Kawasaki Robot

RS03N (A/B00∗)
RA03N (A/B00∗)

Inspection and
Maintenance Manual

Kawasaki Heavy Industries, Ltd.

90205-1136DEA
RS03N, RA03N
Kawasaki Robot Inspection and Maintenance Manual

PREFACE

This manual describes the inspection and maintenance instructions for the Kawasaki Robot
RS03N (A/B00∗)/RA03N (A/B00∗).

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 – RS03N (A/B00∗)/RA03N (A/B00∗)

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.

RS03N (A00∗) ... Standard specifications (Floor/ceiling mount)

RS03N (B00∗) … Standard specifications (Wall mount)
RA03N (A00∗) ... Arc weld specifications (Floor/ceiling mount)
RA03N (B00∗) ... Arc weld specifications (Wall 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 © 2010 Kawasaki Heavy Industries Ltd.

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RS03N, RA03N
Kawasaki Robot Inspection and Maintenance Manual

SYMBOLS

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

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RS03N, RA03N
Kawasaki Robot Inspection and Maintenance Manual

CONTENTS

Preface ..................................................................................................................................................1
Symbols................................................................................................................................................2

1.0 Precautions..................................................................................................................................4

2.0 Items for Maintenance and Inspection.......................................................................................6

3.0 Details of Daily Inspection.........................................................................................................7

4.0 Checking Internal Machine Cables ............................................................................................8

5.0 Bolt Retightening........................................................................................................................9

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RS03N, RA03N 1. Precautions
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.

！ 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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RS03N, RA03N 1. Precautions
Kawasaki Robot Inspection and Maintenance Manual

Warning label

View A

Warning label for pinching point

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RS03N, RA03N 2. Items for Maintenance and Inspection
Kawasaki Robot Inspection and Maintenance Manual

2.0 ITEMS FOR MAINTENANCE AND INSPECTION

Robot maintenance and inspection work consists of daily inspections, 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 inspections 3. Robot movement & abnormal noises
4. Positioning accuracy of robot
5. Safety system
Periodic 1. Checking internal machine cables
10000 hours
inspections 2. Bolt retightening
20000 hours 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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RS03N, RA03N 3. Details of Daily 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 Details of maintenance Troubleshooting

1 Exterior of robot 1. Check for damage to robot parts, due to 1. Remove the cause of
interference etc., especially wrist section. interference, etc.
2. Check for any dents on the arm and base
section covers due to collision.
Damage,
etc.

2 Cables and hoses 1. Check for severe bending, twisting, 1. Remove the cause of trouble
damage, etc. on the cables, hoses, etc. by readjusting the clamps.
connected to hand. 2. Repair/replace the damaged
2. Check for damage and catching on the cables and hoses.
Twisting, cables connected from rotation section to 3. Remove the cause of
etc.
upper arm. interference.
3 Robot movement and 1. Check if each axis moves smoothly. 1. Check the lubrication level.
abnormal noises 2. Check if any abnormal noise and/or 2. Check if any abnormality is

Abnormal noises, vibrations are observed. observed in the driving system.

vibration, etc. 3. Check if the overshoot is excessively 3. If the backlash has increased
large. and thus resulted in vibration,
4. Check if abnormal heating is observed contact nearest Kawasaki.
on the motor.

4 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.
5 Safety systems 1. Check if the safety systems (Emergency 1. Check switches and wiring and
Switch, Deadman Switch, Safety Fence remove the cause.
Switch) can be operated normally.

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

for control system inspection and adjustment.

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RS03N, RA03N 4. Checking Internal Machine Cables
Kawasaki Robot Inspection and Maintenance Manual

4.0 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.)

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RS03N, RA03N 5. Bolt Retightening
Kawasaki Robot Inspection and Maintenance Manual

5.0 BOLT RETIGHTENING

Check if any fixing bolts or nuts are loose. If necessary, firmly retighten the bolts, nuts, etc.
The following bolts shown in the next page are the most important bolts and require
retightening.

① Servo motor fixing bolts

② Motor bracket fixing bolts
③ Reduction unit fixing bolts
④ Tool fixing bolts
⑤ Base fixing bolts

[ NOTE ]

Tightening torque of hexagon socket head cap screws

is below.

M3 1.47 N･m
M4 3.43 N･m
M5 6.86 N･m
M6 11.76 N･m
M8 29.40 N･m
M10 56.84 N･m
M12 98.00 N･m

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RS03N, RA03N 5. Bolt Retightening
Kawasaki Robot Inspection and Maintenance Manual

Cross-section A-A

Cross-section B-B Cross-section C-C

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 Kawasaki Robot RS03N (A/B00∗), RA03N (A/B00∗)
Inspection and Maintenance Manual

March 2010 : 1st Edition

Published by KAWASAKI HEAVY INDUSTRIES, LTD.

90205-1136DEA

All rights reserved. Copyright © 2010 KAWASAKI HEAVY INDUSTRIES, LTD.