ROBOT

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

Repair

Electrical Installations, SafeRobot

Issued: 30 Sep 2009

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Version: 02
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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 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 2
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal of cable set assembly (00--139--811) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of cable set assembly (00--139--811) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal/installation of motor cable A 1 (XM1) (00--122--871) . . . . . . . . . . . . . . . . . . . . . . . . Removal/installation of motor cable A 2 (XM2) (00--122--872) . . . . . . . . . . . . . . . . . . . . . . . . Removal/installation of control cable A 1 (XP1) (00--122--881) . . . . . . . . . . . . . . . . . . . . . . . . Removal/installation of control cable A 2 (XP2) (00--122--882) . . . . . . . . . . . . . . . . . . . . . . . . Removal/installation of motor and control cables A 3 and A 6 . . . . . . . . . . . . . . . . . . . . . . . . Removal/installation of data cable connection X31--X900 (00--124--823) . . . . . . . . . . . . . . . Removal/installation of connecting cable connection ESC X41--X901 (00--124--824) . . . . . Removal/installation of safe I/Os modular X40--X902 (00--138--401) . . . . . . . . . . . . . . . . . . . Removal/installation of connecting cable, reference switch X42--X904 (00--132--407) . . . . Removal/installation of mastering cable connection X32--X10 (00--106--299) . . . . . . . . . . . Removal/installation of Safe RDC cover incl. connector (00--138--396) . . . . . . . . . . . . . . . . Removal/installation of flexible tube A 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal/installation of flexible tube A 2/A 3 (00--119--732) . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 6
7 10 16 20 20 23 23 25 25 26 26 27 27 28 29

Safety precautions when handling lubricants . . . . . . . . . . . . . . . . . . . . . .

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General

Valid for

(V)KR 6 KS; ...- KS -2 (V)KR 16 KS; ...- KS -2 (V)KR 16 L6 KS; ...- KS -2

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

General
This description applies analogously to all the robots listed above, regardless of the robot variant or model shown in the illustrations. The electrical installations of the robot comprise the cable set (see also robot Doc. Module Description, Electrical Installations). This can be exchanged without dismantling major robot parts. If it is necessary for subassemblies, such as cables and flexible tubes, to be exchanged, it is usually advantageous to replace the complete cable set assembly. It is recommended therefore that a spare cable set be kept in reserve. A defective subassembly can then be replaced on the workbench with the cable set fully extended in a straight line. The Doc. Module Safety, General and the robot Doc. Module Repair, General are to be observed! Regardless of its normal installation position, the robot must be brought into the floor position for all extensive repairs to the cable set (see robot Doc. Module Installation, Connection, Exchange) and must be screwed down so that it will not tilt under any circumstances. Before repair work is started, any attached tools or additional equipment that would hinder repair must be dismounted. All periphery cables leading to the robot (e.g. for the tool or collision protection device) or the cables for robot accessories (e.g. working range monitoring) must also be unplugged at the robot. After the installation process has been concluded, all these cables and supply lines must be correctly reconnected to the robot. If the main switch on the control cabinet has been switched to OFF for performing repair work, the connecting cables between the robot and the control cabinet must be disconnected at the robot immediately afterwards. They must then be correctly reconnected before the robot is put into operation again. Utmost caution must be exercised when handling cable grease. The use of protective clothing (at least protective gloves, for example) is strongly recommended. All accident prevention regulations and Section 3 of this Doc. Module must be observed.

Only KUKA-approved cable grease may be used. Performing the following work is greatly facilitated if the robot is at a level which can be easily reached by the personnel carrying out the repairs. Ro/El/03/52.01 04.07.02 en 5 of 31

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Repair jobs
The descriptions of the repair jobs can be quickly located by referring to the following table.

D Table of repair jobs

Repair Removal of cable set assembly Installation of cable set assembly Removal/installation of motor cable A 1 Removal/installation of motor cable A 2 Removal/installation of control cable A 1 Removal/installation of control cable A 2 Removal/installation of motor cable A 3 Removal/installation of motor cable A 4 Removal/installation of motor cable A 5 Removal/installation of motor cable A 6 Removal/installation of control cable A 3 Removal/installation of control cable A 4 Removal/installation of control cable A 5 Removal/installation of control cable A 6 Removal/installation of data cable connection Connecting cable Connection ESC Safe I/Os modular Connecting cable reference switch Safe RDC cover with connector Removal/installation of mastering cable connection Removal/installation of flexible tube A 1 (L = 840 mm) Flexible tube A 2/ Removal/installation of A3 6 of 31 Cable 00--139--811 00--139--811 00--122--871 00--122--872 00--122--881 00--122--882 00--122--873 00--122--874 00--122--875 00--122--876 00--134--849 00--122--878 00--122--879 00--122--880 00--124--823 00--124--824 00--138--401 00--132--407 00--138--396 00--106--299 Connector X32 X10 Connector X30/a Connector X30/b Connector X1 Connector X2 Connector X30/c Connector X30/d Connector X30/e Connector X30/f Connector X3 Connector X4 Connector X5 Connector X6 Connector X31 Connector X41 Connector X40 Connector X42 XM1 XM2 XP1 XP2 XM3 XM4 XM5 XM6 XP3--L Safe XP4 XP5 XP6 X900 X901 X902 X904 2.8 2.9 2.10 2.11 2.13 2.12 from to Section Page 2.1 2.2 2.3 2.4 2.5 2.6 2.7 7 10 16 20 20 23 23 23 23 23 23 23 23 23 25 25 26 26 27 27

00--111--203 PURRB--48F 00--119--732 PURRB--42M

Base frame

Rotating column Arm

2.14

28

Rotating column

2.15

29

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Repair jobs (Fortsetzung)

2.1

Removal of cable set assembly (00-139-811)

Section 1 of this Doc. Module is to be observed! (1) Move robot into its dismantling position and axis 1 into the zero position.

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. If the robot is no longer operable and the clamps cannot be accessed, then the following alternative procedure is possible: 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. (1.1) Remove motor A 1. (1.2) Turn robot about rotational axis 1 until the dismantling position is reached. Continue with step (2). The following applies for any further dismantling: 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. (2) (3) (4) Disconnect connecting cables X30, X31 and X41 on the robot and connectors XM.. and XP.. on all motors. Individually pack connectors XM.. and XP.. together with their designation labels due to risk of fouling (e.g. by means of well--secured plastic bags). Disconnect ground conductors from the respective PE bolts (Fig. 1): Ground conductor connections, rotating column (1) Ground conductor connection, arm (8) Ground conductor connection, base frame (22)

The push--in module, consisting of connection plate (3), metal boxes (5, 6) and junction boxes (4, 11), is a component of the cable set. It is not necessary to dismantle this assembly in order to be able to remove the cable set. (5) Remove all clips for cables and clamps for flexible tubes (Fig. 1): Remove cable clamps (Fig. 1/9, 17 and Fig. 3/26). Remove flexible tube from the clamps (Fig. 1/13, 14, 15) and take off clamps (14, 15). Holders for flexible tube A 1: Remove connection plate (3) with screws (2). Remove bracket A 1 (20) with screws (7) from the rotating column.

(6) (7)

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7 6 5

21

17 16 15

19 20 14 10
X42 X40

18
X02

11

2 22 23 12 13

Fig. 1 Covers, clips, clamps and ground conductor bolts

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Repair jobs (Fortsetzung)

9 8 7 6 5 4 3

1 2

1 2 3 4 5 6 7 8 9

PE bolt: M8x30 mech.galv. DIN 913 stud bolt Cable lug Robot Ground plate VS8 washer M8 nut 8.4 washer VS8 washer M8 nut

Fig. 2 Ground conductor connection (8) The flexible tube A 1 (19) is firmly screwed to the metal boxes (5, 6) and the bracket A 1 (20) and therefore does not need to be unscrewed.

Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (9) Secure flexible tube A 2/A 3 (18) at both ends with adhesive tape in the same way.

(10) Remove cables with connectors XP1, XP2 and XM1, XM2. To do so: (10.1) Remove cable straps. When the installation process has been completed for the new cable set, all cable straps removed for dismantling must be replaced with new ones. Not all cable straps to be attached are mentioned, however, at the installation stage. It is therefore recommended that a note is made of where cable straps are removed. The sequence when pulling the cables out is XP1, XP2, XM1, XM2. (10.2) Bundle all four cables together with adhesive tape. (11) Remove cables with connectors XP3--L--Safe to XP6 and XM3 to XM6. To do so: (11.1) Bundle cables together with adhesive tape and push them downwards through the link arm together with flexible tube A 2/A 3 (18). (12) Lay the detached part of the cable set down next to the robot together with flexible tube A 1 (19). Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (13) Lay the complete cable set down, fully extended, on a clean support surface.

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2.2

Installation of cable set assembly (00-139-811)

Section 1 of this Doc. Module is to be observed! Before installation work is started, 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. The cables in the flexible tubes of the cable set to be installed are already pre--greased, if a genuine KUKA cable set is used. The flexible tubes are fastened with adhesive tape at both ends. This prevents the tube from shifting and the grease from spreading to the exposed parts of the cable set. Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. Lay new cable set, fully extended, onto a clean support surface. (14) White marks are located on the flexible tube (Fig. 3/9) for positioning the hinged clamps (6, 10, 11, 15). (15) Check the marks at the ends of the flexible tube for the cables XM3 -- XM6 and XP3--L-Safe -- XP6. If necessary, pull cables further so that all the white marks are at the same level. The cable straps must be removed to allow for this. After the white marks have been aligned correctly, new cable straps must be fitted.

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Repair jobs (Fortsetzung)

18 12 17 16 15

14 21 4 26 20 23 13 26 11

22

19 24 10
X42 X40

X02

3 5 6 25

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(16) Install cable set on base frame and rotating column (Fig. 3). To do so: (16.1) Screw connection plate (1) to the base frame, using M12x25 screws (2). (16.2) Place bracket A 1 (20) over Motor A 1 and fasten with screws (3, 7). The cable routing must run between the bracket and motor A 1 (see Fig. 3). (17) Install flexible tube A 2/A 3 (9). To do so: (17.1) Pull cable set with connectors XM3 to XM6, XP3--L--Safe to XP6 and ground conductor in through the link arm from below. Shift the cables so that all the white marks are next to each other and are visible at the upper end of flexible tube A 2 / A 3 (9). (17.2) The braided sleeve (16) must be flush with the end of the flexible tube or the mark. (17.3) Route the braided sleeve (16) in a short curve to the cable clip (17) and fasten it. (17.4) Fasten cables XM3 to XM6, XP3--L--Safe to XP6 and PE with RSGU clamp (14) to arm. The markings on the cables must be flush with the end of the tube. (17.5) Fasten flexible tube A 2/A 3 (9) with hinged clamp (15) to the arm (see also Fig. 1/16). Fasten universal collars (Fig. 3/13, 24, 25, 26) onto the flexible tube, observing their correct orientation. (17.6) Fasten flexible tube A 2/A 3 (9) with hinged clamps (6, 10, 11, 15). (17.7) Run cables XM3 to XM6 and XP3--L--Safe to XP6 to the motors and connect them (see Fig. 6 Arrangement of motors on the arm). Then attach cable straps (Fig. 3/22) to ensure proper routing of cables. The tube marks must be visible underneath the hinged clamps (6, 10, 11, 15).

Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (18) Install the cable clips (Fig. 3/6) on the rotating column. To do so: (18.1) Attach RSGU cable clip (26) with an M10x30 screw (4). It must still be possible to move the cables in the cable clip so that the white marks (5) can be exactly positioned. The white marks are visible from the outside. Push the braided sleeve approx. 50 mm into the flexible tube A 2/A 3. (18.2) Set the position of the white marks. (18.3) Tighten cable clip. Take care to ensure parallel cable routing. Route the cable harness to the left of the motors, in accordance with Fig. 3.

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(19) Carry out the installation of cables XM1, XM2 and XP1, XP2. To do so: (19.1) Route the cables as shown in Fig. 4. (19.3) Route XM1, XP1 to motor A 1 and connect them. (19.4) Route XM2, XP2 through the aperture in the rotating column to motor A 2 and connect them. Protective gloves are to be worn if there is any residual cable grease on flexible tube A 1. All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. The cables must not be subjected to any tensile forces. Cable straps are not permitted in this area. (20) Make four ground conductor connections. To do so: (20.1) Connect the metal box/base frame ground conductor to the base frame (Fig. 1/22). (20.2) Connect motor box/rotating column ground conductor (see Fig. 4) to the rotating column (Fig. 1/12). (20.3) Connect rotating column/arm ground conductor (see Fig. 4) to the rotating column (Fig. 1/23). (20.4) Connect rotating column/arm ground conductor to the arm (8). All ground conductor connecting elements, including the PE bolts and the corresponding tapped holes in the robot, must be free from grease and paint.

2
XM1 XP1 PE

XM2 XP2

Fig. 4 Cable configuration diagram

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Ground conductor connection: 1 2 3 Arm Rotating column Base frame

X42

X40

X02

3 9 8 7 6 5 4 3

2 1 2

1 2 3 4 5 6 7 8 9

PE bolt: M8x30 mech.galv. DIN 913 stud bolt Cable lug Robot Ground plate VS8 washer M8 nut 8.4 washer VS8 washer M8 nut

Fig. 5 Ground conductor connections

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Repair jobs (Fortsetzung)

Axis 5 Axis 3 Axis 6 Axis 4

Fig. 6 Arrangement of motors on the arm Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (21) Carry out tests. When the robot electrical installations (cable set) are completely installed in the robot, the following tests must be carried out: - Continuity test of the protective circuit according to DIN EN 60204-1/19.2 - Insulation test according to DIN EN 60204-1/19.3 - Voltage test according to DIN EN 60204-1/19.4 (22) Check the routing of flexible tube A 2/A 3 (Fig. 1/21). To do so: 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 rotating arm. The robot may only be moved at jog speed, with all applicable safety rules and regulations being observed. (23) Put robot into operation and move axis 3. In the process, check whether the required minimum distance between flexible tube A 2/A 3 and the link arm has been maintained. (24) Ensure the correct position of the protector (Fig. 3/8). The minimum distance is 10 mm.

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2.3

Removal/installation of motor cable A 1 (XM1) (00-122-871)

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

D REMOVAL
(1) Move robot into its dismantling position.

See Section 2.1 of this Doc. Module, steps 1 to 1.2. Before starting removal and installation, 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. (2) (3) Unplug connecting cables X30, X31 and X41 from the robot, if they are still connected. Remove cover (Fig. 7/4).

Protective gloves are to be worn due to cable grease on the inside of the cover! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (4) (5) (6) (7) (8) (9) Unplug cables XM1, XP1, XM2, XP2 at the motors and remove the cable straps. Disconnect ground conductor PE (Fig. 4/3). Unscrew bracket (Fig. 3/20) and pull it out from over motor A 1. This facilitates access to the RSGU clamp (19). Unscrew RSGU clip (19). Open junction box X01 (Fig. 7/5) and remove it. Open cable gland (1) on the rear panel of the junction box (5) (unscrew the union nut only).

(10) Press the sealing insert (3) out towards the rear. (11) Eject modules a and d on Harting connector X30 (6). (12) Disconnect jumper on X30 d 3, 5. (The red and blue brake cable is connected to module d Pin 3 and 5 together with brake cable A 3). This jumper must be reconnected when the motor cable is installed. Use special Harting tool. (13) Disconnect ground conductor of cable XM1 at the PE rail and remove cable from the junction box (5).

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Repair jobs (Fortsetzung)

X30 a b c d e f XM1 XM2 XM3 XM4 XM5 XM6

7 1
X01

5 1 4

6 2 3 3 5

Fig. 7 Removing motor cable A 1 (XM1) The sealing insert (3) is provided with slits towards the outside. The cable can be taken out of the sealing insert through the appropriate slit. (14) Pull module X30/a out of the junction box (5) through the aperture in the cable gland.

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D INSTALLATION
(1) Cut off circular connector XM1 from the old cable XM1 and use this cable as a pull--in wire for the new cable XM1.

The new cable XM1 is already cut to length and terminated. (2) Attach pull--in wire to the new connector module X30/a with adhesive tape.

The new connector module X30/a must be fully protected with adhesive tape from being fouled by cable grease. (3) Apply cable grease to the new cable XM1 and push it into flexible tube A 1 (Fig. 3/21), while carefully pulling on the old cable XM1 at the same time.

Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. When pulling in the cable it must be positioned to ensure that the free cable length between the cable gland and the end of the tube is approx. 150 mm (Fig. 8/7). (4) (5) (6) (7) (8) Screw down cable clip (Fig. 3/19) and bundle cables together using cable strap (the same arrangement as before removal). Connect new cable XM1 to the motor. Attach cable straps. Attach cover (Fig. 7/4) and tighten fastening screws. Screw the bracket (Fig. 3/20) back on (same arrangement as before removal).

Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (9) Feed connector module X30/a through the union nut of the cable gland at (Fig. 7/1) and push cable XM1 into the slit sealing insert (3).

The slit on the sealing insert must be widened for this purpose. The cable jacket must end flush with the sealing insert. (10) Pull shield outwards over the sealing insert (3). (11) Push sealing insert (3) into the aperture of the cable gland at (1).

The shield must be clamped between the cable gland and the sealing insert. (12) Tighten the union nut of the cable gland so that all the cables are properly fastened. (13) Screw on junction box X01 (5). (14) Snap connector module X30/a into the mounting frame (6) from the inside. 18 of 31 Ro/El/03/52.01 04.07.02 en

Repair jobs (Fortsetzung)

(15) Connect the ground conductor of cable XM1 to the PE rail, ensuring that the screw is properly tightened. (16) Close junction box X01. (17) Carry out tests. When the robot electrical installations (cable set) are completely installed in the robot, the following tests must be carried out: - Continuity test of the protective circuit according to DIN EN 60204-1/19.2 - Insulation test according to DIN EN 60204-1/19.3 - Voltage test according to DIN EN 60204-1/19.4

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2.4

Removal/installation of motor cable A 2 (XM2) (00-122-872)

Proceed in the same manner as for motor cable A 1 (XM1) (see Section 2.3).

2.5

Removal/installation of control cable A 1 (XP1) (00-122-881)

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

D REMOVAL
(1) Move robot into its dismantling position.

See Section 2.1 of this Doc. Module, steps (1) to (1.2). Before starting removal and installation, 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. (2) Unplug connecting cables X30, X31 and X41 from the robot, if they are still connected. 7

1 6 5 2

150

Fig. 8 Removing control cable A 1 (XP1)

(3) (4) (5) (6)

Remove covers (Fig. 1/5). Unplug cables XP1, XM1, XP2, XM2 from the motors. Disconnect ground conductor PE (Fig. 4/3). Unscrew bracket (Fig. 3/20) and pull it out from over motor A 1. This facilitates access to the RSGU clamp (19). Ro/El/03/52.01 04.07.02 en

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Repair jobs (Fortsetzung)

(7) (8) (9)

Unscrew RSGU clip (19). Open junction box X02 (Fig. 8/1) and remove it. Open cable gland (2) on the rear panel of the junction box (1) (unscrew the union nut only). (10) Unplug connectors X1 to X6 from the board (Fig. 9/1). (11) Disconnect ground conductor (3). (12) Press sealing insert (4) out towards the rear and remove cable from X1 to XP1 from the slit sealing insert (4). 2 3 4 5 6 7 8 9 10 11 12

X10

X900

X901

18

17

16

X904

X1 X2 X3 X4 X5 X6 X7 X8

X41 X902 X32

X31

15

14 13

19 20 21 22

23

Fig. 9 Junction box X02

D INSTALLATION
(1) Use the old cable XP1 as a pull--in wire for the new cable XP1. The new cable XP1 is already cut to length and terminated. (2) Join board connector X1 on the new cable XP1 to the circular connector of the old cable XP1 using adhesive tape (Fig. 10). 21 of 31

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The adhesive tape must protect the length of the new cable XP1 from which the sheath has been stripped from being fouled by cable grease. (3) Apply cable grease to the new cable XP1 and push it into flexible tube A 1 (Fig. 3/21), while carefully pulling on the old cable XP1 at the same time.

Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.

Adhesive tape XP1 (new cable) XP1 (old cable)

Drawing direction

X1 on the new cable XP1

Circular connector on the old cable XP1

Fig. 10 Pulling in new cable XP1 When pulling in the cable it must be positioned to ensure that the free cable length between the cable gland and the end of the tube is approx. 150 mm (Fig. 8/7). (4) (5) (6) (7) (8) (9) Screw on cable clips (Fig. 4/2) and bundle cables together using cable straps, producing the same arrangement as before removal (see Fig. 4). Screw the bracket (Fig. 3/20) back on (same arrangement as before removal). Plug cables XP1, XM1, XP2, XM2 into the motors A 1, A 2. Attach cable strap (Fig. 4/1). Disconnect ground conductor PE (3). Feed board connector X1 through the union nut of the cable gland (Fig. 8/2) and press cable XP1 into the slit sealing insert (Fig. 9/4).

The cable jacket must end flush with the sealing insert. (10) Pull shield outwards over the sealing insert (4). The shield must be clamped between the cable gland and the sealing insert. (11) Feed connectors X1 to X6 through the aperture of the cable gland into junction box X02. (12) Push sealing insert (4) into the aperture of the cable gland. (13) Tighten the union nut of the cable gland so that all the cables are properly fastened. 22 of 31 Ro/El/03/52.01 04.07.02 en

Repair jobs (Fortsetzung)

(14) Connect the ground conductor (3) to the junction box, ensuring that the screw is properly tightened. (15) Plug connectors X1 to X6 into the board (1). (16) Ensure that the cables are routed in a gentle curve from the rear of junction box X02 to flexible tube A 1. (length of curve approx. 150 mm) (17) Close junction box X02. (18) Re--attach cover (as before removal) and tighten fastening screws. Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.

2.6

Removal/installation of control cable A 2 (XP2) (00-122-882)

Proceed in the same manner as for control cable XP1 (see Section 2.5).

2.7

Removal/installation of motor and control cables A 3 and A 6

This section covers the following cables: Motor cable A 3 (XM3) A 4 (XM4) A 5 (XM5) A 6 (XM6) A 3 (XP3--L--Safe) A 4 (XP4) A 5 (XP5) A 6 (XP6) 00--122--873 00--122--874 00--122--875 00--122--876 00--134--849 00--122--878 00--122--879 00--122--880

Control cable

Section 1 of this Doc. Module is to be observed! Before starting removal and installation, 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. All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.

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For the purpose of repairing one of these cables, it is recommended that the complete cable set is removed and installed (see Sections 2.1 and 2.2). The cable set must be laid out fully extended after removal and the defective cable replaced at the junction box. The procedure for the motor cables is essentially the same as in Section 2.3 and for the control cables as in Section 2.5. The defective cable can be used as a pull--in wire. The connectors must be sealed by wrapping them in adhesive tape before the new cable is drawn in so that they are not fouled by cable grease. After the cable has been replaced, the stipulated tests must be carried out: When the robot electrical installations (cable set) are completely installed in the robot, the following tests must be carried out: - Continuity test of the protective circuit according to DIN EN 60204-1/19.2 - Insulation test according to DIN EN 60204-1/19.3 - Voltage test according to DIN EN 60204-1/19.4

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Repair jobs (Fortsetzung)

2.8

Removal/installation of data cable connection X31-X900 (00-124-823)

Before starting removal and installation, 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.

D REMOVAL
(1) (2) (3) (4) Unplug connecting cables X30, X31 and X41 on the robot. Open junction box X02 (Fig. 8/1). Unplug connector X900 (Fig. 9/18) from the board (1) and unscrew right--angle connector (13). Feed connector X900 outwards through the aperture (14).

D INSTALLATION
Installation is carried out by following the removal instructions in reverse. Glue in four screws of the right-angle connector (13) with surface sealant Drei Bond 1118 (protection classification IP65).

2.9

Removal/installation of connecting cable connection ESC X41-X901 (00-124-824)

Before starting removal and installation, 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.

D REMOVAL
(1) (2) (3) (4) Unplug connecting cables X30, X31 and X41 on the robot. Open junction box X02 (Fig. 8/1). Unplug connector X901 (Fig. 9/17) from the board (1) and unscrew right--angle connector (9). Feed connector X901 outwards through the aperture (8).

D INSTALLATION
Installation is carried out by following the removal instructions in reverse. Glue in four screws of the right-angle connector (9) with surface sealant Drei Bond 1118 (protection classification IP65).

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2.10

Removal/installation of safe I/Os modular X40-X902 (00-138-401)

Before starting removal and installation, 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.

D REMOVAL
(1) (2) (3) (4) (5) Unplug connecting cables X30, X31 and X41 on the robot. Open junction box X02 (Fig. 8/1). Unplug connector X902 (Fig. 9/5) from the board (15). Loosen hexagon nut (22) and remove mounting base (19). Remove cable strap (20) from mounting base (19).

When installing the new cable, the mounting base (19) and the hexagon nut (22) are required once again. (6) (7) Loosen three Allen screws M4x10 (23) and Allen screw M4x16 (21). Remove connecting cable X40--X902 from cover.

Glue in four Allen screws (21, 23) with surface sealant Drei Bond 1118 (protection classification IP65).

D INSTALLATION
Installation is carried out by following the removal instructions in reverse.

2.11

Removal/installation of connecting cable, reference switch X42-X904 (00-132-407)

Before starting removal and installation, 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.

D REMOVAL
(1) (2) (3) (4) Unplug connecting cables X30, X31 and X41 on the robot. Open junction box X02 (Fig. 8/1). Unplug connector X904 (Fig. 9/16) from the board (15) and unscrew right--angle connector (12). Feed connector X904 outwards through the aperture (10).

D INSTALLATION
Installation is carried out by following the removal instructions in reverse. Glue in four screws of the right-angle connector (12) with surface sealant Drei Bond 1118 (protection classification IP65).

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Repair jobs (Fortsetzung)

2.12

Removal/installation of mastering cable connection X32-X10 (00-106-299)

Before starting removal and installation, 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.

D REMOVAL
(1) (2) (3) (4) Unplug connecting cables X30, X31 and X41 on the robot. Open junction box X02 (Fig. 8/1). Unplug connector X10 (Fig. 9/2) from the board (1) and remove built--in connector X32 (7) by unscrewing the nut. Feed connector X10 outwards through the installation aperture of X32.

D INSTALLATION
Installation is carried out by following the removal instructions in reverse. Ensure that the seal of the built- socket (7) is correctly seated (protection -in classification IP65).

2.13

Removal/installation of Safe RDC cover incl. connector (00-138-396)

Before starting removal and installation, 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.

D REMOVAL
(1) (2) (3) (4) Unplug connecting cables X30, X31 and X41 on the robot. Open junction box X02 (Fig. 8/1). Unplug connectors X902 (Fig. 9/5) and X904 (16) from the board (15). Unscrew cover (11) complete with hinges from junction box X02 (6).

Glue in four screws of the hinges with surface sealant Drei Bond 1118 (protection classification IP65).

D INSTALLATION
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2.14

Removal/installation of flexible tube A 1

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

D REMOVAL
(1) Move robot into its dismantling position.

See Section 2.1 of this Doc. Module, steps (1) to (1.2). Before starting removal and installation, 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. All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (2) (3) (4) (5) (6) (7) (8) (9) Unplug connecting cables X30, X31 and X41 on the robot. Unscrew bracket (Fig. 3/20) and pull it out from over motor A 1. This facilitates access to the RSGU clamp (19). Unscrew RSGU clip (19). Open junction boxes X01 and X02. Eject all connector modules on connector X30 (Fig. 7/6) of junction box X01. Disconnect ground conductors of cables XM1 to XM6 from the PE rail. Open cable gland (1) on the rear panel of junction box X01 and carefully pull all cables XM1 to XM6 out of the junction box. Unplug all board connectors X1 to X6 of junction box X02 from the board (Fig. 9/1).

(10) Open cable gland on the rear panel of junction box X02 and carefully pull all cables out of the junction box. (11) Pull the rotating column ground conductor out of the gland (Fig. 7/2). (12) Protect the exposed cable ends with the connector modules from fouling by cable grease etc. by means of plastic bags and adhesive tape. (13) Open both tube clamps (Fig. 7/7 and Fig. 3/23) on flexible tube A 1 (Fig. 3/21) and carefully pull flexible tube A 1 off the cables. Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.

Ensure that the working environment is clean. The cables in the area of the tube (greased) must not be fouled.

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Repair jobs (Fortsetzung)

D INSTALLATION
(1) If necessary, regrease cables on all sides with a coating of cable grease at least 2 mm thick.

Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (2) (3) (4) Pull new flexible tube A 1 (Fig. 3/21) onto the cable bundle XM1 to XM6, XP1 to XP6 and onto the base frame/rotating column ground conductor (see Fig. 3). Fasten flexible tube A 1 (21) to the metal boxes (Fig. 1/5, 6) and bracket (Fig. 3/20) using the tube clamps (22, 23). Continue installation by reversing the removal sequence.

2.15

Removal/installation of flexible tube A 2/A 3 (00-119-732)

D REMOVAL
Section 1 of this Doc. Module is to be observed! (1) Remove cable set assembly (see Section 2.1).

Check cables XM... and XP... for defects.

All connectors unplugged from motor units A 3 to A 6 must be individually wrapped together with their designation labels due to risk of fouling (e.g. by covering them with plastic bags). (2) Eject cables XM3 to XM6 from connector X30 and cables XP3--L--Safe to XP6 from the board (Fig. 9/1) and remove them from junction boxes X01 and X02 through the apertures of the cable glands.

Seal off unprotected cable ends with plastic bags and adhesive tape. (3) Pull the cables, including the ground conductor, which have been withdrawn from the junction boxes, out of flexible tube A 1 (Fig. 3/21).

Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (4) (5) Pull old flexible tube A 2/A 3 (Fig. 3/9) off cable bundle. Lay cable bundle down, fully extended, on a clean support surface. 29 of 31

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D INSTALLATION
(1) Cut new flexible tube A 2/A 3 to correct length (Fig. 11) and mark it.

The flexible tube must be cut to the correct length at the humps (1) and not at the grooves (2).
1600 mm

30

300

120

30 460

30 450 mm

30

2 Fig. 11 Cutting flexible tube A 2/A 3 to length (2)

If necessary, regrease cables on all sides with a coating of cable grease at least 2 mm thick.

Protective gloves must be worn! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease. (3) Pull new flexible tube A 2/A 3 onto cable bundle XM3 and XM6, XP3--L--Safe and XP6 and onto rotating column/arm ground conductor. During installation, observe the white marks on the cables. Pull cables XM3, XM6, XP3--L--Safe and XP6 through flexible tube A 1 and feed them into the respective junction boxes. Insert cables into connector X30 and on the board and connect ground conductors according to diagram (see robot Doc. Module Description, Electrical Installations). Install cable set assembly (see Section 2.2).

(4) (5) (6)

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Safety precautions when handling lubricants

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.

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