Grease Procedure (PM) GP25 / YR-1-06VXH25-A00 Manipulator

Model Covered: YR-1-06VXH25-A00

Material Required:

GREASE, MOLYWHITE RE No.00 132412-1

GREASE, HARMONIC SK-1A 479035-2

TAPE, PIPE, TEFLON, 1/2 IN X 1296 IN TB4501/151720-1

ADHESIVE, GASKET, LIQUID, 200 GRAM TUBE, THREEBOND 1206C 479014-6

 
4      Notes on Grease Replenishment/Exchange Procedures

4.1    Grease Exchange Procedures for S-, L-, U-Axis Speed Reducer

4.1.1    Notes on Grease Exchange Procedures
Make sure to follow the instructions listed below at grease replenishment/ exchange. Failure to observe the following notes may result in damage to motor and speed reducer.

4.1.2    Grease Exchange Procedure

Fig. 4-1: S-, L-, U-Axis Speed Reducer Diagram

1.    Before injecting grease, the posture of the manipulator must be set as indicated in table 4-1 “Recommended Posture for Grease Injection” . If it is difficult to make the recommended posture because of external cabling or etc., adjust the posture as much as possible to make the position of grease inlet located in the lower part and the position of exhaust port located in the upper part. If the exhaust port is located in the lower part, grease may not be exchanged properly.

Table 4-1: Recommended Posture for Grease Injection

2.    Remove the hexagon socket head plugs from the grease inlet and grease exhaust port.

3.    Install a grease zerk A-PT3/8 to the grease inlet. (The grease zerk is delivered with the manipulator.)

4.    Inject the grease through the grease inlet using a grease gun.
- Grease type:    Molywhite RE No. 00
- Grease lubricator:  Air-operated grease gun (e.g., Powerlube P3-01JC made by Macnaught)
- Amount of grease: 7 g/s or less (For example, if grease is supplied from the lubricator at 2 times/s, set the amount to 3.5 g/time or less)
- Air supply pressure of grease pump: Approximately 0.3 MPa or less.

Table 4-2: Amount of Grease

5.    Injection stop:
- <When replacing the speed reducer>
Stop injecting grease when grease can be seen from the exhaust port.
- <When exchanging grease>
The old grease is discharged from the grease exhaust port. At this time, stop injection when the mixture of the old grease and the new grease in an equal ratio is seen. And then, skip the steps 6 and 7, and proceed to the step 8.

6.    Operate each axis about 5 times in the teach mode as shown in fig. 4-3 “Teaching Operation for Each Axis”.

Table 4-3: Teaching Operation for Each Axis

7.    Inject grease again, and when grease comes out of the exhaust port, grease injection is completed.

8.    Discharge the specified amount of grease from the grease inlet or grease exhaust port. (Refer to table 4-4 “Amount of Grease Discharged from Each Axis”.) In order to discharge the specified amount of grease, receive the discharged grease by using a container, and then measure the weight of the discharged grease by weighing the container till the amount reaches to the specified amount.

Use one of the following methods to discharge grease:

Method 1: Extruding grease by air
(1)    Connect the joint and the hose to the grease inlet.
(2)    Connect the regulator to the grease exhaust port.
(3)    Inject air from the grease exhaust port to extrude grease by air. (Extrusion air pressure: 0.025 MPa or less)
(4)    If the grease is not discharged enough by injecting air, operate the manipulator about 5 times in the teach mode as shown in table 4-5 “Grease Discharging Operation for Each Axis”.

Method 2: Suctioning grease out
(1)    Keep the inlet open and insert the tube into the exhaust port.
(2)    Discharge grease by suctioning grease out of the exhaust port. (Suction pressure: 0.025 MPa or less)
(3)    If grease is not discharged by suctioning, operate the manipulator again about 5 times in the teach mode as shown in table 4-5 “Grease Discharging Operation for Each Axis”.

Table 4-4: Amount of Grease Discharged from Each Axis

Table 4-5: Grease Discharging Operation for Each Axis

9.    For the axis where grease is exchanged, perform a playback operation indicated in table 4-6 “Running-In Operation for Each Axis” for running-in the speed reducer with grease. At this time, grease may be discharged during the operation. Remove the grease zerk from the grease inlet, and clean and degrease the tap part and the thread part of the plug. Wrap the seal tape TB4501 around the plug. Tighten the plug on the grease inlet
with the tightening torque of 16.5 N m (1.7 kgf m). Also, discharge the excess grease in order not to increase the inner pressure of the speed reducer. Attach a bag to receive grease such as indicated in fig. 4-2 “Grease Receiving Bag (Example)”, and then perform the running-in operation.

Table 4-6: Running-In Operation for Each Axis

Fig. 4-2: Grease Receiving Bag (Example)

10.    Wipe the discharged grease with a cloth. Clean and degrease the tap part and the thread part of the plug. Wrap the seal tape TB4501 around the plug. Reinstall the plug on the grease inlet, and tighten the plug with the tightening torque of 16.5 N m (1.7 kgf m).
 

4.2    Grease Replenishment Procedures for R-, B-Axis Speed Reducer and R-, T-Axis Gear
4.2.1    Notes on Grease Replenishment Procedures
Make sure to follow the instructions listed below at grease exchange. Failure to observe the following notes may result in damage to motor and speed reducer.

4.2.2    Grease Replenishment Procedures for R-Axis Speed Reducer

Fig. 4-3: R-Axis Speed Reducer Diagram

1.    Make the posture of the U-arm horizontal to the ground.

2.    Remove the hexagon socket head plugs from the grease inlet and the air exhaust port.

3.    Install a grease zerk A-PT1/8 to the grease inlet. (The grease zerk is delivered with the manipulator.)

4.    Inject the grease through the grease inlet using a grease gun.
- Grease type:    Harmonic Grease SK-1A
- Amount of grease:    7 g (7.6 cc)

5.    Remove the grease zerk from the grease inlet and install the plug. Wrap the seal tape TB4501 around the plug, and then tighten the plug by using the tightening torque 4.9 N m (0.49 kg fm).

6.    Install the plug to the air exhaust port.
Wrap the seal tape TB4501 around the plug, and then tighten the plug by using the tightening torque 4.9 N m (0.49 kg fm).

4.2.3    Grease Replenishment Procedures for B-Axis Speed Reducer
 

Fig. 4-4: B-Axis Speed Reducer Diagram

1.    Adjust the posture of the manipulator to perform grease replenishment smoothly.

2.    Remove the hexagon socket head cap screws M6 from the grease inlet and the air exhaust port.

3.    Install a grease zerk A-MT6×1 to the grease inlet. (The grease zerk is delivered with the manipulator.)

4.    Inject the grease into the grease inlet.
- Grease type: Harmonic Grease SK-1A
- Amount of grease: 7 g (7.6 cc)

5.    Remove the grease zerk from the grease inlet. Install the hexagon socket head cap screw M6 to the grease inlet. When installing the screw, apply Three Bond 1206C on the thread part of the screw and then tighten the screw with a tightening torque of 6 Nm (0.6 kgfm).

6.    Install the hexagon socket head cap screw M6 to the air exhaust port. When installing the screw, apply Three Bond 1206C on the thread part of the screw and then tighten the screw with a tightening torque of 6 Nm (0.6 kgfm).

4.2.4    Grease Replenishment Procedures for R-Axis Gear
 

Fig. 4-5: R-Axis Gear Diagram

1.    Make the posture of the U-arm horizontal to the ground.

2.    Remove the hexagon socket head plug from the grease inlet and the air exhaust port.

3.    Install a grease zerk A-PT1/8 to the grease inlet. (The grease zerk is delivered with the manipulator.)

4.    Inject the grease into the grease inlet.
- Grease type: Harmonic Grease SK-1A
- Amount of grease: 3 g (3.3 cc) (for replenishment); 85 g (92.4 cc) (when the speed-reducer is replaced)

5.    Remove the grease zerk from the grease inlet and install the plug. Wrap the seal tape TB4501 around the plug and then tighten the plug by using the tightening torque 4.9 Nm (0.49 kgfm).

6.    Install the plug to the air exhaust port.
Wrap the seal tape TB4501 around the plug and then tighten the plug by using the tightening torque 4.9 Nm (0.49 kgfm).
 

4.2.5    Grease Replenishment Procedures for T-Axis Gear

Fig. 4-6: T-Axis Gear Diagram

1.    Adjust the posture of the manipulator to perform grease replenishment smoothly.

2.    Remove the hexagon socket head cap screws M6 from the grease inlet 1 and the air exhaust port.

3.    Install a grease zerk A-MT6×1 to the grease inlet 1. (The grease zerk is delivered with the manipulator.)

4.    Inject the grease into the grease inlet 1.
- Grease type: Harmonic Grease SK-1A
- Amount of grease: 2 g (2.2 cc)

5.    Remove the grease zerk from the grease inlet 1. Install the hexagon socket head cap screw M6 to the grease inlet 1. When installing the screw, apply Three Bond 1206C on the thread part of the screw and then tighten the screw with a tightening torque of 6 Nm (0.6 kgfm).

6.    Remove the hexagon socket head cap screw M6 from the grease inlet 2.

7.    Install a grease zerk A-MT6×1 to the grease inlet 2. (The grease zerk is delivered with the manipulator.)

8.    Inject the grease into the grease inlet 2.
- Grease type: Harmonic Grease SK-1A
- Amount of grease: 2 g (2.2 cc)

9.    Remove the grease zerk from the grease inlet 2. Install the hexagon socket head cap screw M6 to the grease inlet 2. When installing the screw, apply Three Bond 1206C on the thread part of the screw and then tighten the screw with a tightening torque of 6 Nm (0.6 kgfm).

10.    Install the hexagon socket head cap screw M6 to the air exhaust port. When installing the screw, apply Three Bond 1206C on the thread part of the screw and then tighten the screw with a tightening torque of 6 Nm (0.6 kgfm).