Replacing the Motor or the Gearbox on the Main Axis

Overview

The use and application of the information contained herein require expertise in the design and programming of automated control systems. Only you, the user, machine builder or integrator, can be aware of all the conditions and factors present during installation and setup, operation, repair, and maintenance of the machine or process.

You must also consider any applicable standards and/or regulations with respect to grounding of all equipment. Verify compliance with any safety information, different electrical requirements, and normative standards that apply to your machine or process in the use of this equipment.

DANGER
	ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires except under the specific conditions specified in the appropriate hardware guide for this equipment. Always use a properly rated voltage sensing device to confirm the power is off where and when indicated. Operate electrical components only with a connected protective ground (earth) cable. Verify the secure connection of the protective ground (earth) cable to all electrical devices to ensure that connection complies with the connection diagram. Do not touch the electrical connection points of the components when the module is energized. Provide protection against indirect contact. Insulate any unused conductors on both ends of the motor cable. Failure to follow these instructions will result in death or serious injury.

DANGER

ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires except under the specific conditions specified in the appropriate hardware guide for this equipment.
Always use a properly rated voltage sensing device to confirm the power is off where and when indicated.
Operate electrical components only with a connected protective ground (earth) cable.
Verify the secure connection of the protective ground (earth) cable to all electrical devices to ensure that connection complies with the connection diagram.
Do not touch the electrical connection points of the components when the module is energized.
Provide protection against indirect contact.
Insulate any unused conductors on both ends of the motor cable.

Failure to follow these instructions will result in death or serious injury.

Procedure Overview

Perform the following procedures to replace the motor or the gearbox on the main axis:

Removing the motor and the gearbox
Removing the motor from the gearbox
Mounting the new motor and/or the new gearbox
Cabling the motor and the gearbox
Mounting the motor cover

Removing the Motor and the Gearbox

Certain variants have a protective motor cover in place that must be removed. The motor cover is heavy (approximately 5 kg (11 lb)), and could cause damage or injury if it were to fall during removal.

WARNING
	FALLING HEAVY LOAD Support the motor and gearbox while removing. Failure to follow these instructions can result in death, serious injury, or equipment damage.

CAUTION
	FALLING MOTOR COVER Hold the motor cover in place while loosening the screws. Failure to follow these instructions can result in injury or equipment damage.

Step	Action
1	Remove the upper arm as described in Replacing the Upper Arms.
2	Loosen the four threaded rods (1) at the rear end of the motor cover.
3	Lift the motor cover slightly and remove to the rear.
4	For robots with an SH3 motor (VRKP•S): Disconnect and remove the two motor supply cables. For robots with an ILM motor (VRKP•L): Lift up the locking device slightly of the hybrid cable and then remove the cable.
5	Remove the hexagon cap (1) from the ground connection at the motor.
6	Disconnect and remove the ground cable from the motor.
7	Remove the bolts (1) by means of which the gearbox is bolted to the robot housing.
8	Carefully remove the motor and the gearbox (5) from the housing in rearward direction. NOTE: To prevent a damage of the precision hole in the robot housing, do not tilt the gearbox.

Removing the Motor from the Gearbox

Step	Action
1	Remove the plug screw (2) on the gearbox flange.
2	Remove the four screws (3) on the motor which connect the motor to the gearbox.
3	Carefully rotate the motor until the screw (4) on the clamping flange appears in the aperture of the plug screw.
4	Loosen this screw.
5	Carefully remove the motor from the gearbox.

Mounting the New Motor and/or the New Gearbox

Step	Action
1	Ensure that the gearbox and the housing are at the same temperature, as otherwise - in the case of a temperature difference - the gearbox may not fit into the aperture provided.
2	Attach the motor to the gearbox according to the specifications of the manufacturer: Tightening torque of the clamping hub: For VRKP0 / VRKP1: 5 Nm (44 lbf-in) For VRKP2 / VRKP4 / VRKP5 / VRKP6: 9.5 Nm (84 lbf-in) Tightening torque of the motor screws: 3.5 Nm (31 lbf-in) NOTE: Position the motor and the gearbox vertically during mounting if possible.
3	Insert the plug screw into the gearbox flange.
4	Attach the motor/gearbox combination in the orientation specified to the robot housing. Tightening torque: For VRKP0 / VRKP1: 3 Nm (26 lbf-in) For VRKP2 / VRKP4 / VRKP5 / VRKP6: 4.7 Nm (42 lbf-in) For further information, refer to the detail drawing in Mechanical and Electrical Data.

NOTICE
	DAMAGE TO MOTOR AND GEARBOX Only fasten motor and gearbox with all components at the same ambient temperature. Failure to follow these instructions can result in equipment damage.

Cabling the Motor and the Gearbox

Step	Action
1	Attach the ground strap to the motor. Tightening torque: 2.5 Nm (22 lbf-in) NOTE: When routing the cables, ensure that the grounding cap remains on the ground connection of the motors. The motor supply cable may become damaged by the thread of the ground strap attachment.
2	Put the hexagon cap on the ground connection at the motor. For further information, observe the respective operating instructions of the motors: VRKP2S0 / VRKP4S0 / VRKP5S0 / VRKP6S0: SH3 Servo motor Motor Manual VRKP2L0 / VRKP4L0 / VRKP5L0 / VRKP6L0: Lexium 62 ILM Hardware Guide
3	Attach the motor supply cables and lock them in position.
4	Attach a new seal (quad ring) on the front between gearbox and housing by exercising light pressure to press the seal between the housing and the gearbox. NOTE: Do not use any sharp-edged tools so as not to damage the seal.
5	Verify that the seal (1) does not stand out over the gearbox or the housing.
6	When using a new gearbox: Mount the threaded pin (3) as otherwise it may not be possible to mount the upper arm. For further information, refer to the detail drawing in Mechanical and Electrical Data.
7	Mount the upper arm as described in Replacing the Upper Arms.
8	Calibrate the robot mechanics.

DANGER
	ELECTRIC SHOCK DUE TO DAMAGED CABLES Verify that the grounding cap is placed correctly on the grounding connection of the motor. Failure to follow these instructions will result in death or serious injury.

WARNING
	COLLISION OF COMPONENTS Calibrate the robot mechanics after the replacement of an upper arm, a motor, or a gearbox. Failure to follow these instructions can result in death, serious injury, or equipment damage.

Mounting the Motor Cover

Step	Action
1	Attach a new seal (1) on the capture screws (3) for the motor cover (4), as the old seal may cause leakages to occur between the housing and the motor cover.
2	Verify the position of the captive washers (1). The captive washers should be located in the rear of the motor cover (2) on the threaded rods (3). NOTE: The captive washers should be placed so that the threaded rods can not drop out from the aperture of the motor cover (4).
3	Correct the position of the captive washers on the threaded rod if necessary.
4	Verify whether any open cables exist and remove them, if any.
5	Hook the motor cover on the capture screws and tighten the four threaded rods at the motor cover. Tightening torque: 6 Nm (53.1 lbf-in)
6	Mount the telescopic axis and the lower arms. For further information, refer to Replacing the Telescopic Axis and Mounting the Lower Arms.