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JAKA Zu Series Service Manual

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JAKA Robotics
Service Manual
Original Instructions (en)
File Version: V06
Robots: Zu, Pro, S Series
Control Cabinet: CAB V2.1, MiniCab

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Summary of Contents for JAKA Zu Series

  • Page 1 JAKA Robotics Service Manual Original Instructions (en) File Version: V06 Robots: Zu, Pro, S Series Control Cabinet: CAB V2.1, MiniCab...
  • Page 2 The manual is the exclusive property of the JAKA Robotics Ltd. (hereinafter referred to as the “JAKA”) and JAKA fully reserves its copyright and interpretation right. This manual and parts thereof must not be reproduced or copied without JAKA’s written permission.

  • Page 3: Table Of Contents

    Contents Contents ..........................III Manual Instruction ......................6 About the Manual ........................... 6 Manual Reader ..........................6 References ............................. 6 Prerequisites ..........................6 Safety ..........................7 Introduction ............................ 7 Safety Signals and Symbols ......................7 Safety Instructions ......................... 7 Handling ESD Sensitive Parts ....................... 8 Recommended Inspection Activities ....................
  • Page 4 Joint Electromagnet Replacement ....................48 3.4.1 Tool Preparation ........................48 3.4.2 Disassemble Electromagnet ....................49 3.4.3 Assemble Electromagnet ......................51 Tool Flange Replacement ......................54 3.5.1 Tool Preparation ........................54 3.5.2 Flange Replacement ......................55 Lid Replacement ..........................79 3.6.1 Tool Preparation ........................79 3.6.2 Lid Replacement ........................79 Indicator Light Lid Replacement ....................85 3.7.1 Tool Preparation ........................85 3.7.2...
  • Page 5 5.2.2 Assemble Antenna ......................121 Button Cell Replacement ......................127 Hard Disk Replacement ......................131 Troubleshooting......................136 Electrical Drawings ....................138 Packaging and Shipping ................... 140...

  • Page 6: Manual Instruction

    All documents can be found via JAKA official website www.jakarobotics.com. 1.4 Prerequisites The reader should: ⚫ Be trained by JAKA and have the required knowledge of mechanical and electrical installation / repair / maintenance work. ⚫ Be trained to respond to emergencies or abnormal situations.

  • Page 7: Safety

    Maintenance and calibration must be conducted in accordance with the latest manual or receive professional training in JAKA. Maintenance must be performed by an authorized system integrator or JAKA staff. When the Spare parts need to return to JAKA, please operate in accordance with this manual.

  • Page 8: Handling Esd Sensitive Parts

    The control cabinet cannot be repaired by end user. If maintenance or repairing service is required, please contact your distributor or JAKA. 2.4 Handling ESD Sensitive Parts To prevent damage to components susceptible to static electricity, follow the instructions below in addition to normal measures such as turning off the power before removing the PCB.

  • Page 9: Recommended Inspection Activities

    Cleaning Visual No presence of dirt inspection, Dust Cover and blockages cleaning, replacement When the control Visual Exhaust cabinet starts up, the inspection, cooling fan operates cleaning, File Version: V06 9 / 141 JAKA Service Manual...

  • Page 10: Preventive Inspection Activities

    R6189 and above required and with CAN tools. Quarterly All the joints Contact JAKA technical service personnel for support. Evaluate the worn of the reducer inside joints, all joints shall stay steady when the robot is enabled with collision...

  • Page 11: Parts Replacement And Storage

    2. Fires, malfunctions and wrong motions caused by the modification may cause personal injury or damage to the machine. 3. Any loss caused by the user's own modification of JAKA’s products is not covered by the company's warranty. WARNING: ELECTRICITY To prevent electric shock, when replacing parts, please turn off the circuit breaker in advance and cut off the main power supply before proceeding.

  • Page 12: Robot System Cleaning

    3. When cleaning, please be careful to avoid labels and warning signs, excessive cleaning will cause letters on labels to be blurred or faded. 2.6.2 Filter Cleaning 1. Power off the control cabinet. 2. Remove the nut of the filter outer cover. File Version: V06 12 / 141 JAKA Service Manual...

  • Page 13: Storage Of Parts

    ⚫ Use in water or high humidity conditions; ⚫ Use for the purpose of transporting people or animals; ⚫ Use when the robot is squeezed by external force; ⚫ Use in strong magnetic environment. File Version: V06 13 / 141 JAKA Service Manual...

  • Page 14: Robot Maintenance

    Program, all choose “Upgrade upgrade method of the relevant tar.gz file, please refer to 3.2.4 Upgrade the firmware”; please consult JAKA technical service personnel to acquire firmware files; File Version: V06 14 / 141 JAKA Service Manual...

  • Page 15: Tool Preparation

    3.2.1 Tool Preparation Number Name Sample Graph LOCTITE 243 thread locker Torque wrench Diagonal pliers Allen wrench set Open-end wrench set Slotted screwdriver Tweezers Zip tie File Version: V06 15 / 141 JAKA Service Manual...

  • Page 16: Robot Joint Bolt Tightening Torque

    K- 1668 3.2.2 Robot Joint Bolt Tightening Torque 3.2.2.1 Bolt Tightening Torque For joints with two types of bolts in a single joint, the bolt positions are as following figure: File Version: V06 16 / 141 JAKA Service Manual...
  • Page 17 7 mm 5.4 Nm M4×12 mm*10 Hex bolts + spacer Joint 1—Joint 2 7 mm 5.4 Nm M4×12 mm*10 Hex bolts + spacer Base—Joint 1 7 mm 5.4 Nm M4×12 mm*10 File Version: V06 17 / 141 JAKA Service Manual...
  • Page 18 Hex bolts + spacer 10 mm 15.6 Nm Stationary joint M6×20 mm*10 Hex bolts + spacer Lower arm— 15.6 Nm*6 M6×20 mm*6 (B) ； M6×16 10 mm Joint 3 10 Nm*4 mm*4 (A) File Version: V06 18 / 141 JAKA Service Manual...
  • Page 19 7 mm 5.4 Nm M4×14 mm*10 Hex bolts + spacer Joint 5—Joint 6 7 mm 5.4 Nm M4×12 mm*10 Hex bolts + spacer Joint 4—Joint 5 7 mm 5.4 Nm M4×12 mm*10 File Version: V06 19 / 141 JAKA Service Manual...
  • Page 20 Hex bolts + spacer Lower arm— 15.6 Nm*6 M6×25 mm*6 (B) ； M6×20 10 mm Joint 3 10 Nm*4 mm*4 (A) Joint 2—Lower Hex bolts + spacer 14 mm 25 Nm M8×25 mm*10 File Version: V06 20 / 141 JAKA Service Manual...
  • Page 21 Hex bolts + spacer Joint 1—Joint 14 mm 25 Nm M8 25 mm*10 Hex bolts + spacer Base—Joint 1 14 mm 25 Nm M8 25 mm*10 3.2.2.2 Bolt Tightening Order 1. Screw sorting File Version: V06 21 / 141 JAKA Service Manual...

  • Page 22: Joint Replacement

    The following steps take one side as an example, and the steps at the other side are the same. 3.2.3.1 Disassemble Joint 1．Keep your hands dry and wear anti-static bracelets; 2．Power off the control cabinet; File Version: V06 22 / 141 JAKA Service Manual...
  • Page 23 Drive boards of Joint 1 and Joint 2 of Zu 20 and Pro 16 1. 48V DC interface 2. GND interface 3. CAN interface 4. DIP switch 5. Electromagnet interface File Version: V06 23 / 141 JAKA Service Manual...
  • Page 24 1. The interface positions on different joint drive boards are different, and the pictures are for reference only. 2. The joint power wire needs to be carefully pulled out after clamping the transparent clips with tweezers. 7．Remove the cable holder; File Version: V06 24 / 141 JAKA Service Manual...
  • Page 25 8．Use a slotted screwdriver to move the sealing ring to the outer of the joint; slide the gray plastic anti-wear ring to expose the fixing bolts; 9．Use open-end wrench to loosen the hexagonal bolts (see 3.2.2 Robot Joint Bolt Tightening Torque open-end wrench specifications); File Version: V06 25 / 141 JAKA Service Manual...
  • Page 26 10．Pull the joint out a short distance and gently turn it about 10mm until it reaches the big hole of the gourd shape hole, then the joint can be taken out. 11．Remove the hexagonal bolts. File Version: V06 26 / 141 JAKA Service Manual...
  • Page 27 3．Take an O-ring, put it into the groove of the flange surface of the replacement part, and press the O-ring to make the ring completely embedded into the groove of the flange surface; File Version: V06 27 / 141 JAKA Service Manual...
  • Page 28 6．Insert the small anti-wear ring into the position shown in the following figure of the replacement part; 7．Pass the wiring harness (power wire and CAN wire) through the replacement part; File Version: V06 28 / 141 JAKA Service Manual...
  • Page 29 9．Align the protrusion on the replacement part with the groove on the flange surface of the connecting part, slowly place the replacement part, and make bolts on the replacement part pass through the big hole of the gourd shape hole on the flange surface of the connecting part; File Version: V06 29 / 141 JAKA Service Manual...
  • Page 30 11．Tighten the bolt by open-end wrench, then use a torque wrench to tighten to the correct torque in diagonal order, see 3.2.2 Robot Joint Bolt Tightening Torque for tightening order; 12．Reposition the gray anti-wear ring, then move the sealing ring onto the anti-wear ring; File Version: V06 30 / 141 JAKA Service Manual...
  • Page 31 O-ring completely embedded in the groove; 16．Align the through-holes on the lid with the threaded posts on the joints and tighten the screws using an Allen wrench, do not press the inner wiring harness. File Version: V06 31 / 141 JAKA Service Manual...

  • Page 32: Upgrade The Program

    1. Connect the robot by the App, make sure robot is powered on and disabled; 2. Click “JAKA” in the upper left corner of the page for more than 10 times, enter the password (JAKAAMAZING), and click “OK” to enter the system maintenance interface;...
  • Page 33 , enter IP address of the robot, and click “Connect”. 4. Open JAKA Servo Upper Monitor App NOTE Please use the latest version (1.1.9.21) of the JAKA Servo Upper Monitor software. File Version: V06 33 / 141 JAKA Service Manual...
  • Page 34 5. Click “Produce”, select the replacement joint, click “Read” to read the work order number, enter the serial number of the replacement joint in the “9009 serial number” box, and click “Set”. File Version: V06 34 / 141 JAKA Service Manual...
  • Page 35 1. Connect the robot 1) Connect to the same local area network as the control cabinet on the app; 2) Open the JAKA App; 3) Click icon on the upper right corner to find the corresponding robot to connect (CAB V2.1 control...

  • Page 36: Joint Calibration

    Power on control cabinet, open the App, connect the robot, power on the robot and enable the robot; Enter “Manual Operation” interface, dragging joint angle slider to move each joint of the robot to calibration orientation; File Version: V06 36 / 141 JAKA Service Manual...
  • Page 37 Adjust the position of joint 1 so that the angle between the horizontal line of joint 2 and the robot connection cable connector is 90° , and on the right side of the robot connection cable connector; File Version: V06 37 / 141 JAKA Service Manual...
  • Page 38 Make the TIO interface on the tool flange straight up; After moving the robot to the calibration orientation, return to the home page, continuously click “JAKA” in the upper left corner of the page, enter the password (JAKAAMAZING), and then press “OK” to enter the system maintenance interface;...
  • Page 39 Enter “Manual Operation” interface after calibration, check the angle of the calibrated joints, and confirm that whether the actual robot position is consistent with the model position on the App or not; File Version: V06 39 / 141 JAKA Service Manual...
  • Page 40 Open the JAKA Servo Upper Monitor App, connect the robot, click “Produce”, select the joint to be calibrated, and click “Z Calibration” to calibrate. After the calibration is completed, the result will be displayed in the “Log” box. Click “Servo Debug”, select “Index” as “10 Control Word” or “92 DH Parameter”, click “Auto Select” to read “1005 DH Parameter Status”.
  • Page 41 File Version: V06 41 / 141 JAKA Service Manual...

  • Page 42: Base Replacement

    3.3.1 Tool Preparation Number Name Sample Graph LOCTITE 243 thread locker Torque wrench Diagonal pliers Allen wrench set Slotted screwdriver Tweezers Zip tie MOLYKOTE 55 O-ring grease Syringe File Version: V06 42 / 141 JAKA Service Manual...

  • Page 43: Base Replacement

    4．Unscrew screws fixed the base by an Allen wrench and remove the robot base; 5．Unscrew one screw fixing the earth wire with an Allen wrench and remove the screw and wire. File Version: V06 43 / 141 JAKA Service Manual...
  • Page 44 7．Place the removed hold-down plate and rubber washer over the robot connection cable and remove the robot connection cable from the base cable hole. 8．Tilt the new base and place the fixing clip into the slot. File Version: V06 44 / 141 JAKA Service Manual...
  • Page 45 10．Fill the four screw holes fixing hold-down plate with LOCTITE 243 thread locker. 11．Thread the robot connection cable through the cable hole in the base and snap into the fixing clip. File Version: V06 45 / 141 JAKA Service Manual...
  • Page 46 13．Lay the base flat, insert a M3 screw in the earth wire's terminal and use an Allen wrench to fasten it to the earth wire mounting hole. NOTICE: M3 screws are small, to avoid screw stripping, make sure that the tightening torque is between File Version: V06 46 / 141 JAKA Service Manual...
  • Page 47 2．Power off the control cabinet; 3．Disassemble the base and the joint 1, steps refer to 3.2.3.1 Disassemble Joint; 4．Unscrew screws fixed the base by an Allen wrench and remove the robot base; File Version: V06 47 / 141 JAKA Service Manual...

  • Page 48: Joint Electromagnet Replacement

    6．Screw socket head cap screws to mount the robot base by Allen wrench and ensure that the robot is firmly mounted. 3.4 Joint Electromagnet Replacement 3.4.1 Tool Preparation Number Name Sample Graph Allen wrench Tweezer File Version: V06 48 / 141 JAKA Service Manual...

  • Page 49: Disassemble Electromagnet

    4．Remove all dangerous tools on the end of robot if necessary to avoid any dangerous situation; 5．Remove the lid of joint by an Allen wrench; File Version: V06 49 / 141 JAKA Service Manual...
  • Page 50 3.2.3.1 Disassemble Joint for the position of electromagnet interface); 7．Use a 2.5mm Allen wrench to remove the socket head cap screws above the electromagnet, then the electromagnet can be taken out; File Version: V06 50 / 141 JAKA Service Manual...

  • Page 51: Assemble Electromagnet

    3．Put the electromagnet into the corresponding position in the joint, align the holes on the mounting block with the threaded holes on both sides of the electromagnet, and put mounting block into the corresponding position; File Version: V06 51 / 141 JAKA Service Manual...
  • Page 52 5．Use an Allen wrench to gently press down the electromagnet 5-6 times to check whether the slider is stuck, if it is stuck, it needs to be reassembled; File Version: V06 52 / 141 JAKA Service Manual...
  • Page 53 O-ring completely embedded in the groove; 8．Align the through-holes on the lid with the threaded posts on the joints and tighten the screws using an Allen wrench, do not press the inner wiring harness. File Version: V06 53 / 141 JAKA Service Manual...

  • Page 54: Tool Flange Replacement

    3.5 Tool Flange Replacement 3.5.1 Tool Preparation Number Name Sample Graph Torque wrench Phillips screwdriver Slotted screwdriver Open-end wrench Allen wrench Tweezer Syringe File Version: V06 54 / 141 JAKA Service Manual...

  • Page 55: Flange Replacement

    1. TIO wire interface 2. POINT button wire interface 3. FREE button wire interface 4. CAN wire interface 5. Power wire interface 6. Pause/Resume button interface Type B TIO board interface illustration: File Version: V06 55 / 141 JAKA Service Manual...
  • Page 56 3.5.2.2 Disassemble Type A Flange 1. Keep your hands dry and wear anti-static bracelets; 2. Power off the control cabinet; 3. Pry open the white translucent cover by a slotted screwdriver； File Version: V06 56 / 141 JAKA Service Manual...
  • Page 57 3.5.2.1 TIO Board Interface Illustration for the illustration of interfaces); 6. Move the sealing ring to the outer of the joint; slide the gray anti-wear ring to expose the fixing screws; File Version: V06 57 / 141 JAKA Service Manual...
  • Page 58 7. Unscrew the hexagonal bolts by an open-end wrench; 8. Gently turn tool flange about 10mm until it reaches the big hole of the gourd shape hole, then the hexagonal bolts can be taken out. File Version: V06 58 / 141 JAKA Service Manual...
  • Page 59 NOTE As for Pro 12, there is a sealing plate on the end flange. The sealing plate should be removed with an open wrench before removing the wiring harness. File Version: V06 59 / 141 JAKA Service Manual...
  • Page 60 FREE, POINT on the outside of the tool flange), pass the hex nut through the cables, cling to the inner wall of the tool flange, and tighten the hex nut with an open-end wrench; File Version: V06 60 / 141 JAKA Service Manual...
  • Page 61 4. Take an O-ring, put it into the groove of the flange surface of the joint 6, and press the O-ring to make the ring completely embedded into the groove of the flange surface; File Version: V06 61 / 141 JAKA Service Manual...
  • Page 62 If the thread locker overflows, try to wipe it with a cleanroom wiper dipped with alcohol; 7. Pass the wiring harness connected to the tool flange through the central hole of the flange surface of the joint 6; File Version: V06 62 / 141 JAKA Service Manual...
  • Page 63 10. Tighten the bolt by open-end wrench, then use a torque wrench to tighten to the correct torque in diagonal order, see 3.2.2 Robot Joint Bolt Tightening Torque for tightening order; File Version: V06 63 / 141 JAKA Service Manual...
  • Page 64 If there are too many wiring harnesses, they can be fixed with zip ties; 13. Place the indicator light lid on the joint 6 and tighten the three screws by an Allen wrench; File Version: V06 64 / 141 JAKA Service Manual...
  • Page 65 1. Keep your hands dry and wear anti-static bracelets; 2. Power off the control cabinet; 3. Move the sealing ring to the outer of the joint; slide the gray anti-wear ring to expose the fixing screws; File Version: V06 65 / 141 JAKA Service Manual...
  • Page 66 4. Unscrew the hexagonal bolts by an open-end wrench; 5. Gently turn tool flange about 10mm until it reaches the big hole of the gourd shape hole, then the hexagonal bolts can be taken out. File Version: V06 66 / 141 JAKA Service Manual...
  • Page 67 7. Use an open-end wrench to pry off the sealing plate; 8. If the TIO drive board need to be kept, you can unscrew the screws on it by Philips screwdriver to take out the TIO drive board. File Version: V06 67 / 141 JAKA Service Manual...
  • Page 68 NOTE If the hexagonal bolts are removed, it is necessary to clean the removed hexagonal bolt holes and apply new thread locker. After dismantling the hexagonal bolts, the disassembled hexagonal bolts File Version: V06 68 / 141 JAKA Service Manual...
  • Page 69 3. Put the TIO drive board into the new tool flange, tighten the screws by a Philips screwdriver to fix the TIO drive board; 4. Apply LOCTITE 518 gasket sealant along the edge of the end flange and fix the sealing plate to the end flange; File Version: V06 69 / 141 JAKA Service Manual...
  • Page 70 7. Put the grease (MOLYKOTE 55 O-ring grease is recommended) into the syringe and inject it into the groove of the flange surface of the connecting part to ensure that the grease is evenly applied and filled in the groove; File Version: V06 70 / 141 JAKA Service Manual...
  • Page 71 6; 11. Rotate the tool flange counterclockwise to insert bolts into the small hole of the gourd shape hole; File Version: V06 71 / 141 JAKA Service Manual...
  • Page 72 12. Tighten the bolts by open-end wrench, then use a torque wrench to tighten to the correct torque in diagonal order, see 3.2.2 Robot Joint Bolt Tightening Torque for tightening order; 13. Reposition the gray anti-wear ring, then move the sealing ring onto the anti-wear ring; File Version: V06 72 / 141 JAKA Service Manual...
  • Page 73 2. Power off the control cabinet; 3. Move the sealing ring to the outer of the joint; slide the gray anti-wear ring to expose the fixing screws; 4. Unscrew the hexagonal bolts by an open-end wrench; File Version: V06 73 / 141 JAKA Service Manual...
  • Page 74 5. Gently turn tool flange about 10mm until it reaches the big hole of the gourd shape hole, then the hexagonal bolts can be taken out. 6. Unplug the wire terminals on the TIO adapter board. 7. Remove the black O-ring on the flange side of joint 6. File Version: V06 74 / 141 JAKA Service Manual...
  • Page 75 3. Take an O-ring, put it into the groove of the flange surface of the joint 6, and press the O-ring to make the ring completely embedded into the groove of the flange surface; File Version: V06 75 / 141 JAKA Service Manual...
  • Page 76 If the thread locker overflows, try to wipe it with a cleanroom wiper dipped with alcohol; 6. Plug the wire terminals in the TIO adapter board. File Version: V06 76 / 141 JAKA Service Manual...
  • Page 77 9. Tighten the bolt by open-end wrench, then use a torque wrench to tighten to the correct torque in diagonal order, see 3.2.2 Robot Joint Bolt Tightening Torque for tightening order; File Version: V06 77 / 141 JAKA Service Manual...
  • Page 78 10. Reposition the gray anti-wear ring, then move the sealing ring onto the anti-wear ring; File Version: V06 78 / 141 JAKA Service Manual...

  • Page 79: Lid Replacement

    2. Negative power supply, connect GND 3. CAN wire interface 4. DIP switch 5. Brake release button 6. JK-Interface40 board interface 7. Three-phase motor wire (blue) 8. Three-phase motor wire (yellow) 9. Three-phase motor wire (red) File Version: V06 79 / 141 JAKA Service Manual...
  • Page 80 1．Unscrew the socket head cap screws and washers on the lids by an Allen wrench to remove the lids. 2．Unscrew three screws fixing the three-phase motor wires with a Phillips screwdriver and remove wires. 3．Unplug wires on the driver board. File Version: V06 80 / 141 JAKA Service Manual...
  • Page 81 O-ring completely embedded in the groove. 6．Screw six screws fixing the driver board with an Allen wrench to secure the driver board. File Version: V06 81 / 141 JAKA Service Manual...
  • Page 82 9．Align the through-holes on the lid with the threaded posts on the joints and tighten the socket head cap screws and washers using an Allen wrench, do not press the inner wiring harness. File Version: V06 82 / 141 JAKA Service Manual...
  • Page 83 3.6.2.2 Lid Replacement of the Other Models 10．Unscrew the socket head cap screws and washers on the lids by an Allen wrench to remove the lids. File Version: V06 83 / 141 JAKA Service Manual...
  • Page 84 12．Align the through-holes on the lid with the threaded posts on the joints and tighten the socket head cap screws and washers using an Allen wrench, do not press the inner wiring harness. File Version: V06 84 / 141 JAKA Service Manual...

  • Page 85: Indicator Light Lid Replacement

    Type A: There is no indicator light interface on the TIO drive board. Other interfaces are as follows: 1. TIO wire interface 2. POINT button wire interface 3. FREE button wire interface 4. CAN wire interface 5. Power wire interface 6. Pause/Resume button interface File Version: V06 85 / 141 JAKA Service Manual...

  • Page 86: Disassemble Indicator Light Lid

    2. Power off the control cabinet; 3. Pry open the white translucent cover by a slotted screwdriver; 4. Unscrew the three socket head cap screws with an Allen wrench and remove the indicator light lid; File Version: V06 86 / 141 JAKA Service Manual...
  • Page 87 Do not pull it out by force; 6. Unscrew the screws fixing the drive board with a Phillips screwdriver and take out the drive board. File Version: V06 87 / 141 JAKA Service Manual...

  • Page 88: Assemble Indicator Light Lid

    Light Lid Interface Illustration for the illustration of interfaces, its type A TIO board), gently pull the wiring harnesses to check whether they are loose, and fix the wiring harnesses with zip ties; File Version: V06 88 / 141 JAKA Service Manual...
  • Page 89 4. Align the through-holes on the indicator light lid with the threaded posts on the joints and tighten the socket head cap screws using an Allen wrench, do not press the inner wiring harness; 5. Press the white translucent cover into the indicator light lid. File Version: V06 89 / 141 JAKA Service Manual...

  • Page 90: Cab V2.1 Repair

    4 CAB V2.1 Repair 4.1 CAB Internal Interface Introduction The figure below shows the connection description of each interface inside the control cabinet, and the same number represents the interconnection. A: IPC B: SCB File Version: V06 90 / 141 JAKA Service Manual...
  • Page 91 C: PDU D: Power E: CAB bottom panel F: Resistor File Version: V06 91 / 141 JAKA Service Manual...

  • Page 92: Tool Preparation

    4.2 Tool Preparation Number Name Sample Graph Control cabinet key Phillips screwdriver Diagonal pliers Tweezer Allen wrench Open-end wrench Socket wrench LOCTITE 243 thread locker Zip tie File Version: V06 92 / 141 JAKA Service Manual...

  • Page 93: Fan And Dust Cover Replacement

    4. Use a Phillips screwdriver to unscrew those two screws above the front panel, and open the front panel; 5. Remove the zip tie with diagonal pliers and unplug the fan connector to and SCB (there are two wires in total: black 0V and red 24V); File Version: V06 93 / 141 JAKA Service Manual...
  • Page 94 8. Loosen the four screws with a Phillips screwdriver to remove the fan; 9. Put the replaced fan into the corresponding position from the inside of the control cabinet, and tighten the File Version: V06 94 / 141 JAKA Service Manual...
  • Page 95 12. Plug the power connector of the fan to the terminal on SCB board and tighten the cable with zip tie. Lightly pull the wiring harness to ensure they are plugged tightly; 1. Fan interface 13. Use Phillips screwdriver to tighten the two screws above the front panel; File Version: V06 95 / 141 JAKA Service Manual...

  • Page 96: Antenna Replacement

    2. Ensure that the control cabinet is powered off and the power cable of the bottom panel is disconnected; 3. Open the cover with its key; 4. Use a Phillips screwdriver to unscrew those two screws above the front panel, and open the front panel; File Version: V06 96 / 141 JAKA Service Manual...

  • Page 97: Wi-Fi Board Replacement

    4.5.1 Disassemble Wi-Fi Board 1. Keep your hands dry and wear anti-static bracelets; 2. Ensure that the control cabinet is powered off and the power cable of the bottom panel is disconnected; File Version: V06 97 / 141 JAKA Service Manual...
  • Page 98 Ethernet interface Antenna cable interface USB cable interface (to IPC board) 6. Unscrew three screws of Wi-Fi board with Allen wrench; File Version: V06 98 / 141 JAKA Service Manual...

  • Page 99: Assemble Wi-Fi Board

    Wi-Fi board; If it shows that the network cannot be connected, you can try the following operations: a. Open the “Control Panel” on the computer; b. Click “Network and Internet”; File Version: V06 99 / 141 JAKA Service Manual...
  • Page 100 Click “Network and Sharing Center”; d. Click “Change adapter settings”; e. Double-click “Ethernet”; f. Click “Properties”; File Version: V06 100 / 141 JAKA Service Manual...
  • Page 101 Double-click “Internet Protocol Version 4（TCP/IPv4)”; h. Check “Obtain an IP address automatically” and click “OK”; File Version: V06 101 / 141 JAKA Service Manual...
  • Page 102 (2) The default gateway of a new Wi-Fi board is 192.168.16.254. After the network connection is completed, enter the URL on the browser: 192.168.16.254 to enter the login interface. Enter the login account (admin) and password (admin) to enter the configuration interface; (3) Click “Internet Settings”→ “LAN”; File Version: V06 102 / 141 JAKA Service Manual...
  • Page 103 (4) Modify IP Address as 10.5.5.1, then click in the blank space of the interface. After the IP Address of DHCP Default Gateway changes into 10.5.5.1，click “Apply”; File Version: V06 103 / 141 JAKA Service Manual...
  • Page 104 (2) Click “Wireless Settings” > “Basic”； (3) Change the name after the Network Name (SSID) (such as HI-LINK_83AB) to the corresponding control cabinet serial number (such as CAB719070201) and click “Apply” below; File Version: V06 104 / 141 JAKA Service Manual...
  • Page 105 (4) Click “Wireless Settings” > “Security”, set “Pass Phrase” to “12345678”, and click “Apply” below. After the change is completed; File Version: V06 105 / 141 JAKA Service Manual...
  • Page 106 8. Connect the robot: Connect the Wi-Fi of mobile devices (computers, pads and mobile phones) to the newly configured Wi-Fi network (the Wi-Fi name is the control cabinet ID just set). Open JAKA App and connect the robot.

  • Page 107: Button Cell Replacement

    4. Use a Phillips screwdriver to unscrew those two screws above the front panel, and open the front panel. 5. Unplug all wires on the IPC board. Record cable connections before unplug the wires. 6. Unscrew four screws of IPC board with Allen wrench. File Version: V06 107 / 141 JAKA Service Manual...
  • Page 108 9. Install the new button cell as previously, ensure the button cell is locked properly. 10. Tighten the four screws coated with thread locker with Allen wrench. 11. Insert the wires into the corresponding interface. File Version: V06 108 / 141 JAKA Service Manual...
  • Page 109 14. The lack of power in button cell will cause the time display error, so it is necessary to manually calibrate the time. Open JAKA App, connect the robot, click “Settings” > “System Settings” > “Initial Settings”, and manually configure the time.

  • Page 110: Hard Disk Replacement

    (if daily backup is required, it is recommended to select all types), click “Export File”, select the local path to be placed, and click “OK” to File Version: V06 110 / 141 JAKA Service Manual...

  • Page 111: Hard Disk Replacement

    4.7.2 Hard Disk Replacement 1. Keep your hands dry and wear anti-static bracelets; 2. Ensure that the control cabinet is powered off and the power cable of the bottom panel is disconnected; File Version: V06 111 / 141 JAKA Service Manual...
  • Page 112 4. Use a Phillips screwdriver to unscrew those two screws above the front panel, and open the front panel; 5. Unscrew two screws of hard drive with Phillips screwdriver; 6. Remove the hard disk drive carefully and install the new one; File Version: V06 112 / 141 JAKA Service Manual...

  • Page 113: Software Upgrade

    8. Use Phillips screwdriver to tighten the two screws above the front panel to fix the front panel; 4.7.3 Software Upgrade Open the JAKA App, and check whether the current version of controller matches the App version. Upgrade or downgrade it if not match. The steps are as follows: 1.

  • Page 114: File Import

    2. Upgrade the controller (1) Download the controller upgrade package to the local device (contact JAKA technical service personnel to get the package); (2) Open the App to connect the robot and confirm that the robot is powered off;...
  • Page 115 2. Enter the programming control interface, click the program list, click the import button, select the file path of the backup file, select the corresponding program file to be imported, and click “OK” to import; File Version: V06 115 / 141 JAKA Service Manual...
  • Page 116 File Version: V06 116 / 141 JAKA Service Manual...

  • Page 117: Minicab Repair

    2. Press and hold the POWER button on the front panel for more than 3s to power down the MiniCab, and disconnect the power supply. 3. Unscrew two screws in the electrical connector by slotted screwdriver, unplug the connecter and cut the File Version: V06 117 / 141 JAKA Service Manual...
  • Page 118 5. Unscrew three screws on the side panel near the lid with a Phillips screwdriver, unscrew two screws in the lid of MiniCab with an Allen wrench, and remove the lid of the MiniCab. File Version: V06 118 / 141 JAKA Service Manual...
  • Page 119 6. Unplug the terminal of the POWER button cable from the PSCB board. 7. Unscrew the nut fixing the antenna adapter with an open-end wrench, remove the nut and washer, and remove the antenna adapter from the internal of the MiniCab. File Version: V06 119 / 141 JAKA Service Manual...
  • Page 120 8. Unplug all terminals on the side panel of the MiniCab. 9. Unscrew three screws on the side panel close to bottom panel with a Phillips screwdriver, and remove the side panel of the MiniCab. File Version: V06 120 / 141 JAKA Service Manual...

  • Page 121: Assemble Antenna

    1. Align the connector of a new antenna with its circular interface on the back of PSCB board, press the antenna connector, and insert it into the corresponding interface on the back of the PSCB board. File Version: V06 121 / 141 JAKA Service Manual...
  • Page 122 LOCTITE 243 thread locker on two Phillips screws and two hex standoffs, screw Phillips screws with Phillips screwdriver, and screw two hex standoffs with a socket wrench to fix the PSCB board. File Version: V06 122 / 141 JAKA Service Manual...
  • Page 123 3. Apply LOCTITE 243 thread locker on screws, screw three screws on the side panel close to bottom panel with a Phillips screwdriver and install the side panel of the MiniCab. File Version: V06 123 / 141 JAKA Service Manual...
  • Page 124 4. Pass the antenna adapter end through the hole in the side panel of the MiniCab, pass the washer and hex nut through the antenna adapter end from the outside of the MiniCab in turn, and tighten the nut with an open-end wrench. File Version: V06 124 / 141 JAKA Service Manual...
  • Page 125 LOCTITE 243 thread locker on screws, screw three screws on the side panel close to lid with 6. Apply a Phillips screwdriver, screw two screws in the lid with an Allen wrench and install the lid of the MiniCab. File Version: V06 125 / 141 JAKA Service Manual...
  • Page 126 7. T 8. Insert the electrical connector into the side panel, screw two screws in the electrical connector with a File Version: V06 126 / 141 JAKA Service Manual...

  • Page 127: Button Cell Replacement

    2. Press and hold the POWER button on the front panel for more than 3s to power down the MiniCab, and disconnect the power supply. 3. Unscrew two screws in the electrical connector by slotted screwdriver, unplug the connecter and cut the power supply of the MiniCab. File Version: V06 127 / 141 JAKA Service Manual...
  • Page 128 MiniCab with an Allen wrench, and remove the lid of the MiniCab. 5. Lift the button cell from the side without the latch and remove it from the latch. File Version: V06 128 / 141 JAKA Service Manual...
  • Page 129 243 thread locker on screws, screw three screws on the side panel close to lid with 7. Apply LOCTITE a Phillips screwdriver, screw two screws in the lid with an Allen wrench and install the lid of the MiniCab. File Version: V06 129 / 141 JAKA Service Manual...
  • Page 130 8. Insert the electrical connector into the side panel, screw two screws in the electrical connector with a slotted screwdriver, and connect the power supply of the MiniCab. File Version: V06 130 / 141 JAKA Service Manual...

  • Page 131: Hard Disk Replacement

    3. Press and hold the POWER button on the front panel for more than 3s to power down the MiniCab, and disconnect the power supply. 4. Unscrew two screws in the electrical connector by slotted screwdriver, unplug the connecter and cut the power supply of the MiniCab. File Version: V06 131 / 141 JAKA Service Manual...
  • Page 132 MiniCab with an Allen wrench, and remove the lid of the MiniCab. 6. Unscrew two screws fixing the hard disk with a Phillips screwdriver to remove the hard disk from the slot. File Version: V06 132 / 141 JAKA Service Manual...
  • Page 133 7. Insert a new hard disk into the slot, apply LOCTITE 243 thread locker on screws, and screw two screws fixing the hard disk with a Phillips screwdriver. File Version: V06 133 / 141 JAKA Service Manual...
  • Page 134 243 thread locker on the screws, screw three screws on the side panel close to lid 8. Apply LOCTITE with a Phillips screwdriver, screw two screws in the lid with an Allen wrench and install the lid of the MiniCab. File Version: V06 134 / 141 JAKA Service Manual...
  • Page 135 10. Press the POWER button on the front panel of the MiniCab to power up the MiniCab. 11. Upgrade the software and import the backup file, refer to 4.7.3 Software Upgrade 4.7.4 File Import for operation steps. File Version: V06 135 / 141 JAKA Service Manual...

  • Page 136: Troubleshooting

    3. Log display area: See the details by clicking the name of log; 4. Zoom in or zoom out the log information window; 5. Update the log information. The error code can also be found in the JAKA document website, refer to Event code and meaning (jaka.com).
  • Page 137 Source of Error: Error Joint Number: 0: Controller 0-5: From joint 1 to joint 6 1: Servo F: App F: App File Version: V06 137 / 141 JAKA Service Manual...

  • Page 138: Electrical Drawings

    7 Electrical Drawings The electrical drawing of CAB 2.1 is shown as figure below: File Version: V06 138 / 141 JAKA Service Manual...
  • Page 139 The electrical drawing of MiniCab is shown as figure below: File Version: V06 139 / 141 JAKA Service Manual...

  • Page 140: Packaging And Shipping

    If the robot, control cabinet, parts are found to be unable to be safely repaired, JAKA reserves the right to clean the robot, control cabinet and parts, or rejects them and sends them back at the customer's expense.
  • Page 141 JAKA ROBOTICS CO., LTD. Add.: Building 6, No. 646, Jianchuan Road, Minhang District, Shanghai, China E-mail: support@jaka.com Web: www.jakarobotics.com...

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