SP210 / GP225 inspection, grease exchange and battery replacement
The GP225 and the SP210 (type YR-1-06VX225) have the same maintenance. Inspection intervals are counted in hours with the servo power ON. If the axes are used very frequently (for example in handling applications) or in special conditions, ask YASKAWA for an individual review.
Do not remove a motor or release a brake. The arm can turn in an unexpected direction. Turn the power off and tag it out before maintenance. Also, 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 dirty or damaged (or check for misalignment at the check point) |
| 2 | Working area and manipulator | Daily | Check for seeped oil, cracks and damage; clean off dust and spatter |
| 3 | Baseplate mounting bolts | 1000 h cycle | Check for missing or loose bolts and tighten |
| 4 | Covers, bolts for the connector base | 12000 h cycle | Check for missing or loose bolts and tighten |
| 5 | Connector for manipulator cable | 1000 h cycle | Check by hand for loose connectors |
| 6 | Protective tubing | 1000 h cycle | Clean the spatter; check for holes and tears (replace if found) |
| 7 | Gas balancer | 6000 h cycle | Supply grease to the joint of the balancer; check the gas pressure (discharge or charge gas if needed) |
| 8 | Wire harness in manipulator (S- to T-axes, power supply board included) | Daily / 12000 h / 24000 h | Daily visual check for damage and dirt; every 12000 h check the lead wires and wear of the protective spring; replace at 24000 h |
| 9 | Battery pack in manipulator | 24000 h | Replace when the battery alarm occurs or at 24000 h |
| 10 | Motors for all axes | 12000 h cycle | Check for grease leakage |
| 11 | Speed reducers for all axes | 12000 h cycle | Check for malfunction and replace grease |
| 12 | R-, B-, and T-axes gear | 12000 h cycle | Check for malfunction and replace grease |
| 13 | Overhaul | 36000 h | Done by the YASKAWA service department |
The manual also states, for each item, whether it may be done by specified personnel at the user, by trained licensed personnel, or only by the YASKAWA service department. A small amount of the oil that keeps the gas sealed may seep from the bottom of the gas balancer.
Grease used
| Inspected parts | Grease used |
|---|---|
| Speed reducers for all axes, R-, B-, and T-axes gear | Molywhite RE No.00 |
| Joint of the balancer | Gadus S2 V220 2 (*) |
(*) From rev 13, the gas balancer link part uses Gadus S2 V220 2, the successor to Alvania EP Grease 2. The two are compatible, so Alvania EP Grease 2 can still be used. (The Japanese manual writes the product as "ガダス S2 V220J 2 (EP)".)
The drip proof specifications (-C00) use RV grease LB00 for the gear and each axis speed reducer.
Grease exchange for the speed reducers and gears
Conditions to keep
- Always remove the plug from the grease exhaust port before injecting. With the plug in place, grease can enter the motor or push out the oil seal. A tube on the exhaust port must be 150 mm or shorter with an inside diameter of 6 mm or more.
- Inject with a grease pump at 7 g/s or less. At 2 shots per second, that means 3.5 g per shot or less. Keep the air supply pressure of the grease pump at approximately 0.3 MPa or less.
- When extruding grease by air, keep the pressure at 0.025 MPa or less. Grease can shoot out, so lead it into a container with a tube.
- Fill the hoses to the grease inlet with grease first, so no air enters the speed reducer.
- After mounting a speed reducer or motor, wait 30 minutes or more for the sealant to harden before injecting grease.
Amount of grease (approx.)
| Axis to exchange grease | Amount of grease |
|---|---|
| S-axis | 4350 g |
| L-axis | 2180 g |
| U-axis | 2180 g |
| R-, B-, and T-axis gear in the casing | 2260 g |
| R-axis | 1910 g |
| B-, and T-axes | 1130 g |
Key steps
- Set the recommended posture for grease injection: L-axis 0° for the L-axis; L-axis and U-axis 0° for the U-axis; U-, R-, B- and T-axis 0° for the R-, B- and T-axis side (if not possible, make the U-arm horizontal to the ground). If external cabling prevents this, keep the grease inlet low and the grease exhaust port high.
- Remove the hexagon socket head plugs from the grease inlet and exhaust port, install the grease zerk A-PT3/8 (delivered with the manipulator) and inject.
- When exchanging grease, stop when old and new grease come out of the exhaust port in about equal amounts, and go to step 5. When replacing the speed reducer, stop when grease appears at the exhaust port.
- (Speed reducer replacement only) Operate each axis about 5 times in the teach mode (S-, L-, U- and B-axis ±45°, R- and T-axis ±90°, user-specified speed), then inject again until grease comes out of the exhaust port.
- Discharge the amount below. Weigh the grease in a container while you either extrude it by air from the exhaust port (0.025 MPa or less) or suction it out of the exhaust port (suction pressure 0.025 MPa or less). If little comes out, operate the axis about 5 times in the teach mode.
| Axis to exchange grease | Amount of exhausted grease |
|---|---|
| S-axis | 0 (unnecessary) |
| L-axis | 240 ± 30 g (275 ± 35 cc) |
| U-axis | 295 ± 40 g (340 ± 45 cc) |
| R-, B-, and T-axis gear in the casing | 115 ± 15 g (130 ± 15 cc) |
| R-axis | 95 ± 10 g (110 ± 15 cc) |
| B-, and T-axes | 55 ± 5 g (65 ± 10 cc) |
- Remove the grease zerk, clean and degrease the thread of the plug, wrap seal tape TB4501 around it and install it in the grease inlet. Attach a grease receiving bag to the exhaust port.
- Perform the running-in operation by playback: the exchanged axis at ±45° (R- and T-axis ±90°), MOVJ VJ=50.00, timer 1.0 s after each operation, for 15 minutes.
- Wipe off the discharged grease and install the exhaust port plug, also with seal tape.
If too little grease is discharged, the inner pressure rises during operation and grease leaks. If too much is discharged, lubrication is insufficient and the speed reducer wears early.
| Axis | Plug for the grease inlet | Plug for the grease exhaust port |
|---|---|---|
| S-axis | PT1/4, 12 N·m | PT3/8, 23 N·m |
| L-axis, U-axis | PT1/8, 4.9 N·m | PT3/8, 23 N·m |
| R-, B-, and T-axis gear in the casing | PT1/8, 4.9 N·m | PT3/8, 23 N·m (*) |
| R-axis, B- and T-axis | PT1/8, 4.9 N·m | PT1/8, 4.9 N·m |
(*) For the plug of the grease exhaust port (hexagon socket head plug) of the R-, B-, and T-axis gear in the casing, Table 5-6 of the Japanese manual gives PT3/8, 23 N·m. Table 5-6 of the English manual gives PT1/8, 4.9 N·m, but Fig. 5-1 of the same English manual labels it "Grease exhaust port (Hexagon socket head plug PT3/8)". This page follows the Japanese manual. Check the size of the actual plug before tightening.
Stay out of the manipulator's range of motion while it moves.
Gas balancer
Grease for the gas balancer link part (6000 h cycle)
Remove the plugs (PT1/8) from the grease inlet and grease exhaust port of link 1 and link 2, and inject Gadus S2 V220 2 (or Alvania EP Grease 2).
| Link | Amount of grease | First supply only |
|---|---|---|
| Link 1 | 8 cc | 30 cc |
| Link 2 | 8 cc | 16 cc |
Wipe off the discharged grease and tighten the plugs, with seal tape TB4501 on the threads, to 4.9 N·m.
Gas pressure inspection (6000 h cycle)
The gas balancer contains high-pressure nitrogen gas. Do not inject any other gas. Work with enough ventilation, and before you start, make sure the L-axis motor brake is working or the L-arm is fixed.
The adequate gas pressure depends on the surface temperature of the gas balancer.
| Surface temperature | −10 °C | 0 °C | 10 °C | 20 °C | 25 °C | 30 °C | 40 °C | 50 °C | 60 °C |
|---|---|---|---|---|---|---|---|---|---|
| Adequate gas pressure (MPa) | 10.5 | 11.1 | 11.6 | 12.2 | 12.4 | 12.7 | 13.2 | 13.8 | 14.4 |
Move the manipulator to the home position and turn off the controller. Connect the quick connector and the gas filling device (with digital pressure gauge) to the gas inlet, and read the surface temperature and the pressure. If the pressure is above the adequate value, discharge gas down to it. If it is 0.5 MPa or more below, charge gas up to it.
Replacing the battery packs in the manipulator
There are three battery packs (for S-, L-axes, for U-, R-axes and for B-, T-axes), each near a multi-port connector. Replace them when the battery alarm appears on the programming pendant, or at 24000 h.
- When the YRC1000 power can be turned on: turn ON the power supply of the YRC1000, turn OFF the servo power, and work with the emergency stop button pressed. Remove the cover, cut the cable tie, and swap the old battery pack for the new one. The data is kept because the power is on.
- When the power cannot be turned on: prepare the lead wires for battery replacement and a separate battery pack for backup. First connect the lead wires and the backup battery pack to the "IN" (or "Y") port of the multi-port connector, then replace the old pack. Otherwise the encoder absolute data is lost.
In both cases, put the connector and leads back into the protective tube, fix it with cable ties, and refit the cover without pinching any cable.
Main changes in maintenance manual rev 13
This page follows the latest maintenance manual, rev 13. The grease amounts, cycles, tightening torques and gas pressures are the same as in rev 11. The main changes are:
- The grease for the gas balancer link part changed to Gadus S2 V220 2 (also in the items needed for gas balancer replacement).
- Part number changes: spacer HW1303371-1 → HW2302825-1, B holder HW0401509-1 → HW2402632-1, conical spring washer HW9403617-1 → HW2402633-1.
- -D00 added for the YR-1-06VX180-120.
- Safety: do not release the brake except during an emergency or abnormality; a list of warning labels was added.
Related articles
- SP210 / GP225 specifications
- GP225 drip proof specifications (-C00): differences from the standard type
- SP210 / GP225 zeroing function
- Encoder battery replacement
- Home position calibration
- Alarm 4312 ENCODER BATTERY ERROR
Source: based on YASKAWA manuals HW1484441 (SP210 instructions, Japanese), HW1484397 (GP225 instructions, Japanese) and HW1484413.13 (GP225/SP210 maintenance manual rev 13, Japanese). English terms follow HW1484442 (MOTOMAN-SP210 INSTRUCTIONS) and HW1484414.13 (maintenance manual rev 13, English).