90213-1052DEG R Series Zeroing and Motor Replacement Manual PDF

R Series
Zeroing and Motor

Replacement Manual
Kawasaki Heavy Industries, Ltd.
90213-1052DEG
R Series
Kawasaki Robot Zeroing and Motor Replacement Manual
PREFACE
This manual describes the Zeroing and Motor replacement instructions for the Kawasaki Robot R
series.
For operation method of the robot described in this manual, see “Operation Manual” for the
controller.
Read and understand the contents of this manual and the safety manuals thoroughly, and strictly
observe all safety rules before proceeding with any operation. Kawasaki will not take any
responsibility for any accidents and/or damages caused by operations that are based on only a
limited reading 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
！ WARNING
Reset encoder rotation counter without fail before operating the robot
manually after motor replacement. Reset is required to establish a
relationship between the robot mechanical origin and the home position of
encoder for each axis in the software. If robot is operated without resetting,
robot may move unexpectedly resulting in accidents, property damage, etc.
！ CAUTION
For performing zeroing and motor replacement work,
qualify only persons who have completed the specified
maintenance course(s) approved by Kawasaki.
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 © 2016 Kawasaki Heavy Industries Ltd. All rights reserved.
1
R Series
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
CONTENT
Preface ................................................................................................................................................. 1
Symbols ............................................................................................................................................... 2
1.0 Outline of Zeroing .................................................................................................................. 5
2.0 Resetting the Encoder Rotation Counter ............................................................................... 7

2.1 Resetting the Encoder Rotation Counter ............................................................................... 7
2.2 Resetting the Encoder Rotation Counter for Zeroing ......................................................... 10
3.0 Cubic-S Settings ................................................................................................................... 11

3.1 Writing to Cubic-S ............................................................................................................... 11
3.2 Turning OFF/ON Controller Power .................................................................................... 11
4.0 Simple Zeroing for All Axes ................................................................................................ 12
5.0 Simple Zeroing for Individual Axis ..................................................................................... 14
6.0 Precision Zeroing ................................................................................................................. 17

6.1 Preparation Work for Precision Zeroing.............................................................................. 17
6.2 JT1 Precision Zeroing .......................................................................................................... 18
6.2.1 JT1 Precision Zeroing (RS05N, RS05L, RA05L, RC05L) ................................................ 18
6.2.2 JT1 Precision Zeroing (Other than RS05N, RS05L, RA05L and RC05L)........................ 20
6.3.2 JT2 Precision Zeroing (Other than RS05N, RS05L, RA05L and RC05L)........................ 24
6.4.2 JT3 Precision Zeroing (Other than RS05N, RS05L, RA05L, RC05L and RD80N) ......... 28
6.4.3 JT3 Precision Zeroing (RD80N).......................................................................................... 30
3
R Series

6.7.2 JT6 Precision Zeroing (Other than RS05N, RS05L ,RA05L, RC05L and RD80N) ......... 47
7.0 Precautions to be Taken at Motor Replacement .................................................................. 50
8.0 Outline of Motor Replacement ............................................................................................ 51
9.0 Prior to Motor (Encoder) Replacement ............................................................................... 53
10.0 Summary of Motor Replacement Work .............................................................................. 54
11.0 Tasks Before Motor Replacement ....................................................................................... 60
12.0 Motor Replacement .............................................................................................................. 62

12.1 100 W Motor ( 40) Replacement........................................................................................ 62
12.2 100 W Motor ( 60) Replacement........................................................................................ 66
12.3 200 W Motor Replacement .................................................................................................. 69
12.6 1.2 kW Motor Replacement ................................................................................................. 82
13.0 Adjustment of Timing Belt .................................................................................................. 91
14.0 Shim Adjustsment in Bevel Gear Section ........................................................................... 94
15.0 Entire Motor Length Adjustment with Shim....................................................................... 96

15.1 Shim Adjustment of 2.0 kW Motor ..................................................................................... 96
15.2 Shim Adjustment of 675 W Motor ...................................................................................... 98
Appendix: Figures of Motor Replacement..................................................................................... 100
4
R Series 1. Outline of Zeroing
1.0 OUTLINE OF ZEROING
The outline of the zeroing is shown below:
Reset encoder rotation counter
*
Make settings of Cubic-S
① Write to Cubic-S.
② Turn OFF/ON controller power.
Move robot to a desired position in

joint mode
Reset encoder rotation counter

(for zeroing)
Simple zeroing
 All axes collectively
 Each axis individually
Precision zeroing
* Make settings of Cubic-S

① Write to Cubic-S.
② Turn OFF/ON controller power.
NOTE* Operations with the robot in which Cubic-S is installed
5
R Series 1. Outline of Zeroing
For precision zeroing, use the following instruments and jigs:
 Zeroing jig (1)  Zeroing jig (2)  Zeroing jig (3)
 Zeroing jig (4)  Zeroing jig (5)  Zeroing jig (6)
RS05N RS06L RS10L RS30N

RS05L RS10N RS20N RS50N
RS15X
RA05L RA06L RA10L RS80N
RC05L RA10N RA20N RD80N
60154-0027 60154-0027 60154-0027 60154-0027
Zeroing jig (1) -
(2pc) (2pc) (2pc) (2pc)
Zeroing jig (2) - 60154-1826 60154-1826 60154-1826 60154-1826
Zeroing jig (3) - 60154-1887 60154-1827 60154-0028 60154-1827
Zeroing jig (4) - 60154-1888 60154-1828 60154-0614 60154-1828
Zeroing jig (5) - - - 60154-4732 -
Zeroing jig (6) 60154-0928 - - -
6
R Series 2. Resetting the Encoder Rotation Counter
2.0 RESETTING THE ENCODER ROTATION COUNTER
2.1 RESETTING THE ENCODER ROTATION COUNTER
！ DANGER
Before operating the robot manually, do not fail to reset the encoder rotation
counter after motor replacement. Attempting manual operation without
first resetting is dangerous because the robot may move unpredictably.
Controller
● Turn ON CONTROLLER POWER switch.
● Turn OFF motor power by pressing EMERGENCY STOP switch.
● Turn to TEACH mode.
● Reset the encoder rotation counter by AS command as shown below.

Example for JT1 rotation counter reset
Z Z 1 0 1
For other axes, enter applicable axis No. as
shown below.
Axis No.
JT2: 102, JT3: 103
JT4: 104, JT5: 105
JT6: 106, JT7: 107
！ CAUTION
After confirming the axis to reset,
** Encoder rotation counter reset (1st axis) **
enter the applicable axis No.
Current angle (deg.mm)?

When resetting the counters of all axes at
Are you sure (Enter 1 to execute)? the same time, input:
Z Z 1 0 0
Enter the current arm angle here.
 No need to enter an accurate axis angle when resetting immediately after the motor
replacement.
 When resetting for zeroing, enter a precise axis angle corresponding to the scribe mark
position, etc.
7
● For manual operation, write to Cubic-S and turn OFF then ON CONTROLLER
POWER switch when Cubic-S is installed in the robot.
● Release emergency stop and turn ON motor power.
● Enable the robot to move in the TEACH mode.
Arm
● Press the AXIS keys on the Teach Pendant and set the RSxxx, RAxxx and RCxxx robots to
standard pose (pose of 0 for all axes) as shown below.
JT6 zero point

JT6 zero point
scribe mark position
JT5 zero point

JT5 zero point scribe mark position
JT4 zero point JT4 zero point
scribe mark position scribe mark position

JT2 zero point

JT2 zero point
JT1 zero point
scribe mark position JT1 zero point
RS05N, RS05L, RA05L, RC05L RSxxx and RAxxx other than

RS05N, RS05L and RA05L
8
At the standard pose (pose of 0 for all axes), make sure

that zero point scribe marks of each axis are aligned.
zero point scribe mark
For RD80N, set the robot to standard pose (pose of 0 for all axes) as shown below.
JT4 zero point

JT2 zero point

JT1 zero point
At the standard pose (pose of 0 for all axes), make sure that zero point scribe marks of
each axis except for JT3 and JT5 are aligned.
When aligning zero points of JT3 and JT5 for RD80N, move JT2 and JT3 from the
standard pose (pose of 0 for all axes), set the robot to poses shown in the figures below
and align the zero point scribe marks. Press JT5 AXIS key on Teach Pendant when
moving JT5. Return the poses of JT2 and JT3 to their standard pose (pose of 0 for all
axes) again without moving JT5 after aligning the zero point scribe marks of JT3 and JT5.
JT3 zero point
JT5 zero point

9
！ CAUTION
Pay attention to the interference of arm until simple or

precision zeroing of JT2, JT3 and JT5 is complete.
2.2 RESETTING THE ENCODER ROTATION COUNTER FOR ZEROING
Controller
 Turn OFF motor power by pressing EMERGENCY STOP.
 Reset encoder rotation counter shown in 2.1.
10
R Series 3. Cubic-S Settings
3.0 Cubic-S SETTINGS
The error code E9404 is displayed and the motor power cannot be turned ON after resetting the
encoder rotation counter. The following operations are required for the robot in which the
Cubic-S is installed.
3.1 WRITING TO Cubic-S
Refer to a separate manual, “Cubic-S Instruction Manual” for details.
3.2 TURNING OFF/ON CONTROLLER POWER
After writing to the Cubic-S, turn OFF the controller power switch and turn ON the controller
power again.
11
R Series 4. Simple Zeroing for All Axes
4.0 SIMPLE ZEROING FOR ALL AXES
！ CAUTION
This zeroing method zeroes all axes at the same time. When
replacing the motor/encoder of a single axis, do not use this zeroing
method.
Arm
● After completion of the encoder rotation counter reset, keep the robot arm in the standard
pose (pose of 0 for all axes).
RS05N, RS05L, RSxxx and RAxxx other than RD80N

RA05L, RC05L RS05N, RS05L and RA05L
Controller
● Keep the CONTROLLER POWER switch ON.
● Turn OFF motor power by pressing EMERGENCY STOP switch.
12
R Series 4. Simple Zeroing for All Axes
Controller
● Display zeroing data by entering:
Z Z E R O 0

JT1 JT2 JT3 JT4 JT5 JT6
Values displayed
set data XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX
curr. Data XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX
here are currently set
Set current values of all joints as zeroing data? (Enter 1 to set) zeroing values
(Decimal).
Values displayed here

To execute simple To cancel the are current encoder
zeroing, press zeroing, press values (Decimal).
1
● Display current values on screen and confirm.
W H E R E

0.000 0.000 0.000 0.000 To verify zeroing
0.000 0.000
X[mm] Y[mm] Z[mm] O[deg] A[deg] T[deg] has been performed
XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX correctly, check
these values.
Check if values of each axis are as shown above. When Cubic-S is installed in the robot,
write to Cubic-S and turn OFF then ON the CONTROLLER POWER switch after the check.
Then, simple zeroing completes.
13
R Series 5. Simple Zeroing for Individual Axis
5.0 SIMPLE ZEROING FOR INDIVIDUAL AXIS
！ CAUTION
1. Simple zeroing cannot ensure robot moves in absolutely precise line

trajectories and shift amounts.
2. Simple Zeroing (or Precision Zeroing) is a required step in the motor
replacement process, thus read the zeroing instructions without fail when
replacing motors.
3. For the axes in the wrist section, moving one axis induces movement of the
other axes. Accordingly, execute the simple zeroing in the wrist section in
order of JT4, JT5 and JT6 (in order of JT5 and JT4 for RD80N).
Arm
● Align zero points of the axes to be zeroed using zero scribe marks.
JT6 zero point
JT5 zero point


JT2 zero point

JT2 zero point
JT1 zero point
scribe mark position JT1 zero point
RSxxx and RAxxx other than

RS05N, RS05L, RA05L, RC05L
！ DANGER
Before operating the robot manually after motor replacement, execute the reset of
the encoder rotation counter without fail. Starting operations without first
executing this procedure is dangerous and may cause robot to move unexpectedly.
14
For RD80N, set the robot to standard pose (pose of 0 for all axes) as shown below.
JT4 zero point

JT2 zero point

JT1 zero point
At the standard pose (pose of 0 for all axes), make sure that zero point scribe marks of
each axis except for JT3 and JT5 are aligned.
When aligning zero scribe marks of JT3 and JT5 for RD80N, move JT2 and JT3 from the
standard pose (pose of 0 for all axes), set the robot to the pose shown in the figures below
and align the zero point scribe marks. Press JT5 AXIS key on Teach Pendant when
moving JT5. Return the poses of JT2 and JT3 to their standard pose (pose of 0 for all
axes) without moving JT5 after aligning the zero point scribe marks of JT3 and JT5.
JT3 zero point
JT5 zero point

！ CAUTION
Pay attention to the interference of arm until simple or
precision zeroing of JT2, T3 and JT5 is complete.
15
Controller
● Turn OFF the motor power by pressing EMERGENCY STOP.
● Reset the encoder rotation counter.

See 2.1 Resetting the Encoder Rotation Counter.
● Input the zeroing command.

For example, when zeroing JT1,
Z Z E R O 1
enter axis No. 1 after inputting
 the ZZERO command.
Current angle (deg.mm) ?

0 or

Encoder value? (Current = xxxxxx, Enter 1 to set the current value)

1 (To cancel the operation, press only .)

Zeroing value=xxxxxx (268419072-268451840) OK? (Enter 0 to change)

(If re-entry is required, press only 0.)

Setting completed.
Execute zeroing for each axis JT2 - JT6 in the same way as above. When Cubic-S is
installed in the robot, write to Cubic-S and turn OFF then ON the CONTROLLER POWER
switch after the execution. Then, zeroing completes.
16
R Series 6. Precision Zeroing
6.0 PRECISION ZEROING
6.1 PREPARATION WORK FOR PRECISION ZEROING
Controller
● Turn ON CONTROLLER POWER switch.
● Enable the robot to move in the TEACH mode.
Arm
● First, execute the simple zeroing described above for all axes. And, set the robot to
standard pose (pose of 0 for all axes).
● Use a whetstone to remove all paint, rust, burr, etc. from each of the surfaces where jigs are
to be mounted.
17
6.2 JT1 PRECISION ZEROING
6.2.1 JT1 PRECISION ZEROING (RS05N, RS05L, RA05L, RC05L)
Arm
● Check if part A of zeroing jig (6) can be inserted smoothly into two grooves of JT1 zero
point scribe marks.
+
+ -–
Zeroing jig (6)

Part A
● Press AXIS keys on the Teach Pendant and move JT1 if the zeroing jig is caught when
inserted into the grooves.
● Move JT1 slowly until the zeroing jig can be smoothly inserted all the way in the grooves
of the zero point scribe marks.
！ CAUTION
Do not press the zeroing jig forcibly if the zeroing jig is caught when
inserted into the grooves. Moreover, do not move the arm with the
zeroing jig inserted into the grooves of the zero point scribe marks.
Otherwise, the zeroing point scribe marks and the jig may be deformed.
18
Controller
Attempting to zero with motor power ON displays

the message “Turn OFF Motor power”.
Z Z E R O 1


0 or



When zeroing value is out of 268419072 - 268451840, reset the encoder rotation counter
again.

Setting completed.
Write to Cubic-S and turn OFF then ON the CONTROLLER POWER switch when Cubic-S
is installed in the robot. Then, the precision zeroing of JT1 completes.
19
6.2.2 JT1 PRECISION ZEROING (OTHER THAN RS05N, RS05L, RA05L AND
RC05L)
Arm
● Apply a thin coat of grease to zeroing jigs (1) and mount them as shown below. Move
the robot in advance for easy pins alignment.
Zeroing jig (1)
● Press AXIS keys on the Teach Pendant, and move JT1 in + direction.
● Move JT1 slowly by inching until zeroing jigs come into contact with each other.
！ CAUTION
Strong pressing in pins contact may deform mounting holes and the jigs.
Accordingly, be careful not to press strongly in pins contact. (Contact
pins with such a pressing that it begins to be difficult to move a sheet of
copy paper inserted between the pins.)
20
Controller

Z Z E R O 1


0 or



again.

Setting completed.
21
Arm
point scribe marks.
–+
+- Zeroing jig (6)

Part A
● Move JT2 slowly until the zeroing jig can be smoothly inserted all the way into the
grooves of zero point scribe marks.
！ CAUTION
22
Controller

Z Z E R O 2


0 or



again.


Setting completed.
23
6.3.2 JT2 PRECISION ZEROING (OTHER THAN RS05N, RS05L, RA05L AND
RC05L)
Arm
Zeroing jig
(1)
Zeroing jig
(1)
RS06L, RS10N, RS10L, RS20N, RS15X, RS30N, RS50N, RS80N, RD80N

RA06L, RA10N, RA10L, RA20N
● Press AXIS keys on the Teach Pendant, and move JT2 in + direction for RS06L, RS10N,
RS10L, RS20N, RA06L, RA10N, RA10L and RA20N and in – direction for RS15X,
RS30N, RS50N, RS80N and RD80N.
！ CAUTION
Strong pressing in pins contact may deform mounting holes and the jigs.
Accordingly, be careful not to press strongly in pins contact. (Contact
pins with such a pressing that it begins to be difficult to move a sheet of
copy paper inserted between the pins.)
24
Controller

Z Z E R O 2


0 or



again.


Setting completed.
25
Arm
point scribe marks.
++
Zeroing jig (6)

Part A
–-
● Move JT3 slowly until the zeroing jig can be smoothly inserted all the way in the grooves
of zero point scribe marks.
！ CAUTION
26
Controller

Z Z E R O 3


0 or



again.

Setting completed.
27
6.4.2 JT3 PRECISION ZEROING (OTHER THAN RS05N, RS05L, RA05L, RC05L
AND RD80N)
Arm
Zeroing jig (1)
● Press AXIS keys on the Teach Pendant, and move JT3 in - direction.
！ CAUTION
Strong pressing in pins contact may deform mounting holes and the
jigs. Accordingly, be careful not to press strongly in pins contact.
(Contact pins with such a pressing that it begins to be difficult to move a
sheet of copy paper inserted between the pins.)
28
Controller

Z Z E R O 3


0 or



again.

Setting completed.
29
6.4.3 JT3 PRECISION ZEROING (RD80N)
Arm
● Move JT2 until it takes its posture of 90 after JT2 precision zeroing.
Zeroing jig (1)
！ CAUTION
Strong pressing in pins contact may deform mounting holes and the jigs. Accordingly,
be careful not to press strongly in pins contact. (Contact pins with such a pressing that
it begins to be difficult to move a sheet of copy paper inserted between the pins.)
● Move JT2 until it takes its posture of 0 after removing the pins.
JT4 zero point

scribe mark
position
JT2 zero point

scribe mark position JT1 zero point scribe
mark position
30
Controller

Z Z E R O 3


0 or



again.

Setting completed.
31
Arm
point scribe marks.
++ –-
Zeroing jig (6)
Part A
● Move JT4 slowly until the zeroing jig can be smoothly inserted all the way into the
grooves of zero point scribe marks.
！ CAUTION
32
Controller

Z Z E R O 4


0



again.

Setting completed.
33
AND RD80N)
Arm
Zeroing jig (1) Zeroing jig (1)
RS10L, RS20N, RA10L, RA20N RS06L, RS10N, RA06L, RA10N
Zeroing jig (1)

RS15X, RS30N, RS50N, RS80N
● Press AXIS keys on the Teach Pendant, and move JT4 in – direction for RS06L, RS10N,
RS10L, RS20N, RA06L, RA10N, RA10L and RA20N and in + direction for RS15X,
RS30N, RS50N and RS80N.
！ CAUTION
Strong pressing in pins contact may deform mounting holes and the jigs. Accordingly,
be careful not to press strongly in pins contact. (Contact pins with such a pressing that
it begins to be difficult to move a sheet of copy paper inserted between the pins.)
34
Controller

Z Z E R O 4


0



again.

Setting completed.
35
Arm
● Mount zeroing jigs (4) and (5) as shown below.(Zeroing jig (4) mounting bolt: M3-14
hexagon socket head bolt x 2, Zeroing jig (5) mounting bolt: M8-20 hexagon socket head
bolt x 2) Move the robot in advance for easy pins alignment.
Zeroing jig (4)
Zeroing jig (5)
！ CAUTION
(Contact pins with such a pressing that it begins to be difficult to move a
sheet of copy paper inserted between the pins.)
36
Controller

Z Z E R O 4


0



again.

Setting completed.
37
Arm
point scribe marks.
–-
Zeroing jig (6)

++ Part A
● Press AXIS keys on the Teach Pendant and move JT5.
● Move JT5 slowly until the zeroing jig can be smoothly inserted all the way into the grooves
of zero point scribe marks.
！ CAUTION
38
Controller

Z Z E R O 5


0 or



again.


Setting completed.
39
AND RD80N)
Arm
● Apply a thin coat of grease to zeroing jig (2) and mount zeroing jigs (2) and (3) as shown
below.(Zeroing jig (3) mounting bolt: M3-14 hexagon socket head bolt x 2) Move the
robot in advance for easy pins alignment.
Zeroing jig (3)
Zeroing jig (2)
！ CAUTION
(Contact pins with such a pressing that it begins to be difficult to move
a sheet of copy paper inserted between the pins.)
40
Controller

Z Z E R O 5


0 or



again.


Setting completed.
41
Arm
● Move JT3 until it takes its posture of -90 after JT3 precision zeroing.
JT5 zero point

● Apply a thin coat of grease on zeroing jig (2) and mount zeroing jigs (2) and (3) as shown
below.(Zeroing jig (3) mounting bolt: M3-14 hexagon socket head bolt x 2) Move the
robot in advance for easy pins alignment.
Zeroing jig (2)
Zeroing jig (3)
–-
42
！ CAUTION
● Set the postures of JT2 and JT3 to be 0 without moving JT5 after removing pins.
JT4 zero point

JT2 zero point

JT1 zero point
43
Controller

Z Z E R O 5


0 or



again.


Setting completed.
44
Arm
● Align part B of zeroing jig (6) as shown below and check if the zeroing jig fits to grooves
of JT6 zero point scribe marks.
-–
Zeroing jig (6) ++
Part B
● Press AXIS keys on the Teach Pendant, and move JT6 when the jig does not fit to the
grooves.
● Move JT6 slowly until the zeroing jig fits to the groove of zero point scribe marks.
！ CAUTION
45
Controller

Z Z E R O 6


0



again.

Setting completed.
46
6.7.2 JT6 PRECISION ZEROING (OTHER THAN RS05N, RS05L ,RA05L, RC05L
AND RD80N)
Arm
● For RS06L, RS10N, RS10L, RS15X, RS20N, RA06L, RA10N, RA10L and RA20N,
apply a thin coat of grease to zeroing jig (2) and mount zeroing jigs (2) and (4) as shown
in the left figure below. For RS30N, RS50N and RS80N, mount zeroing jigs (4) and (5)
as shown in the right figure below.(Zeroing jig (4) mounting bolt: M3-14 hexagon socket
head bolt x 2, Zeroing jig (5) mounting bolt: M8-20 hexagon socket head bolt x 2) Move
Zeroing jig ++
(2)
Zeroing jig
(4) Zeroing jig (4)
RS10L, RS20N, RS06L, RS10N, RS15X Zeroing jig (5)

RA06L, RA10N, RA10L, RA20N RS30N, RS50N, RS80N
！ CAUTION
47
Controller

Z Z E R O 6


0



again.

Setting completed.
48
Controller
● After completing the precision zeroing process for all axes:
● Release emergency stop and turn ON motor power in REPEAT mode.
● To make the axes coincide accurately, key-in the positioning accuracy range.
D O A C C U R A C Y 0 . 1
● Set the robot to standard pose (pose of 0 for all axes).
D O H O M E
● After the axis coincidence, display the present values on screen and confirm.
W H E R E

0.000 0.000 0.000 0.000 0.000 0.000 Check these
X [mm] Y [mm] Z [mm] 0 [deg] A [deg] [deg] values.
XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX XXXXXX
If the values match those in this figure, it is OK.
49
R Series 7. Precautions to be Taken at Motor Replacement
7.0 PRECAUTIONS TO BE TAKEN AT MOTOR REPLACEMENT
To ensure safety, comply with the following before starting motor replacement.
！ DANGER
Reset encoder rotation counter without fail before operating the robot
manually after motor replacement. If robot is operated without resetting,
robot may move unexpectedly resulting in accidents, property damage, etc.
！ WARNING
1. Prior to starting motor replacement, shut off controller power up to the
external power switch for shutting off power supply to the robot
controller. Display signs indicating clearly “Replacement in progress”,
and lockout/tagout the external power switch to prevent personnel from
accidentally turning ON the power.
2. If the angle of the specified axis needs changing, first switch ON the motor
power. Then, set the robot to the desired posture. After that, shut off
the controller power and the motor power, and lockout/tagout the
external power switch again as mentioned above, and start maintenance.
！ CAUTION
1. When removing an encoder from a motor and replacing it, do not apply
excessively strong shocks to the motor and the encoder.
2. Store motors and encoders under following conditions.
Ambient temperature: minus 10 C - 85 C
Humidity (without dew condensation) Correlation diagram between
temperature and humidity
・ 95 %RH or less (40 C)
・ 57 %RH or less (50 C)
・ 35 %RH or less (60 C)
・ 23 %RH or less (70 C)
・ 15 %RH or less (80 C)
・ 10 %RH or less (85 C)
3. Remove only those screws necessary for replacing the motor and encoder,
all other parts must be kept in place. Do not open any of the covers unless
specified.
4. When connecting the motor with the encoder, put the motor shaft pin into
the key groove of the encoder.
5. When replacing the encoder, prevent dirt, dust, etc. from entering inside the
encoder.
50
R Series 8. Outline of Motor Replacement
8.0 OUTLINE OF MOTOR REPLACEMENT
There are two types of AC motors used in Kawasaki Robots; one is encoder-separable from the
motor section, and the other is an encoder-inseparable type.
 Encoder-inseparable type motors must be replaced together with the encoder even if only the
encoder has failed.
 For the encoder-separable type motor, only the encoder can be replaced if only the encoder
has failed. Refer to separate manuals for the replacement of the encoder section, “2 kW
Motor (50601-1460) Encoder Replacement Manual” for the separable 2 kW motor and
“MK32 Series Encoder Replacement Manual” for the separable 5 kW motor.
RS05N RS06L RS10L

RS30N
Motor RS05L RS10N RS20N
RS50N RD80N RS15X
Capacity RA05L RA06L RA10L
RS80N
RC05L RA10N RA20N
JT4
100 W
JT5
( 40)
JT6
JT4
100 W
JT5
( 60)
JT6
JT4
JT5
200 W JT3 JT5
JT6
JT6
JT1
320 W JT3
JT2
675 W
JT3
(Sanyo)
JT4
675 W JT4
JT5 JT4
(Tamagawa) JT5
JT6
JT1
1.2 kW
JT2
JT1
2.0 kW JT3 JT3 JT3
JT2
5.0 kW
JT1 JT1 JT1
(Tamagawa,
JT2 JT2 JT2
Sanyo)
51
R Series 8. Outline of Motor Replacement
Motor-
Motor Motor Type Motor Assy P/N
Encoder Type
100 W
TS4603N7084E200 50601-0021
( 40)
100 W
R2AA06010FCP3H 50601-1463
( 60)
200 W R2AA06020FCP3G 50601-1462
320 W R2AA06040FCP3P 50601-1464
Inseparable type 675 W
R2AA08075FCP3N 50601-1461
(Sanyo)
675 W
TS4614N7080E201 50601-0011
(Tamagawa)
1.2 kW R2AA13120LCP2E 50601-1465
**5.0 kW
TSM2207N8280E224 50601-0008
(Tamagawa)
2.0 kW R2AA13200LCP2S 50601-1460
**5.0 kW TSM2207N8291E224 50601-0031
Separable type (Tamagawa) *TSM2207N8295E224 50601-0079
**5.0 kW R2AA2250ALCPKL 50601-0128
(Sanyo) *R2AA2250ALCPK2 50601-0129
NOTE* North America spec.

NOTE** The 5.0 kW motors are compatible with each other.
52
R Series 9. Prior to Motor (Encoder) Replacement
9.0 PRIOR TO MOTOR (ENCODER) REPLACEMENT
Prior to motor replacement, confirm if replacement of the present motor is required. Especially
for an encoder-separable type motor, replace the motor after confirming the error does not occur
due to the encoder.
The flowchart below outlines the procedure for determining the source of the motor trouble. For
more details, refer to the Troubleshooting Manual, a separate volume, when proceeding through
these flowchart steps.
・Robot motion is abnormal.

・Positioning accuracy deteriorated.
Is Is rattle
YES YES Check on mechanical
shaking found in
observed? mechanisms? parts and repair/replace
parts if required.
NO
Is NO
abnormal YES
noise heard?
NO
Is Is
YES NO Surrounding NO
abnormal heat there any mechanical
generated? cables, boards, OK ?
interference?
YES
NO
Check on mechanical parts and
repair/replace parts if required. YES
Brake
release YES
impossible?
NO
Does
YES
brake
slip?
NO
Is inside
YES
wiring of motor Repair/replace
disconnected?
Replace motor with a new one. surrounding
NO cables, boards.
Are other YES
erroneous causes
found? Does error recur?
NO YES
The trouble might not be caused by the failure of the
motor/encoder. If the error cannot be removed even after
replacing the motor/encoder, the control system will need to
be checked/adjusted. In this case, contact Kawasaki.
53
R Series 10. Summary of Motor Replacement Work
10.0 SUMMARY OF MOTOR REPLACEMENT WORK
When replacing a motor, prepare the measuring instruments, tools, greases etc. shown below:
● Dial gauge ● Daphne Eponex #3 ● Loctite 242 or 243

(for applying to motor shaft) (strength: middle)
● Pulley puller ● Moly White A ● Three Bond 1206D
(for RV reduction unit and Cyclo reduction unit)
● Torque wrench ● Harmonic grease SK-1A (for H/D)
● Optimol Longtime PD-2 (for harness lubrication)
Specifications of torque wrenches used for fastening of motor fixing bolts

Motor capacity Specifications
Torque wrench (for M2, 3, 4, 5):
100 W
for hexagonal-bar attachment: approx. 150 mm in length
Torque wrench (for M4,5):
200 W
Torque wrench (for M5):
320 W
675 W
1.2 kW
2.0 kW
5.0 kW
● Exclusively designed removing jigs

RS06L, RS10N, RA06L, RA10N
Axis Jig Part No., Quantity
JT1 Rod 60154-0774×2pc
Pipe 60154-0777×2pc
Bolt M4-70L×2pc
Nut M4×2pc
JT2 Rod 60154-0774×2pc
Pipe 60154-0778×2pc
Bolt M4-70L×2pc
Nut M4×2pc
54

JT3 Rod 60154-0774×2pc
Pipe 60154-0778×2pc
Bolt M4-70L×2pc
Nut M4×2pc
RS10L, RS20N, RA10L, RA20N

JT1 Rod 60154-0774×2pc
Pipe 60154-0779×2pc
Bolt M4-80L×2pc
Nut M4×2pc
JT2 Rod 60154-0774×2pc
Pipe 60154-0780×2pc
Bolt M4-70L×2pc
Nut M4×2pc
JT3 Rod 60154-0774×2pc
Pipe 60154-0780×2pc
Bolt M4-70L×2pc
Nut M4×2pc
RS30N, RS50N
JT1 Rod 60154-0775×2pc
Pipe 60154-0781×2pc
Bolt M6-110L×2pc
Nut M6×2pc
JT2 Rod 60154-0775×2pc
Pipe 60154-0782×2pc
Bolt M6-100L×2pc
Nut M6×2pc
JT3 Rod 60154-0776×2pc
Pipe 60154-0779×2pc
Bolt M4-90L (full thread) ×2pc
Nut M4×2pc
55

JT4 Rod 60154-0774×2pc
Pipe 60154-0780×2pc
Bolt M4-70L×2pc
Nut M4×2pc
JT5 Rod 60154-0775×2pc
Pipe 60154-0782×2pc
Bolt M6-100L×2pc
Nut M6×2pc
JT6 Rod 60154-0774×2pc
Pipe 60154-0780×2pc
Bolt M4-70L×2pc
Nut M4×2pc
RS15X
JT1 Rod 60154-0775×2pc
Pipe 60154-0781×2pc
Bolt M6-110L×2pc
Nut M6×2pc
JT2 Rod 60154-0775×2pc
Pipe 60154-0782×2pc
Bolt M6-100L×2pc
Nut M6×2pc
JT3 Rod 60154-0776×2pc
Pipe 60154-0779×2pc
Nut M4×2pc
JT4 Rod 60154-0774×2pc
Pipe 60154-0778×2pc
Bolt M4-70L×2pc
Nut M4×2pc
56
RS80N
JT1 Rod 60154-0775×2pc
Pipe 60154-0781×2pc
Bolt M6-110L×2pc
Nut M6×2pc
JT2 Rod 60154-0775×2pc
Pipe 60154-0782×2pc
Bolt M6-100L×2pc
Nut M6×2pc
JT3 Rod 60154-0776×2pc
Pipe 60154-0779×2pc
Nut M4×2pc
JT4 Rod 60154-0774×2pc
Pipe 60154-0778×2pc
Bolt M4-70L×2pc
Nut M4×2pc
JT5 Rod 60154-0775×2pc
Pipe 60154-0782×2pc
Bolt M6-100L×2pc
Nut M6×2pc
JT6 Rod 60154-0774×2pc
Pipe 60154-0780×2pc
Bolt M4-70L×2pc
Nut M4×2pc
RD80N
JT1 Rod 60154-0775×2pc
Pipe 60154-0781×2pc
Bolt M6-110L×2pc
Nut M6×2pc
JT2 Rod 60154-0775×2pc
Pipe 60154-0782×2pc
Bolt M6-100L×2pc
Nut M6×2pc
57

JT3 Rod 60154-0776×2pc
Pipe 60154-0779×2pc
Nut M4×2pc
JT4 Rod 60154-0774×2pc
Pipe 60154-0780×2pc
Bolt M4-70L×2pc
Nut M4×2pc
JT5 Rod 60154-0775×2pc
Pipe 60154-0782×2pc
Bolt M6-100L×2pc
Nut M6×2pc
！ WARNING
1. When removing a motor from an assembly, support the arm safely
by using a crane/forklift truck so as to prevent the arm from
accidental falling/rotating by its own weight.
2. When replacing the motor, display signs indicating clearly
“Replacement in progress”, and lockout/tagout the external power
switch to prevent personnel from accidentally turning ON the
power.
58
Motor replacement work and its confirmation
1. Set the dial gauge to an adequate place on a part of the arm that is
forward from the axis in which the motor is to be replaced. Next, record
the values measured by the dial gauge. See 11.0 Tasks Before Motor
Replacement.
2. Record the present angle and encoder values of the robot.
3. If the values cannot be recorded, standard pose (pose of 0 for all axes)
zeroing must be executed after motor replacement without fail.
Motor replacement work
1. Prior to motor replacement, turn OFF controller power. Display signs

indicating clearly “Replacement in progress”, and lockout/tagout the
external power switch.
2. In order to prevent a robot arm from accidental falling/rotating, the arm
must be supported by a crane/forklift truck, or placed on a stable support.
3. Use a replacement motor that matches the specifications for that axis and
model. See 8.0 Outline of Motor Replacement.
Tasks after motor replacement
1. Move the robot axis until the dial gauge value accurately coincides with
the recorded value and execute zeroing.
2. If the values cannot be recorded, execute zeroing at the standard pose
(pose of 0 for all axes).
Confirmation after motor replacement
1. Execute the program in Repeat mode, and playback the robot motions.
Observe playback motion carefully, and confirm there are no errors/
abnormalities. If there are abnormalities, re-teach the motion points.
2. If simple zeroing is executed at the standard pose (pose of 0 for all
axes), re-teaching may be required for high accuracy work.
59
R Series 11. Tasks Before Motor Replacement
11.0 TASKS BEFORE MOTOR REPLACEMENT
Note and record the present pose of the robot before starting replacement work without fail.
The recording of the robot’s present pose is defined by the following:

1. Reading of encoder and angle values
2. Confirmation of absolute position of the axis at that time (Confirmation by a dial gauge)
This section explains how to find the values that describe the absolute axis position using the dial
gauge. This procedure assumes that the encoder is normal and accurate, and the display of the
encoder values is precise.
1. Press AXIS keys on the Teach Pendant, and move robot arm until an adequate pose is
obtained.
2. Set the dial gauge to an adequate place (tool, etc.) on a part of the arm that is located ahead of
the axis in which the motor is to be replaced. Set the dial gauge to the places shown in the
figures. (See the next page.)
！ CAUTION
Ensure that the surface to which the dial gauge sets is as flat as
possible. Moreover, this surface must be at right angle (90) to
the rotation of the axis in which motor is to be replaced.
3. Match the value of the dial gauge with 0. Then, keeping this pose, record the encoder and
angle values for the axis. (See values by executing WHERE 1/5 command.)
4. Set robot to a pose where the motor replacement work can be done easily. At this time, be
careful not to move dial gauge position.
60
R Series 11. Tasks Before Motor Replacement
JT2
JT3
JT1
JT5
JT4
JT6
JT1
61
R Series 12. Motor Replacement
12.0 MOTOR REPLACEMENT
12.1 100 W MOTOR ( 40) REPLACEMENT
！ WARNING
1. When replacing the motor, turn OFF controller power up to the
external power switch without fail. Display signs indicating clearly
switch to prevent personnel from accidentally turning ON the power.
2. When replacing a motor, support the arm safely by using a
crane/forklift truck or place the arm on supports so as to prevent the
arm from accidental falling/rotating by its own weight.
Also, see Appendix: Figures of Motor Replacement.
Model RS05N, RS05L, RA05L, RC05L

JT4
Axes JT5
JT6
1. Remove the indicated cover. Remove heat-transfer sheet between the cover and the
encoder section of motor, too.
2. Unscrew bolts (M4 x 2 Hexagon socket head bolts) fixing valve bracket and remove the
valve bracket.
3. Disconnect all connectors from the motor of the axis to be replaced, including connectors
for motor power cable and encoder. (Cut the typing band for fixing plastic sheets
which protect connector sections.)
Connector for motor power cable Connector for encoder
62
4. For JT4 and JT5, remove motor assembly in the following procedure.
(1) Loosen bolts (M3 x 4 Hexagon socket head bolts with washer) fixing motor bracket, and
remove the timing belt.
(2) Unscrew the loosened bolts, and remove the motor together with the motor bracket.
To unscrew bolts, use torque wrench with hexagonal-bar attachment (Length: approx.
150 mm). Be careful not to drop the removed bolts inside the arm during the
replacement work.
M4 Hexagon socket head bolt
Pressing flange
Motor bracket
Pulley
Star lock inner ring

Star lock outer ring Motor base
Coupling
JT4, 5 JT6
！ CAUTION
On the tip of motor shaft, pulley or coupling is mounted.
When removing/reconnecting motor, remove it straightly
without applying excessive force.
5. Remove the motor in the following procedure.

(1) For JT4 and JT5
1) Loosen star lock fixing bolts (M3 x 3 Hexagon socket head bolts) on the tip of the
motor shaft and remove the pulley.
2) Unscrew bolts (M4 x 2 Hexagon socket head bolts) fixing the motor and remove the
motor bracket.
(2) For JT6
1) Loosen fastening bolts (M2 x 2 Hexagon socket head bolts) of coupling.
2) Unscrew bolts (M4 x 2 Hexagon socket head bolts) fixing the motor and remove the
coupling and the motor.
63
！ CAUTION
When removing pulley, remove it without applying excessive
force on the motor.
6. For JT4 and JT5, attach the motor bracket and pulley removed in 5. on a new motor. Apply
Loctite 242 or 243 on the motor fixing bolts. Tightening torque is 3.43 Nm. Pay attention
to the mounting direction when mounting the motor bracket and pulley. Apply a thin coat of
Daphne Eponex #3 on the fastened section of star lock of motor shaft. Apply Loctite 242 or
243 on the hexagon socket head bolt for fixing the star lock and tighten it in the following
procedure.
(1) Tighten the bolt diagonally with about 1/4 of standard tightening torque [0.39 Nm - 0.49
Nm].
Nm].
(3) Tighten the bolt diagonally with standard tightening torque [1.47 Nm] until the bolt
cannot be screwed any more.
7. Apply Loctite 242 or 243 on the fixing bolts and mount the replacement motor assembly.
Tightening torque for JT4 and JT5 is 1.47 Nm. For JT6, assemble it in the following
procedure.
(1) Clean the drive shaft and the motor shaft.
(2) Insert the coupling into the drive shaft.
(3) Insert the coupling into the drive shaft, apply Loctite 242 or 243 on the motor
mounting bolts and fix the motor. Tightening torque is 3.43 Nm.
(4) Confirm that the coupling moves in the rotation direction and axis direction
smoothly with the coupling fastening bolts Ⓐ and Ⓑ loosened.
NOTE At this time, be careful for the motor shaft and the drive shaft not to rotate.
If the coupling does not move smoothly, loosen the motor mounting bolts
and align the centers of the motor shaft and the coupling so that it moves
smoothly.
(5) Tighten the coupling fastening bolt Ⓐ on which Loctite 242 or 243 is applied with
the coupling touching the retaining ring of the drive shaft. Tightening torque is
0.40 Nm.
(6) Tighten the coupling fastening bolt Ⓑ on which Loctite 242 or 243 is applied with
the coupling (+ drive shaft) pulled to the motor side closely. Tightening torque is
0.40 Nm.
64
(M2 Hexagon socket head bolt) Motor shaft

Coupling fastening bolt Ⓐ
Retaining ring
Drive shaft
Coupling M4 Hexagon socket head bolt

Motor base (M2 Hexagon socket head bolt)
Coupling fastening bolt Ⓑ
See (6) above.
See (5) above.
See (4) above.
[ NOTE ]
1. For the adjustment method of timing belt, see 13.0 Adjustment of
Timing Belt.
2. Shim adjustment in bevel gear section is necessary after the
replacement of JT6 motor. See 14.0 Shim Adjustment in Bevel Gear
Section.
8. Reattach the valve bracket removed in 2. Tightening torque is 3.43 Nm
9. Re-connect all the connectors including connectors for motor power cable and encoder.
At this time, tie the motor power cables and encoder signal lines with tying bands.
10. Reattach the indicated cover. When reattaching the cover, attach a heat-transfer sheet
on the worked surface inside the cover and tuck the heat-transfer sheet between the cover
and the encoder section of the motor. Tightening torque is 3.43 Nm. (Part No. of
heat-transfer sheet: 60337-0127)
[ NOTE ]
Be careful not to tuck harnesses between the cover and
the motor.
65
12.2 100 W MOTOR ( 60) REPLACEMENT
！ WARNING

Model RS06L, RS10N, RA06L, RA10N

JT4
Axes JT5
JT6
1. Remove the indicated cover.
3. Remove the motor assembly in the following procedure.

(1) For JT4 and JT5
1) Loosen bolts (M5 x 4 Hexagon socket head bolts) fixing the motor.
2) Remove the motor together with the seal plate using a pulling tap of the seal plate.
(2) For JT6
1) Loosen bolts (M5 x 4 Hexagon socket head bolts and washer) fixing the motor plate
and remove the timing belt.
2) Unscrew the loosened bolts and remove the motor together with the motor plate.
66
To unscrew bolts, use torque wrench with hexagonal-bar attachment for M5 (Length:
approx. 150 mm). Be careful not to drop the removed bolts inside the arm during the
replacement work.
M5 Hexagon socket head bolt M5 Hexagon socket head bolt
Pressing flange
Pressing flange
Pressing flange
Motor plate Seal plate

Seal plate
H/D wave generator
Pulley Gear
Star lock inner ring
Star lock inner ring Star lock inner ring
Star lock outer ring
Star lock outer ring Star lock outer ring
JT6 JT5 JT4
！ CAUTION
On the tip of motor shaft, pulley, gear or wave generator is
mounted. When removing/reconnecting motor, remove it
straightly without applying excessive force.

(1) For JT4
Loosen bolts (M3 x 3 Hexagon socket head bolts) for fixing the star lock on the tip of the
motor and remove the wave generator and seal plate.
(2) For JT5
Loosen bolts (M3 x 3 Hexagon socket head bolts) for fixing the star lock on the tip of the
motor and remove the gear and seal plate.
(3) For JT6
1) Loosen bolts (M3 x 3 Hexagon socket head bolts) for fixing the star lock on the tip
of the motor and remove the pulley.
2) Unscrew bolts fixing the motor and remove the motor plate.
！ CAUTION
When removing pulley, gear or wave generator, remove it
without applying excessive force on the motor.
67
5. Attach the seal plate, motor plate, pulley, gear or the wave generator removed in 4. on a new
motor. Apply Loctite 242 or 243 on the motor fixing bolts. Tightening torque is 6.86 Nm.
Pay attention to the mounting direction when mounting the seal plate, the motor plate, the
pulley, the gear or the wave generator. Apply a thin coat of Daphne Eponex #3 on the
fastened section of star lock of motor shaft. Apply Loctite 242 or 243 on the hexagon socket
head bolt for fixing the star lock and tighten it in the following procedure.
Nm].
(2) Tighten the bolt diagonally with about 1/2 of standard tightening torque [0.78 Nm – 0.88
Nm].
Apply the grease below on the wave generator.

 Harmonic grease SK-1A
！ CAUTION
When mounting wave generator, mount it without
squeezing or applying excessive force.
6. Apply Loctite 242 or 243 on the motor fixing bolt and mount the replacement motor
assembly. Tightening torque is 6.86 Nm.
[ NOTE ]
For the adjustment method of timing belt, see 13.0
Adjustment of Timing Belt.
At this time, tie the motor power cables and encoder signal lines with tying bands.
8. Reattach the indicated cover. Tightening torque is as follows.

JT4 : 6.86 Nm
JT5, JT6 : 3.43 Nm
68
12.3 200 W MOTOR REPLACEMENT
！ WARNING
RS05N, RS05L, RS10L, RS20N, RS15X

Model
RA05L, RC05L RA10L, RA20N
JT4
JT5
Axes JT3 JT5
JT6
JT6
69
3. Remove the motor assembly in the following procedure.

(1) For JT3
1) Remove the harness by cutting 2 tying bands fixing harness guide. (Be careful not
to lose rubber sheet which covers fixing points of the harness.)
Tying band (x2)

Rubber sheet
Harness guide
2) Unscrew bolts (M4 x 4 Hexagon socket head flush bolts) fixing harness guide and
remove the harness guide. Remove the heat-transfer sheet in the back of the harness
guide, too.
3) Unscrew bolts (M4 x 2 Hexagon socket head bolts) fixing harness guide bracket and
remove the harness guide bracket.
4) Unscrew bolts (M3 x 6 Hexagon socket head bolts) fixing motor plate and remove
the motor plate together with the motor.
(2) For JT4
1) Unscrew bolts (M5 x 6 Hexagon socket head bolts – Length: 40) fixing harmonic
and remove the motor together with the harmonic.
2) Unscrew bolts (M5 x 2 Hexagon socket head bolts – Length: 25) fixing spacer and
remove the motor together with the spacer from the harmonic. (Be careful not to
damage/lose O ring between the spacer and the harmonic.)
(3) For JT5
1) Unscrew bolts (M5 x 4 Hexagon socket head bolts) fixing motor and remove the
motor together with the seal plate.
(4) For JT6
1) Loosen bolts (M5 x 4 Hexagon socket head bolts with washer) fixing the plate motor
and remove the timing belt.
2) Unscrew the loosened bolts and remove the motor together with the motor bracket.
70
To unscrew bolts, use torque wrench with hexagonal-bar attachment for M5 (Length:
approx. 150 mm). Be careful not to drop the removed bolts inside the arm during the
replacement work.

Pressing flange
Pressing flange
Motor plate Seal plate

Pulley Gear
Power lock inner ring Power lock inner ring
Power lock outer ring Power lock outer ring
O ring
JT6 JT5
Casing
M5 Hexagon socket head bolt Heat-transfer sheet
Pressing flange
Pressing flange
Spacer Motor plate

H/D wave generator H/D wave generator
Power lock inner ring
Power lock inner ring
Power lock outer ring
Power lock outer ring
JT4
O ring JT3
！ CAUTION
On the tip of motor shaft, pulley, gear or wave generator is
mounted. When removing/reconnecting motor, remove it
straightly without applying excessive force.
71

(1) For JT3
1) Loosen bolts (M4 x 6 Hexagon socket head bolts) fixing the power lock on the
tip of the motor and remove the wave generator.
2) Unscrew bolts (M5 x 4 Hexagon socket head bolts) fixing the motor and
remove the motor from the motor plate.
3) Remove the casing covering the encoder section of the motor and the
heat-transfer sheet.
(2) For JT4
tip of the motor and remove the wave generator.
remove the motor from the motor plate.
(3) For JT5
tip of the motor and remove the gear and seal plate.
(4) For JT6
tip of the motor and remove the pulley.
remove the motor plate.
！ CAUTION
When removing pulley, gear or wave generator, remove it
without applying excessive force on the motor.
5. Attach the casing, heat-transfer sheet, spacer, motor plate, pulley, gear, wave generator
or harmonic removed in 4. on a new motor. Apply Loctite 242 or 243 on the motor
fixing bolts. Tightening torque is 6.86 Nm. Pay attention to the mounting direction
when mounting the casing, heat-transfer sheet, spacer, motor plate, pulley, gear, wave
generator or harmonic. Apply a thin coat of Daphne Eponex #3 on the fastened section
of power lock of motor shaft. Apply Loctite 242 or 243 on the hexagon socket head
bolts for fixing the power lock and tighten it in the following procedure.
(1) Tighten the bolt diagonally with about 1/4 of standard tightening torque [0.78- 0.88 Nm].
(2) Tighten the bolt diagonally with about 1/2 of standard tightening torque [1.47- 1.76 Nm].
72
Apply the grease (Harmonic grease SK-1A) on the wave generator.
When mounting the harmonic, insert O ring into the groove of the harmonic. Apply a thin
coat of Daphne Eponex #3 on the O ring.
Attach a heat-transfer sheet on the wall surface on the casing inside and insert it into the
encoder section of the motor. (Part No. of heat-transfer sheet: 60337-0063)
！ CAUTION
When mounting wave generator, mount it without
squeezing or applying excessive force.
6. Apply Loctite 242 or 243 on the fixing bolts and mount the replacement motor assembly.
Tightening torque is 6.86 Nm (1.47 Nm for JT3).
[ NOTE ]
For the adjustment method of timing belt, see 13.0
Adjustment of Timing Belt.
7. For JT3, mount harness guide, etc. removed in 3. in the following procedure.
(1) Mount the harness guide bracket. Tightening torque is 3.43 Nm.
(2) Attach a heat-transfer sheet on the convex on the back of the harness guide and
mount it on the harness guide bracket. Tightening torque is 1.47 Nm.
(3) Move JT3 with a brake release, etc. until its angle becomes +118. At that time,
be careful not to catch the harness.
Twist harness clockwise

by 1 turn.
Wrap harness with

rubber sheet and fix it
with 2 tying bands.
73
(4) Twist the harness clockwise by 1 turn, adjust the harness so that the harness length
becomes shortest when JT3 takes its posture shown in (3) and fix it with tying bands
to harness guide. Wrap rubber sheets at fixing points. Apply Optimol Longtime
PD-2 for the harness guide and the harness.
At this time, tie the motor power cables and encoder signal lines with tying bands.）

JT3: 0.40 Nm for plastic cover*, 3.43 Nm for metal cover
JT4: 6.86 Nm
JT5: 3.43 Nm
JT6: 3.43 Nm
NOTE* Do not apply Loctite 242 or 243 to the mounting bolts for the plastic cover. Loctite
242 or 243 adhesion to the cover may cause breakage of the cover.
74
！ WARNING
Model RS05N, RS05L, RA05L, RC05L RS06L, RS10N, RA06L, RA10N

JT1
Axes JT3
JT2
2. Disconnect all connectors from the motor of the axis to be replaced, including connectors for
motor power cable and encoder.
3. For JT2, remove the harness guide in the following procedure.

(1) Cut three tying bands fixing the harness guide and remove the harness.
Harness guide
Tying bands (x3)
75
(2) Unscrew bolts (M4 x 6 Hexagon socket head flush bolts) fixing the harness guide and
remove the harness guide. Remove the heat-transfer sheet between the harness guide
and encoder, too.
4. Unscrew bolts (M5 x 4 Hexagon socket head bolts) fixing servo motor. To unscrew bolts,
use torque wrench with hexagonal-bar attachment for M5 (Length: approx. 150 mm). Be
careful not to drop the removed bolts inside the arm during the replacement work.
5. Remove the motor. For JT3, use a pulling tap of the plate seal when removing the motor
without fail. Be careful as the tapered section of the shaft in the gear is too tight to pull out
without using the jig and pulley puller described below. Trying to pull out the gear forcibly
without using the jig and pulley puller is very dangerous and may result in damage to the
motor. Therefore, follow the procedures below without fail.
6. Mount jigs (rod, pipe, bolt) on the motor. At this time, be careful not to apply excessive
force on the motor and the encoder section. Moreover, loosen the center bolt in the gear tip
by approximately 2 mm.
Approx. 2 mm
Gear
Center bolt
Loosen the center bolt approx. 2 mm as shown
above, and confirm bolt is still attached. For
safety, follow this procedure without fail since it can
act as stopper when disconnecting gear.
7. Set pulley puller to the jig. M5 Hexagon socket head bolt
Pulley puller
Bolt
Pipe
Rod
76
8. Remove the gear from the tapered shaft via pulley puller.
！ CAUTION
Be careful when removing the gear. If it is tightened too
strongly, it may come out suddenly. Also, it may hit the
center bolt head (stopper).
9. Apply a thin coat of Daphne Eponex #3 over the tapered surface of a new motor, and attach
the gear on it.
10. Tighten center bolt into the gear firmly applying 3.43 Nm torque without mounting a seal
washer. Then, unscrew the center bolt, mount the seal washer, apply Loctite 242 or 243 on
the screw and remount it by tightening torque of 1.47 Nm. Grip and hold the flat part of
gear with a wrench when tightening and loosening as the motor brake might slip.
！ CAUTION
If gear is attached without loosening after applying 3.43 Nm
torque, gear removal may be impossible the next time it is
serviced. After tightening with 3.43 Nm torque, loosen then
retighten with 1.47 Nm torque without fail.
11. Apply Loctite 242 or 243 on the motor fixing bolt and reassemble the motor. Tightening
torque is 6.86 Nm.
12. For JT2, mount harness guide, etc. removed in 3. in the following procedure.
(1) Attach a heat-transfer sheet on the surface of the cylinder whose radius is approx. 25 mm
inside the harness guide.
(2) Mount the harness guide on the harness guide bracket. At that time, cohere the
heat-transfer sheet attached in (1) to the side of the encoder. Tightening torque is 1.47
Nm.
(3) Move JT2 with a brake release, etc. until its angle becomes -80. At that time, be
careful not to catch the harness.
Heat-transfer sheet
Harness guide
77
(4) Adjust the harness so that the harness length becomes shortest when JT2 takes its posture
shown in (3) and fix it with tying bands to harness guide. Apply Optimol Longtime
PD-2 for the harness guide and the harness.

JT1, JT2 :0.40 Nm for plastic cover*, 3.43 Nm for metal cover
JT3 :6.86 Nm
NOTE* Do not apply Loctite 242 or 243 to the mounting bolts for the plastic cover. Loctite
242 or 243 adhesion to the cover may cause breakage of the cover.
78
！ WARNING
switch to prevent personnel from accidentally turning ON.
Also, see Appendix: Figures of Motor Replacement and 15.0 Entire Motor Length Adjustment
with Shim.
Model RS10L, RS20N, RA10L, RA20N RS30N, RS50N, RS80N RD80N RS15X
JT4
JT4
Axes JT3 JT5 JT4
JT5
JT6
for motor power cable and encoder.
3. Unscrew bolts (M5 x 4 Hexagon socket head bolts) fixing motor. To unscrew bolts,
use torque wrench with hexagonal-bar attachment for M5 (Length: approx. 280 mm).
Be careful not to drop the removed bolts inside the arm during the replacement work.
4. Remove the motor. Use a pulling tap when removing the motor without fail. Be careful as
the tapered section of the shaft in the gear is too tight to pull out without using the jig and
pulley puller described below. Trying to pull out the gear forcibly without using the jig and
pulley puller is very dangerous and may result in damage to the motor. Therefore, follow
the procedures below without fail.
79
5. Mount jigs (rod, pipe, bolt) on the motor. At this time, be careful not to apply excessive
force on the motor and the encoder section. Moreover, loosen the center bolt in the gear tip
by approximately 2 mm.
Approx. 2 mm Gear
Center bolt
Loosen the center bolt approx. 2 mm as shown
above, and confirm bolt is still attached. For
safety, follow this procedure without fail since it can
Pulley puller
Bolt
Pipe
Rod
！ CAUTION
gear on it.
80
！ CAUTION
If gear is attached without loosening after applying 3.43
Nm torque, gear removal may be impossible the next time
it is serviced. After tightening with 3.43 Nm torque,
loosen then retighten with 1.47 Nm torque without fail.
12. Reattach the indicated cover. Tightening torque is 6.86 Nm.
81
12.6 1.2 KW MOTOR REPLACEMENT
！ WARNING

external power switch without fail. Display signs indicating
clearly “Replacement in progress”, and lockout/tagout the external
power switch to prevent personnel from accidentally turning ON.
crane/forklift truck or place the arm on supports so as to prevent
the arm from accidental falling/rotating by its own weight.
Model RS06L, RS10N, RA06L, RA10N

JT1
Axes
JT2
Connector for encoder
Connector for motor power cable
2. Unscrew bolts (M8 x 4 Hexagon socket head bolts) fixing motor. To unscrew bolts, use
torque wrench with hexagonal-bar attachment for M8 (Length: approx. 280 mm). Be
3. Remove the motor.
！ CAUTION
If removing motor is difficult, use pulling out tapped holes

(M6 x 2) on the motor flange.
82
Be careful as the tapered section of the shaft in the gear is too tight to pull out without using
the jig and pulley puller described below. Trying to pull out the gear forcibly without using
the jig and pulley puller is very dangerous and may result in damage to the motor. Therefore,
follow the procedures below without fail.
4. Attach the jigs (rod, pipe, bolt) on the motor. Be careful not to apply excessive force on the
encoder section at this time. Also, loosen the center bolt of the gear tip as shown below.
Gear
Center bolt
Approx.
Approx.
2 mm
2 mm
Loosen the center bolt as shown above, and
JT2 confirm bolt is still attached. For safety, JT1
follow this procedure without fail since it can
5. Set pulley puller to the jig.
Pulley puller Bolt
Pipe
Rod
JT2
Bolt
Pipe
Rod
JT1
83
！ CAUTION
gear on it.
！ CAUTION
84
！ WARNING
Also, see Appendix: Figures of Motor Replacement and 15.0 Entire Motor Length Adjustment
with Shim.
RS10L, RS20N, RS15X, RS30N, RS50N,

Model
RA10L, RA20N RS80N, RD80N
JT1
Axes JT3
JT2
Connector for encoder
3. Unscrew bolts (M10 x 4 Hexagon socket head bolts) fixing motor. To unscrew bolts, use
torque wrench with hexagonal-bar attachment for M10 (Length: approx. 280 mm). Be
！ CAUTION
If removing motor is difficult, use pulling out tapped holes

85
the jig and pulley puller is very dangerous and may result in damage to the motor.
Therefore, follow the procedures below without fail.
encoder section at this time. Also, loosen the center bolt of the gear tip as shown below.
Gear
Center bolt
Approx.
Approx.
2 mm
2 mm
Loosen the center bolt as shown above,
JT2 and confirm bolt is still attached. For JT1
safety, follow this procedure without fail
since it can act as stopper when
disconnecting gear.
Pulley puller
Bolt
Pipe
Rod
JT2
Bolt
Pipe
Rod
JT1
86
！ CAUTION
gear on it.
washer. Then, unscrew the center bolt, apply Loctite 242 or 243 on the screw and remount it
by tightening torque of 6.86 Nm. Grip and hold the flat part of gear with a wrench when
tightening and loosening as the motor brake might slip.
！ CAUTION
12. Reattach the indicated cover. Tightening torque is 6.86 Nm.
87
！ WARNING
Model RS15X, RS30N, RS50N, RS80N, RD80N

JT1
Axes
JT2
1. Remove the encoder cover and disconnect all connectors from the motor of the axis to be
replaced, including connectors for motor power cable and encoder.
Encoder cover
Cut here and remove
cable.
Connector for brake
Motor connector cover

2. Unscrew bolts (M12 Hexagon socket head bolts - 3 bolts for JT1, 4 bolts for JT2) fixing
motor. To unscrew bolts, use torque wrench with hexagonal-bar attachment for M12
(Length: approx. 280 mm). Be careful not to lose or drop the removed bolts inside the rotor
trunk during the replacement work.
88
！ CAUTION
1. If removing motor is difficult, use pulling out tapped holes
2. Be careful as the motor weighs approximately 30 kg.
the jig and pulley puller is very dangerous and may result in damage to the motor.
Therefore, follow the procedures below without fail.
encoder section at this time. Also, loosen the center bolt of the gear tip for approx. 5 mm.
Center bolt
Approx. Gear
5 mm
Gear Loosen the center bolt for approx. 5 mm, and
confirm bolt is still attached. For safety,
Rod
follow this procedure without fail since it can
Center bolt act as stopper when disconnecting gear.
Pipe
5. Set pulley puller to the jig.
Pulley puller
Bar
89
！ CAUTION
7. Apply a thin coat of grease over the tapered surface, and attach gear on it. (Never use
molybdenum grease with antifriction composition.)
washer. Then, unscrew the center bolt, apply Loctite 242 or 243 on the screw and remount it
by tightening torque of 17.15 Nm. Grip and hold the flat part of gear with a wrench when
tightening and loosening as the motor brake might slip.
！ CAUTION
(Remount the encoder cover.)
90
R Series 13. Adjustment of Timing Belt
13.0 ADJUSTMENT 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.
RS06L, RS10N, RS10L,

RS05N, RS05L, RS15X, RS20N, RS30N,
Model RD80N
RA05L, RC05L RS50N, RS80N, RA06L,
RA10N, RA10L, RA20N
JT4
Working location JT6 JT4
JT5
1. RS05N, RS05L, RA05L, RC05L
JT4 motor bracket Cover

mounting bolts (x4)
JT4 timing belt JT5 timing belt
Cross-section A-A
JT5 motor bracket
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)
91
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.
(Tightening torque: RS05N, RS05L, RA05L, RC05L・・・・・1.47 Nm,
Models other than RS05N, RS05L, RA05L and RC05L・・・・・6.86 Nm)
6. After tightening the motor bracket mounting bolts, check the tension again.
7. Return the cover. (Tightening torque:
RS05N, RS05L, RA05L, RC05L ,RS06L, RS10N, RS10L, RS15X, RS20N, RA06L, RA10N,
RA10L, RS20N・・・・・3.43 Nm
RS30N, RS50N, RS80N, RD80N・・・・・・・・・・・6.86 Nm)
Force F
Deflection 
92
RS05N, RS05L, RS05N, RS05L, RS06L, RS30N,

RS10L, RS15X,
RA05L, RC05L RA05L, RC05L RS10N, RS50N,
Model RS20N, RA10L,
(When using a new (When reusing a RA06L, RS80N,
RA20N
belt) belt) RA10N RD80N
Manufacturer
Tsubaki* Unitta* Tsubaki* Unitta* - Tsubaki* Unitta* -
of pulley/belt
3.31 - 3.23 - 2.10 - 1.90 - 2.34 - 5.85 - 5.3 - 6.4 5.76 -
Force F
3.75 N 3.71 N 2.80 N 2.64 N 2.86 N 7.15 N N 7.04 N
Deflection  0.7 mm 0.7 mm 3.7 mm 4.9 mm 6.0 mm
531.5 - 100.8 -
700 - 665 - 505 - 61.2 -
Frequency f 649.5 123.2 81 - 99 Hz
750 Hz 715 Hz 600 Hz 74.8 Hz
Hz Hz
NOTE* There are two types of pulley/belt; One is manufactured by Tsubaki and the other is
manufactured by Unitta. Pulley and belt depend on the time of shipment. Before
work, check if “GT” is stamped on pulley, and check the model stamped on belt,
referring to the figure below. Use values of the manufacturer for adjusted values in
the table above.
Model RS05N, RS05L, RA05L, RC05L RS10L, RS15X, RS20N, RA10L, RA20N
Manufacturer
Tsubaki* Unitta* Tsubaki* Unitta*
of pulley/belt
Not stamped with “GT” Stamped with “GT” Not stamped with “GT” Stamped with “GT”
Pulley
Belt
93
R Series 14. Shim Adjustment in Bevel Gear Section
14.0 SHIM ADJUSTSMENT IN BEVEL GEAR SECTION
！ WARNING
Prior to the shim adjustment in bevel gear section, 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.
Some axes need shim adjustment at predefined sections after motor replacement.
Model RS05N, RS05L, RA05L, RC05L

Working location JT6
Procedure
1. Change the orientation of JT4 so that the left cover of wrist section turns up, and dismount
the cover.
Left cover of wrist

section
2. Unscrew bolts fixing the gear on the back side (M2.5 Hexagon socket head bolt – 3 bolts)
and dismount the gear.
M2.5 Hexagon socket head bolt

Gear on arm base side
94
R Series 14. Shim Adjustment in Bevel Gear Section
3. Dismount the retaining ring, spacer and shim in order, and remount only the retaining ring
and the spacer without the shim.
Retaining ring
End face of bevel gear Spacer
Shim
4. Apply the dial gauge to the end face of the bevel gear and find the difference “a” of the
end face positions measured when the bevel gear is pulled and when it is pressed.
End face of bevel gear
a
When bevel gear is pulled When bevel gear is pushed
5. Calculate the thickness of shim by the following formula based on the position difference “a”
measured in 4.
Thickness of shim [mm] = Position difference “a” [mm] - 0.05 (Round to the nearest 0.05
[mm] above.)
6. Dismount the retaining ring and the spacer, insert the shim with the thickness calculated in 5.
and remount them.
7. Remount the gear on the back side. Apply Loctite 242 or 243 on the fastening bolt.
Tightening torque of fastening bolt is 0.80 Nm.
8. Remount the left cover of wrist section. Tightening torque of fastening bolt is 3.43 Nm.
95
R Series 15. Entire Motor Length Adjustment with Shim
15.0 ENTIRE MOTOR LENGTH ADJUSTMENT WITH SHIM
For some axes, heat generated inside the motor is released from the end face of encoder case to
the outside of robot and entire motor length adjustment with shim is required.
15.1 SHIM ADJUSTMENT OF 2.0 KW MOTOR
Model RS15X, RS30N, RS50N, RS80N, RD80N

Axes JT3
1. Measure the length of a from the flange surface to the end face of encoder case.
2. Decide the required thickness of shim based on the measurement result of a, referring to the
table below, and attach shims on the end face of the encoder case.
Length a [mm] Total thickness of shims Part No. of shim to be used
222-222.5 or less [mm] 3.5 [mm] Thickness 2.0 [mm]: 60331-0082
Thickness 1.5 [mm]: 60331-0081
222.5-223 or less [mm] 3.0 [mm] Thickness 2.0 [mm]: 60331-0082
Thickness 1.0 [mm]: 60331-0080
Thickness 0.5 [mm]: 60331-0079
225.5-226 or less [mm] None
96
Shim
[ NOTE ]
1. One side of the shim is cohesive. Attach the shim after
removing a liner on one side.
2. Do not use more than three shims.
3. Attach a heat-transfer sheet on the shim. (Part No. of the heat-transfer sheet: 60337-0068)
Heat-transfer sheet
[ NOTE ]
Both sides of the sheet are cohesive. Attach the
sheet after removing liners on both sides.
97
15.2 SHIM ADJUSTMENT OF 675 W MOTOR
Model RS15X, RS30N, RS50N, RS80N

Axes JT4
1. Measure the length of a from the flange surface to the end face of encoder case.
2. Decide the required thickness of shim based on the measurement result of a referring to the
table below and attach shims on the end face of the encoder case.
Length a [mm] Total thickness of shims Part No. of shim to be used
153.5-154 or less [mm] None
Shim
[ NOTE ]
1. One side of the shim is cohesive. Attach the shim after
removing a liner on one side.
2. Do not use more than three shims.
98
3. Attach a heat-transfer sheet on the shim. (Part No. of the heat-transfer sheet: 60337-0068)
Heat-transfer sheet
[ NOTE ]
Both sides of the sheet are cohesive. Attach the sheet
after removing liners on both sides.
99
R Series Appendix: Figures of Motor Replacement
APPENDIX: FIGURES OF MOTOR REPLACEMENT
● RS05N, RS05L, RA05L, RC05L ● RSxxx and RAxxx other than

Motor for JT5
Motor for JT6
Motor for JT3

Motor for JT5
Motor for JT3 Motor for JT4
Motor for JT6
Motor for JT4
Motor for JT2
Motor for JT2

Motor for JT1
Motor for JT1
100
R Series
Zeroing and Motor Replacement Manual
October 2009 : 1st Edition

June 2016 : 7th Edition
Published by KAWASAKI HEAVY INDUSTRIES, LTD.
90213-1052DEG
Copyright  2016 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.

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R Series

Zeroing and Motor

Kawasaki Heavy Industries, Ltd.

Failure to comply with indicated matters can result

Failure to comply with indicated matters may

Failure to comply with indicated matters may lead

1.0 Outline of Zeroing .................................................................................................................. 5

2.0 Resetting the Encoder Rotation Counter ............................................................................... 7

3.0 Cubic-S Settings ................................................................................................................... 11

4.0 Simple Zeroing for All Axes ................................................................................................ 12

5.0 Simple Zeroing for Individual Axis ..................................................................................... 14

6.0 Precision Zeroing ................................................................................................................. 17

6.6.3 JT5 Precision Zeroing (RD80N).......................................................................................... 42

7.0 Precautions to be Taken at Motor Replacement .................................................................. 50

8.0 Outline of Motor Replacement ............................................................................................ 51

9.0 Prior to Motor (Encoder) Replacement ............................................................................... 53

10.0 Summary of Motor Replacement Work .............................................................................. 54

11.0 Tasks Before Motor Replacement ....................................................................................... 60

12.0 Motor Replacement .............................................................................................................. 62

13.0 Adjustment of Timing Belt .................................................................................................. 91

14.0 Shim Adjustsment in Bevel Gear Section ........................................................................... 94

15.0 Entire Motor Length Adjustment with Shim....................................................................... 96

Appendix: Figures of Motor Replacement..................................................................................... 100

1.0 OUTLINE OF ZEROING

The outline of the zeroing is shown below:

Reset encoder rotation counter

Move robot to a desired position in

Reset encoder rotation counter

* Make settings of Cubic-S

NOTE* Operations with the robot in which Cubic-S is installed

For precision zeroing, use the following instruments and jigs:

 Zeroing jig (1)  Zeroing jig (2)  Zeroing jig (3)

 Zeroing jig (4)  Zeroing jig (5)  Zeroing jig (6)

RS05N RS06L RS10L RS30N

2.0 RESETTING THE ENCODER ROTATION COUNTER

2.1 RESETTING THE ENCODER ROTATION COUNTER

● Turn ON CONTROLLER POWER switch.

● Turn OFF motor power by pressing EMERGENCY STOP switch.

● Turn to TEACH mode.

● Reset the encoder rotation counter by AS command as shown below.

Current angle (deg.mm)?

● Release emergency stop and turn ON motor power.

● Enable the robot to move in the TEACH mode.

JT6 zero point

JT5 zero point

JT3 zero point JT3 zero point

JT2 zero point

RS05N, RS05L, RA05L, RC05L RSxxx and RAxxx other than

At the standard pose (pose of 0 for all axes), make sure

zero point scribe mark

JT4 zero point

JT2 zero point

JT5 zero point

Pay attention to the interference of arm until simple or

2.2 RESETTING THE ENCODER ROTATION COUNTER FOR ZEROING

3.0 Cubic-S SETTINGS

3.1 WRITING TO Cubic-S

Refer to a separate manual, “Cubic-S Instruction Manual” for details.

3.2 TURNING OFF/ON CONTROLLER POWER

4.0 SIMPLE ZEROING FOR ALL AXES

RS05N, RS05L, RSxxx and RAxxx other than RD80N

● Keep the CONTROLLER POWER switch ON.

● Turn OFF motor power by pressing EMERGENCY STOP switch.