Kuka IONTECKR 70 R2100

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Fig. 7-11: Connecting cable, motor cable X20-X30

1 Interface X20

2 Guide pin

3 Guide bush

KR IONTEC

MA KR IONTEC V4 | Issued: 11.05.2021 www.kuka.com | 185/344

Start-up and recommissioning

Main Page

Table of Contents3
Introduction9
Target Group9
Industrial Robot Documentation9
Representation of Warnings and Notes9
Terms Used10
Product Description15
Description of the Robot System15
Description of the Manipulator16
Intended Use and Misuse17
Safety19
General19
Disclaimer19
EC Declaration of Conformity and Declaration of Incorporation20
Terms in the "Safety" Chapter20
Personnel22
Workspace, Safety Zone and Danger Zone23
Overview of Protective Equipment23
Mechanical End Stops24
Mechanical Axis Limitation (Optional)24
Options for Moving the Manipulator Without Drive Energy24
Labeling on the Industrial Robot25
Safety Measures25
General Safety Measures25
Transportation27
Start-Up and Recommissioning27
Manual Mode29
Automatic Mode30
Maintenance and Repair30
Decommissioning, Storage and Disposal32
Technical Data33
Technical Data, Overview33
Technical Data, KR 20 R310034
Basic Data, KR 20 R310034
Axis Data, KR 20 R310036
Payloads, KR 20 R310039
Foundation Loads, KR 20 R310045
Technical Data, KR 30 R210047
Basic Data, KR 30 R210047
Axis Data, KR 30 R210048
Payloads, KR 30 R210051
Foundation Loads, KR 30 R210058
Technical Data, KR 50 R210060
Basic Data, KR 50 R210060
Axis Data, KR 50 R210061
Payloads, KR 50 R210064
Foundation Loads, KR 50 R210071
Technical Data, KR 50 R250073
Basic Data, KR 50 R250073
Axis Data, KR 50 R250074
Payloads, KR 50 R250078
Foundation Loads, KR 50 R250084
Technical Data, KR 50 R2500 F86
Basic Data, KR 50 R2500 F86
Axis Data, KR 50 R2500 F88
Payloads, KR 50 R2500 F92
Foundation Loads, KR 50 R2500 F98
Technical Data, KR 70 R2100100
Basic Data, KR 70 R2100100
Axis Data, KR 70 R2100101
Payloads, KR 70 R2100104
Foundation Loads, KR 70 R2100111
Technical Data, KR 70 R2100 F113
Basic Data, KR 70 R2100 F113
Axis Data, KR 70 R2100 F115
Payloads, KR 70 R2100 F118
Foundation Loads, KR 70 R2100 F124
Plates and Labels126
REACH Duty to Communicate Information Acc. to Art. 33128
Stopping Distances and Times128
General Information128
Stopping Distances and Times, KR 20 R3100129
Stopping Distances and Stopping Times, STOP 0, A1 to A3129
Stopping Distances and Stopping Times, STOP 1, A1130
Stopping Distances and Stopping Times, STOP 1, A2132
Stopping Distances and Stopping Times, STOP 1, A3134
Stopping Distances and Times, KR 30 R2100134
Stopping Distances and Stopping Times, STOP 0, A1 to A3134
Stopping Distances and Stopping Times, STOP 1, A1136
Stopping Distances and Stopping Times, STOP 1, A2138
Stopping Distances and Stopping Times, STOP 1, A3140
Stopping Distances and Times, KR 50 R2100140
Stopping Distances and Stopping Times, STOP 0, A1 to A3140
Stopping Distances and Stopping Times, STOP 1, A1142
Stopping Distances and Stopping Times, STOP 1, A2144
Stopping Distances and Stopping Times, STOP 1, A3146
Stopping Distances and Times, KR 50 R2500 and KR 50 R2500 F146
Stopping Distances and Stopping Times, STOP 0, A1 to A3146
Stopping Distances and Stopping Times, STOP 1, A1148
Stopping Distances and Stopping Times, STOP 1, A2150
Stopping Distances and Stopping Times, STOP 1, A3152
Stopping Distances and Times, KR 70 R2100 and KR 70 R2100 F152
Stopping Distances and Stopping Times, STOP 0, A1 to A3152
Stopping Distances and Stopping Times, STOP 1, A1154
Stopping Distances and Stopping Times, STOP 1, A2156
Stopping Distances and Stopping Times, STOP 1, A3158
Planning159
Information for Planning159
Mounting Base with Centering159
Machine Frame Mounting161
Connecting Cables and Interfaces163
Transportation167
Transporting the Robot167
Start-Up and Recommissioning171
Overview of Start-Up and Recommissioning171
Starting up Robots (Mounting Base)171
Installing KR IONTEC Fork Slots173
Installing the Robot with a Mounting Base173
Removing KR IONTEC Fork Slots176
Connecting the Connecting Cables177
Concluding Work177
Starting up Robots (Machine Frame Mounting)178
Installing KR IONTEC Fork Slots180
Installing the Machine Frame Mounting Assembly180
Removing KR IONTEC Fork Slots181
Connecting the Connecting Cables182
Concluding Work183
Description of the Connecting Cables183
Description of Overtravel Protection on Axis 4187
Maintenance189
Maintenance Overview189
Maintenance Table, KR IONTEC KR 20 R3100190
Maintenance Table, KR IONTEC Standard and Foundry Variants192
Greasing Cable Set A1195
Checking and Greasing Cable Set A1196
Concluding Work197
Oil Change in A1197
Draining the Gear Oil from A1198
Filling Gear Unit A1 with Gear Oil199
Concluding Work200
Oil Change in A2200
Draining the Gear Oil from A2201
Filling Gear Unit A2 with Gear Oil202
Concluding Work203
Oil Change in A3203
Draining the Gear Oil from A3205
Filling Gear Unit A3 with Gear Oil205
Concluding Work206
Oil Change in A4206
Draining the Gear Oil from A4208
Filling Gear Unit A4 with Gear Oil208
Concluding Work209
Oil Change in A5210
Draining the Gear Oil from A5211
Filling Gear Unit A5 with Gear Oil212
Concluding Work213
Oil Change in A6213
Draining the Gear Oil from A6215
Filling Gear Unit A6 with Gear Oil215
Concluding Work217
Kr 20 R3100217
Oil Change in A4217
Draining the Gear Oil from A4218
Filling Gear Unit A4 with Gear Oil219
Concluding Work220
Oil Change in A5220
Draining the Gear Oil from A5222
Filling Gear Unit A5 with Gear Oil223
Concluding Work223
Oil Change in A6223
Draining the Gear Oil from A6225
Filling Gear Unit A6 with Gear Oil226
Concluding Work227
Cleaning the Robot227
Cleaning228
Concluding Work228
Repair229
Exchanging Motor A1229
Removing Motor A1230
Installing Motor A1231
Concluding Work232
Exchanging Motor A2233
Securing the Link Arm235
Removing Motor A2235
Installing Motor A2236
Removing the Equipment Securing the Link Arm237
Concluding Work238
Exchanging Motor A3238
Securing the In-Line Wrist and Robot Arm240
Removing Cover A3241
Removing Motor A3242
Installing Motor A3243
Mounting the Cover244
Removing the Equipment Securing the In-Line Wrist and Robot Arm245
Concluding Work246
KR IONTEC Foundry246
Exchanging Motor A1246
Removing Motor A1248
Installing Motor A1249
Concluding Work250
Exchanging Motor A2251
Securing the Link Arm252
Removing Motor A2253
Installing Motor A2254
Removing the Equipment Securing the Link Arm255
Concluding Work256
Kr 20 R3100256
Exchanging Motor A4256
Securing the In-Line Wrist and Robot Arm258
Removing Cover A3259
Removing Motor A4260
Installing Motor A4261
Mounting the Cover262
Removing the Equipment Securing the In-Line Wrist and Robot Arm263
Concluding Work264
Exchanging Motor A5264
Securing the In-Line Wrist and Robot Arm266
Removing Cover A3267
Removing Motor A5268
Installing Motor A5269
Mounting the Cover270
Removing the Equipment Securing the In-Line Wrist and Robot Arm271
Concluding Work272
Exchanging Motor A6 and In-Line Wrist272
Securing the In-Line Wrist and Robot Arm274
Removing Cover A3275
Removing Motor A4276
Removing Motor A5277
Removing Motor A6 and In-Line Wrist278
Preparing the New In-Line Wrist278
Installing Motor A6 and In-Line Wrist279
Installing Motor A5280
Installing Motor A4281
Mounting the Cover283
Removing the Equipment Securing the In-Line Wrist and Robot Arm284
Concluding Work285
Exchanging the Connecting Shafts285
Securing the In-Line Wrist and Robot Arm287
Removing Cover A3288
Removing Motor A4289
Removing Motor A5290
Installing Motor A5291
Installing Motor A4292
Mounting the Cover294
Removing the Equipment Securing the In-Line Wrist and Robot Arm295
Concluding Work296
Description of the Electrical Installations296
Decommissioning, Storage and Disposal311
Decommissioning311
Moving the Robot into Its Transport Position311
Removing the Robot312
Concluding Work313
Storage313
Removing the Robot315
Cleaning316
Preparing for Storage316
Concluding Work316
Disposal316
Options319
Release Device319
Starting up the Release Device319
Installing the Release Device320
Moving the Manipulator Without Drive Energy322
Concluding Work324
Purge Option a324
Purge Option B325
Purge Option C327
Starting up PURGE Option C328
Installing PURGE Option C329
Concluding Work330
Purge Option D331
Starting up PURGE Option D332
Installing PURGE Option D333
Concluding Work334
Appendix335
Tightening Torques335
Auxiliary and Operating Materials Used336
Applied Standards and Regulations337
KUKA Service339
Requesting Support339
KUKA Customer Support339
Index341

Kuka IONTECKR 70 R2100 - Page 185

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