ROBOT

KR 125, 150, 200 (/2)

Technical Data

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

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

2 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Technical Data

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 1 General

Valid for KR 125/2

KR 125 L100/2
KR 125 L90/2
KR 125 W/2
KR 150/1, /2
KR 150 L150/2
KR 150 L120/2
KR 200/2

1 General
The robot is a six--axis industrial robot for installation on the floor or on the ceiling, or as the
KR 125 W for installation on the wall. It is suitable for all point--to--point and continuous--path
controlled tasks. The main areas of application are
-- spot welding
-- handling
-- assembly
-- application of adhesives, sealants and preservatives
-- machining
-- MIG/MAG welding
-- YAG laser beam welding.

Using the robot for purposes other than those mentioned above is considered
contrary to its designated use (see Doc. Module “Safety, General”).

Figure 1 shows the robot system, comprising the manipulator (= robot), control cabinet and
connecting cables.

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Technical Data

KR 125/2
3 4 KR 125 L 100/2
KR 125 L90/2
KR 150/2
KR 150 L150/2
2 KR 150 L120/2
KR 200/2

1
6 8

7 9

10

KR 125 W/2

11

1 Hydropneumatic 7 Base frame

counterbalancing system 8 Control cabinet (see separate
2 Counterweight A 3 documentation)
(only on KR 150/2, KR 150 L150/2, 9 Connecting cables
KR 150 L120/2, KR 200/2) 10 Counterweight A 1 (only on KR 125 W/2)
3 Arm 11 Hinged steel base
4 In--line wrist (provided by the customer)
5 Link arm
6 Rotating column

Fig. 1 Principal robot components

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 2 Principal data

2 Principal data
Types KR 125/2 KR 125 L100/2 KR 125 L90/2
KR 125 W/2
KR 150/2 KR 150 L150/2 KR 150 L120/2
KR 200/2

Number of axes 6 (Fig. 3)

Load limits See the following table and Fig. 2

Robot type KR 125/2 KR 125 L100/2 KR 125 L90/2
KR 125 W/2
Wrist (IW)1 125 kg
Rated payload [kg] 125 100 90
Max. supplementary 120 120 120
load with rated
payload [kg]
Max. total distributed 245 220 210
load [kg]
Arm length [mm] 1000 1200 1400

1 IW = in--line wrist

Robot type KR 150/2 KR 150 KR 150 KR 200/2

L150/2 L120/2
Wrist (IW)1 150 kg 200 kg
Rated payload [kg] 150 150 120 200
Max. supplementary 95 80 80 80
load with rated payload
[kg]
Max. total distributed 245 230 200 280
load [kg]
Arm length [mm] 1000 1200 1400 1000

1 IW = in--line wrist
Total distributed load

Supp. load Payload

Fig. 2 Load distribution

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Technical Data

Axis data
All specifications in the “Range of motion” column are referred to the mechanical zero of the
robot axis concerned.
KR 125/2
KR 125 L100/2
KR 125 L90/2
D In--line wrist, rated payload 125/100/90 kg

Axis Range of motion Speed

software limited

1 ±185° 100 ° /s

2 +93°
to 100 ° /s
--40°

3 +58°
to 100 ° /s
--210°

4 ±350° 154 ° /s

5 ±120° 167 ° /s

6 ±350° 251 ° /s

KR 125 W/2
D In--line wrist, rated payload 125 kg

Axis Range of motion Speed

software limited

1 ±90° 70 ° /s

2 +93°
to 100 ° /s
--15°

3 +58°
to 100 ° /s
--90°

4 ±350° 154 ° /s

5 ±120° 167 ° /s

6 ±350° 251 ° /s

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 2 Principal data (continued)

KR 150/2
KR 150 L150/2
KR 150 L120/2
D In--line wrist, rated payload 150/150/120 kg

Axis Range of motion Speed

software limited

1 ±185° 75 ° /s

2 +93°
to 75 ° /s
--40°

3 +58°
to 76 ° /s
--210°

4 ±350° 118 ° /s

5 ±120° 128 ° /s

6 ±350° 168 ° /s

KR 200/2
D In--line wrist, rated payload 200 kg

Axis Range of motion Speed

software limited

1 ±185° 75 ° /s

2 +93°
to 75 ° /s
--40°

3 +58°
to 76 ° /s
--210°

4 ±350° 94 ° /s

5 ±120° 102 ° /s

6 ±350° 120 ° /s

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Technical Data

Fig. 3 Robot axes and their possible motions

Repeatability ± 0.2 mm for KR 125/2

KR 125 L100/2
KR 125 L90/2
KR 125 W/2
KR 150/2
KR 150 L150/2
KR 150 L120/2
± 0.3 mm for KR 200/2

Mounting position All types except KR 125 W/2:

floor or ceiling (permissible angle of inclination = 15° ;
with KR 200/2 = 10° ).
KR 125 W/2: wall

Principal dimensions see Figures 11 and 12

Working envelope The shape and dimensions of the working envelope may be noted
from Figures 11 and 12.

Volume of working envelope

KR 125/2 approx. 39 m3
KR 125 L100/2 approx. 51 m3
KR 125 L90/2 approx. 65 m3
KR 125 W/2 approx. 17 m3
KR 150/2 approx. 39 m3
KR 150 L150/2 approx. 51 m3
KR 150 L120/2 approx. 65 m3
KR 200/2 approx. 39 m3
The reference point is the intersection of axes 4 and 5.

Load center of gravity P

see Figures 4 to 10.
For all rated payloads, the horizontal distance of the load center
of gravity P from the face of the mounting flange is 210 mm; the
vertical distance from rotational axis 6 is 230 mm (nominal dis-
tance in each case).

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 2 Principal data (continued)

Mounting flange DIN/ISO1 mounting flange (Fig. 14).

The flange is depicted with axes 4 and 6 in the zero position. The
symbol indicates the position of the locating element (bushing).
M10 screws of grade 10.9 are to be used for attaching payloads.
The grip length of the screws in the flange must be at least 1.5 x
nominal diameter.
Depth of engagement: min. 12 mm
max. 14 mm
1 DIN/ISO 9409--1--A160

Weight KR 125/2 975 kg

KR 125 L100/2 990 kg
KR 125 L90/2 995 kg
KR 125 W/2 1590 kg
KR 150/2 1120 kg
KR 150 L150/2 1135 kg
KR 150 L120/2 1140 kg
KR 200/2 1120 kg

Principal dynamic loads

See Figures 15 and 16

Drive system Electromechanical, with transistor--controlled

AC servomotors

Installed motor capacity

19.8 kW;
for KR 125 W/2: 27.9 kW

Protection classification of the electric parts

IP 64
ready for operation, with connecting cables plugged in
(according to EN 60529)

Ambient temperature During operation:

283 K to 328 K (+10 °C to +55 °C),
During storage and transportation:
233 K to 333 K (--40 °C to +60 °C).
Other temperature limits available on request.

Sound level < 75 dB (A) outside the working envelope

Special consumables Hydraulic oil and nitrogen gas in standard commercial containers
for recharging the counterbalancing system when the system
pressure is altered.

Zero adjustment For zero adjustment with the electronic probe (accessory) when
the tool is mounted, the latter must be designed to allow sufficient
space for installation and removal of the probe (Fig. 17).

Colors Base (stationary): black (RAL 9005).

Moving parts: orange (RAL 2003).
Counterbalancing system: black (RAL 9005).

Plates See Figures 18 to 31

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Technical Data

IMPORTANT, concerning Figures 4 to 10:

These loading curves and the values in the table correspond to the maximum
load capacity. Exceeding this capacity will reduce the service life of the robot
and generally overload the motors and the gears; in any such case KUKA must
be consulted beforehand.

The values determined here are necessary for planning the robot application. For com-
missioning the robot, additional input data are required in accordance with the KUKA
software documentation.

Payload Principal moment of inertia Is *

[kg] for KR 125/2, KR 125 W/2
Robot flange coordinate system
[kg m2]

125 17.5
--X
Lxy = ?L x 2 + Ly 2
115 16.1
--Z 105 14.7
+Y
95 13.3
85 11.9
75 10.5
--Y 65 9.1
+X +Z
Lxy 55 7.7
Lx Load center of gravity P
45 6.3

Lz *Maximum moment of inertia of the payload, re-

Ly ferred to the principal axes passing through the
Lxy (mm) center of gravity of the payload (kg m2).

45 kg

55 kg

65 kg

75 kg
85 kg
Nominal distance

95 kg
105 kg
115 kg
125 kg
230

KR 125/2; KR125 W/2

Lz
Lz (mm)

210 Lxy 210

1000
Nominal distance

Load center of gravity P

Fig. 4 Load center of gravity P and loading curves for KR 125/2 and KR 125 W/2

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 2 Principal data (continued)

The values determined here are necessary for planning the robot application. For com-
missioning the robot, additional input data are required in accordance with the KUKA
software documentation.

Robot flange coordinate system

Payload Principal moment of inertia Is *
[kg] for KR 125 L100/2
[kg m2]
--X
Lxy = ?L x 2 + Ly 2
--Z 100 14.0
+Y 92 12.9
84 11.7
76 10.6
68 9.5
--Y +X 60 8.4
+Z 52 7.3
Lxy
Lx Load center of gravity P 44 6.2
36 5.0

Lz *Maximum moment of inertia of the pay-

Ly load, referred to the principal axes passing
through the center of gravity of the payload
(kg m2).

Lxy (mm)

36 kg

44 kg

52 kg

60 kg
Nominal distance

68 kg
76 kg
84 kg
92 kg
100 kg
230

KR 125 L100/2

Lz
Lz (mm)

1200 210 Lxy 210

Nominal distance
Load center of gravity P

Fig. 5 Load center of gravity P and loading curves for KR 125 L100/2

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Technical Data

The values determined here are necessary for planning the robot application. For com-
missioning the robot, additional input data are required in accordance with the KUKA
software documentation.

Robot flange coordinate system

Payload Principal moment of inertia Is *
[kg] for KR 125 L90/2
[kg m2]

--X
Lxy = ?L x 2 + Ly 2
90 12.6
--Z 83 11.6
+Y 76 10.6
69 9.6
62 8.7
55 7.7
--Y +X 48 6.7
+Z 41 5.7
Lxy
Lx Load center of gravity P 34 4.7

Lz
*Maximum moment of inertia of the pay-
Ly load, referred to the principal axes passing
through the center of gravity of the payload
(kg m2).

Lxy (mm)

34 kg

41 kg
48 kg

55 kg
Nominal distance

62 kg
69 kg
76 kg
83 kg
230 90 kg

Lz
KR 125 L90/2
Lz (mm)

210 Lxy 210

1400
Nominal distance
Load center of gravity P

Fig. 6 Load center of gravity P and loading curves for KR 125 L90/2

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 2 Principal data (continued)

The values determined here are necessary for planning the robot application. For com-
missioning the robot, additional input data are required in accordance with the KUKA
software documentation.

Robot flange coordinate system

Payload Principal moment of inertia Is *
[kg] for KR 150/2
[kg m2]
150 21.0
--X
Lxy = ?L x 2 + Ly 2 140 19.6
130 18.2
--Z 120 16.8
+Y
110 15.4
100 14.0
90 12.6
--Y 80 11.2
+X 70 9.8
+Z
Lxy
Lx Load center of gravity P
*Maximum moment of inertia of the pay-
load, referred to the principal axes pas-
Lz sing through the center of gravity of the
payload (kg m2).
Ly

Lxy (mm)

70 kg

80 kg

90 kg
Nominal distance

100 kg
110 kg
120 kg
130 kg
140 kg
150 kg
230

KR 150/2

Lz (mm)
Lz 210
1000 210 Lxy
Nominal distance

Load center of gravity P

Fig. 7 Load center of gravity P and loading curves for KR 150/2

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Technical Data

The values determined here are necessary for planning the robot application. For com-
missioning the robot, additional input data are required in accordance with the KUKA
software documentation.

Robot flange coordinate system Payload Principal moment of inertia Is *

[kg] for KR 150 L150/2
[kg m2]

--X
Lxy = ?L x 2 + Ly 2 150 21.0
140 19.6
--Z 130 18.2
+Y 120 16.8
110 15.4
100 14.0
90 12.6
--Y +X 80 11.2
+Z 70 9.8
Lxy
Lx Load center of gravity P
*Maximum moment of inertia of the payload,
Lz referred to the principal axes passing
through the center of gravity of the payload
Ly (kg m2).

Lxy (mm)

70 kg

80 kg

90 kg
100 kg
Nominal distance

110 kg
120 kg
130 kg
140 kg
150 kg
230

KR 150 L150/2

Lz
Lz (mm)

1200 210 Lxy 210

Nominal distance

Load center of gravity P

Fig. 8 Load center of gravity P and loading curves for KR 150 L150/2

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 2 Principal data (continued)

The values determined here are necessary for planning the robot application. For com-
missioning the robot, additional input data are required in accordance with the KUKA
software documentation.

Robot flange coordinate system

Payload Principal moment of inertia Is *
[kg] for KR 150 L120/2
[kg m2]

--X
Lxy = ?L x 2 + Ly 2 120 16.8
110 15.4
--Z 100 14.0
+Y 90 12.6
80 11.2
70 9.8
60 8.4
--Y +X 50 7.0
+Z
Lxy
Lx Load center of gravity P *Maximum moment of inertia of the pay-
load, referred to the principal axes pas-
sing through the center of gravity of the
Lz
payload (kg m2).
Ly

Lxy (mm)

50 kg

60 kg

70 kg
Nominal distance

80 kg
90 kg
100 kg
110 kg
120 kg
230

KR 150 L120/2

Lz
Lz (mm)

1400 210 Lxy 210

Nominal distance
Load center of gravity P

Fig. 9 Load center of gravity P and loading curves for KR 150 L120/2

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Technical Data

The values determined here are necessary for planning the robot application. For com-
missioning the robot, additional input data are required in accordance with the KUKA
software documentation.

Payload Principal moment of inertia Is *

Robot flange coordinate system [kg] for KR 200/2
[kg m2]

--X
Lxy = ?L x 2 + Ly 2 200
185
28.0
25.9
170 23.8
--Z
+Y 155 21.7
140 19.6
120 16.8
100 14.0
--Y 80 11.2
+X
+Z
Lxy
Lx Load center of gravity P *Maximum moment of inertia of the pay-
load, referred to the principal axes passing
through the center of gravity of the payload
Lz (kg m2).
Ly

Lxy (mm)

80 kg

100 kg
Nominal distance

120 kg
140 kg
155 kg
170 kg
185 kg
230 200 kg

KR 200/2
Lz
Lz (mm)

1000 210 Lxy 210

Nominal distance

Load center of gravity P

Fig. 10 Load center of gravity P and loading curves for KR 200/2

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 2 Principal data (continued)

Supplementary load
Y

R 600 x 210
Counterweight A 3 for 150 kg and 200 kg payload
--- 210°
45

+58°
1000
A

B
--- 40°
+93°
1910
865

R720

475 410
G

E D 235
F C

CAUTION: The interference radius

---185° (safe area) lies approx. 235 mm
beyond the reference point for the
working envelope.

NOTE: The center of gravity of the

supplementary load must be lo-
cated as close as possible to rota-
tional axis 3 and to line a in Fig. 13.
The reference point for the work-
ing envelope is the intersection of
rotational axes 4 and 5.
+185°
View Y see Figure 13.

A B C D E F G X

KR 125/2 2866 3054 2410 1405 1005 1234 188 1000

KR 125 L100/2 3066 3454 2610 1525 1085 1434 388 1200
KR 125 L90/2 3266 3854 2810 1603 1207 1634 588 1400
KR 150/2 2866 3054 2410 1405 1005 1234 188 1000
KR 150 L150/2 3066 3454 2610 1525 1085 1434 388 1200
KR 150 L120/2 3266 3854 2810 1603 1207 1634 588 1400
KR 200/2 2866 3054 2410 1405 1005 1234 188 1000

Fig. 11 Principal dimensions (software values) and working envelope

(KR 125 W/2 see Fig. 12)

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Technical Data

2866
1910
865 1000 45

Supplementary load

X
--- 15°
410
556
1005

Y
188
+58°

+93°

--- 90°
2410

1000
1405

210
235

CAUTION: The interference radius (safe area)

lies approx. 235 mm beyond the reference
point for the working envelope.
ca. R 1300

View X

+90° --90°
NOTE: The center of gravity of
the supplementary load must be
located as close as possible to
rotational axis 3 and to line a in
Fig. 13.
The reference point for the work-
ing envelope is the intersection of
rotational axes 4 and 5.
View Y see Figure 13.

Fig. 12 Principal dimensions (software values) and working envelope for KR 125 W/2

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 2 Principal data (continued)

View Y from Figures 11 and 12

Support brackets for suppl. load (2x)

Motor side
a
M12 (4x)
24 deep Wrist side

Max. dimension for suppl. load

Protruding edge of suppl. load

Fig. 13 Attachment holes for supplementary load

210
to A4/A5
Fitting length

M10 fastening screws

Grade 10.9
Depth of engagement: min. 12 mm
max. 14 mm

Fig. 14 DIN/ISO mounting flange for in--line wrist 125/150/200 kg

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Technical Data

Mk

Fv

Fh

Mr

Fv = vertical force Fvmax = 15 600 N

Fh= horizontal force Fhmax = 11 650 N
Mk = tilting moment Mkmax = 27 000 Nm
Mr = turning moment about axis 1 Mrmax = 13 000 Nm

Total mass = robot + total load for type

975 kg + 245 kg KR 125/2

990 kg + 220 kg KR 125 L100/2
995 kg + 210 kg KR 125 L90/2
1120 kg + 245 kg KR 150/2
1135 kg + 230 kg KR 150 L150/2
1140 kg + 200 kg KR 150 L120/2
1120 kg + 280 kg KR 200/2

Fig. 15 Principal loads acting on floor or ceiling due to robot and total load
(KR 125 W/2 see Fig. 16)

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 2 Principal data (continued)

Fh
Fv

Mk

View Z

Mr

Fv = vertical force Fvmax = 24 000 N

Fh = horizontal force Fhmax = 4 000 N
Mk = tilting moment Mkmax = 27 000 Nm
Mr = turning moment about axis 1 Mrmax = 13 000 Nm

Total mass = robot + total load for type

1590 kg + 245 kg KR 125 W/2

Fig. 16 Principal loads acting on the mounting base due to robot and
total load for KR 125 W/2

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Technical Data

155
166
108

161

Fig. 17 Electronic probe, installation on A 4, A 5 and A 6

10
2 4
12
5
6
11
1 3 7
8 9
1

Fig. 18 Plates on robot (see also Fig. 19 to Fig. 31)

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 2 Principal data (continued)

Transportstellung:
Transport position:
Position de transport:
A1 A2 A3 A4 A5 A6
0° --- 40° +58° 0° +90°

ACHTUNG! WARNING! ATTENTION!

Vor dem Lösen der The robot must be Le robot doit être
Fundamentbefesti- in the transport amené en position
gungsschrauben position before the de transport avant de
muß der Roboter in holding--down bolts desserrer les boulons
Transportstellung are slackened! de fixation des
gebracht werden! fondations!
Artikel--Nr. 71--050--425 D/GB/F 1

Fig. 19 Instructions regarding transport position for floor--mounted

and ceiling--mounted robots

Transportstellung:
Transport position:
Position de transport:
A1 A2 A3 A4 A5 A6 !
0° --- 15° +58° 0° +90°

ACHTUNG! WARNING! ATTENTION!

Vor dem Lösen der The robot must be Le robot doit être
Fundamentbefesti- in the transport amené en position
gungsschrauben position before the de transport avant de
muß der Roboter in holding--down bolts desserrer les boulons
Transportstellung are slackened! de fixation des
gebracht werden! fondations!
Artikel--Nr. 71--050--917 D/GB/F
1

Fig. 20 Instructions regarding transport position for wall--mounted robots

ACHTUNG! WARNING! ATTENTION!

System steht unter Druck!
Befülldruck darf 200 bar nicht überschreiten!
System is pressurized!
Filling pressure must not exceed 200 bar!
Système est sous pression!
La pression de remplissage ne doit pas
dépasser 200 bars!
Artikel--Nr. 71--050--425 D/GB/F 2

Fig. 21 Instructions regarding filling pressure

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Technical Data

ACHTUNG! WARNING! ATTENTION!

Bevor hydraulisches Ausgleichssystem drucklos
gemacht wird -- Achse gegen Kippen sichern!

Before depressurizing the hydraulic counterbalancing

system -- link arm must be secured against tipping!

Avant de décomprimer le système d’équilibrage --

bloquer l’axe pour qu’il ne tombe pas!
Artikel--Nr. 71--050--425 D/GB/F 3

Fig. 22 Instructions for safeguarding against toppling of A 2

ACHTUNG! WARNING! ATTENTION!

Vor dem Entfernen des Motors Roboterachse
gegen Kippen sichern!

Only remove motor when robot axis is secured!

Avant démontage du moteur bloquer l’axe

concerné! 4
Artikel--Nr. 71--050--425 D/GB/F 2x

Fig. 23 Instructions for safeguarding against toppling of A 2, A 3

KUKA Roboter GmbH

Augsburg/Germany

Typ Type Type

Werk--Nr. Serial No. No.Série 720 001

Baujahr Date Année de fab. 1996

Zeichn.--Nr. Draw. No. Plan No. 391.984

Gewicht Weight Poids kg
D/GB/F 5

Fig. 24 Robot identification plate (example)

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 2 Principal data (continued)

ACHTUNG! WARNING! ATTENTION!

Vor Aufstellung, Inbetriebnahme, Montage-- und
Wartungsarbeiten die Betriebsanleitung und
Sicherheitshinweise lesen und beachten!
Before installation, start--up, maintenance or
disassembling read and follow the safety
directions and operating instructions!

Avant installation, mise en service, réparation et

maintenance veuillez lire les châpitres
correspondants du manuel ainsi que les
consignes de sécurité et les respecter!
Artikel--Nr. 71--050--425 D/GB/F 6

Fig. 25 Reference to operating instructions

Fig. 26 High voltage warning sign

For floor-- and ceiling--

mounted robots:
4x on motors A 3,
A 4, A 5, A 6.
8
For wall--mounted robots:
4x on all motors.

Fig. 27 Hot surface warning sign

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Technical Data

.................
On all motors.
...........................................................
................................................
...........................................................
................................................
...........................................................
.................................................
9

Fig. 28 Drive motor rating plate

10

Fig. 29 Fastening instructions

11
3x
Fig. 30 Danger area

On all motors. Connect only

when system is
Only on robots with deenergized
explosion protection.
12

Fig. 31 Explosion protection

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ROBOT

KR 125, 150, 200; KR 125 W

Description

In--line Wrist 125/150/200 II

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

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

2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Description

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 1 General

Valid for KR 125/1, /2 KR 125 F/1, /2

KR 125 L100/1, /2 KR 125 L100F/1, /2
KR 125 L90/1, /2 KR 125 L90F/1, /2
KR 125 W/1, /2
KR 150/1, /2 KR 150 F/1, /2
KR 150 L150/1, /2 KR 150 L150F/1, /2
KR 150 L120/1, /2 KR 150 L120F/1, /2
KR 200/1, /2 KR 200 F/1, /2

1 General
The in--line wrist with its three wrist axes constitutes the final element in the power transmis-
sion train of the robot and is equipped with a DIN/ISO standard mounting flange. Other tech-
nical data, such as turning ranges and loading characteristics may be found in the robot Doc.
Module “Technical Data”.
If the permissible turning range of a wrist axis is exceeded, the robot is switched off by means
of software limit switches. The turning range of axis 5 is mechanically limited by limit stops
performing a buffer function.

2 Description
The in--line wrist incorporates robot axes 4, 5 and 6. Figure 1 depicts the rotational axes and
their directions of motion.

Axis 5

Axis 4

Axis 6

Fig. 1 Rotational axes and their directions of motion

The in--line wrist (Fig. 2/3) is flange--mounted on the arm (2). It is driven by the three motors
(1) installed at the rear end of the arm (2) using push--on shafts (4). The allocation of the mo-
tors to the individual axes may be noted from Figure 2.

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Description

1 2 3

A4

A6

A5

1 Motor
4 4 2 Arm
3 In--line wrist
4 Push--on shaft

Fig. 2 Einbausituation

The in--line wrist essentially consists of the following subassemblies

-- Spur gear housing (Fig. 3/1),
-- Gear unit A 4 (2),
-- Main body (3) and
-- Swivel housing (4).

1 2 3 4

Fig. 3 In--line wrist subassemblies

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 2 Description (continued)

The in--line wrist forms an exchangeable unit with a standardized mechanical interface to the
arm (11). It is fastened to the arm (11) with ten Allen screws (Fig. 4/3), being located in the
correct mounting position by two dowel pins (10). The drive power is transmitted by means
of three externally splined shafts (1) to the main body (Fig. 3/3), to the swivel housing (4) and
to the mounting flange (Fig. 4/7).
An end effector can be attached to the mounting flange (7) (see robot Doc. Module “Technical
Data”).
The in--line wrist is oil--tight and incorporates two oil chambers for the purpose of lubricating
gear unit (2), as well as gear units (4) and (8). The bearings and gears are also lubricated
by these two oil chambers.
The high drive speeds are reduced to the low output speeds in the gear units. Each axis is
equipped with one of these gear units, which are rated for the permissible payload.
The reference notches required for setting the mechanical zero position of axes 4 to 6 are
located in the in--line wrist, the associated gage cartridges (5, 6, 9) being externally mounted
on the respective housing section.
In--line wrists with a higher thermal loading capacity are identified by the designation “F”.
These in--line wrists may be subjected to higher temperatures and greater exposure to water
spray. Details of the thermal loading capacity may be found in the robot Doc. Module
“Technical Data”.

1 2 3 4 5 6

11 10 9 8

1 Shafts 7 Mounting flange

2 Gear unit A 4 8 Gear unit A 6
3 Allen screw 9 Gage cartridge (A 4)
4 Gear unit A 5 10 Dowel pin
5 Gage cartridge (A 5) 11 Arm
6 Gage cartridge (A 6)

Fig. 4 Structure of in--line wrist

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ROBOT

KR 30, 45; KR 125, 150, 200; KR 125 W

Description

Energy Supply System A 1

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

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

2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Description

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 1 General

Valid for KR 30/1, /2

KR 30 L15/1, /2
KR 45/2
KR 125/1, /2 KR 125 F/1, /2
KR 125 L100/1, /2 KR 125 L100F/1, /2
KR 125 L90/1, /2 KR 125 L90F/1, /2
KR 125 W/1, /2
KR 150/1, /2 KR 150 F/1, /2
KR 150 L150/1, /2 KR 150 L150F/1, /2
KR 150 L120/1, /2 KR 150 L120F/1, /2
KR 200/1, /2 KR 200 F/1, /2

1 General
The robot can be equipped with an energy supply system (accessory, Fig. 1) integrated into
axis 1. Several types are available, examples being for “Handling” and “Spot welding” ap-
plications. With its interfaces on the base frame, “energy supply system A 1” permits fast un-
coupling of the energy and fluid lines required for the specific application when the complete
robot or the end--effector installed on the robot is exchanged.

2 Description
The electric cables (9) and hoses (10) of an “energy supply system A 1” run in the axis 1 area
within the robot from the interface (1) on the base frame (5) via a common flexible tube A 1
EZ * (6) to the interface (4) on the revolving rotating column (3). The flexible tube A 1 EZ (6)
is located in the base frame on the side diametrically opposite to the flexible tube A 1 of the
robot electric cabling. The two flexible tubes ensure a low--stress routing of the supply lines
as well as reducing the number of mechanical interference contours, without impairing the
rotational motion of axis 1.
The interface (1) is located underneath the two junction boxes (2) and in the “Handling” ver-
sion for example, consists of two sockets (12) for the electric cabling and a 1/2” female thread
(11) for connecting a compressed air line.
The interface (4) includes two sockets (8) for the electric cables and a plug--in connection
(7) for the hose. Cables can also be routed from the interface (4) along the outside of the link
arm and arm to a corresponding interface on the end--effector. This eliminates the need for
a space--consuming supply boom.
Further energy supply systems between axis 1 and axis 3, axis 2 and axis 6 or between axis
2 and axis 3 are available as options. These are described in separate Doc. Modules.

* = Flexible tube axis 1 for energy supply system

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Description

4
7 8

3
3 4
9
2
5 10
1 6 5

1 12 11
1 Interface on the base frame 7 Plug--in connection for compressed air
2 Junction box 8 Socket
3 Rotating column 9 Control cable
4 Interface on the rotating column 10 Compressed air line
5 Base frame 11 1/2” female thread
6 Flexible tube A 1 EZ 12 Socket

Fig. 1 Energy supply system A 1 (on the right: “Handling” example, schematic)

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ROBOT

KR 125, 150, 200; KR 125 W

Installation, Connection, Exchange

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

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

2 Principal loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Mounting variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Variant 1 (391.983--08.001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Variant 2 (391.983--08.002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Variant 3 (391.983--08.003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Wall--mounting variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 Floor--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Ceiling--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Wall--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5 Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Exchanging floor--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Exchanging ceiling--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Exchanging wall--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Installation, Connection, Exchange

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 1 General

Valid for KR 125/1, /2 KR 125 F/1, /2

KR 125 L100/1, /2 KR 125 L100F/1, /2
KR 125 L90/1, /2 KR 125 L90F/1, /2
KR 125 W/1, /2
KR 150/1, /2 KR 150 F/1, /2
KR 150 L150/1, /2 KR 150 L150F/1, /2
KR 150 L120/1, /2 KR 150 L120F/1, /2
KR 200/1, /2 KR 200 F/1, /2

1 General
The Doc. Module “Safety, General” and the robot Doc. Module “Repair, General”
are to be observed!
With all work involving the connection of the robot (and of the control cabinet),
the control cabinet Doc. Module “Initial Start--up” must be observed.
Before any installation and exchange work is started, any attached tools or additional equip-
ment that would hinder the installation and exchange work must be dismounted.

The fork lift truck, lifting tackle and crane must be suitable for handling the
robot. For weight of robot see robot Doc. Module “Technical Data”.

The description of the installation and exchange operations is subdivided into job steps with
numbers in brackets appearing before them. The text which immediately follows these steps
must also be read if it is specially marked by a warning triangle or either of the hand
symbols, as many of these marked texts refer to the preceding job step.

Example:
(8) Lower the robot slowly without tilting it.

The robot must be lowered vertically downwards until the two locating pins are
free.

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

Example:

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

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Installation, Connection, Exchange

2 Principal loads
Forces occur during operation of the robot which must be safely transmitted to the floor,
ceiling or the hinged steel base. The forces that have to be taken into account are specified
in Fig. 1 for floor-- and ceiling--mounted robots and in Fig. 2 for wall--mounted robots. Both
drawings with their specifications can be used as a basis for more extensive static
investigations.

Mk

Fv

Fh
Mr

Fv = vertical force Fvmax = 15 600 N

Fh = horizontal force Fhmax = 11 650 N
Mk = tilting moment Mkmax = 27 000 Nm
Mr = turning moment about axis 1 Mrmax = 13 000 Nm

Total mass = robot + total load for type

975 kg + 245 kg KR 125/1, /2 KR 125 F/1, /2

990 kg + 220 kg KR 125 L100/1, /2 KR 125 L100F/1, /2
995 kg + 210 kg KR 125 L90/1, /2 KR 125 L90F/1, /2
1120 kg + 245 kg KR 150/1, /2 KR 150 F/1, /2
1135 kg + 230 kg KR 150 L150/1, /2 KR 150 L150F/1, /2
1140 kg + 200 kg KR 150 L120/1, /2 KR 150 L120F/1, /2
1120 kg + 280 kg KR 200/1, /2 KR 200 F/1, /2

Fig. 1 Principal loads acting on floor (or ceiling) due to robot and total load
(KR 125 W/1, /2 see Fig. 2)

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 2 Principal loads (continued)

Fh
Fv

Mk

View X

Mr

Fv = vertical force Fvmax = 30 000 N

Fh = horizontal force Fhmax = 4 000 N
Mk = tilting moment Mkmax = 27 000 Nm
Mr = turning moment about axis 1 Mrmax = 13 000 Nm

Total mass = robot + total load for type

1590 kg + 245 kg KR 125 W/1, /2

Fig. 2 Principal loads acting on the mounting base due to robot and total load
for KR 125 W/1, /2

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Installation, Connection, Exchange

3 Mounting variants
Depending on the type, the robot can be installed on the floor, the ceiling or the wall.
There are three mounting variations for installing the robot on the floor or on the ceiling:
G Variant 1 (391.983--08.001), see Section 3.1
G Variant 2 (391.983--08.002), see Section 3.2
G Variant 3 (391.983--08.003), see Section 3.3
For installation of the robot on the wall see Section 3.4.
If the robot is to be installed on the floor, being directly mounted on a concrete base, all perti-
nent construction specifications must be observed concerning the grade of concrete (³ B25
according to DIN 1045) and the load--bearing capacity of the ground when preparing the con-
crete foundation. It must be ensured that the surface of the foundation is level and sufficiently
smooth. The anchors must be inserted with great care to ensure that the forces occurring
during the operation of the robot (Fig. 1) are transmitted safely to the ground.

3.1 Variant 1 (391.983--08.001)

Characteristic features:
-- For floor--mounted robots only.
-- Robot installed directly on the concrete foundation.
-- Robot fastened by means of eight undercut anchors.
Accessory: “floor mounting kit”
(1) Mark a hole pattern as per Fig. 3 on the foundation or set down the robot in the intended
installation position on the foundation.
(2) The intended installation position of the robot, i.e. the correct orientation in relation to
the working envelope (Fig. 3/1), must be taken into account when marking the position
of the boreholes.
(3) Drill eight anchor holes (Fig. 4/6) in accordance with Fig. 3 or through the fastening
boreholes of the robot; minimum depth in concrete 280 mm.
(4) Prepare undercuts (Fig. 4/4) with special tool in accordance with appropriate work
instructions.
(5) Insert compression springs (5).
(6) Insert eight undercut anchors (3).
(7) Set robot down.
(8) Screw on hexagon nuts (2) together with washers and tighten hexagon nuts with torque
wrench in diagonally opposite sequence, increasing the tightening torque to the speci-
fied value in several stages (MA = 250 or 280 Nm).

The tightening torque for the hexagon nuts is 250 Nm for initial installation (with the
plastic anchor ring) or 280 Nm with subsequent installation (without the plastic anchor
ring).

When tightening the hexagon nuts (2), the base frame must not be distorted. The
test dimension (1) of 5 ± 3 mm for checking the undercut anchors must be
reached.

Retorque hexagon nuts (2) after 100 operating hours.

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 3 Mounting variants (continued)

780
220

390
220

220

830
220

Fig. 3 Hole pattern for variant 1

1
2

Test dimension
5 ¦3 mm
3
(35)

190
280
340

5
30

8x 1,5

Fig. 4 Robot installation, variant 1

Installation of the robot is now finished. The robot is ready for connection (see Section 4.1).

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Installation, Connection, Exchange

3.2 Variant 2 (391.983--08.002)

Characteristic features:
-- For floor-- and ceiling--mounted robots.
-- Robot installed on a steel structure prepared by the customer (or on a linear unit
of series KL 1500).
-- Robot fastened by means of eight M24x70 ISO 4017 hexagon bolts; tightening
torque MA = 640 Nm.

Retorque eight hexagon bolts M24x70 ISO 4017 after 100 operating hours.

Accessory: “frame mounting kit”

(1) Prepare mounting surfaces (Fig. 5/1) on steel structure in accordance with Fig. 5.

4x
M24
(2x)
min. 336

M8
220

min. 115

Fig. 5 Mounting surfaces for variant 2

(2) Drill eight holes for holding--down bolts (Fig. 6/3) and two holes for the locating pins (2,
5) as shown in Fig. 6.

The intended installation position of the robot, i.e. the correct orientation in relation to
the working envelope (Fig. 3/1), must be taken into account when drilling the holes.

(3) Insert locating pins (Fig. 6/2, 5) and fasten each one with an M8x55 Allen screw (1)
together with lock washer.

The position of the locating pins in relation to the working envelope is important:
Looking forwards (4) from the robot towards the working envelope -- the robot arm
points in this direction when A1 is in its zero position --, then the sword pin (2) must be
on the right and the round pin (5) on the left.

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 3 Mounting variants (continued)

1 2 3

Section X - X
rotated through 90°
10

max. 6
min. 25

ISO 4017 M24x70--8.8

min. 870
790 ± 0.1
5 780

220

8x

f1 A B
X
4

390
max. 320
M24

front

Center A 1
H7

(2x)

M8
(2x)
20
min. 336

min. 920
max. 690
220

220

A 5 2
830

max. 640
X

min. 115

3
220

Fig. 6 Robot installation, variant 2

The steel foundation is now ready for the robot to be installed. The procedure for installing
the robot is described in Section 4.1 for floor--mounted robots, in Section 4.2 for ceiling--
mounted robots.

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Installation, Connection, Exchange

3.3 Variant 3 (391.983--08.003)

Characteristic features:
-- For floor--mounted robots only.
-- Robot installed with four intermediate plates (Fig. 7/1) on the concrete foundation.
-- Each intermediate plate fastened to robot with two M24x70 hexagon bolts (2) and
to concrete foundation with four undercut anchors (3).
-- Easy removal and installation with optimum repeatability of the installation posi-
tion.
-- Considerable differences in level of the foundation can be bridged.
Accessory: “mounting base kit”
(1) Insert a set--up pin (Fig. 8/1) (for dimensions see Fig. 6) in two of the four intermediate
plates (Fig. 8/5) and fasten with an M6x60 Allen screw (2) together with lock washer.

The set--up pins (1) are only used to install the intermediate plates correctly on the
floor. They are then replaced by locating pins (see step 14).

6
5

Fig. 7 Robot installation, variant 3

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 3 Mounting variants (continued)

(2) Fasten each intermediate plate to the bottom of the robot by means of two M24x70--8.8
hexagon bolts (Fig. 8/3) together with lock washers and centering rings (4) in accor-
dance with Fig. 7.
(3) Lower robot onto the concrete foundation and align it correctly in relation to the working
envelope (Fig. 3/1).
To avoid distorting the robot base frame when fastening it to the intermediate plates, differ-
ences in level between the concrete foundation and the intermediate plates must be cor-
rected using levelling compound (filling compound):
(4) Mark the position of the intermediate plates on the concrete foundation and determine
the magnitude of the differences in level.
(5) Lift off robot again together with intermediate plates.

1 2 3

5 4

Fig. 8 Intermediate plates for variant 3

(6) Apply levelling compound (Fig. 9/2) onto the marked areas on the concrete foundation.

“Knauf levelling compound”, for example, is a suitable compound for this purpose. It is
applied with a toothed spatula (tooth height > 2 x difference in level (5)).

The area (3) under each hexagon bolt (1) must be kept free from levelling com-
pound or it must be cleared after the compound has been applied.

(7) Set down the robot in the still plastic levelling compound and adjust its position slightly
if necessary.

The robot can be levelled by turning an M20x40 hexagon bolt (Fig. 7/4) on ecah inter-
mediate plate.

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Installation, Connection, Exchange

1 2

5 4 3

Fig. 9 Levelling compound

When levelling the robot by turning an M20x40 hexagon bolt (4), the four inter-
mediate plates (1) may be raised a maximum of 2 mm out of the levelling com-
pound.
If differences in level greater than this need to be compensated for, either the
shims must be inserted or more levelling compound must be applied.

(8) Allow the levelling compound to set for about three hours.
(9) Drill four anchor holes (Fig. 10/8) for each intermediate plate; minimum depth in con-
crete 160 mm.

The holes in the concrete foundation must be drilled through the holes (5) in the inter-
mediate plates (6).

3 4
2
1 5

6
160

7
250

ø30

Fig. 10 Anchor boreholes for variant 3

(10) Insert anchors (7).

(11) Screw on hexagon nuts (4) together with lock washers and tighten hexagon nuts with
torque wrench in diagonally opposite sequence, increasing the tightening torque to the
specified value in several stages (MA = 50 Nm).

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 3 Mounting variants (continued)

(12) Unscrew and remove all hexagon bolts (3) together with lock washers.
(13) Carefully lift robot vertically and remove centering rings that are then loose.
(14) Replace both set--up pins (1) with locating pins.

The position of the locating pins in relation to the working envelope is important:
Looking forwards from the robot towards the working envelope -- the robot arm points in
this direction when A1 is in its zero position (Fig. 7) --, then the sword pin (5) must be
on the right and the round pin (6) on the left.

Any levelling compound that has penetrated into the bottom of the holes must
be removed from the eight tapped holes in the intermediate plates, in order that
the robot holding--down bolts can be screwed in completely.

(15) Set robot down onto intermediate plates (Fig. 10/6) and fasten it by means of eight
M24x70 hexagon bolts (3) together with lock washers.
(16) Tighten hexagon bolts (3) with torque wrench in diagonally opposite sequence, increas-
ing the tightening torque to the specified value in several stages (MA = 640 Nm).
(17) Retighten hexagon nuts (4) of the anchors after 24 hours with MA = 300 Nm.

The setting time of 24 hours for the levelling compound must be strictly
observed.

Retorque hexagon bolts (3) and hexagon nuts (4) after 100 operating hours.

The robot is now ready to be installed in accordance with Section 4.1.

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Installation, Connection, Exchange

3.4 Wall--mounting variant

Only the KR 125 W/1, /2 is designed for the “wall” installation position.

The robot is preferably placed on a hinged steel base (Fig. 11/2), provided by the customer,
and fastened by eight hexagon bolts (1). Its installation position, as with the other robot types,
is determined by two locating pins, enabling it to be exchanged in a repeatable manner. The
robot is moved into its working position by swivelling and securing the steel base.
The installation of the robot may vary: the hinged steel base for the robot is either mounted
on a shelf (Fig. 11, left) or directly onto the wall (right).

On a shelf On a wall

1 Hexagon bolt 8x
2 Hinged steel base
(provided by the customer)
3 Counterweight A 1

Fig. 11 Wall installation of the robot using a hinged steel base

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 4 Installation and connection

4 Installation and connection

4.1 Floor--mounted robots

Section 1 of this Doc. Module is to be observed!

This description only applies to robots with mounting variant 2 (Section 3.2) or 3 (Section
3.3). If the robot is to be installed on the floor in an inclined position (max. 15° for KR 125
and KR 150, max. 10° für KR 200) KUKA must be consulted beforehand.
The procedure for installing the robot (whether for the first time or as an exchange) is as fol-
lows:
(1) Check that both locating pins (Fig. 12/2) and their fastening screws (1) are undamaged
and fitted securely.

Damaged locating pins must be replaced by new ones.

1 2

Fig. 12 Locating pins

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Installation, Connection, Exchange

The robot must be in the transport position (Fig. 13)*.

A1 A2 A3 A4 A5 A6
0° -40° +58° 0° +90° any

D
* Angle specifications
C
refer to the
mechanical zero of
the axis concerned.

Position of center of gravity**

Robot type A B C D
[mm] [mm] [mm] [mm]
2124

2030

KR 125/1, /2 90 800 1504 --------

KR 125 L90/1, /2 110 780 1695 --------
KR 125 L100/1, /2 130 760 1885 --------

KR 150/1, /2 --10 930 -------- 1677

KR 200/1, /2 --10 930 -------- 1677

B

A **also applies to robots with in--line wrist II F

-- +

Fig. 13 Transport position for floor--mounted robot

(2) Raise robot with fork lift truck or lifting tackle attached to three eyes on the rotating
column.

For reasons of safety, it is imperative for the lifting tackle to be attached to the
robot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module “Repair, General” must be
observed.

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 4 Installation and connection (continued)

(3) Lower robot (Fig. 14/3) vertically onto intermediate plates (5) or steel structure. If lifting
tackle is used, particular care must be taken to ensure exact vertical positioning in order
to avoid damaging the locating pins or the anchors during this operation.

As the robot is lowered, the boreholes (2) must be aligned as accurately as pos-
sible with the two locating pins (1). If this operation is carried out inaccurately, it
is more likely that parts will be damaged.

3 4

1 5

Fig. 14 Installing the robot on the floor

(4) Insert eight M24x70 ISO 4017 hexagon bolts (4) together with lock washers and tighten
them with a torque wrench in diagonally opposite sequence, increasing the tightening
torque to the specified value in several stages (MA = 640 Nm).

Retorque eight hexagon bolts (4) or, in the case of mounting variant 1
(391.983--08.001), eight hexagon nuts of the undercut anchors (Fig. 4/2) after 100
operating hours.

The robot is fastened with eight hexagon nuts and lock washers in the case of
mounting variant 1 (391.983--08.001); the tightening torque is 280 Nm for subsequent
installation without the plastic ring of the anchors.

(5) Remove lifting tackle.

(6) Connect connecting cables.

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Installation, Connection, Exchange

Before performing the next step, it must be ensured that it is not possible for
anyone to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed, with all applicable
safety rules and regulations being observed.

(7) Put robot into operation and move it into a suitable position to install end--effector and
additional equipment.

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

(8) Install end--effector (tool) and additional equipment.

(9) Connect all other cables and supply lines which have been removed.
(10) Put robot into operation.

4.2 Ceiling--mounted robots

Section 1 of this Doc. Module is to be observed!

This description only applies to ceiling--mounted robots with mounting variant 2 (Section 3.2).
For installation on the ceiling, the robot can be transported in a transport frame -- already in
the correct orientation. It is removed from this frame by fork lift truck and brought to the site
of installation (Fig. 15).

Fig. 15 Transporting the robot for mounting on the ceiling

The procedure for mounting the robot on the ceiling (whether for the first time or as an ex-
change) is as follows:
(1) Check that both locating pins (Fig. 12/2) and their fastening screws are undamaged and
fitted securely.

Damaged locating pins must be replaced by new ones.

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 4 Installation and connection (continued)

The robot must be in the transport position (Fig. 16)*.

A1 A2 A3 A4 A5 A6
0° -40° +58° 0° +90° any

* Angle specifications
refer to the
mechanical zero of
A the axis concerned.
B

+ --

Position of center of gravity**

Robot typ A B C D
[mm] [mm] [mm] [mm]
2124
2030

KR 125/1, /2 90 800 1504 --------

KR 125 L100/1, /2 110 780 1695 --------
KR 125 L90/1, /2 130 760 1885 --------

KR 150/1, /2 --10 930 -------- 1677

KR 150 L150/1, /2 0 910 -------- 1867
KR 150 L120/1, /2 20 890 -------- 2057

KR 200/1, /2 --10 930 -------- 1677

**also applies to robots with in--line wrist II F

C

Fig. 16 Transport position for ceiling--mounted robots

(2) Raise the robot (Fig. 17/4) vertically with the fork--lift truck and place it onto the ceiling
structure (1).

As the robot is lifted, the boreholes (3) must be aligned as accurately as possi-
ble with the two locating pins (2). If this operation is carried out inaccurately, it
is more likely that parts will be damaged.

As soon as the robot is in its exact position on the ceiling, it must be pressed
firmly against the ceiling until it is finally bolted to it.

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Installation, Connection, Exchange

1 2

Fig. 17 Installing the robot on the ceiling

(3) Insert M24x70 ISO 4017 eight hexagon bolts (5) together with lock washers and tighten
them with a torque wrench in diagonally opposite sequence, increasing the tightening
torque to the specified value in several stages (MA = 640 Nm).

Retorque eight hexagon bolts (5) after 100 operating hours.

(4) Remove fork lift truck.

(5) Connect connecting cables.

Before performing the next step, it must be ensured that it is not possible for
anyone to be injured within the range of the slowly moving robot. The robot may
only be moved at manual traversing speed, with all applicable safety rules and
regulations being observed.

(6) Put robot into operation and move it into a suitable position to install end--effector and
additional equipment.

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

(7) Install end--effector (tool) and additional equipment.

(8) Connect all other cables and supply lines which have been removed.
(9) Put robot into operation.

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 4 Installation and connection (continued)

4.3 Wall--mounted robots

Section 1 of this Doc. Module is to be observed!

The procedure for mounting the robot on the wall (whether for the first time or as an ex-
change) is as follows:

Wall--mounted robots on a shelf

The robot must be transported in its transport position (Fig. 18)* to the point
from where it can be raised by the crane for the purpose of installation.

(1) Check that both locating pins (Fig. 12/2) and their fastening screws (1) are undamaged
and fitted securely.

Damaged locating pins must be replaced by new ones.

A1 A2 A3 A4 A5 A6
0° -15° +58° 0° +90° any
1289
1024 * Angle specifications
refer to the
mechanical zero of
the axis concerned.
2304

S1
S2

!
915
835

1
215 215

475

1 Counterweight A 1
S1 Center of gravity of robot without counterweight A 1
(G1 = 975 kg)
S2 Center of gravity of robot with counterweight A 1
(G2 = 1575 kg)

Fig. 18 Transport position for wall--mounted robots

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Installation, Connection, Exchange

(2) Up to serial no. 11:

Raise counterweight A 1 (Fig. 20/2) using lifting tackle and crane and fasten it to the
rotating column with three M20x150--10.9 Allen screws and lock washers.
Tightening torque MA = 500 Nm.

From serial no. 12:

Raise counterweight A 1 (Fig. 20/2) using lifting tackle and crane and fasten it to the
rotating column with two M20x150--10.9 Allen screws and one M24x150--12.9 Allen
screw together with lock washers.
Tightening torque MA = 500 Nm (for M20x150--10.9 screws),
Tightening torque MA = 1030 Nm (for M24x150--12.9 screw).
(3) Remove lifting tackle from counterweight A 1.
(4) Raise robot with lifting tackle attached to three eyes on the rotating column.

For reasons of safety, it is imperative for the lifting tackle to be attached to the
robot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module “Repair, General” must be
observed.

(5) Lower robot (Fig. 19/3) vertically onto the horizontally (0°) positioned hinged steel base
(5). If lifting tackle is used, particular care must be taken to ensure exact vertical posi-
tioning in order to avoid damaging the locating pins during this operation.

As the robot is lowered, the boreholes (2) must be aligned as accurately as pos-
sible with the two locating pins (1). If this operation is carried out inaccurately, it
is more likely that parts will be damaged.

1 5

Fig. 19 Installing the robot on a hinged steel base (on shelf)

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 4 Installation and connection (continued)

(6) Insert eight M24x70 ISO 4017 hexagon bolts (4) together with lock washers and tighten
them with a torque wrench in diagonally opposite sequence, increasing the tightening
torque to the specified value in several stages (MA = 640 Nm).

Retorque eight hexagon bolts (4) after 100 operating hours.

(7) Remove lifting tackle.

(8) Move hinged steel base from 0° to 90° position (Fig. 20, right) and lock it.

The manufacturer’s specifications with regard to handling and safety must be

observed.
The hinged steel base is not part of the KUKA contract.

2
S1 S2
S2
S1

1 Hinged steel base S1 Center of gravity of robot without counterweight A 1

2 Counterweight A 1 S2 Center of gravity of robot with counterweight A 1

Fig. 20 Installing a wall--mounted robot on a shelf

(9) Connect connecting cables.

Before performing the next step, it must be ensured that it is not possible for
anyone to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed, with all applicable
safety rules and regulations being observed.

(10) Put robot into operation and move it into a suitable position to install end--effector and
additional equipment.

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

(11) Install end--effector (tool) and additional equipment.

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Installation, Connection, Exchange

(12) Connect all other cables and supply lines which have been removed.
(13) Put robot into operation.

Wall--mounted robots on wall (not on a shelf)

(1) Check that both locating pins (Fig. 12/2) and their fastening screws (1) are undamaged
and fitted securely.

Damaged locating pins must be replaced by new ones.

The robot must be in the transport position (Fig. 21)*.

A1 A2 A3 A4 A5 A6
0° -15° +58° 0° +90° any
1289
1024 * Angle specifications
refer to the
mechanical zero of
the axis concerned.
2304

S1
S2

!
915
835

1
215 215

475

1 Counterweight A 1
S1 Center of gravity of robot without counterweight A 1
(G1 = 975 kg)
S2 Center of gravity of robot with counterweight A 1
(G2 = 1575 kg)

Fig. 21 Transport position for wall--mounted robots

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 4 Installation and connection (continued)

(2) Raise robot with lifting tackle attached to three eyes on the rotating column.

For reasons of safety, it is imperative for the lifting tackle to be attached to the
robot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module “Repair, General” must be
observed.

(3) Lower robot (Fig. 22/3) vertically onto the horizontally positioned hinged steel base (5).
If lifting tackle is used, particular care must be taken to ensure exact vertical positioning
in order to avoid damaging the locating pins during this operation.

The hinged steel base must be locked in the horizontal position (0°) in accor-
dance with the manufacturer’s specifications.

As the robot is lowered, the boreholes (2) must be aligned as accurately as pos-
sible with the two locating pins (1). If this operation is carried out inaccurately, it
is more likely that parts will be damaged.

1 5

Fig. 22 Installing the robot on a hinged steel base (on wall)

(4) Insert eight M24x70 ISO 4017 hexagon bolts (4) together with lock washers and tighten
them with a torque wrench in diagonally opposite sequence, increasing the tightening
torque to the specified value in several stages (MA = 640 Nm).

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Installation, Connection, Exchange

Retorque eight hexagon bolts (4) after 100 operating hours.

(5) Remove lifting tackle.

(6) Move hinged steel base from 0° to 90° position (Fig. 23, right) and lock it.

The manufacturer’s specification with regard to handling and safety must be

observed.
The hinged steel base is not part of the KUKA contract.

S1

S1

1 Hinged steel base

2 Counterweight A 1

Fig. 23 Installing a wall--mounted robot on a wall (not on a shelf)

(7) Up to serial no. 11:

Raise counterweight A 1 (Fig. 23/2) using lifting tackle and crane and fasten it to the
rotating column with three M20x150--10.9 Allen screws and lock washers.
Tightening torque MA = 500 Nm.

From serial no. 12:

Raise counterweight A 1 (Fig. 23/2) using lifting tackle and crane and fasten it to the
rotating column with two M20x150--10.9 Allen screws and one M24x150--12.9 Allen
screw together with lock washers.
Tightening torque MA = 500 Nm (for M20x150--10.9 screws),
Tightening torque MA = 1030 Nm (for M24x150--12.9 screw).
(8) Remove lifting tackle from counterweight A 1.
(9) Connect connecting cables.

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 4 Installation and connection (continued)

Before performing the next step, it must be ensured that it is not possible for
anyone to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed, with all applicable
safety rules and regulations being observed.

(10) Put robot into operation and move it into a suitable position to install end--effector and
additional equipment.

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

(11) Install end--effector and additional equipment.

(12) Connect all other cables which have been removed.
(13) Put robot into operation.

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Installation, Connection, Exchange

5 Exchange
To avoid the need for any major reprogramming after an exchange, the instructions given in
the Operating Handbook, Software KR C1, Chapter “Start--up”, Section “Robot Mastering/
Unmastering” must be accurately carried out every time a robot is exchanged.

5.1 Exchanging floor--mounted robots

D Removal

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

(1) Remove end--effector (tool) and additional equipment.

The end--effector and additional equipment have to be removed if the robot is to be re-
placed by another one or if they would otherwise impede the exchange work.

If the end--effector and additional equipment remain on the robot, this is liable to
lead to adverse centers of gravity and collisions. The operator is responsible for
any damage resulting in this respect.

Before performing the next step, it must be ensured that it is not possible for
anyone to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed, with all applicable
safety rules and regulations being observed.

(2) Put robot into operation and move it into transport position (Fig. 24)*.

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 5 Exchange (continued)

A1 A2 A3 A4 A5 A6
0° -40° +58° 0° +90° any

D
* Angle specifications
C
refer to the
mechanical zero of
the axis concerned.

Position of center of gravity**

Robot type A B C D
2124

2030

[mm] [mm] [mm] [mm]

KR 125/1, /2 90 800 1504 --------

KR 125 L90/1, /2 110 780 1695 --------
KR 125 L100/1, /2 130 760 1885 --------

KR 150/1, /2 --10 930 -------- 1677

B

A KR 200/1, /2 --10 930 -------- 1677

-- + **also applies to in--line wrist II F

Fig. 24 Transport position for floor--mounted robots

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

(3) Release and unplug connectors (Fig. 25/1, 3) from the junction boxes (2).
(4) Remove electric cables and hose lines from both interfaces of energy supply system
A 1 and all other peripheral supply lines attached to the robot, where necessary.

Depressurize and drain hose lines beforehand.

(5) Remove eight M24x70 hexagon bolts (4) (for mounting variant 1 eight hexagon nuts)
together with lock washers.
(6) Lift robot with lifting tackle attached to three eyes on the rotating column.

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Installation, Connection, Exchange

For reasons of safety, it is imperative for the lifting tackle to be attached to the
robot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module “Repair, General” must be
observed.

1 2 3 4

X30 X31
X01 X02

Fig. 25 Removal of floor--mounted robot

The robot can also be lifted by fork lift truck.

The robot must be lifted as vertically as possible until the locating pins are free.

(7) Lower robot onto a suitable support.

If the robot is not to be reinstalled for some time, it must be protected against corrosion
before being put into storage.

D Installation
See Section 4.1.

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 5 Exchange (continued)

5.2 Exchanging ceiling--mounted robots

D Removal

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

(1) Remove end--effector (tool) and additional equipment.

End--effector and additional equipment have to be removed if the robot is to be

replaced by another one or if they would otherwise impede the exchange work.

If the end--effector and additional equipment remain on the robot, this is liable to
lead to adverse centers of gravity and collisions. The operator is deemed
responsible for any damage resulting in this respect.

Before performing the next step, it must be ensured that it is not possible for
anyone to be injured within the range of the slowly moving robot.
The robot may only be moved at manual traversing speed, with all applicable
safety rules and regulations being observed.

(2) Put robot into operation and move it into transport position (Fig. 26)*.

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Installation, Connection, Exchange

A1 A2 A3 A4 A5 A6
0° -40° +58° 0° +90° any

* Angle specifications refer to

the mechanical zero of the
axis concerned.
A
B

+ --

Position of center of gravity**

Robot typ A B C D
2124 [mm] [mm] [mm] [mm]
2030

KR 125/1, /2 90 800 1504 --------

KR 125 L100/1, /2 110 780 1695 --------
KR 125 L90/1, /2 130 760 1885 --------

KR 150/1, /2 --10 930 -------- 1677

KR 150 L150/1, /2 0 910 -------- 1867
KR 150 L120/1, /2 20 890 -------- 2057

KR 200/1, /2 --10 930 -------- 1677

**also applies to robots with in--line wrist II F

C

Fig. 26 Transport position for ceiling--mounted robots

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

(3) Release and unplug connectors (Fig. 27/1, 3) from the junction boxes (2).
(4) Remove electric cables and hose lines from both interfaces of energy supply system
A 1 and all other peripheral supply lines attached to the robot, where necessary.

Depressurize and drain hose lines beforehand.

(5) Insert the forks of the fork lift truck into the apertures designed for them on the robot
and press robot firmly against the ceiling.

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 5 Exchange (continued)

X02 X01
X31 X30

4 3 2 1

Fig. 27 Removal of ceiling--mounted robot

(6) Remove eight M24x70 hexagon bolts (4) together with lock washers.
(7) Lower robot slowly without tilting it.

The robot must be lowered vertically downwards until both locating pins are
free.

(8) Suspend robot in transport frame and if it needs to be turned over into the floor--mount-
ing position (base frame at bottom, arm at top), turn the robot together with the trans-
port frame.

If the robot is not to be reinstalled for some time, it must be protected against corrosion
before being put into storage.

D Installation
See Section 4.2.

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Installation, Connection, Exchange

5.3 Exchanging wall--mounted robots

D Removal

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

(1) Remove end--effector (tool) and additional equipment.

End--effector and additional equipment have to be removed if the robot is to be

replaced by another one or if they would otherwise impede the exchange work.

If the end--effector and additional equipment remain on the robot, this is liable to
lead to adverse centers of gravity and collisions. The operator is deemed
responsible for any damage resulting in this respect.

Before performing the next step, it must be ensured that it is not possible for
anyone to be injured within the range of the slowly moving robot. The robot may
only be moved at manual traversing speed, with all applicable safety rules and
regulations being observed.

(2) Put robot into operation and move it into transport position*:

A1 A2 A3 A4 A5 A6
0° -15° +58° 0° +90° any

Counterweight A 1 remains on the robot for the time being.

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

(3) Release and unplug connectors (Fig. 28/1, 3) from the junction boxes (2).
(4) Remove electric cables and hose lines from both interfaces of energy supply system
A 1 and all other peripheral supply lines to the robot, where necessary.

Depressurize and drain hose lines beforehand.

*Angle specifications refer to the mechanical zero of the axis concerned.

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 5 Exchange (continued)

1 2 3 4

X30 X31
X01 X02

Fig. 28 Removal of wall--mounted robot

(5) For wall--mounted robots on a wall (not on a shelf):

Up to serial no. 11:
Secure counterweight A 1 (Fig. 29/2) using lifting tackle and crane, remove three
M20x150--10.9 Allen screws and lock washers from the rotating column, and take off
counterweight.

From serial no. 12:

Secure counterweight A 1 (Fig. 29/2) using lifting tackle and crane, remove two
M20x150--10.9 Allen screws and one M24x150--12.9 Allen screw together with lock
washers from the rotating column, and take off counterweight.

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Installation, Connection, Exchange

2 S1

S1

1 Hinged steel base

2 Counterweight A 1

Fig. 29 Removal of wall--mounted robot on a wall

(6) Move hinged steel base (Fig. 29/1 and 30/1) from 90° to 0° position and lock it.

The manufacturer’s specifications with regard to handling and safety must be

observed.
The hinged steel base is not part of the KUKA contract.

S2 S1
1 S2
S1

1 Hinged steel base S1 Center of gravity of robot without counterweight A 1

2 Counterweight A 1 S2 Center of gravity of robot with counterweight A 1

Fig. 30 Removal of wall--mounted robot on a shelf

(7) Remove eight M24x70 hexagon bolts (Fig. 28/4) together with lock washers.
(8) Raise robot with lifting tackle attached to three eyes on the rotating column.

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 5 Exchange (continued)

For reasons of safety, it is imperative for the lifting tackle to be attached to the
robot at the specified points. Risk of injury!
The transport instructions in the robot Doc. Module “Repair, General” must be
observed.

The robot must be lifted as vertically as possible until the locating pins are free.

(9) Lower robot onto a suitable support.

Counterweight A 1 must be removed for all in--plant transportation of the robot.

Center of gravity S1 then applies in the transport position (Fig. 31)*.

A1 A2 A3 A4 A5 A6
0° -15° +58° 0° +90° any

1289
1024 * Angle specifications
refer to the
mechanical zero of
the axis concerned.
2304

S1
S2

!
915
835

1
215 215

475

1 Counterweight A 1
S1 Center of gravity of robot without counterweight A 1
(G1 = 975 kg)
S2 Center of gravity of robot with counterweight A 1
(G2 = 1575 kg)

Fig. 31 Transport position for wall--mounted robots

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Installation, Connection, Exchange

If the robot is not to be reinstalled for some time, it must be protected against corrosion
before being put into storage.

D Installation
See Section 4.3.

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ROBOT

KR 125, 150, 200; KR 125 W

Adjustment Instructions

In--line Wrist 125/150/200 II

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

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

2 Belt tension checking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Checking and adjusting the toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Checking and adjusting the toothed belt tension of A 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Checking and adjusting the toothed belt tension of A 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Measuring and adjusting the toothed belt tension . . . . . . . . . . . . . . . . . . 10

4.1 Measuring and adjusting the toothed belt tension A 5/A 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Adjustment Instructions

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 1 General

Valid for KR 125/1, /2 KR 125 F/1, /2

KR 125 L100/1, /2 KR 125 L100F/1, /2
KR 125 L90/1, /2 KR 125 L90F/1, /2
KR 125 W/1, /2
KR 150/1, /2 KR 150 F/1, /2
KR 150 L150/1, /2 KR 150 L150F/1, /2
KR 150 L120/1, /2 KR 150 L120F/1, /2
KR 200/1, /2 KR 200 F/1, /2

1 General

With a view to avoiding accidents when work is carried out on the robot, the
pertinent regulations are to be observed.

The description of the adjustment operations is subdivided into job steps with numbers in
brackets appearing before them. The text which immediately follows these steps must also
be read if it is specially marked by a warning triangle or either of the hand symbols, as
many of these marked texts refer to the preceding job step.

Example
(9) Remove M5x20 Allen screws (Fig. 2/1) and lock washers and take off in--line wrist
(2).

The in--line wrist weighs 80 kg.

Some of the specially marked texts refer exclusively to everything that follows -- until the in-
struction is expressly revoked or the work is completed at the end of a section.

Example

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

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Adjustment Instructions

2 Belt tension checking device

The two toothed belts A 5 and A 6 of the in--line wrist can be quickly and accurately adjusted
with the aid of a belt tension checking device. This accessory (Fig. 1) features a simple line
mark at (3), indicating the correct tension setting. The use of this mark is described in
Section 3.

When adjusting or checking the toothed belt tension, it must be ensured that for
toothed belt A 5, rotational axis 5 and for toothed belt A 6, rotational axis 6 are
vertical. This torque--neutral position is required in order to prevent different
strand forces from occurring, which would invalidate the measurement.

1 2 3 4 5 11

10 9 8 7 6

Starting position Required position for A 5 and A 6

1 Screw
2 Clamping piece
3 Marking ring for A 5 and A 6
4 Plunger
5 Plunger head
6 Union nut Test insert
7 Inner sleeve
8 Outer sleeve
9 Knurled screw
10 Toothed belt
11 Test force

Fig. 1 Starting position and required position for belt tension checking device

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 3 Checking and adjusting the toothed belt

3 Checking and adjusting the toothed belt

The Doc. Module “Safety, General” and the robot Doc. Module “Adjustment
Instructions” (Section 1) must be observed!

3.1 Checking and adjusting the toothed belt tension of A 5

If the toothed belts are to be adjusted on an operable robot, the main switch on
the control cabinet must be turned to the “OFF” position and secured with a
padlock to prevent unauthorized persons from switching it on again.

(1) Remove 13 M5x20 Allen screws (Fig. 2/1) and lock washers and take off cover (2).

On in--line wrists with the designation “F”, the cover (2) is additionally sealed using a
sealant, which bonds the cover to its mounting.

(2) Place clamping piece (11) together with test insert into groove milled into clamping piece
mount (6) and pointing towards toothed belt A 5, and fasten with one M4x16 Allen screw
(12).
(3) Fasten clamping piece mount (6) to housing A 5 (13) with dowel pin (3) and two M5x45
Allen screws (5) in two tapped holes.
(4) Slacken knurled screw (7) on clamping piece (11), and push outer sleeve (8) towards
toothed belt (4) until its end face just comes into contact with toothed belt.
(5) Tighten knurled screw (7).
(6) Press in plunger head (10) by hand until it just comes into contact with union nut (9).

Toothed belt A 5 (Fig. 1/10) has the correct tension when the mark (3) on the inner
sleeve (7) is just visible on the collar. Required position as shown in Figure 1. If the ten-
sion is too high or too low, steps 7 and 8 are to be carried out.
(7) Slacken nut (Fig. 3/3) on eccentrically mounted axle (2).
(8) Push socket wrench onto hexagon screw (1) and turn axle (2) in required direction.

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Adjustment Instructions

Section A--A
rotated through 90°
1 2 3 4
A

13 A6

12 A5
11

10 9 8 7 6 5

Fig. 2 Checking toothed belt tension for A 5 and A 6

The directions for “tight” and “loose” are marked.

(9) Tighten nut (3) with 18 Nm.

(10) Check toothed belt tension again in accordance with step 6.
(11) Repeat adjustment and checking procedure if necessary until mark (Fig. 1/3) is cor-
rectly positioned.
(12) Remove M4x16 Allen screw (Fig. 3/6) and take out clamping piece with test insert.

Section B-B in Figure 4

Fig. 3 Adjusting toothed belt tension of A 5

(13) Remove two M5x45 Allen screws (4) and take clamping piece mount (5) off housing A 5.

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 3 Checking and adjusting the toothed belt (continued)

(14) Mount cover (Fig. 2/2) and fasten it with 13 M5x20 Allen screws (1) and lock washers.

On in--line wrists with the designation “F”, the cover (2) is additionally sealed. This seal
must be restored by applying the sealant Drei Bond 1118. The directions of the sealant
manufacturer must be observed.

3.2 Checking and adjusting the toothed belt tension of A 6

The procedure for checking and adjusting toothed belt A 6 (Fig. 4/1) is essentially the same
as described in Section 2.1, steps 1 to 14.

The clamping piece together with the test insert must be placed into the groove
milled into the clamping piece mount and pointing towards toothed belt A 6. The
position of the clamping piece mount on the housing is the same as for check-
ing toothed belt A 5.

If the tension is correctly adjusted, the mark (Fig. 1/3) must still be just visible.

Section A-A

Fig. 4 Adjusting the toothed belt tension of A 6

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Adjustment Instructions

4 Measuring and adjusting the toothed belt tension

The Doc. Module ”Safety, General” and the robot Doc. Module “Adjustment
Instructions” (Section 1) must be observed!

When measuring or adjusting the toothed belt tension, it must be ensured that
for toothed belt A 5, rotational axis 5 and for toothed belt A 6, rotational axis 6
are vertical. This torque--neutral position is required in order to prevent different
strand forces from occurring, which would invalidate the measurement.

If the toothed belt tension is measured immediately after the robot has stopped
operating, it is liable to have an elevated surface temperature, in which case
appropriate safety measures must be taken.

4.1 Measuring and adjusting the toothed belt tension A 5/A 6

If the toothed belt is to be measured and adjusted on an operable robot, the

main switch on the control cabinet must be turned to the “OFF” position and
secured with a padlock to prevent unauthorized persons from switching it on
again.

(1) Remove 13 M5x20 Allen screws (Fig. 5/1) and lock washers and take off cover (2).

On in--line wrists with the designation “F”, the cover (2) is additionally sealed using a
sealant, which bonds the cover to its mounting.

1 2

Fig. 5 Cover

(2) Switch on belt tension measuring device (Fig. 6/1).

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 4 Measuring and adjusting the toothed belt tension (continued)

(3) Pluck toothed belt and hold sensor (2) at a distance of 2 to 3 mm from the vibrating
toothed belt. Read measurement on the belt tension measuring device.
(4) Repeat the measurement three times.

Fig. 6 Belt tension measuring device

If the value indicated in Fig. 7 is not obtained, steps 5 to 9 are to be carried out.

Axis Toothed belt Frequency

A5 18AT5/1050--E5/8 140 Hz
A6 14AT5/860--E5/8 215 Hz

Fig. 7 Toothed belt tension

(5) Slacken hexagon nut (Fig. 8/1) on eccentric shaft (2).

(6) Push socket wrench onto hexagon (3) and turn eccentric shaft (2) in required direction.

The directions for “tight” and “loose” are given on the in--line wrist.

When tightening the hexagon nut (1), make sure that adequate locking is
achieved.

(7) Tighten hexagon nut (1) with 18 Nm, at the same time securing the eccentric shaft (2)
to prevent it from turning.
(8) Measure toothed belt tension again as per steps 2 and 4.
(9) Repeat measuring and adjustment procedure if necessary until the value in Fig. 7 is
obtained.

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Adjustment Instructions

1 2

A6 A5

Fig. 8 Adjusting the toothed belt tension

(10) Mount cover (Fig. 5/2) and fasten it with 13 M5x20 Allen screws (1) and lock washers.

On in--line wrists with the designation “F”, the cover (2) is additionally sealed. This seal
must be restored by applying the sealant Drei Bond 1118. The directions of the sealant
manufacturer must be observed.

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ROBOT

KR 125, 150, 200; KR 125 W

Adjustment Instructions

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

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

2 Pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Draining the counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Filling and adjusting the counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Checking and adjusting the oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3 Toothed belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Adjustment Instructions

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 1 General

Valid for KR 125/1, /2 KR 125 F/1, /2

KR 125 L100/1, /2 KR 125 L100F/1, /2
KR 125 L90/1, /2 KR 125 L90F/1, /2
KR 125 W/1, /2
KR 150/1, /2 KR 150 F/1, /2
KR 150 L150/1, /2 KR 150 L150F/1, /2
KR 150 L120/1, /2 KR 150 L120F/1, /2
KR 200/1, /2 KR 200 F/1, /2

1 General

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

With regard to the manipulator, the operator must only carry out adjustments to the hydro-
pneumatic counterbalancing system for assisting axis 2 (counterbalancing system) and to
the toothed belts in the wrist, as long as maintenance specifications (see robot Doc. Module
“Maintenance”) or special circumstances require this.
The counterbalancing system is filled with hydraulic oil and nitrogen. The pressure in this sys-
tem is correctly set for each robot when delivered to the customer and is suitable for load
conditions occurring during normal operation of the robot (cf Fig. 17).
Tools and additional equipment must be removed before the adjustment process is started,
if they are likely to impede the adjustment work.

With a view to avoiding accidents when work is carried out on the

counterbalancing system, the pertinent regulations concerning the handling of
hydraulic oil and nitrogen are to be observed.

The description of the adjustment operations is subdivided into job steps with numbers in
brackets appearing before them. The text which immediately follows these steps must also
be read if it is specially marked by a warning triangle or either of the hand symbols, as
many of these marked texts refer to the preceding job.

Example
(9) Disconnect filling and testing device from diaphragm--type accumulator.

The filling and testing device may only be disconnected if the Allen screw (4)
has been tightened firmly by means of the gas valve rod (1).

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Adjustment Instructions

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

Example

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

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 2 Pressure adjustment

2 Pressure adjustment

Section 1 of this Doc. Module is to be observed.

The following table gives reasons for adjustment of the pressure on the part of the operator
and specifies where the procedures concerned are described.
Reason Procedure
Excessive deviation of the pres-
see Section 2.3
sure value
Replacement of a defective coun-
see Section 2.1 und 2.2
terbalancing system by a new one

Replacement of a floor version of

the counterbalancing system by a
see Section 2.1 und 2.2
ceiling version when the robot
installation position is altered

Load conditions lying far below the

Please consult KUKA.
normal range

2.1 Draining the counterbalancing system

The counterbalancing system is depressurized on the oil side by draining the hydraulic oil,
as described below.
(1) For floor--mounted robots: Move link arm into vertical position and secure it using a
crane (Fig. 1). The arm may be in any position.
For ceiling--mounted robots, inverted: Move link arm into vertical position (Fig. 2).
The arm may be in any position.
For ceiling--mounted robots, upright: Move link arm into vertical position and secure
it using a crane (as in Fig. 1). The arm may be in any position.
For wall--mounted robots on a wall: Move link arm onto (--)stop and secure it using
a crane (Fig. 3). The arm may be in any position.
For wall--mounted robots on a shelf: Swivel steel mounting base from 90° into 0°
position and lock it. Move link arm onto (--)stop (Fig. 4). The arm may be in any position.

It must be ensured that the link arm is not able to move either during or after a
reduction in the oil pressure.

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

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Adjustment Instructions

90° ±2°

90° ±2°

Fig. 1 Position for depressurization on Fig. 2 Position for depressurization on

floor-- and ceiling--mounted robot, ceiling--mounted robot, inverted
upright

--- 15°

--- 15°

Fig. 3 Position for depressurization on Fig. 4 Position for depressurization on

wall--mounted robot on a wall wall--mounted robot on a shelf

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 2 Pressure adjustment (continued)

(2) Remove screw cap (Fig. 5, 6, 7, 8/1) and connect tube (3) to vent valve (2).
(3) Drain hydraulic oil into a suitable receptacle (4).

The draining process is complete when the pressure gage (5) indicating the oil pressure
reads zero and no more oil flows into the receptacle.

Store used hydraulic oil in accordance with regulations and dispose of it with
minimum environmental impact.

1, 2
1, 2

5
4 4
Fig. 5 Draining hydraulic oil from Fig. 6 Draining hydraulic oil from ceiling--
floor--mounted robot mounted robot, inverted

1, 2

1, 2

5
3
3

4 4

Fig. 7 Draining hydraulic oil from Fig. 8 Draining hydraulic oil from
wall--mounted robot on a wall wall--mounted robot on a
shelf and from ceiling--
mounted robot, upright

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Adjustment Instructions

2.2 Filling and adjusting the counterbalancing system

To fill the counterbalancing system with oil and gas, the robot must be brought into the
required position for the mounting arrangement concerned, if it is not in the position described
in Section 2.1.
(1) For floor--mounted robots: Move link arm into vertical position and secure it using
lifting tackle and a crane (Fig. 1). The arm may be in any position.
For ceiling--mounted robots, inverted: Move link arm into vertical position (Fig. 2).
The arm may be in any position.
For ceiling--mounted robots, upright: Move link arm into vertical position and secure
it using lifting tackle and a crane (as in Fig. 1). The arm may be in any position.
For wall--mounted robots on a wall: Move link arm onto (--)stop and secure it using
lifting tackle and a crane (Fig. 3). The arm may be in any position.
For wall--mounted robots on a shelf: Swivel steel mounting base from 90° into 0°
position and lock it. Move link arm onto (--)stop (Fig. 4). The arm may be in any position.

It must be ensured that the link arm is not able to move.

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

D Filling with gas and adjusting gas pressure

Before the diaphragm--type accumulator can be filled with nitrogen, the counter-
balancing system must be depressurized on the oil side (see Section 2.1).

(2) Connect the tube used to drain the oil (see Section 2.1) for the mounting arrangement
of the robot concerned as shown in Fig. 5, 6, 7 or 8.

The oil side of the diaphragm--type accumulator is now open and can be vented during
subsequent filling of the gas side.

(3) Connect the filling and testing device (accessory) for the diaphragm--type accumulator
to a standard commercial nitrogen cylinder (9) via the tube (Fig. 9, 10, 11, 12/7).

If the pressure in the nitrogen cylinder is higher than the permissible pressure of
the diaphragm--type accumulator (230 bar), a pressure reducer and a safety valve
set to 230 bar must be fitted to the nitrogen cylinder.

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 2 Pressure adjustment (continued)

(4) Remove protective cap (5) from the diaphragm--type accumulator (6) and unscrew
Allen screw (4) slightly (without a torque wrench, by a quarter of a turn at the most).

For reasons of safety, the Allen screw (4) may under no circumstances be un-
screwed by more than a quarter of a turn without the filling and testing device
being connected. The pressure in the diaphragm--type accumulator (6) may
never be adjusted without the filling and testing device.

No gas must be allowed to escape. If, in spite of care being taken, gas does
escape (hissing sound!), the sealing ring of Allen screw (4) must be replaced.

(5) Connect the filling and testing device on the gas connection at (4) of the diaphragm--
type accumulator (6). Turn gas valve rod (1) counterclockwise, thereby opening the gas
connection via the Allen screw (4) (a full turn after the start of pointer deflection).

The pressure gage (3) indicates the nitrogen pressure in the diaphragm--type
accumulator (6).
If the nitrogen pressure is too high according to Fig. 17 or Fig. 18, step 6 must be
carried out.
If it is too low, step 7 is required.
Then in either case, continue with step 8.

(6) Discharging nitrogen. To do so:

(6.1) Open pressure relief valve (2) and discharge nitrogen until the specified pressure is
reached.

The reading on the pressure gage (3) must be rechecked after 2 to 3 minutes and the
nitrogen pressure corrected if necessary.

(7) Topping up nitrogen. To do so:

(7.1) Open shut--off valve (8) on the nitrogen cylinder (9) and raise the nitrogen pressure
to 200 bar.
(7.2) Close shut--off valve (8).
(7.3) Open pressure relief valve (2) and discharge nitrogen until the pressure specified in
Fig. 17 or Fig. 18 is reached.

The reading on the pressure gage (3) must be rechecked after 2 to 3 minutes and the
nitrogen pressure corrected if necessary.

(8) Turn Allen screw (4) clockwise by means of the gas valve rod (1) and tighten it. Then
open valve (2) and discharge the remaining pressure in the tube (7).

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Adjustment Instructions

1 2 3 4 5 6 1 2 3 4 5 6

7 7

8 8

9 9

Fig. 9 Changing the gas pressure Fig. 10 Changing the gas pressure on
on floor--mounted robot ceiling--mounted robot, inverted

2 6 5 4 3 2 1 7
7
1 8
8

9 9

Fig. 11 Changing the gas pressure on Fig. 12 Changing the gas pressure on
wall--mounted robot on a wall wall--mounted robot on a shelf and
ceiling--mounted robot, upright

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 (9) Disconnect filing and testing device from diaphragm--type accumulator.

The filling and testing device may only be disconnected if the Allen screw (4)
has been tightened firmly by means of the gas valve rod (1).

(10) Firmly retighten Allen screw (4) (tightening torque MA = 20 Nm).

(11) Check that the gas valve is not leaking.
(12) Screw on protective cap (5).
(13) Remove tube (7) from the nitrogen cylinder (9).

The counterbalancing system is filled with oil directly after this procedure.

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Adjustment Instructions

1 2 3 4 1 2 3 4

6 5 6 5

Fig. 13 Oil filling set--up for floor-- Fig. 14 Oil filling set--up for ceiling--
mounted robot mounted robot, inverted

4 5 6 1 2 3

2
4
1

8 7 6 5
Fig. 15 Oil filling set--up for wall-- Fig. 16 Oil filling set--up for wall--
mounted robot on a wall mounted robot on a shelf or
ceiling--mounted robot, upright

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 D Filling the counterbalancing system with oil and adjusting the oil pressure

The counterbalancing system is filled with oil immediately after it has been filled with
gas and the gas pressure has been adjusted. The numbering of the steps is continued
accordingly.

The following steps are ordered according to the mounting arrangement of the robot con-
cerned and its position for maintenance.

For floor--mounted robots:

The values specified in Fig. 17 or Fig. 18 must be observed when topping up the
hydraulic oil.

(14) Unscrew cap on filling connection (Fig. 13/3) and connect hydraulic tube (1).
(15) Unscrew cap on vent connection (2) and connect tube (4), unless the tube is still con-
nected from the preceding “gas--filling” stage.
(16) Open valve on vent connection (2) (= vent valve) slightly, put hydraulic pump (6) into
operation and allow hydraulic oil to flow out into the oil receptacle (5) until no more
bubbles escape.

The reservoir of the hydraulic pump (6) must only be filled with filtered Aral
Vitam GF 46 (filter gage 3 mm).

The tube (4) must be immersed in the liquid of the oil receptacle (5) to allow the
bubbles to be observed.

(17) Close vent valve at (2).

(18) Continue to operate hydraulic pump (6), until oil pressure is approx. 10 bar above the
specified value (see Fig. 17 or Fig. 18). Then lower pump pressure to “0”.

The oil pressure must be checked after approx. 10 minutes and lowered to the
specified value (see Fig. 17 or Fig. 18) by opening the vent valve.

(19) Unscrew hydraulic tube (1) and screw cap back onto filling connection (3).
(20) Unscrew tube (4) and screw cap back onto vent connection (2).
(21) Check hydropneumatic counterbalancing system for leaks.
(22) Remove lifting tackle and crane if applicable.

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Adjustment Instructions

For ceiling--mounted robots, inverted:

The values specified in Fig.17 or Fig. 18 must be observed when topping up the
hydraulic oil.

(14) Unscrew cap on filling connection (Fig. 14/3) and connect hydraulic tube.
(15) Unscrew cap on vent connection (2) and connect tube (4) unless the tube is still con--
nected from the preceding “gas--filling” stage.
(16) Open valve on vent connection (2) (= vent valve) slightly, put hydraulic pump (6) into
operation and allow hydraulic oil to flow out into the oil receptacle (5) until no more
bubbles escape.

The reservoir of the hydraulic pump (6) must only be filled with filtered Aral
Vitam GF 46 (filter gage 3 mm).

The tube (4) must be immersed in the liquid of the oil receptacle (5) to allow the
bubbles to be observed.

(17) Close vent valve at (2).

(18) Continue to operate hydraulic pump (6), until oil pressure is approx. 10 bar above the
specified value (see Fig. 17 or Fig. 18). Then lower pump pressure to “0”.

The oil pressure must be checked after approx. 10 minutes and lowered to the
specified value (see Fig. 17 or Fig. 18) by opening the vent valve.

(19) Unscrew hydraulic tube (1) and screw cap back onto filling connection (3).
(20) Unscrew tube (4) and screw cap back onto vent connection (2).
(21) Check hydropneumatic counterbalancing system for leaks.

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 For ceiling--mounted robots, upright:

The values specified in Fig.17 or Fig. 18 must be observed when topping up the
hydraulic oil.

(14) Unscrew cap on filling connection (Fig. 16/2) and connect hydraulic tube (1).
(15) Unscrew cap on vent connection (3) and connect tube (4).
(16) Open valve on vent connection (3) (= vent valve) slightly, put hydraulic pump (6) into
operation and allow hydraulic oil to flow out into the oil receptacle (5) until no more
bubbles escape.

The reservoir of the hydraulic pump (6) must only be filled with filtered Aral
Vitam GF 46 (filter gage 3 mm).

The tube (4) must be immersed in the liquid of the oil receptacle (5) to allow the
bubbles to be observed.

(17) Close vent valve at (3).

(18) Continue to operate hydraulic pump (6), until oil pressure is approx. 10 bar above the
specified value (see Fig. 17 or Fig. 18). Then lower pump pressure to “0”.

The oil pressure must be checked after approx. 10 minutes and lowered to the
specified value (see Fig. 17 or Fig. 18) by opening the vent valve.

(19) Unscrew hydraulic tube (1) and screw cap back onto filling connection (2).
(20) Unscrew tube (4) and screw cap back onto vent connection (3).
(21) Check hydropneumatic counterbalancing system for leaks.
(22) Remove lifting tackle and crane.

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Adjustment Instructions

For wall--mounted robots on a wall:

The values specified in Fig.17 or Fig. 18 must be observed when topping up the
hydraulic oil.

(14) Unscrew cap on filling connection (Fig. 15/4) and connect hydraulic tube (6).
(15) Unscrew cap on vent connection (3) and connect tube (2) unless the tube is still con
nected from the previous “gas--filling” stage. Unscrew cap from vent connection (5)
and connect tube (1).
(16) Open valves on vent connection (3, 5) (= vent valves) slightly, put hydraulic pump (7)
into operation and allow hydraulic oil to flow out into the oil receptacle (8) until no more
bubbles escape.

The reservoir of the hydraulic pump (7) must only be filled with filtered Aral
Vitam GF 46 (filter gage 3 mm).

The tubes (1, 2) must be immersed in the liquid of the oil receptacle (8) to allow the
bubbles to be observed.

(17) Close vent valves at (3) and (5).

(18) Continue to operate hydraulic pump (7), until oil pressure is approx. 10 bar above the
specified value (see Fig. 17 or Fig. 18). Then lower pump pressure to “0”.

The oil pressure must be checked after approx. 10 minutes and lowered to the
specified value by opening the vent valve (3) or (5) (see Fig. 17 or Fig. 18).

(19) Unscrew hydraulic tube (6) and screw cap back onto filling connection (4).
(20) Unscrew tubes (1, 2) and screw caps back onto vent connections (5, 3).
(21) Check hydropneumatic counterbalancing system for leaks.
(22) Remove lifting tackle and crane.

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 For wall--mounted robots on a shelf:

The values specified in Fig.17 or Fig. 18 must be observed when topping up the
hydraulic oil.

(14) Unscrew cap on filling connection (Fig. 16/2) and connect hydraulic tube (1).
(15) Unscrew cap on vent connection (3) and connect tube (4).
(16) Open valve on vent connection (3) (= vent valve) slightly, put hydraulic pump (6) into
operation and allow hydraulic oil to flow out into the oil receptacle (5) until no more
bubbles escape.

The reservoir of the hydraulic pump (6) must only be filled with filtered Aral
Vitam GF 46 (filter gage 3 mm).

The tube (4) must be immersed in the liquid of the oil receptacle (5) to allow the
bubbles to be observed.

(17) Close vent valve at (3).

(18) Continue to operate hydraulic pump (6), until oil pressure is approx. 10 bar above the
specified value (see Fig. 17 or Fig. 18). Then lower pump pressure to “0”.

The oil pressure must be checked after approx. 10 minutes and lowered to the
specified value by opening the vent valve (see Fig. 17 or Fig. 18).
(19) Unscrew hydraulic tube (1) and screw cap back onto filling connection (2).
(20) Unscrew tube (4) and screw cap back onto vent connection (3).
(21) Check hydropneumatic counterbalancing system for leaks.

Robot type* Floor--mounted robot Ceiling--mounted robot Wall--mounted robot

Gas Oil pressure Gas Oil pressure Gas Oil pressure

pressure P0 P1 pressure P0 P1 pressure P0 P1

KR 125/1
KR 125 L100/1
KR 125 L90/1 70 bar 88 bar 50 bar 73 bar
in each case
incl. suppl. load
± 80 kg

KR 150/1
KR 150 L150/1
KR 150 L120/1
KR 200/1 98 bar 123 bar 79 bar 105 bar
in each case
incl. suppl. load
± 80 kg

KR 125 W/1,
incl. suppl. load 68 bar 85 bar
± 80 kg

*also applies to robots with in--line wrist II F

Fig. 17 Settings for counterbalancing system on KR 125.../1

(standard settings by manufacturer)

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Adjustment Instructions

Robot type* Floor--mounted robot Ceiling--mounted robot Wall--mounted robot

Gas Oil pressure Gas Oil pressure Gas Oil pressure

pressure P0 P1 pressure P0 P1 pressure P0 P1

KR 125/2
KR 125 L100/2
KR 125 L90/2 70 bar 88 bar 86 bar 96 bar
in each case
incl. suppl. load
± 80 kg

KR 150/2 114 bar 127 bar

KR 150 L150/2 120 bar 131 bar
KR 150 L120/2 108 bar 120 bar
KR 200/2 98 bar 123 bar 114 bar 127 bar
in each case
incl. suppl. load
± 80 kg

KR 125 W/2,
incl. suppl. load 68 bar 85 bar
± 80 kg

*also applies to robots with in--line wrist II F

Fig. 18 Settings for counterbalancing system on KR 125.../2

(standard settings by manufacturer)

2.3 Checking and adjusting the oil pressure

The procedure for checking the oil pressure when performing maintenance work, -- i.e. when
the counterbalancing system has not been replaced -- is as follows:
(1) For floor--mounted robots: Move link arm into vertical position and secure it using
lifting tackle and a crane (Fig. 1). The arm may be in any position.
For ceiling--mounted robots, inverted: Move link arm into vertical position (Fig. 2).
The arm may be in any position.
For ceiling--mounted robots, upright: Move link arm into vertical position and secure
it using lifting tackle and a crane (as in Fig. 1). The arm may be in any position.
For wall--mounted robots on a wall: Move link arm onto (--)stop and secure it using
lifting tackle and a crane (Fig. 3). The arm may be in any position.
For wall--mounted robots on a shelf: Swivel steel mounting base from 90° into 0°
position and lock it. Move link arm onto (--)stop (Fig. 4). The arm may be in any position.

It must be ensured that the link arm is not able to move.

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

(2) Read the pressure gage on the counterbalancing system and compare the reading with
the correct value in Fig. 17 or Fig. 18.

Lower limit value: 5 bar below value specified in Fig. 17 or Fig. 18.

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 If the value is in order,
(3) Remove lifting tackle and crane if applicable.

If adjustment to the correct value is required after checking the oil pressure then -- even if
the counterbalancing system has not been replaced -- the counterbalancing system must be
drained and then refilled. Sections 2.1 and 2.2 must be observed.

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Adjustment Instructions

3 Toothed belt adjustment

See robot Doc. Module “Adjustment Instructions, In--line Wrist 125/150/200 II”.

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ROBOT

KR 125, 150, 200 (/2)

Maintenance

In--line wrist 125/150/200 II

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

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

2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Oil change on in--line wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Other maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 Cleaning and preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5 Safety precautions when handling lubricants . . . . . . . . . . . . . . . . . . . . . . 15

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Maintenance

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 1 General

Valid for KR 125/2

KR 125 L100/2
KR 125 L90/2
KR 125 W/2
KR 150/2
KR 150 L150/2
KR 150 L120/2
KR 200/2

1 General

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

Before any maintenance work is started, any attached tools or additional equipment that
would hinder maintenance must be dismounted.

Explanation of the symbols used in connection with maintenance intervals in the “Lubrica-
tion” and “Other maintenance” tables below:
means: normal maintenance interval (duty cycle D.C. = 50%)

means: extended maintenance interval (duty cycle D.C. < 50%)

The duty cycle (D.C.) is program--dependent and must be determined axis--specifically.

A maintenance interval with the dot symbol F must be observed if determination of the
duty cycle over a long--term operating phase results in a value = 50% for one or more
robot axes. This applies correspondingly for the circle symbol f, with D.C. < 50%.

The maintenance intervals start at commissioning by the customer.

If the robot is operated within an extended maintenance interval ( f ) for a

prolonged period with D.C. =50%, it must be changed over to the normal
maintenance interval ( F ).

Lubrication is performed either at the specified maintenance intervals or every 5 years after
commissioning by the customer — whichever is reached first.
With maintenance intervals of 20,000 hours, the first maintenance (oil change) is performed
either after 20,000 operating hours or 5 years after commissioning by the customer —
whichever is reached first.

It is imperative that lubrication is carried out every 5 years, as prescribed (oil

ageing).

The maintenance intervals given in the tables are valid for the operating
conditions specified in the robot Doc. Module “Technical Data”. In case of
variations from normal conditions (e.g. increased dust or water content in the
environment of the robot, abnormal temperatures), the KUKA design department
must be consulted.

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Maintenance

Explanation of symbols:

Normal maintenance interval (D.C. = 50 %)

Extended maintenance interval (D.C. < 50 %)

1 Maintenance point

Maintenance point, visible on drawing

Maintenance point, hidden on drawing

" Check belt tension

1.0 l Oil change, to be repeated at specific intervals; with indication of oil capacity

Lubricate with grease gun

Lubricate with brush

Tighten screw (nut)

The description of maintenance operations is subdivided into job steps with numbers in
brackets appearing before them. The text which immediately follows these steps must also
be read if it is specially marked by a warning triangle or either of the hand symbols, as
many of these marked texts refer to the preceding job step.

Example
(1) Pour specified amount of oil into the filler hole at (10).

Oils of different viscosities are not miscible; if the type of oil is changed, it is
necessary to flush the oil chamber with the new oil grade.

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 1 General (continued)

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

Example

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

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Maintenance

2 Lubrication

Section 1 of this Doc. Module is to be observed!

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

Store used oil and grease in accordance with regulations and dispose of them
with minimum environmental impact.

D “Lubrication” table
Maintenance point Maintenance Activity Remarks
(see Fig. 1) interval Lubricant
(hours) Manufacturer
Amount
KUKA art. no.
20000
10000

Gear train A 4 Oil change Change oil as described in

À D d Optigear 150 Section 2.1.
Optimol, approx. 1.0 l
KUKA art. no.
83--236--656
O--ring A 4 Greasing Lift O--rings out of
Á D d Aralub 4034 grooves and remove old
Aral, approx. 10 g grease. Grease O--rings with
per O--ring brush and fit them back into
KUKA art. no. grooves.
83--087--900
Gear train A 5, A 6 Oil change Change oil as described in
 D d Optigear 150 Section 2.1
Optimol, approx. 1.3 l
KUKA art. no.
83--236--656
O--rings A 5, A 6 Greasing Lift O--rings out of
à D d Aralub 4034 grooves and remove old
Aral, approx. 10 g grease. Grease O--rings with
per O--ring brush and fit them back into
KUKA art. no. grooves.
83--087--900
D Normal maintenance interval
d Maintenance interval when D.C. < 50 %

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 2 Lubrication (continued)

1.0 l 1.3 l

1 2 3 4

Fig. 1 Lubrication

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Maintenance

2.1 Oil change on in--line wrist

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

The oil is to be changed only at operating temperature.

If the oil change is carried out immediately after the robot has stopped operat-
ing, the oil temperature is liable to be high, in which case appropriate safety
measures must be taken.

D Drain oil

Before performing the next step, it must be ensured that it is not possible for
anyone to be injured within the range of the slowly rotating arm.
The robot may only be moved at manual traversing speed with all applicable
safety rules and regulations being observed.

(1) Put robot into operation and move arm into a horizontal position and in--line wrist (Fig. 2)
into mechanical zero position.
(2) Move axis 5 until screw plug (2) is pointing down (mounting flange facing up).

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

(3) Remove screw plugs (1, 2, 3) and catch oil in a suitable container as it drains out.

Store used oil in accordance with regulations and dispose of it with minimum
environmental impact.

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 2 Lubrication (continued)

D Fill with oil

Maintain arm in horizontal position.

Before performing the next step, it must be ensured that it is not possible for
anyone to be injured within the range of the slowly rotating arm.
The robot may only be moved at manual traversing speed with all applicable
safety rules and regulations being observed.

(1) Put robot into operation and move wrist axes so that oil filler hole (2) is facing upwards.

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

(2) Insert and tighten screw plug (3) and pour specified amounts of oil into oil filler holes
(1, 2).

Oils of different viscosities are not miscible; if the type of oil is changed, it is
necessary to flush the oil chamber with the new oil grade.

(3) Insert and tighten screw plugs (1, 2) (tightening torque MA = 30 Nm).

Fig. 2 Oil change

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Maintenance

3 Other maintenance

Section 1 of this Doc. Module is to be observed!

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

Store used oil in accordance with regulations and dispose of it with minimum
environmental impact.

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 3 Other maintenance (continued)

D “Other maintenance” table

Maintenance point Maintenance Activity Remarks

(see Fig. 3) interval
(hours)

10000
In--line wrist A 5, A 6 Check toothed belt tension See robot Doc. Module,
À D “Adjustment Instructions,
In--line Wrist”.
Check toothed belt Replace toothed belt at first
sign of damage or deteriora-
tion (see robot Doc. Module
“Repair, In--line Wrist”).

Fig. 3 Other maintenance

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Maintenance

4 Cleaning and preventive maintenance

Turn the main switch on the robot control cabinet to “OFF” and secure it with a
padlock to prevent it from being inadvertently being switched on again. This
also applies to any cleaning work, which though not performed directly on the
robot is carried out within or close to its working range.

Cleaning and preventive maintenance work is to be carried out in accordance with the follow-
ing instructions:
-- Clean robot with a cloth soaked with washing agent.
-- Clean cables, plastic parts and hoses with solvent--free washing agents.

The manufacturer’s instructions are to be observed when using washing agents.

-- Remove any lubricant that has escaped with washing agent. If a large amount of
lubricant has emerged, trace and remedy the cause.

It must be ensured that no washing fluid enters bearings, seals, electrical equip-
ment or the hydropneumatic counterbalancing system.

If washing agent does enter bearings, the latter must be re--greased or re--oiled.

-- Remove any corrosion and, where permissible, protect the affected areas with
paint, grease or oil.
-- Apply a thin coat of oil to bare metal parts.
-- Replace damaged, illegible or missing inscriptions, labels and plates.

Do not use compressed air to clean the system, as this could cause dirt to
penetrate seals, bearings and electrical components.
Used cleansing and washing agents and lubricants must be stored and disposed
of in accordance with all pertinent regulations and with minimum environmental
impact.

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 5 Safety precautions when handling lubricants

5 Safety precautions when handling lubricants

The information contained in the safety data sheet according to 91/155 EEC must be
observed when handling lubricants. An excerpt from this data sheet is included in the robot
Doc. Module “Consumables, Safety Data Sheet”.
The following safety procedures must be observed at all times:
-- Avoid prolonged intensive skin contact; wear protective gloves and aprons if nec-
essary (especially when working with cable grease).

All accident prevention regulations must be observed when handling lubricants.

-- If lubricant is likely to come into contact with the skin, e.g. with the hands, suitable
barrier creams must be applied before work is started.
-- On completion of work and before meal breaks (before any intake of food), clean
oil--contaminated skin thoroughly with water and skin--friendly cleansing agents
or soap. After cleaning, replace lost skin grease with appropriate skin creams con-
taining grease.
-- Change oil--soaked clothing immediately. Do not carry oily rags or any cloths
soaked with solvents or mineral oil mixtures in your pockets.
-- Avoid breathing in oil spray or vapors wherever possible.

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