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D C E N D OP O F Y T O R FO R IG R CU H PR S TE T IN O D D TE ME O D R CU D RE M IS F E TR E N IB RE T U N TI C O E N O
MAINTENANCE AND INSPECTION

KAWASAKI HEAVY INDUSTRIES, LTD. ROBOT DIVISION

90205-1031DEB

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Preface
This manual is subject to change without prior notice and without our legal responsibility. Kawasaki pursues a policy of continuing improvement in design and specification of the product. The right is therefore reserved to vary this manual without prior notice. This manual is copyrighted and all rights are reserved by KHI. This manual may not, in whole or part, be reproduced in any form or by any means without prior written permission from KHI.

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This manual is prepared with the best care but anyway it is impossible to exclude any misinterpretation by the user or any spelling mistakes. In case of doubts or if the robot behavior is different from that reported in this manual please would you get in touch with the nearest Kawasaki or Kawasakis agent. KHI cannot anticipate every possible circumstance that might involve a potential hazard. If a procedure, work method or operating technique not specifically recommended by KHI is used, you must satisfy yourself that it is safe for you and others. In this case you are completely responsible for eventual damages on human bodies or things. If you discover physical defects in the manual, KHI will replace the manual at no charge during 90 days period after you purchased the robot. If you do not observe warnings and/or caution to be taken in the manual as described below, it might result in the serious injuries or damages on human bodies or robot. Therefore you must take extreme care to observe these warnings and cautions.
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KAWASAKI ROBOT F series Maintenance and Inspection

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[ SYMBOLS ]

Whenever you see the symbols shown below in this manual or on the machine, read and understand their messages.

DANGER

This danger symbol identifies special warnings or procedures which, if not strictly observed, will result in serious injury or death.

WARNING

This warning symbol identifies special warnings or procedures which, if not strictly observed, could result in serious injury or death.

CAUTION

This caution symbol identifies special instructions or procedures which, if not correctly followed, may result in injury.

[ NOTE ] This note symbol identifies supplementary information, or to emphasize a point or procedure, or to give a tip for easier operation.

KAWASAKI ROBOT F series Maintenance and Inspection

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This Manual has been described for the maintenance and inspection of KAWASAKI ROBOT F Series. We sincerely hope that you will please understand the contents of this Manual well and strictly observed the safety at all times. After that, start operation. You should fully understand the contents of this document and start the work paying special attention to the safety. The manual covers only INSTALLATION AND CONNECTION =ROBOT ARM=. Therefore, if you would desire to know the installation and connection of Controller and cable, you will also please read this together with "INSTALLATION AND CONNECTION =CONTROLLER=".

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D C E N D OP O F Y T O R FO R IG R CU H PR S TE T IN O D D TE ME O D R CU D RE M IS F E TR E N IB RE T U N TI C O E N O
This Manual describes on the following Robot Arms FS06N, FS06L, FA06N, FA06L,FA06E, FC06N, FW06N, FS10C, FS10E, FS10L,FS20C, FS20N, FA20N, FP20N, FS30N, FS30L, FS45C, FS45N All right reserved. Copyright 1998 by KAWASAKI HEAVY INDUSTRIES, LTD.

In addition, for the Arc-welding Robot, you will also please read this together with "INSTALLATION AND CONNECTION =ARC WELDING=".

KAWASAKI ROBOT F series Maintenance and Inspection

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SAFETY
If you do not observe warnings and/or cautions to be taken in the manual as described below, it might result in the serious injuries or damages on human bodies or Robots. Therefore, you must take extreme care to observe these warnings and cautions.

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1 For the confirmation of acceptability and effectiveness of drawings, detailed specification of documents, procedures etc. it shall be still insufficient. Therefore, if you desire to operate/serve/maintain/adjust/ modify, and to do miscellaneous works, you must pay utmost attentions to them. 2 Those persons who engage with the operation/service of your system, they must strictly observe all safety regulation at all times. Never replace and/or adjust the inside parts provided in your Robot system while the power source is being turned ON so as to ensure your own safety.
KAWASAKI ROBOT F series Maintenance and Inspection

WARNING

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CONTENTS
1. Caution Items ...................................................................................6 2. Maintenance & Inspection Location..................................................7

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4. Grease Replenishment to Gears ....................................................12
4.1. JT4 Gear Sections .........................................................................................12 4.2. JT5 Gear Sections .........................................................................................13

3. Daily Checking Procedures ............................................................11

5. Grease Replenishment to Reduction Units ....................................14

5.1. JT1 Reduction Units.......................................................................................14 5.2. JT2 Reduction Units.......................................................................................15 5.3. JT3 Reduction Units.......................................................................................16 5.4. JT4 Reduction Units.......................................................................................17 5.5. JT5 Reduction Units.......................................................................................18 5.6. JT6 Reduction Units.......................................................................................19

6. Grease Change of Reduction Units................................................20

6.1. JT1 Reduction Unit.........................................................................................20 6.2. JT2 Reduction Unit.........................................................................................21 6.3. JT3 Reduction Unit.........................................................................................22 6.4. JT4 Reduction Unit.........................................................................................23 6.5. JT5 Reduction Unit.........................................................................................24 6.6. JT6 Reduction Unit.........................................................................................25

7. Check of Timing Belts ....................................................................26 8. Check of Inside Machine Cables ....................................................27

9. Retightening ...................................................................................28

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1. Caution items

1. Caution Items
Prior to start the maintenance of the Robot, pay attention to the following matters to ensure safety.

WARNING

While the robot is in the hold mode, do not apply undue forces to the robot arm. If not, be careful that the brake mechanisms in the joint will be resulted in service life shortening and/or parts damage. Use KHI designated greases, gear oils and other lubricants.

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In case the joint angle is required to change for the grease replenishment, etc., first, switch ON the motor power. Then set the robot to the desired posture. After that, reswitch OFF the motor power, and start the required work.

Prior to start maintenance, surely press the "EMERGENCY" switch on the controller in the basic operation section. The robot arm motor power will be switched OFF.

CAUTION

KAWASAKI ROBOT F series Maintenance and Inspection

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2. Maintenance & Inspection Location

2. Maintenance & Inspection Location


In the course of robot maintenance & inspection, daily checking, routine inspection (5000 hours , 10000 hours and 15000 hours) and overhaul are available. In this manual, items to be maintained and inspected, as well as inspection methods and adjustment methods are described. These items are very important for the successful using of robot for a long period of time in the stabilized condition, to which Users are requested to pay special attention.

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Maintenance period
Daily checking 5000 hours 10000 hours 15000 hours 20000 hours

Reference page

Items

(1) Flaws on robot

{ {

{ {

{ {

{ {

(2) Movement & abnormal noises of robot

(3) Positioning accuracy of robot

(4) Grease replenishment to gears

(5) Grease replenishment to reduction units (6) Grease change of reduction units (7) Check of timing belts

{ { {

(8) Check of inside machine cables (9) Retightening (10) Overhaul

CAUTION

If the maintenance is not made as specified, it will result in shortening of service life. Be careful that many parts are required to replace at overhaul (approx. every 20000 hours). Upon reaching the 20000-hour overhaul period, please contact with our service engineers.

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2. Maintenance & Inspection Location

2. Maintenance & Inspection Location


z FS06,FS06L,FA06N,FA06L,FA06E,FC06N,FW06N,FS10C,FS10E, FS20C,FS20N,FA20N,FP20N,FS10L

(5)-5

(4)-2 (5)-6

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(5)Grease replenishment to reduction units (7) Check of timing belts (7)-1 (8) Check of inside machine cable (7)-2

(4) Grease replenishment to gears

(6) Grease change of reduction units

(5)-4

(5)-3 (6)-3

(8)

(4)-1

(8)

(5)-2 (6)-2

(8)

(5)-1 (6)-1

KAWASAKI ROBOT F series Maintenance and Inspection

5000,10000,15000 hours

10000 hours

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This figure is model FS10E.

2. Maintenance & Inspection Location

2. Maintenance & Inspection Location


z FS30N,FS30L,FS45C,FS45N
This figure is model FS45N.

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(5) Grease replenishment to reduction units (7) Check of timing belts (5)-5 (6)-5 (7)-1 (7)-2 (4)-2
(5)-3 (6)-3 (5)-6 (6)-6 (5)-4 (6)-4 (8) (8) (5)-2 (6)-2 (8) (5)-1 (6)-1

(4) Grease replenishment to gears

(6) Grease change of reduction units

(8) Check of inside machine cable

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5000,10000,15000 hours

10000 hours

KAWASAKI ROBOT F series Maintenance and Inspection

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KAWASAKI ROBOT F series Maintenance and Inspection

3. Daily Checking Procedures

3. Daily Checking Procedures


When you require to maintain and inspect the Kawasaki Robot daily, maintain and inspect on the following items.
No. (1)

Maintenance item

Details of maintenance

Troubleshooting

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y Check if any dints by interference etc. are observed on the upper arm cover and in the base section.
(2)

Robot

made by interference etc. are observed on the robot. Check particularly wrist section.

Remove the cover, and check if inside cable, hose, etc. are damaged.

Robot movement

y Check if each axis moves smooth. y Check if any abnormal noise and/or vibration is observed. y Check if the overshoot is excessively large.

Check lubrication.

Check driving system for error.

For example, if the backlash was increased and overclearance was found, please contact with us.

(3)

Is the positioning accuracy varied?

y Check if any drift from previously repeated location is observed.

Make sure that any abnormality is existed in the driving system.

y Check if any fluctuations are observed in the stop position.

For example, if the backlash was increased and over-clearance was found, please contact with us.

If the abnormalities as referred to the above can not be correct by the mechanical countermeasures, please contact with us.

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Flaws and/or dints on y Check if any parts of robot for flaws

KAWASAKI ROBOT F series Maintenance and Inspection

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4. Grease Replenishment to Gears

4. Grease Replenishment to Gears


(Maintenance

period : 5000 hours x 10000 hours x 15000hours)

WARNING

4.1. JT4 Gear Sections


Model

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Procedures 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. 4) Remove the grease nipple from the oil filler port. 5) Reinstall 2 plugs to the oil filler port and oil drain port.

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CAUTION
Do not defend, and do not put the amount of the injection too much when you replenish to the robot.
FS06N,FS06L,FA06N,FA06L, FA06E,FC06N,FW06N,FS10C, FS10E,FS20C,FS20N,FA20N, FP20N,FS10L

Remove the plug in the oil drain port without fail, if you replenish to the robot. Pressure hangs if you does not remove the plug and robot might damage the seal.

Working location

(4)-1

Oil rain port

Oil Filler port

(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

Model Amount Grease

FS06N,FS06L,FA06N,FA06L,FA06E , FC06N,FW06N,FS10C,FS10E

FS20C,FS20N,FA20N, FP20N, FS10L

40 CC 70 CC SHELL SUN LIGHT GREASE 1.


KAWASAKI ROBOT F series Maintenance and Inspection

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First, switch "OFF" the "Motor Power" without fail, if you desire to check up the robot.

4. Grease Replenishment to Gears

4. Grease Replenishment to Gears


(Maintenance

period : 5000 hours x 10000 hours x 15000hours)

4.2. JT5 Gear Sections


(4)-2

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Oil filler port Oil drain port Cross section A-A Oil filler port The oil drain port is on the other side of the oil filler port. Procedures 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (The elbow type excluding FS 30/45) to the oil filler port. 3) Refill the grease from the oil filler port. 4) Remove the grease nipple from the oil filler port. 5) Reinstall 2 plugs to the oil filler port and oil drain port.
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

Working location

Model

FS06N,FS06L,FA06N,FA06L,FA06E , FC06N,FW06N,FS10C,FS10E

FS20C,FS20N,FA20N,FS10L, FP20N

FS30N,FS30L,FS45C,FS45N

Amount Grease

8 CC

20 CC SHELL SUN LIGHT GREASE 1.

20 CC

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(4)-2

KAWASAKI ROBOT F series Maintenance and Inspection

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Model

FS06N,FS06L,FA06N,FA06L,FA06E, FC06N,FW06N,FS10C,FS10E, FS20C,FS20N,FA20N,FS10L,FP20N

Model Working location

FS30N,FS30L,FS45C,FS45N

6. Grease Replenishment to Reduction Units

5. Grease Replenishment to Reduction Units


(Maintenance

period : 5000 hours x 10000 hours x 15000hours)

WARNING
First, switch "OFF" the "Motor Power" without fail, if you desire to check up the robot.

5.1.

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Oil filler port Procedures 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. 4) Remove the grease nipple from the oil filler port. 5) Reinstall 2 plugs to the oil filler port and oil drain port.

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Remove the plug in the oil drain port without fail, if you replenish to the robot. Pressure hangs if you does not remove the plug and robot might damage the seal.

CAUTION

Do not defend, and do not put the amount of the injection too much when you replenish to the robot.

JT1 Reduction Units

Model Working location

All models (5)-1

Oil drain port When you replenish to the robot, remove the cover and take out this tube.

(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

Model Amount Grease

FS06N,FS06L,FA06N,FA06L,FA06E, FC06N,FW06N,FS10C,FS10E

FS20C,FS20N,FA20N,FS10L, FP20N

FS30N,FS30L,FS45C,FS45N

30 CC

45 CC MOLY WHITE RE No.00

125 CC

KAWASAKI ROBOT F series Maintenance and Inspection

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5. Grease Replenishment to Reduction Units

5 DGrease Replenishment to Reduction Units


(Maintenance

period : 5000 hours x 10000 hours x 15000hours)

5.2. JT2 Reduction Units


Model Working location All models (5)-2

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Remove the cover Remove the cover
Oil filler port

Oil drain port When you replenish to the robot, remove the cover and take out this tube.

Cross section A-A

Procedures 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. 4) Remove the grease nipple from the oil filler port. 5) Reinstall 2 plugs to the oil filler port and oil drain port.

(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)
FS06N,FS06L,FA06N,FA06L,FA06E , FC06N,FW06N,FS10C,FS10E FS20C,FS20N,FA20N,FS10L, FP20N

Model

FS30N,FS30L,FS45C,FS45 N

Amount Grease

30 CC

45 CC MOLY WHITE RE No.00

125 CC

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6. Grease Replenishment to Reduction Units

5 DGrease Replenishment to Reduction Units


(Maintenance

period : 5000 hours x 10000 hours x 15000hours)

5.3. JT3 Reduction Units


Model Working location All models (5)-3

Remove the cover

Oil drain port When you replenish to the robot, remove the cover and take out this tube.

Procedures 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. 4) Remove the grease nipple from the oil filler port. 5) Reinstall 2 plugs to the oil filler port and oil drain port.

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Remove the cover Oil filler port Cross section A-A
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

Model

FS06N,FS06L,FA06N,FA06L,FA06E , FC06N,FW06N,FS10C,FS10E

FS20C,FS20N,FA20N,FS10L, FP20N

FS30N,FS30L,FS45C,FS45 N

Amount Grease

10 CC

30 CC MOLY WHITE RE No.00

45 CC

KAWASAKI ROBOT F series Maintenance and Inspection

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5. Grease Replenishment to Reduction Units

5 DGrease Replenishment to Reduction Units


(Maintenance

period : 5000 hours x 10000 hours x 15000hours)

Model Working location

(5)-4

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(5)-4 Oil filler port Remove the cover View A Oil drain port Procedures 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. 4) Remove the grease nipple from the oil filler port. 5) Reinstall 2 plugs to the oil filler port and oil drain port.
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

Oil drain port

Oil filler port The oil filler port is the other side of this figure.

Model

FS06N,FS06L,FA06N,FA06L.FA06E , FC06N,FW06N,FS10C,FS10E

FS20C,FS20N,FA20N,FS10L, FP20N

FS30N,FS30L,FS45C,FS45 N

Amount Grease

2 CC 5 CC HARMONIC GREASE 4B No.2

150 CC MOLY WHITE RE No.00

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FS06N,FS06L,FA06N,FA06L,FA06E, FC06N,FW06N,FS10C,FS10E, FS20C,FS20N,FA20N,FS10L,FP20N

Model Working location

FS30N,FS30L,FS45C,FS45N

KAWASAKI ROBOT F series Maintenance and Inspection

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5.4. JT4 Reduction Units

6. Grease Replenishment to Reduction Units

5 DGrease Replenishment to Reduction Units


(Maintenance

period : 5000 hours x 10000 hours x 15000hours)

Model Working location

Procedures 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. 4) Remove the grease nipple from the oil filler port. 5) Reinstall 2 plugs to the oil filler port and oil drain port.

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(5)-5 Oil drain port Oil filler port The oil drain port to the other side of this figure. Oil filler port
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

Model

FS06N,FS06L,FA06N,FA06L.FA06E , FC06N,FW06N,FS10C,FS10E

FS20C,FS20N,FA20N,FS10L, FP20N

FS30N,FS30L,FS45C,FS45N

Amount Grease

5 CC 10 CC HARMONIC GREASE 4B No.2

10 CC MOLY WHITE RE No.00

KAWASAKI ROBOT F series Maintenance and Inspection

FS06N,FS06L,FA06N,FA06L,FA06E, FC06N,FW06N,FS10C,FS10E, FS20C,FS20N,FA20N,FS10L,FP20N

Model Working location

FS30N,FS30L,FS45C,FS45N

(5)-5

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5.5. JT5 Reduction Units

5. Grease Replenishment to Reduction Units

5 DGrease Replenishment to Reduction Units


(Maintenance

period : 5000 hours x 10000 hours x 15000hours)

Model

Procedures

1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Refill the grease from the oil filler port. 3) Reinstall 2 plugs to the oil filler port and oil drain port.
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

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Working location (5)-6 Oil drain port Oil filler port Oil filler port Oil drain port Procedures
Recommendation : LOCTITE 242)

FS06N,FS06L,FA06N,FA06L,FA06E , FC06N,FW06N,FS10C,FS10E, FS20C,FS20N,FA20N,FS10L,FP20N

Model Working location

FS30N,FS30L,FS45C,FS45N

1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. 4) Remove the grease nipple from the oil filler port. 5) Reinstall 2 plugs to the oil filler port and oil drain port.
(Spread the adhesive for the screw on the plug.

Model

FS06N,FS06L,FA06N,FA06L,FA06E , FC06N,FW06N,FS10C,FS10E

FS20C,FS20N,FA20N,FS10L, FP20N

FS30N,FS30L,FS45C,FS45N

Amount Grease

2 CC 5 CC HARMONIC GREASE 4B No.2

10 CC MOLY WHITE RE No.00

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5.6. JT6 Reduction Units

6. Grease Change of Reduction Units

6. Grease Change of Reduction Units


(Maintenance period : 10000 hours)

WARNING
First, switch "OFF" the "Motor Power" without fail, if you desire to check up the robot.

6.1. JT1 Reduction Unit

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Oil filler port Procedures Prepare the cloth to wipe the grease and the container which receives the grease exhausted from the oil drain port beforehand. 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. When you fill the grease, old grease is exhausted from the oil drain port. 4) Remove the grease nipple from the oil filler port. Wipe grease in the vicinity of oil filler part and oil drain port off the cloth etc. 5) Reinstall 2 plugs to the oil filler port and oil drain port.
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

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Remove the plug in the oil drain port without fail, if you replenish to the robot. Pressure hangs if you does not remove the plug and robot might damage the seal.

CAUTION

Do not defend, and do not put the amount of the injection too much when you replenish to the robot.

Model working location

All models (6)-1

Oil drain port When you change the grease to the robot, remove the cover and take out this tube.

Model Amount Grease

FS06N,FS06L,FA06N,FA06L,FA06E , FC06N,FW06N,FS10C,FS10E

FS20C,FS20N,FA20N,FS10L, FP20N

FS30N,FS30L,FS45C,FS45 N

300 CC

450 CC MOLY WHITE RE No.00

1250 CC

KAWASAKI ROBOT F series Maintenance and Inspection

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6. Grease Change of Reduction Units

6 DGrease Change of Reduction Units


(Maintenance period : 10000 hours)

6.2. JT2 Reduction Unit


Model Working location All models (6)-2

Oil drain port When you change the grease to the robot, remove the cover and take out this tube.

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Remove the cover Remove the cover Oil filler port Cross section A-A 5) Reinstall 2 plugs to the oil filler port and oil drain port.
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

Procedures Prepare the cloth to wipe the grease and the container which receives the grease exhausted from the oil drain port beforehand. 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. When you fill the grease, old grease is exhausted from the oil drain port. 4) Remove the grease nipple from the oil filler port. Wipe grease in the vicinity of oil filler part and oil drain port off the cloth etc.

Model Amount Grease

FS06N,FS06L,FA06N,FA06L,FA06E , FC06N,FW06N,FS10C,FS10E

FS20C,FS20N,FA20N,FS10L, FP20N

FS30N,FS30L,FS45C,FS45 N

300 CC

450 CC MOLY WHITE RE No.00

1250 CC

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6. Grease Change of Reduction Units

6. Grease Change of Reduction Units


(Maintenance period : 10000 hours)

6.3. JT3 Reduction Unit


Model Working location FS30L first models (6)-3

Remove the cover

COVER, JT3-1

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Procedures Prepare the cloth to wipe the grease and the container which receives the grease exhausted from the oil drain port beforehand. Remove the parts of each part as shown in the figure above. 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. When you fill the grease, old grease is exhausted from the oil drain port. 4) Remove the grease nipple from the oil filler port. Wipe grease in the vicinity of oil filler part and oil drain port off the cloth etc. 5) Reinstall 2 plugs to the oil filler port and oil drain port.
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

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Oil filler port GUIDE, 3
M3 6 BRACKET, HARNESS 2 HEXAGON SOCKET HEAD BOLT

M5 16 PAN HEAD SCREW

Oil drain port When you change the grease to the robot, remove the cover and take out this tube.

CLAMP,1

M3 65

HEXAGON SOCKET HEAD BOLT M3 65

HEXAGON SOCKET HEAD BOLT

Remove the cover

M4 10

HEXAGON SOCKET HEAD BOLT

COVER, JT3-2

GUIDE, 1 M3 6

BLOCK, 1

FLAT HEAD SCREW

M4 45 PAN HEAD SCREW

M3 70 FLAT HEAD SCREW

M4 10 PAN HEAD SCREW

Assemble parts shown in the above figure according to a reverse procedure. Amount Grease 450 CC MOLY WHITE RE No.00

KAWASAKI ROBOT F series Maintenance and Inspection

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6. Grease Change of Reduction Units

6 DGrease Change of Reduction Units


(Maintenance period : 10000 hours)

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Oil drain port Oil filler port The oil filler port is the other side of this figure.
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

Model Working location

FS30N,FS30L,FS45C,FS45

Procedures Prepare the cloth to wipe the grease and the container which receives the grease exhausted from the oil drain port beforehand. 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. When you fill the grease, old grease is exhausted from the oil drain port. 4) Remove the grease nipple from the oil filler port. Wipe grease in the vicinity of oil filler part and oil drain port off the cloth etc. 5) Reinstall 2 plugs to the oil filler port and oil drain port.

Model Amount Grease

FS30N,FS30L,FS45C,FS45N

1000 CC MOLY WHITE RE No.00

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(6)-4

KAWASAKI ROBOT F series Maintenance and Inspection

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6.4. JT4 Reduction Unit

6. Grease Change of Reduction Units

6 DGrease Change of Reduction Units


(Maintenance period : 10000 hours)

Procedures Prepare the cloth to wipe the grease and the container which receives the grease exhausted from the oil drain port beforehand. 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. When you fill the grease, old grease is exhausted from the oil drain port. 4) Remove the grease nipple from the oil filler port. Wipe grease in the vicinity of oil filler part and oil drain port off the cloth etc. 5) Reinstall 2 plugs to the oil filler port and oil drain port.
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

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D C E N D OP O F Y T O R FO R IG R CU H PR S TE T IN O D D TE ME O D R CU D RE M IS F E TR E N IB RE T U N TI C O E N O
Oil drain port Oil filler port Model Amount Grease
FS30N,FS30L,FS45C,FS45N

Model Working location

FS30N,FS30L,FS45C,FS45N

(6)-5

100 CC MOLY WHITE RE No.00

KAWASAKI ROBOT F series Maintenance and Inspection

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6.5. JT5 Reduction Unit

6. Grease Change of Reduction Units

6 DGrease Change of Reduction Units


(Maintenance period : 10000 hours)

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Oil drain port 5) Reinstall 2 plugs to the oil filler port and oil drain port.
(Spread the adhesive for the screw on the plug. Recommendation : LOCTITE 242)

Model Working location

FS30N,FS30L,FS45C,FS45N

(6)-6

Procedures Prepare the cloth to wipe the grease and the container which receives the grease exhausted from the oil drain port beforehand. 1) Remove 2 plugs from the oil filler port and the oil drain port. 2) Install the grease nipple (M6) to the oil filler port. 3) Refill the grease from the oil filler port. When you fill the grease, old grease is exhausted from the oil drain port. 4) Remove the grease nipple from the oil filler port. Wipe grease in the vicinity of oil filler part and oil drain port off the cloth etc.

Model Amount Grease

FS30N,FS30L,FS45C,FS45N

100 CC MOLY WHITE RE No.00

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KAWASAKI ROBOT F series Maintenance and Inspection

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6.6. JT6 Reduction Unit

7. Check of Timing Belts

7. Check of Timing Belts


(Maintenance period : 10000 hours)
Model Working location All models

Axis Pressure F

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Deflection

D C E N D OP O F Y T O R FO R IG R CU H PR S TE T IN O D D TE ME O D R CU D RE M IS F E TR E N IB RE T U N TI C O E N O
JT5 Timing belt Motor bracket mounting bolts(4) Motor bracket JT6 Timing belt Cover for wrist section Motor bracket Motor bracket mounting bolts(4)

Cover for wrist section

Procedures 1) Remove the 2 cover from the wrist section.

2) Check the tensioning forces of two timing belts. deflects .

Adequate tension : Referring to the below figure, when you the center of belt at pressure F, to a degree that the belt

Pressure F

Deflection

Model

FS06N,FS06L,FA06N,FA06L, FA06E,FC06N,FW06N, FS10C,FS10E JT5 JT6 3.43N 3.43N (0.35kgf) (0.35kgf) 3mm 2mm

FS20L,FS20N,FA20N,FS10L, FP20N JT5 3.92N (0.4kgf) 3mm JT6 3.92N (0.4kgf) 2mm

FS30N,FS30L,FS45C,FS45N

JT5 12.74N (1.3kgf) 5mm

JT6 12.74N (1.3kgf) 3mm

3) If the tension is not adequated, rotate 1 turn and loosen the 4 motor bracket mounting bolt. 4) Move the motor braket, and adjust the distance of pulley. And then, tighten the mounting belts temporary. 5) Upon setting the adequate tension forces as specified above, install the motor brackets and tighten the mounting bolts.

KAWASAKI ROBOT F series Maintenance and Inspection

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(7)-1, (7)-2

8. Check of Inside Machine Cables

8. Check of Inside Machine Cables


(Maintenance period : 10000 hours)

WARNING
Switch OFF the Motor Power and Control Power without fail, if you check the inside machine cable.

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Model Working location All models (8) Check on the following items: y looseness of cable connectors, etc. (If required, retighten the connectors, etc. firmly) y Flaw and/or bending of cable (If you find abnormalities of parts, it should be changed, please contact with us.) y Looseness of terminal block screws provided in the connector box. (If required, retighten the connectors, etc. firmly)

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KAWASAKI ROBOT F series Maintenance and Inspection

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9. Retightening

9. Retightening
(Maintenance period : 10000 hours)
Check if bolts and nuts which fix parts firmly are loosened or not. If required, retighten the bolts, nuts etc. firmly. The following items are required to retighten. y Servo motor mounting bolts y Motor bracket mounting bolts

y Reduction units mounting bolts y Tool mounting bolts y Base mounting bolts

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D C E N D OP O F Y T O R FO R IG R CU H PR S TE T IN O D D TE ME O D R CU D RE M IS F E TR E N IB RE T U N TI C O E N O
m NOTE n The tightening torque of hexagon socket head cap bolt is as shown below: M 3: M 4: M 5: M 6: M 8: M10: M12: M14: M16: M20: 1.47Nm 3.43Nm 6.86Nm 11.76Nm 29.40Nm 56.84Nm 98.00Nm 156.80Nm 235.20Nm 431.20Nm ( 15kgfcm) ( 35kgfcm) ( 70kgfcm) ( 120kgfcm) ( 300kgfcm) ( 580kgfcm) (1000kgfcm) (1600kgfcm) (2400kgfcm) (4400kgfcm)
KAWASAKI ROBOT F series Maintenance and Inspection

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D C E N D OP O F Y T O R FO R IG R CU H PR S TE T IN O D D TE ME O D R CU D RE M IS F E TR E N IB RE T U N TI C O E N O
KAWASAKI ROBOT F Series

MAINTENANCE AND INSPECTION


October 1998 : 1st Edition November 1998 : 2nd Edition

Publication : KAWASAKI HEAVY INDUSTRIES, LTD. ROBOT DIVISION 90205-1031DEB


All rights reserved. Copyright 1998 KAWASAKI HEAVY INDUSTRIES, LTD.

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Kawasaki Robotics (UK) Limited

Kawasaki Heavy Industries, Ltd.

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Kawasaki Robotics Co., Ltd. Kawasaki Robotics (USA), Inc. Kawasaki Robotics (UK) Limited Kawasaki Robotics GmbH Akashi Works

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* All descriptions in this booklet subject to change for improvement without prior notice.

D C E N D OP O F Y T O R FO R IG R CU H PR S TE T IN O D D TE ME O D R CU D RE M IS F E TR E N IB RE T U N TI C O E N O
KAWASAKI HEAVY INDUSTRIES, LTD.
ROBOT DIVISION KAWASAKI ROBOTICS CO., LTD.
4-1, 2-Chome Hamamatsu-cho Minato-ku Tokyo, 105-6116 JAPAN (World Trade Center building) 1-1, Kawasaki-cho Akashi, 673-8666 JAPAM TEL 81-(0)3-3435-6908 FAX 81-(0)3-3437-9880 TEL 81-(0)78-921-1565 FAX 81-(0)78-923-0685 TEL 1-248-305-7610 FAX 1-248-305-7618 TEL 44-(0)161-9565400 FAX 44-(0)161-9565404 TEL 49-(0)2131-3426-0 FAX 49-(0)2131-930973 TEL 81-(0)78-921-1560 FAX 81-(0)78-923-6548 28059 Center Oaks Court Wixom, Michigan, 48393 U.S.A Greengate, Middleton Manchester, M24 1SA UNITED KINGDOM Sperberweg29, 41468 Neuss, GERMANY 1-1, Kawasaki-cho Akashi, 673-8666 JAPAN

Kawasaki Heavy Industries, LTD. Tokyo Head Office

Kawasaki Robotics (USA), Inc.

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Kawasaki Robotics GmbH