Kuka KR 6-2 Operating Instructions Manual
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Kuka KR 6-2 Operating Instructions Manual

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ROBOT
KR 6- -2; KR 16- -2
with KR C4
Operating Instructions
Issued: 19 Feb 2015
Version: 07
BA KR 6, 16 F, KR C4 12.10.07 en
1 of 206

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  • Page 1 ROBOT KR 6- -2; KR 16- -2 with KR C4 Operating Instructions Issued: 19 Feb 2015 Version: 07 BA KR 6, 16 F, KR C4 12.10.07 en 1 of 206...
  • Page 2 Copyright 2015 KUKA Roboter GmbH Zugspitzstrasse 140 D- -86165 Augsburg This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work.

  • Page 3: Table Of Contents

    Contents Introduction ........... . . Robot documentation .
  • Page 4 Operating Instructions 5.6.1 General safety regulations ............5.6.2 Transportation .
  • Page 5 9.3.1 Coding ............... Connector panel on the control cabinet .
  • Page 6 Operating Instructions 12.11 Tightening torques ............. Consumables, safety data sheets .

  • Page 7: Introduction

    Introduction Valid for KR 6; ...- -2 KR 16; ...- -2 KR 16 L6; ...- -2 with the F variant and with KR C4 Introduction Robot documentation The documentation of this robot comprises the following parts: KR 6, 16 F, KR C4 operating instructions Parts catalog on storage medium Each of these parts is a separate document that is attached to the robot.
  • Page 8 Operating Instructions BA KR 6, 16 F, KR C4 12.10.07 en 8 of 206...

  • Page 9: Purpose

    Notice! Deviations from the operating conditions specified in the technical data or the use of special functions or applications can lead to premature wear. KUKA Ro- boter GmbH must be consulted. BA KR 6, 16 F, KR C4 12.10.07 en...

  • Page 10: Target Group

    Information! For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at www.kuka.com or can be obtained directly from our subsidiaries.

  • Page 11: Product Description

    Product description Product description Information! This description applies analogously to all of the industrial robots listed in Chapter 1, regardless of the variant or model shown in the illustrations. General The industrial robot consists of the manipulator (= robot arm and electrical installations), con- trol cabinet and connecting cables (Fig.

  • Page 12: Wrist

    Operating Instructions Wrist The manipulator can be equipped with two different three--axis in--line wrists (Fig. 2) for a 6 kg (IW 6 II) or a 16 kg (IW 16 I) payload. The respective wrist is screwed to the arm via the flange (4).

  • Page 13: Arm

    Product description (continued) For this robot model, the following arm variants (Fig. 3) are employed: Arm for in--line wrist with arm extension (1) Arm for in--line wrist, standard variant (3) Arm for in--line wrist with “F” variant wrist (3) All arm variants are essentially the same in structure and function. The arm for the F variant is pressurized and features a pressure regulator unit for controlling the internal pressure in the arm.
  • Page 14 Operating Instructions Mounted on the front end of the arm via a standardized interface is the in--line wrist (4), which is driven by the motor units (1) via push--on shafts (5) located inside the arm. For attaching supplementary loads, the arm is equipped with four tapped holes on its top side. Motor units for wrist axes Main axis motor unit A3 Link arm...

  • Page 15: Wrist Axis Motor Units A4 To A6

    Product description (continued) 3.3.1 Wrist axis motor units A4 to A6 The wrist axes are driven by three motor units. These are fastened to the arm (Fig. 5/4) by means of screws. Motor units A5 (1) and A4 (3) are of the same design and drive the respec- tive wrist axes via toothed belts and shafts.

  • Page 16: Link Arm

    Operating Instructions Link arm The link arm (Fig. 6/1) is the driven element of axis 2. It pivots about rotational axis A2 (3) through an effective software range from +35° to --155° ⎯ referred to the electrical zero posi- tion of axis A2, which corresponds to the horizontal position of the link arm in Fig. 6. The ef- fective software swivel range is limited by mechanical limit stops with a buffer function in addi- tion to the software limit switches.
  • Page 17 Product description (continued) Reference notches Gear unit A3 Gear unit A2 Rotational axis A2 Link arm housing Rotational axis A3 Fig. 7 Structure of link arm BA KR 6, 16 F, KR C4 12.10.07 en 17 of 206...

  • Page 18: Main Axis Motor Units A1 To A3

    Operating Instructions 3.4.1 Main axis motor units A1 to A3 Axes 1, 2 and 3 are driven by motor units as shown in Fig. 8. Each motor unit for the main axis drives consists of a brushless AC servomotor (1) with a permanent--magnet single--disk brake (3) and hollow--shaft resolver (2), both integrated.

  • Page 19: Rotating Column

    Product description (continued) Rotating column The rotating column (Fig. 9/2) is the assembly located between the link arm and the base frame. Screwed to the base frame (4) through a gear unit (3), which allows it to rotate, it per- forms movements about rotational axis A1 (1).
  • Page 20 Operating Instructions The main axis motor unit for axis 1 (Fig. 10/3) is installed in the rotating column together with its gear unit (4), and the main axis motor unit for axis 2 (1) is mounted on the side of the rotat- ing column together with its gear unit (2).

  • Page 21: Base Frame

    Product description (continued) Base frame The base frame (Fig. 11) is the stationary part of the manipulator, on which the rotating col- umn turns with the link arm, the arm, and the wrist. Its base flange (5) features through--holes (4) for holding the manipulator down and three locating boreholes (6), with which the manipu- lator can be placed on two locating pins (accessories, see also Section 7.5, “Installation”).

  • Page 22: Working Range Limitation For A1 To A3

    A special version is required in such cases, or a corresponding adaptation of the energy supply system. There are no approved KUKA energy supply systems available for the F variants. The energy supply systems are described in separate documentation.

  • Page 23: Technical Data

    Technical data Technical data Information! This description applies analogously to all of the industrial robots listed in Chapter 1, regardless of the variant or model shown in the illustrations. General The industrial robots of the series KR 6 and KR 16 are six--axis industrial robots for installa- tion on the floor, the wall or the ceiling.
  • Page 24 Operating Instructions Base frame In- -line wrist Control cabinet (see separate Link arm documentation) Rotating column Connecting cables Fig. 12 Principal components of the industrial robot (KR 16 depicted) BA KR 6, 16 F, KR C4 12.10.07 en 24 of 206...

  • Page 25: Principal Data

    Technical data (continued) Principal data Types KR 6 KR 16 KR 16 L6 Number of axes 6 (Fig. 14) Load limits see following table and Fig. 13 Industrial robot type KR 6 In--line wrist [kg] IW 6 Rated payload [kg] Suppl.
  • Page 26 Operating Instructions Max. total load Suppl. load Payload Max. suppl. load, link arm/arm Suppl. load, link arm Suppl. load, rotating column (left--hand side) Fig. 13 Load distribution (example KR 16) Axis data All specifications in the “Range of motion” column are referred to the electrical zero of the axis concerned.
  • Page 27 Technical data (continued) KR 16 D In- -line wrist, rated payload 16 kg Axis Range of motion, Speed with rated payload 16 kg software--limited ±185˚ 156 ˚/s +35˚ to --155˚ 156 ˚/s 156 ˚/s +154˚ to --130˚ ±350˚ 330 ˚/s ±130˚...
  • Page 28 Operating Instructions Fig. 14 Robot axes and their possible motions Pose repeatability ± 0.05 mm (ISO 9283) Mounting position Floor, wall or ceiling Permissible angle of A1 for wall installation, see Fig. 15 Principal dimensions see Fig. 18 -- 20 Working envelope The shape and dimensions of the working envelope may be noted from Fig.
  • Page 29 Technical data (continued) Weight KR 6 approx. 235 kg KR 16 approx. 235 kg KR 16 L6 approx. 240 kg Principal dynamic loads See Fig. 25 and Fig. 26 Drive system Electromechanical, with transistor--controlled AC servomotors Installed motor capacity KR 6 approx.
  • Page 30 Operating Instructions Color Manipulator Base (stationary): black (RAL 9005) Moving parts: KUKA orange 2567 With “F” variant, additional special paint finish for the entire manip- ulator. In- -line wrist “F”: Heat--resistant and heat--reflecting special paint finish in silver. Plates see Fig. 29 to Fig. 37.
  • Page 31 (payload and principal moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and generally overload the motors and the gears; in any such case KUKA must be consulted beforehand.
  • Page 32 + Ly - -X 0.36 kgm - -Z CAUTION: The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the controller! - -Y Load center of gravity P Lxy (mm)
  • Page 33 Technical data (continued) View Y Suppl. load R118 1081 CAUTION: The interference radius 1027 1611 (safe area) lies approx. 118 mm beyond the reference point for the working envelope. - -185 NOTE: The supplementary load center of gravity must be located as close as possible to rotational axis 3 1611 and to line a in Fig.
  • Page 34 Operating Instructions Suppl. load View Y +154° - -130° - -155° R118 +35° 1027 1464 1611 CAUTION: The interference radius (safe area) lies approx. 118 mm beyond the reference point for the working envelope. - -185 ° R1611 NOTE: The supplementary load center of gravity must be located as close as possible to rotational axis 3 and to line a in Fig.
  • Page 35 Technical data (continued) View Y Suppl. load 1206 1327 1911 CAUTION: The interference radius (safe area) lies approx. 118 mm beyond the reference point for the working envelope. - -185 NOTE: The supplementary load center of gravity must be located as close as possible to rotational axis 3 1911 and to line a in Fig.
  • Page 36 Operating Instructions View Y from Fig. 18, Fig. 19 and Fig. 20 NOTE: The supplementary load center of gravity must be located as close as possible to rotational axis 3 and to line a. (27) M8, 12 deep (4x) M8 fastening screws, 8.8 min. depth of engagement >1x d Support brackets for suppl.
  • Page 37 Technical data (continued) to A 4/A 5 0.1 A B Fitting length 0.15 A B C M6 --- 7.0 deep Fastening screws M6, Grade 10.9 Depth of engagement: min. 6 mm 0.05 A max. 9 mm Fig. 23 DIN/ISO mounting flange for in- -line wrist 6 kg to A 4/A 5 0.02 8x 45°...
  • Page 38 Operating Instructions The specified forces and moments already include the payload and the inertia force (weight) of the manipulator. Vertical force 4,600 N vmax Horizontal force 5,000 N hmax Tilting moment 5,200 Nm kmax Turning moment about axis 1 M 4,200 Nm rmax Total mass...
  • Page 39 Technical data (continued) Vertical force 4,600 N vmax Horizontal force 3,600 N hmax Tilting moment 4,700 Nm kmax Turning moment about axis 1 M 4,200 Nm rmax Total mass = manipulator total load for type 235 kg 36 kg KR 6 235 kg 46 kg KR 16...
  • Page 40 Operating Instructions Fig. 27 Electronic measuring tool, in- -line wrist 6 kg, installation on A4, A5 and A6 Fig. 28 Electronic measuring tool, in- -line wrist 16 kg, installation on A4, A5 and A6 BA KR 6, 16 F, KR C4 12.10.07 en 40 of 206...
  • Page 41 Technical data (continued) Fig. 29 Plates on manipulator (see also Fig. 30 to Fig. 37) 0° --155° +154° 0° 0° 0° Art. no. 00- -115- -855 Fig. 30 Instructions regarding transport position for floor- -, wall- - and ceiling- -mounted manipulators BA KR 6, 16 F, KR C4 12.10.07 en 41 of 206...
  • Page 42 Operating Instructions Art. no. 00- -115- -855 Fig. 31 Reference to operating instructions Art. no. 00- -115- -855 Fig. 32 Instructions for safeguarding against toppling of A2 and A3 4x on each AC servomotor Fig. 33 Hot surface warning sign BA KR 6, 16 F, KR C4 12.10.07 en 42 of 206...
  • Page 43 Technical data (continued) ................On all motors ....................................................... Fig. 34 Drive motor rating plate 00- -104- -232 Fig. 35 Danger zone Roboter GmbH Zugspitzstrasse 140 86165 Augsburg, Germany Type Type XXXXXXXXXXXXXXXXXXXXXXXXXX Artikel- -Nr. Article No. No.
  • Page 44 Operating Instructions Fig. 37 High voltage warning sign BA KR 6, 16 F, KR C4 12.10.07 en 44 of 206...

  • Page 45: Safety

    Notice! This “Safety” chapter refers to a mechanical component of an industrial robot. If the mechanical component is used together with a KUKA robot controller, the “Safety” chapter of the operating instructions or assembly instructions of the robot controller must be used! This contains all the information provided in this “Safety”...

  • Page 46: Liability

    No modifications may be carried out to the industrial robot without the authorization of KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Ro- boter GmbH, may be integrated into the industrial robot.

  • Page 47: Ec Declaration Of Conformity And Declaration Of Incorporation

    Safety (continued) Misuse Any use or application deviating from the intended use is deemed to be impermissible mis- use. This includes e.g.: Transportation of persons and animals Use as a climbing aid Operation outside the permissible operating parameters Use in potentially explosive environments Operation without additional safeguards Outdoor operation Underground operation...

  • Page 48: Terms Used

    Test mode, Manual High Velocity (> 250 mm/s permissible) External axis Motion axis which is not part of the manipulator but which is controlled using the robot controller, e.g. KUKA linear unit, turn--tilt table, Posiflex. BA KR 6, 16 F, KR C4 12.10.07 en 48 of 206...

  • Page 49: Personnel

    Safety (continued) Personnel The following persons or groups of persons are defined for the industrial robot: User Personnel Notice! All persons working with the industrial robot must have read and understood the industrial robot documentation, including the safety chapter. User The user must observe the labor laws and regulations.

  • Page 50: Workspace, Safety Zone And Danger Zone

    Operating Instructions Operator The operator must meet the following preconditions: The operator must be trained for the work to be carried out. Work on the industrial robot must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and experience, and their famil- iarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards.

  • Page 51: Overview Of Protective Equipment

    If the manipulator or an external axis hits an obstruction or a mechanical end stop or axis range limitation, this can result in material damage to the industrial robot. The manipulator must be taken out of operation and KUKA Roboter GmbH must be consulted before it is put back into operation.

  • Page 52: Mechanical Axis Range Limitation (Optional)

    This increases personal safety and protection of the system. Information! This option is not available for all robot models and not for the KR C4. Information on specific robot models can be obtained from KUKA Roboter GmbH. 5.5.4 Options for moving the manipulator without drive energy...
  • Page 53 Information about the options available for the various robot models and about how to use them can be found in the assembly and operating instructions for the robot or re- quested from KUKA Roboter GmbH. Notice! Moving the manipulator without drive energy can damage the motor brakes of the axes concerned.

  • Page 54: Labeling On The Industrial Robot

    Operating Instructions 5.5.5 Labeling on the industrial robot All plates, labels, symbols and marks constitute safety--relevant parts of the industrial robot. They must not be modified or removed. Labeling on the industrial robot consists of: Identification plates Warning labels Safety symbols Designation labels Cable markings Rating plates...
  • Page 55 Safety (continued) KCP/smartPAD The user must ensure that the industrial robot is only operated with the KCP/smartPAD by authorized persons. If more than one KCP/smartPAD is used in the overall system, it must be ensured that each device is unambiguously assigned to the corresponding industrial robot. They must not be interchanged.

  • Page 56: Transportation

    External axis (optional) The prescribed transport position of the external axis (e.g. KUKA linear unit, turn--tilt table, etc.) must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the external axis.

  • Page 57: Manual Mode

    Safety (continued) Function test The following tests must be carried out before start--up and recommissioning. It must be ensured that: The industrial robot is correctly installed and fastened in accordance with the specifica- tions in the documentation. There are no foreign bodies or loose parts on the industrial robot. All required safety equipment is correctly installed and operational.

  • Page 58: Automatic Mode

    Operating Instructions If the setup work has to be carried out inside the safeguarded area, the following must be taken into consideration: In Manual Reduced Velocity mode (T1): If it can be avoided, there must be no other persons inside the safeguarded area. If it is necessary for there to be several persons inside the safeguarded area, the following must be observed: Each person must have an enabling device.
  • Page 59 Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Roboter GmbH for this purpose. Cleaning and preventive maintenance work is to be carried out in accordance with the operat- ing instructions.

  • Page 60: Decommissioning, Storage And Disposal

    Operating Instructions Hazardous substances The following safety measures must be carried out when handling hazardous substances: Avoid prolonged and repeated intensive contact with the skin. Avoid breathing in oil spray or vapors. Clean skin and apply skin cream. Notice! To ensure safe use of our products, we recommend that our customers regularly request up- -to- -date safety data sheets from the manufacturers of hazardous sub- stances.

  • Page 61: Applied Norms And Regulations

    Safety (continued) Applied norms and regulations Name Definition Edition Machinery Directive: 2006/42/EC 2006 Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast) EMC Directive: 2004 2004/108/EC Directive 2004/108/EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC...
  • Page 62 Operating Instructions BA KR 6, 16 F, KR C4 12.10.07 en 62 of 206...

  • Page 63: Transportation

    Transportation Transportation Information! This description applies analogously to all of the industrial robots listed in Chapter 1, regardless of the variant or model shown in the illustrations. General Caution! If the manipulator is transported by fork lift truck, the forks must be placed in the fork slots.

  • Page 64: Floor--Mounted Manipulators

    Operating Instructions Floor- -mounted manipulators Information! Please observe Section 6.1. The manipulator can be transported as follows: With lifting tackle and crane (Fig. 41, left--hand side) The manipulator can be suspended from the hook of a crane by means of lifting tackle at- tached to three eyebolts on the rotating column.
  • Page 65 Transportation (continued) Fig. 41 Transporting floor- -mounted manipulators If the manipulator is to be transported away from its site of operation, the following is to be observed: Warning! Turn main switch on the manipulator control cabinet to “OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again.
  • Page 66 Operating Instructions (2) Put the manipulator into operation and move it into the transport position (Fig. 42). 0˚ ---155˚ +154˚ 0˚ 0˚ 0˚ * All angles are specified relative to the electrical “zero position” or 1115 to the KCP display. 1184 1416 = 235 kg KR 6, KR 16...

  • Page 67: Ceiling--Mounted Manipulators

    Transportation (continued) Ceiling- -mounted manipulators Information! Please observe Section 6.1. The manipulator can be transported as follows: With fork lift truck (Fig. 43) For installation on the ceiling, the manipulator is delivered inverted in a special transport frame. Already in the correct orientation, it can be taken out of this frame by fork lift truck and transported to the site of installation.
  • Page 68 Operating Instructions 0˚ ---155˚ +154˚ 0˚ 0˚ 0˚ * All angles are specified relative to the electrical “zero position” or to the KCP display. = 235 kg KR 6, KR 16 240 kg KR 16 L6 KR 6 KR 16 KR 16 L6 1115 1184...

  • Page 69: Wall--Mounted Manipulators

    Transportation (continued) Wall- -mounted manipulators Information! Please observe Section 6.1. The manipulator can be transported as follows: With fork lift truck (Fig. 45) To mount the manipulator on the wall without a hinged mounting base, it is picked up using special fork slots (Fig.
  • Page 70 Operating Instructions If the manipulator is to be transported away from its site of operation, the following is to be observed: Warning! Turn main switch on the manipulator control cabinet to “OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again. (1) Remove tools and additional devices should they prevent the transport position from being reached or generally impede transportation.

  • Page 71: Installation, Connection, Exchange

    Installation, connection, exchange Installation, connection, exchange Information! This description applies analogously to all of the industrial robots listed in Chapter 1, regardless of the variant or model shown in the illustrations. General Caution! Observe Chapter 5, “Safety”! With all work involving the connection of the manipulator (and of the control cabinet), the control cabinet documentation “Initial Start- -up”...

  • Page 72: Information For Planning

    Static axis positions, e.g. continuous vertical position of a wrist axis. If one or more of these conditions are to apply during operation of the kinematic system, KUKA Roboter GmbH must be consulted. BA KR 6, 16 F, KR C4 12.10.07 en...

  • Page 73: Principal Loads

    Installation, connection, exchange (continued) Principal loads Forces occur during operation which must be safely transmitted to the floor, wall or ceiling. The forces that have to be taken into account are specified in Fig. 47 for floor-- and ceiling-- mounted manipulators and in Fig. 48 for wall--mounted manipulators. The data given in the illustrations can also be used as a basis for more extensive static investigations.
  • Page 74 Operating Instructions Vertical force 4,600 N vmax Horizontal force 3,600 N hmax Tilting moment 4,700 Nm kmax Turning moment about axis 1 M 4,200 Nm rmax Total mass manipulator + total load for type 235 kg 36 kg KR 6 235 kg 46 kg KR 16...

  • Page 75: Mounting Variants

    Installation, connection, exchange (continued) Mounting variants The manipulator can be installed on the floor, the wall or the ceiling. There are two mounting variants for installing the manipulator on the floor and one variant for ceiling mounting: D Variant 1 Mounting base with centering (see Section 7.4.1 and 7.4.2) Fig.
  • Page 76 Operating Instructions Fig. 50 Orientation of working envelope and concrete foundation D Variant 2 Machine frame mounting (see Section 7.4.3) Fig. 51 Machine frame mounting with centering BA KR 6, 16 F, KR C4 12.10.07 en 76 of 206...

  • Page 77: Variant 1: Mounting Base With Centering (Resin Capsule)

    Installation, connection, exchange (continued) 7.4.1 Variant 1: mounting base with centering (resin capsule) Features: For floor--mounted manipulators only. Mounting of 3 bedplates, each with 2 chemical anchors. Manipulator installed on the three bedplates. Notice! When using chemical anchors (resin- -bonded anchors), only resin capsules and anchors (threaded rods) from the same manufacturer may be used.
  • Page 78 Operating Instructions (3) Mark the position of the manipulator in relation to the working envelope (Fig. 50/1) on the concrete foundation (2). (4) Move manipulator to the installation position. (5) Align the manipulator horizontally. Information! If the bedplates are not fully seated on the concrete foundation (Fig. 53/4), this can re- sult in distortion or loosening of the mounting base.
  • Page 79 Installation, connection, exchange (continued) (11) Mount the hexagon nuts (6) together with washers and tighten the hexagon nuts with a torque wrench in diagonally opposite sequence, increasing the tightening torque to the specified value in several stages (M = 40 Nm). (12) Retighten the hexagon nuts (6) after 100 hours of operation.

  • Page 80: Variant 1, Mounting Base With Centering (Resin Cartridge)

    Operating Instructions 7.4.2 Variant 1, mounting base with centering (resin cartridge) Features: For floor--mounted manipulators only. Mounting of 3 bedplates, each with 2 chemical anchors. Manipulator installed on the three bedplates. Notice! When using chemical anchors (resin- -bonded anchors), only resin cartridges and anchors (threaded rods) from the same manufacturer may be used.
  • Page 81 Installation, connection, exchange (continued) 212,5 108,5 Fig. 55 Bedplates (3) Determine the position of the manipulator on the concrete foundation (2) in relation to the working envelope (Fig. 50/1). (4) Move manipulator to the installation position. (5) Align the manipulator horizontally. Information! If the bedplates are not fully seated on the concrete foundation (Fig.
  • Page 82 Operating Instructions Information! At the end of the curing time, the anchor holes can be drilled. (6) Drill six anchor holes (Fig. 57/4) through the holes of the bedplates into the foundation; depth in concrete 110 mm. (7) Clean the anchor holes by blowing them out, brushing them and then blowing them out again.
  • Page 83 Installation, connection, exchange (continued) (10) Allow the resin to cure. The following processing and curing times must be observed. These times apply to dry concrete; in the case of damp concrete, the curing times are doubled. The resin must not be processed in standing water. Cartridge temperature Processing time <...

  • Page 84: Variant 2: Machine Frame Mounting With Centering

    Operating Instructions 7.4.3 Variant 2: machine frame mounting with centering Features: For floor--, wall-- and ceiling--mounted manipulators. Manipulator installed on a steel structure prepared by the customer (or on a linear unit of series KL 250). Manipulator fastened by means of three M20x55 ISO4017 hexagon bolts. Installation (1) Prepare mounting surfaces (Fig.
  • Page 85 Installation, connection, exchange (continued) Section A - - A H7 (2x) (3x) 38.5° 30° R250 min. 110 21.5° 30° Fig. 58 Robot installation, variant 2 BA KR 6, 16 F, KR C4 12.10.07 en 85 of 206...

  • Page 86: Installation

    Observe Section 7.1! This description applies to all mounting variants for floor--mounted manipulators only. If the manipulator is to be installed on the floor in an inclined position, KUKA Roboter GmbH must be consulted beforehand. The procedure for installing the manipulator (whether for the first time or as an exchange) is as follows: (1) Check that both locating pins (Fig.
  • Page 87 Installation, connection, exchange (continued) 0˚ ---155˚ +154˚ 0˚ 0˚ 0˚ * All angles are specified relative to the electrical “zero position” or to the KCP display. 1115 1184 1416 = 235 kg KR 6, KR 16, 240 kg KR 16 L6 KR 6 KR 16 KR 16 L6...
  • Page 88 Operating Instructions Fig. 61 Installing the manipulator on the floor (4) Insert three M20x55 ISO 4017 hexagon bolts (1) together with conical spring washers and tighten them with a torque wrench in diagonally opposite sequence, increasing the tightening torque M to the specified value in several stages (M = 370 Nm).

  • Page 89: Ceiling--Mounted Manipulators

    Installation, connection, exchange (continued) Ceiling- -mounted manipulators Caution! A manipulator configured for the floor mounting position may not be installed in the ceiling mounting position, as this is liable to cause lubrication problems on axis 1 due to the different quantities of oil in gear unit A1! Information! Observe Section 7.1! This description only applies to ceiling--mounted robots with mounting variant 2 (Section 3.2).
  • Page 90 Operating Instructions 0˚ ---155˚ +154˚ 0˚ 0˚ 0˚ * All angles are specified relative to the electrical “zero position” or to the KCP display. = 235 kg KR 6, KR 16 240 kg KR 16 L6 KR 6 KR 16 KR 16 L6 1115 1184...
  • Page 91 Installation, connection, exchange (continued) Fig. 64 Installing the manipulator on the ceiling (4) Retighten the hexagon bolts (5) after 100 hours of operation. (5) Remove the fork lift truck. (6) Connect the ground conductors, compressed air lines and connecting cables. Warning! Before performing the next step, it must be ensured that it is not possible for anyone to be injured within the range of the slowly moving manipulator.

  • Page 92: Wall--Mounted Manipulators

    Operating Instructions Wall- -mounted manipulators Information! Observe Section 7.1! 7.8.1 Installing wall- -mounted manipulators in the 0 position ˚ The procedure for mounting the manipulator on the wall (whether for the first time or as an exchange) is as follows: Warning! The manipulator must be transported in its transport position (Fig.
  • Page 93 (2) Raise the manipulator with lifting tackle attached to three eyebolts on the rotating col- umn. Caution! For reasons of safety, it is imperative for the lifting tackle to be attached to the manipulator at the specified points. Risk of injury! (3) Lower the manipulator (Fig.
  • Page 94 The specifications concerning handling and safety supplied by the manufacturer of the mounting base must be observed! The hinged steel base is not part of the KUKA Roboter GmbH contract. Hinged steel base Fig. 68 Installing a wall- -mounted manipulator on a hinged steel base (8) Connect ground conductors, compressed air lines and connecting cables.

  • Page 95: Installing Wall--Mounted Manipulators In The 90° Position

    7.8.2 Installing wall- -mounted manipulators in the 90 ˚ position Information! Observe Section 7.1! Before starting work, the robot must be in the 90° position to enable it to be lifted by the fork lift truck. The procedure for mounting the manipulator on the wall (whether for the first time or as an exchange) is as follows: Warning! The manipulator must be transported in the 90°...
  • Page 96 Operating Instructions 0˚ ---155˚ +154˚ 0˚ 0˚ 0˚ * All angles are specified relative to the electrical “zero position” or to the KCP display. 1075 = 235 kg KR 6, KR 16 240 kg KR 16 L6 1115 1184 1416 KR 6 KR 16 KR 16 L6...
  • Page 97 Fig. 71 Installing the manipulator on the wall (4) Insert three M20x55 ISO 4017 hexagon bolts (1) together with lock washers and tighten them with a torque wrench in diagonally opposite sequence, increasing the tightening torque M to the specified value in several stages (M = 370 Nm).
  • Page 98 Operating Instructions Warning! Turn main switch on the robot control cabinet to “OFF” and secure it with a pad- lock to prevent unauthorized persons from switching it on again. (9) Install the end--effector and additional equipment. (10) Connect any further supply lines required. (11) Put the manipulator into operation.

  • Page 99: Exchange

    Exchange To avoid the need for any major reprogramming after an exchange, the instructions given in the Operating Handbook, Software KR C4, Chapter “Start--up”, Section “Robot Mastering/ Unmastering” must be accurately carried out every time a robot is exchanged. 7.9.1 Exchanging floor- -mounted robots D Removal Warning!
  • Page 100 Operating Instructions (2) Put the manipulator into operation and move it into the transport position (Fig. 72). 0˚ ---155˚ +154˚ 0˚ 0˚ 0˚ * All angles are specified relative to the electrical “zero position” or to the KCP display. 1115 1184 1416 = 235 kg KR 6, KR 16...
  • Page 101 Fig. 73 Removal of floor- -mounted robot Information! The robot can also be lifted off using the fork lift truck. Notice! The robot must be lifted as vertically as possible until the locating pins are free. (8) Lower the robot onto a suitable support. Information! If the robot is not to be reinstalled for some time, it must be protected against corrosion before being put into storage.

  • Page 102: Exchanging Ceiling--Mounted Robots

    Operating Instructions 7.9.2 Exchanging ceiling- -mounted robots D Removal Warning! Turn main switch on the robot control cabinet to “OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again. (1) Remove the end--effector (tool) and additional equipment. Information! The end--effector and additional equipment have to be removed if the robot is to be re- placed by another one or if they would otherwise impede the exchange work.
  • Page 103 Warning! Turn main switch on the robot control cabinet to “OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again. (3) Release and unplug the ground conductor and all connectors from the junction box (Fig.

  • Page 104: Exchanging Wall--Mounted Robots

    Operating Instructions 7.9.3 Exchanging wall- -mounted robots D Removal Warning! Turn main switch on the robot control cabinet to “OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again. (1) Remove the end--effector (tool) and additional equipment. Information! The end--effector and additional equipment have to be removed if the robot is to be re- placed by another one or if they would otherwise impede the exchange work.
  • Page 105 (3) Release and unplug the ground conductor and all connectors from the push--in module (Fig. 77/3). (4) Remove electric cables and hose lines from both interfaces of energy supply system A1 and all other peripheral supply lines to the robot, where necessary. Caution! Depressurize and drain hose lines beforehand.

  • Page 106: Unbraked Impact Against Limit Stops

    If the robot hits an obstruction or a buffer on the mechanical end stop or axis range limitation, this can result in material damage to the robot. KUKA Roboter GmbH must be consulted before the robot is put back into operation. The affec- ted buffer must immediately be replaced with a new one.

  • Page 107: Moving The Manipulator Without Drive Energy

    7.11 Moving the manipulator without drive energy The release device (optional) can be used for moving the manipulator (only axes 1 to 3) after an accident or malfunction without drive energy. This option is only for use in exceptional cir- cumstances and emergencies, e.g.
  • Page 108 Operating Instructions BA KR 6, 16 F, KR C4 12.10.07 en 108 of 206...

  • Page 109: Electrical Installations

    Electrical installations Electrical installations Information! This description applies analogously to all of the industrial robots listed in Chapter 1, regardless of the variant or model shown in the illustrations. The electrical installations of the robot (manipulator) form a separate assembly. It includes the “cable set”...
  • Page 110 Operating Instructions Cable from Cable from Protective circuit Bolt on Bolt on Air hose, PUN 6x1, BU Base frame Arm, axis 3 00- -186- -281 base frame rotating column On F variant only Bolt on Bolt on rotating column Motor cable A1 Connector X30/a Control cable A1 Connector X1...
  • Page 111 Electrical installations (continued) Cable set assembly PE push- -in module Multi- -function housing MFH Protective circuit Electronic Data Storage EDS Resolver Digital Converter RDC RDC box Fig. 80 Cable set assembly BA KR 6, 16 F, KR C4 12.10.07 en 111 of 206...

  • Page 112: Cabling Plans And Wiring Diagrams

    Operating Instructions Cabling plans and wiring diagrams X30/a Housing GN/YE Type 10/99 2.5 mm 2.5 mm 2.5 mm 1 mm 1 mm 2.5 mm Power connector Type 07/99 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm X02/X1...
  • Page 113 Electrical installations (continued) X30/b Housing GN/YE Type 10/99 2.5 mm 2.5 mm 2.5 mm 1 mm 1 mm 2.5 mm Power connector Type 07/99 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm X02/X2 Fig.
  • Page 114 Operating Instructions X30/c Housing GN/YE Type 11/99 1 mm 1 mm 1 mm 1 mm 1 mm 1 mm Power connector 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm Type 07/99 X02/X3 Fig.
  • Page 115 Electrical installations (continued) X30/e Housing GN/YE Type 11/99 1 mm 1 mm 1 mm 1 mm 1 mm 1 mm Power connector Type 07/99 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm X02/X4 Fig.
  • Page 116 Operating Instructions X30/e Housing GN/YE Type 11/99 1 mm 1 mm 1 mm 1 mm 1 mm 1 mm Power connector Type 07/99 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm X02/X5 Fig.
  • Page 117 Electrical installations (continued) X30/f Housing GN/YE Type 11/99 1 mm 1 mm 1 mm 1 mm 1 mm 1 mm Power connector Type 07/99 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm X02/X6 Fig.
  • Page 118 Operating Instructions n. c. Type 06/07 WH/GN TPFO_ P TPFO_ N n.c. n. c. n. c. n. c. WH/OG TPFI_ P TPFI_ N n.c. AWG18 AWG18 24 V/PS1 buffered n. c. n. c. Fig. 87 Wiring diagram, RDC internal X31 n.
  • Page 119 Electrical installations (continued) Bolt Bolt Rotating column Bolt Base frame Push- -in module RDC box Ground conductor cross--sections 10 mm Fig. 89 Ground conductor installation, protective circuit BA KR 6, 16 F, KR C4 12.10.07 en 119 of 206...
  • Page 120 Operating Instructions BA KR 6, 16 F, KR C4 12.10.07 en 120 of 206...

  • Page 121: Connecting Cables

    Connecting cables Connecting cables Information! This description applies analogously to all of the industrial robots listed in Chapter 1, regardless of the variant or model shown in the illustrations. Description Connecting cables are all the cables running between the robot (= manipulator) and the con- trol cabinet (Fig.
  • Page 122 Operating Instructions Caution! Before the manipulator is put into operation, the continuity of the ground conductor connection between the control cabinet and the manipulator must be tested with a ground conductor measurement in accordance with DIN EN 60204- -1 and the relevant national regulations. KR C4 Robot control cabinet...

  • Page 123: Routing Of Cables

    Connecting cables (continued) Routing of cables The following points must be observed when routing the cables: Bending radius of the cables for fixed installation • Motor cable 150 mm • Control cable 60 mm must be observed Protect cables against exposure to mechanical stress. Route the cables without tension (no tensile forces on the connectors).

  • Page 124: Junction Boxes On The Manipulator

    Operating Instructions Junction boxes on the manipulator The plug--in connections on the robot are located on the multi--function housing on the base frame for the motor cable, and on the RDC box for the data cable. The allocation of the junc- tion boxes to the respective connectors for the different manipulators may be noted from Fig.

  • Page 125: Connector Panel On The Control Cabinet

    Connecting cables (continued) Connector panel on the control cabinet The connector panel (Fig. 93) is accessed by opening the door to the cabinet. The connected cables are routed under the control cabinet to the rear. Fig. 93 Connector panel on the control cabinet BA KR 6, 16 F, KR C4 12.10.07 en 125 of 206...

  • Page 126: Configuration Of The Connecting Cables

    Operating Instructions Configuration of the connecting cables Fig. 94 Motor cable Fig. 95 Data cable M8 ring cable lug 6 Conical spring washer M8 nut 7 Ground plate Conical spring washer 8 PE bolt 8.4 washer 9 Cable lug M8 nut 10 M8 tapped hole Fig.

  • Page 127: Wiring Diagrams

    Connecting cables (continued) Wiring diagrams 20/08 TPFO_ P TPFO_ N n. c. n. c. n. c. TPFI_ P TPFI_ N 24 V/PS1 buffered n. c. n. c. Cable gland Cable gland Fig. 97 Data cable X21 BA KR 6, 16 F, KR C4 12.10.07 en 127 of 206...
  • Page 128 Operating Instructions Motor M1 U Motor M1 V Motor M1 W Brake + Brake - - Motor M2 U Motor M2 V Motor M2 W Brake + Brake - - Motor M3 U Motor M3 V Motor M3 W Brake + Brake - - Motor M4 U Motor M4 V...

  • Page 129: Maintenance Work

    20,000 operating hours or 5 years after delivery -- whichever is reached first. If oil temperatures of more than 333 K (60 °C) are reached during operation, shorter mainte- nance intervals must be observed; for this, consultation with KUKA Roboter GmbH is neces- sary.
  • Page 130 (1) Pour specified amount of oil into filler hole (10). Notice! Only KUKA- -approved lubricants may be used. Some of the specially marked texts refer exclusively to the subsequent steps -- until the in- struction is expressly revoked or the work is completed at the end of a section.

  • Page 131: Lubrication Work

    Maintenance work (continued) 10.2 Lubrication work Information! Section 10.1 of this chapter must be observed! Warning! Turn the main switch on the robot control cabinet to “OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again. Caution! Utmost caution must be exercised when handling cable grease.
  • Page 132 Maintenance Activity Note (Fig. 99) interval Lubricant (hours) Manufacturer Amount KUKA Art. no. Floor- -mounted mani- Oil change Change oil as described in pulator Optigear Synthetic RO 150 Section 10.3.1. Castrol, approx. 0.500 l Gear unit with bearings KUKA Art. no.
  • Page 133 Maintenance work (continued) Ceiling- -mounted robot Caution: 0,600 l only with 0,60 l 0,50 l 0,20 l compensation vessel Floor- -mounted robot 0,50 l 0,50 l 0,20 l Fig. 99 Lubrication Information! When draining the oil, it is important to remember that the quantity drained is depen- dent on time and temperature.

  • Page 134: Changing The Oil On Main Axis Gear Units

    (6) Screw the sealing cap (7) onto the drain hose (6) and tighten it. D Filling with oil (1) Pour specified amount of oil into filler hole of magnetic screw (8). Notice! Only KUKA- -approved lubricants may be used. BA KR 6, 16 F, KR C4 12.10.07 en 134 of 206...

  • Page 135: 10.3.2 Changing The Oil On Axis 2 Gear Unit

    Maintenance work (continued) Information! Use a hose (2) approx. 1 m long with a straight M18x1.5 union (9) together with a fun- nel (1) which fits into the free end of the hose (2). (2) Remove the filling hose (2). (3) Insert and tighten the magnetic screw (8), tightening torque M = 20 Nm.
  • Page 136 D Filling with oil (1) Pour the specified amount of oil into the filler hole at (4). Notice! Only KUKA- -approved lubricants may be used. (2) Remove the filling hose. (3) Insert and tighten the screw plug (4); M = 20 Nm.

  • Page 137: 10.3.3 Changing The Oil On Axis 3 Gear Unit

    Maintenance work (continued) 10.3.3 Changing the oil on axis 3 gear unit Information! Section 10.2 of this chapter must be observed! D Draining the oil Warning! Before performing the next step, it must be ensured that it is not possible for anyone to be injured within the range of the slowly turning robot.
  • Page 138 D Filling with oil (1) Pour the specified amount of oil into the filler hole at (2). Notice! Only KUKA- -approved lubricants may be used. Information! It is easier to fill the oil if a funnel (1) is used for this purpose.

  • Page 139: Other Maintenance

    Exchange toothed belts, see Section 12.10. 1) Also carried out at KUKA before delivery, or must be performed by the user after a toothed belt has been exchanged. 2) For EX- -variant robots, after 5,000 hours of operation. 3) After 2 years at the latest.
  • Page 140 Operating Instructions Fig. 103 Other maintenance BA KR 6, 16 F, KR C4 12.10.07 en 140 of 206...

  • Page 141: Lubrication, In--Line Wrist Iw 6 Ii

    Maintenance Activity Note (see Fig. 104) interval Lubricant (hours) Manufacturer Amount KUKA Art. no. Gear block A4 Oil change Change oil as described in Optigear Synthetic RO 150 Section 10.5.1. Castrol, approx. 0.10 l KUKA Art. no. 00--144--898 O--ring A4 Lubricate Lift O--rings out of grooves.
  • Page 142 Operating Instructions 0.10 l 0.10 l Fig. 104 Lubrication Information! When draining the oil, it is important to remember that the quantity drained is depen- dent on time and temperature. The quantity of oil drained must be measured, as only this quantity may be used when refilling.

  • Page 143: 10.5.1 Oil Change

    10.5.1 Oil change Information! Section 10.2 of this chapter must be observed! Information! The oil is to be changed only at operating temperature. Caution! If the oil change is carried out immediately after the robot has stopped opera- ting, the oil temperature is liable to be high, in which case appropriate safety measures must be taken.
  • Page 144 Operating Instructions D Filling with oil Information! The arm is still positioned horizontally. (1) If necessary, put robot into operation and move wrist axes into zero position. (2) Check the sealing elements of the magnetic screw plugs and exchange if necessary. (3) Screw in magnetic screw plugs (Fig.

  • Page 145: Other Maintenance

    Replace toothed belts Exchange toothed belts, see Section 12.4.2. 1) Also carried out at KUKA before delivery, or must be performed by the user after a toothed belt has been exchanged. 2) After 2 years at the latest. " Fig. 106 Other maintenance BA KR 6, 16 F, KR C4 12.10.07 en...
  • Page 146 Operating Instructions BA KR 6, 16 F, KR C4 12.10.07 en 146 of 206...

  • Page 147: Lubrication, In--Line Wrist Iw 16

    Grease O--ring with brush O--ring and fit it back into groove. KUKA Art. no. 83--087--241 5,000 hours for in- -line wrist “F” 10,000 hours for in- -line wrist “F” The oil quantities specified are the actual amounts of oil in the gear unit at first filling.
  • Page 148 Operating Instructions 0.32 l 0.16 l 0.18 l Fig. 107 Lubrication Information! When draining the oil, it is important to remember that the quantity drained is depen- dent on time and temperature. The quantity of oil drained must be measured, as only this quantity may be used when refilling.

  • Page 149: Oil Change On In--Line Wrist Iw 16

    10.7.1 Oil change on in- -line wrist IW 16 Information! Section 10.2 of this chapter must be observed! Information! The oil is to be changed only at operating temperature. Caution! If the oil change is carried out immediately after the robot has stopped opera- ting, the oil temperature is liable to be high, in which case appropriate safety measures must be taken.
  • Page 150 Operating Instructions D Filling with oil Information! The arm is still positioned horizontally. (1) If necessary, put robot into operation and move wrist axes into zero position. (2) Screw in the magnetic screw plugs (Fig. 108/4, 5, 6) and pour the specified amounts of oil into the oil filler holes.

  • Page 151: Cleaning And Preventive Maintenance

    10.8 Cleaning and preventive maintenance Warning! Turn the main switch on the robot control cabinet to “OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again. This also applies to any cleaning work which, though not performed directly on the robot, is carried out within or close to its working range.

  • Page 152: Safety Precautions When Handling Lubricants

    Operating Instructions 10.9 Safety precautions when handling lubricants The information contained in the safety data sheet according to 91/155 EEC must be ob- served when handling lubricants. An excerpt from this data sheet is included in the robot sec- tion ”Consumables, Safety Data Sheet”. The following safety procedures must be observed at all times: Avoid prolonged contact with the skin;...

  • Page 153: Adjustment

    Adjustment Adjustment Information! This description applies analogously to all of the industrial robots listed in Chapter 1, regardless of the variant or model shown in the illustrations. General 11.1 Information! Observe Chapter 5, “Safety”! Apart from adjustment of the toothed belts, the robot does not require any further mechanical adjustment.

  • Page 154: Measuring And Adjusting The Toothed Belt Tension On Wrist Axis Motor Units A4 And A5 (Motor Side)

    Operating Instructions Some of the specially marked texts refer exclusively to the subsequent steps -- until the in- struction is expressly revoked or the work is completed at the end of a section. Example: Warning! Turn main switch on the robot control cabinet to “OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again.
  • Page 155 Adjustment (continued) D Frequency measurement (1) Remove the sealing cover (Fig. 109/4). Fig. 109 Sealing cover (2) Switch on the belt tension measuring device (Fig. 110/1). (3) Pluck toothed belt and hold sensor (2) at a distance of 2 to 3 mm from the vibrating toothed belt;...
  • Page 156 Operating Instructions Information! If the value indicated in Fig. 111 is obtained, insert the sealing cover. If this value is not obtained, steps (5) to (11) are to be carried out. (5) Slacken the tensioning screw (Fig. 109/1). (6) Slacken the four Allen screws (3) until motor unit A4 (2) can be shifted without play. (7) Carefully tighten the tensioning screw (1) and measure the toothed belt tension again.

  • Page 157: Measuring And Adjusting Toothed Belt Tension On Wrist Axis Motor Units A5 And A6 (In--Line Wrist Iw 6 Ll)

    Adjustment (continued) 11.3 Measuring and adjusting toothed belt tension on wrist axis motor units A5 and A6 (in- -line wrist IW 6 ll) Information! Section 11.1 of this chapter must be observed! Only the adjustment of the toothed belt stage of axis 5 is described. The adjustment is essen- tially the same for axis 6.
  • Page 158 Operating Instructions Fig. 113 Belt tension measuring device Information! If the value indicated in (Fig. 114) is not obtained, steps (5) to (9) are to be carried out. Axis Toothed belt Frequency 250±3 Hz 8AT3/549- -E3/5S+Z 280±3 Hz 6AT3/450- -E3/5S+Z Fig.
  • Page 159 Adjustment (continued) Fig. 115 Adjusting the toothed belt tension (10) Mount cover (Fig. 112/2) and seal (5) and fasten it with two M5x25 (1) Allen screws and five M5x16 (1) Allen screws together with lock washers. BA KR 6, 16 F, KR C4 12.10.07 en 159 of 206...
  • Page 160 Operating Instructions BA KR 6, 16 F, KR C4 12.10.07 en 160 of 206...

  • Page 161: Repair

    The user’s personnel may not carry out dismantling work going beyond the scope of these operations unless they have been trained by KUKA for that particular purpose and have the necessary measuring and testing equipment at their disposal as well as the appropriate documentation.
  • Page 162 Operating Instructions Example: (5) Unscrew four hexagon screws and remove main axis motor unit. Notice! The main axis motor unit must not be tilted while it is being lifted off. Caution! When removing the main axis motor unit, care must be taken to avoid any injury by crushing! Some of the specially marked texts refer exclusively to everything that follows -- until the in- struction is expressly revoked or the work is completed at the end of a section.

  • Page 163: Bonding Instructions

    Repair (continued) 12.2 Bonding instructions Information! When sealants, adhesives and locking agents are used, the manufacturer’s directions must be strictly observed. This also applies to the cleaning of open sealing, locking and adhesion joints where the parts to be joined are to be used again. D Instructions for bonding components (1) Wash the components with cleaning agent and blow them dry.

  • Page 164: Unbraked Impact Against Limit Stops

    If the manipulator hits an obstruction or a buffer on the mechanical end stop or axis range limitation, this can result in material damage to the manipulator. KUKA Roboter GmbH must be consulted before the manipulator is put back into operation. The affected buffer must immediately be replaced with a new one.

  • Page 165: In--Line Wrist Iw 6 Ii, Repair

    12.4 In- -line wrist IW 6 II, repair Information! Section 12.1 of this chapter must be observed! Before repair work is started, any attached tools or additional equipment that would hinder repair must be dismounted. Performing the following work is greatly facilitated if the robot is at a level which can be easily reached by the personnel carrying out the repairs.
  • Page 166 Operating Instructions Fig. 116 Removal, installation of in- -line wrist Notice! The in- -line wrist may not be further dismantled. The removal and installation of the toothed belts is described in Section 12.4.2. Information! If the in--line wrist is not to be reinstalled, it must be protected against corrosion before being put into storage.

  • Page 167: 12.4.2 Removal, Installation Of Toothed Belts A5 And A6

    12.4.2 Removal, installation of toothed belts A5 and A6 Information! The toothed belts of axes 5 and 6 may only be removed and installed together. Section 12.1 of this chapter must be observed! Caution! If the end- -effector is still mounted on the wrist, it must be either removed or secured to prevent it from moving.
  • Page 168 Operating Instructions D Installation (1) Install the toothed belt by carrying out the removal instructions in reverse. Notice! When the toothed belts are installed, the hexagon nuts (1, 3) must be replaced with new ones. Notice! When fitting toothed belts, it must be ensured that they mesh properly with the toothed belt pulleys (see Fig.
  • Page 169 Correct Incorrect Fig. 118 Meshing of toothed belt/pulleys BA KR 6, 16 F, KR C4 12.10.07 en 169 of 206...

  • Page 170: In--Line Wrist Iw 16, Repair

    Operating Instructions 12.5 In- -line wrist IW 16, repair Information! Section 12.1 of this chapter must be observed! Before repair work is started, any attached tools or additional equipment that would hinder repair must be dismounted. Performing the following work is greatly facilitated if the robot is at a level which can be easily reached by the personnel carrying out the repairs.
  • Page 171 Fig. 119 Removal, installation of in- -line wrist Notice! The in- -line wrist may not be further dismantled. Information! If the in--line wrist is not to be reinstalled, it must be protected against corrosion before being put into storage. D Installation (1) Remove all protective coatings and oil from new in--line wrist, if applicable.

  • Page 172: Removal, Installation Of Main Axis Motor Unit A1

    Operating Instructions 12.6 Removal, installation of main axis motor unit A1 Information! Section 12.1 of this chapter must be observed! Warning! If main axis motor unit A1 is to be removed from or installed on an operable robot, the main switch on the control cabinet must be turned to “OFF” and secured with a padlock to prevent unauthorized persons from switching it on again.
  • Page 173 The manufacturer’s specifications with regard to handling and safety must be observed! The hinged steel base is not part of the KUKA contract. (2) Release and unplug connectors XM1 (Fig. 120/2) and XP1 (3). (3) Remove four M10x30 Allen screws (4) together with lock washers.
  • Page 174 Operating Instructions D Installation (1) Remove all protective coatings and oil from new main axis motor unit A1, if applicable. (2) Clean the toothing (Fig. 120/5) before installation and apply a thin but continuous coat of Microlube GL 261. (3) Clean the mounting surface. (4) Insert main axis motor unit A1 (4).

  • Page 175: Removal, Installation Of Main Axis Motor Unit A2

    12.7 Removal, installation of main axis motor unit A2 Information! Section 12.1 of this chapter must be observed! Warning! If main axis motor unit A2 is to be removed from or installed on an operable robot, the main switch on the control cabinet must be turned to “OFF” and secured with a padlock to prevent unauthorized persons from switching it on again.
  • Page 176 Operating Instructions D For floor- -mounted robots and ceiling- - and wall- -mounted robots in the floor posi- tion Warning! If the link arm is to be moved to its forward limit position, the robot must be fas- tened to the floor or to the hinged steel base. For this purpose, the hinged steel base must be swiveled from the 90˚...
  • Page 177 Fig. 122 Removal, installation of main axis motor unit A2 Information! If the main axis motor unit is not to be reinstalled, it must be protected against corrosion before being put into storage. D Installation (1) Remove all protective coatings and oil from new main axis motor unit A2, if applicable. (2) Clean the toothing (Fig.
  • Page 178 Operating Instructions (8) Remove lifting tackle or prop from the robot (Fig. 121). (9) If necessary, bring robot into its original installation position (see Chapter7, “Installation, connection, exchange”). (10) Carry out zero adjustment (see Operating Handbook, Software KR C4, Chapter “Start--up”, Section “Robot mastering/unmastering”).

  • Page 179: Removal, Installation Of Main Axis Motor Unit A3

    12.8 Removal, installation of main axis motor unit A3 Information! Section 12.1 of this chapter must be observed! Warning! If main axis motor unit A3 is to be removed from or installed on an operable robot, the main switch on the control cabinet must be turned to “OFF” and secured with a padlock to prevent unauthorized persons from switching it on again.
  • Page 180 Operating Instructions Fig. 123 Securing the arm (schematic) D Floor- -mounted robots and ceiling- - and wall- -mounted robots in the floor position Warning! If the robot is to be moved into its transport position, it must be fastened to the floor or to the hinged steel base.
  • Page 181 Information! With F--variant robots, seals are fitted between the arm and main axis motor unit A3. These must be removed and exchanged if necessary during installation. When ordering a main axis motor unit, always indicate if it is for use in these robot va- riants.
  • Page 182 Operating Instructions D Installation Information! With F--variant robots, seals are fitted between the arm and main axis motor unit A3. These must be renewed during installation. In addition, the fastening screws are to be inserted using Drei Bond 1118 sealant. When ordering a main axis motor unit, always indicate if it is for use in these robot va- riants.

  • Page 183: Removal, Installation Of Wrist Axis Motor Units A4 To A6

    12.9 Removal, installation of wrist axis motor units A4 to A6 Information! Section 12.1 of this chapter must be observed! Warning! If wrist axis motor unit A5 is to be removed from or installed in an operable robot, the main switch on the control cabinet must be turned to “OFF” and secured with a padlock to prevent unauthorized persons from switching it on again.
  • Page 184 Operating Instructions Fig. 125 Removal, installation of wrist axis motor units Information! If the wrist axis motor unit is not to be reinstalled, it must be protected against corrosion before being put into storage. BA KR 6, 16 F, KR C4 12.10.07 en 184 of 206...
  • Page 185 D Installation (A4 and A5) Information! With F--variant robots, seals are fitted between the arm and the wrist axis motor units. These must be renewed during installation. In addition, for this robot variant, Drei Bond 1108 sealant is to be used when inserting the following screws: -- Adjusting screws for wrist axis motor units A4 and A5 -- Setscrews for the holes not occupied by the adjusting screws -- Lower fastening screws for wrist axis motor unit A5...
  • Page 186 Operating Instructions Notice! When installing the motor unit, it must be ensured that the toothed belts mesh properly with the toothed belt pulleys, see Fig. 127. Correct Incorrect Fig. 127 Correct toothed belt position (4) Insert the four Allen screws M5x16 (Fig. 125/2) together with lock washers and tighten the Allen screws until the motor unit can be shifted without play.
  • Page 187 D Installation (A6) Information! With F--variant robots, seals are fitted between the arm and the wrist axis motor units. These must be renewed during installation. In addition, for this robot variant, Drei Bond 1108 sealant is to be used when inserting the following screws: -- Setscrews for the holes not occupied by the adjusting screws.

  • Page 188: 12.10 Removal, Installation Of Toothed Belts

    Operating Instructions 12.10 Removal, installation of toothed belts Information! Section 12.1 of this chapter must be observed! D Removal (1) Remove wrist axis motor units A4 (Fig. 129/6), A5 (1) and A6 (8) (see Section 12.9). (2) Remove in--line wrist (see Section 12.4 or 12.5). (3) Remove the four Allen screws (7).

  • Page 189: 12.11 Tightening Torques

    12.11 Tightening torques Information! The following tightening torques are valid for screws and nuts where no other specifica- tions are given. Notice! Too high a tightening torque can cause the screws to be overloaded and to frac- ture. This might result in damage to the components. Tighten the screws with the specified torque in order to avoid damage.
  • Page 190 Operating Instructions BA KR 6, 16 F, KR C4 12.10.07 en 190 of 206...

  • Page 191: Consumables, Safety Data Sheets

    Consumables, safety data sheets Consumables, safety data sheets 13.1 Safety data sheet for Optitemp RB1 cable grease The following extract from the safety data sheet according to 91/155/EEC must be observed when han- dling Optitemp RB1. Designation of substance/formulation and manufacturer Trade name: Optitemp RB1 Art.
  • Page 192 Operating Instructions Handling and storage Handling: No special measures required. Storage: Store product in original container only. Do not store in direct sunlight. Never leave the container open. Technical Instructions on Air Quality Control / Annex E (Class): Water hazard classification: 1 (manufacturer’s classification based on the law of mixtures acc.
  • Page 193 The product may only be used for the scope of work specified above; any other use requires prior consultation with KUKA. Using the product for any purpose other than for its designated use could lead to risks which are not described in this document.

  • Page 194: Safety Data Sheet For Optimol Olit Cls Lubricating Grease

    Operating Instructions 13.2 Safety data sheet for Optimol Olit CLS lubricating grease The following extract from the safety data sheet according to 91/155/EEC must be observed when han- dling Optimol Olit CLS. Designation of substance/formulation and manufacturer Trade name: Optimol Olit CLS Art.
  • Page 195 Consumables, safety data sheets (continued) Handling and storage Handling: No special measures required if handled in accordance with specifications. Storage: Store in a dry, dust--free atmosphere in closed, original containers at temperatures between 10--20 °C. Avoid large variations in temperature! Do not store together with strong oxidizing agents.
  • Page 196 The product may only be used for the scope of work specified above; any other use requires prior consultation with KUKA. Using the product for any purpose other than for its designated use could lead to risks which are not described in this document.

  • Page 197: Safety Data Sheet For Optigear Synthetic Ro 150 Oil

    Consumables, safety data sheets (continued) 13.3 Safety data sheet for Optigear Synthetic RO 150 oil Designation of substance/formulation and manufacturer Product name: Optigear Synthetic RO 150 SDS no.: 465036 Historical SDS no.: DE- -05254, FR- -465036, SK- -5254 Use of substance or formulation: Lubricant For specific instructions for use, see the corresponding technical data sheet or contact a company representative.
  • Page 198 Operating Instructions First aid measures Eye contact: In case of contact, rinse eyes immediately with plenty of water for at least 15 minutes. If irritation occurs, consult a doctor. Skin contact: Wash affected areas of skin with soap and water, or use suitable cleaning agent. Change clothing and shoes if they become contaminated with product.
  • Page 199 Consumables, safety data sheets (continued) Measures after unintended release Personal safety precautions: No measures should be taken that involve a risk to personnel or have not been adequately trained. Evacuate the environment. Refuse access to personnel who are not required or are unprotected. Do not touch or step on any spilled substance. Avoid breathing in any spray or vapors.
  • Page 200 Operating Instructions Exposure limits and personal protective equipment Ingredient name ACGIH TLVs: Base oil – unspecified Limits to monitor: ACGIH (USA). TWA: 5 mg/m 8 hour(s). Form: mineral oil mist STEL: 10 mg/m 15 minute(s). Form: mineral oil mist The ACGIH values are enclosed for information and orientation purposes. Further information can be obtained from your supplier.
  • Page 201 Consumables, safety data sheets (continued) 10 Stability and reactivity Stability: The product is stable. No hazardous polymerization occurs under normal storage conditions and in normal use. Conditions to be avoided: No specific data. Substances to be avoided: Reactive or incompatible with the following substances: oxidizing materials. Hazardous decomposition products: The combustion products may include the following compounds: Carbon oxides...
  • Page 202 Operating Instructions 15 Regulations Classification and labeling have been performed according to EU directives 1999/45/EC and 67/548/EEC as amended and adapted. Labeling requirements Risk (R) phrases: R52/53 -- Harmful to aquatic organisms, may cause long--term adverse effects in the aquatic environment. Safety (S) phrases: S61 -- Avoid release to the environment.
  • Page 203 Consumables, safety data sheets (continued) 16 Other information Full text of R- -phrases referred to in Sections 2 and 3: R41 -- Risk of serious damage to eyes. R38 -- Irritating to skin. R50/53 -- Very toxic to aquatic organisms, may cause long--term adverse effects in the aquatic environment.

  • Page 204: Safety Data Sheet For Microlube Gl 261 Lubricant

    Operating Instructions 13.4 Safety data sheet for Microlube GL 261 lubricant The following extract from the safety data sheet according to 91/155/EEC must be observed when han- dling Microlube GL 261. Designation of substance/formulation and manufacturer Trade name: Microlube GL 261 Article no.: 020195 Use: Lubricant...
  • Page 205 Consumables, safety data sheets (continued) Measures after unintended release Personal safety precautions: No special safety precautions required. Environmental protection measures: Contain polluted or extinguishing water. Prevent it from entering the drainage system, surface waters or other waterways. Procedure for cleaning/removing: Bind lubricant with a suitable binding agent and dispose of it in accordance with regulations.
  • Page 206 Operating Instructions 10 Stability and reactivity Thermal decomposition / conditions to be avoided: No decomposition if handled and stored correctly. Substances to be avoided: Oxidizing agents. Hazardous reactions: No hazardous reactions known. Hazardous decomposition products: None if used for designated purpose. 11 Toxicological information Prolonged contact with the skin can cause irritation and/or dermatitis.

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