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Seiko Epson VT Series Service Manual

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SERVICE
MANUAL
6-Axis Manipulator
VT Series Manipulators
Confidential
Rev.1

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Summary of Contents for Seiko Epson VT Series

  • Page 1 SERVICE MANUAL 6-Axis Manipulator VT Series Manipulators Confidential Rev.1...
  • Page 2 NOTICE  All rights reserved. No part of this manual may be reproduced, stored in retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of SEIKO EPSON CORPORATION.

  • Page 3: Revision History

    After first release of this manual, the parts and mechanism may be subject to change for improvement of their performance and the manual may be revised. Be sure to always keep this manual up to date. Revision Date Page of change Detail of change Rev.1 2020.1.7 First Release SEIKO EPSON Rev.1...
  • Page 4 Parts information, Structure of Robot (Customers and non-contract partners) Level 4 Only for SEC, ESC and contract partners Detailed Specifications, Service Information (Confidential) Level 5 Only for SEC and ESC internal use Epson Encoder, Epson Motor Specifications, Hidden Commands (Strictly Confidential) SEIKO EPSON Rev.1...

  • Page 5: Table Of Contents

    1.1 Maintenance Procedures………………………………………………………………………...7 1.2 Joint #1 Reduction Gear..…………………………………………………………………...…14 1.3 Joint #2 Reduction Gear..…………………………………………………………………...…31 1.4 Joint #3 Reduction Gear..…………………………………………………………………...…52 1.5 Joint #4 Reduction Gear..…………………………………………………………………...…70 1.6 Joint #5 Reduction Gear..…………………………………………………………………...…86 1.7 Joint #6 Reduction Gear..…………………………………………………………………...…104 1.8 Motor Unit Parts Replacement ……………………………………………………………...…116 SEIKO EPSON Rev.1...

  • Page 6: Maintenance Procedures

    CHAPTER Maintenance Procedures...

  • Page 7: Maintenance Tables

    Cross recessed bind screws (General) M2.5 0.36 +/- 0.1 0.45 +/- 0.1 0.45 +/- 0.1 Cross recessed bind screws (Brackets) 0.6 +/- 0.1 0.9 +/- 0.1 Hex bind screws 0.7 +/- 0.1 2.4 +/- 0.1 4.0 +/- 0.2 SEIKO EPSON Rev.1...
  • Page 8 Bevel Gear (J5 side) SK-2 1 ～ 1.5g GR 5-3 Apply with syringe ARM5 inside bottom surface SK-2 5 ～ 6g GR 5-4 Oil Seal (AC1213P1) SK-1A GR 6-4 Applied for lubrication only when pressed into flange SEIKO EPSON Rev.1...
  • Page 9 3. No grease is allowed on the outside surface of the bearing. Refer to Fig 3. 4. Make sure grease is applied evenly. Refer to Fig 4 Example: Flexspline Inner Surface Example: Waveform Generator Inner Surface Fig.4 SEIKO EPSON Rev.1...
  • Page 10 0.2 ～ 0.3g LT6-1 Applying Loctite 641 to the bearing outer surface is required. Without Loctite fletching will occur leading to reduced life of the bearings. Loctite Loctite Gasket Example: J6 Sleeve Example: Standalone ASP Example: Pressed ASP SEIKO EPSON Rev.1...
  • Page 11 Step 6. Check Belt Tension from opposite side using with cover tension when cover is Step 3. Adjust J6 Belt Tension attached. Step 4. Check J5 belt tension using without cover tension Note: Arm 4 will slightly flex by tension of belts Check Tension SEIKO EPSON Rev.1...
  • Page 12 Diagrams VT-Series Service Manual Confidential Level 3 BELT TENSION MEASURMENT POINTS SEIKO EPSON Rev.1...
  • Page 13 J4/ J5/ J6 Motor Pulley/ Brake 3.0 ± 0.5 Gap Large The pulley must be even on all sides or the fixing bolt and Gap Small brake hub will be misaligned causes damage when fixed by the belt. Misaligned Pulley (Incorrect) SEIKO EPSON Rev.1...

  • Page 14: Joint #1 Reduction Gear

    M4x30 bolts incl. WAVE WASHER 1843132 For J1/J2/J3/J4/J6 (No need for centering jig) S01: 10-M4x10 S03: 2-M4x8 S01: 6-M2.5x15 S01: 5-M4x12 S02: 12-M4x30 S03: 1-M4x8 S01: 3-M4x22 S01: 3-M4x10 S01: 2-M4x10 S01: 2-M4x12 S02: 16-M4x20 S01: 4-M4x8 Level 3 SEIKO EPSON Rev.1...
  • Page 15 Remove the cable fixing plate Base Side Cable Plate Hexagon socket head cap : 2-M4x10 Note: Loosen the 2-M4 bolts to allow the plate to be removed Remove the cable tie from the base side Cable Fixing Plate SEIKO EPSON Rev.1...
  • Page 16 Remove the Arm #1 sleeve from the Base Hexagon socket head cap : 4-M4x8 Pulley 10. Remove the Arm #1 pulley Hexagon socket head cap : 6-M2.5x15 Note: Use a flat head screw driver to help remove the pulley SEIKO EPSON Rev.1...
  • Page 17 Note: Loctite is holding the bearing firmly in place. Use a soft hammer to help loosen the Loctite holding the bearing by tapping the Waveform Generator from the base side. Note: Use two M2.5 bolts to help lift the Waveform O-ring Generator from the arm. SEIKO EPSON Rev.1...
  • Page 18 16. Remove the O-ring Note: Be careful not to damage the O-ring. Any small damage may cause oil leakage. 17. Remove the Wave washer 18. Clean Arm #1 of grease and unwanted particles O-ring Wave washer SEIKO EPSON Rev.1...
  • Page 19 Place the O-ring into Arm #1. Note: Applying a little grease (SK-1A) will help stick the O-ring in the arm groove. Caution: Be careful of the O-ring when replacing it into the Base. Any damage to the O-ring will cause oil leakage. SEIKO EPSON Rev.1...
  • Page 20 Tightening Torque: 5.5 ± 0.25N ・ m Crisscross Example Place the wave washer into Arm #1 Note ： Steps 8 to 11 Wave washer centering is not required for wave washer parts code: 1843132 or manipulators Wave washer manufactured after March 13 2020. SEIKO EPSON Rev.1...
  • Page 21 11. Remove the wave washer centering jig from the Base Caution: Make sure to remove the jig without touching or moving the wave washer. If the wave Wave washer washer is moved it will need to be centered again. Centering Jig SEIKO EPSON Rev.1...
  • Page 22 Example: Waveform Generator Unit Note: Loctite requires approx. 8 hours to firmly bond. Caution: Do not allow grease to mix with the Loctite. If grease is on the bearing outer surface the Loctite will not bond correctly. SEIKO EPSON Rev.1...
  • Page 23 Waveform Generator to check if the wave washer is centered correctly. If the Waveform Generator cannot turn smoothly, remove and center the wave washer again. The wave washer can also be viewed from the Base. Not Centered Centered SEIKO EPSON Rev.1...
  • Page 24 Loctite will evenly disperse. Note: Loctite requires approx. 8 hours to firmly bond. Caution: Do not allow grease to mix with the Loctite. If grease is on the bearing outer rim surface the Loctite will not bond correctly. Loctite 641 SEIKO EPSON Rev.1...
  • Page 25 20. Replace the Arm #1 16 fixing bolts Note: Tighten in a crisscross pattern Hexagon socket head cap bolts: 16-M4x20 Tightening Torque: 5.5 0.25N ・ m ± Note: Pre-tighten one bolt to allow the arm to be temporarily fixed in place. SEIKO EPSON Rev.1...
  • Page 26 Note: The pulley can be held firmly in place using the timing belt to allow the correct tension to be applied to the bolts 24. Move the pulley to check for smooth movement SEIKO EPSON Rev.1...
  • Page 27 30. Replace the cable fixing plate to Arm #1 by tightening the 2- M4x12 bolts which hold the fixing plate. Hexagon socket head cap bolts with captive washer: 2-M4x12 Tightening Torque: 4.0 0.2N ・ m ± Arm #1 Cable Fixing Plate & Cable Tie SEIKO EPSON Rev.1...
  • Page 28 35. Replace the cable tie to the base side Cable Fixing Plate 36. Fix the cables to the Arm #1 Cable Fixing Plate. Note: The white markings on the cables can be used as a guide for placement SEIKO EPSON Rev.1...
  • Page 29 44. Copy the Calpls value to Calpls command and make sure Joint #1 is 8538405 and execute Calpls. (Example at Shipment) Command: Calpls 8538405, 4119406, -2598624, 0, 4672602, 0 45. Execute Calib to calculate HOFs Command: Calib 1 FRONT SEIKO EPSON Rev.1...
  • Page 30 47. Move the Manipulator to the 0 pulse position (origin position). Command: Pulse 0,0,0,0,0,0 48. Next test Joint #1 in low power and high power mode. Check for any abnormalities. If there are none you are finished. 0 Pulse Position SEIKO EPSON Rev.1...

  • Page 31: Joint #2 Reduction Gear

    M4x30 bolts incl. WAVE WASHER 1843132 For J1/J2/J3/J4/J6 (No need for centering jig) S01: 5-M4x12 S01: 10-M4x10 S03: 2-M4x8 S01: 3-M4x22 S01: 2-M4x12 S02: 12-M4x30 S03: 1-M4x8 S01: 10-M4x12 S02: 16-M4x20 S01: 3-M4x10 S01: 6-M2.5x15 S01: 4-M4x8 Level 3 SEIKO EPSON Rev.1...
  • Page 32 Base Side Cable Plate Remove the cable fixing plate Hexagon socket head cap : 2-M4x10 Note: Loosen the 2-M4 bolts to allow the plate to be removed Remove the cable tie from the base side Cable Fixing Plate SEIKO EPSON Rev.1...
  • Page 33 10. Loosen 2-M4x12 bolts which hold the fixing plate then remove the Arm #1 Front Cable Fixing Plate. Hexagon socket head cap bolts with captive washer: 2-M4x12 Arm #1 Front 1-M4x6 11. Remove the earth cable fixing screw Cable Fixing Plate Cross-recessed Bind Screw: 1-M4x6 2-M4x12 SEIKO EPSON Rev.1...
  • Page 34 Arm #3 and #4. +66 ° Hexagon socket head cap with washer : 3-M4x22 17. Remove the Joint #2 Timing Belt 18. Move Arm #2 until the arm stops at the mechanical stopper at +66 ° deg SEIKO EPSON Rev.1...
  • Page 35 Caution: When placing the arm on the workbench be careful of the internal cables and be sure to place soft material such as bubble wrapping or paper towels under the arm. O-ring 21. Remove the O-ring from the Circularspline SEIKO EPSON Rev.1...
  • Page 36 O-ring 24. Remove the O-ring Note: Be careful not to damage the O-ring. Any small damage may cause oil leakage. 25. Remove the Wave washer 26. Clean Arm #1 and Arm #2 of grease and unwanted particles SEIKO EPSON Rev.1...
  • Page 37 Note: Applying a little grease (SK-1A) will help stick the O- ring in the arm groove. Caution: Be careful of the O-ring when replacing it into the Arm. Any damage to the O-ring will cause oil leakage. SEIKO EPSON Rev.1...
  • Page 38 Tightening Torque: 5.5 ± 0.25N ・ m Place the wave washer into Arm #1 12-M4x20 Note ： Steps 7 to 10 Wave washer centering is not required for wave washer parts code: 1843132 or manipulators manufactured after March 13 2020 Crisscross Example SEIKO EPSON Rev.1...
  • Page 39 12. Remove the wave washer centering jig from the Base Caution: Make sure to remove the jig without touching or moving the wave washer. If the wave washer is moved it will need to be centered again. SEIKO EPSON Rev.1...
  • Page 40 Bearing (Do not grease) Gap (Do not grease) (5mm) Caution: Waveform Generator Do not apply grease to the outer side bearings. (Apply grease) These bearings need to have Loctite applied in the next step Bearing (Do not grease) SEIKO EPSON Rev.1...
  • Page 41 Caution: Do not allow grease to mix with the Loctite. If grease is on the bearing outer surface the Loctite will not bond correctly. 15. Place Waveform Generator into Flexspline. Note: Make sure the longside of the Waveform Generator and Flexspline match when placing. Longside Shortside Longside SEIKO EPSON Rev.1...
  • Page 42 18. Apply a little SK-1A grease to the O-ring and replace the O-ring onto the Circularspline groove. Not Centered Centered Caution: Be careful not to stretch the O-ring when replacing. Minor damage to the O-ring will cause oil leakage. O-ring SK-1A SEIKO EPSON Rev.1...
  • Page 43 Note: Loctite requires approx. 8 hours to firmly bond. Caution: Do not allow grease to mix with the Loctite. If grease is on the bearing outer rim surface the Loctite will not bond correctly. Apply Loctite to outer rim only SEIKO EPSON Rev.1...
  • Page 44 21. Replace the Arm #2 fixing bolts Hexagon socket head cap and washer: 16-M4x20 Tightening Torque: 5.5 ± 0.25N ・ m Note: The gap between Arm #1 and Arm #2 should be 16-M4x20 evenly spaced around the entire joint. Approx. 2mm Gap: 2mm SEIKO EPSON Rev.1...
  • Page 45 Note: The pulley can be held firmly in place using the timing belt to allow the correct tension to be applied to the bolts 24. Move the pulley to check for smooth movement SEIKO EPSON Rev.1...
  • Page 46 The sleeve must be centered correctly. 28. Thread and push the cables from the Arm #2 through to Arm #1. Caution: Be careful of the connectors catching on the Arm #2 sleeve SEIKO EPSON Rev.1...
  • Page 47 32. Replace the earth cable fixing screw Cross-recessed Bind Screw: 1-M4x6 Arm #1 Front Cable Fixing Plate 33. Replace the Arm #2 Cover Hexagon socket head cap bolts with captive washer: 2-M4x12 10-M4x12 Tightening Torque: 4.0 ± 0.2N ・ m SEIKO EPSON Rev.1...
  • Page 48 Note: The white markings on the cables can be used as a guide for placement. 38. Replace the Joint # 1 Motor Unit and Joint #1 Timing Belt For Details, refer to Manipulator Manual Maintenance: 9.3 Replacing Joint #1 Motor. SEIKO EPSON Rev.1...
  • Page 49 42. Fix the cables to the Arm #1 Cable Fixing Plate. Note: The white markings on the cables can be used Cable Tie as a guide for placement 43. Replace the Controller Unit For Details, refer to Manipulator Manual Maintenance: 18.1 Replacing Controller Unit. SEIKO EPSON Rev.1...
  • Page 50 51. Copy the Calpls value to Calpls command and make sure Joint #1 is 8538405 and execute Calpls. (Example at Shipment) Command: Calpls 8538405, 4119406, -2598624, 0, 4672602, 0 52. Execute Calib to calculate HOFs Command: Calib 1 SEIKO EPSON Rev.1...
  • Page 51 60. Move the Manipulator to the 0 pulse position (origin position). Command: Pulse 0,0,0,0,0,0 61. Next test Joint #1 and Joint #2 in low and high power mode. Check for any abnormalities. If there are none you are finished. 0 Pulse Position SEIKO EPSON Rev.1...

  • Page 52: Joint #3 Reduction Gear

    O-Rings(1670639 & 1773891), M3x28 bolts and washers incl. WAVE WASHER 1843132 For J1/J2/J3/J4/J6 (No need for centering jig) S01: 2-M4x12 S01: 3-M4x12 S01: 8-M2.5x20 S01: 10-M4x12 S02: 12-M3x28 S03: 1-M4x18 S02: 16-M3x28 S01: 4-M3x8 S01: 6-M4x12 Level 3 SEIKO EPSON Rev.1...
  • Page 53 Remove the Arm #2 Cover Hexagon socket head cap bolts with captive washer: 10- 10-M4x12 M4x12 Note: Leave the top bolts until last to stop the cover from falling. Caution: Be careful of the cables and motor units when removing. SEIKO EPSON Rev.1...
  • Page 54 1-M4x6 Caution: Be careful of the connectors catching on the Arm #3 sleeve Remove the Arm #3 sleeve fixing bolts Hexagon socket head cap : 4-M3x8 10. Remove the Arm #3 sleeve 4-M3x6 Arm #3 Sleeve SEIKO EPSON Rev.1...
  • Page 55 Arm #4. Hexagon socket head cap with washer : 3-M4x22 3-M4x22 11. Remove the Joint #3 Timing Belt Timing Belt 12. Move Arm #3 until the arm stops at the mechanical stopper at -56 ° -56 ° SEIKO EPSON Rev.1...
  • Page 56 Caution: When placing the arm on the workbench be careful of the internal cables and be sure to place soft material such as bubble wrapping or paper towels under the arm. 16. Remove the O-ring from the Circularspline O-ring SEIKO EPSON Rev.1...
  • Page 57 19. Remove the O-ring Note: Be careful not to damage the O-ring. Any small damage may cause oil leakage. 20. Remove the Wave washer 21. Clean Arm #2 and Arm #3 of grease and unwanted particles O-ring SEIKO EPSON Rev.1...
  • Page 58 Note: Applying a little grease (SK-1A) will help stick the O- ring in the arm groove. Caution: Be careful of the O-ring when replacing it into the Arm. Any damage to the O-ring will cause oil leakage. SEIKO EPSON Rev.1...
  • Page 59 The wave washer will sit in the center of the bearing attached to the Waveform Generator and the center of the arm. If out of alignment the bearing may be damaged. Wave washer SEIKO EPSON Rev.1...
  • Page 60 Note: 2-M3 bolts can be used to help place the unit into the arm. Replace the reduction Gear fixing bolts Placement Holes Note: Tighten in a crisscross pattern Hexagon socket head cap: 12-M3x28 Tightening Torque: 2.4 0.1N ・ m ± Crisscross Example 12-M3x28 SEIKO EPSON Rev.1...
  • Page 61 Example: Waveform Generator Unit disperse. Note: Loctite requires approx. 8 hours to firmly bond. Caution: Do not allow grease to mix with the Loctite. If grease is on the bearing outer surface the Loctite will not bond correctly. SEIKO EPSON Rev.1...
  • Page 62 O-ring onto the Circularspline groove. 15. Apply SK-1A grease to the Waveform Generator Wave washer surface. Caution: Make sure the grease is applied evenly and within the O-ring. Applying with a syringe is O-ring recommended. Grease: 1.5g SK-1A O-ring SEIKO EPSON Rev.1...
  • Page 63 Hexagon socket head cap bolts with washer: 16- M3x28 Tightening Torque: 2.4 0.1N ・ m ± Note: The gap between Arm #2 and Arm #3 should be Gap: 2mm evenly spaced around the entire joint. Approx.: 2mm SEIKO EPSON Rev.1...
  • Page 64 Hexagon socket head cap bolts: 4-M3x8 Tightening Torque: 2.0 0.1N ・ m ± Note: Gradually tighten the bolts in a crisscross pattern starting with the top bolt. The sleeve must be 4-M3x6 Arm #3 Sleeve centered correctly. SEIKO EPSON Rev.1...
  • Page 65 Caution: Be careful of the connectors catching on the Arm #2 sleeve 26. Replace the Arm #2 cable fixing plate (Joint #3 side) fixing 2-M4x12 bolts Hexagon socket head cap with captive washer : 2-M4x12 Tightening Torque: 4.0 ± 0.2N ・ m SEIKO EPSON Rev.1...
  • Page 66 31. Replace the Joint # 4 Motor Unit and Timing Belt For Details, refer to Manipulator Manual Maintenance: 12.3 Replacing Joint #4 Timing Belt. 0 Pulse Position 32. Move the manipulator to 0 pulse position Command: Pulse 0,0,0,0,0,0 SEIKO EPSON Rev.1...
  • Page 67 For Details, refer to VT6 Service Reference 2598624 and execute Calpls. (Example at Shipment) Calibration (J1,J2,J3 and J5) for more Command: Calpls 8538405, 4119406, -2598624, 0, 4672602, 0 details 40. Execute Calib to calculate HOFs Command: Calib 3 SEIKO EPSON Rev.1...
  • Page 68 44. With the Joint #4 brake released place a level on the Joint #6 flange. (Level Accuracy: 0.5mm/m) 45. Move Joint #4 until the level bubble is centered. Caution: Make sure the table the manipulator on is also level. 0 pulse position Level SEIKO EPSON Rev.1...
  • Page 69 54. Move the Manipulator to the 0 pulse position (origin position). Command: Pulse 0,0,0,0,0,0 55. Next test Joint #3 and Joint #4 in low power and high power mode. Check for any abnormalities. If there are none you are finished. 0 Pulse Position SEIKO EPSON Rev.1...

  • Page 70: Joint #4 Reduction Gear

    O-Rings(1670639 & 1773891), M3x28 bolts and washers incl. WAVE WASHER 1843132 For J1/J2/J3/J4/J6 (No need for centering jig) S01: 3-M4x12 S01: 3-M4x18 S01: 6-M4x12 S01: 8-M2.5x18 S02: 12-M3x28 S01: 2-M4x12 S02: 16-M3x28 Level 3 S01: 4-M3x6 S01: 6-M4x12 SEIKO EPSON Rev.1...
  • Page 71 Pull the cables from Arm #4 through to Arm #3. Caution: Be careful of the connectors catching on the Arm #4 sleeve Remove the Arm #4 sleeve fixing bolts Hexagon socket head cap : 4-M3x6 Remove the Arm #4 sleeve SEIKO EPSON Rev.1...
  • Page 72 Move the pulley a little at a time to wedge Joint #4 Pulley free. Remove the Arm #4 fixing bolts Hexagon socket head cap with washer: 16-M3x28 SEIKO EPSON Rev.1...
  • Page 73 Hexagon socket head cap: 12-M3x28 Caution: Be careful of the O-ring when removing the Wave washer Reduction Gear from Arm #3. Also be careful of the wave washer falling out of Arm #3. Flexspline Side O-ring Joint #4 Reduction Gear Unit SEIKO EPSON Rev.1...
  • Page 74 Loosen the fixing bolts of the Joint #3 motor unit and remove the Timing Belt. Serial Numbers Circularspline/Flexspline Caution: Method 2 will require re-tensioning of the Joint #3 timing belt and calibration of Joint #3 SEIKO EPSON Rev.1...
  • Page 75 The wave washer will sit in the center of the bearing attached to the Waveform Generator and the center of the arm. If out of alignment the bearing may be damaged. Waveform Generator Wave washer Bearing SEIKO EPSON Rev.1...
  • Page 76 Arm #3. Make sure to place with cross-roller O-ring bearing fixing bolts facing in the four inset holes in the arm. Note: 2-M3 bolts can be used to help place the unit into the arm. SEIKO EPSON Rev.1...
  • Page 77 Grease: 11.0g ± 0.5g SK-1A Caution: Do not apply grease to the outer side bearings. These bearings need to have Loctite applied in the next step. Bearing (Do not grease) Waveform Generator (Apply grease) Bearing (Do not grease) SEIKO EPSON Rev.1...
  • Page 78 Generator and Flexspline match when placing. Longside Longside Caution: Do not allow the Loctite to touch the inside of the Flexspline. 13. Confirm that the wave washer is centered. This can be viewed from Arm #3. Wave washer confirmation point SEIKO EPSON Rev.1...
  • Page 79 O-ring onto the Circularspline groove. 15. Apply SK-1A grease to the Waveform Generator Circularspline surface. O-ring groove Caution: Make sure the grease is applied evenly and within the O-ring. Applying with a syringe is recommended. Grease: 1.5g SK-1A O-ring SEIKO EPSON Rev.1...
  • Page 80 Caution: Be careful of the O-ring when replacing Arm #4 to Arm #3. Make sure to replace Arm #4 with both hands. 18. Replace the Arm #4 16 fixing bolts Hexagon socket head cap bolts: 16-M3x28 Tightening Torque: 2.4 0.1N ・ m ± SEIKO EPSON Rev.1...
  • Page 81 Approx. 1.5 ± 0.8mm Caution: If Arm #4 is at a slight angle the accuracy Arm #3 of the robot cannot be assured. Arm #4 or the Waveform Generator will need to be adjusted again. SEIKO EPSON Rev.1...
  • Page 82 Note: Gradually tighten the bolts in a crisscross pattern to allow the pulley to be levelly attached Note: The pulley can be held firmly in place using the timing belt to allow the correct tension to be applied to the bolts Timing Belt SEIKO EPSON Rev.1...
  • Page 83 Tightening Torque: 4.0 0.2N ・ m ± 27. Replace the Joint # 4 Motor Unit and Joint #4 Timing Belt For Details, refer to Manipulator Manual Maintenance: 12.3 Replacing Joint #4 Timing Belt. Arm #4 Cable Fixing Plate SEIKO EPSON Rev.1...
  • Page 84 31. With the Joint #4 brake released place a level on the Joint #6 flange. (Level Accuracy: 0.5mm/m) 32. Move Joint #4 until the level bubble is centered. Caution: Make sure the table the manipulator on is also level. 0 pulse position Level SEIKO EPSON Rev.1...
  • Page 85 41. Move the Manipulator to the 0 pulse position (origin position). Command: Pulse 0,0,0,0,0,0 42. Next test Joint #4 in low and high power mode. Check for any abnormalities. If there are none you are finished. SEIKO EPSON Rev.1...

  • Page 86: Joint #5 Reduction Gear

    Reduction Gear J5/J6 included O-ring [1773892] O-RING 1773892 64.0X1.5 J5, J6 Flexspline side O-RING 1773893 45.4X0.80 J5, J6 Circularspline side WAVE WASHER 1749486 For J5 (must use centering jig) S01: 1-M4x15 S01: 4-M2.5x25 S02:12-M3x22 S02: 10-M3x22 Level 3 SEIKO EPSON Rev.1...
  • Page 87 Note: To stop the pulley turning the pulley holding jig can be used. However, once the bolt is initially loose Joint #6 must be held to stop turning to remove all of the bolt. SEIKO EPSON Rev.1...
  • Page 88 Hexagon socket head cap bolts: 12-M3x22 Joint #5 Reduction Gear Side Pulley Caution: The bolts have marking paint which can make the bolts difficult to remove. Use a sharp object such as a flat head screw driver. SEIKO EPSON Rev.1...
  • Page 89 Arm #5 side. Caution: Be careful not to damage the arm or parts when removing. Circularspline side O-ring Direction to tap 10. Remove the shim from Arm #4 Shim Joint #5 Reduction Gear Pulley & Bearing Unit SEIKO EPSON Rev.1...
  • Page 90 12. Remove the Joint #5 Reduction Gear Unit Note: Attach two bolts to the Circularspline to lift the reduction gear from the arm. Caution: Be careful of the cross-roller bearing side O-ring when removing. 13. Remove the cross-roller bearing side O-ring Lift Upwards SEIKO EPSON Rev.1...
  • Page 91 6-1 Removing Joint #5 Reduction Gear Unit 14. Remove Joint #5 side bevel. Pull the bevel gear upwards to remove. 15. Clean Arm #5 of old grease. Note: New grease should be applied when replacing the reduction gear. Bevel Gear SK2 Grease SEIKO EPSON Rev.1...
  • Page 92 Do not apply pressed bearing in the bevel gear will sit grease Apply grease to the bevel gear teeth SK2 Grease Grease: 1 ～ 1.5g SK-2 Push downwards Bevel Gear Push the bevel gear into Arm #5 Level 3 SEIKO EPSON Rev.1...
  • Page 93 Arm #5. Make sure to place with cross-roller bearing fixing bolts facing in the two inset holes in the arm. Note: 2-M3 bolts can be used to help place the unit into the Waveform Generator arm. Inset Holes Cross-roller bolts Circularspline/Flexspline Placement Bolts Level 3 SEIKO EPSON Rev.1...
  • Page 94 12. Place Waveform Generator into the Flexspline. Note: Make sure the longside of the Waveform Longside Generator and the Flexspline match when placing. Caution: Make sure the direction of the Waveform Longside Generator is correct and is level with the Flexspline. Level 3 SEIKO EPSON Rev.1...
  • Page 95 24V power supply directly to the brake connector Loosen the fixing bolts of the Joint #4 motor unit and remove the Timing Belt. O-ring Caution: Method 2 will require re-tensioning of the Joint #4 timing belt and calibration of Joint #4 Level 3 SEIKO EPSON Rev.1...
  • Page 96 Note: Apply evenly to center of bearing. When bearing is placed in Arm #4 the Loctite will evenly disperse. Shim Note: Loctite requires approx. 8 hours to firmly bond. Larger Hole Flange Bearing Joint #5 Reduction Gear Pulley & Bearing Unit Loctite Level 3 SEIKO EPSON Rev.1...
  • Page 97 Caution: Be careful of the O-ring. Misalignment may occur and will damage or cut the O-ring. 19. Loosely tighten the two bolts until Arm #5 is held by the bolts but the wave washer is not fully pressed and can move. Press firmly Push Hold Level 3 SEIKO EPSON Rev.1...
  • Page 98 Hexagon socket head cap bolts: 12-M3x22 Tightening Torque: 2.4 0.1N ・ m ± Arm #4 1.5 ± 0.5mm Note: Gap between Arm #4 and Arm #5 should be even Arm #5 around the entire joint. (approx.. 1.5 ± 0.5mm) Level 3 SEIKO EPSON Rev.1...
  • Page 99 Tightening Torque: 4.0 0.2N ・ m ± Note: Apply Loctite 242 to the bolt end Loctite 242 (Loctite Depth: 3mm from bolt tip) Note: Use the pulley holding jig to fix the pulley in place while tightening SEIKO EPSON Rev.1...
  • Page 100 For Details, refer to Manipulator Manual Maintenance: 13.3 Replacing Joint #5 Timing Belt. 31. Replace the Joint # 6 Motor Unit and Joint #6 Timing Belt For Details, refer to Manipulator Manual Maintenance: 14.3 Replacing Joint #6 Timing Belt. SEIKO EPSON Rev.1...
  • Page 101 Command: Calpls 8538405, 4119406, -2598624, 0, 4672602, 40. Execute Calib to calculate HOFs Command: Calib 5 41. Next rough calibration must be performed on Joint #6. 42. Move Joint #5 to 0 pulse position. Command: Pulse 0,0,0,0,0,0 SEIKO EPSON Rev.1...
  • Page 102 46. Move Joint #6 until the level bubble is centered. Caution: Make sure the table the manipulator on is also level. Joint #6 Calibration Jigs Pin hole Pin hole 0 pulse position Joint #6 Level 0.5mm/m Level SEIKO EPSON Rev.1...
  • Page 103 53. The manipulator is calibrated. For Advanced calibration please follow the procedure in the Maintenance Manual using a customer’s teaching point. 54. Next test Joint #5 and Joint #6 in low and high power mode. Check for any abnormalities. If there are none you are finished. SEIKO EPSON Rev.1...

  • Page 104: Joint #6 Reduction Gear

    Reduction Gear J5/J6 included O-ring [1773892] O-RING 1773892 64.0X1.5 J5, J6 Flexspline side O-RING 1773893 45.4X0.80 J5, J6 Circularspline side FLANGE_J6_LP 1749510 J6 Flange Oil Seal 1739284 AC1213P1 for J6 S01: 4-M2.5x30 S02: 10-M3x22 Level 3 S01:12-M3x15 SEIKO EPSON Rev.1...
  • Page 105 Joint #6 Sleeve To remove push with flat of hand from front of Joint #6 Note: Before replacing clean the old gasket from the Sleeve Oil-Seal Joint #6 Flange Level 3 SEIKO EPSON Rev.1...
  • Page 106 Joint #6 timing belt will allow the reduction gear to be moved via the pulley. Rear View J5J6 unit Remove the Reduction Gear 10 fixing bolts holding the unit in the arm. Hexagon socket head cap bolts:10-M3x22 Level 3 SEIKO EPSON Rev.1...
  • Page 107 Remove the O-ring from on the J5J6 unit Caution: The O-ring maybe damaged when removing the reduction gear. When replacing always check the O-ring for damage or stretching. Clean the old grease from the J5J6 unit. O-ring Level 3 SEIKO EPSON Rev.1...
  • Page 108 Also the bolts will allow alignment of the placement holes in the J5J6 unit. Caution: Be careful of the O-ring when placing the reduction gear. Be sure it does not catch or move from placement position. Level 3 SEIKO EPSON Rev.1...
  • Page 109 Align the 4 bevel gear bolt holes and the 4 Waveform Generator fixing holes. Place Waveform Generator into Flexspline. Note: Make sure the longside of the Waveform Generator and Flexspline match when placing. Shortside Level 3 Longside Longside SEIKO EPSON Rev.1...
  • Page 110 This can be performed by either releasing the Joint #6 brake or by moving the Joint #6 pulley. Hexagon socket head cap bolts: 4-M3x30 Joint #6 Tightening Torque: 1N 0.1N ・ m ± Centering Jig ① ③ ④ Turn ② Level 3 SEIKO EPSON Rev.1...
  • Page 111 Grease: 1~1.5g SK-2 Note: In the case the oil-seal is not in the flange. Apply SK-2 grease to Oil Seal outside to help press back into flange. Grease: A small amount SK-1A Oil Seal Level 3 SEIKO EPSON Rev.1...
  • Page 112 0.1N ± Note: The gap around the Joint #6 Flange and the J5J6 unit Joint #6 Flange should be even and 1.0 0.5mm. Check at 4 points 90 ° each ± ④ for levelness. ② ① ③ SEIKO EPSON Rev.1...
  • Page 113 20. Clean any excess gasket from the manipulator and tape the back of the rear of the J5J6 unit. Liquid Gasket will require approx.. 8 Hours to be completely dry. However the manipulator may be tested and calibrated after approx.. 1 hour. Level 3 SEIKO EPSON Rev.1...
  • Page 114 25. Move Joint #6 until the level bubble is centered. Caution: Make sure the table the manipulator on is also level. Joint #6 Calibration Jigs Pin hole Pin hole 0 pulse position Joint #6 Level 0.5mm/m Level SEIKO EPSON Rev.1...
  • Page 115 33. The manipulator is calibrated. For Advanced calibration please follow the procedure in the Maintenance Manual using a customer’s teaching point. 34. Next test Joint #6 in low and high power mode. Check for any abnormalities. If there are none you are finished. SEIKO EPSON Rev.1...

  • Page 116: Motor Unit Parts Replacement

    MCNB10-59 Brake for J1, J2, J3 ASP/Brake 1670649 MCNB3-45 Brake for J4, J5, J6 HEAT CONDUCTIVE SHEET2 LP 1755573 For J1,J2,J3 Encoder Parts Name Code Replacement Rank Total Parts J6 Pully Fixing Jig Rotation Preventing JIG for J6 Pulley 1829116 SEIKO EPSON Rev.1...
  • Page 117 VT-Series Service Manual Confidential Level 4 J1 ~ J3 Motor Units 4-M5x12 J4 ~ J6 Motor Units 2-M4x55 029,030,031 032,033 Note: J2 Motor Plate Has Different Bolt Hole Size 3-M3x15 1-M5x6 Loctite 242 1-M4x12 1-M5x12 Loctite 242 SEIKO EPSON Rev.1...
  • Page 118 J1J2J3 Power Terminal and Motor Plate J5J6 Power Terminal and Motor Plate Number are in same direction. groove are in same direction. Number matches joint number. J4 motor plate groove is in the opposite J2 Motor Plate Changed Bolt Hole Size direction. SEIKO EPSON Rev.1...
  • Page 119 ✔ ✔ ✔ MCNB3-45 ⑦ ✔ ✔ ✔ ⑧ J123_MOTOR_PULLEY_LP Pulley ✔ ✔ ✔ J456_MOTOR_PULLEY_LP ⑨ ✔ ✔ ✔ ⑩ THERMAL SHEET HEAT CONDUCTIVE SHEET2 LP ✔ Utilizes Part - Does not utilize part △ Part Changed SEIKO EPSON Rev.1...
  • Page 120 Pulley Caution: Fixing The bolt is held with Loctite and may damage when removing. Caution: Do not apply pressure to the Encoder cover or damage will be caused to the motor unit. Remove Pulley SEIKO EPSON Rev.1...
  • Page 121 Note: The brake hub is part of the Pulley. Once the set Motor screw is removed the brake should be easily removed. Plate Remove the Motor Plate Hexagon socket head cap bolts: 4-M5x12 Screw Motor Hole 4-M5x12 Plate D-Cut SEIKO EPSON Rev.1...
  • Page 122 Pulley Caution: Fixing The bolt is held with Loctite and may damage when removing. Caution: Do not apply pressure to the Encoder cover or damage will be caused to the motor unit. Remove Pulley SEIKO EPSON Rev.1...
  • Page 123 Note: The brake hub is part of the Pulley. Once the set screw is removed the brake should be easily removed. Motor Brake Plate Remove the Motor Plate Hexagon socket head cap bolts: 2-M4x55 2-M4x55 Motor Plate SEIKO EPSON Rev.1...
  • Page 124 Replace the Brake set screw. Hexagon socket set screw: 1-M5x6 Brake Tightening Torque: 4.0 0.2N ・ m ± Apply Loctite 242 to end of set screw Area of Loctite 242 application N ・ m D-Cut Screw 1-M5x6 Set Screw Hole SEIKO EPSON Rev.1...
  • Page 125 Press motor shaft and allow the fixing bolt to be fully Pulley removed. inwards Caution: Do not apply pressure to the Encoder cover 1-M5x12 or damage will be caused to the motor unit. SEIKO EPSON Rev.1...
  • Page 126 The J5 and J6 cable is aligned in same orientation. However the motor plate is in Brake the opposite direction and the cable does not follow the groove. Brake cable Brake cable groove (In case of J4) Brake cable J5/J6 Brake cable J4 SEIKO EPSON Rev.1...
  • Page 127 The pulley must be even on all sides or the fixing bolt and Pulley brake hub will be misaligned causes damage when fixed by the timing belt. Parts Clearance A （ mm ） J4/ J5/ J6 Motor Pulley/ Brake 3.0 ± 0.5 Misaligned Pulley (Incorrect) Gap Large Gap Small SEIKO EPSON Rev.1...
  • Page 128 Caution: Depending on whether the motor unit is used for Joint #5 or Joint #6 the Terminator Switch position will change. Please check the switch position is correct for the motor joint. SW No. Motor Unit Switch Setting J1 ～ J5 SEIKO EPSON Rev.1...

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