MA KR 2000 KR C4 en
MA KR 2000 KR C4 en
MA KR 2000 KR C4 en
Assembly Instructions
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
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
1 Introduction
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.
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.
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.
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.
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
This section is subdivided in accordance with the breakdown of the manipulator into its main
subassemblies.
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
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 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
--90°
--146˚
2
3
0˚
1 Link arm
2 Main axis motor unit A2
3 Rotational axis 2
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”).
4
6
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
4 3 2
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
6
8
3
4
8 5
7 6
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
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
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.
3 4
5 8
6
1 IW = in--line wrist
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
KR 180-- 2
KR 180 L150-- 2
KR 180 L130-- 2
D In--line wrist, rated payload 180/150/130 kg
1 ±185˚ 95 ˚/s
KR 210-- 2
KR 210 L180-- 2
KR 210 L150-- 2
D In--line wrist, rated payload 210/180/150 kg
1 ±185˚ 86 ˚/s
KR 240-- 2
KR 240 L180-- 2
KR 240 L210-- 2
D In--line wrist, rated payload 240/210/180 kg
KR 270-- 2
D In--line wrist, rated payload 270 kg
270 kg
1 ±185˚ 85 ˚/s
A4 +
+ +
A5 A3
-
-
+ -
A1
- - +
A6
+
A2
-
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.
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
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.
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
380
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
150
M12x24
150
M20x30
500
5°
315
149
70
80
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
The specified forces and moments already include the payload and the inertia force (weight)
of the manipulator.
Fv
Mk
Fv
Fh
Mr
View A
3 4 5
10
13
2 12 3 4 5 6
7
11 9
1 8
1
9
4x on each AC servomotor
.................
On all AC
servomotors ...........................................................
................................................
...........................................................
................................................
...........................................................
.................................................
5
Roboter GmbH
Zugspitzstra e 140
86165 Augsburg.Germany
Typ Type Type XXXXXXXXXXXXXXXXXXXXXXXXXX
Reichweite Range ^
Portee XXXX MM
$TRAFONAME[]=”#.....” XXXXXXXXXXXXXXXXXXXXXXXXXXX
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de/en/fr
00--104--232
9
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Fig. 44 Danger zone
10
3
1 2
00--146--665
12
00--123--341
13
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.
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
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.
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.
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.
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
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
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:
Work on the electrical and mechanical equipment of the industrial robot may only be
carried out by specially trained personnel.
This option is not available for all robot models. Information on specific robot models
can be obtained from KUKA Roboter GmbH.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 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.
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
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.
1
max. 5000 N
60°
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).
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
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
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
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.
The manipulator must not be set down until the transport safeguards have been
installed.
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.
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:
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.
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!
Mk
Fv
Fh
Mr
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
(5) Allow the leveling compound to cure for about three hours. The curing time is longer
at temperatures below 293 K (20 °C).
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.
(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.
t=30 mm
1
front
5 3
4
(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
(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).
1
6
30
3
4
≥220
≥210
5
Installation of the manipulator is now finished. The manipulator is now ready for connection
to the controller.
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.
2 1
The drilling template (available as an accessory) makes it easier to drill the holes for the
fastening screws and the locating pins.
(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
(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).
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
Features:
-- 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
1
front
2
(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.
(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).
6
30
2 4x mounting surface
3
170 +5
4
≥220
≥210
5
Installation of the manipulator is now finished. The manipulator is ready for connection (see
Section 7.5.1).
7.5 Connection
7.5.1 Floor--mounted manipulators
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.
1 2
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
1 2
200
100
84
663
499
(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.
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.
(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.
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.
(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.
The relevant documentation must be observed when putting the manipulator and the
attached peripheral equipment into operation.
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
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.
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
(2) Raise the manipulator (Fig. 75/1) vertically with the fork lift truck and place it onto the
ceiling structure (4).
4 5
(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.
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.
The relevant documentation must be observed when putting the manipulator and the
attached peripheral equipment into operation.
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.
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
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
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
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
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
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
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
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
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
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
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
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
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
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.
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.
Bolt
Arm
Bolt
Rotating column
XM6
XM5
XM4
XM3
XM2
XM1
Bolt
Base frame
X30 X30
RDC box X02 MFH
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 ground conductors are fastened with cable lugs to threaded bolts. The threaded bolts
are included in the scope of supply.
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
1 2 3 4
7 6 5
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
X21
X20
Fig. 90 Connector panel on the control cabinet
X20 X30
X21 X31
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
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.
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
3 Possible hazards
This product is NOT classified as hazardous according to the German Dangerous Substances Order.
5 Fire--fighting measures
Extinguishing agents
Suitable extinguishing agents:
Not essential. Sufficient ventilation is recommended in industry, however.
Unsuitable extinguishing agents:
Water jet.
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.
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.
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.
3 Possible hazards
This product is NOT classified as hazardous according to the German Dangerous Substances Order.
5 Fire--fighting measures
Extinguishing agents
Suitable extinguishing agents:
Foam, dry powder, CO2.
Unsuitable extinguishing agents:
Water.
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.
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.
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.
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
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.
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).
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.
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.
3 Possible hazards
This product is NOT classified as hazardous according to the German Dangerous Substances Order.
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.
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.