Epson G-Series User manual

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

G series Maintenance Manual Rev.3

G series Maintenance Rev.3 i
Industrial Robot: SCARA Robots
G series Maintenance Manual
Rev.3
Seiko Epson Corporation 2021-2022

ii G series Maintenance Rev.3
FOREWORD
Thank you for purchasing our robot products.
This manual contains the information necessary for the correct use of the robot controller.
Please carefully read this manual and other related manuals before installing the robot
system.
Keep this manual handy for easy access at all times.
The robot system and its optional parts are shipped to our customers only after being
subjected to the strictest quality controls, tests, and inspections to certify its compliance with
our high performance standards. Please note that the basic performance of the product will
not be exhibited if our robot system is used outside of the usage conditions and product
specifications described in the manuals.
This manual describes possible dangers and consequences that we can foresee. Be sure to
comply with safety precautions on this manual to use our robot system safety and correctly.
TRADEMARKS
Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries. Other brand and
product names are trademarks or registered trademarks of the respective holders.
NOTICE
No part of this manual may be copied or reproduced without authorization.
The contents of this manual are subject to change without notice.
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 iii
DISPOSAL
When disposing this product, dispose in accordance with the laws and regulations of each
country.
Regarding battery disposal
The battery removal/replacement procedure is described in the following manuals:
Maintenance Manual
For European Union customers only
The crossed out wheeled bin label that can be found on your product indicates that this
product and incorporated batteries should not be disposed of via the normal household waste
stream. To prevent possible harm to the environment or human health please separate this
product and its 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. Use
of the chemical symbols Pb, Cd or Hg indicates if these metals are used in the battery.
This information only applies to customers in the European Union, according to
DIRECTIVE 2006/66/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and
accumulators and repealing Directive 91/157/EEC and legislation transposing and
implementing it into the various national legal systems.
For other countries, please contact your local government to investigate the possibility of
recycling your product.
For Taiwanese customers only
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.

iv G series Maintenance Rev.3
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
RC700-A Control Unit
Drive Unit
EPSON RC+ 7.0 Ver.7.1.2 or later
The motions of the manipulators such as in emergency stops vary depending on the
Controllers since they have different control methods. Details are described in the manual.
Setting by Using Software
EPSON
RC+
This manual contains setup procedures using the software.
Those sections are indicated by the symbol on the left.
Turning ON/OFF Controller
When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to turn
ON/OFF all the hardware components.
Shape of Motors
The shape of the motors used for the Manipulator that you are using may be different from
the shape of the motors described in this manual because of the specifications.
Photos and Illustrations Used in This Manual
The appearance of some parts may differ from those on an actual product depending on
when it was shipped or the specifications. The procedures themselves, however, are accurate.
Figures in this Manual
The figures of manipulators indicated in this manual are basically Standard-model
Manipulator. Unless special instruction is provided, the specifications of Standard-model
and Cleanroom-model are the same.

G series Maintenance Rev.3 v
The Manuals of This Product
The following are typical manual types for this product and an outline of the descriptions.
Safety Manual (book, PDF)
This manual contains safety information for all people who handle this product. The
manual also describes the process from unpacking to operation and the manual you should
look at next.
Read this manual first.
-Safety precautions regarding robot system and residual risk
-Declaration of conformity
-Training
-Flow from unpacking to operation
RC700 series Manual (PDF)
This manual explains the installation of the entire robot system and the specifications and
functions of the controller. The manual is primarily intended for people who design robot
systems.
-The installation procedure of the robot system (specific details from unpacking
to operation)
-Daily inspection of the controller
-Controller specifications and basic functions
G series Manual (PDF)
This manual describes the specifications and functions of the Manipulator. The manual is
primarily intended for people who design robot systems.
-Technical information, functions, specifications, etc. required for the
Manipulator installation and design
-Daily inspection of the Manipulator
Status Code/Error Code List (PDF)
This manual contains a list of code numbers displayed on the controller and messages
displayed in the software message area. 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.
-Daily inspection
-Replacement and repair of maintenance parts
-The method of firmware update and controller setting backup etc.

vi G series Maintenance Rev.3
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.

Table of Contents
G series Maintenance Rev.3 vii
G1 series Maintenance
1. Safety Maintenance 3
2. General Maintenance 4
2.1 Maintenance Inspection ............................................................................. 4
2.1.1 Schedule for Maintenance Inspection ............................................. 4
2.1.2 Inspection Point ............................................................................... 5
2.2 Overhaul (Parts Replacement)................................................................... 6
2.3 Greasing ..................................................................................................... 8
Greasing the Ball Screw Spline Unit ........................................................... 9
2.4 Tightening Hexagon Socket Head Cap Bolts........................................... 13
2.5 Matching Origins ...................................................................................... 13
2.6 Layout of Maintenance Parts ................................................................... 14
2.6.1 4-axis spec..................................................................................... 14
2.6.2 3-axis spec..................................................................................... 15
3. Covers 16
3.1 Arm Top Cover.......................................................................................... 17
3.2 Connector Plate........................................................................................ 18
3.3 Connector Sub Plate ................................................................................ 19
3.4 User Plate................................................................................................. 19
4. Cable 20
4.1 Replacing Cable Unit................................................................................ 21
4.2 Wiring Diagrams....................................................................................... 27
4.2.1 Signal Cable................................................................................... 27
4.2.2 Power Cable................................................................................... 28
4.2.3 User Cable ..................................................................................... 29
4.3 Replacing M/C Cable ............................................................................... 30
5. Joint #1 32
5.1 Replacing Joint #1 Motor.......................................................................... 33
5.2 Replacing Joint #1 Reduction Gear Unit.................................................. 36
6. Joint #2 37
6.1 Replacing Joint #2 Motor.......................................................................... 38
6.2 Replacing Joint #2 Reduction Gear Unit.................................................. 40

Table of Contents
viii G series Maintenance Rev.3
7. Joint #3 44
7.1 Replacing Joint #3 Motor ..........................................................................45
7.2 Replacing the Timing Belt .........................................................................49
7.3 Replacing the Brake..................................................................................51
7.4 Setting the Mechanical Stop of Joint #3 ...................................................52
8. Joint #4 54
8.1 Replacing Joint #4 Motor ..........................................................................55
8.2 Replacing the Timing Belt .........................................................................59
9. Bellows 61
9.1 Replacing the Bellows (4-axis spec).........................................................62
9.2 Replacing the Bellows (3-axis spec).........................................................64
10. Ball Screw Spline Unit 66
10.1 Replacing the ball screw spline unit (4-axis spec)..................................67
10.2 Replacing the ball screw spline unit (3-axis spec)..................................70
11. Lithium Battery 73
11.1 Replacing the Battery Unit (Lithium Battery)...........................................75
11.2 Replacing the Battery Board ...................................................................76
12. LED Lamp 78
13. Calibration 79
13.1 About Calibration.....................................................................................79
13.2 Calibration Procedure .............................................................................80
13.3 Accurate Calibration of Joint #2..............................................................90
13.4 Calibration Procedure without using Calibration Wizard ........................92
14. Maintenance Parts List 96
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

Table of Contents
G series Maintenance Rev.3 ix
G3 series Maintenance
1. Safety Maintenance 101
2. General Maintenance 102
2.1 Maintenance Inspection ......................................................................... 102
2.1.1 Schedule for Maintenance Inspection ......................................... 102
2.1.2 Inspection Point ........................................................................... 103
2.2 Overhaul (Parts Replacement)............................................................... 104
2.3 Greasing ................................................................................................. 106
Greasing the Ball Screw Spline Unit ....................................................... 107
2.4 Tightening Hexagon Socket Head Cap Bolts..........................................111
2.5 Matching Origins .....................................................................................111
2.6 Layout of Maintenance Parts ..................................................................112
2.6.1 Table Top Mounting..................................................................... 112
2.6.2 Multiple Mounting......................................................................... 113
3. Covers 114
3.1 Arm Top Cover.........................................................................................116
3.2 Arm Bottom Cover...................................................................................117
3.3 Arm Cap ..................................................................................................118
3.4 Connector Plate.......................................................................................118
3.5 Connector Sub Plate ...............................................................................119
3.6 User Plate................................................................................................119
3.7 Heatsink Plate ........................................................................................ 120
3.8 Base Bottom Cover ................................................................................ 120
4. Cable 121
4.1 Replacing Cable Unit.............................................................................. 121
4.2 Wiring Diagrams..................................................................................... 126
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 #1 132
5.1 Replacing Joint #1 Motor........................................................................ 133
5.2 Replacing Joint #1 Reduction Gear Unit................................................ 137

Table of Contents
xG series Maintenance Rev.3
6. Joint #2 140
6.1 Replacing Joint #2 Motor ........................................................................141
6.2 Replacing Joint #2 Reduction Gear Unit.................................................145
7. Joint #3 148
7.1 Replacing Joint #3 Motor ........................................................................149
7.2 Replacing the Timing Belt .......................................................................153
7.3 Replacing the Brake................................................................................157
8. Joint #4 159
8.1 Replacing Joint #4 Motor ........................................................................160
8.2 Replacing the Timing Belt .......................................................................164
9. Replacing Arm #1 172
10. Bellows 179
11. Ball Screw Spline Unit 181
12. Lithium Battery 185
12.1 Replacing the Battery Unit (Lithium Battery) ........................................187
12.2 Replacing the Battery Board.................................................................189
13. LED Lamp 191
14. Calibration 192
14.1 About Calibration...................................................................................192
14.2 Calibration Procedure ...........................................................................193
14.3 Accurate Calibration of Joint #2............................................................203
14.4 Calibration Procedure without using Calibration Wizard ......................205
15. G3 Maintenance Parts List 209
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

Table of Contents
G series Maintenance Rev.3 xi
G6 series Maintenance
1. Safety Maintenance 215
2. General Maintenance 216
2.1 Maintenance Inspection ......................................................................... 216
2.1.1 Schedule for Maintenance Inspection ......................................... 216
2.1.2 Inspection Point ........................................................................... 217
2.2 Overhaul (Parts Replacement)............................................................... 218
2.3 Greasing ................................................................................................. 220
Greasing the Ball Screw Spline Unit ....................................................... 221
2.4 Tightening Hexagon Socket Head Cap Bolts......................................... 225
2.5 Matching Origins .................................................................................... 225
2.6 Layout of Maintenance Parts ................................................................. 226
2.6.1 Table Top Mounting type ............................................................. 226
2.6.2 Wall Mounting type ...................................................................... 227
2.6.3 Ceiling Mounting type .................................................................. 228
3. Covers 229
3.1 Arm Top Cover........................................................................................ 231
3.2 Arm Bottom Cover.................................................................................. 233
3.3 Arm #1 Cover ......................................................................................... 234
3.3.1 G6-***S* (Standard-model), G6-***C* (Cleanroom-model) ......... 234
3.3.2 G6-***D*/P* (Protected-model).................................................... 235
3.4 Connector Plate...................................................................................... 236
3.5 Connector Sub Plate .............................................................................. 238
3.6 User Plate............................................................................................... 239
3.7 Maintenance Plate.................................................................................. 239
3.8 Base Bottom Cover ................................................................................ 240
4. Cable 241
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 #1 259

Table of Contents
xii G series Maintenance Rev.3
5.1 Replacing Joint #1 Motor ........................................................................260
5.2 Replacing Joint #1 Reduction Gear Unit.................................................262
6. Joint #2 265
6.1 Replacing Joint #2 Motor ........................................................................266
6.2 Replacing Joint #2 Reduction Gear Unit.................................................269
7. Joint #3 272
7.1 Replacing Joint #3 Motor ........................................................................273
7.2 Replacing the Timing Belt .......................................................................277
7.3 Replacing the Brake................................................................................280
8. Joint #4 283
8.1 Replacing Joint #4 Motor ........................................................................284
8.2 Replacing the Timing Belt .......................................................................288
8.3 Replacing the Brake................................................................................296
9. Bellows 298
10. Ball Screw Spline Unit 301
11. Lithium Battery 307
11.1 Replacing the Battery Unit (Lithium Battery).........................................309
11.2 Replacing the Battery Board .................................................................310
12. LED Lamp 312
13. Calibration 313
13.1 About Calibration...................................................................................313
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 330
14.1 Common Parts ......................................................................................330
14.2 Parts by Environment Model.................................................................332

Table of Contents
G series Maintenance Rev.3 xiii
G10 G20 series Maintenance
1. Safety Maintenance 337
2. General Maintenance 338
2.1 Maintenance Inspection ......................................................................... 338
2.1.1 Schedule for Maintenance Inspection ......................................... 338
2.1.2 Inspection Point ........................................................................... 339
2.2 Overhaul (Parts Replacement)............................................................... 340
2.3 Greasing ................................................................................................. 342
2.3.1 Greasing the Ball Screw Spline Unit............................................ 343
2.3.2 Greasing Joint #4 Backlash-less gear (G10 only) ....................... 347
2.4 Tightening Hexagon Socket Head Cap Bolts......................................... 348
2.5 Matching Origins .................................................................................... 348
2.6 Layout of Maintenance Parts ................................................................. 349
2.6.1 Table Top Mounting type ............................................................. 349
2.6.2 Wall Mounting type ...................................................................... 351
2.6.3 Ceiling Mounting type .................................................................. 353
2.6.4 G10-65***: For S/N: 1**** or later ................................................ 355
3. Covers 356
3.1 Arm Top Cover........................................................................................ 358
3.2 Arm Bottom Cover.................................................................................. 360
3.3 Arm #1 Cover ......................................................................................... 361
3.3.1 G10/G20-***S* (Standard-model), G10/G20-***C* (Cleanroom-
model) ...................................................................................................... 361
3.3.2 G10/G20-***D*, P* (Protected-model) ......................................... 362
3.4 Connector Plate...................................................................................... 363
3.5 Connector Sub Plate .............................................................................. 364
3.6 User Plate............................................................................................... 365
3.7 Maintenance Plate.................................................................................. 365
3.8 Base Bottom Cover ................................................................................ 366
4. Cable 367
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

Table of Contents
xiv G series Maintenance Rev.3
4.3 Replacing M/C Cable ..............................................................................383
5. Joint #1 386
5.1 Replacing Joint #1 Motor ........................................................................387
5.2 Replacing Joint #1 Reduction Gear Unit.................................................389
6. Joint #2 392
6.1 Replacing Joint #2 Motor ........................................................................393
6.2 Replacing Joint #2 Reduction Gear Unit.................................................398
7. Joint #3 401
7.1 Replacing Joint #3 Motor ........................................................................402
7.2 Replacing the Timing Belt .......................................................................406
7.2.1 Replacing the Timing Belt : G10...................................................407
7.2.2 Replacing the Timing Belt : G20...................................................411
7.3 Replacing the Brake................................................................................412
8. Joint #4 414
8.1 Replacing Joint #4 Motor ........................................................................415
8.1.1 Replacing the Joint #4 Motor: G10...............................................415
8.1.2 Replacing the Joint #4 Motor: G20...............................................419
8.2 Replacing the Timing Belt .......................................................................421
8.2.1 Replacing the Timing Belt: G10....................................................422
8.2.2 Replacing the Timing Belt: G20....................................................426
8.3 Replacing the Brake................................................................................431
8.4 Replacing the Reduction Gear Unit ........................................................434
8.4.1 Replacing the Reduction Gear Unit (Gear): G10 .........................434
8.4.2 Replacing the Reduction Gear Unit: G20.....................................435
9. Bellows 437
10. Ball Screw Spline Unit 440
10.1 Replacing the Ball Screw Spline Unit: G10 ..........................................441
10.2 Replacing the Ball Screw Spline Unit: G20 ..........................................448
11. Lithium Battery 453
11.1 Replacing the Battery Unit (Lithium Battery).........................................455

Table of Contents
G series Maintenance Rev.3 xv
11.2 Replacing the Battery Board ................................................................ 457
12. LED Lamp 459
13. Radiating Unit 461
14. Calibration 463
14.1 About Calibration.................................................................................. 463
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 480
15.1 Common Parts...................................................................................... 480
15.2 Parts by Environment Model ................................................................ 482

Table of Contents
xvi G series Maintenance Rev.3

G1 Maintenance
This volume contains maintenance procedures with safety precautions for Manipulators.