GP25SV inspection, grease exchange and battery replacement
The GP25SV is maintained the same way as 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. However, the grease amounts differ between documents, so some values are not listed on this page (see the note below).
The Japanese maintenance manual names the axes JT1 to JT6 (JT1 = S-axis, JT2 = L-axis, JT3 = U-axis, JT4 = R-axis, JT5 = B-axis, JT6 = T-axis).
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 |
| 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 | Timing belts for B- and T-axes | 12000 h cycle | Check the belt tension and condition |
| 6 | Wire harness in manipulator (lead for the SLU-axes wires, power supply board included) | Daily / 12000 h / 24000 h | Check for damage / check the flexible hose / replace |
| 7 | Wire harness in manipulator (lead for the BT-axis wires) | 12000 h / 24000 h | Check the fixed part / replace |
| 8 | Battery pack in manipulator | 24000 h | Replace when the battery alarm occurs or at 24000 h |
| 9 | S, L, U, R-axis motor | 12000 h cycle | Check for grease leakage |
| 10 | S, L, U-axis speed reducer | 12000 h cycle | Replace grease (grease gun) |
| 11 | R, B-axis speed reducer | 12000 h cycle | Supply grease (hand pump or injection syringe) |
| 12 | R, T-axis gear | 12000 h cycle | Supply grease (hand pump or injection syringe) |
| 13 | Overhaul | 36000 h | Done by your YASKAWA representative |
Grease used
| Inspected parts | Grease |
|---|---|
| S-, L- and U-axes speed reducers | Molywhite RE No.00 |
| R- and B-axes speed reducers, R, T-axes gear | Harmonic Grease SK-1A |
Grease exchange for the S-, L- and U-axes speed reducers
Key steps
- Remove the plugs from the grease inlet and grease exhaust port, and inject grease from the grease inlet.
- When to stop injecting: when replacing the speed reducer, stop when grease can be seen at the exhaust port; when exchanging grease, stop when the grease coming out of the exhaust port looks about half old and half new.
- (When replacing the speed reducer) Operate the axis about 5 times at ±45° in the teach mode, then inject again until grease overflows from the exhaust port.
- Discharge the specified amount of grease into a container and weigh it. Use one of these methods:
- Extruding grease by air from the grease exhaust port (extrusion air pressure 0.025 MPa or less).
- Suctioning grease out of the exhaust port with a tube (suction pressure 0.025 MPa or less).
- If no grease comes out, operate the axis about 5 times at ±45° in the teach mode.
- Perform the running-in operation by playback: the exchanged axis at ±45°, MOVJ VJ=50.00, timer 1.0 s after each operation, for 15 minutes. Grease can come out during the operation, so attach a grease recovery bag to the exhaust port.
- Wind seal tape TB4501 on the plug and tighten it to 16.5 N·m (1.7 kgf·m).
The values below differ between the Japanese maintenance manual (rev 0) and the English maintenance manual (rev 4), so they are not listed. The English values are the same as the GP25, while the Japanese values are specific to the GP25SV. Always check with YASKAWA which is correct.
- Amount of grease (approx.) for the S-, L- and U-axes speed reducers
- Amount of exhausted grease for the S-, L- and U-axes speed reducers
- Amount of grease for the R-axis gear when the speed reducer is replaced
The following are also not listed because they are not confirmed:
- Which port (grease inlet or grease exhaust port) gets its plug before the running-in operation (worded differently across the GP25-family manuals)
- Plug types of the grease inlet and exhaust port, injection speed, air supply pressure of the grease pump, and the amount and tightening torque for the R-axis speed reducer (the Japanese pages have an unreadable text layer and have not yet been checked visually)
Grease replenishment for the B-axis speed reducer and R-, T-axis gear
Inject a small amount of Harmonic Grease SK-1A. Grease is not exhausted from the air exhaust port, so do not inject too much. Remove the plug (or screw) from the air exhaust port before injecting. For the R-axis gear, make the U-arm horizontal to the ground first. The grease inlet and air exhaust port change depending on the mounting method.
| Part | Amount of grease | Grease inlet | Tightening |
|---|---|---|---|
| B-axis speed reducer | 7 g | Grease zerk A-MT6×1 (hexagon socket head cap screw) | 6 N·m (0.6 kgf·m), apply Three Bond 1206C |
| R-axis gear | 3 g (replenishment) | Grease zerk A-PT1/8 (plug PT1/8) | 4.9 N·m (0.49 kgf·m), seal tape TB4501 |
| T-axis gear | 2 g each into grease inlet 1 and grease inlet 2 | Grease zerk A-MT6×1 (hexagon socket head cap screw M6) | 6 N·m (0.6 kgf·m), apply Three Bond 1206C |
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 (0.29 kgf·m). The mating faces of the U-arm covers are sealed with gaskets.
- 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 wire 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.
Related articles
- GP25SV specifications
- GP25 inspection, grease exchange and battery replacement
- Encoder battery replacement
Source: based on YASKAWA manuals HW1484934 (GP25SV instructions rev 0, Japanese) and HW1484713 (GP25SV maintenance manual rev 0, Japanese). HW1484713 has a broken text layer, so only pages checked against the page images were used. English terms follow HW1484952 (MOTOMAN-GP25SV MAINTENANCE MANUAL rev 4), which differs from the Japanese rev 0 in revision and layout. No English edition of the GP25SV instructions was available.