Ma KR Quantec-2 Pa-Ho en

Robots
KR QUANTEC-2 PA-HO
Assembly Instructions
Issued: 22.09.2023
MA KR QUANTEC-2 PA-HO V4
KUKA Deutschland GmbH
KR QUANTEC-2 PA-HO
© Copyright 2023
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-2 PA-HO (PDF) en

PB18926
Book structure: MA KR QUANTEC-2 PA-HO V3.1

BS16586
Version: MA KR QUANTEC-2 PA-HO V4
2/271 | www.kuka.com MA KR QUANTEC-2 PA-HO V4 | Issued: 22.09.2023

KR QUANTEC-2 PA-HO
Contents
1 Introduction.............................................................................................. 9
1.1 Target group.......................................................................................................... 9
1.2 Industrial robot documentation.............................................................................. 9
1.3 Representation of warnings and notes................................................................. 9
1.4 Terms used............................................................................................................ 10
2 Product description................................................................................. 15
2.1 Overview of the robot system............................................................................... 15
2.2 Description of the manipulator.............................................................................. 16
2.3 Intended use and misuse...................................................................................... 18
3 Safety......................................................................................................... 19
3.1 General.................................................................................................................. 19
3.1.1 Disclaimer.............................................................................................................. 19
3.1.2 EC declaration of conformity and declaration of incorporation............................ 20
3.1.3 Terms in the “Safety” chapter............................................................................... 20
3.2 Personnel............................................................................................................... 22
3.3 Workspace, safety zone and danger zone........................................................... 23
3.4 Overview of protective equipment........................................................................ 23
3.4.1 Mechanical end stops........................................................................................... 23
3.4.2 Mechanical axis limitation (optional)..................................................................... 24
3.4.3 Options for moving the manipulator without drive energy................................... 24
3.4.4 Labeling on the industrial robot............................................................................ 25
3.5 Safety measures.................................................................................................... 25
3.5.1 General safety measures...................................................................................... 25
3.5.2 Transportation........................................................................................................ 27
3.5.3 Start-up and recommissioning.............................................................................. 27
3.5.4 Manual mode......................................................................................................... 29
3.5.5 Automatic mode..................................................................................................... 30
3.5.6 Maintenance and repair........................................................................................ 30
3.5.7 Decommissioning, storage and disposal.............................................................. 32
4 Technical data.......................................................................................... 33
4.1 Technical data, overview....................................................................................... 33
4.2 Technical data, KR 140 R3200-2 PA-HO............................................................. 33
4.2.1 Basic data, KR 140 R3200-2 PA-HO................................................................... 33
4.2.2 Axis data, KR 140 R3200-2 PA-HO..................................................................... 35
4.2.3 Payloads, KR 140 R3200-2 PA-HO...................................................................... 38
4.2.4 Foundation loads, KR 140 R3200-2 PA-HO........................................................ 43
MA KR QUANTEC-2 PA-HO V4 | Issued: 22.09.2023 www.kuka.com | 3/271

KR QUANTEC-2 PA-HO

4.5 Plates and labels................................................................................................... 69
4.6 REACH duty to communicate information acc. to Art. 33................................... 72
4.7 Stopping distances and stopping times with KR C4............................................ 72
4.7.1 General information............................................................................................... 72
4.7.2 Stopping distances and times, KR 140 R3200-2 PA-HO.................................... 73
4.7.2.1 Stopping distances and stopping times, STOP 0, A1 to A3............................... 73
4.7.2.2 Stopping distances and stopping times for STOP 1, axis 1................................ 74
4.8 Stopping distances and stopping times with KR C5............................................ 90
4.8.1 General information............................................................................................... 90
4.8.2.2 Stopping distances and stopping times, STOP 1, A1.......................................... 93
5 Planning.................................................................................................... 113
5.1 Information for planning........................................................................................ 113
5.2 Mounting base with centering............................................................................... 113
5.3 Mounting base 150 mm (optional)........................................................................ 116
5.4 Machine frame mounting....................................................................................... 119
5.5 Connecting cables and interfaces......................................................................... 121
6 Transportation.......................................................................................... 125
6.1 Transporting the robot........................................................................................... 125
7 Start-up and recommissioning............................................................... 131

KR QUANTEC-2 PA-HO
7.1 Starting up floor-mounted robots (mounting base).............................................. 131

7.1.1 Installing the robot with mounting base................................................................ 133
7.1.2 Connecting the connecting cables........................................................................ 135
7.1.3 Concluding work.................................................................................................... 135
7.2 Starting up floor-mounted robots (optional 150 mm mounting base).................. 136
7.2.1 Installing the robot with mounting base 150 mm (optional)................................. 138
7.2.3 Concluding work.................................................................................................... 140
7.3 Starting up robots (machine frame mounting)...................................................... 141
7.3.1 Installing the robot with the machine frame mounting assembly........................ 143
7.3.3 Concluding work.................................................................................................... 145
7.4 Description of the connecting cables, KR C4...................................................... 145
7.4.1 Description of the Motor cable.............................................................................. 146
7.4.2 Description of the Data cable............................................................................... 148
7.4.3 Description of the ground conductor.................................................................... 149
7.5 Description of the connecting cables, KR C5...................................................... 149
7.5.1 Description of the Motor cable.............................................................................. 150
7.5.2 Description of the Data cable............................................................................... 152
7.5.3 Description of the ground conductor.................................................................... 153
8 Maintenance.............................................................................................. 155
8.1 Maintenance overview........................................................................................... 155
8.1.1 Maintenance table................................................................................................. 156
8.2 Oil change in A1................................................................................................... 158
8.2.1 Draining the gear oil from A1............................................................................... 160
8.2.2 Filling A1 with gear oil.......................................................................................... 161
8.2.3 Concluding work.................................................................................................... 161
8.3 Oil change in A2................................................................................................... 162
8.3.3 Concluding work.................................................................................................... 165
8.4 Oil change in A3................................................................................................... 165
8.4.2 Filling gear unit A3 with gear oil........................................................................... 168
8.4.3 Concluding work.................................................................................................... 169
8.5 Oil change in A5................................................................................................... 169
8.5.3 Concluding work.................................................................................................... 172
8.6 Oil change in A6................................................................................................... 173
8.6.3 Concluding work.................................................................................................... 176
8.7 Checking the counterbalancing system................................................................ 176
8.7.1 Inspecting the counterbalancing system............................................................... 177
8.7.2 Concluding work.................................................................................................... 177
8.8 Exchanging the counterbalancing system............................................................ 178
8.8.1 Securing the link arm............................................................................................ 179

KR QUANTEC-2 PA-HO
8.8.2 Removing the counterbalancing system on a floor-mounted robot..................... 180

8.8.3 Installing the counterbalancing system................................................................. 183
8.8.4 Removing the equipment securing the link arm.................................................. 186
8.8.5 Inspecting the counterbalancing system............................................................... 187
8.8.6 Concluding work.................................................................................................... 187
8.9 Cleaning the robot................................................................................................. 187
8.9.1 Cleaning................................................................................................................. 188
8.9.2 Concluding work.................................................................................................... 188
9 Repair........................................................................................................ 189
9.1 Exchanging motor A1............................................................................................ 189
9.1.1 Removing motor A1.............................................................................................. 190
9.1.2 Preparing a new motor for installation................................................................. 191
9.1.3 Installing motor A1................................................................................................ 192
9.1.4 Concluding work.................................................................................................... 193
9.2.2 Removing motor A2.............................................................................................. 196
9.2.6 Concluding work.................................................................................................... 200
9.3.2 Removing motor A3.............................................................................................. 203
9.3.6 Concluding work.................................................................................................... 207
9.4.1 Removing motor A5.............................................................................................. 209
9.4.2 Preparing the new motor...................................................................................... 210
9.4.4 Concluding work.................................................................................................... 211
9.5.1 Removing motor A6.............................................................................................. 213
9.5.2 Preparing the new motor...................................................................................... 213
9.5.4 Concluding work.................................................................................................... 214
9.6 Exchanging the swivel housing............................................................................. 214
9.6.1 Removing motor A5.............................................................................................. 216
9.6.2 Removing motor A6.............................................................................................. 217
9.6.3 Removing the swivel housing............................................................................... 218
9.6.4 Preparing the new swivel housing........................................................................ 219
9.6.5 Installing the swivel housing................................................................................. 219
9.6.8 Concluding work.................................................................................................... 222
9.7 Description of the electrical installations.............................................................. 222

KR QUANTEC-2 PA-HO
10 Decommissioning, storage and disposal............................................. 233

10.1 Decommissioning................................................................................................... 233
10.1.1 Moving the robot into its transport position.......................................................... 233
10.1.2 Removing the robot............................................................................................... 234
10.1.3 Concluding work.................................................................................................... 235
10.2 Storage.................................................................................................................. 235
10.2.1 Moving the robot into its transport position.......................................................... 236
10.2.2 Removing the robot............................................................................................... 237
10.2.3 Cleaning................................................................................................................. 238
10.2.4 Preparing for storage............................................................................................ 238
10.2.5 Concluding work.................................................................................................... 239
10.3 Disposal................................................................................................................. 239
11 Options...................................................................................................... 241
11.1 Release device...................................................................................................... 241
11.1.1 Starting up the release device.............................................................................. 242
11.1.1.1 Installing the release device................................................................................. 243
11.1.1.2 Moving the manipulator without drive energy...................................................... 244
11.1.1.3 Concluding work.................................................................................................... 245
11.2 Cover of hollow shaft A1...................................................................................... 245
11.2.1 Putting the cover for hollow shaft A1 into operation........................................... 246
11.2.1.1 Installing the cover of hollow shaft A1................................................................. 246
11.2.1.2 Concluding work.................................................................................................... 248
11.2.2 Cleaning the cover of hollow shaft A1................................................................. 248
11.2.2.1 Cleaning the cover of hollow shaft A1................................................................. 249
11.2.2.2 Concluding work.................................................................................................... 249
11.3 CBS HO filter......................................................................................................... 249
11.3.1 Putting the CBS HO filter into operation.............................................................. 251
11.3.1.1 Installing the CBS HO filter................................................................................... 252
11.3.1.2 Concluding work.................................................................................................... 252
11.3.2 Exchanging the CBS HO filter.............................................................................. 253
11.3.2.1 Removing the CBS HO filter................................................................................. 253
11.3.2.2 Installing the CBS HO filter................................................................................... 254
11.3.2.3 Concluding work.................................................................................................... 255
12 Appendix................................................................................................... 257
12.1 Tightening torques................................................................................................. 257
12.2 Auxiliary and operating materials used................................................................ 258
12.3 Information sheet for products.............................................................................. 259
12.4 Applied standards and regulations....................................................................... 265
13 KUKA Service........................................................................................... 267

13.1 Requesting support............................................................................................... 267
13.2 KUKA Customer Support...................................................................................... 267
Index 269

KR QUANTEC-2 PA-HO

KR QUANTEC-2 PA-HO
Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and

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

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

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

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

KR QUANTEC-2 PA-HO
This warning draws attention to procedures which serve to prevent or rem-

Introduction
edy emergencies or malfunctions:

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

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

The stopping distance is part of the danger zone.
Workspace Area within which the robot may move. The workspace is derived
from the individual axis ranges.
Arctic Arctic
for use in temperature ranges under 0° C (273 K).
Extension Distance (l in %) between axis 1 and the intersection of axes 4 and

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

(memory card)
EDS cool Electronic Data Storage cool

Memory card with extended temperature range

KR QUANTEC-2 PA-HO
Introduction
EMD Electronic Mastering Device
SPP Spare parts package
EX Explosion-proof zone
F Foundry
F exclusive Foundry exclusive
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
HA High Accuracy
HI High Inertia
HM Hygienic Machine
For the primary and secondary foodstuffs industries
HO Hygienic Oil
For the secondary foodstuffs industry
HP High Protection
HW Hollow Wrist
K Shelf-mounted
KCP KUKA Control Panel

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

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

Introduction KR QUANTEC-2 PA-HO
POV Program override (%) = velocity of the robot motion. This value can
be entered in the controller via the teach pendant, from which it
can be read.
RDC Resolver Digital Converter

The resolver digital converter is used to acquire motor data (e.g.
position data, motor temperatures).
RDC cool Resolver Digital Converter

Resolver Digital Converter with extended temperature range
SC Special Connection
SE Second Encoder
SI Safe Interaction
SL Washdown
smartPAD Teach pendant for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operation and programming. The following models exist:
• KUKA smartPAD
• KUKA smartPAD-2
• KUKA smartPAD pro
For robot controllers of the KR C5 series with KUKA System Soft-
ware or VW System Software, only the model KUKA smartPAD-2
is used.
For robot controllers of the KR C5 series with KUKA iiQKA.OS, on-
ly the model KUKA smartPAD pro is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to all models possible for the respective
controller unless an explicit distinction is made.
Stop categories Note: Information about the stop categories for KUKA robot control-
lers can be found in the “Safety” chapter of the robot controller as-
sembly instructions.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)

For KUKA iiQKA.OS:
With manual guidance in T1, the velocity is not reduced, but rather
limited through a safety-oriented velocity monitoring in accordance
with the safety configuration.
T2 For KUKA iiQKA.OS: not relevant at present

For KUKA System Software / VW System Software:
Test mode, Manual High Velocity (> 250 mm/s permissible)
W Wall
WP Waterproof

KR QUANTEC-2 PA-HO
Introduction
External axis For KUKA iiQKA.OS: not relevant at present
Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. For example, KUKA linear unit, turn-
tilt table and positioner

Introduction KR QUANTEC-2 PA-HO

KR QUANTEC-2 PA-HO
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), robot controller, connecting cables, tool and other equipment.
The Product Family KR QUANTEC-2 PA-HO comprises the following robot
types:
• KR 140 R3200-2 PA-HO
• KR 180 R3200-2 PA-HO
• KR 240 R3200-2 PA-HO
An industrial robot of this product family comprises the following compo-
nents:
• Manipulator
• Robot controller
• Connecting cables
• Teach pendant (KUKA smartPAD)
• Software
• Options, accessories
Fig. 2-1: Example of an industrial robot
1 Manipulator
2 Connecting cable, motor cable
3 Connecting cable, data cable
4 Robot controller
5 smartPAD connecting cable
6 smartPAD

Product description KR QUANTEC-2 PA-HO
2.2 Description of the manipulator
Overview
The manipulators (= robot arm and electrical installations) of the variants

are designed as 5-axis jointed-arm kinematic systems. They consist of the
following main assemblies:
• Wrist
• Arm
• Link arm
• Counterbalancing system
• Rotating column
• Base frame
• Electrical installations
Fig. 2-2: Main assemblies of the manipulator
1 Wrist 5 Base frame

2 Arm 6 Rotating column
3 Counterbalancing system 7 Link arm
4 Electrical installations
DANGER
Axes 1 to 3 are equipped with end stops. These serve to protect the
machine only.
The following options are available for personnel protection:
• The Safe Robot functionality of the controller
• The use of mechanical axis limitations for axes 1 to 3 (optional)
Wrist
The robot is fitted with a 2-axis wrist (swivel housing). It is fastened to the
arm via a gear unit and motor and is driven by these. The wrist is de-
signed as a hollow-shaft wrist and has a mounting flange for attaching
tools.

KR QUANTEC-2 PA-HO
The assembly also has a gauge mount with a gauge cartridge, through
Product description
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 link 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 com-
bination embodies axis 5, which cannot be freely controlled during opera-
tion. The maximum permissible swivel angle is mechanically limited by an
overrun safeguard for each direction, plus and minus. There is an inter-
face on the arm for fastening supplementary loads.
Link arm
The link arm is the assembly located between the arm and the rotating
column. The maximum permissible swivel angle is mechanically limited by
an overrun safeguard for each direction, plus and minus. There is an in-
terface on the link arm 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. The rotating column
also supports the link arm. The bearings of the counterbalancing system
are situated at the rear. There is also an interface for fastening supple-
mentary loads on the rotating column.
Base frame
The base frame is the base of the robot. It is screwed to the mounting
base. The electrical installations are fastened in the base frame. Also lo-
cated on the base frame is the interface for the motor and data cable and
the energy supply system.
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, a pressure gauge and a bursting disc as a safety
element to protect against overfilling. The counterbalancing system is clas-
sified below category I, fluid group 2, of the Pressure Equipment Directive.
Electrical installations
The electrical installations include all the motor and data cables for the
motors of axes 1 to 6. All connections are implemented as plug-in connec-
tors in order to enable the motors to be exchanged quickly and reliably.
The electrical installations also include the RDC box, which is mounted on
the rotating column. The interface on the base frame of the robot for con-
necting the connecting cables has plug-and-socket connections. The con-
necting cables from the robot controller can be plugged in by means of
connectors. The electrical installations also include an integrated
protective circuit.
Options
The robot can, for example, be equipped with the following options. The
option is described in separate documentation.

Product description KR QUANTEC-2 PA-HO
• Axis limitations for axes A1, A2 and A3

• Energy supply systems A1 to A5
• Booster Frame S780
• Adapter ring KR QUANTEC/KR QUANTEC-2
• Brake release device
The following options are also available:
• Release device (>>> 11.1 "Release device" Page 241)
• Rotating column cover (>>> 11.2 "Cover of hollow shaft A1" Page 245)
• Filter CBS HO (>>> 11.3 "CBS HO filter" Page 249)
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. It is employed in food-
related environments (secondary area) and may only be used under the
specified climatic 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
• Direct contact with foodstuffs by parts of the manipulator
• Operation without the required safety equipment
• Transportation of persons and animals
• Outdoor operation
• Use in a potentially explosive area
• Use in radioactive environments
• Operation in underground mining
NOTICE
Deviations from the operating conditions specified in the technical data
or the use of special functions or applications can lead to premature
wear, for example. KUKA Service must be consulted in this event.
The robot system is an integral part of a complete system and may only
be operated in a CE-compliant system.

KR QUANTEC-2 PA-HO
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-2 PA-HO
3.1.2 EC declaration of conformity and declaration of incorporation
The industrial robot constitutes partly completed machinery as defined by

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

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

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

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

KR QUANTEC-2 PA-HO
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.
smartPAD Teach pendant for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operation and programming. The following models exist:
• KUKA smartPAD
• KUKA smartPAD-2
• KUKA smartPAD pro
For robot controllers of the KR C5 series with KUKA System Soft-
ware or VW System Software, only the model KUKA smartPAD-2
is used.
For robot controllers of the KR C5 series with KUKA iiQKA.OS, on-
ly the model KUKA smartPAD pro is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to all models possible for the respective
controller unless an explicit distinction is made.
Stop categories Note: Information about the stop categories for KUKA robot control-
lers can be found in the “Safety” chapter of the robot controller as-
sembly instructions.
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)

For KUKA iiQKA.OS:
With manual guidance in T1, the velocity is not reduced, but rather
limited through a safety-oriented velocity monitoring in accordance
with the safety configuration.
T2 For KUKA iiQKA.OS: not relevant at present

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

External axis For KUKA iiQKA.OS: not relevant at present

Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. For example, KUKA linear unit, turn-
tilt table and 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 (PPE).
Personnel
Personnel must be instructed, before any work is commenced, in the type

of work involved and what exactly it entails as well as any hazards which
may exist. Instruction must be carried out regularly. Instruction is also re-
quired after particular incidents or technical modifications.
Personnel includes:
• System integrator
• Operators, subdivided into:
‒ Start-up, maintenance and service personnel
‒ Operating personnel
‒ Cleaning personnel
System integrator
The industrial robot is safely integrated into a complete system by the sys-
tem integrator.
The system integrator is responsible for the following tasks:
• Installing the industrial robot

KR QUANTEC-2 PA-HO
Safety
• Connecting the industrial robot
• Performing the risk assessment
• Implementing the required safety functions and safeguards
• Issuing the EC declaration of conformity
• Affixing the CE mark
• Creating the operating instructions for the system
Operators
The operator must meet the following preconditions:

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

The danger zone consists of the workspace and the stopping distances of
the manipulator and external axes (optional). The danger zone must be
protected by means of physical safeguards to prevent danger to persons
or the risk of material damage.
The safeguards (e.g. safety gate) must be located outside the danger
zone. In the case of a stop, the manipulator and external axes (optional)
are braked and come to a stop within the danger zone.
There must be no shearing or crushing hazards at the loading and trans-
fer areas.
If there are no physical safeguards present, the requirements for collabo-
rative operation in accordance with EN ISO 10218 must be met.
3.4 Overview of protective equipment
The protective equipment of the mechanical component may include:
• Mechanical end stops

• Mechanical axis limitation (optional)
• Release device (optional)
• Brake release device (optional)
• Labeling of danger areas
Not all equipment is relevant for every mechanical component.
3.4.1 Mechanical end stops
Depending on the robot variant, the axis ranges of the main and wrist ax-
es of the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.

WARNING
Danger to life and limb following collision with obstacle
If the manipulator or an external axis hits an obstruction or a mechani-
cal end stop or mechanical axis limitation, the manipulator can no
longer be operated safely. Death, injuries or damage to property may re-
sult.
• Put manipulator out of operation.
• Put external axis out of operation.
• KUKA must be consulted before they are 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 may be available for moving the manipulator without
drive energy after an accident or malfunction:
• Release device (optional)
The release device can be used for the main axis drive motors and,
depending on the robot variant, also for the wrist axis drive motors.
• Brake release device (option)
The brake release device is designed for robot variants whose motors
are not freely accessible.
• Moving the wrist axes directly by hand
There is no release device available for the wrist axes of variants in
the low payload category. This is not necessary because the wrist ax-
es can be moved directly by hand.
Information about the options available for the various robot models and
about how to use them can be found in the assembly and operating in-
structions for the robot or can be requested from the manufacturer.

KR QUANTEC-2 PA-HO
Safety
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-
ble, the manipulator and external axes must be secured by appropriate
means.
DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.
DANGER
Danger to life and limb of persons under the robot arm
Sagging or falling parts can cause death or serious injuries. This applies
at all times, e.g. also for assembly tasks or with the controller switched
off.
• Never loiter under the robot arm.
CAUTION
Risk of burns from hot motors
The motors reach temperatures during operation which can cause
burns.
• Avoid contact.
• Take appropriate safety precautions, e.g. wear protective gloves.

Implants
WARNING
Danger to life due to malfunction of implants caused by motors
and brakes
Electric motors and brakes generate electric and magnetic fields. The
fields can cause malfunctions in active implants, e.g. pacemakers.
• Affected persons must maintain a minimum distance of 300 mm
from motors and brakes. This applies to both energized and deener-
gized motors and brakes.
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
Danger to life due to disconnected smartPAD/KCP
If a smartPAD/KCP is disconnected, its EMERGENCY STOP device is
not operational. There is a risk of connected and disconnected smart-
PADs/KCPs being interchanged. Death, injuries or damage to property
may result.
• Remove the disconnected smartPAD/KCP from the system immedi-
ately.
• Store the disconnected smartPAD/KCP out of sight and reach of
personnel working on the industrial robot.
The enabling switches on the smartPAD must be subjected to a function

test at least once every 12 months and in certain specific cases.
Information about function testing for KUKA robot controllers can be
found in the “Safety” chapter of the operating or assembly instructions
of the robot controller.
External keyboard, external mouse
An external keyboard and/or external mouse may only be used if the fol-
lowing conditions are met:
• Start-up or maintenance work is being carried out.

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

ensure the required safety level. The valid national or regional work safety
regulations must be observed for this check. The correct functioning of all
safety functions must also be tested.
New or modified programs must always be tested first in Manual Reduced
Velocity mode (T1).

KR QUANTEC-2 PA-HO
After modifications to the industrial robot, existing programs must always
Safety
be tested first in Manual Reduced Velocity mode (T1). This applies to all
components of the industrial robot and includes e.g. modifications of the
external axes or to the software and configuration settings.
Faults
In the case of faults on the industrial robot, the following safety measures
must be implemented immediately:
• Switch off the robot controller and secure it (e.g. with a padlock) to
prevent unauthorized persons from switching it on again.
• Indicate the fault by means of a label with a corresponding warning
(tagout).
• Keep a record of the faults.
Carry out a functional test after the fault has been rectified.
3.5.2 Transportation
Manipulator
The prescribed transport position of the manipulator must be observed.

Transportation must be carried out in accordance with the operating in-
structions or assembly instructions of the robot.
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 system software is supplied with default passwords for the user
groups. If the passwords are not changed, this enables unauthorized
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
The external application of force, such as an impact or a collision,
can cause non-visible damage. For example, it can lead to a gradu-
al loss of drive power from the motor, resulting in unintended move-
ments of the manipulator.
Death, severe injuries or damage to property may result from non-
visible damage.
‒ Check the robot for damage that could have been caused by ex-
ternal forces, e.g. dents or abrasion of paintwork.
Check the motor and counterbalancing system particularly care-
fully.
(Motor inspection not relevant for robots with internal motors.)
‒ In the case of damage, the affected components must be ex-
changed.
• There are no foreign bodies or defective or loose parts on the industri-

al robot.
• All required safety equipment is correctly installed and operational.
• The power supply ratings of the industrial robot correspond to the
local supply voltage and mains type.

KR QUANTEC-2 PA-HO
Safety
• The ground conductor and the equipotential bonding cable are suffi-
ciently rated and correctly connected.
• The connecting cables are correctly connected and the connectors are
locked.
3.5.4 Manual mode
General
Manual mode is the mode for setup work. Setup work is all the tasks that
have to be carried out on the industrial robot to enable automatic opera-
tion. Setup work includes:
• Jog mode
• Teaching
• Programming
• Program verification
The following must be taken into consideration in manual mode:
• New or modified programs must always be tested first in Manual Re-
duced Velocity mode (T1).
• The manipulator, tooling or external axes (optional) must never touch
or project beyond the safety fence.
• Workpieces, tooling and other objects must not jam as a result of the
industrial robot motion, nor must they lead to short-circuits or be liable
to fall off.
• All setup work must be carried out, where possible, from outside the
safeguarded area.
Setup work in T1
If it can be avoided, there must be no persons inside the safeguarded

area.
If it is necessary to carry out setup work from inside the safeguarded
area, the following must be taken into consideration in the operating mode
Manual Reduced Velocity (T1):
• If it can be avoided, there must be no more than one person inside
the safeguarded area.
• If it is necessary for there to be several persons inside the safeguar-
ded area, the following must be observed:
‒ Each person must have an enabling device.
‒ All persons must have an unimpeded view of the industrial robot.
‒ Eye-contact between all persons must be possible at all times.
• The operator must be so positioned that he can see into the danger
zone and get out of harm’s way.
• Unexpected motions of the manipulator cannot be ruled out, e.g. in
the event of a fault. For this reason, an appropriate clearance must be
maintained between persons and the manipulator, including the tool.
Guide value: 50 cm.
The minimum clearance may vary depending on local circumstances,
the motion program and other factors. The minimum clearance that is
to apply for the specific application must be decided by the user on
the basis of a risk assessment.

Setup work in T2
If it is necessary to carry out setup work from inside the safeguarded

area, the following must be taken into consideration in the operating mode
Manual High Velocity (T2):
• This mode may only be used if the application requires a test at a ve-
locity higher than that possible in T1 mode.
• Teaching and programming are not permissible in this operating mode.
• Before commencing the test, the operator must ensure that the ena-
bling devices are operational.
• The operator must be positioned outside the danger zone.
• There must be no other persons inside the safeguarded area. It is the
responsibility of the operator to ensure this.
3.5.5 Automatic mode
Automatic mode is only permissible in compliance with the following safety

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

• There are no persons in the system or the requirements for collabora-
tive operation in accordance with EN ISO 10218 have been met.
• The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for
no apparent reason, the danger zone must not be entered until an EMER-
GENCY STOP has been triggered.
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-2 PA-HO
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-2 PA-HO
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. These must not be exceeded.
The following safety measures must be carried out when working on the
counterbalancing system:
• The assemblies supported by the counterbalancing systems must be
secured.
• Work on the counterbalancing systems must only be carried out by
qualified personnel.
Hazardous substances
The following safety measures must be carried out when handling hazard-
ous substances:
• Avoid prolonged and repeated intensive contact with the skin.
• Avoid breathing in oil spray or vapors.
• Clean skin and apply skin cream.
Use current safety data sheets

Knowledge of the safety data sheets of the substances and mixtures
used is a prerequisite for the safe use of KUKA products. Death,
injuries or damage to property may otherwise result.
• Request up-to-date safety data sheets from the manufacturers of
hazardous substances regularly.
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-2 PA-HO
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 140 R3200-2 PA- • Technical data
HO
(>>> 4.2 "Technical data, KR 140 R3200-2 PA-HO" Page 33)
• Plates and labels
(>>> 4.5 "Plates and labels" Page 69)
• Stopping distances and stopping times
(>>> 4.8.2 "Stopping distances and times, KR 140 R3200-2 PA-
HO" Page 92)
HO
HO" Page 99)
HO
HO" Page 106)
4.2 Technical data, KR 140 R3200-2 PA-HO
4.2.1 Basic data, KR 140 R3200-2 PA-HO
Basic data
KR 140 R3200-2 PA-HO

Number of axes 5
Number of controlled axes 4
Volume of working envelope 81.3 m³
Pose repeatability (ISO 9283) ± 0.07 mm
Weight approx. 1017 kg
Rated payload 140 kg
Maximum payload 180 kg
Maximum reach 3195 mm
Protection rating (IEC 60529) IP65
Protection rating, robot wrist (IEC IP65
60529)

Technical data KR QUANTEC-2 PA-HO
KR 140 R3200-2 PA-HO

Sound level < 75 dB (A)
Mounting position Floor
Footprint 754 mm x 754 mm
Hole pattern: mounting surface for S780
kinematic system
Permissible angle of inclination ± 0 °
Default color Base frame: black (RAL 9005);
Moving parts: light gray (RAL
7035)
Controller KR C5 M6/M7;
KR C4
Transformation name KR C4: KR140R3200_2PA;
KR C5: KR140R3200_2PA
The manipulator is designed in such a way that, in accordance with

standard IEC 60529, no water can penetrate into electrical equipment
spaces in normal operation. Water spray and corrosive additives can
nevertheless lead to corrosion (rust) on uncoated parts. In this case, it
is advisable to provide the equipment with corrosion protection. Corro-
sion does not represent a defect as defined by the standard, as long as
it does not have a detrimental effect on the protection rating. The pro-
tection rating is valid in the case of compliance with the specified ambi-
ent conditions.
Ambient conditions
Humidity class (EN 60204) -

Classification of environmental -
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.
During operation in the low-temperature range, frost and condensation

must be avoided, as damage to property may otherwise arise.
Connecting cables, KR C4
Connector designation
Cable designation robot controller - Interface with robot
robot
Motor cable X20 - X30 Han® 16HP
Data cable X21 - X31 Han® 3A Q12
Ground conductor / equipotential M8 ring cable lug at
bonding both ends
16 mm2
Cable lengths 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m
Max. cable length 50 m

KR QUANTEC-2 PA-HO
Technical data
Number of extensions 1
For detailed specifications of the connecting cables, see (>>> 7.4 "De-
scription of the connecting cables, KR C4" Page 145).
robot
Motor cable 6 motor connectors: Han® 16HP
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
Data cable XF21 - XF31 Han® 3A Q12
bonding both ends
16 mm2
4.2.2 Axis data, KR 140 R3200-2 PA-HO
Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 165 °
A4 -
A5 -55 ° / 150 °
A6 ±350 °
Speed with rated payload
A1 137 °/s
A2 111 °/s
A3 119 °/s
A4 -
A5 225 °/s
A6 321 °/s
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram.

Fig. 4-1: Direction of rotation of the axes
Mastering positions
Mastering position
A1 -25 °
A2 -100 °
A3 100 °
A4 0 °
A5 88.5 °
A6 -15 °
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 flange.

KR QUANTEC-2 PA-HO
Technical data
Fig. 4-2: KR 140 R3200-2 PA-HO, working envelope, side view
Fig. 4-3: KR 140 R3200-2 PA-HO, working envelope, top view

4.2.3 Payloads, KR 140 R3200-2 PA-HO
Payloads

Rated supplementary load, base 0 kg
frame
Maximum supplementary load, 0 kg
base frame
Rated supplementary load, rotating 0 kg
column
Maximum supplementary load, ro- 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
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

KR QUANTEC-2 PA-HO
Technical data
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.
Further information is contained in the KUKA Load documentation.
Payload diagram
NOTICE
This loading curve corresponds to the maximum load capacity. Both val-
ues (payload and mass moment of inertia) must be checked in all ca-
ses. Exceeding this capacity will reduce the service life of the robot and
overload the motors and the gears; in any such case KUKA Service
must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For start-up of the robot, additional input data are required in ac-
cordance with the documentation for the system software.
The mass inertia must be verified using KUKA Load. It is imperative for
the load data to be entered in the robot controller!

Fig. 4-5: Payload diagram, KR 140 R3200-2 PA-HO
The KR 140 R3200-2 PA-HO is designed for a rated payload of 140 kg in

order to optimize the dynamic performance of the robot. With reduced
load center distances and favorable supplementary loads, a maximum
payload of up to 180 kg can be mounted. The specific KUKA Load case
must be verified using KUKA. For further consultation, please contact
KUKA Service.
Mounting flange
Robot wrist type PA-Hand

Mounting flange standard Deviation, see figure
Mounting flange (hole circle) 125 mm

Thread diameter M10
Depth of engagement min. 11 mm, max. 16 mm
Number of threads 11
Screw grade 10.9
Locating element 10 H7
The mounting flange is depicted with axes 4 and 6 in the zero position.

KR QUANTEC-2 PA-HO
Technical data
Fig. 4-6: Mounting flange PA
Flange loads
The motion of the robot causes forces and torques to act on the mounting
flange, which are transmitted to the mounted payload (e.g. tool).
The specified values refer to nominal payloads and do not include any
safety factors. The actual 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. It is imperative for the load data to be entered in the robot
controller. The robot controller takes the payload into consideration during
path planning.
The payload must be able to permanently withstand the forces and tor-
ques generated during normal operation.
The EMERGENCY STOP values only rarely occur during the service life
of the robot (emergency situations). The frequency depends on the config-
uration of the system.
WARNING
Danger to life and limb due to insufficient stability of the tool
Incorrectly dimensioned tools can fracture and fail. Death, severe inju-
ries or damage to property may result.
• Calculate the tool for each individual case, taking the load data into
consideration.
• Use the specified installation equipment.
Fig. 4-7: Flange loads

Flange loads during operation

F(a) 4350 N
F(r) 2900 N
M(k) 1050 Nm
M(g) 650 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 8600 N
F(r) 8050 N
M(k) 5400 Nm
M(g) 3300 Nm
Axial force F(a), radial force F(r), tilting torque M(k), torque about mount-
ing flange M(g)
Supplementary load
The robot can carry supplementary loads. When mounting the supplemen-
tary loads, be careful to observe the maximum permissible total load. The
dimensions and positions of the installation options can be seen in the fol-
lowing diagrams.
Fig. 4-8: Fastening of supplementary load, arm/in-line wrist, KR 140

R3200-2 PA-HO

KR QUANTEC-2 PA-HO
Technical data
Fig. 4-9: Fastening of supplementary load on rotating column/link

arm, KR 140 R3200-2 PA-HO
4.2.4 Foundation loads, KR 140 R3200-2 PA-HO
Depending on the payload (e.g. tool), supplementary load and the robot’s
own mass (weight), the motion of the robot generates forces and torques
which are transmitted to the foundation.

KR QUANTEC-2 PA-HO
Technical data
path planning.
Supplementary loads on A1 (rotating column) and A2 (link arm) are not
taken into consideration in the calculation of the foundation load. These
must be taken into account in the vertical force (Fv).
The foundation must be able to permanently withstand the forces and tor-
WARNING
Danger to life and limb due to insufficient stability of the founda-
tion
An incorrectly dimensioned foundation can fracture and fail. Death, se-
vere injuries or damage to property may result.
• Calculate the foundation loads for each individual case.
Vertical force F(v)

F(v normal) 17250 N
F(v max) 23000 N
Horizontal force F(h)
F(h normal) 6750 N
F(h max) 17250 N
Tilting moment M(k)
M(k normal) 21250 Nm
M(k max) 32500 Nm
Torque about axis 1 M(r)
M(r normal) 8000 Nm
M(r max) 15750 Nm

KR QUANTEC-2 PA-HO
Technical data
Fig. 4-10: Foundation loads
Basic data
KR 180 R3200-2 PA-HO

Number of axes 5
60529)
kinematic system
7035)
KR C4

KR 180 R3200-2 PA-HO

KR C5: KR180R3200_2PA

ent conditions.
Ambient conditions

Ambient temperature

robot.

robot
bonding both ends
16 mm2

KR QUANTEC-2 PA-HO
Technical data
robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 165 °
A4 -
A5 -55 ° / 150 °
A6 ±350 °
A1 137 °/s
A2 111 °/s
A3 119 °/s
A4 -
A5 225 °/s
A6 321 °/s

Mastering positions
Mastering position
A1 -25 °
A2 -100 °
A3 100 °
A4 0 °
A5 88.5 °
A6 -15 °
Working envelope

KR QUANTEC-2 PA-HO
Technical data

Payloads

frame
base frame
column
tating column
arm
arm
Parameter
system

KR QUANTEC-2 PA-HO
Technical data

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

tem
tem
tem
nate axes.
Payload diagram
NOTICE

Fig. 4-15: Payload diagram, KR 180 R3200-2 PA-HO

KUKA Service.
Mounting flange


Thread diameter M10
Screw grade 10.9

KR QUANTEC-2 PA-HO
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 4350 N
F(r) 2900 N
M(k) 1050 Nm
M(g) 650 Nm
F(a) 8600 N
F(r) 8050 N
M(k) 5400 Nm
M(g) 3300 Nm
ing flange M(g)
Supplementary load
lowing diagrams.

R3200-2 PA-HO

KR QUANTEC-2 PA-HO
Technical data


KR QUANTEC-2 PA-HO
Technical data
path planning.
WARNING
tion
Vertical force F(v)

F(v normal) 17250 N
F(v max) 23000 N
F(h normal) 6750 N
F(h max) 17250 N
Tilting moment M(k)
M(k max) 32500 Nm
M(r normal) 8000 Nm
M(r max) 15750 Nm

KR QUANTEC-2 PA-HO
Technical data
Basic data
KR 240 R3200-2 PA-HO

Number of axes 5
60529)
kinematic system
7035)
KR C4

KR 240 R3200-2 PA-HO

KR C5: KR240R3200_2PA

ent conditions.
Ambient conditions

Ambient temperature

robot.

robot
bonding both ends
16 mm2

KR QUANTEC-2 PA-HO
Technical data
robot
XD20.1 … XD20.6 - XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
bonding both ends
16 mm2
Axis data
Motion range
A1 ±185 °
A2 -140 ° / -5 °
A3 0 ° / 165 °
A4 -
A5 -55 ° / 150 °
A6 ±350 °
A1 137 °/s
A2 111 °/s
A3 119 °/s
A4 -
A5 225 °/s
A6 321 °/s

Mastering positions
Mastering position
A1 -25 °
A2 -100 °
A3 100 °
A4 0 °
A5 88.5 °
A6 -15 °
Working envelope

KR QUANTEC-2 PA-HO
Technical data

Payloads

frame
base frame
column
tating column
arm
arm
Parameter
system

KR QUANTEC-2 PA-HO
Technical data

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

tem
tem
tem
nate axes.
Payload diagram
NOTICE

Fig. 4-25: KR 240 R3200-2 PA-HO Payload diagram

KUKA Service.
Mounting flange


Thread diameter M10
Screw grade 10.9

KR QUANTEC-2 PA-HO
Technical data
Flange loads
path planning.
WARNING
consideration.


F(a) 4350 N
F(r) 2900 N
M(k) 1050 Nm
M(g) 650 Nm
F(a) 8600 N
F(r) 8050 N
M(k) 5400 Nm
M(g) 3300 Nm
ing flange M(g)
Supplementary load
lowing diagrams.

R3200-2 PA-HO

KR QUANTEC-2 PA-HO
Technical data


KR QUANTEC-2 PA-HO
Technical data
path planning.
WARNING
tion
Vertical force F(v)

F(v normal) 17250 N
F(v max) 23000 N
F(h normal) 6750 N
F(h max) 17250 N
Tilting moment M(k)
M(k max) 32500 Nm
M(r normal) 8000 Nm
M(r max) 15750 Nm

KR QUANTEC-2 PA-HO
Technical data
4.5 Plates and labels
Plates and labels
The following plates and labels (>>> Fig. 4-31) are attached to the robot.
They must not be removed or rendered illegible. Illegible plates and labels
must be replaced.
Fig. 4-31: Location of plates and labels

Item Description
1
Hot surface
During operation of the robot, surface temperatures may be
reached that could result in burn injuries. Protective gloves must
be worn!
2
Secure the axes

Before exchanging any motor, secure the corresponding axis
through safeguarding by suitable means/devices to protect
against possible movement. The axis can move. Risk of crush-
ing!
3
Identification plate example

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

KR QUANTEC-2 PA-HO
Technical data
4
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!
5
Danger zone
Entering the danger zone of the robot is prohibited if the robot
is in operation or ready for operation. Risk of injury!
6
Cassida Fluid
Affixed to the gear unit or base frame. Unlike the standard gear
unit, this gear unit must be filled with “Cassida Fluid GL150” oil.
Observe the particularities!

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!
8
Work on the robot

Before start-up, transportation or maintenance, read and follow
the assembly and operating instructions.
4.6 REACH duty to communicate information acc. to Art. 33
As of June 2007, the Regulation (EC) 1907/2006 of the European Parlia-

ment and of the Council dated 18 December 2006 on the registration,
evaluation and authorization of chemicals (REACH Regulation) is in force.
Detailed REACH information can be found in the product information in
KUKA Xpert.
4.7 Stopping distances and stopping times with KR C4
4.7.1 General information
Information concerning the data:
• The data are given for the main axes A1, A2 and A3. The main axes
are the axes with the greatest deflection.
• Superposed axis motions can result in longer stopping distances.

KR QUANTEC-2 PA-HO
Technical data
• Stopping distances and stopping times in accordance with DIN EN
ISO 10218-1, Annex B.
• Stop categories:
‒ Stop category 0 » STOP 0
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.
• Measurement method
The stopping distances were measured using the robot-internal meas-
urement method.
• The wear on the brakes varies depending on the operating mode, ro-
bot application and the number of STOP 0 stops triggered. It is there-
fore advisable to perform a brake test at least once a year.
Detailed information about the brake test can be found in the
system software documentation.
• STOP 0 stops generally exert a very high load on the robot system
and result in a shorter service life. They should therefore be avoided
as far as possible.
Determination of stopping distances and times with KR C4
• 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.
4.7.2 Stopping distances and times, KR 140 R3200-2 PA-HO
4.7.2.1 Stopping distances and stopping times, STOP 0, A1 to A3
The table shows the stopping distances and stopping times after a
STOP 0 (category 0 stop) is triggered. The values refer to the following
configuration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)
Stopping distance
A1 40.13°
A2 16.26°
A3 15.16°
Stopping time
A1 0.65 s
A2 0.36 s
A3 0.26 s

KR QUANTEC-2 PA-HO
4.7.2.2 Stopping distances and stopping times for STOP 1, axis 1

Technical data
Fig. 4-32: Stopping distances for STOP 1, axis 1, KR C4

KR QUANTEC-2 PA-HO
Technical data
Fig. 4-33: Stopping times for STOP 1, axis 1, KR C4

KR QUANTEC-2 PA-HO

Technical data

KR QUANTEC-2 PA-HO
Technical data

KR QUANTEC-2 PA-HO

Technical data
configuration:
Stopping distance
A1 40.33°
A2 15.74°

KR QUANTEC-2 PA-HO
Technical data
A3 16.53°
Stopping time
A1 0.69 s
A2 0.41 s
A3 0.33 s

KR QUANTEC-2 PA-HO

Technical data

KR QUANTEC-2 PA-HO
Technical data

KR QUANTEC-2 PA-HO

Technical data

KR QUANTEC-2 PA-HO
Technical data

KR QUANTEC-2 PA-HO

Technical data
configuration:
Stopping distance
A1 35.57°
A2 17.89°

KR QUANTEC-2 PA-HO
Technical data
A3 19.12°
Stopping time
A1 0.72 s
A2 0.51 s
A3 0.43 s

KR QUANTEC-2 PA-HO

Technical data

KR QUANTEC-2 PA-HO
Technical data

KR QUANTEC-2 PA-HO

Technical data

KR QUANTEC-2 PA-HO
Technical data

KR QUANTEC-2 PA-HO

Technical data
4.8 Stopping distances and stopping times with KR C5
4.8.1 General information
Information concerning the data:
• The data are given for the main axes A1, A2 and A3. The main axes
are the axes with the greatest deflection.
• Superposed axis motions can result in longer stopping distances.
• Stopping distances and stopping times in accordance with DIN EN
ISO 10218-1, Annex B.
• Stop categories:
according to IEC 60204-1

KR QUANTEC-2 PA-HO
Technical data
• 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.
• Measurement method
The stopping distances were measured using the robot-internal meas-
urement method.
• The wear on the brakes varies depending on the operating mode, ro-
bot application and the number of STOP 0 stops triggered. It is there-
fore advisable to perform a brake test at least once a year.
Detailed information about the brake test can be found in the
system software documentation.
• STOP 0 stops generally exert a very high load on the robot system
and result in a shorter service life. They should therefore be avoided
as far as possible.
Measurement method for determining the STOP 0 stopping distances and stopping
times according to ISO 10218-1 with KR C5
Motion sequence
• Measurement with single-axis motion (A1, A2 and A3 respectively)

• Axes that are not moved are positioned in such a way that the maxi-
mum distance of the load center of gravity from the moved axis is
reached.
• Use the maximum motion radius of the axis to achieve as high a ve-
locity as possible.
• Trigger point at maximum velocity
Measurement method
1. A safe operational stop is activated at the trigger point; this causes a

STOP 0 to be triggered if the robot is moving.
Start recording with trace functionality.
2. Brakes are closed.
Brake closes (WDI motor status bit 2) is used as the start time of the
measurement.
3. The axis comes to a standstill.
Standstill is used as the end time of the measurement.
As an approximation, it is also possible to carry out the measurement by
means of a STOPMESS interrupt program in which the stopping distance
results from the difference between the position at the trigger point ($AX-
IS_INT) and the position at standstill.
Information concerning the data
• The stopping distance is the angle covered by the axis from the
Brake closes signal (WDI motor status bit 2) to complete standstill.
• The stopping time is the time that elapses from the Brake closes sig-
nal (WDI motor status bit 2) until the robot comes to a complete
standstill.

The values for stop category 0 when a STOP 0 is triggered refer to the
following configuration:
• Mass m = rated payload
Stopping distance
A1 36.69 °
A2 18.02 °
A3 25.46 °
Stopping time
A1 0.66 s
A2 0.47 s
A3 0.36 s

KR QUANTEC-2 PA-HO
4.8.2.2 Stopping distances and stopping times, STOP 1, A1
Technical data


KR QUANTEC-2 PA-HO
Technical data


KR QUANTEC-2 PA-HO
Technical data


KR QUANTEC-2 PA-HO
Technical data
Stopping distance
A1 34.98 °
A2 17.27 °
A3 23.87 °
Stopping time
A1 0.67 s
A2 0.54 s
A3 0.44 s

KR QUANTEC-2 PA-HO

Technical data

KR QUANTEC-2 PA-HO
Technical data

KR QUANTEC-2 PA-HO

Technical data

KR QUANTEC-2 PA-HO
Technical data

KR QUANTEC-2 PA-HO

Technical data

KR QUANTEC-2 PA-HO
Technical data

Stopping distance
A1 33.89 °
A2 19.61 °
A3 26.85 °
Stopping time
A1 0.73 s
A2 0.51 s
A3 0.43 s

KR QUANTEC-2 PA-HO
Technical data


KR QUANTEC-2 PA-HO
Technical data


KR QUANTEC-2 PA-HO
Technical data


KR QUANTEC-2 PA-HO
Planning
5 Planning
5.1 Information for planning
In the planning and design phase, care must be taken regarding the func-
tions or applications to be executed by the kinematic system. The follow-
ing conditions can lead to premature wear. They necessitate shorter main-
tenance intervals and/or earlier exchange of components. In addition, the
permissible operating parameters specified in the technical data must be
taken into account and observed during planning.
• Continuous operation near temperature limits
• Continuous operation in abrasive environments
• Continuous operation close to the performance limits, e.g. high rpm of
an axis
• Start of operation at maximum power from cold, e.g. after an idle peri-
od
• 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 are to apply during operation of the kin-
ematic system, KUKA Service must be consulted.
If the robot reaches its corresponding operation limit or if it is operated
near the limit for a period of time, the built-in monitoring functions come
into effect and the robot is automatically switched off.
This protective function can limit the availability of the robot system.
5.2 Mounting base with centering
Description
Designation Article number Weight

Mounting base set S780 0000-327-118 approx. 58.5 kg
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 anchors
• 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-2 PA-HO
Fig. 5-1: Mounting base
1 Bedplate (4x)
2 Locating pin, cylindrical
3 M24x65-8.8-A2K hexagon bolt with conical spring washer (8x)
4 Chemical anchor (12x)
5 M20 tapped hole for leveling screws (4x)
6 Locating pin, flat-sided
Grade of concrete for foundations
When producing foundations from concrete, observe the load-bearing ca-

pacity of the ground and the country-specific construction regulations.
There must be no layers of insulation or screed between the bedplate/
bedplates and the concrete foundation. The quality of the concrete must
meet the requirements of the following standard:
• C20/25 according to EN 206
WARNING
Danger to life and limb due to incorrect mounting
If not mounted correctly, the kinematic system may topple over or fall
down. Death, severe injury or damage to property may result.
• Only install the kinematic system using the mounting base or ma-
chine frame mounting.
• The stability must be ensured by the integrator or start-up techni-
cian.
Dimensioned drawing
The following illustration (>>> Fig. 5-2) provides all the necessary informa-
tion on the mounting base, together with the required foundation data. The
specified foundation dimensions refer to the safe transmission of the foun-
dation loads into the foundation and not to the stability of the foundation.

KR QUANTEC-2 PA-HO
Planning
Fig. 5-2: Mounting base, dimensioned drawing

2 M24x65-8.8-A2K hexagon bolt (8x)
To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
illustration.
Fig. 5-3: Foundation cross-section
1 Locating pin 4 Chemical anchor

2 Hexagon bolt with lock wash- 5 Concrete foundation
er
3 Bedplate

B Concrete grade A
Min. concrete thick- Min. distance to
ness edge
in mm in mm
180 Without edge reinforcement 360
With edge reinforcement ≥Ø12 290
With edge reinforcement ≥Ø12 and stirrup re- 245
inforcement at a distance of ≤100 mm
5.3 Mounting base 150 mm (optional)
Description

Mounting base S780 0000-338-338 approx. 261 kg
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:
• Bedplate
• Chemical anchors
• 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 bedplate and
the concrete foundation.
The minimum dimensions must be observed.

KR QUANTEC-2 PA-HO
Planning
1 Bedplate
6 Orientation notch, zero position
Grade of concrete for foundations
When producing foundations from concrete, observe the load-bearing ca-

pacity of the ground and the country-specific construction regulations.
There must be no layers of insulation or screed between the bedplate/
bedplates and the concrete foundation. The quality of the concrete must
meet the requirements of the following standard:
• C20/25 according to EN 206
WARNING
cian.
Dimensioned drawing
tion on the mounting base, together with the required foundation data. The
specified foundation dimensions refer to the safe transmission of the foun-
dation loads into the foundation and not to the stability of the foundation.

Fig. 5-5: Mounting base, dimensioned drawing

To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
illustration.
Fig. 5-6: Foundation cross-section

2 Bedplate

KR QUANTEC-2 PA-HO
Planning
3 Concrete foundation
Min. concrete thick- Concrete grade A

ness Min. distance to
in mm edge
in mm
5.4 Machine frame mounting
Description

Machine frame mounting 0000-310-641 approx. 3.52 kg
The machine frame mounting assembly is used when the robot is fas-
tened on a steel structure, a booster frame (pedestal) or a KUKA linear
unit. This assembly is also used if the robot is installed on the ceiling. It
must be ensured that the substructure is able to withstand safely the
forces occurring during operation (foundation loads). The following dia-
gram contains all the necessary information that must be observed when
preparing the mounting surface (>>> Fig. 5-7).
The machine frame mounting assembly consists of:
• Locating pins
• Hexagon bolts with conical spring washers
Fig. 5-7: Machine frame mounting


WARNING
cian.
Dimensioned drawing
tion on machine frame mounting, together with the required foundation da-
ta.

KR QUANTEC-2 PA-HO
Planning
Fig. 5-8: Machine frame mounting, dimensioned drawing
1 Locating pin, cylindrical 3 Mounting surface

2 M24x65-8.8-A2K hexagon bolt 4 Locating pin, flat-sided
(8x)
5.5 Connecting cables and interfaces
Connecting cables
The connecting cables comprise all the cables for transferring energy and
data between the robot and the robot controller. They are connected on
the robot side with connectors at interface A1.
Cable lengths of 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m and 50 m
are available as standard. The maximum length of the connecting cables
must not exceed 50 m. The maximum number of connectors is 1, i.e. a
maximum of 2 connecting cables may be combined with each other. Thus

KR QUANTEC-2 PA-HO
if the robot is operated on a linear unit which has its own energy supply
Planning
chain, this cable must also be taken into account.

For the connecting cables, an additional ground conductor is always re-
quired to provide a low-resistance connection between the robot and the
control cabinet in accordance with DIN EN 60204. The ground conductor
is connected via ring cable lugs. The threaded bolts for connecting the
two ground conductors are located on the base frame of the robot.
The following points must be observed when planning and routing the
connecting cables:
• The bending radius for fixed routing must not be less than 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).
CAUTION
Risk of injury due to tripping hazards
Improper installation of cables can cause tripping hazards. Injuries or
damage to property may result.
• The connecting cables must be installed in such a way (e.g. cable
ducts) as to prevent tripping hazards.
• Potential tripping hazards must be marked accordingly.
Interface A1
Interface A1 is located at the rear of the base frame.

KR QUANTEC-2 PA-HO
Planning
Fig. 5-9: Interface A1
1 Data cable X31 4 Ground conductor (2x)

2 Purging air (for Foundry only) 5 External axis XP8.1
3 Motor cable X30 6 External axis XP7.1
Interface for energy supply system
The robot can be equipped with an energy supply system between axis 1
and axis 2 and a second energy supply system between axis 3 and axis
6. The A1 interface required for this is located on the rear of the base
frame, the A3 interface is located on the side of the arm and the interface
for axis 6 is located on the robot tool. Depending on the application, the
interfaces differ in design and scope. They can be equipped, for example,
with connections for cables and hoses. Detailed information on the con-
nector pin allocation, threaded unions, etc. is given in separate documen-
tation.


KR QUANTEC-2 PA-HO
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 -137 °
A3 160 °
A4 -
A5 67 °
A6 0 °
Fig. 6-1: Transport position
Transport dimensions
The transport dimensions (>>> Fig. 6-2) for the robot can be noted from
the following figure. 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 equipment.

Transportation KR QUANTEC-2 PA-HO
Fig. 6-2: Transport dimensions
Transport dimensions and centers of gravity in mm:

Robot A B C D E SX SY SZ
KR 140 R3200-2 1 803 1 761 794 553 530 -15 -65 725
PA-HO
KR 180 R3200-2 1 803 1 761 794 553 530 -15 -65 725
PA-HO
KR 240 R3200-2 1 803 1 761 794 553 530 -15 -65 725
PA-HO
Transportation
The robot can be transported by fork lift truck or using lifting tackle (op-
tional).
WARNING
Danger to life and limb due to non-authorized handling equipment
If unsuitable handling equipment is used, the robot may topple or be
damaged during transportation. Death, severe injuries or damage to
property may result.
• Only use authorized handling equipment with a sufficient load-bear-
ing capacity.
• Only transport the robot in the manner specified here.
Transportation by fork lift truck
For transport by fork lift truck (>>> Fig. 6-3), four fork slots are mounted
on 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 pay-
load 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-2 PA-HO
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 (optional)

Lifting tackle 0000-342-903 approx. 6.8 kg
The robot can also be transported using a crane and lifting tackle (option-
al) (>>> Fig. 6-4). For this, it must be in the transport position. The lifting
tackle (optional) is attached to the 2 front fork slots and the rotating col-
umn. 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 gravity. Items of equipment, espe-
cially energy supply systems, must be removed to the extent necessary to
avoid them being damaged by the legs of the lifting tackle during transpor-
tation.
Fig. 6-4: Transportation using lifting tackle
1 Lifting tackle assembly

2 Leg G1
3 Leg G3 and leg G4
4 Fork slot

5 Attachment point for swivel

6 Leg G2
All the legs are labeled. Leg G3 is provided with an adjustable chain
which 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 read-
justed. Leg G3 must be slipped around the mount for the
counterbalancing system on the rotating column. It must not subject the
adjacent counterbalancing system to any load.
Fig. 6-5: Lifting tackle, leg G3
1 Leg G3
2 Chain
3 Counterbalancing system
4 Counterbalancing system mount on rotating column
WARNING
Risk of injury during transportation
The robot may tip during transportation. Death, severe injuries or dam-
• When transporting the robot using lifting tackle (optional) / rope
sling, care must be exercised to prevent it from tipping.
• If necessary, additional safeguarding measures must be taken.
• It is forbidden to pick up the robot in any other way using a crane!
Transport safeguard
A transport safeguard is available if the robot is transported by truck, for

example. The robot can be tied down by means of a lashing belt. Care
must be taken to position the lashing belt over the transport safeguard.
The lashing belt must not be placed over the motor or other robot compo-
nents and thus subjected to a load. Damage to property may otherwise
result.
The transport safeguard and fork slots can be removed for operation.

KR QUANTEC-2 PA-HO
Transportation
Fig. 6-6: Transport safeguard
1 Transport safeguard
2 Fork slot


KR QUANTEC-2 PA-HO
Start-up and recommissioning

7 Start-up and recommissioning
The procedure for start-up and recommissioning depends on the type of
fastening and installation position of the manipulator.
Description Information
Robot Installation position: floor and mounting Starting up floor-mounted robots
installation base (mounting base)
(>>> 7.1 "Starting up floor-mounted ro-
bots (mounting base)" Page 131)
Robot Installation position: floor and mounting Starting up floor-mounted robots
installation base 150 mm (option) (mounting base 150 mm option)
(>>> 7.2 "Starting up floor-mounted ro-
bots (optional 150 mm mounting
base)" Page 136)
Robot Installation position: floor, ceiling and Starting up floor-mounted robots (ma-
installation machine frame mounting chine frame mounting)
(>>> 7.3 "Starting up robots (machine
frame mounting)" Page 141)
7.1 Starting up floor-mounted robots (mounting base)
Description
The mounting base is used for installing robots on a foundation.

They are fastened to a suitable concrete foundation using a bedplate /
foundation slats and chemical anchors.
This description is valid for the installation of floor-mounted robots with the
mounting variant “mounting base”.
If the surface of the concrete foundation is not sufficiently smooth and
even, the differences must be evened out with a suitable leveling com-
pound.
When using chemical anchors, use only resin cartridges and anchors from
the same manufacturer. No diamond tools or core drills may be used for
drilling the anchor holes; for preference, drilling tools supplied by the an-
chor manufacturer are to be used. Observe also the manufacturer’s in-
structions for the use of chemical anchors.
The installation and start-up of the robot controller, the tools mounted and
the applications are not described here.
Equipment
The following equipment is required:

Designation Article number
Lifting tackle/rope sling with sufficient 0000-342-903
load-bearing capacity
Crane with sufficient load-bearing capaci- -
ty
Fork lift truck with sufficient load-bearing -
capacity
Drill with a ø 18 mm bit -
Setting tool approved by the anchor -
manufacturer

Start-up and recommissioning KR QUANTEC-2 PA-HO

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 20 to 100 Nm
Torque wrench -
min. 400 to 700 Nm
Material
The following material is required:

Designation Article number Quantity
Mounting base set S780 0000-327-118 1
Tightening torques
The tightening torques can be found under: (>>> 12.1 "Tightening

torques" Page 257)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher as well as screws with test cer-
tification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.
Precondition
• The installation site is accessible with a crane or fork lift truck.

• The robot is in the transport position.
• The substructure has been checked for sufficient safety.
• The concrete foundation must have the required dimensions and
cross-section.
• The surface of the foundation must be smooth and even.
• Have the leveling compound readily at hand.
• Any tools or other system components which would hinder the work
have been removed.
• The connecting cables and ground conductors are routed to the robot
and installed.
Work safety
WARNING
When work is performed on this system, live parts can lead to uninten-
tional motions of the robot, positioner or other components. Failure to
observe this may result in physical injuries and damage to property.
• If work is carried out on an operable system, the main switch on the
control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on
again.
• Inform the persons involved by means of a sign (e.g. affix a warning
sign).
• Warn all persons concerned before putting the system back into op-
eration.

KR QUANTEC-2 PA-HO

WARNING
ing capacity.
WARNING
CAUTION
WARNING
cian.
7.1.1 Installing the robot with mounting base
Procedure
1. Clean the concrete foundation.

2. Screw 2 locating pins into the bedplates with 1 M8x55-8.8 Allen screw
each and check that they are fitted securely (>>> Fig. 7-1).
3. Lift the robot with the crane or fork lift truck and move it to the instal-
lation site.
4. Clean the lower mounting surface on the robot.
5. Fasten the 4 bedplates to the robot using 2 M24x65-8.8 hexagon bolts
with conical spring washers for each one. Ensure that an entirely ver-
tical position is maintained in order to prevent damage to the locating
pins.
6. Tighten 8 M24x65-8.8 hexagon bolts with torque wrench. Increase the
tightening torque to the specified value in several stages.

1 Bedplate (4x)
5 M20 tapped hole for leveling screws (4x)
7. Determine the position of the robot on the mounting base in relation to

the working envelope.
8. Set the robot down on the mounting base in its installation position.
9. Check the surface of the concrete foundation against the specified val-
ue:
• If the surface is sufficiently smooth and even, continue with step
15.
• If the surface is not sufficiently smooth and even, continue with
step 10.
If the evenness of the foundation is outside the specified tolerances,
this can cause strain or result in loosening of the mounting base.
10. Lift robot with crane or fork lift truck.
11. Apply sufficient leveling compound to the underside of the bedplates
(toothed spatula).
The area under the hexagon bolt for robot fastening must be kept free
from leveling compound.
12. Set down the robot and align horizontally with leveling screws if nec-
essary.
13. Remove excess leveling compound. The maximum height of the level-
ing compound must not be exceeded. Observe the manufacturer’s
specifications.
14. Allow the leveling compound to set in accordance with the manufactur-
er’s specifications.
15. 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.

KR QUANTEC-2 PA-HO

7.1.2 Connecting the connecting cables
Procedure
1. Fasten the ground conductor between the robot controller and the ro-
bot to the ground conductor connection with 1 M8 hexagon nut includ-
ing conical spring washer; tightening torque MA= 23.0 Nm.
2. Fasten the ground conductor between the system component and the
robot to the ground conductor connection with 1 M8 hexagon nut in-
cluding conical spring washer; tightening torque MA= 23.0 Nm.
3. Connect data cable:
• KR C4: X31
• KR C5: XF31
When connecting the data cable connectors, it must be ensured that
the connector is locked correctly on the robot. Correct locking is ach-
ieved by closing the clip (>>> Fig. 7-2).
4. Connect motor cable:
• KR C4: X30
• KR C5: XD30
Push on the motor cable connector, insert 4 fastening screws and
tighten with tightening torque MA= 3.0 Nm.
5. Check the equipotential bonding in accordance with VDE 0100 and
EN 60204-1.
Further information is contained in the operating and assembly in-
structions of the robot controller.
Fig. 7-2: Connecting the connecting cables
1 Data cable 3 Fastening screw (4x)

2 Motor cable 4 Ground conductor
7.1.3 Concluding work
The following concluding work must be carried out:

• Mount tooling, if present.
• Start up the robot system in accordance with the chapter “Start-up and
recommissioning” in the operating instructions for the robot controller.

• Put the robot system into operation in accordance with the documen-
tation for the system software.
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.
7.2 Starting up floor-mounted robots (optional 150 mm mounting base)
Description
The mounting base is used for installing robots on a foundation.

They are fastened to a suitable concrete foundation using a bedplate /
foundation slats and chemical anchors.
This description is valid for the installation of floor-mounted robots with the
mounting variant “mounting base”.
If the surface of the concrete foundation is not sufficiently smooth and
even, the differences must be evened out with a suitable leveling com-
pound.
When using chemical anchors, use only resin cartridges and anchors from
the same manufacturer. No diamond tools or core drills may be used for
drilling the anchor holes; for preference, drilling tools supplied by the an-
chor manufacturer are to be used. Observe also the manufacturer’s in-
structions for the use of chemical anchors.
Equipment

ty
capacity
Drill with a ø 18 mm bit -
Setting tool approved by the anchor -
manufacturer
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 20 to 100 Nm

KR QUANTEC-2 PA-HO

Torque wrench -
min. 400 to 700 Nm
Material

Mounting base S780 0000-338-338 1
Tightening torques

torques" Page 257)
en.
ones.
Precondition

• The concrete foundation must have the required dimensions and
cross-section.
• The surface of the foundation must be smooth and even.
• Have the leveling compound readily at hand.
have been removed.
and installed.
Work safety
WARNING
again.
sign).
eration.

WARNING
ing capacity.
WARNING
CAUTION
WARNING
cian.
7.2.1 Installing the robot with mounting base 150 mm (optional)
Procedure
1. Clean the concrete foundation.

2. Screw 2 locating pins into the bedplate with 1 M8x55-8.8 Allen screw
each and check that they are fitted securely (>>> Fig. 7-3).
lation site.
5. Fasten the bedplate to the robot using 8 M24x65-8.8 hexagon bolts
with conical spring washers. Ensure that an entirely vertical position is
maintained in order to prevent damage to the locating pins.
6. Tighten 8 M24x65-8.8 hexagon bolts with torque wrench. Increase the

KR QUANTEC-2 PA-HO

1 Bedplate
6 Orientation notch, zero position
7. Determine the position of the robot on the mounting base in relation to

the working envelope.
8. Set the robot down on the mounting base in its installation position.
9. Check the surface of the concrete foundation against the specified val-
ue:
• If the surface is sufficiently smooth and even, continue with step
15.
• If the surface is not sufficiently smooth and even, continue with
step 10.
If the evenness of the foundation is outside the specified tolerances,
this can cause strain or result in loosening of the mounting base.
10. Lift robot with crane or fork lift truck.
11. Apply sufficient leveling compound to the underside of the bedplate
(toothed spatula).
The area under the hexagon bolt for robot fastening must be kept free
from leveling compound.
12. Set down the robot and align horizontally with leveling screws if nec-
essary.
13. Remove excess leveling compound. The maximum height of the level-
ing compound must not be exceeded. Observe the manufacturer’s
specifications.
14. Allow the leveling compound to set in accordance with the manufactur-
er’s specifications.
15. Drill 16 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.

Procedure
• KR C4: X31
• KR C5: XF31
• KR C4: X30
• KR C5: XD30
EN 60204-1.



KR QUANTEC-2 PA-HO

CAUTION
juries may result.
valve.
3. Move A2 by ±30°.
7.3 Starting up robots (machine frame mounting)
Description
The machine frame mounting is used for installing robots on a steel struc-
ture prepared by the customer.
Fastening is carried out using 8 hexagon bolts with conical spring wash-
ers. A cylindrical pin and a flat-sided pin are provided to ensure correct
positioning.
This description is valid for the installation of floor and ceiling-mounted ro-
bots with the mounting variant “machine frame mounting”.
The ceiling-mounted installation is analogous to installation of the floor-
mounted robot.
Equipment

ty
capacity
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 to 20 Nm
Torque wrench -
min. 400 to 700 Nm
Material

Machine frame mounting 0000-310-641 1

Tightening torques

torques" Page 257)
en.
ones.
Precondition

• The mounting surface has been prepared.
have been removed.
and installed.
Work safety
WARNING
again.
sign).
eration.
WARNING
ing capacity.
WARNING

KR QUANTEC-2 PA-HO

CAUTION
WARNING
cian.
7.3.1 Installing the robot with the machine frame mounting assembly
Procedure
1. Clean the mounting surface.

2. Check the hole pattern on the mounting surface.
3. Screw 2 locating pins into the mounting surface and check that they
are fitted securely.
lation site.
6. Lower the robot vertically onto the mounting surface. Ensure that an
entirely vertical position is maintained in order to prevent damage to
the locating pins.
7. Insert 8 M24x65-8.8 hexagon bolts together with conical spring wash-
ers.
8. Tighten the 8 M24x65-8.8 hexagon bolts with a torque wrench in diag-
onally opposite sequence. Increase the tightening torque to the speci-
fied value in several stages.

Fig. 7-5: Machine frame mounting

Procedure
• KR C4: X31
• KR C5: XF31
• KR C4: X30
• KR C5: XD30
EN 60204-1.

KR QUANTEC-2 PA-HO



CAUTION
juries may result.
valve.
3. Move A2 by ±30°.
7.4 Description of the connecting cables, KR C4
Configuration
The connecting cables are used to transfer power and data between the
robot controller and the robot.
The connecting cables comprise:
• Motor cable
• Data cable

Interface
robot
Motor cable X20 – X30 Han® 16HP
Data cable X21 – X31 Han® 3A Q12
bonding both ends
16 mm2
Standard connecting cable
Fig. 7-7: Connecting cables, overview
7.4.1 Description of the Motor cable
Cable overview
Fig. 7-8: Motor cable
1 X20
2 X30
Connector pin allocation
Connector pin allocation X20 Connector pin allocation X30
The contact assignment on the connector side is shown in each case.

KR QUANTEC-2 PA-HO

Wiring diagram
X20 X30
Description
Pin Pin
a1 Motor M1 U 1
2 Motor M1 V 2
3 Motor M1 W 3
11 Brake + 19
12 Brake - 20
b1 Motor M2 U 4
2 Motor M2 V 5
3 Motor M2 W 6
11 Brake + 21
12 Brake - 22
c1 Motor M3 U 7
2 Motor M3 V 8
3 Motor M3 W 9
11 Brake + 23
12 Brake - 24
d1 Motor M4 U 10
4 Motor M4 V 11
6 Motor M4 W 12
3 Brake + 25
5 Brake - 26
e1 Motor M5 U 13
4 Motor M5 V 14
6 Motor M5 W 15
3 Brake + 27
5 Brake - 28
f1 Motor M5 U 16
4 Motor M5 V 17
6 Motor M5 W 18
3 Brake + 29
5 Brake - 30
Ground conductor
Housing Shield, all pins Housing

7.4.2 Description of the Data cable
Cable overview
Fig. 7-9: Data cable
1 X21
2 X31
Connector pin allocation X21 Connector pin allocation X31
Wiring diagram
X21 X31
Description
Pin Pin
9 TPFO_P 9
11 TPFO_N 11
Housing Shield, pin 9, pin 11 Housing
10 TPFI_P 10
12 TPFI_N 12
Housing Shield, pin 10, pin Housing
12
3 Ground 3
2 24 V/PS1 with bat- 2
tery back-up

KR QUANTEC-2 PA-HO

7.4.3 Description of the ground conductor
Fig. 7-10: Connecting cable, ground conductor
1 Ground conductor 6 Conical spring washer

2 Hexagon nut 7 Robot
3 Conical spring washer 8 Setscrew
4 2x plain washer 9 Ground conductor connection
Ring cable lug
5 Hexagon nut 10 Ground sign
7.5 Description of the connecting cables, KR C5
Configuration
The connecting cables are used to transfer power and data between the
robot controller and the robot.
The connecting cables comprise:
• Motor cable
• Data cable
Interface
Interface with
Cable designation robot controller -
robot
robot
XD20.1 … XD20.6 -
XD30
2 brake connectors:
XD10.1, XD10.2 - XD30
Data cable XF21 – XF31 Han® 3A Q12
Ground conductor / equi- M8 ring cable
potential bonding lug at both ends
16 mm2

Standard connecting cable
Fig. 7-11: Connecting cables, overview
7.5.1 Description of the Motor cable
Cable overview
Fig. 7-12: Motor cable
1 XD20.x / XD10.x
2 XD30

KR QUANTEC-2 PA-HO


Connector pin allocation XD30
XD20.x / XD10.x
Wiring diagram
XD20.x /
XD30
XD10.x
Description Pin
Pin
XD20.1 / 1 M1:U 1
XD20.1 / 2 M1:V 2
XD20.1 / 3 M1:W 3
XD20.1 / PE PE1
PE
XD10.1 / M1_br_+ twisted 19
B:1
XD10.1 / M1_br_GND 20
A:1
Housing Shield B1, A1 Housing
XD20.2 / 1 M2:U 4
XD20.2 / 2 M2:V 5
XD20.2 / 3 M2:W 6
B:2
XD10.1 / M2_br_GND 22
A:2
XD20.3 / 1 M3:U 7
XD20.3 / 2 M3:V 8
XD20.3 / 3 M3:W 9
B:3
XD10.1 / M3_br_GND 24
A:3
XD20.4 / 1 M4:U 10
XD20.4 / 2 M4:V 11
XD20.4 / 3 M4:W 12

XD20.x /
XD30
XD10.x
Description Pin
Pin
XD20.4 / PE PE2
PE
B:2
XD10.2 / M4_br_GND 26
A:1
XD20.5 / 1 M5:U 13
XD20.5 / 2 M5:V 14
XD20.5 / 3 M5:W 15
A:2
XD10.2 / M5_br_GND 28
A:1
Housing Shield A2, A1 Housing
XD20.6 / 1 M6:U 16
XD20.6 / 2 M6:V 17
XD20.6 / 3 M6:W 18
A:3
XD10.2 / M6_br_GND 30
A:4
Housing Shield A3, A4 Housing
Housing Overall shield
7.5.2 Description of the Data cable
Cable overview
Fig. 7-13: Data cable
1 XF21
2 XF31

KR QUANTEC-2 PA-HO

Connector pin allocation XF21 Connector pin allocation XF31
Wiring diagram
XF21 XF31
Pin Description Pin
5 PSU_27V_IO 5
6 PSU_GND 6
7 PSU_27V_POS 2
8 PSU_GND 3
1 Rx+ 10
2 Rx- 12
3 Tx+ 9
4 Tx- 11
7.5.3 Description of the ground conductor
Fig. 7-14: Connecting cable, ground conductor
1 Ground conductor 6 Conical spring washer

2 Hexagon nut 7 Robot
3 Conical spring washer 8 Setscrew

4 2x plain washer 9 Ground conductor connection

Ring cable lug
5 Hexagon nut 10 Ground sign

KR QUANTEC-2 PA-HO
Maintenance
8 Maintenance
Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA. Information about KUKA College and its training
program can be found at college.kuka.com or can be obtained directly
from our subsidiaries.
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.
8.1 Maintenance overview
Description
The maintenance intervals given in the tables are valid for the operating
conditions specified in the technical data (>>> 4 "Technical data"
Page 33). 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 113).
A general inspection of the manipulator is recommended after 7 years or

upon modifying its use. Please contact KUKA Service for this.
If the robot is fitted with a KUKA energy supply system (optional), addi-
tional maintenance work must be carried out.
NOTICE
Only auxiliary substances and consumables approved by KUKA
Deutschland GmbH may be used. Non-approved auxiliary substances
and consumables may cause premature wear and failure of assemblies.
Precondition
• The maintenance points must be freely accessible.

• Remove the tools and any additional items of equipment if they im-
pede maintenance work.
WARNING
Danger to life and limb due to unintended robot motions
When carrying out the following work, the robot must be moved several
times between the individual work steps. Unintentional movements of
the robot can cause death, serious injury or material damage.
• While work is being carried out on the robot, it must always be se-
cured by actuating the EMERGENCY STOP device.
• If work is carried out on an operational robot that is switched on, the
robot must only be moved at reduced velocity. It must be possible to
stop the robot at any time by actuating an EMERGENCY STOP de-
vice. Operation must be limited to what is absolutely necessary.
• Warn all persons concerned before switching on and moving the ro-
bot.

KR QUANTEC-2 PA-HO
If oil temperatures of more than 60 °C (333 K) are reached during opera-

Maintenance
tion, shorter maintenance intervals must be observed. Please contact

KUKA Service for this.
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-2 PA-HO
Maintenance
Fig. 8-1: Maintenance diagram
Maintenance table, KR QUANTEC-2 PA-HO
Interval Item Task Auxiliary substances and

consumables
100 h 9 Check bolts; -
MA 640 Nm
Once only, after start-up (installation)
5 000 h 5 Counterbalancing system bearing on LGEP 2 lubricating grease
or 1 year link arm, lubricate. Grease lubricating
10 cm³
at the latest nipples in middle position and at plus
1) and minus end positions (1 nipple in
each case).
5 000 h 7 Counterbalancing system bearing on LGEP 2 lubricating grease
or 1 year rotating column, lubricate. Grease lu-
10 cm³
at the latest bricating nipples in middle position
1) and at plus and minus end positions
(1 nipple in each case).
5 000 h 6 Counterbalancing system, check pres- -
sure
(>>> 8.7 "Checking the counterbal-
ancing system" Page 176)
20 000 h 1 Perform oil change on gear unit A6. Cassida Fluid GL150
or 5 years (>>> 8.6 "Oil change in A6"
Initial filling quantity: 0.93 l
at the latest Page 173)

Maintenance KR QUANTEC-2 PA-HO
Interval Item Task Auxiliary substances and

consumables
10 years 6 Exchange the counterbalancing sys- -
tem
(>>> 8.8 "Exchanging the counterbal-
ancing system" Page 178)
1) In the case of frequently recurring, short-distance movements, the
maintenance interval is 3 000 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:
(>>> 12.2 "Auxiliary and operating materials used" Page 258)
The service life of the cable set corresponds to that of the robot, provi-
ded that programs are executed in the normal range. If, however, the
programs are at the limits, the service life of the cable set is reduced
and it may be necessary to exchange the cable set prematurely.
8.2 Oil change in A1
Description
The following sections describe the A1 gear oil change for floor-mounted
robots.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 20 to 100 Nm
Socket wrench set -
Collection receptacle -
KUKA oil pump 0000-180-812
Material

Cassida Fluid GL150 (>>> 12.2 "Aux- Initial fill-
iliary and oper- ing quan-
ating materials tity: 5.70 l
used"
Page 258)

KR QUANTEC-2 PA-HO
Maintenance
Refilling quantity
CAUTION
The quantity of oil drained depends on the draining time and the oil
temperature. The refilling quantity is the quantity of oil that was drained
from the gear unit at the correct operating temperature and with the cor-
rect draining time. This oil quantity must be determined. Only this quan-
tity of oil may be used when refilling.
If less than 70 % of the specified oil quantity flows out, flush the gear
unit with the determined quantity of drained oil once, then pour in the
amount of oil that was drained. If less than 50% of the specified oil
quantity flows out (e.g. inclined installation), the flushing operation must
be repeated twice. During the flushing procedure, move the axis at jog
velocity throughout the entire axis range.
The oil quantities specified in the table correspond to the oil quantities
in the gear unit at first filling.
Tightening torques

torques" Page 257)
en.
ones.
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.
Arbeitssicherheit
CAUTION
High oil and surface temperatures after the machine has stopped
operating
Immediately after the machine has stopped operating, it is liable to have
high oil and surface temperatures. Touching them may result in burns.
• Wear personal protective equipment.
CAUTION
Oil chamber could be pressurized
Under certain conditions, the oil chambers of the gear units may be
pressurized. This can result in a sudden oil leak when the oil drain plug
is opened and lead to injuries and damage to property.
• Vent the oil chamber before draining the oil.

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.
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.
8.2.1 Draining the gear oil from A1
Procedure
1. Place a suitable receptacle under the drain hole (>>> Fig. 8-2).
2. Carefully unscrew the M22x1.5 magnetic screw plug on the rotating
column for venting and close it again.
3. Unscrew the union nut from the drain hole.
4. Remove the M22x1.5 magnetic screw plug from the rotating column
for venting and catch the oil as it drains out.
5. Measure the amount of oil drained and store or dispose of the used
oil in accordance with the pertinent regulations.
Fig. 8-2: Draining the gear oil from A1
1 Magnetic screw plug M22x1.5

2 Drain hole
3 Union nut
4 Collection receptacle

KR QUANTEC-2 PA-HO
Maintenance
8.2.2 Filling A1 with gear oil
Procedure
1. Connect the oil pump to the drain hole (>>> Fig. 8-3).
2. Fill the specified amount of oil from below via the drain hole using the
oil pump.
3. Clean the magnetic screw plug and check the sealing element; ex-
change the magnetic screw plug if damaged.
4. Insert and tighten the M22x1.5 magnetic screw plug; MA= 25 Nm.
5. Remove the oil pump from the drain hole.
6. Screw the union nut onto the drain hole and tighten; MA = 45 Nm,
then check for leaks.
Fig. 8-3: Filling A1 with gear oil
1 Magnetic screw plug M22x1.5

2 Drain hole
3 Union nut
4 Oil pump

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

Description
The following sections describe the A2 gear oil change for floor-mounted
robots.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 20 to 100 Nm
Socket wrench set -
Material

used"
Page 258)
Refilling quantity
CAUTION
Tightening torques

torques" Page 257)
en.
ones.

KR QUANTEC-2 PA-HO
Maintenance
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.
Arbeitssicherheit
CAUTION
operating
CAUTION
WARNING
age to property.
tion.

Procedure
1. Place a suitable receptacle under the rotating column (>>> Fig. 8-4).
2. Carefully unscrew the M18x1.5 magnetic screw plug for venting and
close it again.
3. Remove the oil drain hose from the rotating column and undo the un-
ion nut.
4. Remove the M18x1.5 magnetic screw plug for venting and catch the
oil as it drains out.

1 Magnetic screw plug 3 Union nut

M18x1.5
2 Oil drain hose 4 Collection receptacle
Procedure
1. Connect the oil pump to the oil drain hose (>>> Fig. 8-5).
2. Pour in the specified amount of oil via the oil drain hose; the chamber
fills from the bottom.
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.
5. Remove the oil pump.
6. Fit and tighten the union nut.
7. Check the magnetic screw plug and union nut for leaks.

KR QUANTEC-2 PA-HO
Maintenance
Fig. 8-5: Filling gear unit A2 with gear oil
1 Magnetic screw plug 3 Union nut

M18x1.5
2 Oil drain hose 4 Oil pump

Description
The following sections describe the A3 gear oil change.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 20 to 100 Nm


Socket wrench set -
Material

used"
Page 258)
Refilling quantity
CAUTION
Tightening torques

torques" Page 257)
en.
ones.
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.

KR QUANTEC-2 PA-HO
Maintenance
Arbeitssicherheit
CAUTION
operating
CAUTION
WARNING
age to property.
tion.

Procedure
1. Place a receptacle under the lower M16x1.5 magnetic screw plug

(>>> Fig. 8-6).
2. Carefully unscrew the upper M16x1.5 magnetic screw plug for venting
and close it again.
3. Remove the lower M16x1.5 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.
4. Remove the upper M16x1.5 magnetic screw plug for venting and
catch the oil as it drains out.

1 Upper M16x1.5 magnetic 3 Oil drain hose

screw plug
2 Lower M16x1.5 magnetic 4 Collection receptacle
screw plug
8.4.2 Filling gear unit A3 with gear oil
Procedure
1. Connect the oil pump to the oil drain hose (>>> Fig. 8-7).
2. Pour in the specified amount of oil via the oil drain hose; the chamber
fills from the bottom.
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.
5. Remove oil drain hose and oil pump.
6. Insert and tighten the lower M16x1.5 magnetic screw plug;
MA = 20 Nm.
7. Check both magnetic screw plugs for leaks.

KR QUANTEC-2 PA-HO
Maintenance
1 Upper M16x1.5 magnetic 3 Oil pump

screw plug
2 Oil drain hose 4 Lower M16x1.5 magnetic
screw plug

Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 20 to 100 Nm
Socket wrench set -
Material


used"
Page 258)
Refilling quantity
CAUTION
Tightening torques

torques" Page 257)
en.
ones.
Precondition

• The arm is in the horizontal position (A2 + A3 = 0°).
• Oil drain plugs on A5 are freely accessible.
Arbeitssicherheit
CAUTION
operating
CAUTION

KR QUANTEC-2 PA-HO
Maintenance
WARNING
age to property.
tion.

Procedure
1. Place a receptacle under the lower M18x1.5 magnetic screw plug

(>>> Fig. 8-8).
2. Carefully unscrew the upper M18x1.5 magnetic screw plug for venting
and close it again.
3. Remove the lower M18x1.5 magnetic screw plug.
4. Remove the upper M18x1.5 magnetic screw plug for venting and
catch the oil as it drains out.
1 Upper M18x1.5 magnetic 3 Collection receptacle

screw plug
2 Oil drain hose 4 Lower M18x1.5 magnetic
screw plug

Procedure
2. Screw the oil drain hose into the lower vent hole.
3. Connect the oil pump to the oil drain hose.
4. Fill the oil from below via the oil drain hose until the oil level is visible
at the lower edge of the upper vent hole.
5. Insert and tighten the upper M16x1.5 magnetic screw plug;
MA = 20 Nm.
7. Insert and tighten the lower M16x1.5 magnetic screw plug;
MA = 20 Nm (>>> Fig. 8-9).
Fig. 8-9: Filling A5 with gear oil
1 Vent hole
2 Upper M18x1.5 magnetic screw plug
3 Lower M18x1.5 magnetic screw plug
4 Oil drain hose
5 Oil pump


KR QUANTEC-2 PA-HO
Maintenance
Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 20 to 100 Nm
Socket wrench set -
Material

used"
Page 258)
Refilling quantity
CAUTION
Tightening torques

torques" Page 257)
en.
ones.

Precondition

• Payload (tool or device) has been removed from the swivel housing.
• The arm is in the horizontal position (A2 + A3 = 0°).
• Oil drain plugs on A6 are freely accessible.
• Robot wrist can be moved during the oil change.
Arbeitssicherheit
CAUTION
operating
CAUTION
WARNING
age to property.
tion.

Procedure
1. Move A5 to the 0° position (mounting flange points to the front) and

secure the robot by means of an EMERGENCY STOP
(>>> Fig. 8-10).
2. Place a receptacle under the vent hole.
3. Carefully unscrew the M18x1.5 magnetic screw plug by the vent hole
for venting and close it again.
4. Remove the magnetic screw plug M18x1.5 by the vent hole.
5. Remove the M18x1.5 magnetic screw plug from the filler hole for vent-
ing and catch the oil as it drains out.

KR QUANTEC-2 PA-HO
Maintenance
1 Filler hole
2 M18x1.5 magnetic screw plug
3 Vent hole
4 Oil drain hose
5 Collection receptacle
Procedure
1. Move A5 to the +90° position (mounting flange points downwards) and

secure the robot by means of an EMERGENCY STOP (>>> Fig. 8-11).
2. Connect the oil pump to the oil drain hose.
3. Fill oil via oil drain hose until oil level is visible at lower edge of filler
hole.
6. Insert M16x1.5 magnetic screw plug into the filler hole and tighten;
MA = 20 Nm.
7. Insert M16x1.5 magnetic screw plug into the vent hole and tighten;
MA= 20 Nm.

1 Vent hole
2 M18x1.5 magnetic screw plug
3 Filler hole
4 Oil drain hose
5 Oil pump

8.7 Checking the counterbalancing system
Description
The following describes those tasks which must be carried out on the
counterbalancing system at the intervals specified in the maintenance ta-
ble.
The gas pressure must always be checked on all diaphragm accumula-
tors!

KR QUANTEC-2 PA-HO
Maintenance
Equipment

Rag -
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.
Work safety
WARNING
bot.
8.7.1 Inspecting the counterbalancing system
Procedure
1. Manually move A2 to -90° (link arm vertical). The robot arm may be in
any position.
2. Wait 1 minute.
3. Secure the robot by pressing the EMERGENCY STOP device.
4. Check the following pressure on the pressure gauge:
• 176 bar ±15 bar at 20 °C (293 K)
If the permissible value is not correct and/or there are deviations in
the application, the value must be measured with a special pressure
gauge and KUKA Service must be consulted.
5. Check the attachments for dirt and clean them if necessary.
6. Check the attachments for damage and ensure that they do not leak.
In the case of leaks, identify the position of the leaks and remove oil
residues. If necessary, exchange the counterbalancing system.
7. Check the collar for dirt and damage, clean it or have it exchanged by
trained specialist personnel if necessary.


8.8 Exchanging the counterbalancing system
Description
The following sections describe the procedures for exchanging and filling
the counterbalancing system.
The gas pressure must always be checked on both diaphragm accumula-
tors!
Equipment

Torque wrench -
min. 20 Nm to 100 Nm
Socket set, ½ inch -
Rope slings with sufficient load-bearing -
capacity
2 cranes with sufficient load-bearing ca- -
pacity
Pin extractor 0000-131-687
Clamping bush 0000-194-012
Pin locator 0000-190-253
Rag -
Wooden pallet -
Material

CBS assy type GA20-F 0000-347-140 1
Procurement of spare parts
Defective components must only be replaced with original spare parts

from KUKA Deutschland GmbH. Non-compliance nullifies warranty and lia-
bility claims.
A “Repair Card” is supplied with the exchange parts. This must be com-
pleted and returned to KUKA Deutschland GmbH together with the defec-
tive component in the following cases.
• Within the warranty period
• If, after consultation with KUKA Deutschland GmbH, an examination of
the defective component by KUKA is required.
Tightening torques

torques" Page 257)
en.

KR QUANTEC-2 PA-HO
Maintenance
ones.
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.
Work safety
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.
8.8.1 Securing the link arm
Procedure
1. Secure the link arm with a rope sling and attach the rope sling to the
crane hook.
2. Raise the rope sling until it is taut.

Fig. 8-12: Securing the link arm
8.8.2 Removing the counterbalancing system on a floor-mounted robot
Procedure
1. Slacken the worm drive clip and push the bellows backwards
(>>> Fig. 8-13).
2. Move the link arm in the plus direction until the clamping bush can be
inserted between the cylinder and the articulated head.
4. Place clamping bush onto the free piston rod between the articulated
head and the hydraulic cylinder and secure it with a screw.
5. Put the robot into operation and move the link arm carefully in the mi-
nus direction until the clamping bush 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.

KR QUANTEC-2 PA-HO
Maintenance
Fig. 8-13: Counterbalancing system, clamping bush
1 Clamping bush
2 Bellows with worm drive clip
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
(>>> Fig. 8-14).
7. Remove 4 M8x20-10.9 Allen screws and conical spring washers, and
take off the retaining plate.

Fig. 8-14: Counterbalancing system, pin
1 Spacer ring 5 Conical spring washer

2 Pin 6 Pin locator
3 Lock washer 7 Rope sling
4 M8x20-10.9 Allen screw (4x) 8 Thrust ring
8. Insert the pin locator on the right-hand side between the articulated
head and the link arm.
9. 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.
10. 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.
12. Swivel the counterbalancing system up and out of the link arm, mov-
ing the crane and rope sling at the same time.
13. 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.

KR QUANTEC-2 PA-HO
Maintenance
14. Remove 2 M12x30 Allen screws and lock washers, and take the cover
off the rotating column (>>> Fig. 8-15).
15. Force the counterbalancing system off the pin in the rotating column.
While forcing off the counterbalancing system, check the rope tension
and if necessary correct it to prevent the components from being tilted.
Fig. 8-15: Counterbalancing system, rotating column
1 Rope sling 3 Conical spring washer

2 Cover 4 M12x30-10.9 Allen screw
(2x)
16. Continue raising the counterbalancing system with the crane and set it
down on a suitable support.
17. 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.
8.8.3 Installing the counterbalancing system
Description
The (>>> Fig. 8-18) clamping bush is only required for the counterbalanc-
ing system for floor-mounted robots.
Procedure
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 -85° position.

4. Lift the counterbalancing system with a rope sling and bring it to the
site of installation (>>> Fig. 8-16).
5. Mount the counterbalancing system sideways on the pin in the rotating
column, and align.
6. If necessary, adjust the rope tension.
7. Mount cover.
8. Apply Drei Bond 1342 adhesive to 2 M12x30-10.9 Allen screws and
insert them into the cover with conical spring washers.
9. Tighten 2 M12x30-10.9 Allen screws with a torque wrench. Increase
the tightening torque to the specified value in several stages.
Fig. 8-16: Counterbalancing system, rotating column
1 Rope sling 3 Conical spring washer

2 Cover 4 M12x30-10.9 Allen screw
(2x)
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. 8-17).
12. Lower the counterbalancing system.
13. Apply a thin but continuous coat of Microlube GL 261 to the thrust ring
and spacer ring.
Insert the articulated head with the thrust ring and spacer ring into the
link arm, and align.
Observe installation position of thrust ring and spacer ring!
14. Move the link arm and counterbalancing system until the holes are
aligned.
15. Insert the pin with the aid of the device.
16. Mount the retaining plate and insert 4 M8x20-10.9 Allen screws and
conical spring washers.
17. Tighten 4 M8x20-10.9 Allen screws with a torque wrench. Increase the
18. Remove the rope sling on the counterbalancing system.

KR QUANTEC-2 PA-HO
Maintenance
Fig. 8-17: Counterbalancing system, pin
1 Spacer ring 5 Conical spring washer

2 Pin 6 Pin locator
3 Lock washer 7 Rope sling
4 M8x20-10.9 Allen screw (4x) 8 Thrust ring
19. Put the robot into operation.

20. Move the link arm in the plus direction until the clamping bush be-
tween the cylinder and the articulated head is released, slacken the
setscrew and remove the clamping bush (>>> Fig. 8-18).
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.
21. Mount the bellows on the cylinder and the articulated head and fasten
with worm drive clips.

Fig. 8-18: Counterbalancing system, clamping bush
1 Clamping bush
2 Bellows with worm drive clip
22. Check the pressure on the counterbalancing system (>>> 8.7 "Check-
ing the counterbalancing system" Page 176).
8.8.4 Removing the equipment securing the link arm
Procedure
1. Slacken the rope sling and detach from the crane.

2. Remove the rope sling from the robot.

KR QUANTEC-2 PA-HO
Maintenance
8.8.5 Inspecting the counterbalancing system
Procedure
1. Manually move A2 to -90° (link arm vertical). The robot arm may be in
any position.
2. Wait 1 minute.
4. Check the following pressure on the pressure gauge:
• 176 bar ±15 bar at 20 °C (293 K)
If the permissible value is not correct and/or there are deviations in
the application, the value must be measured with a special pressure
gauge and KUKA Service must be consulted.
5. Check the attachments for dirt and clean them if necessary.
6. Check the attachments for damage and ensure that they do not leak.
In the case of leaks, identify the position of the leaks and remove oil
residues. If necessary, exchange the counterbalancing system.
7. Check the collar for dirt and damage, clean it or have it exchanged by
trained specialist personnel if necessary.

• Move link arm and carry out a function test.
• Check the pressure on the counterbalancing system pressure gauge in
the neutral position (piston rod is retracted to the maximum extent)
against the pressure table.
• Move the link arm against the positive and negative software limit
stops, observing the counterbalancing system pressure gauge.
The counterbalancing system pressure must rise constantly from the
neutral position in both the plus and minus directions.
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.
Equipment

Permissible cleaning tools (e.g. cloths, -
brushes)
Material


Neutral cleaning agents - -
solvent-free, water-soluble, non-flamma-
ble, non-aggressive, no steam, no refrig-
erants, chlorine-free, not strongly acidic,
not strongly alkaline
Precondition
• The robot controller is switched off.

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

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

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

KR QUANTEC-2 PA-HO
Repair
9 Repair
Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA. Information about KUKA College and its training
program can be found at college.kuka.com or can be obtained directly
from our subsidiaries.
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.
9.1 Exchanging motor A1
Description
The following instructions describe the exchange of the motor. This de-
scription applies to floor-mounted robots. If the robot is installed in an in-
clined or suspended position, the procedure is to be applied analogously.
During removal of the motor, the robot can independently move about this
axis. Mechanical auxiliary equipment (e.g. support, crane) or a stable end
position (e.g. buffer) can be used to secure against motions.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Brush -
SEMD/MEMD mastering kit 0000-228-936
Material

SPP motor 5.5kW L0 ME 0000-334-485 1

bility claims.

Repair KR QUANTEC-2 PA-HO
Tightening torques

torques" Page 257)
en.
ones.
Precondition
• The robot is secured by means of an EMERGENCY STOP device. It

must be ensured that the robot cannot be switched on by unauthor-
ized persons.
Work safety
CAUTION
Risk of burns on hot surfaces
The surfaces of the motors are often hot immediately after the robot has
been decommissioned. Touching them may result in burns.
• Wear protective gloves.
WARNING
Danger to life and limb due to live components
Components may remain energized after the robot system has been
switched off. Death, severe injuries or damage to property may result.
• Switch off the robot system at the main switch and secure it to pre-
vent unauthorized persons from switching it on again.
• Disconnect the power cable from the supply.
• After switching off, wait at least 5 minutes and then check to ensure
that the robot controller and power cable are deenergized.
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.
9.1.1 Removing motor A1
Procedure
1. Release and unplug connectors XM1 and XP1 at the sockets.

KR QUANTEC-2 PA-HO
Repair
2. Unscrew 4 M12x25-8.8-A2K Allen screws.
3. Release and lift out motor A1, being careful not to tilt it.
4. Cover the input shaft and protect it against fouling.
Fig. 9-1: Motor A1
1 M12x25-8.8-A2K Allen screw

2 Motor A1
3 Connector XM1
4 Connector XP1
5. If the motor is not to be reinstalled, it must be disposed of properly or

protected against corrosion before being put into storage.
9.1.2 Preparing a new motor for installation
Procedure
1. Clean the involute toothing of motor and gear unit before installation
and apply a thin but continuous coat of Microlube GL 261 grease.
2. Clean the mounting surface for the motor.
3. Check the condition of the O-ring on the motor shaft. In the case of
damage and/or wear, the O-ring must be exchanged.

Fig. 9-2: Preparing a new motor A1-A3 for installation
1 Motor
2 O-ring
3 Involute toothing
9.1.3 Installing motor A1
Procedure
1. Position sockets XM1 and XP1 as shown.

2. Insert motor A1, taking care not to tilt it.
Insertion of motor can be facilitated by turning it gently about its ro-
tational axis.
3. Insert 4 M12x25-8.8-A2K Allen screws.

4. Tighten 4 M12x25-8.8-A2K Allen screws with a torque wrench in diag-
5. Plug connectors XM1 and XP1 into the sockets. The pins and coding
elements of the connectors must be taken into consideration. When in-
serting the connectors, turn them until they clearly lock into the coding
elements (twist-proof).

KR QUANTEC-2 PA-HO
Repair
Fig. 9-3: Motor A1

2 Motor A1
3 Connector XM1
4 Connector XP1

• Move A1 of the robot and look out for irregularities.
• Carry out mastering of A1.
Detailed information about mastering can be found in the system
software documentation.
• Test the program in Manual Reduced Velocity (T1) mode.
Description

KR QUANTEC-2 PA-HO
Repair

Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
ty
Rope sling with sufficient load-bearing -
capacity
Brush -
Material

SPP motor 5.5kW L0 ME 0000-334-485 1

bility claims.
Tightening torques

torques" Page 257)
en.
ones.
Precondition

ized persons.
• The removal site is freely accessible for work tasks involving a crane.

KR QUANTEC-2 PA-HO
Repair
Work safety
DANGER
Danger to life and limb due to defective or unsuitable load suspen-
sion devices
If defective or non-approved load suspension devices are used, the load
may fall off or start to swing. Failure to observe this can lead to death,
injury or property damage.
• Before using load suspension devices, check for defects (e.g. dam-
age, corrosion, deformation, wear, cracks) and exchange compo-
nents if necessary.
• Use only inspected and approved load suspension devices.
• Use only load suspension devices with a sufficient load-bearing ca-
pacity.
CAUTION
WARNING
WARNING
NOTICE
damage.
Procedure
crane hook.

Procedure

2. 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.
4. Release and carefully lift out motor A2, taking care not to tilt it.

KR QUANTEC-2 PA-HO
Repair
Fig. 9-5: Motor A2
1 Motor A2
2 Rope sling
3 Connector XM2
4 Connector XP2
5. Cover the aperture on motor mount A2 and protect it against fouling.

Procedure

1 Motor
2 O-ring
3 Involute toothing
Procedure
1. If a new motor is to be installed, remove any corrosion protection it

may have prior to installation.
2. Clean the involute toothing of motor A2 and gear unit A2 before instal-
lation and apply a thin but continuous coat of Microlube GL 261
grease.
3. Clean the mounting surface of motor A2 on the motor mount.
4. Check the condition of the O-ring on the motor shaft; exchange if nec-
essary.
5. Position sockets XM2 and XP2 as shown.
6. With the rope sling, pick up and insert motor A2, being careful not to
tilt it.
tational axis.
7. Insert 4 M12x25-8.8-A2K Allen screws.

8. Tighten 4 M12x25-8.8-A2K Allen screws with a torque wrench in diag-

KR QUANTEC-2 PA-HO
Repair
Fig. 9-7: Motor A2
1 Motor A2
2 Rope sling
3 Connector XM2
4 Connector XP2
Procedure



• Test the program in Manual Reduced Velocity (T1) mode.
Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
ty

KR QUANTEC-2 PA-HO
Repair
capacity
Brush -
Material

SPP motor 5.5kW L0 ME 0000-334-485 1

bility claims.
Tightening torques

torques" Page 257)
en.
ones.
Precondition

ized persons.
• The removal site is freely accessible for work tasks involving a crane.

Work safety
DANGER
sion devices
nents if necessary.
pacity.
CAUTION
WARNING
WARNING
NOTICE
damage.
Procedure
crane hook.

KR QUANTEC-2 PA-HO
Repair
Procedure

2. Place the rope sling around motor A3 and raise it using the crane until
the weight of motor A3 is supported by the rope sling.
4. Release and carefully lift out motor A3, taking care not to tilt it.

Fig. 9-10: Motor A3
1 Crane hook
2 Rope sling
3 M12x25-8.8-A2K Allen screw (4x)
4 Motor A3
5 Connectors XM3 and XP3
5. Cover the aperture on motor mount A3 and protect it against fouling.

Procedure

KR QUANTEC-2 PA-HO
Repair
1 Motor
2 O-ring
3 Involute toothing
Procedure
1. With the rope sling, pick up and insert motor A3, being careful not to
tilt it.
tational axis.
2. Insert and tighten 4 M12x25-8.8-A2K Allen screws. Increase the tight-

ening torque to the specified value in several stages.

Fig. 9-12: Motor A3
1 Crane hook
2 Rope sling
4 Motor A3
5 Connectors XM3 and XP3
Procedure


KR QUANTEC-2 PA-HO
Repair

• Test the program in Manual Reduced Velocity mode (T1).
Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Brush -

Material

SPP Motor 1,7kW L0 ME PA 0000-378-693 1

bility claims.
Tightening torques

torques" Page 257)
en.
ones.
Precondition
• The robot must be prevented from tipping. If necessary, fasten the ro-
bot to the mounting base.
• The robot is secured against axis motions.
• There is no hazard posed by system components.
• Tools have been removed.
Work safety
WARNING
again.
sign).
eration.

KR QUANTEC-2 PA-HO
Repair
CAUTION
burns.
• Avoid contact.
WARNING
NOTICE
damage.
Procedure
1. If not yet carried out: Release and unplug connectors XM5 and XP5 at
the sockets.
2. Unscrew 4 M8x25-8.8-A2K Allen screws from motor A5 and remove
the motor.
Fig. 9-14: Installing/removing motor A5
1 Swivel housing
2 Motor A5
3 Connector XP5
4 Connector XM5


9.4.2 Preparing the new motor
Procedure
1. Check the involute toothing on the motor for damage.

Motor with damaged involute toothing must not be installed.
2. Clean the toothing of the motor and the gear unit before installation
Procedure
1. Apply a thin but continuous coat of Microlube GL 261 grease to the

toothing of the motor and input shafts.
2. Insert motor A5 into the swivel housing; do not tilt during installation
and ensure correct location (toothing).
tational axis.
3. Insert and tighten 4 M8x30-8.8-A2K Allen screws. Increase the tighten-

ing torque to the specified value in several stages.
1 Swivel housing
2 Motor A5
3 Connector XP5
4 Connector XM5

KR QUANTEC-2 PA-HO
Repair

• Move A5 and A6 of the robot and look out for irregularities.
• Carry out mastering of A5 and A6.
Description
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
Brush -
Material

SPP Motor 1,7kW L0 ME PA 0000-378-693 1

bility claims.

Tightening torques

torques" Page 257)
en.
ones.
Precondition
• The robot must be prevented from tipping. If necessary, fasten the ro-
bot to the mounting base.
• The robot is secured against axis motions.
• Tools have been removed.
Work safety
WARNING
again.
sign).
eration.
CAUTION
burns.
• Avoid contact.
WARNING
NOTICE
damage.

KR QUANTEC-2 PA-HO
Repair
Procedure

the motor.

2 Connector XM6
3 Connector XP6
4 Motor A6
5 Swivel housing

9.5.2 Preparing the new motor
Procedure
1. Check the involute toothing on the motor for damage.

Motor with damaged involute toothing must not be installed.
2. Clean the toothing of the motor and the gear unit before installation
Procedure



tational axis.


2 Connector XM6
3 Connector XP6
4 Motor A6
5 Swivel housing

9.6 Exchanging the swivel housing
Description
The following describes the exchange of the swivel housing.
Equipment

KR QUANTEC-2 PA-HO
Repair
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm
Socket wrench set -
ty
capacity
Brush -
Material

SPP swivel housing HO RAL 7035 (wo) 0000-400-068 1

bility claims.
Tightening torques

torques" Page 257)
en.
ones.
Preconditions
• The controller is switched off and secured to prevent unauthorized per-

sons from switching it on again.
• The arm is in the horizontal position.
• Axes 5 and 6 should, if possible, be in their zero positions.
• Payload (tool or device) has been removed from the swivel housing.

Work safety
WARNING
again.
sign).
eration.
DANGER
sion devices
nents if necessary.
pacity.
Procedure
1. If not yet carried out: Release and unplug connectors XM5 and XP5 at
the sockets.
the motor.

KR QUANTEC-2 PA-HO
Repair
1 Swivel housing
2 Motor A5
3 Connector XP5
4 Connector XM5

Procedure

the motor.


2 Connector XM6
3 Connector XP6
4 Motor A6
5 Swivel housing

9.6.3 Removing the swivel housing
Procedure
1. Disconnect the ground conductor connection.

2. Unscrew 20 M10x35-10.9 Allen screws with washers from the swivel
housing.
3. Carefully detach the swivel housing from the robot arm and remove it.
4. Set the swivel housing down on a suitable support surface.

KR QUANTEC-2 PA-HO
Repair
Fig. 9-20
1 M10x35-10.9 Allen screws (16x) with washers

2 Ground conductor connection
3 Swivel housing
5. If the swivel housing is not to be reinstalled, it must be protected

against corrosion before being put into storage.
9.6.4 Preparing the new swivel housing
Procedure
1. Remove corrosion protection from the new swivel housing, if applica-

ble.
2. Clean all toothing before installation and apply a thin but continuous
coat of Microlube GL 261 grease.
9.6.5 Installing the swivel housing
Procedure
1. Place the swivel housing on the robot arm.

2. Insert 20 new M10x35-10.9 Allen screws into the swivel housing and
tighten them. Increase the tightening torque to the specified value in
several stages.
3. Connect the ground conductor.

Fig. 9-21
1 M10x35-10.9 Allen screws (16x) with washers

2 Ground conductor connection
3 Swivel housing
Procedure

tational axis.


KR QUANTEC-2 PA-HO
Repair
1 Swivel housing
2 Motor A5
3 Connector XP5
4 Connector XM5
Procedure

tational axis.



2 Connector XM6
3 Connector XP6
4 Motor A6
5 Swivel housing

• Adapt the MAMES values .
If using KSS 8.3, the plug-in KUKA.WristMamesOffset is required
for this .

9.7 Description of the electrical installations
Overview
The electrical installations of the robot consist of:

• Cable set
• RDC box
Description
The electrical installations consist of the cable set from A1 to A6 as well

as the electronic modules, such as the RDC and EDS. The cable set in-
cludes all the supply and control cables for the motors of axes 1 to 6 as

KR QUANTEC-2 PA-HO
well as the cables for the protective circuit. All the connections on the mo-
Repair
tors are screwed plug-and-socket connections.
RDC and EDS are explained in more detail in the operating instructions of
the robot controller.
The interface for connecting the connecting cables to the robot is located
on the base frame at the rear of the robot. The connecting cables from
the controller (motor cable X30, data cable X31, the ground conductor
and, if applicable, the cables for external axes) are connected to it by
means of connectors.
The selected routing of cables and hoses within the robot arm ensures
that they 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 and hoses on the manipulator (>>> Fig. 9-24).
NOTICE
Break in cables when modifying the cable set
The cable set is designed to stretch sufficiently with each robot motion.
Additional attachments can place a heavy load on the cable set and
thus damage it. Error messages and damage to property could result.
• Do not attach any other lines to the cable set; use an external ener-
gy supply system if necessary.
• Do not fix the cable set in place with cable straps, Velcro cable
straps or the like.
• Keep foreign bodies away.

Fig. 9-24: Overview of electrical installations
1 Motor A6 4 Motor A2
2 Motor A5 5 Motor A1
3 Motor A3 6 RDC box
Wiring diagrams
Designation Connection Figure

Wiring diagram A1 XM1 (>>> Fig. 9-25)
Data cable RDC X31 RDC X31 (>>> Fig. 9-30)
Data cable RDC X32 RDC X32 (>>> Fig. 9-31)
Data cable, external axis X7 XP7 (>>> Fig. 9-32)
Data cable, external axis X8 XP8 (>>> Fig. 9-32)
Protective circuit Ring cable lug (>>> Fig. 9-33)

KR QUANTEC-2 PA-HO
Repair
Fig. 9-25: Wiring diagram A1


KR QUANTEC-2 PA-HO
Repair


KR QUANTEC-2 PA-HO
Repair
Fig. 9-30: Wiring diagram, RDC X31

Fig. 9-31: Wiring diagram, RDC X32
Fig. 9-32: Wiring diagram, data cable X7/X8 - XP7/XP8

KR QUANTEC-2 PA-HO
Repair
Fig. 9-33: Wiring diagram, protective circuit
1 Ground conductor, arm – swivel housing

Cross-section: 4 mm2
2 Ground conductor, arm – rotating column
3 Ground conductor, RDC – rotating column
4 Ground conductor, PE connection plate – base frame
5 Ground conductor, PE connection plate – rotating column
6 2x external ground conductor (KRC/system)
7 Ground conductor, PE connection plate – PE holding plate


KR QUANTEC-2 PA-HO
Decommissioning, storage and disposal

10 Decommissioning, storage and disposal
10.1 Decommissioning
Description
This section describes all the work required for decommissioning the robot
if the robot is to be removed from the system. After decommissioning, it is
prepared for storage or for transportation to a different location.
Following its removal, the robot can be transported by means of transport
tackle and crane or by fork lift truck.
Equipment

ty
capacity
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Precondition
• The removal site must be accessible with a crane or with a fork lift
truck for transportation.
Work safety
WARNING
bot.
10.1.1 Moving the robot into its transport position
Procedure

2. Remove tools and equipment.
3. Put the robot into operation and move it into the transport position.

Decommissioning, storage and disposal KR QUANTEC-2 PA-HO
4. Secure the robot by activating the EMERGENCY STOP device and

then shut down the robot.
Transport position
A1 0 °
A2 -137 °
A3 160 °
A4 -
A5 67 °
A6 0 °
10.1.2 Removing the robot
Procedure
1. Release and disconnect the peripheral connections.

2. Release and disconnect the motor cable and data cable connectors
(>>> Fig. 10-2).
3. Unscrew the hexagon nut from the ground conductor, take off the
washers and lock washers and pull off the ground conductor.
4. Unscrew and remove the 8 hexagon bolts and conical spring washers.
5. 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
Risk of injury due to abrupt detachment of the robot
If the robot is caught on the mounting surface, it may come free
abruptly. Injuries or damage to property may result.
‒ Remove the fastening materials completely.
‒ Remove any adhesives.

KR QUANTEC-2 PA-HO

Fig. 10-2: Removing the robot
1 Fork slots 4 Ground conductor 2x

2 Hexagon bolts 5 Motor cable
3 Pin 6 Data cable

• Prepare the robot for storage if the robot is not to be reinstalled.
10.2 Storage
Description
For storage, the robot must be removed, cleaned and suitably covered.
Storage location
The storage location must meet the following requirements:

• Virtually dry and free of dust
• Avoid temperature fluctuations
• Avoid wind and drafts
• Avoid condensation
• No exposure to direct sunlight
• Maintain the permissible temperature ranges for storage
• The packaging film cannot be damaged.
Equipment


ty
capacity
brushes)
Material

Covers - -
that cannot detach themselves and which
can withstand the expected environmen-
tal conditions
Cleaning agent - -
solvent-free, water-soluble, non-flamma-
ble, non-aggressive, no steam, no refrig-
erants
Precondition
• Loose parts or parts that might knock against other parts have been
removed from the robot.
• Tools and equipment have been removed.
Work safety
WARNING
bot.
10.2.1 Moving the robot into its transport position
Procedure

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

KR QUANTEC-2 PA-HO

Transport position
A1 0 °
A2 -137 °
A3 160 °
A4 -
A5 67 °
A6 0 °
10.2.2 Removing the robot
Procedure
1. Release and disconnect the peripheral connections.

2. Release and disconnect the motor cable and data cable connectors
(>>> Fig. 10-4).
3. Unscrew the hexagon nut from the ground conductor, take off the
washers and lock washers and pull off the ground conductor.
4. Unscrew and remove the 8 hexagon bolts and conical spring washers.
5. 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
Risk of injury due to abrupt detachment of the robot
If the robot is caught on the mounting surface, it may come free
abruptly. Injuries or damage to property may result.
‒ Remove the fastening materials completely.
‒ Remove any adhesives.

Fig. 10-4: Removing the robot
1 Fork slots 4 Ground conductor 2x

2 Hexagon bolts 5 Motor cable
3 Pin 6 Data cable
10.2.3 Cleaning
Procedure
1. Shut down the robot.

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

2. Remove any foreign bodies.
3. Remove any corrosion.
4. Attach all covers to the robot and check that the seals are correctly in
place.
5. Seal off electrical connections with suitable covers.
6. Seal hose connections by suitable means.
7. Cover the robot with plastic film and seal it at the base frame against
dust.
If necessary, add a desiccant beneath the sheeting.

KR QUANTEC-2 PA-HO

No concluding work is required.
10.3 Disposal
When the manipulator reaches the end of its useful life, it can be removed
from the system and dismantled, and the materials can be disposed of
properly by type.
The following table provides an overview of the materials used in the ma-
nipulator. All plastic components are marked with a material designation
and must be disposed of accordingly.
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

Metal
Cast-iron Base frame, rotating col-
material umn, link arm, arm, in-line
wrist
Copper Cables, wires
Light alloy Spur gear housing, swivel
casting housing
Steel Gear units, screws and
washers, connecting shafts,
bearings, holder plates
Electrical parts
Electronic components, Dispose of as electrical
such as RDC scrap without disassem-
bling.
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
EPDM/TPE Clamping pieces, RSGU
clips
POM/PP Sliding elements

Material Subassembly, component Additional information

Auxiliary substances and consumables
Gear oil Gear units Cassida Fluid GL150
Hydraulic oil Counterbalancing system Hyspin ZZ 46 hydraulic oil
Lubricating Counterbalancing system, LGEP 2 lubricating grease
grease bearing on arm / link arm
Lubricating Gear teeth Microlube GL 261 grease
grease
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:
(>>> 12.2 "Auxiliary and operating materials used" Page 258)

KR QUANTEC-2 PA-HO
Options
11 Options
11.1 Release device
Description
The release device can be used to move the manipulator manually after
an accident or malfunction. The release device can be used for the mo-
tors of axes A1 to A6.
The assembly also includes a ratchet, a TORX key wrench and a set of
plates with one plate for each motor. The plate specifies the direction of
rotation for the ratchet and shows the corresponding direction of motion of
the manipulator.
In order to move the manipulator without drive energy in the event of an
accident or malfunction, either a sufficient number of release devices or a
sufficient amount of suitable standard tools (TORX key wrench TX25 or a
size 8 flat-blade screwdriver and 12 mm combination wrench) must be
available.
Fig. 11-1: Product overview
1 Release device
2 TX25 TORX key wrench
3 Base frame
Basic data

Release device PA 0000-384-278 approx. 3 kg
Further information about the ambient conditions is contained in the as-

sembly instructions for the robot and robot controller.
(>>> 11.1.1 "Starting up the release device" Page 242)
Maintenance
If used for its intended purpose, the option requires minimal maintenance,
i.e. visual inspections are recommended. In certain operating conditions,
regular visual inspections may allow timely detection of changes. The na-
ture and scope of the maintenance work depend very much on the specif-

KR QUANTEC-2 PA-HO
ic area of application. This enables early detection of damage, thereby

Options
preventing failure of components and assemblies. Exchange damaged

components or assemblies.
Disposal
When the release device reaches the end of its useful life, it can be re-
moved and disposed of. The materials must be disposed of in accordance
with the pertinent regulations and, where possible, separated and sorted
for recycling.
11.1.1 Starting up the release device
Description
The release device can be used for moving the manipulator after an acci-
dent or malfunction without drive energy.
This section describes all work required to put the release device into op-
eration. Installation of a floor-mounted robot is described. A release device
for ceiling-mounted robots must be fastened to the cell wall.
This option is only for use in exceptional circumstances and emergencies,
e.g. for rescuing people.
Equipment

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

Release device PA 0000-384-278 1
or - 1 each
12 mm combination wrench and TORX
key wrench TX25
Tightening torques

torques" Page 257)
en.
ones.
Precondition


KR QUANTEC-2 PA-HO
Options
Work safety
SAFETY INSTRUCTION
The following procedure must be followed exactly!
CAUTION
Loss of mastering during movement without drive energy
After moving a motor without drive energy, the axis is no longer mas-
tered. Injuries or damage to property may result.
• Remaster all axes.
11.1.1.1 Installing the release device
Procedure
1. Unscrew 4 M8x20-8.8 Allen screws from the cover plate and remove
the cover plate from the base frame (>>> Fig. 11-2).
2. Position the clip plate on the base frame, insert 4 M8x20-8.8 Allen
screws and conical spring washers and fasten in place. Increase the
3. Place the release device and key wrench on the clip plate.
Fig. 11-2: Installing the release device
1 Release device
2 TX25 TORX key wrench
4 Conical spring washer (4x)
5 Clip plate
6 Cover plate
4. Attach the arrow adhesive labels to the cast housing in the vicinity of
the respective motors as shown in the illustration (>>> 11.1.1.1 "Instal-
ling the release device" Page 243).

Options KR QUANTEC-2 PA-HO
Fig. 11-3: Installation location arrow adhesive label
1 Arrow adhesive label A1

11.1.1.2 Moving the manipulator without drive energy
Procedure
1. Unscrew 4 M6x20 TORX slotted screws (TX25/slot size 8) and take

the cover off the corresponding motor (using a flat-blade screwdriver, if
necessary).
2. Push the release device (or combination wrench, size 12 mm) onto
the corresponding motor and move the axis in the desired direction.
It is necessary to overcome the resistance of the mechanical motor
brake and any other loads acting on the axis.
Fig. 11-4: Motor with release device
1 Motor
2 M6x20 TORX screw (TX25/size 8 slot) (4x)
3 Cover
4 Release device
3. Remove any dirt from the motor and cover.

4. Mount the cover on the motor and fit and tighten 4 M6x20 TORX slot-
ted screws (TX25/slot size 8); MA = 4.5 Nm.

KR QUANTEC-2 PA-HO
11.1.1.3 Concluding work
Options
• Master all axes.
• Perform brake test.
• Carry out a test run in T1 mode and look out for irregularities.
11.2 Cover of hollow shaft A1
Description
The cover of hollow shaft A1 is a textile cover that is pulled over the ro-
tating column to prevent dirt and foreign bodies from entering the hollow
shaft. It does not offer additional IP protection.
1 Outlet for energy supply system

2 Cover on hollow shaft A1
3 Aperture for energy supply system bracket with Velcro fastener
Basic data

Cover on hollow shaft A1 0000-346-699 approx. 0.42 kg

(>>> 11.2.1 "Putting the cover for hollow shaft A1 into operation"
Page 246)
Maintenance
(>>> 11.2.2 "Cleaning the cover of hollow shaft A1" Page 248)
Disposal
When the cover reaches the end of its useful life, it can be removed and
disposed of. The materials must be disposed of in accordance with the
pertinent regulations or recycled.

KR QUANTEC-2 PA-HO
The following table provides an overview of the materials used.

Options
Plastics
Aramid Textiles
Polyamide Velcro fastener
Natural rubber Elastic
Metal
PUR and aluminum Textile coating
11.2.1 Putting the cover for hollow shaft A1 into operation
Description
This section describes all work required to put the cover for hollow shaft
A1 into operation.
Equipment

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

Cover on hollow shaft A1 0000-346-699 1
Tightening torques

torques" Page 257)
en.
ones.
Precondition

11.2.1.1 Installing the cover of hollow shaft A1
Procedure
1. With energy supply system: Take off the support bracket of the energy
supply system and mount the holder for the cover of hollow shaft A1
under the support bracket (>>> Fig. 11-6).

KR QUANTEC-2 PA-HO
Options
2. Place the holder for the cover of hollow shaft A1 on the rotating col-
umn.
3. Insert and tighten 2 M8x16-8.8 Allen screws. Increase the tightening
torque to the specified value in several steps.
Fig. 11-6: Mounting the bracket
1 Holder, cover on hollow shaft A1

4. Clamp the cover between the holder and the rotating column.
Fig. 11-7: Clamping the cover on hollow shaft A1
1 Cover on hollow shaft A1

2 Holder, cover on hollow shaft A1
5. With energy supply system: Take off bracket with Velcro fastener.
6. Pull the cover over the rotating column and close it under the counter-
balancing system with the Velcro fastener and the press stud.

Fig. 11-8: Pulling the cover over hollow shaft A1 and closing it

2 Velcro fastener with press stud
3 Aperture for energy supply system bracket with Velcro fastener
7. With energy supply system: Mount the bracket with Velcro fastener on
the rotating column.
Insert and tighten 2 M8x16-8.8 Allen screws. Increase the tightening
torque to the specified value in several stages.
8. Without energy supply system: Close outlet for energy supply system
a using cable strap.
Fig. 11-9: Closing the outlet

2 Cable strap
With energy supply system: Using the Velcro fastener, adapt the outlet
for the energy supply system to the size of the cable bundle and close
it as tightly as possible, but without crushing.

11.2.2 Cleaning the cover of hollow shaft A1
Description
The cover must be cleaned in compliance with the instructions given here
in order to prevent damage. These instructions only refer to the cover.

KR QUANTEC-2 PA-HO
Options
Equipment

brushes)
Material
No material required.
Precondition

11.2.2.1 Cleaning the cover of hollow shaft A1
Procedure
1. Take off the cover and clean it on all sides.

NOTICE
The textile is sensitive to humidity.
Water and cleaning agents must not be used for cleaning. Damage
to property may otherwise result.
‒ Remove dirt with a brush or dry cloth only.
2. Check holder for corrosion and apply corrosion protection if necessary.

3. Check cover for wear and damage and exchange if necessary.
4. Re-install the cover.

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

1 Filter CBS HO
Basic data

Filter CBS HO 0000-409-386 -

(>>> 11.3.1 "Putting the CBS HO filter into operation" Page 251)
Repair
(>>> 11.3.2 "Exchanging the CBS HO filter" Page 253)

KR QUANTEC-2 PA-HO
Options
Maintenance
Interval Task Material

5000 h Visually inspect the CBS -
HO filter and replace if nec-
essary. (>>> 11.3.2 "Ex-
changing the CBS HO fil-
ter" Page 253)
Disposal
When the filter reaches the end of its useful life, it can be removed and
disposed of. The materials must be disposed of in accordance with the
pertinent regulations or recycled.
11.3.1 Putting the CBS HO filter into operation
Description
This section describes all work required to put the CBS HO filter into op-
eration.
Equipment

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

Filter CBS HO 0000-409-386 1
Tightening torques

torques" Page 257)
en.
ones.
Precondition


KR QUANTEC-2 PA-HO
11.3.1.1 Installing the CBS HO filter

Options
Procedure
1. Open the valve cover.

2. Insert and tighten the male coupling and the reducing coupling.
Increase the tightening torque to the specified value in several stages.
3. Mount and tighten the ventilation filter.
Fig. 11-11: Installing/removing the CBS HO filter
1 Ventilation filter
2 Reducing coupling
3 Straight male coupling
4 Valve cover


KR QUANTEC-2 PA-HO
Options
11.3.2 Exchanging the CBS HO filter
Description
If the CBS HO filter turns dark, it must be exchanged. This section de-
scribes all work required to change the CBS HO filter.
Equipment

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

Filter CBS HO 0000-409-386 1
Tightening torques

torques" Page 257)
en.
ones.
Precondition

11.3.2.1 Removing the CBS HO filter
Procedure
1. Unscrew and remove the ventilation filter.

2. Slacken and remove the male coupling and the reducing coupling.
3. Close the valve cover.

2 Reducing coupling
4 Valve cover
11.3.2.2 Installing the CBS HO filter
Procedure
1. Open the valve cover.

2. Insert and tighten the male coupling and the reducing coupling.
Increase the tightening torque to the specified value in several stages.
3. Mount and tighten the ventilation filter.

KR QUANTEC-2 PA-HO
Options
2 Reducing coupling
4 Valve cover



KR QUANTEC-2 PA-HO
Appendix
12 Appendix
12.1 Tightening torques
Tightening torques
The following tightening torques (Nm) are valid for screws and nuts where
no other specifications are given.
The specified values apply to lightly oiled black (e.g. phosphated) and
coated (e.g. mech. galv., zinc flake plating, screw locking elements)
screws and nuts.
Strength class
Thread 8.8 10.9 12.9
M1.6 0.17 Nm 0.24 Nm 0.28 Nm
M2 0.35 Nm 0.48 Nm 0.56 Nm
M2.5 0.68 Nm 0.93 Nm 1.10 Nm
M3 1.2 Nm 1.6 Nm 2.0 Nm
M4 2.8 Nm 3.8 Nm 4.4 Nm
M5 5.6 Nm 7.5 Nm 9.0 Nm
M6 9.5 Nm 12.5 Nm 15.0 Nm
M8 23.0 Nm 31.0 Nm 36.0 Nm
M10 45.0 Nm 60.0 Nm 70.0 Nm
M12 78.0 Nm 104.0 Nm 125.0 Nm
M14 125.0 Nm 165.0 Nm 195.0 Nm
M16 195.0 Nm 250.0 Nm 305.0 Nm
M20 370.0 Nm 500.0 Nm 600.0 Nm
M24 640.0 Nm 860.0 Nm 1030.0 Nm
M30 1330.0 Nm 1700.0 Nm 2000.0 Nm
Strength class
Thread 8.8 10.9
ISO7991 ISO7380, ISO07381
Allen screw Fillister head
screw
M3 0.8 Nm 0.8 Nm
M4 1.9 Nm 1.9 Nm
M5 3.8 Nm 3.8 Nm
Strength class
Thread 10.9
DIN7984
Pan head screws
M4 2.8 Nm
Tighten M5 domed cap nuts with a torque of 4.2 Nm.

Appendix KR QUANTEC-2 PA-HO
12.2 Auxiliary and operating materials used
Product designation / Use Manufacturer designation /

Article number Address
Cassida Fluid GL150 Gear oil FUCHS LUBRITECH GmbH

Werner-Heisenberg-Strasse 1
0000-297-118
D-67661
Kaiserslautern
Germany
Castrol Hyspin ZZ 46 Hydraulic oil Deutsche Castrol Vertriebsgesell-

schaft mbH
0083-236-203
Max-Born-Str. 2
D-22761
Hamburg
Germany
Drei Bond type 1118 Surface sealant Drei Bond GmbH

Carl-Zeiss-Ring 13
0000-265-996
D-85737
Ismaning
Germany
Drei Bond type 1305 Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 13
0000-184-175
D-85737
Ismaning
Germany
Drei Bond type 1342 Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 13
0000-184-174
D-85737
Ismaning
Germany
Drei Bond type 5204HV Adhesive and sealant Drei Bond GmbH
Carl-Zeiss-Ring 13
0000-251-505
D-85737
Ismaning
Germany
LGEP 2 Lubricating grease SKF Maintenance Products

Postboks 1008
0000-119-990
NL-3430
BA Nieuwegein
Netherlands
MARCOL 82 Lubricant ExxonMobil Petroleum & Chemical

BVBA
0000-386-390
POLDERDIJKWEG
B-2030
Antwerp
Belgium
Microlube GL 261 Lubricating grease Klüber Lubrication München KG

Geisenhausenerstr. 7
0000-135-463
D-81379
Munich
Germany

KR QUANTEC-2 PA-HO
Appendix
Optitemp RB 2 Lubricating grease Deutsche BP Aktiengesellschaft - In-
dustrial Lubricants & Services
0000-101-456
Erkelenzer Strasse 20
D-41179
Mönchengladbach
Germany
PETAMO GHY 133 N Lubricating grease Klüber Lubrication München KG

Geisenhausenerstr. 7
0000-269-159
D-81379
Munich
Germany

12.3 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]
Right of access KUKA Deutschland GmbH Quality Assurance
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-

KR QUANTEC-2 PA-HO
ject to the formal requirements of Regulation (EC) No. 1907/2006

Appendix
(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
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 265).

KR QUANTEC-2 PA-HO
Appendix
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 261).
For information on personal protective equipment, see section 8
(>>> "Section 8" Page 262).
For information on disposal, see section 13 (>>> "Section 13"
Page 263).
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 261).
• 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:

KR QUANTEC-2 PA-HO
Appendix
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)
• 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!

KR QUANTEC-2 PA-HO
Appendix
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
12.4 Applied standards and regulations
Name/Edition Definition
2006/42/EC Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Coun-
cil of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)
2014/30/EU EMC Directive:

Directive 2014/30/EU of the European Parliament and of the Coun-
cil dated 26 February 2014 on the approximation of the laws of the
Member States concerning electromagnetic compatibility
2014/68/EU Pressure Equipment Directive:

Directive 2014/68/EU of the European Parliament and of the Coun-
cil dated 15 May 2014 on the approximation of the laws of the
Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing
system.)
ANSI/RIA R15.06-2012 Industrial Robots and Robot System
EN 60204-1:2018 Safety of machinery:

Electrical equipment of machines – Part 1: General requirements
EN 61000-6-2:2005 Electromagnetic compatibility (EMC):

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

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

Ergonomic design principles - Part 1: Terms and general principles
EN ISO 10218-1:2011 Robots and robotic devices – Safety requirements for industri-
al robots:
Part 1: Robots

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-2 PA-HO
KUKA Service
13 KUKA Service
13.1 Requesting support
Introduction
This documentation provides information on operation and operator con-

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

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• The greatest possible amount of information about the hardware and
software components of the overall system
• Information about use in the foodstuffs industry and the auxiliary sub-
stances and consumables used
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
‒ Designation of the gear oil
‒ External axes used
13.2 KUKA Customer Support
The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

KUKA Service KR QUANTEC-2 PA-HO

KR QUANTEC-2 PA-HO
Index D
2006/42/EC................................................... 265 Danger zone.............................................11, 21
2014/30/EU................................................... 265 Declaration of conformity............................... 20
2014/68/EU................................................... 265 Declaration of incorporation.....................19, 20
95/16/EC....................................................... 265 Decommissioning................................... 32, 233
Description of the robot system.....................15
Dimensions, transport...................................125
A Directives...................................................... 265
Accessories.....................................................19 Disclaimer....................................................... 19
Angle of rotation............................................. 11 Disposal......................................... 32, 233, 239
ANSI/RIA R15.06-2012................................ 265 Documentation, industrial robot....................... 9
Appendix....................................................... 257 Drei Bond type 1118.................................... 258
Arctic............................................................... 10 Drei Bond type 1305....................................258
Arm................................................................. 17 Drei Bond type 1342....................................258
Automatic mode..............................................30 Drei Bond type 5204HV...............................258
Auxiliary materials used............................... 258
Axis data, KR 140 R3200-2 PA-HO.............. 35
Axis data, KR 180 R3200-2 PA-HO.............. 47 E
Axis data, KR 240 R3200-2 PA-HO.............. 59 EC declaration of conformity......................... 20
Axis limitation, mechanical............................. 24 EDS.................................................................10
Axis range................................................ 10, 20 EDS cool.........................................................10
Electrical installations.............................17, 222
Electromagnetic compatibility (EMC)........... 265
B Electromagnetic compatibility (EMC):.......... 265
Base frame..................................................... 17 EMC Directive........................................ 20, 265
Basic data, KR 140 R3200-2 PA-HO............ 33 EMD................................................................ 11
Basic data, KR 180 R3200-2 PA-HO............ 45 EN 60204-1:2018......................................... 265
Basic data, KR 240 R3200-2 PA-HO............ 57 EN 61000-6-2:2005...................................... 265
Brake defect................................................... 25 EN 61000-6-4:2007 + A1:2011.................... 265
Brake release device......................................24 EN 614-1:2006+A1:2009..............................265
Braking distance.......................................10, 20 EN ISO 10218-1:2011.................................. 265
EN ISO 12100:2010..................................... 266
EN ISO 13849-1:2015..................................266
EN ISO 13849-2:2012..................................266
C EN ISO 13850:2015..................................... 266
C..................................................................... 10 EX................................................................... 11
Cassida Fluid GL150....................................258 Extension........................................................ 10
Castrol Hyspin ZZ 46...................................258 External axes..................................................19
CBS HO filter................................................249 External axis.............................................13, 22
Exchanging.............................................. 253
Installing.......................................... 252, 254
Putting into operation.............................. 251
Removing.................................................253 F
CE mark..........................................................20 F...................................................................... 11
Center of gravity...........................................125 F exclusive......................................................11
Center of mass ................................ 38, 50, 62 Faults.............................................................. 27
Clean Room....................................................10 Flange loads...................................... 41, 53, 65
Cleaning the robot........................................187 Fork lift truck.................................................126
Cleaning work.................................................31 Foundation loads, KR 140 R3200-2 PA-HO. 43
Connecting cable, standard.................146, 150 Foundation loads, KR 180 R3200-2 PA-HO. 55
Connecting cables.. 19, 34, 35, 46, 47, 58, 59, Foundation loads, KR 240 R3200-2 PA-HO. 67
121 Function test................................................... 28
Counterbalancing system.........................17, 31
Counterbalancing system, checking............ 176
Counterbalancing system, hydropneumatic... 17 G
Cover for hollow shaft A1 General safety measures............................... 25
Putting into operation.............................. 246 Ground conductor................................ 149, 153
Cover of hollow shaft A1............................. 245
Cover of hollow shaft A1, cleaning............. 248
CR...................................................................10 H

KR QUANTEC-2 PA-HO
HA................................................................... 11 micro RDC...................................................... 11

Handling equipment............ 126, 133, 138, 142 Microlube GL 261.........................................258
Hazardous substances................................... 32 Misuse.............................................................18
HI.....................................................................11 Motion velocity................................................12
HM...................................................................11 Motor A1, exchanging.................................. 189
HO...................................................................11 Motor A2, exchanging..........................193, 200
HP................................................................... 11 Motor A5, exchanging.......................... 207, 211
HW.................................................................. 11 Mounting base with centering.............. 113, 116
Mounting flange...........................16, 40, 52, 64
Mouse, external.............................................. 26
I MT................................................................... 11
Industrial robot................................................19
Industrial Robots and Robot System...........265
Information for planning................................113 O
Information sheet for products.....................259 Oil change, A1..............................................158
Interface A1.................................................. 122 Oil change, A2..............................................162
Interface, connecting cables................146, 149 Oil change, A3..............................................165
Interface, energy supply system..................123 Oil change, A5..............................................169
Interfaces...................................................... 121 Oil change, A6..............................................173
Introduction....................................................... 9 Oil temperatures........................................... 156
Operating materials used............................. 258
Operators........................................................ 23
K Options.............................................17, 19, 241
K......................................................................11 CBS HO filter.......................................... 249
KCP.................................................... 11, 21, 26 Optitemp RB 2..............................................259
Keyboard, external......................................... 26 Overload......................................................... 25
KR................................................................... 11
KR C............................................................... 11
KS................................................................... 11 P
KUKA Customer Support............................. 267 P......................................................................11
KUKA Service...............................................267 PA....................................................................11
KUKA smartPAD...................................... 11, 21 Payload diagram................................39, 51, 63
KUKA smartPAD-2................................... 11, 21 Payloads, KR 140 R3200-2 PA-HO.............. 38
Payloads, KR 180 R3200-2 PA-HO.............. 50
Payloads, KR 240 R3200-2 PA-HO.............. 62
L Personal protective equipment...................... 22
Labeling.......................................................... 25 Personnel........................................................22
LGEP 2......................................................... 258 PETAMO GHY 133 N.................................. 259
Lifting tackle..................................................127 Phi................................................................... 11
Lifting tackle (optional)................................. 126 Planning........................................................ 113
Linear unit.......................................................19 Plant integrator............................................... 21
Link arm..........................................................17 Plates and labels............................................69
Low Voltage Directive.....................................20 Positioner........................................................ 19
POV................................................................ 12
PPE.................................................................22
Preparing for storage................................... 238
M Pressure Equipment Directive.........17, 31, 265
Machine frame mounting..............................119
Preventive maintenance work........................ 31
Machinery Directive................................20, 265
Product description.........................................15
Main axes.................................................72, 90
Program override............................................12
Maintenance........................................... 30, 155
Protective circuit............................................. 17
Maintenance symbols...................................156
Protective equipment, overview..................... 23
Manipulator.................................. 11, 16, 19, 21
Manual mode..................................................29
MARCOL 82................................................. 258
Mass...................................................38, 50, 62 R
Mass moments of inertia...................39, 51, 63 RDC................................................................ 12
Material designation..................................... 239 RDC cool........................................................ 12
Mechanical end stops.................................... 23 Reaction distance.....................................10, 20
MEMD............................................................. 11 Recommissioning................................... 27, 131
Refilling quantity......... 159, 162, 166, 170, 173

KR QUANTEC-2 PA-HO
Regulations................................................... 265 Technical data, overview................................ 33

Release device.......................................24, 241 Terms used..................................................... 10
Start-up.................................................... 242 Terms, safety.................................................. 20
Repair..................................................... 30, 189 Tightening torques........................................ 257
Robot controller.............................................. 19 Training............................................ 9, 155, 189
Robot, removing........................................... 233 Transport position......................................... 125
Rotating column..............................................17 Transport safeguard..................................... 128
Transportation........................................ 27, 125
Transportation by fork lift truck.................... 126
S Transportation with lifting tackle.................. 127
Safety..............................................................19 Turn-tilt table...................................................19
Safety instructions............................................ 9
Safety of machinery.............................265, 266
Safety zone.............................................. 21, 23 U
Safety, general................................................19 Use
SC................................................................... 12 Intended..................................................... 18
SE................................................................... 12 User.......................................................... 20, 22
Securing loads..............................................128 Users.................................................................9
Service life...................................................... 21
SI.....................................................................12
SL....................................................................12 W
smartPAD........................................... 12, 21, 26 W.....................................................................12
Software..........................................................19 Warnings........................................................... 9
Spare parts 178, 189, 194, 201, 208, 211, 215 Wiring diagrams, electrical installations.......224
SPP................................................................. 11 Workspace......................................... 10, 20, 23
Standards......................................................265 WP.................................................................. 12
Start-up...................................................27, 131 Wrist................................................................16
Start-up, floor-mounted robots (mounting
base).............................................................131
Start-up, floor-mounted robots (optional
150 mm mounting base)..............................136
Starting up robots (machine frame
mounting)...................................................... 141
STOP 0.................................................... 73, 90
STOP 1.................................................... 73, 90
Stop categories........................................ 12, 21
Stop signal......................................................73
Stopping distance.............................. 10, 20, 73
Stopping distances....... 73, 78, 84, 92, 99, 106
Stopping distances times with KR C5...........90
Stopping distances with KR C4.....................72
Stopping time..................................................73
Stopping times............. 73, 78, 84, 92, 99, 106
Stopping times with KR C4........................... 72
Stopping times with KR C5........................... 90
Storage...........................................32, 233, 235
Supplementary load...........................42, 54, 66
Support request............................................ 267
Swivel housing, new, preparing................... 219
System integrator..................................... 20–22
T
T1 (operating mode)................................ 12, 21
T2 (operating mode)................................ 12, 21
Teach pendant................................................ 19
Technical data.................................................33
Technical data, KR 140 R3200-2 PA-HO......33

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Robots

Publication: Pub MA KR QUANTEC-2 PA-HO (PDF) en

Book structure: MA KR QUANTEC-2 PA-HO V3.1

Version: MA KR QUANTEC-2 PA-HO V4

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4.4.3 Payloads, KR 240 R3200-2 PA-HO...................................................................... 62

7 Start-up and recommissioning............................................................... 131

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7.1 Starting up floor-mounted robots (mounting base).............................................. 131

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8.8.2 Removing the counterbalancing system on a floor-mounted robot..................... 180

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10 Decommissioning, storage and disposal............................................. 233

13 KUKA Service........................................................................................... 267

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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

EDS cool Electronic Data Storage cool

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SPP Spare parts package

F exclusive Foundry exclusive

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

MEMD Micro Electronic Mastering Device

micro RDC micro Resolver Digital Converter

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RDC Resolver Digital Converter

RDC cool Resolver Digital Converter

smartPAD Teach pendant for the robot controller

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

T2 For KUKA iiQKA.OS: not relevant at present

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2.1 Overview of the robot system

Fig. 2-1: Example of an industrial robot

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2.2 Description of the manipulator

The manipulators (= robot arm and electrical installations) of the variants