90202-1038DED Z Install

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY
INSTALLATION
AND
CONNECTION
= Robot Arm =
KAWASAKI HEAVY INDUSTRIES, LTD.
902021038DED
Preface
This manual is subject to change without prior notice and without our legal
responsibility.
Kawasaki pursues a policy of continuing improvement in design and

specification of the product. The right is therefore, reserved to vary this
manual without prior notice.
This manual is copyrighted and all rights are reserved by KHI.

This manual may not, in whole or part, be reproduced in any form or by any
means without prior written permission from KHI.
This manual is prepared with the best care but anyway it is impossible to
exclude any misinterpretation by the user or any spelling mistakes.
In case of doubts or if the robot behavior is different from that reported in this
manual please would you get in touch with the nearest Kawasaki or Kawasakis
agent.
KHI cannot anticipate every possible circumstance that might involve a potential
hazard. If a procedure, work method or operating technique not specifically
recommended by KHI is used, you must satisfy yourself that it is safe for you
and others. In this case you are completely responsible for eventual damages
on human bodies or things.
If you discover physical defects in the manual, KHI will replace the manual at no
charge during 90 days period after you purchased the robot.
If you do not observe warnings and/or caution to be taken in the manual as

described below, it might result in the serious injuries or damages on human
bodies or robot.
Therefore you must take extreme care to observe these warnings and cautions.
KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION 1

[ SYMBOLS ]
Whenever you see the symbols shown below in this manual or on the machine, read and
understand their messages.
DANGER
This danger symbol identifies special warnings or
procedures which, if not strictly observed, will
result in serious injury or death.
WARNING
This warning symbol identifies special warnings
or procedures which, if not strictly observed,
could result in serious injury or death.
CAUTION
This caution symbol identifies special instructions
or procedures which, if not correctly followed, may
result in injury.
[ NOTE ]
This note symbol identifies supplementary
information, or to emphasize a point or
procedure, or to give a tip for easier operation.
2 KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION

This manual describes the instructions concerning the installation and connection of KAWASAKI
ROBOT Z Series. You should fully understand the contents of this document and start the work paying
special attention to the safety.
The manual covers only the installation and connection of "Robot Arm".
Therefore, if you would desire to know the installation and connection of Controller and cable, you will
also please read this together with "INSTALLATION AND CONNECTION =CONTROLLER=".
This Manual describes on the following Robot Arms
ZX130S, ZX130U, ZX130L, ZX165U, ZX200S,
ZX200U, ZX200W,ZX300S,
ZT130S, ZT130U, ZT165U, ZT200S, ZT200U, ZT200W,
ZD130S, ZD250S
All rights reserved. Copyright 2001 by KAWASAKI HEAVY INDUSTRIES, LTD.

SAFETY
WARNING
1 For the confirmation of acceptability and effectiveness of
drawings, detailed specification of documents, procedures etc.
it shall be still insufficient.
Therefore, if you desire to operate/serve/maintain/adjust/
modify, and to do miscellaneous works, you must pay utmost
attentions to them.
2 Those persons who engage with the operation/service of your

system, they must strictly observe all safety regulation at all
times.
Never replace and/or adjust the inside parts provided in your
Robot system while the power source is being turned ON so as
to ensure your own safety.

Safety

Safety
Five safety rules to be observed for KHI robot

The following Five Safety Rules are fundamentals to use your Robot safely. Therefore, you are requested to read
these rules carefully prior to start the Robot without fail.
1 Surely provide a safety fence around the robot,

so as to prevent persons from access to the
robot.
2 Provide a door attached with a safety

plug at the entrance of fence.
Unless the plug is pulled out from the
door, the door can not be opened or
closed.
Whenever the plug is pulled out from the
door during automatic (repeat) operation
mode, the robot's motor power is so
designed as to be switched OFF safely.

Safety

Safety
3 When the robot operator enters inside the

fence to carry out teaching or checking, and
also to prevent any third party from carelessly
switching ON the repeat operation mode,
surely pull-out the safety plug by himself.
Moreover, the operator should be restricted to
a qualified person who was specially trained.
Surely assign a supervisor in front of the Controller, who

is able to stop the robot at all times in an emergency.
Moreover, supervisor must be also a qualified person who

was specially trained.
4 While the robot is being in a repeat

operation mode, or waiting state, never enter
any person in the scope of movement.
5 Clearly indicate "REPEAT OPERATION",

"TEACHING OPERATION",
"EMERGENCY STOP", and other
cautionary indications where they are easy
to be seen.

Safety

Safety
Cautions to be taken during transportation

When the KAWASAKI Robot is required to be transported to a robot installing location,
strictly observe the following cautions to be taken during transportation:
WARNING
When the robot is required to be transported by using a crane or a

forklift, never support the manipulator manually.
Because it is dangerous.
Moreover, during the transportation, no person is allowed to climb the

robot, or to stay under the robot hoisted up.
Because these are very dangerous.
CAUTION
Since the manipulator is composed of precision parts, be careful not

to apply excessive shocks or vibrations to the robot during
transportation.
First, prior to install the robot, remove all obstacles from the place for
installation, and arrange the place properly.
Next, clear a passage for the transportation of robot by using a crane
or forklift.

Safety

Safety
Installing environments of robot arm

When the robot arm is required to be installed, it must be installed to a place where
is satisfied by the following environmental conditions:
When a floor type robot is installed on the floor, the level must be within 5.
Be sure that the floor/stand should be provided with sufficient rigidity.
To secure a leveled place so as to prevent the installing location from undue
force application (If an accurate level is unobtainable, insert liners and adjust
the height).
The ambient temperature during operation should be within the range of 0C
45C. (Deviation or overload error may occur due to high viscosity of
grease/oil when starting operation at low temperatures. In this case,
warm-up robot at low speed before regular operation.)
The ambient humidity during operation should be 35% 85%RH: free from
dew condensation.
The robot installing place should be less dust, hume, smoke, water, and other
foreign matters. (In such a reverse condition, use an Arm with dust-proof &
water-proof spec.).
The robot installing place should be free from inflammable or corrosive liquid
or gas. (Use an arm with explosion-proof spec, in such a inflammable
environmental state)
The robot installing place should be free from excessively large vibration.
The robot installing place should be free from electric noise interference.
The robot installing place should be a sufficiently large place far exceeding
the Robot arm movement. In the peripheral section of Robot installing place,
provide a safety fence that the maximum movement of fully equipped Robot
arm with hands and guns does not interfere with the surrounding objects.
An entrance and a door with a safety plug should be provided to the
safety fence.
Approx.1m
A door
Scope of Robot Motion with Safety Plug
(The hand and gun are included)
Safety Fence
Approx.1m Approx.1m
Mechanical Mechanical
stopper stopper
Approx.1m Approx.1m

CONTENTS

CONTENTS
Safety ........................................................................................................................5
Five safety rules to be observed for KHI robot .................................................................................5
Cautions to be taken during transportation ......................................................................................7
Installing environments of robot arm ................................................................................................8
Working Flow at Arm Installation and Connection ...................................................10
Scope of Movements & Specifications of Robot ......................................................11
1. Robot transportation Method ...............................................................................28
Wire Sling .......................................................................................................................................28
FORKLIFT ......................................................................................................................................29
2. Installing Dimensions of Base Section.................................................................30
3. Movement Reaction Applied to the Installation Face During Operation...............31
4. Installing Method .................................................................................................32
5. Mounting of Tools ................................................................................................35
Dimensions of Wrist(Flange) ..........................................................................................................35
Specification of Fixing Bolt .............................................................................................................35
Load Capacity.................................................................................................................................37
6. Connection of Air System ....................................................................................38
6.1. Air Piping Arrangement ...........................................................................................................38
6.2. Air Supply to the Robot Arm ....................................................................................................40
6.3. Connection to the Tool from the Air Outlet Port ......................................................................41

Working Flow at Arm Installation and Connection

Working Flow at Arm Installation and Connection
This working flow covers only for the robot arm section. For the details of controller, they
should refer to "INSTALLATION AND CONNECTION =CONTROLLER=".
Examination of Place & Motion Refer to "SCOPE OF MOVEMENTS &

SPECIFICATIONS OF ROBOT"
Preparation Refer to "2. INSTALLING DIMENSIONS

Examination & Preparation of OF BASE SECTION",
Installation Place "3. MOVEMENT REACTION APPLIED
TO THE INSTALLATION FACE
DURING OPERATION"
Refer to
Transportation of Robot Arm
"1. ROBOT TRANSPORTATION
METHOD"
Refer to "2. INSTALLING DIMENSIONS OF BASE

Actual Installation of Robot Arm SECTION",
"3. MOVEMENT REACTION APPLIED TO THE
Work
INSTALLATION FACE DURING OPERATION",
4. INSTALLING METHOD
Refer to "5. MOUNTING OF TOOLS"

Mounting of Tool and "6. CONNECTION OF AIR
SYSTEM"
Refer to "INSTALLATION AND

Connection with Controller
Work by CONNECTION MANUAL
=CONTROLLER=".
Using
Controller
Checking of Arm Motion

Refer to "OPERATION MANUAL".
Checking of Tool Motion
Checking of Various Functions Refer to "OPERATION MANUAL".
Completion of Work

Scope of Movements & Specifications of Robot

Determination of Safety Fence Location based on Scope of

Movement:
Scope of
Movement
at Point B
Point B Location
Tool
Work-piece Point B Location
The following scope of movements of Robot is represented by the Scope of Movement at Point B in the figure
above. Therefore, referring to the figure, the safety fence dimensions should be set up as follow: Secure dimensions;
L0+L1+L2. That is; from the center of arm (Point A shown in the figure above) to Dimensions of L0 + Sum of
Dimensions up to the Wrist flange & Tool, Hand and Work-piece Max. dimensions with Allowance : L1.and
allowance dimensions L2. For the Dimensions of L0, refer to the drawings of Scope of Movements & Specifications
of Robot on following pages.
L2 Safety Fence
L1
Location of L0 Location of
Mechanical Mechanical
Stopper Stopper


ZX130S
Type Articulated Robot

Degree of 6
Freedom.
Working JT Motion Range Max. Speed
Envelope and 1 180 130s
Maximum 2 +75 -60 130s
Speed 3 +250 -120 130s
4 360 180s
5 130 180s
6 360 280s
Max. Payload 130kg
Wrist Load JT Torque Moment of Inertia
Capacity 4 735Nm 51.9kgm2
5 735Nm 51.9kgm2
6 421.4Nm 27.4kgm2
Repeatability 0.3mm
Mass Approx. 1500kg


ZX130U

Degree of 6
Freedom.
Maximum 2 +75 -60 110s
Speed 3 +250 -120 110s
4 360 140s
5 130 135s
6 360 230s
Max. Payload 130kg
5 735Nm 51.9kgm2
6 421.4Nm 27.4kgm2
Repeatability 0.3mm
Mass Approx. 1500kg


ZX130L

Degree of 6
Freedom.
Maximum 2 +75 -60 110s
Speed 3 +250 -120 110s
4 360 140s
5 130 135s
6 360 230s
Max. Payload 130kg
5 735Nm 51.9kgm2
6 421.4Nm 27.4kgm2
Repeatability 0.3mm
Mass Approx. 1550kg


ZX165U

Degree of 6
Freedom.
Maximum 2 +75 -60 110s
Speed 3 +250 -120 110s
4 360 135s
5 130 135s
6 360 210s
Max. Payload 165kg
Capacity 4 911.4Nm 78.4kgm2
5 911.4Nm 78.4kgm2
6 450.8Nm 40.2kgm2
Repeatability 0.3mm
Mass Approx. 1500kg


ZX200S

Degree of 6
Freedom.
Maximum 2 +75 -60 100s
Speed 3 +250 -120 95s
4 360 120s
5 120 115s
6 360 180s
Max. Payload 200kg
5 1274Nm 117.6kgm2
6 686Nm 63.7kgm2
Repeatability 0.3mm
Mass Approx. 1550kg


ZX200U

Degree of 6
Freedom.
Maximum 2 +75 -60 95s
Speed 3 +250 -120 95s
4 360 120s
5 130 115s
6 360 180s
Max. Payload 200kg
5 980Nm 93.1kgm2
6 490Nm 46.1kgm2
Repeatability 0.3mm
Mass Approx. 1700kg


ZX200W

Degree of 6
Freedom.
Maximum 2 +75 -60 95s
Speed 3 +250 -120 95s
4 360 93s
5 120 93s
6 360 163s
Max. Payload 200kg
5 1274Nm 117.6kgm2
6 686Nm 63.7kgm2
Repeatability 0.3mm
Mass Approx. 1750kg


ZX300S

Degree of 6
Freedom.
Maximum 2 +60 -75 85s
Speed 3 +165 -95 85s
4 360 90s
5 130 90s
6 360 150s
Max. Payload 300kg
5 1715Nm 166.6kgm2
6 862.4Nm 107.8kgm2
Repeatability 0.3mm
Mass Approx. 1750kg


ZT130S

Degree of 6
Freedom.
Maximum 2 +60 -75 130s
Speed 3 +165 -95 130s
4 360 180s
5 130 180s
6 360 280s
Max. Payload 130kg
5 735Nm 51.9kgm2
6 421.4Nm 27.4kgm2
Repeatability 0.3mm
Mass Approx. 1750kg


ZT130U

Degree of 6
Freedom.
Maximum 2 +60 -75 105s
Speed 3 +165 -95 105s
4 360 140s
5 130 135s
6 360 230s
Max. Payload 130kg
5 735Nm 51.9kgm2
6 421.4Nm 27.4kgm2
Repeatability 0.3mm
Mass Approx. 1750kg


ZT165U

Degree of 6
Freedom.
Maximum 2 +60 -75 105s
Speed 3 +165 -95 105s
4 360 135s
5 130 135s
6 360 210s
Max. Payload 165kg
Capacity 4 911.4Nm 78.4kgm2
5 911.4Nm 78.4kgm2
6 450.8Nm 40.2kgm2
Repeatability 0.3mm
Mass Approx. 1750kg


ZT200S

Degree of 6
Freedom.
Maximum 2 +60 -75 100s
Speed 3 +165 -95 90s
4 360 120s
5 120 115s
6 360 180s
Max. Payload 200kg
5 1274Nm 117.6kgm2
6 686Nm 63.7kgm2
Repeatability 0.3mm
Mass Approx. 1800kg


ZT200U

Degree of 6
Freedom.
Maximum 2 +60 -75 90s
Speed 3 +165 -95 90s
4 360 120s
5 130 115s
6 360 180s
Max. Payload 200kg
5 980Nm 93.1kgm2
6 490Nm 46.1kgm2
Repeatability 0.3mm
Mass Approx. 1750kg


ZT200W

Degree of 6
Freedom.
Maximum 2 +60 -75 90s
Speed 3 +165 -95 90s
4 360 93s
5 130 93s
6 360 163s
Max. Payload 200kg
5 1274Nm 117.6kgm2
6 686Nm 63.7kgm2
Repeatability 0.3mm
Mass Approx. 1800kg


ZD130S
Scope of moment
at point P
15 Flange thick

Degree of 4
Freedom.
Maximum 2 +90 -50 130s
Speed 3 +15 -120 130s
4 360 300s
5 - -
6 - -
Max. Payload 130kg
Capacity 4 - 50kgm2
5 - -
6 - -
Repeatability 0.5mm
Mass Approx. 1500kg


ZD250S
Scope of moment
at point P
15 Flange thick

Degree of 4
Freedom.
Maximum 2 +90 -50 90s
Speed 3 +15 -120 95s
4 360 190s
5 - -
6 - -
Max. Payload 250kg
Capacity 4 - 100kgm2
5 - -
6 - -
Repeatability 0.5mm
Mass Approx. 1500kg

1. Robot Transportation Method

Wire Sling
Referring to the figure, hoist up the robot by triple wire slings utilizing three eyebolts provided on the robot.
When hoisting up the robot, be careful that the robot may

fall forward/backward depending on the robot posture and
installation condition of the gun and options. If the robot will
3 Slings be hoisted up in an inclined posture, it might swing by a
shock, the sling might damage the wrist motor or harness or
piping etc. or it might be damaged interfering with externals.
Moreover, protect the robot with the application board etc. if
Eyebolts the wire and the balancer, etc. come in contact with a part of
the robot.
ZX130S ZX130L ZX200S ZX200U ZT130S ZT200S ZD130S

Model ZX130U ZX200W ZT130U
ZX165U ZT165U
JT1 0 0 0 0 0 0 0
JT2 -52 -52 -52 -52 -70 -70 -45
Shipment JT3 -35 -35 -35 -35 -13 -13 -20
posture JT4 0 0 0 0 0 0 0
JT5 -55 -55 -55 -55 103 103
JT6 0 0 0 0 0 0


FORKLIFT
The jig for the forklift has installed with the base, and utilizing this.
Make the posture of the robot as below when you transport the robot by the forklift.
ZX series : Make the JT2 the posture of 0-25
ZT series : Same as the posture of wire sling (see Page 28)
Ensure the forks of the forklift penetrating enough without fail.
When you transport the robot, do not fall with the forklift losing the balance by the road etc. with the inclination
ground and irregularity.
Use the forks of the forklift with 54mm or less in height when you install the retract stopper or the retract pin option.

2. Installing Dimensions of Base Section

2. Installing Dimensions of Base Section
When installing base section, fix it by means of high tension bolts utilizing the bolt holes.
Dimensions of Base
Section
Cross-section of
Base installation
Bolt Hole 8-22

8-M20
High Tension Bolt Material:SCM435
Strength class:10.9 min.
Tightening torque 431.2Nm
Inclination Within 5

3. Movement Reaction Applied to the Installation Face During Operation

3. Movement Reaction Applied to the Installation
Face During Operation
Load applied to the installation face during robot operation are shown below:
Consider these values at the installation shown in the following pages.
ZX Series
Model ZX 300S ZT Series ZD Series
(Excluding ZX300S)
M
34000Nm 41000Nm 35000Nm 26000Nm
(Inversion Moment)
T
12000Nm 12000Nm 12000Nm 10000Nm
(Rotating Torque)

4. Installing Method

(1) In case base is installed directly on the floor:
Referring to the below figure, steel plate (35mm Min. thick) must be buried on the concrete floor or fixed by
using anchors.
Moreover, the steel plate should be fixed firmly so as to endure reaction forces produced by the robot.
M20
Tightening torque
431.2Nm
30mm
Steel plate min. 35mm
min.
Concrete


(2) In case base plate of correspondence installation compatibility is installed on the floor:
Install the base plate utilizing 8 places of 22 hole.
Install the base plate on a concrete floor or the steel plate floor.
The reaction force received from the robot is the same as occasioning to install the base directly on the floor.
There are two-place pin hole for positioning on the base plate, and it is possible to positioning it between holes on
the base portion. As a result, when abnormally occurring, it is possible to exchange easily for the reserve robot.
(However, the JT1 is not precision zeroing usually. Therefore, correspond by the option when this function is
necessary.)


(3) In case the installing block is used:
Install the installing block to conform to the following dimensions shown below:
200 mm or more Base
200 mm or more
Thickness 32mm or more

5. Mounting of Tools

WARNING
EMERGENCY STOP When tools including hand, etc. are required to mount,
surely press the "EMERGENCY STOP" switch, and make
sure that the "MOTOR POWER" is set to OFF.
Dimensions of Wrist End(Flange)

In the robot arm end section, a flange is provided through which hand, gun, or other tools are installed.
For the fixing bolts, they should be tightened by utilizing tap holes machined on the circumference of D on the flange
referring to the figure below.
Moreover, the positioning of hand and gun are made by utilizing the pin hole and the spigot hole.
ZX Series/ZT Series ZD130
Pin holes
Drill holes
Tap holes
D D
Spigot hole
Specification of Fixing Bolt

The length of fixing bolt should be selected depending on the tap depth of tool mounting flange, and to be the depth of
the specified screwing depth. Moreover, the fixing bolt should be a high tension bolt and tightened with the specified
torque.
Excluding ZD130 ZD130

Tightening torque
Tightening torque
Fixing bolt Fixing bolt
Hand member
Tap depth
Hand mounting
Hand mounting
section (Flange)
section (Flange)
Hand member
CAUTION
If the screwing depth has exceeded the specified depth, the
fixing bolt might bottom out. As a result, the tool can not be
fixed.


ZX130S, ZX130U,
ZX165U, ZX200U, ZX200S, ZX200W
Model ZX130L ZX300S
ZT130S,ZT130U, ZT200S, ZT200W
ZT165U, ZT200U
Tap Holes 10-M10 10-M10
D 125 160
Pin Holes 2-10H7 Deep 12 2-10H7 Deep 12
Spigot hole 80H7 Deep 8 100H7 Deep 8
Tap Depth 12mm 12mm
Screwing Depth 1011mm 1011mm
High Tension Bolt SCM435,10.9 Min SCM435,10.9 Min
Tightening Torque 56.84Nm 56.84Nm
Model ZD130S, ZD250S
Drill Holes 8-11(M10)

D 150
Pin Holes
Spigot Hole
Flange Depth 15mm
High Tension Bolt SCM435,10.9 Min
Tightening Torque 56.84Nm
[ NOTE ]
Above-mentioned installation size (ZX,ZT) conforms to ISO. In case of a
conventional type, install the adapter plate (option), and then, install the tool.


5Mounting of Tools
Load Capacity
The robot's load capacity is being specified by including the mass of hand, gun, etc. per the model of robot. Moreover,
the load capacity of wrist is also provided with the specified condition.
In addition, the following restricted conditions are applied to the rotating load torque and load moment of inertia on
wrist axes (JT4,JT5,JT6). Therefore, the user is requested to observe the conditions strictly.
CAUTION
If you use the robot, exceeding its load capacity; exceeding
over the specified range of movement performance, it might
result in the deterioration of movement performance, as well
as shortening of machine service life. The specified range
includes the hand mass, tool changer mass and spot weld
gun mass. If you desire to use the robot exceeding the
specified specification, please contact with us without fail.
The load torque and the moment of inertia are procurable from the calculation expression below :
Calculation Expression
Load Capacity : MMmax.(kg)

(including hand)
Load Torque : T=9.8ML(Nm)
Load Moment of Inertia: I=ML2+IG(kgm2)

L 6(m)
IG M: Load Capacity (For example)
ZX130 Mmax. : 130kg
L 4 , 5(m) ZX165 Mmax. : 165kg
ZX200 Mmax. : 200kg
L6 :Length from JT6 axis
rotated center to load L: Length from axis rotated center to load
M(kg) center of gravity. center of gravity. (Unit : m)
L 4,5 :Length from JT4(5) IG: Moment of inertia about center of gravity.
axis rotated center to (Unit : kgxm2)
load center of gravity.
If you desire to calculate the load section after divided it into plural numbers of load
(for example, a hand section, load section, and other sections), the total values should
be considered to the load torque and the moment of inertia respectively.

6. Connection of Air System

6.1. Air Piping Arrangement
Z Series houses air piping materials for driving tool in the robot arm.
ZX Series, ZT Series
PT3/8
Joint for air 12 One-touch Joint
(Input:0.1470.588MPa)
Robot Base Section Robot Arm-Internal Robot Wrist Section
The following valves can be installed on the above-mentioned arm as an option. The valve can be ON/OFF by the
Multi Function Panel (or, Teach Pendant) without interlock.
Double Solenoid 1 unit

Double Solenoid 2 units
Option Single Solenoid 1 unit
Single Solenoid 2 units
Double Solenoid 1 unit + Single Solenoid 1 unit
(Note) The valve specification is: CV value = 3.2 and 2-position.


6Connection of Air System
ZD Series
PT3/8
Joint for air PT3/8 Joint for air
(Input:0.1470.588MPa)
Robot Base Section Robot Arm-Internal Robot Wrist Section
The vacuum hose of 1 inch or 2 inch in the inside diameter can be added as an option.


6.2. Air Supply to the Robot Arm
Referring to the figure below, the air connection port is provided on the base section of robot arm.
CAUTION
Supply input pressure; 0.1470.588MPa to the air inlet port
(PT3/8 Joint, 2 places).


< Reference >
Port A
In case air regulator is connected
Connect the hand driving air source externally with

[Filter + Regulator].
Port B
Since the robot upper arm built-in valve is a no-oiling

type, do not use any lubricator (Oiler).
Filter
Input Pressure
+
0.1470.588MPa
Regulator
6.3. Connection to the Tool from the Air Outlet Port

The air outlet port is provided on Z series robot as shown in figure below.
In case of ZX/ZT series ; The outlet ports are 12 joints for air tube on the upper arm section
In case of ZD series ; The outlet ports are PT3/8 joints on the wrist section.
ZX/ZT series ZD series

42
MEMO
KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION

KAWASAKI ROBOT Z Series
INSTALLATION AND CONNECTION MANUAL
March 2000 : 1st Edition

June 2005 : 4th Edition
Publication : KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION
90202-1038DED
All rights reserved. Copyright 2005 KAWASAKI HEAVY INDUSTRIES, LTD.

90202-1038DED Z Install

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COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

KAWASAKI HEAVY INDUSTRIES, LTD.

Kawasaki pursues a policy of continuing improvement in design and

This manual is copyrighted and all rights are reserved by KHI.

If you do not observe warnings and/or caution to be taken in the manual as

KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION 1

2 KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION

This Manual describes on the following Robot Arms

ZX130S, ZX130U, ZX130L, ZX165U, ZX200S,

All rights reserved. Copyright 2001 by KAWASAKI HEAVY INDUSTRIES, LTD.

KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION 3

2 Those persons who engage with the operation/service of your

4 KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

Five safety rules to be observed for KHI robot

1 Surely provide a safety fence around the robot,

2 Provide a door attached with a safety

KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION 5

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3 When the robot operator enters inside the

Surely assign a supervisor in front of the Controller, who

Moreover, supervisor must be also a qualified person who

4 While the robot is being in a repeat

5 Clearly indicate "REPEAT OPERATION",

6 KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION

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Cautions to be taken during transportation

When the robot is required to be transported by using a crane or a

Moreover, during the transportation, no person is allowed to climb the

Since the manipulator is composed of precision parts, be careful not

KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION 7

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Installing environments of robot arm

8 KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION

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Five safety rules to be observed for KHI robot .................................................................................5

Cautions to be taken during transportation ......................................................................................7

Installing environments of robot arm ................................................................................................8

Working Flow at Arm Installation and Connection ...................................................10

Scope of Movements & Specifications of Robot ......................................................11

1. Robot transportation Method ...............................................................................28

Wire Sling .......................................................................................................................................28

2. Installing Dimensions of Base Section.................................................................30

3. Movement Reaction Applied to the Installation Face During Operation...............31

4. Installing Method .................................................................................................32

5. Mounting of Tools ................................................................................................35

Dimensions of Wrist(Flange) ..........................................................................................................35

Specification of Fixing Bolt .............................................................................................................35

6. Connection of Air System ....................................................................................38

6.1. Air Piping Arrangement ...........................................................................................................38

6.2. Air Supply to the Robot Arm ....................................................................................................40

KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION 9

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Examination of Place & Motion Refer to "SCOPE OF MOVEMENTS &

Preparation Refer to "2. INSTALLING DIMENSIONS

Refer to "2. INSTALLING DIMENSIONS OF BASE

Refer to "5. MOUNTING OF TOOLS"

Refer to "INSTALLATION AND

Checking of Arm Motion

Checking of Various Functions Refer to "OPERATION MANUAL".

10 KAWASAKI ROBOT Z Series INSTALLATION and CONNECTION

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Determination of Safety Fence Location based on Scope of