KAWASAKI ROBOT

C4X/C70 CONTROLLER

Troubleshooting
Manual

KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION

90206-1023DEB
 Preface

Read The Operator’s Manual

This operation manual provides important information concerning
proper equipment operation and maintenance. The safety of yourself
and others depends upon your care and judgment in operating the
equipment and properly performing required maintenance. Therefore,
please take the time to read this manual thoroughly, and keep it with the
machine permanently.

Accuracy and Completeness

Although every effort has been made to ensure the accuracy and
completeness of this manual, Kawasaki cannot anticipate every
possible circumstance, use or misuse of the equipment which might
involve a potential hazard. Therefore, the waning and information
presented in this manual may not be all inclusive.
In addition to closely following Kawasaki’s recommendations,
you are encouraged to familiarize yourself with applicable industry safety
guidelines, and exercise due care for the safety of yourself and others in
using this equipment, including the wearing of appropriate protective
apparel. Additionally, due to Kawasaki’s continuing efforts to improve
and refine its products, the specifications herein are subject to change.

Operator Training
If after reading the operation manual you have additional questions
about the use of this equipment, or if you need operator training, please
contact your authorized Kawasaki dealer, or Kawasaki Customer
Service. Kawasaki can provide or recommend available training
courses that address proper procedures for operation of the equipment.

Warranties
The entire warranty for this product is set forth in the “Kawasaki Express
Limited Warranty,” which is provided as a separate document. Nothing
in this manual is intended, or should be interpreted, as creating a waiver
of said warranty provisions and limitations, or as establishing an
independent express or implied warranty concerning the product, its
use, and/or specifications.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual i

 The following symbols are present in all Kawasaki Robot documentation to
signify to the user that proper guidelines, as set forth in the text, are
designed to provide pertinent information.

•I DANGER
This symbol identifies warnings or procedures
which, if not strictly observed, will result in serious
injury or death.

•I WARNING
This symbol identifies special warnings or
procedures which, if not strictly observed, could
result in serious injury.

•I CAUTION
This symbol identifies special instructions or
procedures which, if not correctly followed, may
result in injury or properly damage.

IMPORTANT
This symbol identifies special instructions or
procedures which, if not correctly followed, could
result in machine damage.

NOTE: This symbol identifies supplementary information to

emphasize a point or procedure or to give a tip for
easier operation.

ii Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 This publication contains proprietary information of Kawasaki Heavy
Industries, Ltd., and is furnished solely for customer use only.
No other uses are authorized or permitted without the express written
permission of Kawasaki. The contents of this manual may not be
reproduced, nor transmitted by any means, i.e., mechanical or electrical
photocopy, facsimile, or electronic data mediums, but is not expressly
limited to these mediums without the express written permission of
Kawasaki.

All Rights Reserved.

Copyright © 1999, Kawasaki Heavy Industries Ltd.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual iii

 . MEMO

iv Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 CONTENTS

1. Safety

1.1 INTRODUCTION.................................................................................1-2
1.2 WORK ENVELOPE ............................................................................1-3
1.3 SAFETY IN GENERAL ........................................................................1-4
1.4 SAFETY DURING OPERATION AND PROGRAMMING ....................1-6
1.5 SAFETY DURING INSPECTION AND MAINTENANCE......................1-7

2. Overview

2.1 Major Feature of the System ...............................................................2-2

2.2 Major Components of the Robot System ............................................2-3
2.3 User Interface Panel and Devices.......................................................2-5
2.3.1 Operation Panel.........................................................................2-5
2.3.2 Multi Function Panel (Teach Pendant) ......................................2-7
2.4 Model of “C” controller .........................................................................2-9

3. Description

3.1 Block Diagram .....................................................................................3-2

3.2 1HA PC Board (Main CPU Board).......................................................3-6
3.2.1 IP(Industry-Pack) PC Board....................................................3-11
3.3 1GB PC Board (Servo Board)...........................................................3-12
3.4 1GM PC Board ..................................................................................3-17
3.5 POWER BLOCK...............................................................................3-18
3.5.1 1GC/1GD PC Board................................................................3-18
3.5.2 1HN PC Board.........................................................................3-25
3.5.3 Power block.............................................................................3-29
3.6 1FG PC Board (Encoder Battery Board) ..........................................3-30
3.7 1HG PC Board (Encoder Battery Board) ..........................................3-33
3.8 1GW/1HW PC Board ........................................................................3-35
3.9 1FS PC Board ...................................................................................3-45
3.10 1HZ PC Board (Mother Board) ........................................................3-49
3.11 1HP PC Board.................................................................................3-50
3.12 1HY PC Board (Relay Board).........................................................3-53
3.13 1HJ PC Board (C70 exclusive use motherboard)...........................3-55
3.14 1HK PC Board (C70 exclusive use relay board).............................3-57
3.15 1HM PC Board (C70 exclusive use panel switch board)................3-59

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual v

 3.16 DC Power Supply (Multi-output Switching Power Supply)..............3-60
3.17 Encoder ...........................................................................................3-63
3.18 Multi-Function Panel (MFP) .............................................................3-65

4. Trouble shooting

4.1 Control power source is not ON..........................................................4-2

4.2 Motor Power cannot be turned ON......................................................4-8
4.3 Robot cannot move. ..........................................................................4-12
4.4 Error Code List..................................................................................4-13

5. SEPARATEžINSIDE MACHINE HARNESS

Appendix
Motor List......................................................................................Appendix-2
ABBREVIATIONS .........................................................................Appendix-9

vi Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 SAFETY

OVERVIEW

DESCRIPTIONS

TROUBLESHOOTING

SEPARATEžž INSIDE MACHINE HARNESS

APPENDIX

INDEX

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 1-1

 1. SAFETY

1.1 INTRODUCTION

Safety is an important consideration in the use of automated equipment in

the industrial environment. All operators, maintenance, personnel, and
programmers must be aware of all automated equipment, peripheral
equipment that occupies the work cell, and their associated operational and
maintenance procedures. For this reason it is recommended that all
personnel who operate, maintain, and program the Kawasaki robot attend a
Kawasaki approved training course for the desired topic of instruction that
would be pertinent to each employee’s specific job responsibilities.

The following safety sections in this text are designed to support and
augment existing safety guidelines that may be in use in your plant, and/or
are provided by municipal, state, or federal governments, but are NOT
designed to supplant or supersede any existing rules, regulations, or
guidelines that may be in use.
Because safety is the primary responsibility of the user, owner, and/or
employer, Kawasaki recommends that specific safety guidelines and
recommendations be adopted from groups or individuals that are
professionals in safety design and implementation.

These recommended sources for national and federal safety laws and
regulations include:
• ISO 10218
• ANSI/IRA R15.06-1992
• OSHA
• EN 775

All safety related issues and descriptions, either presented in written or oral
form from any representative of Kawasaki are intended to provide general
safety precautions and procedures and, therefor, are not intended to provide
all safety measures necessary for the protection of all personnel in the work
environment.

Kawasaki cannot anticipate every possible circumstance that might involve

a potential hazard. If a procedure, work method or operating technique not
specifically recommended by Kawasaki is used, you must satisfy yourself
that it is safe for you and others.

Because Kawasaki does not engineer, design or configure robot work cells,
associated automation, and safety equipment, it is not responsible for safety
of personnel or equipment.

1-2 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 1. SAFETY

1.2 WORK ENVELOPE

The work envelope of robot is the hatched area shown in the following
figure. Since this area is dangerous, never enter the work envelope during
automatic operations. Before entering this area for teach operation,
maintenance, etc., make sure of safety without fail.

The work envelope of robot described below corresponds to the work

envelope of point B shown in the above figure. Therefore, referring to the
figure, the safety fence geometry must be set up so that it can securely
cover the dimension, L 0+L1+L2, that is, the maximum dimension from the
arm center (Point A shown in the above figure) to Point B, L 0, plus the sum
L1 of the dimension up to the wrist flange and the maximum dimension for
the tool and work piece, and with allowance L 2 added. Refer to
“INSTALLATION MECHANICAL” manual.

safety fence

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 1-3

 1. SAFETY

1.3 SAFETY IN GENERAL

Safety procedures must be an integral part of operational procedures for the

operator, programmer, and maintenance person. These procedures must
be followed explicitly and on a regular basis. If consistent safety procedures
are followed on a daily basis, they should become a regular part of everyday
operational procedures which are designed to protect the user. Some
guidelines are presented in brief in the following section.

• Before operating or maintaining the

robot or robot controller, be sure you
fully understand and comprehend all
maintenance, operating and
programming procedures, and ensure
that all safety related precautions are
taken and complied with before these
procedures are attempted.

• Avoid wearing loose clothing, scarves, wrist watches, rings, and jewelry
when working on the controller and robot. It is also recommended that if
ties must be worn in your shop environment, that they be the clip-on variety,
rather than tied ties.

• Always wear safety glasses or goggles and approved safety shoes for
your shop conditions. Follow all applicable official and plant safety
specifications and procedures.

• Know the entire work cell ore area that the robot occupies. And be
aware of the entire work envelope of the robot and any peripheral
devices.

• Personnel should never enter the work envelope during automatic

operations.

• Ensure that all personnel are clear of the work envelope before initiating
any motion commands for the robot.

• Be sure that the entire work area is free of debris, tools, fixturing,
lubricants, and cleaning equipment before operation of the robot is
attempted.

• Avoid trap points in which personnel could become trapped between

moving devices and any stationary devices.

1-4 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 1. SAFETY

• If any personnel observe unsafe working conditions, report them

immediately to your supervisor or plant safety coordinator.

• Never defeat, render useless, jumper out, or bypass any safety related
device, whether mechanical or electrical in design.

• All safety devices approved and installed in your installation must be

properly installed and maintained to ensure personnel safety.
• Before initiating any motion commands, know beforehand how the robot
will perform when that command is given.

• All personnel should identify by name and function all switches,

indicators, and control signals that could initiate robot motion.

• Locate all emergency stop buttons or

switches.

• Never attempt to stop or brake the

robot during operation with your body
or person. Utilize Emergency Stop
switches only to stop robot motion.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 1-5

 1. SAFETY

1.4 SAFETY DURING OPERATION AND PROGRAMMING

• During operation of the robot, identify the maximum reach of the robot in
all directions, which is referred to as the work envelope.

• Always keep your work area clean and free of any debris which includes,
but is not limited to, oil, water, tool, fixture, electronic test equipment, etc.

• During operations that involve the teach

pendent, the only person allowed in the
work envelope is the teacher, or the
person operating the teach pendant.

• Never block the operator’s path of retreat.

• During the teach operation of the robot always have a path of retreat
planned.

• Avoid pinch points.

• During point-to-point playback operations, be aware that the robot is

only cognizant of its present location and the next point it is requested to
move to. It will execute this move with total disregard to what may lie in
its path when the move is executed.

• Playback accuracy and speed can affect the geometry of the path
coordinates. Therefore, when changing accuracy or speed, always test
run the program at a slow speed, or point-to-point mode before
attempting the continuous path operation in the repeat mode.

• Always test run a new path program at a reduced speed, or in point-to-

point mode prior to attempting a high-speed playback operation in the
repeat mode.

1-6 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 1. SAFETY

1.5 SAFETY DURING INSPECTION AND MAINTENANCE

• Before entering the work envelope to perform either inspection or

maintenance procedures, turn off three-phase power on the disconnect
and tag, and lock-out the disconnect switch.

• When removing an axis motor, be aware that the axis will fall if left
unsupported. The brake assembly is in the servo drive motor, therefore, the
axis of the robot will be unsupported if removed.

• When using the manual brake release switches in the controller, be aware
that the axis may fail if left unsupported.

• Before working on pneumatic or high pressure water supplies, turn off

supply pressure and purge all lines to remove any residual pressure.

• Assign only qualified personnel to perform all maintenance procedures.

• Consult all available documentation before attempting any repair or

service procedures.

• Use only replacement parts approved by Kawasaki.

• Before attempting to adjust or repair a device in the robot controller that

may have yellow interlock control circuit wires attached, locate the
source of the power and remove it by disconnecting the appropriate
disconnect at its source.

• During inspection and maintenance procedures, if your installation is

equipped with safety fences and safety plugs, remove and hold the
safety plug while performing these operations. In addition, the safety
procedures outlined above should be adhered to.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 1-7

 1. SAFETY

•I CAUTION
• When handling printed circuit boards, hold by their edges and avoid, as much
as possible, touching any circuit parts printed on the boards.
• Never put printed circuit boards on conductive materials like
metal plated !
• Printed circuit boards can be damaged by electro-static discharge. Touch
metal objects before handling printed circuit boards to discharge static
electricity. Use electrostatics.
• When storing printed circuit boards, always place them in static protection
bags.
• When replacing ROMs, check the version of software and/or board type
because different software and/or board types may require different
replacement procedures.
• When replacing ROMs, check the versions of software of other circuit boards,
since their software versions may not be compatible with the new ones !
• When setting new jumpers and DIP switches, follow basically the old settings.
However, when options such as those related to the memory size or IC model
types are different, find proper jumper settings.
• Properly connect all cables and connectors to printed circuit boards. When
the connectors come with locking devices, make sure to lock them as
instructed ! When a printed circuit board has multiple connectors with the
same number of pins, make sure they are placed in the correct connectors.
• When replacing RAM or ROM, check the number of pins of both the memory
and the socket since they may differ from each other.
• When the IC memory has a smaller number of pins than that socket, set the
IC memory as shown the following drawing. (This applies to both RAM and
ROM !)
• In case the IC memory was installed in the opposite direction,
• be sure to replace IC memory. This symbol identifies special instructions or
procedures which, if not correctly followed, may result in injury.
• Since some ROM and PALs may use PLCC types besides the usual DIP
types, make sure to use special IC removal tools when replacing them.
• Some circuit boards may carry the same name but may vary in their contents.
Be sure to check their specifications before replacing.

1-8 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 SAFETY

OVERVIEW

DESCRIPTIONS

TROUBLESHOOTING

SEPARATEžž INSIDE MACHINE HARNESS

APPENDIX

INDEX

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 2-1

 2. OVERVIEW

2.1 Major Feature of the System

The Kawasaki U, and J series Robot System, consists of the mechanical unit, the
Kawasaki robot controller and supporting peripheral equipment, and Kawasaki robot
controller software.
Due to the sophistication of this design, it has the capability to support
the following:

• Joint coordinate movement and programming.

• Cartesian coordinate movement and programming (Base, World) and Tool Cartesian
coordinates.
• Joint Move programming capabilities.
• Linear Move programming capabilities.
• A block step-type programming language.
• Complete programming capabilities of both auxiliary data and program data
through a user-friendly menu system.
• Error message display, self-diagnosis.
• Error logging, operation logging feature.
• Digital Input and Output interface capability.
• The Software Controlled AC brushless servo-drive system utilizing transistor
PWM (Pulse Width Modulation), in conjunction with the excellent design of
the mechanical unit, allows the robot to achieve high speed, high accuracy,
high load, high wrist load capability, and high machine rigidity, while a
reduction in energy consumption is also achieved.
• High mechanical efficiency and smooth movement is assured through the
use of ball-and-roller bearings, gear reduction of the major axes of the robot,
and cycloidal gear reduction of the minor axes.
• Off-line programming through the Kawasaki ROSET (Robot Simulator for
application Engineering and Teaching system) program (optional feature).

The Kawasaki U series mechanical unit, with proper tooling and interface, is
capable of performing many tasks in the industrial environment. Some of these
tasks include spot welding, sealant, and assembly/material handling
applications.

2-2 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 2. OVERVIEW

2.2 Major Components of the Robot System

The two major components of the Kawasaki Robot System are the robot controller and
the mechanical unit (the robot itself). The C series robot controller is shown in Figure 2-1
and Figure 2-1.

Optional Interface
Panel Multi Function Panel
(Teach Pendant)

Operator Panel
Main Disconnect

Figure 2-1 C4[ Robot Controller

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 2-3

 2. OVERVIEW

Multi Function Panel

Operator
Panel

Control
Power
Indicator

Disconnect Switch

Figure 2-2 C70 Controller

2-4 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 2. OVERVIEW

2.3 User Interface Panel and Devices

The primary user interface components of the Kawasaki robot system include the
following:

2.3.1 Operation Panel

The Kawasaki Operation Panel allow the user to perform many tasks such
as
• turning on Motor Power,
• selecting Teach or Repeat modes of operation,
• Hold or Run states,
• Cycle Start,
• resetting Error conditions, and
• selecting the Emergency Stop function.

Emergency Stop
Error Ind.
Motor Power
Error Reset
Cycle Start
Teach/Repeat
Hold or Run

Figure 2-3 C4[ Controller Operation Panel

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 2-5

 2. OVERVIEW

Emergency Stop

Error Ind.

Error Reset

Motor Power

Cycle Start

Hold or Run

Teach / Repeat

Control Power Ind.

Disconnect Switch

Figure 2-4 C70 Controller Operation Panel

2-6 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 2. OVERVIEW

2.3.2 Multi Function Panel (Teach Pendant)

The Kawasaki Multi Function Panel (Teach Pendant) supplied with the robot controller is
equipped with a backlit LCD display, menu-driven touch sensor keys and hard-keys.
Through the use one of the MFP, the user can jog the mechanical unit in the Joint, Base
(XYZ), or Tool coordinates system.

The user can record geometric data for the mechanical unit by using the record button
on the MFP.

The Function Menu Driven Keys allows the user to

• select programs,
• select repeat condition status and speed
• perform program editing,
• change system data,
• change teaching locations and auxiliary data.
• allow the user to program using AS (Advanced Superior)
programming language (high level language).

Program auxiliary data such as:

• Wait signals (WX/Wait External-inputs)
• Outputs (OX/Output external)
• Weld schedules (WS/Weld schedule output)
• Controlling of various tools (Clamping and Gripping)
• Timers
• Accuracy playback
• Joint or Linear Interpolated Move operations

Program system data tables such as:

• Accuracy settings
• Timer settings
• Speed settings
• Tool settings

View
• XYZ position
• Joint angle position
• Joint angle command
• Input signals
• Output signals

The teach pendant is equipped with Deadman switches and a hardwired Emergency Stop,
along with a Teach Lock switch for user safety.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 2-7

 2. OVERVIEW

Emergency Stop Switch Teach Lock Switch

Deadman Switch Deadman Switch

ON OFF

TEACH LOCK

LCD

Inlet PC Card Volume of contrast

Touch Pen

Figure 2-5 displays the Multi-Function Panel (MFP)

2-8 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 2. OVERVIEW

2.4 Model of “C” controller

MODEL MACHINE TYPE

EU MODEL C40 JS5,JC5,JW5,
JS10, FS/FC/FW06*, FS10C/N/E
FA06N/L
FS/FP20*, FS10L
FA20N
C41 JS30/40, FS30N/L, FS045C/N
C42 UX/UT/UZ100,120,150
UX200, UX300
C43 UD100,150
C70 FS02/03, FC02

Figure. 2-6 C40/C41/C42

Figure. 2-7 C43

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 2-9

 2. OVERVIEW

Figure 2-8 C70

2-10 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 SAFETY

OVERVIEW

DESCRIPTIONS

TROUBLESHOOTING

SEPARATEžž INSIDE MACHINE HARNESS

APPENDIX

INDEX

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-1

 3. DESCRIPTIONS

3.1 Block Diagram

The Kawasaki C Controller Circuit Board Block Diagram displayed in Figure 3-1-1
and Figure 3-1-2, depicts the major control printed circuit boards in the Kawasaki
robot controller.

MOTHE R B O A R D
TERMINAL
1HZ b ' d
SERIAL I/F (PERSONAL COMPUTER)
MAIN CPU RS232C
EXTERNAL EQUIPMENT
USER MEMORY
SYSTEM MEMORY
VME BUS

LAN I/F EXTERNAL TERMINAL

SERIAL I/F
RS485 IP I/F
EXTERNAL EQUIPMENT
A
1GA IP I/F
EXTERNAL EQUIPMENT
b'd B

VME BUS

OPTIONAL BOARD
(VISION BOARD, I/O BOARD, etc.)

VME BUS
I/O I/O SIGNAL I/L PANEL

CIRCUIT
1FR
b'd SENSOR SIGNAL,
I/O 24Vdc
BRAKE RELEASE SW

VME BUS POWER FAILURE

DETECTION CONTROL POWER EXTERNAL
+24Vdc CIRCUIT
CONTROL POWER
I/L PANEL
MOTOR POWER EXTERNAL EMG-STOP
CIRCUIT SERIAL COMMUNICATION,
EXTERNAL HOLD
1•`3 CH SERVO DATA
0 CH COMMAND LINE

1HP MC CONDITION, SERVO CONTROL, SERVO ERROR

b'd

SENSOR SIGNAL, I/O 24Vdc, LIMIT SW

OPERATION PANEL
MOTOR POWER ON, CYCLE START, TEACH/REPEAT,
MOTOR POWER
RUN/HOLD, ERROR RESET, EMG-STOP
ON, EMG-STOP,
MC CONDITION

REMOTE,
ERROR

POWER FAILURE
DETECTION RELAY
+5V, +12V, -12V 1HY CIRCUIT
b'd
DC POWER
DC POWER +5V
+12V,-12V
CONTROL POWER POWER CIRCUIT
+24V
AVR CONTROL POWER(210Vac)
MOTOR POWER(300Vdc)
BRAKE POWER(26Vac)

BATTERY
(3.6V)

HOUR METER,
CONTROL POWER LAMP

EMG-STOP,TRIGGER
380-480Vac 50Hz 3ƒÓ(CE)
400-575Vac 60Hz 3ƒÓ(AMERICA)

C O M M U N I C A T I OMFP,
SERIAL N T/P

Figure 3-1-1 C4X Controller Block Diagram

3-2 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

ROBOT ARM
SERVO MOTOR ASSY
Jt1-7

VALVE
ENCODER BRAKE MOTOR
LIMIT SW

SENSOR

DC POWER
(+12Vdc)
1FG b'd
BATTERY BACKUP
CONVEYOR ENCODER DC POWER for ENCODER

ENCODER SIGNAL,
SENSOR SIGNAL,
I/O 24Vdc, LIMIT SW,
BATTERY BACKUP
BATTERY ALARM
DC POWER for
ENCODER MOTOR LINE
BRAKE LINE

POWER BLOCK

SERIAL I/F ENCODER I/F

RS485 BRAKE CONTROL Jt1 UNIT
RS485

PWR SIGNAL,
CH 1 IPM ERROR Jt2 UNIT
CPU A
Jt1, 2, 3 SERVO CONTROL,
ERROR DETECTION,
HARDWARE ERROR MANAGEMENT
Jt3 UNIT
PWM SIGNAL,
CH 2
IPM ERROR
CPU B
Jt4, 5, 6 SERVO CONTROL, Jt4 UNIT
ERROR DETECTION

PWM SIGNAL,
IPM ERROR Jt5 UNIT
CPU C
CH 3 Jt7 SERVO CONTROL,
ERROR DETECTION,
CONVEYOR ENCODER MANAGEMENT
CH 0 Jt6 UNIT
CURRENT
FEEDBACK

BRAKE POWER
1GM b'd Jt7 UNIT

CURRENT FEEDBACK
CURRENT LIMIT
DC POWER

(1GC, 1GD b'd)

1GB
b'd

POWER UNIT
THERMAL
POWER UNIT ERROR, CONTROL CIRCUIT,
SW
INRUSH CURRENT CONTROL SIGNAL P-N POWER ERROR DETECTION
CIRCUIT,
INRUSH CURRENT CONTROL REGENERATE CIRCUIT REGENERATE
RESISTOR

MOTOR POWER
300Vdc

Figure 3-1-1 C4X Controller Block Diagram

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-3

 3. DESCRIPTIONS

MOTHE R B O A R D
TERMINAL(PERSONAL
1HJ b ' d OPTION(FDD UNIT)
SERIAL I/F COMPUTER)
MAIN CPUUSER RS232C EXTERNAL
MEMORYSYSTEM EQUIPMENT
MEMORY
VME BUS

EXTERNAL
LAN I/F
TERMINAL

SERIAL I/F
RS485 IP I/F EXTERNAL 1HF
FDD UNIT
A EQUIPMENT b'd
1GA IP I/F EXTERNAL
b'd B EQUIPMENT

CONTROL POWER(+5Vdc)

VME BUS

OPTION BOARD
(VISON BOARD, I /O BOARD etc.)

I/O I/O SIGNAL I/L PANEL

VME BUS
CIRCUIT
1GW
b'd
SENSOR SIGNAL,
I/O 24Vdc
DC24V

POWER FAILURE POWER CIRCUIT

VME BUS
DETECTION
CONTROL POWER
+24Vdc EXTERNAL CONTROL POWER
CIRCUIT
I/L PANEL
MOTOR POWER
CIRCUIT EXTERNAL EMG-STOP/HOLD
OPERATION PANEL

MOTOR POWER ON, CYCLE START,

T E A C H / R E P E A T , R U N / H O L D1
,4 H M
ERROR RESET, MEG-STOP b'd SERIAL COMMUNICATION
1•`3CH SERVO DATA
0CH DEBAG LINE

MC CONDITION, SERVO CONTROL, SERVO ERROR

SENSOR SIGNAL, I/O 24Vdc, LIMIT SW

1HP
HOURE,
b'd
METERCONTROL
POWER ON LAMP

MOTOR POWER
EMG-STOP
MC ON RELAY CIRCUIT

POWER FAILURE BRAKE POWER

REMOTE,
DETECTION CONTROL
ERROR
+5,+12V, -12V POWER

POWER CIRCUIT
DC POWER
DC POWER
+5V THERMAL SW
+12V, -12V,
200-240Vac
+24V
AVR
POWER UNIT
POWER CIRCUIT

EMG-STOP,
1HK
BATTERY TRRIGER
b'd
(3.6V)

BRAKE, CONTROLL
SERIAL POWER
COMMUNICATION

MULTI FUNCTION PANEL/ 200-240Vac

50/60Hz 1ƒÓ
SMALL T/P

Figure 3-1-2 C70 Controller Block Diagram

3-4 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

ROBOT ARM
SERVO MOTOR ASSY
JT1•`7

VALVE
ENCODER BRAKE MOTOR
LIMIT SW

SENSOR

CONTROL POWER
(+12Vdc)
1HG b'd
BATTERY BACKUP BATTERY
CONVEYOR ENC DC POWER for ENCODER

ENC SIGNAL, SENSOR

BRAKE RELEASE
SW SIGNAL, I/O 24Vdc, LIMIT
BATTERY BACKUP SW, BATTERY ALARM BRAKE LINE
DC POWER for
ENCODER MOTOR LINE

POWER BLOCK

SERIAL I/F
ENCODER I/F
RS485 BRAKE CONTROL JT1 UNIT
RS485

PWM SIGNAL,
CH1 IPM ERROR JT2 UNIT
CPU A
JT1, 2, 3 SERVO CONTROL,
ERROR DETECTION,
HARDWARE ERROR MANEGEMENT
JT3 UNIT
PWM SIGNAL,
CH2
IPM ERROR
CPU B
JT4, 5, 6 SERVO CONTROL, JT4 UNIT
ERROR DETECTION

PWM SIGNAL,
IPM ERROR JT5 UNIT
CPU C
CH3 JT7 SERVO CONTROL,
ERROR DETECTION,
CONVEYOR MANEGEMENT
CH0 JT6 UNIT

CURRENT
BRAKE POWER FEEDBACK

1GM b'd JT7 UNIT

CURRENT FEEDBACK
CONTROL
POWER CURRENT LIMIT
(DC)
•i1HN b'd)

1GB
b'd

THERMAL
POWER UNIT ERROR, POWER ERROR DETECTION
SW
INRUSH CURRENT CONTROL SIGNAL CIRCUIT,
CONTROL POWER REGENERATE CIRCUIT
(200Vac) REGENERATE
RESISTOR

INRUSH CURRENT CONTROL

MOTOR POWER
300Vdc

Figure 3-1-2 C70 Controller Block Diagram

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-5

 3. DESCRIPTIONS

3.2 1HA/1GA PC Board (Main CPU Board)

The 1HA/1GA PC board is the main CPU board of C-controller equipped with 32bit
RISC processor. The 1HA/1GA PC board chiefly does the operation plan of the
robot, the control system processing of the coordinates conversion etc. , and
communication processing with the outside with main CPU board.
The function of 1HA/1GA PC board is shown as follows.
• AS software and servo software are installed in the FLASH memory.
• Execution of AS software system
• Execution of servo position loop operation
• The storage of the user's program and the data (When the battery is connected,
it is possible to back up).
• 1MB(optional 4MB) of battery backup SRAM (The system memory contains).
• Communication function with servo board (5ch.)

Ch. The communication ahead Note

0 Each unit of servo board or optional servo Debugging line
amplifier
A unit of the first piece of 1GB PC board
1
A unit of the first piece of 1GB PC board
2
3 C unit of the first piece of 1GB PC board or A it changes by the composition of
unit of the second piece 1GB PC board or the controller communicating
optional servo amplifier ahead.
4 The second piece of 1GB PC board B unit or
optional servo amplifier

• Communication function with multi function panel or small teach pendant

• VME bus interface function (communication function with option board besides
1HP, 1FS/1GW PC boards)
• The IP(Industry Pack) interface function (The option printed circuit board of the
analog input function etc. is mounted).
port A : 1 piece of 16bit single size board
port B : 1 piece of 16bit single or double size board
• Communication function (2 channel of RS232C) with external equipment such as
personal computers.
• DC power supply abnormal detection function
+5V : beyond the limits of +4.85V to +5.45V.
+12V : +10.75V or less
-12V : -10.4V or more
Battery : +2.5V or less (The battery is installed on the card rack)
The AS software is checked only at control power supply ON time and motor power
supply ON time though hardware is always observed. The error can be reset.
The control power supply is turned off from 1HP PC board when the power supply
voltage is abnormal. And, an automatic return is repeated until returning to a normal
voltage.
(At external control power supply ON/OFF terminal short-circuit)
(The watch of 24+V is executed with 1HP PC board)

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 3. DESCRIPTIONS

1HA/1GA

IMPORTANT
Notes of SRAM backup
• The battery is installed in the motherboard. When Super Capacitor on 1HA/1GA PC
board charges full, the backup time of the memory is about 30 minutes when 1HA/1GA
PC board is detached from the motherboard.
• It takes about three hours or more to the super-capacitor on 1HA/1GA PC board to
charge full in the state of control power supply ON . The longevity of the battery shortens
when a new board (board which discharges the super-capacitor) is installed repeatedly
because consumption current of the battery increases.
• Take notes and save the content of memory to the SRAM card of the Multi-Function
Panel or the hard disk on your personal computer when you detach 1HA/1GA PC board
from the card rack because there is no method of confirming the charge with the super-
capacitor.
• After off the control power supply, the longevity of the battery is about two years when the
option board by which the battery is consumed besides 1HA/1GA PC board is not
installed.

Connector and switch arrangement

TP1,2,3,4
CN1 CN2 CN3
SW2
LD1,2,3
LD 4, 5, 6, 7
CN4 CN5

CN6 CN7

IP-B IP-A

CN8 CN9

SW3

CN10 (P2) CN11 (P1)

Fig. 3-2-1 1HA/1GA PC Board Layout Drawing

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-7

 3. DESCRIPTIONS

1HA/1GA

CN1 : PC terminal port (RS232C B ch.) D-sub 9pin Female

CN2 : Host communication port (RS232C A ch.) D-sub 9pin Male CN1 and CN2 pin assign
CN3 : LAN port (10BASE-T) (option) No. CN1 CN2
CN4 : I/O connector for B side IP PC board
CN5 : I/O connector for A side IP PC board 1 - -
CN6,8 : System connector for B side IP PC board
2 RxD RxD
CN7,9 : System connector for A side IP PC board
CN10 : VME bus connector (P2) (for 1GB, 1FT PC board 3 TxD TxD
communication)
CN11 : VME bus connector (P1) (system bus) 4 - -

5 GND GND
The pin assignment of CN4, 5 is different depending on the 6 - -
kind of the IP PC board.
7 RTS RTS

8 CTS CTS

9 - -

Switches

No. bit Function Setting Setting Note

usually
SW1 System reset PUSH : Reset Use prohibition
SW2 1 VME-SYSRESET Input mask ON : Mask ON The second piece
OFF : Enable is turned off.
2 VME-SYSRESET Output mask ON : Mask OFF The second piece
OFF : Enable is turned on.
3 FLASH-Memory writing mask ON : Enable OFF turn on before
OFF : Mask software
installation
4 Selection of boot device ON : EPROM OFF Set change
OFF : FLASH-Memory prohibition
5 Software start condition setting Refer to the table below OFF Refer to the table
below
6 Software start condition setting Refer to the table below OFF Refer to the table
below
7 RS232C A ch. Setting ON : Debugging port OFF
OFF : Host
communication port
8 Selection of system initialization ON : Initialization screen OFF
start
OFF : Start usually
SW3 1 System setting OFF Set change
prohibition

2 Setting of VME bus system ON : System controller ON The second piece

controller OFF : It is not a system is turned off.
controller.
3 Unused - OFF
4 Unused - OFF

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 3. DESCRIPTIONS

1HA/1GA

SW2 Start condition Note

5 6
ON ON Debugging monitor start Set prohibition
OFF ON The down loader start Set prohibition
(It cannot be down-loading from the multi function panel).
ON OFF The down loader start turn on before
(It can be down-loading from the multi function panel). software
installation
OFF OFF AS system start Setting usually

LEDs
No. color Lighting condition
1 red Light off at usually
Turning on when ACFAIL or CPU error
2 green Turning off when AS system starts
Blinks at 1 cycle of the second at usually.
3 green Turning on when CPU self-test ends normally.
Light usually
Turning off when CPU self-test ends abnormality
4 green LAN Transmit (option)
5 green LAN Link (option)
6 green LAN Collision (option)
7 green LAN Receive (option)

Check pins
No. color Standard
1 black GND -
2 yellow VEE12 (-12V) voltage -12.0V±0.1V
3 yellow VCC12 (+12V) voltage +12.0V±0.1V
4 yellow VCC (+5V) voltage +5.00V±0.05V

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-9

 3. DESCRIPTIONS

1HA/1GA

Block diagram

CPU

EPROM VME I/F

P1
256kbyte a:16/24,d:16

FLASH Memory LAN

2M/4Mbyte Co- Processor 10BASE-T I/F CN3

CN4
SRAM IP I/F

1M/4Mbyte 16bit×2
CN5

RS485 SV-CMD1
RTC SIO Half Duplex

RS485 SV-CMD2
Half Duplex

RS485 SV-CMD3
CIO SIO Half Duplex P2
RS485 SV-CMD4
Half Duplex

RS485 SV-DBG
ASIC SIO Half Duplex

RS485 T/P
Full Duplex

PC
RS232C CN1
ASIC SIO

µP D 7 2 0 0 1 HOST
RS232C CN2

Fig. 3-2-2 1HA/1GA PC Board Block Diagram

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 3. DESCRIPTIONS

3.2.1 IP(Industry-Pack) PC Board

The IP board is an option board installed on 1HA/1GA board. The IP board adds the function of
the analog input etc. to 1HA/1GA board.
It can install one IP board of 16bit single size and a double size on 1HA/1GA board respectively.
The I/O of the IP board is connected with CN4 and CN5 of 1HA/1GA board. However, since the
use state of the pin is different according to kind of the IP board; it connects the adapter
harness with CN4 and CN5 of 1HA/1GA board, and it is connected with Peripheral equipment.
Moreover, by way of the signal from Peripheral equipment according to the IP board and by way
of CN4 and CN5 of 1HA/1GA board. There is the one connected directly with the connector on
the IP board, too.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-11

 3. DESCRIPTIONS

3.3 1GB PC Board (Servo Board)

The 1GB PC board is servo CPU board for C controller installed in the servo unit.
There are six standard axes specification and seven axes specification of the option.
The 1GB PC board has an under-mentioned function.
• Encoder communication interface (The encoder is H20 and M21 type)
Standard : 6 axes
Options : 8 axes ( 7 axes + conveyer one axis)
• Communication function with main CPU board (1HA/1GA PC board)
Standard : 2ch
Options : 3ch
• The servo operation processing function by the current loop and the speed loop
according to the command from main CPU board (1HA/1GA PC board).
• PWM signal output function to PB( Power Block).
• Control function of manual brake release
Standard : 6 axes
Options : 7 axes
(Neither the disconnection nor the short-circuit detection are done.)
• Manual brake release function by manual brake release BOX. However, the manual
brake release function cannot operate when motor power supply (MC) state of
turning off and the emergency stop (The external emergency stop is contained) are
releasing.
• Control function of RGSO and brake
• Relay of robot axis restriction limit switch signal to power sequence board (1HP PC
board)
• Making at magnet ON signal (MSON) delay time
• Servo unit error signal (SVER) output function with power sequence board (1HP PC
board) (RS485). The SVER signal is output to the power sequence board (1HP PC
board) when the 1GB PC boards of an error (error etc. related to the encoder)
which the following, the hardware relation errors, and the servo software detected
and abnormal communications, etc. do the error detection and motor power supply
(MC) is turned off with hardware.
• Various hardware relations, error detection, and error processing functions

Error Detection level Error reset 1GB

Amp overcurrent When the feedback current from a current sensor Acceptable A,B,C
exceeds 144% of the maximum current of the motor
Servo CPU-* When each 1GB PC board CPU stops Impropriety A,B,C
watch dog error
Servo unit 12VDC +12V: +10.7-V or less Acceptable A
error - 12V: -10.3V or more
Current sensor When the current sensor harness is a defective Acceptable A,B,C
disconnect connection
Over heat or Motor When thermal connected with machine harness Acceptable B
harness is operates
disconnect When thermal line TH(P/N) is disconnected

3-12 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

1GB
• Correspondence of axis No. and CPU channel. Three CPUs or less can be installed
in 1GB PC board. The table below shows the correspondence of each axis and the
CPU.(CPU-C is not installed on 1GB PC board of six axes specification.) Three
CPUs are called A, B, and C unit respectively.
.

1GB Axis No.

CPU Unit CPU ch.

1 Jt.1
A 2 Jt.2
3 Jt.3
1 Jt.4
B 2 Jt.5
3 Jt.6
C 1 Jt.7
2 Conveyer

• About 1GB PC board software

The servo software is installed in the FLASH memory of not 1GB PC board but 1HA/1GA
PC board.
It is forwarded from the 1HA/1GA PC board to SRAM of each 1GB PC board at control
power supply ON. (The kernel part of the servo software is written in ROM in the CPU
of the 1GB PC board. The user need not especially consider this because of
commonness to all models.

• Notes when the 1GB PC board is exchanged

Please note leading to the damage of the substrate when the torque of the screw is
multiplied too much when the 1GB PC board is installed in servo unit.
Please note that 1GM PC board installed in the 1GB PC board is different depending on
the correspondence model (combination of motors).
The ID code is set on the 1GM PC board in electricity respectively. The AS software
checks whether to suit the ID code at control power supply ON. The error occurs
when neither the 1GM PC board nor the AS software are suited.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-13

 3. DESCRIPTIONS

1GB
Connector and switch arrangement chart

CN5 CN6 CN4 CN2 CN1

TP1

CN7
TP2 SW1

CN
CPU-A CPU-B CPU-C 3

TP3 TP4 TP5

TP6,TP7
GATE GATE GATE TP8,TP9

ARRAY-A ARRAY-B ARRAY-C

Upper
1GM LED
CN8B
D26,D27,D28
boardÞ D36,D37,D38
Lower
D39,D40,D41 CN8A
CN11

CN9 CN10 CN13

CN12

A dotted line part mounts

Screw for only seven axes
installation specification.

Fig. 3-3-1 1GB PC Board Layout Drawing

No. The connection ahead Contents

CN1 Control unit Command line, Debug line, Servo control signal
24V(for I/O), LS1,2, Sensor input 1∼4
CN2 Robot Encoder signals(Jt1-7), Battery alarm,
24V(for I/O), LS1,2, Sensor input 1∼4
CN3 Conveyer encoder Encoder signal (conveyer)
CN4 Power supply circuit Power supply (DC24V) input for motor brake
CN5 Manual brake release Manual brake release signal
BOX
CN6 Robot Motor brake drive signal , Motor thermal signal
CN7 Highly effective P.U. (unused)
CN8A AVR Control power supply (+5V) and (12V) input
CN8B AVR Control power supply GND
(It is used when the servo unit separates)
CN9 P.B. Current feedback signal from current sensor A1, A2, and A3 ch.
CN10 P.B. Current feedback signal from current sensor B1,B2, and B3 ch.
CN11 P.B. Current feedback signal from current sensor C1
CN12 P.B. PWM signal and IPM error signal of A2, A3, B1, and B2 ch.
CN13 P.B. PWM signal and IPM error signal of A1, B3, and C1 ch.
Regenerating resistor error signal
Regenerating resistor or over-heat error signal
Servo unit P-N high voltage error signal
Servo unit P-N low voltage error signal

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 3. DESCRIPTIONS

1GB
NOTE)
• Do not usually connect the connector with CN8B.
• Connect the cable of “GB-CN8" with CN8A (the lower) with the cable of servo unit.

Switch function

No. Label Function Setting Normal Note

SW1-1 UNIT-B Unit B servo control ON : enable ON
OFF : disable
SW1-2 UNIT-C Unit B servo control ON : enable OFF 0N at seven axes specification.
OFF : disable
SW1-3 HPU Debug line termination ON : enable ON When the second piece is connected, it
OFF : disable is OFF, the second piece of first piece
ON.
SW1-4 HPU- Highly effective P.U . ON : enable OFF
ERR error mask OFF : disable
SW1-5 HPU-MC MSON signal ON : enable ON
termination OFF : disable
SW1-6 Unused - OFF

LED function

No. Label Color Lighting condition

D26 RUN-A Green CPU-A Normal operation
D27 RUN-B Green CPU-B Normal operation
D28 RUN-C Green CPU-C Normal operation
D36 ERR-A Red Unit-A Abnormal
D37 ERR-B Red Unit-B Abnormal
D38 ERR-C Red Unit-C Abnormal
D39 MSON Green MS ON
D40 RGSO Green RGSO ON
D41 BRAKE Green Brake releases

Check pin

No. Label
TP1 BR24G Motor brake power supply GND
TP2 BR24V Motor brake power supply +24V
TP3 RUN_A State of CPU-A operation
TP4 RUN_B State of CPU-B operation
TP5 RUN_C State of CPU-C operation
TP6 GND Control power supply GND
TP7 VCC Control power supply VCC
TP8 -12V Control power supply -12V
TP9 +12V Control power supply +12V

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-15

 3. DESCRIPTIONS

1GB
Block Diagram
CH1
command line
HIC Current feedback
CPU-A 1GMb'd CN
RS485 Overcurrent
(JT1,2,3) I/V Conversion 9
detection
Overcurrent
error

Gate Array Encoder

Encoder I/F
A RS485
CN
SRAM 2
Encoder
Battery alarm

MSON
SVER.
Servo_control Jt2,3 PWM_signals CN
IPM_error 12

Jt1 PWM_signals
IPM_error
CN
PU_error
13
MSON(delay)

Brake
CN Motor thermal
6
Brake drive
circuit
To manual brake BOX
CN
5
CH2
Commnd_line
HIC Current feedback
CPU-B 1GMb'd CN
RS485 Overcurrent
(JT4,5,6) I/V Conversion 10
detection
Overcurrent
error
C Encoder
Gate array Encoder I/F CN
N B RS485 2
1 SRAM
ERR-B

Jt4,5 PWM_signals CN
IPM_error 12

Jt6 PWM_signals CN
IPM_error 13
CH3
Commnd_line
HIC Current feedback
CPU-C 1GMb'd CN
RS485 Overcurrent
(JT7,conveyer) I/V Conversion 11
detection
Overcurrent
error

Gate array Encoder I/F CN

C RS485 2
SRAM ERR-C Encoder

CN
conveyer 3

Jt7 PWM_signals CN
IPM_error 13
CH0
Debug_line

RS485

DC24V,LS,I/O CN
2

1GB PC board Block Diagram

Fig. 3-3-2 1GB PC Board Block Diagram

3-16 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

3.4 1GM PC Board

The 1GM PC board is a board which composes an output signal interface circuit of
motor current detection sensor provided to the Power Block.
The scale of current sensor output is varied depending upon the motor specifications.
This means that the scale conversion is conducted by every motor. There for, be
careful that the 1GM PC board specification is varied depending upon the Robot
model (motor specifications).
Since the 1GM PC board has separated ID codes for different specifications,
electronically denoted by the resistance jumper as shown in the diagram bellow.

NOTE
This ID code Is changed by the software as the control power
source is turned on.
Therefore, when the combination of the software for the 1GB
PC board and the 1GM PC board is incorrect, error messages
will be generated.

1GM PC Board

R R R R R R R R
1585 8
9 10 1
11 12 13 14 15
2

Item Number ID

ID CODE EXAMPLE
MSB LSB
0 1 0 0 0 0 0 1 Jumper with
Resistor
4 1

ID code = 41Hex.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-17

 3. DESCRIPTIONS

3.5 POWER BLOCK

3.5.1 1GC/1GD PC Board

The POWER BLOCK is installed in the SERVO UNIT.

The outline function is described in the following.

(1) POWER UNIT

1) The rectification used three phase diode module. (Exclude 1HN PC Board)
2) The POWER UNIT is possessed of various protection functions.
3) The POWER UNIT controls the rushing into current prevention circuit and the
electrical discharge circuit.
(The control signal of MS is done with the servo board (1GB board).)
4) The POWER UNIT does the regeneration control.
The power device for the regenerating resistor drive uses the brake terminal of JT1
IMP (intelligent power module) in the POWER BLOCK (1GC board).
The power device for the regenerating resistor drive uses the FET in the POWER
BLOCK (1GD board).
The regeneration specification
Specification Beginning volt End volt
Large P/B 1GC board 390 355
Small P/B 1GD board 390 365
C70 1HN board 390 365

(2) AMPLIFIER
1) The AMPLIFIER receives the PWM signal from the servo board (1GB board),
amplifies, and drives the AC SERVO MOTOR.
2) The power device of the AMPLIFIER adopts IPM. ( Intelligent Power module)
3) A current output type current sensor is adopted as a detector of the AMPLIFIER.
4) The AMPLIFIER has various protection functions. Refer to the another
paragraph for details.
When the POWER BLOCK which breaks down is exchanged, you does not exchange
POWER BLOCK for in the POWER BLOCK unit. You becomes an exchange with
SERVO UNIT.

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 3. DESCRIPTIONS

PB
Block diagram
(1) Large POWER BLOCK (1GC board )

R P4 RUSH P THE INCREASE

AC DIODE CURRENT
S PROTECT &
REGENERATING
200V MODULE REGENERATIN
T N DISCHARGE N G RESISTOR TH RESISTOR UNIT
CIRCUIT

P1 B

TO MS ON MS DRIVE VOLTAGE
MONITORING
SER MS OPERATION ACROSS P-N
MS OPERATION
CONFIRMATION CONFIRNATION REGENERATION
VO
SIGNAL
BOA ERROR SIGNAL

RD
U
+12V +15V CD
HIC IPM
V AC SERVO
PWM JT1 CD
W MOTOR

IPM ERR

CURRENT FEEDBACK

N P

U
+12V +15V CD
HIC IPM
V AC SERVO
PWM JT1 CD
W MOTOR

IPM ERR

CURRENT FEEDBACK

1GC PC BOARD

POWER BLOCK

Large Power Block Diagram

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-19

 3. DESCRIPTIONS

PB
(2) Small POWER BLOCK (1GD board )

R P4 RUSH P
AC DIODE CURRENT
S PROTECT &
200V MODULE REGENERATIN
T N DISCHARGE N G RESISTOR TH FAN
CIRCUIT

P1 B

TO MS ON MS DRIVE VOLTAGE
MONITORING
SER MS OPERATION ACROSS P-N
MS OPERATION
CONFIRMATION CONFIRNATION REGENERATION
VO
SIGNAL
ERROR SIGNAL
BOA
RD +24V
U
+12V +15V CD
HIC IPM
V AC SERVO
PWM JT1 CD
W MOTOR

IPM ERR

CURRENT FEEDBACK

N P

+12V
U
+15V CD
HIC IPM
V AC SERVO
PWM JT1 CD
W MOTOR

IPM ERR

CURRENT FEEDBACK

1GD PC BOARD

POWER BLOCK

Small Power Block Diagram

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 3. DESCRIPTIONS

PB
About the error detection of the POWER BLOCK

ERROR ERROR 1GB DETCT ERROR

CONTENT OF
DETECTION LEVEL PROCE RESET UNIT ION No.
ERROR SSSING No. PART
LVEL

P/B IPM ERROR Error which power module (IPM) on P/B detects. There CONTROL

are overcurrent protection, short-circuit current A2 POWER OFF A,B,C P/B -1559

protection, overheating protection, and a control voltage

decrease.
REGENERATIVE When the regeneration continues for six seconds or POSSIBLE
POWER OVER more. The connection between 1GB boards CN13 <-> C A P/B -1567
TIME/B IPM
1GC/1GD- CN9 is abnormal.
ERROR
REGENERATIVE When thermal (140degC) connected with the After
RESISTOR regenerative resistor operates. At the increase C recovering A P/B -1570
OVERHEAT or from the
regenerative resistor unit set up. When thermal (90deg)
DISCONNECT error, it is
heat sink , thermal (140deg) resistor of the regenerative possible.
resistor operate.
In wiring, the connection between 1GB board CN13 <->
1GC/1GD-CN9 and between 1GC/1GD-CN11 <-> thermal
are abnormal. At the increase regenerative resistor unit
set up. The connection between 1GC-CN21 <-> 1GJ -
thermal are abnormal.

ERROR PROCESSING LEVEL

A1: Abnormality by which robot controller might be momentarily damaged : 1GB PC
board stops the PWM instruction of the error axis by hardware at once.
Afterwards, the motor power is cut and the brake of 1GB PC board.
A2: Abnormality by which robot controller might be momentarily damaged : Output
stop by IPM of error axis. The IPM error is received and the PWM instruction of
the error generation axis with hardware is stopped. Afterwards the motor power
is cut and the brake of 1GB PC board.
B: Abnormality by which robot controller might not be momentarily damaged : The
motor power is cut and the brake of 1GB PC board.
C: Abnormality by which robot controller might not be momentarily damaged : Error
processing with the servo software/the AS software.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-21

 3. DESCRIPTIONS

PB

1PM ERROR
ITEM DETECTION PART CONTENT
1GC PC board 1GD PC board NOTE
IPM RATINGS ERROR LEVEL IPM RATINGS ERROR LEVEL

OVER IPM OUTPUT JT1~3 210A o-p 39A o-p min

150 30
CURRENT JT4~6 65A o-p 18A o-p
50 15
TRIP LEVEL JT7 39A o-p 39A o-p
30 30
JT1 IPM BRAKE
BRAKE PART 65A o-p - - - - - -
SHORT IPM OUTPUT JT1~3 420A o-p 80A o-p typ
150 30
CIRCUIT JT4~6 132A o-p 39A o-p
50 15
TRIP LEVEL JT7 80A o-p 80A o-p
30 30
JT1 IPM BRAKE
BRAKE PART 132A o-p - - - - - -
OVER TEMP. IPM BASE-PLATE TEMPERATURE 110 degC or more 110 degC or more
- - - - - -
UNDER VOLT IPM POWER SUPPLY (DC+15v) 12.5v or less 12.5v or less
- - - - - -

•I CAUTION
Attention on handling
• Please confirm the voltage is 0V between power units
P-N after the control power supply is turned off when
working and one minute or more passes because there
is a charge part in the power supply.
• Please mistake neither kind of 1GB board nor the
model of the correspondence of the number of axes
etc. when you exchange the SERVO UNIT.
• Please wire to agree to the terminal stand name and
connector No. the cable mark for the connector and the
cable.

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 3. DESCRIPTIONS

PB
Externals chart
(1) Large POWER BLOCK (1GC board )

R S T CN12 CN21
CN11
D.B CN10
CN20 GB-CN11
+ -

P P1
N CN7
B

U
W

V CN6
V
CN1

W
U

C
N
W 9 U

V CN5 REGENERATING REGENERATING

CN2 V RESISTOR RESISTOR
W
U

‚P‚f‚bboard
U
W
N P

V CN4
CN3 C V
N
U 8 W

FG HEAT SINK

THE THE
GB-CN9 GB-CN10
FACE BACK
Only seven axes specification
is mounted.
LARGE POWER BLOCK
Screw hole for POWER BLOCK
(1GC board)

Fig. 3-5-1 Large Power Block Layout drawing

CN No. Content of signal The connection ahead

CN1 JT1 Current feedback from current sensor 1GB-CN9

CN2 JT2 Current feedback from current sensor ,Signal for current sensor disconnection

CN3 JT3 Current feedback from current sensor

CN4 JT4 Current feedback from current sensor 1GB-CN10

CN5 JT5 Current feedback from current sensor ,Signal for current sensor disconnection

CN6 JT6 Current feedback from current sensor

CN7 JT7 Current feedback from current sensor ,Signal for current sensor d i s1cGoBn-nCeNc1t1i o n

CN8 JT2. 3. 4. 5(1GB A2, A3, B1, B2ch) PWM, IPM ERROR 1GB-CN12

CN9 JT1. 6. 7(1GB A1, B3, C1ch) PWM .IPM ERROR ,OVER TIME OF REGENERATION 1GB-CN13
,OVER VOLTAGE ACROSS P - N,LOW VOLTAGE ACROSS P - N ,OVER HEAT OF
REGENERATING RESISTOR

CN10 SIGNAL OF MS ON MS COIL

CN11 THERMAL OF REGENERATING RESISTOR THREMAL

CN12 CONDITION SIGNAL OF MS MS SPARE CONTACT

CN20 JT7 MOTOR (U, V, W) SV-M4

CN21 FOR THE INCREASE REGENERATING RESISTOR UNIT Short-circuit plug

when unused

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-23

 3. DESCRIPTIONS

PB
(2) Small POWER BLOCK (1GD board )
GB-CN11

D.B

R CN
•| G CN CN CN
27 10 12
S •{ CN 7

N CN11 26
T

CN
C CN ‚e‚`‚m
CN 28
20 N 25
CN
9 CN
1 6

REGENERATING
RESISTOR
CN CN
21 24
CN CN
2 5

‚e‚`‚m
C
N
CN 8 CN
22 23
CN
CN
4
3

‚P‚f‚cboard HEAT SINK

THE THE
GB-CN9 GB-CN10
FACE BACK
Only seven axes specification
is mounted.
SMALL POWER BLOCK
Screw hole for POWER BLOCK
(1GD board)

Fig. 3-5-2 Small Power Block Layout Drawing

CN No. Content of signal The connection ahead

CN1 JT1 Current feedback from current sensor 1GB-CN9

CN2 JT2 Current feedback from current sensor ,Signal for current sensor disconnection

CN3 JT3 Current feedback from current sensor

CN4 JT4 Current feedback from current sensor 1GB-CN10

CN5 JT5 Current feedback from current sensor ,Signal for current sensor disconnection

CN6 JT6 Current feedback from current sensor

CN7 J T 7 C u r r e n t f e e d b a c k f r o m c u r r e n t s e n s o r , S i g n a l f o r c u r r e n t s e n s o r d1iGsBc-oCnNn1e1c t i o n

CN8 JT2. 3. 4. 5(1GB A2, A3, B1, B2ch) PWM, IPM ERROR 1GB-CN12

CN9 JT1. 6. 7(1GB A1, B3, C1ch) PWM .IPM ERROR ,OVER TIME OF 1GB-CN13
REGENERATION ,OVER VOLTAGE ACROSS P - N,LOW VOLTAGE ACROSS P - N
,OVER HEAT OF REGENERATING RESISTOR

CN10 SIGNAL OF MS ON MS COIL

CN11 THERMAL OF REGENERATING RESISTOR THERMAL

CN12 CONDITION SIGNAL OF MS MS SPARE CONTACT

CN20 JT1 MOTOR (U, V, W) SV-M1

CN21 JT2 MOTOR (U, V, W)

CN22 JT3 MOTOR (U, V, W) SV-M2

CN23 JT4 MOTOR (U, V, W) SV-M3

CN24 JT5 MOTOR (U, V, W)

CN25 JT6 MOTOR (U, V, W)

CN26 JT7 MOTOR (U, V, W) SV-M2

CN27 REGENERATING RESISTOR RESISTOR

CN28 24V FOR FAN FAN

3-24 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

3.5.2 1HN PC Board

The POWER BLOCK is installed in the SERVO UNIT.

The outline function is described in the following.

(1) POWER UNIT

1) The POWER UNIT is possessed of various protection functions.
2) The POWER UNIT controls the rushing into current prevention circuit and the
electrical discharge circuit.
(The control signal of K3 is done with the servo board (1GB board).)
3) The POWER UNIT does the regeneration control.
The power device for the regenerating resistor drive uses the FET in the POWER
BLOCK.
Regenerative specification
SPECIFICATION BEGINNING VOLT END VOLT

1HN BOARD 390 365

(2) AMPLIFIER
1) The AMPLIFIER receives the PWM signal from the servo board (1GB board),
amplifies, and drives the AC SERVO MOTOR.
2) The power device of the AMPLIFIER adopts IPM. ( Intelligent Power module)
3) A current output type current sensor is adopted as a detector of the AMPLIFIER.
4) The AMPLIFIER has various protection functions. Refer to the another
paragraph for details.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-25

 3. DESCRIPTIONS

1HN
Block diagram

‚o
RUSH
‚q
CURRENT
AC DIODE
PROTECT & REGENERATING
200V MODULE DISCHARGE TH FAN
RESISTOR
‚m
‚s CIRCUIT
‚o‚P•@•@‚a

K3 ON K3 DRIVE
VOLTAGE
K3 OPERATION K3 OPERATION MONITORING
CONFIRMATION CONFIRMATION ACROSS P-N REGENERATION
REGENERATI
DRIVE CIRCUIT
ERROR SIGNAL ON DRIVE
TO SERVO BOARD

+24V

‚t
CD
+12V +15V
‚u ‚`‚b SERVO
PWM IPM
HIC MOTOR
JT1•`7 ‚v
IPM ERR

CURRENT FEEDBACK

1HN board

•I CAUTION
l The power supply part includes the charge part. Therefore, one minute or more must
passed since turned off the control power supply, and confirm the voltage is 0V while P-N
the power supply part. And, work.
l Mistake neither kind of 1GB board nor the number etc. of axes when you exchange the
servo amplifier.

3-26 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

1HN
About the error detection of the POWER BLOCK

ERROR ERROR 1GB DETCTION AS

CONTENT OF
ERROR
DETECTION LEVEL PROCESSSIN
G LVEL
RESET UNIT
No.
PART ERROR
No.

P/B IPM Error which power module (IPM) on P/B detects. There are CONTROL
overcurrent protection, short-circuit current protection, overheating A2 POWER A,B, P/B -1559
ERROR OFF
protection, and a control voltage decrease.
C
REGENERATIV When the regeneration continues for 6 seconds or more. POSSIBL
E POWER The connection between 1GB boards CN13 <-> 1HN- CN13 is C E A P/B -1567
OVER TIME/B abnormal.
IPM ERROR
REGENERATIV When thermal (140degC) connected with the regenerative resistor After
E RESISTOR operates. At the increase regenerative resistor unit set up. When C recoverin A P/B -1570
OVERHEAT or thermal (70deg) heat sink , thermal (140deg) resistor of the g from
DISCONNECT regenerative resistor operate. the error,
it is
In wiring, the connection between 1GB board CN13 <-> 1HN-CN3
possible.
and between 1HN-CN14 <-> thermal are abnormal. At the increase
regenerative resistor unit set up. The connection between 1HN-CN8
<-> thermal are abnormal.
VOLTAGE of The voltage across P-N detect with DC60V or less. In wiring, the POSSIBL
P-N is LOW connection between 1GB board CN13 <-> 1HN board CN13 is C E A P/B -1568
abnormal. (However it is assumed to make an error only at servo
ON time.)
VOLTAGE of The voltage across P-N detect with DC410V or more. In wiring, the POSSIBL
P-N is HIGH connection between 1GB board CN13 <-> 1HN board CN13 is C E A P/B -1569
abnormal.

ERROR PROCESSING LEVEL

A1: Abnormality by which robot controller might be momentarily damaged : 1GB PC
board stops the PWM instruction of the error axis by hardware at once.
Afterwards, the motor power is cut and the brake of 1GB PC board.
A2: Abnormality by which robot controller might be momentarily damaged : Output stop
by IPM of error axis. The IPM error is received and the PWM instruction of the error
generation axis with hardware is stopped. Afterwards the motor power is cut and the
brake of 1GB PC board.
B: Abnormality by which robot controller might not be momentarily damaged : The
motor power is cut and the brake of 1GB PC board.
C: Abnormality by which robot controller might not be momentarily damaged : Error
processing with the servo software/the AS software.
IPM ERROR
ITEM DETECTION PART 1HN BOARD
IPM RATINGS ERROR LEVEL
OVER CURRENT IPM output JT1(3 15 39A o-p Min
TRIP LEVEL
JT4∼6 15 39A o-p
JT7 15 39A o-p
OVER TEMP. IPM Base plate Temperature 110°C or more
UNDER VOLT IPM POWER SUPPLY (+15VDC) 12. 5V OR LESS

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-27

 3. DESCRIPTIONS

1HN
Externals chart

CN7

CN11 CN9
CN14
CNCS7
CNCS1

CN6
CN13 FAN
CN1
REGENERATE
CNCS6
CNCS2

RESISTOR
CN5

CN12
CN2
CNCS5 FAN
CNCS3

CN4

CN3
CNCS4
CN8

Connector No. Content of signal The connection ahead

CN1 JT1 Motor (U, V, W) X003
CN2 JT2 Motor (U, V, W)
CN3 JT3 Motor (U, V, W)
CN4 JT4 Motor (U, V, W) X002
CN5 JT5 Motor (U, V, W)
CN6 JT6 Motor (U, V, W)
CN7 JT7 Motor (U, V, W)
CN8 P, N Input 1HK-CN13
CN9 K3 On Signal, K3 Status Signal, Inside Controller Thermal 1HK-CN12
CN11 Regenerating resistor Regenerating resistor
CN12 JT2, 3, 4, 5(1GB A2, A3, B1, B2ch) PWM, IPM´×° 1GB-CN12
CN13 JT1, 6, 7(1GB A1, B3, C1ch) PWM, IPM Error, Over Time of 1GB-CN13
Regeneration, Over Voltage Across P-N, Low Voltage Across
P-N Over Heat of Regenerating Resistor
CN14 Thermal of Regenerating Resistor, DC24V(for Fan) Thermal of Regenerating Resistor,
Fan)
CNCS1 JT1 Current feedback (Current sensor output) 1GB-CN9
CNCS2 JT2 Current feedback (Current sensor output)
CNCS3 JT3 Current feedback (Current sensor output)
CNCS4 JT4 Current feedback (Current sensor output) 1GB-CN10
CNCS5 JT5 Current feedback (Current sensor output)
CNCS6 JT6 Current feedback (Current sensor output)
CNCS7 JT7 Current feedback (Current sensor output) 1GB-CN11

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 3. DESCRIPTIONS

3.5.3 Power block

Model correspondence
J*005 J*006 J*030 UD100 UX070 UX200 UZ100 F*02 F*06N F*10N F*20N F*10L F*30
POWER BLOCK J*010 J*040 UD150 UX100 UX300 UZ120 03 F*06L F*10E F*20L 45
J*020 UX120 UZ150 F*10C
UX150

6 axes 7 axes
50607- 50607-
1GC X X X X X X X
1082 1083
50607- 50607-
1GD X X X X X
1084 1085
50607- 50607-
1HN X
1106 1107

X: Correspondence

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-29

 3. DESCRIPTIONS

3.6 1FG PC Board (Encoder Battery Board)

The 1FG PC board is a printed circuit board housed in the Robot manipulator.
The 1FG PC board is provided with the following functions:
• +12V voltage is converted into +5V voltage, which is then applied to the applicable
encoder.
• A battery provided for the backup of encoder data is built-in.
• It detects the voltage decrease of the battery, and notice to the controller.
• Relay of signal line (axis restriction LS etc.) in main body of robot etc.

•I CAUTION
The longevity of the battery is approx. one year-half (Control
Power OFF state, Continue). This value is different in the
condition of the ambient temperature etc.

The approximate installing location and schematic figure of the 1FG PC board are
shown in Fig. 3-6-1.

How to replace the battery of the 1FG PC board with a new battery:
1. Switch OFF controller control power safely.
2. Remove the access cover from robot manipulator.
3. After disconnecting tie-band from the battery provided on the 1FG PC board.
Then dismount the battery from the PC board.
4. Set a new battery to the holder. Then fix it with the tie-band. After that, connect
the connector with the CN1.
5. Fix the once removed the access cover to Robot manipulator as it was before.

NOTE
The encoder is so designed as to maintain power even if the encoder
is disconnected from the battery.
But, in order to protect the internal data from breakage, be careful
that the battery replacement must be made at least within thirty (30)
minuets after removing the battery.

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 3. DESCRIPTIONS

1FG

CN
13

CN
12

BATTERY
CN
CN
11
8
CN
10

CN
CN
7
9
CN1 CN2 CN3 CN4 CN5 CN6

Fig. 3-6-1 1FG PC Board Layout Drawing

CN1~CN7 : Encoder line

CN1 CN2 CN3 CN4 CN5 CN6 CN7
Robot Axis Number JT1 JT2 JT3 JT4 JT5 JT6 JT7
Servo board Channel 1GB board A-1 A-2 A-3 B-1 B-2 B-3 C-1
Conveyer Axis Number Conveyer
Servo board Channel 1GB board C-2

CN8 : From the controller (+12V, ENC Signal, LS1, LS2, Battery alarm etc.)
CN9 : For built-in I/0 board (current Not used) (SIG1~4, 24V for I/O etc.)
CN10 : Battery connect
CN11~13 :For Axis restriction Limit switch connect (Refer to below figure)

Short-circuit
CN11 CN12 CN13 connector

1 2 3 4 1 2 3 4 1 2 3 4

LS1+ LS2+ LS1- LS2-

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-31

 3. DESCRIPTIONS

1FG
Block diagram

Battery Alarm Battery Voltage Battery

CN10
Monitoring Circuit (3.6V)

+12V DC-DC +5V +5V/Baattery

Encoder Power Supply
Converter Changing Circuit

JT1 Encoder Signal CN1

JT2 Encoder Signal CN2

JT3 Encoder Signal CN3

JT4 Encoder Signal CN4

C
N JT5 Encoder Signal CN5
8

JT6 Encoder Signal CN6

JT7 Encoder Signal CN7

Sensor Signal, 24Vdc for I/O

CN9

Limit Switch
CN11

CN12

CN13

3-32 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

3.7 1HG PC Board (Encoder Battery Board)

The 1HG PC board is a printed circuit board housed in the Robot manipulator.
The 1HG PC board is provided with the following functions:
• When controller's power supply is ON, +12V voltage is converted into +5V voltage,
which is then applied to the applicable encoder.
• When controller's power supply is OFF, do the switch of the power supply supplied to
the encoder to the battery power supply to maintain the location data in the encoder.
• Detects the voltage decrease of the battery.

•I CAUTION
The longevity of the battery is approx. one year-half (Control
Power OFF state, Continue). This value is different in the
condition of the ambient temperature etc.

How to replace the battery of the 1HG PC board with a new battery:
1. Be previous by which replaces the battery and record the encoder value.
2. Switch OFF controller control power safely. Remove the access cover from robot
manipulator.
3. After disconnecting tie-band from the battery provided on the 1HG PC board.
Then disconnect connector CN4, and dismount the battery.
4. Set a new battery to the holder. Then fix it with the tie-band. After that, connect
the connector with the CN4.
5. Fix the once removed the access cover to Robot manipulator as it was before.
Switch ON controller control power, and check whether to change the encoder value.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-33

 3. DESCRIPTIONS

1HG
Block diagram

CN4

N
DC-DC Converter
3

CN1 CN2

Battery Battery Voltage Battery

CN4 (3.6V)
Minotoring Circuit

+12V DC-DC +5V +5V/Battery

C Converter Changing Circuit Encoder Power Supply JT1•` 6
CN3
N
1

JT7
JT7 Encoder Signal CN2

Connector No. The connection ahead Content

CN1 Controller +12V, JT7Encoder signal, Battery

Arm
CN2 JT7 Controller JT7Encoder signal, Power supply
CN3 JT1•`JT6 Encoder Encoder power supply
CN4 Battery Battery power supply

3-34 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

3.8 1GW/1HW PC Board

The 1GW/1HW PC board is the parallel I/O board, 32 channels input and 32
channels outputs. As for 1GW and 1HW board, the polarity of the Common terminal
is opposite.

I/O specification
Board Name General-purpose 32 General-purpose Note
Channels Input Output 32 Channels
1GW b’d + Common - Common (sink type) North-American
1HW b’d - Common + Common (source type) Europe

Input specification
Number of input channels 32
Input system Photo coupler
Ratings input voltage DC24V
Range of input voltage DC24V +/- 10%
Ratings input current 10mA
Maximum input channels 100% (16channel/common)
Turning on simultaneously
Common system 16 channels/common
sensor line is 4 channels/common

Output specification
Number of output channels 32
Output system Photo coupler insulate transistor array
Ratings load voltage DC24V
The maximum load current 0.1A/channel (1.6A/common)
The maximum rushing into current 0.4A/channnel
Maximum output channels 100% (16channel/common)
Turning on simultaneously
Common system 16 channels/common
Valve line is 4 channels/common

• The 1GW/1HW PC boards can be used up to four. However, The number of piece
for which the 1GW/1HW PC board can be used might be limited by the use state
of other option boards. (the number of option slots of card rack is six slots)
• When I/O is connected, it is necessary to prepare the power supply of DC24V
• You can allocate 8 points in the output 32 points in the robot built-in valve. Moreover,
you can allocate 4 points in the input 32 points in the robot built-in sensor. However,
supplies DC24V from inside controllers and drives a built-in sensor/valve line.
Therefore, External need not supply DC24V. Moreover, supplies DC24V from inside
controllers and drives the sensor/the valve line. Therefore, External need not supply
DC24V. Moreover, cannot do the separation of the power supply for the sensor line
and the valve line.
Refer to the solenoid value/sensor internal wiring diagram of “INSTALLATION AND
CONNECTION = CONTROLLER =” of the separate volume for wiring to the sensor/valve
line built-in of the robot.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-35

 3. DESCRIPTIONS

1GW/1HW
Block diagram

Output Reset
Circuit OUT 1~8,17~32
Transistor
C
VME I/F Array for
P N
a:16/d:16 Output
1 2
32 Outputs
OUT9~16
JP
SOL 1~7

Valve Sig.

C
N
3

Sensor Sig.

SIG 1~4
IN13~16
JP
Photo C
Coupler
N
for Input IN1~12,17~32 4
32 Inputs

Fig. 3-7-1 1GW/1HW PC Board Block Diagram

3-36 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

1GW/1HW
l Wiring Diagram
1GW : Output

1GW : Input

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-37

 3. DESCRIPTIONS

1GW/1HW
1HW : Output

1HW : Input

3-38 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

1GW/1HW
l 1GW/1HW Board Pin Assignment

CN3 CN2 CN4

1 1 19 COM2
SOL1 OUT 1 (IN17∼32)
9 20 37
SOL5 2 OUT17 2 NC 18 COM1
SOL2 OUT 2 (IN1∼16)
10 21 36
SOL6 3 OUT18 3 NC 17
SOL3 OUT 3 NC
11 22 35
SOL7 4 OUT19 4 IN32 16
SOL4 OUT 4 IN16
12 23 34
SOL8 5 OUT20 5 IN31 15
DC24V(Input) OUT 5 IN15
13 24 33
24G (Input) 6 OUT21 6 IN30 14
DC24V OUT 6 IN14
14 25 32
SIG3 7 OUT22 7 IN29 13
SIG1 OUT 7 IN13
15 26 31
SIG4 8 OUT23 8 IN28 12
SIG2 OUT 8 IN12
27 30
OUT24 9 IN27 11
28 OUT 9 29 IN11
OUT25 10 IN26 10
29 OUT10 28 IN10
OUT26 11 IN25 9
30 OUT11 27 IN 9
OUT27 12 IN24 8
31 OUT12 26 IN 8
OUT28 13 IN23 7
32 OUT13 25 IN 7
OUT29 14 IN22 6
33 OUT14 24 IN 6
OUT30 15 IN21 5
34 OUT15 23 IN 5
OUT31 16 IN20 4
35 OUT16 22 IN 4
OUT32 17 IN19 3
36 COM1 NC 21 IN 3
(OUT1∼16) 18 VIN1 IN18 2
20 IN 2
IN17

Note 1)The above figure shows the pin assignment of connector on PC board.
The connector model for the harness is as follows.
Connector body : CN2 DC-37S-N (JAE) or equivalent
CN4 DC-37P-N (JAE) or equivalent
Connector cover : CN2,CN4 DC19678-3(JAE) or equivalent
Connection screw: CN2 DC20419-16J(JAE) or equivalent (M2.6)
CN4 DC20419-21J(JAE) or equivalent (M2.6)
Note 2)The channel numbers of second and consecutive 1GW/1HW boards, add 32 to the
number above.

•I CAUTION
The harness connected with CN2 and CN4 must be use the harness of the
AWG 22 ∼ 24 equivalent. And harness size is diameter 7.5φ or less.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-39

 3. DESCRIPTIONS

1GW/1HW
l Connector Arrangement

Note) The output side transistor is mounted on the IC socket and is allocated as follows by each
every of the four outputs.
1GW board output transistor : TD62064BP-1 (Toshiba Corporation)
1HW board output transistor : TD62074AP (Toshiba Corporation)

Output Signal Location No. of transistor array

OUT 1-4 U3
OUT 5-8 U10
OUT 9-12 U9
OUT 13-16 U8
OUT 17-20 U12
OUT 21-24 U11
OUT 25-28 U5
OUT 28-32 U2

3-40 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

1GW/1HW
l Jumper Setting
Jumper No. Function Setting Setting usually Note
OUT 1 ∼ 8 Output A-B: Option reset All B-C short
J1 1 reset condition B-C: Standard
setting
A B C
OUT 9 ∼ 16 Output A-B: Option reset
2 1 – – – 1-8
reset condition B-C: Standard
setting 2 – – – 9-16

OUT 17 ∼ 24 Output A-B: Option reset 3 – – – 18-24

3 4 – – –
reset condition B-C: Standard 25-32
setting ON OFF

OUT 25 ∼ 32 Output A-B: Option reset RESET

4 reset condition B-C: Standard
setting
Standard : When the power is turned on and SYSTEM reset, it had reset the output.
Option reset : When the power is turned on, SYSTEM reset, and there is no access from the
Bus line during the fixed time, it had reset the output.
Jumper
No. Function I/O Address Setting Setting usually Note
Jumper for I/O 1 ∼ 32 1: Short Do not mount the
J2 address (IN1 ∼ 32) (Additionally, open) I/O board board as which
switch. (OUT1 ∼ 32) 1 – – 1-32 (T board) the I/O address is
Switches 2 – – -64 of 1 shot the same.
setting in 3 – – -96
proportion to 4 – – -128
the number of ADDR
I/O channels, ESS
and mount the
I/O board.
33 ∼ 64 2: Short
(IN33 ∼ 64) Additionally, open)
(OUT33 ∼ 64)
1 – – 1-32
2 – – -64
3 – – -96
4 – – -128
ADDR
ESS

65 ∼ 96 3: Short
(IN65 ∼ 96) Additionally, open)
(OUT65 ∼ 96)
1 – – 1-32
2 – – -64
3 – – -96
4 – – -128
ADDR
ESS

97 ∼ 128 4: Short
(IN97 ∼ 128) Additionally, open)
(OUT97 ∼ 128)
1 – – 1-32
2 – – -64
3 – – -96
4 – – -128
ADDR
ESS

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-41

 3. DESCRIPTIONS

3-42 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 3. DESCRIPTIONS

1GW/1HW

Jumpe
r Function Setting Setting usually
No.
Case output to Case output to Output to CN2
J3 Switch to which “CN2 connector” or CN2 robot built-in value
“Robot built-in valve line (CN3 line
Connector)” to output the output A B C A B C A B C
signal of OUT9∼12. OUT 9∼12 can
1 • • • 24V 1 • • • 24V 1 • • • 24V
switch only with the collectively.
2 • • • OX9 2 • • • OX9 2 • • • OX9
When you select the robot built-in
value line, the output signal of 3 • • • OX10 3 • • • OX10 3 • • • OX10

OUT9∼12 are switched respectively 4 • • • OX11 4 • • • OX11 4 • • • OX11

as follows. 5 • • • OX12 5 • • • OX12 5 • • • OX12

OUT9→SOL1, OUT10→SOL2, 6 • • • 24G 6 • • • 24G 6 • • • 24G

OUT11→SOL3, and OUT12→SOL4 CN3 CN2 CN3 CN2 CN3 CN2

SIGOUT SIGOUT SIGOUT

B-C is all short A-B is all short B-C is all short

Case output to Case output to Case output to
J4 Switch to which “CN2 connector” or CN2 robot built-in value CN2
“Robot built-in valve line (CN3 line
Connector)” to output the output A B C A B C A B C
signal of OUT13∼16. OUT 13∼16
1 • • • 24V 1 • • • 24V 1 • • • 24V
can switch only with the collectively.
2 • • • OX13 2 • • • OX13 2 • • • OX13
When you select the robot built-in
value line, the output signal of 3 • • • OX14 3 • • • OX14 3 • • • OX14

OUT13∼15 are switched 4 • • • OX15 4 • • • OX15 4 • • • OX15

respectively as follows. 5 • • • OX16 5 • • • OX16 5 • • • OX16

OUT13→SOL5, OUT14→SOL6, 6 • • • 24G 6 • • • 24G 6 • • • 24G

and OUT15→SOL7 CN3 CN2 CN3 CN2 CN3 CN2

Cannot use OUT16 and SOL8. SIGOUT SIGOUT SIGOUT

B-C is all short A-B is all short B-C is all short

Case input from Case input from Case input from
J5 Switch which of “CN4 connector” or CN4 robot built-in value CN4
“Robot built-in sensor line (CN3 line
Connector) “to input the input A B C A B C A B C
signal of IN13∼16. IN13∼16 can
1 • • • 24V 1 • • • 24V 1 • • • 24V
switch only with the collectively.
When you select the robot built-in 2 • • • WX13 2 • • • WX13 2 • • • WX13
3 • • • WX14 3 • • • WX14 3 • • • WX14
sensor line, the input signal of
IN13∼16 are switched respectively 4 • • • WX15 4 • • • WX15 4 • • • WX15

as follows. 5 • • • WX16 5 • • • WX16 5 • • • WX16

IN13→SIG1, IN14→SIG2, CN4 CN3 CN3 CN2 CN3 CN2

IN15→SIG3, and IN16→SIG4 SIGIN SIGIN SIGIN

A-B is all short B-C is all short A-B is all short

•I CAUTION
¤ The power supply for the sensor line and the value line cannot be
separated.
¤ Set each jumper J3, J4, and J5 as all respectively are the same.
¤ When the I/F board for the Arc Welding is installed on the I/O board,
cannot select the robot built-in sensor/valve line.

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 3. DESCRIPTIONS

1GW/1HW

General Purpose Input

General Purpose Output

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 3. DESCRIPTIONS

1GW/1HW
Storing in EPLD (U29) and Version displaying
File name : GW_U29B.POF
Version displaying : GW_U29B
Check sum : C36DD

Jumper setting and Dip switch setting

J1 J2 J3 J4 J5

A B C A B C
1 • • • 24V 1 • • • 24V A B C
A B C 2 • • • OX9 2 • • • OX13 1 • • • 24V

1 • • • 1-8 3 • • • OX10 3 • • • OX14 2 • • • WX13

2 • • •
1 • • 1-32 3 • • • WX14
9-16 4 • • • OX11 4 • • • OX15
2 • • -64 4 • • • WX15
3 • • • 17-24 5 • • • OX12 5 • • • OX16
3 • • -96 5 • • • WX16
4 • • • 25-32 6 • • • 24G 6 • • • 24G
4 • • -128
ON OFF CN3 CN2 CN3 CN2 CN4 CN3
ADDR
RESET ESS SIGOUT SIGOUT SIGIN

J6 J7 SW1 SW2

A B C A B C ON ON

• • • DA • • •
NO.1 NO.2
ON OFF OPT
DA OPTI/O
1 2 3 4 1 2 3 4
RESET I/O ADDRESS

DA1 0-10 0-15 ±10 UNI DA2 0-10 0-15 ±10 UNI

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 3. DESCRIPTIONS

3.9 1FS PC Board

The 1FS PC board is an option board installed in the card rack and the SLOGIC
function is achieved.
There are two kinds of the 1FS PC boards. The one that has the RI/O communication
function and the RS485 communication function and the another one that has the
communication function by Control-Net.
The 1FS PC board has neither PI/O nor an analog output (That differs from AD-
controller 's 1AS PC board). These functions can be achieved by installing the 1HW
PC board or 1GW PC board.

SW2

CN1

CN2

CN4

T T
C P P
N 04 01
5

CN3
T
T 1
P
03 P F
02
S

S1

Fig. 3-8-1 1FS PC Board Layout Drawing

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 3. DESCRIPTIONS

1FS
HARDWARE SPECIFICATION

ITEM SPECIFICATION NOTE

MPU 32bit RISC CPU

DRAM 1Mbyte (2pc X 256 X16) No backup.

EPROM 128kbyte (64k X 16) For debugging

FLASH Memory 2Mbyte (2pc X 256 X 16) System software,

Sharing SRAM 4kbyte (2k X 16) For communication

SIO For line I/F Control-Net or R-I/O Optional

SIO For welder I/F RS485 1ch. Optional

System bus interface VME bus Interface Master/Slave

ACFAIL
H/W Interrupt Watch Dog Error
VME Bus Error
H/W Timer Interrupt
NAC or Control-Net Interrupt
SIO Interrupt

Watch Dog Timer Time out : 100ms

Software start condition
DIP Switch FLASH Memory write enable
Boot device select (FLASH or EPROM)

LED CPU RUN, ERROR, NAC or Control-Net status, WDT

Externals VME double-height

Consumption current : 1.5A or less
Others
Operation temperature : 0 to 70°C

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 3. DESCRIPTIONS

1FS
Block Diagram

FLASH EPROM
2MB 128kB

DRAM VME Bus

1MB Interface P1
DIP
SW MPU SRAM
4kB

SIO Interrupt
WAG
Controller
O

8pin
NA.Chip Timer
& PIO
BNC

C-Net P2
BNC Controller

FLASH
64kB

Fig. 3-8-2 1FS PC Board Block Diagram

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 3. DESCRIPTIONS

1FS
DIP Switches
S1

BIT FUNCTION Standard

setting
1 Software start condition Refer to the table below. OFF
2 OFF
3 FLASH-Memory write enable ON : ENABLE ON
4 Boot device select ON : EPROM, OFF : FLASH OFF
5 Unused - OFF
6 Unused - OFF
7 Unused - OFF
8 Local reset ON : RESET OFF

Software start condition 1 2

Normal OFF OFF
System software down-load ON OFF

LEDs

LOCATION COLOR FUNCTION

LD5 GREEN CPU RUN Normal : blinks at about 1.2sec cycle.
LD4 RED ERROR Normal : off, Abnormal : on
LD3 GREEN C-NET STATUS Normal : on
LD2 RED C-NET ERROR Normal : off, Abnormal : on
LD1 GREEN R-I/O STATUS Normal : on
LD101 RED WATCH DOG TIMER Normal : off, Abnormal : on

Connector Pin Assignment

CN3
BIT SIGNAL
1 R-I/O BLUE WIRE
2 R-I/O CLEAR WIRE
3 R-I/O SHIELD
4 CHASSIS GROUND (FG)
5 N.C.
6 RS485 SIGNAL GROUND
7 RS485 SD+
8 RS485 SD-

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 3. DESCRIPTIONS

3.10 1HZ PC Board (Mother Board)

CN1

CN
2 CN3

C CN
N4 5 S68 S67 S6T S5 S4 S3 S2 S1 S15

S13 S11 S10 S9

CN7

C
N
8

C8 C9
1HZ-50
CN1

Fig 3-9-1 1HZ PC Board Layout Drawing

Parts/Harnesses connected to 1HZ PC board are shown below.

HZ-CN1 Battery(for backup of 1HA/1GA PC board)

HZ-CN2 DC power supply(+5VDC,+12VDC,-12VDC,GND) harness to 1GB PC board

DC power supply(+12VDC, GND) of Encoder harness(to 1FG PC board through
HZ-CN3
Harness-Assy-Separate)

HZ-CN4 Signal(between 1HA/1GA PC board & 1GB PC board) harness to 1GB PC

board
HZ-CN5,6,7
for External Axes
(optional)
built-in signal(Sig-1, Sig-2, Sig-3, Sig-4) harness to 1GW/1HW PC board(CN9
HZ-CN8,9
is optional: Double Arms)

HZ-CN10 DC supply(+24V, +24G) harness to 1HY PC board

Table 3.7.1 shows positions each board can be placed.

1HP slot 6 slot 5 slot 4 slot 3 slot 2 slot 1 1HA/1 AVR

GA
AVR X
1HA/1GA X
1HA/1GA(opt) X
1HP X
1HP(opt) X
1FS X X X
1GW/1HW X X X X X X
option board X X X X X X

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 3. DESCRIPTIONS

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-51

 3. DESCRIPTIONS

3.11 1HP PC Board

LS ORD SW

MPWON
SVCN +12V
-12V
SVERR
+24V
ERR

CN1(L
OWER
DSW1
)
CN2(U
PPER)

F2

CN3(L
OWER
)
CN4(U
PPER) JP1

TP
F3
TP
F1

Fig. 3-10-1 1HP PC Board Layout Drawing

Connection to User Interface(include Safety Circuit)…HP-CN1

Harness from HP-CN1 to TB2(Terminal Blocks for USER)
Connection to Operation Panel…HP-CN2
Connection to 1HY b’d…HP-CN3
Connection to MFP…HP-CN4

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 3. DESCRIPTIONS

1HP
Dip SW (DSW1) set up
1 2 3 4
1HP b’d(standard) ON ON ON OFF
1HP b’d(option) ON ON OFF OFF

Jumper(JP1)
setting
standard 1-2 & 4-5 short
Double Arm 2-3 & 5-6 short

Jumper(JP2)
Specifications setting
6 axes arm & no External axis (No.1 1HP) 1A-2A & 1B-2B short
1-6 External axes(No.2 1HP)
7 axes arm & no External axis(No.1 1HP) 2A-3A & 2B-3B short
6 axes arm & 1-3 External axes(No.1 1HP)
7-9 External axes(No.2 1HP)
6 axes arm & 4-6 External axes(No.1 1HP) 3A-4A & 3B-4B short
7 axes arm & 1-3 External axes(No.1 1HP)
Double 6 axes arms & no External axis(No.1 1HP)
10-12 External axes(No.2 1HP)
Test Pins
+24V(TP1) & +24G(TP1G)
Fuses

Location Capacity KHI P/N Type Maker Used location Caution when
No. exchanging
F1, F3 0.3A 60570- DM03 DAITO Connect location to Confirm the connect
1071 TSUSHIN +24V of the Emergency Stop
Emergency Stop circuit.
circuit. The fuse (Especially, user
melts and cuts off connect part.)
when the
Emergency Stop
circuit is a line-to-
ground-fault.
F2 1A 60570- DM10 DAITO Supply part in +24V Confirm the wiring for
1051 TSUSHIN power for inside the inside machine
machine sensor/value.
sensor/value.

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 3. DESCRIPTIONS

1HP
Connection Between 1HP & 1HY PC Board

1HP PC Board 1HZ PC Board

R
R
S E T
E T
E S P E C C
P E
L E E A O O
S E A + + +
| L A C N N
O A C 2 2 2 2 2
S | T H | |
F T H 4 4 4 4 4
T S # # K K
T # # V V G V G
D E 1 1 1 2
2 2

FUSE

1 2 3 5 6 8 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4

XHP-CN3 XHZ-CN10

XHY-CN1
XHY-CN4
2 3 4 5 6 7 8 9 10 11 12 B5 A6 B6

+24V

CR2

CR3

CR4

24G

1HY PC Board A5 B5 A6 B6 A1 B1 A2 B2 A3 B3 A4 B4

XHY-CN3

13
K1

13
14 K2

14

Fig. 3.10.2 Interconnection Diagram Between 1HP & 1HY PC Board.

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 3. DESCRIPTIONS

3.12 1HY PC Board (Relay Board)

Brake Power In/Out(from V1, to K3 contacts and the 1GB PC board)

Distribution of 210VAC(Fan, Hour Meter, Control Power Lamp, Heat Exchanger, K3
coil)
+24V/+24G In(from 1HZ b’d)
K1 & K2 control signal In(from 1HP b’d)
K1 & K2 coil power Out
K1 & K2 condition signal In(from K1 & K2 contacts)

CN1 CN3

CN10
CN
CN2

CN9

CN8

CR2 CR3 CR4

CR1
CN7

CN6
LD1

CN5

1HY-3x
LD2 LD3 LD4

Fig. 3-11-1 1HY PC Board Layout Drawing

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 3. DESCRIPTIONS

1HY
Jumper(R5) setting
R5 open(standard): Hour Meter runs during MOTOR POWER ON.
R5 short: Hour Meter runs during CONTROL POWER ON

LEDs
LD1 is on while all EMERGENCY STOP Switches are released.
LD2∼4 are on as below during MOTOR POWER ON. While MOTOR POWER is off,
all LED is off.

North America Spec. Europe Spec.

Teach Mode Repeat Mode Teach/Repeat Mode

LD2 - on on
LD3 on on on
LD4 on - -

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 3. DESCRIPTIONS

3.13 1HJ PC Board (C70 exclusive use motherboard)

The card file is rack which mounts the printed-circuit board which controls the robot, and it is
composed of the following parts.
Main body of rack which supports printed-circuit board
Motherboard (1HJ board) which connects supply of power supply to printed-circuit board
and signal while printed-circuit board

The card file of C70 controller installs the printed-circuit board and AVR as shown in the figure
below.

1GA b'd 1HP b'd Option Option Option

AVR (Power
(Main) Sequence) Slot1 Slot2 Slot3

Battery

Card File

The battery for the backup of memory of 1HA/1GA board is installed on the card rack side.

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 3. DESCRIPTIONS

1HJ
Connector, Jumper

S1 S2 S3 S4 S5

JP2
S7
S11 S6 S8 S9 S10 2

CN6
CN7 CN5

CN3 CN4 CN1,2

Connector No. Function Connect destination

CN1 Servo board (1GB) connect 1GB board
CN2 Servo board connect 1GB board (the second piece) or 1 axis
amplifier
CN3 Servo board power supply
CN4 FDD power supply FDD, 1HF board.
CN5 Brake power supply (24V) 1HK board
CN6 Battery Battery
CN7 Inside machine IO connect 1GW/1HW, The separation harness
S1∼5 VME bus 1HA/1GA, 1HP and 1GW/1HW other option VME
board
S6 Teach Pendant, servo board communication 1HA/1GA,1HJS7
line
S7 Teach Pendant, servo board communication 1HP,1HJS6
line, limit switch, signal
S8∼10 Power supply for option board Option board
S11 Power supply connect AVR

Jumper function
Jumper No. Function
JP1∼P21 For VME bus daisy chain
JP22 For FG-24G connect

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 3. DESCRIPTIONS

3.14 1HK PC Board (C70 exclusive use relay board)

1HK board is a printed-circuit board installed in the controller (card rack the under), and it has
the following functions.
• When the control power is turned on, it supplies the power supply to the fan among
controllers etc.
• Drives magnetic contactor at Motor Power ON, and supplies the PN power supply.
• Supplies the brake power supply.
The glass tube fuse is installed on 1HK board. (Refer to details the power supply circuit
diagram)
CN8
HEAT
DIODE
SINK F1
TP4 BRIDGE
RS3 N RS4
DB1 HS1
CN3
TP3 K3 K2
PX
SURGE
RS2 RS1
KILLER CN4
TP5
P
LD1 K1 ON
LD2 K2 ON SK1
CN15A,B LD1 LD2 LD3 LD4 CN5
LD3 K3,4 ON
LD4 K5 ON
K1
TP6 24G-HP TP2 T
P CN6
CN15 K4 CN16
TP1 R
CN10A,B
TP7 24V-HP CN7
CN12 P
K5 CN14
CN1 CN2
CN11 CN9

The connection ahead of connector

Connector No. Connect destination Main content of signal
CN1 Circuit protector CP1 Control power input (AC200-240V)
CN2 AVR Power (AC200-240V)
CN3-CN5 Fan for cooling in board Power (AC200-240V)
CN6,7 Reserve (Not used) Power (AC200-240V)
CN8 Hour meter, Control power Power (AC200-240V)
lamp.
CN9 1HJ board CN7 Power for brake (DC24V)
CN10 1GB board CN4 Power for brake (DC24V)
CN11 1HP board CN1 K1,K2 drive signal, Contact signal, EMERGENCY STOP, Power
supply for MC and relay drive
CN12 1HN board CN9 K3,K4 drive signal, Contact signal, Inside controller thermal
CN13 None
CN14 Fuse (option) F1 fuse line
CN15 Inside controller thermal Thermal contact signal
CN16 1HM CN4 Power for Relay (1HM)

LED
LD No. Function Motion condition
LD1 For Motor Power ON Light at the time of K1 on
LD2 For Motor Power ON Light at the time of K2 on
LD3 For Motor Power ON Light at the time of K3, K4 on.
LD4 For EMERGENCY STOP Light at the time of releasing of EMERGENCY STOP

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 3. DESCRIPTIONS

1HK
l Block diagram
T1 Line
for Outside Fuse
CN14

AC200-240V
CN1 CN2

CN8

AC200-240V
Fuse F1 CN3
(Only T1 side)

CN4

CN5

CN6

Rush in
Resistor

CN7

Diode PN Power Supply

‚j‚P ‚j‚Q Bridge ‚j‚R CN15

Electric
Discharge
Drive Signal Resistor
Contact Signal
Contact Signal
CN16
CN11 Energency Stop
DC24V
DC24V

Drive Signal
CN12 Thermal
CN14

Brake Power Supply

Brake Power Supply
CN9 ‚j‚S ‚j‚T CN10

Power Supply for

Brake Release

l Fuse
Location Capacity KHI P/N Type Maker Used part Caution when
No. exchanging
F1 2A 60570- FGMT FUJI AC 200V system Confirm whether there
1082 250V 2A TANSHI power supply for is defective wiring
inside controller fan inside controller and
and hour meter. defective fan.

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 3. DESCRIPTIONS

3.15 1HM PC Board (C70 exclusive use panel switch board)

1HM board is a board which mounts the miscellaneous operation switch, and the switch is in
front of the controller and it is in the controller the board part.
Front view Rear view

CN3
SW1 (X206)

SW6

CN1

SW7

CN2
SW2 (X204)

SW3

SW4

CN4
SW5

SW No. Function Switch model

SW1 EMERGENCY STOP Push-button
SW2 Motor Power Push-button switch/lamp (orange)
SW3 Cycle Start Push-button switch/lamp (green)
SW4 Hold/Run switch Two selection switch
SW5 Teach/Repeat switch Selection switch with key
SW6 Error lamp Lamp (red)
SW7 Error Reset Push-button switch (yellow)

CN No. Connect destination Main signal

CN1 1HP CN1 Switch signal, Power supply for lamp
CN2(X204) External system Hardware Dedicated Signal (External
EMERGENCY STOP,
External HOLD etc. )
CN3(X206) External system Hardware Dedicated Signal (External
trigger etc.)
CN4 1HK CN16 K1, K2 contact, DC24V

* When shipping, CN2(X204) and CN3(X206) connect the jumper connector.

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 3. DESCRIPTIONS

3.16 DC Power Supply (Multi-output Switching Power Supply)

l C4X controller
There are two types of DC Power Supply, S82W-618 & S82W-619, the differences
are rated output current.

Input Output (S82W-618/S82W-619)

Rating 210VAC 50/60Hz +5VDC 2.5A/20A
Absolute Max. Rating 300VAC +12VDC 4A/10A
Range 168•`252VAC -12VDC 1.5A/3A
+24VDC 5A/5A

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 3. DESCRIPTIONS

DCP

l C70 Controller

Input Output (S82W-620)

Rating 210VAC 50/60Hz +5VDC 10A
Absolute Max. Rating 300VAC +12VDC 4A
Range 168•`252VAC -12VDC 1.5A
+24VDC 5A/

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 3. DESCRIPTIONS

DCP
Error-AC INPUT
momentary power failure
When AC input fails, error signal is output. Detection level shall be 130 to 145VAC.
When this status is continued for 20 to 30 ms from zero phase, error signal is
output.
high level
Detection level shall be 253 to 263VAC or more. When this level of input is continued
for 1 to 2s or more, error signal is output.
low level
Detection level shall be159 to 167VAC or less. When this level of input is continued
for 1 to 2s or more, error signal is output.
• When AC input is turned off as a normal operation, error detection of
momentary power failure is activated and then error signal is output.
• The output voltage is turned on again after output voltage drops to 10% of the
rated voltage or lower. However, the load condition must be as shown below.

S82W - 618 S82W - 619 S82W - 620

+5VDC 2.5 ∼ 10A 2.5∼20A 1.5 ∼ 10A
+12VDC 0 ∼ 4A 0 ∼ 10A 0 ∼ 4A
-12VDC 0 ∼ 1.5A 0 ∼ 3A 0 ∼ 1.5A
+24VDC 0 ∼ 5A 0 ∼ 5A 0 ∼ 5A

Error-DC OUTPUT
When overload or over voltage protection function is activated, DC outputs drop.

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3.17 Encoder
There are two kinds of encoders (the H20 type and the M21 type) for C
controller by the difference of the installation method to the motor. The basic
specification is the same as H20 and the M21 type.

Specifications
Electrical Specifications Optical Encoder Magnetic Encoder
Type Optical Disc Magnetic Incremental
Power 5 ± 0.25V 3.6V or more
Current Consumption 180mA 25µA(30µA•)j
13
Resolution 2 / rev = 8192 rev 1 count / rev
Response 6000 rpm
Countable Rotation Time 216 times = 65,536 times
• Operating Temperature -20 ∼ +80°C
• Storing Temperature -20 ∼ +80°C°
• Humidity 95% RH or less without dew condition
• Vibration 10G,3000Hz or less
• Impact 100G,6msec or less
• Others Dust proof- water and oil resistant

(*) : M21 Encoder

Function
a) Motor rotation angle detection
The encoder data increases when the CCW direction rotates.
(seeing from the motor output axis side)
b) Communication
The position data is transmitted synchronizing with the data request signal from the
1GB PC board. (Half duplex serial communications and baud rate :1M bps)
c) Operation switch by power supply voltage
The operation is the following three kinds.
• State of non-operation : All functions stop when the power supply voltage is 3.0V
or less.
• State of backup : The rotation counter operates when the power supply voltage
3.3v or more.
• State of usual operation : All functions operate when the power supply voltage is
5.0V.
d) Backup
Even in the state to remove connector with the battery board , the rotation
counter can operate for 30 minutes with the super-capacitor.
e) Motor CS signal detection
The magnetic pole position of the motor is detected by installing the encoder in
the position where the starting point in one rotation agrees with 0 crossing point
of motor generation voltage U.

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 3. DESCRIPTIONS

Enc
f) Error detection
The error which occurs in the encoder is transmitted with the data as an alarm
signal. The detected alarm becomes an error shown in " " by three kinds of the
following through the processing of the controller side.
BUSY : "Encoder initialize error"
The scanning of absolute data is begun from the state of the non-
operation and the backup in the encoder immediately after the shift to
the usual-operation. In that case, BUSY=1 is output until the data is
fixed.
ABSALM : "ABS-track error"
When the incremental counter data and absolute data are different ,
ABSALM=1 is output.(When the encoder usually works.)
INPALM : "INC-pulse error"
When the incremental pulse ƒÓA and B are abnormal,INPALM=1 is
output.
(When the encoder usually works.)

Difference point of H20 and M21

As for H20 and M21,the installation method to the motor is different. H20 is for a
large-scale motor. M21 is for a small-scale motor. H20 can be separated with the
motor but M21 cannot be separated.

Block Diagram

Main Board

ASIC-2

Amplifier Rotation Power supply

counter circuit
Backup and usual
operation Capacitor
MR LED Voltage watch
sensor Operation
Only usual sate switch
operation

ASIC-1
Rotor magnet
Incremental Vcc
data 0V
Initial SD
value /SD

Absolute
data
Disc φA,B Amp
ABS
Communication
circuit
Control signals Error detect RS-485
Communication
Sensor Board

Fig. 3-13-1 Encoder Block Diagram

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3.18 Multi-Function Panel (MFP)

The Multi-Function Panel is connected by C controller. and it is thing to put function
of Teach Pendant in AD controller and Separate operation panel and there is
undermentioned characteristic
l Various information and state display by color LCD
l Key input function with color LCD part touch panel
l The SAVE/LOAD function with the PC card.
Besides this, the small Teach pendant type used as AD + controller can be used for
C controller.

The specification of the Multi-Function Panel is shown in the following.•B

Item Specification
Size 200(length)*298(wide)*55(thickness)
Weight 1200g or less .
Operation environment 0-45°C and 20-85%RH (No do be dewy).
Storing environment -20-60°C and 20-85%RH (No do be dewy).
LCD Type Graphic color STN LCD 8inch
Number of dots 640 (side)* 480 (length)
Back light Cold cathode Fluorescent Lamp
Side Light. (It is possible to turn on and off with the MFP
software)
The MFP software turns off the light by the key operation
uninput for about 10 minutes.

Contrast It is changeable because of the volume.

Longevity LCD : 50000Hr (The contrast is reduced by half)

Back light : 10000Hr (The illuminance is reduced by half.)

Touch panel Transparent electrode type
Control part MPU 32bit RISC CPU
ROM FLASH memory 4MB
EP-ROM 128KB (Only the PLCC socket is mounted.)
RAM D-RAM 1MB
PC card PCMCIA2.1 / JEIDA Ver4.2 Conforming Type 1/2
I/F RS485 Full duplex serial communication 1ch (For the
communication between the 1HA/1GA PC board)
RS232C 1ch (For debugging)
Others With built-in buzzer (It is possible to turn on and off with
the MFP software.)

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 3. DESCRIPTIONS

MFP
• Software version of AS and Multi-Function Panel software is sets.
• Therefore, please confirm the combination of the version numbers when you install
software.
• You does not operate normally when the combination of versions is different.
(In present AS software, when the combination of the version is different, the error
display is done by the Multi-Function Panel)
The PC card which can be used with the Multi-Function Panel is an undermentioned street.
P/N Type Capacity Model Maker
60851-1006 SRAM 1MB ML-1M-TB4N Hitachi Maxell Ltd.
60851-1007 SRAM 2MB ML-2M-TB4N
60851-1008 SRAM 4MB ML-4M-TB4N
SRAM 1MB MF31M1-J1DATXX Mitsubishi Electric
SRAM 2MB MF32M1-L6DATXX
SRAM 2MB LPM-S2M Logitec
60851-1013 ATA-FLASH 4MB SA4000F2SDSAA MITSUBISHI PLASTICS
ATA004M MAGIC RAM
60851-1014 ATA-FALASH 8MB SA8000F2SDSAA MITSUBISHI PLASTICS
ATA008M MAGIC RAM
SDP3B-8-101 SAN DISK
AT-8M-TE(H1) MAXELL

(PCMCIA2.1/JEIDA Ver.4.2 Conforming TYPE I/II)

Attention when PC card is used:

• Do not use the operation confirmation by C controller about PC cards of the model
other than the above-mentioned because we does not do.
Moreover, please do not install PC cards other than the PC card.
• In the use of the SRAM card on the personal computer side, there is a necessity for
building in the PC card driver. As for the PC card driver, setting and the driver are
different depending on the personal computer which uses the OS, etc. Set after
confirming the manual such as personal computers. (Obtain the PC card driver from
the personal computer maker and the OS maker, etc.)
• Use the handling of the SRAM card according to the manual of the card.
• Do not detach the card while accessing the SRAM card and do not turn off controller's
control power supply. Damage and the system data of the equipment might be
destroyed.
• The battery for the memory backup is installed on the SRAM card. Exchange the battery
regularly after confirming the battery longevity described to the manual of the card. (If
the battery of the SRAM card decreases when accessing the SRAM card when the card
is installed in the Multi-Function Panel, the message is displayed) Do not use the
SRAM card as permanent backup media of the data. Keep after copying the data onto
the floppy disk, the hard disk, and other media by the personal computer.
• Install the PC card in the Multi-Function Panel only when using .
• Shut and use the cover of the PC slot of the Multi-Function Panel usually. Moreover, do
not put the one other than the PC card in the PC slot.
• Keep the exclusive use of the attachment on the PC card usually about the PC card
encasing because it is weak to static electricity and the boast.
• When the cover of the PC card insertion entrance is shut when the installation of the
PC card is imperfect, it causes the damage of the Multi-Function Panel.

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 3. DESCRIPTIONS

MFP
Attention when Multi-Function Panel is used
• Do not operate the touch panel with the thing with sharp point such as drivers when you operate the
touch panel. This act causes the wound and damage. Use the special touch pen of the attachment
when you operate the touch panel. Use the touch panel after installing the protection seat. (When
delivering the MFP, three pieces in the protection seat are appended usually)
• Do not give a strong impact (fall etc.) to the part LCD and the main body.
• There is no Multi-Function Panel in the waterproof specification. Note water and oil, etc.
• Do not pull the MFP cable forcibly.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-69

 3. DESCRIPTIONS

MFP

Emergency Stop Switch Teach Lock Switch

Deadman Switch Deadman Switch

ON OFF

TEACH LOCK

LCD

Inlet PC Card Volume of contrast

Touch Pen

PC card slot
SW2

Fig. 3-14-1 Multi-Function Panel Layout Drawing

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 3. DESCRIPTIONS

MFP
Multi-Function Panel block diagram

Multi Function
Panel Contrast
Emergency
stop sw adjustment
Back light
CN2 power CN1
supply

CN7 CN4 CN8

LCD CN CN CN CN
22 20 5 1
1FU PC
board
1FT PC board
CN
CN
21
42 CN
2
CN JM8
41 use
CN3 debuggi
Touch Panel J1 ng
Earth
( fixes to
J2 the frame
Deadman Teach Deadman on the left
SW 1 lock SW2 of LCD)
(Left) SW (Right)

To controller T/P

Fig. 3-14-2 MFP Block Diagram

Dip switch function explanation

SW2 Function Note
1 2
OFF OFF Setting usually
ON OFF FLASH memory can be written. Only when the Multi-Function Panel software is installed.
ON ON System start-up from EPROM Don’t use

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 3-71

 3. DESCRIPTIONS

. MEMO

3-72 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 SAFETY

OVERVIEW

DESCRIPTIONS

TROUBLESHOOTING

SEPARATEžž INSIDE MACHINE HARNESS

APPENDIX

INDEX

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 4-1

 4.TROUBLESHOOTING

4.1 Control power source is not ON.

This means no activation of controller's system of Disconnect Switch of turning ON.

The following five are thought as a phenomenon.
Phenomenon 1: When disconnect switch is turned on, CB(Circuit Breaker)
trips at once.
Phenomenon 2: The control power supply lamp does not light up though
Disconnect Switch can be turned ON.
Phenomenon 3: Multi-Function Panel (or, Small T/P) is not appeared though
the control power supply lamp is lit up.
Phenomenon 4: Screen is not appeared though the backing light of Multi-
Function Panel is lit up.
Phenomenon 5: The key cannot be input though Screen of Multi-Function
Panel is appeared.
Each phenomenon is explained as follows.

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 4.TROUBLESHOOTING

Phenomenon 1: When disconnect switch is turned on, CB trips at once.

l C4X Controller
Explanation:
There is a possibility that the AC power supply line is short-circuited among
controllers.

Cause and check item.

Factor Check item
CB detected the over-current and Check the primary power supply supplied to the controller as
tripped. follows after off (Former Breaker to the controller is off).
1. Turn on CB.
2. Check below conductor with the volt meter.
R-S R - FG
R-T S - FG
S-T T - FG
Abnormality is found in parts such as the harness or
transformer among controllers if there is conducting in either.

l C70 Controller
Explanation:
As for the cause, the following item is thought.
It did trip as CB detected the over-current.
There is a possibility that the AC power supply line is short-circuited among
controllers.

Cause and check item.

Factor Check item
CB detected the over-current and Check the primary power supply supplied to the controller as
tripped. follows after off (Former Breaker to the controller is off).
1. Turn on CB.
2. Check below conductor with the volt meter.
R-T R - FG
T - FG
Abnormality is found in parts such as the harness among
controllers if there is conducting in either.

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 4.TROUBLESHOOTING

Phenomenon 2: The control power supply lamp does not light up though
Disconnect Switch can be turned ON.

l C4X Controller
Explanation:
If (disconnect switch) is turned on, the control power supply lamp is lit up.
Therefore, the following are enumerated as a cause where this phenomenon is
generated.
(1) The primary power to the controller is not supplied, or the voltage is too low.
(2) The AC power supply is not supplied to the 1HY PC board.
(3) The power supply is not supplied to the control power supply lamp.

Factor and check item:

Factor Check item
1. The primary power to the controller
is not supplied or, the voltage is too
low.
1. Abnormality of primary power. Confirm the voltage of the primary power is full of the
specification.

2. The AC power supply is not

supplied to the 1HY PC board.
1. The connector on the 1HY PC Confirm whether connector the connector of the 1HY PC
board contact is defective. board is correctly set.

2. F3 turns off in the Power supply Is F3 of the Power supply circuit turned off ?
part.

3. The power supply is not supplied to

the control power supply lamp.
1. Defective the connector of the 1. Is the connector correctly set in the connector on the 1HY
1HY PC board. PC board?

l C70 Controller
Explanation:
If CB turns on, it lights up the control power supply lamp.
Therefore, the following are thought as a cause where this phenomenon occurs.
(1) The primary power to the controller is not supplied.
(2) The AC power supply is not supplied to 1HK board.
(3) The AC power supply is not supplied to the control power supply lamp.

Cause and check item.

Factor Check item
1. The primary power to the controller is not supplied. Confirm the primary power line.
2. The AC power supply is not supplied to 1HK board. Confirm whether 1HK board CN1 is surely
connected.
3. The AC power supply is not supplied to the control Confirm whether 1HK board CN1 is surely
power supply lamp connected.

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 4.TROUBLESHOOTING

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 4-5

 4.TROUBLESHOOTING

Phenomenon 3: Multi-Function Panel is not appeared though the control

power supply lamp is lit up.

l C4X,C70 Controller
Explanation:
The control power supply lamp lights up. Therefore, the DC power supply among
controllers starts normally.
Therefore, the following are enumerated as for the cause to which Screen of Multi-
Function Panel is not appeared and the backing light is not lit up.
(1) +12V power supply to Multi-Function Panel is not supplied.
(2) Defect of Multi-Function Panel.

Factor Check item

+12V power supply to Multi Function Panel is
1.
not supplied.
1. Confirm the T/P harness is correctly connected
C70 Controller
by the controller.
1HP Board 2. Confirm the T/P harness is correctly set in Multi
Function Panel.
3. Exchange Multi-Function Panel.( include the T/P
HP-CN4
harness)
T/P
T/P Harness

2. Defect of Multi Function Panel

1. Defect of backing light for color Exchange Multi-Function Panel.
2. Defect of inverter for back light.
3. Defect of printed circuit board in Multi-
Function Panel.

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 4.TROUBLESHOOTING

Phenomenon 4: Screen is not appeared though the backing light of Multi-

Function Panel is lit up.
l C4X, C70 Controller
Explanation:
+12V power supply to Multi-Function Panel etc. is normally supplied. Therefore, the
backing light lights up.
When the power supply is turned on, Multi-Function Panel ( Small Teach Pendant
)and appears the first Screen without any relation to controller's main board
(1HA/1GA PC board).
As for the cause to which this is not appeared, the defect of Multi-Function Panel
(Small Teach Pendant) is thought.

Factor Check item

1. Defect of printed circuit board in 1. Defect of Multi-Function Panel.
Multi-Function Panel.

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 4.TROUBLESHOOTING

Phenomenon 5: The key and AS command operation cannot be input though

Screen of Multi-Function Panel is appeared.
l C4X,C70 Controller
Explanation:
Key information input by Multi Function Panel is transmitted to 1HA/1GA board by the
route like the figure below.
CN4
T/P
1HJ Board 1GA Board

1HP Board

When key information on Multi Function Panel does not reach 1HA/1GA board or data
does not reach from 1HA/1GA board to the Multi Function Panel side oppositely, it
becomes the above-mentioned phenomenon.
The following is thought as a cause.
(1) Abnormality of disconnection of communication line Multi Function Panel and
while 1HA/1GA board etc.
(2) Defect of Multi Function Panel
(3) Defect of 1HA/1GA board
(4) Defect of 1HP board
(5) Defect of 1HZ/1HJ board
Factor Check item
1. Defect of communication line
1. Defect to Multi Function Panel of T/P harness 1. Confirm the T/P harness is correctly set in Multi Function
connect Panel.
2. Defect to Operation Unit of T/P harness 1. Confirm the T/P harness is correctly set in Operation Unit.
connect
3. The connect to 1HP board connector CN4 is 1. Confirm connector 1HP-CN4 is correctly connected.
defective.
4. The installation is defective of 1HP board. 1. Confirm 1HP board is correctly set.
5. The installation is defective of 1HA/1GA 1. Confirm 1HA/1GA board is correctly set.
board.
6. Defect of T/P harness 1. Confirm whether the surface of the T/P harness includes
the wound etc.
2. Exchanged the T/P harness.
2. Defect of Multi Function Panel
1. The communication circuit is defective of the 1. Exchange Multi Function Panel.
printed-circuit board in Multi Function Panel.
3. Defect of 1HA/1GA board
1. The communication circuit is defective in 1. Exchange 1HA/1GA board.
1HA/1GA board.
4. Defect of 1HP board
1. Connector defective solder on 1. Exchange 1HP board.
communication line etc.
5. Defect of 1HZ/1HJ board
1. Connector defective solder on 1. Exchange 1HZ/1HJ board.
communication line etc.

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 4.TROUBLESHOOTING

4.2 Motor Power cannot be turned ON.

This was to have become following when MOTOR POWER Switch (push-button switch
and lamp) of the operation panel was pressed.
Phenomenon 1: The Motor Power lamp does not light up.
Phenomenon 2: The switch of the operation panel is in the state of “Run/Repeat" and
magnet conductor K1 and K2 is not turned on.
Phenomenon 3: Even if the switch of the operation panel is in the state of
“Run/Teach" and Deadman Switch of Multi-Function Panel etc. is
turned on, magnet conductor K1 and K2 is not turned on.
Each phenomenon is explained as follows.

l C4X Controller

The following either of not turning on magnet contactor K1 and K2 is thought.

(1) The above-mentioned line has been disconnected somewhere.
(2) It does not turn on Relay (STG) by making an error of software.

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 4.TROUBLESHOOTING

Factor and check item:

Factor Check item
1. The Motor Power lamp does not light up.
1. The error lamp of the operation panel Some errors occur. Confirm the content of the error with
lights up. “STATUS" Screen of Multi-Function Panel and correspond.

2. EMERGENCY STOP Switch is Confirm it is “STATUS” Screen of Multi-Function Panel and

pressed. the EMERGENCY STOP Switch is red. (Confirm red even if
error reset is pressed)
1. Confirm the EMERGENCY STOP Switch of the operation
panel.
2. Confirm the EMERGENCY STOP Switch of Multi-
Function Panel.
• Confirm the External EMERGENCY STOP Switch
line. Is not External EMERGENCY STOP Switch
pressed?
• re it performed to wire between 5 and 6, 9 and 10 of
TB2 as shown in the figure below?

TB2 TB2

5 pin 5 pin

6 pin or 6 pin

9 pin 9 pin

10pin 10pin
(Short Circuit)

When EXTERNAL When EXTERNAL

EMERGENCY STOP not used. EMERGENCY STOP used.

2 The line to K1 and K2 is abnormal. Check wiring from the operation panel.
• Is CN2 of 1HP board correctly set?
When abnormality occurs in the line until
EMERGENCY STOP Switch and 1. Are 1HP-CN3 and 1HY-CN4 correctly set at the case
restricting of the axis LS, the error which LD5 of 1HP board lights up? Moreover, confirm
appearing is done. Therefore, it does not whether there is damaging in the harness.
become appearing the error about the 2. Confirm External EMERGENCY STOP.
line such as the operation panels after 3. 1HP board is defective.
that. 4. Is not there loosening in the TP harness connector in Multi
Function Panel?
5. Is not there loosening in the connect of the Operation Unit
connector of Multi Function Panel?
6. Is not there loosening in the connect to CN4 of 1HP
board?
3 Software cannot turn on the Relay “STG”.
1. It does not accurately transmit 1. Confirm whether CN1 of 1HP board which is wiring from
information from the operation panel the operation panel to 1HP board is correctly set.
to 1HA/1GA board. 2. Defect of the 1HP board.
2. It does not accurately transmit Refer to phenomenon 6 that the control power supply does
information from Multi Function Panel not enter.
to 1HA/1GA board.

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 4.TROUBLESHOOTING

l C70 Controller
Explanation:
We shows the route by which turns on magnet contactor K1 and K2 in the outline figure
below.

The following either of not turning on magnet contactor K1 and K2 is thought.

(1) The above-mentioned line has been disconnected somewhere.
(2) It does not turn on Relay (STG) by making an error of software.

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 4.TROUBLESHOOTING

Factor and check item:

Factor Check item
1 The Motor Power lamp does not light up.

1. The error lamp of the operation panel lights Some errors occur. Confirm the content of the error with
up. “STATUS" Screen of Multi-Function Panel and correspond.
2. EMERGENCY STOP Switch is pressed. Confirm it is “STATUS" Screen of Multi-Function Panel and
the EMERGENCY STOP Switch is red. (Confirm red even if
error reset is pressed)
1. Confirm the EMERGENCY STOP Switch of the operation
panel.
2. Confirm the EMERGENCY STOP Switch of Multi-
Function Panel.
• Confirm the External EMERGENCY STOP Switch
line. Is not External EMERGENCY STOP Switch
pressed?
• Are it performed to wire for the CN2 connector 3 and
16 pin, 4 and 17pin on the 1HM PC board as shown
in the figure below?
1HM Board 1HM Board
X204 X204
3pin 3 pin
16 pin or 16 pin

4 pin 4 pin

17pin 17pin
(Short Circuit)

When EXTERNAL When EXTERNAL

EMERGENCY STOP not used. EMERGENCY STOP used.

2. The line to K1 and K2 is abnormal.

The error displaying is done at the case where Check of wiring from operation panel
• Is CN1 of 1HM board correctly set?
abnormality occurs in the line until
• Is CN2 of 1HP board correctly set?
EMERGENCY STOP and restricting the axis LS.

Therefore, it does not become an error 1. Are 1HP-CN3 and 1HK-CN11 correctly set at the case

displaying about the line of the operation panel which LD5 of 1HP board lights up? Moreover, confirm
whether there is damaging in the harness.
after that.
2. Confirm External EMERGENCY STOP.
3. 1HP board is defective.
4. Is not there loosening in the TP harness connector in
Multi Function Panel?
5. Is not there loosening in the connect of the Operation Unit
connector of Multi Function Panel?
6. Is not there loosening in the connect to CN4 of 1HP
board?

3. Software cannot turn on the Relay “STG”.

1.It does not accurately transmit information 1. Confirm whether CN1 of 1HP board which is wiring from
from the operation panel to 1HA/1GA board. the operation panel to 1HP board is correctly set.
2. Defect of 1HP board
2. It does not accurately transmit information Refer to phenomenon 6 that the control power supply does
from Multi Function Panel to 1HA/1GA board. not enter.

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 4.TROUBLESHOOTING

4.3 Robot cannot move.

Factor Check item

1. Some errors occur. Do the measure according to each error.

2. Setting the operation panel is wrong. Set the operation panel correctly.

3. The External Hold signal is input Release the External Hold signal.
(Repeat mode).

4. It becomes waiting for the condition of Release waiting for the condition.
the program in Cycle Start.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 4-13

 4.TROUBLESHOOTING

4.4 Error Code List

Code Error Message Page

-57 Set low speed because of exceeding joint max. speed in check.
-100 Matrix calculation error
-101 Turn off motor power
-102 Application is changed. Turn OFF & ON the control power.
-103 There is no external axis.
-104 Illegal positioner type.
-105 Cannot change data because user data exist.
-106 Graphic area error.
-107 Option is OFF.
-200 Cannot execute a program because motor power is OFF.
-201 Cannot execute a program in TEACH mode.
-202 Cannot execute a program because teach lock is ON.
-207 Turn to HOLD at HOLD/RUN sw
-211 Cannot edit a program because teach lock is ON.
-212 Cannot execute because executed by other device.
-213 Cannot execute a program because of EXT-IT
-300 Program is already running
-301 Robot control program is already running.
-302 Can't continue. Use EXEC.
-303 Robot is moving now.
-304 Cannot execute because in error now. Reset error.
-306 Cannot execute with DO command.
-308 PC program is running.
-314 Cannot execute because the program is already used.
-317 Position offset error at last E-stop jt
-319 Spot sequence is running.
-324 Cannot execute with MC instruction.
-325 Cannot execute MC instruction in Robot program.
-326 Cannot delete because used by another command.
-327 Used in programs.
-328 Used in editor.
-329 KILL or PCKILL to delete program.
-330 Cannot paste.
-350 Illegal input data.
-351 Too many arguments.
-353 Input data is too big.
-360 Illegal WHERE parameter.
-361 Illegal PC number.
-365 Illegal Robot number.
-366 Illegal program.
-367 Illegal priority.
-368 Invalid coordinate value
-400 Syntax error
-401 Invalid statement
-402 Ambiguous statement
-403 Cannot use this command or instruction here.
-404 Cannot execute with DO command.
-405 Statement cannot be executed.
-406 Not a program instruction.
-407 Too many arguments
-408 Missing argument
-410 Illegal expression

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 4.TROUBLESHOOTING

Code Error Message Page

-411 Illegal function
-412 Illegal argument of function
-413 Invalid variable (or program) name.
-414 Illegal variable type.
-415 Illegal array index.
-416 Missing parenthesis
-418 Illegal constant
-419 Illegal qualifier
-420 Invalid label
-421 Invalid name
-422 Missing expected character.
-423 Illegal switch name.
-424 Ambiguous switch name.
-425 Illegal format specifier.
-426 Duplicate statement label
-430 Cannot define as array.
-431 Dimension exceeds 3.
-432 Different dimensional array exist.
-433 Array variable exist.
-434 None array variable exist.
-435 Array variable expected.
-440 Local variable expected.
-441 Unexpected suffix
-442 Mismatch of arguments at subroutine call
-443 Mismatch of argument type at subroutine call
-450 Control structure error
-451 Step: xxx Wrong END statement
-452 Step: xxx Extra END statement
-453 Step: xxx Cannot terminate DO with END
-454 Step: xxx No VALUE statement after CASE
-455 Step: xxx Preceding IF missing
-456 Step: xxx Preceding CASE missing
-457 Step: xxx Preceding DO missing
-458 Step: xxx Can't find END of xxx
-459 Step: xxx Too many control structures.
-460 Variable (or program) already exists.
-461 Variable of different type already exists.
-464 Internal buffer over
-465 Undefined variable ( or program).
-466 Illegal clock value
-470 Expect '='
-471 Expect ')'
-472 Expect ']'
-473 Expect "TO"
-474 Expect "BY"
-475 Expect ':'
-476 Expect "ON/OFF"
-490 Program name not specified.
-494 Program is interlocked by another procedure.
-499 Invalid statement.
-507 Communication error
-514 Device is not ready.
-523 Illegal file name.
-525 File already exists
-543 Data read error

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 4.TROUBLESHOOTING

Code Error Message Page

-544 Floppy disk data transfer error
-545 Record inhibited. Set "record accept" and operate again.
-548 Program-change inhibited. Set "ACCEPT" and operate again.
-551 Cannot open the file
-565 RI/O board is not installed.
-580 Retry error.
-581 Stop of process.
-583 No receive data after receive request
-584 Too long receive data(MAX=255 character).
-585 Abnormal data (EOT) received in communicating.
-586 Time out.
-596 Cannot attach terminal
-597 Cannot attach communication port
-598 Cannot execute on this terminal
-599 Waiting input data for PROPT. Connect input device.
-600 Motor power OFF.
-605 PLC communication error.
-606 Weld controller #%d not connected.
-607 Weld controller #%d no response.
-608 Weld controller #%d response error.
-610 Weld completion time over.
-611 Illegal extend (retract) output signal.
-612 Weld fault input.
-613 Retract pos. monitor error.
-614 Extend pos. monitor error.
-615 Weld completion signal is already inputted.
-616 Gun retract position mismatch.
-656 No dedicated work sensing signal
-657 Already work sensing signal input.
-658 Work sensing signal is not detected.
-659 Too short distance.
-662 Start point position error for circle.
-663 MASTER robot has already existed
-664 This robot is not MASTER
-665 SLAVE robot has already existed.
-666 Interrupt in cooperative control
-667 Already in MASTER mode
-668 Already in SLAVE mode
-669 Force to quit cooperative control
-670 In cooperative mode
-671 Cannot execute in check back mode
-672 Cannot execute in ONE program
-673 Angle between JT2 and JT3 is out of range at start location
-674 Angle between JT2 and JT3 is out of range at end location
-675 Terminal is not connected.
-676 Cannot input/output to multi function panel.
-677 SOFT ABSORBER error. Turn OFF & ON the control power.
-678 Invalid coordinate value X.
-679 Invalid coordinate value Y.
-680 Invalid coordinate value Z.
-681 Illegal pallet number.
-682 Illegal goods number.
-683 Illegal pattern number.
-684 Illegal pattern type.
-685 Illegal goods data.
-686 Illegal pallet data.

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 4.TROUBLESHOOTING

Code Error Message Page

-687 CHANGE GAIN error. Turn OFF & ON the control power.
-688 EXT.AXIS mechanical parameter is not instituted
-690 Cannot use I/F panel signal.
-700 No free memory
-800 Program does not exist.
-801 No program step.
-802 Nonexistent label.
-803 Undefined variable.
-804 Undefined location data.
-805 Undefined string variable.
-807 Undefined program or label.
-808 Illegal value.
-809 Undefined array suffix.
-810 Divided by zero.
-811 Floating point overflow.
-812 Too long string
-813 Illegal exponential operation.
-814 Too complicated expression.
-815 No expressions to evaluate.
-816 Unexpected error while evaluating expression
-817 SQRT parameter is negative.
-820 Illegal array index.
-821 Illegal argument value.
-822 Illegal joint number.
-823 Illegal signal number.
-824 Illegal timer number.
-825 Illegal signal number.
-826 Illegal clamp number.
-827 Illegal time value.
-828 No value set.
-829 Illegal signal number.
-832 Illegal time input data.
-834 Program name already exists.
-835 Can't KILL because the program is running.
-837 Cannot use dedicated signal.
-838 Not RPS mode
-839 Cannot use negative number.
-840 Too many subroutines
-842 Nonexistent subroutine.
-846 No program exist.
-850 Out of absolute lower limit.
-851 Out of absolute upper limit.
-852 Out of user lower limit.
-853 Out of user upper limit.
-855 Motion start location of jt x is out of range.
-856 Motion end location of jt x is out of range.
-857 Destination is out of range.
-858 Illegal configuration for linear motion.
-871 Illegal joint number.
-872 Cannot execute motion instruction in PC program.
-873 Illegal auxiliary data number.
-874 No circular location
-875 No C1MOVE(CIR1) ins.
-876 Cannot create circle.
-896 Because option is not set up, can't execute
-909 Watch-Dog Error RS485 Special Communication board

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 4-17

 4.TROUBLESHOOTING

Code Error Message Page

-919 No RS485 Special Communication board.
-967 No AVC board.
-968 Too many taught points for AVC.
-969 Out of AVC tracking value.
-971 Out of AVC tracking capacity.
-972 AVC voltage deviation error.
-1003 Data base error. 4-19
-1011 Clock service time over.
-1012 Commanded position of jt x suddenly changed. 4-20
-1014 Commanded position of jt X is out of range. 4-21
-1017 Angle between JT2 and JT3 is out of range. 4-22
-1019 Check sum error of system data. 4-23
-1022 RAM battery low voltage <board name> 4-24
-1025 AS Flash memory sum check error 4-26
-1026 Servo Flash memory sum check error 4-27
-1028 IP board memory error.<error code>
-1029 Touch panel switch is short-circuited.
-1031 Other robot is in the interference area.
-1051 Cannot execute in this robot arm.
-1100 CPU error 4-28
-1101 Main CPU BUS error 4-29
-1102 VME BUS error 4-30
-1201 Power sequence board is not installed 4-31
-1202 No2 Power sequence board is not installed 4-32
-1203 No I/O board is not installed 4-33
-1204 Option SIO port is not installed 4-34
-1205 Power sequence board any error 4-35
-1206 Built-in sequence board is not installed.
-1208 RI/O board is not installed.
-1209 RI/O board initialize error.
-1210 INTER-BUS board is not installed.
-1211 Dual port memory to communicate is not installed.
-1247 Axis setting data is incorrect. 4-36
-1249 Servo parameter changed! Control power turn OFF & ON 4-37
-1250 Servo board ( ) initialize error 4-38
-1251 Servo board ( ) communication error 4-40
-1252 Servo board (A) hardware error. Code = 4-41
-1253 Servo board (B) hardware error. Code = 4-41
-1254 Servo board (C) hardware error. Code = 4-41
-1255 Servo board (D) hardware error. Code = 4-41
-1256 Servo board (A) software error. Code = 4-43
-1257 Servo board (B) software error. Code = 4-43
-1258 Servo board (C) software error. Code = 4-43
-1259 Servo board (D) software error. Code = 4-43
-1261 Servo board (A) parameter setting error. 4-45
-1262 EXT.AXIS cutting error.(code xx)
-1263 EXT.AXIS connecting error.(code xx)
-1300 Servo CPU( ) watch dog error 4-47
-1306 Servo board command error 4-48
-1308 Motor power off 4-49
-1333 Monitor ID of servo board mismatch! 4-50
-1334 Servo control line error. 4-51
-1336 Safety gate circuit open. 4-52

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Code Error Message Page

-1337 Two MC lines are not consistent. 4-53
-1338 K1 and/or K2 works wrong. 4-54
-1401 Amp overcurrent jt x. 4-55
-1407 Servo unit error 4-56
-1420 Current detector type (*) mismatch. 4-57
-1500 Jt x of motor overload. 4-59
-1501 Over heat or Motor harness is disconnected 4-61
-1503 Speed error jt x 4-63
-1504 Position envelope error jt x 4-64
-1511 Encoder battery low voltage [Servo( )] 4-66
-1513 Encoder rotation data abnormal jt x 4-68
-1516 Encoder data abnormal jt x 4-69
-1517 Cannot read encoder value jt 4-71
-1521 Miss match ABS and INC encoder of jt x. 4-72
-1550 Encoder initialize error jt 4-73
-1553 Encoder response error jt 4-74
-1554 Encoder communication error jt 4-75
-1555 Encoder data conversion error jt 4-76
-1556 Encoder ABS-track error jt 4-77
-1557 Encoder INC-pulse error jt 4-78
-1559 Power module error jt 4-79
-1561 Current sensor disconnect [Servo( )] 4-80
-1563 Servo unit 12VDC error [Servo( )] 4-81
-1567 Regenerative register error [Servo( )] 4-82
-1568 Servo unit P-N low voltage [Servo( )] 4-84
-1569 Servo unit P-N high voltage [Servo( )] 4-86
-1570 Regenerative resistor overheat [Servo( )] 4-87
-1600 Uncoincidence error jt x. 4-89
-1601 Limit switch of jt * is ON. 4-90
-1602 Limit switch signal line disconnected. 4-93
-1610 Torch is interfered. 4-95
-1800 AC primary power off 4-96
-1801 24VDC power source low. 4-97
-1802 Primary power source is high. 4-98
-1803 Primary power source is low. 4-99
-1804 +12VDC or -12VDC is abnormal. 4-100
-1805 Memory is locked because of AC_FAIL. 4-102
-2008 Clock service time over.

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Error code : -1003

MFP : Data base error.
Message kind : Error Manual division :Standard
Error processing : Motor OFF Error reset : Acceptable(Refer to measure)
Error Logging : YES

Content:
The editor ends. Data base (link list) information to control the teach data in user memory
when the teach data is accessed breaks.

Main cause:
• Memory is not normally backed up.
• Defect of the 1HA/1GA PC board.
• Memory error by noise etc.

Measures:
• Turn on the 1HA/1GA PC board SW2-8 promptly when this error is occurred. And, load
the teach data after initializing. (occur completely in system memory because a part of the
system data is maintained when Initializing does not initializing by “Auxiliary 100 system
initializations”, SYSINT command, .)
• Check the battery for the memory backup. And, exchange the board when the voltage
decreases.
• Exchange the 1HA/1GA PC board when the error relapses.

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Error code : -1012

MFP : Command position of jt * suddenly changed.
Message kind : Error Manual division :Standard
Error processing : Motor OFF Error reset :Acceptable
Error Logging : YES

Content:
“Command value - current value” of each Joint was calculated at Repeat mode and the
following value was exceeded.

Joint max. speed * 1.3

(The Joint max. speed is different depending on the model and Joint.)

Main cause:
• The singularity motion was caused at the robot motion.
• A defective connect etc. of the harness were causes and the robot malfunctioned.

Measure:
• Correct the teach data at the singularity motion.
• As for the malfunction, the connect mistake of the harness and abnormality etc. of the
servo system are thought.
• Check each harness and the boards.

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Error code : -1014

MFP : Command position of jt * is out of range.

Message kind : Error Manual division :Standard

Error processing : Motor OFF Error reset :Acceptable

Error Logging :YES

Content:
The command value of Joint exceeded the user set work envelope at Check, Repeat mode.

Set the user set work envelope of each Joint by “Auxiliary 51 SOFTWARE LIMIT” or ULIMIT,
LLIMIT command.
(The work envelope when the robot is shipped is set in the maximum work envelope usually)

Main cause:
• Set mistake of user set work envelope.
• When the teaching posture(contain the robot moving posture) is the vicinity of the user
set work envelope.

Measure:
• Set the user set work envelope in an appropriate value.
• Change the teaching posture.

•I CAUTION
Set the user set work envelope as becoming to the
following condition.

The maximum work envelope > Mechanical stopper > Axis restriction limit switch > User set
work envelope

(The mechanical stopper and the axis restriction limit switch are the options. The installed
axis is different according to the model and the structure of the machine.)

There is a form which describes set of each value when each model and each title machine
are shipped with in the controller or each manual. Confirm this set table.
Keep this set table importantly so as not to lose.
Keep from a set content in this set table or another form when you change a set content.

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Error code : -1017

MFP : Angle between JT2 and JT3 is out of range.
Message kind : Error Manual division :Standard
Error processing : Appearing Error reset :Acceptable
Error Logging : YES

Content:
The command value of Joint interferes mutually when 2, 3 axes of the UX, UT, UZ, series etc.
are robots of the link mechanism.

(In robots(JS series, etc.) of not link mechanisms 2, 3 axes, this error is detected)

Main cause:
• The teaching posture(including posture in move) is bad.

Measure:
• Change the teaching posture.

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Error code : -1019

MFP : Check sum error of system data.
Message kind : Error Manual division :Standard
Error processing : Motor OFF Error reset :(Refer to the measure)
Error Logging : YES

Content:
The check sum data of the system data (machine model, number of axes, and option
setting, etc.) of the AS software was rewritten for some reasons.

Main cause:
• When the AS software is exchanged, doing LOAD are normal the data file which the
system/the robot data enters when this error is occurred when setting the system/the robot
data (machine model and option) is changed.
• When this error is occurred in situations other than the above-mentioned
a) Defect of memory backup.
b) Defect etc. of the 1HA/1GA PC board.
c) Memory error by noise etc.

Measures:
• Set the error detection invalid function in the valid by “Auxiliary 78 CLEAR CHECK SUM
ERROR”, CHSUM command and do error reset.
• (CHSUM is set to turn ON the control power supply from turning OFF in “Invalid”.)

• When the error cannot do the change by executing the CHSUM command, the command
finding abnormality in the data is appeared. Again, release the error again by CHSUM
command after setting each command. (Refer to the AS LANGUAGE MANUAL and
OPERATION MANUAL.)

• Check the battery and exchange the 1HA/1GA PC board when the error cannot do the
change and the error is occurred again excluding the above-mentioned content.

Caution:
• There is a form which describes set of each value when each model and each title machine
are shipped with in the controller or each manual. Confirm this set table.
• Keep this set table importantly so as not to lose.
• Keep from a set content in this set table or another form when you change a set content.

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Error code : -1022

MFP : Ram battery low voltage.
Message kind : Warning Manual division :Standard
Error processing : Cycle stop Error reset/Possible
Error Logging : YES

Content:
The voltage of the battery for the memory backup supplied to the 1HA/1GA PC board
detected about 2.5V or less (ratings 3.6V) at control power supply ON and Motor Power ON.
(The hardware of the 1HA/1GA PC board is always observed)

Battery Mother Board Battery

Rating : 3.6V
VME Bus VME Bus VME Bus VME Bus
Connector Connector Connector Connector
C4X;XHZ-CN1
C70;XHJ-CN6

Battery Voltage
Monitor Circuit
/ Voltage Change
Circuit

Battery Lower
Signal
to AS software

Option Option Option

Board Board Board
1HA/1GA PC

Main cause:
• The battery is longevity.
• The connect is defective of the battery line.
• Defect of the 1HA/1GA PC board and battery voltage monitor circuit.
• The battery is consumed in large quantities with each board on the motherboard and the
voltage descends.
(Excludes the power sequence board.)

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Measures:
• Execute the all data saving promptly when the teaching data is maintained in memory.
• Execute the memory exchange promptly when the voltage of the battery decreases.

• Confirm each board, state of the connect of the connector, and exchange the 1HA/1GA
PC board when the voltage of the battery is normality.

• Detach each of one board (Excludes the power sequence board.) connected with the
motherboard which contains the 1HA/1GA PC board when the voltage decreases even if
you connect it with the motherboard with normal voltage of the battery unit. Exchange
the board because the board by which the voltage becomes normal is a cause.

•I CAUTION
After error reset is done, this error can be
automatic operation if the teach data is normal
(after LOAD is executed again).
This error can make the error detection an invalid
by using the Auxiliary 101 BATTERY ERROR
CHECK, BATCHK command.
(As for setting BATCHK, the control power supply
is set again in the valid by turning off )

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Error code : -1025

MFP : As flash memory sum check error
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFF à ON
Error Logging : YES

Content:
For abnormality the check sum of the AS system area in the flash memory on the 1HA/1GA
PC board when the control power supply is turned on

(The check sum data is made when the fchk command is executed and is recorded in the
flash memory at the down-load.)

Main cause:
• When the AS system was down-loaded, the fchk command was not executed.
• The addressing of the fchk command was wrong.
• The flash memory and the 1HA/1GA PC board Defective.
• The system in the flash memory damaged.

Measures:
• Confirms the content of the description the command file “as_load.cmd” file in the PC
card if immediately after down-loading the AS system. Execute down-loading again.
• Down-load the AS system again and confirm whether to occur this error.
• Exchange the 1HA/1GA PC board when this error relapses.

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Error code : -1026

MFP : Servo flash memory sum check error
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFF à ON
Error Logging : YES

Content:
For abnormality the check sum of the servo system area in the flash memory on the
1HA/1GA PC board when the control power supply is turned on

(The check sum data is made when the fchk command is executed and is recorded in the
flash memory at the down-load.)

Main cause:
• When the servo system was down-loaded, the fchk command was not executed.
• The addressing of the fchk command was wrong.
• The flash memory and the 1HA/1GA PC board Defective.
• The system in the flash memory damaged.

Measures:
• Confirms the content of the description the command file “as_load.cmd” file in the PC
card if immediately after down-loading the servo system. Execute down-loading again.
• Down-load the servo system again and confirm whether to occur this error.
• Exchange the 1HA/1GA PC board when this error relapses.

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Error code : -1100

MFP : CPU error (Code = ****)
Message kind : Error. Manual division :Standard.
Error processing : Motor OFF Error reset :Control Power OFF à ON
Error logging : YES

Content:
The CPU of the 1HA/1GA PC board stopped. (Detect with the AS software)

Main cause:
• Defect of AS software and servo software.
• Defect of hardware.
• Malfunction by noise etc.

Measure:
• Confirm whether to occur error with which board referring to the message appeared in
the terminal software by the personal computer.(This error is not appeared in Multi-
Function Panel)
Example)
Error (-1100) CPU bus error No=1.
Task (Pc01) Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=******
Occurring place.

IO BUS ERROR : Occurs error in the address on the I/O board such as 1GW/1HW.
PSB BUS ERROR : Occurs error with the power sequence board such as 1HP.
VME BUS ERROR : Occurs error with the board which uses the address on VME buses
other than the power sequence board and the I/O board.
(Which board for two or more boards such as I/O boards and the power sequence
boards which can be mounted cannot be distinguished)
• Turn ON the control power supply from turning OFF.
• At this time, LOAD again in “No” if the message of the initialization confirmation is
appeared.
• Do the teach data in LOAD again after initializing when the error does not return
normally even if this operation is done. (If Multi-Function Panel or the terminal
software by the personal computer is not State of RUN at initialization, initialization
cannot be done. (Initialization cannot be done in Small Teach Pendant alone))
• The defect of the AS system is thought if this error occurs in a certain specific part or
a certain specific operation was done when the teaching program is executed.
Therefore, report details (content of all messages, models, control models, title
machines, AS software/servo software versions, when the above-mentioned error is
occurred, situations such as program lists, and content of the option etc.) to KHI.
• Exchange the 1HA/1GA PC board etc. when reproducibility cannot be confirmed and
error cannot return normally and look at the appearance.

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Error code : -1101

MFP : Main CPU BUS error (Code = ****)
Message kind : Error Manual division :Standard
Error processing : Motor OFF Error reset :Control Power OFF à ON
Error logging : YES

Content:
In the 1HA/1GA PC board, the bus error (In the VME bus line, data processing was not able
to be done normally) was occurred.(Detect with the AS software)

Main cause:
• Defect of the 1HA/1GA PC board.
• Defect of AS software.
• Malfunction by noise etc.

Measure:
• Confirm whether to occur error with which board referring to the message appeared in the
terminal software by the personal computer.(This error is not appeared in Multi-Function
Panel)
Example)
Error (-1101) main CPU bus error No=1.
Task (Pc01)Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=******
Occurring place.

IO BUS ERROR : Occurs error in the address on the I/O board such as 1GW/1HW.
PSB BUS ERROR : Occurs error with the power sequence board such as 1HP.
VME BUS ERROR : Occurs error with the board which uses the address on VME buses
other than the power sequence board and the I/O board.
(Which board for two or more boards such as I/O boards and the power sequence boards
which can be mounted cannot be distinguished)
• Turn ON the control power supply from turning OFF.
• At this time, LOAD again in “No” if the message of the initialization confirmation is
appeared.
• Do the teach data in LOAD again after initializing when the error does not return
normally even if this operation is done. (If Multi-Function Panel or the terminal software
by the personal computer is not State of RUN at initialization, initialization cannot be
done. (Initialization cannot be done in Small Teach Pendant alone))
• The defect of the AS system is thought if this error occurs in a certain specific part or a
certain specific operation was done when the teaching program is executed.
Therefore, report details (content of all messages, models, control models, title
machines, AS software/servo software versions, when the above-mentioned error is
occurred, situations such as program lists, and content of the option etc.) to KHI.
• Exchange the 1HA/1GA PC board etc. when reproducibility cannot be confirmed and
error cannot return normally and look at the appearance.

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Error code : -1102

MFP : VME BUS error (code = ****)
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFF à ON
Error logging : YES

Content:
In the 1HA/1GA PC board, the bus error (In the VME bus line, data processing was not able
to be done normally) was occurred.(Detect with the AS software)

Main cause:
• Defect of the 1HA/1GA PC board.
• Defect of AS software.
• Malfunction by noise etc.

Measure:
• Confirm whether to occur error with which board referring to the message appeared in
the terminal software by the personal computer.(This error is not appeared in Multi-
Function Panel)
Example)
Error (-1102) VME bus error No=1.
Task (Pc01)Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=******
Occurring place.

IO BUS ERROR : Occurs error in the address on the I/O board such as 1GW/1HW.
PSB BUS ERROR : Occurs error with the power sequence board such as 1HP.
VME BUS ERROR : Occurs error with the board which uses the address on VME
buses other than the power sequence board and the I/O board.
(Which board for two or more boards such as I/O boards and the power sequence
boards which can be mounted cannot be distinguished)
• Turn ON the control power supply from turning OFF.
• At this time, LOAD again in “No” if the message of the initialization confirmation is
appeared.
• Do the teach data in LOAD again after initializing when the error does not return
normally even if this operation is done. (If Multi-Function Panel or the terminal
software by the personal computer is not State of RUN at initialization, initialization
cannot be done. (Initialization cannot be done in Small Teach Pendant alone))
• The defect of the AS system is thought if this error occurs in a certain specific part
or a certain specific operation was done when the teaching program is executed.
Therefore, report details (content of all messages, models, control models, title
machines, AS software/servo software versions, when the above-mentioned error is
occurred, situations such as program lists, and content of the option etc.) to KHI.
• Exchange the 1HA/1GA PC board etc. when reproducibility cannot be confirmed and
error cannot return normally and look at the appearance.

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Error code : -1201

MFP : Power sequence board is not installed.
Message kind : Error Manual division : Standard
Error processing : Appearing Error reset : Acceptable
Error logging : YES

Content:
When the control power supply is turned on, the first address of the power sequence board
(1HP PC board etc.) of the first piece cannot be read. (Not mounted)
However, the control power supply does not enter when not mounted actually.

Main cause:
• The power sequence board (1HP PC Board etc.) is not mounted.
• Set mistake in address of power sequence board.
• Defect of power sequence board.

Measure:
• Mount on the position where setting the address of the power sequence board is set
to the first piece and the card rack is correct.
• (When the power sequence board of setting for the first piece is installed in the power
sequence board slave side of the motherboard, does not turn on the control power
supply.)
• Exchange the power sequence board (1HP PC Board etc.).

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Error code : -1202

MFP : No2 power sequence board is not installed.
Message kind : Error Manual division : Option
Error processing : Appearing Error reset : Acceptable
Error logging : YES

Content:
The first address of the power sequence board of the second piece (1HP PC Board etc.)
cannot read for the twin arm specification etc. to turn on the control power supply. (Not
mounted)

Main cause:
• The power sequence board (1HP PC Board etc.) is not mounted.
• Set mistake in address of power sequence board.
• Defect of power sequence board.

Measure:
• Mount on the position where setting the address of the power sequence board is set to
the second piece and the card rack is correct.
• Exchange the power sequence board (1HP PC Board etc.).

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Error code : -1203

MFP : No * -M I/O board is not installed.
Message kind : Error Manual division : Option
Error processing : Only appearing Error reset : Acceptable
Error logging : YES

Content:
Cannot read the first addresses of I/O board (1GW/1HW PC Board etc.) of the number of
signals of having set with DO (output point), DI (input point) of the ZSIGSPEC command
when the control power supply is turned on.(Not mounted)
(However, when the sequencer board is used, this error is not used)
ZSIGSPEC command DO, DI > The number of sheets of mounting I/O board*32 points.

( INT of the ZSIGSPEC command (internal signal point) is unrelated to the I/O board
because of a virtual signal in memory.)

Main cause:
• Set mistake I/O board (1GW/1HW PC Board etc.) in the ZSIGSPEC command is
detached.
• Set mistake in board address of I/O board (1GW/1HW PC Board etc.).
• Defect of I/O board (1GW/1HW PC Board etc.).

Measure:
• Set a correct number of signals with the ZSIGSPEC command.
• Set the board address of the I/O board (1GW/1HW PC Board etc.) correctly and mount
on the card rack.
• (It is basic that the I/O board mounts the card rack from the right side toward., but The
I/O board operates normally on VME bus when mounting.)

•I CAUTION
This error is in the state of the I/O board's not being
mounted after error reset is done and an automatic
operation can be executed.
However, the input not mounted is fixation while turned
off. And, the output is possible in the AS software
ON/OFF as usual.
However, the number of maximum signals in the software
which can be set with the ZSIGSPEC command is DO,
DI=256, INT=512 but DO and DI are restricted by
restricting hardware and other option.
(The I/O board (1HW/1GW PC Board etc.) is every 32
points usually.)

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Error code : -1204

MFP : Option SIO port is not installed.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Impropriety
Error logging : YES

Content:
It is time when is not mounted IC(SIO) for serial communications for command line 3 and
4CH for the communication with the servo board on the 1HA/1GA PC board and it sets more
than seven axes at control power supply ON.

(Because SIO is mounted by the standard excluding an experimental board, this error is not
usually occurred)

Main cause:
• Set more than seven axes with an experimental board with SIO not mounted.
• Defect of the 1HA/1GA PC board.

Measure:
• Exchange the 1HA/1GA PC board.

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Error code : -1205

MFP : Power sequence board any error
Message kind : Error Manual division : Option
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The error is not classified though the error summary signal comes from the power sequence
board (1HP PC Board etc.).
Or, the error message which corresponds to the AS software when the error detection is
newly added on the power sequence board side does not exist.

1HA/1GA PC As for the error summary signal and the error

Board classification, etc. the AS software checks all
register information in EPLD on the power
VME Bus
sequence board by way of VME bus.

Mother Board

Local VME Bus This error is not detected because error is

appeared in each error code usually.

EPLD
Register on VME Bus

Power Sequence Board

(1HP Board etc.)

Main cause:
• The error detection function of the power sequence board does not correspond to the
error processing function of the AS software.
• Defect of power sequence board.
• Defect of AS software.

Measure:
• Exchange the power sequence board.
• Improve the version of the AS software.

•I CAUTION
• This error is shown to occur some errors excluding
the defect of the power sequence board.
• Investigate the situation such as the occurring
situation and reset of the error possible.

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Error code : -1247

MFP : Axis setting data incorrect.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
When the set data was changed by “Auxiliary 901 EXTERNAL AXIS SET”, tried to register
the wrong data.

Example:
When the servo channel (Are the servo CPU and communication processing done with
which channel of the 1HA/1GA PC board command line?) of the external axis is set, it is
changing to the channel number (channel used by another and channel, etc. which do not
exist) which cannot be changed.

Measure:
• Input a set value correctly.

•I CAUTION
There is a form which describes set of each value when
each model and each title machine are shipped with in the
controller or each manual. Confirm this set table.
Keep this setting table importantly so as not to lose.
Keep from a set content in this set table or another form
when you change a set content.

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Error code : -1249

MFP : Servo parameter changed! Control power turn OFF & ON.”
Message kind : Error Manual division : Standard
Error processing : Only displaying Error reset : Possible (Refer to measure).
Error logging : YES

Content:
The servo software and the servo parameter, etc. are usually written on the servo board
(1GB PC Board etc.) only at control power supply ON.
When the data of the servo parameter of the external axis, model setting and number etc. of
correspondence axes are changed with LOAD etc. of the robot/the system data, the new
data should write in the servo board at the 1HA/1GA PC board is exchanged and option axis
since seven axes is used. Therefore, try to turn on the control power supply.

Measure:
• Make the control power supply from turning off to turning on.

•I CAUTION
When the model was changed, the robot motion stripes
had been normally corked if the servo software was not
exchanged for the corresponding model software.

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Error code : -1250

MFP : Servo board (*) Initialize error
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFFàON
Error logging :YES

Content:
When the servo software was written from the flash memory on the 1HA/1GA PC board to
the servo board (1GB PC Board etc.) in the command line, it did not end normally at control
power supply ON.(Check it with the AS software)

The following contents are appeared in “*” of the message.

A 0 7
7: Down-loading mistake of servo program.
6: Down-loading mistake of servo parameter.
4: Trap mistake (Initialization defect of servo software).

CPU channel of servo board.

CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB P Board A unit
or One axis Amplifier
D Second 1GB P Board B unit
or One axis Amplifier

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 4.TROUBLESHOOTING

l C4X,C70 Controller

Power sequence Board Mother Board Servo Board

(1HP PC Board) (1GB Board)
1st Board
Command line CH1
Unit A
1HA/1GA Command line CH2
PC Unit B
Board Command line CH3
Unit C

Servo Board
JP (1GB Board etc.)
2nd Board/One axis Amp.

Unit A
Command line CH4
Unit B
Unit C

Main cause:
• Defect of servo board (one axis amplifier).
• Defect of the harness between power sequence board and servo board.
• Motherboard JP set mistake.
• The servo software is not in the flash memory on the 1HA/1GA PC board.
• Malfunction by noise etc.
• Version suitable combination of servo software and AS software.
• Version suitable combination of monitor ROM in servo software and servo board.

Measure:
• Exchange of 1HA/1GA, servo board, and each harness.

• Confirm the servo software and the servo board monitor ROM version and install the
corresponding servo software again.
• The confirmation of the version can be confirmed by “Auxiliary 90 SOFTWARE VERSION
DISPLAY”, ID command..

Example of appearing servo version:

Y1 A0J - UX120-06
Servo software version.
Servo board monitor ROM version.

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 4.TROUBLESHOOTING

Error code : -1251

MFP : Servo board (*) communication error
Message kind : Error Manual division : Standard.
Error processing : Motor OFF. Error reset : Acceptable
Error logging : YES

Content:
Among communications in the command line of each CPU of the servo board (1GB PC
Board etc.) and the 1HA/1GA PC board, the data reception from the servo board failed twice
continuously.
(The communication of the command line always communicates in each 4msec.)
When each CPU of the servo board stops, system might be detected by this error.
(Refer to ERR-1300)
The channel of the servo board CPU is appeared in “*” in the message.

CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier

l C4X,C70 Controller

Power sequence Board Mother Board Servo Board

(1HP PC Board) (1GB Board)
1st Board
Command line CH1
1HA/1GA Unit A
Command line CH2
PC Unit B
Board Command line CH3
Unit C

Servo Board
(1GB Board etc.)
JP 2nd Board/One axis Amp.

Unit A
Command line CH4
Unit B
Unit C

Main cause:
• Defect of the 1HA/1GA PC board.
• Defect of servo board.
• Defect of each communication harness.
• Defect of the encoder in case of Jt.3(A) or Jt.4(B)
• Malfunction by noise etc.
Measure:
Exchange of the 1HA/1GA, servo board, and each harness.

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 4.TROUBLESHOOTING

Error code : -1252( A ),-1253( B ),-1254( C ),-1255( D )

MFP : Servo board (#) hardware error. Code = ****
Message kind : Error Manual division : Standard.
Error processing : Motor OFF. Error reset : Acceptable
Error logging : YES

Content:
Error not basically occurred.
Though the error on hardware was detected from the servo board (1GB PC Board etc.),
system is processed by this error when there is no error processing corresponding to the AS
software side.

The unit name of the servo board is appeared in #.

CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier

The internal error code number which the servo software detected is appeared in ****.

l C4X,C70 Controller

Power sequence Board Mother Board Servo Board

(1HP PC Board) (1GB Board)
1st Board
Command line CH1
1HA/1GA Unit A
Command line CH2
PC Unit B
Board Command line CH3
Unit C

JP Servo Board
(1GB Board etc.)
2nd Board/One axis Amp.

Unit A
Command line CH4
Unit B
Unit C

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Main cause:
• Defect of servo software.
• Malfunction by noise etc.
• Defect of harness during servo board and power sequence board (1HP PC Board etc.).
• Defect of servo board.
• Suitable combination of version of servo software and AS software.
• Something wrong with servo software and AS software.

Measures:
• The version up of the servo software and the AS software.
• Exchanges such as the 1HA/1GA PC board, servo boards, and each harness.
• When this error is occurred, report details (error code, code number appeared in ****,
models, control models, title machines, AS software/servo software versions,
operation when occurring making an error and situation such as program list, and
content of the option etc.) to KHI.

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 4.TROUBLESHOOTING

Error code : -1256( A),-1257( B),-1258( C ),-1259( D )

MFP : Servo board (#) software error. Code = ****
Message kind : Error Manual division : Standard.
Error processing : Motor OFF. Error reset : Acceptable
Error logging : YES

Content:
Error not basically occurred.
Though the error on hardware was detected from the servo board (1GB PC Board etc.),
system is processed by this error when there is no error processing corresponding to the AS
software side.

The unit name of the servo board is appeared in #.

CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier

The internal error code number which the servo software detected is appeared in ****.

l C4X,C70 Controller

Power sequence Board Mother Board Servo Board

(1HP PC Board) (1GB Board)
1st Board
Command line CH1
1HA/1GA Unit A
Command line CH2
PC Unit B
Board Command line CH3
Unit C

JP Servo Board
(1GB Board etc.)
2nd Board/One axis Amp.

Unit A
Command line CH4
Unit B
Unit C

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Main cause:
• Defect of servo software.
• Malfunction by noise etc.
• Defect of harness during servo board and power sequence board (1HP PC Board etc.).
• Defect of servo board.
• Suitable combination of version of servo software and AS software.
• Something wrong with servo software and AS software.

Measures:
• The version up of the servo software and the AS software.
• Exchanges such as the 1HA/1GA PC board, servo boards, and each harness.
• When this error is occurred, report details (error code, code number appeared in ****,
models, control models, title machines, AS software/servo software versions, operation
when occurring making an error and situation such as program list, and content of the
option etc.) to KHI.

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 4.TROUBLESHOOTING

Error code : -1261

MFP : Servo board (*) parameter setting error.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Impropriety
Error logging : YES

Content:
When setting was changed by “Auxiliary 976 SERVO PARAMETER”, a case different from
the content of the transmission was consecutive and occurred answer-back from the servo
software of each unit two times or more for the transmission of the data to the servo board
(1GB PC Board etc.) through the command line.

The unit name of the servo board is appeared in *.

CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier

The internal error code number which the servo software detected is appeared in ****.

l C4X,C70 Controller

Power sequence Board Mother Board Servo Board

(1HP PC Board) (1GB Board)
1st Board
Command line CH1
Unit A
1HA/1GA Command line CH2
PC Unit B
Board Command line CH3
Unit C

JP Servo Board
(1GB Board etc.)
2nd Board/One axis Amp.

Unit A
Command line CH4
Unit B
Unit C

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Main cause:
• Defect of the 1HA/1GA PC board.
• Defect of servo board.
• Defect of each communication harness.
• The AS software or the servo software does not correspond.
• Malfunction by noise etc.

Measure:
• Exchange of the 1HA/1GA, servo board, and each harness.
• The version up of the AS software or the servo software.
• Resetting the error becomes possible when normally ending by setting again though error
reset is basically impossible.
• The control power supply should be OFFàON when not normally ending.

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 4.TROUBLESHOOTING

Error code : -1300

MFP : Servo CPU-(*) watch-dog error
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFFàON
Error logging : YES

Content:
Watch dog timer built into in each CPU of the 1GB PC board operated.

Detection block:
1GB PC Board
Watch dog
1HA/1GA PC Board Error Signal
CPU-A Gate Array

Mother Board Servo Error Watch dog

Signal Error Signal
CPU-B Gate Array

Watch dog
EPLD Error Signal
CPU-C Gate Array
Command Line

Power Sequence Board(1HP PC board etc.)

The unit name of the servo board is appeared in *.

CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier

Main cause:
• Defect of the servo board.
• Something wrong with the servo software.
Measure:
• Exchange of the servo board.

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Error code : -1306

MFP : Servo board command error
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Possible
Error logging : YES

Content:
The servo software receives a command of the uncorrespondence and a command not
adequate when each command is transmitted from the AS software to the servo software
and servo software has returned the error code (Each error code of the servo system is
another) to the AS software.

l C4X,C70 Controller

Power sequence Board Mother Board Servo Board

(1HP PC Board) (1GB Board)
1st Board
Command line CH1
Unit A
1HA/1GA Command line CH2
PC Unit B
Board Command line CH3
Unit C

JP Servo Board
(1GB Board etc.)
2nd Board/One axis Amp.

Unit A
Command line CH4
Unit B
Unit C

Main cause:
• Defect of the 1HA/1GA PC board and servo board.
• Something wrong with AS software and servo software.
• Suitable combination of version of AS software and servo software. (uncorrespondence
etc. of option)
• Malfunction by noise etc.
• Defect of the harness between servo board and power sequence board.

Measures:
• Exchange of the 1HA/1GA PC board, servo board, and harness.
• Version up of AS software and servo software.

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 4.TROUBLESHOOTING

Error code : -1308

MFP : Motor power off.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reseT/Possible
Error logging : YES

Content:
Though Motor Power (Magnet conductor (MC) for Motor Power) is turning ON in the AS
software, but MC is not turned ON (or, the signal of MCON is not fed back) because there is
a problem in hardware.

MC was turned OFF with the error code was not able to be recognized in the state of MC ON
in the AS software.

(Refer to the power supply circuit chart of Operation Unit for a detailed system chart)

Main cause:
• Defect of power sequence board (1HP PC Board etc.).
• Defect of relay board (1HY/1HK PC Board etc.).
• Something wrong with error detection circuit and error processing of each board.
• The Auxiliary contact of magnet contactor (MC) for Motor Power is coming in contact
defective and operation defective.
• Something wrong with servo software and AS software.

Measure:
• Exchange such as magnet contactor (MC) for power sequence board, relay board, and
Motor Power.

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 4.TROUBLESHOOTING

Error code : -1333

MFP : Monitor ID of servo board mismatch!
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Impropriety
Error logging : YES

Content:
The monitor ROM version (Basic software printed out to CPU. It is not a main body of the
servo software.) of each unit on the 1GB PC board is different.

(Monitor ROM cannot be rewritten)

Main cause:
• Defect of the 1GB PC board.

Measure:
• Exchange the 1GB PC board.

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 4.TROUBLESHOOTING

Error code : -1334

MFP : Servo control line error.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Possible
Error logging : YES

Content:
Information of having done the demand of the brake open (It is not brake opening
confirmation) does not return within the fixed time (2 seconds) according to the command
line communication from the servo board even if servo control ON (SVCN) signal is sent from
the AS software to the servo board (1GB PC Board etc.) through the register of EPLD on
the power sequence board (1HP PC Board etc.).

l C4X,C70 Controller

1HA/1GA
Board

Servo Board
(1GB PC Board )

Command
Line
CPU-A

EPLD /SVCN Brake Drive

EPLD-A
Circuit
Power Sequence Board /BRK-REQ
(1HP Board etc.)

Mother Board

Main cause:
• Defect of the power sequence board.
• Defect of the servo board.
• Defect of the harness between the power sequence board and servo board.

Measure:
• Exchange the power sequence board and the servo board, etc.

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Error code : -1336

MFP : Safety gate circuit open.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Possible
Error logging : YES

Content:
This error occurs when the safety gate is open in the repeat mode (When neither
Emergency stop nor the LS error occur).

Main cause:
• Safety plug open.
• Safety circuit fault.

Measure:
• Safety plug reinsert, etc.

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 4.TROUBLESHOOTING

Error code : -1337

MFP : Two MC lines are not consistent.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Possible
Error logging : YES

Content:
The controller has two system MC line.
When no matching occurs in the motion of the two lines, it becomes this error.

Main cause:
• Emergency stop circuit line open.
• Axis restriction limit switch fault.
• User’s safety circuit fault.
• 1HP,1HY,1HZ PC Board fault or those connectors are not fastened.

Measure:
• Check safety circuit, etc.

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 4.TROUBLESHOOTING

Error code : -1338

MFP : K1 and/or K2 works wrong.
Manual division : Standard
Error processing : Motor OFF Error reset : Possible
Error logging : YES

Content:
Do the watch of MC ON command from controller and motion of actual MC. When no
matching occurs, it becomes this error.

The motion of electromagnetic contact device (K1, K2) in the power supply part is not
correct.
(1) When it should turn ON Motor Power, the following cause is thought as for the case
where it does not turn ON electromagnetic contact device.
Ÿ Look at LD2, LD3, and LD4 of LED on 1HY board. (It is sure to light up LD1.)
i) 2 LED lights up among 3 LED.
Ÿ The coil wiring of K1 and K2 has come off.
Ÿ XHZ-CN10 (connector under the left of motherboard) has come off.
Ÿ XHY-CN2 has come off.
Ÿ Malfunction of K1 and K2.
Ÿ Malfunction of relay on 1HY board.
ii) 1 or 0 LED lights up among 3 LED
Ÿ XHY-CN4 has come off.
Ÿ Connector on 1HP board has come off.
Ÿ Additionally, abnormality of MC line.
Ÿ Malfunction of 1HP board.
Ÿ Malfunction of 1HY board.
(2) When motor power is turning OFF and when it has turned OFF the trigger by the teach
made, the following cause is thought as for the case which is turning ON
electromagnetic Contact device.
Ÿ Malfunction of K1 and K2 (contact stuck etc.)
Ÿ Malfunction of 1HY board.
Ÿ Malfunction of 1HP board.

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 4.TROUBLESHOOTING

Error code : -1401

MFP : Amp over current jt* -M.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
At the savoring, the feedback current from a current sensor in the power block exceeded
144% of the maximum current of the instantaneous of the motor.
A set value of Joint is set with the hardware of the 1GM PC board installed on the servo board
(1GB PC Board) and is detected by HIC.

1GB PC Board
Command
Line HIC 1GM PC Board
CPU Over Current Detect I/V
Conversion
Over Current Error Signal

Servo Error Signal

Gate Array
To Power Sequence
Board (1HP PC Board)

Robot

Current
Sensor U,V,W,E
IPM Each Motor

Power Block

Main cause:
• Short in U, V, W from the power block to motor, and earthing wire line.
• Defect of the motor.
• Defect in the power block.
• Defect of the servo board (1GB PC Board etc.).

Measure:
• Check whether U, V, W to the motor, and the earthing wire line are disconnected from
the power block. And, exchange the separate robot harness/the inside machine
harness.
• Exchange the motor.
• Exchange Servo Unit.

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 4.TROUBLESHOOTING

Error code : -1407

MFP : Servo unit error
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
When the servo system error is occurred, this error is appeared.
Refer to the content of each error because each servo error is appeared at the same
time.

Turning OFF becomes becoming of Motor Power when servo error signal (SVER) is
output from the servo board (1GB PC Board etc.) with the hardware of the power
sequence board (1HP PC Board etc.). Moreover, this signal is transmitted to the AS
software via the register of EPLD. Afterwards, after this error, the error code which
corresponds to each error is appeared because error information from the servo board
is sent through the command line.
1GB PC Board

1HA/1GA PC Board Watch dog

Error Signal
CPU-A Gate Array

Mother Board
Watch dog
Error Signal
Servo Error CPU-B
Signal Gate Array

Watch dog
EPLD Error Signal
CPU-C Gate Array
Motor Power ON
Circuit

Command Line

Power Sequence Board (1HP PC board)

Main cause:
• The servo system error was occurred.
• Disconnection or connect defect of the harness between the power sequence board
and the servo board.

Measure:
• Furnace when error of servo system is occurred referring to each error code.
• Check and exchange the power sequence board for the disconnection of the harness
between the servo boards.

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 4.TROUBLESHOOTING

Error code : -1420

MFP : Current detector type (*) mismatch!
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Impropriety
Error logging : YES

Content:
When the control power supply is turning ON, the ID code data that the ID code and the
AS software of the 1GM PC board installed on the 1GB PC board correspond is not
corresponding.
(The ID code is read by the communication of the command line)

1GM is fixation with 6 axes machine and KHI standard 7 axes machine for the traverse
joint against the model. However, because the model of the motor since the 7th axis is
different, you should specify the ID code on the AS software excluding KHI standard
traverse and more than 7 axes machine.

The unit name of the servo board is appeared in *.

CH to Communication

A First 1GB PC Board A unit However, because it is unit A for 1GB PC

B First 1GB PC Board B unit board to do this error detection to be alone,
First 1GB PC Board C unit appearing “B, D” is not basically appeared.
C
or Second 1GB PC Board A unit
or One axis Amplifier
Second 1GB PC Board B unit
D
or One axis Amplifier

1HA/1GA PC Board

1GB PC Board
Mother Board

1GM PC
Board
ID Code (From Data Bus)

Command Line
CPU-A
Power Sequence Board
(1HP PC board)

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 4.TROUBLESHOOTING

Main cause:
• The 1GM PC board is not suitable for the AS software (robot model).
• The data of the ID code in the AS software is different from the 1GM PC board things
except more than 7 axes and a standard traverse joint.
• The AS software does not correspond to the 1GM PC board (model).

Measure:
• Install the 1GB PC board equipped with the correct 1GM PC board.
• LOAD again the robot/the system data when occurring this error immediately after
initializing.
• Because the read data is wrong when the error is occurred immediately after the
robot/the system data was LOAD. After initializing, try to read be the correct data.

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 4.TROUBLESHOOTING

Error code : -1500

MFP : Jt * -M of motor overload.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The current feedback from the power block was observed and the current which
exceeded the continuous ratings current of the motor flowed more than permissible
time.
The servo software detects this error by the following data (OL curve).

Time 1GB PC Board

Command
Line 1GM PC board
Abnormal CPU HIC I/M Conversion

Servo Error
Signal
Gate Current
Array A Feedback
To Power
Sequence
Board Robot
(1HP PC PWM
Board) Command
Continuous
Rating Current Motor Current Current
U,V,W,E
Sensor Each
IPM
Motor
OL Curve
Power Block

Main cause:
• Mechanical factor.
• The robot arm comes in contact with the treatment device etc.
• The harness etc. are caught to the robot arm.
• The decelerator, the gear, and the bearing, etc. are damaged.
• In the gear deceleration part, the backlash is narrow.
• The weight of the load exceeds the ratings pay load of the robot.
• It is a robot motion (counter teach etc.) by which the robot motion pattern exceeds
ratings of the motor.
• The motor brake is not released.

• Electric factor.
• Motor power line U, V, and W phase are disconnected. (The disconnection is
not checked)
• The brake line is disconnected or the brake drive circuit (Build in the servo
board (1GB PC Board etc.)) is damaged.
(Neither the disconnection of the brake nor the short-circuit are checked)
• The power block is damaged.
• Defect of the servo board.
• Defect of the motor.

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 4.TROUBLESHOOTING

Measure:
• Check the decelerator etc. for a mechanical factor. And, exchange decelerator etc. if it
is necessary.
• Save the robot arm with Teach mode when the robot arm is interfering. Afterwards,
confirm the dislocation by driving part and the arm transformation such as
decelerators.
• Check the harness and Servo Unit for an electric factor. And, exchange the harness
and Servo Unit if it is necessary.

•I CAUTION
If this error is caused repeatedly, the motor will fail
to be burnt. Startup again after solving the cause
without fail.

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 4.TROUBLESHOOTING

Error code : -1501

MFP : Overheat or motor harness is disconnected. (*)
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The thermal contact connected with the machine harness worked. (motion by
disconnection) However, there is a model short-circuited without building a thermal contact
into according to the model in the connector box of the robot arm or model from which
plural series are connected with thermal.
The unit name of the servo board is appeared in *.
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier

Model Harness for C Controller Note

Motor Harness in Harness upper
rotor trunk arm section
JS/JC/JW05 55 degC 55 degC
JS/06/10 55 degC
JS30/40 short-circuit in connector box
JF20 short-circuit in connector box
JM10 55 degC
DSxxx short-circuit in machine harness
NKxxx short-circuit in connector box
Uxxx short-circuit in connector box
Fxxx 65 degC
FS02/03 55 degC

Main cause:
• Disconnection of thermal line.
• The connect is defective of the separate robot harness.
• Defect of the servo board.
• When thermal is built-in
• Immediately after occurring error such as overloads.
• The robot rated weight capacity is exceeded.
• The ambient temperature of the robot exceeds the temperature of the robot of
use environment.

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Command Upper Arm

Line portion Thermal
CPU-B
Switch

Thermal Line
(TH)
Gate Array Thermal
B Rotor Trunk Switch
portion

Servo Error Robot ARM

Signal
Gate Array
A

1GB PC Board

• The robot motion which the load such as the counter teaches rested upon was
executed continuously.
• Hold of cooling fan which places to robot and defect of air purge for cooling.
• The servo ring was continued for a long time by posture hanging the gravity load
on the arm.
• Defect of thermal switch.

Measure:
When a thermal motor works, error reset cannot be done until cooling ends.

• Confirm the use condition of the robot and use the robot in ratings.
• Do the disconnection check of a thermal line and exchange the harness and the
servo board.
• Put from interlock etc. into the state of HOLD when robot continue the servo ring
during a long time (line holding etc.) by the posture hanging the gravity load on the
arm . Or, set “Automatic Servo Off” function with “Auxiliary 91 ENVIRONMENT
DATA” and ENV_DATA command.

Automatic servo off function:

It is a function to turn OFF the servoing when the condition waiting state such as
waiting the signal continues the set time to In Repeat. When the condition such as
waiting the signal is released, the servoing is automatically a function to become
turning ON and to execute the program.
(However, the cycle time lengthens because the robot frequently turns OFF the
servoing because of waiting for the signal etc. if too short time is set and the longevity
of the brake becomes early)

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Error code : -1503

MFP : Speed error jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
Joint speed (motor speed) calculated with encoder value exceeded a regulated value.
(Detect with the servo software)
At the repeat :Joint ratings speed of robot*1.2
At teach/check. :At the equivalent radius position (The slide joint is actual command
value
speed) 250mm/sec*1.5

Robot Arm
Command
Line Servo Board
CPU Encoder
(1GB PC Board) Encoder

Encoder
Gate Array
Servo Error I/F
Signal
(only Output
Gate Array-A) Power
Battery
Supply
Encoder Power
Encoder Backup Board
Supply (+12V) (1FG PC Board)
Controller

Main cause:
• Disconnect the motor power line U, V, and W phase, and fall of arm by power defective
block etc.
• Malfunction due to wiring mistake in motor power line and encoder line.
• Disconnection of the encoder signal line, short-circuit and defect of main body of
encoder.
• The robot depends on the singularity motion.
• Defect in the servo board and power block.
• The moment of inertia exceeded the motor torque by installing the load more than
ratings at the highest velocity robot motion.

Measure:
• Check the disconnection and the short-circuit etc. of the wiring mistake and wiring and
exchange the harness and the encoder, etc.
• Exchange Servo Unit etc.
• Correct the teach data such as the reductions of the modification and setting of the
speed at the position (posture) in case of the singularity motion.

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Error code : -1504

MFP : Position envelope error jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The difference between the current value from the encoder and the command value on
the AS software exceeded a regulated value.
(Detect by processing the servo position loop of the AS software. A regulated value is
different depending on the model and Joint, etc.)

l C4X,C70 Controller
Robot Arm

1HA/1GA PC Command Servo Board Encoder

line
Board CPU (1GB PC Board) Encoder

Mother Board Gate Array Encoder

I/F
1HP PC
Power
Board Battery
Encoder Power Supply (+12V) Supply

Encoder Backup Board

(1FG PC Board)
Controller

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 4.TROUBLESHOOTING

Main cause:
• Mechanical factor:
• The robot arm comes in contact with the treatment device etc.
• The harness etc. are caught to the robot arm.
• The decelerator, the gear, and the bearing, etc. are damaged.
• In the gear deceleration part, the backlash is narrow.
• The weight of the load exceeds the ratings pay load of the robot.
• It is a robot motion (counter teach etc.) by which the robot motion pattern exceeds
ratings of the motor.
• The motor brake is not released.

• Electric factor.
• Motor power line U, V, and W phase are disconnected. (The disconnection is not
checked)
• The brake line is disconnected or the brake drive circuit (Build in the servo board
(1GB PC Board etc.)) is damaged.
(Neither the disconnection of the brake nor the short-circuit are checked)
• The power block is damaged.
• Defect of the servo board.
• Defect of the motor.
• When robot do the singularity motion

Measure:
• Check the decelerator etc. for a mechanical factor. And, exchange decelerator etc. if it
is necessary.
• Save the robot arm with Teach mode when the robot arm is interfering. Afterwards,
confirm the dislocation by driving part and the arm transformation such as
decelerators.
• Check the harness and Servo Unit for an electric factor. And, exchange the harness
and Servo Unit if it is necessary.
• Correct the teach data in case of the singularity motion.

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Error code : -1511

MFP : Encoder battery voltage low [Servo (*)]
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The voltage of the battery connected with the encoder battery board (1FG PC Board
etc.) which built-in the robot arm has decreased to 3.2V or less (ratings 3.6V).
Or, the encoder battery alarm signal (BAT_AL) signal from the encoder battery board
was disconnected.

However, this error is detected only at control power supply ON time and Motor Power
ON time.

The unit name of the servo board is appeared in *.

CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit However, because it is unit A for 1GB PC board to do this
or Second 1GB PC Board A error detection to be alone, appearing “B, D” is not
unit basically appeared.
or One axis Amplifier
D Second 1GB PC Board B
unit
or One axis Amplifier

Robot Arm
Command
Line Servo Board
Encoder
CPU (1GB PC Board) Encoder

Encoder
Gate Array
Servo Error I/F
Signal
(only Output
Gate Array-A) Power
Battery
Supply
Encoder Power
Encoder Backup Board
Supply (+12V) (1FG PC Board)
Controller

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 4.TROUBLESHOOTING

Main cause:
• Longevity of the encoder battery.
• Defect of the encoder battery board.
• The defect of the encoder or, short of the harness from the battery board to the
encoder are a cause, the amount of the consumption of the battery increases, and the
battery is discharged.
• Battery alarm signal (BAT_AL) from the encoder battery board was disconnected.
• Defect of the servo board (1GB PC Board etc.).

Measure:
• There is a possibility that the internal data of the encoder is not maintained when this
error is occurred. Therefore, confirm whether the degree is 0 degrees after putting all
axes together on the position where the robot is marked (mechanical origin) with Teach
mode without fail.
• Execute zeroing when they are not 0 degrees.
• After error reset is done, this error can be automatic operation. However, note that
there is a possibility to cause the dislocation when the robot is operated without
confirming zeroing like the above-mentioned.
• Note that there is a possibility that the internal data of the encoder is not maintained
when the control power supply is turned off when this error is occurred.
• Exchange the battery promptly when the encoder battery decreases.(Exchange the
battery for the conveyer encoder, or for multi axis at the same time).
• Check each harness in disconnecting and the short-circuit and exchange the harness.
• Exchange the encoder, the servo board, and the encoder battery board, etc.

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Error code : -1513

MFP : Encoder rotation data abnormal jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFFàON
Error logging : YES

Content:
There is a difference with the data of the amount of the rotation sent from the data of
the amount of the rotation and the encoder obtained by the carry/borrow of the encoder
data in one rotation more than two rotations In the servo software.
Robot Arm
Command
Line Servo Board
CPU (1GB PC Board) Encoder Encoder

Encoder
Gate Array
Servo Error I/F
Signal
(only Output
Gate Array-A) Power
Battery
Supply
Encoder Power Encoder Backup Board
Supply (+12V) (1FG PC Board)
Controller

Main cause:
• Defect of encoder.
• Malfunction by noise etc.
• Defect of encoder harness.
• Defect of the servo board (1GB PC Board etc.).

Measure:
• Check the disconnection of the encoder signal line and the short-circuit and exchange
the encoder signal line. (Separation signal harness or machine signal harness.)
• Exchange the encoder.
• Check and exchange the 1FG PC board.
• Process specific in the noise source and shield.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Exchange the servo board (1GB PC Board).
• Exchange the encoder.

•I CAUTION
The error of Error -1553, -1554 and -155 etc. are
occasionally occurred because the gap is caused in
the current value in JT ENCODER and the servo
software immediately after the error is occurred.

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 4.TROUBLESHOOTING

Error code : -1516

MFP : Encoder data abnormal jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
When difference between current value when control power supply is turned off and
current value when control power supply is turned on is more than value set by
“Auxiliary 43 ENCODER ERROR RANGE”, ENCCHK_DATA command.
(Detect with the AS software)
The ENCCHK_DATA command is usually set in 2.0 degrees with the rotation axis. This
error is not detected when setting as 0.0 degrees.
When a usual control power supply is turned on, this error is occasionally occurred
when a too small value is set.

l C4X, C70 Controller

Robot Arm

1HA/1GA PC Command Servo Board

Board line
CPU (1GB PC Board) Encoder Encoder

Mother Board Gate Array Encoder

I/F
1HP PC Power
Board Battery
Encoder Power Supply (+12V) Supply

Encoder Backup Board

(1FG PC Board)
Controller

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 4.TROUBLESHOOTING

Main cause:
• The internal data of the encoder is not maintained with a disconnection of the
decrease of the encoder battery and the encoder harness and defective encoders,
etc.
• The control power supply was turned OFF by an abnormal power supply etc. in the
robot motion (Make to turning OFF). The reason for the arm is that the gap might be
caused in the final current value which the AS software memorized and the current
value which stops actually (Turns ON the control power supply) because hold does not
occur rapidly.
• Initializing was executed. (Occur with all axes)
• The motor (encoder) was exchanged.
• The arm (motor) operated by force when the control power supply was turned OFF.

Measure:
• When this error is occurred immediately after initializing is executed, it is not abnormal.
(When initializing, the current value at control power supply OFF of the last time is
initialized. Therefore, the error of all axes occurs.)
• Do zeroing promptly when you exchange the motor (encoder).
• There is a possibility that the internal data of the encoder is not maintained when this
error is occurred. Therefore, confirm whether the degree is 0 degrees after putting all
axes together on the position where the robot is marked (mechanical origin) with Teach
mode without fail.
• Execute zeroing when they are not 0 degrees.
• After error reset is done, this error can be automatic operation. However, note that
there is a possibility to cause the dislocation when the robot is operated without
confirming zeroing like the above-mentioned.
• Exchange the battery promptly when the encoder battery decreases.(Exchange the
battery for the conveyer encoder, or for multi axis at the same time).
• Check each harness in disconnecting and the short-circuit and exchange the harness.
• Exchange the encoder, the servo board, and the encoder battery board, etc.

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 4.TROUBLESHOOTING

Error code : -1517

MFP : Cannot read encoder value jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFFàON
Error logging : YES

Content:
When the encoder data was read immediately after the control power supply was turned
ON, the steady data was not able to be read.
(Detect with the servo software)
Robot Arm
Command
Line Servo Board
Encoder
CPU (1GB PC Board) Encoder

Encoder
Gate Array
Servo Error I/F
Signal
(only Output
Gate Array-A) Power
Supply Battery

Encoder Power
Encoder Backup Board
Supply (+12V) (1FG PC Board)
Controller

Main cause:
• Disconnection of encoder signal line and short-circuit and defect of main body of
encoder.
• Defect of the servo board (1GB PC Board etc.).

Measure:
• Disconnection and short-circuit of encoder signal line and exchange the main body of
the encoder.
• Exchange the servo board (1GB PC Board).

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Error code : -1521

MFP : Mismatch ABS and INC encoder of jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFFàON
Error logging : YES

Content:
The difference of the current value which counts the data in one rotation in the data of
the amount of the rotation and the servo software having obtained by the
communication with the encoder is large.
(Detect with the servo software)
Robot Arm
Command
Line Servo Board
Encoder
CPU (1GB PC Board) Encoder

Gate Array Encoder

Servo Error
Signal I/F
(only Output
Gate Array-A) Power
Battery
Supply
Encoder Power
Encoder Backup Board
Supply (+12V) (1FG PC Board)
Controller

Main cause:
• Defect of the encoder.
• Malfunction by external noise etc.
• Defect of the servo board (1GB PC Board etc.).

Measure:
• Exchange the encoder and/or the servo board.
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Check connections in the separation signal harness.
• Check connections in the machine harness.
• Process specific in the noise source and shield.

Reference:
• Either the magnetic portion or the optical portion of the encoder has a trouble.
• The encoder response error (-1553), the encoder communication error (-1554), and
the encoder data conversion error (-1555) have continued for long time during the
robot moves.

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 4.TROUBLESHOOTING

Error code : -1550

MFP : Encoder initialize error jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFFàON
Error logging : YES

Content:
The encoder was not able to fix the absolute data at control power supply ON. (The
encoder might not be able to fix the absolute data when rotating by 300 rpm or more at
control power supply ON)
Robot Arm
Command
Line Servo Board
(1GB PC Board) Encoder
CPU Encoder

Gate Array Encoder

Servo Error I/F
Signal
(only Output
Gate Array-A) Power
Supply Battery
Circuit
Encoder Power
Supply (+12V) Encoder Backup Board
(1FG PC Board)
Controller

Reference:
The scanning of absolute data is begun from the state of the encoder non-
operation and the state of backup in the encoder immediately after the shift to the
state of the usual operation. In that case, BUSY=1 is output until the data is fixed.

Main cause:
• When the motor (encoder) is rotating by 300 rpm or more
(The conveyer encoder etc. correspond)
• Defect of the encoder and/or encoder connector.
• Defect of the servo board (1GB PC Board etc.).
• Defect of the 1FG PC board.

Measure:
• Adjust control power supply ON. as become 300 rpm or less at times the rotation of the
motor (encoder). (When the motor (encoder) works at control power supply ON,
Excluding the conveyer encoder, it becomes “Error -1517”.)
• Exchange the encoder and/or the servo board.
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Check connections in the separation signal harness.
• Check connections in the machine harness.

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 4.TROUBLESHOOTING

Error code : -1553

MFP : Encoder response error jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
When the communication does not respond from the encoder or slowness
Robot Arm
Command
Line Servo Board Encoder
CPU Encoder
(1GB PC Board)

Gate Array Encoder

Servo Error I/F
Signal
(only Output
Gate Array-A) Power
Supply Battery
Circuit
Encoder Power
Encoder Backup Board
Supply (+12V) (1FG PC Board)
Controller

Main cause:
• Disconnection and short-circuit of encoder signal line.
• Defect of encoder.
• Malfunction by noise etc.
• Defect of the servo board (1GB PC Board).

Measure:
• Check the disconnection of the encoder signal line and the short-circuit and
exchange the encoder signal line. (Separation signal harness or machine signal
harness.)
• Exchange the encoder.
• Check and exchange the 1FG PC board.
• Process specific in the noise source and shield.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Exchange the servo board (1GB PC Board).
• Exchange the encoder.

•I CAUTION
Retry robot program execution or manual
operation carefully at slow speed, after reset error.

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 4.TROUBLESHOOTING

Error code : -1554

MFP : Encoder communication error jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
Abnormality of CRC and flaming error was detected by the communication with the
encoder.
CRC abnormal : CRC data information is added to the communication data and
abnormality is detected by the generation polynomial.
Flaming abnormal : The stop bit was not detected.
Robot Arm
Command Encoder
Line Servo Board
(1GB PC Board) Encoder
CPU

Gate Array Encoder

Servo Error I/F
Signal
(only Output
Gate Array-A) Power Supply
Circuit Battery

Encoder Power Supply

(+12V) Encoder Backup Board
(1FG PC Board)
Controller

Main cause:
• Disconnection and short-circuit of encoder signal line.
• Malfunction by noise etc.
• Defect of encoder.
• Defect of the servo board (1GB PC Board etc.).

Measure:
• Check the disconnection of the encoder signal line and the short-circuit and
exchange the encoder signal line. (Separation signal harness or machine signal
harness.)
• Exchange the encoder.
• Check and exchange the 1FG PC board.
• Process specific in the noise source and shield.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Exchange the servo board (1GB PC Board) or the encoder.

•I CAUTION
Retry robot program execution or manual
operation carefully at slow speed, after reset error.

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 4.TROUBLESHOOTING

Error code : -1555

MFP : Encoder data conversion error jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
It was judged that the location data was absolutely mistaken and the encoder which
contained the redundancy bit was abnormal because of the detection type.

Robot Arm
Command
Line Servo Board
(1GB PC Board) Encoder
CPU
Encoder

Gate Array Encoder

Servo Error I/F
Signal
(only Output
Gate Array-A) Power
Supply Battery
Circuit
Encoder Power
Supply (+12V) Encoder Backup Board
(1FG PC Board)
Controller

Main cause:
• Defect of encoder.
• Disconnection and short-circuit of encoder signal line and defect of main body of
encoder.
• Defect of the servo board (1GB PC Board etc.).
• Malfunction by noise etc.

Measure:
• Exchange the encoder and the servo board (1GB PC Board).
• Check the disconnection of the encoder signal line and the short-circuit and exchange
the encoder signal line. (Separate signal harness or Machine signal harness.)
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Process specific in the noise source and shield.

•I CAUTION
Retry robot program execution or manual
operation carefully at slow speed, after reset
error.

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 4.TROUBLESHOOTING

Error code : -1556

MFP : Encoder ABS-track error jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The absolute data and the incremental data in the encoder are different.
Robot Arm
Command
Line Servo Board
(1GB PC Board) Encoder Encoder
CPU

Encoder
Gate Array
Servo Error I/F
Signal
(only Output
Gate Array-A) Power
Supply Battery
Circuit
Encoder Power Supply
(+12V) Encoder Backup Board
(1FG PC Board)
Controller

Reference:
When the incremental counter data and the absolute data are different in the
encoder, the encoder outputs ABSALM=1.
The cause of ABSALM is that the incremental signal in the encoder is abnormal or
that M-code data has error pattern in the encoder or the absolute track in the
encoder is abnormal.

Main cause:
• Defect of encoder.
• Defect of the servo board (1GB PC Board etc.).
• Disconnection and short-circuit of encoder harness.

Measure:
• Exchange the encoder and the servo board (1GB PC Board).
• Exchange the encoder harness (Separate signal harness or Machine signal harness).
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).

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 4.TROUBLESHOOTING

Error code : -1557

MFP : Encoder INC-pulse error jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
An abnormal pattern was detected in the output signal of the internal insertion circuit of
the incremental pulse in the encoder.

Robot
Command Arm Motor
Line Each CPU

PWM Signal
Servo Error
Signal
(only Output IPM Error Signal
Gate Array-A)
Each Gate Array
DC/DC
HIC IPM

+12V dc +15V dc

Servo Board
Power Block
(1GB PC Board)

Controller

Reference:
When the incremental pulse A and B phases are abnormal, the encoder outputs
INALM=1.
The cause of INALM is that the incremental counter circuit in the encoder has a
trouble or the incremental signal in the encoder is abnormal.

Main cause:
• Defect of the encoder.
• Defect of the servo board (1GB PC Board etc.).
• Disconnection and short-circuit of encoder harness.

Measure:
• Exchange the encoder and the servo board (1GB PC Board).
• Exchange the encoder harness (Separate signal harness or Machine signal harness).
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).

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 4.TROUBLESHOOTING

Error code : -1559

MFP : Power module error jt * -M
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Control Power OFF à ON
Error logging : YES

Content:
The error signal from the IPM module in the power block was detected.

Robot
Command Arm Motor
Line Each CPU

PWM Signal
Servo Error
Signal
(only Output IPM Error Signal
Gate Array-A)
Each Gate Array
DC/DC
HIC IPM

+12V dc +15V dc

Servo Board
Power Block
(1GB PC Board)

Controller

Main cause:
• Defect in the power block.
• Defect of the servo board (1GB PC Board etc.).
• Short-circuit of motor power line U, V, and W phase.
• Cooling by Hold etc. of the cooling fan in Servo Unit is defective.
• Defect the harness between the servo board and the power blocks and defect of
connect.

Measure:
• Exchange Servo Unit.
• Check the short-circuit of the motor harness and exchange it.

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 4.TROUBLESHOOTING

Error code : -1561

MFP : Current sensor disconnect. [Servo (*)]
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The current sensor cable between the servo board (1GB PC Board etc.) and the power
blocks is not connected.
The unit name of the servo board is appeared in *.
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier
In case of the 1GB PC board and the power block (1GC, 1GD PC Board)
1GB PC Board unit A : 1GB-CN9 ßà power block CN2 and (1,3).
1GB PC Board unit B : 1GB-CN10 ßàpower block CN5 and (4,6)
1GB PC Board unit C : 1GB-CN11 ßà power block CN7.

Command
Line
Each CPU
Controller

Servo Error
Signal
(only Output Each Gate Array
Gate Array-A) Current Sensor
Connection
Signal

GND

Power Block
1GB PC Board

Main cause:
• The 1GB PC board is not connected with the current sensor cable between the power
blocks.
• Defect of the 1GB PC board.

Measure:
• Connect a current sensor cable of the 1GB PC board and the power block.

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 4.TROUBLESHOOTING

Error code : -1563

MFP : Servo unit 12VDC error [Servo (*)]
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
When •}12V supplied to the 1GB PC board reaches the below value
+12V : +10.75V or less.
-12V : -10.4V or more.
The unit name of the servo board is appeared in *.
CH to Communication However, because it is unit A for 1GB PC board to do this error
detection to be alone, appearing "B, D " is not basically appeared.
A First 1GB PC Board A unit

B First 1GB PC Board B unit

First 1GB PC Board C unit
C
or Second 1GB PC Board
A unit or One axis Amplifier
Second 1GB PC Board B unit
D
or One axis Amplifier

Command
Line Main cause:
CPU A
• •}12V supplied to 1GB PC board decreases.
(However, there is a possibility turning off the
control power supply in a control abnormal power
Servo Error
Signal supply when the voltage of DC power supply
Gate Array-A
decreases)
• Defect such as the harness between 1GB PC
board <-> motherboards <->DC power supply and
+12Vdc
-12Vdc Power Supply the connect is defective.
Monitor Circuit • Defect of 1GB PC board.

1GB Board

Measure:
• Check the voltage and exchange the 1GB PC board and DC power supply, etc.

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Error code : -1567

MFP : Regenerative resistor error [Servo (*)]
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The regenerating time (time to throw the current to the regenerating resistor) was
consecutive from the power block and 6sec or more continued.
The motor enters the state of power generation by the inertia of the arm when the robot
decelerates. The voltage flows backward to Motor Power (Voltage between P-N) and
the voltage between P-N enters the state of the over-voltage. The regenerating
processing is a processing by which the current is thrown to the regenerating resistor
when the voltage rises more than a constant value and the elevation of the voltage is
prevented.
In the condition to throw the current to the regenerating resistor, the voltage between P-
N is the below condition.(Usual, about DC300V:The voltage changes when the robot is
savoring.)

Regenerating Function Specification

Specification Regenerating start voltage Regenerating end voltage

Foe large Robot 1GC PC Board 390 Vdc 355 Vdc

For small Robot 1GD PC Board 390 Vdc 365 Vdc

The unit name of the servo board is appeared in *.

CH to Communication

A First 1GB PC Board A unit However, because it is unit A for 1GB PC board to do this error
detection to be alone, appearing “B, D” is not basically appeared.
B First 1GB PC Board B unit
First 1GB PC Board C unit
C
or Second 1GB PC Board A
unit or One axis Amplifier
Second 1GB PC Board B unit
D
or One axis Amplifier

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 4.TROUBLESHOOTING

option
Command
Additional Regenerate Regenerate
Line Register
CPU-A Register Drive Circuit
Motor
Power
(P-N)
Regenerate Resistor Drive Signal

Servo Error
Signal
Gate Array Drive Circuit
A
Regenerate 1GC : IPM-1
Control Circuit 1GD : FET
Regenerative
Abnormal
Signal
Regenerate
Resistor
Servo Board
(1GB PC board) Power Block

controller

Main cause:
• The counter teach is high-speed in the robot.
• Fail the scorch of the regenerating resistor etc., and defect in power block.
• Defect of the servo board (1GB PC Board etc.).
• The connect is defective of the harness during the servo board (1GB-CN13) ßà
power block (CN9).
• Defect of regenerating resistor unit for increase when regenerating resistor unit for
built more is connected.

Measure:
• Do not do the counter teach to the robot at the teaching modification. Or, reduce
execution speed.
• Install the built more regenerating resistor unit option.
• Exchange the servo board, the power block, and the regenerating resistor unit for the
built more, etc.

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 4.TROUBLESHOOTING

Error code : -1568

MFP : Servo unit P-N low voltage. [Servo (*)]
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The voltage between P-N supplied to the power block is DC60V or less at the servoing.

•I CAUTION
The arm falls between until detecting of the error because Motor
Power is not supplied at the servo ring when this error occurs.
Other errors of abnormal speed and abnormal deflection, etc.
might be detected.

The unit name of the servo board is appeared in *.

CH to Communication

A First 1GB PC Board A unit However, because it is unit A for 1GB PC board to do this error

B First 1GB PC Board B unit detection to be alone, appearing "B, D " is not basically appeared.
First 1GB PC Board C unit
C
or Second 1GB PC Board A
unit or One axis Amplifier
Second 1GB PC Board B unit
D
or One axis Amplifier

Motor Power
Motor Power Circuit
(MS, Resistance etc.)
Command
Line
CPU A Motor Power
(P-N)

Servo Error
Signal
Gate Array-A Each IPM
Voltage Monitor
Circuit
Voltage Lower between P-N
Error
between
P-N Line

Servo Board
(1GB PC Board) Power Block

(Refer to each power supply circuit chart for details of Motor Power)

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 4.TROUBLESHOOTING

Main cause:
• Operation Unit side:
• Defect of MS.
• Defect of the relay board (1HY/1HK PC Board etc.).
• Defect of the power sequence board (1HP PC Board etc.).
• Servo Unit side:
• Defect of defective power unit .
• Defect of Motor Power circuit (diode bridge and MS, etc.).
• Defect of the servo board (1GB PC Board etc.).
• Defect of each harness between Operation Unit ßà Servo Units and defect of
connect.

Measure:
• Check and exchange the Motor Power circuit and each equipment.
• Exchange the power sequence board, the relay board, and Servo Unit.

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 4.TROUBLESHOOTING

Error code : -1569

MFP : Servo unit P-N high voltage. [Servo (*)]
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The voltage between P-N supplied to the power block exceeded DC410V at the
savoring.
The unit name of the servo board is appeared in *.
CH to Communication
A First 1GB PC Board A unit
However, because it is unit A for 1GB PC board to do this error
B First 1GB PC Board B unit
detection to be alone, appearing “B, D” is not basically appeared.
C First 1GB PC Board C unit
or Second 1GB PC Board A
unit or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier

Motor Power
Motor Power Circuit
Command (MS, Resistance etc.)
Line
CPU A Motor Power
Built more
(P-N) Regenerative
Resistance
Unit
Servo Error Voltage Monitor
Signal Circuit
Gate Array-A between P-N Regenerative
/Regenerative Resistance
Resistance
Voltage Lower Control Circuit
Error Voltage Monitor
between Circuit
P-N Line between P-N

Each IPM
Servo Board
(1GB PC Board) Power Block

Controller
(Refer to each power supply circuit chart for details of Motor Power)

Main cause:
• Defect of regenerating resistor control circuit, fail scorch of regenerating resistor,
defect of voltage watch circuit, and defect in power block.
• Defect of the servo board (1GB PC Board etc.).
• Defect of built more regenerating resistor unit.
• The counter teach etc. which hung excessively the regenerating function were
executed.

Measure:
• Exchange Servo Unit and the built more regenerating resistor unit, etc.
• Add the regenerating resistor unit option when the regenerating function is excessive.

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 4.TROUBLESHOOTING

Error code : -1570

MFP : Regenerative resistor over-heat. [Servo (*)]
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
Thermal (140•Ž) for regenerating resistor in power block, thermal (140•Ž) for
regenerating resistor in built more regenerating resistor unit option, and a heat sink
thermal (90•Ž) are worked. (operation of disconnection)
(Because thermal of each is connected with the series, cannot distinguish on the AS
software)

The unit name of the servo board is appeared in *.

CH to Communication However, because it is unit A for 1GB PC board to do this error
A First 1GB PC Board A unit detection to be alone, appearing “B, D” is not basically
appeared.
B First 1GB PC Board B unit
First 1GB PC Board C unit
C
or Second 1GB PC Board A
unit or One axis Amplifier
Second 1GB PC Board B unit
D
or One axis Amplifier

Motor Power
Thermal
Motor Power Circuit (140•KC)
(MS, Resistance etc.)
Command Regenerative
Line Resistance
CPU A
Motor Power
(P-N)

Servo Built more

Error Voltage Monitor Regenerative
Signal Gate Array-A Circuit Resistance
between P-N Drive Circuit
/Regenerative (1GJ Board)
Resistance Regenerative
Control Circuit Resistance

Thermal
(140•KC)
Servo Board Heat Sink
Thermal
(1GB PC Board) Power Block (140•KC)

Built more Regenerative

Resistance Unit
Controller

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 4.TROUBLESHOOTING

Main cause:
• Defect of cooling by hold of cooling fan in Servo Unit and regenerating resistor unit.
• The regenerating function ability is low at the counter teach etc.
• The temperature of the controller of use environment is high.
• Defect in power block.
• Defect of regenerating resistor unit.
• Defect of the servo board (1GB PC Board etc.).
• The connect is defective of the harness during the servo board (1GB-CN13) ßà
power block (CN9).
• Defect of the harness between power block (1GC-CN21) ßà built more regenerating
resistor units, and defect of connect. (Connect 1GC-CN21 with a short-circuit
connector when the built more regenerating resistor unit is a disconnect)

Measure:
• Exchange Servo Unit and the built more regenerating resistor unit, etc.
• Reduce the ambient temperature.
• Check each harness.

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 4.TROUBLESHOOTING

Error code : -1600

MFP : Uncoincidence error jt *
Message kind : Error Manual division : Standard
Error processing : Only appearing Error reset : Acceptable
Error logging : YES

Content:
Even if the fixed time has passed since the command value arrived at the robot motion
terminal, the current value does not become an axis coincidence (It is not in the range
of the precision setting).
(This error is detected with the AS software)

Main cause:
• Mechanical factor:
• The axis is heavy because of the damage of the decelerator and the bearing, etc.
• In the gear deceleration part, the backlash is narrow.
• The arm is interfering in the treatment device etc., or the harness etc. are caught etc.
• The motor brake is not released.

• Electric factor:
• Defect of the servo board (1GB PC Board etc.).
• Defect in power block etc.
• Disconnection of motor power line and brake line.
• Defect of the encoder and the encoder harness.

• Defect of the teaching data.

The command value is converted into joint command after being calculated with the
wrist posture maintained in the XYZ coordinates system and operates usually, at the
interpolation motion. However, this error might occur when the angle of the wrist at the
operation terminal position is different even if the wrist posture (opposite direction such
as JT6 etc.) at the robot motion beginning point and the terminal position where the
teaching was done is the same on XYZ coordinates.

Measure:
• Adjust the exchange and the backlash such as decelerators for a mechanical factor.
• Exchange Servo Unit and the harness, etc. for an electric factor.
• Do the teach modification when the error occurs by a specific program step.

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 4.TROUBLESHOOTING

Error code : -1601

MFP : Limit switch of jt * is ON.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
l C4X Controller
The axis restriction limit switch operated with the current value exceeded the work
envelope of the user setting. (detection of disconnection)
The work envelope of each Joint of the user setting has been set with “Auxiliary 51
SOFTWARE LIMIT” /ULIMIT, LLIMIT command. (When the robot is shipped, it is set in
the maximum work envelope usually)
Set the work envelope of the user setting as becoming to the follow condition.
Maximum work envelope > Mechanical stopper > Axis restriction limit switch > User set
work envelope
(The mechanical stopper and the axis restriction limit switch are the options, and the
axis installed by the reason on the structure of the model and the machine etc. is
different.)
So as not to operate, the AS software restricts robot more than the angle set by the
user set work envelope usually.

1HA/1GA PC Board

VME Bus

Mother Board

Axis Axis
Local VME Bus Restrict Restrict
1GB PC LS LS
Board
EPLD Register
on VME Bus
Motor Power
ON Circuit
1FG PC board
Power Sequence Board
(1HP PC Board)

Controller Robot Arm

The signal line in two systems is connected from CN4 of the 1HP PC board to the 1FG
PC board in the robot. However, this is connected in parallel in the 1HP PC board. If
either is short-circuits when the limit switch in two systems is connected with the 1FG PC
board to detect only 1CH, it can actually detect the error.
Moreover, CN11, 12, 13 of the 1FG PC board, and a part of model are connected and
when the limit switch is not connected with the LS connector of the inside machine
harness, it should connect the short-circuit connector.(Refer to the figure below)

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 4-91

 4.TROUBLESHOOTING

LS1
CN11
LS2

1HZ
PC 1GB PC CN12
SW1 Board Board

CN13
1HP PC Board
P2 CN4 CN1 CN2 X3 X3A CN8
1FG PC Board

JS30/40 CN5
JS06/10 No.14
JS/JC/JW No.10
only (for JT1 LS)
Main cause:
• When the axis restriction limit switch is turning ON, the user set work envelope was set
in smaller value than the current value.
• The axis was moved by using the manual brake release etc. and the limit switch was
turned ON.
• The signal of the axis restriction limit was disconnected when the robot was outside the
user set work envelope.
• The axis restriction limit was turned ON by wrong of setting the zeroing and reckless
driving, etc.
• The limit was turned ON by the over shot by the inertia when the robot worked when
the user set work envelope is a value close to the robot motion angle of the axis
restriction limit switch..
• Disconnection of axis restriction limit signal and defect of harness.

Measure:
• When this error occurs, robot releases the axis restriction limit switch signal only while
the over ride switch of the power sequence board (1HP PC Board etc.) is being
pressed. You can turn ON Motor Power. And, move the arm with Teach mode in the
work envelope.
• Or, You connects manual brake release BOX of the option with CN5 of the 1GB PC
board. Release the brake with the manual and move the arm in the work envelope.
• Turn OFF Motor Power ( MC OFF) and put into the state to release EMERGENCY
STOP Switch ( contains External EMERGENCY STOP Switch ) when you use the
manual brake release.
• Set the user set work envelope in an appropriate value.
• Change the installation angle of the axis restriction limit switch to an appropriate value.
• Check and exchange the harness and the limit switch.
• Exchange the power sequence board

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 4.TROUBLESHOOTING

l C70 Controller
In FS02/03, Axis restriction limit switch processes the short-circuit in arm base with short-
circuit connector X102.
Therefore, execute the following measure if this error occurred.
•EConfirm whether the arm is in the work envelope.
Release the brake with the manual, and move the arm in the work envelope if outside
the work envelope.
Check that you removes the connector plate in the arm base part, and connector X102 in
arm Base is connected surely.

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 4.TROUBLESHOOTING

Error code : -1602

MFP : Limit switch signal line disconnected.
Message kind : Error Manual division : Standard
Error processing : Motor OFF Error reset : Acceptable
Error logging : YES

Content:
The axis restriction limit switch operated with the current value exceeded the work
envelope of the user setting.
(detection of disconnection)
The work envelope of each Joint of the user setting has been set with “Auxiliary 51
SOFTWARE LIMIT” /ULIMIT, LLIMIT command. (When the robot is shipped, it is set in
the maximum work envelope usually)
Set the work envelope of the user setting as becoming to the follow condition.
Maximum work envelope > Mechanical stopper > Axis restriction limit switch > User set
work envelope
(The mechanical stopper and the axis restriction limit switch are the options, and the
axis installed by the reason on the structure of the model and the machine etc. is
different.)
So as not to operate, the AS software restricts robot more than the angle set by the
user set work envelope usually.

1HA/1GA PC Board

VME Bus

Mother Board

Axis Axis
Local VME Bus Restrict Restrict
1GB PC LS LS
Board
EPLD Register
on VME Bus
Motor Power
ON Circuit

Power Sequence Board 1FG PC Board

(1HP PC Board)

Controller Robot Arm

The signal line in two systems is connected from CN4 of the 1HP PC board to the 1FG
PC board in the robot. However, this is connected in parallel in the 1HP PC board. If
either is short-circuits when the limit switch in two systems is connected with the 1FG PC
board to detect only 1CH, it can actually detect the error.
Moreover, CN11, 12, 13 of the 1FG PC board, and a part of model are connected and
when the limit switch is not connected with the LS connector of the inside machine
harness, it should connect the short-circuit connector.(Refer to the figure below)

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 4.TROUBLESHOOTING

LS1
CN11
LS2

1HZ
1GB PC CN12
PC
SW1 Board Board

CN13
1HP PC Board
P2 CN4 CN1 CN2 X3 X3A CN8
1FG PC Board

JS30/40 CN5
JS06/10 No.14
JS/JC/JW No.10
only (for JT1 LS)

Main cause:
• The signal of the axis restriction limit was disconnected (ON) while had set in the value
whose user set work envelope is larger than the limit switch.
• The axis restriction limit was turned ON by wrong of setting the zeroing and reckless
driving, etc.
• Disconnection of axis restriction limit signal, defect of harness.
• Defect of the limit switch.
• Defect of the power sequence board.

Measure:
• When this error occurs, robot releases the axis restriction limit switch signal only while
the over ride switch of the power sequence board (1HP PC Board etc.) is being
pressed. You can turn ON Motor Power. And, move the arm with Teach mode in the
work envelope.
• Or, You connects manual brake release box of the option with CN5 of the 1GB PC
board. Release the brake with the manual and move the arm in the work envelope.
• Turn OFF Motor Power ( MC OFF) and put into the state to release EMERGENCY
STOP Switch ( contains External EMERGENCY STOP Switch ) when you use the
manual brake release.
• Set the user set work envelope in an appropriate value.
• Change the installation angle of the axis restriction limit switch to an appropriate value.
• Check and exchange the harness and the limit switch.
• Exchange the power sequence board.

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 4.TROUBLESHOOTING

Error code : -1610

MFP : Torch is interfered.
Message kind : Error Manual division : Arc Welding
Error processing : Motor OFF Error reset : Acceptable
Error logging : NO

Content:
LS for the torch interference detection built into the torch holder of the robot operated
by the arc welding specification. (disconnection detection)

Main cause:
The torch interfered with the object, and the limit switch in the torch bracket came off.

After resetting the error, you can move the robot by the teach motion.
In the repeat operation, it is not possible to operate as long as you does not return the
torch to previous state.

Measure:
The robot must by the teach motion after you resets it of the error, and return the torch
previous state.

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 4.TROUBLESHOOTING

Error code : -1800

MFP : AC primary power OFF.
Message kind : Error Manual division : Standard
Error processing : Control Power OFF Error reset : Acceptable
Error logging : YES

Content:
The instantaneous decrease in the primary power was detected in the DC power
supply. (When 20-30msec continues with AC130-145V or less by 0 phases)
However, because the control power supply is turned OFF when this error occurs;
Confirm appearing the error remains when you turn ON the control power supply to next
time.
l C40,C70 Controller

NFB AVR for Control 1HA/1GA PC

Power Supply Board

Error Signal VME Bus

Mother Board (1HZ/1HJ Board)

Relay Board Local VME Bus

(1HY/1HK PC
Board )
EPLD Register
on VME Bus
Control Power
Supply ON
Circuit
Error Signal
+24Vdc
Voltage Monitor

Power Sequence Board

(1HP PC Board)

Motor Power

Controller

(Refer to the power supply circuit for details)

Main cause:
• CB (circuit breaker) for the control power supply was turned OFF.
• AC200/220V supplied to the DC power supply caused the instantaneous decrease.
• Defect of the DC power supply.
• Defect of CB (circuit breaker) for control power supply.
• The voltage of the power supply circuit and Motor Power has decreased short. Or, CB
(circuit breaker) tripped.
• Defect etc. of primary power.
• Defect of the power sequence board (1HP PC Board etc.).
• Defect of the relay board (1HY/1HK PC Board etc.).
Measure:
• It is normal that this error is appeared when CB (circuit breaker) for the control power
supply is turned OFF.
• Check the power supply circuit such as the DC power supply and CB (circuit breaker).
• Confirm whether the primary power is supplied according to ratings.

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 4.TROUBLESHOOTING

Error code : -1801

MFP : 24VDC power source low.
Message kind : Error Manual division : Standard
Error processing : Control Power OFF Error reset : Acceptable
Error logging : YES

Content:
DC+24V supplied to the power sequence board (1HP PC Board etc.) by the DC power
supply detected by about 21.6V or less.
However, because the control power supply is turned OFF when this error occurs;
Confirm appearing the error remains when you turn ON the control power supply to next
time.

l C4X,C70 Controller

1HA/1GA PC
NFB AVR for Control Board
Power Supply

Error Signal VME Bus

Mother Board (1HZ/1HJ Board)

Relay Board Local VME Bus

(1HY/1HK PC
Board )
EPLD Register
on VME Bus
Control Power
Supply ON
Circuit
Error Signal
+24Vdc
Voltage Monitor

Power Sequence Board

(1HP PC Board)

Motor Power

Controller

(Refer to the power supply circuit for details)

Main cause:
• Defect of the DC power supply.
• Defect of the power sequence board.
• Defect of the relay board (1HY/1HK PC Board etc.).
• When Motor Power ON circuit (EMERGENCY STOP Switch line and axis restriction limit
switch line, etc.) is short-circuited to other circuits (power supply) etc.
• Short of inside machine valve and sensor line.

Measure:
• Check the power supply circuit, the machine valve, and the short-circuit of the sensor
line etc., and check the disconnection.
• Exchange the DC power supply, the power sequence board, and the relay board.

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 4.TROUBLESHOOTING

Error code : -1802

MFP : Primary power source is high.
Message kind : Error Manual division : Standard
Error processing : Control Power OFF Error reset : Acceptable
Error logging : YES

Content:
The voltage watch level height (when AC267-277V or more continues 1-2sec) of the DC
power supply was detected.
However, because the control power supply is turned OFF when this error occurs;
Confirm appearing the error remains when you turn ON the control power supply to next
time.

l C4X,C70 Controller

1HA/1GA PC
NFB AVR for Control Board
Power Supply

Error Signal VME Bus

Mother Board (1HZ/1HJ Board)

Relay Board Local VME Bus

(1HY/1HK PC
Board )
EPLD Register
on VME Bus
Control Power
Supply ON
Circuit
Error Signal
+24Vdc
Voltage Monitor

Power Sequence Board

(1HP PC Board)

Motor Power

Controller

(Refer to the power supply circuit for details)

Main cause:
• The primary power exceeds ratings. (defect of primary power) Defect of the DC power
supply.
• Defect of the power sequence board.
• Defect of the relay board and the power supply circuit.

Measure:
• Confirm whether the primary power is supplied according to ratings.
• Check the power supply circuit such as the DC power supply.

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 4.TROUBLESHOOTING

Error code : -1803

MFP : Primary power source is low.
Message kind : Error Manual division : Standard
Error processing : Control Power OFF Error reset : Acceptable
Error logging : YES

Content:
The voltage watch level low (when AC150-158V or less continues 1-2sec) of the DC
power supply was detected.
However, because the control power supply is turned OFF when this error occurs;
Confirm appearing the error remains when you turn ON the control power supply to next
time.

l C4X, C70 Controller

NFB AVR for Control 1HA/1GA PC

Power Supply Board

Error Signal VME Bus

Mother Board (1HY/1HJ Board)

Relay Board Local VME Bus

(1HY/1HK PC
Board )
EPLD Register
on VME Bus
Control Power
Supply ON
Circuit
Error Signal
+24Vdc
Voltage Monitor

Power Sequence Board

(1HP PC Board)

Motor Power

Controller

(Refer to the power supply circuit for details)

Main cause:
• Defect etc. of primary power.
• AC200/220V supplied to the DC power supply became an instantaneous decrease.
• Defect of the DC power supply.
• Defect of CB (circuit breaker) for control power supply.
• Defect of the power sequence board (1HP PC Board etc.).
• Defect of the relay board (1HY/1HK PC Board etc.).

Measure:
• Confirm whether the primary power is supplied according to ratings.
• Check the power supply circuit such as the DC power supply and CB(circuit breaker).

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 4.TROUBLESHOOTING

Error code : -1804

MFP : +12VDC or -12VDC is abnormal.
Message kind : Error Manual division : Standard
Error processing : Control Power OFF Error reset : Acceptable
Error logging : YES

Content:
DC+5V, DC•}12V supplied to the 1HA/1GA PC board are not full of the ratings voltage.
DC+5V : Excluding +4.85-+5.45V
DC+12V : +10.75V or less.
DC-12V : -10.4V or more.

However, because the control power supply is turned OFF when this error occurs;
Confirm appearing the error remains when you turn ON the control power supply to
next time.

l C4X,C70 Controller

NFB AVR for Control 1HA/1GA PC Board

Power Supply

Error Signal VME Bus Servo Board

Control
(1GB Board)
1HZ/1HJ Board Power
Supply

Relay Board Local VME Bus

(1HY/1HK PC
Board )
EPLD Register
on VME Bus
Control Power
Supply ON
Circuit
Error Signal
+24Vdc
Voltage Monitor

Power Sequence Board

(1HP PC Board)

Motor Power

Power Block

Controller

(Power supply circuit and refer to each block chart for details)

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 4.TROUBLESHOOTING

Main cause:
• Defect of the DC power supply.
• Defect of each board such as the 1HA/1GA PC boards.
• The contact of the motherboard is defective.
• Short and defect of MFP harness.
• Short in the servo board and the power block, etc.
• Defect of the encoder battery board (1FG PC Board) such as in robots.
• Short of harness from Servo Unit to the encoder battery board.
• Shorts of operation switch and lamps (error reset switch, cycle start switch, and lamp,
etc.).
• Short in option board and the connect equipment of built-in vision etc.
• The power capacity of the DC power supply is insufficient because of the use such as
the option boards.

Measure:
• Exchange the DC power supply and each board for the control power supply.
• Check short-circuits of each harness such as MFP, the operation panel equipment’s,
and the separation harness and exchange its.

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 4.TROUBLESHOOTING

Error code : -1805

MFP : Memory is locked because of AC_FAIL.
Message kind : Error Manual division : Standard
Error processing : Only display Error reset : Control power OFFàON
Error logging : YES

Content:
After a power supply abnormality (ACFAIL) (the control power supply includes the time
of turning OFF) had been detected, memory was operated.

Measure:
If the control power supply is turned ON again, the error is released though it might
usually be gene rated when the control power supply is turned OFF.

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 4-103

 SAFETY

OVERVIEW

DESCRIPTIONS

TROUBLESHOOTING

SEPARATEžž INSIDE MACHINE HARNESS

APPENDIX

INDEX

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-1

 5. SEPARATEž INSIDE MACHINE HARNESS

n Signal Harness Wiring Diagram (C4X)

X3
Signal Name NO. Destination
Jt1-ENC P 1 X3A-1
Jt3-ENC P 21 X3A-21
Jt4-ENC P 2 X3A-2
Jt6-ENC P 22 X3A-22
Jt2-ENC P 3 X3A-3
Jt7-ENC P 23 X3A-23
Jt5-ENC P 4 X3A-4
BAT AL P 24 X3A-24
LS 1P 6 X3A-6
LS 2P 26 X3A-26
GND 20 X3A-20
I/O 24V 7 X3A-7
I/O 24G 17 X3A-17
SIG-1 5 X3A-5
+12V 8 X3A-8
+12V 9 X3A-9
+12V 10 X3A-10
SIG-3 25 X3A-25
GND 30 X3A-30
Jt1-ENCN 11 X3A-11
Jt3-ENCN 31 X3A-31
Jt4-ENCN 12 X3A-12
Jt6-ENCN 32 X3A-32
Jt2-ENCN 13 X3A-13
Jt7-ENCN 33 X3A-33
Jt5-ENCN 14 X3A-14
BAT AL N 34 X3A-34
LS 1N 16 X3A-16
LS 2N 36 X3A-36
GND 18 X3A-18
I/O 24V 27 X3A-27
I/O 24G 37 X3A-37
SIG-2 15 X3A-15
GND 19 X3A-19
GND 28 X3A-28
GND 29 X3A-29
SIG-4 35 X3A-35
EPV-P 38 X3A-38
EPV-N 39 X3A-39
SHIELD

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 5. SEPARATEž INSIDE MACHINE HARNESS

n Wrist Axis Motor Harness Wiring n Major Axis Motor Harness Wiring
Diagram (C4X) Diagram (C4X)
X5 X4
Signal Name NO. Destination Signal Name NO. Destination
JT4-MOTOR U 5 X5A-5 JT1-MOTOR U 1 X4A-1
JT4-MOTOR V 6 X5A-6 JT1-MOTOR V 2 X4A-2
JT4-MOTOR W 7 X5A-7 JT1-MOTOR W 3 X4A-3
JT4-BRAKE P 3 X5A-3 JT2-MOTOR U 4 X4A-4
JT4-BRAKE N 4 X5A-4 JT2-MOTOR V 5 X4A-5
JT5-MOTOR U 15 X5A-15 THP a X4A-a
JT5-MOTOR V 16 X5A-16 JT2-MOTOR W 6 X4A-6
JT5-MOTOR W 17 X5A-17 JT3-MOTOR U 7 X4A-7
JT5-BRAKE P 13 X5A-13 JT3-MOTOR V 8 X4A-8
JT5-BRAKE N 14 X5A-14 JT3-MOTOR W 9 X4A-9
JT6-MOTOR U 25 X5A-25 EARTH X4A-
JT6-MOTOR V 26 X5A-26 THN b X4A-b
JT6-MOTOR W 27 X5A-27 10
JT6-BRAKE P 23 X5A-23 SHIELD X4A-
JT6-BRAKE N 24 X5A-24
JT7-MOTOR U 35 X5A-35
JT7-MOTOR V 36 X5A-36
JT7-MOTOR W 37 X5A-37
JT7-BRAKE P 33 X5A-33
JT7-BRAKE N 34 X5A-34
JT1-BRAKE P 1 X5A-1
JT1-BRAKE N 2 X5A-2
JT2-BRAKE P 11 X5A-11
JT2-BRAKE N 12 X5A-12
JT3-BRAKE P 21 X5A-21
JT3-BRAKE N 22 X5A-22
SIGO-1 8 X5A-8
SIGO-2 9 X5A-9
SIGO-3 18 X5A-18
SIGO-4 19 X5A-19
SIGO-5 28 X5A-28
SIGO-6 29 X5A-29
SIGO-7 38 X5A-38
SIGO-8 39 X5A-39
EARTH 40 X5A-40
UPPER X5A- UPPER
SHIELD LOWER X5A- LOWER
10
20
30
31
32

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n Motor Harness Wiring Diagram (C4X)

X4 SV-M3
Signal Name NO. Destination Signal Name NO. Destination
JT1-MOTOR U 1 X4A-1 JT4-MOTOR U 6 X4A-6
JT1-MOTOR V 2 X4A-2 JT4-MOTOR V 7 X4A-7
JT1-MOTOR W 3 X4A-3 JT4-MOTOR W 8 X4A-8
JT1,2,3-MOTOR E 26 X4A-26 JT5-MOTOR U 19 X4A-19
JT1-BRAKE P 4 X4A-4 JT5-MOTOR V 20 X4A-20
JT1-BRAKE N 5 X4A-5 JT5-MOTOR W 21 X4A-21
JT2-MOTOR U 14 X4A-14 JT6-MOTOR U 32 X4A-32
JT2-MOTOR V 15 X4A-15 JT6-MOTOR V 33 X4A-33
JT2-MOTOR W 16 X4A-16 JT6-MOTOR W 34 X4A-34
SHIELD L X4A- L THP 43 X4A-43
JT2-BRAKE P 17 X4A-17 THN 44 X4A-44
JT2-BRAKE N 18 X4A-18 JT4-BRAKE P 9 X4A-9
JT3-MOTOR U 27 X4A-27 JT4-BRAKE N 10 X4A-10
JT3-MOTOR V 28 X4A-28 JT5-BRAKE P 22 X4A-22
JT3-MOTOR W 29 X4A-29 JT5-BRAKE N 23 X4A-23
JT4,5,6-MOTOR E U X4A- U JT6-BRAKE P 35 X4A-35
JT3-BRAKE P 30 X4A-30 JT6-BRAKE N 36 X4A-36
JT3-BRAKE N 31 X4A-31 SIGO-1 11 X4A-11
JT7-MOTOR U 45 X4A-45 SIGO-2 12 X4A-12
JT7-MOTOR V 46 X4A-46 SIGO-3 24 X4A-24
JT7-MOTOR W 47 X4A-47 SIGO-4 25 X4A-25
BASE-LS E 13 X4A-13 SIGO-5 37 X4A-37
JT7-BRAKE P 48 X4A-48 SIGO-6 38 X4A-38
JT7-BRAKE N 49 X4A-49 SIGO-7 50 X4A-50
SIGO-8 51 X4A-51
52
BASE LS-1 40 X4A-40
BASE LS-2 41 X4A-41
42

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n Motor Harness Wiring Diagram (C70)

XGB-CN2
Signal Name NO. Destination
JT1-ENC P 1 X401-13
JT1-ENC N 20 X401-14
JT2-ENC P 5 X401-15
JT2-ENC N 24 X401-16
JT3-ENC P 2 X401-25
JT3-ENC N 21 X401-26
JT4-ENC P 3 X401-27
JT4-ENC N 22 X401-28
JT5-ENC P 7 X401-37
JT5-ENC N 26 X401-38
JT6-ENC P 4 X401-39
JT6-ENC N 23 X401-40
JT7-ENC P 6 X401-61
JT7-ENC N 25 X401-62
LS1 P 9 X401-1
LS1 N 28 X401-2
LS2 P 10 X401-3
LS2 N 29 X401-4
BAT-AL+ 8 X401-63
BAT-AL- 27 X401-64
+24V 12 X401-68
GND(+24V) 31 X401-56
13
32
+12V 15 X401-65
GND(+12V) 34 X401-49
+12V 16 X401-50
GND(+12V) 35 X401-51
+12V 17 X401-52
GND(+12V) 36 X401-53
SIG-1 14 X401-66
SIG-3 18 X401-54
SIG-2 33 X401-67
SIG-4 37 X401-55
(N.C) 11
(N.C) 19
(N.C) 30

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XGB-CN6
Signal Name NO. Destination
JT1-BRAKE P 1 X401-17
BRAKE N 9 X401-30
JT2-BRAKE P 2 X401-18
BRAKE N 10 X401-30
JT3-BRAKE P 3 X401-7
BRAKE N 11 X401-31
JT4-BRAKE P 4 X401-8
BRAKE N 12 X401-31
JT5-BRAKE P 5 X401-19
BRAKE N 13 X401-31
JT6-BRAKE P 6 X401-20
BRAKE N 14 X401-31
JT7-BRAKE P 7 X401-5
MTH P 8 X201-9
MTH N 15 X201-10
X201
Signal Name NO. Destination
JT1-BRAKE P 1 X401-41
BRAKE N 2 X401-42
JT2-BRAKE P 3 X401-43
BRAKE N 4 X401-44
JT7-BRAKE P 8 X401-29
MTH P 9 XGB-CN6-8
MTH N 10 XGB-CN6-10

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X002
Signal Name NO. Destination
JT1 MOTOR-U 1 X401-21
JT1 MOTOR-V 2 X401-22
JT1 MOTOR-W 3 X401-23
JT2 MOTOR-U 4 X401-34
JT2 MOTOR-V 5 X401-35
JT2 MOTOR-W 6 X401-36
JT3 MOTOR-U 7 X401-72
JT3 MOTOR-V 8 X401-60
JT3 MOTOR-W 9 X401-48
X003
Signal Name NO. Destination
JT4 MOTOR-U 1 X401-71
JT4 MOTOR-V 2 X401-59
JT4 MOTOR-W 3 X401-47
JT5 MOTOR-U 4 X401-70
JT5 MOTOR-V 5 X401-58
JT5 MOTOR-W 6 X401-46
JT6 MOTOR-U 7 X401-69
JT6 MOTOR-V 8 X401-57
JT6 MOTOR-W 9 X401-45
JT7 MOTOR-U 10 X401-9
JT7 MOTOR-V 11 X401-10
JT7 MOTOR-W 12 X401-11
X001
Signal Name NO. Destination
JT1 MOTOR-E 1 X401-24
JT2 MOTOR-E 2 X401-24
JT3 MOTOR-E 3 X401-12
JT4 MOTOR-E 4 X401-12
JT5 MOTOR-E 5 X401-12
JT6 MOTOR-E 6 X401-12
JT7 MOTOR-E 7 X401-12
(N.C) 8
MTH P 9 X401-32
MTH N 10 X401-33

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n U Series Inside Machine Harness Overall System Diagram

5-8 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

n U Series Inside Machine Harness (M1)

X4A
Signal Name NO. Destination
JT2-MOTOR U 4 XJT2M-B1
JT2-MOTOR V 5 XJT2M-A2
JT2-MOTOR W 6 XJT2M-B2
JT3-MOTOR U 7 XJT3M-B1
JT3-MOTOR V 8 XJT3M-A2
JT3-MOTOR W 9 XJT3M-B2
JT1-MOTOR U 1 XJT1M-B1
JT1-MOTOR V 2 XJT1M-A2
JT1-MOTOR W 3 XJT1M-B2
TH P a X4A-a
TH N b X4A-a
EARTH P EARTH BAR-4

X105
Signal Name NO. Destination
JT1-BRAKE P 1 XJT1B-1
JT2-BRAKE P 2 XJT2B-1
JT3-BRAKE P 3 XJT3B-1
JT1-BRAKE N 4 XJT1B-2
JT2-BRAKE N 5 XJT2B-2
JT3-BRAKE N 6 XJT3B-2

EARTH BAR 1
Signal Name NO. Destination
EARCH 3 XJT1M-A1
EARCH 2 XJT2M-A1
EARCH 1 JT3M-A1

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 5. SEPARATEž INSIDE MACHINE HARNESS

n U Series Inside Machine Harness (M2)

X5A X107
Signal Name NO. Destination Signal Name NO. Destination
JT6-MOTOR U 25 XJT6M-1 EPV P 1 X110-1
JT6-MOTOR V 26 XJT6M-2 EPV N 2 X110-2
JT6-MOTOR W 27 XJT6M-3
JT6-BRAKE N 24 XJT6M-5 X108
JT5-MOTOR U 15 XJT5M-1 Signal Name NO. Destination
JT5-MOTOR V 16 XJT5M-2 SIGO-3 1 X111-3
JT5-MOTOR W 17 XJT5M-3 2 X111-4
JT5-BRAKE N 14 XJT5M-5
JT4-MOTOR U 5 XJT4M-1 X109
JT4-MOTOR V 6 XJT4M-2 Signal Name NO. Destination
JT4-MOTOR W 7 XJT4M-3 SIGO-5 1 X111-5
JT7-BRAKE P 33 X106-A3 SIGO-6 2 X111-6
EARTH 40 EARTH NOTE SIGO-7 3 X111-7
31 SIGO-8 4 X111-8
32
JT4-BRAKE N 4 XJT4M-5 X113
JT7-MOTOR U 35 X106-B1 Signal Name NO. Destination
JT7-MOTOR V 36 X106-A2 SIGO-1 1 X5A-8
JT7-MOTOR W 37 X106-B2 SIGO-2 2 X111-1
JT4-BRAKE P 3 XJT4M-4
JT5-BRAKE P 13 XJT5M-4 X114
JT6-BRAKE P 23 XJT6M-4 Signal Name NO. Destination
JT7-BRAKE N 34 X106-B3 SIGO-1 1 X111-1
JT2-BRAKE P 11 X105-2 SIGO-2 2 X111-2
JT2-BRAKE N 12 X105-5
JT3-BRAKE N 22 X105-6 CN15
JT1-BRAKE N 1 X105-1 Signal Name NO. Destination
JT3-BRAKE P 21 X105-3 SIGO-3 1 X111-3
JT1-BRAKE P 2 X105-4 SIGO-4 2 X111-4
SIGO-1 8 X113-1
SIGO-2 9 X111-2
SIGO-3 18 X108-1 •m NOTE •n
SIGO-4 19 X108-2 CE5
SIGO-5 28 X109-1
SIGO-6 29 X109-2
XJT1M-A1
SIGO-7 38 X109-3 EARCH
XJT2M-A1
SIGO-8 39 X109-4 XJT3M-A1
20

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n U Series Inside Machine Harness (S1)

X3A
Signal Name NO. Destination
JT1-ENCP 1 XFG-CN8-1
JT1-ENCN 11 XFG-CN8-20
JT2-ENCP 3 XFG-CN8-5
JT2-ENCN 13 XFG-CN8-24
JT3-ENCP 21 XFG-CN8-2
JT3-ENCN 31 XFG-CN8-21
JT4-ENCP 2 XFG-CN8-3
JT4-ENCN 12 XFG-CN8-22
JT5-ENCP 4 XFG-CN8-7
JT5-ENCN 14 XFG-CN8-26
JT6-ENCP 22 XFG-CN8-4
JT6-ENCN 32 XFG-CN8-23
JT7-ENCP 23 XFG-CN8-6
JT7-ENCN 33 XFG-CN8-25
BAT-ALP 24 XFG-CN8-8
BAT-ALN 34 XFG-CN8-27
LS1P 6 XFG-CN8-9
LS1N 16 XFG-CN8-28
LS2P 26 XFG-CN8-10
LS2N 36 XFG-CN8-29
EPVP 38 X107-1
EPVN 39 X107-2
+12V 8 XFG-CN8-15
+12V 9 XFG-CN8-16
+12V 10 XFG-CN8-17
I/O24V 7 XFG-CN8-12
I/O24V 27 XFG-CN8-13
GND 18 XFG-CN8-34
GND 19 XFG-CN8-35
GND 20 XFG-CN8-36
GND 28 XFG-CN8-11
GND 29 XFG-CN8-30
GND 30 XFG-CN8-19
I/O 24G 17 XFG-CN8-31
I/O 24G 37 XFG-CN8-32
SIG-1 5 XFG-CN8-14
SIG-2 15 XFG-CN8-33
SIG-3 25 XFG-CN8-18
SIG-4 35 XFG-CN8-37

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n U Series Inside Machine Harness (S2) n U Series Inside Machine Harness (S7)
XFG-CN1 XFG-CN6
Signal Name NO. Destination Signal Name NO. Destination
JT1-ENC P 1 XJT1E-1 JT6-ENC P 1 XJT6E-1
JT1-ENC N 2 XJT1E-2 JT6-ENC N 2 XJT6E-2
JT1+5B 3 XJT1E-3 JT6-+5B 3 XJT6E-3
JT1-GND 4 XJT1E-4 JT6-GND 4 XJT6E-4

n U Series Inside Machine Harness (S3) n U Series Inside Machine Harness (LS)
XFG-CN2 XFG-CN11
Signal Name NO. Destination Signal Name NO. Destination
JT2-ENC P 1 XJT2E-1 LS1P 1 XLS1-N/C
JT2-ENC N 2 XJT2E-2 LS1N 2 XLS2-COM
JT2+5B 3 XJT2E-3 LS2P 3 XFG-CN-4
JT2-GND 4 XJT2E-4 LS2N 4 XFG-CN-3
5
n U Series Inside Machine Harness (S4)
XFG-CN3 XFG-CN13
Signal Name NO. Destination Signal Name NO. Destination
JT3-ENC P 1 XJT3E-1 LS1P 1 CN19-1
JT3-ENC N 2 XJT3E-2 LS1N 2 CN20-2
JT3-+5B 3 XJT3E-3 LS2P 3 CN19-3
JT3-GND 4 XJT3E-4 LS2N 4 CN20-4
5
n U Series Inside Machine Harness (S5)
XFG-CN4 CN20
Signal Name NO. Destination Signal Name NO. Destination
JT4-ENC P 1 XJT4E-1 LS1P 1 CN19-2
JT4-ENC N 2 XJT4E-2 LS1N 2 XFG-CN13-2
JT4-+5B 3 XJT4E-3 LS2P 3 CN19-4
JT4-GND 4 XJT4E-4 LS2N 4 XFG-GN13-4
5
n U Series Inside Machine Harness (S6)
XFG-CN5
Signal Name NO. Destination
JT5-ENC P 1 XJT5E-1
JT5-ENC N 2 XJT5E-2
JT5-+5B 3 XJT5E-3
JT5-GND 4 XJT5E-4

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 5. SEPARATEž INSIDE MACHINE HARNESS

n JS30/40 Inside Machine Harness Overall System Diagram

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-13

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS30/40 Inside Machine Harness (M1) n JS30/40 Inside Machine Harness (M2)
X4A X5A
Signal Name NO. Destination Signal Name NO. Destination
JT2-MOTOR U 4 CN10-B1 JT4-MOTOR U 5 CN13-A1
JT4-MOTOR V 6 CN13-B1
JT2-MOTOR V 5 CN10-A2
JT4-MOTOR W 7 CN13-A2
JT2-MOTOR W 6 CN10-B2
JT5-MOTOR U 15 CN14-B2
JT3-MOTOR U 7 CN11-B1 JT5-MOTOR V 16 CN13-A3
JT3-MOTOR V 8 CN11-A2 JT5-MOTOR W 17 CN13-B3
JT3-MOTOR W 9 CN11-B2 JT6-MOTOR U 25 CN13-A4
JT1-MOTOR U 1 CN9-B1 JT6-MOTOR V 26 CN13-B4
JT1-MOTOR V 2 CN9-A2 JT6-MOTOR W 27 CN13-A5
JT1-MOTORW 3 CN9-B2 JT7-MOTOR E 40 SEE NOTE
MTH N b X4A-a JT7-MOTOR U 35 CN8-B1
JT7-MOTOR V 36 CN8-A2
MTH P a X4A-b
JT7-MOTOR W 37 CN8-B2
EARTH U EARTH BAR-4
EARTH U CN13-B5
JT1-BRAKE P 1 CN12-1
EARTH BAR JT1-BRAKE N 2 CN12-2
JT2-BRAKE P 11 CN14-1
Signal Name NO. Destination JT2-BRAKE N 12 CN14-7
EARTH 1 CN9-A1 JT3-BRAKE P 21 CN14-2
EARTH 2 CN10-A1 JT3-BRAKE N 22 CN14-8
EARTH 3 CN11-A1 JT4-BRAKE P 3 CN14-3
EARTH 4 X4A- U JT4-BRAKE N 4 CN14-9
JT5-BRAKE P 13 CN14-4
JT5-BRAKE N 14 CN14-10
JT6-BRAKE P 23 CN14-5
JT6-BRAKE N 24 CN14-11
[ NOTE ]
JT7-BRAKE P 33 CN8-A3
JT7-BRAKE N 34 CN8-B3
SIGO-1 8 CN6-1
SIGO-2 9 CN6-2
X5A-40 SIGO-3 18 CN15-3
CN8-A1
SIGO-4 19 CN15-4
CN6-3
SIGO-5 28 CN15-5
SIGO-6 29 CN15-6
SIGO-7 38 CN15-7
SIGO-8 39 CN15-8

CN6
Signal Name NO. Destination
SOL-1 1 CN15-1
SOL-2 2 CN15-2
EARTH 3

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n JS30/40 Inside Machine Harness (M3) n JS30/40 Inside Machine Harness (M5)
CN9 CN13
Signal Name NO. Destination Signal Name NO. Destination
EARTH A1 JT1M-A1 JT4-MOTOR U A1 CN18-A1
JT1-MOTOR U B1 JT1M-B1 JT4-MOTOR V B1 CN18-B1
JT1-MOTOR V A2 JT1M-A2 JT4-MOTOR W A2 CN18-A2
JT1-MOTOR W B2 JT1M-B2 JT5-MOTOR U B2 CN18-B2
JT5-MOTOR V A3 CN18-A3
CN12 JT5-MOTOR W B3 CN18-B3
Signal Name NO. Destination JT6-MOTOR U A4 CN18-A4
JT1-BRAKE P 1 JT1B-1 JT6-MOTOR V B4 CN18-B4
JT1-BRAKE N 2 JT1B-2 JT6-MOTOR W A5 CN18-A5
EARTH B5 CN18-B5
n JS30/40 Inside Machine Harness (M4) A6
CN10 B6
Signal Name NO. Destination
EARTH A1 JT2M-A1 CN14
JT2-MOTOR U B1 JT2M-B1 Signal Name NO. Destination
JT2-MOTOR V A2 JT2M-A2 JT2-BRAKE P 1 JT2B-1
JT2-MOTOR W B2 JT2M-B2 JT3-BRAKE P 2 CN17-1
JT4-BRAKE P 3 CN19-1
CN11 JT5-BRAKE P 4 CN19-2
Signal Name NO. Destination JT6-BRAKE P 5 CN19-3
EARTH A1 CN16-A1 6
JT3-MOTOR U B1 CN16-B1 JT2-BRAKE N 7 JT2B-2
JT3-MOTOR V A2 CN16-A2 JT3-BRAKE N 8 CN17-2
JT3-MOTOR W B2 CN16-B2 JT4-BRAKE N 9 CN19-9
JT5-BRAKE N 10 CN19-10
n JS30/40 Inside Machine Harness (M6) JT6-BRAKE N 11 CN19-11
CN16 12
Signal Name NO. Destination
EARTH A1 JT3M- CN15
JT3-MOTOR U B1 JT3M-1 Signal Name NO. Destination
JT3-MOTOR V A2 JT3M-2 SIGO-1 1 CN19-4
JT3-MOTOR W B2 JT3M-2 SIGO-2 2 CN19-12
SIGO-3 3 CN19-5
CN17 SIGO-4 4 CN19-13
Signal Name NO. Destination SIGO-5 5 CN19-6
JT3-BRAKE P A1 JT3M-4 SIGO-6 6 CN19-14
JT3-BRAKE N B1 JT3M-5 SIGO-7 7 CN19-7
SIGO-8 8 CN19-15

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n JS30/40 Inside Machine Harness (M7)

CN19 CN25
Signal Name NO. Destination Signal Name NO. Destination
SIGO-1 1 CN19-4
JT4-BRAKE P 1 JT4M-A3
SIGO-8 2 CN19-15
JT5-BRAKE P 2 JT5M-A3 CN25-4
JT6-BRAKE P 3 JT6M-A3 SIGO-2 3 CN19-12
SIGO-1 4 CN25-1 SIGO-8 4 CN25-2
SIGO-3 5 CN26-1 CN26-2
SIGO-5 6 CN27-1
SIGO-7 7 CN28-1 CN26
8 Signal Name NO. Destination
SIGO-3 1 CN19-5
JT4-BRAKE N 9 JT4M-B3
SIGO-8 2 CN25-4
JT5-BRAKE N 10 JT5M-B3
CN26-4
JT6-BRAKE N 11 JT6M-B3 SIGO-4 3 CN19-13
SIGO-2 12 CN25-3 SIGO-8 4 CN26-2
SIGO-4 13 CN26-3 CN27-2
SIGO-6 14 CN27-3
SIGO-8 15 CN25-2 CN27
16 Signal Name NO. Destination
SIGO-5 1 CN19-6
SIGO-8 2 CN26-4
CN18 CN27-4
Signal Name NO. Destination SIGO-6 3 CN19-14
SIGO-8 4 CN27-2
JT4-MOTOR U A1 JT4M-B1
CN28-2
JT4-MOTOR V B1 JT4M-A2
JT4-MOTOR W A2 JT4M-B2 CN28
JT5-MOTOR U B2 JT5M-B1 Signal Name NO. Destination
JT5-MOTOR V A3 JT5M-A2 SIGO-7 1 CN19-7
JT5-MOTOR W B3 JT5M-B2 SIGO-8 2 CN27-4
JT6-MOTOR U A4 JT6M-B1 3
JT6-MOTOR V B4 JT6M-A2 4
JT6-MOTOR W A5 JT6M-B2
EARTH B5 JT4M-A1
JT5M-A1 NOTE

JT6M-A1 [ NOTE ]

n JS30/40 Inside Machine Harness (M8)

CN30 JT4M-A1
CN18-B5
Signal Name NO. Destination JT5M-A1
JT6M-A1
EARTH A1 JT2M-A1
JT2-MOTOR U B1 JT2M-B1
JT2-MOTOR V A2 JT2M-A2 CN31
JT2-MOTOR W B2 JT2M-B2 Signal Name NO. Destination
JT2-BRAKE P 1 JT2B-1
JT2-BRAKE N 2 JT2B-2

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 5. SEPARATEž INSIDE MACHINE HARNESS

n JS30/40 Inside Machine Harness (S1)

X3A CN5
Signal Name NO. Destination Signal Name NO. Destination
JT1-ENCP 1 FG-CN8-1 LS 1P 1 X3A-6
JT1-ENCN 11 FG-CN8-20 LS 1N 2 FG-CN8-9
JT2-ENCP 3 FG-CN8-5 LS 2P 3 X3A-26
JT2-ENCN 13 FG-CN8-24 LS 2N 4 FG-CN8-10
JT3-ENCP 21 FG-CN8-2 5
JT3-ENCN 31 FG-CN8-21
JT4-ENCP 2 FG-CN8-3 CN7
JT4-ENCN 12 FG-CN8-22 Signal Name NO. Destination
JT5-ENCP 4 FG-CN8-7 E2P-B 1 FG-CN7-1
JT5-ENCN 14 FG-CN8-26 E2N-B 2 FG-CN7-2
JT6-ENCP 22 FG-CN8-4 +5B 3 FG-CN7-3
JT6-ENCN 32 FG-CN8-23 GND 4 FG-CN7-4
JT7-ENCP 23 FG-CN8-6
JT7-ENCN 33 FG-CN8-25
BAT AL P 24 FG-CN8-8
BAT AL N 34 FG-CN8-27
LS1P 6 CN5-1
LS1N 16 FG-CN8-28
SHIELD L SHIELD
EPV P 38 CN24-1
EPV N 39 CN24-2
LS2P 26 CN5-3
+12V 10 FG-CN8-15
+12V 8 FG-CN8-16
+12V 9 FG-CN8-17
+24V 7 FG-CN8-12
+24V 27 FG-CN8-13
LS2N 36 FG-CN8-29
GND(+12V) 20 FG-CN8-34
GND(+12V) 30 FG-CN8-11
GND(+12V) 18 FG-CN8-35
GND(+12V) 28 FG-CN8-30
GND(+12V) 19 FG-CN8-36
GND(+12V) 29 FG-CN8-19
GND(+24V) 17 FG-CN8-31
GND(+24V) 37 FG-CN8-32
SIG-1 5 FG-CN8-14
SIG-2 15 FG-CN8-33
SIG-3 25 FG-CN8-18
SIG-4 35 FG-CN8-37

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-17

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS30/40 Inside Machine Harness (S2)

FG-CN1
Signal Name NO. Destination
JT1-ENC P 1 JT1E-1
JT1-ENC N 2 JT1E-2
JT1-+5B 3 JT1E-3
JT1-GND 4 JT1E-4

n JS30/40 Inside Machine Harness (S3)

FG-CN2 FG-CN9
Signal Name NO. Destination Signal Name NO. Destination
JT2-ENC P 1 No.20-1 SIG-1 1 No.22-5
JT2-ENC N 2 No.20-2 SIG-2 2 No.22-6
JT2-+5B 3 No.20-3 3
JT2-GND 4 No.20-4 4
+24V 5 No.22-9
FG-CN3 24G 6 No.22-10
Signal Name NO. Destination SIG-3 7 No.22-7
JT3-ENC P 1 No.21-1 SIG-4 8 No.22-8
JT3-ENC N 2 No.21-2
JT3-+5B 3 No.21-3 FG-CN12
JT3-GND 4 No.21-4 Signal Name NO. Destination
LS13P 1 No.22-1
FG-CN4 LS13N 2 No.22-2
Signal Name NO. Destination LS23P 3 No.22-3
JT4-ENC P 1 No.21-5 LS23N 4 No.22-4
JT4-ENC N 2 No.21-6 5
JT4-+5B 3 No.21-7
JT4-GND 4 No.21-8

FG-CN5
Signal Name NO. Destination
JT5-ENC P 1 No.21-10
JT5-ENC N 2 No.21-11
JT5-+5B 3 No.21-12
JT5-GND 4 No.21-13

FG-CN6
Signal Name NO. Destination
JT6-ENC P 1 No.21-14
JT6-ENC N 2 No.21-15
JT6-+5B 3 No.21-16
JT6-GND 4 No.21-17

5-18 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS30/40 Inside Machine Harness (S4)

CN20
Signal Name NO. Destination
JT2-ENC P 1 JT2E-1
JT2-ENC N 2 JT2E-2
JT2-+5B 3 JT2E-3
JT2-GND 4 JT2E-4

n JS30/40 Inside Machine Harness (S5)

CN21 CN22
Signal Name NO. Destination Signal Name NO. Destination
JT3-ENC P 1 CN32-1 LS1P 1 CN23-1
JT3-ENC N 2 CN32-2 LS1N 2 CN23-2
JT3+5B 3 CN32-3 LS2P 3 CN23-3
JT3 GND 4 CN32-4 LS2N 4 CN23-4
JT4-ENC P 5 JT4E-1 SIG-1 5 SIG1
JT4-ENC N 6 JT4E-2 SIG-2 6 SIG2
JT4-+5B 7 JT4E-3 SIG-3 7 SIG3
JT4 -GND 8 JT4E-4 SIG-4 8 SIG4
9 +24V 9 24V
JT5-ENC P 10 JT5E-1 24G 10 24G
JT5-ENC N 11 JT5E-2
JT5+5B 12 JT5E-3
JT5 GND 13 JT5E-4
JT6-ENC P 14 JT6E-1
JT6-ENC N 15 JT6E-2
JT6+5B 16 JT6E-3
JT6-GND 17 JT6E-4
18

n JS30/40 Inside Machine Harness (S6)

CN32
Signal Name NO. Destination
JT3-ENC P 1 JT3E-1
JT3-ENC N 2 JT3E-2
JT3-+5B 3 JT3E-3
JT3 -GND 4 JT3E-4

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-19

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS10 Inside Machine Harness Overall System Diagram

5-20 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS10 Inside Machine Harness (P1)

X4A X4A
Signal Name NO. Destination Signal Name NO. Destination
JT1-MOTOR U 1 JT1M-B1 JT1-BRAKE P 4 JT1M-A3
JT1-MOTOR V 2 JT1M-A2 No.7-1
JT1-MOTOR W 3 JT1M-B2 JT1-BRAKE N 5 JT1M-B3
JT1,2,3 - E 26 JT1M-A1 No.7-2
JT2M-A1 JT2-BRAKE P 17 JT2M-A3
No.3-1
JT2-BRAKE N 18 JT2M-B3
JT2-MOTOR U 14 JT2M-B1
JT3-BRAKE P 30 No.5-1
JT2-MOTOR V 15 JT2M-A2
JT2-MOTOR W 16 JT2M-B2 JT3-BRAKE N 31 No.5-5
JT3-MOTOR U 27 No.3-2 JT4-BRAKE P 9 No.5-2
JT3-MOTOR V 28 No.3-3 JT4-BRAKE N 10 No.5-6
JT3-MOTOR W 29 No.3-4 JT5-BRAKE P 22 No.5-3
JT4,5,6 - E U No.4-1 JT5-BRAKE N 23 No.5-7
No.4-3 JT6-BRAKE P 35 No.5-4
No.4-5 JT6-BRAKE N 36 No.5-8
JT4-MOTOR U 6 No.4-7 JT7-BRAKE P 48 No.10-A3
JT4-MOTOR V 7 No.4-2
JT7-BRAKE N 49 No.10-B3 TERMINAL
JT4-MOTOR W 8 No.4-8
TH P 43 THERMAL P
JT5-MOTOR U 19 No.4-9
JT5-MOTOR V 20 No.4-4 TH N 44 THERMAL N
JT5-MOTOR W 21 No.4-10 SIGO-1 11 No.6-1
JT6-MOTOR U 32 No.4-11 SIGO-2 12 No.6-2
JT6-MOTOR V 33 No.4-6 SIGO-3 24 No.6-3
JT6-MOTOR W 34 No.4-12 SIGO-4 25 No.6-4
JT7-MOTOR U 45 No.10-B1 SIGO-5 37 No.6-5
JT7-MOTOR V 46 No.10-A2 SIGO-6 38 No.6-6
JT7-MOTOR W 47 No.10-B2 SIGO-7 50 No.6-7
JT7-MOTOR E 39 No.10-A1
SIGO-8 51 No.6-8
BASE LS-E 13 No.17-3
BASELS-1 40 No.17-1
BASELS-2 41 No.17-2
SHIELD L CABLE SHIELD

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-21

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS10 Inside Machine Harness (P2)

No.3 No.6
Signal Name NO. Destination Signal Name NO. Destination
JT3-EARTH 1 JT3M-A1 SIGO-1 1 No.9-1
JT3-MOTOR U 2 JT3M-B1
SIGO-2 2 No.9-2
JT3-MOTOR V 3 JT3M-A2
JT3-MOTOR W 4 JT3M-B2 SIGO-3 3 No.9-3
SIGO-4 4 No.9-4
No.4 SIGO-5 5 No.9-5
Signal Name NO. Destination SIGO-6 6 No.9-6
JT4-EARTH 1 JT4M-A1 SIGO-7 7 No.9-7
JT4-MOTOR V 2 JT4M-A2 SIGO-8 8 No.9-8
JT5-EARTH 3 No.8-1
SHIELD 9 No.9-9
JT5-MOTOR V 4 No.8-2 [ NOTE ]

JT6-EARTH 5 No.8-4 SHIELD 10 No.9-10

JT6-MOTOR V 6 No.8-5
JT4-MOTOR U 7 JT4M-B1
JT4-MOTOR W 8 JT4M-B2
JT5-MOTOR U 9 No.8-7
JT5-MOTOR W 10 No.8-8
JT6-MOTOR U 11 No.8-10
JT6-MOTOR W 12 No.8-11

No.5
Signal Name NO. Destination
JT3-BRAKE P 1 JT3M-A3
JT4-BRAKE P 2 JT4M-A3
JT5-BRAKE P 3 No.8-3
JT6-BRAKE P 4 No.8-6
JT3-BRAKE N 5 JT3M-B3
JT4-BRAKE N 6 JT4M-B3
JT5-BRAKE N 7 No.8-9
JT6-BRAKE N 8 No.8-12

[ NOTE ]

No.6-9 No.9-9
No.6-10 No.9-10
SHIELD

5-22 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS10 Inside Machine Harness (P3)

No.8 CN.25
Signal Name NO. Destination Signal Name NO. Destination
JT5-EARTH 1 JT5M-A1 SIGO-1 1 No.9-1
JT5-MOTOR V 2 JT5M-A2 SIGO-8 2 No.9-8
JT5-BRAKE P 3 JT5M-A3 CN25-4
JT6-EARTH 4 JT6M-A1 SIGO-2 3 No.9-2
JT6-MOTOR V 5 JT6M-A2 SIGO-8 4 No.25-2
JT6-BRAKE P 6 JT6M-A3 No.26-2
JT5-MOTOR U 7 JT5M-B1
JT5-MOTOR W 8 JT5M-B2 CN.26
JT5-BRAKE N 9 JT5M-B3 Signal Name NO. Destination
JT6-MOTOR U 10 JT6M-B1 SIGO-3 1 No.9-3
JT6-MOTOR W 11 JT6M-B2
SIGO-8 2 CN25-4
JT6-BRAKE N 12 JT6M-B3
CN26-4
SIGO-4 3 No.9-4
No.9 SIGO-8 4 No.26-2
Signal Name NO. Destination No.27-2
SIGO-1 1 CN25-1
SIGO-2 2 CN25-3 CN27
SIGO-3 3 CN26-1 Signal Name NO. Destination
SIGO-4 4 CN26-3 SIGO-5 1 No.9-5
SIGO-5 5 CN27-1 SIGO-8 2 No.26-4
SIGO-6 6 CN27-3 CN27-4
SIGO-7 7 CN28-1 SIGO-6 3 No.9-6
SIGO-8 8 CN25-3 SIGO-8 4 No.27-2
SHIELD 9 No.28-2
SHIELD 10
CN28
Signal Name NO. Destination
SIGO-7 1 No.9-7
SIGO-8 2 CN27-4
3
4

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-23

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS10 Inside Machine Harness (S1)

X3A No.11
Signal Name NO. Destination Signal Name NO. Destination
JT1-ENC P 1 FC-CN8-1 JT7-ENC P 1 FG-CN7-1
JT1-ENC N 11 FG-CN8-20 JT7-ENC N 2 FG-CN7-2
JT2-ENC P 3 FG-CN8-5 JT7-+Vcc 3 FG-CN7-3
JT2-ENC N 13 FG-CN8-24 JT7-GND 4 FG-CN7-4
JT3-ENC P 21 FG-CN8-2
JT3-ENC N 31 FG-CN8-21 No.14
JT4-ENC P 2 FG-CN8-3 Signal Name NO. Destination
JT4-ENC N 12 FG-CN8-22 LS1P 1 X3A-6
SHIELD L CANLE SHIELD LS1N 2 FG-CN8-9
JT5-ENC P 4 FG-CN8-7 LP2P 3 X3A-26
JT5-ENC N 14 FG-CN8-26 LS2N 4 FG-CN8-10
JT6-ENC P 22 FG-CN8-4 5
JT6-ENC N 32 FG-CN8-23
JT7-ENC P 23 FG-CN8-6
JT7-ENC n 33 FG-CN8-25
BAT AL P 24 FG-CN8-8
BAT AL N 34 FG-CN8-27
LS1P 6 No.14-1
LS1N 16 FG-CN8-28
EPV P 38 CN15-1
EPV N 39 CN15-2
LS2P 26 No.14-3
+12V 10 FG-CN8-15
+12V 8 FG-CN8-16
+12V 9 FG-CN8-17
I/O 24V 7 FG-CN8-12
I/O 24V 27 FG-CN8-13
LS2N 36 FG-CN8-29
GND(12G) 20 FG-CN8-34
GND(12G) 30 FG-CN8-11
GND(12G) 18 FG-CN8-35
GND(12G) 28 FG-CN8-30
GND(12G) 19 FG-CN8-36
GND(12G) 29 FG-CN8-19
I/O 24G 17 FG-CN8-31
I/O 24G 37 FG-CN8-32
SIG-1 5 FG-CN8-14
SIG-2 15 FG-CN8-33
SIG-3 25 FG-CN8-18
SIG-4 35 FG-CN8-37

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 5. SEPARATEž INSIDE MACHINE HARNESS

n JS10 Inside Machine Harness (S2) n JS10 Inside Machine Harness (S3)
FG-CN3 No.12
Signal Name NO. Destination Signal Name NO. Destination
JT3-ENC P 1 JT3E-1 JT5-ENC P 1 JT5E-1
JT3-ENC N 2 JT3E-2 JT5-ENC N 2 JT5E-2
JT3-+5B 3 JT3E-3 JT5-+5B 3 JT5E-3
JT3-GND 4 JT3E-4 JT5-GND 4 JT5E-4
JT6-ENC P 5 JT6E-1
FG-CN4
JT6-ENC N 6 JT6E-2
Signal Name NO. Destination
JT6-+5B 7 JT6E-3
JT4-ENC P 1 JT4E-1
JT6-GND 8 JT6E-4
JT4-ENC N 2 JT4E-2
JT4-+5B 3 JT4E-3
No.13
JT4-GND 4 JT4E-4
Signal Name NO. Destination
FG-CN5 SIG-1 1 SIG1
Signal Name NO. Destination SIG-2 2 SIG2
JT5-ENC P 1 No.12-1 SIG-3 3 SIG3
JT5-ENC N 2 No.12-2 SIG-4 4 SIG4
JT5-+5B 3 No.12-3 +24V 5 +24V
JT5-GND 4 No.12-4 24G 6 24G
FG-CN6
Signal Name NO. Destination n JS10 Inside Machine Harness (S4)
FG-CN1
JT6-ENC P 1 No.12-5
Signal Name NO. Destination
JT6-ENC N 2 No.12-6
JT1-ENC P 1 JT1E-1
JT6-+5B 3 No.12-7
JT1-ENC N 2 JT1E-2
JT6-GND 4 No.12-8
JT-+5B 3 JT1E-3
FG-CN9 JT1-GND 4 JT1E-4
Signal Name NO. Destination
SIG-1 1 No.13-1 n JS10 Inside Machine Harness (S5)
SIG-2 2 No.13-2 FG-CN2
3 Signal Name NO. Destination
4 JT2-ENC P 1 JT2E-1
+24V 5 No.13-5 JT2-ENC N 2 JT2E-2
24V 6 No.13-6 JT2-+5B 3 JT2E-3
SIG-3 7 No.13-3 JT2-GND 4 JT2E-4
SIG-4 8 No.13-4
FG-CN12
Signal Name NO. Destination
LS1P 1 No.16-1
LS1N 2 No.16-2
LS2P 3 No.16-3
LS2N 4 No.16-4
5

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-25

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS/JC/JW5 Inside Machine Harness Overall System Diagram

5-26 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS/JC/JW5 Inside Machine Harness (P1)

X4A X4A
Signal Name NO. Destination Signal Name NO. Destination
JT1-MOTOR U 1 JT1M-B1 JT1-BRAKE P 4 JT1M-A3
JT1-MOTOR V 2 JT1M-A2
No.7-1
JT1-MOTOR W 3 JT1M-B2
JT1,2,3-E 26 JT1M-A1 JT1-BRAKE N 5 JT1M-B3
JT2M-A1 No.7-2
No.3-1 JT2-BRAKE P 17 JT2M-A3
JT2-MOTOR U 14 JT2M-B1
JT2-BRAKE N 18 JT2M-B3
JT2-MOTOR V 15 JT2M-A2
JT2-MOTOR W 16 JT2M-B2 JT3-BRAKE P 30 No.5-1
JT3-MOTOR U 27 No.3-2 JT3-BRAKE N 31 No.5-5
JT3-MOTOR V 28 No.3-3 JT4-BRAKE P 9 No.5-2
JT3-MOTOR W 29 No.3-4
JT4-BRAKE N 10 No.5-6
JT4,5,6-E U No.4-1
No.4-3 JT5-BRAKE P 22 No.5-3
No.4-5 JT5-BRAKE N 23 No.5-7
JT4-MOTOR U 6 No.4-7 JT6-BRAKE P 35 No.5-4
JT4-MOTOR V 7 No.4-2
JT6-BRAKE N 36 No.5-8
JT4-MOTOR W 8 No.4-8
JT5-MOTOR U 19 No.4-9 JT7-BRAKE P 48 No.10-A3
JT5-MOTOR V 20 No.4-4 JT7-BRAKE N 49 No.10-B3
JT5-MOTOR W 21 No.4-10 TH P 43 No.6-9
JT6-MOTOR U 32 No.4-11
TH N 44 THERMAL N TERMINAL
JT6-MOTOR V 33 No.4-6
JT6-MOTOR W 34 No.4-12 SIGO-1 11 No.6-1
No.6-10
JT7-MOTOR U 45 No.10-B1 SIGO-2 12 No.6-2
JT7-MOTOR V 49 No.10-A2 SIGO-3 24 No.6-3
JT7-MOTOR W 47 No.10-B2
SIGO-4 25 No.6-4
JT7-MOTOR E 39 No.10-A1
13 SIGO-5 37 No.6-5
SIGO-6 38 No.6-6
SIGO-7 50 No.6-7
SIGO-8 51 No.6-8
40
41
SHIELD L CABLE SHIELD

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-27

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS/JC/JW5 Inside Machine Harness (P2)

No.3 CN25
Signal Name NO. Destination Signal Name NO. Destination
JT3-EARTH 1 JT3M-A1 SIGO-1 1 No.6-1
JT3-MOTOR U 2 JT3M-B1 SIGO-8 2 No.6-8
JT3-MOTOR V 3 JT3M-A2 CN25-4
JT3-MOTOR W 4 JT3M-B2 SIGO-2 3 No.6-2
SIGO-8 4 CN25-2
No.4
CN26-2
Signal Name NO. Destination
JT4-EARTH 1 JT4M-A1
CN26
JT4-MOTOR V 2 JT4M-A2
Signal Name NO. Destination
JT5-EARTH 3 JT5M-A1
SIGO-3 1 No.6-3
JT5-MOTOR V 4 JT5M-A2
SIGO-8 2 CN25-4
JT6-EARTH 5 JT6M-A1
CN26-4
JT6-MOTOR 6 JT6M-A2
SIGO-4 3 No.6-4
JT4-MOTOR U 7 JT4M-B1
SIGO-8 4 CN26-2
JT4-MOTOR W 8 JT4M-B2
CN27-2
JT5-MOTOR U 9 JT5M-B1
JT5-MOTOR W 10 JT5M-B2
CN27
JT6-MOTOR U 11 JT6M-B1
Signal Name NO. Destination
JT6-MOTOR W 12 JT6M-B1
SIGO-5 1 No.6-5
No.5 SIGO-8 2 CN26-4
Signal Name NO. Destination CN27-4
JT3-BRAKE P 1 JT3M-A3 SIGO-6 3 No.6-6
JT4-BRAKE P 2 JT4M-A3 SIGO-8 4 CN27-2
JT5-BRAKE P 3 JT5M-A3 CN28-2
JT6-BRAKE P 4 JT6M-A3
JT3-BRAKE N 5 JT3M-B3 CN28
JT4-BRAKE N 6 JT4M-B3 Signal Name NO. Destination
JT5-BRAKE N 7 JT5M-B3 SIGO-7 1 No.6-7
JT6-BRAKE N 8 JT6M-B3 SIGO-8 2 CN27-4
3
No.6
4
Signal Name NO. Destination
SIGO-1 1 CN25-1
SIGO-2 2 CN25-3
SIGO-3 3 CN26-1
SIGO-4 4 CN26-3
SIGO-5 5 CN27-1
SIGO-6 6 CN27-3
SIGO-7 7 CN28-1 TERMINAL
SIGO-8 8 CN25-2
TH P 9 THERMAL P
TH N 10 THERMAL N
SHIELD 11 AWG22 G/Y
SHIELD 12

5-28 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

n JS/JC/JW5 Inside Machine Harness (S1)

X3A No.9
Signal Name NO. Destination Signal Name NO. Destination
JT1-ENC P 1 FG-CN8-1 JT7-ENC P 1 FG-CN7-1
JT1-ENC N 11 FG-CN8-20 JT7-ENC N 2 FG-CN7-2
JT2-ENC P 3 FG-CN8-5 JT7-Vcc 3 FG-CN7-3
JT2-ENC N 13 FG-CN8-24 JT7-GND 4 FG-CN7-4
JT3-ENC P 21 FG-CN8-2
JT3-ENC N 31 FG-CN8-21 No.10
JT4-ENC P 2 FG-CN8-3 Signal Name NO. Destination
JT4-ENC N 12 FG-CN8-22 LS1P 1 No.1-U
SHIELD L CABLE SHIELD LS1N 2 FG-CN8-9
JT5-ENC P 4 FG-CN8-7 LS2P 3 No.1-Z
JT5-ENC N 14 FG-CN8-26
LS2N 4 FG-CN8-10
JT6-ENC P 22 FG-CN8-4
5
JT6-ENC N 32 FG-CN8-23
JT7-ENC P 23 FG-CN8-6
JT7-ENC N 33 FG-CN8-25
BAT AL P 24 FG-CN8-8
BAT AL N 34 FG-CN8-27
LS1P 6 No.10-1
LS1N 16 FG-CN8-28
38
39
LS2P 26 No.10-3
+12V 10 FG-CN8-15
+12V 8 FG-CN8-16
+12V 9 FG-CN8-17
I/O 24V 7 FG-CN8-12
I/O 24V 27 FG-CN8-13
LS2N 36 FG-CN8-29
GND(12G) 20 FG-CN8-34
GND(12G) 30 FG-CN8-11
GND(12G) 18 FG-CN8-35
GND(12G) 28 FG-CN8-30
GND(12G) 19 FG-CN8-36
GND(12G) 29 FG-CN8-19
I/O 24G 17 FG-CN8-31
I/O 24G 37 FG-CN8-32
SIG-1 5 FG-CN8-14
SIG-2 15 FG-CN8-33
SIG-3 25 FG-CN8-18
SIG-4 35 FG-CN8-37

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 5. SEPARATEž INSIDE MACHINE HARNESS

n JS/JC/JW5 Inside Machine Harness (S2)

FG-CN3
Signal Name NO. Destination
JT3-ENC P 1 JT3E-1
JT3-ENC N 2 JT3E-2
JT3-+5B 3 JT3E-3
JT3-GND 4 JT3E-4
FG-CN4
Signal Name NO. Destination
JT4-ENC P 1 JT4E-1
JT4-ENC N 2 JT4E-2
JT4-+5B 3 JT4E-3
JT4-GND 4 JT4E-4
FG-CN5
Signal Name NO. Destination
JT5-ENC P 1 JT5E-1
JT5-ENC N 2 JT5E-2
JT5-+5B 3 JT5E-3
JT5-GND 4 JT5E-4
FG-CN6
Signal Name NO. Destination
JT6-ENC-P 1 JT6E-1
JT6-ENC N 2 JT6E-2
JT6-+5B 3 JT6E-3
JT6-GND 4 JT6E-4
FG-CN9
Signal Name NO. Destination
SIG-1 1 SIG1
SIG-2 2 SIG2
3
4
+24V 5 +24V
24G 6 24G
SIG-3 7 SIG3
SIG-4 8 SIG4
FG-CN12
Signal Name NO. Destination
LS3P 1 No.19-1
LS3N 2 No.19-2
LS3P 3 No.19-3
LS3N 4 No.19-4
5

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 5. SEPARATEž INSIDE MACHINE HARNESS

n JS/JC/JW5 Inside Machine Harness (S4)

FG-CN1
Signal Name NO. Destination
JT1-ENC P 1 JT1E-1
JT1-ENC N 2 JT1E-2
JT1-+5B 3 JT1E-3
JT1-GND 4 JT1E-4

n JS/JC/JW5 Inside Machine Harness (S5)

FG-CN2
Signal Name NO. Destination
JT2-ENC P 1 JT2E-1
JT2-ENC N 2 JT2E-2
JT2-+5B 3 JT2E-3
JT2-GND 4 JT2E-4

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 5. SEPARATEž INSIDE MACHINE HARNESS

n FS02/03,FC02 Inside Machine Harness Overall System Diagram

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 5. SEPARATEž INSIDE MACHINE HARNESS

n FS02/03 Inside Machine Harness

X401
Signal Name NO. Destination
JT1M-U 21 XJT1M-1
JT1M-V 22 XJT1M-2
JT1M-W 23 XJT1M-3
JT1M-E 24 XJT1M-4
JT2M-U 34 X403-1
JT2M-V 35 X403-2
JT2M-W 36 X403-3
JT2M-E 24 X403-4
JT3M-U 72 XJT3M-1
JT3M-V 60 XJT3M-2
JT3M-W 48 XJT3M-3
JT3M-E 12 XJT3M-4
JT4M-U 71 XJT4M-1
JT4M-V 59 XJT4M-2
JT4M-W 47 XJT4M-3
JT4M-E 12 XJT4M-4
JT5M-U 70 XJT5M-1
JT5M-V 58 XJT5M-2
JT5M-W 46 XJT5M-3
JT5M-E 12 XJT5M-4
JT6M-U 69 XJT6M-1
JT6M-V 57 XJT6M-2
JT6M-W 45 XJT6M-3
JT6M-E 12 XJT6M-4
(JT7M-U) 9 (XJT7M-1)
(JT7M-V) 10 (XJT7M-2)
(JT7M-W) 11 (XJT7M-3)
(JT7M-E) 12 (XJT7M-4)
MTH+ 32 MTH+
MTH- 33 MTH-

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X401
Signal Name NO. Destination
SIG1 66 SIG1
SIG3 54 SIG2
SIG2 67 SIG3
SIG4 55 SIG4
+24V 68 +24V
+24G 56 +24G
LS1P 1 X402-1
LS1N 2 X402-2
LS2P 3 X402-3
LS2N 4 X402-4
SOLC 29 VAL1-1
SOL1 41 VAL1-2
SOLC 29 VAL1-3
SOL2 42 VAL1-4
SOLC 29 VAL2-1
SOL3 43 VAL2-2
SOLC 29 VAL2-3
SOL4 44 VAL2-4
JT1BRK-P 17 XJT1B-1
JT1BRK-N 30 XJT1B-2
JT2BRK-P 18 XJT2B-1
JT2BRK-N 30 XJT2B-2
JT3BRK-P 7 XJT3B-1
JT3BRK-N 31 XJT3B-2
JT4BRK-P 8 XJT4B-1
JT4BRK-N 31 XJT4B-2
JT5BRK-P 19 XJT5B-1
JT5BRK-N 31 XJT5B-2
JT6BRK-P 20 XJT6B-1
JT6BRK-N 31 XJT6B-2
(JT7BRK-P) 5 (XJT7B-1)
(JT7BRK-N) 6 (XJT7B-2)

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 5. SEPARATEž INSIDE MACHINE HARNESS

XJT1E
Signal Name N‚n. Destination
JT1E-P 1 X401-13
JT1E-N 2 X401-14
+5V 3 XHG-CN4-1
GND 4 XHG-CN4-2
XJT2E
Signal Name NO. Destination
JT2E-P 1 X401-15
JT2E-N 2 X401-16
+5V 3 XHG-CN4-3
GND 4 XHG-CN4-4
XJT3E
Signal Name NO. Destination
JT3E-P 1 X401-25
JT3E-N 2 X401-26
+5V 3 X405
GND 4 X406
XJT4E
Signal Name NO. Destination
JT4E-P 1 X401-27
JT4E-N 2 X401-28
+5V 3 X405
GND 4 X406
XJT5E
Signal Name NO. Destination
JT5E-P 1 X401-37
JT5E-N 2 X401-38
+5V 3 X405
GND 4 X406
XJT6E
Signal Name NO. Destination
JT6E-P 1 X401-39
JT6E-N 2 X401-40
+5V 3 X405
GND 4 X406

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XHG-CN1
Signal Name NO. Destination
JT7E-P 1 X401-61
JT7E-N 2 X401-62
BAT-AL+ 3 X401-63
BAT-AL- 4 X401-64
+12V 5 X401-65
GND 6 X401-49
+12V 7 X406
GND 8 X407
X403
Signal Name NO. Destination
JT2M-U 1 XJT2M-1
JT2M-V 2 XJT2M-2
JT2M-W 3 XJT2M-3
JT2M-E 4 XJT2M-4
X404
Signal Name NO. Destination
GND XJT3E-4
XJT4E-4
XJT5E-4
XJT6E-4
X405
Signal Name NO. Destination
+5V XJT3E-3
XJT4E-3
XJT5E-3
XJT6E-3
X406
Signal Name NO. Destination
+12V X401-50
X401-52
X407
Signal Name NO. Destination
GND X401-51
X401-53

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n FS06/10/20 Inside Machine Harness Overall System Diagram

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n FS06/10/20 Inside Machine Harness

X4A
Signal Name NO. Destination
JT1MOTOR-U 1 XJT1M-B1
JT1MOTOR-V 2 XJT1M-A2
JT1MOTOR-W 3 XJT1M-B2
JT1BRAKE-P 4 XJT1M-A3
JT1BRAKE-N 5 XJT1M-B3
JT1MOTOR-FG 26 XJT1M-A1
JT2MOTOR-U 14 XJT2M-B1
JT2MOTOR-V 15 XJT2M-A2
JT2MOTOR-W 16 XJT2M-B2
JT2BRAKE-P 17 XJT2M-A3
JT2BRAKE-N 18 XJT2M-B3
JT2MOTOR-FG 39 XJT2M-A1
JT3MOTOR-U 27 X101-B1
JT3MOTOR-V 28 X101-A2
JT3MOTOR-W 29 X101-B2
JT3MOTOR-FG 26 X101-A1
JT3BRAKE-P 30 X101-A3
JT3BRAKE-N 31 X101-B3
JT4MOTOR-U 6 X102-1
JT4MOTOR-V 7 X102-2
JT4MOTOR-W 8 X102-3
JT4MOTOR-FG 39 X102-6
JT4BRAKE-P 9 X102-4
JT4BRAKE-N 10 X102-5
SIGO-1 11 X102-7
SIGO-2 12 X102-8
SIGO-3 24 X102-9
SIGO-4 25 X102-10
SIGO-5 37 X102-12
SIGO-6 38 X102-13
SIGO-7 50 X102-14
SIGO-8 51 X102-15
JT5MOTOR-U 19 X103-1
JT5MOTOR-V 20 X103-2
JT5MOTOR-W 21 X103-3
JT5MOTOR-FG 13 X103-4
JT5BRAKE-P 22 X103-9
JT5BRAKE-N 23 X103-10
JT6MOTOR-U 32 X103-5
JT6MOTOR-V 33 X103-6
JT6MOTOR-W 34 X103-7
JT6MOTOR-FG 13 X103-8
Signal Name NO. Destination
JT6BRAKE-P 35 X103-11
JT7MOTOR-U 1 X104-1
JT6BRAKE-N 36 X103-12
JT7MOTOR-V 2 X104-2
TH-P 43
JT7MOTOR-W 3 X104-3
TH-N 44
JT7BRAKE-P 4 X104-4
BASELS-1 40 X105-1
JT7BRAKE-N 5 X104-5
BASELS-2 41 X105-2
JT7MOTOR-FG 6 X104-6
BASELS-FG U X105-3

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X3A
Signal Name NO. Destination
EPV-P 36 X125-1
EPV-N 39 X125-2
LS1P 6 X126-1
LS2P 26 X126-3
LS1N 16 X121-2
LS2N 36 X121-4
JT3E-P 21 X121-5
JT3E-N 31 X121-6
JT1E-P 1 XJT1E-1
JT1E-N 11 XJT1E-2
JT2E-P 3 XJT2E-1
JT2E-N 13 XJT2E-2
JT4E-P 2 X122-1
JT4E-N 12 X122-2
JT5E-P 4 X123-1
JT5E-N 14 X123-2
JT6E-P 22 X123-5
JT6E-N 32 X123-6
+24V 7 X124-1
24G 17 X124-2
+24V 27 X124-3
24G 37 X124-4
24G 17 X124-5
SIG1 5 X124-6
24G 17 X124-7
SIG2 15 X124-8
24G 37 X124-9
SIG3 25 X124-10
24G 37 X124-11
SIG4 35 X124-12
JT7E-P 23 XHG-CN1-1
JT7E-N 33 XHG-CN1-2
BAT AL P 24 XHG-CN1-3
BAT AL N 34 XHG-CN1-4
+12V 10 XHG-CN1-5
GND(+12V) 20 XHG-CN1-6
+12V 8 XHG-CN1-7
GND(+12V) 18 XHG-CN1-8
GND(+12V) 28 XHG-CN1-6
GND(+12V) 30 XHG-CN1-6
+12V 9 XHG-CN1-7
GND(+12V) 19 XHG-CN1-8
GND(+12V) 29 XHG-CN1-8

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X101
Signal Name NO. Destination
JT3MOTOR-U B1 XJT3M-B1
JT3MOTOR-V A2 XJT3M-A2
JT3MOTOR-W B2 XJT3M-B2
JT3MOTOR-FG A1 XJT3M-A1
JT3BRAKE-P A3 XJT3M-A3
JT3BRAKE-N B3 XJT3M-B3
X102
Signal Name NO. Destination
JT4MOTOR-U 1 XJT4M-1
JT4MOTOR-V 2 XJT4M-2
JT4MOTOR-W 3 XJT4M-3
JT4MOTOR-FG 6 XJT4M-4
JT4BRAKE-P 4 XJT4B-1
JT4BRAKE-N 5 XJT4B-2
SIGO-1 7 X106-1
SIGO-2 8 X106-3
SIGO-3 9 X107-1
SIGO-4 10 X107-2
SIGO-5 12 X108-1
SIGO-6 13 X108-2
SIGO-7 14 X109-1
SIGO-8 15 X106-2,4,
X107-2,4,
X108-2,4,
X109-2
X103
Signal Name NO. Destination
JT5MOTOR-U 1 XJT5M-1
JT5MOTOR-V 2 XJT5M-2
JT5MOTOR-W 3 XJT5M-3
JT5MOTOR-FG 4 XJT5M-4
JT5BRAKE-P 9 XJT5B-1
JT5BRAKE-N 10 XJT5B-2
JT6MOTOR-U 5 XJT6M-1
JT6MOTOR-V 6 XJT6M-2
JT6MOTOR-W 7 XJT6M-3
JT6MOTOR-FG 8 XJT6M-4
JT6BRAKE-P 11 XJT6B-1
JT6BRAKE-N 12 XJT6B-2

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 5. SEPARATEž INSIDE MACHINE HARNESS

X121
Signal Name NO. Destination
LS1P 1 X127-1
LS2P 3 X127-3
LS1N 2 X127-2
LS2N 4 X127-4
JT3E-P 5 XJT3E-1
JT3E-N 6 XJT3E-2
JT3E-+5V 7 XJT3E-3
JT3E-GND 8 XJT3E-4
X122
Signal Name NO. Destination
JT4E-P 1 XJT4E-1
JT4E-N 2 XJT4E-2
JT4E-+5V 3 XJT4E-3
JT4E-GND 4 XJT4E-4
X123
Signal Name NO. Destination
JT5E-P 1 XJT5E-1
JT5E-N 2 XJT5E-2
JT5E-+5V 3 XJT5E-3
JT5E-GND 4 XJT5E-4
JT6E-P 5 XJT6E-1
JT6E-N 6 XJT6E-2
JT6E-+5V 7 XJT6E-3
JT6E-GND 8 XJT6E-4
X124
Signal Name NO. Destination
+24V 1 X24V
24G 2 X24G
+24V 3 X24V
24G 4 X24G
24G 5 X24G
SIG1 6 XSIG1
24G 7 X24G
SIG2 8 XSIG2
24G 9 X24G
SIG3 10 XSIG3
24G 11 X24G
SIG4 12 XSIG4

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XHG-CN4
Signal Name NO. Destination
JT3E-GND 1 X121-8
JT3E-+5V 2 X121-7
JT1E-GND 3 XJT1E-4
JT1E-+5V 4 XJT1E-3
JT2E-GND 5 XJT2E-4
JT2E-+5V 6 XJT2E-3
JT4E-GND 7 X122-4
JT4E-+5V 8 X122-3
JT5E-GND 9 X123-4
JT5E-+5V 10 X123-3
JT6E-GND 11 X123-8
JT6E-+5V 12 X123-7

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n FS10X Inside Machine harness Overall System Diagram

5-44 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

n FS10X Inside Machine Harness

X4A
Signal Name NO. Destination
JT1MOTOR-U 1 XJT1M-B1
JT1MOTOR-V 2 XJT1M-A2
JT1MOTOR-W 3 XJT1M-B2
JT2MOTOR-U 4 XJT2M-B1
JT2MOTOR-V 5 XJT2M-A2
JT2MOTOR-W 6 XJT2M-B2
TH-P a
TH-N b
JT3MOTOR-U 7 X109-B1
JT3MOTOR-V 8 X109-A2
JT3MOTOR-W 9 X109-B2
X5A
Signal Name NO. Destination
JT1BRAKE-P 1 X110-1
JT1BRAKE-N 2 X110-2
JT2BRAKE-P 11 X110-3
JT2BRAKE-N 12 X110-4
JT3BRAKE-P 21 X112-A3
JT3BRAKE-N 22 X112-B3
SIGO-1 8 X114-1
SIGO-2 9 X114-2
SIGO-3 18 X114-3
SIGO-4 19 X114-4
SIGO-5 28 X114-5
SIGO-6 29 X114-6
SIGO-7 38 X114-7
SIGO-8 39 X114-8
JT4BRAKE-P 3 X113-A3
JT4BRAKE-N 4 X113-B3
JT4MOTOR-U 5 X113-B1
JT4MOTOR-V 6 X113-A2
JT4MOTOR-W 7 X113-B2
JT5BRAKE-P 13 X115-A3
JT5BRAKE-N 14 X115-B3
JT5MOTOR-U 15 X115-B1
JT5MOTOR-V 16 X115-A2
JT5MOTOR-W 17 X115-B2
JT6BRAKE-P 23 X116-A3
JT6BRAKE-N 24 X116-B3
JT6MOTOR-U 25 X116-B1
JT6MOTOR-V 26 X116-A2
JT6MOTOR-W 27 X116-B2
JT7MOTOR-U 35 X104-B1
JT7MOTOR-V 36 X104-A2
JT7MOTOR-W 37 X104-B2
JT7MOTOR-FG 40 X104-A1
JT7BRAKE-P 33 X104-A3
JT7BRAKE-N 34 X104-B3

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X3A
Signal Name NO. Destination
EPV-P 38 X125-1
EPV-N 39 X125-2
LS1P 6 X126-1
LS2P 26 X126-3
LS1N V X121-2
LS2N Sf X121-4
JT3E-P 21 X121-5
JT3E-N 31 X121-6
JT1E-P 1 XJT1E-1
JT1E-N 11 XJT1E-2
JT2E-P 3 XJT2E-1
JT2E-N 13 XJT2E-2
JT4E-P 2 X122-1
JT4E-N 12 X122-2
JT5E-P 4 X123-1
JT5E-N 14 X123-2
JT6E-P 22 X123-5
JT6E-N 32 X123-6
+24V 7 X124-1
24G 17 X124-2
+24V 27 X124-3
24G 37 X124-4
24G 17 X124-5
SIG1 5 X124-6
24G 17 X124-7
SIG2 15 X124-8
24G 37 X124-9
SIG3 25 X124-10
24G 37 X124-11
SIG4 35 X124-12
JT7E-P 23 XHG-CN1-1
JT7E-N 33 XHG-CN1-2
BAT AL P 24 XHG-CN1-3
BAT AL N 34 XHG-CN1-4
+12V 10 XHG-CN1-5
GND(+12V) 20 XHG-CN1-6
+12V 8 XHG-CN1-7
GND(+12V) 18 XHG-CN1-8
GND(+12V) 28 XHG-CN1-6
GND(+12V) 30 XHG-CN1-8
+12V 9 XHG-CN1-7
GND(+12V) 19 XHG-CN1-8
GND(+12V) 29 XHG-CN1-8

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X109
Signal Name NO. Destination
JT3MOTOR-U B1 X112-B1
JT3MOTOR-V A2 X112-A2
JT3MOTOR-W B2 X112-B2
X110
Signal Name NO. Destination
JT1BRAKE-P 1 XJT1B-1
JT1BRAKE-N 2 XJT1B-2
JT2BRAKE-P 3 XJT2B-1
JT2BRAKE-N 4 XJT2B-2
X112
Signal Name NO. Destination
JT3MOTOR-U B1 XJT3M-1
JT3MOTOR-V A2 XJT3M-2
JT3MOTOR-W B2 XJT3M-3
JT3BRAKE-P A3 XJT3M-4
JT3BRAKE-N B3 XJT3M-5
JT3MOTOR-FG A1 XJT3M-
X113
Signal Name NO. Destination
JT4BRAKE-P A3 XJT4M-A3
JT4BRAKE-N B3 XJT4M-B3
JT4MOTOR-U B1 XJT4M-B1
JT4MOTOR-V A2 XJT4M-A2
JT4MOTOR-W B2 XJT4M-B2
JT4MOTOR-FG A1 XJT4M-A1
X114
Signal Name NO. Destination
SIGO-1 1 X106-1
SIGO-2 2 X106-3
SIGO-3 3 X107-1
SIGO-4 4 X107-2
SIGO-5 5 X108-1
SIGO-6 6 X108-2
SIGO-7 7 X109-1
SIGO-8 8 X106-2,4,
X107-2,4,
X108-2,4,
X109-2

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 5. SEPARATEž INSIDE MACHINE HARNESS

X115
Signal Name NO. Destination
JT5BRAKE-P A3 XJT5B-1
JT5BRAKE-N B3 XJT5B-2
JT5MOTOR-U B1 XJT5M-1
JT5MOTOR-V A2 XJT5M-2
JT5MOTOR-W B2 XJT5M-3
JT5MOTOR-FG A1 XJT5M-4
X116
Signal Name NO. Destination
JT6BRAKE-P A3 XJT6B-1
JT6BRAKE-N B3 XJT6B-2
JT6MOTOR-U B1 XJT6M-1
JT6MOTOR-V A2 XJT6M-2
JT6MOTOR-W B2 XJT6M-3
JT6MOTOR-FG A1 XJT6M-4
EARTH BAR
Signal Name NO. Destination
EARTH CN1-P,CN2-P
XJT1M-A1,XJT2M-A1
X112-A1,X113-A1
X115-A1,X116-A1
X121
Signal Name NO. Destination
LS1P 1 X127-1
LS2P 3 X127-3
LS1N 2 X127-2
LS2N 4 X127-4
JT3E-P 5 XJT3E-1
JT3E-N 6 XJT3E-2
JT3E-+5V 7 XJT3E-3
JT3E-GND 8 XJT3E-4
X122
Signal Name NO. Destination
JT4E-P 1 XJT4E-1
JT4E-N 2 XJT4E-2
JT4E-+5V 3 XJT4E-3
JT4E-GND 4 XJT4E-4

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X123
Signal Name NO. Destination
JT5E-P 1 XJT5E-1
JT5E-N 2 XJT5E-2
JT5E-+5V 3 XJT5E-3
JT5E-GND 4 XJT5E-4
JT6E-P 5 XJT6E-1
JT6E-N 6 XJT6E-2
JT6E-+5V 7 XJT6E-3
JT6E-GND 8 XJT6E-4
X124
Signal Name NO. Destination
+24V 1 X24V
24G 2 X24G
+24V 3 X24V
24G 4 X24G
24G 5 X24G
SIG1 6 XSIG1
24G 7 X24G
SIG2 8 XSIG2
24G 9 X24G
SIG3 10 XSIG3
24G 11 X24G
SIG4 12 XSIG4
XHG-CN4
Signal Name NO. Destination
JT3E-GND 1 X121-8
JT3E-+5V 2 X121-7
JT1E-GND 3 XJT1E-4
JT1E-+5V 4 XJT1E-3
JT2E-GND 5 XJT2E-4
JT2E-+5V 6 XJT2E-3
JT4E-GND 7 X122-4
JT4E-+5V 8 X122-3
JT5E-GND 9 X123-4
JT5E-+5V 10 X123-3
JT6E-GND 11 X123-8
JT6E-+5V 12 X123-7

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-49

 5. SEPARATEž INSIDE MACHINE HARNESS

n FS30/45 Inside Machine Harness Overall system Diagram

5-50 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

n FS30/45 Inside Machine Harness

X4A
Signal Name NO. Destination
JT1MOTOR-U 1 XJT1M-B1
JT1MOTOR-V 2 XJT1M-A2
JT1MOTOR-W 3 XJT1M-B2
JT2MOTOR-U 4 XJT2M-B1
JT2MOTOR-V 5 XJT2M-A2
JT2MOTOR-W 6 XJT2M-B2
TH-P a
TH-N b
JT3MOTOR-U 7 X109-B1
JT3MOTOR-V 8 X109-A2
JT3MOTOR-W 9 X109-B2
X5A
Signal Name NO. Destination
JT1BRAKE-P 1 X110-1
JT1BRAKE-N 2 X110-2
JT2BRAKE-P 11 X110-3
JT2BRAKE-N 12 X110-4
JT3BRAKE-P 21 X112-A3
JT3BRAKE-N 22 X112-B3
SIGO-1 8 X114-1
SIGO-2 9 X114-2
SIGO-3 18 X114-3
SIGO-4 19 X114-4
SIGO-5 28 X114-5
SIGO-6 29 X114-6
SIGO-7 38 X114-7
SIGO-8 39 X114-8
JT4BRAKE-P 3 X113-A3
JT4BRAKE-N 4 X113-B3
JT4MOTOR-U 5 X113-B1
JT4MOTOR-V 6 X113-A2
JT4MOTOR-W 7 X113-B2
JT5BRAKE-P 13 X115-A3
JT5BRAKE-N 14 X115-B3
JT5MOTOR-U 15 X115-B1
JT5MOTOR-V 16 X115-A2
JT5MOTOR-W 17 X115-B2
JT6BRAKE-P 23 X116-A3
JT6BRAKE-N 24 X116-B3
JT6MOTOR-U 25 X116-B1
JT6MOTOR-V 26 X116-A2
JT6MOTOR-W 27 X116-B2
JT7MOTOR-U 35 X104-B1
JT7MOTOR-V 36 X104-A2
JT7MOTOR-W 37 X104-B2
JT7MOTOR-FG 40 X104-A1
JT7BRAKE-P 33 X104-A3
JT7BRAKE-N 34 X104-B3

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-51

 5. SEPARATEž INSIDE MACHINE HARNESS

X3A
Signal Name NO. Destination
EPV-P 38 X125-1
EPV-N 39 X125-2
LS1P 6 X126-1
LS2P 26 X126-3
LS1N V X121-2
LS2N Sf X121-4
JT3E-P 21 X121-5
JT3E-N 31 X121-6
JT1E-P 1 XJT1E-1
JT1E-N 11 XJT1E-2
JT2E-P 3 XJT2E-1
JT2E-N 13 XJT2E-2
JT4E-P 2 X122-1
JT4E-N 12 X122-2
JT5E-P 4 X123-1
JT5E-N 14 X123-2
JT6E-P 22 X123-5
JT6E-N 32 X123-6
+24V 7 X124-1
24G 17 X124-2
+24V 27 X124-3
24G 37 X124-4
24G 17 X124-5
SIG1 5 X124-6
24G 17 X124-7
SIG2 15 X124-8
24G 23 37
SIG3 25 X124-10
24G 37 X124-11
SIG4 35 X124-12
JT7E-P 23 XHG-CN1-1
JT7E-N 33 XHG-CN1-2
BAT AL P 24 XHG-CN1-3
BAT AL N 34 XHG-CN1-4
+12V 10 XHG-CN1-5
GND(+12V) 20 XHG-CN1-6
+12V 8 XHG-CN1-7
GND(+12V) 18 XHG-CN1-8
GND(+12V) 28 XHG-CN1-6
GND(+12V) 30 XHG-CN1-8
+12V 9 XHG-CN1-7
GND(+12V) 19 XHG-CN1-8
GND(+12V) 29 XHG-CN1-8

5-52 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

X109
Signal Name NO. Destination
JT3MOTOR-U B1 X112-B1
JT3MOTOR-V A2 X112-A2
JT3MOTOR-W B2 X112-B2
X110
Signal Name NO. Destination
JT1BRAKE-P 1 XJT1B-1
JT1BRAKE-N 2 XJT1B-2
JT2BRAKE-P 3 XJT2B-1
JT2BRAKE-N 4 XJT2B-2
X112
Signal Name NO. Destination
JT3MOTOR-U B1 XJT3M-1
JT3MOTOR-V A2 XJT3M-2
JT3MOTOR-W B2 XJT3M-3
JT3BRAKE-P A3 XJT3M-4
JT3BRAKE-N B3 XJT3M-5
JT3MOTOR-FG A1 XJT3M-
X113
Signal Name NO. Destination
JT4BRAKE-P A3 XJT4M-A3
JT4BRAKE-N B3 XJT4M-B3
JT4MOTOR-U B1 XJT4M-B1
JT4MOTOR-V A2 XJT4M-A2
JT4MOTOR-W B2 XJT4M-B2
JT4MOTOR-FG A1 XJT4M-A1
X114
Signal Name NO. Destination
SIGO-1 1 X106-1
SIGO-2 2 X106-3
SIGO-3 3 X107-1
SIGO-4 4 X107-2
SIGO-5 5 X108-1
SIGO-6 6 X108-2
SIGO-7 7 X109-1
SIGO-8 8 X106-2,4,
X107-2,4,
X108-2,4,
X109-2

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-53

 5. SEPARATEž INSIDE MACHINE HARNESS

X115
Signal Name NO. Destination
JT5BRAKE-P A3 XJT5M-A3
JT5BRAKE-N B3 XJT5M-B3
JT5MOTOR-U B1 XJT5M-B1
JT5MOTOR-V A2 XJT5M-A2
JT5MOTOR-W B2 XJT5M-B2
JT5MOTOR-FG A1 XJT5M-A1
X116
Signal Name NO. Destination
JT6BRAKE-P A3 XJT6M-A3
JT6BRAKE-N B3 XJT6M-B3
JT6MOTOR-U B1 XJT6M-B1
JT6MOTOR-V A2 XJT6M-A2
JT6MOTOR-W B2 XJT6M-B2
JT6MOTOR-FG A1 XJT6M-A1
EARTH BAR
Signal Name NO. Destination
EARTH CN1-P,CN2-P
XJT1M-A1,XJT2M-A1
X112-A1,X113-A1
X115-A1,X116-A1
X121
Signal Name NO. Destination
LS1P 1 X127-1
LS2P 3 X127-3
LS1N 2 X127-2
LS2N 4 X127-4
JT3E-P 5 XJT3E-1
JT3E-N 6 XJT3E-2
JT3E-+5V 7 XJT3E-3
JT3E-GND 8 XJT3E-4
X122
Signal Name NO. Destination
JT4E-P 1 XJT4E-1
JT4E-N 2 XJT4E-2
JT4E-+5V 3 XJT4E-3
JT4E-GND 4 XJT4E-4

5-54 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 5. SEPARATEž INSIDE MACHINE HARNESS

X123
Signal Name NO. Destination
JT5E-P 1 XJT5E-1
JT5E-N 2 XJT5E-2
JT5E-+5V 3 XJT5E-3
JT5E-GND 4 XJT5E-4
JT6E-P 5 XJT6E-1
JT6E-N 6 XJT6E-2
JT6E-+5V 7 XJT6E-3
JT6E-GND 8 XJT6E-4
X124
Signal Name NO. Destination
+24V 1 X24V
24G 2 X24G
+24V 3 X24V
24G 4 X24G
24G 5 X24G
SIG1 6 XSIG1
24G 7 X24G
SIG2 8 XSIG2
24G 9 X24G
SIG3 10 XSIG3
24G 11 X24G
SIG4 12 XSIG4
XHG-CN4
Signal Name NO. Destination
JT3E-GND 1 X121-8
JT3E-+5V 2 X121-7
JT1E-GND 3 XJT1E-4
JT1E-+5V 4 XJT1E-3
JT2E-GND 5 XJT2E-4
JT2E-+5V 6 XJT2E-3
JT4E-GND 7 X122-4
JT4E-+5V 8 X122-3
JT5E-GND 9 X123-4
JT5E-+5V 10 X123-3
JT6E-GND 11 X123-8
JT6E-+5V 12 X123-7

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual 5-55

 SAFETY

OVERVIEW

DESCRIPTIONS

TROUBLESHOOTING

SEPARATEžž INSIDE MACHINE HARNESS

APPENDIX

INDEX

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual Appendix-1

 MOTOR LIST

Motor List
U series
UX UT UZ UD UB UP UR
MOTOR ASSY MOTOR ENCODER 70 200 100 200 100 100 150 100 100K 100H
P/N P/N 100 300 120 120 150
120 150 150
150
50601- 1118 60601- 1087 60490-1033 4 2

50601- 1120 60601- 1089 60490-1034 3,4

50601- 1121 60601- 1090 60490-1032 1,2,3 1,2,3 1,2,3 1,2,3 1,2,3 1,2,3 1,2,3 3

50601- 1122 60601- 1091 60490-1032 1,2,3 1,2,3 1,2,3 1,2,3 1,2,3 1,2,3

50601- 1123 60601- 1092 60490-1032 4,5,6, 7 4,5,6, 7 4,5,6, 4,5,6, 1,2,4, 1,2,4,
7 7 7 7 5 5
50601- 1124 60601- 1093 60490-1032 4,5,6, 7 4,5,6, 7 4,5,6, 4,5,6,
7 7 7 7
50601- 1125 60601- 1094 60490-1032 4,5,6 4,5,6 3

50601- 1126 60601- 1095 60490-1032 4,5,6 4,5,6

50601- 1128 60601- 1096 60490-1034 1

F series
FS FC FS FC FA FW FS FA FP FS
MOTOR ASSY MOTOR ENCODER 02 02 06N 06N 06N 06N 20N 20N 20N 10L
P/N P/N 03 06L 06L 20L 30N
10N 30L
10E 45N
10C 45C
50601- 1121 60601- 1090 60490-1032 1,2

50601- 1123 60601- 1092 60490-1032 1,2 1,2 1,2 7

50601- 1125 60601- 1094 60490-1032 3

50601- 1136 60601- 1104 60490-1034 4,5,6 4,5,6 4,5,6 4,5,6

50601- 1138 60601- 1106 60490-1034 3 3 3 3 4,5,6

50601- 1139 60601- 1107 60490-1033 1,2,7 1,2,7 1,2,7 1,2,7 3,7 3,7 3,7

50601- 1143 60601- 1111 60490-1034 4,5,6 4,5,6 4,5,6

50601- 1132 60601- 1100 60490-1034 5,6 5,6

50601- 1133 60601- 1101 60490-1034 4 4

50601- 1134 60601- 1102 60490-1034 1,7 1,7

50601- 1135 60601- 1103 60490-1034 3 3

50601- 1130 60601- 1098 60490-1034 2 2

Appendix-2 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 MOTOR LIST

J series
MOTOR ASSY MOTOR P/N ENCODER Js Js Js JA
P/N 5 6 30 15
10 40
50601-1118 60601-1087 60490-1033 1,2,7 1,2,3,7 4,5,6 4,5,6
50601-1119 60601-1088 60490-1034 4,5,6 4,5,6
50601-1120 60601-1089 60490-1034 3
50601-1121 60601-1090 60490-1032 1,2 1,2
50601-1123 60601-1092 60490-1032 7 7
50601-1125 60601-1094 60490-1032 3 3

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual Appendix-3

 MOTOR LIST

Main Components Parts List

Controller
CLS P/N PART NAME Qty Material, Detail NOTE NOTE

SA 50630-1049 POWERSUPPLY-ASSY- 1 Std. 10A 5/12/-12/24V OMRON S82W-618

DC 10/4/1.5/2.5A
SB 50630-1050 POWERSUPPLY-ASSY- 1 Opt. 20A 5/12/-12/24V OMRON S82W-619
DC 20/10/3/5A
50630-1052 POWERSUPPLY-ASSY- 1 Std. 10A 5/12/-12/24V
DC 10/4/1.5/5A
SA 50999-1760 PRINTED 1 1GA PC board FLASH-2M, 50999-1548 upper
CIRCUITBOARD-ASSY SRAM-1M, CF compatible
SB 50999-1762 PRINTED 1 1GA PC board FLASH:4M, 50999-1741
CIRCUITBOARD-ASSY SRAM:1M, CF upper compatible
SC 50999-1763 PRINTED 1 1GA PC board FLASH:4M, 50999-1604
CIRCUITBOARD-ASSY SRAM:4M, CF upper compatible
SA 50999-1548 PRINTED 1 1GA PC board FLASH-2M, see P/N 50999-1760
CIRCUITBOARD-ASSY SRAM-1M
SB 50999-1741 PRINTED 1 1GA PC board FLASH:4M, see P/N 50999-1762
CIRCUITBOARD-ASSY SRAM:1M
SC 50999-1604 PRINTED 1 1GA PC board FLASH:4M, see P/N 50999-1763
CIRCUITBOARD-ASSY SRAM:4M
50999-1854 PRINTED 1 1HA PC board FLASH:4M, With ethernet
CIRCUITBOARD-ASSY SRAM:1M
50999-1692 PRINTED 1 1HP PC board
CIRCUITBOARD-ASSY
50999-1694 PRINTED 1 1HY PC board
CIRCUITBOARD-ASSY
50999-1804 PRINTED 1 1HK PC board
CIRCUITBOARD-ASSY
50999-1557 PRINTED 1 1FR PC board DI/O NPN
CIRCUITBOARD-ASSY
50999- PRINTED 1 1HW PC board DI/O PNP
CIRCUITBOARD-ASSY
OA 50999-1701 PRINTED 1 1FS PC board CONTROL-NET
CIRCUITBOARD-ASSY
OB 50999-1702 PRINTED 1 1FS PC board RI/O
CIRCUITBOARD-ASSY
O 50999-1720 PRINTED 1 1GW PC board D/A Output Opt.
CIRCUITBOARD-ASSY & PNP DI/O
50999- PRINTED 1 1HW PC board D/A Output Opt.
CIRCUITBOARD-ASSY & NPN DI/O
50999-1693 PRINTED 1 1HZ PC board Card Rack Ass'y,
CIRCUITBOARD-ASSY Mother board
50999-1803 PRINTED 1 1HJ PC board Card Rack Assy,
CIRCUITBOARD-ASSY Mother board
SA 50999-1592 PRINTED 1 1GB PC board JS005 6 axes,
CIRCUITBOARD-ASSY
SB 50999-1593 PRINTED 1 1GB PC board JS005 7 axes,
CIRCUITBOARD-ASSY
SC 50999-1549 PRINTED 1 1GB PC board JS006/010 6 axes,
CIRCUITBOARD-ASSY
SD 50999-1550 PRINTED 1 1GB PC board JS006/010 7 axes,
CIRCUITBOARD-ASSY
SE 50999-1661 PRINTED 1 1GB PC board JS006/010 7 axes,
CIRCUITBOARD-ASSY JT7:092
SF 50999-1651 PRINTED 1 1GB PC board JS030/40 6 axes,
CIRCUITBOARD-ASSY

Appendix-4 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 MOTOR LIST

SG 50999-1595 PRINTED 1 1GB PC board JS030/40 7 axes,

CIRCUITBOARD-ASSY
SH 50999-1653 PRINTED 1 1GB PC board UD100 4 axes,
CIRCUITBOARD-ASSY
SJ 50999-1650 PRINTED 1 1GB PC board U*120,U*150 6 axes,
CIRCUITBOARD-ASSY
CLS P/N PART NAME Qty Material, Detail NOTE NOTE

SL 50999-1647 PRINTED 1 1GB PC board U*120,U*150 7 axes,

CIRCUITBOARD-ASSY JT7:040
SM 50999-1600 PRINTED 1 1GB PC board U*200, 6 axes,
CIRCUITBOARD-ASSY
SN 50999-1601 PRINTED 1 1GB PC board U*200, 7 axes,
CIRCUITBOARD-ASSY
50999-1806 PRINTED 1 1GB PC board F*002/003,6 axes
CIRCUITBOARD-ASSY
50999-1807 PRINTED 1 1GB PC board F*002/003.7 axes
CIRCUITBOARD-ASSY
SA 50607-1092 SERVOAMP-ASSY 1 for JS5,6,10 6 AXES (include 1GD)
SA 50607-1090 SERVOAMP-ASSY 1 for U series, 6 AXES (include 1GC)
JS30/40
SA1 50607-1084 SERVOAMP-ASSY 1 1GD PC board 1GD 6-AXIS
SA1 50607-1082 SERVOAMP-ASSY 1 1GC PC board 1GC 6-AXIS
SB 50607-1093 SERVOAMP-ASSY 1 for JS5,6,10 7 AXES (include 1GD)
SB 50607-1091 SERVOAMP-ASSY 1 for U series, 7 AXES (include 1GC)
JS30/40
SB1 50607-1085 SERVOAMP-ASSY 1 1GD PC board 1GD 7-AXIS
SB1 50607-1083 SERVOAMP-ASSY 1 1GC PC board 1GC 7-AXIS
50607-1114 SERVOAMP-ASSY 1 for F*002/003 6 AXES (include 1HN)
50607-1115 SERVOAMP-ASSY 1 for F*002/003 7 AXES (include 1HN)
50607-1106 SERVOAMP-ASSY 1 1HN PC board 1HN 6 AXES
50607-1107 SERVOAMP-ASSY 1 1HN PC board 1HN 7 AXES

C4* 50817-1182 BOX-ASSY-TEACH 1 MFP

A00
1
50817- BOX-ASSY-TEACH 1 MFP+HARNESS 10m
A00 1209L10
2
60337-1083 SHEET 3 Protect Sheet for MFP
C00
1
C4*

60569-1052 BREAKER 1 DISCONNECT KLOCKNER

A00 SW. P1-25/EA/SVB-SW
1
C40 60569-1066 BREAKER 1 MATSUSHITA
BAM210031
C41/C 60621-1101 TRANSFORMER 1 EU, J-series ICHIDEN(JPN)
42 C00
1
60621-1100 TRANSFORMER 1 EU, U-series ICHIDEN(JPN)
C00
1
60551-1029 FILTER-ELECTRIC 1 Noise Filter SCHAFFNER
K00 FN660-6/06
1
60551-2022 FILTER-ELECTRIC 1 Noise Filter SOSHIN
NY2010A-YX

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual Appendix-5

 MOTOR LIST

60507-2001 DIODE-ARRAY 1 SHINDENGEN(JPN)

L001 S25VB20
60565-1041 RELAY-CONTACTOR 1 Magnetic (3p + 1a) TELEMECHNICH
M00 Contactor LC1-D4011M7
1
60565-1016 RELAY-CONTACTOR 1 Aux. Contact TELEMECHNICH
M00 LA1-DN22
2
60565-1017 RELAY-CONTACTOR 1 Serge Killer TELEMECHNICH
M00 LA4-DC3U
3
CLS P/N PART NAME Qty Material, Detail NOTE NOTE

60551-2001 FILTER-ELECTRIC 1 SHIZUKI (JPN)

M00 SKVB104120
4
60570-1066 FUSE 1 Circuit Protector 3A TELEMECHNICH
E001 GB2-CB08
60570-1045 FUSE 1 Circuit Protector 12A TELEMECHNICH
F001 GB2-CB20
60570-1069 FUSE 1 Circuit Protector 16A TELEMECHNICH
H00 GV3-M40
1
C40 60570-1068 FUSE 1 Circuit Protector 40A TELEMECHNICH
H00 GV3-M40
1
C41/C 60565-1014 RELAY-CONTACTOR 1 Contactor 24Vdc TELEMECHNICH
42 B00 LP1-D5011BW
1
60565-1017 RELAY-CONTACTOR 1 Serge Killer for MC TELEMECHNICH
B00 LA4-DC3U
2
60565-1014 RELAY-CONTACTOR 1 Contactor 24Vdc TELEMECHNICH
C00 LP1-D5011BW
1
60565-1017 RELAY-CONTACTOR 1 Serge Killer for MC TELEMECHNICH
C00 LA4-DC3U
2
60541-2003 CAPACITOR-AL 1 2700uF MATSUSHITA
J001 ELECTROLYTIC ECOG2GP272EC
C40 60541-2001 CAPACITOR-AL 1 MATSUSHITA
J001 ELECTROLYTIC ECOG2GP682EC
C41/C 60541-2002 CAPACITOR-AL 1 MATSUSHITA
42 T001 ELECTROLYTIC ECEG2GG102XT
C41/C 60376-1025 FAN 3 Change 20000H OMRON
42 B00 R87F-A6A13HP
1
60376-1025 FAN 4 Change 20000H OMRON
B00 R87F-A6A13HP
1
60376-1025 FAN 1 Change 20000H OMRON
B00 R87F-A6A13HP
1
60376-1020 FAN 1 Change 20000H OMRON
R87F-A6A93HP
D00 50750-1007 BATTERY-ASSY 1 for 1FG/1HZ PC board Change 20000H
1
60770-1004 TIE BAND 150MM WHITE 2 NYLON66 for tie Battery Change 20000H
D00
2
60404-1007 FILTER 1 for TRANSFORMER Change 5000H
ROOM

Appendix-6 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 MOTOR LIST

O 60851-1006 SRAM CARD 1MB 1 HITACHI MAXWELL

ML-1M-TB4N
60310-1011 KEY 1 ENCLOSURE KEY 7MM RITTAL
Q00 SQ. SZ2547
2
C4* 60658-1029 LAMP 1 ERROR LAMP IZUMI(JPN)
A00 HW1P-2Q3R
1
60555-1079 SWITCH 1 ERROR RESET SW IZUMI(JPN)
A00 HW1B-M110Y
2
60555-1099 SWITCH 1 MOTOR POWER IZUMI(JPN)
A00 HW1L-M110Q3A
3
CLS P/N PART NAME Qty Material, Detail NOTE NOTE

60555-1097 SWITCH 1 HOLD/RUN IZUMI(JPN)

A00 HW1S-2T22
5
C4* 60606-1005 METER 1 HOUR METER MATSUSHITA
B00 TH638
1
60606-1008 METER 1 HOUR METER MATSUSHITA
TH639
60658-1033 LAMP 1 Control Power Lamp IZUMI(JPN)
C00 HW1P-1M2W
1
O 60555-1117 SWITCH,SELECTOR 1 TEACH/REPEAT FUJI (JPN)
AH22-J2B33
C4* O 60555-1100 SWITCH 1 EMERGENCY STOP IZUMI(JPN)HW1E-BV402R
SW
50977-3065 HARNESS-ASSY- 1 Brake Release SW
Q00 CONTROLLER Ass'y
1
60555-1098 SWITCH 1 CYCLE START IZUMI(JPN)
A00 HW1L-M110Q3G
4

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual Appendix-7

 MOTOR LIST

Robot Cable (between Controller and Manipulator)

CLS P/N PART NAME Qty Material, Detail NOTE NOTE

SA 50979- ROBOT CABLE 1 SIGNAL L** 7m:07, 10m:10,

1784L** 15m:15
C40 SB - - - -

C41/C SB 50979- ROBOT CABLE 1 U,MAJOR L** 7m:07, 10m:10,

42 1785L** MOTOR 15m:15
C40 SC - - - -

C41/C SC 50979- ROBOT CABLE 1 U,MINOR L** 7m:07, 10m:10,

42 1786L** MOTOR 15m:15
C40 SC 50979- ROBOT CABLE 1 J,MOTOR L** 7m:07, 10m:10,
1820L** 15m:15
C41/C SC 50979- ROBOT CABLE 1 -
42 1918L**

Machine Harness
CLS P/N PART NAME Qty Material, Detail NOTE NOTE

JS005 A0 40975-1559 HARNESS-ASSY- 1

MACHINE
JS010 A0 40975-1560 HARNESS-ASSY- 1
MACHINE
JS30/ A0 40975-1543 HARNESS-ASSY- 1
40 MACHINE
UX12 A0 40975-1534 HARNESS-ASSY- 1 UX100/120/150/200
0 MACHINE
UX30
0
UT120 A0 40975-1542 HARNESS-ASSY- 1 UT100/120/150
MACHINE
UZ12
0
UD10 A0 40975-1563 HARNESS-ASSY- 1 UD100/150
0 MACHINE
40975-1560 HARNESS-ASSY- 1 F*002/003
MACHINE

Appendix-8 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 ABBREVIATIONS

ABBREVIATIONS
ABS absolute
AS Advanced Superior
ASIC application specific integrated circuit
CB circuit breaker
CFL cathode fluorescent lamp
CPU central processing unit
CRC cyclic redundancy check
DI digital input
DO digital output
DRAM dynamic random access memory
EPROM erasable and programmable read only memory
FET field effect transistor
GA gate array
HIC hybrid integrated circuit
ID identifier / identification
INC incremental
IP industry pack
IPM intelligent power module
LAN local area network
LCD liquid crystal display
LED light emitting diode
LS ORD SW limit switch override switch
MC magnet contactor
MFP Multi-Function Panel
MPU micro processor unit
NAC Node Adapter Chip
OL overload
OS operating system
PAL programmable array logic
PB Power Block
PC printed circuit
PC personal computer
PI/O parallel input/output
PLCC plastic leaded chip carrier
PLD programmable logic device
PWM pulse width modulation
RAM random access memory
RGSO remote gate servo on
RI/O remote input/output
RISC reduced instruction set computer
ROM read only memory
ROSET Robot Simulator for application Engineering and Teaching
RTC real time clock
SIO serial input/output
SLOGIC Sequential Logic
SRAM static random access memory
T/P Teach Pendant
VME Versus modular European
WDT watchdog timer

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual Appendix-9

 MOTOR LIST

. MEMO

Appendix-10 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 SAFETY

OVERVIEW

DESCRIPTIONS

TROUBLESHOOTING

SEPARATEžž INSIDE MACHINE HARNESS

APPENDIX

INDEX

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual Index-1

 INDEX

1FG PC board 3-30,

1FS PC board 3-45,
1HA/1GA PC board 3-6,
1GB PC board 3-12,
1GC PC board 3-18,
1GD PC board 3-18,
1GM PC board 3-17,
1GW PC board 3-35,
1HG PC board 3-33,
1HN PC board 3-25,
1HP PC board 3-50,
1HW PC board 3-35,
1HY PC board 3-53,
1HZ PC board 3-49,
ABS-track error 4-77.
AC servo motor 3-18, 3-25, 3-19, 3-20,
ACFAIL 3-9, 3-46, 4-102,
amplifier 3-6, 3-18, 3-25, 3-56
automatic servo off function 4-62,
auxiliary data 2-2, 2-7
axis restriction limit switch 3-12, 4-21, 4-53, 4-90, 4-91 4-92
axis restriction limit switch 4-93 4-94, 4-97,
battery 3-6, 3-7, 3-14, 3-30, 3-31, 3-31
battery 3-33, 3-49, 3-55, 3-63, 3-66 4-17,
battery 4-18, 4-19, 4-23, 4-24, 4-25, 4-66
battery 4-67, 4-70, 4-101
brake drive circuit 3-11, 4-59,, 4-65,
brake line 4-59, 4-65, 4-89
brake power 3-15, 3-56, 3-57,
bus error 4-17, 4-28, 4-29, 4-30,
cathode fluorescent lamp 3-65,
CFL(cathode fluorescent lamp) 3-65,
check sum 4-17, 4-23, 4-26, 4-27,
command value 4-20, 4-21, 4-22, 4-63, 4-64, 4-89
Control-Net 3-45, 3-46
counter teach 4-59, 4-62, 4-65, 4-83, 4-86, 4-88,
CPU error 3-9
CS signal detection 3-63,
current detector 4-18, 4-57
current feedback 3-14, 3-28, 3-19, 3-20, 3-19,
current feedback 4-59,
current sensor 3-12, 3-14, 3-17, 3-18, 3-25, 3-28,
current sensor 4-18, 4-55, 4-80,
current value 4-20, 4-64, 4-69, 4-70, 4-72, 4-89,
current value 4-90, 4-91, 4-93,
Cycle Start 2-5, 2-6 4-12, 4-101
DC power supply 3-60
deadman switch 2-7, 2-8, 3-46, 4-8,
diode bridge 4-85,
diode module 3-18, 3-25,
DIP switch 1-8, 3-44, 3-46, 3-48, 3-69
discharge circuit 3-18, 3-25
disconnect switch 1-7
down-load 3-9, 3-48, 4-26, 4-27, 4-38,
emergency stop 2-5, 3-12, 3-51, 3-57, 3-59
emergency stop switch 1-5, 2-8, 3-54, 3-57, 3-68
emergency stop switch 4-9, 4-11, 4-91, 4-94,
encoder 3-63, 4-18, 4-40, 4-63, 4-64, 4-66,
encoder 4-67, 4-68, 4-69, 4-70, 4-71, 4-72
encoder 4-73, 4-74, 4-75, 4-76, 4-77 4-78
encoder 4-89

Index-2 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 INDEX

encoder battery board 3-30, 3-33, 4-66, 4-67, 4-70, 4-101,

encoder battery 4-18, 4-66, 4-67, 4-70, 4-101,
encoder data 4-18, 4-68, 4-69, 4-71, 4-72 4-76,
encoder harness 4-70, 4-77, 4-78,
encoder signal 3-14, 3-34, 4-63, 4-68, 4-71, 4-74,
encoder signal 4-75, 4-76
error code 4-13, 4-41, 4-43, 4-45, 4-48, 4-49,
error code 4-56,
external emergency stop 4-9, 4-11, 4-91, 4-94,
external HOLD 4-12,
flaming error 4-75,
FLASH memory 3-6, 3-8, 3-13, 3-46, 3-65,
FLASH memory 3-69 3-47, 4-17, 4-26, 4-27, 4-38,
FLASH memory 4-39,
I/O board 3-35, 4-15, 4-17, 4-28, 4-29, 4-30
I/O board 4-33,
ID code 3-13, 3-17, 4-57, 4-58,
incremental counter 3-64,
incremental data 3-64, 4-77,
incremental pulse 3-64, 4-78,
IP(Industry Pack) 3-6, 3-8 3-11,
IPM(intelligent power module) 3-21, 3-25, 3-27, 3-19, 3-20,
IPM(intelligent power module) 4-79, 4-85, 4-101, 4-102
LCD 2-7, 3-65, 3-67, 3-68,
limit switch 4-18, 4-21, 4-53, 4-90, 4-91, 4-92,
limit switch 4-93, 4-94, 4-95,
lock-out 1-7,
locking device 1-8,
LS ORD SW 3-50,
machine harness 4-55, 4-61, 4-72, 4-73, 4-90, 4-93,
magnet contactor 4-8, 4-10, 4-49,
main CPU board 3-6, 3-12,
manual brake release 3-12, 3-14, 4-91, 4-94,
manual brake release switch 1-7,
mechanical origin 4-67, 4-70,
mechanical stopper 4-21, 4-90, 4-93,
mechanical unit 2-2, 2-3, 2-7,
MFP (multi-function panel) 2-7, 3-65,
MFP cable 3-67,
MFP software 3-65,
mother board 3-49, 3-55 3-7
motor brake 3-14, 3-15, 4-59, 4-65, 4-89,
motor brake drive signal 3-14,
motor current 3-17,
motor harness 4-18, 4-61, 4-79,
motor power 2-5, 2-6, 3-6, 3-12, 3-21, 3-27,
motor power 4-8, 4-13, 4-24, 4-49, 4-54, 4-56,
motor power 4-59, 4-63, 4-65, 4-66, 4-79, 4-82
motor power 4-84, 4-85, 4-86, 4-89, 4-91, 4-94
motor power 4-96, 4-97,
motor thermal 3-14,
MR-sensor 3-64,
Multi-Function Panel 2-3, 2-4, 2-7, 3-6, 3-9,
Multi-Function Panel 3-65, 3-66 3-67 4-2, 4-5, 4-6,
Multi-Function Panel 4-7, 4-8, 4-9, 4-10, 4-11, 4-28,
Multi-Function Panel 4-29, 4-30,
OL curve 4-59,
one axis amplifier 4-38, 4-39, 4-40, 4-41, 4-43, 4-45,
one axis amplifier 4-47, 4-57, 4-61, 4-66, 4-80, 4-81
one axis amplifier 4-82, 4-84, 4-86, 4-87,

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual Index-3

 INDEX

operation panel 2-5, 2-6 3-50, 4-8, 4-9, 4-11,

operation panel 4-12,
operation unit 4-7, 4-9, 4-11, 4-49, 4-85,
overcurrent 3-12, 3-21, 3-27, 4-55,
overheat 4-8, 4-61,
overload 3-62, 4-18, 4-59, 4-61,
PB 3-12, 3-14, 3-21, 3-22, 3-27
PC card 2-8, 3-65, 3-66, 3-68, 4-26, 4-27,
personal computer 3-6, 3-66, 4-28, 4-29, 4-30,
photo coupler 3-35,
PI/O 3-45, 3-47,
pinch point 1-6,
plant safety coordinator 1-5,
position envelope error 4-18, 4-64,
power block 3-18,
power sequence board 3-12,
power unit 3-16, 3-25,
protection seat 3-67,
PWM 3-12, 3-14, 3-18, 3-21, 3-25, 3-27
PWM 3-28,
regenerating resistor 3-14, 3-18, 3-25, 3-28,
regenerating resistor 3-19, 4-82, 4-83, 4-86, 4-87, 4-88,
regenerating resistor unit 4-83, 4-86, 4-87, 4-88,
relay board 3-53, 3-57, 4-85, 4-96, 4-97, 4-98,
relay board 4-99,
RI/O 3-45, 3-46, 3-48,
robot data 4-23,
robot harness 4-55, 4-61,
rotation counter 3-42,
rotation data 4-18, 4-68,
rotor magnet 3-63,
rotor trunk 4-61,
RS232C 3-6, 3-8 3-65
RS485 3-12 3-45 3-46 3-48 3-65
safety circuit 3-50,
safety gate 4-17, 4-52,
safety plug 1-7, 4-52
sensor line 3-35 3-42 4-97
servo board 3-6, 3-25, 3-31, 3-56
servo control 3-14 3-15, 4-17, 4-51,
servo control signal 3-14
servo CPU 4-17, 4-36, 4-47,
servo error 4-56,
servo parameter 4-17, 4-37, 4-45,
servo position loop operation 3-6
servo system 4-20, 4-27, 4-48, 4-56,
SRAM card 3-66
sum check 4-17, 4-27,
super-capacitor 3-63
teach lock switch 2-7, 2-8,
teach pendant 2-7,
teaching posture 4-21, 4-22,
touch panel 3-65 3-67
touch pen 2-8, 3-67
transistor array 3-35
user set work envelope 4-21, 4-90, 4-91, 4-93, 4-94
valve line 3-35 3-42,
VME bus 3-6 3-8 3-46 3-56
VME bus 4-17, 4-28, 4-29, 4-30,
volume of contrast 2-8,

Index-4 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 INDEX

WDT (watchdog timer) 3-46

work envelope 1-3, 1-4, 1-6, 1-7,
work envelope 4-21, 4-90, 4-91, 4-92, 4-93, 4-94,
zeroing 4-67, 4-70, 4-94

Kawasaki Robot C4[/C70 Controller Trouble shooting Manual Index-5

 INDEX

. MEMO

Index-6 Kawasaki Robot C4[/C70 Controller Trouble shooting Manual

 KAWASAKI ROBOT
C4X/C70 CONTROLLER

Troubleshooting MANUAL
July 1998 : 1st Edition
September 1999 : 2nd Edition

Publication : KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION
90206-1023DEB

All rights reserved. Copyright  1999 KAWASAKI HEAVY INDUSTRIES, LTD.

 Kawasaki Robotics
(UK) Limited

Kawasaki Robotics GmbH

Kawasaki Robotics
Kawasaki Heavy
(USA), Inc.
Industries, LTD.
Tokyo Head Office

KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION

KAWASAKI ROBOTICS CO., LTD.

Kawasaki Heavy 4-1, 2-Chome Hamamatsu-cho Minato-ku Tokyo, 105-6116 JAPAN TEL 81-
(0)3-3435-6908
Industries, Ltd. (World Trade Center building) FAX 81-(0)3-3437-9880

Kawasaki Robotics 1-1, Kawasaki-cho Akashi, 673-8666 JAPAM TEL 81-(0)78-921-1565

Co., Ltd. FAX 81-(0)78-923-0685

Kawasaki Robotics 28059 Center Oaks Court Wixom, TEL 1-248-305-7610

(USA), Inc. Michigan, 48393 U.S.A FAX 1-248-305-7618

Kawasaki Robotics Units 6 & 7 Easter Count, Europa Boulevard, Westbrook TEL 44-(0)1925-713000
(UK) Limited Warrington, WA5 5ZB, UNITED KINGDOM FAX 44-(0)1925-713001

Kawasaki Robotics Sperberweg29, 41468 Neuss, GERMANY TEL 49-(0)2131-3426-0

GmbH FAX 49-(0)2131-930973

Akashi Works 1-1, Kawasaki-cho Akashi, 673-8666 JAPAN TEL 81-(0)78-921-1560

FAX 81-(0)78-923-6548

• All descriptions in this booklet subject to change for improvement without prior notice.