Kuka KR60-3

ROBOT
KR 30, 60--3; KR 30 L16--2 with KR C4
Operating Instructions
Issued: 25 Sep 2012 Version: 01
BA KR 30, 60--3, F, KR C4 01.11.01 en 1 of 192

e Copyright 2012
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 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Robot documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Representation of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 In--line wrist IW 16 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 In--line wrist 30/45/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.1 Wrist axis motor units A4 to A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Link arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5.1 Main axis motor units A1 to A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.6 Rotating column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7 Base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Working range limitation for A1 to A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.9 Working range monitoring for A1 and A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.10 Energy supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1.1 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1.2 Intended use of the industrial robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1.3 EC declaration of conformity and declaration of incorporation . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1.4 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3 Workspace, safety zone and danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.4 Overview of protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.4.1 Mechanical end stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.4.2 Mechanical axis range limitation (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.4.3 Axis range monitoring (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.4.4 Devices for moving the manipulator without the robot controller (options) . . . . . . . . . . . . . . 54
BA KR 30, 60--3, F, KR C4 01.11.01 en 3 of 192

5.4.5 Labeling on the industrial robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.5 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.5.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.5.2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.3 Start--up and recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.4 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.5.5 Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.5.6 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.5.7 Decommissioning, storage and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.6 Applied norms and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7 Installation, connection, exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.2 Principal loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.3 Mounting variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.3.1 Variant 1, mounting base with centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.3.2 Variant 2, machine frame mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.3.3 Variant 3, adapter plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.4 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.4.1 Floor--mounted manipulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.4.2 Ceiling--mounted manipulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.4.3 Wall--mounted manipulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.5 Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.5.1 Floor--mounted manipulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.5.2 Ceiling--mounted manipulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.5.3 Wall--mounted manipulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8 Electrical installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8.2 Cabling plans and wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9 Connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.2 Routing of cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.3 Junction boxes on the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.3.1 Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.4 Connector panel on the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.5 Configuration of the connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
9.6 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.2 Maintenance work, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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10.3 Changing the oil on main axis gear units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.3.1 Changing the oil on axis 1 gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.4 Maintenance work, in--line wrist IW 16 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
10.4.1 Oil change on in--line wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10.5 Maintenance, in--line wrist IW 30/45/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
10.5.1 Changing the oil in in--line wrist IW 30/45/60 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
10.6 Cleaning and preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
10.7 Safety precautions when handling lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
11 Adjustment instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
12 Adjusting the toothed belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

12.1 Measuring and adjusting the toothed belt tension on wrist axis motor units A4 and A5 . . . 141
12.2 Measuring and adjusting the toothed belt tension on in--line wrist A5 and A6 . . . . . . . . . . . 144
13 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
13.2 Bonding instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
13.3 Unbraked impact against limit stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
13.4 In--line wrist IW 16, repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
13.4.1 Removal, installation of in--line wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
13.5 Repairing in--line wrist IW 30/45/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
13.5.1 Removal, installation of in--line wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
13.5.2 Removal, installation of toothed belts for axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
13.6 Repairing AC servomotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
13.6.1 Removal, installation of main axis motor unit A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
13.6.4 Removal, installation of wrist axis motor unit A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
13.6.7 Removal, installation of toothed belts A4/A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
14 Consumables, safety data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

14.1 Safety data sheet for Optitemp RB1 cable grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
14.2 Safety data sheet for Optimol Olit CLS lubricating grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
14.3 Safety data sheet for Optigear Synthetic RO 150 oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
14.4 Safety data sheet for Microlube GL 261 lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
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1 Introduction
Valid for KR 30--3

KR 30 L16--2
KR 60--3
KR 60 L45--3
KR 60 L30--3
with the F variant and with KR C4
1 Introduction
1.1 Robot documentation

The documentation of this robot comprises the following parts:
-- KR 30, 60--3, F, KR C4 assembly instructions
-- Parts catalog on storage medium
Each of these parts is a separate document that is attached to the 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.
BA KR 30, 60--3, F, KR C4 01.11.01 en 7 of 192

2 Purpose
2.1 Intended use
Use
Handling of tools or fixtures for processing or transferring components or products, e.g.
-- Handling
-- Assembly
-- 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.
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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 and electrical installations), con-
trol cabinet, teach pendant and connecting cables (Fig. 1). The manipulator is dealt with in
this document. The control cabinet, teach pendant and connecting cables are described in
separate documentation.
KR 30 L16--2
KR 30, 60--3
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.
BA KR 30, 60--3, F, KR C4 01.11.01 en 9 of 192

3.2 In--line wrist IW 16 II

The robot KR 30 L16 is equipped with a triple--axis in--line wrist (Fig. 3) for a payload of 16 kg
(IW 16 Ii). The in--line wrist is screwed to the arm via the flange (4). The wrist axes A4, A5
and A6 are driven by means of the shafts (1, 2, 3). End effectors are attached to the mounting
flange (6) of axis 6. Each axis has a measuring device (5), through which the mechanical zero
of the respective axis can be checked by means of an electronic probe (accessory) and trans-
ferred to the controller. Directions of rotation, axis data and permissible loads can be found
in Chapter4, “Technical data”.
1 2 3 4 5 6
1 Shaft for axis 6 4 Flange (arm--wrist)

2 Shaft for axis 5 5 Measuring device
3 Shaft for axis 4 6 Mounting flange
Fig. 2 In--line wrist IW 6 II
3.3 In--line wrist 30/45/60

The robot variants KR 30, 60--3 are equipped with a triple--axis in--line wrist (Fig. 3) for a pay-
load of 30, 45 or 60 kg, depending on the type. The function and interfaces correspond to
IW 16 II. This in--line wrist is equipped with toothed belts for driving axes 5 and 6.
The in--line wrist variant “F” is available for operating conditions involving greater mechanical
and thermal stress.
1 2 3 4 5
30/45/60 kg
1 Shaft 4 Flange
2 Shaft 5 Mounting flange
3 Shaft 6 Measuring device
Fig. 3 In--line wrist IW 30/45/60
10 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

3 Product description (continued)
3.4 Arm
The arm assembly (Fig. 4/2) 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 extends for all manipulators from +158 to --120 , re-
ferred to the electrical zero position of axis 3, which is given when the longitudinal axes of
the arm and link arm run parallel. The swivel range is limited by mechanical limit stops with
a buffer function in addition to the software limit switches.
Attached to the rear of the arm housing (8) are the motor units for wrist axes 4 to 6. Arm vari-
ants are available which are 200 mm (KR 60 L45--3) or 400 mm (KR 60 L30--3) longer than
the standard arm. These arm extensions involve a reduction in the rated payloads and the
individual axis speeds. The arm length in the case of the KR 30 L16--2 is 624 mm more than
for the standard variant.
The arm housing consists -- as do the housings of the link arm and rotating column -- of a
light alloy construction optimized 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 wrist axis motor units (1) through push--on shafts (5) located inside the arm.
With “F” variant robots, the arm is pressurized. It is operated with an internal pressure of
0.1 bar.
1 2 3 4
8 7 6 5
1 Motor units for wrist axes 6 Main axis motor unit A3

2 Arm 7 Link arm
3 Rotational axis A3 8 Arm housing
4 In--line wrist
5 Shaft
Fig. 4 Arm
BA KR 30, 60--3, F, KR C4 01.11.01 en 11 of 192

3.4.1 Wrist axis motor units A4 to A6

The wrist axes are driven by three motor units. These are fastened to the arm (Fig. 5/4) by
means of screws. Motor units A4 (3) and A5 (1) are of the same design and drive the respec-
tive wrist axes via toothed belts and shafts. Wrist axis A6 is driven directly by motor
unit A6 (2) via a push--on shaft (5).
Each motor unit for the wrist axis drives consists of a brushless AC servomotor with a perma-
nent--magnet single--disk brake and a hollow--shaft resolver (both integrated).
1 2 3 4
A4
A6
A5
1 Motor unit A5
2 Motor unit A6
3 Motor unit A4
4 Arm
5
5 Shaft
Fig. 5 Wrist axis motor units A4 to A6
12 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

3.5 Link arm

The link arm (Fig. 6/1) is the driven element of axis 2. It pivots about rotational axis 2 (3)
through an effective software range from +35 to --135 referred to the zero position of
axis 2, which corresponds to the horizontal position of the link arm in Fig. 6. The effective
software swivel range is limited by mechanical limit stops with a buffer function in addition
to the software limit switches.
--135
3
+35
1 Link arm
2 Main axis motor unit A2
3 Rotational axis 2
Fig. 6 Link arm and turning range
The link arm (Fig. 7/6) houses gear unit A3 (2) at its upper end, and gear unit A2 (3) at its
lower end. The gear units (2, 3) are used both as drive elements and to support the arm and
link arm assemblies. The reference notch (1) and the gauge cartridge (4) are provided to de-
fine and locate 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 from the rotating
column to the arm.
The link arm of the KR 30 L16--2 has a center distance from A2 to A3 of 1250 mm, compared
with 850 mm for the link arm of the standard variants.
BA KR 30, 60--3, F, KR C4 01.11.01 en 13 of 192

5
4
1 Reference notch A3 5 Rotational axis 2

2 Gear unit A3 6 Link arm
3 Gear unit A2 7 Rotational axis 3
4 Gauge cartridge A2
Fig. 7 Structure of link arm
14 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

3.5.1 Main axis motor units A1 to A3

The robot axes 1, 2 and 3 are driven by motor units as shown in Fig. 8. Each motor unit for
the main axis drives consists of a brushless AC servomotor (1) with a permanent--magnet
single--disk brake and hollow--shaft resolver (2), both integrated. The motor units for
axes 1, 2 and 3 are of the same design.
Axis 2 of the KR 60 variants is equipped with a more powerful motor unit.
Fig. 8 Motor unit for main axis drive
BA KR 30, 60--3, F, KR C4 01.11.01 en 15 of 192

3.6 Rotating column

The rotating column (Fig. 9/2) is the assembly located between the link arm and the base
frame. Screwed to the base frame (4) through a special 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 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 +185

2 Rotating column
3 Special reduction gear unit
4 Base frame
6 Zero position A1
Fig. 9 Rotating column with turning range (shown here: KR 30--3)
16 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

The main axis motor unit for axis 1 (Fig. 10/3) is installed in the rotating column with a special
reduction gear unit (4), and the main axis motor unit for axis 2 (1) is mounted on the side of
the rotating column with its special reduction gear unit (2).
Part of the manipulator electrical installations is routed inside the rotating column.
1
3

2 Special reduction gear unit A2
4 Special reduction gear unit A1
Fig. 10 Structure of rotating column
3.7 Base frame

The base frame (Fig. 11) is the stationary part of the manipulator, on which the rotating col-
umn turns with the link arm, the arm and the wrist. Its base flange (5) features through--
holes (4) for holding the manipulator down and two locating boreholes (6), with which the ma-
nipulator can be placed on two locating pins (accessories, see Chapter 7, “Installation”).
Attached to a flange inside the base frame housing (3) is the special reduction gear unit (1)
of axis 1. Also integrated into this flange is the double--acting trailing 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 of the manipulator in a flexible tube. The space between the rotat-
ing column and the base frame is provided with two detachable, one--piece covers (2, 8).
The sockets for the connecting cables from the manipulator to the control cabinet are located
on the RDC box (7) and on the multi--function housing (10).
The reference notch (11) necessary for determining the mechanical zero position is found
on the bracket (9).
BA KR 30, 60--3, F, KR C4 01.11.01 en 17 of 192

11
10 1
9
3
6
4
1 Special reduction gear unit A1 7 Junction box

2 Cover 8 Cover
3 Base frame housing 9 Bracket
4 Attachment holes (6x) 10 MFH, multi--function housing
5 Base flange 11 Reference notch
6 Locating boreholes (2x)
Fig. 11 Structure of the base frame
3.8 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:
Axis 1: with two supplementary stops:

from +58 to +185 and --58 to --185 , adjustable in steps of 15 .
Axis 2: from +5 to +65 and --5 to --20 , adjustable in steps of 15 .
Axis 3: from +3 and --108 to --153 or --33 to --153 , adjustable in steps of 15 .
The working range limitation system is described in separate documentation.
18 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

3.9 Working range monitoring for A1 and A2

Axes 1 and 2 can be equipped with position switches and slotted rings to which adjustable
cams are attached (see documentation “Working Range Monitoring”). This allows the posi-
tion of the manipulator to be continuously monitored.
Up to three sectors of the movement range can be monitored on axis 1, and a maximum of
one sector on axis 2.
The working range monitoring 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.
BA KR 30, 60--3, F, KR C4 01.11.01 en 19 of 192

20 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

4 Technical data
4 Technical data
4.1 General
The industrial robots are six--axis manipulators for installation on the floor, the wall or the ceil-
ing; the KR 30 L16--2 is for installation only on the floor or ceiling. They are suitable for all
continuous--path controlled tasks. The main areas of application are:
-- Handling
-- Assembly
-- MIG/MAG welding
-- YAG laser beam welding
Using the manipulator for purposes other than those mentioned above is consi-
dered contrary to its designated use (see Chapter 2, “Purpose”).
Fig. 12 shows the industrial robot with the manipulator (= robot arm and electrical installa-
tions) and the control cabinet.
The following data apply, unless otherwise indicated, to both floor--mounted and ceiling--
mounted robots.
BA KR 30, 60--3, F, KR C4 01.11.01 en 21 of 192

KR 30 L16--2
KR 30, 60--3
1
7
4
6
5
1 Arm 5 Base frame

2 In--line wrist 6 Connecting cables
3 Link arm 7 Control cabinet (see
4 Rotating column separate documentation)
Fig. 12 Main components of the industrial robot
22 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

4 Technical data (continued)
4.2 Principal data

Type KR 30--3
KR 30 L16--2
KR 60--3
KR 60 L45--3
KR 60 L30--3
Number of axes 6 (Fig. 14)
Load limits see following table and Fig. 13
Industrial robot type KR 30 KR 60 KR 60

KR 30--3 KR 60--3
L16--2 L45--3 L30--3
Wrist (IW)1 IW IW IW IW
IW 16
30/45/601 30/45/601 30/45/601 30/45/601
Rated payload [kg] 30 16 60 45 30
Suppl. load with
35 35 35 35 35
rated payload [kg]
Max. total load [kg] 65 51 95 80 65
1IW = in--line wrist
Max. total load
Suppl. load Payload
Fig. 13 Load distribution
Axis data see the following tables.
All specifications in the “Range of motion” column are re-

ferred to the electrical zero of the manipulator axis con-
cerned.
BA KR 30, 60--3, F, KR C4 01.11.01 en 23 of 192

KR 30-- 3
D In--line wrist, rated payload 30 kg
Axis Range of motion, Speed

software--limited
1 ġ185 140/s
2
to 126/s
--135
3 +158
to 140/s
--120
4 ġ50 260/s
5 ġ /s
6 ġ50 /s
KR 30 L16-- 2

software--limited
1 ġ185 100/s
2
to 80/s
--135
3 +158
to 80/s
--120
4 ġ50 230/s
5 ġ /s
6 ġ50 /s
KR 60-- 3

software--limited
1 ġ185 128/s
2
to 102/s
--135
3 +158
to 128/s
--120
4 ġ50 260/s
5 ġ /s
6 ġ50 /s
24 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

KR 60 L45-- 3

software--limited
1 ġ185 128/s
2
to 102/s
--135
3 +158
to 128/s
--120
4 ġ50 260/s
5 ġ /s
6 ġ50 /s
KR 60 L30-- 3

software--limited
1 ġ185 128/s
2
to 102/s
--135
3 +158
to 128/s
--120
4 ġ50 260/s
5 ġ /s
6 ġ50 /s
BA KR 30, 60--3, F, KR C4 01.11.01 en 25 of 192

Fig. 14 Rotational axes and their directions of rotation
Pose repeatability KR 30--3 0.06 mm

(ISO 9283) KR 30 L16--2 0.07 mm
KR 60--3 0.06 mm
KR 60 L45--3 0.06 mm
KR 60 L30--3 0.06 mm
Mounting position KR 30, 60--3 Floor, wall or ceiling

(Restrictions on the range of motion of
axis 1, see Fig. 27 and Fig. 28)
KR 30 L16--2 Floor and ceiling
Principal dimensions see Fig. 21 to Fig. 23.
Working envelope The shape and dimensions of the working envelope may be
noted from Fig. 21 to Fig. 23.
26 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Volume of working envelope KR 30--3 approx. 27.24 m3

KR 30 L16--2 approx. 104.5 m3
KR 60--3 approx. 27.24 m3
KR 60 L45--3 approx. 36.89 m3
KR 60 L30--3 approx. 47.78 m3
The reference point is the intersection of axes 4 and 5.

Load center of gravity P see Fig. 15 to Fig. 18.
For the rated payload, the (nominal) distance of the load
center of gravity P is
for KR 30, 60--3: 150 mm (horizontal), 180 mm (vertical)

for KR 30 L16--2: 150 mm (horizontal), 120 mm (vertical)
measured from the face of the mounting flange

(rotational axis 6).
Weight KR 30--3 approx. 665 kg

KR 30 L16--2 approx. 700 kg
KR 60--3 approx. 665 kg
Principal dynamic loads See Fig. 25
Drive system Electromechanical, with transistor--controlled AC servomo-

tors.
Installed motor capacity approx. 14.9 kW
Protection classification of the manipulator

IP 64
ready for operation, with connecting cables plugged in
(according to EN 60529).
Protection classification of the in--line wrist

IP 65 (according to EN 60529)
(standard)
Protection classification of the in--line wrist “F”

IP 67 (according to EN 60529)
BA KR 30, 60--3, F, KR C4 01.11.01 en 27 of 192

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
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
Threaded union: M5
Pressure reducer: 0.1 -- 0.7 bar
Pressure gauge: 0 -- 1 bar
Filter: 25 -- 30 m
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.
Sound level < 75 dB (A) outside the working envelope (Fig. 22 and
Fig. 23)
Color Manipulator
Base (stationary): black (RAL 9005)
Moving parts: orange (RAL 2003)
With “F” variant, additional special paint finish for the entire
manipulator.
In--line wrist “F”:

Heat--resistant and heat--reflecting special paint finish in sil-
ver.
Plates see Fig. 29 to Fig. 38.
Special consumables none
Stopping distances and times

see separate documentation
28 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Fig. 15 to Fig. 18:

The loading curves and the values in the table 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 manipulator, additional input data are required in accordance
with the KUKA software documentation.
Robot flange coordinate system Permissible mass inertia at the

design point
(Lxy = 120 mm,
Lxy L x2 Ly 2 Lz = 150 mm)
--X 0.36 kgm2.
--Z CAUTION: The mass inertia must be
+Y
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)
300
8 kg
200 10 kg
12 kg
14 kg
16 kg
100
A5 Lz (mm)
KR 30 L16-- 2
A4
A6 100 200 300 400 500 600
Fig. 15 Load center of gravity P and loading curves for KR 30 L16--2
BA KR 30, 60--3, F, KR C4 01.11.01 en 29 of 192

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
Lxy Lx 2
Ly 2 design point
(Lxy = 180 mm,
Lz = 150 mm)
9 kgm2.
--X
CAUTION: The mass inertia must be
--Z verified using KUKA Load. It is
+Y
--Y +X
+Z
Lxy
Lx
Load center of gravity P

Lz
Lxy (mm)
Ly
500
13 kg
400
15 kg
300 18 kg
21 kg
24 kg
200 27 kg
30 kg
100
A5 KR 30-- 3
Lz (mm)
KR 60 L30-- 3
A4
A6
100 200 300 400 500 600 700
Fig. 16 Load center of gravity P and loading curves for KR 30--3; KR 60 L30--3
30 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en


design point
(Lxy = 180 mm,
Lxy L x2 Ly 2 Lz = 150 mm)
--X 18 kgm2.
+Y verified using KUKA Load. It is
--Y +X
+Z
Lxy
Lx
Lz
Ly
Load center of gravity P
Lxy (mm)
500
25 kg
400
30 kg
300 35 kg
40 kg
45 kg
50 kg
200 55 kg
60 kg
100
A5
Lz (mm)
A4
KR 60-- 3
A6
100 200 300 400 500 600 700
Fig. 17 Load center of gravity P and loading curves for KR 60--3
BA KR 30, 60--3, F, KR C4 01.11.01 en 31 of 192


design point
(Lxy = 180 mm,
Lxy L x2 Ly 2
Lz = 150 mm)
--X 13.5 kgm2.
+Y verified using KUKA Load. It is
--Y +X
+Z
Lxy
Lx
Lz
Ly
Load center of gravity
Lxy (mm)
500
400
21 kg
25 kg
300
29 kg
33 kg
37 kg
200 41 kg
45 kg
100
A5
Lz (mm)
KR 60 L45-- 3
A4
A6
100 200 300 400 500 600 700
Fig. 18 Load center of gravity P and loading curves for KR 60 L45--3
32 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Mounting flange DIN/ISO1) mounting flange (Fig. 20). The mounting flange
is depicted with axes 4 and 6 in the zero position. The sym-
bol indicates the position of the locating element (bush-
ing). Screws of grade 10.9 are to be used for attaching pay-
loads. The grip length of the screws in the flange must be
at least 1.5 x nominal diameter.
Depth of engagement: IW 16 min. 6 mm

max. 9 mm
Depth of engagement: IW 30/45/60 min. 12 mm
max. 14 mm
1) DIN/ISO 9409--1--A50 for IW 16

DIN/ISO 9409--1--A100 for IW 30/45/60
Section A A
158
xm to A 4/A 5
8x 45 = 360
0.02 A
A 45 6.3
6 H7
0.04 A B
+0.5
50 6 0 7x M6
R 111.6 A
Fitting length 0.1 A B
204 Fastening screws M6,
grade 10.9
Depth of engagement: min. 6 mm
max. 9 mm
Fig. 19 DIN/ISO mounting flange for in--line wrist 16 kg
BA KR 30, 60--3, F, KR C4 01.11.01 en 33 of 192

Ø 8H7 -- 8 deep Ø 0.04 A B
Section A A
Xm
170 Ø 0.02 B
to center A 4 / A 5
A
A A
12
+0.3 B
8.5
0
7.5 ¦0.1
M8 fastening screws,
grade 10.9
Depth of engagement: min. 12 mm
max. 14 mm
Fig. 20 DIN/ISO mounting flange for in--line wrist 30/45/60 kg
34 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Y Suppl. load
--120 +158
1545
158
150
-- --135
+35
350
2050 1085 2017
3102
5152
CAUTION: The interference radius

Dimensions: mm (safe area) lies approx. 163 mm
beyond the reference point for the
working envelope.
NOTE: The supplementary load center

R3102
of gravity must be located as close as
--185
possible to rotational axis 3 and to line
a in Fig. 24.
The reference point for the working
envelope is the intersection of axes 4
and 5.
View Y, see Fig. 24.
+185
163
Fig. 21 Principal dimensions and working envelope for KR 30 L16--2

(software values)
BA KR 30, 60--3, F, KR C4 01.11.01 en 35 of 192

CAUTION: The interference radius

(safe area) lies approx. 181 mm
beyond the reference point for the
working envelope.
--120 +158
820, 1020, 1220 170
Y
150
--135
+35
350
815 1218
868 1362
983 1445
1084 2033
1281 2230
1480 2429
NOTE: The supplementary load center of gravity

must be located as close as possible to rotational
axis 3 and to line a in Fig. 24.
The reference point for the working envelope is
the intersection of axes 4 and 5.
View Y, see Fig. 24.
Fig. 22 Principal dimensions and working envelope (software values)
36 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en


KR 30--3 = R2033
KR 60--3 = R2033
KR 60 L45--3 = R2230
KR 60 L30--3 = R2429

CAUTION: The interference
radius (safe area) lies
approx. 181 mm beyond the
reference point for the
working envelope.
Fig. 23 Turning range A1, KR 30--3, KR 60--3
View Y from Fig. 21 and Fig. 22

195
M8, 16 deep
375 Support brackets for suppl. load (2x)

Max. dimension for suppl. load
Fig. 24 Attachment holes for supplementary load
BA KR 30, 60--3, F, KR C4 01.11.01 en 37 of 192

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 = 13,600 N

Fh = Horizontal force Fhmax = 12,300 N
Mk = Tilting moment Mkmax = 21,600 Nm
Mr = Turning moment about axis 1 Mrmax = 18,400 Nm
Total mass = manipulator + total load for type
665 kg + 65 kg KR 30--3
700 kg + 51 kg KR 30 L16--2
665 kg + 95 kg KR 60--3
671 kg + 80 kg KR 60 L45--3
679 kg + 65 kg KR 60 L30--3
Fig. 25 Principal loads acting on floor (or ceiling) due to manipulator

and total load
38 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

The specified forces and moments already include the payload and the inertia force (weight)
of the manipulator.
Fv
Mk
Fh
View X

665 kg + 65 kg KR 30--3
665 kg + 95 kg KR 60--3
671 kg + 80 kg KR 60 L45--3
679 kg + 65 kg KR 60 L30--3
Mr
Fig. 26 Principal loads acting on wall due to manipulator and total load
BA KR 30, 60--3, F, KR C4 01.11.01 en 39 of 192

ġ
ġ
ġ
ġ
ġ
ġ
ġ
ġ
ġ
ġ

(Wall) Angle to the floor (Floor)
Fig. 27 Restriction of range of motion for axis 1 as a function of the installation

angle of the KR 30--3
ġ
ġ
ġ
ġ
ġ
ġ
ġ
ġ
ġ
ġ

(Wall) Angle to the floor (Floor)
Fig. 28 Restriction of range of motion for axis 1 as a function of the installation

angle of the KR 60--3, KR 60 L45--3 and KR 60 L30--3
40 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

2
5
6
7
5
6
7
3
5
4
6
7 1
Fig. 29 Plates on manipulator (see also Fig. 30 to Fig. 38)
BA KR 30, 60--3, F, KR C4 01.11.01 en 41 of 192

Transportstellung:
Transport position:
Position de transport:
A1 A2 A3 A4 A5 A6

ACHTUNG! WARNING! ATTENTION!

Vor dem Lösen der The robot must be Le robot doit être
Fundamentbefesti- in the transport amené en position
gungsschrauben position before the de transport avant de
muss der Roboter in holding--down bolts desserrer les boulons
Transportstellung are slackened! de fixation des
gebracht werden! fondations!
Artikel--Nr. 00--000--000 D/GB/F 1 2x
Fig. 30 Instructions regarding transport position KR 30, 60--3
Transportstellung:
Transport position:
Position de transport:
A1 A2 A3 A4 A5 A6


Vor dem Lösen der The robot must be Le robot doit être
Fundamentbefesti- in the transport amené en position
gungsschrauben position before the de transport avant de
muss der Roboter in holding--down bolts desserrer les boulons
Transportstellung are slackened! de fixation des
gebracht werden! fondations!
Artikel--Nr. 00--000--000 D/GB/F 1 2x
Fig. 31 Instructions regarding transport position KR 30 L16
42 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en


Vor dem Entfernen des Motors Roboterachse
gegen Kippen sichern!
Only remove motor when robot axis is secu-

red!
Avant démontage du moteur bloquer l’axe
concerné! 2
D/GB/F 2x
Fig. 32 Instructions for safeguarding against toppling of A2 and A3
Roboter GmbH
Zugspitzstraße 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
ReichweiteRange ^
Portee XXXX MM
$TRAFONAME[]=”#.....” XXXXXXXXXXXXXXXXXXXXXXXXXXX
...\MADA\ XXXXXXXXXXXXXXXXXXXXXXXXXXX
de/en/fr
Fig. 33 Robot identification plate (example)
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Vor Aufstellung, Inbetriebnahme, Montage-- und
Wartungsarbeiten die Betriebsanleitung und
Sicherheitshinweise lesen und beachten!
Before installation, start--up, maintenance or
disassembling read and follow the safety
directions and operating instructions!
Avant installation, mise en service, réparation et

maintenance veuillez lire les châpitres
correspondants du manuel ainsi que les
consignes de sécurité et les respecter!
Artikel--Nr. 00--118--545 D/GB/F 4
Fig. 34 Reference to operating instructions
Fig. 35 High voltage warning sign
4x on each motor
Fig. 36 Hot surface warning sign
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.................
...........................................................
................................................
...........................................................
................................................
...........................................................
.................................................
On all motors. 7
Fig. 37 Drive motor rating plate
3x on base frame 00--104--232 8
Fig. 38 Danger zone
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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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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.
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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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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.
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.
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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5.2 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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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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(1) Workspace (3) Stopping distance

(2) Manipulator (4) Safety zone
Fig. 39 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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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.
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.
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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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
(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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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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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
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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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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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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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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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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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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5.6 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
BA KR 30, 60--3, F, KR C4 01.11.01 en 63 of 192

64 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

6 Transportation
6 Transportation
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, “Technical data”.
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 most important factor in deciding on the method of transportation is the installation posi-
tion of the manipulator.
The manipulator can be transported as follows:
G With lifting tackle and crane (Fig. 42, left--hand side)
The manipulator can be suspended from the hook of a crane by means of lifting tackle at-
tached to three M16 DIN 580 eyebolts on the rotating column.
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 the weight of the manipulator, see Chapter 4, “Technical data”.
All three M16 DIN 580 eyebolts on the rotating column must always be used to
suspend the manipulator.
BA KR 30, 60--3, F, KR C4 01.11.01 en 65 of 192

Fig. 40 Transport position
G With fork lift truck (Fig. 42, right--hand side)
fork slots. It is forbidden to pick up the manipulator in any other way using a
fork lift truck!
721 1)
122.5
1 117.5
200 2
187.4
622
31
688 1) KR 60--3
KR 60 L30--3
560 568 KR 60 L45--3
KR 30 L16--2
Fig. 41 Fork slots
For transport with a fork lift truck, two removable, open--ended fork slots (Fig. 41/2) are
mounted on the rotating column. This allows the manipulator (1) to be picked up from two
sides.
66 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

6 Transportation (continued)
Fig. 42 Transporting floor--mounted and ceiling--mounted manipulators
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 the transport position (Fig. 43,
Fig. 44)*.
$ $ $ $ $ $

155 * All angles are specified relative to the electrical
zero position or to the KCP display.
90
135 KR 30--3, 60--3

1) without arm extension
2) 200 mm arm extension
4) KR 30 L16--2
24 1); 38 2); 85 3); 3 4)
659
911 4) 643
1309 1)
1498 2)
1685 3)
1977 4)
BA KR 30, 60--3, F, KR C4 01.11.01 en 67 of 192

Fig. 43 Transport position for floor--mounted manipulators

1309 1)
1498 2) * All angles are specified relative to the electrical
1685 3) zero position or to the KCP display.
1977 4)
643
659
24 1); 38 2); 85 3); 3 4)
911 4)
4) KR 30 L16--2
135
90
155
Fig. 44 Transport position for ceiling--mounted manipulators
For further work steps, see Chapter 7, “Installation, connection, exchange”.
68 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

7 Installation, connection, exchange
7 Installation, connection, exchange
7.1 General
Observe Chapter 5, “Safety”!

With all work involving the connection of the manipulator (and of the control
cabinet), the control cabinet documentation “Initial Start--up” 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”.
slots in the base frame. It is forbidden to pick up the manipulator in any other
way using a fork lift truck!
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.
BA KR 30, 60--3, F, KR C4 01.11.01 en 69 of 192

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:
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!
70 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

7 Installation, connection, exchange (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 are specified in Fig. 45. The
data given in the illustration can also be used as a basis for more extensive static investiga-
tions.
The specified forces and moments already include the payload and the inertia force
(weight) of the manipulator.
Fv
Mk
Fv
Fh
Mr

665 kg + 65 kg KR 30--3
700 kg + 51 kg KR 30 L16--2
665 kg + 95 kg KR 60--3
671 kg + 80 kg KR 60 L45--3
679 kg + 65 kg KR 60 L30--3
Fig. 45 Principal loads acting on floor (or ceiling) due to manipulator and total load
BA KR 30, 60--3, F, KR C4 01.11.01 en 71 of 192

Fv
Mk
Fh
View X

665 kg + 65 kg KR 30--3
665 kg + 95 kg KR 60--3
671 kg + 80 kg KR 60 L45--3
679 kg + 65 kg KR 60 L30--3
Mr
Fig. 46 Principal loads acting on wall due to manipulator and total load
72 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

7.3 Mounting variants

The manipulator can be installed on the floor, the wall or the ceiling.
The robot KR 30 L16--2 is only intended for installation on the floor or on the ceiling.
Mounting variants 1 to 3 are available for installing the manipulator on the floor; variants 2
and 3 can additionally be used for wall or ceiling mounting:
G Variant 1, mounting base with centering, see Section 7.3.1.
Fig. 47 Mounting base with centering
G Variant 2, machine frame mounting; see Section 7.3.2
Fig. 48 Machine frame mounting
BA KR 30, 60--3, F, KR C4 01.11.01 en 73 of 192

G Variant 3, adapter plate; see Section 3.3
Fig. 49 Adapter base plate
If the manipulator is to be installed on the floor, being mounted directly on a concrete base,
all pertinent construction specifications must be observed concerning the grade of concrete
( B25 according to DIN 1045) 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. The anchors must be inserted with great care to ensure that the forces
occurring during the operation of the manipulator (Fig. 45) are transmitted safely to the
ground.
To avoid distorting the manipulator base frame or the adapter plate 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).
460 490
2 1
Fig. 50 Orientation of working envelope and concrete foundation
74 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

7.3.1 Variant 1, mounting base with centering

Features:
-- For floor--mounted manipulators only.
-- Manipulator installed on the concrete foundation.
-- Manipulator fastened by means of nine chemical anchors.
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.
Installation
(1) Lift the manipulator with fork lift truck or lifting tackle.
(2) Fasten each of the three bedplates (Fig. 51/2) to the manipulator (3) by means of two
M20x70--8.8 hexagon bolts (1) and lock washers.
(3) Mark the position of the manipulator in relation to the working envelope (Fig. 50/1) on
the concrete foundation (2) and bring the manipulator to the installation position.
(4) Align the manipulator horizontally.
316
175 6
310
350
Fig. 51 Bedplates
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(5) If necessary, determine the differences in level. If large differences in level are present,
steps (6) to (9) must be followed.
(6) Apply leveling compound (Fig. 52/2) to the concrete foundation (4) or the underside of
the bedplates.
“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).
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.
(7) Place the manipulator in the still plastic leveling compound and adjust its position
slightly if necessary.
(8) Remove excess leveling compound.
Fig. 52 Leveling compound
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.
(9) Allow the leveling compound to cure for about three hours. The curing time is longer
at temperatures below 20 C (293 K).
At the end of the curing time, the anchor holes can be drilled.
(10) Drill nine anchor holes (Fig. 51/1) through the holes of the bedplates; depth in concrete
125 mm.
(11) Insert nine resin capsules (Fig. 53/4).
(12) Insert one threaded rod (3) into each anchor hole (5). To do this, secure the setting tool
(2) in a hammer drill (1), attach the threaded rod, and insert it in the anchor hole at max.
750 r.p.m. The threaded rod is set correctly if the resin is completely mixed and the an-
chor hole in the concrete is completely filled to the upper edge. If the anchor hole is not
completely filled, the threaded rod must be pulled out again immediately and a new resin
capsule inserted.
76 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

(13) Allow the resin to cure.

The curing time is as follows:
Temperature Time:
+20 C (293 K) 20 minutes
+10 C (283 K) 30 minutes
0 C (273 K) 1 hour
--5 C (268 K) 5 hours
(14) Mount the hexagon nuts (6) together with washers and tighten the hexagon nuts with
a torque wrench in diagonally opposite sequence, increasing the tightening torque to
the specified value in several stages (MA = 80 Nm).
Retighten the hexagon nuts (6) after 100 hours of operation.
1
M
A = 80 Nm
6
2
2
3
4
5 18
0.5
>135
Fig. 53 Fastening the manipulator, variant 1
The manipulator is now ready for connection to the controller.
BA KR 30, 60--3, F, KR C4 01.11.01 en 77 of 192

7.3.2 Variant 2, machine frame mounting

Features:
-- For floor--mounted and ceiling--mounted manipulators.
-- Manipulator installed on a steel structure prepared by the customer, on a steel
pedestal or on a linear unit of the KL 1500 series.
-- Manipulator fastened by means of six M20x55 ISO 4017 hexagon bolts.
Installation
(1) Prepare the mounting surfaces (Fig. 54/2) on the steel structure in accordance with
Fig. 54.
The maximum permissible difference in level between the individual mounting surfaces
(2) is 0.5 mm.
(2) Prepare six M20 tapped holes for the fastening screws (3) and two locating holes for
the locating pins (1, 4).
(3) Insert the locating pins (1, 4).
The intended installation position of the manipulator, i.e. the correct orientation in rela-
tion to the working envelope (Fig. 50/1), must be taken into account when drilling the
holes.
The position of the different locating pins in relation to the working envelope is impor-
tant:
Looking forwards from the manipulator towards the working envelope -- the arm of the
manipulator points in this direction when A1 is in its zero position -- the long locating pin
(1) must be on the left and the short locating pin (4) must be situated on the right.
78 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

1 2 3
12H7 16
A 30
590
(147.5)
120
3x 120 (=360 )
H7
12
0.1 A B
Fig. 54 Fastening the manipulator, variant 2
The steel substructure is now ready for the manipulator to be installed. Install the manipulator
in accordance with the procedures given in Section 7.4.1.
BA KR 30, 60--3, F, KR C4 01.11.01 en 79 of 192

7.3.3 Variant 3, adapter plate

Features:
-- For floor--mounted and ceiling--mounted manipulators.
-- Manipulator installed on steel structure or a KUKA linear unit.
-- Easy removal and installation with optimum repeatability of the installation posi-
tion.
Accessory: Machine frame mounting
The adapter plate is mounted and screwed onto a substructure that is prepared by the
user. It must be ensured that the substructure is able to withstand safely the loads spe-
cified in Fig. 45.
(1) Prepare the substructure in accordance with Fig. 55.

(2) Bring the adapter plate (1) to the site of installation, set it down and align it.
(3) Insert eight M25x60 ISO 4017 Allen screws (4) and tighten them with a torque wrench.
950
830
30 0.2 300 (4x)
4 30 H7
M20 (6x) 390

3
0.6 A B C
1
2
0.3 A
30 H7
220
Fig. 55 Manipulator installation, variant 3
(4) Insert the locating pins (2, 3).

The steel substructure is now ready for the installation and connection of the manipulator.
Install the manipulator in accordance with the procedures given in Section 7.4.1.
80 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

7.4 Connection
7.4.1 Floor--mounted manipulators
This description applies to all mounting variants for floor--mounted manipulators only. If the
manipulator is to be installed on the floor in an inclined position, KUKA Roboter GmbH must
be consulted beforehand.
The procedure for installing the manipulator (whether for the first time or as an exchange)
is as follows:
(1) Check that the locating pins (Fig. 56/1) are undamaged and fitted securely.
Damaged locating pins must be replaced by new ones.
Fig. 56 Locating pins
The manipulator must be in the transport position (Fig. 57)*.
$ $ $ $ $ $


90
135 KR 30--3, 60--3

4) KR 30 L16--2
1) 2) 3)
24 ; 38 ; 85 ; 3 4)
659
911 4) 643
1309 1)
1498 2)
1685 3)
1977 4)
BA KR 30, 60--3, F, KR C4 01.11.01 en 81 of 192

(2) Raise the manipulator with a fork lift truck or lifting tackle attached to three eyebolts on
the rotating column.
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. 58/5) vertically onto bedplates (4) or steel structure. If lifting
tackle is used, particular care must be taken to ensure exact vertical positioning in order
to avoid damaging the pins during this operation.
As the manipulator is lowered, the boreholes (2) must be aligned as accurately

as possible with the two pins (3). If this operation is carried out inaccurately, it is
more likely that parts will be damaged.
2
3
Fig. 58 Installing the manipulator on the floor
(4) Insert eight M20x55 ISO 4017 hexagon bolts (1) together with 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 = 370 Nm).
82 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Retighten the hexagon bolts (1) after 100 hours of operation.
(5) Remove the lifting tackle if necessary.

(6) Connect the connecting cables.
(7) Put the manipulator into operation and move it into a suitable position to install the end--
effector and additional equipment.
(8) Install the end--effector and additional equipment.

(9) Connect all other supply lines required.
(10) Put the manipulator into operation.
BA KR 30, 60--3, F, KR C4 01.11.01 en 83 of 192

7.4.2 Ceiling--mounted manipulators

This description applies to all mounting variants for ceiling--mounted robots only, as de-
scribed in Sections 7.3.2 and 7.3.3. If the robot is to be installed in an inclined position, KUKA
Roboter GmbH must be consulted beforehand.
The procedure for installing the manipulator (whether for the first time or as an exchange)
is as follows:
Fig. 59 Locating pins
The manipulator must be in the transport position (Fig. 57)*.
$ $ $ $ $ $

1309 1)
1685 3) “zero position“ or to the KCP display.
1977 4)
643
659
24 1); 38 2); 85 3); 3 4)
911 4)
4) KR 30 L16--2
135
90
155
84 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

(2) Lift the manipulator with a fork lift truck.
Fig. 61 Transporting the manipulator
(3) Move the manipulator (Fig. 62/5) vertically upwards onto the ceiling (4) or onto the steel
structure to prevent damage to the locating pins.
As the manipulator is raised, the boreholes (2) must be aligned as accurately as

possible with the two pins (3). If this operation is carried out inaccurately, it is
more likely that parts will be damaged.
3
2
Fig. 62 Installing the manipulator on the ceiling

(4) Insert eight M20x55 ISO 4017 hexagon bolts (1) together with washers and tighten
(5) Remove the fork lift truck
BA KR 30, 60--3, F, KR C4 01.11.01 en 85 of 192

Retighten the hexagon bolts (1) after 100 hours of operation.
(6) Connect the connecting cables.

(9) Connect all other supply lines required.
(10) Put the manipulator into operation.
86 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

7.4.3 Wall--mounted manipulators
Until reaching its final place of installation on the wall, the robot must be kept in its
transport position (Fig. 64).
The procedure for mounting the robot on a hinged steel base on the wall (whether for the first
time or as an exchange) is as follows:
Fig. 63 Locating pin
$ $ $ $ $ $

* All angles are specified relative to the electrical

“zero position” or to the KCP display.
1793
KR 30, 60--3
1309 1)
1498 2) 155
1685 3)
135
90
Fig. 64 Transport position for wall--mounted manipulators
BA KR 30, 60--3, F, KR C4 01.11.01 en 87 of 192

(2) Raise the manipulator with lifting tackle attached to three eyebolts on the rotating col-
umn.
The transport instructions in Chapter 6, “Transportation” must be observed.
(3) Lower the manipulator (Fig. 65/2) vertically onto the horizontally (0 ) positioned hinged
steel base (5). If lifting tackle is used, particular care must be taken to ensure exact verti-
cal positioning in order to avoid damaging the locating pins during this operation.
As the robot is lowered, the boreholes (3) must be aligned as accurately as pos-
sible with the two pins (4). If this operation is carried out inaccurately, it is more
likely that parts will be damaged.
3
4
5
Fig. 65 Installing the manipulator on a hinged steel base (on shelf)

(4) Insert six M20x55 ISO 4017 hexagon bolts (1) together with lock washers and tighten
Retighten six M20x55 ISO 4017 hexagon bolts (1) after 100 hours of operation.
(5) Remove lifting tackle.

(6) Move the hinged steel base from 0 to 90 position (Fig. 66, right) and lock it.
88 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

The manufacturer’s specifications with regard to handling and safety must be

observed!
The hinged steel base is not part of the KUKA Roboter GmbH contract.
1 Hinged steel base
Fig. 66 Installing a wall--mounted manipulator on a hinged steel base
(7) Connect the ground conductor and connecting cables.
anyone to be injured within the range of the slowly moving robot.
The robot may only be moved at jog speed, with all applicable safety rules and
regulations being observed.
Turn main switch on the robot control cabinet to “OFF” and secure it with a pad-
lock to prevent unauthorized persons from switching it on again.

(10) Connect all other cables.
(11) Put the robot into operation.
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90 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

7.5 Exchange
To avoid the need for any major reprogramming after an exchange, the instructions given in
the Operating Handbook, Software KR C4, Chapter “Start--up”, Section “Robot Mastering/
Unmastering” must be accurately carried out every time a manipulator is exchanged.
7.5.1 Floor--mounted manipulators

D Removal
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.
(1) Remove the end--effector (tool) and additional equipment.
The end--effector and additional equipment have to be removed if the manipulator is to

be replaced by another one or if they would otherwise impede the exchange work.
If the end--effector and additional equipment remain on the manipulator, this is

liable to lead to adverse centers of gravity and collisions. The user is deemed
responsible for any damage resulting in this respect.
(2) Put the manipulator into operation and move it into the transport position (Fig. 67).
BA KR 30, 60--3, F, KR C4 01.11.01 en 91 of 192

$ $ $ $ $ $


90
135 KR 30--3, 60--3

4) KR 30 L16--2
24 1); 38 2); 85 3); 3 4)
659
911 4) 643
1309 1)
1498 2)
1685 3)
1977 4)
(3) Release and unplug all connectors from the junction box (Fig. 68/3).
(4) Disconnect electric cables and hose lines from both interfaces of energy supply system
A1 and all other peripheral supply lines to the manipulator, where necessary.
Depressurize and drain hose lines beforehand.
(5) Remove six M20x55 hexagon bolts (2) and lock washers.
(6) Raise the manipulator (1) with lifting tackle attached to three eyes on the rotating col-
umn.
The transport instructions in chapter 6, “Transportation” must be observed.
92 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

3 1
Fig. 68 Removal of floor--mounted robot
The manipulator can also be lifted by fork lift truck.
The manipulator must be lifted as vertically as possible until the locating pins
are free.
(7) Place the manipulator on a suitable support.
If the manipulator is not to be reinstalled for some time, it must be protected against
corrosion before being put into storage.
D Installation
See Section 7.4.1.
BA KR 30, 60--3, F, KR C4 01.11.01 en 93 of 192

7.5.2 Ceiling--mounted manipulators

D Removal


$ $ $ $ $ $

1309 1)
1685 3) “zero position or to the KCP display.
1977 4)
643
659
24 1); 38 2); 85 3); 3 4) 911 4)
4) KR 30 L16--2
135
90
155
94 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

(3) Release and unplug all connectors from the junction box (Fig. 70/1).
(4) Disconnect electric cables and hose lines from both interfaces of energy supply system
A1 and all other peripheral supply lines to the manipulator, where necessary.
(5) Move the forks of the fork lift truck into the apertures designed for them on the manipula-
tor and press manipulator firmly against the ceiling.
1
2
Fig. 70 Removal of ceiling--mounted manipulator
(6) Remove six M20x55 hexagon bolts (3) and lock washers.
(7) Lower the manipulator slowly without tilting it.
The manipulator must be lowered vertically downwards until both pins (4) are
free.
(8) Suspend the manipulator in the transport frame and if it needs to be turned over into
the floor--mounting position (base frame at bottom, arm at top), turn the manipulator
together with the transport frame.
D Installation
See Section 7.4.2.
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7.5.3 Wall--mounted manipulators

D Removal


96 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

$ $ $ $ $ $

* All angles are specified relative to the electrical

“zero position” or to the KCP display.
1793
KR 30, 60--3
1309 1)
1498 2) 155
1685 3)
135
90
Fig. 71 Transport position for wall--mounted manipulators
(3) Release and unplug all connectors (Fig. 72/1) from the junction box (2, 3).
(4) Remove electric cables and hose lines from the A1 interfaces (4) of energy supply sys-
tem A1 and all other peripheral supply lines to the robot, where necessary.
4
2
Fig. 72 Removal of wall--mounted robot
BA KR 30, 60--3, F, KR C4 01.11.01 en 97 of 192

(5) Swivel the manipulator back into the normal position.

(6) Remove six M20x55 hexagon bolts (Fig. 73/1) and lock washers.
1
2
Fig. 73 Removal of ceiling--mounted robot
The manipulator can also be lifted by fork lift truck.
While being removed, the manipulator must be kept as level as possible until the
locating pins (1) are free.
(7) Set down the manipulator in a suitable support.
D Installation
See Section 7.4.3.
98 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

8 Electrical installations
8 Electrical installations
The electrical installations of the robot (manipulator) form a separate assembly. It includes
the “cable set” (Fig. 76), containing all the electric cables (Fig. 77 to Fig. 85). The cable set
has plug--and--socket connections so that exchanges can be quickly carried out. This dis-
penses 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 push--in module are the RDC box (Fig. 76/7) and the MFH (multi--function
housing) (3). Together with their connectors, these two housings form the interfaces with the
connecting cables.
The motor cables for axes 1 to 6 are grouped together in the multi--function housing
(MFH) (3) and are wired up to connector X30. This connector is at the same time the connec-
tor on the robot for the connecting cable (motor cable) between the robot and the control cabi-
net. The connector consists of six separate connector modules. Each connector module is
assigned a particular motor connector (e.g. XM1).
The protective circuit is connected to terminals on the push--in module (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
robot and the control cabinet is formed by connector X31. Connector X32 is used for connect-
ing 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 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. 74 and are
shown schematically in Fig. 76.
BA KR 30, 60--3, F, KR C4 01.11.01 en 99 of 192

Cable from to Cable from to

Protective circuit Bolt on Bolt on
00--186--281 base frame rotating column
Bolt on rotating Bolt on arm
column
Motor cable A1 Connector X30/a XM1 Control cable A1 Connector X1 XP1
00--181--928 00--181--934
Motor cable A2 Connector X30/b XM2 Control cable A2 Connector X2 XP2
00--181--929 00--181--935
Motor cable A3 Connector X30/c XM3 Control cable A3 Connector X3 XP3
00--181--930 00--181--936
Motor cable A4 Connector X30/d XM4 Control cable A4 Connector X4 XP4
00--181--931 00--181--937
Motor cable A5 Connector X30/e XM5 Control cable A5 Connector X5 XP5
00--181--932 00--181--938
Motor cable A6 Connector X30/f XM6 Control cable A6 Connector X6 XP6
00--181--933 00--181--939
Fig. 74 Table of cables installed on the robot KR 30, 60--3 with KR C4
Cable from to Cable from to

Protective circuit Bolt on Bolt on
00--186--780 base frame rotating column
Bolt on rotating Bolt on arm
column
Motor cable A1 Connector X30/a XM1 Control cable A1 Connector X1 XP1
00--181--928 00--181--934
Motor cable A2 Connector X30/b XM2 Control cable A2 Connector X2 XP2
00--181--929 00--181--935
Motor cable A3 Connector X30/c XM3 Control cable A3 Connector X3 XP3
00--186--761 00--186--765
Motor cable A4 Connector X30/d XM4 Control cable A4 Connector X4 XP4
00--186--762 00--186--766
Motor cable A5 Connector X30/e XM5 Control cable A5 Connector X5 XP5
00--186--763 00--186--767
Motor cable A6 Connector X30/f XM6 Control cable A6 Connector X6 XP6
00--186--764 00--186--768
Fig. 75 Table of cables installed on the robot KR 30 L16--2 with KR C4
100 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

8 Electrical installations (continued)
XM4 XM5
XP4 XP5
XM3 XM6
XP3 XP6
PE
4
4
PE
1
XM1
XP1
XM2
XP2 PE
4
PE
5
4
2 6
3
7
X30 X32
1 Cable set assembly
2 PE push--in module X31
3 Multi--function housing, MFH
4 Protective circuit
5 Electronic Data Storage EDS
6 Resolver Digital Converter RDC
7 RDC box
Fig. 76 Cable set assembly
BA KR 30, 60--3, F, KR C4 01.11.01 en 101 of 192

8.2 Cabling plans and wiring diagrams
X30
a1 a2 a3 a11 a12 Housing
1 2 3 RD BU YE/GN
Type 5/99
SH
4 mm2 4 mm2 4 mm2 1 mm2 1 mm2 4 mm2
XM1 Power connector 1 2 6 4 5 PE
XP1
9 8 7 10 2 1 12 11
Type 07/99 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
8 7 6 5 4 3 2 1
X02/X1
Fig. 77 Wiring diagram for drive A1
102 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

X30
b1 b2 b3 b11 b12 Housing
1 2 3 RD BU YE/GN
Type 4/99 SH
4 mm2 4 mm2 4 mm2 1 mm2 1 mm2 4 mm2
Power connector 1 2 6 4 5 PE
XM2
XP2
9 8 7 10 2 1 12 11
0.25 mm2 0,25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
8 7 6 5 4 3 2 1
X02/X2
BA KR 30, 60--3, F, KR C4 01.11.01 en 103 of 192

X30
c1 c2 c3 c11 c12 Housing
1 2 3 RD BU YE/GN SH
Type 10/99
2.5 mm2 2.5 mm2 2.5 mm2 1 mm2 1 mm2 2.5 mm2
Power connector 1 2 6 4 5 PE
XM3
XP3
9 8 7 10 2 1 12 11
BN WH YE GN PK GY RD BU
Type 07/99 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
8 7 6 5 4 3 2 1
X02/X3
104 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

X30
f1 f4 f6 f3 f5 Housing
Type 11/99
1 mm2 1 mm2 1 mm2 1 mm2 1 mm2 1 mm2
XP4
9 8 7 10 2 1 12 11
0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
8 7 6 5 4 3 2 1
X02/X4
BA KR 30, 60--3, F, KR C4 01.11.01 en 105 of 192

X30
Type 11/99
1 mm2 1 mm2 1 mm2 1 mm2 1 mm2 1 mm2
XP5
9 8 7 10 2 1 12 11
0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
8 7 6 5 4 3 2 1
X02/X5
106 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

X30
Type 11/99
1 mm2 1 mm2 1 mm2 1 mm2 1 mm2 1 mm2
XP6
9 8 7 10 2 1 12 11
0.25 mm2 0.25 mm2 0.25 mm2 0,25 mm2 0.25 mm2 0.25 mm2 0.25 mm2 0.25 mm2
8 7 6 5 4 3 2 1
X02/X6
BA KR 30, 60--3, F, KR C4 01.11.01 en 107 of 192

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. 83 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 AWG22 BU 6
GND
1 AWG22 RD 5
24 V/PS buffered
9
n. c.
10
n. c.
13
n. c.
Fig. 84 Wiring diagram, RDC internal X32
108 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Bolt
Arm
Bolt
Rotating column
Bolt
Base frame
Push--in module
X30 X30
RDC box X02 MFH
Fig. 85 Ground conductor installation, protective circuit
BA KR 30, 60--3, F, KR C4 01.11.01 en 109 of 192

110 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

9 Connecting cables
9 Connecting cables
9.1 Description
Connecting cables are all the cables running between the robot (= manipulator) and the con-
trol cabinet (Fig. 86). They have plug--in connections at both ends. The terminal allocation
of the connectors is given in Section 9.6. In order to avoid the connectors being mixed up,
the ends of each cable are provided with a designation label, which must match the corre-
sponding connection point on the robot or on the control cabinet. The cable connections on
the manipulator and the control cabinet are shown in Fig. 86.
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. 88) and the connector panel
on the control cabinet (Fig. 89).
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.
The ground conductors are not included in the scope of supply for the connecting cables, but
can be ordered separately as an option.
BA KR 30, 60--3, F, KR C4 01.11.01 en 111 of 192

Before the manipulator is put into operation, the continuity of the ground con-
ductor 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 Robot
control cabinet Motor cable
X20 X30
Data cable
X21 X31
Ground conductor 16 mm2
Fig. 86 Connecting cables (diagram)
112 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

9 Connecting cables (continued)
9.2 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 328 K (+55 _C).
-- Route the motor cables and the control cables separately in metal ducts (Fig. 87);
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. 87 Routing of cables in cable ducts
BA KR 30, 60--3, F, KR C4 01.11.01 en 113 of 192

9.3 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 robot may be noted from Fig. 88.
Equipotential bonding (ground conductor) between control cabinet and manipulator must be
established using an M8 PE bolt at each end. The user of the robot is responsible for ensuring
that this is implemented correctly.
The ground conductor is optionally available. It is not part of the connecting cable set as-
sembly.
9.3.1 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. 88 RDC box and MFH
114 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

9.4 Connector panel on the control cabinet

The connector panel (Fig. 89) is accessed by opening the door to the cabinet.
The connected cables are routed under the control cabinet to the rear.
X21
X20
Fig. 89 Connector panel on the control cabinet
BA KR 30, 60--3, F, KR C4 01.11.01 en 115 of 192

9.5 Configuration of the connecting cables
X20 X30
Fig. 90 Motor cable
X21 X31
Fig. 91 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. 92 Ground conductor
116 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

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.
Cable gland Cable gland
Fig. 93 Data cable X21
BA KR 30, 60--3, F, KR C4 01.11.01 en 117 of 192

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. 94 Motor cable X20
118 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

10 Maintenance work
10 Maintenance work
10.1 General
padlock to prevent unauthorized persons from switching it on again. This also
applies to any cleaning work, which though not performed directly on the robot
is carried out within or close to its working range.
Before any maintenance work is started, any attached tools or additional equipment that
would hinder maintenance must be dismounted.
Explanation of the symbols used in connection with maintenance intervals in the “Lubrica-
tion” and “Other maintenance”.
means: maintenance interval
means: recommended maintenance
Lubrication is performed either at the specified maintenance intervals or every 5 years after
commissioning by the customer -- whichever is reached first.
With maintenance intervals of 20,000 hours, the first maintenance (oil change) is performed
either after 20,000 operating hours or 5 years after commissioning by the customer -- which-
ever is reached first.
It is imperative that lubrication is carried out every 5 years, as prescribed (oil

ageing!).
With F--variant robots, this maintenance interval is reduced to 10,000 hours.
It is imperative that lubrication is carried out every 5 years, as prescribed (oil

ageing!).
The maintenance intervals specified in the tables are valid for normal operating
conditions. In case of variations from normal conditions (e.g. increased dust or
water content in the environment of the robot, abnormal temperatures), KUKA
Roboter GmbH must be consulted.
BA KR 30, 60--3, F, KR C4 01.11.01 en 119 of 192

Explanation of symbols:
Normal maintenance interval
1 Maintenance point
Maintenance point, visible on drawing
Maintenance point, hidden on drawing
1.0 l Oil change, to be repeated at specific intervals;
with indication of oil capacity
Tighten screw (nut)
Check and replace toothed belts
Visual inspection
The description of maintenance 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 symbols. This
is because many of these marked texts refer to the preceding job step.
Example:
(9) Pour the specified amount of oil into the filler hole.
Only KUKA--approved lubricants may be used.
Example:
120 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

10 Maintenance work (continued)
10.2 Maintenance work, robot
Please observe Section10.1.
Utmost caution must be exercised when handling cable grease. The use of
protective clothing (at least protective gloves, for example) is strongly
recommended.
All accident prevention regulations and Chapter 5, “Safety” must be observed.
Store used oil and grease in accordance with regulations and dispose of them
with minimum environmental impact.
Key to Maintenance table
1) 5,000 hours for F variant

3) Amount required for complete oil change
4) Also carried out at KUKA before delivery, or must be performed by the user after a toothed belt
has been exchanged.
D Normal maintenance interval
BA KR 30, 60--3, F, KR C4 01.11.01 en 121 of 192

D “Maintenance” table
Maintenance point Maintenance Activity Note

(see Fig. 95) interval Lubricant
(hours) Manufacturer
Amount
KUKA Art. no.
1) 2)
1 Robot mounting base D Check tightening torques for See Chapter 7 “Installation,
bolts and anchor nuts connection, exchange”.
2 Flexible tube A1 for D Lubricate Remove cover A1. Remove
electrical installations Optitemp RB1 old cable grease.
Castrol, approx. 1000 g Lubricate outside of tube as
KUKA Art. no. well as tube contact sur-
00--101--456 faces on base frame and on
cover A1 using brush; coat-
ing thickness 2 mm.
Depending on the state of
the grease coating, either lu-
bricate inside of tube with
grease gun, or remove tube
and grease cables with
brush; coating thickness
2 mm.
3 Gear unit D Oil change Change oil as described in
with bearings A1 Optigear Synthetic RO 150 Section 10.3.1.
Castrol, approx. 3.3 l 3)
KUKA Art. no.
00--144--898
KUKA Art. no.
00--144--898
5 Toothed belts, D Check the toothed belt ten- See Chapter 11, “Adjust-
wrist axis motor unit sion 4) ment”.
A4, A5 Replace toothed belts if
Check toothed belts cracks or signs of deteriora-
tion are found.
See Chapter 13, “Repair”
122 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en


Amount
KUKA Art. no.
1) 2)
2years Replace toothed belts See Chapter 13, “Repair”
KUKA Art. no.
00--144--898
3.3 l 1.0 l 1.0 l
1 2 3 4 5 6
Fig. 95 Maintenance work
When draining the oil, it is important to remember that the quantity drained is depen-
dent on time and temperature.
The quantity of oil drained must be measured, as only this quantity may be used when
refilling. If less than 70% of the specified oil quantity flows out, flush the gear unit with
the measured quantity of drained oil once, then pour in the amount of oil that was
drained. During the flushing procedure, move the axis at jog velocity throughout the
entire axis range.
BA KR 30, 60--3, F, KR C4 01.11.01 en 123 of 192

10.3 Changing the oil on main axis gear units
Please observe Section 10.2.
The oil is to be changed only at operating temperature.
If the oil change is carried out immediately after the robot has stopped
operating, the oil temperature is liable to be high, in which case appropriate
safety measures must be taken.
10.3.1 Changing the oil on axis 1 gear unit
D Draining oil
(1) Remove four M6x10 Allen screws (Fig. 96/3) and take off the cover (4).
If the robot is equipped with peripheral connections these must be removed before-
hand. The cover (4) can then only be tilted down.
(2) Place a suitable receptacle under the drain hose.

(3) Unscrew sealing cap (6).
(4) Remove sealing cap (5) and catch the oil as it drains out.
The oil takes about 5 minutes to drain completely.
Store used oil in accordance with the regulations and dispose of it with mini-
mum environmental impact.
(5) Screw on sealing cap (5) and tighten it.
D Filling with oil

(1) Pour the specified amount of oil into the hose at (4).
124 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Use a hose (9) approx. 1 m long with a straight union together with a funnel which fits
into the free end of the hose (9).
(2) Insert and tighten sealing cap (6) (tightening torque MA = 40 Nm).
(3) Check the sealing cap (5) for leaks.
(4) Mount the cover (4) and fasten it with four M6x10 Allen screws (3) and lock washers.
(5) Connect any peripheral supply lines required.
D Draining oil
(1) Remove M18x1.5 screw plug (Fig. 96/2) and place a suitable receptacle under the drain
hole.
It is easier to collect the drained oil if a hose (9) with an M18x1.5 connecting nipple (10)
is used.
(2) Remove M18x1.5 screw plug (1) and catch oil as it drains out.
Store used oil in accordance with regulations and dispose of it with minimum
environmental impact.
(3) Insert and tighten M18x1.5 screw plug (2) (tightening torque MA = 20 Nm).
D Filling with oil

(1) Pour the specified amount of oil into the filler hole at (1).
BA KR 30, 60--3, F, KR C4 01.11.01 en 125 of 192

It is easier to pour in the oil if a hose (9) with an M18x1.5 connecting nipple (10) and a
funnel are used for this purpose.
(2) Insert and tighten M18x1.5 screw plug (1) (MA = 20 Nm).
(3) Check the M18x1.5 screw plug (2) for leaks.
9 10 1
6
3
4
5
Fig. 96 Oil change on main axes
126 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

D Draining oil
anyone to be injured within the range of the slowly rotating arm.
(1) Put the robot into operation and move axis 3 until the screw plugs (Fig. 96/7, 8) are
aligned vertically.
(2) Remove M10x1 screw plug (7) and place a suitable receptacle under the drain hole.
(3) Remove M10x1 screw plug (8) and catch oil as it drains out.
(4) Insert and tighten M10x1 screw plug (7) (tightening torque MA = 10 Nm).
D Filling with oil

(1) Pour the specified amount of oil into the filler hole at (8).
It is easier to pour in the oil if a hose (9) with an M10x1 connecting nipple (10) and a
funnel are used for this purpose.
(2) Insert and tighten M10x1 screw plug (8) (MA = 10 Nm).
(3) Check the M10x1 screw plug (7) for leaks.
BA KR 30, 60--3, F, KR C4 01.11.01 en 127 of 192

10.4 Maintenance work, in--line wrist IW 16 II
D “Lubrication” table
Amount
KUKA Art. no.
1) 2)
Gear block A4 D Oil change Change oil as described in

Optigear Synthetic RO 150 Section 10.4.1.
Optimol, approx. 0.32 l 3)
KUKA Art. no.
00--144--898
O--ring A4 D Lubricate Lift O--rings out of grooves.
Optigear Olit CLS Remove old grease.
Optimol, approx. 10 g per Grease O--rings with brush
O--ring and fit them back into
KUKA Art. no. grooves.
83--087--241
KUKA Art. no.
00--144--898
KUKA Art. no.
00--144--898
O--ring A6 D Lubricate Lift O--ring out of groove.
Optigear Olit CLS Remove old grease.
Optimol, approx. 10 g per Grease O--ring with brush
O--ring and fit it back into groove.
KUKA Art. no.
83--087--241
128 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

0.32 l 0.16 l 0.18 l
1 2 3 4 5
Fig. 97 Lubrication work
When draining the oil, it is important to remember that the quantity drained is depen-
dent on time and temperature.
The quantity of oil drained must be measured, as only this quantity may be used when
refilling. If less than 70% of the specified oil quantity flows out, flush the gear unit with
the measured quantity of drained oil once, then pour in the amount of oil that was
drained. During the flushing procedure, move the axis at jog velocity throughout the
entire axis range.
BA KR 30, 60--3, F, KR C4 01.11.01 en 129 of 192

10.4.1 Oil change on in--line wrist
If the oil change is carried out immediately after the robot has stopped opera-
ting, the oil temperature is liable to be high, in which case appropriate safety
measures must be taken.
D Drain oil
(1) Put robot into operation and move arm into a horizontal position (Fig. 98).
(2) Move the wrist axes into their zero positions.
(3) Remove screw plugs (1 to 6) and catch oil in a suitable container as it drains out.
(4) Check the magnets of the screw plugs for deposits, and clean the magnets.
Store used oil in accordance with regulations and dispose of it with minimum
environmental impact.
130 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

D Fill with oil
The arm is still positioned horizontally.
(1) If necessary, put robot into operation and move wrist axes into zero position.
(2) Screw in the screw plugs (Fig. 98/4, 5, 6) and pour the specified amounts of oil into the
oil filler holes.
(3) Screw in the screw plugs (1, 2, 3).
M18x1.5 screw plugs (1, 6): tightening torque MA = 20 Nm,
M10x1 screw plugs (2 -- 5): tightening torque MA = 10 Nm.
1 2 3
6 5 4
Fig. 98 Oil change, IW 16
BA KR 30, 60--3, F, KR C4 01.11.01 en 131 of 192

10.5 Maintenance, in--line wrist IW 30/45/60
D “Maintenance” table
(see Fig. 99) interval (hours) Lubricant
Manufacturer
Amount
1) 2) KUKA Art. no.
1 Gear train A 4 D Oil change Change oil as described in
Optigear Synthetic RO Section 10.5.1.
150
KUKA Art. no.
00--144--898
2 O--ring A 4 D Lubricate Lift O--rings out of
Aralub 4034 grooves.
5) Aral, approx. 10 g per Remove old grease.
O--ring Grease O--rings with
KUKA Art. no. brush and fit them back
83--087--900 into grooves.
3 Toothed belts D Check toothed belt tension See Chapter 11,
In--line wrist “Adjustment”.
30/45/60 kg 4)
A 5, A 6
Check toothed belts Replace toothed belts if
cracks or signs of deterio-
ration are found. See
Chapter 13, “Repair”.
D Replace toothed belts Exchanging toothed belts,

see Chapter 13, “Repair”.
5)
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Amount
KUKA Art. no.
1) 2)
4 Gear train A 5, A 6 D Oil change Change oil as described in

KUKA Art. no.
00--144--898
5 O--ring A 5 D Lubricate Lift O--rings out of grooves.
Aralub 4034 Remove old grease.
Aral, approx. 10 g per Grease O--rings with brush
O--ring and fit them back into
KUKA Art. no. grooves.
83--087--900
1) 5,000 hours for in--line wrist “F”
2) 10,000 hours for in--line wrist “F”
4) Carried out at KUKA before delivery, or must be performed by the user after a toothed belt has been exchanged.
5) After 2 years at the latest
0.55 l 0.75 l
1 2 3 4 5
Fig. 99 Maintenance work
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10.5.1 Changing the oil in in--line wrist IW 30/45/60 kg
If the oil change is carried out immediately after the robot has stopped
operating, the oil temperature is liable to be high, in which case appropriate
safety measures must be taken.
D Draining oil
(1) Put the robot into operation and move the arm into a horizontal position and the in--line
wrist (Fig. 100) into mechanical zero position.
The KUKA logo (2) on the wrist must be the right way up.
(2) Move axis 5 until the mounting flange (3) is horizontal and facing upwards.
(3) Remove filler plug (1) from A 4.
(4) Remove drain plug (4) from A 4 and catch oil in a suitable container as it drains out.
(5) Move axis 5 until the drain plug (5) is pointing down (see Fig. 100, right).
(6) Remove drain plug (5) from gear train A 5 and catch oil in a suitable container as it drains
out.
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1 2 3
60
4
Correct Incorrect
Fig. 100 Oil change

Filling with oil
The arm is still positioned horizontally.
anyone to be injured within the range of the slowly rotating in--line wrist.
(1) Close the drain hole (Fig. 100/4) and move the wrist so that the drain plug (5) points
upwards.
(2) Pour in the specified amount of oil.
Check the sealing elements of the screw plugs and insert new screw plugs if necessary.
(3) Close all filler holes (1, 5) and move axis 5 into mechanical zero position.
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10.6 Cleaning and preventive maintenance
applies to any cleaning work, which though not performed directly on the robot
Cleaning and preventive maintenance work is to be carried out in accordance with the follow-
ing instructions:
-- Clean robot with a cloth soaked with washing agent.
-- Clean cables, plastic parts and hoses with solvent--free washing agents.
The manufacturer’s instructions are to be observed when using washing agents.
-- Remove any lubricant that has escaped using washing agent. If a large amount
of lubricant has emerged, trace and remedy the cause.
It must be ensured that no washing fluid enters bearings, seals or electrical

equipment.
If washing agent does enter bearings, these must be re--greased or re--oiled.
-- Remove any corrosion and where permissible protect the affected areas with
paint, grease or oil.
-- Apply a thin coat of oil to bare metal parts.
-- Replace damaged, illegible or missing inscriptions, labels and plates.
Do not use compressed air to clean the system, as this could cause dirt to pene-
trate and damage seals, bearings and electrical components.
Used cleaning agents and lubricants must be stored and disposed of in
accordance with all pertinent regulations and with minimum environmental
impact.
136 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

10.7 Safety precautions when handling lubricants
The information contained in the safety data sheet according to 91/155 EEC must be ob-
served when handling lubricants. An excerpt from this data sheet is included in the robot
chapter ”Consumables, Safety Data Sheet”.
The following safety procedures must be observed at all times:
-- Avoid prolonged contact with the skin; wear protective gloves and aprons if neces-
sary (especially when working with cable grease).
All accident prevention regulations must be observed when handling lubricants.
-- If lubricant is likely to come into contact with the skin, e.g. with the hands, suitable
barrier creams must be applied before work is started.
-- On completion of work and before smoking breaks or meal breaks (before any in-
take of food), clean oil--contaminated skin thoroughly with water and skin--friendly
cleansing agents or soap. After cleaning, replace lost skin grease with appropriate
skin creams containing grease.
-- Change oil--soaked clothing immediately. Do not carry oily rags or any cloths
soaked with solvents, mineral oil mixtures or cable grease in your pockets.
-- Avoid breathing in oil spray or vapors wherever possible.
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138 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

11 Adjustment instructions
11 Adjustment instructions
11.1 General
The Doc. Module “Safety, General” is to be observed!
applies to any cleaning work which, though not performed directly on the robot,
With EX--variant robots, work may only be carried out if there is no risk of
explosion.
Maintenance and cleaning work on “CR” variant robots may only be conducted
outside the cleanroom. Instructions of the cleanroom user must be observed.
Cleaning operations are to be carried out with cleaning agents suitable for use
in the cleanroom.
Apart from adjustment of the toothed belts, the robot does not require any further mechanical
adjustment. For adjustment operations on the electrical/electronic equipment of the robot
system see Operating Handbook, Software KR C4, Chapter “Start--up”, Section “Robot
Mastering/Unmastering”.
Two axes (A5 and A6) of the in--line wrist are driven via toothed belts, as are two of the three
drive shafts in the arm (for A4 and A5). The tension of these toothed belts is to be checked
or adjusted in accordance with the following procedure after removal or installation of related
assemblies and at the maintenance intervals specified in the “Maintenance” chapter.
When a new toothed belt is installed, the belt tension must be rechecked after
approximately 100 hours of operation and adjusted again if necessary.
Tooling and additional equipment must be removed before the adjustment process is started
if they are likely to impede the adjustment work.
The description of the adjustment 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 symbols. This
is because many of these marked texts refer to the preceding job step.
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Example:
(1) Carry out the measurement ten times.
The five highest measured values must lie within a range of 5 Hz. The median of these
five measurements is the frequency that is sought.
Example:
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12 Adjusting the toothed belt tension
12 Adjusting the toothed belt tension

12.1 Measuring and adjusting the toothed belt tension on wrist axis motor
units A4 and A5
Only the adjustment of the toothed belt stage of axis 4 is described. The adjustment is essen-
tially the same for axis 5.
Before starting the adjustment work, it must be ensured that the toothed belts
are relieved of any weight, i.e. axis 5 must be vertical. No tools may be installed
on axis 6.
If the toothed belts are to be adjusted on an operable robot, the main switch on
the control cabinet must be turned to the “OFF” position and secured with a
Only the adjustment of the toothed belt stage of axis 4 is described. The adjustment is
essentially the same for axis 5.
D Frequency measurement
(1) Remove two sealing covers (Fig. 101/1, 2).
4
3
Fig. 101 Sealing cover
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With F-- or EX--variant robots, the sealing covers (1, 2) are of metal and are fitted with
O--rings. In addition, sealant is used when fitting these covers. To remove the sealing
covers, the screws (M5) and the compressed air connection are first to be removed.
The covers can then be pulled out using pullers.
(2) Switch on the belt tension measuring device (Fig. 102/1).

(3) Pluck the toothed belt and hold the sensor (2) at a distance of 2 to 3 mm from the vibrat-
ing toothed belt; read the measurement on the belt tension measuring device.
(4) Repeat the measurement three times and calculate the mean value.
Fig. 102 Belt tension measuring device
KR 30, 60
Axis Toothed belt Frequency

4 200--S--8M--560 93 -- 98 Hz
5 200--S--8M--560 93 -- 98 Hz
KR 30 L16--2

4 16AT5/525 179 3 Hz
5 16AT5/525 179 3 Hz
Fig. 103 Toothed belt tension
If the value indicated in Fig. 103 is obtained, insert sealing cover; if it is not obtained
carry out steps (5) to (11).
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12 Adjusting the toothed belt tension (continued)
(5) Slacken the tensioning screw (Fig. 101/3).

(6) Slacken the four Allen screws (5) until motor unit A4 (3) can be shifted without play.
(7) Carefully tighten the tensioning screw (3) and measure the toothed belt tension again.
(8) Repeat the process until the required frequency is obtained.
(9) Tighten four Allen screws (4) with a torque wrench in diagonally opposite sequence, in-
creasing tightening torque to the specified value in several stages (MA = 23 Nm).
With F-- or EX--variant robots, the sealing covers are of metal and are fitted with
O--rings. In addition, Drei Bond 1108 sealant is used when fitting these covers.
(10) Measure the toothed belt tension again as described in steps 2 to 4.

(11) Repeat the measuring and adjustment procedure if necessary until the value in Fig. 103
is obtained.
(12) Fit the two sealing covers (Fig. 101/1, 2).
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12.2 Measuring and adjusting the toothed belt tension on in--line wrist A5
and A6
Chapter 1 of this Doc. Module is to be observed!
Only the adjustment of the toothed belt stage of axis 5 is described. The procedure is, how-
ever, essentially the same for axis 6. The toothed belt (Fig. 104/3) of axis 6 is accessible after
the cover (2) has been removed.
Before starting the adjustment work, it must be ensured that the toothed belts
are relieved of any weight, i.e. axis 5 must be vertical. No tools may be installed
on axis 6.
If the toothed belts are to be adjusted on an operable robot, the main switch on
the control cabinet must be turned to the “OFF” position and secured with a
(1) Remove 13 M5x20 Allen screws (Fig. 104/1) and lock washers and take off the cover
(2).
(2) Take off seal (4).
Fig. 104 Cover

(3) Switch on the belt tension measuring device (Fig. 105/1).
(4) Pluck the toothed belt and hold the sensor (2) at a distance of 2 to 3 mm from the vibrat-
ing toothed belt; read the measurement on the belt tension measuring device.
(5) Repeat the measurement three times and calculate the mean value.
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12 Adjusting the toothed belt tension (continued)
Fig. 105 Belt tension measuring device
If the value indicated in Fig. 106 is not obtained, steps (6) to (10) are to be carried out.

5 12 AT5/920--E5/8 130ġ5 Hz
6 10 AT5/780--E5/8 185ġ5 Hz
Fig. 106 Toothed belt tension
(6) Unscrew the hexagon nut (Fig. 107/1) on the eccentric shaft (4) and replace it with a
new one.
(7) Push a socket wrench onto the hexagon (3) and turn the eccentric shaft (4) in the re-
quired direction.
The directions for “tight” and “loose” are given on plate (2).
When tightening the hexagon nut (1), make sure that adequate locking is achie-
ved.
(8) Tighten the hexagon nut (1) with 18 Nm, holding the eccentric shaft (4) firmly to prevent
it from turning.
(9) Measure the toothed belt tension again as described in steps 2 to 4.
(10) Repeat the measuring and adjustment procedure if necessary until the value in Fig. 106
is obtained.
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A5 A6
4 3 2
Fig. 107 Adjusting the toothed belt tension
(11) Mount cover (Fig. 104/2) with a new seal (4) and fasten it with 13 M5x20 Allen screws
(1) and lock washers.
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13 Repair
13 Repair
13.1 General
Important repair operations for assemblies to be repaired are described in the sections. This
work comprises the removal and installation of assemblies. The user’s personnel may not
carry out dismantling work going beyond the scope of these operations unless they have
been trained by KUKA for that particular purpose and have the necessary measuring and
testing equipment at their disposal as well as the appropriate documentation.
The description of the repair work is based on the assumption that the work is carried out
by skilled and appropriately trained personnel. Deviations from the specified removal and
dismantling procedures are permitted, provided they are not of a fundamental nature and
endanger neither equipment nor persons. No particular reference is made to safety regula-
tions or trade association regulations; these are always to be observed and are supple-
mented in this manual where necessary by remarks introduced by a warning triangle or a
hand symbol.
When any work is being carried out in the manipulator’s danger area, the robot
must be switched off and the main switch secured with a padlock to prevent
unauthorized persons from starting it up again. If this is not possible in the
opinion of the user, it must be ensured that an EMERGENCY STOP pushbutton
can be immediately actuated at all times.
When assemblies are removed or work is carried out on an installed
manipulator, it must be ensured that the manipulator is not able to move on its
own.
The description of the repair work only covers those operations that do not necessitate
subsequent gauging of the manipulator.
The screw sizes and strength classes (standard strength class 8.8) specified in
the sections for assemblies to be repaired are valid at the copy deadline. The
specifications contained in the Parts Catalog are, however, always to be taken as
the most up--to--date information.
Screws of grade 10.9 and higher may only be tightened once with the rated tightening torque.
When the screws are next slackened they must be replaced with new ones.
The description of the repair 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 symbols. Many of these
marked texts refer to the preceding job step.
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Example:
(5) Unscrew four hexagon screws and remove main axis motor unit.
The main axis motor unit must not be tilted while it is being lifted off.
When removing the main axis motor unit, care must be taken to avoid any injury
by crushing!
Example:
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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13 Repair (continued)
13.2 Bonding instructions
When sealants, adhesives and locking agents are used, the manufacturer’s directions
must be strictly observed. This also applies to the cleaning of open sealing, locking and
adhesion joints where the parts to be joined are to be used again.
D Instructions for bonding components

(1) Wash the components with cleaning agent and blow them dry.
(2) Wash the components with cleaning agent again and dry them with a lint--free cloth.
(3) Apply a thin layer of adhesive to one side of the joint, assemble the components and
insert the screws.
Lightly grease the screw threads in order to prevent the screws from becoming
stuck.
(4) Tighten the screws with the specified torque.

(5) Remove any excess adhesive which has emerged from the joint.
BA KR 30, 60--3, F, KR C4 01.11.01 en 149 of 192

13.3 Unbraked impact against limit stops
If the manipulator hits an obstruction or a buffer on the mechanical end stop or

axis range limitation, this can result in material damage to the manipulator.
KUKA Roboter GmbH must be consulted before the manipulator is put back into
operation. The affected buffer must immediately be replaced with a new one.
If a manipulator collides with a buffer at more than 250 mm/s, the manipulator
must be exchanged or recommissioning must be carried out by KUKA Roboter
GmbH.
150 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

13.4 In--line wrist IW 16, repair
Section 13.1 of this chapter must be observed!
Before repair work is started, any attached tools or additional equipment that would hinder
repair must be dismounted.
Performing the following work is greatly facilitated if the robot is at a level which can be easily
reached by the personnel carrying out the repairs.
13.4.1 Removal, installation of in--line wrist
D Removal
(1) Move the arm into the horizontal position.

(2) If possible, move axes 4, 5 and 6 into their zero positions.
If the in--line wrist is removed immediately after the robot has stopped operating,
it is liable to have an elevated surface temperature.
(3) Secure in--line wrist (Fig. 108/4) with lifting tackle (3) or, if that is not possible, secure
it with a prop underneath.
The wrist must be secured very carefully, as damage could otherwise be caused
not only to the wrist but also to the arm.
(4) Remove 16 M6x90--10.9 (5) Allen screws.
Two pan head screws are also found on the hole circle of the Allen screws (5).
These must not be loosened or removed.
(5) Pull the in--line wrist out of the arm (1).
BA KR 30, 60--3, F, KR C4 01.11.01 en 151 of 192

The in--line wrist must not be tilted as it is being pulled out. The resultant gap (2)
between the arm (1) and the in--line wrist (4) must be uniform at all times round
the entire circumference.
(6) Place the in--line wrist on a suitable support.
1 2 3
5 4
Fig. 108 Removal, installation of in--line wrist
The in--line wrist may not be further dismantled.
If the in--line wrist is not to be reinstalled, it must be protected against corrosion before
being put into storage.
D Installation
(1) Remove all protective coatings and oil from new in--line wrist, if applicable.
(2) Remove sleeve (Fig. 109/1) using suitable tools if necessary (e.g. lever).
The sleeve is only present on new wrists. This step is not applicable if a wrist is being
re--installed.
Clean the shaft toothing before installation and lightly grease it with Microlube GL 261.
152 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

1
Fig. 109 Bushing
(3) Install the in--line wrist by carrying out the removal instructions in reverse.
When installing a new in--line wrist, it must be ensured that axes 4, 5 and 6 are in their
zero positions.
(4) Tighten the 16 M6x90--10.9 Allen screws (Fig. 108/5) with a torque wrench in diagonally
opposite sequence, increasing the tightening torque MA in several stages to the speci-
fied value (MA = 12.5 Nm).
(5) Carry out zero adjustment on axes 4, 5 and 6 (see Operating Handbook, Software
KR C4, Chapter “Start--up”, Section “Robot Mastering/Unmastering”).
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13.5 Repairing in--line wrist IW 30/45/60
13.5.1 Removal, installation of in--line wrist
D Removal
(1) Move the arm into the horizontal position.

(2) If possible, move axes 4, 5 and 6 into their zero positions.
If the in--line wrist is removed immediately after the robot has stopped operating,
it is liable to have an elevated surface temperature.
(3) Secure in--line wrist (Fig. 110/4) with lifting tackle (3) or, if that is not possible, secure
it with a prop underneath.
The wrist must be secured very carefully, as damage could otherwise be caused
not only to the wrist but also to the arm.
(4) Remove 16 M6x100--12.9 (5) Allen screws.

(5) Pull the in--line wrist out of the arm (1).
The in--line wrist must not be tilted as it is being pulled out. The resultant gap (2)
between the arm (1) and the in--line wrist (4) must be uniform at all times round
the entire circumference.
(6) Place the in--line wrist on a suitable support.
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1 2 3
5 4
Fig. 110 Removal, installation of in--line wrist
The in--line wrist may not be further dismantled. The removal and installation of
the toothed belts is described in Section 13.5.2.
If the in--line wrist is not to be reinstalled, it must be protected against corrosion before
being put into storage.
D Installation
(1) Remove all protective coatings and oil from new in--line wrist, if applicable.
Clean the shaft toothing before installation and lightly grease it with Microlube GL 261.
(2) Install the in--line wrist by carrying out the removal instructions in reverse.
When installing a new in--line wrist, it must be ensured that axes 4, 5 and 6 are in their
zero positions.
(3) Tighten the 16 M6x100--12.9 Allen screws (Fig. 110/5) with a torque wrench in diago-
nally opposite sequence, increasing the tightening torque MA in several stages to the
specified value (MA = 15 Nm).
(4) Carry out zero adjustment on axes 4, 5 and 6 (see Operating Handbook, Software
KR C4, Chapter “Start--up”, Section “Robot Mastering/Unmastering”).
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13.5.2 Removal, installation of toothed belts for axes 5 and 6
The toothed belts of axes 5 and 6 may only be removed and installed together.
If the end--effector is still mounted on the wrist, it must be either removed or

secured to prevent it from moving.
If the toothed belt is to be removed from or installed in an operable robot, the
main switch on the control cabinet must be turned to “OFF” and secured with a
D Removal
(1) Put robot into operation, move arm into a horizontal position and turn in--line wrist so
that cover (Fig. 111/1) is facing upwards.
(2) Remove the sealing cover (Fig. 111/5).

(3) Remove 13 M5x20 Allen screws (11) together with lock washers and take off the cover
(1).
Wrists of “F” variant robots have a seal fitted. This must be removed and ex-
changed if necessary upon installation.
(4) Slacken M8 hexagon nut (2).

(5) Turn the eccentric shaft (3) to slacken toothed belt A5 (7).
(6) Take the toothed belt (7) off the pulley (10).
(7) Slacken M8 hexagon nut (4).
(8) Turn the eccentric shaft (6) to slacken toothed belt A6 (8).
(9) Take the toothed belt (8) off the pulley (9).
(10) Take toothed belt A 6 (8) out of the in--line wrist.
(11) Take toothed belt A 5 (7) out of the in--line wrist.
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D Installation
(1) Install the toothed belt by carrying out the removal instructions in reverse.
When installing the toothed belts make sure that adequate locking of the hexa-
gon nuts (2, 4) is achieved.
When fitting toothed belts, it must be ensured that they mesh properly with the
toothed belt pulleys (see Fig. 112).
Wrists of “F” variant robots have a seal fitted. This must be removed and ex-
changed if necessary upon installation.
Before the cover (Fig. 111/1) is mounted, steps 2 and 3 must be carried out.
(2) Carry out zero adjustment on axes 5 and 6 (see Operating Handbook, Software KR C4,
Chapter “Start--up”, Section “Robot Mastering/Unmastering”).
(3) Check the toothed belt tension of axes 5 and 6 in the in--line wrist and adjust it if neces-
sary (see Chapter 11, “Adjustment”).
1 2 3 4 5 6 7 8
11 10 9
Fig. 111 Removal, installation of toothed belts for axis 5 and axis 6
BA KR 30, 60--3, F, KR C4 01.11.01 en 157 of 192

Correct Incorrect
Fig. 112 Meshing of toothed belt/pulleys
158 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

13.6 Repairing AC servomotors
13.6.1 Removal, installation of main axis motor unit A1

If main axis motor unit A1 is to be removed from or installed on an operable
robot, the main switch on the control cabinet must be turned to “OFF” and
secured with a padlock to prevent unauthorized persons from switching it on
again.
D Removal
If main axis motor unit A1 is removed immediately after the robot has stopped
operating, it is liable to have an elevated surface temperature.
(1) Release and unplug connectors XM1 and XP1 at the sockets (Fig. 113/4, 5).
(2) Remove four M12x30 Allen screws (3) together with lock washers.
(3) Lift out main axis motor unit A1 (1).
When lifting off main axis motor unit A1, care must be taken to avoid any injury
by crushing!
Main axis motor unit A1 must not be tilted while it is being lifted out.
BA KR 30, 60--3, F, KR C4 01.11.01 en 159 of 192

1
5
Fig. 113 Main axis motor unit A1
If main axis motor unit A1 is not to be reinstalled, it must be protected against corrosion
before being put into storage.
D Installation
AC servomotors may only be installed in gear units if the toothing is undamaged on

both sides of the connection.
(1) Remove all protective coatings and oil from new main axis motor unit A1, if applicable.
(2) Clean the toothing (Fig. 113/2) of the AC servomotor and gear unit before installation
and apply a thin but continuous coat of Microlube GL 261 grease.
(3) Clean the mounting surface.
(4) Insert main axis motor unit A1 (1).
When lifting off main axis motor unit A1, care must be taken to avoid any injury
by crushing!
Main axis motor unit A1 must not be tilted while it is being installed.
The sockets XM1 (4) and XP1 (5) must be positioned as shown in Fig. 113. Insertion of
main axis motor unit A1 can be facilitated by turning it gently about its rotational axis.
160 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

(5) Insert four M12x30 Allen screws (3) together with lock washers.
(6) Tighten the four Allen screws (3) with a torque wrench, increasing the tightening torque
MA in diagonally opposite sequence in several stages to the specified value (MA = 78
Nm).
(7) Plug connectors XM1 and XP1 into the sockets (4, 5).
For floor--mounted robots in an inclined position: Remove safeguards against

the robot turning about rotational axis 1.
(8) Carry out zero adjustment (see Operating Handbook, Software KR C4,
Chapter “Start--up”, Section “Robot Mastering/Unmastering”).

again.
D Removal
If main axis motor unit A2 is removed immediately after the robot has stopped
(1) Secure the link arm.

(1.1) Move link arm into a vertical position -- if still possible -- and arm into a horizontal posi-
tion, or move link arm into a stable position on the (+) stop(Fig. 114). The arm can be
in any position.
(1.2) Secure link arm appropriately, e.g. with lifting tackle or propped from below (Fig. 114).
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Fig. 114 Securing the link arm (schematic)
The link arm must not be able to move either during or after removal of main
axis motor unit A2.
(3) Slacken four M12x30 Allen screws (6) but do not remove them.
(4) Secure main axis motor unit A2 (4) with lifting tackle (5).
(5) Remove four M12x30 Allen screws (6) together with lock washers and lift off main axis
motor unit A2.
When removing main axis motor unit A2, care must be taken to avoid any injury
by crushing!
Main axis motor unit A2 must not be tilted while it is being lifted off.
The orientation of main axis motor unit A2 is identified from the position of the
sockets (2, 3). When the motor unit is subsequently installed, these sockets
must be positioned in the same way as before removal.
162 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

4 5 6
3 2 1
Fig. 115 Removal, installation of main axis motor unit A2
If main axis motor unit A2 is not to be reinstalled, it must be protected against corrosion
D Installation

(3) Insert main axis motor unit A2 (4) using lifting tackle (5).
When inserting main axis motor unit A2, care must be taken to avoid any injury
by crushing!
Main axis motor unit A2 must not be tilted while it is being installed. Ensure that
the sockets (2, 3) are in the correct position.
BA KR 30, 60--3, F, KR C4 01.11.01 en 163 of 192

Insertion of main axis motor unit A2 can be facilitated by turning it gently.
(4) Fasten main axis motor unit A2 with four M11x30 Allen screws (6) and lock washers.
MA in diagonally opposite sequence in several stages to the specified value
(MA = 78 Nm).
(6) Insert connectors XM2 at (3) and XP2 at (2).
(7) Remove lifting tackle (5).
(8) Remove lifting tackle or prop from the robot (Fig. 2).
(9) If necessary, bring robot into its installation position (see Chapter 7, “Installation, con-
nection, exchange”).
(10) Carry out zero adjustment (see Operating Handbook, KR C4, Chapter “Start--up”, Sec-
tion Robot “Mastering/Unmastering”).

again.
D Removal
If the main axis motor unit is removed immediately after the robot has stopped
(1) Secure the arm.

(1.1) Move link arm into a vertical position, and arm -- if still possible -- into a horizontal posi-
tion (Fig. 116).
(1.2) Secure arm appropriately, e.g. with lifting tackle or propped from below (Fig. 116).
The arm must not move when main axis motor unit A3 is being removed or after
it has been removed in any of the installation versions of the robot.
Continue with step (2).
164 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Fig. 116 Securing the arm (schematic)
If the robot is to be moved into its transport position, it must be fastened to the
floor.
(1.3) Move the robot into its transport position (see Chapter 7, “Installation, connection, ex-
change”).
(1.4) If the arm cannot be moved into its transport position, it must be suitably secured, using
lifting tackle, for example.
The arm must not be able to move either during or after removal of main axis
motor unit A3.
(2) Slacken four Allen screws (Fig. 117/1) but do not remove them.
(3) Secure main axis motor unit A3 (5) with lifting tackle (6).
(4) Release and unplug connectors XM3 and XP3 from the sockets (3, 4).
With F--variant robots, seals are fitted between the arm and main axis motor unit A3.
These must be removed and exchanged if necessary during installation.
When ordering a main axis motor unit, always indicate if it is for use in these robot va-
riants.
(5) Remove four M12x30 Allen screws (1) together with lock washers and lift off main axis
motor unit A3.
When removing main axis motor unit A3, care must be taken to avoid any injury
by crushing!
BA KR 30, 60--3, F, KR C4 01.11.01 en 165 of 192

Main axis motor unit A3 must not be tilted while it is being lifted off.
The orientation of main axis motor unit A3 is identified from the position of the
sockets (3, 4). When the motor unit is subsequently installed, these sockets
must be positioned in the same way as before removal.
5 3, 4
Fig. 117 Removal, installation of main axis motor unit A3
If the main axis motor unit is not to be reinstalled, it must be protected against corrosion
D Installation

With F--variant robots, seals are fitted between the arm and main axis motor unit A3.
These must be renewed during installation. In addition, Drei Bond 1118 sealant is to be
used when inserting the fastening screws.
When ordering a main axis motor unit, always indicate if it is for use in these robot va-
riants.
(3) Insert main axis motor unit A3 (5) using lifting tackle (6).
When inserting main axis motor unit A3, care must be taken to avoid any injury
by crushing!
166 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Main axis motor unit A3 must not be tilted while it is being installed. Ensure that
the sockets (3, 4) are in the correct position.
Insertion of main axis motor unit A3 can be facilitated by turning it gently.
(4) Fasten main axis motor unit A3 (5) with four M12x30 Allen screws (1) and lock washers.
MA in diagonally opposite sequence in several stages to the specified value
(MA = 78 Nm).
(6) Plug connectors XM3 and XP3 into the sockets (3, 4).
(7) Remove lifting tackle (6).
(8) Remove lifting tackle or prop from the robot (Fig. 116).
(9) If necessary, bring robot into its installation position (see Chapter 7, “Installation, con-
nection, exchange”).
(10) Carry out zero adjustment (see Operating Handbook, Software KR C4, Chapter
“Start--up”, Section “Robot Mastering/Unmastering”).
13.6.4 Removal, installation of wrist axis motor unit A4

If wrist axis motor unit A4 is to be removed from or installed in an operable
again.
The removal and installation operations are facilitated if the wrist axes are in their zero posi-
tions and the arm is horizontal.
D Removal
If wrist axis motor unit A4 is removed immediately after the robot has stopped
Any tooling mounted must be either secured to prevent it from turning or

removed.
(2) Remove the sealing cover (2).
(3) Unscrew the adjusting screw (5) by several turns.
BA KR 30, 60--3, F, KR C4 01.11.01 en 167 of 192

With F--variant robots, seals are fitted between the arm and the wrist axis motor units.
When ordering wrist axis motor units, always indicate if they are for use in these robot
variants.
(4) Remove four M6x25 Allen screws (6) together with lock washers and lift off wrist axis
motor unit (4).
If the wrist axis motor unit is not to be reinstalled, it must be protected against
5
A4 A6
4
3 A5
2
Fig. 118 Removal, installation of wrist axis motor unit A4
168 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

D Installation
These must be renewed during installation. In addition, for these robot variants, Drei
Bond 1108 sealant is to be used when inserting the following screws:
-- Adjusting screw for wrist axis motor unit A4
-- Fastening screws for wrist axis motor unit A4
variants.
(1) Remove all protective coatings and oil from wrist axis motor unit A4 (Fig. 118/4), where
applicable, and fit the toothed belt (Fig. 119/1) onto the toothed belt pinion (2).
Insert the wrist axis motor unit so that the sockets (Fig. 118/1, 3) for connectors XM4
and XP4 are located at the bottom.
When installing the motor unit, it must be ensured that the toothed belts mesh
properly with the toothed belt pinions (Fig. 119).
Correct Incorrect
Fig. 119 Toothed belt and toothed belt pinion
(2) Insert the four Allen screws M6x25 (Fig. 118/6) together with lock washers and tighten
Allen screws until motor unit can be shifted without play.
(3) Adjust the toothed belt tension (see Chapter 11, “Adjustment instructions”).
(4) Slightly tighten the adjusting screw (5).
(5) Insert connectors XM4 and XP4.
(6) Fit the sealing cover (2), if applicable.
(8) When a new toothed belt is installed, the belt tension must be rechecked after approxi-
mately 100 hours of operation (see Chapter 11, “Adjustment Instructions”).
BA KR 30, 60--3, F, KR C4 01.11.01 en 169 of 192


again.
D Removal

removed.
(2) Remove the sealing cover (3).
(3) Unscrew the adjusting screw (6) by several turns.
variants.
(4) Remove four M6x25 Allen screws (5) together with lock washers and lift off wrist axis
motor unit (4).
If the wrist axis motor unit is not to be reinstalled, it must be protected against corrosion
170 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

1 2
A4 A6
3
4
A5
5
6
D Installation
These must be renewed during installation.
In addition, for these robot variants, Drei Bond 1108 sealant is to be used when inser-
ting the following screws:
-- Adjusting screw for wrist axis motor unit A5
-- Fastening screws for wrist axis motor unit A5
variants.
(1) Remove all protective coatings and oil from wrist axis motor unit A5 (Fig. 120/4), where
applicable, and fit the toothed belt (Fig. 121/1) onto the toothed belt pinion (2).
Insert the motor unit so that the sockets (Fig. 120/1, 2) for connectors XM5 and XP5
are located on the left.
When installing the motor unit, it must be ensured that the toothed belts mesh
properly with the toothed belt pinions (Fig. 121).
BA KR 30, 60--3, F, KR C4 01.11.01 en 171 of 192

Correct Incorrect
(2) Insert the four Allen screws M6x25 (Fig. 120/5) together with lock washers and tighten
Allen screws until motor unit can be shifted without play.
(3) Adjust the toothed belt tension (see Chapter 11, “Adjustment instructions”).
(4) Slightly tighten the adjusting screw (6).
(7) Fit the sealing cover (3).
(8) When a new toothed belt is installed, the belt tension must be rechecked after approxi-
mately 100 hours of operation (see Chapter 11, “Adjustment Instructions”).

again.
D Removal

removed.
(1) Release and unplug connectors XM6 and XP6.
172 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

(2) Remove four M8x18 Allen screws (Fig. 122/3) together with lock washers and lift off
motor unit A6.
variants.
When motor unit A6 is removed, a ring (9) and disc springs (8) are released and
must be prevented from falling out.
If wrist axis motor unit A6 is not to be reinstalled, it must be protected against corrosion
2
1
3
4
A4 A6
A5
5
6
10 7
BA KR 30, 60--3, F, KR C4 01.11.01 en 173 of 192

D Installation

These must be renewed during installation. In addition, for these robot variants Drei
Bond 1108 sealant is to be used when inserting the fastening screws.
variants.
(1) Remove all protective coatings and oil from wrist axis motor unit A6 (Fig. 122/4) as re-
quired, and clean the spline shaft connection (10), applying a thin but continuous coat
of Microlube GL 261.
(2) Push the ring (9) and disc springs (8) onto the toothing as shown in Fig. 122.
(3) Push wrist axis motor unit A6 (4) onto the spline connection of shaft A6 (7) and into the
centering flange of the arm housing.
Insert wrist axis motor unit A6 so that sockets XM6 and XP6 (1, 2) are located at the
top (Fig. 122).
The shaft stub must not be subjected to any axial loads.
Toothed belts A4 and A5 must be fitted onto the toothed belt pinions before mo-
tor unit A6 is installed.
(4) Insert four M8x18 Allen screws (3) together with lock washers and tighten them with
a torque wrench in diagonally opposite sequence, increasing the tightening torque to
the specified value in several stages (MA = 23 Nm).
174 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

13.6.7 Removal, installation of toothed belts A4/A5
D Removal
(1) Remove wrist axis motor units A4, A5 and A6 (Fig. 123) (see Sections 13.6.4, 13.6.5
and 13.6.6).
(2) Take off toothed belts (1) and (2).
D Installation
(1) Fit toothed belts (Fig. 123/1) and (2).
When fitting the toothed belts, it must be ensured that they mesh properly with
the toothed belt pinions (see Fig. 124).
(2) Install wrist axis motor units A4, A5 and A6 (see Sections 13.6.4, 13.6.5 and 13.6.6).
(3) Adjust the toothed belt tension (see Chapter 11, “Adjustment”).
BA KR 30, 60--3, F, KR C4 01.11.01 en 175 of 192

A4 A6
1
A5 2
A5 A4
Fig. 123 Toothed belts A4/A5
Correct Incorrect
176 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

14 Consumables, safety data sheets
14 Consumables, safety data sheets

14.1 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.
BA KR 30, 60--3, F, KR C4 01.11.01 en 177 of 192

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.
178 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

14 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.
BA KR 30, 60--3, F, KR C4 01.11.01 en 179 of 192

14.2 Safety data sheet for Optimol Olit CLS lubricating grease
dling Optimol Olit CLS.

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

Chemical components:
Lubricating grease based on mineral oil and lithium--calcium soap grease as
thickener.
substance.
3 Possible hazards

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.
Foam, dry powder, CO2.
Water.

No special safety precautions required.
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.
180 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en


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.
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.
10 Reactivity
The product is stable.
Strong acids and oxidizing agents.
Dependent on decomposition conditions: oxides of C, S, P.
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.
General assessment:
Prevent the lubricant from entering soil, surface waters and drainage system.
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.
BA KR 30, 60--3, F, KR C4 01.11.01 en 181 of 192

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)
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.
182 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

14.3 Safety data sheet for Optigear Synthetic RO 150 oil

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: MSDSadvice@bp.com
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.
BA KR 30, 60--3, F, KR C4 01.11.01 en 183 of 192


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.
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.
Do NOT use water jets.
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.
184 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en


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).
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.

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
BA KR 30, 60--3, F, KR C4 01.11.01 en 185 of 192

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.

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.
186 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

10 Stability and reactivity

Stability: The product is stable. No hazardous polymerization occurs under normal storage
conditions and in normal use.
No specific data.
Reactive or incompatible with the following substances: oxidizing materials.
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.
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.
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).
BA KR 30, 60--3, F, KR C4 01.11.01 en 187 of 192

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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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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14.4 Safety data sheet for Microlube GL 261 lubricant

dling Microlube GL 261.

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

Chemical characterization:
-- Mineral oil
-- Lithium special soap
-- UV indicator
substance.
3 Possible hazards

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.
Foam, fine water spray, dry powder, CO2.
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.
190 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en


No special safety precautions required.
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.

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.

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.
BA KR 30, 60--3, F, KR C4 01.11.01 en 191 of 192

10 Stability and reactivity

Thermal decomposition / conditions to be avoided:
No decomposition if handled and stored correctly.
Oxidizing agents.
Hazardous reactions:
No hazardous reactions known.
None if used for designated purpose.
Prolonged contact with the skin can cause irritation and/or dermatitis.
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
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.
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”.
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
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.
192 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Kuka KR60-3

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ROBOT

KR 30, 60--3; KR 30 L16--2 with KR C4

Issued: 25 Sep 2012 Version: 01

BA KR 30, 60--3, F, KR C4 01.11.01 en 1 of 192

KUKA Roboter GmbH

Translation of the original documentation

2 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

BA KR 30, 60--3, F, KR C4 01.11.01 en 3 of 192

5.4.5 Labeling on the industrial robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7 Installation, connection, exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

9 Connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

10 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

4 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

11 Adjustment instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

12 Adjusting the toothed belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

14 Consumables, safety data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

BA KR 30, 60--3, F, KR C4 01.11.01 en 5 of 192

6 of 192 BA KR 30, 60--3, F, KR C4 01.11.01 en

Valid for KR 30--3

1.1 Robot documentation

Each of these parts is a separate document that is attached to the robot.

1.2 Representation of warnings and notes

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Use is only permitted under the environmental conditions specified in Chapter 4.

2.2 Target group

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

BA KR 30, 60--3, F, KR C4 01.11.01 en 9 of 192

3.2 In--line wrist IW 16 II

1 Shaft for axis 6 4 Flange (arm--wrist)

Fig. 2 In--line wrist IW 6 II

3.3 In--line wrist 30/45/60

Fig. 3 In--line wrist IW 30/45/60

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1 Motor units for wrist axes 6 Main axis motor unit A3

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3.4.1 Wrist axis motor units A4 to A6

Fig. 5 Wrist axis motor units A4 to A6

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3.5 Link arm

Fig. 6 Link arm and turning range

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1 Reference notch A3 5 Rotational axis 2

Fig. 7 Structure of link arm

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3.5.1 Main axis motor units A1 to A3

Fig. 8 Motor unit for main axis drive

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3.6 Rotating column

1 Rotational axis 1 +185

Fig. 9 Rotating column with turning range (shown here: KR 30--3)

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1 Main axis motor unit A2

Fig. 10 Structure of rotating column

3.7 Base frame

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1 Special reduction gear unit A1 7 Junction box

Fig. 11 Structure of the base frame

3.8 Working range limitation for A1 to A3

Axis 1: with two supplementary stops:

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3.9 Working range monitoring for A1 and A2

3.10 Energy supply system