Mx-Series & MT400N Maintanance Manual

Kawasaki Robot
MX Series, MD400N, MT400N
Inspection and
Maintenance Manual
Kawasaki Heavy Industries, Ltd.
90205－1082DEE
Kawasaki Robot Maintenance and Inspection
PREFACE
This manual explains maintenance and inspection procedures for Kawasaki Robot MX series,
MD400N and MT400N.
Read and understand the contents of this manual and the safety manuals thoroughly and strictly
observe all rules for safety before proceeding with any operation.
For information on installation and connection of the robot, read manuals separately prepared for
robot arm and controller.
Never proceed with any operation until you understand the contents of this manual completely.
Kawasaki is not responsible for any accidents and/or damages resulting from operations/
maintenance based on only a limited reading or limited understanding of some parts of this
manual.
This Manual describes the following Robot Arms

MX500N, MX420L, MX350L, MD400N, MT400N
1. Kawasaki reserves the rights to change, revise, or update this manual without prior notice.
2. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
3. Though this manual was prepared to be as thorough and accurate as possible, the authors
apologize should any information be found incomplete or erroneous.
4. It is recommended that all personnel assigned for activation of maintenance or inspection of the
robot attend the necessary education/training course(s) prepared by Kawasaki, before
assuming their responsibilities.
5. Store this manual with care and keep it available for use at any time. In the event the manual
is lost or damaged severely, contact your Kawasaki agent.
Copyright © 2008 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.
1
SAFETY
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damages by
complying with the safety matters given in the boxes with these symbols.
！ DANGER
Failure to comply with indicated matters can result in

imminent injury or death.
！ WARNING
Failure to comply with indicated matters may possibly

lead to injury or death.
！ CAUTION
Failure to comply with indicated matters may lead to

physical injury and/or mechanical damage.
[ NOTE ]
Denotes precautions regarding robot specification,
teaching, operation and maintenance.
！ WARNING
1. The accuracy and effectiveness of the diagrams, procedures, and detail
explanations given in this manual cannot be confirmed with absolute
certainty. Accordingly, it is necessary to give one’s fullest attention when
using this manual to perform any work.
2. Safety related contents described in this manual apply to each individual
work and not to all robot work. In order to perform every work in safety,
read and fully understand the safety manual, all pertinent laws, regulations
and related materials as well as all the safety explanation described in each
chapter, and prepare safety measures suitable for actual work.
2
CONTENTS
1.0 Precautions ...............................................................................................................................4
2.0 Items of Maintenance & Inspection ........................................................................................8

2.1 Items of Maintenance & Inspection – MX Series ..................................................................9
2.2 Items of Maintenance & Inspection – MD400N ..................................................................10
2.3 Items of Maintenance & Inspection – MT400N...................................................................11
3.0 Details of Daily Check...........................................................................................................12
4.0 Replenishment and Change...................................................................................................13

4.1 Grease and Oil Replenishment to JT1 Gear and Oil Change...............................................14
4.1.1 Grease Replenishment to JT1 Gear – MX Series, MD400N, MT400N..............................14
4.1.2 Oil Replenishment to Gearbox – MX Series, MD400N, MT400N.....................................15
4.1.3 Oil Change of Gearbox – MX Series, MD400N, MT400N.................................................16
4.2 JT2 Reduction Unit Grease Change – MX Series, MD400N, MT400N.............................17
4.3 JT3 Reduction Unit Grease Change – MX Series, MD400N, MT400N.............................18
4.4 JT4, JT5 and JT6 Wrist Axis Drive Gear Grease Change – MX Series..............................19
4.5 JT4, JT5 and JT6 Wrist Axis Drive Gear Grease Change – MT400N................................20
4.6 JT4 Gear and Reduction Unit Grease Change – MX Series ................................................21
4.7 JT4 Gear and Reduction Unit Grease Change – MD400N..................................................22
4.8 JT4 Gear and Reduction Unit Grease Change – MT400N ..................................................23
4.10 JT5 Reduction Unit Grease Change – MD400N..................................................................25
4.14 Grease Replenishment to JT1 Cross Roller Bearings – MX Series, MD400N, MT400N .29
4.15 Grease Replenishment to JT3 Cross Roller Bearings – MX Series, MN400N, MT400N .30
5.0 Check on Internal Machine Cables – MX Series, MD400N, MT400N ..............................31
6.0 Retightening...........................................................................................................................32
3
MX Series, MD400N, MT400N 1. Precautions
1.0 PRECAUTIONS
Prior to starting maintenance on a Kawasaki Robot, pay attention to the following matters to
ensure safety.
！ WARNING
1. Prior to starting maintenance, turn OFF controller power up to the external

power switch for shutting off power supply to the robot controller. Display signs
indicating clearly “Inspection and Maintenance in progress”, and lockout/tagout
the external power switch to prevent the danger of electric shock and to stop
personnel from accidentally turning ON the power.
2. If changing the joint angle is required for grease replenishment, etc., first, switch
ON the motor power. Then, set the robot to the desired posture. Be careful
not to be caught by or between any moving parts of the robot due to careless
approach to the robot at this time. After driving robot to the specified pose,
turn OFF the power and lockout/tagout the external power switch again as
mentioned above, and start maintenance.
3. Some arm parts may be very hot after continuous operations, depending on
ambient temperature. Be sure arm has cooled before starting any work.
Handling hot machine parts is extremely dangerous and may result in injury,
burns, etc.
4. Warning labels are affixed to the arm to identify areas with possibility of electric
shock, high temperature or pinching/crushing, so check these areas beforehand.
See the next page for the warning labels and their positions.
！ CAUTION
1. Do not apply excessive force to the robot arm as it may result in a shortened
service life and/or damage to parts or the brake mechanisms in the joints.
2. Use only Kawasaki designated greases, gear oils and other lubricants.
3. For replenishing and changing grease, use manual type grease gun instead of air
pump type.
4. When using air pump type grease gun, reduce air pressure on the supply side to
0.26 Mpa (2.5 kgf/cm2) or lower by a regulator, etc. and apply grease using grease
pump P3L (manu. by MacNaught, pressure ratio 1: 50). (Contact Kawasaki
before using any grease pump not described above.)
5. Never remove bolts unless specifically instructed by the maintenance or
inspection procedure.
4
MX series warning label positions
: Warning label for electric shock
: Warning label for high temperature
: Warning label for pinching/crushing
5
MD400N warning label positions
C
D
6
MT400N warning label positions
B
D
C
D
7
MX Series, MD400N, MT400N 2. Items of Maintenance & Inspection
2.0 ITEMS OF MAINTENANCE & INSPECTION
For robot maintenance & inspection, there are daily checks, routine inspections (5,000 hours,
10,000 hours and 15,000 hours) and times for complete overhaul. This manual describes items
to be maintained and inspected, as well as inspection methods and adjustment methods. These
items are very important for using the robot successfully for a long time in a stable condition.
Thus, pay special attention to the following instructions.
Maintenance period
Daily 5,000 10,000 15,000 20,000 See
Check hours hours hours hours Page
Maintenance items
(1) Flaws on exterior of robot { { { { 12

(2) Cables & hoses { { { { 12
(3) Movement & abnormal noises of robot { { { { 12
(4) Positioning accuracy of robot { { { { 12
(5) Grease replenishment to JT1Gear { { { 14
(6) Oil replenishment to JT1 gearbox { { 15
(7) Oil change of JT1 gearbox { 16
(8) Grease change for all gears and reduction
{ 17∼27
units except JT1
(9) Grease replenishment to cross roller
{ 28∼30
bearing
(10) Internal machine cables { 31
(11) Retightening of bolts & nuts { 32
(12) Overhaul { -
！ CAUTION
If the maintenance is not made as specified, it may result in a
shortened service life of robot. Be prepared as the replacement of
many parts is required at overhaul (approx. every 20,000 hours).
Upon reaching the 20,000-hour overhaul period, contact your nearest
Kawasaki service engineer.
8
2.1 ITEMS OF MAINTENANCE & INSPECTION – MX SERIES
This section explains the items requiring periodic inspection/maintenance on MX series robots.
The inspection cycle time for each item can be found by referencing its part number in the figures
below with those in the table in 2.0, (1) to (12).
Inspection part Detail

(5) Grease replenishment to Gear JT1
(6) Oil replenishment to JT1 gear box
(7) Oil change of JT1 gear box
(8) Grease change of gear reduction units except JT1
(9) Grease replenishment to cross roller bearings
(10) Inspection of internal machine cable
(5),(6),(7)
(10)
(8)-4 (8)-6
(8)-3 (8)-5
(9)-2 (8)-1
(8)-2
(9)-1
9
2.2 ITEMS OF MAINTENANCE & INSPECTION – MD400N
This section explains the items requiring periodic inspection/maintenance on MD400N robot.
(5),(6),(7)
(8)-3
(8)-4
(8)-1
(10)
(8)-2
(9)-1
(9)-2
10
2.3 ITEMS OF MAINTENANCE & INSPECTION – MT400N
This section explains the items requiring periodic inspection/maintenance on MT400N robot.
(5),(6),(7)
(10)
(9)-2
(8)-2 (8)-1
(9)-1
(8)-3
(8)-4
(8)-5
(8)-6
11
MX Series, MD400N, MT400N 3. Details of Daily Check
3.0 DETAILS OF DAILY CHECK
Maintenance items Details of maintenance Troubleshooting

1 Exterior of robot 1. Check for damage to robot 1. Remove the cause of
parts, due to interference interference, etc.
etc., especially wrist section.
2 Cables and hoses 1. Check for severe bending, 1. Readjust the clamps.
twisting, damage, etc. on the
cables, hoses and other
component parts connected
with the tool.
3 Robot motion 1. Check if each axis moves 1. Check the lubrication level.
smoothly. 2. Check if any abnormality is
2. Check if any abnormal noise observed in the driving
and/or vibrations are system.
observed. 3. If the backlash has increased
3. Check if the overshoot is and thus resulted in
excessively large. vibration, contact nearest
Kawasaki service center.
4 Positioning accuracy 1. Check if any drift from 1. Check if any abnormality is
previously repeated position observed in the driving
is observed. system.
2. Check if any fluctuations are 2. If the backlash has increased
observed in the stop position. and thus resulted in
vibration, please contact
nearest Kawasaki service
center.
5 Safety systems 1. Check if the safety systems 1. Check switches and wiring
(Emergency Switch, and eliminate the cause.
Deadman grips, Safety
Fence) can be operated
normally.
If the above abnormalities cannot be corrected by mechanical troubleshooting, contact

Kawasaki for control system inspection and adjustment.
12
MX Series, MD400N, MT400N 4. Replenishment and Change
4.0 REPLENISHMENT AND CHANGE
！ WARNING
1. Prior to grease and oil replenishment, turn OFF controller power up to the
external power switch. Display signs indicating clearly “Inspection and
Maintenance in progress” and lockout/tagout the external power switch to
prevent personnel from accidentally turning ON the power.
2. Prior to grease replenishment, remove the plug from drain port without fail. If
grease is replenished without removing the drain plug, internal pressure from
refilling the grease may damage the sealing or cause grease to flow into the
motor.
！ CAUTION
1. During grease or oil replenishment maintain the specified refill level; do not apply
too much grease or oil.
2. Use a hand-pump type grease gun to refill or change the grease.
3. When using air pump type grease gun, reduce air pressure on the supply side to
0.26 Mpa (2.5 kgf/cm2) or lower by a regulator, etc. and apply grease using a
grease pump P3L (manu. by MacNaught, pressure ratio 1: 50). (Contact
Kawasaki before using any grease pump not described above.)
4. When replenishing grease, do not connect a long hose for drainage to the drain
port directly. Grease may not drain smoothly resulting in seal damage or
reversed flow due to increased pressure of refilling, which may lead to grease
leakage.
5. Observe the latest MSDS of the grease before grease replenishment.
13
4.1 GREASE AND OIL REPLENISHMENT TO JT1 GEAR AND OIL CHANGE
Oil filler port for gearbox
Grease nipple (Filler port) Oil gauge
Plug for oil drainage

Plug for grease drainage
(Drain port)
4.1.1 GREASE REPLENISHMENT TO JT1 GEAR – MX SERIES, MD400N, MT400N
！ WARNING
Read WARNING and CAUTION on page 13 before starting operation.
Model MX series, MD400N, MT400N

Fill vol. (rough) 150 cc
Grease Multemp FZ
Working location (5) (See pages 9∼11)
Procedures
1. Prepare a container and a rag in advance to catch the spilled grease from the drain port.
2. Place the container to catch the spilled grease and remove the plug for grease drainage.
3. Replenish the grease into the filler port.
4. Wipe away any grease around the filler and drain ports with the rag, and return the plug
covered with sealant tape to the drain port.
14
4.1.2 OIL REPLENISHMENT TO GEARBOX – MX SERIES, MD400N, MT400N
！ WARNING

Oil Shell Omala #68
Procedures
1. There is an Oil Gauge on the gearbox where you can see the current oil volume. Check the
Oil Gauge to see if oil volume is above the minimum line.
Oil gauge
Oil level
Minimum line
2. Replenish the oil if the volume is less than the minimum line.
3. Change the oil if it has become extremely dark.
15
4.1.3 OIL CHANGE OF GEARBOX – MX SERIES, MD400N, MT400N
！ WARNING

Oil Shell Omala #68
Procedures
1. Remove the plug from the indicated drain port, then tap off the old oil from gearbox.
(Blowing clean air into the filler port of the gearbox helps the old oil come out quickly.)
2. Return the plug to drain port.
3. Replenish new oil into the filler port of the gearbox.
4. Check the Oil Gauge to see if oil volume is above the minimum line and refill the oil until the
oil level becomes higher than the minimum line.
Oil gauge
Oil level
Minimum line
16
4.2 JT2 REDUCTION UNIT GREASE CHANGE – MX SERIES, MD400N, MT400N
！ WARNING
Drain port (Rc1/8)
Filler port (Rc1/8)

Grease Multemp FZ
Working location (8)-1 (See pages 9∼11)
Procedures
2. Set the posture of JT2 to approx. 60°.
3. Remove the plug from the filler port, then put in a grease nipple.
(At this stage, do not remove the plug from drain port.)
4. Place the container to catch the spilled grease and remove the plug from drain port.
5. Inject new grease into the filler port until new grease comes out of the drain port.
6. Wipe away any grease around the filler and drain ports with the rag, then return the plugs
covered with sealant tape to the drain and filler ports in this order.
17
4.3 JT3 REDUCTION UNIT GREASE CHANGE – MX SERIES, MD400N, MT400N
！ WARNING
Drain port (Rc1/8)
Filler port (Rc1/4)

Grease Multemp FZ
Procedures
2. Set the posture of JT3 to 0°.
18
4.4 JT4, JT5 AND JT6 WRIST AXIS DRIVE GEAR GREASE CHANGE – MX
SERIES
！ WARNING
Filler port (Rc1/4)
Drain port (Rc1/4)

Model MX series
Grease Multemp FZ
Working location (8)-3 (See page 9)
Procedures
19
4.5 JT4, JT5 AND JT6 WRIST AXIS DRIVE GEAR GREASE CHANGE – MT400N
！ WARNING
Filler port (Rc1/4)
Drain port (Rc1/4)
Model MT400N
Grease Multemp FZ
Procedures
20
4.6 JT4 GEAR AND REDUCTION UNIT GREASE CHANGE – MX SERIES
！ WARNING
Filler port (Rc1/8)
Drain port (Rc1/8)
Model MX series
Grease Multemp FZ
Procedures
21
4.7 JT4 GEAR AND REDUCTION UNIT GREASE CHANGE – MD400N
！ WARNING
Filler port (Rc1/4)
Drain port (Rc1/8)
Model MD400N
Grease Multemp FZ
Procedures
2. Set the posture of each axis as follows: JT3= 0°, JT5= 0°
3. Remove the plug from filler port, then put in a grease nipple.
4. Place the container to catch the spilled grease and remove the cover for drainage.
5. Inject new grease into the filler port until new grease comes out of the drain port of the drain.
22
4.8 JT4 GEAR AND REDUCTION UNIT GREASE CHANGE – MT400N
！ WARNING
Filler port (Rc1/8)
Drain port (Rc1/8)
Model MT400N
Grease Multemp FZ
Procedures
5. Inject new grease into the filler port until new grease comes out of the drain port of the drain.
23
！ WARNING
Filler port (Rc1/8)

Lower side
Upper side
Remove cover (for drainage)
Model MX series
Grease Multemp FZ
Procedures
2. Set the posture of each axis as follows: JT3= 0°, JT4= 90°, JT5= 0°, JT6= 0°
(Set filler port facing down, and cover for drainage facing up.)
5. Inject new grease into the filler port until new grease comes out of the drain port that faces
up.*
6. Wipe away any grease around the filler and drain ports with the rag, then return the cover for
drainage. Then, return the plugs covered with sealant tape to the drain and filler ports in this
order.
Note* Replenish the grease until about half of the gears near the drain port are submerged by the
grease.
24
4.10 JT5 REDUCTION UNIT GREASE CHANGE – MD400N
！ WARNING
Filler port (Rc1/8)
Drain port (Rc1/8)
Model MD400N
Grease Multemp FZ
Procedures
2. Set the posture of JT3 and JT5 to 0°.
25
！ WARNING
Filler port (Rc1/8)
Drain port (Rc1/8)
Model MT400N
Grease Multemp FZ
Procedures
2. Set the posture of JT3 and JT5 so that the drain port faces downward.
26
！ WARNING
Drain port
(Rc1/8)
Filler port (Rc1/8)
Model MX series
Grease Multemp FZ
Procedures
2. Set the posture of each axis as follows: JT3= 0°, JT4=0°, JT5= 0°, JT6= 0°
27
！ WARNING
Filler port (Rc1/8)
Drain port (Rc1/8)
Model MT400N
Grease Multemp FZ
Procedures
2. Set the posture of each axis so that the drain port faces downward by moving robot.
28
4.14 GREASE REPLENISHMENT TO JT1 CROSS ROLLER BEARINGS – MX

SERIES, MD400N, MT400N
！ WARNING
Filler port (Rc1/4)
Filler port (Rc1/4)

Grease Daphne Eponex #2
Procedures
1. Remove the plugs from the two filler ports, then put in two grease nipples.
2. Set the posture of JT1 to -90°, then replenish grease. (15 cc to each filler port)
3. Rotate JT1 to +90°, then replenish grease again. (15 cc to each filler port)
4. Rotate and set the posture of JT1 to 0°.
5. Wipe off any grease leaking from the sides of the cross roller bearings.
6. Return the plugs covered with sealant tape to the filler ports.
29
4.15 GREASE REPLENISHMENT TO JT3 CROSS ROLLER BEARINGS – MX

SERIES, MN400N, MT400N
！ WARNING
Filler port (Rc1/8)
Filler port (Rc1/8)

Grease Daphne Eponex #2
Procedures
1. Remove the plugs from the two filler ports, then put in two grease nipples.
2. Set the posture of JT3 to 0°, then replenish grease. (10 cc to each filler port)
3. Rotate JT3 to -107°, then replenish grease again. (10 cc to each filler port)
4. Rotate and set the posture of JT3 to 0°.
5. Wipe off any grease leaking from the sides of the cross roller bearings.
6. Return the plugs covered with sealant tape to the filler ports.
30
MX Series, MD400N, MT400N 5. Check on Internal Machine Cables
5.0 CHECK ON INTERNAL MACHINE CABLES – MX SERIES, MD400N, MT400N
！ WARNING
Prior to starting check on internal machine cables, turn OFF
controller power and external power switch. Display signs indicating
clearly “Inspection and Maintenance in progress”, and lockout/tagout
the external power switch to prevent personnel from accidentally
turning ON the power.

Check on the following items:

1. Looseness of cable connectors, etc. → Retighten the connectors firmly, if necessary.
2. Damage and/or bending of cables → If part is faulty, replacement is necessary. Contact
Kawasaki.
31
MX Series, MD400N, MT400N 6. Retightening
6.0 RETIGHTENING
Check if any mounting bolts or nuts are loosened. If necessary, retighten the bolts, nuts, etc.
firmly. The following are the most important items that require retightening.
1. Servo motor mounting bolts

2. Motor bracket mounting bolts
3. Reduction unit mounting bolts
4. Connecting bolts between upper arm 1 and 2
5. Tool mounting bolts
6. Base mounting bolts
[ NOTE ]
The tightening torque for the hexagon socket

head cap bolts is shown below:
M 3: 1.47 Nxm
M 4: 3.43 Nxm
M 5: 6.86 Nxm
M 6: 11.76 Nxm
M 8: 29.40 Nxm
M10: 56.84 Nxm (Motor mounting bolts: 44.10Nxm)
M12: 98.00 Nxm (Motor mounting bolts: 78.40Nxm)
M14: 156.80 Nxm
M16: 235.20 Nxm
M20: 431.20 Nxm
M24: 784.31 Nxm
32
Kawasaki Robot MX series, MD400N, MT400N
INSPECTION AND MAINTENANCE
MANUAL
December 2002 : 1st Edition
May 2008 : 5th Edition
Publication : KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION
90205-1082DEE
Copyright © 2008 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.

Mx-Series & MT400N Maintanance Manual

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Kawasaki Robot

MX Series, MD400N, MT400N

Kawasaki Heavy Industries, Ltd.

This Manual describes the following Robot Arms

Failure to comply with indicated matters can result in

Failure to comply with indicated matters may possibly

Failure to comply with indicated matters may lead to

2.0 Items of Maintenance & Inspection ........................................................................................8

3.0 Details of Daily Check...........................................................................................................12

4.0 Replenishment and Change...................................................................................................13

5.0 Check on Internal Machine Cables – MX Series, MD400N, MT400N ..............................31

1. Prior to starting maintenance, turn OFF controller power up to the external

MX series warning label positions

: Warning label for electric shock

: Warning label for high temperature

: Warning label for pinching/crushing

MD400N warning label positions

: Warning label for electric shock

: Warning label for high temperature

: Warning label for pinching/crushing

MT400N warning label positions

: Warning label for electric shock

: Warning label for high temperature

: Warning label for pinching/crushing

2.0 ITEMS OF MAINTENANCE & INSPECTION

(1) Flaws on exterior of robot { { { { 12

2.1 ITEMS OF MAINTENANCE & INSPECTION – MX SERIES

Inspection part Detail

2.2 ITEMS OF MAINTENANCE & INSPECTION – MD400N

2.3 ITEMS OF MAINTENANCE & INSPECTION – MT400N

3.0 DETAILS OF DAILY CHECK

Maintenance items Details of maintenance Troubleshooting

If the above abnormalities cannot be corrected by mechanical troubleshooting, contact

4.0 REPLENISHMENT AND CHANGE

Oil filler port for gearbox

Grease nipple (Filler port) Oil gauge

Plug for oil drainage

4.1.1 GREASE REPLENISHMENT TO JT1 GEAR – MX SERIES, MD400N, MT400N

Model MX series, MD400N, MT400N

4.1.2 OIL REPLENISHMENT TO GEARBOX – MX SERIES, MD400N, MT400N

Model MX series, MD400N, MT400N

4.1.3 OIL CHANGE OF GEARBOX – MX SERIES, MD400N, MT400N

Model MX series, MD400N, MT400N

4.2 JT2 REDUCTION UNIT GREASE CHANGE – MX SERIES, MD400N, MT400N

Drain port (Rc1/8)

Filler port (Rc1/8)

Model MX series, MD400N, MT400N

4.3 JT3 REDUCTION UNIT GREASE CHANGE – MX SERIES, MD400N, MT400N

Drain port (Rc1/8)

Filler port (Rc1/4)

Model MX series, MD400N, MT400N

Filler port (Rc1/4)

Drain port (Rc1/4)

Filler port (Rc1/4)

Drain port (Rc1/4)

4.6 JT4 GEAR AND REDUCTION UNIT GREASE CHANGE – MX SERIES

Filler port (Rc1/8)

Drain port (Rc1/8)

4.7 JT4 GEAR AND REDUCTION UNIT GREASE CHANGE – MD400N

Filler port (Rc1/4)

Drain port (Rc1/8)

4.8 JT4 GEAR AND REDUCTION UNIT GREASE CHANGE – MT400N

Filler port (Rc1/8)