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Epson G Series Maintenance Manual

Epson G Series Maintenance Manual

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Industrial Robot: SCARA Robots
G series
MAINTENANCE MANUAL
Rev.3
ENM226R5374F
Original instructions

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Summary of Contents for Epson G Series

  • Page 1 Industrial Robot: SCARA Robots G series MAINTENANCE MANUAL Rev.3 ENM226R5374F Original instructions...
  • Page 3 Industrial Robot: SCARA Robots G series Maintenance Manual Rev.3 Seiko Epson Corporation 2021-2022 G series Maintenance Rev.3...
  • Page 4 Please notify us if you should find any errors in this manual or if you have any comments regarding its contents. MANUFACTURER CONTACT INFORMATION Contact information is described in “SUPPLIERS” in the first pages of the following manual: Robot System Safety Manual Read this manual first G series Maintenance Rev.3...
  • Page 5 Please separate used batteries from other waste streams to ensure that it can be recycled in an environmentally sound manner. For more details on available collection facilities please contact your local government office or the retailer where you purchased this product. G series Maintenance Rev.3...
  • Page 6 Before Reading This Manual This section describes what you should know before reading this manual. Structure of Control System The G series Manipulators can be used with the following combinations of Controllers and software. Controller Software Name Structure Control Unit RC700-A EPSON RC+ 7.0 Ver.7.1.2 or later...
  • Page 7 The manual is primarily intended for people who design robot systems or do programming. RC700 series Maintenance Manual (PDF) G series Maintenance Manual (PDF) This manual describes the details of maintenance etc. The manual is intended for people who perform maintenance.
  • Page 8 EPSON RC+ 7.0 User’s Guide (PDF) This manual describes general information about program development software. EPSON RC+ 7.0 SPEL+ Language Reference (PDF) This manual describes the robot programming language “SPEL+”. Other Manual (PDF) Manuals for each option are available. G series Maintenance Rev.3...

  • Page 9: Table Of Contents

    5. Joint #1 5.1 Replacing Joint #1 Motor................33 5.2 Replacing Joint #1 Reduction Gear Unit ..........36 6. Joint #2 6.1 Replacing Joint #2 Motor................38 6.2 Replacing Joint #2 Reduction Gear Unit ..........40 G series Maintenance Rev.3...
  • Page 10 13.3 Accurate Calibration of Joint #2 .............. 90 13.4 Calibration Procedure without using Calibration Wizard ......92 14. Maintenance Parts List 14.1 Common Parts ..................96 14.2 Parts by Environment Model ..............98 14.2.1 S: Standard-model ................ 98 14.2.2 C: Cleanroom-model..............98 viii G series Maintenance Rev.3...
  • Page 11 4.2.1 Signal Cable ................. 126 4.2.2 Power Cable ................. 127 4.2.3 User Cable ................... 128 4.3 Replacing M/C Cable ................129 5. Joint #1 5.1 Replacing Joint #1 Motor................ 133 5.2 Replacing Joint #1 Reduction Gear Unit ..........137 G series Maintenance Rev.3...
  • Page 12 14.3 Accurate Calibration of Joint #2 ............203 14.4 Calibration Procedure without using Calibration Wizard ...... 205 15. G3 Maintenance Parts List 15.1 Common Parts ..................209 15.2 Parts by Environment Model ..............211 15.2.1 S: Standard-model ..............211 15.2.2 C: Cleanroom-model..............211 G series Maintenance Rev.3...
  • Page 13 4. Cable 4.1 Replacing Cable Unit ................242 4.2 Wiring Diagrams ..................253 4.2.1 Signal Cable ................. 253 4.2.2 Power Cable ................. 254 4.2.3 User Cable ................... 255 4.3 Replacing M/C Cable ................256 5. Joint #1 G series Maintenance Rev.3...
  • Page 14 13.2 Calibration Procedure ................314 13.3 Accurate Calibration of Joint #2 ............324 13.4 Calibration Procedure without using Calibration Wizard ...... 326 14. G6 Maintenance Parts List 14.1 Common Parts ..................330 14.2 Parts by Environment Model ..............332 G series Maintenance Rev.3...
  • Page 15 3.7 Maintenance Plate .................. 365 3.8 Base Bottom Cover ................366 4. Cable 4.1 Replacing Cable Unit ................368 4.2 Wiring Diagrams ..................380 4.2.1 Signal Cable ................. 380 4.2.2 Power Cable ................. 381 4.2.3 User Cable ................... 382 G series Maintenance Rev.3 xiii...
  • Page 16 10. Ball Screw Spline Unit 10.1 Replacing the Ball Screw Spline Unit: G10 .......... 441 10.2 Replacing the Ball Screw Spline Unit: G20 .......... 448 11. Lithium Battery 11.1 Replacing the Battery Unit (Lithium Battery) ......... 455 G series Maintenance Rev.3...
  • Page 17 14.2 Calibration Procedure ................464 14.3 Accurate Calibration of Joint #2 ............474 14.4 Calibration Procedure without using Calibration Wizard ..... 476 15. G10/G20 Maintenance Parts List 15.1 Common Parts..................480 15.2 Parts by Environment Model ..............482 G series Maintenance Rev.3...
  • Page 18 Table of Contents G series Maintenance Rev.3...
  • Page 19 G1 Maintenance This volume contains maintenance procedures with safety precautions for Manipulators.
  • Page 21 CAUTION improper function of the robot system. ■ When operating maintenance of manipulator, secure about 50 cm of empty space around the manipulator. G series Maintenance Rev.3...

  • Page 22: General Maintenance

    √ 9 months (2250 h) √ √ 10 months (2500 h) √ 11 months (2750 h) √ 12 months (3000 h) √ √ √ √ 13 months (3250 h) √ √ 20000 h h = hour G series Maintenance Rev.3...

  • Page 23: Inspection Point

    Also, the break is not released even operated release the break, contact the supplier. Check whether unusual sound Check that there is no unusual sound or vibration when operating. or vibration occurs. If there is something wrong, contact the supplier. G series Maintenance Rev.3...

  • Page 24: Overhaul (Parts Replacement)

    EPSON RC+ 7.0. For details, refer to the following manual. Robot Controller RC700 / RC700-A “Maintenance 6. Alarm” For the EPSON RC+ 5.0 Ver. 5.4.7 or later (firmware Ver.1.16.4.x or 1.24.4.x or later), the NOTE  recommended replacement time for the parts subject to maintenance (motors, reduction gear units, and timing belts) can be checked in the [Maintenance] dialog box of the EPSON RC+ 5.0.
  • Page 25 (3) Select the folder where the information is stored. (4) Click <OK> to view the [Controller Status Viewer] dialog. (5) Select [Robot] from the tree menu on the left side (Dialog image: EPSON RC+ 7.0) For the parts subject to overhaul, refer to 14. G1 Maintenance Parts List.

  • Page 26: Greasing

    Perform greasing at 50 km of operation for the first time of greasing. NOTE  For EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the recommended replacement time for the grease on the ball screw spline unit can be checked in the [Maintenance] dialog box of EPSON RC+ 7.0.

  • Page 27: Greasing The Ball Screw Spline Unit

    - Move the shaft to the lower limit manually while by selecting EPSON RC+ 7.0 menu - [Tools] - [Robot Manager] - [Jog & Teach]. NOTE Be sure to keep enough space and prevent ...
  • Page 28 Run for about 5 minutes to spread the grease over the shaft. Turn OFF the controller. (10) Wipe off excess grease on the end of the spline nut and mechanical stop. End of the spline nut G series Maintenance Rev.3...
  • Page 29 - Move the shaft to the upper limit manually while by Lower bellows selecting EPSON RC+ 7.0 menu - [Tools] - [Robot Manager] - [Jog & Teach]. NOTE ...
  • Page 30 (13) After moving to the origin position, move the shaft up and down. To move up and down, use an operation program to move from the upper limit to the lower limit in low power mode. Run about 5 minutes to spread grease over the shaft. (14) Turn OFF the Controller. G series Maintenance Rev.3...

  • Page 31: Tightening Hexagon Socket Head Cap Bolts

    Then, follow the steps below to display the pulse values and record them. Execute the following command from the [Command Window]. EPSON >PULSE PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls [Joint #3 Pulse value] pls [Joint #4 Pulse value] pls G series Maintenance Rev.3...

  • Page 32: Layout Of Maintenance Parts

    Joint #2 reduction gear unit Joint #3 motor Power cable Zbelt U belt Signal cable Joint #3 brake Joint #1 reduction gear unit Lithium battery and Battery board Joint #1 motor G1-***C: Cleanroom-model Gasket Gasket Bellow G series Maintenance Rev.3...

  • Page 33: 3-Axis Spec

    Joint #2 reduction gear unit Joint #3 motor Power cable Z belt Signal cable Joint #3 brake Joint #1 reduction gear unit Lithium battery and Battery board Joint #1 motor G1-***CZ : Cleanroom-model Gasket Bellows Gasket Bellows G series Maintenance Rev.3...

  • Page 34: Covers

    ⋅ ⋅ For M4 truss screw Tools Tightening Torque: Cross-point screwdriver 0.4 N m (4.1 kgf ⋅ ⋅ For bellows removal Wiping cloth For wiping adhesive User plate Arm top cover Connector plate Connector sub plate G series Maintenance Rev.3...

  • Page 35: Arm Top Cover

    Unscrew the arm top cover mounting bolts, and then lift the cover. 4-M4×12 : Truss When bellows are installed to the manipulator, remove / install the arm top cover and then remove 4-M4×8 / install the upper bellows. : Hexagonal G series Maintenance Rev.3...

  • Page 36: Connector Plate

    When routing the cables, observe the cable locations after removing the connector plate. Be sure to place the cables back to their original locations. Unscrew the connector plate mounting bolts and remove the plate. 4-M4×12 G series Maintenance Rev.3...

  • Page 37: Connector Sub Plate

    Unscrew the connector sub plate mounting bolts and remove the plate. 4-M4×5 3.4 User Plate (1) Remove the Arm top cover. For detail, refer to 3.1 Arm top cover. (2) Unscrew the user plate mounting bolts and 2-M4×8 remove the plate. G series Maintenance Rev.3...

  • Page 38: Cable

    The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, CAUTION or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system. G series Maintenance Rev.3...

  • Page 39: Replacing Cable Unit

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. If the error occurs, execute the calibration of all joints and axes.
  • Page 40 The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system. G series Maintenance Rev.3...
  • Page 41 - Remember the cable layout so that the cables can be reconnected correctly after replacement. (10) Remove the duct fitting from the user plate and disconnect the cables. Duct fittings User plate (11) Remove the connector plate. For details, refer to 3.2 Connector Plate. G series Maintenance Rev.3...
  • Page 42 Do not remove the connector X61. - Remember the cable layout so that the cables can be reconnected correctly after replacement. (17) Remove the duct fittings from the mounting plate of the Mounting plate of cable unit. cable unit Duct fittings G series Maintenance Rev.3...
  • Page 43 (11) Connect the connectors on the arm side. Connectors: X21, X22, X31, X32, X33, X41, XB10, X221, X231, X241 (12) Remove the spare battery connected to X60C. (13) Re-bundle the wire tie removed in the removal step (6). G series Maintenance Rev.3...
  • Page 44 (15) Set the Arm #2 cover without cables caught and secure it. For details, refer to 3.1 Arm Top Cover. (16) If a connector falls out from the battery board, you must execute the calibration for all axes. G series Maintenance Rev.3...

  • Page 45: Wiring Diagrams

    G1 Maintenance 4. Cable 4.2 Wiring Diagrams 4.2.1 Signal Cable G series Maintenance Rev.3...

  • Page 46: Power Cable

    G1 Maintenance 4. Cable 4.2.2 Power Cable G series Maintenance Rev.3...

  • Page 47: User Cable

    G1 Maintenance 4. Cable 4.2.3 User Cable Code Cable color Code Cable color Black Brown Violet Green White Blue Yellow G series Maintenance Rev.3...

  • Page 48: Replacing M/C Cable

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. NOTE If the connector connected to the battery was disconnected during cable replacement, ...
  • Page 49 (3) Connect the power cable and signal cable connectors to the controller. (4) Turn ON the Controller. (5) If the connector falls off from the battery, execute the calibration for All Joint. For details, refer to 13 Calibration. G series Maintenance Rev.3...

  • Page 50: Joint #1

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 13. Calibration to perform the calibration. Joint #1 reduction gear Joint #1 motor G series Maintenance Rev.3...

  • Page 51: Replacing Joint #1 Motor

    Be careful not to lose the positioning pin. (5) Loosen the screw of motor flange on the Joint #1 flange. Remove the Joint #1 unit. Joint #1 motor unit 4-M4×40 G series Maintenance Rev.3...
  • Page 52 There is a brass bushing in one of the set screws. Be careful not to lose it. Joint #1 motor (8) Remove the motor flange from the Joint #1 motor. Motor flange Joint #1 motor 2-M4×12 G series Maintenance Rev.3...
  • Page 53 (6) Attach the connectors. Connector: X110, X10, X61 (7) Mount the connector plate. For details, refer to 3.4 Connector Plate. (8) Perform the calibration of Joint #1. For details refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 54: Replacing Joint #1 Reduction Gear Unit

    Reduction gear ■ Never adjust the bolt fixing the reduction gear. If you did, it needs the alignment by the manufacturer. CAUTION (2) Follow the steps in 5.1 Replacing Joint #1 Motor, Installation (2) to (8). G series Maintenance Rev.3...

  • Page 55: Joint #2

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 13. Calibration to perform the calibration. Joint #2 motor Joint #2 reduction gear G series Maintenance Rev.3...

  • Page 56: Replacing Joint #2 Motor

    4-M4×5 (4) Disconnect the connectors. Connectors: X221, X21，X22，XB20 (Hold the clip to remove.) (5) Remove the Joint #2 motor unit. 2-M4×12 Motor 2-M3×3 (6) Remove the wave generator and motor spacer. Wave generator Spacer G series Maintenance Rev.3...
  • Page 57 (5) Put the wire tie cut in the removal step (4) to the original position. Do not allow unnecessary strain on the cables. (6) Mount the arm top cover. For details, refer to 3.1 Arm Top Cover. (7) Perform the calibration of Joint #2. For details refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 58: Replacing Joint #2 Reduction Gear Unit

    (2) Remove the Arm #2 spacer. Removal 2-M4×25 Spacer Arm #2 (3) Loosen the screw fixing the Joint #2 Reduction gear unit reduction gear unit and loosely secure. 2-M4×40 2-M5×40 (4) Remove the Arm #2 unit. 6-M4×12 Arm #2 unit G series Maintenance Rev.3...
  • Page 59 Joint #2 motor flange, reduction gear, and Joint #2 spacer. Hold the Joint #2 spacer upward and pull Joint #2 motor flange it out sideways. Joint #2 reduction gear Joint #2 spacer G series Maintenance Rev.3...
  • Page 60 Make sure the O-ring between the reduction gear and motor flange has not moved and secure the unit loosely. 2-M4×40 2-M5×40 (5) Mount the Arm #2 unit. 6-M4×12 Arm #2 unit (6) Tighten the screw secured loosely in the step (4). G series Maintenance Rev.3...
  • Page 61 G1 Maintenance 6. Joint #2 (7) Mount the Arm #2 spacer. 2-M4×25 Spacer (8) Follow the steps in 6.1 Replacing Joint #2 Motor, installation step (1) to (7). G series Maintenance Rev.3...

  • Page 62: Joint #3

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 13. Calibration to perform the calibration. Joint #3 motor Z belt Joint #3 brake G series Maintenance Rev.3...

  • Page 63: Replacing Joint #3 Motor

    (5) Cut off the wire tie used for binding the motor cables to the Joint #3 motor. (6) Disconnect the connectors. Connectors X231, X31, X32, X33, XB30 (Hold the clip to remove.) (7) Remove the user plate. For details, refer to 3.4 User Plate. G series Maintenance Rev.3...
  • Page 64 Loosen the screw of pulley and slide the pulley toward the motor and then, loosen the screw of brake hub. There is a brass bushing in one of the set screw holes. Be careful not to lose it. G series Maintenance Rev.3...
  • Page 65 Make sure the motor unit can be moved by hand, and it will not tilt when pulled. NOTE  If the unit is secured too loose or too tight, the belt will not have the proper tension. G series Maintenance Rev.3...
  • Page 66 (10) Install the arm top cover and the arm bottom cover. For details, refer to 3.1 Arm Top Cover. (11) Perform the calibration of Joint #3. For details on the calibration method, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 67: Replacing The Timing Belt

    (5) Remove the belt from the Z1 pulley and Z2 pulley. (6) Remove the Z belt. Remove the bolts securing the ball screw nut and hold the ball screw nut up to pull out the Z belt 4-M4×30 upward from the shaft. Z belt G series Maintenance Rev.3...
  • Page 68 (4) Apply the proper tension to the Z belt, and then secure the Joint #3 motor unit. Z belt tension = 30 N (3.0 kgf) Joint #3 Motor unit 2-M4×12 Force gauge (5) Perform the calibration of Joint #3. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 69: Replacing The Brake

    (2) Refer to 7.1 Replacing Joint #3 Motor, Installation step (1) to (11) and mount the Joint #2 motor unit to Arm #2 after the brake hub is replaced. (3) Perform the calibration of Joint #3. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 70: Setting The Mechanical Stop Of Joint #3

    Recommended tightening torque: 1.5 N⋅m (16 kgf⋅cm) (8) Mount the Arm top cover to the base. For details, refer to G1 manipulator - 3.1 Arm Top Cover. (9) Turn ON the Controller. G series Maintenance Rev.3...
  • Page 71 ' Moves to the lower limit-pulse position of Joint #3. >PULSE 0,0,X,0 (In this example, all pulses except those for Joint #3 are “0”. Substitute these “0s” with the other pulse values specifying a position where there is no interference even when lowering Joint #3.) G series Maintenance Rev.3...

  • Page 72: Joint #4

    Controller. After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 13. Calibration to perform the calibration. Joint #4 motor U belt G series Maintenance Rev.3...

  • Page 73: Replacing Joint #4 Motor

    (8) Remove the Joint #4 motor unit from Arm #2. Unscrew the bolts securing the Joint #4 motor to Motor the motor plate. Remove the U1 belt from the 2-M4×12 pulley. Pull the motor unit upward to remove. Pulley U1 belt G series Maintenance Rev.3...
  • Page 74 (9) Remove the motor from the Joint #4 motor Motor housing. 2-M4×12 Motor housing (10) Remove the pulley from the Joint #4 motor. Motor There is a brass bushing in one of the set screw 2-M4×5 holes. Be careful not to lose it. Pulley G series Maintenance Rev.3...
  • Page 75 Make sure the motor unit can be moved by hand, NOTE  and it will not tilt when pulled. If the unit is secured too loose or too tight, the belt will not have the proper tension. U1 pulley U2 pulley G series Maintenance Rev.3...
  • Page 76 (10) Install the arm top cover and the arm bottom cover. For details, refer to 3.1 Arm Top Cover. (11) Perform the calibration of Joint #4. For details on the calibration method, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 77: Replacing The Timing Belt

    For details, refer to 7.2 Replacing the Timing Belt, Z belt Removal step (4) to (6). (8) Remove the U belt. Hold the ball screw nut up and pull out the U belt 4-M3×10 upward from the shaft. G series Maintenance Rev.3...
  • Page 78 (8) Install the arm top cover and the arm bottom cover. For details, refer to 3.1 Arm Top Cover. (9) Perform the calibration of Joints #3 and #4. For details on the calibration method, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 79: Bellows

    Name Quantity Note For each manipulator model Maintenance (Refer to Bellows parts 14.G1 Maintenance Parts List.) Tools Cross-point screwdriver Gasket Liquid gasket 1206C G series Maintenance Rev.3...

  • Page 80: Replacing The Bellows (4-Axis Spec)

    (6) Loosen the set screw of fixing ring. Remove the fixing ring and bearing. Bearing Fixing ring (7) Remove the bellows and the plate securing the bellows. (8) Pull out the bellows from the bellows plate. Bellows plate 4-M3×6 G series Maintenance Rev.3...
  • Page 81 Insert it into the shaft from below. Apply the liquid gasket to the whole inside surface of the bearing case. (7) Insert the bellows lower part into the bearing case and secure with the clamp band. G series Maintenance Rev.3...

  • Page 82: Replacing The Bellows (3-Axis Spec)

    (10) Remove the plate securing the upper bellows. Bellows plate Remove the set screw from inside of the arm top 4-M3×8 cover while pressing the nut. 4-M3 nut (11) Pull out the upper bellows from the bellows plate. G series Maintenance Rev.3...
  • Page 83 To attach the upper bellows, move the shaft 4-M3×8 to its lower limit. To attach the lower bellows, move the shaft to its upper limit. Clamp band screw on Press the brake release switch and move the lower bellows shaft up/down. G series Maintenance Rev.3...

  • Page 84: Ball Screw Spline Unit

    (width across flats: 2.5 mm) Torque wrench Nippers For cutting wire tie Tools Force gauge Belt tension 30 N (3.0 kgf) Suitable cord (Length about 1000 mm) For belt tension For wiping grease (Spline Wiping cloth shaft) G series Maintenance Rev.3...

  • Page 85: Replacing The Ball Screw Spline Unit (4-Axis Spec)

    (11) Pull out the ball screw spline unit from Arm #2. Remove the ball screw nut from the Arm #2 bottom plate and pull out the ball screw spline unit toward the cutout of the Arm #2 upper plate (front). G series Maintenance Rev.3...
  • Page 86 (6) If the position of the lower limit mechanical stop was changed for area limit, secure it to the proper position. (7) Grease the shaft. For details, refer to 10.1. Greasing the Ball Screw Spline Unit. (8) Mount the arm top cover. For details, refer to 3. Covers. G series Maintenance Rev.3...
  • Page 87 For details, refer to 9. Bellows. (11) Mount the end effector, and connect wires and tubes to the end effector. (12) Perform the calibration for the Joints #3 and #4. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 88: Replacing The Ball Screw Spline Unit (3-Axis Spec)

    Spline nut 4-M3×18 (6) Pull out the U belt and ball screw spline unit from Arm #2. For details, refer to 10.2.1 Replacing the ball screw spline unit (4-axis spec), removal step (9) to (11). G series Maintenance Rev.3...
  • Page 89 (7) This step is only for Cleanroom-model. Install the bellows. For details, refer to 9. Bellows. (8) Mount the arm top cover. For details, refer to 3. Covers. (9) Turn OFF the controller power and peripheral equipment. G series Maintenance Rev.3...
  • Page 90 G1 Maintenance 10. Ball Screw Spline Unit (10) Mount the end effector, and connect wires and tubes to the end effector. (11) Perform the calibration for the Joints #3 and #4. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 91: Lithium Battery

    Controller is energized. If warnings of voltage reduction occur, replace the lithium metal battery even if it has not reached the above product life. G series Maintenance Rev.3...
  • Page 92 G1 Maintenance 11. Lithium Battery NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the battery can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.

  • Page 93: Replacing The Battery Unit (Lithium Battery)

    To do so, select 2 points (poses) or more from the registered points (poses) and move the Manipulator to the points (poses). (5) If the Manipulator does not move to the points (poses) correctly, perform the calibration of all joints and axes. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 94: Replacing The Battery Board

    (4) Disconnect the connectors X61, X62, X63, and X64 connected to the battery board. X60B X60A (5) Loosen the screws securing the battery board and remove the battery board. (6) Disconnect the connector X60 (Lithium battery) connected to X60A or X60B. G series Maintenance Rev.3...
  • Page 95 2-M4×45 (4) Mount the Arm #1 on the base. 6-M4×15 (5) Mount the connector plate. For details, refer to 3.2 Connector Plate. (6) Perform the calibration of all joints. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 96: Led Lamp

    (2) Put the arm top cover between the ring and lens holder, and then secure the LED to the user plate. (3) Mount the lens. Connect the connector. Connector: X22. (4) Mount the arm top cover. For details, refer to 3. Covers. G series Maintenance Rev.3...

  • Page 97: Calibration

    Jog Motion The process to set the jog motion is included in the [Jog & Teach] page of the Robot Manager. Select EPSON RC+ menu-[Tools]-[Robot Manager] and select the [Jog & Teach] tab to use the [Jog & Teach] page.

  • Page 98: Calibration Procedure

    13.2 Calibration Procedure EPSON RC+ has a wizard for calibration. This section indicates the calibration using the calibration wizard of EPSON RC+. The same calibration procedure is used for each joint. The steps below are calibration using Joint #1. Follow the steps below to calibrate other joints.
  • Page 99 G1 Maintenance 13. Calibration (2) Confirm the warning message and click the <Yes> button. (3) Move the joint to calibrate manually to approximate 0 pulse position, as shown in the dialog. After moving the joint click the <Next> button. G series Maintenance Rev.3...
  • Page 100 0 pulse Screw hole 1 and flat surface are located Screw hole 2 Screw hole 1 in the center of the shaft. Flat surface Screw hole 1 and 2 are located at right angles to one another. G series Maintenance Rev.3...
  • Page 101 * This window will disappear when the Controller starts up. (6) Select the reference point to use for calibration, and click the <Next> button. Select a point from the current points to use for checking the accuracy. G series Maintenance Rev.3...
  • Page 102 (8) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Before operating the robot, open the [Jog & Teach] tab and execute <Motor ON>. G series Maintenance Rev.3...
  • Page 103 G1 Maintenance 13. Calibration (9) Click the <Next> button. (10) The manipulator moves to the reference point. Click the <Execute> button. Input JUMP P0:z(0). ↑ Point selected in step (6) (11) Confirm the message and click the <Yes> button. G series Maintenance Rev.3...
  • Page 104 G1 Maintenance 13. Calibration (12) After the manipulator moves to the reference point, click the <Next> button. (13) Jog to the accurate reference position. Click the <Jog> button. G series Maintenance Rev.3...
  • Page 105 (14) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Position Joint #2 only and move Joint #3 to around 0 pulse. (15) Click the <Next> button. G series Maintenance Rev.3...
  • Page 106 Move to another point that has different pose (from righty to lefty) using Jump command. Click the <Yes> button. ii. Jog to the accurate reference position. Click the <Jog> button. iii. Jog to the accurate reference position and adjust the position. Click the <OK> button. G series Maintenance Rev.3...
  • Page 107 G1 Maintenance 13. Calibration iv. Click the <Next> button. (17) Calibration is complete. Click the <Finish> button. (18) Move the manipulator to other points and check if it can move without problems. Teach points where appropriate. G series Maintenance Rev.3...

  • Page 108: Accurate Calibration Of Joint #2

    · Switching the arm orientation between right and left at a given point · Using the Pallet command · Executing CP control (such as liner or circular interpolation) · Using the Local command · Pose data specified with relative coordinates <Example: P1+X(100) > · Vision Guide camera calibrations G series Maintenance Rev.3...
  • Page 109 (6), (11). (12) Move the manipulator to other point data and make sure it moves to the correct position. Teach some more points if required. * Delete the two points taught for the Joint #2 calibration. G series Maintenance Rev.3...

  • Page 110: Calibration Procedure Without Using Calibration Wizard

    G1 Maintenance 13. Calibration 13.4 Calibration Procedure without using Calibration Wizard This section indicates the calibration without using the calibration wizard of EPSON RC+. NOTE  For details of calibration using the calibration wizard, refer to 13.2 Calibration Procedure. When coordinates for the Manipulator working point require calculation, it is important for Joint #2 to be calibrated accurately.
  • Page 111 Flat surface Screw hole 1 and 2 are located at right angles to one another. (3)-3 Connect EPSON RC+ to the Controller. Select the robot to be calibrated. Input as below in the [Command Window] and execute. (This example uses “robot 1”.) >...
  • Page 112 Joint #3 >calib 3 Joint #4 >calib 3, 4 Calibration (Accurate Positioning) (5)-1 Turn ON the motors from the EPSON RC+ menu -[Tools] -[Robot Manager]-[Control Panel]. (5)-2 Click the <Free All> button in the [Control Panel] to free all joints. Now, you can move arms by hands.
  • Page 113 (6)-1 Move the Manipulator to another point to confirm that it moves to the same position. If it does not move to the same position, re-calibrate using another point. You must set the point again if reproducibility cannot be assured through calibration. G series Maintenance Rev.3...

  • Page 114: Maintenance Parts List

    2126750 R13B041203 11.2 Installed in Base Lithium battery for replacement R13ZA006003 Battery Unit 2117879 11.1 ER17330V (TOSHIBA) For Joint #1 Joint #1 1523421 R13B031251 motor flange O-ring For Joint #2 Joint #2 1543780 R13B031252 motor flange G series Maintenance Rev.3...
  • Page 115 Regarding purchase of grease, please contact the following manufacturers. If there is anything unclear, please contact the supplier of your region. Product name Manufacturer THK AFB-LF Grease THK CO., LTD. https://www.thk.com/ Harmonic Grease SK-2 Harmonic Drive Systems Inc. https://www.harmonicdrive.net/ https://www.chemours.com/en/brands- Krytox®GPL-224 Chemours and-products 1206C ThreeBond Co.,Ltd https://www.threebond.com G series Maintenance Rev.3...

  • Page 116: Parts By Environment Model

    *2 The bellows for 4-axis spec are provided in a unit of one piece. *3 The bellows for 3-axis spec are provided in a unit of two pieces. The shape varies between the upper and lower bellows. G series Maintenance Rev.3...
  • Page 117 G3 Maintenance This volume contains maintenance procedures with safety precautions for Manipulators.
  • Page 119 CAUTION improper function of the robot system. ■ When operating maintenance of manipulator, secure about 50 cm of empty space around the manipulator. G series Maintenance Rev.3...

  • Page 120: General Maintenance

    √ 9 months (2250 h) √ √ 10 months (2500 h) √ 11 months (2750 h) √ 12 months (3000 h) √ √ √ √ 13 months (3250 h) √ √ 20000 h h = hour G series Maintenance Rev.3...

  • Page 121: Inspection Point

    Also, the break is not released even operated release the break, contact the supplier. Check that there is no unusual sound or vibration when operating. Check whether unusual sound or vibration occurs. If there is something wrong, contact the supplier. G series Maintenance Rev.3...

  • Page 122: Overhaul (Parts Replacement)

    However, it may vary depending on ambient temperature, usage condition and degree of the load (such as when operated with the maximum motion speed and maximum acceleration/deceleration in continuous operation) applied on the Manipulator. For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the NOTE ...
  • Page 123 (3) Select the folder where the information is stored. (4) Click <OK> to view the [Controller Status Viewer] dialog. (5) Select [Robot] from the tree menu on the left side (Dialog image: EPSON RC+ 7.0) For the parts subject to overhaul, refer to 15. G3 Maintenance Parts List.

  • Page 124: Greasing

    Perform greasing at 50 km of operation for the first time of greasing. NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the grease on the ball screw spline unit can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.

  • Page 125: Greasing The Ball Screw Spline Unit

    - Move the shaft to the lower limit manually while by selecting EPSON RC+ 7.0 menu - [Tools] - [Robot Manager] - Arm #1 [Jog & Teach].
  • Page 126 Run for about 5 minutes to spread the grease over the shaft. Turn OFF the controller. (10) Wipe off excess grease on the end of the spline nut and mechanical stop. End of the spline nut G series Maintenance Rev.3...
  • Page 127 - Move the shaft to the upper limit manually while by selecting EPSON RC+ 7.0 menu - [Tools] - [Robot Lower bellows Manager] - [Jog & Teach].
  • Page 128 (13) After moving to the origin position, move the shaft up and down. To move up and down, use an operation program to move from the upper limit to the lower limit in low power mode. Run about 5 minutes to spread grease over the shaft. (14) Turn OFF the Controller. G series Maintenance Rev.3...

  • Page 129: Tightening Hexagon Socket Head Cap Bolts

    Then, follow the steps below to display the pulse values and record them. Execute the following command from the [Command Window]. EPSON >PULSE PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls [Joint #3 Pulse value] pls [Joint #4 Pulse value] pls G series Maintenance Rev.3...

  • Page 130: Layout Of Maintenance Parts

    Joint #3 motor U2 belt Joint #1 Power cable reduction gear unit Signal cable Joint #3 brake Joint #1 motor (Figure: G3-301S) G3-**1C : Cleanroom-model (with bellows) Bellows Gasket Gasket Bellows Heat release sheet (Figure: G3-301C) G series Maintenance Rev.3...

  • Page 131: Multiple Mounting

    U1 belt Joint #1 motor Joint #2 U2 belt Joint #3 brake motor Joint #2 Joint #1 reduction reduction (Figure: G3-301SM) gear gear G3-**1CM : Cleanroom-model (with bellows) Bellows Gasket Gasket Bellows (Figure: G3-301CM) Heat release sheet G series Maintenance Rev.3...

  • Page 132: Covers

    (width across flats: 3 mm) Tightening Torque: 0.9 N⋅m (9.2 kgf⋅cm) Torque wrench For M4 truss screw Tools Tightening torque: 0.4 N⋅m (4.1 kgf⋅cm) Cross-point screwdriver For bellows removal (Only for Cleanroom- model) Wiping cloth For wiping adhesive G series Maintenance Rev.3...
  • Page 133 G3 Maintenance 3. Covers Table Top Mounting Arm top cover bottom cover Arm cap Connector plate Connector sub plate Heatsink plate Base bottom cover Multiple Mounting Connector sub plate Connector plate Heatsink plate Arm top cover Arm bottom cover G series Maintenance Rev.3...

  • Page 134: Arm Top Cover

    NOTE 4-M4×8  Truss remove the upper bellows and then remove the arm top cover. For bellows removal, refer to 10. Bellows. Arm top cover Be careful for user wires and tubes when removing the cover. G series Maintenance Rev.3...

  • Page 135: Arm Bottom Cover

    When bellows are installed to the manipulator, remove or pull down the lower bellows and then remove the arm bottom cover. For bellows removal, refer to 10. Bellows. G3-**1S* (Standard-model) G3-**1C* (Cleanroom-model) 3-M4×12 Gasket Arm bottom cover Arm bottom cover 3-M4×12 A gasket is installed to G3-**1C* (Cleanroom-model). G series Maintenance Rev.3...

  • Page 136: Arm Cap

    Be sure to place the cables back to their original locations. Unscrew the connector plate mounting bolts and remove the plate. G3-**1* Table Top Mounting G3-**1*M Multiple Mounting Truss: 4-M4×8 Truss: 4-M4×8 Connector plate Connector plate G series Maintenance Rev.3...

  • Page 137: Connector Sub Plate

    Connector sub plate 3.6 User Plate Unscrew the user plate mounting bolts and remove the plate. G3-**1S* Standard-model G3-**1C* Cleanroom-model Truss: 4-M4×8 Truss: 4-M4×8 Gasket User plate User plate 3-M4×12 3-M4×12 A gasket is installed to G3-**1C* (Cleanroom-model). G series Maintenance Rev.3...

  • Page 138: Heatsink Plate

    Motor. 3.8 Base Bottom Cover Unscrew the base bottom cover mounting bolts and remove the cover. G3-**1C* Cleanroom-model Base bottom cover Truss: 4-M4×8 NOTE A base bottom cover is not installed to G3-**1S* (Standard-model).  G series Maintenance Rev.3...

  • Page 139: Cable

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. If the error occurs, execute the calibration of all joints and axes.
  • Page 140 G3 Maintenance 4. Cable Table Top mounting Cable Unit (Figure: G3-301S) Multiple Mounting Cable unit (Figure: G3-301SM) G series Maintenance Rev.3...
  • Page 141 - Be sure to keep the connectors of the battery board connected at cables NOTE  replacement. Otherwise, the motor will lose position data and the calibration must be executed again. - Remember the cable layout so that the cables can be reconnected correctly after replacement. G series Maintenance Rev.3...
  • Page 142 Be sure to observe the connection for connecting the disconnected parts after replacement. (14) Remove the mounting screws for the cable unit and remove the unit from the Manipulator. Table Top Mounting Multiple Mounting Cable Cable unit unit 4-M4×10 3-M4×12 3-M4×12 3-M4×10 G series Maintenance Rev.3...
  • Page 143 (11) Set and secure the Arm #2 cover without the cables being stuck. For details, refer to 3.1 Arm Top Cover. (12) When the connector falls off from the battery board, execute the calibration of all axes. For details, refer to 14 Calibration. G series Maintenance Rev.3...

  • Page 144: Wiring Diagrams

    G3 Maintenance 4. Cable 4.2 Wiring Diagrams 4.2.1 Signal Cable G series Maintenance Rev.3...

  • Page 145: Power Cable

    G3 Maintenance 4. Cable 4.2.2 Power Cable G series Maintenance Rev.3...

  • Page 146: User Cable

    The following table shows the types of the use cable. Mounting type Arm length Code 250 mm 1514457 S, C 300 mm 1514458 (Table Top Mounting) 350 mm 1514459 300 mm 1514460 SM, CM (Multiple Mounting) 350 mm 1514461 G series Maintenance Rev.3...

  • Page 147: Replacing M/C Cable

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. NOTE If the connector connected to the battery was disconnected during cable replacement, ...
  • Page 148 G3 Maintenance 4. Cable Table Top Mounting M/C Cable (Figure: G3-301S) Multiple Mounting M/C Cable (Figure: G3-301SM) G series Maintenance Rev.3...
  • Page 149 (3) Connect the power cable and signal cable connectors to the controller. (4) Turn ON the Controller. (5) If the connector (XB10) falls off from the battery, execute the calibration for Joint #1. For details, refer to 14 Calibration. G series Maintenance Rev.3...

  • Page 150: Joint #1

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 14. Calibration to perform the calibration. Joint #1 reduction gear unit Joint #1 motor G series Maintenance Rev.3...

  • Page 151: Replacing Joint #1 Motor

    (5) Remove the heat release sheet from the Motor. (6) Remove the lid mounted to Arm #1. M4 truss screw (7) Remove the screws which secure Arm 4-M3×18 #1 and Joint #1 reduction gear unit. 8-M3×35 12-M3 washer G series Maintenance Rev.3...
  • Page 152 There is a brass bushing in one of the set M4 Brass bushing screw holes. Be sure to keep the bushing. Joint #1 motor (11) Remove the motor flange from the Joint #1 motor. Motor flange Joint #1 motor 4-M5×12 G series Maintenance Rev.3...
  • Page 153 If it is difficult to mount the motor, push it while moving Arm #1 slowly by hand. (5) Secure the screws for tightening Arm #1 4-M3×18 8-M3×35 and Joint #1 reduction gear unit. 12-M3 washer Mount the lid of Arm #1. G series Maintenance Rev.3...
  • Page 154 (9) Mount the connector plate. For details, refer to 3.4 Connector Plate. (10) Mount the heatsink plate. For details, refer to 3.7 Heatsink Plate. (11) Perform the calibration of Joint #1. For details refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 155: Replacing Joint #1 Reduction Gear Unit

    (1) Remove the Joint #1 motor unit. reduction gear Refer to the removal steps (1) to (7) in 5.1 Replacing Joint #1 Motor. unit (2) Remove the Reduction gear unit from the Joint Flange 16-M3×15 Removal #1 flange. Reduction gear unit G series Maintenance Rev.3...
  • Page 156 (3) Face the convex side of the circular spline down, and then fit it into the flexspline. (4) Match the screw holes on the inner ring of the cross roller bearing unit and the through holes of the circular spline. G series Maintenance Rev.3...
  • Page 157 Be careful not to apply too much force since it may damage the parts. (6) Apply grease (SK-1A) inside the flexspline. Grease volume 12 g (7) Execute the installation steps (2) to (10) in 5.1 Replacing Joint #1 Motor. G series Maintenance Rev.3...

  • Page 158: Joint #2

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 14. Calibration to perform the calibration. Joint #2 motor Joint #2 Reduction gear G series Maintenance Rev.3...

  • Page 159: Replacing Joint #2 Motor

    If the motor cannot be removed easily, pull it out while moving Arm #2 slowly by hand. Also, the motor flange touches the intermediate pulley and you cannot pull the motor straight upward. Therefore, tip the motor and pull it avoiding he intermediate pulley. G series Maintenance Rev.3...
  • Page 160 There is a brass bushing in one of the set screw 2-M4×6 Set screw Joint #2 motor holes. Be careful not to lose it. (12) Remove the motor flange from the Joint #2 Motor flange motor. Joint #2 motor 2-M4×10 G series Maintenance Rev.3...
  • Page 161 (8) Connect the connectors. Connectors X221, X21 (9) Connect the backup cable connector X62 to the battery board. Band the cables with a wire tie to prevent the back up cable connectors to fall out by mistake. G series Maintenance Rev.3...
  • Page 162 (7). Do not allow unnecessary strain on the cables. (11) Mount the arm top cover. For details, refer to 3.1 Arm Top Cover. (12) Perform the calibration of Joint #2. For details refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 163: Replacing Joint #2 Reduction Gear Unit

    Joint #2 motor. (5) Remove the mounting screws for the Arm #2 and 10-M3×18 remove the reduction gear unit from the Arm #1. Arm #2 Reduction gear unit O-ring Arm #1 8-M3×35 4-M3×18 G series Maintenance Rev.3...
  • Page 164 (3) Face the convex side of the circular spline down, and then fit it into the flexspline. (4) Match the screw holes on the inner ring of the cross roller bearing unit and the through holes of the circular spline. G series Maintenance Rev.3...
  • Page 165 (7) Install the O ring to the Arm #1. (8) Install and secure the flexspline. Slide the Arm #2 to the right/left to adjust the holes position. (9) Execute installation steps (2) to (12) in 6.1 Replacing Joint #2 Motor. G series Maintenance Rev.3...

  • Page 166: Joint #3

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 14. Calibration to perform the calibration. Joint #3 motor Z belt モーター Joint #3 brake G series Maintenance Rev.3...

  • Page 167: Replacing Joint #3 Motor

    (8) Cut off the wire tie used for bundling the motor cables with the Joint #3 motor. (9) Disconnect the following connectors. Connectors X231, X241, X31, X32, X41 (Hold the clip to remove.) Connector X63, X64 (Backup cable connector of Joint #3 and #4) G series Maintenance Rev.3...
  • Page 168 (16) Remove the pulley and brake hub from the Joint #3 motor Joint #3 motor. There is a brass bushing in one of the set Bush: M5 Pulley screw holes. Be sure to keep them. Brake hub Set screw: 2-M5×8 G series Maintenance Rev.3...
  • Page 169 (6) Place the U1 belt around the pulley. Joint #4 motor unit Place the Joint #4 motor unit on the Arm #2 upper side. 3-M4×12 + washer Joint #3 motor unit Joint #4 intermediate shaft 3-M4×12 + washer 3-M4×12 + washer G series Maintenance Rev.3...
  • Page 170 (16) Mount the battery board to the Arm #2. (17) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (18) Perform the calibration of Joint #3 and #4. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 171: Replacing The Timing Belt

    For details, refer to steps from (1) to (17) in 7.1 Replacing Joint #3 Motor. (6) Remove the brake unit mounting plate from the 3-M3×10 motor blade. Motor plate (7) Remove the Z belt. Z belt Brake unit mounting plate G series Maintenance Rev.3...
  • Page 172 (4) Put the Joint #3 motor unit and the spline upper rotator parts downwards and place them on the Arm #2 upper surface. Be sure to keep the belt on the pulley. Z1 pulley Z belt G series Maintenance Rev.3...
  • Page 173 Joint #4 motor unit near its mounting plate. Then, pull the cord using a force 3-M4×12 gauge or similar tool to apply the specified + washer Force gauge tension shown in the figure on the right. G series Maintenance Rev.3...
  • Page 174 Do not allow unnecessary strain on the cables. (14) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (15) Perform the calibration of Joint #3 and #4. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 175: Replacing The Brake

    For details, refer to 7.1 Replacing Joint #3 Motor - Joint #3 motor removal step (1) to (17). (6) Remove the brake from the brake plate. 3-M3×10 (7) Remove the brake hub from the Joint #3 motor. Brake 2-M3×10 G series Maintenance Rev.3...
  • Page 176 Motor - Joint #3 motor installation - Step (3) - (19). (5) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (6) Perform the calibration of Joint #3. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 177: Joint #4

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 14. Calibration to perform the calibration. Joint #4 motor U2 belt U1 belt Joint #4 brake G series Maintenance Rev.3...

  • Page 178: Replacing Joint #4 Motor

    (7) Cut off a wire tie used for bundling the motor cables and signal cables. (8) Disconnect the following connectors. Connectors X241, X41 (Hold the clip to remove.) Connector X64 (for backup cable connector of Joint #4) G series Maintenance Rev.3...
  • Page 179 (10) Remove the pulley from the Joint #4 motor. M4 bushing There is a brass bushing in one of the set screw holes. 2-M4×6 Be sure to keep them. set screw (11) Remove the motor plate from the Joint #4 motor. Screw: 2-M4×8 G series Maintenance Rev.3...
  • Page 180 Joint #4 motor unit near its mounting plate. Then, pull the cord using a force gauge or 3-M4×12 similar tool to apply the specified tension + washer Force gauge shown in the figure. (6) Connect the connectors. Connectors: X241, X41, X42 G series Maintenance Rev.3...
  • Page 181 Do not allow unnecessary strain on the cables. (11) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (12) Perform the calibration of Joint #4. For details on the calibration method, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 182: Replacing The Timing Belt

    (7) Cut off a wire tie bundling the motor cables and signal cables. 2-M4×12 (8) Disconnect the following connectors. Connectors X231, X241, X31, X32, X41 (Hold the clip to remove.) Connector X63, X64 (for backup cable connector of Joint #3 and 4) G series Maintenance Rev.3...
  • Page 183 + plain washer Pull the Joint #4 intermediate shaft unit upwards. U1 belt (15) Remove the U1 belt. (16) Keep the spline upper rotator part up and remove the U2 belt. U2 belt G series Maintenance Rev.3...
  • Page 184 Arm #2 top + washer surface. At this point, keep the U2 belt on the large pulley of Joint #4 intermediate unit. Make sure the gear grooves of the belt are fit into those of the pulleys completely. G series Maintenance Rev.3...
  • Page 185 #4 motor unit near its mounting plate. Then, pull the cord using a force gauge or 3-M4×12 similar tool to apply the specified tension + washer Force gauge shown in the figure on the right. G series Maintenance Rev.3...
  • Page 186 (17) Mount the user plate and ground wire to Arm #2. (18) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (19) Perform the calibration of Joint #3. For details on the calibration method, refer to 14. Calibration. G series Maintenance Rev.3...
  • Page 187 3-M4×12 + washer Joint #3 motor unit Joint #4 Intermediate shaft 3-M4×12 + washer 3-M4×12 + washer (2) Remove the Joint #4 intermediate shaft unit. 3-M4×12 + plain washer (3) Remove the U1 belt. U1 belt G series Maintenance Rev.3...
  • Page 188 Make sure the motor unit can be moved by U2 pulley hand, and it will not tilt when pulled. If the unit is secured too loose or too tight, the belt will not have the proper tension. U2 belt U1 belt G series Maintenance Rev.3...
  • Page 189 (11) Mount the user plate and ground wire to Arm #2. (12) Install the arm top cover and arm bottom cover. For details, refer to 3. Covers. (13) Perform the calibration of Joint #4. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 190: Replacing Arm #1

    Controller. After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 14. Calibration to perform the calibration. Arm #1 G series Maintenance Rev.3...
  • Page 191 When changes the arm length, it requires the other cable unit for the new arm length. Right / Left-curved arm have the shared maintenance parts. ■ Replacing Arm #1 should be done by two persons. There are dangers of main parts to fall or get damage. CAUTION G series Maintenance Rev.3...
  • Page 192 Remove the O ring which is attached to the Joint #1 mounting part. Table Top mounting Multiple mounting 4-M3×20 8-M3×35 + Washer + Washer Arm #1 unit Arm #1 unit 4-M3×20 8-M3×35 + Washer + Washer G series Maintenance Rev.3...
  • Page 193 Apply a small amount of grease on the O ring. (5) Insert the Arm #2 side on Arm #1 to the harmonic drive of Arm #2. Fit with the space for the screws head of harmonic drive on Arm #2 side. G series Maintenance Rev.3...
  • Page 194 ■ After replacing the arm, do not fail to change the robot model in the software. If the model is different, it may cause a robot to malfunction. Also, the robot may collide with the mechanical stop and break it. CAUTION G series Maintenance Rev.3...
  • Page 195 (9)-6 Type in a name for the new robot and enter the serial number from the robot's nameplate. Any serial number can be used, but it is recommended that you use the number that is stamped on the robot. (9)-7 Click Apply to save settings. G series Maintenance Rev.3...
  • Page 196 If you use [Dry run], all robots selected in step 9 will be shown. (9)-10 Click <OK> and the controller will be rebooted. (10) Perform the calibration of Joint #1, #2. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 197: Bellows

    (2) Remove the wires and tubes from the end effector. (3) Turn ON the controller. Stop motor excitation. (MOTOR OFF) (4) Loosen the two clamp bands on each bellows. (5) Pull the bellows and clamp bands out of the shaft. G series Maintenance Rev.3...
  • Page 198 Make sure that the bellows can expand and contract smoothly without any excessive force. (6) Turn OFF the Controller and peripheral equipment. (7) Attach the end effector. (8) Connect the wires and tubes to the end effector. G series Maintenance Rev.3...

  • Page 199: Ball Screw Spline Unit

    Cross-point screwdriver Only for Cleanroom-model Belt tension Force gauge 98 N (10 kgf) / 74 N (7.5 kgf) Suitable cord (Length about 1000 mm) For belt tension Wiping cloth For wiping grease (Spline shaft) Material Wire tie G series Maintenance Rev.3...
  • Page 200 Remove the bolts securing the Joint #4 motor unit. 3-M4×12 + washer (11) Remove the screws securing the ball screw Joint #2 motor unit spline of Arm #3 surface. Joint #4 intermediate shaft 3-M4×12 + washer 3-M4×12 + washer G series Maintenance Rev.3...
  • Page 201 Remove the U2 belt. U2 belt (18) Remove the mounting screws of the ball screw spline shaft on the lower part of Arm 4-M4×10 (19) Remove the ball screw spline unit by pulling it upward from Arm #2. G series Maintenance Rev.3...
  • Page 202 (7) Install the end effector, and connect wires and tubes. (8) This step is only for Cleanroom-model. Install the bellows. For details, refer to 10. Bellows. (9) Perform the calibration of Joints #3 and #4. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 203: Lithium Battery

    Controller is energized. If warnings of voltage reduction occur, replace the lithium metal battery even if it has not reached the above product life. G series Maintenance Rev.3...
  • Page 204 G3 Maintenance 12. Lithium Battery NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the battery can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.

  • Page 205: Replacing The Battery Unit (Lithium Battery)

    Battery board (5) Cut off the wire tie banding the lithium battery and remove the lithium battery. (6) Cut off the wire tie banding the lithium battery, Lithium battery (battery unit) Remove the battery. Battery board G series Maintenance Rev.3...
  • Page 206 To do so, select 2 points (poses) or more from the registered points (poses) and move the Manipulator to the points (poses). (6) If the Manipulator does not move to the points (poses) correctly, perform the calibration of all joints and axes. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 207: Replacing The Battery Board

    (4) Disconnect the wiring tie connecting the connector cable. (5) Disconnect the connectors X61, X62, X63, and X64 from the battery board. Battery board 2-M4×5 (6) Loosen the screws securing the battery board Battery board and remove the battery board. 2-M4×12 G series Maintenance Rev.3...
  • Page 208 Refer to Removal step (4). (4) Mount the arm top cover. For details, refer to 3.1 Arm Top Cover. (5) Turn ON the Controller. (6) Perform the calibration of all joints. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 209: Led Lamp

    (2) Put the user plate between the ring and lens holder, and then mount the LED on the arm top cover. (3) Install the lens to the lens holder. (4) Mount the user plate to Arm #2. (5) Install the arm top cover. For details, refer to 3.1 Arm Top Cover. G series Maintenance Rev.3...

  • Page 210: Calibration

    Jog Motion The process to set the jog motion is included in the [Jog & Teach] page of the Robot Manager. Select EPSON RC+ menu-[Tools]-[Robot Manager] and select the [Jog & Teach] tab to use the [Jog & Teach] page.

  • Page 211: Calibration Procedure

    14.2 Calibration Procedure EPSON RC+ has a wizard for calibration. This section indicates the calibration using the calibration wizard of EPSON RC+. The same calibration procedure is used for each joint. The steps below are calibration using Joint #1. Follow the steps below to calibrate other joints.
  • Page 212 G3 Maintenance 14. Calibration (2) Confirm the warning message and click the <Yes> button. (3) Move the joint to calibrate manually to approximate 0 pulse position, as shown in the dialog. After moving the joint click the <Next> button. G series Maintenance Rev.3...
  • Page 213 Standard model Cleanroom model 0 pulse position of Joint #4: position where the flat surface (or groove in the up/down mechanical stop) on the shaft 0 pulse faces toward the tip of Arm #2 Groove Flat surface G series Maintenance Rev.3...
  • Page 214 (6) Select the reference point to use for calibration, and click the <Next> button. Select a point from the current points to use for checking the accuracy. (7) Click the <Jog…> button to display the [Jog & Teach] dialog. G series Maintenance Rev.3...
  • Page 215 (8) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Before operating the robot, open the [Jog & Teach] tab and execute <Motor ON>. (9) Click the <Next> button. G series Maintenance Rev.3...
  • Page 216 (10) The manipulator moves to the reference point. Click the <Execute> button. Input JUMP P0:z(0). ↑ Point selected in step (6) (11) Confirm the message and click the <Yes> button. (12) After the manipulator moves to the reference point, click the <Next> button. G series Maintenance Rev.3...
  • Page 217 (14) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Position Joint #2 only and move Joint #3 to around 0 pulse. G series Maintenance Rev.3...
  • Page 218 Go on to the step (17) for the other joints calibration. i. Move to another point that has different pose (from righty to lefty) using Jump command. Click the <Yes> button. ii. Jog to the accurate reference position. G series Maintenance Rev.3...
  • Page 219 G3 Maintenance 14. Calibration iii. Jog to the accurate reference position and adjust the position. Click the <OK> button. iv. Click the <Next> button. G series Maintenance Rev.3...
  • Page 220 G3 Maintenance 14. Calibration (17) Calibration is complete. Click the <Finish> button. (18) Move the manipulator to other points and check if it can move without problems. Teach points where appropriate. G series Maintenance Rev.3...

  • Page 221: Accurate Calibration Of Joint #2

    · Switching the arm orientation between right and left at a given point · Using the Pallet command · Executing CP control (such as liner or circular interpolation) · Using the Local command · Pose data specified with relative coordinates <Example: P1+X(100) > · Vision Guide camera calibrations G series Maintenance Rev.3...
  • Page 222 (6), (11). (12) Move the manipulator to other point data and make sure it moves to the correct position. Teach some more points if required. * Delete the two points taught for the Joint #2 calibration. G series Maintenance Rev.3...

  • Page 223: Calibration Procedure Without Using Calibration Wizard

    G3 Maintenance 14. Calibration 14.4 Calibration Procedure without using Calibration Wizard This section indicates the calibration without using the calibration wizard of EPSON RC+. NOTE  For details of calibration using the calibration wizard, refer to 14.2 Calibration Procedure. When coordinates for the Manipulator working point require calculation, it is important for Joint #2 to be calibrated accurately.
  • Page 224 0 pulse faces toward the tip of Arm #2 Groove Flat surface (3)-3 Connect EPSON RC+ to the Controller. Select the robot to be calibrated. Input as below in the [Command Window] and execute. (This example uses “robot 1”.) > robot 1...
  • Page 225 Joint #3 >calib 3 Joint #4 >calib 3, 4 Calibration (Accurate Positioning) (5)-1 Turn ON the motors from the EPSON RC+ menu -[Tools] -[Robot Manager]-[Control Panel]. (5)-2 Click the <Free All> button in the [Control Panel] to free all joints. Now, you can move arms by hands.
  • Page 226 (6)-1 Move the Manipulator to another point to confirm that it moves to the same position. If it does not move to the same position, re-calibrate using another point. You must set the point again if reproducibility cannot be assured through calibration. G series Maintenance Rev.3...

  • Page 227: G3 Maintenance Parts List

    Joint #2 1856070 R13B010017  Electromag Z axis 1497639 R13B030501  netic Brake Joint #3 1510625 R13B030213  Timing Belt 1510626 R13B030214  Joint #4 1510627 R13B030215  R13A0307002 Joint #1 1653181 O-ring R13A0307001 Joint #2 1653819 G series Maintenance Rev.3...
  • Page 228 Regarding purchase of grease, please contact the following manufacturers. If there is anything unclear, please contact supplier of your region. Product name Manufacturer THK AFB-LF Grease THK CO., LTD. https://www.thk.com/ Harmonic Grease SK-1A Harmonic Drive Systems Inc. https://www.harmonicdrive.net/ Harmonic Grease SK-2 G series Maintenance Rev.3...

  • Page 229: Parts By Environment Model

    Status Viewer] dialog - [Motor On Hours]. For details, refer to 2.2 Overhaul (Parts Replacement). *2 Common with LS3 series. The bellows are provided in a unit of one piece. The upper and lower bellows have the same shape. G series Maintenance Rev.3...
  • Page 230 G3 Maintenance 15. G3 Maintenance Parts List G series Maintenance Rev.3...
  • Page 231 G6 Maintenance This volume contains maintenance procedures with safety precautions for Manipulators.
  • Page 233 CAUTION improper function of the robot system. ■ When operating maintenance of manipulator, secure about 50 cm of empty space around the manipulator. G series Maintenance Rev.3...

  • Page 234: General Maintenance

    √ 9 months (2250 h) √ √ 10 months (2500 h) √ 11 months (2750 h) √ 12 months (3000 h) √ √ √ √ 13 months (3250 h) √ √ 20000 h h = hour G series Maintenance Rev.3...

  • Page 235: Inspection Point

    Also, the break is not released even operated release the break, contact the supplier. Check whether unusual sound Check that there is no unusual sound or vibration when operating. or vibration occurs. If there is something wrong, contact the supplier. G series Maintenance Rev.3...

  • Page 236: Overhaul (Parts Replacement)

    (such as when operated with the maximum motion speed and maximum acceleration / deceleration in continuous operation) applied on the Manipulator. NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the parts subject to maintenance (motors, reduction gear units, and timing belts) can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
  • Page 237 (3) Select the folder where the information is stored. (4) Click <OK> to view the [Controller Status Viewer] dialog. (5) Select [Robot] from the tree menu on the left side (Dialog image: EPSON RC+ 7.0) For the parts subject to overhaul, refer to 4. G6 Maintenance Parts List.

  • Page 238: Greasing

    Perform greasing at 50 km of operation for the first time of greasing. NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the grease on the ball screw spline unit can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.

  • Page 239: Greasing The Ball Screw Spline Unit

    - Move the shaft to the lower limit manually while by selecting EPSON RC+ 7.0 menu - [Tools] - [Robot Manager] - Arm #1 [Jog & Teach].
  • Page 240 Run for about 5 minutes to spread the grease over the shaft. Turn OFF the controller. End of the spline nut G series Maintenance Rev.3...
  • Page 241 - Move the shaft to the upper limit manually while by selecting EPSON RC+ 7.0 menu - [Tools] - [Robot Clamp band Manager] - [Jog & Teach].
  • Page 242 (13) After moving to the origin position, move the shaft up and down. To move up and down, use an operation program to move from the upper limit to the lower limit in low power mode. Run about 5 minutes to spread grease over the shaft. (14) Turn OFF the Controller. G series Maintenance Rev.3...

  • Page 243: Tightening Hexagon Socket Head Cap Bolts

    Then, follow the steps below to display the pulse values and record them. Execute the following command from the [Command Window]. EPSON >PULSE PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls [Joint #3 Pulse value] pls [Joint #4 Pulse value] pls G series Maintenance Rev.3...

  • Page 244: Layout Of Maintenance Parts

    G6-***D, P : Protected-model (D: With bellows option) Brake release switch (for D/P) Gasket (D/P) Bellows (C/D/P) Gasket (P) Gasket (D/P) Gasket (P) Gasket (D/P) Gasket (C/D/P) Bellows (C/D/P) Gasket (D/P) Gasket (D/P) Gasket (D/P) Gasket (D/P) Gasket (D/P) Gasket (D/P) (Figure: G6-551P) G series Maintenance Rev.3...

  • Page 245: Wall Mounting Type

    G6-***DW, PW : Protected-model (D: With bellows option) Brake release switch (for D/P) Gasket (D/P) Gasket (D/P) Gasket (D/P) Gasket (D/P) Bellows (C/D/P) Gasket (P) Gasket (C/D/P) Gasket (D/P) Bellows (C/D/P) Gasket (P) Gasket (D/P) Gasket (D/P) Gasket (D/P) (Figure: G6-551PW) G series Maintenance Rev.3...

  • Page 246: Ceiling Mounting Type

    G6-***DR, PR : Protected-model (D: With bellows option) Brake release switch (for D/P) Gasket (D/P) Gasket (D/P) Gasket (D/P) Bellows (C/D/P) Gasket (D/P) Gasket (D/P) Gasket (P) Gasket (C/D/P) Gasket (D/P) Bellows (C/D/P) Gasket (P) Gasket (D/P) Gasket (D/P) Gasket (D/P) (Figure: G6-551PR) G series Maintenance Rev.3...

  • Page 247: Covers

    Only for Wall mounting / Cleanroom-model and Protected-model Hexagonal wrench For M4 screw Tools (width across flats: 3 Tightening Torque: 0.9 N⋅m (9.2 kgf⋅cm) For bellows removal Cross-point screwdriver Only for Cleanroom-model and Protected-model Wiping cloth For wiping adhesive G series Maintenance Rev.3...
  • Page 248 Maintenance plate Arm top cover Arm top cover Connector sub plate Side cover Connector plate Side cover Arm cap Arm top cover Arm cap Arm cap Side cover Side cover Base bottom cover Arm bottom cover G series Maintenance Rev.3...

  • Page 249: Arm Top Cover

    However, you can continue regular maintenance. LED lamp and the cable of the brake release switch are located between the main part and the cover. Do not pull the cable strong or the connector may be damaged. G series Maintenance Rev.3...
  • Page 250 Shaft When bellows are installed to the manipulator, install the arm top cover and then install the upper bellows. For bellows installation, refer to 9. Bellows. G series Maintenance Rev.3...

  • Page 251: Arm Bottom Cover

    When bellows are installed to the manipulator, remove or pull down the lower bellows and then remove the arm bottom cover. For bellows removal, refer to 9. Bellows. G6-***C* (Cleanroom-model) G6-***S* (Standard-model) G6-***D*, P* (Protected-model) Gasket 4-M4×10 4-M4×10 A gasket is installed to G6-***C* (Cleanroom-model) and G6-***D*, P* (Protected-model). G series Maintenance Rev.3...

  • Page 252: Arm #1 Cover

    : 4-M4×15 For the arm cap Wall mounting : 4-M4×5 For the side cover : 4-M4×15 For the arm cap : 4-M4×5 Ceiling mounting For the side cover : 4-M4×15 For the arm cap : 4-M4×5 G series Maintenance Rev.3...

  • Page 253: G6-***D*/P* (Protected-Model)

    Wall mounting For the side cover : 4-M4×15 Gasket For the arm cap : 4-M4×5 Ceiling mounting For the side cover : 4-M4×15 Gasket For the arm cap : 4-M4×5 Gaskets are installed to G6-***D*, P* (Protected-model). G series Maintenance Rev.3...

  • Page 254: Connector Plate

    When routing the cables, observe the cable locations after removing the connector plate. Be sure to place the cables back to their original locations. G series Maintenance Rev.3...
  • Page 255 A gasket is installed to G6-***D*, P* (Protected-model). When installing the gasket to Table Top mounting (G6-***D, P) or ceiling mounting (G6- NOTE  ***DR, PR), apply silicon adhesive to the gasket installing part on the base side (shaded part in the photo). G series Maintenance Rev.3...

  • Page 256: Connector Sub Plate

    Table Top mounting Gasket 4-M4×10 Spacer 4-M4×15 Sealing washer Wall 4-M4×15 4-M4×10 mounting Sealing washer Spacer Gasket Ceiling 4-M4×10 Gasket 4-M4×15 mounting Spacer Sealing washer A gasket, spacers, and sealing washers are installed to G6-***D*, P* (Protected-model). G series Maintenance Rev.3...

  • Page 257: User Plate

    Table Top Maintenance mounting plate Maintenance plate Gasket 4-M4×10 4-M4×5 Spacer Wall Maintenance 4-M4×5 mounting plate Gasket Spacer 4-M4×10 Ceiling 4-M4×5 mounting Maintenance Gasket plate Spacer 4-M4×10 A gasket and spacers are installed to G6-***D*, P* (Protected-model). G series Maintenance Rev.3...

  • Page 258: Base Bottom Cover

    G6-***C* (Cleanroom-model) G6-***D*, P* (Protected-model) Table Top mounting Gasket 6-M3×8 6-M3×8 Ceiling mounting 6-M3×8 6-M3×8 Gasket NOTE A gasket is installed to G6-***D*, P* (Protected-model).  A base bottom cover is not installed to G6-***S* (Standard-model). G series Maintenance Rev.3...

  • Page 259: Cable

    The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, CAUTION or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system. G series Maintenance Rev.3...

  • Page 260: Replacing Cable Unit

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. If the error occurs, execute the calibration of all joints and axes.
  • Page 261 G6 Maintenance 4. Cable Table Top mounting Cable Unit Wall mounting Cable Unit Ceiling mounting Cable Unit G series Maintenance Rev.3...
  • Page 262 (X10, X20, X30, X111, X121, X131, XB10) connected to the connector plate (inner side). - Remember the cable layout so that the cables can be reconnected correctly after NOTE  replacement. (7) The procedure of step (7) differs by mounting types. Follow the corresponding procedure. G series Maintenance Rev.3...
  • Page 263 (7)-3 Cut the wire tie banding the cables. Wire tie (7)-4 Pull out the spring plate. Spring plate (7)-5 Remove the saddle part mounting the 2-M4×10 cables. Saddle part (7)-6 Cut the wire tie banding the spring. G series Maintenance Rev.3...
  • Page 264 (18) 2-M4×10 (15) Remove the saddle part mounting cables inside Arm #2. Saddle part (16) Remove the spring plate. (17) Cut off the wire ties binding cable and fixing Spring plate spring. Wire tie (17) 2-M5×10 G series Maintenance Rev.3...
  • Page 265 Arm #1 in step (20) to the side of Arm #1. Cable (22) Remove the Arm #1 four mounting bolts on the spring plate side. 4-M6×15 (23) Disconnect the cables to the base side. G series Maintenance Rev.3...
  • Page 266 When using Wall mounting or Ceiling mounting, disconnect the base side cables to the lower part of Arm #1 and pull the cables into the base. Wall / Ceiling mounting Cable G series Maintenance Rev.3...
  • Page 267 Make sure to make allowance. (6)-4 Remove the plastic bags on the base side applied in step (2). (6)-5 Mount the saddle part to the spring plate. Spring plate Saddle part 2-M4×10 G series Maintenance Rev.3...
  • Page 268 Make sure to make allowance. (6)-5 Remove the plastic bags on the base side applied in step (2). (6)-6 Mount the spring plate. Spring plate 2-M4×10 (6)-7 Mount the ground plate. 2-M4×10 Ground plate G series Maintenance Rev.3...
  • Page 269 If you band the cables and tubes without allowance, NOTE  the cables are pulled and may be disconnected during the robot operation. Make sure to make allowance. (12) Remove the plastic bags on the Arm side applied in step (2). G series Maintenance Rev.3...
  • Page 270 (20) Remove the conector plate mounted loosely in the step (8) and remove the spare battery in theXB11. Then, mount the connector plate. NOTE In this replacement method, calibration is not needed.  However, perform the calibration if it is required. G series Maintenance Rev.3...

  • Page 271: Wiring Diagrams

    G6 Maintenance 4. Cable 4.2 Wiring Diagrams 4.2.1 Signal Cable G series Maintenance Rev.3...

  • Page 272: Power Cable

    G6 Maintenance 4. Cable 4.2.2 Power Cable G series Maintenance Rev.3...

  • Page 273: User Cable

    The following table shows the types of the use cable. Environment Arm length Code Note 1497631 450 mm 1497632 S, C 550 mm 1497633 650 mm 1497634 450 mm Waterproof P, D 550 mm 1497635 connector 650 mm 1497636 G series Maintenance Rev.3...

  • Page 274: Replacing M/C Cable

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. NOTE If the connector connected to the battery was disconnected during cable replacement, ...
  • Page 275 G6 Maintenance 4. Cable Table Top mounting M/C Cable Wall mounting M/C Cable Ceiling mounting M/C Cable G series Maintenance Rev.3...
  • Page 276 (7) Connect the power cable and signal cable connectors to the controller. (8) Turn ON the Controller. (9) If the connector (XB10) falls off from the battery, execute the calibration for Joint #1. For details, refer to 13 Calibration. G series Maintenance Rev.3...

  • Page 277: Joint #1

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 13. Calibration to perform the calibration. Joint #1 reduction gear unit Joint #1 motor G series Maintenance Rev.3...

  • Page 278: Replacing Joint #1 Motor

    M5 brass bushing There is a brass bushing in one of the set screw holes. Be careful not to lose it. 2-M5×8 set screw Remove the motor flange from the Joint #1 motor. Motor flange 4-M5×15 G series Maintenance Rev.3...
  • Page 279 (6) Mount the connector plate. For details, refer to 3.4 Connector Plate. (7) Mount the maintenance plate. For details, refer to 3.7 Maintenance Plate. (8) Perform the calibration of Joint #1. For details refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 280: Replacing Joint #1 Reduction Gear Unit

    Tightening torque 22.0 N⋅m Tools (224.3 kgf⋅cm) Nippers Spatula For apply grease For wiping grease (Flange) Wiping cloth For wiping grease (Bolt) About 20mm in length Screw (M4) For flexspline removal Grease Grease (SK-1A) 40 g G series Maintenance Rev.3...
  • Page 281 (4) Use the extracting M4 screws and remove the 8-M6×15 flexspline and the grip ring. Spacer Flexspline Be sure to keep the spacer. Grip ring (5) Remove the circular spline from the base. 16-M4×20 Circular spline G series Maintenance Rev.3...
  • Page 282 (6) Execute steps from (2) to (3) in 5.1 Replacing Joint #1 Motor. (7) Turn and secure the Manipulator to the mounting position. (8) Execute steps from (4) to (7) in 5.1 Replacing Joint #1 Motor. G series Maintenance Rev.3...

  • Page 283: Joint #2

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 13. Calibration to perform the calibration. Joint #2 motor Joint #2 reduction gear unit G series Maintenance Rev.3...

  • Page 284: Replacing Joint #2 Motor

    (6) Cut off the wire tie used for binding the motor cables to the Joint #2 motor. (7) Disconnect the connectors. Connectors X221, X21 (Hold the clip to remove.) Connector X62 (8) Remove the spring plate. 2-M4×10 Spring plate G series Maintenance Rev.3...
  • Page 285 (10) Remove the wave generator from the Joint #2 M4 bushing motor. There is a brass bushing in one of the set screw 2-M4×8 set screw holes. Be careful not to lose it. (11) Remove the motor flange from the Joint #2 motor. 4-M5×15 G series Maintenance Rev.3...
  • Page 286 (7) Make sure that the connectors X22 and X33 are connected. (8) Mount the arm top cover. For details, refer to 3.1 Arm Top Cover. (9) Perform the calibration of Joint #2. For details refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 287: Replacing Joint #2 Reduction Gear Unit

    Torque wrench Tightening torque 12.0 N⋅m Tools (122.3 kgf⋅cm) Nippers Spatula For apply grease For wiping grease (Flange) Wiping cloth For wiping grease (Bolt) Screw (M3) For flexspline removal Material Wire tie Grease Grease (SK-1A) 21 g G series Maintenance Rev.3...
  • Page 288 Joint #2 motor. (5) Use the extracting M3 screws and remove the Spacer 8-M5×15 flexspline and grip ring from Arm #2. Flexspline Grip ring (6) Remove the circular spline from Arm #2. 16-M3×15 Circular spline G series Maintenance Rev.3...
  • Page 289 (4) Apply grease (SK-1A) inside the flexspline. Grease volume 15 g (5) Apply grease (SK-1A) to the bearing part of the waveform generator. (6) Execute steps from (2) to (9) in 6.1 Replacing Joint #2 Motor. G series Maintenance Rev.3...

  • Page 290: Joint #3

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 13. Calibration to perform the calibration. Joint #3 motor Z belt Joint #3 brake G series Maintenance Rev.3...

  • Page 291: Replacing Joint #3 Motor

    OFF status (MOTOR OFF). (The brake for Joint #4 is only installed to G6- **3**.) Note that the brake will not work during the replacement procedure. Move the shaft down to its lower limit before starting the replacement procedure by following the removal steps from (1) to (3). G series Maintenance Rev.3...
  • Page 292 (10) Remove the pulley from the Joint #3 motor. Joint #3 motor (10) M5 bushing There is a brass bushing in one of the set screw holes. Be careful not to lose it. Pulley (10) 2-M5×6 set screw G series Maintenance Rev.3...
  • Page 293 + Washer motor cable faces toward the front of the arm. Make sure that the rotor hub on the end face of the pulley is completely set in the fitting on the brake friction plate. G series Maintenance Rev.3...
  • Page 294 Do not allow unnecessary strain on the cables. (11) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (12) Perform the calibration of Joint #3. For details on the calibration method, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 295: Replacing The Timing Belt

    OFF status (MOTOR OFF). (The brake for Joint #4 is only installed to G6- **3**.) Note that the brake will not work during the replacement procedure. Move the shaft down to its lower limit before the replacement procedure following the removal steps from (1) to (3). G series Maintenance Rev.3...
  • Page 296 (7) Remove the Joint #3 motor unit from Arm #2. Joint #3 4-M4×12 motor unit + Washer (8) Remove the Z belt. 3-M4×12 Z belt Remove the bolts securing the spline plate and pull out the spline plate upward to remove it. Spline plate G series Maintenance Rev.3...
  • Page 297 Do not allow unnecessary strain on the cables. (9) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (10) Perform the calibration of Joint #3. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 298: Replacing The Brake

    OFF status (MOTOR OFF). (The brake for Joint #4 is only installed to G6- **3**.) Note that the brake will not work during the replacement procedure. Move the shaft down to its lower limit before the replacement procedure following the removal steps from (1) to (3). G series Maintenance Rev.3...
  • Page 299 (9) Remove the brake hub from the Z1 pulley. Joint #3 motor Z1 pulley Brake hub (9) 2-M3×4 set screw Z plate (10) Remove the brake from the brake plate. 2-M3×10 Brake Brake plate Z plate G series Maintenance Rev.3...
  • Page 300 Do not allow unnecessary strain on the cables. (7) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (8) Perform the calibration of Joint #3. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 301: Joint #4

    After replacing the parts, it is necessary to match these origins. The process of aligning the two origins is called “Calibration”. Refer to 13. Calibration to perform the calibration. U2 belt Joint #4 motor Joint #4 brake U1 belt G series Maintenance Rev.3...

  • Page 302: Replacing Joint #4 Motor

    OFF status (MOTOR OFF). (The brake for Joint #4 is only installed to G6- **3**.) Note that the brake will not work during the replacement procedure. Move the shaft down to its lower limit before starting the replacement procedure by following the removal steps from (1) to (3). G series Maintenance Rev.3...
  • Page 303 M4 bushing There is a brass bushing in one of the set screw 2-M4×8 holes. Be careful not to lose it. set screw (9) Remove the motor plate from the Joint #4 motor. Motor plate 2-M4×8 G series Maintenance Rev.3...
  • Page 304 Joint #4 motor unit near its mounting plate. Force gauge Then, pull the cord using a force gauge or similar tool to apply the specified tension shown in the 4-M4×12 + Washer figure on the right. G series Maintenance Rev.3...
  • Page 305 Do not allow unnecessary strain on the cables. (9) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (10) Perform the calibration of Joint #4. For details on the calibration method, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 306: Replacing The Timing Belt

    OFF status (MOTOR OFF). (The brake for Joint #4 is only installed to G6- **3**.) Note that the brake will not work during the replacement procedure. Move the shaft down to its lower limit before the replacement procedure following the removal steps from (1) to (3). G series Maintenance Rev.3...
  • Page 307 U1 belt U2 belt Put the Joint #4 motor unit and the Joint #4 intermediate shaft unit to the shaft side and remove the belt from the pulley. U1 pulley U2 small pulley U2 large pulley G series Maintenance Rev.3...
  • Page 308 Joint #4 intermediate shaft unit near its mounting Force gauge plate. Then, pull the cord using a force gauge or similar tool to apply the specified tension 2-M4×12 + Washer shown in the figure on the right. G series Maintenance Rev.3...
  • Page 309 (6) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (7) Perform the calibration of Joint #3. For details on the calibration method, refer to 13. Calibration. G series Maintenance Rev.3...
  • Page 310 + Washer (8) Loosen the bolts securing the Joint #4 motor unit. Joint #4 Joint #4 motor unit intermediate shaft unit (9) Loosen the bolts securing the Joint #4 intermediate shaft unit. 6-M4×12 + Washer G series Maintenance Rev.3...
  • Page 311 U2 large pulley (11) Remove the U2 belt. 3-M4×12 Remove the bolts securing the spline plate. U2 belt Hold the spline plate up and remove the U2 belt from the shaft by pulling them up. Spline plate G series Maintenance Rev.3...
  • Page 312 Loosely secure the unitｓ to Arm #2 so that the motor unit can be moved by hand, and NOTE  it will not tilt when pulled. If the units are secured too loose or too tight, the belt will not have the proper tension. G series Maintenance Rev.3...
  • Page 313 Do not allow unnecessary strain on the cables. (13) Install the arm top cover and arm bottom cover. For details, refer to 3. Covers. (14) Perform the calibration of Joints #3 and #4. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 314: Replacing The Brake

    For details, refer to 3.1 Arm Top Cover. (5) Disconnect the connector. Connector X42 (6) Cut off the wire tie banding brake cables. Rubber cap (7) Remove the rubber cap. (8) Remove the brake hub. Brake hub 2-M2.5×25 Brake (9) Remove the brake. G series Maintenance Rev.3...
  • Page 315 (5) Re-bundle the cables in their original positions with a wire tie removed in step (6). Do not allow unnecessary strain on the cables. (6) Install the arm top cover. For details, refer to 3.1 Arm Top Cover. G series Maintenance Rev.3...

  • Page 316: Bellows

    Bellows (5) Pull the bellows, rubber sheet, and clamp bands Clamp band (medium) out of the shaft. without rubber sheet (The rubber sheet is not used for the upper bellows.) Clamp band (large) Clamp band (small) G series Maintenance Rev.3...
  • Page 317 Then, secure them with clamp bands. (5) After completing the attachment of the bellows, move the shaft up/down by hand several times and rotate Joint #4. Make sure that the bellows can expand and contract smoothly without any excessive force. G series Maintenance Rev.3...
  • Page 318 G6 Maintenance 9. Bellows (6) Turn OFF the Controller and peripheral equipment. (7) Attach the end effector. (8) Connect the wires and tubes to the end effector. G series Maintenance Rev.3...

  • Page 319: Ball Screw Spline Unit

    For cutting wire tie Belt tension Tools Force gauge 70 N (8.2 kgf), 80 N (8.1 kgf), 130 N (13.2 kgf) Suitable cord (Length about 1000 mm) For belt tension Wiping cloth For wiping grease Material Wire tie G series Maintenance Rev.3...
  • Page 320 + Washer (10) Loosen the bolts securing the Joint #4 motor unit. Joint #4 Joint #4 intermediate motor unit shaft unit (11) Loosen the bolts securing the Joint #4 intermediate shaft unit. 4-M4×12 + Washer G series Maintenance Rev.3...
  • Page 321 Z belt from the shaft by pulling them up. Spline plate (15) Remove the nut mounting screws of the ball screw spline shaft on the lower part of Arm #2. 4-M4×12 (16) Pull out the ball screw spline unit from Arm #2. G series Maintenance Rev.3...
  • Page 322 (6) Set the U1 belt around the U1 pulley and U2 large pulley (upper side) so that the gear grooves of the U1 belt belt are fit into those of the pulleys completely. U2 large pulley U1 pulley G series Maintenance Rev.3...
  • Page 323 Joint #4 motor unit near its mounting plate. Force gauge Then, pull the cord using a force gauge or similar tool to apply the specified tension shown in the 4-M4×12 + Washer Battery board figure on the right. G series Maintenance Rev.3...
  • Page 324 (19) This step is only for Cleanroom-model and Protected-model (C, D with bellows option, Install the bellows. For details, refer to 9. Bellows. (20) Perform the calibration of Joints #3 and #4. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 325: Lithium Battery

    Controller is energized. If warnings of voltage reduction occur, replace the lithium metal battery even if it has not reached the above product life. G series Maintenance Rev.3...
  • Page 326 G6 Maintenance 11. Lithium Battery NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the battery can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.

  • Page 327: Replacing The Battery Unit (Lithium Battery)

    To do so, select 2 points (poses) or more from the registered points (poses) and move the Manipulator to the points (poses). (6) If the Manipulator does not move to the points (poses) correctly, perform the calibration of all joints and axes. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 328: Replacing The Battery Board

    (4) Disconnect the wiring tie connecting the connector cable. (5) Disconnect the connectors X61, X62, X63, and X64 connected to the battery board. Battery board (6) Loosen the screws securing the battery board and Battery remove the battery board. board 2-M4×10 G series Maintenance Rev.3...
  • Page 329 Refer to procedure (4). (4) Mount the arm top cover. For details, refer to 3.1 Arm Top Cover. (5) Turn ON the Controller. (6) Perform the calibration of all joints. For details, refer to 13. Calibration. G series Maintenance Rev.3...

  • Page 330: Led Lamp

    (2) Put the arm top cover between the ring and lens holder, and then mount the LED on the arm top cover. (3) Install the lens to the lens holder. (4) Install the arm top cover. For details, refer to 3.1 Arm Top Cover. G series Maintenance Rev.3...

  • Page 331: Calibration

    Jog Motion The process to set the jog motion is included in the [Jog & Teach] page of the Robot Manager. Select EPSON RC+ menu-[Tools]-[Robot Manager] and select the [Jog & Teach] tab to use the [Jog & Teach] page.

  • Page 332: Calibration Procedure

    13.2 Calibration Procedure EPSON RC+ has a wizard for calibration. This section indicates the calibration using the calibration wizard of EPSON RC+. The same calibration procedure is used for each joint. The steps below are calibration using Joint #1. Follow the steps below to calibrate other joints.
  • Page 333 G6 Maintenance 13. Calibration (2) Confirm the warning message and click the <Yes> button. (3) Move the joint to calibrate manually to approximate 0 pulse position, as shown in the dialog. After moving the joint click the <Next> button. G series Maintenance Rev.3...
  • Page 334 0 pulse position of Joint #4: position where the flat surface (or groove in the up/down mechanical stop) on the shaft faces toward the tip of Arm #2 0 pulse Groove Flat surface G series Maintenance Rev.3...
  • Page 335 (6) Select the reference point to use for calibration, and click the <Next> button. Select a point from the current points to use for checking the accuracy. (7) Click the <Jog…> button to display the [Jog & Teach] dialog. G series Maintenance Rev.3...
  • Page 336 (8) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Before operating the robot, open the [Jog & Teach] tab and execute <Motor ON>. (9) Click the <Next> button. G series Maintenance Rev.3...
  • Page 337 (10) The manipulator moves to the reference point. Click the <Execute> button. Input JUMP P0:z(0). ↑ Point selected in step (6) (11) Confirm the message and click the <Yes> button. (12) After the manipulator moves to the reference point, click the <Next> button. G series Maintenance Rev.3...
  • Page 338 (14) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Position Joint #2 only and move Joint #3 to around 0 pulse. G series Maintenance Rev.3...
  • Page 339 Go on to the step (19) for the other joints calibration. i. Move to another point that has different pose (from righty to lefty) using Jump command. Click the <Yes> button. ii. Jog to the accurate reference position. Click the <Jog> button. G series Maintenance Rev.3...
  • Page 340 G6 Maintenance 13. Calibration iii. Jog to the accurate reference position and adjust the position. Click the <OK> button. iv. Click the <Next> button. G series Maintenance Rev.3...
  • Page 341 G6 Maintenance 13. Calibration (17) Calibration is complete. Click the <Finish> button. (18) Move the manipulator to other points and check if it can move without problems. Teach points where appropriate. G series Maintenance Rev.3...

  • Page 342: Accurate Calibration Of Joint #2

    · Switching the arm orientation between right and left at a given point · Using the Pallet command · Executing CP control (such as liner or circular interpolation) · Using the Local command · Pose data specified with relative coordinates <Example: P1+X(100) > · Vision Guide camera calibrations G series Maintenance Rev.3...
  • Page 343 (6), (11). (12) Move the manipulator to other point data and make sure it moves to the correct position. Teach some more points if required. * Delete the two points taught for the Joint #2 calibration. G series Maintenance Rev.3...

  • Page 344: Calibration Procedure Without Using Calibration Wizard

    G6 Maintenance 13. Calibration 13.4 Calibration Procedure without using Calibration Wizard This section indicates the calibration without using the calibration wizard of EPSON RC+. NOTE  For details of calibration using the calibration wizard, refer to 13.2 Calibration Procedure. When coordinates for the Manipulator working point require calculation, it is important for Joint #2 to be calibrated accurately.
  • Page 345 0 pulse position of Joint #4: position where the flat surface (or groove in the up/down mechanical stop) on the shaft faces toward the tip of Arm #2 0 pulse Groove Flat surface G series Maintenance Rev.3...
  • Page 346 Joint #3 >calib 3 Joint #4 >calib 3, 4 Calibration (Accurate Positioning) (5)-1 Turn ON the motors from the EPSON RC+ menu -[Tools] -[Robot Manager]-[Control Panel]. (5)-2 Click the <Free All> button in the [Control Panel] to free all joints. Now, you can move arms by hands.
  • Page 347 (6)-1 Move the Manipulator to another point to confirm that it moves to the same position. If it does not move to the same position, re-calibrate using another point. You must set the point again if reproducibility cannot be assured through calibration. G series Maintenance Rev.3...

  • Page 348: G6 Maintenance Parts List

    *4 As a rough indication, perform the overhaul (parts replacement) before reaching 20,000 operation hours of the Manipulator. The operation hours can be checked in [Controller Status Viewer] dialog - [Motor On Hours]. For details, refer to 2.2 Overhaul (Parts Replacement). G series Maintenance Rev.3...
  • Page 349 A rigid, ring-shaped body with gear teeth on the inner circumference. The circular spline has two more teeth than the flexspline does. Circular spline Flexspline The splines are greased. Be sure to keep the grease from being attaching to the clothes. G series Maintenance Rev.3...

  • Page 350: Parts By Environment Model

    For RC700-A, R12NZ900JZ － 10 m Straight For RC700-A, R12NZ900K3 － L-shaped R12NZ900X For RC700-A, － Straight 15 m For RC700-A, R12NZ900Y1 － L-shaped R12NZ900X For RC700-A, － Straight 20 m For RC700-A, R12NZ900Y2 － L-shaped G series Maintenance Rev.3...
  • Page 351 Manipulator. The operation hours can be checked in [Controller Status Viewer] dialog - [Motor On Hours]. For details, refer to 2.2 Overhaul (Parts Replacement). *6 The bellows are provided in a unit of two pieces. The shape varies between the upper and lower bellows. G series Maintenance Rev.3...
  • Page 352 G6 Maintenance 14. G6 Maintenance Parts List G series Maintenance Rev.3...
  • Page 353 G10 G20 Maintenance This volume contains maintenance procedures with safety precautions for Manipulators.
  • Page 355 CAUTION improper function of the robot system. ■ When operating maintenance of manipulator, secure about 50 cm of empty space around the manipulator. G series Maintenance Rev.3...

  • Page 356: General Maintenance

    √ 9 months (2250 h) √ √ 10 months (2500 h) √ 11 months (2750 h) √ 12 months (3000 h) √ √ √ √ 13 months (3250 h) √ √ 20000 h h = hour G series Maintenance Rev.3...

  • Page 357: Inspection Point

    Also, the break is not released even operated release the break, contact the supplier. Check whether unusual sound Check that there is no unusual sound or vibration when operating. or vibration occurs. If there is something wrong, contact the supplier. G series Maintenance Rev.3...

  • Page 358: Overhaul (Parts Replacement)

    (such as when operated with the maximum motion speed and maximum acceleration / deceleration in continuous operation) applied on the Manipulator. NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the parts subject to maintenance (motors, reduction gear units, and timing belts) can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
  • Page 359 (4) Click <OK> to view the [Controller Status Viewer] dialog. (5) Select [Robot] from the tree menu on the left side (Dialog image: EPSON RC+ 7.0) For the parts subject to overhaul, refer to 15. G10 G20 Maintenance Parts List.

  • Page 360: Greasing

    Perform greasing at 50 km of operation for the first time of greasing. NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the  recommended replacement time for the grease on the ball screw spline unit can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.

  • Page 361: Greasing The Ball Screw Spline Unit

    - Move the shaft to the lower limit manually while by selecting EPSON RC+ 7.0 menu - [Tools] - [Robot Manager] - [Jog & Teach]. NOTE...
  • Page 362 Run for about 5 minutes to spread the grease over the shaft. Turn OFF the controller. (10) Wipe off excess grease on the end of the spline nut and mechanical stop. End of the spline nut G series Maintenance Rev.3...
  • Page 363 Clamp band - Move the shaft to the upper limit manually while Lower bellows by selecting EPSON RC+ 7.0 menu - [Tools] - NOTE  Brake release switch [Robot Manager] - [Jog & Teach].
  • Page 364 (13) After moving to the origin position, move the shaft up and down. To move up and down, use an operation program to move from the upper limit to the lower limit in low power mode. Run about 5 minutes to spread grease over the shaft. (14) Turn OFF the Controller. G series Maintenance Rev.3...

  • Page 365: Greasing Joint #4 Backlash-Less Gear (G10 Only)

    (3) Apply grease with a grease gun or a plastic syringe (grease inlet) (without needle). 10 to 20 g of into the plastic syringe and grease apply 5 g to the backlash-less gear, so as to fill in the gear grooves. G series Maintenance Rev.3...

  • Page 366: Tightening Hexagon Socket Head Cap Bolts

    Then, follow the steps below to display the pulse values and record them. Execute the following command from the [Command Window]. EPSON >PULSE PULSE: [Joint #1 Pulse value] pls [Joint #2 Pulse value] pls [Joint #3 Pulse value] pls [Joint #4 Pulse value] pls G series Maintenance Rev.3...

  • Page 367: Layout Of Maintenance Parts

    Gasket (D, P) O-ring (D, P) Gasket (D, P) Gasket (C, D, P) Bellows (C, D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) (Figure: G10-851P) G series Maintenance Rev.3...
  • Page 368 Gasket (P) Gasket (D, P) Gasket (D, P) Gasket (C, D, P) Bellows (C, D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) (Figure: G20-851P) G series Maintenance Rev.3...

  • Page 369: Wall Mounting Type

    Gasket (D, P) Bellows (C, D, P) Gasket (P) Gasket (P) O-ring (D, P) Gasket (C, D, P) Gasket (D, P) Bellows (C, D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) (Figure: G10-851PW) G series Maintenance Rev.3...
  • Page 370 Gasket (D, P) Gasket (P) Gasket (D, P) Bellows (C, D, P) Gasket (P) Gasket (P) Gasket (C, D, P) Gasket (D, P) Bellows (C, D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) (Figure: G20-851PW) G series Maintenance Rev.3...

  • Page 371: Ceiling Mounting Type

    Bellows (C, D, P) Gasket (P) Gasket (D, P) Gasket (P) O-ring (D, P) Gasket (D, P) Gasket (C, D, P) Gasket (D, P) Bellows (C, D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) (Figure: G20-851PR) G series Maintenance Rev.3...
  • Page 372 Bellows (C, D, P) Gasket (D, P) Gasket (P) Gasket (P) Gasket (D, P) Gasket (C, D, P) Gasket (D, P) Bellows (C, D, P) Gasket (D, P) Gasket (D, P) Gasket (D, P) (Figure: G20-851PR) G series Maintenance Rev.3...

  • Page 373: G10-65***: For S/N: 1**** Or Later

    The following maintenance parts have been added for G10-65*** manipulator of S/N: 1**** or later. Standard model G10-65*S* Radiating unit Heat sink Cleanroom model G10-65*C* Radiating unit Heat sink Protection model G10-65*P* Radiating unit Heat sink G series Maintenance Rev.3...

  • Page 374: Covers

    Hexagonal wrench For M4 screw (width across flats: 3 mm) Tightening Torque: 0.9 N⋅m (9.2 kgf⋅cm) Tools Only for Cleanroom-model and Protected-model For bellows removal Cross-point screwdriver Only for Cleanroom-model and Protected-model Wiping cloth For wiping adhesive G series Maintenance Rev.3...
  • Page 375 Maintenance plate Maintenance plate Arm top cover Arm top cover Side cover Side cover Arm cap Arm cap Connector sub plate Connector plate Arm cap Arm cap Side cover Side cover Arm bottom cover Arm bottom cover G series Maintenance Rev.3...

  • Page 376: Arm Top Cover

    However, you can continue regular maintenance. LED lamp and the cable of the brake release switch are located between the main part and the cover. Do not pull the cable strong or the connector may be damaged. G series Maintenance Rev.3...
  • Page 377 Shaft When bellows are installed to the manipulator, install the arm top cover and then install the upper bellows. For bellows installation, refer to 9. Bellows. G series Maintenance Rev.3...

  • Page 378: Arm Bottom Cover

    When bellows are installed to the manipulator, remove or pull down the lower bellows and then remove the arm bottom cover. For bellows removal, refer to 9. Bellows. G10/G20-***C* (Cleanroom-model) G10/G20-***S* (Standard-model) G10/G20-***D*, P* (Protected-model) Gasket 4-M4×10 4-M4×10 A gasket is installed to G10/G20-***C* (Cleanroom-model) and G10/G20-***D*/P* (Protected-model). G series Maintenance Rev.3...

  • Page 379: Arm #1 Cover

    : 4-M4×15 For the arm cap : 4-M4×8 Wall mounting For the side cover : 4-M4×15 For the arm cap : 4-M4×8 Ceiling mounting For the side cover : 4-M4×15 For the arm cap : 4-M4×8 G series Maintenance Rev.3...

  • Page 380: G10/G20-***D*, P* (Protected-Model)

    : 4-M4×15 Gaskets For the arm cap : 4-M4×8 Ceiling mounting Sealing washer For the side cover : 4-M4×15 Gaskets For the arm cap : 4-M4×8 Gaskets and sealing washers are installed to G10/G20-***D*, P* (Protected-model). G series Maintenance Rev.3...

  • Page 381: Connector Plate

    A gasket is installed to G10/G20-***D*, P* (Protected-model). NOTE When installing the gasket to Table Top mounting (G10/G20-***D, P) or Ceiling mounting  (G10/G20-***DR, PR), apply silicon adhesive to the gasket installing part on the base side (shaded part in the photo). G series Maintenance Rev.3...

  • Page 382: Connector Sub Plate

    Gasket 4-M4×10 4-M4×15 Spacer Sealing washer Wall 4-M4×15 4-M4×10 Sealing washer mounting Spacer Gasket Ceiling 4-M4×10 mounting Gasket 4-M4×15 Spacer Sealing washer A gasket, spacers, and sealing washers are installed to G10/G20-***D*, P* (Protected - model). G series Maintenance Rev.3...

  • Page 383: User Plate

    Table Top Maintenance Maintenance mounting plate plate Gasket 4-M4×5 4-M4×8 Spacer Wall Maintenance 4-M4×5 plate mounting Gasket Spacer 4-M4×8 Ceiling 4-M4×5 Maintenance Gasket mounting plate Spacer 4-M4×8 A gasket and spacers are installed to G10/G20-***D*, P* (Protected-model). G series Maintenance Rev.3...

  • Page 384: Base Bottom Cover

    G10/G20-***C* (Cleanroom-model) G10/G20-***D*, P* (Protected-model) Table Top mounting Gasket 8-M3×8 8-M3×8 Ceiling mounting 8-M3×8 8-M3×8 Gasket A gasket is installed to G10/G20-***D*, P* (Protected-model). NOTE  A base bottom cover is not installed to G10/G20-***S* (Standard-model). G series Maintenance Rev.3...

  • Page 385: Cable

    The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, CAUTION or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system. G series Maintenance Rev.3...

  • Page 386: Replacing Cable Unit

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. If the error occurs, execute the calibration of all joints and axes.
  • Page 387 G10-65*** manipulator of S/N: 1**** or later is different from other models in its form.  For the detail, refer to 2.6.4 G10-65***: For S/N: 1**** or later. Table Top mounting Cable Unit Cable Unit Wall mounting Cable Unit Cable Unit Ceiling mounting Cable Unit Cable Unit G series Maintenance Rev.3...
  • Page 388 The unnecessary strain on the cables may result in damage to the cables, disconnection, and/or contact failure. Damaged cables, disconnection, or contact failure is extremely hazardous and may result in electric shock and/or improper function of the robot system. G series Maintenance Rev.3...
  • Page 389 Wire tie (7)-2 Remove the spring plate. (7)-3 Cut off the two wire ties binding cables. Saddle part (7) 2-M4×10 Spring plate When using Wall mounting type (7)-1 Remove the ground plate. 2-M4×10 Ground plate G series Maintenance Rev.3...
  • Page 390 Be sure to keep the screws. Press the ring on the fitting and pull out the air Air tube tube. (ø6×2, ø4×2) Brake release switch cable Be sure to observe the connection for connecting the disconnected parts after replacement. G series Maintenance Rev.3...
  • Page 391 Wall / Ceiling mounting  the air tubes. Then, disconnect from the smaller connectors in order. Do not try to disconnect the cables forcibly. Cable Otherwise, connectors may be stuck, disconnected, or connector pins may fall off. G series Maintenance Rev.3...
  • Page 392 (22) Remove the spring plate mounting Arm #1 side Arm #2 side bolts on both the Arm #1 side and the Arm #2 side. 2-M5×18 2-M6×30 + washer (23) Disconnect the cables to the base side. G series Maintenance Rev.3...
  • Page 393 (3) Refer to step (1) and insert the cables to Arm #1 in the proper direction. Cable Cable (4) Set the mounting holes of the spring plate to the base side and mount the spring plate to Arm #1. Arm #1 side Arm #2 side 2-M5×18 2-M6×30 + washer G series Maintenance Rev.3...
  • Page 394 Make sure to make allowance. Wire tie (6)-4 Remove the plastic bags on the base Spring plate side applied in step (2). Saddle part (6)-5 Mount the saddle part to the spring 2-M4×10 plate. G series Maintenance Rev.3...
  • Page 395 Make sure make allowance. (6)-5 Remove the plastic bags on the base side applied in step (2). (6)-6 Mount the spring plate. Spring plate 2-M4×15 (6)-7 Mount the ground plate. 2-M4×10 Ground plate G series Maintenance Rev.3...
  • Page 396 If you band the cables and tubes without allowance,  the cables are pulled and may be disconnected during the robot operation. Make sure to make allowance. Wire tie (12) Remove the plastic bags on the Arm side applied in step (2). G series Maintenance Rev.3...
  • Page 397 (20) Remove the conector plate mounted loosely in the step (8) and remove the spare battery in theXB11. Then, mount the connector plate. In this replacement method, calibration is not needed. NOTE  However, perform the calibration if it is required. G series Maintenance Rev.3...

  • Page 398: Wiring Diagrams

    G10 G20 Maintenance 4. Cable 4.2 Wiring Diagrams 4.2.1 Signal Cable G series Maintenance Rev.3...

  • Page 399: Power Cable

    G10 G20 Maintenance 4. Cable 4.2.2 Power Cable G series Maintenance Rev.3...

  • Page 400: User Cable

    Yellow The following table shows the types of the use cable. Environment Arm length Code Note 650 mm 1563046 850 mm 1499531 1000 mm 1499532 650 mm 1563047 850 mm 1499533 Waterproof connector 1000 mm 1499534 G series Maintenance Rev.3...

  • Page 401: Replacing M/C Cable

    Controller is turned OFF. When the battery connectors are disconnected, the position data will be lost, and EPSON RC+ will display an error when the Controller is turned ON. NOTE If the connector connected to the battery was disconnected during cable replacement, ...
  • Page 402 G10-65*** manipulator of S/N: 1**** or later is different from other models in its form.  For the detail, refer to 2.6.4 G10-65***: For S/N: 1**** or later. Table Top mounting M/C Cable M/C Cable Wall mounting M/C Cable M/C Cable Ceiling mounting M/C Cable M/C Cable G series Maintenance Rev.3...
  • Page 403 (7) Connect the power cable and signal cable connectors to the controller. (8) Turn ON the Controller. (9) If the connector (XB10) falls off from the battery, execute the calibration for Joint #1. For details, refer to 14 Calibration. G series Maintenance Rev.3...

  • Page 404: Joint #1

    G10-65** manipulator of S/N: 1**** or later is different from other models in its form.  For the detail, refer to 2.6.4 G10-65***: For S/N: 1**** or later. Joint #1 reduction gear unit Joint #1 reduction gear unit Joint #1 motor Joint #1 motor G series Maintenance Rev.3...

  • Page 405: Replacing Joint #1 Motor

    M5 brass bushing There is a brass bushing in one of the set screw holes. Be careful not to lose it. 2-M5×8 set screw (7) Remove the motor flange from the Joint #1 motor. Motor flange 4-M6×20 G series Maintenance Rev.3...
  • Page 406 (7) Mount the connector plate. For details, refer to 3.4 Connector Plate. (8) Mount the maintenance plate. For details, refer to 3.7 Maintenance Plate. (9) Perform the calibration of Joint #1. For details refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 407: Replacing Joint #1 Reduction Gear Unit

    Spatula For applying grease For wiping grease (Flange) Wiping cloth For wiping grease (Bolt) About 20mm in length Screw (M5) For removing flexspline Proper Materials ROCTITE 241 For locking screw quantity Grease Grease (SK-1A) 71 g G series Maintenance Rev.3...
  • Page 408 (4) Use the extracting M5 screws and remove the spacer, 8-M8×20 flexspline and the grip ring. Spacer Flexspline Grip ring (5) Remove the circular spline from the base. 16-M5×25 Circular spline G series Maintenance Rev.3...
  • Page 409 (6) Execute steps from (2) to (4) in 5.1 Replacing Joint #1 Motor. (7) Turn and secure the Manipulator to the mounting position. (8) Execute steps from (5) to (7) in 5.1 Replacing Joint #1 Motor. G series Maintenance Rev.3...

  • Page 410: Joint #2

    G10-65*** manipulator of S/N: 1**** or later is different from other models in its form.  For the detail, refer to 2.6.4 G10-65***: For S/N: 1**** or later. Joint #2 motor Joint #2 motor Joint #2 reduction Joint #2 reduction gear unit gear unit G series Maintenance Rev.3...

  • Page 411: Replacing Joint #2 Motor

    3 mm For M4 screw width across flats: 4 mm For M5 screw Tools Nippers For cutting wire tie Spatula For grease up Wiping cloth For wiping grease Material Wire tie Grease Grease (SK-1A) 28 g G series Maintenance Rev.3...
  • Page 412 (7)-2 Remove the insulation lock that secures G10-65*** the plate of radiating unit and rotate the radiating unit. At this point, be sure to keep the plate mounted. (8) Remove the spring plate. 2-M4×8 Spring plate G series Maintenance Rev.3...
  • Page 413 (10) Remove the wave generator from the Joint #2 M5 bushing motor. 2-M5×8 There is a brass bushing in one of the set screw set screw holes. Be careful not to lose it. (11) Remove the motor flange from the Joint #2 motor. 4-M5×15 G series Maintenance Rev.3...
  • Page 414 If it is difficult to mount the motor, push it while 6-M4×15 moving Arm #2 slowly by hand. At this point, be careful about the direction of the spring plate mounting hole of the motor flange. G series Maintenance Rev.3...
  • Page 415 (5). Do not allow unnecessary strain on the cables. (9) Mount the arm top cover. For details, refer to 3.1 Arm Top Cover. (10) Perform the calibration of Joint #2. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 416: Replacing Joint #2 Reduction Gear Unit

    30.0 N⋅m (306 kgf⋅cm) Nippers Spatula For apply grease For wiping grease (Flange) Wiping cloth For wiping grease (Bolt) Length about 20 mm Screw (M5) For flexspline removal Material Wire tie Grease Grease (SK-1A) 71 g G series Maintenance Rev.3...
  • Page 417 (4) Execute steps from (1) to (9) in 6.1 Replacing Joint #2 Motor and remove the waveform generator from the Joint #2 motor. (5) Use the extracting M5 screws and remove the flexspline from Arm #2. Spacer 8-M8×20 Flexspline (6) Remove the circular spline from Arm #2. 16-M5×25 Circular spline G series Maintenance Rev.3...
  • Page 418 (4) Apply grease (SK-1A) inside the flexspline. Grease volume 43 g (5) Apply grease to the bearing part of the waveform generator. (6) Execute steps from (2) to (9) in 6.1 Replacing Joint #2 Motor. G series Maintenance Rev.3...

  • Page 419: Joint #3

    G10-65*** manipulator of S/N: 1**** or later is different from other models in its form.  For the detail, refer to 2.6.4 G10-65***: For S/N: 1**** or later. Joint #3 motor Joint #3 motor Z belt Z belt Joint #3 brake Joint #3 brake G series Maintenance Rev.3...

  • Page 420: Replacing Joint #3 Motor

    For details, refer to 3. Covers. (5) Cut off the wire tie used for binding the motor cables to the Joint #3 motor. (6) Disconnect the following connectors. Connectors X231, X31 (Hold the clip to remove.) Connector X63 G series Maintenance Rev.3...
  • Page 421 Leave the brake unit mounted on Arm #2. (11) Remove the pulley from the Joint #3 motor. M4 bushing There is a brass bushing in one of the set screw Pulley holes. Be careful not to lose it. 2-M4×5 set screw G series Maintenance Rev.3...
  • Page 422 Arm #2 so that the motor unit can be moved by hand, and it will not tilt when Joint #3 pulled. If the unit is secured too loose or motor unit too tight, the belt will not have the proper tension. G series Maintenance Rev.3...
  • Page 423 Do not allow unnecessary strain on the cables. (9) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (10) Perform the calibration of Joint #3. For details on the calibration method, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 424: Replacing The Timing Belt

    4 mm For M5 screw Tools Nippers For cutting wire tie Force gauge Belt tension 160 N (16.3 kgf) Suitable cord (Length about 800 mm) For belt tension Wiping cloth For wiping grease Material Wire tie G series Maintenance Rev.3...

  • Page 425: Replacing The Timing Belt : G10

    10.2.1 Replacing the Ball Screw Spline Unit: G10 to engage the gear. (5) Remove the Z belt. 3-M5×15 Remove the bolts securing the spline plate. Hold Z belt the spline plate and pull out the Z belt from the shaft upwards. Spline plate G series Maintenance Rev.3...
  • Page 426 If the unit is secured too loose or too tight, the belt will not have the proper tension. G series Maintenance Rev.3...
  • Page 427 G10 : U belt tension = 160 N (16.3 kgf) Joint #4 Make sure that the brake cables do not motor unit touch the pulley. Force gauge 4-M4×15 + Washer G series Maintenance Rev.3...
  • Page 428 Do not allow unnecessary strain on the cables. (15) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (16) Perform the calibration of Joint #3. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 429: Replacing The Timing Belt : G20

    (3) Loosely secure the spline plate to Arm #2. After moving the shaft up and down several times, secure the spline plate to Arm #2. (4) Execute steps from (2) to (10) in 7.1 Replacing Joint #3. G series Maintenance Rev.3...

  • Page 430: Replacing The Brake

    (2) Remove the brake unit from Arm #2. Brake unit (3) Disconnect the connector. Connector X32 (4) Remove the brake from the brake support. Brake 3-M3×8 Brake support (5) Remove the brake hub from the Z1 pulley. 2-M3×4 Set screw Brake hub G series Maintenance Rev.3...
  • Page 431 (3) Mount back the Joint #3 brake unit to Arm Brake unit The screws are not secured in this step. (4) Connect the connector. Connector X32 (5) Execute steps from (2) to (10) in 7.1 Replacing Joint #3. G series Maintenance Rev.3...

  • Page 432: Joint #4

    For the detail, refer to 2.6.4 G10-65***: For S/N: 1**** or later. Joint #4 brake Joint #4 motor (with brake) U belt U belt Joint #4 motor Joint #4 Reduction gear unit Joint #4 Reduction gear unit (gear) G series Maintenance Rev.3...

  • Page 433: Replacing Joint #4 Motor

    OFF status (MOTOR OFF). Note that the brake will not work during the replacement procedure. Move the shaft down to its lower limit before starting the replacement procedure by following the removal steps. G series Maintenance Rev.3...
  • Page 434 (9) Remove the U1 pulley and the motor plate from the Pulley Joint #4 motor. M4 bushing 2-M4×8 There is a brass bushing in one of the set screw holes. set screw Be careful not to lose it. Bearing Motor plate Joint #4 motor 2-M4×15 G series Maintenance Rev.3...
  • Page 435 Then, pull the cord using a force Force gauge gauge or similar tool to apply the specified tension shown in the figure on the right. 4-M4×15 + Washer Make sure that the brake cables do not touch the pulley. G series Maintenance Rev.3...
  • Page 436 Do not allow unnecessary strain on the cables. (9) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (10) Perform the calibration of Joint #4. For details on the calibration method, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 437: Replacing The Joint #4 Motor: G20

    M3×10 (Securing the motor shaft) (8) Remove the ring from the Joint #4 motor. Ring Bushing There is a brass bushing in the both set screw holes. Be careful not to lose it. 2-M3×8 set screw G series Maintenance Rev.3...
  • Page 438 Do not allow unnecessary strain on the cables. (7) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (8) Perform the calibration of Joint #4. For details on the calibration method, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 439: Replacing The Timing Belt

    4 mm For M5 screw Nippers For cutting wire tie Tools Belt tension: Force gauge 130N, 160N, 200N (13.3 kgf, 16.3 kgf, 20.4 kgf) Suitable cord (Length about 800 mm) For belt tension G series Maintenance Rev.3...

  • Page 440: Replacing The Timing Belt: G10

    Battery unit (6) Loosen the Z belt. 4-M4×15 + Washer Remove the four bolts securing the Joint #3 motor Joint #3 motor unit unit and slide the Joint #3 motor unit to the arm end side. G series Maintenance Rev.3...
  • Page 441 (10) Remove the Z belt from the Z pulley and remove the 3-M5×15 U belt. Spline plate Remove the bolts securing the spline plate. Hold U belt the spline plate and pull out the Z belt from the Z pulley upwards to remove the U belt. G series Maintenance Rev.3...
  • Page 442 NOTE  that the motor unit can be moved by hand, and it will not tilt when pulled. If the unit is secured too loose or too tight, the belt will not have the proper tension. G series Maintenance Rev.3...
  • Page 443 Battery unit Plate (9) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (10) Perform the calibration of Joint #3. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 444: Replacing The Timing Belt: G20

    (6) Loosen the Z belt. 4-M4×15 + Washer Loosen four bolts on the Joint #3 motor unit. Slide Joint #3 the Joint #3 motor unit to the end of the arm. motor unit G series Maintenance Rev.3...
  • Page 445 (8) Remove the Z belt from the Z pulley and remove the U belt U belt. 3-M5×15 Spline plate Remove the bolts securing the spline plate. Hold the spline plate and pull out the Z belt from the Z pulley upwards and remove the U belt. G series Maintenance Rev.3...
  • Page 446 If the unit is secured too loose U1 pulley U2 pulley or too tight, the belt will not have the proper tension. G series Maintenance Rev.3...
  • Page 447 U axis belt. 4. Secure the U axis unit. 5. Place back the bolt to the position. Secure the nut. 6. Loosen the nut. G20: U belt tension Bolt + nut for adjustment (M4) G series Maintenance Rev.3...
  • Page 448 Battery unit Plate (9) Install the arm top cover and the arm bottom cover. For details, refer to 3. Covers. (10) Perform the calibration of Joint #3. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 449: Replacing The Brake

    (3) Turn OFF the Controller. (4) Remove the arm top cover. For details, refer to 3.1 Arm Top Cover. (5) Disconnect the connector X42. (6) Cut off the wire tie used for binding the brake cables. G series Maintenance Rev.3...
  • Page 450 Joint #4 motor unit to the end of the arm. (9) Remove the brake hub. Brake hub 2-M3×4 set screw Loosen the two set screws and pull out the brake hub. (10) Remove the brake. 2-M2.5×22 Brake G series Maintenance Rev.3...
  • Page 451 (7) Re-bundle the cables in their original positions with a wire tie removed in step (6). Do not allow unnecessary strain on the cables. (8) Install the arm top cover. For details, refer to 3.1 Arm Top Cover. G series Maintenance Rev.3...

  • Page 452: Replacing The Reduction Gear Unit

    Reduction Gear (1) Mount a new bearing. Bearing Unit (2) Mount a new reduction gear unit. Installation: G10 (3) Execute the installation steps (3) to (23) in 10.2.1 Replacing the Ball Screw Spline Unit: G10. G series Maintenance Rev.3...

  • Page 453: Replacing The Reduction Gear Unit: G20

    Joint #4 motor shaft and bolt securing the Joint #4 the motor shaft motor. (3) Remove the plate. Plate Joint #4 reduction gear unit 4-M5×18 (4) Remove the U pulley. Joint #4 reduction gear unit Pulley 6-M4×15 G series Maintenance Rev.3...
  • Page 454 Secure the blot of the reduction gear unit securing the Joint #4 motor shaft. Joint #4 motor (4) Execute the installation steps (4) to (10) in Joint #4 8.2.2 Replacing the Timing Belt: G20. reduction gear unit M3×10: To secure the motor shaft G series Maintenance Rev.3...

  • Page 455: Bellows

    Bellows (5) Pull the bellows, rubber sheet, and clamp bands Clamp band (medium) without rubber sheet out of the shaft. (The rubber sheet is not used for the upper bellows.) Clamp band (large) Clamp band (small) G series Maintenance Rev.3...
  • Page 456 Attach the rubber sheet. Be sure to attach the rubber sheet so that no space is made between the bias cut. Bias cut Lower bellow end face Then, secure them with clamp bands. G series Maintenance Rev.3...
  • Page 457 Joint #4. Make sure that the bellows can expand and contract smoothly without any excessive force. (6) Turn OFF the Controller and peripheral equipment. (7) Attach the end effector. (8) Connect the wires and tubes to the end effector. G series Maintenance Rev.3...

  • Page 458: Ball Screw Spline Unit

    Protected-model Tools G10 Belt tension: 130N, 160N (13.3 kgf, 16.3 kgf) Force gauge G20 Belt tension: 130N, 200N (13.3 kgf, 20.4 kgf) Suitable cord (Length about 1000 mm) For belt tension Wiping cloth For wiping grease G series Maintenance Rev.3...

  • Page 459: Replacing The Ball Screw Spline Unit: G10

    When removing the battery unit mounting bolts, be NOTE  3-point mounting sure to keep the connectors connected to the battery unit. If connectors of the battery unity are Plate disconnected, you need to perform calibration again. Battery unit G series Maintenance Rev.3...
  • Page 460 (13) Remove the U belt. 3-M5×15 U belt (14) Remove the Joint #4 intermediate pulley. Intermediate pulley Remove the shaft from the bearing and remove the intermediate pulley from the lower side of Arm #2. Shaft Bearing G series Maintenance Rev.3...
  • Page 461 G10 G20 Maintenance 10. Ball Screw Spline Unit (15) Remove the nut mounting screws of the ball screw spline shaft on the lower part of Arm #2. (16) Pull out the ball screw spline unit from Arm #2. 4-M5×15 G series Maintenance Rev.3...
  • Page 462 3. Make sure that the pin position of the main gear is near the center of the slotted hole. Slotted hole (5) Hold the spline plate and place the U belt to the U2 3-M5×15 pulley. U belt G series Maintenance Rev.3...
  • Page 463 + Washer Place the Joint #4 motor unit in Arm #2 so that the motor cable faces toward the left from the end of the arm. The screws are not secured in this step. G series Maintenance Rev.3...
  • Page 464 When mounting the battery unit, be sure to keep Battery unit the connectors connected to the battery unit. 3-point mounting If connectors of the battery unity are disconnected, you need to perform calibration again. Battery unit Plate G series Maintenance Rev.3...
  • Page 465 (22) This step is only for Cleanroom-model and Protected-model (C / D with bellows option / P). Install the bellows. For details, refer to 9. Bellows. (23) Perform the calibration of Joints #3 and #4. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 466: Replacing The Ball Screw Spline Unit: G20

    Plate unit. If connectors of the battery unity are disconnected, Battery unit you need to perform calibration again. 3-point mounting When you use the plate of 3 mounting, loosen the plate mounting bolts. Battery unit Plate G series Maintenance Rev.3...
  • Page 467 (12) Remove the nut mounting screws of the ball screw spline shaft on the lower part of Arm #2. 4-M5×15 + Washer (13) Pull out the ball screw spline unit from Arm #2. Ball screw spline unit G series Maintenance Rev.3...
  • Page 468 (6) Place the U belt around the U1 pulley and the U2 pulley so that the gear grooves of the belt are fit into U belt those of the pulleys completely. U1 pulley U2 pulley G series Maintenance Rev.3...
  • Page 469 (10) Re-bundle the cables in their original positions with a wire tie removed in the removal procedure. Do not allow unnecessary strain on the cables. (11) If the position of the lower limit mechanical stop was changed for area limit, secure it to the proper position. G series Maintenance Rev.3...
  • Page 470 (16) This step is only for Cleanroom-model and Protected-model (C, D with bellows option, Install the bellows. For details, refer to 9. Bellows. (17) Perform the calibration of Joints #3 and #4. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 471: Lithium Battery

    8 hours a day). When the Controller is not connected to power, the battery consumption will significantly increase compared to when the Controller is energized. If warnings of voltage reduction occur, replace the lithium metal battery even if it has not reached the above product life. G series Maintenance Rev.3...
  • Page 472 G10 G20 Maintenance 11. Lithium Battery NOTE For the EPSON RC+ 7.0 Ver. 7.2.x or later (firmware Ver.7.2.x.x or later), the recommended  replacement time for the battery can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.

  • Page 473: Replacing The Battery Unit (Lithium Battery)

    X60B X60A Battery board (5) Cut off the wire tie banding the cables of used lithium battery. (6) Cut off the wire tie banding the lithium battery and remove the lithium battery. Lithium battery Battery board G series Maintenance Rev.3...
  • Page 474 To do so, select 2 points (poses) or more from the registered points (poses) and move the Manipulator to the points (poses). (6) If the Manipulator does not move to the points (poses) correctly, perform the calibration of all joints and axes. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 475: Replacing The Battery Board

    (4) Cut off the wire tie banding the connector cables. (5) Disconnect the connectors X61, X62, X63, and X64 connected to the battery board. Battery board (6) Loosen the screws securing the battery board and remove the battery board. 2-M4×10 2-M4×10 Battery Battery board board G series Maintenance Rev.3...
  • Page 476 (4) Mount the arm top cover. For details, refer to 3.1 Arm Top Cover. (5) Turn ON the Controller. (6) Perform the calibration of all joints. For details, refer to 14. Calibration. G series Maintenance Rev.3...

  • Page 477: Led Lamp

    Performing any replacement procedure with the power ON is extremely hazardous and may result in electric shock and/or malfunction of the robot system. Name Quantity Note Maintenance LED Lamp 2077258 parts Cross-point screwdriver For wire removal Tools Nippers Material Wire tie G series Maintenance Rev.3...
  • Page 478 (2) Put the arm top cover between the ring and lens holder, and then mount the LED on the arm top cover. (3) Install the lens to the lens holder. (4) Install the arm top cover. For details, refer to 3.1 Arm Top Cover. G series Maintenance Rev.3...

  • Page 479: Radiating Unit

    For the detail, refer to 2.6.4 G10-65***: For S/N: 1**** or later. Name Quantity Note Maintenance Radiating Unit 1546193 parts Hexagonal wrench (width across flats: 3 mm) For M4 screws Tools Spanner (width across flats: 20 mm) For mounting pillar Nippers For cutting wire tie G series Maintenance Rev.3...
  • Page 480 Hold the pillar with the spanners to avoid it from rotating. (5) Mount the arm top cover. For details, refer to 3. Covers. NOTE  During the installation, be sure to keep the plate attached to the pipe. G series Maintenance Rev.3...

  • Page 481: Calibration

    Jog Motion The process to set the jog motion is included in the [Jog & Teach] page of the Robot Manager. Select EPSON RC+ menu-[Tools]-[Robot Manager] and select the [Jog & Teach] tab to use the [Jog & Teach] page.

  • Page 482: Calibration Procedure

    14.2 Calibration Procedure EPSON RC+ has a wizard for calibration. This section indicates the calibration using the calibration wizard of EPSON RC+. The same calibration procedure is used for each joint. The steps below are calibration using Joint #1. Follow the steps below to calibrate other joints.
  • Page 483 G10 G20 Maintenance 14. Calibration (2) Confirm the warning message and click the <Yes> button. (3) Move the joint to calibrate manually to approximate 0 pulse position, as shown in the dialog. After moving the joint click the <Next> button. G series Maintenance Rev.3...
  • Page 484 Arm #2 Screw hole 1 and flat surface are located in the center of the shaft. Screw hole 2 Screw hole 1 Screw hole 1 and 2 are located at right Flat surface angles to one another. G series Maintenance Rev.3...
  • Page 485 (6) Select the reference point to use for calibration, and click the <Next> button. Select a point from the current points to use for checking the accuracy. (7) Click the <Jog…> button to display the [Jog & Teach] dialog. G series Maintenance Rev.3...
  • Page 486 (8) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Before operating the robot, open the [Jog & Teach] tab and execute <Motor ON>. (9) Click the <Next> button. G series Maintenance Rev.3...
  • Page 487 (10) The manipulator moves to the reference point. Click the <Execute> button. Input JUMP P0:z(0). ↑ Point selected in step (6) (11) Confirm the message and click the <Yes> button. (12) After the manipulator moves to the reference point, click the <Next> button. G series Maintenance Rev.3...
  • Page 488 (14) Jog the end effector to approximate reference point in the [Jog & Teach] dialog for rough calibration. Then click the <OK> button. * Position Joint #2 only and move Joint #3 to around 0 pulse. G series Maintenance Rev.3...
  • Page 489 * Go on to the step (19) for the other joints calibration. i. Move to another point that has different pose (from righty to lefty) using Jump command. Click the <Yes> button. ii. Jog to the accurate reference position. Click the <Jog> button. G series Maintenance Rev.3...
  • Page 490 G10 G20 Maintenance 14. Calibration iii. Jog to the accurate reference position and adjust the position. Click the <OK> button. iv. Click the <Next> button. G series Maintenance Rev.3...
  • Page 491 G10 G20 Maintenance 14. Calibration (17) Calibration is complete. Click the <Finish> button. (18) Move the manipulator to other points and check if it can move without problems. Teach points where appropriate. G series Maintenance Rev.3...

  • Page 492: Accurate Calibration Of Joint #2

    · Switching the arm orientation between right and left at a given point · Using the Pallet command · Executing CP control (such as liner or circular interpolation) · Using the Local command · Pose data specified with relative coordinates <Example: P1+X(100) > · Vision Guide camera calibrations G series Maintenance Rev.3...
  • Page 493 Then, go to the step (6), (11). (12) Move the manipulator to other point data and make sure it moves to the correct position. Teach some more points if required. * Delete the two points taught for the Joint #2 calibration. G series Maintenance Rev.3...

  • Page 494: Calibration Procedure Without Using Calibration Wizard

    G10 G20 Maintenance 14. Calibration 14.4 Calibration Procedure without using Calibration Wizard This section indicates the calibration without using the calibration wizard of EPSON RC+. NOTE  For details of calibration using the calibration wizard, refer to 14.2 Calibration Procedure.
  • Page 495 Arm #2 Screw hole 1 and flat surface are located in the center of the shaft. Screw hole 2 Screw hole 1 Screw hole 1 and 2 are located at right Flat surface angles to one another. G series Maintenance Rev.3...
  • Page 496 Joint #3 >calib 3 Joint #4 >calib 3, 4 Calibration (Accurate Positioning) (5)-1 Turn ON the motors from the EPSON RC+ menu -[Tools] -[Robot Manager]-[Control Panel]. (5)-2 Click the <Free All> button in the [Control Panel] to free all joints. Now, you can move arms by hands.
  • Page 497 (6)-1 Move the Manipulator to another point to confirm that it moves to the same position. If it does not move to the same position, re-calibrate using another point. You must set the point again if reproducibility cannot be assured through calibration. G series Maintenance Rev.3...

  • Page 498: G10/G20 Maintenance Parts List

    *4 As a rough indication, perform the overhaul (parts replacement) before reaching 20,000 operation hours of the Manipulator. The operation hours can be checked in [Controller Status Viewer] dialog - [Motor On Hours]. For details, refer to 2.2 Overhaul (Parts Replacement). G series Maintenance Rev.3...
  • Page 499 A rigid, ring-shaped body with gear teeth on the inner circumference. The circular spline has two more teeth than the flexspline does. The splines are greased. Be sure to keep the grease from being attaching to the clothes. G series Maintenance Rev.3...

  • Page 500: Parts By Environment Model

    RC700-A, R12NZ900JX － Straight RC700-A, R12NZ900K1 － L-shaped R12NZ90027 R12B020426 RC180 RC700-A, R12NZ900JY － M/C Cable S, C Straight RC700-A, R12NZ900K2 － L-shaped R12NZ90028 R12B020427 RC180 RC700-A, R12NZ900JZ － 10 m Straight RC700-A, R12NZ900K3 － L-shaped G series Maintenance Rev.3...
  • Page 501 Manipulator. The operation hours can be checked in [Controller Status Viewer] dialog - [Motor On Hours]. For details, refer to 2.2 Overhaul (Parts Replacement). *5 The bellows are provided in a unit of two pieces. The shape varies between the upper and lower bellows. G series Maintenance Rev.3...
  • Page 502 G10 G20 Maintenance 15. G10/G20 Maintenance Parts List G series Maintenance Rev.3...

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