Willow Garage PR2 Use and care manual

Toolkit Doc 24
PR2 Battery R&R
December 20, 2012

2
PR2 Battery Remove & Replace
●Refer to the PR2 Overview doc ment for
additional information.
●Move the spine of the robot all the way p,
t rn the robot off
***Once all covers are removed, do ble
check to make s re that the robot is NOT
PLUGGED IN and completely powered off.
Yo will be servicing areas that have AC
power. Use ESD preca tions
1. Remove the lower back cover, and the
base cover (Doc 2, Fig. 1,2)
Fig. 1
2. Remove the front skirt of the robot sing
the 4mm hex bit with the T-handle driver.
There are 12 co nters nk screws (68-
03063-08) to remove (Fig. 3,4)
3. Using a 2.5mm hex bit with the T-handle driver
remove the screws that are sec ring the battery
mod le yo want to replace(Fig. 5,6)
a)If yo want to remove a bottom mod le
yo have to remove the top as well
b) If yo are trying to remove a robot right
battery mod le yo need to remove the
screws on the left side batteries as well
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6

3
PR2 Battery Remove & Replace
5. Unpl g the serial cable that corresponds to the
battery mod le that yo are trying to remove.
(Fig. 8)
6. Unpl g the other two cables that are leading to
the battery mod le that yo are trying to remove.
a)If yo are removing a left battery it will
now be free to take away.
a) If yo are removing a right battery
mod le, wiggle the serial cable (from
battery side) and try to remove it from the
robot. (this step might be tricky)
Fig. 7
Fig. 8
4.Remove the mod les slowly and lay them next
to the robot (cables may not have lots of slack)
(Fig. 7)
7. Cons lt Willow Garage if yo are having a
problem with removing the right battery serial
cable.
Re-Installing the Battery Mod les
7. When yo are ready to re-install the battery
mod les first begin by pl gging in the “AC Main”
cable and the “battery mod le stack p cable”.
For Left Battery Modules:
a) Pl g the serial cable back into the serial
h b and then slide the mod les back into
the base of the robot (Make s re to not
pinch or damage any cabling)
b) Sec re the battery mod les to the base
of the robot sing Loctite 248, the
provided 68-03063-08 screws, and a
torq e val e of 3.17Nm
For Right Battery Modules:
a) Fish BOTH serial cables thro gh the
base of the robot as shown in the following
series of photos below.
1

4
PR2 Battery Remove & Replace
Slide cables between
sheet metal here
2
3
4
5

5
PR2 Battery Remove & Replace
Tape the cables in
These 3 places
6
Now that the right battery mod le serial cables are fished
thro gh the base of the robot yo may:
1. Pl g the serial cable back into the serial h b and then
slide the mod les back into the base of the robot (Make s re
to not pinch or damage any cabling)
2. Sec re the battery mod les to the base of the robot sing
Loctite 248, the provided 68-03063-08 screws, and a torq e
val e of 3.17Nm
3. After the Battery mod les are sec re re-install the front
skirt on the PR2 sing twelve 68-03063-08 screws, Loctite
248, and a torq e val e of 3.17Nm
4. Re-install the lower back cover and the base cover onto
the PR2

6
E-Cat H b Replacement
Fig. 10
10. Pl g in all cables into the h b (Fig. 10)
11. Reinsert the battery mod les into the base of the robot
being caref l to not pinch any of the wires (Fig. 11, 12)
12v E-cat H b
Base
E-Cat Caster BR
E-Cat Caster BL
E-Cat Caster FL
E-Cat Spine
Lower
E-Cat Caster FR
E-Cat Base H b
Fig. 11
Fig. 12
12. Sec re the two battery mod les into the base
of the robot sing Loctite 248 on the eight 2085-06
screws. Use a 2.5mm hex bit and a torq e of
1.36Nm
13. Reinstall the front skirt of the robot sing
Loctite 248 on the twelve 3063-08 screws. Use a
4mm hex bit and a torq e of 3.17Nm
14.Reinstall the base cover and then the back
cover to complete