Epson C Series User manual

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

Manipulator manual C4 series Maintenance Manual Rev.2

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

ii C Series Maintenance Manual Rev.2
FOREWORD
Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the robot controller.
Please carefully read this manual and other related manuals before installing the robot
system.
Keep this manual handy for easy access at all times.
The robot system 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. Please note that the basic performance of the product will
not be exhibited if our robot system is used outside of the usage conditions and product
specifications described in the manuals.
This manual describes possible dangers and consequences that we can foresee. Be sure to
comply with safety precautions on this manual to use our robot system safety and correctly.
TRADEMARKS
Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries. Other brand and
product names are trademarks or registered trademarks of the 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
CONTACT INFORMATION
Contact information is described in “SUPPLIERS” in the first pages of the following
manual:
Robot System Safety Manual Read this manual first
DISPOSAL
When disposing this product, dispose in accordance with the laws and regulations of each
country.

C Series Maintenance Manual Rev.2 iii
Regarding battery disposal
The battery removal/replacement procedure is described in the following manuals:
Maintenance Manual
For European Union customers only
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.
For Taiwanese customers only
Please separate used batteries from other waste streams to ensure that it can be recycled in
an environmentally sound manner. For more details on available collection facilities please
contact your local government office or the retailer where you purchased this product.

iv C Series Maintenance Manual Rev.2
Before Reading This Manual
This section describes what you should know before reading this manual.
Structure of Robot System
The C4 series Manipulators can be used with the following combinations of software.
Controllers : RC700, RC700-A
Software : EPSON RC+ 7.0
The C8 series Manipulators can be used with the following combinations of software.
Controllers : RC700-A
Software : EPSON RC+ 7.0 Ver.7.1.3 or later (C8XL)
EPSON RC+ 7.0 Ver.7.1.4 or later (C8, C8L)
EPSON RC+ 7.0 Ver.7.2.0 or later (Wall mounting)
The C12 series Manipulators can be used with the following combinations of software.
Controllers : RC700-A
Software : EPSON RC+ 7.0 Ver.7.4.6 or later
Setting by Using Software
EPSON
RC+
This manual contains setup procedures using the software.
Those sections are indicated by the symbol on the left.
Turning ON/OFF Controller
When you see the instruction “Turn ON/OFF the 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.

C Series Maintenance Manual Rev.2 v
The Manuals of This Product
The following are typical manual types for this product and an outline of the descriptions.
Safety Manual (book, PDF)
This manual contains safety information for all people who handle this product. The
manual also describes the process from unpacking to operation and the manual you should
look at next.
Read this manual first.
-Safety precautions regarding robot system and residual risk
-Declaration of conformity
-Training
-Flow from unpacking to operation
RC700 series Manual (PDF)
This manual explains the installation of the entire robot system and the specifications and
functions of the controller. The manual is primarily intended for people who design robot
systems.
-The installation procedure of the robot system (specific details from unpacking
to operation)
-Daily inspection of the controller
-Controller specifications and basic functions
C series Manual (PDF)
This manual describes the specifications and functions of the Manipulator. The manual is
primarily intended for people who design robot systems.
-Technical information, functions, specifications, etc. required for the
Manipulator installation and design
-Daily inspection of the Manipulator
Status Code/Error Code List (PDF)
This manual contains a list of code numbers displayed on the controller and messages
displayed in the software message area. The manual is primarily intended for people who
design robot systems or do programming.
RC700 series Maintenance Manual (PDF)
C series Maintenance Manual (PDF) (xx: Manipulator series name)
This manual describes the details of maintenance etc. The manual is intended for people
who perform maintenance.
-Daily inspection
-Replacement and repair of maintenance parts
-The method of firmware update and controller setting backup etc.

vi C Series Maintenance Manual Rev.2
EPSON RC+ 7.0 User’s Guide (PDF)
This manual describes general information about program development software.
EPSON RC+ 7.0 SPEL+ Language Reference (PDF)
This manual describes the robot programming language “SPEL+”.
Other Manual (PDF)
Manuals for each option are available.

Table of Contents
C Series Maintenance Manual Rev.2 vii
C4 Series Maintenance
1. Safety Maintenance 3
2. General Maintenance 5
2.1 Maintenance Inspection............................................................................5
2.1.1 Schedule for Maintenance Inspection...........................................5
2.1.2 Inspection Point.............................................................................6
2.2 Overhaul (Parts Replacement) .................................................................8
2.3 Greasing..................................................................................................10
2.4 Tightening Hexagon Socket Head Bolts.................................................12
2.5 Layout of Maintenance Parts..................................................................13
3. Covers 14
3.1 Arm #1 Top Cover...................................................................................15
3.2 Arm #1 Side Cover..................................................................................15
3.3 Arm #2 Side Cover..................................................................................16
3.4 Arm #3 Head Cover ................................................................................16
3.5 Arm #3 Bottom Cover .............................................................................17
3.6 Arm #4 side cover...................................................................................17
3.7 Base Bottom Cover.................................................................................18
3.8 Connector Plate ......................................................................................18
3.9 Connector Sub Plate...............................................................................19
3.10 User Plate .............................................................................................19
4. Cable Unit 20
4.1 Replacing the Cable Unit........................................................................20
Removal: Cable unit................................................................................22
Installation: Cable unit.............................................................................29
4.2 Connector Pin Assignments ...................................................................48
4.2.1 Signal Cable................................................................................48
4.2.2 Power Cable................................................................................54
4.2.3 User Cable ..................................................................................57
4.2.4 Color of Cables............................................................................57
5. Joint #1 58
5.1 Joint #1 - Replacing the Motor................................................................59
Removal: Joint #1 Motor.........................................................................59
Installation: Joint #1 Motor......................................................................61

Table of Contents
viii C Series Maintenance Manual Rev.2
5.2 Joint #1 - Replacing the Reduction Gear Unit........................................63
Removal: Joint #1 Reduction gear unit ..................................................64
Installation: Joint #1 Reduction gear unit ...............................................67
5.3 Joint #1 - Replacing the Timing Belt ......................................................71
Removal: Joint #1 Timing belt ................................................................71
Installation: Joint #1 Timing belt .............................................................71
5.4 Joint #1 - Replacing the Electromagnetic Brake ....................................72
Removal: Joint #1 Electromagnetic brake..............................................72
Installation: Joint #1 Electromagnetic brake...........................................72
6. Joint #2 73
6.1 Joint #2 - Replacing the Motor ...............................................................74
Removal: Joint #2 Motor.........................................................................75
Installation: Joint #2 Motor......................................................................77
6.2 Joint #2- Replacing the Reduction Gear Unit.........................................79
Removal: Joint #2 Reduction gear unit ..................................................80
Installation: Joint #2 Reduction gear unit ...............................................83
6.3 Joint #2 - Replacing the Timing Belt ......................................................87
Removal: Joint #2 Timing belt ................................................................87
Installation: Joint #2 Timing belt .............................................................87
6.4 Joint #2 - Replacing the Electromagnetic Brake ....................................88
Removal: Joint #2 Electromagnetic brake..............................................88
Installation: Joint #2 Electromagnetic brake...........................................88
7. Joint #3 89
7.1 Joint #3 - Replacing the Motor (with a Brake)........................................90
Removal: Joint #3 Motor (with a brake)..................................................90
Installation: Joint #3 Motor (with a brake)...............................................92
7.2 Joint #3 - Replacing the Reduction Gear Unit........................................94
Removal: Joint #3 Reduction gear unit ..................................................94
Installation: Joint #3 Reduction gear unit ...............................................98
7.3 Joint #3 - Replacing the Timing Belt ....................................................102
Removal: Joint #3 Timing belt ..............................................................102
Installation: Joint #3 Timing belt ...........................................................102
8. Joint #4 103
8.1 Joint #4 - Replacing the Motor .............................................................104
Removal: Joint #4 Motor.......................................................................104
Installation: Joint #4 Motor....................................................................106

Table of Contents
C Series Maintenance Manual Rev.2 ix
8.2 Joint #4 - Replacing the Reduction Gear Unit......................................109
Removal: Joint #4 Reduction gear unit.................................................109
Installation: Joint #4 Reduction gear unit..............................................112
8.3 Joint #4 - Replacing the Timing Belt.....................................................116
Removal: Joint #4 Timing belt ..............................................................116
Installation: Joint #4 Timing belt ...........................................................116
8.4 Joint #4 - Replacing the Electromagnetic Brake ..................................117
Removal: Joint #4 Electromagnetic brake............................................117
Installation: Joint #4 Electromagnetic brake.........................................117
9. Joint #5 118
9.1 Joint #5 - Replacing the Motor..............................................................119
Removal: Joint #5 Motor.......................................................................119
Installation: Joint #5 Motor....................................................................121
9.2 Joint #5 - Replacing the Reduction Gear Unit......................................123
Removal: Joint #5 Reduction gear unit.................................................123
Installation: Joint #5 Reduction gear unit..............................................127
9.3 Joint #5 - Replacing the Timing Belt.....................................................133
Removal: Joint #5 Timing belt ..............................................................133
Installation: Joint #5 Timing belt. ..........................................................133
9.4 Joint #5 - Replacing the Electromagnetic Brake ..................................134
Removal: Joint #5 Electromagnetic brake............................................134
Installation: Joint #5 Electromagnetic brake.........................................134
10. Joint #6 135
10.1 Joint #6 - Replacing the Motor............................................................136
Removal: Joint #6 Motor.......................................................................136
Installation: Joint #6 motor....................................................................138
10.2 Joint #6 - Replacing the Reduction Gear Unit....................................140
Removal: Joint #6 Reduction gear unit.................................................140
Installation: Joint #6 Reduction gear unit..............................................143
10.3 Joint #6 - Replacing the Timing Belt...................................................145
Removal: Joint #6 Timing belt ..............................................................145
Installation: Joint #6 Timing belt ...........................................................145
10.4 Joint #6 - Replacing the Electromagnetic Brake ................................146
Removal: Joint #6 Electromagnetic brake............................................146
Installation: Joint #5 Electromagnetic brake.........................................146

Table of Contents
xC Series Maintenance Manual Rev.2
11. Replacing the Arm #5 O-ring 147
Removal: Arm #5 O-ring.......................................................................147
Installation: Arm #5 O-ring....................................................................147
12. Replacing the Battery Unit 148
12.1 Replacing the Battery Unit (Lithium Battery)......................................150
12.2 Replacing the Battery Board ..............................................................152
Removal: Battery board........................................................................152
Installation: Battery board.....................................................................153
13. Replacing the Control Board 155
13.1 Replacing the Control Board 1 ...........................................................155
Removal: Control board 1.....................................................................155
Installation: Control board 1..................................................................155
13.2 Replacing the Control Board 2 ...........................................................156
Removal: Control board 2.....................................................................156
Installation: Control board 2..................................................................157
14. Replacing the LED Lamp 158
Removal: LED lamp..............................................................................159
Installation: LED lamp...........................................................................159
15. Replacing the M/C Cable 160
Removal: M/C cable .............................................................................162
Installation: M/C cable ..........................................................................162
16. Calibration 163
16.1. Overview ...................................................................................163
16.2. Calibration Procedure ...............................................................165
17. C4 Maintenance Parts List 170
18. C4 Option Parts List 174

Table of Contents
C Series Maintenance Manual Rev.2 xi
C8 Series Maintenance
1. Safety Maintenance 177
2. General Maintenance 179
2.1 Maintenance Inspection........................................................................179
2.1.1 Schedule for Maintenance Inspection.......................................179
2.1.2 Inspection Point.........................................................................180
2.2 Overhaul (Parts Replacement) .............................................................182
2.3 Greasing................................................................................................184
2.3.1 Joint #1 Reduction Gear Unit (Table Top Mounting)................186
2.3.2 Joint #1 Reduction Gear Unit (Ceiling Mounting, Wall mounting)
..................................................................................................187
2.3.3 Joint #2 Reduction Gear Unit....................................................188
2.3.4 Joint #3 Reduction Gear Unit....................................................189
2.3.5 Joint #4 Reduction Gear Unit....................................................190
2.3.6 Joint #5 Reduction Gear Unit....................................................191
2.3.7 Joint #6 Reduction Gear Unit....................................................192
2.3.8 Joint #6 Bevel Gear...................................................................193
2.4 Tightening Hexagon Socket Head Bolts...............................................194
2.5 Layout of Maintenance Parts................................................................195
3. Covers 196
3.1 Arm #1 Center Cover............................................................................199
3.2 Arm #1 Side Cover................................................................................200
3.3 Arm #2 Side Cover................................................................................202
3.4 Arm #3 Cover........................................................................................203
3.5 Arm #3 Maintenance Cover..................................................................204
3.6 Arm #4 Side Cover................................................................................206
3.7 Arm #4 Maintenance Cover (C8XL only)..............................................208
3.8 Arm #4 D-sub Attachment ....................................................................210
3.9 Base Cover ...........................................................................................211
3.9.1 M/C Cable Backward ................................................................211
3.9.2 M/C Cable Downward ...............................................................212
3.10 Base Maintenance Cover ...................................................................216
3.11 Connector Plate ..................................................................................218
3.11.1 M/C Cable Backward ..............................................................218
3.11.2 M/C Cable Downward .............................................................222
3.12 Connector Sub Plate...........................................................................223

Table of Contents
xii C Series Maintenance Manual Rev.2
4. Cable Unit 225
4.1 Replacing the Cable Unit......................................................................225
4.1.1 Replacing the Cable Unit (M/C Cable Backward) ....................227
4.1.2 Replacing the Cable Unit (M/C Cable Downward) ...................257
4.2 Connector Pin Assignment...................................................................262
4.2.1 Signal Cable..............................................................................262
4.2.2 Power Cable..............................................................................265
4.2.3 User Cable ................................................................................268
4.2.4 Color of Cables .........................................................................268
5. Joint #1 269
5.1 M/C Cable Backward (Joint #1)............................................................270
5.1.1 Joint #1 - Replacing the Motor (M/C Cable Backward)............270
5.1.2 Joint #1 - Replacing the Reduction Gear Unit (M/C Cable
Backward).................................................................................278
5.1.3 Joint #1 - Replacing the Timing Belt (M/C Cable Backward) ...285
5.1.4 Joint #1 - Replacing the Electromagnetic Brake (M/C Cable
Backward).................................................................................292
5.2 M/C Cable Downward (Joint #1) ..........................................................294
5.2.1 Joint #1 - Replacing the Motor (M/C Cable Downward)...........294
5.2.2 Joint #1 - Replacing the Reduction Gear Unit (M/C Cable
Downward)................................................................................298
5.2.3 Joint #1 - Replacing the Timing Belt (M/C Cable Downward)..301
5.2.4 Joint #1 - Replacing the Electromagnetic Brake (M/C Cable
Downward)................................................................................306
6. Joint #2 308
6.1 Joint #2 - Replacing the Motor .............................................................309
6.2 Joint #2- Replacing the Reduction Gear Unit.......................................318
6.3 Joint #2 - Replacing the Timing Belt ....................................................325
6.4 Joint #2 - Replacing the Electromagnetic Brake ..................................326
7. Joint #3 327
7.1 Joint #3 - Replacing the Motor .............................................................328
7.2 Joint #3 - Replacing the Reduction Gear Unit......................................336
7.3 Joint #3 - Replacing the Timing Belt ....................................................342
7.4 Joint #3 - Replacing the Electromagnetic Brake ..................................343

Table of Contents
C Series Maintenance Manual Rev.2 xiii
8. Joint #4 344
8.1 Joint #4 - Replacing the Motor..............................................................345
8.2 Joint #4 - Replacing the Reduction Gear Unit......................................351
8.3 Joint #4 - Replacing the Timing Belt.....................................................358
8.4 Joint #4 - Replacing the Electromagnetic Brake ..................................364
9. Joint #5 365
9.1 Joint #5 - Replacing the Motor..............................................................366
9.2 Joint #5 - Replacing the Reduction Gear Unit (Replacing the Joint #5, #6
Reduction Gear Unit Set)......................................................................373
9.3 Joint #5 - Replacing the Timing Belt.....................................................378
9.4 Joint #5 - Replacing the Electromagnetic Brake ..................................379
10. Joint #6 381
10.1 Joint #6 - Replacing the Motor............................................................382
10.2 Joint #6 - Replacing the Reduction Gear Unit (Replacing the Joints #5,
#6 Reduction Gear Unit Set).................................................................388
10.3 Joint #6 - Replacing the Timing Belt...................................................388
10.4 Joint #6 - Replacing the Electromagnetic Brake ................................389
11. Replacing the Battery Unit 391
11.1 Replacing the Battery Unit (Lithium Battery) ......................................393
11.2 Replacing the Battery Board...............................................................395
12. Replacing the Control Board 398
12.1 Replacing the Control Board 1 ...........................................................399
12.2 Replacing the Control Board 2 ...........................................................401
13. Replacing the LED Lamp 403
14. Replacing the M/C Cable 405
15. Replacing the Fan 408
16. Calibration 410
16.1 Overview .............................................................................................410
16.2 Calibration Procedure .........................................................................413

Table of Contents
xiv C Series Maintenance Manual Rev.2
17. C8 Maintenance Parts List 417
18. C8 Option Parts List 421
C12 Series Maintenance
1. Safety Maintenance 425
2. General Maintenance 427
2.1 Maintenance Inspection........................................................................427
2.1.1 Schedule for Maintenance Inspection ......................................427
2.1.2 Inspection Point ........................................................................428
2.2 Overhaul (Parts Replacement).............................................................430
2.3 Greasing ...............................................................................................432
2.3.1 Joint #1 Reduction Gear Unit....................................................434
2.3.2 Joint #2 Reduction Gear Unit....................................................435
2.3.3 Joint #3 Reduction Gear Unit....................................................436
2.3.4 Joint #4 Reduction Gear Unit....................................................437
2.3.5 Joint #5 Reduction Gear Unit....................................................438
2.3.6 Joint #6 Reduction Gear Unit....................................................439
2.3.7 Joint #6 Bevel Gear ..................................................................440
2.4 Tightening Hexagon Socket Head Bolts ..............................................441
2.5 Layout of Maintenance Parts................................................................442
3. Covers 443
3.1 Arm #1 Center Cover............................................................................445
3.2 Arm #1 Side Cover ...............................................................................446
3.3 Arm #2 Side Cover ...............................................................................447
3.4 Arm #3 Cover........................................................................................447
3.5 Arm #3 Maintenance Cover..................................................................448
3.6 Arm #4 Side Cover ...............................................................................449
3.7 Arm #4 Maintenance Cover..................................................................450
3.8 Arm #4 D-sub Attachment ....................................................................451
3.9 Base Cover ...........................................................................................452
3.9.1 M/C Cable Backward ................................................................452
3.9.2 M/C Cable Downward...............................................................453
3.10 Base Maintenance Cover ...................................................................455
3.11 Connector Plate..................................................................................456
3.11.1 M/C Cable Backward ..............................................................456
3.11.2 M/C Cable Downward.............................................................458

Table of Contents
C Series Maintenance Manual Rev.2 xv
3.12 Connector Sub Plate...........................................................................459
4. Cable Unit 460
4.1 Replacing the Cable Unit......................................................................460
4.1.1 Replacing the Cable Unit (M/C Cable Backward).....................462
4.1.2 Replacing the Cable Unit (M/C Cable Downward) ...................490
4.2 Connector Pin Assignment ...................................................................495
4.2.1 Signal Cable..............................................................................495
4.2.2 Power Cable..............................................................................498
4.2.3 User Cable ................................................................................500
4.2.4 Color of Cables..........................................................................500
5. Joint #1 501
5.1 M/C Cable Backward (Joint #1)............................................................502
5.1.1 Joint #1 - Replacing the Motor (M/C Cable Backward) ............502
5.1.2 Joint #1 - Replacing the Reduction Gear Unit (M/C Cable
Backward) .................................................................................510
5.1.3 Joint #1 - Replacing the Timing Belt (M/C Cable Backward) ...517
5.1.4 Joint #1 - Replacing the Electromagnetic Brake (M/C Cable
Backward) .................................................................................523
5.2 M/C Cable Downward (Joint #1)...........................................................525
5.2.1 Joint #1 - Replacing the Motor (M/C Cable Downward) ...........525
5.2.2 Joint #1 - Replacing the Reduction Gear Unit (M/C Cable
Downward)................................................................................529
5.2.3 Joint #1 - Replacing the Timing Belt (M/C Cable Downward) ..532
5.2.4 Joint #1 - Replacing the Electromagnetic Brake (M/C Cable
Downward)................................................................................537
6. Joint #2 539
6.1 Joint #2 - Replacing the Motor..............................................................540
6.2 Joint #2- Replacing the Reduction Gear Unit.......................................548
6.3 Joint #2 - Replacing the Timing Belt.....................................................555
6.4 Joint #2 - Replacing the Electromagnetic Brake ..................................556

Table of Contents
xvi C Series Maintenance Manual Rev.2
7. Joint #3 557
7.1 Joint #3 - Replacing the Motor .............................................................558
7.2 Joint #3 - Replacing the Reduction Gear Unit......................................566
7.3 Joint #3 - Replacing the Timing Belt ....................................................572
7.4 Joint #3 - Replacing the Electromagnetic Brake ..................................573
8. Joint #4 574
8.1 Joint #4 - Replacing the Motor .............................................................575
8.2 Joint #4 - Replacing the Reduction Gear Unit......................................581
8.3 Joint #4 - Replacing the Timing Belt ....................................................587
8.4 Joint #4 - Replacing the Electromagnetic Brake ..................................593
9. Joint #5 594
9.1 Joint #5 - Replacing the Motor .............................................................595
9.2 Joint #5 - Replacing the Reduction Gear Unit ..(Replacing the Joint #5,
#6 Reduction Gear Unit Set) ................................................................602
9.3 Joint #5 - Replacing the Timing Belt ....................................................605
9.4 Joint #5 - Replacing the Electromagnetic Brake ..................................606
10. Joint #6 608
10.1 Joint #6 - Replacing the Motor ...........................................................609
10.2 Joint #6 - Replacing the Reduction Gear Unit (Replacing the Joints #5,
#6 Reduction Gear Unit Set) ................................................................615
10.3 Joint #6 - Replacing the Timing Belt ..................................................615
10.4 Joint #6 - Replacing the Electromagnetic Brake ................................616
11. Replacing the Battery Unit 618
11.1 Replacing the Battery Unit (Lithium Battery)......................................620
11.2 Replacing the Battery Board ..............................................................622
12. Replacing the Control Board 625
12.1 Replacing the Control Board 1 ...........................................................626
12.2 Replacing the Control Board 2 ...........................................................628
13. Replacing the LED Lamp 630
14. Replacing the M/C Cable 632

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

Table of Contents
xviii C Series Maintenance Manual Rev.2