90213-1054DEA - Zeroing & Motor Repleacement (Z Series)

Kawasaki Robot
Z series
Zeroing & Motor

Replacement Manual
E controller
Kawasaki Heavy Industries, Ltd.
90213－1054DEA
Z Series
Kawasaki Robot Zeroing/Motor Replacement Manual
PREFACE
This manual describes the zeroing and motor replacement instructions for Kawasaki Robot Z
series.
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 describes the following Robot Arms
ZD130S, ZD250S, ZH100U, ZT130L, ZT130S, ZT130U, ZT130Y,
ZT165U, ZT165X, ZT165Y, ZT200S, ZT200U, ZT200Y,
ZX130L, ZX130S, ZX130U, ZX165L, ZX165U, ZX200S, ZX200U,
ZX300G, ZX300S
！ DANGER
Prior to operating robot, do not fail to reset the encoder rotation counter
after motor replacement. Attempting manual motion without first
resetting is dangerous as the robot may move unpredictably.
！ WARNING
Motor replacement duty is limited to Kawasaki service
personnel and those who have completed education and training
in the Kawasaki Robot maintenance course.
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 © 2010 Kawasaki Heavy Industries Ltd. All rights reserved.
1
Z 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
Z Series
CONTENTS
1.0 Outline of Zeroing.................................................................................................................... 5
2.0 Resetting the Encoder Rotation Counter ................................................................................. 6

2.1 Resetting the Encoder Rotation Counter ................................................................................. 6
2.2 Resetting the Encoder Rotation Counter for Zeroing ........................................................... 12
3.0 Simple Zeroing for All Axes.................................................................................................. 13
4.0 Simple Zeroing for Individual Axis....................................................................................... 16
5.0 Precision Zeroing ................................................................................................................... 22

5.1 Preparation Work for Precision Zeroing ............................................................................... 25
5.2 JT2 Precision Zeroing ............................................................................................................ 28
5.3.1 JT3 Precision Zeroing (ZD Series) ........................................................................................ 31
5.3.2 JT3 Precision Zeroing (ZH100U, ZX Series) ....................................................................... 33
5.3.3 JT3 Precision Zeroing (ZT Series, ZTX/ZTY Series)........................................................... 35
6.0 Precautions to be Taken at Motor Replacement.................................................................... 54
7.0 Outline of Motor Replacement .............................................................................................. 55
8.0 Prior to Motor (Encoder) Replacement ................................................................................. 56
9.0 Summary of Motor Replacement Work ................................................................................ 57
10.0 Tasks Before Motor Replacement ......................................................................................... 59
3
Z Series
11.0 Motor Replacement................................................................................................................ 65

11.1 1.0 kW Motor Replacement................................................................................................... 65
Appendix: Figures of Motor Replacement....................................................................................... 72
4
Z Series 1. Outline of Zeroing
1.0 OUTLINE OF ZEROING
The outline of the zeroing is as shown below:
Reset encoder rotation counter

Simple zeroing
x All axes collectively
Move each axis to the desired x Each axis individually
position by joint mode operation
Reset encoder rotation counter Precision zeroing

(For zeroing)
For precision zeroing, use the following instruments and jigs:

● Digital inclinometer ● Zeroing jig (1) ● Zeroing jig (2)
60154-1085 60154-1086
(Angle) Mfd. by KHI

(Plate) Mfd. by KHI
● Zeroing jig (4)
60154-1088(except the following)
Mfg. by NIIGATA SEIKI 60154-1089 ZX200S, ZX300G/S
Levelnic DL-S1 ZT200S, ZT200Y
● Zeroing jig (5)
● Zeroing jig (3) 60154-1623
60154-1087
(Plate) Mfd. by KHI (Angle) Mfd. by KHI (Plate) Mfd. by KHI
For motor replacement, prepare the following instruments, tools, and grease:
● Dial gauge ● Torque wrench with ● Grease other than molybdenum
hexagon-head bar
grease with antifriction
attachment
composition
(Daphne Eponex Grease No.3, etc.)
x M4 Hex. wrench ● Grease for gear and reduction unit
x M5 Hex. wrench
x M6 Hex. wrench (Multemp FZ)
170mm x M8 Hex. wrench ● Plus (+) screw driver
or more x M10 Hex. wrench
(Large, Small)
x M12 Hex. wrench
NOTE* Refer to Chapter 9.0 for length.

5
Z Series 2. Resetting the Encoder Rotation Counter
2.0 RESETTING THE ENCODER ROTATION COUNTER
2.1 RESETTING THE ENCODER ROTATION COUNTER
！ DANGER
Prior to operating robot manually, do not fail to reset the encoder rotation
counter after motor replacement. Attempting manual motion without
first resetting is dangerous as the robot may move unpredictably.
Controller
CONTROLLER POWER EMERGENCY STOP TEACH/REPEAT

ON
OFF
Press HOLD/RUN on
Turn ON controller Turn OFF motor power Turn the the Teach Pendant and
by pressing TEACH/REPEAT make “HOLD/RUN”
power.
EMERGENCY STOP . to TEACH. display on upper right
of the screen “HOLD”.
Reset the encoder rotation counter by AS command as shown below.
Z Z 1 0 1 Example for JT1 rotation counter reset
For other axes, enter applicable axis No.
as shown below.
Axis No.
Example: For JT2: 102
For JT3: 103
For JT4: 104
For JT5: 105
For JT6: 106
For JT7: 107
！ CAUTION
** Encoder rot. counter reset (1st axis) **.
After confirming the axis to reset,
current angle (deg.mm)? enter the applicable axis No.
Are you sure ? (Enter 1 to execute.) 
When resetting the counters of all
axes at the same time, input:
Enter the current arm angle here.
Z Z 1 0 0
1. No need to enter an accurate arm angle when resetting immediately after the motor
replacement.
2. When resetting for zeroing, enter a precise arm angle value corresponding to the
scribe mark position, etc.
6
For manual operation, set switches on the operation panel as follows:

CONTROLLER POWER TEACH/REPEAT
ON
OFF
Turn ON controller power. Turn the TEACH/REPEAT

to TEACH.
Press MOTOR ON while pressing A key on the Teach Pendant and make “MOTOR” display
active.
Press HOLD/RUN while pressing A key on the Teach Pendant and make “HOLD/RUN”
display “RUN”.
7
Arm
Press the AXIS keys on the Teach Pendant and set the robot to standard HOME pose (home
position) as shown below in joint mode.
● ZD series
JT4 zero point

scribe mark position
JT3 zero point

JT2 zero point scribe mark position
JT1 zero point

At the HOME pose, make

sure that zero scribe
marks of each axis are
aligned.
zero scribe mark
8
● ZH100U
JT6 zero point JT4 zero point

scribe mark position scribe mark position
JT3 zero point

JT5 zero point
JT2 zero point
JT1 zero point


aligned.
zero scribe mark
9
● ZT series
JT1 zero point

JT4 zero point

JT5 zero point

JT6 zero point



aligned.
zero scribe mark
10
● ZTX/ZTY series
JT1 zero point

JT4 zero point

JT5 zero point

JT6 zero point

JT3 zero point

JT2 zero point

aligned.
zero scribe mark
11
● ZX series
JT6 zero point

JT3 zero point
scribe mark position JT4 zero point
JT5 zero point

JT2 zero point

JT1 zero point


aligned.
zero scribe mark
2.2 RESETTING THE ENCODER ROTATION COUNTER FOR ZEROING
Controller
1. Turn OFF motor power by pressing EMERGENCY STOP.

2. Reset encoder rotation counter shown in 2.1.
12
Z Series 3. Simple Zeroing for All Axes
3.0 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. For the 3 minor 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.
Arm
1. After completion of the encoder rotation counter reset, keep the robot arm in the standard
HOME pose.
● ZD series
● ZH100U
13
● ZT series
● ZTX/ZTY series
● ZX series
14
Controller
2. Keep the CONTROLLER POWER 3. Turn OFF motor power by pressing

switch ON. EMERGENCY STOP.
CONTROLLER POWER
ON
OFF
4. 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
5. Display current values on screen and confirm.

W H E R E

0.000 0.000 0.000 0.000 0.000 0.000 To verify zeroing
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.
If these values are 0, it is OK.
15
Z Series 4. Simple Zeroing for Individual Axis
4.0 SIMPLE ZEROING FOR INDIVIDUAL AXIS
！ CAUTION
Simple zeroing cannot ensure robot moves in absolutely precise line

trajectories and shift amounts. Simple Zeroing (or Precision Zeroing) is a
required step in the motor replacement process, thus read the zeroing
instructions without fail when replacing motors. For the 3 minor 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.
Arm
1. Align zero points of the axes to be zeroed using zero scribe marks.
● ZD series
JT4 zero point

JT3 zero point

JT2 zero point scribe mark position
JT1 zero point

！ DANGER
Before operating the robot after motor replacement manually, 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.
16
● ZH100U

JT3 zero point

JT5 zero point
JT2 zero point
JT1 zero point

！ DANGER

17
● ZT series
JT1 zero point

JT4 zero point

JT5 zero point

JT6 zero point


！ DANGER

18
● ZTX/ZTY series
JT1 zero point

JT4 zero point

JT5 zero point

JT6 zero point

JT3 zero point

JT2 zero point
！ DANGER

19
● ZX series
JT6 zero point
JT3 zero point
scribe mark position JT4 zero point
JT5 zero point

JT2 zero point

JT1 zero point

！ DANGER

20
Controller
1. Turn OFF the motor power by pressing EMERGENCY STOP.
2. Reset the encoder rotation counter.

See 2.1 Resetting the Encoder Rotation Counter.
3. Input the zeroing command. For example, when zeroing JT1,

enter axis No. 1 after inputting the
Z Z E R O 1
ZZERO command.

Current angle (deg.mm)?

0 or

Encoder value? (Current = xxxxxx, Enter 1 to 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.
21
Z Series 5. Precision Zeroing
5.0 PRECISION ZEROING
Arm
To put the inclinometer on the robot arm, remove the mounting cover as shown in figure
below*. Then, remove all paint, rust, burr etc. from each of the zeroing jig mounting
surfaces with a whetstone.
NOTE* Move the upper arm until it takes the horizontal posture, and remove the cover after
setting JT4 to 90°.
● ZD series
Datum level (C)
Datum level (B)
Datum level (A)
22
● ZH100U
Datum level (C)
Cover
Datum level (D)
Datum level (B)

Datum level (A)
● ZT series
Datum level (A)
Datum level (B)
Cover
Datum level (C) Datum level (D)
23
● ZTX/ZTY series
Datum level (B) Datum level (A)
Cover
Datum level (C) Datum level (D)
● ZX series
Datum level (C)

Cover
Datum level (D)
Datum level (B)
Datum level (A)
24
5.1 PREPARATION WORK FOR PRECISION ZEROING
！ CAUTION
Precision zeroing is applied only to JT2-JT6. For JT1, precision
zeroing is an option and not described in this manual.
Controller
CONTROLLER POWER TEACH/REPEAT

ON
OFF
Turn ON controller power. Turn the TEACH/REPEAT to TEACH.
Press MOTOR ON while pressing A key on the Teach Pendant and make “MOTOR” display
active.
Press HOLD/RUN while pressing A key on the Teach Pendant and make “HOLD/RUN”
display “RUN”.
Arm
1. First, execute the simple zeroing described above for all axes, and match all axes in the state
of 0.
2. Then, place the inclinometer on datum level (A) of arm base section as shown in the next
page. Place the inclinometer on the datum plane in the same direction as the axis zeroed.
Level
Digital display
[0-ADJUST] volume
Power switch
HOLD/RUN sel.
0.01/0.001 unit sel.
！ CAUTION
Once the inclinometer is adjusted by 0-ADJUST volume,
never touch or change the adjusted setting.
25
Arm
● ZD series ● ZH100U
Measurement Inclinometer Measurement
direction Inclinometer
direction
Zeroing jig (5)
Zeroing jig (5)
● ZT series ● ZTX/ZTY series

Inclinometer
Measurement
direction Measurement Inclinometer
direction
● ZX series
Inclinometer
Measurement
direction
26
Arm
3. Next, set the various switches on the inclinometer as follows:

Power : ON
HOLD/RUN : RUN
0.01/0.001 : 0.01
Turn the 0-ADJUST volume and adjust digital display to 0.00 mm/m.
！ CAUTION
Depending on installation conditions, it may not be possible to set
0-ADJUST volume to 0. In this case, set the display to the next
clear and adequate value; for example 1.00 mm/m.
27
5.2 JT2 PRECISION ZEROING
Arm
1. Mount the zeroing jig to datum level (B) of the lower arm section as shown below. Then
place the inclinometer on the datum plane, paying attention not to touch the 0-ADJUST
volume.
● ZD series ● ZH100U
Measurement Measurement
direction direction
Measurement
Measurement
direction Inclinometer Inclinometer
direction Inclinometer
Zeroing jig (1)

Zeroing jig (5)
Inclinometer
Zeroing jig (1)
Zeroing jig (1) Zeroing jig (1)
Zeroing jig (5)
28

Inclinometer
Measurement
direction
Measurement
Measurement direction Inclino-
Measurement direction meter
direction
Inclinometer
Inclino-
meter
Zeroing jig (2)
Zeroing jig (2)
● ZX series
Measurement
direction Measurement
direction
Inclinometer
Inclinometer
Zeroing jig (1)
Zeroing jig (1)
2. Press JT2 AXIS keys on the Teach Pendant, and move JT2. At this time, move JT2 until
the inclinometer display equals the value set on datum level (A) (Standard:0.00). For
example, if the set value at the datum level (A) is 0.00, move the axis until the value at the
datum level (B) becomes 0.000.01.
29
Controller
1. Press the EMERGENCY STOP and set the motor power to OFF.
2. Execute zeroing of JT2.
Z Z E R O 2


0 or



When zeroing value is out of 268419072-268451840, reset the encoder rotation counter
again.


Setting completed.
The precision zeroing of JT2 is now complete.
30
5.3.1 JT3 PRECISION ZEROING (ZD SERIES)
Arm
1. Move the JT4 to +90°. Then, remove the cover of the wrist section as shown below.
2. Mount the inclinometer to datum level (C) of the wrist arm section in the same direction as
the axis zeroed as shown below.
Measurement
direction
Inclinometer
Measurement Inclinometer
direction
the inclinometer display equals the value set on datum level (A) (Standard: 0.00).
！ CAUTION
At zeroing, after setting JT4 to the above posture,

do not move any axes except JT3.
31
Controller
1. Press EMERGENCY STOP and set the motor power to OFF.
Z Z E R O 3


0



again.


Setting completed.
32
5.3.2 JT3 PRECISION ZEROING (ZH100U, ZX SERIES)
Arm
2. Mount the zeroing jig (3) to datum level (C) of the wrist section as shown below. Then
place the inclinometer on the datum plane in the same direction as the axis zeroed, paying
attention not to touch the 0-ADJUST volume.
● ZH100U ● ZX series
Measurement
direction
Measurement
Inclino- direction
meter
Measurement Inclino- Inclino-
direction meter meter
Measurement Inclino-
direction meter
Zeroing jig (3)
Zeroing jig (3)
Zeroing jig (5)
Zeroing jig (3)
Zeroing jig (3)
Zeroing jig (5)
！ CAUTION

33
Controller
Z Z E R O 3


0



again.


Setting completed.
34
5.3.3 JT3 PRECISION ZEROING (ZT SERIES, ZTX/ZTY SERIES)
Arm
2. Mount the zeroing jig (3) to datum level (C) of the wrist section as shown below. Then
Inclinometer
Measurement Measurement
direction direction Inclino-
meter
Zeroing jig (3)

Zeroing jig (3)
Measurement
Measurement direction
direction
Inclinometer
Inclinometer
Zeroing jig (3)
Zeroing jig (3)
！ CAUTION

35
Controller
Z Z E R O 3


9 0



again.


Setting completed.
36
Controller
CONTROLLER POWER
ON
OFF 2. Press MOTOR ON while pressing A

key on the Teach Pendant and make
1. Turn ON controller power. “MOTOR” display active.
Arm
3. Referring to the figure below, while keeping the standard pose (HOME pose), move JT4
rightward at +90 as viewed from rear.
Measurement
direction
Inclino-
meter Measurement
Inclino- direction
Zeroing jig (3) meter
Measurement
direction
Zeroing jig Measurement
(3) direction
Inclino-
Inclino- meter
meter
Zeroing jig (5)
Zeroing jig (3)
Zeroing jig (3)

Zeroing jig (3)
Zeroing jig (5)
37
Arm
To get the pose shown in the figure on the previous page automatically, follow the procedure
below:
TEACH/REPEAT
Press HOLD/RUN while pressing A key on the Teach

Set to REPEAT. Pendant and make “HOLD/RUN” display “RUN”.
To make axis coincidence accurately, key-in the positioning accuracy range as below:
DO ACCURACY 0.1
Keeping the standard pose, key-in:
DO DRIVE 4,90
4. Place zeroing jig (3) on the datum level (A) of the arm base section in the direction shown
above (clockwise inclination of arm is measured), make zero adjustment by turning
0-ADJUST volume. (If 0 setting is not possible, set adequate value.) Place the
inclinometer on the datum plane in the same direction as the axis zeroed.
5. Next, place the zeroing jig (3) on datum level (C) of the wrist section as shown above.
Then, place the inclinometer being careful of the placing direction.
！ CAUTION
At zeroing, do not move any axes except JT4.
38
Controller
Z Z E R O 4


9 0



again.


Setting completed.
39

Controller
CONTROLLER POWER
ON

Arm
3. Referring to the figure below, while keeping the standard pose (HOME pose), move JT4
rightward at +90 as viewed from rear.
● ZT series Measurement
direction
Inclinometer
Zeroing jig (3)
Zeroing jig (3)
Measurement
direction
Inclinometer
Zeroing jig (3)
Measurement
● ZTX/ZTY series direction
Zeroing jig (3)

Inclinometer
Measurement
direction Zeroing jig (3)
Inclinometer
Zeroing jig (3)
40
Arm
To get the pose shown in the figure on the previous page automatically, follow the procedure
below:
TEACH/REPEAT

To make axis coincidence accurately, key-in the positioning accuracy range as below:
DO ACCURACY 0.1
DO DRIVE 2,40 Key-in 30 -
DO DRIVE 3,90 60 for the
angle of JT2.
DO DRIVE 4,90
4. Place zeroing jig (3) on the datum level (A) of the arm base section in the direction shown
above (clockwise inclination of arm is measured), make zero adjustment by turning
0-ADJUST volume. (If 0 setting is not possible, set adequate value.) Place the
5. Next, place the zeroing jig (3) on datum level (C) of the wrist section as shown above.
Then, place the inclinometer being careful of the placing direction.
！ CAUTION
41
Controller
Z Z E R O 4


9 0



again.


Setting completed.
42
Arm
1. Execute the zeroing of JT5 at the standard pose.
2. Make sure that the cover is mounted on the wrist section without fail (otherwise grease flows
out). First, set JT2, JT3 and JT4 to 0. (Executable by HOME command)
3. Mount the zeroing jig (4) to datum level (D) of the flange surface as shown below. Then
Measurement
direction
Measurement
Inclino- Measurement Inclino- direction
meter direction meter Inclino-
meter Inclino-
Zeroing Measurement
meter
jig (4) direction
Zeroing jig (4)
Zeroing jig (5)
Zeroing jig (4)
Zeroing jig (5)

Zeroing jig (4)
！ CAUTION
43
Controller
Z Z E R O 5


0



again.


Setting completed.
44
Arm
1. Execute the zeroing of JT5 at the standard pose.
2. Make sure that the cover is mounted on the wrist section without fail (otherwise grease
flows out). First, set JT2 to 30-60, JT3 to 90, JT4 to 0.
3. Mount the zeroing jig (4) to datum level (D) of the flange surface as shown below. Then
Inclinometer
Measurement
direction Measurement Inclino-
direction meter
Measurement
direction
Inclinometer
Inclinometer
Zeroing jig (4)
Zeroing jig (4)
！ CAUTION
45
Controller
Z Z E R O 5


0



again.


Setting completed.
46

Controller
CONTROLLER POWER
ON

Arm
3. Set robot to the standard pose (HOME pose). Referring to the figure below, mount the
zeroing jig (4) on datum level (D) of the flange surface as shown below. Place the
Measurement
direction
Inclino- Measurement
meter direction
Measurement
direction Measurement
Inclinometer direction
Inclino-
Zeroing meter
jig (4)
Zeroing jig (4)
Inclinometer
Zeroing jig (3)
Zeroing jig (5)
Zeroing jig (4)
Zeroing jig (3)

！ CAUTION
47
Controller
Z Z E R O 6


0



again.


Setting completed.
48
Controller
1. After completing the precision zeroing process for all axes:
Press MOTOR ON while pressing A key on the Teach Pendant and make “MOTOR”
display active.
2. To make the axes coincide accurately, key-in the positioning accuracy range.
D O A C C U R A C Y 0 . 1
3. Set the robot to standard HOME pose (home position*).

NOTE* Home position means mechanical origin.
D O H O M E
4. 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
Controller
CONTROLLER POWER
ON

Arm
3. Set JT2 to 30-60, JT3 to 90 and JT4 to 0. Referring to the figure below, mount the
zeroing jig (4) on datum level (D) of the flange surface as shown below. Place the

Measurement
direction
Measurement
direction
Inclino-
meter
Inclino-
Zeroing jig (3) meter
Measurement Zeroing jig (3)
direction
Zeroing jig (3)

Inclinometer
Inclinometer Zeroing jig (3)
Zeroing jig (4)

Zeroing jig (4)
50
Arm
To get the pose shown in the figure on the previous page automatically after JT4 zeroing,
follow the procedure below:
TEACH/REPEAT


DO DRIVE 2,40 Key-in 30 -
DO DRIVE 3,90 60 for the
angle of JT2.
！ CAUTION
51
Controller
Z Z E R O 6


0



again.


Setting completed.
52
Controller
1. After completing the precision zeroing process for all axes:
Press MOTOR ON while pressing A key on the Teach Pendant and make “MOTOR”
display active.
2. To make the axes coincide accurately, key-in the positioning accuracy range.
D O A C C U R A C Y 0 . 1
3. Set the robot to standard HOME pose (home position*).

NOTE* Home position means mechanical origin.
D O H O M E
4. 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.
53
Z Series 6. Precautions to be Taken at Motor Replacement
6.0 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 dismounting or replacing a motor, do not apply excessively strong

shocks to the motor and encoder.
2. Store motors within the specified ambient temperature and humidity.
3. Remove only those screws necessary for dismounting and replacing the
motor, 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 U-groove of the encoder shaft. Then match the case marking on the
motor with that on the encoder accurately.
54
Z Series 7. Outline of Motor Replacement
7.0 OUTLINE OF MOTOR REPLACEMENT
There are two types of AC servomotors used in Kawasaki Robots; one is encoder-separable from
the motor section, and the other is an encoder-inseparable type.
1. Small-sized motors of 1.0 kW capacity are specified as encoder-inseparable. This means

that even if only the motor or only the encoder has failed, both must be replaced together with
a new set.
2. Large-sized motors of 3.1 kW and 4.2 kW capacity are specified as encoder-separable. This
means that if either the motor or the encoder has failed, the defective unit alone can be
replaced with a new one.
3. For replacement procedure of the separable-type MK32A encoder, refer to “MK32A Encoder
Replacement Manual”, a separate volume.
ZT130L/S/U/Y ZD130S
ZT165U/X/Y ZD250S
ZT200S/U/Y
Motor-Encoder Motor
ZX130S/U/L
Type Capacity
ZX165L/U
ZX200S/U
ZX300G/S
Separable type 1.0 kW JT4
JT4
3.1 kW JT5
Inseparable JT6
type JT1 JT1
4.2 kW JT2 JT2
JT3 JT3
Motor-Encoder Type Motor Motor Assy P/N

50601-1397
Separable type 1.0 kW
(P60B13100HCPU9)
50601-1413
3.1 kW
(P60B13200LCPUA)
Inseparable type
50601-1412
4.2 kW
(P80B22450LCPUB)
55
Z Series 8. Prior to Motor (Encoder) Replacement
8.0 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
shaking YES found in Check on mechanical
observed? mechanisms? parts and repair/replace
parts if required.
NO
Is NO
abnormal YES
noise heard?
NO
Is Is
abnormal heat YES NO Replace the encoder.
there any mechanical
generated? interference?
YES
NO
Check on mechanical parts and
repair/replace parts if required.
Brake Does error recur?
YES
release
impossible?
YES
NO
Does Surrounding NO
YES cables, boards, ok?
brake
slip?
NO YES
Is inside
YES
wiring of motor
disconnected?
Replace motor with a new one.
NO
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 Repair/replace
replacing the motor/encoder, the control system will need to surrounding cables,
be checked/adjusted. In this case, contact Kawasaki. boards.
56
Z Series 9. Summary of Motor Replacement Work
9.0 SUMMARY OF MOTOR REPLACEMENT WORK
When replacing a motor, prepare the measuring instruments, tools, greases etc. shown below:
● Dial gauge ● Grease other than molybdenum grease with antifriction composition
(Daphne Eponex Grease No.3, etc.)
● Loctite 242/515 ● Multemp FZ ● Three Bond 1206C/D
(for Gear Reduction Unit)
● Daphne Eponex #3
(for applying to motor shaft)
● Tools
Motor
Hexagonal-bar or Torque wrench
capacity
Torque wrench (for M8):
1.0 kW
for hexagonal-bar attachment: approx. 170 mm in length
Motor
3.1 kW
4.2 kW
● Exclusively designed removing jigs and pulley puller (for large-sized motor)
Part No. Applicable axes

For ZD series (JT1,2,3)
50154-1035 For ZT series (JT1,2,3)
For ZX series (JT1,2,3)
50154-1122 For ZH100U (JT1,2,3)
！ 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.
57
Z Series 9. Summary of Motor Replacement Work
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 10. Tasks Before Motor
Replacement.
2. Record the present angle and encoder values of the robot.
3. If the values cannot be recorded, home pose 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 7. 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 home pose.
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 zeroing is executed at the home pose, re-teaching may be required for
high accuracy work.
58
Z Series 10. Tasks Before Motor Replacement
10.0 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 next pages.)
！ 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.
59
ZD series
Replacing JT1,2 Replacing JT3
JT1
JT3
JT2
JT3
JT1
JT2
Replacing JT4
JT4
JT4
60
ZH100U
Replacing JT1,2 Replacing JT3,5
JT3
JT5
JT2 JT1
JT3
JT2 JT1
JT5
Replacing JT4,6
JT4
JT6
JT4
JT6
61
ZT series
JT3 JT3
JT1 JT5
JT2
JT1
JT5
JT2
Replacing JT4,6
JT4
JT6
JT4
JT6
62
ZTX/ZTY series
JT3 JT3
JT1 JT5
JT2
JT1
JT5
JT2
Replacing JT4,6
JT4
JT4
JT6
63
ZX series
JT3
JT5
JT2 JT1
JT3
JT2 JT5
JT1
Replacing JT4,6
JT4
JT6
JT4
JT6
64
Z Series 11. Motor Replacement
11.0 MOTOR REPLACEMENT
！ WARNING
1. When replacing the motor, turn OFF controller power up to the 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 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.
3. Confirm in advance if the trouble can be resolved by replacing only the
encoder.
4. If replacing only the motor and keeping the encoder as it is, it is necessary
to remove the encoder and mount it in a new motor. For this, refer to
“H20 Encoder Replacement Manual”, a separate volume.
！ CAUTION
Grease might flow out when removing the motor. Prepare a

container to catch grease, a rag, and grease for replenishment.
11.1 1.0 KW MOTOR REPLACEMENT
Also, see Appendix: Figures of Motor Replacement.
Model ZD series*
Axes JT4
NOTE* Remove the cover of wrist axis beforehand.
1. Remove the indicated cover.
65
2. Disconnect all connectors from the motor of the axis to be replaced, including connectors for
motor power cable and encoder. (Cut the tying band which ties motor power cables and
encoder signal lines.)
Connector for motor power cable Connector for encoder
3. Unscrew bolts (M8 x 4 Hexagon socket head bolts) fixing servo motor. To unscrew bolts,
use a torque wrench with hexagonal-bar attachment for M8 (Length: approx. 350 mm). Be
careful not to drop the removed bolts inside the arm during the replacement work.
Connector for encoder
Connector for motor power cable
[ NOTE ]
Apply Threadlocker
Input gear
(Loctime 242) on the
locking screw.
M8 hexagon socket head locking

screw
Tightening torque: 7.4 Nm
4. Remove the servo motor.
！ CAUTION
On the tip of motor shaft, gear is mounted. When removing/reconnecting

servo motor, remove it straightly without applying excessive force.
5. Loosen the locking screws on the tip of the removed servo motor, and remove the gear.
！ CAUTION
When removing gear, remove it without applying excessive force
on the servo motor.
66
6. Attach the gear removed in 6. on a new servo motor. Pay attention to the mounting direction
when mounting the gear. Apply Loctite 242 on the hexagon socket head locking screw for
fixing the gear. Tightening torque is 7.4 Nm.
Apply the grease below on the gear.
・Input gear of RV reduction unit …… Multemp FZ
7. Mount the replacement servo motor. Tightening torque is 7.4 Nm.
8. 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.）
9. Reattach the indicated cover.
Model ZD series, ZH100U, ZX series, ZT series

Axes JT4, JT5, JT6
1. Disconnect all connectors from the motor of the axis to be replaced, including connectors for
motor power cable and encoder. (Remove the indicated cover.)
Connector for motor power cable Connector for encoder
M10 hexagon socket

head bolt
2. Unscrew bolts (M10 x 4 Hexagon socket head bolts) fixing servo motor. To unscrew
bolts, use a torque wrench with hexagonal-bar attachment for M10 (Length: approx. 280
mm). Be careful not to drop the removed bolts inside the arm during the replacement
work.
67
！ CAUTION
On the tip of motor shaft, gear is mounted. When removing/reconnecting

servo motor, remove it straightly without applying excessive force.
M10 hexagon socket

head bolt
Stop ring
O-ring
4. Remove the stop ring from the end of the removed servo motor, then remove the gear.
！ CAUTION
When removing gear, remove it without applying excessive force
on the servo motor.
5. Attach the gear removed in 4. on a new servo motor. Apply grease (Multemp FZ) on the
gear.
6. Mount the replacement servo motor. Tightening torque is 44.10 Nm.
7. Re-connect all the connectors including connectors for motor power cable and encoder.
8. Reattach the encoder cover.
！ CAUTION
The limit value of tightening torque for encoder mounting bolt is

1.57 Nm. Be careful not to apply excessive torque because seal
washer becomes deformed and its sealing ability deteriorates if
excessive torque is applied.
68
Model ZD series, ZH100U, ZX series, ZT series

Axes JT1, JT2, JT3
1. Disconnect all connectors from the motor of the axis to be replaced, including connectors
for motor power cable and encoder.
Connector for encoder
M4 Hexagon socket head bolt
Connector for motor power cable
Connector for motor

power cable
Encoder cover
Connector for brake

M12 Hexagon socket
head bolt
2. Unscrew bolts (M12 x 4 Hexagon socket head bolts) fixing servo motor. To unscrew
bolts, use a torque wrench with hexagonal-bar attachment (Length: approx. 280 mm) for
M12. Be careful not to lose or drop the removed bolts inside the rotor tank during the
replacement work.
！ CAUTION
1. If it is difficult to dismount the servo motor, use the taps for
pulling bolts in the motor flange section (M12 x 4).
2. Be careful as the servomotor weighs approximately 30 kg.
69
Be careful as the tapered section of the shaft in the coupling 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 servo motor. Per below, use a jig pipe whose length
corresponds to the model and axis. For JT1 of ZH100U, attach the pulley puller on the gear
directly without using a jig.
ZD/ZT/ZX ZH100U
JT1 58 mm
JT2 55 mm 40 mm
JT3 44 mm 36 mm
Be careful not to apply excessive force on the motor and encoder sections at this time. Also,
loosen the center bolt of the coupling gear tip for approximately 5 mm.
Coupling gear
Approx. 5 mm
Center bolt
Loosen the center bolt as shown above,
Rod Bolt and confirm bolt is still attached. For
Pipe Coupling gear
safety, follow this procedure without fail
Center bolt since it can act as stopper when
disconnecting coupling gear.
5. Set pulley puller to the jig.
Pulley puller
Bar 70
6. Remove the coupling gear from the tapered shaft via pulley puller.
！ CAUTION
Be careful when removing the coupling gear. If it is tightened too

strongly, it may come out suddenly. Also, it may hit the center bolt
head (stopper).
7. Apply a thin coat of grease (Multemp FZ) on the taper shaft section, and attach coupling gear
on it. (Never use molybdenum grease with antifriction composition.)
8. Tighten center bolt into the coupling gear firmly applying 56.84 Nm torque. Then, unscrew
the center bolt, apply Loctite on the bolt and remount it. (Apply Threebond 1206C/D
between the coupling gear and end plate.) Grip and hold the flat part of coupling gear steady
with a wrench when tightening and loosening as the motor brake might slip.
！ CAUTION
If gear is attached without loosening after applying 56.84 Nm torque,

gear removal may be impossible the next time it is serviced. After
tightening with 56.84 Nm torque, loosen then retighten with 17.15 Nm
torque without fail.
9. Reassemble the motor. Tightening torque: 78.40 Nm. Apply grease for gear (Multemp
FZ) on the gear.
10. Re-connect all the connectors including connectors for motor power cable and encoder.
11. Remount the encoder cover.
！ CAUTION
The limit value of tightening torque for encoder mounting bolt is 1.57
Nm. Be careful not to apply excessive torque because seal washer
becomes deformed and its sealing ability deteriorates if excessive
torque is applied.
71
Z Series Appendix: Figure of Motor Replacement
APPENDIX: FIGURES OF MOTOR REPLACEMENT
● ZD series
Motor for JT3
Motor for JT4
Motor for JT2

Cover
Motor for JT1
● ZH100U ● ZT series
Motor for JT1
Motor for JT2

Motor for JT4
Motor for JT5

Motor for JT5
Motor for JT4
Motor for JT6

Motor for JT3
Motor for JT1 Motor for JT6

Motor for JT3
Motor for JT2
72
Z Series Appendix: Figure of Motor Replacement
● ZTX/ZTY series ● ZX series
Motor for JT6

Motor for JT1
Motor for JT3
Motor for JT2
Motor for JT5
Motor for JT4

Motor for JT4
Motor for JT5
Motor for JT6

Motor for JT2
Motor for JT3
Motor for JT1
73
Z Series
74
KAWASAKI ROBOT E Series Controller
Z Series
Zeroing & Motor Replacement Manual
February 2010 : 1st Edition
Publication: KAWASAKI HEAVY INDUSTRIES, LTD.
90213-1054DEA
Copyright© 2010 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.

90213-1054DEA - Zeroing & Motor Repleacement (Z Series)

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Kawasaki Robot

Zeroing & Motor

Kawasaki Heavy Industries, Ltd.

Failure to comply with indicated matters can result in

Failure to comply with indicated matters may

Failure to comply with indicated matters may lead to

1. The accuracy and effectiveness of the diagrams, procedures, and detail

2.0 Resetting the Encoder Rotation Counter ................................................................................. 6

3.0 Simple Zeroing for All Axes.................................................................................................. 13

4.0 Simple Zeroing for Individual Axis....................................................................................... 16

5.0 Precision Zeroing ................................................................................................................... 22

6.0 Precautions to be Taken at Motor Replacement.................................................................... 54

7.0 Outline of Motor Replacement .............................................................................................. 55

8.0 Prior to Motor (Encoder) Replacement ................................................................................. 56

9.0 Summary of Motor Replacement Work ................................................................................ 57

10.0 Tasks Before Motor Replacement ......................................................................................... 59

11.0 Motor Replacement................................................................................................................ 65

Appendix: Figures of Motor Replacement....................................................................................... 72

1.0 OUTLINE OF ZEROING

The outline of the zeroing is as shown below:

Reset encoder rotation counter

Reset encoder rotation counter Precision zeroing

For precision zeroing, use the following instruments and jigs:

(Angle) Mfd. by KHI

(Plate) Mfd. by KHI (Angle) Mfd. by KHI (Plate) Mfd. by KHI

NOTE* Refer to Chapter 9.0 for length.

2.0 RESETTING THE ENCODER ROTATION COUNTER

2.1 RESETTING THE ENCODER ROTATION COUNTER

CONTROLLER POWER EMERGENCY STOP TEACH/REPEAT

For manual operation, set switches on the operation panel as follows:

Turn ON controller power. Turn the TEACH/REPEAT

JT4 zero point

JT3 zero point

JT1 zero point

At the HOME pose, make

zero scribe mark

JT6 zero point JT4 zero point

JT3 zero point

JT1 zero point

At the HOME pose, make

zero scribe mark

JT1 zero point

JT4 zero point

JT5 zero point

JT6 zero point

JT2 zero point JT3 zero point

At the HOME pose, make

zero scribe mark

JT1 zero point

JT4 zero point

JT5 zero point

JT6 zero point

JT3 zero point

At the HOME pose, make

zero scribe mark

JT6 zero point

JT5 zero point

JT2 zero point

JT1 zero point

At the HOME pose, make

zero scribe mark

2.2 RESETTING THE ENCODER ROTATION COUNTER FOR ZEROING

1. Turn OFF motor power by pressing EMERGENCY STOP.