Epson C Series - Page 21

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C4 Maintenance

This volume contains maintenance procedures with safety precautions for C4 series Manipulators.

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Table of Contents9
Safety Maintenance23
General Maintenance25
Maintenance Inspection25
Schedule for Maintenance Inspection25
Inspection Point26
Overhaul (Parts Replacement)28
Greasing30
Tightening Hexagon Socket Head Bolts32
Layout of Maintenance Parts33
Covers34
Arm #1 Top Cover35
Arm #1 Side Cover35
Arm #2 Side Cover36
Arm #3 Head Cover36
Arm #3 Bottom Cover37
Arm #4 Side Cover37
Base Bottom Cover38
Connector Plate38
Connector Sub Plate39
User Plate39
Cable Unit40
Replacing the Cable Unit40
Removal: Cable Unit42
Installation: Cable Unit49
Connector Pin Assignments68
Signal Cable68
Power Cable74
User Cable77
Color of Cables77
Joint #178
Joint #1 - Replacing the Motor79
Removal: Joint #1 Motor79
Installation: Joint #1 Motor81
Joint #1 - Replacing the Reduction Gear Unit83
Removal: Joint #1 Reduction Gear Unit84
Installation: Joint #1 Reduction Gear Unit87
Joint #1 - Replacing the Timing Belt91
Removal: Joint #1 Timing Belt91
Installation: Joint #1 Timing Belt91
Joint #1 - Replacing the Electromagnetic Brake92
Installation: Joint #1 Electromagnetic Brake92
Joint #293
Joint #2 - Replacing the Motor94
Removal: Joint #2 Motor95
Installation: Joint #2 Motor97
Joint #2- Replacing the Reduction Gear Unit99
Removal: Joint #2 Reduction Gear Unit100
Installation: Joint #2 Reduction Gear Unit103
Joint #2 - Replacing the Timing Belt107
Removal: Joint #2 Timing Belt107
Installation: Joint #2 Timing Belt107
Joint #2 - Replacing the Electromagnetic Brake108
Removal: Joint #2 Electromagnetic Brake108
Joint #3109
Joint #3 - Replacing the Motor (with a Brake)110
Removal: Joint #3 Motor (with a Brake)110
Installation: Joint #3 Motor (with a Brake)112
Joint #3 - Replacing the Reduction Gear Unit114
Removal: Joint #3 Reduction Gear Unit114
Installation: Joint #3 Reduction Gear Unit118
Joint #3 - Replacing the Timing Belt122
Removal: Joint #3 Timing Belt122
Installation: Joint #3 Timing Belt122
Joint #4123
Joint #4 - Replacing the Motor124
Removal: Joint #4 Motor124
Installation: Joint #4 Motor126
Joint #4 - Replacing the Reduction Gear Unit129
Removal: Joint #4 Reduction Gear Unit129
Installation: Joint #4 Reduction Gear Unit132
Joint #4 - Replacing the Timing Belt136
Removal: Joint #4 Timing Belt136
Installation: Joint #4 Timing Belt136
Joint #4 - Replacing the Electromagnetic Brake137
Removal: Joint #4 Electromagnetic Brake137
Installation: Joint #4 Electromagnetic Brake137
Joint #5138
Joint #5 - Replacing the Motor139
Removal: Joint #5 Motor139
Installation: Joint #5 Motor141
Joint #5 - Replacing the Reduction Gear Unit143
Installation: Joint #5 Reduction Gear Unit147
Joint #5 - Replacing the Timing Belt153
Removal: Joint #5 Timing Belt153
Installation: Joint #5 Timing Belt153
Joint #5 - Replacing the Electromagnetic Brake154
Removal: Joint #5 Electromagnetic Brake154
Installation: Joint #5 Electromagnetic Brake154
Joint #6155
Joint #6 - Replacing the Motor156
Removal: Joint #6 Motor156
Installation: Joint #6 Motor158
Joint #6 - Replacing the Reduction Gear Unit160
Removal: Joint #6 Reduction Gear Unit160
Installation: Joint #6 Reduction Gear Unit163
Joint #6 - Replacing the Timing Belt165
Removal: Joint #6 Timing Belt165
Installation: Joint #6 Timing Belt165
Joint #6 - Replacing the Electromagnetic Brake166
Removal: Joint #6 Electromagnetic Brake166
Installation: Joint #5 Electromagnetic Brake166
Replacing the Arm #5 O-Ring167
Removal: Arm #5 O-Ring167
Installation: Arm #5 O-Ring167
Replacing the Battery Unit168
Replacing the Battery Unit (Lithium Battery)168
Replacing the Battery Board172
Removal: Battery Board172
Installation: Battery Board173
Replacing the Control Board175
Replacing the Control Board 1175
Removal: Control Board 1175
Installation: Control Board 1175
Replacing the Control Board 2176
Removal: Control Board 2176
Installation: Control Board 2177
Replacing the LED Lamp178
Removal: LED Lamp179
Installation: LED Lamp179
Replacing the M/C Cable180
Removal: M/C Cable182
Installation: M/C Cable182
Calibration183
Overview183
Calibration Procedure185
C4 Maintenance Parts List190
Safety Maintenance197
General Maintenance199
Maintenance Inspection199
Schedule for Maintenance Inspection199
Inspection Point200
Overhaul (Parts Replacement)202
Greasing204
Joint #1 Reduction Gear Unit (Table Top Mounting)206
Joint #1 Reduction Gear Unit (Ceiling Mounting, Wall Mounting)207
Joint #1 Reduction Gear Unit207
Joint #2 Reduction Gear Unit208
Joint #3 Reduction Gear Unit209
Joint #4 Reduction Gear Unit210
Joint #5 Reduction Gear Unit211
Joint #6 Reduction Gear Unit212
Joint #6 Bevel Gear213
Tightening Hexagon Socket Head Bolts214
Layout of Maintenance Parts215
Covers216
Arm #1 Center Cover219
Arm #1 Side Cover220
Arm #2 Side Cover222
Arm #3 Cover223
Arm #3 Maintenance Cover224
Arm #4 Side Cover226
Arm #4 Maintenance Cover (C8XL Only)228
Arm #4 Maintenance Cover229
Arm #4 D-Sub Attachment230
Base Cover231
M/C Cable Backward231
M/C Cable Downward232
Base Maintenance Cover236
Connector Plate238
M/C Cable Backward238
M/C Cable Downward242
Connector Sub Plate243
Cable Unit245
Replacing the Cable Unit245
Replacing the Cable Unit (M/C Cable Backward)247
Replacing the Cable Unit (M/C Cable Downward)277
Connector Pin Assignment282
Signal Cable282
Power Cable285
User Cable288
Color of Cables288
Joint #1289
M/C Cable Backward (Joint #1)290
Joint #1 - Replacing the Motor (M/C Cable Backward)290
Joint #1 - Replacing the Reduction Gear Unit298
Backward)298
Joint #1 - Replacing the Timing Belt (M/C Cable Backward)305
Joint #1 - Replacing the Electromagnetic Brake312
Backward)312
M/C Cable Downward (Joint #1)314
Joint #1 - Replacing the Motor (M/C Cable Downward)314
Joint #1 - Replacing the Reduction Gear Unit318
Downward)318
Joint #1 - Replacing the Timing Belt (M/C Cable Downward)321
Joint #1 - Replacing the Electromagnetic Brake326
Downward)326
Joint #2328
Joint #2 - Replacing the Motor329
Joint #2- Replacing the Reduction Gear Unit338
Joint #2 - Replacing the Timing Belt345
Joint #2 - Replacing the Electromagnetic Brake346
Joint #3347
Joint #3 - Replacing the Motor348
Joint #3 - Replacing the Reduction Gear Unit356
Joint #3 - Replacing the Timing Belt362
Joint #3 - Replacing the Electromagnetic Brake363
Joint #4364
Joint #4 - Replacing the Motor365
Joint #4 - Replacing the Reduction Gear Unit371
Joint #4 - Replacing the Timing Belt378
Joint #4 - Replacing the Electromagnetic Brake384
Joint #5385
Joint #5 - Replacing the Motor386
Joint #5 - Replacing the Reduction Gear Unit393
Joint #5 - Replacing the Timing Belt398
Joint #5 - Replacing the Electromagnetic Brake399
Joint #6401
Joint #6 - Replacing the Motor402
Joint #6 - Replacing the Reduction Gear Unit (Replacing the Joints #5, #6 Reduction Gear Unit Set)408
Joint #6 - Replacing the Timing Belt408
Joint #6 - Replacing the Electromagnetic Brake409
Replacing the Battery Unit411
Replacing the Battery Unit (Lithium Battery)413
Replacing the Battery Board415
Replacing the Control Board418
Replacing the Control Board 1419
Replacing the Control Board 2421
Replacing the LED Lamp423

Epson C Series - Page 21

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