Epson ProSix C4 A901S (C4L) Usermanuals 3

EPSON ProSix
C4 series
MANIPULATOR MANUAL
Rev.11 EM163R3126F
Manipulator manual C4 series Rev.11
EPSON ProSix
C4 series Manipulator Manual

Rev. 11
Copyright  2012-2016 SEIKO EPSON CORPORATION. All rights reserved.
C4 Rev.11 i
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
performance standards.
Product malfunctions resulting from normal handling or operation will be repaired free of
charge during the normal warranty period. (Please ask your Regional Sales Office for
warranty period information.)
However, customers will be charged for repairs in the following cases (even if they occur
during the warranty period):
1. Damage or malfunction caused by improper use which is not described in the manual,
or careless use.
2. Malfunctions caused by customers’ unauthorized disassembly.
3. Damage due to improper adjustments or unauthorized repair attempts.
4. Damage caused by natural disasters such as earthquake, flood, etc.
Warnings, Cautions, Usage:
1. If the robot or associated equipment is used outside of the usage conditions and product
specifications described in the manuals, this warranty is void.
2. If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be
responsible for any malfunction or accident, even if the result is injury or death.
3. We cannot foresee all possible dangers and consequences. Therefore, this manual
cannot warn the user of all possible hazards.
ii C4 Rev.11
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.
Please notify us if you should find any errors in this manual or if you have any comments
regarding its contents.
MANUFACTURER
C4 Rev.11 iii
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. For more details on available collection
facilities please contact your local government office or the retailer where you purchased
this product. Use of the chemical symbols Pb, Cd or Hg indicates if these metals are used
in the battery.
This information only applies to customers in the European Union, according to

DIRECTIVE 2006/66/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and
accumulators and repealing Directive 91/157/EEC and legislation transposing and
implementing it into the various national legal systems.
For other countries, please contact your local government to investigate the possibility of
recycling your product.
The battery removal/replacement procedure is described in the following manuals:

Controller manual / Manipulator manual (Maintenance section)
Before Reading This Manual

This section describes what you should know before reading this manual.
Structure of Control System

C4 Manipulators can be used with the following combinations of Controllers and software.
Controller : RC700
Software : EPSON RC+ 7.0
Setting by Software
EPSON This manual contains setup procedures using the software.
RC+
Those sections are indicated by the symbol on the left.
Turning ON/OFF Controller

When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to
turn ON/OFF all the hardware components.
Photos and Illustrations Used in This Manual

The appearance of some parts may differ from those on an actual product depending on
when it was shipped or the specifications. The procedures themselves, however, are
accurate.
iv C4 Rev.11
Table of Contents
Setup & Operation

1. Safety 3
1.1 Conventions............................................................................................3
1.2 Design and Installation Safety................................................................3
1.3 Operation Safety ....................................................................................4
1.4 Emergency Stop .....................................................................................6
1.5 How to Move Arms with the Electromagnetic Brake ..............................8
1.5.1 Moving the Arm using the brake release unit .............................9
1.5.2 Moving the Arm using the software ............................................9
1.6 Precaution for Operation in Low Power Status ......................................9
1.7 Manipulator Labels ...............................................................................10
2. Specifications 12
2.1 Features of Manipulators .....................................................................12
2.2 Model Number ......................................................................................12
2.3 Part Names and Motion Range of Each Arm .......................................13
2.4 Outer Dimensions.................................................................................14
2.5 Standard Motion Range........................................................................16
2.6 Specifications .......................................................................................19
2.7 How to Set the Model ...........................................................................22
3. Environment and Installation 24

3.1 Environmental Conditions ....................................................................23
3.2 Unpacking, Transportation, and Relocation .........................................24
3.3 Mounting Dimensions ...........................................................................28
3.4 Installation ............................................................................................29
3.5 Connecting the Cables .........................................................................32
3.6 User Wires and Pneumatic Tubes........................................................33
3.7 Checking the Basic orientation.............................................................34
4. End Effectors 35
4.1 Attaching an End Effector.....................................................................35
4.2 Attaching Camera and Valves ..............................................................36
4.3 WEIGHT and INERTIA Settings ...........................................................38
4.3.1 WEIGHT setting........................................................................40
4.3.2 INERTIA setting ........................................................................45
4.4 Precautions for Auto Acceleration/Deceleration...................................49
5. Motion Range 50
5.1 Motion Range Setting by Pulse Range (for All Arms) ..........................51
5.2 Motion Range Setting by Mechanical Stops ........................................56
5.3 Restriction of Manipulator Operation by Joint Angle Combination ......58
5.4 Coordinate System ...............................................................................60
5.5 Changing the Robot .............................................................................60
C4 Rev.11 v
Table of Contents
5.6 Setting the Cartesian (Rectangular) Range in the XY Coordinate

System of the Manipulator ................................................................... 62
6. Options 63
6.1 Brake Release Unit .............................................................................. 63
6.2 Camera Plate Unit ................................................................................ 66
6.3 PS Compatible Plate (Tool Adapter) .................................................... 69
6.4 Base Side Angled Fittings .................................................................... 70
6.5 Base Side Fittings ................................................................................ 72
6.6 PS Compatible Plate (Base Adapter)................................................... 75
6.7 Adjustable Mechanical Stop (Joint #2: only C4-A901**)...................... 76
Maintenance
1. Safety Maintenance 79
2. General Maintenance 80
2.1 Maintenance Inspection ....................................................................... 80
2.1.1 Schedule for Maintenance Inspection...................................... 80
2.1.2 Inspection Point ........................................................................ 81
2.2 Overhaul (Parts Replacement) ............................................................ 83
2.3 Greasing ............................................................................................... 85
2.4 Tightening Hexagon Socket Head Bolts .............................................. 87
2.5 Layout of Maintenance Parts ............................................................... 88
3. Covers 89
3.1 Arm #1 Top Cover ................................................................................ 90
3.2 Arm #1 Side Cover ............................................................................... 90
3.3 Arm #2 Side Cover ............................................................................... 91
3.4 Arm #3 Head Cover ............................................................................. 91
3.5 Arm #3 Bottom Cover........................................................................... 92
3.6 Arm #4 side cover ................................................................................ 92
3.7 Base Bottom Cover .............................................................................. 93
3.8 Connector Plate ................................................................................... 93
3.9 Connector Sub Plate ............................................................................ 94
3.10 User Plate........................................................................................... 94
4. Cable Unit 95
4.1 Replacing the Cable Unit ..................................................................... 95
4.2 Connector Pin Assignments ............................................................... 122
4.2.1 Signal Cable ........................................................................... 122
4.2.2 Power Cable ........................................................................... 125
4.2.3 User Cable ............................................................................. 127
4.2.4 Color of Cables....................................................................... 127
vi C4 Rev.11
Table of Contents
5. Arm #1 128
5.1 Joint #1 - Replacing the Motor .......................................................... 129
5.2 Joint #1 - Replacing the Reduction Gear Unit .................................. 133
5.3 Joint #1 - Replacing the Timing Belt ................................................. 141
5.4 Joint #1 - Replacing the Electromagnetic Brake ............................... 142
6. Arm #2 143
6.2 Joint #2- Replacing the Reduction Gear Unit ................................... 149
7. Arm #3 159
7.1 Joint #3 - Replacing the Motor (with a Brake)................................... 160
8. Arm #4 173
9. Arm #5 188
10. Arm #6 205

10.1 Joint #6 - Replacing the Motor ........................................................ 206
10.2 Joint #6 - Replacing the Reduction Gear Unit ................................ 210
10.3 Joint #6 - Replacing the Timing Belt ............................................... 215
10.4 Joint #6 - Replacing the Electromagnetic Brake ............................. 216
11. Replacing the Arm #5 O-ring 217
12. Replacing the Battery Unit 218

12.1 Replacing the Battery Unit (Lithium Battery)................................... 220
12.2 Replacing the Battery Board ........................................................... 222
13. Replacing the Control Board 224

13.1 Replacing the Control Board 1 ........................................................ 224
13.2 Replacing the Control Board 2 ........................................................ 225
C4 Rev.11 vii
Table of Contents
14. Replacing the LED Lamp 227
15. Replacing the M/C Cable 229
16. Calibration 232

16.1. Overview .........................................................................................232
16.2. Calibration Procedure ..................................................................... 234
17. Maintenance Parts List 239
viii C4 Rev.11
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.
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.
Keep this manual handy for easy access at all times.
1.1 Conventions
Important safety considerations are indicated throughout the manual by the following
symbols. Be sure to read the descriptions shown with each symbol.
This symbol indicates that a danger of possible serious injury

or death exists if the associated instructions are not followed
WARNING properly.
This symbol indicates that a danger of possible harm to people

caused by electric shock exists if the associated instructions are
WARNING not followed properly.
This symbol indicates that a danger of possible harm to people

or physical damage to equipment and facilities exists if the
CAUTION associated instructions are not followed properly.
1.2 Design and Installation Safety

Only trained personnel should design and install the robot system. Trained
personnel are defined as those who have taken robot system training and
maintenance training classes held by the manufacturer, dealers, or local
representative companies, or those who understand the manuals thoroughly and
have the same knowledge and skill level as those who have completed the training
courses.
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.
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
WARNING extremely hazardous, and may result in serious bodily injury and/or severe
equipment damage to the robot system.
C4 Rev.11 3
■ The Manipulator and the Controller must be used within the environmental
conditions described in their respective manuals. This product has been
designed and manufactured strictly for use in a normal indoor environment.
Using the product in an environment that exceeds the specified environmental
conditions may not only shorten the life of the product but may also cause serious
safety problems.
WARNING ■ The robot system must be used within the installation requirements described in
the manuals. Using the robot system outside of the installation requirements
may not only shorten the life of the product but also cause serious safety
problems.
Further precautions for installation are described in the chapter Setup & Operation
3. Environment and Installation. Please read this chapter carefully to understand
safe installation procedures before installing the robots and robotic equipment.
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.
■ Do not enter the operating area of the Manipulator while the power to the robot
system is turned ON. Entering the operating area with the power ON is
extremely hazardous and may cause serious safety problems as the Manipulator
may move even if it seems to be stopped.
■ Before operating the robot system, make sure that no one is inside the
safeguarded area. The robot system can be operated in the mode for teaching
even when someone is inside the safeguarded area.
WARNING
The motion of the Manipulator is always in restricted status (low speeds and low
power) to secure the safety of an operator. However, operating the robot
system while someone is inside the safeguarded area is extremely hazardous
and may result in serious safety problems in case that the Manipulator moves
unexpectedly.
■ Immediately press the Emergency Stop switch whenever the Manipulator moves
abnormally during operation. Continuing the operation while the Manipulator
moves abnormally is extremely hazardous and may result in serious bodily injury
and/or severe equipment change to the robot system.
■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect

it directly to a factory power source. To shut off power to the robot system, pull
out the power plug from the power source. Performing any work while
WARNING connecting the AC power cable to a factory power source is extremely hazardous
and may result in electric shock and/or malfunction of the robot system.
4 C4 Rev.11
■ Before performing any replacement procedure, turn OFF the Controller and
related equipment, and then pull out 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.
■ Do not insert or pull out the motor connectors while the power to the robot system
WARNING
is turned ON. Inserting or pulling out 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.
■ 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.
■ If the joints are operated repeatedly with the operating angle less than 5 degrees,
they may get damaged early because the bearings are likely to cause oil film
shortage in such situation. To prevent early breakdown, move the joints larger
than 30 degrees for about five to ten times a day.
CAUTION ■ Oscillation (resonance) may occur continuously in low speed Manipulator motion
(Speed: approx. 5 to 20%) depending on combination of Arm orientation and end
effector load. Oscillation arises from natural oscillation frequency of the Arm
and can be controlled by following measures.
Changing Manipulator speed

Changing the teach points
Changing the end effector load
C4 Rev.11 5
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. Otherwise, the Manipulator may hit the peripheral equipment since
the operating trajectory until the robot system stops is different from that in normal
operation.
Do not press the Emergency Stop switch unnecessarily while the Manipulator is operating.
Pressing the switch during operation makes the brakes work. This will shorten the life of
the brakes due to the worn friction plates.
Normal brake life cycle: About 2 years (when the brakes are used 100 times/day)
Also, the Emergency Stop during operation applies impact on the reduction gear unit, and
it may result in the short life of the reduction gear unit.
To place the robot system in emergency mode during normal operation, press the
Emergency Stop switch while the Manipulator is not moving.
Refer to the Controller manual for instructions on how to wire the Emergency Stop switch
circuit.
Do not turn OFF the Controller while the Manipulator is operating.

If you attempt to stop the Manipulator in emergency situations such as “Safeguard Open”,
make sure to stop the Manipulator using the Emergency Stop switch of the Controller.
If the Manipulator is stopped by turning OFF the Controller while it is operating, the
following problems may occur.
Reduction of the life and damage of the reduction gear unit
Position gap at the joints
In addition, if the Controller was forced to be turned OFF by blackouts and the like while
the Manipulator is operating, make sure to check the following points after power
restoration.
Whether or not the reduction gear is damaged
Whether or not the joints are in their proper positions
If there is a position gap, perform calibration by referring to the Maintenance 16.

Calibration in this manual.
Before using the Emergency Stop switch, be aware of the followings.

- The Emergency Stop (E-STOP) switch should be used to stop the Manipulator only
in case of emergencies.
- To stop the Manipulator operating the program except in emergency, use Pause (halt)
or STOP (program stop) commands.
Pause and STOP commands do not turn OFF the motors. Therefore, the brake does
not function.
- For the Safeguard system, do not use the circuit for E-STOP.
6 C4 Rev.11
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.

Manipulator Manual Maintenance 2.1.2 Inspection Point
- Inspection While the Power is ON
(Manipulator is operating)
Safety and Installation 5.1.1 Manipulator
- Inspection While the Power is ON
(Manipulator is operating)
Free running distance in emergency

The Manipulator in operation cannot stop immediately after the Emergency Stop switch is
pressed. However, time, angle, and distance of the free running vary by following
factors:
Hand weight WEIGHT Setting ACCEL Setting
Workpiece weight SPEED Setting Posture etc.
Approximate time and distance of the free running are as follow:

Conditions of Measurement
C4 series
ACCEL Setting 100
SPEED Setting 100
Load [kg] 4
WEIGHT Setting 4
Manipulator C4-A601** C4-A901**

Robot controller RC700
Arm #1 0.4 0.3
Arm #2 0.4 0.4
Free running time Arm #3 0.4 0.5

[sec.] Arm #4 0.3
Arm #5 0.4
Arm #6 0.3
Arm #1 85 60
Arm #2 60 65
Free running angle Arm #3 55 55

[deg.] Arm #4 40
Arm #5 40
Arm #6 25
C4 Rev.11 7
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.
1.5.2 Moving the arm using the software
Follow the method when you can use the software.
While the electromagnetic brake is ON (such as in emergency mode), you cannot move
any arm by pushing manually.
Arm Motion
Arm #4 Joint #4
Joint #4
Arm #3
Arm #6
Joint #6
Joint #3
Arm #5 Joint #5
Arm #2
Joint #2
Arm #1 (Lower Arm)
Joint #1
Base
8 C4 Rev.11
1.5.1 Moving the Arm using the brake release unit

The C4 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
■ Normally, release the brake of joints one by one. Take extra care if you need to
release the brakes of two or more joints simultaneously. Releasing the brakes
of two or more joints simultaneously may cause hands and fingers to be caught
and/or equipment damage to or malfunction of the Manipulator as the arms of the
Manipulator may move in unexpected directions.
■ 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.
CAUTION The arm falling may cause hands and fingers to be caught and/or may cause
equipment damage to or malfunction of the Manipulator.
■ Before releasing the brake, be sure to keep the Emergency Stop switch handy so
that you can immediately press the Emergency Stop switch. Otherwise, you
cannot immediately stop the arm falling due to an erroneous operation. The arm
falling may cause equipment damage to and/or malfunction of the Manipulator.
EPSON After releasing the Emergency Stop switch, execute the following command in
RC+
[Command Window].
>Reset
>Brake Off,[the number (from 1 to 6) corresponding to the arm whose brake will be
turned off]
Execute the following command to turn on the brake again.

>Brake On,[The number (from 1 to 6) corresponding to the arm whose brake will be
turned on]
1.6 Precaution for Operation in Low Power Status

In the low power status, the Manipulator operates at low speed and low torque. However,
comparatively high torque as shown in the table below may be generated to support the
Manipulator’s own weight.
Carefully operate the Manipulator since it may get your hands or fingers caught during
operation. The Manipulator may also collide with peripheral equipment and cause
Maximum Joint Torque in Low Power Status [Unit: N·m]
Joint #1 #2 #3 #4 #5 #6
Joint Torque 116.24 193.74 59.31 12.45 11.41 6.88
■ Carefully operate the Manipulator in the low power status. A comparatively high
joint torque may be generated. It may cause your hands and fingers caught
and/or cause equipment damage to or malfunction of the Manipulator as it may
CAUTION
collide with peripheral equipment.
C4 Rev.11 9
1.7 Manipulator Labels

The following labels are attached around the locations of the Manipulator where specific
dangers exist.
Be sure to comply with descriptions and warnings on the labels to operate and maintain
the Manipulator safely.
Do not tear, damage, or remove the labels. Use meticulous care when handling those
parts or units to which the following labels are attached as well as the nearby areas.
Location Label NOTE
To avoid getting hands or fingers caught, fold the

A Arm and fix it with a belt or a similar tool before
removing the base mounting screws.
Do not enter the work space when the Manipulator

B is operating. It is extremely hazardous since the
Arm may collide and cause serious safety
problems,
Do not touch the current-carrying parts inside the

C Manipulator while the power is ON. It may cause
electrical shock.
Be careful of the arm falling due to its own weight

when pressing the brake release switch.
D
These labels are attached on the optional brake
release box
10 C4 Rev.11
Location of Labels
C
Top View
C
C
C
A C
B F
Front View Lateral View Back View
C4 Rev.11 11
Setup & Operation 2. Specifications
2. Specifications
2.1 Features of Manipulators
Speed & Accuracy
Increased productivity by balanced, best-in class fast and accurate operation.
C4-A601**
Average cycle time (300 mm) 0.39 s (Speed 100 / Accel 100)
0.37 s (Speed 100 / Accel 120)
Repeatability error ± 0.02 mm
C4-A901**
Average cycle time (300 mm) 0.49 s (Speed 100 / Accel 100)
0.47 s (Speed 100 / Accel 120)
Repeatability error ± 0.03 mm
Slim Body
High space efficiency
Manipulator size is only 1/44 of its motion range
Small elbow area (Joint #3) which is half of that of the existing models
Less interference with peripherals, walls, and ceiling permits more compact
installation
Skillful Wrist
Compact wrist (Joint #5) with wide motion range enables smooth movement and the
ability to work from many angles
Minimal interference with surroundings improves flexibility in hand design
2.2 Model Number

C4 – A 6 0 1 S □
Type
□ : Table Top mounting
(R : Ceiling mounting)*1
Environment
S : Standard model
C : Cleanroom & ESD (electrostatic discharge) model
Brake equipment
1 : Brakes on all joints
Arm length
6 : 600 mm (Model name: C4)
9 : 900 mm (Model name: C4L)
*1 Manipulators are set to “Table Top mounting” at shipment. To use the manipulators
as “Ceiling mounting”, you need to change the model settings.
For details on how to change the model settings, refer to 5.5 Changing the Robot, and
EPSON RC+ User’s Guide Robot Configuration.
12 C4 Rev.11
2.3 Part Names and Motion Range of Each Arm

LED Lamp
Upper Arm (Arms #3 to #6) This lamp lights up
while the motors are ON.
Arm #4 Joint #4
Arm #3
Arm #6
Joint #6
Joint #3
Arm #5 Joint #5
Arm #2
Joint Motion Joint #2
Joint #1 : The whole Manipulator revolves.

Arm #1
Joint #2 : The lower arm swings. (Lower Arm)
Joint #3 : The upper arm swings.
Joint #4 : The wrist revolves. Joint #1

Joint #5 : The wrist swings.
Base
Joint #6 : The hand rotates.
User cable connector

(9-pin D-sub connector)
White
Fitting for ø 4 mm pneumatic tube
Black or blue
(Color differs depending on the shipment time)
Standard-model / Clean-room type

Signal cable Power cable Cover Exhaust port
For ø8 mm pneumatic tube
MT label
(only for custom
specification) CE label
(only for CE specification)
UR label
(only for UL specification)
Signature label
(Serial No. of Manipulator)
NOTE When the LED lamp is lighting or the controller power is on, the current is being applied
 to the manipulator. (The LED lamp may not be seen depending on the Manipulator’s
posture. Be very careful.) Performing any work with the power ON is extremely
hazardous and it may result in electric shock and/or improper function of the robot system.
Make sure to turn OFF the controller power before the maintenance work.
C4 Rev.11 13
2.4 Outer Dimensions

2.4.1 C4-A601**
[Unit: mm]
Space for cables

*1:
Including the LED lamp

*2:
*2:
*2:
(Applicable tolerance is ø6H7)
*1: Applicable area

*2: Same for the other side
14 C4 Rev.11
2.4.2 C4-A901**
[Unit: mm]
Space for cables
*1:
Including the lamp

*2:
*2:
*2:
(Applicable tolerance is ø6H7)
*1: Applicable area

*2: Same for the other side
C4 Rev.11 15
2.5 Standard Motion Range

2.5.1 C4-A601**
[Unit: mm]
Top View
*1
*2
*3
Joint #1
0 pulse position
P point*
Motion range of P point*
Front View Lateral view

Joint #2
0 pulse position
Joints #4, #6
0 pulse position
P point*
Joints #3, #5
0 pulse position
*5
*4
* P point : Intersection of the rotation centers for Joint #4, #5, and #6
*1 : Joint #1 without mechanical stop (±180 deg.)
For the mechanical stop removal procedure, refer to Setup & Operation: 5.2.1 Motion Range
Setting of Arm #1.
*2 : P point from top with Joint #3 declining −51 deg. (Joint #1 center – P point center)
*3 : P point from top with Joint #3 tilting up +225 deg. (Joint #1 center – P point center)
*4 : P point from lateral with Joint #3 declining -51 deg. (Joint #2 center – P point center)
*5 : P point from lateral with Joint #3 tilting up +225 deg. (Joint #2 center – P point center)
 Pay attention to the arm pose of the basic arms (Arms #1, #2, and #3) when
operating the Manipulator. Arm #5 moves keeping a constant angle regardless
of the arm pose. Depending on the arm pose of the basic arms, the wrist may
CAUTION collide with the Manipulator. The collision may cause equipment damage to
and/or malfunction of the Manipulator.
16 C4 Rev.11
2.5.2 C4-A901**
[Unit: mm]
Top View
*1
P point*
*2
*3
Joint #1
0 pulse position
Front View
Joint #2
Lateral view 0 pulse position
Joints #4, #6
0 pulse position
P point*
Joints #3, #5
0 pulse position *5
*4
C4 Rev.11 17
* P point : Intersection of the rotation centers for Joint #4, #5, and #6
*1 : Joint #1 without mechanical stop (±180 deg.)
For the mechanical stop removal procedure, refer to Setup & Operation: 5.2.1 Motion
Range Setting of Arm #1.
*2 : P point from top with Joint #3 declining −50 deg. (Joint #1 center – P point center)
*3 : P point from top with Joint #3 tilting up +210 deg. (Joint #1 center – P point center)
*4 : P point from lateral with Joint #3 declining -50 deg. (Joint #2 center – P point center)
*5 : P point from lateral with Joint #3 tilting up +210 deg. (Joint #2 center – P point center)
■ Pay attention to the arm pose of the basic arms (Arms #1, #2, and #3) when
operating the Manipulator. Arm #5 moves keeping a constant angle regardless
of the arm pose. Depending on the arm pose of the basic arms, the wrist may
CAUTION collide with the Manipulator. The collision may cause equipment damage to
and/or malfunction of the Manipulator.
18 C4 Rev.11
2.6 Specifications
2.6.1 Specifications table
Item Specification
Model Number C4-A601** C4-A901**
Model Name C4 C4L
Mounting type Table Top mounting (Ceiling mounting) *1
Weight (not include the weight of cables
27 kg (59.5 lb.) 29 kg (63.9 lb.)
or shipping jigs)
Driving method All joints AC servo motor
Joint #1 450 deg/s 275 deg/s
Joint #2 450 deg/s 275 deg/s
Max. operating Joint #3 514 deg/s 289 deg/s
speed *2 Joint #4 555 deg/s
Joint #5 555 deg/s
Joint #6 720 deg/s
Maximum synthetic speed 9459 mm/sec 8495 mm/sec
Repeatability Joint #1 ~ #6 ± 0.02 mm ± 0.03 mm
Joint #1 ± 170 deg (± 180 deg without the mechanical stop)
Joint #2 − 160 deg to + 65 deg
Joint #3 − 51 deg to + 225 deg
Max. motion range
Joint #4 ± 200 deg
Joint #5 ± 135 deg
Joint #6 ± 360 deg
± 4951609 ± 8102633
Joint #1 (± 5242880 without the (± 8579259 without the
mechanical stop) mechanical stop)
Max. pulse range Joint #2 − 4660338 to + 1893263 − 7626008 to + 3098066
Joint #3 − 1299798 to + 5734400 − 2310751 to + 10194489
Joint #4 ± 4723316
Joint #5 ± 3188238
Joint #6 ± 6553600
Joint #1 0.0000343 deg/pulse 0.0000210 deg/pulse
Resolution
Joint #4 0.0000423 deg/pulse
Joint #1 400 W
Joint #2 400 W
Joint #3 150 W
Motor power consumption
Joint #4 50 W
Joint #5 50 W
Joint #6 50 W
Rated 1 kg
Payload *3 4 kg
Max.
5 kg with arm downward positioning
Joint #4 4.41 N·m (0.45 kgf·m)
Allowable moment Joint #5 4.41 N·m (0.45 kgf·m)
Joint #6 2.94 N·m (0.3 kgf·m)
Joint #4 0.15 kg·m2
Allowable moment of
inertia (GD2/4) *4
C4 Rev.11 19
Item Specification
Model Number C4-A601** C4-A901**
Model Name C4 C4L
Installed wire for customer use 9 wires (D-sub)
*5 4 pneumatic tubes,
Installed pneumatic tube for customer use
Allowable pressure: 0.59Mpa (6 kgf/cm2) (89 psi)
Ambient
5 to 40 deg C
Temperature
Environmental Ambient relative
requirements *6 humidity
20 to 80 % (no condensation)
Vibration 4.9 m⋅s2 (0.5 G) or less
*7
Noise level LAeq = 80 dB (A) or under
Environment Standard / Cleanroom model & ESD *8
Applicable Controller RC700
SPEED 5 (100)
ACCEL *9 5, 5 (120, 120)
SPEEDS 50 (2000)
Default values
(Max. setting values)
ACCELS 200 (25000) 200 (15000) *10
10000, 10000, 10000, 10000, 10000, 10000
FINE
(65535, 65535, 65535, 65535, 65535, 65535)
WEIGHT 1 (5)
CE Marking : EMC Directive, Machinery Directive,
Safety standard RoHS Directive
KC Marking / KCs Marking
*1: Manipulators are set to “Table Top mounting” at shipment. To use the manipulators as “Ceiling
mounting”, you need to change the model settings.
For details on how to change the model settings, refer to 5.5 Changing the Robot, and EPSON RC+
User’s Guide Robot Configuration.
*2: In case of PTP control
*3: If the payload exceeds the maximum payload, refer to the section “Restrictions on payload exceeding the
maximum payload” in Setup & Operation 4.3.1 WEIGHT Setting.
*4: If the center of gravity is at the center of each arm. If the center of gravity is not at the center of each
arm, set the eccentric quantity using INERTIA command.
*5: For details of the installed pneumatic tube for customer use, refer to the Setup & Operation 3.6 User
Wires and Pneumatic Tubes.
*6: For details of the environmental requirements, refer to the Setup & Operation 3.1 Environmental
Conditions.
*7: Conditions of Manipulator at measurement are as follows:
Operating conditions: Under rated load, 6 arms simultaneous motion, maximum speed,
maximum acceleration, and duty 50%.
Measurement point: 1000 mm apart from the rear of Manipulator
20 C4 Rev.11
*8: The exhaust system in the Cleanroom-model Manipulator draws air from the base interior and arm cover
interior.
A crack or other opening in the base unit can cause loss of negative air pressure in the outer part of the
arm, which can cause increased dust emission.
Do not remove the covers.
Seal the exhaust port and the exhaust tube with vinyl tape so that the joint is airtight.
If the exhaust flow is not sufficient, dust particle emission may exceed the specified maximum level.
Cleanliness level : Class ISO 3 (ISO14644-1)
(Number of particles of 0.1μm or larger in a sample air
(28317cm3:1cft) around the center of the motion area = less than 10 particles)
Exhaust System : Fitting for ø8 mm pneumatic tube
Refer to Setup & Operation: 3.6 User Wires and Pneumatic Tubes.
60 L/min vacuum
Exhaust tube : Polyurethane tube
Outer diameter: ø8 mm (Inner diameter: ø5 to 6 mm)
ESD specification uses resin materials with antistatic treatment. This model controls adhesion of dust
due to electrification.
*9: 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.
*10: Maximum AccelS setting value for payload of 4 kg or more is 12000.
Although setting the value exceeding 12000 does not cause an error, do not set the value in order to
prevent manipulator malfunction.
2.6.2 Option
C4 series have the following options.
Brake release unit
Camera mounting plate
PS compatible plate (Tool adapter, Base adapter)
Base side angled fittings
Base side fittings
Adjustable Mechanical Stop (Joint #2: Only C4-A901**)
For details of options, refer to Setup& Operation: 6. Options.
C4 Rev.11 21
2.7 How to Set the Model

The Manipulator for your system has been set before shipment.
■ When you need to change the setting of the Manipulator model, be sure to set the
Manipulator model properly. Improper setting of the Manipulator model may
result in abnormal or no operation of the Manipulator and/or cause safety
CAUTION problems.
NOTE If an MT label is attached to the side of the Manipulator, the Manipulator has custom
 specifications. If the Manipulator has custom specifications, the methods for setting the
model may differ from those described below. Please contact us with the number on the
MT label.
For details on how to change the model settings, refer to 5.5 Changing the Robot, and
EPSON RC+ User’s Guide Robot Configuration.
22 C4 Rev.11
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
Ambient temperature* 5 deg C to 40 deg C
Ambient relative humidity 20 % to 80 % (no condensation)
First transient burst noise 2 kV or less (Power supply wire)
1 kV or les (Signal wire)
Electrostatic noise 4 kV or less
Environment - Install indoors.
- Keep away from direct sunlight.
- Keep away from dust, oily smoke, salinity, metal
powder or other contaminants.
- Keep away from flammable or corrosive solvents
and gases.
- Keep away from water.
- Keep away from shock or vibration.
- Keep away from sources of electric noise.
* The ambient temperature conditions are for the Manipulators only. For the Controller
the Manipulators are connected to, refer to the Controller manual.
NOTE When using the Manipulators in inadequate environments that do not meet the above
 conditions, please contact us.
Special Environmental Conditions

The surface of the Manipulator has general oil resistance. However, if your
requirements specify that the Manipulator must withstand certain kinds of oil, please
consult your distributor.
Rapid change in temperature and humidity can cause condensation inside the
Manipulator.
If your requirements specify that the Manipulator handles food, please consult your
distributor to check whether the Manipulator gives damage to the food or not.
The Manipulator cannot be used in corrosive environments where acid or alkaline is
used. In a salty environment where the rust is likely to gather, the Manipulator is
susceptible to rust.
C4 Rev.11 23
■ Use an earth leakage breaker on the AC power cable of the Controller to avoid
the electric shock and circuit breakdown caused by an unexpected water leak.
Prepare the earth leakage brake that pertains the controller you are using. For
WARNING details, refer to the controller manual.
■ When cleaning the Manipulator, do not rub it strongly with alcohol or benzene.
It may lose luster on the coated face.
CAUTION
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.
■ Only authorized personnel should perform sling work and operate a crane or a
forklift. When these operations are performed by unauthorized personnel, it is
extremely hazardous and may result in serious bodily injury and/or severe
equipment damage to the robot system.
WARNING ■ Stabilize the Manipulator with your hands when hoisting it. Unstable hoisting is
extremely hazardous and may result in serious bodily injury and/or severe
equipment damage to the robot system as the fall of the Manipulator.
■ When removing the anchor bolts, support the Manipulator to prevent falling.
Removing the anchor bolts without supporting the Manipulator may get hands,
fingers, or feet caught as the Manipulator may fall.
■ To carry the Manipulator, secure it to the delivery equipment or have at least 2
people to hold it by hand. Also, do not hold the bottom of the base (the
screened parts in the figure). Holding these parts by hand is extremely
hazardous and may cause your hands and fingers caught.
C4-A601** C4-A901**
CAUTION
Manipulator weight Manipulator weight
: 27 kg (59.5 lb.) : 29 kg (63.9 lb.)
DO NOT hold
the bottom of the DO NOT hold
base by hand. the bottom of the
base by hand.
■ Avoid excessive vibration or shock during Manipulator transporting. Excessive

vibration or shock may cause equipment damage to and/or malfunction of the
Manipulator.
24 C4 Rev.11
During unpacking and relocation, avoid applying external force to the arms and motors of
the Manipulator.
When transporting the Manipulator for a long distance, secure it to the delivery equipment
so that the Manipulator cannot fall. If necessary, pack the Manipulator in the same way
as it was delivered.
When condensation occurs on the Manipulator during transport or storage, turn ON the
power only after the condensation dries.
Be sure to transport and store the robot system in environments that meet the following
conditions:
Item Conditions
Ambient temperature 0 to 45 deg C
Ambient relative humidity 20 to 80 %
When using the Manipulator for the robot system again after long-term storage, perform a
test run to verify that the Manipulator works properly. Then, operate the Manipulator
thoroughly.
C4 Rev.11 25
Relocating
Follow the procedures described below when relocating the Manipulator.
(1) Turn OFF the power for all devices and unplug the power cable connector and signal
cable connector from the controller.
Do not unplug the M/C cable (power cable and signal cable) from the manipulator.
(MC cable 3 m: 2 kg)
NOTE Remove the mechanical stops if using them to limit the motion range.
 For details on the motion range, refer to the Setup & Operation 5.2 Motion Range
Setting by Mechanical Stops.
(2) Unscrew the anchor bolts. Then, remove the Manipulator from the base table.
(3) C4-A601**
Position the Manipulator as shown in the
figure. Then, secure the Manipulator to the
delivery equipment or have at least 2 people to
carry the Manipulator.
Manipulator weight
Recommend: Joint #2 +65 deg. : 27 kg (59.5 lb.)
Joint #3 −51 deg.
Do not hold the bottom of the base (the DO NOT hold
screened parts in the figure). Holding these the bottom of the
base by hand.
parts by hand is extremely hazardous and may
cause your hands and fingers to be caught.
C4-A901**
Position the Manipulator as shown in the
figure. Then, secure the Manipulator to the
delivery equipment or have at least 3 people to
carry the Manipulator. Manipulator weigh
: 29 kg (63.9 lb.)
Recommend: Joint #2 +53 deg.
Joint #3 −51 deg.
Do not hold the bottom of the base (the DO NOT hold
the bottom of the
screened parts in the figure). Holding these base by hand.
parts by hand is extremely hazardous and may
cause your hands and fingers to be caught.
26 C4 Rev.11
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 and wire must be strong enough to withstand the weight (See the figures
below).
If you use the eyebolts to lift up the Manipulator, be sure to use the bifilar wire of 1 m long
or more to avoid contact with the Arm #4 side cover.
Also, the Manipulator may swing while being lifted up even when using the appropriate
length of wire, so be sure to handle it with care.
Take extra care if you use the wire of 240 mm-long or shorter (for C4-A601**), or 360
mm-long or shorter (for C4-A901**), to lift the Manipulator, because the wire is likely to
touch the Arm #4 side cover and break the Manipulator.
C4-A601**
or longer
or less
Holes for eye bolt
2-M6 depth 12.5
Use the wire of

1000 mm or longer
to avoid contact
with Manipulator.
C4-A901**
Lifting load
or longer
: 29 kg (63.9 lb.) or less
Holes for eye bolt

2-M6 depth 12.5
Use the wire of

1000 mm or longer
to avoid contact
with Manipulator.
C4 Rev.11 27
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
Space for mounting holes (only for V/P model)
NOTE The minimum bend radius of the power cable is 90 mm. When installing the cable, be
 sure to maintain sufficient distance from obstacles. In addition, leave enough space for
other cables so that they are not bent forcibly.
Mounting Dimensions (C4 series) [Unit: mm]
Space for cable
(Reference through hole) (Mounting hole)
28 C4 Rev.11
3.4 Installation
The installation shall be made by qualified installation personnel and should conform to all
national and local codes.
■ To ensure safety, a safeguard must be installed for the robot system. For details
■ 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. Installing the Manipulator at a location with
insufficient space is extremely hazardous and may result in serious bodily injury
and/or severe equipment damage to the robot system as a tool or a work piece
may collide with a wall or a safeguard.
■ Anchor the Manipulator before turning ON the power to or operating the

WARNING
Manipulator. Turning ON the power to or operating the Manipulator that is not
anchored is extremely hazardous and may result in serious bodily injury and/or
severe equipment damage to the robot system as the Manipulator may fall down.
■ Before installing and operating the Manipulator, make sure that all parts of the
Manipulator are in place and have no external defects. Missing or defective
parts may cause improper operation of the Manipulator. Improper operation of
the Manipulator is extremely hazardous and may result in serious bodily injury
and/or severe equipment damage to the robot system.
■ The Manipulator must be installed to avoid interference with buildings, structures,

utilities, other machines and equipment that may create a trapping hazard or
pinch points.
■ Oscillation (resonance) may occur during operation depending on rigidity of the
CAUTION
installation table. If the oscillation occurs, improve rigidity of the table or change
the speed or acceleration and deceleration settings.
Mounting bolt
For the dimensions, refer to Setup & Operation 3.3 Mounting Dimensions.
There are four threaded holes for the Manipulator base.
Use M8 mounting bolts conforming to the strength of ISO898-1 property class 12.9.
Tightening torque: 32.0 N·m (326 kgf·cm)
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. The following is the basic requirements of
Manipulator table for your reference.
The base table must not only be able to bear the weight of the Manipulator but also be able
to withstand the dynamic movement of the Manipulator when it operates at maximum
acceleration. Ensure that there is enough strength on the base table by attaching
reinforcing materials such as crossbeams.
C4 Rev.11 29
The torque and reaction force produced by the movement of the Manipulator are as
follows:
C4-A601** C4-A901**
Max. Horizontal rotating torque 500 N·m 700 N·m
Max. Horizontal reaction force 800 N 800 N
Max. Vertical rotating torque 600 N·m 1000 N·m
Max. Vertical reaction force 2500 N 2500 N
The plate for the Manipulator mounting face should be 30 mm thick or more and made of
steel to reduce vibration. The surface roughness of the steel plate should be 25 μm or
less.
The base table must be secured on the floor to prevent it from moving.
The Manipulator must be installed horizontally.
When using a leveler to adjust the height of the base table, use a screw with M16 diameter
or more.
Connector
If you are passing cables through the holes on the base table, see the figures below.
[unit : mm]
82
95
35
44
11
54 49
Power Cable Signal Cable
M/C Cables
Connector Connector
80
35
85
Power Cable
Connector (L-shaped)
Do not remove the M/C cables from the Manipulator.

NOTE For environmental conditions regarding space when placing the Controller on the base
 table, refer to the Controller manual.
30 C4 Rev.11
When using the Manipulator in the clean room, follow the steps below before the
installation.
(1) Unpack it outside of the clean room.
(2) Secure the Manipulator to delivery equipment such as a pallet with bolts so that the
Manipulator does not fall.
(3) Wipe off the dust on the Manipulator with a little alcohol or distilled water on a
lint-free cloth.
(4) Carry the Manipulator in the clean room.
(5) Secure the Manipulator to the base table.
C4 Rev.11 31
3.5 Connecting the Cables

■ Before performing any replacement procedure, turn OFF the Controller and related
equipment, and then pull out the power plug from the power source.
Performing any replacement procedure with the power ON is extremely hazardous
connecting the AC power cable to a factory power source is extremely hazardous
■ 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.) The unnecessary strain on the cables 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
WARNING shock and/or improper function of the robot system.
■ Before wiring, turn OFF the Controller and related equipment, and then pull up a
warning sign (e.g. DO NOT TURN ON THE POWER.). Wiring with the power
ON is extremely hazardous and may result in electric shock and/or malfunction of
the robot system.
■ Grounding the manipulator is done by connecting with the controller. Ensure that
the controller is grounded and the cables are correctly connected. If the ground
wire is improperly connected to ground, it may result in the fire or electric shock.
■ When connecting or replacing the brake release unit and the external short
connector, turn OFF the power to the Controller and the brake release unit.
Inserting and removing the connector while the power is ON may result in
electrical shock.
■ When connecting the Manipulator and the Controller, make sure that the serial
numbers on each equipment match. Improper connection between the
Manipulator and Controller may not only cause improper function of the robot
system but also safety problems. The connection method varies with the
Controller used. For details on the connection, refer to the Controller manual.
■ Only authorized or certified personnel should be allowed to perform wiring.
Wiring by unauthorized or uncertified personnel may result in bodily injury and/or
CAUTION malfunction of the robot system.
■ If the manipulator is operated without connecting the brake release unit and the
external short connector, the brakes cannot be released and it may cause
damage on them. After using the brake release unit, be sure to connect the
external short connector to the Manipulator, or check connection of the connector
for the brake release unit.
Cleanroom-model Manipulator
For the Cleanroom-model, an exhaust system is necessary. For details, refer to Setup &
Operation: 2.6 Specifications.
M/C Cable Connection method

Connect the power connector and the signal connector of the M/C cables to the Controller.
32 C4 Rev.11
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
CAUTION malfunction of the robot system.
User electrical wires and pneumatic tubes are contained in the cable unit.
Electrical Wires
Allowable Nominal Sectional
Rated Voltage Wires Outer Diameter Note
Current Area
AC/DC30 V 1A 9 0.211 mm2 ø8.3 ± 0.3 mm Shielded
Maker Standard
Suitable Connector JAE DE-9PF-N (Solder type)
9 pin
Clamp Hood JAE DE-C8-J9-F2-1R (Connector setscrew: #4-40 NC)
Pins with the same number, indicated on the connectors on both ends of the cables, are
connected.
Pneumatic Tubes
Max. Usable Pneumatic Pressure Pneumatic Tubes Outer Diameter × Inner Diameter
2
0.59 MPa (6 kgf/cm : 86 psi) 4 ø4 mm × ø2.5 mm
Tubes with the same number, indicated in details of View A and B, are connected.

Detail of “B” (9-pin D-sub connector)
B
No.1 No.2 No.3 No.4
Detail of “A”

(9-pin D-sub connector)
No.1 : White
No.2 : White Fitting for
No.3 : Blue ø4 mm
pneumatic tube
No.4 : Blue
A
Standard-model: Cover
Clean-room type: Exhaust port
( For ø8 mm pneumatic tube)
C4 Rev.11 33
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 home positions stored in each
motor and these stored in the Controller.
The process to compensate the position gap is called “Calibration”.
At shipment, the Manipulator is set the following basic position as origin.
After all setting is done, go through an origin return and make sure the manipulator moves
to the right basic orientation.
To make the manipulator return to origin, select [Tool]-[Robot Manager]-[Control Panel]
and click <Home>.
Contact us, the gap still exists and the manipulator cannot be in the basic orientation as
below after the origin return.
Basic orientation
34 C4 Rev.11
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. Improper connection of the
wires and/or pneumatic tubes may damage the robot system and/or work piece
as the work piece is released when the Emergency Stop switch is pressed.
CAUTION I/O outputs are configured at the factory so that they are automatically shut off (0)
by power disconnection, the Emergency Stop switch, or the safety features of the
robot system.
Wrist Flange
Applicable range
View A detail
Arm #6
Attach an end effector to the end of the Arm #6 using the M4 bolts.
Layouts
When you operate the Manipulator with an end effector, the end effector may interfere
with the Manipulator body depending on the outer diameter of the end effector, the size of
the work piece, or the position of the arms. When designing your system layout, pay
close attention to the interference area of the end effector.
Compatibility with PS series:

To install the end effector used in the PS series to the C4 series, we provide the optional
PS Compatible Plate. For details, refer to Setup & Operation: 6. Options.
C4 Rev.11 35
4.2 Attaching Camera and Valves

Decks are equipped to Arms #3 and #5 to enable the easy installation of air valve.
If the payload exceeds the maximum payload, refer to the section “Restriction on payload
exceeding the maximum payload” in the Setup & Operation 4.3.1 WEIGHT Setting.
To mount the camera, the camera plate unit is necessary.

We provide the optional Camera Plate Unit. For details, refer to Setup & Operation: 6.
Options.
[Unit: mm]
C4-A601**
Deck
Deck
Space for cable
Rotation Center
of the Upper
36 C4 Rev.11
C4-A901**
Deck
Deck
Space for cable
Rotation Center
of the Upper
C4 Rev.11 37
4.3 WEIGHT and INERTIA Settings

The WEIGHT and INERTIA commands are for setting the load parameters of the
Manipulator. These settings optimize the Manipulator motion.
WEIGHT Setting
The WEIGHT command is for setting the load weight. The more the load weight
increases, the more the speed and acceleration/deceleration are reduced.
INERTIA Setting
The INERTIA command is for setting the inertia moment and the eccentricity of the load.
The more the inertia moment increases, the more the acceleration and deceleration of the
Arm #6 are reduced. The more the eccentricity increases, the more the acceleration and
deceleration for the Manipulator movement are reduced.
To ensure optimum Manipulator performance, make sure that the load (weight of the end
effector and work piece) and inertia moment of the load are within the maximum rating for
the Manipulator, and that Arm #6 does not become eccentric.
If the load or the inertia moment exceeds the ratings or if the load becomes eccentric,
follow the steps in the Setup & Operation 4.3.1 WEIGHT Setting and 4.3.2 INERTIA
Setting, to set parameters.
Setting parameters makes the operation of the Manipulator optimal, reduces vibration to
shorten the operating time, and improves the capacity for larger loads. In addition, it
reduces persistent vibration produced when the inertia moment of the end effector and
work piece is bigger.
The allowable load for C4 series Manipulators is as follows:
Up to 4 (5) kg*
Due to the limitations shown in the tables below, the moment and the inertia moment
should also meet these conditions.
If force is applied to the Manipulator instead of weight, it should not exceed the values
shown in the table below.
* If the payload exceeds the maximum payload, refer to the section “Restriction on
payload exceeding the maximum payload” in the Setup & Operation 4.3.1 WEIGHT
Setting.
Allowable Load
Arm Allowable Moment *1 GD2/4 Allowable Moment of Inertia
#4 4.41 N·m (0.45 kgf·m) 0.15 kg·m2
#5 *2 4.41 N·m (0.45 kgf·m) 0.15 kg·m2
#6 2.94 N·m (0.3 kgf·m) 0.1 kg·m2
*1 Torque unit
*2 The allowable load for Arm #5 are calculated as follows:
Distance from the center of Arm #5 rotation (Figure: a + 65 [mm]).
38 C4 Rev.11
Critical Dimension of Load
Position of
Load’s Center
of Gravity
Arm #J6
Rotation
Center
Flange
Arm #J5
Rotation Center [Unit: mm]
Distance from the Arm #J6
Rotation Center
Distance from the Flange
When calculating the critical dimension of the load on the Arm #5 using the allowable
moment and inertia moment, the calculated value represents a distance from the Arm #5
rotation center, not the distance from the flange. Therefore, to get a value of the critical
dimension of the load on Arm #5, subtract 65 (mm) from the calculated distance as shown
in the example below.
Example: Calculate the critical dimension of the load on the Arm #5 (c) when a 2.5 kg load
is on the Arm #6 rotation center line (b = 0).
Allowable Moment of the Arm #5 (N·m) / Load (kg)
= Distance from the Arm #5 rotation center (m)
4.41 (N·m) / 9.8 / 2.5 (kg) = 0.18 → 0.18 (m) = 180 (mm)
c = Distance from the Arm #5 rotation center (mm) − 65 (mm)

c = 180 (mm) − 65 (mm) = 115 (mm)
C4 Rev.11 39
Moment
A moment is a necessary torque (holding torque) to counteract the gravity affecting the
load.
Design an end effector so that the eccentric quantity at the position where the load is
attached is within the allowable moment.
A maximum torque (T) is calculated by the following formula.
T = m (kg) × L (m) × g (m/s2) L
m: Weight of load (kg)

L: Eccentric quantity of load (m)
g: Gravitational acceleration (m/s2) Joint Rotation Center
T
Max. Eccentric Quantity of Load

(Distance between the joint rotation center and the load’s center of gravity)
Axis WEIGHT 1 kg WEIGHT 2 kg WEIGHT 2.5 kg WEIGHT 3 kg
#4 200 mm 200 mm 150 mm 112 mm
#5 200 mm 200 mm 150 mm 112 mm
#6 200 mm 150 mm 100 mm 75 mm
(The maximum eccentric quantity of load is restricted to 200 mm or less.)
4.3.1 WEIGHT setting
■ Set the total weight of the end effector and the work piece smaller than the
maximum payload.
The C4 Manipulators can operate without limitations on the condition unless and
until the load exceeds this maximum payload. When the payload of the
Manipulator exceeds the maximum payload, refer to the section “Restrictions on
payload exceeding the maximum payload” in the later part of this section for
CAUTION details.
Always set the Weight parameters of the WEIGHT command according to the
load. Setting a value that is smaller than the actual load may cause errors,
excessive shock, insufficient function of the Manipulator, and/or shorten the life
cycle of parts/mechanisms.
The acceptable weight capacity (end effector and work piece) for C4 Manipulators is as
follows:
Rated Maximum
1 kg 4(5) kg*
When the load exceeds the rating, change the setting of the Weight parameter.
After changing the Weight parameter setting, the maximum acceleration/deceleration and
speed of the robot system corresponding to the load is set automatically.
Setting.
40 C4 Rev.11
Setting method of Weight parameters

EPSON Select [Tools]-[Robot Manager]-[Weight] panel and set the value in [Weight:].
RC+ You may also execute the Weight command from [Command Window].
Load on the Manipulator

Mounting location of the load
C4-A601** Load on the fore end of Arm #6
Arm #5 Deck Arm #3 Deck
C4-A901** Load on the fore end of Arm #6
Arm #5 Deck
Arm #3 Deck
C4 series
Deck detailed
Arm #5 Deck Arm #3 Deck

[Unit: mm]
When you attach the equipment to the decks on the upper arm, convert its weight into
equivalent weight assuming that the equipment is attached to the end of the Arm #6.
Then, this equivalent weight added to the load will be a Weight parameter.
C4 Rev.11 41
Calculate the Weight parameter by using the formula below and enter the value.
Weight Parameter Formula

Weight parameter = Mw + Wa + Wb
Mw : Load on the fore end of Arm #6 (kg)
Wa : Equivalent weight of the Arm #3 deck (kg)
Wb : Equivalent weight of the Arm #5 deck (kg)
Wa = Ma (La)²/ (L)²
Wb = Mb (Lb)²/ (L)²
Ma : Weight of the air valve on the Arm #3 deck

Mb : Weight of the camera on the Arm #5 deck
L : Length of the upper arm (315 mm)
La : Distance between the Joint #3 and the center of gravity of
the air valve on the Arm #3 deck (mm)
Lb : Distance between the Joint #3 and the center of gravity
of the camera on the Arm #5deck (mm)
<Example> The fore end of the Arm #6 is 315 mm (L) away from the Joint #3.
Load on the fore-end of Arm #6 is 1 kg (Mw).
Load on the Arm #3 deck is 1.5 kg (Ma).
The deck is 0 mm (La) away from Joint #3.
Load on the Arm #5 deck is 0.5 kg (Mb).
The deck is 280 mm (Lb) away from the Joint #3.
Wa=1.5 × 02/3152=0
Wb=0.5 × 2802/3152=0.395 → 0.4(round up)
Mw + Wa + Wb=1 + 0 + 0.4=1.4
Enter “1.4” for the Weight parameter.
42 C4 Rev.11
Automatic speed setting by Weight parameter (C4-A601**)
Acceleration / Deceleration
Speed
Weight Parameter
Automatic speed setting by Weight parameter (C4-A901**)
Acceleration/ Deceleration
Speed
Weight Parameter
* The percentage in the graph is based on the speed at rated weight (1 kg) as 100%.
Setting.
Restrictions on payload exceeding the maximum payload

Maximum payload for C4 Manipulators is as follows:
Payload can be increased by restricting the arm posture of the Arm #5 downward.
Max. Payload Max. Payload with Pose Restriction

4 kg 5 kg
C4 Rev.11 43
If the load exceeds the maximum payload, use the Arm #5 with a posture angle within the
range indicated in the following graph.
The graph shows the relation of the load weight and Arm #5 angle limit (A1) measured in
vertical direction (direction of gravity). Note that the heavier the load on the Arm #6, the
smaller the angle limit becomes.
When the manipulator operates vertically to the operating surface, the limit of the Arm #5
is equivalent to the limit of the operating angle (A2).
In addition, for the eccentric load, the angle limit is an angle of the line joining the center
of the load and the Arm #5 rotation axis with the vertical direction (B).
The eccentric quantity of the load should be within the allowable moment and inertia
moment of Arms #4, #5, and #6.
Relation of load weight and Arm #5 angle limit

Arm #5 Angle Limit
Load on Arm #6 End
Arm #4
Vertical direction Vertical direction

Load on Arm #5 rotation axis
Arm 6 end Operating surface
Arm #5 rotation axis Gravity
2
A : Angle of operating Load on
Arm #5 surface form plane Arm #6 end
Arm #6 Plane Arm #5
B
Arm #6
1
A : Arm #5 angle
from vertical direction
Relation of Arm #5 angle and operating surface Angle limit for eccentric load
44 C4 Rev.11
4.3.2 INERTIA setting

Inertia Moment and the INERTIA Setting
The inertia moment is defined as “the ratio of the torque applied to a rigid body and its
resistance to motion”. This value is typically referred to as “the moment of inertia”,
“inertia”, or “GD2”. When the Manipulator operates with objects such as an end effector
attached to the Arm #6, the moment of inertia of load must be considered.
■ The inertia moment of the load (weight of the end effector and work piece) must
be 0.1 kg·m2 or less. The C4 Manipulators are not designed to work with inertia
moment exceeding 0.1 kg·m2.
Always set the inertia moment (INERTIA) parameter according to the inertia
CAUTION moment. Setting a value that is smaller than the actual inertia moment may
cause errors, excessive shock, insufficient function of the Manipulator, and/or
shorten the life of parts/mechanisms.
The acceptable inertia moment of load for C4 Manipulator is 0.1 kgm2 nominal rating and
0.1 kgm2 maximum. When the inertia moment of the load exceeds the rating, change
the setting of the inertia moment using the INERTIA command. After the setting has
been changed, the maximum acceleration/deceleration speed of Arm #6 responding to
“inertia moment” is set automatically.
Inertia moment of load on Arm #6

The inertia moment of the load (weight of the end effector and work piece) on the Arm #6
can be set by the “inertia moment (INERTIA)” parameter of the INERTIA command.
EPSON Select [Tools]–[Robot Manager]-[Inertia] panel and enter the value in [Load inertia:].
RC+
You may also execute the Inertia command from [Command Window].
C4 Rev.11 45
Eccentric Quantity and the INERTIA Setting

■ The eccentric quantity of the load (weight of the end effector and work piece)
must be 200 mm or less. The C4 Manipulators are not designed to work with
eccentric quantity exceeding 200 mm.
Always set the eccentric quantity parameter according to the eccentric quantity.
CAUTION Setting a value that is smaller than the actual eccentric quantity may cause
errors, excessive shock, insufficient function of the Manipulator, and/or shorten
the life cycle of parts/mechanisms.
The acceptable eccentric quantity of the load for C4 Manipulators is 30 mm at nominal

rating and 200 mm at maximum. When the eccentric quantity of the load exceeds the
rating, change the setting of eccentric quantity parameter using the INERTIA command.
After changing the setting, the maximum acceleration/deceleration speed of Manipulator
corresponding to “eccentric quantity” is set automatically.
Rotation Center
a
a, b = Eccentric Quantity
Flange (200 mm or less)
To set the parameter, enter

b
the larger value of “a” or “b”.
Position of Load’s Center of Gravity
Eccentric Quantity
Eccentric quantity of load on Arm #6

The eccentric quantity of the load (weight of the end effector and work piece) on the Arm
#6 can be set by the “eccentric quantity” parameter of the INERTIA command.
Enter the larger value of either “a” or “b” in the figure above to [Eccentricity].
EPSON Select [Tools]–[Robot Manager]-[Inertia] panel and enter the value into [Eccentricity:].
RC+ You may also execute the Inertia command from [Command Window].
46 C4 Rev.11
Automatic acceleration/deceleration setting by INERTIA (eccentric quantity)
Eccentric Quantity
* The percentage in the graph is based on the acceleration/ deceleration at rated eccentricity (30 mm)
as 100%.
INERTIA (eccentric quantity) is affected by the load setting. Refer to Setup & Operation
4.3: WEIGHT and INERTIA Settings and configure the load setting carefully.
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) Work Piece (c)
Whole Moment = Moment of Inertia + Moment of Inertia + Moment of Inertia

of Inertia of End Effector (a) of Work Piece (b) of Work Piece (c)
The methods for calculating the inertia moment for (a), (b), and (c) are shown in this and
the next page. Figure out the whole inertia moment using the basic formulas below.
C4 Rev.11 47
(a) Inertia moment of a rectangular parallelepiped

Rotation Center Rectangular Parallelepiped’s Center of Gravity
Weight = m 2 2
b +h
+m×L
2
m
12
L
b
h
(b) Inertia moment of a cylinder
Cylinder’s Center of Gravity Rotation Center
r
2
r
+m×L
2
m
Weight = m 2
(c) Inertia moment of a sphere

Sphere’s Center of Gravity
Rotation Center
2
r +m×L
2 2
r m
5
Weight = m
48 C4 Rev.11
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.
The more the load weight increases, the more the speed and acceleration/deceleration are
reduced to prevent residual vibration.
INERTIA Setting
The acceleration/deceleration of Arm #6 are controlled according to the inertia moment set
by the INERTIA command. The acceleration/deceleration of the whole Manipulator are
controlled according to the eccentricity set by the INERTIA command. The more the
inertia moment and eccentricity of the load increase, the more the acceleration/
deceleration are reduced.
Auto Acceleration/Deceleration According to Manipulator’s Posture

The acceleration/deceleration are controlled according to the Manipulator’s posture.
When the Manipulator extends its arms or when the movement of the Manipulator
produces vibration frequently, the acceleration/deceleration are reduced.
Set appropriate values for WEIGHT and INERTIA so that the Manipulator operation is
optimized.
C4 Rev.11 49
Setup & Operation 5. Motion Range
5. Motion Range
■ When limiting the motion range for safety, be sure to set by both the pulse range
and mechanical stops. Failure to do so may cause serious safety problems.
WARNING
The motion range is preset at the factory as describes in the Setup & Operation 2.5
Standard Motion Range. This is the maximum motion range of the Manipulator.
Motion range is set by the following three methods:

1. Setting by pulse range (for all arms)
2. Setting by mechanical stops
3. Setting the Cartesian (rectangular) range in the X, Y coordinate system of the
Manipulator
Rectangular Range Setting
Mechanical Motion Range Mechanical

Stop Stop
Pulse Range
When the motion range is changed due to layout efficiency or safety, follow the
descriptions in 5.1 through 5.4 to set the range.
50 C4 Rev.11
5.1 Motion Range Setting by Pulse Range (for All Arms)

Pulses are the basic unit of Manipulator motion. The motion range of the Manipulator is
controlled by the pulse range (the lower limit and the upper limit) of each axis.
Pulse values are read from the encoder output of the servo motor.
The pulse range should be set within the mechanical stop range.
■ Do not set and/or use the Arm #4 with a pulse range exceeding the maximum
value.
The Arm #4 does not have a mechanical stop. Using the Arm #4 with a pulse
CAUTION range exceeding the maximum pulse range may cause the inner wiring damaged
and/or malfunction to the Manipulator.
Torsion of the inner wiring can be checked by removing the Arm #3 head cover.
Arm #3 head cover
NOTE Once the Manipulator receives an operating command, it checks whether the target
 position specified by the command is within the pulse range before operating. If the
target position is out of the set pulse range, an error occurs and the Manipulator does not
move.
EPSON The pulse range can be set in [Tools]-[Robot manager]-[Range] panel.

RC+
You may also execute the Range command from the [Command Window].
C4 Rev.11 51
5.1.1 Max. Pulse Range of Arm #1

Pulse values in counterclockwise direction are positive (+) and values in clockwise
direction are negative (-).
C4-A601**
(without mechanical stop)
Arm #1
0 pulse position
C4-A901**
Arm #1
0 pulse position
52 C4 Rev.11

Pulse values in clockwise direction are positive (+) and values in counterclockwise
C4-A601** C4-A901**
Arm #2 Arm #2
0 pulse position 0 pulse position

C4-A601** C4-A901**
Arm #3 Arm #3
0 pulse 0 pulse
position position
C4 Rev.11 53

From the angle of arm end, clockwise pulse values are positive (+) and counterclockwise
pulse values are negative (-).
C4-A601** C4-A901**
Arm #4
0 pulse position
Arm #4
0 pulse position
■ Do not set and/or use the Arm #4 with a pulse range exceeding the maximum
value.
The Arm #4 does not have a mechanical stop. Using the Arm #4 with a pulse
CAUTION range exceeding the maximum pulse range may cause the inner wiring damaged
and/or malfunction to the Manipulator.
Torsion of the inner wiring can be checked by removing the Arm #3 head cover.
Arm #3 head cover
54 C4 Rev.11

C4-A601** C4-A901**
Arm #5
Arm #5 0 pulse position
0 pulse position

From the angle of arm end, clockwise pulse values are positive (+) and counterclockwise
pulse values are negative (-).
C4-A601** C4-A901**
Arm #6
0 pulse position
Arm #6
0 pulse position
C4 Rev.11 55
5.2 Motion Range Setting by Mechanical Stops

Mechanical stops physically limit the absolute area that the Manipulator can move.
Be sure to turn OFF the Controller in advance.
Bolts are not provided, arrange for them by yourself.
Use bolts conforming to the strength specified by ISO-898-1, property class: 12.9.
Specify the pulse range again after changing the position of the mechanical stop.
For details on the pulse range setting, refer to the Setup & Operation 5.1 Motion Range
Setting by Pulse Range (for All Arms).
Be sure to set the pulse range not to exceed the setting angles of the mechanical stop.
5.2.1 Motion Range Setting of Arm #1

Install the bolt to the threaded hole corresponding to the
angle you want to set.
Normally a mechanical stop is equipped at [ b ].
a
[ a ] and [ c ] limit the one side of motion range.
Remove the bolts when the motion range of the Arm #1 is b
set to ±180 deg.
c
M8×15 hexagon socket head cap bolt
Tightening torque 37.2 N·m (380 kgf·cm)
a b c
Angle (deg.) −125 ±170 ±180 +125
Pulse C4-A601** −3640889 ±4951609 ±5242880 −3640889
(pulse) C4-A901** −5957819 ±8102633 ±8579259 −5957819
Bolt Applied Applied (Normal) Not applied Applied
56 C4 Rev.11

There are threaded holes corresponding to each angle
on the Manipulator.
Normally there is no mechanical stop equipped.

(−160 deg. - +65 deg.)
d e
[ d ] and [ e ] limit the one side of motion range.
C4-A601**
d e - -
Angle (deg.) −143 +48 −160 +65
Pulse
−4165177 +1398102 −4660338 +1893263
(pulse)
Not applied Not applied
Bolt Applied Applied
(Normal) (Normal)
Contact us about C4-A901**.

There are threaded holes corresponding to each angle on
the Manipulator.
f
Normally mechanical stops are equipped to [ f ] and [ g ].
(+225 deg. - −51 deg.) g
C4-A601**, C4-A901**
f g
Angle (deg.) +225 −51
Pulse C4-A601** +5734400 −1299798
(pulse) C4-A901** +10194489 −2310751
Applied Applied
Bolt
(Normal) (Normal)
C4 Rev.11 57
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.
The Manipulator operation is restricted and the Manipulator stops when the joint angles of
the Arm are within the gray areas in the following figure.
The restriction to Manipulator operation is enabled:

- During CP motion command execution
- When you attempt to execute the motion command for moving the Manipulator to a
target point (or pose) in the specified motion range.
The restriction to the Manipulator operation is disabled:

- The Arms of the Manipulator momentarily go through the specified motion range
during the PTP motion command execution even though the joint angles of the Arms
are in the gray areas of the figures above.
Combination of Joint #1 and #2 (C4-A601**)

Joint #2 Angle
Joint #1 Angle

Joint #3 Angle
Joint #2 Angle
58 C4 Rev.11
Joint #2 Angle
Joint #1 Angle

Joint #3 Angle
Joint #2 Angle
C4 Rev.11 59
5.4 Coordinate System

The origin point is where the Manipulator base 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

+X +Z
+Y
+X +Z
+Y
+X
+
5.5 Changing the Robot

This section describes how to change the manipulator model on EPSON RC+.
(Default setting is “table top mounting”.)
■ Changing the manipulator should be done with great caution. It initializes the robot
calibration parameters (Hofs, CalPls), additional axis information, and PG parameter
data.
Before changing the robot, make sure to save the calibration data by following the
CAUTION procedure below.
1. Select the EPSON RC+ 7.0 menu-[Setup]-[System Configuration].
2. Select [Robot]-[Robot**]-[Calibration] from the tree list. Then, click <Save>.
60 C4 Rev.11
(1) Select the EPSON RC+ 7.0 menu-[Setup]-[System Configuration].

(2) Select [Robot]-[Robot**] from the tree list.
(3) Click the <Change…> button. The following dialog box will be displayed.
(4) Input the robot name and serial number printed on the name plate of the manipulator.
Any serial number can be entered. However, enter the number printed on the
manipulator.
(5) Select the robot type in the [Robot type] box.
(6) Select the series name of the manipulator in the [Series] box.
(7) Select the robot model in the [Model] box. Available robots will be displaed
according to the format of the currently installed motor driver. When [Dry run] is
used, all the manipulators of the series selected in Step 6 will be displayed.
For the ceiling mount type, select the model which ends with “R” (e.g. C4-A601SR).
(8) Click the <OK> button. The controller will be restarted.
C4 Rev.11 61
5.6 Setting the Cartesian (Rectangular) Range in the XY Coordinate

System of the Manipulator
The Cartesian (rectangular) range in the XY coordinate system of the Manipulator is
specified by the limited Manipulator operation area and the XYLIM setting.
The limited Manipulator operation area is defined so that the end effector does not
interfere with the rear side of the Manipulator. The XYLIM setting that you can
determines the upper and lower limits of the X and Y coordinates.
The limited Manipulator operation area and the XYLIM setting apply only to the software.
Therefore, these settings do not change the physical range. The maximum physical range
is based on the position of the mechanical stops.
These settings are disabled during a joint jogging operation. Therefore, be careful not to
allow the end effector to collide with the Manipulator or peripheral equipment.
The method for changing the XYLIM setting varies with the software used.
EPSON Set the XYLIM setting in [Tools]-[Robot manager]-[XYZ Limits] panel.

RC+
You may also execute the XYLim command from the [Command Window].
62 C4 Rev.11
Setup & Operation 6. Options
6. Options
C4 series manipulator has the following options.
6.1 Brake Release Unit
6.2 Camera Mounting Plate
6.3 PS Compatible Plate (Tool Adapter)
6.4 Base Side Angled Fittings
6.5 Base Side Fittings
6.6 PS Compatible Plate (Base Adapter)
6.7 Adjustable Mechanical Stop (Joint #2: Only C4-A901**)
6.1 Brake Release Unit

With the electromagnetic brake is ON (such as in Emergency Stop status), all arms don’t
move.
You can move the Arms by hand using the brake release unit while the controller power is
OFF or right after unpacking.
■ Before connecting/disconnecting the connector of the Brake release unit, be sure

to turn OFF the powers of the controller and break release unit. Otherwise, it
leads to the electrical shock or breakdown.
When connecting or replacing the brake release unit and the external short
WARNING connector, turn OFF the power to the Controller and the brake release unit.
electrical shock.
CAUTION ■ Be careful of the arm falling when releasing the brake.
The arm falling may cause hands and fingers to be caught and/or may cause
Width 180 mm
Depth 150 mm
Height 87 mm
Weight (Cables are not included.) 1.7 kg
Cable to the Manipulator 2m
Power cable length 2m
Power cable (US) 100 V specification
Power cable (EU) 200 V specification
C4 Rev.11 63
A
View from A
Power switch Power cable Power lamp Arm switches
Precautions for use

■ After the brake release unit is disconnected, be sure to connect the external short
connector. Otherwise, you cannot release the brakes.
If the manipulator is operated without connecting the brake release unit and the
■ Keep the external short connector.
Otherwise you cannot release the brakes.
CAUTION ■ If you turn ON the brake release unit while the brake release switch is being
pressed, an unintended arm may move downward.
Before turning ON the brake release unit, make sure that the brake release
switch is not pressed.
■ If you turn ON the brake release unit without the connector, it may lead to the
short for the male pin used in the connector.
Before turning ON the brake release unit, make sure that the connector is
connected.
Mount the brake release unit

(1) Turn OFF the controller.
(2) Remove the external short connector.
External short connector
(3) Connect the brake release unit to the connector

of the connection cable.
Connector of the
connection cable
64 C4 Rev.11
Remove the brake release unit

(1) Turn OFF the brake release unit.
(2) Remove the power cable of the brake release unit.
(3) Disconnect the brake release unit from the connector of the connection cable.
(4) Connect the external short connector to the connector of the connection cable.
How to use the brake release unit
■ Be careful of the arm falling when releasing the brake.

CAUTION ■ If the arm you released its brake moves awkwardly or faster than usual, stop the
operation promptly and contact us. The brake release unit may be broken.
If you keep operating the manipulator, it may lead to the breakdown of the
manipulator or you may get your hand or fingers caught.
(2) Power switch (1) Power cable (2) Power lamp (3) Arm switches connector lock
(1) Disconnect the external short connector.
(2) Plug the power cable into the brake release unit.
(3) Plug the power cable into the power supply plug.
(4) Turn ON the brake release unit.

When the brake release unit is enabled, the power lamp lights up.
(5) Press the switch of the arm (J1 to J6) you want to move and then move the arm.
Press the switch again. The brake will be released.
The brake will be enabled by pressing the switch once again.
NOTE Move the arm the brake is released by two persons or more (one presses the switch
 and one moves the arm). The arm can be very heavy and needs the significant force
to move.
C4 Rev.11 65
6.2 Camera Plate Unit

To mount a camera to the C4 series manipulator, you need to mount the camera plate unit
first.
Appearance of arm end with camera
Camera
D D
Camera plate unit
D
Parts included unit
A Camera adapter plate 1
B Camera mid plate 1
E
C Camera base plate 1
D Hexagon socket head screws F
6 A: Camera adapter plate
M4×12
B: Camera mid plate
E hexagon socket head screws
2 C: Camera base plate
M4×20
F Plain washer for M4
2
(small washer)
To mount the camera plate unit

(1) Mount the camera base plate to the manipulator. Mounting holes of
camera base plate
2-M4 × 20 + Plain washer for M4 (small washer)
(2) Mount the camera mid plate to the base plate.
2-M4 × 12
NOTE The motion range and dimension of the manipulator with the camera installed may
 vary depending on the mounting hole of camera mid plate. The details are
described in the table below.
(3) Mount the camera to the camera adapter plate.
NOTE According to the camera, the available mounting hole of adapter plate will be
 different. The details are described below.
(4) Mount the camera adapter plate and camera to the camera mid plate.
4-M4 × 12
(5) Secure the cables at the position where they do not interfere with the manipulator
motion.
NOTE When securing the cables, check if the cables bend radius is big enough and the
 cables are not rubbing against each other while the manipulator moves. Otherwise,
the cables will be disconnected.
66 C4 Rev.11
Dimension of the camera plate unit
2-M4 depth 5
3-M4 through hole (for securing cables)
(for securing cables)
2-M3 depth 5
Camera
4-M4 depth 8 * same hole on opposite side
Dimensions X and Y will change depending on the position of camera mid plate and
camera size. Refer to the table below for the values.
Camera mid plate

The camera mid plate uses the mounting holes
A to D.
By using the different mounting holes, it can
be mounted to the camera base plate in the
different four positions.
Camera adapter plate

Each camera uses the different mounting holes.
USB camera : J (2 holes)
GigE camera : E (3 holes)
Mounting example
Using the mounting hole A Using the mounting hole C

E.g.) Camera: XC-ES30
C4 Rev.11 67
Camera and 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.
The table below shows the motion range (reference values) based on the available cameras
for this option and the mounting positions of the camera mid plate. The values in the
table may vary depending on how to secure the cables.
By changing the Y position, you can extend the distance from the end effector mounting
surface to the camera. Also, you can attach the larger end effector. However, be careful
about the Joint #5 motion range that will be limited in this case.
(° = degree)
A B C D X
USB camera, GigE camera −135° ~ +60° −135° ~ +50° −135° ~ +35° −135° ~ +25° 72.5 mm
A B C D
Y 57 mm 37 mm 17 mm 7 mm
Direction of the Joint #5 motion
68 C4 Rev.11
6.3 PS Compatible Plate (Tool Adapter)

Using the PS compatible plate, you can mount the end effector used in the PS series to the
C4 series.
Parts included Unit

A PS compatible plate 1
B Dowel pin (M3 hole on one side) 1
C Hexagon socket head screw M4×12 4
Dimensions of PS-compatible plate

Spot faced hole for M4
(at 90 ° pitch)
H7 depth 12
4-M4 depth 12
(at 90 ° pitch)
Insert dowel pin here

(° = degree)
C: Hexagon socket head screw

4-M4×12
A: PS-compatible plate
B: Dowel pin (M3 hole on one side)
To mount the PS compatible plate

(1) Align the hole on the arm end flange (ø12H7) to the projection on the PS compatible
plate (ø12h7).
(2) Insert the dowel pin from the PS compatible plate side and position the arm and PS
compatible plate. One side of the dowel pin has the M3 screw hole and you can
adjust the depth using M3.
NOTE If you move the Manipulator with the dowel pin inserted, the dowel pin will fall out.
 To move the Manipulator with the dowel pin inserted, you need to secure the dowel
pin with glue.
(3) Secure the PS compatible plate with 4 hexagon socket head screws.
4-M4 × 12
C4 Rev.11 69
6.4 Base Side Angled Fittings

By using the base side angled fittings to the C4 series manipulator base, you can mount the
manipulator in skewed position. The motion range expands with this mounting type
compared to the normal ceiling mounting.
Mounting image using the base side angled fittings
For details of the mounting and precautions, refer to Setup & Operation: 3. Environment
and Installation.
Parts included Qty.

A Base side angled plate (Left side) 1
B Base side angled plate (Right side) 1
C Base side plate (for Skewed mounting type) 2
D Pin 6
E Hexagon socket head screw M8 × 25 4
F Hexagon socket head screw M8 × 30 4
F F
C C
D D
E E
A D B
70 C4 Rev.11
To mount the base side angled fittings

(1) Drive pins to the base side plate (for Skewed mounting type).
Protruding part of pins is approx. 2 to 5 mm. Two pins
Protruding part
2mm to 5mm
(2) Drive pins to the base side angled plate (left & right sides).
Protruding part of pins is approx. 2 to 5 mm.
Pin at each side

Protruding part
2mm to 5mm
(3) Create a base side angled fittings.

Fit the pins of the plate for Skewed mounting type in the step
(1) with the holes on the plate in the step (2) and secure with
the screws.
Right side
Hexagon socket head screw M8 × 30
(4) Mount the base side angled fittings to the both sides of manipulator base.
Fit the pins drove in the step (2) with the holes on the base. Secure the fittings by
pressing it to the indicated direction in the figure below.
Left & Right side Hexagon socket heat screw 2- M8 × 25
Base side
angled fittings
2-M8×25
NOTE The shape of the base side angled fittings is asymmetry. Be sure to mount the
 fittings in correct direction.
Otherwise, the motion range of Arm #2 is limited in the backside.
NOTE The recommended base plate thickness is between 30 mm and 40 mm. If the thickness is
 more than 40 mm, the manipulator may contact the base plate when the Arm #1 rotates
depending on the center cut dimension in the base plate.
The base plate securing the manipulator should be prepared by users. The torque value
and reaction force generated in the manipulator motions are described in Setup &
Operation: 3.4 Installation.
C4 Rev.11 71
6.5 Base Side Fittings

Using the base side fittings to the C4 manipulator base, you can mount the manipulator in
the place where limits the mounting height or use the open room for the base.
Mounting image using the base side fittings
For the information on how to mount and precautions, refer to Setup & Operation: 3.
Environment and Installation.
Parts included Qty. A A

A Base side plate 2
B Pin 2 C C
Hexagon socket head
C 4
screw M8 × 60
B
To mount the base side plate

(1) Drive the pins to the base side plate. Pin protruding part
2mm to 5mm
Protruding part of pins is approx. 2 to 5 mm.
(2) Mount the base side plate with the pins driven to the both sides of the base.
Fit the pins with the holes and secure the base side plate by pressing it from above to
the base fixing part.
(With the steps above, the both surfaces of base side fittings can be stable.)
Base fixing
part
2. Press toward this face from above
1. Insert pins into

the holes
2-M8×60
72 C4 Rev.11
Dimension of the manipulator with the base side fittings
2-M10
(Prepared hole ø8.5)
2-M10
(Prepared hole ø8.5)
C4 Rev.11 73
Installation example
Screws
Size Recommended length
A M8 30 mm or more
B M10 15 mm + Base Plate or more
NOTE The base side plate has a M10 screw hole. You can secure the plate with
 a M10 screw or a M8 screw by using a prepared screw hole of ø8.5 to
make a M8 screw hole on the mounting surface.
NOTE A: Securing from above
 To secure from above, use the screw A in the table above.
When you install the manipulator for practical use, you need to insert the
screws in the right/left side from the same direction (above or below).
Table Top mounting
A: Secures B: Secures
from above from above
← Base Plate
(Floor)
B: Secures A: Secures
from below from below
Ceiling mounting
B: Secures A: Secures
from above from above
← Base plate
(Ceiling)
A: Secures B: Secures
from below from below
74 C4 Rev.11
6.6 PS Compatible Plate (Base Adapter)

PC compatible plate is used to use manipulator fixing taps for PS series to the C4 series
manipulator.
Parts included Qty.

A PS compatible plate 1
B Dowel pin (M4 hole on one side) 3
C Dowel pin (M6 hole on one side) 2
D M10×25 hexagon socket head cap bolt 8
E Plain washer 4
F Spring washer 8
Dimensions of PS compatible plate
Installation (1) Fix the mounting table and the PS compatible plate with hexagon socket head cap
bolts and spring washers.
Use dowel pins as needed to adjust positions of the mounting table and the PS
compatible plate.
(2) Fix the C4 series manipulator and the PS compatible plate.
Hexagon socket head cap bolts (4-M10×25) + spring washers + plain washers
Use dowel pins as needed to adjust positions of the manipulator and the PS
compatible plate.
C4 Rev.11 75
6.7 Adjustable Mechanical Stop (Joint #2: only C4-A901**)

Adjustable mechanical stops physically limit the absolute area that the Manipulator can
move.
Be sure to turn OFF the Controller in advance.
Use high corrosion-resistant stainless bolts or equivalent material.
Specify the pulse range again after changing the position of the mechanical stop.
For details on the pulse range setting, refer to the Setup & Operation 5.1 Motion Range
Setting by Pulse Range (for All Arms).
Be sure to set the pulse range not to exceed the setting angles of the mechanical stop.
Parts included Qty.

A Adjustable mechanical stop 1
B M6×40 hexagon socket head cap bolt 2
C Plain washer 2
Installation (1) Remove the bolts fixing the Arm #2 spacer (2- M6×20).
(2) Fix the adjustable mechanical stop with the bolts (2-M6×40) and plain washers.
Direction of the adjustable mechanical stop depends on the angular limitation to be
set.
Installation 1 Installation 2
Installation 1 Installation 2 - -
Angle (deg.) −153 +50 −160 +65
Pulse (pulse) −4456448 +1456356 −7626008 +3098066
Adjustable Not applied Not applied
Applied Applied
mechanical stop (standard) (standard)
76 C4 Rev.11
Maintenance
This volume contains maintenance procedures with safety
precautions for C4 series Manipulators.
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.
The personnel who have taken safety training acquire knowledge of industrial
robots (operations, teaching, etc.), inspections, and related rules/regulations.
The personnel who have completed the robot system-training and maintenance-
training held by the manufacturer, dealer, or locally-incorporated company are
allowed to perform maintenance.
■ Do not remove any parts unless otherwise instructed by this manual. Follow the
maintenance procedure strictly as described. Improper removal of parts or
improper maintenance may cause not only malfunction of the robot system but
serious safety problems.
■ If you have not received training, keep away from the Manipulator while the
power is ON. Do not enter the operating area while the power is ON. Entering
the operating area with the power ON is extremely hazardous and may cause
serious safety problems as the Manipulator may move even it seems to be
stopped.
■ When you check the operation of the Manipulator after replacing parts, be sure to
WARNING
check it while you are outside of the safeguarded area. Checking the operation
of the Manipulator while you are inside of the safeguarded area may cause
serious safety problems as the Manipulator may move unexpectedly.
■ Before operating the robot system, make sure that both the Emergency Stop
switches and safeguard switch function properly. Operating the robot system
when the switches do not function properly is extremely hazardous and may
result in serious bodily injury and/or serious damage to the robot system as the
switches cannot fulfill their intended functions in an emergency.
■ To shut off power to the robot system, pull out the power plug from the power
source. Be sure to connect the AC power cable to a power receptacle. DO
NOT connect it directly to a factory power source.
■ Before performing any replacement, turn OFF the Controller and related
equipment, and then pull out the power plug from the power source.
WARNING
system.
■ When connecting or replacing the brake release unit and the external short
connector, turn OFF the power to the Controller and the brake release unit.
electrical shock.
C4 Rev.11 79
Maintenance 1. Safety Maintenance
cables 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.
■ If the manipulator is operated without connecting the brake release unit and the
CAUTION
2. General Maintenance
This chapter describes maintenance inspection procedures. Performing maintenance
inspection properly is essential to prevent trouble and ensure safety.
Be sure to perform the maintenance inspections in accordance with the schedule.
2.1 Maintenance Inspection

2.1.1 Schedule for Maintenance Inspection
Inspection points are divided into five stages: daily, monthly, quarterly, biannual, and
annual. The inspection points are added every stage.
If the Manipulator is operated for 250 hours or longer per month, the inspection points
must be added every 250 hours, 750 hours, 1500 hours, and 3000 hours operation.
Inspection Point
Daily Monthly Quarterly Biannual Annual Overhaul
inspection inspection inspection inspection inspection (replacement)
1 month (250 h) √
2 months (500 h) √
3 months (750 h) √ √
4 months (1000 h) √
5 months (1250 h) √
Inspect every day
6 months (1500 h) √ √ √
7 months (1750 h) √
8 months (2000 h) √
9 months (2250 h) √ √
10 months (2500 h) √
11 months (2750 h) √
12 months (3000 h) √ √ √ √
13 months (3250 h) √
…
20000 h √
h = hour
80 C4 Rev.11
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
Check looseness or backlash of End effector mounting bolts √ √ √ √ √

bolts/screws. Manipulator mounting bolts √ √ √ √ √
Tighten them if necessary. Each arm locking bolts √ √ √ √ √
(For the tightening torque, refer to Bolts/screws around shaft √
Maintenance: 2.4 Tightening Bolts/screws securing motors,
√
Hexagon Socket Head Cap Bolts.) reduction gear units, etc.
External connectors on
Check looseness of connectors.
Manipulator (on the connector √ √ √ √ √
If the connectors are loosen, push it
plates etc.)
securely or tighten.
Manipulator cable unit √ √ √ √
External appearance of
Visually check for external defects. √ √ √ √ √
Manipulator
Clean up if necessary.
External cables √ √ √ √
Check for bends or improper
location. Repair or place it properly Safeguard etc. √ √ √ √ √
if necessary.
Check tension of timing belts. Base
√ √
Tighten it if necessary. Inside of Arms #1, 2, 3, 4
Grease conditions Refer to Maintenance: 2.3 Greasing.
Battery Refer to Maintenance: 12 Replacing the Battery Unit.
The external short connector
Check either the external short
on the back side of the
connector or the brake release unit √ √ √ √ √
Manipulator, or the brake
connector is connected.
release unit connector.
C4 Rev.11 81
Inspection While the Power is ON (Manipulator is operating)

Inspection Point Inspection Place Daily Monthly Quarterly Biannual Annual
Check motion range Each joint √
Move the cables back and forth lightly to
check whether the cables are External cables √ √
disconnected.
Push each arm in MOTOR ON status to
Each arm √
check whether backlash exists.
Check whether unusual sound or
Whole √ √ √ √ √
vibration occurs.
Measure the accuracy repeatedly by a
Whole √
dial gauge.
When brake release unit is installed:
Connect the brake release unit and
check the sound of the electromagnetic
brake with the brake released.
If there is no sound, replace the brake.
When brake release unit is not installed:
Brake √ √ √ √ √
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.
82 C4 Rev.11
2.2 Overhaul (Parts Replacement)

■ Overhaul timing is based on an assumption that all joints are operated for equal
distance. If a particular joint has a high duty or high load, it is recommended to
overhaul all joints (as many as possible) before exceeding 20,000 operation
CAUTION hours with the joint as a basis.
The parts for the manipulator joints may cause accuracy decline or malfunction due to
deterioration of the manipulator resulting from long term use. In order to use the
manipulator for a long term, it is recommended to overhaul the parts (parts replacement).
The time between overhauls is 20,000 operation hours of the Manipulator as a rough
indication.
However, it may vary depending on usage condition and degree of the load (such as when
operated with the maximum motion speed and maximum acceleration / deceleration in
continuous operation) applied on the Manipulator.
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.
For details, refer to the following manual.
Robot Controller RC700 / RC700-A Maintenance 6. Alarm
Note:
The recommended replacement time for the maintenance parts is when it reaches the L10
life (time until 10% failure probability). In the [Maintenance] dialog box, the L10 life is
displayed as 100%.
C4 Rev.11 83
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.
(3) Select the folder where the information is stored.
(4) Click <OK> to view the [Controller Status Viewer] dialog.
(5) Select [Robot] from the tree menu on the left side.
For the parts subject to overhaul, refer to Maintenance 17. Maintenance Parts List.
For details of replacement of each part, refer to the Maintenance section.
Please contact the distributor of your region for further information.
84 C4 Rev.11
2.3 Greasing
The reduction gear units and the bevel gear need greasing regularly. Only use the grease
specified in the following table.
WARNING hazardous and may result in electric shock and/or malfunction of the robot
system.
■ Keep enough grease in the Manipulator. Operating the Manipulator with

insufficient grease will cause the noise or damage sliding parts and/or result in
insufficient function of the Manipulator. Once the parts are damaged, a lot of
time and money will be required for the repairs.
■ If grease gets into your eyes, mouth, or on your skin, follow the instructions
below.
If grease gets into your eyes:
CAUTION Flush them thoroughly with clean water, and then see a doctor immediately.
If grease gets into your mouth:
If swallowed, do not induce vomiting. See a doctor immediately.
If grease just gets into your mouth, wash out your mouth with water
thoroughly.
If grease gets on your skin:
Wash the area thoroughly with soap and water.
Greasing part Greasing Interval Grease Greasing method

Refer to Maintenance:
5.2, 6.2, 7.2, 8.2
Joint #1, 2, 3, 4 SK-1A
Replacing the Reduction
Gear Unit
Reduction gear units Overhaul timing
Refer to Maintenance:
9.2, 10.2
Joint #5, 6 SK-2
Replacing the Reduction
Gear Unit
Joint # 6 Bevel gear Once a year (every 8000 hours) SK-2 Refer to the next page.
Joint #1, 2, 3, 4, 5, 6 reduction gear units

As a rough indication, perform greasing at the same timing as overhaul.
However, it may vary depending on usage condition and degree of the load (such as when
operated with the maximum motion speed and maximum acceleration / deceleration in
continuous operation) applied on the Manipulator.
C4 Rev.11 85
Greasing Joint #6 bevel gear
Name Quantity Note
Maintenance Part Grease (SK-2) Proper quantity R13ZA00330400

Screw M4×15 (length: 15 mm or more) 1 For unplugging
Tools
Wiping cloth 1 For wiping grease
(1) Secure Arm #5 in the direction you can unplug the plug easily.
(2) Insert the screw into the screw part (M4 depth 5) of the plug.
Screw : M4 length 15 mm or more (easy-to-unplug)
(3) Hold the screw inserted in the step (2) and unplug the plug.
(4) Apply the grease.
Grease: SK-2
Grease amount : 2 g
(5) Insert the plug unplugged in the step (3) to the original position.
To prevent the grease leaking or unplugging, be sure to insert the plug all the way
seated.
(6) Pull out the screw inserted in the step (2). M4×15
Plug
(2)
(3)
(4) Grease inlet
86 C4 Rev.11
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.
Bolt Tightening Torque See below for the set screw.

M3 2.0 ± 0.1 N⋅m (21 ± 1 kgf⋅cm) Set Screw Tightening Torque
M4 4.0 ± 0.2 N⋅m (41 ± 2 kgf⋅cm) M4 2.4 ± 0.1 N⋅m (26 ± 1 kgf⋅cm)
M5 8.0 ± 0.4 N⋅m (82 ± 4 kgf⋅cm) M5 3.9 ± 0.2 N⋅m (40 ± 2 kgf⋅cm)
M6 13.0 ± 0.6 N⋅m (133 ± 6 kgf⋅cm)
M8 32.0 ± 1.6 N⋅m (326 ± 16 kgf⋅cm)
M10 58.0 ± 2.9 N⋅m (590 ± 30 kgf⋅cm)
M12 100.0 ± 5.0 N⋅m (1,020 ± 51 kgf⋅cm)
It is recommended to fasten the bolts aligned on a circumference in a crisscross pattern as

shown in the figure below.
1 Do not fasten all bolts securely at one time.
5 8 Divide the number of times to fasten the bolts into
Bolt hole two or three and fasten the bolts securely with a
3 4
hexagonal wrench. Then, use a torque wrench to
fasten the bolts with tightening torques shown in
the table above.
7 6
2
C4 Rev.11 87
2.5 Layout of Maintenance Parts

Battery
Top: Control board 1

Joint #6 Motor Bottom: Battery board
LED lamp
Joint #3 Motor
Joint #3
Joint #3 Timing belt
Reduction gear unit
Joint #3
Joint #5 Timing belt Electromagnetic brake
Joint #2
Reduction gear unit Joint #2
Joint #5
Electromagnetic brake Electromagnetic brake
Joint #1 Motor
Joint #1
Reduction gear unit
M/C cable
Joint #1 Timing belt Joint #1

Electromagnetic brake
Joint #6 Electromagnetic brake
Control Board 2
Joint #5 Motor
Joint #4 Motor
Joint #4
Reduction gear unit
Joint #4
Joint #2 Motor
88 C4 Rev.11
Maintenance 3. Covers
3. Covers
This chapter describes procedures for removing and installing covers and arm spacers in
maintenance.
■ Do not insert or pull out the motor connectors while the power to the robot
system is ON. Inserting or pulling out 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.
NOT connect it directly to a factory power source.
WARNING related equipment, and then pull out the power plug from the power source.
system.
■ Be careful not to get any foreign substances in the Manipulator, connectors, and
pins during maintenance. Turning ON the power to the robot system when any
foreign substances exist in them is extremely hazardous and may result in
electric shock and/or malfunction of the robot system.
Name Quantity Note

Hexagonal wrench (width across flats: 2.5 mm) 1 For M3 hexagon socket head cap bolts
Tools Hexagonal wrench (width across flats: 3 mm) 1 For M4 hexagon socket head cap bolts
Cross-point screwdriver 1 For covers
User plate
Arm #3 head cover
Arm #4 side cover Arm #2 side cover

Arm #4 side cover
Arm #2 side cover Arm #3
Arm #1 top cover
bottom cover
Connector plate
Arm #1 side cover
Arm #1 side cover
Connector sub plate Base bottom cover
C4 Rev.11 89
3.1 Arm #1 Top Cover

■ When installing the cover, be careful not to get the cables caught in it or bend
them forcibly to push into the cover.
Unnecessary strain on cables may result in damage to the cables, disconnection,
and/or contact failure. These are extremely hazardous and may result in electric
CAUTION shock and/or improper function of the robot system.
When routing the cables, check the cable locations at removing the cover. Be
sure to place the cables back to their original locations.
3-M3×8
(Cross recessed truss head small screws)
Arm #1 top cover
3.2 Arm #1 Side Cover

When routing the cables, check the cable locations at removing the cover. Be
sure to place the cables back to their original locations.
4-M3×8
(Cross recessed truss
4-M3×8 head small screws)
head small screws)
Arm#1 side cover
90 C4 Rev.11
3.3 Arm #2 Side Cover

When routing the cables, check the cable locations at removing the cover.
Be sure to place the cables back to their original locations.
4-M3×8
4-M3×8 (Cross recessed truss
(Cross recessed truss head small screws)
head small screws)
Arm #2 side cover
3.4 Arm #3 Head Cover

4-M3×8
head small screws)
Arm#3 head cover
C4 Rev.11 91
3.5 Arm #3 Bottom Cover

Before removing the Arm #3 bottom cover, move the arm to the position where you can
remove the cover easily.
4-M3×5 (Cross recessed truss head small screws)

Arm#3 bottom cover
3.6 Arm #4 side cover

6-M3×8
head small screws)
6-M3×8
head small screws)
Arm #4 side cover
92 C4 Rev.11
3.7 Base Bottom Cover

Remove the screws (cross-recessed flat head machine screws) securing the cover and
remove the cover.
If you use the other screws than the screws indicated here, the screw head will protrude
from the base surface and it will make it difficult to mount the manipulator firmly. We
recommend using our attached screws or equivalent ones.
4-M3×5
(cross-recessed flat head machine screws)
Base bottom cover
3.8 Connector Plate

■ Do not remove the connector plate forcibly. Removing the connector plate
forcibly may result in damage to the cables, disconnection, and/or contact failure.
Damaged cables, disconnection, or contact failure is extremely hazardous and
may result in electric shock and/or improper function of the robot system.
■ When installing the connector plate, be careful not to get the cables caught in it or
bend them forcibly to push into the cover.
CAUTION Unnecessary strain on cables may result in damage to the cables, disconnection,
shock and/or improper function of the robot system.
When routing the cables, check the cable locations at removing the connector
plate. Be sure to place the cables back to their original locations.
Connector plate
4-M4×8
(Hexagon socket head cap bolts)
C4 Rev.11 93
3.9 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.
■ When installing the connector sub plate, be careful not to get the cables caught in
it or bend them forcibly to push into the cover.
When routing the cables, check the cable locations at removing the connector sub
plate. Be sure to place the cables back to their original locations.
Connector sub plate
4-M4×8
3.10 User Plate

■ Do not remove the connector plate forcibly. It may result in damage to the
■ When installing the user plate, be careful not to get the cables caught in it or bend
When routing the cables, check the cable locations at removing the user plate.
User plate
2-M3×6
94 C4 Rev.11
Maintenance 4. Cable Unit
4. Cable Unit
4.1 Replacing the Cable Unit
system.
the robot system.
■ Be careful not to get any foreign substances in the Manipulator, connectors, and
pins during maintenance. Turning ON the power to the robot system when any
WARNING
foreign substances exist in them is extremely hazardous and may result in
electric shock and/or malfunction of the robot system.
cables forcibly.) Unnecessary strain on the cables may result in damage to the
■ When installing the cover, be careful not to allow the cables to interfere with the
cover mounting and do not bend these cables forcibly to push them into the
cover. Unnecessary strain on cables 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.
When routing the cables, observe the cable locations after removing the cover.
■ 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.
CAUTION For details on the connections, refer to the Maintenance 4.2 Connector Pin
Assignments.
C4 Rev.11 95
■ Carefully use alcohol and adhesive following respective instructions and also
instructions below. Otherwise, it may cause a fire and/or safety problems.
- Never put alcohol or adhesive close to fire.
- Use alcohol or adhesive while ventilating the room.
- Wear protective gear including a mask, protective goggles, and oil-resistant
gloves.
- If alcohol or adhesive gets on your skin, wash the area thoroughly with soap
and water.
- If alcohol or adhesive gets into your eyes or mouth, flush your eyes or wash
out your mouth with clean water thoroughly, and then see a doctor
immediately.
CAUTION ■ Wear protective gear including a mask, protective goggles, and oil-resistant
gloves during grease up. If grease gets into your eyes, mouth, or on your skin,
follow the instructions below.
If grease gets into your eyes : Flush them thoroughly with clean water, and
then see a doctor immediately.
If grease gets into your mouth : If swallowed, do not induce vomiting. See a
doctor immediately.
If grease just gets into your mouth, wash out
your mouth with water thoroughly.
If grease gets on your skin : Wash the area thoroughly with soap and
water.
Name Quantity Note

Cable unit (for C4-A601**) 1 R13N820011
Maintenance
Cable unit (for C4-A901**) 1 R13N820021
Parts
Battery relay cable unit 1 1653173 (Reusable See “Note” below)
Hexagonal wrench
1 For M3 hexagon socket head cap bolt
(width across flats: 2.5 mm)
Hexagonal wrench
(width across flats: 3 mm)
Box wrench
1 For D-Sub connector
Tools
Long nose pliers 1 For removing air connector
Nippers 1
Cross-point screwdriver 1
Brush 1 For applying grease
Force gauge 1 For belt tension
Torque rench 1
Alcohol Proper quantity
Wire tie (AB100) 9
Material
Wire tie (AB150) 11
Wire tie (AB250) 2
Note: The battery relay cable unit is reusable. If the cable or the connector latch is broken during
replacement of the cable unit and battery, replace the cable unit. For details on the replacement, refer
to Removal step (10) and Installation step (55) in Maintenance 4. Cable Unit.
96 C4 Rev.11
Removal: Cable unit

1. Move the manipulator to the origin (0 pulse position).
2. Turn OFF the controller power.
3. Remove the following covers and plates.
For details, refer to Maintenance: 3. Covers.
Arm #4 side cover (Both sides) User plate
Arm #3 head cover Arm #3 bottom cover
Arm #2 side cover (Both sides) Arm #1 side cover (Both sides)
Arm #1 top cover Connector plate
When removing the user plate and the connector plate, remove the following parts together.
D-sub 9-pin connector
Air tube × 4
4. Disconnect the connectors inside the base.

Connectors:
X010, X020, X030, X040, X050, X060,
LED, BR010, BR011, BR020, BR030,
BR040, BR050, BR060, BT1,
X11, X12, X13, X14, X15, X16, XGND,
GS01,GS02
5. Remove the connector connected to the control board 1.

Connector: GS01
C4 Rev.11 97
6. Remove the control board 1 inside the Arm #1.

Cross recessed head screws: 3-M3×8
7. Cross recessed head screws: 3-M3×8

Connectors: 2 connectors for the batteries, BT-CN1, BT-CN2
8. Remove the battery board.

Hexagon socket head cap bolts: 2-M3×8
9. Remove the battery unit.

The battery unit and battery relay cable will be used again.
Be careful not to lose them.
If you are replacing the battery relay cable, follow the step (10).
10. If replacing the battery relay cable:

Remove the connectors connected to the battery.
Connectors: 2 connectors for the batteries, BT
The battery unit will be used again.

Be careful not to lose it.
98 C4 Rev.11
11. Cut off the wire ties binding the cables inside the Arm #3.
12. Remove the connectors inside the Arm #3.

Connectors:
X71, X72, X041, X051, X061,
LED, BR041, BR051, BR061,
BT4, BT51, BT61, X141, X151, X161, XGND,
GS02
13. Remove the Arm #4 cable fixing plate (with the ground wires) from
the Arm #4.
The Arm #4 cable fixing plate will be used again.
14. Remove the connectors inside the Arm #4.

Connectors:
X052, X152, BT52, BR052,
X062, X162, BT62, BR062
C4 Rev.11 99
15. Remove the Joint #5 motor unit and the Joint #5 belt from the Arm
#4.
Hexagon socket head cap bolts: 2-M4×15 (with a plain washer)
16. Remove the Joint #6 motor unit and the Joint #6 belt from the Arm
#4.
17. Cut off the following bands from the Arm #4 cable fixing plate.
Cable band
Coil plate fixing band
18. Remove the following parts from the Arm #3.

Arm #3 cable fixing plate (circle)
Ground wire fixing bolts (triangle)
Control board 2 (square)
Hexagon socket head cap bolt: 1-M4×10
19. Cut off wire ties of the Arm #3 cable fixing plate.
Cable band
Coil plate fixing band
100 C4 Rev.11
20. Pull out four air tubes and a ground wire from the Arm #3.
(See an arrow in the photo for pulling direction.)

21. Pull out the following cables and a small diameter spring from the
Arm #4. (See an arrow in the photo for pulling direction.)
Joint #5 motor cable and brake cable
Joint #6 motor cable, brake cable
Cable for installed wire for customer use
Connector:
X051, X061, X151, X161, XGND,
BR051, BR061, BT51, BT61
When pulling out the cables, carefully treat cables and connectors to prevent damage to them.
Pull out the cables in the order of connector size, from smallest to largest.
22. Pull out the Arm #3 cable unit from the Arm #2.
C4 Rev.11 101
23. Disconnect the connectors of the Joint #3 motor and remove the Joint
#3 motor.
Connectors: X031, X131, BT3, BR031, D
Arm #3, #4, #5 and #6 lean when the motor is removed. Remove
the motor after pushing the Arm to the stopper.
Connector D will be used again. Be careful not to lose it.
24. Cut off the wire tie of the Arm #2.
25. Remove two ground wires.

26. Remove the Arm #2 cable fixing plate.

It is not necessary to remove the fixing bolts completely.
Remaining the bolts on the Arm #2 makes it easy to mount the cable
unit.
Pull out the cables from the Arm #1.
27. Cut off the binding tie of the Arm #1.

28. Remove two ground wires.
29. Disconnect the connectors of the Joint #2 motor and remove the Joint #2 motor.
Connectors: X021, X121, BT2, BR021, D
Arm #3, #4, #5, and #6 lean when the motor is removed.
Remove the motor after pushing the Arm to the stopper.
Connector D will be used again. Do not lose it.
102 C4 Rev.11

Hexagon socket head cap bolt: M4×8, M6×20
M4
31. Cut off the wire tie of the Arm #1 cable fixing plate.
Be careful not to lose it. M6
32. Be careful not to lose it.

Base cable fixing plate
Ground wire
33. Cut off the wire tie of the base cable fixing plate.
The base cable fixing plate will be used again.

34. Pull out the cables in the Arm #2 and the base from the Arm #1.
35. Remove the Arm #2 cable fixing plate from the cables.

C4 Rev.11 103
Installation: Cable unit

1. Check if the cable unit contains the following parts. Silicone sheet
Silicone sheet: 30 mm × 150 mm 30 mm × 150 mm
Silicone sheet: 15 mm × 50 mm
Mark tube
Wire tie: AB100, AB150, AB200
Silicone sheet
15 mm × 50 mm
Mark tube
2. Separate the cable unit.

Connectors:
X051, X061, X151, X161, XGND, BR051, BR061,
BT51, BT61, X71, X72, SW1
3. Cut the mark tube into following length.

68 mm × 2 (for fixing the J1 wire tie)
65 mm (for fixing the J2 wire tie) 23 mm × 2 (for fixing the J2 wire tie)
21 mm × 2 (for fixing the J3 wire tie) 57 mm × 2 (for fixing the J3 wire tie)
46 mm (for fixing the J4 wire tie)
4. Grease the inside of the cable protection spring.

C4-A601**: C4-A901**:
Grease : Krytox 18 g Grease : Krytox 19 g
Spring : ø17.5 (Length: 130 mm) : 3 g Spring : ø17.5 (Length: 280 mm) : 4 g
ø25 (Length: 130 mm) : 5 g × 2 ø25 (Length: 130 mm) :5g×2
ø29 (Length: 130 mm) : 5 g ø29 (Length: 130 mm) :5g
5. Secure the Arm #2 cable fixing plate and the cable unit.
Plate and spring : Wire tie AB100
Cable unit and plate : Wire tie AB150, Mark tube 65 mm
Precautions for cable unit fixation to the plate:

NOTE

Pass the mark tube and the wire tie through the hole of the plate
as shown in the photo on the right.
When installing the cable unit, place the plate, the air tube, and
the cables as shown in the photo on the right (example), and Cable
then fix the plate and the cable unit with a wire tie. Air tube
Plate
104 C4 Rev.11
6. Insert the cable unit with the cable protection spring (ø 17.5) from
the Arm #4.
7. Wrap the end of the spring to the Arm #4 cable fixing plate with a
wire tie.
Wire tie: AB100 × 1
Number of turns of spring to fix: 3 turns
8. Insert the cable unit with the cable protection spring (ø 29) from the
Arm #1 to the base side.
Connectors to be passed through to the base:
X12, X020, X030, X13, X040, X050, X060,
X14, X15, X16, XGND, BR011, BR010, BT1,
BR020, BR030, BR040, BR050, BR060,
LED, SW1, GS01, GS02
9. Pull the wrapped cables from the Arm #2.
C4 Rev.11 105
10. Pass the cable unit to the Arm #3.
11. Fix the Arm #2 cable fixing plate to the Arm #2.
12. Fix the cable protection spring (ø25, 130mm) of the Arm #2 to the
Arm #3 cable fixing plate.
Wire tie: AB100
106 C4 Rev.11
13. Temporally bind two cables.

Wire tie: AB150 × 2
Mark tube: 57 mm × 2
Temporarily bind the cables so that their position can be adjusted

later.

NOTE Pass the mark tube and the wire tie through the hole of the
 plate as shown in the photo on the right.
When installing the cable unit, place the plate, the air tube, and the
cables as shown in the photo on the right (example), and then fix
Cable
the plate and the cable unit with a wire tie.
Air tube
Plate
14. Fix the cable protection spring (ø17.5) to the Arm #3 cable fixing
plate.
Wire tie: AB100
C4 Rev.11 107
15. Pass the four air tubes and the ground wire of the cable unit through
the cable protection spring (ø 17.5) and pull them out from the Arm
#4.
Pass the air tubes through the space on the upper side of the spring.
16. Temporally bind the cables to the Arm #4 cable fixing plate.
Wire tie: AB150
Precautions for cable unit fixation to the plate

NOTE Place the silicone sheet on the plate as shown in the photo on
 the right (example). Fix the wire tie at the center of the
silicone sheet.
108 C4 Rev.11
17. Temporarily fix the Arm #4 cable fixing plate to the Arm #4.
18. Temporarily bind the cables coming from the Arm #4.
Wire tie: AB150
Mark tube: 46 mm

NOTE Pass the mark tube and the wire tie through the hole of the
 plate as shown in the right photo.
When installing the cable unit, place the plate, the air tube,
and the cables as shown in the right photo (example), and then
Plate
fix the plate and the cable unit with a wire tie.
Air tube
Cables
19. Pull out the D-sub connector to the user plate installation part.
C4 Rev.11 109
20. Install the D-sub connector to the user plate.
21. Temporarily fix the Arm #3 cable fixing plate to the Arm #3.
22. Adjust length of each cable and air tube inside the Arm #3.
Length of the cable passed through the Arm #4:
From the Arm #3 cable fixing plate to each connector: 60 mm
Connector: X151, X161, XGND, X051, X061, BR051, BR061

60 mm
BT51, BT61, X71, X72
50 mm
Length of the cable passed through the Arm #3:
From the Arm #3 cable fixing plate to each connector: 50 mm
Connector: X141, X151, X161, XGND, X041, X051, X061

BR041, BR051, BR061, LED, BT4 (BT51, BT61)
X71, X72
30 mm
Air tube length:
From the Arm #3 to the air tube: 30 mm
110 C4 Rev.11
110 mm
Ground wire length:
From the Arm #3 cable fixing plate
To the ground terminal: 110 mm
100 mm
Length of the control board 2 cable passed through the Arm #3:
From the Arm #3 to the control board 2 connector: 100 mm
Connector: GS02
23. Fix the cables temporarily fixed with a wire tie.
24. Install the ground wires to the fixing screws on the Arm #4 cable
fixing plate, and tighten the temporarily fixed screws.
Adjust orientation of terminals as shown in the photo.
Circle (right): Ground terminal, user wire’s ground terminal

Circle (left): X052/X062 ground terminal,
X152/X162 ground terminal
25. Fix the cables temporarily fixed to the Arm #3 cable fixing plate.
C4 Rev.11 111
26. Install the D-sub connector to the user plate.
Be careful of the direction of the user plate.
27. Install the air tubes to the user plate fittings.
Air tube projection length: 45 mm
45 mm
28. Install the user plate to the Arm #4.

112 C4 Rev.11
29. Fix the Joint #5 motor unit to the Arm #4 temporarily and place the
Joint #5 timing belt on the pulleys.
30. Fix the Joint #6 motor unit to the Arm #4 temporarily and place the
Joint #5 timing belt on the pulleys.
31. Connect the Joint #5 and Joint #6 motor connectors.

Connectors:
X051, X061, X151, X161, BR051, BR061, BT51, BT61
32. Put the connected connectors in the Arm #4.
33. Connect the connectors inside the Arm #3.

Connectors:
X71, X72, X041, X051, X061, LED, BR041, BR051,
BR061, BT4, BT51, BT61, X141, X151, X161, XGND
C4 Rev.11 113
34. Fix the control board 2 to the Arm #3 and connect the connectors.
Control board 2
M4
M3
Connector: GS02
35. Fix the ground wires.
Install the following ground terminals to the parts marked with
circles, and fix together with the Arm #3 cable fixing plate. Then,
tighten the temporarily fixed bolts.
Circle (right): X71/X72 ground terminals (J3),
X71/X72 ground terminals (J4)
Circle (left): X061 ground terminal, X041 ground terminal
Install the following ground terminals to the parts marked with

triangles.
Triangle (right): X141 ground terminal
Triangle (left): Ground wire terminal
Adjust the orientation of terminals as shown in the photo on the
right.
36. Put the cables temporarily fixed to the Arm #3 cable fixing plate
together and fix them.
Bind the Arm #3 cables and the connectors with a wire tie.
Wire tie: AB200 (2 ties)
37. Fix the cable protection spring (ø25 Length: 130 mm) to the Arm
#2.
38. Temporarily fix the cables to the cable binder.

Wire tie: AB150
Mark tube: 21 mm (2 tubes)
Mark tube
114 C4 Rev.11
39. Push the cables in the direction of an arrow in the photo on the
right, and fix the cable temporarily fixed by the wire tie.
Pushing depth: 10 mm
40. Temporarily fix the Joint #3 motor unit to the Arm #2 and place the
Joint #3 timing belt to the pulleys.
Pass the cables to the left side of the motor’s rear side as shown in
the photo.
Motor (rear)
41. Connect the Joint #3 motor connectors and put them in the Arm #2.
Connectors: X031, X131, BR031, BT3
42. Fix two ground wires to the Arm #2.
Circle (right): X031 ground terminal, X131 ground terminal
Circle (left): Ground wire terminal
43. Fix the cable protection spring (ø 25 Length: 130 mm) to the Arm
#1.
C4 Rev.11 115
44. Temporarily fix the cables to the cable binder.

Wire tie: AB150
Mark tube
45. Push the cable in the direction of an arrow in the photo on the right,
and fix the cable temporarily fixed by the wire tie.
Pushing depth: 6 mm
46. Fix the cable protection spring (ø25, 130 mm) to the Arm #1 cable
fixing plate.
47. Temporarily fix the cables to the Arm #1 cable fixing plate.
Set the heads of the wire ties to the side of the cables as shown in
the photo on the right.
116 C4 Rev.11
48. Fix the Arm #1 cable fixing plate to the Arm #1.
Hexagon socket head cap bolt: M4×8, M6×20
M6 tightening torque: 17.6 N·m (180 kgf·cm) M4
M6
49. Fix the cables temporarily fixed by the wire tie.

NOTE For the upper side, pass the mark tube and the wire tie through
 the hole of the plate and wrap around the cutout. For the
lower side, pass the other mark tube and the wire tie through
the hole of the plate, as shown in the photo on the right.
and the cables as shown in the photo on the right (example), Cable
and then fix the plate and the cable unit with a wire tie. Air tube
Plate
50. Temporarily fix the Joint #2 motor unit to the Arm #1 and place the
Joint #2 timing belt to the pulleys.
51. Connect the Joint #2 motor connectors and put them in the Arm #2.
Connector: X021, X121, BR021, BT2
52. Fix the ground wires to the Arm #2.
Circle (right): X021 ground terminal, X121 ground terminal
Circle (left): ground wire terminal
C4 Rev.11 117
53. Install the battery board.

54. Install the connector to the battery board.

Connector: CN3
55. * If you are not replacing the battery relay cable, go to the step (56).
If replacing the battery relay cable:

Install the connectors to the battery unit.
Connector: BT (2 connectors)
(The connectors can be installed on either side)
56. Install the connectors to the battery board.
Connector: 2 connectors for the batteries, BT-CN1, BT-CN2, CN3
Wire tie: AB100
57. Install the control board 1 to the Arm #1 and connect the connector.
Connector: GS01
58. Bind the cable protection spring (ø29, 130 mm) to the base cable
fixing plate.
Wire tie: AB100
118 C4 Rev.11
59. Wrap the silicone sheet around the cables as shown in the photo on
the right.
60. Temporarily bind the cables wrapped with the silicone sheet to the
base cable fixing plate.
Precautions for cable unit fixation to the plate

NOTE

and the cables as shown in the photo on the right (example), Plate
and then fix the plate and the cable unit with a wire tie.
Air tube
Cable
Fix the cables with the wire ties so that the silicone sheet
projects 5 mm from the base cable plate.
5 mm
61. Pull the cable out and adjust the plate position.
Plate position: 15 mm
Fix the cable temporarily fixed by the wire tie.
15 mm
C4 Rev.11 119
62. Fix the base cable fixing plate to the base.

63. Fix the ground wires to the base cable fixing plate.
Fix the ground wire terminal to the upper circled part.
Fix the other ground terminals coming from the connectors to the
lower circled part.
Bind two ground wires together and fix to the three screw points.
Adjust orientation of the terminals and fix them as shown in the
photo on the right.
64. Cut the air tubes to the same length

(about 70 mm from the end surface of the base).
70 mm
65. Insert the air tubes to the air tube fitting on the connector plate.
66. Connect the connectors to the M/C cable.

Connector:
X010, X020, X030, X040, X050, X060,
LED, BR010, BR011, BR020, BR030,
BR040, BR050, BR060,
BT1, X11, X12, X13, X14, X15, X16, XGND,
GS01, GS02
67. Connect the D-sub 9-pin connector and the D-sub 15-pin connector to the connector plate.
68. Apply tension to the Joint #5 motor unit and fix it.
For details, refer to Maintenance: 9.1 Joint #5 – Replacing the Motor, Installation step 6.
69. Apply tension to the Joint #6 motor unit and fix the joint #6 motor unit.
120 C4 Rev.11
72. Mount the following covers and plates.

Arm #3 head cover Arm #3 bottom cover
Arm #2 side cover (Both sides) Arm #1 side cover (Both sides)
Arm #1 top cover Connector plate
73. Perform the calibration.

For details, refer to Maintenance: 16. Calibration.
C4 Rev.11 121
4.2 Connector Pin Assignments
4.2.1 Signal Cable
122 C4 Rev.11
C4 Rev.11 123
124 C4 Rev.11
4.2.2 Power Cable
C4 Rev.11 125
126 C4 Rev.11
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

B Black
W White
R Red
G Green
Y Yellow
BR Brown
L Blue
V Violet
A Azure
O Orange
GL Gray
P Pink
C4 Rev.11 127
Maintenance 5. Arm #1
5. Arm #1
hazardous and may result in electrical shock and/or malfunction of the robot
system.
WARNING may move abnormally, and also may result in electric shock and/or malfunction of
the robot system.
■ Be careful not to apply excessive shock to the motor shaft during replacement
procedures. The shock may shorten the life of the motors and encoder and/or
damage them.
CAUTION ■ Never disassemble the motor and encoder. Disassembled motor and encoder
will cause a positional gap and cannot be used again.
After parts have been replaced (motors, reduction gear units, 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.
After replacing the parts, it is necessary to match these origins.
The process of aligning the two origins is called “Calibration”.
Refer to Maintenance 16. Calibration and follow the steps to perform the calibration.
Joint #1 motor
Joint #1 reduction gear unit
Joint #1 timing belt Joint #1 electromagnetic brake
128 C4 Rev.11
5.1 Joint #1 - Replacing the Motor

Name Quantity Note
Maintenance Parts AC servo motor 400 W 1 R13N807011
Hexagonal wrench
1 For M5 hexagon socket head set screws
Hexagonal wrench
1 For M4 hexagon socket head cap bolts
Tools Hexagonal wrench
Torque wrench 1
Force gauge 1 For belt tension adjustment
Removal: Joint #1 Motor

1. Turn ON the controller.
2. Remove the connector plate.

3. Disconnect the connectors.
Connector: X11, X010, BT1, BR011
(Hold the claw to remove.)
4. Remove the Joint #1 motor unit from the base.

To remove the screw fixed to the rear of the motor unit (B), put a
hexagonal wrench through the hole (A) after removing the cap.
C4 Rev.11 129
5. Remove the pulley 1 and the drive boss from the Joint #1 motor
unit.
Drive boss and the pulley:

Hexagon socket head set screws: 2-M5×6 (with a brass bushing)
Pulley and the motor shaft:

There is a brass bushing on one of the set screws fixing the drive
boss and the pulley 1. Be careful not to lose it.
6. Remove the electromagnetic brake of the Joint #1.
Hexagon socket head set screw: 1-M5×8
7. Remove the motor plate from the Joint #1 motor.
130 C4 Rev.11
Installation: Joint #1 Motor

1. Mount the motor plate to the Joint #1 motor. Motor cable

Hole
Be careful of the direction of the motor plate. (See the photo.)

Groove
2. Install the electromagnetic brake of the Joint #1 to the Joint #1 motor

unit.
Be careful of the direction of the electromagnetic brake. Flat surface

Align the wiring position of the brake and the clearance groove on the
motor plate. Fix the flat surface of the electromagnetic brake to the
set screw side.
Be careful not to cut the cable by getting it caught between the brake
and the plate.
Secure the set screw while pressing the electromagnetic brake to the
motor plate.
Hexagon socket head set screw: 1-M5×8

3. Install the drive boss and the pulley 1 to the Joint #1 motor unit.
2-M5×6
Fix the drive boss and the pulley 1 with the end surfaces of each part
together.
2-M5×10
Brass bushing
Fix the pulley 1 and the motor shaft.
Leave 0.5 mm between the electromagnetic brake and the pulley.
Refer to the photo for layout of the set screws.
Fix the parts so that the end of the motor shaft and the surface of the
t = 0.5
pulley become flat.
C4 Rev.11 131
4. Put the Joint #1 timing belt to the Joint #1 pulley 2 on the Joint #1 side.
5. Pass the pulley 1 of the Joint #1 motor unit to the Joint #1 timing belt
and loosely secure it to the base.
Make sure that the gear grooves of the timing belt are fit into those of
the pulley completely.
When securing the motor unit loosely, make sure that the motor unit
can be moved by hand and it does not tilt when being pulled. If the
unit is secured too loose or too tight, the belt will not have proper
tension.
6. Apply proper tension to the Joint #1 motor unit and secure it.
Pass a suitable cord or a string (insulation lock) to the drilled hole on the motor plate. Pull the cord using
a force gauge or a similar tool to apply specified tension.
Joint #1 timing belt tension: 78.4 N ± 9.8 N (8 kgf ± 1 kgf)
Apply proper tension to the Joint #1 motor unit and secure it.
(with a plain washer)
7. Connect the following connectors.

Connectors: X11, X010, BT1, BR011
8. Mount the connector plate.

9. Calibrate the Joint #1.

132 C4 Rev.11
5.2 Joint #1 - Replacing the Reduction Gear Unit

A reduction gear unit consists of the following three parts. Also, two additional parts are included as
accessories. When replacing the reduction gear unit, be sure to replace these parts all together as a set.
Reduction gear unit : Wave generator, Flexspline, Circular spline
Accessory : Spacer, Grip ring
For details, refer to Maintenance: 17. Maintenance Parts List.
It is recommended to replace the O-ring when replacing the reduction gear unit.
Name Quantity Note

Joint #1 reduction gear unit 1 R13N810041
Maintenance Parts
Joint #1 O-ring 1 R13B031223
Hexagonal wrench For M5 hexagon socket head
1
(width across flats: 2.5 mm) set screws
1
(width across flats: 3 mm) cap bolts
1
Tools (width across flats: 5 mm) cap bolts
Torque Wrench 1
Spatula 1 For greasing
C4 Rev.11 133
Removal: Joint #1 Reduction gear unit

1. Turn OFF the controller.
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. Removing the bolts without supporting the arm may result in
CAUTION the arm falling, bodily injury, and/or malfunction of the robot system.
3. Remove the connector plate and the base bottom cover.

4. Loosen the set screws of the Joint #1 motor unit and remove the
Joint #1 timing belt.
5. Remove the pulley 2.
Hexagon socket head set screw: 2-M5×10 (with a brass bushing)
6. Remove the flange.

134 C4 Rev.11
If it is difficult to remove the flange, insert the bolts to two parts

as shown in the photo, and then tighten them evenly to remove
the flange.
Use the dedicated screws for fixing the flange.
Wipe grease from the parts while removing them.
7. Remove the O-ring.
O-ring
8. Remove the wave generator unit from the reduction gear unit.
If it is difficult to remove the wave generator unit, install the

removed pulley 2 to the shaft and pull the parts together.
9. Remove the wave generator from the shaft.

At this point, remove the bearing first. The bearing will be

used again. Be careful not to lose it.
There is a brass bushing on one of the set screws. Be careful

not to lose it.
C4 Rev.11 135
10. Remove the circular spline from the base.

Insert the screws to two parts on the circular spline as shown in

the photo. Tighten them evenly and remove the circular
spline.
11. Remove the flexspline from the base.

12. Remove the friction plate (EKagrip) between the flexspline

installation surface and the flexspline.
13. Wipe grease using a cloth or similar material if it is attached to the base.
136 C4 Rev.11
Installation: Joint #1 Reduction gear unit

1. Unpack the new reduction gear unit package and check if it
contains the parts on the right.
2. Place the friction plate (EKagrip) on the end face of the shaft to
match the screw holes.
3. Apply grease all over the tooth flank of the flexspline.
Grease: SK-1
Grease amount: enough to fill in the grooves
4. Install the flexspline to the shaft end face.

Insert the spacer between the screws and the part.

Install the flexspline to match the air escapement holes of the

flex spline with these of the spacer.
Flexspline Spacer
C4 Rev.11 137
5. Apply grease all over the tooth flank of the circular spline.
Grease: SK-1A
Grease amount: enough to fill the grooves
6. Install the circular spline.

7. Apply grease to the inside of the flexspline.

Grease: SK-1A
Grease volume: 40 g
8. Apply grease to the bearing of the wave generator.

Grease: SK-1A
138 C4 Rev.11
9. Install the wave generator to the shaft.

When installing the part, press the wave generator all the way in
and fix the set screw to the D-cut face of the shaft. Insert the
brass bushing to the end of the other set screw.
10. Install the bearing.
11. Install the assembled wave generator unit to the reduction gear
unit.
12. Put the O-ring into the groove on the flange.

Carefully assemble the parts to avoid damaging the O-ring.
(Otherwise the grease may leak.)
O-ring
O-ring groove
O-ring
Flange
13. Install the flange to the base.

Carefully insert the shaft to the flange to avoid damaging the seal.
C4 Rev.11 139
14. Install the pulley 2.

Align the end of the shaft with the side of the pulley.
15. Loosely secure the Joint #1 motor unit.

Make sure that the motor unit can be moved by hand, and it does not tilt when being pulled. If the unit
is secured too loose or too tight, the belt will not have proper tension.
16. Mount the Joint #1 motor unit

For details, refer to Maintenance: 5.1 Joint #1 motor, Installation step (6).
17. Mount the connector plate and the base bottom cover.

140 C4 Rev.11
5.3 Joint #1 - Replacing the Timing Belt

Name Quantity Note
Joint #1 Timing belt (C4-A601**) 1 R13B030220
Maintenance Part
Joint #1 Timing belt (C4-A901**) 1 R13N832031
Hexagonal wrench For M4 hexagon socket head cap
1
(width across flats: 3 mm) bolt
Tools
Torque wrench 1
Removal: Joint #1 Timing belt

1. Remove the Joint #1 motor unit.
For details, refer to Maintenance: 5.1 Joint #1 motor, Removal step (1) to (4).
2. Remove the Joint #1 timing belt.
Work process is common between C4-A601** and C4-A901**
Installation: Joint #1 Timing belt

1. Place the Joint #1 timing belt around the Joint #1 pulley in the back in the photo.
2. Mount the Joint #1 motor unit.

For details, refer to Maintenance: 5.1 Joint #1 motor, Installation step (5) to (9).
C4 Rev.11 141
5.4 Joint #1 - Replacing the Electromagnetic Brake

Name Quantity Note
Joint #1 electromagnetic brake 1 R13N835021
Maintenance Parts
Noise dissipative diode 1 R13N823011
Hexagonal wrench
1 For M5 hexagon socket head set screw
Hexagonal wrench
Tools 1 For M4 hexagon socket head cap bolt
Torque wrench 1
Removal: Joint #1 Electromagnetic brake

1. Remove the Joint #1 electromagnetic brake from the Joint #1 motor unit.
For details, refer to Maintenance: 5.1 Joint #1 motor, Removal step (1) to (6).
2. Remove the following connector.
Connector: D (for noise dissipative diode)
Installation: Joint #1 Electromagnetic brake

1. Install the following connector to the connector of the
electromagnetic brake.
2. Mount the Joint #1 motor unit.

For details, refer to Maintenance: 5.1 Joint #1 motor, Installation step (2) to (9).
142 C4 Rev.11
6. Arm #2
the robot system.
WARNING NOT connect it directly to a factory power source.
system.
■ Be careful not to apply excessive shock to the motor shaft during replacement.
It may shorten the life of the motors and encoder and/or damage them.
■ Never disassemble the motor and the encoder. Disassembled motor and encoder
CAUTION
will cause a positional gap and cannot be used again.
Therefore, it is necessary to match these origins after replacing the parts.
Refer to Maintenance 16. Calibration and perform the calibration after the parts
replacement.
Joint #2 Joint #2 Timing belt

Reduction gear Joint #2
unit Electromagnetic
brake
Joint #2 Motor
C4 Rev.11 143
Name Quantity Note

AC servo motor 400 W 1 R13N807011
Maintenance Parts
Radiation Sheet R13B031905
Hexagonal wrench
1 For M5 hexagon socket set screw
Hexagonal wrench
Hexagonal wrench
Tools 1 For M5 hexagon socket head cap bolt
Torque wrench 1
Cloth 1 For pressing arms
The brake is mounted on the Joint #2 to prevent the arm from lowering due to its own weight while the
controller power is OFF or the motor is OFF status. However, the brake does not work during replacement.
To replace the Joint #2 motor, tilt the Arm #2 and press it toward the Arm #1. (See the step (3).)
When pressing the arm, put a cloth or a similar material between the arms to avoid each arm from contacting.
This also protects the arm surfaces and coatings.
144 C4 Rev.11

1. Remove the Arm #1 top cover and the Arm #1 side cover.
2. Turn ON the controller power.
3. Tilt Arm #2.

Put a cloth between Arm #1 and Arm #2 so that two arms do not
touch each other.
Tilt the Arm #2
Protect arms
using a cloth, etc.
5. Disconnect the following connectors.

Connector: X121, X021, X64, BR021
6. Tilt the Arm #2 and remove the Joint #2 motor unit and the belt
from the Arm #1.
If the bolts are removed with the Arm #2 is not tilted, the belt
will come off and the Arm #2 will fall. Be sure to tilt the Arm.
Hexagon socket head cap bolt: 3-M4×18 (with a plain washer)
C4 Rev.11 145
7. Remove the Joint #2 pulley 1 and the drive boss from the motor
shaft of the Joint #2 motor unit.
Drive boss and the pulley
Hexagon socket set screws: 2-M5×6 (with a brass bushing)
Pulley and the motor shaft
There is a brass bushing on one of the set screws fixing the driving boss and the pulley.
8. Remove the Joint #2 electromagnetic brake.

Hexagon socket set screw: 1-M5×8

146 C4 Rev.11

1. Install the motor plate to the Joint #2 motor. Cutout

Motor cable
2. Mount the Joint #2 electromagnetic brake to the Joint #2 motor

unit.
Align the position of the brake wire with the groove on the
motor plate. Then, set the flat surface of the brake to the set
screw side and secure the brake. Be careful not to cut the brake
wire by getting it caught between the brake and the motor plate.
Press the brake toward the motor plate and tighten the set screw. Flat surface
Hexagon socket set screw: 1-M5×8

3. Mount the drive boss and the pulley 1 to the Joint #2 motor unit.
2-M5×6
Put the end faces of the brake boss and the pulley 1 together and
fix them.
Tightening torque: 3.9 N·m (40 kgf·cm) 2-M5×10
Brass bushing
Set the pulley 1 and the motor shaft.

Leave 0.5 mm for the electromagnetic brake.
Hexagon socket set screw: 2-M5×10 (with a brass bushing)
Fix the parts so that the end of the motor shaft and the surface of
t = 0.5 mm
the pulley become flat.
See the photo for positions of the set screws.
C4 Rev.11 147
4. Attach the Radiation sheet to the Joint #2 motor.
Radiation
Sheet
5. Put the Joint #2 motor unit in the Arm #1.

Place the timing belt around the pulley 1 and the pulley 2.
Check that the teeth of the timing belt engage with these of the
pulley.
When securing the motor unit temporarily, make sure that the
motor unit can be moved by hand, and it does not tilt when being
pulled. If the unit is secured too loose or too tight, the belt will
not have proper tension.

Install the screw for tension adjustment to the motor plate.
Screw: M4×30 or longer (recommended length)
Pass a suitable cord or a string (insulation lock) to the screw. Pull the cord using a force gauge or a
similar tool to apply specified tension.
Joint #2 timing belt tension = 78.4 N ± 9.8 N (8 kgf ± 1 kgf)
Apply tension by pressing toward the “A” surface in the figure Pulley 2
and secure the motor unit. Timing belt

Make sure to remove the screw for tension adjustment.

Connectors: X121, X021, X62, BR021
8. Mount the Arm #1 cover and the Arm #1 side cover.
148 C4 Rev.11
6.2 Joint #2- Replacing the Reduction Gear Unit

Reduction gear unit: Wave generator, Flexspline (CRB combined), Circular spline
Accessory: O-ring×2
It is recommended replacing the O-ring (for Joint #2) when replacing the reduction gear unit.
Name Quantity Note

Maintenance Parts
Hexagonal wrench For M3 hexagon socket head cap bolt
1
(width across flats: 2.5 mm) For M5 hexagon socket set screw
Hexagonal wrench
Tools Cross-point screwdriver 1 For covers
Torque wrench 1
Spatula 1 For applying grease
C4 Rev.11 149

1. Remove the following covers.
Arm #1 top cover
Arm #1 side cover
Arm #2 side cover
Arm #3 head cover
User plate
When removing the user plate, remove the following parts as well.
4 air tubes

For details, refer to Maintenance: 6.3 Joint #2 – Replacing Pulley 2
Pulley 1
the Motor, Removal steps (1) through (4).
Timing belt
3. Remove the cable unit.

For details, refer to Maintenance: 4.1 Replacing the Cable Unit, removal steps (9) through (26).
4. Pull out the cables from the Arm #1.
5. Turn the Manipulator laterally.
■ 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 other is removing
the bolts.
CAUTION Removing the bolts without supporting the arm may result in the arm falling,
bodily injury, and/or malfunction of the robot system.
150 C4 Rev.11
6. Remove the Arm #1 plate.

Hexagon socket head cap bolt: 6-M4×12 Arm #1 plate
7. Turn the manipulator to the opposite side and remove the

pulley 2.
There is a brass bushing in one of the set screws.

8. Remove the screws securing the reduction gear unit.

By removing the screws, the Arm #2, #3, #4, #5, and #6
(end effector) can be separated.
Have at least two workers so that one can support the
manipulator while the other worker is removing the bolts.
Wipe grease on the parts while removing them.
9. Remove the wave generator from the reduction gear unit.
C4 Rev.11 151
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.
Remove the wave washer on the Arm #2 hole. The wave
washer will be used again. Be careful not to lose it.

Bearing
Remove the bearing. The bearing will be used again.
Be careful not to lose it
There is a brass bushing on one of the set screws.
11. Remove the reduction gear unit from the Arm #2.
O-ring
13. Wipe grease using a cloth or a similar material if it is attached to the Arm #1, and #2, etc.
152 C4 Rev.11

1. Unpack the new reduction gear unit package and check if it Flexspline
contains the parts on the right. +Cross roller bearing unit
O-ring
Tooth grooves of the circular spline and the flexspline, and
the bearing of the wave generator are pre-greased.
Wipe grease if it is attached to the fitting parts.
Circular spline
Wave generator
■ Do not adjust the bolts securing the flexspline and the cross roller bearing. If the
bolts are adjusted, it requires centering of the parts by the reduction gear unit
CAUTION manufacturer.
2. Set the O-rings to the grooves on both faces of the circular Concave surface
spline.
Make sure to fit the rings completely.
Concave surface Groove

Convex surface
Convex surface
Groove
3. Set the flexspline with the convex surface facing down.
4. Match the screw holes on the cross roller bearing's inner ring
and the drilled holes on the circular spline.
C4 Rev.11 153
5. Fix the cross roller bearing's inner ring and the circular
spline.
6. Grease the bearing of the wave generator and install the

wave generator to the shaft. Bearing

When installing the wave generator, push it to the end and set
the set screws on the shaft's flat face.
For the other set screw, set the brass bushing to the end.
7. Install the removed bearing to the shaft.
8. Set the O-ring to the groove on the installation face of the

Arm #2 reduction gear unit.
O-ring
154 C4 Rev.11
9. Install the reduction gear unit.

Installation face of the Arm #2 reduction gear unit has

clearance holes.
Install the reduction gear unit to match the screws and the
clearance holes.
Bolts Holes
10. Grease the inner side of the flexspline.

Grease: SK-1A
Grease amount: 30 g
11. Set the wave washer to the position where the Arm #2
bearing will be set.
12. Insert the wave generator to the reduction gear unit and fix it.
Wave washer
C4 Rev.11 155
13. Install the Arm #2 and the reduction gear unit to the Arm #1.
When installing the shaft to the hole of the Arm #1, be

careful not to damage the seal.
Be careful not to let the O-ring on the groove of the circular
spline comes off.

Join the end of the shaft and the side of the pulley, and then
fix them.
15. Turn the Arm to the opposite side and install the Arm #1
plate. Arm #1 plate
16. Install the cable unit.

For details, refer to Maintenance: 4.1 Replacing the Cable Unit, installation steps (11) through (43)
and (62) through (64).
17. Place the Joint #2 timing belt to the pulley 1 and the pulley
2 of the Joint #2.
For details, refer to Maintenance: 6.1 Joint #2 –
Replacing the Motor, Installation steps (10) through
(13).
19. Install the removed covers.


156 C4 Rev.11
Name Quantity Note

Timing belt (Joint #2 of C4-A601**) 1 R13B030221
Maintenance Parts
Timing belt (Joint #2 of C4-A901**) 1 R13N832041
1
(width across flats: 3 mm) cap bolt
Tools
Torque wrench 1

1. Follow Removal steps (2) through (4) of Maintenance: 6.1 Joint #2 – Replacing the Motor.
2. Remove the Arm #1 side cover.

3. Loosen the Joint #2 motor unit set screw.


Remove the timing belt from the pulley 1 first.
Then, remove the timing belt from the pulley 2.
This procedure is common in C4-A601** and C4-A901**.

1. Place the Joint #2 timing belt to the pulley 1 and the pulley 2 of the Joint #2.
Place the timing belt to the pulley 2 first. Then, place the timing belt to the pulley 1.
2. Secure the Joint #2 motor unit.

For details, refer to Maintenance: 6.1 Joint #2 – Replacing the Motor, Installation steps (6), (8), and (9).
C4 Rev.11 157
Name Quantity Note

Maintenance Parts
Hexagonal wrench
1 For M5 hexagon socket set screw
Hexagonal wrench
Tools
Torque wrench 1

For details, refer to Maintenance: 6.1 Joint #2 – Replacing the Motor, Installation steps (1) through (8).


1. Connect the following connector to the electromagnetic brake
connector.
2. Assemble the Joint #2 electromagnetic brake and mount the motor unit.
158 C4 Rev.11
7. Arm #3
is turned ON. It is extremely hazardous since the Manipulator may move
abnormally. Performing any replacement procedure with the power ON is
extremely hazardous and may result in electric shock and/or malfunction of the
robot system.
system.
The shock may shorten the life of the motors and encoder and/or damage them.
■ Never disassemble the motor and the encoder. Disassembled motor and
CAUTION
encoder will cause a positional gap and cannot be used again.
After parts have been replaced (motors, reduction gear units, electromagnetic 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.
replacement.
Joint #3 motor
+ Electromagnetic brake
Joint #3
Reduction gear unit Joint #3 Timing belt
C4 Rev.11 159
7.1 Joint #3 - Replacing the Motor (with a Brake)
Name Quantity Note

AC servo motor 150 W (with a brake) 1 R13N807021
Maintenance Parts
Hexagonal wrench For M4 hexagon socket set
1
(width across flats: 2 mm) screws
1
(width across flats: 3 mm) cap bolts
Torque wrench 1
Nipper 1
To replace the Joint #3 motor (with a brake), tilt the Arm #3 and press it toward the Arm #2. (See the step (2).)
When pressing the arm, put a cloth or a similar material between the arms to avoid them from contacting.
This also protects the arm surfaces and coatings.
Removal: Joint #3 Motor (with a brake)

2. Tilt the Arm #3. Tilt Arm #3
Put a cloth between the Arm #2 and the Arm #3 so that two
arms do not touch each other.
Protect arms
using cloth, etc.

160 C4 Rev.11

6. Remove the Joint #3 motor unit and the belt from the Arm #2.
7. Remove the connector for the noise dissipative diode.

Connector: D
The noise dissipative diode will be used again.

8. Remove the Joint #3 pulley 1 from the Joint #3 motor unit.

There is a brass bushing in one of the set screw fixing the

drive boss and the pulley. Be careful not to lose it.

C4 Rev.11 161
Installation: Joint #3 Motor (with a brake)

1. Install the motor plate to the Joint #3 motor.
Be careful of the direction of the motor plate. Be sure to
tilt the Arm. (See the figure.)
2. Mount the pulley 1 to the Joint #3 motor unit.

Set the set screw to the flat face of the motor shaft. For the
other set screw, set the brass bushing to the end.
Join the end of the motor shaft and the side of the pulley, and
then fix them.
3. Fix the motor cable to the motor.

30mm to 35mm
Wire tie: AB200
Wire tie fixing position
4. Install the removed noise dissipative diode.

Connector: D
5. Install the motor unit to the Arm #2.

Temporarily tighten the screws.

Tighten the screws loosely enough to hold the motor unit.
162 C4 Rev.11
6. Place the Joint #3 timing belt around the pulley 1 and 2 and
secure temporarily.
Check that the teeth of the timing belt engage with these of
the pulley.
motor unit can be moved by hand, and it does not tilt when
being pulled. If the unit is secured too loose or too tight, the
belt will not have proper tension.
Install the screw for tension adjustment to the motor plate.

Screw: M4×40 or longer (recommended length)
Pass a suitable cord or a string (insulation lock) to the screw.

Pull the cord using a force gauge or a similar tool to apply
specified tension.
Secure the Joint #3 motor unit by applying tention.

Make sure to remove the screw for tension adjustment.

9. Install the Arm #2 side cover.


C4 Rev.11 163

Reduction gear unit: Wave generator, Flexspline (CRB combined), Circular spline
Accessory: O-ring × 2
It is recommended replacing the O-rings (for Joint #3) when replacing the reduction gear unit.
Name Quantity Note

Maintenance Parts
Hexagonal wrench
1 For M4 hexagon socket set screws
Hexagonal wrench
Hexagonal wrench
Tools (width across flats: 3 mm)
Torque wrench 1

1. Remove the following parts.
Arm #2 side cover
Arm #3 head cover
Arm #4 side cover
User plate
When removing the user plate, remove the following parts from the plate.
4 air tubes

For details, refer to Maintenance: 7.3 Joint #3 –
Replacing the Motor, Removal steps (1) through (3).
164 C4 Rev.11
3. Remove the cable unit.

For details, refer to Maintenance: 4.1 Replacing the Cable Unit, steps (9) through (21).
4. Remove the Arm #2 plate.

Arm #2 plate
5. Remove the pulley 2.

Hexagon socket set screws: 2-M4×8
(with a brass bushing)
6. Remove the screws securing the reduction gear unit.

By removing the screws, Arm #3, #4, #5, and #6 (end
effector) can be separated.
Have at least two workers so that one can support the
manipulator while the other worker is removing the
screws.
The parts are greased. Wipe grease while removing
the parts.
C4 Rev.11 165
If the wave generator unit does not come off easily, set the
pulley 2 to the shaft, as shown in the photo, and pull out the
parts.
Remove the wave washer on the Arm #2 hole.

The wave washer will be used again. Be careful not to
lose it.
The parts are greased. Wipe grease while removing the

parts.

(with a brass bushing)
Remove the bearing. The bearing will be used again.
There is a brass bushing on one of the set screws.
parts.
9. Remove the reduction gear unit from the Arm #3.

parts.
166 C4 Rev.11

parts.
O-ring
11. Wipe grease using a cloth or a similar material if it is attached to the Arm #2, and #3, etc.
C4 Rev.11 167

1. Unpack the new reduction gear unit package and check if it Flexspline
contains the parts on the right. ＋Cross roller bearing unit
O-ring
Tooth grooves of the circular spline and the flexspline, and the
bearing of the wave generator are pre-greased. Wipe grease
if it is attached to the fitting parts.
Circular spline
Wave generator
■ Do not adjust the bolts securing the flexspline and the cross roller bearing. If the
bolts are adjusted, it requires centering of the parts by the reduction gear unit
CAUTION manufacturer.
2. Set the O-rings to the grooves on the both faces of the circular Concave surface
spline.
Make sure to fit the rings completely.
Groove
Convex surface
Concave surface
Groove
Convex surface
3. Set the flexspline with the convex surface facing down.
4. Match the screw holes on the cross roller bearing's inner ring
and the drilled holes on the circular spline.
168 C4 Rev.11
5. Fix the cross roller bearing's inner ring and the circular spline.
6. Grease the bearing of the wave generator and install it to the

shaft.
When installing the wave generator, push it to the end and set
the set screws on the shaft's flat face.
For the other set screw, set the brass bushing to the end.
7. Install the removed bearing to the shaft.
8. Set the O-ring to the O-ring groove on the installation face of

the Arm #3 reduction gear unit.
O-ring
C4 Rev.11 169
9. Install the reduction gear unit.

Installation face of the Arm #3 reduction gear unit has clearance

holes.
Install the reduction gear unit to match the screws and the
clearance holes.
Bolts Holes

Grease: SK-1A
Grease amount: 20 g
11. Set the wave washer to the position where the Arm #3 bearing
will be set.
12. Insert the wave generator to the reduction gear unit and fix it.
Wave washer
170 C4 Rev.11
13. Install the assembled Arm #3 to the Arm #2.

When installing the shaft to the hole of the Arm #2, be careful
not to damage the seal.
Be careful not to let the O-ring on the groove of the circular
spline comes off.

Join the end of the shaft and the side of the pulley, and then fix
them.
15. Install the Arm #2 plate.

Arm #2 plate
16. Install the cable unit.

For details, refer to Maintenance: 4.1 Replacing the Cable Unit, Installation steps (14) through (39) and
through (62) to (63).
17. Place the Joint #3 timing belt to the pulley 1 and the pulley 2 of
the Joint #3.
18. Secure the Joint #3 motor unit by applying tension.

For details, refer to Maintenance: 7.1 Joint #3 – Replacing
the Motor (with a Brake), Installation steps (8) through (11).
19. Install the removed covers.


C4 Rev.11 171
Name Quantity Note

Maintenance Parts
1
(width across flats: 3 mm) cap bolt
Tools
Torque wrench 1

1. Follow Removal steps (1) through (4) of Maintenance:
7.1 Joint #3 – Replacing the Motor (with a Brake).


Remove the timing belt from the pulley 1 first.
Then, remove the timing belt from the pulley 2.

Place the timing belt to the pulley 2 first. Then, place the timing belt to the pulley 1.

For details, refer to Maintenance: 7.1 Joint #3 – Replacing the Motor (with a Brake), Installation steps
(6), (8), and (9).
172 C4 Rev.11
8. Arm #4
robot system.
system.
CAUTION
replacement.
Joint #4 reduction gear unit

Joint #4 motor
Joint #4 timing belt
Joint #4 electromagnetic brake
C4 Rev.11 173

Name Quantity Note
Hexagonal wrench
Hexagonal wrench
Tools 1 For M4 hexagon socket head cap bolts

1. Turn OFF the controller power. Tilt Arm #3
2. Remove the Arm #3 head cover and the Arm #3 bottom cover.
3. Pull out the cables from the Arm #3 and disconnect the following Protect arms
connectors. using cloth, etc.

4. Remove the plate of the control board.

5. Remove the Joint #4 motor unit from the Arm #3.

Hexagon socket head cap bolts: 2-M4×15 (with a small plain washer)
174 C4 Rev.11
6. Cut off the wire tie binding the cables of the Joint #4 motor unit.
7. Remove the Joint #4 pulley 1 and the drive boss from the Joint #4
motor unit.
The drive boss and the pulley fixing:
The pulley and the motor shaft fixing:
There is a brass bushing in one of the set screw fixing the drive boss and the pulley.
Drive boss
Pulley
A A : Pulley and motor shaft fixing screws

B : Pulley and drive boss fixing screws
C A C : Bushing
B C
B
Motor shaft
Hexagon socket set screws: 3-M2.5×10

C4 Rev.11 175

2. Mount the Joint #4 electromagnetic brake to the Joint #4 motor

unit.
Be careful of the direction of the Joint #4 electromagnetic brake

wiring. (See the photo.)
Put the end faces of the drive boss and the pulley 1 together.

t = 0.5 mm
Set the set screws to the positions as indicated below.

Drive boss
Pulley
A A : Pulley and motor shaft

fixing screws
C A B : Pulley and drive boss
fixing screws
B C C : Bushing
B
Motor shaft
176 C4 Rev.11
4. Bind the cables of the Joint #4 motor unit with a cable tie.
5. Place the Joint #4 timing belt to the Joint #4 pulley 2.
6. Put the Joint #4 motor unit inside the Arm #4.

Place the timing belt around the pulley 1 and pulley 2.
pulley.
C4 Rev.11 177
7. Apply tension to the Joint #4 timing belt and fix the Joint #4 motor unit.
Turn ON the controller and move the Arm #3 to the position where you can apply tension easily.
Turn OFF the controller power.
Pass a suitable cord or a string (insulation lock) to the drilled hole of the motor plate. Then, pull the cord
using a force gauge or a similar tool and apply specified tension to fix the motor unit.
Joint #4 timing belt tension: 39.2 N ± 9.8 N (4 kgf ± 1 kgf)

Force gauge
8. Install the control board 2.

For details, refer to Maintenance: 13.2 Replacing the Control Board 2, Installation steps (2) through (4).

10. Install the Arm #3 head cover and the Arm #3 bottom cover.

178 C4 Rev.11

A reduction gear unit consists of the waveform generator, flexspline, and circular spline. When replacing the
reduction gear unit, be sure to replace these parts all together as a set.
It is recommended replacing the O-rings (for Joint #4) when replacing the reduction gear unit.
Name Quantity Note
Joint #4 reduction gear unit 1 R13B010023
Maintenance Parts
Hexagonal wrench
Hexagonal wrench
Hexagonal wrench
Tools (width across flats: 3 mm)
Torque wrench 1



4. Remove the cable unit of the Arm #4.

For details, refer to Maintenance: 4.1 Replacing the Cable Unit, Installation steps (9) through (20).

LED lamp

2-M4×5
7. Remove the Joint #4 fitting.
8. Remove the LED lamp.

Joint #4 cable fixing plate Joint #4 fittings
C4 Rev.11 179
9. Remove the Joint #4 output pulley.

There is a brass bushing on the end of the set screw.

When removing the Joint #4 output pulley, remove the bearing

together.
(with a spring washer and a plain bushing)
The bearing will be used again. Be careful not to lose it.
10. Remove the Joint #4 reduction gear unit flange.

When removing the flange, remove the two bearings and the
metal seal together.
The parts will be used again. Be careful not to lose it.
The parts are greased. Wipe grease on the parts while removing
them.
Metal seal
11. Remove the wave generator from the Joint #4 reduction gear unit.
them.
180 C4 Rev.11
12. Remove the circular spline.

Set the screws to the removal taps of the circular spline and tighten
them evenly to remove the circular spline.
Screws: 3-M3×10 or longer
them.
13. Remove the flexspline.

Since the flexspline turns when removing the screws and is difficult
to remove, hold the Arm #4 by two workers as shown in the figure.
them.
14. Remove the O-rings.
O-ring
15. Wipe grease using a cloth or a similar material if it is attached to the Arm #3 or other parts.
C4 Rev.11 181

2. Grease the tooth surface of the circular spline to fill the groove.
Grease: SK-1A
Grease amount: About to fill the tooth grooves of the circular
spline
3. Grease the tooth surface of the flexspline to fill the groove.

Grease: SK-1A
Grease amount: About to fill the tooth grooves of the flexspline

Grease: SK-1A
Grease amount: 10 g
5. Grease the bearing of the wave generator.

Grease: SK-1A
6. Install the O-ring to the Arm #4.
O-ring
182 C4 Rev.11
7. Install the circular spline to the Arm #4 with the inscribed side facing
up.
Be careful of the direction of the circular spline.

(See the figure: M3 screw position)
Mark
8. Install the flexspline.

9. Set the bearing to the wave generator and install it to the flexspline.
10. Install the metal seal.
C4 Rev.11 183
11. Install the bearing to the Joint #4 reduction gear unit flange and
insert it to the cylinder of the circular spline.
Cutout
Be careful of the direction of the flange's cutout.
12. Install the Joint #4 output pulley.

13. Install the bearing.

(with a spring washer and a plain bushing)
14. Install he LED lamp.

LED lamp
15. Install the Joint #4 fitting.

16. Install the Joint #4 timing belt.
2-M4×5
Joint #4 cable fixing plate Joint #4 fittings
17. Install the Joint #4 motor unit.

For details, refer to Maintenance: 8.1 Joint #4 – Replacing the Motor, Installation step (6).


20. Install the cable unit of the Arm #4.

For details, refer to Maintenance: 4.1 Replacing the Cable Unit, Installation steps (4) through (9) and (14)
through (38).
184 C4 Rev.11
24. Install the Arm #3 head cover, the Arm #3 bottom cover, and the Arm #4 side cover.

C4 Rev.11 185
Name Quantity Note

Maintenance Parts Joint #4 timing belt 1 R13N832051
Hexagonal wrench
Tools Cross-point screwdriver For covers
Torque wrench


1. Place the Joint #4 timing belt around the Joint #4 pulley 2.

186 C4 Rev.11
Name Quantity Note

Maintenance
Parts
Hexagonal wrench
Hexagonal wrench
1 For M2.5 hexagon socket head cap bolts
Hexagonal wrench
Nippers 1
Torque wrench 1


1. Mount the Joint #4 electromagnetic brake to the Joint #4 motor unit.
C4 Rev.11 187
9. Arm #5
robot system.
system.
CAUTION
in the Controller.
replacement.
Joint #5
Reduction gear unit

Joint #5 Joint #5 motor
188 C4 Rev.11
Name Quantity Note

Hexagonal wrench
Hexagonal wrench
Nippers 1

3. Pull out the cables from the Arm #4 and disconnect the following
connectors.
4. Loosen the bolts securing the Joint #5 motor unit and remove the
belt.

C4 Rev.11 189
6. Remove the Joint #5 pulley 1 and the drive boss from the motor
shaft of the Joint #5 motor unit.
Drive boss and the pulley fixing screws:
Pulley and the motor shaft fixing screws:
There is a brass bushing in one of the set screws fixing the drive
boss and the pulley. Be careful not to lose it.
Drive boss
Pulley

fixing screws
fixing screws
B C C : Bushing
B
Motor shaft

190 C4 Rev.11

Tightening torque: 4.9 N·m (50 kgf·cm) Motor cable
position
2. Mount the Joint #5 electromagnetic brake to the Joint #5 motor Electromagnetic

brake wiring
unit.

wiring. (See the photo.)
Set the drive boss and the pulley 1 so that their surfaces become
flat.
t = 0.5 mm
Fix the pulley 1 and the motor shaft.
Set the set screws as indicated below.

Drive boss
Pulley

fixing screws
fixing screws
B C C : Bushing
B
Motor shaft
C4 Rev.11 191
4. Put the Joint #5 motor unit to the Arm #4.
5. Place the timing belt around the pulley 1 and pulley 2.

Make sure that the teeth of the timing belt engage with these
of the pulley.
motor unit can be moved by hand, and it does not tilt when
being pulled. If the unit is secured too loose or too tight, the
belt will not have proper tension.
Joint #5 Timing belt tension = 39.2 N ± 9.8 N (4 kgf ± 1 kgf)
Secure the Joint #5 motor unit by applying tension.




192 C4 Rev.11

A reduction gear unit consists of the waveform generator, flexspline, and circular spline. When replacing the
Name Quantity Note

Maintenance Parts Joint #5 reduction gear unit 1 R13B010024
Hexagonal wrench For M3 hexagon socket set screws
1
(width across flats: 1.5 mm) For M2 hexagon socket head cap bolts
Hexagonal wrench
Hexagonal wrench
Tools
Hexagonal wrench
Wrench (width 7) 1
Wrench (width 8) 1


Joint #5 timing belt (6×315 mm).
Joint #6 timing belt (6×324 mm).
C4 Rev.11 193
5. Loosen the set screws of the pulley 2 and remove the Joint #5
pulley 2.
Hexagon socket set screws: 2-M3×5 (with a brass bushing) Pulley 2

6. Loosen the set screws of the pulley 2 and remove the Joint #6
pulley 2.
Pulley 2

7. Remove the bearing retainer plate.

8. Pull out the gear unit.
If it is difficult to remove the gear unit, install the removed pulley

2 to the shaft and remove the parts.
The bearing of the gear unit has shim rings.

Check the position and the number of the shim rings.
Shim ring
When installing the gear unit, make sure to use the same number
of the shim rings to the same position.
9. Remove the Arm #4 plate. Arm #4 plate

194 C4 Rev.11
10. Remove the Joint #6 flange unit.

11. Loosen the set screws securing the Joint #5 reduction gear unit
and remove the Arm #5 unit.
them.
12. Remove the O-rings.

The O-rings are on the installation surfaces of the Arm #4 and #5.
The O-ring of the Arm #4 is on the Arm #4 plate which was
removed in the step (9).
For the O-ring of the Arm #5, see the photo on the right.
O-ring
If it is difficult to remove the wave generator unit, install the
removed pulley 2 to the shaft and remove the parts.
When removing the wave generator, the bearing on the end of the
shaft comes off together. Do not lose the bearing.
them.
Remove the bearing. The bearing will be used again. Be careful
not to lose it.
There is a washer between the nut and the wave generator.
The parts are greased. Wipe grease on the parts while
removing them.
Open-end wrench width for the shaft: 7 mm
Open-end wrench width for the nut: 8 mm
Washer
C4 Rev.11 195
15. Unscrew the set screws of the circular spline and the flexspline.
Circular spline fixing bolts:
Flexspline fixing bolts:
them.
16. Remove the circular spline and the flexspline.
them.
17. Remove the O-ring of the housing.
O-ring
196 C4 Rev.11

Flexspline
Wave generator Circular spline
2. Grease all over the tooth surface of the flexspline.

Grease: SK-2
Grease amount: About to fill the tooth groove of the
flexspline.
3. Grease all over the tooth surface of the circular spline.

Grease: SK-2
Grease amount: About to fill the tooth groove of the circular
spline.
C4 Rev.11 197
4. Install the removed bearing to the Arm #5.
5. Install the O-ring (of the Joint #5 reduction gear unit) to the
housing.
O-ring
6. Install the flexspline so that the hole on the inner side can
match the bearing’s outer ring.
Bearing outer ring
7. Install the circular spline.

198 C4 Rev.11

Grease: SK-2
Grease amount: 3 g
Insert the washer between the nut and the wave generator. Nut
Washer
Set an open-end wrench to the shaft and turn the nut.
Open-end wrench width for the shaft: 7 mm
10. Grease the bearing of the wave generator.

Grease: SK-2
Grease amount: About to fill space between the balls.
11. Insert the wave generator to the reduction gear unit.
12. Install the O-ring (of the Joint #5 reduction gear unit) to the
Arm #4.
O-ring
C4 Rev.11 199
13. Install the Arm #5 unit to the Arm #4.

When installing the unit, insert the key to the groove and Key
match the grooves of the Arm #4 and the housing, then
tighten the screws. Return the key to its original position
after tightening the screws.
The key is on the Arm #1, under the Arm #1 upper cover.
Hexagon socket head cap bolts: M3×6
14. Install the Joint #6 flange unit.

15. Install the Arm #4 plate. Arm #4 plate


200 C4 Rev.11
16. Insert the gear unit.
The bearing of the gear unit has shim rings. Insert them Shim ring
together.
Use the same number of the shim rings to the same position
as removed shim rings.
17. Install the bearing retainer plate.

18. Install the Joint #6 pulley 2. Pulley 2 (large)

Set the set screw on the flat face of the shaft. For the
other set screw, insert the brass bushing to the end.
19. Place the Joint #6 timing belt (6×324 mm) to the Pulley 1 and Pulley 1 Pulley 2
2 and fix it temporarily.
pulley.
When securing the motor unit temporarily, make sure that the motor unit can be moved by hand, and it
does not tilt when being pulled. If the unit is secured too loose or too tight, the belt will not have
proper tension.

C4 Rev.11 201
21. Install the Joint #5 pulley 2. Pulley 2 (small)
Set the set screw on the flat face of the shaft. For the other
set screw, insert the brass bushing to the end.
22. Place the Joint #5 timing belt (6×315 mm) around the Pulley Timing belt
1 and 2 and fix it temporarily.
Check that the teeth of the timing belt engage with these of
the pulleys. Pulley 1
When securing the motor unit temporarily, make sure that the motor unit can be moved by hand, and it
does not tilt when being pulled. If the unit is secured too loose or too tight, the belt will not have
proper tension.



202 C4 Rev.11
Name Quantity Note

Maintenance Parts Joint #5 timing belt (315 mm) 1 R13N832061
Hexagonal wrench
Tools


3. Loosen the Joint #5 motor unit set screws.
Installation: Joint #5 Timing belt.

For details, refer to Maintenance: 9.1 Joint #5 – Replacing the Motor, Installation steps (5), (6), (8), and
(9).
C4 Rev.11 203
Name Quantity Note

Maintenance Parts Joint #5 electromagnetic brake 1 R13N835011
Hexagonal wrench
Hexagonal wrench
Hexagonal wrench
Nippers 1


204 C4 Rev.11
10. Arm #6
robot system.
system.
CAUTION
in the Controller.
replacement.
Joint #6 Reduction gear unit

Joint #6 Motor
Joint #6 electromagnetic brake
C4 Rev.11 205
Name Quantity Note

Hexagonal wrench
Hexagonal wrench
Nippers 1
3. Pull out the cables from the Arm #4 and disconnect the following
connectors.
4. Loosen the bolts securing the Joint #6 motor unit and remove the
belts.

206 C4 Rev.11
6. Remove the Joint #6 pulley 1 and the drive boss from the Joint #6
motor unit.
The drive boss and the pulley fixing screws:
Pulley and the motor shaft fixing screws:
There is a brass bushing in one of the set screws fixing the drive boss and the pulley. Be careful not to
lose it.
Drive boss
Pulley

C A C : Bushing
B C
B
Motor shaft


C4 Rev.11 207
Installation: Joint #6 motor

Tightening torque: 4.9 N·m (50 kgf·cm) Motor cable
position
2. Mount the Joint #6 electromagnetic brake to the Joint #6 motor Electromagnetic

brake wiring
unit.

wiring. (See the figure.)
Set the drive boss and the pulley 1 so that their surfaces become
flat.
t = 0.5 mm
Set the set screws as indicated below.
Drive boss
Pulley

C A C : Bushing
B C
B
Motor shaft
208 C4 Rev.11
4. Put the Joint #6 motor unit to the Arm #4.
5. Place the timing belt around the pulley 1 and pulley 2.
Make sure that the teeth of the timing belt engage with these of the
pulley.

Secure the Joint #6 motor unit by applying tention.




C4 Rev.11 209
Name Quantity Note

Maintenance Parts Joint #6 reduction gear unit 1 R13B010025
Hexagonal wrench For M3 hexagon socket set screws
1
(width across flats: 1.5 mm) For M2 hexagon socket head cap bolts
Hexagonal wrench
Hexagonal wrench
Tools
Hexagonal wrench
Wrench (width 5.5) 1
Wrench (width 8) 1


3. Remove the Joint #5 motor unit and the reduction gear unit.
4. Remove the O-ring on the installation surface of the Arm #4 and #5.
The O-ring of the Arm #4 is on the Arm #4 plate which was
removed in the step (4).
For the O-ring of the Arm #5, see the photo on the right.
The O-ring will be used again. Be careful not to lose it. O-ring
5. Remove the Joint #6 flange.

210 C4 Rev.11
6. Remove the Joint #6 reduction gear unit from the Arm #5.
Use a wrench to move the through holes of the screws. Insert a
tool from the back side of the arm to push the reduction gear unit.
them.
7. Remove the O-ring of the Arm #5.
O-ring
8. Unplug the Arm #5 plug.
Set the screw to the plug and pull out.

Recommended screw length: M4×15 mm or longer
them.
9. Remove the gear.

Remove the bearing. Set the open-end wrench to the nut on the Bearing
Joint #6 reduction gear unit. Insert the tool to the hole where the Nut
plug was, and then turn the screw to remove.
them.
Bolt Gear
10. Remove the wave generator from the Arm #5.
them.
C4 Rev.11 211
If the shaft has a bearing, remove it. The bearing will be used
again. Be careful not to lose it.
There is a washer between the nut and the wave generator.

them.
Open-end wrench width for the shaft: 5.5 mm

212 C4 Rev.11

Insert the washer between the nut and the wave generator.
Washe
Set an open-end wrench to the shaft and turn the nut.
Open-end wrench width for the shaft: 5.5 mm

3. Install the O-ring (of the Joint #6 reduction gear unit) to the Arm #5.
O-ring
4. Insert the wave generator unit to the Arm #5.
C4 Rev.11 213
5. Install the gear.

Set the open-end wrench to the nut on the Joint #6 reduction gear
unit. Insert the tool to the hole where the plug was, and then
tighten the screw.
Bolt Gear
6. Install the Joint #6 reduction gear unit to the Arm #5.

There is a bearing on the back side of the flexspline. If you

removed the bearing during the removal steps, install the bearing
first and install the Joint #6 reduction gear unit to the Arm #5.
7. Install the Joint #6 flange.

8. Inject grease to the gear and insert the plug to the end.
Grease: SK-2
Grease volume: 2 g
9. Install the removed O-ring.
O-ring
10. Install the Arm #5 unit to the Arm #4.

214 C4 Rev.11
Name Quantity Note

Maintenance Parts Joint #6 timing belt (324 mm) 1 R13N832071
Hexagonal wrench
Tools


1. Place the Joint #6 timing belt around the pulley 1 and 2 of the Joint #6.
For details, refer to Maintenance: 10.1 Joint #6 – Replacing the Motor, Installation steps (5), (6), (8) and
(9).
C4 Rev.11 215
Name Quantity Note

Maintenance Parts Joint #6 electromagnetic brake 1 R13N835011
Hexagonal wrench
Hexagonal wrench
Nippers 1


216 C4 Rev.11
Maintenance 11. Replacing the Arm #5 O-ring
11. Replacing the Arm #5 O-ring
Arm #5 O-ring
Name Quantity Note

Maintenance Parts O-ring (Arm #5) 1 R13B031247
Removal: Arm #5 O-ring

2. Move the Arm #5 to the angle where you can unplug the plug M4×15 or longer
easily. Plug
Arm #5
4. Insert a screw to the plug. M4×15 or longer

Plug
5. While holding the screw, disconnect the plug.
6. Remove the O-ring from the plug. O-ring

Screw
Plug
Installation: Arm #5 O-ring

1. Install the O-ring to the plug. O-ring
Screw
Plug
2. Insert the plug to the Arm #5.
Plug M4×15 or longer
Push the plug to the stopper at the end.
Plug
3. Remove the screw. M4×15 or longer

If you move the arm with the screw mounted, it may contact with Plug
the manipulator body. Make sure to remove the screw. Arm #5
C4 Rev.11 217
Maintenance 12. Replacing the Battery Unit
12. Replacing the Battery Unit

robot system.
system.
■ Take meticulous care when handling the lithium battery. Improper handling of
the lithium battery as mentioned below is extremely hazardous and may result in
heat generation, leakage, explosion, or inflammation.
It also may cause serious safety problems.
<Improper Handling>
Attempting to charge Deforming by pressure
Disassembling Short-circuit (Polarity; Positive/Negative)
Connecting batteries improperly Heating (85 °C or more)
WARNING Exposing to fire Soldering the terminal of the lithium battery
Forcing discharge directly
■ When disposing the battery, consult with the professional disposal services or
comply with the local regulation. Make sure that the battery terminal is
insulated, even for a used buttery. If the terminal contacts with the other metals, it
may short and result in heat generation, leakage, explosion, or inflammation.
In case of the low lithium battery power, the error to warn the voltage reduction occurs at
the Controller startup (the software startup). All position data will be lost and you will
need to calibrate all joints.
The life span of the lithium battery varies depending on the energizing hours and
installation environment of the Controller. It is about 1.5 years as a rough guide (when
the Controller is connected to power for 8 hours a day). When the Controller is not
connected to power, the battery consumption will significantly increase compared to when
the Controller is energized. If warnings of voltage reduction occur, replace the lithium
metal battery even if it has not reached the above product life.
NOTE

For the EPSON RC+ 7.0 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.
For details, refer to the following manual.
Robot Controller RC700 / RC700-A Maintenance 6. Alarm
218 C4 Rev.11
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.
Always use the lithium battery and battery board designated by us.
(Refer to Maintenance: 14. Maintenance Parts List.)
Be careful of the battery polarity to connect it correctly.
Battery (lithium battery)
Upper: Control board 1

Bottom: Battery board
Name Quantity Note

R13N860011
Battery unit (Lithium battery) 1
(2 lithium batteries for replacement)
Maintenance Parts Battery board 1 R13N84C011
1653173
Battery relay cable unit 1
(Reusable. See “Note” below)
Nippers 1
Hexagonal wrench
Hexagonal wrench
Note: The battery relay cable unit is reusable. If the cable or the connector latch is broken during
replacement of the cable unit and battery, replace the cable unit. For details on the replacement, refer
to Removal step (10) and Installation step (55) in Maintenance 4. Cable Unit.
C4 Rev.11 219
12.1 Replacing the Battery Unit (Lithium Battery)

2. Remove the Arm #1 upper cover.
3. Loosen the screws fixing the L-shaped plate on the Arm #1 and
remove the plate.
Be careful not to disconnect the battery connector.
NOTE If you removed all the batteries before connecting the new ones, the calibration data will be deleted and
 you will need to perform calibration. Follow the steps below to remove the lithium batteries.
4. Cut off the wire tie of the plate.
5. Disconnect the connector of one of two batteries. Then, connect

the connector of the new battery.
6. Disconnect the connector of the other battery. Then, connect the

connector of the new battery.
220 C4 Rev.11
7. Bind two batteries to the plate using a wire tie.
Set the wire tie on the groove of the plate.
8. Fix the plate to the Arm #1.

9. Install the Arm #1 upper cover.

11. Check operation to see if the manipulator’s position and posture are out of position. Move the
Manipulator to two or three points (poses) of the registered points.
12. If the Manipulator is out of position, calibrate all the joints and axes.
C4 Rev.11 221
12.2 Replacing the Battery Board

After parts have been replaced (motors, reduction gear units, brakes, timing belts, etc.), the
replacement.
Removal: Battery board

2. Remove the Arm #1 upper cover.
3. Disconnect the connector from the control board 1.
Connector: GS01
4. Remove the control board 1.

5. Disconnect the three connectors from the battery board.

Connectors: 2 connectors for the batteries, CN3
6. Remove the battery board fixed to the Arm #1.

222 C4 Rev.11
Installation: Battery board

1. Install the battery board to the Arm #1.
2. Connect the connectors to the battery board.
3. Install the control board 1.

Be careful of the direction of the control board 1.

(See the photo.)
4. Install the connector to the control board 1.

Connector: GS01
5. Install the Arm #1 upper cover.

7. Check operation to see if the manipulator's position and posture are out of position. Move the
Manipulator to two or three points (poses) of the registered points.

C4 Rev.11 223
Maintenance 13. Replacing the Control Board
13. Replacing the Control Board

robot system.
system.
Always use the control board designated by us.
Control board 2
Control board 1
Name Quantity Note

Maintenance Parts Control board (1, 2) 1 R13B040502
Nippers 1
Cross-point screwdriver 1 For control boards
Hexagonal wrench
Hexagonal wrench
13.1 Replacing the Control Board 1
Removal: Control board 1

1. Follow Maintenance: 12.1 Replacing the Battery Unit (Lithium Battery) steps (1) through (4).
Installation: Control board 1

1. Follow Maintenance: 12.1 Replacing the Battery Unit (Lithium Battery) steps (11) through (14).
224 C4 Rev.11
13.2 Replacing the Control Board 2
Removal: Control board 2

2. Remove the Arm #3 head cover.

3. Remove the ground wire fixed to the plate.
4. Remove the connector connected to the control board 2.

Connector: GS02
5. Remove the plate fixed to the Arm #3.
Hexagon socket head cap bolt: M4×10

M4
M3
6. Remove the control board 2 fixed to the plate.

Cross recessed head screw: 4-M3×8
There is a spacer between the plate and the control board 2.

The spacer will be used again. Be careful not to lose it.
Spacer: 4 spacers
Spacer
C4 Rev.11 225
Installation: Control board 2

1. Install the control board 2 to the plate.
Insert the spacer between the plate and the control board 2.
Be careful of the direction of the control board 2.
(See the photo.)
2. Install the plate with the control board 2 to the Arm #3.

M4
M3
3. Connect the connector to the control board 2.

Connector: GS02
4. Install the removed ground wire to the plate.

5. Install the Arm #3 head cover.

7. Check operation to see if the manipulator's position and posture are out of position.
Move the Manipulator to two or three points (poses) of the registered points.
226 C4 Rev.11
Maintenance 14. Replacing the LED Lamp
14. Replacing the LED Lamp

robot system.
system.
LED lamp
Name Quantity Note

Maintenance Parts LED lamp 1 R13N830011
C4 Rev.11 227
Maintenance 14. Replacing the LED Lamp
Removal: LED lamp

2. Remove the Arm #3 head cover.

3. Remove the connector connected to the LED lamp.

The connector for the LED lamp (LED) is under the Arm #3 head cover.
Connector: LED
4. Remove the LED lamp from the Arm #3.
Turn the resin nut securing the LED lamp in the Arm #3
Resin nut
counter-clockwise.
Installation: LED lamp

1. Install the LED lamp to the Arm #3.
Detach the resin nut from the LED lamp and pass the lamp through the Arm #3. Turn the nut
clockwise from the inside of the Arm #3 and secure the lamp to the Arm #3.

Connector: LED
3. Install the Arm #3 head cover.

228 C4 Rev.11
Maintenance 15. Replacing the M/C Cable
15. Replacing the M/C Cable

Each motor is fed power by the battery for backup. Therefore, position data is held even
after turning 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.
robot system.
system.
■ When disconnecting the connectors during the replacement of the cable unit, be
sure to reconnect the connectors to their proper positions by referring to the
connector pin assignments. Improper connection of the connectors may result
in improper function of the robot system.
For details on the connections, refer to the Maintenance 4.2 Connector Pin
Assignments.
■ When installing the cover, be careful not to allow the cables to interfere with the
cover mounting and do not bend these cables forcibly to push them into the
cover. Unnecessary strain on cables may result in damage to the cables,
disconnection, and/or contact failure. These are extremely hazardous and may
CAUTION result in electric shock and/or improper function of the robot system. When
routing the cables, check the cable locations after removing the cover. Be sure
to place the cables back to their original locations.
cables. (Do not put heavy objects on the cables. Do not bend or pull the cables
forcibly.) Unnecessary strain on cables may result in damage to the cables,
disconnection, and/or contact failure. These are extremely hazardous and may
result in electric shock and/or improper function of the robot system.
C4 Rev.11 229
M/C cable
NOTE Make sure to calibrate after the cable replacement.

 For details, refer to Maintenance: 16. Calibration.
Name Quantity Note

Straight 1 R13N824011
3m
L-shaped 1 R13NZ910EW
Maintenance Straight 1 R13N824021
M/C cable 5m
Parts L-shaped 1 R13NZ910EX
Straight 1 R13N824031
10 m
L-shaped 1 R13NZ910EY
Hexagonal wrench
Removal: M/C cable

2. Disconnect the following connectors from the controller.

Power cable connector
Signal cable connector
3. Remove the connector sub plate.

NOTE
 Do not pull the sub plate forcibly.

Do not disconnect the M/C cable from the connector sub plate.
4. Remove the connectors.

Connectors: X11, X12, X13, X14, X15, X16, XGND, BR010, BR020, BR030, BR040, BR050, BR060
X010, X020, X030, X040, X050, X060, LED, GS01, GS02
NOTE Each connector is numbered. Each connector has a different shape.

 Do not disconnect the battery connector (BT1*). Otherwise, you will need to calibrate.
230 C4 Rev.11
Installation: M/C cable

1. Connect the connectors of the new M/C cable to these of the cable unit.
Connect the connectors with the same number.
2. Install the connector sub plate to the connector plate.

3. Connect the following connectors to the controller.

Power cable connector
Signal cable connector
5. 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.
6. If the battery connector (BT1*) was disconnected, perform the calibration.

C4 Rev.11 231
Maintenance 16. Calibration
16. Calibration
16.1. Overview
The process of aligning the two origins is called “Calibration”. Note that calibration is
not the same as teaching*.
* “Teaching” means to teach the Controller coordinate points (including poses) anywhere
in the operating area of the Manipulator.
■ To ensure safety, a safeguard must be installed for the robot system. For details
■ Before operating the robot system, make sure that no one is inside the
safeguarded area. The robot system can be operated in the mode for teaching
even when someone is inside the safeguarded area. The motion of the
WARNING
Manipulator is always in restricted (low speeds and low power) status to secure
the safety of an operator. However, operating the robot system while someone
is inside the safeguarded area is extremely hazardous and may result in serious
safety problems in case that the Manipulator moves unexpectedly.
In EPSON RC+, a coordinate point including the arm pose is defined as “point” and its
data is called “point data”.
There are two methods to move the Manipulator during calibration.

- Releasing the electromagnetic brake and moving the arms manually.
For details, refer to the Setup & Operation 1.5 How to Move Arms with the
Electromagnetic Brake.
- Moving the Manipulator using Jog & Teach.
Moving the Manipulator while releasing the electromagnetic brake involves risk as
described below.
It is recommended to move the Manipulator using Jog & Teach.
CAUTION ■ Be careful of the arm falling when releasing the brake.
232 C4 Rev.11
For details on Jog & Teach, refer to EPSON RC+ User’s Guide 5.11.1 Robot Manager
Command Tools: Robot Manager: Jog and Teach Page.
NOTE - For details about the basic pose, refer to Setup & Operation 3.7 Checking the Basic
 orientation.
- Whenever possible, calibrate one joint at a time. (Also, replace parts of one joint at a
time whenever possible.) If you calibrate the origins for multiple joints simultaneously,
it will be more difficult to verify their origins and obtain the origin correct positions.
However, joint #5 cannot be calibrated alone due to the structure of the Manipulator.
Make sure you calibrate joint #5 and #6 at the same time.
Calibration Flowchart
Start
1. Basic Pose
Confirmation
2. Part Replacement
3. Encoder
Initialization
4. Calibration
5. Calibration More accurate positioning

·····················
Carry out these 6. Accuracy Testing

procedures if necessary
Yes
Re-calibrate?
No
End
C4 Rev.11 233
16.2. Calibration Procedure

Command Input
Command execution is required in some calibration procedures.

Select the EPSON RC+ menu-[Tools]-[Command Window].
This step is omitted in the calibration procedures.
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.
Follow steps 1 to 6 to calibrate the Manipulator.
1. Basic Pose Confirmation
Pose data (Point data) prior to the part replacement (motors, reduction gear unit,
or belt) is necessary for the calibration.
Verify the recorded pulse values of the basic pose obtained in the Setup &
Operation 3.7 Checking the Basic orientation.
2. Part Replacement
Replace parts as instructed in this manual.

Be careful not to injure yourself or damage parts during part replacement.
3. Encoder Initialization
Turn ON the controller while all joints are in the motion range.
The error message “Encoder alarm has occurred. Check robot battery.
EPSON RC+ must be restarted.” will be displayed.
Initialize the encoder at the current position and reset the error.
Initialize the encoder using one of the following procedures.
Execute the following command at the [Monitor Window].
EPSON >Encreset [The joint number (1 to 6) of the encoder to be reset]

RC+
Select EPSON RC+ menu-[Tools]-[Controller], then click <Reset Controller>.
234 C4 Rev.11
After resetting the error, the motor encoder of the joint whose parts have been
replaced will be initialized.
Set the jog mode to “Joint” in [Jog & Teach] and operate the Manipulator in jog
motion to match the home position marks (0 pulse position) of the joint
accurately.
When the joint cannot move to the home position, operate the Manipulator to
match the tram mark placed in Setup & Operation 3.7 Checking the Basic
Orientation as accurate as possible.
Initialize the encoder when the joint matches the home position or the tram
mark.
For the encoder initialization, refer to the procedure indicated above.

NOTE When the origin of the Joint #5 is calibrated, the Joint #6 will be out of position.
 (Due to the structure of the Manipulator, any offset in the position of the Joint #5
affects the Joint #6.)
Calibrate the origin of the Joint #6 together when calibrating the Joint #5.
4. Calibration
Position of grooves for calibration
For Joint #5
Position of the calibration key

For Joint #4
For Joint #6 For Joint #3
The key is secured to the inside of the

For Joint #2 Arm #1 center cover using M4 screw.
Hexagon socket head cap bolts: M3×6
For Joint #1 Be sure to put the key back to the
original position after use.
4-1 Prepare the calibration key.

A calibration key is secured inside the Arm #1 center cover using the M4
screw. Be careful not to lose the screw.
C4 Rev.11 235
4-2 Move the arm you want to calibrate to the position of the calibration
groove.
EPSON Select menu-[Tool]-[Robot Manager]-[Jog & Teach] panel to move the

RC+
Manipulator.
If an error occurs after replacing the motor and you cannot use the [Jog &
Teach] panel or “Brake OFF, *” does not work (* is an axis number to
calibrate.), go through the steps (4) and (5) now.
Then, [Jog & Teach] panel and “Brake OFF, *” will be available. Move the
arm you want to calibrate to the position of the calibration groove and go on
to the step 4-3.
4-3 Set the calibration key to the calibration groove (the grooves for Joints
#1 to #6).
At this point, if the key cannot be set completely, the arm(s) is not in the
origin. Move the arm until the key can be set completely.
The key will be broken if you move any arm with the key in the groove.
Do not move arm(s) once its position is fixed.
4-4 Reset the encoder.
EPSON Execute one of the following commands to reset the encoder of the joint you
RC+ want to calibrate from the menu-[Tool]-[Command Window].
Joint #1 >Encreset 1
Joint #5 >Encreset 5, 6
4-5 Reboot the controller.
EPSON Click EPSON RC+ menu-[Tool]-[Controller]-<Reset Controller>.

RC+
4-6 Input the command in the Command window and execute it.
>calpls 0,0,0,0,0,0
* Manipulator does not move.
236 C4 Rev.11
4-7 Perform the calibration.
Joint #1 >calib 1
Joint #2 >calib 2
Joint #3 >calib 3
Joint #4 >calib 4
Joint #5 >calib 5,6
Joint #6 >calib 6
Move the arm to several points to check if the arm moves to the original
positions properly.
Teach points if fine adjustment is necessary.
4-8 All joints are calibrated.
Put the calibration key back to the original
position in the Arm #1 and secure it with
the screw.
4-9 Mount the Arm #1 cover.

C4 Rev.11 237
5. Calibration (More accurate positioning)
EPSON Move the Manipulator to the selected point data by jogging in [Jog & Teach].
RC+
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.
For example, when the selected point data is “P1”, execute “Motor On” in [Control
Panel] and execute “Go P1” in [Jog & Teach].
Position the calibrating joint* to the selected point data position accurately by jog
command.
* When the Joint #5 is being calibrated, move the Joint #5 and #6 to the home
positions.
Select the “Joint” jog mode from [Jog & Teach] to operate in the jog motion.
Enter the command below in the command window and execute it.
Execute the command below in the menu -[Tools]-[Command Window].

>calpls ppls(P1,1), ppls(P1,2), ppls(P1,3), ppls(P1,4),
ppls(P1,5), ppls(P1,6)
*The Manipulator will not move.
Perform the calibration. Input one of the following commands according to the joint
being calibrated.
Joint #1 : >calib 1
Joint #2 : >calib 2
Joint #3 : >calib 3
Joint #4 : >calib 4
Joint #5 : >calib 5,6
Joint #6 : >calib 6
6. Accuracy Testing
Move the Manipulator to a different pose (point) to verify whether it moves back to
the original position. If accuracy is inadequate, it is necessary to re-calibrate the
origin using a different pose (point). You must set the pose (point) again if the
Manipulator does not move back to the original position after re-calibration.
238 C4 Rev.11
Maintenance 17. Maintenance Parts List
17. Maintenance Parts List

Reference in Overhaul
Name Code Note
Maintenance **
Joint #1, #2 R13N807011 400 W 5.1, 6.1 
150 W
Motor Joint #3 R13N807021 7.1 
+ Electromagnetic brake
Joint #4, #5, #6 R13N807031 50 W 8.1, 9.1, 10.1 
Joint #1 R13N810041 5.2 
Joint #2 R13N810051 6.2 
Reduction Joint #3 R13N810061 7.2 
gear unit * Joint #4 R13B010023 8.2 
Joint #5 R13B010024 9.2 
Joint #6 R13B010025 10.2 
Bevel gear R13B031603 
Electromagnetic Joint #1, #2 R13N835021 5.4, 6.4 
brake Joint #4, #5, #6 R13N835011 8.4, 9.4 10.4 
C4-A601** R13B030220 
Joint #1 5.3
C4-A901** R13N832031 
Width 10 mm
C4-A601** R13B030221 
Joint #2
C4-A901** R13N832041 6.3 
Timing belt C4-A601** R13N832081 
Joint #3 Width 7 mm 7.3
C4-A901** R13N832091 
Joint #4 R13N832051 Width 6 mm 8.3 
Joint #5 R13N832061 315 mm 9.3 
Width 6 mm
Joint #6 R13N832071 324 mm 10.3 
* Reduction Gear Unit: A reduction gear unit consists of the following three parts. When replacing the
Waveform generator Waveform generator

The waveform generator consists of an ellipsoidal
cam and ball bearings on outer circumference.
The inner ring of the bearings is secured to the cam,
while the outer ring is capable of flexible
deformation through the ball bearings.
Flexspline
A thin, elastic, cup-shaped metal body with gear
teeth around the outer circumference of the opening.
Circular spline Flexspline
Circular spline
A rigid, ring-shaped body with gear teeth on the
inner circumference.
The circular spline has two more teeth than the
flexspline does.
The splines are greased. Be sure to keep the grease from being attaching to the clothes.
C4 Rev.11 239
** Overhaul
As a rough indication, perform the overhaul (parts replacement) before reaching 20,000
operation hours of the Manipulator. The operation hours can be checked in [Controller Status
Viewer] dialog - [Motor On Hours].
For details, refer to Maintenance 2.2 Overhaul (Parts Replacement).
Reference in
Name Code Note
Maintenance
Battery board R13N84C011 12.2
Battery unit (Lithium battery) R13N860011 (2 lithium batteries for replacement) 12.1
Seal Joint #4 R13A031200100 8.2
Joint #1, #2, #3, #4 2.3, 5.2, 6.2,
- 7.2, 8.2
: SK-1A
Bevel gear For purchasing grease, please
Grease Joint #5, #6 - contact the sales company in your 2.3, 9.2, 10.2
: SK-2 region.
Cable 4.1
-
: GPL-224
Joint #1 R13B031224
Oil seal
Joint #6 R13B031248
Joint #1, #2 R13B031249
Grease seal
Joint #3 R13B031250
Control board 1, 2 Arm #1, #3 R13B040502 13
Noise
Joint #1, #2, #3 R13N823011 5.4, 6.4, 7.1
dissipative diode
Joint #1 R13B031223 5.2
Joint #2 R13B031242 6.2
Joint #3 R13B031243 7.2
O ring
Joint #4 R13B031244 8.2
Arm #3, #4 R13B031245
Arm #5 R13B031247 For plug 11
LED lamp R13N830011 14
*** Regarding purchase of grease

Due to the chemicals regulations of individual countries (the UN GHS), we are requesting our
customers to purchase grease required for maintenance from the manufacturers listed in the table
below as of April 2015.
Regarding purchase of grease, please contact the following manufacturers. If there is anything
unclear, please contact our suppliers.
Product name Manufacturer URL
Harmonic Grease SK-1A
Harmonic Drive Systems Inc. http://www.harmonicdrive.net/
Harmonic Grease SK-2
http://www2.dupont.com/Our_Company
Krytox®GPL-224 DuPont
/en_US/worldwide/us_country.html
240 C4 Rev.11
Reference in
Name Code Note
Maintenance
Straight R13N824011
3m
L-shaped R13NZ910EW
Straight R13N824021
M/C cable 5m 15
L-shaped R13NZ910EX
Straight R13N824031
10 m
L-shaped R13NZ910EY
Straight R13N824041
3m
L-shaped R13NZ910EZ
Straight R13N824051
M/C power cable 5m
L-shaped R13NZ910F1
Straight R13N824061
10 m
L-shaped R13NZ910F2
3m R13N827011
M/C signal cable 5m R13N827021
10 m R13N827031
C4-A601** R13N820011
Cable Unit
C4-A901** R13N820021
Battery relay cable unit 1653173
Radiation Sheet Joint #2 R13B031905 6.1
Center cover R13N834011
Arm #1
Side cover R13N834021
Arm #2 Side cover R13N834031
3
Arm #3 Head cover R13N834041
Side cover (right) R13N834051
Arm #4
Side cover (left) R13N834061
Cover
Center cover R13N834131
Arm #1
Side cover R13N834141
Arm #2 Side cover R13N834151
Plated 3
Arm #3 Head cover R13N834161
Side cover (right) R13N834171
Arm #4
Side cover (left) R13N834181
Option
Reference in
Name Code Note
Setup & Operation
Brake release unit R12B120805 For Europe
(with cable and short connector) R12B120806 For U.S. & Japan
6.1
R12B120803 For Europe
Brake release unit (Main unit only)
R12B120804 For U.S. & Japan
Camera plate unit R12B031922 6.2
PS compatible plate R12B031923 6.3
Base side angled fitting R12B031924 6.4
Base side fitting R12B031925 6.5
PS Compatible Plate (Base Adapter) R12N73L021 6.6
Adjustable Mechanical Stop R12N73L011 Only C4-A901** 6.7
C4 Rev.11 241
242 C4 Rev.11

Epson ProSix C4 A901S (C4L) Usermanuals 3

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EPSON ProSix

C4 series Manipulator Manual

Copyright  2012-2016 SEIKO EPSON CORPORATION. All rights reserved.

Warnings, Cautions, Usage:

This information only applies to customers in the European Union, according to

The battery removal/replacement procedure is described in the following manuals:

Before Reading This Manual

Structure of Control System

Turning ON/OFF Controller

Photos and Illustrations Used in This Manual

Setup & Operation

3. Environment and Installation 24

5.6 Setting the Cartesian (Rectangular) Range in the XY Coordinate

10. Arm #6 205

11. Replacing the Arm #5 O-ring 217

12. Replacing the Battery Unit 218

13. Replacing the Control Board 224

14. Replacing the LED Lamp 227

15. Replacing the M/C Cable 229

16. Calibration 232

17. Maintenance Parts List 239

This symbol indicates that a danger of possible serious injury

This symbol indicates that a danger of possible harm to people

This symbol indicates that a danger of possible harm to people

1.2 Design and Installation Safety

The following items are safety precautions for design personnel:

1.3 Operation Safety

■ Please carefully read the Safety-related Requirements in the Safety chapter of

■ Be sure to connect the AC power cable to a power receptacle. DO NOT connect

Changing Manipulator speed

1.4 Emergency Stop

Do not turn OFF the Controller while the Manipulator is operating.

If there is a position gap, perform calibration by referring to the Maintenance 16.

Before using the Emergency Stop switch, be aware of the followings.

For details of the Safeguard system, refer to the following manuals.

To check brake problems, refer to the following manuals.

Free running distance in emergency

Approximate time and distance of the free running are as follow:

Manipulator C4-A601** C4-A901**

Free running time Arm #3 0.4 0.5

Free running angle Arm #3 55 55

1.5 How to Move Arms with the Electromagnetic Brake

Arm #1 (Lower Arm)

1.5.1 Moving the Arm using the brake release unit

1.5.2 Moving the Arm using the software

■ Be careful of the arm falling when releasing the brake.

Execute the following command to turn on the brake again.

1.6 Precaution for Operation in Low Power Status

1.7 Manipulator Labels

Location Label NOTE

To avoid getting hands or fingers caught, fold the

Do not enter the work space when the Manipulator

Do not touch the current-carrying parts inside the

Be careful of the arm falling due to its own weight

Front View Lateral View Back View

2.2 Model Number

2.3 Part Names and Motion Range of Each Arm

Joint Motion Joint #2

Joint #1 : The whole Manipulator revolves.

Manipulator C4-A601 C4-A901