Assembly instr uction manualC

2006 KONDO KAGAKU CO.,LTD2006.09 Ver1.0

About safety
Please understand beforehand that there are many cases where the customer has to be responsible for the resultsof using this product because of the character of this product as an assembly kit.
In this manual, in order to prevent any damage to the person who uses this product and other people as well as
their property, prohibited actions are stated as follows.

■The level of danger that is caused when indicatory contents are ignored is divided into following indications.

DangerThis indication means that there is a critical danger of death or serious injury.

Warning

This indication means that there is a possibility of death or serious injury.

CautionThis indication means that there is a possibility of injury or damage to the property.

■Prohibited and compulsory actions are explained by following indications. (These are a part of indications.)
This indicates that the action is prohibited.
This indicates that the action is compulsory.

Danger
The work has to be done in enough space and in healthy condition physicallyand morally.
Prohibition

There is a danger of death or serious injury by an unexpected accident.

WarningPay attention to the children so that they will not touch any part ofthis product.
Prohibition

There is a possibility of injury because of frame material of aluminum.

Pull out the connector of the HV battery immediately when something
wrong happens.
The main part was damaged. A foreign object entered into the main part. The smoke has come out.
There is a bad smell. The main part has become feverish abnormally.
If you keep using the product in such abnormal conditions, fire or electric shock might be caused.
●When something wrong happens, stop using the product immediately, and please contact ourservice section.

Do not damage the charger and the cable.

Do not use them when they are damaged, converted, brought close to a thermal instrument, or are
under too much pressure.
Prohibition If you keep using them when they are damaged, fire or electric shock might be caused.
●Please contact our service section about the repair of the code and the cable.

When you do not use the charger, pull it out from the electrical outlet.
When it is not pulled out from the electrical outlet, a little electrical current flows into the charger.
●Clean the electrical outlet regularly so that the dust does not accumulate.

Do not do servo of the finished product, and do not disassemble andconvert the baseplate.

Disassembling and repairing are prohibited unless they are stated in the manual.
Wrong disassembly and assembly cause breakdown and also fire and electric shock.
Prohibition●In case of breakdown, please depend on our service section.

Do not soak this product, and do not use it in high humidity or in
the circumstance where dew condensation occurs.
This will cause breakdown as this product is composed of precise electronic parts.
This also might cause fire because of electric shock and short circuit.
●When you wet the product, please consult to our service section.

Prohibition

While operating, pay attention to any danger and try to deal withan unexpected accident.

Please be reminded that the safety is not completely guaranteed about the results of the operation
because of the character of this product as an assembly kit. Please be careful as there is apossibility of injury or fracture of fingertips when the movement of the product is totally different
from the one that you expected.

Recognize the possibility that components cause short circuit.
Please recognize the danger that conductive things can easily cause short circuit as the terminalof the control plate is bare. Short circuit causes ignition of the battery or wiring materials. Also,
wrong connection causes the same danger.

CautionWhen you use this in overseas, there are cases where permission
approval is necessary.

There are cases where legal procedure is necessary depending upon area or the country where
you use this.
●Our support does not apply to the use of this product in the countries other than Japan.

Hold the plug part when the charger and the cables are pulled out.
If you hold the cord, it might cause electric shock or fire because of the break of the wire andshort circuit.

Do not operate this on an unstable place.
Prohibition

Ni-MH

It might collapse because of losing balance, or it might cause injury because of falling.

The HV battery of this product is the nickel hydrogen battery, which can berecycled. Effective utilization of the resources is possible by recycling. Conversely,
disassembly and abandonment cause environmental destruction. Please cooperate
to effective recycling.

About the usage of the HV battery
In this kit, the HV battery (the nickel hydrogen electric battery) is used as a power source for
operation. Nickel hydrogen is an accumulator which can be charged and reused. But when
you use it mistakenly, it might lead to serious accident. Please read this instruction manual
carefully before you use it.

How to charge

Charger●The charger is only for AC100V. You use it inserting in
the AC electrical outlet at home.

It is used in order to connect the nickelhydrogen to the charger.

Charge cord

Pay attention to which polarity
to connect. Please do not put
Danger conversely. You can discern it withthe color of the line.

9 N-300HV battery

the charge cord to the
1 Connect
charger.
*Connect it securely so that it will not come out midway.

the charger into the AC
2 Insert
electrical outlet.
*When it is connected to theDanger charger, electricity comes in
the pin ahead the charge cord.
Please do not make shortcircuit with conductive things.

3 Connect the HV battery to the connector of the charge cord.
Charging starts when the lamp of the charger lights up.
Charge time differs depending upon the remaining amount of nickelhydrogen. When it is empty, approximately 12 hours is required.

As charging advances, LED (the lamp) becomes dark, but it does not go
out completely.

warning

Warning While charging, please pay attention to thestate of nickel hydrogen. When there are abnormal
heat generation, strange noise and a stench, please
remove nickel hydrogen immediately.

About the usage of the HV battery
Warnings for the usage

DangerPlease do not do following actions as they are dangerous.
Prohibition

Removing the connector and converting such as exchanging thecords. Do not make short circuit of the battery.
There are cases where explosion, ignition and the fluid leak occur because of short circuitof the battery, and there is a danger of injury and loss of eyesight. In addition, even when
the connector is attached, short circuit can occur in the part of the pin. Attention is always
required when it is used.

Do not place the battery with other things when conveying and storing.
Ignition and the fluid leak can occur because of short circuit which is caused by the damage ofthe connector, the wire and the wrapping of the nickel hydrogen. Please do not place the battery
with other things when conveying and storing. There are examples where the ignition occurredfrom short circuit because of coins and the keys of a car and a house.

Warning
When the following circumstances occur, take necessary
measures.
When the fluid leak occurs, please wash away the liquid on the hand at
once. When it enters into the eye by any chance, after washing away well,please receive the medical examination of the doctor.
The substance inside the battery is harmful. Influence to the human body occurs, as well as
the damage to the furniture and the residence. Eough attention is required because there is apossibility of loss of eyesight when it enters into the eye.

When you do not use the battery, or leave it for a long time, pull out theconnector of the nickel hydrogen from the baseplate or the charger.
It will be impossible to take necessary measures when unexpected circumstances occur. Pleasebe sure to use it where you can see the battery. Please do not leave the connector inserted for along time because there is a possibility of fire.

CautionPlease recycle the nickel hydrogen which is unnecessary, following the methodof each community. Illegal abandonment causes environmental pollution. In
addition, there is a danger of the accident due to the short circuit and the fluid
leak after the abandoning.

About the quality of nickel hydrogen
Nickel hydrogen has an advantage that a big electric current can be produced because internal resistanceis very low comparing with the dry cell battery. On the other hand, if charging is repeated before it is fully
consumed, the memory effect can occur, which makes the life of the battery very short. In order to prevent thismemory effect, charge nickel hydrogen after it is fully consumed.

Preface
Thank you for purchasing robot assembly kit "KHR- 2 HV".
Even though it is a low price, this product is an assembly kit of a two foot walking robot that various operations
are possible.
For the assembly, please read carefully this instruction manual and the other instruction manuals that are
attached. In addition, we recommend to printout the manuals when necessary.

Caution12
3

Please be reminded that we can not necessarily guarantee operations of the assembled product because of
the character of this product as an assembly kit. In addition, please recognize the fact that there are times
when precise replies are not possible for questions about operations, because they are largely influenced by
the method of the assembly.
This product is constituted in order for people of all ages to enjoy two foot walking robot. But as this is not a
toy, there are parts that are difficult to understand or work that can not be done by small children. Therefore,
parents or teachers should help them.
For the assembly and the operation of this product, the personal computer (the Windows2000 or the versions
after that is required as well as the USB port) is used. Because of that, in this instruction manual and the otherattachment instruction manuals, it is presumed that you have the basic skills of the personal computer. In
addition, we can not answer the inquiry regarding personal computer or windows●Company name, trade name, or the logographic mark that are written in this manual aretrade mark or registered trade mark of each company.
●The contents of the manual and the product are subject to change without any notice due toimprovement or other reasons.

Things that have to be prepared
For the assembly and the operation, the following things are necessary other than the kit of this product.

●Personal computer

Microsoft Windows2000 or XP
At least one USB port*
CD-ROM drive (for installation of the software and reading the manuals)
Printer (in case of printing out the manuals)*Please use a USB port of the body of a computer. It might not operate properly when the ports that are expanded by the USB hub are used.

●ToolsDriver of medium size

Scissors

Paint forpolycarbonate
It is used to paint thefront cowl and the board
cover. The paint for model,
which is the spray type, isrecommended.

The one with a thick handle and amagnetic point is convenient.

The standard of driver bit<Full scale>

It is used for cutting the cowl, decal
and the sponge. To cut the cowl
(made of polycarbonate), strong
scissors are suitable.



Other tools thatare convenient if
you have●Gimlet●Pin vise●DrillThey are convenient formaking holes of the board
cover●Cutter●Nipper●File
They are convenient for
cutting the parts and theboard cover.

About the attached products
About KRS-788HVKRS-788HV, which is used to drive the joint in this kit, is a digital FET servo that improved KRS786ICS. In addition to the know-how which was accumulated with the radio control, by making
it a servo applicable to HV, it became a more powerful and energy conservation servo only for arobot than former 6V drives. Functions and specifications are as follows.
●The functions of RedVersion is installed. The use of characteristics change and position
capturing is possible.
●By the use of ICS, setting from outside is possible.
●Fixing with the support of both axes is possible as a servo only for robots.
●Applicable to HV. It conserves more energy though the specifications are upgraded
compared to former products.

■Major specifications
External size -------------- 41×35×21(mm) *Without projections
Weight ---------------------- 47.5g
Torque ---------------------- 10.0kg/cm (when nicad 9 cell is used)
Speed ----------------------- 0.14sec/60°(when nicad 9 cell is used)
Proper voltage ------------ 9-12V

About RCB-3J●Major functions and specifications*For the usage, the software for the computer needs to be used.

■Size --------------------------- 45×35(mm)■Weight ----------------------- 12g■The number of servo that can be controlled ------------ 24■Proper voltage ------------ Direct current9-12V

About the after-sales service
Our service section will reply to the questions about this product.
Kondo Kagaku co., LTD. Service Section
Tel: 03-3807-7648 (Direct to Service Section)
4-17-7, Higashi Nippori, Arakawa, Tokyo
116-0014

9:00-12:00 13:00-17:00
excluding Saturdays, Sundays and national holidays

As for the inquiry by the email, we take it by the following email address, but please
understand that it might take a while until we reply.

support@kondo-robot.com
Notice and updates about the product are shown on our website.

http://www.kondo-robot.com
About the instruction manuals
There are four manuals in total in this product.
1, Kit guidance

The only printed manual.
It explains the kit and how to view the other manuals.

2, Assembly instruction manual for KHR-2HVThis manual. This is provided by a PDF file.
It explains how to assemble the kit.

3, Operation manual for RCB-3J
This is also provided by a PDF file. It explains about the motion making
software and control board RCB-3J.

4, Serial USB adapter
This is a manual for a serial USB adapter that is used when you connect RCB-3J to acomputer.

The composition of this manual and the outline of the assembly
Charge HV battery before assembly

1 Removing servo case screw
2 Installing servo in the bracket
3 Assembly of shoulder unit
4 Assembly of leg unit
5 Assembly of foot unit
6 Assembly of front frame
7 Assembly of body unit
8 Assembly of control unit
9 Setting the origin, installing servo arm
10 Assembly of the entire part
11 Setting home position

In this kit, most jobs can be done
just by tightening screws. But in thecontents after the 9th in the figurein the left, it is necessary to do
the work, connecting servo to thecontrol baseplate, and verifying thestop position of the initial condition(the origin setting).
Therefore, before starting theassembly, please charge the HV
battery.
When tightening plural screws, all
the screws have to be temporarily
locked and then be tightened.
If a screw is tightened hard from thefirst one, other screws might not fit
to the holes.

The list of parts
Name

NumberAmountControl board
Servo motor Cable length 300mm
Servo motor Cable length 480mm
Top cover
Body frame F
Body frame B
Body frame L
Shoulder frame L
Shoulder frame R
Servo bracket A-L
Servo bracket A-R
Servo bracket B
Hand L
Hand R
Leg joint A-L
Leg joint A-R
Leg joint B-L
Leg joint B-R
Foot angle A
Foot angle B-L
Foot angle B-R
Sole
PCB base
Board cover
Front cowl
Cable guideArm supporter 700A
Servo arm 700A upper arm
Servo arm 700A bottom arm
Servo arm 700A base
Body pin
Body post
Low height servo hone
Nylon strap
Screw for flat head hone
2.6-6 tapping screw
M2-4 screw
2.6-8 tapping screw
2-6 plate tapping screw
2.3-6 tapping screw
M2-5 screw
2-4 plate screw
HV power source switch harness
HV battery charge cord
Cable extension
Serial USB adapter
Serial cable extension
HV battery
HV charger

RCB-3J
KRS-788HV C300
KRS-788HV C480
NHR-001
NHR-002
NHR-003
NHR-004
NHR-005
NHR-006
NHR-007
NHR-008
NHR-009
NHR-010
NHR-011
NHR-012
NHR-013
NHR-014
NHR-015
NHR-016
NHR-017
NHR-018
NHR-019

1
13
4
1
1
1
1
1
1
1
1
6
1
1
1
1
1
1
2
1
1
2
1
1
1
12
2
14
14
12
5
3
3
4
30
15
35
30
15
26
15
10
1
1
1
1
1
1
1

9N-300mAh



Notes

for 5 mm100m long

The catalogue of parts
Front cowl (1)*Before assembling, please confirm thatyou have the right amount of each part.
*Some parts are similar
to others.

Board cover (1)Body frame B (1)Body frame F (1)PCB base (1)RCB-3J (1)Top cover (1)Body frame L (1)Pay attention to
the direction of the slits

Servo motor
Cable length 480mm (4)Servo motor
Cable length 300mm (13)Shoulder frame L (1)Pay attention to
the arrangementof the holes

Shoulder frame R (1)Servo bracket A-R (1)Servo bracket A-L (1)Leg joint A-L (1)Leg joint B-L (1)Leg joint A-R (1)Sole (1)The side with punch holes
is the obverse.
Servo bracket B (6)Foot angle B-R (1)Leg joint B-R (1)Foot angle B-L (1)Foot angle A (2)Hand R (1)Hand L (1)10

HV charger (1)HV battery (1)9N 300mAh

The catalogue of parts
Parts Bag A

Parts Bag B

Parts Bag C

Servo arm 700A
base (12)Servo arm 700A
upper arm (14)Servo arm 700A
bottom arm (14)Parts Bag D
Cable guide(3)

Arm supporter
700A (2)*When you use this, be carefulof the obverse and the reverse.
This figure shows the obverse.

Parts Bag E
Low height
servo hone(3)

Body pin(5)

Body post(3)

Parts Bag F
Screw for flat head hone
(30)

Sponge(about 10cm 1)

Nylon strap(4)<Full scale>Parts Bag G
2.6-6 tapping screw(15)

Parts Bag H

Parts Bag I
2.3-6 tapping screw(26)

2.6-8 tapping screw(30)<Full scale><Full scale><Full scale>M2-4 screw(35)

M2-5 screw(15)

2-6 plate tapping screw(15)<Full scale>

2-4 plate screw(10)<Full scale><Full scale>Parts Bag K

Parts Bag J
HV power source
switch harness(1)<Full scale>

HV battery
charge cord
(1)

Cable extension
100m long(1)

11

Serial USB adapter(1)

Serial cable extension
1.5m long(1)

Contents
About safety
About the usage of the HV battery
Preface
About the attached products
About the after-sales service
About the instruction manuals
The list of parts
The catalogue of parts
Contents

Before the assembly? Distinction of servo and channel

14
15
16

Removing case screws
Assembly of bracket B unit
Assembly of shoulder unit
Assembly of leg unit
Assembly of foot unit
Assembly of front frame
Assembly of body unit
Assembly of control unit

17
18
19
20
21
22
23
24

Before the assembly? Names of each part of servo motor
Before the assembly? The types of screws and how to use them

ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY

2-3
4-5
6
7
7
8
9
10-11
12-13

12

Contents
Setting

Setting parts to servo output axis, Cautions

Setting

Setting the origin of servo
Installing servo arm - arm and thighInstalling servo arm - shin and knee Installing servo arm - ankle Installing servo arm - body How to install cable guide
Assembly of leg
Assembly of arm
Installing servo hone
Assembly of head
Assembly of body
Installing control unit
Installing head unit
Wiring to control board
Processing front cowl and board coverInstalling board coverInstalling battery

25
26-28
29
30-31
32-33
34
35
36
37
38
39
40
41
42
43
44
45
46

Setting home position
Operating sample motion
Setting ICS

47-49
50-53
54-55

ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY
ASSY

Setting
Setting
Setting13

Before the assembly
Names of each part of servo motor (KRS-788HV)
Upper side
2.6 tapping screw hole

Upper case(depth 6mm)

Output axis (upper axis)

Middle case

Servo case

It is the rotation axis which outputs
the power inside servo. It is usedfixing parts such as servo hone andservo arm to the serration (notchesof output axis outer circle).

Bottom caseWiringWhite: signal
Red : + (Vcc)
Black: - (GND)

Serration(Seen from above)

Tab(Marker to prevent
opposite connection)

Connecter
It connects servo to
RCB-3 J and the battery

Servo lead

Bottom side
Case screw(Bottom axis)

It is the screw which fixes theservo case. In the process of
the assembly, after removing it
once, it is used to fix the frame
and the bracket.

It is the free rotation axis thatassists the support of the part.It
is used fixing parts such as freehone and servo arm.

2.6 tapping screw hole(depth 6mm)

14

Before the assembly
The types of screws and how to use them
Screw (coarse meter screw)■Characteristics of th e screws
In this kit, this screw is used for most of the fixingsof the aluminum part. ("M" inscribed in the name ofthe screws means that it is the meter bis of JIS
standard.)
It fits only in the screw holes whose screw is cut.
(You can see notches of the screw in the side of
the hole.) It can be used repeatedly unless it wears
or deforms.
■Attentions when tightening the screws
When tightening, be careful not to break the headof a screw with a driver. (Don’t use the driver
whose size of the point does not fit. Also, don’ttighten it too hard.)
Change the screw with a new one when its head issquashed, as it will not be able to remove with adriver.
When you can’t finish tightening a screw, please
see if the screw is bent.
If you continue to use a bent screw, a screw holewill deform and it will be impossible to tighten ascrew even if you change it with a new one.

When fixing parts withplural screws, lock all thescrews temporarily andthen tighten them. In thisway, you can fix the parts
with equal power and flatly.
Tightens lightly

Increasetightening

Right

In addition, when you fix theparts with more than fourscrews, tighten a screw in a
diagonal line first so that theparts will not be under too
much pressure.
3

1(Example of the orderof tightening)
2

4■Maintenance
Even if the screws are tightened securely, theyloosen naturally from vibration. See regularly if thescrews are not loosened.
When screws loosens frequently or fall off withmotions, locking material for screws (lock tight orscrew lock) is effective.
*When you use them, please follow a manual ofmaterials.
If you fix screws with instantaneous adhesive, be
careful because it might be impossible to take off
the screws or the holes might be filled.

Tapping screw
Right■Characteristics of the screws
It is used to fix resin parts and a part of aluminumparts. The screw part of tapping screws is a drill
and its head is thin, and it fixes the parts cutting ascrew in the hole whose diameter is smaller than ascrew. (It is called ‘tapping’ cutting a spiral hole sothat a screw fits into the hole.)It can be tightened
harder than normal screws, but you need more
power to tighten them at first.If the tapping screws
are tightened and taken off repeatedly, holes
become larger and they loosen.

It tightens while pressing it.

■Process of tightening screws
1,Confirmation of screw holesBefore tightening
tapping screws, see if the position and the shape
are as in the manual.
*If you tighten tapping screws into normal screw
holes or the holes of different size, screw holes
deform and it will be impossible to tighten the rightones.

■Tightening a screw again after taking it off
If a tapping screw is loosened after tightening it,
screws are formed in the hole.When tightening it
again, do it as follows.
1,Lock a screw vertically
Rotate a screw conversely before tightening it tosee if the it is locked vertically.
2,Tighten it without pushing
Do it as normal screws.
*If you push a screw, the holes will be damaged
and it will be impossible to fix a screw.

2,Tapping
Tighten a tapping screw pushing its head with adriver so that it stands vertical.
*If resin parts are tightened too hard, the head of ascrew deforms.

15

Before the assemblyDistinction of servo and channel
How to stick decal for servo lead

It is convenient whensticking if you cut themwith scissors or cutter
beforehand.

As for the numberof channel,
see‘Process ofassembly’or‘thelist of channel’.

Cut decal into your favorite
figure seeing the left drawing.

How to stick decal for the body of servo
Stick it on a distinctive part such as the sideof servo.
*Stick decal which has the same number ofchannel as the one on a connector.

KHR-2HV the list of channel*This is the back side

For the assembly of this kit, channel isassigned to servo by the layout of the
figure.
Shoulder unit L

CH1

Head

CH2

CH6

Shoulder unit R

CH7

CH3

Bracket B unit

Bracket B unit

CH4

Hand unit L

The attached control board
RCB-3J has 24 channels (outletof connectors, also describedas ‘CH’) and it can connect 24
servo or option parts.

CH11

Body unit (L)

CH12

CH8

CH17

Hand unit R

Body unit (R)

CH18

Base unit

Base unit

CH13

CH19

CH14

CH20

CH15

CH21

Leg unit R

Leg unit L

Leg unit R*Servo motor Cable length 480mm

Leg unit L*Servo motor Cable length 480mm

Foot unit L*Servo motor Cable length 480mm

Foot unit R*Servo motor Cable length 480mm
CH 5
CH 9
CH 10
CH 16
CH 22-24

16

It doesn't use it in this kit.

Assembly
The image of a complete one
Removing case screw
Preparation of assembly
Necessary parts●Servo motor KRS-788HV
Cable length 300mm

12●Servo motor KRS-788HV
Cable length 480mm

4

Explanationof the icons

Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work
Left

1. Remove case screw which is attachedto the bottom case of servo motor.

Rotate a screw leftward when loosening

For one servo motor (servo) four casescrews are attached.

Case screw (four)
The screws thatwere taken off
should be kept insomewhere as they
will be used later.

Servo case (bottom case)
When taking off a screw, be
careful not to fall off ordismantle servo case. (Itwill be difficult to assemble)

17

Remove all case screws that are
attached to 16 servo in total (length ofservo lead = 300mm: 12, 480mm: 4).
2. See the number of servo and casescrews (64 in total) and keep them in astable place or in a box)

Assembly
Assembly of bracket B unit The image of a complete one
Arm - Upper arm - Thigh

Necessary parts●Servo motor KRS-788HV
Cable length 300mm
6●Servo bracket B
6●Servo arm 700A base6
●2.3-6 tapping screw
24●Case screw
24

Explaining
the points

Explanationof the icons

Knack to do
the work well

Caution of
breaking

Bracket B
unit

Need to be
confirmed

The process of work1

1. Attach base of servo arm 700A (servo)
to servo bracket B (bracket B) with
2.3-6 tapping screws.

Rotate a screw
rightward whentightening

Right

2.3-6 tapping screw(four)
Servo bracket B

The direction of
attaching base might
be wrong. Before
tightening a screw,
see the form. The
surface in the figure is
the reverse side.
Servo arm
700A base2

2. Attach bracket B to servo with casescrews.

Case screw

See again if the direction of attaching base isright. See the form in
the enlarged figure.
Case screws are tightened to the extent which
servo and fixed parts(bracket, frame, etc.) do
not shake or float.

Be careful not to tighten case screws
too hard. They can deform and physicalDangerresistance will be produced in output axis.
This causes servo to be feverish or toignite.
Case screws are tightened as soft as
possible to the extent which servo andfixed parts (bracket, frame, etc.) do notshake or float.

*Assemble 6 same units in total

18

Assembly
Assembly of shoulder unit
Shoulder joint

Necessary parts●Servo motor KRS-788HV
Cable length 300mm●Shoulder frame L●Shoulder frame R●Servo bracket A-L●Servo bracket A-R●Case screw

Explanationof the icons

1

The image of a complete one
Shoulder unit L

Shoulder unit R

2
1
1
1
1
8

Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work

See the holes of theside so that L and R
are not mistaken.

1. Assemble unit L and unit R attachingshoulder L and shoulder R to servo withcase screws (four for each)

Servo bracket
A-R

2. Attach servo bracket A-L and servo
bracket A-R to unit L and unit R.
Screws are not used in this part, soholes are designed a little tight.
Be careful not to bend bracket.

Case screw

Be careful not totighten casescrews too hard.

2

3. Cut decal for servo lead and stick it on
servo lead.
CH 2 : Shoulder unit L
CH 6 : Shoulder unit R

Servobracket A-L

See the position of slits on
the side so that L and R
are not mistaken.

Shoulder unit L

Shoulderframe L

Shoulder unit R

Shoulderframe R

19

Push hard until there is no gap
between parts.
Push bracket with care. It can deform.

Assembly
Assembly of leg unit

The image of a complete one
Thigh - Knee

Necessary parts●Servo motor KRS-788HV
Cable length 300mm●Servo motor KRS-788HV
Cable length 480mm●Leg joint A-L●Leg joint A-R●Leg joint B-L●Leg joint B-R●M2-4 screw●Case screw2

Leg unit R

4
16

2
1
1
1
1

Explaining
the points

Explanationof the icons

Leg unit L

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work1

1. Insert leg joint B-L and leg joint B-R intoservo
Leg joint B-L

2. Attach leg joint A-L and leg joint A-R
with M2-4 screws (2 for each)
3. Attach leg joint A-L and leg joint A-R
to servo with servo case screws (8 foreach).

It insert it.

Cable length 480mm

Leg joint B-R
Cable length 480mm

2

It insert it.

Leg joint A-L

4. Cut decal for servo lead and stick it on
servo lead.
CH13 : Leg unit L (upper part)
CH14 : Leg unit L (lower part)CH19 : Leg unit R (upper part)CH20 : Leg unit R (lower part)3

Leg unit L

M2-4
screw
(two)

Leg joint
A-R

Fix leg joint with holes
outside.

Case screw(eight)Leg unit R

Danger

Be careful not totighten casescrews too hard.

20

Assembly
Assembly of foot unit
Necessary parts●Servo motor KRS-788HV
Cable length 480mm●Sole●Foot angle A●Foot angle B-L●Foot angle B-R●M2-4 plate screw●Case screw

Explanationof the icons

1

The image of a complete one

Ankle - Sole
2
2
2
1
1
8
8

Explaining
the points

Knack to do
the work well

Foot unit L

Caution of
breaking

Foot unit R

Need to be
confirmed

The process of work

It insert it.

1. Insert servo into foot angle B-L andfoot angle B-R

Foot unit R

2. Attach foot angle A with case screws(4 for each).
3. Attach sole to foot unit L and foot unit
R.

Foot unit L
Foot angle B-R(Sole can be attached to both L and R)
Foot angle B-L

2

4. Cut decal for servo lead and stick it
on servo lead.
CH15 : Foot unit L
CH21 : Foot unit R

Case screw(four)
Foot unit R
Foot angle A
Foot unit L

3

Be careful not to tighten
Danger case screws too hard.

Foot unit R

Sole

M2-4 plate screw

21

Foot unit L

Assembly
Assembly of front frame
Hip joint

Necessary parts●Servo motor KRS-788HV
Cable length 300mm●Body frame F●Body frame L●Body post
●M2-4 screw●2.6-6 tapping screw

1

Front Frame

2
1
1
3
2
3

Explaining
the points

Explanationof the icons

The image of a complete one

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work

Body Frame F

1. Fix body post to body frame F with
2.6-6 tapping screws.

Body Post
2.6-6
tapping screw
Front
Back

As for the obverse and the reverse of body
frame, the side where the finger is caught
when touched is the reverse.

2

2. Insert servo into body frame F.

3. Attach body frame L to body frame Fwith M2-4 screws. Pay attention to theposition of servo lead.

It insert it.

How to put servo lead
When inserting, push bottom case of servo
with thumb while pushing the part aroundholes of frame.

3

Do not push servo lead
hard between frame orpull it out hardbecause it causes
contact failure andbroken wire.

Body frame L

See if servo lead is put as in the figure. If it’sput in the wrong direction, wiring will be difficult.

M2-4 screw

22

Assembly
Assembly of body unit
Necessary parts

The image of a complete one
Body

Body unit●Shoulder unit L (assembled) 1●Shoulder unit R (assembled) 1●Front unit (assembled)1●Body frame B
1●M2-4 screw
15●Case screw
8

Explaining
the points

Explanationof the icons

1

Knack to do
the work well

When attaching shoulder frame, attach L
and R with shoulder frame outside.
Shoulderunit R
Shoulderunit L

Caution of
breaking

Need to be
confirmed

The process of work

1. Attach shoulder unit L and shoulder
unit R to front unit with M2-4 screws(3 for each).
2. Fix body frame B and servo of front
unit with case screws.
3. Attach body frame B and servo
bracket A-L and servo bracket A-R ofshoulder unit with M2-4 screws.
4. Cut decal for servo lead and stick it on
servo lead.
CH2 : Shoulder unit (L)CH6 : Shoulder unit (R)CH11 : Front Frame (L)CH17 : Front Frame (R)M2-4 screw(six)

2
Body frame B
had the obverse
and the reverse.
When touching
screw holes, the side
where the finger iscaught is the reverse.
Attach it with theobverse side up.

3

Case screw(eight)Servo lead of CH11 and CH17 has tobe put through so that it come out
from the holes of body frame B to theback.
M2-4 screw(nine)

Body Frame B

Danger

Be careful not to tighten
case screws too hard.

23

Assembly
Assembly of control unit
Necessary parts●RCB-3J●PCB base●M2-4 screw●HV power source
switch harness

Explanationof the icons

1

The image of a complete one

Control part

Control unit

1
1
4
1

Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work

M2-4 screw

1. Attach RCB-3J to PCB base with M2-4
screws.
2. Insert the power source switch harness
in the power source terminal of RCB-3J.

RCB-3J■Is the control board the heart of a robot?
In case of the person’s mechanism to move thebody, the brain orders first by thinking that "I will
move the body”, and the nerve transmits the order tothe muscle, which moves each joint of arms and feetby muscles around them. Blood flows to the brain
and the muscle, and circulating organs such as theheart work so that the energy to exercise (oxygen,nutrition etc.) are always carried.

PCB base

2

The body of the person continues to move in thisway, but how about the robot?

HV power source
switch harness

In KHR-2HV, the control board (RCB-3J) plays arole as a heart and the signal conductor in the wiringas the nerve, and they control servo which plays arole as a joint. This motion is carried out following
the program which is written in the memory in thecontrol board.
The motor inside the servo case and the gear playa role as the muscle. Therefore, if the assembly or
the condition of these parts are bad, the joint of therobot does not move well and it leads to unstablemotions.

Keep the power switch in power source
switch harness off unless it is indicated.(SeeDanger the enlarged figure.) If it’s kept on, the robot
might move suddenly and fall off or break
down when connected to outlet. It also mightcause serious injury with finger scissors.

In addition, for the robot which does not have thecirculatory organ, the electricity instead of blood is
the source of the energy that operates the control
board and moves the joint. The control board alsofunctions as the repeater of the electricity to each
servo.

The connector is designed so that is can not
be inserted conversely. If you try to insert it in
the wrong way, it will damage the connector.

24Assembly
Setting parts to servo output axis, Cautions
Setting the origin is theimportant work that decides thedatum point of the turning angleof servo. By doing this securely,
reproducibility can become
high when sample motions arecarried out.

It does not work if theorigin is not the same.

Good example

Attaching servo hone
There are notches which arecalled the serration in the output
axis of servo. When installing
servo hone, by shifting theposition where you install, theappropriate position can bechosen.

Bad example

Attaching servo arm
In case of the servo arm, as the direction
is fixed, attach it shifting rightward or
leftward slightly when it does not exactly
match the figure.
For example, when setting the origin in
both shoulders, as there are more gaps
in the origin of servo of both shoulders,
they become unstable.
Choose the appropriate position whenassembling.

25

Setting
Setting the origin of servo
The servo-motor KRS-788HV can turn for approximately 180 degrees at the maximum.
Therefore, like joints of humans, it does not turn limitlessly. The robot has to be assembled
so that it can make the best motions considering its restriction.
Setting the origin of servo is important in this respect.
If the origin is not correct, it might not operate properly when doing sample motions.
Therefore, understand the method and do it correctly.
Setting the origin has to be done when the servo arm is installed to each servo. The
following is the process of setting the origin.

1 Things to prepareControl board RCB-3J is used which was attached to PCB base.
Connect the board using USB serial adapter on a personal computer.
Also, install the motion making software ‘HeartToHeart3J’ to the computer.
HV battery
9N-300mAh

Serial USB adapter
Se

ria

M lU
AD S
E B
IN A
JA da
PA pt
N er

Control unit

Serial cable extension
See RCB-3J instruction manual for RCB-3J, the software and USB serial adapter.
Prepare the computer which has Microsoft Windows 2000 or XP.

2 Connection
Connect serial USB adapter to the USB port on the computer.
*Complete the setup following the manual of serial USB
adapter.

26

3● If you turn on the power source harness, the green LED on
the base plate starts to light up.

2● Connect the power source harness to RCB-3J and connect
the HV battery which is charged beforehand.

1● Connect the cable of serial USB adapter to high speed
serial terminal of RCB-3J.

Setting
3 Starting the software
If you start the motion making software‘HeartToHeart3J’, the window on the right
will appear.
First, select the number of thecommunication port (COM).
*For the numbers of COM, see the manual of serial
USB adapter.
*On the right window, COM8 is selected as an example.

Check SYNC on the window.

Put one position on the data sheet.
Click position tool and then click data sheet.

Double click the position that was put on
the data sheet ,and open the position
window.
Right click CH1 and open the menu. SelectSERVO.

The process continues to the next page27

Setting
4 Connect servo and see if it operates.
Power
Connect servo whose origin you set to CH1.
Move the slide bar of CH1 on the position windowof the software and see if servo operates. Move it
widely and you can see easily.

CH-1

A high-speed
serial terminal

5 Set the origin.
Move the slide bar on the position of the origin of each servo.
For most of servo, position 0 is selected, but it differs for some.
Install servo arm or servo hone and remove servo lead from RCB-3J.

If you already used the RCB-3J, it might not be able to assemble
correctly even if you choose the same number. If you set the origin
again after assembling, pay attention to the setting of the software.
( Also see the manual of RCB-3J)

The position of the origin according to channel
CH1
CH2
CH3
CH4
CH6
CH7

0
0
0
0
0
0

CH8
CH11
CH12
CH13
CH14
CH15

0
0
0
-90
0
0

CH17
CH18
CH19
CH20
CH21

Numbers of each setting is not an angle.
It’s the number that you set on the position window of the software.
If you have changed the display magnification, the numbers will bedifferent.

28

0
0
90
0
0

Assembly
Installing servo arm- arm and thigh-

Necessary parts●Bracket B unit (assembled)●Servo arm 700A upper arm●Servo arm 700A bottom arm●Screw for flat head hone

Connectionof servo

6
6
6
12

Explaining
the points

Explanationof the icons

The image of a complete one

Caution of
breaking

Knack to do
the work well

Need to be
confirmed

The process of work2

1. Set the origin of servo. (See ‘Setting
the origin of servo’)

Screw for flathead hone

Select ‘0’ on the slide bar of CH1 andconnect servo to RCB-3J.

Servo arm
700A upper
arm

Bracket B
unit

2. Insert servo arm 700 A upper arm
into bracket B unit and remove theconnector of servo from RCB-3J. Put
the servo arm on the position as close
as the unit on the figure. Attach upperarm and bottom arm by flat headscrews.
3. See the movable range of servo.
(1)Origin*It will not becompletely flat.
Put it as flat as
possible.

Servo arm
700A bottomarmR

Adjust servo arm to the position as in
the figure by hand.
(2)Limit of the movable range on the left
Turn servo arm leftward slowly and it
will stop as in the figure.

3(3)Limit of the movable range on the rightRemove servo lead from RCB-3J. If
you move upper arm with servo leadon ( you can hear the sound), it willcause breakdown.

(1)

(2)

Turn servo arm rightward slowly and it
will stop as in the figure.

(3)

Do not put too much pressure
on servo. It will break.

This process is done for 6 servo
in total.

29

Assembly
Installing servo arm- shin and knee -Necessary parts

Connectionof servo

1●Leg unit (assembled)●Control unit
1●Servo arm 700A upper arm 4●Servo arm 700A bottom arm 4●Screw for flat head hone8

Explanationof the icons

2

The image of a complete one

Explaining
the points

Knack to do
the work well

Screw for flat head hone

Caution of
breaking

The process of work

1. Set the origin of servo. (See ‘Setting
the origin of servo’) Select the numberson the slide bar of CH1 as in the figure
and connect servo to RCB-3J.
CH13: -90
CH19: 90

Leg unit L

Need to be
confirmed

CH14: 0
CH20: 02. Insert upper arm into leg unit andremove the connector of servo from
RCB-3J. Put the servo arm on theposition as close as the unit on the
figure. Attach upper arm and bottom
arm by flat head screws.

Leg unit R

30

After installing servo arm, see the movable range of each servo. If there is a mistake inthe setting of the origin or installing servo arm, servo will not move as supposed.

3

3. See the movable range of servo.
(1)Origin(1)

Adjust servo arm to the position as in
the figure by hand.
(2)Limit of the movable range on the left
Turn servo arm leftward slowly and it
will stop as in the figure.
(3)Limit of the movable range on therightTurn servo arm rightward slowly and it
will stop as in the figure.

(2)

When it touches
the frame, it willstop. Do not put
too much pressure
on it.

Remove servo lead from RCB-3J. If
you move upper arm with servo lead on(you can hear the sound), it will cause
breakdown.
If you turn the servo over the movable
range, gears inside the servo might break
down. So turn servo arm carefully.

(3)

31

Assembly
Installing servo arm - ankle Necessary parts

Installing servo arm

1●Foot unit L (assembled)
1●Foot unit R (assembled)●Servo arm 700A upper arm 2●Servo arm 700A bottom arm 2●Servo arm 700A base2

Explanationof the icons

2

The image of a complete one●Screw for flat head 4hone●2.6-8 tapping screw 4●Control unit
(assembled)
1

Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work

1. Set the origin of servo. (See ‘Setting
the origin of servo’)

Foot unit R

Select ‘0’ on the slide bar of CH1 andconnect servo to RCB-3J.
2. Insert upper arm into flat unit andremove the connector of servo from
RCB-3J. Put the servo arm on theposition as close as the unit on the
figure. Attach upper arm and bottom
arm by flat head screws.

Foot unit L
It vertically installs it in thenearest position as shownin figure.

3. See the movable range of servo.
(1)Origin
Adjust servo arm to the position as in
the figure by hand.

3(2)Limit of the movable range on the
left

(1)

Turn servo arm leftward slowly and it
will stop as in the figure.

(2)(3)Limit of the movable range on the
right

(3)

When ittouches theframe, it willstop. Do not
put too muchpressure on it.

Turn servo arm rightward slowly andit will stop as in the figure.
Remove servo lead from RCB-3J. If you
move upper arm with servo lead on (you canhear the sound), it will cause breakdown.
If you turn the servo over the movable
range, gears inside the servo might break
down. So turn servo arm carefully.

32Assembly
3
Upper arm

Bottom arm

3. Attach servo arm 700A base between upperarm and bottom arm.
(1) See the shape of arm base. The
position of convexity is important.
(2) Adjust arm base on the joints of upperarm and bottom arm. Push arm baseinto the joints and insert it to 1/3.
(3) Insert arm base into the joint ofbottom arm until you hear the sound.

Pay attention to the obverse and reverse
side of the base. Insert it with the obverse
upside.

(4) Insert arm base into the joint ofupper arm until you hear the sound.

If you warm the base of upper arm
and bottom arm by dryer, it will beeasier to assemble.

4. Attach the joints of upper arm, bottom
arm and arm base by 2.6-8 tapping
screws. (1 for each)4

The inset is very tight. Be careful not
to harm your fingers or nails when
warning
inserting servo arm. Also, whenremoving it, the parts of servo base mightblow. Pay attention also to your surroundings.

33

Assembly
Installing servo arm - body - The image of a complete one
Necessary parts

Installing servo arm●Body unit (assembled)●Servo arm 700A upper arm●Servo arm 700A bottom arm●Servo arm 700A base
●Screw for flat head hone
●2.6-8 tapping screw

1
2
2
2
4
8

Explaining
the points

Explanationof the icons

Caution of
breaking

Knack to do
the work well

Need to be
confirmed

The process of work2

1. Set the origin of servo. (See ‘Setting
the origin of servo’)
Set the neutral number and connect
servo to RCB-3J.
Vertical*It vertically installs it in
the nearest position asshown in figure.

3

Body unit

Pay attention to the
obverse and reverse
side of the base.

2.6-8
tapping
screw(four)

Attach upper arm.
2. Remove the connector of servo from
RCB-3J. Attach upper arm and bottom
arm to body unit by hone attaching
screws.
3.Insert arm base and attach it by 2.6-8
tapping screws.
4.See the movable range of servo.
(1)Origin
Adjust servo arm to the position as in
the figure by hand.

4

Arm base(2)Limit of the movable range on the left

When it touches
the frame, it willstop. Do not put
too much pressure on it.

Turn servo arm leftward slowly and it
will stop as in the figure.
(3)Limit of the movable range on therightTurn servo arm rightward slowly andit will stop as in the figure.

Remove servo lead from RCB-3J. If you move
upper arm with servo lead on (you can hear
the sound), it will cause breakdown.
There is the limitation of the movable range ofservo arm. Turn it carefully.

34

Assembly
How to install cable guide1

1. Cut off cable guideYou can cut it off by hand, but if you use anipper and sand paper, it will be better.

2. Attach cable guide to servo arm. For the
position, see the picture.

2

Cross section

2-6 platetapping screw

Lead
cable

4

2

*You can collect 5
cables at the maximum

Attach 4 cables on the arms (1, 2, 3, 4)
after assembling arms.
Attach 6 cables on the feet (7, 8, 9, 10,
11, 12) after assembling feet.
Attach 2 cables on the body (5, 6) whenassembling all the parts.

5

6

1

3
7

35

10

8

11

9

12

Assembly
Assembly of leg

The image of a complete one

Necessary parts

Leg●Bracket unit (assembled)
CH12●Bracket unit (assembled)
CH18●Leg unit L (assembled)●Leg unit R (assembled)●Foot unit L (assembled)●Foot unit R (assembled)

1●2.6-8 tapping screw 8

Leg unit(completion)

1
1
1
1
1

Explaining
the points

Explanationof the icons

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work1

1. Insert arm base of bracket unit into
servo arm of leg unit and attach by
2.6-8 tapping screws ( 2 for each).
2. Pull out servo lead of servo of ankles(CH15, CH21) to the outside of feet.
Put decal on each servo lead.
3. Collect cables by cable guide. Be
careful that the tension does not
become too high.

2.6-8 tapping
screw (four foreach)

3 Reference example(Leg unit R) servo leadshould be collected up
with the block wireoutside(Leg unit L) servo
lead should becollected up withthe white wireoutsideLeg unit L

Leg unit R

2

The mounting
location of thecable guideCH15, CH21 servo leads(arrows) should be put out
through the under sideof the servo arm.

Leg unit R

36

CH19

Leg
unit L

Assembly
Assembly of arm

The image of a complete one
Arm

Necessary parts●Bracket B unit (assembled)●Hand L
●Hand R
●2.6-6 tapping screw●2.6-8 tapping screw

Explanationof the icons

1

4
1
1
4
4

Explaining
the points

Arm unit R

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work

Arm unit L

1. Attach bracket B unit to hand L, R by
2.6-6 tapping screws (two).
2. Insert arm unit into arm base of bracket
B unit and fix it by 2.6-8 tapping screws.
Put decal on each servo lead.
3. Attach cable guide seeing the picture
below. Fix servo leads on cable guide.
In this case, be careful that the servo
leads do not block the movable rangeof each servo.

2.6-6 tapping
screw

Hand LArm unit R

Hand L2
Bracket B
unit

2.6-8
tappingscrew
Arm unit L
Arm unit R

37

Arm unit L

Assembly
Attaching servo hone
Necessary parts●Body unit (assembled)●Low height servo hone●Servo arm 700A base
●Arm supporter 700A
●M2-5 screw●2.6-6 tapping screw

Explanationof the icons

2

The image of a complete one
Shoulder

1
2
2
2
8
2

Explaining
the points

Caution of
breaking

Knack to do
the work well

Need to be
confirmed

The process of work

Low height servo hone

1. Set the origin of servo. (See ‘Setting theorigin of servo’)

2.6-6
tapping
screw

Select ‘0’ on the slide bar of CH1 andconnect servo to RCB-3J.

Arm
supporter
2.6-6
tapping
screw
Low height
servo honeArmsupporter3

In attachingbase, if you
mark at theposition of the
red circle in
the figure, youwill easily findthe origin.

2. Insert arm supporter and low height
servo hone into the body unit andremove the connecter of servo from
RCB-3J. Put the servo arm on theposition as close as the unit on the
figure. Fix low height servo hone by
2.6-6 servo tapping screws. (1 for each)
3. Attach arm base to servo hone by M2-5
screws (4 fro each). Put the base withobverse outside.
4. See the movable range of servo.
(1)Origin

M2-5 screw(four)

Adjust servo arm to the position as in
the figure by hand.
(2)Limit of the movable range on the left
Turn servo arm leftward slowly and it
will stop as in the figure.

4(3)Limit of the movable range on the right
Turn servo arm rightward slowly and it
will stop as in the figure.
Remove servo lead from RCB-3J. If
you move upper arm with servo lead on(you can hear the sound), it will cause
breakdown.
There is the limitation of the movable
range of servo arm. Turn it carefully.

38

Assembly
Assembly of head

The image of a complete one
Head

Necessary parts●Servo motor KRS-788HV
Cable length 300mm●Top cover●Control unit
●Low height servo hone
●Screw for flat head hone
●M2-4 screw

Explanationof the icons

1
1
1
1
4

Explaining
the points

Low height
servo hone

Figure seen fromthe under

Screw forflat headhone

6

Need to be
confirmed

As topcover, thefine side coatedwith alumite isobverse.

1. Cut decal of the number of CH for
servo lead of CH1.
2. Set the origin of servo. Select ‘0’ on theslide bar of CH1 and connect servo to
RCB-3J.
3. Attach low height hone to servo withcase screws by flat head screws. See
the figure for the angle.
4. Attach low height hone and top coverby M2-5 screws.
5. See the movable range of servo.
(1)Origin
Adjust servo to the position as in the
figure by hand.
(2)Limit of the movable range on the left

M2-4 screw(four)

5

Caution of
breaking

Knack to do
the work well

The process of work

3

4

1

Turn servo leftward slowly and it willstop as in the figure.
(3)Limit of the movable range on the right

In this process, doremove servo leadfrom RCB-3.

Turn servo rightward slowly and it willstop as in the figure.

6. Remove power source harness (outlet
switch) from control unit.
7. Push the outlet switch into top cover.

HV power source
switch harness

7

Direction of installation

Servo side

(The cable isattached to the
FRONT district.)

ControlunitBlack Cable

39

Assembly
Assembly of unit
Necessary parts●Body unit (assembled)●Arm unit L (assembled)●Arm unit R (assembled)●Leg L (assembled)●Leg R (assembled)●2.6-8 tapping screw

Explanationof the icons

1
1
1
1
1
8

Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work

1. Attach each part by 2.6-8 tapping
screws as in the figure. (2 for each)40

Assembly
Attaching control unit

The image of a complete one

Necessary parts●Body (assembled)
1●Control unit (assembled) 1●M2-5 screw
4

Explanationof the icons

Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work

1. Attach control unit by M2-5
screws as in the figure.

1

M2-5
screw

Control unit

41

Assembly
Attaching head unit

The image of a complete one

Necessary parts●Head unit
●Body (assembled)

Explanationof the icons

11Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work1

1. Attach head as in the figure.
2. Insert the connecter of the outlet switch
into RCB-3J.

Direction of slide* Head unit is not fixed by screws.
It will be fixed by front cowl.

See the figure for how to put theconnecter of the outlet harness.

Join the slit (cut out)
and the tub (ledge),
and fix them bysliding them.

Pay attention not toshut in the wiring

2

Power connecter(female)Power connecter(male)

42

Assembly
Wiring to control board
Power supply terminal

Insert the connecter of each servo into
RCB-3. See the number of channel on
decal.
Insert it with black cableoutside. The direction changes
depending on the inserted
position.

Output17
Output18
Output19
Output20
Output21
Output22
Output23
Output24

A low speed serial terminal

Output13
Output12
Output11
Output10Output9

Output8
Output7
Output6
Output5
Output4
Output3
Output2
Output1
A setup of a power supply

A high-speed serial terminal

AD input 3
AD input 2
AD input 1

LED1 (Red)
LED2 (Green)

The external switch
connection terminal

Output15 Output14

Output16

Switch1

See the picture in the left for how to collectcables for cable guide of the bottom part ofthe body.
CH14 CH12

CH18 CH20

CH15 CH13 CH11

CH17 CH19 CH21

After inserting each servo lead into
RCB-3J, collect cables by nylon strap
as in the picture above.

As the left below picture, attach cable extension tohigh speed serial terminal.

43

1

2

3

Assembly
Processing front cowl and board cover
Necessary parts●Front cowl
●Board cover

Cowl and Cover
1
1

Paint for polycarbonate
Detergent or alcohol
Scissors, Cutters, Sand papers

Explanationof the icons

Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work2

1. Remove oil from the reverse side ofcowl by detergent or alcohol.
2. Dry it and paint it with spray forpolycarbonate.

3

Ventilate the room when you
Danger use the spray. Also, using thefire is dangerous.
3. After drying, cut the cowl as in the
figure. The part with dense color is cut.

Front cowl

Board cover

It is better to use sand paper.
Part cut out

Be careful for scissors andDanger cutters.

4
4. Put through tapping screws into 4
parts of board cover.

44

Assembly
Installing board cover

Cowl and Cover

Necessary parts●Body (assembled)●Board cover●2.6-6 tapping screw

Explanationof the icons

1

The image of a complete one

11
4

Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work

2.6-6 tappingscrew(four)

1. Attach board cover to PCB base.
See the picture for wiring.

45

Assembly
Installing battery
Necessary parts●Front cowl
●Body pin
●Sponge●HV battery

Explanationof the icons

The image of a complete one
Cowl and Cover

1
3
1
1

Explaining
the points

Knack to do
the work well

Caution of
breaking

Need to be
confirmed

The process of work1

1. Cut the sponge into half and put theseal covering on the head of screws ofbody frame.

It separates by about 10cm.

2. Connect the battery to power source
switch harness.

2

3. Attach front cowl to body post.

3
4

Pay attention not to sandwich the cable ofbattery and power switch harness.

4. Insert body pin into body post and fix
body cowl.

46

Setting
Setting home position 1(1) As in the process of setting the origin,start the software and RCB3-J. Place
position on the datasheet.

Double click the position that was
put on the data sheet, and open theposition window.

Right click the using channel and open
the menu. Select SERVO.

Danger

Be careful as the robot will move
if you move the scroll bar. It isdangerous to put your finger to themoving body or to bring your faceclose to it.

For all channels that are used, selectservo and set 0.

47

Setting
Setting home position 2
In the condition, the body is supposed to be
like the right picture.

After seeing the condition of the robot, open themenu by right click and select ‘Home positioning’
and close POS window.
(2) Adjust the position of the home position on the adjustment window.

Click trim adjustment of the main window andopen the adjustment window. (HomeDlg)

48

Setting
Setting home position 3
In the adjustment window, adjust theposition of each servo and the positionof home position. Select the home
position which stands upright.
Home position is the important position
when operating motions.
Especially, adjust left and right legs
correctly. See the picture below.

* The setting is automatically saved when thewindow is closed.

* This window is an example. The numbers might differ.

Especially, the position of theback of feet is important.

For each servo of thefoot, put the output axisof servo on the straight line
when seen from the side.

Each frame has themark called neutral
gage. Adjusting this markand arm, you can see theneutral position.

49

Setting
Operating sample motion
For the moment, setting of home position is completed for the robot (KHR-2HV). But it does
not move as motions are not registered. Also, home position does not start even if you turnit on. Here, it will be explained about the register and the operation of sample motions andthe operation of basic walking motions so that it will move safely to home position.

Registering start up motion
See the instruction manual of RCB-3J to make start up motion.
Here, sample motions in the CD will be read.

Connection
Connect KHR-2HV and a computer and then connect serial USB adapter.
1, Start ‘HeartToHeart3J’ on the computer.
2, Connect the battery to KHR-2HV and turn the switch on.
3, Check SYNC on the software.
In this condition, it looks like KHR-2HV is off. Each servo is free on the initial condition.

Read start up motions from the file
Click load button on the main window of
the software.
Click the icon and the dialogue box ‘Open
the file’ will appear.
Select the folder ofsample motion fromthe folders that were
copied from theattached CD or hard
disc.
From this folder,
open the file ‘startup motion’.

50Setting
Start up motion appears
Start up motion like the figure on theright will appear on the data sheet.

Write it changing to the home position
Change the last position of start up
motion to the current home position.
If you have made the home position
as in this manual, you don’t have tochange it.
If you click this position, theposition window on the right
will appear.
If you click this icon, it will change
to the home position whose data
is set.
* If you did the process as in this manual, all servo are at the position of 0. Close thewindow after confirming it.

Write motion
Motions are operated after
they are written on the board.
If you click the Write button,
the dialogue box will appear.
M80 is chosen as an example
here.

You can write it on any of them.

51Setting
See the motions that were written
If you click data table button, thewindow on the right appears and you
can see the list of motions in the board.
If you click play button, the dialogue
on the right appears. By selecting a
motion, you can operate it.
If you click this button, you can stop a
motion for a while.
If you click stop button, you can stop
the motion.
* The contents of this motion are used when all servos are free. You cannot see if it’s operating whenit’s done with servo working (home position).

Automatic operation when the power is on

The motions can be played after it started, but RCB-3J has the function that plays a selectedmotion automatically when the power is on. The following shows its setting.

If you click the option button, the option window on theright opens.

On the topic, ‘play motion scenario when the power is on’,select the start up motion that was registered.
Close the window, and this setting is confirmed.

Operating start up motion

After registering start up motion, turn the switch off and turn it on again. If each servo moves
slowly to home position when the power is on, registering is finished.

52

Setting
The mechanism of start up motion and sample motion
Start up motion is an example of motions that utilize the functions of RCB-3J and
KRS-788HV.
When the power is on, servo tries to move to the position that was first given, but as
the position when the power is on is not stable, it moves at the highest speed to theinitial position. This is not safe as it moves suddenly.
In start up motion, select FREE for all servo at the initial position. When FREE isselected, KRS-788HV releases the control of servo but also returns the current
position of the output axis to the control board. The next SET substitutes thereturned position to the position of each servo making use of the mechanism of
instruction.
In the last position, home position is selected. For the original position that moves tohome position, the position which was taken by instruction becomes standard, andthe speed that was selected at the position becomes the speed of servo.

The process of the register of start up motions contains basic contents for operating othersample motions or making motions. The following is the process of using sample motion.

Delete all the data on the data sheet. (*)

On the data sheet, right click and select all
select. On either topic, right click again anddelete.

Read sample motion

Other than opening the file that youuse, you can also open by dragging anddropping the file on the data sheet.

Read sample motion

See motion by play button* When it reads to the data sheet from the file, it becomes additional reading
and original data are necessary. When motion is read from the board, it
becomes superscription. (The originally data does not remain.)53

Setting
Setting ICS
In the setting of home position and start up motion, servo might vibrate and does not stop.
You can react to this by changing motion characteristics of each servo. In RCB-3J, you cando this with control board connected to servo.

What is ICS?
ICS (Interactive Communication System) can change and gain each parameter of the insideby communicating servo motor, PC and the control board for the robot.
It also has the function of instruction and characteristic change.
The function of instruction changes the position data of each servo when the robot is posed
as you like to the position data.
Characteristic change can remember 3 types of the setting of servo and change it whennecessary.

The process of the setting
1. See if the power of the body is on and it is connected to the computer.

2. Click option button and open the setting window.
3. On the topic of ICS function on option window, checkthe channel that servo is connected to. Close the option
window.

This setting does not have to be done again.

4. Click ICS setting button and open the ICS setting
window.
Turn the switch off and turn it on again. If the LED lights up
in red, RCB-3J is in ICS mode.

54

Setting
5. Click read button on ICS setting window and read parameter of each servo that isconnected to RCB-3J.

Reconfirm ICS setting of option
setting when parameter is not
read. When it’s not in ICS mode,the error message will appear.

6. Double click CH1 and open parameter setting window of servo. Change pulse stretch of
SET1 to 3 (MIDI). Do this for CH2, 3, 4, 6, 7, 8.

The meaning of settings

Pulse stretch( initial value = 5) sets the saving
characteristic of servo. As the value is higher, thesaving characteristic is stronger. In KHR-2V, thevalue is optimized like the value is small to preventthe head or arms from having damage.

7. After the setting, close the window of ICS setting. Turn it off and turn it on again.

The servo using ICS, changes mode of normal moving mode and communication
mode by ICS when the power is on. Both case require the reboot when the ICS
settings window is open.

55