KUKA IONTEC Manual

Robots
KR IONTEC
With F and CR lite Variants
Assembly Instructions
Issued: 22.12.2023
MA KR IONTEC V10
KUKA Deutschland GmbH
KR IONTEC
© Copyright 2023
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 IONTEC (PDF) en

PB14091
Book structure: MA KR IONTEC V11.1

BS12700
Version: MA KR IONTEC V10
2/428 | www.kuka.com MA KR IONTEC V10 | Issued: 22.12.2023

KR IONTEC
Contents
1 Introduction.............................................................................................. 11
1.1 Target group.......................................................................................................... 11
1.2 Industrial robot documentation.............................................................................. 11
1.3 Representation of warnings and notes................................................................. 11
1.4 Terms used............................................................................................................ 12
2 Product description................................................................................. 17
2.1 Description of the robot system............................................................................ 17
2.2 Description of the manipulator.............................................................................. 18
2.3 Intended use and misuse...................................................................................... 20
3 Safety......................................................................................................... 23
3.1 General.................................................................................................................. 23
3.1.1 Disclaimer.............................................................................................................. 23
3.1.2 EC declaration of conformity and declaration of incorporation............................ 24
3.1.3 Terms in the “Safety” chapter............................................................................... 24
3.2 Personnel............................................................................................................... 26
3.3 Workspace, safety zone and danger zone........................................................... 27
3.4 Overview of protective equipment........................................................................ 27
3.4.1 Mechanical end stops........................................................................................... 27
3.4.2 Mechanical axis limitation (optional)..................................................................... 28
3.4.3 Options for moving the manipulator without drive energy................................... 28
3.4.4 Labeling on the industrial robot............................................................................ 29
3.5 Safety measures.................................................................................................... 29
3.5.1 General safety measures...................................................................................... 29
3.5.2 Transportation........................................................................................................ 31
3.5.3 Start-up and recommissioning.............................................................................. 31
3.5.4 Manual mode......................................................................................................... 33
3.5.5 Automatic mode..................................................................................................... 34
3.5.6 Maintenance and repair........................................................................................ 34
3.5.7 Decommissioning, storage and disposal.............................................................. 36
4 Technical data.......................................................................................... 37
4.1 Technical data, overview....................................................................................... 37
4.2 Technical data, KR 20 R3100............................................................................... 39
4.2.1 Basic data, KR 20 R3100..................................................................................... 39
4.2.2 Axis data, KR 20 R3100....................................................................................... 41
4.2.3 Payloads, KR 20 R3100....................................................................................... 44
4.2.4 Foundation loads, KR 20 R3100.......................................................................... 50
4.3.1 Basic data, KR 30 R2100..................................................................................... 52
4.3.2 Axis data, KR 30 R2100....................................................................................... 54
4.3.3 Payloads, KR 30 R2100....................................................................................... 57
4.4 Technical data, KR 30 R2100 CR lite.................................................................. 66
4.4.1 Basic data, KR 30 R2100 CR lite........................................................................ 66
4.4.2 Axis data, KR 30 R2100 CR lite.......................................................................... 68
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4.4.3 Payloads, KR 30 R2100 CR lite........................................................................... 71

4.4.4 Foundation loads, KR 30 R2100 CR lite.............................................................. 78
4.5.1 Basic data, KR 50 R2100..................................................................................... 80
4.5.2 Axis data, KR 50 R2100....................................................................................... 82
4.5.3 Payloads, KR 50 R2100....................................................................................... 85
4.7.1 Basic data, KR 50 R2500..................................................................................... 108
4.7.2 Axis data, KR 50 R2500....................................................................................... 110
4.7.3 Payloads, KR 50 R2500....................................................................................... 114
4.8 Technical data, KR 50 R2500 F........................................................................... 122
4.8.1 Basic data, KR 50 R2500 F................................................................................. 122
4.8.2 Axis data, KR 50 R2500 F................................................................................... 124
4.8.3 Payloads, KR 50 R2500 F.................................................................................... 128
4.8.4 Foundation loads, KR 50 R2500 F....................................................................... 134
4.10.1 Basic data, KR 70 R2100..................................................................................... 150
4.10.2 Axis data, KR 70 R2100....................................................................................... 152
4.10.3 Payloads, KR 70 R2100....................................................................................... 155
4.11 Technical data, KR 70 R2100 F........................................................................... 164
4.11.1 Basic data, KR 70 R2100 F................................................................................. 164
4.11.2 Axis data, KR 70 R2100 F................................................................................... 166
4.11.3 Payloads, KR 70 R2100 F.................................................................................... 169
4.11.4 Foundation loads, KR 70 R2100 F....................................................................... 176
4.13 Plates and labels................................................................................................... 192
4.14 REACH duty to communicate information acc. to Art. 33................................... 195
4.15 Stopping distances and times............................................................................... 195
4.15.1 General information............................................................................................... 195
4.15.2 Stopping distances and times, KR 20 R3100...................................................... 196
4.15.2.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 196
4.15.2.2 Stopping distances and stopping times, STOP 1, A1.......................................... 197

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4.15.3 Stopping distances and times, KR 30 R2100 and KR 30 R2100 CR lite........... 201
4.15.4 Stopping distances and times, KR 50 R2100 and KR 50 R2100 CR lite........... 207
4.15.5 Stopping distances and times, KR 50 R2500, KR 50 R2500 F and KR 50
R2500 CR lite........................................................................................................ 213
R2100 CR lite........................................................................................................ 219
5 Planning.................................................................................................... 227
5.1 Information for planning........................................................................................ 227
5.2 Mounting base with centering............................................................................... 227
5.3 Machine frame mounting....................................................................................... 230
5.4 Connecting cables and interfaces......................................................................... 232
6 Transportation.......................................................................................... 235
6.1 Transporting the robot........................................................................................... 235
7 Start-up and recommissioning............................................................... 239

7.1 Overview of start-up and recommissioning.......................................................... 239
7.2 Starting up robots (mounting base)...................................................................... 239
7.2.1 Installing KR IONTEC fork slots........................................................................... 241
7.2.2 Installing the robot with a mounting base............................................................ 242
7.2.3 Removing KR IONTEC fork slots......................................................................... 244
7.2.4 Connecting the connecting cables........................................................................ 245
7.2.5 Concluding work.................................................................................................... 246
7.3 Starting up robots (machine frame mounting)...................................................... 246
7.3.1 Installing KR IONTEC fork slots........................................................................... 249
7.3.2 Installing the machine frame mounting assembly................................................ 249
7.3.3 Removing KR IONTEC fork slots......................................................................... 250
7.3.4 Connecting the connecting cables........................................................................ 251
7.3.5 Concluding work.................................................................................................... 252
7.4 Description of the connecting cables, KR C4...................................................... 252
7.4.1 Description of the Motor cable.............................................................................. 253

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7.4.2 Description of the Data cable............................................................................... 255

7.4.3 Description of the ground conductor.................................................................... 256
7.5 Description of the connecting cables, KR C5...................................................... 256
7.5.1 Description of the Motor cable.............................................................................. 258
7.5.2 Description of the Data cable............................................................................... 260
7.5.3 Description of the ground conductor.................................................................... 261
7.6 Description of overtravel protection on axis 4...................................................... 261
8 Maintenance.............................................................................................. 263
8.1 Maintenance overview........................................................................................... 263
8.1.1 Maintenance table, KR 20 R3100........................................................................ 264
8.1.2 Maintenance table, KR IONTEC standard, Foundry and CR lite variants.......... 266
8.2 Greasing cable set A1.......................................................................................... 269
8.2.1 Checking and greasing cable set A1................................................................... 270
8.2.2 Concluding work.................................................................................................... 271
8.3 Oil change in A1................................................................................................... 271
8.3.1 Draining the gear oil from A1............................................................................... 273
8.3.2 Filling gear unit A1 with gear oil........................................................................... 274
8.3.3 Concluding work.................................................................................................... 274
8.4 Oil change in A2................................................................................................... 274
8.4.3 Concluding work.................................................................................................... 278
8.5 Oil change in A3................................................................................................... 278
8.5.3 Concluding work.................................................................................................... 281
8.6 Oil change in A4................................................................................................... 281
8.6.3 Concluding work.................................................................................................... 284
8.7 Oil change in A5................................................................................................... 285
8.7.3 Concluding work.................................................................................................... 288
8.8 Oil change in A6................................................................................................... 288
8.8.3 Concluding work.................................................................................................... 292
8.9 KR 20 R3100......................................................................................................... 293
8.9.1 Oil change in A4 .................................................................................................. 293
8.9.1.1 Draining the gear oil from A4............................................................................... 294
8.9.1.2 Filling gear unit A4 with gear oil........................................................................... 295
8.9.1.3 Concluding work.................................................................................................... 296
8.9.2 Oil change in A5................................................................................................... 296
8.9.2.3 Concluding work.................................................................................................... 300
8.9.3 Oil change in A6................................................................................................... 300

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8.9.3.3 Concluding work.................................................................................................... 304
8.10 Cleaning the robot................................................................................................. 304
8.10.1 Cleaning................................................................................................................. 305
8.10.2 Concluding work.................................................................................................... 305
9 Repair........................................................................................................ 307
9.1 Exchanging motor A1............................................................................................ 307
9.1.1 Removing motor A1.............................................................................................. 309
9.1.2 Installing motor A1................................................................................................ 310
9.1.3 Concluding work.................................................................................................... 311
9.2.1 Securing the link arm............................................................................................ 314
9.2.2 Removing motor A2.............................................................................................. 315
9.2.4 Removing the equipment securing the link arm.................................................. 316
9.2.5 Concluding work.................................................................................................... 317
9.3.1 Securing the in-line wrist and robot arm.............................................................. 320
9.3.2 Removing cover A3............................................................................................... 320
9.3.3 Removing motor A3.............................................................................................. 321
9.3.5 Mounting the cover................................................................................................ 323
9.3.6 Removing the equipment securing the in-line wrist and robot arm..................... 324
9.3.7 Concluding work.................................................................................................... 325
9.4 KR IONTEC Foundry............................................................................................ 325
9.4.1 Exchanging motor A1............................................................................................ 325
9.4.1.1 Removing motor A1.............................................................................................. 327
9.4.1.2 Installing motor A1................................................................................................ 328
9.4.1.3 Concluding work.................................................................................................... 329
9.4.2.1 Securing the link arm............................................................................................ 332
9.4.2.2 Removing motor A2.............................................................................................. 332
9.4.2.4 Removing the equipment securing the link arm.................................................. 334
9.4.2.5 Concluding work.................................................................................................... 335
9.5 KR 20 R3100......................................................................................................... 335
9.5.1.1 Securing the in-line wrist and robot arm.............................................................. 338
9.5.1.2 Removing cover A3............................................................................................... 338
9.5.1.3 Removing motor A4.............................................................................................. 339
9.5.1.5 Mounting the cover................................................................................................ 342
9.5.1.6 Removing the equipment securing the in-line wrist and robot arm..................... 343
9.5.1.7 Concluding work.................................................................................................... 344
9.5.2.2 Removing cover A3............................................................................................... 347

KR IONTEC
9.5.2.3 Removing motor A5.............................................................................................. 348

9.5.2.7 Concluding work.................................................................................................... 353
9.5.3 Exchanging motor A6 and in-line wrist................................................................. 353
9.5.3.2 Removing cover A3............................................................................................... 356
9.5.3.3 Removing motor A4.............................................................................................. 357
9.5.3.4 Removing motor A5.............................................................................................. 358
9.5.3.5 Removing motor A6 and in-line wrist................................................................... 359
9.5.3.6 Preparing the new in-line wrist............................................................................. 360
9.5.3.7 Installing motor A6 and in-line wrist..................................................................... 361
9.5.3.12 Concluding work.................................................................................................... 368
9.5.4 Exchanging the connecting shafts........................................................................ 368
9.5.4.2 Removing cover A3............................................................................................... 371
9.5.4.3 Removing motor A4.............................................................................................. 372
9.5.4.4 Removing motor A5.............................................................................................. 373
9.5.4.9 Concluding work.................................................................................................... 380
9.6 Description of the electrical installations.............................................................. 380
10 Decommissioning, storage and disposal............................................. 395

10.1 Decommissioning................................................................................................... 395
10.1.1 Moving the robot into its transport position.......................................................... 395
10.1.2 Removing the robot............................................................................................... 396
10.1.3 Concluding work.................................................................................................... 397
10.2 Storage.................................................................................................................. 397
10.2.1 Removing the robot............................................................................................... 399
10.2.2 Cleaning................................................................................................................. 400
10.2.3 Preparing for storage............................................................................................ 400
10.2.4 Concluding work.................................................................................................... 400
10.3 Disposal................................................................................................................. 400
11 Options...................................................................................................... 403
11.1 Release device...................................................................................................... 403
11.1.1 Starting up the release device.............................................................................. 404
11.1.1.1 Installing the release device................................................................................. 405
11.1.1.2 Moving the manipulator without drive energy...................................................... 406
11.1.1.3 Concluding work.................................................................................................... 408
11.2 Purge option A...................................................................................................... 408

KR IONTEC
11.3 Purge option B...................................................................................................... 410

11.4 Purge option C...................................................................................................... 411
11.4.1 Starting up PURGE option C................................................................................ 412
11.4.1.1 Installing PURGE option C................................................................................... 413
11.4.1.2 Concluding work.................................................................................................... 414
11.5 Purge option D...................................................................................................... 415
11.5.1 Starting up PURGE option D................................................................................ 416
11.5.1.1 Installing PURGE option D................................................................................... 417
11.5.1.2 Concluding work.................................................................................................... 418
12 Appendix................................................................................................... 419
12.1 Tightening torques................................................................................................. 419
12.2 Auxiliary substances and consumables................................................................ 420
12.3 Applied standards and regulations....................................................................... 421
13 KUKA Service........................................................................................... 423

13.1 Requesting support............................................................................................... 423
13.2 KUKA Customer Support...................................................................................... 423
Index 425

KR IONTEC

KR IONTEC
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.

KR IONTEC
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 Range within which the axis may move The axis range must be de-
fined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance

The stopping distance is part of the danger zone.
Workspace Area within which the robot may move. The workspace is derived
from the individual axis ranges.
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

KR IONTEC
Introduction
EMD Electronic Mastering Device
SPP Spare parts package
EX Explosion-proof zone
F Foundry
F exclusive Foundry exclusive
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
HA High Accuracy
HI High Inertia
HM Hygienic Machine
For the primary and secondary foodstuffs industries
HO Hygienic Oil
For the secondary foodstuffs industry
HP High Protection
HW Hollow Wrist
K Shelf-mounted
KCP KUKA Control Panel

Teach pendant for the KR C2/KR C2 edition2005
The KCP has all the operator control and display functions required
for operating and programming the industrial robot.
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
micro RDC micro Resolver Digital Converter
MT Machine Tooling
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.

Introduction KR IONTEC
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

The resolver digital converter is used to acquire motor data (e.g.
position data, motor temperatures).
RDC cool Resolver Digital Converter

Resolver Digital Converter with extended temperature range
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 For KUKA iiQKA.OS: not relevant at present

For KUKA System Software / VW System Software:
Test mode, Manual High Velocity (> 250 mm/s permissible)
W Wall
WP Waterproof

KR IONTEC
Introduction
External axis For KUKA iiQKA.OS: not relevant at present
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

Introduction KR IONTEC

KR IONTEC
Product description
2 Product description
2.1 Description of the robot system
A robot system comprises all the assemblies of an industrial robot, includ-

ing the manipulator (robot arm and electrical installations), robot controller,
connecting cables, tool and other equipment. The KR IONTEC product
family comprises the following robot variants:
• KR 20 R3100
• KR 30 R2100
• KR 30 R2100 CR lite
• KR 50 R2100
• KR 50 R2500
• KR 50 R2500 F
• KR 70 R2100
• KR 70 R2100 F
An industrial robot of this product family comprises the following compo-
nents:
• Manipulator
• Connecting cables
• Robot controller
• Teach pendant (KUKA smartPAD)
• Software
• Options, accessories
Fig. 2-1: Example of an industrial robot with KR C4
1 Manipulator
2 Connecting cables
3 Robot controller

Product description KR IONTEC
4 Teach pendant, KUKA smartPAD
Fig. 2-2: Example of an industrial robot with KR C5
1 Manipulator
2 Connecting cables
3 Robot controller
4 Teach pendant, KUKA smartPAD-2
2.2 Description of the manipulator
Overview
The manipulators (= robot arm and electrical installations) of the variants

are designed as 6-axis jointed-arm kinematic systems. They consist of the
following principal components:

KR IONTEC
Product description
Fig. 2-3: Main assemblies of the manipulator
1 In-line wrist/arm
2 Link arm
3 Rotating column
4 Base frame
5 Electrical installations
DANGER
Axes 1 to 3 are equipped with end stops. These serve to protect the
machine only.
The following options are available for personnel protection:
• The Safe Robot functionality of the controller
• The use of mechanical axis limitations for axes 1 to 3 (optional)
In-line wrist/arm
The robot is equipped with a three-axis in-line wrist / arm combination.

This in-line wrist / arm combination is screwed directly to the link arm of
the robot via gear unit A3. End effectors are attached to the mounting
flange of axis 6. Axes A1 to A6 have a measuring device, through which
the mechanical zero of the respective axis can be checked by means of
an electronic probe (MEMD) and transferred to the controller. Directions of
rotation, axis data and permissible loads can be found in the chapter
(>>> 4 "Technical data" Page 37). The in-line wrist is driven by the mo-
tors inside the in-line wrist.
There is an interface on the arm for fastening supplementary loads.
The mounting flange conforms, with minimal deviations, to ISO 9409-1:
2004
Link arm
The link arm is the assembly located between the arm and the rotating
column. There are two length variants of the link arm available. There is
an interface on the link arm for fastening supplementary loads.

Rotating column
The rotating column houses the gear units and motors A1 and A2. The ro-
tational motion of axis 1 is performed by the rotating column. This is
screwed to the base frame via the gear unit of axis 1 and is driven by a
motor in the rotating column. The link arm is also mounted in the rotating
column.
There is an interface on the rotating column for fastening supplementary
loads.
Base frame
The base frame is the base of the robot. It is screwed to the mounting
base. The electrical installations are fastened in the base frame. Also lo-
cated on the base frame is the interface for the motor and data cable and
the energy supply system.
Electrical installations
The electrical installations include all the motor and data cables for the
motors of axes 1 to 6. The complete electrical installations consist of ca-
ble set A1 - A3 and cable set A4 - A6.
All connections are implemented as connectors in order to enable the
main axis motors to be exchanged quickly and reliably. The electrical in-
stallations also include a protective circuit. The ground conductors to the
robot are connected to the base frame by means of ring cable lugs and
setscrews.
Options
The robot can, for example, be equipped with the following options. The
option is described in separate documentation.
• Axis limitations A1, A2 and A3
• Adapter ring
• Booster frame
• Brake release device
• Energy supply system A1 to A3
• Energy supply system A3 to A6
• Fork slots
The following options are also available:
• Release device (>>> 11.1 "Release device" Page 403)
• Purge option A (>>> 11.2 "Purge option A" Page 408)
• Purge option B (>>> 11.3 "Purge option B" Page 410)
• Purge option C (>>> 11.4 "Purge option C" Page 411)
• Purge option D (>>> 11.5 "Purge option D" Page 415)
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

KR IONTEC
individual components, with particular reference to the maintenance speci-
Product description
fications.
Misuse
Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. It will result in the loss of warranty and liability
claims. KUKA is not liable for any damage resulting from such misuse.
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.
The robot system is an integral part of a complete system and may only
be operated in a CE-compliant system.


KR IONTEC
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.

Safety KR IONTEC
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 Range within which the axis may move The axis range must be de-
fined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance

The stopping distance is part of the danger zone.
Workspace Area within which the robot may move. The workspace is derived
from the individual axis ranges.
User The user of the industrial robot can be the management, employer
or delegated person responsible for use of the industrial robot.

KR IONTEC
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 consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
KCP KUKA Control Panel

Teach pendant for the KR C2/KR C2 edition2005
The KCP has all the operator control and display functions required
for operating and programming the industrial robot.
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 For KUKA iiQKA.OS: not relevant at present

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

Safety KR IONTEC
External axis For KUKA iiQKA.OS: not relevant at present

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
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

KR IONTEC
Safety
• 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
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.

Safety KR IONTEC
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.
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.

KR IONTEC
Safety
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
• 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.

Safety KR IONTEC
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).

KR IONTEC
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.
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.

Safety KR IONTEC
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.

KR IONTEC
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.

Safety KR IONTEC
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.

KR IONTEC
Safety
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

KR IONTEC
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.

KR IONTEC
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 20 R3100 • Technical data
(>>> 4.2 "Technical data, KR 20 R3100" Page 39)
• Plates and labels
(>>> 4.13 "Plates and labels" Page 192)
• Stopping distances and stopping times
(>>> 4.15.2 "Stopping distances and times, KR 20 R3100"
Page 196)
(>>> 4.15.3 "Stopping distances and times, KR 30 R2100 and KR
30 R2100 CR lite" Page 201)
KR 30 R2100 CR lite • Technical data
(>>> 4.4 "Technical data, KR 30 R2100 CR lite" Page 66)

Technical data KR IONTEC
Robot Technical data

(>>> 4.15.5 "Stopping distances and times, KR 50 R2500, KR 50
R2500 F and KR 50 R2500 CR lite" Page 213)
KR 50 R2500 F • Technical data
(>>> 4.8 "Technical data, KR 50 R2500 F" Page 122)
KR 70 R2100 F • Technical data
(>>> 4.11 "Technical data, KR 70 R2100 F" Page 164)

KR IONTEC
Technical data
4.2 Technical data, KR 20 R3100
4.2.1 Basic data, KR 20 R3100
Basic data
KR 20 R3100
Number of axes 6
Number of controlled axes 6
Volume of working envelope 117.9 m³
Pose repeatability (ISO 9283) ± 0.05 mm
Weight approx. 549 kg
Rated payload 20 kg
Maximum payload 23.6 kg
Maximum reach 3101 mm
Protection rating (IEC 60529) IP65
Schutzart Arm (IEC 60529) IP65
Protection rating, robot wrist (IEC IP65
60529)
Sound level < 69 dB (A)
Mounting position Floor;
Ceiling;
Wall;
Desired angle
Footprint 603 mm x 480 mm
Hole pattern: mounting surface for R300x400
kinematic system
Permissible angle of inclination -
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)
Controller KR C5 M6/M7;
KR C4
Transformation name KR C4: KR20R3100;
KR C5: KR20R3100
The manipulator is designed in such a way that, in accordance with

standard IEC 60529, no water can penetrate into electrical equipment
spaces in normal operation. Water spray and corrosive additives can
nevertheless lead to corrosion (rust) on uncoated parts. In this case, it
is advisable to provide the equipment with corrosion protection. Corro-
sion does not represent a defect as defined by the standard, as long as
it does not have a detrimental effect on the protection rating. The pro-
tection rating is valid in the case of compliance with the specified ambi-
ent conditions.
Ambient conditions
Humidity class (EN 60204) -

Classification of environmental -
conditions (EN 60721-3-3)

Cleanroom class (ISO 14644-1) -

Ambient temperature
During operation 0 °C to 55 °C (273 K to 328 K)
During storage/transportation -40 °C to 60 °C (233 K to 333 K)
For operation at low temperatures, it may be necessary to warm up the

robot.
Connecting cables, KR C4
Connector designation
Cable designation robot controller - Interface with robot
robot
Motor cable X20 – X30 Han® 16HP
Data cable X21 – X31 Han® 3A Q12
Ground conductor / equipotential M8 ring cable lug at
bonding both ends
16 mm2
Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m
Max. cable length 50 m
Max. number of plug connections 1
For detailed specifications of the connecting cables, see (>>> 7.4 "De-
scription of the connecting cables, KR C4" Page 252).
robot
Motor cable XD30 6 motor connectors: Han® 16HP
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
Data cable XF31 XF21 - XF31 Han® 3A Q12
bonding both ends
16 mm2
Number of extensions 1
Certificates
ESD requirements IEC61340-5-1; ANSI/ESD S20.20

KR IONTEC
Technical data
4.2.2 Axis data, KR 20 R3100
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 170 °
A4 ±350 °
A5 ±130 °
A6 ±350 °
Speed with rated payload
A1 180 °/s
A2 165 °/s
A3 160 °/s
A4 360 °/s
A5 360 °/s
A6 630 °/s
Direction of rotation of robot axes
The following diagram shows the direction of motion and the arrangement
of the individual axes for the listed variants of this product family.
Fig. 4-1: Direction of rotation of the axes
Mastering positions
Mastering position
A1 -9 °
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.
Fig. 4-2: KR 20 R3100, working envelope, side view

KR IONTEC
Technical data
Fig. 4-3: KR 20 R3100, working envelope, top view
Inclined installation
The robot can be installed in any position from 0° (floor) to 180° (ceiling).
The following figure shows the possible limitation of the motion range of
axis 1, as a function of the angle of inclination of the robot.
The inclination angles for the robot must be entered correctly into the con-
troller if the robot is not operated in the floor-mounted position. Configura-
tion of the angles is possible via WorkVisual.
The inclination angles for an unchanged main working direction of the ro-
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
The inclined installation angles must be individually checked and en-
tered. An incorrectly entered inclined installation angle can lead to un-
foreseen motion and/or to an overload and, potentially, damage to the
robot.

Fig. 4-4: Motion range of A1 with inclined installation, KR 20 R3100
4.2.3 Payloads, KR 20 R3100
Payloads
Rated payload 20 kg
Maximum payload 23.6 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- 50 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 30 kg
arm
Rated supplementary load, arm 20 kg

KR IONTEC
Technical data
Maximum supplementary load, arm 30 kg
Load center of gravity and mass moment of inertia
Fig. 4-5: Load center of gravity and mass moment of inertia
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!
Fig. 4-6: KR 20 R3100, payload diagram
The KR 20 R3100 is designed for a rated payload of 20 kg in order to op-

timize the dynamic performance of the robot. With reduced load center
distances and favorable supplementary loads, a maximum payload of up
to 23.6 kg can be mounted. The specific KUKA Load case must be veri-
fied using KUKA. For further consultation, please contact KUKA Service.
Mounting flange D=50
Robot wrist type ZH16/22

Mounting flange standard Deviation, see figure
Mounting flange (hole circle) 50 mm

Screw grade 12.9
Screw size M6
Number of fastening threads 7

KR IONTEC
Technical data
Depth of engagement min. 6 mm; max. 9 mm
Locating element 6 H7
The mounting flange (>>> Fig. 4-7)is depicted with axes 4 and 6 in the
zero position.
Fig. 4-7: KR IONTEC standard variants, mounting flange D=50
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. 4-8: Flange loads
Flange loads during operation

F(a) 748 N
F(r) 946 N
M(k) 143 Nm
M(g) 101 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 1088 N
F(r) 1842 N
M(k) 313 Nm
M(g) 217 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.

KR IONTEC
Technical data
Fig. 4-9: Fastening of supplementary load on arm/in-line wrist, KR 20
R3100

Fig. 4-10: Fastening of supplementary load on rotating column/link

arm, KR 20 R3100
4.2.4 Foundation loads, KR 20 R3100
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.
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-

KR IONTEC
Technical data
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.
Foundation loads for floor mounting position

F(v normal) 7607 N
F(v max) 10107 N
F(h normal) 4605 N
F(h max) 8475 N
M(k normal) 8986 Nm
M(k max) 18031 Nm
M(r normal) 4995 Nm
M(r max) 9575 Nm
Foundation loads for ceiling mounting position
F(v normal) 7682 N
F(v max) 10199 N
F(h normal) 3636 N
F(h max) 8511 N
M(k normal) 9178 Nm
M(k max) 18031 Nm
M(r normal) 4995 Nm
M(r max) 9575 Nm
Foundation loads for wall mounting position
F(v normal) 8833 N
F(v max) 12339 N
F(h normal) 2196 N
F(h max) 5959 N
M(k normal) 11469 Nm
M(k max) 19709 Nm
M(r normal) 4793 Nm
M(r max) 9636 Nm
Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about
axis 1 M(r)

Fig. 4-11: Foundation loads
Basic data
KR 30 R2100
Number of axes 6
Volume of working envelope 36 m³
Rated payload 30 kg
Maximum payload 36 kg
Schutzart Arm (IEC 60529) IP65 / IP67
Protection rating, robot wrist (IEC IP65 / IP67
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 30 R2100
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR30R2100

ent conditions.
Ambient conditions

Ambient temperature

robot.
robot
bonding both ends
16 mm2

robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Certificates
4.3.2 Axis data, KR 30 R2100
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 165 °
A4 ±180 °
A5 ±125 °
A6 ±350 °
A1 180 °/s
A2 165 °/s
A3 180 °/s
A4 250 °/s
A5 250 °/s
A6 360 °/s

KR IONTEC
Technical data
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.


KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.
Payloads
Rated payload 30 kg


frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE


to 36 kg can be mounted. The specific KUKA Load case must be verified
using KUKA. For further consultation, please contact KUKA Service.
Robot wrist type ZH70


Screw grade 10.9
Screw size M8
Depth of engagement min. 14 mm, max. 20 mm
The mounting flange is depicted (>>> Fig. 4-18) with axes 4 and 6 in the
zero position.

KR IONTEC
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 916 N
F(r) 1287 N
M(k) 514 Nm
M(g) 302 Nm
F(a) 1167 N
F(r) 2235 N
M(k) 1174 Nm
M(g) 822 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
Fig. 4-20: Fastening of supplementary load, arm/in-line wrist, KR 30
R2100


arm, KR 30 R2100
path planning.
WARNING
tion

KR IONTEC
Technical data
F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

4.4 Technical data, KR 30 R2100 CR lite
4.4.1 Basic data, KR 30 R2100 CR lite
Basic data
KR 30 R2100 CR lite
Number of axes 6
Rated payload 30 kg
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 30 R2100 CR lite
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR30R2100

ent conditions.
Ambient conditions

Cleanroom class (ISO 14644-1) Class 5 at 40% override;
Class 5 at 80% override
Ambient temperature

robot.
robot
bonding both ends
16 mm2

robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Certificates
4.4.2 Axis data, KR 30 R2100 CR lite
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 165 °
A4 ±180 °
A5 ±125 °
A6 ±350 °
A1 180 °/s
A2 165 °/s
A3 180 °/s
A4 250 °/s
A5 250 °/s
A6 360 °/s

KR IONTEC
Technical data
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.

Fig. 4-24: KR 30 R2100 CR lite, working envelope, side view
Fig. 4-25: KR 30 R2100 CR lite, working envelope, top view

KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.

CR lite
4.4.3 Payloads, KR 30 R2100 CR lite
Payloads
Rated payload 30 kg


frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE

Fig. 4-28: KR 30 R2100 CR lite, payload diagram
The KR 30 R2100 CR lite is designed for a rated payload of 30 kg in or-

der to optimize the dynamic performance of the robot. With reduced load
center distances and favorable supplementary loads, a maximum payload
of up to 36 kg can be mounted. The specific KUKA Load case must be
verified using KUKA. For further consultation, please contact KUKA Serv-
ice.


Screw grade 10.9
Screw size M8
zero position.

KR IONTEC
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 916 N
F(r) 1287 N
M(k) 514 Nm
M(g) 302 Nm
F(a) 1167 N
F(r) 2235 N
M(k) 1174 Nm
M(g) 822 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
R2100 CR lite


arm, KR 30 R2100 CR lite
4.4.4 Foundation loads, KR 30 R2100 CR lite
path planning.
WARNING
tion

KR IONTEC
Technical data
F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

Basic data
KR 50 R2100
Number of axes 6
Rated payload 50 kg
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 50 R2100
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR50R2100

ent conditions.
Ambient conditions

Ambient temperature

robot.
robot
bonding both ends
16 mm2

robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Certificates
4.5.2 Axis data, KR 50 R2100
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 165 °
A4 ±180 °
A5 ±125 °
A6 ±350 °
A1 180 °/s
A2 175 °/s
A3 175 °/s
A4 250 °/s
A5 250 °/s
A6 360 °/s

KR IONTEC
Technical data
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.


KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.
Payloads
Rated payload 50 kg


frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE




Screw grade 10.9
Screw size M8
zero position.

KR IONTEC
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 1478 N
F(r) 1647 N
M(k) 563 Nm
M(g) 395 Nm
F(a) 1698 N
F(r) 3160 N
M(k) 1218 Nm
M(g) 847 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
R2100


arm, KR 50 R2100
path planning.
WARNING
tion

KR IONTEC
Technical data
F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

Basic data
KR 50 R2100 CR lite
Number of axes 6
Rated payload 50 kg
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 50 R2100 CR lite
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR50R2100

ent conditions.
Ambient conditions

Ambient temperature

robot.
robot
bonding both ends
16 mm2

robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Certificates
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 165 °
A4 ±180 °
A5 ±125 °
A6 ±350 °
A1 180 °/s
A2 175 °/s
A3 175 °/s
A4 250 °/s
A5 250 °/s
A6 360 °/s

KR IONTEC
Technical data
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.


KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.

CR lite
Payloads
Rated payload 50 kg


frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE


ice.


Screw grade 10.9
Screw size M8
zero position.

KR IONTEC
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 1478 N
F(r) 1647 N
M(k) 563 Nm
M(g) 395 Nm
F(a) 1698 N
F(r) 3160 N
M(k) 1218 Nm
M(g) 847 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
R2100 CR lite


path planning.
WARNING
tion

KR IONTEC
Technical data
F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

Basic data
KR 50 R2500
Number of axes 6
Rated payload 50 kg
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 50 R2500
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR50R2500

ent conditions.
Ambient conditions

Ambient temperature

robot.
robot
bonding both ends
16 mm2

robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Certificates
4.7.2 Axis data, KR 50 R2500
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 170 °
A4 ±180 °
A5 ±125 °
A6 ±350 °
A1 175 °/s
A2 158 °/s
A3 175 °/s
A4 250 °/s
A5 250 °/s
A6 360 °/s

KR IONTEC
Technical data
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.


KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.

Payloads
Rated payload 50 kg
frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE




Screw grade 10.9
Screw size M8
zero position.

KR IONTEC
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 1398 N
F(r) 1670 N
M(k) 475 Nm
M(g) 364 Nm
F(a) 1937 N
F(r) 3263 N
M(k) 1221 Nm
M(g) 831 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
R2500


arm, KR 50 R2500
path planning.

KR IONTEC
Technical data
WARNING
tion

F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

4.8 Technical data, KR 50 R2500 F
4.8.1 Basic data, KR 50 R2500 F
Basic data
KR 50 R2500 F
Number of axes 6
Rated payload 50 kg
Protection rating (IEC 60529) IP65 / IP67
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 50 R2500 F
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR50R2500
Foundry robots
Overpressure in the 0.03 MPa (0.3 bar) ±10%

arm
Compressed air Free of oil and water
in accordance with ISO 8573-1:2010 (7:4:4)
Compressed air sup- Air line in the cable set
ply line
Operating pressure max. 0.03 MPa (0.3 bar) ±10%
(PURGE)
Air consumption 0.1 m3/h
Air line connection Push-in fitting for hose, 6 mm
Thermal load of the 10 s/min at 180 °C (453 K)
wrist
Resistance Increased resistance to dust, lubricants, cool-
ants and water vapor.
Special paint finish on Special paint finish on the entire robot, and an
the robot additional protective clear coat.
Other ambient condi- KUKA Deutschland GmbH must be consulted if
tions the robot is to be used under other ambient
conditions.

ent conditions.
Ambient conditions

Ambient temperature

pH value 7.0 to 9.0

robot.
During operation in the low-temperature range, frost and condensation

must be avoided, as damage to property may otherwise arise.
robot
bonding both ends
16 mm2
robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
For detailed specifications of the connecting cables, see “Description of
the connecting cables”.
4.8.2 Axis data, KR 50 R2500 F
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 170 °
A4 ±180 °

KR IONTEC
Technical data
A5 ±125 °
A6 ±350 °
A1 175 °/s
A2 158 °/s
A3 175 °/s
A4 250 °/s
A5 250 °/s
A6 360 °/s
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.

Fig. 4-68: KR 50 R2500 F, working envelope, side view
Fig. 4-69: KR 50 R2500 F, working envelope, top view

KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.

F

4.8.3 Payloads, KR 50 R2500 F
Payloads
Rated payload 50 kg
frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE

Fig. 4-72: KR 50 R2500 F, payload diagram
The KR 50 R2500 F is designed for a rated payload of 50 kg in order to

optimize the dynamic performance of the robot. With reduced load center
Foundry mounting flange D=100


Screw grade 10.9
Screw size M8
zero position.

KR IONTEC
Technical data
Fig. 4-73: KR IONTEC Foundry mounting flange D=100
Flange loads
path planning.
WARNING
consideration.


F(a) 1398 N
F(r) 1670 N
M(k) 475 Nm
M(g) 364 Nm
F(a) 1937 N
F(r) 3263 N
M(k) 1221 Nm
M(g) 831 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
R2500 F


arm, KR 50 R2500 F
4.8.4 Foundation loads, KR 50 R2500 F
path planning.

KR IONTEC
Technical data
WARNING
tion

F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

Basic data
KR 50 R2500 CR lite
Number of axes 6
Rated payload 50 kg
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 50 R2500 CR lite
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR50R2500

ent conditions.
Ambient conditions

Ambient temperature

robot.
robot
bonding both ends
16 mm2

robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Certificates
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 170 °
A4 ±180 °
A5 ±125 °
A6 ±350 °
A1 175 °/s
A2 158 °/s
A3 175 °/s
A4 250 °/s
A5 250 °/s
A6 360 °/s

KR IONTEC
Technical data
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.


KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.

CR lite

Payloads
Rated payload 50 kg
frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE


ice.


Screw grade 10.9
Screw size M8
zero position.

KR IONTEC
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 1398 N
F(r) 1670 N
M(k) 475 Nm
M(g) 364 Nm
F(a) 1937 N
F(r) 3263 N
M(k) 1221 Nm
M(g) 831 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
R2500 CR lite


path planning.

KR IONTEC
Technical data
WARNING
tion

F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

Basic data
KR 70 R2100
Number of axes 6
Rated payload 70 kg
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 70 R2100
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR70R2100

ent conditions.
Ambient conditions

Classification of environmental 3K3
Ambient temperature

robot.
robot
bonding both ends
16 mm2

robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Certificates
4.10.2 Axis data, KR 70 R2100
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 165 °
A4 ±180 °
A5 ±125 °
A6 ±350 °
A1 180 °/s
A2 158 °/s
A3 160 °/s
A4 230 °/s
A5 230 °/s
A6 320 °/s

KR IONTEC
Technical data
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.


KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.
4.10.3 Payloads, KR 70 R2100
Payloads
Rated payload 70 kg


frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE




Screw grade 10.9
Screw size M8
zero position.

KR IONTEC
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 1924 N
F(r) 2015 N
M(k) 557 Nm
M(g) 401 Nm
F(a) 2241 N
F(r) 3882 N
M(k) 1263 Nm
M(g) 871 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
R2100


arm, KR 70 R2100
path planning.
WARNING
tion

KR IONTEC
Technical data
F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

4.11 Technical data, KR 70 R2100 F
4.11.1 Basic data, KR 70 R2100 F
Basic data
KR 70 R2100 F
Number of axes 6
Rated payload 70 kg
Protection rating (IEC 60529) IP65 / IP67
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 70 R2100 F
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR70R2100
Foundry robots
Overpressure in the 0.03 MPa (0.3 bar) ±10%

arm
Compressed air Free of oil and water
in accordance with ISO 8573-1:2010 (7:4:4)
Compressed air sup- Air line in the cable set
ply line
(PURGE)
Thermal load of the 10 s/min at 180 °C (453 K)
wrist
Resistance Increased resistance to dust, lubricants, cool-
ants and water vapor.
Special paint finish on Special paint finish on the entire robot, and an
the robot additional protective clear coat.
Other ambient condi- KUKA Deutschland GmbH must be consulted if
tions the robot is to be used under other ambient
conditions.

ent conditions.
Ambient conditions

Ambient temperature

pH value 7.0 to 9.0

robot.
During operation in the low-temperature range, frost and condensation

must be avoided, as damage to property may otherwise arise.
robot
bonding both ends
16 mm2
robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
For detailed specifications of the connecting cables, see “Description of
the connecting cables”.
4.11.2 Axis data, KR 70 R2100 F
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 165 °
A4 ±180 °

KR IONTEC
Technical data
A5 ±125 °
A6 ±350 °
A1 180 °/s
A2 158 °/s
A3 160 °/s
A4 230 °/s
A5 230 °/s
A6 320 °/s
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.

Fig. 4-101: KR 70 R2100 F, working envelope, side view
Fig. 4-102: KR 70 R2100 F, working envelope, top view

KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.

F
4.11.3 Payloads, KR 70 R2100 F
Payloads
Rated payload 70 kg


frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE

Fig. 4-105: KR 70 R2100 F, payload diagram
The KR 70 R2100 F is designed for a rated payload of 70 kg in order to

optimize the dynamic performance of the robot. With reduced load center
Foundry mounting flange D=100


Screw grade 10.9
Screw size M8
zero position.

KR IONTEC
Technical data
Fig. 4-106: KR IONTEC Foundry mounting flange D=100
Flange loads
path planning.
WARNING
consideration.


F(a) 1924 N
F(r) 2015 N
M(k) 557 Nm
M(g) 401 Nm
F(a) 2241 N
F(r) 3882 N
M(k) 1263 Nm
M(g) 871 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
R2100 F


arm, KR 70 R2100 F
4.11.4 Foundation loads, KR 70 R2100 F
path planning.
WARNING
tion

KR IONTEC
Technical data
F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

Basic data
KR 70 R2100 CR lite
Number of axes 6
Rated payload 70 kg
60529)
Ceiling;
Wall;
Desired angle

KR IONTEC
Technical data
KR 70 R2100 CR lite
kinematic system
ange (RAL 2009)
KR C4
KR C5: KR70R2100

ent conditions.
Ambient conditions

Ambient temperature

robot.
robot
bonding both ends
16 mm2

robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Certificates
Axis data
Motion range
A1 ±185 °
A2 -175 ° / 60 °
A3 -120 ° / 165 °
A4 ±180 °
A5 ±125 °
A6 ±350 °
A1 180 °/s
A2 158 °/s
A3 160 °/s
A4 230 °/s
A5 230 °/s
A6 320 °/s

KR IONTEC
Technical data
Mastering positions
Mastering position
A1 -9 °
A2 -90 °
A3 90 °
A4 0 °
A5 50 °
A6 -30 °
Working envelope
and 5.


KR IONTEC
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°
CAUTION
robot.

CR lite
Payloads
Rated payload 70 kg


frame
base frame
column
tating column
arm
arm
Parameter
system

KR IONTEC
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE


ice.


Screw grade 10.9
Screw size M8
zero position.

KR IONTEC
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 1924 N
F(r) 2015 N
M(k) 557 Nm
M(g) 401 Nm
F(a) 2241 N
F(r) 3882 N
M(k) 1263 Nm
M(g) 871 Nm
ing flange M(g)
Supplementary load

KR IONTEC
Technical data
R2100 CR lite


path planning.
WARNING
tion

KR IONTEC
Technical data
F(v normal) 8203 N
F(v max) 11259 N
F(h normal) 4523 N
F(h max) 9133 N
M(k normal) 8952 Nm
M(k max) 17517 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 8204 N
F(v max) 11349 N
F(h normal) 4092 N
F(h max) 9242 N
M(k normal) 9703 Nm
M(k max) 18711 Nm
M(r normal) 5141 Nm
M(r max) 9806 Nm
F(v normal) 9329 N
F(v max) 10835 N
F(h normal) 2955 N
F(h max) 12215 N
M(k max) 18312 Nm
M(r normal) 4815 Nm
M(r max) 9806 Nm
axis 1 M(r)

4.13 Plates and labels
Plates and labels
The following plates and labels (>>> Fig. 4-122) are attached to the robot.
They must not be removed or rendered illegible. Illegible plates and labels
must be replaced.
Fig. 4-122: Plates and labels, location

KR IONTEC
Technical data
Item Description
1
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!
2
Identification plate example

Content according to Machinery Directive.
The QR code contains a link to product information in KUKA
Xpert.
3
Danger zone
Entering the danger zone of the robot is prohibited if the robot
is in operation or ready for operation. Risk of injury!

Example of identification plate for Foundry

Content according to Machinery Directive.
For Foundry only
5
Work on the robot

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

KR IONTEC
Technical data
- This plate is attached to all the motors! No other plates or la-
bels may be affixed to the motors!
Hot surface
During operation of the robot, surface temperatures may be
reached that could result in burn injuries. Protective gloves must
be worn!
4.14 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.
4.15 Stopping distances and times
4.15.1 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:
‒ 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.
• 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.
4.15.2 Stopping distances and times, KR 20 R3100
4.15.2.1 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 30.47 °
A2 29.14 °
A3 16.79 °
Stopping time
A1 0.38 s

KR IONTEC
Technical data
A2 0.42 s
A3 0.20 s
4.15.2.2 Stopping distances and stopping times, STOP 1, A1
Fig. 4-123: Stopping distances for STOP 1, axis 1

Fig. 4-124: Stopping times for STOP 1, axis 1

KR IONTEC
Technical data


KR IONTEC
Technical data
4.15.3 Stopping distances and times, KR 30 R2100 and KR 30 R2100 CR lite
Stopping distance
A1 33.39 °
A2 27.90 °
A3 19.51 °

Stopping time
A1 0.32 s
A2 0.31 s
A3 0.20 s

KR IONTEC
Technical data


KR IONTEC
Technical data


KR IONTEC
Technical data
4.15.4 Stopping distances and times, KR 50 R2100 and KR 50 R2100 CR lite
Stopping distance
A1 23.19 °
A2 30.38 °
A3 18.25 °

Stopping time
A1 0.29 s
A2 0.36 s
A3 0.20 s

KR IONTEC
Technical data


KR IONTEC
Technical data


KR IONTEC
Technical data

R2500 CR lite
Stopping distance
A1 29.60 °
A2 22.57 °

A3 19.59 °
Stopping time
A1 0.37 s
A2 0.37 s
A3 0.22 s

KR IONTEC
Technical data


KR IONTEC
Technical data


KR IONTEC
Technical data

R2100 CR lite
Stopping distance
A1 37.62 °
A2 21.05 °

A3 21.66 °
Stopping time
A1 0.38 s
A2 0.30 s
A3 0.27 s

KR IONTEC
Technical data


KR IONTEC
Technical data


KR IONTEC
Technical data


KR IONTEC
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.
5.2 Mounting base with centering
Description
Designation Article number Weight

Mounting base set R300x400 0000-309-857 approx. 26.7 kg
The mounting base with centering is used when the kinematic system is
fastened to the floor, i.e. directly on a concrete foundation.
The mounting base with centering consists of:
• Bedplates
• 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.
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-

KR IONTEC
plate/bedplates and the concrete foundation. The quality of the concrete

Planning
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 illustration (>>> Fig. 5-1) provides all the necessary informa-
tion 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.

KR IONTEC
Planning
Fig. 5-1: Mounting base, dimensioned drawing
1 Chemical anchor
2 Locating pin; cylindrical
3 M20x60-8.8-A2K hexagon bolt with lock washer (8x)
4 Bedplate (4x)
5 Locating pin; flat-sided
To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
illustration.

Planning KR IONTEC
Fig. 5-2: Foundation cross-section

3 Bedplate
4 Chemical anchor
5 Concrete foundation
A Concrete grade B
min. concrete thick- min. distance to
ness edge
in mm in mm
180 Without edge reinforcement 190
With edge reinforcement ≥Ø12 135
With edge reinforcement ≥Ø12 and stirrup re- 125
inforcement at a distance of ≤100 mm
5.3 Machine frame mounting
Description

Machine frame mounting 0000-331-410 approx. 2.3 kg

KR IONTEC
The machine frame mounting assembly is used when the robot is fas-
Planning
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.
The machine frame mounting assembly consists of:
• Locating pins
• Hexagon bolts with conical spring washers
Dimensioned drawing
The following illustration (>>> Fig. 5-3) provides all the necessary informa-
tion on machine frame mounting, together with the required foundation da-
ta.
Fig. 5-3: Machine frame mounting, dimensioned drawing
1 Locating pin, cylindrical

2 M20x60-8.8-A2K hexagon screw with lock washer (8x)
3 Locating pin, flat-sided

Planning KR IONTEC
WARNING
cian.
5.4 Connecting cables and interfaces
Connecting cables
The connecting cables comprise all the cables for transferring energy and
data between the robot and the robot controller. They are connected on
the robot side with connectors at interface A1. Connection to the controller
is always the same, irrespective of the controller variant.
Cable lengths of 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m and 50 m
are available as standard. The maximum length of the connecting cables
must not exceed 50 m. The maximum number of connectors is 1, i.e. a
maximum of 2 connecting cables may be combined with each other. Thus
if the robot is operated on a linear unit which has its own energy supply
chain, this cable must also be taken into account.
For the connecting cables, an additional ground conductor is always re-
quired to provide a low-resistance connection between the robot and the
control cabinet in accordance with DIN EN 60204. The ground conductor
is connected via ring cable lugs. The threaded bolts for connecting the
two ground conductors 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 A1
Interface A1 is located at the rear of the base frame.

KR IONTEC
Planning
Fig. 5-4: Interface A1
1 Connection for sealing air (for Foundry only)

2 Ground conductor (2x)
3 Data cable X31
4 Motor cable X30
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 ax-
is 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.

Planning KR IONTEC

KR IONTEC
Transportation
6 Transportation
6.1 Transporting the robot
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.
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 -125 °
A3 150 °
A4 0 °
A5 -115 °
A6 0 °
Fig. 6-1: Transport position
Transport dimensions
The transportation dimensions (>>> Fig. 6-2) for the robot can be noted
from the following diagram. The position of the center of gravity and the
weight vary according to the specific configuration and the position of
axes 2 and 3. The specified dimensions refer to the robot without equip-
ment.

Transportation KR IONTEC
Fig. 6-2: Transport dimensions
1 Robot
2 Fork slots, optional
3 Center of gravity
Robot A B C D SX SY SZ
KR 20 R3100 1 829 1 764 791 744 -50 -14 803
KR 30 R2100 1 497 1 288 566 703 8 -1 687
KR 30 R2100 CR
lite
KR 50 R2100 1 497 1 288 566 703 8 -1 687
KR 50 R2100 CR
lite
KR 50 R2500 1 824 1 288 790 744 -84 -11 799
KR 50 R2500 F
KR 50 R2500 CR
lite
KR 70 R2100 1 497 1 288 566 723 8 3 687
KR 70 R2100 F
KR 70 R2100 CR
lite
Transportation
The robot can be transported by fork lift truck or using lifting tackle. The
ceiling-mounted robot in its installation position can only be transported
outside the transport frame using a fork lift truck.

KR IONTEC
Transportation
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 transportation by fork lift truck (>>> Fig. 6-3), fork slots are mounted
on the side of the rotating column. The robot can be picked up by the fork
lift truck from the front or rear. The robot must not be damaged when in-
serting the fork into the fork slot. The fork lift truck must have a minimum
payload capacity of 2.0 t and an adequate fork length.
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. 6-3: Transportation by fork lift truck
Transportation with lifting tackle (optional)

Lifting tackle 0000-355-288 approx. 6 kg
The robot can also be transported using lifting tackle (>>> Fig. 6-4). For
this, it must be in the transport position. The lifting tackle is attached to
the robot at 3 points using lifting accessories approved for transport by
crane. All the legs must be routed as shown in the following illustration so
that the robot is not damaged. Installed tools and items of equipment can
cause undesirable shifts in the center of gravity. Items of equipment, espe-
cially energy supply systems, must be removed to the extent necessary to
avoid them being damaged by the legs of the lifting tackle during transpor-
tation.
All the legs are labeled.
The lifting accessories must be removed from the rotating column after
transportation.

Transportation KR IONTEC
WARNING
Risk of injury during transportation
The robot may tip during transportation. Death, severe injuries or dam-
• 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!
Fig. 6-4: Transportation by crane
1 Lifting tackle assembly

2 Approved M12 lifting accessory, rotating column; for leg G3
3 Approved M12 lifting accessory, base frame; for leg G2
4 Approved M12 lifting accessory, base frame; for leg G1

KR IONTEC
Start-up and recommissioning

7 Start-up and recommissioning
7.1 Overview of start-up and recommissioning
The procedure for start-up and recommissioning depends on the type of

fastening and installation position of the manipulator.
Description Information
Installation position: Starting up floor-mounted robots (mounting base)
floor and mounting
(>>> 7.2 "Starting up robots (mounting base)" Page 239)
base
Installation position: Starting up floor-mounted robots (machine frame mounting)
floor, ceiling, wall and
(>>> 7.3 "Starting up robots (machine frame mounting)" Page 246)
machine frame
mounting
7.2 Starting up robots (mounting base)
Description
These instructions apply to the variant “mounting base with centering”.

The robot is fastened to an appropriate concrete foundation using bed-
plates and chemical anchors with Dynamic Set.
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 chemical 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 an-
chor manufacturer are to be used. It is imperative to follow the manufac-
turer’s instructions for the use of chemical anchors.
Equipment
The following equipment is required:

Designation Article number
Lifting tackle/rope sling with sufficient 0000-355-288
load-bearing capacity
Crane with sufficient load-bearing capaci- -
ty
Fork lift truck with sufficient load-bearing -
capacity
LLA forklift slot KR IONTEC 0000-339-419
Drill with a ø 18 mm bit -
Setting tool approved by the anchor -
manufacturer
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 80 to 400 Nm
For fork slots

Start-up and recommissioning KR IONTEC

Torque wrench -
min. 40 to 80 Nm
Torque wrench -
min. 300 to 500 Nm
Material
The following material is required:

Designation Article number Quantity
Mounting base set R300x400 0000-309-857 1
Tightening torques
The tightening torques can be found under: (>>> 12.1 "Tightening

torques" Page 419)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher as well as screws with test cer-
tification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.
Precondition
• The installation site is accessible with a fork lift truck.

• The robot is in the transport position.
• The substructure has been checked for sufficient safety.
• The concrete foundation must have the required dimensions and
cross-section.
• The surface of the foundation must be level.
• Have the leveling compound readily at hand.
• Any tools or other system components which would hinder the work
have been removed.
• The connecting cables and ground conductors are routed to the robot
and installed.
Work safety
WARNING
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.

KR IONTEC

WARNING
ing capacity.
WARNING
CAUTION
WARNING
cian.
7.2.1 Installing KR IONTEC fork slots
Procedure
1. Mount the fork slots on the rotating column.

2. Fasten each fork slot to the rotating column with 2 M16x35-8.8 Allen
screws including washers.
3. Before lifting the robot, check that the Load Lifting Attachment is cor-
rectly fastened.

Fig. 7-1: Installing the fork slots
NOTICE
The Load Lifting Attachment must be removed before start-up of the ro-
bot. Substantial damage to property may otherwise result.
7.2.2 Installing the robot with a mounting base
Procedure
1. Lift the robot with a fork lift truck.

2. Clean the mounting surface on the robot and the bedplate.
3. Screw 1 locating pin for centering into each bedplate and check that it
is fitted securely.
4. Fasten the 4 bedplates to the robot using 2 M20x60-8.8-A2K hexagon
bolts with conical spring washers for each one.
5. Tighten all M20x60-8.8-A2K hexagon bolts with a torque wrench. In-
crease the tightening torque to the specified value in several stages.
6. Determine the position of the robot on the mounting base in relation to
the working envelope.
7. Set the robot down on the mounting base in its installation position.
8. Align the robot horizontally.
9. Check the surface of the concrete foundation:
If the evenness of the foundation is outside the specified tolerances,
this can cause strain or result in loosening of the mounting base.
• If the surface is sufficiently smooth and even, continue with step
15.
• If the surface is not sufficiently smooth and even, continue with
step 10.
10. Lift the robot with a fork lift truck.
11. Apply sufficient leveling compound to the underside of the bedplates
(toothed spatula).
The area under the hexagon bolt for robot fastening must be kept free
from leveling compound.
12. Set the robot down and align it.
13. Remove excess leveling compound. The maximum height of the level-
ing compound must not be exceeded. Observe the manufacturer’s
specifications.
14. Allow the leveling compound to set in accordance with the manufactur-
er’s specifications.
15. Drill 8 anchor holes in accordance with the manufacturer’s specifica-
tions and fit the anchors as specified in the instructions for use.

KR IONTEC
The instructions for use are enclosed with the anchors and must be

followed precisely.
Fig. 7-2: Mounting base, dimensioned drawing
1 Chemical anchor
4 Bedplate (4x)
5 Locating pin; flat-sided

Fig. 7-3: Foundation cross-section

3 Bedplate
4 Chemical anchor
5 Concrete foundation
A Concrete grade B
Min. concrete thick- Min. distance to
ness edge
in mm in mm
7.2.3 Removing KR IONTEC fork slots
Procedure
1. Remove the M16x35-8.8 Allen screws and lock washers.

2. Remove the Load Lifting Attachment.

KR IONTEC

Fig. 7-4: Removing the fork slots
7.2.4 Connecting the connecting cables
Procedure
1. Fasten the ground conductor between the robot controller and the ro-
bot to the ground conductor connection with 1 M8 hexagon nut includ-
ing conical spring washer; tightening torque MA= 15.0 Nm.
2. Fasten the ground conductor between the system component and the
robot to the ground conductor connection with 1 M8 hexagon nut in-
cluding conical spring washer; tightening torque MA= 15.0 Nm.
3. Connect data cable:
• KR C4: X31
• KR C5: XF31
When connecting the data cable connectors, it must be ensured that
the connector is locked correctly on the robot. Correct locking is ach-
ieved by closing the clip (>>> Fig. 7-5).
4. Connect motor cable:
• KR C4: X30
• KR C5: XD30
Push on the motor cable connector, insert 4 fastening screws and
tighten with tightening torque MA= 3.0 Nm.
5. Check the equipotential bonding in accordance with VDE 0100 and
EN 60204-1.
Further information is contained in the operating and assembly in-
structions of the robot controller.
6. Enter the installation position of the robot in WorkVisual. The default

installation position is the floor.

Fig. 7-5: Connecting the connecting cables

3 Data cable X31
4 Motor cable X30
7.2.5 Concluding work
The following concluding work must be carried out:

• If applicable, mount the tool.
• Start up the robot system in accordance with the chapter “Start-up and
recommissioning” in the operating instructions for the robot controller.
• Put the robot system into operation in accordance with the documen-
tation for the system software.
7.3 Starting up robots (machine frame mounting)
Description
The machine frame mounting assembly is used for installing robots on a

steel structure prepared by the customer, on a carriage of a linear unit, or
on an adapter plate.
8 hexagon bolts with conical spring washers are used for fastening the ro-
bot to a machine frame. A cylindrical pin and a flat-sided pin are provided
to ensure correct positioning.
This description is valid for the installation of floor, wall and ceiling-moun-
ted robots with the mounting variant “machine frame mounting”.
The robot must be rotated for wall and ceiling mounting. In doing so, it
must be secured such that an uncontrolled rotational motion or toppling is
impossible; the center of gravity must be taken into account
(>>> 6.1 "Transporting the robot" Page 235). When rotating the robot,
care must be taken not to damage the connectors, installation material

KR IONTEC
and/or energy supply system (optional). The wall-mounted or ceiling-moun-

ted installation is analogous to installation of the floor-mounted robot.
NOTICE
If a fixture is used, the manipulator must be secured in such a way that
slipping is impossible. Only approved fixtures with an adequate carrying
capacity may be used. Damage to property may otherwise result.
The installation and start-up of the robot controller, the tools mounted and
the applications are not described here.
Equipment

Lifting tackle 0000-355-288
Fork lift truck or crane with adequate car- -
rying capacity
LLA forklift slot KR IONTEC 0000-339-419
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 to 20 Nm
Torque wrench -
min. 300 to 500 Nm
Material

Machine frame mounting 0000-331-410 1
Tightening torques

torques" Page 419)
en.
ones.
Precondition
• The installation site is accessible with a crane or fork lift truck.

• The robot is in the transport position.
• The substructure has been checked for sufficient safety.
• The mounting surface has been prepared.
• Any tools or other system components which would hinder the work
have been removed.
• The connecting cables and ground conductors are routed to the robot
and installed.

Work safety
WARNING
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
ing capacity.
WARNING
CAUTION
WARNING
cian.

KR IONTEC

7.3.1 Installing KR IONTEC fork slots
Procedure
1. Mount the fork slots on the rotating column.

2. Fasten each fork slot to the rotating column with 2 M16x35-8.8 Allen
screws including washers.
3. Before lifting the robot, check that the Load Lifting Attachment is cor-
rectly fastened.
Fig. 7-6: Installing the fork slots
NOTICE
The Load Lifting Attachment must be removed before start-up of the ro-
bot. Substantial damage to property may otherwise result.
7.3.2 Installing the machine frame mounting assembly
Procedure
1. Clean the mounting surface (>>> Fig. 7-7).

2. Check the hole pattern on the mounting surface.
3. Screw 2 locating pins into the mounting surface and check that they
are fitted securely.
4. Lift the manipulator with fork lift truck or crane.
5. Clean the lower mounting surface on the robot (>>> 7.3.2 "Installing
the machine frame mounting assembly" Page 249).
6. Lower the robot vertically onto the mounting surface. Ensure that an
entirely vertical position is maintained in order to prevent damage to
the locating pins.
7. Insert 8 M20x60-8.8 Allen screws with conical spring washers.
8. Tighten 8 M20x60-8.8 Allen screws with a torque wrench in diagonally
opposite sequence. Increase the tightening torque to the specified val-
ue in several stages.

Fig. 7-7: Machine frame mounting, dimensioned drawing
1 Locating pin, cylindrical

2 M20x60-8.8-A2K hexagon screw with lock washer (8x)
3 Locating pin, flat-sided
NOTICE
Incorrectly adjusted pressure regulators or operation with no pressure
regulator may result in damage to the robot. For this reason, the robot
may only be operated with a correctly adjusted pressure regulator and
with the compressed air supply connected.
7.3.3 Removing KR IONTEC fork slots
Procedure
1. Remove the M16x35-8.8 Allen screws and lock washers.

2. Remove the Load Lifting Attachment.

KR IONTEC

Fig. 7-8: Removing the fork slots
7.3.4 Connecting the connecting cables
Procedure
1. Fasten the ground conductor between the robot controller and the ro-
bot to the ground conductor connection with 1 M8 hexagon nut includ-
ing conical spring washer; tightening torque MA= 15.0 Nm.
2. Fasten the ground conductor between the system component and the
robot to the ground conductor connection with 1 M8 hexagon nut in-
cluding conical spring washer; tightening torque MA= 15.0 Nm.
3. Connect data cable:
• KR C4: X31
• KR C5: XF31
When connecting the data cable connectors, it must be ensured that
the connector is locked correctly on the robot. Correct locking is ach-
ieved by closing the clip (>>> Fig. 7-9).
4. Connect motor cable:
• KR C4: X30
• KR C5: XD30
Push on the motor cable connector, insert 4 fastening screws and
tighten with tightening torque MA= 3.0 Nm.
5. Check the equipotential bonding in accordance with VDE 0100 and
EN 60204-1.
Further information is contained in the operating and assembly in-
structions of the robot controller.
6. Enter the installation position of the robot in WorkVisual. The default

installation position is the floor.

Fig. 7-9: Connecting the connecting cables

3 Data cable X31
4 Motor cable X30

• If applicable, mount the tool.
• Start up the robot system in accordance with the chapter “Start-up and
recommissioning” in the operating instructions for the robot controller.
• Put the robot system into operation in accordance with the documen-
tation for the system software.
7.4 Description of the connecting cables, KR C4
Configuration
The connecting cables are used to transfer power and data between the
robot controller and the robot.
The connecting cables comprise:
• Motor cable
• Data cable
Interface
For the connection of the connecting cables between the robot controller
and the robot, the following connectors are available on the junction box-
es.

KR IONTEC

Cable designation Connection
Robot controller - robot
Ground conductor / equi- M8 ring cable
potential bonding lug at both ends
16 mm2
Standard connecting cable
Fig. 7-10: Connecting cables, overview, KR C4
7.4.1 Description of the Motor cable
Cable overview
Fig. 7-11: Motor cable
1 X20
2 X30

Connector pin allocation
Connector pin allocation X20 Connector pin allocation X30
The contact assignment on the connector side is shown in each case.
Wiring diagram
X20 X30
Description
Pin Pin
a1 Motor M1 U 1
2 Motor M1 V 2
3 Motor M1 W 3
11 Brake + 19
12 Brake - 20
b1 Motor M2 U 4
2 Motor M2 V 5
3 Motor M2 W 6
11 Brake + 21
12 Brake - 22
c1 Motor M3 U 7
2 Motor M3 V 8
3 Motor M3 W 9
11 Brake + 23
12 Brake - 24
d1 Motor M4 U 10
4 Motor M4 V 11
6 Motor M4 W 12
3 Brake + 25
5 Brake - 26
e1 Motor M5 U 13
4 Motor M5 V 14
6 Motor M5 W 15
3 Brake + 27
5 Brake - 28
f1 Motor M5 U 16
4 Motor M5 V 17
6 Motor M5 W 18
3 Brake + 29
5 Brake - 30

KR IONTEC

X20 X30
Description
Pin Pin
Ground conductor
Housing Shield, all pins Housing
7.4.2 Description of the Data cable
Cable overview
Fig. 7-12: Data cable
1 X21
2 X31
Connector pin allocation X21 Connector pin allocation X31
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

X21 X31
Description
Pin Pin
2 24 V/PS1 with bat- 2
tery back-up
7.4.3 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
4 2x plain washer 9 Ground conductor connection
Ring cable lug
5 Hexagon nut 10 Ground sign
7.5 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 cable
• Data cable
Interface
For the connection of the connecting cables between the robot controller
and the robot, the following connectors are available on the junction box-
es.
robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30

KR IONTEC

robot
bonding both ends
16 mm2
Standard connecting cable
Fig. 7-14: Connecting cables, overview, KR C5

7.5.1 Description of the Motor cable
Cable overview
Fig. 7-15: Motor cable
1 XD20.x / XD10.x
2 XD30

Connector pin allocation XD30
XD20.x / XD10.x
Wiring diagram
XD20.x /
XD30
XD10.x
Description Pin
Pin
XD20.1 / 1 M1:U 1
XD20.1 / 2 M1:V 2
XD20.1 / 3 M1:W 3

KR IONTEC

XD20.x /
XD30
XD10.x
Description Pin
Pin
XD20.1 / PE PE1
PE
XD10.1 / M1_br_+ twisted 19
B:1
XD10.1 / M1_br_GND 20
A:1
Housing Shield B1, A1 Housing
XD20.2 / 1 M2:U 4
XD20.2 / 2 M2:V 5
XD20.2 / 3 M2:W 6
B:2
XD10.1 / M2_br_GND 22
A:2
XD20.3 / 1 M3:U 7
XD20.3 / 2 M3:V 8
XD20.3 / 3 M3:W 9
B:3
XD10.1 / M3_br_GND 24
A:3
XD20.4 / 1 M4:U 10
XD20.4 / 2 M4:V 11
XD20.4 / 3 M4:W 12
XD20.4 / PE PE2
PE
B:2
XD10.2 / M4_br_GND 26
A:1
XD20.5 / 1 M5:U 13
XD20.5 / 2 M5:V 14
XD20.5 / 3 M5:W 15
A:2
XD10.2 / M5_br_GND 28
A:1
Housing Shield A2, A1 Housing
XD20.6 / 1 M6:U 16
XD20.6 / 2 M6:V 17
XD20.6 / 3 M6:W 18

XD20.x /
XD30
XD10.x
Description Pin
Pin
A:3
XD10.2 / M6_br_GND 30
A:4
Housing Shield A3, A4 Housing
Housing Overall shield
7.5.2 Description of the Data cable
Cable overview
Fig. 7-16: Data cable
1 XF21
2 XF31
Connector pin allocation XF21 Connector pin allocation XF31
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

KR IONTEC

XF21 XF31
Pin Description Pin
2 Rx- 12
3 Tx+ 9
4 Tx- 11
7.5.3 Description of the ground conductor
Fig. 7-17: Connecting cable, ground conductor
1 Ground conductor 6 Conical spring washer

2 Hexagon nut 7 Robot
3 Conical spring washer 8 Setscrew
4 2x plain washer 9 Ground conductor connection
Ring cable lug
5 Hexagon nut 10 Ground sign
7.6 Description of overtravel protection on axis 4
The overtravel protection applies to all robot variants of the KR IONTEC

product family.
On axis A4 there is an orientation indicator consisting of the indicator an-
gle and the indicator pin.
If the mastering is lost, it is necessary to determine which side of the an-
gle the pin is on before addressing the premastering notch. The counter-
clockwise direction of rotation corresponds to minus and the clockwise di-
rection to plus.

Fig. 7-18: Overtravel protection A4
1 Position = 0°
2 Position = -175°
3 Position = +175°
If the pin is located on the left in the minus range, the premastering notch
must be addressed in the plus direction.
The premastering notch is addressed in the minus direction if the pin is
located on the right in the plus range.

KR IONTEC
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.
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 37). 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 227).
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.
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.

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

Maintenance
tion, shorter maintenance intervals must be observed. Please contact

KUKA Service for this.
8.1.1 Maintenance table, KR 20 R3100
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

KR IONTEC
Maintenance
Fig. 8-1: Maintenance chart, KR 20 R3100
Interval Item Task Auxiliary substances and

consumables
100 h 1 Check tightening torque for fastening
once after screws and nuts.
start-up and
recommis-
sioning
5 000 h - Carry out a visual inspection of visible
flexible tubes and check for damage.
In the case of damage and/or cracks,
have the cable set exchanged by
KUKA Service.
20 000 h 2 Grease cable set A1 Lubricating grease Optitemp
(>>> 8.2 "Greasing cable set A1" RB2
Page 269)
0.03 kg
20 000 h 3 Perform oil change on Optigear Synt. ALR 150
or 5 years gear unit A6.
Initial filling quantity: 0.23 l
at the latest (>>> 8.9.3 "Oil change in A6"
Page 300)
at the latest (>>> 8.9.2 "Oil change in A5"
Page 296)

Maintenance KR IONTEC

consumables
at the latest (>>> 8.9.1 "Oil change in A4 "
Page 293)
20 000 h 6 Perform oil change on Optigear ALR 320
at the latest (>>> 8.5 "Oil change in A3"
Page 278)
Page 274)
Page 271)
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 420)
The service life of the cable set corresponds to that of the robot, provi-
ded that programs are executed in the normal range. If, however, the
programs are at the limits, the service life of the cable set is reduced
and it may be necessary to exchange the cable set prematurely.
8.1.2 Maintenance table, KR IONTEC standard, Foundry and CR lite variants
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

KR IONTEC
Maintenance
Exchange component
Check toothed belt tension
Fig. 8-2: Maintenance chart, KR IONTEC standard, Foundry and CR

lite variants
Maintenance table, KR IONTEC, standard and CR lite variants

consumables
100 h 1 Check tightening torque for fastening -
once after screws and nuts.
start-up and
recommis-
sioning
5 000 h - Carry out a visual inspection of visible -
KUKA Service.
Page 269)
0.03 kg


consumables
Page 288)
Page 285)
Page 281)
Page 278)
Page 274)
Page 271)
Maintenance table, KR IONTEC, Foundry variants

consumables
Once only, af- 1 Check the tightening torque for an- -
ter chor nuts and holding-down bolts.
100 h
5 000 h - Carry out a visual inspection of visible -
KUKA Service.
Page 269)
0.03 kg
Page 288)
Page 285)
Page 281)

KR IONTEC
Maintenance
consumables
Page 278)
Page 274)
Page 271)
(>>> 12.2 "Auxiliary substances and consumables" Page 420)
The service life of the cable set corresponds to that of the robot, provi-
ded that programs are executed in the normal range. If, however, the
programs are at the limits, the service life of the cable set is reduced
and it may be necessary to exchange the cable set prematurely.
8.2 Greasing cable set A1
Description
The following sections describe the procedure for greasing cable set A1
on floor-mounted robots. For ceiling-mounted robots, proceed accordingly.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Set of combination wrenches -
6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 17;
19 mm
Brush -
Material

Lubricating grease Optitemp RB2 (>>> 12.2 "Aux- 0.03 kg
iliary substances
and consuma-
bles" Page 420)

Tightening torques

torques" Page 419)
en.
ones.
Precondition
• The robot is accessible in the area of axis 1
Work safety
WARNING
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.
WARNING
Direct contact with cable grease may have an adverse effect on health.
Wear protective gloves and personal protective equipment. The general
safety instructions and the safety data sheet must be observed.
8.2.1 Checking and greasing cable set A1
Procedure
1. Unscrew 6 M6x12-8.8-A2K Allen screws from the large cover plate on

the rotating column and carefully remove it.
2. Unscrew 4 M6x12-8.8-A2K Allen screws from the cover plate on the
base frame and carefully remove it.

KR IONTEC
Maintenance
Fig. 8-3: Greasing cable A1
1 Cover plate on rotating column

2 Cover plate on base frame
3. Carry out a visual inspection of the cable jacket and clean it.
If damage is detected, the cable set must be exchanged.
4. Grease the hollow shaft sleeve and the cable jacket in the contact
area with a brush.
Protective gloves must be worn!
5. After checking and greasing the cable jacket and hollow shaft sleeve,
screw the cover plate onto the base frame and the rotating column.

• Remove grease residue.
• To spread the grease out evenly, move A1 of the robot.
8.3 Oil change in A1
Description
The following sections describe the A1 gear oil change for floor-mounted
robots. For ceiling-mounted robots, the procedure is to be applied analo-
gously, but with the drain and filler holes reversed.
Equipment


Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 Nm to 30 Nm
Socket wrench set -
Receptacle -
Oil drain tube - M18x1.5 0000-265-680
Material

Optigear ALR 320 (>>> 12.2 "Aux- Initial filling
iliary substances quantity: 5.66 l
and consuma-
bles" Page 420)
Tightening torques

torques" Page 419)
en.
ones.
Preconditions
• Move robot axis A1 to minus 90°.

• The gear unit is at operating temperature.
• All magnetic screw plugs for the oil chamber of gear unit A1 are freely
accessible.
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.

KR IONTEC
Maintenance
WARNING
age to property.
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.
8.3.1 Draining the gear oil from A1
Procedure
1. Place a suitable receptacle next to the oil drain hole (>>> Fig. 8-4).
2. Carefully unscrew the M18x1.5 magnetic screw plug on the rotating
column for venting and close it again.
3. Remove the M18x1.5 magnetic screw plug from the base frame and
screw on the oil drain tube.
4. Remove the M18x1.5 magnetic screw plug from the rotating column
for venting and catch the oil as it drains out.
5. Store or dispose of oil in accordance with the pertinent regulations.
Fig. 8-4: Draining the gear oil from A1
1 Vent hole with M18x1.5 magnetic screw plug

2 Oil drain hole with M18x1.5 magnetic screw plug; alternative
3 Oil drain hole with M18x1.5 magnetic screw plug
4 M18x1.5 oil drain tube
5 Collection receptacle

8.3.2 Filling gear unit A1 with gear oil
1. Clean the magnetic screw plugs and check the sealing element; ex-
change the magnetic screw plug if damaged.
2. Connect the oil pump to the oil drain tube. The oil pump can also be
connected directly to the oil drain hole (>>> Fig. 8-5).
3. Unscrew the magnetic screw plug at the inspection hole.
4. Fill the amount of oil from below up to the lower edge of the inspec-
tion hole = vent hole using the oil pump.
5. Insert and tighten the M18x1.5 magnetic screw plug on the rotating
column and in the inspection hole; MA = 20 Nm.
6. Remove the oil pump from the oil drain hole or oil drain tube and
screw in M18x1.5 magnetic screw plug; MA = 20 Nm.
Fig. 8-5: Filling gear unit A1 with gear oil
1 M18x1.5 magnetic screw plug for venting

2 Inspection hole = vent hole

• Remove oil residue.
• Visual inspection, check for leaks.
• Run the program in T1 mode and look out for irregularities.
Description
Equipment

KR IONTEC
Maintenance
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 Nm to 30 Nm
Socket wrench set -
Receptacle -
Oil drain tube - M18x1.5 0000-265-680
Material

and consuma-
bles" Page 420)
Tightening torques

torques" Page 419)
en.
ones.
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.
Arbeitssicherheit
CAUTION
operating
CAUTION

WARNING
age to property.
tion.

Procedure
1. Place a suitable receptacle under the rotating column (>>> Fig. 8-6).
2. Carefully unscrew the upper M18x1.5 magnetic screw plug for venting
and close it again.
3. Remove the lower M18x1.5 magnetic screw plug on the rotating col-
umn.
It is easier to drain the oil if an M18x1.5 oil drain tube is screwed into
the oil drain hole.
4. Remove the upper M18x1.5 magnetic screw plug for venting and
catch the oil as it drains out.
5. Store or dispose of oil in accordance with the pertinent regulations.

2 Inspection hole for floor installation

KR IONTEC
Maintenance
Procedure
1. Clean both M18x1.5 magnetic screw plugs and check the sealing ele-
ment; exchange magnetic screw plugs if damaged.
2. Connect the oil pump to the oil drain tube. The oil pump can also be
connected directly to the oil drain hole (>>> Fig. 8-7).
3. Unscrew the M18x1.5 magnetic screw plug from the inspection hole.
tion hole using the oil pump.
5. Clean the M18x1.5 magnetic screw plug of the inspection hole and
check the sealing element; exchange if damaged.
Insert the M18x1.5 magnetic screw plug into the inspection hole and
tighten it; MA = 20 Nm.
6. Insert and tighten the upper M18x1.5 magnetic screw plug on the ro-
tating column; MA = 20 Nm.
7. Remove the oil pump from the oil drain hole or oil drain tube and
screw in M18x1.5 magnetic screw plug; MA = 20 Nm.

2 Inspection hole for floor installation
4 Oil drain pipe
5 Oil pump


Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 Nm to 30 Nm
Socket wrench set -
Receptacle -
KUKA oil pump 0000-180-812
Material

and consuma-
bles" Page 420)
Tightening torques

torques" Page 419)
en.
ones.
Preconditions
• The robot is in a position in which the oil filler hole and oil drain hole
on the gear unit of axis 3 are accessible.
• The arm and in-line wrist are in horizontal position.

KR IONTEC
Maintenance
Arbeitssicherheit
CAUTION
operating
CAUTION
WARNING
age to property.
tion.

1. Tilt the link arm slightly forward and move the arm to a horizontal po-
sition.
2. Place a receptacle under the oil drain hole (>>> Fig. 8-8).
and close it again.
4. Remove the lower M18x1.5 magnetic screw plug.
6. Store or dispose of the drained oil in accordance with the pertinent
regulations.


Procedure
1. Move the robot to the specified axis position. Axis A2 and axis A3 pro-
duce an angular position of 0° (>>> "Axis position for checking the fill
level on A3" Page 280).
ments; exchange magnetic screw plugs if damaged (>>> Fig. 8-9).
3. Connect the oil pump to the oil drain hole.
tion hole = vent hole.
5. Insert and tighten the M18x1.5 magnetic screw plug; MA = 20 Nm.
6. Remove the oil pump.
Axis position for checking the fill level on A3
Fill level Axis position

A3 A2 + A3 = 0 °

KR IONTEC
Maintenance
1 Inspection hole = vent hole with M18x1.5 magnetic screw plug

3 Oil pump

Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 Nm to 30 Nm
Socket wrench set -
Receptacle -


Material

and consuma-
bles" Page 420)
Tightening torques

torques" Page 419)
en.
ones.
Precondition

Arbeitssicherheit
CAUTION
operating
CAUTION
WARNING
age to property.
tion.

KR IONTEC
Maintenance
Procedure
1. Move the arm and in-line wrist into horizontal position (>>> Fig. 8-10).
2. Place a receptacle under the oil drain hole.
and close it again.
regulations.

Procedure
1. Move the robot to the specified axis position. The position of axes A2
and A3 must produce an angular sum of -68° at axis A4 so that the
oil level can be checked (>>> "Axis position for checking the fill level
on A4" Page 284).
ment; exchange magnetic screw plugs if damaged (>>> Fig. 8-11).

3. Connect the oil pump to the oil filler hole.

tion hole = vent hole.
5. Insert and tighten the M18x1.5 magnetic screw plug; MA
= 20 Nm.
6. Remove the oil pump.

A4 A2 + A3 = -68 °
1 Inspection hole = vent hole with M18x1.5 magnetic screw plug

2 Oil filler hole with M18x1.5 magnetic screw plug
3 Oil pump


KR IONTEC
Maintenance
Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 Nm to 30 Nm
Socket wrench set -
Receptacle -
Material

and consuma-
bles" Page 420)
Tightening torques

torques" Page 419)
en.
ones.
Precondition

Arbeitssicherheit
CAUTION
operating

CAUTION
WARNING
age to property.
tion.

Procedure
1. Move the arm and in-line wrist into horizontal position and turn axis
A4 so that the oil drain plug on axis A5 is at the lowest point.
and close it again.
regulations.

KR IONTEC
Maintenance

Procedure
1. Move the robot to the specified axis position. The positions of axes A2
and A3 must produce 0° and axis A4 must be at -77° so that the oil
level can be checked (>>> "Axis position for checking the fill level on
A5" Page 287).
4. Fill the amount of oil up to the lower edge of the inspection hole =
vent hole, and insert and tighten the M10x1.0 magnetic screw plug;
MA = 7.5 Nm.
5. Remove the oil pump, and insert and tighten the M10x1.0 magnetic
screw plug; MA = 7.5 Nm.

A5 A2 + A3 = 0 °
A4 = -77°


2 M10x1.0 magnetic screw plug
3 Oil filler hole
4 Oil pump

Description
Equipment

KR IONTEC
Maintenance
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 Nm to 30 Nm
Socket wrench set -
Receptacle -
Material

and consuma-
bles" Page 420)
Tightening torques

torques" Page 419)
en.
ones.
Precondition

Arbeitssicherheit
CAUTION
operating
CAUTION

WARNING
age to property.
tion.

Procedure
1. Move the arm and in-line wrist into horizontal position. Turn axis A4 so
that both M10x1.0 magnetic screw plugs on axis A6 are located at the
lowest point.
2. Place the receptacle below the oil drain opening (>>> Fig. 8-14).
and close it again.
regulations.


KR IONTEC
Maintenance
Procedure
1. Move the robot to the specified axis position. The positions of axes A2
and A3 must produce 0°, axis A5 must be at 0° and axis A4 at +53°
so that the oil level can be checked (>>> "Axis position for checking
the fill level on A6" Page 291).
4. Fill the amount of oil up to the lower edge of the inspection hole =
vent hole, and insert and tighten the M10x1.0 magnetic screw plug;
MA = 7.5 Nm.
5. Remove the oil pump, and insert and tighten the M10x1.0 magnetic
screw plug; MA = 7.5 Nm.

A6 A2 + A3 = 0 °
A5 = 0°
A4 = 53°


2 M10x1.0 magnetic screw plug
3 Oil filler hole
4 Oil pump


KR IONTEC
Maintenance
8.9 KR 20 R3100
8.9.1 Oil change in A4
Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 Nm to 30 Nm
Socket wrench set -
Receptacle -
Funnel -
Oil drain tube - M18x1.5 0000-265-680
Material

Optigear Synt. ALR 150 (>>> 12.2 "Aux- Initial filling
and consuma-
bles" Page 420)
Tightening torques

torques" Page 419)
en.
ones.

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.
Precondition

Arbeitssicherheit
CAUTION
operating
CAUTION
WARNING
age to property.
tion.

8.9.1.1 Draining the gear oil from A4
Procedure
1. Move the arm and in-line wrist into horizontal position (>>> Fig. 8-16).

KR IONTEC
Maintenance
2. Place a receptacle under the oil drain hole.
and close it again.
4. Remove the lower M18x1.5 magnetic screw plug and screw in the
M18x1.5 oil drain tube.
6. Measure the amount of oil drained and store or dispose of the used
oil in accordance with the pertinent regulations.

8.9.1.2 Filling gear unit A4 with gear oil
Procedure
2. Remove M18x1.5 oil drain tube.
3. Insert and tighten the lower M18x1.5 magnetic screw plug;
MA = 20 Nm.
4. From the determined quantity of oil, fill the new oil from above using a
funnel.
5. Insert and tighten the upper M18x1.5 magnetic screw plug;
MA = 20 Nm.
6. Check both magnetic screw plugs for leaks.


2 Funnel
3 M18x1.5 magnetic screw plug for oil drain hole
8.9.1.3 Concluding work

Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 Nm to 30 Nm
Socket wrench set -
Receptacle -
Funnel -
Oil drain tube - M10x1 0000-265-663

KR IONTEC
Maintenance
Material

and consuma-
bles" Page 420)
Tightening torques

torques" Page 419)
en.
ones.
Refilling quantity
CAUTION
Precondition

Arbeitssicherheit
CAUTION
operating

CAUTION
WARNING
age to property.
tion.

Procedure
1. Move the arm and in-line wrist into horizontal position and turn axis
A4 so that the oil drain plug on axis A5 is at the lowest point.
and close it again.
5. Screw in the M10x1.0 oil drain tube.

KR IONTEC
Maintenance

Procedure
MA = 7.5 Nm.
funnel.
MA = 7.5 Nm.


2 Funnel
3 Oil filling hose

Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 Nm to 30 Nm
Socket wrench set -
Receptacle -
Funnel -
Oil drain tube - M10x1 0000-265-663

KR IONTEC
Maintenance
Material

and consuma-
bles" Page 420)
Tightening torques

torques" Page 419)
en.
ones.
Refilling quantity
CAUTION
Precondition

Arbeitssicherheit
CAUTION
operating

CAUTION
WARNING
age to property.
tion.

Procedure
1. Move the arm and in-line wrist into horizontal position. Turn axis A4 so
that both M10x1.0 magnetic screw plugs on axis A6 are located at the
lowest point.
2. Place the receptacle below the oil drain opening (>>> Fig. 8-20).
and close it again.
5. Screw in the M10x1.0 oil drain tube.

KR IONTEC
Maintenance

2 Oil drain hole, M10x1.0 magnetic screw plug
3 M10x1.0 oil drain hose
Procedure
MA = 7.5 Nm.
funnel.
MA = 7.5 Nm.

1 Oil filling hose with funnel


8.10 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

Permissible cleaning tools (e.g. cloths, -
brushes)
Material

Neutral cleaning agents - -
solvent-free, water-soluble, non-flamma-
ble, non-aggressive, no steam, no refrig-
erants, chlorine-free, not strongly acidic,
not strongly alkaline

KR IONTEC
Maintenance
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.
8.10.1 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.

• 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.


KR IONTEC
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.
9.1 Exchanging motor A1
Description
The following instructions describe the exchange of the motor. This de-
scription applies to floor-mounted robots. If the robot is installed in an in-
clined or suspended position, the procedure is to be applied analogously.
During removal of the motor, the robot can independently move about this
axis. Mechanical auxiliary equipment (e.g. support, crane) or a stable end
position (e.g. buffer) can be used to secure against motions.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Brush -
SEMD/MEMD mastering kit 0000-228-936
Material

SPP Motor 3,4 kW S0 ME 0000-352-524 1
For the following machines:
• KR 20 R3100
• KR 30 R2100
• KR 50 R2100
• KR 50 R2500
• KR 70 R2100

Repair KR IONTEC
Procurement of spare parts
Defective components must only be replaced with original spare parts

from KUKA Deutschland GmbH. Non-compliance nullifies warranty and lia-
bility claims.
A “Repair Card” is supplied with the exchange parts. This must be com-
pleted and returned to KUKA Deutschland GmbH together with the defec-
tive component in the following cases.
• Within the warranty period
• If, after consultation with KUKA Deutschland GmbH, an examination of
the defective component by KUKA is required.
Tightening torques

torques" Page 419)
en.
ones.
Precondition
• The robot is secured by means of an EMERGENCY STOP device. It

must be ensured that the robot cannot be switched on by unauthor-
ized persons.
Work safety
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
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.

KR IONTEC
Repair
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.
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 right-angle con-
nectors (>>> Fig. 9-1).
2. Unscrew 4 M10x25-8.8-A2K Allen screws.
3. Release and carefully lift out motor A1, taking care not to tilt it.
4. Cover the aperture on gear unit input shaft A1 and protect it against
fouling.
5. If the motor is not to be reinstalled, it must be disposed of properly or
protected against corrosion before being put into storage.

Repair KR IONTEC
Fig. 9-1: Motor A1
1 Motor A1
2 Connector XP1
3 Connector XM1
4 M10x25-8.8-A2K Allen screw
5 Rotating column
9.1.2 Installing motor A1
Procedure
1. If a new motor is to be installed, remove any corrosion protection it

may have prior to installation (>>> Fig. 9-2).
2. Clean the involute toothing of motor A1 and gear unit input shaft A1
before installation and apply a thin but continuous coat of Microlube
GL 261 grease.
3. Clean the mounting surface for motor A1.
4. Check the condition of the O-ring on the motor shaft; exchange if nec-
essary.
5. Position right-angle connectors XM1 and XP1 as shown.
6. Insert motor A1, taking care not to tilt it.
Insertion of motor can be facilitated by turning it gently about its ro-
tational axis.
7. Insert 4 M10x25-8.8-A2K Allen screws.

8. Tighten 4 M10x25-8.8-A2K Allen screws with a torque wrench in diag-
onally opposite sequence. Increase the tightening torque to the speci-
fied value in several stages.

KR IONTEC
Repair
9. Plug connectors XM1 and XP1 into the right-angle connectors. The
pins and coding elements of the connectors must be taken into con-
sideration. When inserting the connectors, turn them until they clearly
lock into the coding elements (twist-proof).
Fig. 9-2: Motor A1
1 Motor A1
2 Connector XP1
3 Connector XM1
5 Rotating column

• Move A1 of the robot and look out for irregularities.
• Carry out mastering of A1.
Detailed information about mastering can be found in the system
software documentation.
• Test the program in Manual Reduced Velocity (T1) mode.

Repair KR IONTEC
Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
ty
Rope sling with sufficient load-bearing -
capacity
Brush -
Material

SPP Motor 3,4 kW S0 ME 0000-352-524 1
• KR 20 R3100
• KR 30 R2100
• KR 50 R2100
SPP Motor 4,2kW S0 ME 0000-352-674 1
• KR 50 R2500
• KR 70 R2100

bility claims.

KR IONTEC
Repair
Tightening torques

torques" Page 419)
en.
ones.
Precondition

ized persons.
• The removal site is freely accessible for work tasks involving a crane.
Work safety
DANGER
Danger to life and limb due to defective or unsuitable load suspen-
sion devices
If defective or non-approved load suspension devices are used, the load
may fall off or start to swing. Failure to observe this can lead to death,
injury or property damage.
• Before using load suspension devices, check for defects (e.g. dam-
age, corrosion, deformation, wear, cracks) and exchange compo-
nents if necessary.
• Use only inspected and approved load suspension devices.
• Use only load suspension devices with a sufficient load-bearing ca-
pacity.
WARNING
sult.
1. De-energize

Repair KR IONTEC
WARNING
CAUTION
NOTICE
damage.
9.2.1 Securing the link arm
Procedure
1. Secure the link arm with a rope sling and attach the rope sling to the
crane hook.
2. Raise the rope sling until it is taut.
Fig. 9-3: Securing the link arm

KR IONTEC
Repair
Procedure
fouling.
Fig. 9-4: Motor A2

2 Motor A2
3 Connector XM2
4 Connector XP2
5 Rotating column
Procedure

GL 261 grease.
essary.

Repair KR IONTEC

tational axis.

Fig. 9-5: Motor A2

2 Motor A2
3 Connector XM2
4 Connector XP2
5 Rotating column
9.2.4 Removing the equipment securing the link arm
Procedure
1. Slacken the rope sling and detach from the crane.

2. Remove the rope sling from the robot.

KR IONTEC
Repair

Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm

Repair KR IONTEC

Socket wrench set -
ty
capacity
Brush -
Material

SPP Motor 2,8kW S0 ME 0000-352-675 1

bility claims.
Tightening torques

torques" Page 419)
en.
ones.
Precondition

ized persons.

KR IONTEC
Repair
Work safety
DANGER
sion devices
nents if necessary.
pacity.
WARNING
sult.
1. De-energize
WARNING
CAUTION
NOTICE
damage.

Repair KR IONTEC
9.3.1 Securing the in-line wrist and robot arm
Procedure
1. Secure the in-line wrist and robot arm with a rope sling and attach the
rope sling to the crane hook.
2. Move the crane upwards until the rope sling is taut.
Fig. 9-7: Securing robot arm
9.3.2 Removing cover A3
Procedure
1. Unscrew 14 M6x16-8.8-A2K Allen screws from cover A3. Take the

cover off the robot arm.

KR IONTEC
Repair
Fig. 9-8: Cover A3
1 In-line wrist
2 Robot arm
4 Cover
Procedure
fouling.

Repair KR IONTEC
Fig. 9-9: Motor A3
1 Robot arm
3 Motor A3
4 Connector XM3
5 Connector XP3
Procedure

GL 261 grease.
essary.
tational axis.

8. Tighten 4 M8x22-8.8-A2K Allen screws with a torque wrench in diago-
nally opposite sequence. Increase the tightening torque to the speci-

KR IONTEC
Repair
Fig. 9-10: Motor A3
1 Robot arm
3 Motor A3
4 Connector XM3
5 Connector XP3
9.3.5 Mounting the cover
Procedure
1. Place the cover on the robot arm and fasten in place using 14
M6x16-8.8-A2K Allen screws. Tighten the screws in diagonally oppo-
site sequence.

Repair KR IONTEC
Fig. 9-11: Cover A3
1 In-line wrist
2 Robot arm
4 Cover
9.3.6 Removing the equipment securing the in-line wrist and robot arm
Procedure

2. Remove rope sling from the in-line wrist and robot arm.

KR IONTEC
Repair

• Test the program in Manual Reduced Velocity mode (T1).
9.4 KR IONTEC Foundry
9.4.1 Exchanging motor A1
Description

Repair KR IONTEC
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Brush -
Material

SPP motor 3.4kW S0 ME Foundry (w/o 0000-387-992 1
adh.)

bility claims.
Tightening torques

torques" Page 419)
en.
ones.
Precondition

ized persons.

KR IONTEC
Repair
Work safety
WARNING
sult.
1. De-energize
WARNING
CAUTION
NOTICE
damage.
9.4.1.1 Removing motor A1
Procedure
4. Remove the seal and dispose of it.
fouling.

Repair KR IONTEC
Fig. 9-13: Motor A1 Foundry
1 M10x25-8.8-A2K Allen screw (4x)

2 Motor A1
3 O-ring 23x4
4 Seal
9.4.1.2 Installing motor A1
Procedure

GL 261 grease.
essary.
6. Insert a seal.
tational axis.

KR IONTEC
Repair
Fig. 9-14: Motor A1 Foundry

2 Motor A1
3 O-ring 23x4
4 Seal


Repair KR IONTEC
Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
ty
capacity
Brush -
Material

SPP motor 4.2kW S0 ME Foundry (w/o 0000-387-993 1
adh.)

bility claims.
Tightening torques

torques" Page 419)
en.

KR IONTEC
Repair
ones.
Precondition

ized persons.
Work safety
DANGER
sion devices
nents if necessary.
pacity.
WARNING
sult.
1. De-energize
WARNING
CAUTION

Repair KR IONTEC
NOTICE
damage.
9.4.2.1 Securing the link arm
Procedure
1. Secure the link arm with a rope sling and attach the rope sling to the
crane hook.
2. Raise the rope sling until it is taut.
Procedure
4. Remove the seal and dispose of it.
fouling.

KR IONTEC
Repair
Fig. 9-16: Motor A2

2 Motor A2
3 O-ring 23x4
4 Seal
Procedure

GL 261 grease.
essary.
6. Insert a seal.
tational axis.

Repair KR IONTEC

Fig. 9-17: Motor A2

2 Motor A2
3 O-ring 23x4
4 Seal
9.4.2.4 Removing the equipment securing the link arm
Procedure

2. Remove the rope sling from the robot.

KR IONTEC
Repair

9.5 KR 20 R3100
Description
Equipment

Repair KR IONTEC

ty
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Brush -
Material

SPP motor 1,0kW (K0) ME 0000-375-962 1

bility claims.
Tightening torques

torques" Page 419)
en.
ones.
Precondition

ized persons.
• Tools have been removed.
• There is no hazard posed by other system components.

KR IONTEC
Repair
Work safety
DANGER
sion devices
nents if necessary.
pacity.
WARNING
sult.
1. De-energize
WARNING
CAUTION
NOTICE
damage.

KR IONTEC
9.5.1.1 Securing the in-line wrist and robot arm

Repair
Procedure
9.5.1.2 Removing cover A3
Procedure


KR IONTEC
Repair
Fig. 9-20: Cover A3
1 Arm extension
2 Robot arm
4 Cover
Procedure
1. Unscrew 2 M6x12-8.8-A2K Allen screws each from both holders.

Mark the position of cable strap on the cable. Cut off the cable strap
at the first holder.
2. Remove holder from the robot arm.
Carefully cut off cable strap on plug-in connection A6 (far right) with
diagonal cutting pliers.
Remove plug-in connection A6 from the holder and disconnect it.
3. Unscrew 18 M6x35-8.8-A2K Allen screws between the in-line wrist
with arm extension and the arm.
Carefully pull the in-line wrist with arm extension a little way out.
4. Remove grounding from in-line wrist with arm extension. Release and
unplug connectors XM4/XP4 and XM5/XP5 at the right-angle connec-
tors.
5. Remove the in-line wrist with arm extension and set it down on a pre-
pared support.
6. Unscrew 4 M5x14-8.8 Allen screws from motor A4 and pull out the
motor. Do not tilt while removing.

Repair KR IONTEC
Fig. 9-21: KR 20 R3100 – Removing/installing motors A4 and A5
1 M5x14-8.8-A2K Allen screw (4x per motor)

2 Motor A4
3 Motor A5
4 Sinuous spring 0.25x11.43x15.88 (2x)
5 Connecting shaft R3100 (2x)
6 Arm extension
7 M6x35-8.8-A2K Allen screw with conical spring washer (18x)
7. Pull the sinuous spring off the motor.

Procedure
1. If a new motor is to be installed, remove any corrosion protection prior

to installation.
2. Clean the toothing on connecting shaft A4 and check for wear.
In the case of damage and/or wear, connecting shaft A4 must be ex-
changed.
3. Apply a thin but continuous coat of Microlube GL 261 to the toothing
on connecting shaft A4.
4. Mount motor A4 onto the connecting shaft together with the lock
washer and sinuous spring. Do not tilt while fitting.

KR IONTEC
Repair
Fig. 9-22: Motor with connecting shaft
1 Connecting shaft (according to robot type)

2 Lock washer
3 Sinuous spring
4 Motor
5. Insert 4 M5x14-8.8 Allen screws and tighten with a torque wrench in

diagonally opposite sequence. Increase the tightening torque to the
specified value in several stages.
6. Lift the in-line wrist and arm extension to the height of the arm using a
sling and crane.
7. Pull the cable for motor A6 through the arm.
8. Plug connectors XM4/XP4 and XM5/XP5 into the right-angle connec-
tors. 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). Reconnect ground-
ing to in-line wrist with arm extension.

Repair KR IONTEC

2 Motor A4
3 Motor A5
6 Arm extension
9. Clean the surface between the in-line wrist with arm extension and the
arm and apply a thin but continuous coat of Drei Bond 5204HV adhe-
sive.
10. Attach the in-line wrist with arm extension to the arm using 18
M6x35-8.8 A2K Allen screws and tighten the screws with a torque
wrench in diagonally opposite sequence. Increase the tightening tor-
que to the specified value in several stages.
11. Fasten the motor cable to the first holder at the marked position with a
cable strap.
12. Plug the plug connection A6 back together and fasten the holder (far
right position) using a cable strap.
13. Fasten both holders with 2 M6x12-8.8-A2K Allen screws each.
9.5.1.5 Mounting the cover
Procedure
site sequence.

KR IONTEC
Repair
Fig. 9-24: Cover A3
1 Arm extension
2 Robot arm
4 Cover
9.5.1.6 Removing the equipment securing the in-line wrist and robot arm
Procedure


Repair KR IONTEC

• Move A4, A5 and A6 of the robot and look out for irregularities.
• Carry out mastering of A4, A5 and A6.
Description
Equipment

ty

KR IONTEC
Repair
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Brush -
Material

SPP motor 1,0kW (K0) ME 0000-375-962 1

bility claims.
Tightening torques

torques" Page 419)
en.
ones.
Precondition

ized persons.

Repair KR IONTEC
Work safety
DANGER
sion devices
nents if necessary.
pacity.
WARNING
sult.
1. De-energize
WARNING
CAUTION
NOTICE
damage.

KR IONTEC
Repair
Procedure
Procedure


Repair KR IONTEC
Fig. 9-27: Cover A3
1 Arm extension
2 Robot arm
4 Cover
Procedure

4. Carefully pull the in-line wrist with arm extension a little way out.
tors.
pared support.

KR IONTEC
Repair

2 Motor A4
3 Motor A5
6 Arm extension

Procedure

to installation.
changed.

Repair KR IONTEC

2 Lock washer
3 Sinuous spring
4 Motor
5. Insert 4 M5x14-8.8-A2K Allen screws and tighten with a torque wrench

in diagonally opposite sequence. Increase the tightening torque to the
sling and crane.

KR IONTEC
Repair

2 Motor A4
3 Motor A5
6 Arm extension
sive.
10. Attach the in-line wrist with arm extension to the arm using 18 Allen
screws and tighten the screws with a torque wrench in diagonally op-
posite sequence. Increase the tightening torque to the specified value
in several stages.
cable strap.
Procedure
site sequence.

Repair KR IONTEC
Fig. 9-31: Cover A3
1 Arm extension
2 Robot arm
4 Cover
Procedure


KR IONTEC
Repair

9.5.3 Exchanging motor A6 and in-line wrist
Description
The following instructions describe the exchange of the motor and in-line
wrist. This description applies to floor-mounted robots. If the robot is in-
stalled in an inclined or suspended position, the procedure is to be
applied analogously.
During removal of the motor and in-line wrist, the robot can independently
move about this axis. Mechanical auxiliary equipment (e.g. support, crane)
or a stable end position (e.g. buffer) can be used to secure against mo-
tions.
Equipment

Repair KR IONTEC

ty
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Brush -
Material

SPP motor 0,6kW (K0) ME 0000-375-971 1
SPP IW 16/22 (w/o adh.) 0000-375-752 1

bility claims.
Tightening torques

torques" Page 419)
en.
ones.
Precondition

ized persons.
• The robot is secured against axis motions.
• Tools and any attachments have been removed.

KR IONTEC
Repair
Work safety
DANGER
sion devices
nents if necessary.
pacity.
WARNING
sult.
1. De-energize
WARNING
CAUTION
NOTICE
damage.

KR IONTEC

Repair
Procedure
Procedure


KR IONTEC
Repair
Fig. 9-34: Cover A3
1 Arm extension
2 Robot arm
4 Cover
Procedure

tors.
pared support.

Repair KR IONTEC

2 Motor A4
3 Motor A5
6 Arm extension

Procedure

tors.
pared support.

KR IONTEC
Repair

2 Motor A4
3 Motor A5
6 Arm extension

9.5.3.5 Removing motor A6 and in-line wrist
Procedure
1. Pull the connecting shafts out of the arm extension.

2. Unscrew 2 M6x12-8.8-A2K Allen screws from the cable holder of mo-
tor cable A6 and detach from the arm extension.
3. Unscrew 16 M6x35-8.8-A2K Allen screws from the arm extension and
remove the in-line wrist from the arm extension.
nectors.
5. Release motor A6 and pull it out of the in-line wrist, being careful not
to tilt it.

Repair KR IONTEC
Fig. 9-37: KR 20 R3100 – Removing/installing motor A6 and

in-line wrist
1 In-line wrist
Fig. 9-38: KR 20 R3100 – Connecting motor A6
1 Partition plate
2 Connectors XM6 and XP6
3 Motor A6

9.5.3.6 Preparing the new in-line wrist
Procedure
1. Remove all protective coatings and oil from new in-line wrist, if appli-
cable.
2. Clean all toothing before installation and apply a thin but continuous
coat of Microlube GL 261 grease.

KR IONTEC
Repair
NOTICE
When installing the in-line wrist, it must be ensured that the toothing
of the in-line wrist and connecting shafts is not damaged. Increased
wear and premature failure may result.
9.5.3.7 Installing motor A6 and in-line wrist
Procedure

to installation.
3. Grease the involute toothing.
4. Insert the sinuous spring and fit motor A6 into the in-line wrist. Do not
tilt while fitting.
6. Clean the surface between the in-line wrist and the arm extension and
apply a thin but continuous coat of Drei Bond 5204HV adhesive.
7. Plug connectors XM6 and XP6 into the right-angle connectors.
Fig. 9-39: KR 20 R3100 – Connecting motor A6
1 Partition plate
2 Connectors XM6 and XP6
3 Motor A6
8. Place the in-line wrist on the arm extension, taking care not to tilt it.
9. Insert 16 M6x35-8.8-A2K Allen screws into the arm extension and
tighten with a torque wrench in diagonally opposite sequence.

Repair KR IONTEC
Fig. 9-40: KR 20 R3100 – Removing/installing motor A6 and

in-line wrist
1 In-line wrist
10. Screw cable holder for motor cable A6 to the arm extension using 2
M6x12-8.8-A2K Allen screws.
11. Clean connecting shafts A4 and A5 and grease with Microlube
GL 261.
Guide the connecting shafts into the arm extension with a mandrel (or
on motor shaft without sinuous spring) and fit them onto the corre-
sponding shafts of the in-line wrist.
Procedure

to installation.
changed.

KR IONTEC
Repair

2 Lock washer
3 Sinuous spring
4 Motor

sling and crane.

Repair KR IONTEC

2 Motor A4
3 Motor A5
6 Arm extension
sive.
in several stages.
cable strap.
Procedure

to installation.
changed.

KR IONTEC
Repair

2 Lock washer
3 Sinuous spring
4 Motor

sling and crane.

Repair KR IONTEC

2 Motor A4
3 Motor A5
6 Arm extension
sive.
cable strap.
Procedure
site sequence.

KR IONTEC
Repair
Fig. 9-45: Cover A3
1 Arm extension
2 Robot arm
4 Cover
Procedure


Repair KR IONTEC

9.5.4 Exchanging the connecting shafts
Description
The following instructions describe the procedure for exchanging connect-

ing shafts A4 and A5. The connecting shafts must always be exchanged
as a pair. This description applies to floor-mounted robots. If the robot is
installed in an inclined or suspended position, the procedure is to be ap-
plied analogously.
Equipment

ty

KR IONTEC
Repair
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Brush -
Material

SPP shaft KR 20 R3100 COS (w/o adh.) 0000-376-145 1

bility claims.
Tightening torques

torques" Page 419)
en.
ones.
Precondition
• The robot must be prevented from tipping. If necessary, fasten the ro-
bot to the mounting base.
• The robot is secured against axis motions.

Repair KR IONTEC
Work safety
DANGER
sion devices
nents if necessary.
pacity.
WARNING
sult.
1. De-energize
WARNING
CAUTION
NOTICE
damage.

KR IONTEC
Repair
Procedure
Procedure


Repair KR IONTEC
Fig. 9-48: Cover A3
1 In-line wrist
2 Robot arm
4 Cover
Procedure

tors.
pared support.

KR IONTEC
Repair

2 Motor A4
3 Motor A5
6 Arm extension

Procedure

tors.
pared support.

Repair KR IONTEC

2 Motor A4
3 Motor A5
6 Arm extension

Procedure

to installation.
changed.

KR IONTEC
Repair

2 Lock washer
3 Sinuous spring
4 Motor

sling and crane.

Repair KR IONTEC

2 Motor A4
3 Motor A5
6 Arm extension
sive.
in several stages.
cable strap.
Procedure

to installation.
changed.

KR IONTEC
Repair

2 Lock washer
3 Sinuous spring
4 Motor

sling and crane.

Repair KR IONTEC

2 Motor A4
3 Motor A5
6 Arm extension
sive.
cable strap.
Procedure
site sequence.

KR IONTEC
Repair
Fig. 9-55: Cover A3
1 In-line wrist
2 Robot arm
4 Cover
Procedure


Repair KR IONTEC

9.6 Description of the electrical installations
Overview
The electrical installations of the robot consist of:

• Cable set
• Micro RDC box
Description
The electrical installations consist of the cable set from A1 to A3 with mi-
cro RDC as well as the cable set from A4 to A6. The cable sets include
all the supply and control cables for the motors of axes 1 to 6 as well as
the cables for the protective circuit.
Micro RDCs are explained in more detail in the operating instructions of
the robot controller.
The interface for connecting the connecting cables to the robot is located
on the base frame at the rear of the robot. The interfaces X30, X31 and
ground conductor (PE) bolts are located on interface A1. The connecting

KR IONTEC
cables from the controller – such as motor cable X30, data cable X31 and
Repair
the ground conductor – are connected here by means of connectors.
The selected routing of cables and hoses within the robot arm ensures
that they are guided without strain or kinking throughout the entire motion
range of the robot
The following diagram gives an overview of the installation and routing of
the cables and hoses on the manipulator (>>> Fig. 9-58).
Fig. 9-57: KR 20 R3100 electrical installations, overview
1 Motor A6 5 Motor A2
3 Motor A4 7 Micro RDC box
4 Motor A3 8 Interface A1

Repair KR IONTEC
Fig. 9-58: KR 30/50/70 R2100 and KR 50 R2500 electrical installations,

overview
3 Motor A4 7 Micro RDC box
4 Motor A3 8 Interface A1
Wiring diagrams
Designation Connection Figure

Wiring diagram XM1; XP1
(>>> Fig. 9-59)
A1_KS-A3
Wiring diagram
XM2; XP2 (>>> Fig. 9-60)
A2_KS A1-A3

KR IONTEC
Repair
Designation Connection Figure
Wiring diagram
XM3; XP3 (>>> Fig. 9-61)
A3_KS A1-A3
Wiring diagram
XM4; XP4 (>>> Fig. 9-62)
A4_KS A1-A3
Wiring diagram
XM5; XP5 (>>> Fig. 9-63)
A5_KS A1-A3
Wiring diagram
XM6; XP6 (>>> Fig. 9-64)
A6_KS A1-A3
Wiring diagram
XM5.1 (>>> Fig. 9-65)
A5_KS A4-A6
Wiring diagram
XM6.1 (>>> Fig. 9-66)
A6_KS A4-A6
Data cable RDC X31 RDC X31 (>>> Fig. 9-67)
Data cable RDC X32 RDC X32 (>>> Fig. 9-68)
Protective circuit Ring cable lug (>>> Fig. 9-70)
Fig. 9-59: Wiring diagram, axis A1_KS A1-A3

Repair KR IONTEC

KR IONTEC
Repair

Repair KR IONTEC

KR IONTEC
Repair

Repair KR IONTEC

KR IONTEC
Repair
Fig. 9-65: Wiring diagram, axis A5_KS A4-A6, KR 30/50/70 R2100 and
KR 50 R2500

Repair KR IONTEC
Fig. 9-66: Wiring diagram, axis A6_KS A4-A6, KR 30/50/70 R2100 and
KR50 R2500
Fig. 9-67: Wiring diagram, RDC X31

KR IONTEC
Repair
Fig. 9-68: Wiring diagram, RDC X32
Fig. 9-69: Wiring diagram, protective circuit, KR 20 R3100
1 Ground conductor, arm – wrist

Cross-section: 4 mm2
2 Ground conductor, rotating column – arm
3 Ground conductor, RDC box – connection plate

Repair KR IONTEC
4 Ground conductor, connection plate – rotating column

5 Ground conductor, interface plate – connection plate and RDC box
6 Ground conductor, interface plate A1 – base frame
7 Ground conductor, interface plate A1 – holding plate
8 External ground conductor (KRC)
9 External ground conductor / system potential
Fig. 9-70: Wiring diagram, protective circuit, KR 30/50/70 R2100 and

KR 50 R2500
1 Ground conductor, wrist main body – wrist swivel housing

Cross-section: 1.5 mm2
2 Ground conductor, arm – wrist main body
Cross-section: 1.5 mm2
3 Ground conductor, arm – spur gear housing
4 Ground conductor, rotating column – arm
5 Ground conductor, RDC box – connection plate
6 Ground conductor, connection plate – rotating column

KR IONTEC
Repair
7 Ground conductor, connection plate and RDC box
8 Ground conductor, interface plate A1 – base frame
9 Ground conductor, interface plate A1 – holding plate
10 External ground conductor (KRC)
11 External ground conductor / system potential

Repair KR IONTEC

KR IONTEC
Decommissioning, storage and disposal

10 Decommissioning, storage and disposal
10.1 Decommissioning
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 rope
slings and a crane (>>> 6 "Transportation" Page 235).
Equipment

Lifting tackle/rope sling with sufficient 0000-355-288
load-bearing capacity
ty
Fork lift truck with sufficient load-bearing -
capacity
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Precondition
• The removal site must be accessible with a crane or with a fork lift
truck for transportation.
• There is no hazard posed by system components.
Work safety
WARNING
bot.
10.1.1 Moving the robot into its transport position
Procedure
1. Secure the robot by pressing the EMERGENCY STOP device.

2. Remove tools and equipment.
3. Put the robot into operation and move it into the transport position.

Decommissioning, storage and disposal KR IONTEC
4. Secure the robot by activating the EMERGENCY STOP device and

then shut down the robot.
Transport position
A1 0 °
A2 -125 °
A3 150 °
A4 0 °
A5 -115 °
A6 0 °
Fig. 10-1: Transport position
10.1.2 Removing the robot
1. Release and unplug all peripheral connections.

2. Release and unplug the motor cable and data cable connectors.
3. Unscrew the M8 hexagon nut from the ground conductor, take off the
washers and lock washers and pull off the ground conductor.
4. Unscrew 8 M20x60-8.8-A2K hexagon bolts.
5. Lift the robot vertically off the mounting surface using a crane or fork
lift truck and transport it away.
Take care not to damage the 2 locating pins when lifting.
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.

KR IONTEC

Fig. 10-2: Removing the robot
1 Sealing air connection (for Foundry only)

3 Data cable X31
4 Motor cable X30
5 Fork slots (optional) attachment
6 Approved lifting accessory for lifting tackle
7 Hexagon bolts and locating pin

• Prepare the robot for storage if the robot is not to be reinstalled.
10.2 Storage
Description
For storage, the robot must be removed, cleaned and suitably covered.
Storage location
The storage location must meet the following requirements:

• Virtually dry and free of dust
• Avoid temperature fluctuations
• Avoid wind and drafts
• Avoid condensation
• No exposure to direct sunlight

• Maintain the permissible temperature ranges for storage

• The packaging film cannot be damaged.
Equipment

ty
Torque wrench -
min. 2 to 20 Nm
Permissible cleaning tools (e.g. cloths, -
brushes)
Material

Covers - -
that cannot detach themselves and which
can withstand the expected environmen-
tal conditions.
Packaging material, - As
e.g. bags for storing small parts needed
Cleaning agent - -
solvent-free, water-soluble, non-flamma-
ble, non-aggressive, not strongly acidic
or alkaline, no steam, no refrigerants
Precondition
• Loose parts or parts that might knock against other parts have been
removed from the robot.
• Tools and equipment have been removed.
Work safety
WARNING
bot.

KR IONTEC

10.2.1 Removing the robot
1. Release and unplug all peripheral connections.

2. Release and unplug the motor cable and data cable connectors.
3. Unscrew the M8 hexagon nut from the ground conductor, take off the
washers and lock washers and pull off the ground conductor.
4. Unscrew 8 M20x60-8.8-A2K hexagon bolts.
5. Lift the robot vertically off the mounting surface using a crane or fork
lift truck and transport it away.
Take care not to damage the 2 locating pins when lifting.
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.
Fig. 10-3: Removing the robot
1 Sealing air connection (for Foundry only)

3 Data cable X31
4 Motor cable X30
5 Fork slots (optional) attachment
6 Approved lifting accessory for lifting tackle
7 Hexagon bolts and locating pin

10.2.2 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.
10.2.3 Preparing for storage
Procedure
1. Perform a visual inspection of the robot.

2. Remove any foreign bodies.
3. Remove any corrosion.
4. Attach all covers to the robot and check that the seals are correctly in
place.
5. Seal off electrical connections with suitable covers.
6. Seal hose connections by suitable means.
7. Cover the robot with plastic film and seal it at the base frame against
dust.
If necessary, add a desiccant beneath the sheeting.
No concluding work is required.
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.
Material Subassembly, component Additional information
Metal
Cast alumi- Wrist, arm, link arm, rotat-
num ing column
Copper Cables, wires
Cast steel Base frame
Steel Gear units, screws, wash-
ers, metal covers, stops
Electrical parts

KR IONTEC

Material Subassembly, component Additional information
Electronic components, Dispose of as electrical
such as RDC, EDS, etc. scrap without disassem-
bling
Motors Dispose of motors without
dismantling them.
Plastics
ABS Enclosure panels, covers
ETFE Flexible tube
FKM Shaft sealing rings
NBR O-rings
PA Hinged clamps
PE End stop buffers
PU Hoses
PUR Cable sheaths
Auxiliary substances and consumables
Gear oil Gear units Optigear Synt. ALR 150
Optigear ALR 320
Adhesive Base frame, rotating col- Adhesive and sealant Drei
and sealant umn, link arm Bond type 1305
Rotating column, arm, in- Adhesive and sealant Drei
line wrist Bond type 1342
Base frame, rotating col- Adhesive and sealant Drei
umn, link arm, arm, in-line Bond 5204HV
wrist
Lubricating Gear teeth Microlube GL 261 grease
grease Cabling Lubricating grease Opti-
temp RB2
Rolling-contact bearing PETAMO GHY 133 N lubri-
grease cating grease
(>>> 12.2 "Auxiliary substances and consumables" Page 420).


KR IONTEC
Options
11 Options
11.1 Release device
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 A3. It is only for use in exceptional circumstances and
emergencies (e.g. for freeing people).
The release device is mounted on the rotating column of the manipulator.
This assembly also includes a ratchet, two TORX key wrenches, one long
key wrench and a set of plates with one plate for each motor. The plate
specifies the direction of rotation for the ratchet and shows the corre-
sponding direction of motion of the manipulator.
In order to move the manipulator without drive energy in the event of an
accident or malfunction, either a sufficient number of release devices or a
sufficient amount of suitable standard tools must be available.
Fig. 11-1: Release device on the robot
1 Key wrench
2 Release device
Basic data

Release device 0000-348-346 approx. 3 kg
Further information about the ambient conditions is contained in the as-

sembly instructions for the robot and robot controller.
(>>> 11.1.1 "Starting up the release device" Page 404)

Options KR IONTEC
Maintenance
If used for its intended purpose, the option requires minimal maintenance,
i.e. visual inspections are recommended. In certain operating conditions,
regular visual inspections may allow timely detection of changes. The na-
ture and scope of the maintenance work depend very much on the specif-
ic area of application. This enables early detection of damage, thereby
preventing failure of components and assemblies. Exchange damaged
components or assemblies.
Disposal
When the release device reaches the end of its useful life, it can be dis-
posed of. The materials must be disposed of in accordance with the perti-
nent regulations and, where possible, separated and sorted for recycling.
11.1.1 Starting up the release device
Description
The release device (optional) for axis 1 to axis 3 can be used for moving
the manipulator after an accident or malfunction without drive energy.
This option is only for use in exceptional circumstances and emergencies,
e.g. for rescuing people.
Equipment

Slotted screwdriver -
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
5 Nm to 50 Nm
Material

Release device 0000-348-346 1
or - 1 each
12 mm combination wrench and TORX
key wrench TX25 and TX30
Tightening torques

torques" Page 419)
en.
ones.

KR IONTEC
Options
Precondition

Work safety
SAFETY INSTRUCTION
CAUTION
Loss of mastering during movement without drive energy
After moving a motor without drive energy, the axis is no longer mas-
tered. Injuries or damage to property may result.
• Remaster all axes.
11.1.1.1 Installing the release device
Procedure
1. Position the clip plate on the rotating column, insert 2 M16x25-8.8-A2K

Allen screws and fasten in place. Increase the tightening torque to the
2. Place the release device and key wrench on the clip plate.
Fig. 11-2: Installing the release device
1 Clip plate
2 TORX 30 key wrench
3 TORX 25 key wrench
4 Hexagon key wrench, long, 5 mm
5 Release device, long
6 M16x25 Allen screw

Options KR IONTEC
7 Conical spring washer
3. Attach the arrow adhesive labels to the cast housing in the vicinity of
the respective motors as shown in the illustration (>>> Fig. 11-3).
Fig. 11-3: Location of arrow adhesive labels
1 Arrow adhesive label A3

11.1.1.2 Moving the manipulator without drive energy
Procedure
1. The motors for axis 1 and axis 2 are not directly accessible. The
cover for the axis 3 motor must first be unscrewed.

KR IONTEC
Options
Fig. 11-4: Cover A3
1 In-line wrist
2 Robot arm
4 Cover
2. Remove the 4 screws on each of the motor covers for the axis 1 and
axis 2 motors using a TX30 key wrench and take the cover off the
corresponding motor. For the axis 3 motor, the 4 screws of the motor
cover are unscrewed using a TX25 key wrench.
The cover can be removed from the motor more easily by lifting it out
using a slotted screwdriver in the groove.
Fig. 11-5: Motor cover, levering groove
1 Levering groove for slotted screwdriver
3. Push the release device (or 12 mm combination wrench) onto the cor-
responding motor and move the axis in the desired direction.
It is necessary to overcome the resistance of the mechanical motor
brake and any other loads acting on the axis.

Options KR IONTEC
Fig. 11-6: Motor with release device
1 Motor
2 Motor cover
3 Release device
4. Remove any dirt from the motor and cover.

5. Mount the cover on the motor and insert and tighten 4 M6x20 TORX
screws.
TX25: MA = 3.5 - 5 Nm
TX30: MA = 6 - 9 Nm

• Master all axes.
• Perform brake test.
• Carry out a test run in T1 mode and look out for irregularities.
11.2 Purge option A
Description
Compressed air preparation system PURGE option A consists of a service

unit and a pressure regulator unit. The service unit prepares the com-
pressed air so that it contains no dirt particles, water or chemical contami-
nation. The pressure regulator unit limits the operating pressure of the
system and compensates for pressure fluctuations.
A compressed air supply with 1 to 12 bar can be connected to the service
unit.
The compressed air preparation system is not suitable for installation in a
hygiene area.

KR IONTEC
Options
Fig. 11-7: PURGE option A
1 Compressed air supply connection

2 Service unit, air
3 Holder for pressure regulator
4 Pressure regulator unit
5 Robot connection
Basic data

PURGE option A 0000-363-924 approx. 5.1 kg


(PURGE)
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)
Maintenance

Options KR IONTEC
Disposal
When the option reaches the end of its useful life, it can be removed and
disposed of. The materials must be disposed of in accordance with the
pertinent regulations and, where possible, separated and sorted for recy-
cling.
11.3 Purge option B
Description
Compressed air preparation system PURGE option B consists of a pres-

sure regulator unit that limits the operating pressure of the system and
compensates for pressure fluctuations.
hygiene area.
Fig. 11-8: PURGE option B
1 Compressed air connection

3 Pressure regulator unit
4 Robot connection
Basic data

PURGE option B 0000-363-925 approx. 1.7 kg


(PURGE)

KR IONTEC
Options
Maintenance
Disposal
cling.
11.4 Purge option C
Description
The functional principle of compressed air preparation system PURGE op-

tion C corresponds to that of PURGE option A. It is additionally equipped
with a holder for installation on the base frame. The option consists of a
service unit and a pressure regulator unit. The service unit prepares the
compressed air so that it contains no dirt particles, water or chemical con-
tamination. The pressure regulator unit limits the operating pressure of the
system and compensates for pressure fluctuations.
A compressed air supply with 1 to 12 bar can be connected to the service
unit.
hygiene area.
Fig. 11-9: PURGE option C
Basic data

PURGE option C 0000-363-926 approx. 5.9 kg


Options KR IONTEC

(PURGE)
(>>> 11.4.1 "Starting up PURGE option C" Page 412)
Maintenance
Disposal
cling.
11.4.1 Starting up PURGE option C
Description
The PURGE option can be used to prepare compressed air for cleaning
purposes.
This section describes all work required to put PURGE option C into oper-
ation.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
5 Nm to 50 Nm
Material

PURGE option C 0000-363-926 1

KR IONTEC
Options
Tightening torques

torques" Page 419)
en.
ones.
Precondition

Work safety
SAFETY INSTRUCTION
WARNING
Use of the option PURGE is limited to cleaning work. Use during run-
ning operation is precluded in order to prevent the emission of foreign
particles.
11.4.1.1 Installing PURGE option C
Procedure
1. Screw the holder for the pressure regulator and the pressure regulator
together to the plate using 2 M4x6-8.8 Allen screws (>>> Fig. 11-10).
2. Screw this assembly to the bracket with 2 M4x6-8.8 Allen screws.
3. Screw the air service unit to the bracket using 2 M4x10-8.8 Allen
screws with washers.
4. Position the bracket with assembly on the base frame and insert and
tighten 2 M6x16-8.8 hexagon bolts. Increase the tightening torque to
the specified value in several stages.
5. Connect compressed air hose to interface A1.

Options KR IONTEC
Fig. 11-10: Installing PURGE option C

2 M6x16 hexagon bolt (2x)
3 Bracket
4 M4x10 Allen screw with washer (2x)
5 Service unit, air
6 M4x6 Allen screw (2x)
7 Plate
8 Pressure regulator
M4x6 Allen screw (2x)
10 Robot connection with plastic hose


KR IONTEC
Options
11.5 Purge option D
Description
The functional principle of compressed air preparation system PURGE op-

tion D corresponds to that of PURGE option B. It is additionally equipped
with a holder for installation on the base frame. The option consists of a
pressure regulator unit that limits the operating pressure of the system
and compensates for pressure fluctuations.
hygiene area.
Fig. 11-11: PURGE option D
Basic data

PURGE option D 0000-363-927 approx. 2.4 kg


(PURGE)
(>>> 11.5.1 "Starting up PURGE option D" Page 416)
Maintenance

KR IONTEC
Options

Disposal
cling.
11.5.1 Starting up PURGE option D
Description
The PURGE option can be used to prepare compressed air for cleaning
purposes.
This section describes all work required to put PURGE option D into oper-
ation.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
5 Nm to 50 Nm
Material

PURGE option D 0000-363-927 1
Tightening torques

torques" Page 419)
en.
ones.
Precondition

Work safety
SAFETY INSTRUCTION

KR IONTEC
Options
WARNING
Use of the option PURGE is limited to cleaning work. Use during run-
ning operation is precluded in order to prevent the emission of foreign
particles.
11.5.1.1 Installing PURGE option D
Procedure
1. Screw the holder for the pressure regulator and the pressure regulator
together to the bracket using 2 M4x6-8.8 Allen screws
(>>> Fig. 11-12)
2. Position the bracket with assembly on the base frame and insert and
tighten 2 M6x16-8.8 hexagon bolts. Increase the tightening torque to
the specified value in several stages.
3. Connect compressed air hose to interface A1.
Fig. 11-12: Installing PURGE option D

2 M6x16 hexagon bolt (2x)
3 Bracket
M4x6 Allen screw (2x)
5 Pressure regulator
6 Robot connection with plastic hose

KR IONTEC

Options


KR IONTEC
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.

Appendix KR IONTEC
12.2 Auxiliary substances and consumables
Product designation / Use Manufacturer designation /

Article number Address
Drei Bond type 1305 Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 13
0000-184-175
D-85737
Ismaning
Germany
Drei Bond type 1342 Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 13
0000-184-174
D-85737
Ismaning
Germany
Drei Bond type 5204HV Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 13
0000-251-505
D-85737
Ismaning
Germany
Loctite 510 Surface sealant Henkel AG & Co. KGaA

Henkelstrasse 67
0000-241-832
D-40191
Düsseldorf
Germany
Microlube GL 261 Lubricating grease Klüber Lubrication München KG

Geisenhausenerstr. 7
0000-135-463
D-81379
Munich
Germany
PETAMO GHY 133 N Lubricating grease Klüber Lubrication München KG

Geisenhausenerstr. 7
0000-269-159
D-81379
Munich
Germany
Optitemp RB 2 Lubricating grease Deutsche BP Aktiengesellschaft - In-

dustrial Lubricants & Services
0000-101-456
Erkelenzer Strasse 20
D-41179
Mönchengladbach
Germany

KR IONTEC
Appendix
Optigear Synt. Gear oil BP Europa SE
ALR 150_EEA Geschäftsbereich Industrieschmierstoffe
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.
Optigear ALR 320_EEA Gear oil BP Europa SE

Geschäftsbereich Industrieschmierstoffe
0000-383-412 for Europe-
an Economic Area
D-41179
Optigear ALR 320_AM1 Mönchengladbach
Germany
0000-405-915 for USA,
Mexico, Chile, Peru,
Ecuador
Optigear Synt.
ALR 320_APeC1
0000-405-917 for Taiwan,
Japan, Thailand, South
Korea, Malaysia
Article numbers for further
regions can be found in
KUKA Xpert.

12.3 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)

Appendix KR IONTEC
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
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 IEC 61000-6-2:2019 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards – Immunity for industrial environments
EN IEC 61000-6-4:2019 Electromagnetic compatibility (EMC):

Part 6-4: Generic standards; Emission standard for industrial envi-
ronments
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

KR IONTEC
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

KUKA Service KR IONTEC

KR IONTEC
Index Cleaning work.................................................35

Connecting cable, standard.................253, 257
2006/42/EC................................................... 421
Connecting cables........................... 17, 23, 232
2014/30/EU................................................... 422
Connecting cables, connecting............245, 251
95/16/EC....................................................... 421
Connecting cables, KR C4.. 40, 53, 67, 81, 95,
109, 124, 137, 151, 166, 179, 252
Connecting cables, KR C5.. 40, 54, 68, 82, 96,
A 110, 124, 138, 152, 166, 180, 256
Accessories.............................................. 17, 23 Connecting shafts, exchanging.................... 368
Angle of rotation............................................. 13 Consumables used.......................................420
ANSI/RIA R15.06-2012................................ 422 Counterbalancing system............................... 35
Appendix....................................................... 419 CR...................................................................12
Arctic............................................................... 12
Automatic mode..............................................34
Auxiliary substances used............................420
Axis data, KR 20 R3100................................41
D
Danger zone.............................................13, 25
Axis data, KR 30 R2100................................54
Declaration of conformity............................... 24
Axis data, KR 30 R2100 CR lite................... 68
Declaration of incorporation.....................23, 24
Axis data, KR 50 R2100................................82
Decommissioning................................... 36, 395
Axis data, KR 50 R2100 CR lite................... 96
Description of the robot system.....................17
Axis data, KR 50 R2500.............................. 110
Diagnosis package....................................... 423
Axis data, KR 50 R2500 CR lite................. 138
Dimensions, transport...................................235
Axis data, KR 50 R2500 F.......................... 124
Dimensions, transportation...........................235
Axis data, KR 70 R2100..............................152
Directives...................................................... 421
Axis data, KR 70 R2100 CR lite................. 180
Disclaimer....................................................... 23
Axis data, KR 70 R2100 F.......................... 166
Disposal......................................... 36, 395, 400
Axis limitation, mechanical............................. 28
Documentation, industrial robot......................11
Axis range................................................ 12, 24
Drei Bond type 1305....................................420
Drei Bond type 1342....................................420
Drei Bond type 5204HV...............................420
B Dynamic Set................................................. 239
Base frame...............................................19, 20
Basic data, KR 20 R3100..............................39
Basic data, KR 30 R2100..............................52
Basic data, KR 30 R2100 CR lite................. 66
E
EC declaration of conformity......................... 24
Basic data, KR 50 R2100..............................80
EDS.................................................................12
Basic data, KR 50 R2100 CR lite................. 94
EDS cool.........................................................12
Basic data, KR 50 R2500............................108
Electrical installations...................... 19, 20, 380
Basic data, KR 50 R2500 CR lite............... 136
Electromagnetic compatibility (EMC)........... 422
Basic data, KR 50 R2500 F........................ 122
Electromagnetic compatibility (EMC):.......... 422
Basic data, KR 70 R2100............................150
EMC Directive........................................ 24, 422
Basic data, KR 70 R2100 CR lite............... 178
EMD................................................................ 13
Basic data, KR 70 R2100 F........................ 164
EN 60204-1:2018......................................... 422
Brake defect................................................... 29
EN 61000-6-2:2005...................................... 422
Brake release device......................................28
EN 61000-6-4:2007 + A1:2011.................... 422
Braking distance.......................................12, 24
EN 61000-6-4:2019...................................... 422
EN 614-1:2006+A1:2009..............................422
EN IEC 61000-6-2:2019...............................422
C EN ISO 10218-1:2011.................................. 422
C..................................................................... 12 EN ISO 12100:2010..................................... 422
Cable set A1, checking and greasing......... 270 EN ISO 13849-1:2015..................................422
Cable set A1, greasing................................ 269 EN ISO 13849-2:2012..................................422
CE mark..........................................................24 EN ISO 13850:2015..................................... 422
Center of gravity...........................................235 Equipment.....................................................404
Center of mass ....45, 58, 72, 86, 100, 114, ESD..... 40, 54, 68, 82, 96, 110, 138, 152, 180
128, 142, 156, 170, 184 EX................................................................... 13
Certificates.. 40, 54, 68, 82, 96, 110, 138, 152, Extension........................................................ 12
180 External axes..................................................23
Clean Room....................................................12 External axis.............................................15, 26
Cleaning the robot........................................304

KR IONTEC
F Interface, energy supply system..................233

F......................................................................13 Interfaces...................................................... 232
F exclusive......................................................13 Introduction..................................................... 11
Faults.............................................................. 31
Flange loads....47, 61, 75, 89, 103, 117, 131,
145, 159, 173, 187 K
Fork lift truck.................................................236 K......................................................................13
Foundation loads, KR 20 R3100................... 50 KCP....................................................13, 25, 30
Foundation loads, KR 30 R2100................... 64 Keyboard, external......................................... 30
Foundation loads, KR 30 R2100 CR lite...... 78 KR................................................................... 13
Foundation loads, KR 50 R2100................... 92 KR C............................................................... 13
Foundation loads, KR 50 R2100 CR lite.... 106 KS................................................................... 13
Foundation loads, KR 50 R2500................. 120 KUKA Customer Support............................. 423
Foundation loads, KR 50 R2500 CR lite.... 148 KUKA Service...............................................423
Foundation loads, KR 50 R2500 F............. 134 KUKA smartPAD................................13, 17, 25
Foundation loads, KR 70 R2100................. 162 KUKA smartPAD-2................................... 13, 25
Foundation loads, KR 70 R2100 CR lite.... 190
Foundation loads, KR 70 R2100 F............. 176
Foundry mounting flange D=100.........130, 172 L
Foundry robots..................................... 123, 165 Labeling.......................................................... 29
Foundry, equipment............................. 123, 165 Lifting tackle......................................... 236, 237
Function test................................................... 32 Linear unit.......................................................23
Link arm..........................................................19
Location, arrow adhesive labels.................. 406
G Loctite 510.................................................... 420
Gear unit A1, draining oil.............................273 Low Voltage Directive.....................................24
Gear unit A1, filling with oil......................... 274
Gear unit A2, draining oil.............................276
Gear unit A2, filling with oil......................... 277 M
Gear unit A3, draining oil.................... 279, 280 Machine frame mounting..............................230
Gear unit A3, filling with oil................. 280, 281 Machine frame mounting, installing............. 249
Gear unit A4, draining oil............283, 294, 295 Machinery Directive................................24, 421
Gear unit A4, filling with oil 283, 284, 295, 296 Main axes..................................................... 195
Gear unit A5, draining oil... 286, 287, 298, 299 Maintenance........................................... 34, 263
Gear unit A5, filling with oil 287, 288, 299, 300 Maintenance symbols.......................... 264, 266
Gear unit A6, draining oil............290, 302, 303 Maintenance table, KR 20 R3100............... 264
Gear unit A6, filling with oil 291, 292, 303, 304 Maintenance table, KR IONTEC standard,
General safety measures............................... 29 Foundry and CR lite variants.......................266
Ground conductor................................ 256, 261 Manipulator........................... 13, 17, 18, 23, 25
Manual mode..................................................33
Mass..45, 58, 72, 86, 100, 114, 128, 142, 156,
H 170, 184
HA................................................................... 13 Mass moments of inertia...45, 59, 73, 87, 101,
Handling equipment.....................237, 241, 248 115, 129, 143, 157, 171, 185
Hazardous substances................................... 36 Material designation..................................... 400
HI.................................................................... 13 Mechanical end stops.................................... 27
HM.................................................................. 13 MEMD............................................................. 13
HO...................................................................13 micro RDC...................................................... 13
HP................................................................... 13 Microlube GL 261.........................................420
HW.................................................................. 13 Misuse.............................................................21
Motion velocity................................................14
Motor A1, exchanging..........................307, 325
I Motor A1, installing.............................. 310, 328
In-line wrist/arm.............................................. 19 Motor A1, removing............................. 309, 327
Industrial robot................................................23 Motor A2, exchanging..........................312, 330
Industrial Robots and Robot System...........422 Motor A2, installing.............................. 315, 333
Information for planning............................... 227 Motor A2, removing............................. 315, 332
Interface A1.................................................. 232 Motor A3, exchanging.................................. 317
Interface, connecting cables................252, 256 Motor A3, installing.......................................322
Motor A3, removing......................................321

KR IONTEC
Motor A4, exchanging.................................. 335 Planning........................................................ 227

Motor A4, installing......................340, 364, 376 Plant integrator............................................... 25
Motor A4, removing.....................339, 357, 372 Plates and labels..........................................192
Motor A5, exchanging.................................. 344 Positioner........................................................ 23
Motor A5, installing......................349, 362, 374 POV................................................................ 14
Motor A5, removing.....................348, 358, 373 PPE.................................................................26
Motor A6 and in-line wrist, exchanging.......353 Preparing for storage................................... 400
Motor A6 and in-line wrist, installing........... 361 Pressure Equipment Directive........................35
Motor A6 and in-line wrist, removing.......... 359 Pressure regulator................................123, 165
Mounting base with centering............. 227, 239 Preventive maintenance work........................ 35
Mounting flange.............................................. 19 Principal components..................................... 18
Mounting flange D=100... 60, 74, 88, 102, 116, Product description.........................................17
144, 158, 186 Program override............................................14
Mounting flange D=50....................................46 Protective equipment, overview..................... 27
Mouse, external.............................................. 30 Purge
MT...................................................................13 Option A.................................................. 408
Option B.................................................. 410
Option C...................................................411
N Option D.................................................. 415
New in-line wrist, preparing......................... 360 PURGE option C
Start-up.................................................... 412
PURGE option D
Start-up.................................................... 416
O
Oil change, A1..............................................271
Oil change, A2..............................................274
Oil change, A3..............................................278 R
Oil change, A4..................................... 281, 293 RDC................................................................ 14
Oil change, A5..................................... 285, 296 RDC cool........................................................ 14
Oil change, A6..................................... 288, 300 Reaction distance.....................................12, 24
Oil temperatures........................................... 264 Recommissioning................................... 31, 239
Operators........................................................ 27 Refilling quantity.......................... 294, 297, 301
Optigear ALR 320........................................ 421 Regulations................................................... 421
Optigear Synt. ALR 150...............................421 Release device.............................. 28, 403, 408
Option............................................................. 17 Start-up.................................................... 404
Options.............................................20, 23, 403 Removing ............................................ 244, 250
Optitemp RB 2..............................................420 Repair..................................................... 34, 307
Overload......................................................... 29 Robot controller........................................17, 23
Overtravel protection.................................... 261 Robot with mounting base, installation........242
Rotating column....................................... 19, 20
P
P......................................................................13 S
PA................................................................... 13 Safety..............................................................23
Payload diagram....46, 59, 73, 87, 101, 115, Safety instructions.......................................... 11
129, 143, 157, 171, 185 Safety of machinery..................................... 422
Payloads, KR 20 R3100................................ 44 Safety zone.............................................. 25, 27
Payloads, KR 30 R2100................................ 57 Safety, general................................................23
Payloads, KR 30 R2100 CR lite....................71 SC................................................................... 14
Payloads, KR 50 R2100................................ 85 SE................................................................... 14
Payloads, KR 50 R2100 CR lite....................99 Service life...................................................... 25
Payloads, KR 50 R2500...............................114 SI.....................................................................14
Payloads, KR 50 R2500 CR lite..................142 SL....................................................................14
Payloads, KR 50 R2500 F...........................128 smartPAD........................................... 14, 25, 30
Payloads, KR 70 R2100.............................. 155 Software................................................... 17, 23
Payloads, KR 70 R2100 CR lite..................183 Spare parts....308, 312, 318, 326, 330, 336,
Payloads, KR 70 R2100 F...........................169 345, 354, 369
Personal protective equipment...................... 26 SPP.................................................................13
Personnel........................................................26 Standards......................................................421
PETAMO GHY 133 N.................................. 420 Start-up...................................................31, 239
Phi...................................................................13

KR IONTEC
Starting up robots (machine frame WP.................................................................. 14

mounting)...................................................... 246
Starting up robots (mounting base).............239
STOP 0.........................................................195
STOP 1.........................................................195
Stop categories........................................ 14, 25
Stop signal....................................................195
Stopping distance............................ 12, 24, 195
Stopping distances....195, 196, 201, 207, 213,
219
Stopping time................................................196
Stopping times... 195, 196, 201, 207, 213, 219
Storage...........................................36, 395, 397
Supplementary load...48, 62, 76, 90, 104, 118,
132, 146, 160, 174, 188
Support request............................................ 423
System integrator..................................... 24–26
T
T1 (operating mode)................................ 14, 25
T2 (operating mode)................................ 14, 25
Teach pendant......................................... 17, 23
Technical data.................................................37
Technical data, KR 20 R3100........................39
Technical data, KR 30 R2100 CR lite........... 66
Technical data, KR 50 R2100 CR lite........... 94
Technical data, KR 50 R2500......................108
Technical data, KR 50 R2500 CR lite......... 136
Technical data, KR 50 R2500 F.................. 122
Technical data, KR 70 R2100......................150
Technical data, KR 70 R2100 CR lite......... 178
Technical data, KR 70 R2100 F.................. 164
Technical data, overview................................ 37
Terms used..................................................... 12
Terms, safety.................................................. 24
Tightening torques........................................419
Training...........................................11, 263, 307
Transport position......................................... 235
Transportation........................................ 31, 235
Transportation by fork lift truck.................... 237
Transportation of robot.................................235
Transportation with lifting tackle (optional).. 237
Turn-tilt table...................................................23
U
Use
Intended..................................................... 20
User.......................................................... 24, 26
Users...............................................................11
W
W.....................................................................14
Warnings......................................................... 11
Wiring diagrams, electrical installations.......382
Workspace......................................... 12, 24, 27

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Robots

Publication: Pub MA KR IONTEC (PDF) en

Book structure: MA KR IONTEC V11.1

Version: MA KR IONTEC V10

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4.4.3 Payloads, KR 30 R2100 CR lite........................................................................... 71

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4.15.2.3 Stopping distances and stopping times, STOP 1, A2.......................................... 199

7 Start-up and recommissioning............................................................... 239

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7.4.2 Description of the Data cable............................................................................... 255

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8.9.3.1 Draining the gear oil from A6............................................................................... 302

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9.5.2.3 Removing motor A5.............................................................................................. 348

10 Decommissioning, storage and disposal............................................. 395

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11.3 Purge option B...................................................................................................... 410

13 KUKA Service........................................................................................... 423

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1.1 Target group

This documentation is aimed at users with the following knowledge and

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

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

1.3 Representation of warnings and notes

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

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

edy emergencies or malfunctions:

Procedures marked with this warning must be followed exactly.

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

1.4 Terms used

Stopping distance Stopping distance = reaction distance + braking distance

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

EDS Electronic Data Storage

EDS cool Electronic Data Storage cool

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SPP Spare parts package

F exclusive Foundry exclusive

KCP KUKA Control Panel

KR C KUKA Robot Control

KUKA smartPAD see “smartPAD”

KUKA smartPAD-2 see “smartPAD”

Manipulator The robot arm and the associated electrical installations

MEMD Micro Electronic Mastering Device

micro RDC micro Resolver Digital Converter

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RDC Resolver Digital Converter

RDC cool Resolver Digital Converter

smartPAD Teach pendant for the robot controller

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

T2 For KUKA iiQKA.OS: not relevant at present

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