Kawasaki Robot FS03N (E00) FS03N (F00) FC03N (E00) FW03N (E00)

Inspection and Maintenance Manual

Kawasaki Heavy Industries, Ltd.

90205-1107DEC

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PREFACE This manual describes the inspection and maintenance instructions for the Kawasaki Robot FS03N (E/F00)/FC03N (E00)/FW03N (E00). Read and understand the contents of this manual and the safety manual thoroughly, and strictly observe all rules for safety before proceeding with any operation. Refer to the following manuals for information on the robot arm and controller respectively. Installation and Connection Manual FS03N (E/F00)/FC03N (E00)/FW03N (E00) Installation and Connection Manual 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 model. FS03N (E00) ... Standard specifications (Floor/ceiling mount) FS03N (F00) Standard specifications (Wall mount) FC03N (E00) ... Clean specifications (Floor/ceiling mount) FW03N (E00) ... Waterproof specifications (Ceiling mount)

1. This manual does not constitute a guarantee of the systems in which the robot is utilized. Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems relating to industrial property rights as a result of using the system. 2. It is recommended that all personnel assigned for activation of operation, teaching, maintenance or inspection of the robot attend the necessary education/training course(s) prepared by Kawasaki, before assuming their responsibilities. 3. Kawasaki reserves the right to change, revise, or update this manual without prior notice. 4. This manual may not, in whole or in part, be reprinted or copied without the prior written consent of Kawasaki. 5. Store this manual with care and keep it available for use at any time. If the robot is reinstalled or moved to a different site or sold off to a different user, attach this manual to the robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki. All rights reserved. Copyright 2006 Kawasaki Heavy Industries Ltd. 1

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FS03N, FC03N, FW03N Kawasaki Robot Inspection and Maintenance Manual

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, handling, 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 ones 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 explanations described in each chapter, and prepare safety measures suitable for actual work.

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FS03N, FC03N, FW03N Kawasaki Robot Inspection and Maintenance Manual

CONTENTS

Preface ..............................................................................................................................................1 Safety................................................................................................................................................2 1.0 Precautions..............................................................................................................................4 2.0 Items for Maintenance and Inspection...................................................................................6 3.0 Details of Daily Inspection.....................................................................................................7 4.0 Gasket Replacement for Cover (FW03N (E00)).................................................................8 5.0 Checking Internal Machine Cables ........................................................................................9 6.0 Bolt Retightening..................................................................................................................10

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FS03N, FC03N, FW03N Kawasaki Robot Inspection and Maintenance Manual

1.0 PRECAUTIONS Prior to starting inspection and maintenance on a Kawasaki robot, pay attention to the following matters to ensure safety.

WARNING

1. Prior to starting inspection and maintenance, turn OFF control power up to the main power source. Display signs indicating clearly Inspection and Maintenance in progress. Lockout/tagout the main power switch to prevent personnel from accidentally turning ON the power. 2. Prior to driving the robot, check no abnormality is observed in installing condition, etc. to ensure safety, and then turn ON the motor power to 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 setting the robot to the specified pose, turn OFF the control power up to the main power source. Display signs indicating clearly Inspection and Maintenance in Progress, and lockout/tagout the main power switch before starting inspection and 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. Per specifications, FC03N (E00) and FW03N (E00) are not affixed with warning labels. However, use figures below to confirm all danger areas on the robot before starting work.

CAUTION

1. Do not apply excessive force to the robot arm while robot is stopped, as it may result in a shortened service life and/or damage to parts or the brake mechanisms in the joints. 2. Never loosen and/or remove bolts unless specifically instructed by the inspection and/or maintenance procedure.

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FS03N, FC03N, FW03N Kawasaki Robot Inspection and Maintenance Manual

1. Precautions

Warning label

View A

Warning label for pinching point

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FS03N, FC03N, FW03N Kawasaki Robot Inspection and Maintenance Manual

1. Precautions

2.0 ITEMS FOR MAINTENANCE AND INSPECTION Robot maintenance and inspection work consists of daily checks, periodic inspections and 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

Check item 1. Exterior of robot 2. Cable and hoses

Daily inspection

3. Robot movement & abnormal noises 4. Positioning accuracy of robot 5. Safety system

Periodic inspection 20000 hours

5000 hours 10000 hours

1. Gasket replacement for cover (FW03N (E00)) 1. Checking internal machine cables 2. Bolt retightening 1. Overhaul

CAUTION

If the maintenance is not made as specified, it may result in shortening of service life of robot and many parts may need to be replaced at overhaul. (approx. every 20000 hours) Upon reaching the 20000-hour overhaul period, contact Kawasaki.

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FS03N, FC03N, FW03N 2. Items for Maintenance and Inspection Kawasaki Robot Inspection and Maintenance Manual

3.0 DETAILS OF DAILY INSPECTION When daily maintenance and inspection of the Kawasaki robot is required, see the table below.
Check items 1 Exterior of robot Details of maintenance 1. Check for damage to robot parts, due to interference etc., especially wrist section. 2. Check for any dents on the arm and base
Damage, etc. 3. Check for any surface damage or

Troubleshooting 1. Remove the cause of interference, etc.

section covers due to collision.

loss/flaking of the finishing and painting (FW03N (E00)). 2 Cables and hoses 1. Check for severe bending, twisting, damage, etc. on the cables, hoses, etc. connected to hand. 2. Check for damage and catching on the
Twisting, etc.

1. Remove the cause of trouble by readjusting the clamps. 2. Repair/replace the damaged cables and hoses. 3. Remove the cause of interference. 1. Check the lubrication level. 2. Check if any abnormality is observed in the driving system. 3. If the backlash has increased and thus resulted in vibration, contact nearest Kawasaki.

cables connected from rotation section to upper arm.

Robot movement and abnormal noises

Abnormal noises, vibration, etc.

1. Check if each axis moves smoothly. 2. Check if any abnormal noise and/or vibrations are observed. 3. Check if the overshoot is excessively large. 4. Check if abnormal heating is observed on the motor. Normal surface temperature is 80 C or less.

Positioning accuracy of robot

1. Check if any drift from previously repeated position is observed. 2. Check if any fluctuations are observed in the stop position.

1. Check if any abnormality is observed in the driving system. 2. If the backlash has increased and thus resulted in vibration, contact nearest Kawasaki.

Drift, etc.

Safety systems

1. Check if the safety systems (Emergency Switch, Deadman Switch, Safety Fence) can be operated normally.

1. Check switches and wiring and remove the cause.

If the above abnormalities cannot be corrected by mechanical troubleshooting, contact Kawasaki for control system inspection and adjustment. 7

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FS03N, FC03N, FW03N Kawasaki Robot Inspection and Maintenance Manual

3. Details of Daily Inspection

4.0 GASKET REPLACEMENT FOR COVER (FW03N (E00))

CAUTION

The standard 5000-hour inspection cycle might become shorter depending on environmental factors such as ambient temperature and chemicals used. Seven areas of replacement points are as indicated in the figure below. For replacing the gasket (opening the cover), prepare gasket according to the table below, corresponding for the area of replacement.

(1), (2): at opposite

(3) (4) (5) (6) (1), (2) (3) (4) (5) (6) (7) Gasket Product Product No. 60347-1374 60347-1371 60347-1370 60347-1373 60347-1372 60347-1369 Quantity 2 1 1 1 1 1

(7)

Replacement procedures are as follows; 1. 2. 3. 4. 5. Remove old gasket, and clean and degrease of the cover, for attaching the gasket. Attach the gasket to the cover. (two-sided tape on one side) Clean and degrease housing surface, for attaching the cover. Spray 3M Repositional Adhesive 75 (made by 3M) all over the gasket attached to the cover. Reattach the cover quickly before spray adhesive dries out. (within 2 minutes or so) [ SUS bolt tightening torque: 0.69 Nm ]

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FS03N, FC03N, FW03N Kawasaki Robot Inspection and Maintenance Manual

4. Gasket Replacement for Cover

5.0 CHECKING INTERNAL MACHINE CABLES

WARNING

Prior to checking the internal machine cables, turn OFF control power up to the main power source. Display signs indicating clearly Inspection and Maintenance in progress. Lockout/tagout the main power switch to prevent personnel from accidentally turning ON the power.

Check on the following items: 1. Looseness of the cable connectors, etc. (Retighten the connectors firmly if necessary.) 2. Damage and/or severe bending of the cables. (If any abnormalities are found, contact Kawasaki for replacement of the parts in question.) 3. Looseness of terminal block screws in the connector box. (Retighten if necessary.)

CAUTION

To open the FW03N (E00) cover, gasket replacement is required. For the replacement procedure, see Chapter 4. Gasket Replacement for Cover (FW03N (E00)).

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FS03N, FC03N, FW03N 5. Checking Internal Machine Cables Kawasaki Robot Inspection and Maintenance Manual

6.0

BOLT RETIGHTENING

Check if any fixing bolts or nuts are loose. If necessary, firmly retighten the bolts, nuts, etc. The following are the most important bolts that require retightening. 1. 2. 3. 4. 5. 6. Servo motor fixing bolts Motor bracket fixing bolts Reduction unit fixing bolts Tool fixing bolts Base fixing bolts Robot mounting stand fixing bolts (FW03N (E00)) [ NOTE ] Tightening torque of hexagon socket head cap screws is below. SCM M3 M4 M5 M6 M8 M10 M12 1.47 Nm 3.43 Nm 6.86 Nm 11.76 Nm 29.40 Nm 56.84 Nm 98.00 Nm SUS 0.69 Nm (FW03N (E00) cover fixing bolt (see Chapter 4)) -

10

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FS03N, FC03N, FW03N Kawasaki Robot Inspection and Maintenance Manual

6. Bolt Retightening

Kawasaki Robot FS03N (E/F00), FC03N (E00), FW03N (E00) Inspection and Maintenance Manual
May 2005 : 1st Edition September 2005 : 2nd Edition April 2006 : 3rd Edition Published by KAWASAKI HEAVY INDUSTRIES, LTD.

90205-1107DEC

All rights reserved. Copyright 2006 KAWASAKI HEAVY INDUSTRIES, LTD.

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY