Ma KR120R3200 Pa

Robots
KR QUANTEC PA
With HO and arctic Variants
Assembly Instructions
Issued: 02.06.2021
MA KR QUANTEC PA V11
KUKA Deutschland GmbH
KR QUANTEC PA
© Copyright 2021
KUKA Deutschland GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties
without the express permission of KUKA Deutschland GmbH.
Other functions not described in this documentation may be operable in the controller. The user
has no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and soft-
ware described. Nevertheless, discrepancies cannot be precluded, for which reason we are not
able to guarantee total conformity. The information in this documentation is checked on a regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation
Publication: Pub MA KR QUANTEC PA (PDF) en

PB1832
Book structure: MA KR QUANTEC PA V12.1

BS3989
Version: MA KR QUANTEC PA V11
2/240 | www.kuka.com MA KR QUANTEC PA V11 | Issued: 02.06.2021

KR QUANTEC PA
Contents
1 Introduction.............................................................................................. 7
1.1 Target group.......................................................................................................... 7
1.2 Industrial robot documentation.............................................................................. 7
1.3 Representation of warnings and notes................................................................. 7
1.4 Terms used............................................................................................................ 8
2 Product description................................................................................. 11
2.1 Overview of the robot system............................................................................... 11
2.2 Description of the manipulator.............................................................................. 12
2.3 Intended use and misuse...................................................................................... 14
3 Safety......................................................................................................... 17
3.1 General.................................................................................................................. 17
3.1.1 Disclaimer.............................................................................................................. 17
3.1.2 EC declaration of conformity and declaration of incorporation............................ 18
3.1.3 Terms in the “Safety” chapter............................................................................... 18
3.2 Personnel............................................................................................................... 20
3.3 Workspace, safety zone and danger zone........................................................... 21
3.4 Overview of protective equipment........................................................................ 21
3.4.1 Mechanical end stops........................................................................................... 22
3.4.2 Mechanical axis limitation (optional)..................................................................... 22
3.4.3 Options for moving the manipulator without drive energy................................... 22
3.4.4 Labeling on the industrial robot............................................................................ 23
3.5 Safety measures.................................................................................................... 23
3.5.1 General safety measures...................................................................................... 23
3.5.2 Transportation........................................................................................................ 25
3.5.3 Start-up and recommissioning.............................................................................. 25
3.5.4 Manual mode......................................................................................................... 27
3.5.5 Automatic mode..................................................................................................... 28
3.5.6 Maintenance and repair........................................................................................ 28
3.5.7 Decommissioning, storage and disposal.............................................................. 30
4 Technical data.......................................................................................... 31
4.1 Technical data, overview....................................................................................... 31
4.2 Technical data, KR 120 R3200 PA....................................................................... 33
4.2.1 Basic data, KR 120 R3200 PA............................................................................. 33
4.2.2 Axis data, KR 120 R3200 PA............................................................................... 34
4.2.3 Payloads, KR 120 R3200 PA............................................................................... 37
4.2.4 Foundation loads, KR 120 R3200 PA.................................................................. 41
4.3 Technical data, KR 120 R3200 PA arctic............................................................. 42
4.3.1 Basic data, KR 120 R3200 PA arctic................................................................... 42
4.3.2 Axis data, KR 120 R3200 PA arctic..................................................................... 44
4.3.3 Payloads, KR 120 R3200 PA arctic..................................................................... 46
4.3.4 Foundation loads, KR 120 R3200 PA arctic........................................................ 50
4.4 Technical data, KR 120 R3200 PA-HO................................................................ 51
4.4.1 Basic data, KR 120 R3200 PA-HO...................................................................... 51
4.4.2 Axis data, KR 120 R3200 PA-HO........................................................................ 53
MA KR QUANTEC PA V11 | Issued: 02.06.2021 www.kuka.com | 3/240

KR QUANTEC PA
4.4.3 Payloads, KR 120 R3200 PA-HO......................................................................... 55

4.4.4 Foundation loads, KR 120 R3200 PA-HO............................................................ 59
4.5.1 Basic data, KR 180 R3200 PA............................................................................. 60
4.5.2 Axis data, KR 180 R3200 PA............................................................................... 62
4.5.3 Payloads, KR 180 R3200 PA............................................................................... 64
4.8.1 Basic data, KR 240 R3200 PA............................................................................. 87
4.8.2 Axis data, KR 240 R3200 PA............................................................................... 89
4.8.3 Payloads, KR 240 R3200 PA............................................................................... 91
4.11 Supplementary load............................................................................................... 114
4.12 Plates and labels................................................................................................... 116
4.13 REACH duty to communicate information acc. to Art. 33................................... 119
4.14 Stopping distances and times............................................................................... 120
4.14.1 General information............................................................................................... 120
4.14.2 Stopping distances and times, KR 120 R3200 PA, KR 120 R3200 PA arctic
and KR 120 R3200 PA-HO................................................................................... 120
4.14.2.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 120
4.14.2.2 Stopping distances and stopping times, STOP 1, A1.......................................... 121
and KR 180 R3200 PA-HO................................................................................... 125
4.14.3.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 125

KR QUANTEC PA
and KR 240 R3200 PA-HO................................................................................... 131
4.14.4.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3................ 131
4.14.4.2 Stopping distances and stopping times for STOP 1, axis 1 .............................. 133
4.14.4.3 Stopping distances and stopping times for STOP 1, axis 2................................ 135
4.14.4.4 Stopping distances and stopping times for STOP 1, axis 3................................ 137
5 Planning.................................................................................................... 139
5.1 Information for planning........................................................................................ 139
5.2 Mounting base with centering............................................................................... 139
5.3 Machine frame mounting....................................................................................... 142
5.4 Connecting cables and interfaces......................................................................... 143
6 Transportation.......................................................................................... 147
6.1 Transporting the robot........................................................................................... 147
7 Start-up and recommissioning............................................................... 151

7.1 Installing the mounting base................................................................................. 151
7.2 Installing the machine frame mounting assembly................................................ 152
7.3 Installing the robot................................................................................................. 153
7.4 Description of the connecting cables.................................................................... 154
7.5 Moving the manipulator without drive energy...................................................... 157
8 Maintenance.............................................................................................. 159
8.1 Maintenance overview........................................................................................... 159
8.1.1 Maintenance table................................................................................................. 160
8.2 Oil change in A1................................................................................................... 165
8.2.1 Draining the gear oil from A1............................................................................... 166
8.2.2 Filling gear unit A1 with gear oil........................................................................... 167
8.3 Oil change in A2................................................................................................... 168
8.4 Oil change in A3................................................................................................... 170
8.4.2 Filling with gear oil on A3..................................................................................... 171
8.5 Oil change in A5................................................................................................... 172
8.5.1 Draining the gear oil on A5.................................................................................. 173
8.5.2 Filling the gear oil on A5...................................................................................... 173
8.6 Oil change in A6................................................................................................... 174
8.7 Checking the counterbalancing system................................................................ 176
8.7.1 Checking the counterbalancing system................................................................ 177
8.8 Greasing the cable set.......................................................................................... 177
8.9 Cleaning the robot................................................................................................. 178
8.10 Exchanging the counterbalancing system on a floor-mounted robot.................. 179
8.10.1 Removing the counterbalancing system............................................................... 180
8.10.2 Installing the counterbalancing system................................................................. 182
9 Setting....................................................................................................... 187
9.1 Counterbalancing system ..................................................................................... 187

KR QUANTEC PA
9.2 Depressurizing the counterbalancing system on a floor-mounted robot............. 187

9.2.1 Depressurizing the counterbalancing system....................................................... 187
9.3 Filling and adjusting the counterbalancing system on a floor-mounted robot..... 188
9.3.1 Filling and adjusting the counterbalancing system.............................................. 189
10 Repair........................................................................................................ 195
10.1 Exchanging motor A1............................................................................................ 195
10.1.1 Removing the motor on axis 1............................................................................. 196
10.1.2 Installing the motor on axis 1............................................................................... 196
10.6 Description of the electrical installations (robot).................................................. 208
11 Decommissioning, storage and disposal............................................. 219

11.1 Decommissioning................................................................................................... 219
11.2 Storage.................................................................................................................. 220
11.3 Disposal................................................................................................................. 221
12 Options...................................................................................................... 223
12.1 Control cable for single axis (optional)................................................................. 223
12.2 Release device (optional)...................................................................................... 223
13 Appendix................................................................................................... 225
13.1 Tightening torques................................................................................................. 225
13.2 Tightening torque for stainless steel screws........................................................ 226
13.3 Auxiliary and operating materials used................................................................ 226
13.4 Information sheet for products.............................................................................. 227
13.5 Applied standards and regulations....................................................................... 233
14 KUKA Service........................................................................................... 235

14.1 Requesting support............................................................................................... 235
14.2 KUKA Customer Support...................................................................................... 235
Index 237

KR QUANTEC PA
Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and

skills:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• Knowledge of the robot controller system
For optimal use of KUKA products, we recommend the training courses

offered by KUKA College. Information about the training program can be
found at www.kuka.com or can be obtained directly from our subsidia-
ries.
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:
• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2 (if used)
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts overview in KUKA Xpert
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety
These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.
WARNING
These warnings mean that death or severe injuries may occur, if no
precautions are taken.
CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.
NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.
These warnings contain references to safety-relevant information or gen-

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

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

Introduction
edy emergencies or malfunctions:

SAFETY INSTRUCTION
The following procedure must be followed exactly!
Procedures marked with this warning must be followed exactly.
Notices
These notices serve to make your work easier or contain references to

further information.
Tip to make your work easier or reference to further information.
1.4 Terms used
The overview may contain terms symbols that are not relevant for this
document.
Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may
move. The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance

The stopping distance is part of the danger zone.
Workspace Area within which the robot may move. The workspace is derived
from the individual axis ranges.
Arctic Arctic
for use in temperature ranges under 0°
Extension Distance (l in %) between axis 1 and the intersection of axes 4 and

5. With parallelogram robots, the distance between axis 1 and the
intersection of axis 6 and the mounting flange.
C Ceiling
CR Clean Room
Designation for KUKA products developed for use in cleanrooms.
EDS Electronic Data Storage

(memory card)
EX Explosion-proof zone
F Foundry

KR QUANTEC PA
Introduction
F exclusive Foundry exclusive
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
HA High Accuracy
HM Hygienic Machine
For the primary and secondary foodstuffs industries
HO Hygienic Oil
For the secondary foodstuffs industry
HP High Protection
HW Hollow Wrist
K Shelf-mounted
KCP KUKA Control Panel

Teach pendant for the KR C2/KR C2 edition2005
The KCP has all the operator control and display functions required
for operating and programming the industrial robot.
KR C KUKA Robot Control

Robot controller
KS Shelf-mounted, small
KUKA smartPAD see “smartPAD”
KUKA smartPAD-2 see “smartPAD”
Manipulator The robot arm and the associated electrical installations
MT Machine Tooling
P Press-to-press robot
PA Palletizer
Phi Angle of rotation (°) about the corresponding axis. This value can
be entered in the controller via the teach pendant, from which it
can be read.
POV Program override (%) = velocity of the robot motion. This value can
be entered in the controller via the teach pendant, from which it
can be read.
RDC Resolver Digital Converter

The resolver digital converter is used to acquire motor data (e.g.
position data, motor temperatures).
SC Special Connection
SE Second Encoder
SI Safe Interaction
SL Washdown

Introduction KR QUANTEC PA
smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the industrial robot. 2 models
exist:
• smartPAD
• smartPAD-2
In turn, for each model there are variants, e.g. with different lengths
of connecting cables.
For robot controllers of the KR C5 series, only the model “smart-
PAD-2” is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to both models unless an explicit distinc-
tion is made.
Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.
• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a
path-maintaining braking ramp.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
W Wall
WP Waterproof
External axis Motion axis which is not part of the manipulator but is controlled by
the robot controller, e.g. KUKA linear unit, turn-tilt table, positioner.

KR QUANTEC PA
Product description
2 Product description
2.1 Overview of the robot system
A robot system (>>> Fig. 2-1) comprises all the assemblies of an industri-
al robot, including the manipulator (mechanical system and electrical in-
stallations), control cabinet, connecting cables, end effector (tool) and oth-
er equipment. The KR QUANTEC PA product family comprises the var-
iants:
• KR 120 R3200 PA
• KR 180 R3200 PA
• KR 240 R3200 PA
These robots are also available as HO variants (operation in the vicinity of
foodstuffs) or arctic variants (operation in deep-freeze environments). All
data and specifications described in this documentation also apply to all
HO and arctic variants except where reference is explicitly made to differ-
ences.
An industrial robot of this type comprises the following components:
• Manipulator
• Robot controller
• Connecting cables
• Teach pendant KCP (KUKA smartPAD)
• Software
• Options, accessories
Fig. 2-1: Example of a robot system
1 Manipulator 3 KR C4 robot controller

2 Connecting cables 4 Teach pendant KCP (KUKA
smartPAD)

Product description KR QUANTEC PA
2.2 Description of the manipulator
Overview
The manipulators (= robot arm and electrical installations) (>>> Fig. 2-2)
of the KR QUANTEC PA variants are designed as 5-axis jointed-arm kine-
matic systems.
“HO” variant manipulators have increased corrosion protection and a spe-
cial type of gear oil that is ideally suited to operation in the vicinity of
foodstuffs.
In accordance with their field of application, the “arctic variants” are like-
wise equipped with a particularly suitable type of gear oil and additional
features that assure operation in deep-freeze environments.
A manipulator consists of the following principal components:
• Wrist
• Arm
• Link arm
• Rotating column
• Base frame
• Counterbalancing system
• Electrical installations (arctic)
Fig. 2-2: Main assemblies of the manipulator
1 Wrist 5 Electrical installations

2 Arm 6 Base frame
3 Link arm 7 Rotating column
4 Counterbalancing system

KR QUANTEC PA
Product description
Wrist
The robot variants KR 120 R3200 PA, KR 180 R3200 PA and KR 240
R3200 PA are equipped with a two-axis wrist for rated payloads of
120 kg, 180 kg or 240 kg. The wrist is fastened to the arm via a gear unit
and motor and is driven by these. The main components of the hollow-
shaft wrist are the swing frame, axis 6 motor and the corresponding gear
unit. The mounting flange embodies the output side of axis 6. The motor
unit consists of a brushless AC servomotor with a permanent-magnet sin-
gle-disk brake and hollow-shaft resolver, both integrated. The permanent-
magnet single-disk brake performs a holding function when the
servomotor is at rest and contributes to the braking of axis 6 in the event
of short-circuit braking (e.g. if one or more of the enabling switches is re-
leased while in Test mode). Short-circuit braking must not be used to stop
the robot under normal circumstances. End effectors can be attached to
the mounting flange of axis 6. The wrist is designed as a hollow-shaft
wrist and features a through-hole with a diameter of 60 mm.
The assembly also has a gauge mount with a gauge cartridge, through
which the mechanical zero of the axis can be determined by means of a
dial gauge or an electronic probe (accessory) and transferred to the con-
troller.
Arm
The arm is the transmission element between the wrist and the link arm.
The swing frame of the wrist is mounted on the arm via gear unit A5. This
motor/gear combination embodies axis 5, which cannot be freely control-
led during operation. The arm is driven by an AC servomotor via gear unit
A3, which is installed between the arm and the link arm. This gear unit is
also the bearing for the arm. The motor of axis 3 is screwed to the arm.
The maximum permissible swivel angle is mechanically limited by a stop
for each direction, plus and minus. The buffers are attached to the arm.
The corresponding stops are situated on the link arm.
Link arm
The link arm is the assembly located between the arm and the rotating
column. It is mounted on one side of the rotating column via the gear unit
of axis 2 and is driven by an AC servomotor. During motion about axis 2,
the link arm moves about the stationary rotating column. The cable har-
ness of the electrical installations is routed inside the link arm and is
mounted in hinged clamps. There is an interface on the link arm with 4
holes for fastening supplementary loads.
Rotating column
The rotating column houses the motors of axes 1 and 2. The rotational
motion of axis 1 is performed by the rotating column. It is screwed to the
base frame via the gear unit of axis 1. The AC servomotor for driving axis
1 is mounted inside the rotating column. The counterbearing for the coun-
terbalancing system is integrated into the rear of the rotating column hous-
ing.
Base frame
The base frame is the base of the robot. It is screwed to the mounting
base. The interfaces for the electrical installations and the energy supply
systems (accessory) are housed in the base frame. The base frame and
rotating column are connected via the gear unit of axis 1. The flexible
tube for the electrical installations and the energy supply system is accom-
modated in the base frame.

Counterbalancing system
The counterbalancing system is installed between the rotating column and

the link arm and serves to minimize the moments generated about axis 2
when the robot is in motion and at rest. A closed, hydropneumatic system
is used. The system consists of two accumulators, a hydraulic cylinder
with associated hoses and a pressure gauge. A bursting disc serves as a
safety element to protect against overload when filling the counterbalanc-
ing system.
The accumulators are classified below category I, fluid group 2, of the
Pressure Equipment Directive.
The arctic variants are equipped with a counterbalancing system suitable
for deep-freeze environments.
Electrical installations
The electrical installations are described in the operating instructions, in

the chapter “Repair” (>>> 10 "Repair" Page 195).
The arctic variants are equipped with electrical installations suitable for
deep-freeze environments and an “RDC cool”.
NOTICE
If the RDC is exchanged, it is imperative to make sure that only an
“RDC cool” is installed. Failure to do so is liable to result in irregular
motion characteristics and malfunctions!
Options
The robot can be fitted and operated with various options, such as energy
supply systems from axis 1 to axis 6, range limitation systems or a control
cable for single axis. The options are described in separate documenta-
tion.
2.3 Intended use and misuse
Intended use
The industrial robot is intended for handling tools and fixtures or for pro-
cessing and transferring components or products. Use is only permitted
under the specified environmental conditions.
Operation of the industrial robot in accordance with its intended use also
requires compliance with the operating and assembly instructions for the
individual components, with particular reference to the maintenance speci-
fications.
Misuse
Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. It will result in the loss of warranty and liability
claims. KUKA is not liable for any damage resulting from such misuse.
This includes e.g.:
• Use as a climbing aid
• Operation outside the specified operating parameters
• Operation without the required safety equipment
• Transportation of persons and animals
• Outdoor operation.
• Use in a potentially explosive area
• Use in radioactive environments

KR QUANTEC PA
Product description
• Operation in underground mining
NOTICE
Deviations from the operating conditions specified in the technical data
or the use of special functions or applications can lead to premature
wear. KUKA Deutschland GmbH must be consulted.
The robot system is an integral part of a complete system and may only
be operated in a CE-compliant system.


KR QUANTEC PA
Safety
3 Safety
3.1 General
• This “Safety” chapter refers to a mechanical component of an indus-

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

component thereof.
Components of the industrial robot:
• Manipulator
• Robot controller
• Teach pendant
• Connecting cables
• External axes (optional)
e.g. linear unit, turn-tilt table, positioner
• Software
• Options, accessories
The industrial robot is built using state-of-the-art technology and in accord-
ance with the recognized safety rules. Nevertheless, misuse of the indus-
trial robot may constitute a risk to life and limb or cause damage to the
industrial robot and to other material property.
The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons who
are fully aware of the risks involved in its operation. Use of the industrial
robot is subject to compliance with this document and with the declaration
of incorporation supplied together with the industrial robot. Any functional
disorders, especially those affecting safety, must be rectified immediately.
Safety information
Information about safety may not be construed against the manufacturer.

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

Safety KR QUANTEC PA
3.1.2 EC declaration of conformity and declaration of incorporation
The industrial robot constitutes partly completed machinery as defined by

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

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

ration in accordance with Annex II B of the Machinery Directive
2006/42/EC. The assembly instructions and a list of essential require-
ments complied with in accordance with Annex I are integral parts of this
declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly
completed machinery is not allowed until the partly completed machinery
has been incorporated into machinery, or has been assembled with other
parts to form machinery, and this machinery complies with the terms of
the EC Machinery Directive, and the EC declaration of conformity is
present in accordance with Annex II A.
3.1.3 Terms in the “Safety” chapter
Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may
move. The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance

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

KR QUANTEC PA
Safety
Service life The service life of a safety-relevant component begins at the time
of delivery of the component to the customer.
The service life is not affected by whether the component is used
or not, as safety-relevant components are also subject to aging dur-
ing storage.
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
KCP KUKA Control Panel

Teach pendant for the KR C2/KR C2 edition2005
The KCP has all the operator control and display functions required
for operating and programming the industrial robot.
KUKA smartPAD see “smartPAD”
KUKA smartPAD-2 see “smartPAD”
Manipulator The robot arm and the associated electrical installations
Safety zone The safety zone is situated outside the danger zone.
Safety options Generic term for options which make it possible to configure addi-
tional safe monitoring functions in addition to the standard safety
functions.
Example: SafeOperation
smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the industrial robot. 2 models
exist:
• smartPAD
• smartPAD-2
In turn, for each model there are variants, e.g. with different lengths
of connecting cables.
For robot controllers of the KR C5 series, only the model “smart-
PAD-2” is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to both models unless an explicit distinc-
tion is made.
Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.


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

Note: This stop category is called STOP 1 - DRS in this document.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a
path-maintaining braking ramp.
System integrator The system integrator is responsible for safely integrating the indus-
(plant integrator) trial robot into a complete system and commissioning it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Motion axis which is not part of the manipulator but is controlled by
the robot controller, e.g. KUKA linear unit, turn-tilt table, positioner.
3.2 Personnel
The following persons or groups of persons are defined for the industrial
robot:
• User
• Personnel
Qualification of personnel
Work on the system must only be performed by personnel that is able
to assess the tasks to be carried out and detect potential hazards.
Death, severe injuries or damage to property may otherwise result. The
following qualifications are required:
• Adequate specialist training, knowledge and experience
• Knowledge of the relevant operating or assembly instructions, knowl-
edge of the relevant standards
• All persons working with the industrial robot must have read and un-
derstood the industrial robot documentation, including the safety
chapter.
User
The user must observe the labor laws and regulations. This includes e.g.:
• The user must comply with his monitoring obligations.

• The user must carry out briefing at defined intervals.
• The user must comply with the regulations relating to personal protec-
tive equipment (PSA).
Personnel
Personnel must be instructed, before any work is commenced, in the type

of work involved and what exactly it entails as well as any hazards which

KR QUANTEC PA
may exist. Instruction must be carried out regularly. Instruction is also re-
Safety
quired after particular incidents or technical modifications.
Personnel includes:
• System integrator
• Operators, subdivided into:
‒ Start-up, maintenance and service personnel
‒ Operating personnel
‒ Cleaning personnel
System integrator
The industrial robot is safely integrated into a complete system by the sys-
tem integrator.
The system integrator is responsible for the following tasks:
• Installing the industrial robot

• Connecting the industrial robot
• Performing risk assessment
• Implementing the required safety functions and safeguards
• Issuing the EC declaration of conformity
• Attaching the CE mark
• Creating the operating instructions for the system
Operators
The operator must meet the following preconditions:

• The operator must be trained for the work to be carried out.
• Work on the system must only be carried out by qualified personnel.
These are people who, due to their specialist training, knowledge and
experience, and their familiarization with the relevant standards, are
able to assess the work to be carried out and detect any potential
hazards.
3.3 Workspace, safety zone and danger zone
Workspaces are to be restricted to the necessary minimum size. A work-

space must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone.
In the case of a stop, the manipulator and external axes (optional) are
braked and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of
the manipulator and external axes (optional). It must be safeguarded by
means of physical safeguards to prevent danger to persons or the risk of
material damage.
3.4 Overview of protective equipment
The protective equipment of the mechanical component may include:
• Mechanical end stops

• Mechanical axis limitation (optional)
• Release device (optional)
• Brake release device (optional)

• Labeling of danger areas

Not all equipment is relevant for every mechanical component.
3.4.1 Mechanical end stops
Depending on the robot variant, the axis ranges of the main and wrist ax-
es of the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.
WARNING
Danger to life and limb following collision with obstacle
If the manipulator or an external axis hits an obstruction or a mechani-
cal end stop or mechanical axis limitation, the manipulator can no
longer be operated safely. Death, injuries or damage to property may re-
sult.
• Put manipulator out of operation.
• KUKA must be consulted before it is put back into operation.
3.4.2 Mechanical axis limitation (optional)
Some manipulators can be fitted with adjustable mechanical axis limitation

systems in axes A1 to A3. The axis limitation systems restrict the working
range to the required minimum. This increases personal safety and pro-
tection of the system.
In the case of manipulators that are not designed to be fitted with me-
chanical axis limitation, the workspace must be laid out in such a way that
there is no danger to persons or material property, even in the absence of
mechanical axis limitation.
If this is not possible, the workspace must be limited by means of photo-
electric barriers, photoelectric curtains or mechanical limitations on the
system side. There must be no shearing or crushing hazards at the load-
ing and transfer areas.
This option is not available for all robot models. Information on specific
robot models can be obtained from the manufacturer.
3.4.3 Options for moving the manipulator without drive energy
Qualification of personnel with regard to behavior in emergency

situations
In emergencies or other exceptional situations, it may be necessary to
move the manipulator without drive energy.
• Personnel must be trained in how to move the manipulator without
drive energy.
Description
The following options are available for moving the manipulator without
drive energy after an accident or malfunction:
• Release device (optional)
The release device can be used for the main axis drive motors and,
depending on the robot variant, also for the wrist axis drive motors.

KR QUANTEC PA
Safety
• Brake release device (option)
The brake release device is designed for robot variants whose motors
are not freely accessible.
• Moving the wrist axes directly by hand
There is no release device available for the wrist axes of variants in
the low payload category. This is not necessary because the wrist ax-
es can be moved directly by hand.
Information about the options available for the various robot models and
about how to use them can be found in the assembly and operating in-
structions for the robot or can be requested from the manufacturer.
NOTICE
Damage to property due to moving the manipulator without drive
energy
Moving the manipulator without drive energy can damage the motor
brakes of the axes concerned.
• Only move the manipulator without drive energy in emergencies,
e.g. for rescuing persons.
• Perform brake test.
• The motor must be replaced if the brake has been damaged.
3.4.4 Labeling on the industrial robot
All plates, labels, symbols and marks constitute safety-relevant parts of

the industrial robot. They must not be modified or removed.
Labeling on the industrial robot consists of:
• Identification plates
• Warning signs
• Safety symbols
• Designation labels
• Cable markings
• Rating plates
Further information is contained in the technical data of the operating in-

structions or assembly instructions of the components of the industrial
robot.
3.5 Safety measures
3.5.1 General safety measures
The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons. Op-
erator errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial ro-
bot even after the robot controller has been switched off and locked out.
Incorrect installation (e.g. overload) or mechanical defects (e.g. brake de-
fect) can cause the manipulator or external axes to sag. If work is to be
carried out on a switched-off industrial robot, the manipulator and external
axes must first be moved into a position in which they are unable to move
on their own, whether the payload is mounted or not. If this is not possi-

KR QUANTEC PA
ble, the manipulator and external axes must be secured by appropriate

Safety
means.
DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.
DANGER
Danger to life and limb of persons under the robot arm
Sagging or falling parts can cause death or serious injuries. This applies
at all times, e.g. also for assembly tasks or with the controller switched
off.
• Never loiter under the robot arm.
CAUTION
Risk of burns from hot motors
The motors reach temperatures during operation which can cause
burns.
• Avoid contact.
• Take appropriate safety precautions, e.g. wear protective gloves.
KCP/smartPAD
The user must ensure that the industrial robot is only operated with the
KCP/smartPAD by authorized persons.
If more than one KCP/smartPAD is used in the overall system, it must be
ensured that each device is unambiguously assigned to the corresponding
industrial robot. They must not be interchanged.
WARNING
The operator must ensure that decoupled KCPs/smartPADs are immedi-
ately removed from the system and stored out of sight and reach of per-
sonnel working on the industrial robot. This serves to prevent operation-
al and non-operational EMERGENCY STOP devices from becoming in-
terchanged.
Failure to observe this precaution may result in death, severe injuries or
considerable damage to property.
External keyboard, external mouse
An external keyboard and/or external mouse may only be used if the fol-
lowing conditions are met:
• Start-up or maintenance work is being carried out.

• The drives are switched off.
• There are no persons in the danger zone.
The KCP/smartPAD must not be used as long as an external keyboard
and/or external mouse are connected to the control cabinet.
The external keyboard and/or external mouse must be removed from the
control cabinet as soon as the start-up or maintenance work is completed
or the KCP/smartPAD is connected.

KR QUANTEC PA
Safety
Modifications
After modifications to the industrial robot, checks must be carried out to

ensure the required safety level. The valid national or regional work safety
regulations must be observed for this check. The correct functioning of all
safety functions must also be tested.
New or modified programs must always be tested first in Manual Reduced
Velocity mode (T1).
After modifications to the industrial robot, existing programs must always
be tested first in Manual Reduced Velocity mode (T1). This applies to all
components of the industrial robot and includes e.g. modifications of the
external axes or to the software and configuration settings.
Faults
The following tasks must be carried out in the case of faults in the indus-
trial robot:
• Switch off the robot controller and secure it (e.g. with a padlock) to
prevent unauthorized persons from switching it on again.
• Indicate the fault by means of a label with a corresponding warning
(tagout).
• Keep a record of the faults.
• Eliminate the fault and carry out a function test.
3.5.2 Transportation
Manipulator
The prescribed transport position of the manipulator must be observed.

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

Transportation must be carried out in accordance with the operating in-
structions or assembly instructions of the robot controller.
damage to the robot controller.
External axis (optional)
The prescribed transport position of the external axis (e.g. KUKA linear
unit, turn-tilt table, positioner) must be observed. Transportation must be
carried out in accordance with the operating instructions or assembly in-
structions of the external axis.
3.5.3 Start-up and recommissioning
Before starting up systems and devices for the first time, a check must be
carried out to ensure that the systems and devices are complete and op-
erational, that they can be operated safely and that any damage is detec-
ted.
The valid national or regional work safety regulations must be observed
for this check. The correct functioning of all safety circuits must also be
tested.

Changing default passwords

The KUKA System Software is supplied with default passwords for the
user groups. If the passwords are not changed, this enables unauthor-
ized persons to log on.
• Before start-up, change the passwords for the user groups.
• Only communicate the passwords to authorized personnel.
WARNING
Danger to life and limb due to incorrectly assigned cables
The robot controller is preconfigured for the specific industrial robot. The
manipulator and other components can receive incorrect data if they are
connected to a different robot controller. Death, severe injuries or dam-
age to property may result.
• Only connect the manipulator to the corresponding robot controller.
Do not impair safety functions

Additional components (e.g. cables and hoses) not supplied by KUKA
may be integrated into the industrial robot. If the safety functions are not
taken into consideration, this may result in death, severe injuries or
damage to property.
• Additional components must not impair or disable safety functions.
NOTICE
Damage to property due to condensation
If the internal cabinet temperature of the robot controller differs greatly
from the ambient temperature, condensation can form. This may result
in damage to property.
• Wait until the internal cabinet temperature has adapted to the ambi-
ent temperature in order to avoid condensation.
Function test
The following tests must be carried out before start-up and recommission-
ing:
It must be ensured that:
• The industrial robot is correctly installed and fastened in accordance

with the specifications in the documentation.
• There is no damage to the robot that could be attributed to external
forces. Example: Dents or abrasion that could be caused by an impact
or collision.
WARNING
Danger to life and limb resulting from external forces
External forces, such as an impact or a collision, can cause non-
visible damage. For example, it can lead to a gradual loss of drive
power from the motor, resulting in unintended movements of the ma-
nipulator.
Death, severe injuries or damage to property may result from non-
visible damage.
‒ Check the robot for damage that could have been caused by ex-
ternal forces, e.g. dents or abrasion of paintwork.
Check the motor and counterbalancing system particularly care-
fully.
‒ In the case of damage, the affected components must be ex-
changed.

KR QUANTEC PA
Safety
• There are no foreign bodies or defective or loose parts on the industri-
al robot.
• All required safety equipment is correctly installed and operational.
• The power supply ratings of the industrial robot correspond to the
local supply voltage and mains type.
• The ground conductor and the equipotential bonding cable are suffi-
ciently rated and correctly connected.
• The connecting cables are correctly connected and the connectors are
locked.
3.5.4 Manual mode
Manual mode is the mode for setup work. Setup work is all the tasks that
have to be carried out on the industrial robot to enable automatic opera-
tion. Setup work includes:
• Jog mode
• Teaching
• Programming
• Program verification
The following must be taken into consideration in manual mode:
• If the drives are not required, they must be switched off to prevent the
manipulator or the external axes (optional) from being moved uninten-
tionally.
• New or modified programs must always be tested first in Manual Re-
duced Velocity mode (T1).
• The manipulator, tooling or external axes (optional) must never touch
or project beyond the safety fence.
• Workpieces, tooling and other objects must not become jammed as a
result of the industrial robot motion, nor must they lead to
short-circuits or be liable to fall off.
• All setup work must be carried out, where possible, from outside the
safeguarded area.
If the setup work has to be carried out inside the safeguarded area, the
following must be taken into consideration:
In Manual Reduced Velocity mode (T1):
• If it can be avoided, there must be no other persons inside the safe-

guarded area.
If it is necessary for there to be several persons inside the safeguar-
ded area, the following must be observed:
‒ Each person must have an enabling device.
‒ All persons must have an unimpeded view of the industrial robot.
‒ Eye-contact between all persons must be possible at all times.
• The operator must be so positioned that he can see into the danger
area and get out of harm’s way.
In Manual High Velocity mode (T2):
• This mode may only be used if the application requires a test at a ve-
locity higher than possible in T1 mode.
• Teaching and programming are not permissible in this operating mode.

• Before commencing the test, the operator must ensure that the ena-
bling devices are operational.
• The operator must be positioned outside the danger zone.
• There must be no other persons inside the safeguarded area. It is the
responsibility of the operator to ensure this.
3.5.5 Automatic mode
Automatic mode is only permissible in compliance with the following safety

measures:
• All safety equipment and safeguards are present and operational.

• There are no persons in the system.
• The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for
no apparent reason, the danger zone must not be entered until an EMER-
GENCY STOP has been triggered.
3.5.6 Maintenance and repair
After maintenance and repair work, checks must be carried out to ensure
the required safety level. The valid national or regional work safety regula-
tions must be observed for this check. The correct functioning of all safety
functions must also be tested.
The purpose of maintenance and repair work is to ensure that the system
is kept operational or, in the event of a fault, to return the system to an
operational state. Repair work includes troubleshooting in addition to the
actual repair itself.
The following safety measures must be carried out when working on the
industrial robot:
• Carry out work outside the danger zone. If work inside the danger
zone is necessary, the user must define additional safety measures to
ensure the safe protection of personnel.
• Switch off the industrial robot and secure it (e.g. with a padlock) to
prevent it from being switched on again. If it is necessary to carry out
work with the robot controller switched on, the user must define addi-
tional safety measures to ensure the safe protection of personnel.
• If it is necessary to carry out work with the robot controller switched
on, this may only be done in operating mode T1.
• Label the system with a sign indicating that work is in progress. This
sign must remain in place, even during temporary interruptions to the
work.
• The EMERGENCY STOP devices must remain active. If safety func-
tions or safeguards are deactivated during maintenance or repair work,
they must be reactivated immediately after the work is completed.

KR QUANTEC PA
Safety
DANGER
Danger to life and limb due to live parts
The robot system must be disconnected from the mains power supply
prior to work on live parts. It is not sufficient to trigger an EMERGENCY
STOP or safety stop, because parts remain live. Death or severe inju-
ries may result.
• Before commencing work on live parts, turn off the main switch and
secure it against being switched on again.
If the controller variant in question does not have a main switch
(e.g. KR C5 micro), turn off the device switch then disconnect the
power cable and secure it so it cannot be reconnected.
• Then check to ensure that the system is deenergized.
• Inform the individuals involved that the robot controller is switched
off. (e.g. by affixing a warning sign)
Faulty components must be replaced using new components with the

same article numbers or equivalent components approved by the manu-
facturer for this purpose.
Cleaning and preventive maintenance work is to be carried out in accord-
ance with the operating instructions.
Robot controller
Even when the robot controller is switched off, parts connected to periph-
eral devices may still carry voltage. The external power sources must
therefore be switched off if work is to be carried out on the robot control-
ler.
The ESD regulations must be adhered to when working on components in
the robot controller.
Voltages in excess of 50 V (up to 780 V) can be present in various com-
ponents for several minutes after the robot controller has been switched
off! To prevent life-threatening injuries, no work may be carried out on the
industrial robot in this time.
On robot controllers with transformers, the transformers must be discon-
nected before working on components in the robot controller.
Water and dust must be prevented from entering the robot controller.
Some robot variants are equipped with a hydropneumatic, spring or gas

cylinder counterbalancing system.
• Counterbalancing system classified below category I: is subject to
the Pressure Equipment Directive but exempt from application of the
Pressure Equipment Directive according to Art. 4, para. 3 and there-
fore not CE marked.
• Counterbalancing system classified as category I or higher: is
subject to the Pressure Equipment Directive and CE marked as a
component (see rating plate of the counterbalancing system). The
pressure equipment is placed on the market in conjunction with partly
completed machinery. Conformity is expressed on the declaration of
incorporation according to the Machinery Directive.
The user must comply with the applicable national laws, regulations and
standards pertaining to pressure equipment.
• In Germany, the counterbalancing system is work equipment according
to the German Ordinance on Industrial Safety and Health (BetrSichV).
Inspection intervals in Germany in accordance with the Ordinance on

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

Safety
user before commissioning at the installation site.

• Inspection intervals in all other countries must be researched and ob-
served. As a rule, however, at least the maintenance intervals speci-
fied by KUKA must be observed. Shorter intervals are not permitted.
The following safety measures must be carried out when working on the
counterbalancing system:
• The assemblies supported by the counterbalancing systems must be
secured.
• Work on the counterbalancing systems must only be carried out by
qualified personnel.
Hazardous substances
The following safety measures must be carried out when handling hazard-
ous substances:
• Avoid prolonged and repeated intensive contact with the skin.
• Avoid breathing in oil spray or vapors.
• Clean skin and apply skin cream.
Use current safety data sheets

Knowledge of the safety data sheets of the substances and mixtures
used is a prerequisite for the safe use of KUKA products. Death,
injuries or damage to property may otherwise result.
• Request up-to-date safety data sheets from the manufacturers of
hazardous substances regularly.
3.5.7 Decommissioning, storage and disposal
The industrial robot must be decommissioned, stored and disposed of in

accordance with the applicable national laws, regulations and standards.

KR QUANTEC PA
Technical data
4 Technical data
4.1 Technical data, overview
The technical data for the individual robot types can be found in the fol-
lowing sections:
Robot Technical data
KR 120 R3200 PA • Technical data
(>>> 4.2 "Technical data, KR 120 R3200 PA" Page 33)
• Supplementary loads
(>>> 4.11 "Supplementary load" Page 114)
• Plates and labels
(>>> 4.12 "Plates and labels" Page 116)
• Stopping distances and times
(>>> 4.14.2 "Stopping distances and times, KR 120 R3200 PA,
KR 120 R3200 PA arctic and KR 120 R3200 PA-HO" Page 120)
arctic
(>>> 4.3 "Technical data, KR 120 R3200 PA arctic" Page 42)
KR 120 R3200 PA- • Technical data
HO
(>>> 4.4 "Technical data, KR 120 R3200 PA-HO" Page 51)

Technical data KR QUANTEC PA
Robot Technical data

arctic
HO
arctic
HO

KR QUANTEC PA
Technical data
4.2 Technical data, KR 120 R3200 PA
4.2.1 Basic data, KR 120 R3200 PA
Basic data
KR 120 R3200 PA
Number of axes 5
Number of controlled axes 4
Volume of working envelope 77.9 m³
Pose repeatability (ISO 9283) ± 0.06 mm
Weight approx. 1075 kg
Rated payload 120 kg
Maximum payload -
Maximum reach 3195 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP65
60529)
Sound level < 75 dB (A)
Mounting position Floor
Footprint 830 mm x 830 mm
Hole pattern: mounting surface for S934
kinematic system
Permissible angle of inclination ≤ 5 °
Default color Base frame: black (RAL 9005);
Moving parts: KUKA orange 2567
Controller KR C4
Transformation name KR C4: KR120R3200PA C4 FLR
Number of cycles 29.1 Cycles per minute

Time per cycle 2.06 s
Palletizing distance 400 mm / 2000 mm / 400 mm
Hollow shaft diameter

A1 139 mm (partially occupied by mo-
tor cables)
A6 60 mm
Ambient conditions
Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Ambient temperature
During operation 0 °C to 55 °C (273 K to 328 K)
During storage/transportation -40 °C to 60 °C (233 K to 333 K)
For operation at low temperatures, it may be necessary to warm up the

robot.

Connecting cables
Cable designation Connector designa- Interface with robot

tion
robot controller - ro-
bot
Motor cable X20 - X30 Harting connector
at both ends
Control cable X21 - X31 Rectangular connec-
tor
at both ends
Ground conductor / M8 ring cable lug at
equipotential bonding both ends
16 mm2
(optional)
Cable lengths 7 m, 15 m, 25 m, 35 m, 50 m
Max. cable length 50 m
Number of extensions 1
Minimum bending radius 5x D
4.2.2 Axis data, KR 120 R3200 PA
Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 155 °
A4 -
A5 -
A6 ±350 °
Speed with rated payload
A1 124 °/s
A2 115 °/s
A3 112 °/s
A4 -
A5 217 °/s
A6 242 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the diagram (>>> Fig. 4-1).

KR QUANTEC PA
Technical data
Fig. 4-1: Direction of rotation of robot axes
Mastering position
Mastering position
A1 -20 °
A2 -120 °
A3 120 °
A4 -
A5 90 °
A6 0 °
Working envelope
The following diagrams show the shape and size of the working envelope
for these variants of this product family.
The reference point for the working envelope is the intersection of the
center of the mounting flange face with axis 6.

Fig. 4-2: KR 120 R3200 PA, working envelope, side view
Fig. 4-3: KR 120 R3200 PA, working envelope, top view

KR QUANTEC PA
Technical data
4.2.3 Payloads, KR 120 R3200 PA
Payloads

Maximum payload -
Rated mass moment of inertia for 60 kgm²
flange Ix
flange Iy
flange Iz
Rated supplementary load, base -
frame
Maximum supplementary load, -
base frame
Rated supplementary load, rotating 0 kg
column
Maximum supplementary load, ro- 300 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 130 kg
arm
Rated supplementary load, arm 50 kg
Maximum supplementary load, arm 150 kg
Nominal distance to load center of gravity
Lxy 100 mm
Lz 300 mm
NOTICE
Exceeding the payloads and supplementary loads will reduce the serv-
ice life of the robot and overload the motors and the gears. We recom-
mend always testing the specific application with KUKA.Load. In cases
where individual values are exceeded, KUKA Deutschland GmbH must
be consulted.

Load center of gravity and mass moment of inertia
Fig. 4-4: Load center of gravity and mass moment of inertia
Parameter
Parameter/unit Description
Mass kg Payload mass
Lx, Ly, Lz mm Position of the center of mass in the reference
system
A, B, C Degrees Orientation of the principal inertia axes
• A: Rotation about the Z axis of the refer-

ence system
The result is a coordinate system named
CS'.
• B: Rotation about the Y axis of CS'
Result: CS''
• C: Rotation about the X axis of CS''
Note: A, B and C are not shown in the dia-
gram.
Mass moments of inertia:

Ix kgm2 Inertia about the X axis of the main axis sys-
tem
Iy kgm2 Inertia about the Y axis of the main axis sys-
tem
Iz kgm2 Inertia about the Z axis of the main axis sys-
tem
Lx, Ly, Lz and A, B, C unambiguously define the main axis system:
• The origin of the main axis system is the center of mass.
• A characteristic feature of the main axis system is that, among other
things, the maximum possible inertia occurs about one of the 3 coordi-
nate axes.
More information is contained in the KUKA.Load documentation.

KR QUANTEC PA
Technical data
Payload diagram
NOTICE
This loading curve corresponds to the maximum load capacity. Both val-
ues (payload and mass moment of inertia) must be checked in all ca-
ses. Exceeding this capacity will reduce the service life of the robot and
overload the motors and the gears; in any such case KUKA Deutsch-
land GmbH must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For commissioning the robot, additional input data are required
in accordance with the operating and programming instructions of the
KUKA System Software.
The mass inertia must be verified using KUKA.Load or KUKA Compose.
It is imperative for the load data to be entered in the robot controller!
Fig. 4-5: KR 120 R3200 PA, payload diagram
Mounting flange
Robot wrist type 120 kg

Mounting flange see drawing
Screw grade 10.9

Screw size M10
Number of fastening screws 11
Clamping length 1.5 x nominal diameter
Depth of engagement min. 12 mm, max. 16 mm
Locating element 10 H7
The mounting flange is depicted with axis 6 in the zero position
(>>> Fig. 4-6). The symbol Xm indicates the position of the locating ele-
ment (bushing) in the zero position.

Fig. 4-6: Mounting flange, adapter
Flange loads
Due to the motion of the payload (e.g. tool) mounted on the robot, forces
and torques act on the mounting flange. These forces and torques depend
on the motion profile as well as the mass, load center of gravity and mass
moment of inertia of the payload.
The specified values refer to nominal payloads and do not include safety
factors. It is imperative for the load data to be entered in the robot control-
ler. The robot controller takes the payload into consideration during path
planning. A reduced payload does not necessarily result in lower forces
and torques.
The values are guide values determined by means of trial and simulation
and refer to the most heavily loaded machine in the robot family. The ac-
tual forces and torques may differ due to internal and external influences
on the mounting flange or a different point of application. It is therefore
advisable to determine the exact forces and torques where necessary on
site under the real conditions of the actual robot application.
The operating values may occur permanently in the normal motion profile.
It is advisable to rate the tool for its fatigue strength.
The EMERGENCY STOP values may arise in the event of an Emergency
Stop situation of the robot. As these should only occur very rarely during
the service life of the robot, a static strength verification is usually suffi-
cient.

KR QUANTEC PA
Technical data
Fig. 4-7: Flange loads
Flange loads during operation

F(a) 4100 N
F(r) 4100 N
M(k) 1500 Nm
M(g) 1660 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 5400 N
F(r) 6100 N
M(k) 3550 Nm
M(g) 4350 Nm
Axial force F(a), radial force F(r), tilting torque M(k), torque about mount-
ing flange M(g)
4.2.4 Foundation loads, KR 120 R3200 PA
Foundation loads
The specified forces and moments already include the payload and the in-
ertia force (weight) of the robot.
Vertical force F(v)
F(v normal) 19100 N
F(v max) 24000 N
Horizontal force F(h)
F(h normal) 9200 N
F(h max) 16000 N
Tilting moment M(k)
M(k normal) 24000 Nm
M(k max) 49000 Nm
Torque about axis 1 M(r)
M(r normal) 10200 Nm
M(r max) 35000 Nm

Fig. 4-8: Foundation loads
WARNING
Normal loads and maximum loads for the foundations are specified in
the table.
The maximum loads must be referred to when dimensioning the founda-
tions and must be adhered to for safety reasons. Failure to observe this
can result in personal injury and damage to property.
The normal loads are average expected foundation loads. The actual
loads are dependent on the program and on the robot loads and may
therefore be greater or less than the normal loads.
The supplementary loads (A1, A2 and A3) are not taken into considera-
tion in the calculation of the foundation load. These supplementary
loads must be taken into consideration for Fv.
4.3 Technical data, KR 120 R3200 PA arctic
4.3.1 Basic data, KR 120 R3200 PA arctic
Basic data
KR 120 R3200 PA arctic

Number of axes 5
Maximum payload -
60529)

KR QUANTEC PA
Technical data
kinematic system
Controller KR C4


tor cables)
A6 60 mm
Ambient conditions

Ambient temperature
During operation -30 °C to 10 °C (243 K to 283 K)

robot.
Connecting cables

tion
bot
at both ends
tor
at both ends
16 mm2
(optional)

4.3.2 Axis data, KR 120 R3200 PA arctic
Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 155 °
A4 -
A5 -
A6 ±350 °
A1 124 °/s
A2 115 °/s
A3 112 °/s
A4 -
A5 217 °/s
A6 242 °/s
Mastering position
Mastering position
A1 -20 °
A2 -120 °
A3 120 °
A4 -
A5 90 °

KR QUANTEC PA
Technical data
A6 0 °
Working envelope

4.3.3 Payloads, KR 120 R3200 PA arctic
Payloads

Maximum payload -
flange Ix
flange Iy
flange Iz
frame
base frame
column
tating column
arm
arm

KR QUANTEC PA
Technical data
Lxy 100 mm
Lz 300 mm
NOTICE
be consulted.
Parameter
system

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

tem
tem
tem

KR QUANTEC PA

Technical data

nate axes.
Payload diagram
NOTICE
Fig. 4-13: KR 120 R3200 PA arctic, payload diagram
Mounting flange

Screw grade 10.9

Screw size M10

KR QUANTEC PA
Technical data
Flange loads
and torques.
cient.


F(a) 4100 N
F(r) 4100 N
M(k) 1500 Nm
M(g) 1660 Nm
F(a) 5400 N
F(r) 6100 N
M(k) 3550 Nm
M(g) 4350 Nm
ing flange M(g)
4.3.4 Foundation loads, KR 120 R3200 PA arctic
Foundation loads
Vertical force F(v)
F(v normal) 19100 N
F(v max) 24000 N
F(h normal) 9200 N
F(h max) 16000 N
Tilting moment M(k)
M(k max) 49000 Nm
M(r max) 35000 Nm

KR QUANTEC PA
Technical data
WARNING
the table.
4.4 Technical data, KR 120 R3200 PA-HO
4.4.1 Basic data, KR 120 R3200 PA-HO
Basic data
KR 120 R3200 PA-HO

Number of axes 5
Maximum payload -
60529)

KR 120 R3200 PA-HO

kinematic system
Controller KR C4


tor cables)
A6 60 mm
Ambient conditions

Ambient temperature

robot.
Connecting cables

tion
bot
at both ends
tor
at both ends
16 mm2
(optional)

KR QUANTEC PA
Technical data
4.4.2 Axis data, KR 120 R3200 PA-HO
Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 155 °
A4 -
A5 -
A6 ±350 °
A1 124 °/s
A2 115 °/s
A3 112 °/s
A4 -
A5 217 °/s
A6 242 °/s
Mastering position
Mastering position
A1 -20 °
A2 -120 °
A3 120 °
A4 -
A5 90 °

A6 0 °
Working envelope

KR QUANTEC PA
Technical data
4.4.3 Payloads, KR 120 R3200 PA-HO
Payloads

Maximum payload -
flange Ix
flange Iy
flange Iz
frame
base frame
column
tating column
arm
arm


Lxy 100 mm
Lz 300 mm
NOTICE
be consulted.
Parameter
system

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

tem
tem
tem

KR QUANTEC PA
Technical data
nate axes.
Payload diagram
NOTICE
Fig. 4-21: KR 120 R3200 PA-HO, payload diagram
Mounting flange

Screw grade 10.9

Screw size M10

KR QUANTEC PA

Technical data
Flange loads
and torques.
cient.

KR QUANTEC PA
Technical data

F(a) 4100 N
F(r) 4100 N
M(k) 1500 Nm
M(g) 1660 Nm
F(a) 5400 N
F(r) 6100 N
M(k) 3550 Nm
M(g) 4350 Nm
ing flange M(g)
4.4.4 Foundation loads, KR 120 R3200 PA-HO
Foundation loads
Vertical force F(v)
F(v normal) 19100 N
F(v max) 24000 N
F(h normal) 9200 N
F(h max) 16000 N
Tilting moment M(k)
M(k max) 49000 Nm
M(r max) 35000 Nm

WARNING
the table.
Basic data
KR 180 R3200 PA
Number of axes 5
Maximum payload -
60529)

KR QUANTEC PA
Technical data
KR 180 R3200 PA
kinematic system
Controller KR C4


tor cables)
A6 60 mm
Ambient conditions

Ambient temperature

robot.
Connecting cables

tion
bot
at both ends
tor
at both ends
16 mm2
(optional)

Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 155 °
A4 -
A5 -
A6 ±350 °
A1 105 °/s
A2 107 °/s
A3 114 °/s
A4 -
A5 173 °/s
A6 242 °/s
Mastering position
Mastering position
A1 -20 °
A2 -120 °
A3 120 °
A4 -
A5 90 °

KR QUANTEC PA
Technical data
A6 0 °
Working envelope

Payloads

Maximum payload -
flange Ix
flange Iy
flange Iz
frame
base frame
column
tating column
arm
arm

KR QUANTEC PA
Technical data
Lxy 100 mm
Lz 300 mm
NOTICE
be consulted.
Parameter
system

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

tem
tem
tem

KR QUANTEC PA

Technical data

nate axes.
Payload diagram
NOTICE
Mounting flange
Robot wrist type 180/240 kg

Screw grade 10.9

Screw size M10

KR QUANTEC PA
Technical data
Flange loads
and torques.
cient.


F(a) 4100 N
F(r) 4100 N
M(k) 1500 Nm
M(g) 1660 Nm
F(a) 5400 N
F(r) 6100 N
M(k) 3550 Nm
M(g) 4350 Nm
ing flange M(g)
Foundation loads
Vertical force F(v)
F(v normal) 19100 N
F(v max) 24000 N
F(h normal) 9200 N
F(h max) 16000 N
Tilting moment M(k)
M(k max) 49000 Nm
M(r max) 35000 Nm

KR QUANTEC PA
Technical data
WARNING
the table.
Basic data

Number of axes 5
Maximum payload -
60529)


kinematic system
Controller KR C4


tor cables)
A6 60 mm
Ambient conditions

Ambient temperature

robot.
Connecting cables

tion
bot
at both ends
tor
at both ends
16 mm2
(optional)

KR QUANTEC PA
Technical data
Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 155 °
A4 -
A5 -
A6 ±350 °
A1 105 °/s
A2 107 °/s
A3 114 °/s
A4 -
A5 173 °/s
A6 242 °/s
Mastering position
Mastering position
A1 -20 °
A2 -120 °
A3 120 °
A4 -
A5 90 °

A6 0 °
Working envelope

KR QUANTEC PA
Technical data
Payloads

Maximum payload -
flange Ix
flange Iy
flange Iz
frame
base frame
column
tating column
arm
arm


Lxy 100 mm
Lz 300 mm
NOTICE
be consulted.
Parameter
system

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

tem
tem
tem

KR QUANTEC PA
Technical data
nate axes.
Payload diagram
NOTICE
Mounting flange

Screw grade 10.9

Screw size M10

KR QUANTEC PA

Technical data
Flange loads
and torques.
cient.

KR QUANTEC PA
Technical data

F(a) 4100 N
F(r) 4100 N
M(k) 1500 Nm
M(g) 1660 Nm
F(a) 5400 N
F(r) 6100 N
M(k) 3550 Nm
M(g) 4350 Nm
ing flange M(g)
Foundation loads
Vertical force F(v)
F(v normal) 19100 N
F(v max) 24000 N
F(h normal) 9200 N
F(h max) 16000 N
Tilting moment M(k)
M(k max) 49000 Nm
M(r max) 35000 Nm

WARNING
the table.
Basic data
KR 180 R3200 PA-HO

Number of axes 5
Maximum payload -
60529)

KR QUANTEC PA
Technical data
KR 180 R3200 PA-HO
kinematic system
Controller KR C4


tor cables)
A6 60 mm
Ambient conditions

Ambient temperature

robot.
Connecting cables

tion
bot
at both ends
tor
at both ends
16 mm2
(optional)

Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 155 °
A4 -
A5 -
A6 ±350 °
A1 105 °/s
A2 107 °/s
A3 114 °/s
A4 -
A5 173 °/s
A6 242 °/s
Mastering position
Mastering position
A1 -20 °
A2 -120 °
A3 120 °
A4 -
A5 90 °

KR QUANTEC PA
Technical data
A6 0 °
Working envelope

Payloads

Maximum payload -
flange Ix
flange Iy
flange Iz
frame
base frame
column
tating column
arm
arm

KR QUANTEC PA
Technical data
Lxy 100 mm
Lz 300 mm
NOTICE
be consulted.
Parameter
system

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

tem
tem
tem

KR QUANTEC PA

Technical data

nate axes.
Payload diagram
NOTICE
Mounting flange

Screw grade 10.9

Screw size M10

KR QUANTEC PA
Technical data
Flange loads
and torques.
cient.


F(a) 4100 N
F(r) 4100 N
M(k) 1500 Nm
M(g) 1660 Nm
F(a) 5400 N
F(r) 6100 N
M(k) 3550 Nm
M(g) 4350 Nm
ing flange M(g)
Foundation loads
Vertical force F(v)
F(v normal) 19100 N
F(v max) 24000 N
F(h normal) 9200 N
F(h max) 16000 N
Tilting moment M(k)
M(k max) 49000 Nm
M(r max) 35000 Nm

KR QUANTEC PA
Technical data
WARNING
the table.
Basic data
KR 240 R3200 PA
Number of axes 5
Maximum payload -
60529)

KR 240 R3200 PA
kinematic system
Controller KR C4


tor cables)
A6 60 mm
Ambient conditions

Ambient temperature

robot.
Connecting cables

tion
bot
at both ends
tor
at both ends
16 mm2
(optional)

KR QUANTEC PA
Technical data
Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 155 °
A4 -
A5 -
A6 ±350 °
A1 105 °/s
A2 101 °/s
A3 107 °/s
A4 -
A5 173 °/s
A6 242 °/s
Mastering position
Mastering position
A1 -20 °
A2 -120 °
A3 120 °
A4 -
A5 90 °

A6 0 °
Working envelope

KR QUANTEC PA
Technical data
Payloads

Maximum payload -
flange Ix
flange Iy
flange Iz
frame
base frame
column
tating column
arm
arm


Lxy 100 mm
Lz 300 mm
NOTICE
be consulted.
Parameter
system

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

tem
tem
tem

KR QUANTEC PA
Technical data
nate axes.
Payload diagram
NOTICE
Mounting flange

Screw grade 10.9

Screw size M10

KR QUANTEC PA

Technical data
Flange loads
and torques.
cient.

KR QUANTEC PA
Technical data

F(a) 4100 N
F(r) 4100 N
M(k) 1500 Nm
M(g) 1660 Nm
F(a) 5400 N
F(r) 6100 N
M(k) 3550 Nm
M(g) 4350 Nm
ing flange M(g)
Foundation loads
Vertical force F(v)
F(v normal) 19100 N
F(v max) 24000 N
F(h normal) 9200 N
F(h max) 16000 N
Tilting moment M(k)
M(k max) 49000 Nm
M(r max) 35000 Nm

WARNING
the table.
Basic data

Number of axes 5
Maximum payload -
60529)

KR QUANTEC PA
Technical data
kinematic system
Controller KR C4


tor cables)
A6 60 mm
Ambient conditions

Ambient temperature

robot.
Connecting cables

tion
bot
at both ends
tor
at both ends
16 mm2
(optional)

Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 155 °
A4 -
A5 -
A6 ±350 °
A1 105 °/s
A2 101 °/s
A3 107 °/s
A4 -
A5 173 °/s
A6 242 °/s
Mastering position
Mastering position
A1 -20 °
A2 -120 °
A3 120 °
A4 -
A5 90 °

KR QUANTEC PA
Technical data
A6 0 °
Working envelope

Payloads

Maximum payload -
flange Ix
flange Iy
flange Iz
frame
base frame
column
tating column
arm
arm

KR QUANTEC PA
Technical data
Lxy 100 mm
Lz 300 mm
NOTICE
be consulted.
Parameter
system

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

tem
tem
tem

KR QUANTEC PA

Technical data

nate axes.
Payload diagram
NOTICE
Mounting flange

Screw grade 10.9

Screw size M10

KR QUANTEC PA
Technical data
Flange loads
and torques.
cient.


F(a) 4100 N
F(r) 4100 N
M(k) 1500 Nm
M(g) 1660 Nm
F(a) 5400 N
F(r) 6100 N
M(k) 3550 Nm
M(g) 4350 Nm
ing flange M(g)
Foundation loads
Vertical force F(v)
F(v normal) 19100 N
F(v max) 24000 N
F(h normal) 9200 N
F(h max) 16000 N
Tilting moment M(k)
M(k max) 49000 Nm
M(r max) 35000 Nm

KR QUANTEC PA
Technical data
WARNING
the table.
Basic data
KR 240 R3200 PA-HO

Number of axes 5
Maximum payload -
60529)

KR 240 R3200 PA-HO

kinematic system
Controller KR C4


tor cables)
A6 60 mm
Ambient conditions

Ambient temperature

robot.
Connecting cables

tion
bot
at both ends
tor
at both ends
16 mm2
(optional)

KR QUANTEC PA
Technical data
Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 155 °
A4 -
A5 -
A6 ±350 °
A1 105 °/s
A2 101 °/s
A3 107 °/s
A4 -
A5 173 °/s
A6 242 °/s
Mastering position
Mastering position
A1 -20 °
A2 -120 °
A3 120 °
A4 -
A5 90 °

A6 0 °
Working envelope

KR QUANTEC PA
Technical data
Payloads

Maximum payload -
flange Ix
flange Iy
flange Iz
frame
base frame
column
tating column
arm
arm


Lxy 100 mm
Lz 300 mm
NOTICE
be consulted.
Parameter
system

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

tem
tem
tem

KR QUANTEC PA
Technical data
nate axes.
Payload diagram
NOTICE
Mounting flange

Screw grade 10.9

Screw size M10

KR QUANTEC PA

Technical data
Flange loads
and torques.
cient.

KR QUANTEC PA
Technical data

F(a) 4100 N
F(r) 4100 N
M(k) 1500 Nm
M(g) 1660 Nm
F(a) 5400 N
F(r) 6100 N
M(k) 3550 Nm
M(g) 4350 Nm
ing flange M(g)
Foundation loads
Vertical force F(v)
F(v normal) 19100 N
F(v max) 24000 N
F(h normal) 9200 N
F(h max) 16000 N
Tilting moment M(k)
M(k max) 49000 Nm
M(r max) 35000 Nm

WARNING
the table.
4.11 Supplementary load
Description
The robot can carry supplementary loads on the rotating column, link arm
and arm. When mounting the supplementary loads, be careful to observe
the maximum permissible total load. The dimensions and positions of the
installation options can be seen in the following diagram.

KR QUANTEC PA
Technical data
Fig. 4-73: Supplementary load, rotating column
Fig. 4-74: Supplementary load, link arm
1 Mounting surface

Fig. 4-75: Supplementary load, arm
1 Axis 3 3 Interference contour, arm

2 Mounting surface
4.12 Plates and labels
Plates and labels
The following plates and labels (>>> Fig. 4-76) are attached to the robot.
They must not be removed or rendered illegible. Illegible plates and labels
must be replaced.
Fig. 4-76: Location of plates and labels

KR QUANTEC PA
Technical data
Item Description
1
High voltage
Any improper handling can lead to contact with current-carrying
components. Electric shock hazard!
2
Hot surface
During operation of the robot, surface temperatures may be
reached that could result in burn injuries. Protective gloves must
be worn!
3
Secure the axes

Before exchanging any motor, secure the corresponding axis
through safeguarding by suitable means/devices to protect
against possible movement. The axis can move. Risk of crush-
ing!
4
Work on the robot

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

Item Description
5
Identification plate
Content according to Machinery Directive.
6
Transport position
Before loosening the bolts of the mounting base, the robot must
be in the transport position as indicated in the table. Risk of
toppling!
7
Danger zone
Entering the danger zone of the robot is prohibited if the robot
is in operation or ready for operation. Risk of injury!

KR QUANTEC PA
Technical data
Item Description
8
Mounting flange on in-line wrist

The values specified on this plate apply for the installation of
tools on the mounting flange of the wrist and must be observed.
9
The system is pressurized with oil and nitrogen. Read and fol-
low the assembly and operating instructions before commencing
work on the counterbalancing system. Risk of injury!
10
FoodProof
Affixed to gear unit. Unlike the standard gear unit, this gear unit
must be filled with “FoodProof 1800” oil. Observe the particular-
ities!
4.13 REACH duty to communicate information acc. to Art. 33
As of June 2007, the Regulation (EC) 1907/2006 of the European Parlia-

ment and of the Council dated 18 December 2006 on the registration,
evaluation and authorization of chemicals (REACH Regulation) is in force.
Detailed REACH information can be found in the product information in
KUKA Xpert.

4.14 Stopping distances and times
4.14.1 General information
Information concerning the data:
• The stopping distance is the angle traveled by the robot from the mo-
ment the stop signal is triggered until the robot comes to a complete
standstill.
• The stopping time is the time that elapses from the moment the stop
signal is triggered until the robot comes to a complete standstill.
• The data are given for the main axes A1, A2 and A3. The main axes
are the axes with the greatest deflection.
• Superposed axis motions can result in longer stopping distances.
• Stopping distances and stopping times in accordance with DIN EN
ISO 10218-1, Annex B.
• Stop categories:
‒ Stop category 0 » STOP 0
‒ Stop category 1 » STOP 1
according to IEC 60204-1
• The values specified for Stop 0 are guide values determined by
means of tests and simulation. They are average values which con-
form to the requirements of DIN EN ISO 10218-1. The actual stopping
distances and stopping times may differ due to internal and external
influences on the braking torque. It is therefore advisable to determine
the exact stopping distances and stopping times where necessary un-
der the real conditions of the actual robot application.
• Measuring technique
The stopping distances were measured using the robot-internal meas-
uring technique.
• The wear on the brakes varies depending on the operating mode, ro-
bot application and the number of STOP 0 stops triggered. It is there-
fore advisable to check the stopping distance at least once a year.
4.14.2 Stopping distances and times, KR 120 R3200 PA, KR 120 R3200 PA
arctic and KR 120 R3200 PA-HO
4.14.2.1 Stopping distances and stopping times, STOP 0, A1 to A3
The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)
Stopping distance
A1 68.54 °
A2 32.64 °
A3 40.09 °
Stopping time
A1 1.02 s

KR QUANTEC PA
Technical data
A2 0.61 s
A3 0.53 s
4.14.2.2 Stopping distances and stopping times, STOP 1, A1
Fig. 4-77: Stopping distances for STOP 1, axis 1

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

KR QUANTEC PA
Technical data


KR QUANTEC PA
Technical data
4.14.3.1 Stopping distances and stopping times, STOP 0, A1 to A3
The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
Stopping distance
A1 61.47 °
A2 36.00 °

A3 46.55 °
Stopping time
A1 1.00 s
A2 0.73 s
A3 0.63 s

KR QUANTEC PA
Technical data


KR QUANTEC PA
Technical data


KR QUANTEC PA
Technical data
4.14.4.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3
The table shows the stopping distances and stopping times after a STOP
0 (category 0 stop) is triggered. The values refer to the following configu-
ration:

Stopping distance (°) Stopping time (s)

Axis 1 57.23 1.009
Axis 2 24.26 0.543
Axis 3 35.21 0.485

KR QUANTEC PA
4.14.4.2 Stopping distances and stopping times for STOP 1, axis 1
Technical data


KR QUANTEC PA
Technical data


KR QUANTEC PA
Technical data


KR QUANTEC PA
Planning
5 Planning
5.1 Information for planning
In the planning and design phase, care must be taken regarding the func-
tions or applications to be executed by the kinematic system. The follow-
ing conditions can lead to premature wear. They necessitate shorter main-
tenance intervals and/or earlier exchange of components. In addition, the
permissible operating parameters specified in the technical data must be
taken into account and observed during planning.
• Continuous operation near temperature limits or in abrasive environ-
ments
• Continuous operation close to the performance limits, e.g. high rpm of
an axis
• High duty cycle of individual axes
• Monotonous motion profiles, e.g. short, frequently recurring axis mo-
tions
• Static axis positions, e.g. continuous vertical position of a wrist axis
• External forces (process forces) acting on the robot
If one or more of these conditions arise during operation of the kinematic
system, KUKA Deutschland GmbH must be consulted.
If the robot reaches its corresponding operation limit or if it is operated
near the limit for a period of time, the built-in monitoring functions come
into effect and the robot is automatically switched off.
This protective function can limit the availability of the robot system.
When planning the site of installation and operation for arctic variants, pro-
vision must be made for the robot to be removed for the performance of
maintenance and repair work as required.
In connection with the installation of chemical (resin-bonded) anchors, it is
also important to comply with the permissible temperatures for processing
and operation. This applies especially to the component temperature (con-
crete foundation).
5.2 Mounting base with centering
Description
The mounting base with centering is used when the kinematic system is
fastened to the floor, i.e. directly on a concrete foundation.
The mounting base with centering consists of:
• Bedplates
• Chemical anchor
• Fastening elements
This mounting variant requires a level and smooth surface on a concrete
foundation with adequate load bearing capacity. The concrete foundation
must be able to accommodate the forces occurring during operation.
There must be no layers of insulation or screed between the bedplates
and the concrete foundation.
The minimum dimensions must be observed.

Planning KR QUANTEC PA
Fig. 5-1: Mounting base
1 Hexagon bolt 4 Resin-bonded anchor

2 M20 thread for adjusting 5 Pin with Allen screw
screw
3 Bedplate
Grade of concrete for foundations
When producing foundations from concrete, observe the load-bearing ca-

pacity of the ground and the country-specific construction regulations.
There must be no layers of insulation or screed between the bedplate/
bedplates and the concrete foundation. The quality of the concrete must
meet the requirements of the following standard:
• C20/25 according to DIN EN 206-1:2001/DIN 1045-2:2008
Dimensioned drawing
The following illustrations provide all the necessary information on the

mounting base, together with the required foundation data. The specified
foundation dimensions refer to the safe transmission of the foundation
loads into the foundation and not to the stability of the foundation.

KR QUANTEC PA
Planning
Fig. 5-2: Mounting base, dimensioned drawing
1 Robot
2 Bedplate
3 Concrete foundation
To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
illustration.
NOTICE
The dimensions specified for the distance to the edge are valid for non-
reinforced or normally reinforced concrete without verification of
concrete edge failure. For safety against concrete edge failure in ac-
cordance with ETAG 001 Annex C, the concrete foundation must be
provided with an appropriate edge reinforcement.

Fig. 5-3: Foundation cross-section
1 Bedplate 3 Pin
2 Concrete foundation 4 Hexagon bolt
5.3 Machine frame mounting
Description
The machine frame mounting assembly with centering is used when the
robot is fastened on a steel structure, a booster frame (pedestal) or a KU-
KA linear unit. It must be ensured that the substructure is able to with-
stand safely the forces occurring during operation (foundation loads). The
following diagram contains all the necessary information that must be ob-
served when preparing the mounting surface (>>> Fig. 5-4).
The machine frame mounting assembly consists of:
• Pins with fasteners
• Hexagon bolts with conical spring washers
Fig. 5-4: Machine frame mounting
1 Pin
2 Hexagon bolt
1 Pin
2 Hexagon bolt

KR QUANTEC PA
Planning
Dimensioned drawing
The following illustration provides all the necessary information on ma-

chine frame mounting, together with the required foundation data.
Fig. 5-5: Machine frame mounting, dimensioned drawing
1 Mounting surface 3 Hexagon bolt (8x)

2 Pin 4 Steel structure
1 Mounting surface 3 Hexagon bolt (8x)

2 Pin 4 Steel structure
5.4 Connecting cables and interfaces
Connecting cables
The connecting cables comprise all the cables for transferring energy and
signals between the robot and the robot controller. They are connected to
the robot junction boxes with connectors. The set of connecting cables
comprises:
• Motor cable, X20 - X30
• Data cable, X21 - X31
• Ground conductor (optional)
Depending on the specification of the robot, various connecting cables are
used. Cable lengths of 7 m, 15 m, 25 m, 35 m and 50 m are available.

KR QUANTEC PA
The maximum length of the connecting cables must not exceed 50 m.

Planning
Thus if the robot is operated on a linear unit which has its own energy
supply chain these cables must also be taken into account.
For the connecting cables, an additional ground conductor is always re-
quired to provide a low-resistance connection between the robot and the
control cabinet in accordance with DIN EN 60204. The ground conductors
are connected via ring cable lugs. The threaded bolt for connecting the
ground conductor is located on the base frame of the robot.
The following points must be observed when planning and routing the
connecting cables:
• The bending radius for fixed routing must not be less than 150 mm for
motor cables and 60 mm for data cables.
• Protect cables against exposure to mechanical stress.
• Route the cables without mechanical stress – no tensile forces on the
connectors.
• Cables are only to be installed indoors.
• Observe the permissible temperature range (fixed installation) of
263 K (-10 °C) to 343 K (+55 °C).
• Route the motor cables and the data cables separately in metal ducts.
If necessary, take additional measures to ensure electromagnetic com-
patibility (EMC).
Interface for energy supply system
The robot can be equipped with an energy supply system between axis 1
and axis 5 and a second energy supply system between axis 5 and axis
6. The A1 interface required for this is located on the rear of the base
frame, the A5 interface is located on the side of the swing frame and the
interface for axis 6 is located on the robot tool. Depending on the applica-
tion, the interfaces differ in design and scope. They can be equipped, for
example, with connections for cables and hoses. Detailed information on
the connector pin allocation, threaded unions, etc. is given in separate
documentation.

KR QUANTEC PA
Planning
Fig. 5-6: Interfaces on the robot
1 Interface for energy supply 4 Ground conductor connection,

system, base frame M8 ring cable lug
2 Data cable connection X31 5 Interface for energy supply
system, axis 5
3 Motor cable connection X30


KR QUANTEC PA
Transportation
6 Transportation
6.1 Transporting the robot
Description
Move the robot into its transport position each time it is transported. It
must be ensured that the robot is stable while it is being transported. The
robot must remain in its transport position until it has been fastened in po-
sition. Before the robot is lifted, it must be ensured that it is free from ob-
structions. Remove all transport safeguards, such as nails and screws, in
advance. First remove any rust or adhesive on contact surfaces.
damage to the manipulator.
Transport position
The robot must be in the transport position before it can be transported.

The robot is in the transport position when the axes are in the following
positions:
Transport position
A1 0 °
A2 -140 °
A3 150 °
A4 -
A5 80 °
A6 0 °
Fig. 6-1: Transport position
Transport dimensions
The transportation dimensions (>>> Fig. 6-2) for the robot can be noted
from the following diagram. The position of the center of gravity and the
weight vary according to the specific configuration and the position of
axes 2 and 3. The specified dimensions refer to the robot without equip-
ment.

Transportation KR QUANTEC PA
Fig. 6-2: Transport dimensions
1 Robot
2 Center of gravity
3 Fork slots
Transportation
The robot can be transported by fork lift truck or using lifting tackle.
WARNING
Use of unsuitable handling equipment may result in damage to the robot
or injury to persons. Only use authorized handling equipment with a suf-
ficient load-bearing capacity. Only transport the robot in the manner
specified here.
Transportation by fork lift truck
For transport by fork lift truck (>>> Fig. 6-3), two fork slots are provided in
the base frame. The robot can be picked up by the fork lift truck from the
front and rear. The base frame must not be damaged when inserting the
forks into the fork slots. The fork lift truck must have a minimum payload
capacity of 2.0 t and an adequate fork length.
For installation situations in which the fork slots are not accessible, the
“Recovery aid” accessory is available. With this device, the robot can also
be transported using the fork lift truck.

KR QUANTEC PA
Transportation
NOTICE
Damage to property due to overloading of the fork slots
Overloading the fork slots during transportation can cause damage to
property.
• Avoid overloading the fork slots through undue inward or outward
movement of hydraulically adjustable forks of the fork lift truck.
Fig. 6-3: Transportation by fork lift truck
Transportation with lifting tackle
The robot can also be transported using lifting tackle (>>> Fig. 6-4). For
this, it must be in the transport position. The lifting tackle is attached at 3
points to M16 DIN 580 eyebolts. All the legs must be routed as shown in
the following illustration so that the robot is not damaged. Installed tools
and items of equipment can cause undesirable shifts in the center of grav-
ity. Items of equipment, especially energy supply systems, must be re-
moved to the extent necessary to avoid them being damaged by the legs
of the lifting tackle during transportation.
All the legs are labeled. Leg G3 is provided with an adjustable chain that
must be adjusted so that the robot is suspended vertically from the crane.
If necessary, the robot must be set down again and the chain readjusted.
WARNING
The robot may tip during transportation. Risk of personal injury and
damage to property.
If the robot is being transported using lifting tackle (optional), special
care must be exercised to prevent it from tipping. Additional safeguard-
ing measures must be taken. It is forbidden to pick up the robot in any
other way using a crane!

Transportation KR QUANTEC PA
Fig. 6-4: Transportation using lifting tackle
1 Lifting tackle assembly

2 Leg G1
3 Leg G3
4 M16 eyebolt, rotating column, rear
5 M16 eyebolt, base frame, front, left
6 M16 eyebolt, base frame, front, right
7 Leg G2

KR QUANTEC PA
Start-up and recommissioning

7 Start-up and recommissioning
7.1 Installing the mounting base
Description
These instructions apply to the variant “mounting base with centering (res-
in cartridge)”. The robot is fastened to an appropriate concrete foundation
using one or more bedplates and resin-bonded anchors.
If the surface of the concrete foundation is not sufficiently smooth and
even, the differences must be evened out with a suitable leveling com-
pound.
When using resin-bonded anchors, use only resin cartridges and anchors
from the same manufacturer. No diamond tools or core drills may be used
for drilling the anchor holes; for preference, drilling tools supplied by the
anchor manufacturer are to be used. The manufacturer’s instructions for
the use of resin-bonded anchors must also be observed.
Precondition
• The concrete foundation must have the required dimensions and

cross-section.
• The surface of the foundation must be smooth and even.
• The mounting base assembly must be complete.
• Have the leveling compound readily at hand.
Special tools
The following special tools are required:

• Drill with a ø 18 mm bit
• Setting tool approved by the anchor manufacturer
Procedure
1. Lift the robot with fork lift truck or lifting tackle.

2. Fasten the 4 bedplates to the robot using 2 M24x65-8.8 Allen screws
with conical spring washers for each one.
Increase the tightening torque to the specified value in several stages.
2 bedplates are fitted with locating pins for centering.
3. Determine the position of the robot on the mounting base in relation to
the working envelope.
4. Set the robot down on the mounting base in its installation position.
5. Align the robot horizontally.
NOTICE
If the bedplates are not fully seated on the concrete foundation, this
can result in distortion or loosening of the mounting base. Fill the
gap with leveling compound. To do this, lift the robot again and ap-
ply sufficient leveling compound to the underside of the bedplates
(toothed spatula). Then set the robot down again and align it, re-
moving any excess leveling compound. The maximum height of the
leveling compound must not be exceeded.
The area under the hexagon bolt for robot fastening must be kept
free from leveling compound.
Allow the leveling compound to set in accordance with the manufac-
turer's instructions.

Start-up and recommissioning KR QUANTEC PA
6. Drill 12 anchor holes in accordance with the manufacturer’s specifica-

tions and fit the anchors as specified in the instructions for use.
The instructions for use are enclosed with the anchors and must be
followed precisely.
7. Allow the resin to cure. See table provided by manufacturer.
The mounting base and robot are now ready for connection of the robot.
7.2 Installing the machine frame mounting assembly
Description
The machine frame mounting assembly is used for installing robots on a

steel structure prepared by the customer or on the carriage of a linear
unit.
Preconditions
• The mounting surface has been prepared as shown in the diagram

(>>> Fig. 5-5).
• The substructure has been checked for sufficient safety.
• The machine frame mounting assembly is complete.
Procedure
1. Clean the mounting surface (>>> Fig. 7-1) of the robot.

2. Check the hole pattern.
3. Insert 2 pins and 2 M8x55-8.8 Allen screws with conical spring wash-
ers and tighten with a torque wrench; MA = 23.9 Nm.
4. Prepare 8 M24x65-8.8-A2K hexagon bolts and conical spring washers.
Fig. 7-1: Installing the machine frame mounting assembly
1 Pin 3 Hexagon bolt with conical

spring washer, 8x
2 Allen screw with conical 4 Mounting surface
spring washer, 2x
The mounting base is now ready for the robot to be installed.

KR QUANTEC PA

7.3 Installing the robot
Description
This description is valid for the installation of robots with the mounting var-
iants: mounting base, machine frame mounting and adapter plates.
The installation and start-up of the robot controller, the tools mounted and
the applications are not described here.
Precondition
• The relevant mounting base is installed.

• The installation site is accessible with a crane or fork lift truck.
• Any tools or other system components which would hinder the work
have been removed.
• The robot is in the transport position.
• The connecting cables and ground conductors are routed to the robot
and installed.
Procedure
1. Check that both pins (>>> Fig. 7-2) (4) are undamaged and fitted se-
curely.
2. Bring the robot to the installation site by crane or fork lift truck.
The lifting tackle must not damage the robot.
3. Clean the mounting surface on the robot.
4. Lower the robot vertically onto the mounting base. Ensure that an en-
tirely vertical position is maintained in order to prevent damage to the
pins.
5. Insert 8 M24x65-8.8 hexagon bolts together with conical spring wash-
ers.
6. Tighten the hexagon bolts with a torque wrench. Gradually increase
the tightening torque to 640 Nm.
7. Remove the lifting tackle and eyebolts.
8. Connect motor cable X30 and data cable X31.
9. Connect the ground conductor between the robot controller and the ro-
bot to the ground conductor connection.
10. Connect the ground conductor between the system component and
the robot to the ground conductor connection.
11. Check the equipotential bonding in accordance with VDE 0100 and
EN 60204-1.
Further information is contained in the assembly or operating instruc-
tions for the robot controller.
12. Mount tooling, if required.

13. Retighten the 8 hexagon bolts with a torque wrench after 100 hours of
operation.

Fig. 7-2: Installing the robot
1 Rotating column 5 Data cable

2 Hexagon bolts 6 Motor cable
3 Conical spring washers 7 Ground conductor connection
4 Pin 8 Ground conductor connection,
robot controller
Put the robot into operation in accordance with the “Start-up” chapter of
the operating and programming instructions for the System Software
and/or the assembly instructions or operating instructions for the robot
controller.
CAUTION
Sudden escape of air in the counterbalancing system
Following storage of the manipulator, an air cushion can build up in the
counterbalancing system. If the air escapes suddenly, this can cause
the protective cap of the vent valve to shoot off in exceptional cases. In-
juries may result.
1. Remove the protective cap of the counterbalancing system vent
valve.
2. Maintain a safe distance.
3. Move A2 by ±30°.
4. Refit the protective cap.
7.4 Description of the connecting cables
Configuration
The connecting cables are used to transfer power and signals between
the robot controller and the robot (>>> Fig. 7-3).
The connecting cables comprise:
• Motor cable
• Data cable
• Ground conductor, optional
Interface
For connection of the connecting cables between the robot controller and
the robot, the following connectors are available at the interfaces:

KR QUANTEC PA

Connector designation
Cable designation Connection
robot controller - robot
Motor cable X20 - X30 Han size 24
Data cable X21 - X31 Rectangular
connector
Ground conductor, option- M8 ring cable
al lug
Standard connecting cable
Fig. 7-3: Connecting cables, overview
Fig. 7-4: Connecting cable, motor cable, X20 - X30

Fig. 7-5: Connecting cable, wiring diagram, motor cable X20 - X30
Fig. 7-6: Connecting cable, data cable X21 - X31

KR QUANTEC PA

Fig. 7-7: Connecting cable, wiring diagram, data cable X21 - X31
Fig. 7-8: Connecting cable, ground conductor
1 Ground conductor 6 Conical spring washer

2 Hexagon nut 7 Robot
3 Conical spring washer 8 Setscrew, M8
4 2x plain washer 9 Ground conductor connection,
M8 ring cable lug
5 Hexagon nut 10 Ground sign
7.5 Moving the manipulator without drive energy
Description
The release device (optional) can be used for moving the manipulator af-
ter an accident or malfunction without drive energy.
This option is only for use in exceptional circumstances and emergencies,
e.g. for freeing people.

Precondition
• Robot controller is switched off.
Procedure
SAFETY INSTRUCTION
The following procedure must be followed exactly!
1. Remove the protective cap from the motor (>>> Fig. 7-9).
2. Push the release device onto the corresponding motor and move the
axis in the desired direction.
The directions are indicated with arrows on the motors. It is necessary
to overcome the resistance of the mechanical motor brake and any
other loads acting on the axis.
Fig. 7-9: Motor with release device
1 Motor
2 Protective cap
3 Release device
WARNING
Danger to life and limb due to damaged motor brake
Moving an axis with the release device can damage the motor brake.
Death, severe injuries or damage to property may result.
• After using the release device, the motor must be exchanged.
WARNING
If a robot axis has been moved by the release device/rechargeable
screwdriver with torque bracket, all robot axes must be remastered. In-
juries or damage to property may otherwise result.

KR QUANTEC PA
Maintenance
8 Maintenance
Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA. Information about KUKA College and its training
program can be found at www.kuka.com or can be obtained directly from
our subsidiaries.
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.
8.1 Maintenance overview
Description
The maintenance intervals given in the tables are valid for the operating
conditions specified in the technical data (>>> 4 "Technical data"
Page 31). KUKA Deutschland must be consulted in the event of
deviations in working conditions or the use of special functions or applica-
tions.
Further information can be found in the section “Information for plan-
ning” (>>> 5.1 "Information for planning" Page 139).
A general inspection of the manipulator is recommended after 7 years or

upon modifying its use. Please contact KUKA Service for this.
If the robot is fitted with a KUKA energy supply system (optional), addi-
tional maintenance work must be carried out.
NOTICE
Only auxiliary substances and consumables approved by KUKA
Deutschland GmbH may be used. Non-approved auxiliary substances
and consumables may cause premature wear and failure of assemblies.
If oil temperatures of more than 333 K (60 °C) are reached during opera-
tion, shorter maintenance intervals must be observed; for this, consultation
with KUKA Deutschland GmbH is necessary.
When draining the oil, remember that the quantity drained is dependent
on time and temperature. The quantity of oil drained must be deter-
mined. Only this quantity of oil may be used when refilling. The oil
quantities specified are the actual amounts of oil in the gear unit at first
filling.
If less than 70% of the specified oil quantity flows out, flush the gear
unit with the determined quantity of drained oil once, then pour in the
amount of oil that was drained. During the flushing procedure, move the
axis at jog velocity throughout the entire axis range.
Precondition
• The maintenance points must be freely accessible.

• Remove the tools and any additional items of equipment if they im-
pede maintenance work.

Maintenance KR QUANTEC PA
WARNING
Danger to life and limb due to unintended robot motions
When carrying out the following work, the robot must be moved several
times between the individual work steps. Unintended robot motions may
result in death, severe injuries or damage to property.
• While work is being carried out on the robot, it must always be se-
cured by activating the EMERGENCY STOP device.
• If work is carried out on an operational robot that is switched on, the
robot must only be moved at reduced velocity. It must be possible to
stop the robot at any time by activating an EMERGENCY STOP de-
vice. Operation must be limited to what is absolutely necessary.
• Warn all persons concerned before switching on and moving the ro-
bot.
8.1.1 Maintenance table
Maintenance symbols
The overview may contain maintenance symbols that are not relevant
for the maintenance work on this product. The maintenance illustrations
provide an overview of the relevant maintenance work.
Oil change
Lubricate with grease gun
Lubricate with brush
Lubricate with spray grease
Tighten screw/nut
Check component, visual inspection
Clean component
Exchange battery
Exchange component
Check toothed belt tension

KR QUANTEC PA
Maintenance
Fig. 8-1: Maintenance work
Maintenance table, KR QUANTEC PA, standard variants
Interval Item Activity Auxiliary substan-

ces and consuma-
bles
Once only, 8 Check bolts -
after MA 640 Nm
100 h
5,000 h 5 Counterbalancing system LGEP 2 lubricating
or 1 year bearing, link arm, grease
at the lubricate.
10 cm³
latest Grease nipples in the mid-
1) dle position and at the plus
and minus end positions of
axis 2.
or 1 year bearing, rotating column, grease
at the lubricate.
10 cm³
axis 2.
5,000 h 4 Counterbalancing system, Hyspin ZZ 46 hy-
check pressure draulic oil
Setpoint, tolerance -5 bar
10 cm³


ces and consuma-
bles
10,000 h 2 Grease cables of cable set Lubricating grease
and energy supply system. Optitemp RB2
(>>> 8.8 "Greasing the ca-
200 cm³
ble set" Page 177)
20,000 h 10 Perform oil change on Optigear Synt. ALR
or 5 years gear unit A6. 150
at the latest (>>> 8.6 "Oil change in
Initial filling quantity:
A6" Page 174)
1.20 l
A5" Page 172)
0.80 l
Initial filling quantity
A3" Page 170)
for in-line wrist type
120 kg: 1.90 l
180/240 kg: 1.80 l
A2" Page 168)
for in-line wrist type:
120 kg: 2.40 l
180/240 kg: 2.90 l
A1" Page 165)
6.50 l
10 years 4 Exchange the counterbal- -
ancing system
(>>> 8.10 "Exchanging the
counterbalancing system
on a floor-mounted robot"
Page 179)
1) In the case of frequently recurring, short-distance movements, the
maintenance interval is 3,000 hours.
The description of the following oil change work applies to all robot var-
iants, irrespective of the variant shown.

KR QUANTEC PA
Maintenance
Maintenance table, KR QUANTEC PA, HO variants

ces and consuma-
bles
after MA 640 Nm
100 h
at the lubricate.
10 cm³
axis 2.
at the lubricate.
10 cm³
axis 2.
5,000 h 4 Counterbalancing system, Hyspin ZZ 46 hy-
check pressure draulic oil
10 cm³
10,000 h 2 Grease cables of cable set Klüberfood NH1 lubri-
and energy supply system. cating grease
200 cm³
ble set" Page 177)
20,000 h 10 Perform oil change on Optileb GT 1800/220
or 5 years gear unit A6.
1.20 l
A6" Page 174)
0.80 l
A5" Page 172)
A3" Page 170)
120 kg: 1.90 l
180/240 kg: 1.80 l
A2" Page 168)
120 kg: 2.40 l
180/240 kg: 2.90 l


ces and consuma-
bles
6.50 l
A1" Page 165)
ancing system
Page 179)
maintenance interval is 3000 hours.
Maintenance table, KR QUANTEC PA, arctic variants

ces and consuma-
bles
after MA 640 Nm
100 h
at the lubricate.
10 cm³
axis 2.
at the lubricate.
10 cm³
axis 2.
5,000 h 4 Counterbalancing system, Hydraulic oil Shell
check pressure Spirax S1 ATF TASA
10 cm³
10,000 h 2 Grease cables of cable set Lubricating grease
and energy supply system. Optitemp RB2
200 cm³
ble set" Page 177)
20,000 h 10 Perform oil change on Alphasyn T 32
1.20 l
A6" Page 174)
0.80 l
A5" Page 172)

KR QUANTEC PA
Maintenance
ces and consuma-
bles
A3" Page 170)
120 kg: 1.90 l
180/240 kg: 1.80 l
A2" Page 168)
120 kg: 2.40 l
180/240 kg: 2.90 l
6.50 l
A1" Page 165)
ancing system
Page 179)
maintenance interval is 3000 hours.
Up-to-date safety data sheets must be requested from the manufacturers
of auxiliary and operating materials. Further information about the auxiliary
substances and consumables used can be found under:
(>>> 13.3 "Auxiliary and operating materials used" Page 226)
The description of the following oil change work applies to all robot var-
iants, irrespective of the variant shown.
8.2 Oil change in A1
Description
The following describes the gear oil change for floor-mounted robots.
Preconditions
• The gear unit is at operating temperature.

• The oil filler hole (magnetic screw plug) in the rotating column is freely
accessible; any covers must be removed beforehand.

CAUTION
High oil and surface temperatures after the robot has stopped op-
erating
If the oil change is carried out immediately after the robot has stopped
operating, the oil temperature and the surface temperature are liable to
be high. Touching them may result in burns.
• Wear protective gloves.
WARNING
Unintended robot motions may result in death, severe injuries and dam-
age to property.
• Secure the robot by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.
8.2.1 Draining the gear oil from A1
Procedure
1. Remove 4 Allen screws with conical spring washers, and take off in-
terface A1 or cover (>>> Fig. 8-2).
2. Pull out the oil drain hose.
3. Place a suitable receptacle under the oil drain hose.
4. Unscrew the union nut of the oil drain hose.
5. Remove the magnetic screw plug.
6. Drain the oil.
7. Check the magnetic screw plug for deposits; take appropriate meas-
ures if necessary.
8. Measure the amount of oil drained and store or dispose of the used
oil in accordance with the pertinent regulations.

KR QUANTEC PA
Maintenance
Fig. 8-2: Draining the oil from A1
1 Collection receptacle 4 Cover

2 Union nut 5 Allen screw
3 Oil drain hose 6 Magnetic screw plug
8.2.2 Filling gear unit A1 with gear oil
Procedure
1. Connect the oil pump to the oil drain hose.

2. Pour in the specified amount of oil via the oil drain hose; the chamber
fills from the bottom.
3. Clean the magnetic screw plug and check the sealing element; ex-
change the magnetic screw plug if damaged.
4. Insert and tighten the magnetic screw plug; MA = 25 Nm.
5. Remove the oil pump.
6. Screw the sealing cap onto the oil drain hose and tighten; then check
for leaks.
7. Stow the oil drain hose in the base frame.
8. Mount interface A1 or cover and fasten it with 4 M6x16 Allen screws
and conical spring washers.

Fig. 8-3: Filling with oil on A1
1 Oil pump 4 Cover

2 Union nut 5 Allen screw
3 Oil drain hose 6 Magnetic screw plug
Description
Precondition
• The robot is in a position in which the oil filler hole and oil drain hole
on the gear unit of axis 2 are accessible.
CAUTION
erating
WARNING
age to property.
tion.

KR QUANTEC PA
Maintenance
Procedure
1. Pull the oil drain hose (>>> Fig. 8-4) out of the rotating column.
2. Release and unscrew the union nut.
3. Place a suitable receptacle under the oil drain hose and remove the
magnetic screw plug.
4. Catch the oil in the receptacle as it drains out.
6. Check the magnetic screw plug for deposits; take appropriate meas-
ures if necessary.
Fig. 8-4: Draining the gear oil from A2
1 Magnetic screw plug 3 Union nut

2 Oil drain hose 4 Collection receptacle
Procedure

3. Clean the M18x1.5 magnetic screw plug and check the sealing ele-
ment; exchange the magnetic screw plug if damaged.
4. Insert and tighten the magnetic screw plug; MA = 20 Nm.
6. Screw the union nut onto the oil drain hose and tighten.
7. Push the oil drain hose back into the rotating column.
8. Check the magnetic screw plug and sealing cap for leaks.

1 Magnetic screw plug 3 Union nut

2 Oil drain hose 4 Oil pump
Description
Preconditions
• The robot is in a position in which the oil filler and drain holes on the
axis 3 gear unit are accessible.
• Axis 3 is in a horizontal position.
CAUTION
erating
WARNING
age to property.
tion.

KR QUANTEC PA
Maintenance
Procedure
1. Place a suitable receptacle (>>> Fig. 8-6) under the lower magnetic
screw plug and remove the magnetic screw plug.
It is easier to drain the oil if an M16x1.5 oil drain hose is screwed into
the tapped hole of the magnetic screw plug.
2. Remove the upper magnetic screw plug.
5. Check both magnetic screw plugs for deposits; take appropriate meas-
ures if necessary.
1 Oil drain hose 3 Lower magnetic screw plug

2 Collection receptacle 4 Upper magnetic screw plug
8.4.2 Filling with gear oil on A3
Procedure

3. Clean both M16x1.5 magnetic screw plugs and check the sealing ele-
ments; exchange magnetic screw plugs if damaged.
4. Insert and tighten the upper M16x1.5 magnetic screw plug; MA = 20
Nm.
6. Remove the oil drain hose, and insert and tighten the lower M16x1.5
magnetic screw plug; MA = 20 Nm.

7. Check both magnetic screw plugs for leaks.

2 Oil pump 4 Upper magnetic screw plug
Precondition
• The robot is in a position in which gear unit A5 is accessible.

• Axis 5 is in a horizontal position.
• An oil drain hose with an M22x1.5 union must be available.
CAUTION
erating
WARNING
age to property.
tion.

KR QUANTEC PA
Maintenance
8.5.1 Draining the gear oil on A5
Procedure
1. Remove the lower magnetic screw plug and check for deposits
(>>> Fig. 8-8).
2. Screw in the oil drain hose with M22x1.5 double nipple.
5. Drain the oil.
6. Check the magnetic screw plugs for deposits; take appropriate meas-
ures if necessary.

2 Collection receptacle 4 Upper magnetic screw plug
8.5.2 Filling the gear oil on A5
Procedure

3. Clean the M22x1.5 magnetic screw plugs and check the sealing ele-
ment; exchange magnetic screw plug if damaged.
4. Insert and tighten the upper magnetic screw plug; MA = 25 Nm.
6. Remove the oil drain hose; insert and tighten the lower magnetic
screw plug; MA = 25 Nm.

7. Check the magnetic screw plugs for leaks.
1 Oil drain hose 4 Upper magnetic screw plug

2 Oil pump 5 Lower magnetic screw plug
CAUTION
erating
WARNING
age to property.
tion.
Precondition
• The tool is removed.

Procedure
1. Remove the lower magnetic screw plug (>>> Fig. 8-10).

KR QUANTEC PA
Maintenance
2. Screw in the oil drain hose with M10x1 double nipple.
5. Drain the oil.
7. Check the magnetic screw plugs for deposits; take appropriate meas-
ures if necessary.
1 Upper magnetic screw plug 3 Oil drain hose

2 Lower magnetic screw plug 4 Collection receptacle
Procedure

3. Clean the magnetic screw plugs and check the sealing elements; ex-
change the magnetic screw plugs if damaged.
4. Insert and tighten the upper M22x1.5 magnetic screw plug; MA =
25 Nm.
6. Remove the oil drain hose; insert and tighten the lower M10x1 mag-
netic screw plug; MA = 7.5 Nm.
7. Check the magnetic screw plugs for leaks.

1 Upper magnetic screw plug 3 Oil drain hose

2 Lower magnetic screw plug 4 Oil pump
8.7 Checking the counterbalancing system
Description
The following describes those tasks which must be carried out at the inter-
vals specified in the maintenance table.
Precondition
• The robot is operational and can be moved at jog velocity.

• There is no hazard posed by system components or other robots.
• The robot is secured if work is being performed directly on the robot.
WARNING
bot.

KR QUANTEC PA
Maintenance
8.7.1 Checking the counterbalancing system
Procedure
Activity Required condition Troubleshooting

Inspect hydraulic The pressure gauge Adjust the counterbalanc-
system. Move the must show the fol- ing system (>>> 9.3 "Fill-
robot and check the lowing values: ing and adjusting the
hydraulic oil pres- counterbalancing system
Link arm in vertical
sure. on a floor-mounted robot"
position: hydraulic oil
Page 188).
pressure 176 bar
Permissible devia-
tion < 5 bar
Check the add-on The add-on parts Clean the counterbalanc-
parts for damage must not be dam- ing system, identify and
and ensure that they aged or leak. eliminate any leaks. If
are clean and do necessary, exchange the
not leak. counter-balancing system
(>>> 8.10 "Exchanging
the counterbalancing sys-
tem on a floor-mounted
robot" Page 179).
Check the condition The collar must not Clean or exchange the
of the collar. be damaged or foul- collar.
ed.
8.8 Greasing the cable set
Precondition
• The robot is accessible in the area of axis 1
WARNING
age to property.
tion.
Procedure
1. Remove 4 Allen screws and conical spring washers, and take off the
cover. If necessary, interface A1 can additionally be carefully pulled
back (>>> Fig. 8-12).
2. Clean the cables between the push-in module and the inlet of the hol-
low shaft of axis 1.
3. Apply cable grease evenly to the cables using a brush and by hand.
Wear protective gloves.
4. Store used grease and grease residues in accordance with the regula-
tions or dispose of it with minimum environmental impact.
5. Mount the cover and fasten it with 4 Allen screws with conical spring
washers.
6. If applicable, carefully insert interface A1 again and fasten it with 4 Al-
len screws and conical spring washers.

Fig. 8-12: Greasing the cable set
1 Inlet of hollow shaft 4 Interface A1

2 Push-in module, flexible tube 5 Allen screws
3 Cover
8.9 Cleaning the robot
Description
The robot must be cleaned in compliance with the instructions given here
in order to prevent damage. These instructions only refer to the robot.
System components, tools and the robot controller must be cleaned in ac-
cordance with the cleaning instructions relevant to them.
The following must be taken into consideration when using cleaning
agents and carrying out cleaning work:
• Only use solvent-free, water-soluble cleaning agents.
• Do not use flammable cleaning agents.
• Do not use aggressive cleaning agents.
• Do not use steam or refrigerants for cleaning.
• Do not use high-pressure cleaners.
• It must be ensured that no cleaning agent enters electrical or mechan-
ical system components.
• Personnel protection measures must be taken.
WARNING
age to property.
tion.

KR QUANTEC PA
Maintenance
Procedure
1. Shut down the robot.

2. If necessary, stop adjacent system components and lock them.
3. Remove enclosures if this is necessary in order to carry out the clean-
ing work.
4. Clean the robot.
5. Fully remove all cleaning agents from the robot.
6. Clean any areas of corrosion and reapply corrosion protection.
7. Remove cleaning agents and equipment from the workspace of the ro-
bot.
8. Dispose of cleaning agents in accordance with the pertinent regula-
tions.
9. Install any safety equipment that has been removed and check that it
is functioning correctly.
10. Replace any damaged or illegible plates and covers.
11. Put back in place any enclosures that have been removed.
12. Only put fully functional robots and systems back into operation.
8.10 Exchanging the counterbalancing system on a floor-mounted robot
Preconditions
• The robot is in the mechanical zero position.

• It must be possible to move the robot about axis 2.
• The robot must be correctly bolted to the floor.
• Any items of equipment that are likely to impede the removal and in-
stallation work have been removed.
• The new counterbalancing system is correctly filled.
WARNING
bot.
WARNING
When removing or installing the counterbalancing system, care must be
taken to avoid injury to arms, hands and fingers by crushing. Wear
gloves and secure the counterbalancing system so that it cannot fall
down or move unexpectedly.
The counterbalancing system weighs approx. 40 kg.
The counterbalancing system is pressurized. Particular caution must
therefore be exercised and special knowledge put to effect when any
work is performed on this system. Any improper handling constitutes a
danger to life and limb.

8.10.1 Removing the counterbalancing system
Procedure
1. Slacken the worm drive clip and push the bellows backwards
(>>> Fig. 8-13).
2. Move the link arm from the -95° position in the plus direction until the
spacer can be inserted between the cylinder and the articulated head.
3. Secure the robot by pressing the EMERGENCY STOP device.
4. Place spacer onto the free piston rod between the articulated head
and the hydraulic cylinder.
5. Put the robot into operation and move the link arm carefully in the mi-
nus direction until the spacer is just clamped.
CAUTION
Material damage due to blocked counterbalancing system
Do not move the counterbalancing system further in the minus direc-
tion. The counterbalancing system, link arm or rotating column may
otherwise be damaged.
‒ Secure the robot by pressing the EMERGENCY STOP device.
6. Secure the counterbalancing system with a rope sling and a crane

and move the crane until the weight is supported by the rope sling.
7. Remove 4 Allen screws and conical spring washers, and take off the
retaining plate.
Fig. 8-13: Removing the counterbalancing system: spacer
1 Clamping bush 4 Lock washer

2 Worm drive clip 5 Allen screw
3 Bellows
8. Secure link arm using a rope sling and crane (>>> Fig. 8-14).

KR QUANTEC PA
Maintenance
Fig. 8-14: Securing the link arm
9. Remove 2 Allen screws and lock washers, and take the cover off the
rotating column (>>> Fig. 8-15).
Fig. 8-15: Removing the counterbalancing system: rotating col-

umn
1 Rope sling 4 Rotating column

2 Allen screw 5 Counterbalancing system
3 Cover
10. Insert the pin locator on the right-hand side between the articulated
head and the link arm (>>> Fig. 8-16).
11. Pull the pin out of the link arm using an M16 pin extractor.
The pin is out of the precision fit area when it has been pulled out ap-
prox. 25 mm.
12. Put the robot into operation and move the link arm carefully in the
plus direction until the articulated head is free. When moving the link
arm, move the crane and rope sling at the same time, so that the
weight of the arm is supported by the crane.
14. Swivel the counterbalancing system up and out of the link arm, mov-
ing the crane and rope sling at the same time.
15. Take off the pin locator, thrust ring and spacer ring that are now loose.

CAUTION
When forcing the counterbalancing system off the rotating column,
an unfavorable position of the center of gravity may cause the coun-
terbalancing system to move unexpectedly. To avoid injury and dam-
age, the tension and position of the rope must be adjusted as nec-
essary.
16. Force the counterbalancing system off the pin in the rotating column in
the direction of the arrow.
While forcing off the counterbalancing system, check the rope tension
and if necessary correct it to prevent the components from being tilted.
17. Continue raising the counterbalancing system with the crane and set it
down on a suitable support.
18. If the counterbalancing system is not to be reinstalled, it must be pro-
tected against corrosion before being put into storage.
If a new counterbalancing system is not being installed immediately, the
robot can be moved into a safe position and the rope securing the link
arm can be removed. The robot may only be moved again in order to in-
stall the new counterbalancing system.
Fig. 8-16: Removing the counterbalancing system: pin
1 Thrust ring 4 Pin

2 Spacer ring 5 Pin locator
3 Articulated head
8.10.2 Installing the counterbalancing system
Procedure for installation
1. Remove corrosion protection from the counterbalancing system and

check that no part of it is missing.
2. If necessary, put the robot into operation and move the link arm into
approximately the -95° position.

KR QUANTEC PA
Maintenance
4. Secure link arm using a rope sling and crane (>>> Fig. 8-17).
5. Lift the counterbalancing system with a rope sling and bring it to the
site of installation (>>> Fig. 8-18).
6. Mount the counterbalancing system sideways on the pin in the rotating
column, and align.
7. If necessary, adjust the rope tension.
8. Mount the cover and fasten with 2 M12x30-10.9 Allen screws and con-
ical spring washers.
9. Tighten the Allen screws with a torque wrench; MA = 104 Nm.
Fig. 8-18: Installing the counterbalancing system: rotating column
1 Rope sling 3 Cover

2 Allen screw 4 Rotating column
10. Put the robot into operation.

11. Move the link arm until the counterbalancing system can be inserted
into the link arm. At the same time, move the element securing the
link arm accordingly (>>> Fig. 8-19).
12. Lower the counterbalancing system, insert the articulated head with
the thrust ring and spacer ring into the link arm, and align.
13. Move the link arm and counterbalancing system until the holes are
aligned.
14. Insert the pin with the aid of the device.

15. Mount the retaining plate and fasten it with 4 M8x20-10.9 Allen screws
and conical spring washers.
16. Tighten the 4 Allen screws with a torque wrench; MA = 31 Nm.
17. Remove the rope sling from the counterbalancing system and the link
arm.
Fig. 8-19: Installing the counterbalancing system: pin
1 Thrust ring 4 Pin

2 Spacer ring 5 Counterbalancing system
3 Articulated head
18. Put the robot into operation.

19. Move the link arm in the plus direction until the spacer between the
cylinder and the articulated head is released, and remove the spacer
(>>> Fig. 8-20).
CAUTION
Material damage due to blocked counterbalancing system
Do not move the counterbalancing system further in the minus direc-
tion. The counterbalancing system, link arm or rotating column may
otherwise be damaged.
‒ Secure the robot by pressing the EMERGENCY STOP device.
20.

KR QUANTEC PA
Secure the robot by pressing the EMERGENCY STOP device.
Maintenance
21. Mount the bellows on the cylinder and the articulated head and fasten
with worm drive clips.
22. Check the pressure on the counterbalancing system (>>> 9.3.1 "Filling
and adjusting the counterbalancing system" Page 189).
Fig. 8-20: Installing the counterbalancing system: link arm
1 Spacer 4 Lock washer

2 Worm drive clip 5 Allen screws
3 Bellows 6 Counterbalancing system


KR QUANTEC PA
Setting
9 Setting
9.1 Counterbalancing system
Description
Depending on various causes, the following work may be required on the

counterbalancing system: These instructions are valid for all variants of
the KR QUANTEC PA.
Cause Activity Description
The counterbalancing Depressu- (>>> 9.2 "Depressurizing the
system must be depres- rize the counterbalancing system on a
surized counterbal- floor-mounted robot" Page 187)
ancing sys-
tem
Incorrect pressure Top up the (>>> 9.3 "Filling and adjusting
gas and oil the counterbalancing system on
pressure a floor-mounted robot"
Page 188)
The counterbalancing Top up the (>>> 9.3 "Filling and adjusting
system has been gas and oil the counterbalancing system on
drained and must be re- pressure a floor-mounted robot"
filled Page 188)
9.2 Depressurizing the counterbalancing system on a floor-mounted robot
Description
These instructions are valid for floor-mounted robots.

• A high-pressure hose and collection receptacle must be available.
• The robot must be correctly bolted to the floor.
WARNING
bot.
9.2.1 Depressurizing the counterbalancing system
Procedure
1. Move the link arm into a vertical position and secure it using a crane
(>>> Fig. 9-1).
The link arm must not be able to move after reducing the oil pressure.

Setting KR QUANTEC PA
2. Remove the screw cap and connect the hose to the vent connection
(>>> Fig. 9-2).
3. Drain the hydraulic oil into the collection receptacle.
The draining process is complete when the pressure gauge indicating
the oil pressure reads zero and no more oil flows into the receptacle.
4. Store used hydraulic oil in accordance with the regulations and dis-
pose of it with minimum environmental impact.
Fig. 9-2: Draining the hydraulic oil
1 Screw cap 4 Collection receptacle

2 Vent valve 5 2nd vent valve
3 Hose 6 Pressure gauge
9.3 Filling and adjusting the counterbalancing system on a floor-mounted

robot
Description
These instructions are valid for floor-mounted robots.

The gas pressure must always be set on both diaphragm accumulators!
The pressure settings for the relevant robots can be taken from the follow-
ing table.

KR QUANTEC PA
Setting
Robot PGas POil
KR 240 R3200 PA 156 bar 176 bar
KR 240 R3200 PA 156 bar 176 bar
arctic
KR 240 R3200 PA-HO 156 bar 176 bar
KR 180 R3200 PA 156 bar 176 bar
KR 180 R3200 PA 156 bar 176 bar
arctic
KR 180 R3200 PA-HO 156 bar 176 bar
KR 120 R3200 PA 156 bar 176 bar
KR 120 R3200 PA 156 bar 176 bar
arctic
KR 120 R3200 PA-HO 156 bar 176 bar
Preconditions
• A high-pressure hose and collection receptacle must be available.

• A nitrogen cylinder with pressure reducer must be available. Minimum
pressure 170 bar.
• An accumulator filling device must be available.
• A hydraulic pump must be available.
NOTICE
The work described below must be carried out at room temperature. If
necessary, the counterbalancing system must be allowed sufficient time
for the temperature to adjust.
Make sure to use the correct oil type when filling (>>> 8 "Maintenance"
Page 159)!
WARNING
bot.
9.3.1 Filling and adjusting the counterbalancing system
Procedure
1. Move the link arm into a vertical position and secure it using a crane
(>>> Fig. 9-3).
The link arm must not be able to move after reducing the hydraulic oil
pressure.

2. Remove the screw cap and connect the hose to the vent valve
(>>> Fig. 9-4).
3. Place a suitable receptacle under the hose and collect the hydraulic
oil.
Fig. 9-4: Draining the hydraulic oil
1 Screw cap 4 Collection receptacle

2 Vent valve 5 2nd vent valve
3 Hose 6 Pressure gauge
4. Drain the oil until the pressure gauge reads zero.

The oil side of the diaphragm accumulator is now depressurized and
can be vented during subsequent filling of the gas side.
Leave hose connected to the vent valve and leave the vent valve
open.
5. Connect the filling and testing device (accessory) for the diaphragm
accumulator to a standard commercial nitrogen cylinder via the hose
and a pressure reducer.
Further information about the filling and testing device can be found
in the supplier documentation.
6. Set the pressure reducer to PGas.

KR QUANTEC PA
Setting
WARNING
For safety reasons, the Allen screw on the accumulator may under
no circumstances be unscrewed by more than a quarter of a turn
without the filling and testing device being connected. The pressure
in the accumulator may never be adjusted without the filling and
testing device connected.
7. Remove the protective caps (>>> Fig. 9-5) from the diaphragm accu-
mulator and unscrew the Allen screw slightly (without a torque wrench,
by a quarter of a turn at the most).
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
must be replaced. This must only be done when the diaphragm accu-
mulator is completely depressurized.
8. Connect the filling and testing device to the gas connection of the dia-
phragm accumulator. Turn the gas valve rod counterclockwise, thereby
opening the gas connection via the Allen screw; a full turn is necessa-
ry after the start of pointer deflection on the pressure gauge of the fill-
ing and testing device.
The pressure gauge on the pressure reducer indicates the nitrogen
pressure in the diaphragm accumulator. If the nitrogen pressure is too
low, continue from step 9. If the nitrogen pressure is greater than
PGas, continue from step 11.
9. Open the shut-off valve on the nitrogen cylinder and raise the nitrogen
pressure to PGas +10 bar.
10. Close the shut-off valve.
11. Open the pressure relief valve and discharge nitrogen until the speci-
fied pressure of PGas is reached.
The reading on the pressure gauge must be rechecked after 2 to 3
minutes and the nitrogen pressure corrected if necessary.
12. Turn the Allen screw clockwise by means of the gas valve rod and
tighten it. Then open the pressure relief valve and discharge the re-
maining pressure in the hose.
13. Disconnect filling and testing device from diaphragm accumulator.
The filling and testing device may only be disconnected if the Allen
screw has been tightened by means of the gas valve rod.
14. Firmly retighten the Allen screw; MA = 20 Nm.

Fig. 9-5: Setting the gas pressure
1 Protective cap 6 Hose

2 Allen screw 7 Pressure reducer
3 Diaphragm accumulator 8 Gas valve rod
4 Nitrogen cylinder 9 Pressure relief valve
5 Shut-off valve 10 Pressure gauge
15. Screw on the protective caps.

16. Release and remove the hose on the nitrogen cylinder.
17. Unscrew the screw cap on the filler neck (>>> Fig. 9-6) and connect
the hydraulic hose.
The hydraulic hose must already be free from air.
18. Dip the high-pressure hose into the liquid in the collection receptacle.
19. Put the hydraulic pump into operation and allow hydraulic oil to flow
out into the collection receptacle until no more bubbles escape.
The reservoir of the hydraulic pump must only be filled with filtered hy-
draulic oil (filter gauge 3 µm).
20. Close the vent valve at the vent connection.
21. Continue to operate the hydraulic pump until the hydraulic oil pressure
is approx. 15 bar above the specified value of POil. Then lower the
pump pressure to “0”. Do not exceed the pressure, as the bursting
disc ruptures at a pressure of 210 bar!
22. After approx. 10 minutes, check the hydraulic oil pressure and reduce
it to POil by opening the vent valve.
23. Unscrew the hydraulic hose and screw the screw cap back onto the
filler neck.
24. Unscrew the high-pressure hose and screw the screw cap back onto
the vent connection.
25. Unscrew the screw plug from the underside of the counterbalancing
system and remove any leaked oil; then screw the screw plug back in
and tighten with MA 20 Nm.
26. Remove crane and elements securing the link arm.

KR QUANTEC PA
Setting
27. Move robot about axis 2.
28. Check the counterbalancing system for pressure loss or leaks.
The pressure must be unchanged and there must be no visible leaks.
Otherwise, the adjustment process must be repeated or the counter-
balancing system exchanged.
Fig. 9-6: Topping up the hydraulic oil
1 Vent connection 5 Hydraulic pump

2 Filler neck 6 Hydraulic hose
3 High-pressure hose 7 Screw plug
4 Collection receptacle


KR QUANTEC PA
Repair
10 Repair
Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA. Information about KUKA College and its training
program can be found at www.kuka.com or can be obtained directly from
our subsidiaries.
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.
CAUTION
For screwed connections, the fastening screws (standard, strength class
8.8) are to be tightened with the tightening torques specified in the ap-
pendix (>>> 13 "Appendix" Page 225). Tightening torques deviating from
these values are specified directly.
The specified screw sizes and strength classes are those valid at the
copy deadline. The specifications contained in the Parts Catalog are,
however, always to be taken as the most up-to-date information.
Screws of strength class 10.9 and higher as well as screws with test
certification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.
Further information about KUKA tightening torques can be found in the

Appendix (>>> 13 "Appendix" Page 225).
10.1 Exchanging motor A1
Description
The following instructions describe the exchange of motor A1.
Precondition
• The robot is secured against motions of axis 1.

• The motor is freely accessible; any covers must be removed before-
hand.
WARNING
age to property.
tion.
CAUTION
Risk of burns on hot surfaces
High motor surface temperatures immediately after the robot has stop-
ped operating can lead to burns. Injuries may result.
• Protective gloves must be worn.

Repair KR QUANTEC PA
WARNING
Risk of crushing during removal and installation of motor
When removing or installing the motor, there is a risk of injury by crush-
ing. This could result in hand injuries.
NOTICE
Wear and premature failure due to damage to toothing
Damage to the toothing of the motor and gear unit can lead to in-
creased wear and premature failure of the components.
• During cleaning, ensure that the toothing is not damaged.
• Before installation, check the toothing of the motor and gear unit for
damage.
10.1.1 Removing the motor on axis 1
Procedure
1. Release and unplug connectors XM1 and XP1 at the sockets

(>>> Fig. 10-1).
2. Remove 4 Allen screws.
3. Release and lift out motor A1, being careful not to tilt it.
4. Dispose of motor A1.
5. Cover the input shaft and protect it against fouling.
Fig. 10-1: Removing motor A1
1 Motor, axis 1 3 Connector XM1

2 Allen screws 4 Connector XP1
10.1.2 Installing the motor on axis 1
Procedure
1. Remove corrosion protection from new motor A1, if applicable

(>>> Fig. 10-2).
2. Clean the toothing of the motor and the gear unit before installation
and apply a thin but continuous coat of Microlube GL 261 grease.
3. Clean the mounting surface of motor A1 on the motor mount.
4. Check the condition of the O-ring on the motor shaft. The additional
back-up ring must be present.
5. Position sockets XM1 and XP1 as shown.
6. Insert motor A1; do not tilt while it is being installed.

KR QUANTEC PA
Repair
Insertion of motor can be facilitated by turning it gently about its ro-
tational axis.
7. Insert 4 M12x25-8.8 Allen screws.

8. Tighten 4 Allen screws with a torque wrench in diagonally opposite se-
quence. Gradually increase the tightening torque to a value of 78 Nm.
9. Plug connectors XM1 and XP1 into the sockets.
10. Remove safeguards against the robot turning about axis 1.
11. Carry out mastering of axis 1.
Detailed information about mastering is contained in the operating
and programming instructions for end users or system integrators.
Fig. 10-2: Installing motor A1
1 Motor A1 4 Allen screws

2 O-ring with back-up ring 5 Connector XM1
3 Toothing 6 Connector XP1
Description
The following instructions describe the removal and installation of motor

A2.
Precondition
• The robot is secured against rotational motions about axis 2.

WARNING
age to property.
tion.
CAUTION
WARNING
NOTICE
damage.
Procedure
1. Secure the link arm using a rope sling (>>> Fig. 10-3).
2. Raise the rope sling until it is ensured that the link arm cannot move
after removal of the motor.

(>>> Fig. 10-4).

KR QUANTEC PA
Repair
4. Place the rope sling around motor A2 and raise it using the crane until
the weight of motor A2 is supported by the rope sling.
6. Release and pull out motor A2, being careful not to tilt it.
7. If the motor on A2 is not to be reinstalled, it must be set down and
protected against corrosion before being put into storage.
1 Connector XM2 4 Motor A2

2 Connector XP2 5 Rope sling
3 Allen screws
Procedure
1. Remove corrosion protection from the new motor A2.

2. Clean the toothing of motor A2 and gear unit before installation and
apply a thin but continuous coat of Microlube GL 261 grease
(>>> Fig. 10-5).
3. Clean the mounting surface of motor A2 on the gear unit.
4. Check the condition of the O-ring on the motor shaft.
6. With the rope sling, pick up and insert motor A2, being careful not to
tilt it.
tational axis.

9. Slacken and remove the rope sling.
11. Remove elements securing the link arm.

1 Connector XM2 4 Toothing

2 Connector XP2 5 Allen screws
3 O-ring 6 Motor A2
Description

A3.
Precondition
• The robot is secured against rotational motions about axis 3.
WARNING
age to property.
tion.
CAUTION

KR QUANTEC PA
Repair
WARNING
NOTICE
damage.
Procedure
1. Secure the arm using a rope sling (>>> Fig. 10-6).

2. Raise the rope sling until it is ensured that the arm cannot move after
removal of the motor.
Fig. 10-6: Securing the arm

(>>> Fig. 10-7).

1 Allen screws 4 Motor A3

2 Connector XP3 5 Rope sling
3 Connector XM3
Procedure

(>>> Fig. 10-8).
tilt it.
tational axis.


KR QUANTEC PA
Repair
1 Allen screws 5 Connector XM3

2 Toothing 6 Motor A3
3 O-ring 7 Rope sling
4 Connector XP3
11. Remove elements securing the arm.

Description
The following describes the removal and installation of motor A5 for floor-
mounted robots.
Preconditions
• The robot is secured against motion about axis 5.

• Tools are removed or secured in such a way that axis 5 cannot move.
WARNING
age to property.
tion.

CAUTION
WARNING
NOTICE
damage.
Procedure
1. Secure the wrist using a rope sling or by supporting it from below.

2. Raise the rope sling until it is ensured that the arm cannot move after
removal of the motor.
(>>> Fig. 10-9).
7. If motor A5 is not to be reinstalled, it must be set down and protected
against corrosion before being put into storage.

KR QUANTEC PA
Repair
1 Allen screws 4 Connector XM5

2 Motor A5 5 Rope sling
3 Connector XP5
Procedure

(>>> Fig. 10-10).
tilt it.
tational axis.



2 Toothing 5 Connector XP5
3 O-ring 6 Connector XM5
11. Remove elements securing the arm.

Description

A6.
Precondition
• The robot is secured against motion about axis 6.

• The tooling is dismounted or secured so that it cannot move once the
motor has been removed.
• The arm is in a near-horizontal position, so that motor A6 is accessi-
ble from above.
• The energy supply system does not block access to the motor.
WARNING
age to property.
tion.

KR QUANTEC PA
Repair
CAUTION
WARNING
NOTICE
damage.
Procedure

(>>> Fig. 10-11).
3. Release and lift out motor A6 vertically, being careful not to tilt it.
1 Motor A6 3 Connector XM6

2 Connector XP6 4 Allen screws
Procedure

2. Clean the toothing on motor A6 and in the gear unit before installation
and apply a thin but continuous coat of Microlube GL 261 grease
(>>> Fig. 10-12).
3. Clean the mounting surface for motor A6 on the swing frame.
5. Lift and insert motor A6; do not tilt while it is being installed.
tational axis.

1 Toothing 4 Connector XM6

2 O-ring 5 Connector XP6
9. Remove the elements securing the tooling.

10.6 Description of the electrical installations (robot)
Overview
The electrical installations of the robot consist of:

• Cable set
• Multi-function housing MFH for motor cable
• Junction box for data cable, RDC box

KR QUANTEC PA
Repair
Description
The electrical installations (>>> Fig. 10-13) include all the supply and con-
trol cables for the motors of axes 1 to 6. All the connections on the mo-
tors are screwed plug-and-socket connections. The assembly consists of
the cable set, the multi-function housing MFH on the push-in module and
the RDC box in the rotating column. The interface for the connecting ca-
bles is located at the back of the base frame on the push-in module. The
motor cable X30 and the data cable X31 are connected here via plug-in
connections. The data and motor cables are routed through the axis 1
gear unit to the motors (XM connectors) or, in the case of the data
cables, to the RDC box on the rotating column. From the RDC box, the
motors are connected via the XP connectors. All the connectors on the
motors are freely accessible.
The protective circuit is also integrated into the cable set. The ground con-
ductor is connected to the base frame via a ground conductor bolt.
The selected cable routing ensures that the cables are guided without
strain or kinking throughout the entire motion range of the robot.
The following diagram gives an overview of the installation and routing of
the cables on the manipulator.
Fig. 10-13: Electrical installations, overview
1 Motor, axis 6 6 Push-in module

2 Motor, axis 5 7 Motor, axis 2
3 Motor, axis 3 8 Flexible tube, A2-A3
4 Motor, axis 1 9 Flexible tube, A3-A6
5 RDC box

Wiring diagrams
Designation Connection Figure

Wiring diagram A1 XM1 (>>> Fig. 10-14)
Wiring diagram, RDC
Data cable (>>> Fig. 10-19)
X31
Wiring diagram, RDC
Data cable (>>> Fig. 10-20)
X32
Protective circuit Ring cable lug (>>> Fig. 10-21)

KR QUANTEC PA
Repair
Fig. 10-14: Wiring diagram, axis 1


KR QUANTEC PA
Repair


KR QUANTEC PA
Repair

Fig. 10-19: Wiring diagram, RDC X31
Fig. 10-20: Wiring diagram, RDC X32

KR QUANTEC PA
Repair
Fig. 10-21: Wiring diagram, protective circuit


KR QUANTEC PA
Decommissioning, storage and disposal

11 Decommissioning, storage and disposal
11.1 Decommissioning
Description
This section describes all the work required for decommissioning the robot
if the robot is to be removed from the system. After decommissioning, it is
prepared for storage or for transportation to a different location.
Following its removal, the robot can be transported by means of transport
tackle and crane or by fork lift truck (>>> 6 "Transportation" Page 147).
Preconditions
• The removal site must be accessible with a crane or with a fork lift
truck for transportation.
• There is no hazard posed by system components.
Procedure
WARNING
bot.
1. Secure the robot.

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

Decommissioning, storage and disposal KR QUANTEC PA
4. Secure the robot by pressing the E-STOP button and then shut down
the robot (>>> Fig. 11-2).
5. Release and unplug all peripheral connections.
6. Release and unplug the motor cable and data cable connectors.
7. Unscrew the hexagon nut from the ground conductor, take off the
washers and lock washers and pull off the ground conductor.
8. Attach lifting tackle to the robot or prepare the robot for transportation
with the fork lift truck. Minimum payload capacity for transportation: ap-
prox. 2.0 t.
If, due to its installation position, it is not possible to lift the robot with
a fork lift truck or with a crane and lifting tackle, the “Recovery aid” ac-
cessory (00-187-214) is available as an option.
9. Unscrew and remove the 8 hexagon bolts and conical spring washers.
10. Lift the robot vertically off the mounting surface and transport it away.
Take care not to damage the two pins when lifting off the robot.
CAUTION
If the robot is caught on the mounting surface, it may come free
abruptly, endangering persons and property.
The robot must stand loosely on the mounting surface; completely
remove all fastening materials and any adhesives.
11. Prepare the robot for storage.
Fig. 11-2: Removing the robot
1 Hexagon bolts 5 Data cable

2 Pin 6 Ground conductor 2x
3 Mounting surface 7 Lifting tackle
4 Motor cable
11.2 Storage
Description
If the robot is to be put into long-term storage, the following points must
be observed:

KR QUANTEC PA
Decommissioning, storage and disposal

• The place of storage must be as dry and dust-free as possible.
• Avoid temperature fluctuations.
• Avoid wind and drafts.
• Avoid condensation.
• Use appropriate coverings that cannot detach themselves and which
can withstand the expected environmental conditions.
• Do not leave any loose parts on the robot, especially ones that might
knock against other parts.
• Do not leave the robot exposed to direct sunlight while in storage.
• Observe and comply with the permissible temperature ranges for stor-
age.
• Select a storage location in which the packaging materials cannot be
damaged.
Procedure
1. Remove tools and equipment.

2. Remove the robot.
3. Clean and dry the robot. No dirt or cleaning agent residue may remain
on or in the robot.
4. Perform a visual inspection of the robot.
5. Remove any foreign bodies.
6. Remove any corrosion.
7. Attach all covers to the robot and check that the seals are correctly in
place.
8. Seal off electrical connections with suitable covers.
9. Seal hose connections by suitable means.
10. Cover the robot with plastic film and seal it at the base frame against
dust.
If necessary, add a desiccant beneath the sheeting.
11.3 Disposal
When the manipulator reaches the end of its useful life, it can be removed
from the system and dismantled, and the materials can be disposed of
properly by type.
The following table provides an overview of the materials used in the ma-
nipulator. All plastic components are marked with a material designation
and must be disposed of accordingly.
WARNING
The hydropneumatic counterbalancing system on the robot is filled with
nitrogen and hydraulic oil under pressure; improper handling can lead to
personal injury and damage to property. If the hydropneumatic counter-
balancing system to be disposed of, it must first be properly depressur-
ized. Only pressure-free counterbalancing systems may be authorized
for disposal.
Material Subassembly, component Additional information

Metals
Cast-iron Base frame, rotating col-
material umn, link arm, wrist main
body

Decommissioning, storage and disposal KR QUANTEC PA
Material Subassembly, component Additional information

Copper Cables, wires
Light alloy In-line wrist housing, spur
casting gear housing, swivel hous-
ing, arm
Steel Gear units, screws and
washers
Electrical parts
Electronic components, Recycle.
such as RDC, EDS, etc.
Motors Dispose of motors without
dismantling.
Plastics
ETFE Flexible tube, protective
fabric sleeve
PA 6, PA R Hinged clamps, flexible
AB tubes
PE 500 End stop buffers
PU Hoses
PUR Cable sheaths
Viton, FKM, O-rings
FPM
Auxiliary substances and consumables
Gear oil Gear units Optigear Synt. ALR 150
Gear oil Gear units, arctic variant Alphasyn T 32
Gear oil Counterbalancing system, Hydraulic oil Shell Spirax
arctic variant S1 ATF TASA
Gear oil Gear units, HO variant Optileb GT 1800/220
Hydraulic oil Counterbalancing system Hyspin ZZ 46 hydraulic oil
Gear oil Counterbalancing system, Hydraulic oil Shell Spirax
arctic variant S1 ATF TASA
Lubricating Counterbalancing system, LGEP 2 lubricating grease
grease bearing on rotating col-
umn / link arm
Lubricating Gear teeth Microlube GL 261 grease
grease
Lubricating Cabling Lubricating grease Opti-
grease temp RB2
Lubricant for Cabling, HO variant Lubricating grease, Klüber-
food machi- food NH1 34-401
nery
Up-to-date safety data sheets must be requested from the manufacturers
of auxiliary and operating materials. Further information about the auxiliary
substances and consumables used can be found under:
(>>> 13.3 "Auxiliary and operating materials used" Page 226).

KR QUANTEC PA
Options
12 Options
12.1 Control cable for single axis (optional)
Description
The control cable for single axis is used when additional axes (e.g. KUKA
linear unit or turntables) are controlled via the robot. In this case, the con-
trol cable is guided from the RDC box through the hollow shaft of A1 to a
connector interface on the push-in module.
12.2 Release device (optional)
Description
The release device can be used to move the manipulator manually after
an accident or malfunction. The release device can be used for all the
motors of this manipulator. It is only for use in exceptional circumstances
and emergencies (e.g. for freeing people).
The release device is mounted on the base frame of the manipulator. This
assembly also includes a ratchet and a set of plates with one plate for
each motor. The plate specifies the direction of rotation for the ratchet and
shows the corresponding direction of motion of the manipulator.

Options KR QUANTEC PA

KR QUANTEC PA
Appendix
13 Appendix
13.1 Tightening torques
Tightening torques
The following tightening torques (Nm) are valid for screws and nuts where
no other specifications are given.
The specified values apply to lightly oiled black (e.g. phosphated) and
coated (e.g. mech. galv., zinc flake plating, screw locking elements)
screws and nuts.
Strength class
Thread 8.8 10.9 12.9
M1.6 0.17 Nm 0.24 Nm 0.28 Nm
M2 0.35 Nm 0.48 Nm 0.56 Nm
M2.5 0.68 Nm 0.93 Nm 1.10 Nm
M3 1.2 Nm 1.6 Nm 2.0 Nm
M4 2.8 Nm 3.8 Nm 4.4 Nm
M5 5.6 Nm 7.5 Nm 9.0 Nm
M6 9.5 Nm 12.5 Nm 15.0 Nm
M8 23.0 Nm 31.0 Nm 36.0 Nm
M10 45.0 Nm 60.0 Nm 70.0 Nm
M12 78.0 Nm 104.0 Nm 125.0 Nm
M14 125.0 Nm 165.0 Nm 195.0 Nm
M16 195.0 Nm 250.0 Nm 305.0 Nm
M20 370.0 Nm 500.0 Nm 600.0 Nm
M24 640.0 Nm 860.0 Nm 1030.0 Nm
M30 1330.0 Nm 1700.0 Nm 2000.0 Nm
Strength class
Thread 8.8 10.9
ISO7991 ISO7380, ISO07381
Allen screw Fillister head
screw
M3 0.8 Nm 0.8 Nm
M4 1.9 Nm 1.9 Nm
M5 3.8 Nm 3.8 Nm
Strength class
Thread 10.9
DIN7984
Pan head screws
M4 2.8 Nm
Tighten M5 domed cap nuts with a torque of 4.2 Nm.

Appendix KR QUANTEC PA
13.2 Tightening torque for stainless steel screws
Tightening torques for stainless steel screws
The tightening torques (Nm) specified here are valid for stainless steel
screws and nuts where no other specifications are given.
The specified values are valid for lightly oiled screws and nuts.
Stainless steel
Stainless steel Stainless steel
Screw size A2-70 and
A4-80 A2-50
A4-70
M3 1.0 0.8 0.4
M4 2.4 1.9 0.9
M5 4.8 3.8 1.9
M6 8.0 6.4 3.1
M8 19.5 15.5 7.5
M10 38.5 30.5 15.0
M12 66.0 52.0 25.5
M14 106.0 84.0 41.0
M16 165.0 130.0 64.0
M20 320.0 253.0 125.0
M24 557.0 441.0 217.0
M30 1107.0 876.0 --
13.3 Auxiliary and operating materials used
Product designation / Use Manufacturer designation /

Article number Address
Alphasyn T 32 Gear oil BP Europa SE

Geschäftsbereich Industrieschmierstoffe
0000-335-761
Erkelenzer Strasse 20
D-41179
Mönchengladbach
Germany
Castrol Hyspin ZZ 46 Hydraulic oil Deutsche Castrol Vertriebsgesell-

schaft mbH
0083-236-203
Max-Born-Str. 2
D-22761
Hamburg
Germany
Klüberfood NH1 34-401 Lubricating grease Klüber Lubrication München KG

Geisenhausenerstr. 7
0000-287-986
D-81379
Munich
Germany
LGEP 2 Lubricating grease SKF Maintenance Products

Postboks 1008
0000-119-990
NL-3430
BA Nieuwegein
Netherlands

KR QUANTEC PA
Appendix
Microlube GL 261 Lubricating grease Klüber Lubrication München KG
Geisenhausenerstr. 7
0000-135-463
D-81379
Munich
Germany
Optigear Synt. Gear oil BP Europa SE

ALR 150_EEA Geschäftsbereich Industrieschmierstoffe
0000-362-835 for Europe-
D-41179
an Economic Area
Mönchengladbach
Optigear Synt. Germany
ALR 150_AM1
0000-361-461 for USA,
Canada, Mexico, Chile,
Peru
Optigear Synt.
ALR 150_CHN
0000-361-473 for China
Optigear Synt.
ALR 150_APeC1
0000-361-476 for India,
Taiwan, Japan, Thailand,
South Korea, Malaysia
Article numbers for further
regions can be found in
KUKA Xpert.
Optileb GT 1800/220 Gear oil Deutsche BP Aktiengesellschaft - In-

dustrial Lubricants & Services
0000-125-302
D-41179
Mönchengladbach
Germany
Optitemp RB 2 Lubricating grease Deutsche BP Aktiengesellschaft - In-

dustrial Lubricants & Services
0000-101-456
D-41179
Mönchengladbach
Germany
Shell Spirax S1 ATF TA- Hydraulic oil Shell Deutschland Oil GmbH
SA Suhrenkamp 71-77
D-22335
0000-188-241
Hamburg
Germany
To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.
13.4 Information sheet for products
Section 1
Designation of the product and of the company

• Product identifier:
‒ Trade name:
KUKA industrial robot with hydropneumatic counterbalancing
system
• Relevant identified use of the product that is advised against:
No further relevant information available.
• Use of the product:
Robot for industrial use
• Details of the supplier providing the information sheet:
Manufacturer/suppli- KUKA Deutschland GmbH
er:
Address: Zugspitzstrasse 140
Postal code: D‑86165 Augsburg
Country: Germany
Phone: +49 821 797 4000
Fax: +49 821 797 40400
e-mail [email protected]
Department for infor- KUKA Deutschland GmbH Quality Assurance
mation: department
+49 821 797 1747
Information in case During normal operating hours
of emergency:
+49 821 797 1747
• Note on the information sheet for products:

There is no legal obligation to create a safety data sheet for a prod-
uct. In order to make information typically contained in a safety data
sheet available for products, however, the present “Information Sheet
for Products” was created.
Your attention is expressly drawn to the fact that the information sheet
for products is an information sheet created voluntarily that is not sub-
ject to the formal requirements of Regulation (EC) No. 1907/2006
(REACH Regulation).
Section 2
Possible hazards
• Classification of the substance or mixture:
‒ Classification acc. to Regulation (EC) No. 1272/2008 (CLP Regula-
tion):
This product is not classified according to the CLP Regulation.
• Classification acc. to Directive 67/548/EEC or Directive 1999/45/EC:
Not applicable
• Particular safety warnings for persons and the environment:
Not applicable
• Classification system:
Not applicable
• Label elements

KR QUANTEC PA
Appendix
Labeling acc. to Reg- Not applicable
ulation (EC) No.
1272/2008 (CLP
Regulation):
Hazard symbol: Not applicable
Signal word: Not applicable
Hazard statements: Not applicable
• Other hazards
‒ Results of PBT and vPvB assessment
PBT Not applicable
vPvB Not applicable
Section 3
Composition / information about the components

• Chemical characterization:
Mixtures
‒ Description:
Robot for industrial use
• Hazardous components:
The robot is equipped with a counterbalancing system, filled with ni-
trogen.
CAS: 7727‑37‑9 Nitrogen Press. Gas, H281
EINECS: 231‑783‑9
The exact wording of the hazard statements listed above can be found
in section 16 (>>> "Section 16" Page 233).
Section 4
First aid measures

• Description of first aid measures:
‒ General information:
No special measures required.
• Most important symptoms and effects, both acute and delayed:
• Indication of any immediate medical attention and special treatment
needed:
Section 5
Fire-fighting measures
• Extinguishing agents:
Suitable Adjust the fire-extinguishing measures to suit
extinguishing agents: the environment.

• Special hazards arising from the substance or mixture:

• Advice for firefighters:
‒ Special protective equipment:
Section 6
Measures after unintended release

• Personal precautions, protective equipment and emergency proce-
dures:
Not required
• Environmental protection measures:
• Methods and material for containment and cleaning up:
• Reference to other sections
For information on safe handling, see section 7 (>>> "Section 7"
Page 230).
For information on personal protective equipment, see section 8
(>>> "Section 8" Page 230).
For information on disposal, see section 13 (>>> "Section 13"
Page 232).
Section 7
Handling and storage

• Precautions for safe handling:
• Instructions relating to fire and explosion protection:
• Conditions for safe storage, including any incompatibilities:
‒ Storage
Requirements re- No special requirements
garding storage
rooms and contain-
ers:
Information on stor- Not required
age with other prod-
ucts:
Further specifica- None
tions concerning
storage conditions:
• Specific end uses:
Section 8
Limitation and monitoring of exposure / Personal protective equip-

ment
• Additional information for the design of technical systems:
No further specifications, see section 7 (>>> "Section 7" Page 230).

KR QUANTEC PA
Appendix
• Control parameters
Components with applicable occupational exposure limit values:
The product contains no relevant amounts of materials that are subject
to monitoring of limit values in the workplace.
• Limitation and monitoring of exposure:
‒ Personal protective equipment:
Respiratory protec- Not required
tion:
Hand protection: Chemical protective gloves are not re-
quired.
Eye protection: Not required
Section 9
Physical and chemical properties

• Information on basic physical and chemical properties:
‒ General information
Form: Solid
Color: As per product description
Odor: Odorless
Melting point/range: Not determined
Flash point: Not applicable
Auto-ignition: The product does not auto-ignite.
Risk of explosion: The product presents no danger of explo-
sion.
Density: Not determined
Solubility/miscibility Insoluble
in water:
Additional informa- No further information available.
tion:
Section 10
Stability and reactivity

• Possibility of hazardous reactions:
No hazardous reactions known.
• Conditions to be avoided
No relevant information available.
• Incompatible materials
• Hazardous decomposition products
No hazardous decomposition products known.
Section 11
Toxicological information
• Information on toxicological effects:
‒ Acute toxicity:

Primary irritation ef- No irritation

fect on skin:
Primary irritation ef- No irritation
fect on eyes:
Sensitization: No sensitizing effect known.
Additional toxicologi- The product is not subject to labeling obli-
cal information: gations due to the method of calculation
in the latest version of the “EC General
Classification Directive for Preparations”.
Section 12
Ecological information
• Toxicity:
Aquatic toxicity: No further relevant information available.
• Persistence and degradability:
• Bioaccumulative potential:
• Mobility in soil:
• Additional ecological information:
General information: No known hazard to water.
• Results of PBT and vPvB assessment:
PBT Not applicable
vPvB Not applicable
• Other adverse effects:

Section 13
Disposal information
• Waste treatment methods:
Recommendation: Speak with manufacturer regarding recycling.
• Contaminated packaging:
Recommendation: Disposal in accordance with the applicable regula-
tions.
Section 14
Transport information
• UN number
‒ ADR, RID, ADN:
Not subject to the provisions (transitional provision 1.6.1.46)
‒ IMDG code, IATA:
UN 3164
• UN proper shipping name:
‒ IMDG code, IATA:
ARTICLES, PRESSURIZED, HYDRAULIC (containing non-flamma-
ble gas)

KR QUANTEC PA
Appendix
• Transport hazard classes:
‒ ADR, RID, ADN:
Not applicable (transitional provision 1.6.1.46)
‒ IMDG code:
Class: 2.2 Non-flammable, non-toxic gas

Hazard label: 2.2
Marine pollutants: No
EmS number: F-C, S-V
Shipping: P003, PP32
‒ IATA:
Class: 2.2 Non-flammable, non-toxic gas
Hazard label: -
Shipping: Packaging instructions 208 (a)
• Packaging group:
Not applicable
• UN “Model Regulation”:
UN 3164 ARTICLES, PRESSURIZED, HYDRAULIC, 2.2
NOTE: Detailed information on the amount of nitrogen contained for each
KUKA industrial robot with a hydropneumatic counterbalancing system is
available at https://xpert.kuka.com.
NOTE: Robots with counterbalancing systems that are not filled with nitro-
gen are not subject to the regulations on dangerous goods!
Section 15
Regulatory information
• Chemical safety assessment:
Chemical safety assessment has not been performed.
Section 16
Other information
The information given is based on our present knowledge. However, this
shall not constitute a guarantee for any specific product characteristics
and shall not establish a legally valid contractual relationship.
• Relevant phrases:
H281: Contains refrigerated gas; may cause cryogenic burns or injury
13.5 Applied standards and regulations
Name/Edition Definition

2006/42/EC:2006 Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Coun-
cil of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)
2014/68/EU:2014 Pressure Equipment Directive:

Directive 2014/68/EU of the European Parliament and of the Coun-
cil dated 15 May 2014 on the approximation of the laws of the
Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing
system.)
EN Safety of machinery:
60204-1:2006+A1:2009
Electrical equipment of machines – Part 1: General requirements
EN 61000-6-2:2005 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial environments
EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

A1:2011
Part 6-4: Generic standards; Emission standard for industrial envi-
ronments
EN 614-1:2006+A1:2009 Safety of machinery:

Ergonomic design principles - Part 1: Terms and general principles
EN ISO 10218-1:2011 Industrial robots – Safety requirements:

Part 1: Robots
Note: Content equivalent to ANSI/RIA R.15.06-2012, Part 1
EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery:

Safety-related parts of control systems - Part 1: General principles
of design
EN ISO 13849-2:2012 Safety of machinery:

Safety-related parts of control systems - Part 2: Validation
EN ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design

KR QUANTEC PA
KUKA Service
14 KUKA Service
14.1 Requesting support
Introduction
This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.
Information
The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used
14.2 KUKA Customer Support
The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

KUKA Service KR QUANTEC PA

KR QUANTEC PA
Index Connecting cables.. 17, 34, 43, 52, 61, 70, 79,
88, 97, 106, 143
2006/42/EC:2006.......................................... 234
Connecting cables interface.........................154
2014/68/EU:2014.......................................... 234
Control cable, single axis.............................223
95/16/EC....................................................... 234
Counterbalancing system.........................14, 29
Counterbalancing system, checking....176, 177
Counterbalancing system, exchanging, floor-
A mounted robot.............................................. 179
Accessories.....................................................17 Counterbalancing system, floor-mounted robot,
Adapter plates.............................................. 153 adjusting........................................................188
Alphasyn T 32.............................................. 226 Counterbalancing system, floor-mounted robot,
Angle of rotation............................................... 9 depressurizing...............................................187
ANSI/RIA R.15.06-2012............................... 234 Counterbalancing system, floor-mounted robot,
Appendix....................................................... 225 filling..............................................................188
Arctic................................................................. 8 Counterbalancing system, hydropneumatic... 14
Arm................................................................. 13 Counterbalancing system, installing............ 182
Automatic mode..............................................28 Counterbalancing system, removing............180
Auxiliary materials used............................... 226 CR.....................................................................8
Axis data, KR 120 R3200 PA........................34
Axis data, KR 120 R3200 PA-HO................. 53
Axis data, KR 120 R3200 PA arctic..............44
Axis data, KR 180 R3200 PA........................62
D
Danger zone...............................................9, 19
Axis data, KR 180 R3200 PA-HO................. 80
Declaration of conformity............................... 18
Declaration of incorporation.....................17, 18
Axis data, KR 240 R3200 PA........................89
Decommissioning................................... 30, 219
Axis data, KR 240 R3200 PA-HO............... 107
Description of the robot system.....................11
Dimensions, transportation...........................147
Axis limitation, mechanical............................. 22
Directives...................................................... 233
Axis range.................................................. 8, 18
Disclaimer....................................................... 17
Disposal......................................... 30, 219, 221
Documentation, industrial robot....................... 7
B
Base frame..................................................... 13
Basic data, KR 120 R3200 PA-HO ..............51
Basic data, KR 120 R3200 PA .................... 33
E
EC declaration of conformity......................... 18
Basic data, KR 120 R3200 PA arctic .......... 42
EDS...................................................................8
Basic data, KR 180 R3200 PA-HO ..............78
Electrical installations.............................14, 208
Basic data, KR 180 R3200 PA .................... 60
Electromagnetic compatibility (EMC)........... 234
Electromagnetic compatibility (EMC):.......... 234
Basic data, KR 240 R3200 PA-HO ............105
EMC Directive.................................................18
Basic data, KR 240 R3200 PA .................... 87
EN 60204-1:2006+A1:2009..........................234
EN 61000-6-2:2005...................................... 234
Brake defect................................................... 24
EN 61000-6-4:2007 + A1:2011.................... 234
Brake release device......................................23
EN 614-1:2006+A1:2009..............................234
Braking distance.........................................8, 18
EN ISO 10218-1:2011.................................. 234
EN ISO 12100:2010..................................... 234
EN ISO 13849-1:2015..................................234
C EN ISO 13849-2:2012..................................234
C....................................................................... 8 EN ISO 13850:2015..................................... 234
Cable set, greasing...................................... 177 Equipotential bonding................................... 153
Castrol Hyspin ZZ 46...................................226 EX..................................................................... 8
CE mark..........................................................18 Extension.......................................................... 8
Center of gravity...........................................147 External axes..................................................17
Center of mass ....38, 47, 56, 65, 74, 83, 92, External axis.............................................10, 20
101, 110
Clean Room......................................................8
Cleaning the robot........................................178
Cleaning work.................................................29
F
F........................................................................8
Connecting cable, standard......................... 155
F exclusive........................................................9
Faults.............................................................. 25

KR QUANTEC PA
Flange loads... 40, 49, 58, 67, 76, 85, 94, 103, KS..................................................................... 9
112 KUKA Customer Support............................. 235
Fork lift truck.................................................148 KUKA Service...............................................235
Foundation loads, KR 120 R3200 PA........... 41 KUKA smartPAD........................................ 9, 19
Foundation loads, KR 120 R3200 PA-HO.... 59 KUKA smartPAD-2..................................... 9, 19
Foundation loads, KR 120 R3200 PA arctic. 50
Foundation loads, KR 180 R3200 PA........... 68
Foundation loads, KR 180 R3200 PA-HO.... 86 L
Foundation loads, KR 180 R3200 PA arctic. 77 Labeling.......................................................... 23
Foundation loads, KR 240 R3200 PA........... 95 LGEP 2......................................................... 226
Foundation loads, KR 240 R3200 PA-HO...113 Lifting tackle......................................... 148, 149
Foundation loads, KR 240 R3200 PA Linear unit.......................................................17
arctic............................................................. 104 Link arm..........................................................13
Function test................................................... 26 Low Voltage Directive.....................................18
G M
Gas pressure, adjusting............................... 189 Machine frame mounting..............................153
Gear unit A1, draining oil.............................166 Machine frame mounting assembly with
Gear unit A1, filling with oil......................... 167 centering....................................................... 142
Gear unit A2, draining oil.............................169 Machinery Directive................................18, 234
Gear unit A2, filling with oil......................... 169 Main axes..................................................... 120
Gear unit A3, draining oil.............................171 Maintenance........................................... 28, 159
Gear unit A3, filling with oil......................... 171 Maintenance symbols...................................160
Gear unit A5, draining oil.............................173 Manipulator.......................................... 9, 17, 19
Gear unit A5, filling oil................................. 173 Manual mode..................................................27
Gear unit A6, draining oil.............................174 Mass........ 38, 47, 56, 65, 74, 83, 92, 101, 110
Gear unit A6, filling with oil......................... 175 Mass moments of inertia....38, 47, 56, 65, 74,
General information...................................... 120 83, 92, 101, 110
General safety measures............................... 23 Material designation..................................... 221
Ground conductor................................ 153, 209 Mechanical end stops.................................... 22
Microlube GL 261.........................................227
Minimum bending radius....34, 44, 53, 62, 71,
H 80, 89, 98, 107
HA..................................................................... 9 Misuse.............................................................14
Handling equipment......................................148 Motion velocity..................................................9
Hazardous substances................................... 30 Motor A1, exchanging.................................. 195
HM.................................................................... 9 Motor A1, installing.......................................196
HO.....................................................................9 Motor A1, removing......................................196
Hollow-shaft wrist, HW................................... 13 Motor A2, exchanging.................................. 197
HP..................................................................... 9 Motor A2, installing.......................................199
HW.................................................................... 9 Motor A2, removing......................................198
Motor A3, exchanging.................................. 200
Motor A3, installing.......................................202
I Motor A3, removing......................................201
Industrial robot................................................17 Motor A5, exchanging.................................. 203
Information for planning............................... 139 Motor A5, installing.......................................205
Information sheet for products.....................227 Motor A5, removing......................................204
Interface, energy supply system..................144 Motor A6, exchanging.................................. 206
Interfaces...................................................... 143 Motor A6, installing.......................................207
Introduction....................................................... 7 Motor A6, removing......................................207
Mounting base.............................................. 153
Mounting base with centering......................139
Mounting base, installing............................. 151
K Mounting flange....13, 39, 48, 57, 66, 75, 84,
K........................................................................9
93, 102, 111
KCP......................................................9, 19, 24
Mouse, external.............................................. 24
Keyboard, external......................................... 24
Moving the robot, without drive energy.......157
Klüberfood NH1 34-401............................... 226
MT.....................................................................9
KR C................................................................. 9

KR QUANTEC PA
O Robot, removing........................................... 219

Oil change, A1..............................................165 Rotating column..............................................13
Oil change, A2..............................................168
Oil change, A3..............................................170
Oil change, A5..............................................172 S
Oil change, A6..............................................174 Safety..............................................................17
Oil pressure, adjusting................................. 189 Safety instructions............................................ 7
Oil quantity....................................................159 Safety of machinery..................................... 234
Oil temperatures........................................... 159 Safety options.................................................19
Operating materials used............................. 226 Safety zone.............................................. 19, 21
Operators........................................................ 21 Safety, general................................................17
Optigear Synt. ALR 150...............................227 SC..................................................................... 9
Optileb GT 1800/220....................................227 SE..................................................................... 9
Options.............................................14, 17, 223 Service life...................................................... 19
Optitemp RB 2..............................................227 Setting...........................................................187
Overload......................................................... 24 Shell Spirax S1 ATF TASA.......................... 227
SI.......................................................................9
Single axis (optional)....................................223
P SL......................................................................9
P........................................................................9 smartPAD........................................... 10, 19, 24
PA..................................................................... 9 Software..........................................................17
Payload diagram....39, 48, 57, 66, 75, 84, 93, Standards......................................................233
102, 111 Start-up...................................................25, 151
Payloads, KR 120 R3200 PA........................ 37 STOP 0............................................ 10, 19, 120
Payloads, KR 120 R3200 PA-HO..................55 STOP 1............................................ 10, 19, 120
Payloads, KR 120 R3200 PA arctic.............. 46 STOP 2.................................................... 10, 20
Payloads, KR 180 R3200 PA........................ 64 Stop category 0....................................... 10, 19
Payloads, KR 180 R3200 PA-HO..................82 Stop category 1....................................... 10, 19
Payloads, KR 180 R3200 PA arctic.............. 73 Stop category 2....................................... 10, 20
Payloads, KR 240 R3200 PA........................ 91 Stop category 1, Drive Ramp Stop............... 20
Payloads, KR 240 R3200 PA-HO................109 Stop signal....................................................120
Payloads, KR 240 R3200 PA arctic............ 100 STOP 1 - DRS............................................... 20
Personal protective equipment...................... 20 Stopping distance.............................. 8, 18, 120
Personnel........................................................20 Stopping distances...................... 120, 125, 131
Phi.....................................................................9 Stopping time................................................120
Planning........................................................ 139 Stopping times.............................120, 125, 131
Plant integrator............................................... 20 Storage................................................... 30, 219
Plates and labels.......................................... 116 Supplementary load......................................114
Positioner........................................................ 17 Support request............................................ 235
POV.................................................................. 9 Swing frame....................................................13
Pressure Equipment Directive.........14, 29, 234 System integrator.............................. 18, 20, 21
Preventive maintenance work........................ 29
Principal components..................................... 12
Product description......................................... 11 T
Program override..............................................9 T1 (operating mode)................................ 10, 20
Protective equipment, overview..................... 21 T2 (operating mode)................................ 10, 20
PSA.................................................................20 Teach pendant................................................ 17
Technical data.................................................31
Technical data, KR 120 R3200 PA................33
R Technical data, KR 120 R3200 PA-HO......... 51
RDC.................................................................. 9 Technical data, KR 120 R3200 PA arctic......42
Reaction distance.......................................8, 18 Technical data, KR 180 R3200 PA................60
Recommissioning................................... 25, 151 Technical data, KR 180 R3200 PA-HO......... 78
Regulations................................................... 233 Technical data, KR 180 R3200 PA arctic......69
Release device............................................... 22 Technical data, KR 240 R3200 PA................87
Release device, option.................................223 Technical data, KR 240 R3200 PA-HO....... 105
Repair..................................................... 28, 195 Technical data, KR 240 R3200 PA arctic......96
Robot controller.............................................. 17 Technical data, overview................................ 31
Robot, installing............................................ 153 Terms used....................................................... 8
Terms, safety.................................................. 18

KR QUANTEC PA
Tightening torques........................................225
Tightening torques, stainless steel screws..226
Training............................................ 7, 159, 195
Transport position......................................... 147
Transportation........................................ 25, 147
Transportation by fork lift truck.................... 148
Transportation with lifting tackle.................. 149
Turn-tilt table...................................................17
U
Use
Intended..................................................... 14
User.......................................................... 18, 20
Users.................................................................7
W
W.....................................................................10
Warnings........................................................... 7
Wiring diagrams, electrical installations.......210
Workspace........................................... 8, 18, 21
WP.................................................................. 10
Wrist................................................................13

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Robots

Publication: Pub MA KR QUANTEC PA (PDF) en

Book structure: MA KR QUANTEC PA V12.1

Version: MA KR QUANTEC PA V11

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4.4.3 Payloads, KR 120 R3200 PA-HO......................................................................... 55

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7 Start-up and recommissioning............................................................... 151

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9.2 Depressurizing the counterbalancing system on a floor-mounted robot............. 187

11 Decommissioning, storage and disposal............................................. 219

14 KUKA Service........................................................................................... 235

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1.1 Target group

This documentation is aimed at users with the following knowledge and

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

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

1.3 Representation of warnings and notes

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

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

edy emergencies or malfunctions:

Procedures marked with this warning must be followed exactly.

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

1.4 Terms used

Stopping distance Stopping distance = reaction distance + braking distance

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

EDS Electronic Data Storage

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KCP KUKA Control Panel

KR C KUKA Robot Control

KUKA smartPAD see “smartPAD”

KUKA smartPAD-2 see “smartPAD”

Manipulator The robot arm and the associated electrical installations

RDC Resolver Digital Converter

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smartPAD Programming device for the robot controller

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

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

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

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2.1 Overview of the robot system

Fig. 2-1: Example of a robot system

1 Manipulator 3 KR C4 robot controller

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2.2 Description of the manipulator

Fig. 2-2: Main assemblies of the manipulator

1 Wrist 5 Electrical installations

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The counterbalancing system is installed between the rotating column and

The electrical installations are described in the operating instructions, in

2.3 Intended use and misuse

Any use or application deviating from the intended use is deemed to be

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