ROBOT

(V)KR 6; (V)KR 16; ...--2

Maintenance

Manipulator without Wrist

Issued: 20 Mar 2013 Version: 08

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e Copyright 2013

KUKA Roboter GmbH

Zugspitzstraße 140
D--86165 Augsburg
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.

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Contents

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

2 Lubrication work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Changing the oil on main axis gear units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.1 Changing the oil on axis 1 gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.2 Changing the oil on axis 2 gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.3 Changing the oil on axis 3 gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Other maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Cleaning and preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 Safety precautions when handling lubricants . . . . . . . . . . . . . . . . . . . . . . 18

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 Maintenance

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1 General

Valid for (V)KR 6; ...--2

(V)KR 16; ...--2 (V)KR 16 EX; ...--2 EX (V)KR 16 CR; ...--2 CR
(V)KR 16 S; ...--2 S (V)KR 16 L6; ...--2

1 General

This description applies analogously to all of the robots listed above, regardless of the
robot variant depicted.

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

With “EX” variant robots, work may only be carried out if there is no risk of
explosion.

Maintenance and cleaning work on CR--variant robots may only be conducted

outside cleanrooms. Instructions of the cleanroom user must be observed.
Cleaning operations are to be carried out with cleaning agents suitable for use
in the cleanroom.

Before any maintenance work is started, any attached tools or additional equipment that
would hinder maintenance must be dismounted.
Lubrication is performed either at the specified maintenance intervals or every 5 years after
commissioning by the customer -- whichever is reached first.
With maintenance intervals of 20 000 hours, the first maintenance (oil change) is performed
either after 20 000 operating hours or 5 years after commissioning by the customer --
whichever is reached first.

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

ageing).

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

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 Maintenance

Explanation of symbols:

1 Maintenance point

Maintenance point, visible on drawing

Maintenance point, hidden on drawing

1.0 l Oil change, to be repeated at specific intervals;

with indication of oil capacity

Tighten screw (nut)

Check and replace toothed belts

Visual inspection

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

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

Only KUKA--approved lubricants may be used.

Some of the specially marked texts refer exclusively to the subsequent steps -- 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 Lubrication work

2 Lubrication work

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

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

Utmost caution must be exercised when handling cable grease. The use of pro-
tective clothing (at least protective gloves, for example) is strongly recommen-
ded.
All accident prevention regulations and Section 5 of this Doc. Module must be
observed.

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

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 Maintenance

D “Lubrication” table
Maintenance point maintenance Activity Comment
(Fig. 1) interval Lubricant
(hours) Manufacturer
Amount
KUKA Art. no.

20000
10000
Floor--mounted ma- Changing the oil Change oil as described in
 nipulator
D D Optigear Synthetic RO 150 Section 2.1.1.
Gear with bearings A 1
2) Castrol, approx. 0.500 l 1)
KUKA Art. no.
00--144--898
Ceiling--mounted ma- Changing the oil Change oil as described in
 nipulator
D D Optigear Synthetic RO 150 Section 2.1.1.
Gear with bearings A 1
2) Castrol, approx. 0.600 l 1)3)
KUKA Art. no.
00--144--898
Gear with bearings A 2 Changing the oil Change oil as described in
 D D Optigear Synthetic RO 150 Section 2.1.2.
2) Castrol, approx. 0.500 l 1)
KUKA Art. no.
00--144--898
Gear with bearings A 3 Changing the oil Change oil as described in
‘ D D Optigear Synthetic RO 150 Section 2.1.3.
2) Castrol, approx. 0.200 l 1)
KUKA Art. no.
00--144--898
D Normal maintenance interval
1) The oil quantities specified are the actual amounts of oil in the gear unit at first filling
2) For EX--variant robots
3) 0,600 l only with compensation vessel

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2 Lubrication work (Fortsetzung)

Ceiling--mounted robot
Caution: 0,600 l only with 0,60 l 0,50 l 0,20 l
compensation vessel

Floor--mounted robot 0,50 l 0,50 l 0,20 l

1 2 3

Fig. 1 Lubrication

When draining the oil, it is important to remember that the quantity drained is depen-
dent on time and temperature.
The quantity of oil drained must be measured, as only this quantity may be used when
refilling. If less than 70% of the specified oil quantity flows out, flush the gear unit with
the measured quantity of drained oil once, then pour in the amount of oil that was
drained. During the flushing procedure, move the axis at jog velocity throughout the
entire axis range.

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 Maintenance

2.1 Changing the oil on main axis gear units

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

The oil is to be changed only at operating temperature.

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

2.1.1 Changing the oil on axis 1 gear unit

Section 2.1 of this Doc. Module is to be observed!

D Draining the oil

(1) Remove four M6x10 Allen screws (Fig. 2/4) and lock washers, and take off cover (5).
(2) Remove cable straps (3) and pull out drain hose (6).
(3) Unscrew sealing cap (7) on drain hose (6) and place receptacle (10) under the drain
hole.
(4) Remove magnetic screw (8) and check magnet for swarf or metal particles.
(5) Catch the oil as it drains out

The oil takes about 15 minutes to drain completely.

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

(6) Screw sealing cap (7) onto drain hose (6) and tighten it.

D Filling with oil

(1) Pour specified amount of oil into filler hole of magnetic screw (8).

Use a hose (2) approx. 1 m long with a straight M18x1.5 union (9) together with a fun-
nel (1) which fits into the free end of the hose (2).

(2) Remove filling hose (2).

(3) Insert and tighten magnetic screw (8), tightening torque MA = 20 Nm.
(4) Check sealing cap (7) for leaks.

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2 Lubrication work (Fortsetzung)

(5) Attach cable straps (3).

(6) Mount cover (5) and fasten it with four M6x10 Allen screws (4) and lock washers.
(7) Connect any peripheral supply lines required.

9
3

10

8 7

Fig. 2 Changing the oil on axis 1

2.1.2 Changing the oil on axis 2 gear unit

Section 2.1 of this Doc. Module is to be observed!

For oil draining and filling use a hose (Fig. 3/2) approx. 1 m long with a straight
M18x1.5 union (3) together with a funnel (1) which fits into the free end of the hose (2).

D Drain oil
(1) Remove screw plug (5).
(2) Screw in drain hose and place receptacle (6) under the hose.
(3) Remove screw plug (4) and catch oil as it drains out.

The oil takes about 15 minutes to drain completely.

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 Maintenance

Store used oil in accordance with regulations and dispose of it with minimum
environmental impact.
(4) Remove drain hose.
(5) Insert and tighten screw plug (5); tightening torque MA = 20 Nm.

D Fill with oil

(1) Pour specified amount of oil into the filler hole at (4).

Only KUKA--approved lubricants may be used.

(2) Remove filling hose.

(3) Insert and tighten screw plug (4); MA = 20 Nm.
(4) Check screw plug (5) for leaks.
1

3
4

Fig. 3 Changing the oil on axis 2

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2 Lubrication work (Fortsetzung)

2.1.3 Changing the oil on axis 3 gear unit

Section 2.1 of this Doc. Module is to be observed!

D Drain oil

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

(1) Put robot into operation and move axis 3 until the magnetic screws (Fig. 4/2, 6) are
aligned vertically.

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

(2) Remove magnetic screw (6) and place receptacle (5) under the drain hole.

It is easier to drain the oil if a hose (4) with a straight M10x1 union (3) is used.

(3) Remove magnetic screw (2) and catch oil as it drains out.

The oil takes about 10 minutes to drain completely.

Store used oil in accordance with regulations and dispose of it with minimum envi-
ronmental impact.

(4) Remove drain hose.

(5) Insert and tighten magnetic screw (6) (tightening torque MA = 10 Nm).

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 Maintenance

D Fill with oil

(1) Pour specified amount of oil into the filler hole at (2).

Only KUKA--approved lubricants may be used.

It is easier to pour in the oil if a funnel (1) is used for this purpose.

(2) Insert and tighten magnetic screw (2); MA = 10 Nm.

(3) Check magnetic screws (2, 6) for leaks.

6
3

4
5

Fig. 4 Changing the oil on axis 3

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 3 Other maintenance

3 Other maintenance

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

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

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

D “Other maintenance” table

Maintenance point maintenance Activity Comment

(Fig. 5) interval
(hours)
10000

Robot installation Check tightening torques for See Doc. Module

 D bolts and anchor nuts. Robot, ”Installation,
Connection, Exchange”.
Electric cables and Check electric cables, flex- Exchange any damaged
 dress package
D
ible tubes and dress pack- cables and flexible tubes.
2) age for wear and tear. See robot Doc. Module,
“Repair, Electrical Installa-
Check the quantity of cable tions”.
D grease in the base frame
and replenish if necessary.
2) Cable grease
Art. no. 00--126--265
Toothed belt, arm D Check toothed belt tension See robot Doc. Module “Ad-
‘ A 4, A 5 justment Instructions”
1)
Checking toothed belts Replace toothed belts if
cracks or signs of deteriora-
tion are found.

See robot Doc. Module,

”Repair, Motor Units”.

D Replace toothed belts To exchange the toothed

belts, see robot Doc. Mod-
3) ule, “Repair, In--line Wrist”.

1) Carried out at KUKA before delivery, or must be performed by the user after a toothed belt has been exchanged.
2) For EX--variant robots, after 5,000 hours of operation.
3) After 2 years at the latest.

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 Maintenance

1 2 3

Fig. 5 Other maintenance

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4 Cleaning and preventive maintenance

4 Cleaning and preventive maintenance

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

With “EX” variant robots, work may only be carried out if there is no risk of
explosion.

Maintenance and cleaning work on CR--variant robots may only be conducted

outside cleanrooms. Instructions of the cleanroom user must be observed.
Cleaning operations are to be carried out with cleaning agents suitable for use
in the cleanroom.

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

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

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

It must be ensured that no washing fluid enters bearings, seals or electrical

equipment.

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

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

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

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 Maintenance

5 Safety precautions when handling lubricants

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

All accident prevention regulations must be observed when handling lubricants.

-- If lubricant is likely to come into contact with the skin, e.g. with the hands, suitable
barrier creams must be applied before work is started.
-- On completion of work and before smoking breaks or meal breaks (before any
intake of food), clean oil--contaminated skin thoroughly with water and
skin--friendly cleansing agents or soap. After cleaning, replace lost skin grease
with appropriate skin creams containing grease.
-- Change oil--soaked clothing immediately. Do not carry oily rags or any cloths
soaked with solvents, mineral oil mixtures or cable grease in your pockets.
-- Avoid breathing in oil spray or vapors wherever possible.
1

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