Page 1 SCARA ROBOT GX4 Series Service Manual Rev. 6 ENSM232R0002...
Page 2 The company names and product names described in this service reference are the trademarks or registered trademarks of the  respective company. EPSON is the registered trademark of Seiko Epson Corporation. Other product names are trademarks or registered trademarks of the respective company. © Seiko Epson Corporation. 2024 ©...
Page 3: Revision History
If, even after the establishment and issue of the first edition of this manual, changes are made in the mechanism or parts of the product with the purpose of improving the performance and reliability, revised editions shall be issued as necessary © Seiko Epson Corporation. 2024 Rev.6...
Page 4: Table Of Contents
2.2.1 Removing the Joint #1 Motor Unit 2.6.2 Installing the Bellows 2.2.2 Installing the Joint #1 Motor Unit 2.7 Ball Screw Spline Unit 2.2.3 Disassembling the Joint #1 Motor Unit 2.7.1 Removing the Ball Screw Spline Unit © Seiko Epson Corporation. 2024 Rev.6...
Page 5 3.1.6.2 Implementing Calibration Only using the Wizard 3.1.6.3 Implementing Joint Accuracy Calibration Only 3.1.6.4 Accurate Calibration of Joint #2 3.1.6.5 Calibration Using Right / Left Arm Orientations 3.1.6.6 Calibration Procedure without Using Calibration Wizard 3.1.7 Verification © Seiko Epson Corporation. 2024 Rev.6...
Page 6: Chapter 1 Maintenance Information
CHAPTER Maintenance Information...
Page 7: Safety Maintenance
Be sure to turn off the power and tag out (e.g., with a "DO NOT TURN ON" sign) before performing wiring.  Performing any work procedure with the power turned on is extremely dangerous and may result in electric shock and/or malfunction of the robot system. WARNING © Seiko Epson Corporation. 2024 Rev.6...
Page 8 If swallowed, do not induce vomiting. See a doctor immediately. If grease just gets into your mouth, wash out your mouth with water thoroughly. - If grease gets on your skin Wash the area thoroughly with soap and water. © Seiko Epson Corporation. 2024 Rev.6...
Page 9: General Maintenance
(2,000 h) √ 9 months (2,250 h) √ √ 10 months (2,500 h) √ 11 months (2,750 h) √ 12 months (3,000 h) √ √ √ √ √ 13 months (3,250 h) 20,000 h √ © Seiko Epson Corporation. 2024 Rev.6...
Page 10: Inspection Point
Check that there is no unusual sound or vibration during operation, no stiffness or looseness in the sliding parts or moving parts, and that the Check whether unusual sound or vibration operation is performed smoothly. occurs. If an abnormality is suspected, replace the part in which the abnormality has occurred. © Seiko Epson Corporation. 2024 Rev.6...
Page 11: Overhaul (Parts Replacement)
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 Gears, Timing Belts, and Ball Screw Spline Unit) can be checked in the [Maintenance] dialog box of the EPSON RC+ 7.0.
Page 12 GX4 Series Service Manual Maintenance Information How to View the Maintenance Information The configured maintenance information can be checked in the EPSON RC+ 7.0 Ver.7.2.x or later. （１） Select the EPSON RC+ 7.0 menu-[Tools]- （3） Select “General” or specify the axis from the tree to [Maintenance] to display the [Controller Tools] dialog display information of the target parts.
Page 13: How To Edit The Maintenance Information
How to Edit the Maintenance Information The configured maintenance information can be edited in the EPSON RC+ 7.0 Ver.7.2.x or later. When replaced the parts subject to maintenance (Motors, Reduction Gears, Timing Belts, and Ball screw spline) or greased to Joint #3 Ball Screw Spline Unit, please edit the Maintenance Information.
Page 14 (3) Select the folder where the information is stored. (4) Click <OK> to view the [Controller Status Viewer] dialog. (5) Select [Robots] from the tree menu on the left side (Dialog image: EPSON RC+ 7.0) © Seiko Epson Corporation. 2024...
Page 15: Tools
For wiping grease from the J1/J2 Reduction Gear and the Ball Screw Spline Sonic Belt Tension Meter 3.2 Adjusting the Timing Belt Tension Force gauge 3.2 Adjusting the Timing Belt Tension Suitable cord (Length about 800 mm) 3.2 Adjusting the Timing Belt Tension © Seiko Epson Corporation. 2024 Rev.6...
Page 16: Materials Used
Proper quantity For details, refer to 1.2.5 Greasing. Alcohol Proper quantity For wiping grease from the J1/J2 Reduction Gear and the Ball Screw Spline AB100 Wire tie AB150 Proper quantity Fixing the cables AB200 © Seiko Epson Corporation. 2024 Rev.6...
Page 17: 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 18 The manufacturer and URL details of each grease type are as follows: Product name: THK AFB-LF Grease Manufacturer: THK CO., LTD. URL: https://www.thk.com/ Product name: Harmonic Grease SK-1A Manufacturer: Harmonic Drive Systems Inc. URL: https://www.harmonicdrive.net/ Product name: Krytox®GPL-224 Manufacturer: Chemours URL: https://www.chemours.com/en/brandsand-products © Seiko Epson Corporation. 2024 Rev.6...
Page 19: Tightening Bolts/Screws
Cross recessed pan head screw (Cable fixing plates, etc.) 0.9 +/- 0.1 0.7 +/- 0.1 Hexagon socket head set screw 2.4 +/- 0.1 4.0 +/- 0.2 Hexagon socket low head cap screw M2.5 1.0 +/- 0.1 © Seiko Epson Corporation. 2024 Rev.6...
Page 20 Do not fasten all bolts securely at one time. Divide the number of times that the bolts are fastened into two or three and fasten the bolts securely with a hexagonal wrench. Then, use a torque wrench so that the bolts are fastened with tightening torques shown in the table above. © Seiko Epson Corporation. 2024 Rev.6...
Page 21: Matching Origins
After parts have been replaced (motors, Reduction Gears, etc.), the Manipulator cannot operate properly because a mismatch exists between the origin stored in each motor and its corresponding origin stored in the Controller. After replacing the parts, perform the calibration to match these origins. For details, refer to Calibration. © Seiko Epson Corporation. 2024 Rev.6...
Page 22: Parts Layout
Cable Duct Cover Joint #2 Motor Z belt Joint #2 Reduction Gear U1 belt M/C connector Rubber Gasket Control Board Joint #1 Bellows Reduction Gear U2 belt Joint #1 Motor DC/DC Board Fan 1 © Seiko Epson Corporation. 2024 Rev.6...
Page 23: Multiple Mounting
Joint #4 Motor Arm2 Upper Cover DC/DC Board Fan 1 Z belt Joint #1 Motor U1 belt Rubber Gasket Joint #2 Motor U2 belt Joint #1 Reduction Joint #2 Control Board Gear Reduction Gear Bellows © Seiko Epson Corporation. 2024 Rev.6...
Page 24: Cable Downward
Arm2 Upper Cover Joint #2 Motor U2 belt Z belt Joint #2 Reduction Gear U1 belt Rubber Gasket Joint #1 Reduction Gear Bellows Fan 1 Control Board Joint #1 Motor DC/DC Board M/C connector © Seiko Epson Corporation. 2024 Rev.6...
Page 25: Differences From The Table Top Mounting
Maintenance Information GX4 Series Service Manual 1.4 Differences from the Table Top Mounting 1.4.1 Base Unit Table top mounting: GX4-***S Multiple mounting: GX4-***SM Cable downward: GX4-***SB © Seiko Epson Corporation. 2024 Rev.6...
Page 26: Arm 1 Unit
GX4 Series Service Manual Maintenance Information 1.4.2 Arm 1 Unit Table top mounting: GX4-***S Multiple mounting: GX4-***SM Cable downward: GX4-***SB © Seiko Epson Corporation. 2024 Rev.6...
Page 27: Base Connector Unit
GX4 Series Service Manual Maintenance Information 1.4.3 Base Connector Unit Table top mounting: GX4-***S Multiple mounting: GX4-***SM Cable downward: GX4-***SB © Seiko Epson Corporation. 2024 Rev.6...
Page 28: Cable Unit/Cable Duct Unit
GX4 Series Service Manual Maintenance Information 1.4.4 Cable Unit/Cable Duct Unit Table top mounting: GX4-***S Multiple mounting: GX4-***SM Cable downward: GX4-***SB © Seiko Epson Corporation. 2024 Rev.6...
Page 29: Cover Unit
GX4 Series Service Manual Maintenance Information 1.4.5 Cover Unit Table top mounting: GX4-***S Cable downward: GX4-***SB © Seiko Epson Corporation. 2024 Rev.6...
Page 30: Chapter 2 Maintenance
CHAPTER Maintenance...
Page 31: Overview
• When applying grease, take care that the grease does not adhere on to the surrounding parts. Oil separation of the surrounding grease may result in oil leakage. Therefore, be sure to wipe off any adhering grease. © Seiko Epson Corporation. 2024 Rev.6...
Page 32: Viewing The Maintenance Page
[Alt] key and the [←] key. viewer. For details, refer to Help of each viewer. * The operation method may differ depending on the viewer. For details, refer to Help of each viewer. © Seiko Epson Corporation. 2024 Rev.6...
Page 33: Joint #1
S01: 4-M4x10 Removing the connectors Step 3 CN311-1 CN111-1 Joint #1 Motor Connector Step 4 Front Cover S04: 4-M4x8 Step 6 Joint #1 Motor unit S01: 4-M4x12 Step 5 Base Bottom Cover S01: 4-M4x10 © Seiko Epson Corporation. 2024 Rev.6...
Page 34 (keep the DC/DC Board on the upper side so that the Step 6 components on the board do not get damaged). Joint #1 Motor unit S01: 4-M4x12 Step 5 Base Bottom Cover S01: 4-M4x10 DC/DC Board © Seiko Epson Corporation. 2024 Rev.6...
Page 35 O-ring Step 5 • Grease may drop from the Waveform Generator. Take care Base Bottom Cover that it does not adhere on to the surrounding parts. S01: 4-M4x10 © Seiko Epson Corporation. 2024 Rev.6...
Page 36 Multiple Mounting Table Top Mounting S01: 4-M4x10 Step 3 Joint #1 Motor Connector Step 4 Front Cover S04: 4-M4x8 Step 6 Joint #1 Motor unit S01: 4-M4x12 Step 5 Base Bottom Cover S01: 4-M4x10 © Seiko Epson Corporation. 2024 Rev.6...
Page 37: Installing The Joint #1 Motor Unit
Waveform Generator Step 3 Front Cover S04: 4-M4x8 4.0 +/-0.2 N·m Step 1 Spatula Motor unit Joint #1 Motor unit S01: 4-M4x12 4.0 +/-0.2 N·m Step 2 Base Bottom Cover S04: 4-M4x10 0.9 +/-0.1 N·m © Seiko Epson Corporation. 2024 Rev.6...
Page 38 (Turn back and forth three times by approximately 90° each time.) Step 2 After the completion of centering, fully Base Bottom Cover tighten the bolts. S04: 4-M4x10 0.9 +/-0.1 N·m © Seiko Epson Corporation. 2024 Rev.6...
Page 39 S01: 4-M4x12 4.0 +/-0.2 N·m Joint #1 Motor unit Heat Radiation Sheet Step 2 CAUTION Base Bottom Cover After assembling the motor unit, perform calibration of Joint #1. S01: 4-M4x10 3.1 Calibration 0.9 +/-0.1 N·m © Seiko Epson Corporation. 2024 Rev.6...
Page 40: Disassembling The Joint #1 Motor Unit
Note for Multiple Mounting The Multiple Mounting type has no Oil Seal because the J1 Motor Unit is attached in the opposite direction and there is no possibility of grease getting inside the motor. © Seiko Epson Corporation. 2024 Rev.6...
Page 41: Assembling The Joint #1 Motor Unit
Motor Unit is attached in the opposite direction and there is no possibility of grease getting inside the motor. • Perform centering when installing the Joint #1 Motor unit into the Manipulator. Here, temporarily tighten the bolts. © Seiko Epson Corporation. 2024 Rev.6...
Page 42 Waveform Generator and Flexspline may deviate, and the performance of the Reduction Gear may not be sufficiently exhibited. Waveform Generator S05: 2-M5x6 Motor shaft Joint #1 Motor unit 0.5±0.1 mm Screws D-Cut © Seiko Epson Corporation. 2024 Rev.6...
Page 43: Removing The Joint #1 Reduction Gear Unit
Remove the bolts to remove Arm1 from the Base. Step 4 O-ring Step 2 Cable Duct S01: 4-M4x10 Base Arm1 Step 3 Bolts CAUTION Arm1 Remove the arm carefully so that it does not hit other parts. S02: 16-M4x20 and washer © Seiko Epson Corporation. 2024 Rev.6...
Page 44 Arm1 after the Arm1 bolts have been S02: 8-M4x40 and washer removed. S02: 4-M3x18 and washer Arm1 Step 4 O-ring Step 2 Cable Duct Bolts S01: 4-M4x10 Joint #1 Reduction Gear Unit Step 3 Arm1 S02: 16-M4x20 and washer © Seiko Epson Corporation. 2024 Rev.6...
Page 45: Installing The Joint #1 Reduction Gear Unit
Take care not to damage the O-ring, when inserting into O-ring the groove. Step 6 O-ring Cable Duct S01: 4-M4x10 4.0 +/-0.2 N·m Joint #1 Step 4 Reduction Gear Unit Arm1 S02: 16-M4x20 and washer 5.5 +/-0.25 N·m © Seiko Epson Corporation. 2024 Rev.6...
Page 46 Base. (Refer to below figure) Step 1 O-ring Step 6 Cable Duct S01: 4-M4x10 4.0 +/-0.2 N·m Step 4 Arm1 Reduction Gear Unit Base S02: 16-M4x20 and washer 5.5 +/-0.25 N·m © Seiko Epson Corporation. 2024 Rev.6...
Page 47 After assembling apply grease to the flexspline as shown in 2.4 +/-0.1 N·m the figure below. SK-1A: 30g Step 1 Base Spatula O-ring Step 6 Cable Duct S01: 4-M4x10 4.0 +/-0.2 N·m Step 4 Arm1 S02: 16-M4x20 and washer 5.5 +/-0.25 N·m © Seiko Epson Corporation. 2024 Rev.6...
Page 48 Step 1 O-ring Step 6 Cable Duct S01: 4-M4x10 4.0 +/-0.2 N·m Step 4 CAUTION Arm1 After assembling the motor unit, perform calibration of Joint #1. S02: 16-M4x20 and washer 3.1 Calibration 5.5 +/-0.25 N·m © Seiko Epson Corporation. 2024 Rev.6...
Page 49: Joint #2
S01: 3-M4x10 User Plate Support can be moved. By freeing the User Plate and the User Plate Support, the connectors can be easily detached or attached. User Plate Step 4 Grease supply part S01: 2-M4x10 © Seiko Epson Corporation. 2024 Rev.6...
Page 50: Removing The Connectors
Joint #4 Intermediate Pulley Unit S01: 3-M4x16 CN440-1 Step 6 Joint #2 Motor unit S01: 3-M4x15 CN3G0-2 CN430-1 S04: 3-M4x6 with Washer Step 2 User Plate S01: 3-M4x10 Step 4 Grease supply part S01: 2-M4x10 © Seiko Epson Corporation. 2024 Rev.6...
Page 51 • The Heat Radiation Sheet is set on the top surface of the Step 2 Joint #2 Motor unit. Remove it while taking care not to User Plate damage it. S01: 3-M4x10 Step 4 Heat Radiation Grease supply part Sheet S01: 2-M4x10 © Seiko Epson Corporation. 2024 Rev.6...
Page 52 If the Greasing port is removed, it becomes easier to remove the Joint #2 Motor unit. Step 2 User Plate S01: 3-M4x10 Greasing port Joint #2 Step 4 Motor unit Grease supply part S01: 2-M4x10 © Seiko Epson Corporation. 2024 Rev.6...
Page 53: Installing The Joint #2 Motor Unit
Before installing, apply grease at the location shown in the Step 1 figure. Joint #2 Motor unit S01: 3-M4x15 SK-1A: 9g Spatula 4.0 +/-0.2 N·m Waveform Generator Step 4 User Plate S01: 3-M4x10 4.0 +/-0.2 N·m Motor unit © Seiko Epson Corporation. 2024 Rev.6...
Page 54 (Turn back and forth three times by 4.0 +/-0.2 N·m approximately 90° each time.) After centering is completed, tighten the bolts on the motor unit. 90° Step 4 User Plate S01: 3-M4x10 4.0 +/-0.2 N·m 90° © Seiko Epson Corporation. 2024 Rev.6...
Page 55 • Heat Radiation Sheet is attached to the User Plate. Be 4.0 +/-0.2 N·m careful not to damage the sheet. Step 4 User Plate User Plate S01: 3-M4x10 4.0 +/-0.2 N·m Heat Radiation Sheet © Seiko Epson Corporation. 2024 Rev.6...
Page 56 User Plate with Silicone Sheet and then fix the a wire tie (AB100). connectors on the User Plate with a wire tie (AB100). Step 4 User Plate User Plate S01: 3-M4x10 4.0 +/-0.2 N·m CN321-1 CN121-1 © Seiko Epson Corporation. 2024 Rev.6...
Page 57 Wrap the connector with the Silicone Sheet and fix the connector to the User Plate with a wire tie (AB100). Step 1 Joint #2 Motor unit S01: 3-M4x15 4.0 +/-0.2 N·m Silicone Sheet Step 4 User Plate CN331-2 S01: 3-M4x10 4.0 +/-0.2 N·m Wire tie © Seiko Epson Corporation. 2024 Rev.6...
Page 58 Wrap the connector with the Silicone Sheet and fix the connector Step 1 to the User Plate with a wire tie (AB100). Joint #2 Motor unit S01: 3-M4x15 4.0 +/-0.2 N·m CN430-1 Step 4 User Plate S01: 3-M4x10 4.0 +/-0.2 N·m CN440-1 CN3G0-2 © Seiko Epson Corporation. 2024 Rev.6...
Page 59 Joint #4 Intermediate Pulley Unit User Plate Step 1 Joint #2 Motor unit S01: 3-M4x15 4.0 +/-0.2 N·m Step 4 User Plate S01: 3-M4x10 4.0 +/-0.2 N·m CAUTION After assembling, perform calibration of Joint #2. 3.1 Calibration © Seiko Epson Corporation. 2024 Rev.6...
Page 60: Disassembling The Joint #2 Motor Unit
Reduction Gear side. Be Step 2 sure to remove it. Waveform Generator S05: 2-M4x6 O-ring Step 3 Connecting shaft 05: 2-M4×6 Step 4 Motor Plate S01: 2-M4x12 and washer Joint #2 Motor unit © Seiko Epson Corporation. 2024 Rev.6...
Page 61: Assembling The Joint #2 Motor Unit
Joint #2 Motor unit connectors after the motor is fixed in the arm. Groove Motor installation position Joint #2 Motor Motor Plate Grease nozzle The connector is on the right side of the motor. © Seiko Epson Corporation. 2024 Rev.6...
Page 62 S01: 2-M4x12 and washer CAUTION 4.0 +/-0.2 N.m As shown in the figure, secure the Waveform Generator with screws to match the D-Cut of the extension shaft. Extension shaft Joint #2 Motor unit Waveform Generator D-Cut © Seiko Epson Corporation. 2024 Rev.6...
Page 63: Removing The Joint #2 Reduction Gear Unit
Remove the bolts on the underneath of Arm1 and then remove the Reduction Gear Unit. Reduction Gear Unit Step 3 Reduction Gear Unit S02: 4-M3x18 and washer S02: 8-M3x40 and washer Arm1 Arm1 bottom surface S02: 4-M3x18 and Washer S02: 8-M3x40 and Washer © Seiko Epson Corporation. 2024 Rev.6...
Page 64 The O-ring attached to the Joint #2 Reduction O-ring Gear Unit may be attached to Arm1. Be sure to remove it. O-ring Step 3 Arm1 Reduction Gear Unit S02: 4-M3x18 and washer S02: 8-M3x40 and washer © Seiko Epson Corporation. 2024 Rev.6...
Page 65: Installing The Joint #2 Reduction Gear Unit
Reduction Gear Unit. O-ring CAUTION Take care not to damage the O-ring, when inserting into the groove. O-ring Step 4 Arm1 Arm2 S02: 16-M3x20 and washer 2.4 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 66 Reduction Gear Unit Arm1 Tighten the bolts on the underneath of Arm1 to fix the Step 4 Reduction Gear Unit to Arm1. Arm2 S02: 4-M3x18 and Washer S02: 16-M3x20 S02: 8-M3x40 and Washer 2.4 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 67 • Tighten the remaining bolts after temporarily tightening the four bolts located diagonally opposite each other. • Tighten the bolts while supporting Arm2 so that it does not fall. Step 4 Arm2 S02: 16-M3x20 and washer 2.4 +/-0.1 N.m Arm2 © Seiko Epson Corporation. 2024 Rev.6...
Page 68 SK-1A: 22 g Before installing, apply grease at the location shown in the figure. Spatula Step 4 Arm2 S02: 16-M3x20 and washer 2.4 +/-0.1 N.m CAUTION After assembling, perform calibration of Joint #2. 3.1 Calibration © Seiko Epson Corporation. 2024 Rev.6...
Page 69: Joint #3
Arm2 Cover S04: 6-M4x12 S03: 4-M4x20 Removing the connectors Step 2 Connectors and cables User Plate Step 3 Joint #3 Motor unit CN131-1 S01: 3-M4x20 with captive washer CN331-1 Joint #3 Motor unit CN430-1 © Seiko Epson Corporation. 2024 Rev.6...
Page 70 Step 3 Joint #3 Motor unit S01: 3-M4x20 with captive washer User Plate Support Joint #3 Motor unit POINT When removing the Timing Belt from the pulley, tilt the motor unit and then remove. © Seiko Epson Corporation. 2024 Rev.6...
Page 71: Installing The Joint #3 Motor Unit
Step 1 Joint #3 Motor unit S01: 3-M4x20 with captive washer 4.0 +/-0.2 N.m Brake cable 3) Arrange and connect the Joint #3 Motor unit brake connector as shown in the figure below. (CN430-1) CN430-1 © Seiko Epson Corporation. 2024 Rev.6...
Page 72 Temporarily tighten the motor unit fixing bolts until the motor unit can slide freely to adjust the belt tension. Belt tension adjustment Adjust the belt tension after installing the motor unit. 3.2 Adjusting the Timing Belt Tension © Seiko Epson Corporation. 2024 Rev.6...
Page 73 Wrap the signal connector with the Silicone Sheet and fix the connector to the User Plate Support with a wire tie (AB100). Silicone Sheet User Plate Support CAUTION CN331-2 After performing the maintenance Wire tie procedure, perform calibration of Joint #3. 3.1 Calibration © Seiko Epson Corporation. 2024 Rev.6...
Page 74: Disassembling The Joint #3 Motor Unit
Motor pulley Brake plate S05: 2-M5x8 Step 4 Brake Unit Motor Plate S01: 2-M4x12 POINT To access the Motor fixing bolt, remove the wire ties securing the motor cables. Joint #3 Motor unit Motor cable © Seiko Epson Corporation. 2024 Rev.6...
Page 75: Assembling The Joint #3 Motor Unit
Motor Plate Fixing the motor cables S01:２-M4x12 Arrange the motor cables as shown in the figure and 4.0 +/-0.2 N.m fix them with wire ties (AB200). Joint #3 Motor unit Motor cable Wire tie © Seiko Epson Corporation. 2024 Rev.6...
Page 76 Motor pulley sufficiently exhibited. Screws S05:2-M5x8 4.0 +/-0.2 N.m Motor shaft Motor pulley Step 1 Motor Plate S01:２-M4x12 4.0 +/-0.2 N.m 0.5-mm D-Cut Joint #3 Motor unit Motor Plate © Seiko Epson Corporation. 2024 Rev.6...
Page 77 4.0 +/-0.2 N.m Pulley Brake plate R-chamfer (6 mm) Fix the Brake Unit on the shafts of the Motor Plate as shown Joint #3 Motor unit in the figure. Brake Unit Shaft Motor Plate © Seiko Epson Corporation. 2024 Rev.6...
Page 78: Joint #4
* Leave the wire tie in place and remove only the connectors S04: 3-M4x6 with Washer POINT Remove the bolts securing the User User Plate Plate so that the User Plate and the User Plate Support can be moved. © Seiko Epson Corporation. 2024 Rev.6...
Page 79 Support comes off from Arm2 and will be still connected to the Cable Duct. Move the User Plate and the User Plate Support to a location where it does not hit the arm or any material during maintenance. © Seiko Epson Corporation. 2024 Rev.6...
Page 80 POINT Step 4 When removing the Timing Belt from the pulley, tilt the Joint #4 Motor unit motor unit and then remove. S01: 3-M4x16 with captive washer Joint #4 Motor unit U1 Timing Belt © Seiko Epson Corporation. 2024 Rev.6...
Page 81: Installing The Joint #4 Motor Unit
Arrange the motor cables as shown in the figure and fix it with wire ties (AB200). Motor cables Wire tie Approx. 35 mm Fix the cables at approximately 35 mm from the upper end of the Motor Plate. © Seiko Epson Corporation. 2024 Rev.6...
Page 82 • The Heat Radiation Sheet may become attached to the User Plate or the Joint #2 Motor Unit. Be careful not to damage the sheet. User Plate Heat Radiation Sheet © Seiko Epson Corporation. 2024 Rev.6...
Page 83 Wrap the signal connector with the on the User Plate with a wire tie Silicone Sheet and fix the connector on (AB100). the User Plate with a wire tie (AB100). User Plate CN321-1 CN121-1 © Seiko Epson Corporation. 2024 Rev.6...
Page 84 4.0 +/-0.2 N.m CN331-1/CN331-2 (J3 Motor Signal) Wrap the signal connector with the Silicone Sheet and secure to the User Plate using a wire tie (AB100). Silicone sheet CN331-2 Wire tie S04: 3-M4x6 with Washer © Seiko Epson Corporation. 2024 Rev.6...
Page 85 Joint #4 Motor unit S01: 3-M4x16 with captive washer 4.0 +/-0.2 N.m CN440-1 CN3G0-2 CN430-1 CN3G0-2 (Control Board) Wrap the connector with the Silicone Sheet and secure it to the User Plate using a wire tie (AB100). © Seiko Epson Corporation. 2024 Rev.6...
Page 86 Replace the User Plate and the User Plate Support. Step 3 User Plate S01: 3-M4x10 User Plate 4.0 +/-0.2 N.m Step 1 Joint #4 Motor unit S01: 3-M4x16 with captive washer 4.0 +/-0.2 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 87: Replacing The Joint #4 Motor Unit
Step 2 Motor Plate S01: 2-M4x10 4.0 +/-0.2 N.m Joint #4 Motor unit * The disassembly procedure is described here. Perform assembly by following the disassembly procedure in the reverse order. © Seiko Epson Corporation. 2024 Rev.6...
Page 88 Approx. 35 mm Fix the cables at approximately 35 mm from the upper end of the Motor Plate. * The disassembly procedure is described here. Perform assembly by following the disassembly procedure in the reverse order. © Seiko Epson Corporation. 2024 Rev.6...
Page 89: Removing The Joint #4 Intermediate Pulley Unit
Support can be moved. By freeing the User Plate and the User Step 2 Plate Support, the connectors can be easily detached or attached. User Plate S01: 3-M4x10 User Plate Step 3 Connectors and cables © Seiko Epson Corporation. 2024 Rev.6...
Page 90 Intermediate Pulley Unit S01: 3-M4x16 with captive washer Step 2 User Plate S01: 3-M4x10 CN430-1/CN430-2 CN3G0-2 CN440-1/CN440-2 Silicone Sheet * Remove only the connectors Wire tie Step 3 Connectors and cables S04: 3-M4x6 with Washer © Seiko Epson Corporation. 2024 Rev.6...
Page 91 Arm2 and will still be connected to the Cable Duct. Move the Connectors and cables User Plate and the User Plate Support to a location where it does not hit the arm or any material during maintenance. © Seiko Epson Corporation. 2024 Rev.6...
Page 92 S01: 3-M4x16 with captive washer Intermediate Pulley Unit Step 2 User Plate POINT S01: 3-M4x10 When removing the Timing Belt from the pulley, tilt the Intermediate Pulley Unit and then remove. Step 3 Connectors and cables © Seiko Epson Corporation. 2024 Rev.6...
Page 93: Installing The Joint #4 Intermediate Pulley Unit
Intermediate Pulley Unit can slide freely to adjust the belt tension. Step 3 Connectors and cables Belt tension adjustment Adjust the tension of the U1 belt and U2 belt after installing the Intermediate Pulley Unit. 3.2 Adjusting the Timing Belt Tension © Seiko Epson Corporation. 2024 Rev.6...
Page 94 • The Heat Radiation Sheet may become attached to the User Plate or the Joint #2 Motor Unit. Be careful not to damage the sheet. Step 2 User Plate S01: 3-M4x10 User Plate 4.0 +/-0.2 N.m Step 2 Heat Radiation Sheet Connectors and cables © Seiko Epson Corporation. 2024 Rev.6...
Page 95 User Plate with a wire tie Sheet and fix the connector on the User (AB100). Plate with a wire tie (AB100). User Plate User Plate S01: 3-M4x10 4.0 +/-0.2 N.m CN321-1 Step 2 Connectors and cables CN121-1 © Seiko Epson Corporation. 2024 Rev.6...
Page 96 Sheet and secure it to the User Plate using a User Plate wire tie (AB100). S01: 3-M4x10 4.0 +/-0.2 N.m Silicone sheet Step 2 Connectors and cables CN331-2 Wire tie S04: 3-M4x6 with Washer © Seiko Epson Corporation. 2024 Rev.6...
Page 97 Step 2 CN3G0-2 User Plate Wrap the connector with the Silicone S01: 3-M4x10 Sheet and secure it to the User Plate 4.0 +/-0.2 N.m using a wire tie (AB100). Step 2 Connectors and cables © Seiko Epson Corporation. 2024 Rev.6...
Page 98 Intermediate Pulley Unit S01: 3-M4x16 with captive washer 4.0 +/-0.2 N.m Replace the User Plate and the User Plate Support. Step 2 User Plate User Plate S01: 3-M4x10 4.0 +/-0.2 N.m Step 2 Connectors and cables © Seiko Epson Corporation. 2024 Rev.6...
Page 99: Replacing The Joint #4 Intermediate Pulley Unit
Brake Unit cable Brake Hub Brake Hub Shaft Brake Unit * The disassembly procedure is described here. Perform assembly by following the Intermediate Intermediate disassembly procedure in the reverse Pulley Intermediate Pulley Pulley order. © Seiko Epson Corporation. 2024 Rev.6...
Page 100: Replacing The Joint #4 Timing Belt (U1)
Joint #4 Motor unit Intermediate Pulley Unit U1 Timing Belt U1 Timing Belt U2 Timing Belt * The disassembly procedure is described here. Perform assembly by following the disassembly procedure in the reverse order. © Seiko Epson Corporation. 2024 Rev.6...
Page 101: Removing The Timing Belt (U2/Z)
Belt. it to be removed more easily. U2 Timing Belt Step 5 Ball Screw U2 Timing Belt Spline Unit Step 3 Remove the bolts securing the Spline Plate S01: 3-M4x10 Spline Plate. Spline Plate © Seiko Epson Corporation. 2024 Rev.6...
Page 102: Installing The Timing Belt (U2/Z)
The Ball Screw Spline Unit will be positioned to the center of the arm. Spline Plate Step 3 Spline Plate S01: 3-M4x10 4.0 +/-0.2 N.m CAUTION After performing adjustment, fix the Spline Plate. © Seiko Epson Corporation. 2024 Rev.6...
Page 103: Bellows
Loosen Clamp band Loosen the Loosen the bolt Lower Holder Resin Ring clamp Clamp band Bellows (Urethane) Step 2 Resin ring Removing the Lower Bellows Clamp band Loosen the clamp Lower Holder S02: 1-M3x10 © Seiko Epson Corporation. 2024 Rev.6...
Page 104: Installing The Bellows
Installing the Lower Clamp band Bellows Stretch the bellows and Install the Lower set them into the resin Lower Holder Holder and tighten ring, and then tighten the the bolt. S02: 1-M3x10 Lower Holder clamp bands. © Seiko Epson Corporation. 2024 Rev.6...
Page 105 Tighten the clamp Tighten the clamp Resin ring Clamp band Bellows (Urethane) Resin ring Step 1 Installing the Lower Clamp band Bellows Lower Holder Stretch the bellows and set S02: 1-M3x10 them into the resin ring. © Seiko Epson Corporation. 2024 Rev.6...
Page 106: Ball Screw Spline Unit
POINT After removing the motor unit and Intermediate Pulley Step 6 Unit, remove the Timing Belts (Z, U1, U2) from the arm. Ball Screw Spline Unit S01: 4-M4x10 Step 5 Under Cover S03: 4-M4x12 © Seiko Epson Corporation. 2024 Rev.6...
Page 107 Spline on the underneath of Arm2, then the Ball Screw Spline Unit can be removed from Arm2. Step 6 Ball Screw Spline Unit S01: 3-M4x10 S01: 4-M4x10 Step 5 Under Cover Shaft S03: 4-M4x12 Ball Screw Spline Unit © Seiko Epson Corporation. 2024 Rev.6...
Page 108: Installing The Ball Screw Spline Unit
Step 2 Set the belt so that it is level with Under Cover respect to the pulley without it S03: 4-M4x12 being placed on the flange. Flange 0.45 +/-0.1 N.m Timing Belt © Seiko Epson Corporation. 2024 Rev.6...
Page 109 Step 1 Ball Screw Spline Unit S01: 3-M4x10, 4.0 +/-0.2 N.m S01: 4-M4x10, 4.0 +/-0.2 N.m Step 2 Underside of Arm2 S01: 4-M4x10 Under Cover S03: 4-M4x12 Spline Plate 0.45 +/-0.1 N.m S01: 3-M4x10 © Seiko Epson Corporation. 2024 Rev.6...
Page 110: Greasing The Ball Screw Spline Unit
Move the shaft to its upper limit manually while pressing the Brake Release Switch, and turn OFF the Controller. Move the shaft to its lower limit manually while pressing the Brake Release Switch, and turn OFF the Controller. Brake Release Switch © Seiko Epson Corporation. 2024 Rev.6...
Page 111 Turn ON the Controller. (10) Move the shaft up and down a few times while pressing the Brake Release Switch so that the grease spreads uniformly in the shaft. © Seiko Epson Corporation. 2024 Rev.6...
Page 112 Wipe off the old grease and then apply new grease. CAUTION Brake Release Switch, and turn OFF the Controller. Apply grease by hand to the extent that the shaft groove is Brake Release Switch filled with grease. Wipe off the excess grease. © Seiko Epson Corporation. 2024 Rev.6...
Page 113 Bellows does not drop below the bottom of the shaft. (10) Wipe off the old grease and then apply new grease. CAUTION Apply grease by hand to the extent that the shaft groove is filled with grease. Wipe off the excess grease. © Seiko Epson Corporation. 2024 Rev.6...
Page 114: Board
S01: 2-M3x6, 2.0 +/-0.1 N.m Hexagonal support LED Board S03: 2-M3x6, 0.45 +/-0.1 N.m S03: 2-M3x6 * The disassembly procedure is described here. Perform assembly by following the disassembly procedure in the reverse order. © Seiko Epson Corporation. 2024 Rev.6...
Page 115: Replacing The Sub-B Board
S04: 2-M3x6 0.6 +/-0.1 N.m CAUTION When installing the board, be careful not to pinch the * The disassembly procedure is described here. cables. Perform assembly by following the disassembly procedure in the reverse order. © Seiko Epson Corporation. 2024 Rev.6...
Page 116: Replacing The Control Board
S03: 2-M2x16 0.2 +/-0.03 N.m Step 1 Under Cover S04: 4-M4x12 Fall Prevention Screw 0.9 +/-0.1 N.m * The disassembly procedure is described here. Perform assembly by following the disassembly procedure in the reverse order. © Seiko Epson Corporation. 2024 Rev.6...
Page 117: Cable Unit
■Be sure to connect the cables properly. Do not put heavy objects on the cables, bend or pull on the cables forcibly, or allow the cables to be pinched. Damaged cables, broken wires, or contact failure is extremely hazardous and may result in electric shock and/or malfunction of the robot system. © Seiko Epson Corporation. 2024 Rev.6...
Page 118: Removing The Cable Unit
S03: 4-M4x20 Step 2 Connector Plate S01: 4-M4x10 Removing the cables Step 3 Connector Plate Cables CN111-1 Step 4 Cable Unit (Base Side) Connector Plate Step 6 Arm2 Cables Step 7 Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 119 Connector Plate Cables CN350-1 Step 4 Cable Unit (Base Side) Air Tubes CN581-2 (LAN) Air Tubes Step 6 Insert or remove the tubes while Arm2 Cables pressing the release button. Step 7 Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 120 Remove the Cable duct upper plate from the Cable Unit. Cable duct upper plate Step 6 Arm2 Cables CAUTION Take care the connectors do not get caught when passing Step 7 them the Cable Duct upper plate. Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 121 Support can be moved. By freeing the User Plate and the User Plate Support, the connectors can be easily Step 6 detached or attached. Arm2 Cables User Plate Step 7 S01: 3-M4x10 Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 122 Remove the wire ties to remove the connectors. Arm2 Cables Reuse the Silicone Sheet (for connector protection) attached to the connectors. There is no need to remove the Silicone Sheet from the connectors. Step 7 Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 123 S04: 6-M4x12 S03: 4-M4x20 Step 2 Connector Plate S01: 4-M4x10 Step 3 Connector Plate Cables CN131-1 Step 4 CN331-1 Cable Unit (Base Side) CN401-1 Step 6 Arm2 Cables Step 7 Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 124 CN521-3 S03: 4-M4x20 Step 2 Connector Plate S01: 4-M4x10 CN300-1 Step 3 Connector Plate Cables Step 4 Cable Unit (Base Side) CN521-3 (D-Sub 15pin) Step 6 Arm2 Cables Step 7 Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 125 S03: 4-M4x20 Step 2 Connector Plate S01: 4-M4x10 CN3G0-1 Step 3 Connector Plate Cables Step 4 Cable Unit (Base Side) Step 6 Arm2 Cables Step 7 S04: 2-M4x6 with Washer Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 126 Step 5 Arm2 Cover S04: 6-M4x12 S03: 4-M4x20 Step 2 Connector Plate S01: 4-M4x10 Step 3 Connector Plate Cables Step 4 Cable Unit (Base Side) Step 6 Arm2 Cables Step 7 Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 127 Connector Plate Cables CN581-3 Step 4 Cable Unit (Base Side) CN581-3 (LAN) Take care the ground pin does not fall off the LAN connector. Tubes Step 6 Arm2 Cables Step 7 Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 128 Step 4 Cable Unit (Base Side) Metal nut CAUTION First remove the hose and thin cables, and then remove the remaining cables. Cable Unit Step 6 Arm2 Cables Step 7 Cable Unit (Arm2 Side) © Seiko Epson Corporation. 2024 Rev.6...
Page 129: Installing The Cable Unit
Air Tube (j6, blue): 95 mm Cable Unit (Arm2 side) GND cable (Arm2 «Connector Plate): 150 mm Air Tube (j6, black): 95 mm GND cable (Arm2 «signal): 160 mm Air Tube (j4, blue): 95 mm © Seiko Epson Corporation. 2024 Rev.6...
Page 130 Air tubes and thin cables. Tighten the cable hose. CAUTION Make sure that the metal nut has been fixed firmly without looseness. Step 2 Arm2 Cables Metal nut Step 1 Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 131 Cable Unit (base side) After securing with the wire ties, apply Krytox grease to the position shown in the figure. Krytox GPL-224 1.5±0.5ｇ Step 2 Cable unit Arm2 Cables Step 1 Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 132 0.45 +/-0.1 N.m Connector Plate S04: 4-M4x8 0.9 +/-0.1 N.m Air Tubes Step 5 Connector Plate Cables Step 4 Cable Unit (base side) Step 2 Arm2 Cables Step 1 Cable Unit (Arm2 side) CN581-3 © Seiko Epson Corporation. 2024 Rev.6...
Page 133 Wrap the connector with the Silicone Sheet and fix the connector at the position shown in the figures with the wire tie (AB100). Step 2 Arm2 Cables Step 1 CN3G0-1 CN3G0-1 Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 134 Step 4 CN300-1 Silicone Sheet Cable Unit (base side) Wire tie (AB100) Fix the User Plate Support. User Plate Support Step 2 Arm2 Cables Step 1 S01: 2-M4x10 4.0 +/-0.2 N.m Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 135 User Plate with a wire tie Sheets and fix the connectors on the User (AB100). Plate with a wire tie (AB100). User Plate ｚ CN321-1 Step 2 Arm2 Cables CN121-1 Step 1 Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 136 Cable Unit (base side) Fix the cables at approximately 35 mm from the upper end of the Motor Plate. Step 2 Approx. 35 mm Arm2 Cables Step 1 Motor Plate Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 137 Sheet together with CN400-2, and fix the connectors to the User Plate Support with a wire tie (AB100). CN401-1 Step 2 CN400-2 Arm2 Cables Silicone Sheet Wire tie Step 1 (AB100) Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 138 Step 6 0.45 +/-0.1 N.m Connector Plate S04: 4-M4x8 0.9 +/-0.1 N.m Step 5 Connector Plate Cables Plate Step 4 Cable Unit (base side) Step 2 Arm2 Cables Step 1 Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 139 Cable Unit (base side) 50 mm Grease 3. Push up the polyester tubing until the marked position reaches the hose end. Step 2 Arm2 Cables 30 mm Marking position Step 1 Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 140 First pass through the larger connectors. Step 4 Cable Unit (base side) Cable duct upper plate Fix the cable hose fixing nut. Step 2 Cable hose fixing nut Arm2 Cables Step 1 Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 141 Connector Plate Cables Air Tubes Step 4 Cable Unit (base side) CN581-2 (LAN） Step 2 Arm2 Cables Air Tubes Insert or remove the Step 1 tubes while pressing the release button. Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 142 0.45 +/-0.1 N.m Connector Plate S04: 4-M4x8 0.9 +/-0.1 N.m CN201-1 Step 5 CN331-1 Connector Plate Cables CN521-2 Step 4 Cable Unit (base side) CN202-2 CN350-1 Step 2 Arm2 Cables Step 1 Cable Unit (Arm2 side) © Seiko Epson Corporation. 2024 Rev.6...
Page 143 Step 5 S04: 1-M4x6 with Washer Connector Plate Cables Step 4 Cable Unit (base side) S04: 1-M4x6 with Washer CN111-1 Step 2 Arm2 Cables Step 1 S04: 1-M4x6 Cable Unit (Arm2 side) with Washer © Seiko Epson Corporation. 2024 Rev.6...
Page 144: Installing/Removing The Cover
S04: 4-M4x8 Connector Plate 4.0 +/- 0.2 N.m (Cable downward) S06: 7-M2.5x10 Base Bottom Cover 1.0 +/-0.1 N.m S01: 4-M4x10 Under Cover 0.9 +/-0.1 N·m S04: 4-M4x18, 0.9 +/-0.1 N.m S04: 2-M4x16, 0.9 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 145: Arm2 Cover
• To remove the cover, slightly lift the 0.45 +/-0.1 N.m cover and widen the rear by pushing slightly outward on the left and right sides. Widen the cover in the same way when passing the Cable Duct. Arm2 Cover © Seiko Epson Corporation. 2024 Rev.6...
Page 146: Cable Cover
0.9 +/-0.1 N.m Installation Pass the wire tie (AB150) through the Cable Duct cradle at two locations to fix the Cable Unit on the Cable Duct. Cable Duct Attach the Cable Cover. Cable Cover © Seiko Epson Corporation. 2024 Rev.6...
Page 147: Connector Plate (Table Top Mounting)
Washer pinched. Do not touch the DC/DC Board with your fingers. DC/DC Board S04: 1-M4x6 • Insert the cabling straight into the Manipulator. with Washer • Confirm that the Connector Plate is closed firmly. © Seiko Epson Corporation. 2024 Rev.6...
Page 148 GX4 Series Service Manual Maintenance 2.10.3 Connector Plate (Table Top ounting) S01: 4-M4x10 4.0 +/-0.2 N.m CN201-1 CN311-1 CN521-2 CN202-2 CN350-1 © Seiko Epson Corporation. 2024 Rev.6...
Page 149 GX4 Series Service Manual Maintenance 2.10.3 Connector Plate (Table Top ounting) S01: 4-M4x10 4.0 +/-0.2 N.m Air Tubes CN581-2 (LAN） Air Tubes Insert or remove the tubes while pressing the release button. © Seiko Epson Corporation. 2024 Rev.6...
Page 150: Connector Plate (Multiple Mounting)
2.10.4 Connector Plate (Multiple Mounting) S01: 7-M4x35 4.0 +/-0.2 N.m POINT Remove only the cables connected to the base side. Joint #1 Power cable （CN111-1） Joint #1 Signal cable （CN311-1） S04: 5-M4x1 with Washer 0.9 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 151: Connector Plate (Cable Downward)
The Base Cover has front and reverse sides. The hairline- finished surface is the front. Step 1 Base Cover Front side S01: 4-M4x10 4.0 +/-0.2 N.m Step 2 Cables Step 3 Connector Plate S06:7-M2.5×10 1.0 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 152 S01: 4-M4x10 4.0 +/-0.2 N.m Blue (φ6) Black (φ4) Black (φ6) Step 2 Cables Air Tubes Insert or remove the Step 3 tubes while pressing the release button. Connector Plate S06:7-M2.5×10 1.0 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 153 Air tube (White) Step 1 Base Cover S01: 4-M4x10 4.0 +/-0.2 N.m Step 2 Cables Step 3 Connector Plate S06:7-M2.5×10 1.0 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 154 Removing the cables Joint #1 motor connectors CN311-1 CN111-1 D-Sub 15 pin cable Step 1 Base Cover S01: 4-M4x10 4.0 +/-0.2 N.m CN521-1 Step 2 Cables Step 3 Connector Plate S06:7-M2.5×10 1.0 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 155 Maintenance 2.10.5 Connector Plate (Cable Downward) Removing the cables Fan cable CN350-1 LAN cable Step 1 Base Cover S01: 4-M4x10 4.0 +/-0.2 N.m Step 2 Cables Step 3 Connector Plate S06:7-M2.5x10 1.0 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 156 2.10.5 Connector Plate (Cable Downward) Removing the cables Signal cable relay connector CN202-2 J2-J4 Power cable Step 1 Base Cover S01: 4-M4x10 CN201-1 4.0 +/-0.2 N.m Step 2 Cables Step 3 Connector Plate S06:7-M2.5x10 1.0 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 157 2.10.5 Connector Plate (Cable Downward) Removing the cables Ground wires FB1 PE7 PE5 PE3 Step 1 Base Cover S01: 4-M4x10 4.0 +/-0.2 N.m Step 2 Cables Step 3 Connector Plate S06:7-M2.5x10 1.0 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 158 GX4 Series Service Manual Maintenance 2.10.5 Connector Plate (Cable Downward) Removing the Connector Plate Step 1 Base Cover S01: 4-M4x10 4.0 +/-0.2 N.m Step 2 Cables Step 3 Connector Plate S06:7-M2.5x10 1.0 +/-0.1 N.m © Seiko Epson Corporation. 2024 Rev.6...
Page 159 CHAPTER Adjustment...
Page 160: Calibration
Calibration is performed using the Calibration Marks that indicates the 0-pulse position. NOTE Calibration is different from teaching*. * Teaching is the operation of teaching set coordinate points (including the posture) within the Manipulator's operating area. © Seiko Epson Corporation. 2024 Rev.6...
Page 161 (Reduction Gear, Ball Screw Spline Unit) for a Manipulator with corrected arm lengths are replaced, re-measurement of the arm length is required. Arm length calibration measurements require precise measurements that cannot be performed by the user. Please contact the supplier of your region for the arm length re-measurement. © Seiko Epson Corporation. 2024 Rev.6...
Page 162 Execute the procedure in “Calibration Using Right / Left Arm Orientations” to accurately calibrate Joint #2. For details, refer to 3.1.6.4 Accurate Calibration of Joint • When calibrating Joint #4, due to the structure of the Manipulator Joint #3 and #4 must be calibrated at the same time. © Seiko Epson Corporation. 2024 Rev.6...
Page 163: Calibration Methods
Adjustment 3.1.2 Calibration Methods Using the calibration wizard EPSON RC+ has a wizard for calibration. The wizard guides you through the calibration process from specifying the joints to be adjusted and the adjustment items (calibration to be performed). Select both [Standard calibration] and [Joint accuracy calibration] to complete the necessary calibrations.
Page 164: Workflow
* J1/J2 only Accurate Calibration of Joint #2 * J2 only The controller which has the safety board is required to verification after adjustment. Verifying Safety board Operation Verification 3.1.7 Verification * RC700E only © Seiko Epson Corporation. 2024 Rev.6...
Page 165 * J2 only Send Hofs to Safety board * RC700E only The controller which has the safety board is required to verification after adjustment. Verifying Safety board Operation Verification 3.1.7 Verification * RC700E only © Seiko Epson Corporation. 2024 Rev.6...
Page 166: Preparation
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 © Seiko Epson Corporation. 2024 Rev.6...
Page 167: 0-Pulse Position Of Each Joint
Position where the Calibration Marks line up in a straight line Position where the Calibration Marks line up in a straight line Calibration Mark (Arm2) Calibration Mark (Arm1) Calibration Mark Calibration Mark (Arm1) (Base) © Seiko Epson Corporation. 2024 Rev.6...
Page 168 Position where the center of the D-Cut on the Ball Spline shaft matches the arrow mark on the Arm2 Under Cover. The height of Joint #3 depends on Manipulator model. Under Cover Mark 45.5 mm 79.5 mm D-Cut Standard model Cleanroom model © Seiko Epson Corporation. 2024 Rev.6...
Page 169: Implementing 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 170: Implementing Calibration And Joint Accuracy Calibration Using The Wizard
This section describes the method of performing calibration and Joint accuracy calibration of Joint #1 and Joint #2. Start the calibration wizard. Confirm the warning message and click the <Yes> button. I. Select EPSON RC+ menu - [Setup] - [System Configuration]. II. Select [Robots] - [Robot**] - [Calibration]. NOTE Only selected robot can be calibrated.
Page 171 Select [Standard calibration] and [Joint accuracy Move the joint to calibrate manually to approximate 0 pulse calibration], and click the <Next> button. position, as shown in the dialog. After moving the joint click the <Next> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 172 (Regardless of the Joint #1 direction.) 0 pulse 0 pulse position of Joint #3: upper limit position in motion range NOTE For details on the 0-pulse position, refer to 3.1.5 0-Pulse Position of Each Joint. © Seiko Epson Corporation. 2024 Rev.6...
Page 173 • Warning 590 is cleared by updating the Hofs value in the safety board after completing calibration. Step (30) • Since RC700D doesn’t have the safety board, warning 590 doesn’t occur. © Seiko Epson Corporation. 2024 Rev.6...
Page 174 The Manipulator moves to the reference point. Click the NOTE • Since RC700E has an error related to the <Execute> button. Safety board, execute <Reset> and then <Motor ON>. Select Jump P0:Z(0) ↑ Point selected in step (7) © Seiko Epson Corporation. 2024 Rev.6...
Page 175 After the Manipulator moves to the reference point, click the <Next> button. (15) Jog to the accurate reference position and adjust the position. Click the <OK> button. Adjust to the accurate position and move Joint #3 to around 0 pulse. © Seiko Epson Corporation. 2024 Rev.6...
Page 176 GX4 Series Service Manual Adjustment (16) Click the <Next> button. (17) Perform Joint accuracy calibration. Check the precautions and click the <Next> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 177 <Yes> button. After clicking the <Yes> button, the position of Joint #3 automatically moves to the 0 pulse position. The position after the movement of Joint #3 is set to movement point 1. © Seiko Epson Corporation. 2024 Rev.6...
Page 178 2 by moving the joint for which calibration is to be performed from movement point 1 through the minimum movement angle or more. (21) Specify movement point 2 for the measurement operation. Click the <Jog> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 179 2 again. (23) Click the <Next> button. NOTE It takes approximately 20 minutes for Joint accuracy calibration to end. (25) Click the <Yes> button. The robot starts moving when you click the <Yes> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 180 Click the <Execute> button again to perform Joint accuracy calibration. • The robot stops as a result of the <STOP> button being clicked or an emergency stop, etc. • An error message appears and the robot stops. © Seiko Epson Corporation. 2024 Rev.6...
Page 181 After the Manipulator moves to the reference point, click the <Next> button. iv. The Manipulator moves to the reference point. Click the <Execute> button. Select Jump P0:Z(0) ↑ Point selected in step (7) © Seiko Epson Corporation. 2024 Rev.6...
Page 182 Move to another point that has different pose (from righty position. Click the <OK> button. to lefty) using Jump command. Click the <Yes> button. viii. Jog to the accurate reference position. Click the <Jog> button. x. Click the <Next> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 183 ⅲ. Confirm the warning message and click the <OK> button. (30) On RC700E, send the Hofs value to the safety board. * On RC700D, go on to the step (31). i. Confirm the warning message and click the <OK> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 184 ⅴ. Confirm the warning message and click the <OK> button. （31） Move the Manipulator to other points and check if it can ⅵ. Confirm the message and click the <OK> button. move without problems. Teach points where appropriate. © Seiko Epson Corporation. 2024 Rev.6...
Page 185: Implementing Calibration Only Using The Wizard
0 (non-correction state). Start the calibration wizard. Confirm the warning message and click the <Yes> button. I. Select EPSON RC+ menu - [Setup] - [System Configuration]. II. Select [Robots] - [Robot**] - [Calibration].
Page 186 To perform only standard calibration, select the [Standard calibration] check box only. When only standard calibration is performed, the correction value of Joint accuracy calibration of joints for which standard calibration has been performed is reset to 0 (non-correction state). © Seiko Epson Corporation. 2024 Rev.6...
Page 187 0 pulse position of Joint #4: position where the D-Cut on the shaft matches the arrow mark on the Arm2 Under Cover 0 pulse 0 pulse NOTE For details on the 0-pulse position, refer to 3.1.5 0-Pulse Position of Each Joint. © Seiko Epson Corporation. 2024 Rev.6...
Page 188 • Warning 590 is cleared by updating the Hofs value in the safety board after completing calibration. Step (19) • Since RC700D doesn’t have the safety board, warning 590 doesn’t occur. © Seiko Epson Corporation. 2024 Rev.6...
Page 189 The Manipulator moves to the reference point. Click the NOTE • Since RC700E has an error related to the <Execute> button. Safety board, execute <Reset> and then <Motor ON>. Select Jump P0:Z(0) ↑ Point selected in step (7) © Seiko Epson Corporation. 2024 Rev.6...
Page 190 Adjustment (12) Confirm the message and click the <Yes> button. (14) Jog to the accurate reference position. Click the <Jog> button. (13) After the Manipulator moves to the reference point, click the <Next> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 191 Adjustment (15) Jog to the accurate reference position and adjust the (16) Click the <Next> button. position. Click the <OK> button. Adjust to the accurate position and move Joint #3 to around 0 pulse. © Seiko Epson Corporation. 2024 Rev.6...
Page 192 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. iv. Click the <Next> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 193 ⅲ. Confirm the warning message and click the <OK> button. (19) On RC700E, send the Hofs value to the safety board. * On RC700D, go on to the step (20). i. Confirm the warning message and click the <OK> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 194 ⅴ. Confirm the warning message and click the <OK> button. （20） Move the Manipulator to other points and check if it can move without problems. ⅵ. Confirm the message and click the <OK> button. Teach points where appropriate. © Seiko Epson Corporation. 2024 Rev.6...
Page 195: Implementing Joint Accuracy Calibration Only
2) are moved. Movement point 1 and movement point 2 are specified according to the wizard. Start the calibration wizard. Confirm the warning message and click the <Yes> button. I. Select EPSON RC+ menu - [Setup] - [System Configuration]. II. Select [Robots] - [Robot**] - [Calibration].
Page 196 Select [Joint accuracy calibration] and click the <Next> button. NOTE When performing only Joint accuracy calibration, perform calibration in advance by either using or not using the calibration wizard. To perform Joint accuracy calibration, specify movement point 1 for the measurement operation. © Seiko Epson Corporation. 2024 Rev.6...
Page 197 <Yes> button. After clicking the <Yes> button, the position of Joint #3 automatically moves to the 0 pulse position. The position after the movement of Joint #3 is set to movement point 1. © Seiko Epson Corporation. 2024 Rev.6...
Page 198 Specify movement point 2 by moving the joint for which calibration is to be performed from movement point 1 through the minimum movement angle or more. Click the <Next> button. (10) © Seiko Epson Corporation. 2024 Rev.6...
Page 199 When Joint accuracy calibration ends, the screen shown below appears. Click the <OK> button. NOTE Joint Accuracy Calibration requires approximately 20 minutes to perform. (12) Click the <Yes> button. The robot starts moving when you click the <Yes> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 200 Click the <Execute> button again to perform Joint accuracy calibration. • The robot stops as a result of the <Pause> button being clicked or an emergency stop, etc. • An error message appears and the robot stops. © Seiko Epson Corporation. 2024 Rev.6...
Page 201 ⅳ. Enter the password and click <Confirm> button. ⅴ. Confirm the warning message and click the <OK> button. ⅲ. Confirm the warning message and click the <OK> button. ⅵ. Confirm the message and click the <OK> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 202 GX4 Series Service Manual Adjustment ⅶ. Confirm the message and click the <OK> button. ⅷ. The Controller restarts. （17） Move the Manipulator to other points and check if it can move without problems. Teach points where appropriate. © Seiko Epson Corporation. 2024 Rev.6...
Page 203: Accurate Calibration Of Joint #2
Manipulator to the teaching point to verify whether there is a positional gap. If there is a positional gap, fine-tune the installation position of the end effector and teach the point again. © Seiko Epson Corporation. 2024 Rev.6...
Page 204 • 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 © Seiko Epson Corporation. 2024 Rev.6...
Page 205: Calibration Using Right / Left Arm Orientations
* If there is interference on the way from right to lefty, click the <Free All> button in the [Control Panel] and change the arm orientation to lefty by hands. Then, go to the step (6), (7). © Seiko Epson Corporation. 2024 Rev.6...
Page 206 (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. © Seiko Epson Corporation. 2024 Rev.6...
Page 207: Calibration Procedure Without Using Calibration Wizard
Adjustment 3.1.6.6 Calibration Procedure without Using Calibration Wizard NOTE This section indicates the calibration without using the calibration wizard of EPSON RC+. For details of calibration using the calibration wizard, refer to 3.1.6.1 Implementing Calibration and Joint Accuracy Calibration using Wizard.
Page 208 Arm2 Under Cover Joint #3: >EncReset 3 Joint #4: >EncReset 3, 4 (3)-5 Reboot the Controller. Select EPSON RC+ menu- [Tools] - [Controller] and 0 pulse click the <Reset Controller> button. NOTE For details on the 0-pulse position, refer to 3.1.5 0-Pulse Position of Each...
Page 209 (4)-1 Execute the following command from the menu - (5)-1 Reboot the Controller. [Tools] - [Command Window]. Select EPSON RC+ menu - [Tools] - [Controller] and >calpls 0,0,0,0 click the <Reset Controller> button. * Manipulator does not move. (5)-2 Click [Control Panel] - <Free All> button to free all...
Page 210 * On RC700D, go on to the step (17). Joint #1: >Calib 1 (8)-1 In EPSON RC+, select [Setup] - [System Joint #2: >Calib 2 Configuration], and then under [Controller] - [Safety Joint #3: >Calib 3 Functions], click [Safety Joint #4: >Calib 3, 4...
Page 211 Enter the password and click <Confirm> button. (8)-6 Confirm the warning message and click the <OK> button. (8)-4 Confirm the warning message and click the <OK> button. (8)-7 Confirm the message and click the <OK> button. © Seiko Epson Corporation. 2024 Rev.6...
Page 212 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. © Seiko Epson Corporation. 2024 Rev.6...
Page 213: Verification
GX4 Series Service Manual Adjustment 3.1.7 Verification RC700E is required to verifying the safety function after completing calibration. For details on the verification procedure, refer to “RC700E Service Manual 3.4 Verifying Safety board operation”. © Seiko Epson Corporation. 2024 Rev.6...
Page 214: Adjusting The Timing Belt Tension
• A new belt tends to be stretched in the initial aging period (during an operation of approximately 12 hours). Therefore, the tension standard values are different for a new product and a reused product (after the passage of the initial aging period). © Seiko Epson Corporation. 2024 Rev.6...
Page 215: Adjustment Method
Example: In the case of 110N, Z belt pull with 220[N] tension. After tightening the bolts securing the Motor Plate, measure the tension once again for confirmation. Pull in the direction of the arrow. © Seiko Epson Corporation. 2024 Rev.6...
Page 216 Tighten the bolts securing the Motor Plate with the correct Pull in the direction of tightening torque. the arrow. After tightening the bolts securing the Motor Plate, measure the tension once again for confirmation. © Seiko Epson Corporation. 2024 Rev.6...
Page 217 After tightening the bolts securing the Motor Plate, measure Pull with approximately twice the the tension once again for confirmation. recommended tension. Example: In the case of 110N, pull with 220[N] tension. Pull in the direction of the arrow. U2 belt © Seiko Epson Corporation. 2024 Rev.6...
Page 218: Chapter 4 Block Diagram/Wiring Diagram
CHAPTER Block Diagram/Wiring Diagram...
Page 219: Block Diagram
Block Diagram/Wiring Diagram GX4 Series Service Manual 4.1 Block Diagram Joint #4 Overexcitation current Brake Brake Release Switch Fan 1 LED Board DC/DC Board Control Board Joint #3 Brake Attachment/ detachment CN © Seiko Epson Corporation. 2024 Rev.6...
Page 220: Wiring Diagram
FB4 - FB1 PE6 - PE5 PE4 - PE3 PE1 - Detachment/attachment CN PE2 - Detachment/attachment CN (10) FB4 - D-Sub 15pin (Ground wire for RJ45) (11) FB2 - RJ45 FB4 (Ground wire for D-Sub 15pin) © Seiko Epson Corporation. 2024 Rev.6...
Page 221: Motor Cable
Joint #4 Motor Connection Joint #4 Motor - CN141 Joint #1 Motor Joint #3 Motor - CN131 - CN201 - Detachment/attachment CN Joint #2 Motor - CN121 Joint #1 Motor - CN111 - Detachment/attachment CN © Seiko Epson Corporation. 2024 Rev.6...
Page 222: Encoder
Joint #3 Motor - CN331 Joint #4 Motor DC/DC Board Joint #1 Motor - CN311 Control Board CN202 Joint #1 Motor - Detachment/attachment CN (CN200) DC/DC Board (CN1) - DC/DC Board (CN3) CN202 - DC/DC Board (CN2) © Seiko Epson Corporation. 2024 Rev.6...
Page 223: Brake Wire, Led Wire, Fan
LED Board (CN1) - CN301 - CN202 Brake Release Switch - CN300 - LED Board (CN1) Joint #4 Brake - CN440 - Divergence - CN400 - Overexcitation power supply FAN - CN350 - CN202 © Seiko Epson Corporation. 2024 Rev.6...
Page 224: User Plate
GX4 Series Service Manual Block Diagram/Wiring Diagram 4.2.5 User Plate D-Sub 15pin RJ45 D-Sub 15pin RJ45 Connection RJ45 - RJ45 D-Sub 15pin - CN521 - CN521 - D-Sub 15pin © Seiko Epson Corporation. 2024 Rev.6...
Page 225: Chapter 5 Exploded View/Maintenance Parts List
CHAPTER Exploded View/Maintenance Parts List...
Page 226: Exploded View
Exploded View/Maintenance Parts List GX4 Series Service Manual 5.1 Exploded View © Seiko Epson Corporation. 2024 Rev.6...
Page 229: Maintenance Parts List
Cable Unit 2234505 350 mm arm, Multiple mounting, Standard model  Cable Unit 2234731 250 mm arm, Table top mounting, Cleanroom/ESD model  Cable Unit 2234732 300 mm arm, Table top mounting, Cleanroom/ESD model  © Seiko Epson Corporation. 2024 Rev.6...
Page 230 1653181 For Joint #2 Reduction Gear O-ring 1739286 For Joint #1 Motor Plate O-ring 1213268 For Arm1 (Joint #1 side) O-ring 1213267 For Arm1 (Joint #2 side) O-ring 1866158 For Joint #2 Motor Plate © Seiko Epson Corporation. 2024 Rev.6...
Page 231 1636149 For 6 dia. tube (Blue) Coupling 1636147 For 4 dia. tube (Blue) RJ45 connector case 2212457 RJ45 connector 2212458 Coupling 1866006 For 6 dia. cleanroom model 2212432 M/C Cable Connector (Robot Side) Harness・Connector © Seiko Epson Corporation. 2024 Rev.6...

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