GP7 and GP8 inspection, grease replenishment and battery replacement
The GP8 and GP7 share the same maintenance. Grease is only replenished, never exchanged, and every axis gets a small amount from an injection syringe. 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 check for damage |
| 2 | Working area and manipulator | Daily | Check for seeped oil, cracks and damage; clean |
| 3 | Baseplate mounting bolts | 1000 h cycle | Check for missing or loose bolts and tighten |
| 4 | Cover mounting screws | 1000 h cycle | Check for missing or loose screws and tighten |
| 5 | Connector base | 1000 h cycle | Check for looseness |
| 6 | Connector of manipulator cable | 1000 h cycle | Check for looseness |
| 7 | L, U, R, B, T-axis timing belt | 12000 h cycle | Check the belt tension and condition |
| 8 | Wire harness in manipulator | 12000 h cycle / 24000 h | Check conduction and wear of the protective spring / replace |
| 9 | Battery pack in manipulator | 24000 h | Replace when the battery alarm occurs or at 24000 h |
| 10 | S-axis speed reducer, S-axis gear | 12000 h cycle | Check for malfunction and supply grease (injection syringe) |
| 11 | LU-axes speed reducers | 12000 h cycle | Check for malfunction and supply grease (injection syringe) |
| 12 | R-axis speed reducer | 12000 h cycle | Check for malfunction and supply grease (injection syringe) |
| 13 | BT-axes speed reducers, T-axis gear | 12000 h cycle | Check for malfunction and supply grease (injection syringe) |
| 14 | Overhaul | 36000 h | Done by your YASKAWA representative |
On the standard specification, all speed reducers and the S- and T-axis gears use Harmonic Grease SK-1A.
Grease replenishment
- Do not use a grease pump. Use the injection syringe for replenishment (a recommended spare part). Soften the grease by stirring before filling the syringe with the necessary amount.
- Injecting more than specified can raise the internal pressure during operation and cause grease leakage.
- Grease may flow out of the inlet, so prepare a cloth and a container to receive it.
- When installing a screw on a grease inlet, apply Three Bond 1206C to the threading part.
- The maintenance manual gives no separate amount for the first supply and no grease exhaust port.
| Part | Amount of grease | Grease inlet | Tightening |
|---|---|---|---|
| S-axis speed reducer | 3 g | Hexagon socket head cap screw M5 | (not listed) |
| S-axis gear | 3 g | Hexagon socket head cap screw M5 | (not listed) |
| L-axis speed reducer | 3 g | Hexagon socket head cap screw M6 (take off the cover) | 5.0 N·m (0.51 kgf·m) |
| U-axis speed reducer | 1.5 g | Hexagon socket head cap screw M6 (take off the cover) | 5.0 N·m (0.51 kgf·m) |
| R-axis speed reducer | 1 g | (not listed) | (not listed) |
| B-axis speed reducer | 1 g | Plug LP-M5 | — |
| T-axis speed reducer, T-axis gear | 1 g | Hexagon socket head cap screw M4 and plug LP-M5 | M4: 1.4 N·m (0.14 kgf·m) |
- The screw size and tightening torque for the R-axis speed reducer grease inlet are not listed: the Japanese maintenance manual says to remove an M5 screw and then install an M6 screw.
- The tightening torque of the S-axis speed reducer and S-axis gear screws is not listed because it could not be read in the Japanese figure.
Check the actual screw before you work and ask YASKAWA if needed.
Replacing the battery packs in the manipulator
There are three battery packs, installed together with the multi-port connectors. Replace them when the battery alarm occurs or at 24000 h.
- When the power can be turned on: turn ON the controller power supply, turn OFF the servo power, and with the emergency stop button pressed, disconnect the old battery pack from the multi-port connector and connect the new one. Fix it with a cable tie and tighten the cover bolts to the specified torque.
- 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. Otherwise the encoder absolute data is lost. Remove the backup battery pack after the replacement.
Food grade grease specification (-F00)
The YR-1-06VX8-F00 / YR-1-06VX7-F00 differ from the standard specification only in the grease, and are for handling applications only.
| Item | Food grade grease specification (-F00) |
|---|---|
| Grease (all axes) | Lubriplate SYNXTREME FG-0 |
| Amount of grease | Same as the standard specification |
| Ambient temperature | +15 to +45 °C |
| Grease supply, timing belt and wire harness check | 9000 h cycle |
| Wire harness replacement, battery pack replacement | 18000 h |
| Overhaul | 18000 h |
Related articles
Source: based on YASKAWA manuals HW1483943 (GP8/AR700, GP7/AR900 instructions rev 12, Japanese), HW1483945 (GP8/AR700, GP7/AR900 maintenance manual rev 1, Japanese) and HW1484384 (GP8, GP7 supplemental instructions, food grade grease, rev 1, Japanese). English terms follow HW1483944 (MOTOMAN-GP8/AR700, -GP7/AR900 INSTRUCTIONS rev 5; older than the Japanese rev 12), HW1483946 (MOTOMAN-GP8/AR700, -GP7/AR900 MAINTENANCE MANUAL rev 1) and HW1484385 (MOTOMAN-GP8,-GP7 SUPPLEMENTAL INSTRUCTIONS rev 1).