ROBOT

(V)KR 150, 180, 210

Installation, Connection, Exchange

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

PD Interleaf

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Contents

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

2 Principal loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Mounting variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Variant 1 (394.016--08.001.00--00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Variant 2 (394.018--08.002.00--00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Variant 3 (394.100--01.005.00--00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Floor--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Ceiling--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6 Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Exchanging floor--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 Exchanging ceiling--mounted robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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 1 General

Valid for (V)KR 150

(V)KR 150 L 130
(V)KR 150 L 110
(V)KR 180
(V)KR 180 L 150
(V)KR 180 L 130
(V)KR 210
(V)KR 210 L 180
(V)KR 210 L 150

1 General

The Doc. Module “Safety, General” and the robot Doc. Module “Repair, General”
are to be observed!
With all work involving the connection of the robot (and of the control cabinet),
the control cabinet Doc. Module “Initial Start--up” must be observed.

When putting the robot into operation either for the first time or after an
exchange, zero adjustment must be carried out in accordance with the Operating
Handbook, Software KR C2, Chapter “Start--up”, Section “Robot Mastering/
Unmastering”.

Before any installation and exchange work is started, any attached tools or additional equip-
ment that would hinder the installation and exchange work must be dismounted.

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

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

Example:

(8) Lower the robot slowly without tilting it.

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

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

Example:

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

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 2 Principal loads

2 Principal loads
Forces occur during operation of the robot which must be safely transmitted to the floor or
ceiling. The forces that have to be taken into account for floor-- and ceiling--mounted robots
are specified in Fig. 1. The drawings with their specifications can also be used as a basis for
more extensive static investigations.
The specified forces and moments already include the payload and the inertia force (weight)
of the robot.

Mk

Fv

Fh
Mr

Fv = Vertical force Fvmax = 24 000 N

Fh = Horizontal force Fhmax = 18 000 N
Mk = Tilting moment Mkmax = 49 000 Nm
Mr = Tilting moment about axis 1 Mrmax = 38 000 Nm

Total mass = robot + total load for type

1245 kg + 550 kg KR 150

1255 kg + 530 kg KR 150 L130
1263 kg + 510 kg KR 150 L110
1267 kg + 580 kg KR 180
1277 kg + 550 kg KR 180 L150
1285 kg + 530 kg KR 180 L130
1267 kg + 610 kg KR 210
1277 kg + 580 kg KR 210 L180
1285 kg + 550 kg KR 210 L150

Fig. 1 Principal loads acting on floor (or ceiling) due to robot and total load

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Installation, Connection, Exchange

3 Mounting variants
Depending on the type, the robot can be installed on the floor or on the ceiling.
There are three mounting variants for installing the robot on the floor, and one mounting
variant for installing the robot on the ceiling:
G Variant 1 (394.016--08.001.00--00), see Section 3.1.

Fig. 2 Mounting base with centering

G Variant 2 (394.018--08.002.00--00), see Section 3.2.

Fig. 3 Machine frame mounting

G Variant 3 (394.100--01.005.00--00), see Section 3.3.

Fig. 4 Booster frame

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 3 Mounting variants (continued)

If the robot is to be installed on the floor and mounted directly on a concrete base (variants
1 and 3), all pertinent construction specifications must be observed concerning the grade of
concrete (³ B25 according to DIN 1045) and the load--bearing capacity of the ground when
preparing the concrete foundation. It must be ensured that the surface of the foundation is
level and sufficiently smooth. If the concrete surface does not meet these criteria, the uneven
areas must be corrected using levelling compound. Great care must be taken when making
the anchor holes and inserting the anchors to ensure that the forces occurring during the op-
eration of the robot (Fig. 1) are transmitted safely to the ground.
To avoid distorting the robot base frame or the booster frame when fastening it to the concrete
foundation, differences in level between the concrete foundation and the base frame must
be corrected using levelling compound (filling compound). If the robot is to be mounted on
a booster frame, corresponding measures are to be taken when installing the booster frame.

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Installation, Connection, Exchange

The procedure is as follows:

(1) Mark the position of the bedplates on the concrete foundation and determine the
magnitude of the differences in level.
(2) Apply levelling compound (Fig. 5/2) onto the marked areas on the concrete foundation
(4) or the underside of the drilling template.

“Knauf levelling compound”, for example, is a suitable compound for this purpose. It is
applied with a toothed spatula (tooth height > 2 x difference in level (5)).
Before applying the levelling compound, coat the drilling template with parting agent.

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

(3) Place the drilling template in the still plastic levelling compound and adjust its position
slightly if necessary.
(4) Remove excess levelling compound.
1 2

5 4 3

Fig. 5 Levelling compound

If large differences in level need to be compensated for, more levelling

compound must be applied. The maximum levelling compound thickness
specified by the manufacturer must not be exceeded.

(5) Allow the levelling compound to cure for about three hours. The curing time is longer
at temperatures below 20 °C.

At the end of the curing time, the holes can be drilled.

(6) Remove drilling template.

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 4 Installation

4 Installation

4.1 Variant 1 (394.016--08.001.00--00)

Features:
-- For floor--mounted robots only.
-- Robot installed directly on the concrete foundation.
-- Robot fastened by means of twelve chemical anchors (resin--bonded anchors).

(1) Mark a hole pattern as per Fig. 7 on the foundation or set down the drilling template in
the intended installation position on the foundation. Please observe Section 3.
(2) The intended installation position of the robot, i.e. the correct orientation in relation to
the working envelope (Fig. 6/1), must be taken into account when marking out the hole
pattern.

Fig. 6 Orientation of working envelope

(3) Drill twelve anchor holes (Fig. 7/1) in accordance with Fig. 7, or drill through the holes
in the drilling template; minimum depth in concrete 170 +5 mm.
(4) Remove the drilling template, if applicable, and clean the boreholes.

The boreholes must be free of dust and loose pieces of concrete. No fluids or dust
bonding agents may be used for cleaning.

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Installation, Connection, Exchange

front

3
4

Min. distance to edge

of concrete 210 mm

Fig. 7 Concrete foundation and hole pattern for variant 1

(5) Fasten each of the four foundation plates (2) to the robot (4) by means of two
M24x70--8.8--A2K hexagon bolts (3) and lock washers.
(6) Insert twelve resin capsules (Fig. 8/4).
(7) Bring robot to the site of installation, and set it down and align it in accordance with the
hole pattern.
(8) Insert one threaded rod (3) into each borehole (5). To do this, secure the setting tool
(2) in a hammer drill (1), attach the threaded rod, and insert it into the borehole using
no more than 750 r.p.m. The threaded rod is set correctly if the resin is completely mixed
and the borehole in the concrete is completely filled to the upper edge. If the borehole
is not completely filled, the threaded rod must be pulled out again immediately and a
new resin capsule inserted.
(9) Allow the resin to cure.

The curing time is as follows:

Temperature Time
+20 °C 20 minutes
+10 °C 30 minutes
0 °C 1 hour
--5 °C 5 hours

(10) Screw on hexagon nuts (6) together with washers and tighten hexagon nuts with torque
wrench in diagonally opposite sequence, increasing the tightening torque MA to the
specified value in several stages (MA = 120 Nm).

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 4 Installation (continued)

Retighten the hexagon nuts (6) after 100 hours of operation.

1
6

Hole depth
2

Minimum concrete thickness

3
4

Fig. 8 Robot installation, variant 1

Installation of the robot is now finished. The robot is now ready for connection to the
controller.

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Installation, Connection, Exchange

4.2 Variant 2 (394.018--08.002.00--00)

Features:
-- For floor-- and ceiling--mounted robots.
-- Robot installed on a steel structure prepared by the customer (or on a linear unit
of series KL 1500).
-- Robot fastened by means of eight M24x70 ISO 4017 hexagon bolts; tightening
torque MA = 640 Nm.
The correct orientation of the hole pattern in relation to the working envelope (Fig. 9/1) is
given in Fig. 9. When determining the hole pattern (installation position), it must be ensured
that the locating pins (2, 3) are correctly positioned.

2 1

Fig. 9 Orientation of working envelope

When preparing mounting surfaces, the specified minimum dimensions must be

strictly observed.

The drilling template (available as an accessory) makes it easier to drill the holes
for the fastening screws and the locating pins.

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 4 Installation (continued)

(1) Prepare four mounting surfaces (Fig. 10/1) on the mounting platform in accordance
with Fig. 10.
1

4x

M24
(2x)
min. 336

M8
125

0.5 Rz 63

min. 120 max. 387.5

Fig. 10 Mounting surfaces

(2) Drill eight holes for the fastening screws (Fig. 11/3).
(3) Make two tapped holes (4) with precision fit for the locating pins (2) as shown in the
illustration.

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

(4) Insert both of the locating pins (2) and fasten each one with an M8x55 Allen screw (1)
together with conical spring washer.
Installation of the robot is now finished. The robot is ready for connection (see Section 5.1
or 5.2).

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Section X -- X 1 2

0,5
Rz 63
40

max. 6
Robot base

3
4

0,1

2 2

Fig. 11 Hole pattern and location of pins

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 4 Installation (continued)

4.3 Variant 3 (394.100--01.005.00--00)

Features:
-- For floor--mounted robots only.
-- Robot installed with booster frame (Fig. 4) on a concrete foundation.
-- Booster frame fastened to robot using eight M24x70 hexagon bolts.
-- Easy removal and installation with optimum repeatability of the installation posi-
tion.
(1) Mark a hole pattern as per Fig. 13 on the foundation or set down the drilling template
in the intended installation position on the foundation. Please observe Section 3.
(2) The intended installation position of the robot, i.e. the correct orientation of the locating
pins (Fig. 12/2, 3) in relation to the working envelope (1), must be taken into account
when marking the position of the boreholes.

2 1

Fig. 12 Orientation of working envelope

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Fig. 13 Hole pattern for variant 3

(3) Drill sixteen anchor holes (Fig. 13/1) in accordance with the dimensions in Fig. 13, or
drill through the holes of the drilling template; minimum depth in concrete 170 +5 mm.
(4) Clean the boreholes.

The boreholes must be free of dust and loose pieces of concrete. No fluids or dust
bonding agents may be used for cleaning.

(5) Bring booster frame to the site of installation, and set it down and align it in accordance
with the hole pattern.
(6) Insert sixteen resin capsules (Fig. 14/4).
(7) Insert one threaded rod (3) into each borehole (5). To do this, secure the setting tool
(2) in a hammer drill (1), attach the threaded rod, and insert it into the borehole using
no more than 750 r.p.m. The threaded rod is set correctly if the resin is completely mixed
and the borehole in the concrete is completely filled to the upper edge. If the borehole
is not completely filled, the threaded rod must be pulled out again immediately and a
new resin capsule inserted.
(8) Allow the resin to cure.

The curing time is as follows:

Temperature Time
+20 °C 20 minutes
+10 °C 30 minutes
0 °C 1 hour
--5 °C 5 hours

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 4 Installation (continued)

(9) Screw on hexagon nuts (6) together with washers and tighten hexagon nuts with torque
wrench in diagonally opposite sequence, increasing the tightening torque MA to the
specified value in several stages (MA = 120 Nm).

Retighten the hexagon nuts (6) after 100 hours of operation.

2 4x mounting surface

Minimum concrete thickness

3

170 +5
4

5 Min. distance from edge 210 mm

Fig. 14 Robot installation, variant 3

Installation of the robot is now finished. The robot is ready for connection (see Section 5.1).

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Installation, Connection, Exchange

5 Connection

5.1 Floor--mounted robots

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

This description only applies to robots with mounting variant 2 (Section 3.2) or 3 (Section
3.3). If the robot is to be installed on the floor in an inclined position (max. 5˚; no inclination
permitted with booster frame), then KUKA must be consulted beforehand.
The procedure for installing the robot (whether for the first time or as an exchange) -- if the
robot is not already securely fastened to the mounting platform -- is as follows:
(1) Check that both locating pins (Fig. 15/2) and their fastening screws (1) are undamaged
and fitted securely.

Damaged locating pins must be replaced by new ones.

1 2

Fig. 15 Locating pin

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 5 Connection (continued)

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

A1 A2 A3 A4 A5 A6
0˚ - -151˚ +155˚ 0˚ 0˚ any

All angles refer to the display on the KCP.

C
1181
1652

Table of dimensions
B

for robot A [mm] B [mm] C [mm]

KR 150, 180, 210
without arm extension 133 750 1767
1100 with 200 mm arm extension 112 750 1966
with 400 mm arm extension 91 751 2165
598
A

Fig. 16 Transport position for floor--mounted robots

Fig. 17 Transporting the robot

(2) Lift robot with fork lift truck or lifting tackle.

If transporting the robot using lifting tackle, three M20 eyebolts (Fig. 17/2) must be
installed; if using a fork lift truck, the fork slots (1) (accessory) must be fully and
properly installed.

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

(3) Lower robot (Fig. 18/1) vertically onto bedplates, steel structure or booster frame. If
lifting tackle is used, particular care must be taken to ensure exact vertical positioning
in order to avoid damaging the locating pins during this operation.

As the robot is lowered, the boreholes (2) must be aligned as accurately as

possible with the two locating pins (4). If this operation is carried out
inaccurately, it is more likely that parts will be damaged.

Fig. 18 Installing the robot on the floor

(4) Insert eight M24x70--8.8 ISO 4017 hexagon bolts (3) together with conical spring wash-
ers and tighten them with a torque wrench in diagonally opposite sequence, increasing
the tightening torque MA to the specified value in several stages (MA = 640 Nm).
(5) Remove lifting tackle.
(6) Plug in connecting cables (see Doc. Module “Connecting Cables”).

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

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 5 Connection (continued)

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

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

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

(9) Connect electric cables and hose lines to interfaces of energy supply system A 1 and
all other peripheral supply lines to the robot, where necessary.
(10) Put robot into operation.

The relevant documentation must be observed when putting the robot and the attached
peripheral equipment into operation

5.2 Ceiling--mounted robots

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

This description only applies to ceiling--mounted robots with mounting variant 2 (Section 3.2).
For installation on the ceiling, the robot can be transported in a transport frame -- already in
the correct orientation. It is removed from this frame by fork lift truck and brought to the site
of installation (Fig. 19).

For transport by fork lift truck, the fork slots (1) (accessory) must be fully and properly
installed.

Fig. 19 Transporting the robot for mounting on the ceiling

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Installation, Connection, Exchange

If the robot is transported by fork lift truck, the forks must be placed in the fork
slots. It is forbidden to pick up the robot in any other way using a fork lift truck!

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

The procedure for mounting the robot on the ceiling (whether for the first time or as an ex-
change) is as follows:
(1) Check that both locating pins (Fig. 15/2) and their fastening screws are undamaged and
fitted securely.

Damaged locating pins must be replaced by new ones.

The robot must be in the transport position (Fig. 20).

A1 A2 A3 A4 A5 A6
0˚ - -151˚ +155˚ 0˚ 0˚ any
All angles refer to the display on the KCP.
A
598
1100
B

1652

Table of dimensions
for robot A [mm] B [mm] C [mm]
KR 150, 180, 210
1181 without arm extension 133 750 1767
with 200 mm arm extension 112 750 1966
C with 400 mm arm extension 91 751 2165

Fig. 20 Transport position for ceiling--mounted robots

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 5 Connection (continued)

(2) Raise the robot (Fig. 21/1) vertically with the fork lift truck and place it onto the ceiling
structure (4).

As the robot is lifted, the boreholes (2) must be aligned as accurately as

possible with the two locating pins (5). If this operation is carried out
inaccurately, it is more likely that parts will be damaged.

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

4 5

Fig. 21 Installing the robot on the ceiling

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

Retighten the eight hexagon bolts (3) after 100 hours of operation.

(4) Remove fork lift truck.

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(5) Plug in connecting cables.

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

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

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

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

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

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 6 Exchange

6 Exchange
To avoid the need for any major reprogramming after an exchange, the instructions given in
the Operating Handbook, Software KR C2, Chapter “Start--up”, Section “Robot Mastering/
Unmastering” must be accurately carried out every time a robot is exchanged.

When putting the robot into operation either for the first time or after an
exchange, zero adjustment must be carried out in accordance with the Operating
Handbook, Software KR C2, Chapter “Start--up”, Section “Robot Mastering/
Unmastering”.

6.1 Exchanging floor--mounted robots

D Removal

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

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

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

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

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

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

(2) Put robot into operation and move it into transport position (Fig. 22).

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Installation, Connection, Exchange

A1 A2 A3 A4 A5 A6
0˚ - -151˚ +155˚ 0˚ 0˚ any
All angles refer to the display on the KCP.

C
1181
1652

Table of dimensions
B

for robot A [mm] B [mm] C [mm]

KR 150, 180, 210
without arm extension 133 750 1767
1100 with 200 mm arm extension 112 750 1966
with 400 mm arm extension 91 751 2165
598

Fig. 22 Transport position for floor--mounted robots

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

(3) Release and unplug connectors (Fig. 23/1, 2) from the junction boxes.
(4) Disconnect electric cables and hose lines from interface (5) of energy supply system
A 1 and all other peripheral supply lines to the robot, where necessary.

Depressurize and drain hose lines beforehand.

(5) Remove eight M24x70 hexagon bolts (3) together with lock washers.
(6) Raise robot with lifting tackle attached to three eyebolts on the rotating column.

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

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 6 Exchange (continued)

5
1
4

3 2

Fig. 23 Removal of floor--mounted robot

The robot can also be lifted by fork lift truck. For transport by fork lift truck, the fork slots
(6) (accessory) must be fully and properly installed.

If the robot is transported by fork lift truck, the forks must be placed in the fork
slots. It is forbidden to pick up the robot in any other way using a fork lift truck!

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

(7) Lower robot onto a suitable support.

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

D Installation
See Section 5.1.

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6.2 Exchanging ceiling--mounted robots

D Removal

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

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

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

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

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

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

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

A1 A2 A3 A4 A5 A6
0˚ - -151˚ +155˚ 0˚ 0˚ any
All angles refer to the display on the KCP.

A
598
1100
B

1652

Table of dimensions
for robot A [mm] B [mm] C [mm]
KR 150, 180, 210
1181 without arm extension 133 750 1767
with 200 mm arm extension 112 750 1966
C with 400 mm arm extension 91 751 2165

Fig. 24 Transport position for ceiling--mounted robots

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 6 Exchange (continued)

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

(3) Release and unplug connectors (Fig. 25/4, 5) from the junction boxes.
(4) Remove electric cables and hose lines from both interfaces of energy supply system
A 1 and all other peripheral supply lines to the robot, where necessary.

Depressurize and drain hose lines beforehand.

(5) Move the forks of the fork lift truck into the fork slots (3) and press robot firmly against
the ceiling.

5 1

2
4

Fig. 25 Removal of ceiling--mounted robot

(6) Remove eight M24x70 hexagon bolts (1) together with lock washers.
(7) Lower robot slowly without tilting it.

The robot must be lowered vertically downwards until both locating pins (2) are
free.

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

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

D Installation
See Section 5.2.
1

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