Robots KUKA Deutschland GmbH

KR AGILUS sixx

With W and C Variants

Operating Instructions

KR AGILUS

sixx

Issued: 17.05.2018

Version: BA KR AGILUS sixx V13

 KR AGILUS sixx

© Copyright 2018
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 software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, 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 BA KR AGILUS sixx (PDF) en

Book structure: BA KR AGILUS sixx V12.3
Version: BA KR AGILUS sixx V13

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 Contents

Contents
1 Introduction .................................................................................................. 7
1.1 Industrial robot documentation ................................................................................... 7
1.2 Representation of warnings and notes ...................................................................... 7
1.3 Terms used ................................................................................................................ 7

2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9

3 Product description ..................................................................................... 11

3.1 Overview of the robot system .................................................................................... 11
3.2 Description of the manipulator ................................................................................... 12

4 Technical data .............................................................................................. 15

4.1 Basic data, KR 6 sixx ................................................................................................. 16
4.2 Axis data, KR 6 sixx ................................................................................................... 18
4.3 Payloads, KR 6 sixx ................................................................................................... 25
4.4 Foundation data, KR 6 sixx ........................................................................................ 28
4.5 Basic data, KR 10 sixx ............................................................................................... 30
4.6 Axis data, KR 10 sixx ................................................................................................. 32
4.7 Payloads, KR 10 sixx ................................................................................................. 39
4.8 Foundation data, KR 10 sixx ...................................................................................... 42
4.9 Supplementary load ................................................................................................... 44
4.9.1 Supplementary load, reach R700 ......................................................................... 44
4.9.2 Supplementary load, reach R900 ......................................................................... 45
4.9.3 Supplementary load, reach R1100 ....................................................................... 46
4.10 Plates and labels ........................................................................................................ 47
4.11 Stopping distances and times .................................................................................... 49
4.11.1 General information .............................................................................................. 49
4.11.2 Terms used ........................................................................................................... 50
4.11.3 Stopping distances and times, KR 6 R700 sixx and KR 6 R700 sixx C ................ 51
4.11.3.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 51
4.11.3.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 52
4.11.3.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 54
4.11.3.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 56
4.11.4 Stopping distances and times, KR 6 R700 sixx W ................................................ 56
4.11.4.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 56
4.11.4.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 58
4.11.4.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 60
4.11.4.4 Stopping distances and stopping times for STOP 1, axis 2 ............................. 62
4.11.5 Stopping distances and times, KR 6 R900 sixx and KR 6 R900 sixx C ................ 62
4.11.5.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 62
4.11.5.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 64
4.11.5.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 66
4.11.5.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 68
4.11.6 Stopping distances and times, KR 6 R900 sixx W ................................................ 68
4.11.6.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 68
4.11.6.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 70

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4.11.6.3 Stopping distances and stopping times for STOP 1, axis 2 ............................ 72
4.11.6.4 Stopping distances and stopping times for STOP 1, axis 3 ............................ 74
4.11.7 Stopping distances and times, KR 10 R900 sixx and KR 10 R1100 sixx ............. 74
4.11.7.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 74
4.11.7.2 Stopping distances and stopping times for STOP 1, axis 1 ............................ 76
4.11.7.3 Stopping distances and stopping times for STOP 1, axis 2 ............................ 78
4.11.7.4 Stopping distances and stopping times for STOP 1, axis 3 ............................ 80
4.11.8 Stopping distances and times, KR 10 R900 sixx W and KR 10 R1100 sixx W .... 80
4.11.8.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 80
4.11.8.2 Stopping distances and stopping times for STOP 1, axis 1 ............................ 82
4.11.8.3 Stopping distances and stopping times for STOP 1, axis 2 ............................ 84
4.11.8.4 Stopping distances and stopping times for STOP 1, axis 3 ............................ 86

5 Safety ............................................................................................................ 87
5.1 General ...................................................................................................................... 87
5.1.1 Liability ................................................................................................................. 87
5.1.2 Intended use of the industrial robot ...................................................................... 88
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 88
5.1.4 Terms used .......................................................................................................... 89
5.2 Personnel .................................................................................................................. 90
5.3 Workspace, safety zone and danger zone ................................................................ 91
5.4 Overview of protective equipment ............................................................................. 91
5.4.1 Mechanical end stops ........................................................................................... 91
5.4.2 Mechanical axis limitation (optional) ..................................................................... 91
5.4.3 Options for moving the manipulator without drive energy .................................... 92
5.4.4 Labeling on the industrial robot ............................................................................ 92
5.5 Safety measures ........................................................................................................ 93
5.5.1 General safety measures ..................................................................................... 93
5.5.2 Transportation ...................................................................................................... 94
5.5.3 Start-up and recommissioning .............................................................................. 94
5.5.4 Manual mode ........................................................................................................ 95
5.5.5 Automatic mode ................................................................................................... 96
5.5.6 Maintenance and repair ........................................................................................ 96
5.5.7 Decommissioning, storage and disposal .............................................................. 98
5.6 Applied norms and regulations .................................................................................. 98

6 Planning ........................................................................................................ 101

6.1 Information for planning ............................................................................................. 101
6.2 Mounting base ........................................................................................................... 101
6.3 Machine frame mounting ........................................................................................... 104
6.4 Connecting cables and interfaces ............................................................................. 105
6.5 Customer interfaces .................................................................................................. 107

7 Transportation ............................................................................................. 113

7.1 Transporting the manipulator ..................................................................................... 113

8 Start-up and recommissioning ................................................................... 119

8.1 Installing the mounting base ...................................................................................... 119
8.2 Installing the machine frame mounting assembly ...................................................... 120
8.3 Installing a floor-mounted robot ................................................................................. 120

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8.4 Installing a wall-mounted robot .................................................................................. 122

8.5 Installing a ceiling-mounted robot .............................................................................. 126
8.6 Description of the connecting cables ......................................................................... 130
8.7 Moving the manipulator without drive energy ............................................................ 136

9 Maintenance ................................................................................................. 137

9.1 Maintenance overview ............................................................................................... 137
9.2 Maintenance table ...................................................................................................... 137
9.3 Greasing the inside of covers A2 and A3 ................................................................... 139
9.4 Exchanging the toothed belts ..................................................................................... 140
9.5 Cleaning the robot ...................................................................................................... 142

10 Repair ........................................................................................................... 145

10.1 Measuring and adjusting the toothed belt tension ..................................................... 145

11 Decommissioning, storage and disposal .................................................. 149

11.1 Decommissioning, floor-mounted robot ..................................................................... 149
11.2 Decommissioning, wall-mounted robot ...................................................................... 150
11.3 Decommissioning, ceiling-mounted robot .................................................................. 153
11.4 Storage ...................................................................................................................... 156
11.5 Disposal ..................................................................................................................... 157

12 Appendix ...................................................................................................... 159

12.1 Tightening torques ..................................................................................................... 159
12.2 Auxiliary and operating materials used ...................................................................... 159

13 KUKA Service .............................................................................................. 161

13.1 Requesting support .................................................................................................... 161
13.2 KUKA Customer Support ........................................................................................... 161

Index ............................................................................................................. 169

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 1 Introduction

1 Introduction
t

1.1 Industrial robot documentation

t

The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the System Software
 Instructions for options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.2 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may

occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if

no precautions are taken.

These warnings mean that damage to property may oc-

cur, if no precautions are taken.

These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.

This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:

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.

1.3 Terms used

Term Description
MEMD Micro Electronic Mastering Device
KL KUKA linear unit

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 KR AGILUS sixx

Term Description
micro RDC micro Resolver Digital Converter
smartPAD The smartPAD teach pendant has all the opera-
tor control and display functions required for
operating and programming the industrial robot.

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 2 Purpose

2 Purpose
2

2.1 Target group

s

This documentation is aimed at users with the following knowledge and skills:
 Advanced knowledge of mechanical engineering
 Advanced knowledge of electrical and electronic systems
 Knowledge of the robot controller system

For optimal use of our products, we recommend that our customers

take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.

2.2 Intended use

Use The industrial robot is intended for handling tools and fixtures or for processing
and transferring components or products. Use is only permitted under the
specified environmental conditions.

Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. This includes e.g.:
 Use as a climbing aid
 Operation outside the specified operating parameters
 Operation without the required safety equipment

Changing the structure of the robot, e.g. by drilling holes,

can result in damage to the components. This is consid-
ered improper use and leads to loss of guarantee and liability entitlements.

Deviations from the operating conditions specified in the

technical data or the use of special functions or applica-
tions can lead to premature wear. KUKA Deutschland GmbH must be con-
sulted.

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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 3 Product description

3 Product description

3.1
t
Overview of the robot system

A robot system (>>> Fig. 3-1 ) comprises all the assemblies of an industrial
s

robot, including the manipulator (mechanical system and electrical installa-

tions), control cabinet, connecting cables, end effector (tool) and other equip-
ment. The KR AGILUS sixx product family consists of the following types:
 KR 6 R700 sixx
 KR 6 R900 sixx
 KR 10 R900 sixx
 KR 10 R1100 sixx
The robots are also available as W and C variants (wall-mounted and ceiling-
mounted versions).
An industrial robot of this type comprises the following components:
 Manipulator
 Robot controller
 smartPAD teach pendant
 Connecting cables
 Software
 Options, accessories

Fig. 3-1: Example of an industrial robot

1 Manipulator
2 smartPAD control panel
3 Connecting cable, smartPAD
4 Robot controller
5 Connecting cable, data cable
6 Connecting cable, motor cable
7 Device connection cable

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3.2 Description of the manipulator

Overview The manipulators (= robot arm and electrical installations) of the variants are
designed as 6-axis jointed-arm kinematic systems made of cast light alloy.
Each axis is fitted with a brake. All motor units and current-carrying cables are
protected against dirt and moisture beneath screwed-on cover plates.
The manipulators consist of the following main assemblies:
 In-line wrist
 Arm
 Link arm
 Rotating column
 Base frame
 Electrical installations

Fig. 3-2: Principal components

1 In-line wrist 4 Rotating column

2 Arm 5 Electrical installations
3 Link arm 6 Base frame

In-line wrist The robot is fitted with a 3-axis in-line wrist. The in-line wrist consists of axes
A4, A5, A6 4, 5 and 6.
There are three 5/2-way solenoid valves and a CAT5 data cable in the in-line
wrist that can be used for controlling tools.
The in-line wrist also accommodates the 10-contact circular connector of the
wrist I/O cable and interface A4 for the energy supply system.

Arm The arm is the link between the in-line wrist and the link arm. The arm is driven
A3 by the motor of axis 3.

Link arm The link arm is the assembly located between the arm and the rotating column.
A2 It houses the motor and gear unit of axis 2. The supply lines of the energy sup-
ply system and the cable set for axes 2 to 6 are routed through the link arm.

Rotating column The rotating column houses the motors of axes 1 and 2. The rotational motion
A1 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.

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 3 Product description

Base frame The base frame is the base of the robot. Interface A1 is located at the rear of
the base frame. It constitutes the interface for the connecting cables between
the robot, the controller and the energy supply system.

Electrical installa- The electrical installations include all the motor and data cables for the motors
tions of axes 1 to 6, as well as the connections for the internal energy supply system
and external axes A7 and A8. All connections are pluggable. The electrical in-
stallations also include the RDC, which is integrated into the robot. The con-
nectors for the motor and data cables are mounted on the robot base frame.
The connecting cables from the robot controller are connected here by means
of connectors. The electrical installations also include a protective circuit.

Options The robot can be fitted and operated with various options, e.g. working range
limitation A1 or brake release device. The option is described in separate doc-
umentation.

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 4 Technical data

4 Technical data
4

The technical data for the individual robot types can be found in the following
sections:

t
Robot Technical data
KR 6 sixx
KR 6 R700 sixx Basic data
 KR 6 R700 sixx (>>> 4.1 "Basic data, KR 6 sixx" Page 16)
 KR 6 R700 sixx W Axis data
 KR 6 R700 sixx C (>>> 4.2 "Axis data, KR 6 sixx" Page 18)
KR 6 R900 sixx Payloads
 KR 6 R900 sixx (>>> 4.3 "Payloads, KR 6 sixx" Page 25)
 KR 6 R900 sixx W Foundation data
 KR 6 R900 sixx C (>>> 4.4 "Foundation data, KR 6 sixx" Page 28)
Plates and labels
(>>> 4.10 "Plates and labels" Page 47)
Stopping distances
 KR 6 R700 sixx and KR 6 R700 sixx C
(>>> 4.11.3 "Stopping distances and times, KR 6 R700 sixx
and KR 6 R700 sixx C" Page 51)
 KR 6 R700 sixx W
(>>> 4.11.4 "Stopping distances and times, KR 6 R700 sixx
W" Page 56)
 KR 6 R900 sixx and KR 6 R900 sixx C
(>>> 4.11.5 "Stopping distances and times, KR 6 R900 sixx
and KR 6 R900 sixx C" Page 62)
 KR 6 R900 sixx W
(>>> 4.11.6 "Stopping distances and times, KR 6 R900 sixx
W" Page 68)

Robot Technical data

KR 10 sixx

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Robot Technical data

KR 10 R900 sixx Basic data
 KR 10 R900 sixx (>>> 4.5 "Basic data, KR 10 sixx" Page 30)
 KR 10 R900 sixx W Axis data
 KR 10 R900 sixx C (>>> 4.6 "Axis data, KR 10 sixx" Page 32)
KR 10 R1100 sixx Payloads
 KR 10 R1100 sixx (>>> 4.7 "Payloads, KR 10 sixx" Page 39)
 KR 10 R1100 sixx W Foundation data
 KR 10 R1100 sixx C (>>> 4.8 "Foundation data, KR 10 sixx" Page 42)
Plates and labels
(>>> 4.10 "Plates and labels" Page 47)
Stopping distances
 KR 10 R900 sixx and KR 10 R900 sixx C
(>>> 4.11.7 "Stopping distances and times, KR 10 R900
sixx and KR 10 R1100 sixx" Page 74)
 KR 10 R900 sixx W
(>>> 4.11.8 "Stopping distances and times, KR 10 R900
sixx W and KR 10 R1100 sixx W" Page 80)
 KR 10 R1100 sixx and KR 10 R1100 sixx C
(>>> 4.11.7 "Stopping distances and times, KR 10 R900
sixx and KR 10 R1100 sixx" Page 74)
 KR 10 R1100 sixx W
(>>> 4.11.8 "Stopping distances and times, KR 10 R900
sixx W and KR 10 R1100 sixx W" Page 80)

4.1 Basic data, KR 6 sixx

Basic data Type KR 6 R700 sixx

KR 6 R700 sixx W
KR 6 R700 sixx C
KR 6 R900 sixx
KR 6 R900 sixx W
KR 6 R900 sixx C
Number of axes 6
Number of controlled 6
axes
Volume of working KR 6 R700 sixx: 1.36 m3
envelope
KR 6 R700 sixx W: 1.36 m3

KR 6 R700 sixx C: 1.36 m3

KR 6 R900 sixx: 2.85 m3

KR 6 R900 sixx W: 2.85 m3

KR 6 R900 sixx C: 2.85 m3

Pose repeatability ±0.03 mm
(ISO 9283)

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 4 Technical data

Working envelope ref- Intersection of axes 4 and 5

erence point
Weight KR 6 R700 sixx: approx. 50 kg
KR 6 R700 sixx W: approx. 50 kg
KR 6 R700 sixx C: approx. 50 kg
KR 6 R900 sixx: approx. 52 kg
KR 6 R900 sixx W: approx. 52 kg
KR 6 R900 sixx C: approx. 52 kg
Principal dynamic See Foundation loads
loads
Protection rating of the IP 54
robot
Ready for operation, with connecting cables
plugged in (according to EN 60529)
Protection rating of the IP 54
in-line wrist
Sound level < 70 dB (A) outside the working envelope
Mounting position Floor, wall, ceiling
Footprint 320 mm x 320 mm
Permissible angle of -
inclination
Standard colors
Base (stationary) and covers on link arm: black
(RAL 9011); moving parts: KUKA orange 2567
Controller KR C4 compact
Transformation name KR 6 R700 sixx: KR6R700 C4SR FLR
KR 6 R700 sixx W: KR6R700 C4SR WLL
KR 6 R700 sixx C: KR6R700 C4SR CLG
KR 6 R900 sixx: KR6R900 C4SR FLR
KR 6 R900 sixx W: KR6R900 C4SR WLL
KR 6 R900 sixx C: KR6R900 C4SR CLG

Ambient condi- Operation 278 K to 318 K (+5 °C to +45 °C)

tions
No condensation permissible.
Storage and transpor- -40 °C to +60 °C (233 K to 333 K)
tation
Ambient conditions Relative air humidity ≤ 90%
DIN EN 60721-3-3,
Class 3K3
Altitude  up to 1000 m above mean sea level with no
reduction in power
 1000 m ... 4000 m above mean sea level with
a reduction in power of 5%/1000 m

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 KR AGILUS sixx

Connecting
Connector designation
cables Interface with
Cable designation robot controller -
robot
robot
Motor cable X20 - X30 Han Yellock 30
Data cable X21 - X31 Han Q12
Data cable CAT5 X65/X66 - XPN1 M12 connector
(can be ordered as an
option)
Connecting cable, exter- XP7 - XP7.1 Connector M17
nal axes A7 and A8 in each case
XP8 - XP8.1
(can be ordered as an
option)
Ground conductor, equi- M4 ring cable
potential bonding lug
(can be ordered as an
option)

Only resolvers can be connected to the connections XP7.1 and XP8.1.

Cable lengths
Standard 4m
Option 1 m, 7 m, 15 m, 25 m

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

connecting cables”.

4.2 Axis data, KR 6 sixx

Axis data The following axis data are valid for the robots:
 KR 6 R700 sixx
 KR 6 R700 sixx W
 KR 6 R700 sixx C
 KR 6 R900 sixx
 KR 6 R900 sixx W
 KR 6 R900 sixx C

Range of motion, software- Speed

Axis
limited with rated payload
1 +/-170° 360 °/s
2 +45° to -190° 300 °/s
3 +156° to -120° 360 °/s
4 +/-185° 381 °/s
5 +/-120° 388 °/s
6 +/-350° 615 °/s

In the case of manipulators with a payload of 6 kg and a reach of

R700, not every angle for axis A4 can be reached in the end position.

The direction of motion and the arrangement of the individual axes may be not-
ed from the diagram (>>> Fig. 4-1 ).

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 4 Technical data

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

Mastering Mastering position

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

Working The following diagrams (>>> Fig. 4-2 ) and (>>> Fig. 4-3 ) show the shape
envelope, KR 6 and size of the working envelope for the robot:
R700 sixx  KR 6 R700 sixx

Fig. 4-2: KR 6 R700 sixx, working envelope, side view

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Fig. 4-3: KR 6 R700 sixx, working envelope, top view

The following diagrams (>>> Fig. 4-4 ) and (>>> Fig. 4-5 ) show the shape
and size of the working envelope for the robot:
 KR 6 R700 sixx W

Fig. 4-4: KR 6 R700 sixx W working envelope, side view

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 4 Technical data

Fig. 4-5: KR 6 R700 sixx W, working envelope, top view

The following diagrams (>>> Fig. 4-6 ) and (>>> Fig. 4-7 ) show the shape
and size of the working envelope for the robot:
 KR 6 R700 sixx C

Fig. 4-6: KR 6 R700 sixx C, working envelope, side view

Fig. 4-7: KR 6 R700 sixx C, working envelope, top view

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Distance to The distance to the flange varies according to the position of the robot. The
flange, KR 6 R700 flange distance (>>> Fig. 4-8 ) is valid for the following robots:
sixx  KR 6 R700 sixx
 KR 6 R700 sixx W
 KR 6 R700 sixx C

Fig. 4-8: Distance to flange, KR 6 R700 sixx (with W and C variants)

Working The following diagrams (>>> Fig. 4-9 ) and (>>> Fig. 4-10 ) show the shape
envelope, KR 6 and size of the working envelope for the robot:
R900 sixx  KR 6 R900 sixx

Fig. 4-9: KR 6 R900 sixx, working envelope, side view

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 4 Technical data

Fig. 4-10: KR 6 R900 sixx, working envelope, top view

The following diagrams (>>> Fig. 4-11 ) and (>>> Fig. 4-12 ) show the shape
and size of the working envelope for the robot:
 KR 6 R900 sixx W

Fig. 4-11: KR 6 R900 sixx W, working envelope, side view

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Fig. 4-12: KR 6 R900 sixx W, working envelope, top view

The following diagrams (>>> Fig. 4-13 ) and (>>> Fig. 4-14 ) show the shape
and size of the working envelope for the robot:
 KR 6 R900 sixx C

Fig. 4-13: KR 6 R900 sixx C, working envelope, side view

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 4 Technical data

Fig. 4-14: KR 6 R900 sixx C, working envelope, top view

Distance to The distance to the flange varies according to the position of the robot. The
flange, KR 6 R900 flange distance (>>> Fig. 4-15 ) is valid for the following robots:
sixx  KR 6 R900 sixx
 KR 6 R900 sixx W
 KR 6 R900 sixx C

Fig. 4-15: Distance to flange, KR 6 R900 sixx (with W and C variants)

4.3 Payloads, KR 6 sixx

Payloads A distinction is made between the nominal and maximum payload. At the nom-
inal payload, the manipulator is rated for optimal cycle times and accuracy.

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Robot KR 6 R700 sixx

KR 6 R700 sixx W
KR 6 R700 sixx C
KR 6 R900 sixx
KR 6 R900 sixx W
KR 6 R900 sixx C
In-line wrist KR 6 R700 sixx: IW 6 R700
KR 6 R900 sixx: IW 6/10
R900
Rated payload 3 kg
Maximum payload 6 kg
Distance of the load center of gravity Lxy 60 mm
Distance of the load center of gravity Lz 80 mm
Max. total load 6 kg
Supplementary load The sum of all loads
mounted on the robot must
not exceed the maximum
total load.

Load center of For all payloads, the load center of gravity refers to the distance from the face
gravity of the mounting flange on axis 6. Refer to the payload diagram for the nominal
distance.

Fig. 4-16: Load center of gravity

Payload diagram Permissible mass inertia at the design point (Lx, Ly, Lz) is 0.045 kgm².
The following figure (>>> Fig. 4-17 ) shows the payload diagram for the fol-
lowing robots:
 KR 6 R700 sixx
 KR 6 R700 sixx W
 KR 6 R700 sixx C
 KR 6 R900 sixx
 KR 6 R900 sixx W
 KR 6 R900 sixx C

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Fig. 4-17: Payload diagram, payload 6 kg

This loading curve corresponds to the maximum load ca-

pacity. Both values (payload and mass moment of iner-
tia) must be checked in all cases. Exceeding this capacity will reduce the
service life of the robot and overload the motors and the gears; in any such
case KUKA Deutschland GmbH must be consulted beforehand.
The values determined here are necessary for planning the robot application.
For commissioning the robot, additional input data are required in accor-
dance with the operating and programming instructions of the KUKA System
Software.
The mass inertia must be verified using KUKA.Load. It is imperative for the
load data to be entered in the robot controller!

Mounting flange Mounting flange 31.5 mm

Screw grade 12.9
Screw size M5
Number of fastening screws 7
Clamping length min. 1.5 x nominal diameter
Depth of engagement min. 5.5 mm, max. 7 mm
Locating element 5 H7
Standard See diagram. (>>> Fig. 4-18 )

The mounting flange is depicted with axis 6 in the zero position (>>> Fig. 4-
18 ) The symbol Xm indicates the position of the locating element in the zero
position.

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Fig. 4-18: Mounting flange

4.4 Foundation data, KR 6 sixx

Foundation loads The specified forces and moments already include the maximum payload and
the inertia force (weight) of the robot.

Fig. 4-19: Loads acting on the foundation, floor mounting

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Fig. 4-20: Loads acting on the foundation, wall mounting

Fig. 4-21: Loads acting on the foundation, ceiling mounting

Force/torque/mass
Type of load
Normal operation Maximum load
Fv = vertical force Fv normal = 967 N Fv max = 1297 N
Fh = horizontal force Fh normal = 1223 N Fv max = 1362 N
Mk = tilting moment Mk normal = 788 Nm Mk max = 1152 Nm
Mr = torque Mr normal = 367 Nm Mr max = 880 Nm
Total mass for KR 6 R700 sixx: 56 kg
foundation load
KR 6 R900 sixx: 58 kg
Robot KR 6 R700 sixx: 50 kg
KR 6 R900 sixx: 52 kg
Total load for
foundation load KR 6 R700 sixx: 6 kg
(suppl. load on arm + KR 6 R900 sixx: 6 kg
rated payload)

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Normal loads and maximum loads for the foundations

are specified in the table.
The maximum loads must be referred to when dimensioning the foundations
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 Basic data, KR 10 sixx

Basic data Type KR 10 R900 sixx

KR 10 R900 sixx W
KR 10 R900 sixx C
KR 10 R1100 sixx
KR 10 R1100 sixx W
KR 10 R1100 sixx C
Number of axes 6
Number of controlled 6
axes
Volume of working KR 10 R900 sixx: 2.85 m3
envelope
KR 10 R900 sixx W: 2.85 m3

KR 10 R900 sixx C: 2.85 m3

KR 10 R1100 sixx: 5.20 m3

KR 10 R1100 sixx W: 5.20 m3

KR 10 R1100 sixx C: 5.20 m3

Pose repeatability ±0.03 mm
(ISO 9283)
Working envelope ref- Intersection of axes 4 and 5
erence point
Weight KR 10 R900 sixx: approx. 52 kg
KR 10 R900 sixx W: approx. 52 kg
KR 10 R900 sixx C: approx. 52 kg
KR 10 R1100 sixx: approx. 55 kg
KR 10 R1100 sixx W: approx. 55 kg
KR 10 R1100 sixx C: approx. 55 kg
Principal dynamic See Foundation loads
loads
Protection rating of the IP 54
robot
Ready for operation, with connecting cables
plugged in (according to EN 60529)
Protection rating of the IP 54
in-line wrist
Sound level < 70 dB (A) outside the working envelope

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Mounting position Floor, wall, ceiling

Footprint 320 mm x 320 mm
Permissible angle of -
inclination
Standard colors Base (stationary) and covers on link arm: black
(RAL 9011); moving parts: KUKA orange 2567
Controller KR C4 compact
Transformation name KR 10 R900 sixx: KR10R900 C4SR FLR
KR 10 R900 sixx W: KR10R900 C4SR WLL
KR 10 R900 sixx C: KR10R900 C4SR CLG
KR 10 R1100 sixx: KR10R1100 C4SR FLR
KR 10 R1100 sixx W: KR10R1100 C4SR WLL
KR 10 R1100 sixx C: KR10R1100 C4SR CLG

Ambient condi- Operation 278 K to 318 K (+5 °C to +45 °C)

tions
No condensation permissible.
Storage and transpor- -40 °C to +60 °C (233 K to 333 K)
tation
Ambient conditions Relative air humidity ≤ 90%
DIN EN 60721-3-3,
Class 3K3
Altitude  up to 1000 m above mean sea level with no
reduction in power
 1000 m ... 4000 m above mean sea level with
a reduction in power of 5%/1000 m

Connecting
Connector designation
cables Interface with
Cable designation robot controller -
robot
robot
Motor cable X20 - X30 Han Yellock 30
Data cable X21 - X31 Han Q12
Data cable CAT5 X65/X66 - XPN1 M12 connector
(can be ordered as an
option)
Connecting cable, exter- XP7 - XP7.1 Connector M17
nal axes A7 and A8 in each case
XP8 - XP8.1
(can be ordered as an
option)
Ground conductor, equi- M4 ring cable
potential bonding lug
(can be ordered as an
option)

Only resolvers can be connected to the connections XP7.1 and XP8.1.

Cable lengths
Standard 4m
Option 1 m, 7 m, 15 m, 25 m

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

connecting cables”.

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4.6 Axis data, KR 10 sixx

Axis data The following axis data are valid for the robots:
 KR 10 R900 sixx
 KR 10 R900 sixx W
 KR 10 R900 sixx C
 KR 10 R1100 sixx
 KR 10 R1100 sixx W
 KR 10 R1100 sixx C

Range of motion, software- Velocity

Axis
limited with rated payload
1 +/-170° 300 °/s
2 +45° to -190° 225 °/s
3 +156° to -120° 225 °/s
4 +/-185° 381 °/s
5 +/-120° 311 °/s
6 +/-350° 492 °/s

The direction of motion and the arrangement of the individual axes may be not-
ed from the diagram (>>> Fig. 4-22 ).

Fig. 4-22: Direction of rotation of robot axes

Mastering Mastering position

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

Working The following diagrams (>>> Fig. 4-23 ) and (>>> Fig. 4-24 ) show the shape
envelope, KR 10 and size of the working envelope for the robot:
R900 sixx  KR 10 R900 sixx

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Fig. 4-23: KR 10 R900 sixx, working envelope, side view

Fig. 4-24: KR 10 R900 sixx, working envelope, top view

The following diagrams (>>> Fig. 4-25 ) and (>>> Fig. 4-26 ) show the shape
and size of the working envelope for the robot:
 KR 10 R900 sixx W

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Fig. 4-25: KR 10 R900 sixx W, working envelope, side view

Fig. 4-26: KR 10 R900 sixx W, working envelope, top view

The following diagrams (>>> Fig. 4-27 ) and (>>> Fig. 4-28 ) show the shape
and size of the working envelope for the robot:
 KR 10 R900 sixx C

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Fig. 4-27: KR 10 R900 sixx C, working envelope, side view

Fig. 4-28: KR 10 R900 sixx C, working envelope, top view

Distance to The distance to the flange varies according to the position of the robot. The
flange, KR 10 flange distance (>>> Fig. 4-29 ) is valid for the following robots:
R900 sixx  KR 10 R900 sixx
 KR 10 R900 sixx W
 KR 10 R900 sixx C

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Fig. 4-29: Distance to flange, KR 10 R900 sixx (with W and C variants)

Working The following diagrams (>>> Fig. 4-30 ) and (>>> Fig. 4-31 ) show the shape
envelope, KR 10 and size of the working envelope for the robot:
R1100 sixx  KR 10 R1100 sixx

Fig. 4-30: KR 10 R1100 sixx, working envelope, side view

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Fig. 4-31: KR 10 R1100 sixx, working envelope, top view

The following diagrams (>>> Fig. 4-32 ) and (>>> Fig. 4-33 ) show the shape
and size of the working envelope for the robot:
 KR 10 R1100 sixx W

Fig. 4-32: KR 10 R1100 sixx W, working envelope, side view

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Fig. 4-33: KR 10 R1100 sixx W, working envelope, top view

The following diagrams (>>> Fig. 4-34 ) and (>>> Fig. 4-35 ) show the shape
and size of the working envelope for the robot:
 KR 10 R1100 sixx C

Fig. 4-34: KR 10 R1100 sixx C, working envelope, side view

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Fig. 4-35: KR 10 R1100 sixx C, working envelope, top view

Distance to The distance to the flange varies according to the position of the robot. The
flange, KR 10 flange distance (>>> Fig. 4-36 ) is valid for the following robots:
R1100 sixx  KR 10 R1100 sixx
 KR 10 R1100 sixx W
 KR 10 R1100 sixx C

Fig. 4-36: Distance to flange, KR 10 R1100 sixx (with W and C variants)

4.7 Payloads, KR 10 sixx

Payloads A distinction is made between the nominal and maximum payload. At the nom-
inal payload, the manipulator is rated for optimal cycle times and accuracy.

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Robot KR 10 R900 sixx

KR 10 R900 sixx W
KR 10 R900 sixx C
KR 10 R1100 sixx
KR 10 R1100 sixx W
KR 10 R1100 sixx C
In-line wrist KR 10 R900 sixx: IW 6/10
R900
KR 10 R1100 sixx: IW 10
R1100
Rated payload 5 kg
Maximum payload 10 kg
Distance of the load center of gravity Lxy 100 mm
Distance of the load center of gravity Lz 80 mm
Max. total load 10 kg
Supplementary load The sum of all loads
mounted on the robot must
not exceed the maximum
total load.

Load center of For all payloads, the load center of gravity refers to the distance from the face
gravity of the mounting flange on axis 6. Refer to the payload diagram for the nominal
distance.

Fig. 4-37: Load center of gravity

Payload diagram Permissible mass inertia at the design point (Lx, Ly, Lz) is 0.045 kgm².
The following figure (>>> Fig. 4-38 ) shows the payload diagram for the fol-
lowing robots:
 KR 10 R900 sixx
 KR 10 R900 sixx W
 KR 10 R900 sixx C
 KR 10 R1100 sixx
 KR 10 R1100 sixx W
 KR 10 R1100 sixx C

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Fig. 4-38: Payload diagram, payload 10 kg

This loading curve corresponds to the maximum load ca-

pacity. Both values (payload and mass moment of iner-
tia) must be checked in all cases. Exceeding this capacity will reduce the
service life of the robot and overload the motors and the gears; in any such
case KUKA Deutschland GmbH must be consulted beforehand.
The values determined here are necessary for planning the robot application.
For commissioning the robot, additional input data are required in accor-
dance with the operating and programming instructions of the KUKA System
Software.
The mass inertia must be verified using KUKA.Load. It is imperative for the
load data to be entered in the robot controller!

Mounting flange Mounting flange 31.5 mm

Screw grade 12.9
Screw size M5
Number of fastening screws 7
Clamping length min. 1.5 x nominal diameter
Depth of engagement min. 5.5 mm, max. 7 mm
Locating element 5 H7
Standard See diagram. (>>> Fig. 4-39 )

The mounting flange is depicted with axis 6 in the zero position (>>> Fig. 4-
39 ) The symbol Xm indicates the position of the locating element in the zero
position.

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Fig. 4-39: Mounting flange

4.8 Foundation data, KR 10 sixx

Foundation loads The specified forces and moments already include the maximum payload and
the inertia force (weight) of the robot.

Fig. 4-40: Loads acting on the foundation, floor mounting

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Fig. 4-41: Loads acting on the foundation, wall mounting

Fig. 4-42: Loads acting on the foundation, ceiling mounting

Force/torque/mass
Type of load
Normal operation Maximum load
Fv = vertical force Fv normal = 967 N Fv max = 1297 N
Fh = horizontal force Fh normal = 1223 N Fv max = 1362 N
Mk = tilting moment Mk normal = 788 Nm Mk max = 1152 Nm
Mr = torque Mr normal = 367 Nm Mr max = 880 Nm
Total mass for KR 10 R900 sixx: 62 kg
foundation load
KR 10 R1100 sixx: 65 kg
Robot KR 10 R900 sixx: 52 kg
KR 10 R1100 sixx: 55 kg
Total load for
foundation load KR 10 R900 sixx: 10 kg
(suppl. load on arm + KR 10 R1100 sixx: 10 kg
rated payload)

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Normal loads and maximum loads for the foundations

are specified in the table.
The maximum loads must be referred to when dimensioning the foundations
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.

4.9 Supplementary load

The robot can carry supplementary loads on the arm, on the in-line wrist, on
the link arm and on the rotating column. The fastening holes on the arm, link
arm and rotating column are used for fastening the covers or external energy
supply systems. Parts of the energy supply system (e.g. holders for com-
pressed air hose) are fastened to the in-line wrist using the fastening holes.
When mounting the supplementary loads, be careful to observe the maximum
permissible total load. The dimensions and positions of the installation options
can be seen in the following diagram.

The sum of all loads mounted on the robot must not exceed the max-
imum total load.

Further information about the supplementary load on the robot can be found
in the following sections.

Robot Description
 KR 6 R700 sixx
(>>> 4.9.1 "Supplementary load, reach
 KR 6 R700 sixx W
R700" Page 44)
 KR 6 R700 sixx C
 KR 6 R900 sixx
 KR 6 R900 sixx W
 KR 6 R900 sixx C (>>> 4.9.2 "Supplementary load, reach
 KR 10 R900 sixx R900" Page 45)
 KR 10 R900 sixx W
 KR 10 R900 sixx C
 KR 10 R1100 sixx
(>>> 4.9.3 "Supplementary load, reach
 KR 10 R1100 sixx W
R1100" Page 46)
 KR 10 R1100 sixx C

4.9.1 Supplementary load, reach R700

The following diagrams (>>> Fig. 4-43 ) and (>>> Fig. 4-44 ) show the di-
mensions and position of the installation options on the arm, in-line wrist, link
arm and rotating column.

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Fig. 4-43: Supplementary load on arm and in-line wrist

1 Support bracket for supplementary load

Fig. 4-44: Supplementary load on link arm and rotating column

1 Support bracket for supplementary load

4.9.2 Supplementary load, reach R900

The following diagrams (>>> Fig. 4-45 ) and (>>> Fig. 4-46 ) show the di-
mensions and position of the installation options on the arm, in-line wrist, link
arm and rotating column.

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Fig. 4-45: Supplementary load on arm and in-line wrist

1 Support bracket for supplementary load

Fig. 4-46: Supplementary load on link arm and rotating column

1 Support bracket for supplementary load

4.9.3 Supplementary load, reach R1100

The following diagrams (>>> Fig. 4-47 ) and (>>> Fig. 4-48 ) show the di-
mensions and position of the installation options on the arm, in-line wrist, link
arm and rotating column.

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Fig. 4-47: Supplementary load on arm and in-line wrist

1 Support bracket for supplementary load

Fig. 4-48: Supplementary load on link arm and rotating column

1 Support bracket for supplementary load

4.10 Plates and labels

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

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Fig. 4-49: Plates and labels

Item Description
1

Secure the axes

Before exchanging any motor, secure the corresponding axis
through safeguarding by suitable means/devices to protect against
possible movement. The axis can move. Risk of crushing!
2

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
3

Danger zone
Entering the danger zone of the robot is prohibited if the robot is in
operation or ready for operation. Risk of injury!
4

Work on the robot

Before start-up, transportation or maintenance, read and follow the
assembly and operating instructions.
5

Identification plate
Content according to Machinery Directive.

4.11 Stopping distances and times

4.11.1 General information

Information concerning the data:

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

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 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 conform to the re-
quirements 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 under the real conditions
of the actual robot application.
 Measuring technique
The stopping distances were measured using the robot-internal measur-
ing technique.
 The wear on the brakes varies depending on the operating mode, robot
application and the number of STOP 0 stops triggered. It is therefore ad-
visable to check the stopping distance at least once a year.

4.11.2 Terms used

Term Description
m Mass of the rated load and the supplementary load on
the arm.
Phi Angle of rotation (°) about the corresponding axis. This
value can be entered in the controller via the
KCP/smartPAD and can be displayed on the
KCP/smartPAD.
POV Program override (%) = velocity of the robot motion.
This value can be entered in the controller via the
KCP/smartPAD and can be displayed on the
KCP/smartPAD.
Extension Distance (l in %) (>>> Fig. 4-50 ) between axis 1 and
the intersection of axes 4 and 5. With parallelogram
robots, the distance between axis 1 and the intersec-
tion of axis 6 and the mounting flange.
KCP KUKA Control Panel
Teach pendant for the KR C2/KR C2 edition2005
The KCP has all the operator control and display func-
tions required for operating and programming the
industrial robot.
smartPAD Teach pendant for the KR C4
The smartPAD has all the operator control and display
functions required for operating and programming the
industrial robot.

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Fig. 4-50: Extension

4.11.3 Stopping distances and times, KR 6 R700 sixx and KR 6 R700 sixx C

The following values are preliminary values and are valid for the following ro-
bots.
 KR 6 R700 sixx
 KR 6 R700 sixx C

4.11.3.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3

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 (°) Stopping time (s)

Axis 1 133.67 0.494
Axis 2 122.43 0.556
Axis 3 79.29 0.371

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

Fig. 4-51: Stopping distances for STOP 1, axis 1

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Fig. 4-52: Stopping times for STOP 1, axis 1

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

Fig. 4-53: Stopping distances for STOP 1, axis 2

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Fig. 4-54: Stopping times for STOP 1, axis 2

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

Fig. 4-55: Stopping distances for STOP 1, axis 3

Fig. 4-56: Stopping times for STOP 1, axis 3

4.11.4 Stopping distances and times, KR 6 R700 sixx W

The following values are preliminary values and are valid for the following ro-
bots.
 KR 6 R700 sixx W

4.11.4.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3

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)

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Stopping distance (°) Stopping time (s)

Axis 1 182.04 0.665
Axis 2 68.31 0.377
Axis 3 63.48 0.379

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

Fig. 4-57: Stopping distances for STOP 1, axis 1

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Fig. 4-58: Stopping times for STOP 1, axis 1

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

Fig. 4-59: Stopping distances for STOP 1, axis 1

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Fig. 4-60: Stopping times for STOP 1, axis 1

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

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

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

4.11.5 Stopping distances and times, KR 6 R900 sixx and KR 6 R900 sixx C

The following values are valid for the following robots:

 KR 6 R900 sixx
 KR 6 R900 sixx C

4.11.5.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3

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)

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Stopping distance (°) Stopping time (s)

Axis 1 113.59 0.507
Axis 2 126.76 0.684
Axis 3 68.10 0.370

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

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

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

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

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

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Fig. 4-66: Stopping times for STOP 1, axis 2

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

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

Fig. 4-68: Stopping times for STOP 1, axis 3

4.11.6 Stopping distances and times, KR 6 R900 sixx W

The following values are valid for the following robots:

 KR 6 R900 sixx W

4.11.6.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3

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)

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Stopping distance (°) Stopping time (s)

Axis 1 163.11 0.745
Axis 2 67.78 0.404
Axis 3 60.96 0.387

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

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

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

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

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

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Fig. 4-72: Stopping times for STOP 1, axis 2

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

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

Fig. 4-74: Stopping times for STOP 1, axis 3

4.11.7 Stopping distances and times, KR 10 R900 sixx and KR 10 R1100 sixx

The following values are preliminary values and are valid for the following ro-
bots.
 KR 10 R900 sixx
 KR 10 R900 sixx C
 KR 10 R1100 sixx
 KR 10 R1100 sixx C

4.11.7.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3

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 %

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 Mass m = maximum load (rated load + supplementary load on arm)

Stopping distance (°) Stopping time (s)

Axis 1 106.21 0.536
Axis 2 96.06 0.647
Axis 3 46.99 0.373

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

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

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

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

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

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Fig. 4-78: Stopping times for STOP 1, axis 2

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

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

Fig. 4-80: Stopping times for STOP 1, axis 3

4.11.8 Stopping distances and times, KR 10 R900 sixx W and KR 10 R1100 sixx W

The following values are preliminary values and are valid for the following ro-
bots.
 KR 10 R900 sixx W
 KR 10 R1100 sixx W

4.11.8.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3

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)

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Stopping distance (°) Stopping time (s)

Axis 1 163.11 0.745
Axis 2 67.78 0.404
Axis 3 60.96 0.387

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

Fig. 4-81: Stopping distances for STOP 1, axis 1

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Fig. 4-82: Stopping times for STOP 1, axis 1

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

Fig. 4-83: Stopping distances for STOP 1, axis 2

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Fig. 4-84: Stopping times for STOP 1, axis 2

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

Fig. 4-85: Stopping distances for STOP 1, axis 3

Fig. 4-86: Stopping times for STOP 1, axis 3

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 5 Safety

5 Safety
f

5.1 General
y

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 assembly
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 controller
which must be observed.
 Where this “Safety” chapter uses the term “industrial robot”, this also re-
fers to the individual mechanical component if applicable.

5.1.1 Liability

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

ponent 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 accor-
dance with the recognized safety rules. Nevertheless, misuse of the industrial
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 accor-
dance with its designated 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 incorpo-
ration supplied together with the industrial robot. Any functional disorders af-
fecting safety must be rectified immediately.

Safety infor- Information about safety may not be construed against KUKA Deutschland
mation GmbH. 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 autho-
rization of KUKA Deutschland GmbH. Additional components (tools, software,
etc.), not supplied by KUKA Deutschland GmbH, 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 instruc-
tions. These must also be observed.

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5.1.2 Intended use of the industrial robot

The industrial robot is intended exclusively for the use designated in the “Pur-
pose” chapter of the operating instructions or assembly instructions.
Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. The manufacturer is not liable for any damage resulting
from such misuse. The risk lies entirely with the user.
Operation of the industrial robot in accordance with its intended use also re-
quires compliance with the operating and assembly instructions for the individ-
ual components, with particular reference to the maintenance specifications.

Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. This includes e.g.:
 Use as a climbing aid
 Operation outside the specified operating parameters
 Operation without the required safety equipment

5.1.3 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 operation 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 com-
plete system.
or: All safety functions and safeguards required for operation in the com-
plete 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 The system integrator must issue an EC declaration of conformity for the com-
conformity plete system in accordance with the Machinery Directive. The EC declaration
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 The partly completed machinery is supplied with a declaration of incorporation

incorporation in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The
assembly instructions and a list of essential requirements complied with in ac-
cordance with Annex I are integral parts of this declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly com-
pleted 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.

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5.1.4 Terms used

Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may move.
The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance
The stopping distance is part of the danger zone.
Workspace The manipulator is allowed to move within its workspace. The work-
space is derived from the individual axis ranges.
Operator The user of the industrial robot can be the management, employer or
(User) delegated person responsible for use of the industrial robot.
Danger zone The danger zone consists of the workspace and the stopping distances.
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 in a
controller or elsewhere or not, as safety-relevant components are also
subject to aging during storage
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”
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 additional
safe monitoring functions in addition to the standard safety functions.
Example: SafeOperation
smartPAD Teach pendant for the KR C4
The smartPAD has all the operator control and display functions
required for operating and programming the industrial robot.
Stop category 0 The drives are deactivated immediately and the brakes are applied. The
manipulator and any external axes (optional) perform path-oriented
braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-main-
taining braking. The drives are deactivated after 1 s and the brakes are
applied.
Note: This stop category is called STOP 1 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 normal
braking ramp.
Note: This stop category is called STOP 2 in this document.
System integrator System integrators are people who safely integrate the industrial robot
(plant integrator) into a complete system and commission it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Axis of motion that does not belong to the manipulator, yet is controlled
with the same controller. e.g. KUKA linear unit, turn-tilt table, Posiflex

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5.2 Personnel

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

All persons working with the industrial robot must have read and un-
derstood the industrial robot documentation, including the safety
chapter.

User The user must observe the labor laws and regulations. This includes e.g.:
 The user must comply with his monitoring obligations.
 The user must carry out briefing at defined intervals.

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 ex-
ist. Instruction must be carried out regularly. Instruction is also required after
particular incidents or technical modifications.
Personnel includes:
 System integrator
 Operators, subdivided into:
 Start-up, maintenance and service personnel
 Operating personnel
 Cleaning personnel

Installation, exchange, adjustment, operation, maintenance and re-

pair must be performed only as specified in the operating or assembly
instructions for the relevant component of the industrial robot and only
by personnel specially trained for this purpose.

System integrator The industrial robot is safely integrated into a complete system by the system
integrator.
The system integrator is responsible for the following tasks:
 Installing the industrial robot
 Connecting the industrial robot
 Performing risk assessment
 Implementing the required safety functions and safeguards
 Issuing the EC declaration of conformity
 Attaching 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 experi-
ence, and their familiarization with the relevant standards, are able to as-
sess the work to be carried out and detect any potential hazards.

Work on the electrical and mechanical equipment of the industrial ro-

bot may only be carried out by specially trained personnel.

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5.3 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A workspace

must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the 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.
The danger zone consists of the workspace and the stopping distances of the
manipulator and external axes (optional). It must be safeguarded by means of
physical safeguards to prevent danger to persons or the risk of material dam-
age.

5.4 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.

5.4.1 Mechanical end stops

Depending on the robot variant, the axis ranges of the main and wrist axes of
the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.

If the manipulator or an external axis hits an obstruction

or a mechanical end stop or mechanical axis limitation,
the manipulator can no longer be operated safely. The manipulator must be
taken out of operation and KUKA Deutschland GmbH must be consulted be-
fore it is put back into operation.

5.4.2 Mechanical axis limitation (optional)

Some manipulators can be fitted with mechanical axis limitation systems in

axes A1 to A3. The axis limitation systems restrict the working range to the re-
quired minimum. This increases personal safety and protection of the system.
In the case of manipulators that are not designed to be fitted with mechanical
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 photoelectric
barriers, photoelectric curtains or obstacles on the system side. There must be
no shearing or crushing hazards at the loading and transfer areas.

This option is not available for all robot models. Information on spe-
cific robot models can be obtained from KUKA Deutschland GmbH.

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5.4.3 Options for moving the manipulator without drive energy

The system user is responsible for ensuring that the training of per-
sonnel with regard to the response to emergencies or exceptional sit-
uations also includes how the manipulator can be moved without
drive energy.

Description The following options are 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, de-
pending 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 axes 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 oper-
ating instructions for the robot or requested from KUKA Deutschland
GmbH.

Moving the manipulator without drive energy can dam-

age the motor brakes of the axes concerned. The motor
must be replaced if the brake has been damaged. The manipulator may
therefore be moved without drive energy only in emergencies, e.g. for rescu-
ing persons.

5.4.4 Labeling on the industrial robot

All plates, labels, symbols and marks constitute safety-relevant parts of the in-
dustrial 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

instructions or assembly instructions of the components of the indus-
trial robot.

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5.5 Safety measures

5.5.1 General safety measures

The industrial robot may only be used in perfect technical condition in accor-
dance with its intended use and only by safety-conscious persons. Operator
errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial robot
even after the robot controller has been switched off and locked out. Incorrect
installation (e.g. overload) or mechanical defects (e.g. brake defect) 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 possible, the manipulator and ex-
ternal axes must be secured by appropriate means.

In the absence of operational safety functions and safe-

guards, the industrial robot can cause personal injury or
material damage. If safety functions or safeguards are dismantled or deacti-
vated, the industrial robot may not be operated.

Standing underneath the robot arm can cause death or

injuries. For this reason, standing underneath the robot
arm is prohibited!

The motors reach temperatures during operation which

can cause burns to the skin. Contact must be avoided.
Appropriate safety precautions must be taken, e.g. protective gloves must be
worn.

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 en-
sured that each device is unambiguously assigned to the corresponding in-
dustrial robot. They must not be interchanged.

The operator must ensure that decoupled KCPs/smart-

PADs are immediately removed from the system and
stored out of sight and reach of personnel working on the industrial robot.
This serves to prevent operational and non-operational EMERGENCY STOP
devices from becoming interchanged.
Failure to observe this precaution may result in death, severe injuries or con-
siderable damage to property.

External An external keyboard and/or external mouse may only be used if the following
keyboard, conditions are met:
external mouse  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 con-
trol cabinet as soon as the start-up or maintenance work is completed or the
KCP/smartPAD is connected.

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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 Ve-
locity 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 compo-
nents of the industrial robot and includes e.g. modifications of the external
axes or to the software and configuration settings.

Faults The following tasks must be carried out in the case of faults in the industrial
robot:
 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 (tag-
out).
 Keep a record of the faults.
 Eliminate the fault and carry out a function test.

5.5.2 Transportation

Manipulator The prescribed transport position of the manipulator must be observed. Trans-
portation must be carried out in accordance with the operating instructions or
assembly instructions of the robot.
Avoid vibrations and impacts during transportation in order to prevent damage
to the manipulator.

Robot controller The prescribed transport position of the robot controller must be observed.
Transportation must be carried out in accordance with the operating instruc-
tions or assembly instructions of the robot controller.
Avoid vibrations and impacts during transportation in order to prevent damage
to the robot controller.

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

5.5.3 Start-up and recommissioning

Before starting up systems and devices for the first time, a check must be car-
ried out to ensure that the systems and devices are complete and operational,
that they can be operated safely and that any damage is detected.
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.

The passwords for logging onto the KUKA System Software as “Ex-
pert” and “Administrator” must be changed before start-up and must
only be communicated to authorized personnel.

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The robot controller is preconfigured for the specific in-

dustrial robot. If cables are interchanged, the manipula-
tor and the external axes (optional) may receive incorrect data and can thus
cause personal injury or material damage. If a system consists of more than
one manipulator, always connect the connecting cables to the manipulators
and their corresponding robot controllers.

If additional components (e.g. cables), which are not part of the scope
of supply of KUKA Deutschland GmbH, are integrated into the indus-
trial robot, the user is responsible for ensuring that these components
do not adversely affect or disable safety functions.

If the internal cabinet temperature of the robot controller

differs greatly from the ambient temperature, condensa-
tion can form, which may cause damage to the electrical components. Do not
put the robot controller into operation until the internal temperature of the
cabinet has adjusted to the ambient temperature.

Function test The following tests must be carried out before start-up and recommissioning:
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.

In the case of such damage, the affected components

must be exchanged. In particular, the motor and counter-
balancing system must be checked carefully.
External forces can cause non-visible damage. For example, it can lead to
a gradual loss of drive power from the motor, resulting in unintended move-
ments of the manipulator. Death, injuries or considerable damage to property
may otherwise result.

 There are no foreign bodies or loose parts on the industrial 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 sufficiently
rated and correctly connected.
 The connecting cables are correctly connected and the connectors are
locked.

5.5.4 Manual mode

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 operation. Setup
work includes:
 Jog mode
 Teaching
 Programming
 Program verification
The following must be taken into consideration in manual mode:
 If the drives are not required, they must be switched off to prevent the ma-
nipulator or the external axes (optional) from being moved unintentionally.

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 New or modified programs must always be tested first in Manual Reduced

Velocity mode (T1).
 The manipulator, tooling or external axes (optional) must never touch or
project beyond the safety fence.
 Workpieces, tooling and other objects must not become jammed as a re-
sult 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 safe-
guarded area.
If the setup work has to be carried out inside the safeguarded area, the follow-
ing must be taken into consideration:
In Manual Reduced Velocity mode (T1):
 If it can be avoided, there must be no other persons inside the safeguard-
ed area.
If it is necessary for there to be several persons inside the safeguarded ar-
ea, 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 area
and get out of harm’s way.
In Manual High Velocity mode (T2):
 This mode may only be used if the application requires a test at a velocity
higher than possible in T1 mode.
 Teaching and programming are not permissible in this operating mode.
 Before commencing the test, the operator must ensure that the enabling
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 re-
sponsibility of the operator to ensure this.

5.5.5 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.
 The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for no ap-
parent reason, the danger zone must not be entered until an EMERGENCY
STOP has been triggered.

5.5.6 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 regulations
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 operation-
al state. Repair work includes troubleshooting in addition to the actual repair
itself.

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The following safety measures must be carried out when working on the indus-
trial 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 additional safety mea-
sures 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 functions
or safeguards are deactivated during maintenance or repair work, they
must be reactivated immediately after the work is completed.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again. The system must then be checked to en-
sure that it is deenergized.
It is not sufficient, before commencing work on live parts, to execute an
EMERGENCY STOP or a safety stop, or to switch off the drives, as this does
not disconnect the robot system from the mains power supply. Parts remain
energized. Death or severe injuries may result.

Faulty components must be replaced using new components with the same
article numbers or equivalent components approved by KUKA Deutschland
GmbH for this purpose.
Cleaning and preventive maintenance work is to be carried out in accordance
with the operating instructions.

Robot controller Even when the robot controller is switched off, parts connected to peripheral
devices may still carry voltage. The external power sources must therefore be
switched off if work is to be carried out on the robot controller.
The ESD regulations must be adhered to when working on components in the
robot controller.
Voltages in excess of 50 V (up to 600 V) can be present in various compo-
nents 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.
Water and dust must be prevented from entering the robot controller.

Counterbal- Some robot variants are equipped with a hydropneumatic, spring or gas cylin-
ancing system der counterbalancing system.
The hydropneumatic and gas cylinder counterbalancing systems are pressure
equipment and, as such, are subject to obligatory equipment monitoring and
the provisions of the Pressure Equipment Directive.
The user must comply with the applicable national laws, regulations and stan-
dards pertaining to pressure equipment.
Inspection intervals in Germany in accordance with Industrial Safety Order,
Sections 14 and 15. Inspection by the user before commissioning at the instal-
lation site.
The following safety measures must be carried out when working on the coun-
terbalancing system:

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 The manipulator assemblies supported by the counterbalancing systems

must be secured.
 Work on the counterbalancing systems must only be carried out by quali-
fied personnel.

Hazardous The following safety measures must be carried out when handling hazardous
substances substances:
 Avoid prolonged and repeated intensive contact with the skin.
 Avoid breathing in oil spray or vapors.
 Clean skin and apply skin cream.

To ensure safe use of our products, we recommend regularly re-

questing up-to-date safety data sheets for hazardous substances.

5.5.7 Decommissioning, storage and disposal

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

cordance with the applicable national laws, regulations and standards.

5.6 Applied norms and regulations

Name/Edition Definition

2006/42/EU:2006 Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Council
of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)

2014/68/EU:2014 Pressure Equipment Directive:

Directive 2014/68/EU of the European Parliament and of the Council
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 ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design

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 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction

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

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

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EN 614- Safety of machinery:

1:2006+A1:2009
Ergonomic design principles - Part 1: Terms and general principles

EN 61000-6-2:2005 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial environments

EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

A1:2011
Part 6-4: Generic standards; Emission standard for industrial envi-
ronments

EN 60204- Safety of machinery:

1:2006/A1:2009
Electrical equipment of machines - Part 1: General requirements

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 6 Planning

6 Planning

6.1 Information for planning

In the planning and design phase, care must be taken regarding the functions
or applications to be executed by the kinematic system. The following condi-
tions can lead to premature wear. They necessitate shorter maintenance in-
tervals and/or earlier exchange of components. In addition, the permissible
operating parameters specified in the technical data must be taken into ac-
count and observed during planning.
 Continuous operation near temperature limits or 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 motions
 Static axis positions, e.g. continuous vertical position of a wrist axis
 External forces (process forces) acting on the robot
If one or more of these conditions are to apply during operation of the kinemat-
ic 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.

6.2 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 mounting base with centering consists of:
 Bedplate
 Resin-bonded anchors (chemical anchors)
 Fastening elements
This mounting variant requires a level and smooth surface on a concrete foun-
dation with adequate load bearing capacity. The concrete foundation must be
able to accommodate the forces occurring during operation. There must be no
layers of insulation or screed between the bedplate and the concrete founda-
tion.
The minimum dimensions must be observed.

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Fig. 6-1: Mounting base

1 Robot base frame 4 Hexagon bolt

2 Locating pin, cylindrical 5 Bedplate
3 Resin-bonded anchor 6 Locating pin, flat-sided

Grade of concrete When producing foundations from concrete, observe the load-bearing capac-
for foundations ity 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 DIN EN 206-1:2001/DIN 1045-2:2008

Dimensioned The following illustration (>>> Fig. 6-2 ) provides all the necessary information
drawing on the mounting base, together with the required foundation data. The speci-
fied foundation dimensions refer to the safe transmission of the foundation
loads into the foundation and not to the stability of the foundation.

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Fig. 6-2: Mounting base, dimensioned drawing

To ensure that the anchor forces are safely transmitted to the foundation, ob-
serve the dimensions for concrete foundations specified in the following illus-
tration (>>> Fig. 6-3 ).

The dimensions specified for the distance to the edge

are valid for non-reinforced or normally reinforced con-
crete without verification of concrete edge failure. For safety against concrete
edge failure in accordance with ETAG 001 Annex C, the concrete foundation
must be provided with an appropriate edge reinforcement.

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Fig. 6-3: Cross-section of foundations

1 Hexagon bolt 4 Resin-bonded anchor

2 Bedplate 5 Concrete foundation
3 Locating pin

6.3 Machine frame mounting

Description The machine frame mounting assembly is used when the robot is fastened on
a steel structure, a booster frame (pedestal) or a KUKA linear unit. This as-
sembly is also used if the robot is installed on the wall or ceiling. It must be
ensured that the substructure is able to withstand safely the forces occurring
during operation (foundation loads). The following diagram contains all the
necessary information that must be observed when preparing the mounting
surface (>>> Fig. 6-4 ).
The machine frame mounting assembly consists of:
 Locating pin
 Hexagon bolts with conical spring washers

Fig. 6-4: Machine frame mounting

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1 Hexagon bolt
2 Locating pin, cylindrical
3 Locating pin, flat-sided

Dimensioned The following illustration (>>> Fig. 6-5 ) provides all the necessary information
drawing on machine frame mounting, together with the required foundation data.

Fig. 6-5: Machine frame mounting, dimensioned drawing

1 Hexagon bolt (4x) 4 Locating pin, flat-sided

2 Locating pin, cylindrical 5 Steel structure
3 Mounting surface

6.4 Connecting cables and interfaces

Connecting The connecting cables comprise all the cables for transferring energy and sig-
cables nals between the robot and the robot controller. They are connected to the ro-
bot junction boxes with connectors. The set of connecting cables comprises:

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 Motor cable
 Data cable
 CAT5 data cable (optional)
 Connecting cable, external axes A7 and A8 (optional)
 Ground conductor (optional)
Depending on the specification of the robot, various connecting cables are
used. The standard cable length is 4 m. Cable lengths of 1 m, 7 m, 15 m and
25 m are available as an option. The maximum length of the connecting cables
must not exceed 25 m. Thus if the robot is operated on a linear unit which has
its own energy supply chain these cables must also be taken into account.

For the connecting cables, a ground conductor is always required to

provide a low-resistance connection between the robot and the con-
trol cabinet in accordance with DIN EN 60204. The ground conductor
is not part of the scope of supply and can be ordered as an option. The con-
nection must be made by the customer. The tapped holes for connecting the
ground conductor are located on the base frame of the robot.

The following points must be observed when planning and routing the con-
necting cables:
 The bending radius for fixed routing must not be less than 50 mm for motor
cables and 30 mm for control cables.
 Protect cables against exposure to mechanical stress.
 Route the cables without mechanical stress – no tensile forces on the con-
nectors
 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 electromagnetic
compatibility (EMC).

Interface A1 Interface A1 is located at the rear of the base frame. The connections for the
motor and data cables are shown in the following illustration.

Fig. 6-6: Interface A1

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1 Motor cable connection X30

2 Data cable connection X31

6.5 Customer interfaces

Interface A1 Interface A1 is located at the rear of the base frame.

Fig. 6-7: Customer interface A1

1 MEMD connection X32

2 CAT5 data cable connection XPN1
3 Air line connection AIR2
Outside diameter: 6 mm
4 Air line connection AIR1
Outside diameter: 6 mm
5 Pressurization connection (optional)
Max. pressure: 0.3 bar
Air, oil-free, dry, filtered
according to: ISO 8573.1-1, 1.2 to 16.2
6 Connection for external axis A8 (XP8.1)
7 Connection for external axis A7 (XP7.1)

Interface A4 Interface A4 is located on top of the in-line wrist.

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Fig. 6-8: Interface A4, example

1 Connection X41 4 Air line AIR2

2 Connection XPN41 5 Air connections
3 In-line wrist

The optional connector bypack is required for use of the air connections. This
option contains a silencer and several plug-in couplings (>>> Fig. 6-9 ).

Fig. 6-9: Connections for connector bypack option

1 Silencer 2 Push-in fitting

The robot has three bistable 5/2-way solenoid valves integrated into the in-line
wrist. The valve unit is activated via the internal energy supply system:

Designation Limit values

Valve type 5/2-way solenoid valve
Max. pressure 7 bar
Switching frequency 10 Hz
Operating temperature +5 °C to +45 °C (278 K to 318 K)
Free from condensation
Threaded union M5

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Designation Limit values

Medium Air, oil-free, dry, filtered
according to: ISO 8573.1-1, 1.2 to 16.2
Degree of filtration: max. 5 µm
Operating voltage 24 V DC
Current 25 mA

Fig. 6-10: Valve diagram

Valve activation
Designation Values
Digital outputs (for valve activation) 6 (DO7 to DO12):
 Valve 1: DO7/DO10
 Valve 2: DO8/DO11
 Valve 3: DO9/DO12
not short-circuit proof
Rated voltage 24 V DC (-15%/+20%)
Output current max. 25 mA

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The inputs and outputs are not preconfigured and must be configured
in WorkVisual.
Further information about mapping inputs and outputs can be found
in the WorkVisual documentation.

Connection X41
Designation Values
Digital outputs (for customer interface X41) 2 (DO13, DO14)
short-circuit proof
Rated voltage 24 V DC (-15%/+20%)
Output current max. 0.5 A
Short-circuit current max. 2 A
Load type Ohmic, inductive
Lamp load
Digital inputs (for customer interface X41) 6 (DI1 to DI6)
Signal voltage “0” -3 V … +5 V
EN 61131-2, type 3
Signal voltage “1” 15 V … 30 V
EN 61131-2, type 3
Input current typically 3 mA
EN 61131-2, type 3
Input filter typically 0.3 ms
Power supply 24 V / 3 A

A 615springtec® connector, 12-pole EMC enclosure E-part from Intercontec

is required for connection X41.
When using the power supply, the customer must protect this against overload
and short-circuit with a 3 A fuse downstream of connector X41.
For the connector bypack option, the pin assignments on the connector insert
are to be noted.

Fig. 6-11: Wiring diagram, connection X41

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Connection
XPN41

Fig. 6-12: Wiring diagram, connection XPN41

A SAISM-4/8S-M12 4P D-ZF connector from Weidmüller is required for con-

nection XPN41.

Connection AIR2 Customer-specific air connection with the following values:

Designation Limit values

Max. pressure 7 bar
Vacuum Atmospheric pressure minus 0.95 bar

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 7 Transportation

7
T
Transportation
s

7.1 Transporting the manipulator

t

Move the robot into its transport position each time it is transported. It must be
t

Description
ensured that the robot is stable while it is being transported. The robot must
remain in its transport position until it has been fastened to the foundation. Be-
fore the robot is lifted, it must be ensured that it is free from obstructions. Re-
move all transport safeguards, such as nails and screws, in advance. First
remove any corrosion or glue on contact surfaces.

Transport The robot must be in the transport position before it can be transported
position (>>> Fig. 7-1 ). The robot is in the transport position when the axes are in the
following positions:

Axis A1 A2 A3 A4 A5 A6
Angle 0° -105° +156° 0º +120º 0º

Fig. 7-1: Transport position

Transport dimen- The transport dimensions for the robot can be noted from the following figures.
sions The position of the center of gravity and the weight vary according to the spe-
cific configuration. The specified dimensions refer to the robot without equip-
ment.
The following transport dimensions (>>> Fig. 7-2 ) are valid for the robots:
 KR 6 R700 sixx
 KR 6 R700 sixx W
 KR 6 R700 sixx C

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Fig. 7-2: Transport dimensions, R700

1 Robot 2 Center of gravity

The following transport dimensions (>>> Fig. 7-3 ) are valid for the robots:
 KR 6 R900 sixx
 KR 6 R900 sixx W
 KR 6 R900 sixx C
 KR 10 R900 sixx
 KR 10 R900 sixx W
 KR 10 R900 sixx C

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Fig. 7-3: Transport dimensions, R900

1 Robot 2 Center of gravity

The following transport dimensions (>>> Fig. 7-4 ) are valid for the robots:
 KR 10 R1100 sixx
 KR 10 R1100 sixx W
 KR 10 R1100 sixx C

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Fig. 7-4: Transport dimensions, R1100

1 Robot 2 Center of gravity

Transportation
Use of unsuitable handling equipment may result in dam-
using lifting age to the robot or injury to persons. Only use authorized
tackle handling equipment with a sufficient load-bearing capacity. Only transport
the robot in the manner specified here.

The robot is transported using lifting tackle (>>> Fig. 7-5 ). The robot must be
in the transport position. The loops of the lifting tackle are passed around the
link arm and rotating column. All ropes must be long enough and must be rout-
ed 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.

The robot may tip during transportation. Risk of personal

injury and damage to property.
If the robot is being transported using lifting tackle, special care must be ex-
ercised to prevent it from tipping. 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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Fig. 7-5: Transportation using lifting tackle

1 Crane 3 Link arm

2 Lifting tackle 4 Rotating column

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 8 Start-up and recommissioning

8 Start-up and recommissioning

t

For screwed connections, the fastening screws (stan-

dard, strength class 8.8) are to be tightened with the
tightening torques specified in the appendix (>>> 12 "Appendix" Page 159).
Tightening torques deviating from these values are specified directly.
The specified screw sizes and strength classes are those valid at the copy
deadline. The specifications contained in the Parts Catalog are, however, al-
ways to be taken as the most up-to-date information.
Screws of strength class 10.9 and higher may only be tightened once with the
rated tightening torque. When the screws are first slackened they must be re-
placed with new ones.

8.1 Installing the mounting base

Description These instructions apply to the variant “mounting base with centering (resin
cartridge)”. The robot is fastened to an appropriate concrete foundation using
one or more bedplates and resin-bonded anchors.
If the surface of the concrete foundation is not sufficiently smooth and even,
the differences must be evened out with a suitable leveling compound.
When using resin-bonded anchors, use only resin cartridges and anchors from
the same manufacturer. No diamond tools or core drills may be used for drill-
ing the anchor holes; for preference, drilling tools supplied by the anchor man-
ufacturer are to be used. The manufacturer’s instructions for the use of resin-
bonded anchors must also be observed.

Precondition  The concrete foundation must have the required dimensions and cross-
section.
 The surface of the foundation must be smooth and even.
 The mounting base assembly must be complete.
 Have the leveling compound readily at hand.

Special tools The following special tools are required:

 Drill with a ø 14 mm bit
 Setting tool approved by the anchor manufacturer

Procedure 1. Determine the position of the plate on the foundation in relation to the
working envelope.
2. Set the bedplate down on the foundation in its installation position.

If the bedplate is not fully seated on the concrete ceiling,

this can cause strain or result in loosening of the mount-
ing base. Fill the gap with leveling compound. To do this, lift the bedplate
again and apply sufficient leveling compound to the underside (toothed spat-
ula). Then set the bedplate down again and align it, removing any excess lev-
eling compound. The maximum height of the leveling compound must not be
exceeded.
The area under the hexagon bolt for robot fastening must be kept free from
leveling compound.
Allow the leveling compound to cure for about 3 hours. The curing time is lon-
ger at temperatures below 293 K (20 °C).

3. Check that the bedplate is horizontal. The maximum permissible deviation

is 3°.
4. Drill 4 anchor holes in accordance with the manufacturer’s specifications
and fit the anchors as specified in the instructions for use.

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The instructions for use are enclosed with the anchors and must be fol-
lowed precisely.
5. Allow the resin to cure. See table provided by manufacturer.

8.2 Installing the machine frame mounting assembly

Description The machine frame mounting is used for installing robots on a steel structure
prepared by the customer.

Precondition  The mounting surface has been prepared as shown in the diagram
(>>> Fig. 6-5 ).
 The substructure has been checked for sufficient safety.
 The machine frame mounting assembly is complete.

Procedure 1. Clean the mounting surface of the robot (>>> Fig. 8-1 ).
2. Check the hole pattern.
3. Insert 2 locating pins into the hole pattern.
4. Prepare 4 M10x35 hexagon bolts together with conical spring washers.

Fig. 8-1: Installing the machine frame mounting assembly

1 M10x35-8.8 hexagon bolt (4x)

2 Locating pin, cylindrical
3 Mounting surface
4 Locating pin, flat-sided

The mounting base is now ready for the robot to be installed.

8.3 Installing a floor-mounted robot

Description This description is valid for the installation of floor-mounted robots.

4 hexagon bolts with conical spring washers are used for fastening to the bed-
plate or to a machine frame. A cylindrical pin and a flat-sided pin are provided
to ensure correct positioning.
The installation and start-up of the robot controller, the tools mounted and the
applications are not described here.

Precondition  The mounting base is installed.

 The installation site is accessible with a crane.
 Any tools or other system components which would hinder the work have
been removed.

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 8 Start-up and recommissioning

 The robot is in the transport position.

 The connecting cables and ground conductors are routed to the robot and
installed.

Procedure 1. Check that the pins are undamaged and fitted securely (>>> Fig. 8-2 ).
2. Bring the robot to the installation site with the crane.
3. Carefully lower the robot vertically onto the mounting surface. Ensure that
an entirely vertical position is maintained in order to prevent damage to the
pins.
4. Insert 4 M10x35 hexagon bolts together with conical spring washers.
5. Tighten 4 M10x35 hexagon bolts with a torque wrench in diagonally oppo-
site sequence. Gradually increase the tightening torque to 45.0 Nm.
6. Remove the lifting tackle.
7. Connect motor cable X30 and data cable X31.
When connecting the motor cable connectors, it must be ensured that the
connectors on the controller and on the robot are locked correctly. Correct
locking 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.
8. Connect the ground conductor between the robot controller and the robot
to the ground conductor connection.
9. Connect the ground conductor between the system component and the ro-
bot to the ground conductor connection.
10. 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.

11. Mount tooling, if present.

12. Retighten the 4 M10x35 hexagon bolts with a torque wrench after 100
hours of operation.

Fig. 8-2: Installing a floor-mounted robot

1 Ground conductor, external 5 Mounting surface

2 Motor cable 6 Locating pin, cylindrical

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3 Data cable 7 Ground conductor, KRC

4 Locating pin, flat-sided 8 Hexagon bolt
Locating pin, cylindrical

Put the robot system into operation in accordance with the “Start-up” chapter
of the operating and programming instructions for the KUKA System Software
(KSS) and the “Start-up” chapter of the operating instructions for the robot con-
troller.

8.4 Installing a wall-mounted robot

Description This description is valid for the installation of wall-mounted robots with the
mounting variant “Machine frame mounting”. For installation on the wall, the
robot must be fastened to the Load Lifting Attachment. The robot is fastened
to the wall using the Load Lifting Attachment. The Load Lifting Attachment
must then be removed.
The installation and start-up of the robot controller, the tools mounted and the
applications are not described here.

Precondition  The machine frame mounting assembly is installed.

 The installation site is accessible with a crane and fork lift truck.
 Any tools or other system components which would hinder the work have
been removed.
 The robot is in the transport position.
 2 instructed persons are required for performing this task.

Procedure 1. Bring the robot to the installation site with the crane and set it down.
2. Carefully push the Load Lifting Attachment onto the base frame of the ro-
bot from the front (>>> Fig. 8-3 ).
3. Remove the lifting tackle.
4. Fasten the robot to the front of the Load Lifting Attachment with 2 M12x30
Allen screws and washers; MA = 40 Nm.

Fig. 8-3: Pushing on the Load Lifting Attachment and fastening it at the
front

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1 Base frame
2 Load lifting attachment
3 M12x30 Allen screw (front)

5. Position swivel holders on base frame (>>> Fig. 8-4 ).

6. Fasten the swivel holders to the rear of the base frame with 2 M12x30 Al-
len screws and washers; MA = 40 Nm.
7. Lock the swivel holders to the Load Lifting Attachment with 2 M12x30 Allen
screws and washers.

Fig. 8-4: Positioning and fastening the swivel holders

1 Swivel holder
2 M12x30 Allen screw (rear)
3 M12x30 Allen screw (locking screw)

8. Attach lifting tackle to the 2 rotating swivel eyebolts on the Load Lifting At-
tachment and to the crane.
9. Person 1:
Slowly and carefully lift the robot with the crane.
Person 2:
Secure the robot against toppling during the lifting operation.

Ensure that the robot does not topple during the lifting
operation. Serious injuries and damage to property may
otherwise result.

10. Slowly rotate the robot through 90°. The arm must point downward.
11. Lift the Load Lifting Attachment with a fork lift truck (>>> Fig. 8-5 ).
The fork lift truck must remain in the fork slots of the Load Lifting Attach-
ment during installation in order to prevent slipping.

When picking up the Load Lifting Attachment with the

fork lift truck, the width of the fork slots (140 mm) must be
taken into consideration. Damage to property may otherwise result.

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Fig. 8-5: Lifting the Load Lifting Attachment with a fork lift truck

12. Position the robot on the wall using the fork lift truck. Ensure that an entire-
ly horizontal position is maintained in order to prevent damage to the pins.
13. Unscrew 2 M12x30 Allen screws (top Allen screws) and washers from the
top of the base frame (>>> Fig. 8-6 ).
14. Unscrew 2 M12x30 Allen screws (locking screws) and washers from the
Load Lifting Attachment.

Fig. 8-6: Removing the top screws

1 M12x30 Allen screw (top)

2 M12x30 Allen screw (locking screw)

15. Rotate the swivel holders outwards (>>> Fig. 8-7 ).

16. Fasten the robot to the wall with 2 M10x35 hexagon bolts (top hexagon
bolts) and washers at the top.
Tighten the hexagon bolts alternately with the torque wrench. Gradually in-
crease the tightening torque to 45 Nm.

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Fig. 8-7: Rotating the swivel holders outwards

1 Swivel holder
2 M10x35 hexagon bolt (top)

17. Unscrew 2 M12x30 Allen screws (bottom Allen screws) and washers from
the bottom of the base frame.
18. Carefully separate the Load Lifting Attachment from the bottom of the base
frame with the fork lift truck.
19. Fasten the robot to the wall with 2 M10x35 hexagon bolts and washers on
the bottom of the base frame.
Tighten the hexagon bolts alternately with the torque wrench. Gradually in-
crease the tightening torque to 45 Nm.
20. Connect motor cable X30 and data cable X31 (>>> Fig. 8-8 ).
When connecting the motor cable connectors, it must be ensured that the
connectors on the controller and on the robot are locked correctly. Correct
locking 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.
21. Connect the ground conductor between the robot controller and the robot
to the ground conductor connection.

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Fig. 8-8: Connecting the supply lines

1 Ground conductor, KRC 3 Data cable

2 Motor cable 4 Ground conductor, external

22. 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.

23. Connect the ground conductor between the system component and the ro-
bot to the ground conductor connection.
24. Mount tooling, if present.
25. Retighten the 4 hexagon bolts with a torque wrench after 100 hours of op-
eration.
Put the robot system into operation in accordance with the “Start-up” chapter
of the operating and programming instructions for the KUKA System Software
(KSS) and the “Start-up” chapter of the operating instructions for the robot con-
troller.

8.5 Installing a ceiling-mounted robot

Description This description is valid for the installation of ceiling-mounted robots. The
mounting base or machine frame mounting assembly is used for this purpose.
For installation on the ceiling, the robot must be fastened to the Load Lifting
Attachment. The robot is fastened to the ceiling using the Load Lifting Attach-
ment. The Load Lifting Attachment must then be removed.
The installation and start-up of the robot controller, the tools mounted and the
applications are not described here.

Precondition  The machine frame mounting assembly is installed.

 The installation site is accessible with a crane and fork lift truck.
 Any tools or other system components which would hinder the work have
been removed.
 The robot is in the transport position.

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 2 instructed persons are required for performing this task.

Procedure 1. Bring the robot to the installation site with the crane and set it down.
2. Carefully push the Load Lifting Attachment onto the base frame of the ro-
bot from the front (>>> Fig. 8-9 ).
3. Remove the lifting tackle.
4. Fasten the robot to the front of the Load Lifting Attachment with 2 M12x30
Allen screws and washers; MA = 40.0 Nm.

Fig. 8-9: Pushing on the Load Lifting Attachment and fastening it at the
front

1 Base frame
2 Load lifting attachment
3 M12x30 Allen screw (front)

5. Position swivel holders on base frame (>>> Fig. 8-10 ).

6. Fasten the swivel holders to the rear of the base frame with 2 M12x30 Al-
len screws and washers; MA = 40.0 Nm.
7. Lock the swivel holders to the Load Lifting Attachment with 2 M12x30 Allen
screws and washers.

Fig. 8-10: Positioning and fastening the swivel holders

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1 Swivel holder
2 M12x30 Allen screw (rear)
3 M12x30 Allen screw (locking screw)

8. Attach lifting tackle to the 2 rotating swivel eyebolts on the Load Lifting At-
tachment and to the crane.
9. Person 1:
Slowly and carefully lift the robot with the crane.
Person 2:
Secure the robot against toppling during the lifting operation.

Ensure that the robot does not topple during the lifting
operation. Serious injuries and damage to property may
otherwise result.

10. Slowly rotate the robot through 180° and lower it.
11. Lift the Load Lifting Attachment with a fork lift truck (>>> Fig. 8-11 ).
The fork lift truck must remain in the fork slots of the Load Lifting Attach-
ment during installation in order to prevent slipping.

When picking up the Load Lifting Attachment with the

fork lift truck, the width of the fork slots (140 mm) must be
taken into consideration. Damage to property may otherwise result.

Fig. 8-11: Lifting the Load Lifting Attachment with a fork lift truck

12. Position the robot on the ceiling using the fork lift truck. Ensure that an en-
tirely vertical position is maintained in order to prevent damage to the pins.
13. Unscrew 2 M12x30 Allen screws (rear Allen screws) and washers from the
rear of the base frame (>>> Fig. 8-12 ).
14. Unscrew 2 M12x30 Allen screws (locking screws) and washers from the
Load Lifting Attachment.

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Fig. 8-12: Removing screws from the rear

1 M12x30 Allen screw (rear)

2 M12x30 Allen screw (locking screw)

15. Rotate the swivel holders outwards (>>> Fig. 8-13 ).

16. Fasten the robot to the ceiling with 2 M10x35 hexagon bolts (rear hexagon
bolts) and washers at the rear.
Tighten the hexagon bolts alternately with the torque wrench. Gradually in-
crease the tightening torque to 45.0 Nm.

Fig. 8-13: Rotating the swivel holders outwards

1 Swivel holder
2 M10x35 hexagon bolt (rear)

17. Unscrew 2 M12x30 Allen screws (front Allen screws) and washers from
the front of the base frame.
18. Carefully push the Load Lifting Attachment down from the rear of the base
frame with the fork lift truck.
19. Fasten the robot to the ceiling with 2 M10x35 hexagon bolts and washers
at the front of the base frame.
Tighten the hexagon bolts alternately with the torque wrench. Gradually in-
crease the tightening torque to 45.0 Nm.
20. Connect motor cable X30 and data cable X31 (>>> Fig. 8-14 ).
When connecting the motor cable connectors, it must be ensured that the
connectors on the controller and on the robot are locked correctly. Correct
locking 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.

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21. Connect the ground conductor between the robot controller and the robot
to the ground conductor connection.

Fig. 8-14: Connecting the supply lines

1 Ground conductor, KRC 3 Motor cable

2 Ground conductor, external 4 Data cable

22. 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.

23. Connect the ground conductor between the system component and the ro-
bot to the ground conductor connection.
24. Mount tooling, if present.
25. Retighten the 4 M10x35 hexagon bolts with a torque wrench after 100
hours of operation.
Put the robot system into operation in accordance with the “Start-up” chapter
of the operating and programming instructions for the KUKA System Software
(KSS) and the “Start-up” chapter of the operating instructions for the robot con-
troller.

8.6 Description of the connecting cables

Setup The connecting cables are used to transfer power and signals between the ro-
bot controller and the robot.
The connecting cables comprise:
 Motor cable
 Data cable
 CAT5 data cable (optional)
 Connecting cable, external axes A7 and A8 (optional)
 Ground conductor (optional)

Interface For connection of the connecting cables between the robot controller and the
robot, the following connectors are available at the interfaces:

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 8 Start-up and recommissioning

Connector designation
Interface with
Cable designation robot controller -
robot
robot
Motor cable X20 - X30 Han Yellock 30
Data cable X21 - X31 Han Q12
Data cable CAT5 X65/X66 - XPN1 M12 connector
(can be ordered as an
option)
Connecting cable, exter- XP7 - XP7.1 Connector M17
nal axes A7 and A8 in each case
XP8 - XP8.1
(can be ordered as an
option)
Ground conductor, equi- M4 ring cable
potential bonding lug
(can be ordered as an
option)

Only resolvers can be connected to the connections XP7.1 and XP8.1.

For the connecting cables, a ground conductor is always required to

provide a low-resistance connection between the robot and the con-
trol cabinet in accordance with DIN EN 60204. The ground conductor
is not part of the scope of supply and can be ordered as an option. The con-
nection must be made by the customer. The tapped holes for connecting the
ground conductor are located on the base frame of the robot.

Standard
connecting cable

Fig. 8-15: Connecting cables, overview

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Fig. 8-16: Connecting cable, motor cable, X20 - X30

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Fig. 8-17: Connecting cable, data cable X21 - X31

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Fig. 8-18: Connecting cable, data cable CAT5 X65/X66 - XPN1

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 8 Start-up and recommissioning

Fig. 8-19: Connecting cable, external axes A7 and A8

Fig. 8-20: Connecting cable, ground conductor

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1 Ground conductor 6 Conical spring washer

2 Hexagon nut 7 Robot
3 Conical spring washer 8 Setscrew, M4
4 Plain washer 2x 9 Ground conductor connection,
M4 ring cable lug
5 Hexagon nut 10 Ground sign

8.7 Moving the manipulator without drive energy

Description The brake release device (optional) an be used for moving the manipulator af-
ter an accident or malfunction without drive energy.
This option is only for use in exceptional circumstances and emergencies, e.g.
for freeing people.

Precondition  The robot controller must be switched off and secured (e.g. with a padlock)
to prevent unauthorized persons from switching it on again.

Procedure
Use of the brake release device may result in unexpect-
ed robot motions, especially sagging of the axes. During
use of the brake release device, attention must be paid to motion of this kind
in order to be able to prevent physical injuries or damage to property. Stand-
ing under moving axes is not permitted.

The following procedure must be followed exactly!

1. Unplug motor cable X30 on the robot.

2. Plug connector X20 into the brake release device and connector X30 into
the robot.
3. Plug connector X1 of the hand-held device into the brake release device.
4. Select the brakes to be released (main axes, wrist axes) via the selection
switch on the brake release device.
5. Press the button on the hand-held device.
The brakes of the main axes or wrist axes are released and the robot can
be moved manually.

Further information about the brake release device can be found in

the documentation for the brake release device.

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 9 Maintenance

9 Maintenance
t

For screwed connections, the fastening screws (stan-

dard, strength class 8.8) are to be tightened with the
tightening torques specified in the appendix (>>> 12 "Appendix" Page 159).
Tightening torques deviating from these values are specified directly.
The specified screw sizes and strength classes are those valid at the copy
deadline. The specifications contained in the Parts Catalog are, however, al-
ways to be taken as the most up-to-date information.
Screws of strength class 10.9 and higher may only be tightened once with the
rated tightening torque. When the screws are first slackened they must be re-
placed with new ones.

9.1 Maintenance overview

Description The table provides an overview of the maintenance work (maintenance inter-
vals, activities, lubrication work) and required lubricants applicable to this ro-
bot.
The maintenance intervals given in the table are valid for the operating condi-
tions specified in the technical data. KUKA Deutschland GmbH must be con-
sulted in the case of discrepancies!

Further information can be found in the section “Information for plan-

ning” (>>> 6.1 "Information for planning" Page 101).

Precondition  The maintenance points must be freely accessible.

 Remove the tools and any additional items of equipment if they impede
maintenance work.

Unintentional robot motions can cause injuries and dam-

age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

9.2 Maintenance table

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

Oil change

Lubricate with grease gun

Lubricate with brush

Lubricate with spray grease

Tighten screw/nut

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Check component, visual inspection

Clean component

Exchange battery

Exchanging the toothed belt

Check toothed belt tension

Fig. 9-1: Maintenance work

Interval Item Activity Lubricant

100 h* 1 Check the tightening torque -
of the 4 holding-down bolts
on the mounting base.
MA = 45 Nm
* Once only, after initial
start-up or recommission-
ing.
1 year 1 If using a mounting base, -
check the tightening torque
of the 4 holding-down bolts.
MA = 45 Nm

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 9 Maintenance

Interval Item Activity Lubricant

5,000 h 2 Grease the inside of covers Grease RB 2
or 1 year A2 and A3. Art. no. 00-101-456
at the latest
(>>> 9.3 "Greasing the in- 10 g
side of covers A2 and A3"
Page 139)
5,000 h 3 Exchange toothed belts on -
or 1 year A5 and A6.
at the latest
(>>> 9.4 "Exchanging the
toothed belts" Page 140)

9.3 Greasing the inside of covers A2 and A3

Description The inside of covers must be greased with Optitemp RB 2.

Precondition  Arm and in-line wrist are horizontal.

Unintentional robot motions can cause injuries and dam-

age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

The motors reach temperatures during operation which

can cause burns to the skin. Contact must be avoided.
Appropriate safety precautions must be taken, e.g. protective gloves must be
worn.

Procedure 1. Remove the following round head screws from cover A2 and take off cover
A2 (>>> Fig. 9-2 ):
 3 M4x14-10.9 round head screws
 2 M4x25-10.9 round head screws
 5 M4x35-10.9 round head screws
2. Remove 7 M3x10-10.9 round head screws from cover A3 and take off cov-
er A3.

Fig. 9-2: Removing covers A2 and A3

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1 Cover A2
2 M4x35-10.9 round head screws
3 M4x25-10.9 round head screws
4 M4x14-10.9 round head screws
5 Cover A3
6 M3x10-10.9 round head screws

3. Grease the inside of both covers with Optitemp RB 2.

4. Fit cover A2 and fasten it with the following screws:
 3 M4x14-10.9 round head screws; MA= 1.9 Nm
 2 M4x25-10.9 round head screws; MA= 1.9 Nm
 5 M4x35-10.9 round head screws; MA= 1.9 Nm
5. Mount cover A3 and fasten it with 7 M3x10-10.9 round head screws;
MA = 0.8 Nm.

9.4 Exchanging the toothed belts

Description The toothed belts of axes 5 and 6 may only be removed and installed together.

Precondition  The arm is in the horizontal position.

 The wrist axes are in their zero positions.
 No tools are installed on axis 6.

Unintentional robot motions can cause injuries and dam-

age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

If the toothed belt is removed and installed immediately

after the robot has stopped operating, surface tempera-
tures are likely to be high and could result in burn injuries; there is also a risk
of hands and fingers being pinched or crushed.
Protective gloves must be worn.

Procedure 1. Remove 7 M3x10-10.9 fillister head screws from the cover and take off the
cover (>>> Fig. 9-3 ).

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Fig. 9-3: Removing the cover from the in-line wrist – example

1 In-line wrist 3 Fillister head screw

2 Cover

2. Slacken 2 M4x10-10.9 fillister head screws on motor A5 and motor A6.

(>>> Fig. 9-4 )
3. Take the old toothed belts A5 and A6 off the pulleys.

Fig. 9-4: Removing the toothed belt – example

1 Fillister head screw 3 Toothed belt A5

2 Toothed belt pulley 4 Toothed belt A6

4. Fit new toothed belts A5 and A6 in the in-line wrist. Ensure that the toothed
belts mesh properly with the toothed belt pinions (>>> Fig. 9-5 ).

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Fig. 9-5: Toothed belt and toothed belt pinion

1 Toothed belt 2 Toothed belt pinion

5. Measure and adjust the toothed belt tension.

(>>> 10.1 "Measuring and adjusting the toothed belt tension" Page 145)
6. Mount the cover and fasten it with 7 new M3x10-10.9 fillister head screws;
MA = 0.8 Nm.
7. Carry out mastering of axes 5 and 6.

Detailed information about mastering is contained in the operating

and programming instructions for end users or system integrators.

9.5 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. System
components, tools and the robot controller must be cleaned in accordance
with the cleaning instructions relevant to them.
The following must be taken into consideration when using cleaning agents
and carrying out cleaning work:
 Only use solvent-free, water-soluble cleaning agents.
 Do not use flammable cleaning agents.
 Do not use aggressive cleaning agents.
 Do not use steam or refrigerants for cleaning.
 Do not use high-pressure cleaners.
 It must be ensured that no cleaning agent enters electrical or mechanical
system components.
 Personnel protection measures must be taken.

Unintentional robot motions can cause injuries and dam-

age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

Procedure 1. Shut down the robot.

2. If necessary, stop adjacent system components and lock them.
3. Remove enclosures if this is necessary in order to carry out the cleaning
work.
4. Clean the robot.
5. Fully remove all cleaning agents from the robot.
6. Clean any areas of corrosion and reapply corrosion protection.

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7. Remove cleaning agents and equipment from the workspace of the robot.
8. Dispose of cleaning agents in accordance with the pertinent regulations.
9. Install any safety equipment that has been removed and check that it is
functioning correctly.
10. Replace any damaged or illegible plates and covers.
11. Put back in place any enclosures that have been removed.
12. Only put fully functional robots and systems back into operation.

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 10 Repair

10 Repair

For screwed connections, the fastening screws (stan-

dard, strength class 8.8) are to be tightened with the
tightening torques specified in the appendix (>>> 12 "Appendix" Page 159).
Tightening torques deviating from these values are specified directly.
The specified screw sizes and strength classes are those valid at the copy
deadline. The specifications contained in the Parts Catalog are, however, al-
ways to be taken as the most up-to-date information.
Screws of strength class 10.9 and higher may only be tightened once with the
rated tightening torque. When the screws are first slackened they must be re-
placed with new ones.

10.1 Measuring and adjusting the toothed belt tension

Description The toothed belt tension on A5 and A6 is measured and adjusted in the same
way. The following description deals with the toothed belt tension for A5.

Precondition  Axis 5 is horizontal.

 No tools are installed on axis 6.

Unintentional robot motions can cause injuries and dam-

age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

If the toothed belt tension is measured and adjusted im-

mediately after the robot has stopped operating, surface
temperatures are likely to be high and could result in burn injuries. Protective
gloves must be worn.

Procedure 1. Remove 7 M3x10-10.9 fillister head screws from the cover and take off the
cover (>>> Fig. 10-1 ).

Fig. 10-1: Removing the cover from the in-line wrist – example

1 In-line wrist 3 Fillister head screw

2 Cover

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2. Slacken 2 M4x10-10.9 fillister head screws on motor A5 (>>> Fig. 10-2 ).

3. Insert a suitable tool (e.g. screwdriver) into the corresponding aperture in
the motor mount and carefully press motor A5 to the left in order to tension
toothed belt A5.

Fig. 10-2: Tensioning the toothed belt – example

1 Fillister head screw 4 Toothed belt A6

2 Aperture in motor mount A5 5 Aperture in motor mount A6
3 Toothed belt A5

4. Lightly tighten 2 M4x10-10.9 fillister head screws on motor A5.

5. Switch on the belt tension measuring device (>>> Fig. 10-3 ).
6. Pluck toothed belt A5 and hold the sensor near its center at a distance of
2 to 3 mm from the vibrating toothed belt. Read the measurement on the
belt tension measuring device.

Fig. 10-3: Belt tension measuring device

1 Belt tension measuring device

2 Sensor

Toothed belt tension

In-line wrist Axis Toothed belt Frequency
5
IW 6 R700 AT3/267 305 ± 5 Hz
6
5
IW 6/10 R900 AT3/351 205 ± 5 Hz
6
5
IW10 R1100 AT3/351 205 ± 5 Hz
6

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7. Tighten 2 M4x10-10.9 fillister head screws on motor A5, MA= 1.9 Nm.
8. Put the robot into operation and move A5 in both directions.
9. Secure the robot by pressing the E-STOP device.
10. Measure the tension of the toothed belt again.
If the value obtained does not correspond to the value in the table, repeat
steps 2 to 10.
11. Carry out steps 2 to 10 for toothed belt A6.
12. Mount the cover and fasten it with 7 new M3x10-10.9 fillister head screws;
MA = 0.8 Nm.

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 11 Decommissioning, storage and dispos...

11 Decommissioning, storage and disposal

11.1 Decommissioning, floor-mounted robot

s

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 pre-
pared 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 (>>> 7 "Transportation" Page 113).

Precondition  The removal site is accessible for transportation with a crane.

 There is no hazard posed by system components.

When carrying out the following work, the robot must be

moved several times between the individual work steps.
While work is being carried out on the robot, it must always be secured by
activating the EMERGENCY STOP device.
Unintentional robot motions can cause injuries and damage to property. 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 activating an EMERGENCY STOP device. Operation must be
limited to what is absolutely necessary.
Warn all persons concerned before switching on and moving the robot.

Procedure 1. Secure the robot.

2. Remove tools and equipment.
3. Put the robot into operation and move it into the transport position
(>>> Fig. 11-1 ).

Fig. 11-1: Transport position

4. Secure the robot by activating the E-STOP device and then shut down the
robot (>>> Fig. 11-2 ).
5. Release and unplug all peripheral connections.
6. Release and unplug the motor cable and data cable connectors.
7. Release and unplug the ground conductor.
8. Attach the lifting tackle.
9. Unscrew and remove the 4 hexagon bolts and conical spring washers.
10. Lift the robot vertically off the mounting surface and transport it away.
Take care not to damage the two pins when lifting off the robot.

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If the robot is caught on the mounting surface, it may

come free abruptly, endangering persons and property.
The robot must stand loosely on the mounting surface; completely remove all
fastening materials and any adhesives.

11. Prepare the robot for storage.

Fig. 11-2: Removing a floor-mounted robot

1 Lifting tackle 5 Hexagon bolt

2 Motor cable 6 Ground conductor
3 Data cable 7 Pin
4 Mounting surface

11.2 Decommissioning, wall-mounted robot

Description This section describes all the work required for decommissioning the wall-
mounted robot if the robot is to be removed from the system. After decommis-
sioning, it is prepared for storage or for transportation to a different location.

Precondition  The removal site is accessible with a crane and fork lift truck.
 There is no hazard posed by system components.

When carrying out the following work, the robot must be

moved several times between the individual work steps.
While work is being carried out on the robot, it must always be secured by
activating the EMERGENCY STOP device.
Unintentional robot motions can cause injuries and damage to property. 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 activating an EMERGENCY STOP device. Operation must be
limited to what is absolutely necessary.
Warn all persons concerned before switching on and moving the robot.

Procedure 1. Secure the robot.

2. Remove tools and equipment.

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3. Put the robot into operation and move it into the transport position
(>>> Fig. 11-3 ).

Fig. 11-3: Transport position

4. Secure the robot by activating the E-STOP device and then shut down the
robot.
5. Release and unplug all peripheral connections.
6. Release and unplug the motor cable and data cable connectors.
7. Release and unplug the ground conductor.
8. Rotate the Load Lifting Attachment so that it can be screwed to the wall-
mounted machine.
9. Lift the Load Lifting Attachment with a fork lift truck.
The fork lift truck must remain in the fork slots of the Load Lifting Attach-
ment during removal in order to prevent slipping.

When picking up the Load Lifting Attachment with the

fork lift truck, the width of the fork slots (140 mm) must be
taken into consideration. Damage to property may otherwise result.

10. Unscrew 2 M10x35 hexagon bolts (bottom hexagon bolts) and washers
from the bottom of the base frame.
11. Carefully push the Load Lifting Attachment onto the base frame of the ro-
bot from underneath (>>> Fig. 11-4 ).
12. Fasten the robot to the Load Lifting Attachment from underneath with 2
M12x30 Allen screws (bottom Allen screws) and washers; MA = 40 Nm.

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 KR AGILUS sixx

Fig. 11-4: Fastening the Load Lifting Attachment to the robot

1 Base frame
2 M10x35 hexagon bolt (bottom)
3 Load Lifting Attachment
4 M12x30 Allen screw (bottom)

13. Unscrew 2 M10x35 hexagon bolts (top hexagon bolts) and washers from
the top of the base frame.
14. Position swivel holders on base frame (>>> Fig. 11-5 ).
15. Fasten the swivel holders to the top of the base frame with 2 M12x30 Allen
screws and washers; MA = 40 Nm.
16. Lock the swivel holders to the Load Lifting Attachment with 2 M12x30 Allen
screws (locking screws) and washers.

Fig. 11-5: Positioning and fastening the swivel holders

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 11 Decommissioning, storage and dispos...

1 Swivel holder
2 M12x30 Allen screw (top)
3 M12x30 Allen screw (locking screw)

17. Slowly move the robot away from the wall with a fork lift truck.
18. Attach lifting tackle to the 2 rotating swivel eyebolts on the Load Lifting At-
tachment and to the crane.
19. Move the fork lift truck slowly and carefully out of the fork slots of the Load
Lifting Attachment.
20. Person 1:
Slowly and carefully lower the robot with the crane.
Person 2:
Secure the robot against toppling during the lowering operation.

Ensure that the robot does not topple during the lowering
operation. Serious injuries and damage to property may
otherwise result.

21. Slowly rotate the robot through 90° and carefully set it down.
22. Unscrew 4 M12x30 Allen screws and washers from the Load Lifting At-
tachment.
23. Unscrew 2 M12x30 Allen screws and washers from the swivel holders.
24. Rotate the swivel holders outwards.
25. Carefully push the Load Lifting Attachment down from the back of the base
frame.
26. Prepare the robot for storage.

11.3 Decommissioning, ceiling-mounted robot

Description This section describes all the work required for decommissioning the ceiling-
mounted robot if the robot is to be removed from the system. After decommis-
sioning, it is prepared for storage or for transportation to a different location.

Precondition  The removal site is accessible with a crane and fork lift truck.
 There is no hazard posed by system components.

When carrying out the following work, the robot must be

moved several times between the individual work steps.
While work is being carried out on the robot, it must always be secured by
activating the EMERGENCY STOP device.
Unintentional robot motions can cause injuries and damage to property. 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 activating an EMERGENCY STOP device. Operation must be
limited to what is absolutely necessary.
Warn all persons concerned before switching on and moving the robot.

Procedure 1. Secure the robot.

2. Remove tools and equipment.
3. Put the robot into operation and move it into the transport position
(>>> Fig. 11-6 ).

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 KR AGILUS sixx

Fig. 11-6: Transport position

4. Secure the robot by activating the E-STOP device and then shut down the
robot.
5. Release and unplug all peripheral connections.
6. Release and unplug the motor cable and data cable connectors.
7. Release and unplug the ground conductor.
8. Rotate the Load Lifting Attachment so that it can be screwed to the ceiling-
mounted machine.
9. Lift the Load Lifting Attachment with a fork lift truck.
The fork lift truck must remain in the fork slots of the Load Lifting Attach-
ment during removal in order to prevent slipping.

When picking up the Load Lifting Attachment with the

fork lift truck, the width of the fork slots (140 mm) must be
taken into consideration. Damage to property may otherwise result.

10. Unscrew 2 M10x35 hexagon bolts (front hexagon bolts) and washers from
the front of the base frame.
11. Carefully push the Load Lifting Attachment onto the base frame of the ro-
bot from the front (>>> Fig. 11-7 ).
12. Fasten the robot to the front of the Load Lifting Attachment with 2 M12x30
Allen screws (front Allen screws) and washers; MA = 40 Nm.

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 11 Decommissioning, storage and dispos...

Fig. 11-7: Fastening the Load Lifting Attachment to the robot

1 Base frame
2 M10x35 hexagon bolt (front)
3 Load Lifting Attachment
4 M12x30 Allen screw (front) and washer

13. Unscrew 2 M10x35 hexagon bolts (rear hexagon bolts) and washers from
the rear of the base frame.
14. Position swivel holders on base frame (>>> Fig. 11-8 ).
15. Fasten the swivel holders to the rear of the base frame with 2 M12x30 Al-
len screws and washers; MA = 40 Nm.
16. Lock the swivel holders on the Load Lifting Attachment with 2 M12x30 Al-
len screws.

Fig. 11-8: Positioning and fastening the swivel holders

1 M12x30 Allen screw (locking screw)

2 M12x30 Allen screw (rear)
3 Swivel holder

17. Slowly lower the robot with a fork lift truck.

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 KR AGILUS sixx

18. Attach lifting tackle to the 2 rotating swivel eyebolts on the Load Lifting At-
tachment and to the crane.
19. Move the fork lift truck slowly and carefully out of the fork slots of the Load
Lifting Attachment.
20. Person 1:
Slowly and carefully lift the robot with the crane.
Person 2:
Secure the robot against toppling during the lifting operation.

Ensure that the robot does not topple during the lifting
operation. Serious injuries and damage to property may
otherwise result.

21. Slowly rotate the robot through 180° and carefully set it down.
22. Unscrew 4 M12x30 Allen screws (front and rear) and washers from the
Load Lifting Attachment.
23. Unscrew 2 M12x30 Allen screws (locking screws) and washers from the
swivel holders.
24. Rotate the swivel holders outwards.
25. Carefully push the Load Lifting Attachment down from the back of the base
frame.
26. Prepare the robot for storage.

11.4 Storage

Description If the robot is to be put into long-term storage, the following points must be ob-
served:
 The place of storage must be as dry and dust-free as possible.
 Avoid temperature fluctuations.
 Avoid wind and drafts.
 Avoid condensation.
 Use appropriate coverings that cannot detach themselves and which can
withstand the expected environmental conditions.
 Do not leave any loose parts on the robot, especially ones that might
knock against other parts.
 Do not leave the robot exposed to direct sunlight while in storage.
 Observe and comply with the permissible temperature ranges for storage.
 Select a storage location in which the packaging materials cannot be dam-
aged.

Procedure 1. Remove tools and equipment.

2. Remove the robot.
3. Clean and dry the robot. No dirt or cleaning agent residue may remain on
or in the robot.
4. Perform a visual inspection of the robot.
5. Remove any foreign bodies.
6. Remove any corrosion.
7. Attach all covers to the robot and check that the seals are correctly in
place.
8. Seal off electrical connections with suitable covers.
9. Seal hose connections by suitable means.
10. Cover the robot with plastic film and seal it at the base frame against dust.
If necessary, add a desiccant beneath the sheeting.

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 11 Decommissioning, storage and dispos...

11.5 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 manipu-
lator. All plastic components are marked with a material designation and must
be disposed of accordingly.

Subassembly, com-
Material Further information
ponent
Metals
Cast aluminum Rotating column, arm,
link arm, wrist, base
frame
Copper Cables, wires
Steel Gear units, screws,
washers
Electrical components
Electronic compo- Dispose of as electri-
nents, such as RDC, cal scrap without dis-
EDS, etc. assembling
Motors Dispose of motors
without dismantling
them.
Plastics
Plastic Panels, covers
NBR Shaft seals, O-rings
PU Hoses
PUR Cable sheaths
Auxiliary substances and consumables
Lubricating grease Cabling Optitemp RB 2
Lubricant for Harmonic Gear unit Flexolub®-A1
Drive gear units

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

auxiliary and operating materials (>>> 12.2 "Auxiliary and operating materials
used" Page 159).

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 12 Appendix

12
2
Appendix
A

12.1 Tightening torques

x

Tightening The following tightening torques (Nm) are valid for screws and nuts where no
torques other specifications are given.
The specified values apply to lightly oiled black (e.g. phosphated) and coated
(e.g. mech. galv., zinc flake plating) screws and nuts.

Strength class
Thread 8.8 10.9 12.9
M1.6 0.17 Nm 0.24 Nm 0.28 Nm
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.

12.2 Auxiliary and operating materials used

Product designation Use Manufacturer designation/Address

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 KR AGILUS sixx

Optitemp RB 2 Lubricating grease Deutsche BP Aktiengesellschaft - In-

dustrial Lubricants & Services
Erkelenzer Straße 20
D-41179
Mönchengladbach
Germany

Flexolub®-A1 Lubricant for Harmonic Harmonic Drive AG

Drive gear units Hoenbergstrasse 14
D-65555
Limburg a. d. Lahn
Germany

To ensure safe use of our products, we recommend regularly re-

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

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 13 KUKA Service

13 KUKA Service
A

13.1 Requesting support

v

Introduction This documentation provides information on operation and operator control,

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

Information The following information is required for processing a support request:

 Description of the problem, including information about the duration and
frequency of the fault
 As comprehensive information as possible about the hardware and soft-
ware components of the overall system
The following list gives an indication of the information which is relevant in
many cases:
 Model and serial number of the kinematic system, e.g. the manipulator
 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 modifica-
tions
 Diagnostic package KRCDiag
Additionally for KUKA Sunrise: Existing projects including applications
For versions of KUKA System Software older than V8: Archive of the
software (KRCDiag is not yet available here.)
 Application used
 External axes used

13.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
[email protected]

Australia KUKA Robotics Australia Pty Ltd

45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
[email protected]
www.kuka-robotics.com.au

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 KR AGILUS sixx

Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
[email protected]
www.kuka.be

Brazil KUKA Roboter do Brasil Ltda.

Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
[email protected]
www.kuka-roboter.com.br

Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
www.robotec.cl

China KUKA Robotics China Co., Ltd.

No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
[email protected]
www.kuka-robotics.com

Germany KUKA Deutschland GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
[email protected]
www.kuka.com

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 13 KUKA Service

France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
[email protected]
www.kuka.fr

India KUKA Robotics India Pvt. Ltd.

Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
[email protected]
www.kuka.in

Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
[email protected]
www.kuka.it

Japan KUKA Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7531
Fax +81 45 744 7541
[email protected]

Canada KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
[email protected]
www.kuka-robotics.com/canada

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 KR AGILUS sixx

Korea KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
[email protected]

Malaysia KUKA Robot Automation (M) Sdn Bhd

South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
[email protected]

Mexico KUKA de México S. de R.L. de C.V.

Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]
www.kuka-robotics.com/mexico

Norway KUKA Sveiseanlegg + Roboter

Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
[email protected]

Austria KUKA Roboter CEE GmbH

Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 7 32 78 47 52
Fax +43 7 32 79 38 80
[email protected]
www.kuka.at

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 13 KUKA Service

Poland KUKA Roboter CEE GmbH Poland

Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
[email protected]

Portugal KUKA Robots IBÉRICA, S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
[email protected]
www.kuka.com

Russia KUKA Russia OOO

1-y Nagatinskiy pr-d, 2
117105 Moskau
Russia
Tel. +7 495 665-6241
[email protected]

Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
[email protected]

Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

Slovakia KUKA Roboter CEE GmbH

organizačná zložka
Bojnická 3
831 04 Bratislava
Slovakia
Tel. +420 226 212 273
[email protected]

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Spain KUKA Iberia, S.A.U.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
[email protected]

South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan KUKA Automation Taiwan Co. Ltd.

1F, No. 298 Yangguang ST.,
Nei Hu Dist., Taipei City, Taiwan 114
Taiwan
Tel. +886 2 8978 1188
Fax +886 2 8797 5118
[email protected]

Thailand KUKA (Thailand) Co. Ltd.

No 22/11-12 H-Cape Biz Sector Onnut
Sukhaphiban 2 road, Prawet
Bangkok 10250
Thailand
Tel. +66 (0) 90-940-8950
[email protected]

Czech Republic KUKA Roboter CEE GmbH

organizační složka
Pražská 239
25066 Zdiby
Czech Republic
Tel. +420 226 212 273
[email protected]

Hungary KUKA HUNGÁRIA Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]

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 13 KUKA Service

USA KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
[email protected]
www.kukarobotics.com

UK KUKA Robotics UK Ltd

Great Western Street
Wednesbury West Midlands
WS10 7LL
UK
Tel. +44 121 505 9970
Fax +44 121 505 6589
[email protected]
www.kuka-robotics.co.uk

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 Index

Index
Symbols Disposal 98, 149
-A1 160 Documentation, industrial robot 7
® 160
E
Numbers EC declaration of conformity 88
2006/42/EU2006 98 Electromagnetic compatibility (EMC) 99
2014/68/EU2014 98 EMC Directive 88
95/16/EC 98 EN 60204-12006/A12009 99
EN 61000-6-22005 99
A EN 61000-6-42007 + A12011 99
Accessories 11, 87 EN 614-12006+A12009 99
Altitude 17, 31 EN ISO 10218-12011 98
Ambient conditions 17, 31 EN ISO 121002010 98
Ambient temperature, operation 17, 31 EN ISO 13849-12015 98
Ambient temperature, storage 17, 31 EN ISO 13849-22012 98
Ambient temperature, transportation 17, 31 EN ISO 138502015 98
Angle of rotation 50 Exchanging, toothed belts 140
ANSI/RIA R.15.06-2012 98 Extension 50
Appendix 159 External axes 87, 89
Applied norms and regulations 98
Automatic mode 96 F
Auxiliary materials used 159 Faults 94
Axes, controlled, number 16, 30 Flexolub 160
Axes, number 16, 30 Floor-mounted robot, installing 120
Axis data, KR 10 sixx 32 Footprint 17, 31
Axis data, KR 6 sixx 18 Foundation data, KR 10 sixx 42
Axis limitation, mechanical 91 Foundation data, KR 6 sixx 28
Axis range 89 Function test 95

B G
Basic data, KR 10 sixx 30 General information 49
Basic data, KR 6 sixx 16 General safety measures 93
Brake defect 93
Brake release device 92 H
Braking distance 89 Handling equipment 116
Hazardous substances 98
C
CE mark 88 I
Ceiling-mounted robot, installing 126 Industrial robot 87
Changing, toothed belts 140 Intended use 88
Cleaning the robot 142 Interface A1 106
Cleaning work 97 Interfaces 105
Connecting cable, standard 131 Introduction 7
Connecting cables 11, 18, 31, 87, 105, 130 ISO 9283, repeatability 16, 30
Controller 17, 31
Counterbalancing system 97 K
Cover A2, greasingCover A3, greasing 139 KCP 50, 89, 93
Customer interfaces 107 Keyboard, external 93
KL 7
D KUKA Customer Support 161
Danger zone 89 KUKA Service 161
Declaration of conformity 88 KUKA smartPAD 89
Declaration of incorporation 87, 88
Decommissioning 98, 149 L
Decommissioning, ceiling-mounted robot 153 Labeling 92
Decommissioning, floor-mounted robot 149 Liability 87
Decommissioning, wall-mounted robot 150 Linear unit 87
Description, manipulator 12 Low Voltage Directive 88

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 KR AGILUS sixx

Lubricants 137 Repair 96, 145

Lubrication work 137 Repeatability 16, 30
Robot controller 11, 87
M
Machine frame mounting 104 S
Machine frame mounting, installing 120 Safety 87
Machinery Directive 88, 98 Safety instructions 7
main axes 50 Safety of machinery 98, 99
Maintenance 96, 137 Safety options 89
Maintenance intervals 137 Safety zone 89, 91
Maintenance overview 137 Safety, general 87
Maintenance symbols 137 Service life 89
Maintenance table 137 smartPAD 8, 11, 50, 89, 93
Manipulator 11, 87, 89 Software 11, 87
Manual mode 95 Sound level 17, 30
Material designation 157 Standard colors 17, 31
Mechanical end stops 91 Start-up 94, 119
MEMD 7 STOP 0 50, 89
micro RDC 8 STOP 1 50, 89
Mounting base 101 STOP 2 89
Mounting base with centering 101 Stop category 0 89
Mounting base, installing 119 Stop category 1 89
Mounting position 17, 31 Stop category 2 89
Mouse, external 93 Stop signal 49
Moving the robot, without drive energy 136 Stopping distance 49, 89
Stopping distances 49
O Stopping distances, KR 10 R1100 sixx 74
Operating materials used 159 Stopping distances, KR 10 R1100 sixx C 74
Operator 89 Stopping distances, KR 10 R1100 sixx W 80
Operators 90 Stopping distances, KR 10 R900 sixx 74
Options 11, 87 Stopping distances, KR 10 R900 sixx C 74
Optitemp RB 2 160 Stopping distances, KR 10 R900 sixx W 80
Overload 93 Stopping distances, KR 6 R700 sixx 51
Overview of the robot system 11 Stopping distances, KR 6 R700 sixx C 51
Stopping distances, KR 6 R700 sixx W 56
P Stopping distances, KR 6 R900 sixx 62
Payload diagram 26, 40 Stopping distances, KR 6 R900 sixx C 62
Payloads, KR 10 sixx 39 Stopping distances, KR 6 R900 sixx W 68
Payloads, KR 6 sixx 25 Stopping time 49
Permissible angle of inclination 17, 31 Stopping times 49
Personnel 90 Stopping times, KR 10 R1100 sixx 74
Planning 101 Stopping times, KR 10 R1100 sixx C 74
Plant integrator 89 Stopping times, KR 10 R1100 sixx W 80
Plates and labels 47 Stopping times, KR 10 R900 sixx 74
Positioner 87 Stopping times, KR 10 R900 sixx C 74
Pressure Equipment Directive 97, 98 Stopping times, KR 10 R900 sixx W 80
Preventive maintenance work 97 Stopping times, KR 6 R700 sixx 51
Principal dynamic loads 17, 30 Stopping times, KR 6 R700 sixx C 51
Product description 11 Stopping times, KR 6 R700 sixx W 56
Program override, motion velocity 50 Stopping times, KR 6 R900 sixx 62
Protection rating, in-line wrist 17, 30 Stopping times, KR 6 R900 sixx C 62
Protection rating, robot 17, 30 Stopping times, KR 6 R900 sixx W 68
Protective equipment, overview 91 Storage 98, 149
Purpose 9 Supplementary load 44
Supplementary load, R1100 46
R Supplementary load, R700 44
Reaction distance 89 Supplementary load, R900 45
Recommissioning 94, 119 Support request 161
Reference point 17, 30 System integrator 88, 89, 90
Relative air humidity 17, 31
Release device 92

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 Index

T
T1 89
T2 89
Teach pendant 11, 87
Technical data 15
Terms used 7, 50
Terms, safety 89
Tightening torques 159
Toothed belt tension, adjustment 145
Toothed belt tension, measurement 145
Toothed belts, exchanging 140
Training 9
Transformation name 17, 31
Transport position 113
Transportation 94, 113
Turn-tilt table 87

U
Use, contrary to intended use 87
Use, improper 87
User 89, 90
Users 9

V
Volume of working envelope 16, 30

W
Wall-mounted robot, installing 122
Warnings 7
Weight 17, 30
Working envelope 19, 22, 32, 36
Workspace 89, 91

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172 / 173 Issued: 17.05.2018 Version: BA KR AGILUS sixx V13

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