5.1.6 Max. Pulse Range of Joint #6 From the angle of arm end, clockwise pulse values are positive (+) and counterclockwise pulse values are negative (-). The max. pulse range of the Arm #6 is common to C8 series Manipulators.
Page 78: Motion Range Setting By Mechanical Stops
Setup & Operation 5. Motion Range 5.2 Motion Range Setting by Mechanical Stops Using the adjustable mechanical stops physically limits the absolute area that the Manipulator can move. Be sure to turn OFF the Manipulator in advance. Use bolts conforming to the specified length and surface processing (ex: ) with nickel plating high corrosion resistance.
Page 79: Motion Range Setting Of Joint #2
Setup & Operation 5. Motion Range 5.2.2 Motion Range Setting of Joint #2 C8-A701*** (C8), C8-A901*** (C8L) Remove the mechanical stop installed as standard and install the adjustable mechanical stop (C8/C8L_J2). (Joint #2 standard motion range −158 to +65°) Hexagon socket head cap bolt M10×35×1 bolt Tightening torque 32.0 ±...
Page 80: Motion Range Setting Of Joint #3
Setup & Operation 5. Motion Range C8-A1401***(C8XL) Remove the mechanical stop installed as standard and install the adjustable mechanical stop (C8XL_J2). (Joint #2 standard motion range −135 to +55°) Hexagon socket head cap bolt M10×35×2 bolts Tightening torque 32.0 ± 1.6 N·m (326 ± 16 kgf·cm) Angle (°) −125, +45 −135, +55...
Page 81: Restriction Of Manipulator Operation By Joint Angle Combination
Setup & Operation 5. Motion Range 5.3 Restriction of Manipulator Operation by Joint Angle Combination To prevent the arms of the Manipulator from interfering each other, the Manipulator operation is restricted in the specified motion range according to the joint angle combination of the Arm #1, #2, and #3.
Page 82 Setup & Operation 5. Motion Range C8-A701***(C8) Combination of Joints #2 and #3 −50 deg. <= J1 <= 50 deg. Joint #2 Angle −120 deg. <= J1< −50 deg. or 50 deg. < J1<= 120 deg. Joint #2 Angle −240 deg. <= J1 < −120 deg. or 120 deg. < J1<= 240 deg. Joint #2 Angle Combination of Joints #1 and #2 −240 deg.
Page 83 Setup & Operation 5. Motion Range C8-A901***(C8L) Combination of Joints #2 and #3 −50 deg. <= J1 <= 50 deg. Joint #2 Angle −120 deg. <= J1< −50 deg. or 50 deg. < J1<= 120 deg. Joint #2 Angle −240 deg. <= J1 < −120 deg. or 120 deg. < J1<= 240 deg. Joint #2 Angle Combination of Joints #1 and #2 −240 deg.
Page 84 Setup & Operation 5. Motion Range C8-A1401***(C8XL) Combination of Joints #2 and #3 −110 deg. <= J1 <= 110 deg. Joint #2 Angle −140 deg. < J1< −110 deg. or 110 deg. < J1< 140 deg. −240 deg. < J1< −220 deg. or 220 deg. < J1< 240 deg. Joint #2 Angle −220 deg.
Page 85: Coordinate System
5.4 Coordinate System The origin point is where the Manipulator’s installation face intersects with the rotation axis of Joint #1. For details on the coordinate system, refer to the EPSON RC+ Users Guide manual. Table Top mounting Ceiling mounting Wall mounting BASE setting is suitable for install the robot obliquely.
Page 86: Changing The Robot
Setup & Operation 5. Motion Range 5.5 Changing the Robot This section describes how to change the manipulator model on EPSON RC+. ■ Changing the Manipulator should be done with great caution. It initializes the robot calibration parameters (Hofs, CalPls), additional axis information, and PG parameter data.
Page 87: Setting The Cartesian (Rectangular) Range In The Xy Coordinate System Of The Manipulator
Manipulator or peripheral equipment. The method for changing the XYLIM setting varies with the software used. Set the XYLIM setting in [Tools]-[Robot manager]-[XYZ Limits] panel. EPSON You may also execute the XYLim command from the [Command Window]. C8 Rev.13...
Page 88: Options
Setup & Operation 6. Options 6. Options C8 series Manipulator has the following options. 6.1 Brake Release Unit 6.2 Camera Plate Unit 6.3 Tool Adapter (ISO flange) 6.4 Adjustable Mechanical Stops 6.5 User Wires and Pneumatic Tubes 6.1 Brake Release Unit With the electromagnetic brake is ON (such as in Emergency Stop status), all arms don’t...
Page 89 Setup & Operation 6. Options Width 180 mm Depth 150 mm Height 87 mm Weight (Cables are not included.) 1.7 kg Cable to the Manipulator Power cable length Power cable (US) 100 V specification Power cable (EU) 200 V specification M/C Short connector For M/C power cable short-circuit View from A...
Page 90: Mount The Brake Release Unit
Setup & Operation 6. Options Mount the brake release unit (1) Turn OFF the Controller. (2) If the M/C power cable is not connected to the Controller: Connect the M/C short connector, or connect the Controller. (Keep the Controller power OFF) The M/C short connector can be purchased singly.
Page 91: How To Use The Brake Release Unit
Setup & Operation 6. Options How to use the brake release unit ■ Be careful of the arm falling when releasing the brake. While the brake is being released, the Manipulator’s arm falls by its own weight. The arm falling may cause hands and fingers to be caught and/or may cause equipment damage to or malfunction of the Manipulator.
Page 92: Camera Plate Unit
Setup & Operation 6. Options 6.2 Camera Plate Unit To mount a camera to the C8 series Manipulator, you need to mount the camera plate unit first. Appearance of arm end with camera Camera Camera plate unit Parts included Qty.
Page 93 Camera and C8 series Manipulator Joint #5 motion range (reference values) The Joint #5 motion range varies depending on the mounting position of camera mid plate and the camera you are using.
Page 94: Tool Adapter (Iso Flange)
Setup & Operation 6. Options 6.3 Tool Adapter (ISO Flange) Using the tool adapter, you can mount the end effector whose dimensions are designed for the ISO flange to the C8 series Manipulators. Parts included Qty. ISO flange Flange Hexagon socket head screw with low head M5×10 Hexagon socket head screw M5×15...
Page 95: Adjustable Mechanical Stops
Setup & Operation 6. Options 6.4 Adjustable Mechanical Stops This option is used to mechanically limit the motion range of the Manipulator. For installation and angle restriction measures, refer to Setup & Operation 5.2 Motion Range Setting by Mechanical Stops. Adjustable mechanical stop (J1) Item Qty.
Page 96: User Wires And Pneumatic Tubes
Setup & Operation 6. Options 6.5 User Wires and Pneumatic Tubes Use the following options when using the internal wiring and tubing for the end effector drive. Fitting for customer use (ø6 straight) Item Qty. Manufacturer Standard ø6 straight fitting KQ2S06-M6N * Attached as standard.
Page 97: Maintenance
Maintenance This volume contains maintenance procedures with safety precautions for C8 series Manipulators.
Page 99: Safety Maintenance
Maintenance 1. Safety Maintenance 1. Safety Maintenance Please read this chapter, this manual, and other relevant manuals carefully to understand safe maintenance procedures before performing any maintenance. Only authorized personnel who have taken safety training should be allowed to perform the robot maintenance. Safety training is the program for industrial robot operators to follow the laws and regulations of each nation.
Page 100: General Maintenance
Maintenance 2. General Maintenance ■ Be sure to connect the cables properly. Do not allow unnecessary strain on the cables. (Do not put heavy objects on the cables. Do not bend or pull the cables forcibly.) It may result in damage to the cables, disconnection, and/or contact failure.
Page 101: Inspection Point
Maintenance 2. General Maintenance 2.1.2 Inspection Point Inspection While the Power is OFF (Manipulator is not operating) Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual End effector mounting bolts √ √ √ √ √ Check looseness or backlash of Manipulator mounting bolts √...
Page 102 √ √ Execute Brake off command (brake off, joint #) from the command window of the EPSON RC+ while the motors are OFF, and then check the sound of the electromagnetic brake. If there is no sound, replace the brake.
Page 103: 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 104 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 105: Greasing
Maintenance 2. General Maintenance 2.3 Greasing The reduction gear units and the bevel gear need greasing regularly. Only use the grease specified in the following table. ■ Before greasing, turn OFF the Controller and related equipment, and then disconnect the power plug from the power source. Performing any replacement procedure with the power ON is extremely hazardous and may result in electric WARNING shock and/or malfunction of the robot system.
Page 106 Maintenance 2. General Maintenance Name Quantity Note 1674592 Grease up kit (A set of grease gun, nipple, and extension jig) Maintenance Grease plug 1656158 parts O-ring for grease inlet 1657289 Hexagonal wrench For M3 hexagon socket countersunk head bolts (width across flats: 2 mm) Hexagonal wrench For M3 hexagon socket head cap bolts Tools...
Page 107: Joint #1 Reduction Gear Unit (Table Top Mounting)
Maintenance 2. General Maintenance 2.3.1 Joint #1 Reduction Gear Unit (Table Top Mounting) Greasing 1. Remove the Arm #1 side cover. For details, refer to Maintenance: 3. Covers. 2. Remove the grease plug from the Joint #1 grease inlet located inside the Arm #1. 3.
Page 108: Joint #1 Reduction Gear Unit (Ceiling Mounting, Wall Mounting)
Maintenance 2. General Maintenance 2.3.2 Joint #1 Reduction Gear Unit (Ceiling Mounting, Wall mounting) Greasing 1. Remove the base grease inlet cover. Hexagon socket flat head bolts: 4-M3×6 2. Remove the O-ring located in the base groove. 3. Remove the grease plug from the Joint #1 grease inlet located inside the base.
Page 109: Joint #2 Reduction Gear Unit
Maintenance 2. General Maintenance 9. Install the base grease inlet cover. Hexagon socket flat head bolts: 4-M3×6 Tightening torque: 2.0 ± 0.1 N·m 2.3.3 Joint #2 Reduction Gear Unit Greasing 1. Remove the grease plug from the Joint #2 grease inlet of the Arm #1. 2.
Page 110: Joint #3 Reduction Gear Unit
Maintenance 2. General Maintenance 2.3.4 Joint #3 Reduction Gear Unit Greasing 1. Remove the grease plug from the Joint #3 grease inlet of the Arm #2. 2. Attach the grease nipple to the Joint #3 grease inlet. 3. Inject grease from the grease nipple using a grease gun Grease: SK-1A Grease amount: 3g...
Page 111: Joint #4 Reduction Gear Unit
Maintenance 2. General Maintenance 2.3.5 Joint #4 Reduction Gear Unit Greasing 1. Remove the grease plug from the Joint #4 grease inlet of the Arm #4. 2. Attach the grease nipple to the Joint #4 grease inlet. NOTE The grease plug attaching hole located near the ...
Page 112: Joint #5 Reduction Gear Unit
Maintenance 2. General Maintenance 2.3.6 Joint #5 Reduction Gear Unit Greasing 1. Remove the grease plug from the Joint #5 grease inlet of the Arm #5. 2. Attach the grease nipple to the Joint #5 grease inlet. NOTE  The grease plug attaching hole located near the label with “5”...
Page 113: Joint #6 Reduction Gear Unit
Maintenance 2. General Maintenance 2.3.7 Joint #6 Reduction Gear Unit Greasing Remove the grease plug from the Joint #6 grease inlet of the Arm #5. Attach the grease nipple to the Joint #6 grease inlet. NOTE  The grease plug attaching hole located near the label with “6”...
Page 114: Joint #6 Bevel Gear
Maintenance 2. General Maintenance 2.3.8 Joint #6 Bevel Gear Greasing Remove the Arm #5 grease inlet cover. Hexagon socket head cap bolts: 4-M3×6 Remove the O-ring located in the base groove. Apply grease to the mating surface of the bevel gear inside the Arm #5.
Page 115: Tightening Hexagon Socket Head Bolts
Maintenance 2. General Maintenance 2.4 Tightening Hexagon Socket Head Bolts Hexagon socket head cap bolts (hereinafter, “bolts”) are used in places where mechanical strength is required. These bolts are fastened with the tightening torque shown in the following tables. When it is required to refasten the bolts in some procedures in this manual (except special cases as noted), use a torque wrench so that the bolts are fastened with appropriate tightening torque as shown below.
Page 116: Layout Of Maintenance Parts
Maintenance 2. General Maintenance 2.5 Layout of Maintenance Parts LED lamp Joint #3 Reduction gear unit Joint #3 Timing belt Joint #3 Motor + Electromagnetic brake Joint #2 Reduction gear unit Joint #2 Timing belt Joint #1 Electromagnetic brake Joint #2 Motor + Electromagnetic brake Joint #1 Reduction gear unit Joint #1 Motor...
Page 117: Covers
Maintenance 3. Covers 3. Covers This chapter describes methods of removing and installing the covers and gaskets which are common to all maintenance procedures by Manipulator model. S: Standard model C: Clean-room & ESD model P: Protection model ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON.
Page 118 Maintenance 3. Covers Cable backward model Arm #4 Arm #3 cover D-sub attachment Arm #4 side cover Arm #2 side cover Arm #2 side cover Arm #4 side cover Arm #4 maintenance cover Arm #1 side cover Arm #1 maintenance cover Arm #3 maintenance Connector...
Page 119 Maintenance 3. Covers Name Quantity Note Metal cover Center cover 1675435 Common to Standard/ Arm #1 Clean-room models Side cover 1674537 Side cover (left) 1655114 Arm #2 Standard model Side cover (right) 1674542 Plastic cover Cover Arm #3 Cover 1674543 Arm #4 Side cover 1674547...
Page 120: Arm #1 Center Cover
Maintenance 3. Covers 3.1 Arm #1 Center Cover ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 121: Arm #1 Side Cover
Maintenance 3. Covers 3.2 Arm #1 Side Cover ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 122 Maintenance 3. Covers Installation S, C models: Install the Arm #1 side cover to the Manipulator. Cross recessed truss head small screws: 4-M4×10 (one side) Tightening torque: 0.9 ± 0.1 N·m P model: Install the gasket to the grove on the Arm #1 side cover.
Page 123: Arm #2 Side Cover
Maintenance 3. Covers 3.3 Arm #2 Side Cover ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 124: Arm #3 Cover
Maintenance 3. Covers 3.4 Arm #3 Cover ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 125: Arm #3 Maintenance Cover
Maintenance 3. Covers 3.5 Arm #3 Maintenance Cover ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 126 Maintenance 3. Covers Installation Install the Arm #3 maintenance cover to the Manipulator. (S, C models) Cross recessed truss head small screws: 4-M4×8 Tightening Torque: 0.9 ± 0.1 N·m Be careful not to get the cables caught between the cover and the Manipulator. Installation 1.
Page 127: Arm #4 Side Cover
Maintenance 3. Covers 3.6 Arm #4 Side Cover ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 128 Maintenance 3. Covers Installation Insert the connectors. RJ45 connector: Insert the RJ45 connector to the connector on the cover. F-sensor connector: Insert the metallic connector to the connector on the cover. S, C models: Install the Arm #4 side cover to the Manipulator. Cross recessed truss head small screws: 7-M4×10 (one side) Tightening torque: 0.9 ±...
Page 129: Arm #4 Maintenance Cover (C8Xl Only)
Maintenance 3. Covers 3.7 Arm #4 Maintenance Cover (C8XL only) ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 130 Maintenance 3. Covers Installation Install the Arm #4 maintenance cover to the Manipulator. S, C models Cross recessed truss head small screws: 4-M4×10 Tightening torque: 0.9 ± 0.1 N·m Be careful not to get the cables caught between the cover and the Manipulator. Installation Install the spacers to the holes on the gasket.
Page 131: Arm #4 D-Sub Attachment
Maintenance 3. Covers 3.8 Arm #4 D-sub Attachment ■ Do not remove the D-sub attachment forcibly. Removing it forcibly may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system.
Page 132: Base Cover
Maintenance 3. Covers 3.9 Base Cover 3.9.1 M/C Cable Backward ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 133: M/C Cable Downward
Maintenance 3. Covers 3.9.2 M/C Cable Downward ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 134 Maintenance 3. Covers C8-A701*B* (C8), C8-A901*B* (C8L) Installation Install the base cover to the Manipulator. (S, C models) Hexagon socket head cap bolts: 11-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. C8-A701*B* (C8), C8-A901*B* (C8L) Installation Install the spacers to the holes on the gasket.
Page 135 Maintenance 3. Covers C8-A1401*B* (C8XL) Removal Remove the fan. For details, refer to Maintenance 15. Replacing the Fan.. 2. Remove the bolts on the heat sink. Hexagon socket head cap bolts: 4-M4×15 3. Remove the heat sink. NOTE For cleanroom and protection models, remove the gasket ...
Page 136 Maintenance 3. Covers Install the base cover to the Manipulator. Hexagon socket head cap bolts: 11-M4×10 Tightening torque: 4.0 ± 0.2 N·m Be careful not to get the gasket and cables caught between NOTE  the cover and the Manipulator. Replace the gasket if there are flaws or deteriorations.
Page 137: Base Maintenance Cover
Maintenance 3. Covers 3.10 Base Maintenance Cover ■ When mounting the cover, be careful not to get the cables caught in it or bend them forcibly to push into the cover. Unnecessary strain on cables may result in damage to the cables, disconnection, and/or contact failure.
Page 138 Maintenance 3. Covers Installation Install the spacers to the holes on the gasket. P model (6 places) Apply the liquid gasket to the base maintenance gasket. Install the base maintenance gasket to the base cover. (See the figure for gasket applying points) Spacer (×6) Gasket applying point...
Page 139: Connector Plate
Maintenance 3. Covers 3.11 Connector Plate 3.11.1 M/C Cable Backward ■ Do not remove the connector plate forcibly. It may result in damage to the cables, disconnection, and/or contact failure. These are extremely hazardous and may result in electric shock and/or improper function of the robot system. ■...
Page 140 Maintenance 3. Covers C8-A701** (C8), C8-A901** (C8L) Installation Install the connector plate to the Manipulator. (S, C models) Hexagon socket head cap bolts: 11-M4×10 Tightening Torque: 4.0 ± 0.2 N·m Be careful not to get the cables caught between the cover and the Manipulator. C8-A701** (C8), C8-A901** (C8L) Installation 1.
Page 141 Maintenance 3. Covers C8-A1401** (C8XL) Removal 1. Remove the fan. For details, refer to Maintenance 15. Replacing the Fan. 2. Remove the bolts on the heat sink Hexagon socket head cap bolts: 4-M4×15 3. Remove the heat sink. For cleanroom and protection models, remove the gasket NOTE ...
Page 142 Maintenance 3. Covers 3. Install the connecter plate to the Manipulator. Hexagon socket head cap bolts: 11-M4×10 Tightening torque: 4.0 ± 0.2 N·m Be careful not to get the gasket and cables caught NOTE  between the cover and the Manipulator. Replace the gasket if there are flaws or deteriorations.
Page 143: M/C Cable Downward
Maintenance 3. Covers 3.11.2 M/C Cable Downward ■ Do not remove the connector plate forcibly. It may result in damage to the cables, disconnection, and/or contact failure. These are extremely hazardous and may result in electric shock and/or improper function of the robot system. ■...
Page 144: Connector Sub Plate
Maintenance 3. Covers 3.12 Connector Sub Plate ■ Do not remove the connector sub plate forcibly. It may result in damage to the cables, disconnection, and/or contact failure. These are extremely hazardous and may result in electric shock and/or improper function of the robot system. ■...
Page 145 Maintenance 3. Covers Installation Install the connector sub plate to the Manipulator. (S, C models) 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. Installation 1.
Page 146: Cable Unit
Maintenance 4. Cable Unit 4. Cable Unit 4.1 Replacing the Cable Unit ■ Before performing any replacement procedure, turn OFF the Controller and related equipment, and then disconnect the power plug from the power source. Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system.
Page 147 Maintenance 4. Cable Unit ■ When disconnecting the connectors during the replacement of the cable unit, be sure to reconnect the connectors to their proper positions. Improper connection of the connectors may result in improper function of the robot system. For details on the connections, refer to the Maintenance 4.2 Connector Pin Assignments.
Page 148: Replacing The Cable Unit (M/C Cable Backward)
Maintenance 4. Cable Unit 4.1.1 Replacing the Cable Unit (M/C Cable Backward) Name Qty. Note For standard, cleanroom 2172929 C8-A701** (C8) models For protection model 2172932 For standard, cleanroom 2172930 models Cable unit C8-A901** (C8L) For protection model 2172933 Maintenance For standard, cleanroom 2172931 Parts...
Page 149 Maintenance 4. Cable Unit Removal: Cable unit (M/C cable backward) 1. Move the Manipulator to the origin posture (0 pulse position). 2. Turn OFF the Controller. 3. Remove the following covers and plate. For details, refer to Maintenance: 3. Covers. Arm #4 side covers (both sides) Arm #4 maintenance cover (C8XL only) Arm #3 cover...
Page 150 Maintenance 4. Cable Unit 8. Remove the ground wire plate (M/C cable backward). Hexagon socket head cap bolts: 2-M4×10 9. Remove the ground wire terminals. Cross recessed head screws with washer S, C models : 9-M4×8, 2-M3×6 P model : 10-M4×8, 2-M3×6 10.
Page 151 Maintenance 4. Cable Unit 14. Remove the base cable bracket (C1) and the cable protection sheet. Hexagon socket head cap bolts: 2-M3×6 15. Remove the Joint #1 timing belt. 16. Remove the battery from the battery box. 17. Disconnect the battery connector. NOTE Hold the board by hand and pull up the battery cable to disconnect ...
Page 152 Maintenance 4. Cable Unit 19. Disconnect the battery connectors. Connectors: CN3, CN6 20. Remove the two ground wire terminals from the Arm #1. Cross recessed head screws with washer: 2-M4×8 21. Remove the Joint #2 motor unit. For details, refer to Maintenance: 6.1 Joint #2 - Replacing the Motor, Removal steps (1) to (3) and (5) to (9).
Page 153 Maintenance 4. Cable Unit 25. Remove the Arm #1 cable brackets (C1: 2 pieces) and cable protection tube. Hexagon socket head cap bolts: 4-M3×6 26. Remove the Arm #1 cable brackets (C2 and S2: one each) and cable protection tube. Hexagon socket head cap bolts: 2-M3×6 (C2) 2-M4×10 (S2) 27.
Page 154 Maintenance 4. Cable Unit 30. Remove the two ground wire terminals from the Arm #2. Cross recessed head screws with washer: 2-M4×8 31. Remove the Joint #3 motor unit. For details, refer to Maintenance: 7.1 Joint #3 - Replacing the Motor, Removal steps (1) to (3) and (5) to (8).
Page 155 Maintenance 4. Cable Unit 37. Remove the fixing plate of the Arm #3 control board 2. Hexagon socket head cap bolts: 2-M4×10 38. Remove the Arm #3 cable bracket (C3B). Hexagon socket head cap bolts: 2-M3×6 39. Remove the Arm #3 cable fixing plate 1. Hexagon socket head cap bolts: 2-M4×10 40.
Page 156 Maintenance 4. Cable Unit 42. Pull out the separated cable unit (base side) from the Arm #1 side to the Arm #2 side. To protect the connectors and facilitate the work, first cover the connectors with a plastic bag. Then, pass the cable unit through the arm.
Page 157 Maintenance 4. Cable Unit 45. Remove the two air tubes inside the Arm #4. 46. Cut off the wire tie that binds the cables of the Arm #4. 47. Loosen the bolts that fix the cable protection plate attached on the Arm #4, and disconnect the cables.
Page 158 Maintenance 4. Cable Unit 49. Remove the Joints #5 and #6 motor units. For details, refer to Maintenance: 9.1 Joint #5 - Replacing the Motor, Removal steps (4) to (8), and 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.
Page 159 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) C8 Rev.13...
Page 160 Maintenance 4. Cable Unit Installation: Cable unit (M/C cable backward) 1. Check if the cable unit contains the following parts. Silicon sheet Silicone sheet: 3 sheets (25 mm × 120 mm) 3 sheets (25 mm × 120 mm) F-sensor connector housing 2 pieces 2.
Page 161 Maintenance 4. Cable Unit 5. Place a mark at the fixing position of each cable you are going to pass 130 mm through the Arm #4. D-sub : 130 mm from the connector end Other cables : 190 mm from the connector end Air tube : 210 mm from the end 6.
Page 162 Maintenance 4. Cable Unit Leave out the other connector cables for a certain length, as shown in the photo, in order to store them in the Arm #3. 7. Pass the Ethernet cable, X052/X062 cable, and ground wire (green/yellow) from the Arm #3 side to the Arm #4 side. C8/C8L: Pass the cables one by one through the arm from the Arm #3 side.
Page 163 Maintenance 4. Cable Unit As shown in the photo, disconnect the Ethernet cable and air tube NOTE  (blue) at one side of the Arm #4. Disconnect the remaining cables at the other side. Align the marked positions and the position on the Arm #4 indicated with the arrow in the photo.
Page 164 Maintenance 4. Cable Unit 11. Install the D-sub connector to the D-sub attachment of the Arm #4. S, C models: A D-sub connector fixing plate is provided. 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.
Page 165 Maintenance 4. Cable Unit 13. Install the motors for the Joints #5 and #6. Connect the cables and air tube and store them inside. Upper photo: Joint #5 motor side Place the Ethernet cable and the air tube (blue) on the near side. Lower photo: Joint #6 motor side Place the other cables and the air tube (clear) on the front side.
Page 166 Maintenance 4. Cable Unit 16. C8XL: Fix the cables to the Arm #4 maintenance cover using a cable bracket (C4). Wrap the cables with the attached silicone sheet. Use a cable bracket to fix the wrapped silicone sheet. Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.4 ±...
Page 167 Maintenance 4. Cable Unit 20. Use the cable protection spring to bind cables at the Arm #3 cable fixing plate 1. Type of wire tie: AB100 Number of wire ties: 4 21. Install the Arm #3 cable fixing plate 1 to the Arm #3. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ±...
Page 168 Maintenance 4. Cable Unit 24. Connect the connector to the control board 2. Connector: GS02 25. Connect the cable connectors inside the Arm #3. Connectors: X141, X151, X161, BR041, BR051, X041, X71, X72, PS, LED, BT51, BT4 (Hold the clip to remove.) 26.
Page 169 Maintenance 4. Cable Unit 28. Use brackets (S3) to fix the cable protection spring to the Arm #2. Hexagon socket head cap bolts: 2-M4×8 Tightening torque: 4.0 ± 0.2 N·m 29. Use cable brackets (C3A) to fix the cables to the Arm #2 temporarily.
Page 170 Maintenance 4. Cable Unit 34. Use the cable protection spring to bind cables at the Arm #2 cable fixing plate. Type of wire tie: AB100 Number of wire ties: 4 Be careful of the orientation of the Arm #2 cable fixing plate. The side with two U-shaped grooves should be placed down.
Page 171 Maintenance 4. Cable Unit 38. Use brackets (S2) to fix the cable protection spring to the Arm #1. Hexagon socket head cap bolts: 2-M4×8 Tightening torque: 4.0 ± 0.2 N·m 39. Use cable brackets (C2) to fix the cables to the Arm #2 temporarily. Place the silicone tube to the position where it is fixed with a cable bracket.
Page 172 Maintenance 4. Cable Unit 43. For the GS01 cable to be installed on the control board 1, place a mark at a position 130 mm from the connector. 44. For the X021, X121, BR021, and CN3 cables, place a mark at a position 160 mm from the connector respectively.
Page 173 Maintenance 4. Cable Unit 46. Fix the Arm #1 cable fixing plate temporarily to the Arm #1 and finely adjust the cable length. Hexagon socket head cap bolts: 2-M4×10 Rough guide of temporary fixing: The plate should not move. Notes for fine adjustment: - No excess looseness or tension on the cables.
Page 174 Maintenance 4. Cable Unit 50. Apply grease to the cables inside the J1 sleeve. Grease: Krytox Amount: Approximately 7.5g Application position: Between fixing section of the bracket (C1) and the mark on the base side 51. Fix the Arm #1 cable fixing plate to the Arm #1. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ±...
Page 175 Maintenance 4. Cable Unit 56. Install the battery board fixing plate. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m 57. Connect the battery connectors. 58. Install the battery to the battery box. 59. Pass the Joint #1 timing belt through the cable. 60.
Page 176 Maintenance 4. Cable Unit 63. Push out the following cables upward through the opening of the base. D-sub cable Ground wire RJ45 connector F-sensor connector 64. Install the brake power supply to the plate. The cables should be located in the direction as shown in the photo. (See the photo.) Cross recessed head screws with washer: 2-M3×6 Tightening torque: 0.45 ±...
Page 177 Maintenance 4. Cable Unit 68. Connect the M/C cable connectors. Connectors: X11, X12, X14, BR010, BR011, X010, X020, X040, LED, GS01, BT1 69. 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 70.
Page 178: Replacing The Cable Unit (M/C Cable Downward)
Maintenance 4. Cable Unit 4.1.2 Replacing the Cable Unit (M/C Cable Downward) Name Qty. Note For standard, cleanroom 2172929 models C8-A701*B* (C8) For protection model 2172932 For standard, cleanroom 2172930 Cable unit C8-A901*B* (C8L) models For protection model 2172933 Maintenance For standard, cleanroom Parts 2172931...
Page 179 Maintenance 4. Cable Unit Removal: Cable unit (M/C cable downward) 1. Move the Manipulator to the origin posture (0 pulse position). 2. Turn OFF the Controller. 3. Turn the Manipulator laterally. ■ When turning the Manipulator laterally, there must be two or more people to work on it so that at least one of them can support the arm while the others are removing the bolts.
Page 180 Maintenance 4. Cable Unit 9. Remove the ground wire terminals. Cross recessed head screws with washer S, C models: : 9-M4×8, 2-M3×6 P model : 10-M4×8, 2-M3×6 10. Remove the brake power supply. Cross recessed head screws with washer: 2-M3×6 11.
Page 181 Maintenance 4. Cable Unit Installation: Cable unit (M/C cable downward) 1. Perform the installation steps (1) to (62) of Maintenance: 4.1.1 Replacing the Cable Unit (M/C Cable Backward). 2. Turn the Manipulator laterally. ■ When turning the Manipulator laterally, there must be two or more people to work on it so that at least one of them can support the arm while the others are removing the bolts.
Page 182 Maintenance 4. Cable Unit 8. Install the two air tubes according to the marks on the connector plate. Air1: Clear Air2: Blue NOTE  Install the air tube with the correct color. 9. Install the following covers and plate. Arm #4 side covers (both sides) Arm #4 maintenance cover (C8XL only) Arm #3 cover Arm #3 maintenance cover...
Page 183: Connector Pin Assignment
Maintenance 4. Cable Unit 4.2 Connector Pin Assignment 4.2.1 Signal Cable C8 Rev.13...
Page 184 Maintenance 4. Cable Unit C8 Rev.13...
Page 185 Maintenance 4. Cable Unit C8 Rev.13...
Page 186: Power Cable
Maintenance 4. Cable Unit 4.2.2 Power Cable C8-A701*** (C8), C8-A901*** (C8L) C8 Rev.13...
Page 187 Maintenance 4. Cable Unit C8-A1401*** (C8XL) C8 Rev.13...
Page 188 Maintenance 4. Cable Unit C8-A701*** (C8), C8-A901*** (C8L), C8-A1401*** (C8XL) C8 Rev.13...
Page 189: User Cable
Maintenance 4. Cable Unit 4.2.3 User Cable 4.2.4 Color of Cables The following table shows the codes and cable colors indicated in the pin assignments 4.2.1 Signal Cable 4.2.2 Power Cable 4.2.3 User Cable Code Cable color Black White Green Yellow Brown Blue...
Page 190: Joint #1
Maintenance 5. Joint #1 5. Joint #1 ■ Before performing any replacement procedure, turn OFF the Controller and related equipment, and then disconnect the power plug from the power source. Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system.
Page 191: M/C Cable Backward (Joint #1)
Maintenance 5. Joint #1 5.1 M/C Cable Backward (Joint #1) 5.1.1 Joint #1 - Replacing the Motor (M/C Cable Backward) Name Qty. Note C8-A701** (C8) 2172921 Motor unit C8-A901** (C8L) (Joint #1) C8-A1401** (C8XL) 2172922 Maintenance Belt tensile jig* 1674582 Parts J1 brake positioning jig* 1675081...
Page 192 Maintenance 5. Joint #1 Removal: Joint #1 Motor (M/C Cable Backward) 1. Turn OFF the Controller. 2. Remove the base maintenance cover. For details, refer to Maintenance: 3. Covers. 3. Remove the connector plate (M/C cable backward). For details, refer to Maintenance: 3. Covers. 4.
Page 193 Maintenance 5. Joint #1 6. Remove the Joint #1 brake plate from the Joint #1 motor unit. Hexagon socket head cap bolts: 3-M4×20 7. Remove the Joint #1 motor unit from the base. Hexagon socket head cap bolts: 3-M6×30 (with a plain washer) Be careful not to tear and lose the heat radiation sheet attached to the motor.
Page 194 Maintenance 5. Joint #1 Installation: Joint #1 Motor (M/C Cable Backward) 1. Put the Joint #1 timing belt on the Joint #1 pulley 2 of the Joint #1. Hold the belt so as not to drop it. 2. Check that the heat radiation sheet is attached on the right side of the motor (when seeing from the rear side of the Manipulator).
Page 195 Maintenance 5. Joint #1 3. Apply proper tension to the Joint #1 motor unit and secure it. When securing the motor unit, attach the heat dissipation sheet to the right side of the base (when seeing from the rear side of the Manipulator).
Page 196 Maintenance 5. Joint #1 4. Install the Joint #1 electromagnetic brake / brake plate to the Joint 1 motor unit. Hexagon socket head cap bolts: 3-M4×20 Tightening torque: 4.0 ± 0.2 N·m Check that the motor and the brake core are aligned. Regarding brake misalignment: - Misalignment of the brake core may cause abnormal sound or apply abnormal torque on the brake.
Page 197 Maintenance 5. Joint #1 Heat radiation block Installation 1. Check that the heat radiation sheet is attached on the heat radiation block. If the Manipulator is operated without the heat radiation sheet, the motor NOTE  generates heat and the error may occur. If the heat radiation sheet has the protection film, remove the film.
Page 198 Maintenance 5. Joint #1 3-4 Wrap the wire tie around the motor. 3-5 Tighten the wire tie to hold the heat radiation sheet firmly. Make sure that the heat radiation sheet sticks out of the heat radiation block. NOTE Do not tighten the wire tie too much. It may result in cable ...
Page 199: Joint #1 - Replacing The Reduction Gear Unit (M/C Cable Backward)
Maintenance 5. Joint #1 5.1.2 Joint #1 - Replacing the Reduction Gear Unit (M/C Cable Backward) Name Qty. Note C8-A701** (C8) 1674602 Reduction gear unit C8-A901** (C8L) 1674603 Maintenance (Joint #1) C8-A1401** (C8XL) 1674604 Parts Belt tensile jig* 1674582 J1 brake positioning jig* 1675081 Wire tie (AB100) 1675753...
Page 200 Maintenance 5. Joint #1 Removal: Joint #1 Reduction gear unit (M/C Cable Backward) ■ This procedure has possibility of hands and fingers being caught and/or damage or malfunction to the Manipulator. Be very careful when performing maintenance. ■ Do not loosen the bolts while the Arm #2 is not tilted. It may cause the belt come off and the Arm #2 falls down, and it is extremely hazardous.
Page 201 Maintenance 5. Joint #1 5. Remove the cable interference prevention plate. Hexagon socket head cap bolts: 2-M3×6 6. Remove the base cable bracket (C1). Hexagon socket head cap bolts: 2-M3×6 7. Remove the Joint #1 timing belt. 8. Remove the Joint #2 motor unit. For details, refer to Maintenance 6.1 Joint #2 - Replacing the Motor, Removal steps (1) to (9).
Page 202 Maintenance 5. Joint #1 11. Disconnect the internal cables from the base to the Arm #1 side. Protect the connectors with masking tapes. - To protect the connector’s clips - To avoid adherence of cable grease Disconnect the cables one by one in order from the smallest NOTE ...
Page 203 Maintenance 5. Joint #1 Installation: Joint #1 Reduction gear unit (M/C Cable Backward) 1. Install the Joint #1 reduction gear unit. Hexagon socket head cap bolts: 12-M6×50 Tightening torque: 18.0 ± 0.9 N·m Installation face of the base reduction gear unit has clearance holes.
Page 204 Maintenance 5. Joint #1 5. Connect the connector to the control board 1. Connector: GS01 6. Install the Joint #1 cable bracket (Arm #1 side). Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m 7. Install the Joint #2 motor unit. For details, refer to Maintenance 6.1 Joint #2 - Replacing the Motor, Installation steps (4) to (9).
Page 205 Maintenance 5. Joint #1 11. Install the Joint #1 motor unit. For details, refer to Maintenance 5.1.1 Joint #1 – Replacing the Motor (M/C Cable Backward), Removal steps (1) to (4). 12. Pass the following parts through the hole inside the base to the upper part of the base.
Page 206: Joint #1 - Replacing The Timing Belt (M/C Cable Backward)
Maintenance 5. Joint #1 5.1.3 Joint #1 - Replacing the Timing Belt (M/C Cable Backward) Name Qty. Note C8-A701** (C8) 560 mm 1655928 Timing belt C8-A901** (C8L) 580 mm 1655929 (Joint #1) C8-A1401** (C8XL) 595 mm 1655930 Maintenance Part Belt tensile jig * 1674582 J1 brake positioning jig* 1675081...
Page 207 Maintenance 5. Joint #1 Removal: Joint #1 Timing belt (M/C Cable Backward) 1. Turn OFF the Controller. 2. Remove the base maintenance cover. For details, refer to Maintenance 3. Covers. 3. Remove the connector plate (M/C cable backward). For details, refer to Maintenance 3. Covers. 4.
Page 208 Maintenance 5. Joint #1 Remove the ground wire from each connector. To remove the ground wire, hold the connector by hand and pull the ground wire. 8. Remove the brake power supply. Cross recessed head screws with washer: 2-M3×6 9. Remove the ground wire plate (M/C cable backward). Hexagon socket head cap bolts: 2-M4×10 10.
Page 209 Maintenance 5. Joint #1 11. Disconnect the following parts downward from the hole inside the base. D-sub cable Ground wire RJ45 connector F-sensor connector 12. Remove the Joint #1 motor unit. For details, refer to Maintenance: 5.1.1 Joint #1-Replacing the Motor (M/C Cable Backward), Removal steps (6) to (7).
Page 210 Maintenance 5. Joint #1 Installation: Joint #1 Timing belt (M/C Cable Downward) 1. Pass the cables and air tubes to the Joint #1 timing belt. 2. Mount the Joint #1 cable fixing plate. Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.0 ± 0.1 N·m 3.
Page 211 Maintenance 5. Joint #1 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 7. Install the brake power supply to the plate. Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo.
Page 212 Maintenance 5. Joint #1 13. Install the base maintenance cover. For details, refer to Maintenance: 3 Covers. 14. Calibrate the Joint #1. For details, refer to Maintenance: 16. Calibration. C8 Rev.13...
Page 213: Joint #1 - Replacing The Electromagnetic Brake (M/C Cable Backward)
Maintenance 5. Joint #1 5.1.4 Joint #1 - Replacing the Electromagnetic Brake (M/C Cable Backward) Name Qty. Note Electromagnetic brake (Joint #1, 2) 2172926 Maintenance J1 brake positioning jig * 1675081 Parts Wire tie (AB100) 1675753 Hexagonal wrench For M4 hexagon socket head cap bolt (width across flats: 3 mm) Tools Cross-point screwdriver (#2)
Page 214 Maintenance 5. Joint #1 Removal: Joint #1 Electromagnetic brake (M/C Cable Backward) 1. Remove the Joint #1 electromagnetic brake from the Joint #1 motor unit. For details, refer to Maintenance: 5.1.1 Joint #1-Replacing the Motor (M/C Cable Backward), Removal steps (1) to (6). NOTE ...
Page 215: M/C Cable Downward (Joint #1)
Maintenance 5. Joint #1 5.2 M/C Cable Downward (Joint #1) 5.2.1 Joint #1 - Replacing the Motor (M/C Cable Downward) Name Qty. Note C8-A701*B* (C8) 2172921 Motor unit C8-A901*B* (C8L) (Joint #1) C8-A1401*B* (C8XL) 2172922 Maintenance Belt tensile jig* 1674582 Parts J1 brake positioning jig* 1675081...
Page 216 Maintenance 5. Joint #1 Removal: Joint #1 Motor (M/C Cable Downward) Turn OFF the Controller. Turn the Manipulator laterally. ■ When turning the Manipulator laterally, there must be two or more people to work on it so that at least one of them can support the arm while the others are removing the bolts.
Page 217 Maintenance 5. Joint #1 Remove the Joint #1 brake plate from the Joint #1 motor unit. 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.
Page 218 Maintenance 5. Joint #1 Installation: Joint #1 Motor (M/C Cable Downward) Mount the Joint #1 motor unit to the base. For details, refer to Maintenance: 5.1.1 Joint #1-Replacing the Motor (M/C Cable Backward), Removal steps (1) to (4). Install the brake power supply to the plate. Make sure to install the brake power supply so that the cables will be in the direction as shown in the photo.
Page 219: Joint #1 - Replacing The Reduction Gear Unit (M/C Cable Downward)
Maintenance 5. Joint #1 5.2.2 Joint #1 - Replacing the Reduction Gear Unit (M/C Cable Downward) Name Qty. Note C8-A701*B* (C8) 1674602 Reduction gear unit C8-A901*B* (C8L) 1674603 (Joint #1) C8-A1401*B* (C8XL) 1674604 Maintenance Parts Belt tensile jig* 1674582 J1 brake positioning jig* 1675081 Wire tie AB100 1675753...
Page 220 Maintenance 5. Joint #1 Removal: Joint #1 Reduction gear unit (M/C cable downward) ■ This procedure has possibility of hands and fingers being caught and/or damage or malfunction to the Manipulator. Be very careful when performing maintenance. ■ Do not loosen the bolts while the Arm #2 is not tilted. It may cause the belt come off and the Arm #2 falls down, and it is extremely hazardous.
Page 221 Maintenance 5. Joint #1 Installation: Joint #1 Reduction gear unit (M/C Cable Downward) Install the Joint #1 reduction gear unit. For details, refer to Maintenance 5.1.2 Joint #1- Replacing the Reduction Gear Unit (M/C Cable Backward), Installation steps (1) to (11). Install the ground terminals to the plate.
Page 222: Joint #1 - Replacing The Timing Belt (M/C Cable Downward)
Maintenance 5. Joint #1 5.2.3 Joint #1 - Replacing the Timing Belt (M/C Cable Downward) Name Qty. Note C8-A701*B* (C8) 560 mm 1655928 Timing belt C8-A901*B* (C8L) 580 mm 1655929 (Joint #1) C8-A1401*B* (C8XL) 595 mm 1655930 Maintenance Part Belt tensile jig* 1674582 J1 brake positioning jig* 1675081...
Page 223 Maintenance 5. Joint #1 Removal: Joint #1 Timing belt (M/C Cable Downward) Turn OFF the Controller. Turn the Manipulator laterally. ■ When turning the Manipulator laterally, there must be two or more people to work on it so that at least one of them can support the arm while the others are removing the bolts.
Page 224 Maintenance 5. Joint #1 Remove the ground wire plate (M/C cable downward). Hexagon socket head cap bolts: 2-M4×12 Remove the Joint #1 motor unit. For details, refer to Maintenance: 5.1.1 Joint #1-Replacing the Motor (M/C cable backward), Removal steps (6) to (7). Remove the Joint #1 motor unit.
Page 225 Maintenance 5. Joint #1 Installation: Joint #1 Timing belt (M/C Cable Downward) 1. Pass the cables and the air tubes to the Joint #1 timing belt. 2. Mount the Joint #1 motor unit. For details, refer to Maintenance: 5.1.1 Joint #1-Replacing the Motor (M/C Cable Backward), Installation steps (1) to (4).
Page 226 Maintenance 5. Joint #1 7. Install the D-sub connector in accordance with the indications on the connector plates. Left: D-sub for brake release (with a wire marker: SW1): B-release Right: D-sub for user wiring (no wire marker: with a round terminal): D-sub 8.
Page 227: Joint #1 - Replacing The Electromagnetic Brake (M/C Cable Downward)
Maintenance 5. Joint #1 5.2.4 Joint #1 - Replacing the Electromagnetic Brake (M/C Cable Downward) Name Qty. Note Electromagnetic brake (Joint #1, #2) 2172926 Maintenance J1 brake positioning jig * 1675081 Parts Wire tie AB100 1675753 Hexagonal wrench For M4 hexagon socket head cap bolt (width across flats: 3 mm) Tools Cross-point screwdriver (#2)
Page 228 Maintenance 5. Joint #1 Removal: Joint #1 Electromagnetic brake (M/C Cable Downward) 1. Remove the Joint #1 brake plate from the Joint #1 motor unit. For details, refer to Maintenance: 5.2.1 Joint #1-Replacing the Motor (M/C Cable Downward), Removal steps (1) to (6). NOTE ...
Page 229 Maintenance 5. Joint #1 Installation: Joint #1 Electromagnetic brake (M/C Cable Downward) 1. Install the Joint #1 brake to the brake plate. Hexagon socket head cap bolts: 3-M4×25 Tightening torque: 4.0 ± 0.2 N·m Be careful of the assembly direction of the Joint #1 electromagnetic brake.
Page 230: Joint #2
Maintenance 6. Joint #2 6. Joint #2 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
Page 231: Joint #2 - Replacing The Motor
Maintenance 6. Joint #2 6.1 Joint #2 - Replacing the Motor Name Qty. Note AC servo motor 750 W 2168683 Maintenance Parts Belt tensile jig* 1674582 width across flats: 2.5 For M5 hexagon socket set screw Hexagonal width across flats: 3 mm For M6 hexagon socket head cap bolt wrench width across flats: 4 mm...
Page 232 Put a cloth between the Arm #1 and Arm #2 so that the arms do not touch each other. Command: EPSON >brake off, 2 ■ There is a possibility of hands and fingers being caught and/or damage or malfunction to the Manipulator. Be very careful when moving the Manipulator.
Page 233 Maintenance 6. Joint #2 6. Disconnect the following connectors of the motor. Connector: X121, X021, BT2, BR021 (Hold the clip to remove.) 7. Remove the brake power supply. Cross recessed head screws with captive washer: 2-M3×6 8. Loosen the bolts securing the Joint #2 motor unit and remove the belt.
Page 234 Maintenance 6. Joint #2 9. Remove the Joint #2 motor unit. 10. Remove the Joint #2 pulley 1 and the drive boss from the motor shaft of the Joint #2 motor unit. Remove two screws at the flat (D-cut) part of the motor shaft when viewing from above.
Page 235 Maintenance 6. Joint #2 12. Remove the motor plate from the Joint #2 motor. Hexagon socket head cap bolts: 4-M6×20 C8 Rev.13...
Page 236 Maintenance 6. Joint #2 Installation: Joint #2 Motor 1. Install the motor plate to the Joint #2 motor. Hexagon socket head cap bolts: 4-M6×20 Tightening torque: 13.0 ± 0.6 N·m Be careful of the assembly direction of the motor plate. NOTE ...
Page 237 Maintenance 6. Joint #2 3. Mount the drive boss and the pulley 1 to the Joint #2 motor unit. Insert the pulley 1 so that the set screw is aligned to the flat surface of the motor shaft. Fix the pulley 1 and the motor shaft. Leave 0.5 mm between the pulley 1 and the electromagnetic brake.
Page 238 Maintenance 6. Joint #2 6. Apply tension to the Joint #2 timing belt and fix Joint #2 motor unit. Joint #2 timing belt tension: 58 to 95 N Belt tension meter setting values Weight: 4.0 g/mm width × m span, Width: 14 mm, Span: 146 mm Hexagon socket set screws: 3-M5×25 (with a plain washer) Tightening torque: 8.0 ±...
Page 239 Maintenance 6. Joint #2 9. Remove the heat dissipation block and the heat dissipation sheet to the Arm #2. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m 10. Mount the Arm #1 cover and the Arm #1 side cover. For details, refer to Maintenance: 3.
Page 240: Joint #2- Replacing The Reduction Gear Unit
Maintenance 6. Joint #2 6.2 Joint #2- Replacing the Reduction Gear Unit Name Qty. Note Reduction C8-A701*** (C8) 1674605 gear unit C8-A901** *(C8L) (Joint #2) C8-A1401*** (C8XL) 1674606 Arm #1 1263978 Maintenance C8-A701*** (C8) Parts O-ring C8-A901** *(C8L) Arm #2 1656161 (Joint #2) C8-A1401***...
Page 241 Maintenance 6. Joint #2 Removal: Joint #2 Reduction gear unit 1. Remove the Joint #2 timing belt. For details, refer to Maintenance 6.3 Joint #2 - Replacing the Timing Belt, Removal steps (1) to (3). 2. Remove the following parts. Battery Battery board Battery connector...
Page 242 Maintenance 6. Joint #2 7. Remove the Arm #2. Hexagon socket head cap bolts (with a plain washer) C8, C8L: 16-M5×30 C8XL: 16-M6×35 Remove a wave washer on the Arm #1 side. The wave washer will be used again. Be careful not to lose it. Wipe grease on the part while removing it.
Page 243 Maintenance 6. Joint #2 10. Remove the O-ring from the groove on the Arm #2. Wipe grease on the part while removing it. C8 Rev.13...
Page 244 Maintenance 6. Joint #2 Installation: Joint #2 Reduction gear unit Apply a thin coat of grease (SK-1A) to the O-ring. Fit the O-ring to the groove on the Arm #2. 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.
Page 245 Maintenance 6. Joint #2 Apply a thin coat of grease (SK-1A) to the O-ring. Fit the O-ring to the groove on the reduction gear unit. 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.
Page 246 Maintenance 6. Joint #2 After fixing the Arm #2, fix the Arm #1 side arm. Hexagon socket head cap bolts: 8-M6×25 (with a plain washer) Tightening torque: 18.0 ± 0.9 N·m Install the Joint #2 pulley 2 to the Joint #2 shaft. Hexagon socket head cap bolts: 2-M5×10 (with a brass washer) Tightening torque: 3.9 ±...
Page 247: Joint #2 - Replacing The Timing Belt
Maintenance 6. Joint #2 6.3 Joint #2 - Replacing the Timing Belt Name Qty. Note C8-A701*** (C8) 475 mm 1655920 Timing belt C8-A901*** (C8L) 485 mm 1655924 Maintenance (Joint #2) Parts C8-A1401*** (C8XL) 540 mm 1655927 Belt tensile jig * 1674582 Hexagonal wrench For M5 hexagon socket head cap bolt...
Page 248: Joint #2 - Replacing The Electromagnetic Brake
Maintenance 6. Joint #2 6.4 Joint #2 - Replacing the Electromagnetic Brake Name Qty. Note Electromagnetic brake (Joint #1, #2) 2172926 Maintenance Parts Belt tensile jig* 1674582 width across flats: 2.5 mm For M5 hexagon socket set screw width across flats: 3 mm For M6 hexagon socket set screw Hexagonal width across flats: 4 mm...
Page 249: Joint #3
Maintenance 7. Joint #3 7. Joint #3 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
Page 250: Joint #3 - Replacing The Motor
Maintenance 7. Joint #3 7.1 Joint #3 - Replacing the Motor Name Qty. Note Maintenance AC servo motor 400 W 2168684 Parts Belt tensile jig* 1674582 width across flats: 2.5 mm For M5 hexagon socket set screws Hexagonal width across flats: 3 mm For M4 hexagon socket head cap bolts wrench width across flats: 4 mm...
Page 251 Therefore, release the brake and tilt the Arm #3 in advance. Command: EPSON >brake off, 3 ■ There is a possibility of hands and fingers being caught and/or damage or malfunction to the Manipulator. Be very careful when moving the Manipulator.
Page 252 Maintenance 7. Joint #3 6. Remove the brake power supply. Cross recessed head screws with captive washer: 2-M3×6 7. Loosen the bolts securing the Joint #3 motor unit and remove the belt. Hexagon socket head cap bolts: 3-M4×20 (with a plain washer) ■...
Page 253 Maintenance 7. Joint #3 8. Remove the Joint #3 motor unit. NOTE Be careful not to drop the removed connectors inside the Arm.  9. Remove the Joint #3 pulley 1 and the drive boss from the motor shaft of the Joint #3 motor unit. Remove two screws at the flat (D-cut) part of the motor shaft when viewing from above.
Page 254 Maintenance 7. Joint #3 10. Remove the Joint #3 electromagnetic brake. Hexagon socket set screws: 2-M5×10 (with a brass bushing) The screws have a brass bushing. Be careful not to lose them. 11. Remove the motor plate from the Joint #3 motor. Hexagon socket head cap bolts: 4-M5×15 C8 Rev.13...
Page 255 Maintenance 7. Joint #3 Installation: Joint #3 Motor 1. Install the motor plate to the Joint #3 motor. Hexagon socket head cap bolts: 4-M5×15 Tightening torque: 8.0 ± 0.4 N·m NOTE Be careful of the assembly direction of the motor plate. (See ...
Page 256 Maintenance 7. Joint #3 3. Mount the drive boss and the pulley 1 to the Joint #3 motor unit. Insert the pulley 1 so that the set screw is aligned to the flat surface of the motor shaft. Fix the pulley 1 and the motor shaft. Leave 0.5 mm between the pulley 1 and the electromagnetic brake.
Page 257 Maintenance 7. Joint #3 6. Apply tension to the Joint #3 timing belt and fix the Joint #3 motor unit. Joint #3 timing belt tension: 25 to 85 N Belt tension meter setting value Weight: 2.5 g/mm width × m span, Width: 10 mm, Span: 168 mm Hexagon socket set screw: 3-M4×20 (with a plain washer) Tightening torque: 4.0 ±...
Page 258: Joint #3 - Replacing The Reduction Gear Unit
Maintenance 7. Joint #3 7.2 Joint #3 - Replacing the Reduction Gear Unit Name Qty. Note Reduction C8-A701*** (C8) 1674607 gear unit C8-A901*** (C8L) (Joint #3) C8-A1401*** (C8XL) 1674608 Maintenance 1263977 Parts Arm #2 side O-ring 1510528 (Joint #3) Arm #3 side Belt tensile jig* 1674582 For M3 hexagon socket head cap bolts...
Page 259 Maintenance 7. Joint #3 Removal: Joint #3 Reduction gear unit 1. Remove the Joint #3 timing belt. For details, refer to Maintenance 7.3 Joint #3 - Replacing the Timing Belt, Removal steps (1) to (3). 2. Remove the Arm #2 side arm fixing bolts. Hexagon socket head cap bolts: 6-M5×20 (with a plain washer) 3.
Page 260 Maintenance 7. Joint #3 5. Remove the wave generator from the reduction gear unit. If the wave generator unit does not come off easily, set the pulley 2 as shown in the photo to the shaft and pull out the parts. Wipe grease on the wave generator while removing it.
Page 261 Maintenance 7. Joint #3 Installation: Joint #3 Reduction gear unit Apply a thin coat of grease (SK-1A) to the O-ring. Fit the O-ring into the groove on the Arm #3. 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.
Page 262 Maintenance 7. Joint #3 Temporarily fix the Arm #1 side arm to the Arm #2. At this time, set the wave washer to the Arm #2. Hexagon socket head cap bolts: 6-M5×20 (with a plain washer) ■ There is a possibility of hands and fingers being caught and/or damage or malfunction to the Manipulator.
Page 263 Maintenance 7. Joint #3 Install the Joint #3 pulley 2 to the Joint #3 shaft. Hexagon socket head cap bolts (with 1 brass bushing) C8, C8L: 2-M5×10 C8XL: 2-M5×12 Tightening torque: 3.9 ± 0.2 N·m Insert the pulley 2 so that one of the set screws is at the flat NOTE ...
Page 264: Joint #3 - Replacing The Timing Belt
Maintenance 7. Joint #3 7.3 Joint #3 - Replacing the Timing Belt Name Qty. Note C8-A701*** (C8) 471 mm 1655915 Timing belt C8-A901*** (C8L) 480 mm 1655918 Maintenance (Joint #3) Parts C8-A1401*** (C8XL) 501 mm 1655919 Belt tensile jig* 1674582 Hexagonal wrench For M4 hexagon socket head cap bolt (width across flats: 3 mm)
Page 265: Joint #3 - Replacing The Electromagnetic Brake
Maintenance 7. Joint #3 7.4 Joint #3 - Replacing the Electromagnetic Brake Name Qty. Note Electromagnetic brake (Joint #3) 2172927 Maintenance Parts Belt tensile jig* 1674582 width across flats: 2.5 mm For M5 hexagon socket set screw Hexagonal width across flats: 3 mm For M4 hexagon socket head cap bolt wrench width across flats: 4 mm...
Page 266: Joint #4
Maintenance 8. Joint #4 8. Joint #4 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
Page 267: Joint #4 - Replacing The Motor
Maintenance 8. Joint #4 8.1 Joint #4 - Replacing the Motor Name Qty. Note 2172051 Maintenance AC servo motor 100 W (common to Joints #4, #5, #6) Parts Belt tensile jig* 1674582 width across flats: 2 mm For M4 hexagon socket set screws Hexagonal width across flats: 2.5 mm For M3 hexagon socket head cap bolts...
Page 268 Maintenance 8. Joint #4 Removal: Joint #4 Motor 1. Turn OFF the Controller power. 2. Remove the following covers. Arm #3 cover Arm #3 maintenance cover Arm #2 side cover For details, refer to Maintenance: 3. Covers. 3. Pull out the cables from the Arm #3 and disconnect the following connectors.
Page 269 Maintenance 8. Joint #4 7. Remove the Joint #4 pulley 1 and the drive boss from the motor shaft of the Joint #4 motor unit. Pulley 1 and drive boss screws Hexagon socket set screws: 2-M4×4 (with a brass bushing) Drive boss and motor shaft screws Hexagon socket set screws: 2-M4×4 There is a brass bushing on one of the set screws fixing the drive...
Page 270 Maintenance 8. Joint #4 Installation: Joint #4 Motor 1. Install the motor plate to the Joint #4 motor. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m Be careful of the assembly direction of the motor plate. NOTE ...
Page 271 Maintenance 8. Joint #4 Drive boss and the motor shaft: Hexagon socket set screws: 2-M4×4 Tightening torque: 2.5 ± 0.2 N·m Align the screws to the two flat faces of the motor shaft and fix them. Drive boss and the pulley 1: Hexagon socket set screws: 2-M4×4 (with a brass bushing) Tightening torque: 2.5 ±...
Page 272 Maintenance 8. Joint #4 Regarding belt tension: - Jumping (position gap) may occur if the value is below the lower limit. NOTE  - Vibration (abnormal noise) or reduction in life of the parts may occur if the value exceeds the upper limit.
Page 273: Joint #4 - Replacing The Reduction Gear Unit
Maintenance 8. Joint #4 8.2 Joint #4 - Replacing the Reduction Gear Unit Name Qty. Note Reduction C8-A701*** (C8) 1674609 gear unit C8-A1401*** (C8XL) Maintenance 1675434 Parts (Joint #4) C8-A901*** (C8L) Belt tensile jig* 1674582 width across flats: 2.5 mm For M3 hexagon socket head cap bolts width across flats: 3 mm For M4 hexagon socket head cap bolts...
Page 274 Maintenance 8. Joint #4 Removal: Joint #4 Reduction gear unit 1. Turn OFF the Controller power. 2. Remove the Arm #4 side cover and Arm #3 cover. For details, refer to Maintenance 3. Covers. 3. Remove the Joints #5 and #6 motors. For details, refer to the Removal steps in Maintenance 9.1 Joint #5 - Replacing the Motor and Maintenance 10.1 Joint #6 - Replacing the Motor.
Page 275 Maintenance 8. Joint #4 7. Remove the bolts fixing the J4 flange and the Joint #4 reduction gear unit. Hexagon socket head cap bolts: 16-M3×20 8. Remove the wave generator of the Joint #4 reduction gear unit together with the J4 flange. If the wave generator does not come off easily, insert a tool in a gap between the J4 flange and the Arm and remove the wave generator little by little.
Page 276 Maintenance 8. Joint #4 11. Remove the bolts of the bearing holder on the pulley. Hexagon socket head cap bolts: 3-M3×8 (with a plain washer) 12. Remove the pulley from the pulley spacer. Hexagon socket set screws: 2-M4×4 13. Remove the pulley spacer from the wave generator. Hexagon socket head cap bolts: 4-M3×8 C8 Rev.13...
Page 277 Maintenance 8. Joint #4 Installation: Joint #4 Reduction gear unit 1. Apply grease to the mating surface of the sleeve and the fixing bolts. (for grease leakage prevention for the reduction gear unit) Fit the J4 sleeve and install the J4 sleeve holder. Hexagon socket head cap bolts: 4-M3×6 Tightening torque: 2.0 ±...
Page 278 Maintenance 8. Joint #4 4. Install the wave generator of the Joint #4 reduction gear unit. 5. Set the O-ring attached to the reduction gear unit to the O-ring groove on the Joint #4 reduction gear unit. Then, install the J4 flange. Hexagon socket head cap bolts: 16-M3×20 Tightening torque: 2.4 ±...
Page 279 Maintenance 8. Joint #4 8. Apply adhesive to the following parts of the J4 pulley. Bearing mating part Inner ring (J4 sleeve) Outer ring (J4 pulley) Adhesive: Loctite 641 Install the J4 pulley bearing, and tighten the bearing bolt. Hexagon socket head cap bolts: 3-M3×8 (with a plain washer) Tightening torque: 2.0 ±...
Page 280: Joint #4 - Replacing The Timing Belt
Maintenance 8. Joint #4 8.3 Joint #4 - Replacing the Timing Belt Name Qty. Note Timing belt (Joint #4) 1655931 Maintenance Parts Belt tensile jig 1674582 width across flats: 2.5 mm Hexagonal For M3 hexagon socket head cap bolt width across flats: 3 mm wrench For M4 hexagon socket head cap bolt Cross-point screwdriver (#2)
Page 281 Maintenance 8. Joint #4 4. Remove the Arm #3 cable bracket and cable protection sheet. Hexagon socket head cap bolts: 2-M3×6 The Arm #3 cable bracket and cable protection sheet will be used again. Be careful not to lose them. 5.
Page 282 Maintenance 8. Joint #4 10. Remove the air tube (blue) from the fitting. C8XL: 11. Remove the Arm #4 maintenance cover. For details, refer to Maintenance: 3 Covers. C8XL: 12. 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.
Page 283 Maintenance 8. Joint #4 Installation: Joint #4 Timing belt 1. Pass the Joint #4 timing belt around the Joint #4 pulley 2 2. Install the Joint #4 motor unit. For details, refer to Maintenance: 8.1 Joint #4 – Replacing the Motor, Installation steps (4) through (6). 3.
Page 284 Maintenance 8. Joint #4 6. Wrap the cables inside the Arm #3 with a cable protection sheet and install the Arm #3 cable bracket. Hexagon socket head cap bolts: 2-M3×6 Tightening torque: 2.0 ± 0.1 N·m 7. Install the cable bracket inside the Arm #3. Hexagon socket head cap bolts: 4-M4×10 Tightening torque: 4.0 ±...
Page 285 Maintenance 8. Joint #4 11. Connect the connectors inside the Arm #4. Connector: X052, X062 12. Fix the cable protection bracket to the Arm #4. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m Be careful not to get the cables caught. NOTE ...
Page 286: Joint #4 - Replacing The Electromagnetic Brake
Maintenance 8. Joint #4 8.4 Joint #4 - Replacing the Electromagnetic Brake Name Qty. Note 2172928 Electromagnetic brake Maintenance (common for Joints #4, #5, #6) Parts Belt tensile jig 1674582 width across flats: 2 mm For M4 hexagon socket set screws Hexagonal width across flats: 2.5 mm For M3 hexagon socket head cap bolts...
Page 287: Joint #5
Maintenance 9. Joint #5 9. Joint #5 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
Page 288: Joint #5 - Replacing The Motor
Maintenance 9. Joint #5 9.1 Joint #5 - Replacing the Motor Name Qty. Note 2172051 Maintenance AC servo motor 100 W (Common for Joints #4, #5, #6) Parts Belt tensile jig * 1674582 width across flats: 2 mm For M4 hexagon socket set screws Hexagonal width across flats: 2.5 For M3 hexagon socket head cap bolts...
Page 289 Maintenance 9. Joint #5 Removal: Joint #5 Motor 1. Turn OFF the Controller power. 2. Remove the Arm #4 side cover. For details, refer to Maintenance: 3. Covers. 3. Loosen the screws fixing the cable protection bracket on the Arm #4 and pull out the cables.
Page 290 Maintenance 9. Joint #5 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) 8. Remove the Joint #5 motor unit. Hexagon socket head cap bolts: 2-M4×15 (with a plain washer) 9.
Page 291 Maintenance 9. Joint #5 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 C8 Rev.13...
Page 292 Maintenance 9. Joint #5 Installation: Joint #5 Motor 1. Install the motor plate to the Joint #5 motor. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m Be careful of the assembly direction of the motor plate. NOTE Motor cable ...
Page 293 Maintenance 9. Joint #5 Drive boss and the motor shaft: Hexagon socket set screws: 2-M4×4 Tightening torque: 2.5 ± 0.2 N·m Align the screws to the two flat faces of the motor shaft and fix them. Drive boss and the pulley 1: Hexagon socket set screws: 2-M4×4 (with a brass bushing) Tightening torque: 2.5 ±...
Page 294 Maintenance 9. Joint #5 When using the belt tension tensile jig (maintenance part): Fix the belt tension tensile jig (for J4, J5, and J6) with the screws (2-M4×15) and push the rubber against the pulley. Tension is applied as the set screw (M6×15) is pushed by the rubber.
Page 295: Joint #5 - Replacing The Reduction Gear Unit (Replacing The Joint #5, #6 Reduction Gear Unit Set)
The Joints #5 and #6 reduction gear unit set is adjusted in advance. Name Qty. Note Maintenance Joints #5, #6 Reduction gear unit set 1674610 (common to C8 series) Parts Belt tensile jig* 1674582 width across flats: 2 mm For M4 hexagon socket set screws width across flats: 2.5 mm...
Page 296 Maintenance 9. Joint #5 Removal: Joints #5, #6 Reduction gear unit set 1. Turn OFF the Controller power. 2. Remove the Arm #4 side cover and Arm #3 cover. For details, refer to Maintenance 3. Covers. 3. Remove the Joints #5 and #6 motors. For details, refer to the Removal steps in Maintenance 9.1 Joint #5 - Replacing the Motor and Maintenance 10.1 Joint #6 - Replacing the Motor.
Page 297 Maintenance 9. Joint #5 6. Follow the following steps according to the model. C8: Remove the Joint #4 reduction gear unit. For details, refer to Removal steps in Maintenance 8.2 Joint #4 – Replacing the Reduction Gear Unit. C8L, C8XL: Remove the Arm #4 extension flange.
Page 298 Maintenance 9. Joint #5 Installation: Joints #5, #6 Reduction gear unit set 1. C8, C8L: Apply grease to the mating part of the sleeve and the fixing bolts. (for grease leakage prevention for the reduction gear unit) Fit the J4 sleeve and install the J4 sleeve holder. Hexagon socket head cap bolts: 4-M3×6 Tightening torque: 2.0 ±...
Page 299 Maintenance 9. Joint #5 C8L,C8XL: Install the Arm #4 extension flange to the Arm #4 extension part. C8L: Apply adhesive to the J4 sleeve and the J4 pulley bearing mating part (indicated by a yellow mark in the right photo) Adhesive: Loctite641 Hexagon socket head cap bolts: 4-M6×20 Tightening torque: 13.0 ±...
Page 300 Maintenance 9. Joint #5 5. Install the Joints #5 and #6 motors. For details, refer to Installation steps in Maintenance 9.1 Joint #5 – Replacing the Motor and Maintenance 10.1 Joint #6 – Replacing the Motor. 6. Install the removed covers. For details, refer to Maintenance 3.
Page 301: Joint #5 - Replacing The Timing Belt
Maintenance 9. Joint #5 9.3 Joint #5 - Replacing the Timing Belt Name Qty. Note Joint #5 timing belt 330 mm 1655932 Maintenance Parts Belt tensile jig 1674582 Hexagonal wrench For M4 hexagon socket head cap bolts (width across flats: 3 mm) Tools Cross-point screwdriver (#2) For cross recessed head screws...
Page 302: Joint #5 - Replacing The Electromagnetic Brake
Maintenance 9. Joint #5 9.4 Joint #5 - Replacing the Electromagnetic Brake Name Qty. Note Electromagnetic brake 2172928 (Common for Joints #4, #5, #6) Maintenance Parts Belt tensile jig 1674582 width across flats: 2 mm For M4 hexagon socket set screws Hexagonal width across flats: 2.5 mm For M3 hexagon socket head cap bolts...
Page 303 Maintenance 9. Joint #5 Removal: Joint #5 Electromagnetic brake 1. Remove the Joint #5 electromagnetic brake. For details, refer to Maintenance: 9.1 Joint #5 – Replacing the Motor, Removal steps (1) through (10). Installation: Joint #5 Electromagnetic brake 1. Mount the Joint #5 electromagnetic brake to the Joint #5 motor unit. For details, refer to Maintenance: 9.1 Joint #5 –...
Page 304: Joint #6
Maintenance 10. Joint #6 10. Joint #6 ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
Page 305: Joint #6 - Replacing The Motor
Maintenance 10. Joint #6 10.1 Joint #6 - Replacing the Motor Name Qty. Note Maintenance AC servo motor 100 W 2172051 (common to Joints #4, #5, #6) Parts Belt tensile jig * 1674582 width across flats: 2 mm For M4 hexagon socket set screws Hexagonal width across flats: 2.5 For M3 hexagon socket head cap bolts...
Page 306 Maintenance 10. Joint #6 Removal: Joint #6 Motor 1. Turn OFF the Controller power. 2. Remove the Arm #4 side cover. For details, refer to Maintenance: 3. Covers. 3. Loosen the screws fixing the cable protection plate on the Arm #4 and pull out the cables.
Page 307 Maintenance 10. Joint #6 8. Remove the Joint #6 motor pulley 1 and the drive boss from the Joint #6 motor unit. Pulley 1 and drive boss screws Hexagon socket set bolts: 2-M4×4 (with a brass bushing) Drive boss and motor shaft screws Hexagon socket set bolts: 2-M4×4 There is a brass bushing on one of the set screws fixing the drive boss and the pulley.
Page 308 Maintenance 10. Joint #6 Installation: Joint #6 motor 1. Install the motor plate to the Joint #6 motor. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ± 0.2 N·m Be careful of the assembly direction of the motor plate. NOTE ...
Page 309 Maintenance 10. Joint #6 Drive boss and the motor shaft: Hexagon socket set screws: 2-M4×4 Tightening torque: 2.5 ± 0.2 N·m Align the screws to the two flat faces of the motor shaft and fix them. Drive boss and the pulley 1: Hexagon socket set screws: 2-M4×4 (with a brass bushing) Tightening torque: 2.5 ±...
Page 310 Maintenance 10. Joint #6 When using the belt tension tensile jig (maintenance part): Fix the belt tension tensile jig (for Joints #4, #5, and #6) with the screws (2-M4×15) and push the rubber against the pulley. Tension is applied as the set screw (M6×15) is pushed by the rubber.
Page 311: Joint #6 - Replacing The Reduction Gear Unit (Replacing The Joints #5, #6 Reduction Gear Unit Set)
The Joints #5 and #6 reduction gear unit set is adjusted in advance. Name Qty. Note Maintenance Joints #5, #6 Reduction gear unit set 1674610 (common to C8 series) Parts Belt tensile jig* 1674582 width across flats: 2 mm For M4 hexagon socket set screws width across flats: 2.5 mm...
Page 312: Joint #6 - Replacing The Timing Belt
Maintenance 10. Joint #6 10.3 Joint #6 - Replacing the Timing Belt Name Qty. Note Maintenance Joint #6 timing belt 339 mm 1655933 Parts Belt tensile jig 1674582 Hexagonal wrench For M4 hexagon socket head cap bolts (width across flats: 3 mm) Tools Cross-point screwdriver (#2) For cross recessed head screws...
Page 313: Joint #6 - Replacing The Electromagnetic Brake
Maintenance 10. Joint #6 10.4 Joint #6 - Replacing the Electromagnetic Brake Name Qty. Note Maintenance Electromagnetic brake 2172928 (Common to Joints #4, #5, #6) Parts Belt tensile jig 1674582 width across flats: 2 mm For M4 hexagon socket set screws Hexagonal width across flats: 2.5 mm For M3 hexagon socket head cap bolts...
Page 314 Maintenance 10. Joint #6 Removal: Joint #6 Electromagnetic brake 1. Remove the Joint #6 electromagnetic brake. For details, refer to Maintenance: 10.1 Joint #6 – Replacing the Motor, Removal steps (1) through (9). Installation: Joint #6 Electromagnetic brake 1. Mount the Joint #6 electromagnetic brake to the Joint #6 motor unit. For details, refer to Maintenance: 10.1 Joint #6 –...
Page 315: 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 316 Maintenance 11. Replacing the Battery Unit The battery may run out if it passes the recommended replacement time. If no warnings of voltage reduction occur, the calibration for all joints is not necessary. You need to perform calibration if the position moves from the originals after replaced the battery.
Page 317: Replacing The Battery Unit (Lithium Battery)
Maintenance 11. Replacing the Battery Unit 11.1 Replacing the Battery Unit (Lithium Battery) Turn OFF the Controller power. Remove the Arm #1 side cover. For details, refer to Maintenance: 3. Covers. Remove the battery from the battery box. If you removed all the batteries before connecting the new ones, the calibration data will be deleted and NOTE ...
Page 318 Maintenance 11. Replacing the Battery Unit Install the Arm #1 side cover. For details, refer to Maintenance: 3. Covers. Turn ON the Controller power. Check operation to see if the Manipulator’s position and posture are out of position. Move the Manipulator to two or three points (poses) of the registered points. 10.
Page 319: Replacing The Battery Board
Maintenance 11. Replacing the Battery Unit 11.2 Replacing the Battery Board After parts have been replaced (motors, reduction gear units, brakes, timing belts, etc.), the Manipulator cannot perform positioning properly because a gap exists between the origin stored in each motor encoder and its corresponding origin stored in the Controller. Therefore, it is necessary to match these origins after replacing the parts.
Page 320 Maintenance 11. Replacing the Battery Unit Remove the battery board fixed to the plate. Cross recessed head screws: 3-M3×6 C8 Rev.13...
Page 321 Maintenance 11. Replacing the Battery Unit Installation: Battery board 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 3. Install the plate where the battery board is installed to. Hexagon socket head cap bolts: 2-M4×10 Tightening torque: 4.0 ±...
Page 322: Replacing The Control Board
Maintenance 12. Replacing the Control Board 12. Replacing the Control Board ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
Page 323: Replacing The Control Board 1
Maintenance 12. Replacing the Control Board 12.1 Replacing the Control Board 1 Removal: Control board 1 Turn OFF the Controller. Remove the Arm #1 center cover. For details, refer to Maintenance 3. Covers. Remove the connector connected to the control board 1. Connector: GS01 Remove the control board 1 fixed to the Arm #1.
Page 324 Maintenance 12. Replacing the Control Board Installation: Control board 1 Install the control board 1 protection plate. Cross recessed head screws with captive washer: M3×6 Tightening torque: 0.45 ± 0.1 N·m NOTE Be careful of the assembly direction of the protection plate. ...
Page 325: Replacing The Control Board 2
Maintenance 12. Replacing the Control Board 12.2 Replacing the Control Board 2 Removal: Control board 2 1. Turn OFF the Controller power. 2. Remove the Arm #3 cover. For details, refer to Maintenance: 3. Covers. 3. Remove the connector connected to the control board 2. Connector: GS02 4.
Page 326 Maintenance 12. Replacing the Control Board Installation: Control board 2 1. Install the control board 2 to the plate. Cross recessed head screws: 4-M3×8 Tightening torque: 0.45 ± 0.1 N·m NOTE Be careful of the assembly direction of the control board 2. ...
Page 327: Replacing The Led Lamp
Maintenance 13. Replacing the LED Lamp 13. Replacing the LED Lamp ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
Page 328 Maintenance 13. Replacing the LED Lamp Removal: LED lamp Turn OFF the Controller power. Remove the Arm #3 cover. For details, refer to Maintenance: 3. Covers. Remove the connector connected to the LED lamp. The connector for the LED lamp (LED) is under the Arm #3 cover. Connector: LED Remove the LED lamp from the Arm #3.
Page 329: 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 330 Maintenance 14. Replacing the M/C Cable Name Qty. Note Straight R12NZ900S1 L-shaped R12NZ900S5 Straight R12NZ900S2 L-shaped R12NZ900S6 Straight R12NZ900S3 M/C cable 10 m L-shaped R12NZ900S7 Straight R12NZ900YC 15 m L-shaped R12NZ900YB Straight R12NZ900S4 20 m Maintenance L-shaped R12NZ900S8 Parts Straight R12NZ900S9 L-shaped R12NZ900SD...
Page 331 Maintenance 14. Replacing the M/C Cable Removal: M/C cable Turn OFF the Controller power. Disconnect the following connectors from the Controller. Power cable connector Signal cable connector Remove the connector plate. For details, refer to Maintenance: 3. Covers. NOTE  Do not pull the connector plate forcibly.
Page 332 Maintenance 14. Replacing the M/C Cable Installation: M/C cable 1. Install the connector sub plate. For details, refer to Maintenance: 3. Covers. 2. Connect the connectors of the new M/C cable to these of the cable unit. Connector: X11, X12, X14, BR010, X010, X020, X040, LED, GS01 3.
Page 333: Replacing The Fan
Maintenance 15. Replacing the Fan 15. Replacing the Fan ■ Do not connect or disconnect the motor connectors while the power to the robot system is turned ON. Connecting or disconnecting the motor connectors with the power ON is extremely hazardous and may result in serious bodily injury as the Manipulator may move abnormally, and also may result in electric shock and/or malfunction of the robot system.
Page 334 Maintenance 15. Replacing the Fan (Figure: Cable backward model) Removal: Fan Remove the fan cover screws while supporting the cover. Cross recessed head screws with washer: 4-M4×35 The cover falls when the screws are removed. NOTE  When removing the screws, be sure to support the cover. Remove the fan cover.
Page 335: 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 336 Maintenance 16. Calibration Also, pay attention to the following points at the encoder initialization. ■ The Joint #1 and Joint #4 have no mechanical stops and they may be rotated more than 360 degrees. If the encoder initialization is performed with improper posture, the Manipulator moves outside the operation range.
Page 337 Maintenance 16. Calibration 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 Setup & Operation 3.7 Checking the Basic NOTE ...
Page 338: Calibration Procedure
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 339 4-1 Move the arm you want to calibrate to the position of the calibration mark. Select menu-[Tool]-[Robot Manager]-[Jog & Teach] panel to move the EPSON Manipulator. If an error occurs after replacing the motor and you cannot use the [Jog &...
Page 340 Joint #5 >Encreset 5, 6 Joint #6 >Encreset 6 4-3 Reboot the Controller. Click EPSON RC+ menu-[Tool]-[Controller]-<Reset Controller>. EPSON 4-4 Input the command in the Command window and execute it. Execute one of the following commands to reset the encoder of the joint you EPSON want to calibrate from the menu-[Tool]-[Command Window].
Page 341 Calibration (More accurate positioning) Move the Manipulator to the selected point data by jogging in [Jog & Teach]. EPSON Move the joint* which is not calibrated to the specified point by motion command. *When the Joint #5 is being calibrated, move the Joints #1 - #4 to the home positions.
Page 342: Maintenance Parts List
Maintenance 17. Maintenance Parts List 17. Maintenance Parts List Reference in Name Code Note Overhaul ** Maintenance Joint #1 C8, C8L 2172921  1000 W, unit 5.1.1, 5.2.1 unit C8XL 2172922  AC servo Joint #2 2168683 750 W, single item ...
Page 343 Maintenance 17. Maintenance Parts List * Reduction Gear Unit: A reduction gear unit consists of the following three parts. When replacing the reduction gear unit, be sure to replace these parts all together as a set. Waveform generator Waveform generator The waveform generator consists of an ellipsoidal cam and ball bearings on outer circumference.
Page 344 Maintenance 17. Maintenance Parts List Reference in Name Code Note Maintenance Control board 1, 2 Arms #1, #3 2138032 1263978 Arm #1 side C8, C8L 1656161 Arm #2 side Joint #2 1670635 Arm #1 side C8XL 1656140 Arm #2 side O ring 1263977 Arm #2 side...
Page 345 Maintenance 17. Maintenance Parts List Reference in Name Code Note Maintenance Metal cover Center cover 1675435 Common to Standard/ Arm #1 Clean-room models Side cover 1674537 Side cover (left) 1655114 Arm #2 Standard model Side cover (right) 1674542 Plastic cover Arm #3 Cover 1674543...
Page 346: Option Parts List
Maintenance 18. Option Parts List 18. Option Parts List Reference in Name Code Note Setup & Operation R12NZ900N4 For Europe (200V) Brake release unit R12NZ900N5 For U.S. & Japan (100V) (with cable and M/C short connector) MC short connector R12NZ900N7 For brake release unit Common to C3 and C4 Camera plate unit...

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