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ROBOT

(V)KR 150, 180, 210, 240, 270--2 with KR C4

Assembly Instructions

Issued: 20 Dec 2011 Version: 01

MA KR 2000, KR C4 01.10.01 en 1 of 136


e Copyright 2011

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.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

Translation of the original documentation

2 of 136 MA KR 2000, KR C4 01.10.01 en


Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Documentation of the industrial robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Representation of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.1 Wrist axis motor units A4 to A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Link arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Rotating column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7 Mechanical counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Hydropneumatic counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.9 Working range limitation for A1 to A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.10 Energy supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.11 Special “Foundry” equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1.1 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1.2 Intended use of the industrial robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.1.3 EC declaration of conformity and declaration of incorporation . . . . . . . . . . . . . . . . . . . . . . . . 56
5.1.4 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.3 Workspace, safety zone and danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.4 Overview of protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.4.1 Mechanical end stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.4.2 Mechanical axis range limitation (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.4.3 Axis range monitoring (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.4.4 Devices for moving the manipulator without the robot controller (options) . . . . . . . . . . . . . . 62

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Assembly Instructions

5.4.5 Labeling on the industrial robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64


5.5 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.5.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.5.2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.5.3 Start--up and recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.5.4 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.5.5 Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.5.6 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.5.7 Decommissioning, storage and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.6 Applied norms and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.2 Principal loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.3 Mounting variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.4.1 Variant 1 (394.016--08.001.00--00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.4.2 Variant 2 (394.018--08.002.00--00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.4.3 Variant 3 (394.100--01.005.00--00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.5 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.5.1 Floor--mounted manipulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.5.2 Ceiling--mounted manipulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

8 Electrical installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101


8.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8.2 Cabling plans and wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

9 Connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113


9.1 Routing of cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.2 Junction boxes on the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.3 Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
9.4 Connector panel on the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.5 Configuration of the connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
9.6 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

10 Consumables, safety data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121


10.1 Safety data sheet for Optitemp RB1 cable grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
10.2 Safety data sheet for Optimol Olit CLS lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.3 Safety data sheet for Optigear Synthetic RO 150 oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
10.4 Safety data sheet for Microlube GL 261 lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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1 Introduction

Valid for (V)KR 150--2


(V)KR 150 L130--2
(V)KR 150 L110--2
(V)KR 180--2
(V)KR 180 L150--2
(V)KR 180 L130--2
(V)KR 210--2
(V)KR 210 L180--2
(V)KR 210 L150--2
(V)KR 240--2
(V)KR 240 L210--2
(V)KR 240 L180--2
(V)KR 270--2
also for the “Foundry” variants

1 Introduction

1.1 Documentation of the industrial robot


The documentation of this industrial robot comprises the following parts:
-- Assembly instructions for KR 2000 with KR C4
-- Parts catalog on storage medium

Each of these parts is a separate document that is attached to the industrial robot.
The assembly instructions and parts catalog for the controller are not part of this documenta-
tion.

1.2 Representation of warnings and notes


Warnings marked with this pictogram are relevant to safety and must be observed.

This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.

This warning means that minor physical injuries or minor material damage may
occur, if no precautions are taken.

Notes marked with this pictogram contain tips to make your work easier or references
to further information.

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Assembly Instructions

2 Purpose
2.1 Intended use
Use
Handling of tools or fixtures for processing or transferring components or products, e.g.
-- Spot welding
-- Handling
-- Assembly
-- Application of adhesives, sealants and preservatives
-- Machining
-- MIG/MAG welding
-- YAG laser beam welding.
Use is only permitted under the environmental conditions specified in Chapter 4.
Misuse
Any use or application deviating from the intended use is deemed to be impermissible mis-
use; examples of such misuse include:
-- Transportation of persons and animals
-- Use as a climbing aid
-- Operation outside the permissible operating parameters
-- Use in potentially explosive environments

Changing the structure of the manipulator, e.g. by drilling holes, etc., can result
in damage to the components. This is considered improper use and leads to
loss of guarantee and liability entitlements.

2.2 Target group


This documentation is aimed at users with the following knowledge and skills:
-- Advanced knowledge of mechanical engineering
-- Advanced knowledge of electrical and electronic systems
-- Knowledge of the robot controller system

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.

6 of 136 MA KR 2000, KR C4 01.10.01 en


3 Product description

3 Product description
3.1 General

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 industrial robot consists of the manipulator (= robot arm), control cabinet and connecting
cables (Fig. 1). The manipulator is dealt with in this documentation. The control cabinet and
connecting cables are described in separate documentation.

1 Manipulator
2 Control cabinet
3 Connecting cables

Fig. 1 Industrial robot (example: floor--mounted)

This section is subdivided in accordance with the breakdown of the manipulator into its main
subassemblies.

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Assembly Instructions

3.2 Wrist
The manipulator is equipped with a triple--axis in--line wrist (Fig. 2) for a payload of 150, 180,
210, 240 or 270 kg, depending on the type. The wrist is fastened onto the arm via the
flange (4). The axes 4, 5 and 6 are driven by shafts (1, 2, 3). An end effector (tool) can be
attached to the mounting flange (5) of axis 6. Each axis has a measuring device (6), through
which the mechanical zero of the respective axis can be checked by means of an electronic
probe (accessory) and transferred to the controller. The design of the in--line wrist makes it
possible to exchange the mounting flange (5), allowing it to be easily adapted to the user’s
requirements.
The in--line wrist variant “F” is available for operating conditions involving greater mechanical
and thermal stress.
Further technical data, such as the directions of rotation of the axes, axis data and protection
ratings can be found in Chapter 4, “Technical data”.

1 2 3 4 5

1 Drive shaft, axis 6


2 Drive shaft, axis 5
3 Drive shaft, axis 4
4 Flange
5 Mounting flange
6 Measuring device (gauge cartridge)

Fig. 2 In--line wrist 150/180/210/210/240/270

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3 Product description (continued)

3.3 Arm
The arm assembly (Fig. 3) embodies the driven element of axis 3 of the manipulator. The
arm is flange--mounted to the side of the link arm (7) through a gear unit with integrated bear-
ings and is driven by main axis motor unit A3 (6). The swivel axis (3) of the arm has been
so selected that with the rated payload there is no need for an additional counterweight to
balance the masses on the arm.
The effective software swivel range for all robot variants extends from +155° to --119°, re-
ferred to the electrical zero position of axis 3, which is given when there is an angle of 180˚
between the longitudinal axes of the arm and link arm, i.e. with both longitudinal axes lying
parallel to each other. In addition to the software limit switches, the swivel range is also limited
by mechanical limit stops with a buffer function.
Attached to the rear of the arm housing (2) are the motor units for wrist axes 4 to 6. It consists
-- as do the housings of the link arm and rotating column -- of a light alloy construction opti-
mized by means of CAD and FEM.
Mounted on the front end of the arm via a standardized interface is the in--line wrist (4), which
is driven by the three AC servomotors (1) through push--on universal shafts (5) located inside
the arm.
The manipulator can be fitted with two different arm extensions, which make it possible to
extend the arm by 200 mm or 400 mm respectively. The arm extensions are installed be-
tween the arm housing (2) and the in--line wrist (4).
With “F” variant manipulators, the arm is pressurized. It is operated with an internal pressure
of 0.1 bar.
If the manipulator is installed on the ceiling, the working envelope to the front of the manipula-
tor is restricted. Depending on the position of the link arm, axis 3 can then only be moved
through a limited range.
2 3 4

--119˚

1
+155˚
6
5

1 AC servomotor for wrist axes 5 Universal shaft


2 Arm housing 6 Main axis motor unit A3
3 Rotational axis A3 7 Link arm
4 In--line wrist

Fig. 3 Arm with turning range

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Assembly Instructions

3.3.1 Wrist axis motor units A4 to A6


The wrist axes are driven by three AC servomotors. These are fastened to the arm (Fig. 4/4)
by means of screws. The AC servomotors for axis 4 (1) to axis 6 (3) are of the same design.
Axes 4 and 6 are driven by AC servomotors (1, 3) via universal shafts (5). Wrist axis A5 is
driven directly by AC servomotor A5 (2) via a push--on shaft (6).
Each wrist axis motor unit consists of a brushless AC servomotor with a permanent--magnet
single--disk brake and a hollow--shaft resolver (both integrated).
The permanent--magnet single--disk brake performs a holding function when the servomo-
tors are at rest and contributes to the braking of the respective axis in the event of short--cir-
cuit braking (e.g. if one or more of the enabling switches is released while in Test mode).
Short--circuit braking must not be used to stop the industrial robot under normal circum-
stances.

1 2 3 4

A4

A5

A6

1 AC servomotor A4
2 AC servomotor A5
3 AC servomotor A6
4 Arm 6 5
5 Universal shaft
6 Shaft

Fig. 4 Wrist axis motor units A4 to A6

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3 Product description (continued)

3.4 Link arm


The link arm (Fig. 5/1) is the driven element of axis 2. It pivots about rotational axis A2 (3)
through an effective software range from +0° to --146° ⎯ referred to the electrical zero posi-
tion of axis 2, which corresponds to the horizontal position of the link arm. In Fig. 5, the link
arm is in the mechanical zero position, i.e. at --90° with respect to the electrical zero position.
The effective software swivel range is limited by mechanical limit stops with a buffer function
in addition to the software limit switches.

--90°

--146˚

2
3

1 Link arm
2 Main axis motor unit A2
3 Rotational axis 2

Fig. 5 Link arm with turning range

The link arm (Fig. 6) contains the gear unit A3 (1) at its upper end, and the gear unit A2 (4)
at its lower end. The gear units (1, 4) are used both as drive elements and to support the arm
and link arm assemblies. The gauge cartridge (3) and reference notch (2) are provided to
define the mechanical zero position of axes 2 and 3. The cables for energy supply and signal
transmission are routed in the interior of the link arm housing (7) from the rotating column
to the arm (see Chapter 8, “Electrical installations”).

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Assembly Instructions

4
6

1 Gear unit A3 5 Main axis motor unit A2


2 Reference notch A3 6 Rotational axis 2
3 Gauge cartridge A2 7 Link arm housing
4 Gear unit A2

Fig. 6 Structure of link arm

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3 Product description (continued)

The robot axes 1, 2 and 3 are driven by main axis motor units as shown in Fig. 7. Each motor
unit for the main axis drives consists of a brushless AC servomotor (1) with a permanent--
magnet single--disk brake and hollow--shaft resolver (2), both integrated. Servomotors with
different power ratings are used in main axes 1 to 3, depending on the rated payload; how-
ever, all are identical in design and function.

The permanent--magnet single--disk brake performs a holding function when the servomo-
tors are at rest and contributes to the braking of the respective axis in the event of short--cir-
cuit braking (e.g. if one or more of the enabling switches is released while in Test mode).
Short--circuit braking must not be used to stop the industrial robot under normal circum-
stances.

2
1

1 AC servomotor 2 Hollow--shaft resolver

Fig. 7 AC servomotor for main axis motor unit

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Assembly Instructions

3.5 Rotating column


Installed in the rotating column is the main axis motor unit for axis 1 (Fig. 8/1), together with
the reduction gear unit (2). The main axis motor unit for axis 2 (2) with its reduction gear
unit (4) is installed on the side of the rotating column, but is counted as part of the link arm
assembly.
Part of the manipulator electrical installations is routed inside the rotating column. If the in-
dustrial robot is equipped with an “energy supply system A1”, interface A2 and part of the
dress package are also installed on/in the rotating column.

4 3 2

1 Main axis motor unit A1


2 Reduction gear unit A1
3 Main axis motor unit A2
4 Reduction gear unit A1

Fig. 8 Structure of rotating column

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3 Product description (continued)

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 reduction gear unit (3), which allows it to
rotate, it performs movements about rotational axis 1 (1). It has an effective software turning
range of 185° in both the (+) and (--) directions, measured from the mechanical zero position
of axis (6). This range is limited by mechanical limit stops with a buffer function in addition
to the software limit switches. This limit stop system operates with a trailing stop acting on
both sides, which is installed in the base frame and mechanically limits the large turning range
of 185˚ in both directions.

--185°

1 Rotational axis 1
2 Rotating column
3 Reduction gear unit
4 Base frame
+185° 5 Main axis motor unit A2
6 Zero position A1

Fig. 9 Rotating column with turning range

MA KR 2000, KR C4 01.10.01 en 15 of 136


Assembly Instructions

3.6 Base frame


The base frame (Fig. 10) is the stationary part of the manipulator, on which the rotating col-
umn turns with the link arm, the arm and the in--line wrist. Its base flange (7) features
through--holes (8) for holding the manipulator down and two locating boreholes (6), with
which the manipulator can be placed on two locating pins (accessories, see Chapter 7,
“Installation”).
Attached to the flange (5) in the base frame housing (2) is the reduction gear unit (4) of axis
1. Also integrated into this flange (5) is the double--acting stop, which together with a stop
block on the rotating column mechanically safeguards the software--limited movement range
of 370° about rotational axis 1.
In the base frame, the installation cables leading to the rotating column are routed stress--
free about rotational axis 1 in a flexible tube. The space between the rotating column and the
base frame is provided with a detachable, one--piece cover (3).
The sockets for the connecting cables from the manipulator to the control cabinet are located
on the RDC box (1) and on the MFH (multi--function housing).
If the manipulator is equipped with an energy supply system A1, the dress package and inter-
face A1 are also installed in/on the base frame.

6
8

3
4

8 5

7 6

1 RDC box and MFH (multi--function housing) 5 Flange


2 Base frame housing 6 Locating boreholes (2x)
3 Cover 7 Base flange
4 Reduction gear unit A1 8 Fastening boreholes (8x)

Fig. 10 Structure of the base frame

16 of 136 MA KR 2000, KR C4 01.10.01 en


3 Product description (continued)

3.7 Mechanical counterbalancing system


The manipulator is equipped with a closed mechanical counterbalancing system for compen-
sating the load moment of axis 2 (Fig. 11). The system is installed between the rotating col-
umn (2) and the link arm (1), and is fitted with a spring assembly according to the rated pay-
load. A corresponding counterbalancing system is available for floor--mounted and
ceiling--mounted manipulators, and there are special counterbalance variants for use in F--
variant manipulators.
The principal components of the mechanical counterbalancing system are the spring assem-
bly (4), the articulated head (3), the bearing block (5) and the two self--aligning roller bear-
ings (6).
Specialist knowledge is required when handling the spring assembly, as the preloaded spring
assembly can cause considerable injury.

1
4

2
5 6 4 3

1 Link arm
2 Rotating column
3 Articulated head
4 Spring assembly
5 Bearing block
6 Self--aligning roller bearing

Fig. 11 Mechanical counterbalancing system (example: floor--mounted manipulator)

MA KR 2000, KR C4 01.10.01 en 17 of 136


Assembly Instructions

3.8 Hydropneumatic counterbalancing system


With ceiling--mounted manipulators of type 240--2 C, a hydropneumatic counterbalancing
system (Fig. 12) is used to compensate the load moment of axis 2. The system is installed
between the rotating column (1) and the link arm (2).
The principal components of the system are the hydraulic cylinder (6), the diaphragm--type
accumulator (4) with gas/oil charge and the articulated head (3).

1
2

12
4
11

10 5
6
9
7
8

1 Rotating column
2 Link arm
3 Articulated head
4 Diaphragm--type accumulator
5 Check valve
6 Hydraulic cylinder
7 Accumulator safety valve
8 Screw coupling
9 Pressure gauge
10 Self--aligning roller bearing
11 Check valve
12 Screw coupling

Fig. 12 Hydropneumatic counterbalancing system

18 of 136 MA KR 2000, KR C4 01.10.01 en


3 Product description (continued)

3.9 Working range limitation for A1 to A3


Mechanical stops for task--related limitation of the respective working range for axes 1 to 3
can be supplied as the “Working range limitation” accessory (see documentation “Working
Range Limitation”). The working range is limited in increments of 15°.
The working range limitation is described in separate documentation.

3.10 Energy supply system


For use in certain production technologies, the industrial robot can be equipped with an en-
ergy supply system installed between the base frame and axis 6. The energy supply system
consists of a dress package (cable and hose bundle) for transmitting the energy and fluids
typical for the specific application, and the “Group of holders for energy supply system” re-
quired for attaching it to the manipulator. The energy supply system accommodates the
cables and hoses and ensures that they are guided with minimum stress throughout the per-
mitted working envelope. The design of the energy supply system is suitable for the majority
of applications in terms of reach and resistance to wear. There may, of course, be applica-
tions for which this version is of only limited use. A special version is required in such cases,
or a corresponding adaptation of the energy supply system.
The energy supply system is described in separate documentation.

3.11 Special “Foundry” equipment


The manipulator variants KR 180--2 F exclusive and KR 210--2 F exclusive are equipped with
additional covers and protective features, making them suitable for use in particularly harsh
ambient conditions. The equipment comprises the option packages “Protection plus” and “F
exclusive”.
“Protection plus” consists of plastic covers for the junction box, rotating column, arm and in--
line wrist, while “F exclusive” comprises metal covers for the counterbalancing system and
the interface between the link arm and the rotating column. Both sets of covers, in combina-
tion with the F variant, provide a high level of protection against erosion and water spray.
The “F exclusive” manipulator variants additionally include an in--line wrist variant with spe-
cial protective features.
Further information is given in separate documentation.

MA KR 2000, KR C4 01.10.01 en 19 of 136


Assembly Instructions

20 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data

4 Technical data
4.1 General

This description applies analogously to all of the industrial robots listed in Chapter 1,
regardless of the variant or model shown in the illustrations.
It does not apply to the following variants:
-- KR 150, 180, 210, 240--2 HO, ...CR
-- KR 240--2 PA
-- KR 240--2 C.
These are detailed in separate documentation.

The industrial robot is a six--axis manipulator for installation on the floor or on the ceiling. It
is suitable for all point--to--point and continuous--path controlled tasks. The main areas of ap-
plication are:
-- Spot welding
-- Handling
-- Assembly
-- Application of adhesives, sealants and preservatives
-- Machining
-- MIG/MAG welding
-- YAG laser beam welding.

Using the industrial robot for purposes other than those mentioned above is
considered contrary to its intended use (see Section 2, “Purpose”).

Fig. 13 shows the industrial robot with the manipulator (= robot arm and electrical installa-
tions), control cabinet and connecting cables.
The following data apply, unless otherwise indicated, to both floor--mounted and ceiling--
mounted robots.

MA KR 2000, KR C4 01.10.01 en 21 of 136


Assembly Instructions

3 4

5 8
6

1 Counterbalancing system 6 Base frame


2 Link arm 7 Control cabinet
3 Arm (see separate documentation)
4 In--line wrist 8 Connecting cables
5 Rotating column

Fig. 13 Main components of the industrial robot

22 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

4.2 Principal data


Types KR 150--2 KR 150 L130--2 KR 150 L110--2
KR 180--2 KR 180 L150--2 KR 180 L130--2
KR 210--2 KR 210 L180--2 KR 210 L150--2
KR 240--2 KR 240 L210--2 KR 240 L180--2
KR 270--2

Number of axes 6 (Fig. 15)

Load limits see following table and Fig. 14

Industrial robot type KR 150--2 KR 150 L130--2 KR 150 L110--2


Wrist (IW)1 150/180 kg
Rated payload [kg] 150 130 110
Suppl. load, arm [kg] 50 50 50
Suppl. load, link arm [kg] 100 100 100
Max. suppl. load,
100
arm and link arm [kg]
Suppl. load, rotating 300 300 300
column [kg]
Max. total load [kg] 550 530 510
Arm length [mm] 1100 1300 1500

Industrial robot type KR 180--2 KR 180 L150--2 KR 180 L130--2


Wrist (IW)1 150/180 kg
Rated payload [kg] 180 150 130
Suppl. load, arm [kg] 50 50 80
Suppl. load, link arm [kg] 100 100 100
Max. suppl. load,
100
arm and link arm [kg]
Suppl. load, rotating 300 300 300
column [kg]
Max. total load [kg] 580 550 530
Arm length [mm] 1100 1300 1500

MA KR 2000, KR C4 01.10.01 en 23 of 136


Assembly Instructions

Industrial robot type KR 210--2 KR 210 L180--2 KR 210 L150--2


Wrist (IW)1 210/240 kg
Rated payload [kg] 210 180 150
Suppl. load, arm [kg] 50 50 50
Suppl. load, link arm [kg] 100 100 100
Max. suppl. load,
100
arm and link arm [kg]
Suppl. load, rotating 300 300 300
column [kg]
Max. total load [kg] 610 580 550
Arm length [mm] 1100 1300 1500

Industrial robot type KR 240--2 KR 240 L210--2 KR 240 L180--2


Wrist (IW)1 210/240 kg
Rated payload [kg] 240 210 180
Suppl. load, arm [kg] 50 50 50
Suppl. load, link arm [kg] 100 100 100
Max. suppl. load,
100
arm and link arm [kg]
Suppl. load, rotating 300 300 300
column [kg]
Max. total load [kg] 640 610 580
Arm length [mm] 1100 1300 1500

Industrial robot type KR 270--2


Wrist (IW)1 270 kg
Rated payload [kg] 270
Suppl. load, arm [kg] 30
Suppl. load, link arm [kg] 100
Max. suppl. load,
100
arm and link arm [kg]
Suppl. load, rotating 300
column [kg]
Max. total load [kg] 670
Arm length [mm] 1100

1 IW = in--line wrist

24 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

Max. total load

Suppl. load Payload

Max. suppl. load,


link arm/arm P

Suppl. load, Suppl. load,


rotating column link arm

Fig. 14 Load distribution

Axis data
All specifications in the “Range of motion” column are referred to the electrical zero of the
robot axis concerned.

KR 150-- 2
KR 150 L130-- 2
KR 150 L110-- 2
D In--line wrist, rated payload 150/130/110 kg

Axis Range of motion, Speed with rated payload


software--limited

150 kg 130 kg 110 kg

1 ±185˚ 110 ˚/s 105 ˚/s 105 ˚/s

2 +0˚ to --146˚ 110 ˚/s 110 ˚/s 110 ˚/s

3 +155˚ to --119˚ 100 ˚/s 95 ˚/s 93 ˚/s

4 ±350˚ 170 ˚/s

5 ±125˚ 170 ˚/s

6 ±350˚ 238 ˚/s

MA KR 2000, KR C4 01.10.01 en 25 of 136


Assembly Instructions

KR 180-- 2
KR 180 L150-- 2
KR 180 L130-- 2
D In--line wrist, rated payload 180/150/130 kg

Axis Range of motion, Speed with rated payload


software--limited

180 kg 150 kg 130 kg

1 ±185˚ 95 ˚/s

2 +0˚ to --146˚ 95 ˚/s

3 +155˚ to --119˚ 90 ˚/s 87 ˚/s 83 ˚/s

4 ±350˚ 162 ˚/s 168 ˚/s 171 ˚/s

5 ±125˚ 164 ˚/s 168 ˚/s 170 ˚/s

6 ±350˚ 229 ˚/s 235 ˚/s 238 ˚/s

KR 210-- 2
KR 210 L180-- 2
KR 210 L150-- 2
D In--line wrist, rated payload 210/180/150 kg

Axis Range of motion, Speed


software--limited

210 kg 180 kg 150 kg

1 ±185˚ 86 ˚/s

2 +0˚ to --146˚ 84 ˚/s

3 +155˚ to --119˚ 84 ˚/s 84 ˚/s 81 ˚/s

4 ±350˚ 100 ˚/s

5 ±125˚ 110 ˚/s

6 ±350˚ 184 ˚/s

26 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

KR 240-- 2
KR 240 L180-- 2
KR 240 L210-- 2
D In--line wrist, rated payload 240/210/180 kg

Axis Range of motion, Speed


software--limited

240 kg 210 kg 180 kg

1 ±185˚ 86 ˚/s 82 ˚/s 82 ˚/s

2 +0˚ to --146˚ 80 ˚/s 78 ˚/s 78 ˚/s

3 +155˚ to --119˚ 79 ˚/s 74 ˚/s 76 ˚/s

4 ±350˚ 100 ˚/s

5 ±125˚ 110 ˚/s

6 ±350˚ 184 ˚/s

KR 270-- 2
D In--line wrist, rated payload 270 kg

Axis Range of motion, Speed


software--limited

270 kg

1 ±185˚ 85 ˚/s

2 +0˚ to --146˚ 79 ˚/s

3 +155˚ to --119˚ 77 ˚/s

4 ±350˚ 100 ˚/s

5 ±125˚ 100 ˚/s

6 ±350˚ 156 ˚/s

MA KR 2000, KR C4 01.10.01 en 27 of 136


Assembly Instructions

A4 +
+ +
A5 A3
-
-
+ -
A1
- - +
A6
+
A2
-

Fig. 15 Robot axes and their possible motions

Pose repeatability ± 0.06 mm


(ISO 9283)

Mounting position Floor or ceiling


KR 270--2: floor
(permissible angle of inclination ≤ 5˚).
Principal dimensions see Fig. 29

Working envelope see Fig. 29

Volume of working envelope


KR 150--2 approx. 55.0 m3
KR 150 L130--2 approx. 72.9 m3
KR 150 L110--2 approx. 93.0 m3
KR 180--2 approx. 55.0 m3
KR 180 L150--2 approx. 72.9 m3
KR 180 L130--2 approx. 93.0 m3
KR 210--2 approx. 55.0 m3
KR 210 L180--2 approx. 72.9 m3
KR 210 L150--2 approx. 93.0 m3
KR 240--2 approx. 55.0 m3
KR 240 L210--2 approx. 72.9 m3
KR 240 L180--2 approx. 93.0 m3
KR 270--2 approx. 55.0 m3
The reference point is the intersection of axes 4 and 5.

Load center of gravity P


see Fig. 16 to Fig. 28
For all rated payloads, the horizontal distance of the load center
of gravity P from the face of the mounting flange is 240 mm; the
vertical distance from rotational axis 6 is 270 mm (nominal dis-
tance in each case).

28 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

Mounting flange DIN/ISO1 mounting flange (Fig. 32).


The mounting flange is depicted with axes 4 and 6 in the zero posi-
tion. The symbol indicates the position of the locating element
(bushing). M10 screws of grade 10.9 are to be used for attaching
payloads. The grip length of the screws in the flange must be at
least 1.5 x nominal diameter.
Depth of engagement: min. 12 mm
max. 14 mm
1 DIN/ISO 9409--1--A160

Weight Floor--mounted Ceiling--mounted

KR 150--2 1412 kg 1425 kg


KR 150 L130--2 1422 kg 1435 kg
KR 150 L110--2 1430 kg 1445 kg
KR 180--2 1412 kg 1425 kg
KR 180 L150--2 1422 kg 1435 kg
KR 180 L130--2 1430 kg 1445 kg
KR 210--2 1412 kg 1425 kg
KR 210 L180--2 1422 kg 1435 kg
KR 210 L150--2 1430 kg 1445 kg
KR 240--2 1412 kg ----*
KR 240 L210--2 1422 kg ----*
KR 240 L180--2 1430 kg ----*
KR 270--2 1412 kg ----

Principal dynamic loads


see Fig. 33

Drive system Electromechanical, with transistor--controlled AC servomotors.

*See Doc. Module Ro/Me/01/33.07


Installed motor capacity
KR 150--2 21.60 kW
KR 180--2 22.80 kW
KR 210--2 23.40 kW
KR 240--2 22.80 kW
KR 270--2 22.80 kW

Protection classification of the manipulator


IP 65
ready for operation, with connecting cables plugged in
(according to EN 60529).

Protection classification of the in--line wrist


IP 65 (acc. to EN 60529).

Protection classification of the in--line wrist “F”


IP 67 (acc. to EN 60529).

MA KR 2000, KR C4 01.10.01 en 29 of 136


Assembly Instructions

Stress limits, in--line wrist “F”


Thermal loading 10 s/min at 453 K (+180 °C)
Surface temperature 373 K (+100 °C)
Resistant to: -- high ambient dust content
-- lubricants and coolants*
-- steam
Special maintenance intervals apply for in--line wrists of type “F”
* after consultation with KUKA.

Ambient temperature during operation:


283 K to 328 K (+10 °C to +55 °C),
for operation with SafeRDC:
283 K to 323 K (+10 °C to +50 °C),
during storage/transportation:
233 K to 333 K (--40 °C to +60 °C).
Other temperature limits available on request.

Special features for the “F” variant


Pressurized arm
Overpressure in arm: 0.1 bar
Compressed air: free of oil and water
Air consumption: approx. 0.1 m3/h
Connection: Quick Star for
hose PLN--6x1--NT
Pressure reducer: 0.1 -- 0.7 bar
Pressure gauge: 0 -- 1 bar
Filter: 25 -- 30 µm

Sound level < 75 dB (A) outside the working envelope.

Zero adjustment For zero adjustment with the electronic probe (accessory) when
the tool is mounted, the latter must be designed to allow sufficient
space for installation and removal of the probe (Fig. 34).

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

Plates see Fig. 35 to Fig. 48


Stopping distances and times
See separate documentation

30 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

Concerning Fig. 16 to Fig. 28:


These loading curves correspond to the maximum load capacity. Both values
(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.

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
75 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P
Lxy (mm)
Lz
Ly

500
100 kg

110 kg

400 120 kg
130 kg
140 kg
150 kg
300

200

100

A5
KR 150-- 2 Lz (mm)
A4
A6
100 200 300 400 500 600 700

Fig. 16 Load center of gravity P and loading curves for KR 150--2

MA KR 2000, KR C4 01.10.01 en 31 of 136


Assembly Instructions

The values determined here are necessary for planning the application.
For commissioning the robot, additional input data are required in accordance with the
KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
65 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P
Lz
Ly

Lxy (mm)

500
90 kg

100 kg
400 110 kg
120 kg
130 kg
300

200

100

A5
Lz (mm)
KR 150 L130-- 2
A4
A6
100 200 300 400 500 600 700

Fig. 17 Load center of gravity P and loading curves for KR 150 L130--2

32 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
55 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P

Lz
Ly

Lxy (mm)

500
80 kg

90 kg
400
100 kg
110 kg

300

200

100

A5
KR 150 L110-- 2 Lz (mm)
4
A6
100 200 300 400 500 600 700

Fig. 18 Load center of gravity P and loading curves for KR 150 L110--2

MA KR 2000, KR C4 01.10.01 en 33 of 136


Assembly Instructions

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
90 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P

Lz
Ly

Lxy (mm)

500
120 kg
130 kg
140 kg
400
150 kg
160 kg
170 kg
180 kg
300

200

100

A5
Lz (mm)
KR 180-- 2
A4
A6
100 200 300 400 500 600 700

Fig. 19 Load center of gravity P and loading curves for KR 180--2

34 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
75 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P

Lz
Ly

Lxy (mm)

500

110 kg

400 120 kg
130 kg
140 kg
150 kg
300

200

100

A5
KR 180 L150-- 2 Lz (mm)
A4
A6
100 200 300 400 500 600 700

Fig. 20 Load center of gravity P and loading curves for KR 180 L150--2

MA KR 2000, KR C4 01.10.01 en 35 of 136


Assembly Instructions

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
65 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P

Lz
Ly

Lxy (mm)

500
90 kg

100 kg
400 110 kg
120 kg
130 kg
300

200

100

A5
KR 180 L130-- 2 Lz (mm)
A4
A6
100 200 300 400 500 600 700

Fig. 21 Load center of gravity P and loading curves for KR 180 L130--2

36 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
105 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P
Lz
Ly

Lxy (mm)

500

150 kg
160 kg
400 170 kg
180 kg
190 kg
200 kg
210 kg
300

200

100

A5
KR 210-- 2 Lz (mm)
A4
A6
100 200 300 400 500 600 700

Fig. 22 Load center of gravity P and loading curves for KR 210--2

MA KR 2000, KR C4 01.10.01 en 37 of 136


Assembly Instructions

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
90 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P
Lz
Ly

Lxy (mm)

500
130 kg
140 kg
400 150 kg
160 kg
170 kg
180 kg
300

200

100

A5
KR 210 L180-- 2 Lz (mm)
A4
A6
100 200 300 400 500 600 700

Fig. 23 Load center of gravity P and loading curves for KR 210 L180--2

38 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
75 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P
Lz
Ly

Lxy (mm)

500
110 kg

120 kg
400 130 kg
140 kg
150 kg

300

200

100

A5
KR 210 L150-- 2 Lz (mm)
A4
A6
100 200 300 400 500 600 700

Fig. 24 Load center of gravity P and loading curves for KR 210 L150--2

MA KR 2000, KR C4 01.10.01 en 39 of 136


Assembly Instructions

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
120 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P
Lz
Ly

Lxy (mm)

500

400 180 kg
190 kg
200 kg
210 kg
220 kg

300
240 kg 230 kg

200

100

A5
KR 240-- 2 Lz (mm)
A4
A6
100 200 300 400 500 600 700

Fig. 25 Load center of gravity P and loading curves for KR 240--2

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4 Technical data (continued)

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
105 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P
Lz
Ly

Lxy (mm)

500

150 kg
160 kg
400 170 kg
180 kg
190 kg
200 kg
210 kg
300

200

100

A5
KR 240 L210-- 2 Lz (mm)
A4
A6
100 200 300 400 500 600 700

Fig. 26 Load center of gravity P and loading curves for KR 240 L210--2

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Assembly Instructions

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
90 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P
Lz
Ly

Lxy (mm)

500
120 kg

130 kg
140 kg
400 150 kg
160 kg
170 kg
180 kg
300

200

100

A5
KR 240 L180-- 2 Lz (mm)
A4
A6
100 200 300 400 500 600 700

Fig. 27 Load center of gravity P and loading curves for KR 240 L180--2

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4 Technical data (continued)

The values determined here are necessary for planning the application.
For commissioning the industrial robot, additional input data are required in accordance
with the KUKA software documentation.

Robot flange coordinate system Permissible mass inertia at the


design point
(Lxy = 270 mm,
Lxy = L x 2 + Ly 2 Lz = 240 mm)
--X
135 kgm2.
--Z
+Y CAUTION: The mass inertia must be
verified using KUKA Load. It is
imperative for the load data to be
entered in the controller!
--Y
+X +Z
Lxy
Lx
Load center of gravity P
Lz
Ly

Lxy (mm)

210 kg
220 kg
230 kg
300 240 kg
250 kg
260 kg
270 kg

200

100

A5
Lz (mm)
KR 270-- 2
A4
A6

100 200 300 400 500

Fig. 28 Load center of gravity P and loading curves for KR 270--2

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Assembly Instructions

Z Suppl. load
--119° +155°
Load center of gravity P
G
A

--146°

+0°

Interference radius

---185˚
IMPORTANT: The interference radius
(safe area) lies approx. 250 mm beyond
the reference point for the working
envelope.

NOTE: The supplementary load center of


gravity must be located as close as possible
to rotational axis 3 and to line a in Fig. 30.

The reference point for the working


envelope is the intersection of axes 4 and 5.
+185˚

View Z, see Fig. 30.

Interference radius of
the mounting flange
A B C D E F G
KR 150--2 3100 3450 2700 1875 825 1788 1100
KR 150 L130--2 3300 3850 2900 2050 850 1987 1300
KR 150 L110--2 3500 4250 3100 2150 950 2187 1500
KR 180--2 3100 3450 2700 1875 825 1788 1100
KR 180 L150--2 3300 3850 2900 2050 850 1987 1300
KR 180 L130--2 3500 4250 3100 2150 950 2187 1500
KR 210--2 3100 3450 2700 1875 825 1788 1100
KR 210 L180--2 3300 3850 2900 2050 850 1987 1300
KR 210 L150--2 3500 4250 3100 2150 950 2187 1500
KR 240--2 3100 3450 2700 1875 825 1788 1100
KR 240 L210--2 3300 3850 2900 2050 850 1987 1300
KR 240 L180--2 3500 4250 3100 2150 950 2187 1500
KR 270--2 3100 3450 2700 1875 825 1788 1100

Fig. 29 Principal dimensions and working envelope, floor--mounted and ceiling--


mounted manipulator (software values)

44 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

380

View Z from Fig. 29 180 M12x18 (4x)


40
40 M8x8 (2x)

35
to --55°
X = 125 mm a
X = 100 mm
110

70

X
to --119°

Support brackets
for suppl. load (2x)
Max. dimension for suppl. load

Fig. 30 Attachment holes for supplementary load on arm

150
M12x24
150

M20x30
500


315
149

70
80

Fig. 31 Attachment holes for supplementary load on rotating column and


link arm

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Assembly Instructions

230
xm to A 4/A 5

10 H7
8.5 +0.3
10 deep R 190
9.5 ¦0.1

8 Fitting length

15 Depth of thread

M10 fastening screws,


grade 10.9
Depth of engagement: min. 12 mm
max. 14 mm

Fig. 32 DIN/ISO mounting flange for in--line wrist 150/180/210/240/270 kg

46 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

The specified forces and moments already include the payload and the inertia force (weight)
of the manipulator.

Fv

Mk

Fv

Fh
Mr

Fv = Vertical force Fvmax = 24,000 N


Fh = Horizontal force Fhmax = 18,000 N
Mk = Tilting moment Mkmax = 49,000 Nm
Mr = Turning moment about axis 1 Mrmax = 38,000 Nm

Total mass = robot + total load for type


floor--mounted ceiling--mounted

1412 kg 1425 kg + 550 kg KR 150--2


1422 kg 1435 kg + 530 kg KR 150 L130--2
1430 kg 1445 kg + 510 kg KR 150 L110--2
1412 kg 1425 kg + 580 kg KR 180--2
1422 kg 1435 kg + 550 kg KR 180 L150--2
1430 kg 1445 kg + 530 kg KR 180 L130--2
1412 kg 1425 kg + 610 kg KR 210--2
1422 kg 1435 kg + 580 kg KR 210 L180--2
1430 kg 1445 kg + 550 kg KR 210 L150--2
1412 kg ----* + 640 kg KR 240--2
1422 kg ----* + 610 kg KR 240 L210--2
1430 kg ----* + 580 kg KR 240 L180--2
1412 kg ---- + 670 kg KR 270--2

*See Doc. Module Ro/Me/01/33.07

Fig. 33 Principal loads acting on the mounting base due to manipulator


and total load

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Assembly Instructions

View A

Fig. 34 Electronic measuring tool, installation on A4, A5 and A6

3 4 5

10

13
2 12 3 4 5 6
7
11 9
1 8
1
9

Fig. 35 Plates on manipulator (see also Fig. 36 to Fig. 48)

48 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

Fig. 36 Instructions regarding transport position for floor--mounted and


ceiling--mounted manipulators

Artikel--Nr. 00--125--658 de/en/fr 2

Fig. 37 Safety instructions regarding counterbalancing system

Artikel--Nr. 00--125--658 de/en /fr 3 2x

Fig. 38 Instructions for safeguarding against toppling of A2 and A3

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Assembly Instructions

4x on each AC servomotor

Fig. 39 Hot surface warning sign

.................
On all AC
servomotors ...........................................................
................................................
...........................................................
................................................
...........................................................
.................................................
5

Fig. 40 Drive motor rating plate

Roboter GmbH
Zugspitzstra e 140
86165 Augsburg.Germany
Typ Type Type XXXXXXXXXXXXXXXXXXXXXXXXXX

Artikel--Nr. Article No. No. d’article XXXXXXXXX

Serie--Nr. Serial No. ^


No. Se’rie# XXXXXX

Baujahr Date ^ de fabric.


Annee XXXX--XX

Gewicht Weight Poids XXXX kg

Traglast Load Charge XXX kg

Reichweite Range ^
Portee XXXX MM

$TRAFONAME[]=”#.....” XXXXXXXXXXXXXXXXXXXXXXXXXXX

...\MADA\ XXXXXXXXXXXXXXXXXXXXXXXXXXX
de/en/fr

Fig. 41 Industrial robot identification plate (example)

50 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

Artikel--Nr. 00--125--658 de/en/fr


7

Fig. 42 Reference to operating instructions

Fig. 43 High voltage warning sign

00--104--232
9
3x
Fig. 44 Danger zone

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Assembly Instructions

10

Fig. 45 Fastening instructions

Artikel--Nr. 00--109--622 de/en/fr 11

Fig. 46 Instructions for safeguarding against toppling of A2

3
1 2
00--146--665
12

Fig. 47 Warning sign for counterbalancing system, ceiling

52 of 136 MA KR 2000, KR C4 01.10.01 en


4 Technical data (continued)

00--123--341
13

Fig. 48 Counterbalancing system with preloaded spring

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Assembly Instructions

54 of 136 MA KR 2000, KR C4 01.10.01 en


5 Safety

5 Safety
5.1 General
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” chapter. It also contains addi-
tional safety information relating to the robot controller which must be observed.
Where this “Safety” chapter uses the term “industrial robot”, this also refers to the indi-
vidual mechanical component if applicable.

5.1.1 Liability
The device described in this document is either an industrial robot or a component thereof.
Components of the industrial robot:
G Manipulator
G Robot controller
G Teach pendant
G Connecting cables
G External axes (optional), e.g. linear unit, turn--tilt table, positioner
G Software
G Options, accessories
The industrial robot is built using state--of--the--art technology and in accordance with the rec-
ognized safety rules. Nevertheless, misuse of the industrial robot may constitute a risk to life
and limb or cause damage to the industrial robot and to other material property.
The industrial robot may only be used in perfect technical condition in accordance with its
intended use and only by safety--conscious persons who are fully aware of the risks involved
in its operation. Use of the industrial robot is subject to compliance with this document and
with the declaration of incorporation supplied together with the industrial robot. Any functional
disorders affecting the safety of the robot system must be rectified immediately.

Safety information
Safety information cannot be held against KUKA Roboter GmbH. Even if all safety instruc-
tions are followed, this is not a guarantee that the industrial robot will not cause personal inju-
ries or material damage.
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. The user is liable for any damage
these components may cause to the industrial robot or to other material property.
In addition to the Safety chapter, this document contains further safety instructions. These
must also be observed.

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Assembly Instructions

5.1.2 Intended use of the industrial robot


The industrial robot is intended exclusively for the use designated in the “Purpose” chapter
of the operating instructions or assembly instructions.

Further information is contained in the “Purpose” chapter of the operating instructions


or assembly instructions of the component.

Using the industrial robot for any other or additional purpose is considered impermissible
misuse. The manufacturer cannot be held liable for any damage resulting from such use. The
risk lies entirely with the user.
Operating the industrial robot and its options within the limits of its intended use also involves
observance of the operating and assembly instructions for the individual components, with
particular reference to the maintenance specifications.

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

5.1.3 EC declaration of conformity and declaration of incorporation


This industrial robot constitutes partly completed machinery as defined by the EC Machinery
Directive. The industrial robot may only be put into operation if the following preconditions
are met:
G The industrial robot is integrated into a complete system.
Or: The industrial robot, together with other machinery, constitutes a complete system.
Or: All safety functions and safeguards required for operation in the complete machine
as defined by the EC Machinery Directive have been added to the industrial robot.
G The complete system complies with the EC Machinery Directive. This has been con-
firmed by means of an assessment of conformity.

Declaration of conformity
The system integrator must issue a declaration of conformity for the complete system in ac-
cordance with the Machinery Directive. The declaration of conformity forms the basis for the
CE mark for the system. The industrial robot must be operated in accordance with the appli-
cable national laws, regulations and standards.
The robot controller is CE certified under the EMC Directive and the Low Voltage Directive.

56 of 136 MA KR 2000, KR C4 01.10.01 en


5 Safety (continued)

Declaration of incorporation
The industrial robot as partly completed machinery is supplied with a declaration of incorpo-
ration in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The assem-
bly instructions and a list of essential requirements complied with in accordance with Annex
I are integral parts of this declaration of incorporation.
The declaration of incorporation declares that the start--up of the partly completed machinery
remains impermissible until the partly completed machinery has been incorporated into ma-
chinery, or has been assembled with other parts to form machinery, and this machinery com-
plies with the terms of the EC Machinery Directive, and the EC declaration of conformity is
present in accordance with Annex II A.
The declaration of incorporation, together with its annexes, remains with the system integra-
tor as an integral part of the technical documentation of the complete machinery.

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Assembly Instructions

5.1.4 Terms used

Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may
move. The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance
The stopping distance is part of the danger zone.
Workspace The manipulator is allowed to move within its workspace. The work-
space is derived from the individual axis ranges.
Operator(User) The user of the industrial robot can be the management, employer or
delegated person responsible for use of the industrial robot.
Danger zone The danger zone consists of the workspace and the stopping distan-
ces.
Service lifeService The service life of a safety--relevant component begins at the time of
life delivery of the component to the customer.
The service life is not affected by whether the component is used in a
robot controller or elsewhere or not, as safety--relevant components are
also subject to ageing during storage.
KCP The KCP (KUKA Control Panel) teach pendant has all the operator
control and display functions required for operating and programming
the industrial robot.
Manipulator The robot arm and the associated electrical installations.
Protected space The safety zone is situated outside the danger zone.
Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path--orien-
ted braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path--main-
taining braking. The drives are deactivated after 1 s and the brakes are
applied.
Note: This stop category is called STOP 1 in this document.
Stop category 2 The drives are not deactivated and the brakes are not applied. The ma-
nipulator and any external axes (optional) are braked with a normal bra-
king ramp.
Note: This stop category is called STOP 2 in this document.
System integrator System integrators are people who safely integrate the industrial robot
(plant integrator) into a complete system and commission it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 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.

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5 Safety (continued)

5.2 Personnel
The following persons or groups of persons are defined for the industrial robot:
G User
G Personnel

All persons working with the industrial robot must have read and understood the indus-
trial robot documentation, including the safety chapter.

User
The user must observe the labor laws and regulations.
This includes e.g.:
G The user must comply with his monitoring obligations.
G The user must carry out instructions at defined intervals.

Personnel
Personnel must be instructed, before any work is commenced, in the type of work involved
and what exactly it entails as well as any hazards which may exist. Instruction must be carried
out regularly. Instruction is also required after particular incidents or technical modifications.
Personnel includes:
G System integrator
G Operators, subdivided into:
-- Start--up, maintenance and service personnel
-- Operating personnel
-- Cleaning personnel

Installation, exchange, adjustment, operation, maintenance and repair must be per-


formed only as specified in the operating or assembly instructions for the relevant com-
ponent of the industrial robot and only by personnel specially trained for this purpose.

System integrator
The industrial robot is safely integrated into a complete system by the system integrator.
The system integrator is responsible for the following tasks:
G Installing the industrial robot
G Connecting the industrial robot
G Performing risk assessment
G Implementing the required safety functions and safeguards
G Issuing the declaration of conformity
G Attaching the CE mark
G Creating the operating instructions for the complete system

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Assembly Instructions

User
The operator must meet the following preconditions:
G The operator must be trained for the work to be carried out.
G 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.

Example
The tasks can be distributed as shown in the following table:

Tasks Operating Programmer System


personnel integrator
Switch robot controller x x x
on/off
Start program x x x
Select program x x x
Select operating mode x x x
Calibration (tool, base) x x
Master the manipulator x x
Configuration x x
Programming x x
Commissioning x
Maintenance x
Repair x
Decommissioning x
Transportation x

Work on the electrical and mechanical equipment of the industrial robot may only be
carried out by specially trained personnel.

5.3 Workspace, safety zone and danger zone


Working zones are to be restricted to the necessary minimum size. A workspace must be
safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone. In the case of a
stop, the manipulator and external axes (optional) are braked and come to a stop within the
danger zone.
The danger zone consists of the workspace and the stopping distances of the manipulator
and external axes (optional). It must be safeguarded by means of physical safeguards to pre-
vent danger to persons or the risk of material damage.

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5 Safety (continued)

(1) Workspace (3) Stopping distance


(2) Manipulator (4) Safety zone

Fig. 49 Example: axis range A1

5.4 Overview of protective equipment


The protective equipment of the mechanical component may include:
G Mechanical end stops
G Mechanical axis range limitation (optional)
G Axis range monitoring (optional)
G Release device (optional)
G Labeling of danger areas
Not all equipment is relevant for every mechanical component.

5.4.1 Mechanical end stops


Depending on the robot variant, the axis ranges of the main and wrist axes of the manipulator
are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.

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.

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Assembly Instructions

5.4.2 Mechanical axis range limitation (optional)


Some manipulators can be fitted with mechanical axis range limitation in axes A1 to A3. The
adjustable axis range limitation systems restrict the working range to the required minimum.
This increases personal safety and protection of the system.
In the case of manipulators that are not designed to be fitted with mechanical axis range limi-
tation, the workspace must be laid out in such a way that there is no danger to persons or
material property, even in the absence of mechanical axis range limitation.
If this is not possible, the workspace must be limited by means of photoelectric barriers, pho-
toelectric curtains or obstacles on the system side. There must be no shearing or crushing
hazards at the loading and transfer areas.

This option is not available for all robot models. Information on specific robot models
can be obtained from KUKA Roboter GmbH.

5.4.3 Axis range monitoring (optional)


Some manipulators can be fitted with dual--channel axis range monitoring systems in main
axes A1 to A3. The positioner axes may be fitted with additional axis range monitoring sys-
tems. The safety zone for an axis can be adjusted and monitored using an axis range moni-
toring system. This increases personal safety and protection of the system.

This option is not available for all robot models. Information on specific robot models
can be obtained from KUKA Roboter GmbH.

5.4.4 Devices for moving the manipulator without the robot controller (options)
Description
The following devices are available for moving the manipulator after an accident or malfunc-
tion:
G Release device
The release device can be used for the main axis drive motors and, depending on the
robot variant, also for the wrist axis drive motors.
G Brake release device
The brake release device is designed for robot variants whose motors are not freely
accessible.
The devices are only for use in exceptional circumstances and emergencies, e.g. for freeing
people.

This option is not available for all robot models. Information on specific robot models
can be obtained from KUKA Roboter GmbH.

The motors reach temperatures during operation which can cause burns to the
skin. Contact must be avoided. Appropriate safety precautions must be taken,
e.g. protective gloves must be worn.

62 of 136 MA KR 2000, KR C4 01.10.01 en


5 Safety (continued)

Procedure
Moving the manipulator with the release device:

(1) Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized
persons from switching it on again.
(2) Remove the protective cap from the motor.
(3) Push the release device onto the corresponding motor and move the axis in the desired
direction.
The directions are indicated with arrows on the motors. It is necessary to overcome the
resistance of the mechanical motor brake and any other loads acting on the axis.

Moving an axis with the release device can damage the motor brake. This can
result in personal injury and material damage. After using the release device, the
affected motor must be exchanged.

If a robot axis has been moved by the release device, all robot axes must be re-
mastered. Serious injuries or damage to property may otherwise result.

Procedure
Moving the manipulator with the brake release device:

Use of the brake release device may result in unexpected robot motions, espe-
cially sagging of the axes. During use of the brake release device, attention must
be paid to motion of this kind in order to be able to prevent physical injuries or
damage to property. Standing under moving axes is not permitted.

(1) Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized
persons from switching it on again.
(2) Connect the brake release device to the base frame of the robot:
Unplug connector X30 from interface A1. Plug connector X20 of the brake release de-
vice into interface A1.
(3) Select the brakes to be released (main axes, wrist axes) via the selection switch on the
brake release device.
(4) Press the button on the hand--held device.
The brakes of the main axes or wrist axes are released and the robot can be moved
manually.

Further information about the brake release device can be found in the documentation
for the brake release device.

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Assembly Instructions

5.4.5 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:
G Identification plates
G Warning labels
G Safety symbols
G Designation labels
G Cable markings
G Rating plates

Further information is contained in the technical data of the operating instructions or


assembly instructions of the components of the industrial robot.

5.5 Safety measures


5.5.1 General safety regulations
The industrial robot may only be used in perfect technical condition in accordance with its
intended use and only by safety--conscious persons. Operator errors can result in personal
injury and damage to property.
It is important to be prepared for possible movements of the industrial robot even after the
robot controller has been switched off and locked. Incorrect installation (e.g. overload) or me-
chanical defects (e.g. brake defect) can cause the manipulator or external axes to sag. If
work is to be carried out on a switched--off industrial robot, the manipulator and external axes
must first be moved into a position in which they are unable to move on their own, whether
the payload is mounted or not. If this is not possible, the manipulator and external axes must
be secured by appropriate means.

In the absence of operational safety functions and safeguards, the industrial


robot can cause personal injury or material damage. If safety functions or
safeguards are dismantled or deactivated, the industrial robot may not be
operated.

Standing underneath the robot arm can cause death or serious injuries. For this
reason, standing underneath the robot arm is prohibited!

The motors reach temperatures during operation which can cause burns to the
skin. Contact must be avoided. Appropriate safety precautions must be taken,
e.g. protective gloves must be worn.

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5 Safety (continued)

KCP
The user must ensure that the industrial robot is only operated with the KCP by authorized
persons.
If more than one KCP is used in the overall system, it must be ensured that each KCP is un-
ambiguously assigned to the corresponding industrial robot. They must not be interchanged.

The operator must ensure that decoupled KCPs are immediately removed from
the system and stored out of sight and reach of personnel working on the indus-
trial robot. This serves to prevent operational and non--operational EMERGENCY
STOP devices from becoming interchanged.
Failure to observe this precaution may result in death, severe physical injuries
or considerable damage to property.

External keyboard, external mouse


An external keyboard and/or external mouse may only be used if the following conditions are
met:
G Start--up or maintenance work is being carried out.
G The drives are switched off.
G There are no persons in the danger zone.
The KCP must not be used as long as an external keyboard and/or external mouse are con-
nected.
The external keyboard and/or external mouse must be removed as soon as the start--up or
maintenance work is completed or the KCP is connected.

Faults
The following tasks must be carried out in the case of faults in the industrial robot:
G Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized
persons from switching it on again.
G Indicate the fault by means of a label with a corresponding warning (tagout).
G Keep a record of the faults.
G Eliminate the fault and carry out a function test.
Modifications
After modifications to the industrial robot, checks must be carried out to ensure the required
safety level. The valid national or regional work safety regulations must be observed for this
check. The correct functioning of all safety circuits must also be tested.
New or modified programs must always be tested first in Manual Reduced Velocity mode
(T1).
After modifications to the industrial robot, existing programs must always be tested first in
Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot
and includes modifications to the software and configuration settings.

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Assembly Instructions

5.5.2 Transportation
Manipulator
The prescribed transport position of the manipulator must be observed. Transportation must
be carried out in accordance with the operating instructions or assembly instructions of the
robot.

Robot controller
The robot controller must be transported and installed in an upright position. Avoid vibrations
and impacts during transportation in order to prevent damage to the robot controller.
Transportation must be carried out in accordance with the operating instructions or assembly
instructions of the robot controller.

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 for the external axis.

5.5.3 Start--up and recommissioning


Before starting up systems and devices for the first time, a check must be carried out to en-
sure that the systems and devices are complete and operational, that they can be operated
safely and that any damage is detected.
The valid national or regional work safety regulations must be observed for this check. The
correct functioning of all safety circuits must also be tested.

The passwords for logging onto the KUKA System Software as “Expert” and “Adminis-
trator” must be changed before start--up and must only be communicated to authorized
personnel.

The robot controller is preconfigured for the specific industrial robot. If cables
are interchanged, the manipulator and the external axes (optional) may receive
incorrect data and can thus cause personal injury or material damage. If a sys-
tem consists of more than one manipulator, always connect the connecting
cables to the manipulators and their corresponding robot controllers.

If additional components (e.g. cables), which are not part of the scope of supply
of KUKA Roboter GmbH, are integrated into the industrial robot, the user is re-
sponsible for ensuring that these components do not adversely affect or disable
safety functions.

If the internal cabinet temperature of the robot controller differs greatly from the
ambient temperature, condensation can form, which may cause damage to the
electrical components. Do not put the robot controller into operation until the
internal temperature of the cabinet has adjusted to the ambient temperature.

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5 Safety (continued)

Function test
The following tests must be carried out before start--up and recommissioning.
It must be ensured that:
G The industrial robot is correctly installed and fastened in accordance with the specifica-
tions in the documentation.
G There are no foreign bodies or loose parts on the industrial robot.
G All required safety equipment is correctly installed and operational.
G The power supply ratings of the industrial robot correspond to the local supply voltage
and mains type.
G The ground conductor and the equipotential bonding cable are sufficiently rated and
correctly connected.
G The connecting cables are correctly connected and the connectors are locked.

Machine data
It must be ensured that the rating plate on the robot controller has the same machine data
as those entered in the declaration of incorporation.
The machine data on the rating plate of the manipulator and the external axes (optional) must
be entered during start--up.

The industrial robot must not be moved if incorrect machine data are loaded.
Death, severe injuries or considerable damage to property may otherwise result.
The correct machine data must be loaded.

5.5.4 Manual mode


Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried
out on the industrial robot to enable automatic operation. Setup work includes:
G Jog mode
G Teach
G Programming
G Program verification
The following must be taken into consideration in manual mode:
G If the drives are not required, they must be switched off to prevent the manipulator or
the external axes (optional) from being moved unintentionally.
New or modified programs must always be tested first in Manual Reduced Velocity
mode (T1).
G The manipulator, tooling or external axes (optional) must never touch or project beyond
the safety fence.
G Workpieces, tooling and other objects must not become jammed as a result of the in-
dustrial robot motion, nor must they lead to short--circuits or be liable to fall off.
G All setup work must be carried out, where possible, from outside the safeguarded area.
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):


G If it can be avoided, there must be no other persons inside the safeguarded area.

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Assembly Instructions

If it is necessary for there to be several persons inside the safeguarded area, the follow-
ing must be observed:
-- Each person must have an enabling device.
-- All persons must have an unimpeded view of the industrial robot.
-- Eye--contact between all persons must be possible at all times.
G The operator must be so positioned that he can see into the danger area and get out
of harm’s way.

In Manual High Velocity mode (T2):


G This mode may only be used if the application requires a test at a velocity higher than
Manual Reduced Velocity.
G Teaching and programming are not permissible in this operating mode.
G Before commencing the test, the operator must ensure that the enabling devices are
operational.
G The operator must be positioned outside the danger zone.
G There must be no other persons inside the safeguarded area. It is the responsibility of
the operator to ensure this.

5.5.5 Automatic mode


Automatic mode is only permissible in compliance with the following safety measures:
G All safety equipment and safeguards are present and operational.
G There are no persons in the system.
G The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for no apparent reason,
the danger zone must not be entered until an EMERGENCY STOP has been triggered.

5.5.6 Maintenance and repair


After maintenance and repair work, checks must be carried out to ensure the required safety
level. The valid national or regional work safety regulations must be observed for this check.
The correct functioning of all safety circuits must also be tested.
The purpose of maintenance and repair work is to ensure that the system is kept operational
or, in the event of a fault, to return the system to an operational state. Repair work includes
troubleshooting in addition to the actual repair itself.
The following safety measures must be carried out when working on the industrial robot:
G Carry out work outside the danger zone. If work inside the danger zone is necessary,
the user must define additional safety measures to ensure the safe protection of per-
sonnel.
G Switch off the industrial robot and secure it (e.g. with a padlock) to prevent it from being
switched on again. If it is necessary to carry out work with the robot controller switched
on, the user must define additional safety measures to ensure the safe protection of
personnel.
G If it is necessary to carry out work with the robot controller switched on, this may only
be done in operating mode T1.
G Label the system with a sign indicating that work is in progress. This sign must remain
in place, even during temporary interruptions to the work.
G The EMERGENCY STOP systems must remain active. If safety functions or safe-
guards are deactivated during maintenance or repair work, they must be reactivated
immediately after the work is completed.

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5 Safety (continued)

Before work is commenced on live parts of the robot system, the main switch
must be turned off and secured against being switched on again by unautho-
rized personnel. The incoming power cable must be deenergized. The robot con-
troller and mains supply lead must then be checked to ensure that it is deener-
gized.
If the KR C4 or VKR C4 robot controller is used:
It is not sufficient, before commencing work on live parts, to execute an EMER-
GENCY STOP or a safety stop, or to switch off the drives, as this does not dis-
connect the robot system from the mains power supply in the case of the drives
of the new generation. Parts remain energized. Death or severe injuries may re-
sult.

Faulty components must be replaced using new components with the same article number
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.

Robot controller
Even when the robot controller is switched off, parts connected to peripheral devices may
still carry voltage. The external power sources must therefore be switched off if work is to
be carried out on the robot controller.
The ESD regulations must be adhered to when working on components in the robot control-
ler.
Voltages in excess of 50 V (up to 600 V) can be present in various components for several
minutes after the robot controller has been switched off! To prevent life--threatening injuries,
no work may be carried out on the industrial robot in this time.
Water and dust must be prevented from entering the robot controller.

Counterbalancing system
Some robot variants are equipped with a hydropneumatic, spring or gas cylinder counterbal-
ancing system.
The hydropneumatic and gas cylinder counterbalancing systems are pressure equipment
and, as such, are subject to obligatory equipment monitoring. Depending on the robot vari-
ant, the counterbalancing systems correspond to category 0, II or III, fluid group 2, of the
Pressure Equipment Directive.
The user must comply with the applicable national laws, regulations and standards pertaining
to pressure equipment.
Inspection intervals in Germany in accordance with Industrial Safety Order, Sections 14 and
15. Inspection by the user before commissioning at the installation site.
The following safety measures must be carried out when working on the counterbalancing
system:
G The manipulator assemblies supported by the counterbalancing systems must be se-
cured.
G Work on the counterbalancing systems must only be carried out by qualified personnel.

Hazardous substances
The following safety measures must be carried out when handling hazardous substances:
G Avoid prolonged and repeated intensive contact with the skin.
G Avoid breathing in oil spray or vapors.
G Clean skin and apply skin cream.

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Assembly Instructions

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.

5.5.7 Decommissioning, storage and disposal


The industrial robot must be decommissioned, stored and disposed of in accordance with
the applicable national laws, regulations and standards.

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5 Safety (continued)

5.6 Applied norms and regulations


Name Definition Edition
2006/42/EC Machinery Directive: 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)
2004/108/EC EMC Directive: 2004
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
97/23/EC Pressure Equipment Directive: 1997
Directive 97/23/EC of the European Parliament and of the
Council of 29 May 1997 on the approximation of the laws
of the Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counter-
balancing system.)
EN ISO 13850 Safety of machinery: 2008
Emergency stop -- Principles for design
EN ISO 13849--1 Safety of machinery: 2008
Safety--related parts of control systems;
Part 1: General principles of design
EN ISO 13849--2 Safety of machinery: 2008
Safety--related parts of control systems;
Part 2: Validation
EN ISO 12100 Safety of machinery: 2010
General principles of design, risk assessment and risk re-
duction
EN ISO 10218--1 Industrial robots: Safety 2011
EN 614--1 Safety of machinery: 2006
Ergonomic design principles -- Part 1: Terms and general
principles
EN 61000--6--2 Electromagnetic compatibility (EMC): 2005
Part 6--2: Generic standards; Immunity for industrial envi-
ronments
EN 61000--6--4 Electromagnetic compatibility (EMC): 2007
Part 6--4: Generic standards; Emission standard for indu-
strial environments
EN 60204--1 Safety of machinery: 2006
Electrical equipment of machines
Part 1: General requirements

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6 Transportation

6 Transportation

This description applies analogously to all of the industrial robots listed in Chapter 1,
regardless of the variant or model shown in the illustrations.

If the manipulator is transported by fork lift truck, the forks must be placed in the
fork slots. It is forbidden to pick up the manipulator in any other way using a
fork lift truck!
The fork lift truck, lifting tackle and crane must be suitable for handling the
manipulator. For weight, see Chapter 4.
The manipulator must be moved into its transport position each time it is
transported. It must be ensured that the manipulator is stable while it is being
transported.
The manipulator must remain in its transport position until it is -- depending on
the type -- fastened to the floor, the ceiling or to a hinged steel base.
Before the manipulator is lifted, it must be ensured that it is free from
obstructions. Transport safeguards, such as nails and screws, are all to be
removed in advance, as is any rust or glue on contact surfaces.

The manipulator can be transported as follows:


G With lifting tackle and crane (Fig. 52, right--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. For transportation, three M20 DIN 580 eye-
bolts (Fig. 50/1) must be installed.

The ropes or belts of the lifting tackle must be positioned so that there is no
possibility of the manipulator tilting to the side and of cabling or connectors
being damaged.

Only approved handling equipment and lifting tackle with an adequate carrying
capacity may be used for transporting the manipulator.
For weight, see Chapter 4.
All three eyebolts on the rotating column must always be used to suspend the
robot.

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Assembly Instructions

Fig. 50 Transport position

G With fork lift truck (Fig. 52, left--hand side)

The manipulator (Fig. 51/1) can also be transported by fork lift truck. For transport by
fork lift truck, the fork slots (2) (accessory) must be fully and properly installed.

If the manipulator is transported by fork lift truck, the forks must be placed in the
fork slots. It is forbidden to pick up the manipulator in any other way using a
fork lift truck!

2
2
505

Fig. 51 Fork slots

For transport with a fork lift truck, two removable, open--ended fork slots (2) are provided on
the rotating column. This allows the manipulator to be picked up from two sides.
Lashing straps (Fig. 52/1) must be used as a transport safeguard. They must be fitted in such
a way that no parts are damaged. The maximum tensile force is 5,000 N.

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6 Transportation (continued)

1
max. 5000 N

60°

Fig. 52 Transporting the manipulator

If the manipulator is to be transported away from its site of operation, the following is to be
observed:

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.

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.
The manipulator may only be moved at jog speed, with all applicable safety rules
and regulations being observed.

(2) Put the manipulator into operation and move it into its transport position (Fig. 53 to
Fig. 54).

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Assembly Instructions

A1 A2 A3 A4 A5 A6
0˚ ---151˚ +155˚ 0˚ 0˚ any
1) 0˚ ---146˚ +150˚ 0˚ ---100˚ any
All angles refer to the display on the KCP.
1) for KR 150, 180, 210, 240, 270--2

C 1)
C
Table of dimensions
Manipulator A B C D E
KR 150, 180, 210
without arm extension 133 750 1767 1181 1652
with 200 mm arm extension 112 750 1966 1181 1652
with 400 mm arm extension 91 751 2165 1181 1652
G
E

Table of dimensions
Manipulator A B C D E
KR 150, 180, 210; 240, 270,-- 2
B

without arm extension 153 781 1710 1109 1671


with 200 mm arm extension 128 793 1821 1109 1671
with 400 mm arm extension 113 805 2020 1109 1671

A 1000 C1) with arm extension


D

Fig. 53 Transport position for floor--mounted manipulators

A1 A2 A3 A4 A5 A6
0˚ ---151˚ +155˚ 0˚ 0˚ any
1) 0˚ ---146˚ +150˚ 0˚ ---100˚ any
2) 0˚ ---133˚ +150˚ 0˚ ---100˚ any
All angles refer to the display on the KCP.
1) for KR 150, 180, 210, 240--2
2) for KR 240--2 C

1000 D
A

Table of dimensions
Manipulator A B C D E
B

KR 150, 180, 210


without arm extension 133 750 1767 1181 1652
G with 200 mm arm extension 112 750 1966 1181 1652
E

with 400 mm arm extension 91 751 2165 1181 1652

Table of dimensions
Manipulator A B C D E
KR 150, 180, 210; 240,-- 2
without arm extension 153 781 1710 1109 1671
with 200 mm arm extension 128 793 1821 1109 1671
C with 400 mm arm extension 113 805 2020 1109 1671
C 1) KR 240-- 2 C 80 841 1627 967 1950

C1) with arm extension

Fig. 54 Transport position for ceiling--mounted manipulators

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6 Transportation (continued)

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.

For further work steps, see Chapter 7.

The manipulator must not be set down until the transport safeguards have been
installed.

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7 Installation

7 Installation
7.1 General

This description applies analogously to all of the industrial robots listed in Chapter 1,
regardless of the variant or model shown in the illustrations.

Observe Chapter 5, “Safety”!


With all work involving the connection of the manipulator and of the control cab-
inet, the control cabinet Doc. Module “Initial Start--up” must be observed.

When putting the manipulator into operation either for the first time or after an
exchange, zero adjustment must be carried out in accordance with the Operating
Handbook, Software KR C4, Chapter “Start--up”, Section “Mastering/Unmaster-
ing”.

Before any installation and exchange work is started, any attached tools or additional equip-
ment that would hinder the installation and exchange work must be dismounted.

The fork lift truck, lifting tackle and crane must be suitable for handling the
manipulator. For weight, see Chapter 4, “Technical data”.

The description of the installation and exchange operations is subdivided into job steps with
numbers in brackets appearing before them. The text which immediately follows these steps
must also be read if it is specially marked by a warning triangle or either of the hand sym-
bols. This is because many of these marked texts refer to the preceding job step.

Example:

(8) Lower the manipulator slowly without tilting it.

The manipulator must be lowered vertically downwards until both locating pins
are free.

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.

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Assembly Instructions

Example:

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.

If it is necessary to carry out work in the area beneath a manipulator, the latter
must be secured to guard against the risk of unintended motion into this area.
This can be done by supporting it from below or by securing it with a rope from
above.
Never work or stand under suspended loads!

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7 Installation (continued)

7.2 Principal loads


Forces occur during operation of the manipulator which must be safely transmitted to the
floor or ceiling. The forces that have to be taken into account for floor--mounted and ceiling--
mounted manipulators are specified in Fig. 55. The drawings with their specifications can
also be used as a basis for more extensive static investigations. The specified forces and
moments already include the payload and the inertia force (weight) of the manipulator.

Mk

Fv

Fh
Mr

Fv = Vertical force Fvmax = 24,000 N


Fh = Horizontal force Fhmax = 18,000 N
Mk = Tilting moment Mkmax = 49,000 Nm
Mr = Turning moment about axis 1 Mrmax = 38,000 Nm

Total mass = manipulator + total load for type

1245 kg + 550 kg KR 150; --2


1255 kg + 530 kg KR 150 L130; --2
1263 kg + 510 kg KR 150 L110; --2
1267 kg + 580 kg KR 180; --2
1277 kg + 550 kg KR 180 L150; --2
1285 kg + 530 kg KR 180 L130; --2
1267 kg + 610 kg KR 210; --2
1277 kg + 580 kg KR 210 L180; --2
1285 kg + 550 kg KR 210 L150; --2
1267 kg + 640 kg KR 240; --2
1277 kg + 610 kg KR 240 L180; --2
1285 kg + 580 kg KR 240 L210; --2
1245 kg + 670 kg KR 270--2

Fig. 55 Principal loads acting on floor (or ceiling) due to manipulator


and total load

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Assembly Instructions

7.3 Mounting variants


Depending on the variant, the manipulator can be installed on the floor or on the ceiling.
There are three mounting variants for installing the manipulator on the floor, and one mount-
ing variant for installing the manipulator on the ceiling.
G Variant 1 (394.016--08.001.00--00), see Section 7.4.1.

Fig. 56 Mounting base with centering

G Variant 2 (394.018--08.002.00--00), see Section 7.4.2.

Fig. 57 Machine frame mounting

G Variant 3 (394.100--01.005.00--00), see Section 7.4.3.

Fig. 58 Booster frame

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7 Installation (continued)

If the manipulator is to be installed on the floor, being mounted directly on a concrete base
(variant 1 and variant 3), all pertinent construction specifications must be observed concern-
ing the grade of concrete (≥ B25 according to DIN 1045:1988 or C20/25 according to
DIN EN 206--1:2001 / DIN 1045--2:2001) and the load--bearing capacity of the ground when
preparing the concrete foundation. It must be ensured that the surface of the foundation is
level and sufficiently smooth. If the concrete surface does not meet these criteria, the uneven
areas must be corrected using leveling compound. Great care must be taken when making
the anchor holes and inserting the anchors to ensure that the forces occurring during the op-
eration of the manipulator (Fig. 55) are transmitted safely to the ground.
To avoid distorting the manipulator base frame or the booster frame when fastening it to the
concrete foundation, differences in level between the concrete foundation and the base
frame must be corrected using leveling compound (filling compound).
The procedure is as follows:
(1) Mark the position of the bedplates on the concrete foundation and determine the magni-
tude of the differences in level.
(2) Apply leveling compound (Fig. 59/2) to the marked areas of the concrete foundation (4)
or the underside of the drilling template.

“Knauf leveling compound”, for example, is a suitable compound for this purpose. It is
applied with a toothed spatula (tooth height > 2 x difference in level (5)).
Before applying the leveling compound, coat the drilling template with parting agent.

The area (3) under each hexagon bolt (1) must be kept free from leveling com-
pound or it must be cleared after the compound has been applied.

(3) Place the drilling template in the still plastic leveling compound and adjust its position
slightly with the leveling screws (Fig. 61/5) if necessary.
(4) Remove excess leveling compound.
1 2

5 4 3

Fig. 59 Leveling compound

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Assembly Instructions

If large differences in level need to be compensated for, more leveling com-


pound must be applied. The maximum leveling compound thickness specified
by the manufacturer must not be exceeded.

(5) Allow the leveling compound to cure for about three hours. The curing time is longer
at temperatures below 293 K (20 °C).

At the end of the curing time, the holes can be drilled.

(6) Remove the drilling template.

7.4 Installation
7.4.1 Variant 1 (394.016--08.001.00--00)
Features:
-- For floor--mounted manipulators only.
-- Manipulator installed directly on the concrete foundation.
-- Manipulator fastened by means of twelve chemical anchors (resin--bonded an-
chors).

When using chemical anchors (resin--bonded anchors), only resin capsules and
anchors (threaded rods) from the same manufacturer may be used.
No diamond tools or core drills may be used for drilling the anchor holes; for
preference, drilling tools supplied by the anchor manufacturer are to be used.
The manufacturer’s instructions for the use of resin--bonded anchors must also
be observed.

(1) Mark a hole pattern as per Fig. 61 on the foundation or set down the drilling template
in the intended installation position on the foundation. Please observe Section 7.4.
(2) The intended installation position of the manipulator, i.e. the correct orientation in rela-
tion to the working envelope (Fig. 60/1), must be taken into account when marking out
the hole pattern.

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7 Installation (continued)

Fig. 60 Orientation of working envelope

(3) Drill twelve anchor holes (Fig. 61/1) in accordance with Fig. 61, or drill through the holes
in the drilling template; minimum depth in concrete 170 +5 mm.
(4) Remove the drilling template, if applicable, and clean the boreholes.

The boreholes must be free of dust and loose pieces of concrete. No fluids or dust
bonding agents may be used for cleaning.

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Assembly Instructions

t=30 mm
1

front

5 3
4

Min. distance to edge


of concrete 210 mm

Fig. 61 Concrete foundation and hole pattern for variant 1

(5) Fasten each of the four foundation plates (2) to the manipulator (4) by means of two
M24x70--8.8--A2K hexagon bolts (3) and lock washers.
(6) Insert twelve resin capsules (Fig. 62/4).
(7) Bring the manipulator to the site of installation, and set it down and align it in accordance
with the hole pattern.
(8) Insert one threaded rod (3) into each borehole (5). To do this, secure the setting tool
(2) in a hammer drill (1), attach the threaded rod, and insert it in the borehole using no
more than 750 r.p.m. The threaded rod is set correctly if the resin is completely mixed
and the borehole in the concrete is completely filled to the upper edge. If the borehole
is not completely filled, the threaded rod must be pulled out again immediately and a
new resin capsule inserted.
(9) Allow the resin to cure.
The curing time is as follows:
Temperature: Time:
+20 °C 20 minutes
+10 °C 30 minutes
0 °C 1 hour
--5 °C 5 hours

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7 Installation (continued)

(10) Screw on hexagon nuts (6) together with washers and tighten with torque wrench in di-
agonally opposite sequence, increasing the tightening torque MA to the specified value
in several stages (MA = 120 Nm).

Retighten the hexagon nuts (6) after 100 hours of operation.

1
6

30
3
4
≥220

≥210
5

Fig. 62 Fastening the manipulator, variant 1

Installation of the manipulator is now finished. The manipulator is now ready for connection
to the controller.

7.4.2 Variant 2 (394.018--08.002.00--00)

Features:
-- For floor--mounted and ceiling--mounted manipulators.
-- Manipulator installed on a steel structure prepared by the customer (or on a linear
unit of series KL 1500).
-- Manipulator fastened by means of eight M24x70 ISO 4017 hexagon bolts; tight-
ening torque MA = 640 Nm.
The correct orientation of the hole pattern in relation to the working envelope (Fig. 63/1) is
given in Fig. 63. When determining the hole pattern (installation position), it must be ensured
that the locating pins (2, 3) are correctly positioned.

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Assembly Instructions

2 1

Fig. 63 Orientation of working envelope

When preparing mounting surface, the specified minimum dimensions must be


strictly observed.

The drilling template (available as an accessory) makes it easier to drill the holes for the
fastening screws and the locating pins.

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7 Installation (continued)

(1) Prepare the mounting surface (Fig. 64/1) on the mounting platform in accordance with
Fig. 64.
1

M 24
(2x)
M8
125

Rz 63
0,5
∅ 520 --1

∅ 1020 +1

Fig. 64 Mounting surface

(2) Drill eight holes for the fastening screws (Fig. 65/3).
(3) Make two tapped holes (4) with precision fit for the locating pins (2) as shown in the il-
lustration.

The intended installation position of the manipulator, i.e. the correct orientation in rela-
tion to the working envelope, must be taken into account when drilling the holes.

(4) Insert both of the locating pins (2) and fasten each one with an M8x55 Allen screw (1)
together with conical spring washer.
Installation of the manipulator is now finished. The manipulator is ready for connection (see
Section 7.5.1 or 7.5.2).

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Assembly Instructions

1 2

Section X - X

0.5
Rz 63
40

max. 6
Robot base

3
4

0.1

X
520 +1

1020 +1

2 3 3 2

Fig. 65 Hole pattern and location of pins

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7 Installation (continued)

7.4.3 Variant 3 (394.100--01.005.00--00)

Features:

-- For floor--mounted manipulators only.

-- Manipulator installed with booster frame (Fig. 58) on a concrete foundation.

-- Booster frame fastened to manipulator using eight M24x70 hexagon bolts.

-- Easy removal and installation with optimum repeatability of the installation posi-
tion.

When using chemical anchors (resin--bonded anchors), only resin capsules and
anchors (threaded rods) from the same manufacturer may be used.
No diamond tools or core drills may be used for drilling the anchor holes; for
preference, drilling tools supplied by the anchor manufacturer are to be used.
The manufacturer’s instructions for the use of resin--bonded anchors must also
be observed.

(1) Mark a hole pattern as per Fig. 67 on the foundation or set down the drilling template
in the intended installation position on the foundation. Please observe Section 7.4.

(2) The intended installation position of the manipulator, i.e. the correct orientation of the
locating pins (Fig. 66/2, 3) in relation to the working envelope (1), must be taken into
account when marking the position of the boreholes.

2 1

Fig. 66 Orientation of working envelope

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Assembly Instructions

1
front
2

Fig. 67 Hole pattern for variant 3

(3) Drill sixteen anchor holes (Fig. 67/2) in accordance with the dimensions in Fig. 67, or
drill through the holes of the drilling template; minimum depth in concrete 170 +5 mm.
(4) Clean the boreholes.

The boreholes must be free of dust and loose pieces of concrete. No fluids or dust
bonding agents may be used for cleaning.

(5) Bring the booster frame to the site of installation, and set it down and align it in accor-
dance with the hole pattern.
The booster frame can be aligned horizontally by means of M16 screws in four threaded
holes (1).
(6) Insert sixteen resin capsules (Fig. 68/4).
(7) Insert one threaded rod (3) into each borehole (5). To do this, secure the setting tool (2)
in a hammer drill (1), attach the threaded rod, and insert it in the borehole using no more
than 750 r.p.m. The threaded rod is set correctly if the resin is completely mixed and
the borehole in the concrete is completely filled to the upper edge. If the borehole is not
completely filled, the threaded rod must be pulled out again immediately and a new resin
capsule inserted.

92 of 136 MA KR 2000, KR C4 01.10.01 en


7 Installation (continued)

(8) Allow the resin to cure.

The curing time is as follows:


Temperature: Time:
+20 °C 20 minutes
+10 °C 30 minutes
0 °C 1 hour
--5 °C 5 hours

(9) Screw on hexagon nuts (6) together with washers and tighten with torque wrench in di-
agonally opposite sequence, increasing the tightening torque MA to the specified value
in several stages (MA = 120 Nm).

Retighten the hexagon nuts (6) after 100 hours of operation.

6
30

2 4x mounting surface

3
170 +5

4
≥220

≥210
5

Fig. 68 Fastening the manipulator, variant 3

Installation of the manipulator is now finished. The manipulator is ready for connection (see
Section 7.5.1).

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Assembly Instructions

7.5 Connection
7.5.1 Floor--mounted manipulators

Please observe Section 7.1.

This description applies only to manipulators with mounting variant 2 (Section 7.3) or 3 (Sec-
tion 7.3). If the manipulator is to be installed on the floor in an inclined position (max. 5˚; no
inclination permitted with booster frame), then KUKA Roboter GmbH must be consulted be-
forehand.
The procedure for installing the manipulator (whether for the first time or as an exchange)
-- if the manipulator is not already securely fastened to the mounting platform -- is as follows:

(1) Check that both locating pins (Fig. 69/2) and their fastening screws (1) are undamaged
and fitted securely.

Damaged locating pins must be replaced by new ones.

1 2

Fig. 69 Locating pin

94 of 136 MA KR 2000, KR C4 01.10.01 en


7 Installation (continued)

The manipulator must be in the transport position (Fig. 70).

A1 A2 A3 A4 A5 A6
0˚ ---151˚ +155˚ 0˚ 0˚ any
1) 0˚ ---146˚ +150˚ 0˚ ---100˚ any
All angles refer to the display on the KCP.
1) for manipulator KR 150--2, KR 180--2, KR 210--2, KR 240--2, KR 270--2

C1)
D Table of dimensions
Manipulator A B C D E
C KR 150, KR 180, KR 210
without arm extension 133 750 1767 1181 1652
with 200 mm arm extension 112 750 1966 1181 1652
with 400 mm arm extension 91 751 2165 1181 1652

G
Table of dimensions, manipulator
E

KR 150-- 2, KR 180-- 2, A B C D E
KR 210-- 2, KR 240-- 2; KR 270-- 2
B

without arm extension 153 781 1710 1109 1617


with 200 mm arm extension 128 793 1821 1109 1617
with 400 mm arm extension 113 805 2020 1109 1617
1100
598 C1) with arm extension
A

Fig. 70 Transport position for floor--mounted manipulators

1 2

200
100
84
663

499

184 202 427.5


1
29
(790)
1158
1174

Fig. 71 Transporting the manipulator

(2) Lift the manipulator with fork lift truck or lifting tackle.

If transporting the manipulator using lifting tackle, three M20 DIN 580 eyebolts
(Fig. 71/2) must be installed; if using a fork lift truck, the fork slots (1) (accessory) must
be fully and properly installed.

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Assembly Instructions

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. 72/1) vertically onto bedplates, steel structure or booster
frame. If lifting tackle is used, particular care must be taken to ensure exact vertical posi-
tioning in order to avoid damaging the locating pins during this operation.

As the manipulator is lowered, the boreholes (2) must be aligned as accurately


as possible with the two locating pins (4). If this operation is carried out inaccu-
rately, it is more likely that parts will be damaged.

Fig. 72 Installing the manipulator on the floor

(4) Insert eight M24x70--8.8 ISO 4017 hexagon bolts (3) together with conical spring wash-
ers and tighten them with a torque wrench in diagonally opposite sequence, increasing
the tightening torque MA to the specified value in several stages (MA = 640 Nm).

Retighten the eight hexagon bolts (3) after 100 hours of operation.

(5) Remove lifting tackle.


(6) Connect the connecting cables (see Chapter 9, “Connecting cables”).

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.
The manipulator may only be moved at jog speed, with all applicable safety rules
and regulations being observed.

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7 Installation (continued)

(7) Put the manipulator into operation and move it into a suitable position to install the end--
effector and additional equipment.

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.

(8) Install the end--effector and additional equipment.


(9) Connect the electric cables and hose lines to the interfaces of the energy supply system
A1 and all other peripheral supply lines to the manipulator, where necessary.
(10) Put the manipulator into operation.

The relevant documentation must be observed when putting the manipulator and the
attached peripheral equipment into operation.

7.5.2 Ceiling--mounted manipulators

Section 7.1 of this chapter must be observed!

This description only applies to ceiling--mounted manipulators with mounting variant 2 (Sec-
tion 7.3).
For installation on the ceiling, the manipulator can be transported in a transport frame -- al-
ready in the correct orientation. It is removed from this frame by fork lift truck and brought
to the site of installation (Fig. 73).

For transport by fork lift truck, the fork slots (1) (accessory) must be fully and properly
installed.

200
1

1
100
84
663

499

184 202 427.5


29
(790)
1158
1174

Fig. 73 Transporting the manipulator for mounting on the ceiling

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Assembly Instructions

If the manipulator is transported by fork lift truck, the forks must be placed in the
fork slots. It is forbidden to pick up the manipulator in any other way using a
fork lift truck!

For reasons of safety, it is imperative for the lifting tackle to be attached to the
manipulator at the specified points. Risk of injury!
The transport instructions in the chapter “Repair, General” must be observed.

The procedure for mounting the manipulator on the ceiling (whether for the first time or as
an exchange) is as follows:
(1) Check that both locating pins (Fig. 69/2) and their fastening screws are undamaged and
fitted securely.

Damaged locating pins must be replaced by new ones.

The manipulator must be in the transport position (Fig. 74).

A1 A2 A3 A4 A5 A6
0˚ ---151˚ +155˚ 0˚ 0˚ any
1) 0˚ ---146˚2) +150˚ 0˚ ---100˚ any
All angles refer to the display on the KCP.
1) for KR 150--2 C, KR 180--2 C, KR 210--2 C, KR 240--2 C
2) for KR 240--2 C; --133˚

A
598
Table of dimensions
1100 Manipulator A B C D E
KR 150 C, KR 180 C, KR 210 C
without arm extension 133 750 1767 1181 1652
with 200 mm arm extension 112 750 1966 1181 1652
with 400 mm arm extension 91 751 2165 1181 1652
B

G
E

Table of dimensions
Manipulator A B C D E
KR 150, 180, 210; ...-- 2 C
without arm extension 153 781 1710 1109 1671
C with 200 mm arm extension 128 793 1821 1109 1671
with 400 mm arm extension 113 805 2020 1109 1671
D KR 240-- 2 C 80 841 1627 967 1950
C1)
C1) with arm extension

Fig. 74 Transport position for ceiling--mounted manipulators

98 of 136 MA KR 2000, KR C4 01.10.01 en


7 Installation (continued)

(2) Raise the manipulator (Fig. 75/1) vertically with the fork lift truck and place it onto the
ceiling structure (4).

As the manipulator is lifted, the boreholes (2) must be aligned as accurately as


possible with the two locating pins (5). If this operation is carried out inaccu-
rately, it is more likely that parts will be damaged.

As soon as the manipulator is in its exact position on the ceiling, it must be


pressed firmly against the ceiling until it is finally bolted to it.

4 5

Fig. 75 Installing the manipulator on the ceiling

(3) Insert eight M24x70 ISO 4017 hexagon bolts (3) together with lock washers and tighten
them with a torque wrench in diagonally opposite sequence, increasing the tightening
torque MA to the specified value in several stages (MA = 640 Nm).

Retighten the eight hexagon bolts (3) after 100 hours of operation.

(4) Remove the fork lift truck.

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Assembly Instructions

(5) Connect the connecting cables (see Chapter 9, “Connecting cables”).

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.
The manipulator may only be moved at jog speed, with all applicable safety rules
and regulations being observed.

(6) Put the manipulator into operation and move it into a suitable position to install the end--
effector and additional equipment.

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.

(7) Install the end--effector and additional equipment.


(8) Connect the electric cables and hose lines to the interfaces of the energy supply system
A1 and all other peripheral supply lines to the manipulator, where necessary.
(9) Put the manipulator into operation.

The relevant documentation must be observed when putting the manipulator and the
attached peripheral equipment into operation.

100 of 136 MA KR 2000, KR C4 01.10.01 en


8 Electrical installations

8 Electrical installations

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 manipulator form a separate assembly. It includes the “cable
set” (Fig. 77), containing all the electric cables (Fig. 78 to Fig. 86). The cable set has plug--
and--socket connections so that exchanges can be quickly carried out. This dispenses with
the need for wiring work.
The arrangement, designation and allocation of the cables may be noted from the various
diagrams. The connectors are provided with identification labels and coded. The ground con-
ductors are fastened with cable lugs to threaded bolts.

8.1 Description
Installed on the base frame are the RDC box (Fig. 77/7) and the MFH (multi--function hous-
ing) (3). Together with their connectors, these two housings form the interfaces with the con-
necting cables.
The motor cables for axes 1 to 6 are grouped together in the multi--function housing
(MFH) (3) and are wired up to rectangular flange--mounted connector X30. This connector
is at the same time the connector on the manipulator for the connecting cable (motor cable)
between the manipulator and the control cabinet. The connector consists of six separate con-
nector modules. Each connector module is assigned a particular motor connector (e.g.
XM1).
The protective circuit is connected to terminals on a PE distributor plate (2) on the base
frame.
The control cables for axes 1 to 6 are grouped together in the resolver digital converter box
(RDC box) (7) and are connected to an RDC board (6). Each control cable has a separate
connector. The interface at the RDC box with the connecting cable (data cable) between the
manipulator and the control cabinet is formed by connector X31. Connector X32 is used for
connecting the EMD for the purpose of zero adjustment. Installed in the RDC box are the
EDS (5) and the RDC (6). Both components (boards) are connected by means of the EMD
and RDC cables.
A cable gland is fitted at the rear of the RDC box. From this gland, the cables are routed to
the base frame and from there via the common flexible tube A1 to the rotating column. The
flexible tube A1 ensures a low--stress routing of the supply lines as well as reducing the num-
ber of mechanical interface contours, without impairing the rotational motion of axis 1. The
cables for the drive units of axes 1 and 2 branch off in the rotating column.
The cables for the motor units of axes 3 to 6 run from the rotating column to the arm in a
flexible tube inside the hollow link arm. The flexible tubes prevent the cables from kinking.
The cables installed in the manipulator are summarized in tabular form in Fig. 76 and are
shown schematically in Fig. 77.

MA KR 2000, KR C4 01.10.01 en 101 of 136


Assembly Instructions

Cable from to Cable from to


Protective circuit Bolt on Bolt on
00--182--831 base frame rotating column
Bolt on Bolt on
rotating column arm
Motor cable A1 Connector X30 XM1 Control cable A1 Connector X1 XP1
00--177--629 00--176--319
Motor cable A2 Connector X30 XM2 Control cable A2 Connector X2 XP2
00--177--630 00--176--320
Motor cable A3 Connector X30 XM3 Control cable A3 Connector X3 XP3
00--177--631 00--176--321
Motor cable A4 Connector X30 XM4 Control cable A4 Connector X4 XP4
00--177--632 00--176--322
Motor cable A5 Connector X30 XM5 Control cable A5 Connector X5 XP5
00--177--633 00--176--323
Motor cable A6 Connector X30 XM6 Control cable A6 Connector X6 XP6
00--177--634 00--176--324

Fig. 76 Table of cables installed, KR 2000 with KR C4

102 of 136 MA KR 2000, KR C4 01.10.01 en


8 Electrical installations (continued)

XM4 XM5
XP4 XP5
XM3 XM6
XP3 XP6

PE

PE
1
XM1
XP1
XM2
XP2 PE
4

2
3 X30

PE
5
1 Cable set assembly
2 PE distributor X31
3 Multi--function housing, MFH
4 Protective circuit
5 Electronic Data Storage EDS X32 6
6 Resolver Digital Converter RDC
7 RDC box 7

Fig. 77 Cable set assembly

MA KR 2000, KR C4 01.10.01 en 103 of 136


Assembly Instructions

8.2 Cabling plans and wiring diagrams

X30
a1 a2 a3 a11 a12 Housing

Cable gland

1 2 3 RD BU YE/GN
TYPE05/99 SH
4 mm2 4 mm2 4 mm2 1 mm2 1 mm2 4 mm2

XM1 Power connector 1 2 6 4 5 PE

Grd. conductor
Motor W
Motor U

Brake +
Motor V

Brake --
Temperature

Temperature

R2

R1

S4

S2

S3

XP1 S1
9 8 7 10 2 1 12 11

TYPE07/99 BN WH YE GN PK GY RD BU
0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
Cable gland

8 7 6 5 4 3 2 1
X02/X1

Fig. 78 Wiring diagram for drive A1

104 of 136 MA KR 2000, KR C4 01.10.01 en


8 Electrical installations (continued)

X30
b1 b2 b3 b11 b12 Housing

Cable gland

1 2 3 RD BU YE/GN
TYPE05/99 SH
4 mm2 4 mm2 4 mm2 1 mm2 1 mm2 4 mm2

XM2 Power connector 1 2 6 4 5 PE

Grd. conductor
Motor W
Motor U

Brake +
Motor V

Brake --
Temperature

Temperature

R2

R1

S4

S2

S3

S1
XP2
9 8 7 10 2 1 12 11

TYPE07/99 BN WH YE GN PK GY RD BU
0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
Cable gland

8 7 6 5 4 3 2 1
X02/X2

Fig. 79 Wiring diagram for drive A2

MA KR 2000, KR C4 01.10.01 en 105 of 136


Assembly Instructions

X30
c1 c2 c3 c11 c12 Housing

Cable gland

1 2 3 RD BU YE/GN
TYPE05/99 SH
4 mm2 4 mm2 4 mm2 1 mm2 1 mm2 4 mm2

XM3 Power connector 1 2 6 4 5 PE

Grd. conductor
Motor W
Motor U

Brake +
Motor V

Brake --
Temperature

Temperature

R2

R1

S4

S2

S3

S1
XP3
9 8 7 10 2 1 12 11

TYPE07/99 BN WH YE GN PK GY RD BU
0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
Cable gland

8 7 6 5 4 3 2 1
X02/X3

Fig. 80 Wiring diagram for drive A3

106 of 136 MA KR 2000, KR C4 01.10.01 en


8 Electrical installations (continued)

X30
e1 e4 d6 d3 d5 Housing

Cable gland

1 2 3 RD BU YE/GN
Type 10/99 SH
2.5 mm2 2.5 mm2 2.5 mm2 1 mm2 1 mm2 2.5 mm2

XM4 Power connector 1 2 6 4 5 PE

Grd. conductor
Motor W
Motor U

Brake +
Motor V

Brake --
Temperature

Temperature

R2

R1

S4

S2

S3

S1
XP4
9 8 7 10 2 1 12 11

TYPE07/99 BN WH YE GN PK GY RD BU
0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
Cable gland

8 7 6 5 4 3 2 1
X02/X4

Fig. 81 Wiring diagram for drive A4

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Assembly Instructions

X30
e1 e4 e6 e3 e5 Housing

Cable gland

1 2 3 RD BU YE/GN
Type 10/99 SH
2.5 mm2 2.5 mm2 2.5 mm2 1 mm2 1 mm2 2.5 mm2

XM5 Power connector 1 2 6 4 5 PE

Grd. conductor
Motor W
Motor U

Brake +
Motor V

Brake --
Temperature

Temperature

R2

R1

S4

S2

S3

S1
XP5
9 8 7 10 2 1 12 11

TYPE07/99 BN WH YE GN PK GY RD BU
0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
Cable gland

8 7 6 5 4 3 2 1
X02/X5

Fig. 82 Wiring diagram for drive A5

108 of 136 MA KR 2000, KR C4 01.10.01 en


8 Electrical installations (continued)

X30
f1 f4 f6 f3 f5 Housing

Cable gland

1 2 3 RD BU YE/GN
Type 10/99 SH
2.5 mm2 2.5 mm2 2.5 mm2 1 mm2 1 mm2 2.5 mm2

XM6 Power connector 1 2 6 4 5 PE

Grd. conductor
Motor W
Motor U

Brake +
Motor V

Brake --
Temperature

Temperature

R2

R1

S4

S2

S3

S1
XP6
9 8 7 10 2 1 12 11

TYPE07/99 BN WH YE GN PK GY RD BU
0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
Cable gland

8 7 6 5 4 3 2 1
X02/X6

Fig. 83 Wiring diagram for drive A6

MA KR 2000, KR C4 01.10.01 en 109 of 136


Assembly Instructions

X18 X31
1
n.c.
1 Type 06/07 9
WH/GN
TPFO_ P
2 GN 11
TPFO_ N
4
n.c. n. c.
5
n. c.
6
n. c.
4 WH/OG 10
TPFI_ P
5 OG 12
TPFI_ N
6
n.c.

X15 2 AWG18 BU 3
GND
1 AWG18 RD 2
24 V/PS buffered
7
n. c.
8
n. c.
13
n. c.

Fig. 84 Wiring diagram, RDC internal X31

X20 X32
1
n.c.
1 Type 06/07 11
WH/GN
TPFO_ P
2 GN 12
TPFO_ N
4
n.c. n. c.
7
n. c.
8
n. c.
4 WH/OG 2
TPFI_ P
5 OG 3
TPFI_ N
6
n.c.

X17 2 AWG18 BU 6
GND
1 AWG18 RD 5
24 V/PS buffered
9
n. c.
10
n. c.
13
n. c.

Fig. 85 Wiring diagram, RDC internal X32

110 of 136 MA KR 2000, KR C4 01.10.01 en


8 Electrical installations (continued)

Bolt
Arm

Bolt

Rotating column

XM6
XM5
XM4
XM3
XM2
XM1
Bolt
Base frame

X30 X30
RDC box X02 MFH

Fig. 86 Ground conductor installation, protective circuit

MA KR 2000, KR C4 01.10.01 en 111 of 136


Assembly Instructions

112 of 136 MA KR 2000, KR C4 01.10.01 en


9 Connecting cables

9 Connecting cables

This description applies analogously to all of the industrial robots listed in Chapter 1,
regardless of the variant or model shown in the illustrations.

Connecting cables are all the cables running between the manipulator and the control cabinet
(Fig. 87). They have plug--in connections at both ends. The terminal allocation of the connec-
tors is given in Section9.6. In order to avoid the connectors being mixed up, the ends of each
cable are provided with a designation label, which must match the corresponding connection
point on the robot or on the control cabinet. The cable connections on the manipulator and
the control cabinet are shown in Fig. 87.
The interfaces of the connecting cables are the RDC box for the data cable and the MFH
(multi--function housing) for the motor cable on the robot (Fig. 89) and the connector panel
on the control cabinet (Fig. 90).

The connectors must be inserted carefully to avoid damaging the contacts.

The ground conductors are fastened with cable lugs to threaded bolts. The threaded bolts
are included in the scope of supply.

MA KR 2000, KR C4 01.10.01 en 113 of 136


Assembly Instructions

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--18.2 and the relevant national regulations.

KR C4 Manipulator
control cabinet Motor cable
X20 X30

Data cable
X21 X31

Ground conductor 16 mm2

Fig. 87 Connecting cables (diagram)

114 of 136 MA KR 2000, KR C4 01.10.01 en


9 Connecting cables (continued)

9.1 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).
-- Cables are only to be installed indoors.
-- Observe permissible temperature range (fixed installation) 263 K (--10 _C)
to 323 K (+55 _C).
-- Route the motor cables and the control cables separately in metal ducts (Fig. 88);
if necessary, additional measures must be taken to ensure electromagnetic com-
patibility (EMC).

1 2 3 4

7 6 5

1 Cable duct 5 Data cables


2 Welding cables 6 Motor cables
3 Separating web 7 Equipotential bonding conductor 16 mm2
4 Cover

Fig. 88 Routing of cables in cable ducts

9.2 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. 89.
Equipotential bonding between control cabinet and manipulator must be established using
an M8 PE bolt at each end.
The ground conductor is part of the connecting cable set assembly.

MA KR 2000, KR C4 01.10.01 en 115 of 136


Assembly Instructions

9.3 Coding
Motor cable:
Connectors X20 and X30 are each fitted with two coding pins, which prevent them from being
used incorrectly.
Data cables:
In the case of the data cable, coding is achieved by the shape of the connector and the pin
configuration.

1 2

1 MFH, multi--function housing 2 RDC box

Fig. 89 Junction boxes

116 of 136 MA KR 2000, KR C4 01.10.01 en


9 Connecting cables (continued)

9.4 Connector panel on the control cabinet


The connector panel (Fig. 90) is accessed by opening the door to the cabinet.
The connected cables are routed under the control cabinet to the rear.

X21

X20
Fig. 90 Connector panel on the control cabinet

MA KR 2000, KR C4 01.10.01 en 117 of 136


Assembly Instructions

9.5 Configuration of the connecting cables

X20 X30

Fig. 91 Motor cable

X21 X31

Fig. 92 Data cable

PE

8
2
9
1 3
4
5
6
7
10
1 M8 ring cable lug 6 Conical spring washer
2 M8 nut 7 Ground plate
3 Conical spring washer 8 PE bolt
4 8.4 washer 9 Cable lug
5 M8 nut 10 M8 tapped hole

Fig. 93 Ground conductor

118 of 136 MA KR 2000, KR C4 01.10.01 en


9 Connecting cables (continued)

9.6 Wiring diagrams

X21 X31
1 1
20/08 n.c.
9 WH 9
TPFO_ P
11 BU 11
TPFO_ N
4 4
n. c.
5 5
n. c.
6 6
n. c.
10 YE 10
TPFI_ P
12 OG 12
TPFI_ N

3 BU 3
GND
2 RD 2
24 V/PS1 buffered
7 7
n. c.
8 8
n. c.

Fig. 94 Data cable X21

MA KR 2000, KR C4 01.10.01 en 119 of 136


Assembly Instructions

X20 X30
1
a1 A1 Motor M1 U
2
2 2 Motor M1 V
3
3 3 Motor M1 W
19
11 11 Brake +
20
12 12 Brake --

4
b1 B1 Motor M2 U
5
2 2 Motor M2 V
6
3 3 Motor M2 W
21
11 11 Brake +
22
12 12 Brake --

7
c1 C1 Motor M3 U
8
2 2 Motor M3 V
9
3 3 Motor M3 W
23
11 11 Brake +
24
12 12 Brake --

10
d1 D1 Motor M4 U
11
4 4 Motor M4 V
12
6 6 Motor M4 W
25
3 3 Brake +
26
5 5 Brake --

13
e1 E1 Motor M5 U
14
4 4 Motor M5 V
15
6 6 Motor M5 W
27
3 3 Brake +
28
5 5 Brake --

16
f1 F1 Motor M6 U
17
4 4 Motor M6 V
18
6 6 Motor M6 W
29
3 3 Brake +
30
5 5 Brake --

GN/YE
Grd. conductor
GN/YE
Grd. conductor

Cable gland Cable gland

Fig. 95 Motor cable X20

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10 Consumables, safety data sheets

10 Consumables, safety data sheets


10.1 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.

1 Designation of substance/formulation and manufacturer


Trade name: Optitemp RB1 Art. no. 08020
Use: Lubrication
Firm: Optimol Ölwerke Industrie GmbH
Address: Postfach 80 13 49, D--81613 Munich
Tel.: +49 89 4183 116
Fax: +49 89 4183 192

2 Composition / Information about the components


Chemical components:
Synthetic oil based lubricating grease, lithium soap and additives.
Hazardous components:
This product contains no substances requiring declaration as a hazardous
substance.

3 Possible hazards
This product is NOT classified as hazardous according to the German Dangerous Substances Order.

4 First aid measures


Eyes: Immediately rinse thoroughly with plenty of water for several minutes.
Skin: Wash thoroughly as soon as possible with soap and water or a suitable skin
cleansing agent. If the skin has a tendency to dry out, apply suitable skin cream.
Inhalation: Remove from zone of exposure – occurrence unlikely.
Ingestion: Consult a doctor immediately. Do NOT induce vomiting.

5 Fire--fighting measures
Extinguishing agents
Suitable extinguishing agents:
Not essential. Sufficient ventilation is recommended in industry, however.
Unsuitable extinguishing agents:
Water jet.

6 Measures after unintended release


Personal safety precautions:
Spilled product constitutes a considerable slip hazard.
Environmental protection measures:
Prevent the product from entering the drainage system or surface waters.
Disposal information:
Pick up in container. Dispose of as waste.

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Assembly Instructions

7 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):
III
Water hazard classification:
1 (manufacturer’s classification based on the law of mixtures acc. to the German
Administrative Regulation on the Classification of Substances Hazardous to Waters
into Water Hazard Classes (VwVwS))

8 Personal protective equipment


Personal protective equipment:
Avoid contact with skin and eyes. Wear oil--proof gloves if handling repeatedly or for
prolonged periods. A high standard of personal hygiene is necessary.

9 Physical and chemical properties

10 Reactivity
Conditions to be avoided:
Temperatures above 180 °C
Substances to be avoided:
Strong oxidizing agents.
Hazardous decomposition products:
None if used for designated purpose.

11 Toxicological information
The following toxicological analysis is based on the known toxicity of the individual components. Expected
LD50 oral (rat) > 2g/kg. Expected LD50 dermal (rabbit) > 2g/kg.
Effects on health
On eyes: Can cause temporary irritation.
On skin: Can make the skin dry. Can cause temporary irritation.
With occasional contact of short duration, irritation is unlikely.
If inhaled The low volatility of the product makes inhalation unlikely at room temperature.
If ingested: Can cause nausea, vomiting and diarrhea.
Chronic effects: Repeated or prolonged skin contact can cause long--term changes in the skin.

12 Ecological information
General assessment:
If used for the designated purpose and disposed of correctly, no adverse effects are
expected on the environment.
Mobility: Non--volatile. Paste--like. Insoluble in water.
Persistence and degradability:
Not determined.
Bioaccumulation potential:
Bioaccumulation is unlikely due to the low water--solubility.
Ecotoxicity: Ecotoxicity for fish, daphniae and algae is not assumed. An inhibitory effect on
activated sludge bacteria is not assumed.

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10 Consumables, safety data sheets (continued)

13 Disposal information
This product must be disposed of in accordance with all pertinent regulations governing the disposal of
waste and used lubricants.
Waste code: Recommended means of disposal:
Unused product: 54 202 SAV
Used/contaminated product: 54 202 SAV
Packaging: 54 202 SAV, SAD
Container reconditioning

14 Transport regulations
This product is NOT classified as a dangerous good for the purpose of transportation according to the
German Law concerning the Conveyance of Dangerous Goods.

15 Regulations
EC regulations: EC Safety Data Sheet Directive 91/155/EEC
EC Directive on Dangerous Preparations 88/379/EEC
EC Framework Directive on Waste 91/156/EEC
EC Directive on Hazardous Waste 91/689/EEC
National regulations (Germany): Law concerning the Conveyance of Dangerous Goods
Water Resources Law (WHG)
Chemicals Law (ChemG)
Dangerous Substances Order (GefStoffV)
Law concerning Life--cycle Management and Waste (KrW--AbfG)
Federal Immission Control Act (BImschG)
Technical Guideline on Air (TA--Luft)

16 Other information
All information is based on the current state of our knowledge. It is intended only to describe our product
with regard to the safety data. It is not intended to provide assurance of particular properties.
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.
Further information on the use of the product may be found in the relevant technical specifications.

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Assembly Instructions

10.2 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.

1 Designation of substance/formulation and manufacturer


Trade name: Optimol Olit CLS Art. no.: 08202
Use: Lubrication
Firm: Optimol Ölwerke Industrie GmbH
Address: Postfach 80 13 49, D--81613 Munich
Tel.: +49 89 4183 116
Fax: +49 89 4183 192

2 Composition / Information about the components


Chemical components:
Lubricating grease based on mineral oil and lithium--calcium soap grease as
thickener.
Hazardous components:
This product contains no substances requiring declaration as a hazardous
substance.

3 Possible hazards
This product is NOT classified as hazardous according to the German Dangerous Substances Order.

4 First aid measures


Eyes: Rinse thoroughly with plenty of water for several minutes; consult a doctor if
necessary.
Skin: Wash thoroughly with soap and water; replace lost skin grease with skin cream.
Inhalation: Not applicable.
Ingestion: Do NOT induce vomiting; consult a doctor immediately.

5 Fire--fighting measures
Extinguishing agents
Suitable extinguishing agents:
Foam, dry powder, CO2.
Unsuitable extinguishing agents:
Water.

6 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 or surface waters.
Disposal information:
Bind lubricant with a suitable binding agent and dispose of it in accordance with
regulations.

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10 Consumables, safety data sheets (continued)

7 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.
Do not leave container outdoors; protect from direct sunlight.
Technical Instructions on Air Quality Control / Annex E (Class):
Not applicable.
Water hazard classification:
Not applicable.

8 Personal protective equipment


Personal protective equipment:
The usual precautions when handling lubricants must be observed. Avoid prolonged
contact with the skin. Do not eat, drink, smoke or take snuff during work. Change
contaminated working clothes. Clean skin and apply skin cream after work.
Wear protective neoprene gloves.

9 Physical and chemical properties

10 Reactivity
Conditions to be avoided:
The product is stable.
Substances to be avoided:
Strong acids and oxidizing agents.
Hazardous decomposition products:
Dependent on decomposition conditions: oxides of C, S, P.

11 Toxicological information
Effects on health
on eyes: Contact with eyes can cause temporary irritation of the conjunctiva.
on skin: Avoid prolonged or repeated contact with the skin, as mild irritation may occur.

12 Ecological information
General assessment:
Prevent the lubricant from entering soil, surface waters and drainage system.

13 Disposal information
This product must be disposed of in accordance with all pertinent regulations governing the disposal of
waste and used lubricants.
Waste code: Recommended means of disposal:
Unused product: 54 202
Packaging: Contaminated packaging should be emptied
optimally; it can then be recycled after
appropriate cleaning.

14 Transport regulations
This product is NOT classified as a dangerous good for the purpose of transportation according to the
German Law concerning the Conveyance of Dangerous Goods.

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Assembly Instructions

15 Regulations
EC regulations: EC Safety Data Sheet Directive 91/155/EEC
EC Directive on Dangerous Preparations 88/379/EEC
EC Framework Directive on Waste 91/156/EEC
EC Directive on Hazardous Waste 91/689/EEC
National regulations (Germany): Law concerning the Conveyance of Dangerous Goods
Water Resources Law (WHG)
Chemicals Law (ChemG)
Dangerous Substances Order (GefStoffV)
Law concerning Life--cycle Management and Waste (KrW--AbfG)
Federal Immission Control Act (BImschG)
Technical Guideline on Air (TA--Luft)

16 Other information
All information is based on the current state of our knowledge. It is intended only to describe our product
with regard to the safety data. It is not intended to provide assurance of particular properties.
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.
Further information on the use of the product may be found in the relevant technical specifications.

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10 Consumables, safety data sheets (continued)

10.3 Safety data sheet for Optigear Synthetic RO 150 oil

1 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.
Supplier: Deutsche BP Aktiengesellschaft, Industrial Lubricants & Services
Address: Erkelenzer Strasse 20, D--41179 Mönchengladbach
Country: Germany
Tel.: +49 (0)2161 909 319
Fax: +49 (0)2161 909 392
Emergency hotline: Carechem: +44 (0)208 762 8322
e--mail address: [email protected]

2 Possible hazards
The preparation is classified as hazardous in accordance with Directive 1999/45/EC in its altered and
adapted version.
Environmental hazards:
Harmful to aquatic organisms, may cause long--term adverse effects in the aquatic
environment.
Sections 11 and 12 contain more detailed information on health hazards, symptoms and environmental
risks.

3 Composition and information about the components


Chemical characterization:
Synthetic lubricant and additives.
Chemical description:
CAS no. % EINECS/ELINCS. Rating
Dithiocarbamic acid,
dibutyl--, methylene ester
10254--57--6 1 -- 5 233--593--1 R52/53

Tridecanamine, n--tridecyl,
branched, compounds with
molybdenum hydroxide
oxide (1:1)
280130--32--7 0.1 -- 1 442--990--0 Xi; R41,
R38 N;
R50/53

Refer to Section 16 for the full text of the above R--phrases.


The occupational exposure limit values, where available, are specified in Section 8.

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Assembly Instructions

4 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. Wash
clothing before reuse. Clean shoes thoroughly before reuse. If irritation occurs
consult a doctor.
Inhalation: Take affected person into fresh air. Consult a doctor if symptoms persist.
Ingestion: Do NOT induce vomiting. If the person is unconscious, do not give anything by
mouth. Consult a physician immediately.

5 Fire--fighting measures
Suitable extinguishing agents
In the event of a fire: use water spray (mist), foam, dry chemicals or CO2. This
substance is harmful to aquatic organisms. Extinguishing water contaminated with
this product must be contained and prevented from entering surface waters or the
sewage or drainage system.
Unsuitable extinguishing agents:
Do NOT use water jets.
Hazardous decomposition products:
The decomposition products may include the following materials:
Carbon oxides
Nitrogen oxides
Sulfur oxides
Unusual fire/explosion hazards:
This product is not inherently explosive in accordance with the applicable rules.
Special fire--fighting measures:
Not specified.
Protection of fire--fighters:
Fire--fighters must wear self--contained positive pressure breathing apparatus
(SCBA) and full protective gear.

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10 Consumables, safety data sheets (continued)

6 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. Ensure adequate ventilation. Where there
is insufficient ventilation, wear suitable respiratory equipment. Use suitable
protective equipment (see Section 8).
Environmental protection measures:
Prevent released material from dispersing or flowing away and from coming into
contact with soil, surface waters and drainage system. Notify the relevant
authorities if the product has caused pollution (sewers, surface waters, ground or
air). Substance is a water pollutant.
Large spills: Stop the leak if you can do so without risk. Remove container from spill area.
Approach the spill area only with a following wind. Prevent entry into drainage
system, surface waters, basements or confined areas. Flush spilled material into a
wastewater treatment plant, or proceed as follows. Contain spilled material using a
non--combustible absorbent (e.g. sand, soil, vermiculite, diatomaceous earth) and
collect it in the designated containers for disposal in accordance with the local
regulations (see Section 13). Disposal should be entrusted to a recognized waste
disposal company. Contaminated absorbents can be just as dangerous as spilled
material. Note: See Section 1 for contact in emergencies and Section 13 for
disposal information.
Small spills: Stop the leak if you can do so without risk. Remove container from spill area.
Absorb spill with inert material and place it in a suitable container for disposal.
Disposal should be entrusted to a recognized waste disposal company.

7 Handling and storage


Handling: Spilled and leaked product must be prevented from coming into contact with soil
and surface waters. Wash thoroughly after handling.
Storage: Keep containers tightly sealed. Keep containers in a cool, well--ventilated area.
Germany -- storage class:
10

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Assembly Instructions

8 Exposure limits and personal protective equipment


Ingredient name ACGIH TLVs:
Base oil – unspecified
Limits to monitor: ACGIH (USA).
TWA: 5 mg/m3 8 hour(s). Form: mineral oil mist
STEL: 10 mg/m3 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.
While this section contains specific OELs for individual components, different components may be
contained in any mists, vapors or dusts that are generated. The specific OELs may thus not necessarily be
applicable to the product as a whole and are merely provided for general information purposes.
Limitation and monitoring of exposure
Limitation and monitoring of exposure in the workplace:
Provide exhaust ventilation or other engineering controls to keep the relevant
airborne concentrations below their respective occupational exposure limits.
Hygiene measures: Wash hands, forearms and face thoroughly after handling chemical products and
before eating, smoking or using the toilet, as well as at the end of the working day.
Personal protective equipment
Respiratory protection:
Not essential. Sufficient ventilation is recommended in industry, however.
Hand protection: Wear protective gloves if prolonged or repeated contact is likely.
Chemical--resistant protective gloves. Recommended: nitrile gloves
The right choice of protective gloves is dependent on the chemicals to be handled,
the working conditions, and the condition of the gloves themselves (even the best
chemical--resistant protective gloves start to leak after repeated contact with
chemicals). Most protective gloves only provide protection for a short period of
time, after which they must be disposed of and replaced. As the specific working
conditions and the chemicals concerned differ from case to case, appropriate safety
measures must be developed for each individual application. Protective gloves
should therefore be selected in consultation with the supplier/manufacturer, giving
full consideration to the specific working conditions.
Eye protection: Protective goggles with side shields to guard against splashing.
Skin and body: Wear appropriate clothing to avoid prolonged skin contact.

9 Physical and chemical properties


General information regarding appearance
Physical state Liquid.
Color: Green.
Odor: Slight.
Important information on health, safety and the environment
Flash point: Open cup: 230 °C (446 °F) [Cleveland]
Vapor pressure: <0.01 kPa (<0.075 mm Hg) at 20°C
Viscosity: Kinematic: 150 mm2/s (150 cSt) at 40°C
Pour point: --36°C
Density: < 1000 kg/m3 (< 1 g/cm3) at 20 °C
Solubility: Insoluble in water.

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10 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
Nitrogen oxides
Sulfur oxides
No hazardous decomposition products should be formed under normal conditions
of storage and use.

11 Toxicological information

12 Ecological information
Persistence / degradability:
Inherently biodegradable.
Mobility: Non--volatile. Liquid. Insoluble in water.
Environmental hazards:
Harmful to aquatic organisms, may cause long--term adverse effects in the aquatic
environment.

13 Disposal information
Disposal information
Disposal information / waste specifications:
Generation of waste should be avoided or minimized if at all possible. Disposal of
surplus material and products not suitable for recycling must be entrusted to a
recognized waste disposal company. Disposal of this product and of its solutions
and by--products must at all times comply with the environmental protection
requirements, waste disposal legislation and the requirements of local authorities.
Prevent released material from dispersing or flowing away and from coming into
contact with soil, surface waters and drainage system.
Unused product
European Waste Catalog (EWC):
13 02 08* Synthetic machine oils, gear oils and lubricating oils
Use of the product for purposes other than those specified and/or the presence of
impurities can necessitate the use of a different waste code number by the waste
producer.
Packaging
European Waste Catalog (EWC):
15 01 10* Packaging containing the residue of hazardous materials or
contaminated by hazardous materials.

14 Transport information
Not hazardous as defined by the transport regulations (ADR/RID, ADNR, IMDG, ICAO/IATA).

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Assembly 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. Refer to special instructions/safety data
sheet.
Miscellaneous provisions
Inventories:
European inventory: All components are listed or exempted.

US inventory (TSCA 8b): All components are listed or exempted.

Australian inventory (AICS): All components are listed or exempted.

Canadian inventory: At least one component is not listed.

Inventory of Existing Chemical Substances in China (IECSC): All components


are listed or exempted.

Japanese inventory of Existing and New Chemical Substances (ENCS):


At least one component is not listed.

Korean Existing Chemicals Inventory (KECI): All components are listed or


exempted.

Philippine Inventory of Chemicals and Chemical Substances (PICCS): All


components are listed or exempted.
Water hazard classification (WGK),
classification acc. to the German Administrative Regulation on the Classification of Substances
Hazardous to Water into Water Hazard Classes (VwVwS):
1, Annex no. 4

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10 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.
R52/53 -- Harmful to aquatic organisms, may cause long--term adverse
effects in the aquatic environment.
History:
Date of issue: 23/11/2007.
Date of previous issue: 31/08/2007.
Prepared by: Product Stewardship Group
Notes for the reader:
All reasonably practicable steps have been taken to ensure this data sheet and the health, safety and
environmental information contained in it is accurate as at the date of issue specified below. No warranty
or representation, express or implied, is made as to the accuracy or completeness of the data and
information in this data sheet.
The data and advice issued are valid if the product is sold for the application(s) specified. The product
should not be used for purposes other than the applications specified without prior consultation with us.
It is the responsibility of the user to check this product and to use it with care, while observing all the
relevant laws and regulations in force.
The BP Group accepts no responsibility for any damage or injury resulting from uses other than the stated
product use of the material, from any failure to adhere to recommendations, or from hazards inherent in
the nature of the material. Those purchasing the product for supply to third parties for use at work have a
duty to take all necessary steps to ensure that any person handling or using the product is provided with
the information on this data sheet. Employers have a duty to tell employees and others who may be
affected of any hazards described in this sheet and of any precautions that should be taken.

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Assembly Instructions

10.4 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.

1 Designation of substance/formulation and manufacturer


Trade name: Microlube GL 261 Article no.: 020195
Use: Lubricant
Firm: KLÜBER LUBRICATION MÜNCHEN KG
Address: Geisenhausenerstr. 7, D--81379 Munich
Tel.: +49 89 7876 0
Fax: +49 89 7876 333

2 Composition / Information about the components


Chemical characterization:
-- Mineral oil
-- Lithium special soap
-- UV indicator
Hazardous components:
This product contains no substances requiring declaration as a hazardous
substance.

3 Possible hazards
This product is NOT classified as hazardous according to the German Dangerous Substances Order.

4 First aid measures


Eyes: Rinse thoroughly with plenty of water for several minutes; consult a doctor if
necessary.
Skin: Wash thoroughly with soap and water; replace lost skin grease with skin cream.
Inhalation: If oil vapor has been inhaled, ensure plentiful supply of fresh air and consult a
doctor if necessary.
Ingestion: Consult a doctor if symptoms persist.

5 Fire--fighting measures
Extinguishing agents
Suitable extinguishing agents:
Foam, fine water spray, dry powder, CO2.
Unsuitable extinguishing agents:
Full water jet.
Special fire--fighting measures:
Cool containers at risk from fire with water spray.
Residue from after a fire and contaminated fire--extinguishing water must be
disposed of in accordance with the applicable regulations.
In the event of fire, the following can be released:
Carbon monoxide (CO), hydrocarbons.
Special protective equipment:
Do not inhale gases from explosions and combustion.
Usual measures for fires involving chemicals.

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10 Consumables, safety data sheets (continued)

6 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.
Additional instructions:
No hazardous materials are released.

7 Handling and storage


Handling: No special measures required.
Storage: Store in well sealed containers in a cool and dry place.
Do not store together with oxidizing agents or food.
Storage class in accordance with VCI:
11

8 Exposure limits and personal protective equipment


Additional information for the design of technical systems:
No further information.
Components with applicable occupational exposure limit values:
The product contains no relevant amounts of materials that are subject to
monitoring of limit values in the workplace.
Additional instructions:
These values are based on the lists valid at the time of issue.
Personal protective equipment
General protective and hygiene measures:
Immediately take off any contaminated, soaked clothing.
Avoid prolonged and intensive contact with the skin.
Thoroughly clean the skin after work and before taking breaks.
Respiratory protection and eye protection:
Not essential.
Hand protection: Appropriate measures for precautionary skin protection are recommended.

9 Physical and chemical properties


State: Paste
Color: Tawny
Odor: Product--specific
Pour point: >220 ˚C (DIN ISO 2176)
Flash point: Not applicable.
Risk of explosion: The product presents no danger of explosion.
Density (20 ˚C): ~ 0.89 g/cm3
Solubility: Insoluble in water.

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Assembly 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.

12 Ecological information
Measures at wastewater treatment facilities:
The product can be separated by mechanical means.
General information: Prevent from entering groundwater, surface waters or the drainage system.
Water hazard classification 1 (manufacturer’s classification): low hazard to waters

13 Disposal information
Waste code number: No waste code number for this product can be defined in accordance with the
European Waste Catalog (EWC) until the purpose of use has been assigned by the
customer.
The waste code number should be determined in consultation with the regional
disposal service.
Contaminated packaging:
Recommendation: Contaminated packaging should be emptied optimally; it can then be recycled after
appropriate cleaning.

14 Transport regulations
This product is NOT classified as a dangerous good for the purpose of transportation according to the
German Law concerning the Conveyance of Dangerous Goods.

15 Regulations
EC regulations: The product is not subject to labeling obligations due to the method of calculation in
the latest version of the “EC General Classification Directive for Preparations”.
Water hazard classification:
WGK 1 (manufacturer’s classification): low hazard to waters in accordance with the
German Administrative Regulation on the Classification of Substances Hazardous
to Water into Water Hazard Classes (VwVwS) 17.5.99 Annex 4

16 Other information
All information is based on the current state of our knowledge. The information does not represent any
assurance of product characteristics, however, and does not establish a legally valid contractual
relationship.

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