Kawasaki Robot

R Series

Inspection & Maintenance

Manual

Kawasaki Heavy Industries, Ltd.

90205－1127DEG
R Series
Kawasaki Robot Inspection and Maintenance Manual

PREFACE

This manual describes inspection and maintenance procedures for Kawasaki Robot R Series.

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. Refer to related manuals as
necessary.

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 is applicable to the following robot arms.

RA05L, RA06L, RA10L, RA10N, RA20N, RC05L, RD80N, RS05L, RS05N,
RS06L, RS10L, RS10N, RS15X, RS20N, RS30N, RS50N, RS80N

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.
Copyright © 2012 Kawasaki Heavy Industries Ltd. All rights reserved.

1
R Series
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.

2
R Series
Kawasaki Robot Inspection and Maintenance Manual

CONTENTS

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

2.0 Items of Maintenance & Inspection ........................................................................................ 7

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

4.0 Grease Replenishment for Gears...........................................................................................13

4.1 Replenishment for JT4 Gears ................................................................................................14
4.2 Replenishment for JT5 Gears ................................................................................................15
4.3 Replenishment for JT6 Gears ................................................................................................17

5.0 Grease Replenishment for Reduction Units .........................................................................19

5.1 JT3 Reduction Unit................................................................................................................19
5.2 JT4 Reduction Unit................................................................................................................22
5.3 JT5 Reduction Unit................................................................................................................23
5.4 JT6 Reduction Unit................................................................................................................25

6.0 Check of Motor Brake Torque ..............................................................................................27

7.0 Grease Replacement for Reduction Units.............................................................................28

7.1 JT1 Reduction Unit................................................................................................................28
7.2 JT2 Reduction Unit................................................................................................................30
7.3 JT3 Reduction Unit................................................................................................................32
7.4 JT4 Reduction Unit................................................................................................................33
7.5 JT5 Reduction Unit................................................................................................................34
7.6 JT6 Reduction Unit................................................................................................................36

8.0 Check of Timing Belt ............................................................................................................37

9.0 Check of Internal Machine Cables and Air Tubes ...............................................................39

10.0 Battery Replacement on 1HG Board ....................................................................................40

11.0 Retightening ...........................................................................................................................42

3
R Series 1. Precautions
Kawasaki Robot Inspection and Maintenance Manual

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 the controller power switch and 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 accidents of electric shock,
etc. caused when someone accidentally turns ON the power.
2. If changing the joint angle is required for grease replenishment, etc., first, turn
ON the motor power. Then, set the robot to the desired pose. 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 moving robot to the specified pose, turn OFF the
controller and external power. Display signs indicating clearly “Inspection and
maintenance in progress”, and lockout/tagout the external power switch before
starting 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 and other lubricants.
3. For replenishing and replacing 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, pump ratio 50:1).
(For all other grease pump models/brands, request permission from Kawasaki
before using.)
5. Never remove any bolts unless specifically instructed by the maintenance or
inspection procedure.

4
R Series 1. Precautions
Kawasaki Robot Inspection and Maintenance Manual

Attachment positions of warning labels for RS05N, RS05L and RA05L

Warning label for pinching

Warning label for electric

shock

5
R Series 1. Precautions
Kawasaki Robot Inspection and Maintenance Manual

Attachment positions of warning labels for models other than RS05N, RS05L and
RA05L

Warning label for high

temperature

Warning label for pinching

Warning label for electric

shock

6
R Series 2. Items of Maintenance & Inspection
Kawasaki Robot Inspection and Maintenance Manual

2.0 ITEMS OF MAINTENANCE & INSPECTION

For robot maintenance & inspection, there are daily checks, routine inspections (5000 hours,
10000 hours and 15000 hours) 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 Daily 5000 10000 15000 20000 Reference

Items Inspection hours hours hours hours Page
(1) Flaws on robot or its exterior ○ ○ ○ ○ 12
(2) Robot movement & abnormal ○ ○ ○ ○ 12
noises
(3) Positioning accuracy of robot ○ ○ ○ ○ 12
(4) Grease replenishment for gears* ○ ○ ○ 13-18
(5) Grease replenishment for reduction ○ ○ ○ 19-26
units*
(6) Check of motor brake torque ○ ○ ○ 27
(7) Grease replacement for reduction ○ 28-36
units
(8) Check of timing belts ○ 37-38
(9) Check of internal machine cables ○
39
and air tubes
(10) Battery replacement on 1HG ○ 40-41
board
(11) Retightening ○ 42
(12) Overhaul ○ －

NOTE* Applicable models: RS05N, RS05L, RS06L, RS10N, RS10L, RS15X, RS20N, RA05L,
RA06L, RA10N, RA10L, RA20N and RC05L

！ CAUTION
If the maintenance is not made as specified, it may result in a
shortened service life of robot and it may require unexpected number
of replacement parts at overhaul (approx. every 20000 hours). In
addition, it is recommended to replace seal parts such as oil seal in
overhaul. Upon reaching the 20000-hour overhaul period, contact
your nearest Kawasaki service center.

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R Series 2. Items of Maintenance & Inspection
Kawasaki Robot Inspection and Maintenance Manual

1. Inspection items for RS05N, RS05L, RA05L and RC05L

5000, 10000, 15000 hours 10000 hours

(4) Grease replenishment for gears (7) Grease replacement for reduction units
(5) Grease replenishment for (8) Check of timing belts
reduction gears (9) Check of inside machine cables and air
tubes
(10) Battery replacement on 1HG board

(9)

(4)-4
(5)-3

(4)-2
(9)

(8)
(5)-2

(5)-1

(10)
(4)-3

(7)-2

(7)-1

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R Series 2. Items of Maintenance & Inspection
Kawasaki Robot Inspection and Maintenance Manual

2. Inspection items for RS06L, RS10N, RS10L, RS20N, RA06L, RA10N, RA10L and
RA20N

5000, 10000, 15000 hours 10000 hours

(4) Grease replenishment for gears (7) Grease replacement for reduction units
(5) Grease replenishment for (8) Check of timing belts
reduction gears (9) Check of inside machine cables and air
tubes
(10) Battery replacement on 1HG board

(7)-3 (4)-1
(5)-4
(5)-2
(9) (9) (4)-3

(5)-1
(8) (4)-2
(5)-3

(9)
(10)

(7)-2

(7)-1

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R Series 2. Items of Maintenance & Inspection
Kawasaki Robot Inspection and Maintenance Manual

3. Inspection items for RS30N, RS50N, RS80N and RD80N

10000 hours
(7) Grease replacement for reduction units
(8) Check of timing belts
(9) Check of inside machine cables and air tubes
(10) Battery replacement on 1HG board

(7)-3

(7)-5
(9)
(9)

(7)-4
(8)
(7)-6
(9)

(7)-2 (10)

(7)-1

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R Series 2. Items of Maintenance & Inspection
Kawasaki Robot Inspection and Maintenance Manual

4. Inspection items for RS15X

5000, 10000, 15000 hours 10000 hours

(4) Grease replenishment for gears (7) Grease replacement for reduction units
(5) Grease replenishment for (8) Check of timing belts
reduction gears (9) Check of inside machine cables and air
tubes
(10) Battery replacement on 1HG board

(7)-3
(5)-2
(9)

(7)-4
(8)
(5)-3

(7)-2

(7)-1
(9)

(4)-3

(4)-2

(9)

(10)

11
R Series 3. Details of Daily Check
Kawasaki Robot Inspection and Maintenance Manual

3.0 DETAILS OF DAILY CHECK

When daily maintenance and inspection of the Kawasaki robot is required, see the table below.

Maintenance
Details of maintenance Troubleshooting
items
1 Exterior of robot 1. Check for damage to robot 1. Remove the cause of
parts, due to interference etc., interference, etc.
especially wrist section.
2 Cables and hoses 1. Check for severe bending, 1. Remove the cause of trouble by
twisting, damage, etc. on the readjusting the clamps, etc.
cables, hoses and other
component parts connected
with the hand.
3 Robot motion 1. Check if each axis moves 1. Check the lubrication level.
smoothly.

2. Check if any abnormal noise 2. Check if any abnormality is

and/or vibrations are observed. observed in the driving system.

3. Check if the overshoot is 3. If the backlash has increased and

excessively large. thus resulted in vibration,
contact nearest Kawasaki
service center.
4 Positioning 1. Check if any drift from 1. Check if any abnormality is
accuracy previously repeated positions observed in the driving system.
is observed.

2. Check if any fluctuations are2. If the backlash has increased and

observed in the stop position. thus resulted in vibration,
contact nearest Kawasaki
service center.
5 Safety systems 1. Check if the safety systems 1. Check switches and wiring for
(Emergency, Deadman, Safety problems and remove the cause.
Fence switches, etc.) can be
operated normally.

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

Kawasaki for control system inspection and adjustment.

12
R Series 4. Grease Replenishment for Gears
Kawasaki Robot Inspection and Maintenance Manual

4.0 GREASE REPLENISHMENT FOR GEARS

！ WARNING
1. Prior to replacing/replenishing the grease and oil, turn OFF the controller and
external power switches. 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 replacing or replenishing the grease, remove the plug from drain port
without fail. If grease is replenished without removing the drain plug, internal
pressure increase by refilling the grease may damage the sealing or cause grease
to flow into the motor.

！ CAUTION
1. When replacing/replenishing grease, maintain the specified refill level; do not
apply too much grease.
2. Use a hand-pump type grease gun to replace or replenish 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
grease pump P3L (manu. by Macnaught, pump ratio 50:1).
(For all other grease pump models/brands, request permission from Kawasaki
before using.)
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 by replenishing, which may lead to
grease leakage.
5. Observe the latest MSDS of the grease before grease replenishment.
6. When replacing/replenishing grease, prepare a container and rags in advance to
catch the spilled grease. The grease might leak from filler port and drain port.
7. Dispose used grease appropriately because it is specified as the industrial waste
by Wastes Disposal and Public Cleansing Act.

[ NOTE ]
Use a hexagonal wrench or a torque wrench with hexagonal-bar
attachment whose size is shown below for mounting/removing a plug.

Plug Width across flat of tool [mm]

R1/32
2
M4
M5 4
M6 3
R1/8 5
R1/4 6

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R Series 4. Grease Replenishment for Gears
Kawasaki Robot Inspection and Maintenance Manual

4.1 REPLENISHMENT FOR JT4 GEARS

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

RS06L, RS10N, RS10L, RS20N,

Model
RA06L, RA10N RA10L, RA20N
Volume 13 cc 30 cc
Grease Harmonic Grease SK-1A Molywhite A
Working location (4)-1 (See 2.0-2.)

Filler port
Drain port (R1/8)
(RS06L, RS10N, RA06L, RA10N-R1/4
RS10L, RS20N, RA10L, RA20N-R1/8)

Cover

Procedure
1. Set the forearm upright and turn OFF the power.
2. Remove the plug from the filler port after removing the cover and put in grease nipple.
3. Put a container for drained grease and remove the plug of drain port.
4. Replenish new grease from the filler port. (Be careful for the drained grease not to get into
rotation section of JT3.)
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, and return the plugs
covered with sealant tape to the drain and filler ports in this order. (R1/8-Tightening torque:
5.9 Nm, R1/4-Tightening torque: 6.9 Nm)
7. Return the cover. (M5 hex. socket screw-Tightening torque: 6.86 Nm)

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R Series 4. Grease Replenishment for Gears
Kawasaki Robot Inspection and Maintenance Manual

4.2 REPLENISHMENT FOR JT5 GEARS

1. RS05N, RS05L, RA05L, RC05L

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS05N, RS05L, RA05L, RC05L

Volume 3 cc
Grease Harmonic Grease SK-1A
Working location (4)-2 (See 2.0-1.)

Filler port (R1/32)

Drain port (R1/32)

Procedure
1. Set the forearm upright and turn OFF the power.
2. Remove the plugs from the filler and drain ports.
3. Replenish the grease from the filler port using an injector, etc.
4. Wipe away any grease around the filler and drain ports with rags, and return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 1.5
Nm)

15
R Series 4. Grease Replenishment for Gears
Kawasaki Robot Inspection and Maintenance Manual

2. RS06L, RS10N, RS10L, RS15X, RS20N, RA06L, RA10N, RA10L, RA20N

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

RS06L, RS10N, RS10L, RS15X, RS20N,

Model
RA06L, RA10N RA10L, RA20N
Volume 8 cc 7 cc
Grease Harmonic Grease SK-1A
Working location (4)-2 (See 2.0-2.)

Filler port (R1/8)

Drain port (R1/8)

Procedure
1. Set the forearm upright and turn OFF the power.
2. Remove the plugs from the filler and drain ports.
3. Put in a grease nipple to the filler port.
4. Replenish the grease from the filler port.
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, and return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 5.9
Nm)

16
R Series 4. Grease Replenishment for Gears
Kawasaki Robot Inspection and Maintenance Manual

4.3 REPLENISHMENT FOR JT6 GEARS

1. RS05N, RS05L, RA05L, RC05L

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS05N, RS05L, RA05L, RC05L

Volume 2 cc 3 cc
Grease Harmonic Grease SK-1A
Working location (4)-3 (See 2.0-1.) (4)-4 (See 2.0-1.)
Upper side
Filler port
(R1/32)

Filler port
(R1/32)

Drain port
Lower side (R1/32)
Drain port
(R1/32)

Procedure
1. Set the forearm horizontally (upper left figure)/upright (upper right figure) and turn OFF the
power.
2. Remove the plugs from the filler port and drain port.
3. Replenish the grease from the filler port using an injector, etc.
4. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 1.5
Nm)

17
R Series 4. Grease Replenishment for Gears
Kawasaki Robot Inspection and Maintenance Manual

2. RS06L, RS10N, RS10L, RS15X, RS20N, RA06L, RA10N, RA10L, RA20N

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

RS06L, RS10N, RS10L, RS15X, RS20N,

Model
RA06L, RA10N RA10L, RA20N
Volume 4 cc 5 cc
Grease Harmonic Grease SK-1A
Working location (4)-3 (See 2.0-2.)

Upper side Upper side

The upper side
has the motion
direction
marking for JT6.

Filler port (M6) Filler port (M6)

Drain port (M6)
Drain port (M6)
Lower side Lower side

RS06L, RS10N, RA06L, RA10N RS10L, RS15X, RS20N, RA10L, RA20N

Procedure
1. Set the forearm horizontally and turn OFF the power.
2. Remove the plugs from the filler port and drain port.
3. Put in a grease nipple to the filler port.
4. Replenish the grease from the filler port.
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 1.96
Nm)

18
R Series 5. Grease Replenishment for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

5.0 GREASE REPLENISHMENT FOR REDUCTION UNITS

5.1 JT3 REDUCTION UNIT

1. RS05N, RS05L, RA05L, RC05L

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS05N, RS05L, RA05L, RC05L

Volume 4 cc
Grease Harmonic grease SK-1A
Working Location (5)-3 (See 2.0-1.)

19
R Series 5. Grease Replenishment for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

Tying band
(Remove)
Tying band
(Do not remove)
Harness guide

Filler port (M5)

Originally attached
tying band
25-35 mm
Tying band
(Attach)

Drain port (M5) Twist one turn

clockwise.

Procedure
1. Set the forearm upright and the rear arm horizontal and turn OFF the power.
2. Remove the cover, and remove the 2 tying bands by cutting them.
3. Remove the harness guide, turning the harness aside.
4. Remove the plugs and seal washers from the filler and drain port.
5. Replenish new grease from the filler port using an injector, etc.
6. Wipe away any grease around the filler and drain ports with rags, then return the plugs and
seal washers to the drain and filler ports in this order. (Tightening torque: 6.86 Nm)
7. Attach the harness guide and in teach mode slowly move JT2 to the angle of 0and JT3 to the
angle of +118, paying attention not to damage the harness. (M4 hex. socket flush
screw-Tightening torque: 1.5 Nm)
8. Adjust the harness length to be the shortest, and fix the harness using 2 tying bands with the
harness twisted one turn clockwise.
9. Return the cover.
Plastic cover* (M4 hex. socket screw-Tightening torque: 0.4 Nm)
Metal cover (M4 hex. socket screw-Tightening torque: 3.43 Nm)
NOTE* Do not apply Loctite 242 to the mounting bolts for the plastic cover. Loctite 242
adhesion to the cover may cause breakage of the cover.

20
R Series 5. Grease Replenishment for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

2. RS06L, RS10N, RA06L, RA10N

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS06L, RS10N, RA06L, RA10N

Volume 10 cc
Grease Harmonic grease SK-1A
Working Location (5)-4 (See 2.0-2.)

Filler port (R1/8)

(Drain port for ceiling
mounted robot)

Drain port (R1/4)

(Filler port for
ceiling mounted
Cover
robot)
Procedure
1. Set both the forearm and the rear arm upright and turn OFF the power.
2. Remove the plug from the filler port after removing the cover.
3. Put in a grease nipple to the filler port.
4. Replenish new grease from the filler port.
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (R1/8-Tightening torque:
5.9 Nm, R1/4-Tightening torque: 6.9 Nm)
7. Return the cover. (M5 hex. socket screw-Tightening torque: 6.86 Nm)

21
 R Series 5. Grease Replenishment for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

5.2 JT4 REDUCTION UNIT

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS06L, RS10N, RA06L, RA10N RS10L, RS20N, RA10L, RA20N

Volume 1 cc 2 cc
Grease Harmonic Grease SK-1A
Working location (5)-1 (See 2.0-2.)
Harness fixing bracket Filler port (M6)

Filler port (M6)

Drain port (M6)

Drain port (M6)

Move the harness
fixing bracket
downward for Cover
approx. 20 mm. Cover
RS06L, RS10N, RA06L, RA10N RS10L, RS20N, RA10L, RA20N
Procedure
1. Set the forearm horizontally and turn OFF the power.
2. Remove the cover. For RS06L, RS10N, RA06L and RA10N, unscrew 2 mounting bolts
(M5) and move harness fixing bracket downward for approx. 20 mm.
3. Remove the plugs from the filler port and drain port.
4. Put in a grease nipple to the filler port.
5. Replenish the grease from the filler port.
6. Remove the grease nipple from the filler port.
7. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 1.96
Nm)
8. For RS06L, RS10N, RA06L and RA10N, remount the harness fixing bracket. (M5 hex.
socket screw-Tightening torque: 6.86 Nm)
9. Return the cover. (M5 hex. socket screw-Tightening torque: 6.86 Nm)

22
R Series 5. Grease Replenishment for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

5.3 JT5 REDUCTION UNIT

1. RS05N, RS05L, RA05L, RC05L

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS05N, RS05L, RA05L, RC05L

Volume 1 cc
Grease Harmonic Grease SK-1A
Working location (5)-2 (See 2.0-1.)

Upper side
Filler port (R1/32)

Lower side

Drain port (R1/32)

Procedure
1. Set the forearm horizontally and turn OFF the power.
2. Remove the plugs from the filler port and drain port.
3. Replenish the grease from the filler port using an injector, etc.
4. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 1.5
Nm)

23
R Series 5. Grease Replenishment for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

2. RS06L, RS10N, RS10L, RS15X, RS20N, RA06L, RA10N, RA10L, RA20N

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

RS06L, RS10N, RS10L, RS15X, RS20N,

Model
RA06L, RA10N RA10L, RA20N
Volume 1 cc 2 cc
Grease Harmonic Grease SK-1A
Working location (5)-2 (See 2.0-2.)

Upper side Filler port (M6) Upper side

The upper side Filler port (M6)
has the motion
direction
marking for JT6.

Lower side Lower side

Drain port (M6)

Drain port (M6)
RS06L, RS10N, RA06L, RA10N RS10L, RS15X, RS20N, RA10L, RA20N

Procedure
1. Set the forearm horizontally and turn OFF the power.
2. Remove the plugs from the filler port and drain port.
3. Put in a grease nipple to the filler port.
4. Replenish the grease from the filler port.
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 1.96
Nm)

24
R Series 5. Grease Replenishment for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

5.4 JT6 REDUCTION UNIT

1. RS05N, RS05L, RA05L, RC05L

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS05N, RS05L, RA05L, RC05L

Volume 1 cc
Grease Harmonic Grease SK-1A
Working location (5)-1 (See 2.0-1.)

Upper side
Filler port (R1/32)

Lower side
Drain port (R1/32)

Procedure
1. Set the forearm horizontally and turn OFF the power.
2. Remove the plugs from the filler and drain ports.
3. Replenish the grease from the filler port using an injector, etc.
4. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 1.5
Nm)

25
 R Series 5. Grease Replenishment for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

2. RS06L, RS10N, RS10L, RS15X, RS20N, RA06L, RA10N, RA10L, RA20N

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

RS06L, RS10N, RS10L, RS15X, RS20N,

Model
RA06L, RA10N RA10L, RA20N
Volume 1 cc 2 cc
Grease Harmonic Grease SK-1A
Working location (5)-3 (See 2.0-2.)
The upper side
has the motion
direction
marking for JT6.

A A

Filler port
(M4)
Filler port
Drain port (M6)
(M4)
View A View A Drain port (M6)
RS06L, RS10N, RA06L, RA10N RS10L, RS15X, RS20N, RA10L, RA20N
Procedure
1. Set the forearm horizontally and turn OFF the power.
2. Remove the plugs from the filler and drain ports.
3. For RS10L, RS15X, RS20N, RA10L and RA20N, put in a grease nipple to the filler port.
4. Replenish the grease from the filler port. For RS06L, RS10N, RA06L and RA10N,
replenish grease from the filler port using an injector, etc.
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order.
(M4-Tightening torque: 0.49 Nm, M6-Tightening torque: 1.96 Nm)

26
R Series 6. Check of Motor Brake Torque
Kawasaki Robot Inspection and Maintenance Manual

6.0 CHECK OF MOTOR BRAKE TORQUE

Model All models

Working location JT1 to 6*
NOTE* JT1 to 5 for RD80N.

Procedure
1. Move JT1 in teach mode.
2. While JT1 is moving, release trigger switch on Teach Pendant and check for overrun of the
arm and brake slippage.
3. Repeat steps 1 and 2 for checking in each axis, JT2 to 6.

！ CAUTION
Motor replacement is required if arm overruns or
brake slippage occurs. If it occurs, contact
Kawasaki.

27
R Series 7. Grease Replacement for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

7.0 GREASE REPLACEMENT FOR REDUCTION UNITS

7.1 JT1 REDUCTION UNIT

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

RS15X, RS30N,
RS05N, RS05L, RS06L, RS10N, RS10L, RS20N,
Model RS50N, RS80N,
RA05L, RC05L RA06L, RA10N RA10L, RA20N
RD80N
Volume 165 cc 740 cc 1300 cc 4400 cc
Grease Molywhite A
Working location (7)-1 (See 2.0-1, 2.0-2 and 2.0-3.)

Filler port (R1/8)

(Drain port for
ceiling mounted
robot)

Drain port (R1/8) RS05N, RS05L, RA05L, RC05L

(Filler port for ceiling
mounted robot)

Filler port (R1/8)

(Drain port for ceiling
mounted robot)

Drain port (R1/4)

(Filler port for
ceiling mounted
robot)

RS06L, RS10N, RA06L, RA10N

28
R Series 7. Grease Replacement for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

Filler port (R1/8)

(Drain port for
ceiling mounted
robot)

Drain port (R1/8)

(Filler port for
ceiling mounted
robot)

RS10L, RS20N, RA10L, RA20N

Drain port (R1/8)

(Filler port for ceiling
mounted robot)

Filler port (R1/8)

(Drain port for
ceiling mounted
robot)

RS15X, RS30N, RS50N, RS80N, RD80N

Procedure
1. Remove the cover for RS05N, RS05L, RA05L and RC05L.
2. Remove the plug from the filler port, then put in a grease nipple.
3. Place the container to catch the spilled grease and remove the plug from drain port.
4. Replenish new grease from the filler port until new grease comes out of the drain port.
5. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (R1/8-Tightening torque:
5.9 Nm, R1/4-Tightening torque: 6.9 Nm)
6. Return the cover for RS05N, RS05L, RA05L and RC05L.
Plastic cover* (M4 hex. socket screw-Tightening torque: 0.4 Nm)
Metal cover (M4 hex. socket screw-Tightening torque: 3.43 Nm)
NOTE* Do not apply Loctite 242 to the mounting bolts for the plastic cover. Loctite 242
adhesion to the cover may cause breakage of the cover.

29
R Series 7. Grease Replacement for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

7.2 JT2 REDUCTION UNIT

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

RS15X, RS30N,
RS05N, RS05L, RS06L, RS10N, RS10L, RS20N,
Model RS50N, RS80N,
RA05L, RC05L RA06L, RA10N RA10L, RA20N
RD80N
Volume 260 cc 300 cc 540 cc 1610 cc
Grease Molywhite A
Working location (7)-2 (See 2.0-1, 2.0-2 and 2.0-3.)

30
R Series 7. Grease Replacement for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

Filler port (R1/8)

(Drain port for ceiling
Drain port (R1/8)
mounted robot)
(Filler port for ceiling
mounted robot)

Filler port (R1/8)

(Drain port for
ceiling mounted
robot) Drain port (R1/4)
(Filler port for ceiling
mounted robot)
RS05N, RS05L, RA05L, RC05L RS06L, RS10N, RA06L, RA10N

Filler port (R1/8)

(Drain port for ceiling
mounted robot) Filler port (R1/8)
Drain port (R1/8) (Drain port for
(Filler port for ceiling mounted
ceiling mounted robot)
robot)

Drain port (R1/8)

(Filler port for
ceiling mounted
robot)

RS10L, RS20N, RA10L, RA20N RS15X, RS30N, RS50N, RS80N, RD80N

Procedure
1. Set the rear arm upright and turn OFF the power.
2. Remove the plug from the filler port, then put in a grease nipple.
3. Place the container to catch the spilled grease and remove the plug from drain port.
4. Replenish new grease from the filler port until new grease comes out of the drain port.
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (R1/8-Tightening torque:
5.9 Nm, R1/4-Tightening torque: 6.9 Nm)

31
R Series 7. Grease Replacement for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

7.3 JT3 REDUCTION UNIT

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

RS10L, RS20N, RS15X, RS30N, RS50N,

Model
RA10L, RA20N RS80N, RD80N
Volume 390 cc 930 cc
Grease Molywhite A
Working Location (7)-3 (See 2.0-2 and 2.0-3.)

Filler port (R1/8)

(Drain port for
ceiling mounted
robot)

Drain port (R1/8)

(Filler port for RS10L, RS20N, RA10L, RA20N Cover
ceiling mounted
robot)
Filler port (R1/8)
(Drain port for ceiling
mounted robot)

Drain port (R1/8)

(Filler port for
ceiling mounted
robot)
RS15X, RS30N, RS50N, RS80N, RD80N
Procedure
1. Set both the forearm and the rear arm upright and turn OFF the power.
2. Remove the cover for RS10L, RS20N, RA10L and RA20N.
3. Remove the plug from the filler port, then put in a grease nipple.
4. Place the container to catch the spilled grease and remove the plug from the drain port.
5. Replenish new grease from the filler port until new grease comes out of the drain port.
6. Remove the grease nipple from the filler port.
7. Wipe away any grease around the filler and drain ports with rags, then return the plugs covered
with sealant tape to the drain and filler ports in this order. (Tightening torque: 5.9 Nm)
8. Return the cover for RS10L, RS20N, RA10L and RA20N. (M5 hex. socket screw-
Tightening torque: 6.86 Nm)

32
R Series 7. Grease Replacement for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

7.4 JT4 REDUCTION UNIT

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS15X, RS30N, RS50N, RS80N

Volume 485 cc
Grease Molywhite A
Working Location (7)-4 (See 2.0-3.)

Filler port (R1/8)

Drain port (R1/8)

RS15X, RS30N, RS50N, RS80N

Procedure
1. Move the robot so that the filler port comes upside and the drain port comes downward.
Then, turn OFF the power.
2. Remove the plug from the filler port, then put in a grease nipple.
3. Place the container to catch the spilled grease and remove the plug from the drain port.
4. Replenish new grease from the filler port until new grease comes out of the drain port.
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 5.9
Nm)

33
R Series 7. Grease Replacement for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

7.5 JT5 REDUCTION UNIT

1. Models without a plug for drain port at the position shown with

Without plug for drain port

RS30N, RS50N, RS80N, RD80N

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS30N, RS50N, RS80N, RD80N

Volume 550 cc
Grease Molywhite A
Working Location (7)-5 (See 2.0-3.)

Air vent hole (R1/8) Cover

O ring

Filler port (R1/8)

RS30N, RS50N, RS80N, RD80N
Procedure
1. Remove the cover.
2. Wipe away the grease in the chamber and measure the amount of grease wiped away.
3. Clean the O ring and the O ring groove, then mount the O ring.
4. Return the cover. (M5 hex. socket screw-Tightening torque: 6.86 Nm)
5. Remove the plug from the filler port, then put in a grease nipple.
6. Remove the plug of air vent port, and apply the amount of grease wiped away.
7. Remove the grease nipple from the filler port.
8. Wipe away any grease around the filler port and the air vent port with rags, then return the
plugs covered with sealant tape to the air vent port and the filler port in this order.
(Tightening torque: 5.9 Nm)
9. Return the cover. (M5 hex. socket screw-Tightening torque: 6.86 Nm)

34
R Series 7. Grease Replacement for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

2. Models with a plug for drain port at the position shown with

With plug for drain port

RS30N, RS50N, RS80N, RD80N

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS30N, RS50N, RS80N, RD80N

Volume 200 cc
Grease Molywhite A
Working Location (7)-5 (See 2.0-3.)

Filler port (R1/8)

Drain port (R1/8)

RS30N, RS50N, RS80N, RD80N

Procedure
1. Move the robot so that the filler port comes downward and the drain port comes upside.
Then, turn OFF the power.
2. Remove the plug from the filler port, then put in a grease nipple.
3. Place the container to catch the spilled grease and remove the plug from the drain port.
4. Replenish new grease from the filler port until new grease comes out of the drain port.
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 5.9
Nm)

35
R Series 7. Grease Replacement for Reduction Units
Kawasaki Robot Inspection and Maintenance Manual

7.6 JT6 REDUCTION UNIT

！ WARNING
Read WARNING and CAUTION in 4.0 before starting operation.

Model RS30N, RS50N, RS80N, RD80N

Volume 285 cc
Grease Molywhite A
Working Location (7)-6 (See 2.0-3.)

Filler port (R1/8)

Drain port (R1/8)

RS30N, RS50N, RS80N, RD80N

Procedure
1. Move the robot so that the filler port comes upside and the drain port comes downward.
Then, turn OFF the power.
2. Remove the plug from the filler port, then put in a grease nipple.
3. Place the container to catch the spilled grease and remove the plug from the drain port.
4. Replenish new grease from the filler port until new grease comes out of the drain port.
5. Remove the grease nipple from the filler port.
6. Wipe away any grease around the filler and drain ports with rags, then return the plugs
covered with sealant tape to the drain and filler ports in this order. (Tightening torque: 5.9
Nm)

36
 R Series 8. Check of Timing Belt
Kawasaki Robot Inspection and Maintenance Manual

8.0 CHECK OF TIMING BELT

！ WARNING
Prior to checking the timing belt, turn OFF the controller and
external power switches. 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.

Model All models

Working location (8) (See 2.0-1, 2.0-2 and 2.0-3.)

1. RS05N, RS05L, RA05L, RC05L

Cover
JT4 motor bracket
mounting bolts
(x4)

JT4 timing belt JT5 timing belt

JT5 motor bracket Cross-section A-A

mounting bolts (x4)

2. Models other than RS05N, RS05L, RA05L and RC05L

Timing belt

Motor bracket

Cover

Hexagon adjusting bolt

Motor bracket mounting bolts (x4)

37
R Series 8. Check of Timing Belt
Kawasaki Robot Inspection and Maintenance Manual

Procedure
1. Remove the cover from the wrist section.
2. Check the tension of the timing belt. Press the center of belt so that the deflection becomes
. (See figure below.) If the pressing force F is within the range shown in table below, the
tension is adequate. In using a no-touch, acoustic vibration meter, if measurement frequency
is within the range shown in table below, the tension is adequate.
3. If the tension is not adequate, loosen the 4 motor bracket mounting bolts by approx. 1 turn.
4. Move the motor bracket by turning the hexagon adjusting bolt and adjust the distance
between the pulleys. Then, tighten the mounting bolts temporarily.
5. Check tension again following the procedure 2 above. If the tension is adequate, tighten the
motor bracket mounting bolts firmly.
RS05N, RS05L, RA05L, RC05L (M3 hex. socket screw-Tightening torque: 1.47 Nm)
Models other than RS05N, RS05L, RA05L and RC05L (M5 hex. socket screw-Tightening
torque: 6.86 Nm)
6. After tightening the motor bracket mounting bolts, check the tension again.
7. Return the cover.*
RS05N, RS05L, RS06L, RS10N, RS10L, RS15X, RS20N, RA05L, RA06L, RA10N, RA10L,
RA20N, RC05L (M4 hex. socket screw-Tightening torque: 3.43 Nm)
RS30N, RS50N, RS80N, RD80N (M5 hex. socket screw-Tightening torque: 6.86 Nm)

NOTE* RS05N, RS05L, RA05L and RC05L release heat generated in motor to outside from
the encoder end surface. Never put off the heat transfer sheet attached inside the
cover.

Force F
Deflection 

RS10L, RS15X,
RS05N, RS05L, RS06L, RS10N, RS30N, RS50N,
Model RS20N, RA10L,
RA05L, RC05L RA06L, RA10N RS80N, RD80N
RA20N
Force F 2.10 - 2.80 N 2.34 - 2.86 N 5.85 - 7.15 N 5.76 - 7.04 N
Deflection  0.7 mm 3.7 mm 4.9 mm 6.0 mm
Frequency f 531.5 - 649.5 Hz 100.8 - 123.2 Hz 81 - 99 Hz 61.2 - 74.8 Hz

38
R Series 9. Check of Internal Machine Cables and Air Tubes
Kawasaki Robot Inspection and Maintenance Manual

9.0 CHECK OF INTERNAL MACHINE CABLES AND AIR TUBES

！ WARNING
Prior to starting check on internal machine cables and air tubes, turn
OFF the controller and external power switches. 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.

Model All models

Working location (9) (See 2.0-1, 2.0-2 and 2.0-3.)

Check for the following items:

1. Looseness of cable connectors, etc.
→ Retighten the connectors firmly, if looseness is observed.
2. Damage and/or kink of cables and air tubes.
→ If damage and/or kink is observed, contact Kawasaki to replace cables and air tubes.

39
 R Series 10. Battery Replacement on 1HG Board
Kawasaki Robot Inspection and Maintenance Manual

10.0 BATTERY REPLACEMENT ON 1HG BOARD

！ WARNING
1. Prior to replacing battery, turn OFF the controller and external
power switches. 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. Use only Kawasaki specified batteries.
3. Never re-charge, dismantle, convert and heat the batteries.
4. Never dump the batteries into water or fire.
5. Batteries with damaged surface may short out internally, and thus
must never be used.
6. Never short out the plus and minus of the batteries with metallic
material such as wire.

Model All models

Working location (10) (See 2.0-1, 2.0-2 and 2.0-3.)

Battery
Battery holder
Tying band

Relay connectors Battery

Battery
holder

Tying band

Relay connectors
RS05N, RS05L, RA05L, RC05L Models other than RS05N,
RS05L, RA05L and RC05L

40
R Series 10. Battery Replacement on 1HG Board
Kawasaki Robot Inspection and Maintenance Manual

Procedure
1. Prior to replacing the battery, record the encoder values of each axis referring to “2.9 Monitor
screen” in operation manual.
2. Turn OFF the controller power, then remove the cover for RS05N, RS05L, RA05L and
RC05L. Unscrew screws fixing the battery holder, and remove the battery holder, paying
attention not to damage the harness.
3. Remove the tying band fixing the battery and disconnect the relay connectors then, remove
the battery.
4. Set a new battery on the holder and reconnect the relay connectors after fixing the battery
with a new tying band. Fix the tying band, paying attention not to interfere with the opening
section, when removing/mounting the battery holder.
5. Return the battery holder to its original position. Turn ON the controller power and check if
the encoder values remain the same. If encoder values change is found, perform zeroing
referring to “Zeroing & Motor Replacement Manual”.
6. Return the cover for RS05N, RS05L, RA05L and RC05L.
Plastic cover* (M4 hex. socket screw-Tightening torque: 0.4 Nm)
Metal cover (M4 hex. socket screw-Tightening torque: 3.43 Nm)
NOTE* Do not apply Loctite 242 to the mounting bolts for the plastic cover. Loctite 242
adhesion to the cover may cause breakage of the cover.

！ CAUTION
Never dump old, depleted batteries with garbage that is disposed in
incinerator, land-fill, dumping-ground, etc. When dumping the
batteries, insulate with tape so as not to contact other metal and
comply with local regulations and rules for battery disposal.

41
R Series 11. Retightening
Kawasaki Robot Inspection and Maintenance Manual

11.0 RETIGHTENING

Check if any fixing 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/Encoder mounting bolts

2. Motor bracket mounting bolts
3. Reduction unit mounting bolts
4. Tool mounting bolts
5. Base mounting bolts
6. Cover mounting bolts

[ NOTE ]

The tightening torque for the hexagon socket head cap bolts is shown
below:

M3 1.47 Nm
3.43 Nm
M4
(Plastic cover mounting bolts: 0.40 Nm)
M5 6.86 Nm
M6 11.76 Nm
M8 29.40 Nm
M10 56.84 Nm
98.00 Nm
M12
(Motor mounting bolts: 78.40 Nm)
M14 156.80 Nm
M16 235.20 Nm
M20 431.20 Nm

42
 Kawasaki Robot R Series
Inspection & Maintenance Manual

January 2009 : 1st Edition

December 2012 : 7th Edition

Publication : KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION

90205-1127DEG

Copyright  2012 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.