Kawasaki Robot
KF19/26

Installation andConnection Manual
E Controller

Kawasaki Heavy Industries, Ltd.

90202-1116DEAKF19/26 Series
Kawasaki Robot

Installation and Connection Manual

PREFACEThis manual describes the installation and connection of Kawasaki Painting Robot KF19/26
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.
This manual describes only the installation and connection of KF19/26 series robot arm. For
installation and connection of the controller and cables, see the separate manual “Installation andConnection Manual” for the controller for explosion-proof robot.
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 models.
KF192, KF262
KF193, KF263
KF194, KF264

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 writtenconsent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot isreinstalled or moved to a different site or sold off to a different user, attach this manual to therobot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2010 Kawasaki Heavy Industries Ltd . All rights reserved.
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KF19/26 Series
Kawasaki Robot

Installation and Connection Manual

SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage bycomplying 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 tophysical 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 absolutecertainty. Accordingly, it is necessary to give one’s fullest attention whenusing 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 eachchapter, and prepare safety measures suitable for actual work.

2

KF19/26 Series
Kawasaki Robot

Installation and Connection Manual

CONTENTS
1.0
1.1
1.2
1.3
1.4

Precautions.............................................................................................................................. 4
Precautions during Transportation and Storage..................................................................... 4
Installing Environment of Robot Arm................................................................................... 5
Cautionary Instructions for Explosion-Proof......................................................................... 6
Warning Label ........................................................................................................................ 7

2.0

Motion Range & Specifications of Robot ............................................................................. 9

3.0

Work Flow at Arm Installation and Connection ................................................................. 17

4.0
4.1

Robot Transportation Method.............................................................................................. 18
Wire Sling ............................................................................................................................. 18

5.0

Installing Dimensions of Base Section ................................................................................ 21

6.0

Installation Space.................................................................................................................. 22

7.0

Installation Method............................................................................................................... 26

8.0
8.1
8.2
8.3

Mounting of Tools................................................................................................................ 28
KF192/262 ............................................................................................................................ 28
KF193/263 ............................................................................................................................ 32
KF194/264 ............................................................................................................................ 37

9.0
9.1
9.2
9.2.1
9.2.2

Connection of Air System .................................................................................................... 42
Explosion-Proof Specifications............................................................................................ 42
Air Supply to Robot Arm..................................................................................................... 42
Japan Explosion-Proof Specification................................................................................... 42
China Explosion-Proof Specification .................................................................................. 43

3

KF19/26 Series
Kawasaki Robot

1. Precautions
Installation and Connection Manual

1.0 PRECAUTIONSThis chapter only describes safety precautions during installation and connection of the robot arm.
For all other safety matters, refer to the “Safety Manual”, a separate-volume.
1.1 PRECAUTIONS DURING TRANSPORTATION AND STORAGE
When transporting the Kawasaki Robot to its installation site, strictly observe the following
cautions.

！

WARNING

1.

When the robot arm is to be transported by using a crane or forklift,
never support the robot arm manually.
2. During transportation, never climb on the robot arm or stay out
from under the lifted robot arm.

！
1.
2.

3.

CAUTION

Since the robot arm is composed of precision parts, be careful not toapply excessive shocks or vibrations during transportation.
Prior to installation, remove all obstacles so the installation is carriedout smoothly and safely. Clear a passage to the installation area fortransportation of the robot arm using a crane or forklift.
During transportation and storage,(1) keep the ambient temperature within the range of minus 10 60C,(2) keep the relative humidity within the range of 35 - 85% RH
without dew condensation,(3) keep free from excessively strong vibration.

4

KF19/26 Series
Kawasaki Robot

1. Precautions
Installation and Connection Manual

1.2 INSTALLING ENVIRONMENT OF ROBOT ARM
The robot arm must be installed in a place that satisfies all the following environmental
conditions:
1. When robot is installed on the floor, the levelness must be within 5.
2. Be sure that the installation floor/pedestal has sufficient rigidity.
3. Secure a flatness to prevent undue force applied to the installation section. (If sufficient
flatness is unobtainable, insert liners and adjust the flatness within 0.3 mm.)
4. Keep the ambient temperature during operation within the range of 0 - 40 °C. (Deviation or
overload error may occur due to high viscosity of grease/oil when starting operation at low
temperatures. In this case, perform warm-up operation at low speed before regular
operation.)
5. Keep the relative humidity during operation within the range of 35-85 %RH without dew
condensation.
6. The robot installing place should be free from dust, dirt, smoke, water, and other foreign
matters.
7. The robot installing place should be free from excessively strong vibration.
8. The robot installing place should be free from electric noise interference.
9. The robot installing place should be sufficiently larger than the motion range of robot arm.
(1) Install safety fence so the maximum movement of fully equipped robot arm (with tools)
does not cause interference.
(2) Provide an entrance door with a safety plug for the safety fence.
(3) Follow national local standards regarding safety fence construction/function.
(e.g. EN953, EN294, EN811, EN1088, ISO13852, ISO13854, ISO/NP14120)
Approx.1 m

A door withsafety plug
Motion range of robot
Approx.1 m
MechanicalstopperApprox.1 m

Safety fence
Approx.1 m

MechanicalstopperApprox.1 m[ NOTE ]Protect sealed joints, etc. on the robot arm axes with vinyl sheets, etc. toprevent paint mist/foreign materials from entering.
5

KF19/26 Series
Kawasaki Robot

1. Precautions
Installation and Connection Manual

1.3 CAUTIONARY INSTRUCTIONS FOR EXPLOSION-PROOF
KF19/26 series robot is an explosion-proof robot protected by pressurized and intrinsically safe
structures. Strictly observe the following instructions for safe operation.

！
1.

2.

DANGER

This painting robot has pressurized enclosures for explosion-proof specifications.
Before loosening the bolts from any pressurized enclosure, always follow
instructions from the person in charge.
(1) Do not loosen tightening bolts of pressurized enclosures without instructions
from the person in charge.
(2) Do not open the cover of a pressurized enclosure while electricity is supplied torobot.
Install controller in a non-hazardous area where there is no possibility of
explosion. Before accessing the robot for maintenance, inspection, or for
inspection and adjustments of painting equipment, always turn OFF controller
power up to the external power switch for shutting off power supply to the robot
controller, close the air supply valve and confirm there is no residual pressure in
any air supply lines.

Non-hazardous area

Hazardous area

Teachpendant

Robot arm

Controller

Air supply source(0.4-0.7 MPa)6

KF19/26 Series
Kawasaki Robot

1. Precautions
Installation and Connection Manual

1.4 WARNING LABEL！

WARNING

During operations, pay attention to the warning labels on
the robot exterior as shown in the figures below.

KF192, KF262

Warning label for pinching
Warning label for hightemperature

7

KF19/26 Series
Kawasaki Robot

1. Precautions
Installation and Connection Manual

KF193, KF263

KF194, KF264

Warning label for pinching

8

Warning label for hightemperatureKF19/26 Series
Kawasaki Robot

2. Motion Range and Specifications of Robot
Installation and Connection Manual

2.0 MOTION RANGE & SPECIFICATIONS OF ROBOTDETERMINATION OF SAFETY FENCE INSTALLATION LOCATION
The figure below shows the robot with BBR type of wrist.
Motion range of Point P
Point P

Tool

Point P

Safety Fence

Tool
Point P
Point P
Motion rangeof Point P

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KF19/26 Series
Kawasaki Robot

2. Motion Range and Specifications of Robot
Installation and Connection Manual

The figure below shows the robot with 3R type of wrist.
Motion range of Point P
Point P

Tool

Point P

Safety Fence

Tool

Point P
Motionrange of
Point P

The motion range of robot arm is represented by Point P in the figure above. Accordingly, thedimensions of safety should be calculated as follows: Determine sum of L0, L1 and L2 as
minimum dimension. That is: dimension from the center of arm (Point A shown in the figure
above) to the center of wrist (=L0) + dimension from the center of wrist to the edge of tool (=L1)+ dimension of allowance (=L2).
10

KF19/26 Series
Kawasaki Robot

2. Motion Range and Specifications of Robot
Installation and Connection Manual

KF192

Wrist partType

Articulated robot

Degree offreedom

6

Motion range

JT

Motion range

1

±150

2

+110 - -60

3+90 - -80

4

±360

5

±360

6

±360
Wrist section: 12 kg (on flange)
Forearm section:20 kg

Load capacity
Wrist load
capacity

JT

TorqueMoment of inertia

4

33.3 Nm

1.28 kgm2

5

28.8 Nm

0.96 kgm2

Repeatability

7.9 Nm
0.10 kgm2±0.5 mm (Face of wrist flange)

Mass

Approx. 690 kg

Acoustic noise

74 dB (A)*6

11

NOTE* measured condition:
・installed on the plate rigidly fixed on
the floor
・3200 mm away from JT1 rotation
center(The noise level depends on theconditions.)

KF19/26 Series
Kawasaki Robot

2. Motion Range and Specifications of Robot
Installation and Connection Manual

KF262

Wrist partType

Articulated robot

Degree offreedom

6

Motion range

JT

Motion range

1

±150

2

+110 - -60

3+90 - -80

4

±360

5

±360

6

±360
Wrist section: 12 kg (on flange)
Forearm section:20 kg

Load capacity

Wrist load
capacity

JT

TorqueMoment of inertia

4

33.3 Nm

1.28 kgm2

5

28.8 Nm

0.96 kgm2

Repeatability

7.9 Nm
0.10 kgm2±0.5 mm (Face of wrist flange)

Mass

Approx. 720 kg

Acoustic noise

74 dB (A)＊6

12

NOTE* measured condition:
・installed on the plate rigidly fixed on
the floor
・3900 mm away from JT1 rotation
center(The noise level depends on theconditions.)

KF19/26 Series
Kawasaki Robot

2. Motion Range and Specifications of Robot
Installation and Connection Manual

KF193

Wrist partType

Articulated robot

Degree offreedom

6

Motion range

JT

Motion range

1

±150

2

+110 - -60

3+90 - -80

4

±720

5

±720

6

±410
Wrist section: 12 kg (on flange)
Forearm section:20 kg

Load capacity

Wrist load
capacity

JT

TorqueMoment of inertia

4

33.1 Nm

1.27 kgm2

26.7 Nm

2

50.82 kgm

Repeatability

7.9 Nm
0.10 kgm2±0.5 mm (Face of wrist flange)

Mass

Approx. 720 kg

Acoustic noise

74 dB (A)*6

13

NOTE* measured condition:
・installed on the plate rigidly fixed on
the floor
・3200 mm away from JT1 rotation
center(The noise level depends on theconditions.)

KF19/26 Series
Kawasaki Robot

2. Motion Range and Specifications of Robot
Installation and Connection Manual

KF263

Wrist partType

Articulated robot

Degree offreedom

6

Motion range

JT

Motion range

1

±150

2

+110 - -60

3+90 - -80

4

±720

5

±720

6

±410
Wrist section: 12 kg (on flange)
Forearm section:20 kg

JT

TorqueMoment of inertia

4

33.1 Nm

1.27 kgm2

5

26.7 Nm

0.82 kgm2

Load capacity

Wrist load
capacity
Repeatability

7.9 Nm
0.10 kgm2±0.5 mm (Face of wrist flange)

Mass

Approx. 740 kg

Acoustic noise

74 dB (A)*6

14

NOTE* measured condition:
・installed on the plate rigidly fixed on
the floor
・3900 mm away from JT1 rotation
center(The noise level depends on theconditions.)

KF19/26 Series
Kawasaki Robot

2. Motion Range and Specifications of Robot
Installation and Connection Manual

KF194

Wrist partType

Articulated robot

Degree offreedom

6

Motion range

JT

Motion range

1

±150

2

+110 - -60

3+90 - -80

4

±720

5

±720

6

±410
Wrist section: 12 kg (on flange)
Forearm section:20 kg

JT

TorqueMoment of inertia

4

35.3 Nm

1.44 kgm2

5

27.7 Nm

0.89 kgm2

Load capacity

Wrist load
capacity
Repeatability

7.9 Nm
0.10 kgm2±0.5 mm (Face of wrist flange)

Mass

Approx. 750 kg

Acoustic noise

74 dB (A)*6

15

NOTE* measured condition:
・installed on the plate rigidly fixed on
the floor
・3200 mm away from JT1 rotation
center(The noise level depends on theconditions.)

KF19/26 Series
Kawasaki Robot

2. Motion Range and Specifications of Robot
Installation and Connection Manual

KF264

Wrist partType

Articulated robot

Degree offreedom

6

Motion range

JT

Motion range

1

±150

2

+110 - -60

3+90 - -80

4

±720

5

±720

6

±410
Wrist section: 12 kg (on flange)
Forearm section:20 kg

JT

TorqueMoment of inertia

4

35.3 Nm

1.44 kgm2

27.7 Nm

2

Load capacity

Wrist load
capacity

50.89 kgm

Repeatability

7.9 Nm
0.10 kgm2±0.5 mm (Face of wrist flange)

Mass

Approx. 770 kg

Acoustic noise

74 dB (A)*6

16

NOTE* measured condition:
・installed on the plate rigidly fixed on
the floor
・3900 mm away from JT1 rotation
center(The noise level depends on theconditions.)

KF19/26 Series
Kawasaki Robot

3. Work Flow at Arm Installation and Connection
Installation and Connection Manual

3.0 WORK FLOW AT ARM INSTALLATION AND CONNECTION

Actual Work

Preparation

This flowchart describes only the robot arm section. For the controller, refer to separate
Installation and Connection Manual for Explosion-proof robot controller.
Examination of Installation
Place and Motion Range

Refer to 2. Motion Range & Specifications of
Robot.

Examination & Preparation of
Installation Plane Surface

Refer to 4. Robot Transportation Method, 5.
Installing Dimensions of Base Section, 6.
Installation Space, 7. Installation Method.

Transportation of Robot Arm

Refer to 4. Robot Transportation Method.

Installation of Robot Arm

Refer to 5. Installing Dimensions of Base
Section, 6. Installation Space, 7. Installation
Method.

Refer to 8. Mounting of Tools and9. Connection of Air System.

Work Using Controller

Mounting of Tools

Connection to Controller

Refer to Installation and Connection Manualfor explosion-proof robot controller.

Check of Arm Motion
Check of Tool Motion

Refer to Operation Manual.

Check of Other Functions

Refer to Operation Manual.

Completion of Work17

KF19/26 Series
Kawasaki Robot

4. Robot Transportation Method
Installation and Connection Manual

4.0 ROBOT TRANSPORTATION METHOD
4.1 WIRE SLING
Place the wires on both sides of the arm by using the four M16 eyebolts on the arm and hoist the
robot as shown in the figures below.

！
1.
2.

WARNING

Adjust the length of wire using chain block, etc. because the height of front
eyebolts differs from that of rear eyebolts.
When hoisting up robot, be careful as robot may lean forward/backward/
left/right depending on the robot posture. Be sure to hoist the robot in thespecified hoisting postures below, otherwise it may swing excessively or the wire
may interfere with other objects, resulting in damage. In places where wire
touches the arm, protect arm with board, cloth, etc.

Model

KF192

KF262

JT1

0

0

JT2

-40

-58

JT3

-77

-77

JT4

90

0

JT5

0

0

JT6

0

0

Hoisted posture

Hoisting
posture18

KF19/26 Series
Kawasaki Robot

4. Robot Transportation Method
Installation and Connection Manual

Model

KF193

KF263

JT1

0

0

JT2

-58

-58

JT3

-77

-77

JT4

0

0

JT5

0

0

JT6

0

0

Hoisted posture

Hoisting
posture19

KF19/26 Series
Kawasaki Robot

4. Robot Transportation Method
Installation and Connection Manual

Model

KF194

KF264

JT1

0

0

JT2

-58

-58

JT3

-77

-77

JT4

0

0

JT5

0

0

JT6

0

0

Hoisted posture

Hoisting
posture20

KF19/26 Series
Kawasaki Robot

5. Installing Dimensions of Base Section
Installation and Connection Manual

5.0 INSTALLING DIMENSIONS OF BASE SECTION
When installing the robot arm, fix it firmly on the foundation with high-tension bolts through thebolt holes on the base section.
Model

KF19/26 series

Drill

Installing
dimensions ofbase section

Cross-sectionof installation
bolt hole

Bolt holes

8-18High tension
bolts

8-M16
Material: SCM435
Strength: 10.9 min.

Tightening
torque235 Nm

Levelness

Within ±5

！

CAUTIONBe sure to install the arm on a surface with flatness of
0.3 mm or less, otherwise robot arm may suffer damage.

21

KF19/26 Series
Kawasaki Robot

6. Installation Space
Installation and Connection Manual

6.0 INSTALLATION SPACEWhen installing the robot arm, secure the installation space for maintenance purposes as shown
below.
1.

2.

For maintenance, keep clearance of at least 600 mm behind the robot arm, at least 500 mm
from the center of the arm on right side of the base, and at least 700 mm from the center of
the arm on left side of the base.
Keep clearance of at least 800 mm above the arm for lifting the robot.

！

CAUTION

This chapter provides the maintenance space in robot arm
installation. For installation space of safety fence, refer to 2.0
Motion Range and Specifications.

22

KF19/26 Series
Kawasaki Robot

6. Installation Space
Installation and Connection Manual

KF192 [Dimension in ( ) shows that of KF262.]

Clearance for lifting

HoistedpostureClearance for maintenance
Clearance for maintenance23

KF19/26 Series
Kawasaki Robot

6. Installation Space
Installation and Connection Manual

KF193 [Dimension in ( ) shows that of KF263.]

Clearance for lifting

HoistedpostureClearance for maintenance
Clearance for maintenance24

KF19/26 Series
Kawasaki Robot

6. Installation Space
Installation and Connection Manual

KF194 [Dimension in ( ) shows that of KF264.]

Clearance for lifting

HoistedpostureClearance for maintenance
Clearance for maintenance25

KF19/26 Series
Kawasaki Robot Installation and Connection Manual

7. Installation Method

7.0 INSTALLATION METHOD
1. When installing the base section of the arm directly on the floor:
In this case, embed steel plate (28 mm Min. thick) in the concrete floor and fix the base section
on it as shown in the figure below or fix the base section directly on the concrete floor withanchors. Fix the steel plate firmly enough to endure the reaction forces produced by the
robot.

Tightening torque:
235 Nm
25
min.

Steel plate
Concrete

28
min.

Model

KF19/26 series

M(Inversion moment)

16000 Nm

T
(Rotating torque)16000 Nm

26

KF19/26 Series
Kawasaki Robot Installation and Connection Manual

7. Installation Method

2. When installing the base section of the arm with the robot base plate (option) (The figure below
is an example.)Do foundation work, etc., referring to the example of arm installation with a base plate shown
below. Fix the base plate on concrete floor or steel floor using 4 of 19 bolt holes on the baseplate and install the arm. (Robot base plate is an option.)
The reaction force received from the robot is same with that when installing the base section of
the arm directly on the floor.
10(for 10 positioning pin)

4-19

10
(for 10 positioning pin)

8-M16 Penetrated

10(for 10 positioning pin)

Base plate

Concrete

Model

KF19/26 series

D16 mmL

25 mm min.
27

KF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

8.0 MOUNTING OF TOOLS！

WARNING

Prior to mounting tools on the robot, turn OFF the controller power switch
and the external power switch. Display signs indicating clearly “Installationand connection in progress”, and lockout/tagout the external power switch toprevent personnel from accidentally turning ON the power.

8.1 KF192/262
1. Dimensions of wrist end (flange)
In the robot arm end section, a flange is provided on which tools are mounted. Screw themounting bolts into the tap holes on the circumference of 40 on the flange, referring to thefigure below. Moreover, position the tool by utilizing the pin hole and the spigot hole.

Cross-section A-A

28

KF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

2. Specification of mounting bolts
Select mounting bolts with proper length to secure the specified engagement length. Use hightension mounting bolts and tighten them to the torque specified in the table below.
Check tightening
torque.
Mounting bolt
Tool flange
Check screwing
depth

Tap depth

Tool mounting
flange！

CAUTION

If the engagement length has exceeded thespecified value, the mounting bolt might bottom
out, and the tool will not be fixed securely.

29

Model

KF192/262

Tap hole

6-M6

P.C.D

40

Pin

6m6 Length 7.5

Spigot hole

25H7

Tap depth

9 mm

Length ofengagement

7.5 - 8.5 mm

High tension
bolt

SCM435, 10.9 min

Tightening
torque11.76 Nm

KF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

3. Calculating the load on wrist axis
(1) The maximum load capacity of the robot is specified per robot model.
(2) Strictly observe the limiting conditions for load torque and load moment of inertia aroundeach wrist axis (JT4, JT5, JT6) as shown below.

！

WARNING

Exceeding the specified load capacity may cause deterioration in
motion performance and shorten the life of robot. The specified
load capacity includes the mass of all attachments such as spray gun,gun bracket, piping/wiring, etc. If total mass exceeds the capacity
specification, consult Kawasaki before starting operations.

The load torque and the moment of inertia can be calculated by the following formula.

Calculating formula for KF192/262

Load mass: M≦Mmax.(kg)Load torque: T=9.8･ML(Nm)
Load moment of inertia : I=ML2(kgm2)
M: Load mass
Mmax.: 12 kg
L(4～6): Length from center of rotation axis toload center of gravity. (Unit: m) (See theleft figure.)
L 4  (L 6  0.14) 2  (L T  0.1) 2 (m)L 5  L 6 2  (L T  0.1) 2 (m)Load center of gravity

30

KF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

Adhere to the following limiting conditions for the load torque and the load moment of inertia
around each wrist axis.

KF192/262
Kgm2
4
3.66

Load moment of inertia

3

JT4

2.61

JT5

2

1.28
1
0.96
0.56

JT6

0.10
0

7.9 1020

28.8

Load torque

31

30

33.3

40 NmKF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

8.2 KF193/263！

WARNING

Prior to mounting tools on the robot, turn OFF the controller power switch
and the external power switch. Display signs indicating clearly “Installationand connection in progress”, and lockout/tagout the external power switch toprevent personnel from accidentally turning ON the power.

1. Dimensions of wrist end (flange)
In the robot arm end section, a flange is provided on which tools are mounted. Screw themounting bolts into the tap holes on the circumference of 102 on the flange, referring to thefigure below. Moreover, position the tool by utilizing the pin hole and the spigot hole.

O ring* S112

Cross-section A-A

32

NOTE* When removing or
replacing tools,
replace the O-ring,too.
Details of BKF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

2. Specification of mounting bolt
Select mounting bolts with proper length to secure the specified engagement length. Use hightension mounting bolts and tighten them to the torque specified in the table below.
Check tightening
torque.
Mounting bolt
Tool flange
Check screwing
depth

Tap depth

Tool mounting
flange！

CAUTION

If the engagement length has exceeded thespecified value, the mounting bolt might bottom
out, and the tool will not be fixed securely.

33

Model

KF193/263

Tap hole

6-M6

P.C.D

102

Pin

5m6 Length 7.5

Spigot hole

116h7

Tap depth

14 mm

Length ofengagement

9 - 12 mm

High tension
bolt

SCM435, 10.9 min

Tightening
torque11.76 Nm

KF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

3. Calculating the load on wrist axis
(1) The maximum load capacity of the robot is specified per robot model.
(2) Strictly observe the limiting conditions for load torque and load moment of inertia aroundeach wrist axis (JT4, JT5, JT6) as shown below.

！

WARNING

Exceeding the specified load capacity may cause deterioration in
motion performance and shorten the life of robot. The specified
load capacity includes the mass of all attachments such as spray gun,gun bracket, piping/wiring, etc. If total mass exceeds the capacity
specification, consult Kawasaki before starting operations.

The load torque and the moment of inertia can be calculated by the following formula.
Calculating formula for KF193/263

Load mass: M≦Mmax.(kg)Load torque: T=9.8･M･L(Nm)
Load moment of inertia : I=M･L2(kgm2)
M: Load mass
Mmax.: 12 kg
L(4～6): Length from center of rotation axis toload center of gravity. (Unit: m) (Seethe left figure.)
L4= LTsin60+ L6cos30+0.156 (m)L5= LTsin60+ L6cos30+0.083 (m)Load center of gravity

34

KF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

Adhere to the following limiting conditions for the load torque and the load moment of inertia
around each wrist axis.
KF193/263
Kgm2

Load moment of inertia

3

2.32
JT4
2
1.51

JT5

1.27
1
0.82
0.28
0.10
0

JT6

7.9 1020
Load torque

35

26.7

30

33.1

40 NmKF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

4. Hose(s) housed in the wrist(1) Inside diameter of wrist of KF193/263 is 40.
The recommended volume ratio of the housed hose(s) is less than 25 %.*d2
D2
volume ratio =n 
100［%］44Area of hose(s) Area of wrist hollow

d x n (number of hoses)！

CAUTION

If the volume ratio of the housed hose(s) exceeds the recommended volume
ratio, hose lifetime may shorten significantly. The hose lifetime also changes
depending on the wrist posture and the motion angle. Moreover, even ifvolume ratio is less than 25 %, hose lifetime may become short greatly
depending on motion conditions. Accordingly, fully examine and test thehose(s) and their arrangement in wrist before starting operations.
NOTE* Consult Kawasaki at application study stage if volume ratio is required to exceed
25 % or when using a hose with 12 or greater diameter.
(2) Nylon is the recommended material for the housed hose.

！

CAUTION

Using a non-nylon hose may significantly reduce hose lifetime.
(3) When housing the hose in the wrist, always apply lubricants, such as vaseline etc., to theentire hose. Inspect the housed hoses regularly** and replace them when any indicationof failure or damage is found.
Recommended inspection period: every 500 hours
Replacement period of hoses (estimated): every 10000 hours
NOTE** Also, whenever inspecting hoses, apply lubricants to the entire housed hoses.
[ NOTE ]The above replacement period is a recommended standard and is not meant
as a period guaranteeing the life of the hoses.
36

KF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

8.3 KF194/264！

WARNING

Prior to mounting tools on the robot, turn OFF the controller power switch
and the external power switch. Display signs indicating clearly “Installationand connection in progress”, and lockout/tagout the external power switch toprevent personnel from accidentally turning ON the power.

1. Dimensions of wrist end (flange)
In the robot arm end section, a flange is provided on which tools are mounted. Screw themounting bolts into the tap holes on the circumference of 102 on the flange, referring to thefigure below. Moreover, position the tool by utilizing the pin hole and the spigot hole.

O ring* S112

NOTE* When removing or
replacing tools,
replace the O-ring,too.
Cross-section A-A

37

Details of BKF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

2. Specification of mounting bolt
Select mounting bolts with proper length to secure the specified engagement length. Use hightension mounting bolts and tighten them to the torque specified in the table below.
Check tightening
torque.
Mounting bolt
Tool flange
Check screwing
depth

Tap depth

Tool mounting
flange！

CAUTION

If the engagement length has exceeded thespecified value, the mounting bolt might bottom
out, and the tool will not be fixed securely.

38

Model

KF194/264

Tap hole

6-M6

P.C.D

102

Pin

5m6 Length 7.5

Spigot hole

116h7

Tap depth

14 mm

Length ofengagement

9 - 12 mm

High tension
bolt

SCM435, 10.9 min

Tightening
torque11.76 Nm

KF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

3. Calculating the load on wrist axis
(1) The maximum load capacity of the robot is specified per robot model.
(2) Strictly observe the limiting conditions for load torque and load moment of inertia aroundeach wrist axis (JT4, JT5, JT6) as shown below.

！

WARNING

Exceeding the specified load capacity may cause deterioration in
motion performance and shorten the life of robot. The specified
load capacity includes the mass of all attachments such as spray gun,gun bracket, piping/wiring, etc. If total mass exceeds the capacity
specification, consult Kawasaki before starting operations.

The load torque and the moment of inertia can be calculated by the following formula.

Calculating formula for KF194/264

Load mass: M≦Mmax.(kg)Load torque: T=9.8･ML(Nm)
Load moment of inertia : I=ML2(kgm2)

Load center of gravity

M: Load mass
Mmax.: 12 kg
L(4～6): Length from center of rotation axis toload center of gravity. (Unit: m) (See theleft figure.)
L4= LTsin60+ L6cos30+0.181 (m)L5= LTsin60+ L6cos30+0.094 (m)39

KF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

Adhere to the following limiting conditions for the load torque and the load moment ofinertia around each wrist axis.
KF194/264

Kgm2

Load moment of inertia

3

2.56
JT4
2
1.61

JT5

1.44
1
0.89
0.28
0.10
0

JT6

7.9 1020
Load torque

40

27.7

30

35.3

40 NmKF19/26 Series
Kawasaki Robot

8. Mounting of Tools
Installation and Connection Manual

4. Hose(s) housed in the wrist(1) Inside diameter of wrist of KF194/264 is 70.
The recommended volume ratio of the housed hose(s) is less than 25 %.*volume ratio =

d2
D2
n 
100［%］44Area of hose(s) Area of wrist hollow

d x n (number of hoses)！

CAUTION

If the volume ratio of the housed hose(s) exceeds the recommended volume
ratio, hose lifetime may shorten significantly. The hose lifetime also changes
depending on the wrist posture and the motion angle. Moreover, even ifvolume ratio is less than 25 %, hose lifetime may become short greatly
depending on motion conditions. Accordingly, fully examine and test thehose(s) and their arrangement in wrist before starting operations.
NOTE* Consult Kawasaki at application study stage if volume ratio is required to exceed
25 % or when using a hose with 12 or greater diameter.
(2) Nylon is the recommended material for the housed hose.

！

CAUTION

Using a non-nylon hose may significantly reduce hose lifetime.
(3) When housing the hose in the wrist, always apply lubricants, such as vaseline etc., to theentire hose. Inspect the housed hoses regularly** and replace them when any indicationof failure or damage is found.
Recommended inspection period: every 500 hours
Replacement period of hoses (estimated): every 10000 hours
NOTE** Also, whenever inspecting hoses, apply lubricants to the entire housed hoses.
[ NOTE ]The above replacement period is a recommended standard and is not meant
as a period guaranteeing the life of the hoses.
41

KF19/26 Series
Kawasaki Robot

9. Connection of Air System
Installation and Connection Manual

9.0 CONNECTION OF AIR SYSTEM
9.1 EXPLOSION-PROOF SPECIFICATIONSKF19/26 series robot is an explosion-proof specified robot protected by pressurized and intrinsicallysafe structures.
9.2 AIR SUPPLY TO ROBOT ARM
9.2.1 JAPAN EXPLOSION-PROOF SPECIFICATION
Air connecting port is provided in base section of robot arm as shown in the figure below.
Supply the air from port A (Tube diameter 12) in rear of robot arm.
Robot arm side regulator (in operation)
Pressure setting: 0.010 MPa
Robot arm side regulator (in purging)
Pressure setting: 0.085 MPa

Robot arm side regulator (in operation)
Pressure setting: 0.010 MPa
Robot arm side regulator (in purging)
Pressure setting: 0.085 MPa

Port A
Tube diameter ø 12

Port A
Tube diameter ø 12

Pilot air for external axis
Tube diameter 8

Pilot air for external axis
Tube diameter 8

Robot (rear)*Spec. in which separate harness
is pulled out from right side

Robot (rear)*Spec. in which separate harness
is pulled out from left side！

CAUTION

Do not change regulator setting on side of robot arm as it isadjusted at factory shipment.

！

CAUTIONUse clean air that meets specifications below.
1. Solid material ....0.01 m or less
2. Oil content .........Mist separation: 99.9999 % or more
3. Humidity............Dew point: -17 C or less at atmospheric pressure.
4. Input pressure...0.4 ~ 0.7 MPa (4.1 - 7.1 kgf/cm2)
5. Input quantity ...300 L/min. (nor) (Only at purging)
When purging completes, the air operated valve set on exhaust side closes. After that, airconsumption is minimized to only a little air leakage from various sealed sections.
42

KF19/26 Series
Kawasaki Robot

9. Connection of Air System
Installation and Connection Manual

9.2.2 CHINA EXPLOSION-PROOF SPECIFICATION
Air connecting port is provided in base section of robot arm as shown in the figure below.
Supply the air from port A (Tube diameter 12) in rear of robot arm.
Robot arm side regulator (in operation)
Pressure setting: 0.010 MPa
Robot arm side regulator (in purging)
Pressure setting: 0.110 MPa

Robot arm side regulator (in operation)
Pressure setting: 0.010 MPa
Robot arm side regulator (in purging)
Pressure setting: 0.110 MPa

Port A
Tube diameter ø 12

Port A
Tube diameter ø 12

Pilot air for external axis
Tube diameter 8

Pilot air for external axis
Tube diameter 8

Robot (rear)*Spec. in which separate harness
is pulled out from right side

Robot (rear)*Spec. in which separate harness
is pulled out from left side！

CAUTION

Do not change regulator setting on side of robot arm as it isadjusted at factory shipment.

！

CAUTIONUse clean air that meets specifications below.
1. Solid material ....0.01 m or less
2. Oil content .........Mist separation: 99.9999 % or more
3. Humidity............Dew point: -17 C or less at atmospheric pressure.
4. Input pressure...0.4 ~ 0.7 MPa (4.1 - 7.1 kgf/cm2)
5. Input quantity ...400 L/min. (nor) (Only at purging)
When purging completes, the air operated valve set on exhaust side closes. After that, airconsumption is minimized to only a little air leakage from various sealed sections.

43

KF19/26 Series
Kawasaki Robot

Installation and Connection Manual

44

Kawasaki Robot KF19/26
Installation and Connection Manual
May 2010 : 1st Edition

Published by KAWASAKI HEAVY INDUSTRIES, LTD.

90202-1116DEA

Copyright  2010 KAWASAKI HEAVY INDUSTRIES, LTD.

All rights reserved.