ROBOT

KR 60 P, KR 100 P

Repair

General

Ro/Me/06/09 10.98.01 en

1 of 11
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

Ro/Me/06/09 10.98.01 en

2 of 11
Contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Unbraked impact against limit stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Safety precautions when handling lubricants . . . . . . . . . . . . . . . . . . . . . . 11

Ro/Me/06/09 10.98.01 en

3 of 11
Repair

Ro/Me/06/09 10.98.01 en

4 of 11
 1 General

Valid for KR 60 P/1, /2

KR 100 P/1, /2

1 General

The Doc. Module “Safety, General” is to be observed!

Important repair operations for assemblies to be repaired are described in the Doc. Modules.
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
regulations or trade association regulations; these are always to be observed and are
supplemented 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 robot’s danger area, the robot must be
switched off and secured with a padlock to prevent unauthorized persons from
starting it up again. If this is not possible in the opinion of the operator, 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 robot, it
must be ensured that the robot is not able to move on its own.

The description of the repair work only covers those operations that do not necessitate
subsequent measurement of the robot.

The screw sizes and grades specified in the Doc. Modules 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.

Ro/Me/06/09 10.98.01 en

5 of 11
Repair

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, as many of
these marked texts refer to the preceding job step.

Example
(1) Unscrew four hexagon screws .... and remove main axis motor unit (1).

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 injury by
crushing!

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

Example

Turn the main switch on the control cabinet to “OFF” and secure it with a pad-
lock to prevent unauthorized persons from switching it on again.

Ro/Me/06/09 10.98.01 en

6 of 11
 2 Transportation

2 Transportation

Section 1 of this Doc. Module and Sections 4 and 5 of the robot Doc. Module
“Installation, Connection, Exchange” are to be observed!

The robot must be moved into its transport position each time it is transported.
It must be ensured that the robot is stable while it is being transported.
The robot must remain in its transport position until it is fastened either to the
floor, the ceiling, the wall or a hinged steel base, depending on the type of robot.

Section 2 of this Doc. Module is to be observed!

The robot can be transported as follows:

G With lifting tackle and crane (or fork lift truck) (Fig. 1, lefthand side)

The robot can be suspended from the hook of a crane or the fork of a fork lift truck by
means of lifting tackle attached to three eyebolts on the rotating column.

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

Only approved lifting tackle and equipment with an adequate carrying capacity
may be used for transporting the robot by crane.
For weight of robot see robot Doc. Module “Technical Data”.
All three eyes on the rotating column must always be used to suspend the robot.

The robot must be secured with the associated transport safeguard. Before the
robot is unbolted from the mounting ring or the steel construction or before the
transport safeguard is removed, the robot must be held in a stable postion with
a crane or fork lift truck. Risk of toppling!

If the robot is to be transported by fork lift truck, the forks must be inserted into
the slots on the base frame of the robot. It is forbidden to pick up the robot in
any other way using a fork lift truck!

Ro/Me/06/09 10.98.01 en

7 of 11
Repair

G With fork lift truck (Fig. 1, righthand side)

For transport by fork lift truck, two fork slots are provided in the base frame, allowing
the robot to be picked up from either of two sides.

Fig. 1 Transporting robots

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

Turn the main switch on the control cabinet to “OFF” and secure it with a pad-
lock 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 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 its transport position (Fig. 2)*.

Ro/Me/06/09 10.98.01 en

8 of 11
 2 Transportation (continued)

A1 A2 A3 A4 A5 A6
0˚ --40˚ +60˚ 0˚ +90˚ any

* Angle specifications are

referred to the mechanical
zero of the axis concerned.

Fig. 2 Transport position

Turn the main switch on the control cabinet to “OFF” and secure it with a pad-
lock to prevent unauthorized persons from switching it on again.

(3) Disconnect cables.

For further procedures see robot Doc. Module “Installation, Connection, Exchange”.

Ro/Me/06/09 10.98.01 en

9 of 11
Repair

3 Unbraked impact against limit stops

If the robot collides with an obstacle or hits the stops of a buffered axis at a
speed greater than manual traversing speed, KUKA must always be consulted
before the robot is put back into operation!
In addition, the buffer concerned must be exchanged immediately for a new one.

Ro/Me/06/09 10.98.01 en

10 of 11
 4 Safety precautions when handling lubricants

4 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 intensive skin contact; wear protective gloves and aprons if nec-
essary (especially when working with cable grease).

All accident prevention regulations must be observed when handling cable

grease.

-- 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 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 or mineral oil mixtures in your pockets.
-- Avoid breathing in oil spray or vapors wherever possible.
1

Ro/Me/06/09 10.98.01 en

11 of 11