ROBOT

KR6,15

Installation, Connection, Exchange

eCopyright KUKA Roboter GmbH

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 claim 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.

Length of documentation: 36 pages

PD Interleaf

07.97.01 Ro/Me/03/13 en 1
Contents

1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 PRINCIPAL LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 MOUNTING VARIANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Variant 1 (391.816--08.003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Variant 2 (391.816--08.002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Variant 3 (391.816--08.001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Wall--mounting variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 INSTALLING AND CONNECTING THE ROBOT . . . . . . . . . . . . . . . . . 14

4.1 Floor--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Ceiling--mounted robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Wall--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5 EXCHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 Exchanging floor--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Exchanging ceiling--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 Exchanging wall--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2 Ro/Me/03/13 en 07.97.01
 Valid for KR 6/2
KR 15/2

1 GENERAL

The Doc. Module ”Safety, General” and the robot Doc. Module ”Repair, General”
are to be observed!
With all work involving the connection of the robot (and of the control cabinet),
the control cabinet Doc. Module ”Initial Start--up” must be observed.

Before any installation and exchange work is started, any attached tools or additional equipment 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 robot.
For weight of robot see robot Doc. Module ”Technical Data”.

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

Example:
(8) Lower the robot slowly without tilting it.

CAUTION! The robot must be lowered vertically downwards until both locating pins are free.

Some of the specially marked texts refer exclusively to everything that follows -- until the instruction
is expressly revoked or the work is completed at the end of a section.

Example:

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.
1
0

07.97.01 Ro/Me/03/13 en 3
2 PRINCIPAL LOADS
Forces occur during operation of the robot which must be safely transmitted to the floor, ceiling or the
hinged steel base. The forces that have to be taken into account are specified in Fig. 1 for floor-- and
ceiling--mounted robots and in Fig. 2 for wall--mounted robots. Both drawings with their specifications
can be used as a basis for more extensive static investigations.

Mk

Fv

Fh

Mr

KR 6/2 KR 15/2
Fv = vertical force Fvmax = 3500 N 3800 N
Fh = horizontal force Fhmax = 2600 N 4100 N
Mk = tilting moment Mkmax = 3400 Nm 4800
Nm
Mr = turning moment about axis 1 Mrmax =
3200 Nm 3200 Nm

Total mass = robot + total load for type

205 kg + 16 kg
KR 6/2
Fig. 1 Principal loads acting on floor (or ceiling) due to robot and total load
222 kg + 25 kg
KR 15/2

4 Ro/Me/03/13 en 07.97.01
 X
Mk
Fh

Fv

View X

Mr

KR 6/2 KR 15/2
Fv = vertical force Fvmax = 5000 N 7000 N
Fh = horizontal force Fhmax = 1000 N 1000 N
Mk = tilting moment Mkmax = 2800 Nm 3700
Nm
Mr = turning moment about axis 1 Mrmax =
3200 Nm 3500 Nm

Total mass = robot + total load for type

205 kg + 16 kg
KR 6/2
Fig. 2 Principal loads acting on the mounting base due to robot and total load
222 kg + 25 kg
for ”wall” installation position
KR 15/2

07.97.01 Ro/Me/03/13 en 5
3 MOUNTING VARIANTS
The robot can be installed on the floor, the ceiling or the wall.
There are three mounting variations for installing the robot on the floor or on the ceiling:
G Variant 1 (391.816--08.003), see Section 3.1
G Variant 2 (391.816--08.002), see Section 3.2
G Variant 3 (391.816--08.001), see Section 3.3
For installation of the robot on the wall see Section 3.4.
If the robot is to be installed on the floor, being directly mounted on a concrete base, all pertinent
construction specifications must be observed concerning the grade of concrete (³ 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 dowels must
be inserted with great care to ensure that the forces occurring during the operation of the robot (Fig. 1)
are transmitted safely to the ground.

3.1 Variant 1 (391.816--08.003)

Characteristic features:
-- For floor--mounted robots only.
-- Robot installed directly on the concrete foundation.
-- Robot fastened by means of three undercut dowels.
Accessory: ”floor mounting kit”
(1) Mark a hole pattern as per Figure 2 on the foundation or set down the robot in the intended
installation position on the foundation.
(2) The intended installation position of the robot, i.e. the correct orientation in relation to the
working envelope (Fig. 2/1), must be taken into account when marking the position of the
boreholes.
(3) Drill three dowel holes (Fig. 3/6) in accordance with Figure 2 or through the fastening bore-
holes of the robot; minimum depth in concrete 190 mm.
(4) Prepare undercuts (Fig. 3/4) with special tool in accordance with appropriate work instruc-
tions.
(5) Insert compression springs (5).
(6) Insert three undercut dowels (3).
(7) Set robot down.
(8) Screw on hexagon nuts (2) together with washers and tighten hexagon nuts with torque
wrench in diagonally opposite sequence, increasing the tightening torque to the specified
value in several stages (MA = 115 or 135 Nm).

NOTE The tightening torque for the hexagon nuts is 115 Nm for initial installation (with the plas-
tic dowel ring) or 135 Nm with subsequent installation (without the plastic dowel ring).

CAUTION! When tightening the hexagon nuts (2), the base frame must not be distorted. The
test dimension (1) of 8 ± 3 mm for checking the undercut dowels must be
reached.

CAUTION! Retorque hexagon nuts (2) after 100 operating hours.

6 Ro/Me/03/13 en 07.97.01
 1

front

Fig. 3 Hole pattern for variant 1

1

MA = 115/135 Nm
2
Test dimension
8 ¦ 3 mm
3
143
190
250

4
5

23

3x 1,5

Fig. 4 Robot installation, variant 1

Installation of the robot is now finished. The robot is ready for connection (see Section 4.1).

07.97.01 Ro/Me/03/13 en 7
3.2 Variant 2 (391.816--08.002)
Characteristic features:
-- For floor-- and ceiling--mounted robots.
-- Robot installed on a steel structure prepared by the customer (or on a linear unit of series KL 250).
-- Robot fastened by means of three M20x55 ISO 4017 hexagon bolts.

CAUTION! Retorque three hexagon bolts M20x55 ISO 4017 after 100 operating hours.

Accessory: ”frame mounting kit”

(1) Prepare mounting surfaces (Fig. 5/1) on steel structure in accordance with Figure 5.

NOTE The maximum permissible difference in level between the individual mounting surfaces
(1) is 0.5 mm.

(2) Drill three holes for holding--down bolts (Fig. 6/3) and two holes for the locating pins (1, 2)
as shown in Figure 6.

NOTE The intended installation position of the robot, i.e. the correct orientation in relation to the
working envelope (Fig. 3/1), must be taken into account when drilling the holes.

(3) Insert locating pins (Fig. 6/1, 2) and fasten each one with an M8x55 Allen screw (1) together
with lock washer.

NOTE The position of the locating pins in relation to the working envelope is important:
Looking forwards (4) from the robot towards the working envelope -- the robot arm points
in this direction when A1 is in its zero position --, then the sword pin (2) must be on the
right and the round pin (1) on the left.

8 Ro/Me/03/13 en 07.97.01
 1

Center A 1

min.180
120°
front
120°

(170) min.90

Fig. 5 Mounting surfaces for variant 2

A 337.5
44.5 Rz 10
Section A--A
3x 12H7 A
f1 A B M20
(2x) 1
1

(68)
7.15

202

4
(30)
(90)

Center A 1
min.180
404 ± 0.05
389.7
M20 (3x)

3 front
120°

min. 18
(170) min.90
max. 6
H7
(2x)

2
f12

^|2
3 (12H7) B
2
A

Fig. 6 Robot installation, variant 2

The steel foundation is now ready for the robot to be installed. The procedure for installing the robot
is described in Section 4.1 for floor--mounted robots, in Section 4.2 for ceiling--mounted robots.

07.97.01 Ro/Me/03/13 en 9
3.3 Variant 3 (391.816--08.001)

Characteristic features:
-- For floor--mounted robots only.
-- Robot installed with an intermediate plate (Fig. 7/1) on the concrete foundation.
-- Intermediate plate fastened to robot with three M20x55 hexagon bolts (4) and to concrete founda-
tion with three undercut dowels (3).

CAUTION! Retorque three hexagon bolts M20x55 ISO 4017 (4) after 100 operating hours.

-- Easy removal and installation with optimum repeatability of the installation position.
-- Considerable differences in level of the foundation can be bridged.
Accessory: ”mounting base kit”

Center A 1 front
4

1 5

Fig. 7 Intermediate plate for variant 3

(1) Place intermediate plate (Fig. 7/1) onto foundation in accordance with the intended installa-
tion position of the robot.

NOTE The position of the locating pins in relation to the working envelope is important:
Looking forwards (5) from the robot towards the working envelope -- the robot arm points
in this direction when A1 is in its zero position --, then the sword pin (6) must be on the
right and the round pin (2) on the left.

10 Ro/Me/03/13 en 07.97.01
 510.9

534.3

Center A 1 front
364

332
18

174 228
232

^ 2

Fig. 8 Robot installation, variant 3

(2) Drill three dowel holes (Fig. 9/1) in accordance with Figure 8 or through the boreholes of the
intermediate plate; minimum depth in concrete 190 mm.
(3) Prepare undercuts (Fig. 9/3) with special tool in accordance with appropriate work instruc-
tions.
(4) Insert compression springs (2).
(5) Insert three undercut dowels (4).
(6) Align intermediate plate (7) horizontally by means of shims (8).
(7) Screw on hexagon nuts (5) together with washers and tighten hexagon nuts with torque
wrench in diagonally opposite sequence, increasing the tightening torque MA to the specified
value in several stages (MA = 115 Nm or 135 Nm).

NOTE The tightening torque for the hexagon nuts is 115 Nm for initial installation (with the plas-
tic dowel ring) or 135 Nm with subsequent installation (without the plastic dowel ring).

CAUTION! When tightening the hexagon nuts (5), the intermediate plate must not be dis-
torted; if necessary, it must be re--aligned with shims. The test dimension (6) of 8
± 3 mm for checking the undercut dowels must be reached.

07.97.01 Ro/Me/03/13 en 11
 5

6 T
e
s
t
d
i- 7
4 m
e 8
n-

143
s

190
i

250
o
3 n
8
2 ¦
3

1.5
1

Fig. 9 Dowel boreholes for variant 3

The robot is now ready to be installed in accordance with Section 4.1.

12 Ro/Me/03/13 en 07.97.01
3.4 Wall--mounting variant
The robot is preferably placed on a hinged steel base (Fig. 10/2), provided by the customer,
and fastened by three hexagon bolts (1). Its installation position, as with the other mounting
positions, is determined by two locating pins, enabling it to be exchanged in a repeatable
manner. The robot is moved into its working position by swivelling and securing the steel
base.
The installation of the robot may vary: The hinged steel base for the robot is either mounted
on a shelf (Fig. 10, left) or directly onto the wall (right).

2
1

on shelf on wall

1 Hexagon bolt 3x
2 Hinged steel base
(provided by the customer)

Fig. 10 Wall installation of the robot using a hinged steel base

07.97.01 Ro/Me/03/13 en 13
4 INSTALLING AND CONNECTING THE ROBOT
4.1 Floor--mounted robots

Section 1 of this Doc. Module is to be observed.

This description only applies to robots with mounting variant 2 (Section 3.2) or 3 (Section 3.3).
The procedure for installing the robot (whether for the first time or as an exchange) is as follows:
(1) Check that both locating pins (Fig. 11/2) and their fastening screws (1) are undamaged and
fitted securely.

CAUTION! Damaged locating pins must be replaced by new ones.

1
2

Fig. 11 Locating pins

The robot must be in the transport position (Fig. 12)*.

A1 A2 A3 A4 A5 A6

L 0° ---55° +70° 0° +90° any

* Angle specifications
refer to the
mechanical zero of
the axis concerned.

Dimension L for KR 6/2:

980 mm

for KR 15/2: 980 mm

1313

Fig. 12 Transport position, floor--mounted robot

14 Ro/Me/03/13 en 07.97.01
 (2) Raise robot with fork lift truck or lifting tackle attached to three apertures on the rotating col-
umn.

For reasons of safety, it is imperative for the lifting tackle to be attached to the ro-
bot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module ”Repair, General” must be ob-
served.

(3) Lower robot (Fig. 13/3) vertically onto intermediate plate (5) or steel structure. If lifting tackle
is used, particular care must be taken to ensure exact vertical positioning in order to avoid
damaging the locating pins or the dowels during this operation.

CAUTION! As the robot is lowered, the boreholes (2) must be aligned as accurately as pos-
sible with the two locating pins (1). If this operation is carried out inaccurately, it
is more likely that parts will be damaged.

(4) Insert three M20x55 ISO 4017 hexagon bolts (4) 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 = 370 Nm).

CAUTION! Retorque three hexagon bolts M20x55 ISO 4017 (4) after 100 operating hours.

3
4

1
5

Fig. 13 Installing the robot on the floor

07.97.01 Ro/Me/03/13 en 15
 NOTE The robot is fastened with three hexagon nuts and lock washers in the case of mounting
variant 1 (391.816--08.003); the tightening torque is 135 Nm for subsequent installation
without the plastic ring of the dowels.

(5) Remove lifting tackle.

(6) Connect ground conductor and connecting cables.

Before performing the next step, it must be ensured that it is not possible for any-
one to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed with all applicable
safety rules and regulations being observed.

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

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.
1
0

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

(9) Connect all other cables which have been removed.
(10) Put robot into operation.

16 Ro/Me/03/13 en 07.97.01
4.2 Ceiling--mounted robot

Section 1 of this Doc. Module is to be observed.

This description only applies to robots with mounting variant 2 (Section 3.2).
For installation on the ceiling, the robot can be picked up off the floor by means of a fork lift
truck and turnover fixture (accessory), turned into the ceiling--mounting orientation and
brought to the site of installation (Fig. 14).

Fig. 14 Transporting the robot for mounting on the ceiling

The procedure for mounting the robot on the ceiling (whether for the first time or as an ex-
change) is as follows:
(1) Check that both locating pins (Fig. 15/1) and their fastening screws (2) are undamaged and
fitted securely.

CAUTION! Damaged locating pins must be replaced by new ones.

Fig. 15 Locating pins

07.97.01 Ro/Me/03/13 en 17
 The robot must be in the transport position (Fig. 16)*.

A1 A2 A3 A4 A5 A6
0° ---55° +70° 0° +90° any

* Angle specifications
refer to the
mechanical zero of
the axis concerned.

Dimension L for KR 6/2:

1313

980 mm

for KR 15/2: 980 mm

Fig. 16 Transport position, ceiling--mounted robot

(2) Grasp robot securely by means of fork lift truck and turnover fixture, and turn it into ceiling--
mounting orientation (base frame at top, arm at bottom).
(3) Raise the robot (Fig. 17/1) vertically and place it onto the ceiling structure (3).

CAUTION! As the robot is lifted, the boreholes (5) must be aligned as accurately as possible
with the two locating pins (4). If this operation is carried out inaccurately, it is
more likely that parts will be damaged.

As soon as the robot is in its exact position on the ceiling, it must be pressed
firmly against the ceiling until it is finally bolted to it.

18 Ro/Me/03/13 en 07.97.01
 Fig. 17 Installing the robot on the ceiling
(4) Insert three
3 M20x55 ISO 4017 hexagon bolts (2) together with lock washers and tighten them
with a torque wrench in diagonally opposite sequence, increasing
4 the tightening torque to the
specified value in several stages (MA = 370 Nm).

5 100 operating hours.

CAUTION! Retorque three hexagon bolts M20x55 ISO 4017 (2) after

(5) Remove fork lift truck and turnover fixture.

2
(6) Connect ground conductor and connecting cables.
1

Before performing the next step, it must be ensured that it is not possible for any-
one to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed with all applicable
safety rules and regulations being observed.

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

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.
1
0

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

(9) Connect all other cables which have been removed.
(10) Put robot into operation.

07.97.01 Ro/Me/03/13 en 19
4.3 Wall--mounted robots

Section 1 of this Doc. Module is to be observed!

The procedure for mounting the robot on the wall (whether for the first time or as an ex-
change) is as follows:
D Wall--mounted robots on a shelf

The robot must be transported in its transport position (Fig. 18)* to the point from
where it can be raised by the crane for the purpose of installation.

(1) Check that both locating pins (Fig. 11/2) and their fastening screws (1) are undamaged and
fitted securely.

CAUTION! Damaged locating pins must be replaced by new ones.

A1 A2 A3 A4 A5 A6
0° ---55° +70° 0° +90° any

L
* Angle specifications
refer to the
mechanical zero of
the axis concerned.

Dimension L for KR 6/2:

980 mm

for KR 15/2: 980 mm

1313

Fig. 18 Transport position, wall--mounted robot

20 Ro/Me/03/13 en 07.97.01
 (2) Raise robot with lifting tackle attached to three apertures on the rotating column.

For reasons of safety, it is imperative for the lifting tackle to be attached to the ro-
bot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module ”Repair, General” must be ob-
served.

(3) Lower robot (Fig. 19/3) vertically onto the horizontally (05) positioned hinged steel base (5).
If lifting tackle is used, particular care must be taken to ensure exact vertical positioning in
order to avoid damaging the locating pins during this operation.

CAUTION! As the robot is lowered, the boreholes (2) must be aligned as accurately as pos-
sible with the two locating pins (1). If this operation is carried out inaccurately, it
is more likely that parts will be damaged.

Fig. 19 Installing the robot on a hinged steel base (on shelf)

07.97.01 Ro/Me/03/13 en 21
 (4) Insert three M20x55 ISO 4017 hexagon bolts (4) 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 = 370 Nm).

CAUTION! Retorque three hexagon bolts M20x55 ISO 4017 (4) after 100 operating hours.

(5) Remove lifting tackle.

(6) Move hinged steel base from 0° to 90° position (Fig. 20, right) and lock it.

The manufacturer’s specifications with regard to handling and safety must be ob-
served!
The hinged steel base is not part of the KUKA contract.

1 Hinged steel base

Fig. 20 Installing a wall--mounted robot on a shelf

(7) Connect ground conductor and connecting cables.

Before performing the next step, it must be ensured that it is not possible for any-
one to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed with all applicable
safety rules and regulations being observed.

(8) Put robot into operation and move it into a suitable position to install end--effector (tool) and
additional equipment.

22 Ro/Me/03/13 en 07.97.01
 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.

1
0

o
(9) Install end--effector (tool) and additional equipment.
(10) Connect all other cables which have been removed.
(11) Put robot into operation.
D Wall--mounted robots on wall (not on a shelf)
(1) Check that both locating pins (Fig. 11/2) and their fastening screws (1) are undamaged and
fitted securely.

CAUTION! Damaged locating pins must be replaced by new ones.

07.97.01 Ro/Me/03/13 en 23
 The robot must be in the transport position (Fig. 21)*.

A1 A2 A3 A4 A5 A6
0° ---15° +58° 0° +90° any
L
* Angle specifications
refer to the
mechanical zero of
the axis concerned.

Dimension L for KR 6/2:

980 mm

for KR 15/2: 980 mm

1313

Fig. 21 Transport position, wall--mounted robot

(2) Raise robot with lifting tackle attached to three apertures on the rotating column.

For reasons of safety, it is imperative for the lifting tackle to be attached to the ro-
bot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module ”Repair, General” must be ob-
served.

(3) Lower robot (Fig. 22/3) vertically onto the horizontally positioned hinged steel base (5). If lift-
ing tackle is used, particular care must be taken to ensure exact vertical positioning in order
to avoid damaging the locating pins during this operation.

The hinged steel base must be locked in the horizontal position (0° ) in accordance
with the manufacturer’s specifications.

24 Ro/Me/03/13 en 07.97.01
 CAUTION! As the robot is lowered, the boreholes (2) must be aligned as accurately as pos-
sible with the two locating pins (1). If this operation is carried out inaccurately, it
is more likely that parts will be damaged.

1
5

Fig. 22 Installing the robot on a hinged steel base (on wall)

(4) Insert three M20x55 ISO 4017 hexagon bolts (4) 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 = 370 Nm).

CAUTION! Retorque three hexagon bolts M20x55 ISO 4017 (4) after 100 operating hours.

(5) Remove lifting tackle.

(6) Move hinged steel base from 90° to 0° position (Fig. 23, right) and lock it.

The manufacturer’s specifications with regard to handling and safety must be ob-
served!
The hinged steel base is not part of the KUKA contract.

07.97.01 Ro/Me/03/13 en 25
 1

1 Hinged steel base

Fig. 23 Installing a wall--mounted robot on a wall (not on a shelf)

(7) Connect ground conductor and connecting cables.

Before performing the next step, it must be ensured that it is not possible for any-
one to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed with all applicable
safety rules and regulations being observed.

(8) Put robot into operation and move it into a suitable position to install end--effector (tool) and
additional equipment.

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.
1
0

(9) Install end--effector (tool) and additional equipment.

(10) Connect all other cables which have been removed.
(11) Put robot into operation.

26 Ro/Me/03/13 en 07.97.01
5 EXCHANGE
To avoid the need for any major reprogramming after an exchange, the instructions given in the robot
Doc. Module ”Robot Mastering/Unmastering”must be accurately carried out every time a robot is ex-
changed.

5.1 Exchanging floor--mounted robots

D REMOVAL

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.
1
0

(1) Remove end--effector (tool) and additional equipment.

NOTE The end--effector and additional equipment have to be removed if the robot is to be re-
placed by another one or if they would otherwise impede the exchange work.

If the end--effector and additional equipment remain on the robot, this is liable to
lead to adverse centers of gravity and collisions. The operator is deemed respon-
sible for any damage resulting in this respect.

Before performing the next step, it must be ensured that it is not possible for any-
one to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed, with all applicable
safety rules and regulations being observed.

07.97.01 Ro/Me/03/13 en 27
 (2) Put robot into operation and move it into transport position (Fig. 24)*.

A1 A2 A3 A4 A5 A6
0° ---55° +70° 0° +90° any
L
* Angle specifications
refer to the
mechanical zero of
the axis concerned.

Dimension L for KR 6/2:

980 mm

for KR 15/2: 980 mm

1313

Fig. 24 Transport position for floor--mounted robots

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.
1
0

(3) Release and disconnect all plugs from the junction boxes (Fig. 25/3, 4).
(4) Remove electric cables and hose lines from both interfaces of energy supply system A 1 and
all other peripheral supply lines to the robot, where necessary.

Depressurize and drain hose lines beforehand.

(5) Unscrew hexagon nut (2) together with washers and lock washers and pull off ground con-
ductor (1).
(6) Remove three M20x55 hexagon bolts (5) (for mounting variant 1 three hexagon nuts) to-
gether with lock washers.
(7) Lift robot with lifting tackle attached to three apertures on the rotating column.

28 Ro/Me/03/13 en 07.97.01
 For reasons of safety, it is imperative for the lifting tackle to be attached to the ro-
bot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module ”Repair, General” must be ob-
served.

4
3
2 5
1

Fig. 25 Removal of floor--mounted robot

CAUTION! The robot must be lifted as vertically as possible until the locating pins are free.

(8) Lower robot onto a suitable support.

NOTE If the robot is not to be reinstalled for some time, it must be protected against corrosion
before being put into storage.

D INSTALLATION
See Section 4.1.

07.97.01 Ro/Me/03/13 en 29
5.2 Exchanging ceiling--mounted robots
D REMOVAL

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.

1
0

(1) Remove end--effector (tool) and additional equipment.

NOTE The end--effector and additional equipment have to be removed if the robot is to be re-
placed by another one or if they would otherwise impede the exchange work.

If the end--effector and additional equipment remain on the robot, this is liable to
lead to adverse centers of gravity and collisions. The operator is deemed respon-
sible for any damage resulting in this respect.

Before performing the next step, it must be ensured that it is not possible for any-
one to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed, with all applicable
safety rules and regulations being observed.

30 Ro/Me/03/13 en 07.97.01
 (2) Put robot into operation and move it into transport position (Fig. 26)*.

A1 A2 A3 A4 A5 A6
0° ---55° +70° 0° +90° any

* Angle specifications
refer to the
mechanical zero of
the axis concerned.

Dimension L for KR 6/2:

1313 980 mm

for KR 15/2: 980 mm

Fig. 26 Transport position for ceiling--mounted robots

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.
1
0

(3) Release and disconnect all plugs from the junction boxes (Fig. 27/4, 5).
(4) Remove electric cables and hose lines from both interfaces of energy supply system A 1 and
all other peripheral supply lines to the robot, where necessary.

CAUTION! Depressurize and drain hose lines beforehand.

(5) Unscrew hexagon nut (3) together with washers and lock washers and pull off ground con-
ductor (2).
(6) Grasp robot securely by means of fork lift truck and turnover fixture, and press robot firmly
against the ceiling (6).

07.97.01 Ro/Me/03/13 en 31
 2
1 3
4
5

Fig. 27 Removal of ceiling--mounted robot

(7) Remove three M20x55 hexagon bolts (1) together with lock washers.
(8) Lower robot slowly without tilting it.

CAUTION! The robot must be lowered vertically downwards until both locating pins are free.

(9) Turn robot over into the normal orientation (base frame at bottom, arm at top), lower it onto
a suitable support and remove turnover fixture.

NOTE If the robot is not to be reinstalled for some time, it must be protected against corrosion
before being put into storage.

D INSTALLATION
See Section 4.2.

32 Ro/Me/03/13 en 07.97.01
5.3 Exchanging wall--mounted robots
D REMOVAL

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.

1
0

(1) Remove end--effector (tool) and additional equipment.

NOTE The end--effector and additional equipment have to be removed if the robot is to be re-
placed by another one or if they would otherwise impede the exchange work.

If the end--effector and additional equipment remain on the robot, this is liable to
lead to adverse centers of gravity and collisions. The operator is deemed respon-
sible for any damage resulting in this respect.

Before performing the next step, it must be ensured that it is not possible for any-
one to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed with all applicable
safety rules and regulations being observed.

(2) Put robot into operation and move it into transport position (Fig. 28)*.

A1 A2 A3 A4 A5 A6
0° ---55° +70° 0° +90° any
L
* Angle specifications
refer to the
mechanical zero of
the axis concerned.

Dimension L for KR 6/2:

980 mm

for KR 15/2: 980 mm

1313

Fig. 28 Transport position for wall--mounted robots

07.97.01 Ro/Me/03/13 en 33
 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.

1
0

o
(3) Release and disconnect all plugs from the junction boxes (Fig. 29/3, 4).
(4) Remove electric cables and hose lines from both interfaces of energy supply system A 1 and
all other peripheral supply lines to the robot, where necessary.

CAUTION! Depressurize and drain hose lines beforehand.

(5) Unscrew hexagon nut (2) together with washers and lock washers and pull off ground con-
ductor (1).

1 2 3 4

Fig. 29 Removal of wall--mounted robot

34 Ro/Me/03/13 en 07.97.01
 1

1 Hinged steel base

Fig. 30 Removal of wall--mounted robot on a wall

(6) Move hinged steel base (Fig. 30/1 and 31/1) from 90° to 0° position and lock it.

The manufacturer’s specifications with regard to handling and safety must be ob-
served!
The hinged steel base is not part of the KUKA contract.

1 Hinged steel base

Fig. 31 Removal of wall--mounted robot on a shelf

(7) Remove three M20x55 hexagon bolts (Fig. 29/5) and lock washers.

07.97.01 Ro/Me/03/13 en 35
 (8) Lift robot with lifting tackle attached to three apertures on the rotating column.

For reasons of safety, it is imperative for the lifting tackle to be attached to the ro-
bot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module ”Repair, General” must be ob-
served.

CAUTION! The robot must be lifted as vertically as possible until the locating pins are free.

(9) Lower robot onto a suitable support.

NOTE If the robot is not to be reinstalled for some time, it must be protected against corrosion
before being put into storage.

D INSTALLATION
See Section 4.3.

36 Ro/Me/03/13 en 07.97.01