Robots

KR CYBERTECH nano-2
Assembly Instructions

Issued: 04.04.2022
MA KR CYBERTECH nano-2 V6
KUKA Deutschland GmbH
KR CYBERTECH nano-2

© Copyright 2022
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 CYBERTECH nano-2 (PDF) en

PB15976

Book structure: MA KR CYBERTECH nano-2 V3.1

BS14416

Version: MA KR CYBERTECH nano-2 V6

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Contents

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

2 Product description................................................................................. 13
2.1 Overview of the robot system............................................................................... 13
2.2 Description of the manipulator.............................................................................. 14
2.3 Intended use and misuse...................................................................................... 16

3 Safety......................................................................................................... 19
3.1 General.................................................................................................................. 19
3.1.1 Disclaimer.............................................................................................................. 19
3.1.2 EC declaration of conformity and declaration of incorporation............................ 20
3.1.3 Terms in the “Safety” chapter............................................................................... 20
3.2 Personnel............................................................................................................... 22
3.3 Workspace, safety zone and danger zone........................................................... 23
3.4 Overview of protective equipment........................................................................ 24
3.4.1 Mechanical end stops........................................................................................... 24
3.4.2 Mechanical axis limitation (optional)..................................................................... 24
3.4.3 Options for moving the manipulator without drive energy................................... 25
3.4.4 Labeling on the industrial robot............................................................................ 25
3.5 Safety measures.................................................................................................... 26
3.5.1 General safety measures...................................................................................... 26
3.5.2 Transportation........................................................................................................ 27
3.5.3 Start-up and recommissioning.............................................................................. 28
3.5.4 Manual mode......................................................................................................... 29
3.5.5 Automatic mode..................................................................................................... 30
3.5.6 Maintenance and repair........................................................................................ 31
3.5.7 Decommissioning, storage and disposal.............................................................. 33

4 Technical data.......................................................................................... 35
4.1 Technical data, overview....................................................................................... 35
4.2 Technical data, KR 6 R1840-2.............................................................................. 36
4.2.1 Basic data, KR 6 R1840-2.................................................................................... 36
4.2.2 Axis data, KR 6 R1840-2...................................................................................... 38
4.2.3 Payloads, KR 6 R1840-2...................................................................................... 42
4.2.4 Foundation loads, KR 6 R1840-2......................................................................... 48
4.3 Technical data, KR 8 R1640-2.............................................................................. 50
4.3.1 Basic data, KR 8 R1640-2.................................................................................... 50
4.3.2 Axis data, KR 8 R1640-2...................................................................................... 52
4.3.3 Payloads, KR 8 R1640-2...................................................................................... 56
4.3.4 Foundation loads, KR 8 R1640-2......................................................................... 62
4.4 Technical data, KR 10 R1440-2............................................................................ 64
4.4.1 Basic data, KR 10 R1440-2.................................................................................. 64
4.4.2 Axis data, KR 10 R1440-2.................................................................................... 66

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4.4.3 Payloads, KR 10 R1440-2.................................................................................... 70

4.4.4 Foundation loads, KR 10 R1440-2....................................................................... 76
4.5 Plates and labels................................................................................................... 78
4.6 REACH duty to communicate information acc. to Art. 33................................... 80
4.7 Stopping distances and stopping times with KR C5 micro.................................. 81
4.7.1 General information............................................................................................... 81
4.7.2 Stopping distances and times, KR 6 R1840-2..................................................... 82
4.7.2.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 82
4.7.2.2 Stopping distances and stopping times for STOP 1, axis 1................................ 83
4.7.2.3 Stopping distances and stopping times for STOP 1, axis 2................................ 85
4.7.2.4 Stopping distances and stopping times for STOP 1, axis 3................................ 87
4.7.3 Stopping distances and times, KR 8 R1640-2..................................................... 89
4.7.3.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 89
4.7.3.2 Stopping distances and stopping times for STOP 1, axis 1................................ 90
4.7.3.3 Stopping distances and stopping times for STOP 1, axis 2................................ 92
4.7.3.4 Stopping distances and stopping times for STOP 1, axis 3................................ 94
4.7.4 Stopping distances and times, KR 10 R1440-2................................................... 96
4.7.4.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 96
4.7.4.2 Stopping distances and stopping times for STOP 1, axis 1................................ 97
4.7.4.3 Stopping distances and stopping times for STOP 1, axis 2................................ 99
4.7.4.4 Stopping distances and stopping times for STOP 1, axis 3................................ 101
4.7.4.5 Stopping distances and stopping times, STOP 0, A1 to A3............................... 102
4.8 Stopping distances and stopping times with KR C5 S........................................ 103
4.8.1 General information............................................................................................... 103
4.8.2 Stopping distances and times, KR 6 R1840-2..................................................... 104
4.8.2.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 104
4.8.2.2 Stopping distances and stopping times, STOP 1, A1.......................................... 105
4.8.2.3 Stopping distances and stopping times, STOP 1, A2.......................................... 107
4.8.2.4 Stopping distances and stopping times, STOP 1, A3.......................................... 109
4.8.3 Stopping distances and times, KR 8 R1640-2..................................................... 111
4.8.3.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 111
4.8.3.2 Stopping distances and stopping times, STOP 1, A1.......................................... 112
4.8.3.3 Stopping distances and stopping times, STOP 1, A2.......................................... 114
4.8.3.4 Stopping distances and stopping times, STOP 1, A3.......................................... 116
4.8.4 Stopping distances and times, KR 10 R1440-2................................................... 118
4.8.4.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 118
4.8.4.2 Stopping distances and stopping times, STOP 1, A1.......................................... 119
4.8.4.3 Stopping distances and stopping times, STOP 1, A2.......................................... 121
4.8.4.4 Stopping distances and stopping times, STOP 1, A3.......................................... 123

5 Planning.................................................................................................... 125
5.1 Information for planning........................................................................................ 125
5.2 Mounting base....................................................................................................... 125
5.3 Machine frame mounting....................................................................................... 128
5.4 Connecting cables and interfaces......................................................................... 130

6 Transportation.......................................................................................... 133
6.1 Transporting the robot........................................................................................... 133

7 Start-up and recommissioning............................................................... 137

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7.1 Starting up floor-mounted robots (mounting base).............................................. 137

7.1.1 Installing fork slots or swivel eyebolts.................................................................. 139
7.1.2 Installing the robot with mounting base................................................................ 140
7.1.3 Removing fork slots or swivel eyebolts................................................................ 142
7.1.4 Connecting the connecting cables........................................................................ 142
7.1.5 Concluding work.................................................................................................... 144
7.2 Starting up robots (machine frame mounting)...................................................... 144
7.2.1 Installing fork slots or swivel eyebolts.................................................................. 147
7.2.2 Installing the robot with the machine frame mounting assembly........................ 147
7.2.3 Removing fork slots or swivel eyebolts................................................................ 148
7.2.4 Connecting the connecting cables........................................................................ 149
7.2.5 Concluding work.................................................................................................... 151
7.3 Description of the connecting cables, KR C5 micro............................................ 151
7.4 Description of the connecting cables, KR C5 S.................................................. 155

8 Maintenance.............................................................................................. 161
8.1 Maintenance overview........................................................................................... 161
8.1.1 Maintenance table................................................................................................. 162
8.2 Greasing cable set A1.......................................................................................... 164
8.2.1 Removing the cover from the base frame........................................................... 165
8.2.2 Checking and greasing cable set A1................................................................... 165
8.2.3 Mounting the cover on the base frame................................................................ 166
8.2.4 Concluding work.................................................................................................... 166
8.3 Exchanging the toothed belt on A5...................................................................... 167
8.3.1 Removing the belt-side cover from the in-line wrist............................................ 168
8.3.2 Removing toothed belt A5.................................................................................... 169
8.3.3 Installing toothed belt A5...................................................................................... 170
8.3.4 Adjusting toothed belt tension on A5................................................................... 171
8.3.5 Installing the belt-side cover on the in-line wrist.................................................. 172
8.3.6 Concluding work.................................................................................................... 173
8.4 Oil change in A1................................................................................................... 173
8.4.1 Removing the covers from the base frame.......................................................... 175
8.4.2 Draining the gear oil from A1............................................................................... 176
8.4.3 Filling gear unit A1 with gear oil........................................................................... 178
8.4.4 Installing the cover on the base frame................................................................. 180
8.4.5 Concluding work.................................................................................................... 181
8.5 Oil change in A2................................................................................................... 181
8.5.1 Draining the gear oil from A2............................................................................... 183
8.5.2 Filling gear unit A2 with gear oil........................................................................... 184
8.5.3 Concluding work.................................................................................................... 185
8.6 Oil change in A3................................................................................................... 185
8.6.1 Draining the gear oil from A3............................................................................... 187
8.6.2 Filling gear unit A3 with gear oil........................................................................... 188
8.6.3 Concluding work.................................................................................................... 189
8.7 Cleaning the robot................................................................................................. 189
8.7.1 Cleaning................................................................................................................. 190
8.7.2 Concluding work.................................................................................................... 190

9 Repair........................................................................................................ 191

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9.1 Description of the electrical installations.............................................................. 191

9.1.1 Cable set A1-A3.................................................................................................... 192
9.1.2 Cable set A4-A6.................................................................................................... 199

10 Decommissioning, storage and disposal............................................. 201

10.1 Decommissioning................................................................................................... 201
10.1.1 Moving the robot into its transport position.......................................................... 201
10.1.2 Installing fork slots or swivel eyebolts.................................................................. 202
10.1.3 Removing the robot............................................................................................... 203
10.1.4 Concluding work.................................................................................................... 204
10.2 Storage.................................................................................................................. 204
10.2.1 Moving the robot into its transport position.......................................................... 205
10.2.2 Installing fork slots or swivel eyebolts.................................................................. 206
10.2.3 Removing the robot............................................................................................... 207
10.2.4 Cleaning................................................................................................................. 208
10.2.5 Preparing for storage............................................................................................ 208
10.2.6 Concluding work.................................................................................................... 209
10.3 Disposal................................................................................................................. 209

11 Options...................................................................................................... 211
11.1 Release device...................................................................................................... 211
11.1.1 Starting up the release device.............................................................................. 211
11.1.1.1 Installing the release device................................................................................. 212
11.1.1.2 Moving the manipulator without drive energy...................................................... 213
11.1.1.3 Concluding work.................................................................................................... 214

12 Appendix................................................................................................... 215
12.1 Tightening torques................................................................................................. 215
12.2 Auxiliary and operating materials used................................................................ 216
12.3 Applied standards and regulations....................................................................... 217

13 KUKA Service........................................................................................... 219

13.1 Requesting support............................................................................................... 219
13.2 KUKA Customer Support...................................................................................... 219

Index 221

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Introduction
1 Introduction

1.1 Target group

This documentation is aimed at users with the following knowledge and

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

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

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

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2 or smartPAD pro (if used)
• Operating and programming instructions 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
precautions are taken.

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

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

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

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

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

Introduction

edy emergencies or malfunctions:

SAFETY INSTRUCTION
The following procedure must be followed exactly!

Procedures marked with this warning must be followed exactly.

Notices

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

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

1.4 Terms used

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

Term Description

Axis range 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°

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

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

C Ceiling

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

EDS Electronic Data Storage

(memory card)

EDS cool Electronic Data Storage cool

Memory card with extended temperature range

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Introduction
EMD Electronic Mastering Device

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

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.

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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 category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Note: This stop category is called STOP 0 in this document.

Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.

• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 in this document.

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Introduction
Stop category 1 – The manipulator and any external axes (optional) perform path-ori-
Drive Ramp Stop ented braking.

• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 - DRS in this document.

Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a
path-maintaining braking ramp.
Note: This stop category is called STOP 2 in this document.

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

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

W Wall

WP Waterproof

External axis Motion axis which is not part of the manipulator but is controlled by
the robot controller, e.g. KUKA linear unit, turn-tilt table, positioner.

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Product description
2 Product description

2.1 Overview of the robot system

A robot system (>>> Fig. 2-2) comprises all the assemblies of an industri-
al robot, including the manipulator (mechanical system and electrical in-
stallations), control cabinet, connecting cables, end effector (tool) and oth-
er equipment. The KR CYBERTECH nano-2 product family comprises the
robot variants:
• KR 6 R1840-2
• KR 8 R1640-2
• KR 10 R1440-2
An industrial robot of this product family comprises the following compo-
nents:
• Manipulator
• Robot controller
• Connecting cables
• Teach pendant (KUKA smartPAD)
• Software
• Options, accessories

Fig. 2-1: Example of an industrial robot with KR C5 micro

1 Manipulator
2 Connecting cables
3 Robot controller (KR C5 micro)
4 Teach pendant, KUKA smartPAD-2

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Fig. 2-2: Example of an industrial robot with KR C5 S

1 Manipulator
2 Connecting cables
3 Robot controller (KR C5 S)
4 Teach pendant, KUKA smartPAD-2

2.2 Description of the manipulator

Overview

The manipulators (manipulator = robot arm and electrical installations) of

the KR CYBERTECH nano robot family are designed as 6-axis jointed-
arm kinematic systems. They consist of the following principal compo-
nents:
• In-line wrist/arm
• Link arm
• Rotating column
• Base frame
• Electrical installations

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Product description
Fig. 2-3: Main assemblies of the manipulator

1 In-line wrist/arm 4 Rotating column

2 Link arm 5 Base frame
3 Electrical installations
Axes 1 to 5 are equipped with end stops. These serve only as machine
protection. There are two options available for personnel protection:
• Safe workspace limitation implemented in the software using Safe Ro-
bot and taking the stopping distances into consideration
• Supplementary mechanical stops for the main axes

In-line wrist/arm

The robot can be equipped with a triple-axis in-line wrist/arm combination

for a payload of 6 to 10 kg. This assembly is screwed directly to the link
arm of the robot via gear unit A3. This in-line wrist/arm assembly is avail-
able in two length variants. 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 (accessory) and transferred to the controller. Direc-
tions of rotation, axis data and permissible loads can be found in the
chapter (>>> 4 "Technical data" Page 35).
The in-line wrist is driven by the motors inside the in-line wrist. Power is
transmitted within the in-line wrist directly to the gear unit in the case of
axes 4 and 6, while for axis 5 a toothed belt stage is used before the
gear unit.
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. It consists of the link arm body with the buffers for axis 2 and the
measurement notch for axis 3. The link arm is available in two length var-
iants.

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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.

Base frame

The base frame is the base of the robot. It is screwed to the mounting
base. The flexible tube for the electrical installations is installed in the
base frame. Also located on the rear of the base frame are the junction
box for the motor and data cable and the energy supply system.

Electrical installations

The electrical installations include all the motor and control 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.
The electrical installations also include the micro RDC cool, the relevant
cable harness and interface A1. The connecting cables to the controller
are connected at interface A1.
All connections are implemented as plug-in connectors in order to enable
the main axis motors to be exchanged quickly and reliably. The electrical
installations 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 limitation A1, A2 and A3
• Brake release device
• Fork slots
• Booster frames
• Cascadable RDC
• Energy supply systems A1 to A3
• Energy supply systems A3 to A6
The following options are also available:
• Release device (>>> 11.1 "Release device" Page 211)

2.3 Intended use and misuse

Intended use

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

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Product description
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. KUKA Deutschland GmbH must be consulted.

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

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Safety
3 Safety

3.1 General

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

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

3.1.1 Disclaimer

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

component thereof.
Components of the industrial robot:

• Manipulator
• Robot controller
• Teach pendant
• Connecting cables
• External axes (optional)
e.g. linear unit, turn-tilt table, positioner
• Software
• Options, accessories
The industrial robot is built using state-of-the-art technology and in accord-
ance with the recognized safety rules. Nevertheless, misuse of the indus-
trial robot may constitute a risk to life and limb or cause damage to the
industrial robot and to other material property.
The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons who
are fully aware of the risks involved in its operation. Use of the industrial
robot is subject to compliance with this document and with the declaration
of incorporation supplied together with the industrial robot. Any functional
disorders, especially those affecting safety, must be rectified immediately.

Safety information

Information about safety may not be construed against the manufacturer.

Even if all safety instructions are followed, this is not a guarantee that the
industrial robot will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the au-
thorization of the manufacturer. Unauthorized modifications will result in
the loss of warranty and liability claims.
Additional components (tools, software, etc.), not supplied by the manufac-
turer, may be integrated into the industrial robot. The user is liable for any
damage these components may cause to the industrial robot or to other
material property.
In addition to the Safety chapter, this document contains further safety in-
structions. These must also be observed.

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3.1.2 EC declaration of conformity and declaration of incorporation

The industrial robot constitutes partly completed machinery as defined by

the EC Machinery Directive. The industrial robot may only be put into op-
eration if the following preconditions are met:
• The industrial robot is integrated into a complete system.
or: The industrial robot, together with other machinery, constitutes a
complete system.
or: All safety functions and safeguards required for operation in the
complete machine as defined by the EC Machinery Directive have
been added to the industrial robot.
• The complete system complies with the EC Machinery Directive. This
has been confirmed by means of a conformity assessment procedure.

EC declaration of conformity

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

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

Declaration of incorporation

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

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

3.1.3 Terms in the “Safety” chapter

Term Description

Axis range 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.

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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.

Safety options Generic term for options which make it possible to configure addi-
tional safe monitoring functions in addition to the standard safety
functions.
Example: SafeOperation

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 category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Note: This stop category is called STOP 0 in this document.

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Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.

• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 in this document.

Stop category 1 – The manipulator and any external axes (optional) perform path-ori-
Drive Ramp Stop ented braking.

• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 - DRS in this document.

Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a
path-maintaining braking ramp.
Note: This stop category is called STOP 2 in this document.

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)

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

External axis Motion axis which is not part of the manipulator but is controlled by
the robot controller, e.g. KUKA linear unit, turn-tilt table, 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.

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User

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

• The user must comply with his monitoring obligations.

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

Personnel

Personnel must be instructed, before any work is commenced, in the type

of work involved and what exactly it entails as well as any hazards which
may exist. Instruction must be carried out regularly. Instruction is also re-
quired after particular incidents or technical modifications.
Personnel includes:

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

System integrator

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

• Installing the industrial robot

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

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.

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The safeguards (e.g. safety gate) must be located outside the danger
Safety

zone. In the case of a stop, the manipulator and external axes (optional)
are braked and come to a stop within the danger zone.
There must be no shearing or crushing hazards at the loading and trans-
fer areas.
If there are no physical safeguards present, the requirements for collabo-
rative operation in accordance with EN ISO 10218 must be met.

3.4 Overview of protective equipment

The protective equipment of the mechanical component may include:

• Mechanical end stops

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

3.4.1 Mechanical end stops

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

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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.

NOTICE
Damage to property due to moving the manipulator without drive
energy
Moving the manipulator without drive energy can damage the motor
brakes of the axes concerned.
• Only move the manipulator without drive energy in emergencies,
e.g. for rescuing persons.
• Perform brake test.
• The motor must be replaced if the brake has been damaged.

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.

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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.

Implants

WARNING
Danger to life due to malfunction of implants due to motors
Electric motors 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 the motors. This applies to both energized and deenergized
motors.

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.

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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.

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).
After modifications to the industrial robot, existing programs must always
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.

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Avoid vibrations and impacts during transportation in order to prevent

Safety

damage to the manipulator.

Robot controller

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

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

External axis (optional)

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

3.5.3 Start-up and recommissioning

Before starting up systems and devices for the first time, a check must be
carried out to ensure that the systems and devices are complete and op-
erational, that they can be operated safely and that any damage is detec-
ted.
The valid national or regional work safety regulations must be observed
for this check. The correct functioning of all safety circuits must also be
tested.
Changing default passwords
The KUKA System Software is supplied with default passwords for the
user groups. If the passwords are not changed, this enables unauthor-
ized persons to log on.
• Before start-up, change the passwords for the user groups.
• Only communicate the passwords to authorized personnel.

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.

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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
External forces, such as an impact or a collision, can cause non-
visible damage. For example, it can lead to a gradual loss of drive
power from the motor, resulting in unintended movements of the ma-
nipulator.
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.
• 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.

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• Workpieces, tooling and other objects must not become jammed 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 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 other persons inside the safe-
guarded 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.

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.

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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.

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.

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Voltages in excess of 50 V (up to 780 V) can be present in various com-

Safety

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

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3.5.7 Decommissioning, storage and disposal

The industrial robot must be decommissioned, stored and disposed of in

accordance with the applicable national laws, regulations and standards.

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Technical data
4 Technical data

4.1 Technical data, overview

The technical data for the individual robot types can be found in the fol-
lowing sections:
Robot Technical data
KR 6 R1840-2 • Technical data
(>>> 4.2 "Technical data, KR 6 R1840-2" Page 36)
• Plates and labels
(>>> 4.5 "Plates and labels" Page 78)
• Stopping distances and times
KR C5 micro:
(>>> 4.7.2 "Stopping distances and times, KR 6 R1840-2"
Page 82)
KR C5 S:
(>>> 4.8.2 "Stopping distances and times, KR 6 R1840-2"
Page 104)
KR 8 R1640-2 • Technical data
(>>> 4.3 "Technical data, KR 8 R1640-2" Page 50)
• Plates and labels
(>>> 4.5 "Plates and labels" Page 78)
• Stopping distances and times
KR C5 micro:
(>>> 4.7.3 "Stopping distances and times, KR 8 R1640-2"
Page 89)
KR C5 S:
(>>> 4.8.3 "Stopping distances and times, KR 8 R1640-2"
Page 111)
KR 10 R1440-2 • Technical data
(>>> 4.4 "Technical data, KR 10 R1440-2" Page 64)
• Plates and labels
(>>> 4.5 "Plates and labels" Page 78)
• Stopping distances and times
KR C5 micro:
(>>> 4.7.4 "Stopping distances and times, KR 10 R1440-2"
Page 96)
KR C5 S:
(>>> 4.8.4 "Stopping distances and times, KR 10 R1440-2"
Page 118)

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Technical data KR CYBERTECH nano-2

4.2 Technical data, KR 6 R1840-2

4.2.1 Basic data, KR 6 R1840-2

Basic data

KR 6 R1840-2
Number of axes 6
Number of controlled axes 6
Volume of working envelope 23.52 m³
Pose repeatability (ISO 9283) ± 0.04 mm
Weight approx. 162 kg
Rated payload 6 kg
Maximum payload 9 kg
Maximum reach 1840 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP67
60529)
Sound level < 75 dB (A)
Mounting position Floor;
Ceiling;
Wall;
Desired angle
Footprint 333.5 mm x 307 mm
Hole pattern: mounting surface for S260
kinematic system
Permissible angle of inclination -
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)
Controller KR C5 micro;
KR C5 S6/S7
Transformation name KR C5: KR6R1840_2

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Cleanroom class (ISO 14644-1) Class 5 at 40% override;
Class 5 at 80% override
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.

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Technical data
Connecting cables, KR C5 micro

Cable designation Connector designation Interface

Robot controller - robot Robot
Motor cable XD30 Motor connector 1: Han-Yellock® 60
XD20.1 - XD30
Connection A1-A3 incl.
brakes
Motor connector 2:
XD20.2 - XD30
Connection A4-A6 incl.
brakes
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipo- Ring cable lug, M8
tential bonding
4 mm2

Cable lengths 1 m, 4 m, 7 m, 15 m, 25 m
Max. cable length 25 m
Number of extensions 1

Minimum bending radius 5x D

For detailed specifications of the connecting cables, see “Description of
the connecting cables”.

Connecting cables, KR C5 S

Cable designation Connector designation Interface

Robot controller - robot Robot
Motor cable XD30 6 motor connectors: Han-Yellock® 60
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipo- M8 ring cable lug at both
tential bonding ends
16 mm2

Cable lengths 4 m, 7 m, 10 m, 15 m, 20 m, 25 m, 35 m
and 50 m
Max. cable length 50 m
Number of extensions 1

Minimum bending radius 5x D

For detailed specifications of the connecting cables, see “Description of
the connecting cables”.

Certificates

ESD requirements IEC61340-5-1; ANSI/ESD S20.20

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Technical data KR CYBERTECH nano-2

4.2.2 Axis data, KR 6 R1840-2

Range of motion

Motion range
A1 ±170 °
A2 -185 ° / 65 °
A3 -137 ° / 163 °
A4 ±185 °
A5 ±120 °
A6 ±350 °

Axis velocities, KR C5 micro

Velocity with rated payload

A1 160°/s
A2 149°/s
A3 270°/s
A4 381°/s
A5 311°/s
A6 433°/s

Axis velocities, KR C5 S

Speed with rated payload

A1 220 °/s
A2 210 °/s
A3 270 °/s
A4 381 °/s
A5 311 °/s
A6 472 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram.

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

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Technical data
Mastering positions

Mastering position
A1 -19 °
A2 -90 °
A3 90 °
A4 90 °
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: Working envelope, side view, KR 6 R1840-2

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Technical data KR CYBERTECH nano-2

Fig. 4-3: Working envelope, top view, KR 6 R1840-2

Inclined installation

The robot can installed anywhere from a 0° position (floor) to a 180° posi-
tion (ceiling). This type of installation results in limitations to the range of
motion in the plus and minus directions about axis 1. 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. A configu-
ration 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.

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Technical data
Motion range of A1 with inclined installation, KR C5 micro

Fig. 4-4: Motion range of A1 with inclined installation, KR 6 R1840-2,

KR C5 micro

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Technical data KR CYBERTECH nano-2

Motion range of A1 with inclined installation, KR C5 S

Fig. 4-5: Motion range of A1 with inclined installation, KR 6 R1840-2,

KR C5 S

4.2.3 Payloads, KR 6 R1840-2

Payloads

Rated payload 6 kg
Maximum payload 9 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- 20 kg
tating column
Rated supplementary load, link 0 kg
arm

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Technical data
Maximum supplementary load, link 15 kg
arm
Rated supplementary load, arm 10 kg
Maximum supplementary load, arm 15 kg

Load center of gravity and mass moment of inertia

Fig. 4-6: 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:

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Technical data KR CYBERTECH nano-2

• 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.

More 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 Deutsch-
land GmbH must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For commissioning the robot, additional input data are required
in accordance with the operating and programming instructions of the
KUKA System Software.
The mass inertia must be verified using KUKA.Load or KUKA Compose.
It is imperative for the load data to be entered in the robot controller!

Fig. 4-7: Payload diagram, KR 6 R1840-2

The KR 6 R1840-2 is designed for a rated payload of 6 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 9 kg can be mounted. The specific load case must be verified using
KUKA.Load or KUKA Compose. For further consultation, please contact
KUKA Support.

Mounting flange

Robot wrist type ZH Arm KR6 kpl.

Mounting flange see drawing

Mounting flange (hole circle) 31.5 mm

Screw grade 12.9
Screw size M5

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Technical data
Number of fastening threads 7
Clamping length 1.5 x nominal diameter
Depth of engagement min. 5.5 mm, max. 7 mm
Locating element 4H7
The mounting flange is depicted (>>> Fig. 4-8) with axes 4 and 6 in the
zero position.

Fig. 4-8: Mounting flange

Flange loads

Due to the motion of the payload (e.g. tool) mounted on the robot, forces
and torques act on the mounting flange. These 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.
The specified values refer to nominal payloads and do not include safety
factors. It is imperative for the load data to be entered in the robot control-
ler. The robot controller takes the payload into consideration during path
planning. A reduced payload does not necessarily result in lower forces
and torques.
The values are guide values determined by means of trial and simulation
and refer to the most heavily loaded machine in the robot family. The ac-
tual forces and torques may differ due to internal and external influences
on the mounting flange or a different point of application. It is therefore
advisable to determine the exact forces and torques where necessary on
site under the real conditions of the actual robot application.
The operating values may occur permanently in the normal motion profile.
It is advisable to rate the tool for its fatigue strength.
The EMERGENCY STOP values may arise in the event of an Emergency
Stop situation of the robot. As these should only occur very rarely during
the service life of the robot, a static strength verification is usually suffi-
cient.

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Technical data KR CYBERTECH nano-2

Fig. 4-9: Flange loads

Flange loads during operation

F(a) 270 N
F(r) 280 N
M(k) 30 Nm
M(g) 30 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 440 N
F(r) 570 N
M(k) 75 Nm
M(g) 60 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.

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Technical data
Fig. 4-10: Fastening the supplementary load, arm

1 Mounting surface on arm

2 Plane of rotation, A4

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Technical data KR CYBERTECH nano-2

Fig. 4-11: Fastening the supplementary load, link arm / rotating col-
umn

1 Mounting surface on link arm

2 Mounting surface on rotating column, both sides

4.2.4 Foundation loads, KR 6 R1840-2

Foundation loads

The specified forces and moments already include the payload and the in-
ertia force (weight) of the robot.
Foundation loads for floor mounting position
F(v normal) 2720 N
F(v max) 3560 N
F(h normal) 1620 N
F(h max) 3180 N
M(k normal) 2060 Nm
M(k max) 4520 Nm
M(r normal) 1120 Nm
M(r max) 2340 Nm
Foundation loads for ceiling mounting position
F(v normal) 2860 N
F(v max) 3520 N
F(h normal) 1480 N
F(h max) 3220 N
M(k normal) 1980 Nm

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Technical data
M(k max) 4520 Nm
M(r normal) 1120 Nm
M(r max) 2340 Nm
Foundation loads for wall mounting position
F(v normal) 3100 N
F(v max) 4380 N
F(h normal) 1300 N
F(h max) 2100 N
M(k normal) 2380 Nm
M(k max) 4780 Nm
M(r normal) 1140 Nm
M(r max) 2460 Nm
Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about
axis 1 M(r)

Fig. 4-12: Foundation loads

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Technical data KR CYBERTECH nano-2

WARNING
Normal loads and maximum loads for the foundations are specified in
the table.
The maximum loads must be referred to when dimensioning the founda-
tions and must be adhered to for safety reasons. Failure to observe this
can result in personal injury and damage to property.
The normal loads are average expected foundation loads. The actual
loads are dependent on the program and on the robot loads and may
therefore be greater or less than the normal loads.
The supplementary loads (A1 and A2) are not taken into consideration
in the calculation of the mounting base load. These supplementary
loads must be taken into consideration for Fv.

4.3 Technical data, KR 8 R1640-2

4.3.1 Basic data, KR 8 R1640-2

Basic data

KR 8 R1640-2
Number of axes 6
Number of controlled axes 6
Volume of working envelope 16.41 m³
Pose repeatability (ISO 9283) ± 0.04 mm
Weight approx. 158 kg
Rated payload 8 kg
Maximum payload 12 kg
Maximum reach 1640 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP67
60529)
Sound level < 75 dB (A)
Mounting position Floor;
Ceiling;
Wall;
Desired angle
Footprint 333.5 mm x 307 mm
Hole pattern: mounting surface for S260
kinematic system
Permissible angle of inclination -
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)
Controller KR C5 micro;
KR C5 S6/S7
Transformation name KR C5: KR8R1640_2

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Technical data
Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Cleanroom class (ISO 14644-1) Class 5 at 40% override;
Class 5 at 80% override
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 C5 micro

Cable designation Connector designation Interface

Robot controller - robot Robot
Motor cable XD30 Motor connector 1: Han-Yellock® 60
XD20.1 - XD30
Connection A1-A3 incl.
brakes
Motor connector 2:
XD20.2 - XD30
Connection A4-A6 incl.
brakes
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipo- Ring cable lug, M8
tential bonding
4 mm2

Cable lengths 1 m, 4 m, 7 m, 15 m, 25 m
Max. cable length 25 m
Number of extensions 1

Minimum bending radius 5x D

For detailed specifications of the connecting cables, see “Description of
the connecting cables”.

Connecting cables, KR C5 S

Cable designation Connector designation Interface

Robot controller - robot Robot
Motor cable XD30 6 motor connectors: Han-Yellock® 60
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipo- M8 ring cable lug at both
tential bonding ends
16 mm2

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Technical data KR CYBERTECH nano-2

Cable lengths 4 m, 7 m, 10 m, 15 m, 20 m, 25 m, 35 m
and 50 m
Max. cable length 50 m
Number of extensions 1

Minimum bending radius 5x D

For detailed specifications of the connecting cables, see “Description of
the connecting cables”.

Certificates

ESD requirements IEC61340-5-1; ANSI/ESD S20.20

4.3.2 Axis data, KR 8 R1640-2

Range of motion

Motion range
A1 ±170 °
A2 -185 ° / 65 °
A3 -137 ° / 163 °
A4 ±185 °
A5 ±120 °
A6 ±350 °

Axis velocities, KR C5 micro

Velocity with rated payload

A1 160°/s
A2 149°/s
A3 270°/s
A4 381°/s
A5 311°/s
A6 433°/s

Axis velocities, KR C5 S

Speed with rated payload

A1 220 °/s
A2 210 °/s
A3 270 °/s
A4 381 °/s
A5 311 °/s
A6 472 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram.

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Technical data
Fig. 4-13: Direction of rotation of robot axes

Mastering positions

Mastering position
A1 -19 °
A2 -90 °
A3 90 °
A4 90 °
A5 0 °
A6 0 °

Working envelope

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

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Technical data KR CYBERTECH nano-2

Fig. 4-14: Working envelope, side view, KR 8 R1640-2

Fig. 4-15: Working envelope, top view, KR 8 R1640-2

Inclined installation

The robot can installed anywhere from a 0° position (floor) to a 180° posi-
tion (ceiling). This type of installation results in limitations to the range of
motion in the plus and minus directions about axis 1. 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.

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The inclination angles for the robot must be entered correctly into the con-

Technical data
troller if the robot is not operated in the floor-mounted position. A configu-
ration 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.

Motion range of A1 with inclined installation, KR C5 micro

Fig. 4-16: Motion range of A1 with inclined installation, KR 8 R1640-2,

KR C5 micro

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Technical data KR CYBERTECH nano-2

Motion range of A1 with inclined installation, KR C5 S

Fig. 4-17: Motion range of A1 with inclined installation, KR 8 R1640-2,

KR C5 S

4.3.3 Payloads, KR 8 R1640-2

Payloads

Rated payload 8 kg
Maximum payload 12 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- 20 kg
tating column
Rated supplementary load, link 0 kg
arm

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Technical data
Maximum supplementary load, link 15 kg
arm
Rated supplementary load, arm 10 kg
Maximum supplementary load, arm 15 kg

Load center of gravity and mass moment of inertia

Fig. 4-18: 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:

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Technical data KR CYBERTECH nano-2

• 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.

More 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 Deutsch-
land GmbH must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For commissioning the robot, additional input data are required
in accordance with the operating and programming instructions of the
KUKA System Software.
The mass inertia must be verified using KUKA.Load or KUKA Compose.
It is imperative for the load data to be entered in the robot controller!

Fig. 4-19: Payload diagram, KR 8 R1640-2

The KR 8 R1640-2 is designed for a rated payload of 8 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 12 kg can be mounted. The specific load case must be verified using
KUKA.Load or KUKA Compose. For further consultation, please contact
KUKA Support.

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Technical data
Mounting flange

Robot wrist type ZH Arm KR8/10 kpl.

Mounting flange see drawing

Mounting flange (hole circle) 31.5 mm

Screw grade 12.9
Screw size M5
Number of fastening threads 7
Clamping length 1.5 x nominal diameter
Depth of engagement min. 5.5 mm, max. 7 mm
Locating element 4H7
The mounting flange is depicted (>>> Fig. 4-20) with axes 4 and 6 in the
zero position.

Fig. 4-20: Mounting flange

Flange loads

Due to the motion of the payload (e.g. tool) mounted on the robot, forces
and torques act on the mounting flange. These 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.
The specified values refer to nominal payloads and do not include safety
factors. It is imperative for the load data to be entered in the robot control-
ler. The robot controller takes the payload into consideration during path
planning. A reduced payload does not necessarily result in lower forces
and torques.
The values are guide values determined by means of trial and simulation
and refer to the most heavily loaded machine in the robot family. The ac-
tual forces and torques may differ due to internal and external influences
on the mounting flange or a different point of application. It is therefore
advisable to determine the exact forces and torques where necessary on
site under the real conditions of the actual robot application.
The operating values may occur permanently in the normal motion profile.
It is advisable to rate the tool for its fatigue strength.
The EMERGENCY STOP values may arise in the event of an Emergency
Stop situation of the robot. As these should only occur very rarely during

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 KR CYBERTECH nano-2

the service life of the robot, a static strength verification is usually suffi-
Technical data

cient.

Fig. 4-21: Flange loads

Flange loads during operation

F(a) 360 N
F(r) 420 N
M(k) 40 Nm
M(g) 35 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 610 N
F(r) 670 N
M(k) 95 Nm
M(g) 70 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.

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Technical data
Fig. 4-22: Fastening the supplementary load, arm

1 Mounting surface on arm

2 Plane of rotation, A4

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Fig. 4-23: Fastening the supplementary load, link arm / rotating col-
umn

1 Mounting surface on link arm

2 Mounting surface on rotating column, both sides

4.3.4 Foundation loads, KR 8 R1640-2

Foundation loads

The specified forces and moments already include the payload and the in-
ertia force (weight) of the robot.
Foundation loads for floor mounting position
F(v normal) 2700 N
F(v max) 3580 N
F(h normal) 1640 N
F(h max) 3220 N
M(k normal) 2080 Nm
M(k max) 4400 Nm
M(r normal) 1120 Nm
M(r max) 2300 Nm
Foundation loads for ceiling mounting position
F(v normal) 2700 N
F(v max) 3600 N
F(h normal) 1660 N
F(h max) 3240 N
M(k normal) 2100 Nm

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Technical data
M(k max) 4400 Nm
M(r normal) 1140 Nm
M(r max) 2300 Nm
Foundation loads for wall mounting position
F(v normal) 3060 N
F(v max) 4340 N
F(h normal) 1220 N
F(h max) 2520 N
M(k normal) 2500 Nm
M(k max) 4660 Nm
M(r normal) 1120 Nm
M(r max) 2440 Nm
Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about
axis 1 M(r)

Fig. 4-24: Foundation loads

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WARNING
Normal loads and maximum loads for the foundations are specified in
the table.
The maximum loads must be referred to when dimensioning the founda-
tions and must be adhered to for safety reasons. Failure to observe this
can result in personal injury and damage to property.
The normal loads are average expected foundation loads. The actual
loads are dependent on the program and on the robot loads and may
therefore be greater or less than the normal loads.
The supplementary loads (A1 and A2) are not taken into consideration
in the calculation of the mounting base load. These supplementary
loads must be taken into consideration for Fv.

4.4 Technical data, KR 10 R1440-2

4.4.1 Basic data, KR 10 R1440-2

Basic data

KR 10 R1440-2
Number of axes 6
Number of controlled axes 6
Volume of working envelope 11.03 m³
Pose repeatability (ISO 9283) ± 0.04 mm
Weight approx. 153 kg
Rated payload 10 kg
Maximum payload 14.3 kg
Maximum reach 1440 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP67
60529)
Sound level < 75 dB (A)
Mounting position Floor;
Ceiling;
Wall;
Desired angle
Footprint 333.5 mm x 307 mm
Hole pattern: mounting surface for S260
kinematic system
Permissible angle of inclination -
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009)
Controller KR C5 micro;
KR C5 S6/S7
Transformation name KR C5: KR10R1440_2

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Technical data
Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Cleanroom class (ISO 14644-1) Class 5 at 40% override;
Class 5 at 80% override
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 C5 micro

Cable designation Connector designation Interface

Robot controller - robot Robot
Motor cable XD30 Motor connector 1: Han-Yellock® 60
XD20.1 - XD30
Connection A1-A3 incl.
brakes
Motor connector 2:
XD20.2 - XD30
Connection A4-A6 incl.
brakes
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipo- Ring cable lug, M8
tential bonding
4 mm2

Cable lengths 1 m, 4 m, 7 m, 15 m, 25 m
Max. cable length 25 m
Number of extensions 1

Minimum bending radius 5x D

For detailed specifications of the connecting cables, see “Description of
the connecting cables”.

Connecting cables, KR C5 S

Cable designation Connector designation Interface

Robot controller - robot Robot
Motor cable XD30 6 motor connectors: Han-Yellock® 60
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipo- M8 ring cable lug at both
tential bonding ends
16 mm2

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Cable lengths 4 m, 7 m, 10 m, 15 m, 20 m, 25 m, 35 m
and 50 m
Max. cable length 50 m
Number of extensions 1

Minimum bending radius 5x D

For detailed specifications of the connecting cables, see “Description of
the connecting cables”.

Certificates

ESD requirements IEC61340-5-1; ANSI/ESD S20.20

4.4.2 Axis data, KR 10 R1440-2

Range of motion

Motion range
A1 ±170 °
A2 -185 ° / 65 °
A3 -137 ° / 163 °
A4 ±185 °
A5 ±120 °
A6 ±350 °

Axis velocities, KR C5 micro

Velocity with rated payload

A1 160°/s
A2 149°/s
A3 270°/s
A4 381°/s
A5 311°/s
A6 433°/s

Axis velocities, KR C5 S

Speed with rated payload

A1 220 °/s
A2 210 °/s
A3 270 °/s
A4 381 °/s
A5 311 °/s
A6 472 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram.

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Technical data
Fig. 4-25: Direction of rotation of robot axes

Mastering positions

Mastering position
A1 -19 °
A2 -90 °
A3 90 °
A4 90 °
A5 0 °
A6 0 °

Working envelope

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

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Fig. 4-26: Working envelope, side view, KR 10 R1440-2

Fig. 4-27: Working envelope, top view, KR 10 R1440-2

Inclined installation

The robot can installed anywhere from a 0° position (floor) to a 180° posi-
tion (ceiling). This type of installation results in limitations to the range of
motion in the plus and minus directions about axis 1. 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.

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The inclination angles for the robot must be entered correctly into the con-

Technical data
troller if the robot is not operated in the floor-mounted position. A configu-
ration 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.

Motion range of A1 with inclined installation, KR 10 R1440-2, KR C5 micro and

KR C5 S

Fig. 4-28: Motion range of A1 with inclined installation, KR 10

R1440-2, KR C5 micro and KR C5 S

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4.4.3 Payloads, KR 10 R1440-2

Payloads

Rated payload 10 kg
Maximum payload 14.3 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- 20 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 15 kg
arm
Rated supplementary load, arm 10 kg
Maximum supplementary load, arm 15 kg

Load center of gravity and mass moment of inertia

Fig. 4-29: 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

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Technical data
Parameter/unit Description
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.

More 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 Deutsch-
land GmbH must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For commissioning the robot, additional input data are required
in accordance with the operating and programming instructions of the
KUKA System Software.
The mass inertia must be verified using KUKA.Load or KUKA Compose.
It is imperative for the load data to be entered in the robot controller!

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Fig. 4-30: Payload diagram, KR 10 R1440-2

The KR 10 R1440-2 is designed for a rated payload of 10 kg in order to

optimize the dynamic performance of the robot. With reduced load center
distances and favorable supplementary loads, a maximum payload of up
to 14.3 kg can be mounted. The specific load case must be verified using
KUKA.Load or KUKA Compose. For further consultation, please contact
KUKA Support.

Mounting flange

Robot wrist type ZH Arm KR8/10 kpl.

Mounting flange see drawing

Mounting flange (hole circle) 31.5 mm

Screw grade 12.9
Screw size M5
Number of fastening threads 7
Clamping length 1.5 x nominal diameter
Depth of engagement min. 5.5 mm, max. 7 mm
Locating element 4H7
The mounting flange is depicted (>>> Fig. 4-31) with axes 4 and 6 in the
zero position.

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Technical data
Fig. 4-31: Mounting flange

Flange loads

Due to the motion of the payload (e.g. tool) mounted on the robot, forces
and torques act on the mounting flange. These 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.
The specified values refer to nominal payloads and do not include safety
factors. It is imperative for the load data to be entered in the robot control-
ler. The robot controller takes the payload into consideration during path
planning. A reduced payload does not necessarily result in lower forces
and torques.
The values are guide values determined by means of trial and simulation
and refer to the most heavily loaded machine in the robot family. The ac-
tual forces and torques may differ due to internal and external influences
on the mounting flange or a different point of application. It is therefore
advisable to determine the exact forces and torques where necessary on
site under the real conditions of the actual robot application.
The operating values may occur permanently in the normal motion profile.
It is advisable to rate the tool for its fatigue strength.
The EMERGENCY STOP values may arise in the event of an Emergency
Stop situation of the robot. As these should only occur very rarely during
the service life of the robot, a static strength verification is usually suffi-
cient.

Fig. 4-32: Flange loads

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Flange loads during operation

F(a) 450 N
F(r) 470 N
M(k) 50 Nm
M(g) 40 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 710 N
F(r) 780 N
M(k) 110 Nm
M(g) 70 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.

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Technical data
Fig. 4-33: Fastening the supplementary load, arm

1 Mounting surface on arm

2 Plane of rotation, A4

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Fig. 4-34: Fastening the supplementary load, link arm / rotating col-
umn

1 Mounting surface on link arm

2 Mounting surface on rotating column, both sides

4.4.4 Foundation loads, KR 10 R1440-2

Foundation loads

The specified forces and moments already include the payload and the in-
ertia force (weight) of the robot.
Foundation loads for floor mounting position
F(v normal) 2560 N
F(v max) 3720 N
F(h normal) 1380 N
F(h max) 3360 N
M(k normal) 1680 Nm
M(k max) 4160 Nm
M(r normal) 1060 Nm
M(r max) 2180 Nm
Foundation loads for ceiling mounting position
F(v normal) 2860 N
F(v max) 3720 N
F(h normal) 1400 N
F(h max) 3280 N
M(k normal) 1700 Nm

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M(k max) 4100 Nm
M(r normal) 1060 Nm
M(r max) 2180 Nm
Foundation loads for wall mounting position
F(v normal) 3100 N
F(v max) 4340 N
F(h normal) 1080 N
F(h max) 2220 N
M(k normal) 2140 Nm
M(k max) 4140 Nm
M(r normal) 1020 Nm
M(r max) 2340 Nm
Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about
axis 1 M(r)

Fig. 4-35: Foundation loads

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WARNING
Normal loads and maximum loads for the foundations are specified in
the table.
The maximum loads must be referred to when dimensioning the founda-
tions and must be adhered to for safety reasons. Failure to observe this
can result in personal injury and damage to property.
The normal loads are average expected foundation loads. The actual
loads are dependent on the program and on the robot loads and may
therefore be greater or less than the normal loads.
The supplementary loads (A1 and A2) are not taken into consideration
in the calculation of the mounting base load. These supplementary
loads must be taken into consideration for Fv.

4.5 Plates and labels

Plates and labels

The following plates and labels (>>> Fig. 4-36) are attached to the robot.
They must not be removed or rendered illegible. Illegible plates and labels
must be replaced. The plates and labels depicted here are valid for all ro-
bots of this robot model.

Fig. 4-36: Location of plates and labels

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Item Description
1

Hot surface
During operation of the robot, surface temperatures may be
reached that could result in burn injuries. Protective gloves must
be worn!
2

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!
3

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!

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Item Description
4

Danger zone
Entering the danger zone of the robot is prohibited if the robot
is in operation or ready for operation. Risk of injury!
5

Identification plate example

Content according to Machinery Directive.
The QR code contains a link to product information in KUKA
Xpert.
6

Work on the robot

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

4.6 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.

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Technical data
4.7 Stopping distances and stopping times with KR C5 micro

4.7.1 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.

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

System configuration

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

• Weight with maximum payload on the flange (no supplementary loads
on the robot)
Motion sequence

• 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.

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Standstill is used as the end time of the measurement.

Technical data

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.

4.7.2 Stopping distances and times, KR 6 R1840-2

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

The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)

Stopping distance
A1 20.77°
A2 19.80°
A3 14.10°
Stopping time
A1 0.34 s
A2 0.23 s
A3 0.10 s

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4.7.2.2 Stopping distances and stopping times for STOP 1, axis 1

Technical data

Fig. 4-37: Stopping distances for STOP 1, axis 1, KR C5 micro

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Fig. 4-38: Stopping times for STOP 1, axis 1, KR C5 micro

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4.7.2.3 Stopping distances and stopping times for STOP 1, axis 2

Technical data

Fig. 4-39: Stopping distances for STOP 1, axis 2, KR C5 micro

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Fig. 4-40: Stopping times for STOP 1, axis 2, KR C5 micro

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4.7.2.4 Stopping distances and stopping times for STOP 1, axis 3

Technical data

Fig. 4-41: Stopping distances for STOP 1, axis 3, KR C5 micro

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Fig. 4-42: Stopping times for STOP 1, axis 3, KR C5 micro

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Technical data
4.7.3 Stopping distances and times, KR 8 R1640-2

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

The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)

Stopping distance
A1 19.05°
A2 17.00°
A3 11.90°
Stopping time
A1 0.21 s
A2 0.21 s
A3 0.09 s

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4.7.3.2 Stopping distances and stopping times for STOP 1, axis 1

Technical data

Fig. 4-43: Stopping distances for STOP 1, axis 1, KR C5 micro

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Technical data

Fig. 4-44: Stopping times for STOP 1, axis 1, KR C5 micro

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4.7.3.3 Stopping distances and stopping times for STOP 1, axis 2

Technical data

Fig. 4-45: Stopping distances for STOP 1, axis 2, KR C5 micro

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Technical data

Fig. 4-46: Stopping times for STOP 1, axis 2, KR C5 micro

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4.7.3.4 Stopping distances and stopping times for STOP 1, axis 3

Technical data

Fig. 4-47: Stopping distances for STOP 1, axis 3, KR C5 micro

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Technical data

Fig. 4-48: Stopping times for STOP 1, axis 3, KR C5 micro

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Technical data KR CYBERTECH nano-2

4.7.4 Stopping distances and times, KR 10 R1440-2

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

The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)

Stopping distance
A1 16.12°
A2 13.14°
A3 12.41°
Stopping time
A1 0.19 s
A2 0.16 s
A3 0.09 s

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4.7.4.2 Stopping distances and stopping times for STOP 1, axis 1

Technical data

Fig. 4-49: Stopping distances for STOP 1, axis 1, KR C5 micro

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Fig. 4-50: Stopping times for STOP 1, axis 1, KR C5 micro

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4.7.4.3 Stopping distances and stopping times for STOP 1, axis 2

Technical data

Fig. 4-51: Stopping distances for STOP 1, axis 2, KR C5 micro

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Fig. 4-52: Stopping times for STOP 1, axis 2, KR C5 micro

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4.7.4.4 Stopping distances and stopping times for STOP 1, axis 3

Technical data

Fig. 4-53: Stopping distances for STOP 1, axis 3, KR C5 micro

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Fig. 4-54: Stopping times for STOP 1, axis 3, KR C5 micro

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

The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
• Extension l = 100%

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Technical data
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)

Stopping distance
A1 19.05°
A2 17.00°
A3 11.90°
Stopping time
A1 0.21 s
A2 0.21 s
A3 0.09 s

4.8 Stopping distances and stopping times with KR C5 S

4.8.1 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.

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

System configuration

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

• Weight with maximum payload on the flange (no supplementary loads
on the robot)

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Motion sequence
Technical data

• 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.

4.8.2 Stopping distances and times, KR 6 R1840-2

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

The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)

Stopping distance
A1 31.54 °
A2 29.74 °
A3 27.33 °
Stopping time
A1 0.42 s
A2 0.34 s
A3 0.16 s

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4.8.2.2 Stopping distances and stopping times, STOP 1, A1

Technical data

Fig. 4-55: Stopping distances for STOP 1, axis 1, KR C5 S

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Fig. 4-56: Stopping times for STOP 1, axis 1, KR C5 S

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4.8.2.3 Stopping distances and stopping times, STOP 1, A2

Technical data

Fig. 4-57: Stopping distances for STOP 1, axis 2, KR C5 S

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Fig. 4-58: Stopping times for STOP 1, axis 2, KR C5 S

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4.8.2.4 Stopping distances and stopping times, STOP 1, A3

Technical data

Fig. 4-59: Stopping distances for STOP 1, axis 3, KR C5 S

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Fig. 4-60: Stopping times for STOP 1, axis 3, KR C5 S

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Technical data
4.8.3 Stopping distances and times, KR 8 R1640-2

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

The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)

Stopping distance
A1 23.26 °
A2 25.29 °
A3 23.50 °
Stopping time
A1 0.26 s
A2 0.35 s
A3 0.14 s

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4.8.3.2 Stopping distances and stopping times, STOP 1, A1

Technical data

Fig. 4-61: Stopping distances for STOP 1, axis 1, KR C5 S

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Technical data

Fig. 4-62: Stopping times for STOP 1, axis 1, KR C5 S

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4.8.3.3 Stopping distances and stopping times, STOP 1, A2

Technical data

Fig. 4-63: Stopping distances for STOP 1, axis 2, KR C5 S

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Technical data

Fig. 4-64: Stopping times for STOP 1, axis 2, KR C5 S

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4.8.3.4 Stopping distances and stopping times, STOP 1, A3

Technical data

Fig. 4-65: Stopping distances for STOP 1, axis 3, KR C5 S

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Technical data

Fig. 4-66: Stopping times for STOP 1, axis 3, KR C5 S

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4.8.4 Stopping distances and times, KR 10 R1440-2

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

The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)

Stopping distance
A1 24.11 °
A2 22.20 °
A3 26.97 °
Stopping time
A1 0.30 s
A2 0.25 s
A3 0.18 s

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4.8.4.2 Stopping distances and stopping times, STOP 1, A1

Technical data

Fig. 4-67: Stopping distances for STOP 1, axis 1, KR C5 S

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Fig. 4-68: Stopping times for STOP 1, axis 1, KR C5 S

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4.8.4.3 Stopping distances and stopping times, STOP 1, A2

Technical data

Fig. 4-69: Stopping distances for STOP 1, axis 2, KR C5 S

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Fig. 4-70: Stopping times for STOP 1, axis 2, KR C5 S

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4.8.4.4 Stopping distances and stopping times, STOP 1, A3

Technical data

Fig. 4-71: Stopping distances for STOP 1, axis 3, KR C5 S

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Fig. 4-72: Stopping times for STOP 1, axis 3, KR C5 S

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Planning
5 Planning

5.1 Information for planning

In the planning and design phase, care must be taken regarding the func-
tions or applications to be executed by the kinematic system. The follow-
ing conditions can lead to premature wear. They necessitate shorter main-
tenance intervals and/or earlier exchange of components. In addition, the
permissible operating parameters specified in the technical data must be
taken into account and observed during planning.
• Continuous operation near temperature limits
• Continuous operation in abrasive environments
• Continuous operation close to the performance limits, e.g. high rpm of
an axis
• 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 arise during operation of the kinematic
system, KUKA Deutschland GmbH 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

Description

The mounting base with centering is used when the robot is fastened to
the floor, i.e. directly on a concrete foundation. The following variant is
available:
• Mounting base with centering
This mounting base variant consists of:
• Bedplates
• Resin-bonded anchors
• Fastening elements
This mounting variant requires a level and smooth surface on a concrete
foundation with adequate load bearing capacity.

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Fig. 5-1: Mounting base

1 Hexagon bolt with conical spring washer (4x)

2 Bedplate (4x)
3 Locating pin (2x)
4 Resin-bonded anchor (4x)

Grade of concrete for foundations

When producing foundations from concrete, observe the load-bearing ca-

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

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

Dimensioned drawing

The following illustration (>>> Fig. 5-2) provides all the necessary informa-
tion on the mounting base, together with the required foundation data.

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

1 Resin-bonded anchor
2 Locating pin
3 Hexagon bolt with conical spring washer
4 Bedplate
To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
illustration (>>> Fig. 5-3). The specified foundation dimensions refer to the
safe transmission of the foundation loads into the foundation and not to
the stability of the foundation.

Fig. 5-3: Cross-section of foundations

1 Resin-bonded anchor 3 Bedplate

2 Concrete foundation 4 Hexagon bolt
with conical spring washer

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NOTICE
The dimensions specified for the distance to the edge are valid for non-
reinforced or normally reinforced concrete without verification of
concrete edge failure. For safety against concrete edge failure in ac-
cordance with ETAG 001 Annex C, the concrete foundation must be
provided with an appropriate edge reinforcement.

5.3 Machine frame mounting

Description

The machine frame mounting (>>> Fig. 5-4) with centering is used for in-
stalling the robot on a steel structure provided by the customer or on the
carriage of a KUKA linear unit. The mounting surface for the robot must
be machined and of an appropriate quality. For the machine frame mount-
ing, the robot is fastened using 4 hexagon bolts with conical spring wash-
ers. Two locating pins are used for centering.
The steel structure used by the customer must be designed in such a way
that the forces generated (mounting base load, maximum load
(>>> 4 "Technical data" Page 35)) are safely transmitted via the screw
connection and the necessary stiffness is ensured. The specified surface
values and tightening torques must be observed.
The following values must be taken into consideration in the design:
• Stripping safety: The material of the substructure must be selected so
that the stripping safety is ensured (e.g. S355J2G3).
The machine frame mounting assembly consists of:
• 2 locating pins
• 4 hexagon bolts with conical spring washers

Fig. 5-4: Machine frame mounting

1 Machine frame
2 Hexagon bolt with conical spring washer
3 Mounting surface, machined
4 Locating pin, flat-sided
5 Locating pin, round

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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 diagram contains all the necessary information that must be
observed when preparing the mounting surface and the holes
(>>> Fig. 5-5).

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

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1 Hexagon bolt with conical spring washer

2 Locating pin
3 Mounting surface, machined

5.4 Connecting cables and interfaces

Connecting cables

The connecting cables comprise all the cables for transferring energy and
signals between the robot and the robot controller. They are connected to
the robot junction boxes with connectors.
The following cable lengths are available as standard:
• KR C5 micro: 1 m, 4 m, 7 m, 15 m, 25 m
• KR C5 S: 4 m, 7 m, 10 m, 15 m, 20 m, 25 m, 35 m and 50 m
The maximum length of the connecting cables must not exceed 25 m for
operation with a KR C5 micro or 50 m for operation with a KR C5 S. The
connecting cables may be extended a maximum of 1 time, i.e. a maxi-
mum 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. A second ground con-
ductor must additionally be installed between the robot and the system.
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 75 mm for
motor cables and 45 mm for control 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 (+70 °C).
• Route the motor cables and the data cables separately in metal ducts;
if necessary, additional measures must be taken to ensure electromag-
netic compatibility (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 (>>> Fig. 5-6) on the base frame is illustrated below for ro-
bots with the standard cable set:

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Planning
Fig. 5-6: Interface A1

1 Connection X30 for motor cable XD30

2 Connection X31 for data cable XF31

Interface for energy supply system

The robot can be equipped with an energy supply system between axis 1
and axis 3 and a second energy supply system between axis 3 and axis
6. The A1 interface required for this is located on the rear of the base
frame, the A3 interface is located on the side of the arm. Depending on
the application, the interfaces differ in design and scope. They can be
equipped, for example, with connections for cables and hoses. Detailed in-
formation about the energy supply A3-A6, e.g. the connector pin alloca-
tion, threaded unions, etc., can be found in separate documentation.

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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.
Avoid vibrations and impacts during transportation in order to prevent
damage to the manipulator.

Transport position

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

The robot is in the transport position when the axes are in the following
positions:
Transport position
A1 0 °
A2 -120 °
A3 155 °
A4 0 °
A5 80 °
A6 0 °

Fig. 6-1: Transport position

Transport dimensions

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

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Fig. 6-2: Transport dimensions

1 Center of gravity
2 Robot
3 Fork slots
Transport dimensions and centers of gravity in mm:
Robot A B C D E F G
KR 6 R1840-2 1212 849 321 10 536 433 -18
KR 8 R1640-2 1212 685 321 -9 562 433 -23
KR 10 R1440-2 1039 685 221 37 490 433 -17

Transportation

The floor-mounted robot is transported using a crane or fork lift truck. The
ceiling-mounted robot in its installation position can only be transported
outside the transport frame using a fork lift truck. In the transport frame,
transportation with fork lift truck or crane is possible.
WARNING
Use of unsuitable handling equipment may result in damage to the robot
or injury to persons. Only use authorized handling equipment with a suf-
ficient load-bearing capacity. Only transport the robot in the manner
specified here.

Transportation by fork lift truck

For transport by fork lift truck (>>> Fig. 6-3), the fork slots must be prop-
erly and fully installed.
The robot must be in the transport position.

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Transportation
Fig. 6-3: Transportation by fork lift truck

Transportation using lifting tackle (optional)

For installation on the floor, the robot can be transported using a crane
and lifting tackle (optional) (>>> Fig. 6-4). For this, it must be in the trans-
port position. The lifting tackle (optional) is attached to swivel eyebolts that
are screwed into the rotating column (1x) and into the base frame (2x). All
ropes must be long enough and must be routed in such a way that the
robot is not damaged. Installed tools and pieces of equipment can cause
undesirable shifts in the center of gravity. These must therefore be re-
moved if necessary.
The swivel eyebolts must be removed from the rotating column after trans-
portation.
WARNING
Risk of injury during transportation
The robot may tip during transportation. Death, severe injuries or dam-
age to property may result.
• When transporting the robot using lifting tackle (optional), 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 (optional)

2 Leg G4

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3 Leg G3
4 M12 swivel eyebolt, rotating column, front
5 Leg G1
6 Leg G2
7 M12 swivel eyebolt, base frame, right and left

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Start-up and recommissioning

7 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
Robot Installation position: floor and mounting Starting up robots (mounting base)
installation base
(>>> 7.1 "Starting up floor-mounted ro-
bots (mounting base)" Page 137)
Installation position: floor, ceiling, wall Starting up robots (machine frame
and machine frame mounting mounting)
(>>> 7.2 "Starting up robots (machine
frame mounting)" Page 144)

7.1 Starting up floor-mounted robots (mounting base)

Description

The mounting base is used for installing robots on a foundation.

They are fastened to a suitable concrete foundation using a bedplate /
foundation slats and chemical anchors.
This description is valid for the installation of floor-mounted robots with the
mounting variant “mounting base”.
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. Observe also the manufacturer’s in-
structions for the use of chemical anchors.
The installation and start-up of the robot controller, the tools mounted and
the applications are not described here.

Equipment

The following equipment is required:

Designation Article number
Lifting tackle / rope sling with sufficient -
load-bearing capacity
Crane with sufficient load-bearing capaci- -
ty
LLA forklift slots KR CYBERTECH 0000-269-312
or
-
3 M12 swivel eyebolts
Drill with a ø 14 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

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Material

The following material is required:

Designation Article number Quantity
Mounting base set S260 S310 0000-260-959 1

Tightening torques

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

torques" Page 215)
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 crane or fork lift truck.

• The robot is in the transport position.
• The concrete foundation must have the required dimensions and
cross-section.
• The surface of the foundation must be smooth and even.
• 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 and unintentional mo-
tions of the robot, positioner or other components can cause 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 posi-
tion and secured with a padlock to prevent unauthorized persons from
switching it on again.
Warn all persons concerned before putting the system back into opera-
tion.

WARNING
Use of unsuitable handling equipment may result in damage to the robot
or injury to persons. Only use authorized handling equipment with a suf-
ficient load-bearing capacity. Only transport the robot in the manner
specified here.

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

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

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

7.1.1 Installing fork slots or swivel eyebolts

Procedure

• Screw 3 M12 swivel eyebolts into the rotating column and base frame
or
Fasten 2 fork slots to the rotating column with 2 M12x25-8.8 Allen
screws including lock washers. Increase the tightening torque to the
specified value.

Fig. 7-1: Installing/removing fork slots or swivel eyebolts

1 M12x25-8.8 Allen screw

2 Lock washer
3 Fork slot
4 Swivel eyebolt

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7.1.2 Installing the robot with mounting base

Procedure

1. Clean the concrete foundation.

2. Screw 2 locating pins into the bedplates and check that they are fitted
securely.
3. Lift the robot with the crane or fork lift truck and move it to the instal-
lation site.
4. Clean the lower mounting surface on the robot.
5. Fasten the 4 bedplates to the robot using 1 M12x40-10.9 hexagon bolt
and lock washer for each one as shown in the illustration
(>>> Fig. 7-2). Ensure that an entirely vertical position is maintained in
order to prevent damage to the locating pins.
6. Tighten 4 M12x40-10.9 hexagon bolts with torque wrench. Increase
the tightening torque to the specified value in several stages.

Fig. 7-2: Mounting base

1 Hexagon bolt with conical spring washer (4x)

2 Bedplate (4x)
3 Locating pin (2x)
4 Resin-bonded anchor (4x)

7. Determine the position of the robot on the mounting base in relation to

the working envelope.
8. Set the robot down on the mounting base in its installation position.
9. Check the surface of the concrete foundation:
• 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.
If the evenness of the foundation is outside the specified tolerances,
this can cause strain or result in loosening of the mounting base.
10. Lift robot with crane or 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.

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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 instructions.
15. Drill 4 anchor holes in accordance with the manufacturer’s specifica-
tions and fit the anchors as specified in the instructions for use.
The instructions for use are enclosed with the anchors and must be
followed precisely.

Fig. 7-3: Installing the robot

1 M12x40-10.9 hexagon bolt

2 Lock washer
3 Base frame
4 Locating pin, flat-sided
5 Resin-bonded anchor
6 Bedplate
7 Locating pin, round

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7.1.3 Removing fork slots or swivel eyebolts

Procedure

• Unscrew 3 M12 swivel eyebolts from the rotating column and base
frame
or
Remove 2 fork slots. To do so, unscrew 2 M12x25-8.8 Allen screws
with lock washers and remove the fork slots.

Fig. 7-4: Installing/removing fork slots or swivel eyebolts

1 M12x25-8.8 Allen screw

2 Lock washer
3 Fork slot
4 Swivel eyebolt

7.1.4 Connecting the connecting cables

Procedure

Fig. 7-5: Connecting cables, overview, KR C5 micro

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Fig. 7-6: Connecting cables, overview, KR C5 S

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. Optionally, fasten the ground conductor between the system compo-
nent and the robot to the ground conductor connection with 1 M8 hex-
agon nut including conical spring washer; tightening torque
MA= 15.0 Nm.
3. Connect the connecting cables (>>> Fig. 7-7):
• Motor cable XD30 to connection X30
• Data cable XF31 to connection X31
When connecting the motor and data cable connectors, it must be en-
sured that the connectors on the controller and on the robot are
locked correctly. Correct locking of the motor cable connector to the
robot is indicated by an audible click. It is indicated optically by the
fact that the red rings on each of the locking buttons are not visible
and are pushed in completely.
As an integrated feature, this pushbutton locking mechanism also has
a blocking function that can be optionally used. Turning the locking
button by 90° blocks the locking mechanism. This prevents the con-
nector from being unintentionally released.
4. 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.

5. Enter the installation position of the robot in WorkVisual. The default

installation position is the floor.

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Fig. 7-7: Connecting the connecting cables

1 Ground conductor, system (can be ordered as an option)

2 External ground conductor (KRC)
3 Motor cable XD30
4 Data cable XF31
Put the robot into operation in accordance with the “Start-up” chapter of
the operating and programming instructions for the System Software
and/or the assembly instructions or operating instructions for the robot
controller.
If the manipulator is operated with an external axis, the “cascadable RDC”
option is required.
Further information can be found in the assembly instructions of the
cascadable RDC.

7.1.5 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 chapter
“Start-up and recommissioning” of the operating and programming in-
structions for the KUKA System Software (KSS).

7.2 Starting up robots (machine frame mounting)

Description

The machine frame mounting is used for installing robots on a steel struc-
ture prepared by the customer.
Fastening is carried out using 4 hexagon bolts with conical spring wash-
ers. 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

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impossible; the center of gravity must be taken into account . When rotat-

Start-up and recommissioning

ing the robot, care must be taken not to damage the connectors, installa-
tion material and/or energy supply system (optional). The wall-mounted or
ceiling-mounted installation is analogous to installation of the floor-moun-
ted 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

The following equipment is required:

Designation Article number
Lifting tackle / rope sling with sufficient -
load-bearing capacity
Crane with sufficient load-bearing capaci- -
ty
LLA forklift slots KR CYBERTECH 0000-269-312
or
-
3 swivel eyebolts
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 80 to 400 Nm

Material

The following material is required:

Designation Article number Quantity
Machine frame mounting 0000-262-108 1

Tightening torques

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

torques" Page 215)
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 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.

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• 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 and unintentional mo-
tions of the robot, positioner or other components can cause 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 posi-
tion and secured with a padlock to prevent unauthorized persons from
switching it on again.
Warn all persons concerned before putting the system back into opera-
tion.

WARNING
Use of unsuitable handling equipment may result in damage to the robot
or injury to persons. Only use authorized handling equipment with a suf-
ficient load-bearing capacity. Only transport the robot in the manner
specified here.

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

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

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

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7.2.1 Installing fork slots or swivel eyebolts

Procedure

• Screw 3 M12 swivel eyebolts into the rotating column and base frame
or
Fasten 2 fork slots to the rotating column with 2 M12x25-8.8 Allen
screws including lock washers. Increase the tightening torque to the
specified value.

Fig. 7-8: Installing/removing fork slots or swivel eyebolts

1 M12x25-8.8 Allen screw

2 Lock washer
3 Fork slot
4 Swivel eyebolt

7.2.2 Installing the robot with the machine frame mounting assembly

Procedure

1. Clean the mounting surface.

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 robot with the crane or fork lift truck and move it to the instal-
lation site.
5. Clean the lower mounting surface on the robot.
6. Lower the robot vertically onto the mounting surface. Align as illustra-
ted (>>> Fig. 7-9). Ensure that an entirely vertical position is main-
tained in order to prevent damage to the locating pins.
7. Insert 4 M12x40-10.9 hexagon bolts.
8. Tighten the 4 M12x40-10.9 hexagon bolts with a torque wrench in di-
agonally opposite sequence. Increase the tightening torque to the
specified value in several stages.

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Fig. 7-9: Installing the machine frame mounting assembly

1 Machine frame
2 M12x40-10.9 hexagon bolts
3 Mounting surface, machined
4 Locating pin, flat-sided
5 Locating pin, round

7.2.3 Removing fork slots or swivel eyebolts

Procedure

• Unscrew 3 M12 swivel eyebolts from the rotating column and base
frame
or
Remove 2 fork slots. To do so, unscrew 2 M12x25-8.8 Allen screws
with lock washers and remove the fork slots.

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Fig. 7-10: Installing/removing fork slots or swivel eyebolts

1 M12x25-8.8 Allen screw

2 Lock washer
3 Fork slot
4 Swivel eyebolt

7.2.4 Connecting the connecting cables

Procedure

Fig. 7-11: Connecting cables, overview, KR C5 micro

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Fig. 7-12: Connecting cables, overview, KR C5 S

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. Optionally, fasten the ground conductor between the system compo-
nent and the robot to the ground conductor connection with 1 M8 hex-
agon nut including conical spring washer; tightening torque
MA= 15.0 Nm.
3. Connect the connecting cables (>>> Fig. 7-13):
• Motor cable XD30 to connection X30
• Data cable XF31 to connection X31
When connecting the motor and data cable connectors, it must be en-
sured that the connectors on the controller and on the robot are
locked correctly. Correct locking of the motor cable connector to the
robot is indicated by an audible click. It is indicated optically by the
fact that the red rings on each of the locking buttons are not visible
and are pushed in completely.
As an integrated feature, this pushbutton locking mechanism also has
a blocking function that can be optionally used. Turning the locking
button by 90° blocks the locking mechanism. This prevents the con-
nector from being unintentionally released.
4. 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.

5. Enter the installation position of the robot in WorkVisual. The default

installation position is the floor.

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Fig. 7-13: Connecting the connecting cables

1 Ground conductor, system (can be ordered as an option)

2 External ground conductor (KRC)
3 Motor cable XD30
4 Data cable XF31
Put the robot into operation in accordance with the “Start-up” chapter of
the operating and programming instructions for the System Software
and/or the assembly instructions or operating instructions for the robot
controller.
If the manipulator is operated with an external axis, the “cascadable RDC”
option is required.
Further information can be found in the assembly instructions of the
cascadable RDC.

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 chapter
“Start-up and recommissioning” of the operating and programming in-
structions for the KUKA System Software (KSS).

7.3 Description of the connecting cables, KR C5 micro

Description

The connecting cables are used to transfer power and signals between
the robot controller and the robot.
The connecting cables comprise:
• Motor cable XD30:
‒ Motor connector 1: XD20.1 - XD30 for connection A1-A3 incl.
brakes
‒ Motor connector 2: XD20.2 - XD30 for connection A4-A6 incl.
brakes

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• Data cable XF31, XF21 - XF31

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.
Cable designation Connector designation Interface
Robot controller - robot Robot
Motor cable XD30 Motor connector 1: Han-Yellock® 60
XD20.1 - XD30
Connection A1-A3 incl.
brakes
Motor connector 2:
XD20.2 - XD30
Connection A4-A6 incl.
brakes
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipo- Ring cable lug, M8
tential bonding
4 mm2

Connecting cables

The following diagram (>>> Fig. 7-14) provides an overview of the con-
necting cables.

Fig. 7-14: Connecting cables, overview, KR C5 micro

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Fig. 7-15: Connecting cable, motor cable, KR C5 micro

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Fig. 7-16: Connecting cable, motor cable, KR C5 micro, circuit dia-

gram

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Fig. 7-17: Connecting cable, data cable, KR C5 micro

Fig. 7-18: Connecting cable, ground conductor

1 Ground conductor 6 Conical spring washer

2 Hexagon nut 7 Robot
3 Conical spring washer 8 Setscrew, M8
4 2x plain washer 9 Ground conductor connection,
M8 ring cable lug
5 Hexagon nut 10 Ground sign

7.4 Description of the connecting cables, KR C5 S

Description

The connecting cables are used to transfer power and signals between
the robot controller and the robot.
The connecting cables comprise:

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• Motor cable XD30:

‒ 6 motor connectors: XD20.1 … XD20.6 - XD30
‒ 2 brake connectors: XD10.1, XD10.2 - XD30
• Data cable XF31, XF21 - XF31

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.
Cable designation Connector designation Interface
Robot controller - robot Robot
Motor cable XD30 6 motor connectors: Han-Yellock® 60
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
Data cable XF31 XF21 - XF31 Han® 3A
Ground conductor / equipo- M8 ring cable lug at both
tential bonding ends
16 mm2

Connecting cables

The following diagram (>>> Fig. 7-19) provides an overview of the con-
necting cables.

Fig. 7-19: Connecting cables, overview, KR C5 S

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Fig. 7-20: Connecting cables, motor cable, KR C5 S Start-up and recommissioning

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Fig. 7-21: Connecting cable, motor cable, KR C5 S, circuit diagram

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Fig. 7-22: Connecting cable, data cable, KR C5 S

Fig. 7-23: Connecting cable, ground conductor

1 Ground conductor 6 Conical spring washer

2 Hexagon nut 7 Robot
3 Conical spring washer 8 Setscrew, M8
4 2x plain washer 9 Ground conductor connection,
M8 ring cable lug
5 Hexagon nut 10 Ground sign

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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 35). 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 125).

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.

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

tion, shorter maintenance intervals must be observed; for this, consultation

with KUKA Deutschland GmbH is necessary.

8.1.1 Maintenance table

Maintenance symbols

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

Oil change

Lubricate with grease gun

Lubricate with brush

Lubricate with spray grease

Tighten screw/nut

Check component, visual inspection

Clean component

Exchange battery

Exchange component

Check toothed belt tension

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Maintenance
Fig. 8-1: Maintenance diagram

Interval Item Task Auxiliary substances and

consumables
Once only, af- 6 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
or 1 year flexible tubes for damage.
at the latest
In the case of damage and/or cracks,
have the cable set exchanged by
KUKA Service.
5,000 h 2 Grease cable set A1 Lubricating grease Optitemp
or 1 year (>>> 8.2 "Greasing cable set A1" RB2
at the latest Page 164)
200 cm³
5,000 h 1 Exchange toothed belt A5
or 1 year (>>> 8.3 "Exchanging the toothed belt
at the latest on A5" Page 167)
20,000 h 4 Oil change, gear unit A3 Optigear Synt. ALR 150
or 5 years (>>> 8.6 "Oil change in A3"
Initial filling quantity: 0.26 l
at the latest Page 185)
20,000 h 3 Oil change, gear unit A2 Optigear Synt. ALR 150
or 5 years (>>> 8.5 "Oil change in A2"
Initial filling quantity: 0.43 l
at the latest Page 181)
20,000 h 5 Oil change, gear unit A1 Optigear Synt. ALR 150
or 5 years (>>> 8.4 "Oil change in A1"
Initial filling quantity: 0.52 l
at the latest Page 173)

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Up-to-date safety data sheets must be requested from the manufacturers

Maintenance

of auxiliary and operating materials. Further information about the auxiliary

substances and consumables used can be found under:

8.2 Greasing cable set A1

Description

The following sections describe the procedure for greasing cable set A1
for floor-mounted robots. For ceiling-mounted robots, proceed accordingly.

Equipment

The following equipment is required:

Designation Article number
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

The following material is required:

Designation Article number Quantity
Lubricating grease Optitemp RB2 (>>> 12.2 "Aux- 0.3 kg
iliary and oper-
ating materials
used"
Page 216)

Tightening torques

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

torques" Page 215)
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 robot is accessible in the area of axis 1

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Maintenance
Work safety

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

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 Removing the cover from the base frame

Procedure

1. Remove 5 M6x8-10.9-A2K round head screws from the cover.

2. Take the cover with brush fitted carefully off the base frame.

Fig. 8-2: Cover on the base frame (example)

1 Brush
2 Cover
3 M6x8-10.9 round head screw (5x)

8.2.2 Checking and greasing cable set A1

Procedure

1. Carry out a visual inspection of the flexible tubes and clean them.
If damage is detected, the cable set must be exchanged.
2. Using a brush, grease the outside of the flexible tubes, the contact
surfaces towards the base frame and the rear side of the cover.
Wear protective gloves.

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Maintenance KR CYBERTECH nano-2

Fig. 8-3: Cable set – base frame

1 Cable set
2 Rotating column
3 Base frame

8.2.3 Mounting the cover on the base frame

Procedure

1. Push the brush onto the cover.

2. Place the cover with brush fitted around the base frame and align it.
3. Fasten the cover using 5 M6x8-10.9 round head screws.

Fig. 8-4: Cover on the base frame (example)

1 Brush
2 Cover
3 M6x8-10.9 round head screw (5x)

8.2.4 Concluding work

The following concluding work must be carried out:

• Remove grease residue.
• To spread the grease out evenly, move A1 of the robot.

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Maintenance
8.3 Exchanging the toothed belt on A5

Description

The following sections describe the procedure for exchanging toothed belt
A5 on a floor-mounted robot.

Equipment

The following equipment is required:

Designation Article number
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Set of combination wrenches -
6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 17;
19 mm
Set of TORX key wrenches -
TX5; TX6; TX7; TX8; TX9; TX10; TX15
Socket wrench set -
Torque wrench -
min. 5 Nm to 50 Nm

Frequency meter TSM alpha 2 0071-053-386

Material

The following material is required:

Designation Article number Quantity
Toothed belt 6 HTD-5M/325 HP 0000-287-149 1

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

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

torques" Page 215)
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 arm is in the horizontal position.

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Maintenance KR CYBERTECH nano-2

• The wrist axes are in their zero positions.

• No tools are installed on axis 6.

Work safety

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.

CAUTION
Risk of burns from lubricants, components and surfaces
Immediately after the robot has been shut down, lubricants, components
and surfaces in the vicinity of the gear units and motors may have high
temperatures. Touching them may result in burns.
• Wear protective gloves.
• Allow components to cool if necessary.

CAUTION
If the toothed belt tension is measured and adjusted immediately after
the robot has stopped operating, surface temperatures are likely to be
high and could result in burn injuries. Protective gloves must be worn.

WARNING
Danger to life and limb due to live components
Components may remain energized after the robot system has been
switched off. Death, severe injuries or damage to property may result.
• Switch off the robot system at the main switch and secure it to pre-
vent unauthorized persons from switching it on again.
• Disconnect the power cable from the supply.
• After switching off, wait at least 5 minutes and then check to ensure
that the robot controller and power cable are deenergized.

8.3.1 Removing the belt-side cover from the in-line wrist

Procedure

1. Unscrew 9 M4x14-10.9 Allen screws together with lock washers from

the cover.
2. Take the cover off the in-line wrist.

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Maintenance
Fig. 8-5: Belt-side cover on in-line wrist

1 In-line wrist
2 Belt-side cover
3 Lock washer
4 M4x14-10.9 Allen screw

8.3.2 Removing toothed belt A5

Procedure

1. Remove M4x16-8.8-A2K hexagon screw (adjusting screw).

2. Remove 2 M3x6-10.9-A2K TORX round head screws with collar.
3. Slacken M4x16-8.8-A2K hexagon screw (adjusting screw) until toothed
belt A5 can be detached from the toothed belt pulleys.

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Maintenance KR CYBERTECH nano-2

Fig. 8-6: Toothed belt A5

1 Toothed belt pulley

2 Toothed belt A5
3 M4x16-8.8-A2K hexagon screw (adjusting screw)
4 M3x6-10.9-A2K TORX round head screw with collar

8.3.3 Installing toothed belt A5

Procedure

1. Fit toothed belt A5 in the in-line wrist and place it on the toothed belt
pulleys. Ensure that the toothed belt meshes properly with the toothed
belt pulleys.

Fig. 8-7: Toothed belt and toothed belt pulley

1 Toothed belt
2 Toothed belt pulley

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Maintenance
Fig. 8-8: Toothed belt A5

1 Toothed belt pulley

2 Toothed belt A5
3 M4x16-8.8-A2K hexagon screw (adjusting screw)
4 M3x6-10.9-A2K TORX round head screw with collar

8.3.4 Adjusting toothed belt tension on A5

Procedure

1. Shift right-hand toothed belt pulley A5 to the right until the toothed belt
is preloaded with roughly the right tension. At the same time, tighten
the 2 new M3x6-10.9-A2K TORX round head screws with collar until
the right-hand toothed belt pulley A5 can no longer shift by itself.

Fig. 8-9: Toothed belt A5

1 Toothed belt pulley

2 Toothed belt A5
3 M4x16-8.8-A2K hexagon screw (adjusting screw)

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Maintenance KR CYBERTECH nano-2

4 M3x6-10.9-A2K TORX round head screw with collar

2. Put the robot into operation and move A5 two to three times by ap-
prox. 20° in the +/- direction before moving the axis into position to
measure the toothed belt tension.
3. Move A5 to the 0° position and secure the robot.
4. Put the frequency meter into operation. (>>> Fig. 8-10)
5. Pluck toothed belt A5 and hold the sensor at a distance of 2 to 3 mm
from the vibrating toothed belt. Read the measurement on the frequen-
cy meter.

Fig. 8-10: Frequency meter

1 Frequency meter
2 Sensor
Setpoint value
Axis Frequency
5 180 ± 5 Hz

6. If the frequency specified in the table is not reached, slacken or tight-

en the M4x16-8.8-A2K hexagon screw (adjusting screw) slightly
(>>> Fig. 8-9).
7. Repeat steps 5 and 6 until the setpoint value has been reached.
8. When the setpoint value is reached, tighten the 2 M3x6-10.9-A2K
TORX round head screws with a torque wrench. Increase the tighten-
ing torque to the specified value in several stages (>>> Fig. 8-9).

8.3.5 Installing the belt-side cover on the in-line wrist

Procedure

1. Check the foam gasket on the inside of the cover for damage and ex-
change if necessary.
2. Place the cover on the in-line wrist and align it.
3. Fasten the cover using 9 new M4x14-10.9 Allen screws together with
lock washers.

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Maintenance
Fig. 8-11: Belt-side cover on in-line wrist

1 In-line wrist
2 Belt-side cover
3 Lock washer
4 M4x14-10.9 Allen screw

8.3.6 Concluding work

The following concluding work must be carried out:

• Carry out mastering of A5.
Detailed information about mastering is contained in the operating
and programming instructions for end users or system integrators.

• Run the program in T1 mode and look out for irregularities.

8.4 Oil change in A1

Description

The following instructions describe the gear oil change for this axis. This
description applies to floor-mounted robots. If the robot is installed in an
inclined or suspended position, it must be ensured that all the oil can flow
out. If necessary, the robot may have to be removed and bolted to the
floor.
If the robot is installed in an inverted position, the procedure is to be ap-
plied analogously, but with the filler and drain holes reversed.

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Maintenance KR CYBERTECH nano-2

Equipment

The following equipment is required:

Designation Article number
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Set of Allen keys -
12; 14; 16; 20; 24; 30 mm
Set of combination wrenches -
6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 17;
19 mm
Socket wrench set -
Torque wrench -
min. 2 Nm to 20 Nm
Collection receptacle -
Cleaning cloth -

KUKA oil pump 0000-180-812

Oil drain hose (M18x1,5) assy. 0000-341-661

Material

The following material is required:

Designation Article number Quantity
Optigear Synt. ALR 150 (>>> 12.2 "Aux- Initial fill-
iliary and oper- ing quan-
ating materials tity: 0.52 l
used"
Page 216)

Refilling quantity

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

Tightening torques

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

torques" Page 215)
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.

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When the screws are first slackened they must be replaced with new

Maintenance
ones.

Preconditions

• The controller is switched off and secured to prevent unauthorized per-

sons from switching it on again.
• The gear unit is at operating temperature.
• The screw plugs are freely accessible.

Work safety

CAUTION
High oil and surface temperatures after the robot has stopped op-
erating
If the oil change is carried out immediately after the robot has stopped
operating, the oil temperature and the surface temperature are liable to
be high. Touching them may result in burns.
• Wear protective gloves.

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

8.4.1 Removing the covers from the base frame

Procedure

1. Unscrew 5 M6x8-10.9 round head Allen screws with collar from the
cover.
2. Unscrew 2 M6 hexagon nuts together with conical spring washer from
the cover.
3. Remove both covers including brushes from the base frame.

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Maintenance KR CYBERTECH nano-2

Fig. 8-12: Covers and brushes on the base frame

1 M6x8-10.9 round head Allen screw with collar

2 M6 hexagon nut with conical spring washer
3 Cover (short)
4 Brush (short)
5 Cover
6 Brush (long)

8.4.2 Draining the gear oil from A1

Procedure

1. Unscrew the M18x1.5 magnetic screw plug on the base frame and
screw in M18x1.5 oil drain hose.
2. Place a suitable receptacle under the oil drain hose.

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Maintenance
Fig. 8-13: Draining the gear oil from A1 – magnetic screw plug on
the base frame

1 M18x1.5 magnetic screw plug

2 M18x1.5 oil drain hose
3 Collection receptacle

3. Remove the M18x1.5 magnetic screw plugs from the rotating column
for venting and catch the oil as it drains out.

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Maintenance KR CYBERTECH nano-2

Fig. 8-14: Draining the gear oil from A1 – magnetic screw plugs
on the rotating column

1 M18x1.5 magnetic screw plug

2 M18x1.5 magnetic screw plug (oil level hole)

4. Inspect the magnetic screw plugs for deposits and clean them.
5. Measure the amount of oil drained and dispose of the used oil in ac-
cordance with the pertinent regulations.

8.4.3 Filling gear unit A1 with gear oil

Procedure

1. Screw in the M18x1.5 oil drain hose.

2. Connect the oil pump to the M18x1.5 oil drain hose.
3. Fill with gear oil via the M18x1.5 oil drain hose up to the lower edge
of the side oil level hole.
4. Clean the magnetic screw plugs and check the sealing element; ex-
change the magnetic screw plug if damaged.

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Maintenance
Fig. 8-15: Filling gear unit A1 with gear oil – magnetic screw plug
on the base frame

1 Oil pump
2 M18x1.5 oil drain hose
3 M18x1.5 magnetic screw plug

5. Insert and tighten both M18x1.5 magnetic screw plugs on the rotating
column; MA = 20 Nm.
6. Remove M18x1.5 oil drain hose and oil pump.
7. Insert and tighten the M18x1.5 magnetic screw plug on the base
frame; MA = 20 Nm.

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Maintenance KR CYBERTECH nano-2

Fig. 8-16: Filling gear unit A1 with gear oil – magnetic screw
plugs on the rotating column

1 Upper M18x1.5 magnetic screw plug

2 Side M18x1.5 magnetic screw plug

8.4.4 Installing the cover on the base frame

Procedure

1. Place both covers including brushes on the base frame and align
them.
2. Fasten the covers with 2 M6 hexagon nuts including conical spring
washers and 5 M6x8-10.9 round head Allen screws with collars.

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Maintenance
Fig. 8-17: Covers and brushes on the base frame

1 M6x8-10.9 round head Allen screw with collar

2 M6 hexagon nut with conical spring washer
3 Cover (short)
4 Brush (short)
5 Cover
6 Brush (long)

8.4.5 Concluding work

The following concluding work must be carried out:

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

8.5 Oil change in A2

Description

The following instructions describe the gear oil change for this axis. This
description applies to floor-mounted robots. If the robot is installed in an

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 KR CYBERTECH nano-2

inclined or suspended position, it must be ensured that all the oil can flow
Maintenance

out. If necessary, the robot may have to be removed and bolted to the
floor.
If the robot is installed in an inverted position, the procedure is to be ap-
plied analogously, but with the filler and drain holes reversed.

Equipment

The following equipment is required:

Designation Article number
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Socket wrench set -
Torque wrench -
min. 2 Nm to 20 Nm
Collection receptacle -
Cleaning cloth -

KUKA oil pump 0000-180-812

Oil drain hose (M18x1,5) assy. 0000-341-661

Material

The following material is required:

Designation Article number Quantity
Optigear Synt. ALR 150 (>>> 12.2 "Aux- Initial fill-
iliary and oper- ing quan-
ating materials tity: 0.43 l
used"
Page 216)

Refilling quantity

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

Tightening torques

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

torques" Page 215)
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.

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When the screws are first slackened they must be replaced with new

Maintenance
ones.

Preconditions

• The controller is switched off and secured to prevent unauthorized per-

sons from switching it on again.
• The gear unit is at operating temperature.
• The screw plugs are freely accessible.
• The robot is in a position in which all of the oil in this axis can flow
out.

Work safety

CAUTION
High oil and surface temperatures after the robot has stopped op-
erating
If the oil change is carried out immediately after the robot has stopped
operating, the oil temperature and the surface temperature are liable to
be high. Touching them may result in burns.
• Wear protective gloves.

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

8.5.1 Draining the gear oil from A2

Procedure

1. Unscrew the M18x1.5 magnetic screw plug and screw in M18x1.5 oil
drain hose.
2. Place a suitable receptacle under the oil drain hose.
3. Remove the M18x1.5 magnetic screw plug from the rotating column
for venting and catch the oil as it drains out.
4. Inspect the magnetic screw plugs for deposits and clean them.
5. Measure the amount of oil drained and dispose of the used oil in ac-
cordance with the pertinent regulations.

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Maintenance KR CYBERTECH nano-2

Fig. 8-18: Draining the gear oil from A2

1 M18x1.5 magnetic screw plug

2 Collection receptacle
3 M18x1.5 oil drain hose

8.5.2 Filling gear unit A2 with gear oil

Procedure

1. Screw in the M18x1.5 oil drain hose.

2. Connect the oil pump to the M18x1.5 oil drain hose.
3. Fill with the specified amount of oil from the bottom via the M18x1.5
oil drain hose.
4. Clean the magnetic screw plugs and check the sealing element; ex-
change the magnetic screw plug if damaged.
5. Insert and tighten the upper M18x1.5 magnetic screw plug, MA =
20 Nm.
6. Remove M18x1.5 oil drain hose and oil pump.
7. Insert and tighten the lower M18x1.5 magnetic screw plug; MA =
20 Nm.

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Maintenance
Fig. 8-19: Filling gear unit A2 with gear oil

1 M18x1.5 magnetic screw plug

2 M18x1.5 oil drain hose
3 Oil pump

8.5.3 Concluding work

The following concluding work must be carried out:

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

8.6 Oil change in A3

Description

The following instructions describe the gear oil change for this axis. This
description applies to floor-mounted robots. If the robot is installed in an
inclined or suspended position, it must be ensured that all the oil can flow
out. If necessary, the robot may have to be removed and bolted to the
floor.
If the robot is installed in an inverted position, the procedure is to be ap-
plied analogously, but with the filler and drain holes reversed.

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Maintenance KR CYBERTECH nano-2

Equipment

The following equipment is required:

Designation Article number
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Socket wrench set -
Torque wrench -
min. 2 Nm to 20 Nm
Collection receptacle -
Cleaning cloth -

KUKA oil pump 0000-180-812

Oil drain hose (M18x1,5) assy. 0000-341-661

Material

The following material is required:

Designation Article number Quantity
Optigear Synt. ALR 150 (>>> 12.2 "Aux- Initial fill-
iliary and oper- ing quan-
ating materials tity: 0.26 l
used"
Page 216)

Refilling quantity

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

Tightening torques

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

torques" Page 215)
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.

Preconditions

• The controller is switched off and secured to prevent unauthorized per-

sons from switching it on again.

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Maintenance
• The gear unit is at operating temperature.
• The screw plugs are freely accessible.
• A2 and A3 are in the following position:
Robot A2 A3
KR 6 R1840-2 -90° +90°
KR 8 R1640-2
KR 10 R1440-2

Work safety

CAUTION
High oil and surface temperatures after the robot has stopped op-
erating
If the oil change is carried out immediately after the robot has stopped
operating, the oil temperature and the surface temperature are liable to
be high. Touching them may result in burns.
• Wear protective gloves.

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

8.6.1 Draining the gear oil from A3

Procedure

1. Remove the lower M18x1.5 magnetic screw plug and screw in the
M18x1.5 oil drain hose.
2. Place a suitable receptacle under the oil drain hose.
3. Remove the upper M18x1.5 magnetic screw plug (oil level indicator)
on the arm for venting and catch the oil as it drains out.
4. Inspect the magnetic screw plugs for deposits and clean them.
5. Measure the amount of oil drained and dispose of the used oil in ac-
cordance with the pertinent regulations.

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Maintenance KR CYBERTECH nano-2

Fig. 8-20: Draining the gear oil from A3

1 M18x1.5 magnetic screw plug

2 Collection receptacle
3 M18x1.5 oil drain hose

8.6.2 Filling gear unit A3 with gear oil

Procedure

1. Screw in the M18x1.5 oil drain hose.

2. Connect the oil pump to the M18x1.5 oil drain hose.
3. Fill with the specified amount of oil from the bottom via the M18x1.5
oil drain hose.
4. Clean the magnetic screw plugs and check the sealing element; ex-
change the magnetic screw plug if damaged.
5. Insert and tighten the upper M18x1.5 magnetic screw plug (oil level in-
dicator); MA = 20 Nm.
6. Remove the M18x1.5 oil drain hose and oil pump.
7. Insert and tighten the lower M18x1.5 magnetic screw plug; MA =
20 Nm.

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Maintenance
Fig. 8-21: Filling gear unit A3 with gear oil

1 M18x1.5 magnetic screw plug

2 M18x1.5 oil drain hose
3 Oil pump

8.6.3 Concluding work

The following concluding work must be carried out:

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

8.7 Cleaning the robot

Description

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

Equipment

The following equipment is required:

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

Material

The following material is required:

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Designation Article number Quantity

Cleaning agent - -
solvent-free, water-soluble, non-flamma-
ble, non-aggressive, no steam, no refrig-
erants

Precondition

• The robot controller is switched off.

• The robot is freely accessible.

Work safety

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

8.7.1 Cleaning

Procedure

1. Shut down the robot.

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

8.7.2 Concluding work

The following concluding work must be carried out:

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

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Repair
9 Repair
Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA. Information about KUKA College and its training
program can be found at college.kuka.com or can be obtained directly
from our subsidiaries.
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.

9.1 Description of the electrical installations

Overview

The electrical installations of the robot comprise the following cable sets
and cables for the energy supply system:
• Cable set A1-A3
• Cable set A4-A6
• micro RDC cool
• EDS cool

Description

The electrical installations essentially consist of cable set A1-A3, cable set
A4-A6 and the electronic modules, such as the micro RDC cool und EDS
cool. Both cable sets are adapted to the robot reach and thus to the
lengths of the link arm and the arm.
The micro RDC cool and EDS cool are explained in more detail in the
documentation of the robot controller.
The cable set includes all the supply and control cables for the motors of
axes 1 to 6 as well as the cables for the protective circuit.
The interface for connecting the connecting cables to the robot is located
on the base frame at the rear of the robot. The connecting cables from
the controller (motor cable XD30, data cable XF31 and the ground con-
ductor) are connected here by means of connectors.
The selected routing of cables and hoses within the robot arm ensures
that the lines 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 on the manipulator.

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Fig. 9-1: Overview of electrical installations

1 Motor A3 6 Interface A1
2 Cable set A1-A3 7 Motor A6
3 Motor A1 8 Motor A5
4 Motor A2 9 Cable set A4-A6
5 micro RDC cool 10 Motor A4

9.1.1 Cable set A1-A3

Wiring diagrams, cable set A1-A3

Designation Connection Figure

X30 XM1
Wiring diagram A1 (>>> Fig. 9-2)
X1 XP1
X30 XM2
Wiring diagram A2 (>>> Fig. 9-3)
X2 XP2
X30 XM3
Wiring diagram A3 (>>> Fig. 9-4)
X3 XP3
XM4
X30 XBR4
Wiring diagram A4 XBR56 (>>> Fig. 9-5)
X4
XP4
X30 XM5.1
Wiring diagram A5 (>>> Fig. 9-6)
X5 XP5.1
X30 XM6.1
Wiring diagram A6 (>>> Fig. 9-7)
X6 XP6.1
X18
Data cable, micro RDC cool X31 (>>> Fig. 9-8)
X15
Protective circuit Ring cable lug (>>> Fig. 9-9)

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Repair
Fig. 9-2: Wiring diagram A1

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Fig. 9-3: Wiring diagram A2

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Repair
Fig. 9-4: Wiring diagram A3

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Fig. 9-5: Wiring diagram A4

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Fig. 9-6: Wiring diagram A5

Fig. 9-7: Wiring diagram A6

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Fig. 9-8: Wiring diagram, micro RDC cool, X31

Fig. 9-9: Wiring diagram, protective circuit, A1-A3

1 Ground conductor, arm – rotating column

Cross-section: 4 mm2
2 Ground conductor, rotating column – micro RDC cool box
Cross-section: 4 mm2
3 Ground conductor, rotating column – connection plate
Cross-section: 4 mm2
4 Ground conductor, base frame – connection plate
Cross-section: 4 mm2
5 Ground conductor, connection plate – PE rail
Cross-section: 4 mm2
6 Ground conductor, interface X30 – PE rail
Cross-section: 4 mm2

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Repair
7 External ground conductor (KRC)
Cross-section: 16 mm2

9.1.2 Cable set A4-A6

Wiring diagrams, cable set A4-A6

Designation Connection Figure

XM5.1 XM5
Wiring diagram A5 (>>> Fig. 9-10)
XP5.1 XP5
XM6.1 XM6
Wiring diagram A6 (>>> Fig. 9-11)
XP6.1 XP6
XBR5
Brakes A5-A6 XBr56 (>>> Fig. 9-12)
XBR6
Protective circuit Ring cable lug (>>> Fig. 9-13)

Fig. 9-10: Wiring diagram A5

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Fig. 9-11: Wiring diagram A6

Fig. 9-12: Wiring diagram, brakes A5-A6

Fig. 9-13: Wiring diagram, protective circuit, A1-A3

1 Ground conductor, arm – in-line wrist

Cross-section: 1.5 mm2
2 Ground conductor, in-line wrist – cover
Cross-section: 1.5 mm2
3 Ground conductor, in-line wrist – A6
Cross-section: 2x0.5 mm2

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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 round
slings and a crane (>>> 6 "Transportation" Page 133).

Equipment

The following equipment is required:

Name Article number
Lifting tackle / rope sling with sufficient -
load-bearing capacity
Crane/fork lift truck with sufficient load- -
bearing capacity
LLA forklift slots KR CYBERTECH 0000-269-312
or
-
3 M12 swivel eyebolts
Torque wrench -
min. 80 to 400 Nm

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
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.

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.

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3. Put the robot into operation and move it into the transport position.
4. Secure the robot by activating the EMERGENCY STOP device and
then shut down the robot.

Transport position
A1 0 °
A2 -120 °
A3 155 °
A4 0 °
A5 80 °
A6 0 °

Fig. 10-1: Transport position

10.1.2 Installing fork slots or swivel eyebolts

Procedure

• Screw 3 M12 swivel eyebolts into the rotating column and base frame
or
Fasten 2 fork slots to the rotating column with 2 M12x25-8.8 Allen
screws including lock washers. Increase the tightening torque to the
specified value.

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Decommissioning, storage and disposal

Fig. 10-2: Installing/removing fork slots or swivel eyebolts

1 M12x25-8.8 Allen screw

2 Lock washer
3 Fork slot
4 Swivel eyebolt

10.1.3 Removing the robot

Procedure

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 4 M12x40-10.9 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 two pins when lifting off the robot.
CAUTION
Risk of injury due to abrupt detachment of the robot
If the robot is caught on the mounting surface, it may come free
abruptly. Injuries or damage to property may result.
‒ Remove the fastening materials completely.
‒ Remove any adhesives.

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Fig. 10-3: Removing the robot

1 M12x40-10.9 hexagon bolt

2 Locating pin
3 External ground conductor (KRC)
4 System ground conductor (optional)
5 Data cable XF31
6 Motor cable XD30
7 Lifting tackle

10.1.4 Concluding work

The following concluding work must be carried out:

• 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

The following equipment is required:

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Decommissioning, storage and disposal

Designation Article number
Lifting tackle / rope sling with sufficient -
load-bearing capacity
Crane with sufficient load-bearing capaci- -
ty
LLA forklift slots KR CYBERTECH 0000-269-312
or
-
3 M12 swivel eyebolts
Torque wrench -
min. 80 to 400 Nm
Permissible cleaning tools (e.g. cloths, -
brushes)

Material

The following material is required:

Designation Article number Quantity
Covers - -
that cannot detach themselves and which
can withstand the expected environmen-
tal conditions
Cleaning agent - -
solvent-free, water-soluble, non-flamma-
ble, non-aggressive, no steam, no refrig-
erants

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
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.

10.2.1 Moving the robot into its transport position

Procedure

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

2. Remove tools and equipment.

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3. Put the robot into operation and move it into the transport position.
4. Secure the robot by activating the EMERGENCY STOP device and
then shut down the robot.

Transport position
A1 0 °
A2 -120 °
A3 155 °
A4 0 °
A5 80 °
A6 0 °

Fig. 10-4: Transport position

10.2.2 Installing fork slots or swivel eyebolts

Procedure

• Screw 3 M12 swivel eyebolts into the rotating column and base frame
or
Fasten 2 fork slots to the rotating column with 2 M12x25-8.8 Allen
screws including lock washers. Increase the tightening torque to the
specified value.

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Decommissioning, storage and disposal

Fig. 10-5: Installing/removing fork slots or swivel eyebolts

1 M12x25-8.8 Allen screw

2 Lock washer
3 Fork slot
4 Swivel eyebolt

10.2.3 Removing the robot

Procedure

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 4 M12x40-10.9 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 two pins when lifting off the robot.
CAUTION
Risk of injury due to abrupt detachment of the robot
If the robot is caught on the mounting surface, it may come free
abruptly. Injuries or damage to property may result.
‒ Remove the fastening materials completely.
‒ Remove any adhesives.

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Fig. 10-6: Removing the robot

1 M12x40-10.9 hexagon bolt

2 Locating pin
3 External ground conductor (KRC)
4 System ground conductor (optional)
5 Data cable XF31
6 Motor cable XD30
7 Lifting tackle

10.2.4 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.

10.2.5 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.

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If necessary, add a desiccant beneath the sheeting.

Decommissioning, storage and disposal

10.2.6 Concluding work

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.
Subassembly, com-
Material, designation Notice
ponent
Metal
Cast aluminum Wrist, arm, link arm
Copper Cables, wires
Cast steel Base frame, rotating
column
Steel Gear units, screws
and washers, metal
covers, stops
Electrical parts
Motors Dispose of motors
without dismantling
them.
Electronic compo- Recycle
nents, such as RDC,
EDS, etc.
Plastics
ABS Enclosure panels, cov-
ers
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
Lubricating grease Gear teeth Microlube GL 261
grease
Cabling Lubricating grease Op-
titemp RB2

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Up-to-date safety data sheets must be requested from the manufacturers

Decommissioning, storage and disposal

of auxiliary and operating materials. Further information about the auxiliary

substances and consumables used can be found under:

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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).
This assembly also includes a ratchet and a set of plates with one plate
for each motor. The plate specifies the direction of rotation for the ratchet
and shows the corresponding direction of motion of the manipulator.
In order to move the manipulator without drive energy in the event of an
accident or malfunction, either release devices or suitable tools (e.g. com-
bination wrenches) must be available in sufficient quantities. The user
must ensure that the release device is accessible at all times.

Basic data

Designation Article number Weight

Release device, KR CYBERTECH 0000-360-187 approx.
nano-2 1.65 kg

Further information about the ambient conditions is contained in the as-

sembly instructions for the robot and robot controller.

Start-up and recommissioning

(>>> 11.1.1 "Starting up the release device" Page 211)

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 can be used for moving the manipulator after an acci-
dent or malfunction without drive energy.
This section describes all work required to put the release device into op-
eration. Installation of a floor-mounted robot is described. A release device
for ceiling-mounted robots must be fastened to the cell wall.
This option is only for use in exceptional circumstances and emergencies,
e.g. for rescuing people.

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Equipment

The following equipment is required:

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

Material

The following material is required:

Designation Article number Quantity
Release device, KR CYBERTECH 0000-360-187 1
nano-2

Tightening torques

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

torques" Page 215)
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 robot controller is switched off.

• The robot is freely accessible.

Work safety

SAFETY INSTRUCTION
The following procedure must be followed exactly!

WARNING
Danger to life and limb due to damaged motor brake
Moving an axis with the release device can damage the motor brake.
Death, severe injuries or damage to property may result.
• After using the release device, the motor must be exchanged.

WARNING
If a robot axis has been moved by the release device/rechargeable
screwdriver with torque bracket, all robot axes must be remastered. In-
juries or damage to property may otherwise result.

11.1.1.1 Installing the release device

Procedure

1. Position the clip plate on the rotating column, insert 2 M12x20-8.8-A2K

Allen screws and fasten in place. Increase the tightening torque to the
specified value in several stages.
2. Place the release device on the clip plate.

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Options
Fig. 11-1: Installing the release device

1 Clip plate
2 M12x20-8.8-A2K Allen screw (2x)
3 Release device

3. Attach the arrow adhesive labels to the cast housing in the vicinity of
the respective motors as shown in the illustration (>>> Fig. 11-2).

Fig. 11-2: Location of arrow adhesive labels, applicable to KR CY-

BERTECH nano-2 and KR CYBERTECH nano-2 ARC

1 Arrow adhesive label A1

2 Arrow adhesive label A2
3 Arrow adhesive label A3

11.1.1.2 Moving the manipulator without drive energy

Procedure

1. Remove the protective cap from the motor. Use the endpiece of the
release device for this (>>> Fig. 11-3).
2. Push the release device onto the relevant 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.

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Fig. 11-3: Motor with release device

1 Motor
2 Protective cap
3 Release device

WARNING
Danger to life and limb due to damaged motor brake
Moving an axis with the release device can damage the motor brake.
Death, severe injuries or damage to property may result.
• After using the release device, the motor must be exchanged.

WARNING
If a robot axis has been moved by the release device/rechargeable
screwdriver with torque bracket, all robot axes must be remastered. In-
juries or damage to property may otherwise result.

11.1.1.3 Concluding work

The following concluding work must be carried out:

• Have the relevant motor exchanged by KUKA Service and master the
robot.
• Carry out a test run in T1 mode and look out for irregularities.
• Stow the release device again.

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Appendix
12 Appendix

12.1 Tightening torques

Tightening torques

The following tightening torques (Nm) are valid for screws and nuts where
no other specifications are given.
The specified values apply to lightly oiled black (e.g. phosphated) and
coated (e.g. mech. galv., zinc flake plating, screw locking elements)
screws and nuts.
Strength class
Thread 8.8 10.9 12.9
M1.6 0.17 Nm 0.24 Nm 0.28 Nm
M2 0.35 Nm 0.48 Nm 0.56 Nm
M2.5 0.68 Nm 0.93 Nm 1.10 Nm
M3 1.2 Nm 1.6 Nm 2.0 Nm
M4 2.8 Nm 3.8 Nm 4.4 Nm
M5 5.6 Nm 7.5 Nm 9.0 Nm
M6 9.5 Nm 12.5 Nm 15.0 Nm
M8 23.0 Nm 31.0 Nm 36.0 Nm
M10 45.0 Nm 60.0 Nm 70.0 Nm
M12 78.0 Nm 104.0 Nm 125.0 Nm
M14 125.0 Nm 165.0 Nm 195.0 Nm
M16 195.0 Nm 250.0 Nm 305.0 Nm
M20 370.0 Nm 500.0 Nm 600.0 Nm
M24 640.0 Nm 860.0 Nm 1030.0 Nm
M30 1330.0 Nm 1700.0 Nm 2000.0 Nm

Strength class
Thread 8.8 10.9
ISO7991 ISO7380, ISO07381
Allen screw Fillister head
screw
M3 0.8 Nm 0.8 Nm
M4 1.9 Nm 1.9 Nm
M5 3.8 Nm 3.8 Nm

Strength class
Thread 10.9
DIN7984
Pan head screws
M4 2.8 Nm
Tighten M5 domed cap nuts with a torque of 4.2 Nm.

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12.2 Auxiliary and operating materials used

Product designation / Use Manufacturer designation /

Article number Address

Optigear Synt. Gear oil BP Europa SE

ALR 150_EEA Geschäftsbereich Industrieschmierstoffe
Erkelenzer Strasse 20
0000-362-835 for Europe-
D-41179
an Economic Area
Mönchengladbach
Optigear Synt. Germany
ALR 150_AM1
0000-361-461 for USA,
Canada, Mexico, Chile,
Peru
Optigear Synt.
ALR 150_CHN
0000-361-473 for China
Optigear Synt.
ALR 150_APeC1
0000-361-476 for India,
Taiwan, Japan, Thailand,
South Korea, Malaysia
Article numbers for further
regions can be found in
KUKA Xpert.

Drei Bond type 1305 Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 17
0000-184-175
D-85737
Ismaning
Germany

Drei Bond type 1385 Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 17
0000-184-173
D-85737
Ismaning
Germany

Drei Bond type 5204HV Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 17
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

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Appendix
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

MARCOL 82 Lubricant ExxonMobil Petroleum & Chemical

BVBA
0000-386-390
POLDERDIJKWEG
B-2030
Antwerp
Belgium

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

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

12.3 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)

2014/30/EU EMC Directive:

Directive 2014/30/EU of the European Parliament and of the Coun-
cil dated 26 February 2014 on the approximation of the laws of the
Member States concerning electromagnetic compatibility

2014/68/EU Pressure Equipment Directive:

Directive 2014/68/EU of the European Parliament and of the Coun-
cil dated 15 May 2014 on the approximation of the laws of the
Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing
system.)

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

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Appendix KR CYBERTECH nano-2

EN 614-1:2006+A1:2009 Safety of machinery:

Ergonomic design principles - Part 1: Terms and general principles

EN ISO 10218-1:2011 Industrial robots – Safety requirements:

Part 1: Robots
Note: Content equivalent to ANSI/RIA R.15.06-2012, Part 1

EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction

EN ISO 13849-1:2015 Safety of machinery:

Safety-related parts of control systems - Part 1: General principles
of design

EN ISO 13849-2:2012 Safety of machinery:

Safety-related parts of control systems - Part 2: Validation

EN ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design

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KUKA Service
13 KUKA Service

13.1 Requesting support

Introduction

This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.

Information

The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• The greatest possible amount of information about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ System Software diagnosis package
Additionally for KUKA Sunrise: Existing projects including applica-
tions
For versions of KUKA System Software older than V8: Archive of
the software (Diagnosis package is not yet available here.)
‒ Application used
‒ External axes used

13.2 KUKA Customer Support

The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

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Index Declaration of incorporation.....................19, 20

Decommissioning................................... 33, 201
2006/42/EC................................................... 217
Description of the robot system.....................13
2014/30/EU................................................... 217
Diagnosis package....................................... 219
2014/68/EU................................................... 217
Dimensions, transport...................................133
95/16/EC....................................................... 217
Directives...................................................... 217
Disclaimer....................................................... 19
Disposal......................................... 33, 201, 209
A Documentation, industrial robot....................... 7
Accessories.............................................. 13, 19 Drei Bond type 1305....................................216
Angle of rotation............................................... 9 Drei Bond type 1385....................................216
ANSI/RIA R.15.06-2012............................... 218 Drei Bond type 5204HV...............................216
Appendix....................................................... 215
Arctic................................................................. 8
Automatic mode..............................................30
Auxiliary materials........................................ 216
E
EC declaration of conformity......................... 20
Axis data, KR 10 R1440-2.............................66
EDS...................................................................8
Axis data, KR 6 R1840-2...............................38
EDS cool...........................................................8
Axis data, KR 8 R1640-2...............................52
Electrical installations...................... 14, 16, 191
Axis limitation, mechanical............................. 24
Electromagnetic compatibility (EMC)........... 217
Axis range.................................................. 8, 20
Electromagnetic compatibility (EMC):.......... 217
EMC Directive........................................ 20, 217
EMD.................................................................. 9
B EN 60204-1:2018......................................... 217
Base frame...............................................14, 16 EN 61000-6-2:2005...................................... 217
Basic data, KR 10 R1440-2...........................64 EN 61000-6-4:2007 + A1:2011.................... 217
Basic data, KR 6 R1840-2.............................36 EN 614-1:2006+A1:2009..............................218
Basic data, KR 8 R1640-2.............................50 EN ISO 10218-1:2011.................................. 218
Brake defect................................................... 26 EN ISO 12100:2010..................................... 218
Brake release device......................................25 EN ISO 13849-1:2015..................................218
Braking distance.........................................8, 20 EN ISO 13849-2:2012..................................218
EN ISO 13850:2015..................................... 218
ESD....................................................37, 52, 66
C EX..................................................................... 9
C....................................................................... 8 Extension.......................................................... 8
Cable set A1-A3........................................... 192 External axes..................................................19
Cable set A1, checking and greasing......... 165 External axis.............................................11, 22
Cable set A1, greasing................................ 164
Cable set A4-A6........................................... 199
CE mark..........................................................20 F
Center of gravity...........................................133 F........................................................................9
Center of mass ................................ 43, 57, 70 F exclusive........................................................9
Certificates......................................... 37, 52, 66 Faults.............................................................. 27
Clean Room......................................................8 Flange loads...................................... 45, 59, 73
Cleaning the robot........................................189 Foundation loads............................... 48, 62, 76
Cleaning work.................................................31 Foundation loads, KR 10 R1440-2................76
Connecting cables.......... 13, 19, 130, 152, 156 Foundation loads, KR 6 R1840-2..................48
Connecting cables, connecting............142, 149 Foundation loads, KR 8 R1640-2..................62
Connecting cables, KR C5 micro....37, 51, 65, Function test................................................... 29
151
Connecting cables, KR C5 S... 37, 51, 65, 155
Counterbalancing system............................... 32
Cover, mounting on base frame.................. 166
G
Cover, removing from base frame...............165 General safety measures............................... 26
CR.....................................................................8

H
D HA..................................................................... 9
Danger zone...............................................9, 21 Handling equipment.....................134, 138, 146
Declaration of conformity............................... 20 Hazardous substances................................... 32

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KR CYBERTECH nano-2

HM.................................................................... 9 Mounting flange...........................15, 44, 59, 72

HO.....................................................................9 Mouse, external.............................................. 27
HP..................................................................... 9 MT.....................................................................9
HW.................................................................... 9

O
I Oil change, A1..............................................173
In-line wrist/arm........................................14, 15 Oil change, A2..............................................181
Industrial robot................................................19 Oil temperatures........................................... 162
Information for planning............................... 125 Operating materials...................................... 216
Interface, connecting cables................152, 156 Operators........................................................ 23
Interface, energy supply system..................131 Optigear Synt. ALR 150...............................216
Interfaces...................................................... 130 Options.......................................13, 16, 19, 211
Introduction....................................................... 7 Optitemp RB 2..............................................217
Overload......................................................... 26

K
K........................................................................9 P
KCP......................................................9, 21, 26 P........................................................................9
Keyboard, external......................................... 27 PA..................................................................... 9
KR..................................................................... 9 Payload diagram................................44, 58, 71
KR C................................................................. 9 Payloads, KR 10 R1440-2............................. 70
KS..................................................................... 9 Payloads, KR 6 R1840-2............................... 42
KUKA Customer Support............................. 219 Payloads, KR 8 R1640-2............................... 56
KUKA Service...............................................219 Personal protective equipment...................... 23
KUKA smartPAD..................................9, 13, 21 Personnel........................................................22
KUKA smartPAD-2..................................... 9, 21 PETAMO GHY 133 N.................................. 217
Phi.....................................................................9
Planning........................................................ 125
L Plant integrator............................................... 22
Labeling.......................................................... 25 Plates and labels............................................78
Lifting tackle (optional)................................. 135 Positioner........................................................ 19
Linear unit.......................................................19 POV................................................................ 10
Link arm................................................... 14, 15 PPE.................................................................23
Loctite 510.................................................... 216 Preparing for storage................................... 208
Low Voltage Directive.....................................20 Pressure Equipment Directive............... 32, 217
Preventive maintenance work........................ 31
Principal components..................................... 14
Product description.........................................13
M Program override............................................10
Machine frame mounting with centering..... 128
Protective circuit............................................. 16
Machinery Directive................................20, 217
Protective equipment, overview..................... 24
Main axes...............................................81, 103
Maintenance........................................... 31, 161
Maintenance symbols...................................162
Maintenance table........................................ 162 R
Manipulator....................................9, 13, 19, 21 RDC................................................................ 10
Manual mode..................................................29 RDC cool........................................................ 10
MARCOL 82................................................. 217 Reaction distance.......................................8, 20
Mass...................................................43, 57, 70 Recommissioning................................... 28, 137
Mass moments of inertia...................43, 57, 71 Refilling quantity.......................... 174, 182, 186
Material designation..................................... 209 Regulations................................................... 217
Mechanical end stops.................................... 24 Release device.......................................25, 211
MEMD............................................................... 9 Start-up.................................................... 211
micro RDC........................................................ 9 Repair..................................................... 31, 191
Microlube GL 261.........................................216 Robot controller........................................13, 19
Minimum bending radius...... 37, 51, 52, 65, 66 Robot system..................................................13
Misuse.............................................................17 Rotating column....................................... 14, 16
Motion velocity................................................10
Mounting base with centering......................125

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S U
Safety..............................................................19 Use
Safety instructions............................................ 7 Intended..................................................... 16
Safety of machinery.............................217, 218 User.......................................................... 20, 23
Safety options.................................................21 Users.................................................................7
Safety zone.............................................. 21, 23
Safety, general................................................19
SC................................................................... 10 W
SE................................................................... 10 W.....................................................................11
Service life...................................................... 21 Warnings........................................................... 7
SI.....................................................................10 Wiring diagrams, cable set A1-A3...............192
SL....................................................................10 Wiring diagrams, cable set A4-A6...............199
smartPAD........................................... 10, 21, 26 Workspace........................................... 8, 20, 23
Software................................................... 13, 19 WP.................................................................. 11
Spare parts................................................... 167
SPP...................................................................9
Standards......................................................217
Start-up...................................................28, 137
Start-up, floor-mounted robots (mounting
base).............................................................137
Starting up robots (machine frame
mounting)...................................................... 144
STOP 0..................................... 10, 21, 81, 103
STOP 1..................................... 10, 22, 81, 103
STOP 2.....................................................11, 22
Stop category 0....................................... 10, 21
Stop category 1....................................... 10, 22
Stop category 2........................................11, 22
Stop category 1, Drive Ramp Stop......... 11, 22
STOP 1 - DRS......................................... 11, 22
Stopping distance.......................................8, 20
Stopping distances....82, 89, 96, 104, 111, 118
Stopping distances with KR C5 micro...........81
Stopping distances with KR C5 S............... 103
Stopping times.......... 82, 89, 96, 104, 111, 118
Stopping times with KR C5 micro................. 81
Stopping times with KR C5 S......................103
Storage...........................................33, 201, 204
Supplementary load...........................46, 60, 74
Support request............................................ 219
System integrator.............................. 20, 22, 23

T
T1 (operating mode)................................ 11, 22
T2 (operating mode)................................ 11, 22
Teach pendant......................................... 13, 19
Technical data.................................................35
Technical data, KR 10 R1440-2.................... 64
Technical data, KR 6 R1840-2...................... 36
Technical data, KR 8 R1640-2...................... 50
Technical data, overview................................ 35
Terms used....................................................... 8
Terms, safety.................................................. 20
Tightening torques........................................ 215
Toothed belt A5, exchanging....................... 167
Training............................................ 7, 161, 191
Transport position......................................... 133
Transportation........................................ 27, 133
Turn-tilt table...................................................19

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