Robots

KR 600 FORTEC
With F Variant
Assembly Instructions

Issued: 12.07.2024
MA KR 600 FORTEC V8
KUKA Deutschland GmbH
KR 600 FORTEC

© Copyright 2024
KUKA Deutschland GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties
without the express permission of KUKA Deutschland GmbH.
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 soft-
ware 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 regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation

Publication: Pub MA KR 600 FORTEC (PDF) en

PB5497

Book structure: MA KR 600 FORTEC V7.2

BS5080

Version: MA KR 600 FORTEC V8

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Contents

1 Introduction.............................................................................................. 7
1.1 Target group.......................................................................................................... 7
1.2 Industrial robot documentation.............................................................................. 7
1.3 Representation of warnings and notes................................................................. 7
1.4 Terms used............................................................................................................ 8

2 Product description................................................................................. 13
2.1 Overview of the robot system............................................................................... 13
2.2 Description of the robot......................................................................................... 13
2.3 Intended use and misuse...................................................................................... 16

3 Safety......................................................................................................... 19
3.1 General.................................................................................................................. 19
3.1.1 Disclaimer.............................................................................................................. 19
3.1.2 EC declaration of conformity and declaration of incorporation............................ 20
3.1.3 Terms in the “Safety” chapter............................................................................... 20
3.2 Personnel............................................................................................................... 22
3.3 Workspace, safety zone and danger zone........................................................... 23
3.4 Overview of protective equipment........................................................................ 23
3.4.1 Mechanical end stops........................................................................................... 23
3.4.2 Mechanical axis limitation (optional)..................................................................... 24
3.4.3 Options for moving the manipulator without drive energy................................... 24
3.4.4 Labeling on the industrial robot............................................................................ 24
3.5 Safety measures.................................................................................................... 25
3.5.1 General safety measures...................................................................................... 25
3.5.2 Transportation........................................................................................................ 27
3.5.3 Start-up and recommissioning.............................................................................. 27
3.5.4 Manual mode......................................................................................................... 29
3.5.5 Automatic mode..................................................................................................... 30
3.5.6 Maintenance and repair........................................................................................ 30
3.5.7 Decommissioning, storage and disposal.............................................................. 32

4 Technical data.......................................................................................... 33
4.1 Technical data, overview....................................................................................... 33
4.2 Technical data, KR 600 R2830............................................................................. 34
4.2.1 Basic data, KR 600 R2830................................................................................... 34
4.2.2 Axis data, KR 600 R2830..................................................................................... 36
4.2.3 Payloads, KR 600 R2830..................................................................................... 39
4.2.4 Foundation loads, KR 600 R2830........................................................................ 44
4.3 Technical data, KR 600 R2830 F......................................................................... 46
4.3.1 Basic data, KR 600 R2830 F............................................................................... 46
4.3.2 Axis data, KR 600 R2830 F................................................................................. 48
4.3.3 Payloads, KR 600 R2830 F.................................................................................. 51
4.3.4 Foundation loads, KR 600 R2830 F..................................................................... 56
4.4 Technical data, KR 510 R3080............................................................................. 58
4.4.1 Basic data, KR 510 R3080................................................................................... 58
4.4.2 Axis data, KR 510 R3080..................................................................................... 59

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4.4.3 Payloads, KR 510 R3080..................................................................................... 61

4.4.4 Foundation loads, KR 510 R3080........................................................................ 67
4.5 Technical data, KR 510 R3080 F......................................................................... 69
4.5.1 Basic data, KR 510 R3080 F............................................................................... 69
4.5.2 Axis data, KR 510 R3080 F................................................................................. 71
4.5.3 Payloads, KR 510 R3080 F.................................................................................. 73
4.5.4 Foundation loads, KR 510 R3080 F..................................................................... 79
4.6 Technical data, KR 420 R3330............................................................................. 81
4.6.1 Basic data, KR 420 R3330................................................................................... 81
4.6.2 Axis data, KR 420 R3330..................................................................................... 82
4.6.3 Payloads, KR 420 R3330..................................................................................... 84
4.6.4 Foundation loads, KR 420 R3330........................................................................ 90
4.7 Technical data, KR 420 R3330 F......................................................................... 92
4.7.1 Basic data, KR 420 R3330 F............................................................................... 92
4.7.2 Axis data, KR 420 R3330 F................................................................................. 94
4.7.3 Payloads, KR 420 R3330 F.................................................................................. 96
4.7.4 Foundation loads, KR 420 R3330 F..................................................................... 102
4.8 Plates and labels................................................................................................... 104
4.9 REACH duty to communicate information acc. to Art. 33................................... 107
4.10 Stopping distances and times............................................................................... 107
4.10.1 General information............................................................................................... 107
4.10.2 Stopping distances and times KR 600 R2830, KR 600 R2830 F....................... 109
4.10.2.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 109
4.10.2.2 Stopping distances and stopping times, STOP 1, A1.......................................... 110
4.10.2.3 Stopping distances and stopping times, STOP 1, A2.......................................... 112
4.10.2.4 Stopping distances and stopping times, STOP 1, A3.......................................... 114
4.10.3 Stopping distances and times KR 510 R3080, KR 510 R3080 F....................... 114
4.10.3.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 114
4.10.3.2 Stopping distances and stopping times, STOP 1, A1.......................................... 116
4.10.3.3 Stopping distances and stopping times, STOP 1, A2.......................................... 118
4.10.3.4 Stopping distances and stopping times, STOP 1, A3.......................................... 120
4.10.4 Stopping distances and times KR 420 R3330, KR 420 R3330 F....................... 120
4.10.4.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 120
4.10.4.2 Stopping distances and stopping times, STOP 1, A1.......................................... 122
4.10.4.3 Stopping distances and stopping times, STOP 1, A2.......................................... 124
4.10.4.4 Stopping distances and stopping times, STOP 1, A3.......................................... 126

5 Planning.................................................................................................... 127
5.1 Information for planning........................................................................................ 127
5.2 Mounting base 175 mm........................................................................................ 127
5.3 Mounting base 200 mm........................................................................................ 130
5.4 Machine frame mounting....................................................................................... 132
5.5 Connecting cables and interfaces......................................................................... 134

6 Transportation.......................................................................................... 137
6.1 Transporting the robot arm................................................................................... 137

7 Start-up and recommissioning............................................................... 143

7.1 Installing the mounting base 175 mm.................................................................. 143
7.2 Installing the mounting base 200 mm.................................................................. 146

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7.3 Installing the machine frame mounting................................................................. 148

7.4 Installing a floor-mounted robot............................................................................ 150
7.5 Description of the connecting cables.................................................................... 153
7.5.1 Description of the Motor cable.............................................................................. 154
7.5.2 Description of the Motor cable.............................................................................. 156
7.5.3 Description of the Data cable............................................................................... 158
7.6 Description of the connecting cables, KR C5...................................................... 159
7.6.1 Description of the Motor cable.............................................................................. 160
7.6.2 Description of the Motor cable.............................................................................. 163
7.6.3 Description of the Data cable............................................................................... 165
7.6.4 Description of the ground conductor.................................................................... 166

8 Maintenance.............................................................................................. 169
8.1 Maintenance overview........................................................................................... 169
8.1.1 Maintenance table................................................................................................. 170
8.2 Regreasing the seal (O-ring A4)........................................................................... 176
8.3 Regreasing the seal (O-ring A5)........................................................................... 177
8.4 Exchanging the counterbalancing system on a floor-mounted robot.................. 178
8.4.1 Precondition........................................................................................................... 178
8.4.2 Removing the counterbalancing system on a floor-mounted robot..................... 179
8.4.3 Installing the counterbalancing system on a floor-mounted robot....................... 182
8.5 Checking the counterbalancing system................................................................ 185
8.6 Checking drive shafts A4 to A6............................................................................ 186
8.6.1 Description............................................................................................................. 186
8.7 Oil change in A1................................................................................................... 189
8.7.1 Draining the gear oil from A1............................................................................... 190
8.7.2 Filling gear unit A1 with gear oil........................................................................... 191
8.8 Oil change in A2................................................................................................... 191
8.8.1 Draining the gear oil from A2............................................................................... 193
8.8.2 Filling gear unit A2 with gear oil........................................................................... 193
8.9 Oil change in A3................................................................................................... 194
8.9.1 Draining the gear oil from A3............................................................................... 195
8.9.2 Filling gear unit A3 with gear oil........................................................................... 196
8.10 Oil change in A4................................................................................................... 197
8.10.1 Draining the gear oil from A4............................................................................... 198
8.10.2 Filling gear unit A4 with gear oil........................................................................... 199
8.11 Oil change in A5................................................................................................... 200
8.11.1 Draining the gear oil from A5............................................................................... 201
8.11.2 Filling gear unit A5 with gear oil........................................................................... 202
8.12 Oil change in A6................................................................................................... 203
8.12.1 Draining the gear oil from A6............................................................................... 204
8.12.2 Filling gear unit A6 with gear oil........................................................................... 205
8.13 Greasing the cable set.......................................................................................... 205
8.14 Cleaning the robot................................................................................................. 206
8.14.1 Cleaning................................................................................................................. 207
8.14.2 Concluding work.................................................................................................... 207

9 Repair........................................................................................................ 209
9.1 Exchanging motor A1............................................................................................ 209

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9.1.1 Removing motor A1.............................................................................................. 210

9.1.2 Installing motor A1................................................................................................ 211
9.2 Exchanging motor A2............................................................................................ 212
9.2.1 Removing motor A2.............................................................................................. 213
9.2.2 Installing motor A2................................................................................................ 214
9.3 Exchanging motor A3............................................................................................ 216
9.3.1 Removing motor A3.............................................................................................. 217
9.3.2 Installing motor A3................................................................................................ 218
9.4 Exchanging motors and drive shafts A4 to A6.................................................... 219
9.4.1 Description............................................................................................................. 219
9.4.2 Removing motors and drive shafts A4 to A6....................................................... 220
9.4.3 Installing motors and drive shafts A4 to A6, universal shafts with setscrews.... 222
9.4.4 Installing motors and drive shafts A4 to A6, universal shafts with O-rings........ 225
9.5 Description of the electrical installations.............................................................. 229

10 Decommissioning, storage and disposal............................................. 239

10.1 Decommissioning, floor-mounted robots............................................................... 239
10.2 Storage.................................................................................................................. 242
10.3 Disposal................................................................................................................. 243

11 Options...................................................................................................... 245
11.1 Release device (optional)...................................................................................... 245
11.1.1 Moving the manipulator without drive energy...................................................... 245
11.1.2 Concluding work.................................................................................................... 246

12 Appendix................................................................................................... 247
12.1 Tightening torques................................................................................................. 247
12.2 Auxiliary substances and consumables................................................................ 248
12.3 Product safety data sheet..................................................................................... 249
12.4 Applied standards and regulations....................................................................... 254

13 KUKA Service........................................................................................... 257

13.1 Requesting support............................................................................................... 257
13.2 KUKA Customer Support...................................................................................... 257

Index 259

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Introduction
1 Introduction

1.1 Target group

This documentation is aimed at users with the following knowledge and

skills:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• Knowledge of the robot controller system

For optimal use of KUKA products, we recommend the training courses

offered by KUKA College. Information about the training program can be
found at www.kuka.com or can be obtained directly from our subsidia-
ries.

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2 or smartPAD pro (if used)
• Documentation for the System Software
• Instructions for options and accessories
• Spare parts overview in KUKA Xpert
Each set of instructions is a separate document.

1.3 Representation of warnings and notes

Safety

These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur if no precautions are taken.

WARNING
These warnings mean that death or severe injuries may occur if no pre-
cautions are taken.

CAUTION
These warnings mean that minor injuries may occur if no precautions
are taken.

NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.

These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.

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This warning draws attention to procedures which serve to prevent or rem-

Introduction

edy emergencies or malfunctions:

SAFETY INSTRUCTION
The following procedure must be followed exactly!

Procedures marked with this warning must be followed exactly.

Notices

These notices serve to make your work easier or contain references to

further information.
Tip to make your work easier or reference to further information

1.4 Terms used

The overview may contain terms symbols that are not relevant for this
document.

Term Description

Axis range Defined range within which each axis may move.

Stopping distance Stopping distance = reaction distance + braking distance

The distance traveled from the moment of reaction up to a com-
plete standstill is the danger zone

Workspace The safe Cartesian workspace of a manipulator.

Arctic Arctic
for use in temperature ranges under 0° C (273 K).

Extension Distance (l in %) between axis 1 and the intersection of axes 4 and

5. With parallelogram robots, the distance between axis 1 and the
intersection of axis 6 and the mounting flange.

C Ceiling

CR Clean Room
Designation for KUKA products developed for use in cleanrooms.

EDS Electronic Data Storage

Memory card

EDS cool Electronic Data Storage cool

Memory card with extended temperature range

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Introduction
EMD Electronic Mastering Device
Technical tool for mastering the axis

SPP Spare parts package

Spare parts supply for durable capital goods

EX Explosion-proof zone

F Foundry
Machining with increased protection requirements

F exclusive Foundry exclusive

Use exclusively in foundry

Danger zone The danger zone results from the workspace and stopping distance
of the manipulator including any external axes (optional)

HA High Accuracy
High-accuracy robot

HI High Inertia

HM Hygienic Machine
For the primary and secondary foodstuffs industries

HO Hygienic Oil
Use in the secondary food sector

HP High Protection
High protection

HW Hollow Wrist

K Shelf-mounted

KCP KUKA Control Panel

Teach pendant for the KR C2/KR C2 edition2005

KR KUKA robot

KR C KUKA Robot Control

Robot controller

KS Shelf-mounted, small

KUKA smartPAD see “smartPAD”

KUKA smartPAD-2 see “smartPAD”

Manipulator The robot arm and the associated electrical installations

MEMD Micro Electronic Mastering Device

Technical tool for mastering the axis

micro RDC micro Resolver Digital Converter

MT Machine Tooling

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P Press-to-press robot

PA Palletizer

Phi Angle of rotation (°) about the corresponding axis. This value can
be entered in the controller via the teach pendant, from which it
can be read.

POV Program override (%) = velocity of the robot motion. This value can
be entered in the controller via the teach pendant, from which it
can be read.

RDC Resolver Digital Converter

Digital converter, detects angular position and rotational speed of
the motor shaft

RDC cool Resolver Digital Converter cool

Digital converter, detects angular position and rotational speed of
the motor shaft (including temperature)

SC Special Connection

SE Second Encoder

SI Safe Interaction

SL Washdown

smartPAD Teach pendant for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operation and programming. The following models exist:

• KUKA smartPAD
• KUKA smartPAD-2
• KUKA smartPAD pro
For robot controllers of the KR C5 series with KUKA System Soft-
ware or VW System Software, only the model KUKA smartPAD-2
is used.
For robot controllers of the KR C5 series with KUKA iiQKA.OS, on-
ly the model KUKA smartPAD pro is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to all models possible for the respective
controller unless an explicit distinction is made.

Stop categories Note: Information about the stop categories for KUKA robot control-
lers can be found in the “Safety” chapter of the robot controller as-
sembly instructions.

T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)

For KUKA iiQKA.OS:
With manual guidance in T1, the velocity is not reduced, but rather
limited through a safety-oriented velocity monitoring in accordance
with the safety configuration.

T2 Test mode, Manual High Velocity (> 250 mm/s permissible)

For KUKA iiQKA.OS: not relevant at present

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Introduction
W Wall

WP Waterproof

External axis Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. For example, KUKA linear unit, turn-
tilt table and positioner
For KUKA iiQKA.OS: not relevant at present

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Product description
2 Product description

2.1 Overview of the robot system

The robot system consists of the following components:

• Manipulator
• Robot controller
• smartPAD teach pendant
• Connecting cables
• Software
• Options, accessories

Fig. 2-1: Example of a robot system

1 Manipulator 3 Robot controller

2 Connecting cables 4 smartPAD
control panel

2.2 Description of the robot

Overview

The robot is designed as a 6-axis jointed-arm kinematic system. The

structural components of the robot are made of light alloy and iron cast-
ings. The axes are driven by AC servomotors. A hydropneumatic counter-
balancing system is used to equalize the load moment about axis 2.
The robot consists of the following principal components:
• In-line wrist
• Arm
• Counterweight
• Link arm
• Rotating column
• Base frame

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• Counterbalancing system
• Electrical installations

Fig. 2-2: Principal components

1 Counterbalancing system 5 Counterweight

2 In-line wrist 6 Electrical installations
3 Link arm 7 Rotating column
4 Arm 8 Base frame

In-line wrist

The robot is fitted with a 3-axis in-line wrist for a rated payload of 600 kg.
The in-line wrist comprises axes 4, 5 and 6. It is driven by 3 AC servomo-
tors installed at the rear end of the arm via drive shafts. The motor unit
consists of brushless AC servomotors with a permanent-magnet single-
disk brake and hollow-shaft resolver, both integrated. The permanent-mag-
net single-disk brakes perform a holding function when the servomotor is
at rest and contribute to the braking of the respective axis in the event of
short-circuit braking (e.g. if the enabling switch is released while in Test
mode). Short-circuit braking must not be used to stop the robot under nor-
mal circumstances. The gear units of the in-line wrist are supplied with oil
from 3 separate oil chambers.
If the permissible turning range of a wrist axis is exceeded, the robot is
switched off by means of software limit switches. The turning range of A5
is mechanically limited by end stops.
The in-line wrist forms an exchangeable unit with a standardized mechan-
ical interface to the arm.
This assembly also includes a mount with a gauge cartridge. Using the
gauge cartridge, the mechanical zero of the axis can be determined by
means of an electronic probe (accessory) and transferred to the controller.

The in-line wrist variant “F” is available for operating conditions involving
greater mechanical and thermal stress.

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Product description
Arm

The arm is the link between the in-line wrist and the link arm. It houses
the motors of the wrist axes A4, A5 and A6, as well as motor A3. The
counterweight for the counterbalancing of masses about axis 3 is mounted
on the side of the arm.
The arm is driven by an AC servomotor via a gear unit that is installed
between the arm and the link arm. The maximum permissible swivel
range is limited by mechanical limit stops with a buffer function in the pos-
itive and negative directions in addition to the software limit switches.
The arm variant “F” is available for operating conditions involving greater
mechanical and thermal stress. The arms of the F variants are pressur-
ized to prevent penetration of moisture and dust.

Link arm

The link arm is the assembly located between the arm and the rotating
column. It is mounted on one side of the rotating column via a gear unit.
The motor unit consists of a brushless AC servomotor with a permanent-
magnet single-disk brake and hollow-shaft resolver, both integrated. The
permanent-magnet single-disk brake performs a holding function when the
servomotor is at rest and contributes to the braking of the respective axis
in the event of short-circuit braking (e.g. if one or more of the enabling
switches is released while in Test mode). Short-circuit braking must not be
used to stop the robot under normal circumstances. During motion about
axis 2, the link arm moves about the stationary rotating column. The usa-
ble software swivel range is limited by mechanical limit stops with a buffer
function in the positive and negative directions in addition to the software
limit switches.

Rotating column

The rotating column houses the motors of axes 1 and 2. The rotational
motion of axis 1 is performed by the rotating column. It is screwed to the
base frame via the gear unit of axis 1. Inside the rotating column is a
brushless AC servomotor with a permanent-magnet single-disk brake and
hollow-shaft resolver, both integrated, for driving axis 1. The permanent-
magnet single-disk brake performs a holding function when the
servomotor is at rest and contributes to the braking of the respective axis
in the event of short-circuit braking (e.g. if the enabling switch is released
while in Test mode). Short-circuit braking must not be used to stop the ro-
bot under normal circumstances. The counterbearing for the counterbal-
ancing system is integrated into the rear of the rotating column housing.

Base frame

The base frame is the base of the robot. It is screwed to the mounting
base. The interfaces for the electrical installations and the energy supply
systems (accessory) are housed in the base frame. The base frame and
rotating column are connected via the gear unit of axis 1. The flexible
tube for the electrical installations and the energy supply system is accom-
modated in the base frame.

Counterbalancing system

The counterbalancing system is an assembly installed between the rotat-

ing column and the link arm. This assembly minimizes the torques gener-
ated about axis 2 when the robot is moving or stationary. A closed hydro-
pneumatic system is used. The system consists of two accumulators, a
hydraulic cylinder, a pressure gauge and an accumulator safety valve. The
accumulators correspond to category III, fluid group 2, of the Pressure

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Equipment Directive. Separate variants of the counterbalancing system

Product description

are used for floor-mounted and F variants, respectively.

Electrical installations

The electrical installations include all the supply and control cables for the
motors of axes 1 to 6. All the connections on the motors are screwed
plug-and-socket connections. The assembly consists of the cable set, the
multi-function housing (MFH) and the RDC box. The interface for the con-
necting cables is located at the back of the base frame. The motor and
data cables are connected here via plug-in connections. The data and mo-
tor cables are routed from the RDC box and the multi-function housing to
the motors (XM and XP connectors).

Options

The robot can, for example, be equipped with the following options. The
option is described in separate documentation.
• Axis limitation A1, A2 and A3
• Energy supply systems A1 to A3
• Energy supply systems A3 to A6
• Booster Frame S960
The following option is also available:
• Release device (>>> 11.1 "Release device (optional)" Page 245)

2.3 Intended use and misuse

Intended use

The industrial robot is intended for handling tools and fixtures or for pro-
cessing and transferring components or products. Use is only permitted
under the specified environmental conditions.
Operation of the industrial robot in accordance with its intended use also
requires compliance with the operating and assembly instructions for the
individual components, with particular reference to the maintenance speci-
fications.

Misuse

Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. Misuse will result in the loss of warranty and
liability claims. KUKA is not liable for any damage resulting from such mis-
use. This includes e.g.:
• Use as a climbing aid
• Operation outside the specified operating parameters
• Operation without the required safety equipment
• Transportation of persons and animals
• Outdoor operation
• Use in a potentially explosive area
• Use in radioactive environments
• Operation in underground mining

NOTICE
Deviations from the operating conditions specified in the technical data
or the use of special functions or applications can lead to premature
wear, for example. KUKA Service must be consulted in this event.

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Product description
The robot system is an integral part of a complete system and may only
be operated in a CE-compliant system.

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Safety
3 Safety

3.1 General

• This “Safety” chapter refers to a mechanical component of an indus-

trial robot.
• If the mechanical component is used together with a KUKA robot
controller, the “Safety” chapter of the operating instructions or as-
sembly instructions of the robot controller must be used!
This contains all the information provided in this “Safety” chapter. It
also contains additional safety information relating to the robot con-
troller which must be observed.
• Where this “Safety” chapter uses the term “industrial robot”, this also
refers to the individual mechanical component if applicable.

3.1.1 Disclaimer

The device described in this document is either an industrial robot or a

component thereof.
Components of the industrial robot:

• Manipulator
• Robot controller
• Teach pendant
• Connecting cables
• External axes (optional)
e.g. linear unit, turn-tilt table, positioner
• Software
• Options, accessories
The industrial robot is built using state-of-the-art technology and in accord-
ance with the recognized safety rules. Nevertheless, misuse of the indus-
trial 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 ac-
cordance 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, especially those affecting safety, must be rectified immediately.

Safety information

Information about safety may not be construed against the manufacturer.

Even if all safety instructions are followed, this is not a guarantee that the
industrial robot will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the au-
thorization of the manufacturer. Unauthorized modifications will result in
the loss of warranty and liability claims.
Additional components (tools, software, etc.), not supplied by the manufac-
turer, 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 in-
structions. These must also be observed.

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3.1.2 EC declaration of conformity and declaration of incorporation

The industrial robot constitutes partly completed machinery as defined by

the EC Machinery Directive. The industrial robot may only be put into op-
eration if the following preconditions are met:
• 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.
• The complete system complies with the EC Machinery Directive. This
has been confirmed by means of a conformity assessment procedure.

EC declaration of conformity

The system integrator must issue an EC declaration of conformity for the

complete system in accordance with the Machinery Directive. The EC dec-
laration of conformity forms the basis for the CE mark for the system. The
industrial robot must always be operated in accordance with the applicable
national laws, regulations and standards.
The robot controller has a CE mark in accordance with the EMC Directive
and the Low Voltage Directive.

Declaration of incorporation

The partly completed machinery is supplied with a declaration of incorpo-

ration in accordance with Annex II B of the Machinery Directive
2006/42/EC. The assembly instructions and a list of essential require-
ments 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 is not allowed until the partly completed machinery
has been incorporated into machinery, or has been assembled with other
parts to form machinery, and this machinery complies with the terms of
the EC Machinery Directive, and the EC declaration of conformity is
present in accordance with Annex II A.

3.1.3 Terms in the “Safety” chapter

Term Description

Axis range Defined range within which each axis may move.

Stopping distance Stopping distance = reaction distance + braking distance

The distance traveled from the moment of reaction up to a com-
plete standstill is the danger zone

Workspace The safe Cartesian workspace of a manipulator.

User The user of the industrial robot can be the management, employer
or delegated person responsible for use of the industrial robot.

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Safety
Service life The service life of a safety-relevant component begins at the time
of delivery of the component to the customer.
The service life is not affected by whether the component is used
or not, as safety-relevant components are also subject to aging dur-
ing storage.

Danger zone The danger zone results from the workspace and stopping distance
of the manipulator including any external axes (optional)

KCP KUKA Control Panel

Teach pendant for the KR C2/KR C2 edition2005

KUKA smartPAD see “smartPAD”

KUKA smartPAD-2 see “smartPAD”

Manipulator The robot arm and the associated electrical installations

Safety zone The safety zone is situated outside the danger zone.

smartPAD Teach pendant for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operation and programming. The following models exist:

• KUKA smartPAD
• KUKA smartPAD-2
• KUKA smartPAD pro
For robot controllers of the KR C5 series with KUKA System Soft-
ware or VW System Software, only the model KUKA smartPAD-2
is used.
For robot controllers of the KR C5 series with KUKA iiQKA.OS, on-
ly the model KUKA smartPAD pro is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to all models possible for the respective
controller unless an explicit distinction is made.

Stop categories Note: Information about the stop categories for KUKA robot control-
lers can be found in the “Safety” chapter of the robot controller as-
sembly instructions.

System integrator The system integrator is responsible for safely integrating the indus-
(plant integrator) trial robot into a complete system and commissioning it.

T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)

For KUKA iiQKA.OS:
With manual guidance in T1, the velocity is not reduced, but rather
limited through a safety-oriented velocity monitoring in accordance
with the safety configuration.

T2 Test mode, Manual High Velocity (> 250 mm/s permissible)

For KUKA iiQKA.OS: not relevant at present

External axis Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. For example, KUKA linear unit, turn-
tilt table and positioner
For KUKA iiQKA.OS: not relevant at present

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3.2 Personnel

The following persons or groups of persons are defined for the industrial
robot:

• User
• Personnel

Qualification of personnel
Work on the system must only be performed by personnel that is able
to assess the tasks to be carried out and detect potential hazards.
Death, severe injuries or damage to property may otherwise result. The
following qualifications are required:
• Adequate specialist training, knowledge and experience
• Knowledge of the relevant operating or assembly instructions, knowl-
edge of the relevant standards
• All persons working with the industrial robot must have read and un-
derstood the industrial robot documentation, including the safety
chapter.

User

The user must observe the labor laws and regulations. This includes e.g.:

• The user must comply with his monitoring obligations.

• The user must carry out briefing at defined intervals.
• The user must comply with the regulations relating to personal protec-
tive equipment (PPE).

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 re-
quired after particular incidents or technical modifications.
Personnel includes:

• System integrator
• Operators, subdivided into:
‒ Start-up, maintenance and service personnel
‒ Operating personnel
‒ Cleaning personnel

System integrator

The industrial robot is safely integrated into a complete system by the sys-
tem integrator.
The system integrator is responsible for the following tasks:

• Installing the industrial robot

• Connecting the industrial robot
• Performing the risk assessment
• Implementing the required safety functions and safeguards
• Issuing the EC declaration of conformity
• Affixing the CE mark
• Creating the operating instructions for the system

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Safety
Operators

The operator must meet the following preconditions:

• The operator must be trained for the work to be carried out.
• Work on the system must only be carried out by qualified personnel.
These are people who, due to their specialist training, knowledge and
experience, and their familiarization with the relevant standards, are
able to assess the work to be carried out and detect any potential
hazards.

3.3 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size.

The danger zone consists of the workspace and the stopping distances of
the manipulator and external axes (optional). The danger zone must be
protected by means of physical safeguards to prevent danger to persons
or the risk of material damage.
The safeguards (e.g. safety gate) must be located outside the danger
zone. In the case of a stop, the manipulator and external axes (optional)
are braked and come to a stop within the danger zone.
There must be no shearing or crushing hazards at the loading and trans-
fer areas.
If there are no physical safeguards present, the requirements for collabo-
rative operation in accordance with EN ISO 10218 must be met.

3.4 Overview of protective equipment

The protective equipment of the mechanical component may include:

• Mechanical end stops

• Mechanical axis limitation (optional)
• Release device (optional)
• Brake release device (optional)
• Labeling of danger areas
Not all equipment is relevant for every mechanical component.

3.4.1 Mechanical end stops

Depending on the robot variant, the axis ranges of the main and wrist ax-
es of the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.
WARNING
Danger to life and limb following collision with obstacle
If the manipulator or an external axis hits an obstruction or a mechani-
cal end stop or mechanical axis limitation, the manipulator can no
longer be operated safely. Death, injuries or damage to property may re-
sult.
• Put manipulator out of operation.
• Put external axis out of operation.
• KUKA must be consulted before they are put back into operation.

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3.4.2 Mechanical axis limitation (optional)

Some manipulators can be fitted with adjustable mechanical axis limitation

systems in axes A1 to A3. The axis limitation systems restrict the working
range to the required minimum. This increases personal safety and pro-
tection of the system.
In the case of manipulators that are not designed to be fitted with me-
chanical axis limitation, 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 limitation.
If this is not possible, the workspace must be limited by means of photo-
electric barriers, photoelectric curtains or mechanical limitations on the
system side. There must be no shearing or crushing hazards at the load-
ing and transfer areas.
This option is not available for all robot models. Information on specific
robot models can be obtained from the manufacturer.

3.4.3 Options for moving the manipulator without drive energy

Qualification of personnel with regard to behavior in emergency

situations
In emergencies or other exceptional situations, it may be necessary to
move the manipulator without drive energy.
• Personnel must be trained in how to move the manipulator without
drive energy.

Description

The following options may be available for moving the manipulator without
drive energy after an accident or malfunction:
• Release device (optional)
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.
• Brake release device (option)
The brake release device is designed for robot variants whose motors
are not freely accessible.
• Moving the wrist axes directly by hand
There is no release device available for the wrist axes of variants in
the low payload category. This is not necessary because the wrist ax-
es can be moved directly by hand.

Information about the options available for the various robot models and
about how to use them can be found in the assembly and operating in-
structions for the robot or can be requested from the manufacturer.

3.4.4 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:
• Identification plates
• Warning signs
• Safety symbols
• Designation labels

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Safety
• Cable markings
• Rating plates

Further information is contained in the technical data of the operating in-

structions or assembly instructions of the components of the industrial
robot.

3.5 Safety measures

3.5.1 General safety measures

The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons. Op-
erator errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial ro-
bot even after the robot controller has been switched off and locked out.
Incorrect installation (e.g. overload) or mechanical defects (e.g. brake de-
fect) 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 possi-
ble, the manipulator and external axes must be secured by appropriate
means.
DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.

DANGER
Danger to life and limb of persons under the robot arm
Sagging or falling parts can cause death or serious injuries. This applies
at all times, e.g. also for assembly tasks or with the controller switched
off.
• Never loiter under the robot arm.

CAUTION
Risk of burns from hot motors
The motors reach temperatures during operation which can cause
burns.
• Avoid contact.
• Take appropriate safety precautions, e.g. wear protective gloves.

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Implants

WARNING
Danger to life due to malfunction of implants caused by motors
and brakes
Electric motors and brakes generate electric and magnetic fields. The
fields can cause malfunctions in active implants, e.g. pacemakers.
• Affected persons must maintain a minimum distance of 300 mm
from motors and brakes. This applies to both energized and deener-
gized motors and brakes.

KCP/smartPAD

The user must ensure that the industrial robot is only operated with the
KCP/smartPAD by authorized persons.
If more than one KCP/smartPAD is used in the overall system, it must be
ensured that each device is unambiguously assigned to the corresponding
industrial robot. They must not be interchanged.
WARNING
Danger to life due to disconnected smartPAD/KCP
If a smartPAD/KCP is disconnected, its EMERGENCY STOP device is
not operational. There is a risk of connected and disconnected smart-
PADs/KCPs being interchanged. Death, injuries or damage to property
may result.
• Remove the disconnected smartPAD/KCP from the system immedi-
ately.
• Store the disconnected smartPAD/KCP out of sight and reach of
personnel working on the industrial robot.

The enabling switches on the smartPAD must be subjected to a function

test at least once every 12 months and in certain specific cases.
Information about function testing for KUKA robot controllers can be
found in the “Safety” chapter of the operating or assembly instructions
of the robot controller.

External keyboard, external mouse

An external keyboard and/or external mouse may only be used if the fol-
lowing conditions are met:

• Start-up or maintenance work is being carried out.

• The drives are switched off.
• There are no persons in the danger zone.
The KCP/smartPAD must not be used as long as an external keyboard
and/or external mouse are connected to the control cabinet.
The external keyboard and/or external mouse must be removed from the
control cabinet as soon as the start-up or maintenance work is completed
or the KCP/smartPAD is connected.

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 functions must also be tested.
New or modified programs must always be tested first in Manual Reduced
Velocity mode (T1).

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After modifications to the industrial robot, existing programs must always

Safety
be tested first in Manual Reduced Velocity mode (T1). This applies to all
components of the industrial robot and includes e.g. modifications of the
external axes or to the software and configuration settings.

Faults

In the case of faults on the industrial robot, the following safety measures
must be implemented immediately:
• Switch off the robot controller and secure it (e.g. with a padlock) to
prevent unauthorized persons from switching it on again.
• Indicate the fault by means of a label with a corresponding warning
(tagout).
• Keep a record of the faults.
Carry out a functional test after the fault has been rectified.

3.5.2 Transportation

Manipulator

The prescribed transport position of the manipulator must be observed.

Transportation must be carried out in accordance with the operating in-
structions or assembly instructions of the robot.
Avoid vibrations and impacts during transportation in order to prevent
damage to the manipulator.

Robot controller

The prescribed transport position of the robot controller must be observed.

Transportation must be carried out in accordance with the operating in-
structions or assembly instructions of the robot controller.
Avoid vibrations and impacts during transportation in order to prevent
damage to the robot controller.

External axis (optional)

The prescribed transport position of the external axis (e.g. KUKA linear
unit, turn-tilt table, positioner) must be observed. Transportation must be
carried out in accordance with the operating instructions or assembly in-
structions of the external axis.

3.5.3 Start-up and recommissioning

Before starting up systems and devices for the first time, a check must be
carried out to ensure that the systems and devices are complete and op-
erational, that they can be operated safely and that any damage is detec-
ted.
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.
Changing default passwords
The system software is supplied with default passwords for the user
groups. If the passwords are not changed, this enables unauthorized
persons to log on.
• Before start-up, change the passwords for the user groups.
• Only communicate the passwords to authorized personnel.

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WARNING
Danger to life and limb due to incorrectly assigned cables
The robot controller is preconfigured for the specific industrial robot. The
manipulator and other components can receive incorrect data if they are
connected to a different robot controller. Death, severe injuries or dam-
age to property may result.
• Only connect the manipulator to the corresponding robot controller.

Do not impair safety functions

Additional components (e.g. cables and hoses) not supplied by KUKA
may be integrated into the industrial robot. If the safety functions are not
taken into consideration, this may result in death, severe injuries or
damage to property.
• Additional components must not impair or disable safety functions.

NOTICE
Damage to property due to condensation
If the internal cabinet temperature of the robot controller differs greatly
from the ambient temperature, condensation can form. This may result
in damage to property.
• Wait until the internal cabinet temperature has adapted to the ambi-
ent temperature in order to avoid condensation.

Function test

The following tests must be carried out before start-up and recommission-
ing:
It must be ensured that:

• The industrial robot is correctly installed and fastened in accordance

with the specifications in the documentation.
• There is no damage to the robot that could be attributed to external
forces. Example: Dents or abrasion that could be caused by an impact
or collision.
WARNING
Danger to life and limb resulting from external forces
The external application of force, such as an impact or a collision,
can cause non-visible damage. For example, it can lead to a gradu-
al loss of drive power from the motor, resulting in unintended move-
ments of the manipulator.
Death, severe injuries or damage to property may result from non-
visible damage.
‒ Check the robot for damage that could have been caused by ex-
ternal forces, e.g. dents or abrasion of paintwork.
Check the motor and counterbalancing system particularly care-
fully.
(Motor inspection not relevant for robots with internal motors.)
‒ In the case of damage, the affected components must be ex-
changed.

• There are no foreign bodies or defective or loose parts on the industri-

al robot.
• All required safety equipment is correctly installed and operational.
• The power supply ratings of the industrial robot correspond to the
local supply voltage and mains type.

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Safety
• The ground conductor and the equipotential bonding cable are suffi-
ciently rated and correctly connected.
• The connecting cables are correctly connected and the connectors are
locked.

3.5.4 Manual mode

General

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 opera-
tion. Setup work includes:
• Jog mode
• Teaching
• Programming
• Program verification
The following must be taken into consideration in manual mode:
• New or modified programs must always be tested first in Manual Re-
duced Velocity mode (T1).
• The manipulator, tooling or external axes (optional) must never touch
or project beyond the safety fence.
• Workpieces, tooling and other objects must not jam as a result of the
industrial robot motion, nor must they lead to short-circuits or be liable
to fall off.
• All setup work must be carried out, where possible, from outside the
safeguarded area.

Setup work in T1

If it can be avoided, there must be no persons inside the safeguarded

area.
If it is necessary to carry out setup work from inside the safeguarded
area, the following must be taken into consideration in the operating mode
Manual Reduced Velocity (T1):
• If it can be avoided, there must be no more than one person inside
the safeguarded area.
• If it is necessary for there to be several persons inside the safeguar-
ded area, the following 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.
• The operator must be so positioned that he can see into the danger
zone and get out of harm’s way.
• Unexpected motions of the manipulator cannot be ruled out, e.g. in
the event of a fault. For this reason, an appropriate clearance must be
maintained between persons and the manipulator, including the tool.
Guide value: 50 cm.
The minimum clearance may vary depending on local circumstances,
the motion program and other factors. The minimum clearance that is
to apply for the specific application must be decided by the user on
the basis of a risk assessment.

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Setup work in T2

If it is necessary to carry out setup work from inside the safeguarded

area, the following must be taken into consideration in the operating mode
Manual High Velocity (T2):
• This mode may only be used if the application requires a test at a ve-
locity higher than that possible in T1 mode.
• Teaching and programming are not permissible in this operating mode.
• Before commencing the test, the operator must ensure that the ena-
bling devices are operational.
• The operator must be positioned outside the danger zone.
• There must be no other persons inside the safeguarded area. It is the
responsibility of the operator to ensure this.

3.5.5 Automatic mode

Automatic mode is only permissible in compliance with the following safety

measures:

• All safety equipment and safeguards are present and operational.

• There are no persons in the system or the requirements for collabora-
tive operation in accordance with EN ISO 10218 have been met.
• 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 EMER-
GENCY STOP has been triggered.

3.5.6 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 regula-
tions must be observed for this check. The correct functioning of all safety
functions 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:
• 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 personnel.
• 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 addi-
tional safety measures to ensure the safe protection of personnel.
• If it is necessary to carry out work with the robot controller switched
on, this may only be done in operating mode T1.
• 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.
• The EMERGENCY STOP devices must remain active. If safety func-
tions or safeguards are deactivated during maintenance or repair work,
they must be reactivated immediately after the work is completed.

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DANGER
Danger to life and limb due to live parts
The robot system must be disconnected from the mains power supply
prior to work on live parts. It is not sufficient to trigger an EMERGENCY
STOP or safety stop, because parts remain live. Death or severe inju-
ries may result.
• Before commencing work on live parts, turn off the main switch and
secure it against being switched on again.
If the controller variant in question does not have a main switch
(e.g. KR C5 micro), turn off the device switch then disconnect the
power cable and secure it so it cannot be reconnected.
• Then check to ensure that the system is deenergized.
• Inform the individuals involved that the robot controller is switched
off. (e.g. by affixing a warning sign)

Faulty components must be replaced using new components with the

same article numbers or equivalent components approved by the manu-
facturer for this purpose.
Cleaning and preventive maintenance work is to be carried out in accord-
ance with the operating instructions.

Robot controller

Even when the robot controller is switched off, parts connected to periph-
eral devices may still carry voltage. The external power sources must
therefore be switched off if work is to be carried out on the robot control-
ler.
The ESD regulations must be adhered to when working on components in
the robot controller.
Voltages in excess of 50 V (up to 780 V) can be present in various com-
ponents 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.
On robot controllers with transformers, the transformers must be discon-
nected before working on components in the robot controller.
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 counterbalancing system.
• Counterbalancing system classified below category I: Is subject to
the Pressure Equipment Directive but exempt from application of the
Pressure Equipment Directive according to Art. 4, para. 3 and there-
fore not CE marked.
• Counterbalancing system classified as category I or higher: Is
subject to the Pressure Equipment Directive and CE marked as a
component (see rating plate of the counterbalancing system). The
pressure equipment is placed on the market in conjunction with partly
completed machinery. Conformity is expressed on the declaration of
incorporation according to the Machinery Directive.
The user must comply with the applicable national laws, regulations and
standards pertaining to pressure equipment.
• In Germany, the counterbalancing system is work equipment according
to the German Ordinance on Industrial Safety and Health (BetrSichV).
Inspection intervals in Germany in accordance with the Ordinance on

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Industrial Safety and Health, Sections 14 and 15. Inspection by the

Safety

user before commissioning at the installation site.

• Inspection intervals in all other countries must be researched and ob-
served. As a rule, however, at least the maintenance intervals speci-
fied by KUKA must be observed. These must not be exceeded.
The following safety measures must be carried out when working on the
counterbalancing system:
• The assemblies supported by the counterbalancing systems must be
secured.
• 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 hazard-
ous substances:
• Avoid prolonged and repeated intensive contact with the skin.
• Avoid breathing in oil spray or vapors.
• Clean skin and apply skin cream.

Use current safety data sheets

Knowledge of the safety data sheets of the substances and mixtures
used is a prerequisite for the safe use of KUKA products. Death,
injuries or damage to property may otherwise result.
• Request up-to-date safety data sheets from the manufacturers of
hazardous substances regularly.

3.5.7 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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Technical data
4 Technical data

4.1 Technical data, overview

The technical data for the individual robot types can be found in the fol-
lowing sections:
Robot Technical data
KR 600 R2830 • Technical data
(>>> 4.2 "Technical data, KR 600 R2830" Page 34)
• Supplementary loads
• Plates and labels
(>>> 4.8 "Plates and labels" Page 104)
• Stopping distances and times
(>>> 4.10.2 "Stopping distances and times KR 600 R2830,
KR 600 R2830 F" Page 109)
KR 600 R2830 F • Technical data
(>>> 4.3 "Technical data, KR 600 R2830 F" Page 46)
• Supplementary loads
• Plates and labels
(>>> 4.8 "Plates and labels" Page 104)
• Stopping distances and times
(>>> 4.10.2 "Stopping distances and times KR 600 R2830,
KR 600 R2830 F" Page 109)
KR 510 R3080 • Technical data
(>>> 4.4 "Technical data, KR 510 R3080" Page 58)
• Supplementary loads
• Plates and labels
(>>> 4.8 "Plates and labels" Page 104)
• Stopping distances and times
(>>> 4.10.3 "Stopping distances and times KR 510 R3080,
KR 510 R3080 F" Page 114)
KR 510 R3080 F • Technical data
(>>> 4.5 "Technical data, KR 510 R3080 F" Page 69)
• Supplementary loads
• Plates and labels
(>>> 4.8 "Plates and labels" Page 104)
• Stopping distances and times
(>>> 4.10.3 "Stopping distances and times KR 510 R3080,
KR 510 R3080 F" Page 114)

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Technical data KR 600 FORTEC

Robot Technical data

KR 420 R3330 • Technical data
(>>> 4.6 "Technical data, KR 420 R3330" Page 81)
• Supplementary loads
• Plates and labels
(>>> 4.8 "Plates and labels" Page 104)
• Stopping distances and times
(>>> 4.10.4 "Stopping distances and times KR 420 R3330,
KR 420 R3330 F" Page 120)
KR 420 R3330 F • Technical data
(>>> 4.7 "Technical data, KR 420 R3330 F" Page 92)
• Supplementary loads
• Plates and labels
(>>> 4.8 "Plates and labels" Page 104)
• Stopping distances and times
(>>> 4.10.4 "Stopping distances and times KR 420 R3330,
KR 420 R3330 F" Page 120)

4.2 Technical data, KR 600 R2830

4.2.1 Basic data, KR 600 R2830

Basic data

KR 600 R2830
Number of axes 6
Number of controlled axes 6
Volume of working envelope 68 m³
Pose repeatability (ISO 9283) ± 0.08 mm
Weight approx. 2650 kg
Rated payload 600 kg
Maximum payload 729 kg
Maximum reach 2826 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP65
60529)
Sound level < 75 dB (A)
Mounting position Floor
Footprint 1050 mm x 1050 mm
Hole pattern: mounting surface for S960
kinematic system
Permissible angle of inclination ± 0 °
Default color Base frame: black (RAL 9011);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)

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Technical data
KR 600 R2830
Controller KR C5 L6/L7;
KR C4
Transformation name KR C4: KR600R2830 C4 FLR;
KR C5: KR600R2830 C4 FLR

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Ambient temperature
During operation 10 °C to 55 °C (283 K to 328 K)
During storage/transportation -25 °C to 60 °C (248 K to 333 K)

For operation at low temperatures, it may be necessary to warm up the

robot.

Connecting cables, KR C4

Cable designation Connector designa- Interface with robot

tion
robot controller -
robot
Motor cable X30.1 X20.1 - X30.1 HAN size 24
Motor cable X30.4 X20.4 - X30.4 HAN size 24
Data cable X31 X21 - X31 Han® 3A
Ground conductor / M8 ring cable lug at
equipotential bonding both ends
16 mm2

Cable lengths 7 m, 15 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see .

Connecting cables, KR C5

Cable designation Connector designation Interface with robot

robot controller -
robot
Motor cable XD30.1 3 motor connectors: HAN size 24
XD20.1/XD20.2/XD20.3 - XD30.1
1 brake connector:
XD10.1 - XD30.1
Motor cable XD30.4 3 motor connectors: HAN size 24
XD20.4/XD20.5/XD20.6 - XD30.4
1 brake connector:
XD10.2 - XD30.4
Data cable XF31 XF21 - XF31 Han® 3A

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Technical data KR 600 FORTEC

Cable designation Connector designation Interface with robot

robot controller -
robot
Ground conductor / equipotential Ring cable lug, M8
bonding
16 mm2

Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see: (>>> 7.6 "De-
scription of the connecting cables, KR C5" Page 159)

4.2.2 Axis data, KR 600 R2830

Axis data

Motion range
A1 ±185 °
A2 -130 ° / 20 °
A3 -100 ° / 144 °
A4 ±350 °
A5 ±120 °
A6 ±350 °
Speed with rated payload
A1 80 °/s
A2 75 °/s
A3 70 °/s
A4 70 °/s
A5 70 °/s
A6 110 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-1).

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Technical data
Fig. 4-1: Direction of rotation of robot axes

Mastering positions

Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 0 °
A5 0 °
A6 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.
The reference point for the working envelope is the intersection of axes 4
and 5.

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Technical data KR 600 FORTEC

Fig. 4-2: Working envelope, side view, KR 600 R2830

Fig. 4-3: Working envelope, top view, KR 600 R2830

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Technical data
4.2.3 Payloads, KR 600 R2830

Payloads

Rated payload 600 kg

Maximum payload 729 kg
Rated supplementary load, base 0 kg
frame
Maximum supplementary load, 0 kg
base frame
Rated supplementary load, rotating 0 kg
column
Maximum supplementary load, ro- 400 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 100 kg
arm
Rated supplementary load, arm 50 kg
Maximum supplementary load, arm 100 kg
Rated mass moment of inertia for flange
Rated mass moment of inertia for 300 kgm²
flange Ix
Rated mass moment of inertia for 300 kgm²
flange Iy
Rated mass moment of inertia for 300 kgm²
flange Iz
Nominal distance to load center of gravity
Lxy 350 mm
Lz 300 mm

Load center of gravity and mass moment of inertia

Fig. 4-4: Load center of gravity and mass moment of inertia

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Technical data KR 600 FORTEC

Parameter

Parameter/unit Description
Mass kg Payload mass
Lx, Ly, Lz mm Position of the center of mass in the reference
system
A, B, C Degrees Orientation of the principal inertia axes

• A: Rotation about the Z axis of the refer-

ence system
The result is a coordinate system named
CS'.
• B: Rotation about the Y axis of CS'
Result: CS''
• C: Rotation about the X axis of CS''
Note: A, B and C are not shown in the dia-
gram.

Mass moments of inertia:

Ix kgm2 Inertia about the X axis of the main axis sys-
tem
Iy kgm2 Inertia about the Y axis of the main axis sys-
tem
Iz kgm2 Inertia about the Z axis of the main axis sys-
tem
Lx, Ly, Lz and A, B, C unambiguously define the main axis system:
• The origin of the main axis system is the center of mass.
• A characteristic feature of the main axis system is that, among other
things, the maximum possible inertia occurs about one of the 3 coordi-
nate axes.

Further information is contained in the KUKA Load documentation.

Payload diagram

NOTICE
This loading curve corresponds to the maximum load capacity. Both val-
ues (payload and mass moment of inertia) must be checked in all ca-
ses. Exceeding this capacity will reduce the service life of the robot and
overload the motors and the gears; in any such case KUKA Service
must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For start-up of the robot, additional input data are required in ac-
cordance with the documentation for the system software.
The mass inertia must be verified using KUKA Load. It is imperative for
the load data to be entered in the robot controller!

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Technical data
Fig. 4-5: KR 600 R2830, payload diagram

The manipulator is designed for its respective rated payload in order to

optimize the dynamic performance of the robot. With reduced load center
distances and favorable supplementary loads, the maximum payload can
be mounted. The specific load case must be verified using KUKA Load.
For further consultation, please contact KUKA Service.

Mounting flange

Robot wrist type ZH600-4

Mounting flange standard ISO 9409-1-200-11-M12

Diameter (hole circle) 335 mm

Thread diameter M12
Depth of engagement min. 14 mm, max. 18 mm
Number of threads 12
Screw grade 12.9
Locating element 12 H7

The mounting flange is depicted with axis 6 in the zero position. The sym-
bol Xm indicates the position of the locating element (bushing) in the zero
position.

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Technical data KR 600 FORTEC

Fig. 4-6: Mounting flange

Flange loads

The motion of the robot causes forces and torques to act on the mounting
flange, which are transmitted to the mounted payload (e.g. tool).
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot
controller. The robot controller takes the payload into consideration during
path planning.
The payload must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the tool
Incorrectly dimensioned tools can fracture and fail. Death, severe inju-
ries or damage to property may result.
• Calculate the tool for each individual case, taking the load data into
consideration.
• Use the specified installation equipment.

Fig. 4-7: Flange loads

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Technical data
Flange loads during operation
F(a) 9200 N
F(r) 7900 N
M(k) 4200 Nm
M(g) 2310 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 10500 N
F(r) 12500 N
M(k) 9000 Nm
M(g) 5600 Nm
Axial force F(a), radial force F(r), tilting torque M(k), torque about mount-
ing flange M(g)

Supplementary load

The robot can carry supplementary loads. The fastening holes on the arm,
link arm and rotating column are used, for example, for fastening the cov-
ers or external energy supply systems. The fastening holes on the in-line
wrist are exclusively for fastening holders for energy supply systems (e.g.
holders for compressed air hose).
When mounting the supplementary loads, be careful to observe the maxi-
mum permissible total load. The dimensions and positions of the installa-
tion options can be seen in the following diagrams.

Fig. 4-8: Supplementary load, arm

1 Support bracket for supplementary load

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Technical data KR 600 FORTEC

Fig. 4-9: Fastening the supplementary load, link arm / rotating col-
umn

4.2.4 Foundation loads, KR 600 R2830

Depending on the payload (e.g. tool), supplementary load and the robot’s
own mass (weight), the motion of the robot generates forces and torques
which are transmitted to the foundation.
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot

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 KR 600 FORTEC

controller. The robot controller takes the payload into consideration during

Technical data
path planning.
Supplementary loads on A1 (rotating column) and A2 (link arm) are not
taken into consideration in the calculation of the foundation load. These
must be taken into account in the vertical force (Fv).
The foundation must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the founda-
tion
An incorrectly dimensioned foundation can fracture and fail. Death, se-
vere injuries or damage to property may result.
• Calculate the foundation loads for each individual case.
• Use the specified installation equipment.

Vertical force F(v)

F(v normal) 37000 N
F(v max) 40500 N
Horizontal force F(h)
F(h normal) 15900 N
F(h max) 23500 N
Tilting moment M(k)
M(k normal) 58900 Nm
M(k max) 84500 Nm
Torque about axis 1 M(r)
M(r normal) 18500 Nm
M(r max) 45500 Nm

Fig. 4-10: Foundation loads, floor mounting

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Technical data KR 600 FORTEC

4.3 Technical data, KR 600 R2830 F

4.3.1 Basic data, KR 600 R2830 F

Basic data

KR 600 R2830 F
Number of axes 6
Number of controlled axes 6
Volume of working envelope 68 m³
Pose repeatability (ISO 9283) ± 0.08 mm
Weight approx. 2650 kg
Rated payload 600 kg
Maximum payload 729 kg
Maximum reach 2826 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP67
60529)
Sound level < 75 dB (A)
Mounting position Floor
Footprint 1050 mm x 1050 mm
Hole pattern: mounting surface for S960
kinematic system
Permissible angle of inclination ± 0 °
Default color Base frame: black (RAL 9011);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)
Controller KR C5 L6/L7;
KR C4
Transformation name KR C4: KR600R2830 C4 FLR;
KR C5: KR600R2830 C4 FLR

Foundry robots

Overpressure in the arm 0.01 MPa (0.1 bar)

Compressed air Free of oil and water
in accordance with ISO
8573-1:2010 (7:4:4)
Compressed air supply line Air line in the cable set
Air consumption 0.1 m3/h
Air line connection Quick Star push-in fitting for hose
PUN-6x1, blue
Pressure regulator connection R 1/8", internal thread
Input pressure 0.1 - 1.2 MPa (1 - 12 bar)
Pressure regulator 0.005 - 0.07 MPa (0.05 - 0.7 bar)
Manometer range 0.0 - 0.1 MPa (0.0 - 1.0 bar)
Thermal load of the wrist 10 s/min at 453 K (180 °C)

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Technical data
Resistance Increased resistance to dust, lubri-
cants, coolants and water vapor.
Special paint finish on the robot Special paint finish on the entire
robot, and an additional protective
clear coat.
Other ambient conditions KUKA Deutschland GmbH must be
consulted if the robot is to be used
under other ambient conditions.

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Ambient temperature
During operation 10 °C to 55 °C (283 K to 328 K)
During storage/transportation -25 °C to 60 °C (248 K to 333 K)

For operation at low temperatures, it may be necessary to warm up the

robot.

Connecting cables, KR C4

Cable designation Connector designa- Interface with robot

tion
robot controller -
robot
Motor cable X30.1 X20.1 - X30.1 HAN size 24
Motor cable X30.4 X20.4 - X30.4 HAN size 24
Data cable X31 X21 - X31 Han® 3A
Ground conductor / M8 ring cable lug at
equipotential bonding both ends
16 mm2

Cable lengths 7 m, 15 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see .

Connecting cables, KR C5

Cable designation Connector designation Interface with robot

robot controller -
robot
Motor cable XD30.1 3 motor connectors: HAN size 24
XD20.1/XD20.2/XD20.3 - XD30.1
1 brake connector:
XD10.1 - XD30.1
Motor cable XD30.4 3 motor connectors: HAN size 24
XD20.4/XD20.5/XD20.6 - XD30.4
1 brake connector:
XD10.2 - XD30.4

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Technical data KR 600 FORTEC

Cable designation Connector designation Interface with robot

robot controller -
robot
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipotential Ring cable lug, M8
bonding
16 mm2

Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see: (>>> 7.6 "De-
scription of the connecting cables, KR C5" Page 159)

4.3.2 Axis data, KR 600 R2830 F

Axis data

Motion range
A1 ±185 °
A2 -130 ° / 20 °
A3 -100 ° / 144 °
A4 ±350 °
A5 ±120 °
A6 ±350 °
Speed with rated payload
A1 80 °/s
A2 75 °/s
A3 70 °/s
A4 70 °/s
A5 70 °/s
A6 110 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-11).

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Technical data
Fig. 4-11: Direction of rotation of robot axes

Mastering positions

Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 0 °
A5 0 °
A6 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.
The reference point for the working envelope is the intersection of axes 4
and 5.

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Technical data KR 600 FORTEC

Fig. 4-12: Working envelope, side view, KR 600 R2830 F

Fig. 4-13: Working envelope, top view, KR 600 R2830 F

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Technical data
4.3.3 Payloads, KR 600 R2830 F

Payloads

Rated payload 600 kg

Maximum payload 729 kg
Rated supplementary load, base 0 kg
frame
Maximum supplementary load, 0 kg
base frame
Rated supplementary load, rotating 0 kg
column
Maximum supplementary load, ro- 400 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 100 kg
arm
Rated supplementary load, arm 50 kg
Maximum supplementary load, arm 100 kg
Rated mass moment of inertia for flange
Rated mass moment of inertia for 300 kgm²
flange Ix
Rated mass moment of inertia for 300 kgm²
flange Iy
Rated mass moment of inertia for 300 kgm²
flange Iz
Nominal distance to load center of gravity
Lxy 350 mm
Lz 300 mm

Load center of gravity and mass moment of inertia

Fig. 4-14: Load center of gravity and mass moment of inertia

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Technical data KR 600 FORTEC

Parameter

Parameter/unit Description
Mass kg Payload mass
Lx, Ly, Lz mm Position of the center of mass in the reference
system
A, B, C Degrees Orientation of the principal inertia axes

• A: Rotation about the Z axis of the refer-

ence system
The result is a coordinate system named
CS'.
• B: Rotation about the Y axis of CS'
Result: CS''
• C: Rotation about the X axis of CS''
Note: A, B and C are not shown in the dia-
gram.

Mass moments of inertia:

Ix kgm2 Inertia about the X axis of the main axis sys-
tem
Iy kgm2 Inertia about the Y axis of the main axis sys-
tem
Iz kgm2 Inertia about the Z axis of the main axis sys-
tem
Lx, Ly, Lz and A, B, C unambiguously define the main axis system:
• The origin of the main axis system is the center of mass.
• A characteristic feature of the main axis system is that, among other
things, the maximum possible inertia occurs about one of the 3 coordi-
nate axes.

Further information is contained in the KUKA Load documentation.

Payload diagram

NOTICE
This loading curve corresponds to the maximum load capacity. Both val-
ues (payload and mass moment of inertia) must be checked in all ca-
ses. Exceeding this capacity will reduce the service life of the robot and
overload the motors and the gears; in any such case KUKA Service
must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For start-up of the robot, additional input data are required in ac-
cordance with the documentation for the system software.
The mass inertia must be verified using KUKA Load. It is imperative for
the load data to be entered in the robot controller!

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Technical data
Fig. 4-15: KR 600 R2830 F, payload diagram

The manipulator is designed for its respective rated payload in order to

optimize the dynamic performance of the robot. With reduced load center
distances and favorable supplementary loads, the maximum payload can
be mounted. The specific load case must be verified using KUKA Load.
For further consultation, please contact KUKA Service.

Mounting flange

Robot wrist type ZH600-4F

Mounting flange standard ISO 9409-1-200-11-M12

Diameter (hole circle) 335 mm

Thread diameter M12
Depth of engagement min. 14 mm, max. 18 mm
Number of threads 12
Screw grade 12.9
Locating element 12 H7

The mounting flange is depicted with axis 6 in the zero position. The sym-
bol Xm indicates the position of the locating element (bushing) in the zero
position.

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Technical data KR 600 FORTEC

Fig. 4-16: Mounting flange

Flange loads

The motion of the robot causes forces and torques to act on the mounting
flange, which are transmitted to the mounted payload (e.g. tool).
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot
controller. The robot controller takes the payload into consideration during
path planning.
The payload must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the tool
Incorrectly dimensioned tools can fracture and fail. Death, severe inju-
ries or damage to property may result.
• Calculate the tool for each individual case, taking the load data into
consideration.
• Use the specified installation equipment.

Fig. 4-17: Flange loads

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Technical data
Flange loads during operation
F(a) 9200 N
F(r) 7900 N
M(k) 4200 Nm
M(g) 2310 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 10500 N
F(r) 12500 N
M(k) 9000 Nm
M(g) 5600 Nm
Axial force F(a), radial force F(r), tilting torque M(k), torque about mount-
ing flange M(g)

Supplementary load

The robot can carry supplementary loads. The fastening holes on the arm,
link arm and rotating column are used, for example, for fastening the cov-
ers or external energy supply systems. The fastening holes on the in-line
wrist are exclusively for fastening holders for energy supply systems (e.g.
holders for compressed air hose).
When mounting the supplementary loads, be careful to observe the maxi-
mum permissible total load. The dimensions and positions of the installa-
tion options can be seen in the following diagrams.

Fig. 4-18: Supplementary load, arm

1 Support bracket for supplementary load

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Technical data KR 600 FORTEC

Fig. 4-19: Fastening the supplementary load, link arm / rotating col-
umn

4.3.4 Foundation loads, KR 600 R2830 F

Depending on the payload (e.g. tool), supplementary load and the robot’s
own mass (weight), the motion of the robot generates forces and torques
which are transmitted to the foundation.
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot

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 KR 600 FORTEC

controller. The robot controller takes the payload into consideration during

Technical data
path planning.
Supplementary loads on A1 (rotating column) and A2 (link arm) are not
taken into consideration in the calculation of the foundation load. These
must be taken into account in the vertical force (Fv).
The foundation must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the founda-
tion
An incorrectly dimensioned foundation can fracture and fail. Death, se-
vere injuries or damage to property may result.
• Calculate the foundation loads for each individual case.
• Use the specified installation equipment.

Vertical force F(v)

F(v normal) 37000 N
F(v max) 40500 N
Horizontal force F(h)
F(h normal) 15900 N
F(h max) 23500 N
Tilting moment M(k)
M(k normal) 58900 Nm
M(k max) 84500 Nm
Torque about axis 1 M(r)
M(r normal) 18500 Nm
M(r max) 45500 Nm

Fig. 4-20: Foundation loads, floor mounting

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Technical data KR 600 FORTEC

4.4 Technical data, KR 510 R3080

4.4.1 Basic data, KR 510 R3080

Basic data

KR 510 R3080
Number of axes 6
Number of controlled axes 6
Volume of working envelope 88 m³
Pose repeatability (ISO 9283) ± 0.08 mm
Weight approx. 2680 kg
Rated payload 510 kg
Maximum payload 635 kg
Maximum reach 3076 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP65
60529)
Sound level < 75 dB (A)
Mounting position Floor
Footprint 1050 mm x 1050 mm
Hole pattern: mounting surface for S960
kinematic system
Permissible angle of inclination ± 0 °
Default color Base frame: black (RAL 9011);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)
Controller KR C5 L6/L7;
KR C4
Transformation name KR C4: KR510R3080 C4 FLR;
KR C5: KR510R3080 C4 FLR

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Ambient temperature
During operation 10 °C to 55 °C (283 K to 328 K)
During storage/transportation -25 °C to 60 °C (248 K to 333 K)

For operation at low temperatures, it may be necessary to warm up the

robot.

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Technical data
Connecting cables, KR C4

Cable designation Connector designa- Interface with robot

tion
robot controller -
robot
Motor cable X30.1 X20.1 - X30.1 HAN size 24
Motor cable X30.4 X20.4 - X30.4 HAN size 24
Data cable X31 X21 - X31 Han® 3A
Ground conductor / M8 ring cable lug at
equipotential bonding both ends
16 mm2

Cable lengths 7 m, 15 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see .

Connecting cables, KR C5

Cable designation Connector designation Interface with robot

robot controller -
robot
Motor cable XD30.1 3 motor connectors: HAN size 24
XD20.1/XD20.2/XD20.3 - XD30.1
1 brake connector:
XD10.1 - XD30.1
Motor cable XD30.4 3 motor connectors: HAN size 24
XD20.4/XD20.5/XD20.6 - XD30.4
1 brake connector:
XD10.2 - XD30.4
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipotential Ring cable lug, M8
bonding
16 mm2

Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see: (>>> 7.6 "De-
scription of the connecting cables, KR C5" Page 159)

4.4.2 Axis data, KR 510 R3080

Axis data

Motion range
A1 ±185 °
A2 -130 ° / 20 °
A3 -100 ° / 144 °
A4 ±350 °

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Technical data KR 600 FORTEC

A5 ±120 °
A6 ±350 °
Speed with rated payload
A1 80 °/s
A2 75 °/s
A3 70 °/s
A4 70 °/s
A5 70 °/s
A6 110 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-21).

Fig. 4-21: Direction of rotation of robot axes

Mastering positions

Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 0 °
A5 0 °
A6 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.
The reference point for the working envelope is the intersection of axes 4
and 5.

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Technical data
Fig. 4-22: Working envelope, side view, KR 510 R3080

Fig. 4-23: Working envelope, top view, KR 510 R3080

4.4.3 Payloads, KR 510 R3080

Payloads

Rated payload 510 kg

Maximum payload 635 kg

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Technical data KR 600 FORTEC

Rated supplementary load, base 0 kg

frame
Maximum supplementary load, 0 kg
base frame
Rated supplementary load, rotating 0 kg
column
Maximum supplementary load, ro- 400 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 100 kg
arm
Rated supplementary load, arm 50 kg
Maximum supplementary load, arm 100 kg
Rated mass moment of inertia for flange
Rated mass moment of inertia for 255 kgm²
flange Ix
Rated mass moment of inertia for 255 kgm²
flange Iy
Rated mass moment of inertia for 255 kgm²
flange Iz
Nominal distance to load center of gravity
Lxy 350 mm
Lz 300 mm

Load center of gravity and mass moment of inertia

Fig. 4-24: Load center of gravity and mass moment of inertia

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Technical data
Parameter

Parameter/unit Description
Mass kg Payload mass
Lx, Ly, Lz mm Position of the center of mass in the reference
system
A, B, C Degrees Orientation of the principal inertia axes

• A: Rotation about the Z axis of the refer-

ence system
The result is a coordinate system named
CS'.
• B: Rotation about the Y axis of CS'
Result: CS''
• C: Rotation about the X axis of CS''
Note: A, B and C are not shown in the dia-
gram.

Mass moments of inertia:

Ix kgm2 Inertia about the X axis of the main axis sys-
tem
Iy kgm2 Inertia about the Y axis of the main axis sys-
tem
Iz kgm2 Inertia about the Z axis of the main axis sys-
tem
Lx, Ly, Lz and A, B, C unambiguously define the main axis system:
• The origin of the main axis system is the center of mass.
• A characteristic feature of the main axis system is that, among other
things, the maximum possible inertia occurs about one of the 3 coordi-
nate axes.

Further information is contained in the KUKA Load documentation.

Payload diagram

NOTICE
This loading curve corresponds to the maximum load capacity. Both val-
ues (payload and mass moment of inertia) must be checked in all ca-
ses. Exceeding this capacity will reduce the service life of the robot and
overload the motors and the gears; in any such case KUKA Service
must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For start-up of the robot, additional input data are required in ac-
cordance with the documentation for the system software.
The mass inertia must be verified using KUKA Load. It is imperative for
the load data to be entered in the robot controller!

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Technical data KR 600 FORTEC

Fig. 4-25: KR 510 R3080, payload diagram

The manipulator is designed for its respective rated payload in order to

optimize the dynamic performance of the robot. With reduced load center
distances and favorable supplementary loads, the maximum payload can
be mounted. The specific load case must be verified using KUKA Load.
For further consultation, please contact KUKA Service.

Mounting flange

Robot wrist type ZH600-4

Mounting flange standard ISO 9409-1-200-11-M12

Diameter (hole circle) 335 mm

Thread diameter M12
Depth of engagement min. 14 mm, max. 18 mm
Number of threads 12
Screw grade 12.9
Locating element 12 H7

The mounting flange is depicted with axis 6 in the zero position. The sym-
bol Xm indicates the position of the locating element (bushing) in the zero
position.

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Technical data
Fig. 4-26: Mounting flange

Flange loads

The motion of the robot causes forces and torques to act on the mounting
flange, which are transmitted to the mounted payload (e.g. tool).
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot
controller. The robot controller takes the payload into consideration during
path planning.
The payload must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the tool
Incorrectly dimensioned tools can fracture and fail. Death, severe inju-
ries or damage to property may result.
• Calculate the tool for each individual case, taking the load data into
consideration.
• Use the specified installation equipment.

Fig. 4-27: Flange loads

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Technical data KR 600 FORTEC

Flange loads during operation

F(a) 9200 N
F(r) 7900 N
M(k) 4200 Nm
M(g) 2310 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 10500 N
F(r) 12500 N
M(k) 9000 Nm
M(g) 5600 Nm
Axial force F(a), radial force F(r), tilting torque M(k), torque about mount-
ing flange M(g)

Supplementary load

The robot can carry supplementary loads. The fastening holes on the arm,
link arm and rotating column are used, for example, for fastening the cov-
ers or external energy supply systems. The fastening holes on the in-line
wrist are exclusively for fastening holders for energy supply systems (e.g.
holders for compressed air hose).
When mounting the supplementary loads, be careful to observe the maxi-
mum permissible total load. The dimensions and positions of the installa-
tion options can be seen in the following diagrams.

Fig. 4-28: Supplementary load, arm

1 Support bracket for supplementary load

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Technical data

Fig. 4-29: Fastening the supplementary load, link arm / rotating col-
umn

4.4.4 Foundation loads, KR 510 R3080

Depending on the payload (e.g. tool), supplementary load and the robot’s
own mass (weight), the motion of the robot generates forces and torques
which are transmitted to the foundation.
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot

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 KR 600 FORTEC

controller. The robot controller takes the payload into consideration during
Technical data

path planning.
Supplementary loads on A1 (rotating column) and A2 (link arm) are not
taken into consideration in the calculation of the foundation load. These
must be taken into account in the vertical force (Fv).
The foundation must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the founda-
tion
An incorrectly dimensioned foundation can fracture and fail. Death, se-
vere injuries or damage to property may result.
• Calculate the foundation loads for each individual case.
• Use the specified installation equipment.

Vertical force F(v)

F(v normal) 37000 N
F(v max) 40500 N
Horizontal force F(h)
F(h normal) 15900 N
F(h max) 23500 N
Tilting moment M(k)
M(k normal) 58900 Nm
M(k max) 84500 Nm
Torque about axis 1 M(r)
M(r normal) 18500 Nm
M(r max) 45500 Nm

Fig. 4-30: Foundation loads, floor mounting

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Technical data
4.5 Technical data, KR 510 R3080 F

4.5.1 Basic data, KR 510 R3080 F

Basic data

KR 510 R3080 F
Number of axes 6
Number of controlled axes 6
Volume of working envelope 88 m³
Pose repeatability (ISO 9283) ± 0.08 mm
Weight approx. 2680 kg
Rated payload 510 kg
Maximum payload 635 kg
Maximum reach 3076 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP67
60529)
Sound level < 75 dB (A)
Mounting position Floor
Footprint 1050 mm x 1050 mm
Hole pattern: mounting surface for S960
kinematic system
Permissible angle of inclination ± 0 °
Default color Base frame: black (RAL 9011);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)
Controller KR C5 L6/L7;
KR C4
Transformation name KR C4: KR510R3080 C4 FLR;
KR C5: KR510R3080 C4 FLR

Foundry robots

Overpressure in the arm 0.01 MPa (0.1 bar)

Compressed air Free of oil and water
in accordance with ISO
8573-1:2010 (7:4:4)
Compressed air supply line Air line in the cable set
Air consumption 0.1 m3/h
Air line connection Quick Star push-in fitting for hose
PUN-6x1, blue
Pressure regulator connection R 1/8", internal thread
Input pressure 0.1 - 1.2 MPa (1 - 12 bar)
Pressure regulator 0.005 - 0.07 MPa (0.05 - 0.7 bar)
Manometer range 0.0 - 0.1 MPa (0.0 - 1.0 bar)
Thermal load of the wrist 10 s/min at 453 K (180 °C)

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Technical data KR 600 FORTEC

Resistance Increased resistance to dust, lubri-

cants, coolants and water vapor.
Special paint finish on the robot Special paint finish on the entire
robot, and an additional protective
clear coat.
Other ambient conditions KUKA Deutschland GmbH must be
consulted if the robot is to be used
under other ambient conditions.

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Ambient temperature
During operation 10 °C to 55 °C (283 K to 328 K)
During storage/transportation -25 °C to 60 °C (248 K to 333 K)

For operation at low temperatures, it may be necessary to warm up the

robot.

Connecting cables, KR C4

Cable designation Connector designa- Interface with robot

tion
robot controller -
robot
Motor cable X30.1 X20.1 - X30.1 HAN size 24
Motor cable X30.4 X20.4 - X30.4 HAN size 24
Data cable X31 X21 - X31 Han® 3A
Ground conductor / M8 ring cable lug at
equipotential bonding both ends
16 mm2

Cable lengths 7 m, 15 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see .

Connecting cables, KR C5

Cable designation Connector designation Interface with robot

robot controller -
robot
Motor cable XD30.1 3 motor connectors: HAN size 24
XD20.1/XD20.2/XD20.3 - XD30.1
1 brake connector:
XD10.1 - XD30.1
Motor cable XD30.4 3 motor connectors: HAN size 24
XD20.4/XD20.5/XD20.6 - XD30.4
1 brake connector:
XD10.2 - XD30.4

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Technical data
Cable designation Connector designation Interface with robot
robot controller -
robot
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipotential Ring cable lug, M8
bonding
16 mm2

Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see: (>>> 7.6 "De-
scription of the connecting cables, KR C5" Page 159)

4.5.2 Axis data, KR 510 R3080 F

Axis data

Motion range
A1 ±185 °
A2 -130 ° / 20 °
A3 -100 ° / 144 °
A4 ±350 °
A5 ±120 °
A6 ±350 °
Speed with rated payload
A1 80 °/s
A2 75 °/s
A3 70 °/s
A4 70 °/s
A5 70 °/s
A6 110 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-31).

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Technical data KR 600 FORTEC

Fig. 4-31: Direction of rotation of robot axes

Mastering positions

Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 0 °
A5 0 °
A6 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.
The reference point for the working envelope is the intersection of axes 4
and 5.

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Technical data
Fig. 4-32: Working envelope, side view, KR 510 R3080 F

Fig. 4-33: Working envelope, top view, KR 510 R3080 F

4.5.3 Payloads, KR 510 R3080 F

Payloads

Rated payload 510 kg

Maximum payload 635 kg

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Technical data KR 600 FORTEC

Rated supplementary load, base 0 kg

frame
Maximum supplementary load, 0 kg
base frame
Rated supplementary load, rotating 0 kg
column
Maximum supplementary load, ro- 400 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 100 kg
arm
Rated supplementary load, arm 50 kg
Maximum supplementary load, arm 100 kg
Rated mass moment of inertia for flange
Rated mass moment of inertia for 255 kgm²
flange Ix
Rated mass moment of inertia for 255 kgm²
flange Iy
Rated mass moment of inertia for 255 kgm²
flange Iz
Nominal distance to load center of gravity
Lxy 350 mm
Lz 300 mm

Load center of gravity and mass moment of inertia

Fig. 4-34: Load center of gravity and mass moment of inertia

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Technical data
Parameter

Parameter/unit Description
Mass kg Payload mass
Lx, Ly, Lz mm Position of the center of mass in the reference
system
A, B, C Degrees Orientation of the principal inertia axes

• A: Rotation about the Z axis of the refer-

ence system
The result is a coordinate system named
CS'.
• B: Rotation about the Y axis of CS'
Result: CS''
• C: Rotation about the X axis of CS''
Note: A, B and C are not shown in the dia-
gram.

Mass moments of inertia:

Ix kgm2 Inertia about the X axis of the main axis sys-
tem
Iy kgm2 Inertia about the Y axis of the main axis sys-
tem
Iz kgm2 Inertia about the Z axis of the main axis sys-
tem
Lx, Ly, Lz and A, B, C unambiguously define the main axis system:
• The origin of the main axis system is the center of mass.
• A characteristic feature of the main axis system is that, among other
things, the maximum possible inertia occurs about one of the 3 coordi-
nate axes.

Further information is contained in the KUKA Load documentation.

Payload diagram

NOTICE
This loading curve corresponds to the maximum load capacity. Both val-
ues (payload and mass moment of inertia) must be checked in all ca-
ses. Exceeding this capacity will reduce the service life of the robot and
overload the motors and the gears; in any such case KUKA Service
must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For start-up of the robot, additional input data are required in ac-
cordance with the documentation for the system software.
The mass inertia must be verified using KUKA Load. It is imperative for
the load data to be entered in the robot controller!

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Technical data KR 600 FORTEC

Fig. 4-35: KR 510 R3080 F, payload diagram

The manipulator is designed for its respective rated payload in order to

optimize the dynamic performance of the robot. With reduced load center
distances and favorable supplementary loads, the maximum payload can
be mounted. The specific load case must be verified using KUKA Load.
For further consultation, please contact KUKA Service.

Mounting flange

Robot wrist type ZH600-4F

Mounting flange standard ISO 9409-1-200-11-M12

Diameter (hole circle) 335 mm

Thread diameter M12
Depth of engagement min. 14 mm, max. 18 mm
Number of threads 12
Screw grade 12.9
Locating element 12 H7

The mounting flange is depicted with axis 6 in the zero position. The sym-
bol Xm indicates the position of the locating element (bushing) in the zero
position.

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Technical data
Fig. 4-36: Mounting flange

Flange loads

The motion of the robot causes forces and torques to act on the mounting
flange, which are transmitted to the mounted payload (e.g. tool).
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot
controller. The robot controller takes the payload into consideration during
path planning.
The payload must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the tool
Incorrectly dimensioned tools can fracture and fail. Death, severe inju-
ries or damage to property may result.
• Calculate the tool for each individual case, taking the load data into
consideration.
• Use the specified installation equipment.

Fig. 4-37: Flange loads

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Technical data KR 600 FORTEC

Flange loads during operation

F(a) 9200 N
F(r) 7900 N
M(k) 4200 Nm
M(g) 2310 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 10500 N
F(r) 12500 N
M(k) 9000 Nm
M(g) 5600 Nm
Axial force F(a), radial force F(r), tilting torque M(k), torque about mount-
ing flange M(g)

Supplementary load

The robot can carry supplementary loads. The fastening holes on the arm,
link arm and rotating column are used, for example, for fastening the cov-
ers or external energy supply systems. The fastening holes on the in-line
wrist are exclusively for fastening holders for energy supply systems (e.g.
holders for compressed air hose).
When mounting the supplementary loads, be careful to observe the maxi-
mum permissible total load. The dimensions and positions of the installa-
tion options can be seen in the following diagrams.

Fig. 4-38: Supplementary load, arm

1 Support bracket for supplementary load

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Technical data

Fig. 4-39: Fastening the supplementary load, link arm / rotating col-
umn

4.5.4 Foundation loads, KR 510 R3080 F

Depending on the payload (e.g. tool), supplementary load and the robot’s
own mass (weight), the motion of the robot generates forces and torques
which are transmitted to the foundation.
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot

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 KR 600 FORTEC

controller. The robot controller takes the payload into consideration during
Technical data

path planning.
Supplementary loads on A1 (rotating column) and A2 (link arm) are not
taken into consideration in the calculation of the foundation load. These
must be taken into account in the vertical force (Fv).
The foundation must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the founda-
tion
An incorrectly dimensioned foundation can fracture and fail. Death, se-
vere injuries or damage to property may result.
• Calculate the foundation loads for each individual case.
• Use the specified installation equipment.

Vertical force F(v)

F(v normal) 37000 N
F(v max) 40500 N
Horizontal force F(h)
F(h normal) 15900 N
F(h max) 23500 N
Tilting moment M(k)
M(k normal) 58900 Nm
M(k max) 84500 Nm
Torque about axis 1 M(r)
M(r normal) 18500 Nm
M(r max) 45500 Nm

Fig. 4-40: Foundation loads, floor mounting

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Technical data
4.6 Technical data, KR 420 R3330

4.6.1 Basic data, KR 420 R3330

Basic data

KR 420 R3330
Number of axes 6
Number of controlled axes 6
Volume of working envelope 114.5 m³
Pose repeatability (ISO 9283) ± 0.08 mm
Weight approx. 2686 kg
Rated payload 420 kg
Maximum payload 515 kg
Maximum reach 3326 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP65
60529)
Sound level < 75 dB (A)
Mounting position Floor
Footprint 1050 mm x 1050 mm
Hole pattern: mounting surface for S960
kinematic system
Permissible angle of inclination ± 0 °
Default color Base frame: black (RAL 9011);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)
Controller KR C5 L6/L7;
KR C4
Transformation name KR C4: KR420R3330 C4 FLR;
KR C5: KR420R3330 C4 FLR

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Ambient temperature
During operation 10 °C to 55 °C (283 K to 328 K)
During storage/transportation -25 °C to 60 °C (248 K to 333 K)

For operation at low temperatures, it may be necessary to warm up the

robot.

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Technical data KR 600 FORTEC

Connecting cables, KR C4

Cable designation Connector designa- Interface with robot

tion
robot controller -
robot
Motor cable X30.1 X20.1 - X30.1 HAN size 24
Motor cable X30.4 X20.4 - X30.4 HAN size 24
Data cable X31 X21 - X31 Han® 3A
Ground conductor / M8 ring cable lug at
equipotential bonding both ends
16 mm2

Cable lengths 7 m, 15 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see .

Connecting cables, KR C5

Cable designation Connector designation Interface with robot

robot controller -
robot
Motor cable XD30.1 3 motor connectors: HAN size 24
XD20.1/XD20.2/XD20.3 - XD30.1
1 brake connector:
XD10.1 - XD30.1
Motor cable XD30.4 3 motor connectors: HAN size 24
XD20.4/XD20.5/XD20.6 - XD30.4
1 brake connector:
XD10.2 - XD30.4
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipotential Ring cable lug, M8
bonding
16 mm2

Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see: (>>> 7.6 "De-
scription of the connecting cables, KR C5" Page 159)

4.6.2 Axis data, KR 420 R3330

Axis data

Motion range
A1 ±185 °
A2 -130 ° / 20 °
A3 -100 ° / 144 °
A4 ±350 °

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Technical data
A5 ±120 °
A6 ±350 °
Speed with rated payload
A1 80 °/s
A2 75 °/s
A3 70 °/s
A4 70 °/s
A5 70 °/s
A6 110 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-41).

Fig. 4-41: Direction of rotation of robot axes

Mastering positions

Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 0 °
A5 0 °
A6 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.
The reference point for the working envelope is the intersection of axes 4
and 5.

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Fig. 4-42: Working envelope, side view, KR 420 R3330

Fig. 4-43: Working envelope, top view, KR 420 R3330

4.6.3 Payloads, KR 420 R3330

Payloads

Rated payload 420 kg

Maximum payload 515 kg

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Technical data
Rated supplementary load, base 0 kg
frame
Maximum supplementary load, 0 kg
base frame
Rated supplementary load, rotating 0 kg
column
Maximum supplementary load, ro- 400 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 100 kg
arm
Rated supplementary load, arm 50 kg
Maximum supplementary load, arm 100 kg
Rated mass moment of inertia for flange
Rated mass moment of inertia for 210 kgm²
flange Ix
Rated mass moment of inertia for 210 kgm²
flange Iy
Rated mass moment of inertia for 210 kgm²
flange Iz
Nominal distance to load center of gravity
Lxy 350 mm
Lz 300 mm

Load center of gravity and mass moment of inertia

Fig. 4-44: Load center of gravity and mass moment of inertia

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Parameter

Parameter/unit Description
Mass kg Payload mass
Lx, Ly, Lz mm Position of the center of mass in the reference
system
A, B, C Degrees Orientation of the principal inertia axes

• A: Rotation about the Z axis of the refer-

ence system
The result is a coordinate system named
CS'.
• B: Rotation about the Y axis of CS'
Result: CS''
• C: Rotation about the X axis of CS''
Note: A, B and C are not shown in the dia-
gram.

Mass moments of inertia:

Ix kgm2 Inertia about the X axis of the main axis sys-
tem
Iy kgm2 Inertia about the Y axis of the main axis sys-
tem
Iz kgm2 Inertia about the Z axis of the main axis sys-
tem
Lx, Ly, Lz and A, B, C unambiguously define the main axis system:
• The origin of the main axis system is the center of mass.
• A characteristic feature of the main axis system is that, among other
things, the maximum possible inertia occurs about one of the 3 coordi-
nate axes.

Further information is contained in the KUKA Load documentation.

Payload diagram

NOTICE
This loading curve corresponds to the maximum load capacity. Both val-
ues (payload and mass moment of inertia) must be checked in all ca-
ses. Exceeding this capacity will reduce the service life of the robot and
overload the motors and the gears; in any such case KUKA Service
must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For start-up of the robot, additional input data are required in ac-
cordance with the documentation for the system software.
The mass inertia must be verified using KUKA Load. It is imperative for
the load data to be entered in the robot controller!

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Technical data
Fig. 4-45: KR 420 R3330, payload diagram

The manipulator is designed for its respective rated payload in order to

optimize the dynamic performance of the robot. With reduced load center
distances and favorable supplementary loads, the maximum payload can
be mounted. The specific load case must be verified using KUKA Load.
For further consultation, please contact KUKA Service.

Mounting flange

Robot wrist type ZH600-4

Mounting flange standard ISO 9409-1-200-11-M12

Diameter (hole circle) 335 mm

Thread diameter M12
Depth of engagement min. 14 mm, max. 18 mm
Number of threads 12
Screw grade 12.9
Locating element 12 H7

The mounting flange is depicted with axis 6 in the zero position. The sym-
bol Xm indicates the position of the locating element (bushing) in the zero
position.

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Fig. 4-46: Mounting flange

Flange loads

The motion of the robot causes forces and torques to act on the mounting
flange, which are transmitted to the mounted payload (e.g. tool).
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot
controller. The robot controller takes the payload into consideration during
path planning.
The payload must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the tool
Incorrectly dimensioned tools can fracture and fail. Death, severe inju-
ries or damage to property may result.
• Calculate the tool for each individual case, taking the load data into
consideration.
• Use the specified installation equipment.

Fig. 4-47: Flange loads

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Technical data
Flange loads during operation
F(a) 9200 N
F(r) 7900 N
M(k) 4200 Nm
M(g) 2310 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 10500 N
F(r) 12500 N
M(k) 9000 Nm
M(g) 5600 Nm
Axial force F(a), radial force F(r), tilting torque M(k), torque about mount-
ing flange M(g)

Supplementary load

The robot can carry supplementary loads. The fastening holes on the arm,
link arm and rotating column are used, for example, for fastening the cov-
ers or external energy supply systems. The fastening holes on the in-line
wrist are exclusively for fastening holders for energy supply systems (e.g.
holders for compressed air hose).
When mounting the supplementary loads, be careful to observe the maxi-
mum permissible total load. The dimensions and positions of the installa-
tion options can be seen in the following diagrams.

Fig. 4-48: Supplementary load, arm

1 Support bracket for supplementary load

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Fig. 4-49: Fastening the supplementary load, link arm / rotating col-
umn

4.6.4 Foundation loads, KR 420 R3330

Depending on the payload (e.g. tool), supplementary load and the robot’s
own mass (weight), the motion of the robot generates forces and torques
which are transmitted to the foundation.
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot

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controller. The robot controller takes the payload into consideration during

Technical data
path planning.
Supplementary loads on A1 (rotating column) and A2 (link arm) are not
taken into consideration in the calculation of the foundation load. These
must be taken into account in the vertical force (Fv).
The foundation must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the founda-
tion
An incorrectly dimensioned foundation can fracture and fail. Death, se-
vere injuries or damage to property may result.
• Calculate the foundation loads for each individual case.
• Use the specified installation equipment.

Vertical force F(v)

F(v normal) 37000 N
F(v max) 40500 N
Horizontal force F(h)
F(h normal) 15900 N
F(h max) 23500 N
Tilting moment M(k)
M(k normal) 58900 Nm
M(k max) 84500 Nm
Torque about axis 1 M(r)
M(r normal) 18500 Nm
M(r max) 45500 Nm

Fig. 4-50: Foundation loads, floor mounting

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4.7 Technical data, KR 420 R3330 F

4.7.1 Basic data, KR 420 R3330 F

Basic data

KR 420 R3330 F
Number of axes 6
Number of controlled axes 6
Volume of working envelope 114.5 m³
Pose repeatability (ISO 9283) ± 0.08 mm
Weight approx. 2686 kg
Rated payload 420 kg
Maximum payload 515 kg
Maximum reach 3326 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP67
60529)
Sound level < 75 dB (A)
Mounting position Floor
Footprint 1050 mm x 1050 mm
Hole pattern: mounting surface for S960
kinematic system
Permissible angle of inclination ± 0 °
Default color Base frame: black (RAL 9011);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)
Controller KR C5 L6/L7;
KR C4
Transformation name KR C4: KR420R3330 C4 FLR;
KR C5: KR420R3330 C4 FLR

Foundry robots

Overpressure in the arm 0.01 MPa (0.1 bar)

Compressed air Free of oil and water
in accordance with ISO
8573-1:2010 (7:4:4)
Compressed air supply line Air line in the cable set
Air consumption 0.1 m3/h
Air line connection Quick Star push-in fitting for hose
PUN-6x1, blue
Pressure regulator connection R 1/8", internal thread
Input pressure 0.1 - 1.2 MPa (1 - 12 bar)
Pressure regulator 0.005 - 0.07 MPa (0.05 - 0.7 bar)
Manometer range 0.0 - 0.1 MPa (0.0 - 1.0 bar)
Thermal load of the wrist 10 s/min at 453 K (180 °C)

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Technical data
Resistance Increased resistance to dust, lubri-
cants, coolants and water vapor.
Special paint finish on the robot Special paint finish on the entire
robot, and an additional protective
clear coat.
Other ambient conditions KUKA Deutschland GmbH must be
consulted if the robot is to be used
under other ambient conditions.

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Ambient temperature
During operation 10 °C to 55 °C (283 K to 328 K)
During storage/transportation -25 °C to 60 °C (248 K to 333 K)

For operation at low temperatures, it may be necessary to warm up the

robot.

Connecting cables, KR C4

Cable designation Connector designa- Interface with robot

tion
robot controller -
robot
Motor cable X30.1 X20.1 - X30.1 HAN size 24
Motor cable X30.4 X20.4 - X30.4 HAN size 24
Data cable X31 X21 - X31 Han® 3A
Ground conductor / M8 ring cable lug at
equipotential bonding both ends
16 mm2

Cable lengths 7 m, 15 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see .

Connecting cables, KR C5

Cable designation Connector designation Interface with robot

robot controller -
robot
Motor cable XD30.1 3 motor connectors: HAN size 24
XD20.1/XD20.2/XD20.3 - XD30.1
1 brake connector:
XD10.1 - XD30.1
Motor cable XD30.4 3 motor connectors: HAN size 24
XD20.4/XD20.5/XD20.6 - XD30.4
1 brake connector:
XD10.2 - XD30.4

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Cable designation Connector designation Interface with robot

robot controller -
robot
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipotential Ring cable lug, M8
bonding
16 mm2

Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see: (>>> 7.6 "De-
scription of the connecting cables, KR C5" Page 159)

4.7.2 Axis data, KR 420 R3330 F

Axis data

Motion range
A1 ±185 °
A2 -130 ° / 20 °
A3 -100 ° / 144 °
A4 ±350 °
A5 ±120 °
A6 ±350 °
Speed with rated payload
A1 80 °/s
A2 75 °/s
A3 70 °/s
A4 70 °/s
A5 70 °/s
A6 110 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-51).

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Technical data
Fig. 4-51: Direction of rotation of robot axes

Mastering positions

Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 0 °
A5 0 °
A6 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.
The reference point for the working envelope is the intersection of axes 4
and 5.

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Fig. 4-52: Working envelope, side view, KR 420 R3330 F

Fig. 4-53: Working envelope, top view, KR 420 R3330 F

4.7.3 Payloads, KR 420 R3330 F

Payloads

Rated payload 420 kg

Maximum payload 515 kg

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Technical data
Rated supplementary load, base 0 kg
frame
Maximum supplementary load, 0 kg
base frame
Rated supplementary load, rotating 0 kg
column
Maximum supplementary load, ro- 400 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 100 kg
arm
Rated supplementary load, arm 50 kg
Maximum supplementary load, arm 100 kg
Rated mass moment of inertia for flange
Rated mass moment of inertia for 210 kgm²
flange Ix
Rated mass moment of inertia for 210 kgm²
flange Iy
Rated mass moment of inertia for 210 kgm²
flange Iz
Nominal distance to load center of gravity
Lxy 350 mm
Lz 300 mm

Load center of gravity and mass moment of inertia

Fig. 4-54: Load center of gravity and mass moment of inertia

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Parameter

Parameter/unit Description
Mass kg Payload mass
Lx, Ly, Lz mm Position of the center of mass in the reference
system
A, B, C Degrees Orientation of the principal inertia axes

• A: Rotation about the Z axis of the refer-

ence system
The result is a coordinate system named
CS'.
• B: Rotation about the Y axis of CS'
Result: CS''
• C: Rotation about the X axis of CS''
Note: A, B and C are not shown in the dia-
gram.

Mass moments of inertia:

Ix kgm2 Inertia about the X axis of the main axis sys-
tem
Iy kgm2 Inertia about the Y axis of the main axis sys-
tem
Iz kgm2 Inertia about the Z axis of the main axis sys-
tem
Lx, Ly, Lz and A, B, C unambiguously define the main axis system:
• The origin of the main axis system is the center of mass.
• A characteristic feature of the main axis system is that, among other
things, the maximum possible inertia occurs about one of the 3 coordi-
nate axes.

Further information is contained in the KUKA Load documentation.

Payload diagram

NOTICE
This loading curve corresponds to the maximum load capacity. Both val-
ues (payload and mass moment of inertia) must be checked in all ca-
ses. Exceeding this capacity will reduce the service life of the robot and
overload the motors and the gears; in any such case KUKA Service
must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For start-up of the robot, additional input data are required in ac-
cordance with the documentation for the system software.
The mass inertia must be verified using KUKA Load. It is imperative for
the load data to be entered in the robot controller!

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Technical data
Fig. 4-55: KR 420 R3330 F, payload diagram

The manipulator is designed for its respective rated payload in order to

optimize the dynamic performance of the robot. With reduced load center
distances and favorable supplementary loads, the maximum payload can
be mounted. The specific load case must be verified using KUKA Load.
For further consultation, please contact KUKA Service.

Mounting flange

Robot wrist type ZH600-4F

Mounting flange standard ISO 9409-1-200-11-M12

Diameter (hole circle) 335 mm

Thread diameter M12
Depth of engagement min. 14 mm, max. 18 mm
Number of threads 12
Screw grade 12.9
Locating element 12 H7

The mounting flange is depicted with axis 6 in the zero position. The sym-
bol Xm indicates the position of the locating element (bushing) in the zero
position.

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Fig. 4-56: Mounting flange

Flange loads

The motion of the robot causes forces and torques to act on the mounting
flange, which are transmitted to the mounted payload (e.g. tool).
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot
controller. The robot controller takes the payload into consideration during
path planning.
The payload must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the tool
Incorrectly dimensioned tools can fracture and fail. Death, severe inju-
ries or damage to property may result.
• Calculate the tool for each individual case, taking the load data into
consideration.
• Use the specified installation equipment.

Fig. 4-57: Flange loads

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Technical data
Flange loads during operation
F(a) 9200 N
F(r) 7900 N
M(k) 4200 Nm
M(g) 2310 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 10500 N
F(r) 12500 N
M(k) 9000 Nm
M(g) 5600 Nm
Axial force F(a), radial force F(r), tilting torque M(k), torque about mount-
ing flange M(g)

Supplementary load

The robot can carry supplementary loads. The fastening holes on the arm,
link arm and rotating column are used, for example, for fastening the cov-
ers or external energy supply systems. The fastening holes on the in-line
wrist are exclusively for fastening holders for energy supply systems (e.g.
holders for compressed air hose).
When mounting the supplementary loads, be careful to observe the maxi-
mum permissible total load. The dimensions and positions of the installa-
tion options can be seen in the following diagrams.

Fig. 4-58: Supplementary load, arm

1 Support bracket for supplementary load

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Fig. 4-59: Fastening the supplementary load, link arm / rotating col-
umn

4.7.4 Foundation loads, KR 420 R3330 F

Depending on the payload (e.g. tool), supplementary load and the robot’s
own mass (weight), the motion of the robot generates forces and torques
which are transmitted to the foundation.
The specified values refer to nominal payloads and do not include any
safety factors. The actual forces and torques depend on the motion profile
as well as the mass, load center of gravity and mass moment of inertia of
the payload. It is imperative for the load data to be entered in the robot

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controller. The robot controller takes the payload into consideration during

Technical data
path planning.
Supplementary loads on A1 (rotating column) and A2 (link arm) are not
taken into consideration in the calculation of the foundation load. These
must be taken into account in the vertical force (Fv).
The foundation must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the founda-
tion
An incorrectly dimensioned foundation can fracture and fail. Death, se-
vere injuries or damage to property may result.
• Calculate the foundation loads for each individual case.
• Use the specified installation equipment.

Vertical force F(v)

F(v normal) 37000 N
F(v max) 40500 N
Horizontal force F(h)
F(h normal) 15900 N
F(h max) 23500 N
Tilting moment M(k)
M(k normal) 58900 Nm
M(k max) 84500 Nm
Torque about axis 1 M(r)
M(r normal) 18500 Nm
M(r max) 45500 Nm

Fig. 4-60: Foundation loads, floor mounting

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4.8 Plates and labels

Plates and labels

The following plates and labels are attached to the robot. They must not
be removed or rendered illegible. Illegible plates and labels must be re-
placed.

Fig. 4-61: Location of plates and labels

Item Description
1

High voltage
Any improper handling can lead to contact with current-carrying
components. Electric shock hazard!
2

Hot surface
During operation of the robot, surface temperatures may be
reached that could result in burn injuries. Protective gloves must
be worn!

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Technical data
Item Description
3

Secure the axes

Before exchanging any motor, secure the corresponding axis
through safeguarding by suitable means/devices to protect
against possible movement. The axis can move. Risk of crush-
ing!
4

Identification plate example

Content according to Machinery Directive.
The QR code contains a link to product information in KUKA
Xpert.
5

Work on the robot

Before start-up, transportation or maintenance, read and follow
the assembly and operating instructions.

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Item Description
6

Transport position
Before loosening the bolts of the mounting base, the robot must
be in the transport position as indicated in the table. Risk of
toppling!
7

Danger zone
Entering the danger zone of the robot is prohibited if the robot
is in operation or ready for operation. Risk of injury!

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Technical data
Item Description
8

Counterbalancing system
The system is pressurized with oil and nitrogen. Read and fol-
low the assembly and operating instructions before commencing
work on the counterbalancing system. Risk of injury!
9

Mounting flange on in-line wrist

The values specified on this plate apply for the installation of
tools on the mounting flange of the wrist and must be observed.

4.9 REACH duty to communicate information acc. to Art. 33

As of June 2007, the Regulation (EC) 1907/2006 of the European Parlia-

ment and of the Council dated 18 December 2006 on the registration,
evaluation and authorization of chemicals (REACH Regulation) is in force.
Detailed REACH information can be found in the product information in
KUKA Xpert.

4.10 Stopping distances and times

4.10.1 General information

Information concerning the data:

• The data are given for the main axes A1, A2 and A3. The main axes
are the axes with the greatest deflection.
• Superposed axis motions can result in longer stopping distances.
• Stopping distances and stopping times in accordance with DIN EN
ISO 10218-1, Annex B.
• Stop categories:

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‒ Stop category 0 » STOP 0

‒ Stop category 1 » STOP 1
according to IEC 60204-1
• The values specified for Stop 0 are guide values determined by
means of tests and simulation. They are average values which con-
form to the requirements of DIN EN ISO 10218-1. The actual stopping
distances and stopping times may differ due to internal and external
influences on the braking torque. It is therefore advisable to determine
the exact stopping distances and stopping times where necessary un-
der the real conditions of the actual robot application.
• Measurement method
The stopping distances were measured using the robot-internal meas-
urement method.
• The wear on the brakes varies depending on the operating mode, ro-
bot application and the number of STOP 0 stops triggered. It is there-
fore advisable to check the stopping distance at least once a year.

Determination of stopping distances and times with KR C4

• The stopping distance is the angle traveled by the robot from the mo-
ment the stop signal is triggered until the robot comes to a complete
standstill.
• The stopping time is the time that elapses from the moment the stop
signal is triggered until the robot comes to a complete standstill.

Measurement method for determining the STOP 0 stopping distances and stopping
times according to ISO 10218-1 with KR C5

Motion sequence

• Measurement with single-axis motion (A1, A2 and A3 respectively)

• Axes that are not moved are positioned in such a way that the maxi-
mum distance of the load center of gravity from the moved axis is
reached.
• Use the maximum motion radius of the axis to achieve as high a ve-
locity as possible.
• Trigger point at maximum velocity
Measurement method

1. A safe operational stop is activated at the trigger point; this causes a

STOP 0 to be triggered if the robot is moving.
Start recording with trace functionality.
2. Brakes are closed.
Brake closes (WDI motor status bit 2) is used as the start time of the
measurement.
3. The axis comes to a standstill.
Standstill is used as the end time of the measurement.
As an approximation, it is also possible to carry out the measurement by
means of a STOPMESS interrupt program in which the stopping distance
results from the difference between the position at the trigger point ($AX-
IS_INT) and the position at standstill.
Information concerning the data

• The stopping distance is the angle covered by the axis from the
Brake closes signal (WDI motor status bit 2) to complete standstill.

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Technical data
• The stopping time is the time that elapses from the Brake closes sig-
nal (WDI motor status bit 2) until the robot comes to a complete
standstill.

4.10.2 Stopping distances and times KR 600 R2830, KR 600 R2830 F

4.10.2.1 Stopping distances and stopping times, STOP 0, A1 to A3

The values for stop category 0 when a STOP 0 is triggered refer to the
following configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = rated payload

Stopping distance
A1 39.21 °
A2 24.16 °
A3 17.84 °
Stopping time
A1 0.88 s
A2 0.75 s
A3 0.46 s

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4.10.2.2 Stopping distances and stopping times, STOP 1, A1

Technical data

Fig. 4-62: Stopping distances for STOP 1, axis 1

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Technical data

Fig. 4-63: Stopping times for STOP 1, axis 1

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4.10.2.3 Stopping distances and stopping times, STOP 1, A2

Technical data

Fig. 4-64: Stopping distances for STOP 1, axis 2

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Technical data

Fig. 4-65: Stopping times for STOP 1, axis 2

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4.10.2.4 Stopping distances and stopping times, STOP 1, A3

Technical data

Fig. 4-66: Stopping distances for STOP 1, axis 3

Fig. 4-67: Stopping times for STOP 1, axis 3

4.10.3 Stopping distances and times KR 510 R3080, KR 510 R3080 F

4.10.3.1 Stopping distances and stopping times, STOP 0, A1 to A3

The values for stop category 0 when a STOP 0 is triggered refer to the
following configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = rated payload

Stopping distance
A1 39.21 °
A2 24.16 °
A3 17.84 °

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Technical data
Stopping time
A1 0.88 s
A2 0.75 s
A3 0.46 s

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4.10.3.2 Stopping distances and stopping times, STOP 1, A1

Technical data

Fig. 4-68: Stopping distances for STOP 1, axis 1

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Technical data

Fig. 4-69: Stopping times for STOP 1, axis 1

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4.10.3.3 Stopping distances and stopping times, STOP 1, A2

Technical data

Fig. 4-70: Stopping distances for STOP 1, axis 2

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Technical data

Fig. 4-71: Stopping times for STOP 1, axis 2

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4.10.3.4 Stopping distances and stopping times, STOP 1, A3

Technical data

Fig. 4-72: Stopping distances for STOP 1, axis 3

Fig. 4-73: Stopping times for STOP 1, axis 3

4.10.4 Stopping distances and times KR 420 R3330, KR 420 R3330 F

4.10.4.1 Stopping distances and stopping times, STOP 0, A1 to A3

The values for stop category 0 when a STOP 0 is triggered refer to the
following configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = rated payload

Stopping distance
A1 41.92 °
A2 23.45 °
A3 19.82 °

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Technical data
Stopping time
A1 1.02 s
A2 0.67 s
A3 0.55 s

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4.10.4.2 Stopping distances and stopping times, STOP 1, A1

Technical data

Fig. 4-74: Stopping distances for STOP 1, axis 1

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Technical data

Fig. 4-75: Stopping times for STOP 1, axis 1

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4.10.4.3 Stopping distances and stopping times, STOP 1, A2

Technical data

Fig. 4-76: Stopping distances for STOP 1, axis 2

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Technical data

Fig. 4-77: Stopping times for STOP 1, axis 2

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4.10.4.4 Stopping distances and stopping times, STOP 1, A3

Technical data

Fig. 4-78: Stopping distances for STOP 1, axis 3

Fig. 4-79: Stopping times for STOP 1, axis 3

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Planning
5 Planning

5.1 Information for planning

In the planning and design phase, care must be taken regarding the func-
tions or applications to be executed by the kinematic system. The follow-
ing conditions can lead to premature wear. They necessitate shorter main-
tenance intervals and/or earlier exchange of components. In addition, the
permissible operating parameters specified in the technical data must be
taken into account and observed during planning.
• Continuous operation near temperature limits
• Continuous operation in abrasive environments
• Continuous operation close to the performance limits, e.g. high rpm of
an axis
• Start of operation at maximum power from cold, e.g. after an idle peri-
od
• High duty cycle of individual axes
• Monotonous motion profiles, e.g. short, frequently recurring axis mo-
tions
• Static axis positions, e.g. continuous vertical position of a wrist axis
• External forces (process forces) acting on the robot
If one or more of these conditions are to apply during operation of the kin-
ematic system, KUKA Service must be consulted.
If the robot reaches its corresponding operation limit or if it is operated
near the limit for a period of time, the built-in monitoring functions come
into effect and the robot is automatically switched off.
This protective function can limit the availability of the robot system.
In the case of high thermal, chemical and mechanical loads and to sup-
port maintenance work, the supplied pressure reducer and the associated
manometer are to be installed away from the robot in a protected area,
e.g. on the safety fence, system controller or control cabinet (max. dis-
tance 10 m from robot base; the greater the distance, the longer it takes
before the overpressure in the robot has dissipated completely). Alterna-
tively, or additionally, the pressure reducer and manometer can be protec-
ted by means of an enclosure.

5.2 Mounting base 175 mm

Description

Designation Article number Weight

Mounting base S960 0000-286-111 approx. 302 kg
The mounting base with centering (>>> Fig. 5-1) is used when the robot
is fastened to the floor, i.e. directly on a concrete foundation with a thick-
ness of at least 175 mm.
The mounting base consists of:
• Foundation plate
• Resin-bonded anchors (chemical anchors)
• Fastening elements
This mounting variant requires a level and smooth surface on a concrete
foundation with adequate load bearing capacity. The concrete foundation
must be able to accommodate the forces occurring during operation.

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There must be no layers of insulation or screed between the bedplates

Planning

and the concrete foundation.

The minimum dimensions must be observed.

Fig. 5-1: Mounting base 175 mm

1 Concrete foundation 4 Hexagon bolt

2 Chemical anchor 5 Bedplate
3 Pin

Grade of concrete for foundations

When producing concrete foundations, the load-bearing capacity of the

ground and the country-specific construction regulations must be ob-
served. There must be no layers of insulation or screed between the bed-
plate/bedplates and the concrete foundation. The quality of the concrete
must meet the requirements of the following standard:
• C20/25 according to EN 206

WARNING
Danger to life and limb due to incorrect mounting
If not mounted correctly, the kinematic system may topple over or fall
down. Death, severe injury or damage to property may result.
• Only install the kinematic system using the mounting base or ma-
chine frame mounting.
• The stability must be ensured by the integrator or start-up techni-
cian.

Dimensioned drawing

The following figure (>>> Fig. 5-2) provides all the necessary information
on the mounting base, together with the required foundation data. The
specified foundation dimensions refer to the safe transmission of the foun-
dation loads into the foundation and not to the stability of the foundation.

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Planning
Fig. 5-2: Mounting base 175 mm, dimensioned drawing

1 Bedplate 2 Robot
To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
figure.

Fig. 5-3: Cross-section of foundation 175 mm

1 Resin-bonded anchor
2 Bedplate
3 Concrete foundation

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5.3 Mounting base 200 mm

Description

Designation Article number Weight

Mounting base Set S960 0000-286-133 approx. 155 kg
The mounting base with centering (>>> 5.3 "Mounting base 200 mm"
Page 130) is used when the robot is fastened to the floor, i.e. directly on
a concrete foundation with a thickness of at least 200 mm.
The mounting base with centering consists of:
• Foundation plate
• Resin-bonded anchors (chemical anchors)
• Fastening elements
This mounting variant requires a level and smooth surface on a concrete
foundation with adequate load bearing capacity. The concrete foundation
must be able to accommodate the forces occurring during operation.
There must be no layers of insulation or screed between the bedplates
and the concrete foundation.
The minimum dimensions must be observed.

Fig. 5-4: Mounting base 200 mm

1 Bedplate 3 Pin with Allen screw

2 Hexagon bolt 4 Resin-bonded anchor

Grade of concrete for foundations

When producing concrete foundations, the load-bearing capacity of the

ground and the country-specific construction regulations must be ob-
served. There must be no layers of insulation or screed between the bed-
plate/bedplates and the concrete foundation. The quality of the concrete
must meet the requirements of the following standard:
• C20/25 according to EN 206

WARNING
Danger to life and limb due to incorrect mounting
If not mounted correctly, the kinematic system may topple over or fall
down. Death, severe injury or damage to property may result.
• Only install the kinematic system using the mounting base or ma-
chine frame mounting.
• The stability must be ensured by the integrator or start-up techni-
cian.

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Planning
Dimensioned drawing

The following figure (>>> Fig. 5-5) provides all the necessary information
on the mounting base, together with the required foundation data. The
specified foundation dimensions refer to the safe transmission of the foun-
dation loads into the foundation and not to the stability of the foundation.

Fig. 5-5: Mounting base 200 mm, dimensioned drawing

1 Bedplates 2 Robot
To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
figure.

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Planning KR 600 FORTEC

Fig. 5-6: Cross-section of foundation 200 mm

1 Hexagon bolt 3 Bedplate

2 Pin 4 Concrete foundation

5.4 Machine frame mounting

Description

Designation Article number Weight

approx. 3.695
Machine frame mounting 0000-107-618
kg
The machine frame mounting assembly is used when the robot is fas-
tened on a steel structure, a booster frame (pedestal) or a KUKA linear
unit. It must be ensured that the substructure is able to withstand safely
the forces occurring during operation (foundation loads). The following dia-
gram contains all the necessary information that must be observed when
preparing the mounting surface (>>> Fig. 5-7).
The machine frame mounting assembly consists of:
• Pins with fasteners
• Hexagon bolts with conical spring washers

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Planning
Fig. 5-7: Machine frame mounting

1 Pin
2 Hexagon bolt

WARNING
Danger to life and limb due to incorrect mounting
If not mounted correctly, the kinematic system may topple over or fall
down. Death, severe injury or damage to property may result.
• Only install the kinematic system using the mounting base or ma-
chine frame mounting.
• The stability must be ensured by the integrator or start-up techni-
cian.

Dimensioned drawing

The following illustrations provide all the necessary information on ma-

chine frame mounting, together with the required foundation data.

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Fig. 5-8: Machine frame mounting, dimensioned drawing

1 Steel structure 3 Hexagon bolt (8x)

2 Pin (2x) 4 Mounting surface

5.5 Connecting cables and interfaces

Connecting cables

The connecting cables comprise all the cables for transferring energy and
signals between the robot and the robot controller. They are connected to
the robot junction boxes with connectors.
Cable lengths of 7 m, 15 m, 25 m, 35 m and 50 m are available as stand-
ard. The maximum length of the connecting cables must not exceed
50 m. The connecting cables may be extended a maximum of 1x, i.e. a
maximum of 2 connecting cables may be combined with each other. Thus

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if the robot is operated on a linear unit which has its own cable carrier,

Planning
this cable must also be taken into account.
For the connecting cables, a ground conductor is always required to
provide a low-resistance connection between the robot and the control
cabinet in accordance with DIN EN 60204. The ground conductor is not
part of the scope of supply and can be ordered as an option. The con-
nection must be made by the customer. The tapped holes for connect-
ing the ground conductor are located on the base frame of the robot.

The following points must be observed when planning and routing the
connecting cables:
• The bending radius for fixed routing must not be less than 150 mm for
motor cables and 60 mm for data cables.
• Protect cables against exposure to mechanical stress.
• Route the cables without mechanical stress – no tensile forces on the
connectors.
• Cables are only to be installed indoors.
• Observe the permissible temperature range (fixed installation) of
263 K (-10 °C) to 343 K (+55 °C).
• Route the motor cables and the data cables separately in metal ducts.
If necessary, take additional measures to ensure electromagnetic com-
patibility (EMC).

CAUTION
Risk of injury due to tripping hazards
Improper installation of cables can cause tripping hazards. Injuries or
damage to property may result.
• The connecting cables must be installed in such a way (e.g. cable
ducts) as to prevent tripping hazards.
• Potential tripping hazards must be marked accordingly.

Interface for energy supply system

The robot can be equipped with an energy supply system between axis 1
and axis 3 and a second energy supply system between axis 3 and axis
6. The A1 interface required for this is located on the rear of the base
frame, the A3 interface is located on the side of the arm and the interface
for axis 6 is located on the robot tool. Depending on the application, the
interfaces differ in design and scope. They can be equipped, for example,
with connections for cables and hoses. Detailed information on the con-
nector pin allocation, threaded unions, etc. is given in separate documen-
tation.

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Fig. 5-9: Connecting cables and interfaces

1 Interface A6, tool

2 Interface A3, arm
3 Motor cable connection X30.4
4 Motor cable connection X30.1
5 Data cable connection X31
6 Interface A1, base frame

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Transportation
6 Transportation

6.1 Transporting the robot arm

Description

Move the robot 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 has been fastened in po-
sition. Before the robot is lifted, it must be ensured that it is free from ob-
structions. Remove all transport safeguards, such as nails and screws, in
advance. First remove any rust or adhesive on contact surfaces.
Avoid vibrations and impacts during transportation in order to prevent
damage to the manipulator.

Transport position

The robot must be in the transport position before it can be transported.

The robot is in the transport position when the axes are in the following
positions:
Transport position
A1 0 °
A2 -130 °
A3 130 °
A4 0 °
A5 90 °
A6 0 °

Fig. 6-1: Transport position

Transport dimensions

The transport dimensions for the robot can be noted from the following fig-
ure. The position of the center of gravity and the weight vary according to
the specific configuration. The specified dimensions refer to the robot with-
out equipment.

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Fig. 6-2: Transport dimensions

1 Robot 3 Fork slots

2 Center of gravity

Robot A B C D
in mm
KR 600 R2830 2 042 1 145 -21 54
KR 600 R2830 F
KR 510 R3080 2 284 1 152 3 54
KR 510 R3080 F
KR 420 R3330 2 532 1 150 25 54
KR 420 R3330 F

Transport position, without buffer A2

In exceptional cases (requirement of minimum transport height), buffer A2

can be removed and the robot can be moved to the following transport
position. Moving to the required angle of A2 must be carried out under
constant collision monitoring for stop A2 and the rotating column.

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Transportation
Fig. 6-3: Buffer A2 (example)

1 Link arm 3 Buffer A2

2 Stop A2 4 Rotating column
After removal, buffer A2 must be fastened to the robot so that it cannot be
lost during transport.
For transport in this transport position, a clearly visible warning sign must
be attached by the customer, indicating that buffer A2 has been removed.
After transport and before start-up, buffer A2 must be reinstalled.
Transport position
A1 0 °
A2 -136.5 °
A3 136.5 °
A4 0 °
A5 90 °
A6 0 °

Fig. 6-4: Transport position, without buffer A2

Transport dimensions, without buffer A2

The transport dimensions for the robot without buffer A2 can be noted
from the following figure. The position of the center of gravity and the
weight vary according to the specific configuration. The specified dimen-
sions refer to the robot without equipment.

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Transportation KR 600 FORTEC

Fig. 6-5: Transport dimensions, without buffer A2

1 Robot 3 Fork slots

2 Center of gravity

Robot A B C D
KR 600 R2830 2 138 1 132 -78 52
KR 600 R2830 F
KR 510 R3080 2 284 1 081 -33 53
KR 510 R3080 F
KR 420 R3330 2 532 1 139 -38 51
KR 420 R3330 F

Transportation

The robot can be transported by fork lift truck or using lifting tackle (op-
tional).
WARNING
Danger to life and limb due to non-authorized handling equipment
If unsuitable handling equipment is used, the robot may topple or be
damaged during transportation. Death, severe injuries or damage to
property may result.
• Only use authorized handling equipment with a sufficient load-bear-
ing capacity.
• Only transport the robot in the manner specified here.

Transportation by fork lift truck

For transport by fork lift truck (>>> Fig. 6-6), 2 fork slots are provided in
the base frame. The robot can be picked up by the fork lift truck from the
front and rear. The base frame must not be damaged when inserting the
forks into the fork slots. The fork lift truck must have a minimum payload
capacity of 3,500 kg and an adequate fork length.

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Transportation
NOTICE
Damage to property due to overloading of the fork slots
Overloading the fork slots during transportation can cause damage to
property.
• Avoid overloading the fork slots through undue inward or outward
movement of hydraulically adjustable forks of the fork lift truck.

Fig. 6-6: Transportation by fork lift truck

Transportation with lifting tackle (optional)

Designation Article number Weight

Lifting tackle 0000-250-857 approx. 10 kg
The robot can also be transported using crane lifting tackle (optional). For
this, it must be in the transport position.
The lifting tackle (optional) must be attached using 3 M20 DIN 580 swivel
eyebolts and positioned along the robot as illustrated (>>> Fig. 6-7). The
lifting tackle (optional) must consist of 3 legs (G1 to G3).
All the legs must be long enough and must be routed in such a way that
the robot is not damaged. Installed tools and items of equipment that
could be damaged during transportation must be removed.
Installed tools and items of equipment can cause undesirable shifts in the
center of gravity, which are liable to cause a collision during transporta-
tion. The user shall be liable for any damage to the robot or to other ma-
terial property resulting from this.
Tools and items of equipment must be removed from a robot before it is
exchanged.
WARNING
Risk of injury during transportation
The robot may tip during transportation. Death, severe injuries or dam-
age to property may result.
• When transporting the robot using lifting tackle (optional) / rope
sling, care must be exercised to prevent it from tipping.
• If necessary, additional safeguarding measures must be taken.
• It is forbidden to pick up the robot in any other way using a crane!

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Transportation KR 600 FORTEC

Fig. 6-7: Transportation using lifting tackle (optional)

1 Lifting tackle assembly (optional)

2 Leg G2
3 M20 DIN 580 swivel eyebolt
4 Leg G1
5 Leg G3

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Start-up and recommissioning

7 Start-up and recommissioning

CAUTION
For screwed connections, the fastening screws (standard, strength class
8.8) are to be tightened with the tightening torques specified in the ap-
pendix (>>> 12 "Appendix" Page 247). Tightening torques deviating from
these values are specified directly.
The specified screw sizes and strength classes are those 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 strength class 10.9 and higher as well as screws with test
certification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.

7.1 Installing the mounting base 175 mm

Description

These instructions apply to the “mounting base with centering (resin car-
tridge)” variant with a concrete thickness of at least 175 mm. The robot is
fastened to an appropriate concrete foundation using a bedplate and res-
in-bonded anchors.
If the surface of the concrete foundation is not sufficiently smooth and
even, the differences must be evened out with a suitable leveling com-
pound.
When using resin-bonded anchors, use only resin cartridges and anchors
from the same manufacturer. 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.
Designation Article number Weight
Mounting base S960 0000-286-111 approx. 302 kg

Precondition

• The concrete foundation must have the required dimensions and

cross-section.
• The surface of the foundation must be smooth and even.
• The mounting base assembly must be complete.
• Have the leveling compound readily at hand.

Special tools

The following special tools are required:

• Drill with a ø 18 mm bit
• Setting tool approved by the anchor manufacturer

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WARNING
Danger to life and limb due to live parts
When work is performed on this system, live parts can lead to uninten-
tional motions of the robot, positioner or other components. Failure to
observe this may result in physical injuries and damage to property.
• If work is carried out on an operable system, the main switch on the
control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on
again.
• Inform the persons involved by means of a sign (e.g. affix a warning
sign).
• Warn all persons concerned before putting the system back into op-
eration.

WARNING
Danger to life and limb due to non-authorized handling equipment
If unsuitable handling equipment is used, the robot may topple or be
damaged during transportation. Death, severe injuries or damage to
property may result.
• Only use authorized handling equipment with a sufficient load-bear-
ing capacity.
• Only transport the robot in the manner specified here.

WARNING
Risk of injury during transportation
The robot may tip during transportation. Death, severe injuries or dam-
age to property may result.
• When transporting the robot using lifting tackle (optional) / rope
sling, care must be exercised to prevent it from tipping.
• If necessary, additional safeguarding measures must be taken.
• It is forbidden to pick up the robot in any other way using a crane!

CAUTION
Risk of injury due to tripping hazards
Improper installation of cables can cause tripping hazards. Injuries or
damage to property may result.
• The connecting cables must be installed in such a way (e.g. cable
ducts) as to prevent tripping hazards.
• Potential tripping hazards must be marked accordingly.

WARNING
Danger to life and limb due to incorrect mounting
If not mounted correctly, the kinematic system may topple over or fall
down. Death, severe injury or damage to property may result.
• Only install the kinematic system using the mounting base or ma-
chine frame mounting.
• The stability must be ensured by the integrator or start-up techni-
cian.

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Start-up and recommissioning

Procedure

1. Lift the bedplate with fork lift truck or lifting tackle (>>> Fig. 7-1). If us-
ing lifting tackle, screw in 4 M24 DIN 580 swivel eyebolts. The bed-
plate weighs approx. 300 kg.

Fig. 7-1: Transporting the plate

1 Crane 4 Plate
2 Lifting tackle 5 Concrete foundation
3 Swivel eyebolt

2. Determine the position of the plate on the foundation in relation to the

working envelope.
3. Set the bedplate down on the foundation in its installation position.
NOTICE
If the bedplate is not fully seated on the concrete ceiling, this can
cause strain or result in loosening of the mounting base. Fill the gap
with leveling compound. To do this, lift the bedplate again and apply
sufficient leveling compound to the underside (toothed spatula).
Then set the bedplate down again and align it, removing any excess
leveling compound. The maximum height of the leveling compound
must not be exceeded.
The area under the hexagon bolt for robot fastening must be kept
free from leveling compound.
Allow the leveling compound to cure for about 3 hours. The curing
time is longer at temperatures below 293 K (20 °C).

4. Check that the bedplate is horizontal. The maximum permissible devi-

ation is 3°.
5. Drill 20 anchor holes in accordance with the manufacturer’s specifica-
tions and fit the anchors as specified in the instructions for use.
The instructions for use are enclosed with the anchors and must be
followed precisely.
6. Remove the 4 swivel eyebolts.
7. Allow the resin to cure. See table provided by manufacturer.

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7.2 Installing the mounting base 200 mm

Description

These instructions apply to the “mounting base with centering (resin car-
tridge)” variant with a concrete thickness of at least 200 mm. The robot is
fastened to an appropriate concrete foundation using a bedplate and res-
in-bonded anchors.
If the surface of the concrete foundation is not sufficiently smooth and
even, the differences must be evened out with a suitable leveling com-
pound.
When using resin-bonded anchors, use only resin cartridges and anchors
from the same manufacturer. 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.
Designation Article number Weight
Mounting base Set S960 0000-286-133 approx. 155 kg

Precondition

• The concrete foundation must have the required dimensions and

cross-section.
• The surface of the foundation must be smooth and even.
• The mounting base assembly must be complete.
• Have the leveling compound readily at hand.

Special tools

The following special tools are required:

• Drill with a ø 18 mm bit
• Setting tool approved by the anchor manufacturer

WARNING
Danger to life and limb due to live parts
When work is performed on this system, live parts can lead to uninten-
tional motions of the robot, positioner or other components. Failure to
observe this may result in physical injuries and damage to property.
• If work is carried out on an operable system, the main switch on the
control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on
again.
• Inform the persons involved by means of a sign (e.g. affix a warning
sign).
• Warn all persons concerned before putting the system back into op-
eration.

WARNING
Danger to life and limb due to non-authorized handling equipment
If unsuitable handling equipment is used, the robot may topple or be
damaged during transportation. Death, severe injuries or damage to
property may result.
• Only use authorized handling equipment with a sufficient load-bear-
ing capacity.
• Only transport the robot in the manner specified here.

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WARNING
Risk of injury during transportation
The robot may tip during transportation. Death, severe injuries or dam-
age to property may result.
• When transporting the robot using lifting tackle (optional) / rope
sling, care must be exercised to prevent it from tipping.
• If necessary, additional safeguarding measures must be taken.
• It is forbidden to pick up the robot in any other way using a crane!

CAUTION
Risk of injury due to tripping hazards
Improper installation of cables can cause tripping hazards. Injuries or
damage to property may result.
• The connecting cables must be installed in such a way (e.g. cable
ducts) as to prevent tripping hazards.
• Potential tripping hazards must be marked accordingly.

WARNING
Danger to life and limb due to incorrect mounting
If not mounted correctly, the kinematic system may topple over or fall
down. Death, severe injury or damage to property may result.
• Only install the kinematic system using the mounting base or ma-
chine frame mounting.
• The stability must be ensured by the integrator or start-up techni-
cian.

Procedure

1. Lift the robot with fork lift truck or lifting tackle.

2. Fasten the 4 bedplates to the robot using 2 M24x70-8.8 hexagon bolts
with conical spring washers for each one.
Increase the tightening torque to the specified value in several stages.
2 bedplates are fitted with locating pins for centering.
3. Determine the position of the robot on the mounting base in relation to
the working envelope.
4. Set the robot down on the mounting base in its installation position.
5. Align the robot horizontally.
NOTICE
If the bedplates are not fully seated on the concrete foundation, this
can result in distortion or loosening of the mounting base. Fill the
gap with leveling compound. To do this, lift the robot again and ap-
ply sufficient leveling compound to the underside of the bedplates
(toothed spatula). Then set the robot down again and align it, re-
moving any excess leveling compound. The maximum height of the
leveling compound must not be exceeded. Observe the manufactur-
er’s specifications.
The area under the hexagon bolt for robot fastening must be kept
free from leveling compound.
Allow the leveling compound to set in accordance with the manufac-
turer's instructions.

6. Drill 16 anchor holes in accordance with the manufacturer’s specifica-

tions and fit the anchors as specified in the instructions for use.

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The instructions for use are enclosed with the anchors and must be
Start-up and recommissioning

followed precisely.
7. Allow the resin to cure. See table provided by manufacturer.

7.3 Installing the machine frame mounting

Description

The machine frame mounting assembly is used for installing robots on a

steel structure prepared by the customer or on the carriage of a linear
unit.
Fastening is carried out using 8 hexagon bolts with conical spring wash-
ers. Locating pins are provided to ensure correct positioning.
The installation and start-up of the robot controller, the tools mounted and
the applications are not described here.
Designation Article number Weight
approx. 3.695
Machine frame mounting 0000-107-618
kg

Precondition

• The mounting surface has been prepared in accordance with Section .

• The substructure has been checked for sufficient safety.
• The machine frame mounting assembly is complete.

WARNING
Danger to life and limb due to live parts
When work is performed on this system, live parts can lead to uninten-
tional motions of the robot, positioner or other components. Failure to
observe this may result in physical injuries and damage to property.
• If work is carried out on an operable system, the main switch on the
control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on
again.
• Inform the persons involved by means of a sign (e.g. affix a warning
sign).
• Warn all persons concerned before putting the system back into op-
eration.

WARNING
Danger to life and limb due to non-authorized handling equipment
If unsuitable handling equipment is used, the robot may topple or be
damaged during transportation. Death, severe injuries or damage to
property may result.
• Only use authorized handling equipment with a sufficient load-bear-
ing capacity.
• Only transport the robot in the manner specified here.

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WARNING
Risk of injury during transportation
The robot may tip during transportation. Death, severe injuries or dam-
age to property may result.
• When transporting the robot using lifting tackle (optional) / rope
sling, care must be exercised to prevent it from tipping.
• If necessary, additional safeguarding measures must be taken.
• It is forbidden to pick up the robot in any other way using a crane!

CAUTION
Risk of injury due to tripping hazards
Improper installation of cables can cause tripping hazards. Injuries or
damage to property may result.
• The connecting cables must be installed in such a way (e.g. cable
ducts) as to prevent tripping hazards.
• Potential tripping hazards must be marked accordingly.

WARNING
Danger to life and limb due to incorrect mounting
If not mounted correctly, the kinematic system may topple over or fall
down. Death, severe injury or damage to property may result.
• Only install the kinematic system using the mounting base or ma-
chine frame mounting.
• The stability must be ensured by the integrator or start-up techni-
cian.

Procedure

1. Clean the mounting surface (>>> Fig. 7-2) of the robot.

2. Check the hole pattern.
3. Insert 2 pins and 2 M8x55-8.8 Allen screws with conical spring wash-
ers and tighten, increasing the torque to the specified value in several
stages using a torque wrench.
4. Prepare 8 M24x70-8.8-A2K hexagon bolts and conical spring washers.

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Fig. 7-2: Installing the machine frame mounting assembly

1 Pin
2 Allen screw with conical spring washer (2x)
3 Hexagon bolt with conical spring washer (8x)
4 Mounting surface

7.4 Installing a floor-mounted robot

Description

This description is valid for the installation of floor-mounted robots with the
following assembly:
• Mounting base 175 mm
(>>> 5.2 "Mounting base 175 mm" Page 127)
• Mounting base 200 mm
(>>> 5.3 "Mounting base 200 mm" Page 130)
8 hexagon bolts with conical spring washers are used for fastening to the
bedplate or to a machine frame. A pin and a sword pin are provided to
ensure correct positioning.
The installation and start-up of the robot controller, the tools mounted and
the applications are not described here.

Precondition

• The required mounting base is installed.

• The installation site is accessible with a crane or fork lift truck.
• Any tools or other system components which would hinder the work
have been removed.
• The robot is in the transport position.
• The connecting cables and ground conductors are routed to the robot
and installed.
• Compressed air supply to the robot available; F variant only.

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CAUTION
Risk of injury due to tripping hazards
Improper installation of cables can cause tripping hazards. Injuries or
damage to property may result.
• The connecting cables must be installed in such a way (e.g. cable
ducts) as to prevent tripping hazards.
• Potential tripping hazards must be marked accordingly.

Procedure

1. Check that the pins are undamaged and fitted securely.

(>>> Fig. 7-3)
(>>> Fig. 7-4)
2. Bring the robot to the installation site by crane or fork lift truck.
The lifting tackle must not damage the robot.
3. Lower the robot vertically onto the mounting base. Ensure that an en-
tirely vertical position is maintained in order to prevent damage to the
pins.
4. Insert 8 M24x70-8.8 hexagon bolts together with conical spring wash-
ers.
5. Tighten 8 hexagon bolts with a torque wrench in diagonally opposite
sequence. Increase the tightening torque to the specified value in sev-
eral stages.
6. Remove the fork lift truck or lifting tackle.
7. Connect the motor cables.
8. Connect the data cable.
9. Establish the equipotential bonding between the robot and the robot
controller and between the robot and the system potential via the
threaded bolts. If the connecting cables are longer than 25 m, the
equipotential bonding must be ensured by the system user.
For operation with KR C4, all connecting cable sets are without equi-
potential bonding; however, these can be ordered with equipotential
bonding as an option.
10. Check the equipotential bonding in accordance with VDE 0100 and
EN 60204-1.
Further information is contained in the assembly or operating instruc-
tions for the robot controller.

11. Connect compressed air supply to the pressure regulator and set the
pressure regulator to zero; F variant only.
12. Open compressed air supply and set pressure regulator to 0.01 MPa
(0.1 bar); F variant only.
13. Mount tooling, if required.
14. Retighten the hexagon bolts with a torque wrench after 100 hours of
operation.

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Fig. 7-3: Installing the robot with mounting base 175 mm

1 Rotating column
2 Hexagon bolt
3 Conical spring washer
4 Foundation plate
5 Pin
6 Motor cable X30.4
7 Motor cable X30.1
8 Data cable
9 Ground conductor connection
10 Ground conductor connection, robot controller

Fig. 7-4: Installing the robot with mounting base 200 mm

1 Rotating column
2 Hexagon bolt
3 Conical spring washer
4 Foundation plate
5 Pin
6 Motor cable X30.4

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7 Motor cable X30.1
8 Data cable
9 Ground conductor connection
10 Ground conductor connection, robot controller
Put the robot into operation in accordance with the documentation for the
system software.
CAUTION
Sudden escape of air in the counterbalancing system
Following storage of the manipulator, an air cushion can build up in the
counterbalancing system. If the air escapes suddenly, this can cause
the protective cap of the vent valve to shoot off in exceptional cases. In-
juries may result.
1. Remove the protective cap of the counterbalancing system vent
valve.
2. Maintain a safe distance.
3. Move A2 by ±30°.
4. Refit the protective cap.

7.5 Description of the connecting cables

Configuration

The connecting cables are used to transfer power and signals between
the robot controller and the robot.
The connecting cables comprise:
• Motor cable (2x)
• Data cable

Interface

For connection of the connecting cables between the robot controller and
the robot, the following connectors are available at the interfaces:
Connector designation
Cable designation Connection
Robot controller - robot
Motor cable X20.1 - X30.1 HAN size 24
Motor cable X20.4 - X30.4 HAN size 24
Data cable X21 - X31 Han® 3A
Ground conductor / equi- M8 ring cable
potential bonding lug at both ends
16 mm2

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Standard connecting cable

Fig. 7-5: Connecting cables, overview

7.5.1 Description of the Motor cable

Cable overview

Fig. 7-6: Motor cable

1 X20.1
2 X30.1

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Connector pin allocation

Connector pin allocation X20.1 Connector pin allocation X30.1

The contact assignment on the connector side is shown in each case.

Wiring diagram

X20.1 X30.1
Pin Description Pin
a / 1 Motor M1 U A / 1
a / 2 Motor M1 V A / 2
a / 3 Motor M1 W A / 3
a / 11 Brake + A / 11
a / 12 Brake - A / 12
b / 1 Motor M2 U B / 1
b / 2 Motor M2 V B / 2
b / 3 Motor M2 W B / 3
b / 11 Brake + B / 11
b / 12 Brake - B / 12
c / 1 Motor M3 U C / 1
c / 2 Motor M3 V C / 2
c / 3 Motor M3 W C / 3

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X20.1 X30.1
Pin Description Pin
c / 11 Brake + C / 11
c / 12 Brake - C / 12
Housing Grd. conductor/PE Housing
Housing Shield, pin a /11, pin Housing
a / 12
Housing Shield, pin b /11, pin Housing
b / 12
Housing Shield, pin c / 11, Housing
pin c / 12
Housing Shield, all pins Housing

7.5.2 Description of the Motor cable

Cable overview

Fig. 7-7: Motor cable

1 X20.4
2 X30.4

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Connector pin allocation

Connector pin allocation X20.4 Connector pin allocation X30.4

The contact assignment on the connector side is shown in each case.

Wiring diagram

X20.4 X30.4
Pin Description Pin
a / 1 Motor M4 U A / 1
a / 2 Motor M4 V A / 2
a / 3 Motor M4 W A / 3
a / 11 Brake + A / 11
a / 12 Brake - A / 12
b / 1 Motor M5 U B / 1
b / 2 Motor M5 V B / 2
b / 3 Motor M5 W B / 3
b / 11 Brake + B / 11
b / 12 Brake - B / 12
c / 1 Motor M6 U C / 1
c / 2 Motor M6 V C / 2
c / 3 Motor M6 W C / 3

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X20.4 X30.4
Pin Description Pin
c / 11 Brake + C / 11
c / 12 Brake - C / 12
Housing Grd. conductor/PE Housing
Housing Shield, pin a /11, pin Housing
a / 12
Housing Shield, pin b /11, pin Housing
b / 12
Housing Shield, pin c / 11, Housing
pin c / 12
Housing Shield, all pins Housing

7.5.3 Description of the Data cable

Cable overview

Fig. 7-8: Data cable

1 X21
2 X31

Connector pin allocation

Connector pin allocation X21 Connector pin allocation X31

The contact assignment on the connector side is shown in each case.

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Wiring diagram

X21 X31
Description
Pin Pin
9 TPFO_P 9
11 TPFO_N 11
Housing Shield, pin 9, pin 11 Housing
10 TPFI_P 10
12 TPFI_N 12
Housing Shield, pin 10, pin Housing
12
3 Ground 3
2 24 V/PS1 with bat- 2
tery back-up
Housing Shield, all pins Housing

7.6 Description of the connecting cables, KR C5

Configuration

The connecting cables are used to transfer power and data between the
robot controller and the robot.
The connecting cables comprise:
• Motor cables (2x)
• Data cable

Interface

Cable designation Connector designa- Interface with robot

tion
Motor cable XD30.1 3 motor connectors: HAN size 24
XD20.1/XD20.2/
XD20.3 - XD30.1
1 brake connector:
XD10.1 - XD30.1
Motor cable XD30.4 3 motor connectors: HAN size 24
XD20.4/XD20.5/
XD20.6 - XD30.4
1 brake connector:
XD10.2 - XD30.4
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / M8 ring cable lug at
equipotential bonding both ends
16 mm2

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Standard connecting cable

Fig. 7-9: Connecting cables, overview

7.6.1 Description of the Motor cable

Cable overview

Fig. 7-10: Motor cable

1 XD20.x / XD10.1
2 XD30.1

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Connector pin allocation

Connector pin allocation

Connector pin allocation XD30.1
XD20.x / XD10.1

The contact assignment on the connector side is shown in each case.

Wiring diagram

XD20.x /
XD30.1
XD10.1
Description Pin
Pin
XD20.1 / 1 M1_U XD30.1.A /
1
XD20.1 / 2 M1_V XD30.1.A /
2
XD20.1 / 3 M1_W XD30.1.A /
3
XD20.1 / PE XD30.1.PE
PE / PE1
XD10.1 / M1_br_+ XD30.1.A /
B:1 11
XD10.1 / M1_br_GND XD30.1.A /
A:1 12
Housing Shield pin XD10.1 / Housing
B:1, A:1

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XD20.x /
XD30.1
XD10.1
Description Pin
Pin
XD20.2 / 1 M2_U XD30.1.B /
1
XD20.2/ 2 M2_V XD30.1.B /
2
XD20.2 / 3 M2_W XD30.1.B /
3
XD10.1 / M2_br_+ XD30.1.B /
B:2 11
XD10.1 / M2_br_GND XD30.1.B /
A:2 12
Housing Shield pin XD10.1 / Housing
B:2, A:2
XD20.3 / 1 M3_U XD30.1.C /
1
XD20.3 / 2 M3_V XD30.1.C /
2
XD20.3 / 3 M3_W XD30.1.C /
3
XD10.1 / M3_br_+ XD30.1.C /
B:3 11
XD10.1 / M3_br_GND XD30.1.C /
A:3 12
Housing Shield pin XD10.1 / Housing
B:3, A:3
Housing Shield, all pins Housing

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7.6.2 Description of the Motor cable

Cable overview

Fig. 7-11: Motor cable

1 XD20.x / XD10.2
2 XD30.4

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Connector pin allocation

Connector pin allocation

Connector pin allocation XD30.4
XD20.x / XD10.2

The contact assignment on the connector side is shown in each case.

Wiring diagram

XD20.x /
XD30.4
XD10.2
Description Pin
Pin
XD20.4 / 1 M4_U XD30.4.A /
1
XD20.4 / 2 M4_V XD30.4.A /
2
XD20.4 / 3 M4_W XD30.4.A /
3
XD20.4 / PE XD30.4.PE
PE / PE1
XD10.2 / M4_br_+ XD30.4.A /
B:2 11
XD10.2 / M4_br_GND XD30.4.A /
B:1 12
Housing Shield pin XD10.2 / Housing
B:2, B:1

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XD20.x /
XD30.4
XD10.2
Description Pin
Pin
XD20.5 / 1 M5_U XD30.4.B /
1
XD20.5/ 2 M5_V XD30.4.B /
2
XD20.5 / 3 M5_W XD30.4.B /
3
XD10.2 / M5_br_+ XD30.4.B /
A:2 11
XD10.2 / M5_br_GND XD30.4.B /
A:1 12
Housing Shield pin XD10.2 / Housing
A:2, A:1
XD20.6 / 1 M6_U XD30.4.C /
1
XD20.6 / 2 M6_V XD30.4.C /
2
XD20.6 / 3 M6_W XD30.4.C /
3
XD10.2 / M6_br_+ XD30.4.C /
A:3 11
XD10.2 / M6_br_GND XD30.4.C /
A:4 12
Housing Shield pin XD10.2 / Housing
A:3, A:4
Housing Shield, all pins Housing

7.6.3 Description of the Data cable

Cable overview

Fig. 7-12: Data cable

1 XF21
2 XF31

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Connector pin allocation

Connector pin allocation XF21 Connector pin allocation XF31

The contact assignment on the connector side is shown in each case.

Wiring diagram

XF21 XF31
Pin Description Pin
5 PSU_27V_IO 5
6 PSU_GND 6
7 PSU_27V_POS 2
8 PSU_GND 3
1 Rx+ 10
2 Rx- 12
3 Tx+ 9
4 Tx- 11
Housing Shield, all pins Housing

7.6.4 Description of the ground conductor

Fig. 7-13: Connecting cable, ground conductor

1 Ground conductor 6 Conical spring washer

2 Hexagon nut 7 Robot
3 Conical spring washer 8 Setscrew

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4 2x plain washer 9 Ground conductor connection
Ring cable lug
5 Hexagon nut 10 Ground sign

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 KR 600 FORTEC

Maintenance
8 Maintenance
Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA.
Information about KUKA College and its training program can be found at
college.kuka.com or can be obtained directly from our subsidiaries.
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.
CAUTION
For screwed connections, the fastening screws (standard, strength class
8.8) are to be tightened with the tightening torques specified in the ap-
pendix (>>> 12 "Appendix" Page 247). Tightening torques deviating from
these values are specified directly.
The specified screw sizes and strength classes are those 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 strength class 10.9 and higher as well as screws with test
certification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.

8.1 Maintenance overview

Description

The maintenance intervals given in the tables are valid for the operating
conditions specified in the technical data (>>> 4 "Technical data"
Page 33). KUKA Deutschland must be consulted in the event of
deviations in working conditions or the use of special functions or applica-
tions.
Further information can be found in the section “Information for plan-
ning” (>>> 5.1 "Information for planning" Page 127).

A general inspection of the manipulator is recommended after 7 years or

upon modifying its use. Please contact KUKA Service for this.
If the robot is fitted with a KUKA energy supply system (optional), addi-
tional maintenance work must be carried out.
NOTICE
Only auxiliary substances and consumables approved by KUKA
Deutschland GmbH may be used. Non-approved auxiliary substances
and consumables may cause premature wear and failure of assemblies.

Precondition

• The maintenance points must be freely accessible.

• Remove the tools and any additional items of equipment if they im-
pede maintenance work.

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Maintenance KR 600 FORTEC

WARNING
Danger to life and limb due to unintended robot motions
When carrying out the following work, the robot must be moved several
times between the individual work steps. Unintentional movements of
the robot can cause death, serious injury or material damage.
• While work is being carried out on the robot, it must always be se-
cured by actuating the EMERGENCY STOP device.
• If work is carried out on an operational robot that is switched on, the
robot must only be moved at reduced velocity. It must be possible to
stop the robot at any time by actuating an EMERGENCY STOP de-
vice. Operation must be limited to what is absolutely necessary.
• Warn all persons concerned before switching on and moving the ro-
bot.

If oil temperatures of more than 60 °C (333 K) are reached during opera-

tion, shorter maintenance intervals must be observed. Please contact
KUKA Service for this.

8.1.1 Maintenance table

Maintenance symbols

The overview may contain maintenance symbols that are not relevant
for the maintenance work on this product. The maintenance illustrations
provide an overview of the relevant maintenance work.

Oil change

Lubricate with grease gun

Lubricate with brush

Lubricate with spray grease

Tighten screw/nut

Check component, visual inspection

Clean component

Exchange battery

Exchange component

Check toothed belt tension

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Maintenance
Fig. 8-1: Maintenance diagram

Maintenance table, standard variants

Interval Item Task Auxiliary substances and

consumables
100 h 13 Check tightening torque for fastening
once after screws and nuts.
start-up and
recommis-
sioning
10 000 h 6 O-ring A4 Microlube GL 261 grease
Lift O-ring out of groove and remove 10 g
old grease. Grease O-ring with brush
and fit it back into groove
(>>> 8.2 "Regreasing the seal (O-ring
A4)" Page 176)

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Maintenance KR 600 FORTEC

Interval Item Task Auxiliary substances and

consumables
10 000 h 10 O-ring A5 Microlube GL 261 grease
Lift O-ring out of groove and remove 10 g
old grease. Grease O-ring with brush
and fit it back into groove
(>>> 8.3 "Regreasing the seal (O-ring
A5)" Page 177)
5 000 h* 1 Lubricate bearings of counterbalanc- Lubricating grease LGEV2/5
or 1 year ing system on rotating column.
10 cm³
at the latest
Grease nipples in the middle position
and at the plus and minus end posi-
tions.
*In the case of frequently recurring,
short-distance movements (less than
40°) about axis 2, the maintenance
interval is 3000 hours.
5 000 h* 3 Lubricate bearings of counterbalanc- Lubricating grease LGEV2/5
or 1 year ing system on link arm.
10 cm³
at the latest
Grease nipples in the middle position
and at the plus and minus end posi-
tions.
*In the case of frequently recurring,
short-distance movements (less than
40°) about axis 2, the maintenance
interval is 3000 hours.
5 000 h 2 Carry out a visual inspection of the
counterbalancing system, check the
condition, check that the pressure is
correct and check for leaks.
(>>> 8.5 "Checking the counterbal-
ancing system" Page 185)
15 000 h 11 Check drive shafts for axial play.
or 6 years
(>>> 8.6 "Checking drive shafts A4 to
at the latest
A6" Page 186)
once after
start-up and In the case of axial play in the univer-
recommis- sal joint, exchange the drive shaft.
sioning
(>>> 9.4 "Exchanging motors and
drive shafts A4 to A6" Page 219)
After initial inspection, the universal
shafts must be checked for play once
a year.
20 000 h 4 Carry out oil change on A3. Optigear Synt. ALR 150
or 5 years
(>>> 8.9 "Oil change in A3" Initial filling quantity: 3.50 l
at the latest
Page 194)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)

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Maintenance
Interval Item Task Auxiliary substances and
consumables
20 000 h 5 Carry out oil change on A4. Optigear Synt. ALR 150
or 5 years
(>>> 8.10 "Oil change in A4" Initial filling quantity: 2.40 l
at the latest
Page 197)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
20 000 h 8 Carry out oil change on A5. Optigear Synt. ALR 150
or 5 years
(>>> 8.11 "Oil change in A5" Initial filling quantity: 2.50 l
at the latest
Page 200)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
20 000 h 9 Carry out oil change on A6. Optigear Synt. ALR 150
or 5 years
(>>> 8.12 "Oil change in A6" Initial filling quantity: 5.20 l
at the latest
Page 203)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
20 000 h 12 Carry out oil change on A2. Optigear Synt. ALR 150
or 5 years
(>>> 8.8 "Oil change in A2" Initial filling quantity: 10.00 l
at the latest
Page 191)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
20 000 h 15 Carry out oil change on A1. Optigear Synt. ALR 150
or 5 years
(>>> 8.7 "Oil change in A1" Initial filling quantities, floor-
at the latest
Page 189) mounted robot: 10.00 l
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
20 000 h - Grease cables of cable set and ener- Lubricating grease Optitemp
or 5 years gy supply system. RB2
at the latest
(>>> 8.13 "Greasing the cable set" 200 cm³
Page 205)
1 year 11 Check drive shafts for axial play.
after initial in-
(>>> 8.6 "Checking drive shafts A4 to
spection
A6" Page 186)
In the case of axial play in the univer-
sal joint, exchange the drive shafts.
(>>> 9.4 "Exchanging motors and
drive shafts A4 to A6" Page 219)
10 years 14 Exchange the counterbalancing sys-
tem.
(>>> 8.4 "Exchanging the counterbal-
ancing system on a floor-mounted ro-
bot" Page 178)

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Maintenance KR 600 FORTEC

Maintenance table, F Variants

Interval Item Task Auxiliary substances and

consumables
100 h 13 Check tightening torque for fastening
once after screws and nuts.
start-up and
recommis-
sioning
5 000 h 6 O-ring A4 Microlube GL 261 grease
Lift O-ring out of groove and remove 10 g
old grease. Grease O-ring with brush
and fit it back into groove
(>>> 8.2 "Regreasing the seal (O-ring
A4)" Page 176)
5 000 h 10 O-ring A5 Microlube GL 261 grease
Lift O-ring out of groove and remove 10 g
old grease. Grease O-ring with brush
and fit it back into groove
(>>> 8.3 "Regreasing the seal (O-ring
A5)" Page 177)
5 000 h* 1 Lubricate bearings of counterbalanc- Lubricating grease LGEV2/5
or 1 year ing system on rotating column.
10 cm³
at the latest
Grease nipples in the middle position
and at the plus and minus end posi-
tions.
*In the case of frequently recurring,
short-distance movements (less than
40°) about axis 2, the maintenance
interval is 3000 hours.
5 000 h* 3 Lubricate bearings of counterbalanc- Lubricating grease LGEV2/5
or 1 year ing system on link arm.
10 cm³
at the latest
Grease nipples in the middle position
and at the plus and minus end posi-
tions.
*In the case of frequently recurring,
short-distance movements (less than
40°) about axis 2, the maintenance
interval is 3000 hours.
5 000 h 2 Carry out a visual inspection of the
counterbalancing system, check the
condition, check that the pressure is
correct and check for leaks.
(>>> 8.5 "Checking the counterbal-
ancing system" Page 185)

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Maintenance
Interval Item Task Auxiliary substances and
consumables
15 000 h 11 Check drive shafts for axial play.
or 6 years
(>>> 8.6 "Checking drive shafts A4 to
at the latest
A6" Page 186)
once after
start-up and In the case of axial play in the univer-
recommis- sal joint, exchange the drive shaft.
sioning
(>>> 9.4 "Exchanging motors and
drive shafts A4 to A6" Page 219)
After initial inspection, the universal
shafts must be checked for play once
a year.
10 000 h 4 Carry out oil change on A3. Optigear Synt. ALR 150
or 5 years
(>>> 8.9 "Oil change in A3" Initial filling quantity: 3.50 l
at the latest
Page 194)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
10 000 h 5 Carry out oil change on A4. Optigear Synt. ALR 150
or 5 years
(>>> 8.10 "Oil change in A4" Initial filling quantity: 2.40 l
at the latest
Page 197)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
10 000 h 8 Carry out oil change on A5. Optigear Synt. ALR 150
or 5 years
(>>> 8.11 "Oil change in A5" Initial filling quantity: 2.50 l
at the latest
Page 200)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
10 000 h 9 Carry out oil change on A6. Optigear Synt. ALR 150
or 5 years
(>>> 8.12 "Oil change in A6" Initial filling quantity: 5.20 l
at the latest
Page 203)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
10 000 h 12 Carry out oil change on A2. Optigear Synt. ALR 150
or 5 years
(>>> 8.8 "Oil change in A2" Initial filling quantity: 10.00 l
at the latest
Page 191)
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
10 000 h 15 Carry out oil change on A1. Optigear Synt. ALR 150
or 5 years
(>>> 8.7 "Oil change in A1" Initial filling quantities, floor-
at the latest
Page 189) mounted robot: 10.00 l
Refilling quantity (>>> "Refill-
ing quantity" Page 189)
20 000 h - Grease cables of cable set and ener- Lubricating grease Optitemp
or 5 years gy supply system. RB2
at the latest
(>>> 8.13 "Greasing the cable set" 200 cm³
Page 205)

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Maintenance KR 600 FORTEC

Interval Item Task Auxiliary substances and

consumables
1 year 11 Check drive shafts for axial play.
after initial in-
(>>> 8.6 "Checking drive shafts A4 to
spection
A6" Page 186)
In the case of axial play in the univer-
sal joint, exchange the drive shafts.
(>>> 9.4 "Exchanging motors and
drive shafts A4 to A6" Page 219)
10 years 14 Exchange the counterbalancing sys-
tem.
(>>> 8.4 "Exchanging the counterbal-
ancing system on a floor-mounted ro-
bot" Page 178)
Up-to-date safety data sheets must be requested from the manufacturers
of auxiliary and operating materials. Further information about the auxiliary
substances and consumables used can be found under:
(>>> 12.2 "Auxiliary substances and consumables" Page 248)

8.2 Regreasing the seal (O-ring A4)

Precondition

• The robot controller is switched off.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

Procedure

1. Pull O-ring A4 out of the groove.

2. Remove old grease from O-ring A4.
3. Perform a visual inspection of O-ring A4.
In the case of damage and cracks, inform KUKA Service.
4. Apply Microlube GL 261 grease to O-ring A4 with a brush.
5. Insert O-ring A4 back into the groove.
NOTICE
The O-ring in the groove must not be twisted.

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Maintenance
Fig. 8-2: Regreasing seal (O-ring) on A4

1 O-ring (marked in red) 3 Gear unit A4

2 Groove

8.3 Regreasing the seal (O-ring A5)

Precondition

• The robot controller is switched off.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

Procedure

1. Pull O-ring A5 out of the groove.

2. Remove old grease from O-ring A5.
3. Perform a visual inspection of O-ring A5.
In the case of damage and cracks, inform KUKA Service.
4. Grease O-ring A5 with Microlube GL 261 using a brush.
5. Push O-ring A5 back into the groove.
NOTICE
The O-ring in the groove must not be twisted.

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Maintenance KR 600 FORTEC

Fig. 8-3: Checking and regreasing the seal on A5

1 O-ring (marked in red) 3 Gear unit A5

2 Groove

8.4 Exchanging the counterbalancing system on a floor-mounted robot

8.4.1 Precondition

• The robot is in the mechanical zero position.

• It must be possible to move the robot about axis 2.
• The robot must be firmly bolted to the floor.
• Any items of equipment that are likely to impede the removal work
have been removed.
• The clamping bush for the piston rod must be present.
• The pin locator must be available.

WARNING
Danger to life and limb due to unintended robot motions
When carrying out the following work, the robot must be moved several
times between the individual work steps. Unintentional movements of
the robot can cause death, serious injury or material damage.
• While work is being carried out on the robot, it must always be se-
cured by actuating the EMERGENCY STOP device.
• If work is carried out on an operational robot that is switched on, the
robot must only be moved at reduced velocity. It must be possible to
stop the robot at any time by actuating an EMERGENCY STOP de-
vice. Operation must be limited to what is absolutely necessary.
• Warn all persons concerned before switching on and moving the ro-
bot.

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Maintenance
WARNING
When removing or installing the counterbalancing system, care must be
taken to avoid injury to arms, hands and fingers by crushing. Wear
gloves and secure the counterbalancing system so that it cannot fall
down or move unexpectedly.
The counterbalancing system is pressurized. Particular caution must
therefore be exercised and special knowledge put to effect when any
work is performed on this system. Any improper handling constitutes a
danger to life and limb.

WARNING
During maintenance and repair work, the robot must be fastened to the
floor. Death, severe injuries or considerable damage to property may
otherwise result.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

8.4.2 Removing the counterbalancing system on a floor-mounted robot

Procedure

1. Slacken the worm drive clip and push the bellows backwards
(>>> Fig. 8-4).
2. Move the link arm in the plus direction until the clamping bush can be
inserted between the cylinder and the articulated head.
3. Secure the robot by pressing the EMERGENCY STOP device.
4. Place clamping bush onto the free piston rod between the articulated
head and the hydraulic cylinder and secure it with a screw.
5. Put the robot into operation and move the link arm carefully in the mi-
nus direction until the clamping bush is just clamped.
CAUTION
Material damage due to blocked counterbalancing system
Do not move the counterbalancing system further in the minus direc-
tion. The counterbalancing system, link arm or rotating column may
otherwise be damaged.
‒ Secure the robot by pressing the EMERGENCY STOP device.

6. Secure the counterbalancing system with a rope sling and a crane

and move the crane until the weight is supported by the rope sling.
7. Remove 6 Allen screws and conical spring washers, and take off the
retaining plate.

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Fig. 8-4: Removing the counterbalancing system: clamping bush

1 Clamping bush
2 Worm drive clip
3 Bellows
4 Lock washer
5 M8x25-10.9 Allen screw with spherical washer and ball cup
(slots on the cover)
M8x20-10.9 Allen screw with conical spring washer (holes on
the cover)
6 Rope sling

8. Secure link arm using a rope sling and crane (>>> Fig. 8-5).

Fig. 8-5: Securing the link arm

9. Remove 1 Allen screw together with lock washer from the rotating col-
umn (>>> Fig. 8-6).

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Maintenance
Fig. 8-6: Removing the counterbalancing system: rotating column

1 Rope sling 4 Rotating column

2 M10x35-10.9 Allen screw 5 Counterbalancing system
with conical spring washer
3 Cover

10. Insert the pin locator on the right-hand side between the articulated
head and the link arm (>>> Fig. 8-7).
11. Pull the pin out of the link arm using an M16 pin extractor.
The pin is out of the precision fit area when it has been pulled out ap-
prox. 25 mm.
12. Put the robot into operation and move the link arm carefully in the
plus direction until the articulated head is free. When moving the link
arm, move the crane and rope sling at the same time, so that the
weight of the arm is supported by the crane.
13. Secure the robot by pressing the EMERGENCY STOP device.
14. Swivel the counterbalancing system up and out of the link arm, mov-
ing the crane and rope sling at the same time.
15. Take off the pin locator, thrust ring and spacer ring that are now loose.
CAUTION
When forcing the counterbalancing system off the rotating column,
an unfavorable position of the center of gravity may cause the coun-
terbalancing system to move unexpectedly. To avoid injury and dam-
age, the tension and position of the rope must be adjusted as nec-
essary.

16. Use an M20 jacking screw to force the counterbalancing system off
the pin in the rotating column in the direction of the arrow.
While forcing off the counterbalancing system, check the rope tension
and if necessary correct it to prevent the components from being tilted.
17. Continue raising the counterbalancing system with the crane and set it
down on a suitable support.
18. If the counterbalancing system is not to be reinstalled, it must be pro-
tected against corrosion before being put into storage.
If a new counterbalancing system is not being installed immediately, the
robot can be moved into a safe position and the rope securing the link
arm can be removed. The robot may only be moved again in order to in-
stall the new counterbalancing system.

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Maintenance KR 600 FORTEC

Fig. 8-7: Removing the counterbalancing system: pin

1 Thrust ring 4 Pin

2 Spacer ring 5 Pin locator
3 Articulated head

8.4.3 Installing the counterbalancing system on a floor-mounted robot

Procedure

1. Remove corrosion protection from the counterbalancing system and

check that no part of it is missing.
2. If necessary, put the robot into operation and move the link arm into
approximately the -85° position (KCP display) (>>> Fig. 8-8).
3. Secure the robot by pressing the EMERGENCY STOP device.
4. Secure link arm using a rope sling and crane.

Fig. 8-8: Securing the link arm

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Maintenance
5. Lift the counterbalancing system with a rope sling and bring it to the
site of installation (>>> Fig. 8-9).
Align the rear counterbalancing system pin in the rotating column cen-
trally with the inner ring of the bearing.
6. Mount the counterbalancing system sideways on the pin in the rotating
column, and align.
7. If necessary, adjust the rope tension.
8. Coat the thread of the new M10x35-10.9 Allen screw with Drei Bond
1342 locking agent.
9. Mount the cover and fasten it to the pin using the new M10x35-10.9
Allen screw and conical spring washer.
10. Tighten the M10x35-10.9 Allen screw to the correct tightening torque
with a torque wrench.

Fig. 8-9: Installing the counterbalancing system: rotating column

1 Rope sling 3 Cover

2 Allen screw 4 Rotating column

11. Put the robot into operation.

12. Move the link arm until the counterbalancing system can be inserted
into the link arm. At the same time, move the element securing the
link arm accordingly (>>> Fig. 8-10).
13. Lower the counterbalancing system, insert the articulated head with
the thrust ring and spacer ring into the link arm, and align; observe
the correct installation position.
14. Move the link arm and counterbalancing system until the holes are
aligned.
15. Secure the robot by pressing the EMERGENCY STOP device.
16. Insert the pin with the aid of the device.

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Maintenance KR 600 FORTEC

Fig. 8-10: Installing the counterbalancing system: pin

1 Thrust ring 3 Articulated head

2 Spacer ring 4 Pin

17. Coat the thread of the 6 new M8x20-10.9 Allen screws with Drei Bond
1342.
18. Mount the cover and fasten it with the 6 M8x20-10.9 Allen screws in-
cluding conical spring washers (>>> Fig. 8-11).
19. Tighten 6 M8x20-10.9 Allen screws with a torque wrench.
20. Remove the rope sling from the counterbalancing system and the link
arm.
21. Put the robot into operation.
22. Move the link arm in the plus direction until the clamping bush be-
tween the cylinder and the articulated head is released, slacken the
setscrew and remove the clamping bush.

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Maintenance
CAUTION
Material damage due to blocked counterbalancing system
Do not move the counterbalancing system further in the minus direc-
tion. The counterbalancing system, link arm or rotating column may
otherwise be damaged.
‒ Secure the robot by pressing the EMERGENCY STOP device.

23. Secure the robot by pressing the EMERGENCY STOP device.

24. Mount the bellows on the cylinder and the articulated head and fasten
with worm drive clips.
25. Check the pressure on the counterbalancing system (>>> 8.5 "Check-
ing the counterbalancing system" Page 185).

Fig. 8-11: Installing the counterbalancing system: link arm

1 Clamping bush
2 Worm drive clip
3 Bellows
4 Cover
5 Allen screws including conical spring washers
6 Counterbalancing system

8.5 Checking the counterbalancing system

Description

The following describes those tasks which must be carried out at the inter-
vals specified in the maintenance table.

Precondition

• The robot is operational and can be moved at jog velocity.

• There is no hazard posed by system components or other robots.
• The robot is secured if work is being performed directly on the robot.

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Maintenance KR 600 FORTEC

WARNING
Danger to life and limb due to unintended robot motions
When carrying out the following work, the robot must be moved several
times between the individual work steps. Unintentional movements of
the robot can cause death, serious injury or material damage.
• While work is being carried out on the robot, it must always be se-
cured by actuating the EMERGENCY STOP device.
• If work is carried out on an operational robot that is switched on, the
robot must only be moved at reduced velocity. It must be possible to
stop the robot at any time by actuating an EMERGENCY STOP de-
vice. Operation must be limited to what is absolutely necessary.
• Warn all persons concerned before switching on and moving the ro-
bot.

Procedure

1. Move axis 2 manually to -90°. The link arm is now vertical, while the
arm may be in any position. Then wait 1 minute.
2. Secure the robot by pressing the EMERGENCY STOP device.
3. Check the following pressure on the pressure gauge:
• Floor-mounted robot: 170 bar ±15 bar at 20 °C (293 K)
If the permissible value is not correct and/or there are deviations in
the application, the value must be measured with a special pressure
gauge and KUKA Service must be consulted.
4. Check the attachments for dirt and clean them if necessary.
5. Check the attachments for damage and ensure that they do not leak.
In the case of leaks, identify and eliminate the cause. If necessary, ex-
change the counterbalancing system.
(>>> 8.4 "Exchanging the counterbalancing system on a floor-mounted
robot" Page 178)
6. Check the collar for dirt and damage, clean or exchange it if necessa-
ry.
(>>> 8.4 "Exchanging the counterbalancing system on a floor-mounted
robot" Page 178)

8.6 Checking drive shafts A4 to A6

8.6.1 Description

There are 3 drive shafts in the arm housing of the robot. The drive shafts
are distinguished between two universal shafts (A4 and A6) and a con-
necting shaft (A5). Described below are those tasks which must be carried
out to check the axial play of the drive shafts.

Precondition

• The robot is operational and can be moved at jog velocity.

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Maintenance
WARNING
Danger to life and limb due to unintended robot motions
When carrying out the following work, the robot must be moved several
times between the individual work steps. Unintentional movements of
the robot can cause death, serious injury or material damage.
• While work is being carried out on the robot, it must always be se-
cured by actuating the EMERGENCY STOP device.
• If work is carried out on an operational robot that is switched on, the
robot must only be moved at reduced velocity. It must be possible to
stop the robot at any time by actuating an EMERGENCY STOP de-
vice. Operation must be limited to what is absolutely necessary.
• Warn all persons concerned before switching on and moving the ro-
bot.

Procedure

1. Move the robot in T1 mode and listen for running noises.

2. Lower load vertically to relieve load on universal shafts.
3. Secure the robot by pressing the E-STOP button.
4. Remove the cover and O-ring (F variant only) from the installation
aperture (>>> Fig. 8-12).

Fig. 8-12: Checking drive shafts A4 to A6

1 Motor A4 6 Installation aperture

2 Motor A5 7 Universal shaft A4
3 Motor A6 8 Connecting shaft A 5
4 Cover 9 Universal shaft A6
5 O-ring (F variant only)

5. Inspect drive shafts A4, A5 and A6 visually for abrasion and blue col-
oration.

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 KR 600 FORTEC

If any abrasion and/or blue coloration is discovered, take the robot out
Maintenance

of operation and exchange the drive shafts (>>> 9.4.1 "Description"

Page 219).
6. Check universal shafts for rotational and axial play by applying a ten-
sile force of 20 N as illustrated (>>> Fig. 8-13). To do so, pull and turn
universal shafts A4 and A6 gently by hand.
If the rotational and axial play is greater than 0.8 mm, take the robot
out of operation and exchange universal shafts A4 and A6
(>>> 9.4.1 "Description" Page 219).
7. Check connecting shaft A5 for rotational play as illustrated
(>>> Fig. 8-13). To do so, turn connecting shaft gently by hand.
If the rotational play is greater than 0.8 mm, take the robot out of op-
eration and exchange connecting shaft A5 (>>> 9.4.1 "Description"
Page 219).

Fig. 8-13: Checking the connecting and universal shafts

8. Fasten the cover and new O-ring (F variant only) in the installation
aperture.

Fig. 8-14: Fastening the cover in the installation aperture

1 Installation aperture 3 Cover

2 O-ring (F variant only)

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Maintenance
8.7 Oil change in A1

Description

The following sections describe the A1 gear oil change for floor-mounted
robots.

Precondition

• The gear unit is at operating temperature.

Refilling quantity

CAUTION
The quantity of oil drained depends on the draining time and the oil
temperature. The refilling quantity is the quantity of oil that was drained
from the gear unit at the correct operating temperature and with the cor-
rect draining time. This oil quantity must be determined. Only this quan-
tity of oil may be used when refilling.
If less than 70 % of the specified oil quantity flows out, flush the gear
unit with the determined quantity of drained oil once, then pour in the
amount of oil that was drained. If less than 50% of the specified oil
quantity flows out (e.g. inclined installation), the flushing operation must
be repeated twice. During the flushing procedure, move the axis at jog
velocity throughout the entire axis range.
The oil quantities specified in the table correspond to the oil quantities
in the gear unit at first filling.

Tightening torques

The tightening torques can be found under: (>>> 12.1 "Tightening

torques" Page 247)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher, stainless steel screws of
strength class 70 or 80, as well as screws with test certification may only
be tightened once with the rated tightening torque. These screws must be
replaced with new ones when they are slackened for the first time.

Arbeitssicherheit

CAUTION
High oil and surface temperatures after the machine has stopped
operating
Immediately after the machine has stopped operating, it is liable to have
high oil and surface temperatures. Touching them may result in burns.
• Wear personal protective equipment.

CAUTION
Oil chamber could be pressurized
Under certain conditions, the oil chambers of the gear units may be
pressurized. This can result in a sudden oil leak when the oil drain plug
is opened and lead to injuries and damage to property.
• Vent the oil chamber before draining the oil.
• Wear personal protective equipment.

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Maintenance KR 600 FORTEC

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

8.7.1 Draining the gear oil from A1

Procedure

1. Pull the oil drain hose out of the base frame (>>> Fig. 8-15).
2. Place a suitable receptacle under the drain hole.
3. Carefully unscrew the magnetic screw plug for venting and close it
again.
4. Unscrew the union nut of the oil drain hose.
5. Remove the magnetic screw plug for venting and catch the oil as it
drains out.
6. Measure the amount of oil drained and store or dispose of the used
oil in accordance with the pertinent regulations.

Fig. 8-15: Draining the oil from A1

1 Magnetic screw plug

2 Oil drain hose
3 Union nut
4 Collection receptacle

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Maintenance
8.7.2 Filling gear unit A1 with gear oil

Procedure

1. Pull the oil drain hose upwards (>>> Fig. 8-16).

The opening of the oil drain hose must point upwards.
2. Fill the specified amount of oil via the oil drain hose using the oil
pump.
3. Remove the oil pump and oil drain hose.
4. Screw the union nut onto the oil drain hose and tighten; MA = 40 Nm.
5. Push the oil drain hose back into the base frame.
6. Insert and tighten the magnetic screw plug; MA = 25 Nm.
7. Check the union nut for leaks and exchange if necessary.

Fig. 8-16: Filling with oil on A1

1 Magnetic screw plug

2 Oil pump
3 Union nut
4 Oil drain hose

8.8 Oil change in A2

Description

The following describes the gear oil change for floor-mounted robots.

Precondition

• The robot is in a position in which the oil filler hole and oil drain hole
on the gear unit of axis 2 are accessible.
• The gear unit is at operating temperature.

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Maintenance KR 600 FORTEC

Refilling quantity

CAUTION
The quantity of oil drained depends on the draining time and the oil
temperature. The refilling quantity is the quantity of oil that was drained
from the gear unit at the correct operating temperature and with the cor-
rect draining time. This oil quantity must be determined. Only this quan-
tity of oil may be used when refilling.
If less than 70 % of the specified oil quantity flows out, flush the gear
unit with the determined quantity of drained oil once, then pour in the
amount of oil that was drained. If less than 50% of the specified oil
quantity flows out (e.g. inclined installation), the flushing operation must
be repeated twice. During the flushing procedure, move the axis at jog
velocity throughout the entire axis range.
The oil quantities specified in the table correspond to the oil quantities
in the gear unit at first filling.

Tightening torques

The tightening torques can be found under: (>>> 12.1 "Tightening

torques" Page 247)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher, stainless steel screws of
strength class 70 or 80, as well as screws with test certification may only
be tightened once with the rated tightening torque. These screws must be
replaced with new ones when they are slackened for the first time.

Arbeitssicherheit

CAUTION
High oil and surface temperatures after the machine has stopped
operating
Immediately after the machine has stopped operating, it is liable to have
high oil and surface temperatures. Touching them may result in burns.
• Wear personal protective equipment.

CAUTION
Oil chamber could be pressurized
Under certain conditions, the oil chambers of the gear units may be
pressurized. This can result in a sudden oil leak when the oil drain plug
is opened and lead to injuries and damage to property.
• Vent the oil chamber before draining the oil.
• Wear personal protective equipment.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

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Maintenance
8.8.1 Draining the gear oil from A2

Procedure

1. Pull the oil drain hose out of the rotating column (>>> Fig. 8-17).
2. Place a suitable receptacle under the oil drain hose.
3. Carefully unscrew the magnetic screw plug for venting and close it
again.
4. Unscrew the union nut of the oil drain hose.
5. Remove the magnetic screw plug for venting and catch the oil as it
drains out.
6. Measure the amount of oil drained and store or dispose of the used
oil in accordance with the pertinent regulations.

Fig. 8-17: Draining the oil from A2

1 Magnetic screw plug

2 Oil drain hose
3 Union nut
4 Collection receptacle

8.8.2 Filling gear unit A2 with gear oil

Procedure

1. Pull the oil drain hose upwards (>>> Fig. 8-18).

The opening of the oil drain hose must point upwards.
2. Fill the specified amount of oil via the oil drain hose using the oil
pump.
3. Remove the oil pump and oil drain hose.
4. Screw the union nut onto the oil drain hose and tighten; MA = 40 Nm.
5. Feed the oil drain hose back into the rotating column.
6. Insert and tighten the M22x1.5 magnetic screw plug; MA = 25 Nm.
7. Check the oil drain hose at both connections for leaks; exchange if
necessary.

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Fig. 8-18: Filling with oil on A2

1 Oil pump
2 Union nut
3 Oil drain hose
4 Magnetic screw plug

8.9 Oil change in A3

Description

The following describes the gear oil change for floor-mounted robots.

Preconditions

• The robot is in a position in which the oil filler and drain holes on the
axis 3 gear unit are accessible.
• The gear unit is at operating temperature.
• Axis 3 is in a horizontal position.

Refilling quantity

CAUTION
The quantity of oil drained depends on the draining time and the oil
temperature. The refilling quantity is the quantity of oil that was drained
from the gear unit at the correct operating temperature and with the cor-
rect draining time. This oil quantity must be determined. Only this quan-
tity of oil may be used when refilling.
If less than 70 % of the specified oil quantity flows out, flush the gear
unit with the determined quantity of drained oil once, then pour in the
amount of oil that was drained. If less than 50% of the specified oil
quantity flows out (e.g. inclined installation), the flushing operation must
be repeated twice. During the flushing procedure, move the axis at jog
velocity throughout the entire axis range.
The oil quantities specified in the table correspond to the oil quantities
in the gear unit at first filling.

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Maintenance
Tightening torques

The tightening torques can be found under: (>>> 12.1 "Tightening

torques" Page 247)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher, stainless steel screws of
strength class 70 or 80, as well as screws with test certification may only
be tightened once with the rated tightening torque. These screws must be
replaced with new ones when they are slackened for the first time.

Arbeitssicherheit

CAUTION
High oil and surface temperatures after the machine has stopped
operating
Immediately after the machine has stopped operating, it is liable to have
high oil and surface temperatures. Touching them may result in burns.
• Wear personal protective equipment.

CAUTION
Oil chamber could be pressurized
Under certain conditions, the oil chambers of the gear units may be
pressurized. This can result in a sudden oil leak when the oil drain plug
is opened and lead to injuries and damage to property.
• Vent the oil chamber before draining the oil.
• Wear personal protective equipment.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

8.9.1 Draining the gear oil from A3

Procedure

1. Place a suitable receptacle under the drain hole (>>> Fig. 8-19).
2. Carefully unscrew the (upper) magnetic screw plug for venting and
close it again.
3. Unscrew the magnetic screw plug (lower) and screw in M18x1.5 oil
drain hose.
4. Remove the (upper) magnetic screw plug for venting and catch the oil
as it drains out.
5. Measure the amount of oil drained and store or dispose of the used
oil in accordance with the pertinent regulations.

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6. Check both magnetic screw plugs for deposits; take appropriate meas-
ures if necessary.
7. Clean both magnetic screw plugs and check the sealing element. Ex-
change damaged magnetic screw plug.

Fig. 8-19: Draining the oil from A3

1 Upper magnetic screw plug

2 Oil drain hose
3 Collection receptacle
4 Lower magnetic screw plug

8.9.2 Filling gear unit A3 with gear oil

Procedure

1. Fill the specified amount of oil via the oil drain hose using the oil
pump (>>> Fig. 8-20).
2. Remove the oil pump and oil drain hose.
3. Insert and tighten both M18x1.5 magnetic screw plugs; MA = 20.0 Nm.
4. Check both magnetic screw plugs for leaks and exchange if necessa-
ry.

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Maintenance
Fig. 8-20: Filling with oil on A3

1 Upper magnetic screw plug

2 Oil pump
3 Union nut
4 Oil drain hose

8.10 Oil change in A4

Description

The following sections describe the A4 gear oil change for floor-mounted
robots.

Precondition

• The robot is in a position in which gear unit A 4 is accessible.

• Axis 4 is in a horizontal position.
• The gear unit is at operating temperature.

Refilling quantity

CAUTION
The quantity of oil drained depends on the draining time and the oil
temperature. The refilling quantity is the quantity of oil that was drained
from the gear unit at the correct operating temperature and with the cor-
rect draining time. This oil quantity must be determined. Only this quan-
tity of oil may be used when refilling.
If less than 70 % of the specified oil quantity flows out, flush the gear
unit with the determined quantity of drained oil once, then pour in the
amount of oil that was drained. If less than 50% of the specified oil
quantity flows out (e.g. inclined installation), the flushing operation must
be repeated twice. During the flushing procedure, move the axis at jog
velocity throughout the entire axis range.
The oil quantities specified in the table correspond to the oil quantities
in the gear unit at first filling.

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Tightening torques

The tightening torques can be found under: (>>> 12.1 "Tightening

torques" Page 247)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher, stainless steel screws of
strength class 70 or 80, as well as screws with test certification may only
be tightened once with the rated tightening torque. These screws must be
replaced with new ones when they are slackened for the first time.

Arbeitssicherheit

CAUTION
High oil and surface temperatures after the machine has stopped
operating
Immediately after the machine has stopped operating, it is liable to have
high oil and surface temperatures. Touching them may result in burns.
• Wear personal protective equipment.

CAUTION
Oil chamber could be pressurized
Under certain conditions, the oil chambers of the gear units may be
pressurized. This can result in a sudden oil leak when the oil drain plug
is opened and lead to injuries and damage to property.
• Vent the oil chamber before draining the oil.
• Wear personal protective equipment.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

8.10.1 Draining the gear oil from A4

Procedure

1. Place a suitable receptacle under the drain hole (>>> Fig. 8-21).
2. Carefully unscrew the (upper) magnetic screw plug for venting and
close it again.
3. Remove the (lower) magnetic screw plug.
4. Remove the (upper) magnetic screw plug for venting and catch the oil
as it drains out.
5. Measure the amount of oil drained and store or dispose of the used
oil in accordance with the pertinent regulations.
6. Measure the amount of oil drained and dispose of the used oil in ac-
cordance with the pertinent regulations.

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Maintenance
7. Check both magnetic screw plugs for deposits; take appropriate meas-
ures if necessary.
8. Clean both magnetic screw plugs and check the sealing element. Ex-
change damaged magnetic screw plug.
9. Insert and tighten the lower M18x1.5 magnetic screw plug; MA =
20.0 Nm.

Fig. 8-21: Draining the oil from A4

1 Upper magnetic screw plug

2 Drain hole
3 Lower magnetic screw plug
4 Receptacle

8.10.2 Filling gear unit A4 with gear oil

Procedure

1. Pour specified amount of oil into filler hole (>>> Fig. 8-22).
Use a funnel when filling with oil.
2. Insert and tighten the upper M18x1.5 magnetic screw plug, MA =
20.0 Nm.
3. Check both magnetic screw plugs for leaks and exchange if necessa-
ry.

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Maintenance KR 600 FORTEC

Fig. 8-22: Filling with oil on A4

1 Upper magnetic screw plug

2 Funnel
3 Filler hole

8.11 Oil change in A5

Precondition

• The gear unit is at operating temperature.

• The arm and wrist are positioned horizontally.

Refilling quantity

CAUTION
The quantity of oil drained depends on the draining time and the oil
temperature. The refilling quantity is the quantity of oil that was drained
from the gear unit at the correct operating temperature and with the cor-
rect draining time. This oil quantity must be determined. Only this quan-
tity of oil may be used when refilling.
If less than 70 % of the specified oil quantity flows out, flush the gear
unit with the determined quantity of drained oil once, then pour in the
amount of oil that was drained. If less than 50% of the specified oil
quantity flows out (e.g. inclined installation), the flushing operation must
be repeated twice. During the flushing procedure, move the axis at jog
velocity throughout the entire axis range.
The oil quantities specified in the table correspond to the oil quantities
in the gear unit at first filling.

Tightening torques

The tightening torques can be found under: (>>> 12.1 "Tightening

torques" Page 247)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher, stainless steel screws of
strength class 70 or 80, as well as screws with test certification may only
be tightened once with the rated tightening torque. These screws must be
replaced with new ones when they are slackened for the first time.

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Maintenance
Arbeitssicherheit

CAUTION
High oil and surface temperatures after the machine has stopped
operating
Immediately after the machine has stopped operating, it is liable to have
high oil and surface temperatures. Touching them may result in burns.
• Wear personal protective equipment.

CAUTION
Oil chamber could be pressurized
Under certain conditions, the oil chambers of the gear units may be
pressurized. This can result in a sudden oil leak when the oil drain plug
is opened and lead to injuries and damage to property.
• Vent the oil chamber before draining the oil.
• Wear personal protective equipment.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

8.11.1 Draining the gear oil from A5

Procedure

1. Place a suitable receptacle under the drain hole (>>> Fig. 8-23).
2. Carefully unscrew the (upper) magnetic screw plug for venting and
close it again.
3. Remove the (lower) magnetic screw plug.
4. Remove the (upper) magnetic screw plug for venting and catch the oil
as it drains out.
5. Measure the amount of oil drained and store or dispose of the used
oil in accordance with the pertinent regulations.
6. Check both magnetic screw plugs for deposits; take appropriate meas-
ures if necessary.
7. Clean both magnetic screw plugs and check the sealing element. Ex-
change damaged magnetic screw plugs.

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Maintenance KR 600 FORTEC

Fig. 8-23: Draining the oil from A5

1 Upper magnetic screw plug

2 Drain hole
3 Lower magnetic screw plug
Collection receptacle

8.11.2 Filling gear unit A5 with gear oil

Procedure

1. Move A4 into the +90° position (>>> Fig. 8-24). The cover faces up-
wards.
2. Pour specified amount of oil into filler hole.
Use a funnel when filling with oil.
3. Insert and tighten both M18x1.5 magnetic screw plugs; MA = 20.0 Nm.
4. Check both magnetic screw plugs for leaks and exchange if necessa-
ry.

Fig. 8-24: Filling with oil on A5

1 Magnetic screw plug

2 Funnel
3 Cover

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Maintenance
8.12 Oil change in A6

Precondition

• The gear unit is at operating temperature.

• The arm and wrist are positioned horizontally.

Refilling quantity

CAUTION
The quantity of oil drained depends on the draining time and the oil
temperature. The refilling quantity is the quantity of oil that was drained
from the gear unit at the correct operating temperature and with the cor-
rect draining time. This oil quantity must be determined. Only this quan-
tity of oil may be used when refilling.
If less than 70 % of the specified oil quantity flows out, flush the gear
unit with the determined quantity of drained oil once, then pour in the
amount of oil that was drained. If less than 50% of the specified oil
quantity flows out (e.g. inclined installation), the flushing operation must
be repeated twice. During the flushing procedure, move the axis at jog
velocity throughout the entire axis range.
The oil quantities specified in the table correspond to the oil quantities
in the gear unit at first filling.

Tightening torques

The tightening torques can be found under: (>>> 12.1 "Tightening

torques" Page 247)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher, stainless steel screws of
strength class 70 or 80, as well as screws with test certification may only
be tightened once with the rated tightening torque. These screws must be
replaced with new ones when they are slackened for the first time.

Arbeitssicherheit

CAUTION
High oil and surface temperatures after the machine has stopped
operating
Immediately after the machine has stopped operating, it is liable to have
high oil and surface temperatures. Touching them may result in burns.
• Wear personal protective equipment.

CAUTION
Oil chamber could be pressurized
Under certain conditions, the oil chambers of the gear units may be
pressurized. This can result in a sudden oil leak when the oil drain plug
is opened and lead to injuries and damage to property.
• Vent the oil chamber before draining the oil.
• Wear personal protective equipment.

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Maintenance KR 600 FORTEC

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

8.12.1 Draining the gear oil from A6

Procedure

1. Move A5 into the -90° position. The mounting flange faces up

(>>> Fig. 8-25).
2. Place a suitable receptacle under the drain hole.
3. Carefully unscrew the side magnetic screw plug for venting and close
it again.
4. Remove the magnetic screw plug on the swivel housing.
5. Remove the side magnetic screw plug for venting and catch the oil as
it drains out.
6. Measure the amount of oil drained and store or dispose of the used
oil in accordance with the pertinent regulations.
7. Inspect both magnetic screw plugs for metallic deposits and clean
them.
8. Insert and tighten the magnetic screw plug at the side; MA= 20.0 Nm.

Fig. 8-25: Draining the oil from A6

1 Move to the -90° position

2 Magnetic screw plug on the side
3 Swivel housing
4 Magnetic screw plug on the swivel housing
5 Collection receptacle

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Maintenance
8.12.2 Filling gear unit A6 with gear oil

Procedure

1. Move A5 into the +90° position. The mounting flange faces down
(>>> Fig. 8-26).
2. Pour specified amount of oil into filler hole.
3. Inspect the magnetic screw plugs of the swivel housing for metallic de-
posits and clean them.
4. Insert and tighten the magnetic screw plug in the swivel housing; MA
= 20 Nm.
5. Check both magnetic screw plugs for leaks and exchange if necessa-
ry.

Fig. 8-26: Filling with oil on A6

1 Magnetic screw plug on the swivel housing

2 Swivel housing
3 Magnetic screw plug on the side
4 Move to the +90° position

8.13 Greasing the cable set

Precondition

• The robot is accessible in the area of axis 1

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

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Maintenance KR 600 FORTEC

Procedure

1. Remove 2 M6x16 Allen screws together with conical spring washers

from the cover and intermediate plate (>>> Fig. 8-27).
2. Remove 7 M6x12 Allen screws and conical spring washers, and take
off the cover.
3. Apply cable grease evenly to the cables in the base frame using a
brush and by hand.
Wear protective gloves.
4. Dispose of used grease and grease residues in accordance with the
pertinent regulations.
5. Mount the cover and fasten it with 7 M6x12 Allen screws and conical
spring washers.
6. Fasten the cover to the intermediate plate with 2 M6x16 Allen screws.

Fig. 8-27: Greasing the cable set

1 Cover
2 Cover
3 Intermediate plate
4 M6x16 Allen screws

8.14 Cleaning the robot

Description

The robot must be cleaned in compliance with the instructions given here
in order to prevent damage. These instructions only refer to the robot.

Equipment

The following equipment is required:

Designation Article number
Permissible cleaning tools (e.g. cloths, -
brushes)

Material

The following material is required:

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Maintenance
Designation Article number Quantity
Corrosion protection without friction-re- - -
ducing substances
Cleaning agent - -
solvent-free, water-soluble, non-flamma-
ble, non-aggressive, no steam, no refrig-
erants

Precondition

• The robot controller is switched off.

• The robot is freely accessible.

Work safety

NOTICE
The following must be taken into consideration when carrying out clean-
ing work (material damage may otherwise result):
• Cleaning must be in accordance with the corresponding cleaning in-
structions.
• Do not use high-pressure cleaners.
• Compressed air must not be used to clean bearing and sealing
points.
• It must be ensured that no cleaning agent enters electrical or me-
chanical system components.

8.14.1 Cleaning

Procedure

1. Shut down the robot.

2. If necessary, shut adjacent system components down and lock them.
3. Remove enclosures if this is necessary in order to carry out the clean-
ing work.
4. Clean the robot.
5. Fully remove all cleaning agents from the robot.
6. Clean any areas of corrosion and reapply corrosion protection.
7. Install any safety equipment that has been removed.
8. Put back in place any enclosures that have been removed.

8.14.2 Concluding work

The following concluding work must be carried out:

• Remove cleaning agents and equipment from the workspace of the ro-
bot.
• Dispose of cleaning agents in accordance with the pertinent regula-
tions.
• Replace any damaged or illegible plates and covers.
• Install any safety equipment that has been removed and check that it
is functioning correctly. Only a functional system with all safety func-
tions may be put back into operation.

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Repair
9 Repair
Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA.
Information about KUKA College and its training program can be found at
college.kuka.com or can be obtained directly from our subsidiaries.
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.
CAUTION
For screwed connections, the fastening screws (standard, strength class
8.8) are to be tightened with the tightening torques specified in the ap-
pendix (>>> 12 "Appendix" Page 247). Tightening torques deviating from
these values are specified directly.
The specified screw sizes and strength classes are those 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 strength class 10.9 and higher as well as screws with test
certification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.

9.1 Exchanging motor A1

Description

The following instructions describe the exchange of motor A1 for floor-

mounted robots. The description also applies to ceiling-mounted robots (C
variant); the same procedure is to be applied analogously. The motor
must be supported from beneath and the vertically hanging link arm must
be secured against motion.

Precondition

• The robot is secured against rotational motions about axis 1.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

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Repair KR 600 FORTEC

WARNING
Danger to life and limb when working on live parts
Before commencing work on live parts of the robot system and/or on
electrical systems, measures must be taken to ensure that the 5 safety
rules are followed. It is essential that the 5 safety steps are followed in
the correct order. Death, severe injuries or damage to property may re-
sult.
1. De-energize
2. Secure against unintentional restart
3. Ensure that the system is de-energized
4. Ground and short-circuit the system
5. Cover or erect barriers around neighboring energized parts
Once the work is completed, tools and equipment must be removed and
the measures rescinded in reverse sequence.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

CAUTION
Risk of burns on hot surfaces
The surfaces of the motors are often hot immediately after the robot has
been decommissioned. Touching them may result in burns.
• Wear protective gloves.

WARNING
Risk of crushing during removal and installation of motor
When removing or installing the motor, there is a risk of injury by crush-
ing. This could result in hand injuries.
• Wear protective gloves.

NOTICE
Wear and premature failure due to damage to toothing
Damage to the toothing of the motor and gear unit can lead to in-
creased wear and premature failure of the components.
• During cleaning, ensure that the toothing is not damaged.
• Before installation, check the toothing of the motor and gear unit for
damage.

9.1.1 Removing motor A1

Procedure

1. Release and unplug connectors XM1 and XP1 at the sockets

(>>> Fig. 9-1).
2. Remove 4 Allen screws.

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3. Release motor A1 and lift out together with the seal. Do not tilt when
lifting out.
4. If the motor on A1 is not to be reinstalled, it must be protected against
corrosion before being put into storage.
5. Cover the gear unit and protect it against fouling.

Fig. 9-1: Removing motor A1

1 Motor A1 3 Connector XP1

2 Connector XM1 4 Allen screws

9.1.2 Installing motor A1

Procedure

1. Remove corrosion protection from new motor A1, if applicable

(>>> Fig. 9-2).
2. Clean the toothing of the motor and the gear unit before installation
and apply a thin but continuous coat of Microlube GL 261 grease.
3. Clean the mounting surface of motor A1 on the gear unit.
4. Check the condition of the O-ring on the motor shaft.
5. Fit seal on motor mount; F variant only.
6. Position sockets XM1 and XP1 as shown.
7. Insert motor A1 with a new seal. Do not tilt during installation.
Insertion of motor can be facilitated by turning it gently about its ro-
tational axis.

8. Insert 4 M12x25-8.8 Allen screws.

9. Tighten 4 Allen screws with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the correct value in several
stages.
10. Plug connectors XM1 and XP1 into the sockets. The pins and coding
elements of the connectors must be taken into consideration.
When inserting the connectors, turn them until they clearly lock into
the coding elements (twist-proof).
11. Remove safeguards against the robot turning about axis 1.
12. Carry out mastering of axis 1.
Detailed information about mastering can be found in the system
software documentation.

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Fig. 9-2: Installing motor A1

1 Motor A1 5 Seal
2 Connector XM1 6 Toothing
3 Connector XP1 7 O-ring
4 Allen screws

9.2 Exchanging motor A2

Description

The following describes the removal and installation of motor A2 for floor-
mounted robots. The description also applies to ceiling-mounted robots (C
variant); the same procedure is to be applied analogously. The motor
must be supported from beneath and the vertically hanging link arm must
be secured against motion.

Precondition

• The robot is secured against rotational motions about axis 2.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

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WARNING
Danger to life and limb when working on live parts
Before commencing work on live parts of the robot system and/or on
electrical systems, measures must be taken to ensure that the 5 safety
rules are followed. It is essential that the 5 safety steps are followed in
the correct order. Death, severe injuries or damage to property may re-
sult.
1. De-energize
2. Secure against unintentional restart
3. Ensure that the system is de-energized
4. Ground and short-circuit the system
5. Cover or erect barriers around neighboring energized parts
Once the work is completed, tools and equipment must be removed and
the measures rescinded in reverse sequence.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

CAUTION
Risk of burns on hot surfaces
The surfaces of the motors are often hot immediately after the robot has
been decommissioned. Touching them may result in burns.
• Wear protective gloves.

WARNING
Risk of crushing during removal and installation of motor
When removing or installing the motor, there is a risk of injury by crush-
ing. This could result in hand injuries.
• Wear protective gloves.

NOTICE
Wear and premature failure due to damage to toothing
Damage to the toothing of the motor and gear unit can lead to in-
creased wear and premature failure of the components.
• During cleaning, ensure that the toothing is not damaged.
• Before installation, check the toothing of the motor and gear unit for
damage.

9.2.1 Removing motor A2

Procedure

1. Secure the link arm using a rope sling (>>> Fig. 9-3).
2. Raise the rope sling until it is ensured that the link arm cannot move
after removal of the motor.

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Fig. 9-3: Securing the link arm

3. Release and unplug connectors XM2 and XP2 at the sockets

(>>> Fig. 9-4).
4. Place the rope sling around motor A2 and raise it using the crane until
the weight of motor A2 is supported by the rope sling.
5. Remove 4 Allen screws.
6. Release and pull out motor A2. Do not tilt while removing.
7. If the motor on A2 is not to be reinstalled, it must be set down and
protected against corrosion before being put into storage.

Fig. 9-4: Removing motor A2

1 Connector XP2 4 Motor A2

2 Connector XM2 5 Rope sling
3 Allen screws

9.2.2 Installing motor A2

Procedure

1. Remove corrosion protection from the new motor A2.

2. Clean the toothing of motor A2 and gear unit before installation and
apply a thin but continuous coat of Microlube GL 261 grease
(>>> Fig. 9-5).

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3. Clean the mounting surface of motor A2 on the input stage.
4. Check the condition of the O-ring on the motor shaft.
5. Position sockets XM2 and XP2 as shown.
6. Lift motor A2 with a rope sling and insert it together with a new seal.
Do not tilt during installation.
Insertion of motor can be facilitated by turning it gently about its ro-
tational axis.

7. Insert 4 M12x25-8.8 Allen screws.

8. Tighten 4 Allen screws with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the correct value in several
stages.
9. Slacken and remove the rope sling.
10. Plug connectors XM2 and XP2 into the sockets. The pins and coding
elements of the connectors must be taken into consideration.
When inserting the connectors, turn them until they clearly lock into
the coding elements (twist-proof).
11. Remove elements securing the link arm.
12. Carry out mastering of axis 2.
Detailed information about mastering can be found in the system
software documentation.

Fig. 9-5: Installing motor A2

1 Rope sling 5 Connector XP2

2 Motor A2 6 Seal
3 Allen screws 7 Toothing
4 Connector XM2 8 O-ring

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9.3 Exchanging motor A3

Description

The following instructions describe the removal and installation of motor

A3.

Precondition

• The robot is secured against rotational motions about axis 3.

WARNING
Danger to life and limb when working on live parts
Before commencing work on live parts of the robot system and/or on
electrical systems, measures must be taken to ensure that the 5 safety
rules are followed. It is essential that the 5 safety steps are followed in
the correct order. Death, severe injuries or damage to property may re-
sult.
1. De-energize
2. Secure against unintentional restart
3. Ensure that the system is de-energized
4. Ground and short-circuit the system
5. Cover or erect barriers around neighboring energized parts
Once the work is completed, tools and equipment must be removed and
the measures rescinded in reverse sequence.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.

CAUTION
Risk of burns on hot surfaces
The surfaces of the motors are often hot immediately after the robot has
been decommissioned. Touching them may result in burns.
• Wear protective gloves.

WARNING
Risk of crushing during removal and installation of motor
When removing or installing the motor, there is a risk of injury by crush-
ing. This could result in hand injuries.
• Wear protective gloves.

NOTICE
Wear and premature failure due to damage to toothing
Damage to the toothing of the motor and gear unit can lead to in-
creased wear and premature failure of the components.
• During cleaning, ensure that the toothing is not damaged.
• Before installation, check the toothing of the motor and gear unit for
damage.

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9.3.1 Removing motor A3

Procedure

1. Secure the arm using a rope sling (>>> Fig. 9-6).

2. Raise the rope sling until it is ensured that the arm cannot move after
removal of the motor.

Fig. 9-6: Securing the arm

3. Release and unplug connectors XM3 and XP3 at the sockets

(>>> Fig. 9-7).
4. Place the rope sling around motor A3 and raise it using the crane until
the weight of motor A3 is supported by the rope sling.
5. Remove 4 Allen screws.
6. Release and pull out motor A3. Do not tilt while removing.
7. If the motor on A3 is not to be reinstalled, it must be set down and
protected against corrosion before being put into storage.

Fig. 9-7: Removing motor A3

1 Allen screws 4 Motor A3

2 Connector XP3 5 Rope sling
3 Connector XM3

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9.3.2 Installing motor A3

Procedure

1. Remove corrosion protection from the new motor A3.

2. Clean the toothing of motor A3 and gear unit before installation and
apply a thin but continuous coat of Microlube GL 261 grease
(>>> Fig. 9-8).
3. Clean the mounting surface of motor A3 on the gear unit.
4. Check the condition of the O-ring on the motor shaft.
5. Position sockets XM3 and XP3 as shown.
6. Lift motor A3 with a rope sling and insert it. Do not tilt during installa-
tion.
Insertion of motor can be facilitated by turning it gently about its ro-
tational axis.

7. Insert 4 M12x25-8.8 Allen screws.

8. Tighten 4 Allen screws with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the correct value in several
stages.
9. Slacken and remove the rope sling.
10. Plug connectors XM3 and XP3 into the sockets. The pins and coding
elements of the connectors must be taken into consideration.
When inserting the connectors, turn them until they clearly lock into
the coding elements (twist-proof).
11. Remove elements securing the arm.
12. Carry out mastering of axis 3.
Detailed information about mastering can be found in the system
software documentation.

Fig. 9-8: Installing motor A3

1 Allen screws 5 Toothing

2 Connector XP3 6 Motor A3

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3 Connector XM3 7 Rope sling
4 O-ring

9.4 Exchanging motors and drive shafts A4 to A6

9.4.1 Description

Axes 4, 5 and 6 of the in-line wrist are driven by three motors of the
same design and three drive shafts. Motors A4, A5 and A6 are located at
the rear of the arm and the drive shafts are located in the arm housing.
The drive shafts are distinguished between two universal shafts (A4 and
A6) and a connecting shaft (A5). Removal and installation of the motors
and/or universal shafts varies depending on the robot version:
• Version A: Universal shafts with setscrew
• Version B: Universal shafts with O-rings

Precondition

• The arm is in the horizontal position.

• The wrist axes are in their zero positions.
• The robot controller is switched off and secured to prevent unauthor-
ized persons from switching it on again.
• The power cable is de-energized.
• No tools are installed on axis 6.

WARNING
Danger to life and limb when working on live parts
Before commencing work on live parts of the robot system and/or on
electrical systems, measures must be taken to ensure that the 5 safety
rules are followed. It is essential that the 5 safety steps are followed in
the correct order. Death, severe injuries or damage to property may re-
sult.
1. De-energize
2. Secure against unintentional restart
3. Ensure that the system is de-energized
4. Ground and short-circuit the system
5. Cover or erect barriers around neighboring energized parts
Once the work is completed, tools and equipment must be removed and
the measures rescinded in reverse sequence.

CAUTION
Risk of burns on hot surfaces
The surfaces of the motors are often hot immediately after the robot has
been decommissioned. Touching them may result in burns.
• Wear protective gloves.

WARNING
Risk of crushing during removal and installation of motor
When removing or installing the motor, there is a risk of injury by crush-
ing. This could result in hand injuries.
• Wear protective gloves.

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When installing the motor with drive shaft, it must be ensured that the
toothing of the motor and drive shaft is not damaged. Increased wear
and premature failure may result.

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

9.4.2 Removing motors and drive shafts A4 to A6

Procedure

1. Secure the counterweight with a rope sling and raise it using the
crane until the weight of the counterweight is supported by the rope
sling (>>> Fig. 9-10).
2. Unscrew 2 M24x65 Allen screws and remove the counterweight.
3. Set the counterweight down on a suitable support surface.
4. Secure the arm using a rope sling (>>> Fig. 9-9).
5. Raise the rope sling until it is ensured that the arm cannot move after
removal of the motor.

Fig. 9-9: Securing the arm

6. Remove the cover and O-ring (F variant only) from the installation
aperture (>>> Fig. 9-10).
7. Release and unplug the following connectors from the motors:
• Motor A4: XM4 and XP4
• Motor A5: XM5 and XP5
• Motor A6: XM6 and XP6
8. Unscrew 4 M10x30-8.8 Allen screws on each motor and pull out motor
together with drive shaft.
When doing so, reach into the installation aperture with one hand and
push the drive shaft towards the motor.

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Fig. 9-10: Removing motors and drive shafts

1 M24x65 Allen screw

2 M10x30 Allen screw
3 Motor A4
4 Motor A5
5 Motor A6
6 Cover
7 O-ring (F variant only)
8 Installation aperture
9 Universal shaft A4
10 Connecting shaft A5
11 Universal shaft A6

9. Remove the seal between the motor and the arm (for F variant only).
10. Set motor with drive shaft down on a suitable support surface.
11. Remove universal shafts A4/A6 and connecting shaft A5 on the re-
spective motor (>>> Fig. 9-11):
Universal shaft a. Slacken 2 setscrews on each universal
A4/A6 with setscrews shaft until the universal shaft is free.
b. Remove the universal shaft from motor
A4/A6.
Universal shaft a. Remove the universal shaft from motor
A4/A6 with O-rings A4/A6.

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Connecting shaft A5 a. Slacken 1 setscrew until the connecting

shaft A5 is free.
b. Remove the connecting shaft A5 from
motor A5.

Fig. 9-11: Releasing and detaching universal shaft

1 Setscrew
2 Universal shaft without setscrew
3 Universal shaft with setscrew

12. Dispose of motor and/or drive shafts in accordance with the pertinent
regulations.

9.4.3 Installing motors and drive shafts A4 to A6, universal shafts with set-
screws

Procedure

1. Remove corrosion protection from new motor and/or new drive shaft
(universal shaft and connecting shaft).
2. Clean motor shafts A4 to A6 before installation and apply a thin but
continuous coat of Microlube GL 261 grease.
CAUTION
During cleaning, it must be ensured that the toothing of the motor
and universal shaft is not damaged.
Damaged parts must be exchanged.

3. Clean the mounting surface on the arm housing.

4. Unscrew 2 M6x10 setscrews from universal shafts A4/A6 and 1
M6x10 setscrew from connecting shaft A5 and clean them thoroughly
(grease-free).
5. Push the drive shafts onto the motor shafts (>>> Fig. 9-12).
6. Apply Drei Bond 1342 locking agent to 5 M6x10 setscrews.
7. Insert 2 M6x10 setscrews into universal shafts A4/A6 and tighten
them. After tightening, loosen the setscrews again by 45°. The set-
screws must engage with the V-groove.

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8. Insert 1 M6x10 setscrew into connecting shaft A5 and tighten it. After
tightening, loosen the setscrew again by 45°. The setscrew must en-
gage with the V-groove.
9. Position the following sockets as shown in the illustration:
• Motor A4: XM4 and XP4
• Motor A5: XM5 and XP5
• Motor A6: XM6 and XP6
10. Insert drive shaft with motor into the arm housing (only for F variant:
together with seal). Be careful not to tilt it during installation and en-
sure that the drive shafts (toothing) are correctly engaged.
Insertion of motor can be facilitated by turning it gently about its ro-
tational axis.

Fig. 9-12: Inserting drive shafts and motors, universal shafts with
setscrews

1 Universal shaft A4
2 Motor A4
3 Motor A5
4 Motor A6
5 Universal shaft A6
6 Connecting shaft A5
7 Setscrew (2x universal shaft A4/A6, 1x connecting shaft A5)
8 V-groove

11. Align the drive shafts as shown in the illustration (>>> Fig. 9-13).

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Fig. 9-13: Aligning the drive shafts

1 Universal shaft A4 3 Universal shaft A6

2 Connecting shaft A5

12. Insert 4 M10x30-8.8 Allen screws into each motor and tighten them
with the torque wrench in a diagonally opposite sequence. Increase
the tightening torque to the correct value.
13. Plug the following connectors into the sockets. The pins and coding el-
ements of the connectors must be taken into consideration.
• Motor A4: XM4 and XP4
• Motor A5: XM5 and XP5
• Motor A6: XM6 and XP6
When inserting the connectors, turn them until they clearly lock into
the coding elements (twist-proof).
14. Clean the installation aperture and apply Drei Bond 1354
(>>> Fig. 9-14).
15. Fasten the cover and new O-ring (F variant only) in the installation
aperture.
16. Remove the element securing the arm.
17. Lift the counterweight with a rope sling and position it to the arm.
18. Insert 2 M24x65-8.8 Allen screws and tighten alternately with a torque
wrench. Increase the tightening torque to the correct value in several
stages.

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Fig. 9-14: Fastening the counterweight and cover in the installa-
tion aperture

1 M24x65-8.8 Allen screw

2 Installation aperture
3 O-ring (F variant only)
4 Cover

19. Master A4, A5 and A6.

Detailed information about mastering can be found in the system
software documentation.

9.4.4 Installing motors and drive shafts A4 to A6, universal shafts with O-
rings

Procedure

1. Remove corrosion protection from new motor and/or new drive shaft
(universal shaft and connecting shaft).
2. Clean motor shafts A4 to A6 prior to installation.
CAUTION
During cleaning, it must be ensured that the toothing of the motor
and universal shaft is not damaged.
Damaged parts must be exchanged.

3. Clean the mounting surface on the arm housing.

4. Mount universal shafts A4 and A6 on the respective motors A4/A6. To
do so, carry out the following work steps 5 to 14.
5. Position and center 1 axial retainer and 1 washer on the motor shaft.
6. Insert 1 M8x20-8.8 Allen screw into the axial retainer and tighten them
to the prescribed tightening torque using a torque wrench.
7. Mount the spacer sleeve and O-ring on the motor shaft.
8. Seal the M8x20-8.8 Allen screw with screw-locking varnish.

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9. Apply a thin but continuous coat of Microlube GL 261 to the O-ring

and motor shaft.
10. Apply a thin but continuous coat of Microlube to the toothing and inner
O-ring of the universal shaft.
The inner O-ring is pre-assembled on the universal shaft.
11. Mount the universal shaft on the motor shaft up to the O-ring.
12. Press the spacer sleeve together with O-ring into the universal shaft
until the O-ring is seated in the universal shaft.
13. Press the universal shaft A4 with the spacer sleeve and O-ring against
motor A4 until the inner O-ring is seated on the axial retainer.
14. Check that the universal shaft is correctly positioned. To do this, carry
out the following steps:
a. Measure the distance between the motor shaft and universal shaft.
This must be 16 mm (>>> Fig. 9-15).
b. Pull gently on the universal shaft. When you let it go, it should
take up the same position automatically.

Fig. 9-15: Distance between motor shaft and universal shaft

If one or both steps in the test yield a negative result, the universal
shaft must be removed from the motor and re-mounted on the motor
shaft.
15. Mount connecting shaft A5 on motor A5. To do so, carry out the fol-
lowing work steps 16 and 19.
16. Apply a thin but continuous coat of Microlube GL 261 to motor shaft
A5.
17. Apply Drei Bond 1342 locking agent to 1 M6x10 setscrew.
18. Insert 1 M6x10 setscrew into connecting shaft A5 and tighten it. After
tightening, loosen the setscrew again by 45°. The setscrew must en-
gage with the V-groove.
19. Push the connecting shaft onto motor shaft A5 (>>> Fig. 9-16).
20. Position the sockets of motors A4, A5 and A6 as shown.
21. Insert universal shafts A4 and A6 as well as connecting shaft A5 with
motor into the arm housing (only for F variant: together with seal).
Be careful not to tilt it during installation and ensure that connecting
shaft A5 (toothing) is correctly engaged.
Insertion of motor can be facilitated by turning it gently about its ro-
tational axis.

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Fig. 9-16: Inserting drive shafts and motors, universal shafts with
O-rings

1 Universal shaft A4
2 Motor A4
3 Motor A5
4 Motor A6
5 Universal shaft A6
6 Universal shaft A4/A6 with O-rings
7 Connecting shaft A5 with setscrew
8 Connecting shaft A5
9 Setscrew (1x connecting shaft A5)
10 V-groove
11 Inner O-ring
12 O-ring
13 Spacer sleeve

22. Align universal shafts A4 and A6 as well as connecting shaft A5 as

shown in the figure (>>> Fig. 9-17).

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Fig. 9-17: Aligning the drive shafts

1 Universal shaft A4 3 Universal shaft A6

2 Connecting shaft A5

23. Insert 4 M10x30-8.8 Allen screws into each motor and tighten to the
correct tightening torque with the torque wrench in a diagonally oppo-
site sequence.
24. Plug the following connectors into the sockets. The pins and coding el-
ements of the connectors must be taken into consideration.
• Motor A4: XM4 and XP4
• Motor A5: XM5 and XP5
• Motor A6: XM6 and XP6
When inserting the connectors, turn them until they clearly lock into
the coding elements (twist-proof).
25. Clean the installation aperture and apply Drei Bond 1354.
(>>> Fig. 9-18)
26. Fasten the cover and new O-ring (F variant only) in the installation
aperture.
27. Remove the element securing the arm.
28. Lift the counterweight with a rope sling and position it to the arm.
29. Insert 2 M24x65-8.8 Allen screws and tighten alternately with a torque
wrench. Increase the tightening torque to the correct value in several
stages.

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Fig. 9-18: Fastening the counterweight and cover in the installa-
tion aperture

1 M24x65-8.8 Allen screw

2 Installation aperture
3 O-ring (F variant only)
4 Cover

30. Master A4, A5 and A6.

Detailed information about mastering can be found in the system
software documentation.

9.5 Description of the electrical installations

Overview

The electrical installations of the robot consist of:

• Cable set
• Multi-function housing (MFH) for motor cable
• Junction box for data cable, RDC box

Description

The electrical installations (>>> Fig. 9-19) include all the supply and con-
trol cables for the motors of axes 1 to 6. All the connections on the mo-
tors are screwed plug-and-socket connections. The assembly consists of
the cable set, the multi-function housing (MFH) and the RDC box. The in-
terface for the connecting cables is located at the back of the base frame.
The motor and data cables are connected here via plug-in connections.
The data and motor cables are routed from the RDC box and the multi-
function housing to the motors (XM and XP connectors).
The protective circuit is also integrated into the cable set. The ground con-
ductor is connected to the adapter plate via the ground conductor bolts.
All the motor cables, data cables and ground conductors are routed
through the flexible tubes A1 and A2-A3. The selected cable routing en-

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sures that the cables are guided without strain or kinking throughout the
Repair

entire motion range of the robot.

The following diagram gives an overview of the installation and routing of
the cables on the manipulator.

Fig. 9-19: Overview of electrical installations

1 Motor, axis 4 5 Motor, axis 1

2 Motor, axis 5 6 RDC box
3 Motor, axis 6 7 Motor, axis 2
4 Motor, axis 3 8 Base frame

Wiring diagrams

Designation Connection Figure

Wiring diagram A1 XM1 (>>> Fig. 9-20)
Wiring diagram A2 XM2 (>>> Fig. 9-21)
Wiring diagram A3 XM3 (>>> Fig. 9-22)
Wiring diagram A4 XM4 (>>> Fig. 9-23)
Wiring diagram A5 XM5 (>>> Fig. 9-24)
Wiring diagram A6 XM6 (>>> Fig. 9-25)
Wiring diagram, RDC
Data cable (>>> Fig. 9-26)
X31
Wiring diagram, RDC
Data cable (>>> Fig. 9-27)
X32
Protective circuit Ring cable lug (>>> Fig. 9-28)

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Repair

Fig. 9-20: Wiring diagram A1

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Fig. 9-21: Wiring diagram A2

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Fig. 9-22: Wiring diagram A3

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Fig. 9-23: Wiring diagram A4

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Fig. 9-24: Wiring diagram A5

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Fig. 9-25: Wiring diagram A6

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Repair
Fig. 9-26: Wiring diagram, RDC X31

Fig. 9-27: Wiring diagram, RDC X32

Fig. 9-28: Wiring diagram, protective circuit

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Decommissioning, storage and disposal

10 Decommissioning, storage and disposal

CAUTION
For screwed connections, the fastening screws (standard, strength class
8.8) are to be tightened with the tightening torques specified in the ap-
pendix (>>> 12 "Appendix" Page 247). Tightening torques deviating from
these values are specified directly.
The specified screw sizes and strength classes are those 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 strength class 10.9 and higher as well as screws with test
certification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.

10.1 Decommissioning, floor-mounted robots

Description

This section describes all the work required for decommissioning the robot
if the robot is to be removed from the system. After decommissioning, it is
prepared for storage or for transportation to a different location.
Following its removal, the robot can be transported by means of lifting
tackle and crane or by fork lift truck (>>> 6.1 "Transporting the robot arm"
Page 137).

Precondition

• The removal site must be accessible with a crane or with a fork lift
truck for transportation.
• There is no hazard posed by other system components.

Procedure

1. Secure the robot.

WARNING
Danger to life and limb due to unintended robot motions
Unintended robot motions may result in death, severe injuries and
damage to property.
‒ Secure the robot by pressing the EMERGENCY STOP device.
‒ Warn all persons concerned before starting to put it back into
operation.

2. Remove tools and equipment.

3. Put the robot into operation and move it into the transport position.

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Fig. 10-1: Transport position

Fig. 10-2: Transport position, without buffer A2

4. Secure the robot again by pressing the E-STOP device.

5. Release and disconnect the peripheral connections.
6. Release and disconnect the motor cable and data cable connectors.
7. Unscrew the hexagon nut from the ground conductor and pull off
washers, lock washers and ground conductor.
8. Shut off the compressed air supply to the robot, disconnect the hose
and remove it from the pressure regulator; F variant only.
9. Attach lifting tackle to the 3 swivel eyebolts or prepare the robot for
transportation with the fork lift truck. Minimum payload capacity for
transportation: 3,500 kg.
10. Unscrew and remove the 8 hexagon bolts and conical spring washers.
11. Lift the robot vertically off the mounting surface and transport it away.
Take care not to damage the centering pins when lifting off the robot.
CAUTION
Risk of injury due to abrupt detachment of the robot
If the robot is caught on the mounting surface, it may come free
abruptly. Injuries or damage to property may result.
‒ Remove the fastening materials completely.
‒ Remove any adhesives.

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Fig. 10-3: Removing the robot from mounting base 175 mm

1 Lifting tackle 5 Motor cable X30.4

2 Hexagon bolts 6 Motor cable X30.1
3 Pin 7 Data cable
4 Foundation plate 8 Ground conductor, threaded
bolt

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Fig. 10-4: Removing the robot from mounting base 200 mm

1 Lifting tackle 5 Motor cable X30.4

2 Hexagon bolts 6 Motor cable X30.1
3 Pin 7 Data cable
4 Foundation plate 8 Ground conductor, threaded
bolt

12. Prepare the robot for storage.

10.2 Storage

Description

If the robot is to be put into long-term storage, the following points must
be observed:
• The place of storage must be as dry and dust-free as possible.
• Avoid temperature fluctuations.
• Avoid wind and drafts.
• Avoid condensation.
• Use appropriate coverings that cannot detach themselves and which
can withstand the expected environmental conditions.
• Do not leave any loose parts on the robot, especially ones that might
knock against other parts.
• Do not leave the robot exposed to direct sunlight while in storage.
• Observe and comply with the permissible temperature ranges for stor-
age.

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Decommissioning, storage and disposal

• Select a storage location in which the packaging materials cannot be
damaged.

Procedure

1. Remove tools and equipment.

2. Remove the robot.
3. Clean and dry the robot. No dirt or cleaning agent residue may remain
on or in the robot.
4. Perform a visual inspection of the robot.
5. Remove any foreign bodies.
6. Remove any corrosion.
7. Attach all covers to the robot and check that the seals are correctly in
place.
8. Seal off electrical connections with suitable covers.
9. Seal hose connections by suitable means.
10. Cover the robot with plastic sheeting and seal it at the base frame
against dust.
If necessary, add a desiccant beneath the sheeting.

10.3 Disposal

When the manipulator reaches the end of its useful life, it can be removed
from the system and dismantled, and the materials can be disposed of
properly by type.
The following table provides an overview of the materials used in the ma-
nipulator. All plastic components are marked with a material designation
and must be disposed of accordingly.
WARNING
The hydropneumatic counterbalancing system on the robot is filled with
nitrogen and hydraulic oil under pressure; improper handling can lead to
personal injury and damage to property. If the hydropneumatic counter-
balancing system to be disposed of, it must first be properly depressur-
ized. Only pressure-free counterbalancing systems may be authorized
for disposal.

Material Subassembly, component Additional information

Metals
Cast-iron Base frame, rotating col-
material umn, link arm, arm; coun-
terweight
Copper Cables, wires
Light alloy Main body, spur gear hous-
casting ing, cover, arm extension
Steel Gear units, screws and
washers
Electrical parts
Motors Dispose of motors without
dismantling.
Plastics
ABS Enclosure panels, covers

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Material Subassembly, component Additional information

Metals
NBR O-rings
PA Hinged clamps, flexible
tube
PE End stop buffers
PU Hoses
PUR Cable sheaths
Auxiliary substances and consumables
Adhesive Fastening screws of the Adhesive and sealant Drei
and sealant counterbalancing system Bond type 1342
pin
Gear oil Gear units Optigear Synt. ALR 150
Hydraulic oil Counterbalancing system Hyspin ZZ 46 hydraulic oil
Lubricating Toothing, O-rings Microlube GL 261 grease
grease Counterbalancing system, LGEV 2 lubricating grease
bearing on arm / link arm
Cabling Lubricating grease Opti-
temp RB2
Up-to-date safety data sheets must be requested from the manufacturers
of auxiliary and operating materials. Further information about the auxiliary
substances and consumables used can be found under:
(>>> 12.2 "Auxiliary substances and consumables" Page 248)

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Options
11 Options

11.1 Release device (optional)

Description

The release device can be used to move the manipulator manually after
an accident or malfunction. The release device can be used for the mo-
tors of axes A1 to A5. It cannot be used for axis A6, as this motor is not
accessible. It is only for use in exceptional circumstances and emergen-
cies (e.g. for freeing people).
The release device is mounted on the base frame of the manipulator. This
assembly also includes a ratchet and a set of plates with one plate for
each motor. The plate specifies the direction of rotation for the ratchet and
shows the corresponding direction of motion of the manipulator.

Precondition

• The robot controller is switched off.

11.1.1 Moving the manipulator without drive energy

Procedure

SAFETY INSTRUCTION
The following procedure must be followed exactly!

1. Remove the protective cap from the motor (>>> Fig. 11-1).
2. 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.

Fig. 11-1: Motor with release device

1 Motor
2 Protective cap
3 Release device

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11.1.2 Concluding work

The following concluding work must be carried out:

• Master all axes.
• Perform brake test.
• Carry out a test run in T1 mode and look out for irregularities.

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Appendix
12 Appendix

12.1 Tightening torques

Tightening torques

The following tightening torques (Nm) are valid for screws and nuts where
no other specifications are given.
The specified values apply to lightly oiled black (e.g. phosphated) and
coated (e.g. mech. galv., zinc flake plating, screw locking elements)
screws and nuts.
Strength class
Thread 8.8 10.9 12.9
M1.6 0.17 Nm 0.24 Nm 0.28 Nm
M2 0.35 Nm 0.48 Nm 0.56 Nm
M2.5 0.68 Nm 0.93 Nm 1.10 Nm
M3 1.2 Nm 1.6 Nm 2.0 Nm
M4 2.8 Nm 3.8 Nm 4.4 Nm
M5 5.6 Nm 7.5 Nm 9.0 Nm
M6 9.5 Nm 12.5 Nm 15.0 Nm
M8 23.0 Nm 31.0 Nm 36.0 Nm
M10 45.0 Nm 60.0 Nm 70.0 Nm
M12 78.0 Nm 104.0 Nm 125.0 Nm
M14 125.0 Nm 165.0 Nm 195.0 Nm
M16 195.0 Nm 250.0 Nm 305.0 Nm
M20 370.0 Nm 500.0 Nm 600.0 Nm
M24 640.0 Nm 860.0 Nm 1030.0 Nm
M30 1330.0 Nm 1700.0 Nm 2000.0 Nm

Strength class
Thread 8.8 10.9
ISO7991 ISO7380, ISO07381
Allen screw Fillister head
screw
M3 0.8 Nm 0.8 Nm
M4 1.9 Nm 1.9 Nm
M5 3.8 Nm 3.8 Nm

Strength class
Thread 10.9
DIN7984
Pan head screws
M4 2.8 Nm
Tighten M5 domed cap nuts with a torque of 4.2 Nm.

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12.2 Auxiliary substances and consumables

Product designation / Use Manufacturer designation /

Article number Address

Drei Bond type 1342 Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 13
0000-184-174
D-85737
Ismaning
Germany

Drei Bond type 1354 Surface sealant Drei Bond GmbH

Carl-Zeiss-Ring 13
0000-435-051
D-85737
Ismaning
Germany

Optigear Synt. Gear oil BP Europa SE

ALR 150_EEA Geschäftsbereich Industrieschmierstoffe
Erkelenzer Strasse 20
0000-362-835 for Europe-
D-41179
an Economic Area
Mönchengladbach
Optigear Synt. Germany
ALR 150_AM1
0000-361-461 for USA,
Canada, Mexico, Chile,
Peru
Optigear Synt.
ALR 150_CHN
0000-361-473 for China
Optigear Synt.
ALR 150_APeC1
0000-361-476 for India,
Taiwan, Japan, Thailand,
South Korea, Malaysia
Article numbers for further
regions can be found in
KUKA Xpert.

Castrol Hyspin ZZ 46 Hydraulic oil Deutsche Castrol Vertriebsgesell-

schaft mbH
0083-236-203
Max-Born-Str. 2
D-22761
Hamburg
Germany

LGEV 2 Lubricating grease SKF Maintenance Products

Postboks 1008
0000-111-652
NL-3430
BA Nieuwegein
Netherlands

Microlube GL 261 Lubricating grease Klüber Lubrication München KG

Geisenhausenerstr. 7
0000-135-463
D-81379
Munich
Germany

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Appendix
Optitemp RB 2 Lubricating grease Deutsche BP Aktiengesellschaft - In-
dustrial Lubricants & Services
0000-101-456
Erkelenzer Strasse 20
D-41179
Mönchengladbach
Germany

To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.

12.3 Product safety data sheet

Section 1: Designation of the product and of the company

• Product identifier:
‒ Trade name:
KUKA industrial robot with hydropneumatic counterbalancing
system
• Relevant identified use of the product that is advised against:
“Intended use and misuse” section of the assembly instructions.
• Use of the product:
“Intended use and misuse” section of the assembly instructions.
• Details of the supplier providing the product safety data sheet:
Manufacturer/suppli- KUKA Deutschland GmbH
er:
Address: Zugspitzstrasse 140
Postal code: 86165 Augsburg
Country: Germany
Phone: +49 821 797 4000
Fax: +49 821 797 40400
e-mail info@kuka.com
Department for infor- KUKA Deutschland GmbH Quality Assurance
mation: department
Phone: +49 821 797 1747
e-mail: DG-Management@kuka.com
Information in case During normal operating hours
of emergency:
Phone: +49 821 797 1747

There is no legal obligation to create a safety data sheet for a product.

In order to make information typically contained in a safety data sheet
available for products, however, the present product safety data sheet
was created.
Your attention is expressly drawn to the fact that the product safety data
sheet for products is an information sheet created voluntarily that is not
subject to the formal requirements of Regulation (EC) No. 1907/2006
(REACH Regulation).

Section 2: Possible hazards

• Classification of the product:

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‒ Classification acc. to Regulation (EC) No. 1272/2008 (CLP Regula-

tion):
This product is not classified according to the CLP Regulation.
• Label elements
Labeling acc. to Reg- Not applicable
ulation (EC) No.
1272/2008 (CLP
Regulation):
Hazard symbol: Not applicable
Signal word: Not applicable
Hazard statements: Not applicable

• Other hazards
‒ Results of PBT and vPvB assessment
PBT Not applicable
vPvB Not applicable

Section 3: Composition / information about the components

• Chemical characterization:
Product
‒ Description:
Industrial robot
• Hazardous components:
The industrial robot contains a hydropneumatic counterbalancing sys-
tem filled with hydraulic oil of type HLP 46 as well as Nitrogen, com-
pressed.
CAS: 7727‑37‑9 Nitrogen Press. Gas, H280
EINECS: 231‑783‑9

The exact wording of the hazard statements listed above can be found
in section 16 (>>> "Section 16: Other information" Page 254).

Detailed information about the amount of nitrogen contained is available

in the respective product information at https://xpert.kuka.com.

Section 4: First aid measures

• Description of first aid measures:

‒ General information:
No special measures required.
• Most important symptoms and effects, both acute and delayed:
No further relevant information available.
• Indication of any immediate medical attention and special treatment
needed:
No further relevant information available.

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Appendix
Section 5: Fire-fighting measures

• Extinguishing agents:
Suitable Adjust the fire-extinguishing measures to suit
extinguishing agents: the environment.

• Special hazards arising from the substance or mixture:

No further relevant information available.
• Advice for firefighters:
‒ Special protective equipment:
No special measures required.

Section 6: Measures after unintended release

• Personal precautions, protective equipment and emergency proce-

dures:
Not required
• Environmental protection measures:
No special measures required.
• Methods and material for containment and cleaning up:
No special measures required.
• Reference to other sections
For information on safe handling, see section 7 (>>> "Section 7: Han-
dling and storage" Page 251).
For information on personal protective equipment, see section 8
(>>> "Section 8: Limitation and monitoring of exposure / Personal
protective equipment" Page 252).
For information on disposal, see section 13 (>>> "Section 13: Dispos-
al information" Page 253).

Section 7: Handling and storage

• Precautions for safe handling:

No special measures required.
• Instructions relating to fire and explosion protection:
No special measures required.
• Conditions for safe storage, including any incompatibilities:
‒ Storage
Requirements re- No special requirements
garding storage
rooms and contain-
ers:
Information on stor- Not required
age with other prod-
ucts:
Further specifica- None
tions concerning
storage conditions:
• Specific end uses:
No further relevant information available.

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Section 8: Limitation and monitoring of exposure / Personal protective equipment

• Additional information for the design of technical systems:

No further information.
• Control parameters
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.
• Limitation and monitoring of exposure:
‒ Personal protective equipment:
Respiratory protec- Not required
tion:
Hand protection: Chemical protective gloves are not re-
quired.
Eye protection: Not required

Section 9: Physical and chemical properties

• Information on basic physical and chemical properties:

‒ General comments
Form: Solid
Color: As per product description
Odor: Odorless
Melting point/range: Not determined
Flash point: Not applicable
Auto-ignition: The product does not auto-ignite.
Risk of explosion: The product presents no danger of explo-
sion.
Density: Not determined
Solubility/miscibility Insoluble
in water:
Additional informa- No further information available.
tion:

Section 10: Stability and reactivity

• Possibility of hazardous reactions:

No hazardous reactions known.
• Conditions to be avoided
No relevant information available.
• Incompatible materials
No further relevant information available.
• Hazardous decomposition products
No hazardous decomposition products known.

Section 11: Toxicological information

• Information on toxicological effects:

‒ Acute toxicity:

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Appendix
Primary irritation ef- No irritation
fect on skin:
Primary irritation ef- No irritation
fect on eyes:
Sensitization: No sensitizing effect known.
Additional toxicologi- The product is not subject to labeling obli-
cal information: gations.

Section 12: Ecological information

• Toxicity:
Aquatic toxicity: No further relevant information available.
• Persistence and degradability:
No further relevant information available.
• Bioaccumulative potential:
No further relevant information available.
• Mobility in soil:
No further relevant information available.
• Additional ecological information:
General information: No known hazard to water.
• Results of PBT and vPvB assessment:
PBT Not applicable
vPvB Not applicable

• Other adverse effects:

No further relevant information available.

Section 13: Disposal information

• Waste treatment methods:

Disposal section of the assembly instructions.
• Contaminated packaging:
Disposal in accordance with the applicable local regulations.

Section 14: Transport information

• UN number
‒ UN 3164
• UN proper shipping name:
‒ ADR, RID, ADN:
ARTICLES UNDER HYDRAULIC PRESSURE (containing non-
flammable gas)
‒ IMDG code, IATA:
ARTICLES, PRESSURIZED, HYDRAULIC (containing non-flamma-
ble gas)
• Transport hazard classes:
‒ ADR, RID, ADN:
Class: Not applicable
Hazard label: Not applicable
Shipping: Not subject to regulations (special regula-
tion 594)

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‒ IMDG code:

Class: 2.2 Non-flammable, non-toxic gas

Hazard label: 2.2
Marine pollutants: No
EmS number: F-C, S-V
Shipping: P003, PP32

‒ IATA:
Class: 2.2 Non-flammable, non-toxic gas
Hazard label: Not applicable
Shipping: Packaging instructions 208 (a)
• Packaging group:
Not applicable
• UN “Model Regulation”:
UN 3164 ARTICLES, PRESSURIZED, HYDRAULIC, 2.2

Detailed information about the amount of nitrogen contained is available

in the respective product information at https://xpert.kuka.com.
Industrial robots with counterbalancing systems that are not filled with
nitrogen are not subject to the regulations on dangerous goods!

Section 15: Regulatory information

• Chemical safety assessment:

Chemical safety assessment has not been performed.

Section 16: Other information

The information given is based on our present knowledge. However, this

shall not constitute a guarantee for any specific product characteristics
and shall not establish a legally valid contractual relationship.
• Relevant phrases:
H280: Contains gas under pressure; may explode if heated.

12.4 Applied standards and regulations

Name/Edition Definition

2006/42/EC Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Coun-
cil of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)

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Appendix
2014/30/EU EMC Directive:
Directive 2014/30/EU of the European Parliament and of the Coun-
cil dated 26 February 2014 on the approximation of the laws of the
Member States concerning electromagnetic compatibility

2014/68/EU Pressure Equipment Directive:

Directive 2014/68/EU of the European Parliament and of the Coun-
cil dated 15 May 2014 on the approximation of the laws of the
Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing
system.)

ANSI/RIA R15.06-2012 Industrial Robots and Robot System

EN 60204-1:2018 Safety of machinery:

Electrical equipment of machines – Part 1: General requirements

EN 61000-6-2:2005 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial environments

EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

A1:2011
Part 6-4: Generic standards; Emission standard for industrial envi-
ronments

EN 614-1:2006+A1:2009 Safety of machinery:

Ergonomic design principles - Part 1: Terms and general principles

EN ISO 10218-1:2011 Robots and robotic devices – Safety requirements for industri-
al robots:
Part 1: Robots

EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction

EN ISO 13849-1:2015 Safety of machinery:

Safety-related parts of control systems - Part 1: General principles
of design

EN ISO 13849-2:2012 Safety of machinery:

Safety-related parts of control systems - Part 2: Validation

EN ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design

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KUKA Service
13 KUKA Service

13.1 Requesting support

Introduction

This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further support,
please contact your local subsidiary.

Information

The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• The greatest possible amount of information about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ System software diagnosis package
Additionally for KUKA Sunrise: Existing projects including applica-
tions
For versions of KUKA System Software older than V8: Archive of
the software (Diagnosis package is not yet available here.)
‒ Application used
‒ External axes used

13.2 KUKA Customer Support

The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

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Index CR.....................................................................8
2006/42/EC................................................... 254
2014/30/EU................................................... 255
2014/68/EU................................................... 255 D
95/16/EC....................................................... 254 Danger zone...............................................9, 21
Declaration of conformity............................... 20
Declaration of incorporation.....................19, 20
A Decommissioning................................... 32, 239
Diagnosis package....................................... 257
Accessories.............................................. 13, 19
Dimensions, transport...................................137
Angle of rotation............................................. 10
Directives...................................................... 254
ANSI/RIA R15.06-2012................................ 255
Disclaimer....................................................... 19
Appendix....................................................... 247
Disposal......................................... 32, 239, 243
Arctic................................................................. 8
Documentation, industrial robot....................... 7
Arm........................................................... 13, 15
Drei Bond type 1342....................................248
Automatic mode..............................................30
Drei Bond type 1354....................................248
Auxiliary substances used............................248
Drive shafts A4 to A6, checking..................186
Axis data, KR 420 R3330..............................82
Drive shafts A4 to A6, exchange................ 219
Axis data, KR 420 R3330 F.......................... 94
Drive shafts A4 to A6, installing, universal
Axis data, KR 510 R3080..............................59
shafts with O-rings....................................... 225
Axis data, KR 510 R3080 F.......................... 71
Drive shafts A4 to A6, removing................. 220
Axis data, KR 600 R2830..............................36
Axis data, KR 600 R2830 F.......................... 48
Axis limitation, mechanical............................. 24
Axis range.................................................. 8, 20 E
EC declaration of conformity......................... 20
EDS...................................................................8
B EDS cool...........................................................8
Electrical installations...................... 14, 16, 229
Base frame...............................................13, 15
Electrical installations, description............... 229
Basic data, .................... 34, 46, 58, 69, 81, 92
Electromagnetic compatibility (EMC)........... 255
Brake defect................................................... 25
Electromagnetic compatibility (EMC):.......... 255
Brake release device......................................24
EMC Directive........................................ 20, 255
EMD.................................................................. 9
EN 60204-1:2018......................................... 255
C EN 61000-6-2:2005...................................... 255
C....................................................................... 8 EN 61000-6-4:2007 + A1:2011.................... 255
Cable set, greasing...................................... 205 EN 614-1:2006+A1:2009..............................255
Castrol Hyspin ZZ 46...................................248 EN ISO 10218-1:2011.................................. 255
CE mark..........................................................20 EN ISO 12100:2010..................................... 255
Center of gravity.................................. 137, 139 EN ISO 13849-1:2015..................................255
Center of mass ............. 40, 52, 63, 75, 86, 98 EN ISO 13849-2:2012..................................255
Clean Room......................................................8 EN ISO 13850:2015..................................... 255
Cleaning the robot........................................206 Equipotential bonding................................... 151
Cleaning work.................................................31 EX..................................................................... 9
Connecting cable, standard.................154, 160 Extension.......................................................... 8
Connecting cables...................13, 19, 134, 153 External axes..................................................19
Connecting cables, KR C4.. 35, 47, 59, 70, 82, External axis.............................................11, 21
93
Connecting cables, KR C5.. 35, 47, 59, 70, 82,
93, 159
Consumables used.......................................248
F
Counterbalancing system.................. 14, 15, 31 F........................................................................9
Counterbalancing system, checking............ 185 F exclusive........................................................9
Counterbalancing system, exchanging, floor- Faults.............................................................. 27
mounted robot.............................................. 178 Flange loads.................42, 54, 65, 77, 88, 100
Counterbalancing system, hydropneumatic... 16 Floor-mounted robot, installing.....................150
Counterbalancing system, installing............ 182 Floor mounting..............................................150
Counterbalancing system, removing, floor- Fork lift truck.................................................140
mounted robot.............................................. 179 Foundation loads, KR 420 R3330................. 90
Counterweight.................................................13 Foundation loads, KR 420 R3330 F........... 102
Foundation loads, KR 510 R3080................. 67

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Foundation loads, KR 510 R3080 F............. 79 KUKA smartPAD-2..................................... 9, 21

Foundation loads, KR 600 R2830................. 44
Foundation loads, KR 600 R2830 F............. 56
Foundry robots.................................. 46, 69, 92 L
Foundry, equipment........................... 46, 69, 92 Labeling.......................................................... 24
Function test................................................... 28 LGEV 2......................................................... 248
Lifting tackle (optional).........................140, 141
Linear unit.......................................................19
G Link arm................................................... 13, 15
Gear unit A1, draining oil.............................190 Low Voltage Directive.....................................20
Gear unit A1, filling with oil......................... 191
Gear unit A2, draining oil.............................193
Gear unit A2, filling with oil......................... 193 M
Gear unit A3, draining oil.............................195 Machine frame mounting..............................132
Gear unit A3, filling with oil......................... 196 Machine frame mounting, installing............. 148
Gear unit A4, draining oil.............................198 Machinery Directive................................20, 254
Gear unit A4, filling with oil......................... 199 Main axes..................................................... 107
Gear unit A5, draining oil.............................201 Maintenance........................................... 30, 169
Gear unit A5, filling with oil......................... 202 Maintenance symbols...................................170
Gear unit A6, draining oil.............................204 Maintenance table........................................ 170
Gear unit A6, filling with oil......................... 205 Manipulator....................................9, 13, 19, 21
General safety measures............................... 25 Manual mode..................................................29
Ground conductor................................ 166, 229 Mass............................... 40, 52, 63, 75, 86, 98
Mass moments of inertia....40, 52, 63, 75, 86,
98
H Material designation..................................... 243
HA..................................................................... 9 Mechanical end stops.................................... 23
Handling equipment............ 140, 144, 146, 148 MEMD............................................................... 9
Hazardous substances................................... 32 micro RDC........................................................ 9
HI...................................................................... 9 Microlube GL 261.........................................248
HM.................................................................... 9 Misuse.............................................................16
HO.....................................................................9 Motion velocity................................................10
HP..................................................................... 9 Motor A1, exchanging.................................. 209
HW.................................................................... 9 Motor A1, installing.......................................211
Motor A1, removing......................................210
Motor A2, exchanging.................................. 212
I Motor A2, installing.......................................214
In-line wrist............................................... 13, 14 Motor A2, removing......................................213
Industrial robot................................................19 Motor A3, exchanging.................................. 216
Industrial Robots and Robot System...........255 Motor A3, installing.......................................218
Installing drive shafts A4 to A6, universal Motor A3, removing......................................217
shafts with setscrews................................... 222 Motors A4 to A6, exchange.........................219
Installing motors A4 to A6........................... 222 Motors A4 to A6, installing.......................... 225
Interface, connecting cables........................ 159 Motors A4 to A6, removing..........................220
Interface, energy supply system..................135 Mounting base 175 mm............................... 127
Interfaces...................................................... 134 Mounting base 175 mm, installation............143
Introduction....................................................... 7 Mounting base 200 mm............................... 130
Mounting base 200 mm, installation............146
Mounting flange....... 14, 41, 53, 64, 76, 87, 99
Mouse, external.............................................. 26
K MT.....................................................................9
K........................................................................9
KCP......................................................9, 21, 26
Keyboard, external......................................... 26
KR..................................................................... 9 O
KR C................................................................. 9 Oil change, A1..............................................189
KS..................................................................... 9 Oil change, A2..............................................191
KUKA Customer Support............................. 257 Oil change, A3..............................................194
KUKA Service...............................................257 Oil change, A4..............................................197
KUKA smartPAD........................................ 9, 21 Oil change, A5..............................................200
Oil change, A6..............................................203

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 KR 600 FORTEC

Oil temperatures........................................... 170 Safety, general................................................19

Operators........................................................ 23 SC................................................................... 10
Optigear Synt. ALR 150...............................248 SE................................................................... 10
Options...................................... 13, 16, 19, 245 Seal (O-ring A4), regreasing........................176
Optitemp RB 2..............................................249 Seal (O-ring A5), regreasing........................177
Overload......................................................... 25 Service life...................................................... 21
Overview of robot system.............................. 13 SI.....................................................................10
SL....................................................................10
smartPAD.....................................10, 13, 21, 26
P Software................................................... 13, 19
P......................................................................10 SPP...................................................................9
PA................................................................... 10 Standards......................................................254
Payload diagram............ 40, 52, 63, 75, 86, 98 Start-up...................................................27, 143
Payloads, KR 420 R3330.............................. 84 STOP 0.........................................................108
Payloads, KR 420 R3330 F...........................96 STOP 1.........................................................108
Payloads, KR 510 R3080.............................. 61 Stop categories........................................ 10, 21
Payloads, KR 510 R3080 F...........................73 Stop signal....................................................108
Payloads, KR 600 R2830.............................. 39 Stopping distance.............................. 8, 20, 108
Payloads, KR 600 R2830 F...........................51 Stopping distances....................................... 107
Personal protective equipment...................... 22 Stopping distances, KR 420 R3330............ 120
Personnel........................................................22 Stopping distances, KR 420 R3330 F.........120
Phi...................................................................10 Stopping distances, KR 510 R3080............ 114
Pin, sword pin...............................................150 Stopping distances, KR 510 R3080 F.........114
Planning........................................................ 127 Stopping distances, KR 600 R2830............ 109
Plant integrator............................................... 21 Stopping distances, KR 600 R2830 F.........109
Plate..............................................................150 Stopping time................................................108
Plates and labels..........................................104 Stopping times..............................................107
Positioner........................................................ 19 Stopping times, KR 420 R3330...................120
POV................................................................ 10 Stopping times, KR 420 R3330 F............... 120
PPE.................................................................22 Stopping times, KR 510 R3080................... 114
Pressure Equipment Directive.........16, 31, 255 Stopping times, KR 510 R3080 F............... 114
Pressure regulator............................. 46, 69, 92 Stopping times, KR 600 R2830...................109
Preventive maintenance work........................ 31 Stopping times, KR 600 R2830 F............... 109
Principal components..................................... 13 Storage................................................... 32, 239
Product description.........................................13 Supplementary load..... 43, 55, 66, 78, 89, 101
Product safety data sheet............................249 Support request............................................ 257
Program override............................................10 Swing frame....................................................14
Protective equipment, overview..................... 23 System integrator..................................... 20–22

R T
RDC................................................................ 10 T1 (operating mode)................................ 10, 21
RDC cool........................................................ 10 T2 (operating mode)................................ 10, 21
Recommissioning................................... 27, 143 Teach pendant......................................... 13, 19
Refilling quantity. 189, 192, 194, 197, 200, 203 Technical data.................................................33
Regulations................................................... 254 Technical data, KR 420 R3330......................81
Release device.......................................24, 245 Technical data, KR 420 R3330 F.................. 92
Release device (optional).............................245 Technical data, KR 510 R3080......................58
Repair..................................................... 30, 209 Technical data, KR 510 R3080 F.................. 69
Robot controller........................................13, 19 Technical data, KR 600 R2830......................34
Robot system..................................................13 Technical data, KR 600 R2830 F.................. 46
Robot, removing........................................... 239 Technical data, overview................................ 33
Rotating column....................................... 13, 15 Terms used....................................................... 8
Terms, safety.................................................. 20
Tightening torques........................................ 247
Training............................................ 7, 169, 209
S Transport position......................................... 137
Safety..............................................................19
Transportation........................................ 27, 137
Safety instructions............................................ 7
Transportation by fork lift truck.................... 140
Safety of machinery..................................... 255
Transportation with lifting tackle (optional).. 141
Safety zone.............................................. 21, 23

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Turn-tilt table...................................................19

U
Use
Intended..................................................... 16
User.......................................................... 20, 22
Users.................................................................7

W
W.....................................................................11
Warnings........................................................... 7
Wiring diagrams, electrical installations.......230
Workspace........................................... 8, 20, 23
WP.................................................................. 11
Wrist................................................................14

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