The Kawasaki ZX300S is a 6-axis articulated heavy-duty industrial robot engineered for robotic spot welding and high-payload material handling across automotive body-in-white and general fabrication lines.With a 300 kg maximum payload,2,501 mm horizontal reach,and positional repeatability of±0.3 mm(ISO 9283),the ZX300S delivers the structural rigidity and cycle-time stability required for automated spot welding of large assemblies such as railcar side sills,heavy truck cabs,and forging press tendering.This unit is supplied in New in Original Packaging(Factory Sealed)condition,ready for E02 controller integration and floor-mount installation.
Overview&Primary Technical Specifications
Brand&Series:Kawasaki Z Series–Large Payload Robots
Model Part Number(MPN):ZX300S
Core Category:6-Axis Articulated Heavy-Duty Industrial Robot
Product Condition:New in Original Packaging(Factory Sealed)
Degrees of Freedom:6 axes
Max.Payload:300 kg
Max.Horizontal Reach:2,501 mm
Max.Vertical Reach:3,115 mm
Positional Repeatability:±0.3 mm(conforms to ISO 9283)
Max.Linear Speed:2,500 mm/s
Motion Range:Arm Rotation(JT1)±180°;Arm Out-in(JT2)+75°/−60°;Arm Up-down(JT3)+250°/−120°;Wrist Swivel(JT4)±360°;Wrist Bend(JT5)±120°;Wrist Twist(JT6)±360°
Max.Speed(JT1–JT6):100°/s,85°/s,85°/s,90°/s,90°/s,150°/s
Allowable Wrist Moment:JT4/JT5=1,715 N•m;JT6=862 N•m
Allowable Moment of Inertia:JT4/JT5=166.6 kg•m²;JT6=107.8 kg•m²
Mass(Robot Arm):1,400 kg
Mounting:Floor installation only
Ambient Operating Temperature:0°C to 45°C
Relative Humidity:35%to 85%(non-condensing)
Controller:E02 Universal Controller
Power Requirement:7.5 kVA(dependent on payload and motion profile)
Integrated Functions:Air piping(12 mm dia.×2 lines);internal cooling water pipes for welding gun;solenoid valve wiring(DC24V);FRL unit
Primary Applications:Robotic spot welding,material handling,assembly,machine tending,palletizing,plasma cutting
Key Features&Engineering Performance
300 kg High-Payload Capacity for Spot Welding:The ZX300S supports heavy welding guns and large workpieces in a single automated cell.Combined with a 2,501 mm reach,this industrial 6 axis robot can access deep cavities and large panel surfaces without requiring additional positioning axes,reducing system complexity and floor-space footprint.
±0.3 mm Repeatability for Consistent Weld Quality:Certified to ISO 9283,the ZX300S delivers positional repeatability of±0.3 mm.This precision ensures consistent electrode alignment across every spot weld cycle,minimizing expulsion and reducing electrode dressing frequency in high-volume robotic spot welder applications.
Wide Wrist Motion Range with High Torque Capacity:Wrist swivel(JT4)and twist(JT6)both offer±360°continuous rotation,with allowable moments of 1,715 N•m at JT4/JT5.This enables complex gun-angling maneuvers and multi-plane welding positions without sacrificing acceleration or settling time.
Heat-Resistant Wrist for Demanding Thermal Environments:The ZX300S features a heat-resistant wrist design,making it suitable for handling high-temperature workpieces in hot forging and plasma cutting operations adjacent to spot welding stations.This extends seal and bearing life in foundry-adjacent or post-heat joining cells.
Integrated Utility Pass-Through for Welding Equipment:Factory-integrated 12 mm diameter air piping(two lines),internal cooling water pipes for welding gun,and DC24V solenoid valve wiring eliminate external cable-dressing complications.The FRL unit and end-effector internal bushing reduce maintenance points and improve mean time between failures(MTBF).
Model Code Decoding&Selection Criteria for ZX300S
Understanding the Kawasaki Z Series nomenclature is essential for proper specification.The“ZX”prefix designates the Z Series articulated robot platform.The numeric“300”indicates maximum payload capacity in kilograms–300 kg at the wrist faceplate.The“S”suffix denotes the standard-reach variant within the ZX300 family.(A“G”suffix,by contrast,would indicate a different configuration within the same payload class).
Key selection criteria for a robotic spot welder application:
Gun Weight+Electrode Force:The total mass of the weld gun,transformer,cables,and tooling must remain within 300 kg.Additionally,the allowable wrist moment(1,715 N•m at JT4/JT5)and moment of inertia(166.6 kg•m²)must accommodate the gun's center-of-gravity offset and the reaction forces from electrode closing.
Reach Envelope vs.Part Geometry:With 2,501 mm horizontal reach and 3,115 mm vertical reach,the ZX300S can access large panels such as truck side frames,railcar sills,and EV battery housings.Verify that all weld points fall within the robot's working envelope without singularities,using offline simulation tools.
Cycle Time vs.Speed Capabilities:Maximum axis speeds range from 85°/s(JT2/JT3)to 150°/s(JT6).For high-density spot patterns,balance path acceleration with settling time to achieve target cycles per minute.
Controller Compatibility:The ZX300S is paired exclusively with the E02 Universal Controller,which supports fieldbus integration(EtherNet/IP,Profinet,DeviceNet)and provides the processing power for coordinated multi-robot spot welding cells.
Environmental Conditions:The robot operates reliably in ambient temperatures from 0°C to 45°C with humidity up to 85%(non-condensing).For foundry or hot-stamping applications,the heat-resistant wrist provides additional thermal protection.
Installation,Wiring,and Commissioning Guidelines
Mechanical Installation:The ZX300S is designed exclusively for floor mounting.The base plate must be rigidly fixed to a concrete foundation capable of supporting the 1,400 kg robot arm plus dynamic loads during high-speed axis motions.Refer to the Z Series Installation and Connection Manual for specified foundation bolt torque values(56.84 N•m for high-tensile bolts SCM435,grade 10.9 or higher).Ensure the mounting surface flatness meets Kawasaki's tolerance specifications.
Electrical and Fieldbus Wiring:The E02 controller requires a 7.5 kVA power supply(dependent on actual payload and motion patterns).All emergency stop circuits are hard-wired with redundant dual-channel safety architecture.The controller's safety circuit satisfies PLd in Category 3 per ISO 13849-1:2006.For spot welding integration,the robot arm includes pre-wired DC24V solenoid valve lines for clamp actuation and internal cooling water pipe pass-throughs for the welding gun.Use shielded cables for feedback and encoder signals to maintain signal integrity in high-EMI welding environments.
Parameterization and Commissioning:The E02 controller supports both teach-pendant programming and offline simulation.The teach pendant includes a three-position enabling device;teach and check mode velocities are limited to 250 mm/s for safety.Key commissioning steps include:
Zeroing and Mastering:Perform absolute encoder zeroing per the instruction manual procedure.
Tool Center Point(TCP)Calibration:Define the weld gun TCP with six-point or direct-entry methods.
Weld Schedule Integration:Map robot positions to weld timers and current profiles via fieldbus or discrete I/O.
Path Optimization:Use the E02 controller's path smoothing and acceleration filtering to reduce cycle time while maintaining±0.3 mm repeatability.
Acoustic Noise:Under typical operating conditions,the ZX300S generates acoustic noise levels below 70 dB(A),meeting standard industrial workplace noise regulations without requiring additional sound enclosures.
Technical&Business FAQ
What are the key differences between the ZX300S and other Z Series robots for spot welding?
The ZX300S is the 300 kg payload variant within Kawasaki's Z Series,distinguished by its combination of 2,501 mm reach,±0.3 mm repeatability,and heat-resistant wrist design.Compared to the ZX200S(200 kg payload),the ZX300S supports heavier weld guns and larger workpieces.Compared to the ZX165U or ZX130S,the ZX300S offers significantly higher wrist torque capacity(1,715 N•m at JT4/JT5 versus lower ratings on smaller models).The“S”suffix denotes the standard-reach configuration;the ZX300G is a different variant within the same payload class.
What is the typical price range and lead time for a Kawasaki ZX300S?
For a New in Original Packaging(Factory Sealed)ZX300S including the E02 controller,pricing typically falls in the$75,000–$110,000 USD range depending on configuration(cable lengths,fieldbus options,and integrated welding-specific utility packages).Lead times vary by region and factory order backlog;standard lead times are approximately 8–16 weeks from order confirmation.For spot welding cells,additional costs include the welding gun,transformer,water circulator,and safety fencing.Contact Beijing Zhongping Technology for a firm quote based on your specific application requirements.
How do I verify the authenticity of a Kawasaki ZX300S and avoid counterfeit units?
Authentic Kawasaki ZX300S units feature a factory-engraved nameplate with the model number,serial number,and Munsell 10GY9/1 equivalent body color.Verify the serial number directly with Kawasaki Robotics'regional service center.The E02 controller includes a factory-applied authentication label.Genuine units are supplied with full documentation(Instruction Manual,Installation and Connection Manual,and CAD data available for download).Units sold as“used”or“reconditioned”without factory-sealed packaging do not carry the New in Original Packaging condition designation.Always procure through Kawasaki's authorized distribution network.
What diagnostic procedures address spot weld quality inconsistencies or path deviations?
Weld quality inconsistencies typically originate from TCP drift,electrode wear,or robot repeatability degradation.Diagnostic workflow:(1)Run a TCP check cycle against a fixed reference point–deviations exceeding±0.3 mm indicate mechanical or mastering issues.(2)Verify wrist moment and inertia remain within allowable limits(1,715 N•m and 166.6 kg•m²)–overload conditions cause deflection and poor repeatability.(3)Check encoder battery voltage and absolute position retention.(4)Inspect the internal cooling water pipes for leaks or restrictions that may cause gun overheating.(5)Use the E02 controller's diagnostic logs to review servo error histories and path interpolation anomalies.For persistent issues,perform a full re-mastering procedure per the instruction manual and recalibrate the weld gun TCP.
What preventive maintenance schedule is recommended for the ZX300S in high-duty spot welding operations?
In high-duty spot welding(2+shifts per day),Kawasaki recommends:grease replacement every 6,000 operating hours or annually(whichever comes first);battery replacement for absolute encoders every 2 years;wrist seal inspection every 3 months–the heat-resistant wrist design extends seal life but thermal cycling still accelerates wear;cooling water pipe inspection weekly for leaks and flow rate;mounting bolt torque verification quarterly(56.84 N•m for M10 high-tensile bolts).Maintain a spare parts inventory including encoder batteries,wrist seals,and the FRL unit service kit.The robot's acoustic noise level(<70 dB(A))can serve as a diagnostic indicator–a sudden increase may signal bearing wear or lubrication degradation
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