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 gearbox on 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 new motor and the gearbox

Removing the Motor and the Gearbox

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.

Step	Action
1	Remove the upper arm as described in Replacing the Upper Arms.
2	For robots with an MH3 motor (VRKT•M): Disconnect and remove the two motor supply cables. For robots with an ILM motor (VRKT•L): Lift up the locking device slightly of the hybrid cable and then remove the cable.
3	Disconnect and remove the ground cable from the motor.
4	Remove the 16 bolts (1) by means of which the gearbox is bolted to the mounting plate.
5	Carefully remove the motor and gearbox (5) from the mounting plate in rearward direction. NOTE: Do not tilt transmission and do not damage the alignment hole at the mounting plate.

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 on the clamping flange appears in the aperture of the plug screw.
4	Loosen the screw in the clamping flange.
5	Carefully remove the motor from the gearbox.

Mounting the New Motor and/or the New Gearbox

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.

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 torques for VRKT1: Clamping hub: 4.5 Nm (40 lbf-in) Motor screws: 3.5 Nm (31 lbf-in) Tightening torques for VRKT2, VRKT3, VRKT5: Clamping hub: 14 Nm (124 lbf-in) Motor screws: 16 Nm (142 lbf-in)
3	Insert the plug screw into the gearbox flange.
4	Attach the motor/gearbox combination to the robot mounting plate in the orientation specified. Tightening torque: 4.7 Nm (42 lbf-in) For further information, refer to the respective detail drawing in Mechanical and Electrical Data.

NOTICE
	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 equipment damage.

Cabling the Motor and the Gearbox

Step	Action
1	Attach the ground strap to the motor. Tightening torque: 2.9 Nm (25.7 lbf-in) For further information about motor assembly, observe the respective operating instructions of the motors: VRKT•M: MH3 Servo motor Motor Manual VRKT•L: Lexium 62 ILM Hardware Guide
2	Attach the motor supply cables and lock them in position.
3	When using a new gearbox: Mount the threaded pin (1) as otherwise it may not be possible to mount the upper arm. NOTE: Verify that the threaded pin protrudes approximately 3 mm (0.118 in) For further information, refer to the respective detail drawing in Mechanical and Electrical Data.
4	Mount the upper arm as described in Replacing the Upper Arms.
5	Calibrate the robot mechanics.
6	Mount the lower arms with parallel plate to the upper arms and mount the parallel rods. For further information, refer to Mounting the Lower Arms with Parallel Plate and Mounting the Rods for Parallel Linkage.

NOTICE
	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 equipment damage.