ROBOT

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

Description

Options Package for KR 16, Protection Plus

Valid for Art. no. 00--159--609

Issued: 13 Oct 2009

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Version: 01
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e Copyright

2009

KUKA Roboter GmbH

Zugspitzstrae 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 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 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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2
3.2.1
3.2.2
3.2.3
3.2.4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the rotating column covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the arm covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the set of covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the junction box cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8
10
11
12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

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Description

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Description

Valid for

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

Description
For use in environments with a high level of exposure to dust, water, chips or other particles,
variants of the KR 16 robot model can be fitted with covers (Fig. 1) to give the robot additional
protection in particularly sensitive areas.
These covers are available as an option package which can be preinstalled by the manufacturer or mounted later as a retrofit.
If the covers are installed on a foundry--variant robot, the pressure regulator for pressurizing
the arm must be relocated. It is fastened on the base frame and protected by the cover for
the junction box. If an energy supply system for A 3 A 6 is used, the adapter bracket must
be installed.
The option package consists of the following assemblies:
--

Junction box cover

--

Rotating column cover

--

Arm cover

--

Set of covers

--

Conversion kit for pressure regulator

--

Adapter bracket
1
2

5
1 Arm cover
2 Adapter bracket
3 Set of covers

4
5
6

Rotating column cover

Junction box cover
Conversion kit for pressure regulator

Fig. 1 KR 16 covers
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Description

Technical data
Weight

Junction box cover

Rotating column cover
Arm cover
Set of covers
Conversion kit for pressure regulator
Adapter bracket

10.40 kg
6.40 kg
3.27 kg
0.09 kg
0.40 kg
1.70 kg

Protection classification of the electric parts

IP 65
ready for operation, with connecting cables plugged in
(according to EN 60529)
Material

MAKROTECH polycarbonate

Ambient temperature

During operation:
278 K to 328 K (+5 C to +55 C).
During storage/transportation:
233 K to 333 K (--40 C to +60 C).
Other temperature limits available on request.

Dimensional stability under heat

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405 K (132 C)

Fire classification

acc. to UL94--V2

Resistance

Acids and alkalis.

With use of cleaning agents and parting agents, KUKA Robot
GmbH must be consulted.

Other characteristics

Resistant to weld spatter and UV radiation from the welding arc.

Color

Black

Restrictions on use

Not with working range monitoring on A 1 and A 2

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Installing the covers

Installing the covers

3.1

General
The Doc. Module Safety, General and the robot Doc. Module Repair, General
are to be observed!
Tools and additional equipment must be removed before work is started if they are likely to
impede the work.
If the main switch on the control cabinet has been switched to OFF for performing installation
work, connector X1 must be disconnected from the control cabinet immediately afterwards,
provided that it is not necessary to move the robot. It must be correctly plugged back in again
before the robot is put into operation again.
Insert all screws with Dreibond 1342 locking agent and tighten them with a torque wrench
as specified in the table below.
Tightening torques
Screws

Tightening torque

ISO4762--M4--A4--70

0.8 Nm

ISO4762--M5--A4--80

5.3 Nm

ISO4762--M6--A4--80

3.0 Nm

ISO4762--M8--A4--80

22.0 Nm

ISO4762--M12--A4--80

25.0 Nm

ISO4762--M4--8.8--A2K

2.80 Nm

ISO4762--M8--8.8--A2K

15.0 Nm

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Remarks

Hinged clamps

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Description

3.2

Installation
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 jog speed, with all applicable safety rules and
regulations being observed.

3.2.1

Installing the rotating column covers

(1)

Move axis 2 into the --90 position and axis 3 into the +90 position.

(2)

Turn the main switch to the OFF position and lock it.

(3)

Remove the holder of energy supply system A 1 A 3 (Fig. 2/1) and the hinged clamp
on the rotating column. Only with energy supply system A 1 A 3.

(4)

Mount the left--hand fastening ring (6) and right--hand fastening ring (4) with seven
M6x25 Allen screws (5) and one M6x30 Allen screw (3) (back left), together with
washers.

(5)

Mount the lower shell (9) and align it.

(6)

Insert and tighten four M4x14--A4--70 Allen screws (7) together with washers.

(7)

Insert and tighten the 80 mm spacer (8) on the left.

(8)

Insert and tighten the 93 mm spacer (2) on the right.

1
2

9
8

7
6

5
Fig. 2 Rotating column cover, lower shell
(9)

Remove the blanking cover (Fig. 3/5) from the upper shell (1). Only with energy supply
system A 1 A 3.

(10) Mount the upper shell (1) and align it.

(11) Insert five M12x25--A4--80 Allen screws (7) together with washers.
(12) Insert and tighten seventeen M4x14--A4--70 Allen screws (6) together with washers.
(13) Insert and tighten one M4x20--A4--80 Allen screw (4) and washer.
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Installing the covers (Fortsetzung)

6
5
4
3
2

Fig. 3 Rotating column cover, upper shell

(14) Tighten the five M12x25--A4--80 Allen screws (7).
(15) Fasten the hinged clamp (2) with two M8x16 Allen screws (3) and washers to the lower
shell.
(16) Place the flexible tube of energy supply system A 1 A 3 in the hinged clamp and close
the hinged clamp.

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Description

3.2.2

Installing the arm covers

(1)

Remove two Allen screws (Fig. 4/2) and washers, and take off the pressure regulator
(1). Unplug the hose (3) from the pressure regulator and plug it directly into the
connection on the arm. Only with foundry--variant robots.

(2)

Remove two Allen screws (4) and take off the hinged clamp (5).

(3)

Fasten the bracket (6) with two M8x20--8.8--A2K Allen screws (7) and washers to the
arm.

(4)

Insert the flexible tube of the electrical installations into the bracket (6).
1
2
7

6
5
4

Fig. 4 Pressure regulator and bracket

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(5)

Mount the upper shell (Fig. 5/2) and insert four M8x20--A4--80 Allen screws (1) and
washers.
If an energy supply system A 3 A 6 is being installed, the adapter bracket (5) is
also installed at the same time. In this case, four M8x25--8.8--A2K Allen screws are
used. The hinged clamp of the energy supply system is fastened to this adapter
bracket.

(6)

Mount the lower shell (4) and align it.

(7)

Insert and tighten fifteen M4x14--A4--70 Allen screws (3).

(8)

Tighten the four Allen screws (1).

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Installing the covers (Fortsetzung)

1
2

3
4

Fig. 5 Arm cover

3.2.3

Installing the set of covers

(1)

Insert and tighten two reducing pins (Fig. 6/1).

(2)

Mount both covers (3, 4) and align them.

(3)

Insert and tighten one M4x12--8.8--A2K Allen screw (2) and washer in each cover.

1
2

3
4
Fig. 6 Arm cover

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Description

Installing the pressure regulator (foundry--variant robots only)

(1)

Remove two Allen screws (Fig. 7/1) and lock washers from the plate (2).

(2)

Mount the bracket (4) with the pressure regulator (5), and insert and tighten two
M6x10--8.8--A2K Allen screws (1).

(3)

Connect the air hose to the input and output of the pressure regulator.

(4)

Check the pressure setting on the pressure regulator.

1

3
4

Fig. 7 Installing the pressure regulator

3.2.4

Installing the junction box cover

(5)

Mount the junction box cover, and insert and tighten two M8x20--A4--80 Allen screws
(Fig. 8/2) and washers.

(1)

Mount the narrow cover plate (4) on the weldment (1), and insert and tighten four
M5x12--A4--80 Allen screws (3) and washers.

(2)

Mount the wide cover plate (5) on the weldment (1), and insert and tighten six
M5x12--A4--80 Allen screws (6) and washers.
2
1

3
4

Fig. 8 Junction box cover

(3)

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Put the robot into operation and move all axes through the entire range of motion,
checking that the covers do not cause any obstruction.
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Maintenance

Maintenance
The Doc. Module Safety, General is to be observed!
Before any maintenance work is started, any attached tools or additional equipment that
would hinder maintenance must be dismounted.

Explanations of the symbols used in connection with maintenance intervals in the

Maintenance tables below:
means: maintenance interval

Explanation of symbols:

Maintenance point 1

Maintenance point, visible on drawing

Maintenance point, hidden on drawing

Check component

Check / adjust component

The maintenance intervals start at commissioning by the customer. The maintenance

intervals are intended as recommendations and must be adapted to the specific ambient
conditions.

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Description

Junction box cover

Pressure regulator

Check that that pressure

regulator is fuctioning
correctly and has the correct
setting. Check that the hoses
are free of kinks and do not
leak.

Check that the components

The covers must not chafe on
are undamaged and fitted
moving parts.
securely. Exchange damaged
parts.
Remove any deposits on or
under the cover.
Check that the cover does
not cause any obstruction;
ensure that the robot can
move freely.

Check that the components

The covers must not chafe on
are undamaged and fitted
moving parts.
securely. Exchange damaged
parts.
Remove any deposits on or
under the cover.
Check that the cover does
not cause any obstruction;
ensure that the robot can
move freely.

Rotating column cover

Arm cover

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Note

Check that the components

are undamaged and fitted
securely. Exchange damaged
parts.
Remove any deposits on or
under the cover.

Activity

monthly

weekly

Maintenance
interval

daily

Maintenance point
(see Fig. 9)

0.1 bar

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Maintenance (Fortsetzung)

Energy supply system

Check that the holders and

flexible tubes are undamaged
and fitted securely. Exchange
damaged parts.
Remove any deposits on the
flexible tubes or holders.

Set of covers

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Check that the components

are undamaged and fitted
securely. Exchange damaged
parts.
Remove any deposits on or
under the cover.

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Description

Fig. 9 Maintenance work

1

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