GP25-12 inspection, grease exchange and battery replacement
Maintenance of the GP25-12 is almost the same as on the GP25: the speed reducers of the basic axes (S-, L- and U-axes) get a grease exchange, while the wrist side (R-, B-axis speed reducer and R-, T-axis gear) only gets a small grease replenishment. Inspection intervals are counted in hours with the servo power ON.
Turn the power off and tag it out before maintenance. If you disconnect the connector between a motor and the multi-port connector, the encoder absolute data (ABSO data) is lost.
Inspection items
| No. | Items | Schedule | What to do |
|---|---|---|---|
| 1 | Alignment mark | Daily | Check that the marks match at the home position and are not misaligned |
| 2 | Working area and manipulator | Daily | Check for seeped oil and cracks; clean |
| 3 | Baseplate mounting bolts | 1000 h cycle | Tighten |
| 4 | Connector for manipulator cable | 1000 h cycle | Check for loose connectors |
| 5 (-A10 / -A11) | Protective tubing (for arc welding use only) | 1000 h cycle / 24000 h | Clean the spatter and check for holes / replace |
| 5 (-C10) | Drain plug | 1000 h cycle | Discharge water content due to dew condensation in the manipulator |
| 6 | Timing belts for B- and T-axes | 12000 h cycle | Check the belt tension and condition |
| 7 | Wire harness in manipulator (lead for the SLU-axes wires, power supply board included) | Daily / 12000 h / 24000 h | Check for damage and dirt / check the flexible hose / replace |
| 8 | Wire harness in manipulator (lead for the BT-axis wires) | 12000 h / 24000 h | Check the fixed part / replace |
| 9 | Battery pack in manipulator | 24000 h | Replace when the battery alarm occurs or at 24000 h |
| 10 | S, L, U, R-axis motor | 12000 h cycle | Check for grease leakage |
| 11 | S, L, U-axis speed reducer | 12000 h cycle | Replace grease (grease gun) |
| 12 | R, B-axis speed reducer | 12000 h cycle | Supply grease (hand pump or injection syringe) |
| 13 | R, T-axis gear | 12000 h cycle | Supply grease (hand pump or injection syringe) |
| 14 | Overhaul | 36000 h | Done by your YASKAWA representative |
Grease used
| Inspected parts | -A10 / -A11 | -C10 (drip-proof) |
|---|---|---|
| S-, L- and U-axes speed reducers | Molywhite RE No.00 | RV grease LB No.00 |
| R- and B-axes speed reducers, R, T-axes gear | Harmonic Grease SK-1A | Harmonic Grease SK-1A |
Grease exchange for the S-, L- and U-axes speed reducers (-A10 / -A11)
The amounts and steps below come from the maintenance manual for -A10 / -A11. A maintenance manual dedicated to the drip-proof -C10 was not available, so check the amounts for -C10 in YASKAWA documentation.
| Axis to exchange grease | Amount of grease (approx.) | Amount of exhausted grease |
|---|---|---|
| S-axis | 1650 g | 50 ± 5 g (57 ± 5 cc) |
| L-axis | 750 g | 90 ± 5 g (103 ± 5 cc) |
| U-axis | 370 g | 60 ± 5 g (69 ± 5 cc) |
- Always remove the plug from the grease exhaust port before injecting. Inject with a grease gun.
- When exchanging grease, stop when old and new grease come out in about equal amounts, then discharge the amount in the table from the exhaust port.
- Perform the running-in operation on the exchanged axis (±45°, MOVJ VJ=50.00, timer 1.0 s after each operation, 15 minutes).
- The maintenance manual gives no separate amount for the first supply only.
| Axis | Grease inlet | Grease exhaust port |
|---|---|---|
| S-, L- and U-axes | Hexagon socket head plug PT3/8 | Hexagon socket head plug NPTF3/8 |
Wind seal tape TB4501 on the plugs and tighten them to 16.5 N·m (1.7 kgf·m). When ceiling-mounted, the grease inlet and exhaust port are swapped.
Which port (grease inlet or grease exhaust port) gets its plug in the last step of the grease exchange is worded differently across the GP25-family manuals. Check with YASKAWA before you work.
Grease replenishment for the R-, B-axis speed reducer and R-, T-axis gear
Inject a small amount of Harmonic Grease SK-1A.
| Part | Amount of grease | Grease inlet | Tightening |
|---|---|---|---|
| R-axis speed reducer | 7 g (7.6 cc) | Hexagon socket head plug PT1/8 | 4.9 N·m (0.49 kgf·m), seal tape TB4501 |
| B-axis speed reducer | 7 g (7.6 cc) | Hexagon socket head cap screw M6 | 6 N·m (0.6 kgf·m), apply Three Bond 1206C |
| R-axis gear | 3 g (3.3 cc) (85 g (92.4 cc) when the speed reducer is replaced) | Hexagon socket head plug | 4.9 N·m (0.49 kgf·m) |
| T-axis gear | 2 g (2.2 cc) each into grease inlet 1 and grease inlet 2 | Hexagon socket head cap screw M6 | 6 N·m (0.6 kgf·m) |
Replacing the battery packs in the manipulator
There are three battery packs (HW1483880-A), installed together with the multi-port connectors. Replace them when the battery alarm occurs or at 24000 h. The cover mounting bolts are M4×12, tightened to 2.8 N·m.
- When the YRC1000 power can be turned on: turn ON the power supply of the YRC1000, turn OFF the servo power, and replace the pack with the emergency stop button pressed. Fix the new pack with a cable tie.
- When the power cannot be turned on: first connect the lead for battery replacement (HW1471281-A) and the battery pack for backup to the "IN" port of the multi-port connector, then replace the pack. Remove the backup battery pack promptly after the replacement; if it stays connected, the voltage of the new battery drops.
Related articles
- GP25-12 specifications
- GP25 inspection, grease exchange and battery replacement
- Encoder battery replacement
Source: based on YASKAWA manuals HW1484889 (GP25-12 instructions rev 4, Japanese), HW1485971 (GP25-12 instructions, drip-proof specification, rev 0, Japanese) and HW1484893 (GP25-12/AR2010 maintenance manual rev 4, Japanese). English terms follow HW1484890 (MOTOMAN-GP25-12 INSTRUCTIONS rev 2; older than the Japanese rev 4), HW1485972 (MOTOMAN-GP25-12 INSTRUCTIONS, drip-proof, rev 0) and HW1484894 (MOTOMAN-GP25-12/AR2010 MAINTENANCE MANUAL rev 4).