KR30 Repai Elec Inst

ROBOT
(V)KR 30, 60 HA; (V)KR 30, 60--3
Repair
Electrical Installations
Issued: 13 May 2004 Version: 00

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e Copyright 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.
PD Interleaf
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Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Removal of cable set assembly (00--117--709) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Installation of cable set assembly (00--117--709) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Removal/installation of motor cable A 1 (XM1) (00--117--703) . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Removal/installation of motor cable A 2 (XM2) (00--117--704) . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Removal/installation of control cable A 1 (XP1) (00--117--697) . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Removal/installation of control cable A 2 (XP2) (00--117--698) . . . . . . . . . . . . . . . . . . . . . . . . 25
2.7 Removal/installation of motor and control cables A 3 to A 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.8 Removal/installation of data cable connection X31--X9 (00--107--132) . . . . . . . . . . . . . . . . . 26
2.9 Removal/installation of mastering cable connection X32--X10 (00--106--299) . . . . . . . . . . . 26
2.10 Removal/installation of flexible tube A 1 (00--106--141) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.11 Removal/installation of flexible tube A 2/A 3 (PURRB--42M) (00--118--469) . . . . . . . . . . . . . 28
3 Safety precautions when handling lubricants . . . . . . . . . . . . . . . . . . . . . . 30
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1 General
Valid for (V)KR 30HA (V)KR 30--3

(V)KR 60 HA (V)KR 60--3
(V)KR 60 L45 HA (V)KR 60 L45--3
(V)KR 60 L30 HA (V)KR 60 L30--3
1 General
The electrical installations of the robot comprise the “cable set” (see also robot Doc. Module
“Description, Electrical Installations”). This can be exchanged without dismantling major
robot parts. If it is necessary for subassemblies, such as cables and flexible tubes, to be
exchanged, it is usually advantageous to replace the complete cable set assembly. It is
recommended therefore that a spare cable set be kept in reserve. A defective subassembly
can then be replaced on the workbench with the cable set fully extended in a straight line.
The Doc. Module “Safety, General” and the robot Doc. Module “Repair, General”
are to be observed!
Regardless of its normal installation position, the robot must be brought into the
floor position for all extensive repairs to the cable set, (see robot Doc. Module
“Installation, Connection, Exchange”) and must be screwed down so that it will
not tilt under any circumstances.
Before repair work is started, any attached tools or additional equipment that would hinder
repair must be dismounted.
All periphery cables leading to the robot (e.g. for the tool or collision protection device) or the
cables for robot accessories (e.g. working range monitoring) must also be unplugged at the
robot.
After the installation process has been concluded, all these cables and supply
lines must be correctly reconnected to the robot.
If the main switch on the control cabinet has been switched to “OFF” for performing repair
work, the connecting cables between the robot and the control cabinet must be disconnected
at the robot immediately afterwards. They must then be correctly reconnected before the
robot is put into operation again.
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 Section 3 of this Doc. Module must be
observed.
Only KUKA--approved cable grease may be used.
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.
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2 Repair work
The descriptions of the repair jobs can be quickly located by referring to the following table.
D Table of repair jobs

Repair Cable from to Section Page
Removal of cable set 00--117--709 2.1 7
assembly
Installation of cable set 00--117--709 2.2 11
assembly
Removal/installation of 00--117--703 Connector X30/a XM1 2.3 18
motor cable A 1
Removal/installation of 00--117--704 Connector X30/b XM2 2.4 21
motor cable A 2
Removal/installation of 00--117--697 Connector X1 XP1 2.5 21
control cable A 1
Removal/installation of 00--117--698 Connector X2 XP2 2.6 25
control cable A 2
Removal/installation of 00--117--705 Connector X30/c XM3 2.7 25
motor cable A 3
Removal/installation of 00--117--706 Connector X30/d XM4 25
motor cable A 4
Removal/installation of 00--117--707 Connector X30/e XM5 25
motor cable A 5
Removal/installation of 00--117--708 Connector X30/f XM6 25
motor cable A 6
Removal/installation of 00--122--996 Connector X3 XP3--L 25
control cable A 3
Removal/installation of 00--117--700 Connector X4 XP4 25
control cable A 4
control cable A 5
control cable A 6
Removal/installation of 00--107--132 Connector X31 X9 2.8 26

data cable connection
Removal/installation of 00--106--299 Connector X32 X10 2.9 26
adjustment cable con-
nection
Removal/installation of 00--106--141 Base frame Rotating 2.10 27
flexible tube A 1 PUR--VB--52G column
Flexible tube A 2/ 00--118--469 Rotating column Arm 2.11 28
Removal/installation PURRB--42M
A3
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2 Repair work (continued)
2.1 Removal of cable set assembly (00--117--709)
Section 1 of this Doc. Module is to be observed!
(1) Move robot into its dismantling position (Fig. 1): axis 1 approx. 45° in (--) direction.
approx. 45˚
Fig. 1 Moving robot into the dismantling position
Doing this ensures that the tube clamp (Fig. 2/21) for flexible tube A 1 (22) and the cable clip
(12) for strain relief of the cables are readily accessible.
Turn main switch on the robot control cabinet to “OFF” and secure it with a
padlock to prevent unauthorized persons from switching it on again.
Continue with step (2).
If the robot is no longer operable and the clamps cannot be accessed, then the following
alternative procedure is possible:
(1.1) Remove motor A 1.

(1.2) Turn robot about rotational axis 1 until the dismantling position is reached.
Continue with step (2).
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The following applies for any further dismantling:
(2) Disconnect connecting cables X30 and X31 on the robot and connectors XM.. and XP..
on all motors.
(3) Individually pack all connectors XM.. and XP.. due to risk of fouling (e.g. by means of
well--secured plastic bags).
(4) Remove covers (Fig. 2):
Cover, axis 1 (17)
Periphery cover, connector panel (3)
Periphery cover, rotating column (6, 8, 18)
The cover (17) is pretensioned. Great care must therefore be taken to avoid
injuries when taking it off.
Protective gloves are to be worn due to cable grease on the inside of the cover!
observed when using cable grease.
(5) Remove all clips for cables and flexible tubes (Fig. 2):
Tube clamp, axis 1, bottom (1)
Tube clamp, axis 1, top (12)
Tube clamp, axis 1, top (15)
Tube clamps, axis 2 (14, 16)
Tube clamps, axis 3 (8, 13)
Cable clip on arm (19)
(6) Disconnect ground conductors from the respective PE bolts (Fig. 2 and Fig. 3):
Ground conductor connection, base frame (Fig. 2/2)
Ground conductor connections, rotating column (21)
Ground conductor connection, arm (19)
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20 11
19
18 21
12
22 4
10
1
7
13
23
8
14
24
15
8
6 16
2
3
5 17
Fig. 2 Covers, clips, clamps and ground conductor bolts
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PE bolt
M8x30 stud
M8 nut mech. galv. DIN 913
VS8 washer
8.4 washer
M8 nut Cable lug
VS8 washer
Ground plate
Robot
Fig. 3 Ground conductor connection
(7) Remove push--in module (10) with two junction boxes (4, 5). The push--in module is an
integral part of the cable set assembly.
(8) Wipe cable grease off flexible tube A 1 (22) using a cloth.
Protective gloves must be worn!

(9) Fix flexible tube A 1 with adhesive tape at both ends to prevent it from moving and thus
fouling the non--greased parts of the cable set with grease.
(10) Secure flexible tube A 2/A 3 (23) at both ends with adhesive tape in the same way.
(11) Remove cables with connectors XP1, XP2 and XM1, XM2. To do so:
(11.1) Remove cable straps.
When the installation process has been completed for the new cable set, all cable
straps removed for dismantling must be replaced with new ones.
Not all cable straps to be attached are mentioned, however, at the installation stage.
It is therefore recommended that a note is made of where cable straps are removed.
(11.2) Pull cables out through the apertures in the rotating column (24).
The sequence when pulling them out is XP1, XP2, XM1, XM2.
(11.3) Bundle all four cables together with adhesive tape.

(12) Remove cables with connectors XP3 to XP6 and XM3 to XM6. To do so:
(12.1) Bundle cables together with adhesive tape and push them downwards through the link
arm together with flexible tube A 2/A 3 (23).
(13) Lay the detached cable set down next to the robot together with flexible tube A 1 (22).

(14) Take hold of push--in module (10) and carefully pull it out with the rest of the cable set.
(15) Lay the complete cable set down, fully extended, on a clean support surface.
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2.2 Installation of cable set assembly (00--117--709)
Before the installation is started, turn main switch on the control cabinet to
“OFF” and secure it with a padlock to prevent unauthorized persons from
switching it on again.
The cables in the flexible tubes of the cable set to be installed are already pre--greased, if
a genuine KUKA cable set is used. The flexible tubes are fastened with adhesive tape at both
ends. This prevents the tube from shifting and the grease from spreading to the exposed
parts of the cable set.
Before the new cable set assembly is installed, the greased surfaces of the robot
must be cleaned of old grease.
(1) Wipe greased surfaces on the base frame free of old cable grease, including the inside
of cover A 1 (Fig. 4).

Lay new cable set, fully extended, onto a clean support surface.
Contact surfaces
between flexible tube A 1
and base frame
2
1
Fig. 4 Cleaning contact surfaces on the base frame
(2) Check the white marks on the flexible tubes (Fig. 5/9, 10, 15, 18, 21) and on the cables
at (22, 25).
If necessary, pull cables further so that all the white marks are at the same level. The
cable straps (24) must be removed to allow for this.
After the white marks have been aligned correctly, new cable straps must be
fitted.
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PE 22 21 20 19 21
XP3 -- XP6
XM3 -- XM6
18
24 23 17
18
15
8 16
15
14
9 10
2x PE
25
13
11 12
3x PE 6 5
4 2
26
PE bolt
Fig. 5 Cable set assembly in installed position
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(3) Install cable set in base frame (Fig. 6). To do so:

(3.1) Insert push--in module (2) with junction boxes carefully into the base frame (6).
-- Lay the cable set down, fully extended, next to the robot.
-- Fasten push--in module (2) to base frame (6) with fastening screws (1).
(3.2) Fasten flexible tube A 1 (4) to push--in module (2) with tube clamp (not in the case of
a new cable set).
5
4
3
2
6 1
Fig. 6 Attaching flexible tube A 1 to the base frame
(4) Install flexible tube A 2/A 3 (Fig. 5/14). To do so:

(4.1) Pull cable set with connectors XM3 to XM6, XP3 to XP6 and ground conductor in
through the link arm and arm from below.
(4.2) Fit tube clamp (19) on flexible tube A 2/A 3 (14) (check that the tube is aligned correctly
at (20)) and fasten it to the arm together with flexible tube A 2/A 3 (see also Fig. 2/13).
The mark (Fig. 5/22) must be flush with end of tube.
(4.3) With hinged clamp (8,14), screw flexible tube A 2/A 3 (Fig. 2/23) to the link arm.
The marks (Fig. 5/9, 10, 15, 18, 21) must be visible on either side of the clamps.
Grease flexible tube with cable grease in the vicinity of the tube clamps. With
hinged clamps (15, 16), screw flexible tube A 2/A 3 (23) to the rotating column.
Protector (Fig. 5/13) must be positioned correctly.

(5) Install flexible tube A 1

Once the tube clamp is fastened to the rotating column (Fig. 5/11), a check must be
made to ensure that mark (25) is correctly positioned and that the clamping piece (6)
is firmly in place in the flexible tube.
(6) Install the cover of the rotating column (Fig. 2/6).
The cables must lie in parallel arrangement in the rotating column.
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(7) Take hold of cable bundle and turn it in a tight curve down to the RSGU clamp (Fig. 5/5)
(see also Fig. 2/12). Observe white mark!
Cables must not be in contact with the metal plate. Bundle tightly together with
cable straps (7).
(8) Insert tube in RSGU clamp (5) and tighten. Check that the flexible tube and clamping
piece are held firmly in place.
If the cables are not installed correctly there is a risk of them being damaged at
the point where they pass from the base frame to the rotating column.
(9) Install cable set on arm. To do so:

(9.1) Align white marks (Fig. 5/22) for all cables.
Shift the cables so that all the white marks are next to each other and are visible at the
upper end of flexible tube A 2/A 3 (14).
(9.2) Run cables XP3 to XP6 and XM3 to XM6 in a tight curve to cable clip (23).
(9.3) Fasten cables and secure them with cable straps (24).
(9.4) Braided sleeve must be flush with end of tube.
Cables must not be trapped or pinched.
(10) Install cables XM1, XM2 and XP1, XP2. To do so:

(10.1) Route cables XM1, XM2 and XP1, XP2 through the aperture (Fig. 2/24) in the rotating
column to the axis 1 motor.
(10.2) Plug connectors XM1, XM2 and XP1, XP2 into axis 1 and axis 2 motors respectively.
(10.3) Bundle cables XM2 and XP2 leading from axis 2 motor with cable strap and push re-
maining lengths back into rotating column housing.
(10.4) Bundle cables XM1, XM2 and XP1, XP2 on the rotating column housing with cable
strap (Fig. 5/8).
Motor and control cables A 1 and A 2 must be routed close to the rotating
column and must not be in contact with the metal plate. Bundle tightly together
with cable straps (7).
Protective gloves are to be worn if there is any residual cable grease on flexible
tube A 1.
(11) Arrange the cable bundle in a gentle curve between the junction boxes (3, 4) and the
tube clamp (1).
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The cables must not be subjected to any tensile forces. Cable straps are not
permitted in this area.
(12) Make four ground conductor connections. To do so:

(12.1) Connect push--in module ground conductor to the base frame at (Fig. 7/1).
(12.2) Connect push--in module ground conductor to the rotating column (2).
(12.3) Connect rotating column/arm ground conductor to the rotating column (2).
(12.4) Connect rotating column/arm ground conductor to the arm (3).
All ground conductor connecting elements, including the PE bolts and the
corresponding tapped holes in the robot, must be free from grease and paint.
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PE bolt
M8 nut M8x30 stud
VS8 washer mech. galv. DIN 913
8.4 washer
M8 nut Cable lug
VS8 washer
Ground plate
Robot
Ground conductor connection, sectional view
Fig. 7 Ground conductor connections
(13) Plug connectors XM3 to XM6 and XP3 to XP6 into the motors of axes 3 to 6.
(14) Align cables and secure them with cable straps (Fig. 8).
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Axis 6 Axis 5
Axis 3
Axis 4
Fig. 8 Arrangement of motors on the arm
(15) Grease the exterior of flexible tube A 1 in the base frame with a coating of cable grease
at least 2 mm thick.

(16) Grease all flexible tube contact surfaces in the base frame that have already been wiped
clean of old cable grease, including the inside of cover A 1, with a coating of cable
grease at least 2 mm thick (Fig. 9).
Contact surfaces
between flexible tube A 1
and base frame
Fig. 9 Cleaning contact surfaces on the base frame
(17) Attach covers (see Section 2.1) and tighten fastening screws.
(18) Carry out tests.
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When the robot electrical installations (cable set) are completely installed in the
robot, the following tests must be carried out:
-- Continuity test of the protective circuit according to
DIN EN 60204--1/20.2
-- Insulation test according to DIN EN 60204--1/20.3
-- Voltage test according to DIN EN 60204--1/20.4
(19) Check the routing of flexible tube A 2/A 3 (Fig. 5/14) as follows:
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 rotating arm.
The robot may only be moved at jog speed, with all applicable safety rules and
regulations being observed.
(20) Put robot into operation and move axis 3. In the process, check whether the required
minimum distance between flexible tube A 2/A 3 and the link arm has been maintained.
The minimum distance is 10 mm.
2.3 Removal/installation of motor cable A 1 (XM1) (00--117--703)
D REMOVAL
(1) Move robot into its dismantling position.
See Section 2.1 of this Doc. Module, steps 1 to 1.2.
Before starting removal and installation, turn main switch on the control cabinet
to “OFF” and secure it with a padlock to prevent unauthorized persons from
(2) Unplug connecting cables X30 and X31 from the robot, if they are still connected.
(3) Remove covers (Fig. 2/3, 6, 8, 17, 18).
(4) Unplug cable XM1 from the motor and loosen cable straps.
(5) Remove cable clip (Fig. 2/12) and tube clamp (Fig. 2/15).
(6) Push cable XM1 back through the aperture (Fig. 2/24).
-- Unscrew ground conductor from PE bolt (Fig. 2/21).
-- Unscrew push--in module (Fig. 10/4).
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(7) Open junction box X01 (Fig. 10/5) and remove it.
(8) Open cable gland (1) on the rear panel of the junction box (5) (unscrew the union nut
only).
(9) Press the sealing insert (3) out towards the rear.
(10) Eject module “a” on Harting connector X30 (6).
Use special Harting tool.
(11) Disconnect ground conductor from cable XM1 at the PE rail and remove cable from the
junction box (5).
6
X30
a XM1 X01
b XM2 1
c XM3
d XM4
e XM5 2
f XM6
A1
A2
A3 3
4 5
Fig. 10 Removing motor cable A 1 (XM1)
The sealing insert (3) is provided with slits towards the outside. The cable can be taken
out of the sealing insert through the appropriate slit.
(12) Pull module X30/a out of the junction box (5) through the aperture in the cable gland.
D INSTALLATION
(1) Cut off circular connector XM1 from the old cable XM1 and use this cable as a pull--in
wire for the new cable XM1.
The new cable XM1 is already cut to length and terminated.
(2) Attach pull--in wire to the new connector module X30/a with adhesive tape.
The new connector module X30/a must be fully protected with adhesive tape
from being fouled by cable grease.
(3) Apply cable grease to the new cable XM1 and push it into flexible tube A 1 (Fig. 5/26),
while carefully pulling on the old cable XM1 at the same time.
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When pulling in the cable, its mark must be located at the aperture of the flexible
tube in the rotating column. Insert cable XM1 into the clamping piece and check
that it is securely seated. Cables in this area must be kept free of grease.
(4) Screw on cable clip (Fig. 5/5) and bundle cables together using cable strap (the same
arrangement as before removal).
(5) Tighten tube clamp (11).
(6) Connect new cable XM1 to the motor.
If necessary, apply a coating of cable grease at least 2 mm thick to the inside of

the cover (17).

(7) Feed connector module X30/a through the union nut of the cable gland at (Fig. 10/1)
and push cable XM1 into the slit sealing insert (3).
The slit on the sealing insert must be widened for this purpose.
The cable jacket must end flush with the sealing insert.
(8) Pull shield outwards over the sealing insert (3).

(9) Push sealing insert (3) into the aperture of the cable gland at (1).
The shield must be clamped between the cable gland and the sealing insert.
(10) Tighten the union nut of the cable gland so that all the cables are properly fastened.
(11) Screw junction box X01 (5) to the push--in module.
(12) Snap connector module X30/a into the mounting frame (6) from the inside.
(13) Connect the ground conductor of cable XM1 to the PE rail, ensuring that the screw is
properly tightened.
(14) Close junction box X01.
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Carefully insert push--in module (Fig. 2/10) into rotating column and tighten
fastening screws.
Screw ground conductor to PE bolt (21).
(15) Attach covers (Fig. 2/3, 6, 8, 17, 18) and tighten fastening screws.
(16) Carry out tests.
DIN EN 60204--1/20.2
2.4 Removal/installation of motor cable A 2 (XM2) (00--117--704)

Proceed in the same manner as for motor cable A 1 (XM1) (see Section 2.3).
2.5 Removal/installation of control cable A 1 (XP1) (00--117--697)
D REMOVAL
(2) Unplug connecting cables X30 and X31 from the robot, if they are still connected.
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7 8 9 10
1
6 4 5 3
Fig. 11 Removing control cable A 1 (XP1)
(3) Remove covers (Fig. 11/6, 8, 9).

-- Unscrew ground conductor from PE bolt (10).
-- Unscrew push--in module (4) (for greater accessibility) and pull it out.
(4) Unplug cable XP1 from the motor and remove cable straps.
(5) Remove cable clip (Fig. 5/5) and tube clamp (11).
(6) Open junction box X02 (Fig. 11/1) and remove it.
(7) Open cable gland (2) on the rear panel of the junction box (1) (unscrew the union nut
only).
(8) Unplug connectors X1 to X6 from the board (Fig. 12/1).
(9) Disconnect ground conductor (9).
(10) Press sealing insert (8) out towards the rear and remove cable from X1 to XP1 from the
slit sealing insert (8).
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9
8
5
7
6
XP1 X1 9--pole
X31 XP2 X2 9--pole
X31
X9 XP3 X3 9--pole
15--pole
XP4 X4 9--pole
XP5 X5 9--pole
3
X10
4--pole
4
XP6 X6 9--pole
2
Fig. 12 Junction box X02
D INSTALLATION
(1) Use the old cable XP1 as a pull--in wire for the new cable XP1.
The new cable XP1 is already cut to length and terminated.
(2) Join board connector X1 on the new cable XP1 to the circular connector of the old cable
XP1 using adhesive tape (Fig. 13).
The adhesive tape must protect the length of the new cable XP1 from which the
sheath has been stripped from being fouled by cable grease.
(3) Apply cable grease to the new cable XP1 and push it into flexible tube A 1 (Fig. 5/26),
while carefully pulling on the old cable XP1 at the same time.

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Adhesive tape
XP1 (new cable)
XP1 (old cable)
Drawing direction
X1 on the new cable XP1 Circular connector on the old cable XP1
Fig. 13 Pulling in new cable XP1
When pulling in the cable, its mark must be located at the aperture of the flexible
tube (Fig. 5/26) in the rotating column. Insert cable XP1 into the clamping piece
and check that it is securely seated.
(4) Screw on cable clip (5) and bundle cables together using cable strap (the same
arrangement as before removal).
(5) Tighten tube clamp (11).
(6) Connect new cable XP1 to motor A 1.
(7) Feed board connector X1 through the union nut of the cable gland (Fig. 11/2) and press
cable XP1 into the slit sealing insert (Fig. 11/8).
The cable jacket must end flush with the sealing insert.
(8) Feed connectors X1 to X6 through the aperture of the cable gland into junction box X02.
(9) Push sealing insert (8) into the aperture of the cable gland.
(10) Tighten the union nut of the cable gland so that all the cables are properly fastened.
(11) Screw junction box X02 to the base frame.
(12) Connect the ground conductor (9) to the PE rail, ensuring that the screw is properly
tightened.
(13) Plug connectors X1 to X6 into the board.
(14) Ensure that the cables are routed in a gentle curve from the rear of junction box X02
to flexible tube A 1.
(15) Close junction box X02.
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Carefully insert push--in module (Fig. 2/10) into rotating column and tighten
fastening screws.
Screw ground conductor to PE bolt (21).
(16) Re--attach covers (as before removal) and tighten fastening screws (Fig. 11/4, 5).
If necessary, apply a thin coating of cable grease to the inside of the cover (4).

2.6 Removal/installation of control cable A 2 (XP2) (00--117--698)

Proceed in the same manner as for control cable XP1 (see Section 2.5).
2.7 Removal/installation of motor and control cables A 3 to A 6

This section covers the following cables:
Motor cable A 3 (XM3) 00--117--705
A 4 (XM4) 00--117--706
A 5 (XM5) 00--117--707
A 6 (XM6) 00--117--708
Control cable A 3 (XP3) 00--122--996
A 4 (XP4) 00--117--700
A 5 (XP5) 00--117--701
A 6 (XP6) 00--117--702
For the purpose of repairing one of these cables, it is recommended that the complete cable
set is removed and installed (see Sections 2.1 and 2.2).
The cable set must be laid out fully extended after removal and the defective cable replaced
at the junction box. The procedure for the motor cables is essentially the same as in Section
2.3 and for the control cables as in Section 2.5.
The defective cable can be used as a pull--in wire.
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Repair
The connectors must be sealed with adhesive tape before the new cable is
drawn in so that they are not fouled by cable grease.
After the cable has been replaced, the stipulated tests must be carried out:
DIN EN 60204--1/20.2
2.8 Removal/installation of data cable connection X31--X9 (00--107--132)
D REMOVAL
(1) Unplug connecting cables X30 and X31 on the robot.
(2) Open junction box X02 (Fig. 11/1).
(3) Unplug connector X9 (Fig. 12/2) from the board (1) and unscrew right--angle
connector (4).
(4) Feed connector X9 outwards through the aperture (6).
D INSTALLATION
Installation is carried out by following the removal instructions in reverse.
2.9 Removal/installation of mastering cable connection X32--X10

(00--106--299)
D REMOVAL
(2) Open junction box X02 (Fig. 11/1).
(3) Unplug connector X10 (Fig. 12/3) from the board (1) and remove built--in connector
X32 (5) by unscrewing the nut.
(4) Feed connector X10 outwards through the installation aperture of X32.
D INSTALLATION
Installation is carried out by following the removal instructions in reverse.
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2.10 Removal/installation of flexible tube A 1 (00--106--141)
D REMOVAL

(3) Unscrew ground conductor from PE bolt (21).
(4) Unscrew and withdraw push--in module (Fig. 2/10).
(5) Open junction boxes X01 (Fig. 10/5) and X02 (Fig. 11/5).
(6) Eject all connector modules on connector X30 of junction box X01.
(7) Disconnect ground conductors of cables XM1 to XM6 from the PE rail.
(8) Open cable gland on the rear panel of junction box X01 and carefully pull all cables XM1
to XM6 out of the junction box.
(9) Unplug all board connectors X1 to X6 of junction box X02 from the board (Fig. 12/1).
(10) Open cable gland on the rear panel of junction box X02 and carefully pull all cables out
of the junction box.
(11) Unscrew base frame/rotating column ground conductor (Fig. 2/2) from the push--in
module.
(12) Protect the exposed cable ends with the connector modules from fouling by cable
grease etc. by means of plastic bags and adhesive tape.
(13) Open both tube clamps on flexible tube A 1 (22) and carefully pull flexible tube A 1 off
the cables.

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Repair
D INSTALLATION
(1) If necessary, regrease cables on all sides with a coating of cable grease at least 2 mm
thick.

(2) Pull new flexible tube A 1 (Fig. 2/22) onto the cable bundle XM1 to XM6, XP1 to XP6
and onto the base frame/rotating column ground conductor.
(3) Fasten flexible tube A 1 (22) to base frame and rotating column with the two tube
clamps.
During installation, observe the white marks on the cables.
(4) Continue installation by reversing the removal sequence.
2.11 Removal/installation of flexible tube A 2/A 3 (PURRB--42M)

(00--118--469)
D REMOVAL
(1) Remove cable set assembly (see Section 2.1).
All connectors unplugged from motor units A 3 to A 6 must be individually

wrapped together with their designation labels (e.g. covering them with plastic
bags).
(2) Eject cables XM3 to XM6 from connector X30 and cables XP3 to XP6 from the board
(Fig. 12/1) and remove them from junction boxes X01 and X02 through the apertures
of the cable glands.
Seal off unprotected cable ends with plastic bags and adhesive tape.
(3) Pull the cables including the ground conductor, which have been withdrawn from the
junction boxes out of flexible tube A 1 (Fig. 5/26).

(4) Pull old flexible tube A 2/A 3 (14) off cable bundle.
(5) Lay cable bundle down, fully extended, on a clean support surface.
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D INSTALLATION
(1) Cut new flexible tube A 2/A 3 (Fig. 5/14) to correct length (Fig. 14) and mark it.
The flexible tube must be cut off at the humps (1) and not at the grooves (2) to
achieve the correct length.
2380 20
30 30 30 30 30 30
30 330 315 200 500 200
1 L 1
2 2
Fig. 14 Cutting flexible tube A 2/A 3 to length
(2) If necessary, regrease cables on all sides with a coating of cable grease at least 2 mm
thick.

(3) Pull new flexible tube A 2/A 3 onto cable bundle XM3 to XM6 and XP3 to XP6 and onto
rotating column/arm ground conductor.
(4) Pull cables XM3 to XM6 and XP3 to XP6 through flexible tube A 1 and feed them into
the respective junction boxes.
(5) Insert cables into connector X30 and on the board and connect ground conductors
according to diagram (see robot Doc. Module “Description, Electrical Installations”).
(6) Install cable set assembly (see Section 2.2).
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Repair
3 Safety precautions when handling lubricants

The information contained in the safety data sheet according to 91/155 EEC must be
observed when handling lubricants. An excerpt from this data sheet is included in the robot
Doc. Module “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
necessary (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
intake 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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KR30 Repai Elec Inst

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ROBOT

(V)KR 30, 60 HA; (V)KR 30, 60--3

Issued: 13 May 2004 Version: 00

3 Safety precautions when handling lubricants . . . . . . . . . . . . . . . . . . . . . . 30

Valid for (V)KR 30HA (V)KR 30--3

Only KUKA--approved cable grease may be used.

D Table of repair jobs

Removal/installation of 00--107--132 Connector X31 X9 2.8 26

2.1 Removal of cable set assembly (00--117--709)

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

Fig. 1 Moving robot into the dismantling position

Continue with step (2).

(1.1) Remove motor A 1.

Continue with step (2).

The following applies for any further dismantling:

Fig. 2 Covers, clips, clamps and ground conductor bolts

Fig. 3 Ground conductor connection

Protective gloves must be worn!

(11.3) Bundle all four cables together with adhesive tape.

Protective gloves must be worn!

2.2 Installation of cable set assembly (00--117--709)

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

Protective gloves must be worn!

Fig. 4 Cleaning contact surfaces on the base frame

Fig. 5 Cable set assembly in installed position

(3) Install cable set in base frame (Fig. 6). To do so:

Fig. 6 Attaching flexible tube A 1 to the base frame

(4) Install flexible tube A 2/A 3 (Fig. 5/14). To do so:

Protective gloves must be worn!

(5) Install flexible tube A 1

The cables must lie in parallel arrangement in the rotating column.

(9) Install cable set on arm. To do so:

Cables must not be trapped or pinched.

(10) Install cables XM1, XM2 and XP1, XP2. To do so:

(12) Make four ground conductor connections. To do so:

Ground conductor connection, sectional view

Fig. 7 Ground conductor connections

Fig. 8 Arrangement of motors on the arm

Protective gloves must be worn!

Fig. 9 Cleaning contact surfaces on the base frame

The minimum distance is 10 mm.

2.3 Removal/installation of motor cable A 1 (XM1) (00--117--703)

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

See Section 2.1 of this Doc. Module, steps 1 to 1.2.

Use special Harting tool.

Fig. 10 Removing motor cable A 1 (XM1)

The new cable XM1 is already cut to length and terminated.

Protective gloves must be worn!

If necessary, apply a coating of cable grease at least 2 mm thick to the inside of

Protective gloves must be worn!

(8) Pull shield outwards over the sealing insert (3).

Screw ground conductor to PE bolt (21).

2.4 Removal/installation of motor cable A 2 (XM2) (00--117--704)

2.5 Removal/installation of control cable A 1 (XP1) (00--117--697)

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

See Section 2.1 of this Doc. Module, steps 1 to 1.2.

Fig. 11 Removing control cable A 1 (XP1)

(3) Remove covers (Fig. 11/6, 8, 9).